Manual Do Soprador Afs

VSB – VALLOUREC & SUMITOMO TUBOS DO BRASIL LTDA BLAST FURNACES 1 & 2 PLANT OF JECEABA

DATA BOOK SINGLE STAGE CENTRIFUGAL BLOWERS TURBLEX INC.

A

Revisão

21/08/2009

RDA

RDA

RDA

0

Emissão Inicial

20/07/2009

RDA

RDA

RDA

Checado Checked

Aprovado Approved

Descrição da Revisão Description of Revision Título do Documento: Title of Document / Designation:

Data Preparado Date Prepared Número PW: PW Number:

Rev. No. Rev. No.

DATA BOOK

1375-02-0065

Rev.

A

SINGLE STAGE Documentos de Referência: Reference Documents:

CENTRIFUGAL BLOWERS TURBLEX INC. Número VSB: VSB Number:

C-81/1375/OC/005 Rev.

Número Subfornecedor: Subsupplier Number:

Número total de páginas Number of pages

Rev.

PRELIMINARY OPERATION & MAINTENANCE MANUAL FOR

VALLOUREC & SUMITOMO TUBOS DO BRASIL LTDA BRAZIL SINGLE-STAGE CENTRIFUGAL BLOWERS

July 30, 2009 VOLUME 1 OF 1 CONTAINS ITEMS A – K TURBLEX JOB #08104607T 1635 W. WALNUT SPRINGFIELD, MO 65806 PHONE: 417-864-5599 FAX: 417-866-0235 www.turblex.com

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

OPERATION & MAINTENANCE MANUAL TABLE OF CONTENTS Item Description Title/Cover Page Table of Contents A

General Information a. Safety Precautions b. Receiving & Handling c. Recommended Lifting Diagram - 4 Point Lift d. Storage Requirements e. Vibration Isolator Installation Instructions f. Instrument Installation Instructions g. Allowable Load on Compressor Discharge Flange h. Recommended Lubricants for Turblex/HV-Turbo Compressors i. Suggested Preventative Maintenance Schedule j. Sample Blower Data Log Sheet k. Turblex/HV-Turbo Service & Spare Parts Capabilities l. Service/Engineering Rate Schedule m. Turblex Recommended Spare Parts n. Troubleshooting Guide

B

Compressor Information a. Compressor Nameplate Data b. Description of Turblex/HV-Turbo Compressor c. VD Description of Operation d. Surging & Recirculation e. Performance Datasheet (PDS) f. Speed Torque Curve

C

Operation Description a. Local Control Panel Operation Description b. Local Control Panel Operator Interface/ Screens c. Operating Restrictions d. Instrument Setpoints

D

Drawings a. General Arrangement Drawing(s) and Installation Notes b. Process & Instrumentation Diagram(s) c. Local Control Panel Electrical Diagrams

E

Coating System

F

Performance/Functional/On-Site Testing a. Compressor Performance Test Report b. Motor Test Report c. Functional/On-Site Testing

G

Pre-Startup Inspection Checklist

H

Turblex Equipment Warranty

I

List of Components

J

Appendix a. Center of Gravity Calculations b. Vibration Isolator Natural Frequency and Transmissibility c. Instrument List

K

Quality Manual

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1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

Document Name: 4607T-Item A Rev A

ITEM A SAFETY PRECAUTIONS 1. ROTATING EQUIPMENT HAZARDS: Beware of the rotating equipment hazards around the blower and motor area. Avoid wearing loose clothing and stay at least three (3) feet away from unit during normal operation. 2. AUTOMATIC EQUIPMENT HAZARDS: Beware that the equipment can start AUTOMATICALLY. All site tag-out/safety lockout procedures must be followed when working or standing on this equipment. The coupling guard, which is painted safety yellow, must be in place at all times. Site tag-out/safety lockout procedures must be followed if the coupling guard is removed for any reason. 3. NOISE HAZARDS: This equipment operates at noise levels of 80 dB(A) and above. All entrances to the blower building must be posted with the appropriate OSHA warning signs. OSHA-approved ear protection must be worn when working in the blower building while the equipment is in operation. 4. ELECTRICAL EQUIPMENT HAZARDS: Beware of the low and high voltage power requirements of the control panels and the motors. All site tag-out/safety lockout procedures must be followed when working in and around this equipment. The appropriate OSHA safety warnings should be posted where necessary. 5. PRESSURIZED OIL HAZARDS: The lube oil system may consist of a pumping system, which supplies oil to the blower bearings at pressures up to 120 psi. Use the proper site tag-out/safety lockout procedures before performing maintenance operations. 6. MOVING AIR HAZARDS: Remove all loose objects and equipment from the vicinity of the blow-off outlet. Use the proper site tag-out/safety lockout procedures before removing any piping from the inlet or discharge of the compressor, including the changing of inlet air filters. 7. SAFETY EQUIPMENT: All site safety equipment rules and procedures must be followed when in this area. This includes wearing proper protective goggles, ear muffs, shoes, clothing, etc. 8. EMERGENCY SHUTDOWN OF THE EQUIPMENT: Should an emergency occur, the equipment will automatically shutdown or can be physically shutdown by pushing the red emergency stop (E-Stop) button located on the front of the appropriate local control panel (LCP) door. CAUTION: Surging will occur when the equipment is shutdown in emergency-stop situations. This is considered normal and will not damage the equipment. 9. SPECIAL HV-TURBO BLOWER TOOLS: This equipment is provided with a special set of tools, which are required to perform certain maintenance and repair operations. These tools are provided in a specially marked toolbox, and should be maintained for their respective uses only. Failure to use the appropriate tools for maintenance and repair operations may damage the equipment and/or injure service personnel.

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1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A RECEIVING & HANDLING Care is taken at the factory to ensure the compressor arrives at its destination in first class condition. Inspect unit to make sure no damage has occurred during shipment. Make the examination before removing from the truck. If damage or indication of rough handling is evident, file a claim with the carrier at once, and notify Turblex. Each compressor skid assembly is provided with lifting lugs at the four corners of the base/skid for lifting the assembled machine. The equipment needed to handle the compressor skid assembly should include a hoist and spreader bar arrangement of sufficient strength to lift the compressor assembly safely. The spreader bar should have lifting hooks positioned to equal the span of the lifting lugs. An experienced rigger should be used to handle the equipment. CAUTION Uneven lifting must always be avoided. Slings of equal lengths must always be used to avoid uneven lifting, when single point lifting is to be used. CAUTION Lifting lugs or eyebolts on the motor/compressor are designed for handling that equipment only. They are not to be used to lift the compressor assembly. WARNING Failure to observe these precautions may result in damage to the equipment or injury to personnel.

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ITEM A

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

STORAGE REQUIREMENTS

ITEM A

If the compressor is not to be installed and placed into service immediately, certain normal precautions must be taken after it has been received to provide proper protection while the compressor is being stored. A unit is considered to be in storage when: 1. 2. 3. 4.

It has been delivered to the jobsite and is awaiting installation It has been installed, but operation is delayed pending completion of plant construction There are long periods between operating cycles The plant is shut-down

Storage requirements for up to six (6) months prior to start-up: The compressor and all accessories, including any free standing control panel, valves, silencers, enclosure, instruments, and spare parts must be stored indoors, under cover, in a clean, dry location. Since moisture can be very detrimental to electrical and rotating equipment, the ambient temperature must be maintained above 50°F (10°C), with relative humidity less than 90%, by providing either external or internal heating. If the motor is equipped with space heaters, they must be energized at the voltage shown by the space heater nameplate attached to the motor. Incandescent light bulbs can be placed within the motor or control panel to provide heat. However, if used, they must not be allowed to come in contact with any parts of the motor or control panel because of the concentrated hot spot that could result. Avoid exposing compressor and sensitive components to vibration. Additional storage requirements after first six (6) months prior to start-up: Compressors and motors having sleeve journal bearings are shipped without oil in the reservoirs. In storage, the reservoirs must be properly filled with the manufacturer’s recommended lubricant. Grease lubricated motors are generally shipped with the bearings lubricated and ready for operation. To prevent the bearings from flattening and the shaft journals from pitting, rotate the compressor and motor shafts onehalf turn (180°) every two (2) to three (3) weeks. If the unit is supplied with an electric oil pump, run electric oil pump for 30 minutes to thoroughly lubricate the bearings prior to rotating the shafts. To prevent the control vanes from sticking, cycle the vanes open and close at least two (2) cycles every two (2) to three (3) weeks. Provide temporary power to the local control panel in order to run the electric oil pump, if supplied, and cycle the control vanes. If the control panel is not pre-wired to the compressor skid assembly, provide temporary connections between motor starters located in the control panel and the terminals in the junction box at the skid assembly. If the control panel is provided with umbilical cords for quick and easy connections to the skid assembly, plug the umbilical cords into the connectors at the skid assembly. Recommended storage procedures after start-up: If the compressor is to remain idle for more than 60 days, follow the above pre-start-up storage requirements. In addition, place the compressor control in the service mode and cycle the valves open and close at least two (2) cycles every two (2) to three (3) weeks. The local control panel is to remain energized while the compressor is idle. NOTE: For more details on motor storage requirements, refer to motor manufacturer’s instructions in the Operation and Maintenance Manual.

WARNING Warranty will be voided if storage instructions are not followed.

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1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A VIBRATION ISOLATOR INSTALLATION INSTRUCTIONS FOR XLW TYPE FOR USE WITH MODELS KA22 – KA66 COMPRESSORS

Proper baseplate leveling is critical and must be achieved in strict accordance with the following instructions prior to start-up. Transverse level is to be set ± ¼” over the width of the baseplate by placing a machinist level on skid beams. Longitudinal level is to be set ± ¼” over the length of the baseplate by placing a machinist level on the motor shaft. The vibration isolators are supplied assembled with a 6”x12”x¾” thick mounting plate and related fasteners. INSTALLATION STEPS 1.

Lower the compressor into position on the concrete floor while positioning the isolators using the holes in the skid and fasteners provided. The top plates of the isolators should rest on their respective housings prior to adjustment. Check for isolators where the top plates do not touch the housings and measure the distances. This indicates that these isolators are resting on low spots on the floor. If the isolator top plates are resting on the housings, and a level bubble confirms that the baseplate is not level, then the isolators are resting on the high spots on the floor. Check the skid to be sure that it is resting level.

2.

If the distance between the top plates and the housing is more than 1/16”, shims may be inserted between the top plates and the compressor base to shorten these distances to within 1/16”. If shims are used, they must be at least the same size as the top plate of the isolators. If the distance is greater than ¼”, this indicates that the concrete in these areas is excessively low (below ¼”) and must be filled in with epoxy and allowed to harden. Alternatively, the high spots under the isolators— where the top plate is resting on the housing—can be ground down to narrow the gap between the top plate and the housings of the isolators located in the low spots.

3.

Once all isolator top plates are either resting on the housings or within 1/16” of the housing, and the compressor base is level, scribe a mark around the 3/4'” isolator mounting plates.

4.

Remove the skid to isolator attachment fasteners, lift the compressor away from the area, and remove the isolators from their mounting position.

ITEM A VIBRATION ISOLATOR INSTALLATION INSTRUCTIONS FOR XLW TYPE FOR USE WITH MODELS KA22 – KA66 COMPRESSORS

5.

The area is now ready for the vibration isolators to be glued to the floor. Follow the directions on the Loctite Depend Adhesive package supplied and apply the adhesive to the scribed area on the floor. Use enough adhesive to completely cover the isolator scribed area. Apply the activator to both the concrete and the bottom of the isolator mounting plates.

6.

Within 15 minutes after the activator is applied, set the isolators into place on the scribed areas taking care to be sure the mounting plates register properly with the glue. Set the skid on top of the isolators taking care to align the isolator and skid mounting holes and attach the skid to the isolators with the fasteners provided. Allow a drying time of 4 hours minimum for the adhesive to reach approximate full strength before leveling the compressor.

7.

Adjust the isolators so that the top plates are a minimum of ¼” or a maximum of ½” off the housings. Start at one isolator by turning its adjusting nut clockwise four (4) times, then move to the next isolator and turn its adjusting nut four (4) times. Continue this procedure until the top plates of each of the isolators are ¼” to ½” off their respective housings. Check the skid to be sure it is level. The skid may now be leveled by making small adjustments of individual isolators at the high and low points.

8.

After the equipment is level, visually check each isolator to make sure spring coils are not closed solid and there is sufficient clearance between the top plate and housing.

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2

INSTALLATION STEPS FOR XLW VIBRATION ISOLATOR

1/2-13 BOLT 1/2- LOCK WASHER 1/2- WASHER ISOLATOR

MEASURE GAP NO GAP

1. NORMAL IF SKID IS LEVEL 2. INDICATES ISOLATOR IS RESTING ON A HIGH SPOT IF SKID IS NOT LEV EL

XLW VIBRATION ISOLATOR STEP 1a

XLW VIBRATION ISOLATOR STEP 1b

1. INDICATES ISOLATOR IS RESTING ON A LOW SPOT

XLW VIBRATION ISOLATOR STEP 1c

GAP NO GAP

ISOLATOR SHIM

x

1. IF GAP IS MORE THAN 1/16 INCH BUT LESS THAN 1/4 INCH ADD SHIMS

XLW VIBRATION ISOLATOR STEP 2a

1. IF GAP IS MORE THAN 1/4 INCH FILL AREA WITH EPOXY TO LEVEL

XLW VIBRATION ISOLATOR STEP 2b

x

x

x

x

x

x

1. HIGH SPOTS CAN BE REMOVED TO CLOSE THE GAP OF ISOLATORS LOCATED IN LOW SPOTS

XLW VIBRATION ISOLATOR STEP 2c

REMOVE FASTENERS

GAP

1. GAP ON ALL ISOLATORS SHOULD BE FROM 0 - 1/16 INCH

XLW VIBRATION ISOLATOR STEP 2d

XLW VIBRATION ISOLATOR STEP 3

XLW VIBRATION ISOLATOR STEP 4a

ITEM A

INSTALLATION STEPS FOR XLW VIBRATION ISOLATOR

XLW VIBRATION ISOLATOR STEP 4c

XLW VIBRATION ISOLATOR STEP 4b

XLW VIBRATION ISOLATOR STEP 5b

XLW VIBRATION ISOLATOR STEP 5c

3

9

3

6 12

6

12

9

XLW VIBRATION ISOLATOR STEP 5d

12

12

9

XLW VIBRATION ISOLATOR STEP 5a

3

6

9

3

6

ADJUSTING NUT

CHECK GAP

TURN ADJUSTING NUT CW 4 TURNS PER ISOLATOR AND REPEAT UNTIL 1/4 TO 1/2 INCH GAP IS ACHIEVED

XLW VIBRATION ISOLATOR STEP 6a

XLW VIBRATION ISOLATOR STEP 6b

XLW VIBRATION ISOLATOR STEP 7a

ITEM A

INSTALLATION STEPS FOR XLW VIBRATION ISOLATOR

SPRING COIL TO COIL CLEARANCE ADJUSTING NUT CW RAISES SKID CCW LOWERS SKID

1. SPRING COILS SHOULD NOT CONTACT EACH OTHER 2. ADJUST GAP AS REQUIRED TO OPEN COIL CLEARANCE

1. CHECK TRAVERSE AND LONGITUDINAL LEVEL OF SKID 2. ADJUST LEVEL AS REQUIRED

XLW VIBRATION ISOLATOR STEP 7b

XLW VIBRATION ISOLATOR STEP 8

ITEM A

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A INSTALLATION INSTRUCTIONS FOR FIELD MOUNTED INSTRUMENTS 1.

¾” Process connections. One on each side. If supplied, install discharge temperature gauge or transmitter here or on opposite side.

PITOT Tube with ½” process connections, one on each side. Install tubing from differential pressure transmitter here. If supplied, install discharge pressure gauge on opposite side.

Reinstall oil pressure gauge when shipped loose. Reinstall oil temperature gauge when shipped loose.

Install Tubing between High-Side of Differential Pressure Transmitter and pitot tube at discharge cone. Recommended tube size is 5/16” stainless steel.

Differential Pressure Transmitter with ¼” process connections.

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A INSTALLATION INSTRUCTIONS FOR FIELD MOUNTED INSTRUMENTS 2.

Inlet Filter Differential Pressure Gauge/Switch. If supplied, install conduits and wires to Local Control Panel (LCP).

Inlet Filter/Silencer Inlet Filter/Silencer shroud with ½” process connection. Install tubing from differential pressure transmitter here.

Install tubing between low-side of Differential Pressure Transmitter and Inlet Filter/Silencer shroud. Recommended tube size is 5/16”stainless steel.

Differential Pressure Transmitter

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A INSTALLATION INSTRUCTIONS FOR FIELD MOUNTED DEVICES

Discharge Valve

A pipe spool piece (minimum one pipe diameter) must be installed between the check valve and the discharge valve to allow clearance for the valve plates to open

Blow-Off Valve

Discharge Check Valve See Note 1

Blow-Off Silencer

Discharge Cone Discharge Expansion Joint

Local Control Panel Vibration Isolators

Note 1: Please note, regardless of the discharge orientation of the blower, Turblex recommends the discharge check valve be installed in the horizontal position. The discharge check valve is to be installed as close to the discharge cone as possible. If it is not installed in the horizontal position, please notify Turblex. The hinge post must be in the vertical position.

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A ALLOWABLE LOAD ON THE COMPRESSOR DISCHARGE FLANGE

The discharge air dynamic forces are absorbed by the static restraint of the base assembly. Likewise, the dynamic forces in the discharge piping must be restrained by independent mounting and support of the discharge piping. The allowable misalignment forces, which can be applied to the compressor discharge flange through the deflection of the expansion joint, are listed in the table below. See Figure 1.

Fax Fax Flat M

= = =

Forces in the discharge pipe direction. Forces perpendicular to Fax. Moment in any direction.

TYPE

FAX LB.

FLAT LB.

M IN. LB.

KA2

247

74

575

KA5

607

180

1991

KA10

899

270

3098

KA22

1236

360

5310

KA44

1708

495

7965

KA66

2248

675

13275

KA80

3035

900

17700

KA100

3934

1124

30976

Flat M

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1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A RECOMMENDED LUBRICANTS FOR TURBLEX/HV-TURBO COMPRESSORS WITH JOURNAL BEARINGS FOR USE WITH GA, GB, GC, & GL SERIES GEARBOXES EXCEPT KA100-GL500 COMPRESSOR

COMPANY

TRADE NAME

VISCOSITY GRADE

cSt @ 40ºC

cSt @ 100ºC

BP

BP Bartran HV 46

46

46.50

8.22

Castrol

Dual Range HV

46

46.50

7.90

Chevron

Rando HDZ ISO 46

46

46.00

8.60

CITGO 76 Lubricants by Conoco Philips Dryden

A/W Hydraulic Oil 46

46

46.50

6.80

76 UnaxAW 46

46

46.5

7.00

Paradene 46AW

46

45.89

6.72

Exxon

Nuto H 46

46

46.00

6.70

Mobil

DTE 25

46

44.20

6.65

Petro-Canada

Hydrex AW46

46

45.70

6.70

Primrose

Syn-0-Gen 46

46

58.50

10.10

Royal Purple

Syndraulic 46

46

46.00

7.10

Schaeffer’s Mfg

112 HTC ISO 46

46

48.50

7.10

Shell

Tellus Premium 46 Premium Anti-wear Hydraulic Oil LE 6110 Monolec Hydraulic Oil Lubriplate HO-46

46

46.00

6.80

46

46.20

6.70

46

48.80

6.84

46

42.00

7.00

Hydraulik AW 46

46

45.70

6.70

Valvoline Lubrication Engineers Int. Lubriplate Ultramar Canada Inc

Oil Temperature Limits In Oil Reservoir: Normal: 120ºF-130ºF/50ºC-55ºC Maximum: 160ºF/71.1ºC Minimum: 50ºF/10ºC NOTE: If the above recommended lubricant is not available, please provide alternate oil specification data sheet and MSDS to Turblex for approval. If improper lubricant is used, any damage that could be caused by this will not be covered under Turblex warranty. 275 OIL VOLUME PER BLOWER____________ GALLONS.

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(1041 Liters)

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A SUGGESTED PREVENTATIVE MAINTENANCE SCHEDULE ROUTINE INSPECTIONS (by Plant Personnel) Inspect for cleanliness and general condition of compressor assembly unit Inspect and replace inlet filter(s) as required Inspect and clean/change oil filter(s) as required (if applicable) Check lube oil level and sample/change oil as required Test safety switches Verify all 4-20 mA current loops are operating properly Verify surge detection unit operates properly (See Item I – 1370) ANNUAL INSPECTIONS (by Plant Personnel) Repeat routine inspections, plus - - Inspect inlet silencer for cleanliness and general condition Verify discharge check valve operates properly to prevent back flows Inspect control arm(s) of variable control vanes for slippage Inspect and tighten all mechanical and electrical connections Check coupling alignment and tightening torques of all bolts 18,000 HOURS -CLASS I INSPECTION (air-end only) First inspection, after 18,000 hours of service (or sooner if site conditions dictate); thereafter, based on conditions and appearance of operating mechanisms. Estimated service time: 2-4 days, per unit, assuming one (1) local helper and crane facilities. A Class I Inspection includes the following: Repeat routine and annual inspection, plus - - Dismantle compressor air-end Inspect and clean variable vane system Check variable vane geometry Check axial movement on high and low-speed shafts Dismantle gearbox (GK series gearbox only) Replace fast shaft ball bearings (GK series gearbox only) Check unit alignment before re-start as required 36,000 HOURS -CLASS II INSPECTION (air-end and gearbox) Only GC and GK series gearboxes require Class II inspections after approximately 36,000 hours of service. Other gearboxes may require Class II inspections only based on conditions and appearance of operating mechanism during Class I inspection. Estimated service time: 2-7 days, per unit, assuming one (1) local helper and crane facilities. A Class II Inspection includes the following: Repeat Class I Inspection, plus - - Dismantle gearbox Inspect gearwheels, bearings & seals and check clearances Replace roller/ball bearings (GC series gearbox only) Replace slow shaft ball bearings (GK series gearbox only) Replace flexible seals (O-rings) Inspect electric motor, oil pump, oil cooler, coupling, valves, etc.

DRIVE MOTOR (by Plant Personnel) Keep motor clean and ventilation openings clear of dust, dirt, or other debris. Lubricate bearings every 3 months. Follow instructions found in the Components section of this manual (Item I). DRIVE COUPLING (by Plant Personnel) N10 Coupling (used on all compressor models except KA2-GK2/B3): Check alignment and outer blades of disc-pack for fatigue cracks every 12 months. Check tightening torques of all drive bolts. Follow instructions found in the Components section of this manual (Item I). T10 Coupling (used on KA2-GK2/B3): Inspect seal ring and gasket every 12 months. Re-lube coupling based on recommendation of lubricant manufacturer. Check tightening torques of all drive bolts and fasteners. Follow instructions found in the Components section of this manual (Item I). AUXILIARY OIL PUMP MOTOR (If applicable, by Plant Personnel) Keep motor clean and ventilation openings clear of dust, dirt, or other debris. Lubricate bearings every 3 years. Follow instructions found in the Components section of this manual (Item I). MAIN OIL PUMP MOTOR (If applicable, by Plant Personnel) Keep motor clean and ventilation openings clear of dust, dirt, or other debris. Lubricate bearings every year. Follow instructions found in the Components section of this manual (Item I). LUBE OIL FILTER (If applicable, by Plant Personnel) Check filter indicator frequently to determine when the element needs servicing. Follow instructions found in the Components section of this manual (Item I). CHANGE OF LUBE OIL (by Plant Personnel) The lube oil should be changed after the first 500 hours of operation. For GA, GB, GC and GL series gearboxes, subsequent oil samples should be evaluated by an oil analysis service every three (3) months, with change of lube oil to take place according to the recommendation of the oil analysis service. For GK series gearbox, subsequent oil change is to take place every 6,000 hours of operation. SOLENOID VALVE AND BUTTERFLY VALVE (If applicable, by Plant Personnel) While unit is off-line, operate the valve once a month to insure proper opening and closing.

To schedule a Turblex Field Service Technician for assistance, please contact the Turblex Service Department (Tel: 417-864-5599; Fax: 417-866-0235) approximately two weeks prior to shut-down. Rates would be per the most current published Turblex Service Rate Schedule. Estimates are available upon request.

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BLOWER DATA LOG SHEET - COMPRESSOR

DATE:

ITEM A

(SAMPLE) TIME

INSTRUMENTS 0800

1200

1600

HOUR METER VARIABLE DIFFUSER POSITION (SCALE) INLET GUIDE VANE POSITION (SCALE) INLET TEMPERATURE DISCHARGE TEMPERATURE OIL PRESSURE OIL TEMPERATURE

NOTE: This chart or facsimile should be filled out on each shift.

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1

2000

2400

0400

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A TURBLEX/HV-TURBO SERVICE & SPARE PARTS CAPABILITIES Turblex in Springfield, Missouri, has field service engineers/technicians capable of reacting within 24 hours to emergency service needs. Spare and replacement parts commonly used for bearing replacement, O-rings, and gaskets, are maintained as stock components, and are available for overnight shipment from Springfield, Missouri. HV-Turbo in Helsingor, Denmark, maintains a staff of service engineers and technicians on 24-hour emergency notice from the Helsingor plant. A complete stock of standard repair and replacement parts, for all machine sizes, are maintained in Springfield, Missouri.

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1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A 2009 INSTALLATION & COMMISSIONING ENGINEERING RATE SCHEDULE USD DESCRIPTION

HOUR/DAY/MILE

Factory Representatives normal working hours (Monday through Friday)

$150.00/hr

1st through 4th working hours in excess of normal working hours and working on Saturday

225.00/hr

Additional overtime hours and working on Sunday and national holidays

$300.00/hr

Engineering Personnel normal working hours (Monday through Friday)

$200.00/hr

1st through 4th working hours in excess of normal working hours and working on Saturday

$300.00/hr

Additional overtime hours and working on Sunday and national holidays

$400.00/hr

Traveling hours

$150.00/hr

Helper working/traveling hours

$75.00/hr

Airfare

Cost, plus 15%

Per diem (domestic), including: lodging, car rental, telephone, fax, meals, gas International per diem, including: lodging, car rental, telephone, fax, meals, gas, Helper per diem (less car rental)

$0.65/mi

Charge for waiting time on Saturdays, Sundays and holidays:

$250.00/day

Replacement parts/supplies (i.e., special sealants, etc.), if necessary:

Delivery of replacement parts (international), if any.

Cost, plus 15% $205.00/day

Traveling expenses by Company car/truck per mile

Delivery of replacement parts (domestic), if any.

$290.00/day

as per Invoice Prepaid/Added to the invoice Collect

TRAVEL TIME All travel time from home base of operation to jobsite and return shall be charged in accordance with the above defined workday rates. Daily travel time to and from lodging will not be included and billed as part of the workday. STAND-BY TIME All time the Factory Representative is on stand-by or is available to work Monday through Friday, but is unable to due to reasons other than his own sickness or injury, shall be charged in accordance with the normal workday rates. TRANSPORTATION AND LIVING EXPENSES All transportation and living expenses during the service period from the time the Factory Representative leaves his base of operation until the time he returns shall be charged as defined above. RESPONSIBILITY The Factory Representative shall interpret the Company's drawings and data for the equipment and advise/assist the Customer regarding the sequence of steps and procedures for installation, start-up, dismantling, repairing and assembly of the equipment as the case may be. The Customer shall supply, at their own expense, all labor, material, replacement parts, special tools (other than Company-supplied tools and instruments required for unique procedures and/or collection of operating data), equipment cranes, rigging tools, outside balancing/machining and facilities required to perform the physical work on the equipment. L:\Turb\SERVICE\Forms\TURBLEX\Svc Rate 2009.doc

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM A TURBLEX RECOMMENDED SPARE PARTS

1 Set

Compressor Bearings

1 Set

Compressor Seals/O-Rings

1 Each

Variable Diffuser Actuator

1 Each

Mechanical Oil Pump

1 Each

Complete Auxiliary Oil Pump Assembly including Motor, Coupling and Pump

1 Set

Oil Filter Elements/Filter

1 Set

STE- Compressor Special Tools

DRIVE MOTOR 1 Set

Bearing - Opposite Drive End (ODE)

1 Set

Bearing - Drive End (DE)

INLET AIR FILTER HOUSING 1 Set

Coarse Primary Filters/Unit

1 Set

Fine Secondary Filters/Unit

NOTE: FOR ACTUAL SPARE PARTS, REFER TO COMPONENTS LIST UNDER TAB I.

Z:\Submittal_O&M\Master_Sub\Item_A_GenInfo\Source_Docs\Recomm_Spare_Parts.doc

GENERAL TROUBLESHOOTING GUIDE OBSERVED PROBLEM 1. Blower fails to start.

CHECK FOR 1a. Check inlet guide vane open/closed status at LCP.

OPERATOR RESPONSE 1a. Set the SERVICE/NORMAL/TEST mode to SERVICE, and close the inlet guide vane.

1b.

Blow-off valve not fully open.

1b. Check blow-off valve status at LCP.

1b.

1c.

NORMAL/SERVICE/TEST switch in SERVICE position NORMAL/TEST switch in TEST position. Alarms not cleared. No power.

1c. Verify switch position.

1c.

Set the SERVICE/NORMAL/TEST selector switch to SERVICE, and open the blow-off valve. Verify limit switches by using handwheel if necessary. Set the switch to NORMAL position.

1d. 1e. 1f.

Set the switch to NORMAL position. Reset the alarm condition. Replace fuse and/or close breaker.

1d. 1e. 1f.

1g.

Wait.

1h.

1d. Verify switch position. 1e. Check for alarms at LCP. 1f. Check at the breaker for blown fuse or breaker not engaged. Restart blocking; attempting more than two 1g. Verify time of last starts. (2) starts per hour. Discharge valve not closed. 1h. Discharge valve closed LED not illuminated.

1h.

Set the SERVICE/NORMAL selector switch to SERVICE and close the discharge valve. Verify valve operation and limit switch settings if closed LED does not illuminate on LCP.

2a.

High discharge pressure.

2a.

Lower discharge pressure; verify flow.

2b.

IGV not at proper position.

2a. Verify discharge pressure is within normal range. 2b. Verify IGV position on compressor scale relative to readout on LCP.

2b.

2c.

IGV arm slipped on shaft

2c. IGV lever arm slipped on shaft.

2c.

2d.

VD not at proper position.

2d. Verify VD position on compressor scale relative to readout on LCP.

2d.

2e. 3a.

VD arm slipped on shaft. Obstruction in piping or diffusers.

2e. VD lever arm slipped on shaft. 3a. Closed valves. 3b. Plugged diffusers.

2e. 3a. 3b.

3d.

Stuck check valve.

3c. 3d.

3e.

Discharge valve not fully open.

3c. Wrong tank level. 3d. Verify pressure upstream and downstream of check valve. 3e. Check control panel indicators to see if "Discharge Valve Open" indicator is lit. 3f. Check power to valve operator.

Verify electronics. Set to SERVICE mode and verify operation of IGV throughout range. Recalibrate 4-20 mA. Verify match marks on IGV shaft. Recalibrate 4-20 mA. Verify electronics. Set to SERVICE mode and verify operation of VD throughout range. Recalibrate 4-20 mA. Verify match marks on VD shaft. Open valves to maximize flow. Visually evaluate diffuser pattern; attempt to spot plugged diffusers. Verify correct tank level. Repair check valve if differential pressure data shows valve is faulty. Visually verify valve position. Reset limit switch. Tighten any loose connections. Verify leads are connected properly. Remove any debris.

1g.

2.

3.

Blower volume discharge low.

High discharge pressure.

ITEM A

PROBABLE CAUSE 1a. Inlet guide vane open, possible failure of interlock.

3g. Check for obstruction in valve, or operator's gears. 1

3e. 3f. 3g.

GENERAL TROUBLESHOOTING GUIDE OBSERVED PROBLEM 4. Blower surge.

PROBABLE CAUSE 4a. High discharge pressure. 4b.

High inlet temperature.

4c.

Plugged inlet air filter.

4d.

Pressure connections loose to surge switch. Water in compressor volute.

4e. 5.

6.

7.

8.

9.

High inlet air temperature.

High discharge air temperature.

Motor overload.

Low oil pressure during start/stop sequence.

Low oil pressure during operation.

o

ITEM A

CHECK FOR 4a. Verify high discharge pressure check points listed under Section 3. o 4b. Verify inlet temperature is over 130 F.

OPERATOR RESPONSE 4a. Check items under Section 3.

4c. Verify differential pressure across air filter. Visually inspect air filter. 4d. Visually inspect connections.

4c. 4d.

4e. Verify operation of blow-off/discharge valve.

4e.

4b.

Operate blower in the 60-80% range. If surging continues, discharge pressure should be reduced. Replace air filter elements. Verify differential pressure meter operation. Tighten connections on blower and surge switch. Remove plug at bottom of volute and drain.

5a.

Inlet temperature over 130 F.

5a. Verify with another thermometer.

5a.

Run Compressor in the 60-80% range.

5b.

Inlet probe too close to volute.

5b. Verify inlet probe is not too close to volute.

5b.

Relocate inlet probe.

5c.

Surge.

5c. Check points listed under Section 4.

5c.

Check points listed under Section 4.

6a.

High inlet temperature.

6a. Verify transmitter/sensor with thermometer.

6a.

Replace the transmitter/sensor if faulty.

6b.

Operating off design.

6b. Verify IGV/VD position.

6b.

6c.

Discharge temperature over 275 oF.

6c. Verify with thermometer.

6c.

7a.

7a. Verify inlet temperature, discharge pressure, and VD position. 7b. Blower can be rotated easily.

7a.

7b.

High inlet temperature; VD's at full open; discharge pressure high. Motor/blower malfunctions.

Operate blower in the 60-80% range if possible. Operate blower in the 60-80% range if possible. Reduce VD position.

7b.

7c. 8a. 8b.

Low input voltage. Auxiliary oil pump overload tripped. Auxiliary oil pump circuit breaker/fuses.

7c. Verify 4160V input voltage. 8a. Verify touchpad warning light. 8b. Verify MCC.

7c. 8a. 8b.

8c.

Low oil level.

8c. View sight glass/level dipstick.

8c.

8d.

Auxiliary oil pump failure.

8d. Verify oil pump malfunction.

8d.

9a. 9b. 9c. 9d.

Main oil pump loss of suction. Lube oil piping failure. Low oil level. Main oil pump failure.

9a. 9b. 9c. 9d.

9a. 9b. 9c. 9d.

2

Low pressure at main oil pump discharge. Inspect piping. Verify oil level. Verify oil pump internals. Check valves operation.

Lockout blower at MCC. Remove coupling guard. Blower and motor should rotate with approximately 200 ft/lb of torque applied to shaft. Correct under voltage situation. Reset overload at MCC. Reset circuit breaker, replace fuses, and verify operating current. Repair low oil level switches and add oil. Operate in SERVICE mode. Verify rotation. Rebuild oil pump. Prime main oil pump. Repair piping. Refill oil reservoir. Refill oil reservoir. Lockout compresor and auxiliary oil pump. Verify oil pump internals.

GENERAL TROUBLESHOOTING GUIDE OBSERVED PROBLEM PROBABLE CAUSE 10. High oil temperature. 10a. Oil cooler fan not operating. 10b. Faulty temperature modulation. 10c. Little or no water flow to cooler.

11. Low oil temperature. 11a. Low ambient temperaure.

11b.

Temperature modulating valve stuck open.

11c. Cold oil.

12. Oil filter bypass.

12a. Dirty oil filter.

13. Blower bearing high temperature.

13a. High oil temperature.

14. Blower/motor/ proximity vibration high and abnormal noise.

15. High motor bearing temperature.

CHECK FOR 10a. Loss of power, motor overloads tripped. 10b. Temperature modulating valve closed. 10c. Low water pressure, faulty solenoid/temperature modulating valve, closed block valves. 11a. Verify auxiliary oil pump is operating.

11b. Verify temperature modulating valve operation. 11c. Verify Oil Temperature.

ITEM A

OPERATOR RESPONSE 10a. Reset. 10b. Repair valve. 10c. Check water pressure, valve operation and position. 11a. Switch to SERVICE mode and start auxiliary oil pump if it has not automatically started. 11b. Repair valve. 11c. Switch to SERVICE mode and operate auxiliary oil pump to raise temperature to at least 100 oF and verify oil pressure. 12a. Replace filter cartridge.

13b. High inlet temperature and high discharge pressure. 13c. Temperature monitor problems.

12a. High differential pressure across oil filter via indicator on oil filter. 13a. Verify that the oil temperature is between 110oF-120oF. 13b. Verify inlet temperature, discharge pressure, and motor current amps. 13c. Verify temperature monitor operation.

13d. Bearing problems.

13d. Abnormal log data.

14a. Low oil temperature. 14b. Coupling out of alignment.

14a. Verify oil temperature is between 110 oF120oF. 14b. Verify coupling alignment.

14c. Fault with vibration monitor.

14c. Verify monitor operation by initiating self-test.

14b. Lockout motor and verify coupling alignment. 14c. Notify TURBLEX.

14d. 14e. 15a. 15b. 15c.

14d. 14e. 15a. 15b. 15c.

14d. 14e. 15a. 15b. 15c.

Mechanical damage within the gearbox. Impeller imbalance. Low motor lube oil level. Contaminated motor bearing lube oil. Wrong lubricant.

Review logs for trends. Verify log for trends. Verify motor lube oil level. Verify color and level of oil. Verify compatible lubricant.

15d. Motor/blower out of alignment.

15d. Misalignment.

15e. Failed motor bearing.

15e. Review operation logs and grease bearings. 3

13a. Check oil cooler. 13b. Reduce VD/IGV setting. 13c. Verify RTD reading, temperature monitor operating, lights green. 13d. Stop machine and let cool. Start-up and record log data every 15 minutes until machine reaches stable temperature. Notify TURBLEX. 14a. Verify modulating valve operation.

Notify TURBLEX. Notify TURBLEX. Add motor lube oil. Replace motor lube oil. Replace motor lubricants per manufacturing recommendations.

15d. Lockout drive motor and verify coupling alignment. 15e. Contact authorized motor service shop.

GENERAL TROUBLESHOOTING GUIDE OBSERVED PROBLEM 16. High motor winding temperature.

PROBABLE CAUSE CHECK FOR 16a. High pressure, high inlet temperature, and 16a. Verify inlet and ambient temperatures, VD/IGV at maximum. discharge pressure, and VD/IGV position. 16b. High motor current. 16b. Verify motor loading.

16c. 16d. 16e. 16f. 16g. 16h. 16i. 17. Stopping; Sequence 17a. fail on shut-down (not shut-down in two (2) minutes 17b.

Undervoltage/overvoltage. Connection resistance. Internal motor damage. High motor winding temperature. Faulty RTD. Faulty transmitter. Motor winding ventilation VD doesn't close.

16c. 16d. 16e. 16f. 16g. 16h. 16i. 17a.

Blow-off does not open.

17b.

17c. Discharge does not open.

17c.

4

ITEM A

OPERATOR RESPONSE 16a. Reduce VD/IGV setting.

16b. Review observed problem at motor overload. Verify 4160V input voltage on each phase. 16c. Correct voltage problem. Verify high voltage connections. 16d. Correct motor connection problem. Review logs for evidence. 16e. Retain authorized motor repair shop. Verify motor winding temperature. 16f. Review motor winding problems. Verify RTD functionality. 16g. Use spare RTD motor. Verify transmitter functionality. 16h. Contact Turblex for new transmitter. Verify free of debris. 16i. Contact authorized motor service shop. 17a. Verify electronics. Set to SERVICE mode Verify VD position on compressor scale relative to readout on LCP. and verify operation of VD throughout range. Recalibrate 4-20 mA. Check control panel indicators to see if "Blow- 17b. Visually verify valve position. Off Valve Open" indicator is lit. Reset limit switch. Check control panel indicators to see if 17c. Visually verify valve position. "Discharge Valve Closed" indicator is lit. Reset limit switch.

Document Name: 4607T-Item B Rev B

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM B DESCRIPTION OF TURBLEX / STE COMPRESSOR The Turblex/STE compressor is of the single-stage, radial type driven by an electric motor through a speed increasing gear. The compressor is furnished as a complete unit with variable control guide vanes, integral speed increasing gear, drive motor, lubrication system, and various other accessories specified by the customer. All parts of the compressor are designed to minimize noise and vibration, and will be suitable for the service intended. Compressor Performance The compressor is designed in accordance with the customer's specifications for inlet capacity, discharge pressure, inlet temperature and pressure, and relative humidity. Compressor Case Housing The casing, rear plate, and flanges are made of close-grained cast iron ASTM A278, Class 30B, have a maximum design temperature of 400 º F and a maximum design pressure of 50 psig. The compressor inlet is a slip ring design that connects to either an inlet silencer or inlet duct by a flexible band. The discharge flange is faced and drilled to ANSI 16.1, 125 pounds. All joints in the casing and rear plate are machined for close fit. The casing is vertically split and designed so that the impeller can be removed from the inlet side without removal of the casing. Lifting eyes capable of supporting the casing and a drain plug at the lowest point of the casing are provided. Impeller The impeller is of radial flow type with open and backward leaning blades that are machined from a forged “hiduminium” aluminum alloy material, ASTM B247 AA2618 (Al Cu2 Mg1.5 Fe1 Ni1, Rolls Royce Aircraft Alloy No. 58). The impeller is attached to the shaft by a shrink-fit and locknut arrangement, and is statically and dynamically balanced. The axial gap between the impeller and the casing is adjustable by means of shims. Variable Control Guide Vanes

KA S Compressor: A single guide van machine with adjustable discharge variable diffuser vanes (VD) for capacity control. The vanes are multi-leaf, pivoted, and attached to permanently lubricated sleeve bearings. The VD assembly is mounted integral with the compressor. The assembly includes a lever/scale arrangement for local indication of vane position, an electric actuator with a built-in position feedback for remote indication of vane position, and two adjustable max/min position limit switches. Integral Gearbox The gear housing is made of high-grade cast iron that is sufficiently rigid to maintain the shaft positions under maximum loads. The gear housing assemblies are machined to close tolerances for bearing fits, gear alignment, and oil tightness. All gears are manufactured according to AGMA 6025-C90, to minimum AGMA quality number of no less than 12, as specified in AGMA 2000/A88. The gear is rated for continuous duty with a minimum service factor of at least 1.8 at ambient temperatures within the customer's operating conditions in accordance with AGMA 421.06. All exposed machined surfaces are coated with a corrosion-resistant compound before shipment.

GL Series Gearbox: The speed increasing gear is a one-stage increase, helical, parallel shaft type. The gear housing is vertically split.

ITEM B DESCRIPTION OF TURBLEX/HV-TURBO COMPRESSOR (REFER TO NAMEPLATE DATA SHEET FOR COMPRESSOR MODEL SUPPLIED) Shafts and Seals The shafts are made of high quality alloy steel, accurately machined, case hardened, and ground to size. The shaft seals are non-contact, multi-point labyrinth type with small clearances and sufficient touch points to minimize air leakage out of or into the casing while the compressor is running in the specified operating range or during shutdown. The seals are operated dry and are suitable for any variations in pressure conditions that may occur during start-up, normal operation, and shutdown. Bearings GL Series Gearbox: The drive shaft radial bearings are cylindrical journal bronze bearings. The drive shaft thrust bearings are multiple segment, double-acting bronze bearings designed for thrust in both directions. The pinion shaft radial bearings are multiple segment babbitted bronze bearings designed to suppress hydrodynamic instabilities and provide sufficient damping to limit motor vibrations. The pinion shaft thrust bearings are multiple segment, tapered land bronze bearings designed for thrust in both directions. The radial and thrust bearings are pressure lubricated and designed for fully hydrodynamic lubrication with sufficient oil film thickness under all operating conditions. Lubrication System A complete lube oil system is provided with each compressor unit. The system is capable of supplying clean oil at suitable pressure and temperature to lubricate the compressor gears and bearings. All components of the lubrication system typically are installed and/or integral with the compressor unit baseplate. The components are arranged to permit ease of accessibility for operation, maintenance, inspection, and cleaning. GL Series Gearbox: The lube oil system consists of a reservoir in the compressor unit baseplate, a gearbox driven main oil pump, an electric motor driven auxiliary oil pump, an oil cooler, a thermostatic control valve, an oil filter, and miscellaneous appurtenances. The thermostatic control valve will maintain constant oil temperature. Oil Pumps The oil pumps are positive displacement type. Typically, one main and one auxiliary pump are provided, except for the GK series gearbox. The motors for electrically driven pumps are TEFC type; the horsepower is rated for the application and usually requires 460 VAC. Oil Cooler A customer specified oil cooler is provided to remove excess heat from the lube oil circuit. The two primary types of oil coolers used by Turblex are the shell and tube water/oil cooler, and the fin and tube air/oil cooler. Oil Reservoir The oil reservoir is integral to the compressor baseplate. The interior of each oil reservoir is de-scaled and rust proofed by the application of a permanent coating of the manufacturer’s standard. The equipment attached to the top of the reservoir will be mounted by means of pads to ensure that no tapped holes will extend into the reservoir. All covered openings are gasketed. Reservoirs will be baffled to minimize air entrainment and to isolate foam. The reservoir is equipped with a suitably sized vent and breather. The oil reservoir will have a minimum working capacity of three minutes retention time based upon the mechanical oil pump flow.

ITEM B DESCRIPTION OF TURBLEX/HV-TURBO COMPRESSOR (REFER TO NAMEPLATE DATA SHEET FOR COMPRESSOR MODEL SUPPLIED) Oil Filter GL Series Gearbox: The oil filter is a full flow, replaceable cartridge type, capable of removing particles 9 microns in diameter with 98.7% efficiency. The clean oil filter pressure drop shall not exceed 5 psi at the design temperature and flow. A duplex (two bowl) or simplex (single bowl) filter is supplied in accordance with the customer’s specification. The filter element collapse pressure is twice the bypass pressure. The minimum bypass pressure is 35 psid. A visual indicator is provided to indicate filter condition and filter replacement. . Coupling GL Series Gearbox: The motor-to-compressor coupling is a forged steel, flexible, spacer type with a design safety factor of at least 1.5 under all operating conditions. The coupling spacer is of sufficient length to permit the dismantling of the compressor without removing the compressor housing or the electric motor. Baseplates The compressor unit is furnished with a baseplate of adequate size to support the compressor, motor, lubricating system, and accessories. The baseplate is constructed of fabricated steel and is provided with four lifting lugs. The baseplate is sufficiently rigid to permit lifting the unit, with all equipment mounted, by the four lifting lugs using a four point lift, without distorting or damaging the baseplate or components mounted to the baseplate.

Z:\Submittal_O&M\Master_Sub\Item_B_CompressorInfo\Source_Docs\Descrip_of_Tublx_Compressor.doc

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM B VARIABLE DIFFUSERS DESCRIPTION OF OPERATION

Single-stage HV-Turbo Type S compressors have the unique capability of turndown from 100 to 45% of capacity utilizing variable diffusers (VD) in concert. This device, used independently, effectively controls capacity, however, maximum efficiencies are achieved through utilization of integrated automatic controls applied to machines equipped with variable diffusers (VD). Variable Diffusers - Variable diffusers are a series of aerodynamic vanes around the discharge of the impeller that essentially act as an extension of the impeller blades. The variable diffusers alter the radial component of the velocity of the air exiting the impeller. Thus, rather than throttling, like the inlet guide vanes, the variable diffusers actually alter the flow direction of the air exiting the impeller. As a result, compressor efficiency is not significantly affected as the capacity is reduced. The diffuser vanes further, streamline the flow of air in the compressor internals and volute and reduce losses due to turbulence. More of the velocity energy of the air is then available at the blower outlet. The direction of rotation, shape and spacing of the vanes are such that the capacity of the machine can be varied from 100% to approximately 45% with virtually no decrease of efficiency.

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM B SURGING AND RECIRCULATION Surging is one of the most discussed and most feared foibles of centrifugal and other non-positive displacement compressors. Surging and recirculation occur when the adiabatic head generated by the compressor is less than is needed to maintain a uniform, forward flow of air through the impeller. If the air flow rate reduces below a certain level, the directions of the air flow inside the impeller are so different from the angles of the impeller blades, that air flow breaks down completely. When this occurs, compressed air from downstream of the compressor expands through the impeller in surges, giving rise to the characteristic surging noise. Other effects of surging are to produce rapid changes in the mechanical load on the rotating impeller and drive components, and to produce momentary pressurizing in the compressor inlet. Siemens Turbomachinery Equipment (STE) uses the pressure rise in the inlet to initiate a surge alarm and to stop the compressor before serious mechanical damage occurs. Recirculation will occur before full scale surging and results in discrete streams of hot air from the compressor outlet channeling into the inlet through low flow surfaces of the impeller. This results in a rapid temperature rise in the inlet of the compressor. Unless it is checked, continued recirculation can result in thermal damage to the compressor internals. A temperature sensor in the inlet is used by STE to shut down the compressor if the temperature in the inlet rises above 130oF. Surging and recirculation result from either a decrease in the adiabatic head being generated by the impeller or an increase in the system pressure ratio to levels above the design pressure ratio. Pressure Ratio =

Absolute outlet pressure = P2 Absolute inlet pressure P1

Factors which can upset the pressure ratio are increases in system pressure downstream of the compressor or decreases in system pressure at the inlet to the compressor. Either can be caused by excessive fouling or throttling. A reduction in the adiabatic head being generated by the compressor can result from: ƒ ƒ ƒ

increased inlet air temperature increased relative humidity of the inlet air reduced operating speed of the compressor

It is important then to design compressors for the worst conditions of pressure ratio, inlet air temperature, relative humidity and flow which they will be expected to endure in service.

Item B Because surging and recirculation occur primarily due to a reduction in flow rate, even compressors such as the STE Types S and SV, which control air flow without throttling, are limited in their turndown capacity. For STE that is usually at 45% of design flow. For other types of compressors, which rely on throttling for flow control, the turn-down limit could be as high as 65% of design flow and such a limited turn-down gives rise to other, more serious problems in process control where more than one compressor is in service. Z:\Submittal_O&M\Master_O&M\Item_B_CompressorInfo\Source_Docs\Surge.doc

2

HV−TURBO Verdichter

HV−TURBO compressor

HV−TURBO kompressor

Anlaufmomentkurve

Speed−torque curve

Opstartsmomentkurve

KA66 S GL400

KA66 S GL400

KA66 S GL400

Dato:01−08−08:09:18:41

Dato:01−08−08:09:18:41

Dato:01−08−08:09:18:41

Pbaro= 0.8980 (Bar) Tmin=281.15 (K) Qmin = 31589. (m3/h)

Torque(Nm)

α >10 rad/s^2 4500 4000

Anlaufmoment (Nm)

3500 3000 2500

Opstartsmoment (Nm)

2000 1500 1000 500 0 0

500 1000 1500 2000 2500 3000 3500 Indgangsaksel−omdrejningstal (o/m) Antriebswelle−Drehzahl (upm) Driveshaft−speed (rpm) I=wk2= 34.3 (kg*m2) Sign:__________

Item B

GD2 = 137.2 (kg*m2)

1635 W. Walnut Street Springfield, Missouri 65806-1643

Document Name: 4607T_LCP_Oper_Descrp_Rev 0

Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM C LOCAL CONTROL PANEL (LCP) OPERATION DESCRIPTION FOR COMPRESSORS WITH GL SERIES GEARBOX AND SINGLE VANE CONTROL The following is the basic concept for controlling the Turblex/HV-Turbo compressor with variable diffusers. 1 - Compressor In Stand-by/Read For Start Conditions Before a compressor may be started, the following stand-by conditions must be established: -

VD [Variable Diffusers] closed (in minimum)

-

BOV [Blow-Off Valve] opened

-

DV [Discharge Valve] closed

-

No alarms

-

Reservoir oil temperature above 50°F

If the above conditions are not met, start is inhibited at the LCP (Local Control Panel). 2 - Start Sequence The start sequence may be initiated by pushing the "Blower Start" button on the Operator Interface, or by a start/stop signal from a MCP (Master Control Panel) or plant control system, where applicable. -

The auxiliary oil pump starts a 2-minute pre-lubrication cycle; the oil pressure at the inlet to the gearbox must be established (higher than 15 psig) within 1 minute of the start sequence. If the oil pressure setpoint is not achieved in 1 minute, the start sequence is terminated on a Low-Low Oil Pressure Alarm (Sequence Failure).

-

At the end of the 2-minute pre-lubrication cycle, the LCP gives a Start/Stop (dry contact) signal to the Main Motor Starter to energize the drive motor.

-

The LCP receives a feed back signal (dry contact) from the Main Motor Starter (normally no later than 20 seconds after the start signal has been given); this confirms that the drive motor is running. If the start verification is not received in 20 seconds, the start sequence is terminated on a No Motor Feedback Alarm (Sequence Failure).

-

After the motor feed back signal is received, the DV starts to open and a 5-minute BOV "guardian" timer starts.

-

The oil pressure at the mechanical oil pump must be established (higher than 29 psig) within 20 seconds after the motor feed back is received. If the oil pressure setpoint is not achieved in 20 seconds, the start sequence is terminated on a Low Oil Pressure Alarm (Sequence Failure). If the oil pressure setpoint is achieved in 20 seconds, the auxiliary oil pump will run for another 10 seconds before going off-line.

-

After the auxiliary oil pump has gone off-line, and the DV is opened, the BOV begins to close slowly via a pulsed motion (closing time normally between 30-120 seconds). Example:

Travel time = 30 seconds 2 seconds "on", 5 seconds "off" 105 seconds closing time

-

If the BOV is not closed when the 5-minute BOV “guardian” timer expires, the start sequence is terminated on a Start Taking Too Long Alarm (Sequence Failure).

-

After the BOV is closed the VD is ready for operational control.

ITEM C LOCAL CONTROL PANEL (LCP) OPERATION DESCRIPTION 2 - Start Sequence – Continued -

The start sequence is finished.

During the start sequence, the surge monitor is bypassed until the auxiliary oil pump has gone off-line. 3 - Remote/Local Operation -

When the LCP is set in the Local mode, the VD is positioned manually by open/close controls on the operator interface. Press “VD open” to increase flow and “VD close” to decrease flow.

-

When the LCP is set in the Remote mode, control of the VD is based on an increase or decrease capacity signal sent from a MCP or plant control system, where applicable.

4 - Stop Sequence Normal Stop: The stop sequence may be initiated by pushing the "Blower Stop" button on the Operator Interface, or by dropping the start/stop signal from a MCP or plant control system, where applicable. -

The VD moves to the minimum position and a 120-second stop timer starts.

-

When the VD is at the minimum position, the BOV opens fast (nominal 15 seconds).

-

When the BOV is opened, the DV closes.

-

When the DV (motorized) is closed, or the 120-second timer expires, the start/run signal will drop to the Main Motor Starter to stop the drive motor.

-

After the motor feedback signal is lost, the auxiliary oil pump starts the 5-minute post-lube cycle.

-

5 minutes after the motor feedback signal is lost, the auxiliary oil pump stops.

-

The stop sequence is finished.

"Soft" Stop: See 5, below, for conditions that initiate a “soft stop”. -

The VD moves to the minimum position, the BOV opens fast, and an 8-second stop timer starts.

-

When the BOV is opened or the 8-second timer has run out, the start/run signal will drop to the Main Motor Starter to stop the drive motor.

-

After the motor feedback signal is lost, the auxiliary oil pump starts the 5-minute post-lube cycle, and the DV closes.

-

5 minutes after the motor feedback signal is lost, the auxiliary oil pump will stop.

-

The stop sequence is finished.

Emergency Stop: See 5, below, for conditions that initiate an “emergency stop”. -

The start/run signal will drop to the Main Motor Starter to stop the drive motor, the BOV opens fast, the DV closes, and the VD moves to the minimum position.

-

After the Main Motor Starter feedback signal is lost. The auxiliary oil pump starts the 5-minute postlube cycle.

-

5 minutes after the motor feedback signal is lost, the auxiliary oil pump stops.

-

The stop sequence is finished.

2

ITEM C LOCAL CONTROL PANEL (LCP) OPERATION DESCRIPTION 4 - Stop Sequence – Continued All of the above stop sequences place the blower in "stand-by" position with the correct positioning of all components for re-start. During any stop sequence, the surge control unit and vibration alarms will be bypassed. 5 - Alarms and Shut-Downs (Trips) There are two ways to stop the blower under abnormal conditions: A. A "Soft" stop is initiated when any of the following trip conditions occur: "High Oil Temperature" "High Inlet Air Temperature" "Surge" "High Drive Motor Amps" "High Blower Bearing Temperature" "High Motor Bearing Temperature" “High Motor Winding Temperature” Some mild surging may occur during a soft stop. B. An "Emergency" is initiated when the "Emergency-Stop" button is pushed or when any of the following trip conditions occur: "Low Oil Pressure" "PLC Failure" “No Motor Feedback at Start” “Lost Motor Feedback During Normal Run” “Start Sequence Taking Too Long” “Motor not Stopped in 2 Minutes of Stop Sequence” "High Blower Casing Vibration" Some surging will occur during an emergency stop. If any of the above alarm/trip conditions occurs, a common alarm signal will be available to a MCP or plant control system, where applicable. If the OIT (Operator Interface) fails, Turblex recommends stopping the machine; do not continue operation. If the PLC fails, the unit will drop all the output/input signals and the unit will shut-down. All the alarms must be re-set or acknowledged one alarm at a time. Furthermore, the alarms will disappear after the reason for the alarm is corrected. 6 - Drive Motor High Amp Warning/Alarm Operation -

If the drive motor begins pulling 98% of its rated amperage during normal operation, the LCP will automatically prevent the VD position from being increased further.

-

If the drive motor begins pulling 102% of its rated amperage during normal operation, the LCP will automatically decrease the VD position to decrease the motor amperage below its alarm setpoint.

-

If the drive motor amperage continues to increase to 105% of its rated amperage, and a 45 second timer starts,the LCP will then initiate a "soft stop” sequence.

7 – Restart Blocking If the blower is started and stopped more than two (2) times in less than an hour from the first start, the LCP will inhibit the next start attempt on a Restart Blocking Alarm until that hour has ended. 8 – Zero Speed Switch (Optional, included if specified) When the blower is stopped, the zero speed switch is activated. Upon detection of rotation, the auxiliary oil pump will start to keep the bearings lubricated. The auxiliary oil pump will run for another 2 minutes after the Zero Speed Alarm is cleared.

3

ITEM C LOCAL CONTROL PANEL (LCP) OPERATION DESCRIPTION 9 - Mechanical & Auxiliary Oil Pump Operation Upon initiation of compressor start, the auxiliary oil pump is started along with a 60-second timer to allow the oil pressure to rise above the PSLL setpoint. If the oil pressure is not greater than the PSLL setpoint within 60 seconds, the start sequence is terminated on a Low-Low Oil Pressure Alarm. Upon start of the drive motor, a 30-second guardian timer is initiated to allow the mechanical oil pump to build oil pressure above the PSL setpoint. If the oil pressure is not greater than the PSL setpoint within 20 seconds, the start sequence is terminated on a Low Oil Pressure Alarm. At a time between 20 and 30 seconds after the drive motor is started and the oil pressure is greater than the PSL setpoint, the auxiliary oil pump shall go off-line. Once oil pressure above the PSL setpoint has been achieved, the drop of oil pressure below PSL and/or PSLL will initiate the start of the auxiliary oil pump and an emergency stop. When the compressor is stopped, the oil temperature is continuously monitored. If the oil temperature falls below the Low Oil Temperature Alarm setpoint (60ºF), the auxiliary oil pump will start to provide a heat source to the oil and will remain energized for 2 minutes after the oil temperature has reached above the Low Oil Temperature Alarm setpoint. If the oil temperature falls below the Low-Low Oil Temperature Alarm setpoint (50ºF), the LCP will inhibit compressor start until the temperature rises above the Low-Low Oil Temperature Alarm setpoint. 10 – “Service-Normal-Test” Switch Operation There is a software switch displayed on the Operator Interface called the "Service-Normal-Test" switch. With this switch in the "Test" position, the dry contact signal for start to the Main Motor Starter is bypassed, and a simulated feedback signal from the Main Motor Starter is created so a start-up procedure can be simulated without running the drive motor. When the “Service-Normal-Test” switch is in the “Service” position, the following components can be manually "exercised" or turned on and off from the Operator Interface: a. b. c. d.

Manual start/stop of electric oil pump Manual open/close of BOV Manual open/close of VD Manual open/close of oil cooler solenoid valve (water cooler)

During normal operation, the “Service-Normal-Test” switch shall be placed in the normal position. While the compressor is running, the VD control can be switched from local to remote (LCP Control or MCP Control), or conversely. 11 – Automatic Vane Exercise Every 12 hours that the blower is setting idle (not running), the processor will automatically exercise the VD from their full closed position to their full open position, and return them to their closed position. This helps prevent unnecessary maintenance due to the unit sitting idle for long periods of time. The LCP will also automatically recalibrate the VD’s if out of calibration. 12 – Automatic Calibration of VD There is a software button displayed on the Operator Interface called the “R/I Automatic Calibration”. Push this button to automatically calibrate the VD scales in the PLC to the mechanical scales on the blower. This button is disabled when the blower is in start sequence or on-line. Z:\Submittal_O&M\Master_Sub\Item_C_OperationDesc\Source_Docs\LCP_Oper_Descrp_GL_GB_V.doc

4

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM C Turblex 4607T – Local Control Panel (LCP) Interface / Screens: Please note: LCP operator interface / screens will be available in the Final Turblex Operation and Maintenance Manual.

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM C OPERATING RESTRICTIONS (REFER TO NAMEPLATE DATA SHEET FOR GEARBOX MODEL SUPPLIED) 1.

Blower cannot be started under load.

2.

Blower cannot start or stop if another blower is starting/stopping.

3.

Maximum lubricating oil temperature is 160ºF for GA, GB, GC, and GL series gearboxes, 230oF for GK series gearboxes.

4.

Minimum lubricating oil temperature is 50ºF for GA, GB, GC, and GL series gearboxes.

5.

Maximum inlet air temperature is 130ºF.

6.

Proper oil level in the oil reservoir or oil sump must be maintained.

7.

Minimum lubricating oil pressure downstream of the oil filters is 15 psig (not applicable to GK2/B3 gearbox).

8.

Minimum lubricating oil pressure at the mechanical pump discharge is 20 psig (applies to GB and GL series gearboxes, only).

9.

Power must be left on to LCP when the blower is not operating, except for maintenance.

10. Blower safety shutdowns must not be bypassed. 11. Program in PLC must not be changed without written permission from Turblex. 12. Blower rotation is unidirectional depending on the gearbox model:

COUNTER-CLOCKWISE ROTATION (looking at the blower input shaft) GA200, GA250, GB225, GK200, GL210, GL225, GL285, GL315, GL400 and GL500

13. Motor starting capability at the motor starter or motor control center (MCC) must be deleted or disabled. Start must be initiated from the local control panel (LCP). 14. The discharge check valve is to be installed as close to the discharge cone as possible. Turblex recommends the discharge check valve be installed in the horizontal position. If it is not installed in the horizontal position, please notify Turblex. The hinge post must be in the vertical position. A pipe spool (minimum one pipe diameter) must be installed between the check valve and the discharge valve to allow clearance for the valve plates to open. Please refer to Item A for Installation Instructions for Field Mounted Components. NOTE:

If safety shutdowns are bypassed and/or PLC program is changed without written permission from Turblex, the Warranty will be VOIDED. Z:\Submittal_O&M\Master_Sub\Item_C_OperationDesc\Source_Docs\Operating Restrictions CCW -1.doc

ITEM C REV DATE:

2/28/2008

INSTRUMENT SETPOINTS (PAGE 1) DESCRIPTION

ACTION

NUM. DEC. PLACES

RISING / FALLING

US SETPOINT

SI SETPOINT

OIT DESCRIPTION

NOTATION

SCALE SCALE PSID

SCALE SCALE kPa D

INLET GUIDE VANE POSITION VARIABLE DIFFUSER VANE POSITION BLOWER DIFFERENTIAL PRESSURE

IGV VD

US SETPOINT

SI SETPOINT

OIT DESCRIPTION

120 PSI 35 PSID 50 PSID 25 PSID 35 PSID 120 °F 120 °F 105 / 95 °F 158 / 131 °F 60 / 50 °F 150 / 160 °F 212 / 220 °F 202 / 212 °F 165 / 176 °F

827 kPa G 241 kPa G 345 kPa G 172 kPa G 241 kPa G 49°C 49°C 41 / 35°C 70 / 55°C 16 / 10°C 66 / 71°C 100 / 104°C 94 / 100°C 74 / 80°C

OIL COOLER FAN ON / OFF OIL COOLER FAN ON / OFF LOW OIL TEMPERATURE - START INHIBIT HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP HIGH OIL RESERVOIR TEMPERATURE - ALARM / TRIP

RISING / FALLING R R R R R NA NA R/F R/F F R R R R

GA

GB

X X

X X

GEARBOX SERIES GC GK GL

OTHERS

N.NNN INLET GUIDE VANE POSITION VARIABLE DIFFUSER VANE POSITION BLOWER DIFFERENTIAL PRESSURE TRANSMITTER

INLET GUIDE VANE POSITION VARIABLE DIFFUSER VANE POSITION BLOWER DIFFERENTIAL PRESSURE TRANSMITTER

1 1 2

N.N N.N N.NN

LUBE OIL SYSTEM DESCRIPTION

ACTION

OIL PRESSURE RELIEF VALVE CRACKING SETPOINT OIL FILTER BYPASS VALVE OIL FILTER BYPASS VALVE OIL FILTER DIFFERENTIAL PRESSURE (H) OIL FILTER DIFFERENTIAL PRESSURE (H) OIL TEMPERATURE REGULATING VALVE OIL TEMPERATURE REGULATING VALVE OIL COOLER FAN MOTOR OIL COOLER FAN MOTOR GK200 & GK190 OIL RESERVOIR TEMPERATURE (L/LL) OIL RESERVOIR TEMPERATURE (H/HH) OIL RESERVOIR TEMPERATURE (H/HH) GK200 OIL RESERVOIR TEMPERATURE (H/HH) GK190 without OIL COOLER OIL RESERVOIR TEMPERATURE (H/HH) GK190 with OIL COOLER GK 190 OIL RESERVOIR TEMPERATURE TRANSMITTER RANGE (NOTE 13)

BYPASS TO RESERVOIR BYPASS FILTER BYPASS FILTER ALARM ALARM WATER FLOW MODULATION HOT/COLD OIL MIX MODULATION TURN FAN ON/OFF TURN FAN ON/OFF ALARM & RUN AUX. PUMP / START INHIBIT ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP

(NOTE 11 et.al.)

0 0 0 0 0

S S S 1/0, N.N 1/0, N.N 1/0 1/0 N. N. N. N. N.

DIP SWITCH SETTINGS

0

N.

32 / 392 °F

0 / 200°C

-

R

OIL PRESSURE (L/LL) OIL PRESSURE (L/LL) OIL PRESSURE (L) OIL PRESSURE (H)

TRIP TRIP TRIP ALARM

1 1 1 1

1/0, N.N 1/0, N.N 1/0, N.N N.N

29 / 15 PSIG 20 / 15 PSIG 15 PSIG 150 PSIG

200 / 103 kPa G 138 / 103 kPa G 103 kPa G 1034 kPa G

LOW OIL PRESSURE - TRIP LOW OIL PRESSURE - TRIP LOW OIL PRESSURE - TRIP HIGH OIL PRESSURE - ALARM

F F F R

US SETPOINT

SI SETPOINT

OIT DESCRIPTION

120 / 130 °F 1" WC 1.5" WC 4.2" WC NOTE 1 NOTE 2

49 / 54°C 0.25 kPa D 0.37 kPa D 1.04 kPa D NOTE 3 NOTE 4

HIGH INLET AIR TEMPERATURE - ALARM / TRIP HIGH INLET AIR PRE-FILTER DIFF PRESS - ALARM HIGH INLET AIR FILTER DIFF PRESS - ALARM HIGH INLET AIR OVERALL DIFF PRESS - ALARM OUTLET AIR TEMPERATURE - ALARM / TRIP OUTLET AIR PRESSURE - ALARM / TRIP

NUM. DEC. PLACES

1 1

(NOTE 11 et.al.)

OIL FILTER DIFFERENTIAL PRESSURE - ALARM OIL FILTER DIFFERENTIAL PRESSURE - ALARM

INLET / DISCHARGE TEMPERATURE AND PRESSURE DESCRIPTION

ACTION

INLET TEMPERATURE (H/HH) INLET 1ST STAGE FILTER DIFF PRES (H) INLET 2ND STAGE FILTER DIFF PRES (H) INLET DIFFERENTIAL PRESSURE (H) DISCHARGE TEMPERATURE (H/HH) DISCHARGE PRESSURE (H/HH)

ALARM / TRIP ALARM ALARM ALARM ALARM / TRIP ALARM / TRIP

NUM. DEC. PLACES 0 2 2 2 0 1

N.N 1/0, N.NN 1/0, N.NN 1/0, N.NN N. N.N

X X

X

X X GL500

X X X X X

X X X X

X X X X

X X

X X

X X

X X X X X X X X X X X

X X X

X X

X

X

X X

X

RISING / FALLING R R R R R R

NOTE 1: ALARM = DESIGN PRESSURE (PSIG) * 14 + MAX. INLET TEMP. (F); TRIP = ALARM + 10 F NOTE 2: ALARM = DESIGN PRESSURE (PSIG) + 0.1 PSIG; TRIP = ALARM + 0.1 PSI NOTE 3: ALARM =DESIGN PRESSURE (kPa G) * 1.13 + MAX INLET TEMP (°C); TRIP = ALARM + 6 NOTE 4: ALARM = DESIGN PRESSURE (kPa G) + 0.7 kPa G; TRIP = ALARM + 0.7 kPa G NOTE 5: For Bently Nevada systems, 20/25 mils pp, this is the limit of the detection system. NOTE 6: Temperature degree symbol, type ALT+0176 or ALT+248 from the NUMLOCK keyboard NOTE 7: GA / GL GEARBOXES NOTE 8: GC GEARBOXES NOTE 9: DE - Drive End, ODE - Opposite Drive End of Motor or Blower NOTE 10: IMP END - Impeller End, OPP IMP END - Opposite Impeller End NOTE 11: Num Dec. Places, i.e. 2=N.NN: S-Switch, 1/0-ON/OFF: 1/0, N.N is either switch or transmitter NOTE 12: As Required for Job Specific Vibration System NOTE 13: See Project Manager for dip switch setting documentation NOTE 14: Reference Document for Terminology: Standard_Vibration_Terminology

Z:\Submittal\Master\Item_C_OperationDesc\Source Docs\Instrument_Setpoints.Feb 2008.xls

Printed: 12/5/2008

ITEM C 2/28/2008

REV DATE:

INSTRUMENT SETPOINTS (PAGE 2)

BLOWER / MOTOR TEMPERATURE DESCRIPTION

ACTION

BLOWER STRAIGHT BABBIT JOURNAL BEARING TEMPERATURE BLOWER INPUT SHAFT STRAIGHT BABBIT JOURNAL BEARING TEMPERATURE BLOWER TILT-PAD JOURNAL BEARING TEMPERATURE

NUM. DEC. PLACES

US SETPOINT

SI SETPOINT

OIT DESCRIPTION

(Note 9,10,14) NOTATION Blwr HIE Blwr HOIE Blwr SODE Blwr SDE Blwr HIE Blwr HOIE Blwr HIE Blwr HOIE Blwr HZ Mtr ODE / DE Mtr ODE / DE Mtr W

ALARM / TRIP

0

N.

194 / 203 °F

90 / 95°C

ALARM / TRIP

0

N.

194 / 203 °F

90 / 95°C

ALARM / TRIP

0

N.

210 / 225 °F

99 / 107°C

BLOWER ANTI-FRICTION BEARING TEMPERATURE

ALARM / TRIP

0

N.

248 / 266 °F

120 / 130°C

BLOWER HIGH SPEED SHAFT THRUST BEARING TEMPERATURE MOTOR SLEEVE BEARING TEMPERATURE MOTOR ANTI-FRICTION BEARING TEMPERATURE MOTOR WINDING TEMPERATURE

ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP

0 0 0 0

N. N. N. N.

194 / 203 °F 194 / 203 °F 212 / 221 °F 320 / 329 °F

90 / 95°C 90 / 95°C 100 / 105°C 160 / 165°C

BLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP BLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP BLWR SS SHAFT ODE BRG TEMP - ALARM / TRIP BLWR SS SHAFT DE BRG TEMP - ALARM / TRIP BLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP BLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP BLWR HS SHAFT IMP END BRG TEMP - ALARM / TRIP BLWR HS SHAFT OPP IMP END BRG TEMP - ALARM / TRIP BLWR HS SHAFT THRUST BRG TEMP - ALARM / TRIP MOTOR DE / ODE BRG TEMP - ALARM / TRIP MOTOR DE / ODE BRG TEMP - ALARM / TRIP MOTOR "A/B/C" WINDING TEMP - ALARM / TRIP

US SETPOINT

SI SETPOINT

OIT DESCRIPTION

MOTOR AMPS DESCRIPTION

ACTION

MOTOR AMPS MOTOR AMPS MOTOR AMPS MOTOR AMPS

LIMIT VD OPENING REDUCE VD TRIP TRIP DELAY TIMER

DESCRIPTION

ACTION

BLOWER HIGH SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTES 7,8) BLOWER HIGH SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) BLOWER SLOW SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) BLOWER SLOW SPEED SHAFT RADIAL VIBRATION (X-Y) (NOTE 7) BLOWER HIGH SPEED THRUST POSITION PLUS (Z) BLOWER HIGH SPEED THRUST POSITION MINUS (Z) BLOWER HIGH SPEED THRUST POSITION MINUS (Z) (NOTE 5) BLOWER GEARBOX VIBRATION BLOWER GEARBOX VIBRATION MOTOR SHAFT VIBRATION (X-Y RADIAL) MOTOR BEARING VIBRATION SHAFT KEYPHASOR (NOTE 12)

ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP ALARM / TRIP -

NUM. DEC. PLACES 0 0 0 0

N. N. N. N.

98% FLA 102% FLA 105% FLA 45 SEC

NUM. DEC. PLACES 2 2 2 2 2 2 2 2 1 2 2 -

N.NN N.NN N.NN N.NN N.NN N.NN N.NN N.NN N.N N.NN N.NN -

GA

GB

R

X

X

X

X

R

X

X

X

X

X

R

X X

R R R R R

OTHERS

X

X

X

2

5

X X X X X X

X X X X X X

X X X X X X

X X

X X

X X

X

RISING / FALLING R R R NA

MOTOR AMP LIMIT - LIMITING VD MOTOR AMP LIMIT - REDUCING VD HIGH MOTOR AMPS - TRIP > (TRIP DELAY TIMER LENGTH) MOTOR TRIP DELAY TIMER

VIBRATION

GEARBOX SERIES GC GK GL

RISING / FALLING

US SETPOINT

SI SETPOINT

OIT DESCRIPTION

(Note 9,10,14) NOTATION

3 / 5 MILS-PP 3 / 5 MILS-PP 3 / 5 MILS-PP 3 / 5 MILS-PP 15 / 20 MILS-PP - 15 / 20 MILS-PP - 25 / 30 MILS-PP 5 0.2/0.3 IPS-PK 13 / 15 G'S 3 / 5 MILS-PP 0.25/0.40 IPS-PK -

0.08 / 0.13 mm-pp 0.08 / 0.13 mm-pp 0.08 / 0.13 mm-pp 0.08 / 0.13 mm-pp 0.38 / 0.51 mm-pp 0.38 / 0.51 mm-pp 0.64 / 0.76 mm-pp 5.1 / 7.6 mm/s-pk 13 / 15 G's-pk 0.08 / 0.13 mm-pp 6.4 / 10.2 mm/s-pk -

BLWR HS SHAFT IMP END VIBRATION X / Y - ALARM / TRIP BLWR HS SHAFT OPP IMP END VIBRATION X / Y - ALARM / TRIP BLWR SS SHAFT ODE VIBRATION X / Y - ALARM / TRIP BLWR SS SHAFT DE VIBRATION X / Y - ALARM / TRIP BLWR HS SHAFT THRUST Z POSITION (+) ALARM / TRIP BLWR HS SHAFT THRUST Z POSITION (-) ALARM / TRIP BLWR HS SHAFT THRUST Z POSITION (-) ALARM / TRIP BLOWER GEARBOX VIBRATION - ALARM / TRIP BLOWER GEARBOX VIBRATION - ALARM / TRIP MOTOR SHAFT DE / ODE VIBRATION X / Y - ALARM / TRIP MOTOR BEARING DE / ODE VIBRATION - ALARM / TRIP

Blwr HIE Blwr HOIE Blwr SODE Blwr SDE Blwr HZ Blwr HZ Blwr HZ Blwr GB Blwr GB Mtr ODE / DE Mtr ODE / DE

RISING / FALLING R R R R R R R R R R R

COMPRESSOR SIZE (KA**) 10 22 44 66 80

100

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X

X X X

X X X

X X X

X X X

SEE PAGE 1 FOR NOTES

Z:\Submittal\Master\Item_C_OperationDesc\Source Docs\Instrument_Setpoints.Feb 2008.xls

Printed: 12/5/2008

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM E HI-TEMP COATING SYSTEM FOR DISCHARGE TEMPERATURES UP TO 260°C/500°F BASE/OIL RESERVOIR Exterior • Surface Preparation: SSPC-SP6 COMMERCIAL BLAST CLEAN • Primer: One (1) Coat Sherwin Williams KEM 400 Metal Primer, B50-Z Series, 2.0-5.0 mils DFT Oil Reservoir Interior • Surface Preparation: SSPC-SP10 NEAR WHITE METAL BLAST CLEANING NOTE: Reservoir coating application required within 10 hours of media blasting • Oil Reservoir Coating: Two (2) Coats Devoe Coating Devchem 257Chemical Resistant Tank Lining, to achieve 10.0 to 15 mils (254-381 μm) DFT. Color Intermediate White. • Coating Application Instructions NOTE:

Strict adherence to the manufacturer’s specification data sheets for minimum and maximum self recoat time (based on ambient conditions) as well as the directions for use is required. 1. Spray one (1) Coat of Devoe Devchem 257 to achieve 5.0-6.0 mils (127-152 μm) DFT. Use a brush as necessary to ensure complete coverage of all hard to reach areas. 2. After minimum recoat time has elapsed but not exceeding the maximum (reference product data sheet), stripe coat all weld joints, gussets, corners and any other hard to spray areas within the reservoir. 4. Immediately after stripe coating, spray one (1) coat of Devoe Devchem 257 to achieve 5.0-6.0 mils (127-152 μm) DFT.

NOTE: Surface preparation and coating application by Detroit Tool.

COMPRESSOR/GEARBOX ASSEMBLY (AIR-END) • Surface Preparation: SSPC-SP2 HAND TOOL CLEANING 1. Solvent Clean; using water and a water based cleansing agent cleaner, (Hydrocarbon Solvents Unacceptable) 2. Rinse Clean; rinse clean using water and a clean sponge, or clean cotton towel with a blotting technique, leaving no lent behind. Note: Do not force dry with pressurized shop air 3. Hand Scuff OEM Base Coat Surface; Using Red Scotch Bright pad to break the gloss of the OEM base primer. 4. Rinse Clean; rinse clean using water and a clean sponge, or clean cotton towel with a blotting technique, leaving no lent behind. • Primer: One (1) Coat Sherwin Williams Hi-Temp Coatings No. 850 Primer, 1.0-1.3 mils DFT • Top Coat: One (1) Coat Sherwin Williams Hi-Temp No. 850 Series, Black, 1.0-1.3 mils DFT COMPRESSOR SKID ASSEMBLY • Surface Preparation: SSPC-SP1 SOLVENT CLEAN; using water and a water based cleansing agent cleaner, (Hydrocarbon Solvents Unacceptable) • Primer: One (1) Coat Sherwin Williams Hi-Temp Coatings No. 850 Primer, 1.0-1.3 mils DFT • Top Coat: One (1) Coat Sherwin Williams Hi-Temp No. 850 Series, Black, 1.0-1.3 mils DFT DISCHARGE CONE / BLOW-OFF SILENCER/ MISCELLANEOUS • Surface Preparation: SSPC-SP6 COMERCIAL BLAST CLEAN • Primer: One (1) Coat Sherwin Williams Hi-Temp Coatings No. 850 Primer, 1.0-1.3 mils DFT • Top Coat: One (1) Coat Sherwin Williams Hi-Temp No. 850 Series, Black, 1.0-1.3 mils DFT

2

COUPLING GUARD • Surface Preparation: SSPC-SP1 SOLVENT CLEAN; using water and a water based cleansing agent cleaner, (Hydrocarbon Solvents Unacceptable) • Primer: One (1) coat Sherwin Williams KEM 400 Metal Primer, B50-Z Series, 2.0-5.0 mils DFT • Top Coat: One (1) coats Sherwin Williams KEM 400 Enamel, F75-400 Series, Safety Yellow, 1-1.5 mils DFT ELECTRICAL ENCLOSURES AND TERMINAL BOXES IF COATED FACTORY FINISH BY MANUFACTURER ANSI 61 Gray Polyester Powder Coating

L:\Project_Engineering\Jobs\4607T\Engineering\Mechanical_Eng\O&M\Electronic_O&M\5044T Item E designed by Barry.doc.aj

3

1635 W. Walnut Street Springfield, Missouri 65806-1643

Document Name: 4607T-Item F Rev B

Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM F COMPRESSOR PERFORMANCE TEST NOTE:

The following is the STE compressor test procedure. The official performance test report will be submitted in the final Operation and Maintenance Manual.

C:\Documents and Settings\beaty00b\Desktop\Blower_Performance_Test.doc

930930050US

TESTING OF TURBOCOMPRESSORS OPTION: ASME PTC-10 PROCEDURE

Revision: 6 Page: 1 of (9) Prepared by: Latest revision:

We We

Item F

Date: 93.04.15 Date: 98.03.31

1.

Purpose

2.

National and International Standards

3.

Measuring Equipment, Instrumentation, and Calibration

4.

Test Procedures/Standard Shop Test (SST)/Witnessed Performance Test

5.

Documentation

6.

Additional Testing

1.

Purpose All testing is performed in order to measure operating data for evaluation of conformity with specified data. Before delivery, each HV-TURBO compressor is tested in accordance with HV-TURBO's Standard Shop Test (SST) Specification. The test procedures have been developed during decades of testing thousands of turbo-machines. The test must fulfil the following purposes:

2.

a)

provide sufficient test data over the entire specified operational range for the quality approval procedure before delivery

b)

provide documentation of the performance data and the performance range in terms of a graphic presentation to the customer

c)

provide conditioned data/software for the automated power saving program of SV-type compressors

d)

provide specific and statistic data as feedback for the compressor design program

e)

ensure accurate, safe, and fast registration of all relevant test data in the shortest possible testing time and at the lowest possible cost.

National and International Standards/Norms It is mandatory that especially all logging and evaluation of performance data conform with the relevant national and international standards.

930930050US Revision: 6 Page: 2 of (9)

TESTING OF TURBOCOMPRESSORS OPTION: ASME PTC-10 PROCEDURE

Item F

HV-TURBO compressor testing procedures, as well as the testing equipment, instrumentation, and calibration are in conformity with the national and international norms of testing turbo-compressors, as follows: ISO 5389 :

International standard: Turbocompressors - Performance Test Code.

ISO 5167 :

International standard: Measurement of Fluid Flow.

ASME PTC-19.5

:

USA-standard for flow measurement, based on the same type of equipment and the same physical laws as ISO 5167, but more complicated to handle due to non metric unites and traditional methods. Compared to ISO 5167, the PTC-19.5 computations of flow, measured by the same concentric orifice plate, will result in flow figures which are equal or up to ½% higher than ISO 5167 computations. For the evaluation of test results HV-TURBO has implemented the ISO 5167, which is assumed to be the most modern/updated standard, and which does not conflict with the PTC19.5.

ISO 10816-1

:

Mechanical Vibration of Machines.

ISO 3744

:

Determination of Sound Power Levels of Noise Sources. If freefield conditions can not be established, ISO 3746 will apply.

ASME PTC-10

:

Compressors and Exhausters, Power Test Codes (please see also § 4.3).

3.

Measuring Equipment, Instrumentation, and Calibration

3.1

Flow Measurements All flow measurements during shop tests are carried out by means of straight, cylindrical measuring pipes on which the entry of each pipe is equipped with a straightener. The pipe length for inflow and outflow, the orifice plate design, and the pressure tappings are in accordance with the specified standards. At the exhaust of each pipe, an electrically activated throttle valve is installed in order to adjust the discharge pressure level. The pipe inlet temperature is measured by 4 calibrated temperature probes. The measuring pipe is carefully insulated to avoid heat losses = temperature errors. The pipe system pressure is measured by different pressure probes. For different flow rates, measuring pipes of different dimensions are installed on the test bed. The orifice plates are inspected, calibrated, sealed, and certified every year by the independent international inspection company SGS (Société Générale de Surveillance). The flow is computed from readings of pressure, temperature, and humidity. The method of computation is described in the above mentioned standards ISO 5167/PTC-19.5.

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3.2

TESTING OF TURBOCOMPRESSORS OPTION: ASME PTC-10 PROCEDURE

Item F

Measuring Shaft Power The shaft power can be measured in various ways, depending on the test rig used.

3.2.1

Direct Method by Torquemeter The torquemeter is an electronic torque measuring coupling installed between the drive motor and the compressor. Different sizes of torquemeter couplings are available. The shaft power is computed from the measurement of torque and RPM. All torquemeter couplings are calibrated on standardized calibration rigs with certified plummets. Calibration of the torquemeter couplings is inspected and certified once a year by the SGS.

3.2.2

Indirect Method of Measurement A.

This method may be applied with compressors packaged with the job motor: When the compressor is driven by an electric motor, the power input at the terminals can be measured. The input power is multiplied by the motor efficiency, which equals the shaft power. In order to obtain true data, two requirements must be fulfilled: a)

The motor power input must be measured with calibrated instruments.

b)

The motor efficiency must be verified by a motor test, involving measuring of the power input and of the shaft power with e.g. a calibrated torquemeter.

Alternatively, the motor efficiency can be determined by other methods equivalent to those required when using the direct method. The accuracy of the test data should always be documented by valid calibration certificates. When measuring the motor power input HV-TURBO have six different power supply systems (380V to 10 kV) at their disposal, with calibrated and sealed kWh-counters. Valid calibration documents are provided by an authorized calibration office for kWhcounters. In addition, each power supply line is monitored by independent meters for kW, Amps and Volts. B.

The heat balance method of shaft power measuring is independent of any motor input measuring or calibration of efficiency. When using the heat balance method, the shaft power is computed from the measurements of the energy input into the gas, the mass flow, the gear losses, bearing losses etc., in accordance with ISO 5389 and ASME PTC-10.

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3.3

TESTING OF TURBOCOMPRESSORS OPTION: ASME PTC-10 PROCEDURE

Item F

Temperature Measurement Standard temperature measurements are carried out by 4 temperature probes at the compressor intake and 4 similar probes at the compressor discharge. The probes are thermocouples of an industrial design, wired to a high precision digital display. All temperature probes and wires are marked for identification, sealed by SGS, and calibrated in a laboratory calibration device. The calibration is performed with reference to certified thermometers. The calibration of temperature probes, incl. wiring and display, is checked regularly and inspected and certified once a year by SGS.

3.4

Pressure Measurement In general pressure measurements are carried out by means of high precision electronic transmitters with digital reading. These instruments are always calibrated. U-tubes with water or mercury filling are installed for the verification of these instruments.

3.5

Transmitters for the Automated Test Data Logging The test facility is equipped with fast-logging multichannel data sampling units connected to the test bed computer system. All test data are converted into electronic data for automatic data logging. All transmitters involved are continuously checked and maintained in a correctly calibrated state. This system is supporting the SST, please see § 4.2.

3.6

ISO - 9001 Procedures HV-TURBO is operating a certified quality assurance system for a.o. continuous calibration in conformity with the requirements of the international ISO 9001 standard. Also this test procedure description including all stated commitments is a registered document within this quality system.

3.7

Certification In general, the a.m. certification of instrument calibration is carried out by SGS. For more than a decade calibration of our test bed instruments have proven that calibration data for the same instruments do not change by more than what is expected within the specified instrument accuracy. SGS (Société Générale de Surveillance) is an independent international inspection company with head office in Geneva, Switzerland, and with more than 100 assigned SGS-offices, placed all over the world. SGS certificates issued for a HV-TURBO calibration or compressor test can be verified by any office of the SGS organisation.

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TESTING OF TURBOCOMPRESSORS OPTION: ASME PTC-10 PROCEDURE

Item F

If other calibration procedures are required, this must be specified in the contract or agreed upon within a suitable space of time prior to the scheduled testing.

4.

Test Procedures

4.1

Planning and Preparation of Test The schedule of testing is planned by the head of the project department in cooperation with the production department and the engineers of the test department. Each turbo compressor must pass the SST. If additional testing is specified, the test will be scheduled and the customer as well as the test department will be informed by the project department well in advance.

4.2

Standard Shop Test (SST) This procedure has been developed from the experience of testing thousands of turbocompressors. Testing with atmospheric air will in general be conducted in an open loop test rig.

4.2.1

Mechanical/Operational Test Before starting the motor, the lubricating-oil system is put into operation and the safety controls are checked and adjusted. During the initial start-up, the labyrinth seals are run into their final operating shape, which is controlled by special procedures. During the first 15 minutes of operation the compressor is running at low load and special attention is paid to the temperature rise of the bearing covers and the labyrinth seal flanges, as well as to the vibrations. During the SST each compressor is operated at maximum design load, and all essential operating data are checked and recorded. The housings, flanges, and pipes, incl. the lube oil system, are checked for tightness. For single-stage turbocompressors the duration of the SST is 6-18 operating hours, depending on the compressor type.

4.2.2

Performance Test This test is always performed and evaluated in accordance with ISO 5389 and ISO 5167. The compressor is set up for testing and connected to the instrumentation of the automatic test bed data logging and processing.

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TESTING OF TURBOCOMPRESSORS OPTION: ASME PTC-10 PROCEDURE

Item F

The compressor guide vane setting and the system pressure will be adjusted step by step to generate from 50 to 300 different operating points within a matrix of test data, where guide vane positions, head and flow figures are altered and combined systematically. The test data matrix is registered and computed individually for each compressor serial no., covering the specific design operating range. The data logging system is programmed to register data from calibrated instruments/transmitters. All data are checked for steady state conditions before acceptance. Registered data are averaged from 4 series of readings. The test matrix data are computed and evaluated versus the design data and will provide documentation for the quality approval procedure (ISO 9001). The test matrix data also provide the basic software for the specific compressor control system (option) which automatically can adjust the guide vanes to operate at best efficiency at required flow and head. Finally the test matrix data provide basic data to document operating curves as shown in the HV-Turbo Performance Certificate (pls. see § 5.1).

4.2.3

Vibration Measurements Vibration measurements, with an accelerometer mounted in a representative point, are carried out on each compressor at max. load, and the actual RMS-value of the vibration velocity is recorded within the range 10-1000 Hz. The measurements must be evaluated and conform to ISO 10816-1, range limit 2.8 mm/s for max. power below 400 kW and 4.5 mm/s for max. power more than 400 kW. Furthermore, frequency analysis will be carried out, documented, and evaluated with reference to our experience from equivalent equipment.

4.2.4

Noise Measurements Noise measurements are carried out at least with one compressor of every order with equal design data in accordance with ISO 3744/3746. A test bed assistant performs the sound pressure measurements and records the data on a test form. A test engineer evaluates the test data in relation to the specified data and data as measured on other compressors of equivalent design. If the compressor is packaged with the job motor, a noise certificate can be issued.

4.2.5

Approval and Preparation for Delivery The SST must meet the requirements of §1. Testing of electrical or electronic controls, connected to the compressor, is not part of the above. The adjustment, test, and inspection of electrical control panels is carried out in accordance with other quality assurance procedures. Having passed the SST with approval of the test results, the compressor is released for witnessed testing (if specified) and/or to be prepared for delivery. In case the test results are not approved of, a non-conforming compressor will be analyzed, reworked, and retested.

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TESTING OF TURBOCOMPRESSORS OPTION: ASME PTC-10 PROCEDURE

Item F

The preparation for delivery will a.o. include flushing of the gearbox, the bearings, etc. with corrosion-preventive oil, long-term preservation (if specified), final adjustments of electronic sensors, adjustment of the discharge flange for installation on site, painting/surface preparation, marking and packing up.

4.3

Additional Performance Testing: ASME PTC-10 Specified operating data can be verified by interpolation of test data from the SST (pls. see § 4.2.2 and 5.1). If the verification of specific performance data in accordance with ASME PTC-10 is a contractual requirement, the following options for additional testing can be offered:

4.3.1

Witnessed Test This test will be witnessed by the customer or by a representative appointed by the customer. A precondition for setting up a witnessed test is that the SST has been finalized and SST data have been evaluated and approved by the test engineer. With uncooled single stage turbocompressors or tandem driven compressors with externally piped intercooler for atmospheric air, the verification of guarantee points will be conducted as follows, if no other requirements are specified: -

The genuine compressor(s) of the order will be tested.

-

The test is conducted with atmospheric air.

-

The test is conducted at specified RPM within a departure of ± 2%.

-

The compressor will be adjusted to the specified volumetric flow within a departure of ± 2%.

-

The discharge pressure will be adjusted equivalent to the specified isentropic head within a departure of ± 1%.

-

Recording of test data from calibrated instruments with a total uncertainty of measurement within all limits of ISO 5389, table 5.

-

Recording of 5 complete sets of test data at steady state conditions for every operating point. Fluctuations of test readings to be within the figures of ASME PTC-10/Table 2.

-

Computation of test data for every operating point with reference to specified operating data and in accordance with ASME PTC-10/§ 5. With reference to API

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Item F

672/4.3.4.1, the test data for flow, pressure and power corrected to specified data must be within the tolerance ÷ 0/+ 4%. If it is not possible to adjust the test data within the above limits, the spotted operating point will be bracketed (ASME PTC-10/§3.13). It is important that the witnessed performance test data are documented and signed by the inspector, and for this reason all test data will be verified from calibrated instruments and documented in a log sheet. During the test, the log sheet data will be computed for evaluation in accordance with the standards mentioned above. A print will document the performance data of the test points with reference to the specified guarantee conditions.

The number of guarantee points to be tested must be specified in advance and the test must be scheduled. A witnessed test will always be conducted by an experienced test engineer in cooperation with the test bed foreman or his assistants. 4.3.2

Witnessed Certified Test This test will be witnessed by third party inspection, i.e. an inspector from an independent and neutral inspection company. The inspection company will on request issue a specific test certificate. The test procedure will be as described in § 4.3.1.

4.3.3

Certified Test This test will be conducted by an experienced HV-Turbo test engineer under the supervision of the HV-Turbo Quality Department. Test log sheets will be signed by the test engineer and stamped by the QA Department. The test procedure will be as described in § 4.3.1.

5.

Documentation

5.1

Standard Documentation In accordance with §1-b the test data of each compressor Serial No. are documented to the customer in terms of a graphic presentation, i.e. the HV-TURBO Performance Certificate. This certificate shows a relevant number of operational curves at different vane settings of the inlet guide vanes, the variable diffuser vanes, or a combination. The curves will show discharge pressure versus inlet volume flow and shaft power. The curves will relate to the specified operating conditions, and the curves will also be numbered in relation to the vane setting pointer on the scale at the compressor.

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Item F

Furthermore, curves of the recorded vibration analysis for each serial No. will be documented. As regards compressors which have been tested as a complete unit with their genuine motor, the noise measurements will be documented in accordance with the standards mentioned. If an ASME PTC-10 Test has been specified, a test report will document selected guarantee points in accordance with ASME PTC-10/§ 7C (class I) or § 7D (class II). 5.2

Documentation from Witnessed Testing Log sheets with test data in accordance with instrument readings and printed computer evaluation from the same test data must be checked by the inspector and test engineer and signed by both persons. Each participant of the test will receive copies of the test documents as well as copies of the test rig system drawing and relevant copies of the instrument calibration certificates.

6.

Budget and Schedule of Additional Testing The HV-TURBO SST is mandatory and will always be conducted. The SST costs are included in the budget of a compressor order. All additional tests will be conducted in accordance with the requirements of the contract. As the manufacturing schedule and the cost budget of a compressor order can easily get out of control by unscheduled activities, we must avoid excessive and unscheduled testing. Optional or other additional testing must be agreed to and specified in the contract, so that we are able to plan, budget, schedule and conduct these activities to the satisfaction of our customers.

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CM CM

Date: 03.01.03 Date: 03.01.03

1.

Purpose

2.

National and International Standards

3.

Measuring Equipment, Instrumentation, and Calibration

4.

Test Procedures/Standard Shop Test (SST)/Witnessed Performance Test

5.

Documentation

6.

Additional Testing

1.

Purpose

ITEM F

All testing is performed in order to measure operating data for evaluation of conformity with specified data. Before delivery, each HV-TURBO compressor is tested in accordance with HV-TURBO's Standard Shop Test (SST) Specification. The test procedures have been developed during decades of testing thousands of turbo-machines. The test must fulfil the following purposes: a) Provide sufficient test data over the entire specified operational range for the quality approval procedure before delivery b) Provide documentation of the performance data and the performance range in terms of a graphic presentation to the customer c) Provide conditioned data/software for the automated power saving program of SV-type compressors d) Provide specific and statistical data as feedback for the compressor design program e) Ensure accurate, safe and fast registration of all relevant test data in the shortest possible testing time and at the lowest possible cost.

2.

National and International Standards/Norms It is mandatory that especially all logging and evaluation of performance data conform to the relevant national and international standards. HV-TURBO compressor testing procedures, as well as the testing equipment, instrumentation, and calibration are in conformity with the national and international norms of testing turbocompressors, as follows:

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ASME PTC 10-1997:

ITEM F

Performance Test Code on Compressors and Exhausters. (Please see § 4.3).

ASME PTC 10 – 1997:

Referenced Specifications:

ASME PTC 1 – 1999:

General Instructions

ASME PTC 2 – 2001:

Definitions and Values

ASME PTC 19.1 – 1998: Measurement Uncertainties ASME PTC 19.2 – 1987 – R: 1998: Pressure Measurement ASME PTC 19.3 – 1974 - R: 1998: Temperature Measurement ASME PTC 19.5 – 1972: Application Part II of Fluid Meters: Interim Supplement to PTC 19.5 on Instruments and Apparatus ASME PTC 19.7 – 1980 – R: 1988: Measurement of Shaft Power ASME PTC 19.13 – 1961: Measurement of Rotary Speed {Withdrawn by ASME.} ASME PTC 19.22 – 1986: Digital Systems Techniques ISO 5389: 1992

International standard: Turbocompressors - Performance Test Code.

VDI 2045 P1(E): 1993

Acceptance and Performance Tests on Turbo Compressors and Displacement Compressors. Test Procedure and Comparison With Guaranteed Values

API Standard 617 Seventh Edition, July 2002 Axial and Centrifugal Compressors and Expander-compressors for Petroleum, Chemical and Gas Industry Services ISO 5167-1: 1991/ Amd. 1:1998(E)

Measurement of Fluid Flow by Means of Pressure Differential Devices – Part 1: Orifice Plates, Nozzles and Venturi Tubes Inserted in Circular Cross-section Conduits Running Full

ISO 10816-1: 1995

Mechanical Vibration—Evaluation of Machine Vibration by Measurements on Non-Rotating Parts—Part 1: General Guidelines

ISO 3744: 1994

Acoustics—Determination of Sound Power Levels of Noise Sources Using Sound Pressure—Engineering Method in an Essentially Free Field Over a Reflecting Plane. Used under free field conditions.

ISO 3746: 1995

Acoustics—Determination of Sound Power Levels of Noise Sources Using Sound Pressure—Survey Method Using an Enveloping Measurement Surface Over a Reflecting Plane Used under non-free field conditions.

ISO 9000-2000

Quality Management Systems- Fundamentals and Vocabulary

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3.

TESTING OF TURBOCOMPRESSORS ASME PTC 10 - 1997 PROCEDURE OPTION: TORQUEMETER TEST

ITEM F

Measuring Equipment, Instrumentation, and Calibration 3.1

Methods of measuring and calculating ”PTC 10 – 1997 § 6.2.1.h & 6.2.6.a”. All results measured as calculated are based on the following: •

The test logs may be print outs resulting from an automatic data recording system; however they will be presented for the signature of witnessing parties Reference 3.14.

•

The test gas ambient air is treated as an ideal gas with constant specific heat, evaluated at the inlet. The test gas composition will not be measured. The computation of results will be via the Ideal Gas Method per section 5.2.1.

•

Pressure Transducer Calibration ( 4.6.5 ) All pressure transducers are calibrated on a yearly basis consistent with international metrology standards by an outside party.

•

Inlet Piping: ( 4.3.2 ) The inlet piping shall consist of an inlet filter silencer with foam covered lamella to reduce test stand noise. Four orthogonal temperature measurements are recorded upstream of the lamella. Inlet pressure is measured downstream of the lamella.

•

The partial pressure of water vapor is found using the steam tables: [ref. NBS/NCR Steam Tables ISBN 0-89116-353-0 paper] Reference 3.4.2

•

The Air specific heat ratio k = Cp/Cv are based on: VDI 2045 Part 2 formula (53) kf = k * (1 - 0,11* x), k = 1.4 for dry air, x = air humidity ratio. Reference: 3.4.2

•

Shaft power will be measured via torque meter installed at the compressor input shaft. Reference: 4.13.1

•

The compressor performance is based on ” Total ” pressure and temperature. Reference: 5.4.2.5 and 5.4.4.2. Calculation based on ”static” pressure and temperature will not be treated by HV-TURBO A/S.

•

The compressor performance is calculated according to an isentropic process. Reference Table 5.1 Calculations based upon a polytropic process will not be treated by HV-TURBO A/S.

•

All instruments, calculations, and equations utilize metric units. Values will be converted according to appendix H SI Units ASME PTC 10-1997.

•

The volume flow rate is based upon the mass flow rate, measured at the discharge. The leakage flow is not a part of this flow. There are no secondary flow streams. Reference 4.8.2.

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ITEM F

•

Witnessed testing is only to verify specified test point conditions, agreed upon prior to the test. Para. 3.11.4 in the PTC 10 – 1997 code will not be fulfilled; however the fluctuation of test readings will comply with table 3.4. The test procedure will be as described in § 4.3.1. Performance curves are not a part of the witnessed test. Performance curves will be measured during the Standard Shop Test.

•

Reference 4.8.1 ASME PTC-19.5 standard for flow measurement is based on the same type of equipment and the same physical laws as ISO 5167, but more complicated to handle due to non metric unites and traditional methods. For the evaluation of test results HV-TURBO has implemented the ISO 5167, which is assumed to be the most modern/updated standard, and which does not conflict with the PTC-19.5. ASME PTC19.5 is under review by ASME and draft versions reference ISO 5167 methods.

•

Specified Operating Conditions Notes Reference: 6.2.3 •

a) Gas composition and source for properties

•

b) Inlet gas state • • • •

•

c) Gas flow rate • • •

•

Total pressure Total temperature Total density Relative humidity

Discharge mass flow rate Inlet volume flow rate Capacity

•

d) Discharge total pressure

•

e) Coolant type, properties, flow rate, and temperature for cooled compressors

•

f) Speed

•

e) Others as needed

Expected Performance at specified Operating Conditions Notes Reference: 6.2.4 • • • • •

a) Developed head b) Efficiency c) Power requirement d) Discharge total temperature e) Other as needed

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3.2

TESTING OF TURBOCOMPRESSORS ASME PTC 10 - 1997 PROCEDURE OPTION: TORQUEMETER TEST

ITEM F

Flow Measurements All flow measurements during shop tests are carried out by means of straight, cylindrical measuring pipes on which the entry of each pipe is equipped with a straightener. The pipe length for inflow and outflow, the orifice plate design, and the pressure tappings are in accordance with the specified standards. At the exhaust of each pipe, an electrically activated throttle valve is installed in order to adjust the discharge pressure level. Four calibrated temperature probes measure the pipe inlet temperature. The measuring pipe is carefully insulated to avoid heat losses = temperature errors. Different pressure probes measure the pipe system pressure. For different flow rates, measuring pipes of different dimensions are installed on the test bed. The orifice plates are inspected, calibrated, sealed, and certified every year by the independent international inspection company SGS (Société Générale de Surveillance). The flow is computed from readings of pressure, temperature, and humidity. The method of computation is described in the above-mentioned standards ISO 5167/PTC-19.5.

3.2

Measuring Shaft Power. Direct Method by Torquemeter The torquemeter is an electronic torque-measuring coupling installed between the drive motor and the compressor. Different sizes of torquemeter couplings are available. The shaft power is computed from the measurement of torque and RPM. All torquemeter couplings are calibrated on standardized calibration rigs with certified plummets. Calibration of the torquemeter couplings is inspected and certified once a year by the SGS.

3.3

Temperature Measurement Four temperature probes at the compressor intake and four similar probes at the compressor discharge carry out standard temperature measurements. The probes are thermocouples of an industrial design, wired to a high precision digital display. All temperature probes and wires are marked for identification, sealed by SGS, and calibrated in a laboratory calibration device. The calibration is performed with reference to certified thermometers. The calibration of temperature probes, incl. wiring and display, is checked regularly and inspected and certified once a year by SGS.

3.4

Pressure Measurement In general, pressure measurements are carried out by means of high precision electronic transmitters with digital reading. These instruments are always calibrated. U-tubes with water or mercury filling are installed for the verification of these instruments.

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3.5

TESTING OF TURBOCOMPRESSORS ASME PTC 10 - 1997 PROCEDURE OPTION: TORQUEMETER TEST

ITEM F

Transmitters for the Automated Test Data Logging The test facility is equipped with fast logging multichannel data sampling units connected to the test bed computer system. All test data are converted into electronic data for automatic data logging. All transmitters involved are continuously checked and maintained in a correctly calibrated state.

3.6

ISO - 9000 Procedures HV-TURBO is operating a certified quality assurance system for a.o. Continuous calibration in conformity with the requirements of the international ISO 9000 standard. Also, this test procedure description including all stated commitments is a registered document within this quality system.

3.7

Certification In general, the a.m. certification of instrument calibration is carried out by SGS. For more than a decade, calibration of our test bed instruments have proven that calibration data for the same instruments do not change by more than what is expected within the specified instrument accuracy. SGS (Société Générale de Surveillance) is an independent international inspection company with head office in Geneva, Switzerland, and with more than 100 assigned SGSoffices, placed all over the world. SGS certificates issued for an HV-TURBO calibration or any office of the SGS organization can verify compressor test. If other calibration procedures are required, this must be specified in the contract or agreed upon within a suitable space of time prior to the scheduled testing.

4.

Test Procedures 4.1

Planning and Preparation of Test The head of the project department in cooperation with the production department and the engineers of the test department plan the schedule of testing. Each turbocompressor must pass the SST. If additional testing is specified, the test will be scheduled and the project department, well in advance, will inform the customer, as well as the test department.

4.2

Standard Shop Test (SST) This procedure has been developed from the experience of testing thousands of turbocompressors. Testing with atmospheric air will in general be conducted in an open loop test rig.

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4.2.1

TESTING OF TURBOCOMPRESSORS ASME PTC 10 - 1997 PROCEDURE OPTION: TORQUEMETER TEST

ITEM F

Mechanical/Operational Test Before starting the motor, the lubricating-oil system is put into operation and the safety controls are checked and adjusted. During the initial start-up, the labyrinth seals are run into their final operating shape, which is controlled by special procedures. During the first 15 minutes of operation, the compressor is running at low load and special attention is paid to the temperature rise of the bearing covers and the labyrinth seal flanges, as well as to the vibrations. During the SST, each compressor is operated at maximum design load, and all essential operating data are checked and recorded. The housings, flanges, and pipes, incl. the lube oil system, are checked for tightness. For single-stage turbocompressors, the duration of the SST is 6-18 operating hours, depending on the compressor type.

4.2.2

Performance Test This test is always performed and evaluated in accordance with the standards detailed under Item 2. The compressor is set up for testing and connected to the instrumentation of the automatic test bed data logging and processing. The compressor guide vane setting and the system pressure will be adjusted step by step to generate from 50 to 300 different operating points within a matrix of test data, where guide vane positions, head and flow figures are altered and combined systematically. The test data matrix is registered and computed individually for each compressor serial no., covering the specific design operating range. The data logging system is programmed to register data from calibrated instruments/transmitters. All data are checked for steady state conditions before acceptance. Registered data are averaged from four series of readings. The test matrix data are computed and evaluated versus the design data and will provide documentation for the quality approval procedure (ISO 9000). The test matrix data also provide the basic software for the specific compressor control system (option), which can automatically adjust the guide vanes to operate at best efficiency at required flow and head. Finally, the test matrix data provides basic data to document operating curves, as shown in the HV-Turbo Performance Certificate (pls. see § 5.1).

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4.2.3

TESTING OF TURBOCOMPRESSORS ASME PTC 10 - 1997 PROCEDURE OPTION: TORQUEMETER TEST

ITEM F

Vibration Measurements Vibration measurements, in vertical direction with an accelerometer mounted in a representative point, are carried out on each compressor at max. Load, and the actual RMS-value of the vibration velocity are recorded within the range 101000 Hz. The measurements must be evaluated and conform to ISO 10816-1, range limit 2.8 mm/s for max. Power below 400 kW and 4.5 mm/s for max. Power more than 400 kW. Furthermore, frequency analysis will be carried out, documented, and evaluated with reference to our experience from equivalent equipment.

4.2.4

Noise Measurements Noise measurements are carried out at least with one compressor of every order with equal design data in accordance with ISO 3746. A test bed assistant performs the sound pressure measurements and records the data on a test form. A test engineer evaluates the test data in relation to the specified data and data as measured on other compressors of equivalent design. If the compressor is packaged with the job motor, a noise certificate can be issued.

4.2.5

Approval and Preparation for Delivery The SST must meet the requirements of §1. Testing of electrical or electronic controls, connected to the compressor, is not part of the above. The adjustment, test, and inspection of electrical control panels are carried out in accordance with other quality assurance procedures. Having passed the SST with approval of the test results, the compressor is released for witnessed testing (if specified) and/or to be prepared for delivery. In case the test results are not approved of, a non-conforming compressor will be analyzed, reworked, and retested. The preparations for delivery will a.o. Include flushing of the gearbox, the bearings, etc. with corrosion-preventive oil, long-term preservation (if specified), final adjustments of electronic sensors, adjustment of the discharge flange for installation on site, painting/surface preparation, marking and packing up.

4.3

Additional Performance Testing: ASME PTC 10 - 1997 Specified operating data can be verified by interpolation of test data from the SST (pls. see § 4.2.2 and 5.1). If the verification of specific performance data in accordance with ASME PTC 10 – 1997 is a contractual requirement, the following options for additional testing can be offered:

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4.3.1

ITEM F

Witnessed Test This test will be witnessed by the customer or by a representative appointed by the customer. A precondition for setting up a witnessed test is that the SST has been finalized and SST data have been evaluated and approved by the test engineer. With uncooled single-stage turbocompressors or tandem driven compressors with externally piped intercooler for atmospheric air, the verification of guarantee points will be conducted as follows, if no other requirements are specified: -

The genuine compressor(s) of the order will be tested.

-

The test is conducted with atmospheric air.

-

A Type 1 test ( para. 3.2.1 ) is typically conducted. Atmospheric conditions on the day of the test control whether test points fall into a Type 1 or 2 category. We cannot control the inlet pressure or ambient temperature.

-

The test is conducted at specified RPM within a departure of ± 2%. Reference Table 3.1.

-

The compressor will be adjusted to the specified volumetric flow within a departure of ± 2%. Reference Table 3.1.

-

The discharge pressure will be adjusted equivalent to the specified isentropic head within a departure of ± 1%. Reference Table 3.1.

-

Recording of test data from calibrated instruments/ datalogger with a total uncertainty of measurement, calculated according to PTC 19.1 – 1998 within all limits of ISO 5389, table 5.

-

According to ASME PTC 10 – 1997: Recording of three complete sets of test data at steady state conditions for every operating point § 3.11.2. The minimum duration of a test point, after stabilization, shall be 15 minutes from the first set of readings to the third set § 3.11.3. Fluctuations of test readings to be within the figures of Table 3.4.

-

Computation of test data for every operating point with reference to specified operating data and in accordance with ASME PTC 10 – 1997 / § 5. With reference to API Standard 617 seventh edition, July 2002, Chapter 3, Integrally geared compressors § 4.3.3.1.2.: For variable speed or variable vane machines, head and capacity shall have zero negative tolerance at the normal operating point (or other point as specified), and the power at this point shall not exceed 104% of the vendor predicted shaft power value. This tolerance shall be inclusive of all test tolerances. Surge shall comply with provisions of 2.1.1.1.

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TESTING OF TURBOCOMPRESSORS ASME PTC 10 - 1997 PROCEDURE OPTION: TORQUEMETER TEST

Revision: 0 Page: 10 of (11)

ITEM F

If it is not possible to adjust the test data within the above limits, the spotted operating point will be bracketed ( ASME PTC 10 – 1997 / § 3.11.4 ). It is important that the witnessed performance test data are documented and signed by the inspector, and for this reason all test data will be verified from calibrated instruments and documented in a log sheet. During the test, the log sheet data will be computed for evaluation in accordance with the standards mentioned above. A print will document the performance data of the test points with reference to the specified guarantee conditions. The number of guarantee points to be tested must be specified in advance and the test must be scheduled. An experienced test engineer will always conduct a witnessed test in cooperation with the test bed foreman or his assistants. 4.3.2

Witnessed Certified Test This test will be witnessed by third party inspection, i.e. an inspector from an independent and neutral inspection company. The Inspection Company will on request issue a specific test certificate. The test procedure will be as described in § 4.3.1.

4.3.3

Certified Test An experienced HV-Turbo test engineer under the supervision of the HV-Turbo Quality Department will conduct this test. Test log sheets will be signed by the test engineer and stamped by the QA Department. The test procedure will be as described in § 4.3.1.

5.

Documentation 5.1

Standard Documentation In accordance with §1-b the test data of each compressor Serial No. are documented to the customer in terms of a graphic presentation, i.e. the HV-TURBO Performance Certificate. This certificate shows a relevant number of operational curves at different vane settings of the inlet guide vanes, the variable diffuser vanes, or a combination. The curves will show discharge pressure versus inlet volume flow and shaft power. The curves will relate to the specified operating conditions, and the curves will also be numbered in relation to the vane setting pointer on the scale at the compressor. Furthermore, curves of the recorded vibration analysis for each serial No. will be documented.

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TESTING OF TURBOCOMPRESSORS ASME PTC 10 - 1997 PROCEDURE OPTION: TORQUEMETER TEST

ITEM F

As regards compressors, which have been tested as a complete unit with their genuine motor, the noise measurements will be documented in accordance with the standards mentioned. If an ASME PTC 10 – 1997 Test has been specified, a test report will document selected guarantee points in accordance with ASME PTC 10 – 1997 Section 6 and this document 930030001UK. 5.2

Documentation from Witnessed Testing Log sheets with test data in accordance with instrument readings and printed computer evaluation from the same test data must be checked by the inspector and test engineer and signed by both persons. Each participant of the test will receive copies of the test documents as well as copies of the test rig system drawing and relevant copies of the instrument calibration certificates.

6.

Budget and Schedule of Additional Testing The HV-TURBO SST is mandatory and will always be conducted. The SST costs are included in the budget of a compressor order. All additional tests will be conducted in accordance with the requirements of the contract. As the manufacturing schedule and the cost budget of a compressor order can easily get out of control by unscheduled activities, we must avoid excessive and unscheduled testing. Optional or other additional testing must be agreed to and specified in the contract, so that we are able to plan, budget, schedule and conduct these activities to the satisfaction of our customers.

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HV-TURBO STANDARD COMPRESSOR TEST ITEM F

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1. 2. 3. 4. 5. 6.

Purpose National and International Standards Measuring Equipment, Instrumentation, and Calibration Test Procedures (Standard Shop Test (SST)/Witnessed Performance Test, etc.) Documentation Additional Testing

1.

Purpose All testing is performed in order to measure operating data for evaluation of conformity with specified data. Before delivery, each HV-TURBO compressor is tested in accordance with the HV-TURBO Standard Shop Test (SST) procedure. The test procedures have been developed from the experience of testing thousands of turbomachines during more than three (3) decades. The test must fulfill the following purposes: a) Provide sufficient test data over the entire specified operational range for the quality approval procedure before delivery. b) Provide documentation of the performance data and the performance range in terms of a graphic presentation to the customer. c) Provide conditioned data/software for the automated power saving program of SV-type compressors. d) Provide specific and statistic data as feedback for the compressor design program. e) Ensure accurate, safe, and fast registration of all relevant test data in the shortest possible testing time and at the lowest possible cost.

2.

National and International Standards/Norms HV-TURBO compressor testing procedures, as well as the testing equipment, instrumentation, and calibration are based on national and international standards as follows: ISO 5389:

International standard: Turbocompressors - Performance Test Code.

ISO 5167:

International standard: Measurement of Fluid Flow.

ISO 10816-1:

Mechanical Vibration of Machines.

ISO 3744:

Determination of Sound Power Levels of Noise Sources. If free-field conditions cannot be established, ISO 3746 will apply.

DIN 1952:

Durchflußmessung.

DIN 45635: (Teil 13)

Geräuschmessung an Maschinen (Verdräanger-, Turbo und Strahlverdichter)

VDI 2045:

Abnahme- und Leistungsversuche an Verdichtern.

VDI 2056:

Beurteilungsmaßstäbe für mechanische Schwingungen von Maschinen.

API Standard 672/4.3.4.1:

Packages, Integrally Geared Centrifugal Air Compressors for General Refinery Service: Combined Mechanical and Performance Test.

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HV-TURBO STANDARD COMPRESSOR TEST ITEM F

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Measuring Equipment, Instrumentation, and Calibration 3.1

Flow Measurements All flow measurements during shop tests are carried out by means of straight, cylindrical measuring pipes on which the entry of each pipe is equipped with a straightener. The pipe length for inflow and outflow, the orifice plate design, and the pressure tapping is in accordance with international standards. At the exhaust of each pipe, an electrically activated throttle valve is installed in order to adjust the discharge pressure level. The pipe inlet temperature is measured by four (4) calibrated temperature probes. The measuring pipe is carefully insulated to avoid heat losses = temperature errors. The pipe system pressure is measured by different pressure probes. For different flow rates, measuring pipes of different dimensions are installed on the test bed. The orifice plates are inspected, calibrated, sealed, and certified every year by the independent international inspection company SGS (Société Générale de Surveillance). The flow is computed from readings of pressure, temperature, and humidity in accordance with ISO 5167.

3.2

Temperature Measurement Temperature measurements are carried out by four (4) temperature probes at the compressor intake and four (4) similar probes at the compressor discharge. The probes are thermocouples of an industrial design, wired to a high precision digital display. All temperature probes and wires are marked for identification, sealed by SGS, and calibrated in a laboratory calibration device. The calibration is performed with reference to certified thermometers. The calibration of temperature probes (including wiring and display) is checked regularly, and inspected and certified once a year by SGS.

3.3

Pressure Measurement In general, pressure measurements are carried out by means of electronic transmitters with digital reading. These instruments are always calibrated by means of U-tube manometers. U-tubes with water or mercury filling are installed for the verification of the electronic instruments.

3.4

Shaft Power The shaft power is computed from the measurements of the energy input into the gas, the mass flow, the gear losses, and the bearing losses. Conversion of test results to guarantee conditions are done according to international standards.

3.5

Transmitters for the Automated Test Data Logging The test facility is equipped with fast-logging multi-channel data sampling units connected to the test bed computer system. All test data is converted into electronic data for automatic data logging. All transmitters involved are continuously checked and maintained in a correctly calibrated state.

3.6

ISO - 9001 Procedures HV-TURBO is operating a certified quality assurance system for a.o. continuous calibration in conformity with the requirements of the international ISO 9001 standard. Also, this test procedure description, including all stated commitments, is a registered document within this quality assurance system.

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HV-TURBO STANDARD COMPRESSOR TEST ITEM F

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Certification In general, the a.m. certification of instrument calibration is carried out by SGS once a year. For more than a decade, calibration of our test bed instruments has proven that calibration data for the same instruments does not change by more than what is expected, within the specified instrument accuracy. SGS (Société Générale de Surveillance) is an independent international inspection company with its head office in Geneva, Switzerland, and with more than 100 assigned SGS-offices, placed all over the world. SGS certificates issued for an HV-TURBO calibration or for specific compressor testing can be verified by any office of the SGS organization. If other calibration procedures are required, this must be specified in the contract or agreed upon within a suitable space of time prior to the scheduled testing.

4.

Test Procedures 4.1

Planning and Preparation of Test The schedule of testing is planned by the head of the project department in cooperation with the production department and the engineers of the test department. Each turbocompressor must pass the SST. If additional testing is specified, the test will be scheduled and the customer, as well as the test department, will be informed by the project department well in advance.

4.2

Stand Shop Test (SST)

4.2.1

Mechanical/Operational Test Testing with atmospheric air will, in general, be conducted in an open loop test rig. Before starting the motor, the lubricating-oil system is put into operation and the safety controls are checked and adjusted. During the initial start-up, the labyrinth seals are run into their final operating shape, which is controlled by special procedures. During the first 15 minutes of operation, the compressor is running at low load and special attention is paid to the temperature rise of the bearing covers and the labyrinth seal flanges, as well as to the vibrations. During the SST, each compressor is operated at maximum design load, and all essential operating data is checked and recorded. The housings, flanges, and pipes, including the lube oil system, are checked for tightness. For single-stage turbocompressors, the duration of the SST is 6-18 operating hours, depending on the compressor type.

4.2.2

Performance Test The compressor is set up for testing and connected to the instrumentation of the automatic test bed data logging and processing.

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HV-TURBO STANDARD COMPRESSOR TEST ITEM F

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The compressor guide vane setting and the system pressure will be adjusted step-by-step to generate from 50 to 300 different operating points within a matrix of test data, where guide vane positions, head and flow figures are altered and combined systematically. The test data matrix is registered and computed individually for each compressor serial no., covering the specific design operating range. The data logging system is programmed to register data from calibrated instruments/transmitters. All data is checked for steady state conditions before acceptance. Registered data is averaged from four (4) series of readings. The test matrix data is computed and evaluated versus the design data, and will provide documentation for the quality approval procedure (ISO 9001). The test matrix data also provides the basic software for the specific compressor control system (option), which can automatically adjust the guide vanes to operate at best efficiency at required flow and head. Finally, the test matrix data provides basic data to document operating curves as shown in the HV-Turbo Performance Certificate (please see § 5.1). 4.2.3

Vibration Measurements Vibration measurements, with an accelerometer mounted in a representative point, are carried out on each compressor at maximum load, so that the actual RMS-value of the vibration velocity is recorded within the range 10-1000 Hz. The measurements must be evaluated and conform to ISO 10816-1. Range limit 2,8 mm/s if maximum power is below 400 kW, and 4,5 mm/s if maximum power is more than 400 kW. Furthermore, frequency analysis will be carried out, documented, and evaluated.

4.2.4

Noise Measurements Noise measurements are carried out at least with one compressor of every order with equal design data in accordance with ISO 3744/3746. A test bed assistant performs the sound pressure measurements and records the data on a test form. A test engineer evaluates the test data in relation to the specified data, and data as measured on other compressors of equivalent design. If the compressor is packaged with the job motor, a noise certificate can be issued.

4.2.5

Approval and Preparation for Delivery The SST must meet the requirements of §1. Testing of electrical or electronic controls, connected to the compressor, is not part of the above. The adjustment, test, and inspection of electrical control panels are carried out in accordance with other quality assurance procedures. Having passed the SST with approval of the test results, the compressor is released for witnessed testing (if specified) and/or to be prepared for delivery. In case the test results are not approved, a non-conforming compressor will be analyzed, reworked, and retested. The preparation for delivery will a.o. include flushing of the gearbox, the bearings, etc. with corrosionpreventive oil, long-term preservation (if specified), final adjustments of electronic sensors, adjustment of the discharge flange for installation on site, painting/surface preparation, marking, and packing.

4.3

Additional Performance Testing Specified operating data can be verified by interpolation of test data from the SST (please see § 4.2.2 and 5.1).

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HV-TURBO STANDARD COMPRESSOR TEST ITEM F

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If the verification of selected guarantee points is a contractual requirement, the following options for additional testing can be offered. 4.3.1

Witnessed Test This test will be witnessed by the customer or by a representative appointed by the customer. A pre-condition for setting up a witnessed test is that the SST has been finalized, and SST data has been evaluated and approved by the test engineer. With non-cooled single-stage turbocompressors, or tandem driven compressors with externally piped intermediate cooler for atmospheric air, the verification of guarantee points will be conducted as follows, if no other requirements are specified: The genuine compressor(s) of the order will be tested. The test is conducted with atmospheric air. The test is conducted at specified RPM within a departure of + 4%. The compressor will be adjusted to the specified volumetric flow within a departure of +4%. The discharge pressure will be adjusted equivalent to the specified isentropic head within a departure of + 4%. Recording of test data from calibrated instruments with a total uncertainty of measurement within the limits of ISO 5389, Table 5. Recording of one (1) complete set of test data at steady state conditions for every operating point. Computation of test data for every operating point with reference to specified operating data and in accordance with ISO 5389, Diagram D8, and within the tolerances of - 0/+ 4% for flow, pressure, and power in accordance with API 672/4.3.4.1. If it is not possible to adjust the test data within the above limits, ISO 5389 §7.2.7 shall apply. If it is not possible to avoid fluctuation within + 1% of the average magnitude of the test data in question, ISO 5389 §7.2.8 shall apply. It is important the witnessed performance test data is approved and signed by the inspector, and for this reason, the test data will be read from the calibrated instruments and set down in a log sheet. During the test, the log sheet data will be computed for evaluation in accordance with the standards mentioned above. A print will document the performance data of the test points with reference to the specified guarantee conditions. The number of guarantee points to be tested must be specified in advance, and the test must be scheduled. A witnessed test will always be conducted by an experienced test engineer in cooperation with the test bed foreman or his assistants.

4.3.2

Witnessed Certified Test This test will be witnessed by third party inspection, i.e. an inspector from an independent and neutral inspection company. The inspection company will, on request, issue a specific test certificate.

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The test procedure will be as described in § 4.3.1. 4.3.2

Certified Test This test will be conducted by an experienced HV-TURBO test engineer under the supervision of the HVTURBO Quality Department. Test log sheets will be signed by the test engineer and stamped by the QA Department. The test procedure will be as described in § 4.3.1.

5.

Documentation 5.1

Standard Documentation In accordance with §1-b, the test data of each compressor’s serial number is documented to the customer in terms of a graphic presentation, i.e. the HV-TURBO Performance Certificate. The certificate shows a relevant number of operational curves at different vane settings of the inlet guide vanes, the variable diffuser vanes, or a combination. The curves will show discharge pressure versus inlet volume flow and shaft power. The curves will relate to the normal operating conditions, and the curves will also be numbered in relation to the vane setting pointer on the scale at the compressor. Furthermore, curves of the recorded vibration analysis for each serial number will be documented. As regards, compressors that have been tested as a complete unit with their genuine motor, the noise measurements will be documented in accordance with the standards mentioned. If additional performance testing has been specified, the test data will be documented as mentioned above.

5.2

Documentation from Witnessed Testing Log sheets with the test data and the computer evaluation print from the same test data must be checked by the inspector and test engineer, and signed by both persons. Each participant of the test will receive copies of the test documents, as well as copies of the test rig system drawing and relevant copies of the instrument calibration certificates.

6.

Budget and Schedule of Additional Testing The HV-TURBO SST is mandatory and will always be conducted. The SST costs are included in the budget of a compressor order. All additional tests will be conducted in accordance with the requirements of the contract. As the cost budget and schedule of a compressor order can easily get out of control by unscheduled activities, we must avoid excessive and unscheduled testing. Optional or other additional testing must be agreed to and specified in the contract, so that we are able to plan, budget, schedule, and conduct these activities to the satisfaction of our customers.

U:\Sub-O&M\Std Compressor Test Proc.doc

ITEM F

ITEM F.b

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Agenda Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 1

Page

1 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

General/Nameplate Information Rated Power:

4000

Number of Phases:

Rated Line Voltage:

6600

# Poles/Full Load RPM:

Rated Line Current:

288

Operating Frequency: Service Factor: Time Rating:

3 2 /

Phase Sequence:

Continuous

Enclosure:

WP2

Stator Number:

N/R

CCW

Rotor Number:

D094611-02

T1:T3:T2

Ambient Temp:

50

Rotation Direction (NDE):

1.15

5616

Wye

Winding:

60

3556

Frame:

LR kVA Code:

F

Insulation Class:

Summary of Customer Purchased Tests (Purchased Items are indicated with a Description :

)

NEMA Test Package

Standard Commercial Tests (Performed on All Machines) Resistance Measurements: Stator Winding, Heater and Temperature Detector Circuits Air Gap Measurement: Average Magnetic Center Determination(Sleeve Bearing Machines Only) Bearing Temperature Rise at Running Speed Shaft Voltage at Rated Voltage and Running Speed No Load Electrical Characteristics: Volts, Amps, KiloWatts No Load Vibration Measurements: Brackets and Shaft Final High Potential and/or Megger Test of Insulation Integrity Engineering Tests (Performed if Specified) IEEE 112, Method F(1) for Performance Determination No Load Saturation Characteristics Locked Rotor Test: 5 Voltage Settings at Rated Frequency 3 Voltage Settings at 25% Rated Frequency Dual Frequency Temperature Run Standard Options (Performed if Specified) Coast Down Vibration Plot Overspeed Test Speed Torque Supplemental Bearing Inspection Following No Load Vibration Test Sound Measurement per IEEE 85 Octave Band Sound Measurement per IEEE 85 1/3 Octave Band Sound Measurement per IEEE 85 Hot Vibration Bearing Modulation Residual Unbalance Vibration Spectrum (FFT) Analysis DC High Potential Test of Insulation Integrity One Point Locked Rotor Test

F

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 1

Page

2 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Resistance Measurements Line to Line Stator Resistance (at 25 Degrees C)

Measured Value (Ohms)

Line 1

0.1284

Line 2

0.1286

Line 3

0.1286

Average:

0.1285 0.1284

Max Deviation: Measurement Temperature (Deg C.): Max Deviation From Average (%):

23.54 -0.13

Soft Foot Measurements:

N/A Heater Resistance (if applicable):

Measured Value (Ohms)

Heater 1

16.48

Final One-Minute HI-POT and Insulation Resistance:

Stator Temp Detector Circuit (if applicable):

Final HI-POT (VAC)

Spec

Measured

Installed Temperature Detector: 100 Ohm Platinum (RTD)

Stator: ETD's: Space Heaters:

14200 Spec 1500 2200

14200 1500 2200

Final Insulation Resistance Value Stator: ETD's: Space Heaters:

Applied Volts

Resistance (MOhms)

5000 500 1000

3119.75 * 917 5620

Measured Value (Ohms) ETD 1: ETD 2: ETD 3: ETD 4: ETD 5: ETD 6: ETD 7:

112.43 112.56 112.31 112.35 112.35 112.40 112.50

Temperature (Degrees C): 31.33

* Resistance is corrected to 40 Deg C.

Note: Measurement Performed After Final HIPOT and Megger.

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 1

Page

3 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Air Gap Measurements

Measured Value (Inches)

Measured Value (mm)

Quadrant 1

0.115

2.921

Quadrant 2

0.110

2.794

Quadrant 3

0.110

2.794

Quadrant 4

0.115

2.921

Average

0.113

2.858

Maximum Deviation (%)

4.444

4.444

Measured Value (Inches)

Measured Value (mm)

Quadrant 1

0.110

2.794

Quadrant 2

0.110

2.794

Quadrant 3

0.105

2.667

Quadrant 4

0.110

2.794

Average

0.109

2.762

Maximum Deviation (%)

4.598

4.598

NonDriveEnd Air Gap

DriveEnd Air Gap

Magnetic Center Measured Value (inches)

Measured Value (mm)

5.500 139.700 Float In (Ref 1) 6.050 153.670 Float Out (Ref 1) 5.750 146.050 Magnetic Center (Ref 1) -0.025 -0.635 Magnetic Center Dev (Ref 2) 0.550 13.970 Total End Play Ref 1: Value determined by measuring distance from shaft shoulder to bearing housing face. Ref 2: Value determined with respect to Mid End Play Line, where: Mid End Play=1/2 * (Float Out - Float In) + Float In Mag Center Dev (Ref 2)=Magnetic Center(Ref 1) Mid End Play

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 1

4 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Bearing Temperature Rise at Running Speed

Final Run NonDrvEnd Brg Temp (Deg C)

41.00 44.10

DrvEnd Brg Temp (Deg C)

ITEM F.b

NonDrvEnd Thrust Temp (Deg C) DrvEnd Thrust Temp (Deg C) NonDrvEnd Ref Temp (Ref1 Deg C)

31.40

DrvEnd Ref Temp(Ref1 Deg C) NonDrvEnd Brg Temp Rise (Deg C)

31.80 9.60

DrvEnd Brg Temp Rise (Deg C)

12.30

NonDrvEnd Thrust Temp Rise (Deg C) DrvEnd Thrust Temp Rise (Deg C) Elapsed Running Time (Hrs)

1.00

NonDrvEnd Water Temp In DrvEnd Water Temp In NonDrvEnd Water Temp Out DrvEnd Water Temp Out NonDrvEnd Water GPM DrvEnd Water GPM NonDrvEnd Water PSI DrvEnd Water PSI NonDrvEnd Oil Temp In

31.40

DrvEnd Oil Temp In

DrvEnd Oil Temp Out

31.80 38.50 38.10

NonDrvEnd Oil GPM

0.60

DrvEnd Oil GPM

0.90

NonDrvEnd Oil Temp Out

NonDrvEnd Oil PSI

46.50

DrvEnd Oil PSI

34.30

Ref 1: Inlet oil temp if flood lube system, ambient if not flood lube. Ref 2: Inlet water temp if bearing cooled by water system, otherwise refer to ref 1

No Load Electrical Characteristics Frequency (Hz)

V T1:T2

V T2:T3

V T3:T1

A1

A2

A3

KiloWatts

60

6600.60

6606.00

6603.00

34.22

35.72

34.80

44.50

No Load RPM =

3600.00

Average No Load Line Volts =

6603.20

Average No Load Line Amps (I0)= 34.91

Direction of Rotation as Viewed from NonDriveEnd (as tested) = CCW

Shaft Voltage Measurement Performed at Rated Voltage and Running Speed

Bearing Inspection - Not Reqd

N/A Bearing Insulation (Meg Ohms) - Not Reqd

Shaft End to Shaft End Voltage= 0.2320

N/A

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 1

5 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Bearing Temperature Rise at Running Speed (Metric)

Final Run NonDrvEnd Brg Temp (Deg C)

41.00 44.10

DrvEnd Brg Temp (Deg C)

ITEM F.b

NonDrvEnd Thrust Temp (Deg C) DrvEnd Thrust Temp (Deg C) NonDrvEnd Ref Temp (Ref1 Deg C)

31.40

DrvEnd Ref Temp(Ref1 Deg C) NonDrvEnd Brg Temp Rise (Deg C)

31.80 9.60

DrvEnd Brg Temp Rise (Deg C)

12.30

NonDrvEnd Thrust Temp Rise (Deg C) DrvEnd Thrust Temp Rise (Deg C) Elapsed Running Time (Hrs)

1.00

NonDrvEnd Water Temp In DrvEnd Water Temp In NonDrvEnd Water Temp Out DrvEnd Water Temp Out NonDrvEnd Water LPM DrvEnd Water LPM NonDrvEnd Water PSI DrvEnd Water PSI NonDrvEnd Oil Temp In

31.40

DrvEnd Oil Temp In

31.80 38.50 38.10

NonDrvEnd Oil Temp Out DrvEnd Oil Temp Out NonDrvEnd Oil LPM

2.27

DrvEnd Oil LPM

3.41

NonDrvEnd Oil PSI

46.50

DrvEnd Oil PSI

34.30

Ref 1: Inlet oil temp if flood lube system, ambient if not flood lube. Ref 2: Inlet water temp if bearing cooled by water system, otherwise refer to ref 1

No Load Electrical Characteristics Frequency (Hz)

V T1:T2

V T2:T3

V T3:T1

A1

A2

A3

KiloWatts

60

6600.60

6606.00

6603.00

34.22

35.72

34.80

44.50

No Load RPM =

3600.00

Average No Load Line Volts =

6603.20

Average No Load Line Amps (I0)= 34.91

Direction of Rotation as Viewed from NonDriveEnd (as tested) = CCW

Shaft Voltage Measurement Performed at Rated Voltage and Running Speed

Bearing Inspection - Not Reqd

N/A Bearing Insulation (Meg Ohms) - Not Reqd

Shaft End to Shaft End Voltage= 0.2320

N/A

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

6 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Motor Number: 1

Vibration Test: No Load Final Specifications

Spec Type: NEMA

Displacement (mils p/p) UF 1/2 X 1X 2X

Velocity (in/sec) UF 1/2 X 1X 2X 0.1000

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket

Vertical

0.1000

(F) NonDriveEnd Bracket

XAxial

0.1000

(R) DriveEnd Bracket (R) DriveEnd Bracket

Horizontal Vertical

0.1000 0.1000

(R) DriveEnd Bracket

XAxial

0.1000

Shaft (F) NonDriveEnd

Horizontal

2.0000

Shaft (F) NonDriveEnd

Vertical

2.0000

Shaft (R) DriveEnd

Horizontal

2.0000

Shaft (R) DriveEnd

Vertical

2.0000

Measurements

Displacement (mils p/p) UF 1/2 X 1X 2X

Velocity (in/sec) UF 1/2 X 1X 2X 0.0710

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket (F) NonDriveEnd Bracket

Vertical XAxial

0.0670 0.0660

(R) DriveEnd Bracket

Horizontal

0.0690

(R) DriveEnd Bracket

Vertical

0.0750

(R) DriveEnd Bracket

XAxial

Shaft (F) NonDriveEnd

Horizontal

0.7320

Shaft (F) NonDriveEnd Shaft (R) DriveEnd

Vertical Horizontal

1.5200 0.8620

Shaft (R) DriveEnd

Vertical

1.1000

0.0620

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

7 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Motor Number: 1

Vibration Test (metric): No Load Final Specifications

Spec Type: NEMA

Displacement (mm) UF 1/2 X 1X 2X

Velocity (mm/sec) UF 1/2 X 1X 2X 2.5400

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket

Vertical

2.5400

(F) NonDriveEnd Bracket

XAxial

2.5400

(R) DriveEnd Bracket (R) DriveEnd Bracket

Horizontal Vertical

2.5400 2.5400

(R) DriveEnd Bracket

XAxial

2.5400

Shaft (F) NonDriveEnd

Horizontal

0.0508

Shaft (F) NonDriveEnd

Vertical

0.0508

Shaft (R) DriveEnd

Horizontal

0.0508

Shaft (R) DriveEnd

Vertical

0.0508

Measurements

Displacement (mm) UF 1/2 X 1X 2X

Velocity (mm/sec) UF 1/2 X 1X 2X 1.8034

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket (F) NonDriveEnd Bracket

Vertical XAxial

1.7018 1.6764

(R) DriveEnd Bracket

Horizontal

1.7526

(R) DriveEnd Bracket

Vertical

1.9050

(R) DriveEnd Bracket

XAxial

Shaft (F) NonDriveEnd

Horizontal

0.0186

Shaft (F) NonDriveEnd Shaft (R) DriveEnd

Vertical Horizontal

0.0386 0.0219

Shaft (R) DriveEnd

Vertical

0.0279

1.5748

ITEM F.b

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Agenda Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 2

Page

1 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/5/2009

General/Nameplate Information Rated Power:

4000

Number of Phases:

Rated Line Voltage:

6600

# Poles/Full Load RPM:

Rated Line Current:

288

Operating Frequency: Service Factor: Time Rating:

3 2 /

Phase Sequence:

Continuous

Enclosure:

WP2

Stator Number:

N/R

CCW

Rotor Number:

D094611-01

T1:T3:T2

Ambient Temp:

50

Rotation Direction (NDE):

1.15

5616

Wye

Winding:

60

3556

Frame:

LR kVA Code:

F

Insulation Class:

Summary of Customer Purchased Tests (Purchased Items are indicated with a Description :

)

NEMA Test Package

Standard Commercial Tests (Performed on All Machines) Resistance Measurements: Stator Winding, Heater and Temperature Detector Circuits Air Gap Measurement: Average Magnetic Center Determination(Sleeve Bearing Machines Only) Bearing Temperature Rise at Running Speed Shaft Voltage at Rated Voltage and Running Speed No Load Electrical Characteristics: Volts, Amps, KiloWatts No Load Vibration Measurements: Brackets and Shaft Final High Potential and/or Megger Test of Insulation Integrity Engineering Tests (Performed if Specified) IEEE 112, Method F(1) for Performance Determination No Load Saturation Characteristics Locked Rotor Test: 5 Voltage Settings at Rated Frequency 3 Voltage Settings at 25% Rated Frequency Dual Frequency Temperature Run Standard Options (Performed if Specified) Coast Down Vibration Plot Overspeed Test Speed Torque Supplemental Bearing Inspection Following No Load Vibration Test Sound Measurement per IEEE 85 Octave Band Sound Measurement per IEEE 85 1/3 Octave Band Sound Measurement per IEEE 85 Hot Vibration Bearing Modulation Residual Unbalance Vibration Spectrum (FFT) Analysis DC High Potential Test of Insulation Integrity One Point Locked Rotor Test

F

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 2

Page

2 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/5/2009

Resistance Measurements Line to Line Stator Resistance (at 25 Degrees C)

Measured Value (Ohms)

Line 1

0.1282

Line 2

0.1285

Line 3

0.1284

Average:

0.1283 0.1282

Max Deviation: Measurement Temperature (Deg C.): Max Deviation From Average (%):

24.00 -0.13

Soft Foot Measurements:

N/A Heater Resistance (if applicable):

Measured Value (Ohms)

Heater 1

16.56

Final One-Minute HI-POT and Insulation Resistance:

Stator Temp Detector Circuit (if applicable):

Final HI-POT (VAC)

Spec

Measured

Installed Temperature Detector: 100 Ohm Platinum (RTD)

Stator: ETD's: Space Heaters:

14200 Spec 1500 2200

14200 1500 2200

Final Insulation Resistance Value Stator: ETD's: Space Heaters:

Applied Volts

Resistance (MOhms)

5000 500 1000

4692.68 * 218000 278000

Measured Value (Ohms) ETD 1: ETD 2: ETD 3: ETD 4: ETD 5: ETD 6: ETD 7:

112.25 112.16 111.87 112.08 111.96 111.88 111.90

Temperature (Degrees C): 30.88

* Resistance is corrected to 40 Deg C.

Note: Measurement Performed After Final HIPOT and Megger.

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 2

Page

3 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/5/2009

Air Gap Measurements

Measured Value (Inches)

Measured Value (mm)

Quadrant 1

0.115

2.921

Quadrant 2

0.120

3.048

Quadrant 3

0.120

3.048

Quadrant 4

0.115

2.921

Average

0.118

2.985

Maximum Deviation (%)

4.255

4.255

Measured Value (Inches)

Measured Value (mm)

Quadrant 1

0.115

2.921

Quadrant 2

0.125

3.175

Quadrant 3

0.120

3.048

Quadrant 4

0.115

2.921

Average

0.119

3.016

Maximum Deviation (%)

8.421

8.421

NonDriveEnd Air Gap

DriveEnd Air Gap

Magnetic Center Measured Value (inches)

Measured Value (mm)

5.500 139.700 Float In (Ref 1) 6.050 153.670 Float Out (Ref 1) 5.780 146.812 Magnetic Center (Ref 1) 0.005 0.127 Magnetic Center Dev (Ref 2) 0.550 13.970 Total End Play Ref 1: Value determined by measuring distance from shaft shoulder to bearing housing face. Ref 2: Value determined with respect to Mid End Play Line, where: Mid End Play=1/2 * (Float Out - Float In) + Float In Mag Center Dev (Ref 2)=Magnetic Center(Ref 1) Mid End Play

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 2

4 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/5/2009

Bearing Temperature Rise at Running Speed

Final Run NonDrvEnd Brg Temp (Deg C)

42.20 44.80

DrvEnd Brg Temp (Deg C)

ITEM F.b

NonDrvEnd Thrust Temp (Deg C) DrvEnd Thrust Temp (Deg C) NonDrvEnd Ref Temp (Ref1 Deg C)

31.70

DrvEnd Ref Temp(Ref1 Deg C) NonDrvEnd Brg Temp Rise (Deg C)

30.30 10.50

DrvEnd Brg Temp Rise (Deg C)

14.50

NonDrvEnd Thrust Temp Rise (Deg C) DrvEnd Thrust Temp Rise (Deg C) Elapsed Running Time (Hrs)

8.28

NonDrvEnd Water Temp In DrvEnd Water Temp In NonDrvEnd Water Temp Out DrvEnd Water Temp Out NonDrvEnd Water GPM DrvEnd Water GPM NonDrvEnd Water PSI DrvEnd Water PSI NonDrvEnd Oil Temp In

31.70

DrvEnd Oil Temp In

DrvEnd Oil Temp Out

30.30 37.30 38.40

NonDrvEnd Oil GPM

0.70

DrvEnd Oil GPM

1.00

NonDrvEnd Oil Temp Out

NonDrvEnd Oil PSI

60.90

DrvEnd Oil PSI

40.40

Ref 1: Inlet oil temp if flood lube system, ambient if not flood lube. Ref 2: Inlet water temp if bearing cooled by water system, otherwise refer to ref 1

No Load Electrical Characteristics Frequency (Hz)

V T1:T2

V T2:T3

V T3:T1

A1

A2

A3

KiloWatts

60

6600.00

6602.40

6600.00

34.56

35.38

35.21

43.20

No Load RPM =

3600.00

Average No Load Line Volts =

6600.80

Average No Load Line Amps (I0)= 35.05

Direction of Rotation as Viewed from NonDriveEnd (as tested) = CCW

Shaft Voltage Measurement Performed at Rated Voltage and Running Speed

Bearing Inspection - Not Reqd

N/A Bearing Insulation (Meg Ohms) - Not Reqd

Shaft End to Shaft End Voltage= 0.1400

N/A

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 2

5 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/5/2009

Bearing Temperature Rise at Running Speed (Metric)

Final Run NonDrvEnd Brg Temp (Deg C)

42.20 44.80

DrvEnd Brg Temp (Deg C)

ITEM F.b

NonDrvEnd Thrust Temp (Deg C) DrvEnd Thrust Temp (Deg C) NonDrvEnd Ref Temp (Ref1 Deg C)

31.70

DrvEnd Ref Temp(Ref1 Deg C) NonDrvEnd Brg Temp Rise (Deg C)

30.30 10.50

DrvEnd Brg Temp Rise (Deg C)

14.50

NonDrvEnd Thrust Temp Rise (Deg C) DrvEnd Thrust Temp Rise (Deg C) Elapsed Running Time (Hrs)

8.28

NonDrvEnd Water Temp In DrvEnd Water Temp In NonDrvEnd Water Temp Out DrvEnd Water Temp Out NonDrvEnd Water LPM DrvEnd Water LPM NonDrvEnd Water PSI DrvEnd Water PSI NonDrvEnd Oil Temp In

31.70

DrvEnd Oil Temp In

30.30 37.30 38.40

NonDrvEnd Oil Temp Out DrvEnd Oil Temp Out NonDrvEnd Oil LPM

2.65

DrvEnd Oil LPM

3.79

NonDrvEnd Oil PSI

60.90

DrvEnd Oil PSI

40.40

Ref 1: Inlet oil temp if flood lube system, ambient if not flood lube. Ref 2: Inlet water temp if bearing cooled by water system, otherwise refer to ref 1

No Load Electrical Characteristics Frequency (Hz)

V T1:T2

V T2:T3

V T3:T1

A1

A2

A3

KiloWatts

60

6600.00

6602.40

6600.00

34.56

35.38

35.21

43.20

No Load RPM =

3600.00

Average No Load Line Volts =

6600.80

Average No Load Line Amps (I0)= 35.05

Direction of Rotation as Viewed from NonDriveEnd (as tested) = CCW

Shaft Voltage Measurement Performed at Rated Voltage and Running Speed

Bearing Inspection - Not Reqd

N/A Bearing Insulation (Meg Ohms) - Not Reqd

Shaft End to Shaft End Voltage= 0.1400

N/A

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

6 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/5/2009

Motor Number: 2

Vibration Test: No Load Final Specifications

Spec Type: NEMA

Displacement (mils p/p) UF 1/2 X 1X 2X

Velocity (in/sec) UF 1/2 X 1X 2X 0.1000

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket

Vertical

0.1000

(F) NonDriveEnd Bracket

XAxial

0.1000

(R) DriveEnd Bracket (R) DriveEnd Bracket

Horizontal Vertical

0.1000 0.1000

(R) DriveEnd Bracket

XAxial

0.1000

Shaft (F) NonDriveEnd

Horizontal

2.0000

Shaft (F) NonDriveEnd

Vertical

2.0000

Shaft (R) DriveEnd

Horizontal

2.0000

Shaft (R) DriveEnd

Vertical

2.0000

Measurements

Displacement (mils p/p) UF 1/2 X 1X 2X

Velocity (in/sec) UF 1/2 X 1X 2X 0.0440

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket (F) NonDriveEnd Bracket

Vertical XAxial

0.0230 0.0330

(R) DriveEnd Bracket

Horizontal

0.0160

(R) DriveEnd Bracket

Vertical

0.0440

(R) DriveEnd Bracket

XAxial

Shaft (F) NonDriveEnd

Horizontal

0.5050

Shaft (F) NonDriveEnd Shaft (R) DriveEnd

Vertical Horizontal

0.3820 1.1800

Shaft (R) DriveEnd

Vertical

1.0800

0.0330

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

7 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/5/2009

Motor Number: 2

Vibration Test (metric): No Load Final Specifications

Spec Type: NEMA

Displacement (mm) UF 1/2 X 1X 2X

Velocity (mm/sec) UF 1/2 X 1X 2X 2.5400

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket

Vertical

2.5400

(F) NonDriveEnd Bracket

XAxial

2.5400

(R) DriveEnd Bracket (R) DriveEnd Bracket

Horizontal Vertical

2.5400 2.5400

(R) DriveEnd Bracket

XAxial

2.5400

Shaft (F) NonDriveEnd

Horizontal

0.0508

Shaft (F) NonDriveEnd

Vertical

0.0508

Shaft (R) DriveEnd

Horizontal

0.0508

Shaft (R) DriveEnd

Vertical

0.0508

Measurements

Displacement (mm) UF 1/2 X 1X 2X

Velocity (mm/sec) UF 1/2 X 1X 2X 1.1176

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket (F) NonDriveEnd Bracket

Vertical XAxial

0.5842 0.8382

(R) DriveEnd Bracket

Horizontal

0.4064

(R) DriveEnd Bracket

Vertical

1.1176

(R) DriveEnd Bracket

XAxial

Shaft (F) NonDriveEnd

Horizontal

0.0128

Shaft (F) NonDriveEnd Shaft (R) DriveEnd

Vertical Horizontal

0.0097 0.0300

Shaft (R) DriveEnd

Vertical

0.0274

0.8382

ITEM F.b

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Agenda Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 3

Page

1 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

General/Nameplate Information Rated Power:

4000

Number of Phases:

Rated Line Voltage:

6600

# Poles/Full Load RPM:

Rated Line Current:

288

Operating Frequency: Service Factor: Time Rating:

3 2 /

Phase Sequence:

Continuous

Enclosure:

WP2

Stator Number:

N/R

CCW

Rotor Number:

D094611-03

T1:T3:T2

Ambient Temp:

50

Rotation Direction (NDE):

1.15

5616

Wye

Winding:

60

3556

Frame:

LR kVA Code:

F

Insulation Class:

Summary of Customer Purchased Tests (Purchased Items are indicated with a Description :

)

NEMA Test Package

Standard Commercial Tests (Performed on All Machines) Resistance Measurements: Stator Winding, Heater and Temperature Detector Circuits Air Gap Measurement: Average Magnetic Center Determination(Sleeve Bearing Machines Only) Bearing Temperature Rise at Running Speed Shaft Voltage at Rated Voltage and Running Speed No Load Electrical Characteristics: Volts, Amps, KiloWatts No Load Vibration Measurements: Brackets and Shaft Final High Potential and/or Megger Test of Insulation Integrity Engineering Tests (Performed if Specified) IEEE 112, Method F(1) for Performance Determination No Load Saturation Characteristics Locked Rotor Test: 5 Voltage Settings at Rated Frequency 3 Voltage Settings at 25% Rated Frequency Dual Frequency Temperature Run Standard Options (Performed if Specified) Coast Down Vibration Plot Overspeed Test Speed Torque Supplemental Bearing Inspection Following No Load Vibration Test Sound Measurement per IEEE 85 Octave Band Sound Measurement per IEEE 85 1/3 Octave Band Sound Measurement per IEEE 85 Hot Vibration Bearing Modulation Residual Unbalance Vibration Spectrum (FFT) Analysis DC High Potential Test of Insulation Integrity One Point Locked Rotor Test

F

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 3

Page

2 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Resistance Measurements Line to Line Stator Resistance (at 25 Degrees C)

Measured Value (Ohms)

Line 1

0.1284

Line 2

0.1286

Line 3

0.1286

Average:

0.1285 0.1284

Max Deviation: Measurement Temperature (Deg C.): Max Deviation From Average (%):

23.41 -0.12

Soft Foot Measurements:

N/A Heater Resistance (if applicable):

Measured Value (Ohms)

Heater 1

16.52

Final One-Minute HI-POT and Insulation Resistance:

Stator Temp Detector Circuit (if applicable):

Final HI-POT (VAC)

Spec

Measured

Installed Temperature Detector: 100 Ohm Platinum (RTD)

Stator: ETD's: Space Heaters:

14200 Spec 1500 2200

14200 1500 2200

Final Insulation Resistance Value Stator: ETD's: Space Heaters:

Applied Volts

Resistance (MOhms)

5000 500 1000

3211.39 * 1860 6130

Measured Value (Ohms) ETD 1: ETD 2: ETD 3: ETD 4: ETD 5: ETD 6: ETD 7:

110.66 110.51 110.73 110.69 110.74 110.73 110.74

Temperature (Degrees C): 26.85

* Resistance is corrected to 40 Deg C.

Note: Measurement Performed After Final HIPOT and Megger.

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 3

Page

3 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Air Gap Measurements

Measured Value (Inches)

Measured Value (mm)

Quadrant 1

0.120

3.048

Quadrant 2

0.125

3.175

Quadrant 3

0.125

3.175

Quadrant 4

0.120

3.048

Average

0.123

3.112

Maximum Deviation (%)

4.082

4.082

Measured Value (Inches)

Measured Value (mm)

Quadrant 1

0.120

3.048

Quadrant 2

0.125

3.175

Quadrant 3

0.125

3.175

Quadrant 4

0.120

3.048

Average

0.123

3.112

Maximum Deviation (%)

4.082

4.082

NonDriveEnd Air Gap

DriveEnd Air Gap

Magnetic Center Measured Value (inches)

Measured Value (mm)

5.470 138.938 Float In (Ref 1) 6.020 152.908 Float Out (Ref 1) 5.750 146.050 Magnetic Center (Ref 1) 0.005 0.127 Magnetic Center Dev (Ref 2) 0.550 13.970 Total End Play Ref 1: Value determined by measuring distance from shaft shoulder to bearing housing face. Ref 2: Value determined with respect to Mid End Play Line, where: Mid End Play=1/2 * (Float Out - Float In) + Float In Mag Center Dev (Ref 2)=Magnetic Center(Ref 1) Mid End Play

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 3

4 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Bearing Temperature Rise at Running Speed

Final Run NonDrvEnd Brg Temp (Deg C)

42.80 45.30

DrvEnd Brg Temp (Deg C)

ITEM F.b

NonDrvEnd Thrust Temp (Deg C) DrvEnd Thrust Temp (Deg C) NonDrvEnd Ref Temp (Ref1 Deg C)

32.50

DrvEnd Ref Temp(Ref1 Deg C) NonDrvEnd Brg Temp Rise (Deg C)

33.10 10.30

DrvEnd Brg Temp Rise (Deg C)

12.20

NonDrvEnd Thrust Temp Rise (Deg C) DrvEnd Thrust Temp Rise (Deg C) Elapsed Running Time (Hrs)

1.47

NonDrvEnd Water Temp In DrvEnd Water Temp In NonDrvEnd Water Temp Out DrvEnd Water Temp Out NonDrvEnd Water GPM DrvEnd Water GPM NonDrvEnd Water PSI DrvEnd Water PSI NonDrvEnd Oil Temp In

32.50

DrvEnd Oil Temp In

DrvEnd Oil Temp Out

33.10 37.70 40.00

NonDrvEnd Oil GPM

0.60

DrvEnd Oil GPM

1.00

NonDrvEnd Oil Temp Out

NonDrvEnd Oil PSI

46.60

DrvEnd Oil PSI

34.00

Ref 1: Inlet oil temp if flood lube system, ambient if not flood lube. Ref 2: Inlet water temp if bearing cooled by water system, otherwise refer to ref 1

No Load Electrical Characteristics Frequency (Hz)

V T1:T2

V T2:T3

V T3:T1

A1

A2

A3

KiloWatts

60

6600.00

6607.20

6601.20

34.73

35.59

34.91

42.98

No Load RPM =

3600.00

Average No Load Line Volts =

6602.80

Average No Load Line Amps (I0)= 35.08

Direction of Rotation as Viewed from NonDriveEnd (as tested) = CCW

Shaft Voltage Measurement Performed at Rated Voltage and Running Speed

Bearing Inspection - Not Reqd

N/A Bearing Insulation (Meg Ohms) - Not Reqd

Shaft End to Shaft End Voltage= 0.1520

N/A

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

Motor Number: 3

5 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Bearing Temperature Rise at Running Speed (Metric)

Final Run NonDrvEnd Brg Temp (Deg C)

42.80 45.30

DrvEnd Brg Temp (Deg C)

ITEM F.b

NonDrvEnd Thrust Temp (Deg C) DrvEnd Thrust Temp (Deg C) NonDrvEnd Ref Temp (Ref1 Deg C)

32.50

DrvEnd Ref Temp(Ref1 Deg C) NonDrvEnd Brg Temp Rise (Deg C)

33.10 10.30

DrvEnd Brg Temp Rise (Deg C)

12.20

NonDrvEnd Thrust Temp Rise (Deg C) DrvEnd Thrust Temp Rise (Deg C) Elapsed Running Time (Hrs)

1.47

NonDrvEnd Water Temp In DrvEnd Water Temp In NonDrvEnd Water Temp Out DrvEnd Water Temp Out NonDrvEnd Water LPM DrvEnd Water LPM NonDrvEnd Water PSI DrvEnd Water PSI NonDrvEnd Oil Temp In

32.50

DrvEnd Oil Temp In

33.10 37.70 40.00

NonDrvEnd Oil Temp Out DrvEnd Oil Temp Out NonDrvEnd Oil LPM

2.27

DrvEnd Oil LPM

3.79

NonDrvEnd Oil PSI

46.60

DrvEnd Oil PSI

34.00

Ref 1: Inlet oil temp if flood lube system, ambient if not flood lube. Ref 2: Inlet water temp if bearing cooled by water system, otherwise refer to ref 1

No Load Electrical Characteristics Frequency (Hz)

V T1:T2

V T2:T3

V T3:T1

A1

A2

A3

KiloWatts

60

6600.00

6607.20

6601.20

34.73

35.59

34.91

42.98

No Load RPM =

3600.00

Average No Load Line Volts =

6602.80

Average No Load Line Amps (I0)= 35.08

Direction of Rotation as Viewed from NonDriveEnd (as tested) = CCW

Shaft Voltage Measurement Performed at Rated Voltage and Running Speed

Bearing Inspection - Not Reqd

N/A Bearing Insulation (Meg Ohms) - Not Reqd

Shaft End to Shaft End Voltage= 0.1520

N/A

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

6 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Motor Number: 3

Vibration Test: No Load Final Specifications

Spec Type: NEMA

Displacement (mils p/p) UF 1/2 X 1X 2X

Velocity (in/sec) UF 1/2 X 1X 2X 0.1000

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket

Vertical

0.1000

(F) NonDriveEnd Bracket

XAxial

0.1000

(R) DriveEnd Bracket (R) DriveEnd Bracket

Horizontal Vertical

0.1000 0.1000

(R) DriveEnd Bracket

XAxial

0.1000

Shaft (F) NonDriveEnd

Horizontal

2.0000

Shaft (F) NonDriveEnd

Vertical

2.0000

Shaft (R) DriveEnd

Horizontal

2.0000

Shaft (R) DriveEnd

Vertical

2.0000

Measurements

Displacement (mils p/p) UF 1/2 X 1X 2X

Velocity (in/sec) UF 1/2 X 1X 2X 0.0360

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket (F) NonDriveEnd Bracket

Vertical XAxial

0.0540 0.0480

(R) DriveEnd Bracket

Horizontal

0.0360

(R) DriveEnd Bracket

Vertical

0.0290

(R) DriveEnd Bracket

XAxial

Shaft (F) NonDriveEnd

Horizontal

0.3370

Shaft (F) NonDriveEnd Shaft (R) DriveEnd

Vertical Horizontal

0.4190 0.6850

Shaft (R) DriveEnd

Vertical

0.7500

0.0310

ITEM F.b

TECO-Westinghouse Motor Company - FINAL REPORT Page

Horizontal Induction Motor Test Report Shop Order: 0Q01AA TURBLEX Customer:

7 of 7

Electrical Engineer: Okoye, Latetia Test Date: 6/8/2009

Motor Number: 3

Vibration Test (metric): No Load Final Specifications

Spec Type: NEMA

Displacement (mm) UF 1/2 X 1X 2X

Velocity (mm/sec) UF 1/2 X 1X 2X 2.5400

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket

Vertical

2.5400

(F) NonDriveEnd Bracket

XAxial

2.5400

(R) DriveEnd Bracket (R) DriveEnd Bracket

Horizontal Vertical

2.5400 2.5400

(R) DriveEnd Bracket

XAxial

2.5400

Shaft (F) NonDriveEnd

Horizontal

0.0508

Shaft (F) NonDriveEnd

Vertical

0.0508

Shaft (R) DriveEnd

Horizontal

0.0508

Shaft (R) DriveEnd

Vertical

0.0508

Measurements

Displacement (mm) UF 1/2 X 1X 2X

Velocity (mm/sec) UF 1/2 X 1X 2X 0.9144

Location (F) NonDriveEnd Bracket

Direction Horizontal

(F) NonDriveEnd Bracket (F) NonDriveEnd Bracket

Vertical XAxial

1.3716 1.2192

(R) DriveEnd Bracket

Horizontal

0.9144

(R) DriveEnd Bracket

Vertical

0.7366

(R) DriveEnd Bracket

XAxial

Shaft (F) NonDriveEnd

Horizontal

0.0086

Shaft (F) NonDriveEnd Shaft (R) DriveEnd

Vertical Horizontal

0.0106 0.0174

Shaft (R) DriveEnd

Vertical

0.0191

0.7874

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

ITEM F FUNCTIONAL/ON-SITE TEST PROCEDURE I)

TEST SET-UP (Turblex Shop) • Interconnect Wiring The blower package, remote mount control panels, and all electrical accessories will be properly electrically connected. • Lubrication The oil reservoir will be filled with sufficient oil for the oil pump to properly function.

II)

PRELIMINARY CHECK-OUT (Turblex Shop) All switches and transmitters will be checked to verify the proper signal is being received by the LCP and calibrated as required.

III)

ROTATIONAL/OPERATIONAL CHECK-OUT (Turblex Shop) All motors (except main drive motor) and actuators will be operated one (1) at a time to ensure proper rotation and/or operation.

IV)

FUNCTIONAL TEST (Turblex Shop) Each of the following operating sequences and alarm/functions will be tested to verify that proper sequences and shutdown procedures are followed for proper operation. Manually tripping the switches and manipulating the PLC setpoints will be utilized to simulate the alarms. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)

V)

Service Mode Operations Normal Start Sequence Normal Stop Sequence Soft Stop Sequence Emergency Stop Sequence Soft Stop Alarms Emergency Stop Alarms Sequence Failure Alarm Warning Alarms Alarm Acknowledge Alarm Reset

ON-SITE PREPARATION (Pre-Startup Checklist) Prior to Turblex start-up service, all mechanical and electrical connections must be completed by contractor. Also, the “Compressor (Blower) Pre-Startup Inspection Checklist” must be completely filled out and returned to Turblex with a request for start-up service.

ITEM F FUNCTIONAL/ON-SITE TEST PROCEDURE VI)

ON-SITE TESTING Turblex' start-up personnel will make a preliminary inspection in order to verify that the contractor is ready for start-up services. Should the contractor not be ready for start-up, personnel will notify all parties and return to their home office. The contractor will be billed for Turblex services provided at the time. Should the Turblex inspection pass, start-up will continue until completed. All items of Sections II and III will be repeated prior to unit start-up. In addition, signals from the field-connected items will be checked. Items 1 through 5 of Section IV will also be repeated prior to start-up with the LCP in "TEST" mode. These and any other checks as deemed necessary by the Turblex Start-Up Engineer will be completed prior to unit start-up. The motor to blower coupling will be removed, alignment checked, and the motor started and run for a minimum of one (1) hour to verify its operation and rotation. The coupling will then be reinstalled. The initial start will be aborted after the motor has reached full speed. The Turblex Start-Up Engineer will be looking and listening for abnormal items. Upon successful completion of these steps, the unit will be started and allowed to run for about 12 hours, being observed for anything abnormal.

Z:\Submittal_O&M\Master_Sub\Item_F_Testing\Source_Docs\Functional_On-Site_Test_Proc.doc

2

FORM: REV: REV DATE: APPRVD. BY:

98012802.QAS 7 6/15/07

COMPRESSOR (BLOWER) PRE-STARTUP INSPECTION CHECKLIST 1635 W. Walnut Street Springfield, MO 65806 Ph: 417-864-5599/Fax: 417-866-0235 ITEM G

Document Name: 4607T-Item G Rev 0

PAGE 1 OF 2 SCOPE:

The following items must be completed by the Installing Contractor prior to start-up of Turblex-supplied equipment. All items must be signed-off as completed, inspected, and accepted (for EACH unit) with a signed copy forwarded (via mail or fax) to Turblex before start-up is intiated by Turblex. Advance notification of 10 working days is requested for scheduling and making travel arrangements for Turblex start-up personnel to proceed to the jobsite. Upon arrival at the jobsite, delays in start-up work or additional visits to the jobsite specifically caused by deficient or uncompleted items detailed in this document will be invoiced in accordance with Turblex's standard service rate schedule (copy attached). Mechanical Items (To Be Completed by the Contractor) Turblex Compressor Serial Number Customer Compressor ID Number

Blower S/N Checkmark to Confirm N/A if Not Applicable 8144

8145

8146

1. Blower mounted and leveled on vibration isolators 2. Inlet and discharge of blowers certified clean of debris 3. Inlet filter silencer installed 4. Inlet flex connector installed 5. Air filter elements installed 6. Inlet air piping clean/certified of all dirt, rust, sand, etc. 7. Discharge expansion joint installed within manufacturer's limits 8. Discharge diffuser cone installed Discharge check valve installed per manufacturer's 9. recommendation 10. Discharge isolation valve(s) installed 11. Downstream air piping supported and clear for blower air flow 12. Blow-off valve installed 13. Blow-off silencer installed 14. Blow-off piping supported & restrained properly to prevent motion 15. Blow-off discharge area clear of ladders, trash, etc. 16. Water piping installed 17. Water pressure available between 60-150 PSIG 18. Water drain path clear 19. Shipped loose oil cooler installed and oil piping connected to blower skid lube system 20. Compressor oil reservoir filled with oil per manufacturer's specification - Type oil used: __________ 21. Motor oil/grease reservoir filled with lubricant per manufacturer's specification 22. Pressure line tubing from high side of differential pressure transmitter attached to total pressure tap in discharge cone 23. Pressure line tubing from low side of differential pressure transmitter attached to inlet piping or filter silencer shroud 24. Shipped loose pressure and temperature transmitters installed 25. Shipped loose pressure and temperature gauges installed 26. Shipped loose sound enclosure installed 27. Clean area in the vicinity of the blowers Blower S/N Electrical Items (To Be Completed by the Contractor) 1. Power for main motor live to MCC 2. Main motor MCC feedback wired and start/stop wiring dry checked 3. If MCC has the capability of starting the motor locally, please remove this capability and verify that it has been done 4. If PFCC is provided for the motor, verify interconnect wiring is complete

Checkmark to Confirm N/A if Not Applicable

FORM:

98012802.QAS

REV: REV DATE: APPRVD. BY:

COMPRESSOR (BLOWER) PRE-STARTUP

7 6/15/07

INSPECTION CHECKLIST 1635 W. Walnut Street Springfield, MO 65806 Ph: 417-864-5599/Fax: 417-866-0235

PAGE 2 OF 2

ITEM G Electrical Items (Continued) (To Be Completed by the Contractor)

Blower S/N Checkmark to Confirm N/A if Not Applicable

5. Main drive motor interconnect wiring integrity verified via Megger or Hi Pot 6. Main motor Smart relay [Westinghouse IQ 1000, or equal] programmed and ready for start 7. Skid is grounded per NEC Article: 250 8. Main motor power leads are enclosed in liquid-tite from stub up to motor terminal box 9. All interconnection between remote mount local control panel (LCP) and skid is complete per "As Built" drawings 10. All interconnection between local control panel (LCP) and blow-off valve and discharge valve is complete per "As Built" drawings 11. All interconnection between local control panel (LCP) and field instrument is complete per "As Built" drawings 12. Auxiliary oil pumps are connected to control panel or other source, as applicable 13. All interconnection between local control panel and sound enclosure 14. Supply power is run to all control panels 15. Supply power is run to blow-off valve and discharge valve 16. Control power is run to blow-off valve and discharge valve 17. Remote transmitters are connected to respective control panels 18. Control panel to DCS wires are connected 19. Communication cable installed 20. Control panel, oil pump, valve and instrument supply power available for service 21. Forward completed storage requirement log, if applicable ALL ITEMS PER THIS CHECKLIST HAVE BEEN COMPLETED AND START-UP OF TURBLEX-SUPPLIED EQUIPMENT IS AUTHORIZED Contractor/Customer: Signature:

____________________________________

Date: ____________________

X:\ISO9001_2000\Revisions_In_Progress\ENG_Compressor_Pre-Startup_Inspection_Checklist.xls

ITEM H Document Name: 4607T-Item H Rev 0

LIMITED WARRANTY WARRANTY For the benefit of the original user only, Turblex warrants that the equipment and software of our manufacture will be free from defects in material and workmanship when installed, operated and maintained under design conditions and in accordance with our written instructions. Turblex will replace or repair, FOB our factories or other locations designated by us, any parts or defective software returned which examination shall show it to have failed under normal use and service by the original user, normal wear and tear excepted. Warranties will expire eighteen (18) months after shipment or twelve (12) months after start-up (which shall be the Turblex certified date the equipment is available for beneficial use), whichever occurs first. Expendable items such as V-belts and filter media are excluded from this warranty. This warranty, including the stated remedies, is expressly made by Turblex and accepted by Purchaser in lieu of all other warranties, and Turblex disclaims any implied warranty of merchantability or fitness for any particular purpose. We will not be liable for any consequential, incidental, or liquidated damages, and in no event shall be liable for any amount in excess of the purchase price of the equipment. This warranty shall not apply to equipment or parts thereof which have been altered or repaired outside of a Turblex factory, or damaged by improper installation, application, erosion or corrosion of any sort, or subjected to misuse, abuse, neglect, or accident. Turblex will make no allowance or reimbursement for repairs, alterations, replacements or work of any kind, done or ordered by others without Turblex' prior, written authorization. This warranty does not include any installation, removal, or freight expenses that might be associated with warranty repair or replacement. Repair, replacement, or refund of the purchase price by Turblex, at our sole option, shall be the exclusive remedy for breach of this warranty. Turblex makes no warranty with respect to parts, accessories, or components manufactured by others. The warranty applicable to such items is that offered by their respective manufacturers and will be passed through Turblex to the original user. Turblex warrants for each item of Technical Services that (i) the advice, recommendations and performance of its personnel will reflect competent knowledge and judgment and (ii) the technical information, reports and analyses transmitted by Turblex will reflect competent knowledge and judgment, beginning with the start of the item of Technical Services and ending one (1) year after completion of Technical Services by Turblex (the “Technical Services Warranty Period”). If during the Technical Services Warranty Period, Turblex is promptly notified in writing that any portion of the Technical Services fails to conform to the Technical Services Warranty, Turblex will promptly reperform the nonconforming portion of the Technical Services. The purchaser shall supply, at their own expense, all labor, material, replacement parts (other than defective parts still covered by warranty), tools (other than special tools and instruments which must be supplied by Turblex), equipment cranes, rigging tools, outside balancing/machining, and facilities required to perform the physical work on the equipment. Free and clear access to the equipment shall be provided for Turblex warranty repair work. STARTUP AND SERVICE Unless specifically stated in our quotation, installation, startup, service supervision, and training are not included in our pricing. These responsibilities shall be the exclusive responsibility of the Purchaser. A trained factory serviceman is available at the rate stated in our quotation and/or Turblex' standard Service Rate Schedule, with all travel and living expenses billed accordingly. Service charges are based on a standard eight (8) hour workday with time charged from date of departure from his home office to the date of his return. Overtime, travel time, hold time and weekend travel will be charged per our quotation and/or Turblex' standard Service Rate Schedule.

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone: (417) 864-5599 Facsimile: (417) 866-0235

Z:\Submittal_O&M\Master_Sub\Item_H_Warranty\Source_Docs\Warranty.DOC

April 2007

Document Name: 4607T COMP LIST Rev C

JOB NO. TURBLEX TID

4607T Unit 1 Tags

Unit 2 Tags

Common Unit Tags

COMPONENTS LIST

ITEM I

DESCRIPTION

TURBLEX P/N

QUANTITY

COMPRESSOR & MAIN MOTOR 0010

3

COMPRESSOR/GEARBOX:

0020

AF1-SOP-MKL-03

AF2-SOP-MKL-03

AFC-SOP-MKL-03

3

MAIN MOTOR: 4000 HP, 3600 RPM, 6600/60/3

0040

AF1-SOP-TQ

AF2-SOP-TQ

AFC-SOP-TQ

3

OIL RESERVOIR

3

COUPLING

0070

KA66S-GL400

4607TBLWR 4607TMTR 4607TCPLG

INLET & DISCHARGE ACCESSORIES 0100

3

SOUND ENCLOSURE

0110

AF1-SOP-FILT-01

AF2-SOP-FILT-01

AFC-SOP-FILT-01

3

INLET LOUVER: 152" H x 156" W

4607TLVR

0130

AF1-SOP-SIL-01

AF2-SOP-SIL-01

AFC-SOP-SIL-01

3

DISCHARGE INLINE SILENCER

4607TSIL30

0140

AF1-SOP-SIL-02

AF2-SOP-SIL-02

AFC-SOP-SIL-02

3

BLOW-OFF SILENCER: 10"

0160

AF1-SOP-FILT-01

AF2-SOP-FILT-01

AFC-SOP-FILT-01

3

INLET FILTER/SILENCER: 4H X 6W

0200

42

VIBRATION ISOLATOR: XLW-3000

0300

3

INLET SPOOL PIECE

0310

AF1-SOP-FILT-01

AF2-SOP-FILT-01

AFC-SOP-FILT-01

4607TSE

71575 4607TIFS 74420 4607TSPOOL

3

INLET PLENUM

0320

3

DISCHARGE CONE/SILENCER: 16" X 30" WITH 10" BOV

4607TPLNM 71677

0405

6

INLET FLEX CONNECTOR: 46.75"

74138

0430

AF1-SOP-JUNEX

AF2-SOP-JUNEX

AFC-SOP-JUNEX

3

EXPANSION JOINT: 16"

0520

AF1-SOP-VV-BOFF1

AF2-SOP-VV-BOFF1

AFC-SOP-VV-BOFF1

3

BLOW-OFF VALVE: 10", 480/60/3

4607TBTRVLV10

4607TEJ

0530

AF1-SOP-VV-BRBA-02

AF2-SOP-VV-BRBA-02

2

DISCHARGE VALVE: 30", 480/60/3

4607TBTRVLV30

0530

AFC-SOP-VV-BRBA-03

1

CROSS-OVER DISCHARGE VALVE: 30", 480/60/3

4607TBTRVLV30

0530

AFC-SOP-VV-BRBA-04

1

CROSS-OVER DISCHARGE VALVE: 30", 480/60/3

4607TBTRVLV30

AFC-SOP-VV-RET-01

3

CHECK VALVE:

0540

AF1-SOP-VV-RET-01

AF2-SOP-VV-RET-01

30"

73676 LUBE OIL COOLER

0705

AF1-SOP-BB-LUB-02

AF2-SOP-BB-LUB-02

AFC-SOP-BB-LUB-02

3

AUXILIARY OIL PUMP, 54.6 GPM

70818

0705

AF1-SOP-MKL-2

AF2-SOP-MKL-2

AFC-SOP-MKL-2

3

AUXILIARY OIL PUMP MOTOR, 10 HP

71411

0740

AF1-SOP-FILT-02

AF2-SOP-FILT-02

AFC-SOP-FILT-02

3

OIL FILTER, DUPLEX WITH VISUAL & ELECTRICAL INDICATOR

74103

0750

AF1-SOP-PRV-3101

AF2-SOP-PRV-3201

AFC-SOP-PRV-3301

3

OIL RELIEF VALVE, 1.5" 300# FLANGE, SET @ 120 PSI

73079

0770

AF1-SOP-LI-3101

AF2-SOP-LI-3201

AFC-SOP-LI-3301

3

LUBE OIL LEVEL INDICATOR

77519

3

OIL RESERVOIR BREATHER

4607TBREATHER

0772 0780

AF1-SOP-TCV-01

AF2-SOP-TCV-01

AFC-SOP-TCV-01

3

o OIL TEMPERATURE CONTROL VALVE: SET @ 110 F

78457

0785

AF1-SOP-PCV-3101

AF2-SOP-PCV-3201

AFC-SOP-PCV-3301

3

MOTOR LUBE OIL PRESSURE REGULATOR

72133

0800

AF1-SOP-RESF

AF2-SOP-RESF

AFC-SOP-RESF

3

OIL - WATER COOLER

4607TCOOLER INSTRUMENTATION

1110

AF1-SOP-TE-3101 AF1-SOP-TE-3119 AF1-SOP-TT-3101 AF1-SOP-TT-3119

AF2-SOP-TE-3201 AF2-SOP-TE-3119 AF2-SOP-TT-3201 AF2-SOP-TT-3119

AFC-SOP-TE-3301 AFC-SOP-TE-3119 AFC-SOP-TT-3301 AFC-SOP-TT-3119

6

INLET TEMPERATURE TRANSMITTER: RANGE 0 - 130 F (0-54 C)

78409

1120

AF1-SOP-PDT-3103

AF2-SOP-PDT-3203

AFC-SOP-PDT-3303

3

COMPRESSOR DIFFERENTIAL PRESSURE TRANSMITTER

78410

1140

AF1-SOP-TE-3108

AF2-SOP-TE-3208

AFC-SOP-TE-3308

3

OIL TEMPERATURE RTD

78411

1140

AF1-SOP-TT-3108

AF2-SOP-TT-3208

AFC-SOP-TT-3308

3

OIL TEMPERATURE TRANSMITTER: RANGE 0-200 oF (0-93 oC)

78412

1190

AF1-SOP-TT-3102

AF2-SOP-TT-3202

AFC-SOP-TT-3302

3

ACOUSTICAL ENCLOSURE TEMPERATURE TRANSMITTER

78412

1190

AF1-SOP-TE-3102 AF1-SOP-TT-3103 AF1-SOP-TT-3104 AF1-SOP-TT-3105 AF1-SOP-TT-3106 AF1-SOP-TT-3107 AF1-SOP-TT-3109 AF1-SOP-TT-3117

AF2-SOP-TE-3202 AF2-SOP-TT-3203 AF2-SOP-TT-3204 AF2-SOP-TT-3205 AF2-SOP-TT-3206 AF2-SOP-TT-3207 AF2-SOP-TT-3209 AF2-SOP-TT-3217

AFC-SOP-TE-3302 AFC-SOP-TT-3303 AFC-SOP-TT-3304 AFC-SOP-TT-3305 AFC-SOP-TT-3306 AFC-SOP-TT-3307 AFC-SOP-TT-3309 AFC-SOP-TT-3337

3

ACOUSTICAL ENCLOSURE TEMPERATURE RTD

74360

15

COMPRESSOR BEARING RTD TRANSMITTER: RANGE 0-300 oF (0-149 oC)

1110

1270 1280

6

6

INLET TEMPERATURE RTD

78408 o

o

o

MOTOR BEARING RTD TRANSMITTER: RANGE 0 - 300 °F (0-149 C)

78413 78413

Document Name: 4607T COMP LIST Rev C

JOB NO. TURBLEX TID

1290 1340 1350

Unit 1 Tags

Unit 2 Tags

Common Unit Tags

AF1-SOP-TT-3111 AF1-SOP-TT-3112 AF1-SOP- TT-3113 AF1-SOP-TT-3114 (No Transmitter) AF1-SOP-TT-3115 (No Transmitter) AF1-SOP-TT-3116 (No Transmitter) AF1-SOP-PDT-3101 AF1-SOP-PDT-3102 AF1-SOP-PSL-3101

AF2-SOP-TT-3211 AF2-SOP-TT-3212 AF2-SOP-TT-3213 AF2-SOP-TT-3214 (No Transmitter) AF2-SOP-TT-3215 (No Transmitter) AF2-SOP-TT-3216 (No Transmitter) AF2-SOP-PDT-3201 AF2-SOP-PDT-3202 AF2-SOP-PSL-3201

AFC-SOP-TT-3311 AFC-SOP-TT-3312 AFC-SOP-TT-3313 AFC-SOP-TT-3314 (No Transmitter) AFC-SOP-TT-3315 (No Transmitter) AFC-SOP-TT-3316 (No Transmitter) AFC-SOP-PDT-3301 AFC-SOP-PDT-3302 AFC-SOP-PSL-3301

4607T

COMPONENTS LIST

ITEM I

QUANTITY

DESCRIPTION

TURBLEX P/N

9

MOTOR WINDING RTD TRANSMITTER: RANGE 0-400 oF (0-204 oC)

78414

6 3

INLET FILTER DIFFERENTIAL PRESSURE TRANSMITTER: RANGE: 1 - 20 mbar LOW OIL PRESSURE SWITCH: SET @ 29 PSIG (2 bar)

78415 71790

1355

AF1-SOP-PT-3101

AF2-SOP-PT-3201

AFC-SOP-PT-3301

3

OIL PRESSURE TRANSMITTER: RANGE 2.3 - 232 PSIG (.16-16 bar)

78416

1370

AF1-SOP-PSH-3101

AF2-SOP-PSH-3201

AFC-SOP-PSH-3301

3

SURGE SWITCH

72508

1375

AF1-SOP-LSL-3101

AF2-SOP-LSL-3201

AFC-SOP-LSL-3301

3

OIL LEVEL SWITCH

71801

1395

AF1-SOP-XS-3101

AF2-SOP-XS-3201

AFC-SOP-XS-3301

3

ZERO SPEED SWITCH

72508

1410

AF1-SOP-TI-3101

AF2-SOP-TI-3201

AFC-SOP-TI-3301

3

o INLET TEMPERATURE GAUGE: RANGE 0 - 200 °F (0-93 C)

78417

1420

AF1-SOP-TI-3102

AF2-SOP-TI-3202

AFC-SOP-TI-3302

3

OIL TEMPERATURE GAUGE: RANGE 0 - 200 °F (0-93 oC)

78419

1430

AF1-SOP-TI-3109

AF2-SOP-TI-3209

AFC-SOP-TI-3309

3

COOLING WATER IN TEMPERATURE GAUGE: RANGE 0-200 oF (0-93 oC)

78419

1435

AF1-SOP-TI-3103

AF2-SOP-TI-3203

AFC-SOP-TI-3303

3

COOLING WATER OUT TEMPERATURE GAUGE: RANGE 0-200 oF (0-93 oC)

78419

1520

AF1-SOP-PI-3101

AF2-SOP-PI-3201

AFC-SOP-PI-3301

3

DISCHARGE PRESSURE GAUGE: 1/2" NPT, RANGE 0 - 30 PSI (0-2 bar)

78418

1540

AF1-SOP-PI-3103

AF2-SOP-PI-3203

AFC-SOP-PI-3303

3

MOTOR FORCED LUBE OIL PRESSURE GAUGE: 1/2" NPT, RANGE 0 - 30 PSI (0-2 bar)

78420

1540

AF1-SOP-PI-3102

AF2-SOP-PI-3202

AFC-SOP-PI-3302

3

LUBE OIL PRESSURE GAUGE: 1/2" NPT, RANGE 0 - 160 PSI (0-11 bar)

78421

1820

AF2-SOP-FI-3201 AF2-SOP-FI3102 AF2-SOP-FI3103

AFC-SOP-FI-3301 AFC-SOP-FI3102 AFC-SOP-FI3103

3

LUBE OIL FLOW INDICATOR

71257

1820

AF1-SOP-FI-3101 AF1-SOP-FI3102 AF1-SOP-FI3103

6

MOTOR LUBE OIL FLOW INDICATOR

1910

AF1-SOP-FT-3101

AF2-SOP-FT-3201

AFC-SOP-FT-3301

3

DISCHARGE FLOW METER

AF2-SOP-VTX-3201 AF2-SOP-VTY-3201 AF2-SOP-VEX-3201 AF2-SOP-VEY-3201

AFC-SOP-VTX-3301 AFC-SOP-VTY-3301 AFC-SOP-VEX-3301 AFC-SOP-VEY-3301

6

BLOWER X-Y VIBRATION TRANSMITTER

74460

2000

AF1-SOP-VTX-3101 AF1-SOP-VTY-3101 AF1-SOP-VEX-3101 AF1-SOP-VEY-3101

6

RADIAL "X-Y" VIBRATION PROXIMITY PROBES

75249

2000

AF1-SOP-VTZ-3101

AF2-SOP-VTZ-3201

AFC-SOP-VTZ-3301

3

BLOWER "Z" THRUST VIBRATION TRANSMITTER

74332

2000

AF1-SOP-VEZ-3101 AF1-SOP-VTX-3101 AF1-SOP-VTY-3102 AF1-SOP-VTX-3103 AF1-SOP-VTY-3104 AF1-SOP-VEX-3101 AF1-SOP-VEY-3102 AF1-SOP-VEX-3103 AF1-SOP-VEY-3104

AF2-SOP-VEZ-3201 AF2-SOP-VTX-3201 AF2-SOP-VTY-3202 AF2-SOP-VTX-3203 AF2-SOP-VTY-3204 AF2-SOP-VEX-3201 AF2-SOP-VEY-3202 AF2-SOP-VEX-3203 AF2-SOP-VEY-3204

AFC-SOP-VEZ-3301 AFC-SOP-VTX-3301 AFC-SOP-VTY-3302 AFC-SOP-VTX-3303 AFC-SOP-VTY-3304 AFC-SOP-VEX-3301 AFC-SOP-VEY-3302 AFC-SOP-VEX-3303 AFC-SOP-VEY-3304

3

THRUST "Z" VIBRATION PROXIMITY PROBE

74508

12

MOTOR "X-Y" VIBRATION TRANSMITTER

74460

12

MOTOR "X-Y" VIBRATION PROXIMITY PROBE

76094

71257 4607TFLWMTR

VIBRATION MONITORING SYSTEM 2000

2000

2000

OPERATOR INTERFACE & PLC 2500

3

OPERATOR INTERFACE

78250

3000

3

PLC

78153

4510

AF1-SOP-IE-3101

AF2-SOP-IE-3201

AFC-SOP-IE-3301

3

CURRENT TRANSFORMER

72258

4510

AF1-SOP-IT-3101

AF2-SOP-IT-3201

AFC-SOP-IT-3301

3

CURRENT TRANSDUCER

72019

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

Turblex 4607T – Item 0010 Compressor O&M: Please note: The Item 0010 O&M will be available in the Final Turblex Operation and Maintenance Manual.

ITEM 0010

ITEM 0020

ITEM 0020

ITEM 0020

ITEM 0020

ITEM 0020

ITEM 0020

ITEM 0020

ITEM 0020

ITEM 0020

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Document Name: 4607T-0020 Rev 0

TECO-WESTINGHOUSE MOTOR COMPANY ROUND ROCK, TEXAS U.S.A. CUSTOMER TURBLEX CUSTOMER ORDER NO. 42866-4607T APPLICATION CENTRIFUGAL COMPRESSOR S.O. 0Q01AA

DATE -

DEC 30, 2008

DATA FOR WORLD SERIES, HORIZONTAL, BRACKET TYPE INDUCTION MOTOR 1. RATING HP RPM FL VOLTS AMPS FL PHASES

4000 3556 6600 288 3

HERTZ 60 SERVICE FACTOR 1.15 RISE C (1.00 SF) 70 METHOD RES AMBIENT C 50

INSUL CLASS F KVA CODE F DUTY CONTINUOUS

2. MECHANICAL FRAME ENCL TYPE

5616 WP2

BRG TYPE SLEEVE LUBE TYPE FLOOD ROTATION(FROM NDE) CCW

3. STARTING PERFORMANCE NOMINAL 100% VOLTS AMPS (LR) 1820 AMPS (LR) % 631 POWER FACTOR % 22.3 START TORQUE % 118 ACCELERATION SEC 2.9 SAFE LOCK SEC SAFE LOCK SEC

FROM HOT FROM COLD

END PLAY INCH MOTOR WK SQ LOAD WK SQ

0.50 918 814

65% VOLTS 1106 384 20.8 44 10.5

7.2 8.5

19.6 23.0

PULLOUT TORQUE AT 100% VOLTS = 268 % 4. EFFICIENCY - NOMINAL LOAD EFFICIENCY

% %

115 95.60

100 95.85

75 96.08

50 95.81

100 94.4

75 94.8

50 94.0

5. POWER FACTOR - NOMINAL LOAD % POWER FACTOR %

115 93.9

6. POWER FACTOR CORRECTION MAX KVAR =

310

MAX FL P.F. = 97.0 %

7. Motor is capable of starting across the line or with a soft starter. Speed torque and thermal limit curves have been provided to allow the customer to set the motor acceleration time for the soft starter. Motor is not suitable for use with soft starter if power factor correction capacitors or surge capacitors are connected to motor leads.

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ITEM 0040

Document Name: 4607T-0040 Rev 0 OIL RESERVOIR VOLUME DATA CALCULATION SHEET (SI UNITS) JOB NUMBER:

4607T

J0B NAME:

PAUL WURTH

BLOWER MODEL:

KA66S-GL400

3962 mm

1842 mm A

1575 mm

1355 mm B

RESERVOIR TOP VIEW

OIL LEVEL

OIL RESERVOIR AREA

C=

C

417 mm

RESERVOIR SIDE VIEW

LITERS PER MINUTE REQUIRED (L/min)

ACTUAL OIL RETENTION TIME (MINUTES):

RESERVOIR LENGTH (A):

1842 mm

TIMES RESERVOIR WIDTH (B):

1355 mm

TIMES OIL LEVEL HEIGHT (C):

417 mm

206.66 L/min

5.03 min. 3

= VOLUME (mm ) EQUALS TO TOTAL LITERS REQUIRED

1,039.96

3

= VOLUME (m ) TIMES 1000 RESERVOIR CAPACITY (LITERS) TIMES 0.8798 Kg/L = TOTAL OIL WEIGHT

1,039,957,153 mm^3 1.04 m3 1,039.96 L 915 kg.

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

Turblex 4607T – Item 0100 Sound Enclosure O&M: Please note: The Item 0100 O&M will be available in the Final Turblex Operation and Maintenance Manual.

® 3900 Dr. Greaves Rd.

•

Document Name: 4607T-0110 Rev 0

Kansas City, MO 64030

•

ITEM 0110

(816) 761-7476

•

FAX (816) 765-8955

ELF811DD STATIONARY LOUVER DOUBLE DRAINABLE BLADE EXTRUDED ALUMINUM STANDARD CONSTRUCTION

FEATURES

FRAME 4" (102) deep, 6063T5 extruded aluminum with .090" (2.3) nominal wall thickness. Downspouts and caulking surfaces provided. BLADES 6063T5 extruded aluminum with .081" (2.1) nominal wall thickness. Double drainable blades are positioned at 45° angle and spaced approximately 5 3/32" (129) center to center. SCREEN 3/4" x .051" (19 x 1.3) expanded, flattened aluminum bird screen in removable frame. Screen adds approximately 1/2" (13) to louver depth. FINISH Mill. MINIMUM SIZE 12"w x 12"h (305 x 305). APPROXIMATE SHIPPING WEIGHT 4 lbs. per sq. ft. MAXIMUM FACTORY ASSEMBLY SIZE Shall be 75 sq. ft. (7m2) per section, not to exceed 120"w x 90"h (3048 x 2286) or 90"w x 120"h (2286 x 3048).

The ELF811DD offers: • Published performance ratings based on testing in accordance with AMCA Publication 511. • Double drain gutters in each blade and downspouts in jambs and mullions to drain water from louver for minimum water cascade from blade to blade. • Architecturally styled hidden mullions allowing continuous line appearance up to 120" (3048). • All aluminum construction for low maintenance and high resistance to corrosion. • Low pressure drop and low water penetration.

B*

VARIATIONS Variations to the basic design of this louver are available at additional cost. They include: • Extended sill. • Hinged frame. • Front or rear security bars. • Filter racks. • A variety of bird and insect screens. • Selection of finishes: prime coat, baked enamel (modified fluoropolymer), epoxy, Acrodize, Kynar, clear and color anodize. (Some variation in anodize color consistency is possible.) Consult Ruskin for other special requirements.

A*

3

Louvers larger than the maximum factory assembly size will require field assembly of smaller sections. SUPPORTS Louvers may be provided with rear mounted blade supports that increase overall louver depth depending on louver size, assembly configuration or windload.

Bird Screen

FRAME CONSTRUCTION

Consult Ruskin for additional information.

11/2" (38) 1" (25) A* x B*

Varies

4" (102)

Dimensions in inches, parenthesis (

) indicate millimeters.

SIZE TAG

QTY.

FRAME A*-WIDE

B*-HIGH

78"

76"

4

PROJECT ARCH./ENGR. REPRESENTATIVE Spec ELF811DD-396/Replaces ELF811DD-692

Flange

STANDARD

INTEGRAL FLANGE

*Units furnished 1/4" (6) smaller than given opening dimensions.

VARIATIONS

FOUR (4) LOUVERS PER COMPRESSOR MAKES TOTAL SIZE 156" WIDE X 152" HIGH

LOCATION CONTRACTOR DATE ALL STATED SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE OR OBLIGATION.

© Ruskin Manufacturing 1996

ITEM 0110

SUGGESTED SPECIFICATION Furnish and install louvers as hereinafter specified where shown on plans or as described in schedules. Louvers shall be stationary double drainable with drain gutters in each blade and downspouts in jambs and mullions. Stationary drainable blades shall be contained within a 4" (102) frame. Louver components (heads, jambs, sills, blades & mullions) shall be factory assembled by the louver manufacturer. Louver sizes too large for shipping shall be built up by the contractor from factory assembled louver sections to provide overall sizes required. Louver design shall limit span between visible mullions to 10 ft. (3) and shall incorporate structural supports required to withstand a wind load of 20 lbs. per sq. ft. (.96kPa) (equivalent of a 90 mph wind [145 KPH] - specifier may substitute any loading required).

Louvers shall be Ruskin Model ELF811DD extruded 6063T5 aluminum alloy construction as follows: Frame: .090" (2.3) wall thickness. Blades: .081" (2.1) wall thickness at 45° angle on approximately 5 3/32" (129) centers. Screen: 3/4" x .051" (19 x 1.3) expanded, flattened aluminum bird screen in removable frame. Finish:

Select finish specification from Ruskin Finishes Brochure.

Published louver performance data bearing the AMCA Certified Ratings Seal for Air Performance & Water Penetration must be submitted for approval prior to fabrication and must demonstrate pressure drop and water penetration equal to or less than the Ruskin model specified.

PERFORMANCE DATA AMCA Standard 500 provides a reasonable basis for testing and rating louvers. Testing to AMCA 500 is performed under a certain set of laboratory conditions. This does not guarantee that other conditions will not occur in the actual environment where louvers must operate.

The louver system should be designed with a reasonable safety factor for louver performance. To ensure protection from water carryover, design with a performance level somewhat below maximum desired pressure drop and .01 oz./sq. ft. of water penetration.

WATER PENETRATION Test size 48" wide x 48" high (1219 x 1219) Beginning point of water penetration at .01 oz./sq. ft. is 974 fpm (297 m/min).

Oz. Water/ft2 and (ounces water/m2) of Free Area 15 min. test period

0.3 (3.23)

0.25 (2.69)

0.2 (2.15)

0.15 (1.61)

0.1 (1.08)

0.05 (.54)

0 900 (274)

1000 (305)

1100 (335)

1200 (366)

Free Area Velocity in feet and (meters) per minute Standard air .075 lb/ft3

ITEM 0110

TYPICAL INSTALLATION DETAILS Masonry Wall

Metal Panel Wall

Metal Siding CMU

Insulation Drip Cap Louver

Louver

Extended Sill Extended Sill

Wood Installation

Flange Mount

CMU Integral Flange Frame

Louver

Louver

Sheating Fasteners (by others)

Siding

Accessories at additional cost.

®

3900 Dr. Greaves Rd. Kansas City, MO 64030 (816) 761-7476 FAX (816) 765-8955

ITEM 0130 Installation, Operation and Maintenance Instructions for U2, U5 and SU Series Silencers Description The U2 and U5 series are straight-through absorptive silencers. The SU series is an annular flow path absorptive silencer with the premium grade SU5 providing a blocked line-of-sight. These silencers provide varying degrees of noise reduction and are most appropriate in fan, blower, compressor and turbine applications where their high frequency insertion loss will be most effective. The standard unit in these series is designed for applications where the temperature does not exceed 325°F, the pressure does not exceed 15 psig and/or vacuum does not exceed 15”Hg. There are no moving parts in the operation of these silencer units. Receiving Inspection • Upon receipt of the unit , check the nameplate against the packing list to verify the correct part numbers are received. • Keep the shipping container to protect the unit until installation. • Prior to unpacking, check for damage. • Advise Universal Silencer of shipping damage within three days. Storage • Leave any cardboard boxing, plywood covering, crating, and/or plastic covering intact until ready to install. • Be sure that all openings are closed so that no debris, vermin, rain, snow and/or ice can get into unit. • Store unit on blocks, a minimum of 4” high so that air can freely circulate around unit. • Do not store in contact with the ground or in a wet or flooded area.

Inspection and maintenance • Components are either complete weldments or permanently assembled having no replaceable parts. • Spare parts are not required. • Periodically inspect exterior paint finish for damage or deterioration. NOTE: Minor localized damage may be touched up using touch-up paint. Areas with extensive damage or deterioration may require spot blasting and recoating. Consult paint manufacturer’s recommendations. • Examine connecting flanges and support/ anchor bolting at least annually. Retighten loose nuts as required.

•

Indoor ambient temperature storage is preferable, especially for these units which have internal absorptive material. If this is not possible, keep the unit covered and protected from the weather. • Clean unit prior to installation. Remove any minor corrosion and refinish per paint manufacturer’s recommendations. If major corrosion has occurred such that the integrity of the unit is in question, contact Universal Silencer. Mounting and alignment • Insure that the necessary equipment to install the unit, including anchor and/or support bolts, flange bolts, saddles and expansion joints, are available before beginning installation. • Anchor and/or support bolting and grouting is not included with the unit. • Align the unit with the piping or ducting connections.

+

• • • • •

IMPORTANT: The unit is not designed to serve as a support for any piping, additional mounting pads or additional loads on the inlet or outlet other than those stated in the Universal Silencer drawing or product bulletin. Mount the unit securely to the foundation, adjacent piping and/or appropriate hangers. Use thread lubricant on all bolted joints. Use all gaskets provided with the unit. If you replace or add bolts or gaskets, use the same size and material as the originals. Ensure that the unit is firmly mounted immediately prior to startup of the equipment, and again 24 hours after startup to verify that supports and/or flange bolts have not vibrated loose.

Safety Issues • C AU TION - All personnel working near hightemperature components during operation and cool down period should use care to prevent injury due to contact with high temperature surfaces. • If performing any work internal to the silencer or adjacent components, ensure that all confined space requirements are met and that all tools and other materials are removed once work is completed.

1999 Universal Silencer Form No. 94-1337, 11/07

914.4 mm

1346.2 mm

1752.6 mm

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

Document Name: 4607T-0140 Rev A

BLOW-OFF SILENCER – 10” 4134"

ITEM 0140

1060.45 mm

2" REF

50.8 mm

4613 16"

1189.03 mm

4213 16"

1087.43 mm

1034" 273.05 mm 1"

25.4 mm

ELEVATION VIEW

ISOMETRIC VIEW

(12) 1" HOLES ON A 14 1/4" B.C. DIA ANSI 150#, 10" PIPE CONNECTION SIZE Ø16"

406.4 mm

NOTES: 1. FASTENERS, NUTS & GASKETS (NOT BY TURBLEX). 2. BLOW OFF SILENCER, SHIP LOOSE, INSTALLATION NOT BY TURBLEX. 3. PLEASE REFER TO TAB “E” FOR PAINT SPECIFICATIONS. 4. BLOW-OFF VALVE\ACTUATOR & BLOW-OFF SILENCER TO BE SUPPORTED BY CUSTOMER PIPING.

BOTTOM VIEW

5. MATERIAL TO BE A36 CARBON STEEL 6. WEIGHT: 635 LBS 288.03 kg

K:\STD DRAWINGS\BLOW OFF SILENCER\BOS-10IN-SUB.

ITEM 0160

3p glide/pack

®

Two-Stage Side-Access Filter Housing The Camfil Farr 3P Glide/Pack® has set the standard for side-access housing integrity for over 20 years. With its integral universal final filter holding frame virtually all of the air seen by the filter will be treated by the filter. Each Camfil Farr 3P Glide/Pack includes:

Less than ½ of 1% air bypass/leakage guaranteed

•

16-gauge galvanized steel construction with pre-drilled standing flanges to mate to existing HVAC equipment. All components are weatherproof for interior or exterior installation

•

Dual-access doors for filter service from either side of the unit. The doors swing-open and are engineered to be square to the housing flange. UV resistant starstyle handles assure a tight seal each time the access doors are opened and closed

•

High-memory sponge neoprene door gaskets to ensure door-to-filter seal (less than one half of 1% housing to ambient leakage)

•

A poly sponge door gasket to assure a proper door-tofilter seal

•

A polypropylene fin seal on the main filter track to eliminate filter air bypass (less than 1/2 of 1% leakage across the final filter assembly at rated airflow)

•

An integral pneumatic fitting for the installation of an optional static pressure gauge capable of evaluating any single stage or multiple stages of installed filters

•

An aluminum filter track allowing for filtration combinations that include: • A 2” nominal size prefilter track (with filter slide rails to facilitate easier prefilter service) • A 6” or 12” deep box-style final filter with 1” nominal size header or full size box style filter in a frame assembly • A pocket style final filter with header for frame or track installation

• A 12” deep box style carbon filter for gaseous contaminant removal For those that are concerned about air quality and desire a housing that assures that the system contaminant removal efficiency is the same as the rated filter efficiency the Camfil Farr Glide/Pack continues to set the standard by which other HVAC components are judged. Top left: Poly fin seal assures a tight seal under demanding conditions.

Top right: Bolt-together construction and weeping flanges for water run-off.

Bottom left: UV resistant star handle forming a new door to housing seal upon each door closure.

Bottom right: Static tap allows pressure drop evaluation of prefilter, final filter, or both.

Camfil Farr

Product sheet

3P Glide/Pack®

2401-0302

Camfil Farr—clean air solutions

ITEM 0160

PERFORMANCE DATA

3P GLIDE/PACK®

Housing Dimensions & Airflow Capacities NUMBER OF FILTERS WIDE

NUMBER OF FILTERS HIGH

HEIGHT

1/2

1/2

1

1-1/2

2

2-1/2

3

3-1/2

4

4-1/2

5

5-1/2

6

1’ 3-1/4”

—

1000

—

2000

—

3000

—

4000

—

5000

—

6000

1

2’ 3-1/4”

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

1-1/2

3’ 3-1/2”

—

3000

—

6000

—

9000

—

12000

—

15000

—

18000

2

4’ 3-1/2”

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

22000

24000

2-1/2

5’ 3-3/4”

—

5000

—

10000

—

15000

—

20000

—

25000

—

30000

3

6’ 3-3/4”

—

6000

9000

12000

15000

18000

21000

24000

27000

30000

33000

36000

3-1/2

7’ 4”

—

7000

—

14000

—

21000

—

28000

—

35000

—

42000

4

8’ 4”

—

8000

12000

16000

20000

24000

28000

32000

36000

40000

44000

48000

1’ 0”

2’ 0”

3’ 0”

4’ 0”

5’ 0”

6’ 0”

7’ 0”

8’ 0”

9’ 0”

10’ 0”

11’ 0”

12’ 0”

WIDTH

DATA NOTES: Airflow rated at 500 fpm, may be operated to 625 fpm. Standard housing operational to ± 6.0” w.g. Contact your Camfil Farr representative for shipping and installed housing weight.

Available Options: Stainless steel construction High-pressure construction (to 8.0” w.g.) Double-wall with insulation Transitions to standard HVAC equipment. Contact factory for more information.

SPECIFICATIONS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1.0 General 1.1 - Filter housing shall be two-stage filter system consisting of 16-gauge galvanized steel enclosure, aluminum filter mounting track, universal filter holding frame, dual-access doors, static pressure tap, filter gaskets and seals. In-line housing depth shall not exceed 21”. 1.2 - Sizes shall be as noted on enclosed drawings or other supporting materials. 2.0 Construction 2.1 - The housing shall be constructed of 16-gauge galvanized steel with pre-drilled standing flanges to facilitate attachment to other system components. Corner posts of Z-channel construction shall ensure dimensional adherence. The housing shall be weatherproof and suitable for rooftop/outdoor installation. 2.2 - The housing shall incorporate the capability of two stages of filtration without modification to the housing. A filter track, of aluminum construction shall be an integral component of housing construction. The track shall accommodate either a 2” deep prefilter, a 6” or 12” deep rigid final filter, or a pocket filter with header.

Camfil Farr, Inc. United States Tel: (973) 616-7300 Fax: (973) 616-7771 Canada Tel: (450) 629-3030 Fax: (450) 662-6035 E-mail: [email protected]

03/02 © Camfil Farr

http://www.camfilfarr.com

2.3 - Dual access doors, swing-open type, shall include high-memory sponge neoprene gasket to facilitate a doorto-filter seal. Each door shall be equipped with adjustable and replaceable positive sealing UV-resistant star-style knobs and replaceable door hinges. 2.4 - A universal holding frame constructed of 18-gauge galvanized steel, equipped with centering dimples, multiple fastener lances, and polyurethane filter sealing gasket, shall be included to facilitate installation of high-efficiency filters. 2.5 - The housing shall include a pneumatic fitting to allow the installation of a static pressure gauge to evaluate pressure drop across a single filter or any combination of installed filters. 3.0 Performance 3.1 - Leakage at rated airflow, upstream to downstream of filter, holding frame, and slide mechanism shall be less than 1% at 3.0” w.g. Leakage in to or out of the housing shall be less than one half of 1% at 3.0” w.g. 3.2 - Accuracy of pneumatic pressure fitting, when to evaluate a single-stage, or multiple filter stages, shall be accurate within ± 3% at 0.6” w.g. Camfil Farr has a policy of continuous research, development and product improvement. We reserve the right to change designs and specifications without notice. Represented by:

aeropleat III ®

Standard-Capacity Pleated Panel Filter Meeting Today’s Standards

ITEM 0160

The Camfil Farr Aeropleat ® III pleated filter offers medium grade ASHRAE efficiency and sets the performance standard for those upgrading from lower efficiency throw-aways or pads. Combining electrostatic and mechanical particle capture principles, the Aeropleat III is a MERV 6 filter when evaluated per ASHRAE Standard 52.2-1999. For Today’s Applications As a stand-alone filter, the Aeropleat III will remove many of the contaminants associated with today’s indoor air quality concerns. Available in 1”, 2” and 4” depths, its increased media area offers an extended

The Aeropleat III - the economical choice for those requiring ASHRAE MERV 6 efficiency for their HVAC applications. Initial Resistance vs Airflow 24” X 24”

service life when compared to lower efficiency throwaways or pads. Applications include commercial buildings, educational facilities and specialty manufacturing. As a pre-filter, the Aeropleat III offers protection for the higher efficiency final filters required for today’s high-technology applications. Built for Today’s HVAC Systems

• •

10 pleats per linear foot (2” deep model) in a radial pleat design for full use of media area 100% synthetic blend media provides medium grade ASHRAE performance and

•

increased dust-holding capacity Welded wire media grid is treated for corrosion resistance and prevents media

• •

oscillation or pull-away High wet-strength beverage board frame creates a rigid and durable filter pack Available in 1”, 2” and 4” depths

Camfil Farr

Product sheet

Aeropleat III

B-1305-16B

Camfil Farr - clean air solutions

ITEM 0160

PERFORMANCE DATA NOMINAL FILTER DEPTH

4"

2"

1"

NOMINAL SIZE (inches) 20 20 24 24 24 25 25 20 20 24 24 24 25 25 20 20 24 24 24 25 25

x x x x x x x x x x x x x x x x x x x x x

16 20 12 20 24 16 20 16 20 12 20 24 16 20 16 20 12 20 24 16 20

x x x x x x x x x x x x x x x x x x x x x

4 4 4 4 4 4 4 2 2 2 2 2 2 2 1 1 1 1 1 1 1

ACTUAL SIZE (inches)

CAPACITIES (cfm)

RESISTANCE AT (1) CAPACITY (inches w.g.)

HEIGHT

WIDTH

DEPTH

MEDIUM

HIGH

MEDIUM

HIGH

19.38 19.38 23.38 23.38 23.38 24.38 24.38 19.50 19.50 23.38 23.50 23.38 24.50 24.50 19.50 19.50 23.50 23.50 23.50 24.50 24.50

15.38 19.38 11.38 19.38 23.38 15.38 19.38 15.50 19.50 11.38 19.50 23.38 15.50 19.50 15.50 19.50 11.50 19.50 23.50 15.50 19.50

3.75 3.75 3.75 3.75 3.75 3.75 3.75 1.75 1.75 1.75 1.75 1.75 1.75 1.75 0.88 0.88 0.88 0.88 0.88 0.88 0.88

560 695 500 835 1000 695 870 560 695 500 835 1000 695 870 390 485 350 585 700 485 610

1110 1390 1000 1670 2000 1390 1740 1110 1390 1000 1670 2000 1390 1740 780 970 700 1170 1400 970 1215

0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.11 0.11 0.11 0.11 0.11 0.11 0.11

0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23 0.23

AEROPLEAT III

TOTAL MEDIA PLEATS PER AREA LINEAR FOOT (sq. ft.) 12.6 15.7 12.3 18.9 22.7 15.7 19.7 6.5 8.6 6.1 10.3 12.1 8.1 10.7 4.3 5.4 3.8 6.5 7.8 5.4 6.7

9 pleats per linear foot

10 pleats per linear foot

12 pleats per linear foot

(1) 4” and 2” filters are rated at 250 fpm (medium) and 500 fpm (high). 1” filters are rated at 175 fpm (medium) and 350 fpm (high). Maximum recommended final resistance for all sizes is 1.0” w.g. System velocity and design may dictate a different final pressure drop. Camfil Farr Aeropleats are rated by Underwriters Laboratories as Class 2.

SPECIFICATIONS Air Filters – Air filters shall be 1”, 2” or 4” deep disposable type. Each filter shall consist of a synthetic media blend, a welded wire media support grid and a high wet-strength beverage board frame. The filter shall be capable of withstanding 2.0” w.g. without distortion of the media pack or filter failure. The filter shall be rated by Underwriters Laboratories as Class 2.

4 INCH – The filter face area shall not be less than nine pleats per linear foot. Initial resistance at 500 feet per minute shall not exceed 0.21” w.g.

Filter Media – Filter media shall be a blend of synthetic fibers, incorporating a mechanical efficiency and an electret charge. The media shall be formed in a radial pleat design to ensure full utilization of the media area. When tested in accordance with ASHRAE Standard 52.2-1999, the filter shall have a minimum efficiency reporting value (MERV) of 6. When tested in accordance with ASHRAE Standard 52.1-1992, the filter shall have an average dust spot efficiency of 25-30%*.

1 INCH – The filter face area shall not be less than 12 pleats per linear foot. Initial resistance at 350 feet per minute shall not exceed 0.23” w.g.

* The Camfil Farr Aeropleat III is categorized as a 25-30% efficiency filter. Average efficiencies may vary 5 points. These variances are not uncommon when tested in accordance with ASHRAE Standard 52.1-1992.

Enclosing Frame – The enclosing frame shall be assembled of a high wet-strength 24-point beverage board. It shall be bonded around the entire periphery, eliminating the possibility of air bypass. Diagonal support members of the same construction shall be bonded to each pleat to ensure pleat spacing and stability.

Camfil Farr 2201 Park Place El Segundo, CA 90245 800-333-7320 • 310-727-6300 310-643-9086 Fax E-mail: [email protected]

2 INCH – The filter face area shall not be less than 10 pleats per linear foot. Initial resistance at 500 feet per minute shall not exceed 0.23” w.g.

Media Support Grid – The media support grid shall be of welded wire construction, spot welded on oneinch centers, and post-treated for corrosion resistance. The welded wire grid shall be bonded to the media to eliminate oscillation or pull-away and formed in such a manner that it supports a radial pleat configuration.

Camfil Farr has a policy of uninterrupted research, development and product improvement and reserves the right to change design and specifications without notice. Represented by:

07/01

Camfil Farr

www.camfilfarr.com

Printed in U.S.A. on Recycled Paper

ITEM 0160

p-series ph

riga-flo

®

High-Lofted Supported Synthetic Media Air Filter For Side-Access Applications The Camfil Farr P-Series Riga-Flo® PH provides highefficiency ASHRAE air filtration performance in a compact, supported media design for installation into side-access housings with 1” nominal filter tracks. The materials of construction preclude contaminant amplification as all components are inert with respect to supporting the growth of captured bacteria or other viable contaminants. The P-Series Riga-Flo PH: •

The Camfil Farr P-Series Riga-Flo PH offers a low-pressure drop, synthetic microfiber performance, in a supported media package for side-access housing installations.

Is available in three efficiencies Model

ASHRAE 52.2-1999 MERV

ASHRAE 52.1-1992 (Dust Spot)

Eurovent

Riga-Flo P65

11

60-65%

F6

Riga-Flo P85

13

80-85%

F7

Riga-Flo P95

14

90-95%

F8

•

Includes an air laid synthetic microfiber media with a spun-bonded air entering and air exiting sandwich scrim. The combination offers efficiencies similar to traditional filter fiber technology with a reduced resistance to airflow.

•

Includes a welded-wire media grid that is bonded to the media to support and maintain tapered radial pleats and prevent media oscillation during varying system airflows.

•

Includes a continuous adhesive bond around the inside of the enclosing frame to eliminate air bypass. The media is mechanically bonded to the frame to assure integrity to 10” w.g.

•

Includes an enclosing frame of steel, coated with an aluminum-zinc alloy, to provide 50% higher corrosion resistance than standard galvanized steel.

•

Includes all-metal contour media stabilizers on the air entering and air existing sides to assure pleat support through turbulent or varying airflows.

•

Includes all-metal diagonal support braces to assure filter rigidity and media pack protection. The braces are mechanically bonded to the contour stabilizers to assist in maintaining a rigid and durable filter pack.

•

Includes a nominal 1” deep header for slide-in slideout installation in side-access filter housings. The Riga-Flo’s supported media is excellent for VAV systems or today’s energy conscious HVAC applications. Values are MERVs when evaluated per ASHRAE 52.2.

Camfil Farr

Product sheet

P-Series Riga-Flo® PH

1403PH-0302

Camfil Farr—clean air solutions

ITEM 0160 P-SERIES RIGA-FLO® PH

PERFORMANCE DATA FILTER EFFICIENCY

P-95 PH 90-95%

P-85 PH 80-85%

P-65 PH 60-65%

RESISTANCE

PART NUMBER

ACTUAL DIMENSIONS HxWxD (inches)

AIRFLOW CAPACITY (cfm)

INITIAL (ins. w.g.)

FINAL** (ins. w.g.)

MEDIA AREA (ft2)

122557-004

23.31 x 23.31 x 11.50

2000

.60

1.5

50

122557-014

23.31 x 11.31 x 11.50

1000

.60

1.5

22

122557-024

23.31 x 19.31 x 11.50

1670

.60

1.5

43

122557-034

19.31 x 19.31 x 11.50

1400

.60

1.5

33

122557-003

23.31 x 23.31 x 11.50

2000

.44

1.5

50

122557-013

23.31 x 11.31 x 11.50

1000

.44

1.5

22

122557-023

23.31 x 19.31 x 11.50

1670

.44

1.5

43

122557-033

19.31 x 19.31 x 11.50

1400

.44

1.5

33

122557-002

23.31 x 23.31 x 11.50

2000

.30

1.5

50

122557-012

23.31 x 11.31 x 11.50

1000

.30

1.5

22

122557-022

23.31 x 19.31 x 11.50

1670

.30

1.5

43

122557-032

19.31 x 19.31 x 11.50

1400

.30

1.5

33

Options: Available without a header (Bulletin 1403-0302). 1.12” header version also available.

DATA NOTES: Standard header is for 1” nominal filter track. Recommended final resistance is 1.5” w.g. System design may dictate a lower change-out point. Maximum continuous operating temperature is 160° F (70° C).

SPECIFICATIONS •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• Air Filters—1.0 General 1.1 - Air filters shall be high-efficiency ASHRAE high lofted supported synthetic media headered disposable type assembled in a compact and secure enclosing frame. 1.2 — Sizes shall be as noted on drawings or other supporting materials. 2.0 Construction 2.1 - Filter media shall be of microfiber core laminated between spun-bonded scrim to form a uniform lofted media blanket. 2.2 - The media blanket shall be formed into uniform tapered radial pleats and bonded to a welded wire media support grid, which is spot-welded on one-inch centers, and treated for corrosion resistance. 2.3 - The media shall be mechanically and chemically bonded to the inside periphery of the enclosing frame to prevent air bypass. Camfil Farr has a policy of uninterrupted research, development and product improvement. We reserve the right to change designs and specifications without notice. Camfil Farr, Inc. United States Tel: (973) 616-7300 Fax: (973) 616-7771 Canada Tel: (450) 629-3030 Fax: (450) 662-6035 E-mail: [email protected]

2.4 - The enclosing frame shall be constructed of an alloy of zinc, aluminum, and steel. Media support contour stabilizers, of the same construction, shall be mechanically fastened to diagonal support members to create a rigid and durable filter enclosure. There shall be a minimum of four contour stabilizers on the air entering side and six on the air exiting side. 2.5 - The filter shall include an integral header for installation in a standard 1” nominal filter track. 3.0 Performance 3.1 - The filter shall have a Minimum Efficiency Reporting Value of MERV (11, 13, 14)* when evaluated under the guidelines of ASHRAE Standard 52.2-1999. It shall have an average dust spot efficiency of (60-65%, 80-85%, 90-95%)* when evaluated under ASHRAE Standard 52.1-1992. 3.2 - Initial resistance to airflow shall not exceed (0.30, 0.44”, 0.60”)* w.g at an airflow of 500 fpm. 3.3 - Filter shall be rated by Underwriters Laboratories as UL Class 2. 3.4 - The filter shall be capable of withstanding 10” w.g. without failure of the media pack. Supporting Data - Provide product test reports for each listed efficiency including all details as prescribed in ASHRAE Standards 52.1 and 52.2. Items in parentheses ( ) require selection. Represented by:

03/02 © Camfil Farr

http://www.camfilfarr.com

ITEM 0160

PFS, PFM, PFL RIGID POCKET FILTERS 100% high performance synthetic fibers

Rigid pocket design for VAV systems

Corrosion free molded header

◗ 100% Synthetic, corrosion free and humidity-resistant product ◗ High Dirt Holding Capacity provides exceptional extended life ◗ Designed for Leak Free Operation even in the most rigorous air pressure and high dust-laden environments ◗ Very Low Resistance results in greatly reduced operating costs

DESCRIPTION Filtrair’s PF Series Rigid Pockets are a premium high efficiency air filter designed for critical or harsh air handling units. Filtrair pockets are extremely durable and will perform flawlessly over a long period of time. The synthetic fiber based pocket filter was developed and manufactured at Filtrair’s own high tech production facility. The use of high performance fibers in a progressive density

multi-layering technique ensures high depth loading with optimal lowest pressure drop performance.

F E AT U R E S A N D B E N E F I T S ◗ MOLDED HEADER does not corrode and can be incinerated ◗ RIGID DESIGN AND SYNTHETIC CONSTRUCTION allows pockets to withstand 100% humidity environments ◗ HIGH DUST HOLDING CAPACITY and low resistance make the PF Series pocket filters an excellent prefilter ◗ UL 900 Class 2—conforms to US fire classifications ◗ LOW RESISTANCE DESIGN greatly reduces operating costs ◗ FULL ADHESIVE SATURATION—proprietary process prevents unloading

A P P L I C AT I O N S Filtrair’s PF Series Rigid Pocket filters are designed for use as final filters in general ventilation and air conditioning equipment installed in offices, shopping centers, theatres, hotels, industrial plants, food processing plants and laboratories. Also as a pre-filter in the supply air units for car paint spray cabins, electrical equipment, electric motors, and superfine and absolute (HEPA) filtration systems.

ITEM 0160

PFS, PFM, PFL RIGID POCKET FILTERS PFS, PFM, PFL RIGID POCKET FILTER TECHNICAL DATA Units

1/1

PFS 5/6

1/2

1/1

PFM 5/6

1/2

1/1

PFL 5/6

1/2

Standard Holding Frame

in

24 x 24

20 x 24

12 x 24

24 x 24

20 x 24

12 x 24

24 x 24

20 x 24

12 x 24

Pocket Depth

in

12

12

12

20

20

20

24

24

24

Number of Pockets

—

6

5

3

8

6

4

6

5

3

Weight

lb

3.8

3.3

2.2

5.3

4.4

2.7

5.3

4.4

2.7

Header Size

in

23.43 x 23.43

Sizes

19.41 x 23.43 11.38 x 23.43 23.43 x 23.43 19.43 x 23.43 11.38 x 23.43 23.43 x 23.43 19.43 x 23.43 11.38 x 23.43

Unit cfm

PFS 1/1 Value 2000

PFM 1/1 Value 2000

PFL 1/1 Value 2000

ft2

23

51

45

Initial Resistance*

"w.g.

0.27

0.15

0.12

Final Resistance*

"w.g.

1.5

1.5

1.5

MERV*

—

8

8

8

DHC @ 1.5"w.g. Final Resistance*

g

600

1100

1100

"w.g.

0.38

0.20

0.17

Temperature Resistance

°F

160

160

160

Short Peaks

°F

200

200

200

"w.g.

>12

>12

>12

Performance Rated Air Flow Media Area

Initial Resistance @ 2500 cfm*

Burst Strength

Aerodynamic pocket separators for uniform air flow and maximum media usage.

Filtrair pocket filters remain rigid during repetitive fan shut-downs to prevent captured particle migration.

* Test performed according to ASHRAE Test Standard 52.2-1999

FRACTIONAL EFFICIENCY vs PARTICLE DIAMETER (PFL 1/1) (2000 cfm)

Initial Efficiency After 1st Loading

DISTRIBUTED BY

After 2nd Loading After Final Loading

PRESSURE DROP vs AIR FLOW RATE

PFS 1/1 PFM 1/1 PFL 1/1

600 Railroad Avenue York, SC 29745 Phone: 803-684-3533 Fax: 803-684-7856 www.filtrair.com © Filtrair 04/05

National Air Filtration Association

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

Filter Installation

ITEM 0160

P/N: 074227003

P/N: 78947-00

Primary Filter Sealing Angle

ITEM 0160

P/N: 060120001

2

ITEM 0160 Step 2: Insert spring clip into hole in filter, as shown. Four clips per filter.

3

ITEM 0160 Step 3: Insert filter frame into filter rack.

4

ITEM 0160 Step 4: Insert sealing angle into filter rack for primary filter.

5

ITEM 0160

Step 5: Slide primary filter over until contact with angle.

6

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

Document Name: 4607T-0200 Rev 0

XLW-3000 VIBRATION ISOLATOR ITEM 1 2 3 4 5

241" CL

QTY 1 1 1 3 2

KIT/PN 73394 81209 80221 70742 73354

ITEM 0200

DESCRIPTION PL., ¾” X 6” X 12” LG., GR. 5, A36, HHCS, ½”-13 UNC X 1 ½” LG., GR. 5, ZINC PLTD. WASHER, LOCK, ½”, ZINC PLTD. WASHER, FLAT, ½”, ZINC PLTD. SHSB, ½” X ¾”, 3/8”-16 UNC THRD., BLACK

1

TOP VIEW 5 SHOULDER SCREW TO TIGHTEN AS RUBBER JUST STARTS TO SQUEEZE. IF NEEDED USE TWO FLAT WASHERS.

4

2

3

4

658" FREE 6" LOADED

3 4"

ISOMETRIC VIEW

MNTG. PL.

ELEVATION VIEW 304.8 mm TURBLEX P/N: 71188

12" 6"

6" 5 416 "

5 416 "

NOTES:

CL DRILL & TAP 3 8"-16 UNC THRU HOLES (TYP. 2 PLCS.)

3"

152.4 mm

6"

1.

VIBRATION ISOLATORS, SHIP LOOSE, INSTALLATION NOT BY TURBLEX.

2.

PLEASE REFER TO TAB “A” FOR INSTALLATION INSTRUCTIONS.

3.

PLEASE REFER TO TAB “E” FOR SURFACE PREPERATION & PAINT.

4.

PLEASE TO REFER TO TAB “D” CONSTRUCTION NOTES DRAWING FOR LOCATIONS.

5.

Adhesive: 32430 SEALANTLoctite KIT, TO BE PROVIDED IS Activator: LOCTITE Loctite 20252 21088 “DEPEND”.

6.

MAXIMUM LOAD = 3000 LBS

CL 3"

DETAIL ITEM 1 MOUNTING PLATE SEE NOTE 4

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

Document Name: 4607T-0320 Rev 0

DISCHARGE CONE – 16”x30”x10” B.O.

ITEM 0320

ROTATING PLATE FLANGE (28) 1 3/8" HOLES ON A 36" B.C. DIA ANSI 150#, 30" PIPE CONNECTION SIZE

Ø3834"

TOP VIEW 1/2" NPTF TYP (2) PLCS FOR PRESSURE DEVICES ONLY

3/4" NPTF TYP (2) PLCS FOR TEMP. DEVICES ONLY

23"

141"

13"

3 4"

AIR FLOW

1 2"

Ø16"

(12) 1" HOLES ON A 14 1/4" B.C. DIA ANSI 150#, 10" PIPE CONNECTION SIZE

7378"

ISOMETRIC VIEW

3 4"

ELEVATION VIEW

RIGHT VIEW

NOTES: 1. FASTENERS, NUTS & GASKETS (NOT BY TURBLEX).

Ø2321"

(16) 1 1/8" HOLES ON A 21 1/4" B.C. DIA ANSI 150#, 16" PIPE CONNECTION SIZE BLOW OFF CONNECTION

Ø35"

BOTTOM VIEW

2. DISCHARGE CONE, SHIP LOOSE, INSTALLATION NOT BY TURBLEX. 3. PLEASE REFER TO TAB “E” FOR PAINT SPECIFICATIONS. 4. DISCHARGE CONE SUPPORTED BY CUSTOMER PIPING. 5. MATERIAL TO BE A36 CARBON STEEL. Tag Material: 304L SS 6. WEIGHT: 666 LBS.

K:\STD DRAWINGS\Discharge Cone\16x30x10-short-SUB

1635 W. Walnut Street Springfield, Missouri 65806-1643 Telephone (417) 864-5599 Facsimile (417) 866-0235 E-mail: [email protected] Web Site: www.turblex.com

Document Name: 4607T-0405 Rev 0

INLET FLEX CONNECTOR – KA66S & SV

ITEM 0405

Ø4634"

6"

ISOMETRIC VIEW

FOAM RUBBER MUST MAKE CONTACT 1" BEFORE CLAMP IS TIGHT

ELEVATION VIEW NOTES: 1. FOR KA66 MODEL MACHINES WITH 45 7/8” DIAMETER INLET 2. CLAMP MATERIAL IS 10GA GALVANIZED STEEL 3. WEIGHT: 17.2 LBS. K:\STD DRAWINGS\Inlet Flex Connector\Flex-Conn-KA66S & SV

Document Name: 4607T-0430 Rev A

UNIVERSAL UNRESTRAINED DISCHARGE EXPANSION JOINT SELECTION SHEET JOB NO.

ITEM 0430

4607T - Paul Wurth 3

Required Qty : Air Flow :

31,488.00 SCFM

Pressure:

30.00 PSIG

Disch. Temp:

SHIPPING RESTRAINTS SUPPLY EXPANSION JOINT WITH WELDED BAR SHIPPING RESTRAINTS. RESTRAINTS TO BE PAINTED YELLOW FOR EASY IDENTIFICATION. A TAG IS TO BE AFFIXED TO THE RESTRAINTS STATING " RESTRAINTS TO BE REMOVED AT TIME OF TURBLEX COMPRESSOR START-UP ONLY". PROVIDE AN ARROW FOR FLOW DIRECTION ON SHIPPING RESTRAINTS.

400.00 ºF

FLUID:

AIR

Blower Type:

KA66 MATERIALS

DESIGN CRITERIA

1. BELLOWS AISI 321 STN STL

1. THE REQUIRED LATERAL STATIC DISPLACEMENT IS +/- 1/2" 2. THE SPECIFIED LINER ID NEEDS TO BE THE FIRST DESIGN CRITERIA 3. THE MINIMUM REQUIRED AXIAL DISPLACEMENT IS +/- 1/4"

2. INNER SLEEVE AISI 321 STN STL 3. FLANGES ANSI 1015 C STL

METAL EXPANSION JOINT SIZE ID = 16" 150 LBS FLOATING FLANGE 150 LBS ANSI FLANGE

LENGTH TBD 14"BY VENDOR

FLOW FLOW

150 LBS ANSI FIXED

LINER WELDED TO INLET SIDE 15º ANGLE THE MINIMUM LINER ID NEEDS TO BE EQUIVALENT TO PIPE SCHEDULE 80THE LINER ID NEEDS TO BE MAXIMIZE YET ALLOW SPEC. MOVEMENT

NOTE: INNER SLEEVE (LINER) TO BE WELDED TO EXPANSION JOINT

Exiting Frequencies 1 time x RPM

10,141.60 rpm

Blade Pass

4,056.64 Hz

Vane Pass

0.00 Hz Fax

Fax = Forces in the discharge pipe direction.

Flat M

Flat = Forces perpendicular to Fax. M = Moment in any direction.

BLOWER TYPE

KA66

FAX

FLAT

M

LB.

LB.

IN. LB.

2248

675

13275

PLEASE SUBMIT YOUR BELLOWS DESIGN ANALYSIS AND DRAWINGS WITH YOUR QUOTATION VIA E-MAIL

ITEM 0430

ITEM 0430 METAL EXPANSION JOINT INSTALLATION AND HANDLING INSTRUCTIONS Metal Expansion Joints come in many configurations- from simple to highly complex. This document covers generic applications. For detailed information, we recommend that you contact EJS directly and inquire about your specific installation. More complex unit

Simple unit

•

Units are packaged on skids or crated for transportation. Do not remove the unit(s) from packaging until you are ready to install. The unit(s) should be stored in a clean, dry area. Long term storage should be done under controlled atmosphere.

•

Unpack the units carefully. The bellows portion of the expansion joint is easily damaged and cannot usually be repaired.

•

Inspect the units directly after unpacking has been completed. Report any damage immediately to your Engineering/Inspection Department for correct disposition. EJS will accept no liability for damage after this point.

•

Do not remove the shipping bars, which are normally painted yellow and marked “Remove after Installation but prior to system start up”.

•

Shipping bars can be of various types, i.e. “horseshoe”, “channel” and “angle”. On Hinged and Gimbal type joints, the hinge plates are locked at the hinge point. All shipping bars will be marked with yellow paint with removal information on them.

•

The intent of shipping bars is to hold the unit at its installation position. Before attempting to fit the unit into the system, ensure the mating equipment is aligned correctly. The expansion joint should not be used for field alignment! It was never designed to do so. Resulting damage to the expansion joint can be catastrophic.

1

M:\proceed\install\standards\instal.doc Last Updated 07/00 10035 Prospect Avenue, Suite 202, Santee, CA 92071 (619) 562-6083 Fax (619) 562-0636 E-mail: [email protected] Website: www.ejsus.com

Expansion Joint Systems, Inc.

ITEM 0430 METAL EXPANSION JOINT INSTALLATION AND HANDLING INSTRUCTIONS •

Do not lift the expansion joint by the shipping bars. Lift at the lift points provided or by the clevis pins attached. If the lift point clevis pins are not apparent, use correct industry practice to lift and position the joint safely. Bellows can be damaged easily with chains and improper procedures. Ensure flanges/weld ends are parallel

Shipping Bars

Ensure alignment

Ensure dimension is correct.

•

If the expansion joint is fitted with internal liners, ensure flow direction is correct. The Open end of liner should be towards the downstream side. Flow arrows are shown on the exterior of the unit. Occasionally, the liner may be marked with the flow direction.

•

Some expansion joints are fitted with permanent covers. These should not be removed unless necessary for installation. If covers have to be removed, ensure they are re-fitted as soon as possible.

•

Installation/Construction covers are removed before the system is started. They can be left in place while construction is continuing around the expansion joint. Removing the construction covers should be done carefully. Simple metal straps around the cover retain these covers. Cut through the strap and remove the cover and plastic wrap under the cover.

•

Any convolution distortion should be reported to EJS at the earliest opportunity. Due to the complexity of some designs and design considerations, some bellows may be very thin. These types of bellows may not have convolutions that are evenly spaced or have equal pitch. If in doubt please call EJS.

2

M:\proceed\install\standards\instal.doc Last Updated 07/00 10035 Prospect Avenue, Suite 202, Santee, CA 92071 (619) 562-6083 Fax (619) 562-0636 E-mail: [email protected] Website: www.ejsus.com

Expansion Joint Systems, Inc.

ITEM 0430 METAL EXPANSION JOINT INSTALLATION AND HANDLING INSTRUCTIONS •

Any field alteration to the expansion joint will void the warranty. If an expansion joint has been designed for field alignment it will be stipulated on the drawing. Find a copy of the drawing before installing the expansion joint. Field adjusted expansion joints usually come with supplemental instructions. Flanged Units • Care should be taken to ensure that mating flanges are correctly aligned. Torsion loads imposed on an expansion joint due to bolt-hole misalignment or other causes can lead to reduced cycle life and in some extreme cases, catastrophic failure. •

Ensure liners will clear the inside diameter of the mating flange and pipe.

•

When bolting the joint, care should be taken not to damage the outside diameter of the end convolutions which may be very close to the flange. Test fit the wrench to ensure when you are pulling the unit tight the wrench is not touching the bellows.

Weld End Units • Always protect the bellows element from weld spatter. Cover the bellows with suitable high temperature cloth or insulation. Never strike an arc on the bellows. Weld spatter on the bellows will void any warranty. •

Care should be taken when welding the unit not to cause an out of round condition due to weld shrinkage.

•

Seal off the open end of liner. Use duct tape or other suitable material. After welding inside the unit, remove all pieces of weld rod and spatter which could penetrate the bellows during operation.

BELLOWS ARE HIGHLY SUSCEPTIBLE TO DAMAGE. DENTS, SCRATCHES, WELD SPATTER AND MECHANICAL DAMAGE ARE NOT ACCEPTABLE. • TREAT THE BELLOWS LIKE IT WAS A PIECE OF FINE PORCELAIN. • •

3

M:\proceed\install\standards\instal.doc Last Updated 07/00 10035 Prospect Avenue, Suite 202, Santee, CA 92071 (619) 562-6083 Fax (619) 562-0636 E-mail: [email protected] Website: www.ejsus.com

Expansion Joint Systems, Inc.

ITEM 0430 METAL EXPANSION JOINT INSTALLATION AND HANDLING INSTRUCTIONS Hinged Joints. (Tied Universal Joints with only two Tie Rods) • Hinged Joints are only designed to move in one plane. Ensure the hinge pins are in the correct plane. Extra care should be taken with Tied Units that only have two Tie Rods. These units may have been designed to accept angulation in one plane. The orientation of the tie rods and hinges is of the utmost importance. Install the hinge pins normal to direction of movement. Cold Set/Sprung (preset) units • If the unit has been factory pre-set, or if the unit is going to be pre-set in the field, ensure the offset is toward the direction from which the thermal growth occurs. Unrestrained Expansion Joints • Joints that do not have Tie Rods, Hinges or Pressure Assemblies exert Pressure Thrust onto the system. Ensure guides and equipment can withstand the Pressure Thrust. pressure gradually and ensure the length of the joint increase.

Balanced all anchor Apply the does not

Restrained/Pressure Balanced Expansion Joints • Restrained (Tied) or Pressure Balanced Expansion Joints are designed to absorb the pressure thrust within the expansion joint. Do not remove the tie rods or hinge pins. Without the tie rods the unit will not function correctly. It is impossible for EJS to cover all the requirements and methods of installing expansion joints in this document. We will be happy to answer any question you may have. Please call EJS at anytime. When the installation is complete remove the shipping bars. Check all anchors, guides and pipe supports and then apply test pressure to system. If the test pressure is greater than 1.5 x the design pressure of the expansion joint, contact EJS prior to applying pressure. During testing there should be little to no movement of the bellows or piping. If movement occurs, immediately lower the pressure and re-check the installation. Never test a system with air or other gases when an expansion joint is installed unless consulting EJS.

4

M:\proceed\install\standards\instal.doc Last Updated 07/00 10035 Prospect Avenue, Suite 202, Santee, CA 92071 (619) 562-6083 Fax (619) 562-0636 E-mail: [email protected] Website: www.ejsus.com

Expansion Joint Systems, Inc.

ITEM 0430 METAL EXPANSION JOINT INSTALLATION AND HANDLING INSTRUCTIONS

SUPPLEMENTAL INSTALLATION INSTRUCTIONS FOR

RECTANGULAR/CIRCULAR STEAM CONDENSER/ TURBINE JOINTS •

Landing Bars should be used to accommodate any misalignment from the Turbine to the Condenser. Moving the bellows to accommodate any such misalignment will be detrimental to the life of the unit.

•

Avoid painting the bellows area of the expansion joint. Some types of paint can cause stress corrosion cracking.

•

During initial start up of the system under vacuum conditions, monitor the bellows and ensure that they do not start to deflect inwards. Shut the system down immediately if this occurs and contact EJS.

•

Ensure the bellows area is covered during any welding operations above the bellows area. Weld spatter on the bellows can cause pre-mature failure or vacuum leaks.

•

In some instances the shipping bars are fitted internally, ensure they are removed before system start up.

•

Monitor the bellows center spool for flow induced vibration during start up.

5

M:\proceed\install\standards\instal.doc Last Updated 07/00 10035 Prospect Avenue, Suite 202, Santee, CA 92071 (619) 562-6083 Fax (619) 562-0636 E-mail: [email protected] Website: www.ejsus.com

Expansion Joint Systems, Inc.

FLOWSEAL ®

A Crane Co. Company

ITEM 0520

INSTALLATION and MAINTENANCE INSTRUCTIONS

MANUAL AND AUTOMATED

HIGH PERFORMANCE BUTTERFLY VALVES

CONTENTS

ITEM 0520

Introduction Valve Description ................................................................................................................................... Valve Design Features .......................................................................................................................... Flange Compatibility .............................................................................................................................. Gasket Compatibility .............................................................................................................................. Pipe Schedule Compatibility .................................................................................................................. Product Identification ............................................................................................................................. Operating Pressures .............................................................................................................................. Seat Alternatives ................................................................................................................................... Offset Disc Design ................................................................................................................................. Seat Retainer Alternatives .....................................................................................................................

3 3 3 3 3 3 3 4 4 5

Installation Recommendations Valve Ratings ........................................................................................................................................ 6 Seat Upstream vs Seat Downstream .................................................................................................... 6 Disc Clearances .................................................................................................................................... 6 Opening Rotation ................................................................................................................................... 6 Installation Position ................................................................................................................................ 6 Valve and Flange Preparation ............................................................................................................... 6 Installation Tools .................................................................................................................................... 6 Required Bolting .................................................................................................................................... 6 Unpacking and Storage Instructions ...................................................................................................... 6 Pre-Installation Procedure ..................................................................................................................... 7 Valve Installation Procedure .................................................................................................................. 7 Bolting Dimensions ............................................................................................................................ 8, 9

Maintenance Instructions Safety Precautions .............................................................................................................................. 10 General Maintenance .......................................................................................................................... 10 Packing Replacement .......................................................................................................................... 10 End Cap Seal Replacement ................................................................................................................ 10 Standard Soft Seat Replacement .................................................................................................. 10, 11 Fire-Flow and Metal Seat Replacement .............................................................................................. 12 Disc, Shaft and Bearing Replacement ................................................................................................. 12 Ratchet Handle Mounting Procedure .................................................................................................. 13 Manual Gear Mounting Procedure ...................................................................................................... 13 Remote Actuator (Male Drive) Mounting Procedure ............................................................................ 13 Remote Actuator (Female Drive) Mounting Procedure ....................................................................... 14 Parts List .............................................................................................................................................. 15 Body Rating Charts............................................................................................................................... 16 Flowseal Figure Number System .......................................................................................... Back Cover

FLOWSEAL

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0520

INTRODUCTION SECTION 1 Valve Description

Pipe Schedule Compatibility

The Flowseal High Performance Butterfly Valve (HPBV) is designed for ASME Class 150, 300 and 600 piping systems and is available in both Wafer and Lug style body designs. The standard size range available is as follows:

The Flowseal valve is designed to allow the disc edge to rotate into the open position without interference with pipe of a schedule equal to or lighter to those shown below:

Valve Design Features • Flowseal's HPBV's feature a double offset (or double eccentric) shaft design to minimize seat abrasion and lower torque. This double offset design allows the disc to lift off and “cam” away from the seat as it rotates open. • The Flowseal valve always rotates clockwise to close (when viewed from above) and counterclockwise to open. • The valve body has an Overtravel Stop which prevents the disc from over rotating into the wrong quadrant. This stop is not to be used as a disc position stop; if the disc contacts the Overtravel Stop, this means it has rotated beyond the seat • The Flowseal valve is bi-directional, but the preferred installation position is with the seat in the upstream position (SUS). Note the arrow on the metal tag attached to the valve body for preferred direction of flow.

Flange Compatibility The Flowseal valve is designed to fit between flanges as follows: ASME Class 150 ............................... 2" through 24" MSS SP-44 Class 150 ..................... 30" through 48" ASME Class 300 ............................... 2" through 24" MSS SP-44 Class 300 ..................... 30" ASME Class 600 ............................... 2" through 16"

Size 2" – 12" 14" – 24" 30" 36" – 42" 48"

ASME 150 SCH 80 SCH 40 SCH 30 STD WT XS

ASME 300 SCH 80 SCH 80 SCH 80

ASME 600 SCH 120 SCH 120

Product Identification Every Flowseal valve has a metal identification tag attached to the valve body. Information on this tag includes the valve Figure Number, Size and Pressure Class, Materials of Construction, and Operating Pressures and Temperatures. The metal tag also includes a Serial Number. This number, unique for each valve, is recorded by the Flowseal Quality Control Department along with the valve hydrostatic test results and material certification data for individual traceability and verification of every valve produced.

FLOWSEAL PREFERRED FLOW DIRECTION

ASME Class 150 ............................... 2" through 48" ASME Class 300 ............................... 2" through 30" ASME Class 600 ............................... 2" through 16"

SERIAL NO. FIGURE NO. SIZE/CLASS STEM/PINS SEAT

BODY DISC BRGS

BODY COLD WORKING PRESSURE MAX. SHUT–OFF PRESS. @ 100 °F @

°F

PSI PSI PSI

TAG NO.

Gasket Compatibility

Operating Pressures

The Flowseal valve is designed to accomodate the use of standard fiber gaskets (such as non-asbestos, flexible graphite, asbestos or equivalent gasket materials) of 1⁄16" or less, meeting the dimensional requirements of ASME B16.21. Thick elastomeric gaskets are not recommended. Metallic wound (Flexitallic) gaskets may be used with the wedge ring retainer configuration.

All Flowseal HPBV's may be applied to full ASME ratings. However, different materials of construction may affect the rated pressure. The shut-off pressure rating is determined by the valve shaft and disc materials as well as the seat design, and is reflected on the metal identification tag attached to the valve.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

FLOWSEAL 3

ITEM 0520

INTRODUCTION Seat Alternatives Flowseal HPBV's have three seat alternatives, all of which are bi-directional.

Metal Seats are well suited for higher temperature applications and provide shut-off to ASME B16.104 Class IV.

Soft Seats provide tight shut-off to zero leakage specifications. Standard Soft Seat material includes virgin TFE or reinforced TFE (RTFE).

Disc

Disc

Seat Retainer

Seat Retainer

Body

Body

Metal Seat Profile

Soft Seat Profile

Fire-Flow™ Seats are designed for critical piping applications in installations such as Refinery and Petrochemical Plants. These seats are a combination of both metal and soft seats with the metal seat being designed to function during and after a fire. Valves of this type are referred to as “FireSafe” and are tested to meet API 607 “Fire-Safe” specifications and operation criteria.

Offset Disc Design All Flowseal HPBV's have both off-set discs and eccentric shafts. The off-set is applicable to the disc edge seating surface relative to the shaft center line. By off-setting the seating surface from the rotational center line, a contact with the seat is possible throughout the 360° circumference. The shaft is eccentric in the body by 0.060 inches and this enhances seat life by imparting a camming action to the disc as it rotates both in and out of the seat. Seat wear points are eliminated at the top and bottom of the disc and operating torque is reduced.

Disc

Seat Retainer

Body

Fire-Flow™ Seat Profile

FLOWSEAL 4

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0520

INTRODUCTION Seat Retainer Alternatives Flowseal HPBV's are designed to be easily maintained and, in particular, to allow rapid and simple replacement of the seat. The seat is held in the valve body by a seat retainer

which, when assembled, becomes part of the raised face flange mating surface. Two types of seat retainer fastening designs are used in Flowseal HPBFV's.

Disc

Seat Retainer

Body

Set Screw

Wedge Ring

Wedge Ring Retainer (Wafer and old-style lug valves) This wedge ring design is for wafer and old design standard lug style valves. A wedge ring is forced ( outward into a groove machined in the body by the insertion of set screws in the face of the retainer.

Disc

Seat Retainer

Body

Cap Screw

Cap Screw Retainer (Double-Deadend lug style) C The cap screws in retainer rings on double deadend service lug valves. The retainer is held to the valve body by cap screws recessed in the retainer face.

(

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

FLOWSEAL 5

ITEM 0520

INSTALLATION RECOMMENDATIONS SECTION 2 Valve Ratings

Valve and Flange Preparation

Flowseal HPBV's are intended for use at the pressure and temperatures indicated on the metal nameplate attached to each individual valve. Check the valve operating temperature and pressure ratings on the valve nameplate before proceeding with installation.

If the valve and mating pipe are properly prepared for installation, future problems can be avoided. All valve and pipe flange faces should be free of dirt, grit, dents, or surface irregularities which may disrupt flange sealing and cause external leakage. The valve seat and disc sealing surface should also be inspected to eliminate any dirt or foreign material that will adversely affect the operation of the valve.

Seat Upstream vs Seat Downstream

Installation Tools

Although all Flowseal seat designs are completely bi-directional, every effort should be made to install the valve with pressure and flow from the seat side of the valve (seat upstream). Positive shutoff will be achieved with the valve in either orientation. However, installation with the seat in the upstream position will result in longer service life and lower torque valves.

The only tool required in the installation of a Flowseal HPBFV is a wrench suitable for tightening the flange bolts and/or nuts required to secure the valve in-line. A hoist may be required to help manipulate valves 10" and larger. Smaller sized valves can usually be installed by hand. Temporary pipe supports may be used to keep mating flange faces parallel in order to aid in valve installation.

Required Bolting Disc Clearances Prior to installing the valve, it is important to make sure the ID of the pipe and pipe flanges is large enough to allow the disc edge to swing into the opening without interference. Damage to the disc edge can severly affect the performance of the valve. Pipe schedule compatibility for Flowseal valves is shown in Section 1 of this manual.

Opening Rotation The Flowseal valve is designed to open with counterclockwise rotation of the shaft, and to close with clockwise rotation of the shaft when viewed from above with the shaft in the vertical position. An over-travel stop is provided in the body to prevent over-travel of the disc in the wrong direction. This stop is not to be used as a disc position stop. Contact with this stop means the disc has travelled past the seat.

Installation Position To prevent damage during installation the valve disc must be fully closed before installing the valve in the line. It is preferable to install HPBV's with the shaft horizontal. This is important for valves applied to fluids which contain particulates. For HPBV's 16" and larger, installation should always be made with the shaft horizontal.

FLOWSEAL 6

The tables outlined on the following pages are furnished to provide information regarding the size, type, and quantity of bolting recommended for the installation of Flowseal HPBFV's. These tables are intended for use as a planning and procurement guide. All recommendations are based on pipe flanges in accordance with ASME B16.5 for 2" through 24" valves and MSS-SP-44 for valves 30" and larger. Flange bolting is not included with the valve shipment.

Unpacking and Storage Instructions 1. Check the packing list against the valve received to verify that the size, material, and trim are correct. 2. Check to make sure that the valve and operator were not damaged during shipment. 3. When lifting the valve, take care to avoid damage to the flange faces, disc sealing edge, or operator. On larger valves, lifting holes are provided on the periphery of the valve body to aid in valve handling. 4. If the valve is to be stored before being installed, it should be protected from harsh environmental conditions. 5. Store the valve with the disc in the closed position to protect the sealing edge and the seat. 6. Keep the valve in a clean location, away from dirt, debris and corrosive materials. 7. Keep the valve in a dry area with the flange protectors attached and on a suitable skid or pallet. 8. Keep the valve in a cool location if possible, out of direct sunlight.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0520

INSTALLATION RECOMMENDATIONS Pre-Installation Procedure 1. Remove the protective flange covers from the valve. 2. Inspect the valve to be certain the waterway is free from dirt and foreign matter. Be certain the adjoining pipeline is free from any foreign material such as rust and pipe scale or welding slag that could damage the seat and disc sealing surfaces. 3. Actuators should be mounted on the valve prior to installation to facilitate proper alignment of the disc in the valve seat. 4. The valve should be in the closed position. Make sure the open and closed positions of the actuator correspond to the counter-clockwise to open direction of rotation of the valve.

5. Cycle the valve to the fully open position, then back to the fully closed position, checking the actuator travel stop settings for proper disc alignment. 6. Check the valve identification tag for valve class, materials, and operating pressure to be sure they are correct for the application. WARNING! Personal injury or property damage may result if the valve is installed where service conditions could exceed the valve ratings. 7. Check the flange bolts or studs for proper size, threading, and length.

Valve Installation Procedure The Flowseal High Performance Butterfly Valve can be installed in the pipeline with the shaft in the vertical, horizontal, or other intermediate position. Based on applications experience, however, in media with concentrations of solid or abrasive particles or media subject to solidification buildup, valve performance and service life will be enhanced by mounting the valve with the shaft in the horizontal position. All Flowseal valves are bi-directional and can be mounted in the pipeline in either flow direction; however, the preferred flow direction for all seat styles and materials is with the seat retainer ring located upstream (SUS) to provide maximum seat protection. 1. For Wafer Style Valves: a. Loosely install the lower flange bolts to form a cradle between the flanges. (See Figure 1.) b. Noting the flow direction arrow on the tag, place the valve and flange gaskets between the flanges, making sure the arrow on the tag points in the direction of the flow. c. Install the remaining flange bolts, shifting the valve as necessary to permit the bolts to pass by or through the valve body.

For Lug Style Valves: a. Noting the flow direction arrow on the tag, place the valve between the flanges, making sure the arrow on the tag points in the direction of the flow. b. Install the lower flange bolts loosely, leaving space for the flange gaskets. c. After inserting the flange gaskets, install the remaining bolts. 2. Using the sequence shown in Figure 2, tighten the flange bolts evenly to assure uniform gasket compression. CAUTION!

The Flowseal valve should be centered between the flanges and gaskets to prevent damage to the disc edge and shaft as a result of the disc striking the flange, gasket, or pipe.

3. If an actuator is to be used, air hoses or electricity should be connected to the unit as specified by the actuator manufacturer. 4. The valve is now ready for operation.

Remember: Install the valve with the disc in the FULL CLOSED POSITION.

1

3

4

1

5

8

2

3

4

12

1

5

6

2

1

13

5 9

12

3

4

7 10

15 8

3

4

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

2

9

8

Figure 1

7 6

11 7

10

11

6

Figure 2

14

2

16

FLOWSEAL 7

ITEM 0520

INSTALLATION RECOMENDATIONS BOLTING DIMENSIONS LUG BODY HEX HEAD MACHINE BOLTS F

LUG BODY

WAFER BODY

STUDS & NUTS

STUDS & NUTS

G

D

C B*

A*

Body

Flange

Body

Flange

Body

ASME Class 150 2" – 24" MSS SP-44 Class 150 30" – 48" LUG VALVES BOLT ENGAGEMENT IN VALVE* VALVE SIZE

VALVE SERIES

2"

J

21/2" 3" 4" 5"

J J J J

6"

THREAD SIZE

QTY

LG

QTY

WAFER VALVES

STUDS & NUTS

LG

QTY

B

LG

QTY

MACHINE BOLTS LG

QTY

LG

QTY

STUDS & NUTS LG

QTY

A

A

B

C

C

D

D

F

F

G

G

5

/8-11

4

.940

4

.570

4

2.50

4

2.12

4

1.75

4

1.50

4

5.00

5

4 4 8

.960 1.139 1.071

4 4 8

.680 .725 .745

4 4 8

2.62 3.00 3.00

4 4 8

2.38 3.00 3.00

4 4 8

2.00 1.88 2.00

4 4 8

1.62 1.62 1.62

4 4 8

5.25 6.00 6.00

/8-11 /8-11 5 /8-11 5

E

LG E

3

8

1.220

8

.790

8

3.12

8

2.62

8

2.25

8

1.75

8

6.00

J

3

8

1.401

8

.839

8

3.50

8

2.75

8

2.38

8

1.75

8

6.50

8"

J

3

10" 12" 14"

J J J J J J J

8 12 12 12 16 16 16

1.492 1.752 2.147 2.330 2.648 2.723 3.396

8 12 12 12 16 16 20

.948 1.000 1.025 1.210 1.270 1.645 1.434

8 12 12 12 16 16 16

3.75 4.50 4.50 5.00 5.25 5.50 6.25

8 12 12 12 16 16 20

3.00 3.25 3.25 3.75 4.00 4.50 4.50

8 12 12 12 16 16 16

2.50 2.62 3.38 3.62 4.00 4.25 5.12

8 12 12 12 16 16 20

2.00 2.38 2.25 2.62 2.62 3.12 3.19

8 12 12 12 16 16 16

6.50 7.50 8.00 9.00 10.00 10.50 11.00

4** 20

2.325 3.690

– 20

– 2.250

4** 20

5.25 6.75

– 20

– 5.25

4** 20

4.06 5.50

– 20

– 4.12

8** 20

5.25 12.50

16" 18" 20" 24" 30" 36" 42" 48"

J H H H H H H H H

/4-10

/4-10

/4-10 7 /8-9 7 /8-9 1-8 1-8 11/8-8 1 1/8-8 1 1/8-8 1 1/4-8 11/4-8

24

3.471

24

3.159

24

7.75

24

7.50

24

6.47

24

6.15

24

15.25

11/4-8 11/2-8 11/ 2-8 11/2-8

4** 28 4** 32

1.908 3.760 1.760 4.160

4** 28 4** 32

1.592 3.740 1.740 4.090

4** 28 4** 32

6.00 9.00 6.75 9.75

4** 28 4** 32

5.75 9.00 6.75 9.50

4** 28 4** 32

4.91 7.19 5.25 6.62

4** 28 4** 32

4.59 5.25 5.25 4.25

8** 28 8** 32

6.00 18.25 6.75 19.25

11/2-8 11/2-8 11/2-8

4** 40 4**

1.782 5.520 2.815

4** 40 4**

1.718 4.850 2.190

4** 40 4**

7.25 11.75 7.75

4** 40 4**

7.25 11.00 7.75

4** 40 4**

4.25 9.83 7.12

4** 40 4**

4.25 9.16 6.50

8** 40 8**

7.25 21.00 7.75

Length of machine bolts based on: 1. Gasket thickness of 0.06 inches. 2. Minimum flange thickness of weld neck flanges per ASME B16.5. Every effort is made to provide accurate information, but no liability for claims arising from erroneous data will be accepted by Flowseal.

FLOWSEAL 8

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0520

INSTALLATION RECOMONDATIONS BOLTING DIMENSIONS ASME Class 300 2" – 24" MSS SP-44 Class 300 30" LUG VALVES BOLT ENGAGEMENT IN VALVE* VALVE SIZE

2" 21/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30"

VALVE SERIES

THREAD SIZE

QTY

LENGTH

QTY

QTY

LENGTH

QTY

MACHINE BOLTS LENGTH

QTY

LENGTH

STUDS & NUTS LENGTH

QTY

LENGTH

A

A

B

C

C

D

D

F

G

G

E

5

8 8 8

.940 .970 1.034

8 8 8

.570 .670 .826

8 8 8

2.25 2.75 3.00

8 8 8

2.62 3.00 3.00

8 8 8

1.50 1.75 2.12

8 8 8

2.00 2.00 .75

8 8 8

5.25 5.75 6.00

3

J J J

3

8 8 12

1.196 1.220 1.301

8 8 12

.870 .790 .929

8 8 12

3.50 5.25 3.75

8 8 12

3.25 3.62 3.50

8 8 12

2.50 2.25 2.75

8 8 12

2.00 2.75 2.25

8 8 12

6.50 7.00 7.00

12 16 – 16 – 16

1.702 1.867 – 2.057 – 2.442

12 16 – 16 – 16

1.128 1.300 – 1.475 – 2.118

12 16 – 16 – 16

4.50 5.00 – 5.50 – 6.00

12 16 – 16 – 16

4.00 4.50 – 5.00 – 5.75

12 16 – 16 – 16

3.25 3.25 – 4.00 – 4.62

12 16 – 16 – 16

2.75 3.12 – 3.38 – 4.25

12 14 4** 12 8** 16

8.25 9.25 5.00 10.00 5.25 11.50

4** 16 4**

1.608 2.562 1.538

4** 16 4**

1.267 2.628 1.588

4** 16 4**

5.25 6.50 5.25

4** 16 4**

4.75 6.50 5.25

4** 16 4**

3.75 4.88 3.88

4** 16 4**

3.44 4.88 4.25

8** 16 8**

5.25 13.00 5.25

20 4**

2.870 1.657

20 4**

2.890 1.437

20 4**

7.00 5.50

20 4**

7.00 5.50

20 4**

5.25 4.00

20 4**

5.25 3.88

20 8**

14.00 5.50

20 4** 20

3.184 1.681 3.560

20 4** 20

3.006 1.750 3.510

20 4** 20

7.50 5.75 8.25

20 4** 20

7.25 5.50 8.25

20 4** 20

5.69 4.19 6.31

20 4** 20

5.69 4.00 6.25

20 8** 20

14.50 5.75 16.50

4** 24 4**

1.800 4.331 2.039

4** 24 4**

1.750 4.429 2.071

4** 24 4**

6.25 10.25 8.00

4** 24 4**

6.25 10.50 8.00

4** 24 4**

4.56 7.88 5.44

4** 24 4**

4.50 7.88 5.47

8** 24 8**

6.25 20.50 8.00

J J J J H H

/4-10 /4-10 3 /4-10 7

/8-9 1-8 1-8 1 1/8-8 1 1/8-8 11/8-8 11/8-8

H H

11/4-8 11/4-8 11/4-8 11/4-8 11/4-8

H H H

11/4-8 11/2-8 11/2-8

H H

13/4-8 13/4-8

H H H

F

QTY

J J J J

/8-11 5 /8-11 3 /4-10

B

LENGTH

WAFER VALVES

STUDS & NUTS

E

ASME Class 600 3" – 14" LUG VALVES BOLT ENGAGEMENT IN VALVE* VALVE SIZE

VALVE SERIES

3" 4" 6" 8"

J J J J H

10" 12" 14"

THREAD SIZE

QTY

3

8 8 12 12

1.034 1.274 1.274 1.794

12 4** 16 4** 16 4**

/4-10 7 /8-9 1-8 11/8-8 11/4-8

H H H

11/4-8 11/4-8 11/4-8

H H

13/8-8 13/8-8

A

LENGTH

QTY

LENGTH

QTY

B

B

C

8 8 12 12

1.026 1.165 1.306 1.795

8 8 12 12

2.495 1.375 2.683

12 4** 16

2.000 2.000 2.697

1.325 2.994 1.506

4** 16 4**

1.765 2.996 1.869

A

WAFER VALVES

STUDS & NUTS LENGTH

MACHINE BOLTS

QTY

LENGTH

QTY

LENGTH

LENGTH

QTY

D

D

F

F

G

G

E

E

3.50 3.50 4.75 5.75

8 8 12 12

3.50 3.25 4.75 5.75

8 8 12 12

2.25 2.75 3.25 4.12

8 8 12 12

2.38 2.75 3.25 4.12

8 8 12 12

7.00 7.75 9.50 11.50

12 4** 16

6.75 5.50 7.00

12 4** 16

6.25 6.25 7.00

12 4** 16

5.00 3.88 5.38

12 4** 16

4.50 4.50 5.38

12 8** 16

13.00 6.25 14.00

4** 16 4**

5.25 7.50 6.00

4** 16 4**

6.00 7.50 6.50

4** 16 4**

4.00 CF CF

4** 16 4**

4.38 CF CF

8** 16 8**

6.00 15.00 6.50

C

QTY

STUDS & NUTS LENGTH

* Bolt lengths “A” & “B” are from face of valve body to minimum depth in lug. Flange & gasket thickness must be added to calculate minimum bolt length. ** Special length required for tapped blind holes on either side of the valve shaft at the top and bottom ends of the valve body.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

FLOWSEAL 9

ITEM 0520

MAINTENANCE INSTRUCTIONS SECTION 3 Safety Precautions

Table 1

Before removing the valve from the line or loosening any bolts, it is important to verify the following conditions: 1. 2.

3. 4.

5. 6.

Be sure the line is depressurized and drained. Be sure of the pipeline media. Proper care should be taken for protection against toxic and/or flammable fluids. Never install the valve without an Operator (Manual or Automatic) already attached to the valve shaft. Never remove the Operator from the valve while the valve is in the pipeline under pressure. Flowseal's eccentric valve design may allow line pressure to open the valve if the handle/actuator is not in place while the valve is under pressure. Always be sure that the disc is in the full-closed position before removing or installing the valve. Take care in handling the valve. Personal injury or property damage may result if the valve is damaged or mishandled during maintenance operations.

Valve Size (in.) 2 to 8 10 to 12 14 to 20 24 to 30 36 to 48

Torque (in-lb) 25 35 50 75 100

End Cap Seal Replacement (where applicable) Remove the end cap bolts and lockwashers. Rotate the end cap to break the seal, then pull the cap out. Remove the old seal. Clean the body and end cap prior to installing the new seal. Slide the new seal into place, then guide the end cap into the body. 6. Align the bolt holes and reinstall the lockwashers and bolts. 7. Tighten the bolts evenly to the torque specified in Table 2. 1. 2. 3. 4. 5.

General Maintenance Normal maintenance for a Flowseal HPBFV is limited to adjustment of the shaft packing by tightening down evenly on the gland flange using the gland flange studs and nuts. Overtightening of the gland should be avoided since this will shorten the life of the packing. During commissioning, it is common for dirt and foreign objects to be left in the pipeline during construction. This debris can damage the HPBV seat or disc edge which will prevent the valve from providing tight shut-off. In such cases seat replacement may be necessary.

Packing Replacement 1. 2. 3. 4.

5. 6. 7. 8. 9.

Remove the handle or actuator and the mounting hardware from the valve. Remove the gland flange nuts and lockwashers. Remove the gland flange and gland. Replace the old packing with new packing. Correct packing selection is important. On larger valves it may be necessary to compress each stem seal into the stuffing box before adding the next one. Reinstall gland, gland flange, lockwashers and nuts. Tighten the gland flange nuts evenly to torque specified in Table 1. Operate the disc several times. Reinstall the handle or actuator and mounting hardware. Set the actuator stops.

FLOWSEAL 10

Table 2 Valve Size (in.) 2 to 8 10 to 12 14 to 30

Torque (in-lb) 50 80 100

Standard Soft Seat Replacement 1. Place the valve on a bench with the seat retainer facing up. Use blocks to elevate the valve above the work surface to provide enough clearance to prevent the disc from being damaged when the valve is opened. 2. (a) Cap Screw Retainer: Remove the cap screws and lift the seat retainer out of the valve. (b) Wedge Ring Retainer: Unlock the retainer by removing the set screws. If difficulty is experienced in removing the retainer, open the disc approximately 20 degrees and then tap the retainer with a non-metallic hammer. Lift the retainer from the body. 3. Remove the old seat from the seat retainer and discard. 4. Thoroughly clean the seat cavity in the body and the seat retainer prior to installing a new seat.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

MAINTENANCE INSTRUCTIONS

ITEM 0520

Standard Soft Seat Replacement (cont.) Carefully clean and polish the disc sealing surface with a soft cloth. The disc sealing surface should be free of all grooves and scratches. 6. Place the seat retainer on a flat surface with the seat locating area facing up. 7. Place the new preformed seat assembly (Seat and Oring) on the seat retainer with the marked (tape) side facing down. 8. Using the balls of each thumb, press down on the seat engaging the shoulder of the seat behind the lip in the seat retainer. Stretch the seat into place by sliding each thumb around the circumference of the seat maintaining downward pressure and forcing the seat shoulder over the seat retainer lip. 9. With the disc in the closed position place the seat retainer with seat into the counterbore of the body. (a) Cap Screw Retainer: Apply lubricant to the cap screw threads and tighten them down uniformly. (b) Wedge Ring Retainer: Place the wedge ring in the groove on the outside edge of the retainer taking care to position the wedge ring gap away from any set screw. Using opposing C-clamps, pull the retainer into a position flush with body face. (The C-clamps should not block access to the set screw holes.) 10. Open the disc and relax the retainer pressure slightly to permit the seat to expand fully inward against the seat retaining lip machined in the retainer and body seat cavities. A positive “snap” action will be observed. (a) Cap Screw Retainer: Leaving the valve disc open, retighten the cap screws to the torques specified in Table 3. (b) Wedge Ring Retainer: Leaving the valve disc open, retighten the Cclamps and install the set screws. Remove the Cclamps after all screws have been tightened. 11. Operate the disc several times and inspect the seat for damage before reinstalling the valve in the pipeline. 12. Inspect the position of the disc in the closed position to determine whether the actuator stops are adjusted properly. The face of the disc should be parallel to the seat retainer face when the valve is in the fully closed position. 5.

Table 3 Valve Size (in.) 2 to 12 14 to 20 24 to 48

Torque (in-lb) 50 75 100

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

FLOWSEAL 11

MAINTENANCE INSTRUCTIONS

ITEM 0520

Fire-Flow and Metal Seat Replacement 1. Follow Steps 1 and 2 of Soft Seat Replacement instructions. 2. Remove old soft seat and graphite gaskets and discard. Clean and inspect the metal seat. 3. If metal seat is scored, bent or otherwise damaged it will require replacement. 4. Thoroughly clean the seat cavity in the body and the seat retainer prior to installing the new seat. 5. Carefully clean and polish the disc edge sealing surface with a soft cloth. The disc sealing surface should be free of all grooves and scratches. 6. A graphite gasket is required on both sides of the metal seat. Gaskets can be made from self-adhesive graphite tape as follows: (a) Suggested graphite tape size: 2" - 12" valves – 1/2" wide 14" - 48" valves – 1" wide (b) To install the tape, peel off 6" of backing paper at a time. Apply the tape to the metal seat covering the flat outer edge area on both sides. Overlap the two ends of the tape a minimum of 1/8 inch. Note: It is important that both sides have gaskets. (c) Smooth tape as much as possible by hand. Slight roughness is acceptable and will be pressed flat during final assembly. Avoid tearing tape. If a tear occurs, tape should be overlapped a minimum of 1/8 inch. Trim excess tape from outside diameter of the seat. (d) If cap screw retainer design, bolt holes in metal seat should be opened by slitting an “X” in the hole. Do not attempt to cut round holes. 7. For Fire-Flow valves, place the preformed seat assembly in the body seat cavity with the marked (tape) side up. For metal seated valves, place the 316 SS back-up ring in the body seat cavity. 8. Place the metal seat with graphite gaskets on the TFE seat or 316 SS back-up ring already in the body. The metal seat should be installed with the rounded edge down against the TFE seat or the 316 SS back-up ring. 9. Follow steps 9 thru 12 of Soft Seat Replacement instructions.

Disc, Shaft and Bearing Replacement

FLOWSEAL 12

Flowseal uses a wedge pin method of disc/shaft pinning. This method permits the replacement of either a disc or a shaft since they are not required to be matched sets. 1. Remove any actuator and mounting bracket from top of valve. 2. Remove all top and bottom packing and/or end seals as required. 3. To prepare for removal of existing wedge pins, grind away any disc material that has been peened over pin heads. 4. (a) For Through Shaft Design: Using a punch approximately the same size as the wedge pins, drive each pin out of the disc hub from the non-peened side of the disc to the peened side of the disc. (b) For Split Shaft Design: Pull the wedge pins out of the disc hub using thethreaded holes on top of each pin and a jack screw. 5. Support the valve body and disc on a flat surface in the horizontal position. Slowly remove shaft(s). 6. Remove the disc from the body. 7. To remove bearings, cut or grind a slot lengthwise in each bearing in order to be able to collapse bearing prior to removal. Be careful not to damage bearing seating bore within the body. 8. Clean all components thoroughly. 9. Inspect all parts for damage prior to reassembly. Damaged parts should be repaired or replaced with new parts. 10. Carefully clean and polish the disc sealing surface with a soft cloth. The disc sealing surface should be free of all grooves and scratches. Install the new bearings by gently tapping them into the body with a soft rod and hammer. The bearings should be 11. installed into the shaft bore firmly against the counterbore or bottom of shaft hole. 12. (a) Valves 2" thru 12": With the valve body on edge on the bench, shaft horizontal, and the body overtravel stop nearest to the bench, position the disc in the open position with the flat face upward. Present the disc to the valve body from the side opposite the seat retainer cavity. (b) Valves 14" and larger: Support the disc on a bench, flat side down and elevated above the bench top to a height of approximately 4 inches. Lower the valve body over the disc, seatretainer side facing upward, until the bearing bore and disc hole are aligned. Install the shaft into the body and disc. 13. The shaft keyway when viewed from the top of the valve should be to the right, which is also the direction from which the pins are installed.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

MAINTENANCE INSTRUCTIONS 14. Line up the shaft flat to permit the insertion of the wedge pins. Install the first wedge pin in the disc hole closest to the top of the valve. Finger tight installation is appropriate. 15. Move the shaft fully into the valve and against this first installed pin. Insert the second pin. Tap both wedge pins in equal amounts until all play between shaft and disc is removed. Care should be taken not to attempt to over seat the wedge pins. If the pin is flush or protruding after tapping in, tack weld on the opposite side for security. Otherwise, peening of the installing side is recommended. 16. Install a new end seal if applicable with the end cap as described in Steps 4 through 7 of the End Cap Seal Replacement procedure. 17. Install new packing box components as described in Steps 4 through 10 of the Packing Replacement procedure. 18. Install new seat as described in the Seat Replacement procedure. 19. Cycle the valve several times to ensure the disc is pinned tightly to the shaft and there is no shaft binding or seat damage before reinstalling the valve in the pipeline. 20. Reinstall the actuator mounting hardware and actuator. 21. Set the actuator stops.

Ratchet Handle Mounting Procedure 1. Position the disc in the closed position. 2. Install the ratchet plate using socket head cap screws and lockwashers, but do not tighten the fasteners. 3. Install the drive key in the shaft. Tap the key into place to ensure it is fully seated in the keyway . 4. Install the handle so that it is parallel with the disc face. The locking lever must be fully retracted before it will pass through the ratchet plate. Tighten the set screw in the handle against the key. 5. With the handle installed flush with the ratchet plate, engage the locking lever with the ratchet plate. Using the handle, adjust the position of the ratchet plate until the disc face is parallel with the valve face, then tighten the fasteners securely. Changing the Quadrant: If it is necessary to relocate the handle 180° from its standard position, complete the following steps: 1. Remove the handle by disengaging the locking lever and lifting up. The locking lever will slide thru the ratchet plate only in the disengaged position. 2. Remove the ratchet plate fasteners and rotate the plate 180°. Reinstall the fasteners but do not tighten them. 3. Reinstall the handle 180° from the standard position so that it is parallel with the disc (Note: The locking lever must be disengaged). Tighten the handle set screw against the key. 4. Adjust the ratchet plate as described above. 9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0520 Manual Gear Mounting Procedure 1. Position the disc in the closed position. 2. Install the mounting bracket on the valve body. Fasten it tightIy in place with the appropriate machine bolts and lockwashers. 3. Install the drive key in the shaft. Tap the key into place to ensure it is fully seated. 4. Rotate the gear shaft to the full clockwise position. Align the keyway in the gearbox bore with the key in the shaft and slide the gearbox onto the shaft. 5. Fasten the gearbox to the mounting bracket with the appropriate machine bolts and lockwashers. It may be necessary to rotate the gear shaft slightly to align the mounting holes in the gear with the plate. 6. Adjust the stops in the gearbox to position the face of the disc parallel with the face of the valve in the closed position and perpendicular to the face of the valve in the open position. Changing the Quadrant: If it is necessary to relocate the manual gear handwheel 180° from its standard position, complete the following steps: 1. Close the valve. 2. Remove the bolts and lockwashers holding the gearbox to the mounting bracket. Lift the gearbox off the shaft. 3. Rotate the gearbox 180° around the shaft. 4. Align the key with the gearbox keyseat and slide the gearbox onto the shaft. 5. Reinstall the bolts and lockwashers to fasten the gearbox to the mounting bracket. 6. Adjust the gearbox stops as described previously.

Remote Actuator (Male Drive) Mounting Procedure 1. Position the disc in the closed position. 2. Install the actuator mounting bracket on the valve body with the actuator mounting holes facing up-ward. Fasten the bracket securely in place with the appropriate machine bolts and lockwashers. 3. Install the drive key in the keyway of the shaft. Tap the key in place to insure it is fully seated. 4. Install the drive coupling on the shaft by lining up the proper keyway in the coupling with the key in the shaft. 5. Rotate the actuator shaft to the full clockwise position. Align the drive coupling with the actuator shaft and install the actuator on the mounting bracket. 6. Fasten the actuator to the mounting bracket with the appropriate machine bolts and lockwashers. It may be necessary to slightly rotate the actuator shaft to align the mounting holes in the actuator with the mounting bracket.

FLOWSEAL 13

MAINTENANCE INSTRUCTIONS

ITEM 0520

Remote Actuator (Male Drive) Mounting Procedure (cont.) 7. Adjust the stops in the actuator to position the face of the disc parallel with the face of the valve body in the closed position and perpendicular to the face of the valve body in the open position. Caution: The overtravel stop in the valve body is not to be used as an actuator stop. Changing the Quadrant: If it is necessary to rotate the actuator 90° from standard position, complete the following steps: 1. Close the valve. 2. Remove the bolts and lockwashers holding the actuator to the mounting bracket. Lift the actuator off the mounting bracket. 3. Remove the drive coupling from the valve shaft and rotate it 90° to the adjacent keyway. 4. Reinstall the drive coupling on the valve shaft. 5. Align the drive coupling with the actuator shaft and install the actuator on the mounting bracket. 6. Reinstall the bolts and lockwashers to fasten the actuator to the mounting bracket. 7. Adjust the actuator stops as described above. If it is necessary to rotate the actuator 180° from standard position, complete the following steps. 1. Close the valve. 2. Remove the bolts and lockwashers holding the actuator to the mounting bracket. 3. Lift the actuator off the mounting bracket. Rotate the actuator 180°. 4. Align the drive coupling with the actuator shaft and install the actuator on the mounting bracket. 5. Reinstall the bolts and lockwashers to fasten the actuator to the mounting bracket. 6. Adjust the actuator stops as described previously.

Remote Actuator (Female Drive) Mounting Procedure 1. Position the disc in the closed position. 2. Install the actuator mounting bracket on the valve body with the actuator mounting holes facing up. Fasten the bracket securely in place with the appropriate machine bolts and lockwashers. 3. Install the drive key in the shaft. Tap the key in place to insure it is fully seated. 4. Install the drive coupling on the shaft by lining up the proper coupling keyway with the key in the shaft. 5. Install the drive key in the drive coupling. Tap the key in place to insure it is properly seated.

FLOWSEAL 14

6. Rotate the actuator to the full clockwise position. Align the keyway in the actuator bore with the key in the drive coupling and slide the actuator on the drive coupling. 7. Fasten the actuator to the mounting bracket with the appropriate machine bolts and lockwashers. It may be necessary to rotate the actuator slightly to align the actuator with the mounting bracket. 8. Adjust the stops in the actuator to position the face of !he disc parallel with the face of the valve body in the closed position and perpendicular to the face of the valve body in the open position. Caution: The overtravel stop in the valve body is not to be used as an actuator stop. Changing the Quadrant: If it is necessary to rotate the actuator 90° from standard position complete the following steps: 1. Close the valve. 2. Remove the bolts and lockwashers holding the actuator to the mounting bracket. 3. Lift the actuator off the mounting bracket. 4. Remove the key from the drive coupling and reinstall in the adjacent keyway 90° away. Tap the key in place to ensure it is fully seated. 5. Align the keyway in the actuator bore with the key in the drive coupling and slide the actuator onto the drive coupling. 6. Reinstall the bolts and lockwashers to fasten the actuator to the mounting bracket. 7. Adjust the actuator stops as described previously. If it is necessary to rotate the actuator 180° from its standard position, complete the following steps: 1. Close the valve. 2. Remove the bolts and lockwashers holding the actuator to the mounting bracket. 3. Lift the actuator off the mounting bracket. 4. Remove the drive coupling from the valve shaft and rotate it 90°. 5. Reinstall the drive coupling on the valve shaft. 6. Remove they key from the drive coupling and reinstall the key in the adjacent keyway 90° away. Tap the key in place to ensure it is fully seated. 7. Align the keyway in the actuator bore with the key in the drive coupling and slide the actuator onto the drive coupling. 8. Reinstall the bolts and lockwashers to fasten the actuator to the mounting bracket. 9. Adjust the actuator stops as described previously.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0520

MAINTENANCE INSTRUCTIONS Parts List

4 15, 16

10

14 9 8 1

4 16, 17 15

9 8 1

7

2 5

10

7

2 5

11 13

14

3

3

14

11

6 12, 17

7

6

7

13,18

11, 19

12

Through Shaft Design Item

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Body Seat Retainer Disc Shaft Seat Seat O-ring Bearing Packing Gland Gland Follower Disc Thrust Spacer (2"-5") Set Screws Wedge Pins Gland Flange Stud Gland Flange Nut Lockwasher Wedge Ring

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

Split Shaft Design Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Description Body Seat Retainer Disc Shaft Seat Seat O-ring Bearing Packing Gland Gland Follower End Cap End Cap Bolts Set Screws Wedge Pins Gland Flange Stud Gland Flange Nut Lockwasher Wedge Ring End Cap Seal

FLOWSEAL 15

ITEM 0520

MAINTENANCE INSTRUCTIONS BODY RATING

The charts below reflect the pressure/temperature ratings for carbon steel and stainless steel valves, in accordance with ASME B16.34. The hydrostatic shell test is performed on the body at 150% of the cold working pressure (C.W.P. is defined as the pressure rating between -20 to 100°F and the hydrostatic seat test is performed on the disc and seat at 110% of the cold working pressure.

°F ASME Class

Maximum Non-Shock Working Pressure-PSI Carbon Steel (2) 316SS Carbon Steel (1) 150 300 600 150 300 600 150 300 600

°C ASME Class

Maximum Non-Shock Working Pressure-Bars Carbon Steel (2) 316SS Carbon Steel (1) 150 300 600 150 300 600 150 300 600

HYDROSTATIC 450 1125 2225 SHELL TEST

450 1125 2225

425 1100 2175

HYDROSTATIC SHELL TEST

30

HYDROSTATIC 315 SEAT TEST

315

305

HYDROSTATIC SEAT TEST

22

56.9 112.4

19.6 19.6 19.2 17.7 15.8 14.0 12.1 10.2 8.4 6.5 5.6

51.1 102.1 - 19.0 49.6 51.1 102.1 19.6 51.1 102.1 19.0 49.6 50.1 100.2 19.2 50.1 100.2 18.4 48.1 46.4 92.8 17.7 46.4 92.8 16.2 42.2 45.2 90.5 15.8 45.2 90.5 14.8 38.5 43.8 87.6 14.0 43.8 87.6 13.7 35.7 41.7 83.4 12.1 41.7 83.4 12.1 33.4 38.7 77.5 10.2 38.7 77.5 10.2 31.6 37.0 73.9 8.4 37.0 73.9 8.4 30.4 34.5 69.0 6.5 34.5 69.0 6.5 29.1 28.8 57.5 5.6 28.8 57.5 5.6 28.7 4.7 28.1 2.8 26.8 1.9 25.8

-20 - 32 32-100 200 300 400 500 600 650 700 750 800 850 900 1000 (1) (2)

285 285 260 230 200 170 140 125 110 95 80

815 740 740 675 655 635 600 550 535 535 505 410

1630 1480 1480 1350 1315 1270 1200 1095 1075 1065 1010 825

285 260 230 200 170 140 125 110 95 80

815 740 675 655 635 600 550 535 535 505 410

1630 1480 1350 1315 1270 1200 1095 1075 1065 1010 825

275 275 240 215 195 170 140 125 110 95 80 65 50 20

800 720 720 620 560 515 480 450 445 430 425 415 405 395 365

1585 1440 1440 1240 1120 1030 955 905 890 865 845 830 810 790 725

CE impact tested materials and standard non-impact tested materials. CE non-impact tested materials.

COMPONENTS RATING The chart at right reflects the maximum temperature ratings for individual components of the Flowseal HPBFV. Special care should be taken when specifying component materials for valves at elevated temperatures, especiallymetal seat valves. Consult factory if additional information is required re-garding the suitability of components for specific pressure/temperature applications.

-29 to 0 0 to 38 50 100 150 200 250 300 350 400 425 450 500 525 (1) (2)

77

22

77

153

29

75

150

56.9 112.4 20.9 54.6 109.3 99.3 99.3 96.3 84.4 77.0 71.3 66.8 63.3 60.8 58.2 57.3 56.2 53.7 51.6

Temperature

Description & Material °F Seat Seal (Soft Seated) TFE RTFE UHMWPE Seat Seal (Fire-Flow) TFE/Inconel RTFE/Inconel Seat Seal (Metal Seats) Inconel 718 316 Stainless Steel Seat O-Ring Silicone (Standard with RTFE) Viton (Standard with TFE) Stem Packing TFE Graphite

Bearings TFE/Fiberglass Composite RTFE/316 Stainless Steel Bronze Steel 316 Stainless Steel Disc Treatment Electroless Nickel Plating Stellite Malcomizing

16

30

CE impact tested materials and standard non-impact tested materials. CE non-impact tested materials.

Shaft 17-4PH H1150 17-4PH H1150M 316 Stainless Steel K-Monel 500 Inconel 718

FLOWSEAL

153

°C

-100 to 400 -100 to 500 -100 to 200

-73 to 204 -73 to 260 -73 to 93

-100 to 400 -100 to 500

-73 to 204 -73 to 260

-100 to 1150 -100 to 1000

-73 to 621 -73 to 538

-100 to 500 -50 to 400 -100 to 500 -100 to 1150

-73 to 260 -46 to 204 -73 to 260 -73 to 621

-100 to 800 -100 to 800 -100 to 1150 -100 to 1150 -100 to 1150

-73 to 427 -73 to 427 -73 to 621 -73 to 621 -73 to 621

-100 to 500 -100 to 500 -100 to 750 -100 to 1150 -100 to 1000

-73 to 260 -73 to 260 -73 to 339 -73 to 621 -73 to 538

-100 to 750 -100 to 1150 -100 to 900

-73 to 399 -73 to 621 -73 to 482

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0520 FLOWSEAL FIGURE NUMBER SYSTEM 0

1

1. Size

1

Code

2" 2 1/2" 3" 3 1/2" 4" to 48"

A

W

Code

3. Body Type

0 1 3 6 Code

Wafer Lugged Lugged DDES

5. Body Material

A

C

1 2 3 4 5 8 A B C H X

Note 1: Shaft materials other than 17-4 PH or Monel will affect working pressure ratings. Please consult factory. Note 2: DDES = Double Dead End Service. Note 3: For CE marked valves, see Body Rating chart on page 16, as temp ranges can vary per material.

0 2 3 4 5 7 8 9 A B C H J X Code

8. Seat Material / O-Ring

Code

Carbon Steel 316 SS Monel Alloy 20 Alum Bronze MIL-B-24480 Alum Bronze B148 ASTM C958 ASTM A744 CN-3MN 2205 Duplex ASTM A890 Gr 4A 254 SMO Hastelloy C Special

T

Code

17-4PH SS (See Note 1) 316 SS Monel (See Note 1) Alloy 20 Inconel 718/750 Ferralium A479 Nitronic 50 ASTM A744 CN-3MN 2205 Duplex ASTM A890 Gr 4A 254 SMO Hastelloy C Special

Code

Straight Class 150 2" - 12" Class 150 36" - 48" Class 300 2" - 12" & 30" Class 600 2" - 8" Balanced Class 150 14" - 30" Derated 36" - 48" (150 psig max.) Class 300 14" - 24" Class 600 10" - 16"

R

7. Shaft Material

W L D

4. Shaft Design

1

Alum Bronze/ENP B148 C958 316 SS Monel Alloy 20 Alum Bronze MIL-B-24480 316 SS Nitrided Alum Bronze B148 ASTM C958 316 SS/ENP ASTM A744 CN-3MN 2205 Duplex ASTM A890 Gr 4A 254 SMO Hastelloy C Hastelloy C/ENP Special

48

150 PSI Max. Diff. Pressure ASME 150 ASME 300 ASME 600

2

6. Disc Material

02 025 03 035 04

2. Body Class

1

TFE / Viton TFE/Neoprene RTFE / ** RTFE / AFLAS Polyethylene (UHMWPE) / Viton Fire-Flow (TFE & Metal) / Viton Fire-Flow (RTFE & Metal)/Viton Fire-Flow (RTFE & Metal) / Silicone Inconel 300 SS Fire-Flow (TFE & Monel) / Viton Fire-Flow (RTFE & Monel) / Silicone Fire-Flow (TFE & Hastelloy C) / Viton Fire-Flow (RTFE & Hastelloy C) / Silicone Special

** Original may be Silicone or Viton.

1 2 3 4 6 7 0 A B C H X Code T N R O L F A B M S C J H K X

Example: 12 - 1WA - 171MTG - 3 Gear Operated

B

O

J

9. Packing Material TFE Graphite Fire-Flow Special Live-Load Packing/TFE Live-Load Packing/Graphite Live-Load Packing/Fire-Flow EF Seal (Viton O-Rings)/TFE 10. Bearing Material

Hydraulic Actuator: Pneumatic Actuators:

• Crane Revo® spring return pneumatic actuator • Crane Revo® double acting pneumatic actuator

Electric Actuators:

• Series 44000 electric actuator

T G F X A B C D Code

316 SS Backed TFE

H

Stainless Steel Nitrided Bronze Monel Hastelloy C Backed TFE Special

S B K J X

11. Actuator Type Bare Shaft Ratchet Handle Ratchet Handle w/Lock Throttle Worm Gear Worm Gear (4-Way keyed) Pneumatic Double Acting Pneumatic SR Fail Close Pneumatic SR Fail Open Hydraulic Electric Other 12. Special Feature

Code B H L T 3 9 4 5 6 7 8 X Code

None O Level 2 Commercial Oxygen Cleaning A Bi-directional B Chlorine Service C Dead-end Service (DDES) D CE Marked (impact tested) PI CE Marked (non-impact tested) PN Flat Face F Silicone Free G Epoxy Coated Body H Chainwheel J Stem Extension K Lockable Gear L Mil-V-24624 M NACE Construction N 60 to 125 AARH Facing S Vacuum Service V Further Description Required X

*Factory Assigned

Lever: Five types available: • High temperature service • Buried service • Submersible service • Marine service • Standard aluminum handwheel

Code

13. Series

FLOWSEAL ACTUATOR OPTIONS: Worm Gear Operators:

G

Optional: • Chain wheel • Output shaft extension • Input shaft extension • Military special operator • AWWA special operator

J

ITEM 0530

CENTER LINE INSTALLATION and MAINTENANCE INSTRUCTIONS

MANUAL AND AUTOMATED

RESILIENT SEAT BUTTERFLY VALVES

CONTENTS

ITEM 0530

Introduction Valve Description ................................................................................................................................... Valve Design Features .......................................................................................................................... Flange and Pipe Schedule Compatibility ............................................................................................... Gasket Compatibility .............................................................................................................................. Operating Pressures .............................................................................................................................. Product Identification .............................................................................................................................

3 3 3 3 3 3

Installation Recommendations Valve Ratings ........................................................................................................................................ 4 Valve Seat Position ............................................................................................................................... 4 Disc Clearances .................................................................................................................................... 4 Opening Rotation ................................................................................................................................... 4 Installation Position ................................................................................................................................ 4 Valve and Flange Preparation ............................................................................................................... 4 Installation Tools .................................................................................................................................... 4 Required Bolting .................................................................................................................................... 4 Unpacking and Storage Instructions ...................................................................................................... 4 Pre-Installation Procedure ..................................................................................................................... 5 Valve Installation Procedure ............................................................................................................ 5 & 6 Flange Bolting Recommendations ......................................................................................................... 7

Maintenance Instructions Safety Precautions ................................................................................................................................ 8 General Maintenance ............................................................................................................................ 8 Butterfly Valve Disassembly .................................................................................................................. 8 Butterfly Valve Assembly ................................................................................................................. 8 & 9 Check Valve Disassembly ..................................................................................................................... 9 Check Valve Assembly ........................................................................................................................ 10 Ratchet Handle Mounting Procedure .................................................................................................. 10 Manual Gear Mounting Procedure ...................................................................................................... 10 Remote Actuator (Male Drive) Mounting Procedure ............................................................................ 10 Remote Actuator (Female Drive) Mounting Procedure ....................................................................... 10 Parts List .............................................................................................................................................. 11 Centerline Figure Number System ................................................................................................. 12-16

CENTER LINE 2

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

INTRODUCTION

ITEM 0530

SECTION 1 Valve Description

Gasket Compatibility

The Center Line Resilient Seat Butterfly Valve (RSBFV) is designed for use in ASME Class 150 piping systems and is available in both Wafer and Lug style body designs. The standard valve size range available is as follows: • Series 200 200 psi Standard BFV 2" to 12" 150 psi Standard BFV 14" to 36" • Series 225 285 psi BFV 2" to 24" • Series 250 285 psi BFV (SS & CS) 2" to 24" • Series 300 Two-piece Stem 2" to 12" • Series 800 Check Valve 2" to 24" Center Line Series 225 Butterfly Valve are also available with an ASME Class 300 bolt pattern for Lug bodies of sizes 2" through 12".

In the Center Line butterfly valve and check valve design, the elastomer seat extends beyond the valve face and provides a leakproof seal between the valve and the mating pipe flange faces. Gaskets are not needed and should not be used when the valve is installed between standard weld neck or slip-on type flanges.

Valve Design Features • The unique Center Line seat and disc design insures positive valve sealing while maintaining low seating torque. • All Center Line Butterfly Valve discs are precision machined to a half ball profile, providing a precise disc to seat relationship. • Center Line's cartridge style seat incorporates an elastomer bonded to a phenolic stabilizing ring, eliminating elastomer movement and reducing seat tearing or fatiguing due to bunching. • Center Line's basic three bushing design completely isolates the valve shaft from the body, resulting in increased control of the valve disc, lower valve seating torque, and longer valve life. • The Center Line cartridge seat has a much smaller mass of elastomer than traditional boot seat designs, limiting seat swell and the accompaning variations in seating torque.

Operating Pressures All Center Line Series 200 and 205 Butterfly Valves are rated at 200 psi bubble tight shut-off for sizes 2" to 12" and 150 psi bubble tight shut-off for sizes 14" and larger. Center Line Series 225 Butterfly Valves are rated for bubble tight shutoff at 285 psi, while Series 400 Damper Valves which are not designed for bubble tight shut-off have a body working pressure of 200 psi. Center Line Series 800 Check Valves are rated at a minimum pressure differential of 25 psi and a maximum pressure differential of 150 psi for bubble tight shut-off.

Product Identification Each Center Line valve has an identification tag attached to the valve body. Information on this tag includes the valve Series Number, materials of construction for the Body, Disc, and Seat, and the valve Pressure Rating.

Flange and Pipe Schedule Compatibility The Center Line RSBFV is designed to fit between standard piping flanges as follows: • ASME 125 Cast Iron Flanges (All Sizes) • ASME 150 Steel Flanges, Schedule 40 (All Sizes) • ASME 150 Steel Flanges, Schedule 80 (2" to 10") • ASME 300 Steel Flanges, Schedule 40 (Series 225 Lug, 2" to 12" only). When using Schedule 80 piping, special care must be taken to make sure the valve is centered between the flanges to prevent damage to the disc edge when opening or closing.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

CENTER LINE SERIES BODY DISC SEAT RATING

PSI

CENTER LINE 3

ITEM 0530

INSTALLATION RECOMMENDATIONS SECTION 2 Valve Ratings

Valve and Flange Preparation

Center Line valves are intended for use at the pressure indicated on the nameplate attached to each individual valve. Check the valve operating temperature and pressure rating before proceeding with installation.

If the valve and mating pipe are properly prepared for installation, future problems can be avoided. All valve seat and pipe flange faces should be free of dirt, grit, dents, or surface irregularities which may disrupt flange sealing and cause external leakage. The valve disc sealing surface should also be inspected to eliminate any dirt or foreign material that will adversely affect the operation of the valve.

Valve Seat Position All Center Line butterfly valves are completely bi-directional, so installation is not dependent on seat orientation. For Center Line Series 800 Check Valves, every effort should be made for installation with backflow protection (no flow) into the seat side of the valve. Bubble-tight shutoff will be achieved in this orientation with 25 to 150 psi ∆P across the valve.

Disc Clearances Prior to installing the valve, it is important to make sure the ID of the pipe and the pipe flanges are large enough to allow the disc edge to swing into the opening without interference. Damage to the disc edge can severly affect the performance of the valve. Flange and pipe schedule compatibility for Center Line valves is shown in Section 1 of this manual.

Opening Rotation The Center Line valve disc can rotate 360° without damaging the valve or elastomer seat. The valve is designed to open with either clockwise or counterclockwise rotation of the shaft.

Installation Tools The only tool required in the installation of a Center Line RSBFV is a wrench suitable for tightening the flange bolts and/or nuts required to secure the valve in-line. A hoist may be required to help manipulate valves 10" and larger. Smaller sized valves can usually be installed by hand. Temporary pipe supports may be used to keep mating flange faces parallel in order to aid in valve installation.

Required Bolting The table outlined on Page 7 is furnished to provide information regarding the size, type, and quantity of bolting recommended for the installation of Center Line RSBFV's. This table is intended for use as a planning and procurement guide. All recommendations are based on pipe flanges in accordance with ASME 125/150 specifications. Flange bolting is not included with the valve shipment.

Installation Position

Unpacking and Storage Instructions

To prevent damage to the disc and seat during installation, the valve disc should be slightly open but not extending beyond the valve liner face. Positioning the disc in this “almost closed” position will reduce seat interference and initial torque build-up during valve installation.

1. Check the packing list against the valve received to verify that the size, material, and trim are correct. 2. Check to make sure that the valve and operator were not damaged during shipment. 3. When lifting the valve, take care to avoid damage to the flange faces, disc sealing edge, or operator. 4. If the valve is to be stored before being installed, it should be protected from harsh environmental conditions. 5. Store the valve with the disc in the “almost closed” position to protect the sealing edge and the seat. 6. Keep the valve in a clean location, away from dirt, debris and corrosive materials. 7. Keep the valve in a dry area with the flanges protected and on a suitable skid or pallet. 8. Keep the valve in a cool location if possible, out of direct sunlight.

In general, it is preferable to install RSBFV's with the shaft in a horizontal orientation. In this position, shaft and disc weights are evenly distributed, minimizing seat wear. Additionally, any foreign matter which may accumulate at the bottom of the disc and shaft is effectively removed each time the valve is opened. Center Line butterfly valves are designed to operate between two flanges. If the valve installation calls for the use of one pipe flange only, a Lug style valve with Dead End Service feature must be used.

CENTER LINE 4

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

INSTALLATION RECOMMENDATIONS

ITEM 0530

Pre-Installation Procedure 1. Remove any protective flange covers from the valve. 2. Inspect the valve to be certain the waterway is free from dirt and foreign matter. Be certain the adjoining pipeline is free from any foreign material such as rust and pipe scale or welding slag that could damage the seat and disc sealing surfaces. 3. Any actuator should be mounted on the valve prior to installation to facilitate proper alignment of the disc in the valve seat. 4. Check the valve identification tag for materials, and operating pressure to be sure they are correct for the application. WARNING! Personal injury or property damage may result if the valve is installed where service conditions could exceed the valve ratings. 5. Check the flange bolts or studs for proper size, threading, and length.

Valve Installation Procedure Position the connecting pipe flanges in the line to insure proper alignment prior to valve installation. Spread the pipe flanges apart enough to allow the valve body to be located between the flanges without actually contacting the flange surfaces (See Figure 1.) Exercise particular care in handling the valve so as to prevent possible damage to the disc or seat faces. 1. For Wafer style valves: a. Place the valve between the flanges. b. Loosely install the two upper and lower flange bolts that pass through the body alignment holes. c. Install the remaining flange bolts, shifting the valve as necessary to permit the bolts to pass by the valve body. Hand tighten all bolts as necessary.

For Lug style valves: a. Place the valve between the flanges. b. Install all bolts between the valve and the mating flanges. Hand tighten bolts as necessary. For Check Valves: a. Note the opening direction of the disc for proper valve orientation. b. Place the valve between the flanges using the four (4) alignment holes provided. c. Install the remaining flange bolts, shifting the valve as necessary to permit the bolts to pass by the valve body. Hand tighten bolts as necessary. 2. Before completing the tightening of any bolts, the valve should be centered between the flanges and then carefully opened and closed to insure free, unobstructed disc movement (See Figure 2.) 3. Using the sequence shown in Figure 3, tighten the flange bolts evenly to assure uniform compression. 4. If an actuator is to be used, air hoses or electricity should be connected to the unit as specified by the actuator manufacturer. 5. Cycle the valve to the fully open position, then back to the fully closed position, checking the actuator travel stop settings for proper disc alignment. The valve should be operated to assure that no binding is taking place. 6. The valve is now ready for operation.

Remember: Install the valve with the disc in the “ALMOST CLOSED” position. Do not use any flange gaskets.

Figure 1-Initial Installation of Valve Incorrect Disc opened beyond valve body face. Pipe flanges not spread sufficiently.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

Correct Disc positioned in the almost closed position. Pipe flange spread allows sufficient room for valve.

CENTER LINE 5

INSTALLATION RECOMMENDATIONS

ITEM 0530

Figure 2-Centering and Flanging of Valve Correct No flange gaskets used. Disc in the “almost closed” position.

Incorrect Disc in closed position. Gaskets installed between valve and mating flanges.

Gasket

Figure 3-Flange Bolt Tightening Sequence

1 1 4

3

8

2

4

5

12 3 7

6

2

1

15

5 9

1

13

5

8

9

8

3

12

3

4

7

4

11

10

6

2

11

7

10 6

14

2

16

Figure 4-Final Valve Alignment and Tightening of Flange Bolts

Incorrect Pipe Flanges mis-aligned. Uneven torque applied to bolting.

CENTER LINE 6

Correct Piping aligned. Thread engagement even on both sides of valve.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0530

INSTALLATION RECOMMENDATIONS Flange Bolting Recommendations

Center Line Wafer And Lug Valves, 2"-30", ASME 125/150 Bolt Pattern Valve Size

Thread Size

Number Required

Stud Length Wafer B'fly (in.)

Stud Length Check Valve (in.)

2"

5/8-11

4

4.750

5.125

1.250

15-60

2 1/2"

5/8-11

4

5.250

5.375

1.500

15-60

3"

5/8-11

4

5.250

5.375

1.500

15-60

4"

5/8-11

8

5.750

6.000

1.750

15-60

5"

3/4-10

8

6.000

6.375

1.750

25-100

6"

3/4-10

8

6.250

7.000

2.000

25-100

8"

3/4-10

8

6.750

8.000

2.250

25-100

10"

7/8-9

12

7.250

8.500

2.250

50-200

12"

7/8-9

12

7.750

9.750

2.500

50-200

14"

1-8

12

8.250

12.250

2.750

70-300

16"

1-8

16

8.750

11.750

2.750

70-300

18"

1 1/8-7

16

10.000

13.000

3.500

100-400

20" Series 200

1 1/8-7

20

11.250

14.500

4.250

100-400

20" Series 225

1 1/8-7

16 + 4 ea.

11.250 5.000

4.250 3.250

100-400 100-400

24" Series 200

1 1/4-7

20

12.750

4.750

150-500

24" Series 225

1 1/4-7

16 +4 ea.

12.750 5.250

4.750 3.750

150-500 150-500

30" Series 200

1 1/4-7

24 +4 ea.

13.750 5.750

4.500 4.250

150-500 150-500

15.125

Bolt Length Lug B'fly (in.)

Req. Torque (Ft-lbs)

Bolting and torque recommendations are made without a warranty, and apply only to steel weld-neck or slip-on flanges. The use of lock washers and/or lubrication with the bolting will affect stated torque values.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

CENTER LINE 7

MAINTENANCE INSTRUCTIONS

ITEM 0530

SECTION 3 Safety Precautions

Butterfly Valve Assembly

Before removing the valve from the line or loosening any bolts, it is important to verify the following conditions:

1. Thoroughly clean all parts. Inspect components for any defects. 2. Apply a small amount of silicone grease to the inside surfaces of the body, including the upper and lower shaft holes. 3. Insert the shaft bushings into the body being careful not to allow intrusion into the body seat bore. 4. Install the seat into the center of the body, making sure the shaft holes in the seat line up with the holes in the body.

1. 2.

3. 4. 5.

Be sure the line is depressurized and drained. Be sure of the pipeline media. Proper care should be taken for protection against toxic and/or flammable fluids. Never remove the valve without an Operator (Manual or Automatic) already attached to the valve shaft. Never remove the Operator from the valve while the valve is in the pipeline under pressure. Always be sure that the disc is in the closed position before removing the valve.

General Maintenance The following periodic preventative maintenance practices are recommended for all Center Line Butterfly Valves. 1. 2. 3. 4.

Operate the valve from full open to full closed to assure operability. Check flange bolting for evidence of loosening and correct as needed. Inspect the valve and surrounding area for previous or existing leakage at flange faces or shaft connections. Check piping and/or wiring to actuators and related equipment for looseness and correct as needed.

Resilient Seat Bushings

5. Completely coat the inside surfaces of the seat with silicone grease. Carefully push the disc into the seat in the open position (90 degrees to the body.) Line up the shaft holes of the disc as close as possible with the shaft holes in the seat body.

Butterfly Valve Disassembly 1. 2.

3. 4. 5.

6.

Position valve flat with the disc in the closed position. Loosen the taper pin(s) from the valve disc using a hammer and punch. Note: Punch should be of same size or larger diameter as small end of taper pin to avoid mushrooming of taper pin. Remove taper pin(s) from disc. Extract the valve shaft from the body using a twisting motion. Remove the valve disc from body making sure not to damage the seat or disc sealing edge. Cartridge seat removal can be accomplished from either direction by applying pressure evenly on one face to push the seat through the body. If the valve is of dead end service design, remove set screws around periphery of body extending into seat prior to seat removal. Remove shaft bushings from body as required.

CENTER LINE 8

Disc

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0530

MAINTENANCE INSTRUCTIONS Butterfly Valve Assembly

Check Valve Disassembly

(continued from page 8)

1. Remove set screw (7) from the alignment body (1).

6. Insert the shaft through the body and disc, use a twisting motion to align the keyway parallel with the disc.

Shaft

2. Remove the valve insert (4) from the alignment body (1). 3. Remove shaft plugs (8) from the insert with a screwdriver. Note: Plugs are sometimes difficult to loosen. When this happens, apply heat with small torch directly to the plug for 30 seconds. Do not allow the flame to touch the elastomer face on either side of the inset. 4. Remove the shaft (3) from the valve insert. Note: When the stem is removed, the springs (5) behind the check plates (2) will be released. On sizes 8" to 20", these springs must be securely held to prevent recoil upon loss of tension. 5. Remove the check valve plates (2) from the valve insert. Note the location of the thrust washers (6). These must be replaced in the same location upon reassembly.

7. Insert taper pin(s) into the disc and set with two or three sharp blows. Wipe dust shield o-ring with silicone grease and place over the shaft into the top of the body. 8. If the valve is of dead end service design, insert set screws through the body into the seat.

8 3

Key O-Ring

4 8 1 6

2

Taper Pins

2

6

5 5

1 7

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

CENTER LINE 9

MAINTENANCE INSTRUCTIONS Check Valve Assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Place valve plates (2) into the insert (4). Replace thrust washers (6) in original location. Install shaft (3) half way into the insert. Pre-load first spring (5) with 1/2 turn windup. Do not unwind spring. Legs of spring should be horizontal, 180° apart. Place spring (5) on shaft (3) and release. Install shaft (3) just far enough to allow installation of second spring (5). Push shaft (3) completely into insert (4). Replace shaft plugs (8) in insert (4) with pipe thread sealant and tighten firmly. Place insert (4) in body (1) with tapped hole in body aligned with drill point in insert. Replace set screw (7) and tighten.

Ratchet Handle Mounting Procedure 1. Position the disc in the closed position. 2. Install the ratchet plate using machine bolts, nuts and lock washers, but do not tighten the fasteners. 3. Install the drive key in the shaft. Tap the key into place to ensure it is fully seated in the keyway . 4. Install the handle so that it is parallel with the disc face. The locking lever must be fully retracted before it will pass through the ratchet plate. Tighten the set screw in the handle against the key. 5. With the handle installed flush with the ratchet plate, engage the locking lever with the ratchet plate. Using the handle, adjust the position of the ratchet plate until the disc face is parallel with the valve face, then tighten the fasteners securely.

Manual Gear Mounting Procedure 1. Position the disc in the closed position. 2. Install the drive key in the shaft. Tap the key into place to ensure it is fully seated. 3. Rotate the gear shaft to the full clockwise position. Align the keyway in the gearbox bore with the key in the shaft and slide the gearbox onto the shaft. 4. Fasten the gearbox to the mounting bracket with the appropriate machine bolts and lock washers. It may be necessary to rotate the gear shaft slightly to align the mounting holes in the gear with the plate. 5. Adjust the stops in the gearbox to position the face of the disc parallel with the face of the valve in the closed position and perpendicular to the face of the valve in the open position.

CENTER LINE 10

ITEM 0530 Remote Actuator (Male Drive) Mounting Procedure 1. Position the disc in the closed position. 2. Install the actuator mounting bracket on the valve body with the actuator mounting holes facing up-ward. Fasten the bracket securely in place with the appropriate machine bolts, nuts, and lock washers. 3. Install the drive key in the keyway of the shaft. Tap the key in place to insure it is fully seated. 4. Install the drive coupling on the shaft by lining up the proper keyway in the coupling with the key in the shaft. 5. Rotate the actuator shaft to the full clockwise position. Align the drive coupling with the actuator shaft and install the actuator on the mounting bracket. 6. Fasten the actuator to the mounting bracket with the appropriate machine bolts and lock washers. It may be necessary to slightly rotate the actuator shaft to align the mounting holes in the actuator with the mounting bracket. 7. Adjust the stops in the actuator to position the face of the disc parallel with the face of the valve body in the closed position and perpendicular to the face of the valve body in the open position.

Remote Actuator (Female Drive) Mounting Procedure 1. Position the disc in the closed position. 2. Install the actuator mounting bracket on the valve body with the actuator mounting holes facing up. Fasten the bracket securely in place with the appropriate machine bolts, nuts, and lock washers. 3. Install the drive key in the shaft. Tap the key in place to insure it is fully seated. 4. Install the drive coupling on the shaft by lining up the proper coupling keyway with the key in the shaft. 5. Install the drive key in the drive coupling. Tap the key in place to insure it is properly seated. 6. Rotate the actuator to the full clockwise position. Align the keyway in the actuator bore with the key in the drive coupling and slide the actuator on the drive coupling. 7. Fasten the actuator to the mounting bracket with the appropriate machine bolts and lock washers. It may be necessary to rotate the actuator slightly to align the actuator with the mounting bracket. 8. Adjust the stops in the actuator to position the face of !he disc parallel with the face of the valve body in the closed position and perpendicular to the face of the valve body in the open position.

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

ITEM 0530

MAINTENANCE INSTRUCTIONS

Parts List Series 200, 225, 250 Butterfly Valve

6 4 7 8

Item

Description

1

9 3 5

2

6

Body

2

Disc

3*

Seat

4

Shaft

5*

Taper Pin

6

Key

7*

O-Ring

8

Bushing

9

Bushing

10

Bushing

11

8

Detail A

*Recommended Spare Parts

10 1 Series 800 Check Valve Item

4

Description

1*

Valve Body

2*

Liner (Molded to Item 1)

3

Shaft

4

Shaft Plug (Qty. 2)

5

Plate (Qty. 2)

6

Thrust Washer (Qty. 4)

7

Spring (Qty. 2)

8

Alignment Body

9

Set Screw

10

Plate Travel Stop (14" & larger only)

* Items 1 and 2 Must Be Ordered Together.

3

6

2 1

7 5

9 7

4

8

6 10

9860 Johnson Road, Montgomery, TX 77316 936/588-4447 FAX 936/588-4427

CENTER LINE 11

Center Line Series 200 Custom Product

ITEM 0530

EXAMPLE: 02 AV02135X-D 2" 200 Wafer Series, Epoxy Coated Ductile Iron Body, 200 PSI, DI-ENP Disc, 416 SS Stem, PTFE Bushings, EPDM liner, No Operator (Bare Stem), Custom 1

30

2

A

3

4

2

6

1. Size 2" 2½" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" 30" 36" 42"

Code 02 25 03 04 05 06 08 10 12 14 16 18 20 24 30 36 42

2. Series/Style

Code

200 Wafer - 2" - 30" 200 Lug - 2" - 30" (Standard) 200 Lug - 2" - 30" DES* 200 Flanged (36" - 42") * DES = Double Dead End Service

(

3. Body Material Epoxy Coated CI (2" - 12" Standard) Epoxy Coated DI - A536 (2"-12") Cast Iron (14" - 30") Ductile Iron - A536 (14" - 42" Standard) Ductile Iron - A395 (2" - 30") 4. Pressure 200 PSI (2" - 12") 75 PSI Undercut (8 - 30" ) 150 PSI (14" - 42") 125 PSI (2" - 12") PTFE liner 5. Disc DI - ENP (2" - 12") 316 SS DI - (14" - 42") Al Brnz. (2" - 42") Monel 400

A B C D Code S V 1 2 G Code 0 3 6 8 Code 2 4 5 6 7

5

5

6

7

1

8

P

9

X

6. Stem/Shaft Code 416 SS 1 316 SS * 4 Monel 400 7 17-4 PH 9 * Standard with 316 SS disc only 7. Bushings Bronze PTFE

Code 0 3

8. Seat /Liner Code 1 Buna-N 2 Abrasion Res. Buna-N 3 Neoprene (Black) 5 EPDM Viton (275 F°) std. phenolic backing 6 7 Hypalon 8 Perx. Crd. Buna-N L PTFE/Buna-N** P Viton (400 F°) V EPDM (FDA) W White Buna-N (FDA) D Potable Water EPDM B White Buna-N ** 2½ & 5" not available 9. Actuator Handle Gear Operator No Operator Lockable/Infinite (2" - 6") Infinite (8") Pneumatic Double Acting Pnue. Spring Return - Fail Close Pneu. Spring Return - Fail Open Electric Gear Operator/Memory Stop Buried Gear w/2" Sq. Nut 2" Nut Direct to Valve Stem Chain Wheel 10. Custom Special Features CE Marked - Non Impact Tested

PED Certification: Series 200 valve can be supplied with PED Certification from 2" - 24" only

12

3

Code 2 5 X 3 4 6 7 8 9 G C D U Code D P

ITEM 0520, 0530

Electric multi-turn actuators SA 07.1 – SA 30.1 SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 for flange type FA Item: 0520 = SAR07.5-54B/GS63.3 Item 0530 = SA10.1-26B/GS100.3

®

Operation instructions

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 Scope of these instructions:

ITEM 0520, 0530

Operation instructions

These instructions valid for multi-turn actuators of the type range SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with the actuator controls AM 01.1 / AM 02.1. These operation instructions are only valid for “clockwise closing”, i.e. driven shaft turns clockwise to close the valve.

Table of contents

Page

1. Safety instructions 1.1 Range of application 1.2 Electrical connection 1.3 Maintenance 1.4 Warnings and notes

4 4 4 4 4

2.

Short description

5

3.

Technical data

6

4.

Additional information to the wiring diagram legend

9

5. Transport, storage and packaging 5.1 Transport 5.2 Storage 5.3 Packaging

10 10 10 11

6.

Mounting to valve/ gearbox

12

7.

Mounting positions of the local controls

14

8. Electrical connection 8.1 Connection with AUMA plug/ socket connector (S, SH, SE)

15 17

9.

Manual operation

19

Operation and indications of the local controls

20

11. Opening the switch compartment 11.1 Removing the cover from the switch compartment 11.2 Pulling off the indicator disc (option)

22 22 22

12. Setting the limit switching 12.1 Setting end position CLOSED (black section) 12.2 Setting end position OPEN (white section) 12.3 Checking the limit switches

23 23 23 23

13. Setting the DUO limit switching (option) 13.1 Setting direction CLOSE (black section) 13.2 Setting direction OPEN (white section) 13.3 Checking the DUO limit switches

24 24 24 24

14. Setting the torque switching 14.1 Setting 14.2 Checking the torque switches

25 25 25

15. Test run 15.1 Checking the direction of rotation 15.2 Checking the setting of the limit switching 15.3 Checking the type of seating 15.4 Checking the PTC tripping device (option)

26 26 27 27 27

16.

29

10.

2

Setting the potentiometer (option)

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530 Page

17. Setting the electronic position transmitter RWG (option) 17.1 Setting 2-wire system 4 – 20 mA and 3- /4-wire system 0 – 20 mA 17.2 Setting 3- / 4- wire system 4 – 20 mA

30 31 32

18.

Setting the mechanical position indicator (option)

33

19.

Closing the switch compartment

33

20. Actuator controls AUMA MATIC 20.1 Functions of the diagnosis LEDs on the interface board (standard version) 20.2 Programming the logic board 20.3 EMERGENCY - OPEN and EMERGENCY - CLOSE signal (option)

34 34 35 36

21. Electronic positioner (option) 21.1 Technical data 21.2 Setting 21.2.1 Setting type of signal 21.2.2 Setting actuator behavior on loss of signal 21.3 Positioner adjustment for end position CLOSED (standard version) 21.4 Positioner adjustment for end position OPEN (standard version) 21.5 Setting the sensitivity 21.6 Positioner adjustment for end position OPEN (inverse operation) 21.7 Positioner adjustment end position CLOSED (inverse operation) 21.8 Positioner in Split Range version (option) 21.8.1 Split Range: description of functions 21.8.2 Programming 21.8.3 Positioner adjustment for Split Range

37 37 37 39 40 41 43 43 45 46 47 47 47 47

22. Timer (option) 22.1 Functions of the diagnosis LEDs (timer) 22.2 Setting start and end of stepping mode via DUO limit switching (option) 22.3 Setting ON and OFF times

49 49 50 51

23. Fuses 23.1 Fuses within the actuator controls 23.2 Motor protection

52 52 54

24.

Enclosure protection IP 68 (option)

55

25.

Maintenance

56

26.

Lubrication

56

27.

Disposal and recycling

56

28.

Service

57

29.

Spare parts list Multi-turn actuator SA(R) 07.1 – SA(R) 16.1

60

30.

Spare parts list controls AUMA MATIC

62

Index

63

Addresses of AUMA offices and representatives

64

3

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

1.

Safety instructions

1.1

Range of application

ITEM 0520, 0530

Operation instructions

AUMA actuators are designed for the operation of industrial valves, e.g. globe valves, gate valves, butterfly valves and ball valves. For other applications, please consult us. The manufacturer is not liable for any possible damage resulting from use in other than the designated applications. Such risk lies entirely with the user. Observance of these operation instructions is considered as part of the controls’/ actuator’s designated use. 1.2

Electrical connection During electrical operation, certain parts inevitably carry lethal voltages. Work on the electrical system or equipment must only be carried out by a skilled electrician themselves or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules.

1.3

Maintenance The maintenance instructions (refer to page 56) must be observed, otherwise a safe operation of the actuator is no longer guaranteed.

1.4

Warnings and notes Failure to observe the warnings and notes may lead to serious injuries or damage. Qualified personnel must be thoroughly familiar with all warnings and notes in these operation instructions. Correct transport, proper storage, mounting and installation, as well as careful commissioning are essential to ensure a trouble-free and safe operation. During operation, the multi-turn actuator warms up and surface temperatures > 140 °F may occur. Check the surface temperature prior to contact in order to avoid burns. The following references draw special attention to safety-relevant procedures in these operation instructions. Each is marked by the appropriate pictograph. This pictograph means: Note! “Note” marks activities or procedures which have major influence on the correct operation. Non-observance of these notes may lead to consequential damage. This pictograph means: Electrostatically endangered parts! If this pictograph is attached to a printed circuit board, it contains parts which may be damaged or destroyed by electrostatic discharges. If the boards need to be touched during setting, measurement, or for exchange, it must be assured that immediately before a discharge through contact with a grounded metallic surface (e.g. the housing) has taken place. This pictograph means: Warning! “Warning” marks activities or procedures which, if not carried out correctly, can affect the safety of persons or material.

4

Operation instructions

2.

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

Short description AUMA multi-turn actuators of the type range SA 07.1 – SA 30.1/SAR 07.1 – SAR 30.1 are driven by an electric motor and controlled by the actuator controls AUMA MATIC AM 01.1/ AM 02.1, which is included in the scope of delivery. A handwheel is provided for manual operation. The limitation of travel is realized via limit switches in both end positions. Torque seating is also possible in both end positions. The type of seating is determined by the valve manufacturer. Both the multi-turn actuator and the controls have a modular design, i.e. they are designed in accordance with the principle of a modular construction system. This means that each actuator or each controls are individually manufactured and combined for a specific valve automation task. An order-specific commission number, printed on the name plate, is assigned to each actuator/ controls. Commissioning Please note that for low temperature versions (– 58 °F), the controls requires a heat-up time. This heat-up time is applicable in case the actuator and the controls are not live and have cooled down to ambient temperature. In case commissioning has to be performed under these conditions, the following heat-up times have to be observed: 60 min. at – 58 °F 80 min. at – 76 °F Figure A: Heat-up time chart t [min.] 80 70 60 50 40 30 20 10 0

0

– 14

–4

– 22

– 40

– 58

– 76

ϑ [°F]

5

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

3.

ITEM 0520, 0530

Operation instructions

Technical data

Features and functions Type of duty 1)

Motors Insulation class Motor protection Self-locking Limit switching

Torque switching

Position feedback signal, analogue (options) Mechanical position indicator (option) Running indication (option) Heater in switch compartment

Motor heater (option) Manual operation Connection to controls Output drive types

Standard:

SA SAR SA SAR

Short time duty S2 - 15 min Intermittent duty S4 - 25 % Option: Short time duty S2 - 30 min Intermittent duty S4 - 50 % Intermittent duty S5 – 25 % Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 34 Option: Special motors Standard: F, tropicalized Option: H, tropicalized Standard: Thermoswitches (NC) Option: PTC thermistors (according to DIN 44082) Yes, for output speeds from 5.6 to 108 rpm Counter gear mechanism for end positions CLOSED and OPEN for 1 to 500 turns per stroke (optional for 1 to 5,000 turns per stroke) Standard: Tandem switch (2 NC and 2 NO) for each end position Options: Single switch (1 NC and 1 NO) for each end position, switches galvanically isolated Triple switch (3 NC and 3 NO) for each end position, switches galvanically isolated Intermediate position switch (DUO limit switching), adjustable for any intermediate position Infinitely adjustable torque switching for direction OPEN and CLOSE Standard: Single switch (1 NC and 1 NO) for each direction Options: Tandem switch (2 NC and 2 NO) for each direction, switches galvanically isolated Potentiometer or 0/4 – 20 mA (RWG) For further details, see separate data sheet Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED Blinker transmitter Standard: Resistance type heater with 5 W, 24 V DC Options: Self-regulating PTC heater, 5 – 20 W 24 – 48 V AC/DC, 110 – 250 V AC/DC or 380 – 400 V AC SA(R) 07.1 – 10.1: 12.5 W SA(R) 14.1 – 16.1: 25 W SA(R) 25.1 – 30.1: 50 W Manual drive for setting and emergency operation, handwheel does not rotate during electrical operation. Option: Handwheel lockable AUMA plug/ socket connector with screw type connection A, B1, B2, B3, B4 according to EN ISO 5210 A, B, D, E according to DIN 3210 C according to DIN 3338 Special output drives: AF, AK, AG, IB1, IB3

Power supply, mains frequency For mains voltage and mains frequency, refer to name plates at the controls and the motor and current consumption Permissible variation of the nominal voltage: ± 10 % Permissible variation of the mains frequency: ± 5 % Motor current consumption: Refer to motor name plate Current consumption of the controls depending on the mains voltage: 100 to 120 V AC = max. 600 mA 208 to 240 V AC = max. 300 mA 380 to 500 V AC = max. 150 mA External supply of the 24 V DC + 20 % / – 15 %, electronics (option) Observe current consumption of the controls Rated power Refer to motor name plate Note: The controls is designed for the rated power of the actuator Overvoltage category Category III

1) Based on 68 °F ambient temperature and at an average load with running torque according to Technical data SA or SAR

6

Operation instructions Switchgear

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530 Standard: Options:

Control

Standard: Option:

Output signals

Standard:

Option:

Voltage output

Standard: Option:

Local controls

Standard:

Functions

Option: Standard:

Options:

Motor protection evaluation

Standard: Options:

Electrical connection

Standard: Options:

Reversing contactors2) (mechanically and electrically interlocked) for motor power up to 1.5 kW Reversing contactors2) (mechanically and electrically interlocked) for nominal motor current up to 18 A (OPEN - CLOSE- duty) or 16 A (modulating duty) Thyristor unit3) (recommended for modulating actuators) for motor power up to 1.5 kW, 500 V AC with internal fuses for motor power up to 5.5 kW, 500 V AC, external fuses required Control inputs 115 V AC, OPEN - STOP - CLOSE (via opto-isolator, with one common), current consumption: approx. 10 mA per input Observe min. duration of impulse for modulating actuators Control inputs 24 V DC, OPEN - STOP - CLOSE (via opto-isolator, with one common), current consumption: approx. 15 mA per input 5 output relays with gold-plated contacts: 4 potential-free NO contacts with one common: max. 250 V AC, 0.5 A (resistive load) Standard configuration: End position OPEN, end position CLOSED, selector switch REMOTE, selector switch LOCAL 1 potential-free change-over contact, max. 250 V AC, 0.5A (resistive load) for collective fault signal Standard configuration: Torque fault, phase failure, motor protection tripped Signals in connection with positioner: End position OPEN, end position CLOSED (requires tandem switch within actuator) Selector switch REMOTE, selector switch LOCAL via 2nd level selector switch 1 potential-free change-over contact, max. 250 V AC, 0.5A (resistive load) for collective fault signal: Torque fault, phase failure, motor protection tripped Auxiliary voltage 115 V AC, max. 30 mA for supply of the control inputs,3), galvanically isolated from internal voltage supply Auxiliary voltage 24 V DC, max. 50 mA for supply of the control inputs, galvanically isolated from internal voltage supply Selector switch LOCAL - OFF - REMOTE (lockable in all three positions) Push buttons OPEN - STOP - CLOSE 3 indication lights: End position CLOSED (red), collective fault signal (yellow), end position OPEN (green) Protection cover, lockable Switch-off mode adjustable Limit or torque seating for end position OPEN and end position CLOSED Overload protection against excessive torques over the whole travel Excessive torque (torque fault) can be excluded from collective fault signal Phase failure monitoring with automatic phase correction Push-to-run operation or self-retaining in REMOTE Push-to-run operation or self-retaining in LOCAL Blinker transmitter signal of actuator can be switched on or off (option) Positioner4): Nominal position value via analogue input E1 = 0/4 – 20 mA Adjustable behavior on loss of signal Adjustable sensitivity (dead band) and pause time Split Range operation Monitoring of the motor temperature in combination with thermoswitches in the actuator motor Additional thermal overload relay in the controls in combination with thermoswitches within the actuator PTC tripping device in combination with PTC thermistors in the actuator motor AUMA plug/ socket connector with screw type connection Parking frame for wall mounting of the disconnected plug Protection cover for plug compartment (when plug is removed)

2) The lifetime guaranteed by the manufacturer amounts to min. 2 million cycles. If a higher number of switching cycles is to be expected, thyristor units with virtually unlimited lifetime should be used 3) Not possible in combination with PTC tripping device 4) Requires position transmitter (potentiometer or RWG) in actuator

7

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

Threads for cable glands

Standard: NPT-threads Options: Pg-threads, G-threads Wiring diagram Wiring diagram according to commission number included in delivery Further options for version with RWG in the actuator Position feedback (option) Analogue output E2 = 0/4 – 20 mA (load max. 500 Ω) Service conditions Enclosure protection according Standard: IP 67 to EN 60 529 5) Options: IP 68 IP 67-DS (Double Sealed) IP 68-DS (Double Sealed) (Double Sealed = additional protection of the interior of the housing against ingress of dust and dirt when removing the plug) Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plants with a low pollutant concentration Options: KS Suitable for installation in occasionally or permanently aggressive atmosphere with a moderate pollutant concentration (e.g. in wastewater treatment plants, chemical industry) KX Suitable for installation in extremely aggressive atmosphere with high humidity and high pollutant concentration KX-G Same as KX, however aluminium-free version (outer parts) Finish coating Standard: Two-component iron-mica combination Standard color Standard: AUMA silver-grey (similar to RAL 7037) Option: Other colors are possible on request Ambient temperature Standard: SA: – 25 °C to + 70 °C SAR: – 25 °C to + 60 °C Options: – 40 °C to + 60 °C/ – 40 to 140 °F, low temperature version – 50 °C to + 60 °C/ – 75 to 140 °F, extreme low temperature version incl. heating system – 60 °C to + 60 °C/ – 75 to 140 °F, extreme low temperature version incl. heating system Vibration resistance 1 g, from 10 Hz to 200 Hz according to IEC 60 068-2-6 Resistant to vibrations during start-up or for failures of the plant. However, a fatigue strength may not be derived from this. Applies to actuator with actuator controls, not valid in combination with gearboxes Lifetime SA 07.1 – 10.1: 20,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke SA 14.1 – 16.1: 15,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke SA 25.1 – 30.1: 10,000 operations (OPEN - CLOSE - OPEN) with 30 turns per stroke SAR 07.1 – 10.1: 5 million operations/ starts6) SAR 14.1 – 16.1: 3.5 million operations/ starts6) SAR 25.1 – 30.1: 2.5 million operations/ starts6) Weight Multi-turn actuator: Refer to Technical data SA/ SAR Actuator controls: Approx. 7 kg (including AUMA plug/ socket connector) Accessories Wall bracket7) AUMA MATIC mounted separately from the actuator, including plug/ socket connector. Connecting cables on request. Recommended for high ambient temperatures, difficult access, or in case of heavy vibrations during service. Further information Reference documents Product description “Electric multi-turn actuators SA/ SAR” Product description “Actuator controls AUMA MATIC” Dimension sheets SA/ SAR “...with integral controls AUMA MATIC” Technical data sheets AM 01.1/AM 02.1 Technical data sheets SA/ SAR Electrical data sheets SA/ SAR

5) For 3-phase asynchronous motors in enclosure protection IP 68, higher corrosion protection KS or KX is strongly recommended. Additionally, for enclosure protection IP 68, we recommend to use the double sealed terminal compartment DS. For special motors, the enclosure protection according to the name plate applies 6) The lifetime of modulating actuators depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process 7) Cable length between actuator and AUMA MATIC max. 100 m. Not suitable for version with potentiometer in the actuator. Instead of the potentiometer, an RWG has to be used in the actuator

8

Operation instructions

4.

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530

Additional information to the wiring diagram legend Information A: A running indication is possible if blinker transmitter (S5) is installed (opening and closing of contacts). Direction CLOSE: Connections XK 6 - XK 7 Direction OPEN: Connections XK 6 - XK 8 Contacts remain closed in end position. When connected to an external PLC, the blinking signal can be switched off via the DIP-switches (table 4, page 35). Information B: The type of seating in the end positions is determined by the valve manufacturer. The setting is done at the programming switches S1-2 and S3-2 (see page 35). The tripping of a torque switch in an intermediate position switches off the actuator and causes a fault signal. The limit switches serve for signalization when switching off by torque seating. They need to be set so that the appropriate switch is tripped shortly before reaching the end position. If the torque switch trips before the limit switch, the actuator is switched off and a fault signal is generated. For further programming possibilities, e.g. self-retaining in operation mode REMOTE, see table 4, page 35. Information D: The following faults are registered and can be transmitted to the control room as a potential-free collective fault signal: - Power failure - Phase failure - Motor protection tripped - Torque switch tripped in mid-travel. This signal can be switched off on the logic board, see table 4, page 35. Information E: Input signals according to DIN 19 240. The nominal operation current of inputs XK 2, XK 3, and XK 4 amounts to 10 – 15 mA. If the internal voltage 24 V DC is used for remote control, it must only be connected via potential-free contacts. Information F: In case of wrong phase sequence, the running direction is automatically adjusted. In case of a phase failure, the actuator stops. The fault is indicated at LED V14 on the interface board (see page 34). For collective fault signal, see information D. Information G: Potential-free contacts are available for signals. The internal control voltage (XK 11 / + 24 V and XK 5 / – 24V) must not be used for external lamps, relays, etc. Please note that this information only pertains to point to point drawings.

9

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

5.

Transport, storage and packaging

5.1

Transport

ITEM 0520, 0530

Operation instructions

.. .

For transport to place of installation, use sturdy packaging. Do not attach ropes or hooks to the handwheel for the purpose of lifting by hoist. If multi-turn actuator is mounted on valve, attach ropes or hooks for the purpose of lifting by hoist to valve and not to multi-turn actuator. Fitting the handwheel: For transport purposes, handwheels from a diameter of 400 mm are supplied separately. Engage manual operation prior to mounting the handwheel! If the manual operation is not engaged, damage can occur at the change-over mechanism. Engage manual operation (figure B-1): Manually lift the red change-over lever while slightly turning the shaft back and forth until manual operation engages. The manual operation is correctly engaged if the change-over lever can be lifted by approx. 85°.

. .. .

Manual force is sufficient for operating the change-over lever. It is not necessary to use an extension. Excessive force may damage the change-over mechanism. Install handwheel over the red change-over lever on to the shaft (figure B-1). Release change-over lever (should snap back into initial position by spring action, figure B), if necessary, push it back manually. Secure handwheel using the snapring supplied.

Figure B-1

Figure B-2

85°

5.2

Storage

.. .. . .

Store in well-ventilated, dry room. Protect against floor dampness by storage on a shelf or on a wooden pallet. Cover to protect against dust and dirt. Apply suitable corrosion protection agent to uncoated surfaces. If multi-turn actuators are to be stored for a long time (more than 6 months), the following points must be observed additionally: Prior to storage: Protect uncoated surfaces, in particular the output drive parts and mounting surface, with long-term corrosion protection agent. Check for corrosion approximately every 6 months. If first signs of corrosion show, apply new corrosion protection. After mounting, connect actuator immediately to electrical system, so that the heater prevents condensation.

10

Operation instructions 5.3

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 0530 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

Packaging Our products are protected by special packaging for the transport ex works. The packaging consists of environmentally friendly materials which can easily be separated and recycled. We use the following packaging materials: wood, cardboard, paper, and Polyurethane foam. For the disposal of the packaging material, we recommend recycling and collection centers.

11

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

6.

Mounting to valve/ gearbox

. .

ITEM 0520, 0530 Operation instructions

Prior to mounting the multi-turn actuator must be checked for damage. Damaged parts must be replaced by original spare parts. After mounting to valve/ gearbox, touch up any possible damage to paint finish.

The multi-turn actuator leaves the factory in position CLOSED (limit switch CLOSED tripped).

.

Check if mounting flange fits the valve/ gearbox.

Spigot at flanges should be loose fit! The output drive types B1, B2, B3, or B4 (figure B-3) are delivered with bore and keyway (usually according to ISO 5210). Figure B-3 Output drive type B1/B2 Plug sleeve

Output drive type B3/B4 Bore with keyway

For output drive type A (figure C-1), the internal thread of the stem nut must match the thread of the valve stem. If not ordered explicitly with thread, the stem nut is unbored or with pilot bore when delivered. For finish machining of stem nut, refer to next page. Check whether bore and keyway match the input shaft of valve/ gearbox. Thoroughly degrease mounting faces at multi-turn actuator and valve/ gearbox. Apply a small quantity of grease to input shaft of valve/gearbox. Place actuator on valve/gearbox and fasten. Fasten bolts (quality min. grade 5, refer to table 1) evenly crosswise.

.. ..

Table 1: Standard dry fastening torque for bolts UNC bolts – grade 5 - 18 3 - 16 8 1 - 13 2 5 - 11 8 3 - 10 4 Conversion factor: 1 Nm corresponds to 1.3529 ft lbs. 5

12

16

TA (ft lbs.) 19 33 78 155 255

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 0530 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 Finish machining of stem nut (output drive type A): Figure C-1 Output drive type A Stem nut 80.3 80.01/80.02 80.2

The output drive flange does not have to be removed from the actuator.

.. .. .. . ..

Remove spigot ring (80.2, figure C-1) from mounting flange. Take off stem nut (80.3) together with thrust bearing (80.01) and thrust bearing races (80.02). Remove thrust bearing and thrust bearing races from stem nut. Drill and bore stem nut and cut thread. When fixing in the chuck, make sure stem nut runs true! Clean the machined stem nut. Apply Lithium soap EP multi-purpose grease to thrust bearing and races, then place them on stem nut. Re-insert stem nut with thrust bearings into the mounting flange. Ensure that dogs are placed correctly in the slots of the hollow shaft. Screw in spigot ring until it is firm against the shoulder. Press Lithium soap EP multi-purpose grease on mineral oil base into the grease nipple with a grease gun (for quantities, please refer to table):

Table 2: Grease quantities for output drive type A Output drive Qty1)

A 07.2

A 10.2

A 14.2

A 16.2

A 25.2

A 30.2

A 35.2

A 40.2

A 48.2

1.5 g 2g 3g 5g 10 g 14 g 20 g 25 g 30 g 1) For greases with a density ρ = 0.9 kg/dm³3; conversion factor: 1 oz corresponds to 28.35 g

.. ..

Protection tube for rising valve stem Seal thread with hemp, Teflon tape, or thread sealing material. Screw protection tube (1) into thread (figure C-2) and tighten it firmly. Push down the sealing (2) to the housing. Check whether cap (3) is available and without damage. Figure C-2: Protection tube for rising valve stem

3

1 2

13

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

7.

ITEM 0520, Operation instructions 0530

Mounting positions of the local controls The mounting position of the local controls is designed according to the order. If, after mounting the actuator to the valve or the gearbox on site, the local controls is in an unfavorable position, the mounting position can easily be changed at a later date. Four mounting positions are possible: Figure D-1: Mounting position A

Actuator

Figure D-3: Mounting position C

Actuator

Figure D-2: Mounting position B

Actuator

Figure D-4: Mounting position D

Actuator

Changing the mounting position

.. .. . 14

.. .

Disconnect actuator from the mains before opening. Turn local controls by a maximum of 180°, rotate circuit board accordingly! Ensure that the wires are neither twisted nor jammed.

Loosen 4 bolts and remove the local controls. Turn local controls in one of the four positions and re-place on the actuator, rotate circuit board accordingly. Clean sealing faces of housing and cover. Check whether O-ring is in good condition. Replace cover on switch compartment and fasten bolts evenly crosswise.

Operation instructions

8.

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530

Electrical connection Work on the electrical system or equipment must only be carried out by a skilled electrician themselves or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules. Wiring diagram The terminal plan applicable to the actuator is placed inside the terminal compartment, the operation instructions are attached to the handwheel in a weather-proof bag. External fuse For short-circuit protection and for protecting the actuator, fuses and disconnect switches have to be provided by the customer. The current values for sizing the switch can be derived from the current consumption of the motor plus the current consumption of the controls. Motor current consumption: Refer to name plate on motor (nominal current). Current consumption of the controls depending on the mains voltage: 100 to 120 V AC = max. 650 mA 208 to 240 V AC = max. 325 mA 380 to 500 V AC = max. 190 mA The maximum permissible fuse for controls with a rated power of 1.5 kW is 16 A (gL/ gG), and for controls with a rated power of 7.5 kW, the value amounts to 32 A (gL/ gG). Cable installation in accordance with EMC Signal and bus cables are susceptible to interference. Motor cables are interference sources. Lay cables being susceptible to interference or sources of interference at the highest possible distance from each other. The interference immunity of signal and bus cables increases if the cables are laid close to the ground potential. If possible, avoid laying long cables and make sure that they are installed in areas being subject to low interference. Avoid long parallel paths with cables being either susceptible to interference or interference sources. For the connection of remote position transmitters (potentiometer, RWG), screened cables must be used.

. . . . .

Heater As standard, the control unit of the actuator is equipped with a heater to prevent condensation within the actuator. Unless ordered otherwise, the heater is internally supplied. For external supply (option), the heater always has to be connected. Some actuators are optionally equipped with an additional motor heater. The motor heater is always externally supplied and has to be connected according to the wiring diagram.

15

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530 Operation instructions

Actuator controls on wall bracket (accessory) For version on wall bracket, please observe the following: Figure E: AUMA MATIC on wall bracket

Connecting cables to actuator

. . . ..

Versions with potentiometer in the actuator are not suitable. Instead of the potentiometer, an RWG has to be used in the actuator Permissible cable distance between actuator and AUMA MATIC amounts to a maximum of 100 m. Factory supplied cables for the connection between actuator and AUMA MATIC on wall bracket can be obtained from AUMA on request. In case non factory supplied cables are used, the following additionally has to be observed: Use suitable flexible and screened connecting cables. Connect the wires in correct phase sequence. Check the direction of rotation before switching on (see page 26)

Subsequent mounting of the actuator controls on the actuator In case the actuator and the actuator controls have different commission numbers (refer to name plates), the designations of the terminal plan and the wiring diagram (KMS . . .) have to match for both devices.

16

Operation instructions 8.1

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

Connection with AUMA plug/ socket connector (S, SH, SE)

Figure F-1: Version SH (standard)

Figure F-2: Version S

Figure F-3: Version SE

Before mains connection Check whether type of current, supply voltage, and frequency comply with motor data (refer to name plate at motor): VD00 63-4/45 Art. No.: Z006.413 3 ~ 480V 60Hz 0.09 kW Y 0.60A

Current type/mains voltage/mains frequency

.. .

Opening the terminal compartment Loosen bolts (1) and remove cover (figure G). Loosen screws (2) and remove socket carrier from cover. Insert cable glands suitable for connecting cables (The enclosure protection stated on the name plate is only ensured if suitable cable glands are used.). NEMA 4X Thermal protection: Th Insulation class: F

.

Enclosure protection

Seal cable entries which are not used with suitable plugs.

Figure G: Opening the terminal compartment

Cover Cable gland and screw plug in enclosure protection according to name plate

(1)

Socket carrier (2)

17

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

.

Connecting the cables Connect cables according to order-related wiring diagram. Cross sections: - Power terminals (U1, V1, W1, U2, V2, W2) and protective earth (symbol: ) max. 6 mm² flexible, max. 10 mm² solid - Control contacts (1 to 50) = max. 2.5 mm² All PE conductors have to be tightened firmly to the PE connection (symbol: ) using either ring lugs (flexible cables), or lugs (solid cables) (figure H).

.

Each time the PE connection has been disconnected, it has to be ensured that the PE conductors are firmly connected. Figure H: PE connection

Screw Washer Circlip Protective earth with ring lugs/lugs PE connection Socket carrier

.. .. ..

Closing the terminal compartment Insert socket carrier into the cover and fasten with screws (2) (figure G). Clean sealing faces at the cover and the housing. Check whether O-ring is in good condition. Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces. Replace cover and fasten bolts (1) evenly crosswise. Fasten cable glands with the specified torque to ensure the required enclosure protection.

Parking frame, protection cover (accessories) A special parking frame (figure J) for protection against touching the exposed contacts and against environmental influences is available. The open terminal compartment can be closed using a protective cover (not illustrated). Figure J: Parking frame (accessory)

Parking frame

18

Operation instructions

9.

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530

Manual operation The actuator may be operated manually for purposes of setting and commissioning and in case of motor failure or power failure. Manual operation is engaged by an internal change-over mechanism.

.

Engaging manual operation Lift up change-over lever in the center of the handwheel to approx. 85°, while slightly turning the handwheel back and forth until manual operation engages (figure K-1).

Figure K-1

.

Figure K-2

Manual force is sufficient for operating the change-over lever. It is not necessary to use an extension. Excessive force may damage the change-over mechanism. Release change-over lever (should snap back into initial position by spring action, figure K), if necessary, push it back manually.

Operating the change-over lever while the motor is running (figure L-1) can lead to increased wear at the change-over mechanism. Figure L-1

.

Figure 13-2

Turn handwheel into desired direction (figure 13-2).

Disengaging manual operation Manual operation is automatically disengaged when motor is started again. The handwheel does not rotate during motor operation.

19

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

10. Operation and indications of the local controls Figure M: Local controls

Push buttons

Indication lights

Selector switch

Selector switch 0

I

0

I

I

0

20

I

Position Remote control (II): The actuator can be controlled from remote, e.g. via the control room.

Position Test (III): Test PTC tripping device (refer to page 27) Only available in combination with motor protection III Reset (PTC thermistor). Yellow indication light (fault) is illuminated.

I

0

II

I

0

II

Test

Test

Position Local control (I): The actuator can be operated locally via the push buttons OPEN - STOP - CLOSE.

I

III

III

Position OFF (0): - No remote control possible - No local control possible - Actuator remains ready for signalization signalization (the controls’ power supply is maintained)

I

Position Reset (III): Reset fault signal (yellow indication light) after the motor protection has tripped (refer to page 54). III Reset Only available in combination with motor protection (PTC thermistor).

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530 Push buttons If the selector switch is in position local control (I), use the push buttons OPEN STOP - CLOSE to operate the actuator locally.

OPEN: Actuator runs in direction OPEN

STOP: Actuator stops

CLOSE: Actuator runs in direction CLOSE

The operation commands OPEN - CLOSE can be used for control during push-to-run operation or in the self-retaining mode. In the push-to-run operation, the actuator runs as long as the push button is pressed. In the self-retaining mode, the actuator runs to the defined end position, unless another command has been received beforehand. For further information on the programming, refer to page 35. Indication lights The 3 indication lights give the following signals (standard indication).

Illuminated (red):

Actuator is in end position OPEN

Collective fault signal (yellow)

Illuminated (green): Actuator is in end position CLOSED Collective fault signal: The collective fault signal (yellow indication light) will be activated if one of the following events occurs: Torque fault, i.e. the set torque (page 25) was exceeded before reaching an end position. Motor protection has tripped (refer to page 54), i.e. the motor is overheated. A phase failure (for 3-phase AC motors) has occurred. Test PTC tripping device

. .. .

Indication lights are blinking: If the actuator is equipped with a blinker, the indication lights can be used as running indication. If the blinker transmitter is active (page 35), the respective indication light blinks during operation.

21

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, Operation instructions 0530

11. Opening the switch compartment To be able to carry out the following settings (up to and including clause 18.), the switch compartment must be opened and, if installed, the indicator disc must be removed. These settings are only valid for “clockwise closing”, i.e. driven shaft turns clockwise to close the valve. Work on the electrical system or equipment must only be carried out by a skilled electrician themselves or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules. 11.1 Removing the cover from the switch compartment

.

Loosen 4 bolts and take off the cover at the switch compartment (figure N-1 or figure N-2).

Figure N-1: Cover with indicator glass

Figure N-2: Cover without indicator glass

11.2 Pulling off the indicator disc (option)

.

If installed, pull off indicator disc (figure O). Open end wrench may be used as lever.

Figure O: Pulling off the indicator disc

RSD

RDW

Indicator disc

22

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530

12. Setting the limit switching 12.1 Setting end position CLOSED (black section)

.. .

Turn handwheel clockwise until valve is closed. Turn handwheel back by approximately half a turn (overrun). During test run check overrun and, if necessary, correct setting of the limit switching. Press down and turn setting spindle A (figure P-1) with a flat blade screw driver in direction of arrow, thereby observe pointer B. While a ratchet is felt and heard, the pointer B moves 90° every time. When pointer B is 90° from mark C, continue turning slowly. When pointer B has reached the mark C, stop turning and release setting spindle. If you override the tripping point inadvertently (ratchet is heard after the pointer has rotated), continue turning the setting spindle in the same direction and repeat setting process.

Figure P-1: Control unit

A

D

P

T B

E C

F

12.2 Setting end position OPEN (white section)

.. .

Turn handwheel counterclockwise until valve is open. Turn handwheel back by approximately ½ a turn (overrun). During test run check overrun and, if necessary, correct setting of the limit switching. Press down and turn setting spindle D (figure P-1) with a flat blade screw driver in direction of arrow, thereby observe pointer E. While a ratchet is felt and heard, the pointer E moves 90° every time. When pointer E is 90° from mark F, continue turning slowly. When pointer E has reached the mark F, stop turning and release setting spindle. If you override the tripping point inadvertently (ratchet is heard after the pointer has rotated), continue turning the setting spindle in the same direction and repeat setting process.

12.3 Checking the limit switches The red test buttons T and P (figure P-1) are used for manual operation of the limit switches.

. . .

Turning T in direction of the arrow LSC (WSR) triggers limit switch CLOSED. The green indication light on the local controls is illuminated as long as the test button is pushed down. Turning P in direction of the arrow LSO (WÖL) triggers limit switch OPEN. The yellow indication light (fault) on the local controls is illuminated. The red indication light on the local controls is illuminated as long as the test button is pushed down.

23

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

Operation instructions

13. Setting the DUO limit switching (option) Any application can be switched on or off via the two intermediate position switches. For setting, the switching point (intermediate position) must be approached from the same direction as later during electrical operation.

..

13.1 Setting direction CLOSE (black section) Move valve to desired intermediate position. Press down and turn setting spindle G (figure P-2) with a flat blade screw driver in direction of arrow, while observing pointer H. While a ratchet is felt and heard, the pointer H moves 90° every time. When pointer H is 90° from mark C, continue turning slowly. When pointer H has reached the mark C, stop turning and release setting spindle. If you override the tripping point inadvertently (ratchet is heard after the pointer has rotated), continue turning the setting spindle in the same direction and repeat setting process. Figure P-2: Control unit

P

T

F

C H

L G

K

..

13.2 Setting direction OPEN (white section) Move valve to desired intermediate position. Press down and turn setting spindle K (figure P-2) with a flat blade screw driver in direction of arrow, while observing pointer L. While a ratchet is felt and heard, the pointer L moves 90° every time. When pointer L is 90° from mark F, continue turning slowly. When pointer L has reached the mark F, stop turning and release setting spindle. If you override the tripping point inadvertently (ratchet is heard after the pointer has rotated), continue turning the setting spindle in the same direction and repeat setting process. 13.3 Checking the DUO limit switches The red test buttons T and P (figure P-2) are used for manual operation of the DUO limit switches. Turning T in direction of the arrow TSC (DSR) triggers DUO limit switch CLOSED. The torque switch CLOSED is actuated at the same time. Turning P in direction of the arrow TSO (DÖL) triggers DUO limit switch OPEN. The torque switch OPEN is actuated at the same time. After checking the switches, the fault (red indication light) has to be reset using the OPEN or CLOSE push buttons of the local controls for operation in the opposite direction.

. . .

24

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530

14. Setting the torque switching

..

14.1 Setting

The set torque must suit the valve! This setting must only be changed with the consent of the valve manufacturer!

Figure Q: Torque switching heads Setting OPEN

Setting CLOSED Ft. Lbs

Ft. Lbs

45

.. .

35

25

45

15

P

O

15

25

35

Loosen both lock screws O at the torque dial (figure Q). Turn torque dial P to set it to the required torque. Example: Figure Q shows the following setting: 35 ft lbs for direction CLOSE 25 ft lbs for direction OPEN Tighten lock screws O again

. .

The torque switches can also be operated in manual operation. The torque switching acts as overload protection over full travel, also when stopping in the end positions by limit switching.

14.2 Checking the torque switches The red test buttons T and P (figure P-1) are used for manual operation of the torque switches:

. . . .

Turning T in direction of the arrow TSC (DSR) triggers torque switch CLOSED. The yellow indication light (fault) on the local controls is illuminated. Turning P in direction of the arrow TSO (DÖL) triggers torque switch OPEN. The yellow indication light (fault) on the local controls is illuminated. If a DUO limit switching (optional) is installed in the actuator, the intermediate position switches will be operated at the same time. After checking the switches, the fault (yellow indication light) has to be reset using the OPEN or CLOSE push buttons of the local controls for operation in the opposite direction.

25

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

15. Test run 15.1 Checking the direction of rotation

. .

If provided, place indicator disc on shaft. The direction of rotation of the indicator disc (figure R-1) indicates the direction of rotation of the output drive. If there is no indicator disc, the direction of rotation can also be observed on the hollow shaft. For this purpose, remove screw plug (no. 27) (figure R-2).

Figure R-1: Indicator disc CLOSED

Figure R-2: Opening the hollow shaft OPEN

27 S1/S2

. .

Move actuator manually to intermediate position or to sufficient distance from end position. Set selector switch to local control (I) (figure S).

Figure S: Selector switch LOCAL

..

Switch on the voltage supply. Press push button CLOSE (figure T-1) and observe the direction of rotation: If the indicator disc turns counterclockwise, the direction of rotation is correct.

Figure T-1: Push button CLOSE

Figure T-2: Push button STOP

If the direction of rotation is wrong, switch off immediately. Afterwards, correct phase sequence in the connecting cable from the wall bracket to the actuator and repeat test run.

26

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

.

15.2 Checking the setting of the limit switching Set selector switch to position OFF (0) (figure U-1). Figure U-1: Selector switch OFF

The controls’ power supply is maintained in position OFF.

..

Move actuator manually into both end positions of the valve. Check if limit switching is set correctly for both end positions. Hereby observe that the appropriate switch is tripped in each end position and released again after the direction of rotation is changed. If this is not the case, the limit switching must be set again.

..

When limit switching is set correctly: Set selector switch to local control (I) (figure S). Perform test run at the local controls via push buttons OPEN - STOP CLOSE. 15.3 Checking the type of seating The valve manufacturer states whether switching off in the end positions should be by limit switch (limit seating) or torque switch (torque seating). For checking the setting, refer to page 35, subclause 20.2.

. .

15.4 Checking the PTC tripping device (option) Turn selector switch to position TEST (wiping) (figure U-2). If the PTC tripping device is working properly, the tripping of the motor protection is signaled via the collective fault signal (refer to wiring diagram) and via the fault indication light on the local controls. Figure U-2: Selector switch TEST

.

Turn selector switch to position RESET (wiping) (figure U-3): The fault signal is reset if the device is working properly.

Figure U-3: Selector switch RESET

27

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, Operation instructions 0530

In case the selector switch position TEST does not initiate a fault signal, the wiring and the selector switch have to be checked by the AUMA service.

.

If no other options (clauses 16. to 18.) require setting: Close switch compartment (see page 33, clause 19.).

28

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

16. Setting the potentiometer (option) — For remote indication —

.. . .

Move valve to end position CLOSED. Turn potentiometer (E2) clockwise to the stop. End position CLOSED corresponds to 0 %, end position OPEN to 100 %. Turn potentiometer (E2) slightly back. Due to the ratio of the reduction gearings for the position transmitter, the complete resistance range is not always utilized for the whole travel. Therefore, an external possibility for adjustment (setting potentiometer) must be provided. Perform fine-tuning of the zero point at external setting potentiometer (for remote indication).

Figure V: Control unit

E2

29

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

17. Setting the electronic position transmitter RWG (option) — For remote indication or external control — After mounting the actuator on the valve, check setting and adjust, if necessary (refer to subclauses 17.1 or 17.2). Table 3: Technical data RWG 4020 KMS TP_ _ 4 / _ _ _ Terminal plans

Output current Power supply Max. input current Max. load

Ia Uv I RB

3- or 4- wire system 0 – 20 mA, 4 – 20 mA 24 V DC, ±15 % smoothed 24 mA at 20 mA output current 600 Ω

KMS TP _ 4 _ / _ _ _ KMS TP _ 5 _ / _ _ _ 2-wire system 4 – 20 mA 14 V DC + (I x RB), max. 30 V 20 mA (Uv - 14 V) / 20 mA

The position transmitter board (figure W) is located under the cover plate (figure Y). Figure W: Position transmitter board

S1

30

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

17.1 Setting 2-wire system 4 – 20 mA and 3- /4-wire system 0 – 20 mA

.. . ..

Connect voltage to electronic position transmitter via AM. Move valve to end position CLOSED. Connect ammeter for 0 – 20 mA to measuring points (figure Y-1). The circuit (external load) must be connected (observe max. load RB), or the appropriate poles at the terminals (refer to wiring diagram) must be linked, otherwise no value can be measured. Turn potentiometer (E2) clockwise to the stop. Turn potentiometer (E2) back a little.

Figure Y-1 “0” (0/4 mA) Cover plate Meas.point (+) 0/4 – 20 mA

.. .. .

“max.” (20 mA) E2 Meas.point (–) 0/4 – 20 mA

Turn potentiometer “0” clockwise until output current starts to increase. Turn potentiometer “0” back until the following value is reached: for 3- or 4-wire system: approx. 0.1 mA for 2-wire system: approx. 4.1 mA. This ensures that the signal remains above the dead and live zero point. Move valve to end position OPEN. Set potentiometer “max.” to end value 20 mA. Approach end position CLOSED again and check minimum value (0.1 mA or 4.1 mA). If necessary, correct the setting. If the maximum value cannot be reached, the selection of the reduction gearing must be checked.

31

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

17.2 Setting 3- / 4- wire system 4 – 20 mA

.. . ..

Connect voltage to electronic position transmitter via AM. Move valve to end position CLOSED. Connect ammeter for 0 – 20 mA to measuring points (figure Y-2). The circuit (external load) must be connected (observe max. load RB), or the appropriate poles at the terminals (refer to wiring diagram) must be linked, otherwise no value can be measured. Turn potentiometer (E2) clockwise to the stop. Turn potentiometer (E2) back a little.

Figure Y-2 “0” (0/4 mA) Cover plate Meas. point (+) 0/4 – 20 mA

.. .. .. .

“max.” (20 mA) E2 Meas. point (–) 0/4 – 20 mA

Turn potentiometer “0” clockwise until output current starts to increase. Turn back potentiometer “0” until a residual current of approx. 0.1 mA is reached. Move valve to end position OPEN. Set potentiometer “max.” to end value 16 mA. Move valve to end position CLOSED. Set potentiometer “0” from 0.1 mA to initial value 4 mA. This results in a simultaneous shift of the end value by 4 mA, so that the range is now 4 – 20 mA. Approach both end positions again and check setting. If necessary, correct the setting.

If the maximum value cannot be reached, the selection of the reduction gearing must be checked.

32

ITEM 0520, 0530 18. Setting the mechanical position indicator (option)

.. . ..

Place indicator disc on shaft. Move valve to end position CLOSED. Turn lower indicator disc (figure Z-1) until symbol CLOSED is in alignment with the mark on the cover (figure Z-2). Move actuator to end position OPEN. Hold lower indicator disc CLOSED in position and turn upper disc with symbol OPEN until it is in alignment with the mark on the cover.

Figure Z-1

Figure Z-2

Indicator disc

Mark

Indicator disc rotates approximately 180° to 230° at full travel from OPEN to CLOSED or vice versa. For this purpose, a suitable reduction gearing was installed in our factory. If the turns per stroke of the actuator are changed at a later date, the reduction gearing may have to be exchanged.

19. Closing the switch compartment

.. ..

Clean sealing faces of housing and cover Check whether O-ring is in good condition. Apply a thin film of non-acidic grease to the sealing faces. Replace cover on switch compartment and fasten bolts evenly crosswise. Check the multi-turn actuator for damage to paint finish. If damage to paint-finish has occurred after mounting, it has to be touched up to avoid corrosion.

33

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

20. Actuator controls AUMA MATIC Figure AA: Positions of the boards within the controls Cover Timer board (option) Cover plate Interface board

Logic boards Positioner board (option)

20.1 Functions of the diagnosis LEDs on the interface board (standard version) V14 is illuminated: Phase failure and/ or motor protection tripped. In combination with motor protection (PTC thermistor) (option): Reset by selector switch position III at local controls V15 is illuminated: Torque fault: Torque switch operated in mid-travel The LEDs STOP, CLOSE, OPEN indicate the available control commands (only in selector switch position REMOTE). Figure AB: Cover plate on interface board

34

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

20.2 Programming the logic board The type of seating – limit or torque seating – (switch S1-2 and switch S3-2, figure AC) must be determined by the valve manufacturer. Figure AC: Logic board A2 Position 1:

Limit seating in end position OPEN Position 2: S3-2 S2-2

Torque seating in end position OPEN Position 1:

S1-2

Limit seating in end position CLOSED Position 2:

Torque seating in end position CLOSED

.

Set desired programming according to table 4 at the switch S2-2.

Table 4 DIP switch S2-2

Programming (ON = pressed) Direction CLOSE Direction OPEN

Self-retaining REMOTE Push-to-run operation REMOTE Self-retaining LOCAL Push-to-run operation LOCAL activated

deactivated

included

not included

Blinker transmitter (option) Torque fault: Torque switch tripping (in mid-travel) contained in collective fault signal

35

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530 Operation instructions

20.3 EMERGENCY - OPEN and EMERGENCY - CLOSE signal (option) (5th digit in wiring diagram MSP … C, D, or P) When an EMERGENCY run command is given, the actuator operates the valve to the predetermined end position (effective in all three selector switch positions: LOCAL, OFF, REMOTE).

. .

The input at terminal XK 1 (refer to wiring diagram) must be connected to an NC contact (closed circuit principle). If EMERGENCY - OPEN or EMERGENCY - CLOSE signal is generally not desired: Take off cover plate and disconnect links B1 (for EMERGENCY - CLOSE) and B2 (for EMERGENCY - OPEN).

Figure AD: Cover plate for EMERGENCY - OPEN or EMERGENCY - CLOSE option Links:B1 (EMERGENCY-CLOSE) B2 (EMERGENCY-OPEN)

LED for EMERGENCY run command B2 B1

36

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

21. Electronic positioner (option) 21.1 Technical data Table 5: Technical data for positioner Command signal (input signal E1, set value) 0/4 – 20 mA (option: 0 – 5 V) Feedback (input signal E2, actual value) 0 – 5 V (option: 0/4 – 20 mA) 0.5 % – 2.5 % Sensitivity (dead band) ΔE (P9) Fine tuning “Sens” (P7) (useful for output speeds < 16 rpm only; min. 0.25 % not possible with 1-phase AC motors) Pause time “t-off ”(P10) 0.5 – 10 s Input resistance 250 Ohm Modulating duty with stepping mode (not required for modulating setting): Running time “t-on” (P8) effective until error is ≤ 25 %; then set value is 0.5 – 15 s automatically reduced by 3.

21.2 Setting The positioner in the actuator controls AUMA MATIC is programmed according to the purchase order details and is set together with the actuator prior to delivery. Due to peculiarities of the regulating system not known beforehand, a readjustment may become necessary. Before adjusting the positioner, the programming of the positioner should be checked.

. .

Check programming of the logic board according to subclause 20.2.

The self-retaining REMOTE function (see table 4) must be switched off in conjunction with the positioner. Take off cover plate (figure AE) and carry out required programming at positioner board (figure AF) according to tables 6 and 7.

37

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

Prior to setting, it must be ensured that the circuit for the position feedback E2 (see wiring diagram) is closed (measuring device or link). In case of missing signal E2, the LED (V10) “E1/E2 < 4 mA” (figure AE) is illuminated and the positioner shows no reaction. Figure AE: Cover plate positioner Label with signal indication (in our example: E1 = 4 – 20 mA, E2 = 4 – 20 mA)

V10 (red) P10 P8

Figure AF: Positioner board A7 P9 (ΔE) P7 (Sens) P3 (0) P4 (max)

S2-7 S3-7

V28 V27 V18 V10

Meas. points:

{

E2

P10 MP2(+) MP1(–) S1-7 Measuring points: MP3(+)/MP4(–) for E1

21.2.1 Setting type of signal The signal type (current/ voltage signal) of nominal value E1 and actual value E2 is set in the factory and marked with a label on the cover plate of the positioner (refer to figure AE). For split range version (page 38) and for versions with a setpoint E1 ≠ 0/4 – 20 mA, it is possible to change the type of signalling. For these versions, the positioner board is equipped with an additional switch S1-7.

38

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 0530 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

If the setting is subject to subsequent change, the marking also has to be changed. Furthermore, the wiring diagram indicated on the name plate of the actuator controls also changes (see page 61). Table 6: Possible settings Programming Command signal Setpoint E1

Feedback Actual value E21)

4 – 20 mA 0 – 20 mA

4 – 20 mA 0 – 20 mA

4 – 20 mA 0 – 20 mA

0–5V

0–5V

4 – 20 mA 0 – 20 mA

0–5V

0–5V

0 – 10 V

4 – 20 mA 0 – 20 mA

0 – 10 V

0–5V

1)

via DIP switch S1-7 (see figure AF)

Signals for internal feedback: 0/4 – 20 mA from electronic position transmitter or 0 – 5 V from precision potentiometer 5 k Ω

39

ITEM 0520, Operation instructions 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 21.2.2 Setting actuator behavior on loss of signal

In case of a loss of signal of nominal value E1 or actual value E2, the reaction of the actuator can be programmed via the switch S2-7. The complete range of choices, however, is only available with signals 4 – 20 mA. The following reactions are possible: Fail as is: Actuator stops immediately and remains in this position. Fail close Actuator moves the valve to the end position CLOSED. Fail open: Actuator moves the valve to the end position OPEN. Table 7: Possible settings Prerequisite1)

Behavior on loss of signal of E1

E2 fail as is

fail close

Feedback Actual value E22)

4 – 20 mA

4 – 20 mA

4 – 20 mA

4 – 20 mA

0 – 20 mA 0–5V

4 – 20 mA

4 – 20 mA

4 – 20 mA

4 – 20 mA

0 – 20 mA 0–5V

4 – 20 mA

0–5V

4 – 20 mA 0 – 20 mA

0–5V

0 – 20 mA

4 – 20 mA

0 – 20 mA 0–5V 0 – 10 V

0 – 20 mA 0–5V

0 – 20 mA

4 – 20 mA

0 – 10 V

4 – 20 mA

fail open

fail as is

fail close

fail close

1) 2)

40

fail open

fail open

Programming

Command signal Setpoint E1

via DIP switch S2-7 (see figure AF)

fail as is

During loss of signal, signals from 0 – 20 mA and 0 – 5 V may be misinterpreted since E1 or E2 (without any fault) can also be < 4 mA (end position CLOSED = 0 mA or 0 V) when working properly. Signals for internal feedback: 0/4 – 20 mA from electronic position transmitter or 0 – 5 V from precision potentiometer 5 k Ω

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

21.3 Positioner adjustment for end position CLOSED (standard version)

.. .. . .

Before beginning the setting of the positioner, it has to be ensured that the limit and torque switching of the actuator as well as the feedback have been set (clauses 16. and 17.). Set selector switch (local controls) to position LOCAL. Move multi-turn actuator by pressing push button to end position CLOSED. Supply nominal value E1 of 0 or 4 mA (see wiring diagram). Turn potentiometer “t-off” (P10) counterclockwise to the stop (figure AG).

Missing signals E1/ E2 or wrong polarity are indicated by LED (V10) “E1/E2 < 4 mA" (figures AE or AG) Connect voltmeter to measuring points MP3 and MP4 (figure AG) for measuring the nominal value (0 – 5 V). For a nominal value E1 of 0 mA, the voltmeter shows 0 V. For a nominal value E1 of 4 mA, the voltmeter shows 1 V. In case nominal value (0 V or 1 V) is not correct: Correct nominal value signal from control room. Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value signal. For an actual value E2 of 0 V, the voltmeter shows 0 V. For an actual value E2 of 5 V, the voltmeter shows 1 V. If measured value is not correct: Adjust position feedback according to clause 16. and 17. and repeat “positioner adjustment”.

Table 8 Possible LED display: (refer to figures AG and AH)

LED (V28 green) is illuminated LED (V27 yellow) is illuminated

Then

If

the LEDs are not illuminated

Required setting in end position CLOSED: (refer to figures AG and AH) Turn potentiometer “0” (P3) slowly clockwise until LED (V27 yellow) is illuminated Turn potentiometer “0” (P3) slowly clockwise until LED (V28 green) is no longer illuminated and LED (V27 yellow) is illuminated Turn potentiometer “0” (P3) counterclockwise until LED (V27 yellow) is no longer illuminated. Then turn potentiometer “0” (P3) slightly clockwise until LED (V27 yellow) is illuminated

41

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Figure AG: Positioner board A7 P9 (ΔE) P7 (Sens) P3 (0) P4 (max)

{

E2

Operation instructions

S2-7 S3-7

Meas. points:

V28 V27 V18 V10

MP4(–) MP3(+) MP2(+) MP1(–)

P10

S1-7 Measuring points: MP3(+)/MP4(–) for E1

42

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 0530 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

21.4 Positioner adjustment for end position OPEN (standard version)

. . ..

Run multi-turn actuator by pressing push button (local controls) to end position OPEN. Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value E2: When position feedback is set correctly, the voltmeter shows approx. 5 V. If measured value is not correct: Adjust position feedback according to clause 16. and 17. and repeat “positioner adjustment”. Connect max. command signal (nominal value E1) = 20 mA. Connect voltmeter to measuring points MP4 and MP3 for measuring the nominal value E1: For a nominal value of 20 mA, the voltmeter shows 5 V. If measured value is not 5 V: Check the externally supplied command signal E1.

Table 9 LED display: (refer to figures AG and AH)

Then

If

the LEDs are not illuminated LED (V28 green) is illuminated LED (V27 yellow) is illuminated

21.5 Setting the sensitivity

.. . .

Required setting in end position OPEN: (refer to figures AG and AH) Turn potentiometer “max.” (P4) slowly counterclockwise until LED (V28 green) is illuminated Turn potentiometer “max” (P4) clockwise until LED (V28 green) is no longer illuminated. Then turn potentiometer “max” (P4) slowly counterclockwise until LED (V28 green) is illuminated Turn potentiometer “max” (P4) slowly counterclockwise until LED (V27 yellow) is no longer illuminated and LED (V28 green) is illuminated

Set selector switch at the local controls to position REMOTE. Set command signal E1 according to label on cover plate (see figure AH). The sensitivity (ΔE / dead band) is set to maximum value (2.5 %) in the factory. The deadband can be increased by turning the potentiometer ΔE (P9) clockwise. Left stop = small dead band (= high sensitivity). For a precise setting of the dead band, a set point device with setting options in the 0.1 mA range is required. A better sensitivity (ΔEmin= 0.25 %) can be achieved by turning the potentiometer P7 (sens) clockwise. When setting E, the following must be observed: If the number of starts is too high, this will lead to unnecessary wear at the valve and actuator. Therefore the maximum possible dead band acceptable for the process must be set.

To prevent exceeding the max. permissible number of starts (refer to Technical data sheets for modulating actuators) in extreme cases, a pause time between 0.5 s (left stop) and 10s (right stop) may be set with the potentiometer “t-off” (P10).

43

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

Figure AH: Cover plate for positioner Label with signal indication (in our example: E1 = 4 – 20 mA, E2 = 4 – 20 mA)

V28 (green) V27 (yellow) V18 (red) V10 (red) P10

Figure AI: Cover plate for positioner A7 P9 (ΔE) P7 (Sens) P3 (0) P4 (max)

S2-7 S3-7

V28 V27 V18 V10

Meas. points:

{

E2

P10 MP2(+) MP1(–) S1-7 Measuring points: MP3(+)/MP4(–) for E1

44

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530

21.6 Positioner adjustment for end position OPEN (inverse operation) In standard version the maximum input signal (E1 = 20 mA) results in operation to end position OPEN. By switching the code switch S3-7 (figure AJ) to position “1”, an inversion of this signal definition (inverse operation) can be achieved. In case an RWG (option) is installed, the connections 7 (red) and 5 (black) on the positioner board (figure W) of the actuator have to be exchanged. In case a potentiometer is installed, (option) the connections 21 (red) and 22 (black) at XA (connection for actuator) must be interchanged.

. . . .. .. . .

Before beginning the setting of the positioner, it has to be ensured that the limit and torque switching of the actuator as well as the feedback have been set (clauses 16. and 17.). Set selector switch (local controls) to position LOCAL. Run actuator with push button to end position OPEN . Supply nominal value E1 of 0 or 4 mA (see wiring diagram). Turn potentiometer “t-off” (P10) counterclockwise to the stop (figure AJ).

Missing signals E1/ E2 or wrong polarity are indicated by LED (V10) “E1/E2 < 4 mA" (figures AH or AJ) Connect voltmeter to measuring points MP3 and MP4 (figure AJ) for measuring the nominal value (0 – 5 V). For a nominal value E1 of 0 mA, the voltmeter shows 0 V. For a nominal value E1 of 4 mA, the voltmeter shows 1 V. In case nominal value (0 V or 1 V) is not correct: Correct nominal value signal in control room. Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value signal. For an actual value E2 of 0 V, the voltmeter shows 0 V. For an actual value E2 of 5 V, the voltmeter shows 1 V. Adjust position feedback according to clause 16. and 17. and repeat “positioner adjustment”.

Table 10 Possible LED display: (refer to figures AH and AJ)

LED (V27 yellow) is illuminated LED (V28 green) is illuminated

Then

If

the LEDs are not illuminated

Required setting in end position OPEN: (refer to figures AH and AJ) Turn potentiometer “0” (P3) slowly clockwise until LED (V28 green) is illuminated Turn potentiometer “0” (P3) slowly clockwise until LED (V27 yellow) is no longer illuminated and LED (V28 green) is illuminated Turn potentiometer “0” (P3) counterclockwise until LED (V28 green) is no longer illuminated. Then turn potentiometer “0” (P3) slowly clockwise until LED (V27 yellow) is illuminated

45

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

21.7 Positioner adjustment end position CLOSED (inverse operation)

.. ..

Run actuator with push button (local controls) to end position CLOSED. Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value E2: When position feedback is set correctly, the voltmeter shows 5 V. If measured value is not correct: Adjust position feedback according to clauses 16. and 17. and repeat “positioner adjustment”. Connect max. command signal (nominal value E1) = 20 mA. Connect voltmeter to measuring points MP4 and MP3 for measuring the nominal value E1: For a nominal value of 20 mA, the voltmeter shows 5 V. If measured value is not 5 V: Check the externally supplied command signal E1.

Table 11 LED display: (refer to figures AH and AJ)

LED (V27 yellow) is illuminated

Then

If

the LEDs are not illuminated

LED (V28 green) is illuminated

Required setting in end position CLOSED: (refer to figures AH and AJ) Turn potentiometer “max” (P4) slowly counterclockwise until LED (V27 yellow) is illuminated Turn potentiometer “max” (P4) clockwise until LED (V27 yellow) is no longer illuminated. Then turn potentiometer “max” (P4) slowly counterclockwise until LED (V27 yellow) is illuminated. Turn potentiometer “max” (P4) slowly counterclockwise until the LED (V28 green) is no longer illuminated and LED (V27 yellow) is illuminated.

Figure AJ: Positioner board A7 P9 (ΔE) P7 (Sens) P3 (0) P4 (max)

S2-7 S3-7

V28 V27 V18 V10

Meas. points:

P10 MP2(+) MP1(–) S1-7 Measuring points: MP3(+)/MP4(–) for E1

46

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

21.8 Positioner in Split Range version (option) For Split Range, a modified version of the positioner is used. The standard version is not suitable for Split Range operation. Split Range operation is only possible with the position transmitter RWG. 21.8.1 Split Range: description of functions In Split Range operation, a setpoint is shared by up to four positioners. A typical example is a pipeline with a bypass. The actuator mounted on the bypass reacts in the lower range (0 – 10 mA), the actuator on the main valve in the upper range (10 – 20 mA). Other values such as 4 – 12 mA and 12 – 20 mA can also be set. 21.8.2 Programming DIP 5 at code switch S1-7 must always be in position ON for Split Range version. Table 12: Possible settings for Split Range operation Programming Command signal Setpoint E1

Feedback1) Actual value E2

4 – 12/12 – 20 mA 0 – 10/10 – 20 mA

4 – 20 mA 0 – 20 mA

4 – 12/12 – 20 mA 0 – 10/10 – 20 mA

0–5V

1)

via DIP switch S1-7 (see figure AK)

Signals for internal feedback: 0/4 – 20 mA from electronic position transmitter

The further programming of the positioner via the code switch S2-7 can be made in the same way as during normal operation. 21.8.3 Positioner adjustment for Split Range

. . . . . . .

(see also example further down the page)

Supply the specified minimum command signal (nominal value E1) for the positioner and check by measuring with voltmeter at the measuring points MP3 and MP4 (figure AK). Connect voltmeter between measuring point M3 and measuring point MP1. Calculate setting value: Initial value = E 1min [in Ampere] x 250 Ohm Set initial value with potentiometer P5. Supply specified maximum command signal (nominal value E1) and check by measuring at the measuring points MP3 and MP4. Connect voltmeter between measuring point M9 and measuring point MP1. Set potentiometer P6 to 5 V. Supply input signal E1 from minimum to maximum value and check the set range 0 – 5 V at measuring point M9. If necessary, readjust with P5 or P6. Apply the same procedure to the second actuator’s positioner and set according to the specified nominal values E1. After setting the Split Range operation, perform further readjustment as described on page 41.

47

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

Figure AK: Positioner board A7, Split Range version P9 (ΔE) P7 (Sens) P3 (0) P4 (max)

S2-7 P6 P5

S3-7

Meas.points M9 M3

V28 (green) V27 (yellow) V18 (red) V10 (red)

{ E2{

E1 Meas.points

P10

S1-7

Example: Two actuators are to be operated in Split Range version. Actuator 1 must be in position CLOSED with a nominal value signal E1 of 0 mA and in position OPEN with a signal of 10 mA. Actuator 2 must be in position CLOSED with a nominal value signal of 10 mA and in position OPEN with a signal of 20 mA.

. . .

48

Positioner actuator 1: Supply E1 = 0 mA, set with P5 = 0 V at M3 (measured against MP1), supply E1 = 10 mA, set with P6 = 5V at M9 (measured against MP1). Positioner actuator 2: Supply E1 = 10 mA, set with P5 = 0 V at M3 (measured against MP1), supply E1 = 20 mA, set with P6 = 5V at M9 (measured against MP1). Perform adjustments and settings for E2, etc. Afterwards the nominal value E1 can be transmitted through both actuators (connected in series). When operating within range E1 = 0 – 10 mA, actuator 1 moves, actuator 2 remains in end position CLOSED. When operating within range E1 = 10 – 20 mA, actuator 2 moves, actuator 1 remains in end position OPEN.

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

22. Timer (option) The timer board is used to increase the operating time for the entire or any portion of the valve travel. Example: In order to avoid water hammer in long pipelines, stepping mode can be chosen for any part of the travel.

. .

The timer is installed in the actuator controls AUMA MATIC instead of the interface board. Electronic timer is not possible in combination with positioner.

22.1 Functions of the diagnosis LEDs (timer) Figure AL: Cover plate for timer A1.6

V14 is illuminated: Phase failure and/ or motor protection tripped. For version with PTC thermistor: reset by selector switch position III at local controls. V15 is illuminated: Torque fault: Tripping torque was exceeded before reaching the end position. V21 is illuminated: Stepping mode in direction CLOSE is switched on. V22 is illuminated: Stepping mode in direction OPEN is switched on.

49

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

22.2 Setting start and end of stepping mode via DUO limit switching (option) Start and end of stepping mode can also be set via external switches (use potential-free contacts).

.. normal operation V 22 off

stepping V22 on

Direction OPEN, first normal operation then stepping mode Run valve in direction OPEN to the desired start of stepping mode. Press down and turn setting spindle K (figure AM) with screw driver in direction of arrow, thereby observe LED V22 (figure AL). Start of stepping mode in direction OPEN is set correctly if the LED changes from off to on (see sketch on the left).

Start stepping mode OPEN

.. stepping

normal operation

V 21 on

V21 off

Start stepping mode CLOSED

Direction CLOSE, first normal operation then stepping mode Run valve in direction CLOSE to the desired start of stepping mode. Press down and turn setting spindle G (figure AM) with screw driver in direction of arrow, thereby observe LED V21 (figure AL). Start of stepping mode in direction CLOSE is set correctly if the LED changes from off to on (see sketch on the left). Figure AM: Control unit

G

K

.. stepping

normal operation

V 22 on

V22 off

Direction OPEN, first stepping mode then normal operation Run valve in direction OPEN to the desired end of stepping mode. Press down and turn setting spindle K (figure AM) with screw driver in direction of arrow, thereby observe LED V22 (figure AL). End of stepping mode is correctly set if the LED changes from on to off (see sketch on the left).

End stepping mode OPEN

.. normal operation V 21 off

stepping V21 on

End stepping mode CLOSED

50

Direction CLOSE, first stepping mode then normal operation Run valve in direction CLOSE to the desired end of stepping mode. Press down and turn setting spindle G (figure AM) with screw driver in direction of arrow, thereby observe LED V21 (figure AL). End of stepping mode is correctly set if the LED changes from on to off (see sketch on the left).

Operation instructions

ITEM 0520, Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1 0530

22.3 Setting ON and OFF times ON and OFF times can be set independently of each other between 1 – 30 seconds at the 4 potentiometers R10 to R13. Clockwise rotation: Counterclockwise rotation:

Time extension Time reduction

R10 (t-off)

: OFF time in direction OPEN

R11 (t-on)

: Running time in direction OPEN

R12 (t-off)

: OFF time in direction CLOSE

R13 (t-on)

: Running time in direction CLOSE

Figure AN: Cover plate for timer A1.6 R 10 R 11

R 12 R 13

51

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

23. Fuses

..

ITEM 0520, 0530

Operation instructions

Switch off the mains before changing the fuses. When replacing fuses, only fuses according to table 13 may be used.

23.1 Fuses within the actuator controls Fuses (figures AP and AO) are accessible after removal of the local controls. Figure AP: Fuses on signal and control board

Figure AO: Fuses on power supply board 1F1

F3 F4

1F2

Table 13 Switchgear

Voltage supply (mains voltage)

≤ 500 V Reversing contactors

24 V 115 V 24 V

> 500 V

Thyristors

Voltage output (power supply unit)

≤ 500 V

115 V 24 V 115 V

G fuses: (figures AP and AO) F 1/F 2 F 4*) F 3*) (Board A20, refer to (Boards A2, refer to (Boards A8, refer to wiring diagram) wiring diagram) wiring diagram) 1 A T; 500 V AUMA article no.: K002.277 2 A FF; 660 V AUMA article no.: K002.665

0.4 A T; 250 V 1.6 A T; 250 V 500 mA T; 250 V

16 A FF; 500 V AUMA article no.: K001.189 6.3 x 32 mm

Size

1.6 A T; 250 V

0.4 A T; 250 V 1.6 A T; 250 V 0.4 A T; 250 V

5 x 20 mm

5 x 20 mm

*) according to IEC 60127-2/III

F1/ F2: F3: F4:

. 52

Primary fuses on power supply unit Internal 24 V DC supply, RWG, logic board Internal 115 V AC supply (optional: 24 V AC); Heater, tripping device for PTC thermistors, control of reversing contactors, remote operation

After replacing the fuses, screw local controls back on again.

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

Carefully lead cables back into the housing to prevent them from pinching.

53

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

23.2 Motor protection In order to protect against overheating and impermissibly high temperatures at the actuator, PTC thermistors or thermoswitches are embedded in the motor winding. The thermoswitch is tripped as soon as the max. permissible winding temperature has been reached. The actuator is stopped and the yellow indication light on the local controls is illuminated. The motor has to cool down before the operation can be resumed. Version with thermoswitch (standard) The actuator can be controlled again after the motor has cooled down. As soon as the actuator receives a run command (OPEN - CLOSE), the fault signal (yellow indication light) is no longer illuminated. Version with thermoswitch and additional thermal overload relay within the controls (option): The operation can only be continued after the fault signal (yellow indication light) has been reset. The fault signal is reset automatically via an overload relay integrated in the actuator controls after the motor has cooled down. Version with PTC thermistor (option) The operation can only be continued after the fault signal (yellow indication light) has been reset. The fault signal is reset via selector switch position RESET (figure AQ) of the local controls. Figure AQ: Selector switch RESET

54

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

24. Enclosure protection IP 68 (option) Definition According to EN 60 529, the conditions for meeting the requirements of enclosure protection IP 68 are to be agreed between manufacturer and user. AUMA actuators and controls in enclosure protection IP 68 meet the following requirements according to AUMA: Duration of submersion in water max. 72 hours Head of water max. 6 m Up to 10 operations during submersion Modulating duty is not possible during submersion

.. ..

Enclosure protection IP 68 refers to the interior of the actuators (motor, gearing, switch compartment, controls, and terminal compartment). Inspection AUMA actuators and controls in enclosure protection IP 68 undergo a routine testing for tightness in the factory.

.

Cable glands For the entries of the motor and control cables, appropriate cable glands in enclosure protection IP 68 must be used. The size of the cable glands must be suitable for the outside diameter of the cables, refer to recommendations of the cable gland manufacturers. As standard, actuators and controls are delivered without cable glands. For delivery, the threads are sealed with plugs in the factory. When ordered, cable glands can also be supplied by AUMA at an additional charge. For this, it is necessary to state the outside diameter of the cables. The cable glands must be sealed against the housing at the thread with an O-ring. It is recommended to additionally apply a liquid sealing material (Loctite or similar).

. . . .

Commissioning When commissioning, the following should be observed: Sealing faces of housing and covers must be clean. O-rings of the covers must not be damaged. A thin film of non-acidic grease should be applied to sealing faces. Covers should be tightened evenly and firmly.

.. .. ..

After submersion Check actuator. In case of ingress of water, dry actuator correctly and check for proper function.

Further notes When using output drive types A and AF (stem nut), it cannot be prevented that water enters the hollow shaft along the valve stem during submersion. This leads to corrosion. The water also enters the thrust bearings of output drive type A, causing corrosion and damage to the bearings. The output drive types A and AF should therefore not be used during submersion for this application.

55

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

25. Maintenance After commissioning, check multi-turn actuator for damage to paint finish. Do a thorough touch-up to prevent corrosion. Original paint in small quantities can be supplied by AUMA. AUMA multi-turn actuators require very little maintenance. Precondition for reliable service is correct commissioning. Seals made of elastomers are subject to ageing and must therefore regularly be checked and, if necessary, be exchanged. It is also very important that the O-rings at the covers are placed correctly and cable glands fastened firmly to prevent ingress of dirt or water.

. . .

We recommend additionally: If rarely operated, perform a test run about every 6 months. This ensures that the actuator is always ready to operate. Approximately six months after commissioning and then every year check bolts between multi-turn actuator and valve/ gearbox for tightness. If required, tighten applying the torques given in table 1, page 12. For multi-turn actuators with output drive type A: At intervals of approx. 6 months from commissioning, press in Lithium soap EP multi-purpose grease on mineral oil base at the grease nipple with grease gun (quantity see table 2, page 13).

26. Lubrication

.. ..

The gear housing is filled with lubricant in the factory. A grease change is recommended after the following operation time: If rarely operated, after 10 – 12 years. If operated frequently, after 6 – 8 years.

Lubrication of the valve stem must be done separately.

27. Disposal and recycling AUMA actuators have an extremely long lifetime. However, they have to be replaced at one point in time. The actuators have a modular design and may therefore easily be disassembled, separated, and sorted according to materials, i.e.:

.. .. . . .

electronic scrap various metals plastics greases and oils

The following generally applies:

56

Collect greases and oils during disassembly. As a rule, these substances are hazardous to water and must not be released into the environment. Arrange for controlled waste disposal of the disassembled material or for separate recycling according to materials. Observe the regional regulations for waste disposal.

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

28. Service AUMA offers extensive services such as maintenance and inspection for actuators as well as various training courses. Addresses of AUMA offices and representatives can be found on page 64 and on the Internet (www.auma.com).

57

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

Notes

58

ITEM 0520, 0530

Operation instructions

Sample name plate AUMA ACTUATORS INC. PITTSBURGH PA USA SA 07.1-FA10 Com No:1309533 No: 3302MD 19302 n: 11 rpm T open: 7-22Nm T close 7-22Nm Lubr.: F1 NEMA4 Temp -25°C/+80°C

- Actuator type - Commission number - Comm./ sales order number Works/ Serial number - Protection type Torque range in CLOSE/ OPEN - Lubricant - Temperature range

Operation instructions

ITEM 0520, 0530 Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

29. Spare parts list Multi-turn actuator SA 07.1 – SA 16.1/SAR 07.1 – SAR 16.1

59

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability. Delivered spare parts may slightly vary from the representation.

No. 001.0 002.0 003.0 005.0 005.1 005.2 005.3 005.4 006.0 009.0 010.0 017.0 018.0 019.0 020.0 022.0 023.0 024.0 025.0 058.0 061.0 070.0 079.0 080.0 155.0 500.0 501.0 502.0 503.0 504.0 505.0 506.0 507.0 511.0 514.0 514.1

60

Designation Housing Bearing flange Hollow shaft without worm wheel Worm shaft Motor coupling Coupling pin Manual drive coupling Pull rod Worm wheeel Planetary gear for manual drive Retaining flange Troque lever Gear segment Crown wheel Swing lever Drive pinion II for torque switching Output drive wheel for limit switching Intermediate wheel for limit switching Locking plate Wire for protective earth (pin) Torque switching head Motor (VD motor incl. no. 079.0) Planetary gear for motor drive (SA/SAR) 07.1 – 14.1 for VD motor) Planetary gear for motor drive (SA/SAR 16.1 for AD90 motor) Reduction gearing Cover for switch compartment Socket carrier (complete with sockets) Pin carrier without pins Socket for controls Socket for motor Pin for controls Pin for motor Plug cover Screw plug Output drive form A (without stem nut) Axial needle roller bearing

Type Sub-assembly Sub-assembly Sub-assembly Sub-assembly

Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly

No. 516.1 535.1 539.0 542.0 549.1 551.1 553.0 554.0 556.0 556.1 557.0 558.0 559.0-1

559.0-2 560.0-1 560.0-2 560.1 560.2 566.0 566.1 566.2 566.3 567.1 568.1 568.2 568.3 569.0 569.1 569.2 574.1 575.1 S1 S2

Designation Output drive shaft D Snap ring Screw plug Handwheel with ball handle Output socket B3/B4/E Parallel key Mechanical position indicator Socket carrier with motor cable harness Potentiometer for position transmitter Potentiometer without slip clutch Heater Blinker transmitter including pins at wires (without impulse disc and insulation plate) Control unit without torque heads switching and switches control unit with magnetic limit and torque transmitter (MWG) for Non-intrusive version in combination with AUMATIC integral controls Switch stack for direction OPEN Switch stack for direction CLOSE Switch for limit/torque switching Switch case Positioner transmitter RWG Potentiometer for RWG without slip clutch Electronic board RWG Wire harness for RWG Slip clutch for potentiometer/RWG Stem protection tube (without cap) Cap for stem protection tube V-seal Change-over lever assy Change-over lever Notched pin Radial seal output drive A for ISO flange Stem nut type A Seal kit, small Seal kit, large

Type

Sub-assembly

Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly

Sub-assembly

Sub-assembly

Sub-assembly Sub-assembly Sub-assembly Sub-assembly Sub-assembly

Set Set

AM 01.1 P:1.5kW Com. no:1309533 No.: 2302MA04225 KMS: TP101/001 MSP:1Q1-C3Q-F18E1 3 ~ 400V IP67 Control: 24V DC

Sample name plate

- Type of controls - Commission number - Works number - Terminal plan actuator - Wiring diagram - Mains voltage/ Enclosure protection - Control voltage

Operation instructions

ITEM 0520, 0530 Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

30. Spare parts list controls AUMA MATIC

61

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

ITEM 0520, 0530

Operation instructions

Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any liability. Delivered spare parts may slightly vary from the representation.

No.

Designation

001.0

Housing

002.0

Local controls

Sub-assembly

002.5

Selector switch

Sub-assembly

003.0

Local controls board

Sub-assembly

003.1

Primary fuse

003.2

Fuse cover

004.0

Carrier for contactors

006.0

Power supply including mounting plate

Sub-assembly

006.1

Mounting plate for power supply

Sub-assembly

006.2

Power supply

006.2-1

Secondary fuse F3

006.2-2

Secondary fuse F4

62

Type

008.0

Interface board

008.1

Interface board

008.2

Cover plate for interface board

009.0

Logic board

Sub-assembly

013.0

Adapter board

Sub-assembly

500.0

Cover

Sub-assembly

501.0

Socket carrier (complete with sockets)

Sub-assembly

502.0

Pin carrier without pins

Sub-assembly

503.0

Socket for controls

Sub-assembly

504.0

Socket for motor

Sub-assembly

505.0

Pin for controls

Sub-assembly

506.0

Pin for motor

Sub-assembly

507.0

Plug cover

Sub-assembly

508.0

Motor power board

Sub-assembly

509.0

Padlock

S1

Seal kit

Sub-assembly

Set

Operation instructions

ITEM 0520, 0530

Multi-turn actuators SA 07.1 – SA 30.1/ SAR 07.1 – SAR 30.1 with actuator controls AUMA MATIC AM 01.1 / AM 02.1

Index A Ambient temperature B Blinker transmitter C Collective fault signal Command signal Corrosion protection Cross sections Current consumption D Direction of rotation Disconnect switches Disposal and recycling DUO limit switching

8 35 34,35 37,39,40 10,56 18 6,15 26 15 56 24

E Electrical connection 15 Electronic position transmitter RWG 30 2-wire system 31 3-/ 4-wire system 32 EMERGENCY signal 36 Enclosure protection IP 68 55 F Finish machining of the stem nut13 Fuses 52 H Handwheel Heater I Indicator disc Interface board Internet Inverse operation L Limit switching Local controls Logic board Loss of signal Lubrication

19 15 22,33 34 5 45,46

M Mains frequency Maintenance Manual operation Mechanical position indicator Motor protection Mounting positions of the local controls Mounting to valve/ gearbox

6 4 19 33 54 14 12

N Name plate

61

O Output drive types Overvoltage category

12 6

P Packaging Pause time Position indicator Position transmitter RWG Positioner Potentiometer Power supply Protection tube Protective earth PTC thermistors PTC tripping device Push-to-run operation

10 37,51 33 15,30 37 29 6 13 18 54 27 21,35

R Rate power 6 Remote indication 29,30 RESET (Selector switch position) 27 Running time 37,51

S Safety instructions Selector switch Self-retaining Sensitivity Service Short description Short-circuit protection Signals Spare parts list Multi-turn actuator Controls Split Range Version Stepping mode Operating time Pause time Storage

4 27 21,35 43 57 5 15 9 59 59 61 47 49 51 10

T Technical data TEST (Selector switch position) Test run Thermoswitches Timer Torque setting Transport Tripping torque Type of duty Type of seating

6 27 26 54 49 25 10 25 6 35

W Wall bracket

16

23,24,27 27 35 40 56

63

ITEM 0520, 0530

North American Sales and Service: US Headquarters and Factory: AUMA Actuators, Inc. 100 Southpointe Blvd. Canonsburg PA 15317 Tel: 724-743-AUMA (2862) Fax: 724-743-4711 email: [email protected] www.auma-usa.com

Regional Offices: Northeast (Maryland and New York) Southeast (South Carolina) Midwest (Illinois) Midwest (Kansas) Houston (Texas) West Coast (Northern and Southern California)

Representatives and Distributors Anchorage Atlanta Baltimore Baton Rouge Birmingham Boston Charlotte Chicago Cincinnati Corpus Christi Dallas Denver Detroit Hawaii Houston Indianapolis Kansas City Los Angeles Mexicali (Mexico) Mexico City Milwaukee Minneapolis Montana Monterrey (Mexico) New York Omaha Orlando Philadelphia Phoenix Pittsburgh Rochester Salt Lake City San Diego San Francisco San Juan Seattle St. Louis Toronto Tulsa

International Headquarters: AUMA Riester GmbH & Co. KG Muellheim/ Germany www.auma.com

International Sales and Service: South America: Argentina Brazil Chile Colombia Peru Venezuela

Europe: Austria Benelux Czech Republic Denmark Finland France Greece Hungary Italy Norway Poland Portugal Russia Spain Sweden Switzerland Turkey Ukraine United Kingdom

Africa Egypt South Africa

Asia, Australia Australia China Hong Kong India Japan Korea Kuwait Oman Qatar Singapore Taiwan Thailand UAE

For the name and phone number of the office nearest you, call us at 724-743-2862 or visit our website at www.auma-usa.com/saleserv.htm 2005-06-27

Y000.176/047/us/1.08

ITEM 0520, 0530

ITEM 0520, 0530

ITEM 0520, 0530

10" Blow Off Valve

ITEM 0520, 0530

30" Discharge Valve

ITEM 0520, 0530

Part-turn gearboxes Worm gearboxes GS 50.3 – GS 250.3 for flange types FA

Operation instructions

Worm gearboxes GS 50.3 – GS 250.3 Scope of these instructions:

ITEM 0520, 0530

Operation instructions

These operation instructions are valid for worm gearboxes of the type range GS 50.3 – GS 125.3 with primary reduction gearings VZ 2.3 – VZ 4.3. and GS 160.3 – GS 250.3 with primary reduction gearings GZ 160.3 – GZ 250.3.

Table of contents 1. 1.1 1.2 1.3 2. 3. 3.1 3.2 3.3 4. 5. 6. 7. 8. 8.1 8.2 9. 9.1 9.2 10. 10.1 10.2 11. 12. 12.1 12.2

Safety instructions Range of application Maintenance Warnings and notes Technical data Transport, storage and packaging Transport Storage Packaging Fitting the handwheel Mounting positions of the different versions Mounting multi-turn actuators SA/SAR Mounting to valve Setting the end stops for manual operation Worm gearboxes on butterfly valves Worm gearboxes on ball valves Setting the end stops with mounted multi-turn electric actuator Worm gearboxes on butterfly valves Worm gearboxes on ball valves Changing the swing angle Changing the swing angle for sizes GS 50.3 – GS 125.3 (option) Changing the swing angle for sizes GS 160.3 – GS 250.3 Enclosure protection IP 68 Maintenance General notes Grease change for worm gearboxes GS 50.3 – GS 125.3 and primary reduction gearing VZ 2.3 – VZ 4.3 12.2.1 Worm gearboxes 12.2.2 Primary reduction gearing 12.3 Grease change for worm gearboxes GS 160.3 – GS 250.3 and primary reduction gearing GZ 160.3 – GZ 250.3 12.3.1 Worm gearboxes 12.3.2 Single-stage reductions gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1 and 8:1) 12.3.3 Double-stage primary reduction gearing GZ 200.3 – GZ 250.3 (reduction ratio 16:1) 12.4 After maintenance 13. Disposal and recycling 14. Service 15. Spare parts list worm gearboxes GS 50.3 – GS 125.3 and reduction gearing VZ 2.3 – VZ 4.3 16. Spare parts list worm gearboxes GS 160.3 – GS 250.3 17. Spare parts list reduction gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1) Index Addresses of AUMA offices and representatives

2

Page 3 3 3 3 4 7 7 7 7 7 8 9 11 12 12 13 13 13 14 16 16 17 18 19 19 20 20 20 21 21 21 22 22 23 23 24 26 28 31 32

Operation instructions

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

1.

Safety instructions

1.1

Range of application

AUMA worm gearboxes GS 50.3 – GS 250.3 are used for the operation of valves (e.g. butterfly valves and ball valves). They are designed for manual operation as well as motor operation in conjunction with electric actuators. For other applications, please consult us. The manufacturer is not liable for any possible damage resulting from use in other than the designated applications. Such risk lies entirely with the user. Observance of these operation instructions is considered as part of the gearboxes’ designated use.

1.2

Maintenance

The maintenance instructions (refer to page 19) must be observed, otherwise a safe operation of the worm gearbox is no longer guaranteed.

1.3

Warnings and notes

Non-observance of the warnings and notes may lead to serious injuries or damage. Qualified personnel must be thoroughly familiar with all warnings and notes in these operation instructions. Correct transport, proper storage, mounting and installation, as well as careful commissioning are essential to ensure a trouble-free and safe operation. The following references draw special attention to safety-relevant procedures in these operation instructions. Each is marked by the appropriate pictograph. This pictograph means: Note! “Note” marks activities or procedures which have major influence on the correct operation. Non-observance of these notes may lead to consequential damage.

This pictograph means: Warning! “Warning” marks activities or procedures which, if not carried out correctly, can affect the safety of persons or material.

3

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

2.

Operation instructions

Technical data

Features and functions Version Housing material Self-locking Output torques

ITEM: 0520 ITEM: 0530

End stops Strength of end stop

Swing angle GS 50.3 – GS 125.3

Swing angle GS 160.3 – GS 250.3 Mechanical position indicator

Input shaft Operation Motor operation Type of duty Manual operation5)

Standard: clockwise rotation RR, counterclockwise rotation LL, option: RL or LR Standard: cast iron (GJL-250), Option: spheroidal cast iron (GJS-400-15) The gearboxes are self-locking when at stand-still under normal service conditions; strong vibrations may cancel the self-locking effect. While in motion, safe breaking is not guaranteed. If this is required, a separate brake must be used. Type

Output torques 100 % max. ft lbs.

140 % max. ft lbs.

175 %1) max. ft lbs.

200 %1) max. ft lbs.

Modulating torque2) max. ft lbs.

184 369 738 1,475 2,950 5,900 11,801 23,602

258 516 1,033 2,065 4,130 8,298 16,595 32,822

– – – – – 10,326 20,652 41,303

369 738 1,475 2,950 5,900 – – –

92 184 369 738 1,475 2,950 5,900 16,000

GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3 GS 160.3 GS 200.3 GS 250.3

Positive for both end positions by traveling nut, sensitive adjustment Guaranteed strength of end stop (in ft lbs.) for input side operation Type Reduction gearing

GS 50.3

GS 63.3

GS 80.3

–

–

–

ft lbs.

185

330

330

GS 100.3 VZ 2.3

VZ 3.3 370

Type

GS 160.3

GS 200.3

GZ 160.3

GZ 200.3

4:1

8:1

ft lbs.

370

330

4:1

VZ 2.3

185

Reduction gearing Reduction ratio

GS 125.3 VZ 4.3

8:1

VZ 3.3 370

VZ 4.3 185

GS 250.3 GZ 250.3 16:1

4:1

8:1

370

16:1

370

Standard: Options:

Fixed swing angle up to max. 100°; set in the factory to 92° unless ordered otherwise. Adjustable in steps of: 10°– 35°, 35° – 60°, 60° – 80°, 80° – 100°, 100° – 125°, 125° – 150°, 150° – 170°, 170° – 190° For version with worm wheel made of bronze: swing angle > 190°, Multi-turn version without end stops, version GSD3) Standard: Adjustable 80° – 100°; set in the factory to 92° unless ordered otherwise. Options: Adjustable in steps of: 20° – 40°, 40° – 60°, 60° – 80°, For version with worm wheel made of bronze: swing angle > 100°, ‘ Multi-turn version without end stops, version GSD3) Standard: Pointer cover for continuous position indication Options: Sealed pointer cover for horizontal outdoor installation4) Protection cover for buried service instead of pointer cover Cylindrical with parallel key according to DIN 6885.1 With electric multi-turn actuator, directly or through primary reduction gearing VZ/GZ Flanges for mounting of actuator, refer also to separate technical data sheets. According to actuator Via handwheel, directly or through primary reduction gearing VZ/GZ Available handwheel diameters, selection according to the max. output torque: Type Reduction gearing

GS 50.3

GS 63.3

GS 80.3

–

–

–

–

GS 100.3

Handwheel Ø mm

160 200 250

250 315

315 400

400 500

GS 160.3

Type Reduction gearing

–

Handwheel Ø mm

630 800

315 400

315 400

250 315

– 500 630 800

GS 200.3

GZ 160.3 400

GS 125.3

VZ 2.3 VZ 3.3 VZ 4.3

315

– –

400

400 500

400 500

315 400

GS 250.3

GZ 200.3 500 630

VZ 2.3 VZ 3.3 VZ 4.3

– 315

–

GZ 250.3 800

500 630

400

25.4 mm correspond to 1 inch 1) 2) 3) 4) 5)

4

With worm wheel made of spheroidal cast iron Requires worm wheel made of bronze Special sizing is required For gas applications with sealed pointer cover, an air vent in the pointer cover or venting grooves in the valve mounting flange must be provided Handwheel sizes shown reflect general industrial selection criteria. For information on gearbox/handwheel selection in accordance with AWWA Standard C504, please refer to separate selection list/chart.

ITEM 0520, 0530

Operation instructions Primary reduction gearing Primary reduction gearing Valve attachment Valve attachment

Splined coupling for connection to the valve shaft Service conditions Enclosure protection according to EN 60 5296)

Corrosion protection

Paint Color Ambient temperature

Lifetime

Worm gearboxes GS 50.3 – GS 250.3

Planetary gear with various reduction ratios for reducing the input torques Dimensions according to SP 101 Standard: GS 50.3 – GS 125.3: without spigot GS 160.3 – GS 250.3: without spigot Options: GS 50.3 – GS 125.3: with spigot GS 160.3 – GS 250.3: with spigot Standard: without bore or pilot bore from GS 160.3 Worm gearbox can be repositioned 4 x 90° on coupling Options: Machined with bore and keyway, square bore or bore with two-flats Standard: Options7):

IP 68-3, dust and water tight up to max. 3 m head of water IP 68-6, dust and water tight up to max. 6 m head of water IP 68-10, dust and water tight up to max. 10 m head of water IP 68-20, dust and water tight up to max. 20 m head of water Standard: KN Suitable for installation in industrial units, in water or power plants with a low pollutant concentration Options: KS Suitable for installation in occasionally or permanently aggressive atmosphere with a moderate pollutant concentration (e.g. in wastewater treatment plants, chemical industry) KX Suitable for installation in extremely aggressive atmosphere with high humidity and high pollutant concentration Standard: GS 50.3 – GS 125.3: Two-component iron-mica combination GS 160.3 – GS 250.3: Two-component iron-mica combination Standard: Grey (DB 702, similar to RAL 9007) Option: Other colors on request Standard: – 20 °F to + 175 °F/ – 25 °C to + 80 °C Options: – 40 °F to + 140 °F/ – 40 °C to + 60 °C (low temperature), version L – 75 °F to + 140 °F/ – 60 °C to + 60 °C (extreme low temperature), version EL + 32 °F to + 250 °F/ – 0 °C to + 120 °C (high temperature), version H Open-close duty: The lifetime is based on a load profile typical for part-turn valves Type

GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3 GS 160.3 GS 200.3 GS 250.3

100 % 15,000 15,000 15,000 15,000 15,000 15,000 15,000 10,000

Operating cycles (OPEN - CLOSE - OPEN) for swivel movements of 90° (max. 100°) and a maximum output torque of 140 % 175 %8) 5,000 – 5,000 – 5,000 – 5,000 – 5,000 – 5,000 1,000 5,000 1,000 3000 750

200 %9) 1,000 1,000 1,000 1,000 1,000 – – –

Modulating duty: min. 2.5 million operations8)

6) 7) 8) 9)

Refer to section enclosure protection IP 68 Not available for GS 50.3 With worm wheel made of spheroidal cast iron The lifetime for modulating duty depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process

5

Worm gearboxes GS 50.3 – GS 250.3 Accessories Valve position indicators

Limit switching Further information Reference documents

Lever gearboxes

6

ITEM 0520, Operation instructions 0530

Valve position indicator WSG for the signalization of intermediate and end positions for precise and low-backlash feedback for swing angles ranging from 82° – 98° (refer to separate data sheet) Valve position indicator WGD for signalization of intermediate and end positions for swing angles > 180° (refer to separate data sheet) Limit switching WSH for manually operated valves. For the signalization of intermediate and end positions (refer to separate data sheet) Product description Worm gearboxes GS 50.3 – GS 250.3 /GS 315 – GS 500 Dimension sheets GS 50.3 – GS 125.3, GS 160.3 – GS 250.3 Technical data GS 50.3 – GS 125.3, GS 160.3 – GS 250.3 Technical data SA, SAR, WSG, WGD, WSH See separate documents

ITEM 0520, 0530

Operation instructions

3.

Transport, storage and packaging

3.1

Transport

3.2

Storage

.. . .. ..

Worm gearboxes GS 50.3 – GS 250.3

Transport to place of installation in sturdy packing. If mounted together with actuator: Attach ropes or hooks for the purpose of lifting by hoist only to the gearbox and not to the actuator. If eyebolts are supplied with the gearbox, they should be used to lift the gearbox only and not the valve Store in well-ventilated, dry room. Protect against floor dampness by storage on a shelf or on a wooden pallet. Cover to protect against dust and dirt. Apply suitable corrosion protection agent to bare surfaces.

In case worm gearboxes are to be stored for a long period (more than 6 months), the following points must be observed additionally:

. .

Prior to storage: Protect bare surfaces, in particular the output drive parts and mounting surface, with long-term corrosion protection agent. Check for corrosion approximately every 6 months. If first signs of corrosion show, apply new corrosion protection.

3.3

Packaging

Our products are protected by special packaging for the transport ex works. The packaging consists of environmentally friendly materials which can easily be separated and recycled. For the disposal of the packaging material, we recommend recycling and collection centers.

4.

Fitting the handwheel

For worm gearboxes designed for manual operation the handwheel may be supplied separately. Fitting is done on site according to figure A. Figure A: Handwheel Spacer (may be required) Circlip

Worm shaft gearbox

Ball handle (option) Spacer (may be required) Circlip

Handwheel

7

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

5.

Operation instructions

Mounting positions of the different versions

RR

LL

RL

LR

Description of the 4 versions (viewed at the pointer cover): Code RR LL RL LR

Direction of rotation at input shaft clockwise clockwise clockwise clockwise

Position of worm shaft Right side Left side Right side Left side

Direction of rotation at output drive clockwise counterclockwise counterclockwise clockwise

Mounting positions of AUMA multi-turn actuator with AUMA worm gearbox (please indicate when ordering) GS versions RR / RL

RR

RR

RR

RR

RL

RL

RL

RL

B

A

C

D

GS versions LL / LR

A

LL

LL

LL

LL

LR

LR

LR

LR

B

C

D

Mounting positions can easily be changed at a later date. Limitation: For SA/SAR 14.1/14.5 with GS 125.3, mounting position “C” in version RR/RL and “A” in version LL/LR is only possible for a handwheel diameter up to 12.4 ”. Up to size GS 125.3, the actuator-gearbox combination is delivered in the ordered mounting position. For packing reasons, actuator and gearbox is delivered separately from size GS 160.3.

8

ITEM 0520, 0530

Operation instructions

6.

Worm gearboxes GS 50.3 – GS 250.3

Mounting multi-turn actuators SA/SAR When gearboxes and multi-turn actuators are supplied together, the mounting has been done in the factory up to gearbox size GS 125.3. For sizes GS 160.3 and larger, the mounting of gearboxes is performed as follows. In case flange for actuator is not attached to gearbox or reduction gearing: Thoroughly degrease the mounting faces of the gearbox or reduction gearing as well as the flange for actuator. For GS 100.3 – GS 250.3: Insert pin in the corresponding groove of the bearing cover. Fit flange for actuator and fasten with bolts and lock washers. Fasten bolts crosswise with a torque according to table 2.

. . ..

Figure B: Mounting multi-turn actuator to worm gearbox Flange for actuator

Bearing flange

Flange for actuator

Primary reduction gearing Bearing flange

. . . . .

Mounting the multi-turn actuator: Thoroughly degrease the faces of the flange for actuator at the gearbox or reduction gearing as well as the actuator’s bearing flange. Place the multi-turn actuator on the worm gearbox or reduction gearing. The multi-turn actuator can be mounted on the valve at every 90° (see page 8, mounting positions). Ensure that the spigot mates uniformly in the recess and that the mounting faces are in complete contact. Fasten actuator with bolts and lock washers (see table 1) at the flange of the worm gearbox. Fasten bolts crosswise with a torque according to table 2. Do not attach ropes or hooks for the purpose of lifting the actuator by hoist to the handwheel. If multi-turn actuator is mounted on gearbox, attach ropes or hooks for the purpose of lifting by hoist to gearbox and not to multi-turn actuator.

9

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

Table 1:

Operation instructions

Bolts for mounting AUMA actuators to worm gearboxes/ primary reduction gearing (strength class min. 8.8)

Worm gearbox/ primary reduction gearing

SA(R) 07.1-FA10 Bolt Lock Qty. (UNC) washer

GS

50.3

3/8-16x1

3/8

4

GS

63.3

3/8-16x1

3/8

4

GS

80.3

SA(R) 07.5-FA10 Bolt Lock Qty. (UNC) washer 3/8-16x1

3/8

4

3/8-16x1

3/8

4

3/8-16x1

3/8

4

3/8-16x1

3/8

4

GS 100.3 GS 100.3/VZ

3/8-16x1

3/8

4

GS 125.3 GS 125.3/VZ GS 160.3 GS 160.3/GZ

3/8-16x1

3/8

4

3/8-16x1

3/8

4

3/8-16x1

3/8

4

3/8-16x1

3/8

4

GS 200.3 GS 200.3/GZ Worm gearbox/ primary reduction gearing GS 63.3 GS 80.3 GS 100.3 GS 100.3/VZ GS 125.3 GS 125.3/VZ GS 160.3 GS 160.3/GZ GS 200.3 GS 200.3/GZ GS 250.3 GS 250.3/GZ Worm gearbox/ primary reduction gearing GS 160.3 GS 160.3/GZ GS 200.3 GS 200.3/GZ GS 250.3 GS 250.3/GZ

10

SA(R) 10.1-FA10 Bolt Lock Qty. (UNC) washer 3/8-16x1 3/8 4 3/8-16x1 3/8 4 3/8-16x1 3/8 4 3/8-16x1 3/8 4 3/8-16x1 3/8-16x1

3/8 3/8

SA(R) 14.1-FA14 Bolt Lock Qty. (UNC) washer

5/8-11x11 2

5/8

4

4

5/8-11x11 2 5/8-11x11 2

5/8 5/8

4 4

4

5/8-11x1

1

2

5/8

SA(R) 14.5-FA14 Bolt Lock Qty. (UNC) washer

5/8-11x11 2

5/8

4

5/8-11x11 2

5/8

4

SA(R) 16.1-FA16 Bolt Lock Qty. (UNC) washer

3

3/8-16x1

3/8

4

5/8-11x11 2

5/8

4

5/8-11x11 2

5/8

4

3/8-16x1

3/8

4

5/8-11x11 2

5/8

4

5/8-11x11 2

5/8

4

5/8-11x2

5/8

8

5/8-11x2

5/8

8

SA(R) 30.1-FA30 Bolt Lock Qty. (UNC) washer

3

4

-10x2

3/4

-10x2

3/4

4

4

-10x2

3/4

4

4

-10x2

3/4

4

4 3

SA(R) 25.1-FA25 Bolt Lock Qty. (UNC) washer

4

8

3

ITEM 0520, Worm gearboxes GS 50.3 – GS 250.3 0530

Operation instructions

7.

Mounting to valve

AUMA worm gearboxes GS and primary reduction gearings VZ/GZ can be operated in any mounting position. For butterfly valves, the recommended mounting position is end position CLOSED (Prior to mounting, bring the gearbox to the mechanical end stop CLOSED by turning the handwheel clockwise). For ball valves, the recommended mounting position is end position OPEN (Prior to mounting, bring the gearbox to the mechanical end stop OPEN by turning the handwheel counterclockwise). Alternatively, the limit stop housing can be turned up to the end position of the respective valve. Thoroughly degrease mounting faces of gearbox and valve. Place coupling sleeve onto valve shaft and secure (refer to figure C, detail A or B), ensure that dimensions X, Y, and Z are observed (refer to table 2). Apply non-acidic grease at splines of coupling. Mount gearbox on valve. Ensure that the spigot (if provided) mates uniformly in the recess and that the mounting faces are in complete contact. Fasten gearbox with bolts (quality min. 8.8) and lock washers. Fasten bolts crosswise with a torque according to table 2.

. . . .. .. ..

Figure C A

B

Coupling Grub screw

Z Y

X

Valve

Table 2: Standard dry fastening torques for bolts Gearbox

Dimensions

Bolts

Flange type

X Y max Z max max 14 5 61 7 18 73 10 13 76 23 5 88 22 13 123 22 8 123 17 35 126 17 27 126 15 11 130 30 0 140 19 19 160 44 0 190 8 8 220 13 0 230

Qty. x threads (UNC) 4 x 3 8 - 16 4 x 3 8 - 16 4 x 1 2 - 13 4 x 5 8 - 11 4 x 5 8 - 11 4 x 3 4 - 10 4 x 3 4 - 10 8 x 5 8 - 11 8 x 5 8 - 11 8 x 3 4 - 10 8 x 3 4 - 10 8x1-8 8x1-8 8 x 11 4 - 7

GS 50.3-FA10 GS 63.3-FA10 GS 63.3-FA12 GS 80.3-FA14 GS 100.3-FA14 GS 100.3-FA16 GS 125.3-FA16 GS 125.3-FA25 GS 160.3-FA25 GS 160.3-FA30 GS 200.3-FA30 GS 200.3-FA35 GS 250.3-FA35 GS 250.3-FA40

Strength class Grade 5 Fastening torque TA [Ft lbs.] 33 33 78 155 155 257 257 155 155 255 255 590 590 1,200

Note: Experience showed that it is very difficult to fasten bolts or nuts of 1-8 UNC or larger with the defined torques. The worm gearbox may be moved radially against the valve flange by accident. To improve adhesion between valve and gearbox, we recommend to apply Loctite 243 (or similar products) on mounting faces.

11

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

8.

Operation instructions

Setting the end stops for manual operation If worm gearboxes GS are supplied on a valve the end stops are already set by the valve manufacturer.

8.1

Worm gearboxes on butterfly valves Setting end position CLOSED

.. . . ..

Remove all bolts (03) at limit stop housing (figures D, E). Turn valve manually to end position CLOSED. In case limit stop housing (10) has not yet rotated, turn it clockwise up to the stop. If the holes of limit stop housing (10) do not align with the threads of the housing (1), take off the limit stop housing (10) and replace it in the required position. Fasten bolts (03) with lock washers (04). Fasten bolts crosswise with a torque according to table 3.

Table 3 Gearbox

GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3 GS 160.3 GS 200.3 GS 250.3

End stops fastened with bolts (03) M8 M8 M8 M 12 M 12 M 10 M 12 M 16

Material

Protective cap fastened with bolts (054)

A2-80 A2-80 A2-80 A2-80 A2-80 A2-80 A2-80 A2-80

M6 M6 M6

Material

Fastening torque TA [Nm] 24 24 24 82 82 48 82 200

A2-80 A2-80 A2-80

Conversion factor: 1 Nm corresponds to 0.74 ft lbs.

Figure D: End stop up to GS 125.3

03/04

03/04

. Setting end position OPEN

12

10

Figure E: End stop from GS 160.3

1

10

1

If the position of the pointer cover does not correspond to the symbol CLOSED, slightly loosen the screws of the pointer cover. Turn the pointer cover to the CLOSED symbol and fasten the screws again.

The end stop need not be set since the required swing angle has been set in the factory. If the swing angle does not match, refer to section 10.

ITEM 0520, 0530

Operation instructions 8.2

Worm gearboxes on ball valves

Setting end position OPEN

Setting end position CLOSED

9.

9.1

Worm gearboxes GS 50.3 – GS 250.3

In case end stops require adjustment, set end position OPEN first. If the exact end position of the valve cannot be seen through a position marking at the valve shaft, the setting may have to be done with the valve removed. Remove all bolts (03) at limit stop housing (10) (figures D, E). Turn valve manually to end position OPEN. In case limit stop housing (10) has not yet rotated, turn it counterclockwise up to the stop. If the holes of limit stop housing (10) do not align with the threads of the housing (1), take off the limit stop housing (10) and replace it in the required position. Fasten bolts crosswise with a torque according to table 3. If the position of the pointer cover does not correspond to the symbol OPEN, slightly loosen the screws of the pointer cover. Turn the pointer cover to the OPEN symbol and fasten the screws again. The end stop need not be set since the required swing angle has been set in the factory. If the swing angle does not match, refer to section 10.

.. . . ..

Setting the end stops with mounted multi-turn electric actuator

. . .

If worm gearboxes GS and multi-turn actuators are supplied on a valve, the end stops as well as limit and torque switching should already have been set by the valve manufacturer. If the limit and torque switching have not yet been set, they have to be set according to the operation instructions SA/SAR and the specifications of the valve manufacturer. The valve manufacturer states whether the valve should be limit or torque seated.

. .. . . . .. .

Worm gearboxes on butterfly valves Determine the overrun of the multi-turn actuator for both directions, i. e. how much does the valve move after the motor has been switched off? Setting end position CLOSED Remove all bolts (03) at limit stop housing (figures D, E). Change actuator to manual drive and move the valve manually to end position CLOSED. In case limit stop housing (10) has not yet rotated, turn it clockwise up to the stop. Turn limit stop housing (10) back counterclockwise by ½ turn. This ensures that the mechanical end stop is not reached in electric operation and thus the valve can close tightly, provided that torque seating has been specified. If the fixing holes of limit stop housing (10) do not align with the threads of the housing (1), take off the limit stop housing (10) and replace it in required position. Fasten bolts (03) with lock washers (04). Fasten bolts crosswise with a torque according to table 3. If the position of the pointer cover does not correspond to the symbol CLOSED, slightly loosen the screws of the pointer cover. Turn the pointer cover to the CLOSED symbol and fasten the screws again.

13

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

Setting end position OPEN

.. . .. . .

Operation instructions

Limit seating in end position CLOSED Turn back the valve from the end position by an amount equal to the overrun. Set limit switching according to the operation instructions SA/SAR. Check torque switching for end position CLOSED according to the operation instructions SA/SAR, and, if necessary, set to the required value. Torque seating in end position CLOSED Turn handwheel counterclockwise by approx. 4 – 6 turns. Set limit switching for the end position CLOSED according to the operation instructions SA/SAR (for actuator indication). Check torque switching for end position CLOSED or set to the required value.

The end stop need not be set since the required swing angle has been set in the factory. Move gearbox to the end stop in position OPEN. The last part of the travel has to be made manually.

. .

To turn the valve back manually from the end position by an amount equal to the overrun, proceed as follows: For actuators mounted directly: by approx. 4 to 6 turns at the handwheel. With mounted primary reduction gearing VZ/GZ: by approx. 10 to 15 turns at the handwheel, according to the reduction ratio of the primary reduction gearing. Set limit switching in actuator for the end position OPEN according to the operation instructions SA/SAR. If the swing angle does not match, refer to section 10. Figure F: End stop up to GS 125.3

03/04

03/04

10

9.2

Figure G: End stop from GS 160.3

1

10

1

Worm gearboxes on ball valves In case end stops require adjustment, set end position OPEN first. If the exact end position of the valve cannot be seen through a position marking at the valve shaft, the setting may have to be done with the valve removed.

. 14

Determine overrun of the actuator for both directions, i. e. how much does the valve move after the motor has been switched off?

Operation instructions Setting end position OPEN

Switching off in end position OPEN Setting end position CLOSED

.. . . . .. . . .

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

Remove all bolts (03) at limit stop housing (10) (figures F, G). Change to manual drive and move the valve manually to end position OPEN. In case limit stop housing (10) has not yet rotated, turn it counterclockwise up to the stop. Turn limit stop housing (10) back by ½ turn clockwise. This ensures that the mechanical end stop is not reached in electric operation. If the holes of limit stop housing (10) do not correspond to the threads of the housing (1), take off the limit stop housing (10) and replace it in the required position. Fasten bolts (03) with lock washers (04). Fasten bolts crosswise with a torque according to table 3. If the position of the pointer cover does not align with the symbol OPEN, slightly loosen the screws of the pointer cover. Turn the pointer cover to the OPEN symbol and fasten the screws again. Turn back the valve from the end position by an amount equal to the overrun. Set limit switching according to the operation instructions SA/SAR.

The end stop need not be set since the required swing angle has been set in the factory.

.

Move gearbox to the end stop in position CLOSED. The last part of the travel has to be made manually.

. .

To turn the valve back manually from the end position by an amount equal to the overrun, proceed as follows: For actuators mounted directly: by approx. 4 to 6 turns at the handwheel. With mounted primary reduction gearing VZ/GZ: by approx. 10 to 15 turns at the handwheel, according to the reduction ratio of the primary reduction gearing. Set limit switching in actuator for the end position CLOSED according to the operation instructions SA/SAR. If the swing angle does not match, refer to section 10.

15

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

10. Changing the swing angle

Operation instructions

The adjustment is made in end position OPEN. Optional for size GS 50.3 – GS 125.3 Standard for size GS 160.3 – GS 250.3 Accuracy: GS 50.3 – GS 125.3: GS 160.3 – GS 250.3:

0.6° 0.11° to 0.14°

10.1 Changing the swing angle for sizes GS 50.3 – GS 125.3 (option)

.. .

Unscrew protective cap (16) at limit stop housing (10) (figure H). Remove roll pin (020) with appropriate tool (available from AUMA). Increasing the swing angle Turn end stop nut (15) back counterclockwise. When turning back the end stop nut (015), make sure the roll pin (020) can still be tapped in within the oblong hole.

.. ..

Move valve into the desired end position. Turn end stop nut (15) clockwise until it is tight up to the stop nut (7). Reducing the swing angle Move valve into the desired end position. Turn end stop nut (15) clockwise until it is tight up to the stop nut (7). The end stop nut (15) must entirely cover the roll pin (020).

Figure H: End stop up to GS 125.3

Figure J: End stop from GS 160.3

082/083 03/04 058

16 34 15

16 020 15 08 10

. .. . 16

7

054 055

056 10

7

Tap in roll pin (020) with tool. If slot in end stop nut (15) does not align with the hole in the worm shaft, turn end stop nut (15) slightly counterclockwise until it is in alignment, then tap in roll pin. Check O-ring (08) and replace, if damaged. Replace protective cap (16). If gearbox is mounted to a multi-turn actuator, set limit switching again for the end position OPEN according to the operation instructions SA/SAR. Allow for overrun.

ITEM 0520, 0530

Operation instructions

Worm gearboxes GS 50.3 – GS 250.3

10.2 Changing the swing angle for sizes GS 160.3 – GS 250.3

. . .. . .. .. .. .

Remove all bolts (054) and pull off protective cap (16) (figure J). Remove screw (082) with washer (058) and setting ring (34). Increasing the swing angle Turn end stop nut (15) back counterclockwise. Move valve into the desired end position. Turn end stop nut (15) clockwise until it is tight up to the stop nut (7). Reducing the swing angle Move valve into the desired end position. Turn end stop nut (15) clockwise until it is tight up to the stop nut (7). Place setting ring (34), secure with washer (058) and screw (082). Check O-ring (056) and replace, if damaged. Place protective cap (16), fasten bolts (054) with lock washers (055). Fasten bolts crosswise with a torque according to table 3. If gearbox is mounted to a multi-turn actuator, set limit switching again for the end position OPEN according to the operation instructions SA/SAR. Allow for overrun.

17

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

Operation instructions

11. Enclosure protection IP 68 Definition

According to EN 60 529, the conditions for meeting the requirements of enclosure protection IP 68 (requirements exceed those of IP 67) are to be agreed between manufacturer and user. AUMA worm gearboxes and primary reduction gearings in enclosure protection IP 68 meet the following requirements according to AUMA:

.. ..

IP 68-3, IP 68-6, IP 68-10, IP 68-20,

submersible in water submersible in water submersible in water submersible in water

up to up to up to up to

3 m head of water 6 m head of water 10 m head of water 20 m head of water

For size GS 50.3, only enclosure protection IP 68-3 is available. If submersed in other media, additional measures for corrosion protection may be necessary; please consult AUMA. Submersion in aggressive media, e.g. acids or alkaline solutions, is not permitted. Review

Note:

Gearboxes in enclosure protection IP 68-3 were type tested in the factory. Gearboxes in enclosure protection IP 68-6, IP 68-10 and IP 68-20 undergo a routine testing for tightness in the factory.

. . . . . .. .

18

The enclosure protection IP 68 refers to the interior of the gearboxes, but not to the coupling compartment. If the gearboxes are likely to be repeatedly submersed, a higher corrosion protection KS or KX is required. For gearboxes intended for buried service we strongly recommend to use the higher corrosion protection KS or KX. For horizontal outdoor installation of the gearboxes, a sealed pointer cover should be used. For gas applications with sealed pointer cover, an air vent in the pointer cover or venting grooves in the valve mounting flange must be provided. In case of permanent submersion of the gearboxes or for buried service, a protection cover must be fitted instead of a pointer cover. This will be taken into account in the factory if indicated on the purchase order. Subsequent exchange of the pointer cover for the protection cover is possible. Use suitable sealing material between valve flange and gearbox. Water can enter into the coupling compartment along the valve shaft. This would lead to corrosion of hub and coupling. Therefore a suitable anticorrosive (or sticky grease) must be applied to the hub and coupling of the gearbox before mounting. With corrosion protection KX, the hub and coupling are provided with a high quality corrosion protection as standard.

ITEM 0520, 0530

Operation instructions

Worm gearboxes GS 50.3 – GS 250.3

12. Maintenance 12.1 General notes

After commissioning, check worm gearbox for damage to paint finish. Do a thorough touch-up to prevent corrosion. Original paint in small quantities can be supplied by AUMA. AUMA worm gearboxes require only very little maintenance. To ensure that the worm gearbox is always ready to operate, we recommend for gearboxes operated less than 10 times per year, the following measures:

. .. . .

Approximately six months after commissioning and every year after check bolts between multi-turn actuator, worm gearbox, and valve for tightness. If required, tighten applying the torques given in table 2 (page 11). Perform a test run every six months. Perform a visual inspection for grease leakage on each gearbox every 2 years. Carry out a detailed functional test for each gearbox every 5 years. Record the results for future reference. For gearboxes permanently exposed to ambient temperatures above 104 °F, maintenance must be performed at shorter intervals.

Seals: Seals made of elastomeric materials are subject to ageing. The theoretical usable lifetime of the seals made of NBR is 13.5 years from the date of manufacture. These figures are based on an average ambient temperature of 104 °F. Seal kits may be obtained from AUMA. Grease: A grease and seal change is recommended after the following operation time: if operated seldom after 10 – 12 years if operated frequently, after 6 – 8 years in modulating duty after 4 – 6 years

.. .

.. .

Only original AUMA grease must be used. For the grease type, refer to the name plate. Lubricants should not be mixed.

Table 4: Grease quantities for worm gearboxes and primary reduction gearings GS Qty Weight1)

dm³ g

Primary reduction gearing Quantity Weight1)

dm³ g

50.3 0.1 90

63.3 0.3 270

80.3 0.4 360

100.3 1.0 900

2.3

VZ 3.3

4.3

160.3

0.35 320

0.35 320

0.35 320

1.0 900

125.3 1.3 1,170

160.3 3.3 3,000

200.3 250.3 6.6 12.2 6,000 11,000

GZ 200.3 250.3 4:1/8:1 16:1 4:1/8:1 16:1 1.5 2.0 2.2 2.8 1,400 1,800 2,000 2,250

1) for ρ = approx. 900 g/dm3; conversion factor: 1 oz corresponds to 28.35 g

The removed lubricant and the cleaning agent used must be disposed of according to the relevant regulations.

19

Worm gearboxes GS 50.3 – GS 250.3

ITEM 0520, 0530

Operation instructions

12.2 Grease change for worm gearboxes GS 50.3 – GS 125.3 and primary reduction gearing VZ 2.3 – VZ 4.3

..

For gearboxes with multi-turn actuator: Remove multi-turn actuator. Remove gearbox from the valve: During this time, the valve/pipeline must not be under pressure!

12.2.1 Worm gearboxes

Refer to spare parts list GS 50.3 – GS 125.3, page 24. Grease type, see name plate; grease quantities, see page 19, table 4.

. . . . . . .. . .

Mark position of the gearbox on the valve, loosen connecting bolts to the valve and remove the worm gearbox. Remove fastening bolts with lock washers from the housing cover (518.0) and take off housing cover. Remove bolts with lock washers from the bearing cover (522.0). Lift worm wheel carefully from the housing. For this, the worm shaft must be pulled from the bearings and tilted slightly in the worm channel. Remove old grease completely from the housing and the individual parts and clean gear housing. For this purpose, a suitable cleaning agent should be used. Clean mounting faces at housing and housing cover (518.0). Replace O-rings at the worm wheel (010, 011) by new ones. Re-insert worm wheel carefully and bring worm shaft into correct position, fasten bearing cover (522.0) at housing with bolts and lock washers. Fill with new grease. Place housing cover (518.0) on housing, while ensuring the proper position of the O-rings (010, 011) at the worm wheel. Place bolts with lock washers and fasten them evenly crosswise. – Thoroughly degrease mounting faces at mounting flange. – Apply non-acidic grease at splines of coupling – Mount worm gearbox to valve, ensure correct position, observe mark made in previous step – Fasten with bolts of minimum quality 8.8 using lock washers, fasten bolts crosswise to the appropriate torque according to table 2, page 11. Gearbox without primary reduction gearing: Continue with section “After maintenance”. Gearbox with reduction gearings VZ 2.3 – VZ 4.3: Perform grease change at the reduction gearing according to the following subsection.

12.2.2 Primary reduction gearing Refer to spare parts list VZ 2.3 – VZ 4.3., page 24. Grease type, see name plate; grease quantities, see page 19, table 4.

. . . . .. . .

20

Remove bolts with lock washers from housing cover (020.0) and pull off housing cover (020.0) with the complete input drive shaft (021.0). Take off plate with internal teeth (045.0) and planet carrier (022.0) with the planet wheels. Remove old grease completely from the housing and the individual parts and clean them. For this purpose, a suitable cleaning agent should be used. Clean mounting faces at housing (019.0), housing cover (020.0) and plate with internal teeth (045.0). Replace O-rings by new ones. Insert planet carrier (022.0) with planet wheels. Fill with new grease. Place plate with internal teeth (045.0) and insert the input drive shaft (021.0) completely. Screw in bolts with lock washers and fasten them evenly crosswise to the appropriate torque according to table 2, page 11. Continue with section “After maintenance”, page 22.

ITEM 0520, 0530

Operation instructions

Worm gearboxes GS 50.3 – GS 250.3

12.3 Grease change for worm gearboxes GS 160.3 – GS 250.3 and primary reduction gearing GZ 160.3 – GZ 250.3

..

For gearboxes with multi-turn actuator: Remove multi-turn actuator. Remove gearbox from the valve: During this time, the valve/pipeline must not be under pressure!

12.3.1 Worm gearboxes

Refer to spare parts list GS 160.3 – GS 250.3, page 26. Grease type, see name plate; grease quantities, see page 19, table 4. Tools: Lock nut tool, can be obtained from AUMA.

. . . . . . .. . .

Mark position of the gearbox on the valve, loosen connecting bolts to the valve and remove the worm gearbox. Remove bolts with lock washers from the housing cover (518.0) and take off housing cover. Remove bolts with lock washers from the bearing cover (522.0). Take off bearing lock nut (537.0) by loosening the grub screw. Remove protective cap (536.0), pull off snap ring from end nut (526.0). Remove end stop (523.0). Lift worm wheel carefully from the housing. For this, the worm shaft must be pulled from the bearings and tilted slightly in the worm channel. Pull out worm shaft from housing in direction of the input shaft. Remove old grease completely from the housing and the individual parts and clean gear-housing. For this purpose, a suitable cleaning agent should be used. Clean mounting faces at housing and housing cover (518.0). Replace O-rings at the worm wheel (010, 011) by new ones. Re-insert worm wheel carefully and bring worm shaft into correct position. Screw in bearing lock nut (537.0) and secure with grub screw. Fasten bearing cover (522.0) at the housing with bolts and lock nuts. Fill with new grease. Place housing cover (518.0) on housing, while ensuring the proper position of the O-rings (010, 011) at the worm wheel. Place bolts with lock washers and fasten them evenly crosswise. – Thoroughly degrease mounting faces at mounting flange and valve. – Apply non-acidic grease at splines of coupling. – Mount worm gearbox to valve, ensure correct position, observe mark. – Fasten with bolts of minimum quality 8.8 using lock washers, fasten bolts crosswise to the appropriate torque according to table 2, page 11. Gearbox without primary reduction gearing: Continue with section “After maintenance”. Gearbox with reduction gearings GZ 160.3 – GZ 250.3: Perform grease change at the reduction gearing according to the following sections.

12.3.2 Single-stage reductions gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1 and 8:1) Refer to spare parts list GZ 160.3 – GZ 250.3, page 28. Grease type, see name plate; grease quantities, see page 19, table 4.

. . . .. ..

Remove bolts with lock washers at housing cover (002.0) and pull off housing cover (002.0) with the input drive shaft (003.0) and the plate with internal teeth). Remove screws from the plate with internal teeth and separate the plate with internal teeth from the input drive shaft. Remove old grease completely from the housing and the individual parts and clean them. For this purpose, a suitable cleaning agent should be used. Clean mounting faces at housing (001.0), housing cover (002.0) and plate with internal teeth. Replace O-rings by new ones. Fill housing cover (002) with new grease. Fix plate with internal teeth (006.0) with screws at housing cover.

21

Worm gearboxes GS 50.3 – GS 250.3

. .

ITEM 0520, 0530

Operation instructions

Fill housing (001.0) with remaining grease and fit the complete housing cover with input drive shaft (003.0). Screw in bolts with lock washers and fasten them evenly crosswise to the appropriate torque according to table 2, page 11. Continue with section “After maintenance”, page 22.

12.3.3 Double-stage primary reduction gearing GZ 200.3 – GZ 250.3 (reduction ratio 16:1) Refer to spare parts list GZ 160.3 – GZ 250.3, page 28. Grease type, see name plate; grease quantities, see page 19, table 4.

. . . . . . .. . .. .

12.4 After maintenance

22

.. . ..

Remove bolts with lock washers from housing cover (002.0) and pull off housing cover with the complete input drive shaft (003.0). Take off screws with lock washers from housing frame (010.0) and remove housing frame with planet carrier and hollow wheel. Remove screws from the plate with internal teeth and separate the plate with internal teeth from the input drive shaft (003.0). Remove screws (021) from the second stage of the plate with internal teeth and separate it from the pinion (011.1). Remove old grease completely from the housing and the individual parts and clean them. For this purpose, a suitable cleaning agent should be used. Clean mounting faces at housing (001.0), housing frame, housing cover (002.0) and hollow wheels. Replace O-rings by new ones. Fill housing (001.0) with new grease. Fix second stage of the plate with internal teeth on housing frame (010.0). Replace complete housing frame. Screw in bolts with lock washers and fasten them evenly crosswise to the appropriate torque according to table 2, page 11. Fill housing frame (010.0) and housing cover (002.0) with the remaining grease. Fix first stage of the plate with internal teeth on the housing cover (002.0). Place complete housing cover with input drive shaft onto housing frame. Screw in bolts with lock washers and fasten them evenly crosswise to the appropriate torque according to table 2, page 11. If applicable, mount multi-turn actuator. Reset the end stops. For gearboxes with multi-turn actuator, check the setting of the limit switching according to the operation instructions for multi-turn actuators; if required, reset. Perform test run to ensure the proper function. Check worm gearbox for damage to paint finish. Do a thorough touch-up to prevent corrosion. Original paint in small quantities can be supplied by AUMA.

ITEM 0520, 0530

Operation instructions

Worm gearboxes GS 50.3 – GS 250.3

13. Disposal and recycling AUMA gearboxes have an extremely long lifetime. However, they have to be replaced at one point in time. Our gearboxes have a modular design and may therefore easily be disassembled, separated and sorted according to materials, i.e.:

.. . . . .

various metals plastics greases and oils

The following generally applies: Collect greases and oils during disassembly. As a rule, these substances are hazardous to water and must not be released into the environment. Send disassembled material to a sound disposal or to separate recycling center according to materials. Observe the local regulations for waste disposal.

14. Service

AUMA offers extensive services such as maintenance and inspection for gearboxes. The AUMA service department can be reached at: phone: 724-743-AUMA (2862) fax: 724-743-4711 email: [email protected] www.auma-usa.com or www.auma.com.

23

527.0

S1(073)

24

019.0

S1(009)

S1(076)

523.0

S1(009)

518.0

517.0

022.0

525.0

S1(010)

519.1

S1(010)

526.0

S1(012)

S1(011)

S1(033)

045.0

521.1

524.0

S1(033)

520.0

520.0

520.0

021.0

534.0

S1(017)

522.0

S1(034)

S1(009)

S1(009)

S1(017)

512.0

S1(009) S1(017)

522.0

020.0

512.0

512.0

Worm gearboxes GS 50.3 – GS 250.3

ITEM 0520, 0530 Operation instructions

15. Spare parts list worm gearboxes GS 50.3 – GS 125.3 and reduction gearing VZ 2.3 – VZ 4.3

Operation instructions

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Delivered spare parts may slightly vary from the representation in these instructions. No.

Designation

Type

019.0

Housing VZ

Sub-assembly

020.0

Housing cover VZ

Sub-assembly

021.0

Input drive shaft VZ

Sub-assembly

022.0

Planet carrier VZ

Sub-assembly

045.0

Plate with internal teeth VZ

Sub-assembly

512.0

Flange for actuator

Sub-assembly

517.0

Housing

Sub-assembly

518.0

Housing cover

Sub-assembly

519.1

Worm wheel

Component

520.0

Worm shaft

Sub-assembly

521.1

Travelling nut

Component

522.0

Bearing cover

Sub-assembly

523.0

Limit stop housing

Sub-assembly

524.0

Pointer cover

Sub-assembly

525.0

Coupling

Sub-assembly

526.0

End stop nut

Sub-assembly

527.0

Protection cover

Sub-assembly

534.0

Input shaft

Sub-assembly

536.0

Cap

Sub-assembly

Seal kit

Set

S1

25

527.0

S1(073)

26

536.0

S1(056)

523.0

525.0

S1(010)

519.1

S1(010)

513.1

S1(009)

517.0

S1(012)

S1(011)

518.0

524.0

526.0

538.1

538.0

521.1

S1(017)

S1(009)

522.0

520.0

512.0

537.0

Worm gearboxes GS 50.3 – GS 250.3

ITEM 0520, 0530 Operation instructions

16. Spare parts list worm gearboxes GS 160.3 – GS 250.3

Operation instructions

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Delivered spare parts may slightly vary from the representation in these instructions. No.

Designation

Type

512.0

Flange for actuator

Sub-assembly

513.0

Grub screw

Component

517.0

Housing

Sub-assembly

518.0

Housing cover

Sub-assembly

519.1

Worm wheel

Component

520.0

Worm shaft

Sub-assembly

521.1

Travelling nut

Component

522.0

Bearing cover

Sub-assembly

523.0

Limit stop housing

Sub-assembly

524.0

Pointer cover

Sub-assembly

525.0

Coupling

Sub-assembly

526.0

End stop nut

Sub-assembly

527.0

Protection cover

Sub-assembly

536.0

Cap

Sub-assembly

538.0

Input shaft

Sub-assembly

538.1

Input shaft

Sub-assembly

Seal kit

Set

S1

27

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

Operation instructions

17. Spare parts list reduction gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1) S1(003)

006.0

GZ 200.1 – GZ 250.1 16:1 GZ 160.1 – GZ 250.1 4:1 / 8:1

006.0 S1(003)

S1(003) S1(003)

003.0 S1(004) S1(009)

S1(029)

001.0

003.3

S1(004) S1(009)

S1(029)

001.0 003.0

S1(014) 512.0 002.0

003.3

011.1 013.0

512.0 S1(014) 002.0

010.0

S1(003)

006.0

GZ 200.1 – GZ 250.1 16:1

S1(003)

003.0 S1(004) S1(009)

S1(029)

001.0

003.3 S1(029)

S1(014) 512.0 002.0

011.1 013.0

010.0

28

Operation instructions

ITEM 0520, 0530

Worm gearboxes GS 50.3 – GS 250.3

Note: Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA spare parts should be used. Delivered spare parts may slightly vary from the representation in these instructions. No.

Designation

001.0

Housing

Sub-assembly

002.0

Housing cover

Sub-assembly

003.0

Housing cover

Sub-assembly

003.3

Input drive shaft

Sub-assembly

006.0

Planetary gear

Sub-assembly

010.0

Housing frame

Sub-assembly

011.1

Pinion

Sub-assembly

013.0

Planetary gear 1st stage

Sub-assembly

512.0

Flange for actuator

Sub-assembly

Seal kit

Set

S1

29

Worm gearboxes GS 50.3 – GS 250.3 Notes

30

ITEM 0520, 0530

Operation instructions

ITEM 0520, 0530

Operation instructions

Worm gearboxes GS 50.3 – GS 250.3

Index B Bolts for mounting actuators

10

C Changing the swing angle Corrosion protection

16 7

D Disposal and recycling

23

E Enclosure protection IP 68

18

F Fitting the handwheel

7

H Handwheel

7

L Lubricant

19

M Maintenance 3,19 Manual operation 12 Motor operation 13 Mounting positions 8 Mounting the multi-turn actuators 9 Mounting to valve 11

P Packaging

7

R Range of application

3

S Safety instructions Service support/ Parts Setting the end stop with mounted multi-turn actuator Setting the end stops for manual operation Spare parts list GS 50.3 - GS 125.3 GS 160.3 - GS 250.3 GZ 160.3 - GZ 250.3 (4:1/8:1/16:1) Storage T Technical data Transport

3 23 13 12 24,25 26,27 28,29 7 4 7

31

ITEM 0520, 0530

North American Sales and Service: US Headquarters and Factory: AUMA Actuators, Inc. 100 Southpointe Blvd. Canonsburg PA 15317 Tel: 724-743-AUMA (2862) Fax: 724-743-4711 email: [email protected] www.auma-usa.com

Regional Offices: Northeast (Maryland and New York) Southeast (South Carolina) Midwest (Illinois) Midwest (Kansas) Houston (Texas) West Coast (Northern and Southern California)

Representatives and Distributors Anchorage Atlanta Baltimore Baton Rouge Birmingham Boston Charlotte Chicago Cincinatti Corpus Christi Dallas Denver Detroit Hawaii Houston Indianapolis Kansas City Los Angeles Mexicali (Mexico) Mexico City Milwaukee Minneapolis Montana Monterrey (Mexico) New York Omaha Orlando Philadelphia Phoenix Pittsburgh Rochester Salt Lake City San Diego San Francisco San Juan Seattle St. Louis Toronto Tulsa

International Headquarters: AUMA Riester GmbH & Co. KG Müllheim/ Germany www.auma.com

International Sales and Service: South America: Argentina Brazil Chile Colombia Peru Venezuela

Europe: Austria Benelux Czech Republic Denmark Finland France Greece Hungary Italy Norway Poland Portugal Russia Spain Sweden Switzerland Turkey Ukraine United Kingdom

Africa Egypt South Africa

Asia, Australia Australia China Hong Kong India Japan Korea Kuwait Oman Qatar Singapore Taiwan Thailand UAE

For the name and phone number of the office nearest you, call us at 724-743-2862 or visit our website at www.auma-usa.com/saleserv.htm 2005-06-27

Y003.822/031/us/1.06

(CV-600)Duo-Chek II Cover

3/28/03

11:51 AM

Page 1 Dan K. Snelson Clients:171-Crane Valves:171- Job Files:171-Open Jobs:0319-(CV-600

ITEM 0540 Document Name: 4607T-0540 Rev 0

®

Duo-Chek II High Performance Check Valves

ITEM 0540 Duo-Chek® II Valves Duo-Chek II – The High Performance Check Valve Duo-Chek II high performance check valves are the original Mission wafer check valves introduced to the market in the late 50's. They are available in the sizes, pressure classes and configurations you need to meet the most demanding of applications. Our product range includes, but is not limited to, • • • • • •

Sizes: 2" to 72" ASME Pressure Class 125 through 2500 API 6A and 6D pressure classes DIN, JIS, BS, AS, and ISO standards are also available. Wafer, lug, double flanged and extended body styles Configurations available in retainerless style. Retainerless valves for critical applications without pin retainer penetration through the body are available in Wafer and are

• Body Materials: Cast Iron, Ductile Iron, WCB Cast Steel, 316 Stainless Steel. All alloys. • Resilient Seat Materials: EPDM, Buna-N, Neoprene, Refrigeration-grade elastomer, Viton • Integral and overlaid metal seats also available • End Connections: Raised Face, Plain Face, Ring Joint, Weld-End, Hub-End.

standard in Lug and Double Flange valves.

Dual plate lightweight design

Spring action closes plates

for efficient seating

independently. (6" and larger)

and operation

Long-leg spring action allows plates to open and

Hinge support sleeve reduces

close without seat scrubbing.

friction and minimizes water hammer through independent plate suspension (on larger

Industry Standards*

sizes).

API 594 API 598 ASME B16.5 & B16.47

Valve Design Valve Pressure Testing & Inspection Flanges

ASME B16.34 API 6D API 6A

Pressure / Temperature Ratings Pipeline Valves Production Valves

*Duo-Chek II meets or exceed these industry standards.

2

(CV-600)Duo-Chek II

T: 936-588-4447 •

2

F: 936-588-4427

•

www.cranevalve.com

3/28/03, 11:56 AM

ITEM 0540 Duo-Chek® II Valves Specify the Duo-Chek II ...to your advantage Leading engineering specifiers specify the Duo-Chek II for check valve applications because it provides high performance. Extensive research and testing with demonstrated performance has earned worldwide recognition, unmatched in the industry. The Duo-Chek II wafer valve design is generally stronger, lighter, smaller, more efficient and less expensive than conventional swing check valves. Its design meets API 594 which is approximately one fourth the face to face dimension and 15% to 20% the weight, on most popular sizes, making them less expensive than a swing check valve. It is much easier to install between standard gaskets and line flanges. The savings compound during installation due to ease of handling and only one set of flange studs is required. Therefore, it is more cost effective to install, and also to maintain. The Duo-Chek II also offers special design features that make it a high performance non-slam check valve. These include a scrub-free opening, and in most sizes a unique independent spring design as well as an independent plate support system. These features may not be found in other check valves. Other configurations offered include lug, double flange and extended body.

Fs F F Fs

Plates in closed position. Top view.

Heel opens first as flow begins.

The innovative dual-plate design of the Duo-Chek II employs two spring-loaded plates (disc halves) suspended on a central vertical hinge pin. As flow begins, the plates open in response to a resultant force (F) which acts as the center of the sealed surface area. The contact point of the reacting spring leg’s force (Fs) acts beyond the center of the plate area, causing the heel to open first. This prevents rubbing of the seal surface prior to normal plate opening, eliminating wear. As the velocity of flow decreases, torsion spring action reacts automatically. This moves the plates closer to the body seats, reducing the distance and time of travel for closure. By having the plates closer to the body seats at the time of flow reversal, the valve dynamic response is greatly accelerated. This dramatically reduces the water hammer effect for non-slam performance.

4

(CV-600)Duo-Chek II

Plates fully opened (85°)

At closing, the point of spring force causes the toe of the plates to close first. This prevents dragging of the heels of the plates and maintains seal integrity for much longer periods.

Independent Spring Design Plate in open position

Spring with valve wide open

Spring with valve closed

Plate in closed position

55°

140°

A spring design of the Duo-Chek II (sizes 6" and larger) allows higher torque to be exerted against each plate with independent closing in response to the process stream. Testing has proved this action provides up to 25% improvement

F: 936-588-4427

Plates fully seated for bubble-tight shutoff.

in valve life and 50% reduction in water hammer. Each of the dual plates has its own spring or springs, which provide independent closing action. These independent springs undergo less angular deflection, only 140° as compared to 350° for conventional springs with two legs.

Independent Plate Suspension Design Unstressed spring

T: 936-588-4447 •

4

Plate toe closes first as flow decreases.

•

The Duo-Chek II unique hinge design reduces friction forces by 66%, which improves valve response significantly. Support sleeves are inserted through the outboard hinges so that the upper hinge is independently supported by the lower sleeve during valve operation. This allows both plates to close at the same time for quick response, and exellent dynamic performance.

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3/28/03, 11:56 AM

ITEM 0540 Duo-Chek® II Valves Style G Installation Dimensions D

B

A Ring Joint Facing

A

A C

Serrated

Flow Direction

Minimum Flange Bore

Raised Face Valves Only

Plain Face

Section A

This view is rotated 90° to show the actual operating position of the valve. The pin must be vertical for horizontal flow.

Style G wafer style body valves are designed with flangeless bodies with relatively short face-to-face dimensions. They are clamped between mating flanges which are connected by studs and nuts. ASME Class 125 (Cast Iron valves only) Size A B C in mm in mm in mm in mm 2" 50 4 1⁄8 105 2 1⁄8 54 2 1⁄16 52 2 1⁄2" 65 4 7⁄8 124 2 1⁄8 54 2 15⁄32 63 3" 80 5 3⁄8 137 2 1⁄4 57 3 1⁄16 78 4" 100 6 7⁄8 175 2 1⁄2 64 4 102 5" 125 7 3⁄4 197 2 3⁄4 70 5 127 6" 150 8 3⁄4 222 3 76 6 1⁄16 154 8" 200 11 279 3 3⁄4 95 8 203 10" 250 13 3⁄8 340 4 1⁄4 108 10 254 12" 300 16 1⁄8 410 5 5⁄8 143 11 15⁄16 303 14" 350 17 3⁄4 451 7 1⁄4 184 12 1⁄2 318 16" 400 20 1⁄4 514 7 1⁄2 191 15 381 18" 450 21 5⁄8 549 8 203 16 7⁄8 429 20" 500 23 7⁄8 606 8 3⁄8 213 18 13⁄16 478 24" 600 28 1⁄4 718 8 3⁄4 222 22 5⁄8 575 30" 750 34 3⁄4 883 12 305 29 1⁄4 743 36" 900 41 1⁄4 1048 14 1⁄2 368 35 889 42" 1050 48 1219 17 432 41 1041 48" 1200 54 1⁄2 1384 20 5⁄8 524 47 1194 54" 1350 61 1549 21 1⁄4 540 51 1⁄2 1308 60" 1500 67 1⁄2 1715 26 660 56 1422 66" 1650 74 1⁄4 1886 31 787 65 1⁄4 1657 914 68 1727 72" 1800 80 3⁄4 2051 36

D in – –

mm – – 5 ⁄8 16 1 25 1 5⁄16 33 1 15⁄16 35 3 7⁄16 54 3 3⁄8 70 3 9⁄16 83 3 1⁄16 83 4 1⁄4 113 5 3⁄8 137 6 3⁄16 160 8 1⁄4 210 9 9⁄16 229 12 5⁄16 303 15 381 16 3⁄4 425 19 3⁄4 502 – – – – – –

Weight lbs. kg. 4 1.8 6 2.7 7 3.2 12 5.4 15 6.8 20 9 40 18 65 29 110 50 183 83 255 116 315 143 380 172 575 261 1070 486 1962 890 2800 1270 3920 1178 6172 2800 7800 3538 12000 5443 14000 6350

ASME Class 150 Size A in mm in mm 2" 50 4 1⁄8 105 2 1⁄2" 65 4 7⁄8 124 3" 80 5 3⁄8 137 4" 100 6 7⁄8 175 5" 125 7 3⁄4 197 6" 150 8 3⁄4 222 8" 200 11 279 10" 250 13 3⁄8 340 12" 300 16 1⁄8 410 14" 350 17 3⁄4 451 16" 400 20 1⁄4 514 18" 450 21 5⁄8 549 20" 500 23 7⁄8 606 24" 600 28 1⁄4 718 26" 650 30 1⁄2 775 30" 750 34 3⁄4 883 36" 900 41 1⁄4 1048 42" 1050 48 1219 48" 1200 54 1⁄2 1384 54" 1350 61 1549 60" 1500 67 1⁄2 1715 66" 1650 74 1⁄4 1886 72" 1800 80 3⁄4 2051

in 2 3⁄8 2 5⁄8 2 7⁄8 2 7⁄8 3 3⁄8 3 7⁄8 5 5 3⁄4 7 1⁄8 7 1⁄4 7 1⁄2 8 8 5⁄8 8 3⁄4 14 13 15 1⁄4 17 20 5⁄8 21 1⁄4 26 31 36

B mm 60 67 73 73 86 98 127 146 181 184 191 203 219 222 356 330 387 432 524 540 660 787 914

C in mm 1 15⁄16 49 2 11⁄32 60 2 29⁄32 74 3 53⁄64 97 4 13⁄16 122 5 49⁄64 146 7 5⁄8 194 9 9⁄16 243 11 3⁄8 289 12 1⁄2 318 15 381 16 7⁄8 429 18 13⁄16 478 22 5⁄8 575 24 1⁄4 616 29 1⁄4 743 35 889 41 1041 47 1194 51 1⁄2 1308 56 1422 65 1⁄4 1657 68 1727

D

Weight mm lbs. kg. – 6 3 – 10 5 1 ⁄4 6 13 6 5 ⁄8 16 17 8 7 ⁄8 22 27 12 1 3⁄8 35 35 16 2 1⁄8 54 70 32 2 3⁄4 70 106 48 3 1⁄4 83 172 78 3 1⁄4 83 200 91 4 7⁄16 113 275 125 5 3⁄8 137 315 143 6 5⁄16 160 435 197 8 1⁄4 210 620 281 8 203 1555 705 9 229 1230 558 1115⁄16 303 2017 915 15 381 2800 1270 16 3⁄4 425 3920 1178 19 3⁄4 502 6172 2800 – – 7800 3538 – – 12000 5443 – – 14000 6350 in – –

Duo-Cheks are available in accordance with DIN, BS, JIS, AS and ISO Dimensions. For other sizes and pressure classes contact factory.

T: 936-588-4447

(CV-600)Duo-Chek II

9

•

F: 936-588-4427

•

www.cranevalve.com

3/28/03, 11:56 AM

9

ITEM 0540 Duo-Chek® II Valves Styles G and H Stud Selection Flat or Raised Face flanges C Min

B

ASME Class 125 Valve Size in mm 2" 50 2 1⁄2" 65 3" 80 4" 100 5" 125 6" 150 8" 200 10" 250 12" 300

ASME Class 150

B No. of Bolt Diameter Studs in mm 5 4 ⁄8 16 5 4 ⁄8 16 5 4 ⁄8 16 5 8 ⁄8 16 3 8 ⁄4 19 3 8 ⁄4 19 3 8 ⁄4 19 7 12 ⁄8 22 7 12 ⁄8 22

C Flat Face in mm 5 1⁄4 133 5 1⁄2 140 5 3⁄4 146 6 1⁄4 159 6 3⁄4 171 7 178 8 203 9 229 10 1⁄2 267

*For larger sizes, see Class 150 table.

14

(CV-600)Duo-Chek II

D Min Ring Joint flanges

T: 936-588-4447 •

14

Valve Size in mm 2" 50 2 1⁄2" 65 3" 80 4" 100 5" 125 6" 150 8" 200 10" 250 12" 300 14" 350 16" 400 18" 450 20" 500 24" 600 26" 650 30" 750 36" 900 42" 1050 48" 1200 54" 1350 60" 1500 66" 1650 72" 1800

F: 936-588-4427

•

B No. of Studs Bolt Diameter in mm 5 4 ⁄8 16 5 4 ⁄8 16 5 4 ⁄8 16 5 8 ⁄8 16 3 8 ⁄4 19 3 8 ⁄4 19 3 8 ⁄4 19 7 12 ⁄8 22 7 12 ⁄8 22 12 1 25 16 1 25 1 16 1 ⁄8 29 20 1 1⁄8 29 20 1 1⁄4 32 24 1 1⁄4 32 28 1 1⁄4 32 1 32 1 ⁄2 38 1 36 1 ⁄2 38 1 44 1 ⁄2 38 44 1 3⁄4 44 52 1 3⁄4 44 52 1 3⁄4 44 60 1 1⁄8 29

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3/28/03, 11:57 AM

C Raised Face in mm 5 3⁄4 146 6 1⁄4 159 3 6 ⁄4 171 6 3⁄4 171 7 1⁄2 191 8 203 9 1⁄2 241 10 1⁄2 267 12 305 3 12 ⁄4 324 1 13 ⁄4 337 1 14 ⁄4 362 15 381 15 3⁄4 400 22 3⁄4 578 21 1⁄4 540 1 26 ⁄4 667 1 28 ⁄2 724 33 838 35 889 -

D Ring Joint in mm 6 1⁄4 159 7 178 7 1⁄4 184 7 1⁄4 184 8 203 8 1⁄2 216 10 254 11 279 1 12 ⁄2 318 1 13 ⁄4 337 3 13 ⁄4 349 3 14 ⁄4 375 15 1⁄2 394 16 1⁄4 413 23 1⁄4 591 22 3⁄4 578 39 679 -

ITEM 0540

®

Duo-Chek II Valves Ordering Information Figure Number System Size

Style

24" 30"

H G

Pressure Class Body & Plate

Seal

End Connection

Body Configuration

M V

F P

3

H S

2 15

Modification Number

9

—

DESCRIPTION: 24" Style H, ASME Class 150, Carbon Steel Body and Plates, Buna-N Seal, raised face flanges, with double flange body, (modification number indicates Inconel X spring)

Valve Size

Style Ordering Letter

Nominal valve sizes are expressed in inches or millimeters. In Inches: For use with ASME, API and BS Flange Standards. In Millimeters: For use with DIN, AS or JIS rated valves (size preceded by "M" for DIN, "A" for AS or "J" for JIS).

Body Type

Size Range

G

Standard Design, Wafer

2" through 88" (50mm through 2200mm)

H

Retainerless Duo-Chek Design Wafer, Lug or Double Flange

2" through 88" (50mm through 2200mm)

X

Extended Body Design

2" through 72" (50mm through 1800mm)

U

Underwriters’ Laboratories Listed Valves for Fire Protection Service

4" through 12" (except 5") (U12 HMP Valves Only)

Bodies with Integral Weld-Ends

2" through 72" (50mm through 1800mm)

W*

*Weld-end valves also require the additional designation of the pipe schedule they are designed to fit.

Pressure Classes DIN / JIS1

API∆

ASME

BS / AS2

Ordering No.

Class

Ordering No.

Class

Ordering No.

PN Rating

12 15

125 150

21

2000

Flange Standard:

31

3000

M - DIN

51

5000

J - JIS

101

10000

151

15000

6 10 16 25 40 64 100 160 250 320

30 40 60 90 150 250 450

300 400 600 900 1500 2500 4500

Ordering No.

Table

B - BS

A thru T

A - AS

∆ API Class is shown in psig, cold working pressure. 1 Metric valves with DIN or JIS standard flanges are designated by having the nominal size expressed in millimeters, preceded by "M" or "J'. Flange ratings in PN numbers are then listed after the valve style, as in ANSI or API Valves.

Example:

M 100 (4" ) G16 SPF

Flange Standard (M - DIN) 100mm Size

This specifies a metric valve, designed to fit between DIN flanges. Nominal size is 100 millimeters (corresponding to 4"), Style G Duo-Chek II with a pressure rating of 16 bars, carbon steel body and plate, metal seat, and raised face end connections.

Pressure Rating, PN for DIN or JIS (in bars)

2 Valves designed for use with British Standard 10 or Australian Standard 2129 are defined by adding two letters between the style of construction and pressure rating. First letter designates the standard, and the second letter denotes the table in that standard.

Example:

6" G B E 15 BNF ANSI Class is made from

Flange Standard B - British Std. 10

Table in corresponding Standard

24

(CV-600)Duo-Chek II

T: 936-588-4447 •

24

F: 936-588-4427

•

Figure number lists a 6" Style G Duo-Chek II, designed to fit between British Standard 10, Table E Flanges, using a Class 150 Valve, having an aluminum bronze body and plates, Neoprene seal and raised face end connections.

www.cranevalve.com

3/28/03, 11:57 AM

ITEM 0540

Duo-Chek® II Valves Ordering Information Body and Plates Ordering Letter

Material

Specification

B

Aluminum Bronze

C E F G H

316 Stainless Steel 410 Stainless Steel Alloy 20 Low Temp. C.S. Cast Iron with Al. Br. Plates Hastelloy® C C12 Alloy Steel Monel Nickel Carbon Steel

K L M N S

ASTM B148 Alloy 952 BS 1400, Alloy AB2 ASTM A351 Gr. CF-8M ASTM A217 Gr. CA15 (12% Cr) ASTM A351 Gr. CN7M ASTM A352, Gr. LCB ASTM A126; BS 1452, Gr. 220 ASTM B148 (952); BS 1400 (AB2) A494, Gr. CW2M / CW12MW ASTM A217, Gr. C12 (9% Cr) ASTM A494, Gr. M-35-1 ASTM A494, Gr. CZ-100 ASTM A216, Gr. WCB

Seal* Ordering Letter A

EPDM

-29 to 149

M

Buna-N

-23 to 121

-10 to 250

N

Neoprene

-12 to 107

+10 to 225

†P

Metal

-267 to 537 -450 to 1000+

U

Refrigeration Grade Elastomer

V

Viton-B

®

Material

T U V W Y Z CA DZ EA FN GC SC TT

317 S.S. WC6 Alloy Steel 347 S.S. 316 L S.S. C5 Alloy Steel WC9 Alloy Steel Duplex European S.S. 6% Moly S.S. Inconel® 625 LCC Low Temp. Steel WCC Steel Titanium

End Connections

Operating Temperature °C °F

Material

Ordering Letter

Ordering Letter

Connections

F G P R W

Serrated raised face Grayloc® Hub Plain Face Ring Joint Weld-End

-20 to 300

-40 to 120

-40 to 250

-18 to 204

0 to 400

Specification ASTM A351, Gr. CG-8M ASTM A217, Gr. WC6 (11⁄4% Cr) ASTM A351, Gr. CF-8C ASTM A351, Gr. CF-3M ASTM A217, Gr. C5 (5% Cr) ASTM A217, Gr. WC9 (21⁄2% Cr) ASTM A351 UNS S31803 UNS S31254 (254 SMO) ASTM A494, Gr. CW-6MC ASTM A352, Gr. LCC ASTM A216, Gr. WCC ASTM B367, Gr. C2 or ASTM B384, Gr. 2

Special Body Configurations Designation Number None (Blank)

1 2 3

Configuration Wafer Style, inserted between mating flanges with studs spanning entire length Lug design w/threaded holes bolted from each end Lug design with through-bolt holes to protect studs Double flanged design with valve flanges bolted to individual line flanges

* This range of operating temperatures is for general guidance. The range varies with application, body and plate material. † Metal seals may be furnished as integral or special overlay materials. ® Viton is a registered name of DuPont.

Common Modifications Number -9 -14 -39 -201 -233 -169 -772

Material Changes

Note:

Inconel X-750 Springs 316 S.S. Plate, Pins 410 S.S. Plate, Pins & Inconel X-750 Springs 316 S.S. Plate, Pins, Inconel X-750 Springs 316 S.S. Plate, Pins, Inconel X-750 Springs and 316 S.S. Overlay Seat 410 S.S. Plate, Pins, Inconel X-750 Springs and 410 S.S. Overlay Seat Monel Plate, Pins, Springs, Bearings and Monel Overlay Seat

Numerous additional modifications may be specified. Please consult factory.

Standard trim (Wetted Parts) Materials Typical Figure No. BMF CMF CPF CVF EPF SMF SNF SPF SVF

Body & Plate Al. Bronze 316 Stainless 316 Stainless 316 Stainless 410 Stainless Carbon Steel Carbon Steel Carbon Steel Carbon Steel

Seal

Hinge Pin

Buna-N Buna-N 316 Stainless Viton-B® 410 Stainless Buna-N Neoprene Carbon Steel Viton-B®

316 S.S. 316 S.S. 316 S.S. 316 S.S. 410 S.S. 316 S.S. 316 S.S. 316 S.S. 316 S.S.

T: 936-588-4447

(CV-600)Duo-Chek II

25

•

F: 936-588-4427

•

Spring 316 S.S. 316 S.S. Inconel 600 Inconel 600 Inconel 600 316 S.S. 316 S.S. Inconel 600 Inconel 600

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3/28/03, 11:57 AM

Stop Pin 316 S.S. 316 S.S. 316 S.S. 316 S.S. 410 S.S. 316 S.S. 316 S.S. 316 S.S. 316 S.S.

Retainer 316 S.S. 316 S.S. 316 S.S. 316 S.S. 410 S.S. Steel Steel Steel Steel

25

ITEM 0540 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTION MANUAL

Equipment Description Duo-Chek II & Marlin Valves

1. 2.

3. 4. 5.

6.

Installation and Operation Remove the valve from carton or packing skid. The protective rust proof coating on the internal parts of steel or cast iron valves should be removed by brushing out with any standard petroleum solvent (Varsol, Kerosene), and air dry. Insure internal parts operate freely. Stainless Steel or Bronze valves need only to be wiped clean and installed. In horizontal flow installation, the hinge pin must be vertical. Insert the valve between two companion flanges of the same series as the valve and place gaskets on flange faces. The arrow on the valve or name plate indicating direction of flow should coincide with line flow. Install studs through companion flanges and tighten, using standard industry practice. In liquid service we recommend valve be installed at least five (5) pipe diameters downstream from a pump discharge and/or other pipe fittings for maximum service life. Consult factory.

Maintenance Caution! Make sure the valve is not under pressure before starting any maintenance. Disassembly** (Refer to assembly drawing on next page.) 1. Lay valve down with the downstream side of the valve upward. 2. Remove stop pin retainers (6) and hinge pin retainers (7). 3. Remove stop pin (3), being careful with the short hooked spring legs on valves 6” and larger. 4. Remove hinge pin (4) out of the body (1) while holding spring(s) firmly as some are preloaded and may snap out. Observe caution. 5. Remove springs (5), plates (2), and bearings (8), (9), and (10). Assembly** 1. Lay body down with downstream side of valve upward. 2. Clean all parts in a suitable solvent. 3. Position both plates (2) in body (1) with hinge lugs together and align with pin holes. If valve is equipped with support sleeves (11), assemble into plate with body bearings (9). 4. Lay springs (5) in plate (2) recess, between lugs, with short hooked leg extending upward on valves 6” and larger (other longer leg to contact plate). On smaller valves, spring(s) (5) without short leg, wind spring legs 180°, install with legs contacting each plate and hold to insert hinge pin (4) in step 6. 5. Insert all bearings provided, (8), (9) and (10). 6. Insert hinge pin (4) through plate lugs (2), bearings, (8), (9), (10), and through spring coils (5). 7. Pull stop pin leg of spring (short hooked leg) toward plate leg and insert stop pin (3). Repeat until stop pin is fully inserted in body holes. 8. Install hinge pin retainers (7) and stop pin retainers (6) using PTFE tape or a suitable thread sealing compound. ** No Special tools are required.

ITEM 0540 Crane Duo-Chek II & Marlin Valves 10* 5* Item No.

No. Req’d

1

1

Body

2

2

Plate

3

1

Stop Pin

4

1

Hinge Pin

5

2*

Spring

6

2

Stop Pin Retainer

7

2

Hinge Pin Retainer

8

4**

Plate Lug Bearing

9

4**

Body Lug Bearing

10

3*

Spring Bearing

11†

2

Support Sleeve

Description

10 5 8 9

11

2

* Some valves require 4 springs & 5 spring bearings ** These quantities may vary according to the valve size

1

† Not required on valves smaller than 24”

3 6

4 7 ®

ENGINEERED VALVES

Australia Operations 322 Settlement Road Thomastown, VIC 3074 tel: +613-9465-2755 fax: +613-9466-1365

Belfast Operations 6 Alexander Road Cregagh, Belfast BT6 9HJ tel: +44-2890-704222 fax: +44-2890-401582

Crane Duo-Chek II 9860 Johnson Road Montgomery, TX 77316 tel: 936.588.4447 fax: 936.588.4427

ITEM 0705 EMERSON MOTOR COMPANY 8100 WEST FLORISSANT AVE. P.O. BOX 3946 * BLDG. K * ST. LOUIS, MO 63136 FAX (314) 553-1101

DATE: 2/17/2006

P.O. NO.: USEM Order/Line NO.: NA

TO: S677 Model Number: U10E1DC Catalog Number: U10E1DC,TEFC,ENE,AC MTR 60/50,208-230/460&190/380V FUT,10HP,2P,215TC

REVISIONS:

ALL DOCUMENTS HEREIN ARE CONSIDERED CERTIFIED BY US ELECTRICAL MOTORS. THANK YOU FOR YOUR ORDER AND THE OPPORTUNITY TO SERVE YOU. Features: HorsePower . . . . . . . . 10 Enclosure. . . . . . . . . TE Poles. . . . . . . . . . . 02/00 RPM (Full Load). . . . . . 3510 / 2865 Motor Frame Size . . . . . 215TC Phase. . . . . . . . . . . 3 Frequency. . . . . . . . . 60 / 50 Voltage. . . . . . . . . . 230-460-208 / 190-380 Motor Type Code. . . . . . FUT Rotor Inertia (LB-FT²) 0.390 LB-FT² Bearing Number PE (Shaft) 6208-2Z-J/C3 Bearing Number SE (OPP) 6206-2Z-J/C3

Emerson Motor Company is a division of Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co.

ITEM 0705 CATALOG NUMBER:

U10E1DC

S677

MODEL

FR

SHAFT END BRG

215TC

TYPE

3

MAX AMB

INSUL CLASS

F

Asm. Pos.

10

422702-002

FUT

ENCL

OPP END BRG

6208-2Z-J/C3

PH

HP

NAMEPLATE PART #:

40 C

6206-2Z-J/C3

ID# DUTY

RPM

TE

3510

CONT

10

HP

RPM

VOLTS

230

460

208

VOLTS

190

380

FL AMPS

23.8

11.9

26.7

FL AMPS

29.8

14.9

SF AMPS

30

15

2865

SF AMPS

SF

1.25

DESIGN

B

CODE

NEMA NOM EFFICIENCY

89.5

NOM PF

88.1

KiloWatt

GUARANTEED EFFICIENCY

87.5

MAX KVAR

2

HZ

G

60

SF

1.00

DESIGN

#

NEMA NOM EFFICIENCY

86.5

NOM PF

88

GUARANTEED EFFICIENCY

84.0

MAX KVAR

1.7

UL DATA (IF APPLICABLE): DIVISION

CLASS I

GROUP I

TEMP CODE

CLASS II

GROUP II

VFD DATA (IF APPLICABLE): VOLTS AMPS TORQUE 1

TORQUE 2

VFD LOAD TYPE 1 VFD HERTZ RANGE 1 VFD SPEED RANGE 1

VFD LOAD TYPE 2 VFD HERTZ RANGE 2 VFD SPEED RANGE 2

SERVICE FACTOR NO. POLES VECTOR MAX RPM Radians / Seconds

FL SLIP MAGNETIZING AMPS Encoder PPR Encoder Volts

TEAO DATA (IF APPLICABLE): HP (AIR OVER) FPM AIR VELOCITY

HP (AIR OVER M/S) FPM AIR VELOCITY M/S

RPM (AIR OVER) FPM AIR VELOCITY SEC

RPM (AIR OVER M/S)

CODE

E

HZ

50

ADDITIONAL NAMEPLATE DATA: Decal / Plate

WD=109144

ITEM 0705

Customer PN

Notes

Non Rev Ratchet

Max Temp Rise

OPP/Upper Oil Cap

Thermal (WDG)

SHAFT/Lower Oil Cap

Altitude EPACT Note

EPACT Compliance

COS

Marine Duty

Balance

Arctic Duty

3/4 Load Eff.

Inrush Limit

Motor Weight

Direction of Rotation

Sound Level

Special Note 1

Vertical Thrust

Special Note 2

Thrust Percentage

Special Note 3

Bearing Life

Special Note 4

Starting Method

Special Note 5

Number of Starts 200/208V 60Hz Max Amps 190V 50 hz Max Amps

Special Note 6 32.6

SH Max. Temp. SH Voltage

380V 50 Hz Max Amps

SH Watts

NEMA Inertia

Load Inertia

Sumpheater Voltage

Sumpheater Wattage

Special Accessory Note 1

Special Accessory Note 16

Special Accessory Note 2

Special Accessory Note 17

Special Accessory Note 3

Special Accessory Note 18

Special Accessory Note 4

Special Accessory Note 19

Special Accessory Note 5

Special Accessory Note 20

Special Accessory Note 6

Special Accessory Note 21

Special Accessory Note 7

Special Accessory Note 22

Special Accessory Note 8

Special Accessory Note 23

Special Accessory Note 9

Special Accessory Note 24

Special Accessory Note 10

Special Accessory Note 25

Special Accessory Note 11

Special Accessory Note 26

Special Accessory Note 12

Special Accessory Note 27

Special Accessory Note 13

Special Accessory Note 28

Special Accessory Note 14

Special Accessory Note 29

Special Accessory Note 15

Special Accessory Note 30

EMERSON MOTOR COMPANY ST. LOUIS, MO

TYPICAL NAMEPLATE DATA ACTUAL MOTOR NAMEPLATE LAYOUT MAY VARY SOME FIELDS MAY BE OMITTED

CC 030A

ITEM 0705 MODEL NO. S677

CATALOG NO. U10E1DC

PHASE 3

TYPE FUT

NA

ORDER NO. MPI: HP: POLES: VOLTS: HZ: SERVICE FACTOR: EFFICIENCY (%):

FRAME 215TC LINE NO.

8033 10 2 460 60 1.25

8034 10 2 230 60 1.25

8035 10 2 208 60 1

8036 10 2 380 50 1

8037 10 2 190 50 1

S.F. FULL 3/4 1/2 1/4

88.2 89.5 91 90.3 85.5

88.2 89.5 91 90.3 85.5

88.5 90.3 90.3 86.4

86.5 90 90.9 88.1

86.5 90 90.9 88.1

S.F. FULL 3/4 1/2 1/4 NO LOAD LOCKED ROTOR

87.8 88.1 86.7 82.1 66 11.5 37

87.8 88.1 86.7 82.1 66 11.5 37

87.7 87.8 84.9 72.1 12.9 36.3

88 88 84.8 71.2 10.2 40.4

88 88 84.8 71.2 10.2 40.4

15.1 11.9 8.9 6.3 4.1 3 73.1 G B 3510 89.5 87.5 2 40 3300 23 65

30 23.8 17.8 12.6 8.3 6 147.3 G B 3510 89.5 87.5 2 40 3300 23 65

26.7 19.6 13.5 8.3 5.4 128.8 E # 3480 88.5 86.5 1.7 40 3300 30 65

14.9 10.7 7.4 4.5 3 70 E # 2870 86.5 84 1.6 40 3300 28 64

29.8 21.5 14.7 9 5.9 140.1 E # 2870 86.5 84 1.6 40 3300 28 64

271 160 15

271 160 15

216 125 15.1

209 126 18.3

209 126 18.3

POWER FACTOR (%):

AMPS: S.F. FULL 3/4 1/2 1/4 NO LOAD LOCKED ROTOR NEMA CODE LETTER NEMA DESIGN LETTER FULL LOAD RPM NEMA NOMINAL EFFICIENCY (%) GUARANTEED EFFICIENCY (%) MAX KVAR AMBIENT (°C) ALTITUDE (FASL) SAFE STALL TIME-HOT (SEC) SOUND PRESSURE (DBA @ 1M) TORQUES: BREAKDOWN{% F.L.} LOCKED ROTOR{% F.L.} FULL LOAD{LB-FT}

The Above Data Is Typical, Sinewave Power Unless Noted Otherwise

EMERSON MOTOR COMPANY ST. LOUIS, MO

Emerson Motor Company is a division of Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co.

ITEM 0705 B109144 Motor Wiring Diagram 9 Lead, Dual Voltage (WYE Conn.) T1

T4 T7

T6

T9

T8

T5

T3

T2

Y - Connection Lo - Volts

Hi - Volts

6

5

4

6

5

4

9

8

7

9

8

7

3

2

1

3

2

1

Line

Line

B109144

To reverse direction of rotation interchange connections L1 and L2. Each lead may have one or more cables comprising that lead. In such case each cable will be marked with the appropriate lead number.

Connection Plate: B109144 Connection Decal: 344136

ITEM 0705 FRAMES - 182 THRU B256 UNIMOUNT TOTALLY ENCLOSED MOTORS TYPES: FUT, FUT4, FUTF, FUTF4, FUTFN, FUTN, UT, UT1, UT2, UT3, UT4, UTE, UTE1, UTE3, UTE4, UTEF, UTEF1, UTEF4, UTEN, UTF, UTF1, UTF4, UTFI, UTFN, UTI, UTI1, UTI4, UTN, UTNI, UTQ, UTV

THIS PARTS LIST IS GOOD FOR THE FOLLOWING TYPES: Types UT

Frames 182T, TC, TCH, TD, TCZ 184T, TC, TCH, TD, TCZ 213T, TC, TD, TCZ 215T, TC, TD, TCZ 254T, TC, TD, TCZ 256T, TC, TD, TCZ B215TC, TCZ B256TC, TCZ

UT-1

182, 184, B184, 213, 215, B215, 254, 256, B256JP

UT-2

182, 184, B184JPY

UT-3

213, 215, B215JPZ

UT-4

182, 184, B184, 213, 215, B215, 254, 256, B256JM

UTE, UTN, UTQ

Types

Frames

UTF

182TC, TCH, TD 184TC, TCH, TD 213TC, TD 215TC, TD 254TC, TD 256TC, TD

UTV

182TCV, TCHV, JMV, JPV, JPYV 184TCV, TCHV, JMV, JPV, JPYV 213TCV, JMV, JPV 215TCV, JMV, JPV B215TCV, JMV, JPV 254TCV, JMV, JPV 256TCV, JMV, JPV

182, 184, 213, 215, 254, 256T

WARNING: Any disassembly or repair work on explosionproof motors will void the Underwriters Laboratories, Inc. label unless done by the manufacturer, or a facility approved by the Underwriters Laboratories, Inc. Refer to your nearest U.S. Elecrical Motors office for assistance.

BEARINGS: Refer to motor nameplate for the bearing numbers.

PRICES: Parts stocking distributors: refer to USEM renewal parts numerical index. All Others: refer to your nearest USEM parts distributor. reference: Renewal Parts Section 700, Pages 14 & 15

ITEM 0705 FRAMES - 182 THRU B256 UNIMOUNT TOTALLY ENCLOSED MOTORS TYPES: FUT, FUT4, FUTF, FUTF4, FUTFN, FUTN, UT, UT1, UT2, UT3, UT4, UTE, UTE1, UTE3, UTE4, UTEF, UTEF1, UTEF4, UTEN, UTF, UTF1, UTF4, UTFI, UTFN, UTI, UTI1, UTI4, UTN, UTNI, UTQ, UTV

ITEM NO.

QTY

ITEM NO.

1

1

QTY

Fan Cover (not used on type UTN)

52

2

Hex Head Cap Screw

2 3

4

Self Tapping Screw (not used on type UTN)

53

1

Water Deflector

1

Fan Assembly (not used on type UTN)

54

1

4

1

Bracket Assembly

Hex head Cap Screw (used on frames 182 & 184JC, JPV, types UT, UT-2 and UTF)

5

2

Hex Countersunk Pipe Plug

-

Not Used

NAME OF PART

55-59

NAME OF PART

For types UT and UTF with "D" bracket, omit items 9 & 37, and item 38 on frames 182 & 182 &184TD, and add the following parts

6

1

Bracket Plug (type UTN only)

7

4

Hex Head Cap Screw

60

1

"D" Bracket Assembly

8

2

Lifting Lug (not used on type UTV)

61

1

Clamping Plate

9

1

Spring Wave Washer (not used on types UT-1, UT-2, UT-3, UT-4 and UTV)

62

2

Hex Head Cap Screw

63

1

Water Deflector

64

1

Hex Head Cap Screw (used on 182 & 184 TD)

65-69

-

Not Used

10

1

11

1

12

1

Ball Bearing Rotor Assembly (includes items 12 and 13) Rotor Core

13

1

Shaft

14-19

-

Not Used

20

1

Wound Stator Assembly (includes itesm 21 and 22 if used)

For type UTV and units with canopy cap, omit item 8 and add the following 70

1

Canopy Cap

71

3

Spacer (qty.1 on frames 182 and 184)

3

Hex Head Cap Screw and Lockwasher (qty.1 on frames 182 and 184)

21

2

Mounting Foot (not used on types UTF and UTV)

72

22

6

Hex Head Cap Screw (not used on types UTF and UTV)

73

3

Square Nut (qty.1 on frames 182 and 184)

23

1

Gasket

74

2

Lifting Lug

24

1

Outlet Box Base

75-79

-

Not Used

25

2

Hex Head Cap Screw

26

1

Gasket

27

1

Outlet Box Cover

28

2

Self Tapping Screw

29-34

-

Not Used

80

1

Brake (for replacement parts for brake, refer to brake manufacturer)

35

1

Ball Bearing

81

4

Socket Head Cap Screw (qty. 2 on brakes under 10 lb.ft.)

82

1

Key

1

Retaining Snap Ring (qty. 2 on frames 182 & 184T, TC TCH, TCV, TCHV, types UT, UTE, UTF, UTQ,& UTV) (not used on frames 213T thru 256T, type UTN)

83

1

Baffle Plate

Bracket Assembly (type UT, UTE, UTN and UTQ only)

84

4

Brake Mounting Bracket

4

Hex Head Cap Screw

36 37

1

For SHUR-STOP brakes, omit items 1 & 3, and qty. one of item 8. Refer to section 770 for part addition For Dings and Stearns beake, omit items 1, 2 and 4, and qty. one of items 5, and add the following

38

4

Hex Nut

85

39

2

Hex Countersunk Pipe Plug

86

2

Groove Pin

40

1

Square Key

87

1

Brake Adaptor Bracket

41-49

-

Not Used

88

2

Screen

89

1

Nipple Fitting

90

1

Pipe Coupling

91

1

Nipple Fitting

92

1

Pipe Cap

For types UT, UTF and UTV with "C" bracket, and types UT-1, UT-3 and UT-4 omit items 9 & 37 and items 38 on frames 182 & 182TC, JPV, types UT, UT-2 and UTF, and add the following parts 50 51

1 1

"C" Bracket Assembly Clamping Plate

WARNING: Any disassembly or repair work on explosionproof motors will void the Underwriters Laboratories, Inc. label unless done by the manufacturer, or a facility approved by the Underwriters Laboratories, Inc. Refer to your nearest U.S. Elecrical Motors office for assistance.

BEARINGS: Refer to motor nameplate for the bearing numbers.

PRICES: Parts stocking distributors: refer to USEM renewal parts numerical index. All Others: refer to your nearest USEM parts distributor. reference: Renewal Parts Section 700, Pages 14 & 15

Copyright © 2005 Emerson Electric Co. All rights reserved

03-1900 _Emerson_tri.qxd

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7:47 AM

Page 1

ITEM 0705

Installation, Operation & Maintenance Instructions For your safety, read and retain this manual

E N G L I S H

GEARMOTORS HORIZONTAL MOTORS

TITAN MOTORS

VARIABLE SPEED DRIVES

VERTICAL MOTORS

Emerson Motor Company 8050 West Florissant Ave. PO Box 36912 St. Louis, MO 63136

Send for free brochure by product name

448888

Rev. 01/04

03-1900 _Emerson_tri.qxd

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7:47 AM

ITEM 0705

SAFETY FIRST E N G L I S H

Page 2

High voltage and rotating parts can cause serious or fatal injury. Safe installation, operation and maintenance must be performed by qualified personnel. Familiarization with, and adherence to, NEMA MG2, the National Electrical Code (NEC), and local codes is required. It is important to observe safety precautions to protect personnel from possible injury.

PERSONNEL SHOULD BE INSTRUCTED TO: 1. 2. 3. 4.

Be familiar with the equipment and read all instructions thoroughly before installing or working on equipment. Avoid contact with energized circuits or rotating parts. Disconnect all power sources before initiating any maintenance or repair. Act with care in accordance with prescribed procedures in handling and lifting this equipment.

5. 6.

Be sure unit is electrically grounded in accordance with code requirements. Be sure equipment is properly enclosed or protected to prevent access by children or other unauthorized personnel to prevent possible accidents. 7. Be sure shaft key is fully captive before unit is energized. 8. Avoid contact with capacitors until safe discharge procedures have been completed. 9. Provide proper guarding for personnel against rotating parts and applications involving high inertia loads which can cause overspeed. 10. Avoid extended exposure to equipment with high noise levels.

INSPECTION AND HANDLING Inspect unit to make sure no damage has occurred during shipment. Check nameplate for correct speed, horsepower, voltage, hertz and phase for conformance with power supply and equipment. Units should be lifted using all eyebolts or lugs if provided. These eyebolts or lugs are provided for lifting this unit only and must not be used to lift any additional weight. Lifting angle, from shank of eyebolt, must not exceed 30 degrees for machines with single and 45 degrees for machines with multiple lifting means. Replacement eyebolts must be per ASTM A489 or equivalent. All eyebolts must be securely tightened. Be careful not to touch overhead power lines with lifting equipment. Failure to observe this warning may result in serious personal injury.

STORAGE Units should be stored indoors, in a clean, dry location & winding should be protected from excessive moisture absorption. NOTE: If motors are to be stored for over one year, refer to Emerson Motor Company. If motors are to be stored for over one year and if gear and belt transmission units are to be stored for over six months, refer to Emerson Motor Company.

LOCATION Use only UL Listed Hazardous Location Motors for service in Hazardous Locations as defined in Article 500 of the NEC. Units should be located in a clean, well-ventilated area. Units should be located in a suitable enclosure or protected to prevent access by children or other unauthorized personnel to prevent possible accidents. 2-En

03-1900 _Emerson_tri.qxd

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INSTALLATION / MOUNTING

Page 3

ITEM 0705

Mount unit on a firm, flat surface sufficiently rigid to prevent vibration. Drive belts and chains should be tensioned in accordance with supplier recommendations. Couplings should be properly aligned and balanced. For belt, chain and gear drive selection refer to the drive or equipment manufacturer. For application of drive equipment refer to applicable information in NEMA MG1. Motors have been dynamically balanced using a half key the same length as the full key shipped with the motor. If pulley length keyway is less than this length, rework long key by removing one-half of excess length between pulley and end of key to maintain balance. Do not restrict motor ventilation. Unless otherwise specified on nameplate, motor is designed for operation in accordance with NEMA MG1 “Usual Service Conditions” which states an ambient temperature range of -15º C to 40º C (5º F to 104º F). Standard grease lubricated units are suitable for operation within this temperature range. Special lubricants may be required for ambient temperatures outside of this range. Note: Motors operating under rated load and allowable ambient conditions may feel hot when touched; this is normal and should not be cause for concern. When in doubt, measure frame surface temperature and confer with nearest office. Enclosed motors normally have condensation drain openings. Insure that drain openings are properly located and open (plugs removed) for the motor mounting position. Drain openings should be at lowest point of end brackets, frame housing and terminal housing when the motor is installed. This may require modification of motor to accomplish. If unit appears wet, and/or has been stored in a damp location, dry out thoroughly and check for adequate insulation resistance to ground before operating. Guards should be provided for all exposed rotating parts to prevent possible personal injury. Keep fingers and foreign objects away from ventilation and other openings. Applications involving high inertia loads may damage this equipment due to motor overspeed during coast shutdown. Such applications should be referred to Emerson Motor Company. Do not force drive coupling or other equipment onto shaft, as bearing damage may result.

POWER SUPPLY AND CONNECTIONS The power supply must agree with values on nameplate. Terminal voltage should not vary more than ±10% of nameplate voltage at rated frequency. Unbalanced line voltage, greater than one percent, can cause overheating. Do not exceed the rated load amperes on the nameplate. Starting controls and overload protection should be properly sized in accordance with the NEC and the control manufacturer's recommendations. Motor connections should be made by following instructions on connection diagram. Determine direction of rotation before connecting driven equipment. If direction of rotation label is supplied, operate only in specified direction. Rotation may be reversed on three phase motors by interchanging any two line connections. On single phase motors interchange leads per connection diagram on motor. Wiring of units, controls and grounding shall be in accordance with local and NEC requirements. Failure to properly ground unit may cause serious injury to personnel. Where unexpected starting could be hazardous to personnel, do not use automatic reset starting devices.

USE OF VARIABLE FREQUENCY DRIVES Electric motors can be detrimentally affected when applied with variable frequency drives (VFD's). The non-sinusoidal waveforms of VFD's have harmonic content which causes additional motor heating; and high voltage peaks. 3-En

E N G L I S H

03-1900 _Emerson_tri.qxd

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7:47 AM

Page 4

ITEM 0705 E N G L I S H

Other effects of VFD's on motor performance include reduced efficiency, increased load current, vibration and noise. Standard motors utilized with VFD's must be limited to those application considerations defined in NEMA MG-1 Part 30. Refer to PDS #811-215 available at www.usmotors.com. NEMA MG-1 Part 31 defines performance and application considerations for Definite-Purpose Inverter Fed Motors. To insure satisfactory performance and reliability, U.S. Electrical Motors offers and recommends nameplated inverter duty motor products which meet the requirements of NEMA MG-1 Part 31. The use of non-inverter duty motors may result in unsatisfactory performance or premature failure, which may not be warrantable under the Terms and Conditions of Sale. Contact your Emerson Motor Company Field Sales Engineer for technical assistance for motor selection, application and warranty details.

OIL LUBRICATION Most oil lubricated units are shipped without oil. Refer to Instruction Manual with unit for specific type and grade of oil to be used, change interval and level. If lubrication instructions specify synthetic oil, do not substitute. For applications in the food and drug industry (including animal food), consult the petroleum supplier for lubricants that are acceptable to the Food and Drug Administration and other governing bodies.

MAINTENANCE Inspect units at regular intervals. Keep units clean and ventilation openings clear of dust, dirt or other debris. Lubricate units per this operating instruction folder and instruction plate on unit. Excessive lubrication may damage the unit. Do not over grease. Disconnect all power sources to the unit and discharge all parts which may retain an electrical charge before attempting any maintenance or repair. Screen and covers must be maintained in place when unit is in operation. Failure to observe this warning may result in personal injury. U.L. Listed Motors for use in Hazardous Locations: Repair of these motors must be made by the manufacturer or manufacturer's authorized service station approved to repair U.L. Listed Motors. The U.L. listing applies to the electric motor only and not the belt or gear transmissions or other devices that may be connected to the motor.

COOLING TOWER DUTY MOTORS During installation, insure drain plugs are removed from lower drain holes in bracket and outlet box. All upper drain holes must be plugged at all times. External umbrella seal must be in place for shaft up applications. Motors with Bearing numbers “XXXX-2RS” are double sealed and not to be relubricated.

VARIDRIVE UNITS Do not turn speed control hand wheel while unit is not operating; this may cause damage to the unit. Hand wheel position is a relative speed indication only. Use direct speed sensing accessory for precise speed indication. Units equipped with electric remote speed indicator accessory are not calibrated at the factory and must be calibrated at site. Refer to calibration instructions with the unit. VARIDRIVES equipped with ENDOLUBE construction do not require lubrication of the sliding Varidisc. Operate VARIDRIVE through its entire speed range weekly.

4-En

03-1900 _Emerson_tri.qxd

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7:47 AM

Page 5

ITEM 0705 Do not force control wheel beyond speed limits shown on the nameplate. The mechanism and belt are designed for the rated speed and horsepower shown on the nameplate. Operation beyond these limits may result in damage to the belt and mechanism and possible injury to personnel. The covers on the frame case must not be removed or left off while unit is in operation. Do not attempt to disassemble or repair the driven pulley discs because high spring tension may be released causing injury to personnel. Refer to authorized Service Center. Refer to VARIDRIVE Installation and Maintenance Manual for complete belt changing instructions. For additional detailed information, request specific product installation and maintenance manual.

GREASE LUBRICATION INSTRUCTIONS Units are prelubricated at the factory and do not require initial lubrication. Relubricating interval depends upon speed, type of bearing and service. Refer to Table 1 for suggested regreasing intervals. Operating conditions may dictate more frequent lubrication. Motor must be at rest and electrical controls should be locked open to prevent energizing while motor is being serviced (refer to section on Safety). If motor is being taken out of storage, refer to storage procedures. To relubricate bearings, remove the drain plug. Inspect grease drain and remove any blockage with a mechanical probe taking care not to damage bearing. Under no circumstances should a mechanical probe be used while the motor is in operation. Add new grease at the grease inlet, refer to Table 1 for replenishment quantities. New grease must be compatible with grease in the motor (See Caution Note). Run the motor for 15 to 30 minutes with the drain plug removed to allow purging of any excess grease. Shut off unit and replace the drain plug. Return motor to service. Some motors have sealed bearings and are not regreasable. Over greasing can cause excessive bearing temperatures, premature lubricant breakdown and bearing failure. Care should be exercised against over greasing.

Table 1 Recommended Grease Replenishment Quantities & Intervals (For lubrication of units in service) Bearing Number-Common 62XX 6203-6207 6208-6212 6213-6215 6218-6220 6221-6228

63XX 6303-6306 6307-6309 6310-6311 6312-6315 6316-6320

Bearing Number-AFBMA XXBC02 17-35 40-60 65-75 80-100 105-140

Grease FL Oz.

XXBC03 17-30 35-45 50-55 60-75 80-100

0.2 0.4 0.6 1.0 1.8

Lubrication Interval 3600 RPM 2 Years 1 Year 1 Year 6 Mos. 6 Mos.

1800 RPM 3 Years 2 Years 2 Years 1 Year 1 Year

1200 RPM 3 Years 2 Years 2 Years 2 Years 1 Year

For motors mounted vertically or in hostile environments, reduce intervals shown by 50 percent. Refer to motor nameplate for bearings provided on a specific motor. For bearings not listed in table above, the amount of grease required may be calculated by the formula: G=0.11 x D x B Where; G = Quantity of grease in fluid ounces. D = Outside diameter of bearing in inches. B = Width of bearing in inches. 5-En

E N G L I S H

03-1900 _Emerson_tri.qxd

5/27/2004

7:47 AM

Page 6

ITEM 0705

Table 2 RECOMMENDED GREASES E N G L I S H

THE FOLLOWING GREASES ARE INTERCHANGEABLE WITH THE GREASE AS PROVIDED IN UNITS SUPPLIED FROM FACTORY (UNLESS STATED OTHERWISE ON A LUBRICATION NAMEPLATE PROVIDED ON MOTOR). MANUFACTURER EXXON CORP. CHEVRON U.S.A. INC.

GREASE (NLGI No. 2) POLYREX - EM SRI NO. 2

Greases of different bases (lithium, polyurea, clay, etc.) may not be compatible when mixed. Mixing such greases can result in reduced lubricant life and premature bearing failure. When necessary, prevent such intermixing by disassembling the motor, removing all old grease from bearings and housings (including all grease fill and drain holes). Inspect and replace damaged bearings. Fill bearing housings and bearing approximately 30% full of new grease. Remove any excess grease extending beyond the edges of the bearing races and retainers. Refer to Table 2 for recommended greases.

WARRANTY LIMITED WARRANTY All U.S.E.M. products are warranted against defects in workmanship and materials for 12 months from date of installation, not to exceed 18 months from date of shipment from EMC. Some of U.S.E.M's products carry a warranty period longer than 12 months. Please refer to the current price catalog or to EMC for details on specific products. This limited warranty does not apply to any product which has been subject to misuse, misapplication, neglect (including without limitation, inadequate maintenance), accident, improper installation, modification, adjustment, or repair. This constitutes EMC's only warranty in connection with this sale and is in lieu of all other warranties, expressed or implied, written or oral. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THAT APPLY TO THIS SALE. No employee, agent, dealer or other person is authorized to give any warranties on behalf of EMC nor to assume for EMC any other liability in connection with any of its products.

EXCLUSIVE REMEDY EMC's liability shall be limited exclusively to repairing or replacing any product found by EMC to be defective, or at EMC's option, to refund the purchase price of its product. Such product shall be returned, freight prepaid, to the nearest U.S.E.M. authorized service station or EMC factory. It is agreed that such replacement, repair, or refund be the sole and exclusive remedies available from EMC. EMC shall not be liable for damages of any sort whatsoever beyond these exclusive remedies including incidental and consequential damages regardless of whether any claim is based upon contract, negligence, strict liability, tort, warranty, or other basis. The repair or replacement of the product, or the refund of the purchase price, at EMC's option, constitutes fulfillment of all liabilities of EMC to the buyer for defective products.

RENEWAL PARTS AND WARRANTY SERVICE When inquiring for renewal parts, call the nearest U.S. Electrical Motors Parts Stocking Distributor. For warranty service, call the nearest U.S. Electrical Motors Authorized Service Station. Give them complete Nameplate data, including identification number, etc. Request installation and maintenance manuals by product name. 6-En

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

C C

3E 3E

B B

C C

143J 162

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0705

ITEM 0740

Moduflow™ Series IL2 /RF2/CF2 Low Pressure Filters

Global Filtration Technology 35

Low Pressure Filters Moduflow™ Series Features

ITEM 0740

Flanges

Cover

SAE ¾” to 2” ■ Lightweight aluminum

■ Lightweight

■ NPT or

■ Slotted for

quick release aluminum

Bowl

Indicators

■ Single or

■ Visual or electrical ■ Mounted on either side ■ Optional “no element”

double length

■ Durable steel

construction

indication

Bypass/Diverter

Element

(not visible) ■ 5 different

(not visible) ■ Available in

pressure settings

cellulose, wire mesh or high performance Microglass II media ■ Single or double length

■ No bypass option

available

Feature

Advantage

Benefit

• Top access element service

• Oil remains in housing • Quicker element change

• No spills • Reduced maintenance costs

• Slotted cover

• Quick release cover • Cap screws remain in housing

• Reduced maintenance costs • No loose parts to lose

• Closed bottom elements (RF2 and IL2 only)

• Removes all contaminant during element service

• No downstream contamination from servicing

• Visual or electrical indicators

• Know exactly when to service elements

• Helps prevent bypass condition • No premature disposal

• Flange face ports

• Flexible mounting (3/4” to 2”)

• Easy plumbing to your system

37

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™ Series Specifications: DIL2

ITEM 0740

3.3 .013

Pressure Ratings: Maximum Allowable Operating Pressure (MAOP): 200 psi (13.8 bar) Design Safety Factor: 2:1 Rated Fatigue Pressure: 150 psi (10.3 bar)

116.8 4.60

79.0 3.11

76.2 3.00

Element Burst Rating: 70 psid (4.8 bar) Filter Materials: Diverter Valve Assembly: die cast aluminum Check Valve Assembly: die cast aluminum Filter Assembly: see IL2 specifications

½-13 SHCS TORQUE 32-38 FT-LB

¼-18 NPT DRAIN VENT CONNECT TO TANK

173.0 6.81

330.2 SINGLE 13.0

Operating Temperatures: Buna: -40°F to 225°F (-40°C to 107°C) Fluorocarbon: -15°F to 275°F (-26°C to 135°C)

617.5 DOUBLE 24.31

Weight (approximate): Single: 55 lbs. (24.9 kg) / Double: 65 lbs. (29.5 kg)

110.5 4.35

Indicators: Visual (optional) Electrical (optional) 15A@250VAC / .5A@125 VDC Electrical (“D” option) 5A@250VAC / 3A@28 VDC

Linear Measure: millimeter inch

479.3 18.87

Color Coding: White (normally closed) Red (normally open) Black (common)

AIR BLEED EACH FILTER

30.2 1.19

FILTER SCHEMATIC

OPTIONAL FLANGE

OUTLET

FILTER

FILTER 177.8 7.00

INLET BYPASS

INLET

402.8 15.86

OUTLET

345.9 13.62

BYPASS

DRAIN VENT

OPTIONAL MECHANICAL INDICATOR

BOTH CHECK VALVES MOVE SAME DIRECTION

Approximate handle torque required for changeover.

Typical Flow/Pressure Curves For Duplex Valves 1.75 1.5

25 LPM

30

(Add to differential pressure of filter assembly for total duplex pressure differential)

20

0.75

10

DIFF. PRESSURE

1

*Diverter/check valves combined

S SU S 00 SU 0 3 0 20

15

10

0.5 5 0.25

0 100

200

300

GPM

Torque (Ft-Lbs)

1.25

20

0

System Pressure (psi)

43

0

10 GPM

0

25

20

50

30

40

50 FLOW

60

70

80

90 100 LPM

75 100 125 150 175 200 225 250 275 300 325 375

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™ Series Accessories “M” OPTION-VISUAL INDICATOR, NO ELEMENT WARNING

Linear Measure: millimeter inch

ITEM 0740

OPTIONAL MOUNTING BRACKET (924904)

161.5 6.5 8.7 0.344 DIA. THRU PLACES

122.9 4.84

60 TYP

7.9 0.31

114.3 4.500

R 114.3 4.500

6.44 0.25 “V” OPTION-VISUAL INDICATOR

13.5 0.531 DIA. THRU 4 PLACES 114.3 4.500 57.2 2.25

13.5 .531 DIA. THRU TYP. 41.1 1.62

25.4 1.00

OPTIONAL TANK FLANGE (925167)

10.3 0.406 DIA. THRU 8 PLACES

“E” OPTION-ELECTRICAL INDICATOR "D"

235.0 9.25

98.4 3.875 TYPICAL 8.7 0.344 DIA. THRU 6 PLACES

196.9 7.750 TYPICAL

MATERIAL THICKNESS 4.60 .18

149.2 5.875 DIA. B.C.

45

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

ITEM 0740

Low Pressure Filters Moduflow™ Series Parts List Index Description 1 2 3 4 5 6

7

8 9 10 11 12

13 14 15

16

17 18

19 20

Screws, Nameplate .............................. Name Plate, Unstamped ...................... Cover Screws, 5/16-18 UNC x 1” ........ Bowl Screws, 5/16-18 UNC x 1” .......... Cover, Without nameplate .................... O-Ring, cover, bowl and diverter Buna ................................................. Fluorocarbon ..................................... Diverter/Bypass Valve Assembly ....... 35 psid, Purple .................................. 25 psid, Metalic Aluminum ................ 15 psid, Light Blue ............................ 3 psid, Yellow .................................... 2 psid, Pink ....................................... No Bypass ........................................ Head, Machined only ............................ Flange Kits Grommet (Buna) .................................. Grommet, (Fluorocarbon) .................... Single Elements, RF, IL Bowl, Select desired model .................. IL2-1 .................................................. IL2-2 .................................................. RF2-1 ................................................ RF2-1 with 2 inch NPTF fitting .......... RF2-2 ................................................ RF2-2 with 2 inch NPTF fitting .......... CF1-1 with 2 inch NPTF fitting .......... CF2-2 with 2 inch NPTF fitting .......... Double Elements, CF Plug Kit, Fastener, self-sealing, o-ring seal included with fastener ......... Indicator Electrical .............................. 35 psid .............................................. 25 psid .............................................. 15 psid .............................................. 3 psid ................................................ 2 psid ................................................ Indicator Visual ................................... 35 psid 4-band .................................. 25 psid 4-band .................................. 15 psid 4-band .................................. 3 psid 4-band .................................... 2 psid 4-band .................................... 35 psid 3-band .................................. 25 psid 3-band .................................. 15 psid 3-band .................................. 3 psid 3-band .................................... 2 psid 3-band .................................... Flange, In-tank mounting ..................... Bracket, Inline mounting ...................... Indicator Kit Remote mount ................ Indicator Kit, Bulkhead mount ............. Check Valve Assy. (Submersible) ........ Check Rod Assy. ................................. 2” - 1 CF ............................................ 2” - 2 CF ............................................ Changeover Valve Assy., Duplex ........ Check Valve Assy., Duplex ..................

Flange Kits (flange, 4 bolts, o-ring) Part Quanity No. 900028 2 924928 1 926633 6 926633 6 924634 1 N72350 V72350 926783 926582 926581 926580 926579 926578 925972 Refer to Table 924433 925026 Refer to Table 925916 924816 925917 924676 924815 924818 926207 924817 Refer to Table 925974

3 3 1

Fluorocarbon

¾ inch NPTF

YB

924788

926013

1 inch NPTF

YC

924787

926012

1¼ inch NPTF

YD

924912

926004

1½ inch NPTF

YE

924786

926011

2 inch NPTF

YF

924785

926010

SAE - 12

YM

924784

926009

SAE - 16

YN

924783

926008

SAE - 20

YO

924913

926005

SAE - 24

YP

924782

926007

BLANK FLANGE

—

924781

926006

1 2 2 1

RF2 / IL2 / DIL2 Replacement Elements BUNA Single Double 932686Q 932692Q

Fluorocarbon Single Double 932689Q 932695Q

05Q

932687Q

932693Q

932690Q

932696Q

10Q

932688Q

932694Q

932691Q

932697Q

20Q

933116Q

933117Q

933118Q

933119Q

03C

932361

932567

932367

932574

10C

932360

932467

932366

932473

20C

932359

932469

932365

932474

40SA

932358

932468

932364

932475

25W

932563

932566

932570

932573

40W

932562

932565

932569

932572

74W

932561

932564

932568

932571

WR

932363

932476

932370

932575

MEDIA 02Q

1

2 Optional

CF2 Replacement Elements

Optional

926954 925140 926758 926757

Buna

1

926643 924964 924965 924966 924967 926748 924776 924777 924778 924779 926750 924929 924824 924927 924926 925167 924904 924894 *925021 925120

Part Number

Code

Size

BUNA Single Double 924452Q 934264Q

Fluorocarbon Single Double 925039Q 935534Q

10Q

924453Q

934265Q

925040Q

935535Q

03C

924449

924791

925036

925046

10C

924450

924792

925037

925047

MEDIA 05Q

Optional Optional Optional Optional Optional Optional

20C

924451

924793

925038

925048

40SA

924448

924790

925035

925045

25W

924454

924796

925041

925051

40W

924455

924797

925042

925052

74W

924456

924798

925043

925053

WR

927584

927585

928908

928925

Optional Optional

*Two kits required for differential indication

46

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

Low Pressure Filters Moduflow™ Series Filter Assembly Exploded View

ITEM 0740 12

4

10 13

6

10 12 4

11 6

10

17

8 6

7

6

5 3 19

2

20

1

9

14 15 16 18

47

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

ITEM 0740

Low Pressure Filters Moduflow™ Series

HOW TO ORDER: Select the desired symbol (in the correct position) to construct a model code. Example: BOX 1

BOX 2

BOX 3

BOX 4

BOX 5

BOX 6

BOX 7

BOX 8

BOX 9

1

10Q

MDMD

MP

35

Y9Y9

1

Design number assigned by Parker

IL2

DIL2

2

BOX 5: Indicators (See Note A)

BOX 1: Seals Symbol

Description

Symbol

None F3 E8

Buna Fluorocarbon EPR

P

M Description

CF2

Suction filter, inlet on bottom; outlet on side Return-line filter, inlet on side; outlet on bottom In-line filter In-line duplex

RF2 IL2 DIL2

E

V D S

Note: Add “W before “2” for HWCF modification.

BOX 3: Length Symbol Description

1 2

Single element Double element

Description

Pressure ports drilled and plugged; no indicator Visual indicator w/ no element warning Electrical indicator; no visual Visual indicator Electrical indicator; 3-pin male quick disconnect Pressure or vacuum switch (Selected based on bypass setting.)

BOX 2: Basic Assembly Symbol

(Two Required)

Note A: (First letter of indicator code = left side of filter head when looking into inlet with bowl down; second letter = right side of filter head when looking into inlet with bowl down.)

BOX 6: Bypass & Indicator Setting BOX 4: Filter Media Symbol

Description

74W 40W 25W 40SA 20C 10C 03C 02Q* 05Q* 10Q* 20Q WR

74-micron wire mesh 40-micron wire mesh 25-micron wire mesh 40-micron synthetic 20-micron cellulose 10-micron cellulose 3-micron cellulose Microglass III Microglass III Microglass III Microglass III Water removal

Symbol

Pressure Setting

2 3 15 25 35

2 psid 3 psid 15 psid 25 psid 35 psid

BOX 7: Port Options Filter Inlet Model Symbol/Description

Y9 2” flange face F9 2” NPTF CF2

RF2

IL2

DIL2

F8 External check valve

Y9 2” flange face P9 SAE-24 integral threads E9 1½ NPTF integral threads *See table below Y9 2” flange face P9 SAE-24 integral threads E9 1½ NPTF integral threads *See table below Y9 2” flange face *See table below

Outlet Symbol/Description

Y9 2” flange face P9 SAE-24 integral threads E9 1½ NPTF integral threads *See table below 99 No fitting F9 2” NPTF F8 External check value

Y9 2” flange face P9 SAE-24 integral threads E9 1½ NPTF integral threads *See table below Y9 2” flange face *See table below

1)First pair of symbols denotes inlet for all filter styles; second pair of symbols denotes outlet. 2)Four symbols required: two for inlet, two for outlet. 3)Unused ports in CF2 and RF2 filters come plugged with a blank flange. 4)On CF2, F8 option includes internal rod assembly.

* Available Port Flange Options For Filter Head

Note: Indicators installed on filters will be matched to the bypass valve.

*Not available for CF2 model

YB

¾” NPTF flange

YC

1” NPTF flange

YD

1¼” NPTF flange

YE

1½” NPTF flange

YF

2” NPTF flange

YM

SAE-12 flange

YN

SAE-16 flange

YO

SAE-20 flange

YP

SAE-24 flange

BOX 8: Modifications Symbol Description

1 3 11

Please note the bolded options reflect standard options with a reduced lead-time. Consult factory on all other lead-time options.

None Magnets No-bypass

BOX 9: Design Number Applied to the filter by Parker Hydraulic Filter Division. Use the full model code, including the design number when ordering replacement parts.

48

Parker Hannifin Corporation Hydraulic Filter Division Metamora, OH

V-SERIES VALVES

ITEM 0750

V-SERIES VALVES

Standard with Screw Connections

Standard with Flange Connections

Stainless Steel with Screw Connections

APPLICATION

Handwheel with Screw Connections

Handwheel with Flange Connections

Widely used in a variety of applications, the “V” series valves are ideally suited in hydraulic and lubricating systems for load regulation and system protection. Special trim or packings are available for use with fire resisting fluids and other liquids of this type. Unusual applications and special requirements should be referred to our engineering staff for recommendation.

The Fulflo “V” Series range in size from 1/4” through 2” and operate efficiently with liquids of any viscosity at pressures from 2 to 1000 P.S.I. The “V” series valves are available in flange or screw type...cartridge or handwheel in a choice of brass, cast iron, steel and stainless steel.

INSTALLATION

should be piped back to the tank. Care must be taken to have the discharge well below the oil level in the tank to prevent air entrainment and erratic operation. Only if the valve is used as safety or overload relief and operates infrequently may its discharge be piped back into the pump suction line. Frequent or continuous operation under these conditions will cause excessive heating of the oil and possible damage.

Fulflo valves can be mounted in any position. A tee may be inserted in the pump discharge line to mount the valve. The correct size of valve should be installed, preferably matching the pump discharge line. Screw the valve into the nipple in the tee, or in the case of the flange style, bolt the valve to the companion flange screwed into the nipple. When the valve is used for frequent bypassing of oil pressure, its outlet

11

V-SERIES

ITEM 0750

SETTING VALVES

having a flow meter in the pump discharge line must be available. With a valve adjusted for cracking pressure as above, continue closing bypass until the required flow registers on the flow meter and observe pressure. Readjust pressure, if necessary, to obtain desired pressure at desired flow.

V-SERIES VALVES

Valves may be set with a hydraulic hand pump for cracking pressure. If a test stand is available, valve should be connected to the discharge header with the pump bypass open, and the bypass gradually closed until the desired pressure registers on the gauge. Adjust valve adjusting screw until valve slightly bleeds at the set bypass pressure and lock adjusting screw.

MAINTENANCE

Fulflo valves are not designed to be positive shut-off, and will pass a minimal amount of leakage before the set pressure. If a valve is required to bypass a given amount of fluid at a given pressure, a test stand

Fulflo valves provide reliable “chatter-free” operation when the system is free of abrasives and foreign matter. Continuous filtration of the liquid used is strongly recommended.

TYPICAL DISASSEMBLY OF STANDARD TYPE VALVE To 1. 2. 3. 4. 5. 6. 7. 8.

G B E F

I H A

dismantle valve for inspection or cleaning: Remove cap “B” Remove O-Ring “E” Remove lock nut “F” Remove adjusting screw “C” Remove retainer “D” Remove spring “G” Remove piston “I” Remove stop ring “H” (Not Recommended) (Special tooling is required to install new stop ring.)

C

Inspect valve bore and piston for wear and scoring. Replace broken or damaged parts. Clean all parts thoroughly and re-assemble by reversing the above procedure.

D

TYPICAL DISASSEMBLY OF HANDWHEEL TYPE VALVE

A

J

B

F

D

K

E

H

G

L

C I

To dismantle the valve for inspection or cleaning: 1. Release spring tension by backing off handwheel as far as it will go. 2. Remove lock nut “A” or set screw and take off handwheel “B” 3. Remove lock nut “D” 4. Unscrew and remove gland “E” 5. Unscrew and remove bonnet “F” 6. Remove O-Ring “H” 7. Remove adjusting screw “C” (turn clockwise and pull out from bottom of bonnet “F”) 8. Remove O-ring packing “G” 9. Remove spring “J” 10. Remove piston “K” 11. Remove stop ring “L” (Not Recommended) (Special tooling is required to install new stop ring.)

Inspect valve bore and piston for wear or scoring. Replace broken or damaged parts. Clean all parts thoroughly and re-assemble by reversing the above procedure.

12

V-SERIES

ITEM 0750

ASSEMBLY NUMBER IDENTIFICATION CHART Symbol No. 1

Designation Style

2 3

Series Material

4

Connections

Description Standard Model Handwheel Model Cast iron Brass Steel 316 Stainless Steel Screw Connections Flange Connections

300# Flange Class Standard (250# Flange Class - Cast Iron Standard)

1/4” 3/8” 1/2” 3/4” 1” 11/4” 11/2” 2”

5

Size

-1 -2 -3 -4 -5 -6 -7 -8

6,7,8

ASA Flange Rating Flange Style 150# & 600# Only O-Ring Material

None -150 -600 A B C D R RV RS RT RA SP P

300# Flange Standard (no designation required)

/HS /SS /3SS AS US WS XS YS ZS

Hardened Steel 416 Stainless Steel 303 Stainless Steel

9

10

11

Options

12

Piston Material

13

Spring

14

Setting

Raised Face, Staggered Bolt Centers (standard on all Flange rating) Smooth Face, Staggered Bolt Centers Raised Face, Bolts on Valve Centerline Smooth Face, Bolts on Valve Centerlne Buna O-Ring Cap Seal (standard) Viton O-Ring Cap Seal Silicone O-Ring Cap Seal Teflon O-Ring Cap Seal (standard on VSS Series) Aflas O-Ring Cap Seal Steel Parts (used on cast iron only) Panel Mount on Handwheel Series

Desired Pressure Setting

EXAMPLES: VJ-1RVSP/HS/WS V

J

-1

RV

Series Cast Iron 1/4” Viton O-Ring

VJF-5R/HS/WS

SP

/HS

WS

Steel Parts

H.S. Piston

WS Spring

V

J

Series Cast Iron

VJF-5-150AR/HS/WS

F

-5

R

/HS

WS

V

J

F

Flanged

1”

Buna O-Ring

H.S. Piston

WS Spring

Series

Cast Iron

Flanged

-5 -150 A 1”

Rating

Style

R

/HS

WS

Buna O-Ring

H.S. Piston

WS Spring

NOTE: Stainless steel pistons are supplied on brass valves, unless hardened steel is specified. Hardened steel pistons are supplied on cast iron or steel unless stainless steel is specified. Buna O-Rings are supplied as standard unless other material is specified.

STANDARD PRESSURE RANGE CHART Valve Pipe Size

Valve Flange Size

1/4” 3/8” 1/2” 3/4” 1” 11/4” 11/2” 2”

1” 11/4” 11/2” 2”

BLACK-AS Low High 3 15 3 15 3 15 3 15 3 15 3 15 3 15 3 15

SPRING PRESSURE AND IDENTIFICATION NO. RED-US GREEN-WS YELLOW-XS WHITE-YS BLUE-ZS PURPLE-TS BROWN-RS Low High Low High Low High Low High Low High Low High Low High 7 35 30 100 60 175 150 350 300 500 400 600 550 750 7 35 30 100 60 175 150 350 300 500 400 600 550 750 7 35 30 100 60 175 150 350 300 500 400 600 550 750 7 35 30 100 60 175 150 350 300 500 7 35 30 100 60 175 150 350 300 500 7 35 30 100 60 175 150 350 300 500 7 35 30 100 60 175 150 350 300 500 7 35 30 100 60 175 150 350 250 600 13

V-SERIES VALVES

Code None H V J B S SS None F

ITEM 0750 VJF Cast Iron VSF Steel VBF Brass VSSF Stainless Steel VJF-SP Cast Iron with Steel Parts

V-SERIES DIMENSIONS J

DIMENSIONS IN INCHES

B C F E D

K

Valve Size

AA

BB

1”

91/2”

31/2”

11/4” 1013/16” 33/4” 11/2” 127/16” 41/16” 2”

Note: Dimensions reflect 150# and 300# only AA REF.

45˚

45˚

(GASKET SEAL)

G A I

221/2˚

PIPE SIZE

45˚

H

PIPE SIZE

-------

-------

-------

-------

BB

221/2˚

FOR 2” VALVE ONLY

BB

PARTS LIST SYM.

NAME

A

BODY

B

(O-RING SEAL)

CAP

C

ADJUSTING SCREW

D

RETAINER

E

O-RING ✝

F

LOCK NUT

G

SPRING ✝

H

STOP RING

I

PISTON ✝

J

CAP

K

GASKET ✝

(GASKET SEAL)

MODEL

1” VJF, VJF-SP 500-F VBF 500-BF VSF 500-SF VSSF 500-SSF VJF, VJF-SP 501-R VBF 501-BR VSF 501-SR VSSF 501-SSR VJF, VBF 502-B VSF, VJF-SP 502-S VSSF 502-SS VJF, VBF 503-B VSF, VJF-SP 503-S VSSF 503-SS VJF, VJF-SP 504* VBF, VSF 504-* VSSF 504-RT VJF, VJF-SP 505-S VBF, VSF 505-S VSSF 505-SS ALL MODELS 507-** VJF, VBF 508-B VJF-SP, VSF 508-S VSSF 508-SS HARDENED STEEL 506 416 STAINLESS STEEL 506-A 303 STAINLESS STEEL 506-SS VJF, VJF-SP 501 VBF 501-B VSF 501-S VJF, VBF 504 VJF-SP, VSF 504-S

* See o-ring selection chart ** See spring pressure chart ✝ Recommended spare parts 15

11/4” 600-F 600-BF 600-SF 600-SSF 601-R 601-BR 601-SR 601-SSR 602-B 602-S 602-SS 603-B 603-S 603-SS 604* 604-* 604-RT 605-S 605-S 605-SS 607-** 608-B 608-S 608-SS 606 606-A 606-SS 601 601-B 601-S 604 604-S

VALVE SIZE 11/2” 700-F 700-BF 700-SF 700-SSF 701-R 701-BR 701-SR 701-SSR 702-B 702-S 702-SS 703-B 703-S 703-SS 704* 704-* 704-RT 705-S 705-S 705-SS 707-** 708-B 708-S 708-SS 706 706-A 706-SS 701 701-B 701-S 704 704-S

2” 800-F 800-BF 800-SF 800-SSF 801-R 801-BR 801-SR 801-SSR 802-B 802-S 802-SS 803-B 803-S 803-SS 804* 804-* 804-RT 805-S 805-S 805-SS 807-** 808-B 808-S 808-SS 806 806-A 806-SS 801 801-B 801-S 804 804-S

V-SERIES VALVES

CAP

149/16” 49/16”

ITEM 0770 This page is formatted for printing: To print, hold down the control key (Ctrl) then press the letter "P". (Ctrl+P)

AB - 1010 - 13 - G - DS-13 - CH

(CH is for Chain)

ITEM 0772

SOLBERG OIL MIST ELIMINATORS Installation, Operation and Maintenance Instructions

DISCLAIMER Although instructions and recommendations are included for installation of the Oil Mist Eliminator, the Manufacturer (Solberg Manufacturing, Inc. or Solberg International Ltd) does not assume any responsibility for the final installation of this Oil Mist Eliminator. The Manufacturer will not be held liable for direct or any consequential damages resulting from inappropriate methods of handling or installation. The Oil Mist Eliminator needs to have adequate support or the unit may suffer a premature failure due to stress and vibration. Designs and layouts may change based on specific application conditions. All the information in this manual has been thoroughly perused; the Manufacturer assumes no accountability for any possible errors or omissions. This is only intended to be a guide and it is to be used by the customer with proper caution. If there are any doubts or questions, please contact a Solberg office or representative before installation. • •

For inquiries within the USA, please call Solberg Manufacturing, Inc. at +1-630-616-4400 For all inquiries outside of the USA, please call Solberg International, Ltd at +1-630-616-4900 or contact your local Solberg sales representative. For a list of our international offices and representatives please visit our website at www.solbergmfg.com and click on “International Representatives” at the bottom of our homepage.

DESCRIPTION The Solberg Oil Mist Eliminator (OME) is designed to remove oil mist emissions from a polluted air/gas stream and discharge clean air to the atmosphere. The filter element inside the OME vessel is a coalescing separator (Item 2 on schematic) which operates at an efficiency of 99.97% for 0.3 micron oil mist. Mist laden air goes through the element, coalesces and drains to the bottom of the vessel. The collected oil is drained out of the filter through a drain port back to the oil reservoir, crankcase or waste receptacle. Clean air is discharged to the atmosphere through the outlet. There are two primary types of mist eliminators: Static (CV Series) and Vacuum Assisted Oil Mist Eliminator (VAE Series) CV Series: The CV product line is designed to remove all visible oil mist emissions. It is easily installed and can operate for a number of years with little to no maintenance while maintaining high efficiency. This is not vacuum extraction model, and is usually installed on systems that tolerate positive pressure. With these systems, the reservoir or crankcase can usually handle the differential pressure contributed by the air/gas flow through the Oil Mist Eliminator. Solberg Oil Mist Eliminators

1

ITEM 0772 VAE Series: This product line is designed to remove all visible oil mist emissions. Many turbines and compressors are designed to operate with the oil reservoir or crankcase maintained at a negative pressure typically between -25 to -200 mm/1-4” of H20. The VAE uses a blower or fan to create vacuum and overcome the differential pressure created by the filter element. The result is negative pressure inside the oil reservoir/crankcase. With the help of valves or a VFD (Variable Frequency Drive), the negative pressure is controlled. OPERATION Pressure Differential & Efficiency: Pressure differential is a very significant factor in designing OME’s for lube oil applications. This value varies throughout the life of the OME, and will have an effect on maintaining the pressure inside the reservoir/crankcase. The customer requirement determines the size of the internal filter element, connection sizes and vessel. Most Solberg OME filter elements are rated 99+% for 0.3 micron oil mist which typically results in low outlet oil concentrations. The elements are sized properly, so the saturated pressure differential is as low as possible. The increase in pressure differential from the clean initial reading to the saturated reading should also be kept to a minimum. Differential pressure increases as the filter element saturates and reaches equilibrium after a certain time period (usually 48-72 hours). Also, over the element life span, it becomes dirty and contaminated with particulate from the oil reservoir/crankcase. This causes an increase in differential pressure, Drain Port: All the oil mist eliminators used to eliminate visible emissions are equipped with a drain port (Item 4 on schematic) so coalesced oil can be returned to the lube oil reservoir, crankcase or waste receptacle. The drain line is typically supplied by the operator/end-user. The filter vessels are typically installed vertically; thus the oil uses the force of gravity to drain. The drain port and installed line must be free of any kinks, obstructions and debris. Any of these occurrences can cause oil to collect in the line and migrate into the vessel resulting in oil bypass out into the atmosphere.

2

6

3

5

4 1

Solberg Static Oil Mist Eliminator (CV Series) Schematic Solberg Oil Mist Eliminators

2

ITEM 0772 Temperature: Since the OME is designed to capture and coalesce oil mist emissions, temperature is an important factor. Solberg recommends a maximum air/gas stream temperature of 180 degrees F. Oil tends to stay vaporized at higher temperatures, and this can lead to oil carryover past the filter element. Mounting height above the mist source and/or a heat exchanger are two methods to limit the effect of temperature. Applications: 1.

The Solberg OME is intended for separation of only oil mist. It is neither an inlet air filter nor a dust collector. It should be not be used to capture solid particulate.

2.

It is also important to note that certain applications such as metal shearing may result in a build-up of heavy solid particulate on the OME’s high efficiency filter element. In these cases, the results may be excessive differential pressure, limited life span and resulting oil mist emissions.

3.

It is important that an OME is properly sized for each application. The air flow is a critical parameter. Air flow from the oil reservoir or crankcase determines the differential pressure contributed by the filter element(s) and the type/size of the vacuum source for a VAE.

4.

Questions regarding the sizing of the units can be directed to the Solberg Oil Mist Solutions team at [email protected] or by visiting the Solberg Oil Mist Solutions website at http://www.oilmistsolutions.com

INSTALLATION 1.

Inspection: Inspect the shipping box or the skid carefully for damage. If everything is intact, open and check the unit for damage. Care should be taken to check the blower thoroughly if it is a VAE unit. If any damage has occurred, please notify the shipping company. All units are inspected for quality before shipment

2.

Orientation: Solberg OME’s are installed vertically. Please refer to the manufacturer’s sales drawings for information as this varies from unit to unit. The drawings will show the correct inlet and outlet markings for correct direction of flow. (Items 1 and 3 respectively on the schematic) Also, adequate clearance should be given for the drain line as well as the removal of top cover and filter element.

3.

Location: The unit is typically mounted as close as possible to the source of the oil mist emissions. This will minimize the pressure differential contributed by the piping. However, the temperature of the air/gas stream is important. Mounting height can determine the temperature of oil mist when it reaches the OME.

4.

Vessel Connections: The OME’s typically are equipped with a male pipe, female coupling or a flange on the inlet side of the vessel. This must be secured properly to the reservoir/crankcase connection. If ducting is used, Solberg recommends that the length and number of bends are minimized to reduce pressure differential across the pipe span.

5.

Drain Line Connections: Either rigid or flexible hose are acceptable for the drain connection. Solberg recommends that the line is vacuum rated to avoid collapse under negative pressure. Sometimes, larger units are equipped with two drain connections. The two drain lines should never be connected or manifolded together.

6.

First 24-72 Hours: As the coalescing filter element becomes saturated with lube oil, the pressure differential will increase and then stabilize.

7.

Filter Element Life Span: As the coalescing filter element ages, it will capture particulate that is present in the lube oil. This will increase the differential pressure over time. Periodically monitor your reservoir or crankcase pressure level to ensure the proper level is maintained. This can be done with a digital or analog gauge. (Item 5 on the schematic) When pressure

Solberg Oil Mist Eliminators

3

ITEM 0772 levels in the reservoir or crankcase reach the maximum tolerated levels, the internal element should be replaced.

MAINTENANCE The maintenance of the mist eliminator requires an inspection of the filter element differential pressure at regular intervals. This is easily accomplished with a digital or analog gauge. The replacement interval is a function of the solid contaminants in the lube oil and subsequent mist emissions. When only clean oil mist is being fed to the OME, it will function for an extended period of time (usually a year or more) without maintenance of any kind. In applications where excessive solid contaminant or high humidity is present in the air stream, frequent filter replacements may be necessary. Filter Element Replacement 1.

Never run the unit with the vessel cover removed. With smaller units, the v-band style clamp (Item 6 on schematic) will need to be removed in order to access the filter.

2.

Remove the bolt which holds the element in position.

3.

Lift out the element(s). Care should be taken when removing them as the saturated weight may exceed normal handling limits. Large elements will have lifting handles to facilitate removal.

4.

IMPORTANT: The used elements can’t be used again. They should be disposed immediately after removal. Since the elements are saturated with used oil, please dispose in accordance with local regulations. They can’t be cleaned, and no attempt should be made to clean or reuse these cartridges.

5.

Check the filter vessel cover’s o-ring or gasket for damage and replace if necessary. Also, check the sealing butterfly gasket for damage, which is located on the bottom of some vessel sizes. Replace if necessary. Ensure that gaskets adhered to the replacement element are intact. These are critical for proper sealing and performance

6.

Center the element seals seals positively to the canister and top plate of the element. Tighten the bolt to secure the cartridge. Close the top cover by clamping the v-band or by tightening the bolts.

7.

Solberg recommends a maintenance plan for monitoring pressure differential readings and pressure/vacuum readings in the reservoir/crankcase.

8.

Line Inspection: Periodically, check hoses and drain lines for any possible leaks. Solberg suggests a planned maintenance program to ensure optimum performance

9.

Cleaning: Do not use any hydrocarbon based solvents or toxic solvents for cleaning. Vapors discharged from any residues will cause health hazards. Detergents or soaps may be used in cleaning the vessel.

The remaining components require no regular maintenance and only need to be replaced in the case of damage. When ordering replacement parts always reference the sales drawing number or the full model number of the OME on your request. For parts and service information, please contact Solberg team at +1-630-616-4400 (USA inquiries) or +1-630-616-4900 (International inquiries); or by visiting www.solbergmfg.com or www.oilmistsolutions.com to email our Customer Service Representatives.

Solberg Oil Mist Eliminators

4

ITEM 0772

ITEM 0800 ...world leaders in heat transfer technology

OPERATING INSTRUCTIONS BASCO TYPE “500” EXCHANGERS INSTALLATION Except when the hot fluid is dirty or is prone to fouling, it is preferable to pass the cooling medium through the tubes and the hot medium through the shell. Since the tubes can be mechanically cleaned it is sometimes advantageous to pass the hot dirty fluid through the tubes. When installing a single pass unit the shell inlet must be at the same end of the exchanger as the tubeside outlet (counter current flow). When the BASCO Type “500” is used with steam as the heating medium, the steam must be in the shell. Either or both shell connections may be used as steam inlets. Water to be flowing prior to injection of steam to avoid differential expansion. OPERATIONS At start up or after maintenance inspection, both shell and tubeside should be carefully vented and full of liquid. Improper venting and fouling are the most common causes of heat exchanger malfunction. To obtain maximum performance the following precautions should be taken: 1. Make sure all other equipment in the fluid ciruits are functioning properly. 2. Maintain rated flow of both fluids but be sure flow rates are not excessive. Frequently, tube failures can be directly traced to excessive fluid flow, causing tube erosion and corrosion. In the case of heavy oils high flow rates can reduce cooler efficiency. 3. A periodic venting program should be followed if air or vapor tends to accumulate in the system. 4. Observe a regular maintenance program. INSPECTION A periodic inspection and maintenance program should be followed with any heat exchanger. To ensure continuous satisfactory performance of your Type “500” exchanger the following steps should be taken. 1. Inspect filters in system and replace or clean as required. 2. Remove bonnets from heat exchanger and inspect the zinc pencils for erosion or oxide deposits. Scrape to bright surface and replace if more than half corroded away. 3. Carefully examine tubes for scale and clean if necessary. After cleaning, examine for erosion or corrosion. CLEANING The interior surfaces of the tubes can be cleaned in several ways. Many deposits can be removed by flushing a high velocity stream of water through them. For more stubborn deposits, wire brushes or rods can be used. If the special air or water gun is available rubber plugs can be forced through the tubes. Both shell and tubeside can be cleaned chemically by circulating cleaning solutions through the exchanger. For most deposits a mild oakite solution is satisfactory. Circulate the cleaning solution until exchanger is clean. Be sure to wash out all chemicals thoroughly with clean water before returning the exchanger to service.

API Basco

2777 Walden Avenue Buffalo, New York 14225 Toll Free - 877-API-HEAT Fax (716)684-2129 [email protected] www.apiheattransfer.com

ITEM 0800

Operating Instructions Edition 06/2006

Temperature transmitter SITRANS TH100 for sensor head installation 7NG3211-0*N00

sitrans Siemens Aktiengesellschaft Automation and Drives Process Instrumentation and Analytics 76181 KARLSRUHE GERMANY A5E00331168-01

A5E00331168D-01

GN: 30380_TH100

www.siemens.com/processinstrumentation

ITEM 1110, 1140, 1190, 1270, 1280, 1290

SITRANS TH100 7NG3211--0*N00 Edition 06/2006

Temperature transmitter for sensor head installation Operating instructions

www.siemens.com/sitranst

SITRANS TH100 A5E00331168--01

1

ITEM 1110, 1140, 1190, 1270, 1280, 1290 Safety information This manual contains instructions which must be complied with for the sake of your personal safety and also to prevent damage to property. The information concerning your personal safety is indicated with a warning triangle; information solely concerning damage to property is given without a warning triangle. Depending on the level of danger, the warnings are given in decreasing order, as follows:

!

Danger means that death or severe injury will result if the corresponding precautions are not taken. Warning

!

means that death or severe injury may result if the corresponding precautions are not taken. Caution with a warning triangle means that slight injury may result if the corresponding precautions are not taken.

!

Caution without a warning triangle means that damage to property may result if the corresponding precautions are not taken. Notice means that an undesirable event or condition may result if the corresponding note is not observed. If more than one level of danger applies, warnings for the highest level will always be given. If a warning against personal injury is given with a warning triangle, it may contain an additional warning against damage to property.

Qualified personnel This device/system may only be installed and operated together with this document. Commissioning and operation of devices/systems are to be carried out only by qualified personnel. Qualified personnel is defined within the context of the safety information contained in this document as persons who have been authorized to operate, ground or mark devices, systems and electrical circuits in accordance with accepted technical safety standards. Intended use Observe the following: Warning The device may only be used in the cases prescribed in the catalog and in the technical description and only in conjunction with third-party devices and components recommended or approved by Siemens. Proper shipping, storage, installation, operation and maintenance of the product are essential for ensuring correct and safe operation. Trademarks

!

All names marked with the symbol ® are registered trademarks of Siemens AG. Other names in this document may be trademarks, whose use by a third party for their own purposes may impinge on the rights of the owner.

Copyright Siemens AG All rights reserved. The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by the granting of patents or registration of a utility model or design, are reserved.

Exclusion of liability We have checked to ensure that the information contained in this document corresponds to the characteristics of the actual hardware and software. Nevertheless, we cannot assume responsibility for any deviations that may arise. The information contained in this document is checked regularly for errors. Necessary corrections made to the text appear in later editions.

Siemens AG Automation and Drives, Postfach 4848, D--90327 Nürnberg

Siemens AG Technical changes may be made without prior notice.

Siemens corporation

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A5E00331168

SITRANS TH100 A5E00331168--01

Operating instructions

Table of contents

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ITEM 1110, 1140, 1190, 1270, 1280, 1290

1 1.1 1.2 1.3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 5 5 5

2 2.1 2.2 2.3 2.4

General safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Correct usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laws and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 7 7 7 7

3 3.1 3.2 3.3 3.4

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structure of the type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How It works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 9 9 9 10

4 4.1 4.2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation in the connection head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation on DIN rail and G rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 13 14

5 5.1 5.2 5.3

Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General connection notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection in hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 15 16 17

6

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

7 7.1 7.2 7.3 7.4 7.5 7.6

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output current in case of error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wire break monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short circuit monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type of characteristic curve (rising or falling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 21 21 21 21 21 21

8

Operating with PC and modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

9

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

10

Ordering data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

11

Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

13

Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SITRANS TH100 A5E00331168--01

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SITRANS TH100 A5E00331168--01

Operating instructions

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1

Introduction

1.1

Purpose of this documentation

This programming manual contains all the information you need for commissioning and using the transmitter. It is aimed at persons who install the device mechanically, connect it electrically, parameterize and commission it, as well as at service and maintenance engineers.

1.2

History

This history establishes the correlation between the current documentation and the valid firmware of the device. The documentation of this edition is applicable for the following firmware: Edition

Firmware identifier on type plate

System integration

Installation path for PDM

01 06/2006

FW: 01.01.00

TH100: SIPROM T V1.07

TH100: not relevant

The most important changes in the documentation when compared with the respective previous edition are given in the following table. Edition

Remark

01 06/2006

First edition

1.3

Additional information

Information The contents of this programming manual shall not become part of or modify any prior or existing agreement, commitment or legal relationship. All obligations on the part of Siemens AG are contained in the respective sales contract, which also contains the complete and solely applicable warranty conditions. Any statements contained in the programming manual do not create new warranties or modify the existing warranty. The content reflects the technical status at the time of printing. We reserve the right to make technical changes in the course of further development.

SITRANS TH100 A5E00331168--01

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Regional offices

Operating instructions

ITEM 1110, 1140, 1190, 1270, 1280, 1290

If you need more information or have particular problems which are not covered sufficiently by this programming manual, contact your local Siemens regional office. You will find your local Siemens regional office on the Internet at: www.siemens.com/processinstrumentation/contacts Click on “Contact“ and select your closest city/town. Product information on the Internet The programming manual is a constituent part of the CD “sitrans t -- temperature transmitters”, order number A5E00364512 and are available on the homepage at: www.siemens.com/sitranst Click on “More Info” and then “--> Instructions and Manuals”. On the CD, you will find an extract of the catalog FI 01 “Field Instruments for Process Automation” with the current ordering data. The entire FI 01 catalog is also available at the above web address.

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SITRANS TH100 A5E00331168--01

Operating instructions

2

General safety notes

2.1

General instructions

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This device left the factory free from safety problems. In order to maintain this status and to ensure safe operation of the device, please observe the notes and warnings contained in this programming manual.

2.2

Correct usage

The device may only be used for the purposes specified in this programming manual. Insofar as they are not expressly stated in this programming manual, all changes to the device are the sole responsibility of the user.

2.3

Laws and directives

The regulations of the test certification valid in your country are to be observed.

!

WARNING This device may only be installed and operated once qualified personnel have ensured that appropriate power supplies are in use. These power supplies must guarantee that no hazardous voltage can reach the device, whether during normal operation or in the event of a malfunction of the system or one of its parts.

2.4

Qualified personnel

”Qualified personnel” means those who are familiar with the installation, mounting, commissioning and operation of the product. They must have the following, appropriate qualifications for their activities: D Training or instruction/authorization in operating and maintaining devices/systems according to the safety regulations for electrical circuits, high pressures and aggressive media. D Training and instruction in maintenance and use of adequate safety equipment according to safety regulations. D For devices with explosion protection: Training or instruction/authorization in carrying out work on electrical circuits for hazardous systems. D First aid training

.

NOTE The general regulations for operation of the system must be followed during operation and maintenance of the transmitter. The content reflects the technical status at the time of printing. We reserve the right to make technical changes in the course of further development.

SITRANS TH100 A5E00331168--01

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Operating instructions

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SITRANS TH100 A5E00331168--01

Operating instructions

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3

Description

3.1

Field of application

The SITRANS TH100 transmitter is suitable for measuring Pt100 resistance thermometers in all industry sectors. Its compact size means that it can be installed in connection head of type B (DIN 43729) or larger. The output signal is an output current of 4 to 20 mA that is proportional to the temperature. Parameters are assigned to the device using a PC and the SIPROM T parameterization software together with the modem for SITRANS TH100/TH200. If you already have a “modem for SITRANS TK” (order number 7NG3190--6KB), you can use it for the parameterization of the SITRANS TH100. The version of the transmitter with the “protection type ”intrinsically safe” can be installed in hazardous areas. The devices are compliant with Directive 94/9/EC (ATEX) and the FM regulations.

3.2 D D D D

Product features

Transmitter with two--wire technology Installation in connection heads of type B (DIN 43729) or larger, or on a DIN rail Programmable: sensor activation, measuring range and many other variables can be programmed Intrinsically safe version for use in hazardous areas

3.3

Structure of the type plate

The type plate is located on the housing and carries the order number and other important product information.

(2)

(1)

(7) (1) (2) (3) (4)

Figure 1

(6)

(3)

(5)

(4)

Manufacturer Product name Order number Pay attention to the operating instructions

(5) (6) (7)

Firmware revision Hardware revision Place of manufacture

Structure of the type plate

SITRANS TH100 A5E00331168--01

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3.4

How It works

Operating instructions

ITEM 1110, 1140, 1190, 1270, 1280, 1290

The measurement signal sent by a Pt100 resistance thermometer (two-wire, three-wire, four-wire connection) is amplified in the input stage. The voltage proportional to the input variable is then converted to digital signals by a multiplexer in an analog-to-digital converter. In the microcontroller, they are recalculated according to the sensor characteristic curve and other factors (measuring range, damping, etc.). After being prepared in this way, the signal is converted in a digital-to-analog converter into an output current of 4 to 20 mA. The input circuit and the output circuit are both protected from electromagnetic interference by EMC filters.

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SITRANS TH100 A5E00331168--01

Operating instructions

7NG3211--0*N00

ITEM 1110, 1140, 1190, 1270, 1280, 1290

Uref

Ic 6 Pt100

5 4

A/D EMC_1 MUX μC

3 D/A Uref U

I

+1 EMC_2

4 ... 20 mA

Uaux, Iout --2

Input: Pt100

Pt100 resistance thermometer

EMC_1

Input stage with protective components

Ic

Constant-current source

MUX

Multiplexer

A/D

Analog-to-digital converter

Output: D/A

Digital-to-analog converter

U/I

Voltage transformer, current transformer, constant-voltage source and reference-voltage source

EMC_2

Output stage with protective components

Uaux

Auxiliary power

Iout

Output current

Microcontroller: μC

Computing functions and saving of all parameters

Figure 2 Function diagram of the SITRANS TH100

SITRANS TH100 A5E00331168--01

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SITRANS TH100 A5E00331168--01

Operating instructions

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4

Installation

4.1

Installation in the connection head CAUTION The following must be observed before the head--mounted transmitter is installed: - The SITRANS TH100 transmitter needs to be installed in a suitable housing. - The degree of protection and housing material need to be adapted to meet the relevant requirements. - The ambient conditions specified in the technical data (chapter 9, page 25) need to be adhered to.

Springs and screws for securing the transmitter are included with the device. The SITRANS TH100 can be secured either in the base of the connection head or in the raised cover of the connection head.

Transmitter

Figure 3 Securing the transmitter in the connection head cover

Transmitter Figure 4 Securing the transmitter in the connection head base

!

WARNING When installing the device in hazardous areas (Zone 1), the housing must have at least IP54 degree of protection according to the IEC 60529.

SITRANS TH100 A5E00331168--01

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4.2

Operating instructions

Installation on DIN rail and G rail

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The transmitters can be secured either on a 35 mm DIN rail (DIN EN50022) or a 32 mm G rail (DIN EN50035). The DIN rail adapter required for installation can be ordered as an accessory under the order number 7NG3092--8KA. The ambient conditions in the technical data (chapter 9, page 25) need to be adhered to for rail installation.

Figure 5 Securing the transmitter on the DIN rail

Figure 6 Securing the transmitter on the G rail

(1.99) (1.30)

(2.35)

(0.55)

Figure 7 DIN rail dimensions (7NG3092--8KA)

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SITRANS TH100 A5E00331168--01

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Electrical connection

5.1

General connection notes

!

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WARNING Electrical connection in hazardous areas The national directives and laws for hazardous areas valid in your country must be observed for electrical connection. In Germany these are, for example: - the “working reliability regulation” - the directive for “Installation of electrical systems in hazardous areas”, DIN EN60079--14 (previously VDE 0165, T1) - the EC type examination certificate Where power supply is required, we recommend checking the power supply to ensure that it corresponds with that on the type plate and with the test certification valid for your country.

D Connection of the sensor, see Figure 8 D Power supply Connect the wires for the power supply to terminals ‘’1(+)’’ and ‘’2(--)’’, as shown in Figure 8, ensuring polarity is correct (device is reverse polarity protected). . D Connection cable Max. cable cross section 2.5 mm2 Lay signal cables separately from cables with voltages > 60 V Use cable with twisted wires. Avoid getting too close to large electrical systems or use shielded cables.

SITRANS TH100 A5E00331168--01

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Operating instructions

Three--wire connection 1)

Two--wire connection (programmable line resistance)

Uaux +

Four--wire connection 1)

--

Connection of power supply (Uaux)

Terminal no. 5 does not have any function in the device version with three-wire connection and must not be connected. If the three-wire connection is selected, wires of the unused fourth sensor cable should be isolated electrically using insulation tape when using RTDs in the device version with four--wire connection.

Figure 8 Terminal plate for Pt100 resistance thermometer and power supply

5.2

Connection in hazardous areas

Zones 0 and 1 The transmitter is only allowed to be connected to devices that are certified as intrinsically safe in accordance with the EC type examination certificate. The parameters and limit values listed there must be complied with. Zone 2 in protection type “nL” -- Limited energy The transmitter is only allowed to be connected to the following devices: D Devices that are certified as intrinsically safe in category 1 or 2. D “nL”--certified devices (limited energy) in category 3. The maximum permitted input voltage is Ui = DC 30 V. The relevant permitted values for external capacitance and inductance must be adhered to. Zone 2 in protection type “nA” -- Non-sparking The conditions for installers applicable to this protection type must be adhered to. The maximum permitted input voltage is U = DC 35 V.

16

SITRANS TH100 A5E00331168--01

Operating instructions

Connection assignment

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(0.82)

5.3

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(1.73) Internal diameter of center hole 6.3 (0.25) Fixing screw M4x25

(1.3)

1(+) and 2 (--)

Power supply Uaux, output current Iout

3, 4, 5 and 6

Sensor (Pt100) (connections see chapter 5 Electrical Connection, page 15)

Figure 9 Connection assignment

SITRANS TH100 A5E00331168--01

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6

Commissioning

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The operating data of the transmitter have to be set in accordance with the requirements of the measurement task at hand. Ensure that the operating data corresponds to the data on the type plate. When the transmitter is installed in the connection head, the connection head cover needs to be closed after the sensor and the power supply are connected. When you switch the power supply on, the transmitter begins operation after a response time of about 10 seconds.

SITRANS TH100 A5E00331168--01

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7

Functions

7.1

General information

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You can use the SIPROM T parameterization software to carry out the following functions for the SITRANS TH100: -

Setting the upper/lower overrange of the output current Storing data for the identification of measuring points Setting the sensor activation (two-wire, three-wire, four-wire connection) Set sensor offset, measuring range, unit and damping Setting the output current in case of error (e.g. ensor failure)

7.2

Output current in case of error

Sensor wires and transmitter electronics are continuously monitored. In the event of a fault, the output current is set to fault current. The fault current can be freely selected within the preset limits of the current control range (3.6 mA to 23 mA).

7.3

Wire break monitoring

All sensor wires are permanently monitored for wire breaks. The programmed fault current (3.6 mA to 23 mA) is output in case of error. The wire break monitoring cannot be switched off.

7.4

Short circuit monitoring

The sensor connected to the transmitter is permanently monitored for sensor short circuits. A sensor short circuit has occurred if the measured resistance for the connected Pt100 is less than 10 Ohm. The programmed fault current (3.6 mA to 23 mA) is output in the event of a sensor short circuit. Sensor short circuit monitoring cannot be switched off. The short circuit limit is fixed at 10 Ohm and, likewise, cannot be changed.

7.5

Line compensation

Line compensation is required when measuring the Pt100 in two--wire input. The trimming is performed by numerical preset of the measured line resistance (combined total of sending and return conductors).

7.6

Type of characteristic curve (rising or falling)

The type of the characteristic curve at the 4 to 20 mA analog output can be selected (rising or falling). The characteristic curve type is defined as follows by setting the parameters for the start of scale value and full scale value: D Rising characteristic: Full scale value is greater than start of scale value D Falling characteristic: Full scale value is smaller than start of scale value SITRANS TH100 A5E00331168--01

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Operating with PC and modem

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NOTICE Parameters may only be assigned to the SITRANS TH100 when “offline” using the modem for SITRANS TH100/TH200 and the SIPROM T parameterization software. Any 4 to 20 mA current loop connected to the transmitter needs to be completely disconnected before the parameterization process.

The transmitter can be configured using a PC and the SIPROM T parameterization software together with the modem for SITRANS TH100/TH200. To do so, simply connect the transmitter to the PC via the modem. The power required by the transmitter is provided by: - the USB port on the PC (in the case of a USB modem) - an external power adapter (in the case of an RS232 modem)

SITRANS TH100 A5E00331168--01

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ITEM 1110, 1140, 1190, 1270, 1280, 1290

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Operating instructions

Connector power adapter 6 V COM1 COM2

USB cable (included in the scope of delivery)

+

COM1

COM 3

COM2

COM 4

COM 3

USB

COM 4 USB

PC

POWER Comm. Error

+ (positive) (red)

(included in the scope of delivery)

PC

Modem for SITRANS TH100/TH200 via USB 7NG3092--8KU

-- (negative) (black)

--

Figure 10Parameterization of SITRANS TH100 via the USB modem

POWER Comm. Error

+ (positive) (red)

Modem for SITRANS TH100/TH200 via RS232 7NG3092--8KM

-- (negative) (black)

+

--

Figure 11Parameterization of SITRANS TH100 via the RS232 modem

For detailed information on the parameterization of the transmitter, please refer to the operating instructions for the following products: - Modem for SITRANS TH100/TH200 and the SIPROM T parameterization software (order number: 7NG3092--8KM and 7NG3092--8KU, respectively) - CD “sitrans t -- temperature transmitters”, order number A5E00364512

.

24

NOTE If you already have a “modem for SITRANS TK” (order number 7NG3190--6KB), you can use it for the parameterization of the SITRANS TH100. A description of how to connect the SITRANS TH 100 to the “modem for SITRANS TK” is given in the operating instructions for the modem.

SITRANS TH100 A5E00331168--01

Operating instructions

9

Technical data

Input Resistance thermometer Measured variable Input type Characteristic curve Type of connection Resolution Measuring accuracy Measuring span < 250_C (450_F) Measuring span > 250_C (450_F) Repeatability Measured current Measuring cycle Measuring range Measuring span Unit Offset Line resistance Noise suppression Output Output signal Power supply Max. load Overrange Error signal (in case of sensor failure) Damping time Protection Resolution Accuracy at 23_C Temperature influence Influence of power supply Influence of load Long--term drift

Ambient conditions Range of ambient temperature Range of storage temperature Relative humidity Electromagnetic compatibility Error due to EMC influences (when installed in metallic connection head) ESD according to EN 61000--4--2 SITRANS TH100 A5E00331168--01

7NG3211--0*N00

ITEM 1110, 1140, 1190, 1270, 1280, 1290

Temperature Pt100 as per IEC 60751 Linear to temperature Two--wire, three--wire and four--wire connection 14 bit < 0,25_C (0.45_F) < 0,1% of the measuring span < 0,1_C (0.18_F) approx. 0.4 mA < 0,7 s --200 ... 850_C (--328 ... 1562_F) 25 ... 1050_C (77 ... 1922_F) _C or _F Programmable: --100 ... +100_C (--180 ... 180_F) Max. 20 Ω (combined total of sending and return conductors) 50 and 60 Hz 4 ... 20 mA, two--wire 8,5 ... 36 V DC (30 V for Ex) (Uaux --8.5 V)/0.023 A 3,6 mA ... 23 mA infinitely adjustable (default range: 3,84 mA ... 20,50 mA) 3,6 mA to 23 mA, infinitely adjustable (default value: 3,6 mA or 22.8 mA) 0 ... 30 s Against reverse polarity 12 bit < 0,1% of the measuring span Max. 0.1%/10_C (0.1%/18_F) < 0,01% of the measuring span/V <0,025% of the maximum measuring span/100 Ω <0,025% of the maximum measuring span in the first month <0,035% of the maximum measuring span after one year <0,05% of the maximum measuring span after five years --40 ... +85_C (--40 ... +185_F) --40 ... +85_C (--40 ... +185_F) ≤ 98%, condensing According to EN 61326--2 and NAMUR NE21

< 0,10% of the measuring span

25

7NG3211--0*N00

ITEM 1110, 1140, 1190, 1270, 1280, 1290

RF irradiation according to EN61000--4--3 Burst according to EN 61000--4--4 RF energizing according to EN 61000--4--6

Operating instructions

< 1,0% of the measuring span < 0,2% of the measuring span < 0,3% of the measuring span

Greater measuring errors may occur if the transmitter is installed on a DIN rail in an environment with severe interference. The applicable ESD directives must be adhered to.

Construction Weight 50 g Dimensions See Figure 12, page 29 Material Plastic, potted Cross section of the connecting Max. 2.5 mm2 (AWG 13) cables Degree of protection According to IEC 60529 Housing IP40 Terminals IP00 Certificates Operation in the territory of EC member states EC type examination certificate PTB 05 ATEX 2049X Protection type “intrinsic safety” II 1 G EEx ia IIC T6/T4 II 2 (1) G EEx ia/ib IIC T6/T4 according to ATEX Protection type “non--sparking and power--limited resources” II 3G EEx nAL IIC T6/T4 Refer to the EC--type examination certificate for detailed electrical specifications and conditions for operating in hazardous areas. Operation in the USA and in Canada FM approval PID 3024169, applies to USA and Canada (cFMus) Protection types IS Cl I, II, III, Div 1, GP ABCDEFG T4/T5/T6 IS Cl I, ZN 0.1 AEx ia IIC T4/T5/T6 NI Cl I, II, III, Div 2, GP ABCDFG T4/T5/T6 Cl I, ZN 2, GP IIC T4/T5/T6 Refer to the FM Certificate of Compliance no. 3024169 and the corresponding Control Drawing C10145--A4--X2--33 for electrical specifications, operating conditions and installation notes for operating in hazardous areas.

26

SITRANS TH100 A5E00331168--01

Operating instructions

10

7NG3211--0*N00

Ordering data

ITEM 1110, 1140, 1190, 1270, 1280, 1290

Designation

Order number

Temperature transmitter SITRANS TH100 for installation in connection heads of type B (DIN 43729), two-wire technology 4 to 20 mA, programmable, without electrical isolation without explosion protection

7NG3211--0NN00

with ”protection typ -intrinsically safe” explosion protection -- EEx ia (ATEX) -- FM (cFMUS)

7NG3211--0AN00 7NG3211--0BN00

Modem for SITRANS TH100 and TH200 including the SIPROM T parameterization software with USB connection with RS232 connection

7NG3092--8KU 7NG3092--8KM

CD “sitrans t -- temperature transmitters” containing documentation in German/English/French/Spanish/Italian/Portuguese and the SIPROM T parameterization software

A5E00364512

DIN rail adapter for sensor head (packing unit = 5 pcs.)

7NG3092--8KA

Additional specifications

Abbreviated specification

Complete order no. with “--Z”, add abbreviated specification Adjust operational data as desired (Operational data should be described in plain text)

Y01

with test report (five measurement points)

C11

Factory setting -

Pt100 Measuring range In case of sensor failure Sensor offset Damping

in three-wire connection 0 ... 100_C (32 ... 212 _F) 22.8 mA 0_C (0_F) 0.0 s

You can obtain all instructions, catalogs and certificates for SITRANS T from the following website: www.siemens.com/sitranst

SITRANS TH100 A5E00331168--01

27

7NG3211--0*N00

Operating instructions

ITEM 1110, 1140, 1190, 1270, 1280, 1290

28

SITRANS TH100 A5E00331168--01

Operating instructions

Dimensional drawing

ITEM 1110, 1140, 1190, 1270, 1280, 1290

(0.82)

11

7NG3211--0*N00

(1.73) Internal diameter of center hole 6.3 (0.25) Fixing screw M4x25

(1.3)

1(+) and 2 (--)

Power supply Uaux, output current Iout

3, 4, 5 and 6

Sensor (Pt100) (connections see chapter 5 Electrical Connection, page 15)

Figure 12SITRANS TH100, dimensions in mm (inch)

SITRANS TH100 A5E00331168--01

29

7NG3211--0*N00

Operating instructions

ITEM 1110, 1140, 1190, 1270, 1280, 1290

30

SITRANS TH100 A5E00331168--01

Operating instructions

12

Maintenance

7NG3211--0*N00

ITEM 1110, 1140, 1190, 1270, 1280, 1290

The transmitter is maintenance--free.

13

Certificates

You can find the certificates on the “sitrans t -- temperature transmitters” CD, which can be ordered separately, order number A5E00364512; and on the Internet at www.siemens.com/processinstrumentation/certificates.

SITRANS TH100 A5E00331168--01

31

7NG3211--0*N00

Operating instructions

ITEM 1110, 1140, 1190, 1270, 1280, 1290

32

SITRANS TH100 A5E00331168--01

Non-hazardous location

Hazardous location

Cl I, DIV 1, GP A,B,C,D Cl II, DIV 1, GP E,F,G Cl III, DIV 1 Cl I, ZN 0,1 GP IIC

(+) see note 1

(-)

see note 2

T6 @ Ta = -40°C ... +55°C T5 @ Ta = -40°C ... +70°C T4 @ Ta = -40°C ... +85°C Temperature Transmitter TH100 Connection head see note 3

+

1

_

For Intrinsic Safety application use approved associated apparatus or barrier

2

3

Entity parameters: Voc or Vt 30 VDC Isc or It 100 mA Po or Pt 0.75 W Ca > Sum (Ci) + Ccable La > Sum (Li) + Lcable

6 4

5

PE

Entity parameters: Terminals 1(+), 2(-): Ui, Vmax = 30 VDC Ii, Imax = 100 mA Pi, Pmax = 0.75 W Li = 106 mH Ci = 13 nF Terminals 3, 4, 5, 6: Uo, Voc, Vt = 9.6 VDC Io, Isc, It = 7.6 mA Po, Pt = 12.5 mW Lo, La = 290 mH Co, Ca = 3.5 mF

ITEM 1110, 1140, 1190, 1270, 1280, 1290 Notes: 1. The nonintrinsically safe terminals (power rail) must not be connected to any device which uses or generates more than 250 Vrms or d.c. unless if has been determinated that the voltage has been adequately isolated. 2. The installation must meet the requirements of the National Electrical Code / Canadian Electrical Code 3. The SITRANS TH100 must be installed in a housing, e.g. Type B connection head

This document contains safety-relevant information based on technical standards (i.e. Norms, internal standards) or certifications that the apparatus is subject to and may only be altered with the approval of the norm expert (NFM) Scale:

Tol.:

Fab-Gr.:

SAP No.:

Engineering Obligation for Delivery Change No.: Revision:

Date:

1

Date of change:

Modify by: Change for:

FK:

14.03.2006

Product:

Edited by:

Pižeta

Temperature Transmitter SITRANS TH100

Approved by:

Sudeta

Type 7NG3211-0B***

Sheet

Control Drawing for DIV 1, Zone 0,1

of

A & D PD

Siemens d.d.

Title:

Document No.:

1 2

Doc. Type:

C10145-A3-X2-33

Hazardous location

Non-hazardous location

Cl I, Zone 2, GP IIC Cl I, DIV 2, GP A, B, C, D Cl II, DIV 2, GP F, G Cl III, DIV 2

(+) see note 4

(-)

see note 3

T6 @ Ta = -40°C ... +55°C T5 @ Ta = -40°C ... +70°C T4 @ Ta = -40°C ... +85°C Temperature Transmitter TH100 Connection head see note 5

+

1

_

Parameters for Zone 2 Limited Energy Applications and NI Field Wiring Apparatus Concept:

2

3

Uo,V oc, V t 30 VDC Io, Isc, It see note 2 Ca > Sum (Ci) + Ccable La > Sum (Li) + Lcable

6 4

5

Zone 2 Non-Sparking Applications and DIV 2 Applications:

PE

Entity parameters:

V max = 30 VDC Observe note 3!

Terminals 1(+), 2(-): Ui, Vmax = 30 VDC Ii, Imax see note 2 Li = 106 H Ci = 13 nF Terminals 3, 4, 5, 6: Uo, Voc, Vt = 9.6 VDC Io, Isc, It see note 2 Lo, La = 290 mH Co, Ca = 3.5 mF

Functional Ratings: Inormal = 4 ... 20 mA

ITEM 1110, 1140, 1190, 1270, 1280, 1290 Zone 2 and Division 2 Installations (for Current Controlled Circuits): Note 1: The nonincendive field wiring concept allows interconnection of nonincendive field wiring apparatus with associated nonincendive field wiring apparatus not specifically examined in combination. Note 2: For current controlled circuits, the input current (Imax) of the receiving device need not match the output current (It or Isc) of the barrier or associated nonincendive field wiring apparatus source. Note 3: The installation must meet the requirements of the National Electrical Code / Canadian Electrical Code Note 4: The supply terminals must not be connected to any device which uses or generates more than 250 Vrms or d.c. unless adequately isolattion is used. Note 5: The SITRANS TH100 must be installed in a housing, e.g. Type B connection head

This document contains safety-relevant information based on technical standards (i.e. Norms, internal standards) or certifications that the apparatus is subject to and may only be altered with the approval of the norm expert (NFM) Scale:

Tol.:

Fab-Gr.:

SAP No.:

Engineering Obligation for Delivery Change No.:

Date:

Revision:

Edited by:

Pižeta

Approved by:

Sudeta

1

Date of change:

Modify by: Change for:

FK:

14.03.2006

A & D PD

Siemens d.d.

Product:

Title:

Document No.:

Temperature Transmitter SITRANS TH100 Type 7NG3211-0B*** Control Drawing for DIV 2, Zone 2

Sheet

2

of

2 Doc. Type:

C10145-A3-X2-33

ITEM 1110, 1140, 1190, 1270, 1280, 1290

ITEM 1110, 1140, 1190, 1270, 1280, 1290 Operating Instructions Edition 06/2006

Temperature transmitter SITRANS TH100 for sensor head installation 7NG3211-0*N00

sitrans Siemens Aktiengesellschaft Automation and Drives Process Instrumentation and Analytics 76181 KARLSRUHE GERMANY A5E00331168-01

A5E00331168D-01

GN: 30380_TH100

www.siemens.com/processinstrumentation

Operating Instructions Edition 12/2007

SITRANS P, DS III series with HART communication

Operating Instructions

12/2007

ITEM 1120, 1340, 1355

@1PA5E00047092@

Siemens Aktiengesellschaft

A5E00047092

Automation and Drives (A&D) Sensors and Communication Process Sensors 76181 KARLSRUHE GERMANY

A5E00047092-06

A5E00047092D-06

GN: 30060_DuoDrDif

www.siemens.com/processinstrumentation

Pressure transmitter SITRANS P, DS III series with HART communication

sitrans

ITEM 1120, 1340, 1355

ITEM 1120, 1340, 1355

Introduction

1

General safety notes

2

SITRANS

Description

3

Pressure transmitter SITRANS P, DS III series with HART communication

Install

4

Connecting

5

Operation

6

Operating functions through HART

7

Functional safety

8

Commissioning

9

Operating Instructions

7MF4*33

12/2007

A5E00047092-06

Service and maintenance

10

Technical data

11

Dimension drawings

12

Spare parts/accessories

13

Appendix

A

List of abbreviations

B

ITEM 1120, 1340, 1355 Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage Note the following: WARNING This device may only be used for the applications described in the catalog or the technical description and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance.

Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Automation and Drives Postfach 48 48 90327 NÜRNBERG GERMANY

Ordernumber: A5E00047092 Ⓟ 03/2008

Copyright © Siemens AG 2007. Technical data subject to change

ITEM 1120, 1340, 1355

Table of contents 1

2

3

4

Introduction................................................................................................................................................ 9 1.1

Objective of this documentation.....................................................................................................9

1.2

History ............................................................................................................................................9

1.3

Scope of this manual ...................................................................................................................10

1.4

Further information.......................................................................................................................10

General safety notes................................................................................................................................ 11 2.1

General information .....................................................................................................................11

2.2

Correct usage...............................................................................................................................11

2.3

Laws and directives .....................................................................................................................11

2.4

Measures .....................................................................................................................................11

2.5

Qualified Personnel......................................................................................................................13

Description............................................................................................................................................... 15 3.1

System configuration ...................................................................................................................15

3.2

Application range .........................................................................................................................16

3.3

Structure.......................................................................................................................................17

3.4

Structure of the type plate and approval plate .............................................................................18

3.5 3.5.1 3.5.2 3.5.3 3.5.3.1 3.5.3.2 3.5.3.3 3.5.3.4 3.5.3.5 3.5.3.6 3.5.3.7

Functional principle ......................................................................................................................20 Overview of mode of operation ....................................................................................................20 Operation of the electronics .........................................................................................................20 Measuring cell operation..............................................................................................................21 Measuring cell for gauge pressure...............................................................................................22 Measuring cell for differential pressure and flow rate ..................................................................23 Measuring cell for level ................................................................................................................24 Measuring cell for absolute pressure from the differential pressure series .................................25 Measuring cell for absolute pressure from the gauge pressure series........................................26 Measuring cell for gauge pressure, front-flush membrane ..........................................................26 Measuring cell for absolute pressure, front-flush membrane ......................................................27

3.6

Remote seal .................................................................................................................................28

3.7

SIMATIC PDM..............................................................................................................................28

Install ....................................................................................................................................................... 29 4.1

Safety notes for installation..........................................................................................................29

4.2 4.2.1 4.2.2 4.2.3

Installation (except level) .............................................................................................................31 Instructions for installation (except level).....................................................................................31 Installation (except level) .............................................................................................................32 Fastening .....................................................................................................................................32

4.3

"Level" installation ........................................................................................................................34

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

3

ITEM 1120, 1340, 1355 Table of contents

5

6

4.3.1 4.3.2 4.3.3

Instructions for level installation .................................................................................................. 34 Installation for level ..................................................................................................................... 35 Connection of the negative pressure line.................................................................................... 36

4.4 4.4.1 4.4.2

"Remote seal" installation ........................................................................................................... 38 Remote seal installation .............................................................................................................. 38 Installation of the remote seal with the capillary line................................................................... 40

4.5

Turing the measuring cell against housing ................................................................................. 46

4.6

Turning the digital display ........................................................................................................... 47

Connecting .............................................................................................................................................. 49 5.1

Safety notes for connection......................................................................................................... 49

5.2

Connecting the device................................................................................................................. 50

5.3

Connecting the Han plug............................................................................................................. 52

5.4

Connecting the M12 connector ................................................................................................... 52

Operation................................................................................................................................................. 55 6.1

Overview of operation ................................................................................................................. 55

6.2

Safety information for operation.................................................................................................. 56

6.3

Instructions for operation............................................................................................................. 56

6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6

Digital display .............................................................................................................................. 57 Elements of the digital display .................................................................................................... 57 Units display................................................................................................................................ 58 Error display ................................................................................................................................ 59 Mode display ............................................................................................................................... 60 Status display.............................................................................................................................. 60 Overflow range............................................................................................................................ 61

6.5 6.5.1 6.5.2 6.5.3 6.5.3.1 6.5.3.2 6.5.3.3 6.5.4 6.5.5 6.5.5.1 6.5.5.2 6.5.5.3 6.5.5.4 6.5.5.5 6.5.6 6.5.7 6.5.8 6.5.9 6.5.10 6.5.11 6.5.12 6.5.13

Local operation............................................................................................................................ 63 Local control elements ................................................................................................................ 63 Operation using buttons .............................................................................................................. 65 Start of scale value/full scale value............................................................................................. 66 Difference between setting and adjusting ................................................................................... 66 Setting/adjusting the start of scale value .................................................................................... 70 Setting/adjusting the full scale value........................................................................................... 71 Setting/adjusting electrical damping ........................................................................................... 72 Blind start of scale value/full scale value .................................................................................... 73 Difference between setting/adjusting and blind setting/adjusting ............................................... 73 Blind setting of start of scale value ............................................................................................. 75 Blind setting of full scale value .................................................................................................... 76 Blind adjusting of the start of scale value.................................................................................... 76 Blind adjustment of the full scale value....................................................................................... 77 Trimming the zero point .............................................................................................................. 77 Current transmitter ...................................................................................................................... 78 Output current in case of fault ..................................................................................................... 79 buttons and function lock ............................................................................................................ 80 Releasing key lock or function lock............................................................................................. 81 Flow rate measurement (only differential pressure) ................................................................... 82 Measured value display .............................................................................................................. 85 Unit .............................................................................................................................................. 86

7

Operating functions through HART .......................................................................................................... 91

4

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Table of contents

7.1

Operating functions through HART communication ....................................................................91

7.2

Process tag data ..........................................................................................................................92

7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11

Selecting the measuring modes...................................................................................................92 Overview of measuring modes ....................................................................................................92 Measuring mode selector.............................................................................................................93 Variable mapper...........................................................................................................................93 Measuring mode "Pressure" ........................................................................................................94 Customized characteristic curve ..................................................................................................95 Measuring mode "Level" ..............................................................................................................95 Measuring mode "Flow rate"........................................................................................................98 Measuring mode "User" ...............................................................................................................99 Measured value status...............................................................................................................101 Analog output .............................................................................................................................105 Scaling the digital display value .................................................................................................106

7.4

Setting zero point and limit point................................................................................................107

7.5

Blind setting of zero point and limit point ...................................................................................108

7.6

Zero point calibration (position correction).................................................................................108

7.7

Electrical damping......................................................................................................................109

7.8

Fast response mode ..................................................................................................................109

7.9

Current sensor ...........................................................................................................................109

7.10

Fault current ...............................................................................................................................109

7.11

Setting the current limits ............................................................................................................110

7.12

Key lock and write protection .....................................................................................................111

7.13

Measured value display .............................................................................................................112

7.14

Selection of the physical unit .....................................................................................................113

7.15

Bar graph ...................................................................................................................................113

7.16 7.16.1 7.16.2

Sensor calibration ......................................................................................................................113 Sensor trim.................................................................................................................................113 Trimming of the sensor trim point ..............................................................................................114

7.17

Current sensor trim ....................................................................................................................115

7.18

Factory calibration......................................................................................................................116

7.19

Static configuration data ............................................................................................................117

7.20

Flow rate measurement (only differential pressure) ..................................................................118

7.21 7.21.1 7.21.2 7.21.3 7.21.4 7.21.5

Diagnostic functions...................................................................................................................119 Overview ....................................................................................................................................119 Operating hours counter ............................................................................................................119 Calibration timer and service timer ............................................................................................120 Min/max indicator.......................................................................................................................120 Limit modules .............................................................................................................................121

7.22 7.22.1 7.22.2 7.22.3

Simulation ..................................................................................................................................123 Overview of simulation...............................................................................................................123 Simulation as fixed value ...........................................................................................................124 Simulation with a ramp function .................................................................................................124

7.23

Limit monitor...............................................................................................................................125

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

5

ITEM 1120, 1340, 1355 Table of contents

8

9

10

11

Functional safety.................................................................................................................................... 129 8.1 8.1.1 8.1.2

General safety instructions........................................................................................................ 129 Safety-instrumented system...................................................................................................... 129 Safety Integrity Level (SIL)........................................................................................................ 130

8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6

Device-specific safety instructions ............................................................................................ 131 Safety function .......................................................................................................................... 131 Requirements............................................................................................................................ 132 Settings ..................................................................................................................................... 132 Behavior in case of faults .......................................................................................................... 133 Maintenance/Checking.............................................................................................................. 133 Safety characteristics ................................................................................................................ 134

Commissioning ...................................................................................................................................... 135 9.1

Safety notes for commissioning ................................................................................................ 135

9.2

Notes on commissioning ........................................................................................................... 136

9.3

Introduction to commissioning .................................................................................................. 136

9.4 9.4.1 9.4.2

Gauge pressure, absolute pressure from the differential pressure series and absolute pressure from the gauge pressure series ................................................................................. 137 Commissioning for gases.......................................................................................................... 137 Commissioning with steam or liquid.......................................................................................... 138

9.5 9.5.1 9.5.2 9.5.3 9.5.4

Differential pressure and flow rate ............................................................................................ 139 Safety notes for commissioning with differential pressure and flow rate .................................. 139 Commissioning in gaseous environments ................................................................................ 140 Commissioning for liquids ......................................................................................................... 142 Commissioning with vapor ........................................................................................................ 144

Service and maintenance ...................................................................................................................... 147 10.1

Notes for servicing .................................................................................................................... 147

10.2

Display in case of a fault ........................................................................................................... 147

10.3

Modular structure ...................................................................................................................... 148

10.4

Notes for servicing of the remote seal ...................................................................................... 149

Technical data ....................................................................................................................................... 151 11.1

Overview of technical data ........................................................................................................ 151

11.2

Input point.................................................................................................................................. 152

11.3

Output........................................................................................................................................ 157

11.4

Measuring accuracy .................................................................................................................. 158

11.5

Operating conditions ................................................................................................................. 164

11.6

Construction .............................................................................................................................. 167

11.7

Display, keyboard and auxiliary power ..................................................................................... 171 0

Certificates and approvals ........................................................................................................................ 172 11.9 12

6

HART communication ............................................................................................................... 173

Dimension drawings .............................................................................................................................. 175 SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Table of contents

13

A

B

12.1

SITRANS P, DS III series for gauge pressure and absolute pressure from the gauge pressure series...........................................................................................................................175

12.2

SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from the differential pressure series...................................................................................................176

12.3

SITRANS P, DS III series for level.............................................................................................179

12.4 12.4.1 12.4.2 12.4.3 12.4.4 12.4.5

SITRANS P, DS III series (flush mounted) ................................................................................180 Note 3A and EHDG....................................................................................................................181 Connections as per EN and ASME............................................................................................181 F&B and pharma flange .............................................................................................................182 PMC Style ..................................................................................................................................185 Special connections ...................................................................................................................186

Spare parts/accessories ........................................................................................................................ 187 13.1

Order data ..................................................................................................................................187

13.2

Order data for SIMATIC PDM ....................................................................................................190

Appendix................................................................................................................................................ 195 A.1

Certifications ..............................................................................................................................195

A.2

Literature and standards ............................................................................................................195

A.3

SIL Declaration of Conformity ....................................................................................................196

A.4

exida proven in use....................................................................................................................199

A.5

Overview of HART operating structure ......................................................................................203

A.6

Pressure equipment directive ....................................................................................................206

List of abbreviations............................................................................................................................... 209 B.1

Functional safety ........................................................................................................................210

Glossary ................................................................................................................................................ 211 Index...................................................................................................................................................... 215

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

7

ITEM 1120, 1340, 1355 Table of contents

8

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

1

Introduction 1.1

Objective of this documentation This programming manual contains all information that you will require to commission and use the device. It is aimed at persons who install the device mechanically, connect it electrically, parameterize and commission it, as well as at service and maintenance engineers. This document also contains special information and safety notes that you will require when using an SIL-certified device in safety-instrumented systems.

1.2

History This history establishes the correlation between the current documentation and the valid firmware of the device. The documentation of this edition is applicable for the following firmware: Edition

Firmware identification type plate

System integration

Installation path for PDM

08/2007

FW: 11.03.03, FW: 11.03.04, FW: 11.03.05, FW: 11.03.06, FW: 11.03.07

PDM 6.01); Dev. R.3 DD Rev. 2

SITRANS P DSIII.2

1)

up to SP02

The most important changes in the documentation when compared with the respective previous edition are given in the following table. Edition

Remark

06 08/2007

Illustrations of the device have been changed owing to the changes in the device housing. The following chapters have also been changed: • Chapter "Description" > "Functional principle" has new enhanced contents for the "flush mounted diaphragm" topic • Chapter "Description" > "SIMATIC PDM" - NEW • Chapter "Functional safety" - NEW • Chapter "Technical data" has new enhanced contents for the "flush mounted diaphragm" topic • Chapter "Dimension drawings" has new contents for the "flush mounted diaphragm" topic • Chapter "Appendix" has new contents for the "Functional safety" topic

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

9

ITEM 1120, 1340, 1355 Introduction 1.3 Scope of this manual

1.3

Scope of this manual Table 1-1

1.4

"7MF4*33" stands for:

Order number

SITRANS P, DS III series for

7MF4033

Gauge pressure

7MF4133

Gauge pressure, flush mounted diaphragm

7MF4233

Absolute pressure from the gauge pressure series

7MF4333

Absolute pressure from the differential pressure series

7MF4433

Differential pressure and flow rate, PN 32/160 (MWP 464/2320 psi)

7MF4533

Differential pressure and flow rate, PN 420 (MWP 6092 psi)

7MF4633

Level

Further information

Information The contents of these instructions shall not become part of or modify any prior or existing agreement, commitment or legal relationship. All obligations on the part of Siemens AG are contained in the respective sales contract which also contains the complete and solely applicable warranty conditions. Any statements contained herein do not create new warranties or modify the existing warranty. The content reflects the technical status at the time of printing. We reserve the right to make technical changes in the course of further development.

Worldwide contact person If you need more information or have particular problems which are not covered sufficiently by the operating instructions, get in touch with your contact person. You can find contact information for your local contact person in the Internet.

Product information on the Internet The Programming Manual is an integral part of the companion CD, which may be ordered separately. In addition, the Programming Manual is available on the Internet on the Siemens homepage. On the CD you will also find the technical data sheet containing the ordering data, the Device Install software for SIMATIC PDM for subsequent installation and the required software.

See also Contacts (http://www.siemens.com/processinstrumentation/contacts) Product information on SITRANS P in the Internet (http://www.siemens.com/sitransp) Instructions and Manuals (http://www.siemens.com/processinstrumentation/documentation)

10

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

General safety notes 2.1

2

General information This device left the factory free from safety problems. In order to maintain this status and to ensure safe operation of the device, please observe the safety information and warnings contained in these instructions.

See also Safety-instrumented system (Page 129)

2.2

Correct usage The device may only be used for the purposes specified in these instructions. Insofar as they are not expressly stated in these instructions, all changes to the device are the sole responsibility of the user.

2.3

Laws and directives Observe the test certification, provisions and laws applicable in your country during connection, assembly and operation. For hazardous areas, these are for example: ● IEC 60079-14 (international) ● National Electrical Code (NEC - NFPA 70) (USA) ● Canadian Electrical Code (CEC) (Canada) ● EN 60079-14 (formerly VDE 0165, T1) (EU, Germany) ● The working reliability regulation (Germany)

2.4

Measures For the sake of safety, the following precautions must be observed:

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

11

ITEM 1120, 1340, 1355 General safety notes 2.4 Measures

WARNING "Explosion-proof" type of protection Devices with the "explosion-proof" type of protection may only be opened in the hazardous area only in a de-energized state. WARNING "Intrinsically safe" protection type "Intrinsically-safe" devices lose their certification as soon as they are operated on circuits which do not correspond with the test certification valid in their country. The "ia" protection level of the device is decreased to the "ib" protection level when intrinsically safe circuits having the "ib" protection level are connected. WARNING Protection type "limited energy" nL (zone 2) Devices with "limited energy" may be connected and disconnected while in operation. Protection type "non-sparking" nA (zone 2) Devices with "non-sparking" protection may only be connected and disconnected when off circuit. Refer to the specifications on the examination certificate for exceptions to this standard. WARNING Exposure to aggressive and hazardous media The device can be operated both at high pressure and with aggressive and hazardous media. Therefore, improper use of this device may lead to serious injury and or considerable damage to property. Above all, it must be noted when the device was in use and is to be exchanged. CAUTION Electrostatic Sensitive Devices (ESD) This device contains electrostatic sensitive devices. Electrostatic sensitive devices may be destroyed by voltages that are undetectable to a human. Voltages of this kind occur as soon as a component or an assembly is touched by a person who is not grounded against static electricity. The damage to a module as a result of overvoltage cannot usually be detected immediately. It may only become apparent after a long period of operation.

12

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 General safety notes 2.5 Qualified Personnel

2.5

Qualified Personnel Qualified personnel are people who are familiar with the installation, mounting, commissioning, and operation of the product. These people have the following qualifications: ● They are authorized, trained or instructed in operating and maintaining devices and systems according to the safety regulations for electrical circuits, high pressures and aggressive as well as hazardous media. ● For explosion-proof devices: They are authorized, trained, or instructed in carrying out work on electrical circuits for hazardous systems. ● They are trained or instructed in maintenance and use of appropriate safety equipment according to the safety regulations.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

13

ITEM 1120, 1340, 1355 General safety notes 2.5 Qualified Personnel

14

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

3

Description 3.1

System configuration

Overview The pressure transmitter can be used in a number of system configurations: ● as a stand-alone version, supplied with the necessary auxiliary power ● as part of a complex system environment, e.g. SIMATIC S7

System communication Communication is via the HART protocol, using: ● HART communicator with at least 4 MB available memory ● PC with HART modem, on which appropriate software is available, e.g. SIMATIC PDM ● Control system which is able to communicate via the HART protocol, e.g. SIMATIC S7 with ET 200M &RQWUROV\VWHP

6,0$7,&3'0

6 (70

RU $



 



/RDG

7UDQVPLWWHU

+$57 &RPPXQLFDWRU

RU

+$57 0RGHP

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3&ODSWRSZLWK 6,0$7,&3'0 56&

Figure 3-1

Possible system configurations

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

15

ITEM 1120, 1340, 1355 Description 3.2 Application range

3.2

Application range

Overview Depending on the version, a transmitter measures corrosive, non-corrosive and hazardous gases, vapors and liquids. It can be used for the following measurement types: ● Gauge pressure ● Absolute pressure ● Differential pressure With appropriate parameterization, it can also be used for the following additional measurement types: ● Level ● Volume ● Mass ● Volume of flow ● Mass flow rate The output signal is always a load-independent direct current between 4 and 20 mA. You can install the "intrinsically-safe" or "explosion-proof" version of the transmitter in hazardous areas. The devices have an EC type examination certificate and comply with the appropriate harmonized European CENELEC directives. Transmitters with remote seals of different shapes can be delivered for special applications. For example, measuring high-viscosity substances is a special application.

Gauge pressure This version measures aggressive, non-aggressive and hazardous gases, vapors and liquids. The smallest measuring span is 0.01 bar g (0.145 psi g), and the largest 400 bar g (5802 psi g).

Differential pressure and flow rate This version measures corrosive, non-corrosive and hazardous gases, vapors and liquids. You can use this version for the following measurement types: ● differential pressure, e.g. effective differential pressure ● small positive or negative overpressure ● in combination with a restrictor device: flow rate q ~

∆p

The smallest measuring span is 1 mbar (0.0145 psi), the largest 30 bar (435 psi).

16

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Description 3.3 Structure

Level This version with mounting flange measures the level of non-corrosive, corrosive and hazardous liquids in open and closed containers. The smallest measuring span is 25 mbar (0.363 psi), the largest 5 bar (72.5 psi). The nominal diameter of the mounting flange is DN 80 or DN 100 or 3" or 4". The negative connection of the measuring cell is kept open when measuring the level of open containers. This measurement is referred to as "measurement against atmosphere". The negative connection is normally connected with the container when measuring the level of closed containers. This balances the static pressure. Wetted parts are made of various materials, depending on corrosion resistance requirements.

Absolute pressure This version measures the absolute pressure of aggressive, non-aggressive and hazardous gases, vapors and liquids. There are two series: a "differential pressure" series and a "gauge pressure" series. The "differential pressure" series is distinguished by a high overload capability. The smallest measuring span of the "differential pressure" series is 8.3 mbar a (0.12 psi a), and the largest is 100 bar a (1450 psi a). The smallest measuring span of the "gauge pressure" series is 8.3 mbar a (0.12 psi a), and the largest is 30 bar a (435 psi a).

3.3

Structure Depending on a customer-specific order, the device comprises different parts. The electronic housing is made of aluminum die casting or stainless steel precision casting. The housing has a removable circular cover at the front and the back. Depending on the device version, the front cover ④ is designed as an inspection window. You can directly read the measured values on the digital display through this inspection window. The infeed ② for the electrical terminal compartment is provided on either side, optionally at the right or the left. The corresponding unused opening is closed with a blanking plug ⑨. The protective conductor connection ⑪ is provided at the back of the housing. The electrical terminal compartment for power supply and shield is accessible when you remove the rear cover ⑩. The measuring cell with a process connection ⑧ is provided in the lower section of the housing. This measuring cell is secured against twisting using a retaining screw ⑦. Thanks to the modular structure of the transmitter, the measuring cell, the electronic unit or the network card can be replaced if required. A keyboard cover ③ is provided at the top of the housing. This cover can be opened. The keypad is provided below this cover.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

17

ITEM 1120, 1340, 1355 Description 3.4 Structure of the type plate and approval plate



 





(OHFWULFDO WHUPLQDO FRPSDUWPHQW





 









Figure 3-2

Device view of the transmitter

①

Type plate

②

Infeed with a cable gland

③

Keyboard cover for accessing the buttons

④

Removable cover, optionally with an inspection window

⑤

Digital display

⑥

Measuring point label

⑦

Retaining screw

⑧

Process connection

⑨

Blanking plug

⑩

Removable cover for accessing the electrical terminal compartment

⑪

Protective conductor connection

⑫

Alternative measuring point label

⑬

Approval plate

See also Safety notes for installation (Page 29)

3.4

Structure of the type plate and approval plate

Structure of the type plate The type plate which bears the order number and other important information such as design or technical data is provided at the side of the housing.

18

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Description 3.4 Structure of the type plate and approval plate

D-761 81 K arlsr uhe

SITRANS

P

0 032

PED:SEP Tr ansmit ter fo r pressur e 7MF4033-1EB1 0-1D A1



Fab. Nr. N1LN1 1-0 047 11



V H :DC1 0.5-45 V (not intr.s ave ) outp.:4-20 mA Mat.: Connec. Diaphr. 1.4404 2.481 9

F illing Silik onöl

: 0.6 3 - 6 3 bar : -1 - 100 bar

Measuring span Ove rrange limits

Type of protection IP 65 Made in Fr ance

Figure 3-3

Example of a type plate

①

Order number (machine-readable product code)

②

Serial number

Structure of the approval plate The approval plate is provided on the opposite side. The approval plate has information about the version of the hardware and firmware.

D-761 81 K arlsr uhe

SITRANS

P

II 1/2 G EE x d IIC T4/T6

V H :DC 10. 5 - 4 5 V outp.: 4 - 2 0 m A

PTB 99 ATEX 1160 Observ e EC-T ype Examination Cer tificate !

T a = -40 ... 85/60 °C FW : 1 3.0 1.02 HW : 01.02.03

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Figure 3-4

Example of an approval plate

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

19

ITEM 1120, 1340, 1355 Description 3.5 Functional principle

3.5

Functional principle

3.5.1

Overview of mode of operation This chapter describes how the transmitter works. First the electronics are described, then the physical principle of the sensors which are used with the various device versions for the individual measurement types.

3.5.2

Operation of the electronics

Description  





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Figure 3-5

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Operation of the electronics with HART communication

①

Measuring cell sensor

②

Measuring amplifier

③

Analog-to-digital converter

④

Microcontroller

⑤

Digital-to-analog converter

⑥

Each with an EEPROM in the measuring cell and in the electronics

⑦

HART modem

⑧

Buttons (local operation)

⑨

Digital display

⑩

Connection for external ammeter

IA

Output current

UH

Auxiliary power

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Description 3.5 Functional principle The input pressure is converted into an electrical signal by the sensor ①. This signal is amplified by the measuring amplifier ② and digitized in an analog-to-digital converter ③. The digital signal is analyzed in a microcontroller ④ and corrected with regard to linearity and thermal characteristics. It is then converted in a digital-to-analog converter ⑤ to the output current of 4 to 20 mA. A diode circuit provides reverse voltage protection. You can make an uninterrupted current measurement with a low resistance ammeter at the connection ⑩. The data specific to the measuring cell, the electronic data and parameterization data are stored in two EEPROMs ⑥. The first memory is linked with the measuring cell, the second with the electronics. The buttons ⑧ can be used to call up individual functions, so-called modes. If you have a device with a digital display ⑨, you can track the mode settings and other messages on it. The basic mode settings can be changed with a computer via the HART modem ⑦.

3.5.3

Measuring cell operation CAUTION If the measurement signal fails because of sensor breakage, the separating diaphragm may also be destroyed. In the worst case scenario, the process medium leaks from the reference pressure opening in the devices used for gauge pressure with a measuring span of ≤ 63 bar. In the following sections, the process variable to be measured is called general input pressure.

Overview The following modes of operation are described: ● Gauge pressure ● Absolute pressure ● Differential pressure and flow rate ● Level The following process connections are available, for example: ● G½, ½-14 NPT ● EN61518 compliant flanged connection ● Flush mounted diaphragm

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

21

ITEM 1120, 1340, 1355 Description 3.5 Functional principle

3.5.3.1

Measuring cell for gauge pressure   





 SH

Figure 3-6 ①

Function chart of measuring cell for gauge pressure

Reference pressure opening

②

Measuring cell

③

Process connection

④

Separating diaphragm

⑤

Fill liquid

⑥

Gauge pressure sensor

pe

Input pressure

The input pressure (pe) is transferred to the gauge pressure sensor ⑥ via the separating diaphragm ④ and the fill fluid ⑤, displacing its measuring diaphragm. The displacement changes the resistance value of the four piezo resistors in the measuring diaphragm in a bridge circuit. The change in the resistance causes a bridge output voltage proportional to the input pressure. Transmitters with measuring span ≤ 63 bar measure the input pressure against atmosphere, those with spans ≥ 160 bar against vacuum.

22

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Description 3.5 Functional principle

3.5.3.2

Measuring cell for differential pressure and flow rate



 





 



Figure 3-7







Function chart of the measuring cell for differential pressure and flow rate

①

Input pressure P+

②

Pressure cap

③

O-ring

④

Measuring cell body

⑤

Silicon pressure sensor

⑥

Overload diaphragm

⑦

Fill liquid

⑧

Separating diaphragm

⑨

Input pressure P-

Differential pressure is transmitted to the silicon pressure sensor ⑤ through the separating diaphragms ⑦ and the fill fluid ⑧. When measuring limits are exceeded, the overload diaphragm ⑥ is displaced until one of the separating diaphragms ⑦ rests on the measuring cell body ④. The separating diaphragm thus protects the silicon pressure sensor ⑤ from overload. The measuring diaphragm is displaced using differential pressure. The displacement changes the resistance value of the four piezo resistors in the measuring diaphragm in a bridge circuit. The change in the resistance causes a bridge output voltage proportional to the differential pressure.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

23

ITEM 1120, 1340, 1355 Description 3.5 Functional principle

3.5.3.4

Measuring cell for absolute pressure from the differential pressure series

 

SH

 



Figure 3-9







Function chart of measuring cell for absolute pressure

①

Pressure cap

②

Separating diaphragm on the measuring cell

③

O-ring

④

Measuring cell body

⑤

Silicon pressure sensor

⑥

Overload diaphragm

⑦

Fill liquid of the measuring cell

⑧

Reference pressure

pe

Pressure input variable

Absolute pressure is transmitted to the silicon pressure sensor ⑤ through the separating diaphragm ② and the fill fluid ⑦. When measuring limits are exceeded, the overload diaphragm ⑥ is displaced until the separating diaphragm ② rests on the measuring cell body ④. The separating diaphragm thus protects the silicon pressure sensor ⑤ from overload. The pressure difference between the input pressure (pe) and the reference pressure ⑧ on the negative side of the measuring cell displaces the measuring diaphragm. The displacement changes the resistance value of the four piezo resistors in the measuring diaphragm in a bridge circuit. The change in the resistance causes a bridge output voltage proportional to the absolute pressure.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

25

ITEM 1120, 1340, 1355 Description 3.5 Functional principle

3.5.3.5

Measuring cell for absolute pressure from the gauge pressure series





 

 SH

Figure 3-10

Function chart of measuring cell for absolute pressure

①

Measuring cell

②

Process connection

③

Separating diaphragm

④

Fill liquid

⑤

Absolute pressure sensor

pe

Input pressure

The input pressure (pe) is transferred to the absolute pressure sensor ⑤ via the separating diaphragm ③ and the fill fluid ④, displacing its measuring diaphragm. The displacement changes the resistance value of the four piezo resistors in the measuring diaphragm in a bridge circuit. The change in the resistance causes a bridge output voltage proportional to the input pressure.

3.5.3.6

Measuring cell for gauge pressure, front-flush membrane   



 SH

Figure 3-11

26



Function chart of the measuring cell for gauge pressure, flush mounted diaphragm

①

Reference pressure opening

②

Measuring cell

③

Process connection

④

Separating diaphragm

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Description 3.5 Functional principle ⑤

Fill liquid

⑥

Gauge pressure sensor

pe

Input pressure

The input pressure (pe) is transferred to the gauge pressure sensor ⑥ via the separating diaphragm ④ and the fill fluid ⑤, displacing its measuring diaphragm. The displacement changes the resistance value of the four piezo resistors in the measuring diaphragm in a bridge circuit. The change in the resistance causes a bridge output voltage proportional to the input pressure. Transmitters with measuring span ≤ 63 bar measure the input pressure against atmosphere, those with measuring spans ≥ 160 bar against vacuum.

3.5.3.7

Measuring cell for absolute pressure, front-flush membrane

 



 SH

Figure 3-12 ①



Function chart of the measuring cell for absolute pressure, flush mounted diaphragm

Measuring cell

②

Process connection

③

Separating diaphragm

④

Fill liquid

⑤

Absolute pressure sensor

pe

Input pressure

The input pressure (pe) is transferred to the absolute pressure sensor ⑤ via the separating diaphragm ③ and the fill fluid ④, displacing its measuring diaphragm. The displacement changes the resistance value of the four piezo resistors in the measuring diaphragm in a bridge circuit. The change in the resistance causes a bridge output voltage proportional to the input pressure.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

27

ITEM 1120, 1340, 1355 Description 3.6 Remote seal

3.6

Remote seal

Product description A remote seal measuring system comprises the following elements: ● Remote seal ● Transmission line, e.g. capillary line ● Measuring device Do not separate these components under any circumstance. The measuring system based on a hydraulic principle is used to transfer pressure. The capillary line and the remote separating diaphragm are the most sensitive components in the remote seal measuring system. The material thickness of the remote separating diaphragm is only ~0.1 mm. The smallest of leakages in the transmission system leads to the loss of transmission fluid. The loss of transmission fluid leads to inaccuracies in the measurement and the failure of the measuring system. In order to avoid leakages and measuring errors, please observe the following general installation and maintenance instructions in addition to the safety notes.

3.7

SIMATIC PDM SIMATIC PDM is a software package for the configuration, paramaterization, commissioning, diagnostics, and servicing of the device and other process devices. SIMATIC PDM includes simple process monitoring of process values, alarms, and device status information. Using SIMATIC PDM, you can do the following with process device data: ● display ● set ● change ● compare ● check for plausibility ● administer ● simulate

28

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

4

Install 4.1

Safety notes for installation

Condition You can install the transmitter in different areas of application. Depending on the area of application and the system configuration, there may be differences in the installation. WARNING Protection against incorrect use of the measuring device Take particular care to ensure that the selected materials for the wetted parts are suitable for the process media used. Ignoring these safety measures may cause bodily and life-threatening injury and be harmful to the environment. WARNING "explosion-proof" type of protection Devices with the "explosion-proof" type of protection may only be opened in the hazardous area only in a de-energized state.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

29

ITEM 1120, 1340, 1355 Install 4.1 Safety notes for installation

WARNING "Intrinsically-safe" protection type Information for operating the intrinsically-safe version in hazardous areas: Operation is only permissible in certified intrinsically-safe circuits. The transmitter corresponds to category 1/2 and may be installed in Zone 0. The EC-type examination certificate applies to installation of the device in the walls of containers and pipes in which explosive gas/air or vapor/air mixtures occur only under atmospheric conditions (pressure: 0.8 bar to 1.1 bar; temperature: -20 °C to +60 °C). The permissible range of ambient temperature is -40 °C to +85 °C; -40 °C to a maximum of +85 °C (at T4) in hazardous areas. The operator may use the device under non-atmospheric conditions outside the limits specified in the EC-type examination certificate (or the certification applicable in the country of use) at the operator's own risk if safety measures which may be necessary in accordance with use conditions (explosive mixture) have been taken. The limit values specified in the general technical data are to be complied with in all cases. Additional information for zone 0 Additional requirements apply for installation in zone 0: The installation must be sufficiently tight (IP67 according to EN 60 529). For instance, an industry standard (e.g. DIN, NPT) threaded connector is suitable. When operating intrinsically safe supply units of category "ib" or in the case of device version flameproof enclosure "Ex d" and simultaneous use in zone 0, the protection against explosion of the transmitter depends on the tightness of the sensor diaphragm. Under these operating conditions, the transmitter may only be used for such combustible gases and liquids for which diaphragms are sufficiently resistant to chemicals and corrosion. CAUTION Touch protection is required for surface temperatures > 70 °C. The touch protection must be designed in such a way that, if there is a buildup of heat, the maximum permissible ambient temperature at the device is not exceeded. The permissible ambient temperature can be found in the technical data. CAUTION The device may only be used within the measuring spans, overload pressure limits and voltage limits dependent on the protection type specified on the type plate. NOTICE Install the device such that automatic emptying is ensured. For example, do not install the device at the bottom of the tank, instead of its side. External loads may not be allowed to affect the transmitter as this may result in an incorrect measured value or even destruction of the device. In the worst case scenario, the process medium will escape.

30

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Install 4.2 Installation (except level)

4.2

Installation (except level)

4.2.1

Instructions for installation (except level)

Conditions NOTICE Compare the desired operating data with the data on the type plate. NOTICE The housing may only be opened for maintenance or to make electrical connections. Note Protect the transmitter against: • Direct heat radiation • Rapid temperature fluctuations • Heavy contamination • Mechanical damage The installation location is to be as follows: ● Easily accessible ● As close as possible to the measuring point ● Vibration-free ● Within the permitted ambient temperature values

Installation configuration The transmitter may in principle be configured above or below the pressure tapping point. The recommended configuration depends on the medium.

Installation configuration for gases Install the transmitter above the pressure tapping point. Lay the pressure tubing with a constant gradient to the pressure tapping point, so that any condensate produced can drain in the main line and thereby avoid corruption of the measured values.

Installation configuration for vapor and liquid Install the transmitter below the pressure tapping point.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

31

ITEM 1120, 1340, 1355 Install 4.2 Installation (except level) Lay the pressure tubing with a constant gradient to the pressure tapping point so that any gas pockets can escape in the main line.

4.2.2

Installation (except level) NOTICE When installing the process connection of the pressure transmitter, do not turn it on the housing.

Procedure To install the transmitter for pressure or absolute pressure, proceed as follows: Attach the transmitter to the process connection with an appropriate tool.

See also Introduction to commissioning (Page 136)

4.2.3

Fastening

Fastening without the mounting bracket You can fasten the transmitter directly on the process connection.

Fastening with the mounting bracket You can fasten the mounting bracket as follows: ● On a wall or a mounting frame using two screws ● On a vertical or horizontal mounting tube (Ø 50 to 60 mm) using a tube bracket Fasten the transmitter mounting bracket using the two screws provided.

32

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Install 4.2 Installation (except level)

Figure 4-1

Fastening the transmitter on the mounting bracket

Figure 4-2

An example of fastening the transmitter on the mounting bracket in the case of differential pressure and horizontal differential pressure lines

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

33

ITEM 1120, 1340, 1355 Install 4.3 "Level" installation

Figure 4-3

An example of fastening on the mounting bracket in the case of differential pressure and vertical differential pressure lines

4.3

"Level" installation

4.3.1

Instructions for level installation

Conditions NOTICE Compare the desired operating data with the data on the type plate. NOTICE The housing may only be opened for maintenance or to make electrical connections. Note Protect the transmitter against: • Direct heat radiation • Rapid temperature fluctuations • Heavy contamination • Mechanical damage

34

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Install 4.3 "Level" installation

Note Select the height of the container flange for recording of the transmitter (measuring point) such that the lowest level to be measured is always over the flange or at its upper edge. The installation location is to be as follows: ● Easily accessible ● The measuring point must be as close as possible ● Vibration-free ● Within the permitted ambient temperature values

4.3.2

Installation for level Note Seals are required for the installation. Seals are not included in the delivery.

Procedure To install the transmitter for level, proceed as follows: 1. Attach the seal to the container's mating flange. Ensure that the seal is centrically positioned and that it does not restrict the movement of the flange's seal diaphragm in any way as otherwise the tightness of the process connection is not guaranteed. 2. Screw on the transmitter's flange. 3. Observe the installation position.

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ITEM 1120, 1340, 1355 Install 4.3 "Level" installation

4.3.3

Connection of the negative pressure line

Measurement in an open container A line is not required when taking measurements in an open container since the negative chamber is connected with the atmosphere. The open connection gland should point downwards to prevent dirt from entering. Formula: Start of scale value: pMA = ρ · g · hU

)XOOVFDOHYDOXH

Full scale value: pME = ρ · g · hO K2

6WDUWRIVFDOHYDOXH

K8

+

Measurement assembly on an open container

36

hU

Start of scale value

ΔpMA

Start of scale value to be adjusted

hO

Full scale value

ΔpME

Full scale value to be adjusted

p

Pressure

ρ

Density of the measured medium in the container

g

Local gravitational acceleration

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Install 4.3 "Level" installation

Measurement in a closed container When taking measurements in a closed container without or with little condensate formation, the negative pressure line is not filled. Lay the line such that condensate pockets do not form. Install a condensation container if required. Formula:

6WDWLF 3UHVVXUH

JDVILOOHGQHJDWLYH SUHVVXUHOLQH

Start of scale value: ΔpMA = ρ · g · hU Full scale value: ΔpME = ρ · g · hO

0D[LPXPOHYHO

)XOOVFDOHYDOXH

6WDUWRIVFDOHYDOXH K2 K8

7UDQVPLWWHU UHIHUHQFHOLQH

Measurement assembly on a closed container (no or little condensate separation)

hU

Start of scale value

ΔpMA

Start of scale value to be adjusted

hO

Full scale value

ΔpME

Full scale value to be adjusted

p

Pressure

ρ

Density of the measured medium in the container

g

Local gravitational acceleration

When taking measurements in a closed container with strong condensate formation, you must fill the negative pressure line (mostly with the condensate of the measured medium) and install a condensate pot. You can cut off the device using the dual pneumatic block 7MF9001-2.

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ITEM 1120, 1340, 1355 Install 4.4 "Remote seal" installation

6WDWLF 3UHVVXUH

Formula:

FRQVWDQW FRPSDULVRQ OHYHO

Start of scale value: ΔpMA = g · (hU · ρ- hV · ρ') Full scale value: ΔpMA = g · (hO · ρ- hV · ρ')

0D[LPXPOHYHO

)XOOVFDOHYDOXH

6WDUWRIVFDOHYDOXH

OLTXLGILOOHG QHJDWLYHSUHVVXUHOLQH

K

'

K2 K8

7UDQVPLWWHU UHIHUHQFHOLQH

-

Measurement assembly on a closed container (strong condensate formation)

hU

Start of scale value

ΔpMA

Start of scale value to be adjusted

hO

Full scale value

ΔpME

Full scale value to be adjusted

hV

Gland distance

ρ

Density of the measured medium in the container

p

Pressure

Ρ'

Density of fluid in the negative pressure line, corresponds to the temperature prevailing there

g

Local gravitational acceleration

The process connection on the negative side is a female thread 1/4-18 NPT or an oval flange. Lay the line for the negative pressure using a seamless steel tube 12 mm x 1.5 mm.

4.4

"Remote seal" installation

4.4.1

Remote seal installation

General installation instructions ● Keep the measuring system in the factory packing until it is installed in order to protect it from mechanical damage. ● When removing from the factory packing and installing: ensure that damage to and mechanical deformations in the diaphragm are prevented.

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SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Install 4.4 "Remote seal" installation ● Never loosen the sealed filling screws on the remote seal and the measuring device. ● Do not cause damage to the remote separating diaphragm; scratches on the remote separating diaphragm, e.g. due to sharp-edged objects, are the main starting points for corrosion. ● Select suitable gaskets for sealing. ● Use a gasket having an adequately large inner diameter for flanging. Insert the gasket concentrically; contact with the diaphragm leads to deviations in measurements. ● When using gaskets made of soft materials or PTFE: follow the guidelines of the gasket manufacturer, especially regarding the tightening torque and setting cycles. ● At the time of installation, use suitable fastening components such as screws and nuts that are compliant with fitting and flange standards. ● Excessive tightening of screwed joints on the process connection may displace the zero point on the pressure transmitter.

Note: Commissioning Follow the instruction given below if a shut-off valve exists: Open the shut-off valve slowly when commissioning in order to avoid pressure surges.

Note: permissible ambient and operating temperatures Install the pressure measuring device such that the permissible limits of ambient and measured medium temperatures are not overshot or undershot even with the consideration of the effect of convection and heat radiation. Pay attention to the effect of temperature on the accuracy of display. When selecting the remote seals, ensure that fittings and flange components have adequate pressure-temperature resistance by selecting suitable materials and pressure ratings. The pressure rating specified on the remote seal is applicable for ambient temperatures. For the maximum permissible pressure at higher temperatures, please refer to the standard specified on the remote seal.

Using remote seals with pressure measuring devices for hazardous areas: ● When using remote seals with pressure measuring devices for hazardous areas, the permissible limits of ambient temperatures for the transmitter should not be exceeded. Hot surfaces on the cooling section (capillaries or cooling elements) are a possible source of ignition. Initiate suitable measures. ● When remote seals with a flame arrester are used, the pressure measuring device determines the permissible ambient temperature. In the case of potentially explosive gaseous atmosphere, the temperature around the flame arrester should not exceed +60 °C.

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ITEM 1120, 1340, 1355 Install 4.4 "Remote seal" installation

4.4.2

Installation of the remote seal with the capillary line

Notes ● Do not rest the measurement assembly on the capillary line. ● Do not bend capillary lines; risk of leakages and/or risk of considerable increase in the setting time of the measuring system. ● Owing to the risk of bending and breakages, pay attention to mechanical overloads at the joints such as capillary line-remote seal and capillary line-measuring device. ● Unwinding the excess capillary lines with a radius of at least 150 mm. ● Fasten the capillary line such that there are no vibrations. ● Permissible height differences When installing the pressure measuring device above the measuring point, keep the following in mind: in the case of remote seal measuring systems with silicon, glycerin or paraffin oil filling, the height difference of H1should not exceed a maximum of 7 m. If halocarbon oil is used as a fill fluid, this maximum height difference should be H1 4 m (see installation types A and B). If negative overpressure is observed during measurements, reduce the permissible height difference accordingly.

Installation type for gauge pressure and level measurements (open containers) Installation type A Start of scale value: pMA = ρFL * g * HU + ρoil * g * H1

+

Full scale value: pME = ρFL * g * HO + ρoil * g * H1

+R +X

+

Pressure transmitter above the measuring point

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SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Install 4.4 "Remote seal" installation Installation type B Start of scale value: pMA = ρFL * g * HU - ρoil * g * H1

+

Full scale value: pME = ρFL * g * HO - ρoil * g * H1

+R +X

+

Pressure transmitter below the measuring point H1 ≤ 7 m (23 ft), for halocarbon oil, however only H1 ≤ 4 m(13.1 ft) Legend pMA

Start of scale value to be adjusted

pME

Full scale value to be adjusted

ρFL

Density of the measured medium in the container

ρoil

Density of the filling oil in the capillary line of the remote seal

g

Local gravitational acceleration

HU

Start of scale value

HO

Full scale value

H1

Distance between the container flange and the pressure transmitter

For absolute pressure measurements (vacuum), install the measuring device at least at the height of the remote seal or below it (see installation types C).

Installation types for absolute pressure measurements (closed containers) Installation type C1 Start of scale value: pMA = pstart + ρoil * g * H1 +

Full scale value: pME = pend + ρoil * g * H1

SDEV

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ITEM 1120, 1340, 1355 Install 4.4 "Remote seal" installation Installation type C2

SDEV

+

Pressure transmitter for absolute pressure always below the measuring point: H1 ≥ 200 mm (7.9 inch) Legend pMA

Start of scale value to be adjusted

pME

Full scale value to be adjusted

pstart

Start of scale value

pend

Full scale value

ρoil

Density of the filling oil in the capillary line of the remote seal

g

Local gravitational acceleration

H1

Distance between the container flange and the pressure transmitter

Note Effects of temperature Keep the following instructions in mind in order to minimize keep the effects of temperature in remote seal measuring systems with the differential pressure measuring device: Install the device such that the positive and negative sides are symmetrical as far as ambient effects, especially ambient temperatures, are concerned.

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ITEM 1120, 1340, 1355 Install 4.4 "Remote seal" installation

Installation type for differential pressure and flow rate measurements Installation type D Start of scale value: pMA = pstart - ρoil * g * HV +

+9

Full scale value: pME = pend - ρoil * g * HV

+

Legend pMA

Start of scale value to be adjusted

pME

Full scale value to be adjusted

pstart

Start of scale value

pend

Full scale value

ρoil

Density of the filling oil in the capillary line of the remote seal

g

Local gravitational acceleration

HV

Gland distance

Installation types for level measurements (closed containers) Installation type E Start of scale value: pMA = ρFL * g * HU - ρoil * g * HV Full scale value: pME = ρFL * g * HU - ρoil * g * HV + +9

+2 +8

Legend pMA

Start of scale value to be adjusted

pME

Full scale value to be adjusted

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ITEM 1120, 1340, 1355 Install 4.4 "Remote seal" installation ρFL

Density of the measured medium in the container

ρoil

Density of the filling oil in the capillary line of the remote seal

g

Local gravitational acceleration

HU

Start of scale value

HO

Full scale value

HV

Gland distance

Installation type G H1 ≤ 7 m (23 ft), for halocarbon oil, however only H1 ≤ 4 m(13.1 ft) Start of scale value: pMA = ρFL * g * HU - ρoil * g * HV

+

+9

+

+

Full scale value: pME = ρFL * g * HO - ρoil * g * HV

+R +X

Pressure transmitter for differential pressure above the upper measuring point, no vacuum Installation type H Start of scale value: pMA = ρFL * g * HU - ρoil * g * HV Full scale value: pME = ρFL * g * HO - ρoil * g * HV +

+

Below the lower measuring point

44

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Install 4.4 "Remote seal" installation Installation type J H2 ≤ 7 m (23 ft), for halocarbon oil, however only H1 ≤ 4 m(13.1 ft) +

Start of scale value: pMA = ρFL * g * HU - ρoil * g * HV Full scale value: pME = ρFL * g * HO - ρoil * g * HV

+

Between the measuring points, no vacuum Legend pMA

Start of scale value to be adjusted

pME

Full scale value to be adjusted

ρFL

Density of the measured medium in the container

ρoil

Density of the filling oil in the capillary line of the remote seal

g

Local gravitational acceleration

HU

Start of scale value

HO

Full scale value

HV

Gland distance

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

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ITEM 1120, 1340, 1355 Install 4.5 Turing the measuring cell against housing

4.5

Turing the measuring cell against housing

Description You can turn the measuring cell against the housing. Turning simplifies the transmitter operation in the case of an angled installation environment. The buttons and the current connection can thus also be operated for an external measuring device. The digital display also remains visible in the case of housing covers with an inspection window. Only limited turning is permissible! The turning range ① is marked at the foot of the electronic housing. An orientation mark ③ is provided at the throat of the measuring cell. This mark must remain in the marked section when turning. 

  



Figure 4-4

①

Example: turning range of transmitters for pressure and absolute pressure from the gauge pressure series

Turning range

②

Retaining screw

③

Orientation mark

The turning range for transmitters for differential pressure and flow rate, absolute pressure from the differential pressure series and level is identified in a similar manner.

Procedure CAUTION Follow the turning range, otherwise electrical connections of the measuring cell may get damaged. 1. Loosen the retaining screw ② (Allen screw 2.5 mm). 2. Turn the electronic housing against the measuring cell. Follow the marked turning range ① while doing so. 3. Tighten the retaining screw (torque: 3.4 to 3.6 Nm).

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SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Install 4.6 Turning the digital display

4.6

Turning the digital display

Description You can rotate the digital display in the electronic housing. You can then read the digital display better when the device is not operated in a vertical installation position.

Procedure WARNING "Explosion-proof" type of protection Devices with the "explosion-proof" type of protection may only be opened in the hazardous area only in a de-energized state. Proceed as follows: 1. Unscrew the housing cover of the electronic compartment. 2. Unscrew the digital display. Depending on the application position of the transmitter, you can reinstall it at four different positions. You can turn it by ±90° or ±180°. 3. Screw the housing cover back into place.

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ITEM 1120, 1340, 1355 Install 4.6 Turning the digital display

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SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

5

Connecting 5.1

Safety notes for connection WARNING Laying of cables Connect the devices that are operated in hazardous areas as per the stipulations applicable in your country, e.g. for Ex "d" and "nA", permanent cables must be laid. WARNING Cable glands If you use the provided cable glands M20x1.5 and ½-14" NPT, only the cables having a diameter of 6 to 12 mm must be laid into the device. "nA" type of protection In the case of devices with "nA" type of protection (zone 2), only use cables having a diameter of 8 to 12 mm owing to the required tensile strength, or use a suitable cable gland in case of smaller diameters. WARNING When connecting and installing, follow only the test certifications, stipulations and laws applicable in your country. For example, for hazardous areas these are: • IEC 60079-14 (international) • National Electrical Code (NEC - NFPA 70) (USA) • Canadian Electrical Code (CEC) (Canada) • EN 60079-14 (earlier VDE 0165, T1) (EU, Germany) • Ordinance on Industrial Safety and Health (Germany) WARNING If auxiliary power is required, check that it corresponds with that on the type plate and with the test certification valid for your country.

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ITEM 1120, 1340, 1355 Connecting 5.2 Connecting the device

WARNING Replace the sealing caps in cable entries with suitable cable glands or blanking plugs that are certified for transmitters of the "explosion-proof" type of protection. Note To improve the reliability: • Install the signal cable separately from cables with voltages > 60 V. • Use cable with twisted strands. • Stay away from large electrical systems. • Use shielded cable to guarantee the full specification according to HART. • Connect a load of at least 230 ohm into the signal circuit in sequence in order to guarantee fault-free HART communication. When using supply isolation for SMART transmitters, for example: Siemens 7NG4021 a load is already installed in the device.

5.2

Connecting the device

Procedure To connect the device, proceed as follows: 1. Unscrew the cover of the electrical cable compartment. An identification text "FIELD TERMINAL" is provided at the side of the housing. 2. Insert the connecting cable through the cable gland. 3. Connect the wires to the connecting terminals "+" and "-". Observe the polarity when doing this. 4. Place a shield on the shield support screw if required. This is electrically connected with the external protective conductor connection. 5. Screw the cover back into place. WARNING In the case of transmitters with the "explosion-proof" type of protection, screw the housing cover firmly and secure it with a cover latch.

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SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Connecting 5.2 Connecting the device

  ˖  



  





Figure 5-1

Schematic electrical connection

①

Feed separator with integrated load

②

Auxiliary power

③

Cable entry for auxiliary power/analog output

④

Connecting terminals

⑤

Test connector for direct current measuring device or connection for external display

⑥

Shield support

⑦

Protective conductor connection/equipotential bonding terminal

⑧

Cable entry for sensor signals

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ITEM 1120, 1340, 1355 Connecting 5.3 Connecting the Han plug

5.3

Connecting the Han plug

Introduction The contact parts for the coupling socket are also supplied.

Procedure To connect the plug, proceed as follows: 1. Slide the sleeve and the screwed joint on the cable. 2. Strip approx. 8 mm of the cable ends. 3. Crimp the contact parts on the cable ends. 4. Assemble the coupling socket.









IA

Output current

UH

Auxiliary power

 





,$



8+

Connector pin assignment with Han 7D or Han 8U plug

5.4

Connecting the M12 connector

Procedure CAUTION A conductive connection should not exist between the shield and the connector housing. For devices in which a connector is already assembled on the housing, the connection is established using a jack coupling. 1. Thread the parts of the jack coupling as described by the connector manufacturer. 2. Strip approximately 18 mm of the bus cable ①. 3. Twist the shield. 4. Thread the shield in the insulating sleeve. 5. Draw 8 mm of shrink sleeve over the cable, wires and shield up to the reference edge ②.

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SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Connecting 5.4 Connecting the M12 connector 6. Screw the cable ends and the shield in the pin insert. 7. Fix the parts of the jack coupling as described by the connector manufacturer. 



 







Figure 5-2



Preparing the fieldbus cable

①

Reference edge for stripping

③

Insulating sleeve over the shield

②

Reference edge for the dimension specifications for cable assembly

④

Shrink sleeve

Pin assignment

 



















Layout for M12 connector

Layout for M12 jack

①

M12 x 1 thread

①

Positioning slot

②

Positioning catch

1

+

1

+

2

Not connected

2

Not connected

3

-

3

-

4

Shield

4

Shield Middle jack not assembled

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ITEM 1120, 1340, 1355 Connecting 5.4 Connecting the M12 connector

54

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

6

Operation 6.1

Overview of operation

Introduction The following description contains an overview of the operating functions that you can execute using the pressure transmitter, and the safety notes that are to be observed when doing so. You can operate the transmitter on-site through HART communication. First, the on-site operation and then, the operating functions using HART are described.

Contents of the chapter ● Safety information for operation (Page 56) ● Instructions for operation (Page 56) ● Digital display (Page 57) ● Local operation (Page 63)

Overview of operating functions You can configure basic settings of the pressure transmitter using the buttons on the device. You can configure all settings through HART communication. The following table describes the basic operating functions. More operating functions for special applications are accessible through HART. Basic variables of the device are marked in bold. Table 6-1

Operating functions

Function

Using buttons

Using HART

Start of scale value

Yes

Yes

Full scale value

Yes

Yes

Electrical damping

Yes

Yes

Blind adjustment of the start of scale value

Yes

Yes

Blind adjustment of the full scale value

Yes

Yes

Zero point calibration (position correction)

Yes

Yes

Current transmitter

Yes

Yes

Fault current

Yes

Yes

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ITEM 1120, 1340, 1355 Operation 6.2 Safety information for operation Function

Using buttons

Using HART

Keyboard lock and write protection

Yes

Yes, release except for write protection

Unit type, unit

Yes

Yes

Characteristic curve (lin., rad.) (Not relevant for absolute and gauge pressure)

Yes

Yes

Customized characteristic curve

No

Yes

Diagnostic function

No

Yes

More operating functions for special applications are accessible through HART. If a device that does not have a digital display, its operations are limited. This is however not applicable for selecting functions using HART.

6.2

Safety information for operation NOTICE If you have set the basic functions of the pressure transmitter as user defined, the display and measurement output terminal can be adjusted such that the true process pressure is not reproduced. The basic variables should therefore be checked prior to commissioning.

6.3

Instructions for operation The following rules are applicable for the operation of the pressure transmitter: ● The device counts numerical values always in an ascending order step by step starting from the least significant digit displayed. If you keep the button pressed for a longer time, it counts the next higher digit displayed. This procedure is used for fast coarse adjustment over a wide number range. Release the [↑] or [↓] button again for fine adjustment. Press the button again. Violations of the measured value limits are displayed on the digital display with

or .

● The keyboard must have been unlocked in order to operate the device using the keyboard. ● If you are operating the transmitter locally, write access is denied through HART during this time. However, it is always possible to read the data, e.g. measured values.

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SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operation 6.4 Digital display

Note The setting is saved and the measured values are automatically displayed again if more than two minutes have passed after a button was pressed for the last time. The operating instructions mentioned in the "Local operation without digital display" chapter are applicable if the device has been delivered with a blind cover.

6.4

Digital display

6.4.1

Elements of the digital display

Structure 

 







Figure 6-1

①





Structure of the digital display

Measured value

⑤

Violation of lower limit

②

Unit/bar graph

⑥

Symbol for measured value

③

Root display

⑦

Violation of higher limit

④

Mode/button lock

⑧

Communication display

Description The digital display is used for local display of the measured value ① with: ● Unit ② ● Mode ④ ● Sign ⑥ ● Statuses ⑤ and ⑦ Depending on the customer setting, the displayed measured value ① represents the following:

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ITEM 1120, 1340, 1355 Operation 6.4 Digital display ● The current emitted by the transmitter ● The percentage measurement value of the adjusted measurement type, e.g. level, related to the adjusted measurement range. ● The measurement value in a selectable physical unit The Violation of lower limit ⑤ and Violation of upper limit ⑦ displays are also referred to as status since they have meanings dependent on the settings. If the communication display ⑧ blinks, this indicates an active communication.

6.4.2

Units display

Description The unit display comprises five 14-segment fields for representing the unit as a percentage value, physical unit or current value. A bar graph showing the percentage measured value range from 0 to 100% can be displayed as an alternative to the unit. The bar graph function is disabled by default.

Display

Figure 6-2

Examples for measured value display for current and bar graph

The following messages may appear as a ticker in the bottom line of the digital display. They have no influence on the current output. Table 6-2

58

Message as ticker

Ticker

Meaning

"DIAGNOSTIC WARNING"

Is always displayed if: • An event configured by the user is to be signaled with a warning. For example: – Limit reached – Event counter for limit values exceeded – Calibration time expired – Current saturation reached • The status of one of the device variables is "UNCERTAIN".

"SIMULATION"

Is always displayed when the simulation of a pressure value or temperature value is active.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operation 6.4 Digital display

See also Measured value status (Page 101)

6.4.3

Error display

Description If hardware faults, software errors or diagnostic alarms occur in the transmitter, the message "Error" appears in the measured value display. A ticker appears in the lower line of the digital display indicating the type of error. This diagnostic information is also available via HART communication.

Display

Figure 6-3

Example of error message

The following messages may appear as a ticker in the bottom line of the digital display. Ticker

Meaning

"HARDWARE FIRMWARE ALARM"

Contains hardware faults such as: • incorrect checksum • incorrect EEPROM data • Defective EEROM • RAM fault • ROM fault • inconsistent data • EEPROMs not initialized

"DIAGNOSTIC ALARM"

Is always displayed if • an event configured by the user is to be signaled with an alarm. For example: – Limit reached – Event counter for limit values exceeded – Calibration time expired – Current saturation reached • the status of one of the device variables is "BAD".

"SENSOR BREAK"

Appears when there is a sensor break.

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ITEM 1120, 1340, 1355 Operation 6.4 Digital display

See also Measured value status (Page 101)

6.4.4

Mode display

Description The selected active mode is shown in the mode display.

Display

Figure 6-4

Example for mode display

In the example, a damping of 0.2 seconds was set in mode 4.

6.4.5

Status display

Description The arrows of the status display have a different meaning depending on the mode setting. The table below shows the meanings of the arrows in the respective functions.

Meaning Table 6-3

60

Meaning of the arrow displays

Function

Mode

Display

Display

Adjusting start of scale value

2

if the upper current limit is exceeded

if the value falls below the lower current limit

Adjusting full scale value

3

if the upper current limit is exceeded

if the value falls below the lower current limit

Adjusting damping

4

if the upper damping value is if the value falls below the exceeded lower damping value only for the pressure device version only for the pressure device version

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operation 6.4 Digital display Function

Mode

Display

Display

Blind adjustment of the start of scale value

5

if the upper sensor limit is exceeded

if the value falls below the lower sensor limit

Blind adjustment of the full scale value

6

if the upper sensor limit is exceeded

if the value falls below the lower sensor limit

Position correction

7

if the max span is exceeded by more than 5% of the upper current limit

if the value falls below the lower current limit

if the root application point of 15% is exceeded

if the value falls below the root application point of 5%

Root application point 12 Keyboard operation

2, 3, 5, when the span to be adjusted is 6 larger than the maximum span

Normal operation

6.4.6

Current exceeds the upper saturation limit Pressure exceeds the upper sensor limit.

when the span to be adjusted is smaller than the minimum span Current falls below the lower saturation limit Pressure falls below the lower sensor limit.

Overflow range

Description The output signal is divided into defined ranges: ● Measuring range ● Saturation limits ● Fault current The transmitter emits the output current according to the device variables selected as primary variable (PV). The working range of the current lies between 4 mA and 20 mA.

Meaning When the measurement limits are exceeded or not reached, the measured values are correctly displayed in the overflow range. A ticker is displayed in the lower line of the digital display showing the message UNDER or OVER with respect to the selected unit. The possible overflow range can be adjusted via HART communication. If either of the overflow limits are violated, the output current remain constant. Violations of the measured value limits are displayed on the digital display with or . Note The setting of the overflow range and the fault current range can be freely selected via HART communication.

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ITEM 1120, 1340, 1355 Operation 6.4 Digital display

Reference NAMUR recommendation NE43 dated 03.02.2003 "Standardization of the signal level for the breakdown information of digital transmitters"

See also Fault current (Page 109) Setting the current limits (Page 110)

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

6.5

Local operation

6.5.1

Local control elements

Introduction The transmitter can be operated on-site using the buttons. Selectable modes can be used to choose and execute the functions described in the table. The number of functions is limited if the device does not have a digital display.

Control elements 



 





Figure 6-5

Position of buttons and digital display

➀

Digital display

➁

Connecting plug for the digital display

➂

Mode button

➃

Increment button

➄

Decrement button

Operating functions NOTICE Zero point calibration For absolute pressure transmitters, the start of scale value is at vacuum. A zero point calibration with transmitters which do not measure absolute pressure leads to faulty settings.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation Table 6-4

Operating functions using buttons

Function

Mode

Button function

[M]

[↑]

[↓]

Display, explanations [↑] and [↓]

Measured value

The modes are selected here.

The current measured value is displayed as you have adjusted it in the "Measured value display, mode 13" function.

Start of scale value (only in "Pressure" measuring mode)

2

Current higher

Current lower

Set to 4 mA

Output current in mA

Full scale value (only in "Pressure" measuring mode)

3

Current higher

Current lower

Set to 20 mA

Output current in mA

Electrical damping

4

Damping higher

Damping lower

Set to 0

Time constant T63 in seconds

Start of scale value 5 in the so-called blind adjustment

Pressure higher

Pressure lower

Set start of scale value to 0

Full scale value in the so-called blind adjustment

6

Pressure higher

Pressure lower

Set full scale Full scale value in the selected pressure unit value to upper measuring limit

Zero point calibration (position correction)

7

Correctio n value higher

Correctio n value lower

execute

Ventilate the transmitter for gauge pressure, differential pressure, flow rate or level. Evacuate the transmitter for absolute pressure (< 0.1 ‰ of the measuring span). (Start of scale value remains unaffected) Measured value in pressure unit

Current transmitter

8

Current higher

Current lower

switch on

constant output current in mA

Adjustment range: 0.0 s to 100.0 s Start of scale value in the selected pressure unit

"3.6"; "4", "12", "20" or "22.8" Switch off using the [M] button.

Output current in case of fault

9

Switch between lower fault current and upper fault current.

lower fault current

selected output current possible: Fault current limits adjusted by user

Button lock or function lock

10

Switch between the five functions

–

0

None

LA

all locked

LO

all locked except for start of scale value

LS

all locked except for start of scale value and full scale value

L

Write protection Operation via HART not possible.

lin

linear

srlin

square root extracting (linear up to the application point)

sroff

Square root extracting (deactivated up to the application point)

srli2

square root extracting (linear up to the application point 10%)

Characteristic curve1)

64

11

Switch between the four functions

linear

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operation 6.5 Local operation Function

Mode

Button function

[M]

[↑]

[↓]

Display, explanations [↑] and [↓]

Application point of 12 the square root extracting characteristic curve1)

Greater

Measured value display

13

Select from three options.

–

• • •

Unit

14

Select from the table for measured value display.

In each case, the first value from the table of the physical unit

Physical unit

1)

Smaller 10% flow rate

Adjustment range of 5 to 15% flow rate.

Display type (input value) Output current in mA Measured value in %

Not relevant for gauge and absolute pressure)

See also Overview of operation (Page 55) Operating functions through HART communication (Page 91)

6.5.2

Operation using buttons

Introduction This overview informs you about the most important safety notes to be observed when operating the pressure transmitter. Furthermore, the overview guides you in adjusting the operating functions on site.

Condition The keyboard must have been unlocked in order to operate the device using the buttons.

Procedure In the default setting, the device is in the measured value display. To adjust the operating functions, proceed as follows: 1. Loosen both the screws of the keyboard cover and lift it upwards. 2. Keep pressing the [M] button until the desired mode is displayed. 3. Keep pressing the [↑] or [↓] button until the desired value is displayed. 4. Press the [M] button. Now you have saved the values and the device goes to the next mode. 5. Close the keyboard cover using the two screws.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Note The setting is saved and the measured values are automatically displayed again if more than two minutes have passed after a button was pressed for the last time.

See also Releasing key lock or function lock (Page 81)

6.5.3

Start of scale value/full scale value

6.5.3.1

Difference between setting and adjusting

Introduction In "Pressure" measuring mode, you can set or adjust the start of scale value and full scale value using the buttons. Modes 2 and 3 are used for this. Rising and falling characteristic curves can be realized with appropriate use of the buttons. If the transmitter is not in "Pressure" measuring mode, this mode is skipped in local operation.

Difference The difference between setting and adjusting lies in the calculation.

Setting with reference pressure Condition Two reference pressures pr1 and pr2 are available. The reference pressures are initialized by the process or generated by a pressure sensor. When setting, a desired start of scale value or a full scale value is allocated to the standard current values (4 mA or 20 mA). After setting, the measuring span entered on the type plate may no longer correspond with the adjustment. Depending on the series and measuring range, a maximum downscaling of 1:100 can be achieved (measuring span ratio = r, turn down). Note Setting the start of scale value does not change the measuring span. Setting the full scale value does not change the start of scale value. The start of scale value should therefore be set first, then the full scale value. The correlation between the measured pressure and the output current generated is linear. The square root extracting characteristic curve for differential pressure transmitters is an exception. Calculate the output current using the following formula.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

,

S0$ 0(0$

Figure 6-6

P$P$

Current calculation formula for setting

I

Output current

MAactual Old start of scale value

p

Pressure

MEactual Old full scale value

MA

Start of scale value

MAtarget New start of scale value

ME

Full scale value

MEtarget New full scale value

Example of setting with reference pressure A Initial situation









S>EDU@ ,>P$@

B Setting start of scale value

0$DFWXDO 0$WDUJHW  

0(DFWXDO 





S>EDU@ 

,>P$@

C Setting full scale value



0$DFWXDO 

0$WDUJHW 



0(WDUJHW 



S>EDU@ 





,>P$@

Explanations for the example of setting with reference pressure A The measuring range is from 0 to 16 bar. You are changing the start of scale value from 0 to 2 bar and the full scale value from 16 to 14 bar. The measuring span is then 12 bar. B 2 bar process pressure is created. Use the [M] button to set the transmitter to mode 2. To set the start of scale value, press the [↑] and [↓] buttons simultaneously for 2 seconds. If there is 2 bar input pressure, the transmitter produces an output current of 4 mA. C 14 bar process pressure is created. Use the [M] button to set the transmitter to mode 3. To set the full scale value, press the [↑] and [↓] buttons simultaneously for 2 seconds. If there is 14 bar input pressure, the transmitter produces an output current of 20 mA. D The output current can be calculated for any input pressure using the "current calculation formula for setting".

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Note If the value exceeds or falls below the preset measuring limits by more than 20% when setting, the setting function is not carried out. The old value is retained in this case. With a marked elevation of the zero point, the full scale value must therefore previously be reduced such that it still lies within the permitted range after elevation of the zero point. This setting function is only possible in "Pressure" measuring mode.

Adjusting with reference pressure Condition: The reference pressure, the adjusted start of scale value and adjusted full scale value are known. When adjusting, a start of scale value or a full scale value can be allocated to a desired current value with the aid of a reference pressure. This function is particularly suitable when the required pressures for the start of scale value and the full scale value are not available After adjustment, the measuring range specified on the type plate may no longer correspond with the setting. Using the formulae below, the current to be set for the desired start of scale value and the full scale value can be calculated. To calculate the output currents when setting the start of scale value or the full scale value, the reference pressure must be selected such that a value between 4 and 20 mA results for the current. ,

,0(

S0$ 0(0$

SUHI0$WDUJHW

P$P$ 0(WDUJHW0$WDUJHW

Figure 6-7

68

P$P$

Current calculation formula for setting with reference pressure

I

Output current

MAactual Old start of scale value

IMA

Current to be adjusted with MAtarget

MEactual Old full scale value

IME

Current to be adjusted with MEtarget

MAtarget New start of scale value

p

Pressure

MEtarget New full scale value

pref

Existing reference pressure

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Example of adjusting with reference pressure A Initial situation 

SUHI 









0$DFWXDO 0$WDUJHW  



0(,VW 







0(WDUJHW  

S>EDU@ ,>P$@

B Calculating start of scale value

S>EDU@  VHW

,>P$@

C Calculating full scale value

0$DFWXDO 0$WDUJHW   S>EDU@ 

VHW





,>P$@

Explanations for the example of adjusting with reference pressure A The measuring range is from 0 to 16 bar. You are changing the start of scale value from 0 to 2 bar and the full scale value from 16 to 14 bar. The measuring span is then 12 bar. A reference pressure of 11 bar is created. B Use the [M] button to set the transmitter to mode 2. The "Current calculation formula for adjusting with reference pressure" can be used to calculate the current to be adjusted for the desired start of scale value IMA (13 mA at 2 bar) with the existing reference pressure. It can be adjusted with the [↑] or [↓] buttons IMA. C Use the [M] button to set the transmitter to mode 3. The "Current calculation formula for adjusting" can be used to calculate the current to be adjusted for the desired full scale value IME (16 mA at 14 bar) with the existing reference pressure. It can be adjusted with the [↑] or [↓] buttons IM. Note If the preset measuring limits are exceeded or fallen below by more than 20% during adjustment, the resulting current cannot be set above these limits. With a marked elevation of the zero point, the full scale value must therefore previously be reduced such that it still lies within the permitted range after elevation of the zero point.

See also Unit (Page 86)

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

6.5.3.2

Setting/adjusting the start of scale value

Introduction Set or adjust the start of scale value of the pressure transmitter in mode 2. You can also adjust the start of scale value or the full scale value separately as well as adjust both these values one after the other.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes. You have selected a reference pressure that corresponds to the start of scale value and is within the permissible tolerance range. The transmitter is in "Pressure" measuring mode.

Setting start of scale value To set the output current of the start of scale value to 4 mA, proceed as follows: 1. Create the reference pressure. 2. Set mode 2. 3. Set the start of scale value to 4 mA. 4. Save with the [M] button.

Adjusting start of scale value If you do not set the output current but constantly adjust it, you need to calculate the currents to be adjusted mathematically. To the adjust the output current of the start of scale value, proceed as follows: 1. Create the reference pressure. 2. Set mode 2. 3. Adjust the output current of the start of scale value to the calculated value. 4. Save with the [M] button.

Setting the start of scale value without a digital display You have a device with a cover that does not have an inspection window and you wish to set the start of scale value. To set the output current of the start of scale value to 4 mA, proceed as follows: 1. Create the reference pressure. 2. Press the [↑] and [↓] buttons simultaneously. The device has set the start of scale value to 4 mA. 3. When you release the buttons, the device saves the adjusted value automatically.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Adjusting the start of scale value without a digital display You have a device with a cover that does not have an inspection window and you do not wish to set the start of scale value, but adjust it. You will need an ammeter for this purpose. To the adjust the output current of the start of scale value, proceed as follows: 1. Connect the ammeter to the test connector. 2. Create the reference pressure. 3. Adjust the output current of the start of scale value using the [↑] or [↓] button. 4. When you release the button, the device saves the adjusted value automatically.

6.5.3.3

Setting/adjusting the full scale value

Introduction Set or adjust the full scale value of the pressure transmitter in mode 3. You can also adjust the start of scale value or the full scale value separately as well as adjust both these values one after the other.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes. You have selected a reference pressure that corresponds to the full scale value and is within the permissible tolerance range. The transmitter is in "Pressure" measuring mode.

Setting full scale value To set the output current of the full scale value to 20 mA, proceed as follows: 1. Create the reference pressure. 2. Set mode 3. 3. Set the full scale value to 20 mA. 4. Save with the [M] button.

Adjusting full scale value If you do not set the output current but constantly adjust it, you need to calculate the currents to be adjusted mathematically. To the adjust the output current of the full scale value, proceed as follows: 1. Create the reference pressure. 2. Set mode 3. 3. Adjust the output current of the full scale value to the calculated value.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation 4. Save with the [M] button.

Setting the full scale value without a digital display You have a device with a cover that does not have an inspection window and you wish to set the full scale value. To set the output current of the full scale value to 20 mA, proceed as follows: 1. Create the reference pressure. 2. Press and hold the [M] button. 3. Also press the [↑] and [↓] buttons simultaneously. The device has set the full scale value to 20 mA. 4. When you release the buttons, the device saves the adjusted value automatically.

Adjusting the full scale value without a digital display You have a device with a cover that does not have an inspection window and you do not wish to set the full scale value, but adjust it continuously. You will need an ammeter for this purpose. To the adjust the output current of the full scale value, proceed as follows: 1. Connect the ammeter to the test connector. 2. Create the reference pressure. 3. Press and hold the [M] button. 4. Adjust the output current of the full scale value to the calculated value using the [↑] or [↓] button. 5. When you release the button, the device saves the adjusted value automatically.

6.5.4

Setting/adjusting electrical damping

Difference between setting and adjusting You can set or adjust the time constant of electrical damping using the buttons. Setting means that the time constant is automatically set to 0 seconds. Adjusting means that the time constant is adjusted between 0 and 100 seconds using the steps of 0.1 seconds. This electrical damping also has an effect on the built-in basic damping of the device.

Condition for "setting" You are familiar with the correct operation of the transmitter and the associated safety notes.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Setting electrical damping To set electrical damping to 0 seconds, proceed as follows: 1. Set mode 4. 2. Press the [↑] and [↓] buttons simultaneously. 3. Save with the [M] button.

Result Electrical damping has been set to 0 seconds.

Condition for "adjusting" The default setting of steps is an interval of 0.1 seconds. If you press the [↑] or [↓] button for a longer time, the step is increased.

Adjusting electrical damping To adjust electrical damping, proceed as follows: 1. Set mode 4. 2. Adjust the desired damping. 3. Save with the [M] button.

Result Electrical damping has been set to the desired time constant.

6.5.5

Blind start of scale value/full scale value

6.5.5.1

Difference between setting/adjusting and blind setting/adjusting

Differences In contrast to setting/adjusting with a reference pressure, you do not need a reference pressure for blind setting/adjusting. You can adjust a value in the physical variable "pressure" without a reference pressure, and an output current with a reference pressure.

Blind adjusting First select the desired physical unit. Then, adjust two pressure values using the [↑] and [↓] buttons and save them in the device. These theoretical pressure values are allocated to the standard current values 4 mA and 20 mA. Depending on the series and measuring range, a maximum downscaling of 1:100 can be achieved (measuring span ratio = r, turn down).

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation The correlation between the measured pressure and the output current generated is linear. The square root extracting characteristic curve for differential pressure transmitters is an exception.

Example of blind adjusting A Initial situation









S>EDU@

,>P$@

B Blind adjustment of the start of scale value

0$DFWXDO 

0$WDUJHW

0(DFWXDO













S>EDU@

,>P$@

C Blind adjustment of the full scale value

0$DFWXDO 

0$WDUJHW 

0(WDUJHW  

S>EDU@ 



,>P$@

I

Output current

p

Pressure

MAactu

Old start of scale value

MAtarget

New start of scale value

Old full scale value

MEtarget

New full scale value

al

MEactu al

Explanations for the blind adjusting example A The measuring range is from 0 to 16 bar. You are changing the start of scale value from 0 to 2 bar and the full scale value from 16 to 14 bar. The measuring span is then 12 bar. In this example you create no pressure. B Use the [M] button to switch the transmitter to mode 5. To adjust the start of scale value to 2 bar, press one of the [↑] or [↓] buttons. If there is 2 bar input pressure, the transmitter produces an output current of 4 mA. C Use the [M] button to switch the transmitter to mode 6. To adjust the full scale value to 14 bar, press one of the [↑] or [↓] buttons. If there is 14 bar input pressure, the transmitter produces an output current of 20 mA.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Note If the preset measuring limits are exceeded or fallen below by more than 20% during adjustment, the resulting current cannot be set above these limits. With a marked elevation of the zero point, the full scale value must therefore previously be reduced such that it still lies within the permitted range after elevation of the zero point.

Setting without reference pressure Blind setting resets the start of scale value to the lower sensor limit and the full scale value to the upper sensor limit. Note If the value exceeds or falls below the preset measuring limits by more than 20% when setting, the setting function is not carried out. The old value is retained in this case. With a marked elevation of the zero point, the full scale value must therefore previously be reduced such that it still lies within the permitted range after elevation of the zero point.

6.5.5.2

Blind setting of start of scale value

Introduction Blind setting resets the start of scale value to the lower sensor limit. Note Changes in modes 5 and 6 have an exclusive effect on pressure scaling. This does not affect the scaling for level or customized characteristic curve. Therefore, only measured pressure values and pressure units are displayed in these modes.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes. You have not created any reference pressure and have selected a pressure unit.

Procedure To the set the start of scale value blindly, proceed as follows: 1. Set mode 5. 2. Press the [↑] and [↓] buttons simultaneously for 2 seconds.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

6.5.5.3

Blind setting of full scale value

Introduction Blind setting resets the full scale value to the upper sensor limit. Note Changes in modes 5 and 6 have an exclusive effect on pressure scaling. This does not affect the scaling for level or customized characteristic curve. Therefore, only measured pressure values and pressure units are displayed in these modes.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes. You have not created any reference pressure and have selected a pressure unit.

Procedure To the set the full scale value blindly, proceed as follows: 1. Set mode 6. 2. Press the [↑] and [↓] buttons simultaneously for 2 seconds.

6.5.5.4

Blind adjusting of the start of scale value

Introduction In the case of blind adjustment, adjust the pressure value of the start of scale value continuously and without a reference pressure. Note Changes in modes 5 and 6 have an exclusive effect on pressure scaling. This does not affect the scaling for level or customized characteristic curve. Therefore, only measured pressure values and pressure units are displayed in these modes. You can toggle between rising and falling characteristic curves.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes. You have not created any reference pressure and have selected a pressure unit.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Procedure To the adjust the pressure value of the start of scale value blindly, proceed as follows: 1. Set mode 5. 2. Adjust the pressure value of the start of scale value. 3. Save with the [M] button.

6.5.5.5

Blind adjustment of the full scale value

Introduction In the case of blind adjustment, adjust the pressure value of the full scale value continuously and without a reference pressure. Note Changes in modes 5 and 6 have an exclusive effect on pressure scaling. This does not affect the scaling for level or customized characteristic curve. Therefore, only measured pressure values and pressure units are displayed in these modes. You can toggle between rising and falling characteristic curves by swapping the start of scale value and the full scale value.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes. You have not created any reference pressure and have selected a pressure unit.

Procedure To the adjust the pressure value of the full scale value blindly, proceed as follows: 1. Set mode 6. 2. Adjust the pressure value of the full scale value. 3. Save with the [M] button.

6.5.6

Trimming the zero point

Introduction The zero point is calibrated in mode 7. Zero point calibration corrects zero point errors resulting from the installation position of the pressure transmitter. The device type determines the way in which you proceed. SIMATIC PDM or the HART communicator will display the total of all zero point corrections.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Condition You are familiar with the correct operation of the transmitter and the associated safety notes.

Zero point calibration for gauge pressure transmitter To calibrate the zero point, proceed as follows: 1. Pressurize the transmitter. 2. Set mode 7. 3. Press the [↑] and [↓] buttons simultaneously. 4. Save with the [M] button.

Zero point calibration for absolute pressure transmitter Note You need a reference pressure known to you which lies within the measuring limits. To calibrate the zero point, proceed as follows: 1. Create the reference pressure. 2. Set mode 7. 3. Set the reference pressure on the digital display. 4. Save with the [M] button.

6.5.7

Current transmitter

Introduction In mode 8, switch the pressure transmitter into the constant current operation. You can connect an external current transmitter in the constant current operation. The current then no longer corresponds to the process variable. The following output current can be adjusted irrespective of the input pressure: ● 3.6 mA ● 4.0 mA ● 12.0 mA ● 20.0 mA ● 22.8 mA You can use HART communication to adjust intermediate values.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Procedure To switch on the constant current operation, proceed as follows: 1. Set mode 8. "Cur" in the digital display stands for current. 2. Press the [↑] and [↓] buttons simultaneously. 3. Select constant current.

Switching off the constant current operation To switch off the constant current operation, proceed as follows: Press the [M] button in mode 8.

6.5.8

Output current in case of fault

Introduction When a fault occurs, the lower fault current is displayed in the basic setting. In mode 9, you can choose between the output of the upper and lower fault current. The standard values 3.6 mA and 22.8 mA are set. The standard values of the upper and lower fault current can be changed via HART communication.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes.

Procedure To change the fault current, proceed as follows: 1. Set mode 9. 2. Select the fault current. 3. Save with the [M] button. Note If a current saturation interrupt is active, the setting of the output current may deviate from your setting in the case of a fault.

Resetting fault current To reset the fault current to the basic setting, proceed as follows: Press the [↑] and [↓] buttons simultaneously.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Fault causes Fault currents may be triggered by: ● FW alarm ● HW alarm ● Diagnostic interrupt ● Sensor breakage ● Measured value status BAD

Reference NAMUR recommendation NE43 dated 03.02.2003 "Standardization of the signal level for the breakdown information of digital transmitters"

6.5.9

buttons and function lock

Introduction In mode 10, you can disable the functions that can be executed using buttons. Application example for a lock is e.g. safeguarding the saved parameters.

Lock options You have the following lock options on the pressure transmitter: Table 6-5 Lock mode

Meaning of lock modes Meaning

0

The device can be operated by means of the keys and HART communication.

LA

Keys on the transmitter are locked. Exception: • Releasing key lock The device can be operated by means of HART communication.

LO

Keys on the transmitter are partially locked. Exception: • Setting start of scale value • Releasing key lock The device can be operated by means of HART communication.

LS

Keys on the transmitter are partially locked. Exception: • Setting start of scale value • Setting full scale value • Releasing key lock The device can be operated by means of HART communication.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation Lock mode L

Meaning Write protection Operation via keys and HART communication is blocked. Exception: • Releasing key lock

Note If you want to select the LO or LS lock, we recommend you first select the measured value display of "Current" in "mA" or "%" in mode 13. Otherwise, a change in the output variable using the [↑] and [↓] buttons is not detected. If the blind cover is provided, the LS lock mode is effective, i.e. only the zero point and the span can be changed. If you continuously operate the device with the blind cover, ensure that the LS lock mode is constantly set.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes. Note In the measured value display function, check whether the desired setting is displayed.

Procedure To disable the buttons, proceed as follows: 1. Set mode 10. 2. Select the desired lock mode. 3. Confirm the lock mode with the [M] button.

6.5.10

Releasing key lock or function lock

Releasing key lock WARNING In the case of devices used for safety-relevant applications, only authorized personnel may release the key lock, e.g. overflow protection. To release a set key lock (LA, LO, LS) using buttons, proceed as follows: Press the [M] button for 5 seconds.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Releasing the write protection To release a write protection for HART (L) using buttons, proceed as follows: Press the [M] button for 5 seconds.

6.5.11

Flow rate measurement (only differential pressure)

Introduction The characteristic curve representing the relationship between the output current and input pressure can be adjusted in mode 11. Adjust the root application point in mode 12. You can select the following characteristic curve types of the output current: ● linear "lin": proportional to differential pressure ● square root extracting "sroff": proportional to flow rate, deactivated up to the application point ● square root extracting "srlin": proportional to flow rate, linear up to the application point ● square root extracting "srli2": proportional to flow rate, two-step linear up to the application point

Variable application point The output current for the "srlin" and "sroff" functions can be displayed linearly or set to zero below the application point of the square root extracting characteristic curve.

Fixed application point The "srli2" function has a permanently defined application point of 10%. The range up to this point contains two linear characteristic curve sections. The first section ranges from the zero point to 0.6% of the output value and 0.6% of the pressure value. The second section has a higher gradient and it goes up to the root application point at 10% of the output value and 1% of the pressure value. See the following figure for this purpose.

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

Procedure Proceed as follows to set or adjust the type of characteristic curve: 1. Set mode 11. 2. Select the type of characteristic curve. To set the characteristic curve to "linear", press the [↑] and [↓] buttons simultaneously. 3. Save with the [M] button. Proceed as follows to set or adjust the root application point: This procedure is not applicable for "srli2": 1. Set mode 12. 2. Select an application point between 5 and 15%. To set the application point to 10%, press the [↑] and [↓] buttons simultaneously. 3. Save with the [M] button. Note Mode 12 cannot be selected if the "linear" or "srli2" measuring mode has been adjusted in mode 11. If the square root extracting characteristic curve has been adjusted in mode 11 and if the measured value display has been set to "Pressure" in mode 13, the root sign and the differential pressure corresponding to the flow rate are displayed.

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83

ITEM 1120, 1340, 1355 Operation 6.5 Local operation

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84

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operation 6.5 Local operation

6.5.12

Measured value display

Introduction In mode 13, adjust the following types of measured value display: ● mA ● % ● Display of the selected measuring mode. See the following table. Table 6-6

Display of measuring mode/device variables

Digital display

DV

Meaning

P

0

Pressure

t-SE

1

Sensor temperature

t-EL

2

Electronics temperature

P-UNC

3

Pressure (untrimmed)

LEVEL

4

Level

Vol

5

Volume

MASS

6

Mass

V-Flo

7

Volume of flow (not relevant for gauge and absolute pressure)

M-Flo

8

Mass flow rate (not relevant for gauge and absolute pressure)

CUSt

9

Users

Condition You are familiar with the correct operation of the transmitter and the associated safety notes.

Procedure To select the display type, proceed as follows: 1. Set mode 13. 2. Select the measured value display. 3. Save with the [M] button.

See also Measured value display (Page 112)

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85

ITEM 1120, 1340, 1355 Operation 6.5 Local operation

6.5.13

Unit

Introduction In mode 14, select the physical unit in which the measured value display of the device should be shown.

Condition You are familiar with the correct operation of the transmitter and the associated safety notes. You have already selected the desired measured value display in mode 13.

Procedure To adjust the physical unit, proceed as follows: 1. Set mode 14. 2. Select a unit. Press the [↑] and [↓] buttons simultaneously to set the unit to the first value in the following table depending on the measuring mode set. 3. Save with the [M] button.

Instructions for selecting the unit ● The unit is selected depending on the measurement type set. For example, only pressure units are made available in "Pressure" measuring mode and only level unit are made available in the "Level" measuring mode. ● The displayed measured value is always converted into the new unit. When the display capacity of the digital display is exceeded, "9.9.9.9.9" appears on the display. ● The selected unit is visible on the display in the measuring mode only if you have selected the display of a physical unit in mode 13. If you have not selected mode 13, "mA" or "%" is displayed.

Units Table 6-7

86

Units available for pressure

Pressure units

Display

mbar

mbar

bar

bar

mm water column (20°C / 68°F)

mmH2O

Inch water column (20°C / 68°F)

inHG

Feet water column (20°C / 68°F)

FTH2O

mm mercury column

mm_HG

Inch mercury column

in_HG

mm water column (4°C / 39°F)

m4H2O

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operation 6.5 Local operation Pressure units

Display

Inch water column (4°C / 39°F)

i4H2O

Psi

PSi

Pa

Pa

KPa²

KPa

MPa

MPa

g/cm2

Gcm2

Kg/cm2

KGcm2

Torr

TORR

ATM

ATM

Table 6-8

Units available for volume

Volume unit

Display

m3

m3

Liter

L

Hectoliter

Hl

US gallon

Gal

British gallon

in Gal

British barrel

bbl

British barrel liquid

bblli

Buschels

buShl

yard3

Yd3

Feet3

FT3

inch3

in3

Standard l

STdl

Standard m3

STdm3

Standard feet3

STFT3

Table 6-9

Units available for mass

Mass unit

Display

Gram

G

Kilogram

KG

Ton

T

Short ton

STon

Long ton

lTon

Pound

lb

Ounce

OZ

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation Table 6-10

Units available for volume of flow

Unit for volume of flow m3 / second

m3/S

m3 / minute

m3/M

m3 / hour

m3/H

m3 / day

m3/D

Liter / second

L/S

Liter / minute

L/M

Liter / hour

L/H

Million liter / day

ml/ D

Feet3 / second

FT3/S

Feet3 / minute

FT3/M

Feet3 / hour

FT3/H

Feet3 / day

FT3/D

Gallon / second

Gal/S

Gallon / minute

Gal/M

Gallon / hour

Gal/H

Gallon / day

Gal/D

Million gallon / day

MGl/D

British gallon / second

iGL/S

British gallon / minute

iGL/M

British gallon / hour

iGL/H

British gallon / day

iGL/D

Standard m3 / hour

Sm3/H

Standard l / hour

STI/H

Standard feet3 / minute

SFT3M

British barrel liquid / second

bbl/S

British barrel liquid / minute

bbl/M

British barrel liquid / hour

bbl/H

British barrel liquid / day

bbl/D

Table 6-11

88

Display

Units available for mass flow rate

Mass flow rate unit

Display

g/s

G_S

g / min

G_MIN

g/h

G_H

Kg / s

KG/S

Kg / min

KG/M

Kg / h

KG/H

Kg / d

KG/D

T / min

T/M

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operation 6.5 Local operation Mass flow rate unit

Display

T/h

T/H

T/d

T/D

Pound / s

P/S

Pound / min

lb/M

Pound / h

lb/H

Pound / d

lb/D

Short ton / min

ShT/M

Short ton / h

ShT/H

Short ton / d

ShT/D

Long ton / h

lT/H

Long ton / d

lT/D

Table 6-12

Units available for level

Level unit

Display

Feet

FT

Inch

inch

m

m

cm

cm

mm

mm

Table 6-13

Units available for temperature

Temperature unit

Display

° Celsius

°/C

° Fahrenheit

°/F

Kelvin

K

Rankine

R

See also Selection of the physical unit (Page 113)

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ITEM 1120, 1340, 1355 Operation 6.5 Local operation

90

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ITEM 1120, 1340, 1355

Operating functions through HART 7.1

7

Operating functions through HART communication

Condition You can operate the transmitter through HART communication. The following is required for this purpose: ● A HART communicator or PC software such as SIMATIC PDM. ● A HART modem to connect a PC with the transmitter or a lead to connect a HART communicator with the transmitter.

Introduction The full functionality of the transmitter is available via HART communication. The HART communicator and PC software are not supplied with the transmitter. How to connect and operate a HART communicator or the PC software is described in separate operating instructions or in the online help for both these tools.

Fundamental description The input signal is provided in the form of digital information in the following variables through HART communication: ● Pressure ● Level ● Volume ● Mass ● Volume of flow ● Mass flow rate ● User programmable "characteristic curve" As soon as you have set up the HART communication and the transmitter, you can adapt the transmitter to your relevant measuring task. When doing so you are assisted by the selectable measuring modes "Pressure", "Level", "Flow rate" and a user programmable "Characteristic curve". One or more device variables are permanently allocated to each measuring mode in order to execute corresponding measuring tasks.

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ITEM 1120, 1340, 1355 Operating functions through HART 7.2 Process tag data

See also Overview of operation (Page 55)

7.2

Process tag data You can store your process tag data in user definable fields. The following table contains information about the structure of these fields and the format in which you can enter information in these fields: Table 7-1

Process tag data

Field

Explanations

Tag designation

Eight characters

Date

Day:Month:Year

Description

16 characters

Message

32 characters

Works number

Integer number

Tag designation long

32 characters

Freely definable material parameter

21 x 16 characters

7.3

Selecting the measuring modes

7.3.1

Overview of measuring modes

Overview The transmitter can be set for the corresponding measuring task using a few parameters. You can select the following measuring modes: ● Pressure ● Level ● Flow rate ● Users: user programmable characteristic curve You can use the measuring mode selector to activate measuring modes "Level", "Flow rate" and "User".

Selecting the device variables One or more device variables are permanently allocated to each measuring mode. The following device variables are always active and are therefore always displayed:

92

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes ● Pressure ● Sensor temperature ● Electronics temperature ● Pressure (untrimmed) The following device variables are activated only when the allocated measuring mode is activated and parameterized simultaneously: ● "Level", "Volume" and "Mass" are allocated to the "Level" measuring mode. ● "Volume of flow" and "Mass flow rate" are allocated to the "Flow rate" measuring mode. ● "User" is allocated to the "User" measuring mode. The inactive device variables have the CONSTANT status.

7.3.2

Measuring mode selector You can use this switch to toggle between measuring modes "Pressure", "Level", "Flow rate" and a characteristic curve programmable by a "User". If a measuring mode has been selected using the measuring mode selector, it has to be configured. This does not mean that this block has an automatic effect on the current output (4 to 20 mA). For that, you need to switch the corresponding device variable to the primary variable (PV) using a so-called variable mapper.

7.3.3

Variable mapper

Introduction In this transmitter, the dynamic variable that determines the behavior of current output is always called the primary variable (PV). You need to use the variable mapper for a number of purposes, including selecting which device variable is to be switched to PV. The variable selected as PV using a PC program such as SIMATIC PDM or using the HART Communicator is scaled once again in the analog output stage to a zero value and a limit value. These two values then correspond to the current values 4 and 20 mA. As soon as the PV is switched over using the variable mapper, the start of scale value and full scale value in the analog output stage are preset to the limit values of the new device variables. You can define these limit values within the individual block functions. The dynamic variables "Primary", "Secondary", "Tertiary" and "Quarternary" (PV, SV, TV, QV) can be interconnected with any active device variables. Various different measuring mode examples are conceivable with a 4 bar pressure transmitter.

See also Measured value status (Page 101)

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ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes

7.3.4

Measuring mode "Pressure" The "Pressure" measuring mode contains the "Sensor trim" function, and is always active since it is the standard measuring mode. When the measuring mode selector is set to "Off", further measuring variables are not derived from the "Pressure" measuring variable. Except the first four variables, all other device variables are marked as inactive and have the CONSTANT status. These four variables are mapped with dynamic variables PV, SV, TV and QV by default. Switching an inactive device variable to the primary variable (PV) generates an error message since the variable currently does not have a valid measured value. This message is displayed in SIMATIC PDM or the HART communicator. /LQHDUL ]DWLRQ

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DV

Device variable

MA

Start of scale value

ME

Full scale value

PV

Primary variable

QV

Quarternary variable

SV

Secondary variable

TV

Tertiary variable

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes

7.3.5

Customized characteristic curve

Introduction The customized "characteristic curve" is continuously active as an identical function in the three following measuring modes "Level", "Flow rate" and "User". This means that the customized "characteristic curve" always provides a result for the following function, thus also influencing the measured value status of the affected device variables. In the device, the characteristic curve vertices are only provided once in the EEPROM. Therefore, if the measuring mode is changed, you will usually need to adjust the characteristic curve accordingly. The characteristic curve function expects at least two and at the most 30 characteristic curve vertices as input parameters. Characteristic curve vertices are entered in pairs of values x %;y %. The values for the x-coordinate are only accepted by the device when they run monotonically. The y-coordinates, on the other hand, may also be non-monotonic. A warning will however be issued by the configuring device, which you as the user have to recognize and acknowledge. The output of the characteristic curve is not explicitly stored in a device variable, but rather is directly interconnected with the input of the next function block in each case. The pairs of values 0%;0% and 100%;100% are set as default values. In principle, rising and falling characteristic curves can be configured. With regard to the device variable status, rising characteristic curves are however preferred. Otherwise the meanings of HIGH LIMIT and LOW LIMIT are swapped.

See also Measured value status (Page 101)

7.3.6

Measuring mode "Level"

Description Once you have configured the measuring mode "Level", the device variables "Level", "Volume" and "Mass" are activated. They are all inferred from the measured pressure. The "Level" block here represents a series of permanently interconnected functions which you need to configure with appropriate parameters. Only then will you be given a meaningful measured value for the three device variables.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

95

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes 6HQVRU

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DV

Device variable

MA

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ME

Full scale value

Functions of the "Level" block The first function, "Input scaling, pressure", sets the pressure range used by the following functions in all three blocks in the same way. Ideally, this range corresponds to the sensor limits of the transmitter. In the following calculation examples, 0 and 4 bar are assumed for these sensor limits for all blocks. You can however also set a downscaling, e.g. 1:2. The downscaling of 1:2 means that 50% of the rated measuring range, here 2 bar, can control the following characteristic curve 100%. Use the "Output scaling, level" to set the measuring limits for the measuring mode "Level" with a unit from the level range. Parameter settings in this example are 10 and 20 m. At 0 bar process pressure, 10 m is displayed in DV4 and 20 m is displayed at 2 bar. The values for the start of scale value and the full scale value, which are effective for the analog output, are configured in the "analog output" block. In the calculation example, the two pairs of values 0%;0% and 100%;100% are configured for the customized "characteristic curve". This is the default setting. The measured value from the pressure scaling is transferred 1:1 in this example.

96

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes '9>@EDU

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Functions of the "Level" block

DV [x]

Device variable x

L

Level

m

Mass

MA

Start of scale value

ME

Full scale value

P

Pressure

V

Volume

Configure the "Output scaling, volume" with a unit from the volume range and the measuring limits for the device variable "Volume". The characteristic curve output directly affects the volume scaling input. In the calculation example, for the measuring limits from 0 and 100 l, a volume of 50 l is yielded for process pressure of 1 bar. The "Level" parameter setting also still automatically activates the device variable for the mass. If you have not yet configured a value for the density, the initial value of 1 kg/l is preset. In the calculation example for the "Mass" device variable, a mass of 250 kg is derived at a density of 5 kg/l. Note When the density changes, the measuring range limits have to be adjusted accordingly. You can configure all parameter settings for the "Level" block in SIMATIC PDM or the HART communicator. Activate the "Level" measuring mode for this purpose. For all settings, the measuring limits may be exceeded by +/-20%. Values which lie above or below that will be rejected by the device.

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ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes

7.3.7

Measuring mode "Flow rate"

Description When you activate the "Flow rate" measuring mode, only two other device variables are active: Volume of flow and Mass flow rate. If another block was active earlier, the corresponding device variables remain inactive and have the "CONSTANT" status. The "Flow rate" block here represents a series of permanently interconnected functions which you need to configure with appropriate parameters. /LQHDUL ]DWLRQ

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DV

Device variable

MA

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ME

Full scale value

Functions of the "Flow rate" block The "Input scaling, pressure" function defines the pressure range of 0 to 2 bar that is interpreted as 0 and 100% by the following square root extracting function. A process pressure of 0.5 bar has been assumed in the following figure. In the "Flow rate" measuring mode, a square root extracting characteristic curve "srlin2" is plotted with a fixed root application point of 10%. In the calculation example, the input value for the "square root extracting function" is approximately 25% at a process pressure of 0.5 bar. The output value is approximately 50%.

98

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes

Note When using the "Flow rate" block, other square root extracting characteristic curves must be deactivated if required.

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Functions of the "Flow rate" block

DV [x]

Device variable x

MF

Mass flow rate

MA

Start of scale value

p

Pressure

ME

Full scale value

VF

Volume of flow

In the calculation example, the two pairs of values 0%;0% and 100%;50 % are configured for the customized "characteristic curve". This setting corresponds to a bisection of the input value for all output values. Configure the "Output scaling, volume of flow" with a unit from the volume of flow range and the measuring limits for the device variable "Volume of flow". In the calculation example, 0 l/s and 1000 l/s are defined as lower and upper measuring limits. The volume of flow is thus 250 l/s at a process pressure of 0.5 bar. The "Mass flow rate" device variable is automatically activated when the "Flow rate" block is configured. If you have not yet configured a value for the density, the initial value of 1 kg/l is preset. In the calculation example, a mass of 1000 kg/s is derived for the "Mass flow rate" device variable at a value of 4 kg/l. The value of density entered is used only to calculate the mass flow rate. The entered value of density has no effect on the diaphragm calculation that is to be carried out by the user. In SIMATIC PDM or the HART communicator, the "Flow rate" block is configured in an online dialog box in an extremely compact manner. In this online dialog box, you can compile all values in a menu and transfer them to the device collectively.

7.3.8

Measuring mode "User"

Description The "User" measuring mode is the simplest of the measuring modes that you can select with the measuring mode selector. Only one further device variable, "User", is activated in this measuring mode in addition to the four standard device variables. The variables "Level",

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

99

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes "Volume", "Mass", "Volume of flow" and "Mass flow rate" are marked as inactive and are given the status CONSTANT. In the "User" measuring mode, you have an option to define a customized unit for output scaling. This customized unit is, e.g. a specific quantity of liquid. This quantity of liquid depends on the input process pressure. Example: Fill the beverages in cans having a capacity of 0.33 l. You can now define a customized unit "Can" that is exactly equal to 0.33 l. The quantity of "cans" depends on the input process pressure. Note Permissible input values All alphabetic a...z, A...Z and numeric 0...9 inputs are allowed for the customized unit. The following characters are also allowed: °"$/<>*,_+-=@

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DV

Device variable

MA

Start of scale value

PV

Primary variable

ME

Full scale value

SV

Secondary variable

TV

Tertiary variable

QV

Quarternary variable

Functions of the "User" block The first function, "Input scaling, pressure", defines the pressure range which is used by the customized characteristic curve. Ideally, this range corresponds to the sensor limits.

100

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes In the calculation example, 0 and 2 bar are assumed. This means that with process pressure of 0.5 bar, there is a value of 25% on the characteristic curve. '9>@EDU

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DV [x]

Device variable x

MA

Start of scale value

p

Pressure

ME

Full scale value

In the calculation example, the two pairs of values 0%;0% and 100%;100% are configured for the customized "characteristic curve". Any curve shapes can be calculated with the help of 30 characteristic curve vertices. These curve shapes can be stored in the device using SIMATIC PDM or the HART communicator. In the calculation example, the value at the input of the characteristic curve is transferred 1:1 to the output. In the calculation example, a number of filled cans is set for the output scaling. You can enter up to five characters for any given unit. Do not confuse this with the userprogrammable display unit of the "Analog output" block. In the calculation example, you have a start of scale value of 0 cans and a full scale value of 1000 cans. At a process pressure of 0.5 bar, you get a value of 250 cans for the "User" device variable.

See also Analog output (Page 105) Measured value status (Page 101)

7.3.9

Measured value status

Introduction Every device variable is assigned a status byte to indicate the quality of the measured values. This status byte can have the following values: ● BAD ● GOOD ● MANUAL ● UNCERTAIN

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

101

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes The following values are also possible: ● CONSTANT ● HIGH LIMIT ● LOW LIMIT A higher-level diagnosis program can display and analyze these states.

GOOD status During smooth, uninterrupted operation, the measured value status of all active device variables is GOOD.

BAD/CONSTANT status All inactive device variables have CONSTANT/BAD status. If a variable having the BAD status is an output value for calculation, the measured value is BAD. The basic measured values, namely pressure and temperatures, have the BAD status in the following cases: ● The analog-to-digital converter does not function. ● Linearization values in the EEPROM are defective. ● If the two end points of the customized characteristic curve are exceeded for the status of the device variables of the following function.

UNCERTAIN status If a pressure value exceeds or falls below the sensor limits of the device by more than 20%, the corresponding measured value and the variables inferred from it are UNCERTAIN. If the analog-to-digital converter for pressure control is over/underrange, the status is UNCERTAIN.

HIGH LIMIT and LOW LIMIT If the analog-to-digital converter is overrange, the HIGH LIMIT label is allocated. If the analog-to-digital converter is underrange, the LOW LIMIT label is allocated.

Change in status If the status of a device variable changes and it was right at the front of the sequence of operations for a block, e.g. pressure, then all variables that are derived from it will take on the same status. In the following example, the device variable "Pressure" has the BAD status. Since the measuring mode selector is set to "USER", the device variable "User" is also given the BAD status. The reasons for changes in the status of a device variable are summarized in the table. If there were several reasons for a change in status, MANUAL always has the highest priority. BAD has the second highest and UNCERTAIN the third highest priority.

102

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes

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Primary variable

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SV

Secondary variable

TV

Tertiary variable

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Quarternary variable

Table 7-2



Events which result in a change of status

DV

Measuring mode

BAD

MANUAL

UNCERTAIN

CONSTANT HIGH LIMIT

LOW LIMIT

0

Pressure

DV3 = BAD, fault in linearization

When DV0 is simulated

DV3 = UNCERTAIN

-

DV3 = HIGH LIMIT

DV3 = LOW LIMIT

1

Sensor temperature

DV2 = BAD, When analog-toDV1 is digital converter simulated in over/underrang e, fault in linearization

DV1 more than 20% outside the sensor limits

-

Analog-todigital converter in overrange

Analog-todigital converter in underrange

Analog-toWhen digital converter DV2 is in simulated over/underrang e, fault in linearization

DV2 more than 20% outside the sensor limits

-

Analog-todigital converter in overrange

Analog-todigital converter in underrange

2

Electronics temperature

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

DV2 = UNCERTAIN DV2 = MANUAL

103

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes DV

Measuring mode

BAD

3

Pressure (untrimmed)

MANUAL

UNCERTAIN

CONSTANT HIGH LIMIT

LOW LIMIT

Analog-todigital converter in over/underrang e, DV1 sensor breakage, DV2 = BAD, fault in linearization

Analog-to-digital converter in overrange/underran ge, DV3 more than 20% outside the sensor limits

-

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Analog-todigital converter in underrange

DV0 = HIGH LIMIT

DV0 = LOW LIMIT

DV2 = MANUAL

4

Level

If DV0 = BAD

When DV0 is simulated

DV0= UNCERTAIN

DV not active

5

Volume

DV0 = BAD, Characteristic curve is faulty

When DV0 is simulated

DV0 = UNCERTAIN, input value is outside the specified characteristic curve range

Characteristi DV4 = c curve is HIGH LIMIT, faulty Characteristic curve for DV not maximum active value with gradient 0

6

Mass

DV5 = BAD

When DV0 is simulated

DV5= UNCERTAIN

DV not active,

Volume of flow DV0 = BAD, characteristic (not absolute curve is faulty and gauge

When DV0 is simulated

DV0 = UNCERTAIN, input value is outside the specified characteristic curve range

Characteristi DV4 = HIGH LIMIT, c curve is Characteristic faulty, curve for DV not maximum active value with gradient 0

DV4 = LOW LIMIT, Characteristic curve for minimum value with gradient 0

Mass flow rate DV5 = BAD

When DV0 is simulated

DV5= UNCERTAIN

DV not active

DV5 = LOW LIMIT

When DV0 is simulated

DV0 = UNCERTAIN, input value is outside the specified characteristic curve range

7

pressure)

8

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Users

DV0 = BAD, Characteristic curve is faulty

DV5 = HIGH LIMIT

DV4 = LOW LIMIT, Characteristic curve for minimum value with gradient 0 DV5 = LOW LIMIT

DV5 = CONSTANT

DV5 = #HIGH LIMIT

DV5 = CONSTANT Characteristi DV0 = HIGH LIMIT, c curve is Characteristic faulty curve for DV not maximum active value with gradient 0

DV0 = LOW LIMIT, Characteristic curve for minimum value with gradient 0

If you use falling characteristic curves in the blocks, the meanings of HIGH LIMIT and LOW LIMIT are swapped around. If you mix falling and rising characteristic curves, the meanings will be swapped each time a falling characteristic curve is run.

104

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes

7.3.10

Analog output

Introduction The "Analog output" block converts the value provided by the dynamic primary variable (PV) into a current value of 4 to 20 mA. When you actuate the measuring mode selector, you automatically define the start of scale value and the full scale value to the current values 4 and 20 mA, respectively. Limit values of corresponding device variables are used for scaling the analog output by default. You have entered these limits when setting the parameters of your measuring mode.

Example for measuring mode "Level" This means that for a "Level" device variable as PV, 10 m corresponds to the value for 4 mA and 20 m corresponds to the value for 20 mA. You can change this presetting again in the "Analog output" block. This is done by restricting the range of the "Level" device variable for scaling the output current to e.g. 12 to 18 m. This downscaling has no effect on the previous block scaling. In this case, a current of 4 mA is output for a measured height of 12 m, and a current of 20 mA for 18 m. 6HQVRU

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DV

Device variable

MA

Start of scale value

PV

Primary variable

ME

Full scale value

SV

Secondary variable

TV

Tertiary variable

QV

Quarternary variable

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

105

ITEM 1120, 1340, 1355 Operating functions through HART 7.3 Selecting the measuring modes

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MA

Start of scale value

p

Pressure

ME

Full scale value

PV

Primary variable

Note If, when setting the analog output, the values for the start of scale value zero and the full scale value are more than 20% below or above the limit values of the set PV (set using the variable mapper), the values will be rejected by the device. The values configured previously are retained. Similarly, the span must not fall below the minimum. Minimum span = ME - MA The square root extracting function can only be selected in the "Pressure" measuring mode. The "srlin2" square root extracting function is set as default in the "Flow rate" measuring mode.

7.3.11

Scaling the digital display value

Introduction You can freely scale the value shown in the digital display and allocate any unit of 5 characters to it. The scaling of the value is independent of the selection of the measuring mode selector, the primary variable (PV) and the display unit defined. Use the "Digital display settings" item in SIMATIC PDM or the HART communicator for this purpose. The percent value of the PV is the basis for this scaling. This percent value is also used to scale the current output. In SIMATIC PDM, this item is referred to as "Setting the PV output scaling". After selecting the "Digital display settings" menu command, you must enter a startof-scale value, full scale value and a unit string. This display option has the highest priority amongst all options. A switch over to %, mA or any other unit is not possible in this status. You need to deactivate the LCD scaling again for this purpose.

106

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.4 Setting zero point and limit point

Example In the Level measuring mode, the start of scale value is assumed as 0 m and the full scale value as 10 m in the example illustrated in the following picture. The value of 2 m is displayed at a process pressure of 0.4 bar. 6HQVRU

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Primary variable

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Secondary variable

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Setting zero point and limit point You can set the zero point and the limit point using the SIMATIC PDM or HART Communicator. You can use this function to realize rising or falling characteristic curves. The pressure unit can be set separately for the display and for HART communication.

See also Difference between setting and adjusting (Page 66)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

107

ITEM 1120, 1340, 1355 Operating functions through HART 7.5 Blind setting of zero point and limit point

7.5

Blind setting of zero point and limit point ● The start of scale value and the full scale value can be set without creating a reference pressure. ● Both values can be selected as any point within the sensor limits. ● The maximum downscaling is 1:100, depending on the series and the measuring range.

7.6

Zero point calibration (position correction)

Description A zero point calibration is used to correct a zero point error resulting from the installation position.

Procedure ● Pressurize the device or evacuate it (at absolute pressure, < 0.1 ‰ of the measuring span). ● Perform the zero point calibration using SIMATIC PDM or the HART Communicator. ● If you do not have a vacuum, perform a trimming of the lower sensor calibration point at a known reference pressure. CAUTION For absolute pressure transmitters, the zero point is at vacuum. A zero point calibration with a pressurized transmitter will lead to faulty settings! Note The effective measuring range is reduced by the amount of the upstream pressure. Example: With an upstream pressure of 100 mbar, the effective measuring range of a 1-bar transmitter is reduced to a point between 0 and 0.9 bar.

See also Trimming of the sensor trim point (Page 114)

108

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.7 Electrical damping

7.7

Electrical damping

Description You can set the time constant of electrical damping to a point within a range from 0 to 100 s. It always applies to the "Pressure" device variable (DV0) and thus to the measured values derived from it.

7.8

Fast response mode

Description This mode is only intended for special applications such as fast recognition of jumps in pressure, e.g. pressure drop in the event of pipe breakage. The internal recording of measured values is sped up at the cost of accuracy. From your point of view, an increased low-frequency noise is caused for the measured value. For this reason, good accuracy can only be achieved by setting the measuring span to the maximum.

7.9

Current sensor

Description The transmitter can be switched to constant current operation for test purposes. In that case, the current no longer corresponds to the process variable. A "C" appears in the mode display of the digital display.

7.10

Fault current

Description You can use this function to set the size of the lower (< 4 mA) and upper (> 20 mA) fault current. Both signal a hardware/firmware fault, sensor breakage, or that the alarm limit has been reached (diagnostic interrupt). In that case, ERROR appears in the digital display. You can obtain a detailed guide to the display using SIMATIC PDM or the HART Communicator.

Reference NAMUR recommendation NE43 dated 03.02.2003 "Standardization of the signal level for the breakdown information of digital transmitters"

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

109

ITEM 1120, 1340, 1355 Operating functions through HART 7.11 Setting the current limits

See also Error display (Page 59) Limit modules (Page 121)

7.11

Setting the current limits

Description The level of the upper and lower fault current and the upper and lower saturation limits can be freely selected within the preset limits of the current output signal. The specified accuracy of the current output signal is only valid within the current limits 4 to 20 mA.

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110

Current limits

①

Linear control range

②

Lower saturation limit (default value)

③

Upper saturation limit (default value)

④

Lower fault current value (default value)

⑤

Upper fault current value (default value)

⑥

Recommended setting range for lower fault current range and lower control range limit

⑦

Recommended setting range for upper fault current range and upper control range limit

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.12 Key lock and write protection

7.12

Key lock and write protection

Introduction You can use this function to lock the keys or activate write protection to safeguard the saved parameters.

Lock options You have the following lock options: Table 7-3

Meaning of the HART lock modes

Lock mode

Meaning

0

The device can be operated by means of the keys and HART communication.

LA

Keys on the transmitter are locked. Exception: • Releasing key lock The device can be operated by means of HART communication.

LO

Keys on the transmitter are partially locked. Exception: • Setting start of scale value • Releasing key lock The device can be operated by means of HART communication.

LS

Keys on the transmitter are partially locked. Exception: • Setting start of scale value • Setting full scale value • Releasing key lock The device can be operated by means of HART communication.

LL

Write protection You can now only release the lock using HART communication.

See also buttons and function lock (Page 80) Releasing key lock or function lock (Page 81)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

111

ITEM 1120, 1340, 1355 Operating functions through HART 7.13 Measured value display

7.13

Measured value display

Introduction You can use this function to set one of three options for the device display: ● Display in mA ● Display in % (of the set measuring range) ● Display in terms of a physical unit, e.g. bar, l, m3/ h etc.

Description If the Primary Variable is mapped to the "Pressure" device variable, you can configure the displayed pressure unit with an add-on, GAUGE (G) or ABS (A). The add-on has no effect on the real measured value. To do so, select the option Gauge or Absolute under the "Pressure display type" menu command. There are two options for the display: ● If the pressure unit is < 5 characters, an A or a G is added at the end, respectively. ● If the pressure unit is ≥ 5 characters, the letters GAUGE or ABS flash alternately with the pressure unit.

Figure 7-13

Add-on with example GAUGE

Note The change of the display with GAUGE or ABS does not change the physical pressure used by the transmitter, rather only the nature of the display.

See also Measured value display (Page 85)

112

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.14 Selection of the physical unit

7.14

Selection of the physical unit

Introduction You can use this function to select a unit from a table with predefined units.

Description The only units available will be those of the device variable that was mapped as the Primary Variable (PV). The unit can be set separately for the display and for HART communication. You can also choose to link the setting of the two units.

See also Unit (Page 86)

7.15

Bar graph

Description You can use this to switch on the "Bar graph" function in the device display as an alternative to the unit display. The "Bar graph" function is disabled in the factory state.

See also Elements of the digital display (Page 57)

7.16

Sensor calibration

7.16.1

Sensor trim

Description The sensor trim can be used to set the characteristic curve of the transmitter at two sensor trim points. The results are then correct measured values at the sensor trim points. The sensor trim points can be selected as any points within the nominal range. Devices that are not turned down prior to delivery are trimmed at 0 bar and the upper limit of the nominal range; devices that are turned down prior to delivery are trimmed at the lower and upper limits of the set pressure measuring range.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

113

ITEM 1120, 1340, 1355 Operating functions through HART 7.16 Sensor calibration

Application examples ● For a particular device that is not turned down (e.g. 63 bar), the typical measured value is 50 bar. To attain the highest possible accuracy for this value, set the upper sensor calibration at 50 bar. ● A 63-bar transmitter is turned down to 4 to 7 bar. You can attain the highest possible accuracy by selecting 4 bar for the lower sensor calibration point and 7 bar for the upper. ● A 250-mbar absolute pressure transmitter shows 25 mbar at 20 mbar (abs). A reference pressure of 100 mbar is available. You can carry out zero point correction by performing a lower sensor trim at 100 mbar. Note The accuracy of the test device should be at least three times as high as that of the transmitter.

7.16.2

Trimming of the sensor trim point

Trimming the lower sensor trim point The pressure at which the lower sensor trim is to be performed is applied at the transmitter. Via SIMATIC PDM or the HART Communicator, you instruct the transmitter to accept this pressure. This represents an offset shift of the characteristic curve.

Trimming the upper sensor trim point The pressure at which the upper sensor trim is to be performed is applied at the transmitter. Via SIMATIC PDM or the HART Communicator, you instruct the transmitter to accept this pressure. A gradient correction is thereby applied to the characteristic curve. The lower sensor trim point is not affected by this. The upper trim point needs to be greater than the lower trim point.

114

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

Operating functions through HART 7.17 Current sensor trim

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B

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C

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Current sensor trim

Description The current that is output by the transmitter can be trimmed independently of the pressure measuring circuit. This function is designed for compensating inaccuracies in the processing chain following the transmitter.

Example of an application The current is to be measured as a voltage drop from 1 to 5 V at a resistance of 250 Ohm +/5%. To trim the tolerance of the resistance, set the current transmitter so that the voltage drop at 4 mA is exactly 1 V and at 20 mA is exactly 5 V. ● Trim at 4 mA: Use the current transmitter trim menu option to instruct the transmitter to output 4 mA. Read the measured value from the ammeter and enter it, via SIMATIC PDM for example. The transmitter uses this value for offset correction of the current. ● Trim at 20 mA: Use the current transmitter trim menu option to instruct the transmitter to output 20 mA. Read the measured value from the ammeter and enter it, via SIMATIC PDM for example.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

115

ITEM 1120, 1340, 1355 Operating functions through HART 7.18 Factory calibration The transmitter uses this value for gradient correction of the current. The value for 4 mA is not affected by this. Note If a multimeter is used, it must always be sufficiently accurate.  $% 3DUDOOHOYHUVFKLHEXQJ

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B

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C

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Factory calibration

Introduction You can use factory calibration to reset the transmitter to the factory state.

Description You can use the menu-guided interface of SIMATIC PDM or HART Communicator to select the range of parameters to be reset: 1. Current trim 2. Sensor zero point calibration (position correction) 3. Pressure corrections (zero point calibration and sensor trim)

116

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Operating functions through HART 7.19 Static configuration data 4. All parameters relevant for the processing of measured values, such as zero point, limit point, electrical damping, display unit, current trim, zero point calibration (position correction), sensor trim, measuring speed, interrupt current limits, interrupt setting, overflow ranges of current. 5. Variable mapper. This performs the following setting: PV= Pressure, SV= Sensor temp., TV= Electronics temp., QV= Non-linearized pressure

7.19

PV

Primary variable

SV

Secondary variable

TV

Tertiary variable

QV

Quarternary variable

Static configuration data

Description A further menu command in the corresponding operating program allows you to read and also write a series of sensor-specific material data. With the factory state, this data is preallocated according to the particular device model. These values are not contained in the "Factory calibration" function; in other words, changes in the device are permanently saved. List of variable material parameters: ● Flange type ● Flange material ● Remote seal type ● Filling medium ● O-ring material ● Remote seal ● Remote seal diaphragm material ● Number of remote seals ● Sensor filling medium ● Sensor seal diaphragm material ● Transmitter model ● Housing material ● Tube length ● Process connection ● Electrical connection ● Material of pressure cap screws ● Vent valve position For a series of these material data items, you can enter any designation of your choice under the option "Special". This applies to the following parameters:

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ITEM 1120, 1340, 1355 Operating functions through HART 7.20 Flow rate measurement (only differential pressure) ● Process connection ● Flange type ● Pressure cap screws ● O-ring material ● Material of vent valve ● Vent valve position ● Remote seal type ● Remote seal ● Diaphragm material ● Remote seal filling medium You can use up to 16 characters for each entry.

7.20

Flow rate measurement (only differential pressure)

Description For the "Differential pressure and flow rate" device version, you can select the characteristic curve of output current as follows without actuating the measuring mode selector: ● linear "lin": proportional to differential pressure ● square root extracting "sroff": proportional to flow rate, deactivated up to the application point ● square root extracting "srlin": proportional to flow rate, linear up to the application point ● square root extracting "srlin2": proportional to flow rate, two-step linear up to the application point

Variable application point The output current for the "srlin" and "sroff" functions can be displayed linearly or set to zero below the application point of the square root extracting characteristic curve.

Fixed application point The "srlin2" function has a permanently defined application point of 10%. The range up to this point contains two linear characteristic curve sections. The first section ranges from the zero point to 0.6% of the output value and 0.6% of the pressure value. The second section has a higher gradient and it goes up to the root application point at 10% of the output value and 1% of the pressure value.

See also Flow rate measurement (only differential pressure) (Page 82)

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ITEM 1120, 1340, 1355 Operating functions through HART 7.21 Diagnostic functions

7.21

Diagnostic functions

7.21.1

Overview

Description HART communication allows you to activate and evaluate a wide range of diagnostic functions from a central control room or onsite: ● Calibration/service timer ● Min/max indicator ● Limit monitoring modules ● Simulation of measured pressure and temperature values ● Limit monitoring of all device variables The diagnostics strategy employed for the transmitter incorporates a diagnostic warning and a diagnostic interrupt for diagnostic functions for monitoring limit values, e.g. for monitoring current saturation. This warning and interrupt can be configured: ● Diagnostic warning: The device transmits via HART communication the diagnostic event that has occurred. The current output value is unaffected. The message "Diagnostic Warning" alternates with the unit on the display. ● Diagnostic interrupt: The device goes into the fault current state. The message "Diagnostic Warning" or "Diagnostic Alarm" appears on the display, along with the message ERROR. In addition, the diagnostic event is made available via HART communication. In the default settings, all warnings and alarms are switched off. You can choose to set either the diagnostic warning only or the diagnostic interrupt and warning. For HART communication, use the HART Communicator or PC software such as SIMATIC PDM. To see the steps required, refer to the attached table for operation of the HART Communicator or the help functions in the SIMATIC PDM software.

7.21.2

Operating hours counter

Description An operating hours counter can be read via HART communication for the electronics and another for the sensor. For HART communication, use the HART Communicator or PC software such as SIMATIC PDM. The counters are activated the first time the transmitter is put into operation. If the device is separated from its power supply, the counter readings are automatically stored in the non-volatile memories. That means that the current counter readings can be accessed at the next restart. The operating hours counters cannot be reset.

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ITEM 1120, 1340, 1355 Operating functions through HART 7.21 Diagnostic functions

7.21.3

Calibration timer and service timer

Description To guarantee regular calibration of the electronics and for servicing work on the sensor, you can fit a two-stage timer to each. After the first time period has elapsed, a calibration or service warning will be issued. After a second time period, which can be configured as a time differential, a diagnostic interrupt is reported and fault current is output. To perform calibration work, you need to acknowledge warnings and interrupts. You can then reset the timers and switch off the monitoring function. The calibration intervals for the electronics are calculated using the following formula: &DOLEUDWLRQLQWHUYDO

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For operating/acknowledging the warnings and interrupts in SIMATIC PDM and via the HART Communicator, the following applies:

As long as the warning/interrupt limit has not been reached, the following applies: ● "Reset" resets the timer and starts again from count 0. Monitoring remains active. ● "Acknowledge" has no effect; the timer continues running and monitoring remains active. ● "Reset and deactivate" stops the timer, resets it, and deactivates monitoring.

When the warning/interrupt limit has been reached, the following applies: ● "Acknowledge" resets the warning/interrupt message, but allows the timer to keep running. In this state, a new interrupt or warning is not possible since the time limits have already been exceeded. ● "Reset" resets the warning/interrupt message and the timer. It acknowledges the interrupt or warning at the same time. The timer immediately starts running again from zero and will report again when the warning/interrupt limit is next reached. The next calibration interval is therefore immediately active. ● "Reset and deactivate W/I" resets the warning/interrupt message and the timer and deactivates it.

7.21.4

Min/max indicator

Description The measuring transmitter provides three min/max indicator pairs, which you can use to monitor the three measured variables Pressure, Sensor temperature, and Electronics temperature for negative and positive peak values. For each measured value, a resettable min/max indicator saves the maximum and minimum peak values in long-term storage in the two non-volatile memories. Consequently, the values are available even after the device is restarted. The min/max indicators are also updated during a simulation.

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ITEM 1120, 1340, 1355 Operating functions through HART 7.21 Diagnostic functions S

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Basic representation of min/max indicators

Pressure

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Limit modules

Introduction The diagnostic functions of this device give you an option to monitor the measured values in programmable limits. If the limits are not adhered to, the device sends a warning through HART communication or notifies a higher-level instance about an analog fault current.

Monitoring of current saturation You can monitor the current output in the saturation range using a simple limit module. This limit module is configured and activated via HART communication. For HART communication, use a HART communicator or PC software such as SIMATIC PDM. You need to set two time periods to configure the limit module: The first time period specifies how long the current output is allowed to be in saturation before an interrupt is triggered and the device outputs its set fault current. This first time period is the response time. The second time period specifies the duration of the interrupt. This second time period is the stop time. Different outputs of the fault current corresponding to the set response and stop times are shown in the following example.

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ITEM 1120, 1340, 1355 Operating functions through HART 7.21 Diagnostic functions

Configuring the direction of fault current The current value is proportional to pressure within the saturation limits. When the saturation limits are exceeded, the direction of fault current can however vary from the direction of saturation. The upper or the lower fault current is displayed depending on the parameter settings of the direction of fault current. You can configure the direction of fault current for a current saturation interrupt depending on your requirements. The following settings are possible under the current saturation menu: Active interrupt value

The applicable settings are those under the current interrupt type menu command.

Inverse interrupt value

The applicable settings are the inverse settings under the current interrupt type menu command.

Saturated interrupt value The fault current is output in the direction of current saturation. Inverse saturated interrupt value

The fault current is output in the opposite direction to current saturation.

The difference between different settings is evident in examples 3 and 4 in the following figure. Example 3 shows the direction of fault current with the "Saturated current value" setting. Example 4 shows the direction of fault current with the "Active upper interrupt value" setting.

Example The configured saturation limits in the following figures are 3.8 mA and 20.5 mA. Example 1: the response time starts at t1. At t1, current reaches the configured saturation limit of 20.5 mA for the first time. At t2, the response time ends. The stop time begins and the interrupt is triggered. Time t3 is the configured end of the stop time. At t3, the interrupt is immediately revoked even if the current then drops below the saturation limit again. Example 2: the duration of the current saturation is shorter than the response time (t1, t2). In that case, the device does not go into "fault current" state. Example 3: the current drops below the lower saturation limit only for a short time. The fault current is not switched off until after the end of the stop time (t3). The direction of fault current corresponds to the "Saturated interrupt value" setting. The fault current is output in the direction of current saturation. Example 4: the current drops below the lower saturation limit only for a short time. The fault current is not switched off until after the end of the stop time (t3). The direction of fault current corresponds to the "Active upper interrupt value" setting. The upper fault current is outputted although the direction of current saturation is downward.

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ITEM 1120, 1340, 1355 Operating functions through HART 7.22 Simulation

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See also Fault current (Page 109)

7.22

Simulation

7.22.1

Overview of simulation

Description With the "Simulation" diagnostic function, you can receive and process simulated measurement data onsite or in the control room without having process pressure or a temperature value. This allows you to run individual process sequences in the "cold" state and thus simulate process states. In addition, if you inject simulation values you can test the line routing from the control room to the individual transmitter. The value to be simulated can be provided as a fixed value or in the form of a ramp function. Simulation of pressure and temperature values is handled in the same way in terms of parameter settings and function, so the following will only deal with the general simulation procedures "Fixed value" and "Ramp function".

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ITEM 1120, 1340, 1355 Operating functions through HART 7.22 Simulation For reasons of safety, all simulation data are held only in the non-volatile user memory. This means that when the device is restarted any simulation which may be active will be shut down. You can simulate the pressure and both temperature values. It should be noted here that changing the temperatures by simulation will have no effect on the measured pressure value. 0HDVXUHPHQW 6HQVRU S

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Block diagram of simulation

Simulation as fixed value

Description Taking the physical unit into account you can set a fixed simulation value for all three possible simulation paths. You can simulate the pressure value and both temperature values simultaneously. While pressure simulation is activated, the transmitter will not react to changes in the process pressure. The output value for the current adjusts itself in accordance with the preset pressure value. Simulation of the temperature values has no effect on the current output. It can only be observed via HART communication.

7.22.3

Simulation with a ramp function

Description In addition to the adjustable fixed values for all three simulation paths, you can, as a second option, also configure one ramp function in each case. Adjustable lower and upper values together determine the limits between which the simulation values with a rising or falling

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ITEM 1120, 1340, 1355 Operating functions through HART 7.23 Limit monitor tendency can move. The step width can be calculated with the step number, which is also adjustable. You can specify the rate of rise of the ramp via the duration of the individual ramp steps. ,QFUHPHQW

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Limit monitor

Description You can activate up to three limit monitors in order to monitor any of the device variables. The limit monitor monitors a value at an upper or lower limit value. If this limit is violated it sends a diagnostic warning or a diagnostic interrupt. Select the "Limit Monitor" menu command in SIMATIC PDM or in the HART communicator. You can program the following values for each of the three limit monitors: Table 7-4

Parameter of the limit monitor

Monitoring variable

You will be shown a list of the active device variables. This list is independent of the measuring mode selected.

Limit monitoring: warning / interrupt

Select whether a warning or a warning plus an interrupt should be triggered when a limit is violated.

Limit monitoring: upper / lower

Specify here whether a device variable monitors the upper limit, the lower limit, or both limits.

Upper limit value

Upper limit value in the unit of the device variable.

Lower limit value

Lower limit value in the unit of the device variable.

Hysteresis

Operating point for chatter suppression in the case of small pressure changes.

Response time

The time which must pass after the limit is violated before this violation is registered.

Stop time

The time for which a limit interrupt or warning will always be sustained even when the event which triggered it is no longer present.

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You can count the limit violations for each limit monitor by activating an event counter that provides separate, cumulative totals of upper and lower limit violations. A diagnostic warning and / or a diagnostic interrupt can be issued once a certain number of violations is reached, a number which you can also program. You can program the following values for the event counter: Table 7-5

Parameters of the event counter

Event counter: upper limit

Select here whether a warning or a warning plus an interrupt should be triggered when the comparison value is exceeded.

Event counter: lower limit

Select here whether a warning or a warning plus an interrupt should be triggered when the comparison value is not met.

Comparison value: upper limit

Specify here the number of overflows at which a warning or a warning plus an interrupt should be triggered.

Comparison value: upper limit

Specify here the number of underflows at which a warning or a warning plus an interrupt should be triggered.

Limit monitoring, warning/interrupt: upper limit

Select whether a warning or a warning plus an interrupt should be triggered when the event counter upper limit is violated.

Limit monitoring, warning/interrupt: lower limit

Select whether a warning or a warning plus an interrupt should be triggered when the event counter lower limit is violated.

Reset event counter upper limit

Here you can reset the upper limit counter to zero. A new event is not possible until the counter has been reset.

Reset event counter lower limit

Here you can reset the lower limit counter to zero. A new event is not possible until the counter has been reset.

Warning/interrupt acknowledgement

Here you can acknowledge each warning or interrupt separately.

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Limit monitor and event counter

Messages from the limit monitor and from the event counter can be acknowledged separately. Resetting the event counter starts a new monitoring interval.

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ITEM 1120, 1340, 1355 Operating functions through HART 7.23 Limit monitor

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ITEM 1120, 1340, 1355

8

Functional safety 8.1

General safety instructions

8.1.1

Safety-instrumented system This chapter describes the functional safety in general and not specific to a device. The devices in the examples are selected as representative examples. The device-specific information follows in the next chapter.

Description The sensor, logic unit/control system and final controlling element combine to form a safetyinstrumented system, which executes a safety function. &RQWUROV\VWHP 3/&

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ITEM 1120, 1340, 1355 Functional safety 8.1 General safety instructions

Functioning of the system as shown in the example The transmitter generates a process-specific analog signal. The downstream control system monitors this signal to ensure that it does not fall below or exceed a set limit value. In case of a fault, the control system generates a failure signal of < 3.6 mA or > 22 mA for the connected positioner, which switches the associated valve to the specified safety position.

8.1.2

Safety Integrity Level (SIL) The international standard IEC 61508 defines four discrete Safety Integrity Levels (SIL) from SIL 1 to SIL 4. Each level corresponds to the probability range for the failure of a safety function.

Description The following table shows the dependency of the SIL on the "average probability of dangerous failures of a safety function of the entire safety-instrumented system" (PFDAVG) The table deals with "Low demand mode", i.e. the safety function is required a maximum of once per year on average. Table 8-1

Safety Integrity Level

SIL

Interval

4

10-5 ≤ PFDAVG < 10-4

3

10-4 ≤ PFDAVG < 10-3

2

10-3 ≤ PFDAVG < 10-2

1

10-2 ≤ PFDAVG < 10-1

The "average probability of dangerous failures of the entire safety-instrumented system" (PFDAVG) is normally split between the three sub-systems in the following figure.

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The following table shows the achievable Safety Integrity Level (SIL) for the entire safetyinstrumented system for type B subsystems depending on the safe failure fraction (SFF) and the hardware fault tolerance (HFT). Type B subsystems include analog transmitters and shut-off valves without complex components, e.g. microprocessors (also see IEC 61508, Section 2). SFF < 60 %

130

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SIL 2

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Functional safety 8.2 Device-specific safety instructions HFT 60 to 90 %

SIL 1

SIL 2

SIL 3

90 to 99 %

SIL 2

SIL 3

SIL 4

> 99 %

SIL 3

SIL 4

SIL 4

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As per IEC 61511-1, Section 11.4.4

According to IEC 61511-1, Section 11.4.4, the hardware fault tolerance (HFT) can be reduced by one (values in brackets) for sensors and final controlling elements with complex components if the following conditions are applicable for the device: ● The device is proven-in-use. ● The user can configure only the process-related parameters, e.g. control range, signal direction in case of a fault, limiting values, etc. ● The configuration level of the firmware is blocked against unauthorized operation. ● The function requires SIL of less than 4. The device fulfills these conditions.

See also Safety characteristics (Page 134)

8.2

Device-specific safety instructions

8.2.1

Safety function

Safety function for pressure transmitters Measuring pressures is the safety function for SITRANS P. It is applicable for output current from 4 to 20 mA and ensures an accuracy of ± 2% of the measured value in this range. The safety function ensures that the diagnosis function responds within 4 seconds in the worst case scenario. WARNING The binding settings and conditions are listed in the "Settings" and "Safety characteristics" sections. These conditions must be met in order to fulfil the safety function. The calculated Mean Time Between Failures (MTBF) for the SITRANS P pressure transmitter is approximately 400 years.

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ITEM 1120, 1340, 1355 Functional safety 8.2 Device-specific safety instructions

See also Safety characteristics (Page 134)

8.2.2

Requirements

Requirements Functional safety has the following requirements: ● Functional safety to SIL 2 under IEC 61508 or IEC 61511-1, from firmware version FW: from 11/02/03 ● Explosion protection for corresponding versions ● Electromagnetic compatibility in compliance with EN 61326

8.2.3

Settings The following settings must be adhered to after installing and commissioning as per the Operating Instructions:

Operation/configuration While operating/configuring, ensure that the technical data of the pressure transmitter are adhered to in their respective version.

Checking the safety function We recommend that: ● You check the status for warnings and alarms. ● You check the measurement value limits. ● You simulate different current values. ● You check the measuring accuracy that must be in the range of ± 2% for the safety function. – You check the zero point, e.g. in a pressure-less state, for gauge and differential pressure. – You check the zero point, e.g. with a defined pressure, for absolute pressure.

Protection against configuration changes After parameterizing/commissioning: 1. Set the lock mode in Mode 10 to write protection "L". Operation via keys and HART communication is blocked. 2. Protect the keys from unintended change in the parameters, e.g. by lead-sealing.

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ITEM 1120, 1340, 1355 Functional safety 8.2 Device-specific safety instructions

8.2.4

Behavior in case of faults

Repairs Defective devices should be sent in to the repair department with details of the fault and the cause. When ordering replacement devices, please specify the serial number of the original device. The serial number can be found on the rating plate. The address of the responsible SIEMENS repair center, contacts, spare parts lists, etc. can be found on the Internet.

See also Services & Support (http://www.siemens.com/automation/services&support) Partner (http://www.automation.siemens.com/partner)

8.2.5

Maintenance/Checking

Interval We recommend that the functioning of the pressure transmitter be checked at regular intervals of one year.

Checking the safety function We recommend that: ● You check the status for warnings and alarms. ● You check the measurement value limits. ● You simulate different current values. ● You check the measuring accuracy that must be in the range of ± 2% for the safety function. – You check the zero point, e.g. in a pressure-less state, for gauge and differential pressure. – You check the zero point, e.g. with a defined pressure, for absolute pressure.

Checking safety You should regularly check the safety function of the entire safety circuit in line with IEC 61508/61511. The testing intervals are determined during the calculation for each individual safety circuit in a system (PFDAVG).

Electronics The safety function of the transmitter is ensured only with the electronics delivered by the factory. It cannot be replaced.

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ITEM 1120, 1340, 1355 Functional safety 8.2 Device-specific safety instructions

8.2.6

Safety characteristics The safety characteristics necessary for using the system are listed in the "SIL declaration of conformity". These values apply under the following conditions: ● The SITRANS P pressure transmitter is only used in applications with a low demand rate for the safety function (low demand mode). ● Communication with the HART protocol is used only for the following: – Device configuration – Reading diagnostic values – However, it is not used for operations critical to safety. In particular, the trace function must not be activated in safety related operation. ● The safety-related parameters/settings have been entered by local operation or HART communication before commencing safety-instrumented operation. They are checked on the local display. (see "Settings" section) ● The safety function test is concluded successfully. ● The transmitter is blocked against unwanted and unauthorized changes/operation. ● The current signal of 4 to 20 mA of the transmitter is evaluated by a safe system. ● The calculation of fault rates is based on a Mean Time To Repair (MTTR) of eight hours.

See also Settings (Page 132)

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ITEM 1120, 1340, 1355

Commissioning 9.1

9

Safety notes for commissioning WARNING "explosion-proof" type of protection Devices with the "explosion-proof" type of protection may only be opened in the hazardous area only in a de-energized state. WARNING Hazardous areas If the transmitters are to be used as category 1/2 operational resources, please observe the type examination certificates or the test certifications applicable in your country. WARNING Incorrect or improper use of the shut-off modules can lead to serious physical injuries or considerable damage to property. WARNING Using toxic substances The transmitter should not be depressurized if toxic substances are being used. WARNING Intrinsically safe circuits With intrinsically-safe circuits, use only certified ammeters appropriate for the transmitter. "Intrinsically safe" If a non-conforming supply unit is used, the "fail-safe" type of protection will no longer be effective and the approval certification will be invalid.

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ITEM 1120, 1340, 1355 Commissioning 9.2 Notes on commissioning

WARNING Laying of cables Connect the devices that are operated in hazardous areas as per the stipulations applicable in your country, e.g. for Ex "d" and "nA", permanent cables must be laid. WARNING Devices with the common approval "Intrinsically safe" and "Flameproof" The following is applicable for devices with the common approval "Intrinsically safe" and "Flameproof" (EEx ia and EEx d): The type of protection that is not suitable must be permanently defaced on the type plate before commissioning. NOTICE Before commissioning, check the basic parameters. Due to changes in the operating functions, the display and the measurement output could be set such that the actual process pressure is not reproduced.

9.2

Notes on commissioning Note In order to obtain stable measured values, the transmitter must be allowed to warm up for at least 5 minutes after the power supply is switched on. The order data must match with the values given on the type plate. The transmitter is in operation as soon as the power supply is switched on. The following cases of commissioning can be taken as the typical examples. Changing the arrangements specified here may be practical depending on the system configuration.

9.3

Introduction to commissioning Following commissioning, the transmitter is immediately ready for use. To obtain stable measured values, the transmitter needs to be allowed to warm up for five minutes or so after the power supply is switched on. The measuring span which can be set corresponds to the information on the nameplate. Even in the case of a customer-specific setting configured in the factory, the zero point and the limit point will appear on the nameplate. If need be, you can change the parameters by simple user operations on the device even during commissioning.

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ITEM 1120, 1340, 1355

Commissioning 9.4 Gauge pressure, absolute pressure from the differential pressure series and absolute pressure from the gauge pressur

9.4

Gauge pressure, absolute pressure from the differential pressure series and absolute pressure from the gauge pressure series

9.4.1

Commissioning for gases

Overview Usual arrangement

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Pressure transmitter

②

Shut-off module

③

Shut-off valve to process

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Shut-off valve for test connection or for bleed screw

⑤

Pressure line

⑥

Shut-off valve

⑦

Shut-off valve (optional)

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ITEM 1120, 1340, 1355 Commissioning 9.4 Gauge pressure, absolute pressure from the differential pressure series and absolute pressure from the gauge pressure series ⑧

Condensation vessel (optional)

⑨

Drain valve

Condition All valves are closed.

Procedure To commission the transmitter for gases, proceed as follows: 1. Open the shut-off valve for the test connection ③. 2. Via the test connection of the shut-off module ②, apply the pressure corresponding to the start of scale value to the pressure transmitter ①. 3. Check the start of scale value. 4. If the start of scale value differs from the value desired, correct it. 5. Close the shut-off valve for the test connection ④.. 6. Open the shut-off valve ⑥ at the pressure tapping point. 7. Open the shut-off valve for the process ③.

9.4.2

Commissioning with steam or liquid

Overview



 











Figure 9-1

138

Measuring steam

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Commissioning 9.5 Differential pressure and flow rate ①

Pressure transmitter

②

Shut-off module

③

Shut-off valve to process

④

Shut-off valve for test connection or for bleed screw

⑤

Pressure line

⑥

Shut-off valve

⑦

Drain valve

⑧

Compensation vessel (steam only)

Condition All valves are closed.

Procedure To commission the transmitter for steam or liquid, proceed as follows: 1. Open the shut-off valve for the test connection ④. 2. Via the test connection of the shut-off module ②, apply the pressure corresponding to the start of scale value to the pressure transmitter ①. 3. Check the start of scale value. 4. If the start of scale value differs from the value desired, correct it. 5. Close the shut-off valve for the test connection ④. 6. Open the shut-off valve ⑥ at the pressure tapping point. 7. Open the shut-off valve for the process ③.

9.5

Differential pressure and flow rate

9.5.1

Safety notes for commissioning with differential pressure and flow rate WARNING Ensure that the locking screw and/or the vent valve are connected and adequately fixed. Ensure that the valves are operated correctly and properly. If the lock screws are missing or are not sufficiently tight, and/or if the valves are operated incorrectly or improperly, it could lead to serious physical injuries or considerable damage to property.

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ITEM 1120, 1340, 1355 Commissioning 9.5 Differential pressure and flow rate

WARNING Hot mediums In the case of hot mediums, the individual operational steps should be carried out one after the other. Otherwise, it could lead to excessive heating, thus causing damage to the valves and the transmitter.

9.5.2

Commissioning in gaseous environments

Overview Usual arrangement

Special arrangement







































 

Transmitter above the differential pressure transducer

140



Transmitter below the differential pressure transducer

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Commissioning 9.5 Differential pressure and flow rate

①

Pressure transmitter

②

Stabilizing valve

③,④

Differential pressure valves

⑤

Differential pressure lines

⑥

Shut-off valves

⑦

Blowout valves

⑧

Condensation vessels (optional)

⑨

Differential pressure transducer

Condition All shut-off valves are closed.

Procedure To commission the transmitter for gases, proceed as follows: 1. Open both the shut-off valves ⑥ at the pressure tapping point. 2. Open the stabilizing valve ②. 3. Open the differential pressure valve (③ or ④). 4. Check and if required correct the zero point when the start of scale value is 0 mbar (4 mA). 5. Close the stabilizing valve ②. 6. Open the other differential pressure valve (③ or ④).

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ITEM 1120, 1340, 1355 Commissioning 9.5 Differential pressure and flow rate

9.5.3

Commissioning for liquids

Overview Usual arrangement

Special arrangement









 































Transmitter below the differential pressure transducer

①

142











Transmitter above the differential pressure transducer

Pressure transmitter

②

Stabilizing valve

③,④

Differential pressure valves

⑤

Differential pressure lines

⑥

Shut-off valves

⑦

Blowout valves

⑧

Gas collector vessels (optional)

⑨

Differential pressure transducer

⑩

Vent valves

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Commissioning 9.5 Differential pressure and flow rate

Condition All valves are closed.

Procedure WARNING The transmitter should not be depressurized if toxic substances are being used. To commission the transmitter with liquids, proceed as follows: 1. Open both the shut-off valves ⑥ at the pressure tapping point. 2. Open the stabilizing valve ②. 3. In the case of Transmitter below the differential pressure transducer Open both the blowout valves one after the other ⑦ until the air-free liquid emerges. In the case of a transmitter above the differential pressure transducer, open both the vent valves one after the other ⑩ until the liquid emerges. 4. Close both the blowout valves ⑦ or vent valves ⑩. 5. Open the differential pressure valve ③ and the vent valve at the plus chamber of the transmitter ① until the liquid emerges. 6. Close the vent valve. 7. Open the vent valve at the minus chamber of the transmitter ① until the liquid emerges. 8. Close the differential pressure valve ③. 9. Open the differential pressure valve ④ until the liquid emerges and then close it. 10.Close the vent valve at the minus chamber of the transmitter ①. 11.Open the differential pressure valve ③ by rotating it in half a turn. 12.Check and if required correct the zero point in case of start of scale value 0 bar (4 mA). 13.Close the stabilizing valve ②. 14.Open the differential pressure valves (③ and ④) completely.

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ITEM 1120, 1340, 1355 Commissioning 9.5 Differential pressure and flow rate

9.5.4

Commissioning with vapor

Overview



















 





Figure 9-2

①

144



Measuring steam

Pressure transmitter

②

Stabilizing valve

③,④

Differential pressure valves

⑤

Differential pressure lines

⑥

Shut-off valves

⑦

Blowout valves

⑧

Condensate pots

⑨

Differential pressure transducer

⑩

Insulation

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Commissioning 9.5 Differential pressure and flow rate

Condition All valves are closed.

Procedure CAUTION The measuring result is error-free only if the differential pressure lines ⑤ have equally high condensate columns with the same temperature. The zero calibration must be repeated if required if these conditions are fulfilled. If the shut-off valves ⑥ and the differential pressure valves ③ are open at the same time and the stabilizing valve ② is opened, there is a possibility of the transmitter ① being damaged due to the streaming vapor. To commission the transmitter for vapor, proceed as follows: 1. Open both the shut-off valves ⑥ at the pressure tapping point. 2. Open the stabilizing valve ②. 3. Wait till the vapor in the differential pressure lines ⑤ and in the condensate pots ⑧ condenses. 4. Open the differential pressure valve ③ and the vent valve at the plus chamber of the transmitter ① till the air-free condensate. 5. Close the vent valve. 6. Open the vent valve at the minus chamber of the transmitter ① till the air-free condensate goes out. 7. Close the differential pressure valve ③. 8. Open the differential pressure valve ④ till the air-free condensate goes out and then close it. 9. Close the vent valve at the minus chamber ①. 10.Open the differential pressure valve ③ by rotating it in half a turn. 11.Check and if required correct the zero point in case of start of scale value 0 bar (4 mA). 12.Close the stabilizing valve ②. 13.Open the differential pressure valve ③ and ④ completely.

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ITEM 1120, 1340, 1355 Commissioning 9.5 Differential pressure and flow rate

146

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ITEM 1120, 1340, 1355

Service and maintenance 10.1

10

Notes for servicing Note Depending on the use of the device and certain empirical values, determine a maintenance interval for the tests to be carried out repeatedly. The maintenance interval is influenced by the corrosion resistance depending on the site of use. Note Checking the gaskets Check the gaskets of the pressure transmitter at regular intervals. Grease or replace the gaskets if required.

10.2

Display in case of a fault Check the start of scale value of the device from time to time. Differentiate between the following in case of a fault: ● The internal self test has detected a fault, e.g. sensor break, hardware fault/Firmware fault. Displays: – Digital display: "ERROR" display and ticker with an error text – Analog output: Factory setting: Failure current 3.6 or 22.8 mA Or depending on the parameterization – HART: detailed error breakdown for display in the HART communicator or SIMATIC PDM ● Grave hardware faults, the processor is not functioning. Displays: – Digital display: no defined display – Analog output: failure current < 3.6 mA In case of defect, you can replace the electronic unit by following the warning notes and the provided instruction manual.

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ITEM 1120, 1340, 1355 Service and maintenance 10.3 Modular structure

See also Modular structure (Page 148) Error display (Page 59)

10.3

Modular structure

Safety note NOTICE The structure of this device is modular. You can thus replace different parts with original spare parts. When replacing components, always adhere to the notes provided with the components to be replaced. This is especially applicable for devices that are used in hazardous areas.

Related Both the individual components "Measuring cell" and "Electronics" always have a nonvolatile memory (EEPROM). Every EEPROM has a data structure that is permanently allocated to the measuring cel, or the electronics. Measuring cell data (e.g.: measuring range, measuring cell material, oil filling) are stored in the EEPROM of the measuring cell. Data of the electronics (e.g.: downscaling, electrical additional damping) is located in the EEPROM of the electronics. It is thus ensured that the data that is relevant for the remaining components is retained when replacing the electronic unit. Before starting the replacement work, you have the following setting options via HART: ● After replacement, the common measuring range settings from the measuring cell or from the electronic unit are adopted. ● A standard parameterization is carried out. The measuring accuracy in the specified measuring limits with a 1:1 downscaling can be reduced by the temperature error in unfavorable cases. In the course of further technical development, it is possible to implement advanced functions in the measuring cell or the electronic unit. This is indicated by modified Firmware statuses (FW). The Firmware status does not have an effect on the replaceability. The scope of functions however is limited to the functioning of the older components. If a combination of certain Firmware statuses of measuring cell and electronic unit is not possible due to technical reasons, the device identifies this status and goes into the "Fault current" status. This information is provided via the HART interface.

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ITEM 1120, 1340, 1355 Service and maintenance 10.4 Notes for servicing of the remote seal

10.4

Notes for servicing of the remote seal The remote seal measuring system usually does not need servicing. If the mediums are contaminated, viscous or crystallized, it could be necessary to clean the diaphragm from time to time. Use only a soft brush and a suitable solvent to remove the deposits from the diaphragm. Do not use corrosive cleaning agents. Prevent the diaphragm from getting damaged due to sharp-edged tools.

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ITEM 1120, 1340, 1355 Service and maintenance 10.4 Notes for servicing of the remote seal

150

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ITEM 1120, 1340, 1355

Technical data 11.1

11

Overview of technical data

Introduction The following overview of technical data provides you with a quick and easy access to relevant data and characteristic numbers. Remember that the tables partially contain the data of the three communication types HART, PROFIBUS and FoundationFieldbus. This data deviates in many cases. Therefore, adhere to the communication type used by you when using the technical data.

Contents of the chapter ● Input point (Page 152) ● Output (Page 157) ● Measuring accuracy (Page 158) ● Operating conditions (Page 164) ● Construction (Page 167) ● Display, keyboard and auxiliary power (Page 171) ● Certificates and approvals (Page 172) ● HART communication (Page 173)

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ITEM 1120, 1340, 1355 Technical data 11.2 Input point

11.2

Input point

DS III input with PMC connection HART Measured variable

Gauge pressure

Measuring span (continuously adjustable) or measuring range, max permissible operating pressure and max. permissible test pressure

Measuring range

PROFIBUS PA or Foundation Fieldbus Maximum permissible operating pressure

Maximum permissible test pressure

Measuring span

Maximum permissible operating pressure

Maximum permissible test pressure

0.01 … 1 bar g 4 bar g (0.15 … (58 psi g) 14.5 psi g) 1)

6 bar g (87 psi g)

1 bar g (14.5 psi g) 1)

4 bar g (58 psi g)

6 bar g (87 psi g)

0.04 … 4 bar g 7 bar g (0.58 … (102 psi g) 58 psi g)

10 bar g (145 psi g)

4 bar g (58 psi g)

7 bar g (102 psi g)

10 bar g (145 psi g)

0.16 … 16 bar g (2.3 … 232 psi g)

32 bar g (464 psi g)

16 bar g (232 psi g)

21 bar g (305 psi g)

32 bar g (464 psi g)

21 bar g (305 psi g)

Lower measuring limit •

Measuring cell with silicon oil filling 2)

100 mbar a (1.45 psi a)

•

Measuring cell with inert liquid 2)

100 mbar a (1.45 psi a)

•

Measuring cell with neobee 2)

30 mbar a (0.44 psi a)

Upper measuring limit

100 % of the max. measuring range

100% of maximum measuring span

1)

1 bar g (14.5 psi g) only in PMC-Style Standard, not in Minibolt

2)

For PMC-Style Minibolt, the measuring span should not be less than 500 mbar

Gauge pressure input HART Measured variable

Gauge pressure

Measuring span (continuously adjustable) or measuring range, max permissible operating pressure (as per 97/23/EC pressure device guideline) and max. permissible test pressure (as per DIN 16086) (for oxygen measurement max. 160 bar)

Measuring range

152

PROFIBUS PA or Foundation Fieldbus Maximum permissible operating pressure

Maximum permissible test pressure

Measuring span

Maximum permissible operating pressure

Maximum permissible test pressure

0.01 … 1 bar g 4 bar g (0.15 … (58 psi g) 14.5 psi g)

6 bar g (87 psi g)

1 bar g (14.5 psi g)

4 bar g (58 psi g)

6 bar g (87 psi g)

0.04 … 4 bar g 7 bar g (0.58 … (102 psi g) 58 psi g)

10 bar g (145 psi g)

4 bar g (58 psi g)

7 bar g (102 psi g)

10 bar g (145 psi g)

0.16 … 16 bar g (2.3 … 232 psi g)

32 bar g (464 psi g)

16 bar g (232 psi g)

21 bar g (305 psi g)

32 bar g (464 psi g)

21 bar g (305 psi g)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.2 Input point Gauge pressure input HART

PROFIBUS PA or Foundation Fieldbus

0.63 … 63 bar g (9.1 … 914 psi g)

67 bar g (972 psi g)

100 bar g (1450 psi g)

63 bar g (914 psi g)

67 bar g (972 psi g)

100 bar g (1450 psi g)

1.6 … 160 bar g (23 … 2321 psi g)

167 bar g (2422 psi g)

250 bar g (3626 psi g)

160 bar g (2321 psi g)

167 bar g (2422 psi g)

250 bar g (3626 psi g)

4 … 400 bar g (58 … 5802 psi g)

400 bar g (5802 psi g)

600 bar g (8702 psi g)

400 bar g (5802 psi g)

400 bar g (5802 psi g)

600 bar g (8702 psi g)

Lower measuring limit •

Measuring cell with silicon oil filling

30 mbar a (0.44 psi a)

•

Measuring cell with inert liquid

30 mbar a (0.44 psi a)

Upper measuring limit

100 % of the max. measuring range (for oxygen measurement max. 160 bar g (2321 psi g))

100 % of the max. measuring span (for oxygen measurement max. 160 bar g (2321 psi g))

Start of scale value

between the measuring limits (continuously adjustable)

gauge pressure input, with flush mounted diaphragm HART

PROFIBUS PA or Foundation Fieldbus

Measured variable

Gauge pressure

Measuring span (continuously adjustable) or measuring range, max permissible operating pressure and max. permissible test pressure

Measuring range

Maximum permissible operating pressure

Maximum permissible test pressure

Measuring span

Maximum permissible operating pressure

Maximum permissible test pressure

8… 250 mbar g (0.12 … 3.6 psi g)

4 bar g (58 psi g)

6 bar g (87 psi g)

250 mbar g (3.6 psi g)

4 bar g (58 psi g)

6 bar g (87 psi g)

0.01 … 1 bar g 4 bar g (0.15 … (58 psi g) 14.5 psi g)

6 bar g (87 psi g)

1 bar g (14.5 psi g)

4 bar g (58 psi g)

6 bar g (87 psi g)

0.04 … 4 bar g 7 bar g (0.58 … (102 psi g) 58 psi g)

10 bar g (145 psi g)

4 bar g (58 psi g)

7 bar g (102 psi g)

10 bar g (145 psi g)

0.16 … 16 bar g (2.3 … 232 psi g)

32 bar g (464 psi g)

16 bar g (232 psi g)

21 bar g (305 psi g)

32 bar g (464 psi g)

100 bar g (1450 psi g)

63 bar g (914 psi g)

67 bar g (972 psi g)

100 bar g (1450 psi g)

21 bar g (305 psi g)

0.6 … 63 bar g 67 bar g (9.1 … (972 psi g) 914 psi g) Lower measuring limit •

Measuring cell with silicon oil filling

100 mbar a (1.45 psi a)

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ITEM 1120, 1340, 1355 Technical data 11.2 Input point gauge pressure input, with flush mounted diaphragm HART

PROFIBUS PA or Foundation Fieldbus

•

Measuring cell with inert liquid

100 mbar a (1.45 psi a)

•

Measuring cell with neobee

30 mbar a (0.44 psi a)

Upper measuring limit

100 % of the max. measuring range

100% of maximum measuring span

Absolute pressure input (from the gauge pressure series) HART

PROFIBUS PA or Foundation Fieldbus

Measured variable

Absolute pressure

Measuring span (continuously adjustable) or measuring range, max permissible operating pressure (as per 97/23/EC pressure device guideline) and max. permissible test pressure (as per DIN 16086)

Measuring range

Maximum permissible operating pressure

Maximum permissible test pressure

Measuring span

Maximum permissible operating pressure

Maximum permissible test pressure

8.3 … 250 mbar a (0.12 … 3.6 psi a)

1.5 bar a (21.8 psi a)

6 bar a (87 psi a)

250 mbar a (3.6 psi a)

1.5 bar a (21.8 psi a)

6 bar a (87 psi a)

43 … 1300 mbar a (0.62 … 18.9 psi a)

2.6 bar a (37.7 psi a)

10 bar a (145 psi a)

1.3 bar a (18.9 psi a)

2.6 bar a (37.7 psi a)

10 bar a (145 psi a)

160 … 5000 bar a (2.32 … 72.5 psi a)

10 bar a (145 psi a)

30 bar a (435 psi a)

5 bar a (72.5 psi a)

10 bar a (145 psi a)

30 bar a (435 psi a)

1 … 30 bar a (14.5 … 435 psi a)

45 bar a (653 psi a)

100 bar a (1450 psi a)

3 bar a (435 psi a)

45 bar a (653 psi a)

100 bar a (1450 psi a)

Lower measuring limit •

Measuring cell with silicon oil filling

0 mbar a (0 psi a)

•

Measuring cell with inert liquid

0 mbar a (0 psi a)

154

for process temperature -20°C < ϑ ≤ 60°C (-4°F < ϑ ≤ +140°F)

30 mbar a (0.44 psi a)

for process temperature 60°C < ϑ ≤ 100°C (max. 85°C for measuring cell 30 bar) (140°F < ϑ ≤ 212°F (max. 185°F for measuring cell 435 psi))

30 mbar a + 20 mbar a • (ϑ - 60°C)/°C (0.44 psi a + 0.29 mbar a • (ϑ - 108°F)/°F)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

Technical data 11.2 Input point

Absolute pressure input (from the gauge pressure series) HART

PROFIBUS PA or Foundation Fieldbus

Upper measuring limit

100 % of the max. measuring range (for oxygen measurement max. 160 bar g (2321 psi g))

100 % of the max. measuring span (for oxygen measurement max. 160 bar g (2321 psi g))

Start of scale value

between the measuring limits (continuously adjustable)

Absolute pressure input (from the differential pressure series) HART

PROFIBUS PA or Foundation Fieldbus

Measured variable

Absolute pressure

Measuring span (continuously adjustable) or measuring range and max permissible operating pressure (as per 97/23/EC pressure device guideline)

Measuring range

Overload limits

Measuring span

Overload limits

8.3 … 250 mbar a (0.12 … 3.6 psi a)

32 bar a (464 psi a)

250 mbar a (3.6 psi a)

32 bar a (464 psi a)

43 … 1300 mbar a (0.62 … 18.9 psi a)

32 bar a (464 psi a)

1300 mbar a (18.9 psi a)

32 bar a (464 psi a)

160 … 5000 bar a (2.32 … 72.5 psi a)

32 bar a (464 psi a)

5 bar a (72.5 psi a)

32 bar a (464 psi a)

1 … 30 bar a (14.5 … 435 psi a)

160 bar a (2320 psi a)

30 bar a (435 psi a) 160 bar a (2320 psi a)

5.3 … 100 bar a (76.9 … 1450 psi a)

160 bar a (2320 psi a) (for connection thread M10 and 7/16-20 UNF in the pressure caps)

100 bar a (1450 psi a)

160 bar a (2320 psi a) (for connection thread M10 and 7/16-20 UNF in the pressure caps)

Lower measuring limit •

Measuring cell with silicon oil filling

•

Measuring cell with inert liquid

0 mbar a (0 psi a)

for process temperature -20°C < ϑ ≤ 60°C (-4°F < ϑ ≤ +140°F)

30 mbar a (0.44 psi a)

for process temperature 60°C < ϑ ≤ 100°C (max. 85°C for measuring cell 30 bar) (140°F < ϑ ≤ 212°F (max. 185°F for measuring cell 435 psi))

30 mbar a + 20 mbar a • (ϑ - 60°C)/°C (0.44 psi a + 0.29 mbar a • (ϑ - 108°F)/°F)

Upper measuring limit

100 % of the max. measuring range (for oxygen measurement max. 160 bar g (2321 psi g))

Start of scale value

between the measuring limits (continuously adjustable)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

100 % of the max. measuring span (for oxygen measurement max. 160 bar g (2321 psi g))

155

ITEM 1120, 1340, 1355 Technical data 11.2 Input point Differential pressure and flow rate input HART

PROFIBUS PA or Foundation Fieldbus

Measured variable

Differential pressure and flow rate

Measuring span (continuously adjustable) or measuring range and max permissible operating pressure (as per 97/23/EC pressure device guideline)

Measuring range

Maximum permissible operating pressure

Measuring span

Maximum permissible operating pressure

1 … 20 mbar (0.4015 … 8.031 inH2O)

32 bar (464 psi)

20 mbar (8.031 inH2O)

32 bar a (464 psi)

1 … 60 mbar (0.4015 … 24.09 inH2O)

160 bar (2320 psi)

60 mbar (24.09 inH2O)

160 bar (2320 psi)

2.5 … 250 mbar (1.004 … 100.4 inH2O)

250 mbar (100.4 inH2O)

6 … 600 mbar (2.409 … 240.9 inH2O)

600 mbar (240.9 inH2O)

16 … 1600 mbar (6.424 … 642.4 inH2O)

1600 mbar (642.4 inH2O)

50 … 5000 mbar (20.08 … 2008 inH2O)

5 bar (2008 inH2O)

0.3 … 30 bar (4.35 … 435 psi)

30 bar (435 psi)

2.5 … 250 mbar 420 bar (6091 psi) (1.004 … 100.4 inH2O)

250 mbar (100.4 inH2O)

6 … 600 mbar (2.409 … 240.9 inH2O)

600 mbar (240.9 inH2O)

16 … 1600 mbar (6.424 … 642.4 inH2O)

1600 mbar (642.4 inH2O)

50 … 5000 mbar (20.08 … 2008 inH2O)

5 bar (2008 inH2O)

0.3 … 30 bar (4.35 … 435 psi)

30 bar (435 psi)

420 bar (6091 psi)

Lower measuring limit •

Measuring cell with silicon oil filling

•

Measuring cell with inert liquid

156

-100% of the max. measuring range (-33% for measuring cell (435 psi)) or 30 mbar a (0.44 psi a)

for process temperature -20°C < ϑ ≤ 60°C (-4°F < ϑ ≤ +140°F)

-100% of the max. measuring range (-33% for measuring cell (435 psi)) or 30 mbar a (0.44 psi a)

for process temperature 60°C < ϑ ≤ 100°C (max. 85°C for measuring cell 30 bar) (140°F < ϑ ≤ 212°F (max. 185°F for measuring cell 435 psi))

• •

-100% of the max. measuring range (-33% for measuring cell (435 psi)) 30 mbar a + 20 mbar a • (ϑ - 60°C)/°C (0.44 psi a + 0.29 mbar a • (ϑ - 108°F)/°F)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.3 Output Differential pressure and flow rate input HART

PROFIBUS PA or Foundation Fieldbus

Upper measuring limit

100 % of the max. measuring range (for oxygen measurement max. 160 bar g (2321 psi g))

100 % of the max. measuring span (for oxygen measurement max. 160 bar g (2321 psi g))

Start of scale value

between the measuring limits (continuously adjustable)

Level input HART

PROFIBUS PA or Foundation Fieldbus

Measured variable

Level

Measuring span (continuously adjustable) or measuring range and max permissible operating pressure (as per 97/23/EC pressure device guideline)

Measuring range

Maximum permissible operating pressure

Measuring span

Maximum permissible operating pressure

25 … 250 mbar (0.36 … 3.63 psi)

see the mounting flange

250 mbar (3.63 psi)

see the mounting flange

25 … 600 mbar (0.36 … 8.7 %)

600 mbar (8.7 %)

53 … 1600 mbar (0.77 … 23.2 psi)

1600 mbar (23.2 psi)

160 … 5000 mbar (2.32 … 72.5 psi)

5 bar (72.5 psi)

Lower measuring limit •

Measuring cell with silicon oil filling

-100% of the max. measuring range or 30 mbar a (0.44 psi a) depending on the mounting flange

•

Measuring cell with inert liquid

-100% of the max. measuring range or 30 mbar a (0.44 psi a) depending on the mounting flange

Upper measuring limit

100 % of the max. measuring range

Start of scale value

between the measuring limits continuously adjustable

11.3

100% of maximum measuring span

Output

Output Output signal

HART

PROFIBUS PA or Foundation Fieldbus

4 … 20 mA

Digital PROFIBUS-PA or Foundation Fieldbus signal

•

Lower limit (continuously adjustable)

3.55 mA, set to 3.84 mA in the factory

–

•

Upper limit (continuously adjustable)

23 mA, set to 20.5 mA or optionally 22.0 mA in the factory

–

•

Ripple (without HART communication)

ISS ≤ 0.5 % of the max. output current

–

0 … 100 s, in steps of 0.1 s

0 … 100 s, in steps of 0.1 s

set to 0.1 s in the factory

set to 0.1 s in the factory

settable time constants (T63)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

157

ITEM 1120, 1340, 1355 Technical data 11.4 Measuring accuracy Output HART

PROFIBUS PA or Foundation Fieldbus

•

Current transmitter

3.55 … 23 mA

–

•

Failure signal

3.55 … 23 mA

–

Resistor R [Ω]

–

Load •

•

Without HART communication

5

8+9 P$

UH

Power supply in V

–

With HART communication

–

HART communicator

R =230 … 500 Ω

–

SIMATIC PDM

R =230 … 1100 Ω

–

Linearly increasing or linearly decreasing Linear increase or decrease or square root extracting increasing (only for DS III differential pressure and flow rate)

Characteristic curve

• •

Bus physics

–

IEC 61158-2

Polarity-independent

–

Yes

11.4

Measuring accuracy

Measuring accuracy (as per EN 60770-1) DS III with PMC connection HART Reference conditions

PROFIBUS PA or Foundation Fieldbus

• • • • •

Rising characteristic curve Start of scale value 0 bar Seal diaphragm: stainless steel Measuring cell with silicon oil filling Room temperature 25°C (77°F)

•

Measuring span ratio r r = maximum measuring span or set measuring span

–

Measurement deviation with cut-off point setting, including hysteresis and repeatability. Linear characteristic curve

≤ 0.075 %

•

r ≤ 10

≤ (0.0029 • r + 0.071) %

–

•

10 < r ≤ 30

≤ (0.0045 • r + 0.071) %

–

•

30 < r ≤ 100 *)

≤ (0.005 • r + 0.05) %

–

Repeatability

Included in the measuring deviation

Hysteresis

Included in the measuring deviation

Settling time T63 without electrical damping

approx. 0.2 s

158

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.4 Measuring accuracy Measuring accuracy (as per EN 60770-1) DS III with PMC connection HART

PROFIBUS PA or Foundation Fieldbus

Long-term drift at ±30°C (±54°F)

In 5 years ≤ (0.25 • r) %

In 5 years ≤ 0.25 %

Effect of the ambient temperature (double values for measuring cell 20 mbar g (0.29 psi g))

As percentage

•

at -10 … +60°C (14 … 140°F)

≤ (0.1 • r + 0.1) %

≤ 0.3 %

•

at -40 … -10°C and +60 … +85°C (-40 … 14°F and 140 … 185°F)

≤ (0.1 • r + 0.15) % per 10 K

≤ 0.25 % per 10 K

Process temperature influence •

In pressure per temperature change

Temperature difference between 3 mbar per 10 K (0.04 psi per 10 K) process temperature and ambient temperature

Influence of mounting position

In pressure per change in angle ≤ 0.1 mbar g (0.00145 psi g) per 10° inclination correction via zero offset

Power supply influence

In percent per change in voltage 0.005 % per 1 V

–

Measuring value resolution

–

3 • 10-5 from the nominal measuring span

*) not for 4 bar PMC Minibolt Measuring accuracy (as per EN 60770-1) gauge pressure HART Reference conditions

• • • • •

Rising characteristic curve Start of scale value 0 bar Seal diaphragm: stainless steel Measuring cell with silicon oil filling Room temperature 25°C (77°F)

•

Measuring span ratio r r = maximum measuring span or set measuring span

PROFIBUS PA or Foundation Fieldbus

–

Measurement deviation with cut-off point setting, including hysteresis and repeatability. Linear characteristic curve

≤ 0.075 %

•

r ≤ 10

≤ (0.0029 • r + 0.071) %

–

•

10 < r ≤ 30

≤ (0.0045 • r + 0.071) %

–

•

30 < r ≤ 100

≤ (0.005 • r + 0.05) %

–

Repeatability

Included in the measuring deviation

Hysteresis

Included in the measuring deviation

Settling time T63 without electrical damping

approx. 0.2 s

Long-term drift at ±30°C (±54°F)

In 5 years ≤ (0.25 • r) %

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

In 5 years ≤ 0.25 %

159

ITEM 1120, 1340, 1355 Technical data 11.4 Measuring accuracy Measuring accuracy (as per EN 60770-1) gauge pressure HART Effect of the ambient temperature (double values for measuring cell 20 mbar g (0.29 psi g))

PROFIBUS PA or Foundation Fieldbus

As percentage

•

at -10 … +60°C (14 … 140°F)

≤ (0.1 • r + 0.1) %

≤ 0.3 %

•

at -40 … -10°C and +60 … +85°C (-40 … 14°F and 140 … 185°F)

≤ (0.1 • r + 0.15) % per 10 K

≤ 0.25 % per 10 K

Influence of mounting position

≤ 0.05 mbar g (0.000725 psi g) per 10° inclination correction via zero offset

Power supply influence

In percent per change in voltage 0.005 % per 1 V

–

Measuring value resolution

–

3 • 10-5 from the nominal measuring span

Gauge pressure measuring accuracy, with flush mounted diaphragm HART Reference conditions

PROFIBUS PA or Foundation Fieldbus

• • • • •

Rising characteristic curve Start of scale value 0 bar Seal diaphragm: stainless steel Measuring cell with silicon oil filling Room temperature 25°C (77°F)

•

Measuring span ratio r r = maximum measuring span or set measuring span

–

Measurement deviation with cut-off point setting, including hysteresis and repeatability. Linear characteristic curve

≤ 0.075 %

•

r ≤ 10

≤ (0.0029 • r + 0.071) %

–

•

10 < r ≤ 30

≤ (0.0045 • r + 0.071) %

–

•

30 < r ≤ 100

≤ (0.005 • r + 0.05) %

–

Settling time T63 without electrical damping

approx. 0.2 s

Long-term drift at ±30°C (±54°F)

In 5 years ≤ (0.25 • r) %

Effect of the ambient temperature (double values for measuring cell 20 mbar g (0.29 psi g))

As percentage

In 5 years ≤ 0.25 %

•

at -10 … +60°C (14 … 140°F)

≤ (0.1 • r + 0.2) %

≤ 0.3 %

•

at -40 … -10°C and +60 … +85°C (-40 … 14°F and 140 … 185°F)

≤ (0.1 • r + 0.15) % per 10 K

≤ 0.25 % per 10 K

Process temperature influence

160

In pressure per temperature change

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.4 Measuring accuracy Gauge pressure measuring accuracy, with flush mounted diaphragm HART •

PROFIBUS PA or Foundation Fieldbus

Temperature difference between 3 mbar per 10 K (0.04 psi per 10 K) process temperature and ambient temperature

Influence of mounting position

In pressure per change in angle 0.4 mbar (0.006 psi) per 10° inclination Correction via zero offset

Power supply influence

In percent per change in voltage 0.005 % per 1 V

–

Measuring value resolution

–

3 • 10-5 from the nominal measuring span

Absolute pressure measuring accuracy (from gauge and differential pressure series) HART Reference conditions

• • • • •

Rising characteristic curve Start of scale value 0 bar Seal diaphragm: stainless steel Measuring cell with silicon oil filling Room temperature 25°C (77°F)

•

Measuring span ratio r r = maximum measuring span or set measuring span

PROFIBUS PA or Foundation Fieldbus

–

Measurement deviation with cut-off point setting, including hysteresis and repeatability. Linear characteristic curve

≤ 0.1 %

•

r ≤ 10

≤ 0.1 %

–

•

10 < r ≤ 30

≤ 0.2 %

–

Settling time T63 without electrical damping

approx. 0.2 s

Long-term drift at ±30°C (±54°F)

per year ≤ (0.1 • r) %

Effect of the ambient temperature (double values for measuring cell 20 mbar g (0.29 psi g))

As percentage

per year ≤ 0.1 %

•

at -10 … +60°C (14 … 140°F)

≤ (0.1 • r + 0.2) %

≤ 0.3 %

•

at -40 … -10°C and +60 … +85°C (-40 … 14°F and 140 … 185°F)

≤ (0.1 • r + 0.15) % per 10 K

≤ 0.25 % per 10 K

Influence of mounting position

In pressure per change of angle • for absolute pressure (from the gauge pressure series): 0.05 mbar (0.000725 psi) per 10° inclination • for absolute pressure (from the differential pressure series): 0.7 mbar (0.001015 psi) per 10° inclination Correction via zero offset

Power supply influence

In percent per change in voltage 0.005 % per 1 V

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

–

161

ITEM 1120, 1340, 1355 Technical data 11.4 Measuring accuracy Absolute pressure measuring accuracy (from gauge and differential pressure series) Measuring value resolution

HART

PROFIBUS PA or Foundation Fieldbus

–

3 • 10-5 from the nominal measuring span

Differential pressure and flow rate measuring accuracy HART Reference conditions

PROFIBUS PA or Foundation Fieldbus

• • • • •

Rising characteristic curve Start of scale value 0 bar Seal diaphragm: stainless steel Measuring cell with silicon oil filling Room temperature 25°C (77°F)

•

Measuring span ratio r r = maximum measuring span or set measuring span

–

Measurement deviation with cut-off point setting, including hysteresis and repeatability. Linear characteristic curve

≤ 0.075

•

r ≤ 10

≤ (0.0029 • r + 0.071) %

–

•

10 < r ≤ 30

≤ (0.0045 • r + 0.071) %

–

•

30 < r ≤ 100

≤ (0.005 • r + 0.05) %

–

Square root extracting characteristic curve (flow rate > 50%)

≤ 0.1 %

•

r ≤ 10

≤ 0.1 %

–

•

10 < r ≤ 30

≤ 0.2 %

–

square root extracting characteristic curve (flow rate 25 … 50%)

≤ 0.2 %

•

r ≤ 10

≤ 0.2 %

–

•

10 < r ≤ 30

≤ 0.4 %

–

approx. 0.2 s approx 0.3 s for measuring cell 20 and 60 mbar (0.29 and 0.87 psi)

Settling time T63 without electrical damping

• •

Long-term drift at ±30°C (±54°F)

≤ (0.25 • r) % per five years static pressure max. 70 bar g (1015 psi g)

≤ 0.25 % per five years static pressure max. 70 bar g (1015 psi g)

≤ (0.2 • r) % per year

≤ 0.2 % per year

•

Measuring cell 20 mbar (0.29 psi)

Effect of the ambient temperature (double values for measuring cell 20 mbar g (0.29 psi g))

As percentage

•

At -10 … +60°C (14 … 140°F)

≤ (0.08 • r + 0.1) %

≤ 0.3 %

•

At -40 … -10°C and +60 … +85°C (-40 … 14°F and 140 … 185°F)

≤ (0.1 • r + 0.15) % per 10 K

≤ 0.25 % per 10 K

≤ (0.15 • r) % per 100 bar (1450 psi)

≤ 0.15% per 100 bar (1450 psi)

Effect of static pressure •

162

At the start of scale value

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.4 Measuring accuracy Differential pressure and flow rate measuring accuracy Measuring cell 20 mbar (0.29 psi) •

On the measuring span Measuring cell 20 mbar (0.29 psi)

Influence of mounting position

HART

PROFIBUS PA or Foundation Fieldbus

≤ (0.15 • r) % per 32 bar (464 psi)

≤ 0.15% per 32 bar (464 psi)

≤ 0.2 % per 100 bar (1450 psi) ≤ 0.2 % per 32 bar (464 psi) In pressure per change of angle ≤ 0.7 mbar (0.001015 psi) per 10° inclination Correction via zero offset

Power supply influence

In percent per change in voltage 0.005 % per 1 V

–

Measuring value resolution

–

3 • 10-5 from the nominal measuring span

Level measuring accuracy HART Reference conditions

• • • • •

Rising characteristic curve Start of scale value 0 bar Seal diaphragm: stainless steel Measuring cell with silicon oil filling Room temperature 25°C (77°F)

•

Measuring span ratio r r = maximum measuring span or set measuring span

PROFIBUS PA or Foundation Fieldbus

–

Measurement deviation with cut-off point setting, including hysteresis and repeatability. Linear characteristic curve

≤ 0.075

•

r ≤ 10

≤ 0.15 %

–

•

10 < r ≤ 30

≤ 0.3 %

–

•

30 < r ≤ 100

≤ (0.0075 • r + 0.075) %

–

Settling time T63 without electrical damping

approx. 0.2 s

Long-term drift at ±30°C (±54°F)

≤ (0.25 • r) % per five years static pressure max. 70 bar g (1015 psi g)

Ambient temperature influence

As percentage

•

≤ 0.25 % per five years static pressure max. 70 bar g (1015 psi g)

At -10 … +60°C (14 … 140°F) (0.4 instead of 0.2 at 10 < r ≤ 30) Measuring cell 250 mbar (3.63 psi)

≤ (0.5 • r + 0.2) %

≤ 0.7 %

Measuring cell 600 mbar (8.7 psi)

≤ (0.3 • r + 0.2) %

≤ 0.5 %

Measuring cell 1.6 and 5 bar (23.2 and 72.5 psi)

≤ (0.25 • r + 0.2) %

≤ 0.45 %

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

163

ITEM 1120, 1340, 1355 Technical data 11.5 Operating conditions Level measuring accuracy •

HART

PROFIBUS PA or Foundation Fieldbus

Measuring cell 250 mbar (3.63 psi)

≤ (0.25 • r + 0.15) %/10 K (≤ (0.25 • r + 0.15) %/18°F)

≤ 0.4 %/10 K (≤ 0.4 %/18°F)

Measuring cell 600 mbar (8.7 psi)

≤ (0.15 • r + 0.15) %/10 K (≤ (0.15 • r + 0.15) %/18°F)

≤ 0.3 %/10 K (≤ 0.3 %/18°F)

Measuring cell 1.6 and 5 bar (23.2 and 72.5 psi)

≤ (0.12 • r + 0.15) %/10 K (≤ (0.12 • r + 0.15) %/18°F)

≤ 0.27 %/10 K (≤ 0.27 %/18°F)

Measuring cell 250 mbar (0.29 psi)

≤ (0.3 • r) % per nominal pressure

≤ 0.3 % per nominal pressure

Measuring cell 600 mbar (8.7 psi)

≤ (0.15 • r) % per nominal pressure

≤ 0.15 % per nominal pressure

Measuring cell 1.6 and 5 bar (23.2 and 72.5 psi)

≤ (0.1 • r) % per nominal pressure

≤ 0.1 % per nominal pressure

≤ (0.1 • r) % per nominal pressure

≤ 0.1 % per nominal pressure

At -40 … -10°C and +60 … +85°C (-40 … 14°F and 140 … 185°F) (double values for 10 < r ≤ 30)

Effect of static pressure •

•

At the start of scale value

On the measuring span

Influence of mounting position

depending on the fill fluid in the mounting flange

Power supply influence

In percent per change in voltage 0.005 % per 1 V

Measuring value resolution

–

11.5

3 • 10-5 from the nominal measuring span

Operating conditions

Rated conditions DS III with PMC connection Installation conditions Ambient temperature Note

Observe the temperature class in hazardous areas.

•

Measuring cell with silicon oil filling

-20 … +85°C (-4 … 185°F)

•

Digital display

-30 … +85°C (-22 … 185°F)

•

Storage temperature

-50 … +85°C (-58 … 185°F)

Climate class •

Condensation

Degree of protection (as per EN 60529)

permitted IP65

Electromagnetic Compatibility •

164

Interference emission and interference immunity

As per EN 61326 and NAMUR NE 21

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.5 Operating conditions Rated conditions DS III with PMC connection Medium conditions •

Process temperature

-20 … +100°C (-4 … +212°F)

Rated conditions for gauge pressure and absolute pressure (from the gauge pressure series) Installation conditions •

Installation instruction

Process connection vertically downward

Ambient conditions •

Ambient temperature

Note Measuring cell with silicon oil filling

Observe the temperature class in hazardous areas. --40 … +100°C (-40 … 212°F)

Measuring cell with inert liquid

-20 … +100°C (-40 … 212°F)

Digital display

-30 … +85°C (-22 … 185°F)

Storage temperature

-50 … +85°C (-58 … 185°F)

•

Climate class

•

Degree of protection (as per EN 60529)

•

Electromagnetic Compatibility

Condensation

Interference emission and interference immunity

Permitted IP65

As per EN 61326 and NAMUR NE 21

Medium conditions •

Process temperature Measuring cell with silicon oil filling

-40 … +100°C (-40 … 212°F)

Measuring cell with inert liquid

-20 … +100°C (-40 … 212°F)

in conjunction with dust explosion protection

-20 … +60°C (-4 … 140°F)

Gauge pressure rated conditions, with flush mounted diaphragm Installation conditions Ambient temperature Note

Observe the temperature class in hazardous areas.

•

Measuring cell with silicon oil filling

-40 … +85°C (-40 … 185°F)

•

Measuring cell with inert liquid

-40 … +85°C (-40 … 185°F)

•

Measuring cell with neobee

-10 … +85°C (+14 … 185°F)

•

Digital display

-30 … +85°C (-22 … 185°F)

•

Storage temperature

-50 … +85°C (-58 … 185°F)

Climate class Condensation

permitted

Degree of protection

IP65, IP68

•

In accordance with EN 60 529

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

165

ITEM 1120, 1340, 1355 Technical data 11.5 Operating conditions Gauge pressure rated conditions, with flush mounted diaphragm Electromagnetic Compatibility •

Interference emission and interference immunity

As per EN 61326 and NAMUR NE 21

Medium conditions Process temperature •

Measuring cell with silicon oil filling

-40 … +150°C (-40 … 302°F) -40 … +200°C (-40 … 392°F) with temperature decoupler -10 … +250°C (+14 … 482°F) with temperature decoupler

•

Measuring cell with inert liquid

-40 … +150°C (-40 … 302°F) -40 … +200°C (-40 … 392°F) with temperature decoupler

•

Measuring cell with neobee

-10 … +150°C (+14 … 302°F) -40 … +200°C (-40 … 392°F) with temperature decoupler

Rated conditions for absolute pressure (from the differential pressure series), differential pressure and flow rate Installation conditions •

Installation instruction

any

Ambient conditions •

Ambient temperature

Note

Observe the temperature class in hazardous areas.

Measuring cell with silicon oil filling •

Measuring cell 30 bar (435 psi)

-40 … +100°C (-40 … 212°F) • •

-40 … +85°C (-40 … +185°F) for flow rate: -20 … +85°C (-4 … +185°F)

Measuring cell with neobee

-20 … +100°C (-4 … 212°F)

Digital display

-30 … +85°C (-22 … 185°F)

Storage temperature

-50 … +85°C (-58 … 185°F)

•

Climate class

•

Degree of protection (as per EN 60529)

•

Electromagnetic Compatibility

Condensation

Interference emission and interference immunity

Permitted IP65

As per EN 61326 and NAMUR NE 21

Medium conditions •

Process temperature Measuring cell with silicon oil filling •

Measuring cell 30 bar (435 psi)

Measuring cell with inert liquid •

Measuring cell 30 bar (435 psi)

In conjunction with dust explosion protection

166

-40 … +100°C (-40 … 212°F) • •

-40 … +85°C (-40 … +185°F) for flow rate: -20 … +85°C (-4 … +185°F)

-20 … +100°C (-40 … 212°F) • •

-40 … +85°C (-40 … +185°F) for flow rate: -20 … +85°C (-4 … +185°F)

-20 … +60°C (-4 … +140°F)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

Technical data 11.6 Construction

Rated conditions for level Installation conditions •

Installation instruction

specified through the flange

Ambient conditions •

Ambient temperature

Note

•

Observe the allocation of the max. permissible operating temperature to the max. permissible operating pressure of the relevant flange connection.

Measuring cell with silicon oil filling

-40 … +100°C (-40 … 212°F)

Digital display

-30 … +85°C (-22 … 185°F)

Storage temperature

-50 … +85°C (-58 … 185°F)

Climate class Condensation

•

Degree of protection (as per EN 60529)

•

Electromagnetic Compatibility Interference emission and interference immunity

Permitted IP65

As per EN 61326 and NAMUR NE 21

Medium conditions •

Process temperature Measuring cell with silicon oil filling

11.6

• •

Plus side: see the mounting flange Minus side: -40 … +100°C (-40 … +212°F)

Construction

DS III construction with PMC connection Weight

approx 1.5 kg (3.3 lb)

Material •

•

Wetted parts materials Gasket (standard)

PTFE flat gasket

O-ring (minibolt)

• •

FPM (Viton) FFPM or NBR (optional)

•

Non-copper aluminum die casting GD-AlSi 12 or stainless steel precision casting, mat. no. 1.4408 Lacquer on polyester base Type plate made of stainless steel

Non-wetted parts materials Electronics housing

• • Mounting bracket Measuring cell filling

Steel, zinc plated and yellow chrome plated or stainless steel • • •

Silicone oil Neobee M20 Inert liquid

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

167

ITEM 1120, 1340, 1355 Technical data 11.6 Construction DS III construction with PMC connection Process connection •

Standard

• • •

Flush mounted 11/2'' PMC Standard design

•

Minibolt

• • •

Flush mounted 1'' PMC Minibolt design

Electrical connection

Cable inlet using the following screwed joints: • Pg 13.5 (adapter) • M20 x 1.5 • ½-14 NPT • Han 7D/Han 8U plug connector • M12 connector

Construction for gauge pressure and absolute pressure (from the gauge pressure series) Weight

approx 1.5 kg (3.3 lb)

Material •

•

Wetted parts materials Connection pins

Stainless steel, mat. no. 1.4404/316L or Hastelloy C4, mat. no. 2.4610

Oval flange

Stainless steel, mat. no. 1.4404/316L

Seal diaphragm

Stainless steel, material no. 1.4404/316L or Hastelloy C276, material no. 2.4819

Non-wetted parts materials Electronics housing

• • •

Mounting bracket Measuring cell filling

Non-copper aluminum die casting GD-AlSi 12 or stainless steel precision casting, mat. no. 1.4408 Lacquer on polyester base Type plate made of stainless steel

Steel, zinc plated and yellow chrome plated or stainless steel • • •

Silicone oil Neobee M20 Inert liquid

(max. 160 bar g (2320 psi g) for oxygen measurement) Process connection

Connection pin G1/2A as per DIN EN 837-1; female thread 1/2-14 NPT or oval flange (PN 160 (MWP 2320 psi g)) with fastening screw thread M10 as per DIN 19213 or 7/16-20 UNF as per EN 61518

Electrical connection

Screw terminals Cable inlet using the following screwed joints: • Pg 13.5 (adapter) • M20 x 1.5 • ½-14 NPT or Han 7D/Han 8U plug connector • M12 connector

Construction for gauge pressure, with flush mounted diaphragm Weight

approx. 1.5 … 13.5 kg (3.3 … 30 lb)

Material

168

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.6 Construction Construction for gauge pressure, with flush mounted diaphragm •

•

Wetted parts materials Process connection

Stainless steel, mat. no. 1.4404/316L

Seal diaphragm

Stainless steel, mat. no. 1.4404/316L

Non-wetted parts materials Electronics housing

• • •

Mounting bracket

Non-copper aluminum die casting GD-AlSi 12 or stainless steel precision casting, mat. no. 1.4408 Lacquer on polyester base Type plate made of stainless steel

Steel, zinc plated and yellow chrome plated or stainless steel

Measuring cell filling

• • •

Silicone oil Neobee M20 Inert liquid

Process connection

• • • •

Flanges as per EN and ASME F&B and pharma flange Bioconnect/Biocontrol PMC style

Electrical connection

Cable inlet using the following screwed joints: • Pg 13.5 (adapter) • M20x1.5 • ½-14 NPT • Han 7D/Han 8U plug connector • M12 connector

Construction for absolute pressure (from the gauge pressure series), differential pressure and flow rate Weight

approx. 4.5 kg (9.9 lb)

Material •

•

Wetted parts materials Seal diaphragm

Stainless steel, mat. no. 1.4404/316L, Hastelloy C276, mat. no. 2.4819, Monel, mat. no. 2.4360, tantalum or gold

Pressure caps and locking screw

Stainless steel, mat. no. 1.4408 to PN 160, mat. no. 1.4571/316Ti for PN 420, Hastelloy C4, 2.4610 or Monel, mat. no. 2.4360

O-ring

FPM (Viton) or optionally: PTFE, FEP, FEPM and NBR

Non-wetted parts materials Electronics housing

• • •

Non-copper aluminum die casting GD-AlSi 12 or stainless steel precision casting, mat. no. 1.4408 Lacquer on polyester base Type plate made of stainless steel

Pressure cap screws

Steel, zinc plated and yellow chrome plated or stainless steel

Mounting bracket

Steel, zinc plated and yellow chrome plated or stainless steel

Measuring cell filling

• • •

Silicone oil Neobee M20 Inert liquid

(max. 160 bar g (2320 psi g) for oxygen measurement)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

169

ITEM 1120, 1340, 1355 Technical data 11.6 Construction Construction for absolute pressure (from the gauge pressure series), differential pressure and flow rate Process connection

Female thread 1/4-18 NPT and flat connection with fastening screw thread M10 as per DIN 19213 (M12 for PN 420 (MWP 6092 psi)) or 7/16-20 UNF as per EN 61518

Electrical connection

Screw terminals Cable inlet using the following screwed joints: • Pg 13.5 (adapter) • M20 x 1.5 • ½-14 NPT or Han 7D/Han 8U plug connector • M12 connector

Construction for level Weight •

as per EN (pressure transmitter with mounting flange, without tube)

approx 11 … 13 kg (24.2 … 28.7 lb)

•

as per ASME (pressure transmitter with mounting flange, without tube)

approx 11 … 18 kg (24.2 … 39.7 lb)

Material •

Wetted parts materials Plus side •

Seal diaphragm on the mounting flange

Stainless steel, mat. no. 1.4404/316L, Monel 400, mat. no. 2.4360, Hastelloy B2, mat. no. 2.4617, Hastelloy C276, mat. no. 2.4819, Hastelloy C4, mat. no. 2.4610, tantalum, PTFE, ECTFE

•

Sealing surface

smooth as per EN 1092-1, form B1 or ASME B16.5 RF 125 … 250 AA for stainless steel 316L, EN 2092-1 form B2 or ASME B16.5 RFSF for the remaining materials

Sealing material in the pressure caps •

for standard applications

Viton

•

for underpressure applications on the mounting flange

Copper

Minus side

•

•

Seal diaphragm

Stainless steel, mat. no. 1.4404/316L

•

Pressure caps and locking screws

Stainless steel, mat. no. 1.4408

•

O-ring

FPM (Viton)

Non-wetted parts materials Electronics housing

• • •

Pressure cap screws Measuring cell filling •

Mounting flange fill fluid

Non-copper aluminum die casting GD-AlSi 12 or stainless steel precision casting, mat. no. 1.4408 Lacquer on polyester base Type plate made of stainless steel

Steel, zinc plated and yellow chrome plated or stainless steel Silicone oil Silicon oil or a different design

Process connection •

170

Plus side

Flange as per EN and ASME

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.7 Display, keyboard and auxiliary power Construction for level •

Minus side

Female thread 1/4-18 NPT and flat connection with fastening screw thread M10 as per DIN 19213 (M12 for PN 420 (MWP 6092 psi)) or 7/16-20 UNF as per EN 61518

Electrical connection

Screw terminals Cable inlet using the following screwed joints: • Pg 13.5 (adapter) • M20 x 1.5 • ½-14 NPT or Han 7D/Han 8U plug connector • M12 connector

11.7

Display, keyboard and auxiliary power Display and user interface Keys

3 for on-site programming directly at the device

Digital display

• •

Installed Cover with inspection window (optional)

Auxiliary power UH HART DC 10.5 V … 45 V In the case of intrinsically safe operation 10.5 V … 30 V DC

PROFIBUS PA or Foundation Fieldbus

Terminal voltage at transmitter

• •

–

Ripple

USS ≤ 0.2 V (47 … 125 Hz)

–

Noise

Ueff ≤ 1.2 V (0.5 … 10 Hz)

–

Auxiliary power

–

Bus-powered

Separate supply voltage

–

Not necessary

Bus voltage •

Not

–

9 … 32 V

•

For intrinsically safe operation

–

9 … 24 V

Current consumption •

Max. basic current

–

12.5 mA

•

Starting current ≤ basic current

–

Yes

•

Max. current in event of fault

–

15.5 mA

–

Yes

Error shut-down electronics (FDE) present

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

171

ITEM 1120, 1340, 1355 Technical data 11.8 Certificates and approvals

11.8

Certificates and approvals

Certificates and approvals HART Classification according to Pressure Equipment Directive (PED 97/23/EC)

• •

Water, waste water

PROFIBUS PA or Foundation Fieldbus

for gases of Fluid Group 1 and liquids of Fluid Group 1; meets requirements of Article 3 Para. 3 (good engineering practice) only for flow rate: for gases of Fluid Group 1 and liquids of Fluid Group 1; fulfills the basic safety requirements as per article 3, Para 1 (appendix 1); classified as category III, module H conformity evaluation by TÜV Nord

In preparation

Explosion protection •

Intrinsic safety "i" Identifier

•

II 1/2 G EEx ia/ib IIB/IIC T6

Permissible ambient temperature

-40 … +85°C (-40 … +185°F) temperature class T4 -40 … +70°C (-40 … +158°F) temperature class T5 -40 … +60°C (-40 … +140°F) temperature class T6

Connection

To a certified intrinsically safe circuit with the max. values:

FISCO supply unit Ui = 17.5 V, Ii = 380 mA, Pi = 5.32 W

Ui = 30 V, Ii = 100 mA, Pi = 750 mW, Ri = 300 Ω

Linear barrier Ui = 24 V, Ii = 250 mA, Pi = 1.2 W

Effective inner capacitance:

Ci = 6 nF

Ci = 1.1 nF

Effective inner inductance:

Li = 0.4 mH

Li = 7 µH

Flameproof enclosure encapsulation "d" Identifier

•

PTB 99 ATEX 2122

PTB 99 ATEX 1160 II 1/2 G EEx d IIC T4/T6

Permissible ambient temperature

-40 … +85°C (-40 … +185°F) temperature class T4 -40 … +60°C (-40 … +140°F) temperature class T6

Connection

To a circuit with the operating values: UH = DC 10.5 … 45 V

Dust explosion protection for Zone 20 Identifier

To a circuit with the operating values: UH = DC 9 … 32 V

PTB 01 ATEX 2055 II 1 D IP65 T 120°C,

II 1/2 D IP65 T 120°C

Permissible ambient temperature

-40 ... +85 °C (-40 ... +185 °F)

max. surface temperature

120°C (248°F)

Connection

To a certified intrinsically safe circuit with the max. values:

FISCO supply unit Ui = 17.5 V, Ii = 380 mA, Pi = 5.32 W

Ui = 30 V, Ii = 100 mA, Pi = 750 mW, Ri = 300 Ω

•

Effective inner capacitance:

Ci = 6 nF

Ci = 1.1 nF

Effective inner inductance:

Li = 0.4 mH

Li = 7 µH

Dust explosion protection for Zone 21/22 Identifier Connection

172

PTB 01 ATEX 2055 II 2 D IP65 T 120°C To a circuit with the operating values: UH = DC 10.5 … 45 V; Pmax = 1.2 W

To a circuit with the operating values: UH = DC 9 … 32 V; Pmax = 1.2 W

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Technical data 11.9 HART communication Certificates and approvals HART •

Type of protection "n" (Zone 2)

PROFIBUS PA or Foundation Fieldbus

TÜV 01 ATEX 1696 X

Identifier

II 3 G EEx nA L IIC T4/T5/T6 only for gauge pressure, with flush mounted diaphragm: II 3 G EEx nL IIC T4/T5/T6

•

•

Connection "nA"

Un = 45 V

Connection "nL"

Un = 45 V

FISCO supply unit Ui = 32 V, Ii = 515 mA, Pi = 5.25 W

Effective inner capacitance:

Ci = 6 nF

Ci = 1.1 nF

Effective inner inductance:

Li = 0.4 mH

Li = 7 µH

n

= 32 V

Explosion protection in accordance Certificate of Compliance 3008490 with FM Designation (XP/DIP) or IS; NI; S

CL I, DIV 1, GP ABCD T4 ... T6; CL II, DIV 1, GP EFG; CL III; CL I, ZN 0/1 AEx ia IIC T4 ... T6; CL I, DIV 2, GP ABCD T4 ... T6; CL II, DIV 2, GP FG; CL III

Permissible ambient temperature

Ta = T4: -40 ... +85°C (-40 ... +185°F) Ta = T5: -40 ... +70°C (-40 ... +158°F) Ta = T6: -40 ... +60°C (-40 ... +140°F)

Entity parameters

As per "control drawing" A5E00072770A: Ui = 30 V, Ii = 100 mA, Pi = 750 mW, Ri = 300 Ω, Ci = 6 nF, Li = 0.4 mH

Explosion protection as per CSA

As per "control drawing" A5E00072770A: Umax = 17.5 V, Imax = 380 mA, Pmax = 5.32 W, Cmax = 6 nF, Lmax = 0.4 mH

Certificate of Compliance 1153651

Designation (XP/DIP) or (IS)

CL I, DIV 1, GP ABCD T4 ... T6; CL II, DIV 1, GP EFG; CL III; CL I, DIV 2, GP ABCD T4 ... T6; CL II, DIV 2, GP FG; CL III

Permissible ambient temperature

Ta = T4: -40 ... +85°C (-40 ... +185°F) Ta = T5: -40 ... +70°C (-40 ... +158°F) Ta = T6: -40 ... +60°C (-40 ... +140°F)

Entity parameters

As per "control drawing" A5E00072770A: Ui = 30 V, Ii = 100 mA, Pi = 750 mW, Ri = 300 Ω, Li = 0.4 mH, Ci = 6 nF

11.9

ia IIC T4 ... T6:

HART communication HART communication Load for a •

HART communicator connection

230 … 1100 Ω

•

HART modem

230 … 500 Ω

Cable

2-wire, shielded: ≤ 3.0 km (1.86 miles), multiwired, shielded: ≤ 1.5 km (0.93 miles)

Protocol

HART Version 5.x

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

173

Technical data 11.9 HART communication

ITEM 1120, 1340, 1355

HART communication

174

PC/laptop requirements

IBM-compatible, user memory > 32 MB, hard disk > 70 MB, depending on the type of modem: RS 232 interface or USB connection, VGA graphic

Software for computer

SIMATIC PDM

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

12

Dimension drawings

SITRANS P, DS III series for gauge pressure and absolute pressure from the gauge pressure series  

 

 

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12.1

  

Figure 12-1

Pressure transmitter SITRANS P, DS III HART series for absolute pressure, from gauge pressure series, dimensions in mm (inch)

①

Electronic side, digital display (greater design length for cover with inspection window)

②

Process connection: • 1/2-14 NPT, • Connection pin G1/2A or • Oval flange

③

Connection side

④

Electrical connection: • Screwed point Pg 13,5 (adapter)2)3), • Screwed point M20 x 1,53), • Screwed point 1/2-14 NPT • Han 7D/Han 8U2)3) plug connector • M12 connector

⑤

Protective cap of the operating buttons

⑥

Blanking plug

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

175

ITEM 1120, 1340, 1355 Dimension drawings 12.2 SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from the differential pressure series

12.2

Screw cover - lock bracket (only for "explosion-proof" type of protection, not shown in the drawing)

⑧

Mounting bracket (optional)

1)

Take additional 20 mm (0.79 inch) thread length into account

2)

Not with "Explosion-proof" type of protection

3)

Not for "FM + CSA [is + XP]" type of protection

4)

For Pg 13,5 with adapter approx 45 mm (1.77 inch)

5)

Minimum distance when rotating

SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from the differential pressure series  





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Figure 12-2

 

Pressure transmitter SITRANS P, DS III HART series for differential pressure and flow rate, dimensions in mm (inch)

①

176

 

 

Electronic side, digital display (greater design length for cover with inspection window)

②

Connection side

③

Electrical connection: • Screwed point Pg 13,5 (adapter)2)3), • Screwed point M20 x 1,53), • Screwed point 1/2-14 NPT • Han 7D/Han 8U2)3) plug connector • M12 connector

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

Dimension drawings 12.2 SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from the differential pressure serie ④

Protective cap of the operating buttons

⑤

Blanking plug

⑥

Screw cover - lock bracket (only for "explosion-proof" type of protection, not shown in the drawing)

⑦

Mounting bracket (optional)

⑧

Electrical connection: • Screwed point Pg 13,5 (adapter)2)3), • Screwed point M20 x 1,53), • Screwed point 1/2-14 NPT or • Han 7D/Han 8U2)3) plug connector

⑨

Lateral ventilation for gas measurement (addition H02)

⑩

Sealing plug, with valve (optional)

⑪

Lateral ventilation for liquid measurement

⑫

Process connection: 1/4-18 NPT (EN 61518)

1)

Take additional 20 mm (0.79 inch) thread length into account

2)

Not with "Explosion-proof" type of protection

3)

Not for "FM + CSA [is + XP]" type of protection

4)

92 mm (3.62 inch) minimum distance for rotating the pointer

5)

For Pg 13,5 with adapter approx 45 mm (1.77 inch)  



 

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Figure 12-3

①

DSSUR[

Pressure transmitter SITRANS P, DS III HART series for differential pressure and flow rate with caps for vertical differential pressure lines, dimensions in mm (inch)

Electronic side, digital display (greater design length for cover with inspection window)

②

Connection side

③

Electrical connection: • Screwed point Pg 13,5 (adapter)2)3), • Screwed point M20 x 1,53), • Screwed point 1/2-14 NPT or • Han 7D/Han 8U2)3) plug connector

④

Protective cap of the operating buttons

⑤

Blanking plug

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

177

ITEM 1120, 1340, 1355 Dimension drawings 12.2 SITRANS P, DS III series for differential pressure, flow rate and absolute pressure from the differential pressure series

178

⑥

Screw cover - lock bracket (only for "explosion-proof" type of protection, not shown in the drawing)

⑦

Sealing plug, with valve (optional)

⑧

Process connection: 1/4-18 NPT (EN 61518)

1)

Take additional 20 mm (0.79 inch) thread length into account

2)

Not with "Explosion-proof" type of protection

3)

Not for "FM + CSA [is + XP]" type of protection

4)

92 mm (3.62 inch) minimum distance for rotating the pointer

5)

74 mm (2.9 inch) for PN ≥ 420 (MWP ≥ 6092 psi)

6)

91 mm (3.6 inch) for PN ≥ 420 (MWP ≥ 6092 psi)

7)

219 mm (8.62 inch) for PN ≥ 420 (MWP ≥ 6092 psi)

8)

For Pg 13,5 with adapter approx 45 mm (1.77 inch)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Dimension drawings 12.3 SITRANS P, DS III series for level

12.3

SITRANS P, DS III series for level 

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Figure 12-4







Pressure transmitter SITRANS P, DS III HART series for level, including mounting flange, dimensions in mm (inch)

①

Electrical connection: • Screwed point Pg 13,5 (adapter)2)3), • Screwed point M20 x 1,53), • Screwed point 1/2-14 NPT • Han 7D/Han 8U2)3) plug connector • M12 connector

②

Protective cap of the operating buttons

③

Blanking plug

④

Electronic side, digital display (greater design length for cover with inspection window)

⑤

Protective cap of the operating buttons

⑥

Connection side

⑦

Sealing plug with valve (optional)

⑧

Screw cover - lock bracket (only for "explosion-proof" type of protection, not shown in the drawing)

⑨

Process connection: Minus side 1/4-18 NPT (EN 61518)

1)

Take additional 20 mm (0.79 inch) thread length into account

2)

Not with "Explosion-proof" type of protection

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

179

ITEM 1120, 1340, 1355 Dimension drawings 12.4 SITRANS P, DS III series (flush mounted) Not for "FM + CSA [is + XP]" type of protection

4)

92 mm (3.62 inch) minimum distance for rotating the pointer

5)

For Pg 13,5 with adapter approx 45 mm (1.77 inch)

SITRANS P, DS III series (flush mounted)  

 

 

 

FD FD

 



 

 







+ FD + FD  





 

12.4

3)



+  FD +  FD





>@  >@ 

Figure 12-5

SITRANS P DS III (flush mounted)

①

Electronics side, "digital display" option

④

Protective caps for buttons

②

Connection side, "analog display" option

⑤

Blanking plug

③

Cable gland

⑥

Screw cover - lock bracket, only for flameproof encapsulation, not shown in the dimension drawings

⑦

Process connection

1)

Take additional 20 mm (approx.) thread length into account

4)

Minimum distance for turning without display and [ ] with display

The screen consists of a SITRANS P DS III with an example flange. On this screen, the height is divided into H1 and H2. H1

Height of the device up to a defined cut

H2

Height of the flange up to this defined cut

In the flange dimensions, only the height H2 is specified.

180

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Dimension drawings 12.4 SITRANS P, DS III series (flush mounted)

12.4.1

Note 3A and EHDG Note The SITRANS P, DS III series is approved by "EHEDG". The SITRANS P300 is approved by "EHEDG" and "3A" for example. The same flanges and flush mounted connections are used for both the pressure transmitters. The connections for both the abovementioned approvals are thus specified. Since the SITRANS P, DS III series transmitter is not approved by "3A", the connections marked with "3A" are not applicable for the SITRANS P, DS III series.

12.4.2

Connections as per EN and ASME

Flange as per EN

+

EN 1092-1

'

DN

PN

⊘D

H2

25

40

115 mm (4.5'')

Approx. 52 mm (2'')

25

100

140 mm (5.5'')

40

40

150 mm (5.9'')

40

100

170 mm (6.7'')

50

16

165 mm (6.5'')

50

40

165 mm (6.5'')

80

16

200 mm (7.9'')

80

40

200 mm (7.9'')

DN

PN

⊘D

H2

2''

63

78 mm (3.1'')

Approx. 52 mm (2'')

Threaded connections

+

G2" as per DIN 3852

'

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

181

ITEM 1120, 1340, 1355 Dimension drawings 12.4 SITRANS P, DS III series (flush mounted)

Flanges as per ASME

+

ASME B 16.5

'

12.4.3

DN

CLASS

⊘D

H2

1''

150

110 mm (4.3'')

Approx. 52 mm (2'')

1''

300

125 mm (4.9'')

1 1/2''

150

130 mm (5.1'')

1 1/2''

300

155 mm (6.1'')

2''

150

150 mm (5.9'')

2''

300

165 mm (6.5'')

3''

150

190 mm (7.5'')

3''

300

210 mm (8.1'')

4''

150

230 mm (9.1'')

4''

300

255 mm (10.0'')

DN

PN

⊘D

H2

25

40

63 mm (2.5'')

Approx. 52 mm (2'')

32

40

70 mm (2.8'')

40

40

78 mm (3.1'')

50

25

92 mm (3.6'')

80

25

127 mm (5'')

F&B and pharma flange

Connections as per DIN

+

DIN 11851

'

3A1)

Approvals

1) If the transmitter is approved by 3A, use only 3A-approved sealing rings.

+

DIN 11864-1 DN

PN

⊘D

H2

25 40

40

52 mm (2'')

Approx. 52 mm (2'')

40

65 mm (2.6'')

50

40

78 mm (3.1'')

100

40

130 mm (5.1'')

'

Approvals

182

3A, EHEDG

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Dimension drawings 12.4 SITRANS P, DS III series (flush mounted)

+

DIN 11864-2

'

Approvals

DN

PN

⊘D

H2

25

40

70 mm (2.8'')

Approx. 52 mm (2'')

40

40

82 mm (3.2'')

50

40

94 mm (3.7'')

100

40

159 mm (6.3'')

DN

PN

⊘D

H2

25

40

50.5 mm (2'')

Approx. 52 mm (2'')

40

40

64 mm (2.5'')

50

40

77.5 mm (3.1'')

100

40

130 mm (5.1'')

DN

PN

⊘D

H2

20

16

34 mm (1.3'')

Approx. 52 mm (2'')

25

16

50.5 mm (2'')

32

16

50.5 mm (2'')

40

16

50.5 mm (2'')

50

16

64 mm (2.5'')

65

10

91 mm (3.6'')

80

10

106 mm (4.2'')

100

40

119 mm (4.7'')

DN

PN

⊘D

H2

25-32

40

66 mm (2.6'')

Approx. 52 mm (2'')

40-125

40

84 mm (3.3'')

3A, EHEDG

+

DIN 11864-3

'

Approvals

3A, EHEDG

+

Tri-Clamp as per DIN 32676

'

Approvals

3A

Other connections

+

Varivent® connector

'

Approvals

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

3A, EHEDG

183

ITEM 1120, 1340, 1355 Dimension drawings 12.4 SITRANS P, DS III series (flush mounted)

BioconnectTM connector

+

BioconnectTM screwed joint DN

PN

⊘D

H2

25

16

55 mm (2.2'')

Approx. 52 mm (2'')

50

16

82 mm (3.2'')

100

16

145 mm (5.7'')

DN

PN

⊘D

H2

25

16

85 mm (3.3'')

Approx. 52 mm (2'')

50

16

110 mm (4.3'')

100

16

175 mm (6.9'')

DN

PN

⊘D

H2

25

16

50.4 mm (1.9'')

Approx. 52 mm (2'')

40

16

64 mm (2.5'')

50

16

77.4 mm (3'')

65

10

90.9 mm (3.6'')

80

10

106 mm (4.2'')

100

10

119 mm (4.7'')

DN

PN

⊘D

H2

50

16

90 mm (3.5'')

Approx. 52 mm (2'')

65

16

120 mm (4.7'')

80

16

140 mm (5.5'')

'

Approvals

3A, EHEDG

+

BioconnectTM flange connector

'

Approvals

3A, EHEDG

+

BioconnectTM clamp connector

'

Approvals

3A, EHEDG

Other connections

+

BiocontrolTM connector

'

Approvals

184

3A, EHEDG

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Dimension drawings 12.4 SITRANS P, DS III series (flush mounted)

+

Connect STM flanged joint

'

Approvals

12.4.4

DN

PN

⊘D

H2

25

16

97 mm (3.8'')

Approx. 52 mm (2'')

32

16

105 mm (4.1'')

40

16

115 mm (4.5'')

50

16

125 mm (4.9'')

65

10

145 mm (5.7'')

80

10

155 mm (6.1'')

100

10

180 mm (7.1'')

3A, EHEDG

PMC Style

Connections for the paper industry PMC Style Standard DN

PN

⊘D

H2

–

–

40.4 mm (1.6'')

Approx. 52 mm (2'')

+

M44x1.25 cap nut

'

PMC-Style Minibolt PN

⊘D

H2

–

26.3 mm (1'')

Approx. 52 mm (2'')

+

DN –

'

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

185

ITEM 1120, 1340, 1355 Dimension drawings 12.4 SITRANS P, DS III series (flush mounted)

12.4.5

Special connections

Tank connection TG52/50 and TG52/150 DN

PN

⊘D

H2

40

63 mm (2.5'')

Approx. 63 mm (2.5'')

40

63 mm (2.5'')

Approx. 170 mm (6.7'')

TG52/50 +

25 TG52/150 25 '

186

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

13

Spare parts/accessories 13.1

Order data In order to ensure that the ordering data you are using is not outdated, the latest ordering data is always available on the Internet:

See also Catalog process instrumentation (http://www.siemens.com/processinstrumentation/catalogs) Selection and order data

Order no.

CD "sitrans p - pressure transmitters" with documentation in German/English/French/Spanish/Italian, etc.

A5E00090345

HART modem •

With serial interface RS232

7MF4997-1DA1) D)

•

With USB interface

7MF4997-1DB1) D)

Weld-in support for PMC connection For DS III and P300 series •

PMC Style Standard: Thread 1½"

7MF4997-2HA

•

PMC-Style Minibolt: flush mounted 1"

7MF4997-2HB

Gaskets for PMC connection, (1 set = 5 pieces) •

PTFE gasket for PMC Style Standard: Thread 1½"

7MF4997-2HC

•

Viton gasket for PMC Style Minibolt: flush mounted 1"

7MF4997-2HD

Weld-in adapter for PMC connection For connection of weld-in support delay during welding for: •

PMC Style Standard: Thread 1½"

7MF4997-2HE

•

PMC-Style Minibolt: flush mounted 1"

7MF4997-2HF

Selection and order data

Order no.

Mounting bracket and fastening parts For DS III, DS III PA and DS III FF series For gauge pressure transmitter (7MF403.-.....-..C.) For transmitter for absolute pressure (7MF423.-.....-..C.) •

Made of steel

7MF4997-1AB

•

Made of stainless steel

7MF4997-1AH

Mounting bracket and fastening parts

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

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ITEM 1120, 1340, 1355 Spare parts/accessories 13.1 Order data Selection and order data

Order no.

For DS III, DS III PA and DS III FF series For gauge pressure transmitter (7MF403.-.....-..A., -..B. and -..D.) For transmitter for absolute pressure (7MF423.-.....-..A., -..B. and ..D.) •

Made of steel

7MF4997-1AC

•

Made of stainless steel

7MF4997-1AJ

Mounting bracket and fastening parts For DS III, DS III PA and DS III FF series Differential pressure transmitter with flange thread •

•

Made of steel For thread M10 (7MF433.-... and 7MF443.-...)

7MF4997-1AD

For thread M12 (7MF453.-...)

7MF4997-1AE

Made of stainless steel For thread M10 (7MF433.-... and 7MF443.-...)

7MF4997-1AK

For thread M12 (7MF453.-...)

7MF4997-1AL

Mounting bracket and fastening parts For DS III, DS III PA and DS III FF series Differential and absolute transmitter with flange thread 7/16-20 UNF (7MF433.-..., 7MF443.-... and 7MF453.-...) •

Made of steel

7MF4997-1AF

•

Made of stainless steel

7MF4997-1AM

Cover For DS III, DS III PA and DS III FF series •

•

Made of aluminum die casting, including gasket Without inspection window

7MF4997-1BB

With inspection window

7MF4997-1BE

Made of stainless steel, including gasket Without inspection window

7MF4997-1BC

With inspection window

7MF4997-1BF

Analog display •

Scale 0 ... 100%

7MF4997-1BN

•

Customer-specific scale division as per the plain text specifications

7MF4997-1BP-Z Y20: ................

Digital display For DS III, DS III PA and DS III FF series Including the fastening material

7MF4997-1BR

Measuring point label

188

•

not labelled (five pieces)

7MF4997-1CA

•

labelled (one piece) Specifications as per Y01 or Y02, Y15 and Y16 (refer to SITRANS P transmitter)

7MF4997-1CB-Z Y..: ................

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Spare parts/accessories 13.1 Order data Selection and order data

Order no.

Fastening screws, 50 pieces for: • Measuring point label • Earthing and connecting terminals • Digital display

7MF4997-1CD

Locking screws, (1 set = 2 pieces) for pressure cap •

Made of stainless steel

7MF4997-1CG

•

Made of Hastelloy

7MF4997-1CH

Vent valves, complete (1 set = 2 pieces) •

Made of stainless steel

7MF4997-1CP

•

Made of Hastelloy

7MF4997-1CQ

Electronic •

For DS III series

7MF4997-1DK

•

For DS III PA series

7MF4997-1DL

•

For DS III FF series

7MF4997-1DM

Network card •

For DS III series

7MF4997-1DN

•

For DS III PA and DS III FF series

7MF4997-1DP

Sealing rings for pressure caps off •

FPM (Viton)

7MF4997-2DA

•

PTFE (Teflon)

7MF4997-2DB

•

FEP (with silicon core, suitable for food)

7MF4997-2DC

•

FFPM (Kalrez, Compound 4079)

7MF4997-2DD

•

NBR (Buna N)

7MF4997-2DE

1)

Available from stock

D)

Subject to export regulations AL: N, ECCN, EAR99H

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

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ITEM 1120, 1340, 1355 Spare parts/accessories 13.2 Order data for SIMATIC PDM

13.2

Order data for SIMATIC PDM Selection and order data

Order no.

SIMATIC PDM Single Point SIMATIC PDM Single Point V6.0

6ES7 658-3HX06-0YA5

for operating and parameterizing one field device at a time, Communication via PROFIBUS DP/PA or HART modem, incl. 1 TAG, neither functional nor expandable via TAGOption/PowerPack in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Floating License for one user Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions; 2 CDs with SIMATIC PDM V6.0 and Device Library and an additional Microsoft ServicePacks and Tools DVD SIMATIC PDM Basic SIMATIC PDM Basic V6.0 for operating and parameterizing field devices and components, communication via PROFIBUS DP/PA, HARTModem/Interface, RS 232, Modbus, SIREC-Bus, SIPART DR, incl. 4 TAGs in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions; 2 CDs with SIMATIC PDM V6.0 and Device Library and an additional Microsoft ServicePacks and Tools DVD •

Floating License for one user

6ES7 658-3AX06-0YA5

•

Rental License for 50 hours

6ES7 658-3AX06-0YA6

Functional options for SIMATIC PDM V6.0 Integration in STEP 7 / SIMATIC PCS 7 required only when the integration of SIMATIC PDM in HW Config is to be used in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions •

Floating License for one user

6ES7 658-3BX06-2YB5

Routing via S7-400

190

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ITEM 1120, 1340, 1355 Spare parts/accessories 13.2 Order data for SIMATIC PDM Selection and order data

Order no.

in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions •

Floating License for one user

6ES7 658-3CX06-2YB5

Communication via Standard HART-Multiplexer in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions •

Floating License for one user

6ES7 658-3EX06-2YB5

TAG options/ PowerPacks SIMATIC PDM TAG-Option for TAG expansion, in addition to SIMATIC PDM Basic V6.0 in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Floating License for one user Delivery form: License Key Disk, Certificate of License, Terms and Conditions •

up to 128 TAGs

6ES7 658-3XA06-2YB5

•

up to 512 TAGs

6ES7 658-3XB06-2YB5

•

up to 1,024 TAGs

6ES7 658-3XC06-2YB5

•

up to 2,048 TAGs

6ES7 658-3XD06-2YB5

SIMATIC PDM PowerPack for subsequent TAG expansion of all SIMATIC PDM product configurations V6.0 in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Floating License for one user Delivery form: License Key Disk, Certificate of License, Terms and Conditions •

from 128 TAGs to 512 TAGs

6ES7 658-3XB06-2YD5

•

from 512 TAGs to 1.024 TAGs

6ES7 658-3XC06-2YD5

•

from 1,024 TAGs to 2,048 TAGs

6ES7 658-3XD06-2YD5

•

from 2.048 TAGs to TAGs unlimited

6ES7 658-3XH06-2YD5

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191

ITEM 1120, 1340, 1355 Spare parts/accessories 13.2 Order data for SIMATIC PDM Selection and order data Order no. Pre-defined SIMATIC PDM V6.0 product configurations for special applications SIMATIC PDM Service V6.0

6ES7 658-3JX06-0YA5

Complete pack for stand-alone users in the service, with: • SIMATIC PDM Basic V6.0 • Option "128 TAGs" in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional, Floating License for one user Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions; 2 CDs with SIMATIC PDM V6.0 and Device Library and an additional Microsoft ServicePacks and Tools DVD SIMATIC PDM S7 V6.0

6ES7 658-3KX06-0YA5

Complete pack for use in an SIMATIC S7 project planning environment, with • SIMATIC PDM Basic V6.0 • Option "Integration in STEP 7/PCS 7" • Option "128 TAGs" in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional, Floating License for one user Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions; 2 CDs with SIMATIC PDM V6.0 and Device Library and an additional Microsoft ServicePacks and Tools DVD SIMATIC PDM PCS 7 V6.0

6ES7 658-3LX06-0YA5

Complete pack for integration in the engineering toolset of the SIMATIC PCS 7 engineering system Floating License for one user, with • SIMATIC PDM Basic • Option "Integration in STEP 7 / PCS 7" • Option "Routing via S7-400" • Option "128 TAGs" in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions; 2 CDs with SIMATIC PDM V6.0 and Device Library and an additional Microsoft ServicePacks and Tools DVD Demo-software SIMATIC PDM Demo V6.0

192

6ES7 658-3GX06-0YC8

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Spare parts/accessories 13.2 Order data for SIMATIC PDM Selection and order data

Order no.

without online communication and memory functionality in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional Delivery form: 2 CDs with SIMATIC PDM V6.0 and Device Library and an additional Microsoft ServicePacks and Tools DVD SIMATIC PDM Upgrade/Update Service SIMATIC PDM Upgrade from V5.x to V6.0

6ES7 651-5CX06-0YE5

for all product versions and combinations in five languages (German, English, French, Italian and Spanish), can be run on Windows 2000 Professional or Windows XP Professional, Floating License for one user Delivery form: License Key Disk, Emergency Key Disk, Certificate of License, Terms and Conditions; 2 CDs with SIMATIC PDM V6.0 and Device Library and an additional Microsoft ServicePacks and Tools DVD SIMATIC PDM Software Update Service

6ES7 658-3XX00-0YL8

One-year subscription with automatic extension Condition: current software version Plug-in line for PROFIBUS

6ES7 901-4BD00-0XA0

designed with two 9-pin Sub-D connectors; max. transmission rate 12 Mbit/s; 3 m

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

193

ITEM 1120, 1340, 1355 Spare parts/accessories 13.2 Order data for SIMATIC PDM

194

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

A

Appendix A.1

Certifications The certifications are enclosed as a loose collection of operating instructions or on CD..

A.2

Literature and standards No.

Standard

Description

/1/

IEC 61508

Functional safety of following systems: • Safety-instrumented • Electrical • Electronic • Programmable

Section 1-7

Target group: Manufacturers and suppliers of equipment /2/

IEC 61511

Functional safety - Safety systems for the process industry

Section 1-3

Target group: Planners, constructors and users

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

195

ITEM 1120, 1340, 1355 Appendix A.3 SIL Declaration of Conformity

A.3

196

SIL Declaration of Conformity

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Appendix A.3 SIL Declaration of Conformity

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

197

ITEM 1120, 1340, 1355 Appendix A.3 SIL Declaration of Conformity

198

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Appendix A.4 exida proven in use

A.4

exida proven in use

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

199

ITEM 1120, 1340, 1355 Appendix A.4 exida proven in use

200

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

Appendix A.4 exida proven in use

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

201

ITEM 1120, 1340, 1355 Appendix A.4 exida proven in use

202

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Appendix A.5 Overview of HART operating structure

A.5

Overview of HART operating structure The following overview applies to the HART communicator operating structure. 2 Online 1 2 3 4

(PV meas) *) (PV) status Module type Identification

1 Operation Unit

2 Device

3 Basic Parameters

5 Config Inp/Outp

1 Quick-Setup & Meas.

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6 7 8 1

Tag Long Tag --> M **) Descriptor Message Date Manufacturer Model Device identification Distributor MLFB Order Number Measurement type Fabrication-No Final asembly number Sensor serial number Revisions

Pressure unit LSL (Lower Sensor Limit) USL (Upper Sensor Limit) Minimum Span LRV (Lower Range Value) URV (Upper Range Value)) Pressure damping Pressure xfer function PV, Current, Status

2 Meas.Val. & Status

1 MLFB Order No --> M

1 2 3 4

Universal rev. Field device rev. Software rev. Hardware rev.

1 2 3 4 5 1

xfer = transfer (PV meas) *) AO (analogue output) (PV) % range Status see ---> Measurement type Pressure Values

2 Temperature Values

3 Level, Vol, Mass Values (shown if valid items)

4 Vol-, Mass- & Flow (shown if valid items)

3 Quick-Setup

2 Input

1 Config Pres/Temp

2 Display Process Variables

3 Meas Switch/Mapper

5 Appl & Stat (shown if valid items) 1 Tag 2 Ext TAG --> M 3 PV is 4 (PV) unit 5 Position correction 6 LRV 7 URV 8 Pressure damping 9 Pressure xfer function 1 Pressure sensor

6 Diagnosis/Service 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 1 2

Pressure Pres status Untrimmed pressure Untrimmed pres status Sens-Temp Sens-Temp status Electr-Temp Electr-Temp status Level Level status Volume Volume status Mass Mass status Vol-Flow Vol-Flow status Mass-Flow Mass-Flow status Customer Customer Status

1 Position corr --> M

1 Pressure 2 Untrimmed pres 3 Pressure units

2 Temperature sensor

1 Sens-Temp 2 Electr-Temp 3 Temp units

3 Pres units see --> 4 Temp units see --> 1 Prozess variables

1 1 1 2 3 4 5 6

1 2 3 4 5 6

measurement PV is SV is TV is QV is (measurement) config e.g. Level

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

1 Sens-Temp unit 2 Electr-Temp unit

Pressure sensor Temperature sensor (PV measurement) (PV) %rnge AO (SV measurement) (TV measurement) (QV measurement)

1 Input scaling

2 Level scaling e.g. Level scaling to be continued

1 Pres abs/rel 2 Pressure unit 3 Untrimmed pres unit

1 2 3 4 1 2 3

Pres abs/rel Pressure unit Input LRV Input URV Level unit Level LRV Level URV

203

ITEM 1120, 1340, 1355 Appendix A.5 Overview of HART operating structure continuance 5 Config Inp/Outp

continuance 2 Input

continuance 3 Meas Switch/Mapper

continuance 6 (measurement) config e.g. Level

3 Volume scaling

6 (measurement) config e.g. Flow

1 Input scaling

2 Flow scaling

6 (measurement) config e.g. Customer

1 Input scaling

3 Customer scaling

7 Unser linearization if Level, Flow or Customer this is valid - otherwise not 4 Meas.Limits & Span

1 Module range 2 Active Device Variables

1 2 3 4

1 Pressure

3 Electr-Temp

4 Untrimmed Pres

1 Analog output

1 2 3 4 5

additional if measurement is mapped to level

5 Level

additional if measurement is mapped to level

6 Volume

additional if measurement is mapped to level

7 Mass

additional if measurement is mapped to flow

5 Vol-Flow

additional if measurement is mapped to flow

6 Mass-Flow

additional if measurement is mapped to customer

5 Customer

Analog output Percent range Zero and Span Pres xfer function Startpoint square root

1 Zero/Span set

>1 Out Scaling PV

6 Current Limits 7 Alarms

2 Sensor trim points 3 HART output

4 Local meter to be continued

204

1 2 1 2 3

>2 1 2 1 2 3

Volume unit Vol LRV Vol URV Density unit Density Mass unit Pres abs/rel Pressure unit Input LRV Input URV Vol flow unit Vol flow LRV Vol flow URV Density unit Density Mass flow unit Pres abs/rel Pressure unit Input LRV Input URV Cust unit (5 Ch) Cust LRV Cust URV only if meas not pres

1 2 3 4 5 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

Pressure unit Pres USL Pres LSL Trimpoint sum Pres min.span Sens-Temp unit Sens-Temp USL Sens-Temp LSL Sens-Temp min.span Electr-Temp unit Electr-Temp USL Electr-Temp LSL Electr-Temp min.span Untrimmed Pres unit Untrimmed Pres USL Untrimmed Pres LSL Untr Pres min.span Level unit Level USL Level LSL Level min.span Volume unit Volume USL Volume LSL Volume min.span Mass unit Mass USL Mass LSL Mass min.span Vol-Flow unit Vol-Flow USL Vol-Flow LSL Vol-Flow min.span Mass-Flow unit Mass-Flow USL Mass-Flow LSL Mass-Flow min.span (PV) unit Customer USL Customer LSL Customer min. span

Special Curve status --> No curve points Setup special char --> M Display special char --> M

2 Sens-Temp

3 Output

1 2 3 2 3 3 1 2 3 4 1 2 3 2 3 3 1 2 3 4 1 2 3

Apply values Lower AO Limit Upper AO Limit AO Alarm Type Alarm LRV Alarm URV

1 Apply values >1 2 Out Scaling PV 1 2 3 4 5 1

>2

Unit LRV URV LSL USL Apply values --> M

Lower sensor trim point Upper sensor trim point Polling address Num request preambles Num response preambles

1 Meter type 2 Unit tracking 3 Local Display unit

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Appendix A.5 Overview of HART operating structure continuance 5 Config Inp/Outp

continuance 4 Local Meter

5 Mech. Construction Mech = mechanical

4 LCD Settings 5 Bargraph

1 LCD Scaling, if On:

6 Access Control

1 Lokal keys control mode 2 Write protect 3 Set write protect --> M

1 No of electronic changes 2 Design

1 Sensor

2 Remote Seal

3 Process Connection

4 Electronic Connection 6 Certif & Approv 7 Diagnosis/Service

1 Explos. Protection 1 Status

1 2 3 4

Status summary Extended device status Simulation status Hardw/Firmw status

5 Diag Alarm Status 6 Diag Warn Status 2 Device

1 Selftest/Reset

2 Sensor trim

1 2 3 4 5 6 1 2

2 LCD Unit 3 LCD LRV 4 LCD URV

1 2 3 4 1 2 3 4 5 6 7

Fill fluid Isolation material O ring material Module range Number remote seal (RS) RS type RS isolator material RS fill fluid Extension length Extension type Capillar length

Process Connection DrainVent / plug mat DrainVent / plug pos Process flange bolt Flange type Flange material Electr housing material Electr connection Explos = Explosion Certif = Certification Approv = Approval

1 2 3 4 1 2 1 2 1 2 3 4 1 2

Status group 2 Status group 3 Status group 4 Status group 5 Status group 15 Status group 16 Status group 19 Status group 20 Selftest --> M Display Test --> M Master reset --> M Changes Config Restore mfgr trims --> M Sensor trim

1 Config changed counter 1 Sensor trim points 2 Sensor trim

3 Trim analog output

3 Simulation/Test 4 Access Control

3 Diagnostic settings

1 W/A time unit 2 Calib interval

3 Service interval

4 AO saturation

5 Limiter setup

4 View

1 Operating hours 3 Min/Max pointer

4 1 2 1 2 3

Position correction Loop test --> M Inputs --> M Local keys control mode Write protect Set write protect --> M W/A = warning/alarm 1 Calib status 2 W/A acknowledge --> M 3 Calib timer 4 5 6 1 2 3

Calib warning Calib alarm W/A activation Service status W/A acknowledge --> M Service timer

4 5 6 1 2 3 4 1 2 3 4 5 6 1 2 1

Service warning Service alarm W/A activation AO alarm type Saturation alarm Alarm duration Alarm activation Display limiter --> M Setup limiter --> M Limiter status --> M Limiter: Ack W/A --> M CmpCnt: Ack W/A --> M Reset counter. --> M Operating hours Electr Operating hours Sensor Pressure pointer

2 Electr-Temp pointer

3 Sens-Temp pointer

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

3 1 2 1

1 2 1 2 3

mfgr = manufacturer Lower sensor trim point Upper sensor trim point Pres zero trim--> M Lower sensor trim --> M Upper sensor trim --> M

Trimpoint summary D/A trim --> M Scaled D/A trim --> M Position corr --> M Simulation AO Simulation Fixed / Ramp

1 Calib time 2 Reset timer --> M

1 Service time 2 Reset timer --> M

Ack = acknowledge CmpCnt = Comparation Counter

1 2 3 1 2 3 1 2 3

Pres max Pres min Reset pointer --> M Electr-Temp max Electr- Temp min Reset pointer --> M Sens-Temp max Sens-Temp min Reset pointer --> M

205

ITEM 1120, 1340, 1355 Appendix A.6 Pressure equipment directive

A.6

Pressure equipment directive The monitoring of the design, dimensioning, testing and manufacture to ensure it is in accordance with Module H (comprehensive quality assurance) by TÜV North as the appointed body.

General

Division of media (liquid/gaseous) into the fluid groups

The pressure equipment directive 97/23/EC applies to the alignment of the statutory orders of the European member states for pressure equipment. Such equipment in the sense of the directive includes vessels, pipelines and accessories with a maximum permissible pressure of more than 0.5 bar above atmospheric. The pressure equipment directive can be used starting November 29, 1999, and is compulsory starting May 29, 2002.

Fluids are divided according to Article 9 into the following fluid groups: Group 1

Division according to the danger potential Equipment is divided in line with the pressure equipment directive according to the danger potential (medium/pressure/volume/nominal diameter) into the categories I to IV or Article 3 Paragraph 3. The following criteria are decisive for assessment of the danger potential, and are also shown in Diagrams 1 to 4 and 6 to 9: • Fluid group

Group 1 or 2

• Aggregate state

Liquid or gaseous

• Type of pressurized equipment - Vessel - Pipeline

Product of pressure and volume (PS * V [barL]) Nominal diameter, pressure or product of pressure and nominal diameter (PS * DN)

Fuelled pressure equipment or equipment heated in another manner are shown separately in Diagram 5. Note: Liquids according to Article 3 are those liquids whose steam pressure is not more than 0.5 bar above standard atmospheric pressure (1013 mbar) at the maximum permissible temperature. The maximum permissible temperature for the used liquids is the maximum process temperature which can occur, as defined by the user. This must be within the limits defined for the equipment.

Potentially explosive R phrases: e.g.: 2, 3 (1, 4, 5, 6, 9, 16, 18, 19, 44)

Highly toxic R phrases: e.g.: 26, 27, 28, 39 (32)

Highly flammable R phrases: e.g.: 12 (17)

Toxic R phrases: e.g.: 23, 24, 25 (29, 31)

Readily flammable R phrases: e.g.: 11, 15, 17 (10, 30)

Fire stimulating R phrases: e.g.: 7, 8, 9 (14, 15, 19)

Flammable if the maximum permissible temperature is above the flash point. Group 2 All fluids not belonging to Group 1. Also applies to fluids which are e.g. dangerous to the environment, corrosive, dangerous to health, irritant or carcinogenic (if not highly toxic).

Conformity rating Pressure equipment of categories I to IV must comply with the safety requirements of the directive and be assigned the CE symbol. They must comply with a conformity rating procedure according to Appendix III of the directive. Pressure equipment according to Article 3 Paragraph 3 must be designed and manufactured in agreement with the sound engineering practice SEP applying in a member country, and must not be assigned a CE symbol (CE symbols from other directives are not affected). Siemens has carried out a conformity rating, assigned a CE symbol, and issued a declaration of conformity for its products (providing the equipment is not within the context of Article 3 Paragraph 3). Supervision of the design, dimensioning, testing and manufacture is carried out according to module H (comprehensive quality assurance). Notes: • Equipment designed for media with a high danger potential (e.g. gases of fluid group 1) may also be used for media with a lower danger potential (e.g. gases of fluid group 2, or liquids of fluid groups 1 and 2). • The pressure equipment directive according to Article 1 Paragraph 1 does not apply to equipment such as e.g. mobile offshore plants, ships, aircraft, water supply and waste water networks, nuclear plants, rockets and pipelines outside industrial plants.

Figure A-1

206

Pressure equipment directive, sheet 1

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Appendix A.6 Pressure equipment directive

Diagrams

• Gases of fluid group 1 • Vessels according to Article 3 Number 1.1 Letter a) First dash • Exception: unstable gases belonging to Categories I and II must be included in Category III.

• Gases of fluid group 2 • Vessels according to Article 3 Number 1.1 Letter a) Second dash • Exception: fire extinguishers and bottles for breathing apparatus: at least Category III.

• Liquids of fluid group 1 • Vessels according to Article 3 Number 1.1 Letter b) First dash

• Liquids of fluid group 2 • Vessels according to Article 3 Number 1.1 Letter b) Second dash • Exception: modules for producing warm water

• Fuelled pressure equipment or equipment heated in another manner above 110 °C and liable to overheating. • Vessel according to Article 3 Number 1.2 • Exception: pressure cooker, test procedure at least according to Category III.

Figure A-2

Pressure equipment directive, sheet 2

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207

ITEM 1120, 1340, 1355 Appendix A.6 Pressure equipment directive

• Gases of fluid group 1 • Pipelines according to Article 3 Number 1.3 Letter a) First dash • Exception: unstable gases belonging to Categories I and II must be included in Category III.

• Gases of fluid group 2 • Pipelines according to Article 3 Number 1.3 Letter a) Second dash • Exception: liquids at temperatures > 350 °C belonging to Category II must be included in Category III.

• Liquids of fluid group 1 • Pipelines according to Article 3 Number 1.3 Letter b) First dash

• Liquids of fluid group 2 • Pipelines according to Article 3 Number 1.3 Letter b) Second dash

Figure A-3

208

Pressure equipment directive, sheet 3

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

B

List of abbreviations List of abbreviations Table B-1

Variables

Abbreviation

In full

PV

Primary variable

SV

Secondary variable

TV

Tertiary variable

QV

Quarternary variable

Table B-2

Meaning

Units

Abbreviation

In full

Meaning

bar a

bar absolute

Unit of pressure for absolute pressure

bar g

bar gauge

Unit of pressure for gauge pressure

lb

Pfund (engl.: Pound)

Unit of weight

psi a

psi absolute

Unit of pressure for absolute pressure

psi g

psi gauge

Unit of pressure for gauge pressure

Table B-3

Other abbreviations

Abbreviation

In full

PED

Pressure equipment directive

HART

Highway Addressable Remote Transducer

MA

Start of scale value

ME

Full scale value

NFPA

National Fire Protection Association

F&B

Food and beverage industry

PDM

Engl.: Process Device Manager

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

Meaning Standard protocol for the transmission of information between field device and automation system

209

ITEM 1120, 1340, 1355 List of abbreviations B.1 Functional safety

B.1

Functional safety

Abbreviation

Full term in English

Meaning

FIT

Failure in Time

Frequency of failure Number of faults withing 109 hours

HFT

Hardware Fault Tolerance

Hardware fault tolerance: Capability of a function unit to continue executing a required function in the presence of faults or deviations.

MooN

"M out of N" voting

Classification and description of the safety-instrumented system in terms of redundancy and the selection procedures used. A safety-instrumented system or part that consists of "N" independent channels. The channels are connected to each other in such a way that "M" channels are in each case sufficient for the device to perform the safety instrumented function. Example: Pressure measurement: 1oo2 architecture. A safetyinstrumented system decides that a specified pressure limit has been exceeded if one out of two pressure sensors reaches this limit. In a 1oo1 architecture, there is only one pressure sensor.

MTBF

Mean Time Between Failures

Average period between two failures

MTTR

Mean Time To Restoration

Average period between the occurrence of a fault in a device or system and restoration of functionality

PFD

Probability of Failure on Demand

Probability of dangerous failures of a safety function on demand

PFDAVG

Average Probability of Failure on Demand

Average probability of dangerous failures of a safety function on demand

SFF

Safe Failure Fraction

Proportion of safe failures: Proportion of failures without the potential to bring the safetyinstrumented system into a dangerous or non-permissible functional status.

SIL

Safety Integrity Level

The international standard IEC 61508 defines four discrete Safety Integrity Levels (SIL 1 to SIL 4). Each level corresponds to a range of probability for failure of a safety function. The higher the Safety Integrity Level of the safety-instrumented system, the lower the probability that it will not execute the required safety functions.

SIS

Safety Instrumented System

A safety-instrumented system (SIS) executes the safety functions that are required to achieve or maintain a safe status in a system. It consists of a sensor, logic unit/control system and final controlling element.

TI

Test Interval

Testing interval of the protective function

210

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

Glossary ATEX ATEX is an abbreviation of the French term "Atmosphère explosible" (potentially explosive atmosphere). ATEX stands for both EC directives in the area of explosion protection: ATEX product directive 94/9/EC and ATEX operating directive 1999/92/EC.

Auxiliary power supply Auxiliary power supply refers to an electrical supply or reference voltage which some electrical circuits require apart from the standard supply. The auxiliary power supply can, for example, be specially stabilized, have a particular level or polarity and/or other properties which are important for the correct functioning of switch components.

Auxiliary voltage → Auxiliary power supply

Dangerous failure Failure with the potential to bring the safety-instrumented system into a dangerous or nonfunctional status.

EEPROM EEPROM (Electrically Erasable Programmable Read-Only Memory): a non-volatile, electronic memory module. EEPROMs are often used where individual bytes of data (e.g. configuration data or runtime meters) change over time and must be stored safely in the event of a mains power failure.

Fail-safe The capability of a control to maintain the safe state of the controlled device, e.g. machine, process, or to bring the device to a safe state even when faults/failures occur.

Failure/Fault Failure: A resource is no longer capable of executing a required function. Fault: Undesired state of a resource indicated by the incapability of executing a required function.

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

211

ITEM 1120, 1340, 1355 Glossary

Fault → Failure/Fault

Fault tolerance Fault tolerance N means that a device can execute the intended task even when N faults exist. The device fails to execute the intended function in case of N+1 faults.

Final controlling element Converter that converts electrical signals into mechanical or other non-electrical variables.

Firmware Firmware (FW) is software, which is embedded in a chip in electronic devices – unlike software that is stored on hard disks, CD ROMs or other media. These days, firmware is mostly stored in a flash memory or EEPROM. Firmware usually contains the elementary functions for controlling the device, as well as input and output routines.

Frequency shift keying Frequency shift keying in a simple form of modulation in which the digital values 0 and 1 are represented by two different frequencies.

Frequency Shift Keying (FSK) → Frequency shift keying

HART HART (Highway Addressable Remote Transducer) is a standardized, widely used communications system used to structure industrial fieldbusses. The communications system provides digital communications for multiple participants (field devices) via a common databus. HART is based especially on the equally widely used 4/20 mA standard for the transfer of analog sensor signals. The cabling from existing older systems can be used directly and both systems operated in parallel. HART specifies several protocol levels in the OSI model. It facilitates the transfer of process and diagnostics data and control signals between field devices and high-level control systems. Standardized parameter sets can be used for the manufacture-independent operation of all HART devices. Typical applications include transmitters for measuring mechanical and electrical dimensions.

Non-volatile memory → EEPROM

212

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Glossary

Risk The combination of probability of a damage occurring and its magnitude.

Safety function Defined function executed by a safety-instrumented system with the objective of achieving or maintaining a safe system status taking into account a defined dangerous occurrence. Example: Limit pressure monitoring

Safety Instrumented Function → SIF

Safety Integrity Level → SIL

Safety-instrumented system A safety-instrumented system executes the safety functions that are required to achieve or maintain a safe status in a system. It consists of a sensor, logic unit/control system and final controlling element. Example: A safety-instrumented system is made up of a pressure transmitter, a limit signal sensor and a control valve.

Sensor Converter that converts mechanical or other non-electrical variables into electrical signals.

SIF A part/function of a safety-instrumented system that reduces the risk of a dangerous failure occurring.

SIL The international standard IEC 61508 defines four discrete Safety Integrity Levels (SIL) from SIL 1 to SIL 4. Each level corresponds to the probability range for the failure of a safety function. The higher the SIL of the safety-instrumented system, the higher probability that the required safety function will work. The achievable SIL is determined by the following safety characteristics: ● Average probability of dangerous failure of a safety function in case of demand (PFDAVG) ● Hardware fault tolerance (HFT) ● Safe failure fractions (SFF)

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

213

ITEM 1120, 1340, 1355 Glossary

srli2 → srlin2

srlin2 "srli2" or "srlin2" is a type of square root extracting characteristic curve for the output current. This characteristic curve type is proportional to the flow rate, linear in two levels up to the application point and has a pre-defined application point of 10%. "srli2" or "srlin2" are synonymous and technically, there is no difference in them. The abbreviation "srli2" is used in sections that refer to the on-site operation of the pressure transmitter. The reason for this abbreviation is that the digital display of the pressure transmitter is restricted to five characters. The abbreviation "srlin2" is used for HART operation.

214

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355

Index A Acknowledgement, 120 Ambient temperature, 164, 165, 166, 167 Influence, 159, 160, 161, 162, 163 Analog output, 105 Analog output block, 105 Analog output stage, 93 Arrow display, 60 Assembly At electrostatic risk, 12

B Bar graph, 113 Basic variables, 55 Blind adjustment, 108 Bridge output voltage, 22, 23, 24

C Calibration Current transmitter, 115 Sensor, 113 Calibration interval, 120 Calibration timer, 120 Certificate, 195 Certification, 195 Characteristic curve lin, 82 srli2, 82 srlin, 82 sroff, 82 characteristics Safety, 134 Checking, 133 Commissioning, 136 Configuration data, 117 Connector M12, 52 Constant current operation, 78, 109 Control system, 129 Correct usage, 11 SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

Current limit, 110 Current transmitter, 78, 109

D Device variable, 61, 101 DV, 94 Device view, 18 Diagnostic interrupt, 109, 119 Diagnostic warning, 119 Differential pressure, 16, 17, 82, 118 Display of unit, 58 Downscaling, 66 DV Device variable, 94 Dynamic variable (DV), 93

E Electrical damping, 109 Electromagnetic Compatibility, 164, 165, 166, 167 Compatibility, 132 Electronics, 133 Electrostatic Sensitive Devices (ESD), 12 EMC, 164, 165, 166, 167 Error display, 59

F Factory calibration, 116 Failure current, 109 Failure signal, 129 Fast recording of measured values, 109 Fast Response Mode, 109 Fill liquid, 22, 24, 25 Final controlling element, 129 Firmware, 9 Firmware version Safety Integrity Level, 132 Flameproof enclosure, 12 Flange, 24, 35 Full scale value Set, 66 Function chart, 26

215

ITEM 1120, 1340, 1355 Index

H Han plug, 52 HART Modem, 15 HART communicator, 91 Hazardous area, 11 History, 9

I Input scaling, 96, 98, 101 Install Remote seal, 38 Installation, 31, 32 Intrinsic safety, 12

K Keyboard lock, 80

L L (level), 97 LCD scaling, 106 Level, 17 Limit monitor, 125 lin, 82, 118 Load, 158

M M12 connector, 52 MA Start of scale value, 94 Maintenance, 133 Mapper, 93, (Also see: Variable mapper) Mass, 95, 97 ME Full scale value, 94 Mean Time Between Failures, 131 Measured value display, 65 Measured value display, 85 Measured value status, 102 Measuring accuracy, 132 Measuring cell Absolute pressure, 26 Differential pressure and flow rate, 23 Gauge pressure, 22 Level, 24 Measuring mode, 66, 92, 94, 98

216

Measuring mode selector, 93, 94 Measuring span, 66 Message OVER, 61 UNDER, 61 Modular structure, 148 More information, 10 Mounting bracket, 32 Mounting flange, 24 MTTR, 134

O Operating structure, 203 operation Local, 65 Output scaling, 96, 101 Output scaling, 99

P Pair of min/max pointer, 120 Pairs of values, 99, 101 PED, 206 Plug Han, 52 Position correction, 77 Precautions, 11 Pressure equipment directive Conformity evaluation, 206 Diagrams, 207, 208 Hazard potential, 206 Pressure simulation, 124 Pressure unit, 113 Primary variable, 61 Process connection, 17 Product information on the Internet, 10 PV Primary variable, 94

Q Qualified personnel, 13 QV Quarternary variable, 94

R Ramp function, 123, 125 Remote seal

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

ITEM 1120, 1340, 1355 Index

Description, 28 Install, 38 Maintenance, 149 Response time, 121 Root application point, 83, 98

S Safety Checking, 133 Safety function, 131 Checking, 132, 133 Safety Integrity Level, 132 Saturation limit, 110 Sensor, 129 sensor calibration, 113 Service timer, 120 Settings, 132 Shut-off valve, 139, 141, 143, 144, 145 Signal range, 61 Simulation, 120, 123 srli2, 82 srlin, 82, 118 srlin2, 118 sroff, 82, 118 Stabilizing valve, 141, 143, 145 Start of scale value Set, 66 Stop time, 121 Structure, 17 SV Secondary variable, 94

V Variable mapper, 93 Vent valve, 117, 143, 145 Volume, 97

W Working reliability regulation, 11 worldwide Contact person, 10 Worldwide contact person, 10 Write protection, 80, 132

Z Zero point calibration, 77, 108 Zone 2, 12

T Tank connection, 186 Technical data, 132 Test certification, 11 Trim Lower sensor calibration, 114 Upper sensor calibration, 114 Turning range, 46 TV Tertiary variable, 94 Type of protection Flameproof enclosure, 12 Intrinsic safety, 12 Limited energy nL (zone 2), 12 Non-sparking nA (zone 2), 12

SITRANS P, DS III series with HART communication Operating Instructions, 12/2007, A5E00047092-06

217

SITRANS P measuring instruments for pressure TID 1355

2

Transmitters for gage, absolute and differential pressure, flow and level DS III series for gage pressure

ITEM: 1120,1340, 1355

Selection and Ordering data

Order No.

1)

SITRANS P pressure transmitters for gage pressure, series DS III HART

7MF 4 0 3 3 -

2)

Measuring cell filling

77777 - 7777

Silicone oil Inert liquid1)

Measuring cell cleaning Standard Grease-free

} 1 3

Span 0.01 ... 1 bar g 0.04 ... 4 bar g 0.16 ... 16 bar g 0.63 ... 63 bar g 1.6 ... 160 bar g 4.0 ... 400 bar g

(0.15 ... 14.5 psi g) (0.58 ... 58 psi g) (2.32 ... 232 psi g) (9.14 ... 914 psi g) (23.2 ... 2320 psi g) (58.0 ... 5802 psi g)

} } } } } }

3)

4) 5)

B C D E F G

6) 7) 8)

Wetted parts materials Seal diaphragm Process connection Stainless steel Stainless steel Hastelloy Stainless steel Hastelloy Hastelloy Version as diaphragm seal 2) 3) Process connection • Connection shank G½A to EN 837-1 • Female thread ½-14 NPT • Oval flange made of stainless steel, max. span 160 bar g (2320 psi g) - Mounting thread 7/16-20 UNF to EN 61518 - Mounting thread M10 to DIN 19213 Non-wetted parts materials • Housing made of die-cast aluminium • Housing stainless steel precision casting4)

}

}

}

Explosion protection • Without • With ATEX, Type of protection: - "Intrinsic safety (EEx ia)" - "Explosion-proof (EEx d)" 5) - "Intrinsic safety and explosion-proof enclosure (EEx ia + EEx d)" 6) - "n (Zone 2)" - "Intrinsic safety, explosion-proof enclosure and } dust explosion protection (EEx ia + EEx d + Zone 1D/2D)" 6) • With FM + CSA, Type of protection: - "Intrinsic safety and explosion-proof (is + xp)" 5)

Display • Without (digital indicator hidden, setting: mA)

0 1

2 3

Version • Standard version • International version, English label inscriptions, } documentation in 5 languages on CD

Electrical connection / cable entry • Screwed gland Pg 13.5 (adapter) 7) • Screwed gland M20x1.5 • Screwed gland ½-14 NPT • Han 7D plug (plastic housing) incl. mating connector 7) • M12 connector (metall) 8)

A B C Y

}

0 3 1 2

A B D P E R

NC

A B C D F

}

• With visible digital indicator, setting: mA • with customer-specific digital indicator (setting as specified, Order code "Y21" or "Y22" required)

}Available ex stock Power supply units see "SITRANS I power supply units and isolation amplifiers". Included in delivery of the device: • Brief instructions (Leporello) • CD-ROM with detailed documentation

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Siemens FI 01 · 2007

1 6 7

For oxygen application, add Order code E10. When the manufacture’s certificate M (calibration certificate) has to be ordered for transmitters with diaphragm seals, it is recommended only to order this certificate exclusively with the diaphragm seals. The measuring accuracy of the total combination is certified here. Whe the acceptance test certificate 3.1 for transmitters with direct-connected diaphragm seals is ordered, this certificate must also be ordered with the corresponding seals. Not together with Electrical connection „Screwed gland Pg 13.5“ and „Han7D plug“. Without cable gland, with blanking plug With enclosed cable gland EEx ia and blanking plug Not together with type of protection "Explosion-proof" Cannot be used together with the following types of protection: "Explosion-proof" and "Intrinsic safety and explosion-proof"

SITRANS P measuring instruments for pressure Transmitters for gage, absolute and differential pressure, flow and level DS III series for gage pressure

2

Selection and Ordering data

ITEM: 1120,1340, 1355 Order code

Further designs Add "-Z" to Order No. and specify Order code.

Selection and Ordering data

HART PA

Pressure transmitter with mounting bracket made of: • Steel • Stainless steel

A01 A02

9 9

Plug • Han 7D (metal, gray) • Han 8U (instead of Han 7D)

A30 A31

9 9

Cable sockets for M12 connectors (metal)

A50

Rating plate inscription (instead of German) • English • French • Spanish • Italian

FF

9 9

9 9

9

9

9

B11 B12 B13 B14

9 9 9 9

9 9 9 9

9 9 9 9

English rating plate Pressure units in inH2O or psi

B21

9

9

9

Manufacturer's test certificate M (calibration certificate)1) To DIN 55350, Part 18 and to ISO 8402

C11

9

9

9

Acceptance test certificate2) To EN 10204-3.1

C12

9

9

9

Factory certificate To EN 10204-2.2

C14

9

9

9

"Functional Safety (SIL)" certificate

C20

9

Setting of upper limit of output signal to 22.0 mA

D05

9

Manufacturer's declaration acc. to NACE

D07

9

9

9

Type of protection IP68 (not together with 7D/ Han 8U plug, cable gland Pg 13.5)

D12

9

9

9

Digital indicator alongside the input keys (only together with the devices 7MF4033....0-.A.6 or -.A.7-Z, Y21 or Y22 + Y01)

D27

9

9

9

Supplied with oval flange (1 item), PTFE packing and screws in thread of oval flange

D37

9

9

9

Use in or on zone 1D/2D (only together with type of protection "Intrinsic safety (EEx ia)")

E01

9

9

9

Use on zone 0 (only together with type of protection "Intrinsic safety (EEx ia)")

E02

9

9

9

Oxygen application (max. 160 bar g (2320 psi g) for oxygen measurement and inert liquid)

E10

9

9

9

Explosion-proof "Intrinsic safety" to INMETRO (Brazil) (only for transmitter 7MF4...-.....-.B..)

E25

9

9

9

Explosion-proof "Intrinsic safety" to NEPSI (China) (only for transmitter 7MF4...-.....-.B..)

E55

9

9

9

Explosion protection "Explosion-proof" to E56 NEPSI (China) (only for transmitter 7MF4...-.....-.D..)

9

9

9

Explosion-proof "Zone 2" to NEPSI (China) E57 (only for transmitter 7MF4...-.....-.E..)

9

9

9

1)

2)

When the manufacture’s certificate M (calibration certificate) has to be ordered for transmitters with diaphragm seals, it is recommended only to order this certificate exclusively with the diaphragm seals. The measuring accuracy of the total combination is certified here. Whe the acceptance test certificate 3.1 for transmitters with direct-connected diaphragm seals is ordered, this certificate must also be ordered with the corresponding seals.

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Siemens FI 01 · 2007

Order code

Additional data Add "-Z" to Order No. and specify Order code.

HART PA

FF

Measuring range to be set Specify in plain text (max. 5 digits): Y01: ... up to ... mbar, bar, kPa, MPa, psi

Y01

9

Measuring point number (TAG No.) Max. 16 characters, specify in plain text: Y15: ...........................................

Y15

9

9

9

Measuring point text Max. 27 characters, specify in plain text: Y16: ...........................................

Y16

9

9

9

Entry of HART address (TAG) Max. 8 characters, specify in plain text: Y17: ...........................................

Y17

9

Setting of pressure indication in pressure Y21 units Specify in plain text (standard setting: mA): Y21: mbar, bar, kPa, MPa, psi, ... Note: The following pressure units can be selected: bar, mbar, mm H2O*), inH2O*), ftH2O*), mmHG, inHG, psi, Pa, kPa, MPa, g/cm2, kg/cm2, Torr, ATM oder % *) ref. temperature 20 °C

9

9

9

Setting of pressure indication in non-pressure units Specify in plain text: Y22: ..... up to ..... l/min, m3/h, m, USgpm, ... (specification of measuring range in pressure units "Y01" is essential, unit with max. 5 characters)

Y22 + Y01

9

Preset bus address Specify in plain text: Y25: .....................

Y25

Only "Y01", "Y21", "Y22", "Y25" and "D05" can be factory preset 9 = available Ordering example Item line: 7MF4033-1EA00-1AA7-Z B line: A01 + Y01 + Y21 C line: Y01: 10 ... 20 bar (145 ... 290 psi) C line: Y21: bar (psi)

9

SITRANS P measuring instruments for pressure Transmitters for gage, absolute and differential pressure, flow and level TID TID 1120 1340

ITEM: 1120,1340, 1355

DS III series for differential pressure and flow

2

Selection and Ordering data

Order No.

Selection and Ordering data

Order No.

SITRANS P pressure transmitters for differential pressure and flow, Series DS III HART PN 32/160 (MWP 464/2320 psi)

7MF 4 4 3 3 -

SITRANS P pressure transmitters for differential pressure and flow, Series DS III HART PN 32/160 (MWP 464/2320 psi)

77777 - 7777

Measuring cell filling Silicone oil Inert liquid1)

77777 - 7777

Measuring cell cleaning Standard Grease-free

} 1 3

(0.4015 ... 8.03 inH2O)

}

B

Power supply units see "SITRANS I power supply units and isolation amplifiers".

(0.4015 ... 24.09 inH2O) (1.004 ... 100.4 inH2O) (2.409 ... 240.9 inH2O) (6.424 ... 642.4 inH2O) (20.08 ... 2008 inH2O) (4.35 ... 435 psi)

} } } } } }

C D E F G H

Included in delivery of the device: • Brief instructions (Leporello) • CD-ROM with detailed documentation • Sealing plug(s) or sealing screw(s) for the process flanges(s)

TID 1120 TID 1340

TID 1340 Span PN 32 (MWP 464 psi) 1 ... 20 mbar2) PN 160 (MWP 2320 psi) TID 1120 1 ... 60 mbar 2.5 ... 250 mbar 6 ... 600 mbar 16 ... 1600 mbar 50 ... 5000 mbar 0.3 ... 30 bar

7MF 4 4 3 3 -

Display • without (digital indicator hidden, setting: mA) } • With visible digital indication • With customer-specific digital indication (setting as specified, Order code "Y21" or required)

1 6 7

} Available ex stock

1) 2) 3)

Wetted parts materials (stainless steel process flanges) Seal diaphragm Parts of measuring cell Stainless steel Stainless steel Hastelloy Stainless steel Hastelloy Hastelloy Tantalum3) Tantalum Monel3) Monel Gold3) Gold Version for diaphragm seal4) 5)

4)

}

Process connection Female thread ¼-18 NPT with flange connection • Sealing screw opposite process connection - Mounting thread M10 to DIN 19213 } - Mounting thread 7/16-20 UNF to EN 61518 • Vent on side of process flange 2) - Mounting thread M10 to DIN 19213 - Mounting thread 7/16-20 UNF to EN 61518

A B C E H L Y

5)

6) 7) 8) 9)

For oxygen application, add Order code E10. Not suitable for connection of remote seal Only together with max. spans 250, 1600, 5000 and 30000 mbar (100.4, 240.9, 2008 inH2O and 435 psi) When the manufacture’s certificate M (calibration certificate) has to be ordered for transmitters with diaphragm seals, it is recommended only to order this certificate exclusively with the diaphragm seals. The measuring accuracy of the total combination is certified here. Whe the acceptance test certificate 3.1 for transmitters with direct-connected diaphragm seals is ordered, this certificate must also be ordered with the corresponding seals. Not together with Electrical connection „Screwed gland Pg 13.5“ and „Han7D plug“. Without cable gland, with blanking plug With enclosed cable gland EEx ia and blanking plug Not together with type of protection "Explosion-proof"

0 2 4 6

Non-wetted parts materials Process flange screws Electronics housing Stainless steel Stainless steel

Die-cast aluminium } Stainless steel precision 6) casting

Version • Standard version • International version, English label inscriptions, } documentation in 5 languages on CD Explosion protection • Without • With ATEX, Type of protection: - "Intrinsic safety (EEx ia)" - "Explosion-proof (EEx d)"7) - "Intrinsic safety and explosion-proof enclosure (EEx ia + EEx d)"8) - "n (Zone 2)" - "Intrinsic safety, explosion-proof enclosure } and dust explosion protection (EEx ia + EEx d + Zone 1D/2D)"8) • With FM + CSA, Type of protection: - "Intrinsic safety and explosion-proof (is + xp)"7) Electrical connection / cable entry • Screwed gland Pg 13.59) • Screwed gland M20x1.5 • Screwed gland ½-14 NPT • Han 7D plug (plastic housing) incl. mating connector9)

}

2 3

1 2

A B D P E R

NC

A B C D

Siemens FI 01 · 2007

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SITRANS P measuring instruments for pressure Transmitters for gage, absolute and differential pressure, flow and level ITEM: 1120,1340, 1355 Selection and Ordering data

Order code

Further designs Add "-Z" to Order No. and specify Order code.

FF

A01 A02

9 9

9 9

9 9

O-rings for process flanges (instead of FPM (Viton)) • PTFE (Teflon) • FEP (with silicone core, approved for food) • FFPM (Kalrez, compound 4079) • NBR (Buna N)

A20 A21 A22 A23

9 9 9 9

9 9 9 9

9 9 9 9

A30 A31 A40

9 9 9

9

9

Cable sockets for M12 connectors (metal)

A50

9

9

9

Rating plate inscription (instead of German) • English • French • Spanish • Italian

B11 B12 B13 B14

9 9 9 9

9 9 9 9

9 9 9 9

English rating plate (calibration certificate) B21 Pressure units in inH2O or psi

9

9

9

Manufacturer's test certificate M1) To DIN 55350, Part 18 and to ISO 8402

C11

9

9

9

Acceptance test certificate2) To EN 10 204-3.1

C12

9

9

9

Factory certificate To EN 10 204-2.2

C14

9

9

9

"Functional Safety (SIL)" certificate

C20

9

Setting of upper limit of output signal to 22.0 mA

D05

9

Manufacturer's declaration acc. to NACE (only together with seal diaphragm made of Hastelloy and stainless steel)

D07

9

Type of protection IP68 (not together with 7D/ Han 8U plug, cable gland Pg 13.5)

D12

9

9

9

Digital indicator alongside the input keys (only together with the devices 7MF4433....2-.A.6 or -.A.7-Z, Y21 or Y22 + Y01)

D27

9

9

9

Process flange screws made of Monel (max. nominal pressure PN20)

D34

9

9

9

Supplied with oval flange set (2 items), PTFE packings and screws in thread of process flanges

D37

9

9

9

Use in or on zone 1D/2D (only together with type of protection "Intrinsic safety (EEx ia)")

E01

9

9

9

Use on zone 0 (only together with type of protection "Intrinsic safety (EEx ia)")

E02

9

9

9

TÜV approval to AD/TRD (only together with type of protection "Intrinsic safety (EEx ia)")

E06

9

Overfilling safety device for flammable and non-flammable liquids (max. PN 32 (MVWP 464 psi), basic device with type of protection "Intrinsic safety (EEx ia)", to WHG and VbF, not together with measuring cell filling "inert liquid")

E08

9

9

9

Sealing screws ¼-18 NPT, with valve in mat. of process flanges

Order code

Selection and Ordering data

HART PA

Pressure transmitter with mounting bracket made of: • Steel • Stainless steel

Plug • Han 7D (metal, gray) • Han 8U (instead of Han 7D)

DS III series for differential pressure and flow

Further designs Add "-Z" to Order No. and specify Order code.

FF

Oxygen application (max. 160 bar (2320 psi) with oxygen measurement and inert liquid)

E10

9

9

9

Explosion-proof "Intrinsic safety" to INMETRO (Brazil) (only for transmitter 7MF4...-.....-.B..)

E25

9

9

9

Explosion-proof "Intrinsic safety" to NEPSI E55 (China) (only for transmitter 7MF4...-.....-.B..)

9

9

9

Explosion protection "Explosion-proof" to E56 NEPSI (China) (only for transmitter 7MF4...-.....-.D..)

9

9

9

Explosion-proof "Zone 2" to NEPSI (China) E57 (only for transmitter 7MF4...-.....-.E..)

9

9

9

Interchanging of process connection side

H01

9

9

9

Vent on side for gas measurements

H02

9

9

9

Stainless steel process flanges for vertical H03 differential pressure lines (not together with K01, K02 and K04)3)

9

9

9

9 9 9

9 9 9

9 9 9

Process flange • Hastelloy K01 • Monel K02 • Stainless steel with PVDF insert K04 max. PN 10 (MWP 145 psi), max. temperature of medium 90 °C (194 °F) For ½-14 NPT inner process connection on the side in the middle of the process flange, vent valve not possible 9 = available 1)

2)

9

HART PA

9 3)

When the manufacture’s certificate M (calibration certificate) has to be ordered for transmitters with diaphragm seals, it is recommended only to order this certificate exclusively with the diaphragm seals. The measuring accuracy of the total combination is certified here. Whe the acceptance test certificate 3.1 for transmitters with direct-connected diaphragm seals is ordered, this certificate must also be ordered with the corresponding seals. Not suitable for connection of remote seal

Siemens FI 01 · 2007

2/103

2

SITRANS P measuring instruments for pressure Transmitters for gage, absolute and differential pressure, flow and level DS III series for differential pressure and flow

2

Selection and Ordering data

ITEM: 1120,1340, 1355 Order code

Additional data Add "-Z" to Order No. and specify Order code. Measuring range to be set Specify in plain text: • With linear characteristic (max. 5 digits): Y01: ... up to ... mbar, bar, kPa, MPa, psi • With square-rooted characteristic (max. 5 digits): Y01: ... up to ... mbar, bar, kPa, MPa, psi

HART PA

FF

Y01

9

Y02

9

Measuring point number (TAG No.) Y15 Max. 16 char., specify in plain text: Y15: .......

9

9

9

Measuring point text Y16 Max. 27 char., specify in plain text: Y16: .......

9

9

9

Entry of HART address (TAG) Y17 Max. 27 char., specify in plain text: Y17: .......

9

Setting of pressure indicator in pressure Y21 units Specify in plain text (standard setting: mA): Y21: mbar, bar, kPa, MPa, psi, ... Note: The following pressure units can be selected: bar, mbar, mm H2O*), inH2O*), ftH2O*), mmHG, inHG, psi, Pa, kPa, MPa, g/cm2, kg/cm2, Torr, ATM oder % *) ref. temperature 20 °C

9

9

9

Setting of pressure indicator in Y22 1) non-pressure units + Y01 or Specify in plain text: Y22: ..... up to ..... l/min, m3/h, m, USgpm, ... Y02 (specification of measuring range in pressure units "Y01" or "Y02" is essential, unit with max. 5 characters)

9

Preset bus address Specify in plain text: Y25: .....................

Y25

Only "Y01", "Y21", "Y22", "Y25" and "D05" can be factory preset 9 = available 1)

Not together with over-filling safety device for flammable and non-flammable liquids (Order code "E08")

2/104

Siemens FI 01 · 2007

9

ITEM 1120, 1340, 1355

Operating Instructions Edition 12/2007

SITRANS P, DS III series with HART communication

Operating Instructions

12/2007

ITEM 1120, 1340, 1355

@1PA5E00047092@

Siemens Aktiengesellschaft

A5E00047092

Automation and Drives (A&D) Sensors and Communication Process Sensors 76181 KARLSRUHE GERMANY

A5E00047092-06

A5E00047092D-06

GN: 30060_DuoDrDif

www.siemens.com/processinstrumentation

Pressure transmitter SITRANS P, DS III series with HART communication

sitrans

ITEM 1350 100 Series Type H100 (Pressure Switch)

IMP100-08

UNITED ELECTRIC CONTROLS

Type H100K (Differential Pressure)

Installation and Maintenance Instructions

Please read all instructional literature carefully and thoroughly before starting. Refer to the final page for the listing of Recommended Practices, Liabilities and Warranties.

GENERAL

UNIT IS  beING installed where heavy condensation is expected, vertical mounting (pressure connection down) is Required. DO not mount in ambient Temperatures exceeding published limits.

BEFORE INSTALLING, CHECK THE SENSOR MODEL SELECTED FOR COMPATIBILITY TO THE PROCESS MEDIA IN CONTACT WITH THE SENSOR AND WETTED PARTS.

Controls may be mounted and oper ated in any position. They may be surface mounted via the two mounting ears on either side of the enclosure, or directly to a rigid pipe by using the pressure connection. Low pressure and differential pressure units, models 520-535, 540-543, 544-548, are also available with an optional surface mounting bracket. Should the control be installed where condensation is expected, vertical mounting is recommended as a means of keeping water away from switch terminals. Never use the enclosure for leverage to hand tighten the pressure connection. Always use a wrench to tighten the pressure connection to the pipe.To prevent damaging the pressure sensor, use a back-up wrench to hold the hex nut in place when surface mounting.

The H100 and H100K differential pressure switches are activated when a bellows, diaphragm or piston sensor responds to a pressure change. This response, at a pre-determined set point, actuates a single snapacting switch, converting the pressure signal into an electrical signal. Control set point may be varied by turning the internal adjustment hex. (See Adjustment -PART II). PROOF PRESSURE* LIMITS STATED IN THE LITERATURE AND ON NAMEPLATES MUST NEVER BE EXCEEDED, EVEN BY SURGES IN THE SYSTEM. OCCASIONAL OPERATION OF UNIT UP TO PROOF PRESSURE IS ACCEPTABLE (E.G., START-UP, TESTING). CONTINUOUS OPERATION SHOULD NOT EXCEED THE DESIGNATED OVER RANGE PRESSURE.

On models supplied with an external manual reset button, be sure to leave sufficient finger space over the reset button for the operator to reset the control.

*Proof Pressure

WIRing

The maximum pressure to which a pressure sensor may be occasionally subjected, which causes no permanent damage (e.g., start-up, testing). The unit may require re-gapping.

Disconnect all supply circuits before WIring.

These products do not have any field replaceable parts.

Electrical ratings stated in literature and ON nameplates SHOULD NEVER be exceeded. overload on a switch can cause failure on the first cycle.

Please refer to product bulletin for product specifications. Product bulletin may be found at www.ueonline.com.

Wire units according to national and local electrical codes. Maximum recommended wire size IS 14 AWG.



Part I - Installation

Tools Needed Adjustable Wrench Screwdriver Hammer (for alternate wire knockouts)

Remove the two screws retaining the cover and cover gasket. A 1/2” NPT conduit connection is provided on the left hand side of the enclosure. Two cast-in knockouts for the 1/2” conduit are located on the side and back of the enclosure. These can easily be knocked out by placing the blade of a screwdriver in the groove and tapping sharply with a hammer. The three switch ter minals are clear ly labeled “common”, “nor mally open” and “nor mally closed”. For optional switches supplied with leadwires, the following color coding applies:

Mounting Install unit where shock, vibration and temperature fluctuations are minimal. Orient unit so that moisture is prevented from entering the enclosure. IF

IMP100-08

ITEM 1350 Manual Reset (Option 1530)

DPDT (Option 1010)

SPDT SWT1 SWT2 Common Violet Violet Yellow Normally Open Blue Blue Orange Normally Closed Black Black Red A grounding screw and clamp (cast in symbol) is provided which meets a 35 lb. pull test. Keep the wire as short as possible to prevent interface with the plunger and the optional adjustable differential switch wheel, if applicable.

Part II - Adjustments

Tools Needed 5/8” Open End Wrench 1/4” Wrench 3/16” Wrench

SOME models have a two-piece, adjustable plunger. THis feature is characterized by a 3/16” Hex head screw installed in the 1/4” hex plunger. The length of this assembly is adjusted at our factory and is critical to the function of the control.

Models 171-174

Flats 2-2 1/2

Approx. Gap .0085 to .0105”

183-194 483-494 358-376 700-706 521-525 15737 531-535 540-548 560-567 15623 15731-15736

1-1 1/2 1-1 1/2 5-6 3 1/2 - 4 2-2 1/2 5-6 2-2 1/2 2-2 1/2 1-1 1/2 5-6 5-6

.004 to .006” .004 to .006” .020 to .025” .014 to .017” .0085 to .0105” .020 to .025 .0085 to .0105” .0085 to .0105” .004 to .006” .020 to .025” .020 to .025

Chart 1

- DO NOT ADJUST

H100 and H100K Remove pressure switch cover. Loosen Phillips screw adjustment lock. Adjust set point by turning 5/8” hex adjustment screw clockwise (left) to raise set point, or counter clockwise (right) to lower set point. Tension on adjustment screw can be increased by tightening adjustment lock onto it. (See diagram 1). Controls include uncalibrated reference scales for high, low or mid range settings.

Set-point

Adjustable Deadband Models

Diagram 1

Model 15623, 15731-15737, and control types with option code 1519 incorporate a snap switch with internal adjustment wheel. Turning this wheel raises or lowers the pressure rise set point. The fall set point remains constant. Consult factory for additional information.

Manual Reset Button Control types with option code 1530 incorporate a snap switch which when actuated, remains actuated until the pressure drops sufficiently to allow the reset button (located on top of the control) to be manually depressed to reset the switch. Gapping 1) Loosen adjustment lock. 2) Turn 5/8” hex adjustment screw clockwise (left), to approximately mid range. This puts a load on the sensor and exposes the plunger flats. Using a 1/4” wrench on the plunger and a 3/16” wrench on the plunger hex screw, turn hex screw counter-clockwise (right) from plunger until switch actuates. If switch is already actuated, turn plunger hex screw clockwise (left), until switch deactuates. Turn hex screw clockwise (left) from this point. (See chart 1 for Flats and approximate Gap.) 3) Check set point per above. 4) Connect wires and replace cover securely. IMP100-08

ITEM 1350 Dimensions

Dimensional drawings for all models may be found at www.ueonline.com.

4" WITH COVER (101.6mm)

2.34 (59.4mm) 1/2 NPT CONDUIT

KNOCK OUT

.895 (22.7mm) DIA. KNOCK-OUT 2 PLACES

4.22 (107.2mm)

A

1.63 (41.4mm)

Dimension A Models

CLEARANCE FOR 1/4 (6.35mm) SCREW 2 MT'G HOLES

Inches

mm

NPT

Pressure

2.75 (69.9mm)

171-174

7.63

193.8

1/2”

183-186, 484-486

7.56

192.0

1/2”

188-189, 488-489

6.63

168.4

1/2”

190-194, 490-494

6.63

168.4

1/2”

218

6.56

166.6

1/4”

270-274

7.00

177.8

1/4”

358-376

7.00

177.8

1/4”

520-525, 15737

8.44

214.4

1/2”

530-535

8.00

203.2

1/2”

560-564

6.63

168.4

2” Sanitary Fitting

565-567

6.63

168.4

1-1/2” Sanitary Fitting

610-616, 680

7.00

177.8

1/4”

701-706, 15623, 15731-15736

6.63

168.4

1/4”

Differential Pressure 540-543

8.47

215.1

1/8”

544-548

8.53

216.7

1/8”

Pressure Connections

Models 171-174, 471-474

Models 218-376, 610-706, 15623, 15731-15736

Models 183-186, 483-486

Models 520-525 IMP100-08

Models 188-194. 488-494

Models 530-535, 15737

ITEM 1350 RECOMMENDED PRACTICES AND WARNINGS

Model 540-543

Models 544-548

Models 560-564

Models 565-567

United Electric Controls Company recommends careful consideration of the following factors when specifying and installing UE pressure and temperature units. Before installing a unit, the Installation and Maintenance instructions provided with unit must be read and understood. • To avoid damaging unit, proof pressure and maximum temperature limits stated in literature and on nameplates must never be exceeded, even by surges in the system. Operation of the unit up to maximum pressure or temperature is acceptable on a limited basis (e.g., start-up, testing) but continuous operation must be restricted to the designated adjustable range. Excessive cycling at maximum pressure or temperature limits could reduce sensor life. • A back-up unit is necessary for applications where damage to a primary unit could endanger life, limb or property. A high or low limit switch is necessary for applications where a dangerous runaway condition could result. • The adjustable range must be selected so that incorrect, inadvertent or malicious setting at any range point cannot result in an unsafe system condition. • Install unit where shock, vibration and ambient temperature fluctuations will not damage unit or affect operation. When applicable, orient unit so that moisture does not enter the enclosure via the electrical connection. When appropriate, this entry point should be sealed to prevent moisture entry. • Unit must not be altered or modified after shipment. Consult UE if modification is necessary. • Monitor operation to observe warning signs of possible damage to unit, such as drift in set point or faulty display. Check unit immediately. • Preventative maintenance and periodic testing is necessary for critical applications where damage could endanger property or personnel. • Electrical ratings stated in literature and on nameplate must not be exceeded. Overload on a switch can cause damage, even on the first cycle. Wire unit according to local and national electrical codes, using wire size recommended in installation sheet. • Do not mount unit in ambient temp. exceeding published limits. LIMITED WARRANTY Seller warrants that the product hereby purchased is, upon delivery, free from defects in material and workmanship and that any such product which is found to be defective in such workmanship or material will be repaired or replaced by Seller (Ex-works, Factory, Watertown, Massachusetts. INCOTERMS); provided, however, that this warranty applies only to equipment found to be so defective within a period of 36 months from the date of manufacture by the Seller. Seller shall not be obligated under this warranty for alleged defects which examination discloses are due to tampering, misuse, neglect, improper storage, and in any case where products are disassembled by anyone other than authorized Seller’s representatives. EXCEPT FOR THE LIMITED WARRANTY OF REPAIR AND REPLACEMENT STATED ABOVE, SELLER DISCLAIMS ALL WARRANTIES WHATSOEVER WITH RESPECT TO THE PRODUCT, INCLUDING ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. Limitation OF Seller’s Liability Seller’s liability to Buyer for any loss or claim, including liability incurred in connection with (i) breach of any warranty whatsoever, expressed or implied, (ii) a breach of contract, (iii) a negligent act or acts (or negligent failure to act) committed by Seller, or (iv) an act for which strict liability will be inputted to seller, is limited to the “limited warranty” of repair and/or replacement as so stated in our warranty of product. In no event shall the Seller be liable for any special, indirect, consequential or other damages of a like general nature, including, without limitation, loss of profits or production, or loss or expenses of any nature incurred by the buyer or any third party. UE specifications subject to change without notice.

UNITED ELECTRIC CONTROLS 180 Dexter Ave. P.O. Box 9143, Watertown, MA 02472-9143 USA 617 926-1000 Fax 617 926-2568 www.ueonline.com CP120810000 IMP100-08

100 Seri es

100 S e r i e s

ITEM 1350

pressure model chart Model Adjustable Set Point Range Deadband Low end of range on fall;

Over Range Pressure*

High end of range on rise psi bar (unless noted) psi bar (unless noted) psi Type H100

Proof Pressure**

bar

psi

bar

1.5” sanitary welded 316L stainless steel diaphragm and pressure connection. Mates with Tri-Clamp® fitting systems (not UE supplied) 565 566 567

5 to 30 10 to 100 15 to 300

0,3 to 2,1 0,7 to 6,9 1,0 to 20,7

1 to 5 1 to 12 3 to 22

68,9 mbar to 0,3 bar 68,9 mbar to 0,8 bar 0,2 to 1,5

1000 1000 1000

68,9 68,9 68,9

1500 1500 1500

103,4 103,4 103,4

Buna-N diaphragm and O-ring with nickel-plated brass 1/4” NPT (female) pressure connection; Option M540 Viton® diaphragm and O-ring available for models 701-705 701 702 703 704 705 706

1.5 to 30 3 to 100 9 to 300 15 to 500 30 to 1000 100 to 1700

103,4 mbar to 2,1 bar 1 to 2 0,2 to 6,9 1 to 4 0,6 to 20,7 1 to 5 1,0 to 34,5 2 to 8 2,1 to 68,9 3 to 20 6,9 to 117,2 10 to 30

68,9 mbar to 0,1 bar 68,9 mbar to 0,3 bar 68,0 mbar to 0,3 bar 0,1 to 0,6 0,2 to 1,4 0,7 to 2,1

500 500 500 1500 1500 2000

34,5 34,5 34,5 103,4 103,4 103,4

600 600 600 2500 2500 2500

41,4 41,4 41,4 172,4 172,4 172,4



psi

bar

bar

psi

bar

psi

bar

psi

Viton® diaphragm and O-Ring with 316 stainless steel 1/4” NPT (female) pressure connection (includes adjustable deadband switch) 15623

20 to 200

1,4 to 13,8

12 to 26

0,8 to 1,8

500

34,5

1000

68,9

Model Adjustable Set Adjustable Deadband Point Range

Over Range Proof Pressure* Pressure**

psi bar

psi

psi

Low End bar

Mid Range psi bar

High End psi bar

bar

psi

bar

Buna N diaphragm and O-Ring nickel-plated brass 1/4” NPT (female) pressure connection; includes adjustable deadband microswitch 15731 15732 15733 15734 15735 15736

3 to 30 5 to 100 9 to 300 15 to 500 30 to 1000 100 to 1700

0,2 to 2,1 0,3 to 6,9 0,6 to 27,0 1,0 to 34,5 2,1 to 68,9 6,9 to 117,2

1.5 to 4 3 to 6 4 to 11 8 to 25 9 to 30 25 to 60

0,1 to 0,3 0,2 to 0,4 0,3 to 0,8 0,6 to 1,7 0,6 to 2,1 1,7 to 4,1

Model Adjustable Set Point Range

2 to 4.5 4 to 7.5 5 to 13 9 to 28 10 to 35 40 to 80

0,1 to 0,3 0,3 to 0,5 0,3 to 0,9 0,6 to 1,9 0,7 to 2,4 2,8 to 5,5

2.5 to 5 5 to 9 5 to 16 10 to 31 30 to 90 50 to 100

Deadband

0,2 to 0,3 0,3 to 0,6 0,3 to 1,1 0,7 to 2,1 2,1 to 6,2 3,4 to 6,9

500 500 500 1500 1500 2000

Over Range

34,5 34,5 34,5 103,4 103,4 137,9

1000 1000 1000 2500 2500 2500

68,9 68,9 68,9 172,4 172,4 172,4

Proof

Lower 75% Top 25% Pressure* Pressure** range span range span psi bar psi bar psi bar psi bar psi bar Welded 316 stainless steel diaphragm and 1/2” NPT (female) pressure connection, large 0.72” orifice for clean-out purposes (NACE MR-0175 compliant) 190 191 192 193 194

5 to 30 10 to 100 15 to 300 20 to 500 80 to 1700

0,3 to 2,1 0,7 to 6,9 1,0 to 20,7 1,4 to 34,5 5,5 to 117,2

1 to 3 1 to 8 3 to 18 4 to 30 5 to 120

0,1 to 0,2 0,1 to 0,6 0,2 to 1,2 0,3 to 2,1 0,3 to 8,3

6 max 15 max 25 max 45 max 150 max

0,4 1,0 1,7 3,1 10,3

1500 1500 1500 1500 2000

103,4 103,4 103,4 103,4 137,9

2500 2500 2500 2500 2500

172,4 172,4 172,4 172,4 172,4

Tri-Clamp® is a registered trademark of Tri-Clover Inc. Application Note: The use of metallic diaphragms where higher pressure shock or heavy cycling is expected should be avoided. Models 171-174 should not be used where system or start-up vacuum pressure might exceed 26” Hg Vac (-0.9 bar).



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1 0 0 - B - 0 6

ITEM 1350

100 Seri es

100 S e r i e s

how to order Building a part number Select a Type

Select a Model

Select an Option

Refer to the “Type” section below.

Refer to the “Model Charts”.

Refer to the “Options” section.

Determine type number based on switch output, enclosure, adjustment and reference.

Determine model based on adjustable range, deadband and proof pressure.

Determine option number based on switch output, optional materials or other product enhancements.

Fill in the type portion of your part number with the corresponding number.

Fill in the model portion of your part number with the corresponding number.

Fill in the option portion of your part number with the corresponding number. Leave “option” portion blank if no options are needed. For multiple options: Call United Electric Controls.

type DESCRIPTION Pressure

Type H100 - One SPDT output; epoxy coated enclosure; internal adjustment with “High-Low” reference scale

Differential Pressure Type H100K- One SPDT output; epoxy coated enclosure; internal adjustment with “High-Low” reference scale Temperature

Type B100 - Immersion stem; one SPDT output; internal adjustment with reference dial Type C100 - Immersion stem; one SPDT output; internal adjustment with no reference Type E100 - Bulb and capillary; one SPDT output; internal adjustment with reference dial Type F100 - Bulb and capillary; one SPDT output; internal adjustment with no reference

switch options* 0140 0500 1010 1070 1519 1530 1535 1537 2000 3000 * All switches have limited DC capabilities. 10 w w w . u e o n l i n e . c o m

Gold contacts, 1A 125 VAC resistive. Not available models 13545, 13546, 15623, 15731-15737 Close deadband, 5A 125/250 VAC resistive. Not available models 520-535, 13545, 13546, 15623, 15731-15737 DPDT switch, 10A 125/250 VAC resistive; deadband and minimum set point will increase. Not available temperature versions, type H100K or models 171-194, 483-567, 680, 15623, and 15731-15737 10 A 125 VDC resistive; deadband and minimum set point will increase. Not available models 171-194, 483-535, 560-567, 13545, 13546, 15623, 15731-15737 Adjustable deadband, 15 A 125/250/480 VAC resistive; adjustment wheel changes rise setting only. If adjustment on fall setting is required, use primary adjustment. Not available types B100, E100 or models 171-194, 483-494, 560-567, 610-616, 51623, 15731-15737 External manual reset, 15 A 125/250/480 VAC resistive; latches on rise, only. Not available models 13545, 13546, 15623, 15731-15737 High ambient, 15 A 125/250 VAC resistive; temperatures up to 250°F (121.1°C). NOT AVAILABLE MODELS 520-535, 13545, 13546, 15623, 15731-15737 Vapor sealed switch, 15 A 125/250 VAC resistive. NOT AVAILABLE MODELS 523, 533, 13545, 13546, 15623, 15731-15737 20 A 125/250/480 VAC resistive. Not available type H100K or models 520-535, 13545, 13546, 15623, 15731-15737 30 A 125/250/277 VAC resistive. Not available type H100K or models 171-194, 483-567, 680, 13545, 13546, 15623, 15731-15737 Consult factory for details.

1 0 0 - B - 0 6

ITEM 1350 10 0 S e r i e s

other options M020 M201 M277 M278 M405 M406 M444 M446 M449 M504 M540 M550 M914 M921 6361-704 SD6286-51

Red status light, 115 VAC only. Not available models 13545, 13546, 15623, 15731-15737 Factory set one switch; specify increasing or decreasing pressure or temperature and setpoint Range indicated on nameplate in kPa or MPa, factory selected. Not available on temperature versions Range indicated on nameplate in Kg/cm2. Not available on temperature versions Intrinsic safety compliance for European Union per ATEX standards Intrinsic Safety compliance for Russia per Gosgortechnadzor standards. Paper ID tag Stainless steel ID tag & wire attachment Mounting bracket kit. Required for models 520-535, 15737 when surface mounting. Use kit part number 6361-704 for other models 316L stainless steel immersion stem. Available temperature models 120, 121 only Viton® construction (deadband and low end range may increase slightly); wetted parts include Viton® diaphragm and O-ring plus stainless steel pressure connection. AVAILABLE on models 610-616 (O-ring only), 701-705 (Viton diaphragm & O-ring, stainless steel pressure connection), AND 540-548 (sealing diaphragms only, main diaphragm remains Kapton®, pressure connections remain aluminum) Oxygen service cleaning; internal construction may change. NOT AVAILABLE ON PRESSURE MODEL 706 1/2” NPT (female) stainless steel pressure connection. AVAILABLE MODELS 358-376, 610-616 Brass pressure connection. AVAILABLE MODELS 610-616 Surface and Pipe Mounting Hardware (required for model 520-535, 15737, 540-548 when surface mounting) Watertight conduit fitting; connects 7/8” hole to 1/2” NPT (female) fitting

Optional sensor material for “wc ranges. Available models 520-525 XC001 XC002 XC003 XC004 XC005 XC006 XC007

Aluminum pressure connection, Viton® diaphragm, Viton® O-ring Aluminum pressure connection, Kapton® diaphragm, Buna N O-ring Aluminum pressure connection, Kapton® diaphragm, Viton® O-ring 316L Stainless steel pressure connection, 316L stainless steel diaphragm, Viton® O-ring. (Over range pressure is limited to 100 psi) 316L Stainless steel pressure connection, Viton® diaphragm, Viton® O-ring 316L Stainless steel pressure connection, Kapton® diaphragm, Viton® O-ring 316L Stainless steel pressure connection, Teflon® diaphragm, Viton® O-ring

Optional sensor materials for corrosive media. Available models 183-189, 483-489 XD002 XD003 XP112 XP113 XR211 XR212 XR213 XR214

Hastelloy C diaphragm Monel diaphragm Hastelloy C pressure connection Monel pressure connection Kalrez® O-ring Silicone O-ring. Not available models 188-189, 488-489 Ethylene propylene O-ring Aflas® O-ring

Optional Flush mount flanges. Available models 560-567 Other flanges (150# and 300#) available, please consult UE. Flanges conform to ANSI B16.5. Maximum pressure is limited by flange rating.

F196 F197 F198 F199

Flush mounted flange, 150#, 1” lap joint, raised face Flush mounted flange, 150#, 2” lap joint, raised face Flush mounted flange, 300#, 1” lap joint, raised face Flush mounted flange, 300#, 2” lap joint, raised face

AVAILABLE MODELS 565-567 ONLY AVAILABLE MODELS 560-564 ONLY AVAILABLE MODELS 565-567 ONLY AVAILABLE MODELS 560-564 ONLY

Note: No options are available on Heat Trace and Freeze Protection models 13546 and 13545 or pump switch model 15623 except M201, M444 and M446.

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w w w . u e o n l i n e . c o m

11

Document Name: 4607T-1370 Rev 0

ITEM 1370

Document Name: 4607T-1375 Rev 0

ITEM 1375

ITEM 1375

ITEM 1375

ITEM 1395

Sensors and Cabling Accessories XS Tubular Inductive Sensors 18mm Diameter, AC/DC; Universal Standard Length

thread

2.36 60

2.02 51.5

M18x1

2.75 70

2.02 51.5

LED

XS1M18 LED

Nominal Sensing Distance

2.95 75

2.16 55

.31 8

XS1M18•K

Features • 360° LED indicators • Extended temperature range • Extended supply voltage range • IP68 AC/DC power supply • Patented plastic mounting bracket • Connector options • Extensive protective circuitry • Metal locknuts for metal or plastic mounting nuts for plastic housings included • Normally closed (N.C.) output available on versions markeda • UL Listed, CSA Certified and CE Mark AC or AC/DC

Output Mode

Voltage Range Max

Operating Frequencies SCP

Indicator LED ➀

Mating Connector Style (see p. 297)

3000 Hz 3000 Hz

no yes

A C

— —

25 Hz 25 Hz

3000 Hz 3000 Hz

no yes

B B

13,14 13,14

XS1M18MA230K XS1M18MA250K

25 Hz 25 Hz

3000 Hz 3000 Hz

no yes

B C

18, 20 18, 20

XS1M18MA230A XS1M18MA250A

25 Hz

3000 Hz

no

B

—

XS1M18MA230B

25 Hz 25 Hz

2000 Hz 2000 Hz

no yes

A C

— —

XS2M18MA230 XS2M18MA250

25 Hz 25 Hz

2000 Hz 2000 Hz

no yes

B B

13,14 13,14

XS2M18MA230K XS2M18MA250K

25 Hz 25 Hz

2000 Hz 2000 Hz

no yes

B C

18 18

XS2M18MA230A XS2M18MA250A

25 Hz

3000 Hz

no

A

—

XS3P18MA230

25 Hz

3000 Hz

no

B

13,14

XS3P18MA230K

25 Hz

3000 Hz

no

B

17,18,19,20

XS3P18MA230A

25 Hz

2000 Hz

no

A

—

25 Hz

2000 Hz

no

A

13,14

XS4P18MA230K

25 Hz

2000 Hz

no

A

18,20

XS4P18MA230A

25 Hz

2000 Hz

no

B

—

XS4P18MA230B

AC

DC

25 Hz 25 Hz

Catalog Number

2.04 52

1.71 43.5

Nickel brass case LED

XS1M18•A .31 8

LED

LED

2.63 67

1.85 47

2.44 62

1.71 43.5

.31 8

XS2M18•

XS2M18•K LED

2.36 60

2.02 51.5

XS2M18•A

2.75 70

2.02 51.5 LED

XS3/XS4P18•230K

2.89 73.5

2.04 52

XS1M18MA230 XS1M18MA250

Plastic case

LED

XS3/XS4P18•230

Shielded, 2m (6.6') cable 5 mm AC/DC N.O. a 20-264 Vac/dc 5 mm AC/DC N.O. a 20-264 Vac/dc Shielded, connector - micro style AC 5 mm AC/DC N.O. a 20-264 Vac/dc 5 mm AC/DC N.O. a 20-264 Vac/dc Shielded, connector - mini style 5 mm AC/DC N.O.a 20-264 Vac/dc 5 mm AC/DC N.O.a 20-264 Vac/dc Shielded, screw terminal connection 5 mm AC/DC N.O.a 20-264 Vac/dc Non-shielded, 2m (6.6') cable 8 mm AC/DC N.O.a 20-264 Vac/dc 8 mm AC/DC N.O.a 20-264 Vac/dc Non-shielded, connector - micro style AC 8 mm AC/DC N.O.a 20-264 Vac/dc 8 mm AC/DC N.O.a 20-264 Vac/dc Non-shielded, connector - mini style 8 mm AC/DC N.O.a 20-264 Vac/dc 8 mm AC/DC N.O.a 20-264 Vac/dc Shielded, 2m (6.6') cable 5 mm AC/DC N.O.a 20-264 Vac/dc Shielded, connector - micro style 5 mm AC/DC N.O.a 20-264 Vac/dc Shielded, connector - mini style 5 mm AC/DC N.O.a 20-264 Vac/dc Non-shielded, 2m (6.6') cable 8 mm AC/DC N.O.a 20-264 Vac/dc Non-shielded, connector - micro style 8 mm AC/DC N.O.a 20-264 Vac/dc Non-shielded, connector - mini style 8 mm AC/DC N.O.a 20-264 Vac/dc Shielded, screw terminal connection 8 mm AC/DC N.O.a 20-264 Vac/dc

XS4P18MA230

a To order a normally closed (N.C.) version change the A to B, example: XS1M12PA260 to XS1M12PB260. ➀ See next page under specifications for LED function.

LED

XS3/XS4P18•230A

Minimum mounting clearances (mm/inches) Face to face

Side by side

Mounting in a metal support D

Facing a metal object

H e

e

e

XS1/XS3 Shielded

e: 10/.39

e: 60/2.36

e: 15/.59

D: 18/.71, H: 0/0

XS2/XS4 Non-shielded

e: 16/.63

e: 96/3.78

e: 24/.94

D: 54/2.13, H: 16/.63

190

© 1997 Schneider Electric All Rights Reserved

4/00

ITEM: 1410, 1420, 1430, 1435

INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR ASHCROFT® TYPE 91 SERIES ADAPTER KIT The Type 91 Series Adapter Sets were designed to provide a simple means of installing a bimetal dial thermometer into an existing industrial glass thermometer well. The adapter set consists of: 1. A metal liner and spring assembly. 2. An adapter nut. 3. A small supply of heat conducting medium.

METHOD OF SELECTING THE SET The Adapter Sets are available in four different sizes, to cover various depths of wells. The “Selection Chart” shows the Adapter Set number and the Bimetal Dial Thermometer stem length to use for any well depth from 35⁄8˝ up to 251⁄8˝. To select the proper Adapter Set and Bimetal Dial Thermometer stem length, measure first the well depth by inserting a pencil, or any small diameter rod or stiff wire until it reaches the bottom. (See Figure 1.) Be sure the rod does not hang up on any shoulder inside the well. Using your thumb as an index, withdraw the rod and measure the distance from the end of the rod to the index point. (See Figure 2.)

INSTALLATION Assemble the adapter nut into the well and tighten securely. (See Figure 3.) Before installing the Bimetal Dial Thermometer into the adapter and well, coat the lower 3˝ section of the thermometer with a layer of heat conducting medium. This will improve the temperature response of the thermometer. The metal liner is then slipped over the end of the thermometer stem and a coating of heat conducting medium is applied to the outside wall of the liner. The thermometer and the liner are then inserted into the well and tightened in position. Do not tighten more than is necessary to prevent the thermometer from turning. Where service temperatures exceed 350°F the heat conducting medium may smoke when first subjected to a high temperature. This is caused by the vehicle, in the heat conducting medium, vaporizing and leaving the dry solids behind. This should not be cause for alarm. The dry solids will act equally well as a heat conducting medium for temperatures up to 1000°F.

Then use the chart to select the Adapter Set and the Bimetal Dial Thermometer stem length to fit the well. Note that one stem length of thermometer covers several different well depths by using the correct Adapter Set. For example, a thermometer with a 9˝ long stem can be used for well depths between 71⁄8˝ and 101⁄8˝, by choosing the correct Adapter Set. The liner is tapped with a 5⁄16˝ - 18 machine thread so it can be removed from the well if desired.

Figure 3 SELECTION CHART WELL DEPTH IN INCHES

ADAPTER SET NO.

STEM LENGTH “S”

WELL DEPTH IN INCHES

ADAPTER SET NO.

STEM LENGTH “S”

10

WELL DEPTH IN INCHES

ADAPTER SET NO.

STEM LENGTH “S”

18 91B 18

91D 3

91A

11

19 91C 12

4

91B

12

91B

20

13

91A

21

4 5

91A 91C

Figure 1 6

91B

91D 6

14

22 91C

7

91D

15

91A

15

91B

16

91A

23 91C

91D 8

24 24

91B

91C 91D

9 9

91B

17

Figure 2

10

91A

© 2007 Ashcroft Inc., 250 East. Main Street, Stratford, CT 06614-5145, USA Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com All sales subject to standard terms and conditions of sale. I&M008-10004K-11/05 AMR

18

91A 18

91C

25 Note: If the measured well depth falls on the dividing line between two stem lengths and/or two Adapter Sets choose the stem and/or Adapter Set above the line.

ITEM: 1410, 1420, 1430, 1435

INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR ASHCROFT® BIMETAL DIAL THERMOMETERS

GENERAL In removing the thermometer out of the packing box, handle it by the case or case outlet. Avoid handling it by the stem.

CAUTION: Thermowells should be used on all pressurized applications, to protect the thermometer from corrosion or physical damage, and to facilitate removal of the thermometer without disturbing the process.

INSTALLATION OF THERMOMETERS The thermometer should be mounted at any convenient location where it will be subjected to the average temperature variations to be indicated. Avoid bending the stem as this will cause misalignment of the internal parts, resulting in undue frictional errors. To tighten the thermometer to the apparatus, use a wrench applied to the hexagon head of the threaded connection located just outside of the case.

INSTALLATION Locate the stem so that at least two inches will be subjected to the average temperature to be measured. Exposing the stem to a temperature in excess of the highest dial reading should be avoided. The thermometer is normally provided with a threaded connection. To tighten the thermometer to the apparatus or into the well, use an open-end wrench applied to the hexagon head of the threaded connection.Turn until reasonably tight, then tighten still further in the same manner as a pipe elbow or similar pipe fitting until the scale is in the desired position for reading. DO NOT TIGHTEN BY TURNING THE THERMOMETER CASE. Install the dry type thermometer so that the maximum case temperature is kept below 200°F at all times. Install the liquid filled type thermometer so that the maximum case temperature is kept below 150°F at all times. When a thermometer is equipped with a well, the well should be installed onto the apparatus first. The stem of the thermometer should then be coated with a heat conducting medium (a mixture of glycerin and graphite or vaseline or any other heavy lubricant may be used), after which the thermometer stem is inserted, and tightened into the well.

XC2 INSTALLATION The XC2 variation meets the NSF/ANSI standard 2 (2002E) guidelines for non-exposed applications. Please refer to the NSF guidelines for certified installation instructions and approved materials.

TESTING Ashcroft Bimetal Dial Thermometers are carefully calibrated at the factory and under most operating conditions will retain their accuracy indefinitely. However, as in the case of all instruments, it is well to make periodic checks for accuracy against known standards.

ADJUSTMENT If it is necessary to make an adjustment to the thermometer proceed as follows: On thermometers fitted with an “External Adjustment” – Use a small wrench, small screwdriver or a coin to turn the slotted hexagon head in the back of the case until the pointer indicates the proper temperature on the dial.

MAINTENANCE OF DIAL THERMOMETERS Aside from occasional testing, little or no maintenance is required. Be sure that the gasketed glass cover is on the case at all times, as moisture and dirt inside the case will eventually cause the thermometer to lose its accuracy. (See caution note below.) If the thermometer is used for measuring the temperature of a material that may harden and build up an insulating layer on the stem, the thermometer should be removed from the apparatus occasionally, and the stem cleaned. Observe this precaution to ensure the sensitivity of the instrument. CAUTION: Bimetal Thermometers operating below freezing must have a perfectly tight case to prevent entrance of moisture which eventually will condense and freeze inside the stem. This condition shows up as a failure of the thermometer to read accurately below 32°F or 0°C. For this reason it is important to avoid damage to the glass front while the stem temperature is at freezing or below. All thermometers are hermetically sealed in a dry atmosphere at the factory and require no further maintenance.

© 2007 Ashcroft Inc., 250 East. Main Street, Stratford, CT 06614-5145, USA Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com All sales subject to standard terms and conditions of sale. I&M008-10004K-11/05 AMR

ITEM 1410

114

Bimetal Thermometers Series EI, Grade A (1%)

This series has a hermetic seal and an external adjustment in the rear of the case. As with other Ashcroft® industrial bimetal thermometers, it has a Maxivision® dial which eliminates parallax by placing the pointer on the same plane as the graduations. The connection locations are rear, lower, and Everyangle.™ The hermetic seal prevents entry of moisture into the casing, thus minimizing the possibility of icing or fogging inside the case. The window stays clear, and with the Maxivision dial, precise readings are certain.

• Hermetically sealed • External adjustment • Maxivision® dial • 1% full-span accuracy (ASME B40.3 Grade A) • All-welded stainless steel construction • Silicone on the coil provides vibration dampening and superior time response • Heavy-duty glass standard; plastic or shatterproof glass optional • Limited five-year warranty

SELECTION TABLE Case Size Dial

2˝

Code

Stem Style Code

20

Connection

Code

Location

Code

Plain

40

Rear

R

Pointed Plain 1

⁄4 NPT

1

⁄2 NPT Union

3˝

30

5˝

50

Rear

R

2 ⁄2

025

–20/120††

R

4

040

30/130††

Everyangle

E

Rear Lower

42

1

⁄2 NPT

60

⁄2 NPT Union

42

1

⁄2 NPT ⁄2 NPT

60 60

6

060

0/200

9

090

0/250

R

12

120

50/300

L

15

150

50/400

18

180

50/550

24

240

200/700†

2

20

1

10 20

2

Everyangle

E

Rear

R

100/800†

Lower

L

200/1000**†

* Dual scale ranges available for all standard °F ranges (3˝ and 5˝ case only) ** Satisfactory for continuous service up to 800°F or 425°C. Can be used for intermittent service from 800 to 1000°F, or 425 to 500°C. Use Ashcroft Duratemp thermometers for ranges above and below those listed above. † Minimum stem length for these ranges is 4˝. †† Minimum stem length lower connection and Everyangle 4˝.

Fig. °/Div. Inter.

–80/120 1

Rear

60

1

°F* Fahrenheit

50

⁄2 NPT

1

Temperature Range

60

1

EI

Stem Lengths Available “S” Length Code (inches)

Thermowells must be used on all pressure or velocity applications, to protect the stem of thermometer from corrosion and physical damage, and to facilitate removal of the thermometer without disturbing the process. Maximum ambient temperature 200°F (95°C).

°C Celsius

°/Div.

Fig. Inter.

–50/50

1

10

–20/120

2

20

0/50††

1

5

0/100

1

10

2

20

5

50

10/150 0/200 50

5

0/300 50/450**† 100/500**†

10

100

Overtemperature Limits Maximum Top of Range °F Overtemperature up to 250

100% of span

250/550

50% of span

550/1000

800°F **

TO ORDER THIS EI SERIES BIMETAL THERMOMETER:

Select: 1. Case Size: 3˝ Code 30

30

EI

60

R

040

0/250°F

XNH

2. Style: Code EI 3. Stem Conn: 1⁄2 NPT Code 60 4. Stem Location: Rear Code R 5. Stem Length: 4˝ Code 040 6. Range: Code 0/250°F 7. Options: Stainless Steel Tag (see page 33)

Reference Bulletin BM-1 MADE IN U.S.A.

Consult factory for guidance in product selection Phone (203) 378-8281, FAX (203) 385-0499 or visit our web site at www.ashcroft.com

a Halliburton company

ITEM 1420 114

ITEM 1430

Bimetal Thermometers Series EI, Grade A (1%) ITEM 1435

This series has a hermetic seal and an external adjustment in the rear of the case. As with other Ashcroft® industrial bimetal thermometers, it has a Maxivision® dial which eliminates parallax by placing the pointer on the same plane as the graduations. The connection locations are rear, lower, and Everyangle.™ The hermetic seal prevents entry of moisture into the casing, thus minimizing the possibility of icing or fogging inside the case. The window stays clear, and with the Maxivision dial, precise readings are certain.

• Hermetically sealed • External adjustment • Maxivision® dial • 1% full-span accuracy (ASME B40.3 Grade A) • All-welded stainless steel construction • Silicone on the coil provides vibration dampening and superior time response • Heavy-duty glass standard; plastic or shatterproof glass optional • Limited five-year warranty

SELECTION TABLE Case Size Dial

2˝

Code

Stem Style Code

20

Connection

Code

Location

Code

Plain

40

Rear

R

Pointed Plain 1

⁄4 NPT

1

⁄2 NPT Union

3˝

30

5˝

50

Rear

R

2 ⁄2

025

–20/120††

R

4

040

30/130††

Everyangle

E

Rear Lower

42

1

⁄2 NPT

60

⁄2 NPT Union

42

1

⁄2 NPT ⁄2 NPT

60 60

6

060

0/200

9

090

0/250

R

12

120

50/300

L

15

150

50/400

18

180

50/550

24

240

200/700†

2

20

1

10 20

2

Everyangle

E

Rear

R

100/800†

Lower

L

200/1000**†

* Dual scale ranges available for all standard °F ranges (3˝ and 5˝ case only) ** Satisfactory for continuous service up to 800°F or 425°C. Can be used for intermittent service from 800 to 1000°F, or 425 to 500°C. Use Ashcroft Duratemp thermometers for ranges above and below those listed above. † Minimum stem length for these ranges is 4˝. †† Minimum stem length lower connection and Everyangle 4˝.

Fig. °/Div. Inter.

–80/120 1

Rear

60

1

°F* Fahrenheit

50

⁄2 NPT

1

Temperature Range

60

1

EI

Stem Lengths Available “S” Length Code (inches)

Thermowells must be used on all pressure or velocity applications, to protect the stem of thermometer from corrosion and physical damage, and to facilitate removal of the thermometer without disturbing the process. Maximum ambient temperature 200°F (95°C).

°C Celsius

°/Div.

Fig. Inter.

–50/50

1

10

–20/120

2

20

0/50††

1

5

0/100

1

10

2

20

5

50

10/150 0/200 50

5

0/300 50/450**† 100/500**†

10

100

Overtemperature Limits Maximum Top of Range °F Overtemperature up to 250

100% of span

250/550

50% of span

550/1000

800°F **

TO ORDER THIS EI SERIES BIMETAL THERMOMETER:

Select: 1. Case Size: 3˝ Code 30

30

EI

60

R

040

0/250°F

XNH

2. Style: Code EI 3. Stem Conn: 1⁄2 NPT Code 60 4. Stem Location: Rear Code R 5. Stem Length: 4˝ Code 040 6. Range: Code 0/250°F 7. Options: Stainless Steel Tag (see page 33)

Reference Bulletin BM-1 MADE IN U.S.A.

Consult factory for guidance in product selection Phone (203) 378-8281, FAX (203) 385-0499 or visit our web site at www.ashcroft.com

a Halliburton company

ITEM: 1520, 1540

PRESSURE GAUGE INSTALLATION, OPERATION AND MAINTENANCE

I&M008-10098-5/02 (250-1353H) 1M AMR 5P1/08

ITEM: 1520, 1540

CONTENTS 1.0

2.0

Page

Selection and Application 1.1 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1.3 Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1.4 Oxidizing media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1.5 Pulsation/Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1.6 Gauge fills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1.7 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Temperature 2.1 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 2.2 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 2.3 Steam service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 2.4 Hot or very cold media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 2.5 Diaphragm seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 2.6 Autoclaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.0

Installation 3.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3.2 Gauge reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3.3 Tightening of gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3.4 Process isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3.5 Surface mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3.6 Flush mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.0

Operation 4.1 Frequency of inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4.2 In-service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4.3 When to check accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4.4 When to recalibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4.5 Other considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 4.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

5.0

Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

6.0

Accuracy: Procedures/Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 6.1 Calibration - Rotary movement gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 6.2 Calibration - 1009 Duralife® Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 6.3 Positive Pressure Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15

3

ITEM: 1520, 1540

CONTENTS Page

7.0

Diaphragm Seals 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 7.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 7.5 Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

8.0

Dampening Devices 8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 8.2 Throttle Screws & Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 8.3 Ashcroft Gauge Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 8.4 Ashcroft Pulsation Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 8.5 Ashcroft Pressure Snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 8.6 Campbell Micro-Bean® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 8.7 Ashcroft Needle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 8.8 Chemiquip® Pressure Limiting Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

9.0

Resources 9.1 Training Videos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 9.2 Pressure Instrument Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 9.3 Tools & Tool Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Cover photo courtesy of Johnson/Yokogawa Co. Campbell Micro-Bean® is a registered trademark of J.A. Campbell Co. Chemiquip® is a registered trademark of Chemiquip Products Co. Inc.

4

ITEM: 1520, 1540

contain heavy particulates (slurries) or (c) are very viscous including those that harden at room temperature.

1.0 SELECTION & APPLICATION Users should become familiar with ASME B40.1 (Gauges – Pressure Indicating Dial Type – Elastic Element) before specifying pressure measuring instruments. That document – containing valuable information regarding gauge construction, accuracy, safety, selection and testing – may be ordered from:

1.4 Oxidizing media – Gauges for direct use on oxidizing media should be specially cleaned. Gauges for oxygen service should be ordered to variation X6B and will carry the ASME required dial marking “USE NO OIL” in red letters. Gauges for direct use on other oxidizing media may be ordered to variation X6W. They will be cleaned but carry no dial marking. Plus!® gauges or Halocarbon filled gauge or diaphragm fill is required for use with oxidizing media; order variation XCF.

ASME International Three Park Avenue New York, N.Y. 10016-5990 800-843-2763 (US/Canada) 95-800-843-2763 (Mexico) 973-882-1167 outside North America Email: [email protected]

1.5 Pulsation/Vibration – Pressure pulsation can be dampened by several mechanisms; the patented PLUS! Performance gauge will handle the vast majority of applications. One exception to this is high frequency pulsation which is difficult to detect. The only indication may be an upscale zero shift due to movement wear. These applications should be addressed with a liquid filled gauge, or in extreme cases, a remotely mounted liquid filled gauge connected with a length of capillary line. The small diameter of the capillary provides excellent dampening, but can be plugged. The Ashcroft 1106 pulsation dampener and 112 snubber are auxiliary devices which dampen pulsation with less tendency to plug.

WARNING: To prevent misapplication, pressure gauges should be selected considering media and ambient operating conditions. Improper application can be detrimental to the gauge, causing failure and possible personal injury, property damage or death. The information contained in this manual is offered as a guide in making the proper selection of a pressure gauge. Additional information is available from Ashcroft Inc. The following is a highlight of some of the more important considerations: 1.1 Range – The range of the instrument should be approximately twice the maximum operating pressure. Too low a range may result in (a) low fatigue life of the elastic element due to high operating stress and (b) susceptibility to overpressure set due to pressure transients that exceed the normal operating pressure. Too high a range may yield insufficient resolution for the application.

1.6 Gauge fills. – Once it has been determined that a liquid filled gauge is in order, the next step is selecting the type of fill. Glycerin satisfies most applications. While being the least expensive fill, its usable temperature range is 20/250°F. Silicone filled gauges have a broader service range: –40/250°F. Oxidizing media require the use of Halocarbon, with a service range of –50/250°F. Pointer motion will be slowed at the low end of the low end of these temperature ranges.

1.2 Temperature – Refer to page 6 of this manual for important information concerning temperature related limitations of pressure gauges, both dry and liquid filled.

1.7 Mounting – Users should predetermine how the gauge will be mounted in service: stem (pipe), wall (surface) or panel (flush). Ashcroft wall or panel mounting kits should be ordered with the gauge. See paragraph 3 Installation.

1.3 Media – The material of the process sensing element must be compatible with the process media. Use of a dia-phragm seal with the gauge is recommended for process media that (a) are corrosive to the process sensing element; (b)

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2.3 Steam service – In order to prevent live steam from entering the Bourdon tube, a siphon filled with water should be installed between the gauge and the process line. Siphons can be supplied with ratings up to 4,000 psi. If freezing of the condensate in the loop of the siphon is a possibility, a diaphragm seal should be used to isolate the gauge from the process steam. Siphons should also be used whenever condensing, hot vapors (not just steam) are present. Super heated steam should have enough piping or capillary line ahead of the siphon to maintain liquid water in the siphon loop.

2.0 TEMPERATURE 2.1 Ambient Temperature – To ensure long life and accuracy, pressure gauges should preferably be used at an ambient temperature between –20 and +150F (–30 to +65C). At very low temperatures, standard gauges may exhibit slow pointer response. Above 150F, the accuracy will be affected by approximately 1.5% per 100F. Other than discoloration of the dial and hardening of the gasketing, non-liquid filled type 1279 (phenolic case) and 1379 (aluminum case) Duragauge®, with standard glass windows, and Duralife® gauges types 1008 and 1009, can withstand continuous operating temperatures up to 250F. Liquid filled gauges can withstand 200F but glycerin fill and the acrylic window of Duragauge® gauges will tend to yellow. Silicone fill will have much less tendency to yellow. Low pressure, liquid filled types 1008 and 1009 gauges may have some downscale errors caused by liquid fill expansion. This can be alleviated by “burping” the gauge by gently pushing the top fill plug to one side to admit air to the case.

2.4 Hot or very cold media – A five foot capillary line assembly will bring most hot or cold process media within the recommended gauge ambient temperature range. For media above 750F (400C) the customer should use his own small diameter piping to avoid possible corrosion of the stainless steel. The five foot capillary will protect the gauges used on the common cryogenic (less than –300F (200C) gases, liquid argon, nitrogen, and oxygen. The capillary and gauge must be cleaned for oxygen service. The media must not be corrosive to stainless steel, and must not plug the small bore of the capillary.

Although the gauge may be destroyed and calibration lost, gauges can withstand short times at the following temperatures: gauges with all welded pressure boundary joints, 750F (400C); gauges with silver brazed joints, 450F (232C) and gauges with soft soldered joints, 250F (121C). For expected long term service below –20F (–30C) Duragauge® and 41⁄2˝ 1009 gauges should be hermetically sealed and specially lubricated; add “H” to the product code for hermetic sealing. Add variation XVY for special lubricant. Standard Duralife gauges may be used to –50F (–45C) without modification.

2.5 Diaphragm seals – As mentioned above, a diaphragm seal should be used to protect gauges from corrosive media, or media that will plug the instrument. Diaphragm seals are offered in a wide variety of designs and corrosion resistant materials to accommodate almost any application and most connections. Request bulletin OH-1 for details. 2.6 Autoclaving – Sanitary gauges with clamp type connections are frequently steam sterilized in an autoclave. Gauges equipped with polysulfone windows will withstand more autoclave cycles than those equipped with polycarbonate windows. Gauges equipped with plain glass or laminated safety glass should not be autoclaved. Gauge cases should be vented to atmosphere (removing the rubber fill/safety plug if necessary) before autoclaving to prevent the plastic window from cracking or excessively distorting. If the gauge is liquid filled, the fill should

2.2 Accuracy – Heat and cold affect accuracy of indication. A general rule of thumb for dry gauges is 0.5% of full scale change for every 40°F change from 75°F. Double that allowance for gauges with hermetically sealed or liquid filled cases, except for Duragauge® gauges where no extra allowance is required due to the elastomeric, compensating back. Above 250°F there may exist very significant errors in indication. 6

ITEM: 1520, 1540

mounting. Gauges should be kept free of piping strains. The gauge case mounting feet, if applicable, will ensure clearance between the pressure relieving back and the mounting surface.

also be drained from the case and the front ring loosened before autoclaving.

3.0 INSTALLATION

3.6 Flush mounting – Also known as panel mounting. The applicable panel mounting cutout dimensions can be found at www.ashcroft.com

3.1 Location – Whenever possible, gauges should be located to minimize the effects of vibration, extreme ambient temperatures and moisture. Dry locations away from very high thermal sources (ovens, boilers etc.) are preferred. If the mechanical vibration level is extreme, the gauge should be remotely located (usually on a wall) and connected to the pressure source via flexible tubing.

4.0 OPERATION 4.1 Frequency of inspection – This is quite subjective and depends upon the severity of the service and how critical the accuracy of the indicated pressure is. For example, a monthly inspection frequency may be in order for critical, severe service applications. Annual inspections, or even less frequent schedules, are often employed in non-critical applications.

3.2 Gauge reuse – ASME B40.1 recommends that gauges not be moved indiscriminately from one application to another. The cumulative number of pressure cycles on an in-service or previously used gauge is generally unknown, so it is generally safer to install a new gauge whenever and wherever possible. This will also minimize the possibility of a reaction with previous media.

4.2 In-service inspection – If the accuracy of the gauge cannot be checked in place, the user can at least look for (a) erratic or random pointer motion; (b) readings that are suspect – especially indications of pressure when the user believes the true pressure is 0 psig. Any gauge which is obviously not working or indicating erroneously, should be immediately valved-off or removed from service to avoid a possible pressure boundary failure.

3.3 Tightening of gauge – Torque should never be applied to the gauge case. Instead, an open end or adjustable wrench should always be used on the wrench flats of the gauge socket to tighten the gauge into the fitting or pipe. NPT threads require the use of a suitable thread sealant, such as pipe dope or teflon tape, and must be tightened very securely to ensure a leak tight seal.

4.3 When to check accuracy – Obviously any suspicious behavior of the gauge pointer warrants a full accuracy check be performed. Even if the gauge is not showing any symptoms of abnormal performance, the user may want to establish a frequency of bench type inspection.

CAUTION: Torque applied to a diaphragm seal or its attached gauge, that tends to loosen one relative to the other, can cause loss of fill and subsequent inaccurate readings. Always apply torque only to the wrench flats on the lower seal housing when installing filled, diaphragm seal assemblies or removing same from process lines.

4.4 When to recalibrate – This depends on the criticality of the application. If the accuracy of a 3-2-3% commercial type gauge is only 0.5% beyond specification, the user must decide whether it’s worth the time and expense to bring the gauge back into specification. Conversely if the accuracy of a 0.25% test gauge is found to be 0.1% out of specification then obviously the gauge should be recalibrated.

3.4 Process isolation – A shut-off valve should be installed between the gauge and the process in order to be able to isolate the gauge for inspection or replacement without shutting down the process. 3.5 Surface mounting – Also known as wall 7

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4.5 Other considerations – These include (a) bent or unattached pointers due to extreme pressure pulsation; (b) broken windows which should be replaced to keep dirt out of the internals; (c) leakage of gauge fill; (d) case damage – dents and/or cracks; (e) any signs of service media leakage through the gauge including its connection; (f) discoloration of gauge fill that impedes readability.

f.

Gauges showing significant friction error and/or wear of the movement and linkage.

g. Gauges having damaged sockets, especially damaged threads. h. Liquid filled gauges showing loss of case fill. NOTE: ASME B40.1 does not recommend moving gauges from one application to another. This policy is prudent in that it encourages the user to procure a new gauge, properly tailored by specification, to each application that arises.

4.6 Spare parts – As a general rule it is recommended that the user maintain in his parts inventory one complete Ashcroft® instrument for every ten (or fraction thereof) of that instrument type in service.

6.0 ACCURACY: PROCEDURES/DEFINITIONS

5.0 GAUGE REPLACEMENT

Accuracy inspection – Readings at approximately five points equally spaced over the dial should be taken, both upscale and downscale, before and after lightly rapping the gauge to remove friction. A pressure standard with accuracy at least 4 times greater than the accuracy of the gauge being tested is recommended.

It is recommended that the user stock one complete Ashcroft® instrument for every ten (or fraction thereof) of that instrument type in service. With regard to gauges having a service history, consideration should be given to discarding rather than repairing them. Gauges in this category include the following: a. Gauges that exhibit a span shift greater than 10%. It is possible the Bourdon tube has suffered thinning of its walls by corrosion.

Equipment – A finely regulated pressure supply will be required. It is critical that the piping system associated with the test setup be leaktight. The gauge under test should be positioned as it will be in service to eliminate positional errors due to gravity.

b. Gauges that exhibit a zero shift greater than 25%. It is likely the Bourdon tube has seen significant overpressure leaving residual stresses that may be detrimental to the application.

Method – ASME B40.1 recommends that known pressure (based on the reading from the pressure standard used) be applied to the gauge under test. Readings including any error from the nominal input pressure, are then taken from the gauge under test. The practice of aligning the pointer of the gauge under test with a dial graduation and then reading the error from the master gauge (“reverse reading”) can result in inconsistent and misleading data and should NOT be used.

c. Gauges which have accumulated over 1,000,000 pressure cycles with significant pointer excursion. d. Gauges showing any signs of corrosion and/or leakage of the pressure system. e. Gauges which have been exposed to high temperature or simply exhibit signs of having been exposed to high temperature – specifically 250°F or greater for soft soldered systems; 450°F or greater for brazed systems; and 750°F or greater for welded systems.

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ITEM: 1520, 1540

Calibration chart – After recording all of the readings it is necessary to calculate the errors associated with each test point using the following formula: ERROR in percent = 100 times (TRUE VALUE minus READING) ÷ RANGE. Plotting the individual errors (Figure 1 on page 10) makes it possible to visualize the total gauge characteristic. The plot should contain all four curves: upscale – before rap; upscale – after rap; downscale – before rap; downscale – after rap. Rap means lightly tapping the gauge before reading to remove friction as described in ASME B40.1.

intermediate points if the response of the gauge as seen in Figure 1 on page 10 is not linear. The Ashcroft Duragauge® pressure gauge is equipped with a rotary movement feature which permits the user to minimize this class of error. Other Ashcroft gauge designs (e.g., 1009 Duralife®) require that the dial be moved left or right prior to tightening the dial screws. Hysteresis – Some Bourdon tubes have a material property known as hysteresis. This material characteristic results in differences between the upscale and downscale curves. This class of error can not be eliminated by adjusting the gauge movement or dial position.

Referring to Figure 1 on page 10, several classes of error may be seen: Zero – An error which is approximately equal over the entire scale. This error can be manifested when either the gauge is dropped or overpressured and the bourdon tube takes a permanent set. This error may often be corrected by simply repositioning the pointer. Except for test gauges, it is recommended that the pointer be set at midscale pressure to “split” the errors.

Friction – This error is defined as the difference in readings before and after lightly tapping the gauge case at a check point. Possible causes of friction are burrs or foreign material in the movement gearing, “bound” linkages between the movement and the bourdon tube, or an improperly tensioned hairspring. If correcting these potential causes of friction does not eliminate excessive friction error, the movement should be replaced.

Span – A span error exists when the error at full scale pressure is different from the error at zero pressure. This error is often proportional to the applied pressure. Most Ashcroft gauges are equipped with an internal, adjusting mechanism with which the user can correct any span errors which have developed in service.

(Continued on page 10)

Linearity – A gauge that has been properly spanned can still be out of specification at

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ITEM: 1520, 1540

TYPICAL CALIBRATION CHART INDICATED VALUE (PSI) True Value – PSI

Increasing – Without RAP

Increasing – With RAP

Decreasing – Without RAP

Decreasing – With RAP

0 40 80 120 160 200

–.4 +.8 +.4 –.4 –.8 +.4

0 +1.0 +.5 –1.0 –.5 +.8

–.4 +1.4 +1.2 +.8 +.6 +.4

0 +1.1 +1.0 +.6 +.4 +.4

ERROR (% OF FULL SCALE) True Value – % of Range

Increasing – Without RAP

Increasing – With RAP

Decreasing – Without RAP

Decreasing – With RAP

0 20 40 60 80 100

–.20 +.40 +.20 –.20 –.40 +.20

0 +.50 +.25 –.05 –.25 +.40

–.20 +.70 +.60 +.40 +.30 +.20

0 +.55 +.50 +.30 +.20 +.20

1.0

Fig. 1 ◆ ◆ ■ ●

0.5

■

Error (% of Full Scale)

▲

●

◆ ■ ● ▲

◆ ■

0.0 ●

▲

● ▲

▲

● ▲

–0.5

▲

▲ upscale – without rap

●

● upscale – with rap

◆ ■

◆ downscale – without rap ■ downscale – with rap

–1.0 0

20

40

60 % of Range

10

80

100

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6.1 Calibration – Rotary Movement Gauges – Inspect gauge for accuracy. Many times gauges are simply “off zero” and a simple pointer adjustment using the micrometer pointer is adequate. If inspection shows the gauge warrants recalibration to correct span and/or linearity errors, proceed as follows:

movement should be rotated counter clockwise. Rotating the movement one degree will change this error by approximately 0.25%. Rotating the movement often affects span and it should be subsequently rechecked and readjusted if necessary according to step 6.1e and 6.1f.

a. Remove ring, window and, if solid front case, the rear closure assembly.

h. While recalibrating the gauge, the friction error – difference in readings taken with and without rap – should be noted. This error should not exceed the basic accuracy of the gauge. If the friction error is excessive, the movement should be replaced. One possible cause of excessive friction is improper adjustment of the hairspring. The hairspring torque,or tension, must be adequate without being excessive. The hairspring should also be level, unwind evenly (no turns rubbing) and it should never tangle.

b. Pressurize the gauge once to full scale and back to zero. c. Refer to Figure 2 on page 8 for a view of a typical Ashcroft system assembly with component parts identified. d. For solid front gauges, adjust the micrometer pointer so that it rests at the true zero position. For open front gauges the pointer and dial must also be disassembled and the pointer should then be lightly pressed onto the pinion at the 9:00 o’clock position.

NOTES: 1 For operation of test gauge external zero reset, refer to Figure 3 on page 12. 2 For test gauge calibration procedure, refer to Figure 4 on page 13.

e. Apply full scale pressure and note the magnitude of the span error. With open front gauges, ideal span (270 degrees) will exist when at full scale pressure the pointer rests exactly at the 6:00 o’clock position.

6.2 Calibration – 1009 Duralife® Gauge – Inspect gauge for accuracy. Many times gauges are simply “off zero” and a simple pointer adjustment using the adjustable pointer is adequate. If the inspection shows that the gauge warrants recalibration to correct span and/or linearity errors, proceed as follows:

f. If the span has shifted significantly (span error greater than 10%), the gauge should be replaced because there may be some partial corrosion inside the bourdon tube which could lead to ultimate failure. If the span error exceeds 0.25%, loosen the lower link screw and move the lower end of the link toward the movement to increase span or away to decrease span. An adjustment of 0.004 inch will change the span by approximately 1%. This is a repetitive procedure which often requires more than one adjustment of the link position and the subsequent rechecking of the errors at zero and full scale pressure.

Remove ring, window, gasket and pointer using Ashcroft tool kits 1205T and 1206T. 6.3 Positive Pressure Ranges – a. Remove dial and lightly press pointer onto pinion at 9:00 o’clock position. b. Apply full scale pressure and rotate span block as shown in Figure 5a on page 15 until pointer rests at 6:00 o’clock position.

g. Apply midscale pressure and note error in reading. Even though the gauge is accurate at zero and full scale, it may be inaccurate at the midpoint. This is called linearity error and is minimized by rotating the movement. If the error is positive, the

c. Fully exhaust pressure and check that pointer still is at 9:00 o’clock position. If not repeat steps 1 and 2 until span is correct. (Continued on page 10)

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ITEM: 1520, 1540

ASHCROFT SYSTEM ASSEMBLY

Fig. 2

BOURDON TUBE

SEGMENT TIP

HAIRSPRING PINION

LINK

ROTARY MOVEMENT

BACKPLATE

SOCKET

TYPE 1082 EXTERNAL ZERO ADJUST FEATURE*

Fig. 3

B A

INSTRUCTIONS FOR USE: LOOSEN RING LOCKING SCREW “A’’ OBTAIN REQUIRED ADJUSTMENT BY ROTATING KNOB “B’’ CLOCKWISE OR COUNTER-CLOCKWISE. TIGHTEN SCREW “A’’ DOWN ON KNOB “B.’’

*Applicable only for test gauge with hinged ring design. 12

RING

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Fig. 4

TYPE 1082 TEST GAUGE CALIBRATION PROCEDURE

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d. Remove pointer and reassemble dial and dial screws (finger tight).

h. Repeat steps 4 through 8 until span is correct.

e. Lightly press pointer onto pinion.

i. Remove the pointer.

f. Check accuracy at full scale. If error exceeds 1% return to step 1, otherwise proceed.

j. With 25 inches of Hg vacuum applied, reassemble dial, dial screws (finger tight) and pointer.

g. Check accuracy at midscale. If error exceeds 1% slide dial left or right to compensate.

k. Apply 15 inches of Hg vacuum and note accuracy of indication. If required, slide dial left or right to reduce error to 1% maximum.

h. Continue at * below. Vacuum range –

l. Continue at * below.

a. Using a pencil, refer to dial and mark the 0 and 25 inch of Hg positions on the case flange.

*Now complete calibration of the gauge as follows: a. Firmly tighten dial screws.

b. Remove the dial.

b. Firmly tap pointer onto pinion, using brass back-up tool from Ashcroft kit 1205T if gauge has rear blow-out plug. If gauge has top fill hole no back-up is required.

c. Apply 25 inches of Hg vacuum. d. Lightly press pointer onto pinion carefully aligning it with the 25 inch of Hg vacuum mark on case flange.

c. Recheck accuracy at zero, midscale and full scale points (Figures 5a & 5b on page 15).

e. Release vacuum fully.

d. Reassemble window, gasket and ring.

f. Note agreement of pointer to zero mark on case flange. g. If span is high or low, turn span block as shown in Figure 5b on page 15.

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1009 DURALIFE® PRESSURE GAUGE CALIBRATION

V

25

s

15

ITEM: 1520, 1540

filled prior to being placed in service. Ashcroft diaphragm seal assemblies should only be filled by a seal assembler certified by Ashcroft Inc. Refer to section 3.3 for a cautionary note about not applying torque on either the instrument or seal relative to the other.

7.0 DIAPHRAGM SEALS 7.1 General – A diaphragm seal (isolator) is a device which is attached to the inlet connection of a pressure instrument to isolate its measuring element from the process media. The space between the diaphragm and the instrument’s pressure sensing element is solidly filled with a suitable liquid. Displacement of the liquid fill in the pressure element, through movement of the diaphragm, transmits process pressure changes directly to a gauge, switch or any other pressure instrument. When diaphragm seals are used with pressure gauges, an additional 0.5% tolerance must be added to the gauge accuracy because of the diaphragm spring rate.

7.3 Operation – All Ashcroft® diaphragm seals, with the exception of Type 310 miniseals, are continuous duty. Should the pressure instrument fail, or be removed accidentally or deliberately, the diaphragm will seat against a matching surface preventing damage to the diaphragm or leakage of the process fluid. 7.4 Maintenance – Clamp type diaphragm seals – Types 100, 200 and 300 – allow for replacement of the diaphragm or diaphragm capsule, if that ever becomes necessary. The Type 200 top housing must also be replaced with the diaphragm. With all three types the clamping arrangement allows field disassembly to permit cleaning of the seal interior.

Used in a variety of process applications where corrosives, slurries or viscous fluids may be encountered, the diaphragm seal affords protection to the instrument where: • The process fluid being measured would normally clog the pressure element.

7.5 Failures – Diaphragm failures are generally caused by either corrosion, high temperatures or fill leakage. Process media build-up on the process side of the diaphragm can also require seal cleaning or replacement. Consult Customer Service, Stratford CT for advice on seal failures and/or replacement.

• Pressure element materials capable of withstanding corrosive effects of certain fluids are not available. • The process fluid might freeze due to changes in ambient temperature and damage the element.

WARNING: All seal components should be selected considering process and ambient operating conditions to prevent misapplication. Improper application could result in failure, possible personal injury, property damage or death.

7.2 Installation – Refer to sales bulletin OH-1 for information regarding (a) seal configurations; (b) filling fluids; (c) temperature range of filling fluids; (d) diaphragm material pressure and temperature limits; (e) bottom housing material pressure and temperature limits; (f) pressure rating of seal assembly; (g) accuracy/temperature errors of seal assembly; (h) diaphragm seal displacement. The volumetric displacement of the diaphragm must at least equal the volumetric displacement of the measuring element in the pressure instrument to which the seal is to be attached.

8.0 DAMPENING DEVICES 8.1 General – Some type of dampening device should be used whenever the pressure gauge may be exposed to repetitive pressure fluctuations that are fairly rapid, high in magnitude and especially when transitory pressure spikes exceeding the gauge range are present (as with starting and stopping action of valves and pumps). A restricted orifice of some kind is employed through which pressure fluctua-

It is imperative that the pressure instrument/diaphragm seal assembly be properly

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ITEM: 1520, 1540

8.4 Ashcroft Pulsation Dampener – Type 1106 Ashcroft pulsation dampener is a moving pin type in which the restricted orifice is the clearance between the pin and any one of five preselected hole diameters. Unlike a simple throttle screw/plug, this device has a selfcleaning action in that the pin moves up and down under the influence of pressure fluctuations.

tions must pass before they reach the bourdon tube. The dampener reduces the magnitude of the pressure pulse thus extending the life of the Bourdon tube and movement. This reduction of the pressure pulsation as “seen” by the pressure gauge is generally evidenced by a reduction in the pointer travel. If the orifice is very small the pointer may indicate the average service pressure, with little or no indication of the time varying component of the process pressure.

8.5 Ashcroft Pressure Snubber – The heart of the Type 1112 pressure snubber is a thick porous metal filter disc. The disc is available in four standard porosity grades.

Commonly encountered media (e.g. – water and hydraulic oil) often carry impurities which can plug the orifice over time thus rendering the gauge inoperative until the dampener is cleaned or replaced.

8.6 Campbell Micro-Bean® – Type 1110 Micro-Bean is a precision, stainless steel, needle valve instantly adjustable to changing conditions of flow and viscosity. A very slight taper on the valve stem fits into tapered hole in the body. The degree of dampening is easily adjusted by turning the valve handle. A filter is built into the Micro-Bean to help prevent plugging.

Highly viscous media and media that tend to periodically harden (e.g., asphalt) require a diaphragm seal be fitted to the gauge. The seal contains an internal orifice which dampens the pressure fluctuation within the fill fluid.

8.7 Ashcroft Needle Valves – Type 7001 thru 7004 steel needle valves provide varying degrees of dampening similar to the Campbell Micro-Bean but with a less precise and less costly adjustability. Like the Micro-Bean these devices, in the event of plugging, can easily be opened to allow the pressure fluid to clear away the obstruction.

8.2 Throttle Screws & Plugs – These accessories provide dampening for the least cost. They have the advantage of fitting completely within the gauge socket and come in three types: (a) a screwed-in type which permits easy removal for cleaning or replacement; (b) a pressed in, non-threaded design and (c) a pressed in, threaded design which provides a highly restrictive, helical flow path. Not all styles are available on all gauge types.

8.8 Chemiquip® Pressure Limiting Valves – Model PLV-255, PLV-2550, PLV-5460, PLV5500 and PLV-6430, available with and without built-in snubbers, automatically “shut off” at adjustable preset values of pressure to protect the gauge from damage to overpressure. They are especially useful on hydraulic systems wherein hydraulic transients (spikes) are common.

8.3 Ashcroft Gauge Saver – Type 1073 Ashcroft gauge saver features an elastomeric bulb that fully isolates the process media from the bourdon tube. In addition to providing dampening of pressure pulses, the bourdon tube is protected from plugging and corrosion. The space between the bulb and bourdon tube is completely filled with glycerin. Felt plugs located between the bulb and bourdon tube are first compressed some amount to restrict the flow of glycerin through an orifice and thus provide a degree of dampening. The greater the compression of the felts the greater the degree of dampening.

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ITEM: 1520, 1540

9.0 RESOURCES 9.1

Training Videos 9.1.1 Test gauge calibration 9.1.2 1009 Duralife® gauge calibration 9.1.3 Duragauge® gauge calibration 9.1.4 Diaphragm seal filling

9.2

Pressure Instrument Testing Equipment 9.2.1 Type 1305D Deadweight Tester 9.2.2 Type 1327D Pressure Gauge Comparator 9.2.3 Type 1327CM “Precision” Gauge Comparator

9.3

Tools & Tool Kits 9.3.1 Type 2505 universal carrying case for 1082 test gauge 9.3.2 Type 266A132-01 span wrench for 1082 test gauge 9.3.3 Type 1280 conversion kit for 41⁄2˝ lower connect 1279/1379 9.3.4 Type 1283 conversion kit for 41⁄2˝ back connect 1279/1379 9.3.5 Type 1284 conversion kit for 6˝ lower & back connect 9.3.6 Type 1281 socket O-Ring kit for 1279/1379 lower connect 9.3.7 Type 1285 41⁄2˝ ring wrench for 1279/1379 lower & back connect 9.3.8 Type 1286 6˝ ring wrench for 1379 lower & back connect 9.3.9 Type 1287 cone tool for installing diaphragm & spring on 1279/1379 back connect 9.3.10 Type 1105T calibration tool kit (all gauges except 1009 Duralife®) 9.3.11 Type 3220 pointer puller (all gauges except 1009 Duralife®) 9.3.12 Type. 3530 pinion back-up tool for 1009 Duralife® 9.3.13 Type 1230 throttle plug insertion (1⁄4 NPT) for 1009 Duralife® 9.3.14 Type 1231 throttle plug insertion (1⁄2 NPT) for 1009 Duralife® (body only) 9.3.15 Type 1205T calibration hand tools for 1009 Duralife® 9.3.16 Type 1206T ring removal & assembly tools for 1009 Duralife

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ITEM 1520

14

Duragauge® Pressure Gauge Type 1279, Grade 2A (±0.5%)

• Exclusive Teflon coated 400 series stainless steel rotary movement for longer life • Patented Duratube™ with “WeldedTube” construction controls stress for longer life • Exclusive “Round Cap Tip” construction lowers stresses for longer life • Easily adjustable, self-locking micrometer pointer • New PLUS!™ Performance Option: - Liquid-filled performance in a dry gauge - Fights vibration and pulsations without liquid-filled headaches - See page 174 for details - Order as option XLL

Type 1279 Duragauge® pressure gauge is offered in 41/2˝ phenolic case for superior chemical and heat resistance. Solid-front case design with blow-out back for safety. Dry, liquid-filled, hermetically sealed or PLUS! options available. Field convertible to liquid-fill with conversion kit (detailed on page 170). All case styles provide full temperature compensation.

STANDARD RANGES

BOURDON SYSTEM SELECTION Ordering Code

Bourdon Tube & Tip Material(1) (all joints TIG welded except “A”)

A

Grade A Phosphor Bronze Tube-Brass Tip, Silver Brazed

B

4130 alloy steel

R S P(3)

316L stainless steel 316L stainless steel K Monel

Socket Material

Tube Type

Range Selection Limits (psi)

Brass

C-Tube

12/1000

1

C-Tube

15/1500

1

Helical

2000/5000

1

C-Tube

12/1500

1

Helical

2000/20,000

1

C-Tube

12/1500

1

Helical

2000/20,000

1

C-Tube

15/1500

1

Helical

2000/30,000

1

1019 steel 1019 steel 316 stainless steel Monel 400

NPT Conn.(2) /4, 1⁄2 ⁄4,1⁄2, ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2(4)

(1) For selection of the correct bourdon system material, see the media application table on page 178. (2) Other connections available on application. (3) Use for applications where NACE standard MR-01-75 is specified. (4) 30,000 psi range supplied with 1⁄4 high pressure connection, 1⁄2 NPT optional.

Pressure psi

Compound psi

0/15 0/30 0/60 0/100 0/160 0/200 0/300 0/400 0/600 0/800 0/1000 0/1500 0/2000 0/3000 0/5000 0/10,000 0/20,000 0/30,000

30˝ Hg/15 psi 30˝ Hg/30 psi 30˝ Hg/60 psi 30˝ Hg/100 psi 30˝ Hg/150 psi 30˝ Hg/300 psi Vacuum 30/0 in.Hg 34/0 ftH2O

NOTE: Equivalent standard kg/cm2, and kPa metric ranges are available.

TO ORDER THIS 1279 DURAGAUGE: Select: 1. Dial size–41⁄2˝ 2. Case type–1279 Ring–threaded reinforced polypropylene 3. Bourdon system selection ordering code 4. Connection–1⁄4 NPT (02), 1⁄2 NPT (04), Lower (L), Back (B) 5. Optional features–see page 108 6. Standard pressure range 7. Accessories–see pages 165-171

Reference Bulletin DU-1 MADE IN U.S.A.

45

1279

RS*

04L

( ) “S” denotes solid front case design

*

Consult factory for guidance in product selection Phone (203) 378-8281, FAX (203) 385-0499 or visit our web site at www.ashcroft.com

XXX

0/2000 psi

ITEM 1540

14

Duragauge® Pressure Gauge Type 1279, Grade 2A (±0.5%)

• Exclusive Teflon coated 400 series stainless steel rotary movement for longer life • Patented Duratube™ with “WeldedTube” construction controls stress for longer life • Exclusive “Round Cap Tip” construction lowers stresses for longer life • Easily adjustable, self-locking micrometer pointer • New PLUS!™ Performance Option: - Liquid-filled performance in a dry gauge - Fights vibration and pulsations without liquid-filled headaches - See page 174 for details - Order as option XLL

Type 1279 Duragauge® pressure gauge is offered in 41/2˝ phenolic case for superior chemical and heat resistance. Solid-front case design with blow-out back for safety. Dry, liquid-filled, hermetically sealed or PLUS! options available. Field convertible to liquid-fill with conversion kit (detailed on page 170). All case styles provide full temperature compensation.

STANDARD RANGES

BOURDON SYSTEM SELECTION Ordering Code

Bourdon Tube & Tip Material(1) (all joints TIG welded except “A”)

A

Grade A Phosphor Bronze Tube-Brass Tip, Silver Brazed

B

4130 alloy steel

R S P(3)

316L stainless steel 316L stainless steel K Monel

Socket Material

Tube Type

Range Selection Limits (psi)

Brass

C-Tube

12/1000

1

C-Tube

15/1500

1

Helical

2000/5000

1

C-Tube

12/1500

1

Helical

2000/20,000

1

C-Tube

12/1500

1

Helical

2000/20,000

1

C-Tube

15/1500

1

Helical

2000/30,000

1

1019 steel 1019 steel 316 stainless steel Monel 400

NPT Conn.(2) /4, 1⁄2 ⁄4,1⁄2, ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2 ⁄4,1⁄2(4)

(1) For selection of the correct bourdon system material, see the media application table on page 178. (2) Other connections available on application. (3) Use for applications where NACE standard MR-01-75 is specified. (4) 30,000 psi range supplied with 1⁄4 high pressure connection, 1⁄2 NPT optional.

Pressure psi

Compound psi

0/15 0/30 0/60 0/100 0/160 0/200 0/300 0/400 0/600 0/800 0/1000 0/1500 0/2000 0/3000 0/5000 0/10,000 0/20,000 0/30,000

30˝ Hg/15 psi 30˝ Hg/30 psi 30˝ Hg/60 psi 30˝ Hg/100 psi 30˝ Hg/150 psi 30˝ Hg/300 psi Vacuum 30/0 in.Hg 34/0 ftH2O

NOTE: Equivalent standard kg/cm2, and kPa metric ranges are available.

TO ORDER THIS 1279 DURAGAUGE: Select: 1. Dial size–41⁄2˝ 2. Case type–1279 Ring–threaded reinforced polypropylene 3. Bourdon system selection ordering code 4. Connection–1⁄4 NPT (02), 1⁄2 NPT (04), Lower (L), Back (B) 5. Optional features–see page 108 6. Standard pressure range 7. Accessories–see pages 165-171

Reference Bulletin DU-1 MADE IN U.S.A.

45

1279

RS*

04L

( ) “S” denotes solid front case design

*

Consult factory for guidance in product selection Phone (203) 378-8281, FAX (203) 385-0499 or visit our web site at www.ashcroft.com

XXX

0/2000 psi

p212:Layout 6

7/9/09

8:28 AM

Page 1

Series 500

Sight Window Shows Level or Contents of Tanks, Pipelines; Tempered, Replaceable Glass Window Dimensions — Inches (mm)

Flow

Model A SFI-500-3/4 3/4 SFI-500-1 1 SFI-500-1-1/4 1-1/4 SFI-500-1-1/2 1-1/2 SFI-500-2 2

Tough, tempered glass window resists chemical attack and abrasion. Seamless gasket assures perfect seal and is easily field replaceable. In addition to the standard brass body, Model 500 Sight Windows are also available in carbon steel or 316 SS to suit a wide range of chemical compatibility.

Model 316 SS SFI-500SS-3/4 SFI-500SS-1 SFI-500SS-1-1/4 SFI-500SS-1-1/2 SFI-500SS-2

Model Brass SFI-500B-3/4 SFI-500B-1 SFI-500B-1-1/4 SFI-500B-1-1/2 SFI-500B-2

Series 550

D E C B 1-3/8 (35) 45/64 (18) 1-3/8 (35) 3/4 (19) 15/16 (24) 1-3/8 (35) 45/64 (18) 1-3/8 (35) 1-1/4 (32) 2-1/8 (54) 27/32 (22) 1-9/16 (40) 1-27/64 (37) 2-1/8 (54) 27/32 (22) 1-9/16 (40) 1-1/4 (32) 2-1/2 (64) 15/32 (12) 1-21/32(42)

SPECIFICATIONS Service: Compatible gases and liquids. Wetted Materials: Window: Tempered glass. Body: Brass, carbon steel, or 316 SS. Gasket: Buna-N on brass and carbon steel body, PTFE on 316 SS body. Temperature Limit: 200°F (93°C). Pressure Limit: 125 psig (8.6 bar). Connections: 3/4˝ to 2˝ male NPT.

Model Carbon Steel SFI-500CS-3/4 SFI-500CS-1 SFI-500CS-1-1/4 SFI-500CS-1-1/2 SFI-500CS-2

APPLICATIONS • Hydraulic Tanks • Pressure Vessels • Coolant Tanks

• Hydraulic Lines • Oil Reservoirs

Sight Window

ITEM 1820

Shows Level or Contents of Tanks, Pipelines; Fused Glass and Steel Construction Dimensions — Inches (mm) Model D C B A SFI-550-1/4 1/4 11/32 (9) 5/8 (16) 3/16 (5) SFI-550-3/8 3/8 7/16 (11) 3/4 (19) 7/32 (6) SFI-550-1/2 1/2 9/16 (14) 15/16 (24) 7/32 (6) SFI-550-3/4 3/4 3/4 (19) 1-1/16 (27) 5/16 (8) SFI-550-1 15/16 (24) 1-3/8 (35) 5/16 (8) 1 SFI-550-1-1/4 1-1/4 1-3/16 (30) 1-3/4 (45) 13/32 (10) SFI-550-1-1/2 1-1/2 1-7/16 (37) 2 (51) 13/32 (10) SFI-550-2 1-7/8 (48) 2-1/2 (64) 13/32 (10) 2

Fused glass style sight windows feature glass to metal bond for utmost reliability. Plated steel bodies have convenient hex wrench surfaces. Connections are standard NPT in sizes from 1/4" to 2". Windows are clear, ripple free, and flush with the front face, having no recess on which dirt might collect.

Model SFI-550-1/4 SFI-550-3/8 SFI-550-1/2 SFI-550-3/4

212

SPECIFICATIONS Service: Compatible gases and liquids. Wetted Materials: Window: Glass. Body: Plated steel. Temperature Limit: 200°F (93°C). Pressure Limit: 125 psig (8.6 bar). Connections: 1/4˝ to 2˝ male NPT.

Model SFI-550-1 SFI-550-1-1/4 SFI-550-1-1/2 SFI-550-2

VISIT OUR WEBSITES:

APPLICATIONS • Hydraulic Tanks • Pressure Vessels • Coolant Tanks www.dwyer-inst.com

•

www.dwyer-inst.co.uk

• Hydraulic Lines • Oil Reservoirs

•

www.dwyer-inst.com.au

E 5/8 (16) 23/32 (18) 25/32 (19) 15/16 (24) 1-1/16 (27) 1-7/32 (31) 1-7/32 (31) 1-9/32 (33)

ITEM 1910

SAGE THERMAL GAS MASS FLOW METER

Operations and Instruction Manual For General Purpose “Blind” Models SIL and SRL

Make the Wise Choice. Choose Sage Flow Meters.

SAGE METERING, INC. 8 Harris Court, D1 Monterey, CA 93940 1-866-677-SAGE (7243) Tel 831-242-2030 Fax 831-655-4965 www.sagemetering.com

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

3

ITEM 1910 Table of Contents Introduction

Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

SECTION A Getting Started

Unpacking Your Sage Meter . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Installation and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 In-line Flow Meter Application . . . . . . . . . . . . . . . . . . . . . . . . . 10 Locating Proper Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 11 Self-Powered 4-20 ma or User-Powered 4-20 ma . . . . . . . . . . . . . . . . 11 Sage Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Compression Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Probe Insertion Guideline Drawing. . . . . . . . . . . . . . . . . . . . . . . 13 Installation Depth Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Configuration for Utilizing Four Flow Meters for Large Round Pipes . . . . . 15 Terminal Hook-Up Series SIL, SRL (SIL NT Version) . . . . . . . . . . . . . . 16 Circuit Board Wiring for General Purpose NT Style Meter . . . . . . . . . . . 17 Junction Box Wiring Terminals for Remote Style Meters . . . . . . . . . . . 18 Cable Connector Diagram for AC Powered General Purpose Sage Lite (SIL or SRL) Meters. . . . . . . . . . . . . . . . . . . . . . . . . 19 SECTION B Theory / Styles / Specifications

Sage Thermal Mass Flow Meters . . . . . . . . . . . . . . . . . . . . . . . . 23 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Basic General Purpose (Blind) Sage Flow Meter Styles . . . . . . . . . . . . . 24

SECTION C Drawing

SIL Series Integral Style Lite (Blind) General Purpose Mass Flow Meters . . . 27 SRL Series Remote Style Lite (Blind) General Purpose Mass Flow Meters . . . 28 SIL Series Integrated Style Lite (Blind) Optional Explosion Proof Mass Flow Meters (XP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SRL Series Integrated Style Lite (Blind) Optional Explosion Proof Mass Flow Meters (XP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mounting Hardware: SVA Series Isolation Valve Assembly for Insertion Meters . . . . . . . . . 31 Wall Mounting Procedure for Remote General Purpose Enclosure . . . . . . 32 Flanged Ends for In-Line Meter (Optional) . . . . . . . . . . . . . . . . . . . 33 Flow Conditioning Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 General Purpose Probe and Transmitter Head Assembly Procedure . . . . . . 34 continued on next page

REV. 02-SIL/SRL

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SAGE METERING, INC.

Operations and Instruction Manual

ITEM 1910

SECTION D User Interface

Sensor Functionality and Zero Calibration Self Check . . . . . . . . . . . . . 37 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Pulsed Outputs on SIL NT . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SILCOM Interface Cable Instructions. . . . . . . . . . . . . . . . . . . . . . 40

SECTION E Diagnostics

Common Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SECTION F Warranties and Service Work

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Cancellation/Return Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Returning Your Sage Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . 51 Return Material Authorization Form . . . . . . . . . . . . . . . . . . . . . . 52

SECTION G Appendix

Junction Box and Upstream Orientation . . . . . . . . . . . . . . . . . . . . 55 Captive Flow Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 What Is a Thermal Mass Flow Meter? . . . . . . . . . . . . . . . . . . . . . 57

REV. 02-SIL/SRL

Operations and Instruction Manual

SAGE METERING, INC.

5

ITEM 1910 Welcome We are pleased that you have purchased a Sage Metering Mass Flow Meter for your requirement. We hope that you are satisfied with the performance, operation and design of our highly precise, NIST traceable Thermal Gas Mass Flow Meter. The innovative Sage design (whether configured as an In-Line or Insertion Flow Meter) provides high accuracy and repeatability for optimum measurement and control of your process and provides a 4-20 ma output (isolated [user powered], or ground based) of flow rate as well as a 0-5 VDC output of temperature. Alternately, the meter can be offered with pulsed outputs of totalized flow (in lieu of flow rate and temperature outputs). For even greater flexibility, specify SILCOM, and you will be provided with an interconnect cable and software for user configurability via a laptop (change Full Scale, Filtering, Output Configuration, etc.). If a display of flow rate and total is required, please contact Sage for assistance in selecting other Sage products and styles. Sage Meters measure mass flow directly — there is no need for ancillary instrumentation such as temperature or pressure transmitters. Furthermore, our instruments have exceptional signal sensitivity, have no moving parts, require little if any maintenance, have negligible pressure drop and have a rangeability as high as 1000 to 1. Sage Flow Meters can measure and control the mass flow rate and consumption of air, oxygen, natural gas, nitrogen, digester gas, biogas, flare gas, hydrogen, argon, carbon dioxide and other gases and gas mixes. We anticipate that our Flow Meter will provide you with the means to increase productivity, reduce energy costs, and/or improve product yields. Please let us know if we can assist you in any way with your Sage Meter, or if you have any questions about its installation, operation, or features. Simply phone us at 866-677-SAGE (7243), or visit our website at www.sagemetering.com to contact a factory representative in your area. (To access this manual on the website, enter in passcode 7243737 when prompted.) Sincerely,

Robert Steinberg President

REV. 02-SIL/SRL

ITEM 1910

ITEM 1910

Section A GETTING STARTED

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

9

ITEM 1910 Getting Started UNPACKING YOUR SAGE METER

POWER SUPPLY PRIOR TO ANY CLEANING OR MAINTENANCE. A simple blast of compressed air

Your Sage flow meter is a sensitive, yet rugged,

may be sufficient; or a detergent or appropriate

precision built electronic instrument. Upon delivery,

non-corrosive solvent for removing the buildup

care should be taken when opening the shipping

may be required. A soft brush can be used to gently

container and removing your meter. The meter

clean the sensing element’s surface, using caution

should be inspected for any damage that may have

to avoid damaging the RTDs. If any disassembly is

occurred during transit. If damage is found, please

necessary, contact Sage Metering, Inc. for instruc-

contact the carrier immediately to place a claim for

tions. In general, it is recommended that your

damaged goods. The contents of the container

Sage Thermal Mass Flow Meter be returned to

should be checked against the packing list for any

the factory if cleaning, repair, or recalibration is

discrepancies. If there are any questions as to the

needed. This is usually the most cost-effective

contents or configuration of the equipment includ-

and reliable alternative.

ing calibration ranges, or mounting hardware, contact Sage Metering as soon as possible. Please

CALIBRATION

save shipping container and packaging materials (including PVC tube probe protector on Sage

Sage thermal mass flow meters have built-in diag-

Insertion Flow Meters) in case the unit needs to

nostics. The menuing system (accessible if you

be returned for any reason.

purchased the SILCOM Cable/Assembly) has provisions to check the sensor’s operation by accessing the sensor’s output and comparing it to the original

MAINTENANCE

reported “zero flow” value noted on the next to last Sage thermal mass flow meters essentially require

line of your meter’s Certificate of Conformance. This

little or no maintenance. While the sensing element

method helps validate the meter’s performance, and

is somewhat resistant to dirt and particulate build

depending on your company’s quality control pro-

up, it may become necessary to clean it from time to

cedures, may eliminate, or at least postpone the

time if mounted in extremely dirty environments.

need for annual factory calibrations. See “Sensor

NOTE: ALWAYS DISABLE THE TRANSMITTER

Functionality and Zero Calibration Self Check” on page 37.

a

CAUTION cable glands shipped with unit are for shipping purposes only. Remove shipping cable glands before installing.

REV. 02-SIL/SRL

10

SAGE METERING, INC.

Operations and Instruction Manual

ITEM 1910

INSTALLATION AND MOUNTING

Transmitter (Probe or Flow Body). There will be Metal Serial Number Tags on both ends. Do not

■

Check the Certificate of Conformance included

mismatch the serial numbers of the Remote

with your Sage Thermal Mass Flow Meter for

Electronics and the Transmitter, or calibration

system pressure, temperature, gas composition,

errors will occur.

power input, and signal output. ■

Check the installation. Choose the longest

IN-LINE FLOW METER APPLICATION

straight-run section of pipe available to allow a uniform, well-developed flow profile. Allow for

In-line mounting styles are available through Sage

a minimum ten (10) diameters (15 preferred)

Metering, Inc. in sizes from 1/4" pipe through 4"

straight-run upstream of the sensors and five (5)

pipe. Threaded male NPT ends are standard up to

diameters straight-run downstream of the sensors.

2-1/2"; ANSI 150lb flanged ends are standard for 3"

Avoid, if possible, installations immediately down-

and 4" models. Contact the factory if optional end

stream of bends, fans, nozzles, heaters, or anything

mounting styles are required. Pipe sizes in excess

else installed in the line that may cause non-

of 4" require the insertion style mass flow meter.

uniform flow profiles and swirls which can result

■

in signal output errors (refer to “Probe Insertion

The In-line style flow meter assembly flow section is

Guideline Drawing” on page 13). If insufficient

typically specified to match the user’s flow conduit

straight run, consider Sage Captive Flow

and is plumbed directly in the flow line by thread-

Conditioners (see Appendix).

ing, flanging, welding, etc. DO NOT USE REDUCERS.

Check the orientation: Standard calibration flow direction is left to right when facing the flow meter. Gas flow direction is marked with an arrow on In-line flow meters; UPSTREAM is marked on insertion probes.

■

It includes the sensing element (a self-heated flow sensor and a temperature/reference sensor) mounted directly in the specified flow section for exposure to the process gas; a sensor drive circuit; microprocessor meter board, and transmitter enclosure.

Hook up the system per the wiring diagram pro-

5.00

vided with your Sage flow meter. Double check that wiring for the proper power and signal con-

5.00

nections are correct. ■

Check that all plumbing and electrical hook-ups

B

are in accordance with OSHA, NFPA, and all other safety requirements. ■

For Remote Style Meter (SRL), be sure that the Remote Electronics is matched with the

REV. 02-SIL/SRL

2.55

L

Operations and Instruction Manual

SAGE METERING, INC.

11

ITEM 1910

LOCATING PROPER WIRING DIAGRAM

SAGE VALVE ASSEMBLY OPERATION

1) Look at the sticker on your meter. The first three digits describe the basic model that you have. Refer to the appropriate page numbers below for your wiring diagram

Valve assemblies (SVA05) are an optional mounting hardware available through Sage Metering Inc. They allow the removal of insertion style meters for service, cleaning, re-calibration, relocation, etc. without the need to "shut-down" your process. The probe insertion depth is adjustable to permit sensor to be located at center to optimize measurement accuracy. (Refer to PROBE INSERTION GUIDELINE DRAWING and CHART.) The ball valve will seal off leaks of the process gas at the point of insertion after the probe assembly has been removed. The assembly includes a valve, threadolet, compression fitting with Teflon ferrule, a cable restraint, and a collar clamp.

2) SIL: See page 16 3) SRL: See page 16 for input/output terminals; see page 18 (Junction Box Wiring Terminals for Remote Style Meters)

SELF-POWERED 4-20 ma or USER POWERED 4-20 ma Please note, Sage Meters are not loop powered. The 4-20 ma outputs can be Self-Powered or UserPowered. All Sage Meters ship set up for Self-Power. A jumper is pre-installed to bring 24 VDC to the 4-20 ma outputs. If you require isolated 4-20 ma outputs, the Terminal Hook-Up Drawings will instruct you to remove the jumper and connect to different terminals. In addition, in the User-Powered Mode, you will need to supply separate power for the 4-20 ma circuit (between 9 and 27 volts DC).

A threaded half coupling (3/4" FNPT) properly sized to accommodate the isolation valve retractor assembly must be fitted to the pipe/duct to which the insertion probe will be inserted. Direct threading together (or with necessary bushings) of the retractor assembly may be required. In other cases, the threadolet must be welded in place and a clearance hole must be drilled through the pipe/ duct to accept the probe assembly. If the pipe/duct is under pressure during installation, a hot tap drill (not available through Sage Metering) may be required.

NOTE: Detailed Drawing is shown on page 31.

REV. 02-SIL/SRL

12

Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910

COMPRESSION FITTING

INSTALLATION INSTRUCTIONS

A bored through tube fitting, properly sized to

1. Insert tubing into the tube fitting.

accommodate an insertion probe’s particular OD, can be provided by the user or purchased as an option from Sage Metering. Prior to installation, a clearance hole to accommodate the insertion probe assembly must be drilled in the pipe/duct. A fitting

2. Make sure that the tubing is positioned properly per the PROBE INSERTION GUIDELINE DRAWING AND CHART, pages 13 &14. 3. Due to the variations of tubing diameters, a

(1/2" FNPT) is then welded in place or threaded into

common starting point is desirable. Therefore,

the half-threadolet which has been welded to the

tighten the nut until the tubing will not turn

pipe/duct. The probe insertion depth is adjustable

by hand or move axially in the fitting.

to permit sensor to be located at center, to optimize

4. Scribe the nut at the 6 o’clock position.

measurement accuracy. (Refer to PROBE INSERTION GUIDELINE DRAWING and CHART, pages 13 &14.)

5. While holding fitting body steady, tighten the nut 11⁄4 turns to the 9 o’clock position.

Insert the probe shaft tubing into the compression fitting to the position indicted in the Probe Insertion guidelines.

REV. 02-SIL/SRL

Mark the nut at the 6 o’clock position.

While holding the fitting body steady, tighten the nut one and one-quarter turns to the 9 o’clock position.

Operations and Instruction Manual

13

SAGE METERING, INC.

ITEM 1910 Probe Insertion Guideline Drawing1 INSERTION FLOW METER APPLICATION Straight Run Requirements. Choose the longest straight run section of pipe available to allow a uniform, well developed flow profile. Allow for a minimum of 10 diameters straight run (15 preferred) upstream of the sensors, and 5 down stream to minimize flow profile inaccuracies. Alternately, refer to Appendix for Optional Captive Flow Conditioners. Insertion styles are available through Sage Metering, Inc. with a standard 1/2" OD probe support assembly; 3/4" is also available. Standard probe lengths are 6", 12", 15", 18", 24", 30", 36" and 48". A common method of mounting the probe assembly through a pipe wall or duct is with a compression fitting. A Sage valve assembly is useful and highly

or duct (as small as 1”). Sage insertion flow meters include a probe assembly that supports the sensing element (a self-heated flow sensor and a temperature/ reference sensor); a sensor drive circuit; microprocessor meter board, and transmitter enclosure. The probe assembly must be inserted into the correct position in the process gas flow conduit to allow the gas to flow through the sensor “window” across the sensor element. The “sensing point” or active part of the sensor (0.5" from the end of the probe) should be positioned as described below:

INSTALLATION DEPTH The center of the pipe (assuming a well developed turbulent flow profile) is fairly flat, and easy to locate. See “Installation Depth Chart” on next page to determine proper insertion depth.

recommended. Flange mounting is optionally available. Sage insertion style flow meters can be assembled and calibrated for use in virtually any size pipe

Z

4" PIPE SHOWN

Y

Center of Pipe

X

LESS THAN IDEAL LOCATION (User needs to traverse the pipe to establish the point of average velocity location, and will then need to add a K-Factor of 1.22 in Menu Item 304. Also see "Menu Item Descriptions on page 43.)

GOOD LOCATION2,3,4 (See Installation Depth Chart for X and Y Dimension) 1. SIL General Purpose Meter shown in drawing. 2. Probe should be inserted per Installation Depth Chart (see following page), so sensors are in the center of the pipe. 3. The portion of the probe that remains outside of the pipe, is simply the factory ordered probe length (i.e. “-15” = 15 inches) minus the “Y” dimension. 4. If gas stream is prone to condensation, the pipe walls tend to form droplets which may roll down probe support and hit sensors (this can be avoided by keeping pipe wall above 32ºF). The output would read maximum flow until the droplet evaporates (usually about 5 minutes). To prevent the droplets from hitting the sensors, install the probe with a 30-45º tilt (moving probe forward or backward).

REV. 02-SIL/SRL

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Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910 Installation Depth Chart METHODS FOR PROBE INSERTION TO PIPE CENTER METHOD 1

METHOD 2

Using charts below, select pipe size (column 1),

Using charts below, select pipe size (column 1),

determine X. Insert probe until the end touches the

determine Y. Subtract Y from the factory supplied

bottom of the pipe (ID), mark probe as it exits top

probe length. That difference, Z, should be outside

of fitting. Lift probe distance X and tighten com-

of the pipe, and is measured from the bottom of the

pression fitting.

probe weld to pipe OD.

SCHEDULE 40 PIPE PIPE SIZE 1"

REV. 02-SIL/SRL

OD

ID

X

C O N S U L T

SCHEDULE 80 PIPE Y

PIPE AREA

F A C T O R Y

PIPE SIZE 1"

OD

ID

X

C O N S U L T

Y

PIPE AREA

F A C T O R Y

1.5"

1.900

1.610

.20"

1.56"

0.0141

1.5"

1.900

1.500

.15"

1.56"

0.0123

2"

2.375

2.067

.40"

1.82"

0.0233

2"

2.375

1.939

.35"

1.82"

0.0205

2.5"

2.875

2.469

.60"

2.07"

0.0332

2.5"

2.875

2.323

.55"

2.07"

0.0294

3"

3.500

3.068

.90"

2.38"

0.0513

3"

3.500

2.900

.80"

2.38"

0.0459

4"

4.500

4.026

1.40"

2.86"

0.0884

4"

4.500

3.826

1.30"

2.86"

0.0798

6"

6.625

6.065

2.40"

3.95"

0.2006

6"

6.625

5.761

2.25"

3.95"

0.1810

8"

8.625

7.981

3.40"

4.90"

0.3474

8"

8.625

7.625

3.25"

4.90"

0.3171

10"

10.750

10.020

4.40"

6.00"

0.5476

10"

10.750

9.750

4.25"

6.00"

0.5185

12"

12.750

11.938

5.50"

7.00"

0.7773

12"

12.750

11.374

5.13"

7.00"

0.7056

14"

14.000

13.124

6.00"

7.50"

0.9394

14"

14.000

12.500

5.70"

7.50"

0.8522

16"

16.000

15.000

7.00"

8.60"

1.2272

16"

16.000

14.312

6.60"

8.60"

1.1172

18"

18.000

16.876

8.00"

9.60"

1.5533

18"

18.000

16.124

7.50"

9.60"

1.4180

24"

24.000

22.625

10.75"

12.60"

2.7919

24"

24.000

21.562

10.25"

12.60"

2.5357

Operations and Instruction Manual

SAGE METERING, INC.

15

ITEM 1910 Configuration for Utilizing Four (4) Sage Insertion Mass Flow Meters for Large Round Pipes or Ducts Larger than 36" to Minimize Effects of Varying Flow Profiles

Insert Probes 15% into round pipe or duct

NOTE: Each Probe is mounted in the centroid (geometric center) of each quadrant. By averaging the outputs of all four probes, better accuracy is achieved.

The outputs of the four meters will be averaged by customer’s PLC or other method to improve overall accuracy in measuring the flow rate. (For medium sized round pipes [18" to 36"], two meters, on the opposite side of the same diameter, may be sufficient [insert parallel to an upstream 90 degree bend for optimal benefit.]) Note, in this configuration, each sensor needs to be averaged. A K-factor (Menu 304) of 1.22 is required in each meter to correct for this averaging method of insertion or alternately, put a 1.22 factor in your PLC, if Factory meter was supplied for Center, versus Average, installation. REV. 02-SIL/SRL

16

Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910 Terminal Hook-Up Series SIL, SRL (SIL NT Version)

2

1

4-20 FLOW

3

0-5 VDC

4

NOTE: When configured for Pulsed Outputs, the 4–20mA outputs are disabled. (You cannot have both pulse and 4–20mA flow outputs.)

GROUND

5

GROUND

6

DC INPUT (24 VDC)

4-20 FLOW

Temp2 or pulsed outputs3

0-5 VDC

FLOW1

Temp2 or pulsed outputs3

GROUND

FLOW1

6

5

4

JUMPERS4 6

5

4

3

GROUND

REMOTE HOOK-UP (SRL)

DC INPUT (24 VDC)

INTEGRAL HOOK-UP (SIL)

2

1

JUMPERS4 3

2

1

6

5

4

3

2

1

1

2

3

4

5

6

Power and Signal Terminal Block

Probe/Flowbody Sensor Terminal Block

1 4-20mA outputs could also be configured for Temperature

REV. 02-SIL/SRL

BLACK

ORANGE

6

WHITE

5

See page 19 which shows removable Power Cable Plug for AC Powered Meters

BLUE

4

6

WHITE

3

5

GREEN

2

4

RED

1

3

WHITE

2

RED

1

RED

Probe Support

1

2

3

4

5

6

4 Remove Jumpers for User-Powered 4-20 ma Outputs and connect between 3

2 0-5 VDC outputs could also be configured for Flow

and 4 instead of 4 and 6. In User-Powered mode, user must supply power to the

3 Pulsed Outputs of Totalized Flow (50msec Pulse)

4-20 mA (9-27 volts) to power the loop.

Operations and Instruction Manual

SAGE METERING, INC.

17

ITEM 1910 Circuit Board Wiring for General Purpose NT Style Meters (DO NOT MISMATCH SERIAL NUMBER OF ELECTRONICS WITH SERIAL NUMBER ON JUNCTION BOX SENSOR)1

SENSOR SIDE PIN 1

FACTORY PRE-WIRED SENSOR DRIVER BOARD NT STYLE

REMOTE HOOKUP 6– Orange (Temperature & Sense Return) 5– Black (Temperature Sense) 4– White (Temperature Send) 3– Blue (Flow & Sense Return) 2– Green (Flow Sense) 1– Red (Flow Send)

SENSOR SIDE PIN 1

SENSOR DRIVER BOARD NT STYLE

INTEGRAL HOOKUP 6– White (Temp) 5– N/C 4– White (Temp) 3– Red (Flow) 2– N/C 1– Red (Flow)

1 A Sage Thermal Mass Flow Meter with remote electronics is a custom calibrated meter. All components (sensors, electronics, boards, etc.) are matched-sets that share the same serial number and MUST BE INSTALLED TOGETHER AS A SYSTEM. Mixing components from different meters can result in significant errors/malfunctions.

REV. 02-SIL/SRL

18

Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910 Junction Box Wiring Terminals for Remote Style Meters (THERE ARE NO ELECTRONICS INSIDE JUNCTION BOX) SEE THE PREVIOUS PAGE FOR THE OTHER END OF THE REMOTE WIRING HOOKUP (the electronics side).

CUSTOMER SIDE (Wired at Installation Site)

Blue Green Red Orange Black White

CAUTION: Strip wires 3/8" and do not crimp insulation.

NOT USED

Grounding Screw GROUNDING SCREW NOT USED1 (The shield [drain wire] is only connected on the other end [the electronics end]).

4.37

Metal Conduit is recommended with appropriate grounding to minimize effects from external noise sources.

Red Black Red White Black White

FACTORY SIDE (Wired at Factory)

NOT USED

3/4” FNPT Conduit Receptacle

NOTE: The Sensor Junction Box will have a serial number tag. It is important to match this serial number with the serial number of the electronics. Mixing components from different meters can result in significant errors.

Sage supplies 25 feet of cable for the interconnect wires between the junction box and the Remote Enclosures: Carroll (manufacturer), Part #C0783, 20 gauge, 6 conductor, foil shielded, grey PVC jacket.

1 CSA standards require grounding this end as well. Refer to proper electrical code: CEC Part 1 Appendix J18-100

a CAUTION: Cable and cable glands are not for use in hazardous area environments. Power, ground, outputs, shielded cable, seal fittings and conduits are to be supplied by customer. CSA approved installations must comply with CEC Part 1 Appendix J18-100

REV. 02-SIL/SRL

Operations and Instruction Manual

SAGE METERING, INC.

19

ITEM 1910 Cable Connector Diagram for AC Powered General Purpose Sage Lite (SIL or SRL) Meters XP AC115 Power Board

Read Terminal Block Left to Right

Green (Earth) White (AC2) Black (AC1)

Power Cable Plug Receptacle Power Cable Plug with Screw Clamp Wire Terminals

NOTE: Screw for terminals on bottom of terminal block.

REV. 02-SIL/SRL

ITEM 1910

ITEM 1910

Section

B

THEORY / STYLES / SPECIFICATIONS

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

23

ITEM 1910 Theory / Styles / Specifications SAGE THERMAL MASS FLOW METERS

PRINCIPLE OF OPERATION OF THE THERMAL MASS FLOW METER

Sage Thermal Mass Flow Meters are designed for high performance mass flow measurement of flow

Sage Thermal Mass Flow Meters have two sensors

rate and consumption of gases such as air, oxygen,

constructed of reference grade platinum windings

natural gas, nitrogen, digester gas, bio gas, flare gas,

(RTDs). The two RTDs are clad in a protective 316SS

hydrogen, argon, carbon dioxide and other gases

sheath and are driven by a proprietary sensor drive

and gas mixes. They are field rangeable and have

circuit. One of the sensors is self-heated (flow sen-

a convenient user interface.

sor), and the other sensor (temperature/reference

Our state-of-the-art, microprocessor technology

sensor) measures the gas temperature. The pair is

features fault tolerant multiprocessors that transfer

referred to as the sensing element, and is either in-

bi-directional system information via digital proto-

stalled in a probe as an Insertion style, or inserted

col. This ensures a clean, error-free flow signal is

into a pipe section as an In-Line style flow meter.

transferred as high resolution digital data within

As gas flows by the flow sensor, the gas molecules

the Sage meter subsystems which makes the unit

carry heat away from the surface, and the sensor

virtually impervious to external analog noise.

cools down as it loses energy. The sensor drive circuit replenishes the lost energy by heating the

Features and Benefits

flow sensor until it is a constant temperature dif-

The Sage SIL/SRL high performance gas mass flow

ferential above the reference sensor. The electrical

meter product line (“Sage Lite”) has many features of the standard product line, but does not have a display, does not have a menuing keypad, does not support multiple channels, and does not support relay outputs. However it has linear outputs of flow rate and temperature. It is offered in a 5x5x4 NEMA 4X enclosure, or optional Explosion Proof Enclosure (XP2), or as a single circuit board for customized end-user packaging. Sage also offers “Sage Prime” Industrial Thermal Mass Flow Meters (Series SIP or SRP) or the Heavy Industrial Series (Series SIE or SRE). Sage also offers the General Purpose (SIG or SRG) Series. The SIE/SRE and SIG/SRG Models provide an easy-to-use menuing system via a 4-button Keypad as well as RS232 communication to an extensive menuing system for user configurability. Also, these Models are available with multiple calibrations (up to four channels, A-D).

power required to maintain a constant temperature differential is directly proportional to the gas mass flow rate and is linearized to be the output signal of the meter. It is essential that this constant temperature differential be maintained, even if there are wide fluctuations in gas temperature. It is the “job” of the Sage proprietary sensor drive circuit to maintain the differential, whether or not the gas temperature changes, or however quickly molecules cool off the flow sensor. It is also necessary to properly calibrate the device with the actual gas (or close equivalent with certain gases), in the Sage National Institute of Standards certified (NIST) calibration facility. By accomplishing these two critical objectives, the Sage meters provide an extremely repeatable (0.2% of full scale) and accurate output directly proportional to the mass flow rate of the gas being measured.

Contact Sage for details. If there are any features that you require, or if you need application assistance, feel free to contact our local factory trained representative in your area. Refer to www.sagemetering.com, or phone the Sage Sales or Service Staff to assist you (866-677-7243). REV. 02-SIL/SRL

Operations and Instruction Manual

SAGE METERING, INC.

24

ITEM 1910

BASIC GENERAL PURPOSE “BLIND’ SAGE FLOW METER STYLES

INTEGRAL GENERAL PURPOSE

REMOTE GENERAL PURPOSE

IN-LINE

INSERTION

IN-LINE

INSERTION

SIL-XXX

SIL-XX-XX

SRL-XXX

SRL-XX-XX

REV. 02-SIL/SRL

ITEM 1910

Section

C

DRAWINGS

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

27

ITEM 1910 SIL Series Integral Style Lite1 (Blind) General Purpose Mass Flow Meters IN-LINE STYLE2,3,5

IN-LINE METER DIMENSIONS

NEMA 4X Enclosure. 150#, 300#, or 600# flanged ends are optionally available. (1" Flow Body Shown)

5.00

4.00

5.00 B 2.55

L

Pipe Size x Flow Body Length (L)3

Gen. Purpose (A)

1/4" x 6"

8.03"

3/8" x 6"

8.09"

1/2" x 7"

8.15"

3/4" x 7"

8.28"

1" x 8"

8.40"

1-1/4" x 10"

8.53"

1-1/2" x 12" 2" x 12"

8.65"

2-1/2" x 12"

9.15"

8.90"

3" x 12"

9.40”

4" x 12"

9.90"

INSERTION STYLE4,5 NEMA 4X Enclosure. 150#, 300#, or 600# flanged mounting is optionally available. Available probe lengths (C) are 6", 12", 15", 18", 24", 30", 36" or 48".

5.00

4.00

5.00

C 1 “Lite”refers to Sage “Lite”Product Line for OEM customers (consisting of blind enclosures) or optionally offered as a single round circuit board only. Also available upon request with explosion proof enclosures. 2 NPT Fittings standard 3 Flow Conditioning built in to Flow Meter Pipe Sizes 3/4" and up. Contact Sage for optional 1/4" tube flow body. 4 Flanged Mounting available for high pressure operation 5 Cord Grips shown have 1/2" NPT access holes.

REV. 02-SIL/SRL

28

Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910 SRL Series Remote Style Lite1 (Blind) General Purpose Mass Flow Meters IN-LINE STYLE2,3

INSERTION STYLE4

NEMA 4X Enclosure. 150#, 300#, or 600# flanged mounting is optionally available. (1" Flow Body shown)

NEMA 4X Enclosure. 150#, 300#, or 600# flanged mounting is optionally available. Available probe lengths (C) are 6", 12", 15", 18", 24", 30", 36" or 48".

5.00

5.00

5.00

4.00” DEPTH

HUB FITTING

JUNCTION BOX (No Electronics) 4.00” DEPTH

3.00 dia. CONDUIT FITTING (Customer Supplied)

C

5.00

25' CABLE SUPPLIED Can be shortened or even lengthened in the field by up to 1000 feet without affecting calibration.

HUB FITTING

1.5

JUNCTION BOX (No Electronics) 25' CABLE SUPPLIED Can be shortened or even lengthened in the field by up to 1000 feet without affecting calibration.

L 1 “Lite” refers to Sage “Lite” Product Line for OEM customers (consisting of blind enclosures) or optionally offered as a single round circuit board only. Also available upon request with explosion proof enclosures. 2 NPT Fittings standard

CONDUIT FITTING (Customer Supplied)

3 Flow Conditioning built in to Flow Meter Pipe Sizes 3/4" and up. Contact Sage for optional 1/4" tube flow body. 4 Flanged Mounting available for high pressure operation 5 Cord Grips shown have 1/2" NPT access holes.

a CAUTION: Cable and cable glands are not for use in hazardous area environments. Power, ground, outputs, shielded cable, seal fittings and conduits are to be supplied by customer. CSA approved installations must comply with CEC Part 1 Appendix J18-100

JUNCTION BOX Class I, Group B, C, D Class II, Group E, F, G NEMA 7 & NEMA 9

REV. 02-SIL/SRL

Operations and Instruction Manual

SAGE METERING, INC.

29

ITEM 1910 SIL Series Integral Style Lite1 (Blind) Optional Explosion Proof Mass Flow Meters (XP2) IN-LINE STYLE2,3

IN-LINE METER DIMENSIONS

Class I, Division I, Group B, C, D. 150#, 300#, or 600# flanged ends are optionally available. (1" Flow Body shown)

4.50

3.44

4.69 B

L

Pipe Size x Flow Body Length (L)3

Expl. Proof (B)

1/4" x 6"

7.33"

3/8" x 6"

7.39"

1/2" x 7"

7.45"

3/4" x 7"

7.58"

1" x 8"

7.70"

1-1/4" x 10"

7.83"

1-1/2" x 12"

7.95"

2" x 12"

8.20"

2-1/2" x 12"

8.45"

3" x 12"

8.70”

4" x 12"

9.20"

INSERTION STYLE4 Class I, Division I, Group B, C, D. 150#, 300#, or 600# flanged mounting is optionally available. Available probe lengths (C) are 6", 12", 15", 18", 24", 30", 36" or 48".

3.44

4.50

4.81

4.81 TRANSDUCER ENCLOSURE

C

C

Class I, Group B, C, D Class II, Group E, F, G Class III CENELEC: EExd IIC, 1P66 NEMA 4X, 7BCD, 9EFG

1 “Lite”refers to Sage “Lite”Product Line for OEM customers (consisting of blind enclosures) or optionally offered as a single round circuit board only. 2 NPT Fittings standard 3 Flow Conditioning built in to Flow Meter Pipe Sizes 3/4" and up. Contact Sage for optional 1/4" tube flow body. 4 Flanged Mounting available for high pressure operation

REV. 02-SIL/SRL

30

Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910 SRL Series Remote Style Lite1 (Blind) Optional Explosion Proof Mass Flow Meters (XP2) IN-LINE STYLE2,3

INSERTION STYLE4

Class I, Division I, Group B, C, D. 150#, 300#, or 600# flanged ends are optionally available. (1" Flow Body shown)

Class I, Division I, Group B, C, D. 150#, 300#, or 600# flanged mounting is optionally available. Available probe lengths (C) are 6", 12", 15", 18", 24", 30", 36" or 48".

4.50

3.44 4.50

3.44

4.69 C

4.69

HUB FITTING

JUNCTION BOX (No Electronics)

3.00 dia.

HUB FITTING

1.5

CONDUIT FITTING (Customer Supplied) JUNCTION BOX (No Electronics)

3.00

CONDUIT FITTING (Customer Supplied)

25' CABLE SUPPLIED Can be shortened or even lengthened in the field by up to 1000 feet without affecting calibration.

L 25' CABLE SUPPLIED Can be shortened or even lengthened in the field by up to 1000 feet without affecting calibration.

1 “Lite”refers to Sage “Lite”Product Line for OEM customers (consisting of blind enclosures) or optionally offered as a single round circuit board only. 2 NPT Fittings standard 3 Flow Conditioning built in to Flow Meter Pipe Sizes 3/4" and up. Contact Sage for optional 1/4" tube flow body. 4 Flanged Mounting available for high pressure operation

a CAUTION: Cable and cable glands are not for use in hazardous area environments. Power, ground, outputs, shielded cable, seal fittings and conduits are to be supplied by customer. CSA approved installations must comply with CEC Part 1 Appendix J18-100

JUNCTION BOX Class I, Group B, C, D Class II, Group E, F, G NEMA 7 & NEMA 9

REV. 02-SIL/SRL

TRANSDUCER ENCLOSURE Class I, Group B, C, D Class II, Group E, F, G Class III CENELEC: EExd IIC, 1P66 NEMA 4X, 7BCD, 9EFG

Operations and Instruction Manual

SAGE METERING, INC.

31

ITEM 1910 Mounting Hardware3 SVA SERIES ISOLATION VALVE ASSEMBLY FOR INSERTION METERS

SVA SERIES ISOLATION VALVE ASSEMBLY DETAIL Cut away view of probe inserted through isolation

Used for pressures to 650 psig1 (shown for use

ball valve assembly.

with 1/2" diameter insertion meters). 150# or 300# flanged mounting is optionally available. Available sizes are 1/2" x 3/4" NPT (shown) and 3/4" x 1" NPT.

SENSOR ASSEMBLY EXTENDS 2.25" L BELOW THE LOWER EDGE OF THE WELDED COLLAR CLAMP WITH CHAIN TAUT

11.00

PROBE LENGTH (with sensor)

NOTE: User needs to weld a 3/4" female weldlet (of appropriate radius) to mate with existing pipe after a 3/4" hole has been drilled in pipe. The 3/4" Male Coupling of the Sage Isolation Valve Assembly will thread into the user’s 3/4" weldlet.

1/2" BORE SINGLE PIECE COLLAR CLAMPS

12" 15" 18" 24"

STCF SERIES TEFLON FERRULE COMPRESSION FITTING

2

SAFETY CHAIN

1/2"–3/4" BALL VALVE WELDMENT WITH 1/2" TUBE TO PIPE COMPRESSION FITTING

SAFETY CHAIN LENGTH2

3/4"x1.5" PIPE NIPPLES 3/4"x3" BALL VALVE

8.25" 11.25" 14.25" 20.25"

3/4"x1" HALF COUPLING (WELDLET)

MOUNTING PLATE FOR THIN WALLED DUCTS (INCLUDES STCF05 COMPRESSION FITTING)

1/2" tube x 1/2" pipe fitting (shown, not to scale), is used for low pressure insertion applications to 125 psig (Stainless Steel Ferrule optional for higher pressure applications – up to 225 psig). Also available in 3/4" tube x 3/4" pipe size.

1.92 4"

1 At 650 psig, force exerted on 1/2" diameter probe is approx. 125 psig 2 Safety chain is designed to prevent probe from accidentally escaping from assembly during removal from pressurized pipe 3 Insertion meters can have optional flanged mounting (generally used for high pressure or very hot gases).This adaptation is not shown. Consult factory for details.

4" REV. 02-SIL/SRL

32

Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910 Wall Mounting Procedure for Remote General Purpose Enclosure A 6-32 Pan Head Phillips machine screw is recommended for each corner of the SRL remote enclosure. The screw will have to pass through .296 inches (roughly 19/64") of overall thickness at the bottom of the enclosure mounting hole before the screw threads emerge. The thickness of the enclosure material is 1/8". The over-all length of the screw depends on the customers mounting configuration and how much depth they have to penetrate on their mounting plate that the enclosure is being fastened to.

4.21

4.21

DIMENSIONS ABOVE ARE FROM HOLE CENTER TO HOLE CENTER

REV. 02-SIL/SRL

Operations and Instruction Manual

SAGE METERING, INC.

33

ITEM 1910 Flanged Ends for In-Line Meter (OPTIONAL)

Flanges for 3" pipe sizes and smaller have 4 bolt holes

Flanges for 31⁄2" pipe sizes and up, have 8 bolt holes

Flow Conditioning Screens FOR FLOW BODIES 3/4" AND UP

LENGTH “L” SAME AS NON-FLANGED METER (See table on page 29. For example, 1"x8" flow body has an 8" length.The length will be the same whether an NPT flow body, or whether flanged. If a flanged flow body, the 8" dimension will be a Face-to-Face dimension.)

Screens shown with NPT fitting.

REV. 02-SIL/SRL

34

Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910 General Purpose Probe and Transmitter Head Assembly Procedure

3/4" EXTERNAL TOOTH LOCK WASHER THREADS OVER 3/4 MNPT THREADS ON PROBE

C

B BUNA GASKET

ASSEMBLY STEPS A Slip Buna Gasket over 3/4" MNPT threads on probe so it fits flush against the face of the flat stainless gasket sealing ring. B Place 3/4" MNPT threaded end of probe through the receiving hole in the center of the bottom bulkhead of the electronic enclosure. C Thread the 3/4" external tooth lock washer on the 3/4" MNPT threaded probe end. D Secure probe with 1/4-1/2 turn past hand tight to seal probe support in place. Make sure that sensor window aperture is properly positioned in upstream/downstream orientation.

A

ENLARGED TO SHOW DETAIL

D

REV. 02-SIL/SRL

ITEM 1910

Section D USER INTERFACE

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

37

ITEM 1910 Sensor Functionality and Zero Calibration Self Check USING A LAPTOP WITH OPTIONAL SILCOM CABLE ASSEMBLY (see page 40) Sage Meters have provisions to check the meter’s Zero Flow calibration against the original factory calibration using Sage VIP. This procedure confirms that the sensor is functioning properly, that the sensor is clean, and is also a strong indication that the entire meter is still in calibration. Refer to the last line of the Certificate of Conformance that was supplied with the meter, and note the gases’ Flow Zero value in mw. Also note the calibration pressure of the gas on the certificate. In order to access the Flow Zero value with Sage VIP, you will first need to create a Zero Flow condition (usually done by closing valves in your system) with the same gas and at the same pressure as the calibration pressure (that is, the pressure must be maintained to simulate the factory’s original “zero” calibration point). The procedure is as follows: Open up Sage VIP. 1) Load Sage VIP onto Desktop 2) CAUTION: POWER MUST BE OFF BEFORE YOU PROCEED TO THE FOLLOWING THREE STEPS (3, 4, and 5), OR SERIOUS DAMAGE WILL OCCUR. 3) Connect the optionally supplied cable/connector assembly to the mating connector on the round board 4) Connect other end (DB9) to mating connector to computer

8) Wait approximately 2 minutes for the data to stabilize (i.e., value will remain relatively constant [within a few mw]), then type “g” to freeze and record the last reading 9) You can take, and freeze, additional points by repeatedly typing “g” 10) Optionally, you can press the “Print Screen” key on your computer, and later print and store the calibration information 11) The value should closely match Flow Zero value (within a few mw, depending on full scale range) on the next to last line of your Certificate of Conformance. (Note: Meters are checked with sensor in vertical position. The mw will be slightly lower in horizontal position) 12) To exit, hit the “Tab” key 13) Alternately, remove probe from process, cap sensor with a plastic bag or other means of preventing flow, and compare to the “Air Flow Zero Value” in mw on the last line of Certificate, instead of the actual process gas (both values are shown on the certificate.)

1 If data is not transmitting, select “View”“Settings”to select the active COM port (1-4), then shut down and restart VIP. If necessary, verify that your computer’s Serial Port has the correct Serial Cable Port Settings. Open Control Panel (Start, Control Panel).Then select System, Hardware, Device Manager, Ports (COM & LPT), Communications, Port Settings. Bits per Second: 19200 Parity: None

Data Bits: 8 Stop Bits: 1

Flow Control: None

5) Power up the Sage Meter, and the menus below will appear (see footnote 1, if problems)1 6) At the prompt enter “39” to bring up flow output data in mw 7) Look at the “air=cal” values. The system is reporting real time flow output (of whatever gas it was calibrated with, not necessarily “air”).

REV. 02-SIL/SRL

38

SAGE METERING, INC.

Operations and Instruction Manual

ITEM 1910 SIL NT Version Menuing Interface—Rev. 3.029 USED WITH REV. 2.066 METERS (SILCOM NT RS232 INTERCONNECT CABLE/ASSEMBLY REQUIRED [See Page 40]) STEPS 1. Load Sage VIP onto Desktop 2. CAUTION: POWER MUST BE OFF BEFORE YOU PROCEED TO THE FOLLOWING THREE STEPS (3, 4, and 5), OR SERIOUS DAMAGE WILL OCCUR. 3. Connect the optionally supplied cable/connector assembly to the mating connector on the round board

SIL MENUING INTERFACE2 Upon power-up, the SIL will transmit the following menu to a host PC through its factory interface plug (SILCOM). The data is 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32) 33) 34) 35) 36) 37) 38) 39) 40)

Calib mw Val TempExciteRes Temp VREFVal Flow Load Res Temp Calib [A] Temp Calib [B] Temp Calib [C] Temp Calib [D] Temp Displ [A] Temp Displ [B] Temp Displ [C] Temp Displ [D] Flow Coeff [A] Flow Coeff [B] Flow Coeff [C] Flow Coeff [D] Flow Coeff [E] Flow Coeff [F] IIR Coeff Min SCFM Max SCFM Min Temp F Max Temp F DAC1 Min DAC1 Max DAC2 Min DAC2 Max Output Config Serial Number RealTime Disp Save2EEPROM

REV. 02-SIL/SRL

formatted as ASCII text for a VT-100 at 19200,8,None,1,None settings. VIP Terminal will default to these settings.

FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED NORMALLY NOT USED BY CUSTOMER UNLESS FACTORY AUTHORIZED CAN BE USED BY CUSTOMER (Filtering)3 CAN BE USED BY CUSTOMER CAN BE USED BY CUSTOMER CAN BE USED BY CUSTOMER (however, if item 37=8, contact Factory) CAN BE USED BY CUSTOMER (however, if item 37=8, then Value Entered corresponds to how many SCF per pulse (50 msec pulse width is fixed) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) FACTORY ONLY (not for customer use) CAN BE USED BY CUSTOMER (see Table) FACTORY ONLY (not for customer use) CAN BE USED BY CUSTOMER CAN BE USED BY CUSTOMER

1 If data is not transmitting, select “View”“Settings” to select the active COM port (1-4), then shut down and restart VIP. If necessary, verify that your computer’s Serial Port has the correct Serial Cable Port Settings. Open Control Panel (Start, Control Panel).Then select System, Hardware, Device Manager, Ports (COM & LPT), Communications, Port Settings. Bits per Second: 19200 Parity: None

4. Connect other end (DB9) to mating connector to computer 5. Power up the Sage Meter, and the menus below will appear (footnote 1, if problems)1

Data Bits: 8 Stop Bits: 1

Flow Control: None

VALUE 0-3 4 5 6 7 8

FUNCTION DAC1 NOP1 Flow Flow Temp Temp NOP

DAC2 NOP Flow Temp Flow Temp Pulse

1 NOP=No Operation

2 Period (.) escapes out without changing setting; if in item 39.Type “g”to freeze and record the last reading.You can take, and freeze, additional points by repeatedly typing “g” 3 (Low Value=Fast, High Value=Slow, Factory Default=10)

Operations and Instruction Manual

SAGE METERING, INC.

39

ITEM 1910 Pulsed Outputs on SIL NT DETAILS OF OPTIONAL CONFIGURATION (OPTIONAL SILCOM RS232 INTERCONNECT CABLE/ASSEMBLY REQUIRED [See page 40]) SIL NT MENU DESCRIPTIONS THAT APPLY TO PULSED OUTPUTS

DAC2 controls the 0-5 VDC output driver amplifier.

The following menu items have been changed to

set in menu items #35 & #36. The output will gen-

provide for additional functionality including PULSE

erate a 0-5 volt pulse at 50 msec in width. Contact

output of the SIL2 product line. These functions are

Factory if it is required to have a pulse output

only active during standalone operation.

amplitude other than 0-5 volts.

This amplifier will drive the output pin to the limits

While Output Configuration register setting is 0-7 31) Min Temp F – 32) Max Temp F – Lower and upper limits of reported temperature output value.

While Output Configuration register setting is 8 31) Min Temp F – Enter the timebase value for pulse updates. (See table) TIMEBASE

VALUE

Seconds

.02

Minutes

.000333333

The pulse width is not adjustable; however the repetition of pulses is proportional to the flow rate over time. The pulse amplitude is adjusted by the menu item limits. Since the output is controlled by the menu item limits, any pulse amplitude and steady state voltage

32) Max Temp F – Enter totalizer trip reset value. Example, enter 100 to send a pulse out every 100 SCF.

The IDAC and VDAC names have been changed to DAC1 and DAC2 respectively. The following menu items reflect this change. The operation is the same as in previous revisions. 33) 34) 35) 36)

DAC1 MIN—Factory Only (unless authorized) DAC1 MAX—Factory Only (unless authorized) DAC2 MIN—Factory Only (unless authorized) DAC2 MAX—Lower and upper limits of both DAC channels. The units are in DAC values and range from 0 to 4095. Contact Factory if pulse output is other than a 0-5 volt pulse (All pulse settings are 50 msec pulse width).

level can be generated. Typically, the output will idle at logic low or zero volts and pulse high at 5 volts. However, the menu item limits may be swapped to create a high logic level idle with a 50 msec pulse driving low level. The pulse output can drive loads not to exceed 20mA. This allows it to directly interface with TTL logic, optoisolators, and low power relays. The output pulse is logic level compatible with no mechanical contacts to wear out. Do not apply any voltage to the output pin as it will damage the drive amplifier.

Pulse output has been added to DAC2 and is selected by entering an 8 in the output configuration register. DAC1 will be inoperative during pulse output selection. 37) Output Config—Selects DAC output routing. (See table at right)

VAL

FUNCTION

0-3 4 5 6 7 8

DAC1 nop flow flow temp temp nop

DAC2 nop flow temp flow temp Pulse

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SAGE METERING, INC.

Operations and Instruction Manual

ITEM 1910 SILCOM Interface Cable Instructions The SILCOM computer interface cable must be attached to the SILNT board assembly as shown in the drawing below. The cable itself is 6 feet in length and has a dual row ten pin header socket on one end which attaches to the SILNT board assembly and a DB9 pin socket on the other end which attaches to your computer.

REV. 02-SIL/SRL

ITEM 1910

Section

E

DIAGNOSTICS

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

43

ITEM 1910 Common Diagnostics SYMPTOM: Meter output reading zero continuously,

of the Junction Box. Disconnect the red wires on

or full scale continuously, or temperature reading is

the Factory Side to isolate and measure the resist-

abnormally low (hundreds of degees below zero).

ance. If the reading is infinity or a short, it means

POSSIBLE CAUSES/SUGGESTED CORRECTIVE ACTION:

that sensor is burned out.

a) It is likely that a wire is loose. But in rare cases, a sensor could fail (i.e., if a standard sensor, HT01 or HT02 sensor exceeds a process temperature of 450˚F, or if a very high temperature sensor, HT03, exceeds 800˚F). b) Check for continuity to be sure the wiring is mak-

f) Now check the Temperature Sensor. Disconnect the white wires on the Factory Side to isolate and measure the resistance. If you have infinity or a short, it means that sensor is burned out. Note: Normally the sensors will read approximately 110 ohms at 70˚ F. At higher temperatures they should

ing good contact at the terminals of the Junction

read a higher resistance, but both sensors should have

Box. (See the note on the Junction Box drawing

a similar value.

on page 18 requiring that the wires be stripped 3/8" and that the insulation is not interfering with the contact.) (An Ohm Meter can be placed between the Electronics end of the wire and the Sensor side [the left side] of the Junction Box to assure of continuity and good contact.) c) Also, to verify that the electronics is not mixed up with the sensors, the serial number will come up upon power up, right after Initializing on the Display. Alternately, depress the Back/Down button and it reports the serial number. If the serial number doesn't agree with the Junction Box labels, that would effect calibration (in other words, sensors and electronics are a matched pair—mixing them up will cause false readings). Also metal Serial Number Tags are fastened to both the electronics as well as the Junction Box. They must have identical Serial numbers. d) To check if a sensor has failed on a remote style

g) On integral style meters (SIL), there is no Junction Box. In that case, refer to the Circuit Board Wiring drawing on page 17 and check the sensor on the SDB Terminal. Remove the appropriate wires first (red pair for flow, then white pair for temperature). Measure their resistance. If reading infinity or short, it means that sensor is burned out. h) In some instances, a user may have inadvertently changed menu settings inappropriately. If so, the meter can report erroneous readings, or possibly exhibit the symptoms described above. In that case, item 708 can be used. On the System Set Up Menu, 708 (Factory All), restores meter to original factory settings (remember to first put in passcode 99999 for item 708 to successfully restore settings). SYMPTOM: Meter output Railing (Pegging) or Reading High POSSIBLE CAUSES/SUGGESTED CORRECTIVE ACTION:

meter, it is easy to use the Junction Box to do so.

a) Possibly caused by water droplets hitting the sen-

You must Power Down (shut off power), but you

sor (which generally causes output to spike; but if

do not need to remove the probe from the pipe.

droplets are near continuous, output may rail).

Refer to page 18. e) An Ohm Meter is required to check across the sensor leads of the Flow Sensor. Look at the drawing

b) Poor Wiring. c) A downstream valve too close to the meter (flow may be reflecting back).

REV. 02-SIL/SRL

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SAGE METERING, INC.

Operations and Instruction Manual

ITEM 1910

d) Possible jet effect if upstream pipe is smaller than

SYMPTOM: Reading Low

meter flow body or if valve is too close upstream)

POSSIBLE CAUSES:

to meter.

a)

straight run).

e) Not following Probe Insertion Guideline. f) Sensor may be contaminated. Remove probe,

b) Insufficient power supply—require minimum 250 mA (see Specifications).

wipe off or clean with a solvent. Reinsert. g) Insufficient straight run (i.e. flow profile is dis-

c)

d) Ground loop problem. Solution: hook up meters in opto-isolated mode (user-powered 4-20 mA

was specified and calibrated for. i)

If a Remote Style Meter (SRL), be sure Serial Numbers of Probe and Remote Electronics are

mode). e)

display reads as expected (if so, see “c” or “d”).

table). To confirm, verify that Junction Box Serial on Remote Enclosure. j)

f)

Not following Probe Insertion Guideline.

g)

Sensor may be contaminated. Remove probe,

If sensor is not aligned properly, with Upstream” mark facing upstream, rotation greater than ± 5 degrees may cause change in reading (greater

wipe off or clean with a solvent. Reinsert. h) Using a different gas or gas mix than the meter was specified and calibrated for.

than ± 5 degrees and less than ± 20 degrees causes meter to over-report; a greater rotation

To check if problem is due to 4-20 mA output device, temporarily remove device, and observe if

identical (if not, errors in calibration are ineviNumber Tag has identical Serial Numbers to Tag

Excessive load on the 4-20 mA if using SelfPowered terminal hook up (Ground based).

turbed, causing errors). h) Using a different gas or gas mix than the meter

Poor flow profile Upstream (insufficient upstream

i)

If a Remote Style Meter (SRL), be sure Serial

actually blocks the sensor, and causes meter to

Numbers of Probe and Remote Electronics are

under-report).

identical (if not, errors in calibration are inevitable). To confirm, verify that Junction Box Serial

k) Meter may appear to be reading high if user is

Number Tag has identical Serial Numbers to Tag

comparing Sage flow meter readings (SCFM) to

on Remote Enclosure.

an uncorrected volumetric device (ACFM). For example, at constant volume, a decrease in gas

j)

If sensor is not aligned properly, with “Upstream”

temperature will increase the mass flow (SCFM).

mark facing upstream, rotation greater than ± 5

That is completely normal.

degrees may cause change in reading (greater than ± 5 degrees and less than ± 20 degrees causes meter to over-report; a greater rotation actually blocks the sensor, and causes meter to under-report).

REV. 02-SIL/SRL

Operations and Instruction Manual

SAGE METERING, INC.

45

ITEM 1910

k) Meter may appear to be reading low if user is comparing Sage flow meter readings (SCFM) to an uncorrected volumetric device (ACFM). For example, at constant volume, an increase in gas temperature will lower the mass flow (SCFM). That is completely normal. l)

If gas temperature falls significantly below freezing, flow meter may slightly over-report or under-report.

SYMPTOM: Display does not have power POSSIBLE CAUSE: Mis-wiring may have caused one or both of the Fuses to blow. CORRECTIVE ACTION: Contact Sage to send replacement fuse(s). ALL FUSES ARE PLUG IN, NOT SOLDER IN.

REV. 02-SIL/SRL

ITEM 1910

ITEM 1910

Section

F

WARRANTIES AND SERVICE WORK

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

49

ITEM 1910 Warranties and Service Work LIMITED WARRANTY

CANCELLATION / RETURN POLICY

Sage Metering’s products are warranted against faulty

Cancellation or Return: After issuance of a purchase

materials or workmanship for one year from the date

order (by phone, mail, e-mail or fax) or a credit card

of shipment from the factory. Sage’s obligation is

order (by phone, mail, e-mail or fax), there will be a

limited to repair, or at its sole option, replacement of

cancellation fee for any cancelled order. Cancella-

products and components which, upon verification

tions must be in writing (by mail, e-mail or fax):

by Sage at our factory in Monterey, California, prove to be defective. Sage shall not be liable for installation charges, for expenses of Buyer for repairs or replacement, for damages from delay or loss of use, or other indirect or consequential damages of any kind. This warranty is extended only to Sage prod-

1) If credit card order or non-credit card order is cancelled within 7 days of issuance of purchase order or date order was placed (which ever is earlier), there will be a 10% cancellation fee. 2) If credit card order or non-credit card order is

ucts properly used and properly installed for the par-

cancelled after 7 days, but prior to shipment,

ticular application for which intended and quoted;

there will be a 20% cancellation fee. (If order is

and does not cover water damage due to improper

cancelled due to late delivery, the cancellation

use of cord grips or removal of protective caps; and

fee will be waived. Late delivery is defined as

does not cover Sage products which have been

shipping a meter 7 days or later than the delivery

altered without Sage authorization or which have

date acknowledged by Sage Metering at time of

been subjected to unusual physical or electrical

placing order).

stress. Sage makes no other warranty, express or implied, and assumes no liability that goods sold to any purchaser are fit for any particular purpose. Transportation charges for materials shipped to the factory for warranty repair are to be paid by the shipper although, in the case of International returns, the inbound shipping charges can be initially billed to Sage, and then recovered in the final invoice upon returning the repaired or warranteed product. Sage will return items repaired or replaced under warranty prepaid. NOTE: No items will be returned for warranty repair without prior written authorization from Sage Metering, Inc. Sage does not warranty damage due to corrosion.

3) If a credit card customer decides to return the equipment after shipment for credit, credit will not be issued if equipment is damaged or if equipment is returned after four (4) months of shipment. If equipment is not damaged, then equipment can be returned after issuance of a Return Meter Authorization (RMA) by Sage. Returned package must be insured by customer and must reference proper RMA# on outside of package, or package may be rejected (i.e., package will be returned unopened). Credit Card customers will be charged a 30% re-stocking fee (70% balance will be credited back). Customer is responsible for return shipping charges and any damage if improperly packaged. continued on next page

REV. 02-SIL/SRL

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SAGE METERING, INC.

Operations and Instruction Manual

ITEM 1910 4) If a non-credit card customer decides to return the equipment after shipment for credit, credit will not be issued if equipment is damaged or if equipment is returned after 1 month of shipment, unless authorized by a representative at Sage Metering, Inc. The Sage representative will issue a Return Material Authorization (RMA) at that time and will advise of the restocking fee. Returned package must be insured by customer and must reference proper RMA# on outside of package, or package may be rejected (i.e., package will be returned unopened). Customer is responsible for return shipping charges and any damage if improperly packaged.

REV. 02-SIL/SRL

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SAGE METERING, INC.

51

ITEM 1910

RETURNING YOUR SAGE METER A Return Material Authorization Number (RMA#) must be obtained prior to returning any equipment to Sage Metering for any reason. RMA#s may be obtained by calling Sage Metering at 866-677-7243 or 831-242-2030 between 8:00 am and 5:00 pm Monday through Friday. A Sage RMA Form (see page 52) must be filled out and included with the meter being returned to Sage Metering.

1. The equipment must be completely cleaned and decontaminated prior to shipment to Sage Metering. This decontamination includes the sensor, probe, electronics and enclosures internally and externally. All packaging must be clean and free from contamination. 2. A Material Safety Data Sheet (MSDS) is required for all process fluids and gases that have been in contact with the equipment. This includes fluids or gases used in cleaning the equipment. A Decontamination Statement is also required for

A purchase order is required prior to an RMA being

each meter returned using a different gas or fluid.

issued. Most repairs or recalibrations can be quoted

Both the MSDS and the Decontamination

over the phone. For equipment that must be evaluat-

Statement are to be attached to the OUTSIDE of

ed, an Evaluation purchase order in the amount of

the shipping container. If both documents are not

$150 is required. Once an evaluation is completed

attached, you will be called, and the equipment

and a quote has been issued, you can choose to pro-

sent back to you at your expense.

ceed with the work or have the unit returned with only the evaluation and freight fee billed. In accordance with the “Right to Know Act” and applicable US Department of Transportation (DOT) regulations, Sage Metering will not accept delivery of equipment that has been contaminated without written evidence of decontamination, and has instituted the following Return/Repair conditions. Strict adherence to these conditions is required. Returned equipment that does not conform to the requirements listed below will not be processed. If Sage Metering finds

3. The decontamination Statement must include the following required information A. A list of all chemicals and process fluids used in the equipment, including decontamination fluids or gases. B. The model and serial number of the equipment being returned. C. A company officer or other authorized person’s signature on the statement.

evidence of contamination, we may, at our option, have the unit returned at your expense. For your ref-

Return Shipping Address:

erence, the requirements for packaging and labeling

Sage Metering, Inc.

hazardous substances are listed in DOT regulations

8 Harris Court, Building D1

49 CFR 172, 178, and 179.

Monterey, CA 93940

REV. 02-SIL/SRL

52

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

RETURN MATERIAL AUTHORIZATION

RMA #

RETURN CUSTOMER INFORMATION Customer’s Name

Fax #

Customer’s Contact Name

Phone #

Email Address CUSTOMER’S RETURN ADDRESS Bill to:

Ship to:

RETURN PRODUCT INFORMATION Model No.

Serial No(s).

TEMP:

MIN

NORMAL

MAX

PRESSURE:

MIN

NORMAL

MAX

GAS REASON FOR RETURN / DESCRIPTION OF SYMPTOMS

(All non-warranty repairs could be subject to a minimum evaluation charge)

Recommended steps to be used to duplicate problem/symptoms

Sage Metering Technical Contact

SAGE METERING, INC. 8 Harris Court, Building D-1 / Monterey, California 93940 PHONE: 831-242-2030 / FAX: 831-655-4965 REV. 02-SIL/SRL

ITEM 1910

Section G

G APPENDIX

ITEM 1910

Operations and Instruction Manual

SAGE METERING, INC.

55

ITEM 1910 Junction Box and Upstream Orientation FRONT VIEW

LOOKING DOWNSTREAM

LOOKING UPSTREAM

4.40

2.72

2.72

5.0

5.0

FLOW DIRECTION

FLOW DIRECTION

FLOW DIRECTION

REV. 02-SIL/SRL

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Operations and Instruction Manual

SAGE METERING, INC.

ITEM 1910 CAPTIVE FLOW CONDITIONERS

NOTE: The larger of the two perforated plates of the Sage conditioning basket is positioned between two flanges and two gaskets as shown. The smaller of the two perforated plates of the conditioner will freely slide into the application pipe, facing downstream. The compression will be placed one diameter downstream of the downstream plate.

REV. 02-SIL/SRL

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57

ITEM 1910 What is a Thermal Mass Flow Meter? • What is a Thermal Mass Flow Meter? It is a meter

• The Sage proprietary sensor drive circuitry main-

that directly measures the gas mass flow based

tains a constant overheat between the flow sensor

on the principle of conductive and convective

and the reference sensor. As gas flows by the

heat transfer.

heated sensor (flow sensor), the molecules of flowing gas carry heat away from this sensor, and the

• All Meters have probes (Insertion Style) or Flow

sensor cools down as it loses energy. The circuit

Bodies (In-Line Style) that support a pair of

equilibrium is disturbed, and momentarily the

sensors, which are in contact with the gas.

temperature difference between the heated sensor and the reference sensor has changed. The circuit

• The sensors are RTDs, which are resistance tem-

will automatically (within 1 second) replace this

perature detectors. They consist of highly stable

lost energy by heating up the flow sensor so the

reference-grade platinum windings. In fact, we

overheat temperature is restored.

use the same material that is used as Platinum Resistance Standards at the NIST.

• The current required to maintain this overheat represents the mass flow signal. There is no need

• The RTDs are clad in a protective 316 SS sheath

for external temperature or pressure devices.

for industrial environments. • One of the RTDs [See Diagram below] is self-heated by the circuitry and serves as the flow sensor. The other RTD acts as a reference sensor, and measures the gas temperature. Essentially it is used for temperature compensation.

FLOW SENSOR (Self Heated)

TEMPERATURE SENSOR (Reference Sensor)

REV. 02-SIL/SRL

ITEM 2000 Part No. 123655-01 Revision D, November 1999

990 TRANSMITTER SYSTEM

MANUAL

ITEM 2000 990 Transmitter System Manual

System Description The System The 990 series of transmitters consists of two systems, the 990 Vibration Transmitter System and the 991 Thrust Transmitter System. Both systems contain three parts - a 3300 NSv or 3300 RAM proximity probe and extension cable (If probe is 5 or 7 metres, no extension cable is required), and a transmitter. Both systems provide two types of output signals - a 4 to 20 mA current loop and a voltage signal. Note: The 3300 NSv Probe and extension cable replaced and assumed the part numbers of the 3300 RAM Probe and extension cable. The 3300 NSv Probe and extension cable has blue coaxial cable with grey shrink at the connectors and the 3300 RAM Probe and extension cable has grey coaxial cable with no shrink at the connectors. These products are identical in form, fit, and function. The 990 Vibration Transmitter System measures the radial vibration of a shaft or other part of a machine in relation to the location of the probe tip. The following equation represents the relationship between the vibration and the loop current.

Vibration =

Current (mA) & 4 mA × Full Scale Mils (or µm) pp 16 mA

The 991 Thrust Transmitter System measures the distance between the target and a reference (zero) point. The following equation represents the relationship between the thrust position and the loop current.

Thrust Position =

Current (mA) & 12 mA × Full Scale 8 mA

Where Full Scale is 25 mils for the 25 - 0 - 25 mils thrust range or 0.6 mm for the 0.6 - 0 - 0.6 mm thrust range. Both transmitters provide a voltage proportional to the distance between the target and the probe tip. This voltage is available at the terminal strip and on the BNC connector for use when gapping the probe and for diagnostic purposes. You may apply this voltage to any battery powered instrumentation with a 1 MS or larger input impedance or AC powered equipment when using test adapter part number 122115-01. The phase of the Prox Out signal is inverted from the Bently Nevada standard of a signal going positive when there is motion toward the probe. The Prox Out signal is not isolated and a false alarm may result from connecting it directly to grounded AC powered equipment. The test adapter provides isolation to avoid grounding problems, changes the gap voltage to a negative voltage, and corrects the phase of the signal.

1

ITEM 2000 990 Transmitter System Manual

Maintenance and Troubleshooting Maintenance This section shows how to verify that the system is operating properly, adjust the system, and identify parts of the system that are not working properly. The transmitter system does not require verification at regular intervals. You should, however, verify operation by using the scale factor verification on page 10 if any of the following conditions occur: ! components of the system are replaced or disturbed ! the performance of the system changes or becomes erratic ! you suspect that the transmitter is not calibrated correctly The adjustment procedures on pages 11 thru 16 are included for your information. For target materials other than 4140 steel and for other special applications, contact your local Bently Nevada office. The scale factor verification procedure, the scale factor adjustment procedure, and the zero/span adjustment procedure require the following instruments: digital multimeter (2) spindle micrometer power supply

CAUTION Electrostatic discharge on the exposed calibration resistor terminals can cause the accuracy of the system to go out of specification, or cause the system to fail. Use appropriate precautions for handling static sensitive devices. The adjustment procedure also requires the following items: variable resistor, 0 to 100 kS vulcanizing compound (for example, Dow 3110 RTV) soldering iron (with grounded tip) and soldering supplies The scale factor verification and the scale factor adjustment procedure both use the test setup as shown in the following figure:

9

ITEM 2000 Maintenance and Troubleshooting

990 Transmitter System Manual

Scale Factor Verification 1

2

Compensate for mechanical backlash, then adjust the micrometer to the initial gap setting.

3

With the micrometer at the intitial gap, adjust the probe position so that the voltage is 1.00 Vdc (Electrical Zero).

Record voltages at each gap increment, and calculate scale factors.

4 n

µm 1 2 3 4 5 6 7

or 250 500 750 1000 1250 1500 1625

Calculate Scale Factor

Record Voltages

Adjust Micrometer to.. mil 10 20 30 40 50 60 65

Vdcn

ISFn (Incremental Scale Factor)

ASF (Average Scale Factor)

____ ____ ____ ____ ____ ____ ____

_____ _____ _____ _____ _____ ____*

____

* Calculate ISF for the increment between 1500 and 1625 µm (60 - 65 mil) ISF by dividing by 125 µm (5 mils).

ISF n '

ISF

10

n

'

Vdc n & Vdc n&1 250 µm

(

Vdc n & Vdc 10 mil

(

n&1

ASF '

ASF '

Vdc 1625 µm & Vdc 250

µm

1375 µm

Vdc

65 mil

& Vdc

55 mil

10 mil

ITEM 2000 990 Transmitter System Manual

If the incremental scale factor (ISF) or the average scale factor (ASF) of the system is out of tolerance (refer to page 26), contact Bently Nevada Corporation for further information on possible calibration problems or perform the following adjustment.

Scale Factor Adjustment Procedure 1

2

3

Remove label and vulcanizing compound.

Desolder calibration resistors. Use a soldering iron with a grounded tip and less than a 60 watt rating. Leave the iron in contact with the terminal for less than 10 seconds.

Attach variable resistors across the calibration terminals.

4

5

6

Compensate for mechanical backlash, then adjust the micrometer to the initial calibration gap.

Adjust the probe gap to the electrical zero voltage.

Record the voltage at the initial calibration gap.

11

ITEM 2000 Maintenance and Troubleshooting

990 Transmitter System Manual

7

8

9

Change gap to second calibration gap.

Adjust the variable resistor across Rcal-1 until V2 = ( V1 + 6 ± 0.03 ) Vdc.

Change gap to final calibration gap.

10

11

12

Repeat steps 4 through 10 until the variable resistors are not changed to obtain V2 and V3.

Adjust the variable resistor across Rcal-2 until V3 = ( V1 + 11 ± 0.06 ) Vdc.

Remove variable resistors

13

14

15

Measure resistance of variable resistors.

Solder correct resistors in place.

Reassemble transmitter.

12

ITEM 2000 990 Transmitter System Manual

Zero/Span Adjustment Procedure - Vibration Follow these steps to adjust the zero and span for the 990 vibration transmitter.

1

Adjust zero potentiometer with no input signal.

2

Adjust span potentiometer with full scale input signal.

13

ITEM 2000 Maintenance and Troubleshooting

990 Transmitter System Manual

Zero/Span Adjustment Procedure - Thrust You may adjust the 991 thrust transmitter zero and span by using either the probe input (Mechanical method) or an external test signal (Test input method). After you install the system at the machine, you may need to readjust the zero. 991 Mechanical Method

1

2

Set probe gap for a 6.5 Vdc signal measured between Prox Out and COM.

Adjust the zero potentiometer to set the loop current to 12 mA.

3

4

Set the probe gap for a full scale signal measured between Prox Out and COM.

Adjust the span potentiometer to set the full scale loop current.

14

ITEM 2000 990 Transmitter System Manual

991 Test Input Method

1

2

Short the test jumper pins together to enable the test inputs.

Set the DC test input voltage to 6.5 Vdc.

3

4

Adjust the zero potentiometer to set the loop current to 12 mA.

Set the DC test input voltage to the full scale voltage shown.

5

6

Adjust the span potentiometer to set the full scale loop current.

Remove the short across the test jumper pins.

15

ITEM 2000 Maintenance and Troubleshooting

990 Transmitter System Manual

Adjusting the 991 Zero Potentiometer at the Machine

1

With the rotor set against the active thrust shoe or in the center of the float (depending on your procedure), gap the probe so that the voltage between Prox Out and COM is 6.5 ± 0.4 Vdc.

2

If necessary, adjust the zero potentiometer until the loop current is 12 mA. Do not adjust the span potentiometer. Your may need to readjust the zero after you start the machine.

16

ITEM 2000 990 Transmitter System Manual

Troubleshooting This section shows how to interpret a fault indication and isolate faults in an installed transducer system. Before beginning this procedure, be sure the system has been installed correctly and all connectors have been secured properly in the correct locations. When a malfunction occurs, locate the appropriate fault, check the probable causes for the fault indication, and follow the procedure to isolate and correct the fault. Use a digital multimeter to measure voltage and resistance. If you find faulty transducers, please return them to the Product Repair Manager at Bently Nevada Corporation for failure analysis. The troubleshooting procedures use measured voltages as shown in the following figure and table: Vsig

Transmitter Power (-) Transmitter Power (+) Vps

Vxmtr

Symbols for Measured Voltages Symbol

Meaning

Voltage measured between...

Vsig

Signal voltage from the transmitter

Prox out and Prox com

Vps

Power supply voltage

Power Supply (+) and Power Supply (-)

Vxmtr

Transmitter supply voltage

Transmitter Power (+) and Transmitter Power (-)

Definitions Symbol A>B B
Definition "A" value is more positive than "B" "B" value is more negative than "A" "A" same value as "B"

17

ITEM 2000 990 Transmitter System Manual

Fault Type 1:

Vxmtr < 12 Vdc or Vxmtr rel="nofollow"> 35 Vdc

Possible Causes: ! Faulty power source ! Faulty field wiring ! Faulty Transmitter

Vps

Measure Vps: Vps < 12 Vdc or Vps > 35 Vdc

Faulty Power Supply

Vxmtr

Measure Vxmtr: Vxmtr < 12 Vdc or Vxmtr > 35 Vdc

Faulty Transmitter

18

Faulty Field Wiring

ITEM 2000 990 Transmitter System Manual

Fault Type 2:

Vsig = O Vdc

Possible Causes: ! Incorrect power source voltage ! Short circuit in field wiring ! Short circuit at Transmitter terminal connection ! Faulty Transmitter

Fault Type 1?

Vsig

Measure Vsig:

Short in Field Wiring

Vsig = 0 Vdc?

Test as Fault Type 3

19

ITEM 2000 990 Transmitter System Manual

Fault Type 3:

0 Vdc < Vsig < 1 Vdc

Possible Causes: ! Incorrect power source voltage ! Faulty Transmitter ! Short circuit in the probe ! Short circuit in the extension cable ! Short circuit in a connector ! Probe is incorrectly gapped (too close to target) ! Probe is detecting other material than target, such as the counterbore or part of the machine case Fault Type 1?

Vsig

Measure Vsig: 0 Vdc < Vsig < 1 Vdc

Faulty Probe, cable or connector See Fault Type 6

20

Faulty Transmitter

ITEM 2000 990 Transmitter System Manual

Fault Type 4:

13 Vdc < Vsig

Possible Causes: ! Probe is incorrectly gapped (too far from target) ! Open circuit in the probe ! Open circuit in the extension cable ! Open circuit in a connector ! Faulty Transmitter Fault Type 1?

Vsig

Short the BNJR connector

Measure Vsig: 0 Vdc < Vsig < 1 Vdc?

Faulty Transmitter

Faulty Probe, cable or connector See fault type 6

21

ITEM 2000 990 Transmitter System Manual

Fault Type 5:

Vsig = Vxmtr

Possible Causes: ! Incorrect power source voltage ! Faulty field wiring ! Faulty transmitter

Fault Type 1?

Vsig

Measure Vsig:

Faulty Transmitter

Vsig = Vxmtr?

Faulty Field Wiring

22

ITEM 2000 990 Transmitter System Manual

Fault Type 6:

Faulty probe, cable, or connector

Possible Causes: ! Short or open circuit in the probe ! Short or open circuit in the extension cable ! Short or open circuit in a connector

Inspect for clean connection: Dirty, rusty, or poor connection?

Clean connector and retest original system

Rtotal Measure resistance, Rtotal Within specifications? 5 m system: 5.3 S ± 0.7 S 7 m system: 6.5 S ± 0.9 S

Retest original system

Continued on next page

23

ITEM 2000 990 Transmitter System Manual

Rprobe

Measure resistance, Rprobe Within specifications? 0.5 m Probe: 4.0 ± 0.5 S 1.0 m Probe: 4.2 ± 0.5 S

Faulty Probe

Rshield

Rcenter

Measure Resistances, Rcenter and Rshield Within specifications? See Cable Resistance, page 31

Retest original system

24

Faulty Extension Cable

ITEM 2000 990 Transmitter System Manual

Fault Type 7:

Supply Current < 3.6 mA

Possible Causes: ! Incorrect power source voltage ! Faulty transmitter ! Short or open circuit in the probe ! Short or open circuit in the extension cable ! Short or open circuit in a connector ! Probe is incorrectly gapped (too close to target) ! Probe is detecting other material than target such as the counterbore or part of the machine case ! Thrust position is over range in the direction toward the probe (991 thrust transmitter only) Fault Type 1?

Vsig

Measure Vsig

See Fault Type 3

Vsig < 1 Vdc

Measure Vsig

See Fault Type 4

Vsig > 13 Vdc

Faulty Transmitter

25

ITEM 2000

Document Name: 4607T-2000 Rev A

ITEM 2000

ITEM 2000

ITEM 2000

ITEM 2000

ITEM 2000

ITEM 2000

ITEM 2000

ITEM 2000 3300 NSv  Proximity Probes, Metric:

Ordering Information 3300 NSv  Proximity Probes:

330901 3300 NSv  Probe, 1/4-28 UNF thread, armor 330902 3300 NSv  Probe, 1/4-28 UNF thread, armor 330908 3300 NSv  Probe, 3/8-24 UNF thread, armor 330909 3300 NSv  Probe, 3/8-24 UNF thread, armor Part Number-AXX-BXX-CXX-DXX-EXX Option Descriptions A: Unthreaded Length Option:

without with

330903 3300 NSv Probe, M8 x 1 thread, without armor 330904 3300 NSv Probe, M8 x 1 thread, with armor 330905 3300 NSv Probe, M10 x 1 thread, without armor 330910 3300 NSv Probe, M10 x 1 thread, with armor Part Number-AXX-BXX-CXX-DXX-EXX Option Descriptions

without with

A: Unthreaded Length Option:

Order in increments of 10 mm. Length configuration: Maximum unthreaded length: 230 mm

Note: Unthreaded length must be at least 0.7 inch less than the case length.

Minimum unthreaded length: 0 mm

Order in increments of 0.1 in Motor (X-Y): 05 Compressor (X-Y): 65 Compressor (Z): 15

Example: 0 6 = 60 mm

Length configurations: Maximum unthreaded length: 9.2 in

B: Overall Case Length Option:

Minimum unthreaded length: 0.0 in

Motor (X-Y): 40 Compressor (X-Y): 90 Compressor (Z): 40

Maximum length: 250 mm Minimum length: 20 mm

Order in increments of 0.1 in

Example: 0 6 = 60 mm

Threaded length configurations: Maximum case length: 9.9 in

C: Total Length Option:

Minimum case length: 0.8 in Example: 2 4 = 2.4 in

C: Total Length Option:

D: Connector and Cable-Type Option:

E: Agency Approval Option:

Part number 147385-01 Revision A, February 2001

Order in increments of 10 mm. Metric thread configurations:

Example: 0 4 = 0.4 in B: Overall Case Length Option:

Note: Unthreaded length must be at least 20 mm less than the case length.

05

0.5 metre (20 in)

10

1.0 metre (39 in)

50

5.0 metres (16.4 feet)

70

7.0 metres (23.0 feet)

00

No connector provided, standard cable

01

Miniature coaxial ClickLoc connector with connector protector

D: Connector and Cable-Type Option:

02

Miniature coaxial ClickLoc connector

00

Not required

05

Multiple Approvals

E: Agency Approval Option:

Specifications and Ordering Information

05

0.5 metre (20 in)

10

1.0 metre (39 in)

50

5.0 metres (16.4 feet)

70

7.0 metres (23.0 feet)

00

No connector provided

01

Miniature coaxial ClickLoc connector with connector protector

02

Miniature coaxial ClickLoc connector

00

Not required

05

Multiple Approvals

Page 6 of 26

ITEM 2000 3300 NSv  Reverse Mount Probe

3300 NSv  Extension Cable

330906-02-12- CXX-DXX-EXX, 3/8-24 UNF threads 330907-05-30- CXX-DXX-EXX, M10 x 1 threads Option Descriptions

330930-AXXX-BXX-CXX

C: Total Length Option:

Option Descriptions

D: Connector Option:

E: Agency Approval Option:

05

0.5 metre (20 in)

10

1.0 metre (39 in)

50

5.0 metres (16.4 feet)

70

7.0 metres (23.0 feet)

00

No connector provided

02

Miniature ClickLoc coaxial connector

Note: Make sure that the extension cable length and the probe length, when added together, equal the Proximitor® Sensor total length.

A: Cable Length Option:

00

Not required

05

Multiple Approvals

B: Connector and Cable Option:

Note: For a shorter delivery time, order commonly stocked probes. Currently, stocked probes consist of the following part numbers: 330901-00-2405-02-00, 330901-00-90-05-02-00, 330902-00-5005-02-00, 330902-00-95-05-02-00, 330903-00-0210-02-00, 330903-00-03-10-02-00, 330906-02-1205-02-00.

3300 XL NSv  Proximitor® Sensor

C: Agency Approval Option:

330980-AXX-BXX Option Descriptions A: Total Length and Mounting Option:

B: Agency Approval Option:

040

4.0 metres (13.1 feet)

045

4.5 metres (14.8 feet)

060

6.0 metres (19.7 feet)

065

6.5 metres (21.3 feet)

00

Without stainless steel armor

01

With stainless steel armor, with FEP jacket

02

With stainless steel armor, without FEP jacket

03

Without stainless steel armor, with connector protectors

04

With stainless steel armor, with FEP jacket, with connector protectors

05

With stainless steel armor, without FEP jacket, with connector protectors

00

Not required

05

Multiple Approvals

50

5.0 metre (16.4 feet) system length, panel mount

51

5.0 metre (16.4 feet) system length, DIN mount

147357-01

Manual

52

5.0 metre (16.4 feet) system length, no mounting hardware 1

147347 02120015

Performance Specification Bulk field wire. 1.0 mm 2 (18 AWG),

Accessories

3 conductor, twisted, shielded cable with drain wire. Specify length in feet.

70

7.0 metres (23.0 feet) system length, panel mount

71

7.0 metres (23.0 feet) system length, DIN mount

138492-01

Replacement panel-mount mounting pad

72

7.0 metres (23.0 feet) system length, no mounting hardware 1

138493-01

Replacement DIN-mount mounting pad

01609137

BNC (F) to banana plugs

00

Not required

05

Multiple approvals

01609138

Proximitor® Connector Test Pin wiring (two test pins to a BNC (F) connector)

BNC Part number 147385-01 Revision A, February 2001

Specifications and Ordering Information

Page 7 of 26

ITEM 2000 Hex Nut 5.26 Dia. Max. (0.207) Probe Tip

Wrench Flats Case Thread

75 ohm Cable 2.8 (0.11) Max. Outside Dia. 7.6 (0.30) Max. Outside Dia. of Armor

Miniature Male 3.23 (0.127) Coaxial Connector Unthreaded Length 7.23 (0.285) Outside "A" Dia. Maximum "D" Case Length "B" 2.92 (0.115) Max. Total Length "C", +30%, -0% Figure 18 3300 NSv  Proximity probes, Standard Mount 330901, ¼ -28 UNF-2A, without armor 330902, ¼ -28 UNF-2A, with armor 330903, M8x1 thread, without armor 330904, M8x1 thread, with armo r 330905, M10x1 thread, without armor 330908, 3/8-24 UNF-2A, without armor 330909, 3/8-24 UNF 2A, with armo r 330910, M10x1 thread, with armo r

Figure 19 Installed Connector Protectors

BNC Part number 147385-01 Revision A, February 2001

Specifications and Ordering Information

Page 23 of 26

ITEM 2000 7/16 or 10mm Case 5.26 Hex Dia. Max. Thread (0.207) 75 ohm Cable Probe Tip 2.8 (0.11) outside Dia.

5.08 (0.20) Unthreaded Length "A" 5.08 (0.20)

Miniature Male Coaxial Connector 7.23 (0.285) Outside Dia. Maximum "D"

Case Length "B" 30.48 (1.20) 2.92 (0.115) Max. Total Length "C", +30%, -0% Figure 20 3300 NSv  Proximity Probes, Reverse Mount 330906, 3/8-24 UNF-2A threads 330907, M10x1 threads

75 ohm cable 2.80 (0.11) max. O.D. 7.6 (0.30) Max. O.D. of Armor FEP Coated or 7.0 (0.275) Max. O.D. of Uncoated Armor Uncoated Armor 51 7.2 (0.285) 51 Armor Length: Max. Dia. (2.0) (2.0) 300 (11.8) less than cable length

Miniature Male Coaxial Connector 7.2 (0.285) Max. Dia.

82.6 82.6 FEP Insulated (3.25) (3.25) Coaxial Cable Stainless Steel Ferrules Miniature Female Coaxial Connector 8.4 (0.33) Dia. Cable Length +20%, -0%

Figure 21 330930, 3300 NSv  Extension Cable

BNC Part number 147385-01 Revision A, February 2001

Specifications and Ordering Information

Page 24 of 26

ITEM 2000 take reasonable precautions to avoid electrostatic discharge during handling.

Proximitor® Sensor The 3300 XL NSv Proximitor® Sensor has similar features to those found in the 3300 XL 8 mm Proximitor® Sensor. Its thin design allows it to be mounted in either a highdensity DIN-rail installation or a more traditional panel mount configuration. Improved RFI/EMI immunity allows the 3300 XL NSv™ Proximitor® Sensor to achieve European CE mark approvals without any special mounting considerations. This RFI immunity also prevents the transducer system from being adversely affected by nearby high frequency radio signals. SpringLoc terminal strips on the Proximitor® Sensor require no special installation tools and facilitate faster, highly robust field wiring connections.

Proximity Probe and Extension Cable The 3300 NSv™ probe and extension cable are mechanically and electrically compatible and interchangeable with our previous 3300 RAM proximity probe and extension cable. The NSv™ probe has increased chemical resistance compared to the 3300 RAM probe, allowing it to be used in many process compressor applications. The 3300 NSv™ probe also has superior side-view characteristics compared to the 3000-series 190 probe when gapping the 3300 NSv™ probe at the same distance from the probe target. The 3300 NSv probe comes in varying probe case configurations, including armored and unarmored ¼ -28, 3 ⁄ 8 -24, M8 X 1 and M10 X 1 probe threads. The reverse mount 3300 NSv probe comes standard with either 3 ⁄ 8 -24 or M10 X 1 threads. All components of the transducer system have gold-plated brass ClickLoc™ connectors. ClickLoc™ connectors lock into place, preventing the connection from loosening. The patented TipLoc™ molding method provides a robust bond between the probe tip and the probe body. The probe cable is securely attached to the probe tip utilizing our patented CableLoc™ design that provides 220 N (50 lb) pull strength.

Notes: 1

Proximitor® Sensors are supplied by default from the factory calibrated to AISI 4140 steel. Calibration to other target materials is available upon request.

2

Silicone tape is also provided with each 3300 NSv  extension cable and can be used instead of connector protectors. Silicone tape is not recommended in applications where the probe-to-extension cable connection will be exposed to turbine oi l .

Specifications Unless otherwise noted, the following specifications are for a 3300 XL NSv™ Proximitor® Sensor, extension cable and probe between 0 °C and +45°C (+32°F to +113°F), with a 24 Vdc power supply, a 10 k Ω load, a Bently Nevada supplied AISI 4140 steel target that is 31 mm (1.2 in) diameter or larger, and a probe gap of 1.0 mm (40 mils). The system accuracy and interchangeability specifications do not apply when using a transducer system calibrated to any target other than a Bently Nevada AISI 4140 steel target.

Electrical Proximitor® Sensor Input

Accepts one noncontacting 3300 RAM or 3300 NSv™ Proximity Probe and Extension Cable.

Power

Requires -17.5 Vdc to -26 Vdc without barriers at 12 mA maximum consumption, -23 Vdc to -26 Vdc with barriers. Operation at a more positive voltage than -23.5 Vdc can result in reduced linear ra n g e .

Supply Sensitivity

Less than 2 mV change in output voltage per volt change in input voltage.

Output resistance

50 Ω

Connector protectors are recommended for use on the probe-to-extension cable connection, as well as on the cable-to-Proximitor® Sensor connection. Connector protectors prevent most liquids from entering into the ClickLoc™ connectors and adversely affecting the electrical signal 2 .

Part number 147385-01 Revision A, February 2001

Specifications and Ordering Information

Page 2 of 26

ITEM 2000 Probe dc resistance: Resistance from the Center Conductor to the Outer

Probe Length (m)

Conductor (RPROBE) (ohms)

0.5

4.0 ± 0.5

1.0

4.2 ± 0.5

5.0

5.3 ± 0.7

7.0

5.9 ± 0.9

Extension cable dc resistance:

Target Size (flat target):

Field wiring:

Recommended Gap Setting:

Center conductor: 0.220Ω/m(0.067 Ω/ft) Shaft Diameter

69.9 pF/m (21.3 pF/ft) typical 0.2 to 1.5 mm 2 (16 to 24 AWG)

Measurements on shaft diameters smaller than 30 mm (1.2 in) usually require close spacing of radial vibration or axial position transducers with the potential for their electromagnetic emitted fields to interact with one another (crosstalk), resulting in erroneous readings. To prevent cross-talk, maintain minimum separation of transducer tips of at least 25 mm (1.0 in) for axial position measurements or 23 mm (0.9 in) for radial vibration measurements (see Figure 14 and Figure 15 for additional information.) Radial vibration or radial position measurements on shaft diameters smaller than 20 mm (0.8 in) will generally result in greater than a 10% change in Average Scale Factor (ASF). See Figure 13 for additional information.

1.0 mm (40 mils)

Counterbore

Less than ± 0.06 mm (± 2.3 mils).

BNC Part number 147385-01 Revision A, February 2001

Minimum (standard X-Y probe configuration): 30 mm (1.2 in) Minimum (X-Y proximity probes offset axially by 23 mm (0.9 in)): 20 mm (0.8 in)

1.5 mm (60 mils). Linear range begins at approximately 0.25 mm (10 mils) from target and is from 0.25 to 1.75 mm (10 to 70 mils) (approximately -1 to -13 Vdc).

System performance over ambient temperature range (0°° C to 45°° C): Incremental Scale Factor (ISF ) 7.87 V/mm (200 mV/mil) +12.5%/20% including interchangeability error when measured in increments of 0.25 mm (10 mils) over the 1.5 mm (60 mil) linear range. Deviation from best fit straight line (DSL)

Minimum: 8.9 mm (0.35 in) diameter

Axial position measurements on shaft diameters smaller than 13mm (0.5 in) will generally result in a change in scale factor. Reducing the gap between the probe and target will help limit the change in scale factor. See Figure 12 for additional information.

[0.25 to 0.75 mm 2 (18 to 23 AWG) with ferrules]. Recommend using three-conductor shielded triad cable. Maximum length of 305 metres (1,000 feet) between the 3300 XL NSv™ Proximitor® Sensor and the monitor. See the frequency response graphs Figure 16 and Figure 17 for signal rolloff at high frequencies when using longer field wiring lengths. Linear Range:

0 to 10 kHz: +0, -3 dB typical, with up to 305 metres (1000 feet) of field wiring.

Recommended minimum: 13 mm (0.5 in) diameter

Shield: 0.066 Ω/m (0.020 Ω/ft) Extension cable capacitance:

Frequency Response:

Specifications and Ordering Information

Minimum: 9.5 mm (0.375 in) Recommended minimum: 13 mm (0.5 in) Counterbores smaller than 13 mm (0.5 in) generally result in a change in scale factor at far gaps. Page 3 of 26

ITEM 2000 T5 @ Ta= -35°C to +85°C.

Reducing the gap between the probe and the target will allow the transducer system to maintain its Average Scale Factor (ASF) over a reduced linear range. See Figure 9 for additional information.

EEx nA for Zone 2, Group IIC, BASEEFA certificate number BAS99ATEX3100U.

Effects of 60 Hz Magnetic Fields Up to 300 Gauss (5 metre system) Output voltage in mil pp/gauss: Proximitor  Sensor

Probe

0.25 mm (10 mil)

0.006

0.001

1.0 mm (40 mil)

0.007

0.002

0.001

1.75 mm (70 mil)

0.008

0.002

0.003

Gap

Electrical Classification:

Ext. Cable

0.001

Complies with the European CE mark.

Probe Tip Material:

Polyphenylene sulfide (PPS).

Probe Case Material:

AISI 304 stainless steel (SST).

Probe Cable Specifications:

Extension Cable Material: Proximitor® Sensor Material: System Length:

Hazardous Area Approvals Multiple approvals for hazardous areas certified by Canadian Standards Association (CSA/NRTL/C) in North America and by BASEEFA/CENELEC in Europe. North America:

Mechanical

Ex ia IIC T5; Class I Zone 0 or Exia IIC T5 for Class 1 Division 1; Groups A, B, C, and D, when installed with intrinsically safe zener barriers per drawing 141092 or when installed with galvanic isolators.

Extension Cable Armor (optional): Tensile Strength (maximum rated):

Connector material:

75 Ω coaxial, fluoroethylene propylene (FEP) insulated probe cable in the following total probe lengths: 0.5, 1, 5, or 7 metres. 75 Ω coaxial, fluoroethylene propylene (FEP) insulated. A380 aluminu m 5 or 7 metres including extension cable Flexible AISI 302 SST with/without FEP outer jacket. 220 N (50 lb) probe case to probe lead. 220 N (50 lb) at probe lead to extension cable connectors. 220 N (50 lb) probe case to stainless steel armor. Gold-plated bras s

ExnA IIC T5 Class I Zone 2 or ExnA IIC T5 for Class I, Division 2, Groups A, B, C, and D when installed without barriers per drawing 1 4 0 9 7 9 . T 5 @ Ta = -35°C to +85°C. Europe:

Part number 147385-01 Revision A, February 2001

EExia IIC T5 for Zones 0, 1 and 2, Group IIC, BASEEFA certificate number BAS99ATEX1101, when installed with intrinsically safe zener barriers or galvanic isolators, Specifications and Ordering Information

Page 4 of 26

ITEM 2000 Connector-to-connector torque Probe case torque:

Maximum Rated

Recommended

¼ -28 or M8x1 probe cases

7.3 N•m

5.1 N•m

(65 in•lb)

(45 in•lb)

33.9 N•m

11.3 N•m

(300 in•lb)

(100 in•lb)

22.6 N•m

7.5 N•m

(200 in•lb)

(66 in•lb)

22.6 N•m

7.5 N•m

(200 in•lb)

(66 in•lb)

3/8-24 or M10x1 probe cases 3/8-24 or M10x1 probe cases – first three threads Reverse mount probes

Recommended torque:

Finger tight

Maximum torque:

0.56 N•m (5 in•lb)

Minimum Bend Radius (with or without sst armor):

25.4 mm (1.0 in)

Extension Cable Temperature Range Operating and Storage Temperature: -51° C to +177° C (-60° F to +351° F) Proximitor® Sensor Temperature Range Operating Temperature: -35° C to +85° C (-31° F to +185° F) Storage Temperature:

-51° C to +105° C (-60° F to +221° F)

Relative Humidity:

100% condensing, non-submersible when connectors are protected. Tested to IEC 68-2-3 damp heat.

Probe Pressure:

3300 NSv™ probes are designed to seal differential pressure between the probe tip and case. The probe sealing material consists of a Viton® O-ring. Probes are not pressure tested prior to shipment. Contact our custom design department if you require a test of the pressure seal for your application Note: It is the responsibility of the customer or user to ensure that all liquids and gases are contained and safely controlled should leakage occur from a proximity probe. In addition, solutions with high or low pH values may erode the tip assembly of the probe causing media leakage into surrounding areas. Bently Nevada Corporation will not be held responsible for any damages resulting from leaking 3300 NSv™ Proximity Probes. In addition, 3300 NSv™ Proximity Probes will not be replaced under the service plan due to probe leakage.

System Weight (typical) : Probe:

Approximately 14 to 150 g (0.5 to 5 oz)

Extension Cable:

45 g/m (0.5 oz /ft)

Armored Extension Cable:

64 g/m (0.7 oz /ft)

Proximitor® Sensor:

255 g (9 oz )

Patents:

5,016,343 5,126,664

Environmental Limits

5,351,388

Probe Temperature Range Operating Temperature: -34° C to +177° C (-30° F to +351° F)

5,685,884

Storage Temperature:

Components or procedures described in these patents apply to this product.

-51° C to +177° C (-60° F to +351° F) Note: Exposing the probe to temperatures below -34°C (-30°F) for a sustained period of time may cause premature failure of the pressure seal.

BNC Part number 147385-01 Revision A, February 2001

Specifications and Ordering Information

Page 5 of 26

ITEM 2500 Preface SIMATIC HMI HMI devices MP 377, MP 377 PRO (WinCC flexible)

SIMATIC HMI HMI devices MP 377, MP 377 PRO (WinCC flexible) Operating Instructions

1 Overview ______________ Safety instructions and approvals

2 ______________ 3 Planning application ______________ 4 Mounting and connecting ______________ Operator controls and displays

5 ______________ Configuring the operating system

6 ______________ 7 Commissioning a project ______________ 8 Operating a project ______________ 9 Operating alarms ______________ 10 Operating recipes ______________ 11 Maintenance and care ______________ 12 Technical specifications ______________ A Appendix ______________

Ordernumber: 6AV6691-1DR01-0AB0

10/2008

A5E01003518-03

B Abbreviations ______________

ITEM 2500 Legal information

Legal information

Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.

Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed.

Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY

Ordernumber: 6AV6691-1DR01-0AB0 Ⓟ 11/2008

Copyright © Siemens AG 2008. Technical data subject to change

ITEM 2500

Preface Purpose of the operating instructions These operating instructions provide information based on the requirements defined by DIN EN 62079 for mechanical engineering documentation. This information relates to the place of use, transport, storage, mounting, use and maintenance. These operating instructions are intended for: ● Users ● Commissioning engineers ● Maintenance personnel Read especially the information in the section "Safety instructions" (Page 37). The help integrated in WinCC flexible, the WinCC flexible Information System, contains detailed information. The information system contains instructions, examples and reference information in electronic form.

Basic knowledge required General knowledge of automation technology and process communication is needed to understand the operating instructions. It is also assumed that those using the manual have experience in using personal computers and knowledge of Microsoft operating systems.

Scope of the operating instructions The operating instructions apply to the following HMI devices in conjunction with the WinCC flexible software package: ● MP 377 12" Touch ● MP 377 12" Key ● MP 377 15" Touch ● MP 377 19" Touch ● MP 377 PRO 15" Touch

Trademarks The following designations marked with the symbol ® are registered trademarks of Siemens AG: ● HMI® ● SIMATIC® ● WinCC® ● SIMATIC MP 377®

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

3

ITEM 2500 Preface

Position in the information landscape These operating instructions form part of the SIMATIC HMI documentation. You can obtain an overview of SIMATIC hardware and SIMATIC software products and SIMATIC systems and information that can be called up in PDF format in various languages at the following address: "http://www.automation.siemens.com/simatic/portal/html_76/techdoku.htm" The following designations are used in these operating instructions to represent multiple HMI devices: "MP 377" designates all MP 377 HMI devices. "MP 377 mounting device" designates the following HMI devices: ● MP 377 12" Touch ● MP 377 12" Key ● MP 377 15" Touch ● MP 377 19" Touch "MP 377 PRO" designates the following HMI devices: ● MP 377 PRO 15" Touch

Conventions The following text notation will facilitate reading the Operating Instructions: Notation

Scope

"Add screen"

• • •

Terms that appear in the user interface, for example, dialog names, tabs, buttons, menu commands Inputs required, for example limit values, tag values. Path information

"File > Edit"

Operational sequences, for example, menu commands, shortcut menu commands

,

Keyboard operation

Please observe notes labeled as follows: Note Notes contain important information concerning the product, its use or a specific section of the documentation to which you should pay particular attention.

Figures in this documentation This documentation contains figures pertaining to the hardware described herein. Newer versions of the HMI device may differ from these figures.

4

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Preface

Representatives and office locations If you have any further questions relating to the products described in this manual, please contact your local representative at the Siemens branch nearest you. Locate your contact person at "http://www.automation.siemens.com/partner".

Training center Siemens AG offers a variety of training courses in order to familiarize you with automation systems. Contact your regional Training Center or the central Training Center in D-90327 Nuremberg, Germany. Internet: "http://www.sitrain.com"

Technical support Technical support for all industry sector products is available as follows: Using the web form to request support "http://www.siemens.com/automation/support-request" Additional information about our technical support is available on the Internet under "http://support.automation.siemens.com".

Service & Support on the Internet Service & Support provides additional comprehensive information on SIMATIC products through online services at "http://support.automation.siemens.com": ● The newsletter offers you the latest information about your products ● A large document base is available using our Service & Support search engine ● A forum for global exchange of information by users and experts ● Current product information, FAQs and downloads ● You local representative ● Information about on-site services, repairs, spare parts, and more

Recycling and disposal The HMI devices described in these operating instructions can be recycled due to the low levels of pollutants. Contact a certified disposal service company for environmentally sound recycling and disposal of your old devices.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Preface

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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Table of contents Preface ...................................................................................................................................................... 3 1

2

3

Overview.................................................................................................................................................. 13 1.1

Product overview .........................................................................................................................13

1.2 1.2.1 1.2.2 1.2.3 1.2.4

MP 377 mounting devices............................................................................................................15 Design of the MP 377 12" Touch .................................................................................................15 Design of the MP 377 12" Key.....................................................................................................17 Design of the MP 377 15" Touch .................................................................................................19 Design of the MP 377 19" Touch .................................................................................................21

1.3 1.3.1 1.3.2

MP 377 PRO ................................................................................................................................23 Design of the MP 377 PRO 15" Touch ........................................................................................23 Structure of the basic adapter......................................................................................................24

1.4

Accessory kit ................................................................................................................................25

1.5

Accessories..................................................................................................................................26

1.6

The HMI device in the operating process ....................................................................................28

1.7

Functional scope with WinCC flexible..........................................................................................29

1.8

Software options ..........................................................................................................................32

1.9

Communication ............................................................................................................................33

Safety instructions and approvals ............................................................................................................ 37 2.1

Safety instructions........................................................................................................................37

2.2

Standards, certificates and approvals..........................................................................................39

2.3

Notes about usage.......................................................................................................................41

2.4

Electromagnetic compatibility ......................................................................................................42

2.5

Transport and storage conditions ................................................................................................44

Planning application................................................................................................................................. 45 3.1

Notes about usage.......................................................................................................................45

3.2 3.2.1 3.2.2 3.2.3 3.2.4

MP 377 mounting devices............................................................................................................47 Mounting positions and type of fixation........................................................................................47 Preparing for installation ..............................................................................................................48 Information on insulation tests, protection class and degree of protection..................................50 Rated voltages .............................................................................................................................50

3.3 3.3.1 3.3.2 3.3.3 3.3.4

MP 377 PRO ................................................................................................................................51 Mounting positions .......................................................................................................................51 Preparing for installation ..............................................................................................................51 Information on insulation tests, protection class and degree of protection..................................52 Rated voltages .............................................................................................................................52

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ITEM 2500 Table of contents

4

5

6

8

Mounting and connecting......................................................................................................................... 53 4.1

Checking the package contents.................................................................................................. 53

4.2 4.2.1 4.2.2

Installing the HMI device ............................................................................................................. 54 Installing the MP 377 mounting device ....................................................................................... 54 Installing MP 377 PRO................................................................................................................ 58

4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.3.9 4.3.10

Connecting the HMI device ......................................................................................................... 61 Overview ..................................................................................................................................... 61 Ports ............................................................................................................................................ 62 Connecting the equipotential bonding circuit .............................................................................. 63 Connecting the power supply...................................................................................................... 65 Connecting an uninterruptible power supply............................................................................... 67 Connecting the PLC .................................................................................................................... 68 Connecting the configuration PC ................................................................................................ 71 Connecting a USB device ........................................................................................................... 74 Connecting a printer.................................................................................................................... 75 Connecting an audio device........................................................................................................ 76

4.4

Switching on and testing the HMI device .................................................................................... 77

4.5 4.5.1 4.5.2

Securing the cables..................................................................................................................... 79 Securing cables on the MP 377 mounting device....................................................................... 79 Securing cables on the MP 377 PRO ......................................................................................... 79

4.6

Closing the housing rear wall of MP 377 PRO............................................................................ 80

Operator controls and displays ................................................................................................................ 81 5.1

Front operator controls................................................................................................................ 81

5.2

Inserting a memory card ............................................................................................................. 83

5.3

Securing memory card ................................................................................................................ 84

5.4

Unplugging the memory card...................................................................................................... 85

5.5

Labeling the function keys on the MP 377 12" Key .................................................................... 86

Configuring the operating system ............................................................................................................ 89 6.1

Loader ......................................................................................................................................... 89

6.2

Setting up and disabling SecureMode ........................................................................................ 94

6.3

Viewer ......................................................................................................................................... 95

6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.4.1 6.4.4.2 6.4.4.3

Control Panel .............................................................................................................................. 96 Overview ..................................................................................................................................... 96 Opening the Control Panel.......................................................................................................... 97 Reference for functions ............................................................................................................... 98 Operating the Control Panel ....................................................................................................... 99 Overview ..................................................................................................................................... 99 Operation using the touch screen ............................................................................................. 100 Operation with the keyboard ..................................................................................................... 102

6.5 6.5.1 6.5.2 6.5.3 6.5.4

Changing settings for operation ................................................................................................ 106 Configuring the screen keyboard .............................................................................................. 106 Setting the character repeat...................................................................................................... 107 Setting the double-click ............................................................................................................. 108 Calibrating the touch screen ..................................................................................................... 110

6.6

Setting up password protection................................................................................................. 112

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6.7

Canceling password protection..................................................................................................113

6.8 6.8.1 6.8.2 6.8.3 6.8.4 6.8.5 6.8.6 6.8.7 6.8.8 6.8.9 6.8.10 6.8.11 6.8.12

Changing HMI device settings ...................................................................................................114 Setting the date and time ...........................................................................................................114 Changing regional settings ........................................................................................................115 Backup registry information .......................................................................................................116 Changing monitor settings .........................................................................................................118 Setting the screen saver ............................................................................................................119 Changing the printer properties .................................................................................................120 Enabling sound and setting sound volume ................................................................................122 Assigning sound to an event......................................................................................................124 Restarting the HMI device..........................................................................................................125 Displaying information about the HMI device ............................................................................127 Displaying system properties .....................................................................................................128 Displaying memory distribution ..................................................................................................129

6.9

Setting storage location .............................................................................................................130

6.10

Setting the delay time ................................................................................................................131

6.11

Setting the uninterruptible power supply....................................................................................132

6.12

State of uninterruptible power supply ........................................................................................133

6.13

Enabling PROFINET IO .............................................................................................................134

6.14 6.14.1 6.14.2

Changing transfer settings .........................................................................................................136 Configuring the data channel .....................................................................................................136 Changing MPI/PROFIBUS DP settings .....................................................................................139

6.15 6.15.1 6.15.2 6.15.3 6.15.4 6.15.5 6.15.6 6.15.6.1 6.15.6.2 6.15.6.3 6.15.6.4

Configuring network operation ...................................................................................................142 Overview of network operation ..................................................................................................142 Setting the device name of the HMI device ...............................................................................144 Changing the network configuration ..........................................................................................145 Changing the logon data............................................................................................................147 Changing e-mail settings ...........................................................................................................148 Changing Internet settings .........................................................................................................149 Changing general Internet settings............................................................................................149 Setting the proxy server .............................................................................................................150 Changing privacy settings..........................................................................................................150 Importing and deleting certificates .............................................................................................152

6.16

Saving to external storage device (backup)...............................................................................153

6.17

Restoring from external storage device .....................................................................................155

6.18

Activate memory management ..................................................................................................158

Commissioning a project ....................................................................................................................... 159 7.1

Overview ....................................................................................................................................159

7.2

Operating modes .......................................................................................................................160

7.3

Using existing projects ...............................................................................................................161

7.4

Data transmission options..........................................................................................................162

7.5 7.5.1 7.5.2 7.5.3 7.5.4 7.5.5

Transfer......................................................................................................................................163 Overview ....................................................................................................................................163 Starting manual transfer.............................................................................................................163 Starting automatic transfer.........................................................................................................164 Starting backtransfer..................................................................................................................166 Testing a project ........................................................................................................................167

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7.6 7.6.1 7.6.2 7.6.3

Backup and restore ................................................................................................................... 168 Overview ................................................................................................................................... 168 Backup and restore using WinCC flexible................................................................................. 169 Backup and restore using ProSave .......................................................................................... 171

7.7 7.7.1 7.7.2 7.7.3 7.7.4 7.7.5 7.7.6

Updating the operating system ................................................................................................. 173 Overview ................................................................................................................................... 173 Resetting factory settings.......................................................................................................... 174 Updating the operating system using WinCC flexible............................................................... 175 Updating the operating system using ProSave......................................................................... 176 Resetting to factory settings with WinCC flexible ..................................................................... 177 Resetting to factory settings with ProSave ............................................................................... 180

7.8 7.8.1 7.8.2 7.8.3

Installing and removing options ................................................................................................ 182 Overview ................................................................................................................................... 182 Installing and removing options using WinCC flexible .............................................................. 183 Installing and removing options using ProSave........................................................................ 185

7.9 7.9.1 7.9.2

Transferring and transferring back license keys ....................................................................... 186 Overview ................................................................................................................................... 186 Transferring and transferring back license keys ....................................................................... 187

Operating a project ................................................................................................................................ 189 8.1

Overview ................................................................................................................................... 189

8.2

Direct keys ................................................................................................................................ 192

8.3

Setting the project language ..................................................................................................... 193

8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6

Entries using the touch screen.................................................................................................. 193 Overview ................................................................................................................................... 193 Entering and editing numerical values ...................................................................................... 195 Entering and editing alphanumerical values ............................................................................. 197 Entering the date and time ........................................................................................................ 199 Entering symbolic values .......................................................................................................... 199 Displaying infotext ..................................................................................................................... 200

8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.5.8 8.5.9

Entries using the keys ............................................................................................................... 201 Control keys .............................................................................................................................. 201 Example: enter characters using the alphanumeric keyboard.................................................. 204 Function keys ............................................................................................................................ 204 General procedures .................................................................................................................. 205 Entering and editing numerical values ...................................................................................... 205 Entering and editing alphanumerical values ............................................................................. 207 Entering the date and time ........................................................................................................ 208 Entering symbolic values .......................................................................................................... 208 Displaying infotext ..................................................................................................................... 209

8.6

Bar and gauge........................................................................................................................... 210

8.7

Operating the switch ................................................................................................................. 211

8.8

Operating the trend view ........................................................................................................... 212

8.9

Operating the slider control ....................................................................................................... 214

8.10 8.10.1 8.10.2 8.10.3

Operating the Status Force ....................................................................................................... 216 Overview ................................................................................................................................... 216 Touch operation ........................................................................................................................ 217 Key control ................................................................................................................................ 218

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10

8.11 8.11.1 8.11.2 8.11.3

Operating the Sm@rtClient view ...............................................................................................220 Overview ....................................................................................................................................220 Touch operation .........................................................................................................................221 Key control .................................................................................................................................223

8.12 8.12.1 8.12.2 8.12.3 8.12.4 8.12.5 8.12.5.1 8.12.5.2 8.12.6 8.12.6.1 8.12.6.2 8.12.7

Project security ..........................................................................................................................224 Overview ....................................................................................................................................224 User view ...................................................................................................................................226 User logon..................................................................................................................................227 User logoff..................................................................................................................................228 Creating users............................................................................................................................229 Creating users with touch operation ..........................................................................................229 Creating users with key operation..............................................................................................230 Changing user data....................................................................................................................233 Changing user data with touch operation ..................................................................................233 Changing user data with key operation .....................................................................................234 Deleting users ............................................................................................................................235

8.13

Closing the project .....................................................................................................................236

Operating alarms ................................................................................................................................... 237 9.1

Overview ....................................................................................................................................237

9.2

Detecting queued alarms ...........................................................................................................239

9.3

Message display ........................................................................................................................240

9.4

Displaying infotexts ....................................................................................................................242

9.5

Acknowledge alarm....................................................................................................................243

9.6

Editing alarms ............................................................................................................................244

Operating recipes .................................................................................................................................. 245 10.1

Overview ....................................................................................................................................245

10.2

Structure of a recipe...................................................................................................................246

10.3

Recipes in the project ................................................................................................................248

10.4

Recipe displays..........................................................................................................................250

10.5

Recipe values in the HMI device and the PLC ..........................................................................253

10.6 10.6.1 10.6.2 10.6.3 10.6.4 10.6.5 10.6.6 10.6.7

Operating the recipe view ..........................................................................................................254 Overview ....................................................................................................................................254 Creating a recipe data record ....................................................................................................255 Editing a recipe data record .......................................................................................................257 Deleting a recipe data record.....................................................................................................258 Synchronizing tags.....................................................................................................................259 Reading a recipe data record from the PLC ..............................................................................260 Transferring a recipe data record to the PLC ............................................................................261

10.7 10.7.1 10.7.2 10.7.3 10.7.4 10.7.5 10.7.6

Operating the simple recipe view...............................................................................................262 Overview ....................................................................................................................................262 Creating a recipe data record ....................................................................................................264 Editing a recipe data record .......................................................................................................265 Deleting a recipe data record.....................................................................................................266 Reading a recipe data record from the PLC ..............................................................................267 Transferring a recipe data record to the PLC ............................................................................268

10.8

Importing a recipe data record ...................................................................................................269

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ITEM 2500 Table of contents

10.9

Exporting a recipe data record.................................................................................................. 270

10.10 Examples .................................................................................................................................. 271 10.10.1 Entering a recipe data record.................................................................................................... 271 10.10.2 Manual production sequence.................................................................................................... 272 11

12

A

B

Maintenance and care ........................................................................................................................... 273 11.1

Maintaining and caring for the touch screen and keyboard overlay ......................................... 273

11.2

Clean screen on MP 377 Touch ............................................................................................... 274

11.3

Spare parts and repairs............................................................................................................. 274

Technical specifications......................................................................................................................... 275 12.1 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5

Dimension drawings.................................................................................................................. 275 Dimension drawings of the MP 377 12" Touch......................................................................... 275 Dimension drawings of the MP 377 12" Key............................................................................. 276 Dimension drawings of the MP 377 15" Touch......................................................................... 277 Dimension drawings of the MP 377 19" Touch......................................................................... 278 Dimension drawings of the MP 377 PRO 15" Touch ................................................................ 279

12.2

Specifications ............................................................................................................................ 280

12.3

Bit assignment of the direct keys .............................................................................................. 282

12.4 12.4.1 12.4.2 12.4.3 12.4.4 12.4.5

Description of the ports ............................................................................................................. 283 Power supply............................................................................................................................. 283 X10/IF 1B (RS 422/RS 485)...................................................................................................... 283 X1 (PROFINET) ........................................................................................................................ 284 X20, X21 (USB)......................................................................................................................... 284 X40 (line out)............................................................................................................................. 285

Appendix................................................................................................................................................ 287 A.1

ESD guideline ........................................................................................................................... 287

A.2

System alarms .......................................................................................................................... 289

Abbreviations......................................................................................................................................... 321 Glossary ................................................................................................................................................ 323 Index...................................................................................................................................................... 329

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1

Overview 1.1

Product overview The Multi Panel MP 377 HMI devices are an innovative advanced development of the 370 series. In addition to the established display sizes of 12", 15", and 19", the product series was expanded to include the Multi Panel MP 377 PRO 15" Touch offering all around IP65 degree of protection. The distinguishing feature of the HMI devices is that they fulfill the increasing demands for technical innovation – especially in regard to display, performance and extended applications.

Hardware equipment The Multi Panel MP 377 has a TFT display with 64 K colors and improved performance compared to predecessor devices. The Multi Panel MP 377 is based on Microsoft Windows CE 5.0. Compared with previous devices, its multimedia functionality has been greatly extended. Integration of the Microsoft Media Player allows the MP 377 to play videos. Internet Explorer 6.0 for pocket PCs is pre-installed on the HMI devices and extends the ways in which web pages can be displayed. Word documents, Excel spreadsheets and PDF documents can be displayed with Microsoft Viewer. The user memory has been expanded, and a retentive maintenance-free alarm buffer integrated. A retentive memory for PLC data is provided to support WinAC MP. Thanks to the wide range of devices, you can use the device best suited to your needs. The MP 377 can be used for a wide range of applications, and offers high performance and a favorable cost/performance ratio. The HMI device has: ● 1 PROFIBUS interface ● 2 Ethernet ports for connection to PROFINET ● 2 USB 2.0 ports ● 1 slot for an SD memory card or multimedia card ● 1 CF card slot ● 1 TFT display with up to 64 K colors The following extra software options have been added to the functions of the MP 377 as a "multifunctional platform": ● WinCC flexible /Sm@rtService ● WinCC flexible /Sm@rtAccess ● WinCC flexible /OPC Server ● WinCC flexible /ProAgent ● WinCC flexible /Audit ● WinAC MP 2007

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Overview 1.1 Product overview

IP65 all-round The Multi Panel MP 377 PRO, which features a housing with IP65 degree of protection, all around protection against dust and water jets. The ready-to-use HMI device can be fixed either from the top or the bottom to a support arm system or to a stand. A basic adapter and adapter sets that can be ordered separately support fixing systems from various manufacturers (including VESA standard for flat screens). The rear wall can be removed quite easily. The interfaces of the HMI device can therefore be reached without any problems. You do not require any special cables or connectors. The Multi Panel MP 377 PRO is impressive not only due to ease of servicing but also because of its sophisticated design and slimline device depth.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Overview 1.2 MP 377 mounting devices

1.2

MP 377 mounting devices

1.2.1

Design of the MP 377 12" Touch

Front view and side view

  



 ①

Slot for an SD memory card or multimedia card

②

Slot for a CF memory card

③

Display/touch screen

④

Oblong holes for mounting clamps

⑤

Mounting seal

Bottom view   ①

Ports

②

Oblong holes for mounting clamps

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ITEM 2500 Overview 1.2 MP 377 mounting devices

Rear view

   



①

Slot for an SD memory card or multimedia card

②

Rating label

③

Slot for a CF memory card

④

DIP switch

⑤

Interface name

See also Ports (Page 62)

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Overview 1.4 Accessory kit

1.4

Accessory kit

Accessory kit for MP 377 mounting device The accessory kit contains the following: ● Mains terminal for the power supply ● Mounting clamps for mounting the HMI device Additional documents may be enclosed with the accessory kit.

Accessory kit for MP 377 PRO The accessory kit contains the following: ● Mains terminal for the power supply ● Basic adapter as a basic element for fixing to a support arm ● Four screws for fixing the basic adapter to an adapter from an adapter set Additional documents may be enclosed with the accessory kit.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Overview 1.5 Accessories

1.5

Accessories Accessories are not included in the product package of the HMI device, but can ordered in the Internet at "http://mall.automation.siemens.com".

RS 422 to RS 232 converter The converter is required for the connection of controllers of other manufacturers. Connect the RS 422 to RS 232 converter to the RS 422 / RS 485 interface. The converter converts the input signals to RS-232 signals. Order number for RS 422 to RS 232 converter: 6AV6 671-8XE00-0AX0.

90° elbow adapter If space is limited, you can use an elbow adapter at the RS 422/RS 485 interface. Order number for 90° elbow adapter: 6AV6 671-8XD00-0AX0.

Protective foil for HMI devices with touch screen The protective foil prevents the touch screen from being scratched. The protective foil can be ordered using the following order numbers: HMI device

Order no.

MP 377 12" Touch

6AV6 574-1AD00-4CX0

MP 377 15" Touch

6AV6 574-1AD00-4EX0

MP 377 PRO 15" Touch MP 377 19" Touch

6AV7 672-1CE00-0AA0

Clamping frame A clamping frame is available for the MP 377 12" Touch. If the material thickness around the mounting cutout is < 2 mm, the clamping frame allows IP65 degree of protection or enclosure type 4X/Type 12 to be achieved. Order number for clamping frame for MP 377 12" Touch: 6AV6 671-8XS00-0AX0.

Key labeling strips For the MP 377 12" Key, a kit containing two sets of blank key labeling strips can be ordered. Order number for key labeling strips: 6AV6 574-1AB00-2BA0.

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ITEM 2500 Overview 1.5 Accessories

Service packages The service packages include: ● Mounting seals ● Mounting clamps ● Power supply terminal, 2-pin Service packages can be ordered for the following HMI devices using the following order numbers: HMI device

Order no.

MP 377 12" Key

6AV6 574-1AA00-2BX0

MP 377 12" Touch

6AV6 671-4XA00-0AX0

MP 377 15" Touch MP 377 19" Touch

Basic adapter One basic adapter is included in the delivery scope of the MP 377 PRO 15" Touch. Order number for the basic adapter as accessory: 6AV7674-0KA00-0AA0.

Adapter sets for support arm systems The following adapter sets can be ordered for the MP 377 PRO: Adapter set

Suitable for support arm systems

Order no.

Adapter set VESA75/VESA100

VESA75 and VESA100 compatible systems, Rose GTN II support arm systems

6AV7674-0KF00-0AA0

Adapter set CP-L

Rittal CP-L support arm systems

6AV7674-0KC00-0AA0

Adapter set PLUS

Bernstein CS-3000 Coupler 48, Rolec tara Plus, Rolec Quadro, Rittal CP-S, Rose GT48/2, Rose GTK electronic

6AV7674-0KB00-0AA0

Memory card Only use SD memory cards, CF memory cards or MultiMediaCards tested and approved by Siemens AG.

SIMATIC PC USB flash drive The SIMATIC PC USB flash drive is a mobile form of data storage with a high data throughput, designed for industrial use.

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ITEM 2500

Overview 1.6 The HMI device in the operating process

1.6

The HMI device in the operating process The HMI device is part of the operating process. The following two phases are key to the way the HMI device is integrated in the operating process: ● Project design ● Process management

Project design Visualization of the operating process is known as project design. Project design comprises: ● writing project data ● saving project data ● testing project data ● simulating project data Project design is undertaken independently of the HMI device and results in a project. Once this has been generated, the project can be transferred to the HMI device to control the operating process.

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+0,GHYLFH

Process management Process management is marked by two-way communication between HMI device and controller. This lays the foundations for operator control and monitoring. &RQWURO

&RQWURO +0,GHYLFH

The operator can intervene in the operating process on the HMI device for control purposes. The controller in turn supplies the results of the operating process which are displayed on the HMI device.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Overview 1.7 Functional scope with WinCC flexible

1.7

Functional scope with WinCC flexible The following tables show the objects that can be integrated in a project for an MP 377. Note The specified values are maximum values of the individual objects. Simultaneous use of multiple objects with their maximum value can lead to problems in the active project.

Alarms Object

Specification

Alarms

Number of discrete alarms Number of analog alarms Length of the alarm text Number of tags in an alarm Display Acknowledge error alarm individually Acknowledge multiple error alarms simultaneously (group acknowledgement) Edit alarm

MP 377 4 000 200 80 characters Max. 8 Alarm line, Alarm window, Alarm view Yes 16 alarm groups Yes

Alarm indicator

Yes

ALARM_S

Display S7 alarms

Yes

Alarm buffer, retentive

Alarm buffer capacity Simultaneously queued alarm events View alarm

1024 alarms Max. 500 Yes

Delete alarm buffer

Yes

Print alarms line by line

Yes

Tags, values and lists Object

Specification

Tags

Quantity

Limit value monitoring

Input/output

Yes

Linear scaling

Input/output

Yes

Text lists

Quantity

500 1)

Graphics lists

Quantity

500 1)

1)

MP 377 2 048

The maximum total of text and graphics lists is 500.

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ITEM 2500

Overview 1.7 Functional scope with WinCC flexible

Screens Object

Specification

MP 377

Screens

Quantity

500

Fields per screen

200

Tags per screen

400

Complex objects per screen (for example, bars)

20

Template

Yes

Recipes Object

Specification

Recipes

Quantity

MP 377 500

Data records per recipe

1000

Entries per recipe

1000

Recipe memory

128 Kb

Location1)

1)

• • •

Memory card USB memory stick Network drive

The number of recipe data records might be restricted by the capacity of the storage medium.

Logs Note The HMI devices are suitable for the logging of relatively small volumes of data. Manage the data in several adjacent archives in a segmented circular log. The use of a large circular log has a negative effect on performance. Object

Specification

MP 377

Logs

Number of logs

50

Number of partial logs in a segmented circular log

400

Entries per log

10 000

Filing format Location1)

1)

30

CSV with ANSI character set • • •

Memory card USB memory stick Network drive

The number of entries in the log may be restricted by the capacity of the storage medium. MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Overview 1.7 Functional scope with WinCC flexible

Safety Object

Specification

MP 377

User view

Number of user groups

50

Number of users

50

Number of authorizations

32

Info texts Object

Specification

Info texts

Length (no. of characters)

MP 377 320 (depending on font)

For alarms

Yes

For screens

Yes

For screen objects (for example, for I/O field, switch, button, invisible button)

Yes

Additional functions Object

Specification

Screen settings

Calibrating the touch screen 1)

MP 377 Yes

Brightness setting

Yes

Language change

Number of languages

16

VBScript

User-specific extension of the functionality Number of scripts

100

Graphic objects

Vector and pixel graphics

Yes

Trends

Quantity

400

Yes

Task planner

Number of tasks

Text objects

Quantity

Direct keys

PROFIBUS DP direct keys

Yes

PROFINET IO direct keys

Yes

1)

48 30 000

MP 377 with touch screen only

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Overview 1.8 Software options

1.8

Software options The following software options are available for the MP 377: ● WinCC flexible /Sm@rtService The WinCC flexible /Sm@rtService option enables you to access a remote HMI device or PC via Ethernet. ● WinCC flexible /Sm@rtAccess The WinCC flexible /Sm@rtAccess option enables you to set up communication between different HMI systems. ● WinCC flexible /Audit The WinCC flexible /Audit option extends the HMI device to include functions for recording operations in an audit trail and electronic signature. ● WinCC flexible /OPC-Server (OPC XML) The WinCC flexible /OPC-Server option enables you to create communications to OPC-capable applications from an HMI device or PC via Ethernet. ● WinAC MP 2007 WinAC MP 2007 is PLC software capable of running on the MP 377. ● WinCC flexible /ProAgent The WinCC flexible /ProAgent option enables you to extend the HMI device to include specific and high-speed process fault diagnostics. ● Uninterruptible Power Supply (UPS) with USB support When interfacing an uninterruptible power supply, the HMI device is shut down in a controlled manner after a buffer time in the event of a power failure. The MP 377 supports SITOP DC UPS modules connected via the USB port. ● Microsoft Excel Viewer Microsoft Excel Viewer enables you to view Excel documents. ● Microsoft PDF Viewer Microsoft PDF Viewer enables you to view PDF documents. ● Microsoft Word Viewer Microsoft Word Viewer enables you to view Word documents.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Overview 1.9 Communication

1.9

Communication

Number of connections Connection

MP 377

Number using a bus connection

6

Number of connections based on "SIMATIC HMI HTTP Protocol"

8

NOTICE Communication faults with PROFINET IO When you release PROFINET IO in the HMI device's control panel, communication faults may arise in the following cases: • Use of PLCs from other manufacturers • Use of SIMATIC 500/505 via NITP Do not release PROFINET IO in the HMI device's control panel in the cases given.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500

Overview 1.9 Communication

PLCs The following table shows the PLCs which can be used with the HMI devices and the protocols or profiles which can be used. PLC

Protocol

SIMATIC S7

• • • •

PPI MPI 1) PROFIBUS DP PROFINET

Yes

SIMATIC S5

•

PROFIBUS DP

Yes

SIMATIC 500/505

• •

NITP PROFIBUS DP

Yes

SIMATIC HMI HTTP Protocol

•

HTTP/HTTPS (Ethernet)

Yes

Allen-Bradley

PLC series SLC500, SLC501, SLC502, SLC503, SLC504, SLC505, MicroLogix and PLC5/11, PLC5/20, PLC5/30, PLC5/40, PLC5/60, PLC5/80 • DF1 2) 5) 6) • DH+ via KF2 module 3) 5) 6) • DH485 via KF3 module 4) 5) 6) • DH485 4) 6)

Yes

ControlLogix and CompactLogix PLC series • Ethernet/IP

Yes

GE Fanuc Automation

PLC series 90-30, 90-70, VersaMax Micro • SNP6)

Yes

LG Industrial Systems (Lucky Goldstar)/IMO

PLC series GLOFA GM (GM4, GM6 and GM7), Series G4, G6 and G7 • Dedicated communication 6)

Yes

Mitsubishi Electric

PLC series MELSEC FX and MELSEC FX0 • FX6)

Yes

PLC series MELSEC FX0, FX1n, FX2n, AnA, AnN, AnS, AnU, QnA and QnAS • Protocol 46)

Yes

PLC series Modicon 984, TSX Quantum and TSX Compact • Modbus RTU 5) 6)

Yes

PLC series Quantum, Momentum, Premium and Micro PLC series Compact and 984 via Ethernet bridge • Modbus TCP/IP (Ethernet)

Yes

Modicon (Schneider Automation)

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MP 377

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Overview 1.9 Communication PLC

Protocol

OMRON

PLC series SYSMAC C, SYSMAC CV, SYSMAC CS1, SYSMAC alpha and CP • Hostlink/Multilink (SYSMAC Way)6)

Yes

Telemecanique

PLC series TSX 7 with P47 411, TSX 7 with P47/67/87/107 420, TSX 7 with P47/67/87/107 425, module TSX SCM 21.6 with the specified TSX 7 CPUs, TSX 17 with module SCG 1161, TSX 37 (Micro) and TSX 57 (Premium) • Hostlink/Multilink (SYSMAC Way)6)

Yes

1)

Not possible when connected to S7-212.

2)

Applies to controllers SLC503, SLC504, SLC505, PLC5, MicroLogix.

3)

Applies to controllers SLC504, PLC5 over DF1.

4)

Applies to controllers SLC500 to SLC 505 and MicroLogix.

5)

Only with converter RS 422-RS 232 6AV6 671-8XE00-0AX0 (option).

6)

PROFINET IO must be locked.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

MP 377

35

Overview 1.9 Communication

36

ITEM 2500

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500

Safety instructions and approvals 2.1

2

Safety instructions

High frequency radiation NOTICE Unwanted operating states High-frequency radiation, for example, from cellular phones, can trigger unwanted operating states.

Proper use WARNING Commissioning the HMI device is prohibited until it has been absolutely ensured that the machine in which the HMI device is to be installed complies with Directive 98/37/EC or Directive 2006/42/EC as of December 29, 2009.

Hazardous areas When operating the HMI device in hazardous areas the following warning applies. WARNING Explosion Hazard Do not disconnect while circuit is live unless area is known to be non-hazardous. Substitution of components may impair suitability for Class I, Division 2 or Zone 2.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500

Safety instructions and approvals 2.1 Safety instructions

Working on the control cabinet The following information applies to MP 377 mounting devices. WARNING Open equipment The HMI device is open equipment. This means that the HMI device may only be mounted in housings or cabinets, whereby the device can be operated from the front panel. The cubicle or cabinet in which the HMI device is installed may only be accessed with a key or tool and only by trained, authorized personnel. Dangerous voltage Opening the cabinet will expose high voltage parts. Contact with these parts could be fatal. Always disconnect the cabinet from the mains before opening it.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Safety instructions and approvals 2.2 Standards, certificates and approvals

2.2

Standards, certificates and approvals

Approvals CAUTION The following overview shows possible approvals. The HMI device itself is certified as shown on the rear panel labels.

CE approval

The HMI device meets the general and safety-related requirements of the following EC directives and conforms to the harmonized European standards (EN) for programmable logic controllers published in the official gazettes of the European Union: ● 2004/108/EC "Electromagnetic Compatibility" (EMC Directive) ● 2006/95/EC "Electrical equipment for use within specific voltage limits" (Low-Voltage Directive) EC Declaration of Conformity The EC Declarations of Conformity are available to the relevant authorities at the following address: Siemens Aktiengesellschaft Industry Sector I IA AS RD ST PLC P.O. Box 1963 D-92209 Amberg

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ITEM 2500 Safety instructions and approvals 2.2 Standards, certificates and approvals

UL approval

Underwriters Laboratories Inc., to ● UL 508 (Industrial Control Equipment) ● CSA C22.2 No. 142 (Process Control Equipment) or

Underwriters Laboratories Inc., to ● UL 508 (Industrial Control Equipment) ● CSA C22.2 No. 142 (Process Control Equipment) ● UL 1604 (Hazardous Location) ● CSA-213 (Hazardous Location) Approved for use in ● Class I, Division 2, Group A, B, C, D or ● Class I, Zone 2, Group IIC or ● non-hazardous locations

FM approval (MP 377 mounting device only)

FM APPROVED

Factory Mutual Research (FM) conforming to ● Approval Standard Class Number 3611, 3600, 3810 Approved for use in ● Class I, Division 2, Group A, B, C, D T4 ● Class I, Zone 2, Group IIC T4

Marking for Australia

N117 The HMI device fulfills the requirements of standard AS/NZS 2064 (Class A).

IEC 61131 The HMI device fulfills requirements and criteria to IEC 61131-2, Programmable Logic Controllers, Part 2: Operating resource requirements and tests.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Safety instructions and approvals 2.3 Notes about usage

2.3

Notes about usage

Industrial applications The HMI device is designed for industrial applications. It conforms to the following standards: ● Requirements for emissions EN 61000-6-4: 2007 ● Requirements for interference immunity EN 61000-6-2: 2005

Use in residential areas Note The HMI device is not intended for use in residential areas. Operation of an HMI device in residential areas can have a negative influence on radio/TV reception. If the HMI device is used in a residential area, you must take measures to achieve Limit Class B conforming to EN 55011 for RF interference. Suitable measures for achieving the degree of noise suppression for Limit Class B include, for example: ● Installation of the HMI device in grounded control cabinets ● Use of filters in electrical supply lines Individual acceptance is required.

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ITEM 2500 Safety instructions and approvals 2.4 Electromagnetic compatibility

2.4

Electromagnetic compatibility

Introduction The HMI device fulfills, among other things, the requirements of the EMC law pertaining to the domestic European market.

EMC-compatible installation of the HMI device The EMC-compliant installation of the HMI device and the application of interference-proof cable is the basis for interference-free operation. The "Directives for interference-free installation of PLCs" and the "PROFIBUS Networks" manual also apply for the installation of the HMI device.

Pulse-shaped disturbance The following table shows the electromagnetic compatibility of modules with regard to pulseshaped interference. The precondition for electromagnetic compatibility is that the HMI device meets the specifications and guidelines for electrical installation. Pulse-shaped disturbance

Tested with

Degree of severity

Electrostatic discharge in accordance with IEC 61000-4-2

Air discharge: 8 kV Contact discharge: 6 kV

3

Burst pulses (high-speed transient interference) in accordance with IEC 61000-4-4

2 kV power supply cable 2 kV signal cable, > 30 m 1 kV signal cable, < 30 m

3

High-power surge pulses in accordance with IEC 61000-4-5, external protective circuit required (refer to the manual Automation System S7-300, Installation, "Lightning and overvoltage protection" section) Asymmetrical coupling

2 kV power cable DC voltage with protective elements

3

2 kV signal/data cable, > 30 m, with protective elements as required Symmetrical coupling

1 kV power cable DC voltage with protective elements

3

1 KV signal cable, > 30 m, with protective elements as required

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Safety instructions and approvals 2.4 Electromagnetic compatibility

Sinusoidal interference The following table shows the EMC behavior of the modules with respect to sinusoidal interference. This requires the HMI device to meet the specifications and directives for electrical installation. Sinusoidal interference

Test values

HF radiation (in electromagnetic fields) in accordance with IEC 61000-4-3

•

RF interference current on cables and cable shielding conforming to IEC 61000-4-6

Test voltage 10 V, with 80% amplitude modulation of 1 kHz in the 9 MHz to 80 MHz range

•

80% amplitude modulation at 1 kHz with 10 V/m in the range of 80 MHz to 1 GHz with 3 V/m in the range 1.4 GHz to 2 GHz with 1 V/m the range 2 GHz to 2.7 GHz 10 V/m with 50% pulse modulation at 900 MHz 10 V/m with 50% pulse modulation at 1.89 GHz

Degree of severity 3

3

Emission of radio interference The following table shows the unwanted emissions from electromagnetic fields in accordance with EN 55011, Limit Value Class A, Group 1, measured at a distance of 10 m. From 30 to 230 MHz

< 40 dB (μV/m) quasi-peak

From 230 to 1000 MHz

< 47 dB (μV/m) quasi-peak

Additional measures If you want to connect an HMI device to the public power supply system, you must ensure Limit Value Class B in accordance with EN 55022.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500

Safety instructions and approvals 2.5 Transport and storage conditions

2.5

Transport and storage conditions

Mechanical and climatic conditions for transportation and storage This HMI device meets the requirements for IEC 61131-2 relating to transport and storage conditions. The following specifications apply to the transport and storage of an HMI device in its original packaging. The climatic conditions conform to the following standards: ● IEC 60721-3-3, Class 3K7 for storage ● IEC 60721-3-2, Class 2K4 for transport Mechanical requirements conform to EC 60721-3-2, Class 2M2. Type of condition

Permitted range

Drop test (in transport package)

≤1m

Temperature

From –20 to +60 °C

Atmospheric pressure

From 1 080 hPa to 660 hPa, corresponds to an elevation of –1000 to 3500 m

Relative humidity

From 10 to 90%, without condensation

Sinusoidal vibration in accordance with IEC 60068-2-6

5 to 9 Hz: 3.5 mm 9 Hz to 500 Hz: 9.8 m/s2

Shock in accordance with IEC 60068-2-29

250 m/s2, 6 ms, 1000 shocks

NOTICE Avoid dewing If the HMI device is subjected to low temperatures or extreme fluctuations in temperature during transportation, moisture could occur on or inside the HMI device. Dewing can occur. This can cause malfunctions. The HMI device must have acquired room temperature before it is put into operation. Do not expose the HMI device to direct radiation from a heater in order to warm it up. If there is condensation, wait approximately 4 hours until the HMI device has dried completely before switching it on. Proper transport and storage, installation and assembly as well as careful operation and maintenance are required to ensure trouble-free and safe operation of the HMI device. The warranty for the HMI device will be deemed void if these stipulations are not heeded.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500

3

Planning application 3.1

Notes about usage

Mechanical and climatic conditions of use The HMI device is designed for use in a location protected from the effects of the weather. The conditions of use meet the requirements for DIN IEC 60721-3-3: ● Class 3M3 (mechanical requirements) ● Class 3K3 (climatic requirements)

Use with additional measures The HMI device should not be used at the following locations unless additional measures are taken: ● In locations with a high degree of ionizing radiation ● In locations with severe operating conditions, for example, due to: – Corrosive vapors, gases, oils or chemicals – Electrical or magnetic fields of high intensity ● In plants that require special monitoring - for example: – Elevators – Systems in especially hazardous rooms

Mechanical ambient conditions The mechanical ambient conditions for the HMI device are specified in the following table in terms of sinusoidal vibration. Frequency range in Hz

Constant

Occasional

10 ≤ f ≤ 58

Amplitude 0,0375 mm

Amplitude 0.075 mm

58 ≤ f ≤ 150

Constant acceleration 0,5 g

Constant acceleration 1 g

Reducing vibrations If the HMI device is subjected to greater shocks or vibrations, you must take appropriate measures to reduce acceleration or amplitudes. We recommend mounting the HMI device on damping materials (on rubber-metal vibration dampers, for example).

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ITEM 2500

Planning application 3.1 Notes about usage

Testing mechanical ambient conditions The following table provides information on the type and scope of tests for mechanical ambient conditions. Tested for

Test standard

Comments

Vibrations

Vibration test in accordance with IEC 60068, part 2–6 (sinusoidal)

Type of vibration: Transitional rate of the frequency: 1 octave/minute. 10 ≤ f ≤ 58, Constant amplitude 0.075 mm 58 ≤ f ≤ 150, constant acceleration 1 g, with support arm 0.5 g on the basic adapter Vibration duration: 10 frequency cycles per axis at each of the three associated vertical axes

Shock

Shock test in accordance with IEC 60068, Part 2 –27

Type of shock: Half-sine Shock intensity: Peak value 15 g, duration 11 ms Direction of impact: 3 shocks in ± direction at each one of the three associated vertical axes

Climatic ambient conditions The following table shows the climatic ambient conditions for operation of the HMI device. Ambient conditions Temperature • Vertical installation MP 377 12" Touch MP 377 12" Key MP 377 15" Touch MP 377 19" Touch MP 377 PRO 15" Touch • Inclined installation MP 377 12" Touch MP 377 12" Key MP 377 15" Touch MP 377 19" Touch MP 377 PRO 15" Touch

46

Permitted range

Comments MP 377 12" Touch, MP 377 12" Key, MP 377 15" Touch, MP 377 19" Touch: See section Mounting positions and type of fixation (Page 47)

From 0 to 50° C From 0 to 50° C From 0 to 50° C From 0 to 50° C From 0 to 45° C

MP 377 PRO 15" Touch: See section Mounting positions (Page 51)

From 0 to 40° C From 0 to 40° C From 0 to 35° C From 0 to 35° C From 0 to 45° C

Relative humidity

10 to 90%, without condensation

Atmospheric pressure

1 080 to 795 hPa

Corresponds to an elevation of –1 000 m to 2 000 m

Pollutant concentration

SO2: < 0.5 vpm; Relative humidity < 60%, no condensation

Test: 10 cm3/m3; 10 days

H2S: < 0.1 vpm; Relative humidity < 60%, no condensation

Test: 1 cm3/m3; 10 days

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Planning application 3.2 MP 377 mounting devices

3.2

MP 377 mounting devices

3.2.1

Mounting positions and type of fixation

Mounting position The HMI device is suitable for installation in: ● Mounting cabinets ● Control cabinets ● Switchboards ● Consoles In the following, all of these mounting options are referred to by the general term "cabinet". The HMI device is self-ventilated and approved for vertical and inclined mounting in stationary cabinets. –



+





Mounting position

Deviation from the vertical

①

Inclined

≤ 35°

②

Vertical

0°

CAUTION Damage due to overheating An inclined installation reduces the convection by the HMI device and therefore the maximum permissible ambient temperature for operation. If there is sufficient forced ventilation, the HMI device can also be operating in the inclined mounting position up to the maximum permissible ambient temperature for vertical installation. Otherwise, the HMI device may be damaged and the approvals and warranty for the HMI device may become void. For information regarding the permissible ambient temperatures, refer to Notes about usage (Page 45).

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ITEM 2500 Planning application 3.2 MP 377 mounting devices

Mounting Metal mounting clamps are provided for mounting. The mounting clamps hook into the oblong holes on the HMI device.

 

3.2.2

①

Threaded pin

②

Hook

Preparing for installation

Select the mounting location of the HMI device Points to observe when selecting the mounting location: ● Position the HMI device so that it is not subjected to direct sunlight. ● Position the HMI device such that it is ergonomically accessible for the user. Choose a suitable mounting height. ● Ensure that the air vents of the HMI device are not covered as a result of the mounting. ● Note the permissible mounting positions. NOTICE Stability of the mounting cutout The material in the area of the mounting cutout must provide sufficient strength to guarantee the enduring and safe mounting of the HMI device. The force of the clamps or operation of the device may not lead to deformation of the material in order to achieve the degrees of protection described below.

Degrees of protection The protection ratings are only ensured if the mounting cutout conforms to the following: ● Material thickness at the mounting cutout for IP65 degree of protection or for enclosure type 4X/type 12 (indoor use only): 2 mm to 6 mm ● Permitted deviation from plane at the mounting cutout: ≤ 0.5 mm This condition must be fulfilled for the mounted HMI device. ● Permissible surface roughness in the area of the seal: ≤ 120 µm (Rz 120) A clamping frame is additionally available for mounting the MP 377 12" Touch to panels with a material thickness < 2 mm at the mounting cutout. The frame enables IP65 degree of protection or enclosure type 4X/type 12 to be achieved.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Planning application 3.2 MP 377 mounting devices

Dimensions of the mounting cutout The following table shows the dimensions of the required mounting cutout: Mounting cutout

MP 377 12" Touch

MP 377 12" Key

MP 377 15" Touch

Width

310+1 mm

450+1 mm

367+1 mm

449 +1 mm

Height

248+1

290+1

289+1

379+1 mm

HMI device depth, not including front panel

mm

72 mm

mm

59 mm

mm

72 mm

MP 377 19" Touch

75 mm

Note You can insert an MP 377 12" Key into the mounting cutout of the following HMI devices: • MP 370 12" Key • MP 277 10" Key • MP 270 10" Key • OP 270 10" You can insert an MP 377 12" Touch into the mounting cutout of the following HMI devices: • MP 370 12" Touch • MP 277 10" Touch • MP 270 10" Touch • OP 270 10" You can insert an MP 377 15" Touch into the mounting cutout of the following HMI device: • MP 370 15" Touch

Maintaining clearances The HMI device must be installed with the following clearances: ● 50 mm above and below the mounting cutout respectively for ventilation ● 15 mm to the right and left of the mounting cutout respectively for suspending the mounting clamps for mounting ● At least 10 mm behind the rear panel of the HMI device NOTICE Ensure that the maximum ambient temperature is not exceeded when mounting the device in a cabinet and especially in a closed enclosure.

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ITEM 2500

Planning application 3.2 MP 377 mounting devices

3.2.3

Information on insulation tests, protection class and degree of protection

Test voltages Insulation strength is demonstrated in the type test with the following test voltages in accordance with IEC 61131-2: Circuits with a nominal voltage of Ue to other circuits or ground

Test voltage

< 50 V

500 V DC

Protection class Protection Class I in accordance with IEC 60536, i.e. PE/ground terminal to profile rail required!

Protection against foreign objects and water Degree of protection in accordance with IEC 60529

Explanation

Front

When mounted: • IP65 • Enclosure Type 4X/Type 12 (indoor use only)

Rear panel

IP20 Touch protection test with standard test probes. There is no protection against ingress by water.

The degree of protection at the front can only be guaranteed if the mounting seal is installed flush to the mounting cutout.

3.2.4

Rated voltages The table below shows the rated voltage and the corresponding tolerance range.

50

Rated voltage

Tolerance range

+24 VDC

19.2 to 28.8 V (+/–20%)

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Planning application 3.3 MP 377 PRO

3.3

MP 377 PRO

3.3.1

Mounting positions

Mounting position The HMI device is self-ventilated and approved for vertical and inclined mounting. –



3.3.2

+





Mounting position

Deviation from the vertical

①

Inclined

≤ 35°

②

Vertical

0°

Preparing for installation

Select the mounting location of the HMI device Points to observe when selecting the mounting location: ● Position the HMI device so that it is not subjected to direct sunlight. ● Position the HMI device such that it is ergonomically accessible for the user. Choose a suitable mounting height. ● Observe the permissible mounting positions for the HMI device.

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ITEM 2500

Planning application 3.3 MP 377 PRO

3.3.3

Information on insulation tests, protection class and degree of protection

Test voltages Insulation strength is demonstrated in the type test with the following test voltages in accordance with IEC 61131-2: Circuits with a nominal voltage of Ue to other circuits or ground

Test voltage

< 50 V

500 VDC

Protection class Protection Class I in accordance with IEC 60536, i.e. PE/ground terminal to profile rail required!

Protection against foreign objects and water The following degree of protection applies to the HMI device:

3.3.4

Device side

Degree of protection in accordance with IEC 60529

all sides

• • •

IP65 Enclosure Type 12 (indoor use only) Enclosure Type 4X/Type 12 (indoor use only)

Rated voltages The table below shows the rated voltage and the corresponding tolerance range.

52

Rated voltage

Tolerance range

+24 VDC

19.2 to 28.8 V (+/–20%)

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500

Mounting and connecting 4.1

4

Checking the package contents Check the package content for visible signs of transport damage and for completeness. NOTICE Damaged parts A damaged part will cause the HMI device to malfunction. Do not install parts damaged during shipment. In the case of damaged parts, contact your Siemens representative. The following is included in the product package of the MP 377 mounting device: ● HMI device ● Accessory kit with mounting clamps and mains terminal The following is included in the product package of the MP 377 PRO: ● HMI device ● Basic adapter for fixing to a support arm ● Four screws for fitting the basic adapter ● Mains terminal Additional documents may be included in the product package of all HMI devices. The documentation belongs to the HMI device and is required for subsequent commissioning. Retain all enclosed documentation for the entire service life of the HMI device. You must pass on the enclosed documentation to any subsequent owner or user of the HMI device. Make sure that every supplement to the documentation that you receive is stored together with the operating instructions.

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ITEM 2500 Mounting and connecting 4.2 Installing the HMI device

4.2

Installing the HMI device

4.2.1

Installing the MP 377 mounting device

Requirement All packaging components and protective foils should be removed from the HMI device. To install the HMI device, you need the mounting clamps from the accessory kit. The mounting seal must be fitted on the HMI device. If the mounting seal is damaged, order a replacement seal. The mounting seal is part of the associated service pack. To ensure the necessary degree of protection on the HMI device, the mounting clamps must observe the positions listed below. The following photo shows how positions 1 to 10 are counted.

  



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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Mounting and connecting 4.2 Installing the HMI device

Positions of mounting clamps on the MP 377 12" Touch The following figure shows the counting direction for the insertion of the mounting clamps.

The following table shows the positions of the mounting clamps on the MP 377 12" Touch. Observe the counting direction. Page

Number of mounting clamps

Position 1

Position 2

Position 3

Top

3

2

11

20

Right

3

2

9

16

Bottom

3

2

11

20

Left

3

2

9

16

Positioning the mounting clamps on the MP 377 12" Key A total of 10 mounting clamps are needed for mounting. Fit mounting clamps in all the cutouts.

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ITEM 2500

Mounting and connecting 4.2 Installing the HMI device

Positioning the mounting clamps on the MP 377 15" Touch The following figure shows the counting direction for the insertion of the mounting clamps.

The following table shows the positioning of the mounting clamps on the MP 377 15" Touch. Observe the counting direction. Page

Number of mounting clamps

Position 1

Position 2

Position 3

Position 4

Top

4

2

9

17

24

Right

3

3

10

17

–

Bottom

4

2

9

17

24

Left

3

3

10

17

–

Positions of the mounting clamps on the MP 377 19" Touch The positions of the mounting clamps are marked by stamps on the cutouts. The following diagram shows examples of these stamps.



①

Stamps identifying the position of a mounting clamp

A total of 18 mounting clamps are needed for mounting. Fit mounting clamps in all the stamped cutouts.

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ITEM 2500 Mounting and connecting 4.2 Installing the HMI device

Procedure NOTICE Installation of the HMI device Always mount the HMI device according to the instructions in this manual. Risk of guaranteed level of protection not being met If the mounting seal is damaged or protrudes beyond the HMI device, the level of protection is not ensured. Check the fit of the mounting seal. Note Tighten the threaded pins of the mounting clamps until the HMI device is flush with the surface of the control cabinet. Alternatively, tighten the mounting clamps using a maximum torque of 0.2 Nm. Proceed as follows: 1. Check that the mounting seal is fitted on the HMI device. Do not install the mounting seal turned inside out. This may cause leaks in the mounting cutout. 2. Insert the HMI device into the mounting cutout from the front. 3. Insert a mounting clamp into the cutout provided on the HMI device.

 

4. Fasten the mounting clamp ① by tightening the threaded pin ②. 5. Repeat steps 3 and 4 for all mounting clamps. 6. Check the fit of the mounting seal. If necessary, repeat steps 1 to 6.

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Mounting and connecting 4.2 Installing the HMI device

ITEM 2500

Result The HMI device is mounted and the relevant level of protection is ensured at the front.

See also Accessory kit (Page 25) Accessories (Page 26) Information on insulation tests, protection class and degree of protection (Page 50)

4.2.2

Installing MP 377 PRO

Requirement All packaging components and protective foils should be removed from the HMI device. To install the HMI device, you need the basic adapter and an adapter set from the accessories. The following cables are fed through the stand or the support arm to which the HMI device will be fixed: ● Equipotential bonding cable ● Power supply cable ● Data cables, such as PROFINET, USB NOTICE Warranty endangered If you install the HMI device not in accordance with the specifications given in these operating instructions, the warranty for the HMI device will become void. Always install the HMI device according to these operating instructions. IP65 degree of protection at risk If there are no seals on the adapters or these are damaged, then IP65 degree of protection is at risk. Check the condition and seating of the seals. If the seal on the rear panel of the housing is damaged, it can be repaired. For a repair scenario, follow the procedure described in the section "Spare parts and repairs (Page 274). Note The warranty for the IP65 degree of protection assumes that the support arm or the stand also complies with IP65.

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ITEM 2500 Mounting and connecting 4.2 Installing the HMI device

Procedure This section describes how to install the device on a support arm system. Installation on a stand is carried out analogously. Proceed as follows: 1. Remove the 10 screws ⑥ of the housings rear panel using a size 2 Allen wrench.



  









2. Remove the rear panel of the housing ⑦ and store it in a secure location. 3. Fasten the support arm head ② to the adaptor plate ③ using the four M6 x 12 screws from the accessory kit of the adapter set. Ensure that the seal is properly seated. 4. Fasten the base adapter ⑤ to the adaptor plate ③ using the four M6 x 12 screws from the accessory kit of the adapter set. Ensure that the seal is properly seated. NOTICE Do not exceed the permissible torque If you fasten the screw ④ with a torque > 1.2 Nm, the threads in the housing may be damaged. Alternatively, tighten the screws using a maximum torque of 1.2 Nm. 5. Fasten the base adapter ⑤ to the mechanical interface using the four screws ④ of the cover. Ensure that the seal is properly seated.

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ITEM 2500

Mounting and connecting 4.2 Installing the HMI device 6. Fasten the HMI device to the support arm ①.

In doing so, ensure that all connections are fed (without damage) through the adapter into the inside of the HMI device. 7. If you want to connect the cables at a later point in time, fasten the housing rear panel ⑦ to the HMI device.

Result The HMI device is fitted and can be connected electrically.

See also Accessory kit (Page 25)

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

4.3

Connecting the HMI device

4.3.1

Overview

Requirement ● The HMI device must be mounted according to the specifications of these operating instructions. ● Always use shielded standard cables for the data cable. Additional information is available in the catalog and online order system at "http://mall.automation.siemens.com".

Connection sequence Connect the HMI device in the following sequence: 1. Equipotential bonding 2. Power supply Perform a power-up test to ensure the power supply is connected with the correct polarity. 3. PLC 4. Configuring PC as necessary 5. I/Os as necessary NOTICE Damage to the HMI device If you do not keep to the connection sequence you could damage the HMI device. Ensure you connect the HMI device in the sequence stipulated above. Disconnect the HMI device by completing the above steps in reverse order.

Connecting the cables When connecting the cables, ensure that the contact pins are not bent. Secure the cable connectors by screwing the connector onto the socket. Provide adequate strain relief for the cables. For this purpose, the MP 377 PRO contains a strain relief bar below the ports on the rear of the HMI device.

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ITEM 2500

Mounting and connecting 4.3 Connecting the HMI device

4.3.2

Ports The following figure shows the ports of the HMI device MP 377.





①

Power supply connector

②

RS-422/RS-485 port X10 / IF1b

③

PROFINET, 2 ports X1 P1 and X1 P2

④

USB, ports X20 and X21

⑤

Line in and micro

⑥

Line out









Connect PROFIBUS DP or MPI to the X10 / IF1b port. You can affix the USB and PROFINET connecting cables to the rear panel of the HMI device with cable ties.

See also Design of the MP 377 12" Touch (Page 15) Design of the MP 377 12" Key (Page 17) Design of the MP 377 15" Touch (Page 19) Design of the MP 377 19" Touch (Page 21) Design of the MP 377 PRO 15" Touch (Page 23)

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

4.3.3

Connecting the equipotential bonding circuit

Differences in electrical potential Differences in electrical potential can develop between spatially separated plant components. Such electrical potential differences can lead to high equalizing currents over the data cables and therefore to the destruction of their interfaces. Equalizing currents can develop if the cable shielding is terminated at both ends and grounded to different plant parts. Differences in potential may develop when a system is connected to different mains supplies.

General requirements for equipotential bonding Differences in potential must be reduced by means of equipotential bonding in order to ensure trouble-free operation of the relevant components of the electronic system. The following must therefore be observed when installing the equipotential bonding circuit: ● The effectiveness of equipotential bonding increases as the impedance of the equipotential bonding conductor decreases or as its cross-section increases. ● If two plant parts are interconnected by means of shielded data cables and their shielding is bonded at both ends to the grounding/protective conductor, the impedance of the additionally installed equipotential bonding cable must not exceed 10% of the shielding impedance. ● The cross-section of an equipotential bonding conductor must be capable of handling the maximum equalizing current. Experience has shown that equipotential bonding conductors with a minimum cross-section of 16 mm² should be fitted between the control cabinets or the ground point of the supporting arm or the stand for PRO HMI devices. ● Use equipotential bonding conductors made of copper or galvanized steel. Establish a large surface contact between the equipotential bonding conductors and the grounding/protective conductor and protect these from corrosion. ● Use a suitable cable clip to clamp the shield of the data cable flush to the equipotential bonding rail. Keep the length of cable between the HMI device and the equipotential bonding rail as short as possible. ● Route the equipotential bonding conductor and data cables in parallel and with minimum clearance between these.

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

Wiring diagram 

  





 









①

Chassis terminal on the HMI device, example

②

Equipotential bonding conductor cross-section: 4 mm2

③

Control cabinet

④

Equipotential bonding conductor cross-section: min. 16 mm2

⑤

Ground connection

⑥

Cable clip

⑦

Equipotential bonding rail

⑧

Parallel routing of the equipotential bonding conductor and data cable

CAUTION Damage to the interface modules possible Cable shielding is not suitable for equipotential bonding. Use only the prescribed equipotential bonding conductors. The equipotential bonding conductor ④ must not be less than 16 mm². The interface modules may otherwise be damaged or destroyed.

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

4.3.4

Connecting the power supply

Wiring diagram The following figure shows the connection between the power supply and HMI device.

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Note when connecting The mains terminal for connecting the power supply is contained in the accessory kit. The mains terminal is designed for cables with a maximum cross-section of 1.5 mm².

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

Connecting the mains terminal NOTICE Damage Do not tighten the screws of the power supply terminal if it is plugged into the HMI device. The pressure from the screwdriver may otherwise damage the HMI device socket. Only connect the wires when the mains terminal is withdrawn.

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Connect the power supply terminal to the cables of the power supply as shown in the figure above. Ensure that the lines are connected properly to the correct terminals. Refer to the label for the contact pins on the rear of the HMI device.

Reverse polarity protection The HMI device is equipped with a reverse polarity protection circuit.

Connecting the power supply CAUTION Safe electrical isolation Use only 24 VDC power supply units with safe electrical isolation in accordance with IEC 60364-4-41 or HD 384.04.41 (VDE 0100, Part 410), e.g. to PELV standard. The supply voltage must be within the specified voltage range. Otherwise, malfunction at the HMI device cannot be ruled out. Applies to non-isolated plant configurations: Connect the GND 24 V connection from the 24 V power supply output to equipotential bonding for uniform reference potential. You should always select a central point of termination.

See also Connecting an uninterruptible power supply (Page 67)

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

4.3.5

Connecting an uninterruptible power supply

Connection graphic The following figure shows the connection between the uninterruptible power supply and HMI device. The uninterruptible power supply is connected to the 24-V input and one of the HMI device's USB ports. When connected to the HMI device's USB port, the following uninterruptible power supplies are supported: SITOP DC UPS modules as of a rated power value of 6 A, e.g. 6EP1931-2DC42 8QLQWHUUXSWLEOHSRZHUVXSSO\

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Note Observe all the notes relating to connecting a power supply.

See also Connecting the power supply (Page 65)

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

4.3.6

Connecting the PLC

Wiring diagram The following figure shows the connection between the PLC and HMI device. 6,0$7,&6 3/&

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56

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56 56

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

NOTICE Approved cable If you do not use approved cables to connect a SIMATIC S7 controller, you may experience malfunctions. Only use approved cables to connect a SIMATIC S7 controller. Standard cables are available for the connection. You can find additional information on this in the Internet at "http://mall.automation.siemens.com".

Connecting PROFINET NOTICE Damage to the HMI device Only connect the HMI device to public Ethernet networks using a switch or comparable device. PROFINET IO communication For instructions regarding the installation of PROFINET networks, refer to the "PROFINET System Description" manual.

Note the following for the MP 377 PRO 15" Touch: Use an angled tool, such as an Allen wrench, to loosen the latch of the RJ45 connector for PROFINET.

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

Configuring an RS-422/RS-485 port A DIP switch S1 for the configuration of the RS-422/RS-485 port is located on the rear of the HMI device. In the factory state, the DIP switch is set for communication with the SIMATIC S7 PLC via RS 485. Note Note the diagrams of DIP switch settings on the rear panel of the HMI device. The following table shows the DIP switch settings. The send and receive direction is toggled internally using the RTS signal. Communication RS 485

Switch setting     21

Meaning No RTS on connector, • During data transfer between the PLC and HMI device • During data transfer between the HMI device and PC (delivery condition) RTS on pin 4, same as PLC, for example for commissioning

    21

RTS on pin 9, same as programming device, for example for commissioning

    21

RS 422

RS-422 port is active.

    21

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

4.3.7

Connecting the configuration PC

Wiring diagram The following figure shows the connection between the configuring PC and HMI device. 86%

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56

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The ports are described in the specifications. For the RS-485 to RS-232 conversion, you can order the PC/PPI cable from Siemens AG using order number 6ES7 901-3CB30-0XA0.

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

Configuring the PC/PPI cable Use the DIP switches to configure the transfer rate of the PC/PPI cable. Note Set a lower bit rate if the connection is lost during the operating system update. If you use a higher bit rate, you must use the PC/PPI cable version 3 or higher. The version code is printed on the cable ("E stand 3," for example, corresponds to version 3).

 ①

DIP switch

②

LEDs



Set DIP switches 1 to 3 to the same bit rate as in WinCC flexible. DIP switches 4 to 8 must be set to "0".          

①



DIP switch

The following bit rates can be set: Bit rate in Kbps

DIP switch 1

DIP switch 2

DIP switch 3

115.2

1

1

0

57.6

1

1

1

38.4

0

0

0

19.2

0

0

1

9.6

0

1

0

4.8

0

1

1

2.4

1

0

0

1.2

1

0

1

In the figure, the bit rate is set to 115.2 Kbps.

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

Note when connecting NOTICE USB connection sequence Observe the following sequence when connecting by USB: 1. HMI device 2. PC USB host-to-host cable Use only the driver for the USB host-to-host cable that is included in the WinCC flexible package. Never use the driver supplied with the USB host-to-host cable. Note Updating the operating system If there is no serviceable HMI device image on the HMI device, you can only update the operating system by restoring the factory setting. When restoring the factory settings, connect the PC to the HMI device by PROFINET. HMI device changeover If you connect more than one HMI device with the same IP address in succession to a single configuring PC, you need to ping the configuring PC once from the HMI device on each changeover of the HMI device.

Note for MP 377 PRO 15" Touch Use an angled tool, such as an Allen wrench, to loosen the latch of the RJ45 connector for PROFINET.

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

4.3.8

Connecting a USB device Below are examples of devices you can connect to the USB port of the HMI device: ● External mouse ● External keyboard ● Printer ● USB memory stick ● Industrial USB Hub 4 Industrial USB hub 4 can be obtained using order number 6AV6671-3AH00-0AX0.

Note when connecting NOTICE Functional problem with USB port If you connect an external device with a 230-V power supply to the USB port without using an non-insulated installation, you may experience functional problems. Ensure a non-insulated installation. Excessive rated load on port A USB device with too high a power load may possibly cause functional problems. Observe the values for the maximum load of the USB interface. You will find the values in the section "Technical specifications" (Page 284).

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ITEM 2500 Mounting and connecting 4.3 Connecting the HMI device

4.3.9

Connecting a printer

Wiring diagram The following figure shows the connection between the printer and HMI device.

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ITEM 2500

Mounting and connecting 4.3 Connecting the HMI device

Note when connecting NOTICE Data exchange cables If you use cables without a metallic netting shield between the HMI device and printer, you may experience functional problems. Only use cables with metal-braided shielding grounded at both ends for connecting the HMI device and printer. Note Some printers may require the ASCII character set used in the project to also be defined on the printer. You can find the list of current printers and required settings for HMI devices in the Internet at "http://support.automation.siemens.com/WW/view/en/11376409". Observe the supplied printer documentation when you connect the printer.

4.3.10

Connecting an audio device You can connect an active speaker or another audio amplifier to the HMI device's "Line Out" port. Note The "Micro" and "Line In" ports are provided for future applications. The microphone and audio source share one port.

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ITEM 2500 Mounting and connecting 4.4 Switching on and testing the HMI device

4.4

Switching on and testing the HMI device

Procedure Proceed as follows: 1. Switching on the power supply. The screen lights up after power is switched on. A progress bar is displayed during startup. If the HMI device fails to start, you have probably crossed the wires on the mains terminal. Check the connected wires and change their connection. The Loader opens after the operating system has started.

The HMI device automatically switches to "Transfer" mode during initial startup under the following conditions: – No project is loaded on the device. – At least one data channel has been configured. During this process the following dialog appears:

2. Press "Cancel" to stop the transfer.

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ITEM 2500 Mounting and connecting 4.4 Switching on and testing the HMI device

Result The Loader appears again. Note When restarting the system, a project may already be loaded on the HMI device. The project will then start after an adjustable delay or when you press the "Start" button. Use the relevant operating element to close the project. Refer to your plant documentation to find any additional information on this topic.

Function test Perform a function test following commissioning. The HMI device is fully functional when one of the following states is indicated: ● The "Transfer" dialog is displayed. ● The Loader is displayed. ● A project is started.

Shutting down the HMI Device Terminate the project at the HMI device before switching it off. You have the following options for switching off the HMI device: ● Switch off the power supply. ● Remove the mains terminal from the HMI device.

See also Configuring the data channel (Page 136)

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ITEM 2500 Mounting and connecting 4.5 Securing the cables

4.5

Securing the cables

4.5.1

Securing cables on the MP 377 mounting device After the power-on test, to ensure strain relief, use cable ties to secure the connected cables to the marked fixing elements.

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4.5.2

Securing cables on the MP 377 PRO After the power-on test, use cable ties to secure the connected cables to the marked clasps to ensure strain relief.

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ITEM 2500 Mounting and connecting 4.6 Closing the housing rear wall of MP 377 PRO

4.6

Closing the housing rear wall of MP 377 PRO

Requirement ● All cables are connected.

Procedure Proceed as follows: 1. Check that the seal is properly seated on the housing. NOTICE IP65 degree of protection at risk If the seal on the rear wall of the housing is damaged, the IP65 degree of protection is at risk. This is a repair case. Proceed as described in the section Spare parts and repairs (Page 274). 2. Position the housing rear wall on the housing. Ensure the housing rear wall cannot fall down. NOTICE Do not exceed the permissible torque If you tighten up the screws with a torque of > 1.2 Nm, you could damage the thread in the housing. Alternatively, tighten the screws using a maximum torque of 1.2 Nm. 3. Use an Allen key, size 2, to remove the 10 screws ① of the housing rear wall.







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ITEM 2500

5

Operator controls and displays 5.1

Front operator controls

MP 377 Touch



①

Display with touch screen

The MP 377 Touch is operated via the touch screen. All operating elements required for operator input are displayed on the touch screen once the HMI device has started. NOTICE Unintentional action possible Do not carry out several operations simultaneously. You may otherwise trigger an unintentional action. Always touch only one operating element on the screen Damage to the touch screen possible Never touch the touch screen with pointed or sharp objects. Avoid applying excessive pressure to the touch screen with hard objects. Both these will substantially reduce the useful life of the touch screen and even lead to total failure. Always operate the HMI touch screen with your fingers or with a touch pen.

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ITEM 2500 Operator controls and displays 5.1 Front operator controls

MP 377 12" Key 

    

 ①

Function keys with LED

②

System keys - alphanumeric keys

③

Display

④

System keys – control keys

⑤

System keys - cursor keys

The MP 377 12" Key is operated using the system keys and the function keys. The function assigned to a specific function key is defined during configuration. The function keys have no function prior to the project being opened. NOTICE Unintentional action possible Do not carry out several operations simultaneously. You may otherwise trigger an unintentional action. Do not press more than two keys simultaneously Damage to the keyboard possible Using hard instruments to press the keys considerably reduces the service life of the key mechanism. Only use your fingers to operate the HMI device keys.

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ITEM 2500 Operator controls and displays 5.2 Inserting a memory card

5.2

Inserting a memory card

Introduction The following can be saved to the memory card of the HMI device: ● Backup of the HMI device ● Logs ● Recipes ● Operating system ● Applications ● Other data such as video files, Word, Excel or PDF files The memory card can be inserted during operation. Note The multimedia card of the SIMATIC S7 PLC cannot be used.

Procedure Proceed as follows: 1. Insert the memory card into the relevant slot. When inserting the memory card, please note that it can only be inserted in the slot when the front side of the memory card is visible.

2. Check that the memory card is properly seated.

See also Securing memory card (Page 84)

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ITEM 2500 Operator controls and displays 5.3 Securing memory card

5.3

Securing memory card

Introduction The HMI device is designed for the tough conditions experienced in industry. Therefore use the locking bracket to secure the memory card in its slot.

Requirements A memory card has been inserted.

Procedure Proceed as follows: 1. Loosely screw in the Torx screw ①.

 

2. Place the locking bracket ② against the memory card. 3. Tighten the Torx screw ①.

Result The memory card is secure.

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ITEM 2500 Operator controls and displays 5.4 Unplugging the memory card

5.4

Unplugging the memory card

Introduction The memory card can be unplugged during operation. Do not remove the memory card while data is being accessed by an application, e.g. during backup or recipe transfer.

Procedure NOTICE Loss of data possible The data on the memory card is lost if you attempt to remove it while the HMI device is accessing its data. Do not remove the memory card while data is being accessed. Observe the corresponding alarms on the screen. Proceed as follows: 1. Unplug the memory card from the memory card slot. 2. Store the memory card in a safe place.

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ITEM 2500 Operator controls and displays 5.5 Labeling the function keys on the MP 377 12" Key

5.5

Labeling the function keys on the MP 377 12" Key

Introduction You can label the function keys as required for your project. Use the labeling strips for this purpose. Preprinted key labeling strips may be ordered as accessories, see section Accessories (Page 26). Note Do not write on the keyboard to label the function keys.

Printing labeling strips WinCC flexible comes with a range of labeling strip templates. You can find additional information on the location of the templates in the WinCC flexible online help. Any printable and writable foil can be used as labeling strips. You can use transparency film, the keyboard membrane of the HMI device is printed on the reverse side. Use transparent foil so that the LEDs of the function keys can be seen. The permitted thickness of the labeling strip is 0.13 mm. Paper labeling strips are inappropriate.

Dimensions of the labeling strip for the MP 377 12" Key [r 

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ITEM 2500 Operator controls and displays 5.5 Labeling the function keys on the MP 377 12" Key

Procedure Proceed as follows: 1. Edit and then print the template. You can also print blank templates and label them manually. 2. Apply a fixing spray film to the labeling strips. The fixing spray ensures that the text is water resistant and does not smear, and that the printer ink on the keyboard membrane does not run. 3. Cut out the labeling strip. Ensure that the corners are cut according to the diagram shown above as this makes it easier to slide them into the slot. 4. Remove any existing labeling strips. Note Wait for the printed labeling strips to dry before you insert them. 5. Slide the labeling strips ② into the slot ①.

  6. Slide the labeling strips into the slot up to the stop. The labeling strip will protrude approximately 3 cm from the slot. The template dimensions for the labeling strips are designed so that the labeling is correctly placed for the function keys. It is not necessary to secure the labeling strip. When mounting the HMI device, ensure that the labeling strips do not become jammed between the mounting cut-out and the HMI device.

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Operator controls and displays 5.5 Labeling the function keys on the MP 377 12" Key

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ITEM 2500

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ITEM 2500

Configuring the operating system 6.1

6

Loader

Overview The following figure shows the Loader. The header line contains details of the loader version. These details are not shown in the following figure.

The Loader buttons have the following functions: ● Press the "Transfer" button to set the HMI device to "Transfer" mode. The transfer mode can only be activated when at least one data channel has been enabled for the transfer. ● Press the "Start" button to start the project on the HMI device. If you do not perform an operation, the project on the HMI device will automatically start after a delay. ● Press the "Control Panel" button to open the control panel of the HMI device. You can change various settings in the Control Panel, for example, the transfer settings. ● Press the "Taskbar" button to activate the taskbar with the Windows CE start menu open.

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ITEM 2500 Configuring the operating system 6.1 Loader The following figure shows the open start menu.

Depending on the software installed, other symbols may be displayed in the desktop's status bar.

Open Loader The following options are available to open the Loader: ● The Loader appears briefly after starting the HMI device. ● The Loader appears when the project is closed. If configured, use the relevant operating element to close the project. For further information on this, refer to your plant documentation.

Key operation in the Loader The following table shows the key combinations for navigating in the Loader. Key combination ,

, {

ENTER

90

or

TAB

}

Function The next or previous entry is selected. The selected button is operated.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Configuring the operating system 6.1 Loader

Key operation in the Windows CE interface The following table shows the key combinations for navigating in the user interface. Key combination CTRL

+

ESC

ALT

+

ESC

ALT

+

TAB

Function The taskbar is activated with the open Windows CE start menu. The next active program is displayed. The Task Manager is opened.

Key operation in the Explorer The following table shows the key combinations for navigating in the Explorer. Key combination

Function • •

TAB

FN

+

FN

+

CTRL

+

Toggles the active window. Toggles between the Windows CE Desktop and the window.

Selects the first entry. HOME

Selects the last entry. END

A

B

Selects everything, if the left LED of the key

A-Z

lights up

Activates the menu bar.

ALT

Changes to the higher level.

ALT

+

CTRL

ALT

+

ENTER

Opens the shortcut menu. Displays the properties.

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ITEM 2500 Configuring the operating system 6.1 Loader

Protection against unauthorized use You can protect the control panel against unauthorized access by using a password. You can also protect the taskbar and the Desktop with the help of SecureMode. If the HMI device is protected, "secure mode" is displayed on the Windows CE desktop. You can find additional information on this in the section "Setting up and disabling SecureMode (Page 94)". The "Transfer" and "Start" buttons can always be used without having to enter a password. Password protection prevents maloperation. This increases the security of the system or equipment because settings for the current project can only be changed after entering the password. NOTICE Loss of data possible If the password is no longer available, you can only cancel password protection by updating the operating system. All data on the HMI device will be deleted when you update the operating system. Back up the HMI device's data.

Internet Explorer Internet Explorer for Windows CE is installed on the HMI device.

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Note Internet Explorer for Windows CE and the Internet Explorer version which can run on a PC differ in terms of functionality. Internet Explorer for Windows CE has separate proxy settings that are independent of the settings in the control panel of the HMI device. You can find additional information at the Microsoft Website.

Media Player Media Player for Windows CE is installed on the HMI device. Media Player is used, for example, to play video sequences for maintenance and servicing.

Media Player supports the following formats: ● WMA ● MPEG Note Media Player for Windows CE and the Media Player version that can run on a PC differ in terms of functionality. You can find additional information at the Microsoft Website.

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Configuring the operating system 6.2 Setting up and disabling SecureMode

6.2

Setting up and disabling SecureMode

Overview You can protect the control panel against unauthorized access with a password. You can also protect the taskbar and the Desktop with the help of the SecureMode.

Function of SecureMode You set up SecureMode by setting up a password in the control panel. SecureMode is then automatically activated. The label "secure mode" is displayed in the Windows CE Desktop. If you now want to use a function on the taskbar or Desktop, you have to enter the password. When you have entered the password, the label "secure mode" is no longer displayed. All the functions of the taskbar and Desktop can now be used freely. To reactivate SecureMode, double-click the

icon on the Desktop. The "secure mode" label is displayed again. The

HMI device is protected again.

Canceling SecureMode To completely cancel SecureMode, delete the password.

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ITEM 2500 Configuring the operating system 6.3 Viewer

6.3

Viewer

Introduction You can use ProSave to install viewers for various data formats. You can tell which viewers are installed by a symbol on the desktop and from the Start menu under "Programs". The following viewers can be installed: Viewer

Icon

PDF Viewer

Word Viewer

Excel Viewer

Functional scope The viewers can read and print the following file formats: Viewer

Readable file formats

PDF Viewer

PDF

Word Viewer

DOC, RTF

Excel Viewer

XL*

All viewers share a Zoom function. The Excel Viewer also offers the following functions: ● Switch between spreadsheet tabs ● Split the spreadsheet ● Change line height and column width

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ITEM 2500 Configuring the operating system 6.4 Control Panel

6.4

Control Panel

6.4.1

Overview The HMI device's Control Panel is similar to the control panel on a PC. The Control Panel looks like this:

The control panel can be used to modify the following settings: ● Date and time ● Screen saver ● Regional settings ● Transfer settings ● Network settings ● Delay time ● Password

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6.4.2

Opening the Control Panel

Introduction The HMI device Control Panel can be opened as follows: ● Independently of a running project – Press the "Control panel" button in the loader. – By calling up from the Windows CE start menu. ● With active project An operating element must be configured to open the control panel for this purpose.

Procedure – open the Control Panel via the Start menu Proceed as follows: 1. Open the Windows CE start menu. – Procedure using the keys: Select the

ESC

+

CTRL

key combination.

– Procedure using the touch screen: Press the

key twice on the alpha-numeric VDU keyboard.

2. Select "Settings > Control panel".

Result The control panel is opened.

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ITEM 2500 Configuring the operating system 6.4 Control Panel

6.4.3

Reference for functions

Overview of functions The following table shows the settings in the Control Panel. Icon

Functions

Tab / entry

Saving and restoring with external storage device

–

Importing, displaying and deleting certificates

"Stores"

Setting the date and time

"Date/Time"

Configuring the screen keyboard

–

Changing the browser startup page and general browser settings

"General"

Changing connection and proxy server settings

"Connection"

Changing cookie settings

"Privacy"

Changing privacy settings

"Advanced"

Setting the character repeat for the keyboard

"Repeat"

Setting the double-click

"Double-Click"

Parameterizing the LAN connection

"ERTEC400"

Setting the IP address

"ERTEC400 Ethernet Driver' Settings"

"IP Address"

Set name server

"ERTEC400 Ethernet Driver' Settings"

"Name Servers"

Changing the logon data

"Identification"

Backup registry information

"Persistent Storage"

Changing monitor settings

"Display"

Displaying information about the HMI device

"Device"

Restarting the HMI device

"Device"

Touch screen calibration

98

1)

"Touch"

Activate memory management

"Memory Monitoring"

Changing password protection

"Password Settings"

Changing the printer properties

–

Changing the PROFINET IO setting

–

Changing regional settings

"Regional Settings"

Changing the number format

"Number"

Changing the currency format

"Currency"

Changing the time format

"Time"

Changing the date format

"Date"

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ITEM 2500 Configuring the operating system 6.4 Control Panel Icon

Functions

Tab / entry

Changing transfer settings

"MPI"

Changing the PROFIBUS DP transfer settings

"PROFIBUS"

Setting the screen saver

–

Reducing the backlighting Displaying the system information

"General"

Displaying memory information

"Memory"

Setting the device name of the HMI device

"Device Name"

Configuring the data channel

"Channel"

Setting the delay time

"Directories"

Setting the uninterruptible power supply

"Configuration"

State of uninterruptible power supply

"Current Status"

Setting operation feedback with key and touch screen operation

"Volume"

Setting operation feedback with key operation Setting acoustic signal for inadvertent operations Assigning sounds to events. Changing e-mail

settings2)

"Sounds" "Email"

1)

Only with MP 377 Touch

2)

Additional tabs may appear in the "WinCC flexible Internet Settings" dialog. This depends on the options that have been enabled for network operation in the project.

6.4.4

Operating the Control Panel

6.4.4.1

Overview

Operator input options The hardware of the HMI device determines, which of the following operator control options are available: ● Touch screen The operating elements shown in the dialogs are touch-sensitive. Touch objects are basically operated in the same way as mechanical keys. You activate operating elements by touching them with your finger. To double-click them, touch an operating element twice in succession. ● HMI device keyboard The operating elements shown in the dialogs are selected and operated using the keys of the HMI device. ● External USB keyboard ● External USB mouse

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ITEM 2500 Configuring the operating system 6.4 Control Panel

Entries using an external keyboard An external keyboard can be used to operate the Control Panel in exactly the same way as the HMI device keyboard. Use the keys of the external keyboard which correspond to the HMI device keys in the description.

Operator entries using an external mouse An external mouse can be used to operate the Control Panel in exactly the same way as the HMI device touch screen. Click the described operating elements with the mouse.

6.4.4.2

Operation using the touch screen

Introduction The control panel is operated with the HMI device touch screen or a connected mouse.

Requirements An active project has been terminated. The Loader appears.

Procedure Proceed as follows to change settings in the Control Panel: 1. Open the Control Panel with the "Control Panel" button. 2. To open the required dialog, double-click its symbol. 3. Change the tab as required. 4. Make the necessary changes. Touch the corresponding input object. – Use the screen keyboard of the HMI device to enter the new values in the text boxes. – Touch a button to operate it. – Touch the selection box to open a drop down list box. Touch the required entry from the drop down list box. – Touch the check box to activate or deactivate a check box. – Touch a radio button to select it. 5. Confirm the selection with the

button or abort the entry with the

button.

The dialog closes. 6. Close the Control Panel with the "

" button.

The Loader appears.

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Input with the screen keyboard A screen keyboard is available for data input. The screen keyboard is displayed as soon as you touch a text box. You can also call up the screen keyboard directly from the Control Panel.

Display methods for the screen keyboard You can change the display method for the screen keyboard and fix the position on the screen. Confirm the entry with the

button or abort the entry with the

key. Either

action closes the screen keyboard. ● Numerical screen keyboard

● Alphanumerical screen keyboard

The alphanumerical keyboard is organized in the following two layers: – Normal level – Shift level ● Reduced screen keyboard

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Changing the display of the screen keyboard Key

Functions Switching between the numerical and alphanumerical keyboard Switching between the normal level and Shift level of the alphanumerical screen keyboard Switchover to special characters Switching from full display to reduced display Switching from reduced display to full display Close the screen keyboard

6.4.4.3

Operation with the keyboard

Introduction The Control Panel is operated with the system keys of the HMI device.

Requirements An active project has been terminated. The Loader appears.

Procedure Proceed as follows to change settings in the Control Panel: 1. Open the Control Panel. 2. Select the "Control Panel" button in the loader using the cursor keys. 3. Press

ENTER

.

The Control Panel is opened. 4. Select the symbol of the required dialog with the cursor keys. 5. Press

ENTER

to open the dialog.

6. Change the tab as required. Press

TAB

until the name of the tab is selected. Now switch between the tabs using

the cursor keys. 7. Use the

102

TAB

key to return to the input area.

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ITEM 2500 Configuring the operating system 6.4 Control Panel 8. Make the necessary changes. To do this, highlight the corresponding input object using the

TAB

key.

– Use the system keys of the HMI device to enter the new values in the text boxes. – To operate a button, select the button with the cursor keys and then press – Open the drop down list boxes with the key combination

+

ALT

ENTER

.

.

Select the required entry from the drop down list box using the cursor keys. Confirm the selected entry by pressing – Press

{

}

ENTER

.

to activate or deactivate a check box.

– Select a radio button from a group using the cursor keys. 9. Confirm your entries with

ENTER

or discard your entries with

ESC

.

If you have selected an input object, you first have to complete entry. The dialog closes. 10. Close the Control Panel. Press the

ALT

key to do this.

The control panel menu is opened. 11. Select the "Close" entry using the cursor keys. 12. Press

ENTER

.

The Loader appears.

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Control keys The following tables show the control keys used to select and operate the control panel. ● Select operating elements Key TAB

SHIFT

+

Functions

Description

Tabulator

Selects the next/previous operating element in the tab sequence.

Cursor keys

Selects the next operating element to the left, right, above or below the current screen object.

TAB

Navigates in the operating element.

● Using operating elements Key

Functions

Description

Scroll back

Scrolls back a page in a list.

Scroll to the beginning

Scrolls to the beginning of a list.

Scroll forward

Scrolls one page forward in a list.

Scroll to the end

Scrolls to the end of a list.

ENTER key

• •

Operates a button. Accepts and ends an entry.

Cancel

•

Deletes the characters of a value entry and restores the original value. Closes the active dialog.

HOME

FN

+

HOME

END

FN

+

END

ENTER

ESC

• INS DEL

104

ALT

+

CTRL

+

ENTER

Delete characters

Deletes the character to the right of the current cursor position.

Delete characters

Deletes the character to the left of the current cursor position.

Open drop down list box

Opens a drop down list box.

Accept value

Accepts the selected value in the drop down list box without closing the list.

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Enter key combinations Key A-Z

Functions

Purpose

Toggle key assignment

Toggles the assignment for a key with multiple assignment. • No LED is lit

•

The number assignment is enabled. Pressing the button once toggles to letter assignment. An LED is lit The left or right letter assignment is enabled.

Each time the key is pressed, the system toggles between the left letter assignment, the right letter assignment and the number assignment. SHIFT

FN

Toggle between upper-case and lower-case

Used in key combinations, for example for entering upper-case letters.

Switch to additional key assignment

Some of the keys contain a blue imprinted key assignment, for example the "%" character. Used in key combinations for the blue key assignment.

CTRL

ALT

General control function

Used in key combinations

General control function

Used in key combinations

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Configuring the operating system 6.5 Changing settings for operation

6.5

Changing settings for operation

6.5.1

Configuring the screen keyboard

Introduction The details provided below will explain how the screen keyboard can be displayed and positioned.

Requirements You have opened the "Siemens HMI Input Panel - Options" dialog with icon.

the "InputPanel"

   ①

Check box for displaying the

button in the screen keyboard

②

Button for displaying the screen keyboard

③

Button for saving the screen keyboard settings

Procedure Proceed as follows: 1. If you want to change the size of the screen keyboard, activate the "Show Resize Button" check box. The

button is displayed in the screen keyboard awaiting opening.

2. If you want to prevent the size of the screen keyboard from being changed, deactivate the "Show Resize Button" check box. The

button is removed from the screen keyboard awaiting opening.

3. Use the "Open Input Panel" button to open the screen keyboard. 4. If you want to switch between the numerical and alphanumerical screen keyboard, press the

106

key.

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ITEM 2500 Configuring the operating system 6.5 Changing settings for operation 5. If you want to change the position of the screen keyboard, use the mouse pointer to select a free space between the keys. Release the mouse pointer when the required position has been reached. 6. If you want to increase or decrease the size of the keyboard screen, place your mouse pointer over the button

.

7. Adapt the screen keyboard size by dragging it to size with the mouse pointer. 8. Release the mouse pointer when the required size has been reached. 9. If you want to save the settings, press the "Save" button. 10. Confirm your entries. The dialog closes.

Result The screen keyboard settings have been modified.

6.5.2

Setting the character repeat

Introduction The details provided below will explain how to set the character repetition and the associated delay for the keyboard and/or screen keyboard.

Requirements You have opened the "Keyboard Properties" dialog with the "Keyboard"

icon.



   ①

Check box for activating the character repeat

②

Slider control and buttons for the delay time before character repeat

③

Slider control and buttons for the rate of the character repeat

④

Test field

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Configuring the operating system 6.5 Changing settings for operation

Procedure Proceed as follows: 1. If you want to enable character repetition, activate the "Enable character repeat" check box. 2. If you want to change the delay, press a button or the slider in the "Repeat delay" group. Moving the slider to the right will shorten the delay. Moving to the left will extend the delay. 3. If you want to change the repeat rate, press a button or the slider in the "Repeat rate" group. Moving the slider to the right will shorten the repeat rate. Moving to the left will extend the repeat rate. 4. Check the settings. Procedure using the touch screen: – Touch the test field. The screen keyboard opens. – Move the screen keyboard as needed. Procedure using the keys: – Select the test field. 5. Press an alphanumeric key and keep the key pressed down. Check the implementation of the character repetition and the rate of the character repetition in the test field. 6. If the settings are not perfect, correct them. 7. Confirm your entries. The dialog closes.

Result The character repetition and delay are set.

6.5.3

Setting the double-click

Introduction You can start applications in the Control Panel and in Windows CE with a double-click. A double-click corresponds to two brief touches in sequence. In the "Mouse Properties" dialog, make the following adjustments for touch screen operation and operation with external mouse: ● Interval between touch contacts on the touch screen ● Interval between mouse clicks

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ITEM 2500 Configuring the operating system 6.5 Changing settings for operation

Requirements You have opened the "Mouse Properties" dialog with the "Mouse"

icon.





①

Pattern

②

Icon

Procedure Proceed as follows: 1. Click the pattern twice. After the second click, the colors of the pattern will be reversed and the white fields will change to gray. The time before the second click is saved.

2. Check the double-click. Click on the icon twice in succession to do this. If the double-click is recognized, the icon is displayed as follows:

3. If the settings are not perfect, correct them. To do this, repeat steps 1 to 2. 4. Confirm your entries. The dialog closes.

Result The double-click adjustment is completed.

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ITEM 2500 Configuring the operating system 6.5 Changing settings for operation

6.5.4

Calibrating the touch screen

Introduction Depending on the mounting position and viewing angle, it is possible that parallax may occur when operating the touch screen. In order to prevent any operating errors as a result, calibrate the touch screen again in the startup phase or during runtime.

Requirements You have opened the "OP Properties" dialog "Touch" tab with the "OP"

icon.

Procedure Proceed as follows: 1. Click on the "Recalibrate" button. The following dialog opens: &DUHIXOO\SUHVVDQGEULHIO\KROGVW\OXVRQWKHFHQWHURI WKHWDUJHW5HSHDWDVWKHWDUJHWPRYHVDURXQGWKHVFUHHQ



2. Briefly touch the middle of the calibration crosshairs ①. The calibration crosshairs is then displayed at four more positions.

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ITEM 2500 Configuring the operating system 6.5 Changing settings for operation 3. Briefly touch the middle of the calibration crosshairs for each position. Once you have touched all the positions of the calibration crosshairs, the following dialog appears: New calibration settings have been measured. Tape the screen to register saved data. Wait for 30 seconds to cancel saved data and keep the current setting.

Time limit: 30 sec

4. Touch the touch screen. The calibration is saved. The "OP Properties" dialog, "Touch" tab is displayed again. If you do not touch the touch screen within the time shown, your original setting will be retained. 5. Close the dialog.

Result The HMI device touch screen is calibrated.

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Configuring the operating system 6.6 Setting up password protection

6.6

Setting up password protection

Introduction You can protect access to the Control Panel and the Windows CE taskbar with a password.

Requirements You have opened the "Password Properties" dialog with the "Password"

icon.

NOTICE Password not available If the password is no longer available, you will have to wait for the operating system to be updated again. • Change settings in the Control Panel • Use the Windows CE taskbar All data on the HMI device will be deleted when you update the operating system! Therefore use the password to protect against loss. Note The following characters cannot be used in passwords: • Blank • Special characters * ? . % / \ ' "

Procedure Proceed as follows: 1. Enter a password in the "Password" text box. 2. Repeat the password entry in the "Confirm password" text box. 3. Confirm your entries. The dialog closes.

Result You cannot open the Control Panel or Windows CE taskbar without entering a password.

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ITEM 2500 Configuring the operating system 6.7 Canceling password protection

6.7

Canceling password protection

Requirements You have opened the "Password Properties" dialog with the "Password"

icon.

Procedure Proceed as follows: 1. Delete the entries in the "Password" and "Confirm password" text boxes. 2. Confirm your entries. The dialog closes.

Result Password protection for the Control Panel and Windows CE taskbar is canceled and they can be freely accessed.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings

6.8

Changing HMI device settings

6.8.1

Setting the date and time

Introduction You can set the date and time on the HMI device. The HMI must be restarted in the following cases: ● You have changed the time zone setting ● You have changed the "Daylight savings time currently in effect" check box setting.

Requirements You have opened the "Date/Time Properties" dialog with the "Date/Time Properties"

icon.

  

  ①

Time zone selection box

②

Input field for the time

③

Date selection box

④

"Daylight savings" check box

⑤

Button for applying changes

Procedure Proceed as follows: 1. Select the appropriate time zone for the HMI device from the "Time Zone" selection field. 2. Touch the "Apply" button to confirm your entry. The time of day shown in the "Current Time" field is adjusted correspondingly to the selected time zone. 3. Set the date in the selection box. 4. Set the current time of day in the "Current Time" text box.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings 5. Confirm your input by clicking on the "Apply" button. The values you have set are now in effect. Note The system does not automatically switch between winter and summer time. 6. If you want to switch from winter to summer time, activate the "Daylight savings time currently in effect" check box. When you press the "Apply" button, the time is brought forward by one hour. 7. If you want to switch from summer to winter time, deactivate the "Daylight savings time currently in effect" check box. When you press the "Apply" button, the time is taken backward by one hour. 8. Confirm your entries. The dialog closes.

Result The settings for the data and time of day have now been changed.

Internal clock The HMI device has an internal buffered clock.

Synchronizing the date and time with the PLC The date and time of the HMI device can be synchronized with the PLC if this has been configured in the project and the PLC program. Further information on this subject is available in the "WinCC flexible" system manual. NOTICE Time-dependent reactions You have to synchronize the date and time when time-controlled responses are triggered in the PLC by the HMI device.

6.8.2

Changing regional settings

Introduction In different countries, for example, the date, time and decimal points are displayed differently. You can adjust this display to meet the requirements of different regions. The country-specific settings apply to the current project. If the project language is changed, the country-specific settings are also changed.

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Configuring the operating system 6.8 Changing HMI device settings

Requirements You have opened the "Regional and Language Settings" dialog with the "Regional Settings"

icon.

 ①

Region selection box

Procedure Proceed as follows: 1. Select the region from the selection box. 2. Change to the "Number", "Currency", "Time" and "Date" tabs and set the selection boxes to the desired settings. 3. Confirm your entries. The dialog closes.

Result The HMI device's regional settings have been changed.

6.8.3

Backup registry information

Registry information and temporary data You can install and uninstall your own programs on the HMI devices under Windows CE. You must save the registry settings after installation or uninstallation. You can save the following data to the flash memory: ● Registry Information ● Temporary files

Restoring the file system of a memory card If memory cards are used, the file system on the memory card may become damaged, perhaps due to a power failure. The HMI device detects the defective file system on start-up or when the memory card is inserted. The HMI device can restore the file system automatically or on request.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings

Requirements You have opened the "OP Properties" dialog, "Persistant Storage" tab with the "OP"

icon.

     ①

Significance of the text: Saves the current registry information to the flash memory. The HMI device loads the saved registry information the next time it boots.

②

Button for saving registry information

③

Button for saving temporary files

④

Significance of the text: Saves all the files in temporary storage to the flash memory (for example, from the "Program Files" directory). These files are written back when the HMI device is started. The "\Temp" directory is not saved.

⑤

Automatically restores the file system on the memory card when the HMI device starts up and when a memory card is inserted.

Procedure Proceed as follows: 1. If you want the system to be restored automatically, activate the "Automatically repair file system errors ..." check box. If the check box is unchecked, the system is only restored once prompted to do so. 2. Click on the necessary buttons. 3. Confirm your entries. The dialog closes.

Result The HMI device uses the saved registry information the next time it starts. The temporary files are copied back.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings

6.8.4

Changing monitor settings

Requirements You have opened the "OP Properties", dialog "Display" tab with the "OP"

icon.

Procedure Proceed as follows: 1. If you want to increase the brightness, press the "UP" button. 2. If you want to decrease the brightness, press the "DOWN" button. 3. Confirm your entries. The dialog closes.

Result The screen settings have been changed.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings

6.8.5

Setting the screen saver

Introduction You can set the following time intervals on the HMI device: ● For the automatic activation of the screen saver ● For the automatic reduction in the screen's backlighting When you do not undertake an operation within the configured interval, the configured function will be activated automatically. The screen saver and the reduced screen backlighting functions are switched back off by means of the following actions: ● By pressing any key ● By touching the touch screen The function associated to the key or button will not be executed by this. NOTICE Reduce backlighting The brightness of the backlighting decreases incrementally during its operational life. In order to not shorten the operational lifetime of the backlighting unnecessarily, activate the backlighting reduction. Activating the screen saver Screen contents may occasionally leave a burn-in effect in the background if they appear too long. This burn-in effect will automatically disappear after a certain amount of time if the screensaver is activated, for example. The longer the same content is displayed on the screen, the longer it will take for the burn-in effect to disappear. Generally, you should always activate the screen saver. When the screen saver is active, the backlighting is reduced at the same time.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings

Requirement You have opened the "Screensaver" dialog with the "ScreenSaver"

icon.

  

①

Time interval in minutes until backlighting is reduced

②

Period of time in minutes before the screen saver is activated

③

Radio buttons for the screensaver

Procedure Proceed as follows: 1. Enter the interval in minutes after which the backlighting is to be reduced. Entering "0" will deactivate the backlighting reduction. 2. Enter the number of minutes before the screen saver is to be activated. The minimum time is 5 minutes and the maximum time is 71582 minutes. Entering "0" disables the screen saver. 3. Select either the screen saver or an empty screen. – If you want the screen saver to function, activate the "Standard" radio button. – If you do not want the screen saver to function, activate the "Blank Screen" radio button. 4. Confirm your entries. The dialog closes.

Result The screen saver and the reduced backlighting for the HMI device is set.

6.8.6

Changing the printer properties

Introduction The HMI device can print on local printers or network printers. You can print hardcopies and reports on a network printer. Line printing of alarms is not possible on a network printer. You can find the list of current printers and required settings for HMI devices in the Internet at "http://support.automation.siemens.com/WW/view/en/11376409".

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Requirement You have opened the "Printer Properties" dialog with the "Printer"

icon.

     



①

Selection box for the printer

②

Interface selection box

③

Network address of the printer

④

Paper format selection box

⑤

Group orientation with radio buttons for print orientation

⑥

Print quality check box

⑦

Color printing check box

Procedure Proceed as follows: 1. Select a printer from the "Printer Language" selection box. 2. Select the port for the printer from the "Port" selection box. 3. If you wish to print via the network, enter the printer's network address in the "Network" text box. 4. Select the paper format from the"Paper Size" selection box. 5. Activate a radio button in the "Orientation" group. – "Portrait" for portrait – "Landscape" for landscape 6. Select the print quality. – Select the "Draft Mode" check box if you wish to print in draft mode. – Clear the "Draft Mode" check box if you wish to print with higher quality. 7. If the printer selected can print in color and you wish it to do so, activate the "Color" check box. 8. Confirm your entries. The dialog closes.

Result The settings for the printer have now been changed.

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Configuring the operating system 6.8 Changing HMI device settings

6.8.7

Enabling sound and setting sound volume

Introduction You can activate an acoustic feedback for keyboard and touch screen operations. With each touch or activation of a key, a sound is emitted.

Requirements You have opened the "Volume & Sounds Properties" dialog, "Volume" tab with the "Volume & Sounds"

icon.

     ①



Acoustic warnings and system events

②

Program-specific sounds

③

Notification sounds

④

Acoustic feedback when using keys

⑤

Acoustic feedback when using touch screen

⑥

Keys and controller for setting volume for the "Enable sounds for" group

Note If you deactivate the settings under "Enable sounds for", no more acoustic signals will be emitted during inadvertent operations.

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Procedure Proceed as follows: 1. Activate the check boxes needed in the "Enable sounds for" group. If no check boxes are activated, no acoustic feedback will be output. 2. If you want signaling for entries to be audible, activate the following check box: – With key control: "Hardware buttons". – With touch control: "Screen taps". 3. Use the "Loud" and "Soft" radio buttons to select between loud and quiet signaling. 4. If you want to change the volume for acoustic messages, use the controller or "Loud" and "Soft" keys to do this. 5. Confirm your entries. The dialog closes.

Result The properties of the acoustic operation feedback are now set up.

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6.8.8

Assigning sound to an event

Introduction When acoustic feedback is activated, a sound is used to report an event. You can select the sound to reflect the event.

Requirements ● A loudspeaker is connected to the HMI device. ● You have opened the "Volume & Sounds Properties", dialog "Sound" tab with the "Volume & Sounds"

icon.

Procedure Proceed as follows: 1. Select a suitable sound from the "Event" group. The sound selected is displayed in the "Sound" group in the associated list box. 2. If you want to listen to the sound, press the "

" button.

The sound is output by a loudspeaker connected to the HMI device. Use the

button

to stop the output. 3. If you haven't managed to find a suitable sound, you can use the "Browse" button to switch to a folder of your choice. The sound selected is displayed in the "Sound" group in the associated list box. 4. Confirm your entries. The dialog closes.

Result The sound is set for acoustic feedback on operations.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings

6.8.9

Restarting the HMI device

Introduction You can restart the HMI device or reset the factory settings before rebooting. Further information on this can be found in the section "Resetting factory settings (Page 174)".

Required restart The HMI device must be restarted in the following cases: ● You have activated or deactivated the PROFINET IO direct keys. ● You have changed the time zone setting. ● You have changed the automatic daylight savings and standard setting NOTICE Data loss when the HMI device is restarted All volatile data is lost when the HMI device is restarted. Check the following: • The project on the HMI device is complete. • No data is being written to the flash memory. The HMI device must be restarted in the following cases:

Requirement ● You have opened the "OP Properties" dialog box, "Device" tab, by touching the "OP"

icon.



①

Button for restarting the HMI device

● If you want to reset the HMI device to the factory settings: the HMI deice is connected to a configuration PC via PROFINET.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings

Procedure 1. If you want to restart the HMI device, press the "Reboot" button. The following message is displayed:





①



If you run this function, all data which has not been backed up will be lost. Please close all applications before restarting.

②

Button for reset to factory settings and subsequent restart

③

Button for restart

2. Press one of the buttons. ● If you want to restart the HMI device, press the "Reboot" button. The HMI device restarts without delay. ● If you want to reset the HMI device to the factory settings and then restart, press the "Prepare for Reset" button. You are given the option of resetting the HMI device to the factory settings through ProSave. The HMI device then restarts. ● If you do not want to restart the HMI device, press the "No" button. The message closes. There will be no restart.

Result The HMI device starts.

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ITEM 2500 Configuring the operating system 6.8 Changing HMI device settings

6.8.10

Displaying information about the HMI device

Introduction You will need the device-specific information if you contact Technical Support.

Requirement You have opened the "OP Properties" dialog box, "Device" tab, by touching the "OP"

icon.

The following figure applies to the MP 377 15" Touch. The data displayed are device-specific and may therefore deviate from that of your HMI device.

       ①

HMI device name

②

Version of the HMI device image

③

Version of the boot loader

④

Boot loader release date

⑤

Size of the internal flash memory in which the HMI device image and project are stored

⑥

MAC address of the HMI device

⑦

See section "Restarting HMI device"

The HMI device-specific information is displayed in the "Device" tab. Note The size of internal flash memory is not equivalent to application memory available for a project.

See also Restarting the HMI device (Page 125)

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ITEM 2500

Configuring the operating system 6.8 Changing HMI device settings

6.8.11

Displaying system properties

Introduction The general system-specific information provides you with information about the processor, operating system and memory.

Requirements You have opened the "System Properties", dialog "General" tab with the "System"

icon.

The data displayed are device-specific and may therefore deviate from that of your HMI device.





①

Copyright to Microsoft Windows CE

②

Details on processor and size of internal Flash memory

Displaying system properties The system properties are displayed. This dialog is read-only. Close the dialog.

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6.8.12

Displaying memory distribution

Introduction The "Memory" system-specific information provides you with information about the distribution and size of the memory in the HMI device. NOTICE "Memory" tab Do not change the memory distribution in the "Memory" tab. Applies for the usage of options: An alteration to the memory distribution may be necessary. Please refer to the accompanying documentation for further information.

Requirements You have opened the "System Properties", dialog "Memory" tab with the "System"

icon.

Procedure 1. Determine the HMI device's current memory structure 2. Close the dialog.

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ITEM 2500

Configuring the operating system 6.9 Setting storage location

6.9

Setting storage location

Introduction There are various storage locations available for storing the compressed source file of your project. The following describes how you can set the storage location.

Requirements You have opened the "Transfer Settings", dialog "Directories" tab with the "Transfer"

icon.

 



①

Directory where the project file is saved

②

Directory where the compressed source file of your project is saved

③

Storage location and initialization file of the HMI device for process operation

NOTICE Settings under "Project File" and "Path" The project may not open the next time the HMI device is started if changes are made in the "Project File" and "Path" text boxes. Do not change the entries in the "Project File" and "Path" text boxes.

Procedure 1. Select a memory location from the "Project Backup" text box. The external memory card or the location in the data network can be defined as the storage location. During the next backup process, the project's source file is stored in the specified location. 2. Confirm your entries. The dialog closes.

Result The storage location for the HMI device is now set.

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ITEM 2500 Configuring the operating system 6.10 Setting the delay time

6.10

Setting the delay time

Introduction Once the HMI device has been switched on, a project can be started after a delay. The Loader is displayed during the delay time.

Requirements You have opened the "Transfer Settings", dialog "Directories" tab with the "Transfer"

icon.

NOTICE Settings under "Project File" and "Path" The project may not open the next time the HMI device is started if changes are made in the "Project File" and "Path" text boxes. Do not change the entries in the "Project File" and "Path" text boxes.

Procedure 1. Select the desired delay time in seconds from the "Wait [sec]" selection box. With the value "0", the project starts immediately. It is then no longer possible to call the Loader after switching on the HMI device. If you still wish to access the Loader, an operating element must be configured to close the project. 2. Confirm your entries. The dialog closes.

Result The delay time for the HMI device is now set.

See also Overview (Page 163) MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500

Configuring the operating system 6.11 Setting the uninterruptible power supply

6.11

Setting the uninterruptible power supply

Introduction UPS monitoring is an option you load as an add-on with ProSave. A UPS ensures that the HMI device is shut down in a controlled manner after a buffer time in the event of a power failure. This avoids the loss of data. The following uninterruptible power supplies are supported: SITOP DC UPS modules as of a rated power value of 6 A, e.g. 6EP1931-2DC42 Connect the UPS to the 24-V input and a USB port. Configure the USB port for UPS monitoring.

Requirements You have opened the "UPS Properties", dialog "Configuration" tab with the "UPS"

icon.

    ①

Text box for the time after which the "Battery mode activated" message is displayed

②

Check box for enabling battery mode

③

Text box for the time after which the "Faulty port" message is displayed

④

Check box for the "Faulty port" message

Procedure Proceed as follows: 1. If you want to enable battery mode, activate the "Battery mode" check box. 2. Enter the time for terminating applications in the "min" and "s" text boxes. You will receive a message when UPS takes effect. Applications such as HMI Runtime and WinAC MP are then terminated depending on the time entered. 3. If the port to which the UPS is connected is faulty and you therefore want to receive a message, activate the "Port disturbed" check box. 4. Select the message you want from the list box. 5. Enter the time after which the "Faulty port" message is displayed in the "min" and "s" text boxes.

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ITEM 2500 Configuring the operating system 6.12 State of uninterruptible power supply

Result Port monitoring for the UPS is set.

See also State of uninterruptible power supply (Page 133)

6.12

State of uninterruptible power supply

Introduction If you have connected a UPS to a USB port, you can display the monitoring state of this port.

Requirements You have opened the "UPS Properties", dialog "Current status" tab with the "UPS"

icon.



①

The "UPS program is not running. No current status available." message appears when the UPS is not connected.

Procedure Proceed as follows: 1. Installing the UPS monitoring software. 2. Connect the UPS. 3. If you want to update the monitoring state, press the "Update" button. The message is changed according to the current setting. The message will remain unchanged if no check boxes in the "Configuration" tab have been activated.

Result The current monitoring state for the UPS is displayed.

See also Setting the uninterruptible power supply (Page 132)

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ITEM 2500

Configuring the operating system 6.13 Enabling PROFINET IO

6.13

Enabling PROFINET IO

PROFINET IO If the HMI device is connected to the PLC via PROFINET, function keys or buttons, for example, can be configured as PROFINET IO direct keys. If PROFINET IO direct keys are used in the project, they must be enabled. Note If you enable PROFINET IO direct keys, you cannot use the RS 422/RS 485 port for serial communication. PROFINET IO direct keys and PROFIBUS DP direct keys are mutually exclusive.

Requirements You have opened the "PROFINET" dialog with the "PROFINET"

icon.



  ①

Activating or deactivating the PROFINET IO direct keys

②

Text box for the device name

③

MAC address of the HMI device

NOTICE Inconsistent device name If the device name does not match the device name entered in the HW Config of STEP 7, the direct keys do not work. Use the device name from the HW Config of STEP 7. This device name does not correspond to the device name used under Windows CE.

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ITEM 2500 Configuring the operating system 6.13 Enabling PROFINET IO Within the ETHERNET data network, the device name must be unique and satisfy the DNS conventions. These include: ● Restriction to 127 characters in total (letters, digits, hyphen or point) ● A name component within the device name, e.g. a string between two points, may not exceed 63 characters. ● Special characters such as umlauts, brackets, underscores, slashes, spaces etc. are not permitted. The hyphen is the one exception. ● The device name must not start or end with a the "-" character. ● The device name must not take the form n.n.n.n (n = 0 to 999). ● The device name must not start with the character sequence "port-xyz-" (x, y, z = 0 to 9).

Procedure Proceed as follows: 1. If you want to enable the PROFINET IO direct keys, activate the "PROFINET IO enabled" check box. 2. Enter the device name of the HMI device. 3. Confirm your entries. The dialog closes.

Result The PROFINET IO direct keys are enabled.

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ITEM 2500

Configuring the operating system 6.14 Changing transfer settings

6.14

Changing transfer settings

6.14.1

Configuring the data channel

Introduction If you block all data channels, the HMI device is protected against unintentional overwriting of the project data and HMI device image. Note A project can only be transferred from the configuring PC to the HMI device when at least one of the data channels is enabled on the HMI device.

Requirements The "Transfer Settings" dialog, "Channel" tab has been opened with the "Transfer Settings"

icon.



  ①

Group for the data channel 1 (Channel 1)

②

Group for the data channel 2 (Channel 2)

③

Button for the "MPI/DP-Transfer Settings" and/or "Network and Dial-Up Connections" dialog

WARNING Unintentional transfer mode Unintentional transfer mode could cause unintentional actions to be triggered in the plant. Ensure that the configuring PC does not inadvertently switch the HMI device to transfer mode during the open project.

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ITEM 2500 Configuring the operating system 6.14 Changing transfer settings

NOTICE "Remote control" for "Channel 1" If the "Remote Control" check box is activated during "Online" operating mode, the X10 port cannot be used for communication. The "Remote Control" check box must be deactivated for "Online" operating mode. Once the serial transfer is complete, in the "Channel 1" group you must therefore deactivate the "Remote Control" check box. Transfer mode using "Channel 2" When the project on the HMI device starts, transfer parameters, e.g. HMI device address, for MPI/PROFIBUS DP are overwritten with the values from the project. You can change the settings for the transfer via "Channel 2". The following steps are required: • Close the project. • Change the settings on the HMI device. • Then return to "Transfer" mode. The next time the project is started on the HMI device, the settings will be overwritten by the values from the project. Note If the HMI device is in "Transfer" mode while changes are made to the transfer settings, the settings only go into effect after the transfer function is restarted. This may occur if the Control Panel is opened to change the transfer properties in an active project.

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Configuring the operating system 6.14 Changing transfer settings

Procedure Proceed as follows: 1. If you want to enable a data channel, activate the "Enable Channel" check box in the "Channel 1" or "Channel 2" group. In the "Channel 1" group, the RS-422/RS-485 port is enabled for the serial data transfer. The network port is enabled in the "Channel 2" group. 2. If you want to enable the automatic transfer, activate the associated "Remote Control" check box. 3. If you have enabled the data channel for "Channel 2", select the log from the selection box. 4. Enter further parameters if required. Applies to "MPI/PROFIBUS DP": – Press the "Advanced" button to switch to the "S7-Transfer Settings" dialog box. You can change the settings for MPI/PROFIBUS DP there. – Confirm your entries. – The "S7-Transfer Settings" dialog box closes. Applies to "ETHERNET": – Use the "Advanced" button to change to "Network&Dial-Up Connections". – Open the "ERTEC400" entry. You can change the TCP/IP settings there. – Confirm your entries. – Close "Network&Dial-Up Connections". Applies to "USB": – No settings are needed for "USB". 5. Confirm your entries. The dialog closes.

Result The data channel is configured.

See also Overview (Page 163) Backup and restore using WinCC flexible (Page 169) Backup and restore using ProSave (Page 171) Changing MPI/PROFIBUS DP settings (Page 139) Changing the network configuration (Page 145)

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ITEM 2500 Configuring the operating system 6.14 Changing transfer settings

6.14.2

Changing MPI/PROFIBUS DP settings

Introduction The communication settings for MPI or PROFIBUS DP are defined in the HMI device project. In the following cases, the transfer settings might have to be changed: ● The first time the project is transferred ● If changes are made to the project but are only applied later NOTICE Transfer mode using MPI/PROFIBUS DP The bus parameters are read from the project currently loaded on the HMI device. The settings for MPI/PROFIBUS DP transfer can be modified. The following steps are required: • Close the project. • Change the settings on the HMI device. • Then return to "Transfer" mode. The changed MP/PROFIBUS DP settings will be overwritten in the following cases: • The project is started again • A project is transferred and started Transfer settings If the HMI device is in "Transfer" mode while changes are made to the transfer settings, the settings only go into effect after the transfer function is restarted.

Requirements You have opened the "S7-Transfer Settings" dialog with the "S7-Transfer Settings"

icon.

  ①

Network selection

②

Button for opening the properties dialog

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ITEM 2500 Configuring the operating system 6.14 Changing transfer settings

Procedure Proceed as follows: 1. Select a network. 2. Use the "Properties" button to open the "MPI" or "PROFIBUS" dialog.

    

       ①

The HMI device is the only master on the bus.

②

Bus address of the HMI device

③

Time-out

④

Data transmission rate in total network

⑤

Highest station address in the network

⑥

Profile

⑦

Button for displaying the bus parameters

3. If there are several masters connected on the bus, deactivate the "Panel is the only master on the bus" check box. 4. Enter the bus address for the HMI device in the "Address" text box. NOTICE The bus address in the "Address" text box must be unique throughout the MPI/PROFIBUS DP network. 5. Select the transmission rate from the "Transmission Rate" text box. 6. Enter the highest station address on the bus in the "Highest Station Address" or "Highest Station" text box. 7. Select the desired profile from the "Profile" selection box.

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ITEM 2500 Configuring the operating system 6.14 Changing transfer settings 8. If you want to view the profile data, press the "Busparameter" button of the PROFIBUS dialog. The profile data are displayed. The "Profile" dialog is read-only. NOTICE The bus parameters must be the same for all stations in the MPI/PROFIBUS DP network.

9. Close the "Profile" dialog. 10. Confirm your entries. The dialog closes.

Result The MPI/PROFIBUS DP settings of the HMI device have been changed.

See also Configuring the data channel (Page 136)

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ITEM 2500 Configuring the operating system 6.15 Configuring network operation

6.15

Configuring network operation

6.15.1

Overview of network operation

Introduction You can connect the HMI device to a PROFINET network via the Ethernet port. NOTICE The HMI device only has client functionality in the PC network. This means that users can access files of a node with TCP/IP server functionality from the HMI device via the network. However, you cannot, for example, access files of the HMI device from a PC via the network. Note Information on communication using SIMATIC S7 via PROFINET is provided in the "WinCC flexible communication" user manual. The connection to a network offers, for example, the following options: ● Printing via a network printer ● Saving, exporting and importing of recipe data records on or from a server ● Setting up of message and data archives ● Transferring a project ● Saving data

Addressing Within a PROFINET network, computers are usually addressed using computer names. These device names are translated from a DNS or WINS server to TCP/IP addresses. This is why a DNS or WINS server is needed for addressing via computer names when the HMI device is in a PROFINET network. The corresponding servers are generally available in PROFINET networks. Note The use of TCP/IP addresses to address PCs is not supported by the operating system. Consult your network administrator if you have questions in this regard.

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ITEM 2500 Configuring the operating system 6.15 Configuring network operation

Printing via a network printer The HMI device's operating system does not support line by line alarm logging via a network printer. All other printing functions, for example, hardcopy or logs, are available without restriction via the network.

Preparation Before beginning the configuration, request the following network parameters from your network administrator. ● Does the network use DHCP for dynamic assignment of network addresses? If not, get a new TCP/IP network address for the HMI device. ● Which TCP/IP address does the default gateway have? ● If a DNS network is used, what are the addresses of the name server? ● If a WINS network is used, what are the addresses of the name server?

General procedure for configuring the network The HMI device must be configured prior to network operation. The configuration is basically divided into the following steps: Proceed as follows: 1. Enter the device name of the HMI device. 2. Configure the network address. 3. Set the logon information. 4. Save the settings.

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ITEM 2500

Configuring the operating system 6.15 Configuring network operation

6.15.2

Setting the device name of the HMI device

Introduction The HMI device uses the device name to identify itself in the communication network.

Requirements You have opened the "System Properties", dialog "Device Name" tab with the "System"

icon.

  ①

Device name of the HMI device

②

Description for the HMI device (optional)

Note To activate the network functions, enter a unique computer name in the "Device name" text box.

Procedure Proceed as follows: 1. Enter the device name for the HMI device in the "Device name" text box. 2. If necessary, enter a description for the HMI device in the "Device description" text box. 3. Confirm your entries. The dialog closes.

Result The device name for the HMI device is now set.

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ITEM 2500 Configuring the operating system 6.15 Configuring network operation

6.15.3

Changing the network configuration

Introduction You can change the network settings for the LAN connection under "Network&Dial-Up Connections".

Requirements You have opened the following display using the "Network&Dial-Up Connections"

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icon.

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Configuring the operating system 6.15 Configuring network operation

Procedure Proceed as follows: 1. Open the "ERTEC400" entry. The "'ERTEC400 Ethernet Driver' Settings" dialog is opened.

2. If you need automatic issuing of addresses, select the "Obtain an IP address via DHCP" radio button. 3. If you need manual issuing of addresses, select the "Specify an IP address" radio button. 4. If you have selected manual issuing of addresses, enter the corresponding addresses in the "IP Address", "Subnet Mask" text boxes and if necessary in "Default Gateway". 5. If a name server is used in the network, change to the "Name Servers" tab.

6. Enter the respective addresses in the text boxes. 7. Confirm your entries. The dialog closes. 8. Close the "Network&Dial-Up Connections" display. The Control Panel is displayed again.

Result The LAN connection parameters for the HMI device have been changed.

See also Configuring the data channel (Page 136)

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ITEM 2500 Configuring the operating system 6.15 Configuring network operation

6.15.4

Changing the logon data

Introduction Windows CE uses this information to gain access to the network resources. Enter the user name, password and domain you have received from your administrator.

Requirements You have opened the "Network ID" dialog with the "Network ID"

icon.

Procedure Proceed as follows: 1. Enter the user name in the "User name" text box. 2. Enter your password in the "Password" text box. 3. Enter the domain name in the "Domain" text box. 4. Confirm your entries. The dialog closes.

Result The logon information has now been set.

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Configuring the operating system 6.15 Configuring network operation

6.15.5

Changing e-mail settings

Requirements You have opened the "WinCC flexible Internet Settings" dialog with the "WinCC Internet Settings"

icon.

   ①

Setting the SMTP server

②

Name for the sender

③

E-mail account

Note Additional tabs may appear in the "WinCC flexible Internet Settings" dialog. This depends on the options that have been enabled for network operation in the project.

Procedure Proceed as follows: 1. Specify the SMTP server. – Activate the "Use the default of the project file" radio button if you want to use the SMTP server configured in the project. – Deactivate the "Use the default of the project file" radio button if you do not want to use the SMTP server configured in the project. Specify the required SMTP server. 2. Enter the name for the sender in the "Sender" text box. 3. Enter the e-mail account for your e-mail in the "Authentication" text box. Some e-mail providers only allow you to send mail if you specify the e-mail account. The "Authentication" text box can remain empty if your e-mail provider allows you to send mail without checking the account. 4. Confirm your entries. The dialog closes.

Result The e-mail settings have been changed.

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ITEM 2500 Configuring the operating system 6.15 Configuring network operation

6.15.6

Changing Internet settings

6.15.6.1

Changing general Internet settings

Requirements You have opened the "Internet Options", dialog "General" tab with the "Internet Options"

icon.

Note Do not change the settings in the "User Agent" field.

Procedure Proceed as follows: 1. Enter the homepage for the Internet browser in the "Start Page" text box. 2. Enter the address of the required search engine in the "Search Page" text box. 3. Enter the required cache memory size in the "Cache" text box. 4. If you want to delete the cache memory, press the "Clear Cache" button. 5. If you want to delete the history, press the "Clear History" button. 6. Confirm your entries. The dialog closes.

Result The general parameters for the Internet browser have been set.

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ITEM 2500 Configuring the operating system 6.15 Configuring network operation

6.15.6.2

Setting the proxy server

Requirements You have opened the "Internet Options", dialog "Connection" tab with the "Internet Options"

icon.

Procedure Proceed as follows: 1. Select the "Use LAN (no autodial)" check box. 2. If you are using a proxy server, in the "Network" group, activate the "Access the Internet using a proxy server" check box. Specify the address of the proxy server and the port. 3. If you want to bypass the proxy server for local addresses, activate the "Bypass proxy server for local addresses" check box. 4. Confirm your entries. The dialog closes.

6.15.6.3

Changing privacy settings

Cookies and encryption Cookies are pieces of information sent by a web server to a browser. In the event of subsequent access to the web server, the cookies are sent back. This enables information to be stored between the accesses. In order to ensure a high level of privacy, data are sent via the Internet in encrypted form. Common encryption protocols include SSL and TLS. You can activate or deactivate the usage of encryption protocols. The required settings can be obtained from your network administrator.

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ITEM 2500 Configuring the operating system 6.15 Configuring network operation

Requirements You have opened the "Internet Options" dialog, "Privacy" tab with the "Internet Options"

icon.

Procedure Proceed as follows: 1. Select the required cookie behavior by means of the radio buttons. – "Accept" Cookies are stored without request. – "Block" Cookies will not be stored. – "Prompt" Cookies will be stored on request. 2. If you want allow cookies which are restricted to a single session, activate the "Always allow session cookies" check box. 3. Change to the "Advanced" tab.

4. Activate the required encryption protocol. 5. Confirm your entries. The dialog closes.

Result The logon information has now been set. MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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Configuring the operating system 6.15 Configuring network operation

6.15.6.4

Importing and deleting certificates

Overview You can import, view and delete certificates that have been imported for the HMI device. The certificates differ in the following ways: ● Certificates that you trust ● Own certificates ● Other certificates You can import additional certificates and delete certificates that are not required. The required settings can be obtained from your network administrator.

Requirements You have opened the "Certificates" dialog with the "Certificates"

icon.

Procedure Proceed as follows: 1. Select the type of certificate from the selection box: – "Trusted Authorities" – "My Certificates" – "Other Certificates" 2. If required, start the importing process with the "Import" button. A dialog with source details will open. 3. If required, delete certificates with the "Remove" button. Mark the desired certificate. 4. If you want to list the properties of the certificate marked, press the "View" button. 5. Confirm your entries. The dialog closes.

Result The changes to the certificates have been undertaken.

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ITEM 2500 Configuring the operating system 6.16 Saving to external storage device (backup)

6.16

Saving to external storage device (backup)

Introduction A backup involves copying the operating system, applications and data from the internal in flash memory of the HMI device to an external storage device. The following external storage devices are possible: ● External memory ● USB memory stick

Requirements ● The HMI device features an external storage device with sufficient free space. ● You have opened the "Backup/Restore" dialog with the "Backup/Restore"

icon.

Procedure - using a memory card for the first time NOTICE Loss of data possible The first time you use a memory card the HMI device will request that you format the card. Save a backup copy of memory card data to a PC before formatting. Proceed as follows: 1. Cancel the formatting procedure by pressing "ESC". 2. Remove the memory card from the HMI device. 3. Save a backup copy of vital data to a PC. 4. Insert the memory card into the HMI device. 5. Format the memory card on the HMI device.

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Configuring the operating system 6.16 Saving to external storage device (backup)

Procedure Proceed as follows: 1. Press the "BACKUP" button to open the "Select Storage Card" dialog. The "--- no storage card available ---" message appears if there is no external memory in the HMI device or if this memory is defective. Insert an external memory or a different one. 2. Select the external memory for backup from the "Please select a Storage Card" list box. 3. Click on the "Start Backup" button. The HMI device checks the external memory. If the "This storage card..." message appears, an external memory with a greater memory capacity is needed. Acknowledge this message. Backup is aborted. Insert an external memory with a greater memory capacity and restart the backup process. If the "You may have an old backup on the storage card. Do you want to delete it?" message appears, there is already a backup on the external memory. If you do not want to overwrite the backup, press the "No" button. Otherwise click on the "Yes" button. Several messages are displayed in sequence during the backup process: – Saving registry data – Copy files A progress bar shows the status of the backup process. When the backup process is completed, the following message is displayed: "The operation completed successfully." 4. Acknowledge this message. The dialog closes.

Result The HMI device data is now saved on the external memory.

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ITEM 2500 Configuring the operating system 6.17 Restoring from external storage device

6.17

Restoring from external storage device

Introduction A restore operation deletes the old data from flash memory of the HMI device on confirmation. The data stored on the external memory is then copied to the internal flash Flash memory.

Requirements ● The external memory holding the backed up data is inserted in the HMI device. ● You have opened the "Backup/Restore" dialog with the "Backup/Restore"

icon.

NOTICE Loss of data possible All data on the HMI device will be deleted during a restore operation. License keys are deleted after counter-inquiry. Back up the HMI device's data before restoring if required. External memory with data backup If several external memories with data backups are plugged in, the data cannot be restored. Remove the external memory with the data backups not needed.

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ITEM 2500 Configuring the operating system 6.17 Restoring from external storage device

Procedure Proceed as follows: 1. Press the "RESTORE" button to open the "Storage Card" dialog.





①

No storage card available

②

Only one storage card containing backup is allowed. No storage card detected. Insert a storage card and press the "Refresh" button.

2. Select the external memory with the backup from the "Storage Card with Backup detected" selection box. The "--- no storage card available ---" message appears if there is no external memory in the HMI device or if this memory is defective. 3. If the "--- no storage card available ---" message appears, press the "Cancel" button. Restoring is then aborted. – Insert a memory card or a different one. – Click on the "Refresh" button. The content of the selection box will be changed. – Select the external memory with the backup from the "Storage Card with Backup detected" selection box. 4. Click on the "Start Restore" button. Restoring is started.

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ITEM 2500 Configuring the operating system 6.17 Restoring from external storage device 5. The data to be restored is checked. The following messages are displayed in sequence during the check. – "Starting Restore" – "Checking data" When the data has been checked, the following message is displayed: "You are starting RESTORE now. All files (except files on storage cards) and the registry will be erased. Are you sure?" The message means that the restore process can be started. All files files except those located on the external memory will be deleted. Tab entries are also deleted. Are you sure? 6. If you do not want to allow the data to be deleted from the HMI device, abort the restore process by pressing the "ESC" button. 7. Start to restore the data by selecting "Yes". The following messages are displayed in sequence during the restore: – "Deleting files on flash" – "Restore CE Image" A progress bar shows the status of the restore process. When restore is completed, the following message is displayed: "Restore succesfully finished. Press ok, remove your storage card and reboot your device." 8. Remove the external memory. 9. Acknowledge this message. The HMI device starts.

Result The data from the external memory is now on the HMI device. Note Calibrating the touch screen After the reset, you may have to recalibrate the touch screen.

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Configuring the operating system 6.18 Activate memory management

6.18

Activate memory management

Memory management Provided the memory management is activated, the HMI device will automatically close the project if the memory needs reorganizing during an active project. The project is shut down and the HMI device will display a message. You have to restart the project. NOTICE Memory management If you do not activate memory management, undefined states can occur during the runtime of the project. Active memory management from the "OP Properties" dialog.

Requirements You have opened the "OP Properties" dialog, "Memory Monitoring" tab with the "OP"

icon.

  

①

Maximum memory used since the HMI device was last switched on

②

Percentage of memory currently used

③

Activate memory management

Procedure Proceed as follows: 1. If you want to enable memory management, activate the check box. If memory management is active and there is not enough working memory, the SIMATIC HMI runtime and therefore the current project will be closed. 2. Confirm your entries. The dialog closes.

Result Memory management is activated.

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ITEM 2500

Commissioning a project 7.1

7

Overview

Configuration phase A project – the process image of the working process – is produced during configuration to visualize automated working processes. The process displays for the project contain displays for values and messages which provide information about process statuses. The process control phase follows the configuration phase.

Process control phase The project must be transferred to the HMI device if it is to be used in process control. Another precondition for process control is that the HMI device is connected online to a controller. Current working processes - operating and observing - can then be subject to process control.

Transferring the project to the HMI device You can transfer a project to an HMI device as follows: ● Transfer from the configuring PC ● Restore from a PC using ProSave In this case, an archived project is transferred from a PC to the HMI device. The configuration software need not be installed on this PC.

Commissioning and recommissioning Initial and re-start-ups differ in the following respects: ● When the HMI device is commissioned there is no project at first. The HMI device is also in this state after the operating system has been updated. ● When recommissioning, any project already on the HMI device is replaced.

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ITEM 2500 Commissioning a project 7.2 Operating modes

7.2

Operating modes

Operating modes The HMI device may be in the following operating modes: ● Offline ● Online ● Transfer "Offline mode" and "Online mode" can be set on both the configuring PC and the HMI device. To set these modes on the HMI device, use a corresponding operating element of the project.

Changing the operating mode The configuration engineer must have configured an appropriate operating element to allow a change of the operating mode on the HMI device during ongoing operation. Further information on this may be available in your plant documentation

"Offline" operating mode In this mode, there is no communication between the HMI device and PLC. Although the HMI device can be operated, it cannot exchange data with the PLC.

"Online" operating mode In this mode, the HMI device and PLC communicate. You can operate the plant on the HMI device according to your system configuration.

"Transfer" mode In this mode, you can transfer a project from the configuring PC to the HMI device or backup and restore HMI device data, for example. The following options are available for setting "Transfer" mode on the HMI device: ● When the HMI device starts up Start "Transfer" mode manually in the HMI device Loader. ● During ongoing operation Start the "Transfer" mode manually within the project using an operating element. The HMI device toggles to "Transfer" mode when automatic mode is set and a transfer is initiated on the configuring PC.

See also Backup and restore using WinCC flexible (Page 169) Backup and restore using ProSave (Page 171)

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ITEM 2500 Commissioning a project 7.3 Using existing projects

7.3

Using existing projects The following table shows how you can reuse existing projects, while observing the screen size: HMI device in the existing project

New HMI device

MP 370 12" Touch

MP 377 12" Touch

MP 370 12" Key

MP 377 12" Key

MP 370 15" Touch

MP 377 15" Touch, MP 377 PRO 15" Touch

The following cases are possible: 1. Project exists in ProTool Migrate the project to WinCC flexible and then replace the HMI device. 2. Project exists in WinCC flexible Carry out an HMI device switch in WinCC flexible. If you migrate existing projects from HMI devices with a different screen size, images which have already been configured are converted during the migration. Further information on the subject can be found in the WinCC flexible Online Help or in the "WinCC flexible Migration" manual.

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ITEM 2500 Commissioning a project 7.4 Data transmission options

7.4

Data transmission options

Overview The following table shows the options for data transfer between the MP 377 and the configuring PC. Type

Data channel

Backup

Serial 1)

Yes

MPI/PROFIBUS DP

Yes

Restoring

Updating the operating system

Transferring a project

Installing or removing an option

License key transferring or transferring back

MP 377

USB

Yes

PROFINET

Yes

Serial 1)

Yes

MPI/PROFIBUS DP

Yes

USB

Yes

PROFINET

Yes

Serial 1)

Yes

MPI/PROFIBUS DP

Yes

USB

Yes

PROFINET

Yes

PROFINET with restore to factory setting

Yes

Serial 1)

Yes

MPI/PROFIBUS DP

Yes

USB 2)

Yes

PROFINET

Yes

Serial

Yes

1)

MPI/PROFIBUS DP

Yes

USB

Yes

PROFINET

Yes

Serial 1)

Yes

MPI/PROFIBUS DP

Yes

USB

Yes

PROFINET

Yes

1)

Applies when PC/PPI cable 6ES7 901-3CB30-0XA0 is used

2)

You must not connect the HMI device to a USB 2.0 hub.

See also Overview (Page 163) Backup and restore using WinCC flexible (Page 169) Backup and restore using ProSave (Page 171)

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ITEM 2500 Commissioning a project 7.5 Transfer

7.5

Transfer

7.5.1

Overview

Transfer Transfer the executable project from the configuring PC to the HMI device. You can start the "Transfer" mode manually or automatically on the HMI device. Transferred data is written directly to the internal flash memory on the HMI device. For the transfer, you use a data channel which you have to configure before starting a transfer.

Backtransfer You have the option to transfer the compressed project file together with the runtime project to the HMI device. If necessary, the compressed project file can be transferred back to the configuring PC and edited. The HMI device must be equipped with an external memory card to which the compressed project file can be saved. NOTICE Compressed project file WinCC flexible does not check whether the compressed project file stored on the HMI device corresponds to the existing runtime project.

See also Setting the delay time (Page 131) Configuring the data channel (Page 136) Data transmission options (Page 162)

7.5.2

Starting manual transfer

Introduction You can manually switch the HMI device to "Transfer" mode as follows: ● With a configured operating element during ongoing operation. ● In the Loader of the HMI device.

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ITEM 2500 Commissioning a project 7.5 Transfer

Requirements ● The project "*.hmi" is opened in WinCC flexible. ● The HMI device is connected to a configuring PC. ● The data channel is configured on the HMI device. ● The HMI device is in "Transfer" mode.

Procedure Proceed as follows: 1. On the configuring PC, select the "Transfer settings" command in the menu "Project > Transfer" in WinCC flexible. The "Select devices for transfer" dialog opens. 2. Select the HMI device in the left area of the dialog. 3. Select the type of connection between the HMI device and the configuring PC. Set the connection parameters. 4. Set the transfer parameters in the right area of the dialog. 5. If you wish to transfer the compressed project file together with the runtime project to the HMI device: Select the "Enable backtransfer" check box. 6. Start transfer in WinCC flexible with "Transfer". The configuring PC checks the connection to the HMI device. The project is transferred to the HMI device. If the connection is not available or is defective, an error message is displayed on the configuring PC.

Result When the transfer is completed successfully, the project can be found on the HMI device. The transferred project is then started automatically.

7.5.3

Starting automatic transfer

Introduction If automatic transfer is activated, the HMI device automatically changes into "Transfer" mode during operations as soon as a transfer starts on the configuring PC connected. Note With automatic transfer, the HMI device only changes into "Transfer" mode when the project is running on the HMI device. Automatic transfer is particularly suited for the test phase of a new project since transfer is completed without interfering with the HMI device.

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ITEM 2500 Commissioning a project 7.5 Transfer

NOTICE If the automatic transfer has been activated on the HMI device and a transfer is initiated on the configuring PC, the project currently running is automatically stopped. The HMI device then automatically switches to "Transfer" mode. After the commissioning phase, deactivate the automatic transfer so that the HMI device cannot be inadvertently switched to transfer mode. The transfer mode can trigger unintentional actions in the device. You can issue a password in the control panel to restrict access to the transfer settings and thus avoid unauthorized modifications.

Requirements ● The project *.hmi is opened in WinCC flexible. ● The HMI device is connected to a configuring PC. ● The data channel is configured on the HMI device. ● The automatic transfer is activated in the data channel for the transfer. ● The project is started on the HMI device.

Procedure Proceed as follows: 1. On the configuring PC, select the "Transfer settings" command in the menu "Project > Transfer" in WinCC flexible. The "Select devices for transfer" dialog opens. 2. Select the HMI device in the left area of the dialog. 3. Select the type of connection between the HMI device and the configuring PC. Set the connection parameters. 4. Set the transfer parameters in the right area of the dialog. 5. If you wish to transfer the compressed project file together with the runtime project to the HMI device: Select the "Enable backtransfer" check box. 6. Start transfer in WinCC flexible with "Transfer". The configuring PC checks the connection to the HMI device. The HMI device shuts down the current project and automatically switches to "Transfer" mode. The project is transferred to the HMI device. If the connection is not available or is defective, an error message is displayed on the configuring PC.

Result When the transfer is completed successfully, the project can be found on the HMI device. The transferred project is then started automatically.

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ITEM 2500 Commissioning a project 7.5 Transfer

7.5.4

Starting backtransfer

Requirements ● No project is open in WinCC flexible. ● The HMI device is connected to a configuring PC. ● The data channel is configured on the HMI device. ● The HMI device is in "Transfer" mode. ● The memory card containing the compressed project file is inserted into the HMI device.

Procedure Proceed as follows: 1. On the configuring PC, select the "Communication settings" command in the menu "Project > Transfer" in WinCC flexible. The "Communication Settings" dialog opens. 2. Select the type of HMI device. 3. Select the type of connection between the HMI device and the configuring PC. Set the connection parameters. 4. Close the dialog with "OK". 5. Select the "Transfer" > "Backtransfer" command in the "Project" menu. The "Backtransfer" dialog opens. 6. Click "OK" to start the backtransfer process. The configuring PC checks the connection to the HMI device. The compressed project file is transferred back from the HMI device to the configuring PC. If the connection is not available or is defective, an error message is displayed on the configuring PC.

Result After successful backtransfer, the project is opened on the configuring PC in WinCC flexible.

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ITEM 2500 Commissioning a project 7.5 Transfer

7.5.5

Testing a project

Introduction There are two options to test a project: ● Test the project on the configuring PC You can test a project at a configuring PC, using a simulator. For detailed information, refer to the "WinCC flexible" user manual and to the WinCC flexible Online Help. ● Offline testing of the project on the HMI device Offline testing means that communication between the HMI device and PLC is down while the test is being carried out. ● Online testing of the project on the HMI device Online testing means that the HMI device and PLC communicate with each other during testing. Perform the tests, starting with the "Offline test", followed by the "Online test". Note You should always test the project on the HMI device on which the project will be used. Check the following: 1. Check the correct layout of the screens 2. Check the screen navigation 3. Check the input objects 4. Enter the tag values The test increases the certainty that the project will run error-free on the HMI device.

Requirements for offline testing ● The project has been transferred to the HMI device. ● The HMI device is in "Offline" mode.

Procedure In "Offline" mode, you can test individual project functions on the HMI device without them being affected by the PLC. PLC tags, therefore, are not updated. Test the operating elements and visualization of the project as far as possible without connecting to the PLC.

Requirements for online testing ● The project has been transferred to the HMI device. ● The HMI device is in "Online" mode.

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Commissioning a project 7.6 Backup and restore

Procedure In "Online" mode, you can test individual project functions on the HMI device without them being affected by the PLC. PLC tags are updated in this case. You have the option to test all communication-dependent functions, for example alarms, etc. Test the operating elements and views of the project.

7.6

Backup and restore

7.6.1

Overview

Backup and restore You can back up and restore the following data in the internal flash memory of the HMI device with a PC: ● Project and HMI device image ● Password list ● Recipe data ● License keys Use one of the following tools for backup and restore: ● WinCC flexible ● ProSave Note Alternatively, use the control panel to back up to an external memory device.

General information NOTICE Power failure If a complete restore operation is interrupted due to power failure on the HMI device, the operating system of the HMI device may be deleted! In this case, you have to reset the HMI device to its factory settings. Compatibility conflict If a message is output on the HMI device warning of a compatibility conflict during the restore operation, the operating system must be updated.

See also Saving to external storage device (backup) (Page 153)

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ITEM 2500 Commissioning a project 7.6 Backup and restore

7.6.2

Backup and restore using WinCC flexible

Requirements ● No project is open on the configuring PC in WinCC flexible. ● The HMI device is connected to this configuring PC. ● The data channel is configured on the HMI device.

Procedure for backup Proceed as follows: 1. On the configuring PC, select the "Communication settings" command in the menu "Project > Transfer" in WinCC flexible. The "Communication Settings" dialog opens. 2. Select the type of HMI device. 3. Select the type of connection between the HMI device and the configuring PC. Set the connection parameters. 4. Close the dialog with "OK". 5. Select the "Backup" command in the menu "Project > Transfer" in WinCC flexible. The "Backup Settings" dialog opens. 6. Select the data to be backed up. 7. Select a destination folder and a file name for the "*.psb" backup file. 8. Set "Transfer" mode on the HMI device. If automatic transfer mode is enabled on the HMI device, the HMI device automatically sets "Transfer" mode when a backup is initiated. 9. Start the backup operation in WinCC flexible with "OK" on the configuring PC. Follow the instructions in WinCC flexible. A status view opens to indicate the progress of the operation.

Result The system outputs a message when the backup is completed. The relevant data is now backed up on the configuring PC.

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Commissioning a project 7.6 Backup and restore

Procedure for restore Proceed as follows: 1. On the configuring PC, select the "Communication settings" command in the menu "Project > Transfer" in WinCC flexible. The "Communication Settings" dialog opens. 2. Select the type of HMI device. 3. Select the type of connection between the HMI device and the configuring PC. 4. Set the connection parameters. 5. Close the dialog with "OK". 6. Select the "Restore" command in the menu "Project > Transfer" in WinCC flexible. The "Restore Settings" dialog opens. 7. Select the "*.psb" backup file to be restored from the "Open" field. You can see the HMI device for which the backup file was created and the type of backup data the file contains. 8. Set "Transfer" mode on the HMI device. If automatic transfer mode is enabled on the HMI device, the device automatically sets "Transfer" mode when a restore operation is initiated. 9. Start the restore operation in WinCC flexible with "OK" on the configuring PC. If there are license keys both on the HMI device and in the backup, a dialog will appear. Use this dialog to establish whether you want to overwrite the license keys or abort the restore process. – If necessary, abort the backup and first back up the HMI device's license keys. – Then restart the restore process. Follow the instructions in WinCC flexible. A status view opens to indicate the progress of the operation.

Result When the restore is successfully completed, the data backed up on the configuring PC is now on the HMI device.

See also Transferring and transferring back license keys (Page 186) Configuring the data channel (Page 136) Operating modes (Page 160) Data transmission options (Page 162)

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ITEM 2500 Commissioning a project 7.6 Backup and restore

7.6.3

Backup and restore using ProSave

Requirements ● The HMI device is connected to a PC on which ProSave is installed. ● The data channel is configured on the HMI device.

Procedure for backup Proceed as follows: 1. From the Windows Start menu, start ProSave on the PC. 2. Select the HMI device type in the "General" tab. 3. Select the type of connection between the HMI device and the PC. Set the connection parameters. 4. Select the data to be backed up in the "Backup" tab. 5. Select a destination folder and a file name for the "*.psb" backup file. 6. Set "Transfer" mode on the HMI device. If automatic transfer mode is enabled on the HMI device, the HMI device automatically sets "Transfer" mode when a backup is initiated. 7. Start the backup operation in ProSave with "Start Backup". Follow the instructions in ProSave. A status view opens to indicate the progress of the operation.

Result The system outputs a message when the backup is completed. The relevant data is now backed up on the PC.

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Procedure for restore Proceed as follows: 1. From the Windows Start menu, start ProSave on the PC. 2. Select the HMI device type in the "General" tab. 3. Select the type of connection between the HMI device and the PC. 4. Set the connection parameters. 5. Select the "*.psb" backup file to be restored from the "Restore" tab. You can see the HMI device for which the backup file was created and the type of backup data the file contains. 6. Set "Transfer" mode on the HMI device. If automatic transfer mode is enabled on the HMI device, the device automatically sets "Transfer" mode when a restore operation is initiated. 7. Start the restore operation in ProSave on the PC with "Start Restore". If there are license keys both on the HMI device and in the backup, a dialog will appear. Use this dialog to establish whether you want to overwrite the license keys or abort the restore process. – If necessary, abort the backup and first back up the HMI device's license keys. – Then restart the restore process. 8. Follow the instructions in ProSave. A status view opens to indicate the progress of the operation.

Result When the restore is successfully completed, the data backed up on the PC is now on the HMI device.

See also Configuring the data channel (Page 136) Operating modes (Page 160) Data transmission options (Page 162) Transferring and transferring back license keys (Page 186)

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ITEM 2500 Commissioning a project 7.7 Updating the operating system

7.7

Updating the operating system

7.7.1

Overview

Updating the operating system A compatibility conflict may occur when transferring a project to the HMI device. This is caused by different versions of the configuration software used and the HMI device image available on the HMI device. If there are different versions, the transfer is aborted. A message indicating a compatibility conflict is displayed on the configuration PC. There are two ways to match the versions: ● Update the HMI device image if the project was created with the most recent version of the configuration software. ● Transfer a matching version of the HMI device image if you do not want to adapt the project for the HMI device to the most recent version of the configuration software for the project. NOTICE Data loss All data on the HMI device, such as the project and licenses, will be deleted when you update the operating system. Note When WinAC MP is used, all data channel parameters are reset. Note Calibrating the touch screen After the update, you may have to recalibrate the touch screen.

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7.7.2

ITEM 2500

Resetting factory settings In ProSave or WinCC flexible, you can update the operating system with or without resetting to factory settings. ● Updating the operating system without resetting to factory settings First, switch into "Transfer" mode on the HMI device or use the automatic transfer function if the project is active. Then start the operating system update in ProSave or WinCC flexible. ● Updating the operating system with resetting to factory settings NOTICE Loss of license keys The license keys on the HMI device will be deleted when resetting to factory settings. The license keys on the HMI device will be retained when updating the operating system without resetting to factory settings. NOTICE Data channels When resetting to factory settings, all data channel parameters are reset. The transfer can only be started following reconfiguration of the data channels. Note You have to perform an operating system update with reset to factory settings if the HMI device does not yet have an operating system or if the HMI device's operating system is corrupt. First, start the operating system update in ProSave or WinCC flexible and switch the power on the HMI device off and on again when prompted.

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ITEM 2500 Commissioning a project 7.7 Updating the operating system

7.7.3

Updating the operating system using WinCC flexible

Requirements ● No project is open on the configuring PC in WinCC flexible. ● The HMI device is connected to this configuring PC. ● The data channel is configured on the HMI device.

Procedure Proceed as follows: 1. On the configuring PC, select the "Communication settings" command from the "Projekt > Transfer" menu in WinCC flexible. The "Communication Settings" dialog opens. 2. Select the type of HMI device. 3. Select the type of connection between the HMI device and the configuring PC. 4. Set the connection parameters. 5. Close the dialog with "OK". 6. In WinCC flexible, select the command "OS Update" from the "Projekt > Transfer" menu. 7. In "Image path", select the HMI device image file "*.img". The HMI device image files are available under "WinCC flexible Images" in the WinCC flexible installation folder or on the WinCC flexible installation CD. In the output area, you are provided information on the version of the HMI device image file after it is opened. 8. Switch into "Transfer" mode on the HMI device. If you have activated automatic transfer mode for the HMI device, the device automatically switches to "Transfer" mode when an update is initiated. 9. In WinCC flexible, select "Update OS" on the configuring PC to run the operating system update. 10. Follow the instructions in WinCC flexible. During the operating system update a status view opens to indicate progress.

Result A message is displayed when the operating system update is successfully completed. This operation has deleted the project data from the HMI device.

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7.7.4

Updating the operating system using ProSave

Requirements ● The HMI device is connected to a PC on which ProSave is installed. ● The data channel is configured on the HMI device.

Procedure Proceed as follows: 1. From the Windows Start menu, start ProSave on the PC. 2. Select the HMI device type in the "General" tab. 3. Select the type of connection between the HMI device and the PC. 4. Set the connection parameters. 5. Select the "OS Update" tab. 6. In "Image path", select the HMI device image file "*.img". The HMI device image files are available under "WinCC flexible Images" in the WinCC flexible installation folder or on the WinCC flexible installation CD. In the output area, you are provided information on the version of the HMI device image file after it is opened. 7. Switch into "Transfer" mode on the HMI device. If you have activated automatic transfer mode for the HMI device, the device automatically switches to "Transfer" mode when an update is initiated. 8. Select "Update OS" n the PC to run the operating system update. 9. Follow the instructions in ProSave. During the operating system update a status view opens to indicate progress.

Result A message is displayed when the operating system update is successfully completed. This operation has deleted the project data from the HMI device.

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ITEM 2500 Commissioning a project 7.7 Updating the operating system

7.7.5

Resetting to factory settings with WinCC flexible

Requirements ● No project is open on the configuring PC in WinCC flexible. ● The HMI device is connected to this configuration PC over the standard Ethernet cable. ● Have the MAC address of the Ethernet interface on your HMI device to hand. – The MAC address is displayed briefly when the HMI device is turned on. – The MAC address is displayed in the "PROFINET" dialog in the Control Panel.

Procedure - Setting the PC interface 1. Select "Start > Control Panel > Set PG / PC interface" on the configuration PC. 2. Select "S7ONLINE (STEP7) -> TCP / IP" from the "Application access point" area. 3. Select the interface which is connected to the HMI device from the "Interface parameterization used" area. 4. Confirm your entries.

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Procedure - Restoring factory settings Proceed as follows: 1. On the configuring PC, select the "Communication settings" command in the menu "Project > Transfer" in WinCC flexible. The "Communication Settings" dialog opens. 2. Select the HMI device type from the "General" tab, and select "Ethernet" from the "Connection" area. 3. Enter an IP address. Note Possible address conflicts with incorrect IP address Do not use a dynamic IP configuration for "Reset to factory settings". Specify a unique IP address in which the configuration PC is located. For the duration of the update process, the HMI device is automatically assigned to the specified address. If the HMI device has already been used with WinCC flexible or ProSave you can use the existing IP address for "Reset to factory settings."

4. Confirm your entries. 5. In WinCC flexible, select the command "Update OS" in the "Project > Transfer" menu. 6. Activate the "Reset to factory settings" check box. A text box opens where you can enter the MAC address. 7. Enter the HMI device's MAC address in the text box. 8. In "Image path", select the HMI device image file "*.img". The HMI device image files are available under "WinCC flexible Images" in the WinCC flexible installation folder or on the WinCC flexible installation CD. In the output area, you are provided information on the version of the HMI device image file after it is opened.

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ITEM 2500 Commissioning a project 7.7 Updating the operating system 9. In WinCC flexible, select "Update OS" on the configuring PC to run the operating system update. 10. In the Control Panel of the HMI device, open the "OP Properties" dialog and select the "Device" tab. 11. Click on the "Reboot" button. A query is opened. 12. Click on the "Prepare for Reset" button. 13. On the configuration PC, follow the instructions in WinCC flexible. During the operating system update a status view opens to indicate progress.

Result A message is displayed when the operating system update is successfully completed. This operation has deleted the project data from the HMI device. The factory settings are reset. Note If you can no longer call the Control Panel on the HMI device, as the operating system is missing, switch off the HMI device. Then reset to factory settings and restart the HMI device. If the HMI device doesn´t start up, switch it off and then on again. Note Calibrating the touch screen After the reset, you may have to recalibrate the touch screen.

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7.7.6

Resetting to factory settings with ProSave

Requirement ● The HMI device is connected over the Ethernet to a PC on which ProSave is installed. ● Have the MAC address of the Ethernet interface on your HMI device to hand. – The MAC address is displayed briefly when the HMI device is turned on. – The MAC address is displayed in the "PROFINET" dialog in the Control Panel.

Procedure - Setting the PC interface 1. Select "Start > Control Panel > Set PG / PC interface" on the configuration PC. 2. Select "S7ONLINE (STEP7) -> TCP / IP" from the "Application access point" area. 3. Select the interface which is connected to the HMI device from the "Interface parameterization used" area. 4. Confirm your entries.

Procedure - Restoring factory settings Proceed as follows: 1. From the Windows Start menu, start ProSave on the PC. 2. Select the HMI device type from the "General" tab, and select "Ethernet" from the Connection area. 3. Enter an IP address. Note Possible address conflicts with incorrect IP address Do not use a dynamic IP configuration for "Reset to factory settings". Specify a unique IP address of the subnet in which the configuration PC is located. For the duration of the update process, the HMI device is automatically assigned to the specified address of ProSave. If the HMI device has already been used with WinCC flexible or ProSave you can use the existing IP address for "Reset to factory settings."

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ITEM 2500 Commissioning a project 7.7 Updating the operating system

4. Change to the "OS Update" tab. 5. Activate the "Reset to factory settings" check box. A text box opens where you can enter the MAC address. 6. Enter the HMI device's MAC address in the text box. 7. In "Image path", select the HMI device image file "*.img". The HMI device image files are available under "WinCC flexible Images" in the WinCC flexible installation folder or on the WinCC flexible installation CD. In the output area, you are provided information on the version of the HMI device image file after it is opened. 8. Select "Update OS" on the PC to start the "Reset to factory settings" process. 9. In the Control Panel of the HMI device, open the "OP Properties" dialog and select the "Device" tab. 10. Click on the "Reboot" button. A query is opened. 11. Click on the "Prepare for Reset" button. 12. Follow the instructions in ProSave. During the operating system update a status view opens to indicate progress.

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Result A message is displayed when the operating system update is successfully completed. This operation has deleted the project data from the HMI device. The factory settings are reset. Note If you can no longer call the Control Panel on the HMI device, as the operating system is missing, switch off the HMI device. Then reset to factory settings and restart the HMI device. If the HMI device doesn´t start up, switch it off and then on again. Note Calibrating the touch screen After the reset, you may have to recalibrate the touch screen.

7.8

Installing and removing options

7.8.1

Overview

Installing and removing options You can install options on the HMI device, for example, additional programs developed especially for the HMI device. You can also remove the option from the HMI device again. Note License key A license key may be needed to run an option. The license key unlocks the option for use.

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ITEM 2500 Commissioning a project 7.8 Installing and removing options

7.8.2

Installing and removing options using WinCC flexible

Requirements ● No project is open on the configuring PC in WinCC flexible. ● The HMI device is connected to this configuring PC. ● The data channel is configured on the HMI device.

Procedure for installing an option Proceed as follows: 1. On the configuring PC, select the "Communication settings" command in the menu "Project > Transfer" in WinCC flexible. The "Communication Settings" dialog opens. 2. Select the type of HMI device. 3. Select the type of connection between the HMI device and the configuring PC, then set the connection parameters. 4. Close the dialog with "OK". 5. Select the "Options" command in the menu "Project > Transfer" in WinCC flexible. 6. Select the desired option under "Available options". 7. Set "Transfer" mode on the HMI device. If automatic transfer mode is enabled on the HMI device, the device automatically sets "Transfer" mode when the installation of an option is initiated. 8. Start the installation of the option in WinCC flexible on the configuring PC with the ">>" button. Follow the instructions in WinCC flexible. A status display appears indicating the progress of the installation.

Result The option has now been installed on the HMI device.

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Procedure for removing an option Proceed as follows: 1. On the configuring PC, select the "Communication settings" command in the menu "Project > Transfer" in WinCC flexible. The "Communication Settings" dialog opens. 2. Select the type of HMI device. 3. Select the type of connection between the HMI device and the configuring PC, then set the connection parameters. 4. Close the dialog with "OK". 5. Select the "Options" command in the menu "Project > Transfer" in WinCC flexible. 6. Press the "Device status" button to update the display. 7. Select the desired option under "Installed options". 8. Set "Transfer" mode on the HMI device. If automatic transfer mode is enabled on the HMI device, the device automatically sets "Transfer" mode when the removal of an option is initiated. 9. Start the removal of the option in WinCC flexible on the configuring PC with the "<<" button. Follow the instructions in WinCC flexible. A status display appears indicating the progress of the removal.

Result The option has now been removed on the HMI device.

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ITEM 2500 Commissioning a project 7.8 Installing and removing options

7.8.3

Installing and removing options using ProSave

Requirements ● The HMI device is connected to a PC on which ProSave is installed. ● The data channel is configured on the HMI device.

Procedure for installing an option Proceed as follows: 1. From the Windows Start menu, start ProSave on the PC. 2. Select the HMI device type in the "General" tab. 3. Select the type of connection between the HMI device and the PC, then set the connection parameters. 4. Select the "Options" tab. 5. Select the desired option under "Available options". 6. Set "Transfer" mode on the HMI device. If automatic transfer mode is enabled on the HMI device, the device automatically sets "Transfer" mode when the installation of an option is initiated. 7. Start the installation of the option in ProSave with the ">>" button. Follow the instructions in ProSave. A status display appears indicating the progress of the installation.

Result The option has now been installed on the HMI device.

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Procedure for removing an option Proceed as follows: 1. From the Windows Start menu, start ProSave on the PC. 2. Select the HMI device type in the "General" tab. 3. Select the type of connection between the HMI device and the PC, then set the connection parameters. 4. Select the "Options" tab. 5. Press the "Device status" button to update the display. 6. Select the desired option under "Installed options". 7. Set "Transfer" mode on the HMI device. If automatic transfer mode is enabled on the HMI device, the device automatically sets "Transfer" mode when the removal of an option is initiated. 8. Start the removal of the option in ProSave with the "<<" button. Follow the instructions in ProSave. A status display appears indicating the progress of the removal.

Result The option has now been removed on the HMI device.

7.9

Transferring and transferring back license keys

7.9.1

Overview

Transferring and transferring back license keys With the purchase of an optional package, you obtain a specific user license with an associated license key. Once you have installed an option, transfer a license key to the HMI device. The license key unlocks an option for use. You can also transfer back the license key from the HMI device to the storage location. Note You only transfer license keys with the Automation License Manager or WinCC flexible.

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ITEM 2500 Commissioning a project 7.9 Transferring and transferring back license keys

7.9.2

Transferring and transferring back license keys

Requirements ● When transferring or transferring back using WinCC flexible: No project is open on the configuring PC in WinCC flexible. ● The HMI device is connected to this configuring PC. ● The data channel is configured on the HMI device. ● The storage location and the license key awaiting transfer are ready.

Procedure for transferring a license key Proceed as follows: 1. Switch to "Transfer" mode on the HMI device. 2. When transferring using WinCC flexible: Select the "License Keys" command in the menu "Project > Transfer". The Automation License Manager opens. When transferring using the Automation License Manager: Start the Automation License Manager via the Windows Start menu. 3. In the Automation License Manager, select the command "Connect HMI device" in the menu "Edit > Connect target system". The "Connect Target System" dialog opens. 4. Under "Device Type", select the appropriate HMI device type. 5. Select the type of connection from the "Connection" box. 6. Set the connection parameters. 7. Select "OK". The connection to the HMI device is established. The connected HMI device is displayed in the left window of the Automation License Manager. 8. In the left window, select the source drive. The right window displays the available license keys. 9. Drag one or more license keys from the right window and drop them on the HMI device in the left window. The license keys are then transferred to the HMI device.

Result The license key is transferred from the storage location to the HMI device.

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Commissioning a project 7.9 Transferring and transferring back license keys

Procedure for transferring a license key back Proceed as follows: 1. Switch to "Transfer" mode on the HMI device. 2. When transferring back using WinCC flexible: Select the "License Keys" command in the menu "Project > Transfer". The Automation License Manager opens. When transferring back using the Automation License Manager: Start the Automation License Manager via the Windows Start menu. 3. In the Automation License Manager, select the command "Connect HMI device" in the menu "Edit > Connect target system". The "Connect Target System" dialog opens. 4. Under "Device Type", select the appropriate HMI device type. 5. Select the type of connection from the "Connection" box. 6. Set the connection parameters. 7. Select "OK". The connection to the HMI device is established. The connected HMI device is displayed in the left window of the Automation License Manager. 8. In the left window, select the HMI device. The right window displays the available license keys. 9. Drag one or more license keys from the right window and drop them on the destination drive in the left window. The license keys are transferred back to the storage location.

Result The license key is transferred back from the HMI device to the storage location.

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ITEM 2500

Operating a project 8.1

8

Overview

Configuration and process control phase HMI devices can be used to operate and monitor tasks in process and production automation. The plant screens on the HMI devices are used to provide a clear overview of the active processes. The HMI device project, which includes the plant screens, is created during the configuration phase. The configuration engineer defines which tasks the HMI device has in the process and defines the following in detail: ● Which process data is displayed on the individual HMI device ● Which plant components are controlled by this HMI device The configuration engineer stores this information in the project's screens. The project is transferred to the HMI device during commissioning. After transfer to the HMI device, current processes can be operated and monitored in the project's screens. The screens enable you to observe, for example, operational states, current process data and faults in a plant. Operating elements which are used to operate the process, for example buttons, I/O fields and alarm windows, are displayed in the screens.

Operator input options The hardware of the HMI device determines which of the following operator control options are available: ● Touch screen The operating elements shown in the dialogs are touch-sensitive. Touch objects are basically operated in the same way as mechanical keys. You activate operating elements by touching them with your finger. To double-click them, touch an operating element twice in succession. ● HMI device keyboard The operating elements shown in the screens are selected and operated using the keys of the HMI device. ● External keyboard, connected via USB ● External mouse, connected via USB CAUTION Do not use any pointed or sharp objects when operating the touch screen. Otherwise this may damage the plastic membrane of the touch screen. The following provides instructions for operating a project with the touch screen and the keyboard.

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Operating a project with an external keyboard An external keyboard can be used to operate a project in exactly the same way as with the HMI keyboard or screen keyboard. Note The function keys of the external keyboard are disabled. Use the other keys of the external keyboard, which correspond to the HMI device keys in the description.

Operating a project with an external mouse An external mouse can be used to operate a project in exactly the same way as with the HMI touch screen. Click the described operating elements with the mouse.

Unintentional actions CAUTION Do not carry out several operations simultaneously. You may otherwise trigger unintentional actions. • With touch control: Always touch only one operating element on the screen • With key control: Do not press more than two keys simultaneously

Observing the plant documentation Some operations with the project may require in-depth knowledge about the specific plant on the part of the operator. Proceed with caution, for example, when you use jog mode. Further information on this may be available in your plant documentation.

Operation feedback from operating elements The HMI device provides operation feedback as soon as it detects that an operating element has been selected. This operation feedback is independent of any communication with the PLC. Therefore, this operation feedback does not indicate whether the relevant action is actually executed or not.

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ITEM 2500 Operating a project 8.1 Overview

Optical feedback from operating elements The operating element receives the focus and is selected. The configuration engineer can also configure the selection of an operating element so that it deviates from the standard. Further information on this may be available in your plant documentation. The type of optical feedback depends on the operating element: ● Buttons The HMI device outputs different views of the "Pressed" and "Unpressed" states, provided the configuration engineer has configured a 3D effect: – "Pressed" state:

– "Unpressed" state:

The configuration engineer determines the appearance of a selected field, for example, line width and color for the focus. ● Invisible buttons By default, invisible buttons are not displayed as pressed when they are touched. No optical operation feedback is provided in this case. The configuration engineer may, however, configure invisible buttons so that their outline appears as lines when touched. This outline remains visible until you select another operating element. ● I/O fields When you select an I/O field, the content of the I/O field is displayed against a colored background. With touch operation, a screen keyboard is displayed for the entering of values.

Acoustic feedback from operating elements As soon as the HMI device detects a touch of the touch screen or that a key has been pressed, an acoustic signal is issued. You can activate or deactivate this acoustic operation feedback. Note The acoustic feedback is only possible if you interact with the project directly on the touch screen or press one of the keys of the HMI device. If you use an external mouse or keyboard for interaction, no acoustic signal is issued.

Acoustic signal for inadvertent operations If you try to enter an invalid character, the HMI device issues an acoustic signal in accordance with the setting.

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ITEM 2500 Operating a project 8.2 Direct keys

8.2

Direct keys

Introduction Direct keys on the HMI device are used to set bits in the I/O area of a SIMATIC S7. Direct keys enable operations with short reaction times that are, for example, a jog mode requirement. NOTICE Direct keys are still active when the HMI device is in "offline" mode. NOTICE If you operate a function key with direct key functionality in a running project, the direct key function is always executed, independent of the current screen contents. Note You can only use direct keys when there is a connection via PROFIBUS DP or PROFINET IO. Direct keys result in additional basic load on the HMI device.

Direct keys The following objects can be configured as a direct key: ● Buttons ● Function keys You can also define image numbers in the case of HMI devices with touch operation. In this way, the project engineer can configure the direct keys on an image-specific basis. Further information on configuring direct keys can be found in the "WinCC flexible Communication" system manual.

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ITEM 2500 Operating a project 8.3 Setting the project language

8.3

Setting the project language

Introduction The HMI device supports multilingual projects. You must have configured a corresponding operating element which lets you change the language setting on the HMI device during runtime. The project always starts with the language set in the previous session.

Requirements ● The required language for the project must be available on the HMI device. ● The language switching function must be logically linked to a configured operating element such as a button.

Selecting a language You can change project languages at any time. Language-specific objects are immediately output to the screen in the new language when you switch languages. The following options are available for switching the language: ● A configured operating element switches from one language to the next in a list ● A configured operating element directly sets the desired language Further information on this may be available in your plant documentation

8.4

Entries using the touch screen

8.4.1

Overview

Screen keyboard When you touch an operating element requiring entry on the HMI device touch screen, a screen keyboard appears. The screen keyboard is displayed in the following cases: ● An I/O field is selected for input ● A password must be entered for accessing a password-protected function The screen keyboard is automatically hidden again when input is complete. Based on the configuration of the operating element, the system displays different screen keyboards for entering numerical or alphanumerical values. Note The screen keyboard display is independent of the configured project language.

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ITEM 2500 Operating a project 8.4 Entries using the touch screen

General procedure The operating elements of a screen are operated by touching the touch screen. Proceed as follows: 1. Touch the desired operating element within the screen. 2. Depending on the operating element, perform further actions. Detailed descriptions can be found under the respective operating element. Examples: – I/O field: Enter numerical, alphanumeric or symbolic values in the I/O field – Symbolic I/O field: Select an entry from the drop down list box – Slider control: Move the slider control

Procedure for text boxes Values are entered in the project text boxes. Based on your configuration, the values are saved to tags and transferred, for example, to the PLC. Proceed as follows: 1. Touch the desired text box within the screen. The screen keyboard opens. Depending on your configuration, you can enter values in the text box in the following manner: – Numerical values, for example decimal numbers, hexadecimal numbers, binary values – Alphanumerical values, for example digits and letters – Date/time 2. Enter the value. 3. Confirm your entry with

194

or discard your entry with the button

.

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ITEM 2500 Operating a project 8.4 Entries using the touch screen

8.4.2

Entering and editing numerical values

Numerical screen keyboard When you touch an operating element for numerical input on the HMI-device touch screen, the numerical screen keyboard appears. This is the case, for example, for a text box. The screen keyboard is automatically hidden again when input is complete.

Note Opened screen keyboard PLC job 51 "Select screen" has no effect while the screen keyboard is open.

Formats for numerical values You can enter values in numerical text boxes based on the following formats: ● Decimal ● Binary ● Hexadecimal Note Entry of hexadecimal values When you enter values in hexadecimal format, the alphanumerical screen keyboard opens.

Checking numerical value limits Tags can be assigned limit values. If you enter a value that lies outside of this limit, it will not be accepted, for example, 80 with a limit value of 78. In this case the HMI device will deliver a system alarm, if an alarm window is configured. The original value is displayed again.

Decimal places of numerical values The configuration engineer can define the number of decimal places for a numerical text box. The number of decimal places is checked when you enter a value in this type of I/O field. ● Decimal places in excess of the limit are ignored ● Empty decimal places are filled with "0"

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Procedure Numerical values can be entered character-by-character via the buttons on the numerical screen keyboard. Proceed as follows: 1. Touch the desired operator control on the screen. The numerical screen keyboard opens. The existing value is displayed in the screen keyboard and is selected. 2. Enter the value. The keys with for example the letters G to Z are available to enter a hexadecimal value; however, the characters are not entered. Depending on the settings, the HMI device outputs an audible signal. You have the following options to enter a value: – The selected value is deleted when you enter the first character. Completely reenter the value. – Use the

and

keys to move the cursor within the current value. You can

now edit the characters of the current value or add characters. Use the

key to delete the character to the left of the cursor. If the value is

selected, use this key to delete the selected part of the value. The

key deletes the character positioned to the right of the cursor. If the value is

selected, use this key to delete the selected part of the value. – Use the

key to display the infotext of the I/O field.

This key is only enabled if infotext has been configured for the input object or the current screen. 3. Use the

key to confirm your entry or cancel it with

. Either action closes

the screen keyboard.

Result You have changed the numerical value or entered a new one.

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8.4.3

Entering and editing alphanumerical values

Alphanumerical screen keyboard When you touch an operating element for alphanumerical input on the HMI-device touch screen, the alphanumerical screen keyboard appears. This is the case, for example, for a text box. The screen keyboard is automatically hidden again when input is complete.

Note Opened screen keyboard PLC job 51 "Select screen" has no effect while the screen keyboard is open. Language change Language change in the project has no influence on the alphanumerical screen keyboard. This means you cannot enter Cyrillic or Asian characters.

Keyboard levels The alphanumerical screen keyboard has various levels. ● Normal level ● Shift level If you change the levels with key

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

, the key assignments change.

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ITEM 2500 Operating a project 8.4 Entries using the touch screen

Procedure Alphanumerical values can be entered character-by-character via the buttons on the alphanumerical screen keyboard. Proceed as follows: 1. Touch the desired operator control on the screen. The alphanumerical screen keyboard opens. The existing value is displayed in the screen keyboard and is selected. 2. Enter the value. You have the following options to enter a value: – The selected value is deleted when you enter the first character. Completely reenter the value. and

– Use the

keys to move the cursor within the current value. You can

now edit the characters of the current value or add characters. key to delete the character to the left of the cursor. If the value is

Use the

selected, use this key to delete the selected part of the value. The

key deletes the character positioned to the right of the cursor. If the value is

selected, use this key to delete the selected part of the value. it is possible to switch between the keyboard levels of the screen

– Using key

keyboard. On switchover, the key assignments of the screen keyboard change. key to display the infotext of the I/O field.

– Use the

This key is only enabled if infotext has been configured for the input object or the current screen. 3. Use the

key to confirm your entry or cancel it with

. Either action closes the

screen keyboard.

Result You have changed the alphanumeric value or entered a new one.

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8.4.4

Entering the date and time

Entering the date and time Enter the date and time in the same way you enter alphanumerical values. Note When entering the date and time, please note that the format is determined by the configured project language.

8.4.5

Entering symbolic values

Drop down list Operating elements for entering symbolic values offer you a list from which you can select the input values. When you touch a symbolic I/O field on the HMI device touch screen, the following drop down list opens.

Procedure Proceed as follows: 1. Touch the required operating element. The drop down list of the operating element opens. Select

and

to scroll in the drop

down list. 2. Touch the required entry in the drop down list. The selected entry is accepted as an entry.

Result You have changed the symbolic value or entered a new one.

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8.4.6

Displaying infotext

Purpose The configuration engineer uses infotext to provide additional information and operating instructions. The configuration engineer can configure infotext on screens and operating elements. The infotext of an I/O field may contain, for example, information on the value to be entered.

Opening infotext for operating elements 1. Touch the required operating element. The screen keyboard opens. You can see from the appearance of the

key whether

infotext has been configured for the operating element or the current screen. 2. Touch the

key on the screen keyboard.

The infotext for the operating element is displayed. If there is no infotext for the selected screen object, the infotext for the current screen is displayed, if it has been configured. You can scroll through the contents of long infotext with

and

.

Note Switching between displayed infotext The configuration engineer can configure infotext for an I/O field and the associated screen. You can switch between two infotexts by touching the infotext window. 3. Close the displayed infotext by pressing

.

Alternative procedure Depending on your configuration, infotext can also be called via a configured operating element. Refer to your plant documentation to find any additional information on this topic.

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ITEM 2500 Operating a project 8.5 Entries using the keys

8.5

Entries using the keys

8.5.1

Control keys

Introduction The following tables show the control keys with which you operate the project. You will also find detailed descriptions under the individual operating elements.

Select operating elements Key TAB

SHIFT

+

Functions

Description

Tabulator

Selects the next/previous operating element in the tab sequence.

Cursor keys

Selects the next operating element to the left, right, above or below the current screen object.

TAB

Navigates in the operating element.

Using operating elements Key SHIFT

+

SHIFT

+

SHIFT

+

SHIFT

+

Functions

Description

Position the cursor

Positions the cursor within an operating element, for example in the I/O field.

Scroll back

Scrolls back a page in a list.

Scroll to the beginning

Scrolls to the beginning of a list.

Scroll forward

Scrolls one page forward in a list.

Scroll to the end

Scrolls to the end of a list.

HOME

FN

+

HOME

END

FN

+

END

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Operating a project 8.5 Entries using the keys Key

Functions

Description

ENTER

Enter key

• • • •

Operates buttons. Accepts and ends an entry. Opens a drop down list box. Toggles within a text box between character mode and normal mode. In character mode, a single character is selected. In this mode, you can advance in the character set using the cursor keys.

Cancel

ESC

• •

INS DEL

ALT

+

CTRL

+

ENTER

Deletes the characters of a value entry and restores the original value. Closes the active dialog.

Delete characters

Deletes the character to the right of the current cursor position.

Delete characters

Deletes the character to the left of the current cursor position.

Open drop down list box

Opens a drop down list box.

Accept value

Accepts the selected value in the drop down list box without closing the list.

Functions

Purpose

Toggle key assignment

Switches over key assignment of keys with multiple assignment. • No LED is lit:

Enter key combinations Key A-Z

•

The number assignment is enabled. Pressing the button once toggles to letter assignment. An LED is lit: The left or right letter assignment is enabled.

Each time the key is pressed, the system toggles between the left letter assignment, the right letter assignment and the number assignment. SHIFT

FN

Toggle between upper-case and lower-case

Used in key combinations, for example for entering upper-case letters.

Switch to additional key assignment

Some of the keys contain a blue imprinted key assignment , for example the "%" character. Used in key combinations for the blue key assignment.

202

CTRL

General control function

Used in key combinations

ALT

General control function

Used in key combinations

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Operating a project 8.5 Entries using the keys

Acknowledge alarms Key ACK

Functions

Description

Acknowledge

Acknowledges the currently displayed fault alarm or all the alarms of an alarm group as group acknowledgment. The LED lights up as long as unacknowledged fault alarms are active.

Displaying infotext Key HELP

Functions

Description

Displaying infotext

Opens a window with the configured infotext at the selected object, for example alarm or I/O field. If an infotext exists for the selected object, the LED lights up.

Multi-key operation Unwanted actions may be triggered, if the operator unintentionally actuates a key combination. CAUTION Unintentional actions In "Online" mode, simultaneous operation of more than two keys may cause unintentional actions in the plant. Never press more than two keys simultaneously.

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8.5.2

Example: enter characters using the alphanumeric keyboard Using the same keys of the alphanumeric keyboard you can enter up to six different characters. The entry result depends on the combination of the keys pressed. The values "5", "M", "m", "N", "n" and "%" are entered using the same key the keyboard. You can use the keys

A-Z

,

SHIFT

and

FN

M %

N

5

of

to switch between the

different assignments. The following table shows the entry options using the key

Key

8.5.3

A-Z

Key

SHIFT

Key

M %

N

.

5

Result

FN

No LED is lit

Not relevant

Not pressed

5

Left LED is illuminated.

Not pressed

Not pressed

m

Left LED is illuminated.

Pressed

Not pressed

M

Right LED is illuminated.

Not pressed

Not pressed

n

Right LED is illuminated.

Pressed

Not pressed

N

Not relevant

Not relevant

Pressed

%

Function keys

Function keys Function key assignment is defined during configuration. The configuration engineer can assign function keys globally and locally.

Function keys with global function assignment A globally assigned function key always triggers the same action on the HMI device or in the PLC irrespective of the screen displayed. Such an action could be, for example, the activation of a screen or the closure of an alarm window.

Function keys with local function assignment A function key with local function assignment is screen-specific and is therefore only effective within the active screen. The function assigned locally to a function key can vary from screen to screen. The function key of a screen can be assigned one function only, either a global or local one. The local assignment function takes priority over the global setting. The configuration engineer can assign function keys in such a way that you can operate operating elements with function keys, for example, the alarm view, trend view, recipe view or Status Force.

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ITEM 2500 Operating a project 8.5 Entries using the keys

8.5.4

General procedures

Introduction The control keys and function keys of the HMI device are available for key control

General procedure The operating elements of a screen are operated using the control keys of the HMI device. Proceed as follows: 1. Continue to press the key

TAB

or the cursor keys until the required operating element is

selected on the screen. 2. Depending on the operating element, perform further actions. Detailed descriptions can be found under the respective operating element. Examples: – I/O field: Enter numerical, alphanumeric or symbolic values in the I/O field – Slider control: Move the slider control 3. Confirm the operation with the key

8.5.5

ENTER

or abort the operation with the key

ESC

.

Entering and editing numerical values

Formats for numerical values You can enter values in numerical text boxes based on the following formats: ● Decimal ● Hexadecimal ● Binary

Limit value test of numerical values Tags can be assigned limit values. If you enter a value that lies outside of this limit, it will not be accepted, for example, 80 with a limit value of 78. In this case the HMI device will deliver a system alarm, if an alarm window is configured. The original value is displayed again.

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ITEM 2500 Operating a project 8.5 Entries using the keys

Procedure Numerical and alphanumerical values can be entered in character mode using the system keys. Proceed as follows: 1. Select the desired text box within the screen with

TAB

.

The existing value is selected in the text box. 2. Enter the value using the numerical keypad. You have the following options to enter a value: – The existing value is deleted when you enter the first character. Completely reenter the value. – Press

SHIFT

and a cursor key simultaneously. The selection of the field content is

canceled. Move the cursor in the existing value. You can now edit the characters of the current value or add characters. The

INS DEL

key deletes the character positioned to the right of the cursor. Use the

key to delete the character to the left of the cursor. To enter the hexadecimal characters "A" to "F", switch the numerical keypad to letter assignment using the key – If the LED of the

HELP

A-Z

.

key is lit, infotext is available for the selected object or the

current screen. Use the key 3. Select

ENTER

HELP

to display the infotext for the operating element or current screen.

to confirm your entry.

Result You have changed the numerical value or entered a new one.

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ITEM 2500 Operating a project 8.5 Entries using the keys

8.5.6

Entering and editing alphanumerical values

Procedure Alphanumerical values can be entered in character mode using the system keys. Proceed as follows: 1. Select the desired text box within the screen with

TAB

.

The existing value is selected in the text box. 2. Enter the value using the system keys. You have the following options to enter a value: – The existing value is deleted when you enter the first character. Completely reenter the value. – Press

SHIFT

and a cursor key simultaneously. The selection of the field content is

canceled. Move the cursor in the existing value. You can now edit the characters of the current value or add characters. The

INS DEL

key deletes the character positioned to the right of the cursor. Use the

key to delete the character to the left of the cursor. To enter letters, switch the numerical keypad to letter assignment using the key – If the LED of the

HELP

A-Z

.

key is lit, infotext is available for the selected object or the

current screen. Use the key 3. Select

ENTER

HELP

to display the infotext for the operating element or current screen.

to confirm your entry.

Result You have changed the alphanumeric value or entered a new one.

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ITEM 2500 Operating a project 8.5 Entries using the keys

8.5.7

Entering the date and time

Entering the date and time Enter the date and time in the same way you enter alphanumerical values. Note When entering the date and time, please note that the format is determined by the configured project language.

8.5.8

Entering symbolic values

Drop down list When you select a symbolic I/O field, a drop down list opens.

Procedure Symbolic values are selected from the entries of a drop down list. Proceed as follows: 1. Select the desired symbolic text box within the screen with 2. Open the drop down list using the key

ENTER

ENTER

.

. The drop down list opens.

3. Select the required entry using the cursor keys 4. Select

TAB

,

or

.

to confirm your entry.

Result You have changed the symbolic value or entered a new one.

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8.5.9

Displaying infotext

Purpose The configuration engineer uses infotext to provide additional information and operating instructions. The configuration engineer can configure infotext on screens and operating elements. The infotext of an I/O field may contain, for example, information on the value to be entered.

If the LED of the key

HELP

lights up, an infotext has been configured for the selected display

object or for the current screen.

Procedure 1. Press

HELP

.

The infotext for the selected screen object is displayed. If there is no infotext for the selected screen object, the infotext for the current screen is displayed, if it has been configured. You can scroll through the contents of long infotexts using the cursor keys

and

.

Note Switching between displayed infotext The configuration engineer can configure infotext for an I/O field and the associated screen. You can switch between two infotexts by pressing the key 2. Close the infotext by pressing key

ESC

ENTER

.

.

Alternative procedure Depending on your configuration, infotext can also be called via a function key or via an existing operating element. Refer to your plant documentation to find any additional information on this topic. MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Operating a project 8.6 Bar and gauge

8.6

Bar and gauge

Bar The bar is a dynamic display object. The bar displays a value from the PLC as a rectangular area. The bar allows you to recognize the following at a glance: ● The distance of the current value from the configured limit values ● Whether a set point value has been reached The bar can display values such as fill levels or batch counts.

Layout The layout of the bar depends on the configuration: ● The bar may feature a scale of values ● The configured limit values can be indicated by lines ● Color changes can signal when a limit value has been exceeded or has not been reached

Gauge The gauge is a dynamic display object. The gauge displays numeric values in analog form by means of a pointer. This enables an operator at the HMI device to see at a glance if the boiler pressure is in the normal range, for example.

Layout The layout of the gauge depends on the configuration: ● A trailing pointer can display the maximum value reached so far on the scale. The trailing pointer is reset when the screen is reloaded ● The label on the scale can show the measured variable, for example boiler pressure and the physical unit, for example bar

Operation The bar and the gauge are for display only. Both objects cannot be controlled by the operator.

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ITEM 2500 Operating a project 8.7 Operating the switch

8.7

Operating the switch

Introduction The switch is an operating element and display object with two predefined switching states, for example "On" and "Off". Switches can signalize the state of a plant section, for example if a motor is running or not. At the same time, you can use the switch to change the state of the corresponding plant section via the HMI device, for example from "On" to "Off".

Layout The layout of the switch depends on the configuration: ● Switch with slider The two states are displayed by the position of the slider

 ①

Slider

● Switch with text or graphic The two states are displayed by the label on the slider Depending on the switching state, the switch is labeled with one of two texts or one of two graphics. Examples: "Backward" or "Forward" or

Procedure using the touch screen ● Switch with slider Proceed as follows: Move the slider to the other position or double-click the slider area ● Switch with text or graphic Proceed as follows: Touch the switch

Procedure using the keys Proceed as follows: 1. Select the desired switch within the screen with 2. Press

ENTER

TAB

.

.

Result The switch changes its appearance. The associated value is switched.

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ITEM 2500 Operating a project 8.8 Operating the trend view

8.8

Operating the trend view

Trends Trends continuously display the current process data or process data from a log.

Trend view Trends are displayed in the trend view. A trend view can display several trends simultaneously.



 7UHQG

7DJDVVLJQPHQW

3UHVVXUH

3UHVVXUHSDWWHUQ

9DOXH

'DWHWLPH  

 ①

Ruler

②

Buttons for trend operation

③

Trend value in the value table

Layout and operation The layout and operation of the trend view depends on the configuration. The configuration engineer determines, for example, the following: ● Appearance of the trend view, the axes, value ranges and labels ● Operating options of the trend view ● Limit values for the trend values ● The change of color of the trend in the event of limit violation Refer to your plant documentation to find any additional information on this topic.

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ITEM 2500 Operating a project 8.8 Operating the trend view

Value table The trend values can be read from the value table if this is configured: ● When the ruler is displayed, the trend values are shown at a position of the ruler in the value table ● When the ruler is hidden, the latest trend values are displayed in the value table

Ruler When configured, a ruler is available to provide an exact reading of the trend values in the value table. You can move the ruler to the desired position of the trend view.

Operation The trend view can be operated as follows: ● Enlarge or reduce the time interval displayed ● Scroll forward or back by one display width ● Stop and resume trend recording ● Move the ruler ● Hide and display the ruler The following table shows the trend view buttons: Buttons

Key combination

Function Stops or continues trend recording.

Y

Enlarges the displayed time section.

Z

CTRL

+ +

CTRL

+

SHIFT

+

SHIFT

+

CTRL

+

ENTER

CTRL

+

ALT

+

CTRL

+

ALT

+

Reduces the displayed time section. Scrolls one display width backwards (to the left) Scrolls one display width forwards (to the right) Scrolls back to the beginning of the trend recording. The start values of the trend recording are displayed there. Moves the ruler backwards (to the left) Moves the ruler forwards (to the right) Shows or hides the ruler.

In addition, the configuration engineer can configure function keys or operating elements with which you can control trend views. Refer to your plant documentation to find any additional information on this topic.

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ITEM 2500

Operating a project 8.9 Operating the slider control

Touch operation Touch the required button in the trend view. The position of the ruler can also be changed by means of touching and dragging the ruler on the touch screen.

Procedure using the keys Proceed as follows: 1. Using the key

TAB

select the desired button within the trend view.

2. Confirm your entry by pressing the key

8.9

ENTER

.

Operating the slider control

Introduction The slider control can be used to monitor and change process values within a defined range. The slider control can also be configured without a slider. In this case, you cannot enter a value. The slider control is then only used for displaying values.



 ①

Slider control for entering values

②

Value display with current value

Layout The layout of the slider control depends on the configuration: ● The slider control can contain a label and a setting range ● The current value can be displayed below the area of the slider control

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ITEM 2500 Operating a project 8.9 Operating the slider control

Procedure using the touch screen Proceed as follows: 1. Touch the slider of the desired slider control. 2. Move the slider to the required value. If a value display has been configured, you can check the exact value that has been set. 3. Release the slider.

Key control The following table shows the control keys used to set the slide to a desired value: Key combination

Description

SHIFT

+

or

SHIFT

+

SHIFT

+

or

SHIFT

+

Increase value by 1 Reduce value by 1 Increase value in 5% increments.

HOME

Decrease value in 5% increments. END

Set maximum value

FN

+

HOME

FN

+

END

Set minimum value

Procedure using the keys Proceed as follows: 1. Using the key

TAB

mark the desired switch within the screen.

2. Move the slider to the required value. If a value display has been configured, you can check the exact value that has been set.

Result The set value is applied.

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ITEM 2500

Operating a project 8.10 Operating the Status Force

8.10

Operating the Status Force

8.10.1

Overview

Application You read or write access values of the connected PLC directly with Status Force. Status Force allows you to monitor or change addresses of the PLC program, etc. You don't need to connect an additional programming device or additional PC to the PLC. Note Status Force can only be used in combination with SIMATIC S5 or SIMATIC S7.

Layout The layout of Status Force depends on the configuration. The figure shows the general layout of Status Force. A value can be monitored or controlled on every line. The following figure shows an example of Status Force.

The configuration engineer specifies which columns appear in Status Force. The table shows the significance of all configurable columns. Column

Functions

"Connection"

The PLC whose address ranges must be displayed.

"Type", "DB Number", "Offset", "Bit"

The address range of the value

"Data Type", "Format"

The data type of the value

"Status Value"

The value read from the specified address.

"Control Value"

The value to be written to the specified address.

Further information on this may be available in your plant documentation

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ITEM 2500 Operating a project 8.10 Operating the Status Force

Operating elements Depending on your configuration, you can operate the Status Force using the following buttons: Buttons

Functions "Read" button Updates the display in the "Status Value" column. This button engages when it is pressed. You cannot operate any text boxes until the button is actuated again and the refresh is stopped. "Write" button Applies the new value in the "Control Value" column. The control value is written to the PLC.

8.10.2

Touch operation

Operator input options Status Force can be operated as follows: ● Change the column sequence ● Read the status values of the connected PLC ● Enter values and transfer them to the PLC

Change column sequence Depending on the configuration, you can change the column sequence of Status Force. Proceed as follows: 1. Touch the column header which you wish to exchange with a different column header 2. Keeping the touch screen pressed, move the column heading to the column heading you wish to exchange it with

Result The columns are displayed in the modified sequence.

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ITEM 2500 Operating a project 8.10 Operating the Status Force

Procedure for reading the status value Proceed as follows: 1. Enter the address and the desired format of a value for each line. Touch the respective columns to display the screen keyboard. 2. Once you have entered all of the desired values, touch the

button.

Result All values are read cyclically by the PLC and entered in the "Status Value" column until the

button is touched again.

Requirements for forcing The following requirements must be fulfilled in order to force values: ● The "Control Value" column must be available ● The "Write" button must be available

Procedure for forcing a value Proceed as follows: 1. Enter the address of a value for each line. Enter the desired value in the "Control Value" column. Touch the respective columns to display the screen keyboard. 2. Once you have entered all of the desired values, touch the

button.

Result The values from the "Control Value" column are transferred once to the PLC.

8.10.3

Key control

Operator input options Status Force can be operated as follows: ● Change the column width. ● Read the status values of the connected PLC ● Enter values and transfer them to the PLC

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Key control The following table lists the key combinations for operating the Status Force: Keys

Functions {

CTRL

+

CTRL

+

CTRL

+

CTRL

+

CTRL

+

CTRL

+

CTRL

+

Operates the "Read" button.

}

Operates the "Write" button.

ENTER

Selects the first/last field in the current line.

Selects the first/last field in the current column.

Deletes the current line.

INS DEL

Otherwise: Do not select a PLC in the "Connection" column. Opens selection box.

ENTER

CTRL

+

ALT

+

CTRL

+

ALT

+

CTRL

+

Y

Increases the width of the current column. Decreases the width of the current column. Optimizes column width.

Z

+

Procedure for reading the status value Proceed as follows: 1. Enter the address and format of the status value for each status value you wish to read in one line. Select the respective fields and enter the values using the keyboard. {

2. Press

CTRL

}

+

.

Result All status values are read cyclically from the PLC and entered in the "Status Value" column until the

CTRL

+

{

}

keys are pressed again.

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Requirements for forcing The following requirements must be fulfilled in order to force values: ● The "Control Value" column must be available ● The "Write" button must be available

Procedure for forcing a value Proceed as follows: 1. Enter the address of a value for each line. Enter the desired control value in the "Control Value" column. Select the respective fields and enter the values using the keyboard. 2. Once you have entered all of the desired control values, press the

CTRL

+

ENTER

key.

Result The values from the "Control Value" column are transferred once to the PLC.

Alternative procedure Alternatively, you can also select the buttons and operate it using key

ENTER

and

using the key

TAB

.

8.11

Operating the Sm@rtClient view

8.11.1

Overview

Application The Sm@rtClient view enables you to monitor and remotely operate the current project of a remote HMI device. With the correct configuration, several equal priority HMI devices can access a remote HMI device. Note If another HMI device accesses your HMI device via the Sm@rtClient view, this leads to an additional load on your HMI device.

Layout In the Sm@rtClient view, the remote HMI is displayed with the complete layout. Depending on the configuration, you can monitor and also operate this screen. You can also operate the function keys like buttons on an HMI device with a touch screen.

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Monitoring mode On a Sm@rtClient view which is configured for monitoring mode, you can only monitor the remote HMI device. You cannot control its operation.

Operation Note It is not possible to operate the direct keys of the remote HMI device from the local HMI device. The available operating elements depend on the HMI devices used: ● Same type of HMI devices You can operate the project of the remote HMI device with the operating elements of your HMI device ● Operate keys from a local touch screen All the keys of the remote HMI device are displayed as buttons on the touch screen. You can also touch them to operate them ● Touch operation from a local HMI device using keys You operate the buttons in the usual manner.

8.11.2

Touch operation

Operator input options The Sm@rtClient view can be operated as follows: ● Starting remote control ● Forcing permission ● Ending remote operation

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Procedure for starting remote operation Proceed as follows: 1. On the HMI device change to the screen with the Sm@rtClient view. The following options are available for establishing the connection to the remote HMI device: – The connection is established automatically. – The connection must be established by touching the appropriate button. Depending on the configuration, you may be required to enter the address of the remote HMI device and a password. 2. The current screen of the project running on the remote device is displayed on the screen of your HMI device. 3. You can now monitor and control this screen depending on your configuration. Scroll bars are displayed if the screen of the remote HMI device is larger than that of the current HMI device.

Procedure for forcing permissions If several HMI devices have access to a HMI device, only one HMI device has operating permission at any one time. Two cases must be distinguished for this case: ● If another HMI device is already controlling the remote HMI device, if configured accordingly, you can force operating permission for the remote HMI device – You are trying to operate the remote HMI device – A dialog appears in which you are prompted to enter the appropriate password for forcing remote control – You are now authorized to operate the remote HMI device ● If another HMI device is accessing your HMI device via the Sm@rtClient view, you can force local operating permission for your HMI device – Touch the screen of your HMI device five times consecutively – You are given permission to operate your local HMI device

Procedure for ending remote control You can end monitoring and control of a remote HMI device with one of the following methods depending on the configuration: ● Touch a button configured for this action ● Exit the screen containing the Sm@rtClient view ● If configured, a menu is displayed after you have touched an empty space over a longer period. Select the "Close" menu item. Further information on this may be available in your plant documentation

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8.11.3

Key control

Operator input options The Sm@rtClient view can be operated as follows: ● Starting remote control ● Forcing permission ● Ending remote control

Procedure for starting remote operation Proceed as follows: 1. On the HMI device change to the screen with the Sm@rtClient view. The following options are available for establishing the connection to the remote HMI device: – The connection is established automatically. – Continue to press the key

TAB

until the Sm@rtClient view is selected.

Depending on the configuration, you may be required to enter the address of the remote HMI device and a password. The connection is established. The current screen of the project running on the remote device is displayed on the screen of your HMI device. 2. You can now monitor and control this screen depending on your configuration. 3. Scroll bars are displayed if the screen of the remote HMI device is larger than that of the current HMI device. Move the scroll bars in the direction required using keys or

CTRL

+

CTRL

+

.

Procedure for forcing permissions If several HMI devices access an HMI device, only one HMI device has permission to operate. Two cases must be distinguished for this case: ● If another HMI device is already controlling the remote HMI device, if configured accordingly, you can force operating permission for the remote HMI device – You are trying to operate the remote HMI device – A dialog appears in which you are prompted to enter the appropriate password for forcing remote control You are now authorized to operate the remote HMI device ● If another HMI device is accessing your HMI device via the Sm@rtClient view, you can force local operating permission for your HMI device – Press

SHIFT

five times consecutively.

You are given permission to operate your local HMI device

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Procedure for ending remote control You can end monitoring or control of a remote HMI device with one of the following methods depending on the configuration: ● Press the key configured for this ● Exit the screen containing the Sm@rtClient view ● If configured, display a menu with with

ALT

SHIFT

+

CTRL

. Select the desired menu command

and the respective identification letter.

Further information on this may be available in your plant documentation.

8.12

Project security

8.12.1

Overview

Design of the security system The configuration engineer can protect the operation of a project by implementing a security system. The security system is based on authorizations, user groups and users. If operating elements protected by a password are operated, the HMI device first requests that you log on. A logon screen is displayed in which you enter your user name and password. After logging on, you can operate the operating elements for which you have the necessary authorizations. The logon dialog can be set up by the configuration engineer via an individual operating element. In the same way, the configuration engineer can set up an operating element to log off. After logging off, objects assigned password protection can no longer be operated; to do so, log on again. Further information on this may be available in your plant documentation.

User groups and authorizations Project-specific user groups are created by the configuration engineer. The "Administrators" and "PLC User" groups are included in all projects by default. User groups are assigned authorizations. Authorization required for an operation is specifically defined for each individual object and function in the project.

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Users and passwords Each user is assigned to exactly one user group. The following people are allowed to create users and assign them passwords: ● The configuration engineer during configuration ● The administrator on the HMI device ● A user with user management authorization on the HMI device Irrespective of the user group, each user is allowed to change his own password.

Logoff times A logoff time is specified in the system for each user. If the time between any two user actions, such as entering a value or changing screens, exceeds this logoff time, the user is automatically logged off. The user must then log on again to continue to operate objects assigned password protection.

Backup and restore The user data is encrypted and saved on the HMI device to protect it from loss due to power failure. The users, passwords, group assignments and logoff times set up on the HMI device can be backed up and restored. This prevents you having to enter all of the data again on another HMI device. NOTICE The currently valid user data is overwritten in the following cases: • Depending on the transfer settings, when the project is transferred again • Upon restore of a backed-up project • Upon import of the user administration via an operating element. Further information on this may be available in your plant documentation The retransferred or restored user data and passwords are valid with immediate effect.

Limits for user, password and user View Number of characters Length of user name, maximum

40

Length of password, minimum

3

Length of password, maximum

24

Entries in user view, maximum

50

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8.12.2

User view

Application The user view is used to display the users on the HMI device: ● All users on the HMI device are displayed in the user view to the administrator or to a user with administrator authorizations ● If you are a user without user management authorization, you can only see your personal user entry The authorizations of a user after logging on depends on the user group to which the user is assigned. Further information on this may be available in your plant documentation

Layout The configuration engineer can implement a simple or enhanced user view. The two user views offer the same functions. They differ only in the display of information.

Simple user view If you are not logged on to the HMI device, the only entry contained in the simple user view is "<ENTER>". If you are logged on to the HMI device, the simple user view only displays the user name and user group.

Enhanced user view The enhanced user view displays information about the users.

The enhanced user view contains the following columns: ● Users ● Password ● Group ● Logoff time The passwords are encrypted by appear as asterisks.

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8.12.3

User logon

Logon dialog Use the logon dialog to log on to the security system of the HMI device. Enter your user name and password in the logon dialog.

The logon dialog opens in the following cases: ● You are operating an operating element with password protection ● You are operating an operating element that was configured for displaying the logon dialog ● You activate the "<ENTER>" entry in the simple user view ● You activate a blank entry in the extended user view ● The logon dialog will be automatically displayed when the project is started, depending on the configuration Further information on this may be available in your plant documentation.

Requirements The logon dialog is open.

Procedure using the touch screen Proceed as follows: 1. Enter the user name and password. Touch the corresponding text box. The alphanumerical screen keyboard is displayed. 2. Select "OK" to confirm logon.

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Procedure using the keys Proceed as follows: 1. Using the key

TAB

select the "User" text box within the logon dialog.

2. Enter the user name using the system keys. To enter letters, switch the numerical keypad to letter assignment using the key 3. Using the key

TAB

A-Z

.

select the "Password" text box.

4. Enter the password using the system keys. 5. Touch the "OK" button to confirm your entries. Note The user name is not case-sensitive. The password is case-sensitive.

Result After successful logon to the security system, you can execute password-protected functions on the HMI device for which you have authorizations. If you enter a wrong password, an error message is displayed when an alarm window has been configured.

8.12.4

User logoff

Requirements You have logged into the security system of the HMI device.

Procedure You have the following options for logging off: ● You operate an operating element that was configured for logoff ● You will be logged off automatically if you are not operating the project and if the logoff time has been exceeded You will also be automatically logged off if you enter an incorrect password.

Result You are no longer logged into the project. In order to operate an operating element with password protection, you must first log on again.

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8.12.5

Creating users

8.12.5.1

Creating users with touch operation

Requirements You have opened a screen containing the user view. You have user management authorization or you are the administrator. NOTICE The following characters cannot be used in passwords: • Blank • Special characters * ? . % / \ ' "

Procedure for creating a user in the simple user view Proceed as follows: 1. Touch the "" entry in the user view. The following dialog opens:

2. Enter the desired user name and password. Touch the corresponding text box. The alphanumerical screen keyboard is displayed. 3. Touch the "OK" button. The following dialog opens:

4. Assign the user to a group. In order to do so, open the "Group" drop down list box by means of the and

button. Select

to scroll in the drop down list box.

5. Touch the required entry in the drop down list box. The selected entry is then accepted as input. MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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6. Touch the text box "Logoff time". The screen keyboard is displayed. 7. Enter a value between 0 and 60 for the logoff time in minutes. The value 0 stands for "no automatic logoff." 8. Touch the "OK" button to confirm your entries.

Procedure for creating a user in the enhanced user view Proceed as follows: 1. Touch the desired field in the blank line of the user view. The appropriate screen keyboard is displayed. 2. Switch into input mode by means of the

key.

3. Enter the respective user data in the field: – Assign the user to one of the groups from the drop down list box. – Enter a value between 0 and 60 for the logoff time in minutes. The value 0 stands for "no automatic logoff."

Result The new user is created.

8.12.5.2

Creating users with key operation

Requirements You have opened a screen containing the user view. You have user management authorization or you are the administrator. NOTICE The following characters cannot be used in passwords: • Blank • Special characters * ? . % / \ ' "

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Procedure for creating a user in the simple user view Proceed as follows: 1. Select the user view using the key

TAB

or using the cursor keys.

2. Select the entry "" in the user view with the cursor keys and confirm with

ENTER

.

The following dialog opens:

3. Enter the desired user name using the system keys. 4. Select the next text box with the

TAB

key and enter a password using the system keys.

5. Touch the "OK" button to confirm your entries. The following dialog opens:

6. Select the "Group" selection box with

TAB

.

7. Assign the user to a group. – Select

ENTER

to open the drop down list box. The drop down list box opens.

– Select the required entry using

or

– Confirm your entry by pressing the key 8. Select the text box "Logoff time" with

TAB

. ENTER

.

.

9. Enter the desired logoff time using the system keys. Enter a value between 0 and 60 for the logoff time in minutes. The value 0 stands for "no automatic logoff." 10.Touch the "OK" button to confirm your entries.

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Procedure for creating a user in the enhanced user view Proceed as follows: 1. Select the user view with the 2. Select a blank line with the

TAB

key via the configured tab order.

or

keys.

3. Select the desired field in the blank line of the user view with the 4. Confirm your entry by pressing the key

ENTER

or

keys.

.

5. Enter the desired user data: – Enter the data using the system keyboard. To enter letters, switch the numerical keypad to letter assignment using the key

A-Z

.

– Assign the user to one of the groups from the drop down list box. Open the drop down list box with the

ENTER

key and select the desired entry with the

or

keys.

– Enter a value between 0 and 60 for the logoff time in minutes. The value 0 stands for "no automatic logoff." 6. Confirm your entry by pressing the key

ENTER

.

Result The new user is created.

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8.12.6

Changing user data

8.12.6.1

Changing user data with touch operation

Requirements You have opened a screen containing the user view. Which data you are allowed to change depends on your authorization: ● You are an administrator or a user with user management authorization. In these cases you are allowed to change the data for all the users on the HMI device in the user view: – User name – Group assignment – Password – Logoff time ● You are a user without user management authorization. In this case you are only allowed to change your personal user data: – Password – Logoff time, if configured Note You can only change the logoff time and password for the "Admin" user. You can only change the logoff time for the "PLC_User". This user is used for logging on via the PLC.

Procedure for changing user data in the simple user view Proceed as follows: 1. In the user view, touch the user whose user data you want to change 2. When entering the data, use exactly the same procedure as for creating a user

Procedure for changing user data in the enhanced user view Proceed as follows: 1. In the user view, touch the user whose user data you want to change 2. When entering the data, use exactly the same procedure as for creating a user

Result The user data for the user is changed.

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8.12.6.2

Changing user data with key operation

Requirements You have opened a screen containing the user view. Which data you are allowed to change depends on your authorization: ● You are an administrator or a user with user management authorization. In these cases you are allowed to change the data for all the users on the HMI device in the user view: – User name – Group assignment – Password – Logoff time ● You are a user without user management authorization. In this case you are only allowed to change your personal user data: – Password – Logoff time, if configured Note You can only change the logoff time and password for the "Admin" user. You can only change the logoff time for the "PLC_User". This user is used for logging on via the PLC.

Procedure for changing user data in the simple user view Proceed as follows: 1. Confirm your entry by pressing the key

TAB

.

2. In the user view, use the cursor keys to select the user whose user data you want to change. Confirm your entry by pressing the key

ENTER

.

3. When entering the data, use exactly the same procedure as for creating a user.

Procedure for changing user data in the enhanced user view Proceed as follows: 1. Confirm your entry by pressing the key

TAB

.

2. Use the cursor keys to select the field in which you want to change data. Confirm your entry by pressing the key

ENTER

.

3. When entering the data, use exactly the same procedure as for creating a user

Result The user data for the user is changed.

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8.12.7

Deleting users

Requirements You have opened a screen containing the user view. To delete a user, you must be an administrator or have user management authorization. Note The "Admin" and "PLC_User" users exist by default. These users cannot be deleted.

Procedure To delete a user, delete the user name entered.

Result The user has been deleted and may no longer log onto the project.

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ITEM 2500 Operating a project 8.13 Closing the project

8.13

Closing the project

Procedure Proceed as follows: 1. Use the corresponding operating element object to close the project. Wait for the Loader to open after you closed the project. 2. Switch off power to the HMI device.

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ITEM 2500

Operating alarms 9.1

9

Overview

Alarms Alarms indicate events and states on the HMI device which have occurred in the system, in the process or on the HMI device itself. A status is reported when it is received. An alarm could trigger one of the following alarm events: ● Incoming ● Outgoing ● Acknowledge The configuration engineer defines which alarms must be acknowledged by the user. An alarm may contain the following information: ● Date ● Time ● Alarm text ● Location of fault ● State ● Alarm class ● Alarm number ● Alarm group ● Diagnostics capability

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Operating alarms 9.1 Overview

Alarm classes Alarms are assigned to various alarm classes: ● Error Alarms in this class must always be acknowledged. Error alarms normally indicate critical errors within the plant such as "Motor temperature too high" ● Operation Warning alarms usually indicate states of a plant such as "Motor switched on" ● System System alarms indicate states or events which occur on the HMI device ● SIMATIC diagnostic alarms SIMATIC diagnostic alarms show states and events of the SIMATIC S7 or SIMOTION PLCs ● User-specific alarm classes The properties of this alarm class must be defined in the configuration Further information on this may be available in your plant documentation.

Alarm groups The configuration engineer can group alarms into alarm groups. When you acknowledge an individual alarm of an alarm group, you acknowledge all alarms which belong to the same alarm group.

Alarm buffer The alarm events are stored in an internal buffer. The size of this alarm buffer depends on the HMI device type.

Alarm report The configuration engineer can activate alarm reporting on the project. In this case, alarm events are output directly on the connected printer. The configuration engineer can define whether each individual alarm is logged. An alarm of this type is printed when the alarm events "Incoming" and "Outgoing" occur. If you want to print alarms of the "System" alarm class, you have to print the contents of the associated alarm buffer. For this case the configuration engineer has to configure an operating element for printing the alarm buffer.

Alarm log Alarm events are stored in an alarm log, provided this log file is configured. The capacity of the log file is limited by the storage medium and system limits.

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ITEM 2500 Operating alarms 9.2 Detecting queued alarms

9.2

Detecting queued alarms

Introduction You can recognize the presence of alarms which must be acknowledged by the following: ● For an HMI device with keys: The LED in the key

ACK

lights up.

● Depending on the configuration: An alarm indicator is displayed on screen. The configuration determines whether an alarm has to be acknowledged or not. This is also defined by the alarm class which an alarm belongs to.

LED in the "ACK" key On an HMI device with keys, an LED is integrated in the key

ACK

. The LED is lit if there are

alarms requiring acknowledgment which must still be acknowledged. The LED goes out when you acknowledge all alarms requiring acknowledgment.

Alarm indicator The alarm indicator is a graphic symbol indicating pending alarms or alarms requiring acknowledgment, depending on the configuration.

The alarm indicator flashes as long as alarms are pending for acknowledgment. The number displayed indicates the number of pending alarms. The configuration engineer can assign functions to be executed when the alarm indicator is operated. Usually, the alarm indicator is only used for error alarms. Further information may be available in your plant documentation.

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9.3

Message display

Displaying alarms Alarms are displayed in the alarm view or in the alarm window on the HMI device.

Alarm view Depending on the configuration, the alarm view is displayed as follows: ● As a single line. Alarm numbers and alarm texts are displayed as single lines ● As simple alarm view ● As enhanced alarm view In the simple or enhanced alarm views the configuration engineer specifies the alarm information to be displayed. Depending on the configuration, alarms from alarm logs are also displayed in the alarm view.

Simple alarm view  0RWRUWRRKRW

The buttons have the following functions: Buttons

Functions Displaying infotext for an alarm. Process alarm. Acknowledge alarm. Select the next or previous alarm in the list. Scroll one page up or down.

Enhanced alarm view 1R 7LPH    0RWRUWRRKRW

240

'DWH 

6WDWXV .

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ITEM 2500 Operating alarms 9.3 Message display The buttons have the following functions: Buttons

Functions Displaying infotext for an alarm. Process alarm. Acknowledging alarms.

Changing the column sequence and sorting in the enhanced alarm view Depending on the configuration, you can change the column sequence and sorting order on HMI devices with touch operation. ● Change column sequence – Touch the column header which you wish to exchange with a different column header – Keeping the touch screen pressed, move the column heading to the column heading you wish to exchange it with ● Change sorting order To change the sorting order of the alarms, touch the respective column header on the touch screen

Alarm class layout The various alarm classes are identified in order to distinguish between them in the alarm view. Icon

Alarm class

!

Error

Without a symbol

Operation

Symbol depending on the configuration

User-defined alarm classes

S7

SIMATIC or SIMOTION diagnostic alarms

$

System

The configuration engineer can change the symbols for the alarm classes. Further information on this may be available in your plant documentation.

Alarm window The alarm window is independent of the process screen. Depending on the configuration, the alarm window opens automatically as soon as a new alarm is pending for acknowledgment. The alarm window can be configured so that it only closes after all the alarms have been acknowledged. The layout and the operation of the alarm window are the same as for the alarm view. Further information on this may be available in your plant documentation.

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9.4

Displaying infotexts

Displaying infotext The configuration engineer can also provide infotext for alarms.

Procedure using the touch screen Proceed as follows: 1. Touch the desired alarm in the alarm view or the alarm window. The alarm is selected. button in the simple alarm view or

2. Touch the

in the enhanced alarm view.

If configured, the infotext assigned to this alarm is displayed. 3. Close the screen for displaying the Infotext by means of the

button.

Procedure using the keys Proceed as follows: 1. Select the desired alarm in the alarm view. 2. Press

HELP

.

If configured, the infotext assigned to this alarm is displayed. 3. Close the infotext by pressing key

242

HELP

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ITEM 2500 Operating alarms 9.5 Acknowledge alarm

9.5

Acknowledge alarm

Requirements The alarm to be acknowledged is displayed in the alarm window or the alarm view.

Procedure using the touch screen Proceed as follows: 1. Touch the desired alarm in the alarm view or the alarm window. The alarm is selected. button in the simple alarm view or

2. Touch the

in the enhanced alarm view.

Procedure using the keys The alarm view and the alarm window have a tab sequence with which you can select operating elements and the last selected alarm using the keyboard. 1. Select the desired alarm view or alarm window with 2. Select the desired alarm. Use the 3. Press

ACK

HOME

,

END

,

or

TAB

. keys.

.

Alternative operation Depending on the configuration, you can also acknowledge an alarm with a function key.

Result The alarm is acknowledged. If the alarm belongs to an alarm group, all the alarms of the associated group are acknowledged. More information on acknowledgment and on available alarm groups may be found in your plant documentation.

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Operating alarms 9.6 Editing alarms

9.6

Editing alarms

Introduction The configuration engineer can assign additional functions to each alarm. These functions are executed when the alarm is processed. Note When you edit an unacknowledged alarm, it is acknowledged automatically.

Requirements The alarm to be edited is displayed in the alarm window or the alarm view.

Procedure using the touch screen Proceed as follows: 1. Touch the desired alarm in the alarm view or the alarm window. The alarm is selected. 2. Touch the

button in the simple alarm view or

in the enhanced alarm view.

Procedure using the keys Proceed as follows: 1. Select the desired alarm view or alarm window with 2. Select the desired alarm. Use the 3. Continue to press the key

TAB

HOME

,

END

,

or

until the button

TAB

. keys.

is selected in the simple alarm view or

in the extended alarm view. 4. Confirm your entry by pressing the key

ENTER

.

Result The system executes the additional functions of the alarm. Further information on this may be available in your plant documentation.

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ITEM 2500 Operating recipes 10.1

10

Overview

Introduction Recipes are used when different variants of a product are manufactured with the same process. In this case, the product variants differ in terms of their type and quantity of the components, but not in terms of the manufacturing process sequence. The configuration engineer can store the combination of each individual product variant in a recipe.

Field of application Recipes can be used everywhere the same product components are used in variable combinations to create different product variants. Examples: ● Beverage industry ● Food processing industry ● Pharmaceutical industry ● Paint industry ● Building materials industry ● Steel industry

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Operating recipes 10.2 Structure of a recipe

10.2

Structure of a recipe

Recipes The recipe collection for the production of a product family can be compared to a file cabinet. A recipe which is used to manufacture a product corresponds to a drawer in a file cabinet. Example: In a plant for producing fruit juice, recipes are required for different flavors. There is a recipe, for example, for the flavors orange, grape, apple and cherry.







 

246

①

File cabinet

Recipe collection

Recipes for a fruit juice plant

②

Drawer

Recipe

Orange flavored drinks

③

Drawer

Recipe

Grape flavored drinks

④

Drawer

Recipe

Apple flavored drinks

⑤

Drawer

Recipe

Cherry flavored drinks

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Operating recipes 10.2 Structure of a recipe

Recipe data records The drawers of the file cabinet are filled with suspension folders. The suspension folders in the drawers represent records required for manufacturing various product variants. Example: Product variants of the flavor apple might be a soft drink, a juice or nectar, for example. 







①

Drawer

②

Suspension folder Recipe data record

Recipe

Product variants of apple flavored drinks Apple drink

③

Suspension folder Recipe data record

Apple nectar

④

Suspension folder Recipe data record

Apple juice

Elements In the figure showing the file cabinet, each suspension folder contains the same number of sheets. Each sheet in the suspension folder corresponds to an element of the recipe data record. All the records of a recipe contain the same elements. The records differ, however, in the value of the individual elements. Example: All drinks contain the same components: water, concentrate, sugar and flavoring. The records for soft drink, fruit juice or nectar differ, however, in the quantity of sugar used in production.

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Operating recipes 10.3 Recipes in the project

10.3

Recipes in the project

Overview If recipes are used in a project, the following components interact: ● Recipe view / recipe screen On the HMI device, recipes are displayed and edited in the recipe view or in a recipe screen. – The recipe data records from the internal memory of the HMI device are displayed and edited in the recipe view. – The values of the recipe tags are displayed and edited in the recipe screen Depending on the configuration, the values displayed in the recipe view are synchronized with the values of recipe tags. ● HMI device recipe memory Recipes are saved in the form of data records in the HMI device recipe memory. The recipe data can also be saved in recipe tags. ● Recipe tags The recipe tags contain recipe data. When you edit recipes in a recipe screen, the recipe values are stored in recipe tags. Depending on the configuration, the values of the recipe tags are exchanged with the PLC. The recipe tags can be synchronized with the recipe data records so that the same values are saved in both. ● Memory card The memory card is an external storage medium for recipe data records. The recipe data records are exported from the HMI device recipe memory and are saved on the memory card in a *.csv file. The records can be reimported from the memory card to the recipe memory.

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ITEM 2500 Operating recipes 10.3 Recipes in the project

Data flow The following figure shows the data flow in a project with recipes. +0,GHYLFH

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5HFLSHYLHZ

  5HFLSH VFUHHQ

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5HFLSHWDJ



  3/&



 0HPRU\FDUG

①

Editing, saving or deleting a recipe data record

②

Display recipe data record

③

Synchronize or do not synchronize recipe tags

④

Display and edit recipe tags in the recipe screen

⑤

Write records from the recipe view to the PLC or read records from the PLC and display them in the recipe view

⑥

Recipe tags are to the PLC online or offline

⑦

Export or import recipe data record to memory card

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500

Operating recipes 10.4 Recipe displays

10.4

Recipe displays

Displaying recipes You can display and edit recipes on the HMI device with a recipe view or recipe screen.

Recipe view A recipe view is a screen object used to manage recipe data records. The recipe view shows recipe data records in tabular form. Depending on the configuration, the recipe view is displayed as follows: ● As enhanced recipe view ● As simple recipe view The configuration engineer also defines which operating elements are displayed in the recipe view.

Enhanced recipe view The following figure shows an example of the enhanced recipe view.













 

250

①

Selection box for the recipe

②

Selection box for the recipe data record

③

Element name The element name designates a specific element in the recipe data record

④

Display field This show the number of the selected recipe or the selected recipe data record

⑤

Value of the element

⑥

Buttons for editing a recipe data record

⑦

Status bar for display of the status messages

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Operating recipes 10.4 Recipe displays

Simple recipe view The simple recipe view consists of three areas: ● Recipe list ● Record list ● Element list In the simple recipe view, each area is shown separately on the HMI device. Depending on the configuration, the simple recipe view starts with the recipe list or data record list. The following figure shows an example of the record list.   

-XLFH %HYHUDJH 1HFWDU







①

Number of the recipe data record

②

Recipe data records

③

Buttons for changing the displayed list and calling the menu

Display of values NOTICE Changing the recipe data record in the background Applies to the processing of a recipe data record: If values of the corresponding recipe data record are changed by a PLC job, the recipe view is not updated automatically. To update the recipe view, reselect the respective recipe data record.

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ITEM 2500

Operating recipes 10.4 Recipe displays

Recipe screen A recipe screen allows the correlation between the plant and the recipe data to be displayed in graphic form. The configuration engineer combines I/O fields and screen objects to form a custom input screen. The configuration engineer can distribute the I/O fields of a recipe over several recipe screens, thus allowing recipe elements to be arranged by subject. The recipe screen can be operated using buttons configured accordingly. The following figure shows an example of the recipe screen. :DWHU



O

&RQFHQWUDWH



O

6XJDU



NJ

$URPD



O



5HFLSHQDPH 2UDQJH

1R 

'DWDUHFRUGQDPH 1HFWDU

1R 

6DYH

'DWDIURPWKH3/&

/RDG

'DWDWR3/&







①

Element name and associated values The element name designates a specific element in the recipe data record

②

Buttons for editing a recipe data record

③

Modified recipe view

④

Buttons for transferring recipe data

The values displayed or entered in the recipe screen are saved in recipe tags. The recipe values are exchanged with the PLC immediately or later via these tags. A configured recipe view can itself be a component of a recipe screen. You must synchronize the tags in order to synchronize data between the tags of the recipe screen and the recipe data records displayed in the recipe view. Synchronization of tags is only possible in the enhanced recipe view. Further information on this may be available in your plant documentation.

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ITEM 2500 Operating recipes 10.5 Recipe values in the HMI device and the PLC

10.5

Recipe values in the HMI device and the PLC

Introduction You can change the values of a recipe on the HMI device and therefore influence the manufacturing process or a machine. Depending on the configuration, the recipe values are displayed, edited and saved in different ways: ● If you are editing recipes with a recipe view in your project, the values are saved in recipe data records ● If you are editing recipes in a recipe screen in your project, the values are saved in recipe tags Differences may occur between the display values in the recipe view and the values saved in the associated tags in an ongoing project when you edit recipes with a recipe view and in a recipe screen. To prevent this, the recipe data record values must be synchronized with the values of the recipe tags. You have however the option to perform synchronization operations at any time. Synchronization only takes place if the configuration engineer has activated the respective settings for a recipe. Note Recipe tags can only be synchronized in the enhanced recipe view.

Synchronizing recipe tags Synchronization of the recipe tags depends on the configuration: ● Automatic synchronization: The values of the recipe view are synchronized with the associated recipe tags. In this case, changes to values in the recipe view have an immediate effect on the values of the associated recipe tags. The values are only synchronized, when an operating element that is outside the recipe view is operated. ● Synchronization by the user: The values of the recipe view and the associated recipe tags are not synchronized automatically. The configuration engineer has assigned the same function to the button or a different operating element in the recipe view. The recipe tags and the recipe view are only synchronized when you operate the buttons or the appropriate operating element.

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ITEM 2500

Operating recipes 10.6 Operating the recipe view

Recipe tags online / offline The configuration engineer can configure a recipe so that changes to the values of the recipe tags do not have an immediate effect on the current process. Synchronization of the recipe values between the HMI device and the PLC depends on whether the configuration engineer has selected the settings "Tags online" or the setting "Tags offline" for a recipe. ● "Tags online": This setting has the following effect: – When you change recipe values in the recipe screen, these changes are applied immediately by the PLC and immediately influence the process – If recipe values are changed in the PLC, the changed values are displayed immediately in the recipe screen ● "Tags offline": With this setting, changed recipe values are not synchronized immediately between the HMI device and the PLC In this case, the configuration engineer must configure operating elements for transferring the values to the PLC or reading them from the PLC in a recipe screen. The recipe values are only synchronized between HMI device and PLC when you operate the appropriate operating element

10.6

Operating the recipe view

10.6.1

Overview

Operation The recipe view can be operated as follows: ● Enter values for the recipe elements ● Create recipe data records ● Save recipe data records or save them under a new name ● Delete recipe data records ● Synchronize values of the recipe view with the associated recipe tags ● Transfer recipe data records from the PLC and to the PLC

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ITEM 2500 Operating recipes 10.6 Operating the recipe view

Operating elements of the recipe view The following table shows the operating elements of the recipe view. Buttons

Key combination {

}

CTRL

+

CTRL

+

CTRL

+ *

CTRL

+

CTRL

+

CTRL

+

CTRL

+

ENTER

INS DEL

=

Functions Creates a new recipe data record. If a start value is configured, it is shown in the text box. Saves the displayed values of the recipe data record. The storage location is predefined by the project. The recipe data record is saved under a different name irrespective of the recipe view. A dialog box opens in which the name is entered. The displayed recipe data record is deleted.

The values of the recipe view are synchronized with the associated recipe tags. The values changed during editing are written to the associated recipe tags. Subsequently all the values of the tags are read out and updated in the table. The recipe values from the PLC are displayed in the recipe view.

The values of the set recipe data record displayed in the recipe view are transferred to the PLC.

Operating the recipe screen You operate the recipes in a recipe screen with the operating elements provided by the configuration engineer. Further information on this may be available in your plant documentation.

10.6.2

Creating a recipe data record

Introduction You create a new recipe data record by modifying an existing record. You then save the modified data record under a new name.

Requirements A screen with a recipe view is displayed.

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ITEM 2500 Operating recipes 10.6 Operating the recipe view

Procedure using the touch screen Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe for which you want to create a new recipe data record. .

2. Touch

A new recipe data record with the next available number is created. If you change the new data record number to an existing data record number, the existing data record is overwritten. 3. Enter values for the elements of the data record. The elements of the recipe data record can be assigned default values depending on the configuration. .

4. Touch

5. Enter a name for the data record. The data record is saved under the new name. If the recipe data record already exists, a dialog is opened. In this dialog, specify whether the existing data record is to be overwritten.

Procedure using the keys Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe for which you want to create a new recipe data record. 2. Press

CTRL

+

{

}

.

A new recipe data record with the next available number is created. If you change the new data record number to an existing data record number, the existing data record is overwritten. 3. Enter values for the elements of the data record. The elements of the recipe data record can be assigned default values depending on the configuration. 4. Press

CTRL

+ * .

5. Enter a name for the data record. 6. Confirm your entry. The data record is saved under the new name. If the recipe data record already exists, a dialog is opened. In this dialog, specify whether the existing data record is to be overwritten.

Result The new recipe data record is saved to the selected recipe.

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ITEM 2500 Operating recipes 10.6 Operating the recipe view

10.6.3

Editing a recipe data record

Introduction Edit the values of the recipe data records and save them in a recipe view.

Synchronization with the PLC If you want to display the current recipe values from the PLC in the recipe view, you first have to read the current values from the PLC with

.

The values changed in the recipe view only become effective when the amended data record is transferred to the PLC by means of the

button.

Requirements A screen with a recipe view is displayed.

Procedure using the touch screen Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record you want to change. 3. Change the data record as required. 4. Save your changes by means of the

button.

If you want to save the recipe data record under a different name, touch the

key.

5. The recipe data record is saved.

Procedure using the keys Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record you want to change. 3. Change the data record as required. 4. Save your changes with

CTRL

+

ENTER

.

If you want to save the recipe data record under a different name, press

CTRL

+ * .

The recipe data record is saved.

Result The edited recipe data record has now been saved in the selected recipe. MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Operating recipes 10.6 Operating the recipe view

10.6.4

Deleting a recipe data record

Introduction You can delete all the data records of a recipe which are not required.

Requirements A screen with a recipe view is displayed.

Procedure using the touch screen Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record you want to delete. .

3. Touch

Procedure using the keys Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record you want to delete. 3. Press

CTRL

+

INS DEL

.

Result The recipe data record is deleted.

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ITEM 2500 Operating recipes 10.6 Operating the recipe view

10.6.5

Synchronizing tags

Introduction The values of the recipe elements can be saved to recipe tags, depending on the configuration. Differences may occur between the display values in the recipe view and the actual values of tags in an ongoing project. Synchronize the tags to equalize such differences. Synchronization always includes all the variables which belong to a recipe data record. NOTICE Changed tag name Tags and the value of the recipe data record cannot be assigned to each other if the tag name of the tag to be synchronized has been changed. The tags in question are not synchronized. Note Recipe tags can only be synchronized in the enhanced recipe view.

Requirements A screen with a recipe view is displayed.

Procedure using the touch screen Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record you want to synchronize. .

3. Touch

Procedure using the keys Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record you want to synchronize. 3. Press

CTRL

+

=

.

Result The elements of the recipe data record are synchronized with the recipe tags. If the values of the recipe view and the tag do not match, the more current value is accepted. MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Operating recipes 10.6 Operating the recipe view

10.6.6

Reading a recipe data record from the PLC

Introduction In the current project, the values which are also stored in the recipes in the HMI device can be changed directly in the plant. This is the case, for example, if a valve was opened further directly at the plant than is stored in the recipe. The values of the recipe data records saved in the HMI device possibly no longer match the values in the PLC. To synchronize the recipe values, read the values from the PLC and display them in the recipe view.

Requirements A screen with a recipe view is displayed.

Procedure using the touch screen Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record to which you want to apply the values from the PLC. .

3. Touch

The values are read from the PLC. 4. If you want to store the displayed values in the HMI device, touch the

button.

Procedure using the keys Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record to which you want to apply the values from the PLC. 3. Press

CTRL

+

.

The values are read from the PLC. 4. If you want to store the displayed values in the HMI device, press the keys

CTRL

+

ENTER

.

Result The values were read from the PLC, displayed on the HMI device and saved to the selected recipe data record.

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ITEM 2500 Operating recipes 10.6 Operating the recipe view

10.6.7

Transferring a recipe data record to the PLC

Introduction In order for an edited recipe data record to take effect in the process, you must transfer the values to the PLC. The display values in the recipe view are always transferred to the PLC.

Requirements A screen with a recipe view is displayed.

Procedure using the touch screen Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record whose values you want to transfer to the PLC. .

3. Touch

Procedure using the keys Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record whose values you want to transfer to the PLC. 3. Press

CTRL

+

.

Result The display values in the recipe view were transferred to the PLC and take effect in the process.

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Operating recipes 10.7 Operating the simple recipe view

10.7

Operating the simple recipe view

10.7.1

Overview

Introduction The simple recipe view consists of three areas: ● Recipe list ● Record list ● Element list You can use the context menu to operate each of these display areas.

Operation The simple recipe view can be operated as follows: ● Enter values for the recipe elements ● Create recipe data records ● Save recipe data records or save them under a new name ● Delete recipe data records ● Transfer recipe data records from the PLC and to the PLC

Operating elements of the simple recipe view Toggle between the display areas and the context menus to operate the simple recipe views. The following table shows the operation of the display area. Touch operation Touching an entry

Key control ENTER

ESC

Functions The next lower display area opens. The next higher display area opens. The context menu of the display area opens.

The following table shows the operation of the context menu. Touch operation

Key control ESC

Touch the menu command

262

Input of the number of the menu command

Functions The menu is closed. The display area opens. The menu command is executed.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Operating recipes 10.7 Operating the simple recipe view

Context menus of the simple recipe view A number is assigned to each menu command which you can use to call the menu command with key control. With touch operation, touch the menu command to execute it. Some menu functions can also be called directly in the lists of the simple recipe view using the keys. ● Recipe list No.

Menu command

0

New

1

Displaying infotext

2

Open

Key combination

Functions A new recipe data record is created for the selected recipe. If a start value is configured, it is shown in the text box.

HELP

ENTER

The infotext configured for the simple recipe view is displayed. The record list of the selected recipe opens.

● Record list No.

Menu command

Key combination

Functions

0

New

1

Delete

2

Save as

The selected record is saved under a different name irrespective of the simple recipe view. A dialog box opens in which the name is entered.

3

Rename

The selected record is renamed. A dialog box opens in which the name is entered.

A new recipe data record is created for the selected recipe. If a start value is configured, it is shown in the text box. INS DEL

The selected record is deleted.

● Element list No.

Menu command

Key combination

Functions

0

Save

The selected record is renamed.

1

To PLC

The display values of the selected record are transferred from the HMI device to the PLC.

2

From PLC

The recipe values from the PLC are displayed on the HMI device in the recipe view.

3

Save as

The selected record is renamed. A dialog box opens in which the name is entered.

Touch operation of the menu Touch the desired menu command. The command is executed.

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ITEM 2500 Operating recipes 10.7 Operating the simple recipe view

Key control of the menu Select the required entry using

or

. Press

ENTER

.

Alternatively, press the numerical key with the number of the desired menu command. The command is executed.

Operating the recipe screen You operate the recipes in a recipe screen with the operating elements provided by the configuration engineer. Further information on this may be available in your plant documentation.

10.7.2

Creating a recipe data record

Introduction Create a new recipe data record in the recipe list or in the record list. Then enter the values for the new record in the element list and save the record.

Requirements A screen with a simple recipe view is displayed.

Procedure Proceed as follows: 1. If the recipe list contains several recipes: Select the recipe for which you want to create a new recipe data record. 2. Open the recipe list menu. 3. Select the menu command "0 New". A new record is created. The element list of the new record opens. 4. Enter values for the elements of the data record. The tags of the record can be assigned default values depending on the configuration. 5. Open the element list menu and select the menu command "0 Save". 6. Enter a name for the new record. 7. Confirm your entries. If you change the new data record number to an existing data record number, the existing data record is overwritten.

Result The new recipe data record is saved to the selected recipe.

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ITEM 2500 Operating recipes 10.7 Operating the simple recipe view

10.7.3

Editing a recipe data record

Introduction Edit the values of the recipe data records in a simple recipe view.

Synchronization with the PLC If you want to display the current recipe values from the PLC in the simple recipe view, you first have to read the current values from the PLC with the menu command "2 from PLC" in the element list. The values changed in the recipe view only take effect in the PLC when you transfer the edited data record to the PLC with the menu command "1 to PLC".

Requirements A screen with a simple recipe view is displayed.

Procedure Proceed as follows: 1. If the recipe list contains several recipes: Select the recipe which contains the desired recipe data record. 2. Open the data record list. 3. Select the recipe data record you want to change. 4. Open the element list. 5. Change the values of the records as required. 6. Save your changes with the menu command "0 Save". The recipe data record is saved.

Result The edited recipe data record has now been saved in the selected recipe.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Operating recipes 10.7 Operating the simple recipe view

10.7.4

Deleting a recipe data record

Introduction You can delete all the data records which are not required.

Requirements A screen with a simple recipe view is displayed.

Procedure using the touch screen Proceed as follows: 1. If the recipe list contains several recipes: Select the recipe which contains the desired recipe data record. 2. Open the data record list. 3. Select the data record you want to delete. 4. Open the menu. 5. Select the menu command "1 Delete".

Procedure using the keys Proceed as follows: 1. If the recipe list contains several recipes: Select the recipe which contains the desired recipe data record. 2. Open the data record list. 3. Select the data record you want to delete. 4. Press

INS DEL

.

Result The data record is deleted.

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ITEM 2500 Operating recipes 10.7 Operating the simple recipe view

10.7.5

Reading a recipe data record from the PLC

Introduction The values of recipe elements are exchanged with the PLC via tags. In the current project, the values which are also stored in the recipes in the HMI device can be changed directly in the plant. This is the case, for example, if a valve was opened further directly at the plant than is stored in the recipe. The values of the tags on the HMI device possibly no longer match the values in the PLC. To synchronize the recipe values, read the values from the PLC and display them in the recipe view.

Requirements A screen with a simple recipe view is displayed.

Procedure Proceed as follows: 1. If the recipe list contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the element list of the recipe data record to which you want to apply the values from the PLC. 3. Open the menu. 4. Select the menu command "2 from PLC". The values are read from the PLC. 5. If you want to save the display values in the HMI device, select the menu command "0 Save".

Result The values were read from the PLC, displayed on the HMI device and saved to the selected recipe data record.

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ITEM 2500 Operating recipes 10.7 Operating the simple recipe view

10.7.6

Transferring a recipe data record to the PLC

Introduction In order for an edited recipe data record to take effect in the process, you must transfer the values to the PLC. The display values in the recipe view are always transferred to the PLC.

Requirements A screen with a simple recipe view is displayed.

Procedure Proceed as follows: 1. If the recipe list contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the element list of the recipe data record whose values you want to transfer to the PLC. 3. Open the menu. 4. Select the menu command "1 To PLC".

Result The values of the recipe data record were transferred to the PLC and take effect in the process.

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ITEM 2500 Operating recipes 10.8 Importing a recipe data record

10.8

Importing a recipe data record

Introduction You can import values from a CSV file to a recipe data record, depending on the configuration.

Requirements ● An operating element with the function "Import data record" has been configured, for example a button ● A screen with a recipe view is displayed.

Procedure Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the recipe data record to be imported. 2. Operate the operating element with the function "Import data record". The record is imported from an external data medium as a CSV file and then displayed in the recipe view after import.

Result The imported recipe data record is saved on the HMI device.

Deviating structure If the structure of the CSV file differs from the structure of the recipe, deviations are handled as follows: ● Any additional values in the CSV file will be rejected ● The system applies the configured default value to the recipe data record if the CSV file contains an insufficient number of values ● If the CSV file contains values of the wrong data type, the configured default value is set in the recipe data record Example: The imported CSV file contains values that were entered as floating point numbers. However, the corresponding tag expects an integer value. In this case, the system discards the imported value and uses the configured default.

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ITEM 2500 Operating recipes 10.9 Exporting a recipe data record

10.9

Exporting a recipe data record

Introduction You can export one or more recipe data records to a CSV file, depending on the configuration. After export, the values in the recipe data record can be further processed in a spreadsheet program such as MS Excel. The degree to which you can influence the export depends on the configuration.

Requirements ● A screen with a recipe view is displayed. ● An operating element with the function "Export record" has been configured. ● The following tags are configured equally in the recipe view and for the "Export record" operating element: – Recipe number – Data record number

Procedure Proceed as follows: 1. If the recipe view contains several recipes: Select the recipe which contains the desired recipe data record. 2. Select the recipe data record you want to export. 3. Operate the operating element which was configured for export, for example the "Export data record" button. The data record is exported as a CSV file to an external data medium. Further information on this may be available in your plant documentation.

Result The recipe data record is exported.

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ITEM 2500 Operating recipes 10.10 Examples

10.10

Examples

10.10.1

Entering a recipe data record

Introduction You would like to enter production data on the HMI device without interrupting the process in the machine or plant. For this reason, the production data should not be transferred to the PLC.

Procedure Proceed as follows: 1. Call the recipe view or a recipe screen. 2. Select the desired recipe data record. 3. Enter the values of the elements. 4. Save the recipe data record. The recipe data record is saved in the internal memory of the HMI device. The following figure shows the data flow schematically. +0,GHYLFH

5HFLSHPHPRU\



5HFLSHYLHZ

  5HFLSH VFUHHQ

5HFLSH 5HFLSH 5HFLSH 5HFLSHQ

5HFLSHWDJ



 3/&

①

Display recipe data record

②

Save recipe data record

③

Tags are synchronized

④

Display and edit recipe tags in the recipe screen

⑤

Tags are offline

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ITEM 2500 Operating recipes 10.10 Examples

10.10.2

Manual production sequence

Introduction You request the production data of different workpieces from the PLC and display this data on the screen of the HMI device for inspection. You want to correct the transferred production data in the recipe view or the recipe screen if necessary.

Procedure A scanner connected to the PLC reads the barcode of a workpiece. The barcode names correspond to the names in the recipe data record. Based on the barcode name, the PLC can read the required recipe data record. The recipe data record is displayed for inspection on the HMI device. You can now edit and save the recipe data record. Then transfer the edited recipe data record to the PLC again. The following figure shows the data flow schematically. +0,GHYLFH 5HFLSHYLHZ

5HFLSHPHPRU\

 5HFLSH 5HFLSH 5HFLSH 5HFLSHQ

 5HFLSH VFUHHQ

5HFLSHWDJ



 

272

3/&

①

The recipe data record is read from the PLC and written to the PLC again following changes

②

Display and edit recipe tags in the recipe screen

③

Tags are synchronized

④

Recipe data records are saved in the recipe memory of the HMI device

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Maintenance and care 11.1

11

Maintaining and caring for the touch screen and keyboard overlay

Introduction The HMI device is designed for maintenance-free operation. The touch screen and keyboard overlay should nevertheless be cleaned regularly.

Requirement ● Damp cleaning cloth ● Washing up liquid or foaming screen cleaning agent

Procedure NOTICE Unintentional response If you clean the touch screen or an HMI device with a keyboard overlay when it is switched on, you may cause maloperations. Switch off the HMI device, or if the HMI device is running, clean the touch screen only in a blocked state! Note that the touch screen block automatically ends after 15 seconds. Damage caused by unauthorized cleaning products Using compressed air or steam cleaners, or aggressive solutions or scouring agents will damage the HMI device. Do not clean the HMI device with compressed air or steam jet blowers. Do not use aggressive solvents or scouring powder. Proceed as follows: 1. Switch off the HMI device or block the touch screen. 2. Spray the cleaning solution onto a cleaning cloth. Do not spray directly onto the HMI device. 3. Clean the HMI device. When cleaning the display wipe from the screen edge inwards.

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ITEM 2500

Maintenance and care 11.2 Clean screen on MP 377 Touch

11.2

Clean screen on MP 377 Touch

Introduction The HMI touch screen can be cleaned when it is switched on and a project is running. An operating element must be available in the project that can be used to call the "clean" screen. Once the clean screen is activated, touch screen operation is locked for a configured period of time. The time the touch screen is locked can be set between 5 and 30 seconds. The time remaining for the lockout is indicated by a progress bar. NOTICE Unintentional responses When cleaning the touch screen, an unintentional response in the controller can be triggered by touching keys. Always open the clean screen or switch off the HMI device before you clean the touch screen while the system is running! Once the period for the clean screen has passed, operations are again possible. Avoid data inadvertent operations. Cannot be operated when the clean screen is active When the clean screen is active, operations on the HMI device are not possible. Wait for the period for the clean screen to lapse. Then you can operate the plant again with the HMI device.

11.3

Spare parts and repairs

Repairs In case of repair, the HMI device must be shipped to the Return Center in Fürth. Repairs may only be carried out at the Return Center in Fürth. Depending on the work necessary to repair the device, the Center may decide to give you a credit note. A credit note is only granted when the sender orders a new HMI device. The address is: Siemens AG Industry Sector Returns Center Siemensstr. 2 90766 Fürth Germany

Spare parts You can find spare parts and accessories for the HMI devices in the section Accessories (Page 26).

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ITEM 2500

12

Technical specifications Dimension drawings

12.1.1

Dimension drawings of the MP 377 12" Touch









12.1









 $OOGLPHQVLRQVLQPP 7ROHUDQFHsPP

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ITEM 2500 Technical specifications 12.2 Specifications

12.2

Specifications

HMI device MP 377 12" Touch Weight without packaging

3.75 kg

MP 377 12" Key 5.41 kg

MP 377 15" Touch

MP 377 PRO 15" Touch

4.69 kg

Approx. 7.3 kg, with basic adapter approx. 7.7 kg

MP 377 19" Touch 7.65 kg

Display MP 377 12" Touch

MP 377 12" Key

Type Display area, active

Resolution

MP 377 15" Touch

MP 377 PRO 15" Touch

MP 377 19" Touch

LCD TFT 246 mm x 184.5 mm (12.1")

304.1 mm x 228.1 mm (15")

376.3 mm x 301.1 mm (19")

800 x 600 pixels

1 024 x 768 pixels

1 280 x 1 024 pixels

Colors, displayable

64 K

Brightness control

Yes

Backlighting

CCFL

Half brightness life time, typical

50 000 h

Pixel error class according to DIN EN ISO 13406-2

II

Input device MP 377 12" Touch Type

Touch screen, analog, resistive

MP 377 12" Key

MP 377 15" Touch

Keyboard

MP 377 PRO 15" Touch

MP 377 19" Touch

Touch screen, analog, resistive

Memory MP 377 12" Touch Application memory

280

MP 377 12" Key

MP 377 15" Touch

MP 377 PRO 15" Touch

MP 377 19" Touch

12 MB

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Technical specifications 12.2 Specifications

Interfaces MP 377 12" Touch

MP 377 12" Key

1 x RS 422/RS 485

MP 377 15" Touch

MP 377 PRO 15" Touch

MP 377 19" Touch

Max. 12 Mbps, applies to DP operations

2 x USB 2.0

USB host Conforms to USB standard 2 (supporting low-speed and full-speed USB devices), maximum load 500 mA

2 x Ethernet

RJ45 10/100 Mbps

Audio

Line out

Supply voltage MP 377 12" Touch

MP 377 12" Key

Rated voltage

MP 377 15" Touch

MP 377 PRO 15" Touch

MP 377 19" Touch

+24 V DC

Voltage range, permissible

19.2 to 28.8 V (–20%, +20%)

Transients, maximum permissible

35 V (500 ms)

Time between two transients, minimum

50 s

Current consumption • Typical • Constant current, maximum • Power on current surge I2t

Approx. 1 300 mA

Approx. 1 700 mA

Approx. 1 800 mA

Approx. 2 500 mA

Approx. 4 A2s

Approx. 4 A2s

Approx. 2 200 mA Approx. 3 100 mA Approx. 4 A2s

Fuse, internal

Electronic

Miscellaneous MP 377 12" Touch Realtime clock, buffered 1)

MP 377 12" Key

MP 377 15" Touch

MP 377 PRO 15" Touch

MP 377 19" Touch

Yes

Loudspeaker

Onboard

Magnetic field intensity

1)

50/60 Hz;100 A/m RMS

Bridging time of the buffering - approx. 6 weeks.

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ITEM 2500

Technical specifications 12.3 Bit assignment of the direct keys

12.3

Bit assignment of the direct keys The following figures show the assignment of the keys and LEDs to the bytes in the PLC process image. Further information may be available in your plant documentation. Note Do not use the LED bits "ACK", "A-Z", and "HELP" when a project is running on the HMI device.

Bit assignment of the direct keys for the MP 377 12" Key %XWWRQELWV

/('ELWV

















%\WH

















6

6

6

6

6

6

6

6

Q

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

Q

6

6

6

6

6

6

6

6

)

)

)

)

)

)

)

)

Q

)

)

)

)

)

)

)

)

)

)

)

)

)

)

)

)

Q

)

)

)

)

)

)

)

)

$&.

$/7

&75/ 6+,)7 )

)

)

)

Q

$&.

$=  $=  ,1)2

)

)

)

)

1)

Left LED

2)

Right LED

Bit assignment of the direct keys for the MP 377 12" Touch, MP 377 15" Touch and MP 377 19" Touch 7RXFKDVVLJQPHQW

282

















%\WH

















Q

















Q

















Q

















Q

















Q

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Technical specifications 12.4 Description of the ports

12.4

Description of the ports

12.4.1

Power supply Plug connector, 2-pin 



Pin

12.4.2

Assignment

1

+24 VDC (L+)

2

GND 24 V (M)

X10/IF 1B (RS 422/RS 485) Sub-D socket, 9-pin, with screw lock 







Pin

1)

Assignment for the RS 422

Assignment for the RS 485

1

n. c.

n. c.

2

GND 24 V

GND 24 V

3

TxD+

Data channel B (+)

4

RD+

RTS 1)

5

GND 5 V, floating

GND 5 V, floating

6

+5 VDC, floating

+5 VDC, floating

7

+24 VDC, out (max. 100 mA)

+24 VDC, out (max. 100 mA)

8

TxD–

Data channel A (–)

9

RxD–

RTS 1)

On pin 4 or pin 9, can be set with DIP switch on the rear of the device

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ITEM 2500

Technical specifications 12.4 Description of the ports

12.4.3

X1 (PROFINET) RJ45 plug connector



12.4.4



Pin

Assignment

1

Tx+

2

Tx–

3

Rx+

4

n. c.

5

n. c.

6

Rx–

7

n. c.

8

n. c.

X20, X21 (USB) USB socket 

284



Pin

Assignment

1

+5 VDC, out (max. 500 mA)

2

USB-DN

3

USB-DP

4

GND

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Technical specifications 12.4 Description of the ports

12.4.5

X40 (line out) Line out connector   

Pin

Assignment

1

Left audio channel

2

Right audio channel

3

GND

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Technical specifications 12.4 Description of the ports

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ITEM 2500

A

Appendix A.1

ESD guideline

Definition of ESD All electronic modules are equipped with large-scale integrated ICs or components. Due to their design, these electronic elements are highly sensitive to overvoltage, and thus to any electrostatic discharge. These electronic components are therefore specially identified as ESDs.

Abbreviations The following abbreviation is commonly used for electrostatic sensitive devices: ● EGB – Elektrostatisch Gefährdete Bauteile/Baugruppen (Germany) ● ESD – Electrostatic Sensitive Device (internationally recognized term)

Labeling ESDs are labeled with the following symbol:

Electrostatic charging CAUTION Electrostatic charging ESDs may be destroyed by voltages far below the level perceived by human beings. Voltages of this kind develop when a component or an assembly is touched by a person who is not grounded against static electricity. Usually, it is unlikely that damage to an ESD as a result of overvoltage is detected immediately but may become apparent only after a longer period of operation. Prevent electrostatic charging of your body before you touch the ESD!

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ITEM 2500

Appendix A.1 ESD guideline

Anyone who is not connected to the electrical potential of their surroundings is subjected to electrostatic charging.

9ROWDJH

The following figure indicates the maximum electrostatic charge anyone is subjected to when coming into contact with the materials shown. These values correspond with specifications to IEC 801-2. >N9@                



            >@ 5HODWLYHKXPLGLW\

①

Synthetic materials

②

Wool

③

Antistatic materials such as wood or concrete

Protective measures against electrostatic discharge CAUTION Observe grounding measures When working with electrostatic sensitive devices, make sure that the person, the workplace and the packaging are properly grounded. This helps to avoid electrostatic charging. As a rule, only touch the ESD if this is unavoidable, for example for maintenance. When you touch modules, make sure that you do not touch the pins on the modules or the PCB tracks. In this way, the discharged energy can not affect the sensitive devices. Discharge electrostatic electricity from your body if you are performing measurements on an ESD. Do so by touching grounded metallic parts. Always use grounded measuring instruments.

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ITEM 2500 Appendix A.2 System alarms

A.2

System alarms

Introduction System alarms on the HMI device provide information about internal states of the HMI device and PLC. The following overview shows the causes of system alarms and how to eliminate the cause of error. Some of the system alarms described in this section are relevant to individual HMI devices based on their range of features. Note System alarms are only indicated if an alarm window was configured. System alarms are output in the language currently set on your HMI device.

System alarm parameters System alarms may contain encrypted parameters which are relevant to troubleshooting because they provide a reference to the source code of the runtime software. These parameters are output after the text "Error code:"

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ITEM 2500

Appendix A.2 System alarms

Meaning of the system alarms All the system alarms that can be displayed are listed below. The system alarms are divided into different ranges: 10000 - Printer alarms Number

Effect/cause

Remedy

10000

The print job could not be started or was canceled due to an unknown error. Faulty printer setup. Or: No authorization is available for accessing the network printer. Power supply failure during data transfer.

Check the printer settings, cable connections and the power supply. Set up the printer once again. Obtain a network printer authorization. If the error persists, contact the Hotline!

10001

No printer is installed or a default printer has not been set up.

Install a printer and/or select it as the default printer.

10002

Overflow of the graphics buffer for printing. Up to two images are buffered.

Allow sufficient intervals between successive print jobs.

10003

Images can now be buffered again.

--

10004

Overflow of the buffer for printing lines in text mode (e.g. alarms). Up to 1000 lines are buffered.

Allow sufficient intervals between successive print jobs.

10005

Text lines can now be buffered again.

--

10006

The Windows printing system reports an error. Refer to the output text and the error ID to determine the possible causes. Nothing is printed or the print is faulty.

Repeat the action if necessary.

20000 - Global script alarms Number

Effect/causes

Remedy

20010

An error has occurred in the specified script line. Execution of the script was therefore aborted. Note the system alarm that may have occurred prior to this.

Select the specified script line in the configuration. Ensure that the tags used are of the allowed types. Check system functions for the correct number and types of parameters.

20011

An error has occurred in a script that was called by the specified script. Execution of the script was therefore aborted in the called script. Note the system alarm that may have occurred prior to this.

In the configuration, select the script that has been called directly or indirectly by the specified script. Ensure that the tags used are of the allowed types. Check system functions for the correct number and types of parameters.

20012

The configuration data is inconsistent. The script could therefore not be generated.

Recompile the configuration.

20013

The scripting component of WinCC flexible Runtime is not correctly installed. Therefore, no scripts can be executed.

Reinstall WinCC flexible Runtime on your PC. Rebuild your project with "Project > Generator > Generate" and transfer the project to the HMI device.

20014

The system function returns a value that is not written in any return tag.

Select the specified script in the configuration. Check whether the script name has been assigned a value.

20015

Too many successive scripts have been triggered in short intervals. When more than 20 scripts are queued for processing, any subsequent scripts are rejected. In this case, the script indicated in the alarm is not executed.

Find what is triggering the scripts. Extend the times, e.g. the polling time of the tags which trigger the scripts.

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ITEM 2500 Appendix A.2 System alarms 30000 - Alarms for IFwSetValue: SetValue() Number

Effect/causes

Remedy

30010

The tag could not accept the function result, e.g. when it has exceeded the value range.

Check the tag type of the system function parameter.

30011

A system function could not be executed because the function was assigned an invalid value or type in the parameter.

Check the parameter value and tag type of the invalid parameter. If a tag is used as a parameter, check its value.

30012

A system function could not be executed because the function was assigned an invalid value or type in the parameter.

Check the parameter value and tag type of the invalid parameter. If a tag is used as a parameter, check its value.

40000 - Linear scaling alarms Number

Effect/causes

Remedy

40010

The system function could not be executed since the parameters could not be converted to a common tag type.

Check the parameter types in the configuration.

40011

The system function could not be executed since the parameters could not be converted to a common tag type.

Check the parameter types in the configuration.

50000 - Data server alarms Number

Effect/causes

Remedy

50000

The HMI device is receiving data faster than it is capable of processing. Therefore, no further data is accepted until all current data have been processed. Data exchange then resumes.

--

50001

Data exchange has been resumed.

--

60000 - Win32 function alarms Number

Effect/causes

Remedy

60000

This alarm is generated by the “DisplaySystemAlarms” function. The text to be displayed is transferred to the function as a parameter.

--

60010

The file could not be copied in the direction defined because one of the two files is currently open or the source/target path is not available. It is possible that the Windows user has no access rights to one of the two files.

Restart the system function or check the paths of the source/target files. Using Windows NT/2000/XP: The user executing WinCC flexible Runtime must be granted access rights for the files.

60011

An attempt was made to copy a file to itself. It is possible that the Windows user has no access rights to one of the two files.

Check the path of the source/target file. Using Windows NT/2000/XP with NTFS: The user executing WinCC flexible Runtime must be granted access rights for the files.

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Appendix A.2 System alarms 70000 - Win32 function alarms Number

Effect/causes

Remedy

70010

The application could not be started because it could not be found in the path specified or there is insufficient memory space.

Check whether the application exists in the specified path or close other applications.

70011

The system time could not be modified. The error alarm only appears in connection with area pointer "Date/time PLC". Possible causes: • An invalid time was transferred in the job mailbox. • The Windows user has no right to modify the system time.

Check the time which is to be set. Using Windows NT/2000/XP: The user executing WinCC flexible Runtime must be granted the right to change the system time of the operating system.

If the first parameter in the system alarm is displayed with the value 13, the second parameter indicates the byte containing the incorrect value. 70012

An error occurred when executing the function "StopRuntime" with the option "Runtime and operating system". Windows and WinCC flexible Runtime are not closed. One possible cause is that other programs cannot be closed.

Close all programs currently running. Then close Windows.

70013

The system time could not be modified because an Check the time which is to be set. invalid value was entered. Incorrect separators may have been used.

70014

The system time could not be modified. Possible causes: • An invalid time was transferred. • The Windows user has no right to modify the system time.

Check the time which is to be set. Using Windows NT/2000/XP: The user executing WinCC flexible Runtime must be granted the right to change the system time of the operating system.

Windows rejects the setting request. 70015

The system time could not be read because Windows rejects the reading function.

--

70016

An attempt was made to select a screen by means of a system function or job. This is not possible because the screen number specified does not exist. Or: A screen could not be generated due to insufficient system memory.

Check the screen number in the function or job with the screen numbers configured. Assign the number to a screen if necessary. Check the details for the screen call and whether the screen is blocked for specific users.

Or: The screen is blocked. Or: Screen call has not been executed correctly. 70017

Date/time is not read from the area pointer because Change the address or set up the address in the PLC. the address set in the PLC is either not available or has not been set up.

70018

Acknowledgment that the password list has been successfully imported.

--

70019

Acknowledgment that the password list has been successfully exported.

--

70020

Acknowledgment for activation of alarm reporting.

--

70021

Acknowledgment for deactivation of alarm reporting.

--

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

70022

Acknowledgment to starting the Import Password List action.

--

70023

Acknowledgment to starting the Export Password List action.

--

70024

The value range of the tag has been exceeded in the system function. The calculation of the system function is not performed.

Check the desired calculation and correct it if necessary.

70025

The value range of the tag has been exceeded in the system function. The calculation of the system function is not performed.

Check the desired calculation and correct it if necessary.

70026

No other screens are stored in the internal screen memory. No other screens can be selected.

--

70027

The backup of the RAM file system has been started.

--

70028

The files from the RAM have been copied in the Flash memory. The files from the RAM have been copied in the Flash memory. Following a restart, these saved files are copied back to the RAM file system.

--

70029

Backup of the RAM file system has failed. No backup copy of the RAM file system has been made.

Check the settings in the "Control Panel > OP" dialog and save the RAM file system using the "Save Files" button in the "Persistent Storage" tab.

70030

The parameters configured for the system function are faulty. The connection to the new PLC was not established.

Compare the parameters configured for the system function with the parameters configured for the PLCs and correct them as necessary.

70031

The PLC configured in the system function is not an S7 PLC. The connection to the new PLC was not established.

Compare the S7 PLC name parameter configured for the system function with the parameters configured for the PLC and correct them as necessary.

70032

The object configured with this number in the tab order is not available in the selected screen. The screen changes but the focus is set to the first object.

Check the number of the tab order and correct it if necessary.

70033

An e-mail cannot be sent because a TCP/IP Check the network connection to the SMTP server and connection to the SMTP server no longer exists. re-establish it if necessary. This system alarm is generated only at the first attempt. All subsequent unsuccessful attempts to send an e-mail will no longer generate a system alarm. The event is regenerated when an e-mail has been successfully sent in the meantime. The central e-mail component in WinCC flexible Runtime attempts, in regular intervals (1 minute), to establish the connection to the SMTP server and to send the remaining e-mails.

70034

Following a disruption, the TCP/IP connection to the SMTP server could be re-established. The queued e-mails are then sent.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

--

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ITEM 2500

Appendix A.2 System alarms Number

Effect/causes

Remedy

70036

No SMTP server for sending e-mails is configured. An attempt to connect to an SMTP server has failed and it is not possible to send e-mails. WinCC flexible Runtime generates the system alarm after the first attempt to send an e-mail.

Configure an SMTP server:

70037

An e-mail cannot be sent for unknown reasons. The contents of the e-mail are lost.

Check the e-mail parameters (recipient etc.).

70038

The SMTP server has rejected sending or forwarding an e-mail because the domain of the recipient is unknown to the server or because the SMTP server requires authentication. The contents of the e-mail are lost.

Check the domain of the recipient address or deactivate the authentication on the SMTP server if possible. SMTP authentication is currently not used in WinCC flexible Runtime.

70039

The syntax of the e-mail address is incorrect or contains illegal characters. The contents of the e-mail are discarded.

Check the e-mail address of the recipient.

70040

The syntax of the e-mail address is incorrect or contains illegal characters.

--

70041

The import of the user management was aborted due to an error. Nothing was imported.

Check your user management or transfer it again to the panel.

70042

The value range for the tags has been exceeded while executing the system function.

Check the desired calculation and correct it if necessary.

In WinCC flexible Engineering System using "Device settings > Device settings" In the Windows CE operating system using "Control Panel > Internet Settings > E-mail > SMTP Server"

The system function calculation has not been carried out. 70043

The value range for the tags has been exceeded while executing the system function.

Check the desired calculation and correct it if necessary.

The system function calculation has not been carried out.

80000 - Archive alarms Number

Effect/causes

Remedy

80001

The log specified is filled to the size defined (in percent) and must be stored elsewhere.

Store the file or table by executing a ‘move’ or ‘copy’ function.

80002

A line is missing in the specified log.

--

80003

The copying process for logging was not successful. In this case, it is advisable to check any subsequent system alarms, too.

--

80006

Since logging is not possible, this causes a permanent loss of the functionality.

In the case of databases, check whether the corresponding data source exists and start up the system again.

80009

A copying action has been completed successfully.

--

80010

Since the storage location was incorrectly entered in WinCC flexible, this causes a permanent loss of the functionality.

Configure the storage location for the respective log again and restart the system when the full functionality is required.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

80012

Log entries are stored in a buffer. If the values are read to the buffer faster than they can be physically written (using a hard disk, for example), overloading may occur and recording is then stopped.

Archive fewer values. Or: Increase the logging cycle.

80013

The overload status no longer applies. Archiving resumes the recording of all values.

--

80014

The same action was triggered twice in quick succession. Since the process is already in operation, the action is only carried out once.

--

80015

This system alarm is used to report DOS or database errors to the user.

--

80016

The logs are separated by the system function "CloseAllLogs" and the incoming entries exceed the defined buffer size. All entries in the buffer are deleted.

Reconnect the logs.

80017

The number of incoming events cause a buffer overflow. his can be caused, for example, by several copying actions being activated at the same time. All copy jobs are deleted.

Stop the copy action.

80019

The connection between WinCC flexible and all -logs were closed, for example, after executing the system function "CloseAllLogs". Entries are written to the buffer and are then written to the logs when a connection is re-established. There is no connection to the storage location and the storage medium may be replaced, for example.

80020

The maximum number of simultaneously copy operations has been exceeded. Copying is not executed.

Wait until the current copying actions have been completed, then restart the last copy action.

80021

An attempt was made to delete a log which is still busy with a copy action. Deletion has not been executed.

Wait until the current copying actions have been completed, then restart the last action

80022

An attempt was made to use the system function "StartSequenceLog" to start a sequence log for a log which is not configured as a sequence log. No sequence log file is created.

In the project, check • If the "StartSequenceLog" system function was properly configured • if the tag parameters are properly provided with data on the HMI device

80023

An attempt was made to copy a log to itself. The log is not copied.

In the project, check • if the "CopyLog" system function was properly configured • if the tag parameters are properly provided with data on the HMI device

80024

The "CopyLog" system function does not allow copying when the target log already contains data ("Mode" parameter). The log is not copied.

Edit the "CopyLog" system function in the project if necessary. Before you initiate the system function, delete the destination log file.

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ITEM 2500

Appendix A.2 System alarms Number

Effect/causes

Remedy

80025

You have canceled the copy operation. Data written up to this point are retained. The destination log file (if configured) is not deleted. The cancellation is reported by an error entry $RT_ERR$ at the end of the destination log.

--

80026

This alarm is output after all logs are initialized. Values are written to the logs from then on. Prior to this, no entries are written to the logs, irrespective whether WinCC flexible Runtime is active or not.

--

80027

The internal Flash memory has been specified as the storage location for a log. This is not permissible. No values are written to this log and the log file is not created.

Configure "Storage Card" or a network path as the storage location.

80028

The alarm returns a status report indicating that the logs are currently being initialized. No values are logged until the alarm 80026 is output.

--

80029

The number of logs specified in the alarm could not be initialized. The logs are initialized. The faulty log files are not available for logging jobs.

Evaluate the additional system alarms related to this alarm. Check the configuration, the ODBC (Open Database Connectivity) and the specified drive.

80030

The structure of the existing log file does not match the expected structure. Logging is stopped for this log.

Delete the existing log data manually, in advance.

80031

The log in CSV format is corrupted. The log cannot be used.

Delete the faulty file.

80032

Logs can be assigned events. These are triggered as soon as the log is full. If WinCC flexible Runtime is started and the log is already full, the event is not triggered. The log specified no longer logs data because it is full.

Close WinCC flexible Runtime, delete the log, then restart WinCC flexible Runtime. Or: Configure a button which contains the same actions as the event and press it.

80033

"System Defined" is set in the data log file as the Install MSDE again. data source name. This causes an error. No data is written to the database logs, whereas the logging to the CSV logs works.

80034

An error has occurred in the initialization of the No action is necessary. However, it is recommended to logs. An attempt has been made to create the save the backup files or delete them in order to make tables as a backup. This action was successful. A the space available again. backup has been made of the tables of the corrupted log file and the cleared log was restarted.

80035

An error has occurred in the initialization of the logs. An attempt has been made to create backups of the tables and this has failed. No logging or backup has been performed.

It is recommended to save the backups or to delete them in order to release memory.

80044

The export of a log was interrupted because Runtime was closed or due to a power failure. It was detected that the export needed to be resume when Runtime restarted.

The export resumes automatically.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

80045

The export of a log was interrupted due to an error in the connection to the server or at the server itself.

The export is repeated automatically. Check: • The connection to the server • If the server is running • If there is enough free space on the server

80046

The destination file could not be written while exporting the log.

Check whether there is enough space on the server and it you have permission to create the log file.

80047

The log could not be read while exporting it.

Check whether the storage medium is correctly inserted.

80049

The log could not be renamed while preparing to export it. The job can not be completed."

Check whether the storage medium is correctly inserted and if there is sufficient space on the medium.

80050

The log which shall be exported is not closed. The job can not be completed.

Make sure the "CloseAll Logs" system function is called before using the "ExportLog" system function. Change the configuration as required.

90000 - FDA alarms Number

Effect/causes

90024

No operator actions can be logged due to lack of Make more space available by inserting an empty space on the storage medium for log. The operator storage medium or swapping out the log files on the action will therefore not be executed. server using "ExportLog".

Remedy

90025

No user actions can be logged because of error state of the archive. Therefore the user action will not be executed.

90026

No operator actions can be logged because the log Before further operator actions are carried out, the log is closed. The operator action will therefore not be must be opened again using the system function executed. "OpenAllLogs". Change the configuration as required.

Check whether the storage medium is correctly inserted.

90028

The password you entered is incorrect.

Enter the correct password.

90029

Runtime was closed during ongoing operation (perhaps due to a power failure) or a storage medium in use is incompatible with Audit Trail. An Audit Trail is not suitable if it belongs to another project or has already be archived.

Ensure that you are using the correct storage medium.

90030

Runtime was closed during ongoing operation (perhaps due to a power failure).

--

90031

Runtime was closed during ongoing operation (perhaps due to a power failure).

--

90032

Running out of space on the storage medium for log.

Make more space available by inserting an empty storage medium or swapping out the log files on the server using "ExportLog".

90033

No more space on the storage medium for log. As of now, no more operator actions requiring logging will be executed.

Make more space available by inserting an empty storage medium or swapping out the log files on the server using "ExportLog".

90039

You do not have the necessary authorization to perform this action.

Adapt or upgrade your authorizations.

90040

Audit Trail is switched off because of a forced user action.

Activate the "Audit Trail" again using the system function "StartLog".

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ITEM 2500

Appendix A.2 System alarms Number

Effect/causes

Remedy

90041

A user action which has to be logged has been executed without a logged on user.

A user action requiring logging should only be possible with permission. Change the configuration by setting a required permission for the input object.

90044

A user action which has to be confirmed was blocked, because there is another user action pending.

Repeat the user action if necessary.

110000 - Offline function alarms Number

Effect/causes

Remedy

110000

The operating mode was changed. "Offline" mode is now set.

--

110001

The operating mode was changed. "Online" mode is now set.

--

110002

The operating mode was not changed.

Check the connection to the PLCs. Check whether the address area for the area pointer 88 “Coordination" in the PLC is available.

110003

The operating mode of the specified PLC was changed by the system function "SetConnectionMode". The operating mode is now "offline".

--

110004

The operating mode of the specified PLC has been -changed by the system function "SetConnectionMode". The operating mode is now "online".

110005

An attempt was made to use the system function SetConnectionMode to switch the specified PLC to "online" mode, although the entire system is in "offline" mode. This changeover is not allowed. The PLC remains in "offline" mode.

Switch the complete system to "online" mode, then execute the system function again.

110006

The content of the "project version" area pointer does not match the user version configured in WinCC flexible. WinCC flexible Runtime is therefore closed.

Check: • The project ID entered on the PLC. • The project ID entered in WinCC flexible.

120000 - Trend alarms Number

Effect/causes

Remedy

120000

The trend is not displayed because you configured an incorrect axis to the trend or an incorrect trend.

Change the configuration.

120001

The trend is not displayed because you configured an incorrect axis to the trend or an incorrect trend.

Change the configuration.

120002

The trend is not displayed because the tag assigned attempts to access an invalid PLC address.

Check whether the data area for the tag exists in the PLC, the configured address is correct and the value range for the tag is correct.

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ITEM 2500 Appendix A.2 System alarms 130000 - System information alarms Number

Effect/causes

Remedy

130000

The action was not executed.

Close all other programs. Delete files no longer required from the hard disk.

130001

The action was not executed.

Delete files no longer required from the hard disk.

130002

The action was not executed.

Close all other programs. Delete files no longer required from the hard disk.

130003

No data medium found. The operation is canceled.

Check, for example, if • The correct data medium is being accessed • The data medium is inserted

130004

The data medium is write-protected. The operation is canceled.

Check whether access has been made to the correct data carrier. Remove the write protection.

130005

The file is read only. The operation is canceled.

Check whether access has been made to the correct file. Edit the file attributes if necessary.

130006

Access to file failed. The operation is canceled.

Check, for example, if • The correct file is being accessed • The file exists • Another action is preventing simultaneous access to the file

130007

The network connection is interrupted. Records cannot be saved or read over the network connection.

Check the network connection and eliminate the cause of error.

130008

The storage card is not available. Records cannot be saved to / read from the storage card.

Insert the storage card.

130009

The specified folder does not exist on the storage card. Any files saved to this directory are not backed up when you switch off the HMI device.

Insert the storage card.

130010

The maximum nesting depth can be exhausted when, for example, a value change in a script results in the call of another script and the second script in turn has a value change that results in the call of yet a further script etc. The configured functionality is not supported.

Check the configuration.

140000 - Connection alarms chns7: Connection + device Number

Effect/causes

Remedy

140000

An online connection to the PLC is established.

--

140001

The online connection to the PLC was shut down.

--

140003

No tag updating or writing is executed.

Check the connection and if the PLC is switched on. Check the parameter definitions in the Control Panel using "Set PG/PC interface". Restart the system.

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ITEM 2500

Appendix A.2 System alarms Number

Effect/causes

Remedy

140004

No tag update or write operations are executed because the access point or the module configuration is faulty.

Verify the connection and check whether the PLC is switched on. Check the access point or the module configuration (MPI, PPI, PROFIBUS) in the Control Panel with "Set PG/PC interface". Restart the system.

140005

No tag updating or writing is executed because the Use a different HMI device address. HMI device address is incorrect (possibly too high). Verify the connection and check whether the PLC is switched on. Check the parameter definitions in the Control Panel using "Set PG/PC interface". Restart the system.

140006

No tag updating or writing is executed because the baud rate is incorrect.

Select a different baud rate in WinCC flexible (according to module, profile, communication peer, etc.).

140007

Tags are not updated or written because the bus profile is incorrect (see %1). The following parameters could not be written to the registry: 1: Tslot 2: Tqui 3: Tset 4: MinTsdr 5: MaxTsdr 6: Trdy 7: Tid1 8: Tid2 9: Gap Factor 10: Retry Limit

Check the user-defined bus profile. Check the connection and if the PLC is switched on. Check the parameter definitions in the Control Panel using "Set PG/PC interface". Restart the system.

140008

No tag updating or writing is executed because baud rate is incorrect. The following parameters could not be written to the registry: 0: General error 1: Wrong version 2: Profile cannot be written to the registry. 3: The subnet type cannot be written to the registry. 4: The Target Rotation Time cannot be written to the registry. 5: Faulty Highest Address (HSA).

Check the connection and if the PLC is switched on. Check the parameter definitions in the Control Panel using "Set PG/PC interface". Restart the system.

140009

Tags are not updated or written because the module for S7 communication was not found.

Reinstall the module in the Control Panel using "Set PG/PC interface".

140010

No S7 communication partner found because the PLC is shut down. DP/T: The option “PG/PC is the only master” is not set in the Control Panel under “Set PG/PC interface.”

Switch the PLC on. DP/T: If only one master is connected to the network, disable "PG/PC is the only master" in "Set PG/PC interface". If several masters are connected to the network, enable these. Do not change any settings, for this will cause bus errors.

140011

No tag updating or writing is executed because communication is down.

Check the connection and that the communication partner is switched on.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

140012

There is an initialization problem (e.g. when WinCC flexible Runtime was closed in Task Manager). Or: Another application (e.g.STEP7) with different bus parameters is active and the driver cannot be started with the new bus parameters (transmission rate, for example).

Restart the HMI device. Or: Run WinCC flexible Runtime, then start your other applications.

140013

The MPI cable is disconnected and, thus, there is no power supply.

Check the connections.

140014

The configured bus address is in already in use by another application.

Edit the HMI device address in the PLC configuration.

140015

Wrong transmission rate Or: Faulty bus parameters (e.g. HSA) Or: OP address > HSA or: Wrong interrupt vector (interrupt does not arrive at the driver)

Correct the relevant parameters.

140016

The hardware does not support the configured interrupt.

Change the interrupt number.

140017

The set interrupt is in use by another driver.

Change the interrupt number.

140018

The consistency check was disabled by SIMOTION Scout. Only a corresponding note appears.

Enable the consistency check with SIMOTION Scout and once again download the project to the PLC.

140019

SIMOTION Scout is downloading a new project to the PLC. Connection to the PLC is canceled.

Wait until the end of the reconfiguration.

140020

The version in the PLC and that of the project (FWX file) do not match. Connection to the PLC is canceled

The following remedies are available: Download the current version to the PLC using SIMOTION Scout. Regenerate the project using WinCC flexible ES, close WinCC flexible Runtime and restart with a new configuration.

150000 - Connection alarms chnAS511: Connection Number

Effect/causes

Remedy

150000

No more data is read or written. Possible causes: • The cable is defective • The PLC does not respond, is defective, etc. • The wrong port is used for the connection • System overload

Ensure that the cable is plugged in, the PLC is operational, the correct port is being used. Restart the system if the system alarm persists.

150001

Connection is up because the cause of the interruption has been eliminated.

--

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ITEM 2500 Appendix A.2 System alarms 160000 - Connection alarms IVar (WinLC) / OPC: Connection Number

Effect/causes

Remedy

160000

No more data is read or written. Possible causes: • The cable is defective • The PLC does not respond, is defective, etc. • The wrong port is used for the connection • System overload

Ensure that the cable is plugged in, the PLC is operational, the correct port is being used. Restart the system if the system alarm persists.

160001

Connection is up because the cause of the interruption has been eliminated.

--

160010

No connection to the server because the server identification (CLS-ID) cannot be determined. Values cannot be read or written.

Check access rights.

160011

No connection to the server because the server identification (CLS-ID) cannot be determined. Values cannot be read or written.

Check, for example, if • The server name is correct • The computer name is correct • The server is registered

160012

No connection to the server because the server identification (CLS-ID) cannot be determined. Values cannot be read or written.

Check, for example, if • The server name is correct • The computer name is correct • The server is registered Note for advanced users: Interpret the value from HRESULT.

160013

The specified server was started as InProc server. This has not been released and may possibly lead to incorrect behavior because the server is running in the same process area as the WinCC flexible Runtime software.

Configure the server as OutProc Server or Local Server.

160014

Only one OPC server project can be started on a PC/MP. An alarm is output when an attempt is made to start a second project. The second project has no OPC server functionality and cannot be located as an OPC server by external sources.

Do not start a second project with OPC server functionality on the computer.

170000 - S7 dialog alarms Number

Effect/causes

Remedy

170000

S7 diagnostics events are not indicated because it is not possible to log on to the S7 diagnostics functions at this device. The service is not supported.

--

170001

The S7 diagnostics buffer cannot be viewed because communication with the PLC is shut down.

Set the PLC to online mode.

170002

The S7 diagnostics buffer cannot be viewed because reading of the diagnostics buffer (SSL) was canceled with error.

--

170003

An S7 diagnostics event cannot be visualized. The system returns internal error %2.

--

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

170004

An S7 diagnostics event cannot be visualized. The system returns an internal error of error class %2, error number %3.

--

170007

It is not possible to read the S7 diagnostics buffer -(SSL) because this operation was canceled with an internal error of class %2 and error code %3.

180000 - Misc/common alarms Number

Effect/causes

Remedy

180000

A component/OCX received configuration data with Install a newer component. a version ID which is not supported.

180001

System overload because too many actions running in parallel. Not all the actions can be executed, some are rejected.

Several remedies are available: • Generate the alarms at a slower rate (polling) • Initiate scripts and functions at greater intervals If the alarm appears more frequently: Restart the HMI device.

180002

The screen keyboard could not be activated. Possible causes:

Reinstall WinCC flexible Runtime.

"TouchInputPC.exe" was not registered due to a faulty Setup.

190000 - Tag alarms Number

Effect/causes

Remedy

190000

It is possible that the tag is not updated.

--

190001

The tag is updated after the cause of the last error state has been eliminated (return to normal operation).

--

190002

The tag is not updated because communication with the PLC is down.

Select the system function "SetOnline" to go online.

190004

The tag is not updated because the configured tag address does not exist.

Check the configuration.

190005

The tag is not updated because the configured PLC type does not exist for this tag.

Check the configuration.

190006

The tag is not updated because it is not possible to Check the configuration. map the PLC type in the data type of the tag.

190007

The tag value is not modified because the connection to the PLC is interrupted or the tag is offline.

Set online mode or reconnect to the PLC.

190008

The threshold values configured for the tag have been violated, for example, by • A value entered • A system function • A script

Observe the configured or current threshold values of the tag.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

190009

An attempt has been made to assign the tag a Observe the range of values for the data type of the value which is outside the permitted range of tags. values for this data type. For example, a value of 260 was entered for a byte tag or a value of -3 for an unsigned word tag.

190010

Too many values are written to the tag (for example, in a loop triggered by a script). Values are lost because only up to 100 actions are saved to the buffer.

190011

Possible cause 1: The value entered could not be written to the configured PLC tag because the high or low limit was exceeded.

Remedy

The following remedies are available: • Increase the time interval between multiple write actions. • Do not use an array tag longer than 6 words when you configure an acknowledgment on the HMI device using "Acknowledgment HMI". Make sure that the value entered lies within the range of values of the control tags.

The system discards the entry and restores the original value. Possible cause 2: 190012

The connection to the PLC was interrupted.

Check the connection to the PLC.

It is not possible to convert a value from a source format to a target format, for example:

Check the range of values or the data type of the tags.

An attempt is being made to assign a value to a counter that is outside the valid, PLC-specific value range. A tag of the type Integer should be assigned a value of the type String. 190013

304

The user has entered a string that is longer than Only enter strings that do not exceed the permitted tag the tag. The string is automatically shortened to the length. permitted length.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Appendix A.2 System alarms 190100 - Area pointer alarms Number

Effect/causes

Remedy

190100

The area pointer is not updated because the address configured for this pointer does not exist. Type 1 Warnings 2 Errors 3 PLC acknowledgment 4 HMI device acknowledgment 5 LED mapping 6 Trend request 7 Trend transfer 1 8 Trend transfer 2 No.: Consecutive number displayed in WinCC flexible ES.

Check the configuration.

190101

The area pointer is not updated because it is not possible to map the PLC type to the area pointer type. Parameter type and no.: see alarm 190100

--

190102

The area pointer is updated after the cause of the last error state has been eliminated (return to normal operation). Parameter type and no.: See alarm 190100.

--

200000 - PLC coordination alarms Number

Effect/causes

Remedy

200000

Coordination is not executed because the address configured in the PLC does not exist/is not set.

Change the address or set up the address in the PLC.

200001

Coordination is canceled because the write access to the address configured in the PLC is not possible.

Change the address or set the address in the PLC at an area which allows write access.

200002

Coordination is not carried out at the moment because the address format of the area pointer does not match the internal storage format.

Internal error

200003

Coordination can be executed again because the last error state is eliminated (return to normal operation).

--

200004

The coordination may not be executed.

--

200005

No more data is read or written. Possible causes: • The cable is defective • The PLC does not respond, is defective, etc. • System overload

Ensure that the cable is plugged in and the PLC is operational. Restart the system if the system alarm persists.

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ITEM 2500 Appendix A.2 System alarms 200100 - PLC user version alarms Number

Effect/causes

Remedy

200100

Coordination is not executed because the address configured in the PLC does not exist/is not set.

Change the address or set up the address in the PLC.

200101

Coordination is canceled because the write access to the address configured in the PLC is not possible.

Change the address or set the address in the PLC at an area which allows write access.

200102

Coordination is not carried out at the moment because the address format of the area pointer does not match the internal storage format.

Internal error

200103

Coordination can be executed again because the last error state is eliminated (return to normal operation).

--

200104

The coordination may not be executed.

--

200105

No more data is read or written. Possible causes: • The cable is defective • The PLC does not respond, is defective, etc. • System overload

Ensure that the cable is plugged in and the PLC is operational. Restart the system if the system alarm persists.

210000 - PLC job alarms Number

Effect/causes

Remedy

210000

Jobs are not processed because the address configured in the PLC does not exist/has not been set up.

Change the address or set up the address in the PLC.

210001

Jobs are not processed because read/write access to the address configured in the PLC is not possible.

Change the address or set up the address in the PLC in an area which allows read/write access.

210002

Jobs are not executed because the address format of the area pointer does not match the internal storage format.

Internal error

210003

The job buffer is processed again because the last error status has been eliminated (return to normal operation).

--

210004

It is possible that the job buffer will not be processed.

--

210005

A control request with an illegal number was initiated.

Check the PLC program.

210006

An error occurred while attempting to execute the control request. As a result, the control request is not executed. Observe the next/previous system alarms.

Check the parameters of the control request. Recompile the configuration.

220000 - WinCC channel adapter alarms Number

Effect/causes

Remedy

220001

The tag is not downloaded because the associated communication driver / HMI device does not support the download of Boolean/discrete data types.

Change the configuration.

220002

The tag is not downloaded because the associated communication driver / HMI device does not support write access to the data type BYTE.

Change the configuration.

220003

The communication driver cannot be loaded. The driver may not be installed.

Install the driver by reinstalling WinCC flexible Runtime.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

220004

Communication is down and no update data is transferred because the cable is not connected or defective etc.

Check the connection.

220005

Communication is up.

--

220006

The connection between the specified PLC and the specified port is active.

--

220007

The connection to the specified PLC is interrupted at the specified port.

Check whether • The cable is plugged in • The PLC is OK • The correct port is used • Your configuration is OK (port parameters, protocol settings, PLC address)

220008

The communication driver cannot access or open the specified port. The port may be in use by another application or the port used is not available on the destination device. There is no communication with the PLC.

Close all the applications which access this port and restart the computer. Use another port of the system.

Restart the system if the system alarm persists.

230000 - View alarms Number

Effect/causes

Remedy

230000

The value entered could not be accepted. The system discards the entry and restores the previous value. Either • The value range has been exceeded • Illegal characters have been entered • The maximum permitted number of users has been exceeded

Enter a practical value or delete any unneeded users.

230002

The currently logged in user has not the required authorization. The system therefore discards the input and restored the previous value.

Log on as a user with appropriate authorization.

230003

Changeover to the specified screen failed because the screen is not available/configured. The current screen remains selected.

Configure the screen and check the screen selection function.

230005

The value range of the tag has been exceeded in the I/O field. The original value of the tag is retained.

Observe the range of values for the tag when entering a value.

230100

During navigation in the web browser, the system returned a message which may be of interest to the user. The web browser continues to run but may not (fully) show the new page.

Navigate to another page.

230200

The connection to the HTTP channel was interrupted due to an error. This error is explained in detail by another system alarm. Data is no longer exchanged.

Check the network connection. Check the server configuration.

230201

The connection to HTTP channel was established. Data is exchanged.

--

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ITEM 2500

Appendix A.2 System alarms Number

Effect/causes

Remedy

230202

WININET.DLL has detected an error. This error usually occurs when an attempt to connect to the server fails or the server refuses to connect because the client lacks the proper authorization. An unknown server certificate may also be the cause if the connection is encrypted by means of SSL. The alarm text provides details. This text is always in the language of the Windows installation because it is returned by the Windows OS. Process values are no longer exchanged.

Depending on the cause: When an attempt to connect fails or a timeout error occurs: • Check the network connection and the network • Check the server address • Check whether the WebServer is actually running on the destination station. Faulty authorization: • The configured user name and/or password do not match those on the server. Establish consistency When the server certificate is rejected: Certificate signed by an unknown CA ( ): • Either ignore this item in your project, or • Install a certificate that has been signed with a root certificate known to the client computer The date of the certificate is invalid: • Either ignore this item in your project, or • Install a certificate with a valid date on the server Invalid CN (Common Name or Computer Name): • Either ignore this item in your project, or • Install a certificate with a name that corresponds to that of the server address

230203

Although a connection can be made to the server, the HTTP server refuses to connect because • WinCC flexible Runtime is not running on the server, or • The HTTP channel is not supported (503 Service unavailable)

Error 503 Service unavailable: Check that WinCC flexible Runtime is running on the server and the HTTP channel is supported.

Other errors can only occur if the Webserver does not support the HTTP channel. The language of the alarm text depends on the Webserver. Data is not exchanged. 230301

An internal error has occurred. An English text explains the error in more detail. This may be caused by insufficient memory. OCX does not work.

--

230302

The name of the remote server cannot be resolved. The attempt to connect failed.

Check the configured server address. Check whether the DNS service is available on the network.

230303

The remote server is not running on the addressed computer. Wrong server address. The attempt to connect failed

Check the configured server address. Check whether the remote server is running on the target computer.

230304

The remote server on the addressed computer is incompatible with VNCOCX. The attempt to connect failed.

Use a compatible remote server.

230305

The authentication has failed because the password is incorrect. The attempt to connect failed.

Configure the correct password.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

230306

Error in the connection to the remote server. This may Check whether occur as a result of network problems. • The bus cable is plugged in The attempt to connect failed. • There are network problems

230307

The connection to the remote server was shut down because • The remote server was shut down, or • The user instructed the server to close all connections

--

The connection is closed. 230308

This alarm provides information on the connection status. An attempt is made to connect.

--

240000 - Authorization alarms Number

Effect/causes

Remedy

240000

WinCC flexible Runtime is operating in demo mode. You have no authorization or your authorization is corrupted.

Install the authorization.

240001

WinCC flexible Runtime is operating in demo mode. Too many tags are configured for the installed version.

Load an adequate authorization / powerpack.

240002

WinCC flexible Runtime is operating with a timelimited emergency authorization.

Restore the full authorization.

240004

Error while reading the emergency authorization. WinCC flexible Runtime is operating in demo mode.

Restart WinCC flexible Runtime, install the authorization or repair the authorization (see Commissioning Instructions Software Protection).

240005

The Automation License Manager has detected an internal system fault. Possible causes: • A corrupt file • A defective installation • No free space for the Automation License Manager etc.

Reboot the HMI device or PC. If this does not solve the problem, remove the Automation License Manager and install it again.

250000 - S7 Force alarms Number

Effect/causes

Remedy

250000

The tag in the specified line in "Status Force" is not updated because the address configured for this tag is not available.

Check the set address and then verify that the address is set up in the PLC.

250001

The tag in the specified line in "Status Force" is not updated because the PLC type configured for this tag does not exist.

Check the set address.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

250002

The tag in the specified line in "Status Force" is not updated because it is not possible to map the PLC type in the tag type.

Check the set address.

250003

An attempt to connect to the PLC failed. The tags are not updated.

Check the connection to the PLC. Check that the PLC is switched on and is online.

260000 - Password system alarms Number

Effect/causes

Remedy

260000

An unknown user or an unknown password has been entered in the system. The current user is logged off from the system.

Log on to the system as a user with a valid password.

260001

The logged in user does not have sufficient authorization to execute the protected functions on the system.

Log on to the system as a user with sufficient authorization.

260002

This alarm is triggered by the system function "TrackUserChange".

--

260003

The user has logged off from the system.

--

260004

The user name entered into the user view already exists in the user management.

Select another user name because user names have to be unique in the user management.

260005

The entry is discarded.

Enter a shorter user name.

260006

The entry is discarded.

Use a shorter or longer password.

260007

The logon timeout value entered is outside the valid range of 0 to 60 minutes. The new value is discarded and the original value is retained.

Enter a logon timeout value between 0 and 60 minutes.

260008

An attempt was made to read a PTProRun.pwl file -created with ProTool V 6.0 in WinCC flexible. Reading the file was canceled due to incompatibility of the format.

260009

You have attempted to delete the user "Admin" or "PLC User". These users are fixed components of the user management and cannot be deleted.

If you need to delete a user, because perhaps you have exceeded the maximum number permitted, delete another user.

260012

The passwords entered in the "Change Password" dialog and the confirmation field are not identical. The password has not been changed. User will be logged off.

You have to log on to the system again. Then enter the identical password twice to be able to change the password.

260013

The password entered in the "Change Password" dialog is invalid because it is already in use. The password has not been changed. User will be logged off.

You have to log on to the system again. Then enter a new password that has not been used before.

260014

You have tried unsuccessfully to log on 3 times in succession. You will be locked out and assigned to group no. 0.

You can log on to the system with your correct password. Only an administrator can change the assignment to a group.

260023

The password you entered does not meet the necessary security guidelines.

Enter a password that contains at least one number.

260024

The password you entered does not meet the necessary security guidelines.

Enter a password that contains at least one character.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

260025

The password you entered does not meet the necessary security guidelines.

Enter a password that contains at least one special character.

260028

Upon system start-up, an attempt to log on, or when trying to change the password of a SIMATIC log-on user, the system attempts to access the SIMATIC Logon Server.

Check the connection to the SIMATIC Logon Server and its configuration; for example:

The SIMATIC Logon user is not associated to any or several groups.

Check the user data on the SIMATIC Logon Server and the configuration in your WinCC flexible project. A user may only be assigned to one group.

1. Port number

2. IP address If attempting to log on, the new user is not logged in. If 3. Server name a different user was logged on before, then this user 4. Functional transfer cable is logged off. Or use a local user. 260029

The new user is not logged in. If a different user was logged on before, then this user is logged off. 260030

The SIMATIC Logon user could not change his password on the SIMATIC Logon Server. The new password may not comply with the password regulations on the server or the user does not have the right to change his password.

260031

It was not possible to log the user on to the SIMATIC Logon Server. The user name or the password could be incorrect or the user does not have sufficient rights to log on.

Log in again and choose a different password. Check the password rules on the SIMATIC Logon Server.

The old password remains and the user is logged off. Try again. If necessary, check the password data on the SIMATIC Logon Server.

The new user is not logged in. If a different user was logged on before, then this user is logged off. 260032

It was not possible to log the user on to the SIMATIC Logon Server as his account is blocked.

Check the user data on the SIMATIC Logon Server.

The new user is not logged in. If a different user was logged on before, then this user is logged off. 260033

The action change password or log on user could not be carried out.

Check the configuration of the SIMATIC Logon Server.

260034

The last logon operation has not yet ended. A user action or a logon dialog can therefore not be called.

Wait until the logon operation is complete.

The logon dialog is not opened. The user action is not executed. 260035

The last attempt to change the password was not completed. A user action or a logon dialog can therefore not be called.

Wait until the procedure is complete.

The logon dialog is not opened. The user action is not executed. 260036

There are insufficient licenses on the SIMATIC Logon Sever. The logon is not authorized.

Check the licensing on the SIMATIC Logon Server.

260037

There is no license on the SIMATIC Logon Sever. A logon is not possible.

Check the licensing on the SIMATIC Logon Server.

It is not possible to log on via the SIMATIC Logon Server, only via a local user.

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Appendix A.2 System alarms 270000 - System alarms Number

Effect/causes

Remedy

270000

A tag is not indicated in the alarm because it attempts to access an invalid address in the PLC.

Check whether the data area for the tag exists in the PLC, the configured address is correct and the value range for the tag is correct.

270001

There is a device-specific limit as to how many alarms -may be queued for output (see the operating instructions). This limit has been exceeded. The view no longer contains all the alarms. However, all alarms are written to the alarm buffer.

270002

The view shows alarms of a log for which there is no data in the current project. Wildcards are output for the alarms.

Delete older log data if necessary.

270003

The service cannot be set up because too many devices want to use this service. A maximum of four devices may execute this action.

Reduce the number of HMI devices which want to use the service.

270004

Access to persistent buffer is not possible. Alarms cannot be restored or saved.

If the problems persist at the next startup, contact Customer Support (delete Flash).

270005

Persistent buffer damaged: Alarms cannot be restored.

If the problems persist at the next startup, contact Customer Support (delete Flash).

270006

Project modified: Alarms cannot be restored from the persistent buffer.

The project was generated and transferred new to the HMI device; The error should no longer occur when the device starts again.

270007

A configuration problem is preventing the restore (a DLL is missing, a directory is unknown, etc.).

Update the operating system and then transfer your project again to the HMI device.

280000 - DPHMI alarms Connection Number

Effect/causes

Remedy

280000

Connection is up because the cause of the interruption has been eliminated.

--

280001

No more data is read or written. Possible causes: • The cable is defective • The PLC does not respond, is defective, etc. • The wrong port is used for the connection • System overload

Check whether • The cable is plugged in • The PLC is OK • The correct port is used

The connection used requires a function block in the PLC. The function block has responded. Communication is now enabled.

--

280002

312

Restart the system if the system alarm persists.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

280003

The connection used requires a function block in the PLC. The function block has not responded.

Check whether • The cable is plugged in • The PLC is OK • The correct port is used Restart the system if the system alarm persists. Remedy depends on the error code: 1: The function block must set the COM bit in the response container. 2: The function block must not set the ERROR bit in the response container. 3: The function block must respond within the specified time (timeout). 4: Go online to the PLC.

280004

The connection to the PLC is interrupted. There is no data exchange at present.

Check the connection parameters in WinCC flexible. Ensure that the cable is plugged in, the PLC is operational, the correct port is being used. Restart the system if the system alarm persists.

290000 - Recipe system alarms Number

Effect/causes

Remedy

290000

The recipe tag could not be read or written. It is assigned the start value. The alarm can be entered in the alarm buffer for up to four more failed tags if necessary. After that, alarm 290003 is output.

Check in the configuration that the address has been set up in the PLC.

290001

An attempt has been made to assign a value to a recipe tag which is outside the value range permitted for this type. The alarm can be entered in the alarm buffer for up to four more failed tags if necessary. After that, alarm 290004 is output.

Observe the value range for the tag type.

290002

It is not possible to convert a value from a source format to a target format. The alarm can be entered in the alarm buffer for up to four more failed recipe tags if necessary. After that, alarm 290005 is output.

Check the value range or type of the tag.

290003

This alarm is output when alarm number 290000 is triggered more than five times. In this case, no further separate alarms are generated.

Check in the configuration that the tag addresses have been set up in the PLC.

290004

This alarm is output when alarm number 290001 is triggered more than five times. In this case, no further separate alarms are generated.

Observe the value range for the tag type.

290005

This alarm is output when alarm number 290002 is triggered more than five times. In this case, no further separate alarms are generated.

Check the value range or type of the tag.

290006

The threshold values configured for the tag have been Observe the configured or current threshold values violated by values entered. of the tag.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

290007

There is a difference between the source and target structure of the recipe currently being processed. The target structure contains an additional data recipe tag which is not available in the source structure. The data recipe tag specified is assigned its start value.

Insert the specified data recipe tag in the source structure.

290008

There is a difference between the source and target Remove the specified data recipe tag in the specified structure of the recipe currently being processed. The recipe from the project. source structure contains an additional data recipe tag which is not available in the target structure and therefore cannot be assigned. The value is rejected.

290010

The storage location configured for the recipe is not permitted. Possible causes: Illegal characters, write protection, data carrier out of space or does not exist.

Check the configured storage location.

290011

The record with the specified number does not exist.

Check the source for the number (constant or tag value)

290012

The recipe with the specified number does not exist.

Check the source for the number (constant or tag value)

290013

An attempt was made to save a record under a record The following remedies are available: number which already exists. • Check the source for the number (constant or tag The action is not executed. value) • First, delete the record • Change the "Overwrite" function parameter

290014

The file specified to be imported could not be found.

Check: • The file name • Ensure that the file is in the specified directory

290020

Alarm reporting that the download of records from the HMI device to the PLC has started.

--

290021

Alarm reporting that the download of records from the HMI device to the PLC was completed.

--

290022

Alarm reporting that the download of records from the HMI device to the PLC was canceled due to an error.

Check in the configuration whether: • The tag addresses are configured in the PLC • The recipe number exists • The record number exist • The "Overwrite" function parameter is set

290023

Alarm reporting that the download of records from the PLC to the HMI device has started.

--

290024

Alarm reporting that the download of records from the PLC to the HMI device was completed.

---

290025

Alarm reporting that the download of records from the PLC to the HMI device was canceled due to an error.

Check in the configuration whether: • The tag addresses are configured in the PLC • The recipe number exists • The record number exist • The "Overwrite" function parameter is set

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

290026

An attempt has been made to read/write a record although the record is not free at present. This error may occur in the case of recipes for which downloading with synchronization has been configured.

Set the record status to zero.

290027

Unable to connect to the PLC at present. As a result, the record can neither be read nor written. Possible causes: No physical connection to the PLC (no cable plugged in, cable is defect) or the PLC is switched off.

Check the connection to the PLC.

290030

This alarm is output after you selected screen which contains a recipe view in which a record is already selected.

Reload the record from the storage location or retain the current values.

290031

While saving, it was detected that a record with the specified number already exists.

Overwrite the record or cancel the action.

290032

While exporting records it was detected that a file with the specified name already exists.

Overwrite the file or cancel the process.

290033

Confirmation request before deleting records.

--

290040

A record error with error code %1 that cannot be described in more detail occurred. The action is canceled. It is possible that the record was not installed correctly on the PLC.

Check the storage location, the record, the "Data record" area pointer and if necessary, the connection to the PLC. Restart the action after a short time. If the error persists, contact Customer Support. Forward the relevant error code to Customer Support.

290041

A record or file cannot be saved because the storage location is full.

Delete files no longer required.

290042

An attempt was made to execute several recipe actions simultaneously. The last action was not executed.

Trigger the action again after waiting a short period.

290043

Confirmation request before storing records.

--

290044

The data store for the recipe has been destroyed and is deleted.

--

290050

Alarm reporting that the export of records has started.

--

290051

Alarm reporting that the export of records was completed.

--

290052

Alarm reporting that the export of records was canceled due to an error.

Ensure that the structure of the records at the storage location and the current recipe structure on the HMI device are identical.

290053

Alarm reporting that the import of records has started.

--

290054

Alarm reporting that the import of records was completed.

--

290055

Alarm reporting that the import of records was canceled due to an error.

Ensure that the structure of the records at the storage location and the current recipe structure on the HMI device are identical.

290056

Error when reading/writing the value in the specified line/column. The action was canceled.

Check the specified line/column.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

290057

The tags of the recipe specified were toggled from "offline" to "online" mode. Each change of a tag in this recipe is now immediately downloaded to the PLC.

--

290058

The tags of the specified recipe were toggled from "offline" to "online" mode. Modifications to tags in this recipe are no longer immediately transferred to the PLC but must be transferred there explicitly by downloading a record.

--

290059

Alarm reporting that the specified record was saved.

--

290060

Alarm reporting that the specified record memory was cleared.

--

290061

Alarm reporting that clearing of record memory was canceled due to an error.

--

290062

The record number is above the maximum of 65536. This record cannot be created.

Select another number.

290063

This occurs with the system function Check the "ExportDataRecords" system function. "ExportDataRecords" when the parameter "Overwrite" is set to No. An attempt has been made to save a recipe under a file name which already exists. The export is canceled.

290064

Alarm reporting that the deletion of records has started.

--

290065

Alarm reporting that the deletion of records has successfully completed.

--

290066

Confirmation request before deleting records.

--

290068

Security request to confirm if all records in the recipe should be deleted.

--

290069

Security request to confirm if all records in the recipe should be deleted.

--

290070

The record specified is not in the import file.

Check the source of the record number or record name (constant or tag value).

290071

During the editing of record values, a value was entered which exceeded the low limit of the recipe tag. The entry is discarded.

Enter a value within the limits of the recipe tag.

290072

When editing record values, a value was entered which exceeds the high limit of the recipe tag. The entry is discarded.

Enter a value within the limits of the recipe tag.

290073

An action (e.g. saving a record) failed due to an unknown error. The error corresponds to the status alarm IDS_OUT_CMD_EXE_ERR in the large recipe view.

--

290074

While saving, it was detected that a record with the specified number already exists but under another name.

Overwrite the record, change the record number or cancel the action.

290075

A record with this name already exists. The record is not saved.

Please select a different record name.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

290110

The default values could not be set due to an error.

--

290111

The Recipes subsystem cannot be used. Recipe views have no content and recipe-specific functions will not be performed.

Transfer the project to the device again, together with the recipes (the corresponding check box in the Transfer dialog must be checked).

Possible causes: • An error occurred while transferring the recipes. • The recipe structure was changed in ES. When the project was downloaded again, the recipes were not transferred with it. This means that the new configuration data is not being transferred to the old recipes on the device.

300000 - Alarm_S alarms Number

Effect/causes

Remedy

300000

Faulty configuration of process monitoring (e.g. using PDiag or S7-Graph): More alarms are queued than specified in the specifications of the CPU. No further ALARM_S alarms can be managed by the PLC and reported to the HMI devices.

Change the PLC configuration.

300001

ALARM_S is not registered on this PLC.

Select a controller that supports the ALARM_S service.

310000 - Report system alarms Number

Effect/causes

Remedy

310000

An attempt is being made to print too many reports in Wait until the previous active log was printed. parallel. Repeat the print job if necessary. Only one log file can be output to the printer at a given time; the print job is therefore rejected.

310001

An error occurred on triggering the printer. The report is either not printed or printed with errors.

Evaluate the additional system alarms related to this alarm. Repeat the print job if necessary.

320000 - Alarms Number

Effect/causes

Remedy

320000

The movements have already been indicated by another device. The movements can no longer be controlled.

Deselect the movements on the other display units and select the motion control screen on the required display unit.

320001

The network is too complex. The faulty addresses cannot be indicated.

View the network in STL.

320002

No diagnosable alarm message (error) selected. The unit associated with the alarm message could not be selected.

Select a diagnostics alarm from the ZP_ALARM alarm screen.

320003

No alarm message (error) exists for the selected unit. The detail view cannot visualize any networks.

Select the defective unit from the overview screen.

320004

The required signal states could not be read by the PLC. The faulty addresses cannot be found.

Check the consistency between the configuration on the display unit and the PLC program.

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ITEM 2500 Appendix A.2 System alarms Number

Effect/causes

Remedy

320005

The project contains ProAgent elements which are not In order to run the project, install the optional installed. ProAgent diagnostic functions cannot be ProAgent package. performed

320006

You have attempted to execute a function which is not Check the type of the selected unit. supported in the current constellation.

320007

No error-triggering addresses were found on the networks. ProAgent cannot indicate any faulty addresses.

320008

The diagnostic data stored in the configuration are not Transfer the project to the HMI device again. synchronized with those in the PLC. ProAgent can only indicate the diagnostic units.

320009

The diagnostic data stored in the configuration are not Transfer the project to the HMI device again. synchronized with those in the PLC. The diagnostic screens can be operated as usual. ProAgent may be unable to show all diagnostic texts.

320010

The diagnostic data stored in the configuration are not Transfer the project to the HMI device again. synchronized with those in STEP7. The ProAgent diagnostics data is not up-to-date.

320011

A unit with the corresponding DB number and FB number does not exist. The function cannot be executed.

Check the parameters of the "SelectUnit" function and the units selected in the project.

320012

The "Step sequence mode" dialog is no longer supported.

Use the ZP_STEP step sequence screen from the corresponding standard project for your project. Instead of calling the Overview_Step_Sequence_Mode function, call the "FixedScreenSelection" function using ZP_STEP as the screen name.

320014

The selected PLC cannot be evaluated for ProAgent. The Alarm view assigned to the "EvaluateAlarmDisplayFault" system function could not be found.

Check the parameters of the "EvaluateAlarmDisplayFault" system function.

Switch the detail screen to STL layout mode and check the status of the addresses and exclusion addresses.

330000 - GUI alarms Number

Effect/causes

Remedy

330022

Too many dialogs are open on the HMI device.

Close all dialogs you do not require on the HMI device.

330026

The password will expire after the number of days shown.

Enter a new password.

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ITEM 2500 Appendix A.2 System alarms 350000 - GUI alarms Number

Effect/causes

Remedy

350000

PROFIsafe packages have not arrived within the necessary period. There is a communication problem with the F-CPU.

Check the WLAN connection.

RT is terminated 350001

PROFIsafe packages have not arrived within the necessary period. There is a communication problem with the F-CPU.

Check the WLAN connection.

The PROFIsafe connection is re-established. 350002

An internal error has occurred.

Internal error

Runtime is terminated 350003

Feedback concerning the connection established with the F-CPU.

--

The Emergency-Off buttons are active immediately. 350004

PROFIsafe communication was set and the connection was cleared. The Runtime can be terminated.

--

The Emergency-Off buttons are deactivated immediately. 350005

Incorrect address configured for the F-slave. No PROFIsafe connection.

Check and modify the address of the F slave in WinCC flexible ES.

350006

The acknowledgement buttons in the "Acknowledgement" and "Panic" functions were not tested before logging on.

Press the two acknowledgement buttons one after another in the "Acknowledgement" and "Panic" positions.

It is not possible to log onto the effective range. 350008

The wrong number of failsafe buttons was configured.

Change the number of failsafe buttons in the project.

No PROFIsafe connection. 350009

The device is in Override mode.

Exit Override mode.

It may no longer be possible to detect the location because transponder detection fails. 350010

Internal error: The device has no failsafe buttons.

Send the device back. Worldwide contact person

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ITEM 2500

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ITEM 2500

B

Abbreviations

ANSI

American National Standards Institution

CPU

Central Processing Unit

CSV

Comma Separated Values

CTS

Clear To Send

DC

Direct Current

DCD

Data Carrier Detect

DHCP

Dynamic Host Configuration Protocol

DIL

Dual-in-Line (electronic chip housing design)

DNS

Domain Name System

DP

Distributed I/O

DSN

Data Source Name

DSR

Data Set Ready

DTR

Data Terminal Ready

IO

Input and Output

ESD

Components and modules endangered by electrostatic discharge

EMC

Electromagnetic Compatibility

EN

European standard

ES

Engineering System

ESD

Components and modules endangered by electrostatic discharge

GND

Ground

HF

High Frequency

HMI

Human Machine Interface

IEC

International Electronic Commission

IF

Interface

IP

Internet Protocol

LED

Light Emitting Diode

MAC

Media Access Control

MOS

Metal Oxide Semiconductor

MPI

Multipoint Interface (SIMATIC S7)

MS

Microsoft

MTBF

Mean Time Between Failures

n. c.

Not connected

OP

Operator Panel

PC

Personal Computer

PG

Programming device

PPI

Point-to-Point Interface (SIMATIC S7)

RAM

Random Access Memory

PELV

Protective Extra Low Voltage

RJ45

Registered Jack Type 45

RTS

Request to send

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Abbreviations

322

RxD

Receive Data

SD Card

Security Digital Card

SELV

Safety Extra Low Voltage

SP

Service Pack

PLC

Programmable Logic Controller

STN

Super Twisted Nematic

Sub-D

Subminiature D (plug)

TAB

Tabulator

TCP/IP

Transmission Control Protocol/Internet Protocol

TFT

Thin Film Transistor

TTY

Teletype

TxD

Transmit Data

UL

Underwriter’s Laboratory

USB

Universal Serial Bus

UPS

Uninterruptible power supply

WINS

Windows Internet Naming Service

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Glossary "Transfer" mode An operating mode of the HMI device in which an executable project is transferred from the configuring PC to an HMI device.

Acknowledge Acknowledgment of an alarm confirms that it has been noted.

Alarm logging Output of user-specific alarms to a printer, in parallel to their output to the HMI device screen.

Alarm, acknowledging Acknowledgment of an alarm confirms that it has been noted.

Alarm, activated Moment at which an alarm is triggered by the PLC or HMI device.

Alarm, deactivated Moment at which the initiation of an alarm is reset by the PLC.

Alarm, user-specific A user-specific alarm designates a certain operating status of the plant connected to the HMI device via the PLC.

Automation device PLC of the SIMATIC S5 series, for example the AG S5-115U

Automation system Controller of the SIMATIC S7 series, for example a SIMATIC S7-300

Bootloader Used to start the operating system. Automatically started when the HMI device is switched on. After the operating system has been loaded, the Loader opens.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500

Glossary

Configuration software Software used to generate projects used for the purpose of process visualization. An example of configuring software is WinCC flexible.

Configuring PC A configuring PC is a programming device or PC on which plant projects are created using an engineering software.

Display duration Defines whether a system alarm is displayed on the HMI device and the duration of the display.

EMC Electromagnetic compatibility is the ability of electrical equipment to function properly in its electromagnetic environment without influencing this environment.

Event Functions are triggered by defined incoming events. Events can be configured. Events which can be assigned to a button include "Press" and "Release", for example.

Field array Area reserved in configured screens for the input and output of values.

Flash memory Non-volatile memory with EEPROM chips, used as mobile storage medium or as memory module installed permanently on the motherboard.

Function keys Key on the HMI device which supports user-specific functions. A function is assigned to the key in the configuration. The assignment of the keys may be specific to an active screen or not.

Half Brightness Life Time Time period after which the brightness reaches 50% of the original value. The specified value is dependent on the operating temperature.

Hardcopy Output of the screen content to a printer.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Glossary

HMI device An HMI device is a device used for the operation and monitoring of machines and plants. The statuses of the machine or plant are indicated by means of graphic elements or by indicator lamps on the HMI device. The operating elements of the HMI device allow the operator to interact with the processes of the machine or plant.

HMI device image A file that can be transferred from the configuring PC to the HMI device. The HMI device image contains the operating system and elements of the runtime software required to run a project.

I/O field An I/O field enables the input or output of values on the HMI device which are transferred to the PLC.

Infotext An infotext is a configured information on objects within a project. Infotext for an alarm, for example, may contain information on the cause of the fault and troubleshooting routines.

Object An object is a component of a project. Example: screen or alarm. Objects are used to view or enter texts and values on the HMI device.

Operating element Component of a project used to enter values and trigger functions. A button, for example, is an operating element.

Plant General term referring to machines, processing centers, systems, plants and processes which are operated and monitored on an HMI device.

PLC A PLC is a general term for devices and systems with which the HMI device communicates, e.g. SIMATIC S7.

PLC job A PLC job triggers a function for the PLC at the HMI device.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500

Glossary

Process visualization Visualization of technical processes by means of text and graphic elements. Configured plant screens allow operator intervention in active plant processes by means of the input and output data.

Project Result of a configuration using a configuration software. The project normally contains several screens with embedded system-specific objects, basic settings and alarms. The project file of a project configured in WinCC flexible is saved under the file name extension *.hmi. You need to distinguish between a project on the configuring PC and that on an HMI device. A project may be available in more languages on the configuring PC than can be managed on the HMI device. The project on the configuring PC can also be set up for different HMI devices. Only the runtime project that has been generated for the respective HMI device can be transferred to it.

Project file File generated from the runtime project file for use on the HMI device. The project file is normally not transferred and remains on the configuring PC. The file name extension of a source file is *.hmi.

Project file, compressed Compressed format of the project file. The compressed project file can be transferred together with the runtime project file to the respective HMI device. For this purpose, backtransfer must be enabled in the project on the configuring PC. The compressed project file is normally stored on an external memory card. The file extension of a compressed file is *.pdz.

Recipe Combination of tags forming a fixed data structure. The data structure configured can be assigned data on the HMI device and is then referred to as a record. The use of recipes ensures that all the assigned data is transferred synchronously to the PLC during the transfer of a record.

Runtime project file File generated from the project file for a specific HMI device. The runtime project file is transferred to the corresponding HMI device and used to operate and monitor plants. The extension of a compressed file is *.pdz.

Runtime software The runtime software is a process visualization software used to test a project on a configuring PC.

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MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Glossary

Screen Form of the visualization of all logically related process data for a plant. The visualization of the process data can be supported by graphic objects.

Screen object Configured object used to display or operate the plant, e.g. rectangle, I/O field or alarm view.

STEP 7 STEP 7 is the programming software for SIMATIC S7, SIMATIC C7 and SIMATIC WinAC PLCs.

STEP 7 Micro/WIN STEP 7 Micro/WIN is the programming software for SIMATIC S7-200 PLCs.

Symbolic I/O field A symbolic I/O field is a field for the input and output of the value. Contains a list of default entries from which one can be selected.

System alarm A system alarm is assigned to the "System" alarm class. A system alarm refers to internal states on the HMI device and the PLC.

Tab sequence During configuration, this defines the sequence in which objects are activated on pressing the key.

Tag Defined memory location to which values can be written to and read from. This can be done from the PLC or the HMI device. Based on whether the tag is interconnected with the PLC or not, we distinguish between "external" tags (process tags) and "internal" tags.

Transfer Transfer of a runtime project from the configuring PC to the HMI device.

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

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ITEM 2500 Glossary

328

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Index / /Audit, 32

A Accessory kit, 25 ACK, 239 ACK key, 203 Acknowledge Alarm, 203, 243 Error alarm, 243 Acknowledge key, 203 Acoustic feedback, 191 Acoustic signal, 196 For inadvertent operation, 191 with inadvertent operation, 99 Acoustics Feedback, 122, 124 Address assignment TCP/IP network, 145 Addressing, 142 Admin, 233, 234, 235 Alarm, 237 Acknowledge, 203, 243 Editing, 244 Functional scope, 29 LED, 240 Alarm buffer, 238 Functional scope, 29 Alarm class, 238, 241 Alarm event, 237 Alarm group, 238 Alarm indicator, 239 Alarm line, 240 Alarm log, 238 Alarm report, 238 Alarm view, 240 Expanded, 240 Simple, 240 Alarm window, 241 ALARM_S, 29 Alphanumerical Key assignment, 105, 202 Screen keyboard, 197 Alphanumerical value Changing, 207 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

Editing, 198 Entering, 198, 207 ALT key, 105, 202 Ambient conditions Climatic, 46 Mechanical, 45 Test, 46 Approvals, 39 Authorization, 224 Automatic Transfer, 164 Automation License Manager, 186 A-Z key, 105, 202

B Backlighting Reducing, 119 Setting, 99 Backspace key, 104, 202 Backtransfer, 163, 166 Backup, 98, 155, 162, 168, 169, 171, 225 Registry Information, 98, 116 Temporary files, 116 to external storage device, 98, 153 With ProSave, 171 With WinCC flexible, 169 Bar, 210 Basic adapter, 27 Basic knowledge Required, 3 Booting, 125 Bottom view, 15, 17, 19, 21, 23 Brightness Changing, 118 Browser Home page, 98 Setting, 98 Bus connection, 33 Bus parameters Profile, 141

C Cable Data exchange, 76 Cables Connecting, 61

329

ITEM 2500

Index

Calibrating Touch screen, 98, 110 Cancel Secure mode, 94 Cancel Password protection, 113 Cancel key, 104, 202 Care, 273 CE approval, 39 Certificate Delete, 98, 152 Importing, 98, 152 LED, 98 Changing Brightness, 118 User data, 233, 234 Character repeat, 98 Screen keyboard, 107 Clean screen, 274 Cleaning product, 273 Clearance MP 377, 49 Climatic Storage conditions, 44 Transport conditions, 44 Closing Project, 236 Rear wall, 80 Column sequence Alarm view, 241 Compatibility conflict, 168 Conductor cross-section, 65 Equipotential bonding, 63 Configuration PC Connecting, 71 Wiring diagram, 71 Configuration phase, 159 Configure Screen keyboard, 98, 106 Configuring Network, 143 Operating system, 89 PC/PPI cable, 72 RS-422/RS-485 port, 70 Configuring PC, 159 Connecting Configuration PC, 71 Equipotential bonding, 63 Mains terminal, 66 PLC, 68 Power supply, 65, 66 Printer, 75 PROFINET, 69

330

UPS, 67 USB device, 74 Connection, 33 Connection graphic UPS, 67 Connection sequence, 61 Connections to PLC Number, 33 Contact person, 5 Control cabinet Working on, 38 Control key, 82 Keyboard unit, 104 Control panel Password protection, 92 Control Panel, 96 MPI, 140 Open, 97 Operating, 100, 102 PROFIBUS, 140 Screen keyboard, 101 Conventions, 4 Cookies, 98, 150 Creating Recipe data record, 255, 264 Users, 230 C-Tick mark (Australia), 40 CTRL key, 105, 202 Currency, 98 Cursor key, 82, 104, 201

D Data channel Enabling, 136 Locking, 136 Parameter assignment, 99, 136 Data flow, 249 Date, 98 Entering, 199, 208 Setting, 114 Synchronizing, 115 Date format, 98, 116 Date/time properties, 98, 114 Decimal, 195 Default gateway, 146 Degree of protection, 48 Protection against ingress of solid foreign bodies, 50, 52 Protection against water, 50, 52 Delay time Setting, 99, 131 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Delete Certificate, 98, 152 Recipe data record, 258, 266 Users, 235 Delete key, 104, 202 Device name For network operation, 144 Setting, 99 Dewing, 44 DHCP, 146 DIP switch Setting, 70 Direct key, 192 Bit assignment, 282 Functional scope, 31 Display MP 377, 280 Display format, 205 Displaying Info text, 200, 209 Information on the MP 377, 127 Infotext, 203 Memory information, 129 System information, 129 Disposal, 5 Disturbance Pulse-shaped, 42 Sinusoidal, 43 DNS, 146 Server, 142 Documentation Enclosed, 53 Double-click, 98 Setting, 108 Drop down list, 199, 208 Drop down list box Open, 104, 202

E EC Declaration of Conformity, 39 Editing Alarm, 244 Recipe data record, 257, 265 Elbow adapter, 26 Electrical isolation Safe, 66 Electrical potential difference, 63 Electrostatic charging, 287 Electrostatic discharge Electrostatic, 287 Precautions, 288 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

Index

Element list, 251, 262 E-Mail Setting, 99, 148 EMC directive, 39 Emission, 41, 43 Encryption, 150 END key, 104, 201 Enhanced alarm view, 240 Enhanced recipe view, 250 Enhanced user view, 226 Enter key, 202 ENTER key, 104, 202 Entering Alphanumerical value, 198, 207 Date, 199, 208 Key combination, 105, 202 Numerical value, 196, 206 Recipe data record, 271 Symbolic value, 199 Text box, 194 Time, 199, 208 Entry on the HMI device By means of function key, 204 Using operating elements, 189 Equipotential bonding Cable, 64 Connecting, 63 Requirements, 63 Wiring diagram, 64 Equipotential bonding rail, 64 Error alarm Acknowledge, 243 ESC key, 104, 202 ESD Abbreviations, 287 Labeling, 287 Ethernet settings IP address, 146 Excel Viewer, 32 Explorer Operating, 91 Exporting Recipe data record, 270 External Keyboard, 100 Mouse, 100

F Factory setting With ProSave, 180 With WinCC flexible, 178

331

ITEM 2500

Index

Factory settings, 73 Feedback Acoustic, 122, 124, 191 Optical, 191 FM Approval, 40 FN key, 105, 202 Front view, 15, 17, 19, 21, 23 Function Additional, 31 Function key Labeling, 86 Function keys, 82 Global assignment, 204 Local assignment, 204 Function test, 78 Functional scope Alarm buffer, 29 ALARM_S, 29 Alarms, 29 Graphics list, 29 Info text, 31 Limit value monitoring, 29 Log, 30 Recipe, 30 Safety, 31 Scaling, 29 Screen, 30 Tags, 29 Text list, 29

G Gauge, 210 Graphics list Functional scope, 29 Group acknowledgement, 203

H High frequency radiation, 37 HMI device EMC-compatible installation, 42 Information, 98 Mounting, 57, 59 Ports, 62 Restart, 125 Restarting, 98 Shutting down, 78 Switching on, 77 Technical specifications, 280 Testing, 77 HMI Input Panel

332

Options, 106 HOME key, 104, 201 Home page Internet, 149 Host cable Safety instruction, 73

I Identification, 147 Importing Certificate, 98, 152 Recipe data record, 269 Inadvertent operation Acoustic signal, 99, 191 Info text Displaying, 200, 209 Functional scope, 31 Information For the HMI device, 127 Infotext Displaying, 203 Key, 203 LED, 242 Initial startup, 159 Input device MP 377, 280 Input Panel, 98 Installing Option, 162, 182, 183, 185 Instructions General, 41 Insulation test Test voltage, 50, 52 Interface Rated load, 74 Interfaces MP 377, 281 Internal clock, 115 Internet Browser, 92 Explorer, 92 Home page, 149 Options, 98 Search engine, 149 Security settings, 98 Service, 5 Settings, 99, 148 Support, 5 Internet options Privacy, 151 IP address MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Ethernet, 146 Setting, 98

K Key ACK, 203 ALT, 105, 202 A-Z, 105, 202 Backspace, 202 Cancel, 104 CTRL, 105, 202 Cursor, 104, 201 Delete, 104, 202 END, 104, 201 ENTER, 104, 202 ESC, 104, 202 FN, 105, 202 HOME, 104, 201 Infotext, 203 Scroll back, 104, 201 Scroll forward, 104, 201 SHIFT, 105, 202 TAB, 104, 201 Tabulator, 104 Key combination Entering, 105, 202 Key control, 201, 205 Trend view, 214 Keyboard External, 100 Safety instruction, 82 Keyboard properties, 98

L Labeling Approvals, 40 EC Declaration of Conformity, 39 Function key, 86 Labeling strips Attaching, 87 Dimensions, 86 Printing, 86 LAN connection, 98 Language change Functional scope, 31 Layout Slider control, 214 Sm@rtClient view, 220 Trend view, 212 LED MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

Index

Alarm, 240 Certificate, 98 HMI device information, 98 Infotext, 242 Memory information, 128 System information, 128 LED ACK, 239 License key, 186 Transferring, 162, 187 Transferring back, 162, 188 Limit value For password, 225 For user, 225 For user view, 225 Limit value check, 195 Limit value monitoring Functional scope, 29 Limit value test, 205 List of abbreviations, 321 Loader, 89 Opening, 90 Operating, 90 Log Functional scope, 30 Logoff Users, 228 Logoff time, 225 Logon Users, 227 Logon data, 147

M MAC address, 134 Main dimensions MP 377 PRO 15" Touch, 279 Mains terminal Connecting, 66 Maintenance, 273, 274 Manual Production sequence, 272 Transfer, 163 Mechanical Storage conditions, 44 Transport conditions, 44 Media Player, 93 Memory MP 377, 280 Memory card, 27 Backup, 84 First use, 153 Inserting, 83

333

ITEM 2500

Index

Restoring file system, 116 Unplug, 85 Memory information, 99 Displaying, 129 LED, 128 Memory management, 98, 158 Menu command Simple recipe view, 263 Microsoft Excel Viewer, 32 Microsoft PDF Viewer, 32 Microsoft Word Viewer, 32 Monitoring mode Sm@rtClient view, 221 Mounting, 48 EMC-compatible, 42 HMI device, 57, 59 Mounting clamp, 56 Mounting clamp Mounting, 55, 56 Mounting cutout Dimensions, 49 Preparing, 49 Mounting location, 48, 51 Mounting position, 47 Thin Client 15, 51 Mouse External, 100 Mouse properties, 98 MP 377 Clearance, 49 Display, 280 Displaying information, 127 Input device, 280 Interfaces, 281 Memory, 280 Operating element, 81 Ports, 62 Weight, 280 MP 377 12" Key Bottom view, 17 Front view, 17 Overall dimensions, 276 Rear view, 18 Side view, 17 MP 377 12" Touch Bottom view, 15 Front view, 15 Overall dimensions, 275 Rear view, 16 Side view, 15 MP 377 15 PRO Bottom view, 23 Front view, 23

334

Rear view, 24 Side view, 23 MP 377 15" Touch Bottom view, 19 Front view, 19 Overall dimensions, 277 Rear view, 20 Side view, 19 MP 377 19" Touch Bottom view, 21 Front view, 21 Overall dimensions, 278 Rear view, 22 Side view, 21 MP 377 PRO 15" Touch Main dimensions, 279 MPI Setting, 99, 140 Multi-key operation, 190, 203 Multimedia card, 83

N Name server, 146 Network Configuring, 143 Logon data, 98 Set up, 142 Setting, 145 Network & dial-up connections, 98 Network ID, 98 Network operation Device name, 144 Options, 99 Non-isolated plant configuration, 66 Notice of protected rights, 3 Number format, 98, 116 Numerical Key assignment, 105, 202 Screen keyboard, 195 Numerical value Changing, 206 Decimal places, 195 Display format, 205 Editing, 196 Entering, 196, 206 Limit value check, 195 Limit value test, 205

O Office location, 5 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Offline Operating mode, 160 Recipe tag, 254 Test, 167 Online Operating mode, 160 Recipe tag, 254 Test, 167 OP properties, 98 Device, 127 Memory monitoring, 158 Persistent storage, 117 Touch, 110 OPC server, 32 Open Control Panel, 97 Drop down list box, 104, 202 Opening Loader, 90 Operating Control Panel, 100, 102 Explorer, 91 Feedback, 190 Key, 201, 205 Loader, 90 Operating element, 104, 201 Project, 189 Recipe screen, 255, 264 Slider control, 215 Switches, 211 Trend view, 213 Windows CE interface, 91 With external keyboard, 190 With external mouse, 190 Operating element Operating, 104, 201 Recipe view, 255 Selecting, 104 Simple recipe view, 262 Operating instructions Purpose of, 3 Scope, 3 Operating mode, 160 Changing, 160 Offline, 160 Online, 160 Transfer, 77, 160 Operating system Configuring, 89 Update, 173 Update via ProSave, 176 Updating using WinCC flexible, 175 Operation feedback, 190 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

Index

Setting, 99 Operator control options, 99 Optical feedback, 191 Option Installing, 162, 182 Installing with ProSave, 185 Installing with WinCC flexible, 183 Removing, 162, 182 Removing with ProSave, 186 Removing with WinCC flexible, 184 Options, 32 Network operation, 99 Overall dimensions MP 377 12" Key, 276 MP 377 12" Touch, 275 MP 377 15" Touch, 277 MP 377 19" Touch, 278

P Parameter assignment Data channel, 99, 136 Password, 225 Backup, 225 Restoring, 225 Specifying, 112 Password list, 225 Password properties, 98, 112, 113 Password protection, 92, 98 Cancel, 113 Set up, 112 Windows CE taskbar, 92 PC/PPI Configuring the cable, 72 Setting the adapter, 72 PDF Viewer, 32 PELV, 66 Permissions in remote control, 222, 223 Plant configuration Non-isolated, 66 PLC Configuring the interface, 70 Connecting, 68 Number of connectable, 33 Protocol, 34 Reading recipe data record, 260, 267 Transferring recipe data record, 261, 268 Wiring diagram, 68 PLC_User, 233, 234, 235 Power failure, 168 Power supply Connecting, 65, 66

335

Index

Setting, 99 State, 99 Wiring diagram, 65 Precautions Electrostatic discharge, 288 Printer Connecting, 75 Setting properties, 98 Wiring diagram, 75 Printer connection Setting, 120 Printer properties, 98, 121 Printing Labeling strips, 86 Via network printer, 143 ProAgent, 32 Process control phase, 159 Production sequence Manual, 272 PROFIBUS DP Setting, 99, 140 PROFINET, 142 Addressing, 142 Connecting, 69 PROFINET IO Communication, 69 Communication fault, 33 Disabling direct keys, 134 Enabling direct keys, 134 Setting, 98 Project Closing, 236 in ProTool, 161 In WinCC flexible, 161 Offline testing, 167 Operating, 189 Reuse, 161 Testing online, 167 Transferring, 159, 162 Proper use, 37 Protected trademark, 3 Protection class, 50, 52 Protective foil, 26 Protocol PLC, 34 Proxy Server, 98, 148, 150 Setting, 98

R Radiation

336

ITEM 2500 High frequency, 37 Radio interference, 41 Emission, 43 Rated load Interface, 74 Rated voltage, 50, 52 Reading out Recipe data record, 260, 267 Real-time clock Internal, 115 Rear view, 16, 18, 20, 22, 24 Rear wall Closing, 80 Recipe, 246 Control, 247 Data flow, 249 Data record, 247 Field of application, 245 Functional scope, 30 Recipe screen, 250 Recipe view, 250 Synchronizing tags, 259 Recipe data record Creating, 255, 264 Delete, 258, 266 Editing, 257, 265 Entering, 271 Exporting, 270 Importing, 269 Reading from PLC, 260, 267 Synchronize with PLC, 257 Transferring to PLC, 261, 268 Recipe list, 251, 262 Recipe screen, 252 Operating, 255, 264 Overview, 252 Recipe tag Offline, 254 Online, 254 Synchronizing, 253, 259 Recipe view, 250 Expanded, 250 Operating element, 255 Simple, 251 Recommissioning, 159 Record list, 251, 262 Recycling, 5 Regional and language settings, 98, 116 Regional settings, 116 Registered trademark, 3 Registry Information Backup, 98, 116 Regulations for the prevention of accidents, 38 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 Remote control Forcing permission, 222, 223 Start, 222, 223 Removing Option, 162, 182, 184, 186 Repairs, 274 Reset to factory setting, 162 Restore, 98, 153, 168 Restoring, 162, 170, 172, 225 from external storage device, 98, 155 From memory card, 116 With ProSave, 172 With WinCC flexible, 170 Restoring factory settings, 73 Returns Center, 274 Reverse polarity protection, 66 RS 422 to RS 232 converter, 26 RS-422/RS-485 port Configuring, 70 Ruler Trend view, 213

S S7 transfer settings, 99 Safe electrical isolation, 66 Safety Functional scope, 31 Standards, 39 Safety instruction Backlighting, 119 Changed tag name, 259 Compatibility conflict, 168 Compressed project file, 163 Damage to the HMI device, 61 Data channel, 174 Data loss, 153, 173 Device name, 134 Direct key, 192 Electrostatic charging, 287 Equipotential bonding cable, 64 Functional problem, 74 High frequency radiation, 37 Keyboard, 82 License key, 174, 182 Loss of data possible, 155 Memory card, 85 Memory distribution, 129 Multi-key operation, 190 Observe grounding measures, 288 Path, 130, 131 Power failure, 168 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

Index

Preventing inadvertent operation, 273, 274 Project file, 130, 131 Recipe data record in background, 251 Remote control for channel 1, 137 Restart, 125 Storage, 44 Switching infotext, 200, 209 Time-dependent reactions, 115 Touch screen, 81 Transfer mode, 139 Transfer mode channel 2, 137 Transport, 44 Unintentional action, 81, 82, 203 Unintentional response, 273, 274 Unintentional transfer mode, 136 USB connection sequence, 73 USB host-to-host cable, 73 USB port, 74 Working on the control cabinet, 38 Safety regulations, 38 Scaling Functional scope, 29 Screen Functional scope, 30 Screen keyboard, 98, 193 Alphanumerical, 197 Change layout, 102 Character repeat, 107 Configure, 106 For Control Panel, 101 Keyboard level, 197 Language change, 197 Numerical, 195 Representation types, 101 Screen saver, 99, 120 Setting, 119 Screen settings Changing, 98 Scroll back key, 104, 201 Scroll forward key, 104, 201 Search engine Internet, 149 Secure mode, 94 Cancel, 94 Security settings, 98 Security system, 224 Selecting Operating element, 104 Service In the Internet, 5 Service pack, 274 Set up Network, 142

337

Index

Password protection, 112 Secure mode, 94 Setting Backlighting, 99 Browser, 98 Date, 114 Date format, 116 Date/Time, 98 Delay time, 99, 131 Device name, 99 DIP switch, 70 Double-click, 108 E-Mail, 99 E-mail connection, 148 IP address, 98 Language, 193 MPI, 99, 140 Name server, 98 Network, 145 Number format, 116 Operation feedback, 99 PC/PPI adapter, 72 Power supply, 99 Printer connection, 120 Printer properties, 98 PROFIBUS, 140 PROFIBUS DP, 99 PROFINET IO, 98 Proxy, 98 Regional data, 116 Screen saver, 119 Sound, 124 Storage location, 130 Time, 114 Time format, 116 UPS, 132 Setting language, 193 Settings Internet, 99 Language, 98 Regional, 98 S7-Transfer, 99 Shift key, 105 SHIFT key, 105, 202 Shutting down HMI device, 78 Side view, 15, 17, 19, 21, 23 Siemens HMI input panel options, 98 Simple alarm view, 240 Simple recipe view, 251 Menu command, 263 Operating element, 262 Simple user view, 226

338

ITEM 2500 Slider control, 214 Sm@rtAccess, 32 Sm@rtClient view, 220, 221 Monitoring mode, 221 Usage, 220 Sm@rtService, 32 SMTP server, 148 Software options, 32 Sort order Alarm view, 241 Sound Setting, 99, 124 Setting event, 124 Start HMI device, 98, 125 Status Force, 216 Key control, 219 Touch operation, 217 Storage conditions, 44 storage device Restoring from external, 155 Storage device Saving to external, 153 Storage location Setting, 130 Strain relief, 79 Subnet mask, 146 Supply voltage MP 377, 281 Support In the Internet, 5 Support arm system Adapter set CP-L, 27 Adapter set PLUS, 27 Adapter set VESA 100, 27 Adapter set VESA 75, 27 Basic adapter, 27 Switches, 211 Switching on MP 377, 77 Symbolic value Editing, 199 Entering, 199 Synchronizing Date and time, 115 Recipe tag, 253, 259 System alarm Meaning, 290 Parameters, 289 System information, 99 Displaying, 129 LED, 128 System key, 82 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 2500 System properties, 99 Device name, 144 General, 128 Memory, 129

T TAB key, 104, 201 Tabulator key, 104, 201 Tags Functional scope, 29 Task planner Functional scope, 31 Taskbar, 89 TCP/IP address, 145 Technical specifications Display, 280 Input device, 280 Interfaces, 281 Memory, 280 MP 377, 280 Supply voltage, 281 Technical support, 5 Temporary files Backup, 116 Test For ambient conditions, 46 Test voltage, 52 Testing MP 377, 77 Text box, 194 Character mode, 202 Normal mode, 202 Text list Functional scope, 29 Time, 98 Entering, 199, 208 Setting, 114 Synchronizing, 115 Time format, 98, 116 Time zone Setting, 114 Time-dependent reactions, 115 Touch operation Trend view, 214 Touch screen Calibrating, 98, 110 Safety instruction, 81 Trademark, 3 Training center, 5 Transfer, 159, 160, 163 Automatic, 164 MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

Index

Cancel, 77 Manual, 163 Transfer mode Unintentional, 136 Via MPI, 139 Via PROFIBUS DP, 139 Transfer settings, 99, 136 Channel, 136 Directories, 130, 131 Transferring License key, 162, 187 Project, 159, 162 Recipe data record, 261, 268 Transferring back License key, 162, 188 Transport conditions, 44 Transport damage, 53 Trend view, 212 Key control, 214 Touch operation, 214 Trends Functional scope, 31 Limit violation, 212

U UL approval, 40 Unintentional action, 81, 82, 190 Unintentional transfer mode, 136 Update Operating system, 173 Updating About ProSave, 176 using WinCC flexible, 175 Updating the operating system, 162 UPS Connecting, 67 Connection graphic, 67 Setting, 132 UPS properties Configuration, 132 Current status, 133 USB Connection sequence, 73 USB connection sequence Safety instruction, 73 USB device Connecting, 74 USB flash drive, 27 USB memory stick, 27 Use Conditions, 45

339

ITEM 2500

Index

In residential areas, 41 Industrial, 41 With additional measures, 45 User data Backup, 225 Changing, 233, 234 Restoring, 225 User group, 224 User name, 147 User view, 226 Expanded, 226 Simple, 226 Users, 225 Admin, 233, 234, 235 Changing, 229 Creating, key control, 230 Delete, 235 Logoff, 228 Logon, 227 PLC_User, 233, 234, 235

V Value table Trend view, 213 VBScript Functional scope, 31

340

Volume, 122 Setting, 99 Volume & Sounds Properties, 99

W Weight MP 377, 280 WinCC flexible internet settings E-mail, 148 E-Mail, 99 Windows CE interface Operating, 91 Windows CE taskbar, 89 Password protection, 92 WINS, 146 Server, 142 Wiring diagram Configuration PC, 71 Equipotential bonding, 64 PLC, 68 Power supply, 65 Printer, 75 Word Viewer, 32 Working on the control cabinet, 38

MP 377, MP 377 PRO (WinCC flexible) Operating Instructions, 10/2008, 6AV6691-1DR01-0AB0

ITEM 3000 Preface SIMATIC S7-300 CPU 31xC and CPU 31x: Installation

SIMATIC S7-300 CPU 31xC and CPU 31x: Installation Operating Instructions

Guide to the S7-300 documentation

1 ______________ 2 Installation Sequence ______________ 3 S7-300 components ______________ 4 Configuring ______________ 5 Installing ______________ 6 Wiring ______________ 7 Addressing ______________ 8 Commissioning ______________ 9 Maintenance ______________ Debugging functions, diagnostics and troubleshooting

10 ______________ 11 General technical data ______________ A Appendix ______________

This manual is part of the documentation package with order number: 6ES7398-8FA10-8BA0

02/2009

A5E00105492-09

ITEM 3000 Legal information

Legal information

Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.

Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be adhered to. The information in the relevant documentation must be observed.

Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY

A5E00105492-09 Ⓟ 03/2009

Copyright © Siemens AG 2009. Technical data subject to change

ITEM 3000

Preface Preface Purpose of this manual This manual contains essential information about the following: ● Installation ● Communication ● Memory concept ● Cycle and response times ● Technical specifications of the CPUs ● Switching to one of the CPUs discussed here

Basic knowledge required ● In order to understand this manual, you require a general knowledge of automation engineering. ● You require knowledge of STEP 7 basic software.

Scope Table 1

Scope of the manual

CPU

Convention: CPU designations:

Order number

As of firmware version

CPU 312C

CPU 31xC

6ES7312-5BE03-0AB0

V2.6

CPU 313C

6ES7313-5BF03-0AB0

V2.6

CPU 313C-2 PtP

6ES7313-6BF03-0AB0

V2.6

CPU 313C-2 DP

6ES7313-6CF03-0AB0

V2.6

CPU 314C-2 PtP

6ES7314-6BG03-0AB0

V2.6

CPU 314C-2 DP

6ES7314-6CG03-0AB0

V2.6

6ES7312-1AE14-0AB0

V3.0

CPU 312

CPU 31x

CPU 314

6ES7314-1AG14-0AB0

V3.0

CPU 315-2 DP

6ES7315-2AH14-0AB0

V3.0

CPU 315-2 PN/DP

6ES7315-2EH13-0AB0

V2.6

CPU 317-2 DP

6ES7317-2AJ10-0AB0

V2.6

CPU 317-2 PN/DP

6ES7317-2EK13-0AB0

V2.6

CPU 319-3 PN/DP

6ES7318-3EL00-0AB0

V2.8

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ITEM 3000 Preface

Note The special features of the F-CPUs of the S7 spectrum can be found as product information on the Internet at following address: (http://support.automation.siemens.com/WW/view/en/11669702/133300). Note We reserve the right to include a Product Information containing the latest information on new modules or modules of a more recent version.

Changes in comparison to the previous version The following table contains changes from the previous versions of the following documentation from the S7-300 documentation package: ● Manual of technical specifications, version 06/2008, A5E00105474-08 ● Installation manual, version 06/2008, A5E00105491-08 CPU 312, V3.0

CPU 314, V3.0

CPU 315-2 DP, V3.0

CPU 319, V2.8

Data set routing

-

-

x

x*

Increased performance due to shorter instruction processing times

x

x

x

-

Extended system diagnostics of PROFINET interface: Overview and detailed diagnostics of connections of "open communication via Industrial Ethernet"

-

-

x

Increase •

the number of blocks that can be monitored by the status block (from 1 to 2)

x

x

x

x

•

of the amount of status information that can be monitored with the status block as of STEP7 V5.4 + SP5

x

x

x

x

•

of the number of breakpoints from 2 to 4

x

x

x

x

•

of the work memory size

-

x

x

-

•

of the local data stack (32 KB per execution level/2 KB per block)

x

x

x

x

•

Number of block-related messages (Alarm_S) is uniformly limited to 300

x

x

x

x*

•

of S7 timers, S7 counters

x

-

-

-

•

the number of bit memories

x

-

-

-

Adjustable process image

x

x

x

x*

Expansion of the block number range

x

x

x

x

Uniform size of data blocks: Max. 64 KB (exception: CPU312 only 32 KB due to maximum size of work memory)

x

x

x

x*

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Preface

CPU 312, V3.0

CPU 314, V3.0

CPU 315-2 DP, V3.0

CPU 319, V2.8

Time-delay interrupts: uniform for OB21/OB22

x

x

x

x*

Watchdog interrupts: uniform for OB32 - OB35

x

x

x

x*

Uniform block nesting depth of 16

x

x

x

x*

Global communication: uniformly 8 GD circles

x

x

x*

x*

Size of the diagnostic buffer: generally 500 entries (the 100 most recent entries are retentive)

x

x

x

x*

Number of displayed diagnostic buffer entries in CPU RUN mode is configurable.

x

x

x

x

New function: Reading out service data

x

x

x

x

Additional Web server functionalites for CPU 319-3 PN/DP V2.8 or higher and STEP7 V5.4 + SP5 •

Extended topology views

-

-

-

x

•

Link between device view in topology and module state

-

-

-

x

•

Link to Web servers of other configured devices

-

-

-

x

•

Status overview of all configured devices of the PROFINET IO system

-

-

-

x

•

Updating of the "Module state" and "Topology" Web pages during activation/deactivation of stations

-

-

-

x

•

Automatic page update for all dynamic pages on the Web server

-

-

-

x

•

Number of displayed diagnostic buffer entries in CPU RUN mode is configurable.

-

-

-

x

•

Diagnostic buffer entries and messages can be downloaded as CSV file.

-

-

-

x

•

Reference view in the topology display of the CPU Web server

-

-

-

x

* This function is already available to the CPU since an earlier version

Standards and approvals In the Chapter General technical specifications, you will find information about standards and approvals

Recycling and disposal The devices described in this manual can be recycled due to their ecologically compatible components. For environment-friendly recycling and disposal of your old equipment, contact a certified disposal facility for electronic scrap.

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Preface

Service & Support on the Internet In addition to our documentation, we offer a comprehensive knowledge base online on the Internet (http://www.siemens.com/automation/service&support). There you will find: ● Our newsletter containing up-to-date information on your products ● Up-to-date documents using the Search function in Service & Support ● A forum for global information exchange by users and specialists ● Your local representative for automation and drives in our contact database ● Information about on-site services, repairs, spare parts, and lots more. ● Applications and tools for the optimized use of the SIMATIC S7. Performance measurements for DP and PN, for example, are published here on the Internet (http://www.siemens.com/automation/pd).

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Table of contents Preface ...................................................................................................................................................... 3 1

Guide to the S7-300 documentation ........................................................................................................ 11 1.1

Documentation classification .......................................................................................................11

1.2

Guide to the S7-300 documentation ............................................................................................14

2

Installation Sequence .............................................................................................................................. 19

3

S7-300 components................................................................................................................................. 21

4

3.1

Example of an S7-300 configuration............................................................................................21

3.2

Overview of the most important S7-300 modules........................................................................22

Configuring .............................................................................................................................................. 25 4.1

Overview ......................................................................................................................................25

4.2

Basic engineering principles ........................................................................................................26

4.3

Component dimensions ...............................................................................................................28

4.4

Specified clearances....................................................................................................................30

4.5

Arrangement of modules on a single rack ...................................................................................31

4.6

Distribution of modules to several racks ......................................................................................32

4.7

Selection and installation of cabinets...........................................................................................35

4.8

Example: Selecting a cabinet.......................................................................................................38

4.9 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 4.9.6

Electrical assembly, protective measures and grounding ...........................................................39 Grounding concept and overall structure.....................................................................................39 Installing an S7-300 with grounded reference potential ..............................................................41 Installing an S7-300 with ungrounded reference potential (not CPU 31xC)................................42 Isolated or non-isolated modules? ...............................................................................................43 Grounding measures ...................................................................................................................45 Overview display: Grounding .......................................................................................................48

4.10

Selection of the load power supply ..............................................................................................50

4.11 4.11.1 4.11.2 4.11.2.1 4.11.2.2 4.11.2.3 4.11.2.4 4.11.2.5 4.11.2.6

Planning subnets .........................................................................................................................52 Overview ......................................................................................................................................52 Configuring MPI and PROFIBUS subnets ...................................................................................54 Overview ......................................................................................................................................54 Basic principles of MPI and PROFIBUS subnets ........................................................................54 Multi-Point Interface (MPI) ...........................................................................................................57 PROFIBUS DP interface..............................................................................................................59 Network components of MPI/DP and cable lengths ....................................................................62 Cable lengths of MPI and PROFIBUS subnets ...........................................................................67

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Table of contents

4.11.3 4.11.3.1 4.11.3.2 4.11.3.3 4.11.3.4 4.11.3.5 4.11.3.6 4.11.3.7 4.11.3.8 4.11.4 4.11.5 4.11.6 5

6

7

8

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Configuring PROFINET subnets................................................................................................. 72 Overview ..................................................................................................................................... 72 PROFINET devices..................................................................................................................... 72 Integration of fieldbuses into PROFINET.................................................................................... 75 PROFINET IO and PROFINET CBA .......................................................................................... 76 PROFINET cable lengths and network expansion ..................................................................... 81 Connectors and other components for Ethernet......................................................................... 84 Example of a PROFINET subnet ................................................................................................ 84 PROFINET IO System ................................................................................................................ 86 Routed network transitions.......................................................................................................... 88 Point-to-point (PtP)...................................................................................................................... 90 Actuator/sensor interface (ASI) ................................................................................................... 90

Installing .................................................................................................................................................. 91 5.1

Installing a S7-300 ...................................................................................................................... 91

5.2

Installing the mounting rail .......................................................................................................... 93

5.3

Installing modules on the mounting rail....................................................................................... 96

5.4

Labeling modules ........................................................................................................................ 98

Wiring .................................................................................................................................................... 101 6.1

Requirements for wiring the S7-300 ......................................................................................... 101

6.2

Bonding the Protective Conductor to the Mounting Rail ........................................................... 103

6.3

Adjusting the Power Supply Module to Local Mains Voltage.................................................... 104

6.4

Wiring the Power Supply Module and the CPU ........................................................................ 105

6.5

Wiring front connectors ............................................................................................................. 107

6.6

Plugging the front connectors into modules.............................................................................. 110

6.7

Wiring I/O modules and compact CPUs with Fast Connect ..................................................... 111

6.8

Labeling the module I/Os .......................................................................................................... 116

6.9

Terminating shielded cables on the shielding contact element ................................................ 117

6.10 6.10.1 6.10.2

Wiring the MPI / PROFIBUS connectors .................................................................................. 120 Connecting the bus connector .................................................................................................. 120 Setting the terminating resistor on the bus connector .............................................................. 121

Addressing............................................................................................................................................. 123 7.1

Slot-specific addressing of modules ......................................................................................... 123

7.2 7.2.1 7.2.2 7.2.3 7.2.4

User-specific addressing of modules ........................................................................................ 125 User-specific addressing of modules ........................................................................................ 125 Addressing digital modules ....................................................................................................... 126 Addressing analog modules...................................................................................................... 128 Addressing the integrated I/Os of CPU 31xC ........................................................................... 129

7.3

Addressing on PROFIBUS DP.................................................................................................. 131

7.4

Addressing on PROFINET ........................................................................................................ 132

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Table of contents

Commissioning ...................................................................................................................................... 133 8.1

Overview ....................................................................................................................................133

8.2 8.2.1 8.2.2

Commissioning procedure .........................................................................................................133 Procedure: Commissioning the hardware..................................................................................133 Procedure: Software commissioning .........................................................................................135

8.3

Commissioning check list...........................................................................................................136

8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.5.1 8.4.5.2 8.4.5.3 8.4.5.4 8.4.5.5 8.4.6 8.4.7

Commissioning the Modules......................................................................................................138 Inserting/Replacing a Micro Memory Card ................................................................................138 Initial power on ...........................................................................................................................140 CPU memory reset by means of mode selector switch.............................................................141 Formatting the Micro Memory Card ...........................................................................................144 Connecting the programming device (PG) ................................................................................145 Connect PG/PC to the integrated PROFINET interface of the CPU 31x PN/DP ......................145 Connecting the PG to a node.....................................................................................................146 Connecting the PG to several nodes .........................................................................................147 Using the PG for commissioning or maintenance......................................................................148 Connecting a PG to ungrounded MPI nodes (not CPU 31xC) ..................................................150 Starting SIMATIC Manager........................................................................................................151 Monitoring and modifying I/Os ...................................................................................................152

8.5 8.5.1 8.5.2 8.5.3 8.5.4

Commissioning PROFIBUS DP .................................................................................................156 Commissioning PROFIBUS DP .................................................................................................156 Commissioning the CPU as DP master.....................................................................................157 Commissioning the CPU as DP Slave.......................................................................................161 Direct data exchange .................................................................................................................166

8.6 8.6.1 8.6.2

Commissioning PROFINET IO ..................................................................................................168 Requirements.............................................................................................................................168 Configuring and commissioning the PROFINET IO system ......................................................168

Maintenance .......................................................................................................................................... 175 9.1

Overview ....................................................................................................................................175

9.2

Backing up firmware on a SIMATIC Micro Memory Card..........................................................175

9.3 9.3.1 9.3.2 9.3.3

Updating the firmware................................................................................................................176 Backing up firmware on a SIMATIC Micro Memory Card..........................................................176 Firmware update using a Micro Memory Card...........................................................................177 Updating the firmware online (via networks)..............................................................................179

9.4

Backup of project data to a Micro Memory Card .......................................................................180

9.5

Resetting to the Delivery State ..................................................................................................182

9.6

Module installation / removal .....................................................................................................183

9.7

Digital output module AC 120/230 V: Changing fuses ..............................................................187

Debugging functions, diagnostics and troubleshooting .......................................................................... 189 10.1

Overview ....................................................................................................................................189

10.2

Reading out service data ...........................................................................................................189

10.3

Identification and maintenance data of the CPU .......................................................................190

10.4

Overview: Debugging functions .................................................................................................192

10.5

Overview: Diagnostics ...............................................................................................................194

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10.6

Diagnostics functions available in STEP 7................................................................................ 198

10.7

Network infrastructure diagnostics (SNMP) .............................................................................. 199

10.8 10.8.1 10.8.2 10.8.3 10.8.4 10.8.5 10.8.6 10.8.7

Diagnostics using status and error LEDs.................................................................................. 201 Introduction ............................................................................................................................... 201 Status and error displays of all CPUs ....................................................................................... 201 Evaluating the SF LED in case of software errors .................................................................... 202 Evaluating the SF LED in case of hardware errors................................................................... 204 Status and Error Indicators: CPUs with DP Interface ............................................................... 205 Status and error indicators: CPUs with PROFINET interface for the S7-300........................... 206 Status and Error Indicators: PROFINET IO Devices ................................................................ 207

10.9 10.9.1 10.9.2 10.9.3 10.9.4

Diagnostics of DP CPUs ........................................................................................................... 208 Diagnostics of DP CPUs operating as DP Master .................................................................... 208 Reading out slave diagnostic data ............................................................................................ 211 Interrupts on the DP Master ...................................................................................................... 216 Structure of the slave diagnostic data when the CPU is operated as intelligent slave............. 217

10.10 Diagnostics of PROFINET CPUs .............................................................................................. 225 10.10.1 Diagnostics options of PROFINET IO....................................................................................... 225 10.10.2 Maintenance.............................................................................................................................. 226 11

A

10

General technical data........................................................................................................................... 229 11.1

Standards and approvals .......................................................................................................... 229

11.2

Electromagnetic compatibility ................................................................................................... 233

11.3

Transportation and storage conditions for modules.................................................................. 235

11.4

Mechanical and climatic environmental conditions for S7-300 operation................................. 236

11.5

Specification of dielectric tests, protection class, degree of protection, and rated voltage of S7-300................................................................................................................................... 238

11.6

Rated voltages of S7-300.......................................................................................................... 238

Appendix................................................................................................................................................ 239 A.1

General rules and regulations for S7-300 operation................................................................. 239

A.2 A.2.1 A.2.2 A.2.2.1 A.2.2.2 A.2.2.3 A.2.2.4 A.2.2.5 A.2.3 A.2.4 A.2.5 A.2.6 A.2.7 A.2.8 A.2.9

Protection against electromagnetic interference....................................................................... 241 Basic Points for EMC-compliant system installations ............................................................... 241 Five basic rules for securing EMC ............................................................................................ 243 1. Basic rule for ensuring EMC ................................................................................................. 243 2. Basic rule for ensuring EMC ................................................................................................. 243 3. Basic rule for ensuring EMC ................................................................................................. 244 4. Basic rule for ensuring EMC ................................................................................................. 244 5. Basic rule for ensuring EMC ................................................................................................. 245 EMC-compliant installation of automation systems .................................................................. 245 Examples of an EMC-compliant installation: Cabinet configuration ......................................... 247 Examples of an EMC-compliant installation: Wall mounting..................................................... 248 Cable shielding.......................................................................................................................... 249 Equipotential Bonding ............................................................................................................... 251 Cable routing inside buildings ................................................................................................... 253 Outdoor routing of cables.......................................................................................................... 255

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Table of contents

A.3 A.3.1 A.3.2 A.3.3 A.3.4 A.3.5 A.3.6 A.3.7

Lightning and surge voltage protection......................................................................................256 Overview ....................................................................................................................................256 Lightning protection zone concept .............................................................................................257 Rules for the interface between the lightning protection zones 0 and 1 ....................................259 Rules for the interface between the lightning protection zones 1 and 2 ....................................262 Rules for the interface between the lightning protection zones 2 and 3 ....................................264 Example: Surge protection circuit for networked S7-300 CPUs ................................................266 How to protect digital output modules against overvoltages caused by inductance .................268

A.4

Functional safety of electronic control equipment......................................................................270

Glossary ................................................................................................................................................ 273 Index...................................................................................................................................................... 301

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1

Guide to the S7-300 documentation 1.1

Documentation classification

Documentation classification The documentation listed below is part of the S7-300 documentation package. You can also find this on the Internet (http://support.automation.siemens.com/WW/view/en/) and the corresponding entry ID. Name of the manual

Description

Manual

• • • • •

Operator control and display elements Communication Memory concept Cycle and response times Technical data

• • • • • • •

Configuring Installing Wiring Addressing Commissioning Maintenance and the test functions Diagnostics and troubleshooting

CPU 31xC and CPU 31x: Technical Data Entry ID: 12996906

Operating Instructions CPU 31xC and CPU 31x: Installation Entry ID: 13008499

Manual CPU 31xC: Technological functions incl. CD Entry ID: 12429336

Description of the specific technological functions: • Positioning • Counting • Point-to-point connection • Rules The CD contains examples of the technological functions.

Manual S7-300 Automation System: Module data Entry ID: 8859629

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

Functional descriptions and technical specifications of the following modules: • Signal modules • Power supplies • Interface modules

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Guide to the S7-300 documentation 1.1 Documentation classification Name of the manual

Description

Operation lists • CPU 31xC, CPU 31x, IM151-7 CPU, IM154-8 CPU, BM 147-1 CPU, BM 147-2 CPU

The instruction list contains: • List of the instruction set of the CPUs and their execution times. • List of the executable blocks (OBs/SFCs/SFBs) and their execution times.

•

Entry ID: 13206730 CPU 312, CPU 314, CPU 315-2 DP, V3.0 or higher Entry ID: 31977679

Getting Started • S7-300 Getting Started Collection Entry ID: 15390497 • PROFINET Getting Started Collection Entry ID: 19290251

The collections use concrete examples to provide step-by-step instructions on how to commission a fully functional application. S7-300 Getting Started Collection: • CPU 31x: Commissioning • CPU 31xC: Commissioning • CPU 314C: Positioning with analog output • CPU 314C: Positioning with digital output • CPU 31xC: Counting • CPU 31xC: Point-to-point connection • CPU 31xC: Rules PROFINET Getting Started Collection: • CPU 315-2 PN/DP, CPU 317-2 PN/DP and CPU 319-3 PN/DP: Configuring the PROFINET interface • CPU 317-2 PN/DP: Configuring an ET 200S as PROFINET IO device

14

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ITEM 3000 Guide to the S7-300 documentation 1.1 Documentation classification

Further Information You also require information from the following descriptions: Name of the manual

Description

STEP 7 System software for S7-300/400 system and standard functions Volume 1/2 Entry ID: 1214574

Overview of the OBs, SFCs, SFBs, IEC functions, diagnostics data, system status list (SSL) and events in the operating systems of the CPUs of the S7-300 and S7-400. This manual is part of the STEP 7 reference information. You can also find the description in the online help for STEP 7.

Programming with STEP 7 Entry ID: 18652056

This manual provides a complete overview of programming with the STEP 7 Standard Package. This manual is part of the STEP 7 Standard Package basic information. A description is also available in the online help for STEP 7.

PROFINET PROFINET System Description Entry ID: 19292127

From PROFIBUS DP to PROFINET IO Entry ID: 19289930 SIMATIC NET: Twisted Pair and Fiber-Optic Networks Entry ID: 8763736

• • • • • •

Basic description of PROFINET: Network components Data exchange and communication PROFINET IO Component Based Automation Application example of PROFINET IO and Component Based Automation

Guideline for the migration from PROFIBUS DP to PROFINET I/O. Description of Industrial Ethernet networks, network configuration, components, installation guidelines for networked automation systems in buildings, etc.

Component Based Automation Configure SIMATIC iMap plants Entry ID: 22762190 SIMATIC iMap STEP 7 AddOn, create PROFINET components Entry ID: 22762278 Isochronous mode Entry ID: 15218045 SIMATIC communication Entry ID: 1254686

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

Description of the SIMATIC iMap configuration software Descriptions and instructions for creating PROFINET components with STEP 7 and for using SIMATIC devices in Component Based Automation Description of the system property "Isochronous mode" Basics, services, networks, communication functions, connecting PGs/OPs, engineering and configuring in STEP 7.

15

ITEM 3000 Guide to the S7-300 documentation 1.2 Guide to the S7-300 documentation

Service & support on the Internet Information on the following topics can be found on the Internet (http://www.siemens.com/automation/service): ● Contacts for SIMATIC (http://www.siemens.com/automation/partner) ● Contacts for SIMATIC NET (http://www.siemens.com/simatic-net) ● Training (http://www.sitrain.com)

1.2

Guide to the S7-300 documentation

Overview The following tables contain a guide through the S7-300 documentation.

Ambient influence on the automation system Information about ...

is available in the manual ...

In Section ...

What provisions do I have to make for automation system installation space?

CPU 31xC and CPU 31x: Installation

Configuring – Component dimensions Mounting – Installing the mounting rail

How do environmental conditions influence the automation system?

CPU 31xC and CPU 31x: Installation

Appendix

Information about ...

is available in the manual ...

In Section ...

Which modules can I use if electrical isolation is required between sensors/actuators?

CPU 31xC and CPU 31x: Installation

Configuring – Electrical assembly, protective measures and grounding

Galvanic isolation

Module data Under what conditions do I have to isolate the modules electrically?

CPU 31xC and CPU 31x: Installation

How do I wire that? Under which conditions do I have to isolate stations electrically?

Configuring – Electrical assembly, protective measures and grounding Wiring

CPU 31xC and CPU 31x: Installation

Configuring – Configuring subnets

How do I wire that?

16

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ITEM 3000 Guide to the S7-300 documentation 1.2 Guide to the S7-300 documentation

Communication between sensors/actuators and the PLC Information about ...

is available in the manual ...

Which module is suitable for my sensor/actuator?

• •

How many sensors/actuators can I connect to the module?

• •

In Section ...

CPU 31xC and CPU 31x: Technical Data For your signal module

Technical Data

CPU 31xC and CPU 31x: Technical Data For your signal module

Technical Data

How do I connect my sensors/actuators to the automation system, using the front connector?

CPU 31xC and CPU 31x: Installation

Wiring – Wiring the front connector

When do I need expansion modules (EM) and how do I connect them?

CPU 31xC and CPU 31x: Installation

Configuring – Distribution of modules to several racks

How do I mount modules on racks / mounting rails?

CPU 31xC and CPU 31x: Installation

Assembly – Installing modules on the mounting rail

Information about ...

is available in the manual ...

In Section ...

Which range of modules do I want to use?

•

The use of local and distributed IOs

•

Module data (for centralized IOs and expansion devices) of the respective peripheral (for distributed IOs / PROFIBUS DP)

–

Configuration consisting of the central controller and expansion units Information about ...

is available in the manual ...

In Section ...

Which rack / mounting rail is most suitable for my application?

CPU 31xC and CPU 31x: Installation

Configuring

Which interface modules (IM) do I need to connect the expansion units to the central controller?

CPU 31xC and CPU 31x: Installation

Configuring – Distribution of modules to several racks

What is the right power supply (PS) for my application?

CPU 31xC and CPU 31x: Installation

Configuring

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Guide to the S7-300 documentation 1.2 Guide to the S7-300 documentation

CPU performance Information about ...

is available in the manual ...

In Section ...

Which memory concept is best suited to my application?

CPU 31xC and CPU 31x: Technical Data

Memory concept

How do I insert and remove Micro Memory Cards?

CPU 31xC and CPU 31x: Installation

Commissioning – Commissioning modules – Removing / inserting a Micro Memory Card (MMC)

Which CPU meets my demands on performance?

S7-300 instruction list: CPU 31xC and CPU 31x

–

Length of the CPU response / execution times

CPU 31xC and CPU 31x: Technical Data

–

Which technological functions are implemented?

Technological functions

–

How can I use these technological functions?

Technological functions

–

Communication Information about ...

is available in the manual ...

Which principles do I have to take into account?

• • •

CPU 31xC and CPU 31x: Technical Data Communication with SIMATIC PROFINET System Description

In Section ... Communication

Options and resources of the CPU

CPU 31xC and CPU 31x: Technical Technical Data Data

How to use communication processors (CPs) to optimize communication

CP Manual

–

Which type of communication network is best suited to my application?

CPU 31xC and CPU 31x: Installation

Configuring – Configuring subnets

How do I network the various components?

CPU 31xC and CPU 31x: Installation

Configuring – Configuring subnets

What to take into account when configuring PROFINET networks

SIMATIC NET, twisted-pair and fiber-optic networks (6GK1970-1BA10-0AA0)

Network configuration

PROFINET System Description

Installation and commissioning

Information about ...

is available in the manual ...

In Section ...

Software requirements of my S7-300 system

CPU 31xC and CPU 31x: Technical Technical Data Data

Software

18

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ITEM 3000 Guide to the S7-300 documentation 1.2 Guide to the S7-300 documentation

Supplementary features Information about ...

is available in ...

How can I implement operation and monitoring functions?

The relevant Manual: • For text-based displays • For Operator Panels • For WinCC

(Human Machine Interface) How to integrate process control modules

Respective PCS7 manual

What options are offered by redundant and failsafe systems?

S7-400H – Fault-Tolerant Systems

Information to be observed when migrating from PROFIBUS DP to PROFINET IO

From PROFIBUS DP to PROFINET IO

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

Failsafe systems

19

Guide to the S7-300 documentation 1.2 Guide to the S7-300 documentation

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ITEM 3000

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

ITEM 3000

2

Installation Sequence

We will start by showing you the sequence of steps you have to follow to install your system. Then we will go on to explain the basic rules that you should follow, and how you can modify an existing system.

Installation procedure

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Basic rules for trouble-free operation of the S7 system In view of the many and versatile applications, we can only provide basic rules for the electrical and mechanical installation in this section. You have to at least keep to these basic rules in order to obtain a fully functional SIMATICS7 system.

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

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ITEM 3000 Installation Sequence

Modifying the existing S7 system structure To modify the configuration of an existing system, proceed as described earlier. Note When adding a new signal module, always refer to the relevant module information.

Reference Also refer to the description of the various modules in the manual: SIMATIC S7-300 Automation Systems, Module Data Manual.

22

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

ITEM 3000

3

S7-300 components 3.1

Example of an S7-300 configuration 





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Number

Description

①

Power supply (PS) module

②

Central processing unit (CPU); the example in the diagram shows a CPU 31xC with integrated I/O.

③

Signal module (SM)

④

PROFIBUS bus cable

⑤

Cable for connecting a programming device (PG)

You use a programming device (PG) to program the S7300 PLC. Use the PG cable to interconnect the PG with the CPU. To commission or program a CPU with PROFINET interface, you may also use an Ethernet cable to interconnect the PG with the PROFINET connector of the CPU. Several S7-300 CPUs communicate with one another and with other SIMATIC S7 PLCs via the PROFIBUS cable. Several S7-300 are connected via the PROFIBUS bus cable.

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ITEM 3000

S7-300 components 3.2 Overview of the most important S7-300 modules

3.2

Overview of the most important S7-300 modules You can choose from a number of modules for installing and commissioning the S7-300. The most important modules and their functions are shown below.

Table 3- 1

S7-300 components:

Component

Function

Mounting rail

S7-300 racks

Illustration

Accessories: • Shielding terminal

Power supply (PS) module

The PS converts the line voltage (120/230 VAC) into a 24 VDC operating voltage, and supplies the S7-300 and its 24 VDC load circuits.

CPU

The CPU executes the user program, supplies 5 V to the S7-300 backplane bus, and communicates with other nodes of an MPI network via the MPI interface.

Accessories: • Front connectors (CPU 31xC only)

Additional features of specific CPUs: • DP master or DP slave on a PROFIBUS subnet • Technological functions • Point-to-point connection • Ethernet communication via integrated PROFINET interface

6,(0(16

A CPU 31xC, for example

A CPU 312, 314, or 315-2 DP, for example

A CPU 317, for example

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CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

ITEM 3000 S7-300 components 3.2 Overview of the most important S7-300 modules Component

Function

Signal modules (SM) • Digital input modules • Digital output modules • Digital I/O modules, • Analog input modules • Analog output modules • Analog I/O modules

The SM matches different process signal levels to the S7-300.

Illustration

Accessories: • Front connectors Function modules (FM) Accessories: • Front connectors

Communication processor (CP)

The FM performs time-critical and memory-intensive process signal processing tasks. Positioning or controlling, for example

Accessories: Connecting cable

The CP relieves the CPU of communication tasks.

SIMATIC TOP connect

Wiring of digital modules

Example: CP 342-5 DP for connecting to PROFIBUS DP

Accessories: • Front connector module with ribbon cable terminals Interface module (IM) Accessories: • Connecting cable

The IM interconnects the various rows in an S7-300

PROFIBUS cable with bus connector

Interconnect the nodes of an MPI or PROFIBUS subnet

PG cable

Connects a PG/PC to a CPU

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

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ITEM 3000 S7-300 components 3.2 Overview of the most important S7-300 modules Component

Function

RS 485 repeater

The repeater is used to amplify the signals and to couple segments of an MPI or PROFIBUS subnet.

RS 485 Diagnostic Repeater

Illustration

Switch

A switch is used to interconnect the Ethernet nodes.

Twisted-pair cables with RJ45 connectors.

Interconects devices with Ethernet interface (a switch with a CPU 317-2 PN/DP, for example)

Programming device (PG) or PC with the STEP 7 software package

You need a PG to configure, set parameters, program and test your S7300

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ITEM 3000

Configuring 4.1

4

Overview There, you can find all the necessary information ● for the mechanical configuration of an S7-300, ● for the electrical configuration of an S7-300, ● that has to be observed in networking.

Reference For more detailed information, refer to ● the Communication with SIMATIC manual or ● the SIMATIC NET Twisted-Pair and Fiber-Optic Networks Manual (6GK1970-1BA100AA0)

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ITEM 3000

Configuring 4.2 Basic engineering principles

4.2

Basic engineering principles

Important information for engineering WARNING Open equipment S7-300 modules are open equipment. That is, the S7-300 must be installed in a cubicle, cabinet or electrical control room which can only be accessed using a key or tool. Only trained or authorized personnel are allowed access to such cubicles, cabinets or electrical operating rooms. CAUTION Operation of an S7-300 in plants or systems is defined by special set of rules and regulations, based on the relevant field of application. Observe the safety and accident prevention regulations for specific applications, for example, the machine protection directives. This chapter and the appendix General rules and regulations on S7-300 operation provide an overview of the most important rules you need to observe when integrating an S7-300 into a plant or a system.

Central Rack (CR) and Expansion Rack (ER) An S7-300 PLC consists of a central unit (CU) and of one or multiple expansion modules. The rack containing the CPU is the central unit (CU). Racks equipped with modules and connected to the CU form the expansion modules (EMs) of the system.

Use of an expansion module (EM) You can use EMs if the CU runs out of slots for your application. When using EMs, you might require further power supply modules in addition to the extra racks and interface modules (IM). When using interface modules you must ensure compatibility of the partner stations.

Racks The rack for your S7-300 is a mounting rail. You can use this rail to mount all modules of your S7-300 system.

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ITEM 3000

Configuring 4.2 Basic engineering principles

Horizontal and vertical installation You can mount an S7-300 either vertically or horizontally. The following ambient air temperatures are permitted: ● Vertical assembly: 0 °C to 40 °C ● Horizontal assembly: 0 °C to 60 °C Always install the CPU and power supply modules on the left or at the bottom. 

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 Number

Description

①

the vertical installation of an S7-300

②

the horizontal installation of an S7-300

③

The mounting rail

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Configuring 4.3 Component dimensions

4.3

Component dimensions

Length of the mounting rails Table 4- 1

Mounting rails - Overview

Mounting rail length

Usable length for modules

Order No.

160 mm

120 mm

6ES7 390-1AB60-0AA0

482.6 mm

450 mm

6ES7 390-1AE80-0AA0

530 mm

480 mm

6ES7 390-1AF30-0AA0

830 mm

780 mm

6ES7 390-1AJ30-0AA0

2000 mm

cut to length as required

6ES7 390-1BC00-0AA0

In contrast to other rails, the 2 m mounting rail is not equipped with any fixing holes. These must be drilled, allowing optimal adaptation of the 2 m rail to your application.

Installation Dimensions of the Modules Table 4- 2

Module width

Module

Width

Power supply module PS 307, 2 A

50 mm

Power supply module PS 307, 5 A

80 mm

Power supply module PS 307, 10 A

200 mm

CPU

For information on assembly dimensions, refer to the Technical Data in CPU 31xC and CPU 31x Manual, Technical Data.

Analog I/O modules

40 mm

Digital I/O modules

40 mm

Simulator module SM 374

40 mm

Interface modules IM 360 and IM 365

40 mm

Interface module IM 361

80 mm

● Module height: 125 mm ● Module height with shielding contact element: 185 mm ● Maximum assembly depth: 130 mm ● Maximum assembly depth of a CPU with an inserted DP connector with angled cable feed: 140 mm ● Maximum assembly depth with open front panel (CPU): 180 mm Dimensions of other modules such as CPs, FMs etc. are found in the relevant manuals.

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Configuring 4.3 Component dimensions

Shielding contact element The direct contact between the shielding contact element and the mounting rail makes it easy for you to connect all shielded cables of your S7 modules to ground.

36

&38



 Number

Description

①

Shielding terminals

②

The bracket.

Mount the bracket (order number. 6ES7 390-5AA0-0AA0) to the rail using the two screw bolts. If you use a shielding contact element, the specified dimensions are measured from the base of the element. ● Width of the shielding contact element: 80 mm ● Mountable terminal elements per shield connecting element max. 4 Table 4- 3

Shielding terminals - Overview

Cable with shielding diameter

Shielding terminal order no.

Cable with 2 mm to 6 mm shielding diameter

6ES7 390-5AB00–0AA0

Cable with 3 mm to 8 mm shielding diameter

6ES7 390-5BA00–0AA0

Cable with 4 mm to 13 mm shielding diameter

6ES7 390-5CA00–0AA0

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Configuring 4.4 Specified clearances

4.4

Specified clearances You must maintain the clearance shown in the figure in order to provide sufficient space for installing the modules, and to allow the dissipation of heat generated by the modules. The S7-300 assembly on multiple racks shown in the figure below shows the clearance between racks and adjacent components, cable ducts, cabinet walls etc. For example, when routing your module wiring through cable duct, the minimum clearance between the bottom of the shield connection element and the cable duct is 40 mm.

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Description

①

Wiring with cable duct

②

Minimum clearance between the cable duct and the bottom edge of the shielding contact element is 40 mm

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Configuring 4.5 Arrangement of modules on a single rack

4.5

Arrangement of modules on a single rack

Reasons for using one or multiple racks The number of racks you need will depend on your application. Reasons for using a single rack: • • •

Compact, space-saving use of all your modules Local use of all modules Fewer signals to be processed

Reasons for distributing modules between several racks • •

More signals to be processed Insufficient number of slots

Note If you opt for the installation on a single rack, insert a dummy module to the right of the CPU (order no.: 6ES7 370-0AA01-0AA0). This gives you the option of adding a second rack for your application, simply by replacing the dummy module with an interface module, and without having to reinstall and rewire the first rack.

Rules: Layout of modules on a single module rack The following rules apply to module installations on a single rack: ● No more than eight modules (SM, FM, CP) may be installed to the right of the CPU. ● The accumulated power consumption of modules mounted on a rack may not exceed 1.2 A on the S7-300 backplane bus.

Reference Further information is available in the technical data, for example, in the SIMATIC S7-300 Automation Systems Manual, Module data, or in the S7-300 Manual, CPU 31xC and CPU 31x, Technical Data.

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Configuring 4.6 Distribution of modules to several racks

Example The figure below shows a layout with eight signal modules in an S7-300 assembly.

36

4.6

&38

60 60 60 60 60 60 60 60

Distribution of modules to several racks

Exceptions With CPU 312 and CPU 312C, only a single-row configuration on a rack is possible.

Using interface modules If you are planning an assembly in multiple racks, then you will need interface modules (IM). An interface module routes the backplane bus of an S7-300 to the next rack. The CPU is always located on rack 0. Table 4- 4

Interface modules - Overview

Properties

Two or more rows

Cost-effective 2-row configuration

Send IM in rack 0

IM 360 order no..: 6ES7 360-3AA01-0AA0

IM 365 order no..: 6ES7 365-0AB00-0AA0

Receiver IM in racks 1 to 3

IM 361 order no..: 6ES7 361-3CA01-0AA0

IM 365 (hard-wired to send IM 365)

Maximum number of expansion modules

3

1

Length of connecting cables

1 m (6ES7 368-3BB01-0AA0) 2.5 m (6ES7 368-3BC51-0AA0) 5 m (6ES7 368-3BF01-0AA0) 10 m (6ES7 368-3CB01-0AA0)

1 m (hard-wired)

Remarks

-

Rack 1 can only receive signal modules; the accumulated current load is limited to 1.2 A, whereby the maximum for rack 1 is 0.8 A These restrictions do not apply to operation with interface modules IM 360/IM 361

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Configuring 4.6 Distribution of modules to several racks

Rules: Distribution of modules to several racks Please note the following points if you wish to arrange your modules on multiple racks: ● The IM always uses slot 3 (slot 1: power supply module; slot 2: CPU, slot 3: Interface module) ● It is always on the left before the first signal module. ● No more than 8 modules (SM, FM, CP) are permitted per rack. ● The number of modules (SM, FM, CP) is limited by the permitted current consumption on the S7-300 backplane bus. The accumulated power consumption may not exceed 1.2 A per row. Note For information on the current consumption of the modules, refer to the SIMATIC

Automation Systems S7-300, Module Specifications Manual.

Rules: Interference-proof interfacing Special shielding and grounding measures are not required if you interconnect the CU and EM using suitable interface modules (Send IM and Receive IM). However, you must ensure ● a low impedance interconnection of all racks, ● that the racks of a grounded assembly are grounded in a star pattern, ● that the contact springs on the racks are clean and not bent, thus ensuring that interference currents are properly discharged to ground.

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Configuring 4.6 Distribution of modules to several racks

Example: Full assembly using four racks The figure shows the arrangement of modules in an S7-300 assembly on 4 racks.



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Number

Description

①

Rack 0 (central unit)

②

Rack 1 (expansion module)

③

Rack 2 (expansion module)

④

Rack 3 (expansion module)

⑤

The connecting cable 368

⑥

Restriction for CPU 31xC. When this CPU is used, do not insert SM 8 into Rack 4.

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

ITEM 3000

Configuring 4.7 Selection and installation of cabinets

4.7

Selection and installation of cabinets

Reasons for installing an S7-300 in a cabinet Your S7-300 should be installed in a cabinet, ● if you plan a larger system, ● if you are using your S7-300 systems in an environment subject to interference or contamination, and ● to meet UL/CSA requirements for cabinet installation.

Selecting and dimensioning cabinets Take the following criteria into account: ● ambient conditions at the cabinet's place of installation ● the specified mounting clearance for racks (mounting rails) ● accumulated power loss of all components in the cabinet. The ambient conditions (temperature, humidity, dust, chemical influence, explosion hazard) at the cabinet's place of installation determine the degree of protection (IP xx) required for the cabinet.

Reference for degrees of protection For further information on the degrees of protection, refer to IEC 529 and DIN 40050.

The power dissipation capability of cabinets The power dissipation capability of a cabinet depends on its type, ambient temperature and on the internal arrangement of devices.

Reference for power loss For detailed information on dissipatable power loss, refer to the Siemens catalogs. You can find these at: https://mall.automation.siemens.com/de/guest/guiRegionSelector.asp

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Configuring 4.7 Selection and installation of cabinets

Specification of cabinet dimensions Note the following specifications when you determine the dimensions of a cabinet for your S7-300 installation: ● Space required for racks (mounting rails) ● Minimum clearance between the racks and cabinet walls ● Minimum clearance between the racks ● Space required for cable ducts or fan assemblies ● Position of the stays WARNING Modules may get damaged if exposed to excess ambient temperatures.

Reference for ambient temperatures For information on permitted ambient temperatures, refer to the S7-300 Automation System,

Module Data Manual.

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Configuring 4.7 Selection and installation of cabinets

Overview of typical cabinet types The table below gives you an overview of commonly used cabinet types. It shows you the applied principle of heat dissipation, the calculated maximum power loss and the degree of protection. Table 4- 5

Cabinet types

Open cabinets

Closed cabinets

Through-ventilation by natural convection

Increased throughventilation

Natural convection

Mainly inherent heat dissipation, with a small portion across the cabinet wall.

Higher heat dissipation Heat dissipation only with increased air across the cabinet movement. wall; only low power losses permitted. In most cases, the heat accumulates at the top of the cabinet interior.

Heat dissipation only across the cabinet wall. Forced convection of the interior air improves heat dissipation and prevents heat accumulation.

Heat dissipation by heat exchange between heated internal air and cool external air. The increased surface of the pleated profile of the heat exchanger wall and forced convection of internal and external air provide good heat dissipation.

Degree of protection IP 20

Degree of protection IP 20

Degree of protection IP 54

Degree of protection IP 54

Degree of protection IP 54

Forced convection with Forced convection with rack fan, improvement heat exchanger, of natural convection internal and external auxiliary ventilation

Typical power dissipation under following marginal conditions: • Cabinet size: 600 mm x 600 mm x 2,200 mm • Difference between the outer and inner temperature of the cabinet is 20 °C (for other temperature differences refer to the temperature charts of the cabinet manufacturer) up to 700 W

up to 2,700 W (with fine filter up to 1,400 W)

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

up to 260 W

up to 360 W

up to 1,700 W

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ITEM 3000

Configuring 4.8 Example: Selecting a cabinet

4.8

Example: Selecting a cabinet

Introduction The sample below clearly shows the maximum permitted ambient temperature at a specific power loss for different cabinet designs.

Installation The following device configuration should be installed in a cabinet: ● Central unit, 150 W ● Expansion modules, each with 150 W ● Load power supply under full load, 200 W This results in an accumulated power loss of 650 W.

Power loss dissipated The diagram in the figure below shows guide values for the permitted ambient temperature of a cabinet with the dimensions 600 mm x 600 mm x 2000 mm, based on the accumulated power loss. These values only apply if you maintain the specified assembly and clearance dimensions for racks (rails).

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Number

Description

①

Closed cabinet with heat exchanger (heat exchanger size 11/6 (920 mm x 460 mm x 111 mm))

②

Cabinet with through-ventilation by natural convection

③

Closed cabinet with natural convection and forced convection by equipment fans

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Configuring 4.9 Electrical assembly, protective measures and grounding

Result The figure below shows the resultant ambient temperatures, based on an accumulated power loss of 650 W: Table 4- 6

Cabinet selection

Cabinet design

Maximum permitted ambient temperature

Closed with natural convection and forced convection (trend 3)

Operation not possible

Open with through-ventilation (trend 2)

approx. 38 ℃

Closed with heat exchanger (trend 1)

approx. 45 °C

Cabinet types suitable for horizontal installation of the S7-300: ● open, with closed ventilation ● closed, with heat exchanger

4.9

Electrical assembly, protective measures and grounding

4.9.1

Grounding concept and overall structure This section contains information about the overall configuration of an S7-300 connected to a grounded TN-S network: ● Circuit-breaking devices, short-circuit and overload protection to VDE 0100 and VDE 0113 ● Load power supplies and load circuits ● Grounding concept Note An S7-300 can be used in many different ways, so we can only describe the basic rules for the electrical installation in this document. Those basic rules are a must in order to achieve a fully functional S7-300 system.

Definition: Grounded mains In a grounded mains network, the neutral conductor is always bonded to ground. A shortcircuit to ground of a live conductor, or of a grounded part of the system, trips the protective devices.

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ITEM 3000

Configuring 4.9 Electrical assembly, protective measures and grounding

Specified components and protective measures A number of components and protective measures are prescribed for plant installations. The type of components and the degree of compulsion pertaining to the protective measures will depend on the VDE specification applicable to your particular plant. The table below shows components and protective measures. Table 4- 7

VDE specifications for the installation of a PLC system

Compare ...

1)

VDE 0100

VDE 0113

Disconnect devices for control systems, signal generators and final control elements

(1)

...Part 460:

... Part 1:

Master switch

Load disconnect switch

Short-circuit / overload protection:

(2)

...Part 725:

... Part 1: • With grounded secondary power circuit: single-pole fusing • Otherwise: fusing of all poles

Single-pole fusing of circuits

In groups for signal generators and final control elements Load power supply for AC load circuits with more than five electromagnetic devices

(3)

Galvanic isolation by transformer recommended

Electrical isolation by transformer mandatory

1) This column refers to the indexes of the figure in the chapter "Overview: Grounding".

Reference For further information on protective measures, refer to the Appendix.

See also Overview display: Grounding (Page 50)

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Configuring 4.9 Electrical assembly, protective measures and grounding

4.9.2

Installing an S7-300 with grounded reference potential

Introduction When the S7-300 is configured with a grounded reference potential, any interference currents are discharged to the grounding conductor / ground. A grounding slide contact is used for this except with CPU 31xC. Note Your CPU is supplied with grounded reference potential. Therefore, if you wish to install an S7-300 with grounded reference potential, you do not need to modify your CPU!

Grounded reference potential of the CPU 31x The figure shows an S7-300 configuration with grounded reference potential (factory state.)



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 Number Description ①

Grounding slide contact in grounded state

②

Ground of the internal CPU circuitry

③

The mounting rail

Note Do not pull out the grounding slide contact when you install an S7-300 with grounded reference potential.

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Configuring 4.9 Electrical assembly, protective measures and grounding

4.9.3

Installing an S7-300 with ungrounded reference potential (not CPU 31xC)

Introduction When the S7-300 is configured with an ungrounded reference potential, interference currents are discharged to the ground conductor / to ground via an RC combination integrated in the CPU. Note An S7-300 with a CPU 31xC cannot be configured ungrounded.

Application In large systems, the S7-300 may require a configuration with grounded reference potential due to ground-fault monitoring. This is the case, for example, in chemical industry and power stations.

Ungrounded reference potential of the CPU 31x The figure shows an S7-300 configuration with floating potential

 0

/ 0

0˖

0

Q)



 Number Description ①

How to implement an ungrounded reference potential in your CPU: Use a screwdriver with 3.5 mm blade width to push the grounding slide contact forwards in the direction of the arrow until it snaps into place.

②

Ground of the internal CPU circuitry

③

The mounting rail.

Note You should set up the ungrounded reference potential before you mount the device on the rail. If you have already installed and wired up the CPU, you may have to disconnect the MPI interface before you pull out the grounding slide contact.

44

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Configuring 4.9 Electrical assembly, protective measures and grounding

4.9.4

Isolated or non-isolated modules?

Isolated modules

Isolated modules are installed with galvanic isolation between the reference potentials of the control circuit (Minternal) and load circuit (Mexternal.)

Field of application Use isolated modules for: ● All AC load circuits ● DC load circuits with separate reference potential Examples: – DC load circuits containing sensors which are connected to different reference potentials (for example, if grounded sensors are located at a considerable distance from the control system and equipotential bonding is not possible) – DC load circuits with grounded positive pole (L+) (battery circuits.)

Isolated modules and grounding concept

You can always use isolated modules, irrespective of the grounding state of the control system's reference potential.

Example: Assembly with CPU 31xC and isolated modules

The figure below shows an example of such a configuration: A CPU 31xC with isolated modules. The CPU 31xC (1) is automatically grounded. 36

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CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

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ITEM 3000

Configuring 4.9 Electrical assembly, protective measures and grounding

Common potential modules In a configuration containing modules with common potential, the reference potentials of the control circuit (Minternal) and analog circuit (Manalog) are not galvanically isolated.

Example: Installing an S7-300 with common potential modules When using an SM 334 AI 4/AO 2 analog I/O module, connect one of the grounding terminals Manalog to the CPU's chassis ground. The figure below shows an example of such a configuration: An S7-300 with common potential modules 36

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46

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Configuring 4.9 Electrical assembly, protective measures and grounding

4.9.5

Grounding measures

Bonding to ground Low-impedance connections to ground reduce the risk of electric shock as a result of a short-circuit or system fault. Low-impedance connections (large surface, large-surface contact) reduce the effects of interference on the system or the emission of interference signals. An effective shielding of cables and devices is also a significant contribution. WARNING All protection class 1 devices, and all larger metal parts, must be bonded to protective ground. That is the only way to safely protect operators from electrical shock. This also discharges any interference transmitted from external power supply cables, signal cables or cables to the I/O devices.

Measures for protective grounding The table below shows an overview of the most important measures for protective grounding. Table 4- 8

Measures for protective grounding

Device

Measures

Cabinet / mounting frame

Connection to central ground (equipotential busbar, for example) using cables with protective conductor quality

Rack / mounting rail

Connection to central ground, using cables with a minimum crosssection of 10 mm2, if the rails are not installed in the cabinet and not interconnected with larger metallic parts.

Module

None

I/O Device

Grounding via grounding-type plug

Sensors and final control elements

Grounding in accordance with regulations applying to the system

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Rule: Connect the cable shielding to ground You should always connect both ends of the cable shielding to ground / system ground. This is the only way to achieve an effective interference suppression in the higher frequency range. Attenuation is restricted to the lower frequency range if you connect only one end of the shielding (that is, at the start or end of the cable) to ground. One-sided shielding connections could be more favorable in situations ● not allowing the installation of an equipotential bonding conductor, ● where analog signals (some mA or µA) are transferred, ● or if foil shielding is used (static shielding). Note Potential differences between two grounding points might cause an equipotential current flow across shielding connected at both ends. In this case, you should install an additional equipotential bonding conductor. CAUTION Always avoid the flow of operating current to ground.

Rule: Load circuit grounding You should always ground the load circuits. This common reference potential (ground) ensures proper functioning. Note (not valid for CPU 31xC): If you want to locate a fault to ground, provide your load power supply (terminal L or M) or the isolating transformer with a removable connection to the protective conductor (see Overview: Grounding section 4).

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Connecting the load voltage reference potential A complex system containing many output modules requires an additional load voltage for switching the final control elements. The table below shows how to connect the load voltage reference potential Mexternal for the various configurations. Table 4- 9

Connecting the load voltage reference potential

Installation

common potential modules

isolated modules

Note

grounded

Connect Mexternal with M on the CPU

Connect or do not connect Mexternal to the grounding busbar

-

ungrounded Connect Mexternal with M on the CPU

Connect or do not connect Mexternal to the grounding busbar

Ungrounded installation with CPU 31xC is not possible

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4.9.6

Overview display: Grounding

CPU 31xC

The figure below shows you the complete assembly of an S7-300 with CPU 31xC with a power supply from TN-S mains. Apart from powering the CPU, the PS 307 also supplies the load current for the 24 VDC modules. Remark: The layout of the power connections does not correspond with their physical arrangement; it was merely selected to give you a clear overview.

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Description The main switch The short-circuit / overload protection The load current supply (galvanic isolation) This connection is made automatically for the CPU 31xC Connecting the load voltage reference potential

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Configuring 4.9 Electrical assembly, protective measures and grounding

All CPUs except CPU 31xC The figure below shows you the complete assembly of an S7-300 with TN-S mains supply (does not apply to CPU 31xC). Apart from powering the CPU, the PS 307 also supplies the load current for the 24 VDC modules. Remark: The layout of the power connections does not correspond with their physical arrangement; it was merely selected to give you a clear overview. / / / 1 3(

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Number Description ①

The main switch

②

The short-circuit / overload protection

③

The load current supply (galvanic isolation)

④

The removable connection to the grounding conductor, for ground fault localization

⑤

The grounding slide contact of the CPU (not CPU 31xC)

Figure 4-2

Connecting the load voltage reference potential

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4.10

Selection of the load power supply

Task of the load power supply The load power supply feeds the input and output circuits (load circuits), and the sensors and actuators.

Features of load power supply units You will have to adapt the load power supply unit to your specific application. The table below shows a comparison of the various load power supply units and their features to help you make your choice: Table 4- 10

Features of load power supply units

Necessary for ...

Feature of the load power supply

Modules requiring voltage Safety isolation supplies ≤ 60 VDC or ≤ 25 VAC.

This is a common feature of the Siemens power supply series PS 307 and SITOP power series 6EP1.

24 VDC load circuits Output voltage tolerances: 24 VDC load circuits 48 VDC load circuits 60 VDC load circuits

Remarks

-

20.4 V to 28.8 V 40.8 V to 57.6 V 51 V to 72 V

Load power supply requirements Only an extra-low voltage of ≤ 60 VDC which is safely isolated from mains may be used as load voltage. Safe isolation from mains can be achieved, for example, in accordance with VDE 0100 Part 410 / HD 384-4-41 / IEC 364-4-41 (as functional extra-low voltage with safe isolation) or VDE 0805 / EN 60950 / IEC 950 (as safety extra-low voltage SELV) or VDE 0106 Part 101.

Load current determination The required load current is determined by the accumulated load current of all sensors and actuators connected to the outputs. A short-circuit induces a surge current at the DC outputs which is 2 to 3 times higher than the rated output current, until the clocked electronic short-circuit protection comes into effect. Make allowances for this increased short-circuit current when selecting your load power supply unit. Uncontrolled load power supplies usually provide this excess current. With controlled load power supplies, and particularly for low output power up to 20 A, always ensure that the supply can handle this excess current.

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Example: S7-300 with load power supply from PS 307 The figure below shows the overall S7-300 configuration (load power supply unit and grounding concept), with TN-S mains supply. The PS 307 supplies the CPU and the load current circuit of the 24 VDC modules. Note The layout of the power connections does not correspond with their physical arrangement; it was merely selected to give you a clear overview.

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Example: S7-300 with load power supply from PS 307

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4.11

Planning subnets

4.11.1

Overview

Subnets Subnets available in SIMATIC for the various automation levels (process, cell, field and actuator/sensor level ): ● Multi-Point Interface (MPI) ● PROFIBUS ● PROFINET (Industrial Ethernet) ● Point-to-point communication (PtP) ● Actuator/Sensor Interface (ASI)

Multi-Point Interface (MPI) Availability: For all CPUs described in this document. MPI is a small area subnet containing a small number of nodes at the field/cell level. It is a multipoint-capable interface in SIMATIC S7/M7 and C7, designed as PG interface, for networking a small number of CPUs, or for low volume data exchange with PGs. MPI always retains the last configuration of the transmission rate, node number and highest MPI address, even after CPU memory reset, power failure or deletion of the CPU parameter configuration. It is advisable to use the PROFIBUS DP network components for your MPI network configuration. The same configuration rules apply. Exception: OWG modules are not allowed in the MPI network.

PROFIBUS Availability: CPUs with the "DP" name suffix are equipped with a PROFIBUS interface (CPU 315-2 DP, for example). PROFIBUS represents the network at the cell and field level in the SIMATIC open, multivendor communication system. PROFIBUS is available in two versions: 1. PROFIBUS DP field bus for high-speed cyclic data exchange, and PROFIBUS-PA for intrinsically safe applications (requires DP/PA coupler). 2. The cell level as PROFIBUS (FDL or PROFIBUS FMS) for high-speed data exchange with communication partners at the same authorization level (can only be implemented via CP).

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PROFINET (Industrial Ethernet) Availability: CPUs with the "PN" name suffix are equipped with a PROFINET interface (CPU 317-2 PN/DP or CPU 319-3 PN/DP for example). A PROFINET interface, or communication processors, can be used to implement Industrial Ethernet in an S7-300 CPU system. Industrial Ethernet, in an open multivendor communication system, represents the SIMATIC network at the process and cell level. PROFINET CPUs, however, also support real-time communication at the field level. This structure also supports S7 communication. Industrial Ethernet is suitable for high-speed and high-volume data exchange, and for remote network operations via gateway. PROFINET is available in two versions: ● PROFINET IO and ● PROFINET CBA. PROFINET IO is a communication concept for the implementation of modular, distributed applications. PROFINET IO allows you to create automation solutions you are familiar with from PROFIBUS. PROFINET CBA (Component based Automation) is an automation concept for the implementation of applications with distributed intelligence. PROFINET CBA lets you create distributed automation solutions, based on default components and partial solutions. This concept satisfies demands for a higher degree of modularity in the field of mechanical and systems engineering by extensive distribution of intelligent processes. Component-Based Automation allows you to use complete technological modules as standardized components in complex systems.

Point-to-point communication (PtP) Availability: CPUs with "PtP" name suffix are equipped with a second interface, namely the PtP interface (CPU 314C-2 PtP, for example) PtP does not represent a subnet in the common sense, because it is used to interconnect only two stations. If a PtP interface is not available, you require PtP Communication Processors (CP).

Actuator/Sensor Interface (ASI) Implementation by means of communication processors (CP). The ASI, or actuator/sensor interface, represents a subnet system on the lowest process level for automation systems. It is designed especially for networking digital sensors and actuators. The maximum data volume is 4 bits per slave station. S7-300 CPUs require communication processor for the ASI connection.

Reference For further information on communication, refer to the Communication with SIMATIC manual.

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4.11.2

Configuring MPI and PROFIBUS subnets

4.11.2.1

Overview The next section contains all the information you require to configure MPI, PtP and PROFIBUS subnets:

Contents ● MPI, PtP and PROFIBUS subnets ● Multi-Point Interface ● PROFIBUS DP ● MPI and PROFIBUS network components ● Example of networks - MPI

4.11.2.2

Basic principles of MPI and PROFIBUS subnets

Convention: device = node All devices you interconnect on the MPI or PROFIBUS network are referred to as nodes.

Segment A segment is a bus line between two terminating resistors. A segment may contain up to 32 nodes. It is also limited with respect to the permitted line length, which is determined by the transmission rate.

Baud rate Maximum transmission rates: ● MPI: – CPU 315-2 PN/DP, CPU 317 and CPU 319-3 DP/DP 12 Mbps – All other CPUs: 187.5 Kbps ● PROFIBUS DP: 12 Mbps

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Number of nodes Maximum number of nodes per subnet: Table 4- 11

Subnet nodes

Parameters

MPI

PROFIBUS DP

Number

127

126 1)

Addresses

0 to 126

0 to 125

Remark

Default: 32 addresses

of those: • 1 master (reserved) • 1 PG connection (address 0 reserved) • 124 slaves or other masters

Reserved addresses: • Address 0 for PG • Address 1 for OP 1

Note the CPU-specific maximum specifications in the relevant CPU manual.

MPI/PROFIBUS DP addresses You need to assign an address to all nodes in order to enable intercommunication: ● On the MPI network: an "MPI address" ● On the PROFIBUS DP network: "a PROFIBUS DP address" You can use the PG to set the MPI/PROFIBUS addresses for each one of the nodes (some of the PROFIBUS DP slaves are equipped with a selector switch for this purpose).

Default MPI/PROFIBUS DP addresses The table below shows you the default setting of the MPI/PROFIBUS DP addresses, and the factory setting of the highest MPI/PROFIBUS DP addresses for the nodes. Table 4- 12

MPI/PROFIBUS DP addresses

Node (device) Default MPI/PROFIBUS DP address

Default highest MPI address

Default highest PROFIBUS DP address

PG

0

32

126

OP

1

32

126

CPU

2

32

126

Rules: Assignment of MPI/PROFIBUS DP addresses Note the following rules before assigning MPI/PROFIBUS addresses: ● All MPI/PROFIBUS subnet addresses must be unique. ● Highest MPI/PROFIBUS address ≥ physical MPI/PROFIBUS address, and must be identical for each node. (Exception: connecting a PG to multiple nodes; refer to the next chapter).

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Differences in the MPI addresses of CPs/FMs in an S7300 system Table 4- 13

MPI addresses of CPs/FMs in an S7-300 system

Options

Example

Example: A system containing an S7-300 CPU and 2 CPs.

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You have two options of assigning MPI addresses to CPs/FMs installed in a system: CP

CP

1st option: The CPU accepts the MPI addresses MPI addr. you set for the CPs in STEP 7.

CPU

MPI addr.+x

MPI add.+y

2nd option: The CPU automatically assigns MPI addresses to the CPs in its system, based on the following syntax: MPI addr. CPU; MPI addr.+1; MPI addr.+2.

MPI addr.+1

MPI addr.+2

MPI addr.

(Default) Special feature: CPU 315-2 PN/DP, CPU 317 and CPU 319-3 DP/DP

When the central rack of an S7-300 contains FM/CPs with their own MPI address, the CPU forms its own communication bus via the backplane bus for these FM/CPs and separates it from the other subnets. The MPI address of those FM/CPs is thus no longer relevant for the nodes on other subnets. The MPI address of the CPU is used to communicate with these FMs/CPs.

Recommendation for MPI addresses Reserve MPI address "0" for a service PG, or "1" for a service OP, for temporary connections of these devices to the subnet. You should therefore assign different MPI addresses to PGs/OPs operating on the MPI subnet. Recommended MPI address of the CPU for replacement or service operations: Reserve MPI address "2" for the CPU. This prevents duplication of MPI addresses after you connect a CPU with default settings to the MPI subnet (for example, when replacing a CPU). That is, you should assign an MPI address greater than "2" to CPUs on the MPI subnet.

Recommendation for PROFIBUS addresses Reserve PROFIBUS address "0" for a service PG that you can subsequently connect briefly to the PROFIBUS subnet as required. You should therefore assign unique PROFIBUS addresses to PGs integrated in the PROFIBUS subnet.

PROFIBUS DP: Electrical cables or fiber-optic cables? Use fiber optic cables on a field bus with greater length, rather than copper conductors, in order to be independent on the transmission rate, and to exclude external interference.

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Equipotential bonding For information on what to take into account with respect to equipotential bonding in your network configuration, refer to the corresponding chapter in the appendix.

Reference For further information, refer to the Communication section in CPU 31xC and CPU 31x

Manual, Technical Data.

4.11.2.3

Multi-Point Interface (MPI)

Availability All the CPUs described here are equipped with an MPI interface A CPU equipped with an MPI/DP interface is configured and supplied as MPI interface.

Properties The MPI (Multi-Point Interface) represents the CPU interface for PG/OP connections, or for communication on an MPI subnet. The default transmission rate of all CPUs is 187.5 Kbps. You can also set 19.2 Kbps for communication with an S7-200. The 315-2 PN/DP, 317-2 and 319-3 PN/DP CPUs support transmission rates to 12 Mbps. The CPU automatically broadcasts its bus configuration via the MPI interface (the transmission rate, for example). A PG, for example, can thus receive the correct parameters and automatically connect to a MPI subnet.

Devices capable of MPI communication ● PG/PC ● OP/TP ● S7-300 / S7-400 with MPI interface ● S7-200 (only at 19.2 Kbps) NOTICE You may only connect PGs to an MPI subnet which is in RUN. Do not connect other stations (for example, OP, TP) to the MPI subnet while the system is running. Otherwise, transferred data might be corrupted as a result of interference, or global data packages may be lost.

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Clock synchronization The CPU's MPI interface supports clock synchronization. The CPU can be programmed for operation as time-of-day master (with default synchronization intervals) or slave clock. Default setting: No clock synchronization The synchronization mode is set in the "Clock" tab of the CPU or interface properties dialog box in HW Config.

CPU as a time slave When operated as a slave clock, the CPU receives a synchronization message frame from exactly one time-of-day master and sets its internal time accordingly.

CPU as a time master When operated as time-of-day master, the CPU broadcasts clock synchronization message frames at programmed synchronization intervals at the MPI interface to other node stations of the MPI subnet. Condition: The CPU real-time clock may no longer be in the default state. It has to be set once. Note The real-time clock of the CPU is not yet set in the state of delivery or after resetting to the state of delivery using the mode selector or after a firmware update. The clock synchronization starts as a time-of-day master: ● As soon as you have set the time the first time using SFC 0 "SET_CLK" or the programming device function. ● By another time-of-day master if the CPU is also parameterized as a slave clock using the MPI/DP or PROFINET interface.

Interfaces for clock synchronization Clock synchronization is possible at the following interfaces: ● At the MPI Interface ● At the DP Interface ● At the PROFINET Interface ● In the automation system of the central configuration Note The CPU may only be operated as a slave clock at one of these interfaces.

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Example 1 A CPU operating as a slave clock on the DP interface can only operate as a time-of-day master on the MPI interface and/or within the automation system.

Example 2 If the CPU time is already synchronized through clock synchronization by means of a PROFINET interface via NTP (corresponds to the functionality as a slave clock), the CPU can only be operated as a time-of-day master at the DP interface and/or the MPI interface within the automation system.

4.11.2.4

PROFIBUS DP interface

Availability CPUs with the "DP" have at least one DP interface. The 315-2 PN/DP and 317-2 PN/DP CPUs feature an integrated MPI/DP interface. The 317-2 DP and 319-3 PN/DP CPUs feature an MPI/DP interface plus an additional DP interface. The factory setting of the CPU's MPI/DP interface is MPI mode. You need to set DP mode in STEP 7 if you want to use the DP interface.

Operating modes for CPUs with two DP interfaces Table 4- 14

Operating modes for CPUs with two DP interfaces

MPI/DP interface • • • 1)

MPI DP master DP slave 1)

PROFIBUS DP interface • • •

not configured DP master DP slave 1)

simultaneous operation of the DP slave on both interfaces is excluded

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Properties The PROFIBUS DP interface is mainly used to connect distributed I/O. PROFIBUS DP allows you to create large subnets, for example. The PROFIBUS DP interface can be configured for operation in master or slave mode, and supports transmission rates up to 12 Mbps. The CPU broadcasts its bus parameters (transmission rate, for example) via the PROFIBUS DP interface when master mode is set. This functionality automatically provides the correct parameters for online operation of a programming device, for example. In your configuration you can specify to disable bus parameter broadcasting. Note (for DP interface in slave mode only) When you disable the "Test, Commissioning, Routing" check box in the DP interface properties dialog box in STEP 7, the transmission rate settings of the master automatically override corresponding user-specific settings. This disables the routing function at this interface.

Devices capable of PROFIBUS DP communication ● PG/PC ● OP/TP ● DP slaves ● DP master ● Actuators/Sensors ● S7-300/S7-400 with PROFIBUS DP interface

Clock synchronization The CPU's DP interface supports clock synchronization. The CPU can be programmed for operation as time master (with default synchronization intervals) or time slave. Default setting: No clock synchronization The synchronization mode is set in the "Clock" tab of the interface properties dialog box in HW Config.

CPU as a time slave When operated as a slave clock, the CPU receives a synchronization message frame from exactly one time-of-day master and sets its internal time accordingly.

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CPU as a time master When operated as time-of-day master, the CPU broadcasts clock synchronization message frames at programmed synchronization intervals at the DP interface to other node stations of the DP subnet. Condition: The CPU real-time clock may no longer be in the default state. It has to be set once. Note The real-time clock of the CPU is not yet set in the state of delivery or after resetting to the state of delivery using the mode selector or after a firmware update. The clock synchronization starts as a time-of-day master: ● As soon as you have set the time the first time using SFC 0 "SET_CLK" or the programming device function. ● By another time-of-day master if the CPU is also parameterized as a slave clock using the MPI/DP or PROFINET interface.

Interfaces for clock synchronization Clock synchronization is possible at the following interfaces: ● At the MPI Interface ● At the DP Interface ● At the PROFINET Interface ● In the automation system of the central configuration Note The CPU may only be operated as a slave clock at one of these interfaces.

Example 1 A CPU operating as a slave clock on the DP interface can only operate as a time-of-day master on the MPI interface and/or within the automation system.

Example 2 If the CPU time is already synchronized through clock synchronization by means of a PROFINET interface via NTP (corresponds to the functionality as a slave clock), the CPU can only be operated as a time-of-day master at the DP interface and/or the MPI interface within the automation system.

Reference Further information on the PROFIBUS can be found on the Internet.

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4.11.2.5

Network components of MPI/DP and cable lengths

MPI subnet segment You can install cables with a length of up to 50 m in an MPI subnet segment. This length of 50 m is the distance between the first and the last node of the segment. Table 4- 15

Permissible cable length of a segment on the MPI subnet

Baud rate

S7-300 CPUs (non-isolated MPI interface) without CPU 315-2 PN/DP / CPU 317 / CPU 319

CPU 315-2 PN/DP / CPU 317 / CPU 319

19.2 Kbps

50 m

1000 m

-

200 m

187.5 Kbps 1.5 Mbps 3.0 Mbps

100 m

6.0 Mbps 12.0 Mbps

Segment on the PROFIBUS subnet The maximum cable length of a segment on the PROFIBUS subnet is determined by the set transmission rate. Table 4- 16

Permissible cable length of a segment on the PROFIBUS subnet

Baud rate

Maximum cable length of a segment

9.6 Kbps to 187.5 Kbps

1000 m

500 Kbps

400 m

1.5 Mbps

200 m

3 Mbps to 12 Mbps

100 m

Longer cable lengths via RS 485 Repeater / RS 485-Diagnostics Repeater You need to install RS485 repeaters for segments requiring cable lengths longer than the allowed length. For further information about the RS485 Repeater refer to the Module Specifications Manual.

Stub cables Make allowances for the maximum stub cable length when you connect bus nodes to a segment by means of stub cables, for example, a PG via standard PG cable. For transmission rates up to 3 Mbps, you can use a PROFIBUS bus cable with bus connector as stub cable. For transmission rates higher than 3 Mbps, use the patch cord to connect the PG or PC. You can connect several PG patch cords to the bus (for order numbers see table 4-20). Other types of stub cables are not permitted.

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Length of stub cables The table below shows the maximum permitted lengths of stub cables per segment: Table 4- 17

Lengths of stub cables per segment

Baud rate

Max. length of stub cables per segment

Number of nodes with stub cable length of ... 1.5 m or 1.6 m

3m

9.6 Kbps to 93.75 Kbps

96 m

32

32

187.5 Kbps

75 m

32

25

500 Kbps

30 m

20

10

1.5 Mbps

10 m

6

3

3 Mbps to 12 Mbps

1)

1)

1)

1) To connect PGs or PCs when operating at rates higher than 3 Mbps, use PG connecting cable with the order number 6ES7 901-4BD00-0XA0. In your bus configuration, you can use multiple PG patch cords with this order number. Other types of stub cables are not permitted.

PG connecting cable Table 4- 18

PG connecting cable

Type

Order No.

PG connecting cable

6ES7 901-4BD00-0XA0

PROFIBUS cables For PROFIBUS DP or MPI networking we offer you the following bus cables for diverse fields of application: Table 4- 19

Available bus cables

Bus cable

Order No.

PROFIBUS cable

6XV1 830-0AH10

PROFIBUS cable, halogen-free

6XV1 830-0LH10

PROFIBUS underground cable

6XV1 830-3AH10

PROFIBUS trailing cable

6XV1 830-3BH10

PROFIBUS cable with PUR sheath for environments subject to 6XV1 830-0DH10 chemical and mechanical stress PROFIBUS cable with PE sheath for the food and beverages industry

6XV1 830-0BH10

PROFIBUS cable for festooning

6XV1 830-3CH10

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Properties of PROFIBUS cables The PROFIBUS bus cable is a 2-wire, shielded twisted-pair cable with copper conductors. It is used for hardwired transmission in accordance with US Standard EIA RS485. The table below lists the characteristics of these cables. Table 4- 20

Properties of PROFIBUS cables

Properties

Values

Wave impedance

approx. 135 Ω to 160 Ω (f = 3 MHz to 20 MHz)

Loop resistance

≤ 115 Ω/km

Effective capacitance

30 nF/km

Attenuation

0.9 dB/100 m (f = 200 kHz)

Permitted conductor cross-sections

0.3 mm2 to 0.5 mm2

Permitted cable diameter

8 mm ± 0.5 mm

Installation of bus cables When you install PROFIBUS bus cables, you must not ● twist, ● stretch ● or compress them. When wiring indoor bus cables, also maintain the following marginal conditions (dA = outer cable diameter): Table 4- 21

Marginal conditions for wiring interior bus cables

Characteristics

Condition

Bending radius (one-off)

≥ 80 mm (10 x dA)

Bending radius (multiple times)

≥ 160 mm (20 x dA)

Permitted temperature range during installation

–5 °C to +50 °C

Shelf and static operating temperature range

–30 °C to +65 °C (–22 °F to +149 °F)

Reference For information on the use of fiber-optic cables for PROFIBUS, refer to the SIMATIC NET, PROFIBUS Networks Manual.

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Bus connector RS 485 Table 4- 22

Bus connector

Type

Order No.

Bus connector RS 485 up to 12 Mbps with 90° cable exit without programming device interface with programming device interface

6ES7 972-0BA11-0XA0 6ES7 972-0BB11-0XA0

Fast connect bus connector RS 485 up to 12 Mbps with 90° cable outlet in insulation displacement method without programming device interface with programming device interface

6ES7 972-0BA50-0XA0 6ES7 972-0BB50-0XA0

Bus connector RS 485 up to 12 Mbps with 35° cable outlet (not for CPU 31xC, 312, 314 and 315-2 DP) without programming device interface with programming device interface

6ES7 972-0BA40-0XA0 6ES7 972-0BB40-0XA0

Field of application You need bus connectors to connect the PROFIBUS bus cable to an MPI or PROFIBUS-DP interface You do not require a bus connector for: ● DP slaves with degree of protection IP 65 (ET 200pro, for example) ● RS 485 repeater.

RS485 Repeater 485 Type

Order No.

RS 485 repeater

6ES7 972-0AA01-0XA0

RS 485 Diagnostic Repeater

6ES7 972-0AB01-0XA0

Note SFC 103 "DP_TOPOL" can be used to initiate identification of the bus topology of a DP master system by way of the interconnected diagnostic repeaters.

Purpose RS485 repeaters are used to amplify data signals on bus lines and to couple bus segments. You require this RS 485 Repeater in the following situations: ● more than 32 network nodes ● when interconnecting a grounded with an ungrounded segment ● when exceeding the maximum line length in a segment

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Longer cable lengths If you want to implement cable lengths above those permitted in a segment, you must use RS485 repeaters. The maximum cable length between two RS 485 repeaters corresponds to the maximum cable length of a segment. Please note that these maximum cable lengths only apply if there is no further node interconnected between the two RS 485 repeaters. You can connect up to nine RS 485 repeaters in series. Please note that you have to add the RS 485 repeater when you determine the number of nodes in your subnet, even if it is not assigned its own MPI/PROFIBUS address.

Reference For further information about the RS485 Repeater, refer to the Module Specifications

Manual.

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4.11.2.6

Cable lengths of MPI and PROFIBUS subnets

Example: Installation of an MPI subnet The figure below shows you the block diagram of a MPI subnet. 6 2 36

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②

S7-300 and OP 277 have subsequently been connected to the MPI subnet using their default MPI address.

③

CPU 31xC, 312, 314, 315-2 DP: You can also assign user-specific MPI addresses to the CPs/FMs at these CPUs. CPU 317-2 DP, 315-2 PN/DP, 317-2 PN/DP, 319-3 PN/DP: CPs and FMs do not have their own MPI address on this CPU.

④

In addition to the MPI address, the CP also has a PROFIBUS address (7 in this case).

⑤

Connected via stub cable using the default MPI address only for commissioning/maintenance.

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Example: Maximum distances in the MPI subnet The figure below shows you: ● a possible MPI subnet configuration ● maximum distances possible in an MPI subnet ● the principle of "Line extension" using RS 485 repeaters  6 36

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②

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Example: Terminating resistor in the MPI subnet The figure below shows you an example of an MPI subnet and where to enable the terminating resistor. The figure below illustrates where the terminating resistors must be enabled in an MPI subnet. In this example, the programming device is connected via a stub cable only for the duration of commissioning or maintenance. 6 36

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②

PG connected by means of stub cable for maintenance purposes

WARNING Disturbance of data traffic might occur on the bus. A bus segment must always be terminated at both ends with the terminating resistor. This, for example, is not the case if the last slave with bus connector is off power. The bus connector draws its power from the station, and the terminating resistor is thus disabled. Please make sure that power is always supplied to stations on which the terminating resistor is active. Alternatively, the PROFIBUS terminator can also be used as active bus termination.

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Example: Installation of a PROFIBUS subnet The figure below shows you the basic principles of a PROFIBUS subnet installation.

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②

PG connected by means of stub cable for maintenance purposes

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Example: CPU 314C-2 DP as MPI and PROFIBUS node. The figure below shows you an assembly with a CPU 314C-2 DP integrated in an MPI subnet and also operated as DP master in a PROFIBUS subnet. 6

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4.11.3

Configuring PROFINET subnets

4.11.3.1

Overview The next section contains all the information you require to configure PROFINET subnets:

Contents

4.11.3.2

● ● ● ● ● ● ●

PROFINET devices Integration of field bus system into PROFINET PROFINET IO and PROFINET CBA (Component-Based Automation) PROFINET cable lengths Ethernet bus cable and connector Example of a PROFINET subnet Example of a PROFINET IO system

PROFINET devices

Definition: Devices in the PROFINET environment Within the context of PROFINET, "device" is the generic term for: ● Automation systems (e.g. PLC, PC) ● Field devices (for example, PLC, PC, hydraulic devices, pneumatic devices) ● Active network components (for example, switches, gateways, routers) ● PROFIBUS or other fieldbus systems The main characteristics of a device is its integration into PROFINET communication by means of Ethernet or PROFIBUS. The following device types are distinguished based on their attachment to the bus: ● PROFINET devices ● PROFIBUS devices

Definition: PROFINET devices A PROFINET device always has at least one Industrial Ethernet port. A PROFINET device can also have a PROFIBUS port, that is, as master with proxy functionality.

Definition: PROFIBUS devices A PROFIBUS device has at least one PROFIBUS link with an electric interface (RS485) or an optical interface (polymer optical fiber, POF). A PROFIBUS device cannot take part directly in PROFINET communication, but must be implemented by means of PROFIBUS master with PROFINET link or Industrial Ethernet/PROFIBUS link (IE/PB Link) with proxy functionality.

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Comparison of the terminology in PROFIBUS DP and PROFINET IO The following schematic shows you the general names of the most important devices in PROFINET IO and PROFIBUS DP. The table below shows the designation of the various components in the PROFINET IO and PROFIBUS DP context. 1 2

3

4 6

6 5

Numb PROFINET er

PROFIBUS

①

IO system

DP master system

②

IO controller

DP master

Remark

Device used to address the connected IO devices/DP slaves. That is: The IO controller/DP master exchanges input and output signals with field devices. The IO controller/DP master is often the controller on which the automation program runs.

③

PG/PC

PG/PC

(IO supervisor)

(Class 2 DP master)

④

Industrial Ethernet

PROFIBUS

⑤

HMI (Human Machine HMI Interface)

Device for operating and monitoring functions.

⑥

IO device

Distributed field device assigned to one of the IO controllers/DP masters, for example, distributed IO, valve terminal, frequency converter, and switches with integrated PROFINET IO functionality.

Figure 4-3

DP slave

PG/PC/HMI device for commissioning and diagnostics Network infrastructure

PROFINET and PROFIBUS devices

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Slots and Submodules A PROFINET IO device is modularly structured - similar to a PROFIBUS DP slave. In doing so, modules are fitted to slots and submodules to subslots. Channels are located on the modules / submodules using which process signals can be read in and issued. The following graphic illustrates the situation.

   







  

    

Figure 4-4

Module, Submodule, Slot, and Channel

Number Description ①

Interface module

②

Module with components

③

Submodule

④

Channel

In principle it is possible to divide a slot into additional subslots on which the submodules are connected.

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4.11.3.3

Integration of fieldbuses into PROFINET

Fieldbus integration PROFINET allows you to use a proxy to integrate existing fieldbus systems (for example, PROFIBUS, ASI) into PROFINET. In this way, you can set up hybrid systems consisting of fieldbus and Ethernet-based subsystems. A continuous technological transition to PROFINET is thus possible.

Interconnecting PROFINET and PROFIBUS You can interconnect PROFIBUS devices to the local PROFIBUS interface of a PROFINET device. This allows you to integrate existing PROFIBUS configurations in PROFINET. The following picture illustrates the network types that are supported for PROFINET: ● Industrial Ethernet and ● PROFIBUS.

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PROFINET devices, PROFIBUS devices, and proxy

Number Description ①

PROFINET devices

②

PROFINET device with proxy functionality

③

PROFIBUS devices

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PROFINET device with proxy functionality = substitute

The PROFINET device with proxy functionality is the substitute for a PROFIBUS device on Ethernet. The proxy functionality allows a PROFIBUS device to communicate not only with its master but also with all nodes on PROFINET. With PROFINET, existing PROFIBUS systems can be integrated into the PROFINET communication with the aid of an IE/PB link, for example. The IE/PB link then handles communication via PROFINET on behalf of the PROFIBUS components. In this way, you can link both DPV0 and DPV1 slaves to PROFINET.

Further information

For information on the differences and common features of PROFINET IO and PROFIBUS DP and information on migrating from PROFIBUS DP to PROFIBUS IO, refer to the From PROFIBUS DP to PROFINET IO programming manual.

4.11.3.4

PROFINET IO and PROFINET CBA

What is PROFINET IO?

As part of PROFINET, PROFINET IO is a communication concept that is used to implement modular, distributed applications. PROFINET IO allows you to create automation solutions, which are familiar to you from PROFIBUS. PROFINET IO is implemented using the PROFINET standard for programmable controllers. The STEP 7 engineering tool helps you to structure and configure an automation solution. In STEP 7 you have the same application view, regardless of whether you are configuring PROFINET devices or PROFIBUS devices. You will program your user program in the same way for both PROFINET IO and PROFIBUS DP since you will use the extended blocks and system status lists for PROFINET IO.

Reference

Information on new and modified blocks and system status lists can be found in the From

PROFIBUS DP to PROFINET IO programming manual.

What is PROFINET CBA?

As part of PROFINET, PROFINET CBA (Component Based Automation) is an automation concept that focuses on the following: ● Implementation of modular applications ● Machine - machine communication PROFINET CBA lets you create distributed automation solutions, based on default components and partial solutions. This concept meets the demand for a greater modularity in the field of mechanical and systems engineering by extensive distribution of intelligent processes. With Component Based Automation you can implement complete technological modules as standardized components that can be used in large systems. You create the modular, intelligent components of the PROFINET CBA in an engineering tool (which may differ according to the device manufacturer). Components that are formed from SIMATIC devices are created with STEP 7, and are interconnected using the SIMATIC iMAP tool.

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Interaction between PROFINET IO and PROFINET CBA PROFINET CBA is used to integrate PROFINET IO systems into machine-to-machine communication. A PROFINET component is created from a PROFINET IO system in STEP 7, for example. With SIMATIC iMap, you can configure systems consisting of several such components. The communication connections between the devices are configured simply as interconnection lines. The following graphic illustrates a distributed automation solution with several components which communicate via PROFINET. The components on the right have IO devices and an IO controller on PROFINET IO. 352),1(7 &RPSRQHQW L0$3

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Extent of PROFINET CBA and PROFINET IO PROFINET IO and CBA represent two different views of automation devices on Industrial Ethernet.

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Component Based Automation divides the entire system into various functions. These functions are configured and programmed. PROFINET IO provides an image of the system that is very similar to the view obtained in PROFIBUS. You continue to configure and program the individual automation devices.

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Controllers in PROFINET IO and PROFINET CBA You can also use some PROFINET IO controllers for PROFINET CBA. The following PROFINET devices act as a PROFINET CBA or IO controller: ● Programmable logic controllers, – S7-300 CPU 31x-2 PN/DP, firmware version V2.3 or later – S7-300 CPU 319-3 PN/DP, firmware version V2.4.0 or later ● CP 343-1 - version 6GK7 343-1EX21-0XE0 and 6GK7 343-1GX21-0XE0 or later ● CP 443-1 Advanced with MLFB 6GK7 443-1EX40 version V2.1 and 6GK7 443-1EX41 version V1.0 or later. The following PROFINET devices can only act as a PROFINET IO controller: ● PCs that are linked to a PROFINET IO-compatible CP (CP 1616 for example) or via SOFTNET PN IO (with CP 1612 for example). With the CP 1616 and SOFTNET PN IO, the user program runs in the CPU of the PC. ● SIMOTION devices for particularly stringent real-time requirements. Some PROFINET devices can only be used as PROFINET CBA controllers, for example, PCs with standard Ethernet interfaces and the WinLC software. CP443-1 EX 40 V2.1 or later or CP443-1 EX41 V 1.0 or later

Proxy in PROFINET IO and PROFINET CBA The proxies for PROFINET IO and proxies for PROFINET CBA are different. In PROFINET IO, the proxy for PROFINET IO represents each connected PROFIBUS DP slave as a PROFINET IO device on the PROFINET. In PROFINET CBA, the proxy for PROFINET CBA represents every connected PROFIBUS DP slave as one component, which can participate in PROFINET communication. There are thus different IE/PB links for PROFINET IO and PROFINET CBA, for example. At present you can currently only use a CPU 31x PN/DP as a proxy for PROFINET CBA.

Linking PROFIBUS devices via an IE/PB link Please note that proxy functionality is available in both PROFINET IO and PROFINET CBA. For the IE/PB link, this means that you must use different devices depending on the system you are using.

Configuring and integrating components and devices in PROFINET communication In Component Based Automation, an interconnection editor is used to incorporate the components (SIMATIC iMap for example). The components are described in a PCD file. With PROFINET IO, the devices are incorporated using an engineering system (STEP 7 for example). The devices are described in a GSD file.

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Interaction between PROFINET CBA and PROFINET IO PROFINET IO integrates field devices (IO devices) into PROFINET. The input and output data of the IO devices are processed in the user program. The IO devices with their IO controller can, in turn, be part of a component in a distributed automation structure. Communication between a CPU as the IO controller and the assigned IO devices as PROFINET IOs is configured in the same way as for a PROFIBUS DP master system in STEP 7. The user program is also created in STEP 7. From the entire PN IO system, you create a component in STEP 7 (see Figure PROFINET CBA). You then configure communication between the components in user-friendly SIMATIC iMAP.

Update time The IO controller (outputs) provides new data to all IO devices in the PROFINET IO system within the update time. This means that all the IO devices have sent their latest data to the IO controller (inputs). Note Send Cycles for Cyclical Data Exchange STEP 7 determines the update time on the basis of the existing hardware configuration and the resulting cyclical data traffic. During this time, a PROFINET IO device has exchanged its user data with the associated IO controller. You can set the update date either for a whole bus segment of an IO controller, or for an individual IO device. In STEP 7, the update time can be changed manually. The smallest possible update time in a PROFINET system depends on the following factors: • Number of PROFINET IO devices • Quantity of configured user data • Volume of PROFINET IO communication traffic (compared to the volume of PROFINET CBA communication traffic) Additional cyclical PROFINET services The update time dialog in STEP 7/HW Config is used to set an update date for the device to be reserved for PROFINET IO. See the STEP 7 Online Help for more information.

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Send clock Period between two successive intervals for IRT or RT communication. The send clock is the shortest possible transmit interval for exchanging data. The calculated update times are multiples of the send clock. The minimum possible update time thus depends on the minimum send clock of the IO controller that can be set. If both the IO controller and the IO device support a send clock of 250 µs, you can achieve a minimum update time of 250 µs. It is also possible to operate IO devices that only support a send clock of 1 ms on an IO controller that works with a send clock of 250 µs. The minimum update time for the IO devices concerned is then at least 1 ms, however.

Update times of CPU 319-3 PN/DP Programmable update times when using CPU 319-3 PN/DP: Send clock

Update time

250 µs

⇒

250 µs to 128 ms

500 µs

⇒

500 µs to 256 ms

1 ms

⇒

1 ms to 512 ms

The minimum update time depends on the number of IO devices used, and on the volume of configured user data, and on the load in PROFINET IO communication. STEP 7 automatically considers these dependencies during configuration.

Details of the possible uses of the individual products See also the documentation for the product concerned.

4.11.3.5

PROFINET cable lengths and network expansion Network expansion options are based on various factors (hardware design used, signal propagation delay, minimum distance between data packets, etc.)

Twisted-pair patch cables TP Cords are used to interconnect terminal devices with the Industrial Ethernet FC cabling system. It is designed for use in environments with low EMC load, for example, in offices or in control cabinets. The length of twisted-pair cords between two devices may not exceed 10 m. Compared to Industrial Ethernet twisted-pair cables, the TP cords are significantly thinner and more flexible due to the reduced effort for their shielding. The connectors used in connecting industrial twisted-pair components are standardized RJ45 connectors and sub D connectors.

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Product range Twisted-pair patch cords available: Table 4- 23

Data for twisted-pair patch cables

Cable designation

Application

TP Cord RJ45/RJ45

TP connecting cable with two RJ45 connectors

TP XP cord RJ45/RJ45

TP crossover cable with two RJ45 connectors

TP cord 9/RJ45

TP patch cable with 9-pin sub-D connector and RJ45 connector

TP XP cord 9/RJ45

Crossover TP patch cable with 9-pin sub-D connector and RJ45 connector.

TP patch cable 945/RJ45

TP patch cable with RJ45 connector and sub-D connector, 45° cable exit (only for OSM/ESM) Cross-over TP patch cable with RJ45 connector and sub-D connector with 45° cable exit (for OSM/ESM only) Crossover TP patch cable for direct interconnection of two industrial Ethernet network components with ITP interface, with two 9-pin sub-D connectors TP patch cable with 15-pin sub-D connector and RJ45 connector

TP XP patch cable 945/RJ45 TP XP patch cable 9/9

TP cord RJ45/15

TP XP patch cable RJ45/15

84

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Available lengths 0.5 m 1.0 m 2.0 m 6.0 m 10.0 m 0.5 m 1.0 m 2.0 m 6.0 m 10.0 m 0.5 m 1.0 m 2.0 m 6.0 m 10.0 m 0.5 m 1.0 m 2.0 m 6.0 m 10.0 m 1.0 m

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Industrial Ethernet Fast Connect twisted-pair cables The FastConnect Twisted-Pair cabling system is ideal for structured cabling in the production hall. FastConnect cables allow for the quick and easy on-site assembly of patch cables. The RJ45 cabling technology is the existing standard and is also available as an industrial version which allows structured cabling.

Product range Industrial Ethernet Fast Connect twisted-pair cables available: Table 4- 24

Data for user assemblies using patch cables of the Fast Connect product family

Cable designation

Application

Available lengths

Order number

SIMATIC NET IE FC RJ 45 PLUG 145

RJ45 connector for Industrial Ethernet with rugged metal housing and four integrated insulation displacement terminals for connecting Industrial Ethernet FC installation cables; 145° cable outlet.

1 piece

6GK1 901-1BB30-0AA0

10 items

6GK1 901-1BB30-0AB0

50 items

6GK1 901-1BB30-0AE0

SIMATIC NET IE FC RJ 45 PLUG 180

RJ45 connector for Industrial Ethernet with rugged metal housing and four integrated insulation displacement terminals for connecting Industrial Ethernet FC installation cables; 180° cable outlet.

1 piece

6GK1 901-1BB10-2AA0

10 items

6GK1 901-1BB10-2AB0

50 items

6GK1 901-1BB10-2AE0

Reference Detailed information is available in the ● SIMATIC NET Manual: Twisted-Pair and Fiber-Optic Networks (6GK1970-1BA10-0AA0) ● On the Internet at http://www.siemens.com/automation/service&support. ● Catalog IK PI, SIMATIC NET (E86060-K6710-A101-B5)

See also Connecting the PG to a node (Page 148) Connecting the PG to several nodes (Page 149)

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4.11.3.6

Connectors and other components for Ethernet The selection of the bus cable, bus connector and other components for Ethernet (for example, switches, etc.) depends on the intended application. We offer a range of products covering a variety of applications for the installation of an Ethernet connection.

Reference ● SIMATIC NET: Twisted-Pair and Fiber-Optic Networks (6GK1970-1BA10-0AA0)

4.11.3.7

Example of a PROFINET subnet

Example: Installation of a PROFINET subnet The graphic illustrates the combination of corporate level and process control level via industrial Ethernet. PCs in a classical office environment can be used to acquire data of the process automation system. 6XEQHW

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86

Example of a PROFINET subnet

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Installation guidelines PROFINET allows you to set up a high-performance and continuous communication system. You can further increase performance by using the following installation guidelines. ● Interconnect a router between the office network and the PROFINET system. Use the router to define access privileges for your PROFINET system. ● Set up your PROFINET in a star architecture where this is useful (for example: in a switch cabinet). ● Keep the number of switches low. This increases clarity of your PROFINET system architecture. ● Connect your programming device (PG) close to the communication partner (for example: connect the PG and the communication partner to the same switch). ● Modules with PROFINET interfaces may only be operated in LANs where all nodes are equipped with SELV/PELV power supplies or protection systems of equal quality. ● A data transfer device that ensures this safety must be specified for the coupling to the WAN.

Reference For detailed information on Industrial Ethernet networks or network components, refer to: ● the Internet URL http://www.siemens.com/automation/service&support. ● The STEP 7 Online Help. There you can also find further information on IP address assignment. ● The Communication with SIMATIC (EWA 4NEB 710 6075-01) manual ● The SIMATIC NET manual: Twisted-Pair and Fiber Optic Networks (6GK1970-1BA100AA0)

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4.11.3.8

PROFINET IO System

Functions of PROFINET IO The following graphic shows the new functions in PROFINET IO: &RPSDQ\QHWZRUN

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The graphic shows

Examples of connection paths

The connection of company network and field level

You can access devices at the field level from PCs in your company network

Connections between the automation system and field level

You can, of course, also access other areas on the Industrial Ethernet from a PG at the field level.

The IO controller of the CPU IM 154-8 CPU ② directly controls devices on the Industrial Ethernet and PROFIBUS.

At this point, you can see the extended IO feature between the IO controller and IO device(s) on the Industrial Ethernet: • The IM 154-8 CPU ② is operated as IO controller for the IO devices ET 200S ③ and ET 200S ④ • The IM 154-8 CPU ② is also the IO controller for ET 200 (DP slave) ⑦ by way of IE/PB Link.

Example: • PC - Switch 1 - Router - Switch 2 - CPU 319-3 PN/DP ①.

Example: • PG - integrated switch IM 154-8 CPU ② - Switch 2 - integrated switch IO device ET 200S ⑤ - on IO device: ET 200S ⑥.

The CPU 319-3 PN/DP ① can Here you can see that a CPU can be both the IO controller for an IO device and the DP be operated as IO controller or master for a DP slave: DP master • The 319-3 PN/DP CPU ① is operated as IO controller for the IO devices ET 200S ⑤ and ET 200 S ⑥ • The CPU 319-3 PN/DP ① is the DP master for a DP slave ⑧. The DP slave ⑧ is assigned locally to the CPU ① and is not visible on the Industrial Ethernet.

Further information You will find further information about PROFINET in the documents listed below: ● in the System Description PROFINET. ● In the From PROFIBUS DP to PROFINET IO programming manual. This manual also provides a clear overview of the new PROFINET blocks and system status lists.

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4.11.4

Routed network transitions

Example: Programming device access beyond network limits (routing) A CPU with several interfaces can also serve as a router for intercommunication with different subnets. With a PG you can access all modules on local and remote networks.

Requirements: ● Implement STEP 7 starting with Version 5.0. Note: For STEP 7 requirements with respect to the CPUs used, refer to the technical specifications. ● Assign the PG/PC to a network in your STEP 7 project (SIMATIC Manager, assigning a PG/PC). ● The various networks are interconnected using modules with routing functions. ● After you configured all networks in NETPRO, initiated a new compilation for all stations, and then download the configuration to all modules with routing function. This also applies to all changes made in the network. All routers therefore know all paths to a destination station.

90

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Access to remote networks 3*3& 6

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Example 1 To access the CPU 31x-2 DP using PG/PC 1: PG/PC 1 - MPI network ① - CPU 417 as router - PROFIBUS network ③ - CPU 31x-2 DP Example 2 To access the the S7-300 CPU (on the right in the figure) using PG/PC 2: PG/PC 2 - PROFIBUS network ③ - CPU 31x-2 DP as router - MPI network ② - S7-300 CPU Example 3 To access the 416 CPU using PG/PC 3: PG/PC 3 - MPI network ② - CPU 31x-2 DP as router - PROFIBUS network ③ - CPU 417 as router - MPI network ① - CPU 416 Note Only for CPUs with DP interface: If these CPUs are operated as I-slaves and you want to use routing functionality, set the Commissioning / Debug Mode / Routing check box in the DP Interface for DP Slave dialog box in STEP 7.

Reference You can find more information on the subject of routing in the Communication with SIMATIC manual.

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4.11.5

Point-to-point (PtP)

Availability CPUs with the "PtP" name suffix have at least one PtP interface.

Properties Using the PtP interface of your CPU, you can connect external devices with serial interface. You can operate such a system at transmission rates up to 19.2 Kbps in full duplex mode (RS 422), and up to 38.4 Kbps in half duplex mode (RS 485).

Baud rate ● Half duplex: 38.4 Kbps ● Full duplex: 19.2 Kbps

Drivers PtP communication drivers installed in those CPUs: ● ASCII drivers ● 3964(R) Protocol ● RK 512 (CPU 314C-2 PtP only)

Devices capable of PtP communication Devices equipped with a serial port, for example, barcode readers, printers, etc.

Reference CPU 31xC: Technological functions manual

4.11.6

Actuator/sensor interface (ASI)

Actuator/Sensor Interface (ASI) Implementation using communication processors (CP). The ASI, or Actuator/Sensor Interface, represents a subnet system on the lowest process level for automation systems. It is designed especially for networking digital sensors and actuators. The maximum data volume is 4 bits per slave station. S7-300 CPUs require communication processor for the ASI connection.

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5

Installing 5.1

Installing a S7-300 Here we will explain the steps required for the mechanical assembly of an S7-300. Note Note the installation guidelines and notes on safety in this manual when mounting, commissioning and operating S7-300 systems.

Open components S7-300 modules are "Open Components" according to IEC 61131-2 and EC directive 2006/95/EC (low-voltage directive), and to UL/CSA Approval an "open type". In order to conform with specifications on safe operation relating to mechanical strength, inflammability, stability and touch-protection, the following alternative installation modes are prescribed: ● Installation in a suitable cubicle ● Installation in a suitable cabinet ● Installation in an appropriately equipped and closed operating area Access to these areas must only be possible with a key or tool. Only trained or authorized personnel are allowed access to these cubicles, cabinets or electrical operating rooms.

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Accessories included Installation accessories are included with the module package. The appendix contains a list of accessories and spare parts together with the corresponding order numbers. Table 5- 1

Module accessories

Module

Accessories included

Explanation

CPU

1 x Slot number label

For assigning slot numbers

Inscription labels

for the MPI address and Firmware Version (all CPUs) for labeling of integrated inputs and outputs (CPU 31xC only)

Signal module (SM) Function Module (FM) Communication module (CP)

Interface module (IM)

1 Bus connector

For electrical interconnection of modules

1 Labeling strip

For labeling module I/O

1 Bus connector

For electrical interconnection of modules

1 Inscription label (only CP 342-2)

For labeling the AS interface connector

1 x Slot number label (only IM 361 and IM 365)

For assigning slot numbers on racks 1 to 3

Tip: Templates for the labeling strips are available on the Internet (http://support.automation.siemens.com/WW/view/en/11978022).

Tools and material required To install the S7-300, you require the tools and materials listed in the table below. Table 5- 2

Installation tools and materials

You require ...

for ...

cutting the 2 m rail to length

commonly available tool

scribing and drilling holes on the 2 m rail

commonly available tool, 6.5 mm diameter drill bit

screw-mounting the rail

wrench or screwdriver, matching the selected fixing screws diverse M6 screws (length depends on the place of installation) with nuts and spring lock washers

94

screw-fastening the modules on the rail

screwdriver with 3.5 mm blade width (cylindrical design)

pulling out the grounding slide contact to achieve ungrounded state

screwdriver with 3.5 mm blade width (cylindrical design)

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Installing 5.2 Installing the mounting rail

5.2

Installing the mounting rail

Mounting rail versions available ● Ready-to-use, four standard lengths (with 4 holes for fixing screws and 1 ground conductor bolt) ● One meter mounting rail May be shortened to any special length. Supplied without holes for fixing screws and without ground conductor bolt.

Requirement Prepare the 2 m mounting rail for installation.

Preparing the 2 m mounting rail for installation 1. Cut the 2 m mounting rail to the required length. 2. Mark out: – four bores for the fixing screws (for dimensions, refer to "Dimensions for fixing holes") – one hole for the protective conductor bolt. 3. If the length of your rail exceeds 830 mm, you must stabilize it by providing additional holes for fixing it with more screws. Mark out these holes along the groove in the middle section of the rail (see the Figure below). The pitch should be approx. 500 mm. 4. Drill the marked holes, bore diameter = 6.5 +0,2mm for M6 screws. 5. Mount an M6 bolt for fixing the ground conductor. 3

2

4

1 5 Number

Identifier

①

Hole for the ground conductor bolt

②

Groove for drilling additional holes for mounting screws

③

Hole for the mounting screw

④

Additional hole for mounting screw

⑤

Hole for the mounting screw

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Dimension of the mounting holes The mounting hole dimensions for the mounting rail are shown in the table below. Table 5- 3

Mounting holes for rails

"Standard" mounting rail

2 m mounting rail

PP

PP

PP

PP

aPP

D

Length of rail

PP

E

Dimension a

Dimension b

160 mm

10 mm

140 mm

482.6 mm

8.3 mm

466 mm

530 mm

15 mm

500 mm

830 mm

15 mm

800 mm

aPP

PP

–

Fixing screws You can use the following screw types for mounting the rails: For ...

you can use ...

Explanation

outer fixing screws

Cylindrical head screw M6 to ISO 1207/ISO 1580 (DIN 84/DIN 85)

Choose a suitable screw length for your assembly.

M6 hexagonal head screw to ISO 4017 (DIN 4017) Additional fixing screws (only 2 m mounting rail)

96

You also need size 6.4 washers to ISO 7092 (DIN 433)

Cylindrical head screw M6 to ISO 1207/ISO 1580 (DIN 84/DIN 85)

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Installing the mounting rail 1. Install the mounting rails so that sufficient space is available for installing modules and to allow heat dissipation (clearance of at least 40 mm above and below the modules. See the figure below). 2. Mark up the mounting holes on the mounting surface. Drill the holes, diameter = 6.5 +0.2 mm. 3. Screw the rail (M6 screws) onto the mounting surface. Note Always make sure of a low-impedance contact between the rail and a mounting surface, if the latter is a grounded metal panel or equipment mounting panel. On varnished or anodized metals, for instance, use a suitable contacting agent or contact washers.

The figure below shows the clearance required for the installation of an S7-300.

PP

PP

PP PP

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Installing 5.3 Installing modules on the mounting rail

5.3

Installing modules on the mounting rail

Rules governing The table below shows you points to follow when wiring, installing or removing S7-300 modules. Rules for the tightening torque of..

... power supply, CPU,SM, FM, CP

Fixing modules to the mounting rail

from 0.8 N/m to 1.1 N/m

Requirements for module installation ● The configuration of the automation system is completed. ● The mounting rail is installed.

Mounting order of the modules Hang the modules onto the rail, starting at the left and in the following order: 1. Power supply module 2. CPU 3. SMs, FMs, CPs, IMs Note Please check before you insert any SM 331 analog input modules whether you have to reposition the measuring range submodules at the side of the module. For more information see the "Analog Modules" chapter in the Module Data Manual. Note When installing an S7-300 system with ungrounded reference potential, make the relevant settings on the CPU. You ideally do so before you mount any modules onto the rail.

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Installing 5.3 Installing modules on the mounting rail

Installation steps The various steps in module installation are explained below. 1.

Plug the bus connectors into the CPU and SMs / FMs / CPs / IMs. Except for the CPU, each module is supplied with a bus connector. • Always start at the CPU when you plug in the bus connectors. Remove the bus connector from the "last" module of the assembly. • Plug the bus connectors into the other modules. The "last" module does not receive a bus connector.

2.

Add all modules to the rail in the specified order ①, slide them up to the module on the left ①, then swing them down ①.

 

 3.

Screw-tighten the modules.

See also Installing an S7-300 with ungrounded reference potential (not CPU 31xC) (Page 44)

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Installing 5.4 Labeling modules

5.4

Labeling modules

Assign slot numbers You should assign a slot number to each one of the mounted modules, thus making it easier to assign the modules in the configuration table in STEP 7. The table below shows the slot number assignment. Table 5- 4 Slot numbes

100

Slot numbers for S7 modules Module

Remark

1

Power supply (PS) module

–

2

CPU

–

3

Interface module (IM)

to the right of the CPU

4

1. Signal module (SM)

to the right of the CPU or IM

5

2. Signal module (SM)

–

6

3. Signal module (SM)

–

7

4. Signal module (SM)

–

8

5. Signal module (SM)

–

9

6. Signal module (SM)

–

10

7. Signal module (SM)

–

11

8. Signal module (SM)

–

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Installing 5.4 Labeling modules

Attach the slot numbers to the modules. 1. Hold the corresponding slot number in front of the relevant module. 2. Place the tongue in the opening on the module ①. 3. Press the slot number into the module ②. The slot number breaks off from the wheel. The figure below illustrates this procedure. The slot number labels are included with the CPU.





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Installing 5.4 Labeling modules

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6

Wiring 6.1

Requirements for wiring the S7-300

This chapter describes the requirements for wiring the power supply, CPU and front connectors.

Accessories required The following accessories are required for wiring the S7-300. Table 6- 1

Wiring accessories

Accessories

Explanation

Front connectors

for connecting the sensors / actuators of the system to the S7-300

Labeling strips

for labeling the module I/Os

Shielding contact element, shielding terminals (matching the shielding diameter)

for connecting cable shielding

Tools and material required Tools and materials required for wiring the S7-300. Table 6- 2

Tools and material for wiring

To ...

you need ...

Connect the protective conductor to the rail

Wrench (size 10) Protective conductor cable (crosssection ≥ 10 mm2) with M6 cable lug M6 nut, washer, spring lock washer

Adjust the power supply module to mains voltage

Screwdriver with a blade width of 4.5 mm

Wire the power supply module and the CPU

Screwdriver with a 3.5-mm blade, side-cutters, stripping tool Flexible cable, for example, sheathed flexible cable 3 x 1.5 mm2 Wire end ferrules to DIN 46228

Wire the front connector

Screwdriver with a 3.5-mm blade, side-cutters, stripping tool Flexible cables, 0.25 mm2 to 0.75/1.5 mm2 Shielded cables as required Wire end ferrules to DIN 46228

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Wiring 6.1 Requirements for wiring the S7-300

Wiring conditions for power supply and CPU Table 6- 3

Wiring conditions for power supply and CPU

Connectable cables

to power supply and CPU

Solid conductors

No

Flexible conductors • without wire end ferrule • With wire end ferrule

0.25 mm2 to 2.5 mm2 0.25 mm2 to 1.5 mm2

Number of conductors per terminal

1 or 2, up to 1.5 mm2 (total) in a common wire end ferrule

Diameter of the conductor insulation

max. 3.8 mm

Stripped length

11 mm

Wire end ferrules to DIN 46228 • without insulating collar • with insulating collar

Design A, 10 mm to 12 mm length

Tightening torque

from 0.5 N/m to 0.8 N/m

Design E, up to 12 mm length

Wiring conditions for front connectors Table 6- 4

Wiring conditions for front connectors

Connectable cables

Front connectors 20-pole

40-pole

Solid conductors

No

No

Flexible conductors • without wire end ferrule • with wire end ferrule

0.25 mm2 to 1.5 mm2

Number of conductors per terminal

1 or 2, up to 1.5 mm2 (total) in a common wire end ferrule

1 or 2, up to 0.75 mm2 (total) in a common wire end ferrule

Diameter of the conductor insulation

max. 3.1 mm

•

0.25

mm2

to 1.5

0.25 mm2 to 0.75 mm2 0.25 mm2 to 0.75 mm2 • Mains feed 1.5 mm2

mm2

• Stripped length Wire end ferrules to DIN 46228 • without insulating collar • with insulating collar Tightening torque

104

max. 2.0 mm for 40-pole cables max. 3.1 mm for 20-pole cables

6 mm

6 mm

Design A, 5 mm to 7 mm length

Design A, 5 mm to 7 mm length

Design E, up to 6 mm length

Design E, up to 6 mm length

from 0.4 N/m to 0.8 N/m

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Wiring 6.2 Bonding the Protective Conductor to the Mounting Rail

6.2

Bonding the Protective Conductor to the Mounting Rail

Requirement The mounting rail is fixed onto the mounting surface.

Connecting the protective conductor Connect the mounting rail to the protective conductor. The mounting rail is provided with a M6 protective conductor screw for this purpose. Minimum cross-section of the protective conductor: 10 mm2 The figure below shows how the protective conductor has to be bonded to the rail.

Note Always make sure of a low-impedance contact between the protective conductor and the rail. You can achieve this by using a low-impedance cable, keeping it as short as possible and contacting it to a large surface. For example, an S7-300 mounted on a hinged frame must be connected to ground using a flexible grounding strap.

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ITEM 3000

Wiring 6.3 Adjusting the Power Supply Module to Local Mains Voltage

6.3

Adjusting the Power Supply Module to Local Mains Voltage

Introduction You can operate the S7-300 power supply module on 120 VAC or 230 VAC. The default setting for the PS 307 is 230 VAC.

Setting the mains voltage selector switch Verify that the setting of the voltage selector switch matches your local mains voltage. To set the selector switch: 1. Remove the protective cap with a screwdriver. 2. Set the selector switch to match the local line voltage. 3. Reinsert the protective cap. 



106

Numb er

Identifier

①

Remove the protective cap with a screwdriver

②

Set selector switch to mains voltage

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Wiring 6.4 Wiring the Power Supply Module and the CPU

6.4

Wiring the Power Supply Module and the CPU

Requirement All modules are mounted onto the rail.

Wiring the PS and CPU Note The PS 307 power supply module is equipped with two additional 24 VDC terminals L+ and M for the supply to I/O modules. Note The power supply connector of your CPU is a plug-in device and can be removed. WARNING There is a risk of contact to live wires if the power supply module, or any additional load power supply units, are connected to the mains. You should therefore isolate the S7-300 from power before you start wiring it. Always use crimp ferrules with insulating collars for the conductors. Close all front panels of the modules when you completed the wiring. This is conditional before you reconnect the S7300 to power. 1. Open the PS 307 power supply module and CPU front panels. 2. Open the strain relief on the PS 307. 3. Strip the power cable to a length of 11 mm and connect it to L1, N and to the protective earth (PE) terminal of the PS 307. 4. Screw-tighten the strain relief again. 5. Next, wire the PS and CPU The power supply connector of the CPUs is a removable plug-in device. Strip the connecting cables for the CPU power supply to a length of 11 mm. Wire the lower terminal M on the PS 307 to the terminal M of the CPU and the lower terminal L+ on the PS 307 to terminal L+ of the CPU. WARNING Reversing the polarity of the M and L+ terminals trips the internal fuse on your CPU. Always interconnect the M and L+ terminals of the power supply module and of the CPU. 6. Close the front panels.

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ITEM 3000

Wiring 6.4 Wiring the Power Supply Module and the CPU The figure below illustrates the procedures described earlier.

,

/ 1

/ 0 / /

0

0

99

1

2

3

Numb er

Identifier

①

Strain relief of the power supply cable

②

Connection cables between the PS and CPU

③

Removable power supply connector

Note The PS 307 power supply module is equipped with two additional 24 VDC terminals L+ and M for the supply to I/O modules.

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Wiring 6.5 Wiring front connectors

6.5

Wiring front connectors

Introduction The sensors and actuators of your system are connected to the S7-300 AS by means of front connectors. Wire the sensors and actuators to the relevant front connector and then plug it into the module.

Front connector versions Front connectors come in 20-pin and 40-pin versions with screw contacts or spring terminals. You require 40-pin front connectors for the CPUs 31xC and 32-channel SMs. Use the following front connectors as required for the module: Table 6- 5

Assignment of front connectors to modules

Module

Front connector with screw terminals, order no.:

Front connector with spring terminals, order no.:

Signal modules (not 32-channel),

6ES7 392-1AJ00-0AA0

6ES7 392-1BJ00-0AA0

6ES7 392-1AM00-0AA0

6ES7 392-1BM01-0AA0

Function modules, Communication module CP 342-2 Signal modules (32-channel) and CPU 31xC

Connecting on spring terminals It is quite easy to wire a front connector with spring terminals: Simply insert the screwdriver vertically into the opening with the red opening mechanism, insert the wire into the terminal and remove the screwdriver. WARNING You might damage the spring clamp mechanism of the front connector if you turn the screwdriver sideways or use the wrong size of screwdriver. Always slide a matching screwdriver vertically into the desired opening until it reaches the mechanical stop. This ensures that the spring terminal is fully open.

Tip There is a separate opening for test probes up to 2 mm in diameter to the left of the opening for the screwdriver.

Requirement The modules (SM, FM, CP 342-2) are mounted on the rail.

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Wiring 6.5 Wiring front connectors

Preparing the front connectors and cables WARNING There is a risk of contact to live wires if the power supply module, or any additional load power supply units, are connected to the mains. You should therefore isolate the S7-300 from power before you start wiring it. Close all front panels of the modules when you completed the wiring. This is conditional before you reconnect the S7-300 to power. 1. Switch off the power supply. 2. Open the front door. 3. Place the front connector into wiring position. Push the front connector into the signal module until it latches. In this position, the front connector still protrudes from the module. Advantage of this wiring position: Comfortable wiring. The front connector pins do not contact the module in this wiring position. 4. Strip the conductors to a length of 6 mm. 5. Crimp the wire end ferrules, for example, to terminate two conductors at one terminal.







110

Number

Identifier

①

The switched off power supply module (PS)

②

The opened module

③

The front connector in wiring position

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Wiring 6.5 Wiring front connectors

Wiring front connectors Table 6- 6

Wiring front connectors

Step

20-pin front connector

40-pin front connector

1.

Place the included cable strain relief into the front connector.

–

2.

Cable exit at the bottom of the module? If yes: Starting at terminal 20, work your way down to terminal 1.

Start wiring at terminal 40 or 20, and work in alternating passes from terminals 39, 19, 38, 18 etc. until you have reached terminals 21 and 1.

If not: Start wiring at terminal 1, and work your way up to terminal 20.

Start wiring at terminal 1 or 21, and work in alternating passes from terminals 2, 22, 3, 23 etc. until you have reached terminals 20 and 40.

3.

Front connectors with screw terminals:

4.

–

5.

Tighten the strain relief for the cable harness. Push in the strain relief to the left to increase cable space.

Always screw-tighten the unused terminals. Place the strain relief around the cable harness and the front connector.

–



 







The work step numbers are shown in the figure above ① Insert the strain relief.

① to ③ Wire the terminals.

② Wire the terminals.

④ Tighten the strain relief clamp.

Reference For information on wiring the integrated I/O of 31xC CPUs, refer to the CPU 31xC and CPU 31x, Technical Data manual.

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ITEM 3000

Wiring 6.6 Plugging the front connectors into modules

6.6

Plugging the front connectors into modules

Requirement The front connectors are completely wired.

Inserting the front connector Table 6- 7

Inserting the front connector

Step

20pin front connector

40pin front connector

1.

Push in the unlocking mechanism on top of the module.

Tighten the mounting screw in the center of the connector.

Keeping the locking mechanism pressed, insert the front connector into the module. Provided the front connector is seated correctly in the module, the unlocking mechanism automatically returns to the initial position when you release it.

This pulls the front connector completely into contact with the module.

Note When you insert the front connector into the module, an encoding mechanism engages in the front connector, thus ensuring that the connector can only be inserted into modules of the same type. 2.

Close the front panel.

Close the front panel.

 

 



The work step numbers are shown in the figure above ① Keep the release mechanism pressed

① Tighten the mounting screw,

② Insert the front connector

③ Only then close the front panel

③ Only then close the front panel

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Wiring 6.7 Wiring I/O modules and compact CPUs with Fast Connect

6.7

Wiring I/O modules and compact CPUs with Fast Connect

Order numbers for Fast Connect Connectors ● 20-pin connector: 6ES7392-1CJ00-0AA0 ● 40-pin connector: 6ES7392-1CM00-0AA0

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Wiring 6.7 Wiring I/O modules and compact CPUs with Fast Connect

Wiring I/O modules and compact CPUs with Fast Connect ● I/O modules and compact CPUs can be wired with Fast Connect. The individual wires are connected by means of the front connector using Fast Connect technology, which requires no stripping. ● Fast Connect is a connection method that requires no conductor preparation (i.e., the conductor insulation does not have to be stripped). ● Each terminal with Fast Connect has a test opening (e.g. for measuring the voltage). The test opening is suitable for test probes with a maximum diameter of 1.5 mm. ● Wire end ferrules are not permitted.

  











 

Figure 6-1

Schematic representation of Fast Connect connectors

Numb er

Identifier

①

Opening for testing: max. Ø 1.5 mm

②

Opening for a conductor: 0.25 mm2 to 1.5 mm2

③

Toothing for opening the terminal

④

Guide clip opened (the wire can be inserted)

⑤

Guide clip closed (the wire is connected)

Wiring rules for front connector with Fast Connect

Solid wires

20-pin front connector

40-pin front connector

No

No

Connectable wire cross-section of flexible wires •

Without wire end ferrule

0.25 mm2 to 1.5 mm2

0.25 mm2 to 1.5 mm2

•

With wire end ferrule

---

---

Number of wires per terminal

1

1

Number of terminating cycles for the same conductor cross-section

25

Maximum external diameter of the wire insulation

∅ 3.0 mm

1

25 1 ∅ 3.0 mm

For 1.5 10 terminating cycles are possible. If different conductor cross-sections are used in a connecting terminal as a result of rewiring, it can be wired a maximum of 10 times. 1

114

mm2 only

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Wiring 6.7 Wiring I/O modules and compact CPUs with Fast Connect

Required tools Screwdriver, 3.0 mm or 3.5 mm.

Connectable wires ● Flexible conductors with PVC insulation and a conductor cross-section of: 0.25 mm2 to 1.5 mm2 A list of the tested conductors can be found at: http://www .weidmueller.de

UL-compliant cables and connections Wiring range for insulating piercing connection 22 -16 AWG solid/stranded PVC insulated conductors, UL style no. 1015 only.

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Wiring 6.7 Wiring I/O modules and compact CPUs with Fast Connect

ITEM 3000

Procedure for wiring with Fast Connect 1. Insert the unstripped wire into the round opening until it stops (the insulation and conductor must form a flat surface) and secure the conductor in this position. – For 20-pin connector: at a 90° angle – For 40-pin connector: at a 45° angle 2. Insert the screwdriver into the indentation on the topside of the guide clip. 3. Press the screw driver downwards until the guide clip is engaged in the end position. The wire is connected.

PP



 r





r

Note If you would like to reuse a conductor after it was already connected once then it must be trimmed beforehand.

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Wiring 6.7 Wiring I/O modules and compact CPUs with Fast Connect

Procedure for disconnecting the wiring with Fast Connect 1. Insert the screwdriver into the opening next to the guide clip until it stops. 2. Using the screwdriver, apply upward leverage to the guide clip by means of the appropriate toothing. Repeat this action until the guide clip is engaged in the top position. 3. The wiring is disconnected. Remove the wire.









Figure 6-2

Disconnecting the wiring of a 40-pin Fast Connect connector









Figure 6-3

Disconnecting the wiring of a 20-pin Fast Connect connector

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Wiring 6.8 Labeling the module I/Os

6.8

Labeling the module I/Os

Introduction The labeling strips are used to document the assignment of module I/Os to the sensors / actuators of your system. You have to use the following labeling strips, depending on the module: Table 6- 8

Assignment of labeling strips to modules

Module

Labeling strip Order no.:

SMs (not 32-channel),

6ES7 392-2XX00-0AA0

Function modules, Communication module CP 342-2 SMs (32-channel)

6ES7 392-2XX10-0AA0

Filling out and inserting labeling strips 1. Label the strips with the addresses of the sensors / actuators. 2. Slide the labeled strips into the front panel.

Tip Templates for labeling strips are available on the Internet at http://www.siemens.com/automation/csi_en_WW, under entry ID 11978022.

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Wiring 6.9 Terminating shielded cables on the shielding contact element

6.9

Terminating shielded cables on the shielding contact element

Application The shield connecting element allows easy grounding of all shielded cables of S7 modules, due to its direct contact to the mounting rail.

Design of the shielding contact element The shielding contact element consists of: ● a bracket with two screw bolts for rail mounting (order no.: 6ES5 390-5AA00-0AA0) and ● the shielding terminals. You must use the following shielding terminals, based on the shielding diameter of your cables: Table 6- 9

Shielding diameter assignment to shielding terminals

Cable with shielding diameter

Shielding terminal order no.:

2 cables, each with shielding diameter of 2 mm to 6 mm

6ES7 390-5AB00-0AA0

1 cable, shielding diameter 3 mm to 8 mm

6ES7 390-5BA00-0AA0

1 cable, shielding diameter 4 mm to 13 mm

6ES7 390-5CA00-0AA0

The shielding contact element width is 80 mm and provides two rows, each with 4 shielding terminals.

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Wiring 6.9 Terminating shielded cables on the shielding contact element

Installing the shield connecting element underneath two signal modules 1. Push the two screw bolts of the bracket into the guide on the underside of the mounting rail. 2. Place the bracket underneath the modules whose shielded cables are to be terminated. 3. Screw-tighten the bracket onto the rail. 4. The shielding terminal is equipped with a slotted web underneath. Place the shielding terminal at this position onto the edge of the bracket (see figure below). Push the shielding terminal down and pivot it into the desired position. You can install up to 4 shielding terminals on each of the two rows of the shielding contact element.

   Number Identifier

120

①

Bracket of shielding contact element

②

Edge of the bracket where the shielding terminal(s) has to be placed.

③

Shielding terminals

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ITEM 3000 Wiring 6.9 Terminating shielded cables on the shielding contact element

Terminating 2-wire cables on shielding contact elements Only one or two shielded cables may be terminated per shielding terminal (see the figure below). The cable is clamped down at the stripped cable shielding. 1. Strip the cable shielding to a length of at least 20 mm. 2. Clamp in the stripped cable shielding underneath the shielding terminal. Push the shielding terminal towards the module ① and feed the cable through the clamp opening ①.. If you need more than four shielding terminals, start wiring at the rear row of the shielding contact element.



  Number

Identifier

①

Magnified view of the shielding terminal

②

Wiring of the shielding terminal

Tip Provide a sufficient cable length between the shielding terminal and the front connector. This allows you to disconnect the front connector for repairs, without having to disconnect the shielding terminal also, for example.

See also Cable shielding (Page 251)

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ITEM 3000

Wiring 6.10 Wiring the MPI / PROFIBUS connectors

6.10

Wiring the MPI / PROFIBUS connectors

6.10.1

Connecting the bus connector

Introduction You need to network all the nodes you integrate into a subnet of your system. Information on how to wire the bus connector can be found in the article below.

Wiring a bus connector with screw terminals 1. Strip the bus cable. Details on stripped lengths are found in the product information supplied with the bus connector. 2. Open the bus connector housing. 3. Insert the green and the red wire into the screw-terminal block. Always connect the same wires to the same terminal (green wire to terminal A, red wire to terminal B, for example). 4. Press the cable sheath into the clamp. Make sure that the shielding directly contacts the shielding contact surfaces. 5. Screw-tighten the wire terminals. 6. Close the bus connector housing.

Wiring a Fast Connect bus connector 1. Strip the bus cable. Details on stripped lengths are found in the product information supplied with the bus connector. 2. Open the strain relief of the bus connector. 3. Insert the green and red wire into the open contacting covers. Always connect the same wires to the same terminal (green wire to terminal A, red wire to terminal B, for example). 4. Close the contacting cover. This presses the conductors into the insulation displacement terminals. 5. Screw-tighten the strain relief clamp. Make sure that the shielding directly contacts the shielding contact surfaces. Note Use a bus connector with 90° cable exit.

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ITEM 3000

Wiring 6.10 Wiring the MPI / PROFIBUS connectors

See also Network components of MPI/DP and cable lengths (Page 64)

6.10.2

Setting the terminating resistor on the bus connector

Inserting a bus connector in a module 1. Connect the wired bus connector to the module. 2. Screw the bus connector tightly onto the module. 3. If the bus connector is at the start or end of a segment, you have to switch on the terminator resistance (Switch position "ON"; see following figure). Note 6ES7 972-0BA30-0XA0 bus connectors are not equipped with a terminating resistor. You cannot insert this type of bus connector at the beginning or end of a segment. Please make sure during startup and normal operation that power is always supplied to nodes where the terminating resistor is active. The figure below shows the switch settings of a bus connector: 7HUPLQDWLQJUHVLVWRUDFWLYDWHG

7HUPLQDWLQJUHVLVWRUQRWDFWLYDWHG

RQ

RQ

RII

RII

2Q

2Q

2II

2II

Removing the fiber-optic cable You can unplug a bus connector with a looped-through bus cable at any time from the PROFIBUS DP interface without interrupting data exchange on the bus.

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Wiring 6.10 Wiring the MPI / PROFIBUS connectors

ITEM 3000

Possible data traffic errors WARNING Data traffic error might occur on the bus! A bus segment must always be terminated at both ends with the terminating resistor. For example, this is not the case when the last slave with the bus connector is deactivated. Because the bus connector takes its voltage from the station, this terminating resistor is ineffective. Please make sure that power is always supplied to stations on which the terminating resistor is active.

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Addressing 7.1

7

Slot-specific addressing of modules

Introduction In slot-specific addressing (default addressing if configuration data was not loaded to the CPU yet), each slot number is assigned a module start address. This is a digital or analog address, based on the type of module. This section shows you which module start address is assigned to which slot number. You need this information to determine the start addresses of the installed modules.

Maximum assembly and the corresponding module start addresses The figure below shows you an S7-300 assembly on four racks, and the optional slots with their modules.Start addresses The input and output addresses for I/O modules begin at the same module start address. Note On a CPU 31xC system you cannot insert any modules into slot 11 of rack 3. The address range is reserved for the integrated I/O.

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ITEM 3000

Addressing 7.1 Slot-specific addressing of modules

The figure below shows the slots of an S7-300 and the corresponding module start addresses: 1RW&38[&

5DFN(0

6ORWQXPEHU 0RGXOHLQLWLDODGGUHVVGLJLWDO 0RGXOHLQLWLDODGGUHVVDQDORJ

,0

60 60 60 60 60 60 60 60 60



                       

,0

60 60 60 60 60 60 60 60 60



                       

5DFN(0

6ORWQXPEHU 0RGXOHLQLWLDODGGUHVVGLJLWDO 0RGXOHLQLWLDODGGUHVVDQDORJ

5DFN(0

60 60 60 60 60 60 60 60 60

,0

6ORWQXPEHU 0RGXOHLQLWLDODGGUHVVGLJLWDO 0RGXOHLQLWLDODGGUHVVDQDORJ

6) %86)



     

                 

6,(0(1 6

'&9 )5&(

5DFN&8

581 6723

36

6ORWQXPEHU 0RGXOHLQLWLDODGGUHVVGLJLWDO 0RGXOHLQLWLDODGGUHVVDQDORJ

126



&38



,0



60 60 60 60 60 60 60 60 60

                       

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ITEM 3000

Addressing 7.2 User-specific addressing of modules

7.2

User-specific addressing of modules

7.2.1

User-specific addressing of modules

User-specific addressing User-specific addressing means that you can assign an address of your choice to any module (SM/FM/CP). The addresses are assigned in STEP 7. There you specify the module start address that forms the basis for all other addresses of the module.

Advantages in user-specific addressing: ● Optimization of available address space as there are no "address gaps" between the modules. ● In your standard software configuration, you can define addresses which are independent of the relevant S7300 configuration. Note You always configure the hardware in HW Config of STEP 7 when using PROFIBUS DP or PROFINET IO field devices. User-specific addressing is automatically set in this case. There is no fixed slot addressing for such a configuration.

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ITEM 3000

Addressing 7.2 User-specific addressing of modules

7.2.2

Addressing digital modules This section describes how to assign addresses to digital modules. You need this information in order to be able to address the channels of the digital module in the user program.

Addresses of digital modules The address of an input or output of a digital module consists of a byte address plus a bit address. Example: I 1.2 The example consists of: ● input I, ● byte address 1 and ● bit address 2 The byte address is based on the module start address. The bit address is the number printed on the module. When the first digital module is located in slot 4, its default start address is 0. The start address of each further digital module increments by the count of 4. The figure below shows you how the scheme by which the addresses of the various channels of a digital module are derived.

       

%\WHDGGUHVV 0RGXOHVWDUWDGGUHVV

       

%\WHDGGUHVV 0RGXOHVWDUWDGGUHVV

%LWDGGUHVV

128

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ITEM 3000

Addressing 7.2 User-specific addressing of modules

An example of digital modules The example in the figure below shows which default addresses are derived when a digital module is located in slot 4 (that is, when the module start address is 0). Slot number 3 is not assigned, because the example does not contain an interface module.

36

6ORW QXPEHU



CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

&38



60

       

$GGUHVV $GGUHVV

       

$GGUHVV $GGUHVV

  $GGUHVV  

  $GGUHVV



129

ITEM 3000

Addressing 7.2 User-specific addressing of modules

7.2.3

Addressing analog modules This section describes how to address analog modules. You need this information in order to be able to address the channels of the analog modules in your user program.

Addresses of analog modules The analog input or output channel is always assigned a word address. The channel address is based on the module start address. When the first analog is located in slot 4, its default start address is 256. The start address of each further analog module increments by the count of 16. An analog I/O module has the same start addresses for its input and output channels.

An example of analog modules The example in the figure below shows you which default channel addresses are derived for an analog module located at slot 4. As you can see, the input and output channels of an analog I/O module are addressed starting at the same address, namely the module start address. Slot number 3 is not assigned, because the example does not contain an interface module. ,QSXWV &KDQQHO$GGUHVV &KDQQHO$GGUHVV

 

36

&38

60

2XWSXWV &KDQQHO$GGUHVV &KDQQHO$GGUHVV

 

6ORW QXPEHU

Figure 7-1

130







I/O addresses of an analog module at slot 4

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ITEM 3000

Addressing 7.2 User-specific addressing of modules

7.2.4

Addressing the integrated I/Os of CPU 31xC

CPU 312C Addresses of the integrated I/Os of this CPU: Table 7- 1

Integrated I/Os of CPU 312C

Inputs / outputs

Default addresses

Remarks

10 digital inputs

124.0 to 125.1

All digital inputs can be assigned an interrupt function.

of which 8 Inputs are for technological functions: 124.0 to 124.7 6 digital outputs

124.0 to 124.5 of which 2 inputs are for technological functions: 124.0 to 124.1

Optional technological functions: • Counting • Frequency measurement • Pulse width modulation

CPU 313C Addresses of the integrated I/Os of this CPU: Table 7- 2

Integrated I/Os of CPU 313C

Inputs / outputs

Default addresses

Comments

24 digital inputs

124.0 to 126.7

All digital inputs can be assigned an interrupt function.

of which 12 inputs are for technological functions: 124.0 to 125.0 125.4 to 125.6 16 digital outputs

124.0 to 125.7 of which 3 inputs are for technological functions: 124.0 to 124.2

4+1 analog inputs

752 to 761

2 analog outputs

752 to 755

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Optional technological functions: • Counting • Frequency measurement • Pulse width modulation

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ITEM 3000

Addressing 7.2 User-specific addressing of modules

CPU 313C-2 PtP and CPU 313C-2 DP Addresses of the integrated I/Os of these CPUs: Table 7- 3

Integrated I/Os of CPU 313C-2 PtP/DP

Inputs / outputs

Default addresses

Comments

16 digital inputs

124.0 to 125.7

All digital inputs can be assigned an interrupt function.

of which 12 inputs are for technological functions: 124.0 to 125.0 125.4 to 125.6 16 digital outputs

124.0 to 125.7 of which 3 inputs are for technological functions: 124.0 to 124.2

Optional technological functions: • Counting • Frequency measurement • Pulse width modulation

CPU 314C-2 PtP and CPU 314C-2 DP Addresses of the integrated I/Os of these CPUs: Table 7- 4

Integrated I/Os of CPU 314C-2 PtP/DP

Inputs / outputs

Default addresses

Comments

24 digital inputs

124.0 to 126.7

All digital inputs can be assigned an interrupt function.

of which 16 inputs are for technological functions: 124.0 to 125.7 16 digital outputs

124.0 to 125.7 of which 4 inputs are for technological functions: 124.0 to 124.3

4+1 analog inputs

752 to 761

2 analog outputs

752 to 755

Optional technological functions: • Counting • Frequency measurement • Pulse width modulation • Positioning

Special features You cannot influence outputs with transfer instructions if they are assigned to technological functions. I/Os not configured for technological functions can be used as standard I/Os.

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ITEM 3000 Addressing 7.3 Addressing on PROFIBUS DP

7.3

Addressing on PROFIBUS DP

Overview The corresponding DP slaves must be commissioned for operation on PROFIBUS DP in order to enable addressing of distributed I/O in the user program. This commissioning includes ● the assignment of DP slaves to PROFIBUS addresses ● the assignment of slots or address ranges to the I/O modules in order to enable their addressing in the user program. Slots which do not contain user date are assigned diagnostics addresses. This applies likewise when the CPU is operated as DP slave. Further information about CPU operation in DP master or DP slave mode is available in the chapter Commissioning PROFIBUS DP.

User-specific addressing of distributed PROFIBUS IO Distributed PROFIBUS DP IO requires user-specific addressing. Further information is available in the User-specific addressing of modules chapter.

Addressing consistent user data areas The table below shows items to be taken into consideration in terms of communication in a PROFIBUS DP master system when transferring I/O areas with "Total length" consistency. Rule for 1 byte to 32 bytes data consistency on PROFIBUS DP: The address range of consistent data in the process image is automatically updated. You can also use SFC14 "DPRD_DAT" and SFC15 "DPWR_DAT" to read and write consistent data. SFC14 and SFC15 are required to read and write consistent data of address ranges which are not available in the process image. The length of areas with "Total length" consistency accessed by the SFC must match the programmed range. Direct access to consistent areas is also possible (L PEW or T PAW, for example). PROFIBUS DP supports the transfer of up to 32 bytes of consistent data.

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Addressing 7.4 Addressing on PROFINET

7.4

Addressing on PROFINET

Overview The corresponding I/O devices must be commissioned for operation on PROFINET in order to enable addressing of distributed peripherals on PROFINET IO in the user program. This commissioning includes ● the definitions of I/O device numbers and names ● the definition of I/O device names in order to enable the assignment of IP addresses and access to the IO devices by the CPU 31x PN/DP operated as IO controller. Note Name assignment at "Device replacement without removable medium" If the functionality "Device replacement without removable medium" is configured in HW Config, IO devices can be replaced without the user having to assign a name. To do so, the IO device has to be reset to the state of delivery by using "Reset to factory setting". ● Address ranges are assigned to the input/output modules or slots/subslots so that they can be addressed from the user program. Slots which do not contain user date are assigned diagnostics addresses. Further information about CPU operation as I/O controller is available in the chapter Commissioning PROFINET IO.

User-specific addressing of distributed PROFINET IO Distributed peripherals on PROFINET IO require user-specific addressing. Further information is available in the User-specific addressing of modules chapter.

Addressing consistent user data areas The table below shows items to be taken into consideration in terms of communication in a PROFINET IO system when transferring I/O areas with "Total length" consistency. Rule for 1 byte to 254 bytes data consistency on PROFINET IO: The address range of consistent data in the process image is automatically updated. You can also use SFC14 "DPRD_DAT" and SFC15 "DPWR_DAT" to read and write consistent data. SFC14 and SFC15 are required to read and write consistent data of address ranges which are not available in the process image. The length of areas with "Total length" consistency accessed by the SFC must match the programmed range. Direct access to consistent areas is also possible (L PEW or T PAW, for example). PROFINET IO supports the transfer of up to 254 bytes of consistent data.

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ITEM 3000 Commissioning 8.1

8

Overview This section contains important notes on commissioning which you should strictly observe in order to avoid injury or damage to machines. Note Your commissioning phase is determined primarily by your application, so we can only offer you general information, without claiming completeness of this topic.

Reference Note the information about commissioning provided in the descriptions of your system components and devices.

8.2

Commissioning procedure

8.2.1

Procedure: Commissioning the hardware

Hardware requirements ● S7-300 is installed ● S7-300 is wired With networked S7-300, the following applies to the interfaces: ● MPI/ PROFIBUS – The MPI/PROFIBUS addresses are configured – The terminating resistors on the segments are enabled. ● PROFINET – The integrated PROFINET interface of CPU 31x PN/DP is configured in STEP 7 (IP address and device name are set in HW Config) – The CPU is connected to the subnet.

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ITEM 3000

Commissioning 8.2 Commissioning procedure

Recommended procedure: Hardware The S7-300 system can be very large and extremely complex due to its modular structure and versatile expansion options. It is therefore inappropriate to initially start up an S7-300 with multiple racks and all inserted (installed) modules. Rather, we recommend a step-bystep commissioning procedure. We recommend the following initial commissioning procedure for an S7-300: Table 8- 1

Recommended commissioning procedure: Hardware

Tasks An installation and wiring check according to checklist Disconnecting drive aggregates and control elements

Preparing the CPU Central unit (CU): commission the CPU and power supply, check the LEDs

Remarks -

Information can be found

This prevents negative effects on your system as a result of program errors.

-

in the chapter: Checklist for commissioning

Tip: By redirecting data from your outputs to a data block, you can always check the status at the outputs Connecting the PG Commission the CU with inserted power supply module and CPU. First, switch on the expansion devices (EMs) which are equipped with their own power supply module, and then switch on the power supply module of the CU. Check the LED displays on both modules.

Reset CPU memory and check the LEDs

-

CU: commission the remaining modules Expansion module (EM): Connecting

Insert further modules into the CU and commission these, working successively.

EM: Commissioning

Interconnect the CU with EMs as required: Insert only one send IM into the CU, and insert the matching receive IM into into the EM. Insert further modules into the EMs and commission these, working in successively.

in the chapter: Connecting the programming device (PG). in the chapter: Initial power on

in the chapter: Debugging functions, diagnostics and troubleshooting in the chapter: CPU memory reset by means of mode selector switch in the Module specifications Manual

in the chapter: Installation See above.

DANGER Proceed step-by-step. Do not go to the next step unless you have completed the previous one without error / error message.

Reference Important notes can also be found in the section Debugging Functions, Diagnostics and

Troubleshooting.

See also Procedure: Software commissioning (Page 137)

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Commissioning 8.2 Commissioning procedure

8.2.2

Procedure: Software commissioning

Requirements

● You must have installed and wired up your S7-300. ● You are using the current programming package of STEP 7 in order to utilize the complete functional scope of your CPU. ● In case of networking of the S7-300 with MPI or PROFIBUS – The MPI/PROFIBUS addresses are configured – The terminating resistors on the segments are enabled ● In case of networking of the S7-300 with PROFINET – The integrated PROFINET interface of CPU 31x PN/DP is configured in STEP 7 (IP address and device names are set in HW Config) – The CPU is connected to the subnet. Note Observe the procedure for commissioning the hardware.

Recommended procedure: Software Table 8- 2

Recommended commissioning procedure - Part II: Software

Tasks • •

Remarks

Switch on the PG and run SIMATIC Manager Download the configuration and the program to the CPU

Debugging the I/Os

Helpful functions are here: • Monitoring and controlling tags • Testing with program status • Forcing • Controlling outputs in STOP mode (PO enable)

Information can be found ... In the STEP 7 Programming Manual

In the STEP 7 Programming Manual

Chapter: Debugging functions, diagnostics and troubleshooting

Tip: Test the signals at the inputs and outputs using the simulation module SM 374, for example. Commissioning PROFIBUS DP or Ethernet

-

in the PROFINET System Description System Manual

Commissioning PROFINET IO Connect the outputs

in the chapter: Commissioning PROFIBUS DP in the chapter: Configuring PROFINET interface X2

Commissioning the outputs successively.

-

DANGER Proceed step-by-step. Do not go to the next step unless you have completed the previous one without error / error message.

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Commissioning 8.3 Commissioning check list

Reaction to errors React to errors as follows: ● Check the system with the help of the check list in the chapter below. ● Check the LED displays on all modules. For information on their meaning, refer to the chapters describing the relevant modules. ● If required, remove individual components to trace the error.

Reference Important notes can also be found in the section Debugging Functions, Diagnostics and

Troubleshooting.

See also Procedure: Commissioning the hardware (Page 135)

8.3

Commissioning check list

Introduction After you mounted and wired your S7-300, we advise you to check all previous steps once again. The check list tables below are a guide for your examination of the S7-300. They also provide cross-references to chapters containing further information on the relevant topic.

Racks

138

Points to be examined are in the manual

S7-300: Installation in chapter

Are the rails mounted firmly to the wall, in the frame or in the cabinet?

Configuring, Installation

Have you maintained the free space required?

Configuring, Installation

Are the cable ducts installed properly?

Configuring

Is the air circulation OK?

Installing

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Commissioning 8.3 Commissioning check list

Concept of grounding and chassis ground

Points to be examined are in the manual

S7-300: Installation in chapter

Have you established a low-impedance connection (large surface, large contact area) to local ground?

Configuring, Appendix

Are all racks (rails) properly connected to reference potential and local ground (direct electrical connection or ungrounded operation)?

Configuring, Wiring, Appendix

Are all grounding points of electrically connected modules and of the load power supply units connected to reference potential?

Configuring, Appendix

Module installation and wiring

Points to be examined are in the manual

S7-300: Installation in chapter

Are all modules properly inserted and screwed in?

Installing

Are all front connectors properly wired, plugged, screwtightened or latched to the correct module?

Installation, Wiring

Points to be examined

S7-300: Installation in chapter

See manual; Section ...

Is the correct mains voltage set for all components?

Wiring

Module data

Points to be examined

S7-300: Installation in chapter

See manual; Section ...

Is the mains plug wired correctly?

Wiring

-

Is mains voltage connected?

-

-

Mains voltage

Power supply module

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8.4

Commissioning the Modules

8.4.1

Inserting/Replacing a Micro Memory Card

ITEM 3000

SIMATIC Micro Memory Card (MMC) as memory module The memory module used on your CPU is a SIMATIC Micro Memory Card. You can set up the SIMATIC Micro Memory Card as a load memory or a portable data medium. Note A SIMATIC Micro Memory Card must be inserted for CPU operation. Note The CPU goes into STOP and requests a memory reset when you remove the SIMATIC MMC while the CPU is in RUN state. CAUTION Data on a SIMATIC Micro Memory Card can be corrupted if you remove the card while it is being accessed by a write operation. You may have to delete the SIMATIC Micro Memory Card using the PG or format it in the CPU if you remove it from the live system. DO NOT remove the SIMATIC Micro Memory Card when the system is in RUN state; always shut down power or set the CPU to STOP state in order to prevent any write access of a programming device. When the CPU is in STOP mode and you cannot not determine whether or not a PG is writing to the card (e.g. load/delete block), disconnect the communication lines. WARNING Make sure that the SIMATIC Micro Memory Card to be inserted contains a user program which is suitable for the CPU (system). The wrong user program may have fatal processing effects.

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Inserting/replacing the SIMATIC Micro Memory Card 1. Switch the CPU to STOP mode. 2. Is a SIMATIC Micro Memory Card inserted? If yes, ensure that no write operations are running on the PG (such as loading a block). If you cannot ensure this state, disconnect all communication lines of the CPU. Press the ejector and remove the SIMATIC MMC. The frame of the module slot is equipped with an ejector for removing the SIMATIC MMC (see CPU 31xC and CPU 31x Manual, Technical Data CPU31x Operator Control and Display Elements). You need a small screwdriver or ball-point pen to eject the SIMATIC Micro Memory Card. 3. Insert the ("new") SIMATIC MMC into the card slot with its beveled edge facing the ejector. 4. Carefully push the SIMATIC MMC into the CPU slot to engage the interlock. 5. Reset CPU memory (see Resetting CPU memory by means of mode selector switch)

Inserting and removing a SIMATIC MMC when CPU power is switched off After you replaced a SIMATIC MMC in POWER OFF state, the CPUs ● automatically detect a physically identical SIMATIC MMC with changed content ● automatically detect a new MMC with contents to the previous SIMATIC MMC It automatically performs a CPU memory reset after POWER ON.

Reference ● Chapter Properties of the SIMATIC Micro Memory Card , CPU 31xC and CPU 31x Manual, Technical data ● Chapter Technical data of the SIMATIC Micro Memory Card (MMC), CPU 31xC and CPU 31x Manual, Technical data

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8.4.2

Initial power on

Requirements ● You must have installed and wired up the S7-300. ● Insert the Micro Memory Card into the CPU ● Your CPU's mode selector switch must be set to STOP.

Initial power on of a CPU with Micro Memory Card Switch on the PS 307 power supply module. Result: ● The 24 VDC LED on the power supply module is lit. ● On the CPU – The 5 VDC LED is lit. – The STOP LED flashes at 2 Hz when the CPU executes an automatic memory reset. – The STOP LED is lit after memory reset.

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8.4.3

CPU memory reset by means of mode selector switch

When to reset CPU memory You reset CPU memory ● in order to clear all retentive memory bits, timers and counters, and to initialize work memory with the start values of the retentive DBs in load memory. ● if the new retentive new memory bits, timers and counters downloaded to the CPU user program using the "Download user program to Memory Card" function are liable to cause unwanted reactions. Reason: the "Download user program to Memory Card" function does not delete any retentive memory areas. ● when the CPU requests a memory reset; indicated by the STOP LED flashing at 0.5 Hz intervals Table 8- 3

Possible reasons of a CPU request to reset memory

Causes of a CPU request to reset memory

Special features

The SIMATIC MMC has been replaced.

–

RAM error in CPU

–

Insufficient work memory for loading all user program blocks from a SIMATIC MMC.

CPU with inserted SIMATIC Micro Memory Card: Recursive request of a CPU memory reset.

Attempts to load faulty blocks; if a wrong instruction was programmed, for example.

For further information on the behavior of the SIMATIC MMC during CPU memory reset, refer to the CPU 31xC and CPU 31x Manual, Technical data, Memory Reset

and Restart

How to reset memory There are two ways to reset CPU memory: CPU memory reset using the mode selector switch

CPU memory reset using the PG

... is described in this chapter.

... is only possible when CPU is in STOP mode (see STEP 7 Oneline Help ).

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Resetting CPU memory using the mode selector switch The table below shows the steps in resetting CPU memory. Table 8- 4

Procedure for CPU memory reset

Step

Reset CPU memory

1.

Turn the key to STOP position ①.

2.

Turn the key to MRES position Hold the key in this position until the STOP LED lights up for the second time and remains on (this takes 3 seconds). ② Now release the key.

3.

You must turn the key to MRES position again within 3 seconds and hold it there until the STOP LED flashes (at 2 Hz). ③ You can now release the switch. When the CPU has completed memory reset, the STOP LED stops flashing and remains lit. The CPU has reset the memory.

The procedure described earlier is only required to reset CPU memory when the CPU has not requested (indicated by slow flashing of the STOP LED) a memory reset. If the CPU requests a memory reset you only have to briefly set the mode selector switch to the MRES position in order to initiate the memory reset. The figure below shows how to use the mode selector switch to reset CPU memory: 6723 /('

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You may have to format the SIMATIC MMC if memory was successfully reset and the CPU once again requests a memory reset (see Formatting the SIMATIC Micro Memory Card).

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STOP LED does not flash during the memory reset What should I do if the STOP LED does not flash during the memory reset or if other LEDs are lit? 1. You must repeat steps ② and ③. 2. If the CPU still does not reset memory, evaluate the diagnostic buffer of the CPU.

What happens in the CPU during a memory reset Table 8- 5

Internal CPU events on memory reset

Event

Action in CPU

CPU activities

1.

The CPU deletes the entire user program in the main memory.

2.

The CPU deletes the retentive data.

3.

The CPU tests its own hardware.

4.

The CPU copies the runtime-relevant content of the SIMATIC Micro Memory Card (load memory) to work memory. Tip: If the CPU is unable to copy the contents from the SIMATIC MMC and requests a memory reset: • Remove the SIMATIC Micro Memory Card. • Reset CPU memory • Read the diagnostic buffer.

Memory contents after reset

The user program is once again transferred from the SIMATIC MMC to work memory. Memory utilization is indicated accordingly.

Data retained

Data in the diagnostics buffer. You can read the diagnostic buffer with the PG (see STEP 7 Online Help). • •

The MPI parameters (MPI address and highest MPI address, transmission rate, configured MPI addresses of CPs/FMs in an S7300). Same applies to CPU 315-2 PN/DP /CPU 317 / CPU 319 if the MPI/DP interface of the CPU is programmed for operation as DP interface (PROFIBUS address, highest PROFIBUS address, baud rate, configured as active or passive interface).

Content of elapsed time counter

Special feature: Interface parameters (MPI or MPI/DP interface) The following parameters hold a special position when CPU memory is reset. ● Parameters of interface (MPI parameters or MPI-/DP parameters for MPI-/DP interfaces). The table below describes which interface parameters remain valid after a CPU memory reset. CPU memory reset ...

MPI/DP parameters

with inserted SIMATIC Micro Memory Card:

...the MPI parameters on the SIMATIC Micro Memory Card or integrated read-only load memory are valid. If this location does not contain any parameter data (SDB), the previously set parameters stay valid.

without inserted SIMATIC Micro Memory Card:

... are retained and valid.

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8.4.4

Formatting the Micro Memory Card

Situations which require formatting of the SIMATIC Micro Memory Card: ● The SIMATIC Micro Memory Card module type is not a user module ● The SIMATIC Micro Memory Card is not formatted ● The SIMATIC Micro Memory Card is defective ● Invalid content of the SIMATIC Micro Memory Card The content of the SIMATIC Micro Memory Card has been marked invalid ● The "Download user program" operation was interrupted as a result of Power Off. ● The "Write to EPROM" operation was interrupted as a result of Power Off. ● Error when evaluating the module content during CPU memory reset. ● Formatting error, or formatting failed. If one of these errors has occurred, the CPU prompts you for yet another memory reset, even after a memory reset operation has been performed. The contents of the SIMATIC MMC are retained until it is formatted, unless the "Download user program" or "Write to EPROM" operation was interrupted due to Power Off. The SIMATIC Micro Memory Card is only formatted if a specific reason is given (see above). It is not formatted, for example, when the CPU requests a memory reset after module replacement. In this case, a switch to MRES triggers a normal memory reset for which the module content remains valid.

How to format your SIMATIC Micro Memory Card If the CPU has requested a memory reset (STOP LED flashing slowly) you can format the SIMATIC MMC using the mode selector switch as described below: 1. Toggle the switch to the MRES position and hold it there until the STOP LED lights up and remains on (after approx. 9 seconds). 2. Within the next three seconds, release the switch and toggle it once again to MRES position. The STOP LED flashes to indicate that formatting is in progress. Note Always perform these steps within the specified time, for the SIMATIC Micro Memory Card will otherwise not be formatted and returns to memory reset status.

See also CPU memory reset by means of mode selector switch (Page 143)

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8.4.5

Connecting the programming device (PG)

8.4.5.1

Connect PG/PC to the integrated PROFINET interface of the CPU 31x PN/DP

Requirement ● CPU with integrated PROFINET interface (CPU 319-3 PN/DP, for example) ● PG/PC with network card

Connect PG/PC to the integrated PROFINET interface of the CPU 31x PN/DP 1. Connect the PG/PC to a switch, using a TP patch cable ①. 2. In the same way, connect the switch to the integrated PROFINET interface of your CPU ②.

36

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Result You connected the PG/PC to the integrated PROFINET interface of the CPU.

Tip Using an Ethernet crossover cable, you can also connect your PG/PC directly to the integrated PROFINET interface of the CPU 31x PN/DP.

Reference ● For information on PROFINET, refer to the PROFINET System Description. ● For information on passive network components such as switches, refer to the SIMATIC

NET manual: Twisted Pair and Fiber-Optic Networks.

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See also Configuring and commissioning the PROFINET IO system (Page 170)

8.4.5.2

Connecting the PG to a node

Requirement The PG must be equipped with an integrated MPI interface or an MPI card in order to connect it via MPI.

Connecting a PG to the integrated MPI interface of the CPU Interconnect the PG with the MPI interface of your CPU by way of a PG patch cable ①. You can use a self-made PROFIBUS bus cable with bus connectors. The figure below illustrates the connection between the PG and the CPU

36

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60

03,

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Identifier

①

PG cable used to interconnect the PG with the CPU

Procedure for PROFIBUS DP The procedure is basically the same, if the CPU interface is set to PROFIBUS DP mode

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8.4.5.3

Connecting the PG to several nodes

Requirements The PG must be equipped with an integrated MPI interface or an MPI card in order to connect it to an MPI.

Connecting the PG to several nodes Use bus connectors to connect a PG which is permanently installed on the MPI subnet to the other nodes of the MPI subnet. The figure below shows two networked S7-300s which are interconnected by means of bus connectors.

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Identifier

①

PROFIBUS bus cable

②

Connectors with enabled terminating resistors

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8.4.5.4

Using the PG for commissioning or maintenance

Requirement The PG must be equipped with an integrated MPI interface or an MPI card in order to connect it to an MPI.

Using the PG for commissioning or maintenance Use a stub cable to connect the commissioning and maintenance PG to the other subnet nodes. The bus connector of these nodes must be equipped with a PG socket. The figure below shows the interconnection of two networked S7-300 and a PG.

36 3*

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150

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Identifier

①

Stub cable used to interconnect the PG with the CPU

②

Connectors with enabled terminating resistors

③

PROFIBUS bus cable used to network both CPUs

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Commissioning 8.4 Commissioning the Modules

MPI addresses for service PGs If there is no stationary PG, we recommend: To connect a PG to an MPI subnet with "unknown" node addresses, set the following addresses on the service PG: ● MPI address: 0 ● Highest MPI address: 126 IN STEP 7, you then determine the highest MPI address on the MPI subnet and match the highest MPI address in the PG to that of the MPI subnet.

See also Procedure: Commissioning the hardware (Page 135) Procedure: Software commissioning (Page 137)

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8.4.5.5

Connecting a PG to ungrounded MPI nodes (not CPU 31xC)

Requirement The PG must be equipped with an integrated MPI interface or an MPI card in order to connect it to an MPI.

Connecting a PG to ungrounded nodes on an MPI subnet (not CPU 31xC) Connecting a PG to ungrounded nodes Always use an ungrounded PG to connect to ungrounded MPI subnet nodes or to ungrounded S7-300 PLCs. Connecting a grounded PG to the MPI You want to operate with ungrounded nodes. If the MPI at the PG is grounded, you must interconnect the nodes and the PG with an RS485 repeater. You must connect the ungrounded nodes to bus segment 2 if the PG is connected to bus segment 1 (terminals A1 B1) or to the PG/OP interface (refer to chapter 9 in the Module Data Manual). The figure below shows an RS485 repeater as interface between grounded and ungrounded nodes of an MPI subnet.

36



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①

Connectors with enabled terminating resistors

②

RS485 Repeaters, with activated terminating resistors

See also PROFINET cable lengths and network expansion (Page 83) Network components of MPI/DP and cable lengths (Page 64)

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8.4.6

Starting SIMATIC Manager

Introduction SIMATIC Manager is a GUI for online/offline editing of S7 objects (projects, user programs, blocks, hardware stations and tools). The SIMATIC Manager lets you ● manage projects and libraries, ● call STEP 7 tools, ● access the PLC (AS) online, ● edit Memory Cards.

Starting SIMATIC Manager After installation, the SIMATIC Manager icon appears on the Windows desktop, and the Start menu contains entry SIMATIC Manager under SIMATIC. 1. Run SIMATIC Manager by double-clicking the icon, or from the Start menu (same as with all other Windows applications).

User interface A corresponding editing tool is started up when you open the relevant objects. You start the program editor by double-clicking the program block you want to edit (object-oriented start).

Online Help The online help for the active window is always called by pressing F1.

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8.4.7

Monitoring and modifying I/Os

The "Monitor and modify tags" tool The STEP 7 "Monitor and modify tags" tool lets you: ● monitor program tags in any format ● edit the tag status or data in the CPU (modifying).

Creating a tag table You have two options of creating a tag table (VAT): ● in the LAD / FBD / STL editor by selecting the PLC > Monitor/Modify Variables command This table is also available directly online. ● in SIMATIC Manager with the Blocks container open via menu item Insert New Object > Variable table This table created offline can be saved for future retrieval. You can also test it after switching to online mode. VAT structure: In the VAT, every address to be monitored or modified (e.g. inputs, outputs) occupies one row. The meaning of the VAT columns is as follows: Column text

This field ...

Address

contains the absolute address of the tag

Icon

contains the symbolic descriptor of the tag

Symbol comment

shows the symbol comment of the Symbol Table

Status format

contains the default format setting, e.g. HEX.

This is identical to the specification in the Symbol Table.

You can change the format as follows: • right-click in the format field. The Format List opens. •

or left-click in the format field until the relevant format appears

Status value

shows the content of the tag at the time of update

Modify value

is used to enter the new tag value (modify value)

Monitor tag You have two options for monitoring tags: ● updating the status values once via menu item Tag > Update Status Values or ● continuous update of status values via menu item Tag > Monitor

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Modifying tags To modify tags , proceed as follows: 1. Left-click the field Modify value of the relevant tag. 2. Enter the modify value according to the data type. 3. To update modify values once, select the menu item Tag > Activate Modify Value. or Enable modify values permanently via menu item Tag > Modify. 4. In the Monitor test function, verify the modify value entry in the tag. Is the modify value valid? You can disable the modify value entered in the table. An invalid value is displayed same as a comment. You can re-enable the modify value. Only valid modify values can be enabled.

Setting the trigger points Trigger points: ● The "Trigger point for monitoring" determines the time of update for values of tags to be monitored. ● The "Trigger point for modifying" determines the time for assigning the modify values to the tags to be modified. Trigger condition: ● The "Trigger condition for monitoring" determines whether to update values once when the trigger point is reached or continuously every time the trigger point is reached. ● The "Trigger condition for modifying" determines whether to assign modify values once or permanently to the variable to be modified. You can customize the trigger points using the tool "Monitor and modify tag" in the menu item Tag > Set Trigger ... . Special features ● If "Trigger condition for monitoring" is set to once , the menu items Tag > Update Status Values or Tag > Monitor have the same effect, namely a single update. ● If "Trigger condition for modifying" is set to once , the menu items Tag > Update Status Values or Tag > Modify have the same effect, namely a single assignment. ● If trigger conditions are set to permanent , the said menu items have different effects as described above. ● If monitoring and modifying is set to the same trigger point, monitoring is executed first. ● If Process mode is set under Debug > Mode, values are not cyclically updated when permanent modification is set. Remedy: Use the Force test function.

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Saving/opening the variable table Saving the VAT 1. After aborting or completing a test phase, you can save the variable table to memory. The name of a variable table starts with the letters VAT, followed by a number from 0 to 65535; e.g. VAT5. Opening VAT 1. Select the menu item Table > Open. 2. Select the project name in the Open dialog. 3. In the project window below, select the relevant program and mark the Blocks container. 4. In the block window, select the desired table. 5. Confirm with OK.

establishing a connection to the CPU The variables of a VAT represent dynamic quantities of a user program. In order to monitor or modify variables it is required to establish a connection to the relevant CPU. Every variable tables can be linked to another CPU. In menu item PLC > Connect to ... , establish a connection to one of the following CPUs: ● configured CPU ● directly connected CPU ● available CPU ... The table below lists the display of variables. CPUs

The CPU variables are displayed, ...

configured CPU

in their S7 program (Hardware Station) in which the VAT is stored.

directly connected CPU

that is connected directly to the PG.

available CPU.

that is selected in the dialog window. Use the menu items PLC > Connect to ... > Available CPU ... to connect to an available CPU. This can be used to connect to any CPU available on the network.

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Modifying outputs in CPU STOP mode The function Enable PO resets the output disable signal for the peripheral outputs (PO), thus enabling modifying of the PO in CPU STOP mode. In order to enable the POs, proceed as follows: 1. In menu item Table > Open the variable table (VAT), open the VAT that contains the PO you want to modify, or activate the window containing the corresponding VAT. 2. To modify the PO of the active VAT, select the CPU connection in menu command PLC > Connect to ... . 3. Use menu command PLC > Operating Mode to open the Operating Mode dialog and switch the CPU to STOP mode. 4. Enter your values in the "Modify value" column for the PO you want to modify. Examples: PO: POB 7 modify value: 2#0100 0011 POW 2 W#16#0027 POD 4 DW#16#0001 5. Select Variable > Enable PO to set "Enable PO" mode. 6. Modify the PO by selecting Variable > Activate Modify Values. "Enable PO" mode remains active until reset by selecting Variable > Enable PO once again. "Enable PO" is also terminated when the connection to the PG goes down. 7. Return to step 4 if you want to set new values. Note For example, a message pops up to indicate a CPU mode transition from STOP to RUN or START-UP. A message also pops up when the "Enable PO" function is set while the CPU is in RUN mode.

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Commissioning 8.5 Commissioning PROFIBUS DP

8.5

Commissioning PROFIBUS DP

8.5.1

Commissioning PROFIBUS DP

Requirements Requirements for commissioning a PROFIBUS DP network: ● A PROFIBUS DP network is installed. ● You have configured the PROFIBUS DP network using STEP 7 Standard Package and have assigned a PROFIBUS DP address and the address space to all the participants. ● Note that you must also set address switches at some of the DP slaves (see the description of the relevant DP slave). ● Software requirements are shown in the table below, based on the CPU used: Table 8- 6

Software requirements

CPU

Order No.

Software required

313C-2 DP

6ES7313-6CF03-0AB0

314C-2 DP

6ES7314-6CG03-0AB0

COM PROFIBUS V 5.0 or higher

315-2 DP

6ES7315-2AH14-0AB0

STEP 7, V 5.4 + SP6 or higher or STEP 7, V5.2 + SP1 + HSP or higher

315-2 PN/DP

6ES7315-2EH13-0AB0

STEP 7 V5.4 + SP1 + HSP or higher

317-2 DP

6ES7317-2AJ10-0AB0

STEP 7 V5.2 + SP1 + HSP or higher

317-2 PN/DP

6ES7317-2EK13-0AB0

STEP 7 V 5.4 + SP2 or higher

319-3 PN/DP

6ES7318-3EL00-0AB0

STEP 7 V 5.4 + SP4 or higher

STEP 7 V 5.2. or higher + SP1 + HSP

DP address ranges of the CPUs Table 8- 7

DP address ranges of the CPUs

Address area

313C-2 DP 314C-2 DP

315-2 DP 315-2 PN/DP

317-2 DP 317-2 PN/DP

319-3 PN/DP

Entire address range of inputs and of outputs

1024 bytes

2048 bytes

8192 bytes

8192 bytes

of these in the process image, for inputs and outputs respectively:

max. 128 bytes

max. 2048 bytes

max. 2048 bytes

Max. 8192 bytes

128 bytes 1

128 bytes

256 bytes

256 bytes

•

Default 1 default

158

cannot be changed

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Commissioning 8.5 Commissioning PROFIBUS DP

DP diagnostics addresses DP diagnostic addresses occupy 1 byte per DP master and DP slave in the input address range. For example, at these addresses DP standard diagnostics can be called for the relevant node (LADDR parameter of SFC 13). The DP diagnostic addresses are specified in your configuration. If you do not specify any DP diagnostic addresses, STEP 7 assigns these DP diagnostic addresses in ascending order, starting at the highest byte address. In the case of a CPU 31xC-2 DP, CPU 31x-2 DP or CPU 31x PN/DP assigned as a master, two different diagnostic addresses must be assigned for S7 slaves. ● Diagnostic address of the slave (address for slot 0) At this address all slave events are reported in the DP master (Node representative), e.g. Node failure. ● Diagnostic address of the module (address for slot 2) All module (CPU 313C-2 DP as I-Slave, for example) events are reported in the master (OB82) at this address. With a CPU as DP Slave, for example, diagnostic interrupts for operating mode transitions are reported at this address.

See also Connecting the PG to a node (Page 148) Connecting the PG to several nodes (Page 149)

8.5.2

Commissioning the CPU as DP master

Requirements for commissioning ● The PROFIBUS subnet has been configured. ● The DP slaves are ready for operation (see relevant DP slave manual). ● In order to operate the MPI/DP interface as DP interface it must be configured accordingly (only CPU 315-2 PN/DP/ CPU 317 and CPU 319). ● You must configure the CPU as DP master prior to commissioning. That is, in STEP 7 you have to – configure the CPU as a DP master, – assign a PROFIBUS address to the CPU, – assign a master diagnostic address to the CPU, – integrate the DP slaves into the DP master system. Is the DP CPU a DP slave? If so, this DP slave appears in the PROFIBUS-DP catalog as configured station. In the DP master, assign a slave diagnostic address to this DP slave CPU. You must interconnect the DP master with the DP slave CPU and specify the address ranges for data exchange with the DP slave CPU.

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Commissioning 8.5 Commissioning PROFIBUS DP

Commissioning Commission the DP CPU as a DP master in the PROFIBUS subnet as follows: 1. Download the PROFIBUS subnet configuration created with STEP 7 (preset configuration) from the PG to the DP CPU. 2. Switch on all of the DP slaves. 3. Switch the DP CPU from STOP to RUN.

Startup of DP CPU as DP master

During startup, the DP CPU checks the configured preset configuration of its DP master system against the actual configuration. If preset configuration = actual configuration, the CPU switches to RUN mode. If the preset configuration ≠ to the actual configuration, the configuration of parameter Startup if preset configuration ≠ actual configuration determines the startup behavior of the CPU. Startup when the preset configuration ≠ actual configuration = yes (default setting)

Startup when the preset configuration ≠ actual configuration = no

DP CPU switches to RUN.

DP CPU remains in STOP mode, and the BUS LED flashes after the set Monitoring time for transfer of parameters to modules.

(BUSF LED flashes if any of the DP slaves cannot be addressed)

The flashing BUSF LED indicates that at least one DP slave cannot be accessed. In this case, check whether all DP slaves are switched on or correspond with your configuration, or read out the diagnostic buffer with STEP 7.

Recognizing the operating state of DP slaves (Event recognition)

The table below shows how the DP CPU operating as a DP master recognizes operating mode transitions of a CPU operating as a DP slave or data exchange interruptions. Table 8- 8

Event recognition by CPUs 31xC-2 DP / 31x-2 DP / 31x PN/DP operating as DP master

Event

What happens in the DP master?

Bus interruption (short circuit, connector removed)

•

Call of OB 86 with the message Station failure

•

(coming event; diagnostic address of the DP slave assigned to the DP master) With I/O access: call of OB 122 (I/O access error)

DP slave:

•

RUN → STOP DP slave: STOP → RUN

Call of OB 82 with the message Module error (incoming event; diagnostic address of the DP slave assigned to the DP master; Variable OB82_MDL_STOP=1)

•

Call of OB 82 with the message Module OK (outgoing event; diagnostic address of the DP-Slave assigned to the DP master; Variable OB82_MDL_STOP=0)

Tip: When commissioning the CPU as DP master, always program OB82 and OB86. This helps you to recognize and evaluate data exchange errors or interruption.

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Programming, status/control via PROFIBUS As an alternative to the MPI interface, you can program the CPU or execute the PG's status and control functions via the PROFIBUSDP interface. Note The use of Status and Control function via the PROFIBUS-DP interface extends the DP cycle.

Constant Bus Cycle Time This is a property of PROFIBUS DP. The "Constant bus cycle time" function ensures that the DP master always starts the DP bus cycle within a constant interval. From the perspective of the slaves, this means that they receive their data from the master at constant time intervals. In STEP 7 V 5.x or higher you can configure constant bus cycle times for PROFIBUS subnets. Details on constant bus cycle times are found in the STEP 7 Online Help.

Isochronous updating of process image partitions SFC126 "SYNC_PI" is used for the isochronous update of the process image partition of inputs. An application program which is interconnected with a DP cycle (by means of OB61) can use this SFC for consistent updates of data recorded in the process image partition of inputs in synchronism with this cycle. SFC126 accepts interrupt control and can only be called in OB61. SFC 127 "SYNC_PO" is used for the isochronous update of the process image partition of outputs. An application program which is interconnected to a DP cycle can use the SFC for the consistent transfer of the computed output data of a process image partition of outputs to the I/O in synchronism with this cycle. SFC 127 accepts interrupt control and can only be called in OB 61. The SFCs 126 and 127 are described in the STEP 7 Online Help and in the System Software S7-300/400, System and Standard Functions Reference Manual. The following CPUs support isochronous mode: ● CPU 315-2 DP ● CPU 315-2 PN/DP ● CPU 317 DP ● CPU 317-2 PN/DP ● CPU 319-3 PN/DP CPUs with two DP interfaces (CPU 317-2 DP and CPU 319-3 PN/DP) only support isochronous mode on their second (DP) interface.

Reference For further information on isochronous mode, refer to the "Isochronous mode" Manual.

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Clock synchronization Further information about time synchronization on PROFIBUS DP is available in the chapter Interfaces > PROFIBUS DP.

Sync/Freeze The SYNC control command is used to set sync mode on the DP slaves of selected groups. In other words, the DP master transfers current output data and instructs the relevant DP slaves to freeze their outputs. The DP slaves writes the output data of the next output frames to an internal buffer; the state of the outputs remains unchanged. Following each SYNC control command, the DP slaves of the selected groups transfer the output data stored in the internal buffer to the process outputs. The outputs are only updated cyclically again after you transfer the UNSYNC control command using SFC11 "DPSYC_FR". The FREEZE control command is used to set the relevant DP slaves to Freeze mode, in other words, the DP master instructs the DP slaves to freeze the current state of the inputs. It then transfers the frozen data to the input area of the CPU. Following each FREEZE control command, the DP slaves freeze the state of their inputs again. The DP master receives the current state of the inputs cyclically again not until you have sent the UNFREEZE control command with SFC11 "DPSYC_FR". The SFCs 11 are described in the corresponding STEP 7 Online Help and in the System Software S7-300/400, System and Standard Functions Reference Manual.

Startup of the DP master system CPU 31xC-2 DP / 31x-2 DP / 31x PN/DP is DP master The Parameter transfer to modules parameter is also used to define the startup monitoring time for DP slaves. That is, the DP slaves must startup and must have received all parameters from the CPU (as DP master) within the defined time.

PROFIBUS address of the DP master For the DP CPU, you must not set "126" as a PROFIBUS address.

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8.5.3

Commissioning the CPU as DP Slave

Requirements for commissioning ● The DP master is configured and programmed. ● If the MPI/DP interface of your CPU must be a DP interface, you must configure the interface as DP interface. ● Prior to commissioning, you must set the relevant parameters and configure the DP CPU for operation as DP slave. That is, in STEP 7 you have to – "power on" the CPU as DP slave, – assign a PROFIBUS address to the CPU, – assign a slave diagnostic address to the CPU, – specify whether the DP master is an S7 DP master or another DP master, – specify the address ranges for data exchange with the DP master. ● All other DP slaves are programmed and configured.

GSD files If you are working on an IM 308-C or third-party system, you require a GSD file in order to be able to configure the DP CPU as a DP slave in a DP master system. COM PROFIBUS V 4.0 or later includes this GSD file. When working with an older version or another configuration tool, you can download the GSD file from the Internet (http://support.automation.siemens.com/WW/view/en/10805317/133100). Note This note applies to the CPUs 31xC-2 DP, CPU 315, CPU 317 and CPU 319. If you wish to use the CPU as a standard slave using the GSD file, you must not set the Commissioning / Test mode check box on the DP interface properties dialog box when you configure this slave CPU in STEP 7.

Configuration and parameter assignment message frame STEP 7 assists you during configuration and parameter assignment of the DP CPU. If you need a description of the configuration and parameter assignment frame, for example in order to use a bus monitor, you can find it on the Internet (http://support.automation.siemens.com/WW/view/en/1452338).

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Commissioning Commission the DP CPU as a DP slave in the PROFIBUS subnet as follows: 1. Switch on power, but hold the CPU in STOP mode. 2. First, switch on all other DP masters/slaves. 3. Now switch the CPU to RUN mode.

Startup of DP CPU as DP slave When the DP-CPU is switched to RUN mode, two mutually independent operating mode transitions are executed: ● The CPU switches from STOP to RUN mode. ● The CPU starts data exchange with the DP master via the PROFIBUS DP interface.

Recognizing the Operating State of the DP master (Event Recognition) The table below shows how the DP CPU operating as a DP slave recognizes operating state transitions or data exchange interruptions. Table 8- 9

Event recognition by CPUs 31xC-2 DP / 31x-2 DP / 31x PN/DP operating as DP slave

Event

What happens in the DP slave?

Bus interruption (short circuit, connector removed)

•

Call of OB 86 with the message Station failure

•

(coming event; diagnostic address assigned to the DP slave) With I/O access: Call of OB 122

DP master.

•

Call of OB 82 with the message Module error

(I/O access error) RUN → STOP DP master STOP → RUN

(coming event; diagnostic address assigned the DP slave; variable OB82_MDL_STOP=1) •

Call of OB 82 with the message Module OK (outgoing event; diagnostic address assigned to the DP slave; variable OB82_MDL_STOP=0)

Tip: When commissioning the CPU as DP slave, always program OB82 and OB86. This helps you to recognize and evaluate the respective operating states or data exchange errors.

Status/control, programming via PROFIBUS As an alternative to the MPI interface, you can program the CPU or execute the PG's status and control functions via the PROFIBUS DP interface. Note The execution of status and control function via PROFIBUS DP interface extends the DP cycle.

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User data transfer by way of transfer memory The DP CPU operating as intelligent DP slave provides a transfer memory for PROFIBUS DP. User data are always exchanged between the CPU (DP slave) and the DP master by way of this transfer memory. You can configure up to 32 address ranges for this function. That is, the DP master writes its data to these transfer memory address ranges, the CPU reads these data in the user program, and vice versa. '3PDVWHU

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,2



352),%86

Numb er

Description

①

The functions which control data exchange between transfer memory and the distributed I/O of the slave CPU must be implemented in the user program. The DP master cannot access this I/O directly.

address ranges of transfer memory In STEP 7, configure the I/O address ranges: ● You can configure up to 32 I/O address ranges. ● Maximum length per address range is 32 bytes. ● You can configure a maximum of 244 input bytes and 244 outputs bytes. The table below shows the principle of address ranges. You can also find this figure in the STEP 7 configuration. Table 8- 10

Configuration example for the address ranges of transfer memory

Type

Master address

Type

Slave address

1

I

222

O

310

2

O

0

I

13

Length

Unit

Consistency

2

BYTE

Unit

10

Word

Total length

: 32 address ranges in the DP master CPU

CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

address ranges in the DP slave CPU

These paramaters of the address ranges must be the same for DP master and DP slave.

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Sample program

Below you will see a small sample program for data exchange between the DP master and the DP slave. The addresses used in the example are found in the table above.

In the DP slave CPU L

2

In the DP master CPU

//Data preparation in the //DP slave

T

MB

6

L

IB

0

T

MB

7

L

MW

6

T

PQW

310

//Forward data to //DP master

L

PIB

T

MB

50

L

PIB

223

L

B#16#3

+

I

T

MB

L

10

+

3

222

//continued processing of //received data in DP master

51 //Data preparation in the //DP master

T

MB

60

CALL

SFC

15

//Send data to the DP slave

LADDR:= W#16#0 RECORD:=P#M60.0 Byte20

//In the user program of the masters //a block of 20 bytes length starting at MB60 //is written consistently to the output area //PAB0 to PAB19 //(transfer area from master to //slave)

RET_VAL :=MW 22 CALL

SFC

14

LADDR:=W#16#D

//Receive data from //DP master //In the slave, the //peripheral bytes PEB13 //to PEB32 (data //transferred from master) //are read consistently and //stored in MB30 //to MB49

RET_VAL :=MW 20 RECORD:=P#M30.0 byte 20 L

MB

30

L

MB

7

+

I

T

MW

166

//Received data //continue processing

100

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Working with transfer memory Note the following rules when working with the transfer memory: ● Assignment of address ranges: – Input data of DP slaves are always output data of the DP master – Output data of DP slaves are always input data of the DP master ● The user can define these addresses. In the user program, access data with load/transfer instructions or with SFC 14 and SFC 15. You can also define addresses of the process image of inputs or outputs. ● The lowest address of specific address ranges is their respective area start address. ● The length, unit and consistency of the address ranges for DP master and DP slave must be identical. ● The master and slave addresses may differ in logically identical transfer memory (independent logical I/O address spaces in the master and slave CPU). Note Assign addresses from the I/O address range of the DP CPU to the transfer memory. You cannot use any addresses which have been assigned to transfer memory for other I/O modules.

S5 DP master If you use an IM 308-C as a DP master and the DP CPU as a DP slave, the following applies to the exchange of consistent data. Use IM 308-C in the S5 control to program FB192 for enabling exchange of consistent data between the DP master and slave. With the FB192, the data of the DP CPU are only output or read out in a consistent block.

S5-95 as DP master If you set up an AG S5-95 for operation as DP master, you also have to set its bus parameters for the DP CPU as DP slave.

User data transfer in STOP mode User data is treated in transfer memory according to the STOP state of the DP master or DP slave. ● The DP slave CPU goes into STOP: Data in transfer memory of the CPU are overwritten with "0" value, that is, the DP master reads "0" in direct data exchange mode. ● The DP master goes into STOP: Current data in transfer memory of the CPU are retained and can be read by the CPU.

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PROFIBUS address For the DP CPU, you must not set "126" as a PROFIBUS address.

See also User-specific addressing of modules (Page 127)

8.5.4

Direct data exchange

Requirements STEP 7 V 5.x or higher lets you configure "Direct data exchange" for PROFIBUS nodes. DP CPUs can take part in direct data exchange as senders and receivers.

Definition "Direct data exchange" is a special communication relationship between PROFIBUS DP nodes. Characteristic of direct data exchange are the PROFIBUS DP nodes "Listening" on the bus for data a DP slave returns to its DP master. This mechanism allows "Listening stations" (receivers) direct access to modified input data of remote DP slaves.

address ranges In your STEP 7 configuration of the relevant peripheral input addresses, specify which address range of the receiving node is to receive data requested from the sending node. The following types of DP-CPU are possible: ● DP slave sending station ● Receiving station, as DP slave or DP master, or as CPU not integrated in a master system.

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Example: Direct data exchange via DP CPUs The example in the figure below shows the relationships you can configure for direct data exchange. In the figure all the DP masters and all the DP slaves that are marked as "CPU" are each a DP CPU. Note that other DP slaves (ET 200M, ET 200pro, ET 200S) can only operate as sending nodes.

'3PDVWHU V\VWHP

'3PDVWHU V\VWHP

&38 '3PDVWHU

&38

&38 '3PDVWHU

352),%86

'3VODYH &38 '3VODYH

Figure 8-1

&38 '3VODYH

&38 '3VODYH

'3VODYH

Direct data exchange via DP CPUs

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8.6

Commissioning PROFINET IO

8.6.1

Requirements

Requirements PROFINET IO is supported in STEP 7 V 5.3 SP1 or higher. A later version of STEP 7 may be required to support specific CPU functionality. Information about the STEP 7 versions required for specific CPUs is available in the CPU 31xC and CPU 31x, Technical Data Manual.

PROFINET IO address ranges of the CPUs Table 8- 11

PROFINET IO address ranges of the CPUs

address range

315-2 PN/DP

317-2 PN/DP

319-3 PN/DP

Entire address range of inputs and of outputs

2048 bytes

8192 bytes

8192 bytes

of these in the process image, for inputs and outputs respectively:

max. 2048 bytes

max. 2048 bytes Max. 8192 bytes

128 bytes

256 bytes

•

Default

256 bytes

Diagnostics addresses use 1 byte each in the input address space for ● the IO controller, PROFINET interface and ports ● each IO device (header module on slot 0, ports of the PROFINET interface) and all internal modules / submodules of the device which do not contain any user data (power module of ET 200S, or ports of the PROFINET interface, for example). You can use these addresses, for example, to read module-specific diagnostics data records by calling SFB52. STEP 7 assigns diagnostics addresses in descending order, starting at the highest byte address. Information about the structure of module-specific diagnostics data records is available in the

From PROFIBUS DP to PROFINET IO Programming Manual.

8.6.2

Configuring and commissioning the PROFINET IO system

Overview There are several ways for you to start with commissioning the PROFINET IO interface of the CPU, and then the PROFINET IO system: ● Online via MPI/ DP interface ● Online via switch and PROFINET interface ● Offline, by saving the data to a Micro Memory Card in SIMATIC Manager on your programming device, and then inserting the Micro Memory Card into the CPU

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Commissioning a PROFINET IO system via MPI/DP

36

&38 03,

31

(76 ,2GHYLFH

2 1

,QGXVWULDO(WKHUQHW

6ZLWFK

3*3&

Number

Meaning

①

Use the PG cable to connect the PG to the integrated MPI/DP interface of the CPU.

②

Use the twisted-pair patch cable to interconnect the integrated PROFINET IO interface of the CPU with the Industrial Ethernet (for example, connection to a switch).

Commissioning a PROFINET IO system directly via PROFINET interface

36

&38 31

(76 ,2GHYLFH

2 1

,QGXVWULDO(WKHUQHW

6ZLWFK

3*3& Number

Meaning

①

Use a twisted-pair patch cable to connect the PG/PC to a switch

②

In the same way, connect the switch to the integrated PROFINET interface of your CPU

Commissioning requirements: ● The CPU is in STOP mode. ● The IO devices are switched on. ● The PROFINET subnet is installed, and the communication partners (for example, PD, IO controller, IO devices) are connected to the PROFINET subnet.

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Configuring the PROFINET IO system Step

Tasks

Configuring hardware in the STEP 7 SIMATIC Manager 1

Select File > New... Assign a name to your project and confirm with OK.

2 3

Select Insert > Station > SIMATIC 300 Station to add an S7-300 station. Double-click "Hardware." Result: HW Config opens.

4

Insert your components by means of drag-and-drop: • Mounting rail • Power supply • CPU 31x PN/DP (CPU 317-2 PN/DP, for example) Result: The "Properties – Ethernet Interface PN-IO" dialog box opens. The properties of the PROFINET X2 interface are shown in the Parameters tab.

Assigning the IP address 5

Click "New" on the "Properties – Ethernet Interface PN-IO" dialog box to create a new subnet. Result: The "Properties – New Industrial Ethernet Subnet" dialog box opens.

6

Assign a name and confirm with "OK." Result: You are back to the "Properties – Ethernet Interface PN-IO" dialog box.

7

Enter the IP address and the subnet mask in the dialog box. This information is available from your network administrator. Note: The worldwide unique MAC address is preset by the manufacturer and cannot be changed.

8

If you setup a connection via router, you must also enter the address of the router. This information is also available from your network administrator.

9

Click "OK" to close the properties dialog box.

Configuring the PROFINET IO system

172

10

Insert the IO devices at the PROFINET IO system, for example, an IM 151-3 PN (ET 200S under PROFINET IO), then configure the slots and set their parameters by means of drag-and-drop, based on the physical assembly.

11

Select Edit > Object properties to assign device names and numbers to the IO devices.

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Step

Tasks

12

When operating PROFINET IO and PROFINET CBA in parallel, set up the PROFINET IO system properties by • activating the "Use this module for PROFINET CBA communication" check box • adapting the "Communication portion (PROFINET IO)" in the "Update time" tab (change the communication portion of PROFINET IO to 87.5 %, for example).

13

Save your configuration with Station > Save and compile.

Configuration Download 14

Download the configuration to the CPU. You have three options: • Online via MPI/ DP interface (the PG and CPU must be located on the same subnet). When you download the configuration in a system containing several node addresses, select the appropriate MPI or PROFIBUS address of the destination CPU. • Online via switch and PROFINET interface When you download the configuration in a system containing several nodes, select the appropriate IP address of the destination CPU. The "available users" can be displayed in a download dialog box. Select the MAC address of the CPU if you have not assigned it an IP address yet. In the next dialog box, you can assign the configured IP address to the CPU.

•

The PG must be connected to the subnet. The PG interface must be set to TCP/IP (Auto) mode. Setting in the IE-PG Access tab of the interface properties dialog box: Assign Project-Specific IP Address. Offline, by saving the data to a Micro Memory Card in SIMATIC Manager on your programming device, and then inserting the Micro Memory Card into the CPU

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Tasks

Assigning IO device names * 15

Requirements: The programming device must be connected to the subnet. The PG interface must be set to TCP/IP (Auto) mode. Setting in the IE-PG Access tab of the interface properties dialog box: Assign Project-Specific IP Address. Procedure: In online mode, select the various IO devices in HW Config, then select PLC > Ethernet > Assign Device Name to assign the corresponding device names. Note: The CPU can only assign the IP address automatically, and thus enable its correct communication with the IO device, after you assigned a device name to the latter. If the configuration of the IO devices you downloaded to the CPU actually corresponds with their physical configuration on the subnet, the CPU addresses the IO devices, and the BF LED stops flashing both on the CPU and on the IO device. You can now switch the CPU to RUN, provided there are no other conditions preventing a startup, and the CPU and IO devices exchange data (read inputs, write outputs, for example). * If the functionality "Device replacement without removable medium" is configured in HW Config and the setpoint topology of the PROFINET IO system has been specified using the topology editor, IO devices can be replaced without the user having to assign a device name to the IO device. Requirement: The IO device has been reset to the state of delivery by using "Reset to factory setting" and the actual topology agrees with the setpoint topology.

Result You used STEP 7 to configure the PROFINET interface of your CPU and the and the PROFINET IO system. The CPU can now be reached by other nodes in your Industrial Ethernet subnet.

Reference Detailed information about addressing of the PROFINET IO interface and on the configuration of its properties and ports is available in the: ● STEP 7 Online Help and ● PROFINET System Description System Manual.

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CPU startup for operation as IO controller In its startup sequence, and based on the preset configuration, the CPU verifies the actual configuration ● of the local I/O, ● of the distributed I/O on the PROFIBUS DP system, and ● the PROFINET IO system. The startup of the CPU is determined by the corresponding configuration in the "Startup" tab: Table 8- 12

CPU startup for operation as IO controller

Preset = Actual configuration

Preset ≠ Actual configuration

CPU goes into RUN.

CPU goes into RUN. After POWER CPU startup fails ON, and after the parameter monitoring time has expired, the CPU goes into RUN.

Startup permitted when target configuration does not match the actual configuration

Startup not permitted when target configuration does not match the actual configuration

If the BF2/BF3 LED flashes, this means that at least one IO device cannot be addressed. In this case, verify that all IO devices are switched on and correspond with the set configuration. For further information, read the diagnostics buffer in STEP 7.

Detecting interruptions in the data transfer to the IO device The following table shows, how the CPU 31x PN/DP recognizes interruptions of the data transfer: Table 8- 13

Even recognition of the CPU 31x PN/DP as IO controller

Event

What happens in the IO controller? CPU in RUN

Bus interruption (short circuit, connector removed)

•

•

Call of OB86 with the message Station failure

CPU in STOP •

The event is written to the diagnostics buffer

(coming event; diagnostics address of the IO device) With I/O access: call of OB 122 (I/O access error)

Tip: Always program OB86 when you commission the CPU. This allows you to detect and analyze interruptions in the data transfer.

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Status/control, programming via PROFINET As an alternative to the MPI /DP interface, you can program the CPU or execute the PG's status and control functions via the PROFINET interface.. If you have not commissioned the PROFINET interface of the CPU yet, you can connect to the CPU using its MAC address (see also Configuring the PROFINET IO System in the table above). To do so, use HW Config to download your project to the CPU. Address the CPU using its MAC address. The CPU is also assigned the configured IP address after you downloaded the configuration. With that you can then use all programming device functions, such as download program, status/control etc., on the interface.

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Maintenance 9.1

9

Overview S7-300 is a maintenance-free automation system. Thus, maintenance is considered ● Backing up of the operating system on a SIMATIC Micro Memory Card ● Updating of the operating system from a SIMATIC Micro Memory Card ● Updating of the firmware online ● Backing up of project data on a SIMATIC Micro Memory Card ● Replacement of modules ● Replacement of fuses in digital output modules

9.2

Backing up firmware on a SIMATIC Micro Memory Card

Situations which require backup of the firmware It is advisable in certain situation to backup your CPU firmware: You may want to replace the CPU in your system with a CPU out of storage. In this case you should make sure that the firmware of the shelf CPU and of the system firmware are identical. It is also advisable to create an emergency backup copy of the firmware.

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Maintenance 9.3 Updating the firmware

9.3

Updating the firmware

9.3.1

Backing up firmware on a SIMATIC Micro Memory Card

On which CPUs can you backup the firmware? You can generate a backup copy of the the firmware as of the following CPU versions: CPU

Order No.

312

314

315-2 DP 312C 313C 313C-2 DP 313C-2 PtP 314C-2 DP 314C-2 PtP 315-2 PN/DP

Required Micro Memory Card ≥ in MB

as of 6ES7312-1AD10-0AB0

V2.0.0

2

as of 6ES7312-1AE13-0AB0

V2.0.12

as of 6ES7312-1AE14-0AB0

V3.0

as of 6ES7314-1AF10-0AB0

V2.0.0

6ES7314-1AG13-0AB0 or later

V2.0.12

as of 6ES7314-1AG14-0AB0

V3.0

as of 6ES7315-2AG10-0AB0

V2.0.0

as of 6ES7315-2AH14-0AB0

V3.0

as of 6ES7312-5BD00-0AB0

V1.0.0

as of 6ES7312-5BE03-0AB0

V2.0.12

as of 6ES7313-5BE00-0AB0

V1.0.0

as of 6ES7313-5BF03-0AB0

V2.0.12

as of 6ES7313-6CE00-0AB0

V1.0.0

as of 6ES7313-6CF03-0AB0

V2.0.12

as of 6ES7313-6BE00-0AB0

V1.0.0

as of 6ES7313-6BF03-0AB0

V2.0.12

as of 6ES7314-6CF00-0AB0

V1.0.0

as of 6ES7314-6CG03-0AB0

V2.0.12

as of 6ES7314-6BF00-0AB0

V1.0.0

as of 6ES7314-6BG03-0AB0

V2.0.12

2

4 2 2 4 2 4 2

as of 6ES7315-2EG10-0AB0

V2.3.0

as of 6ES7315-2EH13-0AB0

V2.3.4

317-2 DP

as of 6ES7317-2AJ10-0AB0

V2.1.0

4

317-2 PN/DP

as of 6ES7317-2EJ10-0AB0

V2.2.0

4

as of 6ES7317-2EK13-0AB0

V2.3.4

as of 6ES7318-3EL00-0AB0

V2.4.0

319-3 PN/DP

178

Firmware as of

4

8

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ITEM 3000

Maintenance 9.3 Updating the firmware

Backing up the firmware of your CPU to the SIMATIC Micro Memory Card Table 9- 1

Backing up the firmware to the SIMATIC Micro Memory Card

Step

Action required:

This happens in the CPU:

1.

Insert the new SIMATIC Micro Memory Card into the CPU.

The CPU requests memory reset

2.

Turn the mode selector switch to MRES position and hold it there.

-

3.

POWER OFF / POWER ON. Hold the mode selector switch in MRES position until ...

... the STOP, RUN and FRCE LEDs start flashing.

4.

Mode selector switch to STOP.

-

5.

Mode selector switch briefly to MRES position, then let it return to STOP.

• • •

6.

9.3.2

Remove the SIMATIC Micro Memory Card.

The CPU starts to backup the operating system on the SIMATIC MMC. All LEDs are lit during the backup operation. The STOP LED flashes when the backup is complete to indicate that the CPU requires a memory reset.

-

Firmware update using a Micro Memory Card

In which situations should I update the firmware? After (compatible) function expansions, or after an enhancement of operating system performance, the firmware of the CPU should be upgraded (updated) to the latest version. Note Prioritized startup At a prioritized startup a firmware update using the Micro Memory Card is not possible. A firmware update using the LAN network is possible.

Where do I get the latest version of the firmware? You can order the latest firmware (as *.UPD files) from your Siemens partner, or download it from the Siemens Internet homepage: http://www.siemens.com/automation/service&support

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Firmware update using a SIMATIC Micro Memory Card Table 9- 2

Firmware update using a SIMATIC Micro Memory Card

Step

Action required:

1.

Recommendation

This happens in the CPU:

Before you update the CPU firmware, create a backup copy of the "old" firmware on an empty SIMATIC Micro Memory Card. If problems occur during the update, you can reload your old firmware from the SIMATIC Micro Memory Card. 2.

Transfer the update files to a blank SIMATIC Micro Memory Card using STEP 7 and your programming device.

-

3.

Switch off CPU power and insert a SIMATIC Micro Memory Card containing the firmware update.

-

4.

Switch on power.

•

• •

5.

Switch off CPU power and remove a SIMATIC Micro Memory Card containing the firmware update.

The CPU automatically detects the SIMATIC Micro Memory Card with the firmware update and runs the update. All LEDs are lit during firmware update. The STOP LED flashes when the FW update is completed, and indicates that the CPU requires a memory reset.

-

Result You updated the CPU with a new firmware version. The address and baud rate of the 1st interface are retentive. All the other parameters have been reset by the firmware update.

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Maintenance 9.3 Updating the firmware

9.3.3

Updating the firmware online (via networks)

On which CPUs can you update the firmware online? You can carry out a firmware update online at all the CPUs V 2.2 and higher. Information about the firmware update online using MPI or DP networks for older modules is available on the Service&Support pages (http://www.siemens.com/automation/service).

Requirements ● An online firmware update is possible in STEP 7 V 5.3 or higher. ● To update the firmware, you require the *.UPD files which contain the current firmware version. ● The files (*.UPD) containing the current firmware version must be available in the file system on your PG/PC. A folder may contain only the files of one firmware version. ● The CPU can be accessed online.

Performing a firmware update 1. Run STEP 7 and change to HW Config. 2. Open the station containing the CPU you want to update. 3. Select the CPU. 4. Select the menu command PLC > Update Firmware. The menu command can only be executed if the selected CPU supports the "Update Firmware" function. 5. The Update firmware dialog box opens. Click Browse to select the path to the firmware update files (*.UPD) 6. After you selected a file, the information in the lower fields of the Update Firmware dialog box shows you the firmware file and version for the corresponding modules. 7. Click the Run button. STEP 7 verifies that the selected file can be interpreted by the module, and then downloads the file to the CPU. If this requires changing the operating state of the CPU, you will be asked to perform these tasks in the relevant dialog boxes. The CPU then automatically updates the firmware. 8. In STEP 7 (reading the CPU diagnostics buffer), verify that the CPU can start with the new firmware.

Result You have updated the CPU online with a new firmware version. The address and baud rate of the 1st interface are retentive. All the other parameters have been reset by the firmware update.

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Maintenance 9.4 Backup of project data to a Micro Memory Card

9.4

Backup of project data to a Micro Memory Card

Function principles Using the Save project to Micro Memory Card and Retrieve project from Micro Memory Card functions, you can save all project data to a SIMATIC Micro Memory Card, and retrieve these at a later time. The SIMATIC Micro Memory Card can be located in a CPU or in the Micro Memory Card programming adapter of a PG or PC. Project data is compressed before it is saved to a SIMATIC Micro Memory Card, and uncompressed on retrieval. Note In addition to project data, you may also have to save your user data to the SIMATIC MMC. Always select a SIMATIC Micro Memory Card with sufficient memory capacity. A message warns you of insufficient memory capacity on your SIMATIC Micro Memory Card. The volume of project data to be saved corresponds with the size of the project's archive file. Note For technical reasons, you can only transfer the entire contents (user program and project data) using the Save project to Micro Memory Card action.

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Maintenance 9.4 Backup of project data to a Micro Memory Card

Handling the functions How you use the Save project to memory card / Retrieve project from memory card functions depends on the location of the SIMATIC micro memory card: ● When the SIMATIC MMC is inserted in the MMC slot, select a project level (for example, CPU, programs, sources or blocks) which is uniquely assigned to the CPU from the project window in SIMATIC Manager. Select the PLC > Save project to Memory Card or PLC > Retrieve project from Memory Card menu command. The program now writes all configuration data to the SIMATIC Micro Memory Card, or retrieves these data from the card. ● If project data are not available on the currently used programming device (PG/PC) you can select the source CPU from the "Available nodes" window. Select PLC > Show available nodes command to open the "Available nodes" window. Select the connection/CPU that contains your project data on SIMATIC Micro Memory Card. Now select menu command Retrieve project from Memory Card. ● If the SIMATIC MMC is located in the MMC programming unit of a PG or PC, open the "S7 memory card window" using the File > S7 Memory Card > Open command. Select the PLC > Save project to Memory Card or PLC > Retrieve project from Memory Card menu command. to open a dialog in which you can select the source or target project. Note Project data can generate high data traffic. Especially in RUN mode with read/write access to the CPU, this can lead to waiting periods of several minutes.

Sample application When you assign more than one member of your service and maintenance department to perform maintenance tasks on a SIMATIC PLC, it may prove difficult to provide quick access to current configuration data to each staff member. However, CPU configuration data available locally on any CPU that is to be serviced can be accessed by any member of the service department. They can edit these data and then release the updated version to all other personnel.

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Maintenance 9.5 Resetting to the Delivery State

9.5

Resetting to the Delivery State

Delivery state of the CPU Default values set at the CPU properties: Table 9- 3

Properties of the CPU in the delivery state

Properties

Value

MPI address

2

MPI baud rate

187.5 Kbps

Retentive bit memories, timers and counters All retentive bit memories, timers and counters are deleted Retentive range set for bit memories, timers and counters

Default settings (16 memory bytes, no timers and 8 counters)

Contents of the diagnostics buffer

deleted

IP address

none

Operating hours counter

0

Time

1.1.94 00:00:00

Procedure Proceed as follows in order to reset a CPU to the delivery state via the mode selector switch: 1. Switch off the supply voltage. 2. Remove the SIMATIC Micro Memory Card from the CPU. 3. Hold the mode selector switch in the MRES setting and switch the supply voltage on again. 4. Wait until LED lamp image 1 from the subsequent overview is displayed. 5. Release the mode selector switch, set it back to MRES within 3 seconds and hold it in this position. 6. Wait until LED lamp image 2 from the next overview is displayed. This lamp image lights up for approximately five seconds, that is for the duration of RESET. During this period you can abort the resetting procedure by releasing the mode selector switch. 7. Wait until LED lamp image 3 from the subsequent overview is displayed and release the mode selector switch again. The CPU is now reset to the delivery state. It starts without buffering (all LEDs are lit) and changes to the STOP mode

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Maintenance 9.6 Module installation / removal

Lamp images while the CPU is being reset While you are resetting the CPU to the delivery state, the LEDs light up consecutively in the following lamp images: Table 9- 4

Lamp images

LED

Color

Lamp image 1

Lamp image 2

Lamp image 3

STOP

Yellow

⃝

⃞

⃞

RUN

Green

⃝

⃞

⃞

FRCE

Yellow

⃝

⃞

⃞

5 VDC

Green

∆

∆

∆

SF

Red

⃞

⃝

∆

BFx

Red

⃞

⃞

⃞

∆ = LED lit ⃞ = LED dark ⃝ = LED flashes at 0.5 Hz

9.6

Module installation / removal

Installation and wiring rules The table below shows you points to follow when wiring, installing or removing S7-300 modules. Rules governing

... Power supply

Blade width of the screwdriver

3.5 mm (cylindrical design)

Tightening torque • Fixing modules to the mounting rail • Connecting cables

from 0.8 N/m to 1.1 N/m

from 0.8 N/m to 1.1 N/m

from 0.5 N/m to 0.8 N/m

–

POWER OFF when replacing the ...

Yes

Yes

S7-300 operating mode when replacing ...

–

STOP

Load voltage OFF when replacing the ...

Yes

Yes

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... CPU

... SM/FM/CP

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Initial situation The module you want to replace is still mounted and wired. You want to install the same type of module. WARNING Disturbances can corrupt data if you insert or remove S7-300 modules while data are being transferred via the integrated interface of your CPU. You should never replace any modules of the S7-300 while data traffic is active at an integrated interface. If you are not certain whether or not data transfer is active on the interface, unplug the connector at the interface before you replace the module.

Removing the module (SM/FM/CP) To remove the module: Step

20-pin front connector

40-pin front connector

1.

Switch the CPU to STOP.

2.

Switch off the load voltage to the module.

3.

Remove the labeling strip from the module.

4.

Open the front door.

5.

Unlock the front connector and remove it. To do so, press down the unlocking mechanism with one hand and pull out the front connector at the grips using the other hand.

6.

Undo the module fixing screw(s).

7.

Swing the module out.

Remove the fixing screw from the middle of the front connector. Pull the front connector out, holding it at the grips.

 





186

Number

Identifier

①

Remove labeling strips.

②

Open module.

③

Press unlocking mechanism/loosen mounting screw, and pull out front connector.

④

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ITEM 3000 Maintenance 9.6 Module installation / removal

Removing the front connector coding from the module Before you start installing the new module, remove the upper part of the front connector coding pin from this module. Reason: This part is already inserted in the wired front connector.

Installing a new module To install the new module: 1. Hang in a new module of same type. 2. Swivel the module down into place. 3. Screw-tighten the module. 4. Slide the labeling strips into the module.  





Number Identifier ①

Hang module onto rail.

②

Swivel module downward.

③

Screw-tighten the module

④

Insert labeling strips.

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Removing the front connector coding from the front connector You may take a "used" front connector to wire another module by removing its coding mechanism: Simply use a screwdriver to push out the front connector coding. This upper part of the coding key must then be plugged back into the old module.

Putting a new module into service Proceed as follows to put the new module into service: 1. Open the front door. 2. Reinstall the front connector. 3. Close the front panel. 4. Switch the load voltage back on. 5. Reset the CPU to RUN mode.





Number

Identifier

①

Move the front connector into operating position

②

Close front panel.

Reaction of the S7-300 after module replacement After a module replacement, the CPU switches to run mode, provided no error has occurred. If the CPU stays in STOP you can view the cause of error in STEP 7 (see the Programming with STEP 7 User manual).

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ITEM 3000

Maintenance 9.7 Digital output module AC 120/230 V: Changing fuses

9.7

Digital output module AC 120/230 V: Changing fuses

Fuses for digital outputs The digital outputs of the following digital output modules are short-circuit protected by fusing of the channel groups: ● Digit output module SM 322; DO 16 × 120 VAC ● Digit output module SM 322; DO 8 × 120/230 VAC

System check Eliminate the causes of fuse tripping.

Replacement fuses If replacement is required, you can use the following fuses: ● 8 A, 250 V fuse – Wickmann 19 194-8 A – Schurter SP001.013 – Littlefuse 217.008 ● Fuse holder – Wickmann 19 653 WARNING Improper handling of digital output modules could result in injury or damage to property. There are dangerous voltages > 25 VAC or > 60 VDC beneath the covers to the right of the module. Before you open these covers, make sure that you have either unplugged the front connector from the module or isolated the module from power. WARNING Improper handling of front connectors could result in injury or damage to property. When you remove the front connector while the system is in RUN, beware of dangerous live voltage > 25 VAC or > 60 VDC across the pins. If the front connector is wired to such voltages, hot swapping of modules must always be carried out by skilled or instructed electrical staff, in order to avoid unintentional contact to the module pins.

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Maintenance 9.7 Digital output module AC 120/230 V: Changing fuses

Location of fuses in the digital module 120/230 VAC Digital output modules are equipped with 1 fuse per channel group. The fuses are located at the left side of the digital output module. The following figure shows you where to find the fuses on the digital output modules.

 

Replacing fuses The fuses are located at the left side of the module. Replace the fuses as follows: 1. Switch the CPU to STOP. 2. Switch off the load voltage of the digital output module. 3. Remove the front connector from the digital output module. 4. Loosen the fixing screw of the digital output module. 5. Swing out the digital output module. 6. Remove the fuse holder from the digital output module ①. 7. Replace the fuse. 8. Screw the fuse holder back into the digital output module. 9. Reinstall the digital output module.

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.1

10

Overview This chapter helps you to get acquainted with tools you can use to carry out the following tasks: ● Hardware/software error diagnostics. ● Elimination of hardware/software errors. ● Testing the hardware/software – for example, during commissioning. Note It would go beyond the scope of this manual to provide detailed descriptions of all the tools you can use for diagnostics, testing and troubleshooting functions. Further notes are found in the relevant hardware/software manuals.

10.2

Reading out service data

Application (for CPUs ≥ V2.8) In the case of a service, for example if the CPU signals the state "DEFECTIVE" (all LEDs blinking), you have the option of saving special information for analyzing the CPU state. This information is stored in the diagnostic buffer and in the actual service data. Select the “Target system -> Save service data” command to read and this information and save the data to a file to forward to Customer Support.

Procedure 1. If the CPU is in the state "DEFECTIVE" (all LEDs blinking), switch the power supply off and on (power off/on). Result: The CPU is now in STOP mode. 2. As soon as the CPU goes to "STOP" mode, select the corresponding CPU with the menu command in the SIMATIC Manager: Target system > Available nodes". 3. Use the SIMATIC Manager menu command "Target system > Save service data" to save the service data. Result: A dialog box opens in which you specify the storage location and name of the two files. 4. Save the file. 5. Forward these files to Customer Support on request.

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Debugging functions, diagnostics and troubleshooting 10.3 Identification and maintenance data of the CPU

10.3

Identification and maintenance data of the CPU

Definition and properties Identification and maintenance data (I&M) is information that is stored in a module for the purpose of providing you with support when ● checking the system configuration ● locating modified plant hardware ● troubleshooting a plant Identification data (I data) is information about the module (some of which may be printed on the module housing) such as the order and serial number. I data is manufacturer´s information about the module. It is fixed and can only be read. Maintenance data (M data) represent system-specific information such as the installation location. M data is created during configuration and written to the module. I&M data can be used to identify modules uniquely on the network.

Reading and writing I&M data with STEP 7 Read ● STEP 7 returns I&M data in "Module status" ("General" and Identification" tab) and in "Available nodes" (detail view). See the STEP 7 Online Help. ● You can read I&M data by calling SFC51 in the user program. Declare the SSL parts list number and index at the input parameters of SFC51 (see the table below). ● CPUs which support reading of I&M data on the "Start page" and "Identification" page using the web server: CPU

Firmware

CPU 315-2 PN/DP

as of V 2.5

CPU 317-2 PN/DP

as of V 2.5

CPU 319-3 PN/DP

as of V 2.5

Write You always required STEP 7 HW Config to write M-data of the modules. Data you can enter in the course of configuration , for example: ● Name of the AS (station name) The station name is assigned in SIMATIC Manager when you create the station. The program generates a default station, for example, "SIMATIC 300(1)". You can always change this name. ● Data you can enter in STEP 7 HW Config, "CPU properties", "General" tab: – Name of the module HW Config assigns a default name – Plant ID of the module No default setting – Location identifier (LID) of a module No default setting

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.3 Identification and maintenance data of the CPU

Reading the I&M data in the user program In order to read I&M data of the CPU in the user program, define the SSL ID and index and read the corresponding SSL by calling SFC51. The table below shows the SSL IDs and associated indexes.

SSL partial lists with I&M data The I&M data are available in the SSL partial lists at the defined indexes. Table 10- 1 SSL-ID W#16#…

SSL partial lists with I&M data Index W#16#…

Meaning Module identification

0111

an identification data record 0001

Identification of the module The module order number and release version are stored here.

0006

Identification of the basic software Returns information about the SW version of the module. (These identification data are identical to index 0001, as a basic software is not available for S7-300 CPUs.)

0007

Identification of the basic firmware Indicates the firmware version of the module. Component identification

011C

Component identification 0001

Name of the AS Returns the name of the AS (station name).

0002

Name of the module Returns the name of the module.

0003

Plant ID of the module Returns a unique identifier for the module.

000B

Location identifier (LID) of a module Returns the installation location of the module.

Reference For detailed information about the structure an content of the SSLs, refer to the System Software for S7-300/400, System and Standard Functions Manual and to the STEP 7 Online Help.

I&M data of connected I/O Information about the I&M data of I/O connected to the CPU is available in the manuals of the corresponding I/O modules.

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Debugging functions, diagnostics and troubleshooting 10.4 Overview: Debugging functions

10.4

Overview: Debugging functions

Determining addressed nodes with "Node flashing test" (for CPUs >= V2.2.0) To identify the addressed node, select PLC > Diagnostics/Setting > Node/Flashing Test in STEP 7. A dialog appears in which you can set the flashing time and start the flashing test. The directly connected node can be identified by a flashing FORCE LED. The flashing test cannot be performed if the FORCING function is active.

Debugging functions of the software: Monitoring and controlling tags, stepping mode STEP 7 offers you the following testing functions you can also use for diagnostics: ● Monitoring and controlling tags Can be used for PG/PC monitoring of specific CPU or user program tags. You can also assign constant values to the tags. ● Testing with program status You can test your program by viewing the program status of each function (result of logical links, status bit) or the data of specific registers in real-time mode. For example, if you have selected the programming language LAD in STEP 7 for your presentation, the color of the symbol will indicate a closed switch or an active circuit. Note The STEP 7 testing function with program status extends the CPU cycle time! For CPUs < V2.8 you have the option of setting a maximum cycle increase in STEP 7. To do this, set process mode and the desired maximum cycle increase for the CPU parameters in STEP 7, HW Config. The option of adjusting the maximum cycle increase is not required for CPUs ≥ V2.8, as the effect on the cycle time during set process mode is generally very low with these CPUs. ● Stepping mode When testing in single-step mode, you can process your program instructions in sequence (= single-step) and set breakpoints. This is only possible in testing mode and not in process mode. For the CPUs 312, 314, 315-2 DP, ≥V3.0; CPU 319-3 PN/DP, ≥V2.8, however, the parameters of testing and process mode are not assigned in HW Config, but instead the changeover is made directly in the LAD/FBD/STL editor under "Test/Mode". Tip Number of blocks and breakpoints that can be monitored with status block • CPU 312, 314, 315-2 DP, ≥V3.0; CPU 319-3 PN/DP, ≥V2.8 With these CPUs, you can monitor two blocks at the same time and set up to four breakpoints in stepping mode. • All other CPUs of the range of validity With these CPUs, you can monitor one block set up to two breakpoints in stepping mode.

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.4 Overview: Debugging functions

Debugging functions of the software: Forcing tags The Force function can be used to assign the tags of a user program or CPU (also: inputs and outputs) constant values which can not be overwritten by the user program. For example, you can use it to jumper sensors or switch outputs permanently, irrespective of the user program. DANGER This could result in severe injury or even death, and damage to property. Incorrect use of the Force function could result in death or severe injury, and damage to machinery or even the entire plant. Always follow the safety instructions in the STEP 7 manuals. DANGER Forcing with S7-300 CPUs The force values in the process image of the inputs can be overwritten by write commands (such as T IB x, = I x.y, Copy with SFC, etc.) and by read I/O commands (such as L PIW x) in the user program, or by write PG/OP functions! Outputs initialized with forced values only return the forced value if not accessed by the user program via peripheral write instructions (TPQB x, for example) or by PG/OP write functions! Always ensure that forced values in the I/O process image cannot be overwritten by the user program or PG/OP functions!

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Figure 10-1

Principle of forcing in S7-300 CPUs

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Differences between forcing and controlling tags Table 10- 2

Differences between forcing and controlling tags

Characteristics/function

Forcing

Controlling tags

Memory bit (M)

-

Yes

Timers and counters (T, C)

-

Yes

Data blocks (DB)

-

Yes

Inputs and outputs (I, O)

Yes

Yes

Peripheral inputs (PI)

-

-

Peripheral outputs (PO)

-

Yes

User program can overwrite modify/force values

Yes

Maximum number of force values Power off retentive

10 Yes

Yes No

Reference Details on debugging functions of the software are available in the STEP 7 Online Help and in the Programming with STEP 7 Manual. For additional information on the cycle times, please refer to the "Cycle time" chapter.

10.5

Overview: Diagnostics

Introduction System errors can occur especially in the commissioning phase. Tracking these errors might be a time-consuming effort, since they can occur both on the hardware and software side. Here, the multitude of testing functions ensures commissioning without problems. Note Errors during operation are almost always a result of faults or damage to the hardware.

Type of error Errors the S7 CPUs can recognize and to which you can react with the help of organization blocks (OBs) can be split into the following categories: ● Synchronous error: Errors you can relate to a specific point in the user program (error when accessing a peripheral module, for example). ● Asynchronous error: Errors you can not relate to a specific point in the user program (cycle time exceeded, module error, for example).

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.5 Overview: Diagnostics

Troubleshooting Programming with foresight and, above all, knowledge and proper handling of diagnostic tools puts you into an advantageous position in error situations: ● You can reduce the effects of errors. ● It makes it easier for you to locate errors (by programming error OBs, for example). ● You can limit downtimes.

Diagnostics with LED display SIMATIC S7 hardware offers diagnostics with LEDs. These LEDs are implemented in three colors: LED color

State of CPU

Green

Regular operation. Example: Power is on.

Yellow

Non-regular operating status. Example: Forcing is active.

Red

Fault. Example: Bus error

LED flashing

Special event Example: CPU memory reset

Two LEDs are used for Ethernet: LED designation

Color

State

Meaning

LINK

Green

Off

No other device is connected with the integrated PROFINET interface of the CPU.

On

Another device (in most cases a switch) is connected to the integrated PROFINET interface of the CPU, and the physical connection is in place.

Off

No activity:

RX/TX

Yellow

No data are transferred via the integrated PROFINET interface of the CPU. On

Activity: Data are transferred via the integrated PROFINET interface of the CPU. Note: The LED flickers when small data volumes are transferred.

Reference Notes on diagnostics of I/O modules capable of diagnostics are found in the relevant Manual.

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Debugging functions, diagnostics and troubleshooting 10.5 Overview: Diagnostics

Diagnostic buffer If an error occurs, the CPU writes the cause of error to the diagnostic buffer. In STEP 7 you use the programming device to read the diagnostic buffer. This location holds error information in plain text. Other modules capable of diagnostics can be equipped with their own diagnostic buffer. In STEP 7 (HW Config -> Diagnosing hardware) you can use the programming device to read this buffer. Diagnosable modules without diagnostic buffer write their error information to the CPU's diagnostic buffer. When an error or an interrupt event occurs, (e.g. time-of-day interrupt), the CPU switches to STOP mode, or you can react in the user program via error/interrupt OBs. For a diagnostics interrupt you would call OB82.

Diagnostics of field devices on PROFINET Further information: ● PROFINET System Description System Manual. ● From PROFIBUS DP to PROFINET IO Programming Manual The topics in the next chapters are focused on the diagnostics of local or distributed modules on PROFIBUS.

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.5 Overview: Diagnostics

Diagnostics with system functions If the following CPUs are used, we recommend that you use the more user-friendly SFB 54 RALRM (called in diagnostic OB82) to evaluate the diagnostics from centralized or distributed modules or DP slaves: CPU

As of firmware version

31xC,

V 2.0.0

312, 314, 315-2 DP 315-2 PN/DP

V 2.3.0

317-2 DP

V 2.1.0

317-2 PN/DP

V 2.2.0

319-3 PN/DP

V 2.4.0

Further options for diagnostics with system functions are listed below: ● Using SFC 51 "RDSYSST" to read an SSL partial list or an extract thereof. ● Reading the diagnostic data (slave diagnostics) of a DP slave, using SFC 13 "DPNRM_DG" Every DP slave provides slave diagnostic data according to EN 50 170 Volume 2, PROFIBUS. You can use SFC 13 "DPNRM_DG" to read these diagnostic data. Error information is stored in hex code. Refer to the relevant module manual for information on the meaning of the read code. For example, the entry of the value 50H (= dual 0101 0000) in byte 7 of the slave diagnostics for the distributed I/O module ET 200B indicates a faulty fuse or missing load voltage in channel group 2 and 3. ● Reading data records by calling SFC52 "RDREC" You can call SFC52 "RDREC" (read record) to read a specific data record from the addressed module. Data records 0 and 1 are especially suitable for reading diagnostic information from a diagnosable module. Data record 0 contains 4 bytes of diagnostic data describing the current state of a signal module. Data record 1 contains the 4 bytes of diagnostic data also stored in data record 0, plus module-specific diagnostic data. ● Reading out the start information of the current OB, using the SFC 6 "RD_SINFO" Error information is also found in the start information of the relevant error OB. You can use SFC 6 "RD_SINFO" (read start information) to read the start information of the OB that was last called and not yet processed completely, and of the start-up OB that was last called. ● Triggering detection of the bus topology in a DP master system with the SFC103 "DP_TOPOL" The diagnostics repeater improves the ability to locate faulty modules or an interruption on the DP cable when failures occur in ongoing operation. It operates in slave mode and is capable of logging faults based on the determination of the DP segment topology. You can use SFC103 "DP_TOPOL" to trigger the identification of the bus topology of a DP master system by the diagnostic repeater. The SFCs 103 are described in the corresponding STEP 7 Online Help and in the System Software S7-300/400, System and Standard Functions Reference Manual. The diagnostic repeater is described in the manual Diagnostic Repeater for PROFIBUS DP.

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10.6

Diagnostics functions available in STEP 7

Diagnostics using the "Diagnosing Hardware" function Locate the cause of a module error by viewing the online information on the module. You can locate the cause of an error in the user program cycle with the help of the diagnostic buffer and of the stack content. You can also check whether a user program will run on a specific CPU. Hardware diagnostics give you an overview of the PLC status. In an overview representation, a symbol can display the error status of every module. A double-click on the faulty module opens detailed error information. The scope of this information depends on the specific module. You can view the following information: ● Display of general information on the module (e.g. order No., version, designation) and module status (e.g. error). ● Indication of module errors (channel error, for example) at local I/O and PROFIBUS DP slaves or PROFINET IO devices. ● Display of messages from the diagnostic buffer. ● Maintenance information: Maintenance demanded and maintenance required ● In addition, diagnostics data about the PROFINET interface are presented. For CPUs you can also view the following module status information: ● Cause of an error in the user program cycle. ● Indication of the cycle time (longest, shortest and last cycle). ● Options and utilization of MPI communication. ● Indication of performance data (number of possible I/O, memory bits, counters, timers and blocks). ● Diagnostics (network connection, communications diagnostics and statistics, for example) of the PROFINET interface and of its ports For details on diagnostic functions in STEP 7 and on procedures, refer to the Programming

with STEP 7 Manual and to the HW Config Online Help.

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10.7

Network infrastructure diagnostics (SNMP)

Availability As an open standard, you can use any SNMP-based systems or software solutions for diagnostics in PROFINET.

Network diagnostics SNMP (Simple Network Management Protocol) makes use of the connectionless UDP transport protocol. It consists of two network components, similar to the client/server model. The SNMP manager monitors the network nodes and the SNMP agents collect the various network-specific information in the individual network nodes and stores it in a structured form in the MIB (Management Information Base). This information allows a network management system to run detailed network diagnostics.

MIB An MIB (Management Information Base) is a data base of a device. SNMP clients access this data base in the device. The S7 device family supports, among others, the following standard MIBs: ● MIB II, standardized in the RFC 1213 ● LLDP MIB, standardized in the international standard IEE 802.1AB ● LLDP PNIO-MIB, standardized in the international standard IEE 61158-6-10

Detecting the network topology LLDP (Link Layer Discovery Protocol) is a protocol that is used to detect the closest neighbors. It enables a device to send information about itself and to save information received from neighboring devices in the LLDP MIB. This information can be looked up via the SNMP. This information allows a network management system to determine the network topology.

Integrating HMI devices via the SNMP OPC server Configuration of the OPC server is integrated in the STEP 7 hardware configuration application. The communication with the OPC server is carried out without an S7 connection. You therefore do not need to configure S7 connections. Stations that have already been configured in the STEP 7 project can be transferred directly. As an alternative to STEP 7, the configuration can also be run with the NCM PC (included on the SIMATIC NET CD) or can be determined automatically and transferred to the project configuration.

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Use of SNMP in the SIMATIC NET environment SNMP-compliant devices from the SIMATIC NET family can be monitored and operated via a conventional standard Internet browser. The management system known as web-based management offers a range of devicespecific information (network statistics, status of redundant supply, for example).

Diagnostics with the SIMATIC NET SNMP OPC server The SNMP OPC server software enables the diagnostics and configuration of any SNMP devices, even via, e.g. HMI devices that cannot read SNMP variables from other devices. The OPC server uses the SNMP protocol to exchange data with these devices. All information can be integrated into OPC-compatible systems, into WinCC HMI system for example. This enables process and network diagnostics to be combined in the HMI system.

Uses of SNMP SNMP can be used as follows: ● By users to integrate network diagnostics into a central HMI / SCADA system using the SNMP OPC server. ● By the IT administration of machines and plant owners to monitor their Industrial Ethernet network using standard network management systems. ● By the IT administration, to primarily monitor the office network, but often also the automation network using standard network management systems (for example, HP Open view).

Additional information Information relating to SNMP in the network management standardization group can be found at Internet (http://www.snmp.org/). Additional information on SNMP can be found on the Internet (http://www.profibus.com/rpa/germany/). Additional information on SNMP OPC servers can be found on the Internet (http://www.automation.siemens.com/net/html_76/produkte/040_snmp.htm).

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10.8

Diagnostics using status and error LEDs

10.8.1

Introduction Diagnostics with LEDs is an initial tool for error localization. Usually, you evaluate the diagnostic buffer for further error localization. The buffer contains plain text information on the error that has occurred. For example, you will find the number of the appropriate error OB here. You can prevent the CPU from going into STOP mode by generating this OB and downloading it to the CPU.

10.8.2

Status and error displays of all CPUs

Table 10- 3

Status and error displays

LED SF Off

5 VDC Off

FRCE Off

Off

On

On

On

X (see Off the descripti on) X Off

X

On

X

Off

X

On

X

Off

X

On

X

X

On

X

On

On

X

Flashes (2 Hz) Flashes (0.5 Hz) X

X

X

On

X

X

X

X

X

X

Flash es

Flashes

Flashes (2 Hz) Flashes

Flashes

Flashes

RUN Off

STOP Off

On

On Flashes (0.5 Hz) Flashes (2 Hz) On On X

Meaning CPU power supply missing. Remedy: Check whether the power supply module is connected to mains and switched on. The CPU is in STOP mode. Remedy: Start the CPU. The CPU is in STOP mode as a result of error. Remedy: refer to the tables below, evaluation of the SF LED The CPU requests memory reset. The CPU executes memory reset. The CPU is in startup mode. The CPU was halted by a programmed break point. For details refer to the Programming with STEP 7 Manual. Hardware or software error Remedy: refer to the tables below, evaluation of the SF LED You enabled the Force function For details refer to the Programming with STEP 7 Manual. Node flashing test was activated. Your CPU has an internal system error. The procedure is as follows: 1. Set the mode selector switch to STOP. 2. Perform POWER ON/OFF. 3. Read the diagnostics buffer with STEP 7. 4. Contact your local SIEMENS partner.

Explanation of the State X: This status is irrelevant for the current CPU function.

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Reference ● Details on the OBs and on SFCs required for their evaluation can be found in the STEP 7 Online Help and in the Manual System Software for S7-300/400 - System and Standard Functions.

10.8.3

Evaluating the SF LED in case of software errors Table 10- 4

204

Evaluation of the SF LED (Software error)

Possible problem

Response of the CPU

Remedies

TOD interrupt is enabled and triggered. However, a matching block is not loaded. (Software/configuration error)

Call of OB85. CPU goes into STOP if OB85 is not loaded.

Load OB10 (OB number is apparent from the diagnostic buffer).

Start time of the enabled TOD interrupt was jumped, e.g. by advancing the internal clock.

Call of OB80. goes into STOP if OB80 is not loaded

Disable the TOD interrupt before you set the time-of-day with SFC 29.

Delay interrupt triggered by SFC 32. However, a matching block is not loaded. (Software/configuration error)

Call of OB85. CPU goes into STOP if OB85 is not loaded.

Load OB 20 or 21 (CPU 317 only) (the OB number can be viewed in the diagnostic buffer).

Process interrupt is enabled and Call of OB85. triggered. However, a matching CPU goes into STOP if block is not loaded. OB85 is not loaded. (Software/configuration error)

Load OB40 (OB number is apparent from the diagnostic buffer).

Status alarm is generated, but the appropriate OB55 is not loaded.

Call of OB85. CPU goes into STOP if OB85 is not loaded.

Load OB55

Update alarm is generated, but the appropriate OB 56 is not loaded.

Call of OB85. CPU goes to STOP if OB 85 is not loaded.

Load OB56

Vendor-specific alarm is generated, but the appropriate OB57 is not loaded.

Call of OB85. CPU goes into STOP if OB85 is not loaded.

Load OB57

Access to missing or defective module upon updating the process image (software or hardware error)

Call OB 85 (depending on the configuration in HW Config). CPU goes into STOP if OB 85 is not loaded.

Load OB85, the start information of the OB contains the address of the relevant module. Replace the relevant module or eliminate the program error.

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.8 Diagnostics using status and error LEDs Possible problem

Response of the CPU

Remedies

The cycle time was exceeded. Probably too many interrupt OBs called simultaneously.

Call of OB80. CPU goes into STOP if OB80 is not loaded. The CPU switches to STOP despite loaded OB80 if the doubled cycle time was exceeded without retriggering cycle time 80.

Extension of the cycle time (STEP 7 – Hardware configuration), changing the program structure. Remedy: If necessary, retrigger cycle time monitoring by calling SFC 43

Programming error Calls OB121. CPU does not STOP if OB121 is • Block not loaded loaded. • Wrong block number • Wrong timer/counter number • Read/write access to wrong area • etc.

Eliminate the programming error. The STEP 7 testing function helps you to locate the error.

I/O access errors

Calls OB122. CPU does not STOP if OB122 is loaded.

Check module addressing in HW Config or whether a module/DP slave has failed.

Call of OB87. CPU goes into STOP if OB87 is not loaded.

Check global data communication in STEP 7. If required, correct the DB size.

An error has occurred when module data was accessed Global data communication error, e.g. insufficient length of the DB for global data communication.

Tip: ● You can use SFC 39 to disable all interrupts and asynchronous error events. Note The shorter the selected cyclic interrupt period, the more likely it is that cyclic interrupt errors will occur. You must take into account the operating system times of the CPU in question, the user program runtime and extension of the cycle time by active PG functions, for example.

Reference Details on the OBs and on the SFCs required for their evaluation are available in the STEP 7 Online Help and in the System Software for S7-300/400 - System and Standard Functions

Reference Manual.

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10.8.4

Evaluating the SF LED in case of hardware errors Table 10- 5

Evaluation of the SF LED (Hardware error)

Possible problem

CPU reaction

Possible remedies

A module was removed or CPU goes into STOP. inserted while the system was in RUN.

Screw-tighten the modules and restart the CPU.

A distributed module was removed or inserted on PROFIBUS DP while the system was in RUN.

Call of OB86. CPU goes into STOP if OB86 is not loaded.

Load OB86 or OB82.

A distributed module was removed or inserted on PROFINET IO while the system was in RUN.

Call of OB83. CPU goes into STOP if OB83 is not loaded.

When the module is integrated by means of GSD file: Call of OB 82. CPU goes into STOP when OB 82 is not loaded. Load OB 83 and OB 86.

OB 86 is also called when one or several modules of an ET 200S (IO device) are removed or inserted while the system is in RUN. CPU switches to STOP if OB 86 is not loaded.

A diagnosable module reports Call of OB82. a diagnostic interrupt. CPU goes into STOP if OB82 is not loaded.

Reaction to the diagnostic event, based on the module configuration.

Attempt to access a missing or faulty module. Loose connector (software or hardware error).

Call of OB85, if access was attempted during update of the process image (OB 85 call must be enabled accordingly in the parameters). Call of OB 122 with direct I/O access. CPU switches to STOP if the OB is not loaded.

Load OB 85, the start information of the OB contains the address of the relevant module. Replace the relevant module, tighten the plug or eliminate the program error.

Faulty SIMATIC MMC.

The CPU goes into STOP mode and requests memory reset.

Replace the SIMATIC MMC, reset CPU memory, transfer the program again, then set the CPU to RUN mode.

Reference Details on the OBs and on the SFCs required for their evaluation are available in the STEP 7 Online Help and in the System Software for S7-300/400 - System and Standard Functions

Reference Manual.

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10.8.5

Status and Error Indicators: CPUs with DP Interface

Description of the BF, BF1 and BF2 LEDs Table 10- 6

LEDs BF, BF1 and BF2

LED SF On

5 VDC BF BF1 On On/ flashes -

On

On

-

On/ flashes X

On

On

-

X

BF2 -

On/ flashes

Meaning PROFIBUS DP interface error. Remedy: See the table below Fault at the second PROFIBUS DP interface of CPU 317 or CPU 319-3 PN/DP. Remedy: See the table below Error on the second PROFIBUS DP interface of the CPU 317-2 DP or CPU 319-3 PN/DP. Remedy: See the tables below

Explanation of the State X: The LED can assume the On or Off state. This status, however, is irrelevant for the current CPU function. For example, the Force On or Off states do not influence the CPU STOP status Table 10- 7

BF LED is lit

Possible problem • Bus fault (hardware fault). • DP interface error. • Different transmission rates in multiple DP master mode. • If the DP slave / master interface is active: short-circuit on the bus. • With passive DP slave interface: transmission rate search, i.e. there are no other active nodes on the bus (a master, for example)

CPU reaction Call of OB 86, if CPU is in RUN mode and if the communication between the DP master and DP slave functioned properly before the error occurred. CPU switches to STOP if OB 86 is not loaded.

Possible remedies • Check the bus cable for short-circuit or breaks. • Analyze the diagnostic data. Edit the configuration.

Possible problem The CPU is DP master: • Failure of a connected station • At least one of the configured slaves cannot be accessed. • Bad engineering configuration

CPU reaction Call of OB 86, if CPU is in RUN mode and operated DP slaves before the error occurred. CPU switches to STOP if OB 86 is not loaded.

The CPU is active DP slave Possible causes: • The response monitoring time has elapsed. • PROFIBUS DP communication is down. • Wrong PROFIBUS address. • Bad engineering configuration

Call of OB 86, if CPU is in RUN mode and communicated as a DP slave with the DP master before the error occurred. CPU switches to STOP if OB 86 is not loaded.

Possible remedies Verify that the bus cable is connected to the CPU, or that the bus is not interrupted. Wait until the CPU has completed its startup. If the LED does not stop flashing, check the DP slaves or evaluate the diagnostic data for the DP slaves. • Check the CPU. • Verify that the bus connector is properly seated. • Check for breaks in the bus cable to the DP master. • Check the configuration data and parameters.

Table 10- 8

BF LED flashes

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Reference Details on the OBs and on the SFCs required for their evaluation are available ● in the STEP 7 Online Help ● in the System Software for S7-300/400, System and Standard Functions Reference Manual

10.8.6

Status and error indicators: CPUs with PROFINET interface for the S7-300

Status and Error Indicators: PROFINET devices Note The RX and TX LEDs can also be grouped in one LED, as with the CPU 319-3 PN/DP. The RX/TX LED on this device is located, for example, under the front cover.

LED LINK

RX

LED status

Description of the status

Not lit

Flashes

Lit

–

–

X

There is no connection between the PROFINET interface of your PROFINET device and a communication partner in the Ethernet (a switch, for example).

–

X

–

Only with an IO device: The user activated flashing from STEP 7.

X

–

–

The Ethernet connection between the PROFINET interface of the PROFINET device and the communication partner is down.

–

–

X

At the current time, data are being received from a communication partner on Ethernet via PROFINET interface of the PROFINET device.

(flickers)

TX

X

–

–

No data are currently received via the PROFINET interface.

–

–

X

Data are currently sent to a communication partner on Ethernet via the PROFINET interface of the PROFINET device.

(flickers) X

–

–

No data are currently transmitted via the PROFINET interface.

BF2 or – BF3

–

X

Error on the PROFINET interface, communication no longer possible (for example, with a CPU as IO controller, when the connection to the switch is down)

–

X

–

Error on the PROFINET interface (for example, due to station failure of one or more IO devices)

Remedy: See the table below

Remedy: See the table below X

208

–

–

No error at the PROFINET interface

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.8 Diagnostics using status and error LEDs

Remedy of faults at the PROFINET interface - BF2/ BF3 LED is lit Table 10- 9

BF2 / BF3 LED is lit

Possible problem • • •

Bus fault (no cable connection to a subnet/switch) Wrong transmission speed Full duplex mode not set

Reaction based on the example of a CPU Call of OB 86, if CPU is in RUN mode and operated PNIO slaves before the error occurred. CPU switches to STOP if OB 86 is not loaded.

Possible remedies • • • •

Check the bus cable for a short-circuit or break. Check that the module is connected to a switch and not to a hub. Check that data are being transmitted at 100 Mbps and in full duplex mode. Analyze the diagnostic data. Edit the configuration.

Remedy of faults at the PROFINET interface of an IO controller - BF2 / BF3 LED flashes Table 10- 10 BF2 / BF3 LED flashes at a PROFINET IO controller Possible problem • • •

Failure of a connected IO device At least one of the assigned IO devices cannot be addressed Bad engineering configuration

10.8.7

Reaction based on the example of a CPU Call of OB 86, if CPU is in RUN mode and operated PNIO slaves before the error occurred. CPU switches to STOP if OB 86 is not loaded.

Possible remedies • •

•

Check that the Ethernet cable is connected to the module or whether the bus is interrupted. Wait until the CPU has completed its startup. If the LED does not stop flashing, check the IO devices or evaluate its diagnostic information. Verify that the configured device name matches its actually assigned name.

Status and Error Indicators: PROFINET IO Devices

Remedy with faults at the PROFINET interface of an IO Device - BF LED flashes Table 10- 11 BF LED flashes on a PROFINET IO device Possible problem • The IP address is incorrect • Bad engineering configuration • Bad parameter assignment • IO controller not found / switched off, but there is an Ethernet connection. • Bad or no device name • The response monitoring time has elapsed.

Possible remedies • Check that the Ethernet cable is correctly connected. • Check whether the Ethernet cable to the controller is interrupted. • Check the configuration data and parameters. • On the IO device: Switch on the IO controller. • Check whether the expected configuration matches the actual configuration. • Check the physical communication connection for interruption

Tip: Identification of the PROFINET device in the cubicle When they are first commissioned, PROFINET IO devices must be assigned a device name. In STEP 7/HW Config, you can make the LINK LED of a PROFINET IO device you are naming flash usingPLC > Ethernet > Assign Device Name. This allows you, for example, to clearly identify a PROFINET IO device among several identical devices in a control cabinet. CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

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10.9

Diagnostics of DP CPUs

10.9.1

Diagnostics of DP CPUs operating as DP Master

Evaluate diagnostics in the user program The figure below illustrates the procedure for evaluating diagnostics data in the user program.

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.9 Diagnostics of DP CPUs

Diagnostic addresses for DP masters and DP slaves At a CPU 31x-2, you assign diagnostic addresses for PROFIBUS DP. Verify in your configuration that the DP diagnostic addresses are assigned once to the DP master and once to the DP slave. &38[DVWUDQVPLWWHU

&38[DVUHFHLYHU

352),%86

'LDJQRVWLFVDGGUHVV

Description of the DP master configuration

Description of the DP slave configuration

When you configure the DP master, assign two different diagnostic addresses for an intelligent slave, that is, one diagnostic address for slot 0, and one for slot 2. Functions of those two addresses: • The diagnostic address for slot 0 reports in the master all events relating to the entire slave (station representative), for example, node failure. • The diagnostic address for slot 2 is used to report events concerning this slot. For example, if the CPU is acting as an intelligent slave, it returns the diagnostic interrupts for operating state transitions.

When you configure the DP slave, you also assign it a diagnostic address (in the associated DP slave project). Below, this diagnostic address is labeled assigned to DP slave. This diagnostic addresses is used by the DP slave to obtain information on the status of the DP master, or on bus interruptions.

Hereinafter, these diagnostic addresses are referred to as assigned to the DP master. These diagnostic addresses are used by the DP master to obtain information about the status of DP slave, or about bus interruptions.

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Event detection The table below shows how a CPU 31x-2 operating as DP master detects operating mode transitions of a CPU operating as DP slave, or data exchange interruptions. Table 10- 12 Event detection of CPU 31x2 operating as DP master Event

What happens in the DP master?

Bus interruption (shortcircuit, connector removed)

•

DP slave: RUN → STOP

•

Call of OB 86 with the message Station failure (incoming event; diagnostic address of Slot 0 of the DP slave that is assigned to the DP master) with I/O access: call of OB 122 (I/O access error)

•

Call of OB 82 with the message Module error (incoming event; diagnostic address of Slot 2 of the DP slave that is assigned to the DP master; Variable OB82_MDL_STOP=1)

DP slave: STOP → RUN

•

Call of OB 82 with the message Module OK (outgoing event; diagnostic address of Slot 2 of the DP slave that is assigned to the DP master; Variable OB82_MDL_STOP=0)

Evaluation in the user program The table below shows how you can, for example, evaluate RUN to STOP transitions of the DP slave in the DP master. Table 10- 13 Evaluating RUN to STOP transitions of the DP slave in the DP master In the DP master

In the DP slave (CPU 31x-2 DP)

Diagnostic addresses: (Example)

Diagnostic addresses: (Example)

Master diagnostic address =1023

Slave diagnostic address =422

Slave diagnostic address =1022

Master diagnostic address = irrelevant

(Slot 0 of slave) (Diagnostic) address for "Slot 2"=1021 (Slot 2 of slave) The CPU calls OB82 with the following information: • OB82_MDL_ADDR:=1021 • OB82_EV_CLASS:=B#16#39 (incoming event) • OB82_MDL_DEFECT: = Module error

CPU: RUN -> STOP The CPU generates a DP slave diagnostics message frame

Tip: The CPU diagnostic buffer also contains this information In the user program you should also include SFC 13 "DPNRM_DG" for reading out DP slave diagnostic data.

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10.9.2

Reading out slave diagnostic data The slave diagnostic data is compliant with EN 50170, Volume 2, PROFIBUS. Depending on the DP master, diagnostic data for all DP slaves conforming to standard can be read with STEP 7.

Diagnostic addresses for the receiving station with direct data exchange For direct data exchange, you assign a diagnostic address in the receiving station: &38[DVWUDQVPLWWHU

&38[DVUHFHLYHU

352),%86

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Figure 10-2

PROFIBUS DP diagnostics address

In this figure, you see that assign a diagnostic address to the receiving station in your configuration. The receiving station receives information about the status of the transmitting station or about a bus interruption by means of this diagnostic address.

Reading out the diagnostic data The table below shows you how the various DP master systems can read diagnostic information from a slave. Table 10- 14 Reading out diagnostic data in the master system, using STEP 5 and STEP 7 Automation system with DP master

Blocks or registers in STEP 7

Application

Further Information

SIMATIC S7/M7

"DP Slave Diagnostics" tab

Output of slave diagnostic data in plain text to a STEP 7 user interface

Found under the keyword Hardware diagnostics in the STEP 7 Online Help and in the

SFB 54 "RALRM"

Reading additional interrupt information from a DP slave or local module from the relevant OB.

System and Standard Functions Reference Manual

SFC13 "DP NRM_DG"

Reading out slave diagnostics (store in the data area of the user program)

System and Standard Functions Reference Manual

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Programming with STEP 7

Manual

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SIMATIC S5 with IM 308-C operating in DP master mode

Blocks or registers in STEP 7

Application

Further Information

SFC 51 "RDSYSST"

Reading SSL sublists. In System and Standard the diagnostic interrupt, Functions Reference Manual call SFC 51 with the SSL ID W#16#00B4, and then read out the SSL of the slave CPU.

SFB 52 “RDREC” andSFC 59 “RDREC”

Reading the data records System and Standard of S7 diagnostics (stored Functions Reference Manual in the data area of the user program)

FB 125/FC 125

Evaluating slave diagnostic data

FB 192 "IM308C"

Reading slave diagnostic Distributed I/O System ET 200 data (store in the data Manual area of the user program)

On the Internet under http://www.siemens.com/auto mation/csi_en_WW7Product under the entry ID. 387 257

Example for reading the slave diagnosis with FB 192 "IM308C" This shows you an example of how to use FB 192 in the STEP 5 user program to read out slave diagnostics data for a DP slave.

Assumptions regarding the STEP 5 user program For this STEP 5 user program it is assumed that: ● The IM 308-C operating in DP master mode uses the page frames 0 to 15 (number 0 of IM 308-C). ● The DP slave is assigned PROFIBUS address 3. ● Slave diagnostics data should be stored in DB 20. You may also use any other DB. ● Slave diagnostics data consist of 26 bytes.

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STEP 5 user program STL

Explanation :A

DB 30

:SPA

FB 192

Name

:IM308C

DPAD

:

KH F800

//Default address range of IM 308-C

IMST

:

KY 0, 3

//IM no. = 0, PROFIBUS address of the DP slave = 3

FCT

:

KC SD

//function: Read slave diagnostics

GCGR

:

KM 0

//not evaluated

TYP

:

KY 0, 20

//S5 data area: DB 20

STAD

:

KF +1

//Diagnostic data starting at data word 1

LENG

:

KF 26

//Length of diagnostic data = 26 bytes

ERR

:

DW 0

//Error code storage in DW 0 of DB 30

Example of reading out S7 diagnostic data with SFC 59 "RD REC" Here you will find an example of how to use SFC 59 in the STEP 7 user program to read S7 diagnostics data records for a DP slave. The process of reading the slave diagnostics is similar to SFC 13.

Assumptions regarding the STEP 7 user program Exceptions for this STEP 7 user program: ● Diagnostic data for the input module at address 200H is to be read. ● Data record 1 is to be read out. ● Data record 1 is to be stored in DB 10.

STEP 7 user program STL

Explanation

CALL SFC 59

REQ

:=TRUE

//Request to read

IOID

:=B#16#54

//Identifier of the address range, here the I/O input

LADDR

:=W#16#200

//Logical address of the module

RECNUM

:=B#16#1

//Data record 1 is to be read

RET_VAL :=MW2

//An error code is output if an error occurs

BUSY

:=MO.0

//Read operation not finished

RECORD

:=P# DB10.DBX 0.0 BYTE 240

//DB 10 is target area for the read data record 1

Note: Data is only returned to the target area if BUSY is reset to 0 and if no negative RET_VAL has occurred.

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Diagnostic addresses At a CPU 31x-2, you assign diagnostic addresses for PROFIBUS DP. Verify in your configuration that the DP diagnostic addresses are assigned once to the DP master and once to the DP slave. &38[DVWUDQVPLWWHU

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Description of the DP master configuration

Description of the DP slave configuration

When you configure the DP master, assign two different diagnostic addresses for an intelligent slave, that is, one diagnostic address for slot 0, and one for slot 2. Functions of those two addresses: • The diagnostics address for slot 0 reports in the master all events relating to the entire slave (station representative), for example, node failure. • The diagnostics address for slot 2 is used to report events concerning this slot. For example, if the CPU is acting as an intelligent slave, it returns the diagnostic interrupts for operating state transitions.

When you configure the DP slave, you also assign it a diagnostic address (in the associated DP slave project). Below, this diagnostic address is labeled assigned to DP slave. This diagnostic addresses is used by the DP slave to obtain information on the status of the DP master, or on bus interruptions.

From now on, these diagnostic addresses are referred to as assigned to the DP master. These diagnostic addresses are used by the DP master to obtain information about the status of DP slave, or about bus interruptions.

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Event recognition The table below shows how CPU 31x-2 operating as DP slave recognized operating state transitions or data exchange interruptions. Table 10- 15 Event recognition of CPUs 31x-2 operating in DP slave mode Event

What happens in the DP slave?

Bus interruption (short circuit, connector removed)

• •

Calls OB86 with the message Station failure (incoming event; diagnostic address of the DP slave, assigned to the DP slave) With I/O access: call of OB 122 (I/O access error)

DP master RUN → STOP

•

Calls OB82 with the message Module error (incoming event; diagnostic address of the DP slave assigned to the DP slave; tag OB82_MDL_STOP=1)

DP master STOP → RUN

•

Call of OB82 with the message Module OK. (outgoing event; diagnostic address of the DP slave, assigned to the DP slave; tag OB82_MDL_STOP=0)

Evaluation in the user program The table below shows an example of you how you can evaluate RUN-STOP transitions of the DP master in the DP slave (see also the previous table). Table 10- 16 Evaluating RUN-STOP transitions in the DP Master/DP Slave In the DP master

In the DP slave

Diagnostics addresses: (Example)

Diagnostics addresses: (Example)

Master diagnostic address =1023

Slave diagnostic address =422

Slave diagnostic address in the master system=1022

Master diagnostic address = irrelevant

(Slot 0 of slave) (Diagnostic) address for "Slot 2"=1021 (Slot 2 of slave) CPU: RUN → STOP

→ The CPU calls OB 82 with the following information, for example: • OB82_MDL_ADDR:=422 • OB82_EV_CLASS:=B#16#39 (incoming event) • OB82_MDL_DEFECT:=module malfunction Tip: The CPU diagnostic buffer also contains this information

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10.9.3

Interrupts on the DP Master

Interrupts with S7 DP master Process interrupts from an intelligent slave with SFC 7 In the CPU 31x-2 operating in DP slave mode, you can trigger a user-defined process interrupt from the DP master from the user program. A call of SFC 7 "DP_PRAL" triggers the execution of OB 40 in the user program on the DP master. The SFC 7 allows you to forward interrupt information to the DP master in a double word. This information can then be evaluated in the OB40_POINT_ADDR variable in the OB40. The interrupt information can be programmed user-specific. For a detailed description of SFC 7 "DP_PRAL", refer to the System Software for S7-300/400 - System and Standard Functions Reference Manual. Setting user-defined interrupts of Intelligent Slaves using SFB 75 In the CPU 31x-2 operating in DP slave mode, you can trigger user-defined interrupts from the user program in the DP master. SFB 75 "SALRM" is used to send a process or diagnostic interrupt from a slot in the transfer area (virtual slot) to the associated DP master from the user program on an intelligent slave. This starts the associated OB on the DP master. Additional interrupt-specific information may be included. You can read this additional information in the DP master using SFB 54 "RALRM."

Interrupts with another DP master When CPU 31x-2 operates with another DP master, an image of these interrupts is created in its device-specific diagnostic data. You have to post-process the relevant diagnostic events in the DP master's user program. Note In order to allow the evaluation of diagnostics and process interrupts by means of devicespecific diagnostics using a different DP master, please note that: The DP master should be able to save the diagnostics messages to its ring buffer. For example, if the DP master can not save the diagnostic messages, only the last incoming diagnostic message would be saved. In your user program, you have to poll the relevant bits in the device-specific diagnostic data in cyclic intervals. Make allowances for the PROFIBUS DP bus cycle time, for example, to be able to poll these bits at least once and in synchronism to the bus cycle time. With an IM 308-C operating in DP master mode, you cannot utilize process interrupts in device-specific diagnostics, because only incoming events are reported, rather than outgoing events.

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10.9.4

Structure of the slave diagnostic data when the CPU is operated as intelligent slave

Syntax of the diagnostics datagram for slave diagnostics

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Figure 10-4

Structure of slave diagnostic data

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Station Status 1 Table 10- 17 Structure of station status 1 (Byte 0) Bit

Meaning

Remedy

0

1: DP slave cannot be addressed by DP master.

• • • • •

Is the correct DP address set on the DP slave? Is the bus connector in place? Does the DP slave have power? Correct configuration of the RS485 Repeater? Perform a reset on the DP slave.

1

1: DP slave is not ready for data exchange.

•

Wait for the slave to complete start-up.

2

1: Configuration data sent by DP master to the DP slave is inconsistent with slave configuration.

•

Was the software set for the correct station type or DP slave configuration?

3

1: Diagnostic interrupt, generated by a STOP to RUN transition on the CPU or by the SFB 75

•

You can read the diagnostic data.

0: Diagnostic interrupt, generated by a STOP to RUN transition on the CPU or by the SFB 75 4

1: Function not supported; e.g. changing the DP address at software level

•

Check configuration data.

5

0: The bit is always "0".

•

-

6

1: DP slave type inconsistent with software configuration.

•

Was the software set for the right station type? (parameter assignment error)

7

1: DP slave was configured by a DP master other than the master currently accessing the slave.

•

The bit is always 1 if, for example, you are currently accessing the DP slave via PG or a different DP master.

The DP address of the parameter assignment master is in the "master PROFIBUS address" diagnostic byte.

Station Status 2 Table 10- 18 Structure of station status 2 (Byte 1) Bit

Meaning

0

1: The DP slave requires new parameters and configuration.

1

1: A diagnostic message was received. The DP slave cannot resume operation until the error has been cleared (static diagnostic message).

2

1: This bit is always "1" if a DP slave exists with this DP address.

3

1: The watchdog monitor is enabled on this DP slave.

4

1: DP slave has received control command "FREEZE".

5

1: DP slave has received control command "SYNC".

6

0:The bit is always set to "0".

7

1: DP slave is disabled, that is, it has been excluded from cyclic processing.

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Station Status 3 Table 10- 19 Structure of station status 3 (Byte 2) Bit

Meaning

0 to 6

0: These bits are always "0"

7

1:The incoming diagnostic messages exceed the memory capacity of the DP slave. The DP master cannot write all diagnostic messages sent by the DP slave to its diagnostic buffer.

Master PROFIBUS address The "Master PROFIBUS address" diagnostic byte stores the DP address of the DP master: ● that has configured the DP slave and ● has read and write access to the DP slave. Table 10- 20 Structure of the Master PROFIBUS address (byte 3) Bit

Meaning

0 to 7

DP address of the DP master that has configured the DP slave and has read/write access to that DP slave. FFH: DP slave was not configured by a DP master

Manufacturer ID The vendor ID contains a code specifying the type of the DP slave. Table 10- 21 Structure of the manufacturer ID (byte 4 and 5) Byte 4

Byte 5

Vendor ID for the CPU

80H

D0H

313C-2-DP

80H

D1H

314C-2-DP

81H

76H

315-2 DP

81H

17H

315-2 PN/DP

80H

F0H

317-2 DP

80H

F1H

317-2 PN/DP

81H

1DH

319-3 PN/DP

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Structure of identifier-related diagnostics of CPU 31x-2 / CPU 319-3 Module diagnostics indicate the configured address range of intermediate memory that has received an entry.

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Figure 10-5

222

Identifier-related diagnostic data

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ITEM 3000 Debugging functions, diagnostics and troubleshooting 10.9 Diagnostics of DP CPUs

Structure of the module status The module status reflects the status of the configured address ranges, and provides detailed ID-specific diagnostics with respect to the configuration. Module status starts with module diagnostics and consists of a maximum of 13 bytes.

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Figure 10-6

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Structure of the interrupt status: The interrupt status of module diagnostics provides details on a DP slave. Device-specific diagnostics starts at byte y and has a maximum length of 20 bytes. The following figure describes the structure and content of the bytes for a configured address range of transfer memory.

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Structure of the interrupt data for a process interrupt (from byte y+4) When a process interrupt occurs (code 02H for process interrupt in byte y+1), 4 bytes of interrupt information after byte y+4 are transferred. These 4 bytes are transferred to the intelligent slave using SFC 7 "DP_PRAL" or SFC 75 "SALRM" when the process interrupt for the master was generated.

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Structure of the interrupt data when a diagnostic interrupt is generated in response to an operating status change by the intelligent slave (after byte y+4) Byte y+1 contains the code for a diagnostic interrupt (01H). The diagnostic data contains the 16 bytes of status information from the CPU. The figure below shows the allocation of the first four bytes of diagnostic data. The next 12 bytes are always 0. The data in these bytes correspond to the contents of data record 0 of diagnostic data in STEP 7 (in this case, not all bits are used). %\WH\













 















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Figure 10-8

Bytes y+4 to y+7 for a diagnostic interrupt (operating status change by intelligent slave)

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Structure of the interrupt data when a diagnostic interrupt is generated by SFB 75 on the intelligent slave (after byte y+4)        

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Bytes y+4 to y+19 for the diagnostics interrupt (SFB75)

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10.10

Diagnostics of PROFINET CPUs

10.10.1

Diagnostics options of PROFINET IO

Diagnostics Concept

PROFINET IO supports you with an integrated diagnostics concept. The diagnostics concept of PROFINET IO is similar to that of PROFIBUS DP.

The diagnostics functions allow you ● to react to an error (event-related diagnostics, evaluation of interrupts) or ● to check the current status of the AS (status-related diagnostics).

Overview of diagnostics information You have three options of obtaining diagnostics information: 1. Diagnostics using status LEDs

Diagnostics option LEDs on a PROFINET interface

Benefits The LED displays indicate: • whether data are being sent or received • communication error.

For detailed information refer ... this manual, chapter: Status and Error Indicators: CPUs with PROFINET interface for the S7-300

2. Diagnostics using the STEP 7 and NCM PC configuration and engineering tool

Diagnostics option Online diagnostics using a PG/PC/HMI Reporting system errors Network diagnostics

Benefits This allows you to evaluate the current status of your automation system.

For detailed information refer ... the System Manual: PROFINET System Description, chapter: Support by STEP 7/NCM PC Diagnostic information is output in plain text the System Manual: PROFINET format to the PC / HMI. System Description, chapter: Support by STEP 7/NCM PC The SNMP protocol allows you to this manual, determine the network infrastructure chapter: Network infrastructure diagnostics (SNMP)

3. Diagnostics in the STEP 7 user program

Diagnostics option Reading system status lists (SSLs)

Reading diagnostics data records

Diagnostics interrupt

Benefits The SSLs will help you to track down an error.

For detailed information refer ... the System Manual: PROFINET System Description, chapter: Evaluation of Diagnostics in the User Program Reference manual: System software for S7-300/400 System and Standard Functions You can obtain detailed information about the System Manual: PROFINET the type and source of faults by reading the System Description, diagnostic data records. chapter: Evaluation of Diagnostics in the User Program Can be used to evaluate diagnostics data in the System Manual: PROFINET the user program. System Description, chapter: Evaluation of Diagnostics in the User Program

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Evaluation of diagnostics information PROFINET IO supports a vendor-independent structure of data records with diagnostics information. Diagnostics information is only generated for faulty channels. The SSLs, SFB54 and SFB52 were enhanced in order to include information about the status of the PROFINET IO systems and the diagnostics information for an S7 user program: ● Call SFC51 (read system status lists) to read module status information of the PROFINET IO system from SSL 0x0X91. ● Call SFB52 (read data record) to read status-related diagnostics data records directly from a faulty module. – Status-related diagnostics data represent error information, for example. ● Call SFB54 (read additional interrupt info) in the corresponding error OB to read eventrelated diagnostics data records from a module. – Event-related diagnostics data represent interrupt information of the error OBs, for example.

Further Information Further information about diagnostics and diagnostics data, on the structure of diagnostics data records and on SSLs for PROFINET is available in: ● the From PROFIBUS DP to PROFINET IO Programming Manual ● the PROFINET System Description System Manual ● the System Software for S7-300/400, System and Standard Functions Reference Manual ● in the STEP 7 Online Help

10.10.2

Maintenance

Enhanced maintenance concept PROFINET devices support the comprehensive diagnostics and maintenance concept according to the IEC 61158-6-10 standard. In addition to "ok" and "faulty" information, the PROFINET components can also display information for preventive maintenance when operating with STEP 7 V5.4 Servicepack 1 or higher. Preventive maintenance is displayed, for example, if the attenuation of a fiber optic cable deteriorates.

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Maintenance information Maintenance information returns maintenance priorities. The concept distinguishes between maintenance information based on two levels: Maintenance information

Symbol in STEP 7

Example

Maintenance requirement (maintenance required):

green wrench

The attenuation on a fiber-optic conductor is becoming too high. Although operation is still possible, the transmission link may fail completely in the near future.

yellow wrench

Failure of the synchronization master in a synchronization domain for the IRT operation of a PNIO system.

Maintenance recommended Maintenance request (maintenance demanded): Maintenance required

Further Information Further information is available in: ● the From PROFIBUS DP to PROFINET IO Programming Manual ● in the PROFINET System Description System Manual. ● in the CPU 31xC and CPU 31x, Manual, Technical Data, chapter Webserver ● in the STEP 7 Online Help

See also Diagnostics options of PROFINET IO (Page 227)

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General technical data 11.1

11

Standards and approvals

Introduction Contents of general technical data: ● standards and test values satisfied by modules of the S7-300 automation system ● test criteria of S7-300 modules.

CE Label The S7-300 automation system satisfies requirements and safety-related objectives according to EC Directives listed below, and conforms with the harmonized European standards (EN) for programmable controllers announced in the Official Journals of the European Community: ● 2006/95/EC "Electrical Equipment Designed for Use within Certain Voltage Limits" (LowVoltage Directive) ● 2004/108/EC "Electromagnetic Compatibility" (EMC Directive) ● 94/9/EC "Equipment and protective systems intended for use in potentially explosive atmospheres" (Explosion Protection Directive) The EC declaration of conformity is held on file available to competent authorities at: Siemens Aktiengesellschaft Bereich Automatisierungs- und Antriebstechnik Industry Sector AS RD ST PLC Postfach 1963 D-92209 Amberg

UL approval Underwriters Laboratories Inc. complying with ● UL 508 (Industrial Control Equipment)

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CSA approval Canadian Standards Association to ● C22.2 No. 142 (Process Control Equipment) or Underwriters Laboratories Inc. complying with ● UL 508 (Industrial Control Equipment) ● CSA C22.2 No. 142 (Process Control Equipment) or Underwriters Laboratories Inc. complying with ● UL 508 (Industrial Control Equipment)

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● CSA C22.2 No. 142 (Process Control Equipment) ● UL 1604 (Hazardous Location) ● CSA-213 (Hazardous Location) APPROVED for use in Class I, Division 2, Group A, B, C, D Tx; Class I, Zone 2, Group IIC Tx Note Currently valid approvals can be found on the rating plate of the relevant module.

FM approval Factory Mutual Research (FM) to Approval Standard Class Number 3611, 3600, 3810 APPROVED for use in Class I, Division 2, Group A, B, C, D Tx; Class I, Zone 2, Group IIC Tx

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ITEM 3000 General technical data 11.1 Standards and approvals

ATEX approval to EN 60079-15:2005 (Electrical apparatus for potentially explosive atmospheres; Type of protection "n")

,,*([Q$,,77

WARNING Personal injury and property damage can occur. In potentially explosive environments, there is a risk of injury or damage if you disconnect any connectors while the S7-300 is in operation. Always isolate the S7-300 operated in such areas before you disconnect and connectors. WARNING Explosion hazard If you replace components, compliance with Class I, DIV.2 could be compromised. WARNING This device is only appropriate for use in Class I, Div. 2, Group A, B, C, D, or in nonhazardous areas.

Tick-mark for Australia The S7-300 automation system satisfies requirements of standards to AS/NZS 2064 (Class A).

IEC 61131 The S7-300 automation system satisfies requirements and criteria to IEC 61131-2 (Programmable Controllers, Part 2: Equipment requirements and tests).

Marine approval Classification societies: ● ABS (American Bureau of Shipping) ● BV (Bureau Veritas) ● DNV (Det Norske Veritas) ● GL (Germanischer Lloyd) ● LRS (Lloyds Register of Shipping) ● Class NK (Nippon Kaiji Kyokai)

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ITEM 3000 General technical data 11.1 Standards and approvals

Use in industrial environments SIMATIC products are designed for industrial applications. Table 11- 1

Use in industrial environments

Field of application

Noise emission requirements

Noise immunity requirements

Industry

EN 61000-6-4: 2001

EN 61000-6-2: 2001

Use in residential areas To operate an S7-300 in a residential area, it's RF emission must comply with Limit Value Class B to EN 55011. The following measures are recommended to ensure the interference complies with limit value class B: ● S7-300 installation in grounded switch cabinets / cubicles ● Use of noise filters in the supply lines WARNING Personal injury and damage to property may occur. In potentially explosive environments, there is a risk of injury or damage if you disconnect any connectors while the S7-300 is in operation. Always isolate the S7-300 operated in such areas before you disconnect and connectors.

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ITEM 3000 General technical data 11.2 Electromagnetic compatibility

11.2

Electromagnetic compatibility

Definition Electromagnetic compatibility (EMC) is the ability of an electrical installation to function satisfactorily in its electromagnetic environment without interfering with that environment. The S7-300 modules also satisfy requirements of EMC legislation for the European domestic market. Compliance of the S7-300 system with specifications and directives on electric design is prerequisite.

Pulseshaped disturbance The table below shows the EMC compatibility of S7 modules in areas subject to pulseshaped disturbance. Pulse-shaped disturbance Electrostatic discharge to IEC 61000-4-2 Burst pulses (high-speed transient disturbance) to IEC 61000-4-4.

Test voltage

corresponds with degree of severity

Air discharge: ± 8 kV

3

Contact discharge ± 4 kV

2

2 kV (power supply lines) 2 kV (signal lines > 3 m) 1 kV (signal lines < 3 m)

3 3

High-energy single pulse (surge) to IEC 61000-4-5 External protective circuit required (refer to S7-300 Automation System, Hardware and Installation, Chapter "Lightning and overvoltage protection") •

asymmetric coupling

2 kV (power supply lines) DC with protective elements

3

2 kV (signal/ data line only > 3 m), with protective elements as required •

symmetric coupling

1 kV (power supply lines) DC with protective elements 1 kV (signal/ data line only > 3 m), with protective elements as required

Additional measures When connecting an S7-300 system to the public network, always ensure compliance with Limit Value Class B to EN 55022.

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General technical data 11.2 Electromagnetic compatibility

Sinusoidal disturbance The table below shows the EMC compatibility of S7-300 modules in areas subject to sinusoidal disturbance. Sinusoidal disturbance

Test values

corresponds with degree of severity

RF radiation (electromagnetic fields) to IEC 61000-4-3

10 V/m, with 80% amplitude modulation of 1 kHz in the 80 MHz to 1000 MHz range

RF conductance on cables and cable shielding to IEC 61000-4-6

Test voltage 10 V, with 80% amplitude modulation of 1 kHz in the 9 MHz to 80 MHz range

10 V/m, with 50% pulse modulation at 900 MHz

3

3

Emission of radio interference Electromagnetic interference to EN 55011: Limit Class A, Group 1 (measured at a distance of 10 m.) Frequency

Emitted interference

30 MHz to 230 MHz

< 40 dB (µV/m)Q

230 MHz to 1000 MHz

< 47 dB (µV/m)Q

Noise emission via AC mains to EN 55011: Limit value class A, Group 1.

236

Frequency

Emitted interference

0.15 MHz to 0.5 MHz

< 79 dB (µV/m)Q < 66 dB (µV/m)M

0.5 MHz to 5 MHz

< 73 dB (µV/m)Q < 60 dB (µV/m)M

5 MHz to 30 MHz

< 73 dB (µV/m)Q < 60 dB (µV/m)M

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ITEM 3000 General technical data 11.3 Transportation and storage conditions for modules

11.3

Transportation and storage conditions for modules

Introduction The shipping and storage conditions of S7-300 modules surpass requirements to IEC 611312. The data below apply to modules shipped or put on shelf in their original packing. The modules are compliant with climatic conditions to IEC 60721-3-3, Class 3K7 (storage), and with IEC 60721-3-2, Class 2K4 (shipping.) Mechanical conditions are compliant with IEC 60721-3-2, Class 2M2.

Shipping and storage conditions for modules Type of condition

Permissible range

Free fall (in shipping package)

≤1m

Temperature

- 40 °C to + 70 °C

Barometric pressure

1080 hPa to 660 hPa (corresponds with an altitude of -1000 m to 3500 m)

Relative humidity

10% to 95%, no condensation

Sinusoidal oscillation to IEC 60068-2-6

5 Hz to 9 Hz: 3.5 mm 9 Hz to 150 Hz: 9.8 m/s2

Shock to IEC 60068-2-29

250 m/s2, 6 ms, 1000 shocks

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ITEM 3000 General technical data 11.4 Mechanical and climatic environmental conditions for S7-300 operation

11.4

Mechanical and climatic environmental conditions for S7-300 operation

Operating conditions S7-300 systems are designed for stationary use in weather-proof locations. The operating conditions surpass requirements to DIN IEC 60721-3-3. ● Class 3M3 (mechanical requirements) ● Class 3K3 (climatic requirements)

Use with additional measures The S7-300 may not be used under the conditions outlined below without taking additional measures: ● at locations with a high degree of ionizing radiation ● in aggressive environments caused, for example, by – the development of dust – corrosive vapors or gases – strong electric or magnetic fields ● in installations requiring special monitoring, for example – elevators – electrical plants in potentially hazardous areas An additional measure could be an installation of the S7-300 in a cabinet or housing.

Mechanical environmental conditions The table below shows the mechanical environmental conditions in the form of sinusoidal oscillations. Frequency band

Continuous

Infrequently

10 Hz ≤ f ≤ 58 Hz

0.0375 mm amplitude

0.75 mm amplitude

58 Hz ≤ f ≤ 150 Hz

0.5 g constant acceleration

1 g constant acceleration

Reducing vibrations If your S7-300 modules are exposed to severe shock or vibration, take appropriate measures to reduce acceleration or the amplitude. We recommend the installation of the S7-300 on damping materials (for example, rubberbonded-to-metal mounting.)

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ITEM 3000 General technical data 11.4 Mechanical and climatic environmental conditions for S7-300 operation

Test of mechanical environmental conditions The table below provides important information with respect to the type and scope of the test of ambient mechanical conditions. Condition tested

Test Standard

Comment

Vibration

Vibration test to IEC 60068-2-6 (sinusoidal)

Type of oscillation: Frequency sweeps with a rate of change of 1 octave/minute. 10 Hz ≤ f ≤ 58 Hz, constant amplitude 0.075 mm 58 Hz ≤ f ≤ 150 Hz, constant acceleration 1 g Duration of oscillation: 10 frequency sweeps per axis at each of three vertically aligned axes

Shock

Shock, tested to IEC 60068-2-27

Type of shock: half-sine Severity of shock: 15 g peak value, 11 ms duration Direction of shock: 3 shocks in each direction (+/-) at each of three vertically aligned axes

Continuous shock

Shock, tested to IEC 60068-2-29

Type of shock: Half-sine Shock intensity: 25 g peak value, 6 ms duration Shock direction: 1000 shocks in each direction (+/-) at each of three vertically aligned axes

Climatic environmental conditions The S7-300 may be operated on following environmental conditions: Environmental conditions

Permissible range

Temperature: horizontal mounting position: vertical mounting position:

0°C to 60°C 0°C to 40°C

Relative humidity

10 % to 95 %

No condensation, corresponds to relative humidity (RH) Class 2 to IEC 61131, Part 2

Barometric pressure

1080 hPa to 795 hPa

Corresponds with an altitude of -1000 m to 2000 m

Concentration of pollutants

SO2: < 0.5 ppm; RH < 60 %, no condensation H2S: < 0.1 ppm; RH < 60 %, no condensation

Test: 10 ppm; 4 days

ISA-S71.04 severity level G1; G2; G3

-

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Comments -

Test: 1 ppm; 4 days

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ITEM 3000

General technical data 11.5 Specification of dielectric tests, protection class, degree of protection, and rated voltage of S7-300

11.5

Specification of dielectric tests, protection class, degree of protection, and rated voltage of S7-300

Test voltage Proof of dielectric strength must be provided in the type test at a test voltage to IEC 61131-2: Circuits with rated voltage Ve to other circuits or ground.

Test voltage

< 50 V

500 VDC

< 150 V

2500 VDC

< 250 V

4000 VDC

Protection class Protection class I to IEC 60536, i.e., a protective conductor must be connected to the mounting rail!

Protection against the ingress of foreign matter and water ● Degree of protection IP 20 to IEC 60529, i.e., protection against contact with standard probes. No protection against the ingress of water.

11.6

Rated voltages of S7-300

Rated operating voltages The S7-300 modules operate at different rated voltages. The table shows the rated voltages and corresponding tolerances.

240

Rated voltages

Tolerance

24 VDC

20.4 VDC to 28.8 VDC

120 VAC

93 VAC to 132 VAC

230 VAC

187 VAC to 264 VAC

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ITEM 3000

A

Appendix A.1

General rules and regulations for S7-300 operation

Introduction Seeing that an S7-300 can be used in many different ways, we can only describe the basic rules for the electrical installation in this document. WARNING Always observe these basic rules for electrical installation in order to achieve a fully functional S7-300 system.

EMERGENCY-OFF equipment EMERGENCY-OFF equipment to IEC 204 (corresponds to VDE 113) must remain effective in all operating modes of the plant or system.

System startup after specific events The table below shows what you have to observe when restarting a plant after specific events. Table A- 1

System startup after specific events

If there is...

then ...

Restart following a voltage dip or power failure,

dangerous operating states must be excluded. If necessary, force EMERGENCY-OFF.

Startup after releasing the EMERGENCY OFF device,

uncontrolled or undefined startup operations must be excluded.

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ITEM 3000 Appendix A.1 General rules and regulations for S7-300 operation

Mains voltage The table below shows what you have to watch with respect to the mains voltage. Table A- 2

Mains voltage

In the case of ...

the ...

Stationary systems or systems without all-pole mains disconnect switch

building installation must contain a mains disconnect switch or a fuse.

Load power supplies, power supply modules

set rated voltage range must correspond to local mains voltage.

All circuits of the S7-300

rated mains voltage fluctuation / deviation must lie within the permitted tolerance (refer to Technical Data of S7-300 modules).

24 VDC power supply The table below shows what you must observe for the 24 VDC power supply. Table A- 3

Protection against external electrical interference

In the case of ...

you need to observe ...

Buildings

external lightning protection

24 VDC power supply cables, signal cables

internal lightning protection

24 VDC power supply

safe (electrical) extra-low voltage isolation

Install lightning protection (e.g. lightning conductors).

Protection against external electrical interference The table below shows how you must protect your system against electrical interference or faults. Table A- 4

242

Protection against external electrical interference

In the case of ...

Make sure that ...

All plants or system in which the S7-300 is installed

the plant or system is connected to a protective conductor for the discharge of electromagnetic interference.

Supply / signal / bus cables

the cable routing and installation is correct.

Signal and bus cables

a cable/conductor break does not cause undefined plant or system states.

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ITEM 3000 Appendix A.2 Protection against electromagnetic interference

A.2

Protection against electromagnetic interference

A.2.1

Basic Points for EMC-compliant system installations

Definition: EMC

Introduction

EMC (electromagnetic compatibility) describes the capability of electrical equipment to operate free of errors in a given electromagnetic environment, without being subject to external influence and without influencing external devices in any way.

Although your S7-300 and its components are developed for an industrial environment and high electromagnetic compatibility, you should draw up an EMC installation plan before you install the controller taking into consideration all possible sources of interference.

Possible interferences

Electromagnetic interference can influence a PLC in various ways: ● Electromagnetic fields having a direct influence on the system ● Interference coupling caused by bus signals (PROFIBUS DP etc.) ● Interference coupling via the system wiring ● Interference influencing the system via the power supply and/or protective ground The figure below shows the likely paths of electromagnetic interference. (OHFWURPDJQHWLFILHOGV

%XVVLJQDO

36

&38

60

60

60

60

60

60

60

60

3URFHVVZLULQJ

3RZHUVXSSO\PRGXOH 3URWHFWLYHHDUWK

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Appendix A.2 Protection against electromagnetic interference

Coupling mechanisms Depending on the emitting media (line or isolated) and the distance between the interference source and the device, four different coupling mechanisms can influence the PLC. Table A- 5

Coupling mechanisms

Coupling mechanisms

Cause

Typical interference sources

Electrical coupling

Electrical or mechanical coupling always occurs when two circuits use one common cable.

•

• • •

Capacitive coupling Capacitive or electrical coupling occurs between conductors connected to different potentials. The coupling effect is proportional to voltage change over time. Inductive coupling

Radio frequency coupling

244

Inductive or magnetic coupling occurs between two current circuit loops. Current flow in magnetic fields induces interference voltages. The coupling effect is proportional to current change over time.

• • •

• • • • •

Radio frequency coupling occurs • when an electromagnetic wave reaches a conductor system. This • wave coupling induces currents and voltages.

Clocked devices (influence on the network due to converters and thirdparty power supply modules) Starting motors Potential differences on component enclosures with common power supply Static discharge Interference coupling due to parallel routing of signal cables Static discharge of the operator Contactors

Transformers, motors, arc welding devices Power supply cables routed in parallelism Switched cable current High-frequency signal cable Coils without suppression circuit Neighboring transmitters (e.g. radio phones) Sparking (spark plugs, collectors of electrical motors, welding devices)

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ITEM 3000 Appendix A.2 Protection against electromagnetic interference

A.2.2

Five basic rules for securing EMC

A.2.2.1

1. Basic rule for ensuring EMC

If you comply with theses five basic rules ... you can ensure EMC in many cases!

Rule 1: Large area grounding contact When you install the automation equipment, make sure that the surfaces of inactive metal parts are properly bonded to chassis ground. ● Bond all passive metal parts to chassis ground, ensuring large area and low-impedance contact. ● When using screw connections on varnished or anodized metal parts, support contact with special contact washers or remove the protective insulating finish on the points of contact. ● Wherever possible, avoid the use of aluminum parts for ground bonding. Aluminum oxidizes very easily and is therefore less suitable for ground bonding. ● Create a central connection between chassis ground and the equipotential grounded/protective conductor system.

A.2.2.2

2. Basic rule for ensuring EMC

Rule 2: Proper cable routing Always ensure proper cable routing when wiring your system. ● Sort your wiring system into groups (high-voltage/power supply/signal/data cables). ● Always route high-voltage, signal or data cables through separated ducts or in separate bundles. ● Install the signal and data cables as close as possible to grounded surfaces (e.g. supporting beans, metal rails, steel cabinet walls ).

See also Cable routing inside buildings (Page 255) Outdoor routing of cables (Page 257)

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A.2.2.3

3. Basic rule for ensuring EMC

Rule 3: Fixing the cable shielding Ensure proper fixation of the cable shielding. ● Always use shielded data cable. Always connect both ends of the shielding to ground on a large area. ● Analog cables must always be shielded. For the transmission of low-amplitude signals it might prove to be more efficient to have only one side of the shielding connected to ground. ● Directly behind the cable entry in the cabinet or enclosure, terminate the shielding on a large area of the shielding/protective ground bar and fasten it with the help of a cable clamp. Then, route the cable to the module; however, do not connect the shielding once again to ground in this place. ● Connections between the shielding/protective ground conductor bar and the cabinet/enclosure must be of a low impedance. ● Always install shielded data cables in metal/metallized connector housings.

See also Cable shielding (Page 251)

A.2.2.4

4. Basic rule for ensuring EMC

Rule 4: Special EMC measures Take special EMC measures for particular applications. ● Connect anti-surge elements to all inductive devices not controlled by S7-300 modules. ● For cabinet or cubicle lighting in the immediate range of your controller, use incandescent lamps or interference suppressed fluorescent lamps.

See also How to protect digital output modules against overvoltages caused by inductance (Page 270)

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ITEM 3000 Appendix A.2 Protection against electromagnetic interference

A.2.2.5

5. Basic rule for ensuring EMC

Rule 5: Homogeneous reference potential Create a homogeneous reference potential and ground electrical equipment whenever possible (refer to the section on Equipotential bonding). ● Route your equipotential conductors over a wide area if potential differences exist or are expected between your system components. ● Make sure you carefully direct your grounding measures. Grounding measures protect the controller and its functions. ● Form a star circuit to connect the equipment in your system and the cabinets containing central/expansion units to the grounding/protective conductor system. This prevents the formation of ground loops.

See also Equipotential Bonding (Page 253)

A.2.3

EMC-compliant installation of automation systems

Introduction Quite often it is the case that interference suppression measures are not taken until corruption of user signals is detected after the controller is actually in operation. Frequently, the causes of such interference are found in inadequate reference potentials as a result of faulty installation. This section shows you how to avoid such errors.

Inactive metal parts Inactive parts are referred to as electrically conductive elements, separated from active elements by a basic insulating and only subject to electrical potential if an error occurs.

Installation and ground bonding of inactive metal parts Bond all inactive metal parts to a large-surface ground when you install the S7-300. Proper ground bonding ensures a homogeneous reference potential for the controller and reduces the effect of interference coupling. The ground connection establishes an electrically conductive interconnection of all inactive parts. The sum of all interconnected inactive parts is referred to as chassis ground. This chassis ground must never develop a hazardous potential even if a fault occurs. Therefore, chassis ground must be connected to the protective conductor using cables with an adequate conductor cross-section. To avoid ground loops, physically separate chassis ground elements (cabinets, parts of the building construction or machine) must be bonded to the protective conductor system in a star circuit.

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ITEM 3000 Appendix A.2 Protection against electromagnetic interference

Observe the following for ground connection: ● In the same way as with active elements, exercise meticulous care to interconnect inactive metal elements. ● Always make sure that you have a low-impedance interconnection between metal elements (e.g. large and highly conductive contact surface). ● The protective insulating finish on varnished or anodized metal elements must be pierced or removed. Use special contact washers or completely remove the finish on the point of contact. ● Protect your connecting elements against corrosion (e.g. with a suitable grease). ● Interconnect moving chassis ground elements (e.g. cabinet doors) with flexible ground straps. Always use short ground straps with a large surface (the surface is decisive for the diversion of high-frequency currents).

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ITEM 3000 Appendix A.2 Protection against electromagnetic interference

A.2.4

Examples of an EMC-compliant installation: Cabinet configuration

Cabinet configuration The figure below shows a cabinet installation with the measures described above (bonding of inactive metal parts to chassis ground and connecting the cable shielding to ground). This sample applies only to grounded operation. Note the points in the figure when you install your system. 





     Figure A-1

Example of an EMC compatible cabinet installation

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Appendix A.2 Protection against electromagnetic interference

Key to installation The numbers in the following list refer to the numbers in the figure above.

A.2.5

Number

Identifier

Explanation

①

Ground straps

If no large-surface metal-to-metal connections are available, you must either interconnect inactive metal parts (e.g. cabinet doors or mounting plates) or bond them to chassis ground using ground straps. Use short ground straps with a large surface.

②

Supporting bars

Interconnect the supporting bars on a large area to the cabinet walls (metal-to-metal connection).

③

Mounting the rail

The mounting bar and rack must be interconnected with large-area metal-to-metal connections.

④

Signal cables

Connect the shielding of signal cables on a large area of the protective conductor/additional shielding conductor bar and fasten them with cable clamps.

⑤

Cable clamp

The cable clamp must cover a large area of the shielding braid and ensure good contact.

⑥

Shielding conductor bar

Interconnect the shielding conductor bar on a large surface with the supporting bars (metal-to-metal connection). The cable shielding is terminated on the conductor bar.

⑦

Protective ground bar

Interconnect the protective conductor bar on a large surface with the supporting bars (metal-to-metal connection). Interconnect the grounding busbar with the protective ground system, using a separate cable (minimum cross-section 10 2).

⑧

Cable to the protective ground system (equipotential ground)

Interconnect the cable on a large area with the protective ground system (equipotential ground).

Examples of an EMC-compliant installation: Wall mounting

Wall mounting When operating your S7 in a low-noise environment that conform with permitted ambient conditions (see Appendix Ambient conditions), you can also mount your S7 in frames or to the wall. Interference coupling must be diverted to large metal surfaces. Therefore, always mount standard profile/shielding/protective conductor rails on metal parts of the construction. Steel sheet panels reference potential surfaces have been found especially suitable for wallmounting. Provide a shielding conductor bar for connecting your cable shielding. This shielding conductor bar can also be used as protective ground bar.

Reference for ambient conditions For information on ambient conditions, refer to the S7-300 Automation System, Module data Reference Manual.

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Appendix A.2 Protection against electromagnetic interference

Please note ● When mounting on varnished or anodized metal parts, use special contact washers or remove the insulating layers. ● Provide a large-surface and low-impedance metal-to-metal connection for fastening the shielding/protective protective ground bar. ● Always touch-protect live mains conductors. The figure below shows an example of EMC compatible wall-mounting of an S7.

A.2.6

Cable shielding

Purpose of the shielding A cable is shielded to attenuate the effects of magnetic, electrical and electromagnetic interference on the cable.

Operating principle Interference currents on cable shielding is diverted to ground conductive interconnection between the shielding and the cabinet. To avoid interference as a result of these currents, it is imperative to provide a low-impedance connection to the protective conductor.

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Appendix A.2 Protection against electromagnetic interference

ITEM 3000

Suitable cables Whenever possible, use cables equipped with a shielding braid. Shielding density should be at least 80%. Avoid cables with film shielding, because the film can be easily damaged by tensile or pressure stress, thus reducing its shielding effect.

Handling of the shielding Note the following points on handling the shielding: ● Always use metal clamps to mount shielding braid. The clamps must contact a large area of the shielding and provide appropriate contact force. ● Directly behind the cabinet's cable entry, terminate the shielding on a shielding bus. Then, route the cable to the module; however, do not connect the shielding once again to ground in this place. ● In installations outside of cabinets (e.g. for wall-mounting) you can also terminate the shielding on a cable duct. The figure below shows some options for mounting shielded cables, using cable clamps.

See also Terminating shielded cables on the shielding contact element (Page 119)

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Appendix A.2 Protection against electromagnetic interference

A.2.7

Equipotential Bonding

Potential differences Potential differences can occur between separate system elements. This can result in high equipotential currents, e.g. if the cable shielding is terminated at both ends and grounded to different system components. The cause of potential difference can be differences in the power supplies.

WARNING Cable shielding is not suitable for equipotential bonding. Always use the prescribed cables (e.g. with a cross-section of 16 mm2). When installing MPI/DP networks, provide a sufficient conductor cross-section. Otherwise, interface hardware might get damaged or even be destroyed.

Equipotential bonding conductor To reduce potential differences and ensure proper functioning of your electronic equipment, you must install equipotential bonding conductors. Note the following points on the use of equipotential bonding conductors: ● The lower the impedance of an equipotential bonding conductor, the more effective is equipotential bonding. ● When shielded signal cables interconnect two system components and the shielding is connected on both ends to ground/protective conductors, the impedance of the additional equipotential bonding conductor must not exceed 10% of the shielding impedance. ● Determine the cross-section of your equipotential bonding conductor on the basis of the maximum equalizing current that will flow through it. The equipotential bonding conductor cross-section that has proven best in practice is 16 mm2.

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ITEM 3000 Appendix A.2 Protection against electromagnetic interference ● Always use equipotential bonding conductors made of copper or galvanized steel. Always connect the cables on a large surface to the equipotential conductor bar/protective conductor and protect it against corrosion. ● Route your equipotential bonding conductor to minimize the area between the equipotential bonding conductor and signal lines as far as possible (see the figure below).

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ITEM 3000

Appendix A.2 Protection against electromagnetic interference

A.2.8

Cable routing inside buildings

Introduction Inside buildings (inside and outside cabinets), clearances must be maintained between groups of different cables to achieve the necessary electromagnetic compatibility (EMC). The table contains information on the general rules governing clearances to enable you to choose the right cables.

How to read the table To find out how to run two cables of different types, proceed as follows: 1. Look up the type of the first cable in column 1 (Cables for ...). 2. Look up the type of the second cable in the corresponding field in column 2 (and cables for ...). 3. Note the applicable directives in column 3 (Run ...). Table A- 6

Cable routing inside buildings

Cables for ... • •

• • • • •

Bus signals, shielded (PROFIBUS) Data signals, shielded (programming devices, operator panels, printers, counter inputs, etc.) Analog signals, shielded DC voltage ( ≤ 60 V), unshielded Process signals ( ≤ 25 V), shielded AC voltage (≤ 25 V), unshielded Monitors (coaxial cable)

and cables for ... • •

• • • • • • • •

Run ...

Bus signals, shielded (PROFIBUS) Data signals, shielded (programming devices, operator panels, printers, counter inputs, etc.) Analog signals, shielded DC voltage ( ≤ 60 V), unshielded Process signals ( ≤ 25 V), shielded AC voltage (≤ 25 V), unshielded Monitors (coaxial cable)

In common bundles or cable ducts

DC voltage (> 60 V and ≤ 400 V), unshielded AC voltage (> 25 V and ≤ 400 V), unshielded

In separate bundles or cable ducts (no minimum clearance necessary)

DC and AC voltage (> 400 V), unshielded

Inside cabinets: In separate bundles or cable ducts (no minimum clearance necessary) Outside cabinets: On separate cable racks with a clearance of at least 10 cm

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ITEM 3000

Appendix A.2 Protection against electromagnetic interference Cables for ... • •

DC voltage (> 60 V and ≤ 400 V), unshielded AC voltage (> 25 V and ≤ 400 V), unshielded

and cables for ... • •

• • • • • • • •

Run ...

Bus signals, shielded (PROFIBUS) Data signals, shielded (programming devices, operator panels, printers, counter inputs, etc.) Analog signals, shielded DC voltage ( ≤ 60 V), unshielded Process signals ( ≤ 25 V), shielded AC voltage (≤ 25 V), unshielded Monitors (coaxial cable)

In separate bundles or cable ducts (no minimum clearance necessary)

DC voltage (> 60 V and ≤ 400 V), unshielded AC voltage (> 25 V and ≤ 400 V), unshielded

In common bundles or cable ducts

DC and AC voltage (> 400 V), unshielded

Inside cabinets: In separate bundles or cable ducts (no minimum clearance necessary) Outside cabinets: On separate cable racks with a clearance of at least 10 cm

DC and AC voltage (> 400 V), unshielded

• •

• • • • • • ETHERNET

256

Bus signals, shielded (PROFIBUS) Data signals, shielded (programming devices, operator panels, printers, counter inputs, etc.) Analog signals, shielded DC voltage ( ≤ 60 V), unshielded Process signals ( ≤ 25 V), shielded AC voltage (≤ 25 V), unshielded Monitors (coaxial cable)

Inside cabinets:

DC and AC voltage (> 400 V), unshielded

In common bundles or cable ducts

In separate bundles or cable ducts (no minimum clearance necessary) Outside cabinets: On separate cable racks with a clearance of at least 10 cm

ETHERNET

In common bundles or cable ducts

Others

In separate bundles or cable ducts with a clearance of at least 50 cm

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ITEM 3000

Appendix A.2 Protection against electromagnetic interference

A.2.9

Outdoor routing of cables

Rules for EMC-compliant cable routing The same EMC-compliant rules apply both to indoor and outdoor routing of cables. The following also applies: ● Running cables on metal cable trays. ● Electrical connection of the joints of cable trays/ducts. ● Ground the cable carriers. ● If necessary, provide adequate equipotential bonding between connected devices. ● Take the necessary (internal and external) lightning protection and grounding measures in as far as they are applicable to your particular application.

Rules for lightning protection outside buildings Run your cables either: ● in metal conduits grounded at both ends, or ● in concrete cable ducts with continuous end-to-end armoring.

Overvoltage protection equipment An individual appraisal of the entire plant is necessary before any lightning protection measures are taken.

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Appendix A.3 Lightning and surge voltage protection

A.3

Lightning and surge voltage protection

A.3.1

Overview

ITEM 3000

Introduction One of the most common causes of failure is overvoltage caused by: ● Atmospheric discharges ● Electrostatic discharges ● Switching overvoltages The concepts or measures for protection from overvoltages is based on the lightning protection zone concept. The rules to be complied with for the transitions between the individual lightning protection zones are presented here. Note This section can only provide you with the general guide on protecting the S7-300 from overvoltage. Complete protection from overvoltage is only guaranteed if the entire system design is based on the lightning protection zone concept. Comprehensive consideration must be given to this when planning construction of facilities. We therefore recommend that you contact your Siemens representative or a company specialized in lightning and overvoltage protection if you require more detailed information about overvoltage. In the following we refer to the overvoltage protection device using the normative terminology, i.e., according to the degree of hazard expected, overvoltage suppressor for pulse shape 8/20 μs and lightning current suppressor for pulse shape 10/350 μs.

Further references The following information is based on the lightning protection zone concept described in IEC IEC 62305-4 - "Protection against LEMP".

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection

A.3.2

Lightning protection zone concept

Principle of the lightning protection zone concept according to IEC 62305-4, DIN EN 62305-4, VDE 0185-305-4 The principle behind the lightning protection zone concept is the division of the volume to be protected from overvoltages (e.g. a control room) into lightning protection zones based on EMC considerations (see figure A-2). The various lightning protection zones (LPZ: Lightning Protection Zone) are delimited spatially as follows and not necessarily by physical boundaries, such as walls, floors, etc. Lightning protection zones (LPZ: Lightning Protection Zone) Outside areas of a building with risk of a direct strike

Lightning protection zone LPZ 0A

Outside areas of a building that are not at risk of a direct strike

Lightning protection zone LPZ 0B

Inside areas of a building that follow lightning protection zone 0B

Lightning protection zone LPZ 1

Inside areas of a building that normally represent separate EMC-reducing rooms and are in lightning protection zone 1

Lightning protection zone LPZ 2

Electrical equipment (with shielding properties) in lightning protection zone 2

Lightning protection zone LPZ 3

Effects of the Lightning Strike Direct lightning strikes occur in lightning protection zone 0A. Effects of the lightning strike are high-energy lightning currents and strong electromagnetic fields. Effects must be reduced from one lightning protection zone to the next through suitable lightning current or surge arresters/shielding measures.

Overvoltage Electromagnetic fields of the lightning channel can be reduced with appropriate shielding measures. Overvoltages due to inductions can be reduced to an non-dangerous level starting in lightning protection zone 0B using surge arresters.

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ITEM 3000 Appendix A.3 Lightning and surge voltage protection

Diagram of the lightning protection zones The following schematic diagram shows the implementation of the lightning protection zone concept for a building with outside lightning protection. /3=$ /LJKWQLQJFRQGXFWLQJ HTXLSPHQW

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Figure A-2

Lightning protection zones of a building with outside lightning protection

Principle of interfaces between the lighting protection zones Measures must be taken to reduce the peak current load and the magnetic fields at the interfaces between the lightning protection zones. Each zone-penetrating metallic/electrical system must be incorporated into the equipotential bonding at the zone transition. Note Metal systems include channels, structural parts, pipelines (water, gas and heat), etc. Electrical systems include power and IT cables and wires (e.g. line voltage, bus cable).

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection

A.3.3

Rules for the interface between the lightning protection zones 0 and 1

Rules for the interface 0A to 1 (lightning protection equipotential bonding) For lightning protection equipotential bonding at the interface of lightning protection zone 0A to 1, the following applies: ● Use of surge arresters prevents introduction of lightning partial currents into buildings. ● Creation of a local equipotential bonding at the transition of lightning protection zones, with incorporation of metal supply systems (pipes, air ducts, cable ducts, cable channels etc.) and electrical wire and cable systems.

Components for the lightning protection equipotential bonding Table A- 7

Components for the lightning protection equipotential bonding

Seq. No.

Cables for ...

Connection at the interface 0A to 1 with:

Item number

1

3-phase TN-C system

DEHNventil® DV M TNC 255

951 300

DEHNventil® DV M TNC 255 FM *

951 305 *

DEHNventil®

951 400

2 3 4 5 6

7

8

3-phase TN-S system 3-phase TT system AC TN-S system AC TT system Supply UN = 24 VDC:

Supply UN = 24 VDC:

MPI bus cable, RS485, RS 232 (V.24)

DV M TNS 255

DEHNventil® DV M TNS 255 FM *

951 405 *

DEHNventil®

951 310

DV M TT 255

DEHNventil® DV M TT 255 FM *

951 315 *

DEHNventil®

951 200

DV M TN 255

DEHNventil® DV M TN 255 FM *

951 205 *

DEHNventil®

951 110

DV M TT 2P 255

DEHNventil® DV M TT 2P 255 FM *

951 115 *

BLITZDUCTOR®

920 300

XT, basic unit BXT BAS

BLITZDUCTOR®

XT, Module BXT ML2 B 180 (IL = 1.2A) (2-wire)

920 211

DEHNbloc® M, DB M 1 150

961 110

DEHNbloc® M, DB M 1 150 FM * (2 ea. required)

961 115 *

BLITZDUCTOR® XT, basic unit BXT BAS

920 300

BLITZDUCTOR® XT, Module BXT ML2 B 180 (2-wire)

920 211

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection Seq. No. 9

10

11

Cables for ...

Connection at the interface 0A to 1 with:

Item number

Inputs/outputs of digital modules UN = 24 VDC:

BLITZDUCTOR® XT, basic unit BXT BAS

920 300

BLITZDUCTOR®

XT, Module BXT ML4 B 180 (IL = 1.2A) (4-wire)

920 310

Inputs/outputs of digital modules UN = 230 VAC:

DEHNbloc® M, DB M 1 255

961 120

DEHNbloc® M, DB M 1 255 * (2 ea. required)

961 125 *

Inputs/outputs of analog modules (e.g. 4-20 mA, 110V)

BLITZDUCTOR® XT, basic unit BXT BAS

920 300

BLITZDUCTOR® XT, Module BXT ML4 B 180 (IL = 1.2A) (4-wire)

920 310

* Version: With remote indication contact Components of the series BLITZDUCTOR® XT can be remotely monitored with the appropriate accessories. For further information, refer to http://www.dehn.de Direct order of components via: DEHN+SÖHNE GMBH+CO.KG. Hans-Dehn-Str. 1 D-92318 Neumarkt Tel. +49 (0)9181-906-730

Rules for the interface 0B to 1 (strong electromagnetic coupling) For overvoltage protection at the interface of lightning protection zone 0B to 1, the following applies: ● Use of power cables with peak current-capable cable shields (e.g., NYCWY) or twistedpair IT cables (e.g. A2Y(K)Y). ● Laying cables and lines – In continuous, peak current-capable metal pipes that are grounded at both ends – In reinforced concrete channels in which the reinforcement is grounded at both ends – On closed metal cable racks that are grounded at the beginning and end. ● Use of fiber optic cables without a metal shield if such a transmission is intended. ● Creation of a local equipotential bonding at the transition of lightning protection zones, with incorporation of metal supply systems (pipes, air ducts, cable ducts, cable channels etc.) and electrical wire and cable systems.

Additional measures If the actions listed above cannot be performed, protection by means of surge arresters must be provided. The following table A-8 contains surge arrestors that may be used to protect the system.

Overvoltage protection of 24 VDC power supply Always use the BLITZDUCTOR VT, type AD 24 V for the 24 VDC power supply module of the S7-300. All other surge arrestors do not meet the tolerance range (20.4-28.8 V) of the S7-300

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection

General information on use of surge arresters If, taking into account the tolerance range, the voltages that occur in the system exceed the specified maximum limits of the surge arresters used, surge arrestors of the next highest rated voltage series are to be used.

Components for the overvoltage protection Table A- 8

Components for the overvoltage protection

Seq. No.

Cables for ...

Connection at the interface 0B to 1 with:

Item number

1

3-phase TN-C system

DEHNguard® DG M TNC 275

952 300

DEHNguard® DG M TNC 275 FM *

952 305 *

DEHNguard®

952 400

2 3 4 5

3-phase TN-S system 3-phase TT system AC TN-S system AC TT system

DG M TNS 275

DEHNguard® DG M TNS 275 FM *

952 405 *

DEHNguard®

952 310

DG M TT 275

DEHNguard® DG M TT 275 FM *

952 315 *

DEHNguard®

952 200

DG M TN 275

DEHNguard® DG M TN 275 FM *

952 205 *

DEHNguard®

DG M TT 2P 275

952 110

DEHNguard®

DG M TT 2P 275 FM *

952 115 *

6

Supply UN = 24 VDC:

BLITZDUCTOR® VT, BVT AD 24

918 402

7

MPI/DP RS485 bus cable

BLITZDUCTOR® XT, basic unit BXT BAS

920 300

BLITZDUCTOR® XT, Module BXT ML2 BD HFS 5

920 271

BLITZDUCTOR®

920 300

8

RS 232 (V.24) bus cable

XT, basic unit BXT BAS

BLITZDUCTOR® XT, Module BXT ML2 BE S 12

920 222

9

Industrial Ethernet

DEHNpatch DPA M CLE RJ45B 48

929 121

10

Inputs/outputs of digital modules UN = 24 VDC:

DEHNconnect RK, DCO RK ME 24 (IL = 0.5 A)

919 921

11

Outputs of digital modules UN DEHNconnect RK, DCO RK D 5 24 = 24 VDC: (IL = 10.0 A)

919 986

12

Inputs/outputs of digital modules UN = 230 VAC:

952 070 952 090 *

DEHNguard® DG S 275 DEHNguard® DG S 275 FM * N-PE arrester in the TT system

13

Inputs/outputs of analog modules (e.g. 4-20 mA, 110V)

DEHNgap C S, DGP C S DEHNgap C S, DGP C S FM *

952 030 952 035 *

DEHNconnect RK, DCO RK ME 24 (IL = 0.5 A)

919 921

* Version: With remote indication contact Components of the series BLITZDUCTOR® XT can be remotely monitored with the appropriate accessories. For further information, refer to http://www.dehn.de Direct order of components via: DEHN+SÖHNE GMBH+CO.KG. Hans-Dehn-Str. 1 D-92318 Neumarkt Tel. +49 (0)9181-906-730

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Appendix A.3 Lightning and surge voltage protection

A.3.4

ITEM 3000

Rules for the interface between the lightning protection zones 1 and 2

Rules for the interface 1 to 2 (strong electromagnetic coupling) For overvoltage protection at the interface 1 to 2, the following applies: ● Use of power cables with peak current-capable cable shields (e.g., NYCWY) or twistedpair IT cables (e.g. A2Y(K)Y). ● Laying cables and lines – In continuous, peak current-capable metal pipes that are grounded at both ends, or – In reinforced concrete channels in which the reinforcement is grounded at both ends, or – On closed metal cable racks that are grounded at the beginning and end. ● Use of fiber optic cables without a metal shield if such a transmission is intended. ● Creation of a local equipotential bonding at the transition of lightning protection zones, with incorporation of metal supply systems (pipes, air ducts, cable ducts, cable channels etc.) and electrical wire and cable systems.

Additional measures If the actions listed above cannot be performed, protection by means of surge arresters must be provided. The following table A-9 contains surge arrestors that may be used to protect the system.

Overvoltage protection of 24 VDC power supply Always use the BLITZDUCTOR VT, type AD 24 V for the 24 VDC power supply module of the S7-300. All other surge arrestors do not meet the tolerance range (20.4-28.8 V) of the S7-300

General information on use of surge arresters If, taking into account the tolerance range, the voltages that occur in the system exceed the specified maximum limits of the surge arresters used, surge arrestors of the next highest rated voltage series are to be used.

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection

Components for the overvoltage protection Table A- 9

Components for the overvoltage protection

Seq. No.

Cables for ...

Connection at the interface 1 to 2 with:

Item number

1

3-phase TN-C system

DEHNguard® DG M TNC 275

952 300

DEHNguard® DG M TNC 275 FM *

952 305 *

DEHNguard®

952 400

2 3 4 5

3-phase TN-S system 3-phase TT system AC TN-S system AC TT system

DG M TNS 275

DEHNguard® DG M TNS 275 FM *

952 405 *

DEHNguard®

952 310

DG M TT 275

DEHNguard® DG M TT 275 FM *

952 315 *

DEHNguard®

952 200

DG M TN 275

DEHNguard® DG M TN 275 FM *

952 205 *

DEHNguard®

DG M TT 2P 275

952 110

DEHNguard®

DG M TT 2P 275 FM *

952 115 *

6

Supply UN = 24 VDC:

BLITZDUCTOR® VT, BVT AD 24

918 402

7

MPI/DP RS485 bus cable

BLITZDUCTOR® XT, basic unit BXT BAS

920 300

BLITZDUCTOR® XT, Module BXT ML2 BD HFS 5

920 271

BLITZDUCTOR®

920 300

8

RS 232 (V.24) bus cable

XT, basic unit BXT BAS

BLITZDUCTOR® XT, Module BXT ML2 BE S 12

920 222

9

Industrial Ethernet

DEHNpatch DPA M CLE RJ45B 48

929 121

10

Inputs/outputs of digital modules UN = 24 VDC:

DEHNconnect RK, DCO RK ME 24 (IL = 0.5 A)

919 921

11

Outputs of digital modules UN DEHNconnect RK, DCO RK D 5 24 = 24 VDC: (IL = 10.0 A)

919 986

12

Inputs/outputs of digital modules UN = 230 VAC:

952 070 952 090 *

DEHNguard® DG S 275 DEHNguard® DG S 275 FM * N-PE arrester in the TT system

13

Inputs/outputs of analog modules (e.g. 4-20 mA, 110V)

DEHNgap DGP C S DEHNgap DGP C S FM *

952 030 952 035 *

DEHNconnect RK, DCO RK ME 24 (IL = 0.5 A)

919 921

* Version: With remote indication contact Components of the series BLITZDUCTOR® XT can be remotely monitored with the appropriate accessories. For further information, refer to http://www.dehn.de Direct order of components via: DEHN+SÖHNE GMBH+CO.KG. Hans-Dehn-Str. 1 D-92318 Neumarkt Tel. +49 (0)9181-906-730

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ITEM 3000 Appendix A.3 Lightning and surge voltage protection

A.3.5

Rules for the interface between the lightning protection zones 2 and 3

Rules for the interface 2 to 3 (electromagnetic coupling) For overvoltage protection at the interface 2 to 3, the following applies: ● Use of power cables with peak current-capable cable shields (e.g., NYCWY) or twistedpair IT cables (e.g. A2Y(K)Y). ● Laying cables and lines – In continuous, peak current-capable metal pipes that are grounded at both ends, or – In reinforced concrete channels in which the reinforcement is grounded at both ends, or – On closed metal cable racks that are grounded at the beginning and end. ● Use of fiber optic cables without a metal shield if such a transmission is intended. ● Creation of a local equipotential bonding at the transition of lightning protection zones, with incorporation of metal supply systems (pipes, air ducts, cable ducts, cable channels etc.) and electrical wire and cable systems.

Additional measures If the actions listed above cannot be performed, protection by means of surge arresters must be provided. The following table A-10 contains surge arrestors that may be used to protect the system.

Overvoltage protection of 24 VDC power supply Always use the BLITZDUCTOR VT, type AD 24 V for the 24 VDC power supply module of the S7-300. All other surge arrestors do not meet the tolerance range (20.4-28.8 V) of the S7-300

General information on use of surge arresters If, taking into account the tolerance range, the voltages that occur in the system exceed the specified maximum limits of the surge arresters used, surge arrestors of the next highest rated voltage series are to be used.

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection

Components for the overvoltage protection Table A- 10

Components for the overvoltage protection

Seq. no.

Cables for ...

Connection at the interface 2 to 3 with:

Item number

1

3-phase TN-S system, TT system

DEHNrail® DR M 4P 255

953 400

DEHNrail® DR M 4P 255 FM * (IL = 25.0 A)

953 405 *

3-phase TN-S system, TT system

DEHNrail® DR M 2P 255

953 200

DEHNrail®

DR M 2P 255 FM * (IL = 25.0 A)

953 205 *

Supply UN = 24 VDC:

BLITZDUCTOR® VT, BVT AD 24

918 402

MPI/DP RS 485 bus cable

BLITZDUCTOR®

920 300

2

3 4 5

RS 232 (V.24) bus cable

XT, basic unit BXT BAS

BLITZDUCTOR® XT, Module BXT ML2 BD HFS 5

920 271

BLITZDUCTOR®

XT, basic unit BXT BAS

920 300

BLITZDUCTOR®

XT, Module BXT ML2 BE S 12

920 222

6

Industrial Ethernet

DEHNpatch DPA M CLE RJ45B 48

929 121

7

Inputs/outputs of digital modules UN = 24 VDC:

DEHNconnect RK, DCO RK ME 24 (IL = 0.5 A)

919 921

8

Outputs of digital modules UN DEHNconnect RK, DCO RK D 5 24 = 24 VDC: (IL = 10.0 A)

919 986

9

Inputs/outputs of digital modules UN = 230 VAC:

952070 952 090 *

DEHNguard® DG S 275 DEHNguard® DG S 275 FM * N-PE arrester in the TT system

10

Inputs/outputs of analog modules (e.g. 4-20 mA, 110V)

DEHNgap C S, DGP C S DEHNgap C S, DGP C S FM *

952 030 952 035 *

DEHNconnect RK, DCO RK ME 24 (IL = 0.5 A)

919 921

* Version: With remote indication contact Components of the series BLITZDUCTOR® XT can be remotely monitored with the appropriate accessories. For further information, refer to http://www.dehn.de Direct order of components via: DEHN+SÖHNE GMBH+CO.KG. Hans-Dehn-Str. 1 D-92318 Neumarkt Tel. +49 (0)9181-906-730

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection

A.3.6

Example: Surge protection circuit for networked S7-300 CPUs The figure shows the required measures for the protection of two networked S7-300 against lightning strikes and overvoltage. /3=$

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection

Components of the application example The following table explains the components of the application example: Seq. No.

Component

Meaning

①

Combination arrester 230/400 VAC supply, DEHNventil® DV M TNC 255 Part. no. 951 300

Protection against indirect lighting strikes and overvoltages at zone transition 0A-> 1 and 0A -> 2

DEHNventil® DV M TNC 255 FM * Part no. 951 305 * DEHNventil® DV M TNS 255 Part no. 951 400 DEHNventil® DV M TNS 255 FM * Part no. 951 405 * ②

Combination arrester, 230/400 VAC supply, DEHNguard® DG M TNC 275 Part no. 952 300

Protection against indirect lightning strikes and overvoltages at the zone transition 1 -> 2

DEHNguard® DG M TNC 275 FM * Part no. 952 305 * DEHNguard® DG M TNS 275 Part no. 952 400 DEHNguard® DG M TNS 275 FM * Part No. 952 405 * ③

Surge arrester, 230 VAC supply, DEHNrail DR M 2P 255 Art. Nr. 953 200

Protection against indirect lightning strikes and overvoltages at the zone transition 2 -> 3

DEHNrail DR M 2P 255 FM * Part no. 953 205 * (IL = 25.0 A) ④

Surge arrester, BLITZDUCTOR® VT, BVT AD 24, 24 VDC supply Part no. 918 402

Protection against indirect lightning strikes and overvoltages at the zone transition 2 -> 3

⑤

Surge arrester, RS 485 interface BLITZDUCTOR® XT Basic unit BXT BAS, Part no. 920 300

Protection against indirect lightning strikes and overvoltages at the zone transition 2 -> 3

BLITZDUCTOR® XT Module BXT ML2 BD HFS 5, Part no. 920 271 (2-wire) ⑥

Surge arrester, digital inputs of modules DEHNconnect RK, DCO RK ME 24 Part no. 919 921 (IL = 0.5 A) (2-wire)

Protection against indirect lightning strikes and overvoltages at the zone transition 2 -> 3

⑦

Surge arrester, digital outputs of modules DEHNconnect RK, DCO RK D 5 24 Part no. 919 986 (IL = 10.0 A) (2-wire)

Protection against indirect lightning strikes and overvoltages at the zone transition 2 -> 3

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection Seq. No.

Component

Meaning

⑧

Surge arrester, inputs/outputs of the modules BLITZDUCTOR® XT Basic unit BXT BAS, Part no. 920 300

Protection against indirect lighting strikes and overvoltages at the zone transition 0A -> 1

BLITZDUCTOR® XT, Module BXT ML2 B 180, Part no. 920 211 (IL = 1.2 A) (2-wire) ⑨

2 EMC spring terminals for the basic unit of the BLITZDUCTOR® XT Part no. 920 395

Direct or indirect shield grounding

⑩

Protective equipotential bonding line ≥ 6 mm2 Cu

Protective equipotential bonding

* Version: With remote indication contact Components of the series BLITZDUCTOR® XT can be remotely monitored with the appropriate accessories. For further information, refer to http://www.dehn.de Direct order of components via: DEHN+SÖHNE GMBH+CO.KG. Hans-Dehn-Str. 1 D-92318 Neumarkt Tel. +49 (0)9181-906-730

A.3.7

How to protect digital output modules against overvoltages caused by inductance

Inductive overvoltage Overvoltage occurs, for example, when inductance is deactivated. Examples are relay coils and contactors.

Integrated surge arrester S7-300 digital output modules are equipped with an integrated surge arrester.

Additional overvoltage protection Inductive devices require additional surge arresters only in following cases: ● If these can be switched off by additional contacts (e.g. relay contacts). ● If the inductance cannot be controlled by SIMATIC modules, but the overvoltages that occur can nevertheless have a negative effect on SIMATIC. Note: Request information on relevant surge protection rating from the supplier of inductive devices.

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ITEM 3000

Appendix A.3 Lightning and surge voltage protection

Example: EMERGENCY-OFF relay contact in the output circuit The figures illustrates an output circuit requiring additional overvoltage protectors.

36

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Refer also to the rest of the information in this section.

Circuit for coils operated with DC voltage The figure below shows DC-operated coils equipped with diode or Zener diode circuit. ZLWKGLRGH

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Diode/Zener diode circuits have the following characteristics: ● Switching overvoltages can be avoided. The Zener diode has a higher switch-off voltage capacity. ● High switch-off delay (6 to 9 times higher than without protective circuit). The Zener diode switches off faster than a diode circuit.

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Circuit for coils operated with AC voltage The figure shows coils operated with AC voltage and varistor or RC circuit. ZLWKYDULVWRU

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Properties of a protective circuit with varistor: ● The amplitude of the opening surge is limited rather than attenuated. ● The surge rise-ratio remains the same. ● Short off-delay. Properties of a protective circuit with RC elements: ● Amplitude and steepness of the opening surge are reduced. ● Short off-delay.

A.4

Functional safety of electronic control equipment

Reliability through basic measures SIMATIC devices and components are extremely reliable thanks to extensive measures in development and production. The basic measures include: ● Selection of high-quality components and strategic cooperation with high-performance suppliers ● Measures to prevent static discharge when handling MOS circuits ● Checks and monitoring of the production processes using statistical methods and visual inspections at various production stages ● Heat endurance run at higher ambient temperature as monitoring run-in ● Thorough computer-controlled final inspection and testing of all modules. ● Statistical evaluation of all returned systems and components and analysis of service requests to enable the immediate initiation of suitable corrective measures ● Comprehensive computer-aided acquisition of the quality data in the production in order to ensure all the adopted measures

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Increased safety measures In all cases where the occurrence of failures can result in material damage or injury to persons, special measures must be taken to enhance the safety of the entire installation. For these there exist special plant-specific regulations that also have to be taken into consideration by the owner-operator when structuring the control system. For electronic control equipment with a safety function, the measures that have to be taken to prevent or rectify faults are based on the risks involved in the installation. As of a certain degree of hazard the basic measures mentioned above are no longer sufficient. The owneroperator has to ensure that additional measures are realized for the plant, for example by using SIMATIC S7-F fail-safe control systems.

Important note The instructions in the operating manual must be followed exactly. Incorrect handling can render measures intended to prevent dangerous faults ineffective, or generate additional sources of danger.

Fail-safe systems in SIMATIC S7 Two fail-safe systems are available for the integration of the safety technology in the SIMATIC S7 automation systems: ● The fail-safe S7 Distributed Safety automation system – For the implementation of safety concepts in the field of machine and person protection, for example EMERGENCY-OFF facilities for the operation of machine tools/processing machines. – In the process industry, for example for carrying out protection functions for instrumentation-and-control protective systems and burners. ● The fail-safe and optionally fault-tolerant S7 F/FH Systems automation system for plants for example in process technology and the oil industry.

Fail-safe and redundant system S7 F/FH system To increase the availability of the automation system and thereby avoid process interruption in the case of errors, it is possible to build in fail-safe systems as optionally redundant S7 F/FH systems. The increased availability is achieved through the redundancy of the following components: Power supply, CPU module, communications and IO devices.

Attainable safety requirements S7 Distributed Safety F systems and S7 F/FH systems can meet the following safety requirements: ● Safety Integrity Level SIL1 to SIL3 to IEC 61508 ● Categories 2 to 4 according to EN 954-1.

Reference You can find further information in the Safety Engineering in SIMATIC S7 system description (A5E00109528-05). CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

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Glossary Accumulator Accumulators represent CPU register and are used as buffer memory for download, transfer, comparison, calculation and conversion operations.

Address An address is the identifier of a specific address or address area. Examples: Input I 12.1; Flag Word MW 25; Data Block DB 3.

Analog module Analog modules convert process values (e.g. temperature) into digital values which can be processing in the CPU, or they convert digital values into analog manipulated variables.

Application → User program

Application An application is a program that runs directly on the MS-DOS / Windows operating system. Applications on the programming device are for example STEP 7.

ASIC ASIC is the acronym for Application Specific Integrated Circuits. PROFINET ASICs are components with a wide range of functions for the development of your own devices. They implement the requirements of the PROFINET standard in a circuit and allow extremely high packing densities and performance. Because PROFINET is an open standard, SIMATIC NET offers PROFINET ASICs for the development of your old devices under the name ERTEC .

Backplane bus The backplane bus is a serial data bus. It supplies power to the modules and is also used by the modules to communicate with each other. Bus connectors interconnect the modules.

Backup memory Backup memory ensures buffering of the memory areas of a CPU without backup battery. It backs up a configurable number of timers, counters, flag bits, data bytes and retentive timers, counters, flag bits and data bytes).

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Bit memory Flag bits are part of the CPU's system memory. They store intermediate results of calculations. They can be accessed in bit, word or dword operations.

See System memory

Bus A bus is a communication medium connecting several nodes. Data can be transferred via serial or parallel circuits, that is, via electrical conductors or fiber optic.

Bus segment A bus segment is a self-contained section of a serial bus system. Bus segments are interconnected by way of repeaters, for example, in PROFIBUS DP.

Central module → CPU

Changing IO devices during operation (changing partner ports) Functionality of a PROFINET device. A PROFINET device that supports this function can communicate during operation with changing communication partners at the same port.

Clock flag bits flag bit which can be used to generate clock pulses in the user program (1 byte per flag bit). Note When operating with S7-300 CPUs, make sure that the byte of the clock memory bit is not overwritten in the user program!

Coaxial cable A coaxial cable, also known as "coax", is a metal conductor system used in HF transmission circuits, for example, as radio and TV antenna cable, and in modern networks demanding high data transmission rates. The inner conductor of a coaxial cable is sheathed by a tubelike outer conductor. These conductors are separated by plastic insulation. In contrast to other cables, this type of cable provides a high degree of immunity to interference and EMC compatibility.

Code block A SIMATIC S7 code block contains part of the STEP 7 user program. (in contrast to a DB: this contains only data.)

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Code block → Global data

Code block → Nesting depth

Communication processor Communication processors are modules used for point-to-point and bus topologies.

Component Based Automation → PROFINET CBA

Compress The PG online function "Compress" is used to rearrange all valid blocks in CPU RAM in a contiguous area of load memory, starting at the lowest address. This eliminates fragmentation which occurs when blocks are deleted or edited.

Configuration Assignment of modules to module racks/slots and (e.g. for signal modules) addresses.

Consistent data Data which belongs together in terms of content and must not be separated is known as consistent data. For example, the values of analog modules must always be handled as a whole, that is, the value of an analog module must not be corrupted as a result of read access at two different points of time.

Counter Counters are part of CPU system memory. The content of "Counter cells" can be modified by STEP 7 instructions (for example, up/down count.)

See also System memory

CP → Communication processor

CPU Central processing unit = CPU of the S7 automation system with a control and arithmetic unit, memory, operating system, and interface for programming device.

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Cycle time The cycle time represents the time a CPU requires for one execution of the user program.

Cyclic interrupt → Interrupt, cyclic interrupt

Data block Data blocks (DB) are data areas in the user program which contain user data. There are global data blocks which can be accessed by all code blocks, and instance data blocks which are assigned to a specific FB call.

Data exchange broadcast → Direct data exchange

Data exchange traffic → Direct data exchange

Data set routing Functionality of a module with several network connections. Modules that support this function are able to pass on data of an engineering system (for example parameter data generated by SIMATIC PDM) from a subnetwork such as Ethernet to a field device at the PROFIBUS DP.

Data, static Static data can only be used within a function block. These data are saved in an instance data block that belongs to a function block. Data stored in an instance data block are retained until the next function block call.

Data, temporary Temporary data represent local data of a block. They are stored in the L-stack when the block is executed. After the block has been processed, these data are no longer available.

Default Router The default router is the router that is used when data must be forwarded to a partner located within the same subnet. In STEP 7, the default router is named Router. STEP 7 assigns the local IP address to the default router.

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Detecting the network topology LLDP (Link Layer Discovery Protocol) is a protocol that is used to detect the closest neighbors. It enables a device to send information about itself and to save information received from neighboring devices in the LLDP MIB. This information can be looked up via the SNMP. This information allows a network management system to determine the network topology.

Determinism → Real Time

Device Name Before an IO device can be addressed by an IO controller, it must have a device name. In PROFINET, this method was selected because it is simpler to work with names than with complex IP addresses. The assignment of a device name for a concrete IO device can be compared with setting the PROFIBUS address of a DP slave. When it ships, an IO device does not have a device name. An IO device can only be addressed by an IO controller, for example for the transfer of project engineering data (including the IP address) during startup or for user data exchange in cyclic operation, after it has been assigned a device name with the PG/PC .

Device replacement without medium change IO devices having this function can be replaced simply: ● A removable medium (such as Micro Memory Card) with the stored device name is not required. ● The device name does not have to be assigned using the programming device. The replaced IO device obtains the device name from the IO controller, not from the removable medium or from the programming device. The IO controller uses the configured topology and the neighboring relationships determined by the IO devices to this purpose. The configured setpoint topology must agree with the actual topology. ● In case of a part being replaced, an IO device already in operation has to be reset to the state of delivery using "Reset to factory setting".

Diagnostic interrupt Modules capable of diagnostics operations report detected system errors to the CPU by means of diagnostic interrupts.

Diagnostics → System diagnostics

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Diagnostics buffer The diagnostics buffer represents a buffered memory area in the CPU. It stores diagnostic events in the order of their occurrence.

Direct data exchange Direct data exchange is a special communication relationship between PROFIBUS DP nodes. Direct data exchange is characterized by PROFIBUS DP nodes that "listen" on the bus and know which data a DP slave returns to its DP master.

DP master A master which behaves in accordance with EN 50170, Part 3 is known as a DP master.

DP slave A slave operated on PROFIBUS with PROFIBUS DP protocol and in accordance with EN 50170, Part 3 is referred to as DP slave.

DPV1 The designation DPV1 means extension of the functionality of the acyclical services (to include new interrupts, for example) provided by the DP protocol. The DPV1 functionality has been incorporated into IEC 61158/EN 50170, volume 2, PROFIBUS.

Electrically isolated The reference potential of the control and on-load power circuits of isolated I/O modules is electrically isolated; for example, by optocouplers, relay contact or transformer. Input/output circuits may be grouped.

Equipotential bonding Electrical connection (equipotential bonding conductor) which eliminates potential difference between electrical equipment and external conductive bodies by drawing potential to the same or near the same level, in order to prevent disturbing or dangerous voltages between these bodies.

Error display One of the possible reactions of the operating system to a runtime error is to output an error message. Further reactions: Error reaction in the user program, CPU in STOP.

Error handling via OB After the operating system has detected a specific error (e.g. access error with STEP 7), it calls a dedicated block (Error OB) that determines further CPU actions.

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Error response Reaction to a runtime error. Reactions of the operating system: It sets the automation system to STOP, indicates the error, or calls an OB in which the user can program a reaction.

ERTEC → ASIC

Fast Ethernet Fast Ethernet describes the standard with which data is transmitted at 100 Mbps. Fast Ethernet uses the 100 Base-T standard.

FB → Function block

FC → Function

FEPROM → Memory Card (MC)

Flash EPROM FEPROMs can retain data in the event of power loss, same as electrically erasable EEPROMs. However, they can be erased within a considerably shorter time (FEPROM = Flash Erasable Programmable Read Only Memory). They are used on Memory Cards.

Force The Force function can be used to assign the variables of a user program or CPU (also: inputs and outputs) constant values. In this context, please note the limitations listed in the Overview of the test functions section

in the chapter entitled Test functions, Diagnostics and Troubleshooting in the S7-300 Installation manual.

Function According to IEC 1131-3, a function (FC) is a code block without static data. A function allows parameters to be passed in the user program. Functions are therefore suitable for programming frequently occurring complex functions, e.g. calculations.

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Function block According to IEC 1131-3, a function block (FB) is a code block with static data. A function block allows parameters to be transferred to the user program. Function blocks are therefore suitable for programming frequently recurring, complex functions, e.g., closed-loop controls, mode selection.

Functional ground Grounding which has the sole purpose of safeguarding the intended function of electrical equipment. With functional grounding you short-circuit interference voltage which would otherwise have an unacceptable impact on equipment.

GD circuit A GD circuit comprises a number of CPUs sharing data by means of global data communication, and is used as follows: ● A CPU broadcasts a GD packet to the other CPUs. ● A CPU sends and receives a GD packet from another CPU. A GD circuit is identified by a GD circuit number.

GD element A GD element is generated by assigning shared global data. It is identified by a unique global data ID in the global data table.

GD packet A GD packet can consist of one or several GD elements transmitted in a single message frame.

Global data Global data can be addressed from any code block (FC, FB, OB). In particular, this refers to flag bits M, inputs I, outputs Q, timers, counters and data blocks DB. Global data can be accessed via absolute or symbolic addressing.

Global data communication Global data communication is a method of transferring global data between CPUs (without CFBs).

Ground The conductive earth whose electrical potential can be set equal to zero at any point. Ground potential can be different from zero in the area of grounding electrodes. The term reference ground is frequently used to describe this situation.

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Grounding means, to connect an electrically conductive component via an equipotential grounding system to a grounding electrode (one or more conductive components with highly conductive contact to earth). Chassis ground is the totality of all the interconnected passive parts of a piece of equipment on which dangerous fault-voltage cannot occur.

Ground The conductive earth whose electrical potential can be set equal to zero at any point. Ground potential can be different from zero in the area of grounding electrodes. The term reference ground is frequently used to describe this situation. Grounding means, to connect an electrically conductive component via an equipotential grounding system to a grounding electrode (one or more conductive components with highly conductive contact to earth). Chassis ground is the totality of all the interconnected passive parts of a piece of equipment on which dangerous fault-voltage cannot occur.

Ground The conductive earth whose electrical potential can be set equal to zero at any point. Ground potential can be different from zero in the area of grounding electrodes. The term reference ground is frequently used to describe this situation. Grounding means, to connect an electrically conductive component via an equipotential grounding system to a grounding electrode (one or more conductive components with highly conductive contact to earth). Chassis ground is the totality of all the interconnected passive parts of a piece of equipment on which dangerous fault-voltage cannot occur.

GSD file The properties of a PROFINET device are described in a GSD file (General Station Description) that contains all the information required for configuration. As with PROFIBUS, you can link a PROFINET device in STEP 7 by means of a GSD file. In PROFINET IO, the GSD file is in XML format. The structure of the GSD file conforms to ISO 15734, which is the world-wide standard for device descriptions. In PROFIBUS, the GSD file is in ASCII format.

HART English: Highway Adressable Remote Transducer

Hub → Switch

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Industrial Ethernet → Fast Ethernet

Industrial Ethernet Industrial Ethernet (formerly SINEC H1) is a technology that allows data to be transmitted free of interference in an industrial environment. Due to the openness of PROFINET, you can use standard Ethernet components. We recommend, however, that you install PROFINET as Industrial Ethernet.

Instance data block The STEP 7 user program assigns an automatically generated DB to every call of a function block. The instance data block stores the values of input, output and in/out parameters, as well as local block data.

Interface, MPI-compatible → MPI

Interrupt The CPU's operating system distinguishes between different priority classes for user program execution. These priority classes include interrupts, e.g. process interrupts. When an interrupt is triggered, the operating system automatically calls an assigned OB. In this OB the user can program the desired response (e.g. in an FB).

Interrupt, cyclic interrupt A cyclic interrupt is generated periodically by the CPU in a configurable time pattern. A corresponding OB will be processed.

Interrupt, delay The delay interrupt belongs to one of the priority classes in SIMATIC S7 program processing. It is generated on expiration of a time started in the user program. A corresponding OB will be processed.

Interrupt, delay → Interrupt, delay

Interrupt, diagnostic → Diagnostic interrupt

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Interrupt, process → Process interrupt

Interrupt, status A status interrupt can be generated by a DPV1 slave or a PNIO device respectively. At the DPV1 master or the PNIO controller respectively the receipt of the interrupt causes the OB 55 to be called up. For detailed information on OB 56, refer to the Reference Manual System Software for S7-

300/400: System and Standard Functions.

Interrupt, time-of-day The time-of-day interrupt belongs to one of the priority classes in SIMATIC S7 program processing. It is generated at a specific date (or daily) and time-of-day (e.g. 9:50 or hourly, or every minute). A corresponding OB will be processed.

Interrupt, update An update interrupt can be generated by a DPV1 slave or a PNIO device respectively. At the DPV1 master or the PNIO controller respectively the receipt of the interrupt causes the OB 56 to be called up. For detailed information on OB 56, refer to the Reference Manual System Software for S7-

300/400: System and Standard Functions.

Interrupt, vendor-specific A vendor-specific interrupt can be generated by a DPV1 slave or a PNIO device respectively. At the DPV1 master or the PNIO controller respectively the receipt of the interrupt causes the OB 57 to be called up. For detailed information on OB 57, refer to the Reference Manual System Software for S7-

300/400: System and Standard Functions.

IP address To allow a PROFINET device to be addressed as a node on Industrial Ethernet, this device also requires an IP address that is unique within the network. The IP address is made up of 4 decimal numbers with a range of values from 0 through 255. The decimal numbers are separated by a period. The IP address is made up of ● The address of the (subnet) network and ● The address of the node (generally called the host or network node).

IRT → Isochronous Real Time communications

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Isochronous Real Time communications Synchronized transmission procedure for the cyclic exchange of IO data between PROFINET devices. A reserved bandwidth within the send clock is available for the IRT / IO data. The reserved bandwidth guarantees that the IRT data can also be transferred even during another high network load (for example TCP/IP communication or additional real time communication) at reserved, synchronized intervals.

LAN Local Area Network; interconnects multiple computers within a company. The geographical topology of a LAN is limited to the local premises and is only available to the operating company or institution.

LLDP LLDP (Link Layer Discovery Protocol) is a protocol that is used to detect the closest neighbors. It enables a device to send information about itself and to save information received from neighboring devices in the LLDP MIB. This information can be looked up via the SNMP. This information allows a network management system to determine the network topology.

Load memory This memory contains objects generated by the programming device. Load memory is implemented by means of a plug-in Micro Memory Card of different memory capacities. The SIMATIC Micro Memory Card must be inserted to allow CPU operation.

Load power supply Power supply to the signal / function modules and the process I/O connected to them.

Local data → Data, temporary

MAC address Each PROFINET device is assigned a worldwide unique device identifier in the factory. This 6-byte long device identifier is the MAC address. The MAC address is divided up as follows: ● 3 bytes vendor identifier and ● 3 bytes device identifier (consecutive number). The MAC address is normally printed on the front of the device. Example: 08-00-06-6B-80-C0

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Master When a master has the token, it can send data to other nodes and request data from other nodes (= active node).

Memory Card (MC) Memory Cards are memory media for CPUs and CPs. They are implemented in the form of RAM or FEPROM. An MC differs from a Micro Memory Card only in its dimensions (MC is approximately the size of a credit card).

MIB An MIB (Management Information Base) is a data base of a device. SNMP clients access this data base in the device. The S7 device family supports, among others, the following standard MIBs: ● MIB II, standardized in the RFC 1213 ● LLDP MIB, standardized in the international standard IEE 802.1AB ● LLDP PNIO-MIB, standardized in the international standard IEE 61158-6-10

MIB An MIB (Management Information Base) is a database of a device. SNMP clients access this database in the device. The S7 device family supports, among others, the following standard MIBs: ● MIB II, standardized in the RFC 1213 ● LLDP MIB, standardized in the international standard IEE 802.1AB ● LLDP PNIO-MIB, standardized in the international standard IEE 61158-6-10

Micro Memory Card (MMC) Micro Memory Cards are memory media for CPUs and CPs. Their only difference to the Memory Card is the smaller size.

Module parameters Module parameters are values which can be used to configure module behavior. A distinction is made between static and dynamic module parameters.

MPI The multipoint interface (MPI) represents the programming device interface of SIMATIC S7. It enables multiple nodes (PGs, text-based displays, OPs) to be operated simultaneously by one or more CPUs. Each node is identified by its unique (MPI) address.

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NCM PC → SIMATIC NCM PC

Nesting depth A block can be called from another by means of a block call. Nesting depth is referred to as the number of simultaneously called code blocks.

Network A network consists of one or more interconnected subnets with any number of nodes. Several networks can exist alongside each other.

Network A network is a larger communication system that allows data exchange between a large number of nodes. All the subnets together form a network.

Non-isolated The reference potential of the control and on-load power circuits of non-isolated I/O modules is electrically interconnected.

NTP The Network Time Protocol (NTP) is a standard for synchronizing clocks in automation systems via Industrial Ethernet. NTP uses the UDP wireless network protocol.

OB → Organization blocks

OB priority The CPU operating system distinguishes between different priority classes, for example, cyclic program execution, process interrupt controlled program processing. Each priority class is assigned organization blocks (OBs) in which the S7 user can program a response. The OBs are assigned different default priority classes. These determine the order in which OBs are executed or interrupt each other when they appear simultaneously.

Operating state SIMATIC S7 automation systems know the following operating states: STOP, START, RUN.

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Operating system The CPU operating system organizes all the CPU functions and processes which are not associated with a specific control task.

Organization blocks Organization blocks (OBs) form the interface between the CPU operating system and the user program. The order in which the user program is executed is defined in the organization blocks.

Parameters 1. Variable of a STEP 7 code block 2. Variable for declaring module response (one or several per module). All modules have a suitable basic factory setting which can be customized in STEP 7. There are static and dynamic parameters.

Parameters, dynamic Unlike static parameters, you can change dynamic module parameters during runtime by calling an SFC in the user program, e.g. limit values of an analog signal input module.

Parameters, static Unlike dynamic parameters, static parameters of modules cannot be changed by the user program. You can only modify these parameters by editing your configuration in STEP 7, for example, modification of the input delay parameters of a digital signal input module.

PC station → SIMATIC PC Station

PG → Programming device

PLC → Programmable logic controller

PLC A PLC in the context of SIMATIC S7 --> is a programmable logic controller.

PNO Technical committee that defines and further develops the PROFIBUS and PROFINET standards with the following homepage: http://www.profinet.com.

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Prioritized startup The term "prioritized startup" is used for the PROFINET functionality for accelerating the startup of IO devices in a PROFINET IO system with RT and IRT communications. The function reduces the time that the correspondingly configured IO devices require in order to return to the cyclic user data exchange in the following cases: ● After the power supply has returned ● After a station has come back online ● After IO devices have been activated

Priority class The S7 CPU operating system provides up to 26 priority classes (or "Program execution levels"). Specific OBs are assigned to these classes. The priority classes determine which OBs interrupt other OBs. Multiple OBs of the same priority class do not interrupt each other. In this case, they are executed sequentially.

Process image The process image is part of CPU system memory. At the start of cyclic program execution, the signal states at the input modules are written to the process image of the inputs. At the end of cyclic program execution, the signal status of the process image of the outputs is transferred to the output modules.

Process interrupt A process interrupt is triggered by interrupt-triggering modules as a result of a specific event in the process. The process interrupt is reported to the CPU. The assigned organization block will be processed according to interrupt priority.

Process-Related Function → PROFINET Component

Product version The product version identifies differences between products which have the same order number. The product version is incremented when forward-compatible functions are enhanced, after production-related modifications (use of new parts/components) and for bug fixes.

PROFIBUS Process Field Bus - European field bus standard.

PROFIBUS devicePROFIBUS device Within the context of PROFINET, "device" is the generic term for:

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● Automation systems (e.g. PLC, PC) ● Field devices (for example, PLC, PC, hydraulic devices, pneumatic devices) ● Active network components (for example, switches, gateways, routers) ● PROFIBUS or other fieldbus systems The main characteristics of a device is its integration into PROFINET communication by means of Ethernet or PROFIBUS. The following device types are distinguished based on their attachment to the bus: ● PROFINET devices ● PROFIBUS devices A PROFIBUS device has at least one PROFIBUS link with an electric interface (RS485) or an optical interface (polymer optical fiber, POF). A PROFIBUS device cannot take part directly in PROFINET communication, but must be implemented by means of PROFIBUS master with PROFINET link or Industrial Ethernet/PROFIBUS link (IE/PB Link) with proxy functionality.

PROFIBUS devicePROFIBUS device Within the context of PROFINET, "device" is the generic term for: ● Automation systems (e.g. PLC, PC) ● Field devices (for example, PLC, PC, hydraulic devices, pneumatic devices) ● Active network components (for example, switches, gateways, routers) ● PROFIBUS or other fieldbus systems The main characteristics of a device is its integration into PROFINET communication by means of Ethernet or PROFIBUS. The following device types are distinguished based on their attachment to the bus: ● PROFINET devices ● PROFIBUS devices A PROFIBUS device has at least one PROFIBUS link with an electric interface (RS485) or an optical interface (polymer optical fiber, POF). A PROFIBUS device cannot take part directly in PROFINET communication, but must be implemented by means of PROFIBUS master with PROFINET link or Industrial Ethernet/PROFIBUS link (IE/PB Link) with proxy functionality.

PROFIBUS DP A PROFIBUS with the DP protocol that complies with EN 50170. DP stands for distributed peripheral (IO) = fast, real-time, cyclic data exchange. From the perspective of the user program, the distributed IOs are addressed in exactly the same way as the central IOs.

PROFINET Within the framework of Totally Integrated Automation (TIA), PROFINET is the consistent further development of:

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● PROFIBUS DP, the established fieldbus and ● Industrial Ethernet, the communication bus for the cell level. The experience gained from both systems was and is being integrated in PROFINET. PROFINET as an Ethernet-based automation standard from PROFIBUS International (previously PROFIBUS Users Organization) defines a vendor-independent communication, automation, and engineering model.

PROFINET ASIC → ASIC

PROFINET CBA As part of PROFINET, PROFINET CBA (Component Based Automation) is an automation concept that focuses on the following: ● Implementation of modular applications ● Machine - machine communication PROFINET CBA lets you create distributed automation solutions, based on default components and partial solutions. This concept meets the demand for a greater modularity in the field of mechanical and systems engineering by extensive distribution of intelligent processes. With Component Based Automation you can implement complete technological modules as standardized components that can be used in large systems. You create the modular, intelligent components of the PROFINET CBA in an engineering tool (which may differ according to the device manufacturer). Components that are formed from SIMATIC devices are created with STEP 7, and are interconnected using the SIMATIC iMAP tool.

PROFINET Component A PROFINET component includes the entire data of the hardware configuration, the parameters of the modules, and the corresponding user program. The PROFINET component is made up as follows: ● Technological Function The (optional) technological (software) function includes the interface to other PROFINET components in the form of interconnectable inputs and outputs. ● Device The device is the representation of the physical programmable controller or field device including the I/O, sensors and actuators, mechanical parts, and the device firmware.

PROFINET device → PROFIBUS device

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Glossary

PROFINET device A PROFINET device always has at least one Industrial Ethernet port. A PROFINET device can also have a PROFIBUS port, that is, as master with proxy functionality.

PROFINET IO As part of PROFINET, PROFINET IO is a communication concept that is used to implement modular, distributed applications. PROFINET IO allows you to create automation solutions, which are familiar to you from PROFIBUS. PROFINET IO is implemented using the PROFINET standard for programmable controllers. The STEP 7 engineering tool helps you to structure and configure an automation solution. In STEP 7 you have the same application view, regardless of whether you are configuring PROFINET devices or PROFIBUS devices. You will program your user program in the same way for both PROFINET IO and PROFIBUS DP since you will use the extended blocks and system status lists for PROFINET IO.

PROFINET IO controller Device used to address the connected IO devices. This means that the IO controller exchanges input and output signals with assigned field devices. The IO controller is often the controller on which the automation program runs.

PROFINET IO device A decentralized field device that is assigned to one of the IO controllers (e.g. remote IO, valve terminals, frequency converters, switches)

PROFINET IO Supervisor Programming device, PC or HMI device used for commissioning and diagnostics.

PROFINET IO system PROFINET IO controller with assigned PROFINET IO devices.

Programmable logic controller Programmable controllers (PLCs) are electronic controllers whose function is stored as a program in the control unit. The structure and wiring of the device does not therefore depend on the controller's function. A programmable logic controller is structured like a computer. It consists of a CPU with memory, input/output modules and an internal bus system. The IOs and the programming language are oriented to control engineering needs.

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Glossary

Programming device Programming devices are essentially compact and portable PCs which are suitable for industrial applications. They are identified by a special hardware and software for programmable logic controllers.

Proxy → PROFINET device

Proxy The PROFINET device with proxy functionality is the substitute for a PROFIBUS device on Ethernet. The proxy functionality allows a PROFIBUS device to communicate not only with its master but also with all nodes on PROFINET. With PROFINET, existing PROFIBUS systems can be integrated into the PROFINET communication with the aid of an IE/PB link, for example. The IE/PB link then handles communication via PROFINET on behalf of the PROFIBUS components. In this way, you can link both DPV0 and DPV1 slaves to PROFINET.

Proxy → Proxy

Proxy functionality → Proxy

RAM → Memory Card (MC)

RAM RAM (Random Access Memory) is a semiconductor read/write memory.

Real Time Real time means that a system processes external events within a defined time. Determinism means that a system reacts in a predictable (deterministic) manner. In industrial networks, both these requirements are important. PROFINET meets these requirements. PROFINET is implemented as a deterministic real-time network as follows:

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Glossary

● The transfer of time-critical data between different stations over a network within a defined interval is guaranteed. To this end, PROFINET has an optimized communication channel for real-time communication: real time (RT): Real Time (RT). ● An exact prediction of the time at which the data transfer takes place is possible. ● It is guaranteed that problem-free communication using other standard protocols, for example industrial communication for a programming device / PC, can take place within the same network.

Real Time → Real Time

Reduction factor The reduction rate determines the send/receive frequency for GD packets on the basis of the CPU cycle.

Reference ground → Ground

Reference potential Voltages of participating circuits are referenced to this potential when they are viewed and/or measured.

Restart On CPU start-up (e.g. after is switched from STOP to RUN mode via selector switch or with POWER ON), OB100 (restart) is initially executed, prior to cyclic program execution (OB1). On restart, the input process image is read in and the STEP 7 user program is executed, starting at the first instruction in OB1.

Retentive memory A memory area is considered retentive if its contents are retained even after a power loss and transitions from STOP to RUN. The non-retentive area of memory flag bits, timers and counters is reset following a power failure and a transition from the STOP mode to the RUN mode. Retentive can be the: ● Bit memory ● S7 timers ● S7 counters ● Data areas

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Router A router interconnects two subnets. A router works in a similar way to a switch. You can also enable/disable nodes for communication at the router. The communication nodes on various sides of a router can only communicate with one another if you have explicitly enabled communication between these nodes via the router. Real-time data cannot be exchanged beyond subnet boundaries.

Router → Default Router

Router → Switch

RT → Real Time

Runtime error Errors occurred in the PLC (that is, not in the process itself) during user program execution.

Scan cycle check point The cycle control point is the section of the CPU program processing in which the process image is updated.

Segment → Bus segment

Send clock Period between two successive intervals for IRT or RT communication. The send clock is the shortest possible transmit interval for exchanging data. The calculated update times are multiples of the send clock. The minimum possible update time thus depends on the minimum send clock of the IO controller that can be set. If both the IO controller and the IO device support a send clock of 250 µs, you can achieve a minimum update time of 250 µs. It is also possible to operate IO devices that only support a send clock of 1 ms on an IO controller that works with a send clock of 250 µs. The minimum update time for the IO devices concerned is then at least 1 ms, however.

SFB → System function block

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Glossary

SFC → System function

Signal module Signal modules (SM) form the interface between the process and the PLC. There are digital input and output modules (input/output module, digital) and analog input and output modules. (Input/output module, analog)

SIMATIC The term denotes Siemens AG products and systems for industrial automation.

SIMATIC NCM PC SIMATIC NCM PC is a version of STEP 7 tailored to PC configuration. For PC stations, it offers the full range of functions of STEP 7. SIMATIC NCM PC is the central tool with which you configure the communication services for your PC station. The configuration data generated with this tool must be downloaded to the PC station or exported. This makes the PC station ready for communication.

SIMATIC NET Siemens Industrial Communication division for Networks and Network Components.

SIMATIC PC Station A "PC station" is a PC with communication modules and software components within a SIMATIC automation solution.

Slave A slave can only exchange data after being requested to do so by the master.

SNMP SNMP (Simple Network Management Protocol) makes use of the connectionless UDP transport protocol. It consists of two network components, similar to the client/server model. The SNMP manager monitors the network nodes and the SNMP agents collect the various network-specific information in the individual network nodes and stores it in a structured form in the MIB (Management Information Base). This information allows a network management system to run detailed network diagnostics.

STARTUP A START-UP routine is executed at the transition from STOP to RUN mode. Can be triggered by means of the mode selector switch, or after power on, or by an operator action on the programming device. An S7-300 performs a restart.

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Glossary

STEP 7 STEP 7 is an engineering system and contains programming software for the creation of user programs for SIMATIC S7 controllers.

Subnet mask The bits set in the subnet mask decides the part of the IP address that contains the address of the subnet/network. In general: ● The network address is obtained by an AND operation on the IP address and subnet mask. ● The node address is obtained by an AND NOT operation on the IP address and subnet mask.

Subnetwork All the devices connected by switches are located in the same network - a subnet. All the devices in a subnet can communicate directly with each other. All devices in the same subnet have the same subnet mask. A subnet is physically restricted by a router.

Substitute value Substitute values are configurable values which output modules transfer to the process when the CPU switches to STOP mode. In the event of an I/O access error, a substitute value can be written to the accumulator instead of the input value which could not be read (SFC 44).

Switch PROFIBUS is based on a bus topology. Communication nodes are connected by a passive cable - the bus. In contrast, Industrial Ethernet is made up of point-to-point links: Each communication node is connected directly to one other communication node. If a communication node needs to be connected to several other communication nodes, this communication node is connected to the port of an active network component- a switch. Other communications nodes (including switches) can then be connected to the other ports of the switch. The connection between a communication node and the switch remains a point-to-point link. The task of a switch is therefore to regenerate and distribute received signals. The switch "learns" the Ethernet address(es) of a connected PROFINET device or other switches and forwards only the signals intended for the connected PROFINET device or connected switch. A switch has a certain number of ports). At each port, connect a maximum of one PROFINET device or a further switch.

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Glossary

System diagnostics System diagnostics refers to the detection, evaluation, and signaling of errors that occur within the PLC, for example programming errors or module failures. System errors can be indicated by LEDs or in STEP 7.

System function A system function (SFC) is a function that is integrated in the operating system of the CPU and can be called in the STEP 7 user program, when necessary.

System function block A system function block (SFB) is a function block integrated in the CPU operating system that can be called in the STEP 7 user program when required.

System memory System memory is an integrated RAM memory in the CPU. System memory contains the address areas (e.g. timers, counters, flag bits) and data areas that are required internally by the operating system (for example, communication buffers).

System memory → Counter

System memory → Timers

System status list The system status list contains data that describes the current status of a SIMATIC S7. You can always use this list to obtain an overview of the following points: ● Status of the SIMATIC S7 extension. ● The current CPU configuration and configurable signal modules. ● The current states and processes in the CPU and in configurable signal modules.

Terminating resistor The terminating resistor is used to avoid reflections on data links.

Timer → Timers

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Glossary

Timers Timers are part of CPU system memory. The content of timer cells is automatically updated by the operating system, asynchronously to the user program. STEP 7 instructions are used to define the precise function of the timer cell (for example, on-delay) and to initiate their execution (for example, start).

TOD interrupt → Interrupt, time-of-day

Token Allows access to the bus for a limited time.

Tool changer → Changing IO devices during operation (changing partner ports)

Topology Network structure. Commonly used structures: ● Bus topology ● Ring topology ● Star topology ● Tree topology

Transmission rate Data transfer rate (in bps)

Twisted-pair Fast Ethernet over twisted-pair cables is based on the IEEE 802.3u standard (100 base TX). The transmission medium is a shielded 2x2 twisted-pair cable with an impedance of 100 Ohm (AWG 22). The transmission characteristics of this cable must meet the requirements of category 5 (see glossary). The maximum length of the connection between the terminal and the network component must not exceed 100 m. The cables are wired according to the 100 base TX standard using the RJ45 connector system.

Ungrounded Having no direct electrical connection to ground

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Glossary

Update time Within this time interval an IO device/IO controller in the PROFINET IO system is supplied with new data by the IO controller/IO device. The send cycle can be configured separately for each IO device and determines the interval at which data are sent from the IO controller to the IO device (outputs) as well as data from the IO device to the IO controller (inputs).

User program In SIMATIC, we distinguish between the operating systems of the CPU and user programs. The user program contains all instructions, declarations and data for signal processing required to control a plant or a process. It is assigned to a programmable module (for example CPU, FM) and can be structured in smaller units (blocks).

Varistor Voltage-dependent resistor

WAN Wide Area Network. Network beyond LAN boundaries which allows, for example, intercontinental communication. Legal rights do not belong to the user but to the provider of the communication network.

Work memory The working memory is integrated in the CPU and cannot be extended. It is used to run the code and process user program data. Programs only run in the working memory and system memory.

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Index ( (PtP, 53

A Accessories, 92 for wiring, 101 Actuator/Sensor Interface, 53, 90 Addresses Analog module, 128 Digital module, 126 Technological functions, 129 Addressing Addressing PROFINET IO, 132 On PROFIBUS DP, 131 slotspecific, 123 Analog module Addresses, 128 Application in industrial environments, 232 in residential areas, 232 Application View, 76, 81 Approval CE, 229 CSA, 230 FM, 230 Marine, 231 UL, 229 Approvals Standards, 229 Arrangement of the modules, 31 ASI, 53 Assembly dimensions of the modules, 28 Asynchronous error, 194 Automation concept, 53, 76

Bus cables Installation rules, 64 Bus connector, 65 Connecting the bus cable, 120 removing, 121 Setting the terminating resistor, 121 Bus connector Connecting to module, 121 Bus connectors plugging, 97 Bus termination, 69 Bus topology Detection, 197

C Cabinet Dimensions, 36 power loss dissipated, 38 Selecting and dimensioning, 35 Types, 37 Cable lengths longer, 62 maximum, 66 MPI subnet, 62 PROFIBUS subnet, 62 Stub cables, 63 Cable routing inside buildings, 253 Cable shielding, 249 Ground, 46 Cables Preparing, 108 shield, 249 Category, 271 CE Approval, 229 Central unit, 26 Clock synchronization DP interface, 60, 61 MPI interface, 58 PROFIBUS DP Interface, 60

B Back up Operating system, 176 Basic knowledge required, 3 Burst pulses, 233

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ITEM 3000 Index

Commissioning Check list, 136 CPU 31x-2 DP as a DP master, 157 CPU 31x-2 DP as a DP slave, 161, 212 CPU 31xC-2 DP as a DP master, 157 CPU 31xC-2 DP as a DP slave, 161 Hardware Requirements, 133 Procedure with the hardware, 134 Procedure with the software, 135 PROFINET IO, 168 Reaction to errors, 136 Software requirement, 135 Commissioning the CPU as DP master Constant Bus Cycle Time, 159 Isochronous Updating of Process Image Partitions, 159 Sync/Freeze, 160 Communications concept, 53, 76 Component based Automation, 53 Component Based Automation, 76 Connecting PG, 145, 146, 147, 148, 150 Sensors and actuators, 107 Spring terminals, 107 Connecting actuators, 107 Connecting cables for interface modules, 32 Connecting sensors, 107 Consistency, 131, 132 Continuous shock, 237 Controlling of tags, 192 CP 343-1, 79 CP 443-1 Advanced, 79 CPU CPU memory reset, 141, 144 Wiring, 105 CPU 313C-2 DP commissioning as a DP master, 158 commissioning as DP-Slave, 162 CPU 314C-2 DP commissioning as a DP master, 158 commissioning as DP-Slave, 162 CPU 315-2 DP commissioning as a DP master, 158 commissioning as DP-Slave, 162 CPU 317-2 DP commissioning as a DP master, 158 CPU memory reset, 141 CPU activities, 143 MPI parameters, 143 CSA Approval, 230

304

D Data consistency, 131, 132 Default addressing, 123 Definition Electromagnetic compatibility, 233 Degree of protection IP 20, 238 Delivery state of the CPU Lamp images during reset, 183 Properties, delivery state, 182 Restore delivery state, 182 Device-specific diagnostics, 222 Diagnostic address, 209, 214 with direct data exchange, 211 Diagnostic buffer, 196 Diagnostics configured address range, 220 device-specific, 222 in DP Master mode, 208 with Diagnosing Hardware, 198 with LEDs, 201 with system functions, 197 Digital module Addresses, 126 Digital output module Replacement fuse, 187 Replacing fuses, 188 Direct data exchange, 166 DP interface Clock synchronization, 60, 61 DP master, 73 Class 2, 73 Interrupts, 216 DP master system, 73 DP slave, 73

E Electromagnetic compatibility, 233 Electrostatic discharge, 233 EMC, 233 Definition, 241 Fault-free installation, 245 Emission of radio interference, 234 Engineering tool, 76 Equipotential bonding, 251 Equipotential bonding - lightning protection, 259, 260 Equipotential bonding conductor, 46 Error Asynchronous, 194 Synchronous, 194 Error-free operation of the S7-300, 239 Event detection, 210, 215 Expansion module, 26

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ITEM 3000 F F system, 271 Fail-safe system, 271 Fieldbus integration, 75 FM Approval, 230 Forcing, 193 Front connector coding Removing from front connector, 186 Removing from module, 185 Front connectors encoding, 110 plugging, 110 Preparing, 108 Wiring, 102, 109 Full assembly, 34

G General technical data, 229 Ground bonding for EMC-compliant installation, 245 Grounding Grounding, 48 Grounding concept, 43 GSD file, 79

H Highest MPI address, 55 Highest PROFIBUS DP address, 55 HMI, 73

I I&M data, 190 Identification, 207 Identification and maintenance data, 190 Identification code for Australia, 231 Identification data, 190 Identifier-related diagnostic data, 220 IE/PB link, 76 IEC 61131, 231 Industrial Ethernet, 53, 73 Inscription labels, 92 installation arranging modules, 31 horizontal, 27 vertical, 27

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Index

Installation in cabinets, 35 of the modules, 97 ungrounded reference potential, 42 Installation grounded reference potential, 41 Installing of the modules, 185 Installing EMC plants, 241 Insulation test, 238 Interconnection, 75 Interface module Connecting cables, 32, 172 Interfaces MPI interface, 57 MPI interface:Connectable devices, 57 PROFIBUS DP interface, 59 PROFIBUS DP interface:Operating modes with two DP interfaces, 59 PtP interface, 90 Interfaces PROFIBUS DP interface Connectable devices, 60 Interferences electromagnetic, 241 Interrupt on the DP master, 216 IO controller, 73 IO device, 73 IO supervisor, 73 IO system, 73

L Labeling strips Assignment to modules, 116 inserting, 116 Lightning protection S7-300, 256 Lightning protection equipotential bonding, 259, 260 Lightning protection zone concept, 257 Lightning protector, 262, 264 Load circuit Ground, 46 Load current determining, 50 Load power supply from PS 307, 51 Load voltage Connecting the reference potential, 47 Local equipotential bonding, 262, 264

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ITEM 3000 Index

M Mains grounded, 39 Mains voltage Selecting the mains voltage, 104 Mains voltage selector switch, 104 Maintenance data, 190 Manufacturer ID, 219 Marine Approval, 231 Material Structure, 92 Mechanical environmental conditions, 236 MIB, 199 Micro Memory Card, 138 Formatting, 144 Inserting and removing when power is switched off, 139 Inserting/removing, 139 Module Arrangement, 31, 33 Assembly dimensions, 28 installing, 185 Installing, 97 isolated, 43 labeling, 116 non-isolated, 43 removing, 184 replacing, 183 Replacing, 96 Start addresses, 123 Module replacement Reaction of the S7-300, 186 Rules, 96, 183 Monitoring of tags, 192 Monitoring and modifying tags Creating a tag table, 152 establishing a connection to the CPU, 154 Modifying outputs in CPU STOP mode, 155 modifying tags, 153 Monitor tag, 152 opening the VAT, 154 Saving the variable table, 154 setting the trigger points, 153 Mounting rail connecting the protective conductor, 103 Fixing screws, 94 Ground conductor, 93 Length, 28 mounting holes, 94 Preparing, 93

306

MPI, 52 Maximum number of nodes, 55 Maximum transmission rate, 54 MPI address default, 55 highest, 55 Recommendation, 56 Rules, 55 MPI and PROFIBUS subnet, 71 MPI interface, 57 Clock synchronization, 58 MPI subnet Example, 67 maximum distances, 68 Segment, 62 Terminating resistor, 69 Multi-Point Interface, 52

O Open components, 91 Operating system Back up, 176 Outdoor routing of cables, 255 Overvoltage protection S7-300, 256

P PC, 79 PG Access to remote networks, 88 Connecting, 145, 146, 147, 148, 150 ungrounded configuration, 150 Point-to-point connection, 53 Potential differences, 46 Power on initial, 140 Requirements, 140 Power supply module Selecting the mains voltage, 104 PROFIBUS, 52, 73, 76 PROFIBUS address Recommendation, 56 PROFIBUS cable Properties, 64 PROFIBUS device, 72

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ITEM 3000 PROFIBUS DP Commissioning, 156 Direct data exchange, 166 DP address ranges, 156 DP diagnostics addresses, 157 Maximum number of nodes, 55 Maximum transmission rate, 54 PROFIBUS DP address default, 55 highest, 55 Rules, 55 PROFIBUS DP Interface, 59 PROFIBUS DP Interface Clock synchronization, 60 PROFIBUS subnet Cable lengths, 62 Example, 70 PROFIBUS terminator, 69 PROFINET, 53, 73, 76 CBA, 53 Commissioning, 168, 196 Commissioning via MPI/DP, 169 Commissioning via PN interface, 169 Configuring, 170 Environment, 72 Implementation, 76 IO, 53 Send clock, 81 Standard, 76 Update times, 80 Update times of CPU 319-3 PN/DP, 81 PROFINET CBA, 53, 76 PROFINET devices, 72 PROFINET diagnostics Evaluation, 226 Information, 225 Maintenance, 226 Maintenance information, 227 PROFINET IO, 53, 78 Commissioning, 168 Programming, 76 Protect digital output modules from inductive surge, 268 Protection class, 238 Protective conductor Connecting to the mounting rail, 93 Connecting to the rail, 103 Protective grounding measures, 45 Protective measures for the overall system, 40 Proxy, 76 Proxy functionality, 76 CPU 31xC and CPU 31x: Installation Operating Instructions, 02/2009, A5E00105492-09

Index

PtP interface, 90 Pulse-shaped disturbance, 233 Purpose of this documentation, 3

R Redundancy, 271 Redundant system, 271 Reference potential grounded, 41 ungrounded, 42 Removing of the modules, 184 Replacing Fuses, 188 Module, 96, 183 Replacing fuses Digital output module, 188 Routing, 88 Routing an equipotential bonding conductor, 251 RS 485 Bus connector, 65 RS 485 repeater, 65 Rules and regulations for error-free operation, 239

S S7 Distributed Safety, 271 S7 F/FH Systems, 271 S7-300 initial power on, 140 Lightning protection, 256 Overvoltage protection, 256 S7-300 configuration Components, 22 Example, 21 Safety integrity level, 271 Scope of the manual, 3 Scope of this documentation, 11 Segment, 54 in the MPI subnet, 62 on the PROFIBUS subnet, 62 Service data Application, 189 Procedure, 189 SF LED, evaluation, 202 SFB52, 197 SFC 103, 65, 197 SFC 13, 197 SFC 51, 197 SFC 6, 197

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ITEM 3000 Index

SFC14, 131, 132 SFC15, 131, 132 Shielding contact element, 29, 117 installing, 118 Terminating cables, 119 Shielding terminals, 29 Shipping conditions, 235 Shock, 237 SIL, 271 SIMATIC iMap, 76 SIMATIC Manager, 151 start, 151 SIMOTION, 79 Sinusoidal disturbance, 234 Slave diagnostics installation, 217 Reading, example, 212 Slot number label, 92 Slot numbers Assigning, 98 Mounting, 99 SNMP, 200 MIB, 199 Network diagnostics, 199 SOFTNET PROFINET, 79 Standards and certifications, 229 Startup CPU 31x-2 DP as a DP master, 158 CPU 31x-2 DP as a DP master, 173 CPU 31x-2 DP as a DP slave, 162 CPU 31xC-2 DP as a DP master, 158, 173 CPU 31xC-2 DP as a DP slave, 162 Station status, 218 stepping mode, 192 Storage conditions, 235 Strain relief, 109 Stub cables Length, 63 Subnet, 52 SYNC/FREEZE, 160 Synchronous error, 194

Terminating resistor MPI subnet, 69 Setting the bus connector, 121 Test voltage, 238 Tools Structure, 92 Transfer memory, 163 Troubleshooting, 194

U UL

Approval, 229 Ungrounded configuration connecting a PG, 150 Update Requirements, 177 Via network, 179 Update using a network Requirements, 179 Update via Micro Memory Card, 178

V Vibration, 237

W WinLC, 79 Wiring Accessories required, 101 Front connectors, 109 Front Connectors, 102 PS and CPU, 105 Tools and materials required, 101

T Tags Controlling, 192 Forcing, 193 Monitoring, 192 Technical data Electromagnetic compatibility, 233 Shipping and storage conditions, 235 Temperature, 235

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ITEM 4510

MODEL 278

AC Current Transducer l High accuracy, low cost l Isolated input and output l Socket-mounted, solid-state design l Five year unconditional warranty

DESCRIPTION

SPECIFICATIONS

The Model 278 AC Current Transducer is designed to accept an AC current input, and provide a proportional DC current output. A linear transformer input is coupled to a solid-state output amplifier. The Model 278 is powered by a 115 VAC source, and is socket-mounted for ease of use.

MODEL

Model 278 Current Transducers can be used with computer and programmable controls to provide:

Input burden

- Motor and power control - Supervisory data acquisition - Load monitoring - Feedback control - Energy management

A278

Supply voltage Input current Input frequencies

Output accuracy Output ripple Response time

1.95"

3.25"

0-5 amps

25-400 Hz

0-1ma 10k ohms

60 Hz

4-20ma

4-20ma

500 ohms

500 ohms

2% at 77°F 1% max at nominal frequency 800 msec from 0-99%

Overload withstand

2 times rated output-continuous 10 times rated input-1 second

Dielectric withstand voltage (isolation)

1500 VRMS input, output, case

Operating temperature

DIMENSIONS

1-5 amps

0.5VA at 120VAC

Output @ rated input

C278

115VAC @ 50/60 Hz 0-5 amps

Maximum load

The Model 278 is available in three standard input/output configurations.

B278

-40° to +131°F

Humidity tolerance

0-97% w/o condensation

Enclosure material

ABS plastic

Mounting Weight

8-pin socket (*order separately) 6 oz. *Order 8-pin socket number 51X120

1.95"

Access Control Sales 6110 Ordan Drive, Unit 9 Mississauga, Ontario Canada L5T 2B4 E-Mail: [email protected]

Access Control Sales Tel: 905 564-1472 Fax: 905 564-3349 Toll Free: 1-800-567-1041 Web Site: www.accesscontrolsales.com

MODEL 278

ITEM 4510

AC Current Transducer

READ ALL INSTRUCTIONS BEFORE INSTALLING, OPERATING OR SERVICING THIS DEVICE.

KEEP THIS DATA SHEET FOR FUTURE REFERENCE.

GENERAL SAFETY POTENTIALLY HAZARDOUS VOLTAGES ARE PRESENT AT THE TERMINALS OF THE MODEL 278. ALL ELECTRICAL POWER SHOULD BE REMOVED WHEN CONNECTING OR DISCONNECTING WIRING. THIS DEVICE SHOULD BE INSTALLED AND SERVICED BY QUALIFIED PERSONNEL.

Installation Instructions TYPICAL APPLICATION

INSTALLATION The Model 278 AC Current Transducer requires an 8pin mounting socket, such as the Time Mark Model 51X120.

CT-Model 276-xxx

The base connecting diagram on the unit shows the pin connection numbers for the 115 volt power, the AC Current input, and the DC Current Out. Connect the appropriate wiring to the socket as required (See the Typical Application diagram).

PIN DRAWING

2

115 VAC

1

6

8

7

DC CURRENT OUT

6

8

4

1

3

2

DC Current Out

Model 278

7

5

3

115 VAC

AC CURRENT

NOTE: When installing the Model 278 Transducer in areas of high humidity or contamination, it is recommended that the base area and all exposed metal parts of the socket be coated liberally with a good quality silicon grease, such as Dow Corning DC-4 or DC-4X. Insert the unit into the socket and wipe off excess grease around the base. This will prevent the entrance of moisture and other contaminates into the base and socket areas.

Access Control Sales 6110 Ordan Drive, Unit 9 Mississauga, Ontario Canada L5T 2B4 E-Mail: [email protected]

TROUBLESHOOTING Should the Model 278 AC Current Transducer fail to operate properly, check that all voltage is present, and is of the correct voltage level. Check all fuses and verify that all wiring connections are correct. If problems persist, contact your local Time Mark Distributor, or the factory for assistance, MondayFriday, 8 a.m. to 5 p.m. CST.

WARRANTY The Model 278 AC Current Transducer is warranted to be free from defects in materials and workmanship, and is covered by our exclusive 5-year Unconditional Warranty. If this device fails to operate, for any reason, we will repair or replace it free, for five years from the date of purchase. Contact the Time Mark Sales department, Monday through Friday; 8 a.m. to 5 p.m., CST, for further details.

Access Control Sales Tel: 905 564-1472 Fax: 905 564-3349 Toll Free: 1-800-567-1041 Web Site: www.accesscontrolsales.com

ITEM 4510

MODEL 276 SERIES

Current Transformers l 25 to 400 HZ l 0 to 5 Amp Secondary l Wide Application Range l Agency Approved DESCRIPTION Model 276A Current Transformer - A low cost, openframe type current transformer (CT). For use with up to 8 gauge wire, and up to 40 amps on the primary. 2500 VRMS insulation is standard. Frequency range is 25-400 Hz. The Model 276A CT is CSA Certified.

SPECIFICATIONS Ratio

Part No.

Ratio

Part No. Burden

Ratio

Part No.

Burden

50:5

276B-50

1.0

300:5

276B-300

12.5

10:5

276A-10

60:5

276B-60

1.0

400:5

276B-400

12.5

15:5

276A-15

75:5

276B-75

1.5

500:5

276B-500

25.0

Model 276B Current Transformer - A ring-type current transformer for currents from 50 to 1200 amps. The Model 276B has an accuracy rating of ± 2% for 50-100 amp CT’s and ± 1% over 100 amps at 60 Hz.

20:5

276A-20

80:5

276B-80

1.5

600:5

276B-600

15.0

25:5

276A-25

100:5

276B-100

2.0

750:5

276B-750

7.0

30:5

276A-30

150:5

276B-150

5.0

800:5

276B-800

8.0

35:5

276A-35

200:5

276B-200

5.0

1000:5 276B-1000

10.0

This CT also features a 25-400 Hz frequency range, #8-32 secondary terminals and mounting brackets. Polarity markings are stamped on the CT. The Model 276B is UL Recognized and CSA Certified.

40:5

276A-40

250:5

276B-250

12.5

1200:5 276B-1200

12.5

Burden VA @ 60 Hz

276A DIMENSIONS 2.38"

276A APPLICATION DIAGRAM Model 276A One primary turn Loop one leg of AC line thru transformer

.19" dia. typ.

.43"

1.95"

1.25" Space for primary turn :0 .25" x 0.38" Secondary

1.63"

276B DIMENSIONS 4.50"

276B APPLICATION DIAGRAM

3.88" 1.25"

Model 276B One primary turn

B 0.44"

3.90"

2.00"

CL

Telephone: Main - (918) 438-1220 Sales - (800) 862-2875 Fax: (918) 437-7584 E-mail: Internet:

[email protected] http://www.time-mark.com

11440 East Pine Street Tulsa, Oklahoma 74116 Doc No. 87A013 12/00 © 2000 TIME MARK CORPORATION TIME MARK is a division of

MODEL 276

ITEM 4510

Current Transformers

READ ALL INSTRUCTIONS BEFORE INSTALLING, OPERATING OR SERVICING THIS DEVICE.

KEEP THIS DATA SHEET FOR FUTURE REFERENCE.

GENERAL SAFETY POTENTIALLY HAZARDOUS VOLTAGES ARE PRESENT AT THE TERMINALS OF THE MODEL 276. ALL ELECTRICAL POWER SHOULD BE REMOVED WHEN CONNECTING OR DISCONNECTING WIRING. THIS DEVICE SHOULD BE INSTALLED AND SERVICED BY QUALIFIED PERSONNEL.

Installation Instructions PRIMARY TURN RATIO MODIFICATION The nameplate ratio of the current transformer is based on the condition that the primary conductor will be passed once through the transformer window. This rating can be reduced in even multiples by looping the conductor two or more times through the window. A transformer having a rating of 200 to 5 amps will be changed to 50 to 5 amps if four loops or turns are made with the primary cable as illustrated. 1 Primary Turn Nameplate Ratio 100:5 150:5 200:5 300:5

Actual Ratio 100:5 150:5 200:5 300:5

Nameplate Ratio 100:5 150:5 200:5 300:5

Actual Ratio 50:5 75:5 100:5 150:5

Nameplate Ratio 400:5 500:5 600:5 800:5

Actual Ratio 400:5 500:5 600:5 800:5

The ratio of the current transformer can be modified by altering the number of secondary turns by forward or back-winding the secondary lead through the window of the CT. By adding secondary turns the same primary amperage will result in a decrease in secondary output. By subtracting secondary turns the same primary amperage will result in greater secondary output. Again using the 300:5 example, adding 5 secondary turns will require 325 amps on the primary to maintain the 5 amp secondary output, or

325p 65s 5s 1p

Deducting 5 secondary turns will only require 275 amps on the primary to maintain the 5 amp secondary output, or

275p 55s 5s 1p

2 Primary Turns Nameplate Ratio 400:5 500:5 600:5 800:5

Actual Ratio 200:5 250:5 300:5 400:5

4 Primary Turns Nameplate Ratio 100:5 150:5 200:5 300:5

SECONDARY MODIFICATION Formula: Where:

Example:

Actual Ratio 25:5 37.5:5 50:5 75:5

Nameplate Ratio 400:5 500:5 600:5 800:5

TURN

Actual Ratio 100:5 125:5 150:5 200:5

RATIO

The above ratio modifications are achieved in the following manner.

•

•

To add secondary turns, the white lead should be wound through the CT from the side opposite the polarity mark.

To subtract secondary turns, the white lead should be wound through the CT from the same side as the polarity mark.

Ip Ns Is Np

Ip - Primary amperage Is - Secondary amperage Np - Number of primary turns Ns - Number of secondary turns A 300:5 current transformer

300p 60s 5s 1p

X2 BLACK LEAD X1 WHITE LEAD

INCOMING POWER POLARITY MARKING

TURNS ARE COUNTED IN THIS WINDOW

X2 BLACK LEAD X2 WHITE LEAD

INCOMING POWER POLARITY MARKING

TURNS ARE COUNTED IN THIS WINDOW

WARRANTY The Model 276 Series Current Transformers are warranted to be free from defects in materials and workmanship for one year. Should the device fail to operate, we will repair or replace it for one year from the date of purchase. For complete warranty details, see the Terms and Conditions of Sales page in the front section of the Time Mark catalog.

(in practicality, one turn is dropped from the secondary as a ratio correction factor).

Telephone: Main - (918) 438-1220 Sales - (800) 862-2875 Fax: (918) 437-7584 E-mail: Internet:

[email protected] http://www.time-mark.com

11440 East Pine Street Tulsa, Oklahoma 74116 Doc No. 87A013 12/00 © 2000 TIME MARK CORPORATION TIME MARK is a division of

Document Name: 4607T-FOUND Rev A

ITEM J CENTER OF GRAVITY CALCULATIONS (SI UNITS) JOB NUMBER:

4607T

J0B NAME:

PAUL WURTH

BLOWER MODEL:

KA66S-GL400

1150 mm

Y

Z

X

1480mm INPUTS: Total Weight

OUTPUTS: 15,914 kg.

TURBLEX P/N:

71188

C.G. X'

-8 mm

RATED LOAD/UNIT

1,361 kg.

C.G. Y'

1102 mm

LOAD/ISO

1,137 kg.

C.G. Z'

-1611 mm

Base length

3962 mm

Motor Horsepower

2,983 kw

COMPRESSIVE STRESS/ISO TARGET LOAD PERCENTAGE PER VIBRATION ISOLATOR ACTUAL LOAD PERCENTAGE PER VIBRATION ISOLATOR QTY of ISO's USED

Motor RPM

3,600 RPM

Isolator Model/Size

XLW-3000

QTY of ISO's/SIDE

288.20 kPa 85% 84% 14 7

ISOLATOR LOCATIONS: LAST ISOLATOR

3861 mm

1st ISOLATOR

102 mm

2nd ISOLATOR

556 mm

3rd ISOLATOR

1009 mm

4th ISOLATOR

1463 mm

5th ISOLATOR

1917 mm

6th ISOLATOR

2371 mm

7th ISOLATOR

0 mm

Note: Load percentage per Vibration Isolator is acceptable.

DOCUMENT NAME: 4607T INST LIST REV D

VENDOR

TURBLEX TID

TURBLEX P&ID

UNIT 1 CUSTOMER TAG UNIT 2 CUSTOMER TAG UNIT 3 CUSTOMER TAG INSTRUMENT TYPE NUMBER NUMBER NUMBER

TAG DESCRIPTION

MANUFACTURER

MODEL

FLUID TYPE

WET MATERIAL TYPE

ELEMENT LENGTH

ENCLOSURE CLASSIFICATION

Alarm (LL)

Alarm (L)

Alarm (H)

Alarm (HH)

RANGE

FRAMO

FOR COMPRESSOR KA66

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

FULL CLOSED TO FULL OPEN

ZERO VALUE

SPAN

ENGINEERING UNITS

MAX TEMP AMBIENT

CONNECTION SIZE

REV

REV DATE

REMARKS

INSTRUMENTATION 0010

4607T- PD02B01, PD02B02, PD02B03

TURBLEX

0520

4607T- PD02B01, PD02B02, PD02B03

AF1-SOP-VV-BOFF1

TURBLEX

0530

4607T- PD02B04

AF1-SOP-VV-BRBA-01

TURBLEX

0530

4607T- PD02B04

TURBLEX

0530

4607T- PD02B04

TURBLEX

0530

4607T- PD02B04

TURBLEX

0740

TURBLEX

0740

TURBLEX

TURBLEX

0770

TURBLEX

0775

TURBLEX

1110

TURBLEX

1110

TURBLEX

1110

TURBLEX

1110

TURBLEX

1120

TURBLEX

1140

TURBLEX

1140

TURBLEX

1190

TURBLEX

1190

TURBLEX

1270

TURBLEX

1270

TURBLEX

1270

TURBLEX

1270

TURBLEX

1270

TURBLEX

1280

TURBLEX

1280

TURBLEX

1290

TURBLEX

1290

TURBLEX

1290

TURBLEX

1340

TURBLEX

1340

TURBLEX

1350

TURBLEX

1355

TURBLEX

1370

TURBLEX

1375

TURBLEX

1395

TURBLEX

1410

TURBLEX

1420

TURBLEX

1430

TURBLEX

1435

TURBLEX

1520

TURBLEX

1540

TURBLEX

1540

TURBLEX

1830

TURBLEX

1830

TURBLEX

1820

TURBLEX

1910

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

2000

TURBLEX

4510

TURBLEX

4510

4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03 4607T- PD02B01, PD02B02, PD02B03

AF1-SOP-ZI-3101

AF2-SOP-ZI-3201 AF2-SOP-VV-BOFF1

AFC-SOP-ZI-3301 AFC-SOP-VV-BOFF1

TRANSMITTER

VARIABLE DIFFUSERS

VALVE ACTUATOR BLOW OFF VALVE ACTUATOR

AUMA

SAR07.5-54B/GS63.3

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

VALVE ACTUATOR DISCHARGE VALVE ACTUATOR

AUMA

SA10.1-26B/GS100.3

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

VALVE ACTUATOR DISCHARGE VALVE ACTUATOR

AUMA

SA10.1-26B/GS100.3

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

AFC-SOP-VV-BRBA-03

VALVE ACTUATOR CROSS OVER DISCHARGE VALVE ACTUATOR

AUMA

SA10.1-26B/GS100.3

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

AFC-SOP-VV-BRBA-04

VALVE ACTUATOR CROSS OVER DISCHARGE VALVE ACTUATOR

AUMA

SA10.1-26B/GS100.3

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

AF2-SOP-VV-BRBA-02

FULL CLOSED TO OPEN FULL CLOSED TO OPEN FULL CLOSED TO OPEN FULL CLOSED TO OPEN FULL CLOSED TO OPEN

FULL FULL FULL FULL FULL

TBD FOLLOWING TBD FOLLOWING DENMARK DENMARK PERFORMANCE PERFORMANCE TESTING TESTING

SCALE

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

-

4mA = CLOSED

100%

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

-

4mA = CLOSED

100%

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

-

4mA = CLOSED

100%

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

4mA = CLOSED

100%

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

-

4mA = CLOSED

100%

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-FILT-02

AF2-SOP-FILT-02

AFC-SOP-FILT-02

SWITCH/GAUGE

OIL FILTER, DUPLEX WITH VISUAL & ELECTRICAL INDICATOR

PARKER

DIL2210QMD35Y9Y91

OIL

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

2.41 bar G

NOT APPLICABLE

0 - 2.41 bar G

NOT APPLICABLE

NOT APPLICABLE

bar G

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-FILT-02

AF2-SOP-FILT-02

AFC-SOP-FILT-02

SWITCH/GAUGE

OIL FILTER, DUPLEX WITH VISUAL & ELECTRICAL INDICATOR

PARKER

DIL2110QMD35Y9Y91

OIL

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

2.41 bar G

NOT APPLICABLE

0 - 2.41 bar G

NOT APPLICABLE

NOT APPLICABLE

bar G

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

-

FLOW EZY FILTERS

AB-1010-13-G-DS-13-CH

OIL

NOT APPLICABLE

13"

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

148º C

NOT APPLICABLE

A

24-Jun-09

ASCO

8210B59

WATER

BRASS

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

52º C

NOT APPLICABLE

A

24-Jun-09

-

SIEMENS

7NG3211-0NN00-Z+C11+Y01

AIR

316 SS

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

49 ºC

54 ºC

0 to 54°C

4mA = 0 ºC

54

°C

85º C

1/2" NPT

C

20-Jul-09

-

AF1-SOP-LI-3101

AF2-SOP-LI-3201

AFC-SOP-LI-3301

AF1-SOP-SVO-3101

AF2-SOP-SVO-3201

AFC-SOP-SVO-3301

LEVEL INDICATOR OIL LEVEL INDICATOR

AF1-SOP-TT-3101

AF2-SOP-TT-3201

AFC-SOP-TT-3301

TRANSMITTER

SOLENOID VALVE WATER COOLER SOLENOID VALVE INLET TEMPERATURE #1

AF1-SOP-TT-3119

AF2-SOP-TT-3119

AFC-SOP-TT-3119

TRANSMITTER

INLET TEMPERATURE #2

SIEMENS

7NG3211-0NN00-Z+C11+Y01

AIR

316 SS

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

49 ºC

54 ºC

0 to 54°C

4mA = 0 ºC

54

°C

85º C

1/2" NPT

C

20-Jul-09

-

AF1-SOP-TE-3101

AF2-SOP-TE-3201

AFC-SOP-TE-3301

RTD

INLET TEMPERATURE #1

SMART SENSORS

CA-NUN-3-SS-6-R.1.75-PO14SR

AIR

316 SS

6"

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

260 º C

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-TE-3119

AF2-SOP-TE-3119

AFC-SOP-TE-3119

RTD

INLET TEMPERATURE #2

SMART SENSORS

CA-NUN-3-SS-6-R.1.75-PO14SR

AIR

316 SS

6"

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

260 º C

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-PDT-3103

AF2-SOP-PDT-3203

AFC-SOP-PDT-3303

TRANSMITTER

SIEMENS

7MF4433-1GA22-1AC1-Z+B11+C11+Y01

AIR

316 SS

NOT APPLICABLE

IP65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0-2.00 bar D

4mA = 0 bar

2

bar D

85º C

1/2-14"FNPT

C

1-Jul-09

-

COMPRESSOR DIFFERENTIAL PRESSURE

AF1-SOP-TT-3108

AF2-SOP-TT-3208

AFC-SOP-TT-3308

TRANSMITTER

OIL RESERVOIR TEMPERATURE

SIEMENS

7NG3211-0NN00-Z+C11+Y01

OIL

316 SS

NOT APPLICABLE

NEMA 4X

10 ºC

16 ºC

66 ºC

71 ºC

0 - 93 °C

4mA = 0 ºC

93

°C

85º C

3/4" NPT

B

1-Jul-09

-

AF1-SOP-TE-3108

AF2-SOP-TE-3208

AFC-SOP-TE-3308

RTD

OIL RESERVOIR TEMPERATURE

SMART SENSORS

CA-NUN-3-SSO-9-R.1.75-PO14SR

AIR

316 SS

9"

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-TT-3102

AF2-SOP-TT-3202

AFC-SOP-TT-3302

TRANSMITTER

ACOUSTICAL ENCLOSURE TRANSMITTER

ROSEMOUNT

7NG3211-0NN00-Z+C11+Y01

AIR

316 SS

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0 - 93 °C

4mA = 0 ºc

93

°C

85º C

NOT APPLICABLE

B

1-Jul-09

AFC-SOP-TE-3302

TRANSMITTER

ACOUSTICAL ENCLOSURE RTD

MINCO

S454PD

AIR

NOT APPLICABLE

5.6"

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

A

24-Jun-09

AF1-SOP-TT-3103

AF1-SOP-TE-3102

AF2-SOP-TT-3203

AF2-SOP-TE-3202

AFC-SOP-TT-3303

TRANSMITTER

COMPRESSOR BEARING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

90 º C

95 º C

0 - 148 °C

4mA = 0 ºC

148

°C

85º C

NOT APPLICABLE

B

1-Jul-09

-

AF1-SOP-TT-3104

AF2-SOP-TT-3204

AFC-SOP-TT-3304

TRANSMITTER

COMPRESSOR BEARING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

90 º C

95 º C

0 - 148 °C

4mA = 0 ºC

148

°C

85º C

NOT APPLICABLE

B

1-Jul-09

-

AF1-SOP-TT-3105

AF2-SOP-TT-3205

AFC-SOP-TT-3305

TRANSMITTER

COMPRESSOR BEARING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

90 º C

95 º C

0 - 148 °C

4mA = 0 ºC

148

°C

85º C

NOT APPLICABLE

B

1-Jul-09

-

AF1-SOP-TT-3106

AF2-SOP-TT-3206

AFC-SOP-TT-3306

TRANSMITTER

COMPRESSOR BEARING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

90 º C

95 º C

0 - 148 °C

4mA = 0 ºC

148

°C

85º C

NOT APPLICABLE

B

1-Jul-09

-

AF1-SOP-TT-3107

AF2-SOP-TT-3207

AFC-SOP-TT-3307

TRANSMITTER

COMPRESSOR BEARING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

90 º C

95 º C

0 - 148 °C

4mA = 0 ºC

148

°C

85º C

NOT APPLICABLE

B

1-Jul-09

-

AF1-SOP-TT-3109

AF2-SOP-TT-3209

AFC-SOP-TT-3309

TRANSMITTER

DRIVE END MOTOR BEARING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

90 º C

95 º C

0 - 148 °C

4mA = 0 ºC

148

°C

85º C

NOT APPLICABLE

B

1-Jul-09

-

AF1-SOP-TT-3117

AF2-SOP-TT-3217

AFC-SOP-TT-3317

TRANSMITTER

NON DRIVE END MOTOR BEARING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

90 º C

95 º C

0 - 148 °C

4mA = 0 ºC

148

°C

85º C

NOT APPLICABLE

B

1-Jul-09

-

AF1-SOP-TT-3111

AF2-SOP-TT-3211

AFC-SOP-TT-3311

TRANSMITTER

MOTOR WINDING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

160 º C

165 º C

0 - 204 °C

4mA = 0 ºC

204

°C

85º C

NOT APPLICABLE

C

6-Jul-09

-

AF1-SOP-TT-3112

AF2-SOP-TT-3212

AFC-SOP-TT-3312

TRANSMITTER

MOTOR WINDING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

160 º C

165 º C

0 - 204 °C

4mA = 0 ºC

204

°C

85º C

NOT APPLICABLE

C

6-Jul-09

-

AF1-SOP-TT-3113

AF2-SOP-TT-3213

AFC-SOP-TT-3313

TRANSMITTER

MOTOR WINDING RTD

SIEMENS

7NG3211-0NN00-Z+C11+Y01

EMBEDDED

100 OHM Pt

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

160 º C

165 º C

0 - 204 °C

4mA = 0 ºC

204

°C

85º C

NOT APPLICABLE

C

6-Jul-09

-

AF1-SOP-PDT-3101

AF2-SOP-PDT-3201

AFC-SOP-PDT-3301

TRANSMITTER

INLET FILTER 1ST STAGE DIFFERENTIAL PRESSURE

SIEMENS

7MF4433-1BA22-1AC6-Z+B11+C11+Y01

VACUUM

316 SS

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

.0025 bar D

NOT APPLICABLE

.001 - .02 bar D

4mA = .001 bar D

0.019

bar D

85º C

1/2-14" FNPT

D

20-Jul-09

-

AF1-SOP-PDT-3102

AF2-SOP-PDT-3202

AFC-SOP-PDT-3302

TRANSMITTER

INLET FILTER 2ND STAGE DIFFERENTIAL PRESSURE

SIEMENS

7MF4433-1BA22-1AC6-Z+B11+C11+Y01

VACUUM

316 SS

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

.0037 bar D

NOT APPLICABLE

.001 - .02 bar D

4mA = .001 bar D

0.019

bar D

85º C

1/2-14" NPT

D

20-Jul-09

-

AF1-SOP-PSL-3101

AF2-SOP-PSL-3201

AFC-SOP-PSL-3301

SWITCH

OIL (LL) PRESSURE

UE

H100-702, M540, M201

OIL

316 SS

NOT APPLICABLE

NEMA 4X

1.03 bar G

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0 - 6.89 bar G

NOT APPLICABLE

NOT APPLICABLE

bar G

71º C

1/4 " NPTF

A

24-Jun-09

-

AF1-SOP-PT-3101

AF2-SOP-PT-3201

AFC-SOP-PT-3301

TRANSMITTER

OIL (L) PRESSURE

SIEMENS

MF4033-1DA10-1AC6-Z+B11+A02+C11+Y0

OIL

316 SS

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

2 bar G

NOT APPLICABLE

NOT APPLICABLE

0 - 11 bar G

4mA = 0 bar G

11

bar G

71º C

1/2 " NPTF

C

20-Jul-09

-

AF1-SOP-PSH-3101

AF2-SOP-PSH-3201

AFC-SOP-PSH-3301

SWITCH

SURGE

TURBLEX

SUC III

VACUUM

316 SS

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

70º C

1/2" NPT

A

24-Jun-09

-

AF1-SOP-LSL-3101

AF2-SOP-LSL-3201

AFC-SOP-LSL-3301

SWITCH

OIL RESERVOIR LEVEL

THOMAS PROD.

4000-4084SPST

OIL

BRASS, SS

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

148 ºC

2" NPT

A

24-Jun-09

-

AF1-SOP-XS-3101

AF2-SOP-XS-3201

AFC-SOP-XS-3301

SWITCH

ZERO SPEED

TELEMACANIQUE

XS1M18MA250

NOT APPLICABLE

316 SS

N/A

IP 65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

70º C

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-TI-3101

AF2-SOP-TI-3201

AFC-SOP-TI-3301

GAUGE

INLET TEMPERATURE

ASHCROFT

50EI-60E060XCS

AIR

BRASS

6"

IP 65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0- 93 °C

NOT APPLICABLE

93

°C

93 ºC

1/2" NPT

B

19-Aug-09

-

AF1-SOP-TI-3102

AF2-SOP-TI-3202

AFC-SOP-TI-3302

GAUGE

OIL TEMPERATURE

ASHCROFT

50EI-60E025XCS

OIL

BRASS

2 1/2"

IP 65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0 - 93 °C

NOT APPLICABLE

93

°C

93 ºC

1/2" NPT

A

24-Jun-09

-

AF1-SOP-TI-3109

AF2-SOP-TI-3209

AFC-SOP-TI-3309

GAUGE

COOLING WATER INLET TEMPERATURE

ASHCROFT

50EI-60E025XCS

WATER

BRASS

2 1/2"

IP 65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0 - 93 °C

NOT APPLICABLE

93

°C

93 ºC

1/2" NPT

A

24-Jun-09

-

AF1-SOP-TI-3103

AF2-SOP-TI-3203

AFC-SOP-TI-3303

GAUGE

COOLING WATER OUTLET TEMPERATURE

ASHCROFT

50EI-60E025XCS

WATER

BRASS

2 1/2"

IP 65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0 - 93 °C

NOT APPLICABLE

93

°C

93 ºC

1/2" NPT

A

24-Jun-09

-

AF1-SOP-PI-3101

AF2-SOP-PI-3201

AFC-SOP-PI-3301

GAUGE

DISCHARGE PRESSURE

ASHCROFT

451279RS04LXXL30 psi and bar

AIR

316L SS

NOT APPLICABLE

IP 65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0 - 2.07 bar G

NOT APPLICABLE

2.07

bar G

121 ºC

1/2" NPT

C

19-Aug-09

-

AF1-SOP-PI-3102

AF2-SOP-PI-3202

AFC-SOP-PI-3302

GAUGE

LUBE OIL PRESSURE

ASHCROFT

451279RS04LXXL160 psi and bar

OIL

316L SS

NOT APPLICABLE

IP 65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0 - 11.03 bar G

NOT APPLICABLE

11.03

bar G

121 ºC

1/2" NPT

C

19-Aug-09

-

AF1-SOP-PI-3103

AF2-SOP-PI-3203

AFC-SOP-PI-3303

GAUGE

MOTOR LUBE OIL PRESSURE

ASHCROFT

25-1009-SW-02L-XLL 30psi and bar

OIL

316L SS

NOT APPLICABLE

IP65

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0 - 2.07 bar G

NOT APPLICABLE

2.07

bar G

66 ºC

1/4"NPT

C

19-Aug-09

-

AF1-SOP-FI3102

AF2-SOP-FI3102

AFC-SOP-FI3102

FLOW INDICATOR MOTOR LUBE OIL

JOHN C. ERNST

E-540-S1 1/4

OIL

316 SS

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

93 ºC

NOT APPLICABLE

B

19-Aug-09

-

AF1-SOP-FI3103

AF2-SOP-FI3103

AFC-SOP-FI3103

FLOW INDICATOR MOTOR LUBE OIL

JOHN C. ERNST

E-540-S1 1/4

OIL

316 SS

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

93 ºC

NOT APPLICABLE

B

19-Aug-09

-

AF1-SOP-FI-3101

AF2-SOP-FI-3201

AFC-SOP-FI-3301

FLOW INDICATOR COMPRESSOR LUBE OIL

WE ANDERSON

SFI550SS-1/2

OIL

316 SS

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

93 ºC

NOT APPLICABLE

B

19-Aug-09

-

AF1-SOP-FT-3101

AF2-SOP-FT-3201

AFC-SOP-FT-3301

TRANSMITTER

SAGE

SRL

AIR

316 SS

18"

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

0-97000 nm3/h

4mA = 0 nm3/h

97000

nm3/h

85 ºc

1"ANSI 150# FLNG

A

24-Jun-09

-

AF1-SOP-VTX-3101

AF2-SOP-VTX-3201

AFC-SOP-VTX-3301

TRANSMITTER

AF1-SOP-VEX-3101

AF2-SOP-VEX-3201

AFC-SOP-VEX-3301

PROBE

AF1-SOP-VTY-3101

AF2-SOP-VTY-3201

AFC-SOP-VTY-3301

TRANSMITTER

AF1-SOP-VEY-3101

AF2-SOP-VEY-3201

AFC-SOP-VEY-3301

AF1-SOP-VTZ-3101

AF2-SOP-VTZ-3201

AFC-SOP-VTZ-3301

DISCHARGE FLOW COMPRESSOR X VIBRATION

BENTLY NEVADA

990-05-50-01-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

.08 mm-pp

.13 mm-pp

0 - .13 mm-pp

4mA = 0 mm-pp

0.13

mm-pp

48º C

NOT APPLICABLE

A

24-Jun-09

COMPRESSOR RADIAL "X" VIBRATION

BENTLY NEVADA

330909-65-90-10-02-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

3/8" UFN - 24

A

19-Aug-09

-

COMPRESSOR Y VIBRATION

BENTLY NEVADA

990-05-50-01-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

.08 mm-pp

.13 mm-pp

0 - .13 mm-pp

4mA = 0 mm-pp

0.13

mm-pp

48º C

NOT APPLICABLE

A

24-Jun-09

-

PROBE

COMPRESSOR RADIAL "Y" VIBRATION

BENTLY NEVADA

330909-65-90-10-02-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

3/8" UFN - 24

A

19-Aug-09

-

TRANSMITTER

COMPRESSOR "Z" THRUST VIBRATION

BENTLY NEVADA

991-25-50-01-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

+/- .64 mm-pp

+/- .76 mm-pp

-.51 TO .51 mm-pp

4mA = -.51 mm-pp

0.13

mm-pp

48º C

NOT APPLICABLE

B

6-Jul-09

-

COMPRESSOR THRUST "Z" VIBRATION

BENTLY NEVADA

330909-15-40-10-02-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

3/8" UFN - 24

A

19-Aug-09

-

DRIVE END MOTOR "X" VIBRATION

BENTLY NEVADA

990-05-50-01-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

.08 mm-pp

.13 mm-pp

0 - .13 mm-pp

4mA = 0 mm-pp

0.13

mm-pp

48º C

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-VEZ-3101

AF2-SOP-VEZ-3201

AFC-SOP-VEZ-3301

PROBE

AF1-SOP-VTX-3101

AF2-SOP-VTX-3201

AFC-SOP-VTX-3301

TRANSMITTER

AF1-SOP-VEX-3101

AF2-SOP-VEX-3201

AFC-SOP-VEX-3301

PROBE

DRIVE END MOTOR "X" VIBRATION

BENTLY NEVADA

330909-05-40-10-02-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

3/8" UFN - 24

A

19-Aug-09

-

AF1-SOP-VTY-3102

AF2-SOP-VTY-3202

AFC-SOP-VTY-3302

TRANSMITTER

DRIVE END MOTOR "Y" VIBRATION

BENTLY NEVADA

990-05-50-01-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

.08 mm-pp

.13 mm-pp

0 - .13 mm-pp

4mA = 0 mm-pp

0.13

mm-pp

48º C

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-VEY-3102

AF2-SOP-VEY-3202

AFC-SOP-VEY-3302

PROBE

DRIVE END MOTOR "Y" VIBRATION

BENTLY NEVADA

330909-05-40-10-02-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

3/8" UFN - 24

A

19-Aug-09

-

AF1-SOP-VTX-3103

AF2-SOP-VTX-3203

AFC-SOP-VTX-3303

TRANSMITTER

NON DRIVE END MOTOR "X" VIBRATION

BENTLY NEVADA

990-05-50-01-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

.08 mm-pp

.13 mm-pp

0 - .13 mm-pp

4mA = 0 mm-pp

0.13

mm-pp

48º C

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-VEX-3103

AF2-SOP-VEX-3203

AFC-SOP-VEX-3303

PROBE

NON DRIVE END MOTOR "X" VIBRATION

BENTLY NEVADA

330909-05-40-10-02-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

3/8" UFN - 24

A

19-Aug-09

-

AF1-SOP-VTY-3104

AF2-SOP-VTY-3204

AFC-SOP-VTY-3304

TRANSMITTER

NON DRIVE END MOTOR "Y" VIBRATION

BENTLY NEVADA

990-05-50-01-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

.08 mm-pp

.13 mm-pp

0 - .13 mm-pp

4mA = 0 mm-pp

0.13

mm-pp

48º C

NOT APPLICABLE

A

24-Jun-09

-

AF1-SOP-VEY-3104

AF2-SOP-VEY-3204

AFC-SOP-VEY-3304

PROBE

NON DRIVE END MOTOR "Y" VIBRATION

AF1-SOP-IE-3101

AF2-SOP-IE-3201

AFC-SOP-IE-3301

TRANSFORMER

AF1-SOP-IT-3101

AF2-SOP-IT-3201

AFC-SOP-IT-3301

TRANSMITTER

BENTLY NEVADA

330909-05-40-10-02-00

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

3/8" UFN - 24

A

19-Aug-09

-

CURRENT TRANSFORMER

TIME MARK

MODEL 276B-400

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

400 AMPS

NOT APPLICABLE

NOT APPLICABLE

AMPS

48º C

NOT APPLICABLE

A

24-Jun-09

-

CURRENT TRANSMITTER

TIME MARK

C278

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NEMA 4X

NOT APPLICABLE

NOT APPLICABLE

294 Amps

303 Amps

0 AMPS - 400 AMPS

4mA = 0 AMPS

400

AMPS

48º C

NOT APPLICABLE

A

24-Jun-09

-

VALLOUREC & SUMITOMO TUBOS DO BRASIL LTDS BRAZIL Quality Assurance Plan and Documents

www.turblex.com

Revision 0 June 25, 2009

Foreword Dear valued customer, Turblex recognizes its responsibility as a provider of quality products and services. Our quality policy is to exceed customer expectations. To this end, Turblex has developed a Quality Assurance Plan to document internal business practices to better satisfy the needs of its customers and improve management of the company. The Turblex Quality Assurance Plan complies with ISO 9001:2000 requirements. The Turblex Quality Assurance Plan defines the quality system, establishes the responsibilities of the personnel affected by the system, and provides general procedures for all activities comprising the quality system. This manual is used internally by Turblex employees for guidance and training on the Turblex quality system, and externally to inform our customers of the quality system and what specific controls are implemented in each stage of the project to ensure quality. We hope you find this manual to be useful in understanding the quality procedures used in the design and manufacture of your product. In addition to information about Turblex quality assurance procedures, you will find details of inspections made on individual components used in the manufacture of your product. From initial design through completion of the project, we are committed to providing a quality experience. Best regards,

Your Management Team

Contents Item

Description Page

-

Title Page

-

Table of Contents

A

ISO Certificate

B

Turblex, Inc. Organization Chart 1. Company - June 17, 2008 2. Industrial Project Engineering – December 18, 2008

C

Turblex, Inc. Quality Manual 1. Revisions List 2. Circulation List 3. Introduction 4. Quality Management System 5. Management Responsibility 6. Resource Management 7. Product Realization 8. Measurement, Analysis, and Improvement

6 7 8 9 10-12 13-15 16 17-22 23-26

D

Procedures 1. Project Design Change (QAP # 4.4-02) 2. Inspection/Testing (QAP # 4.10-01) 3. Control of Inspection Equipment (QAP # 4.11-01) 4. Non-Conforming Product (QAP # 4.13-01) 5. Corrective/Preventive Action (QAP # 4.14-01) 6. Statistical Techniques (QAP # 4.20-01) 7. Quality Management Process Flow Chart 8. Servicing

27 28-29 30-32 33-34 35-36 37-38 39-40 41

E

Production Traveler Quality Assurance

42-69

1-2 3 4 5

Plant name, plant location Quality Assurance Plan and Documents

www.turblex.com

Item A ISO Certificate

www.turblex.com

@ CERTIFICATEOF APPROVAL This is to certifythat the Quality Management System of:

TURBLEX, Inc. Springfield, Missouri, USA has been approved by Lloyd'sRegisterQuality Assurance to the following Quality Management SystemStandards: ISO 9001 :2000 The Quality Management Systemis applicable to:

Design and Manufacturing of Single Stage Compressorsfor the Waste Water Treatment Industry and other Industrial Applicationswhere large Volumes of low Pressure Regulated Air is Needed.

Approval CertificateNo:

Original Approval:

October 29, 2008

Current Certificate:

October 29, 2008

UQA 4000762

Certificate Expiry: July 16, 2011

Issued by: L

This document is subject to the provision on the reverse 1401 Enclave Parkway, Suite 200, Houston, Texas 77077, USA This approval is carried out in accordance with the lRQA assessment and certification procedures and monitored by LRQA. Maaolllwislon1J

-

-

Item B Organization Chart

www.turblex.com

Industrial Project Engineering Organization Chart April 23, 2009 INDUSTRIAL PROJECT ENG. MGR. Gerardo Serralde

Nikki Westmoreland

April Cole

Audrey Johnson

Project Engineer

Carlos Callender

Amber Bridges

Jeanne Seals

Project Manager

Fernando Blanco

Mark Deckard

Quality Engineer

Brian Beaty

John Platz

Barry Bougher

Item C Quality Manual

www.turblex.com

Revisions List

CHANGE REV.

DATE

000

03/16/95

Original issue of all sections of the Quality Manual

All Sections

001

09/12/95

Various Minor Revisions

2.0, 4.2, 4.8, 4.9, 4.15, 4.16

002

11/30/95

Changed Policy Manual to Quality. Defined Management Review Board

4.1, 4.2

003

03/26/96

Various Minor Revisions

2.0, 4.1, 4.4, 4.8, 4.15

004

09/24/96

Minor Revisions to Circulation List

2.0

005

01/23/97

Minor Revision to Management Responsibility

4.1

006

06/26/98

Minor Revisions to Circulation List

2.0

007

09/10/98

Minor Revisions to Circulation List

2.0

008

12/16/98

Added Quality Planning Statement

4.2

009

12/22/98

Changed Semblex to Mace Industries

All sections

010

01/21/99

Date corrected on the introduction.

3.0

011

07/28/99

Various Minor Revisions

2.0, 4.1, 4.8

012

10/05/99

Placed Job Descriptions in separate book

4.1

013

11/12/99

Management Review Board topics discussed

4.1

014

01/21/00

Circulation List

2.0

015

02/04/00

Revisions made to Introduction and Mgmt. Resp.

3.0, 4.1

016

02/09/00

Circulation List

2.0

017

03/15/00

Circulation List

2.0

018

09/07/01

Introduction

3.0

019

03/18/03

Issue all sections of the Quality Management System (SO 9001:2000 E.)

All Sections

020

4/15/03

Add scope to QMS 4, include Quality Objectives in the MRB meeting requirements

QMS 4, QMS 5

Revisions List Turblex, Inc. Quality Manual Section 1.0 Revision: 021 Date: 4/24/09

BRIEF DESCRIPTION OF CHANGE

SECTION(S) INVOLVED

PAGE NOS. All Pages

All Pages

All Pages

Circulation List

This manual is a controlled and maintained document. The only controlled copies are the electronic files located in L:\Turblex\ISO9001_2000\ISO_REQUIREMENTS and the master copy maintained by the Asst. ISO Coordinator: Note: Electronic or master copies may be printed or photocopied by anyone and are not considered controlled documents, they are not allowed on the premises unless used for training purposes...at the end of which they are collected and destroyed.

Circulation List Turblex, Inc. Quality Manual Section 2.0 Revision: 014 Date: 4/24/09

Introduction

3.1

Place of the Quality Manual in the Quality Assurance Documentation This manual is part of Turblex, Inc. controlled Quality Assurance documentation. Described in this document is the Quality Policy, the responsibilities, authorities and inter relationships of personnel who manage, perform, verify or review work affecting quality. The Quality Manual is controlled by circulation and revision. Only the latest revision number is valid. The ISO Coordinator controls all revisions, issues and circulation. The Quality Manual has been approved by management of Turblex, Inc. and expresses the policies and philosophy of the Quality Assurance System.

3.2

Quality Policy Statement Turblex pledges total commitment to provide products and services to the Customer that always meet or exceed the requirements. Management will provide the environment and resources where every employee contributes toward the never-ending process of improvement and innovation in all aspects of our business.

3.3

Turblex, Inc. Brief History Turblex, Inc. was incorporated in 1988. Turblex has experience dynamic growth since its inception and has turned into a multi-million dollar corporation that is continuing to grow. Turblex designs and assembles a wide range of the most efficient single stage compressors available today. Sales are generated through a network of manufacturers' representatives located throughout the United States and overseas. Approximately 20 percent of sales are shipped outside of the United States.

Introduction Turblex, Inc. Quality Manual Section 3.0 Revision: 005 Date: 4/24/09

QMS 4 Quality Management System 4.0

Scope/Exclusions Turblex, Inc.'s Quality Management System covers design and manufacturing of singlestage compressors for the wastewater treatment industry and other industrial applications where large volumes of low pressure regulated air are needed. Turblex’s Quality Management System covers the manufacture of aerators, positive displacement blowers, constant pressure water supply systems; polymer feed equipment and other related products for the wastewater treatment industry. Turblex, Inc. claims no exclusions from the Quality Management System.

4.1

General Requirements Turblex, Inc. has established documented, implemented and maintained a quality management system and continually improves its effectiveness in accordance with the requirements of ISO 9001: 2000 E. Turblex, Inc. has a) identified the processes needed for the quality management system and their application throughout the organization b) determined the sequence and interaction of these processes, c) determined criteria and methods needed to ensure that both the operation and control of these processes are effective, d) ensured the availability of resources and information necessary to support the operation and monitoring of these processes, e) monitored, measured and analyzed these processes, and f) implemented actions necessary to achieve planned results and continual improvement of these processes. These processes are managed by Turblex, Inc. in accordance with the requirements of ISO 9001: 2000 E. Where Turblex, Inc. chooses to outsource any process that affects product conformity with requirements, Turblex, Inc. shall ensure control over such processes. Control of such outsourced processes is identified within the quality management system.

QMS 4 Quality Management System Turblex, Inc. Quality Management System Revision: 005 Date: 4/24/09

4.2

Documentation Requirements 4.2.1

General The quality management system documentation includes a) documented statements of a quality policy and quality objectives, b) a quality manual, c) documented procedures required by ISO 9001: 2000 E, d) documents need by Turblex, Inc. to ensure the effective planning, operation and control of its processes, and records required by ISO 9001: 2000 E (see 4.2.4).

4.2.2

Quality Manual Turblex, Inc. has established and maintained a quality manual that includes: a) the scope of the quality management system, including details of and justification for any exclusions, b) the documented procedures established for the quality management system, or reference to them, and c) a description of the interaction between the processes of the quality management system. The following is a table referencing QMS requirements to procedures or work instructions that address those requirements: QMS 4.2.3 4.2.4 5.4.2 6.2 7.2 7.2.3 7.3 7.4 7.5.2 7.5.4 7.5.5 7.6 8.2.1 8.2.2 8.2.3 8.2.4 8.3 8.4 8.5.2 8.5.3

PROCEDURE / WORK INSTRUCTION 4.5-01 QAP 4.16-01 QAP 4.5-01 QAP 4.18-01QAP 4.3-01QAP 4.3-01QAP 4.4-01 / 4.4-02 / 4.4-03QAP 4.6-01 & 4.10-01QAP 4.9-01 & 4.19-01, 4.7-01QAP 4.7-01QAP 4.10-01QAP 4.11-01QAP 4.20-02QAP 4.17-01QAP 4.20-01QAP 4.10-01QAP 4.13-01QAP 4.20-01QAP 4.14-01QAP 4.14-01QAP

QMS 4 Quality Management System Turblex, Inc. Quality Management System Revision: 05 Date: 4/24/09

4.2.3

Control of documents Documents required by the quality management system are controlled. Records are a special type of document and are controlled according to the requirements given in 4.2.4. A documented procedure has been established to define the controls needed a) to approve documents for adequacy prior to issue, b) to review and update as necessary and re-approve documents, c) to ensure that changes and the current revision status of documents are identified, d) to ensure that relevant versions of applicable documents are available at points of use, e) to ensure that documents remain legible and readily identifiable, f) to ensure that documents of external origin are identified and their distribution controlled, and g) to prevent the unintended use of obsolete documents, and to apply suitable identification to them if they are retained for any purpose.

4.2.4

Control of records Records have been established and maintained to provide evidence of conformity to requirements and of the effective operation of the quality management system. Records are legible, readily identifiable and retrievable. A documented procedure has been established to define the controls needed for the identification, storage, protection, retrieval time and disposition of records.

QMS 4 Quality Management System Turblex, Inc. Quality Management System Revision: 05 Date: 4/24/09

QMS 5 Management Responsibility

5.1

Management Commitment Top management has provided evidence of its commitment to the development and implementation of the quality management system and continually improves its effectiveness by: a) communicating to the organization the importance of meeting customer as well as statutory and regulatory requirements, b) establishing the quality policy, c) ensuring that quality objectives are established, d) conducting management reviews, and ensuring the availability of resources.

5.2

Customer Focus Top management has ensured that customer requirements are determined and are met with the aim of enhancing customer satisfaction (see 7.2.1 and 8.2.1).

5.3

Quality policy Top management has ensured that the quality policy: a) is appropriate to the purpose of the organization, b) includes a commitment to comply with requirements and continually improve the effectiveness of the quality management system, c) provides a framework for establishing and reviewing quality objectives, d) is communicated and understood within the organization, and e) is reviewed for continuing suitability. The following Quality Policy is the guideline by which employees perform their work. Quality Policy Turblex, Inc. pledges to: EXCEED CUSTOMER EXPECTATIONS

QMS 5 Management Responsibility Turblex, Inc. Quality Management System Revision: 03 Date: 4/24/09

5.4

Planning 5.4.1

Quality Objectives Top management has ensured that quality objectives, including those needed to meet requirements for product (see 7.1 a) are established at relevant functions and levels within the organization. The quality objectives are measurable and consistent with the quality policy. Quality Objectives are established for the coming year in the final Management Review Board Meeting each year. The Quality Objectives are then issued in a memo from the President.

5.4.2

Quality management system planning Top management has ensured that a) the planning of the quality management system is carried out in order to meet the requirements given in 4.1, as well as the quality objectives, and b) the integrity of the quality management system is maintained when changes to the quality management system are planned and implemented.

5.5

Responsibility, Authority, and Communication 5.5.1

Responsibility and Authority Turblex, Inc. has ensured that responsibilities and authorities are defined and communicated within the organization by maintaining a current organization chart that lists the position titles and direct reporting relationships of each position. There will also be a current job description for each position that defines the title, scope, responsibility, and authority of that position. The job description will also include the direct and indirect reporting relationships for the position. The job descriptions will be kept in a separate book with the Master ISO documentation. Furthermore, when the Organizational Chart is revised, the Assistant ISO Coordinator will compare it to the current job descriptions ensuring that a current job description always exists for each position reflected on the Organizational Chart.

5.5.2

Management Representative Turblex, Inc. has appointed a member of management as the ISO Coordinator who, irrespective of other responsibilities, has responsibility and authority that includes: a) ensuring that processes needed for the quality management system are established, implemented and maintained, b) reporting to top management on the performance of the quality management system and any need for improvement, and c) ensuring the promotion of awareness of customer requirements throughout the organization.

5.5.3

Internal Communication Top management has ensured that appropriate communication processes are established within the organization and that communication takes place regarding the effectiveness of the quality management system (see 5.6.1).

QMS 5 Management Responsibility Turblex, Inc. Quality Management System Revision: 03 Date: 4/24/09

5.6

Management Review 5.6.1

General Top management consisting of the President, Controller, Chief Engineer, and Manufacturing Manager, or the President and two of the three mentioned, review the organization’s quality management system semi-annually to ensure its continuing suitability, adequacy and effectiveness. This review includes assessing opportunities for improvement and the need for changes to the quality management system, including the quality policy and quality objectives. Records from management reviews are made available to all personnel within the organization and maintained in accordance with ISO requirements (see 4.2.4).

5.6.2

Review Input The input to management review includes information on a) results of audits, b) customer feedback, c) process performance and product conformity, d) status of preventive and corrective actions, e) follow-up actions from previous management reviews, f) changes that could affect the quality management system, and recommendations for improvement.

5.6.3

Review Output The output from the management review includes any decisions and actions related to a) improvement of the effectiveness of the quality management system and its processes, b) improvement of product related to customer requirements, and c) resource needs Review status of quality objectives and as necessary establish quality objectives for the coming year.

QMS 5 Management Responsibility Turblex, Inc. Quality Management System Revision: 03 Date: 4/24/09

QMS 6 Resource Management

6.1

Provisions of Resources Turblex, Inc. has determined and provided the resources needed a) to implement and maintain the quality management system and continually improve its effectiveness, and b) to enhance customer satisfaction by meeting customer requirements.

6.2

Human Resources 6.2.1

General Personnel performing work affecting product quality are competent on the basis of appropriate education, training, skills and experience.

6.2.2

Competence, Awareness, and Training Turblex, Inc. has a) determined the necessary competence for personnel performing work affecting product quality, b) provided training or take other actions to satisfy these needs, c) evaluated the effectiveness of the actions taken, d) ensured that its personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of the quality objectives, and maintained appropriate records of education, training, skills and experience (see 4.2.4).

6.3

Infrastructure Turblex, Inc. shall determine, provide and maintain the infrastructure needed to achieve conformity to product requirements. Infrastructure includes, as applicable a) buildings, workspace and associated utilities, b) process equipment (both hardware and software), and c) supporting services (such as transport or communication)

6.4

Work Environment Turblex, Inc. has determined and managed the work environment needed to achieve conformity to product requirements.

QMS 6 Resource Management Turblex, Inc. Quality Management System Revision: 01 Date: 3/18/03

QMS 7 Product Realization

7.1

Planning of Product Realization Turblex, Inc. has planned and developed the processes needed for product realization. Planning of product realization has been consistent with the requirements of the other processes of the quality management system (see 4.1). In planning product realization, the organization has determined the following, as appropriate: a) quality objectives and requirements for the product; b) the need to establish processes, documents, and provide resources specific to the product; c) required verification, validation, monitoring, inspection and test activities specific to the product and the criteria of the product acceptance; d) records needed to provide evidence that the realization processes and resulting product meet requirements (see 4.2.4). The output of the planning is in a form suitable for the organization’s method of operations.

7.2

Customer-Related Processes 7.2.1

Determination of Requirements Related to the Product Turblex, Inc. determines a) Requirements specified by the customer, including the requirements for delivery and post-delivery activities, b) Requirements not stated by the customer but necessary for specified or intended use, where known, c) Statutory and regulatory requirements related to the product, and d) Any additional requirements determined by the organization.

QMS 7 Product Realization Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

7.2.2

Review of Requirements Related to the Product Turblex, Inc. reviews the requirements related to the product. This review is conducted prior to the organization’s commitment to supply a product to the customer (e.g. submission of tenders, acceptance of contracts or orders, acceptance of changes to contracts or orders) and ensures that a) product requirements are defined, b) contract or order requirements differing from those previously expressed are resolved, and c) Turblex, Inc. has the ability to meet the defined requirements. Records of the results of the review and actions arising from the review are maintained (see 4.2.4). Where the customer provides no documented statement of requirement, the customer requirements are confirmed by the organization before acceptance. Where product requirements are changed, the organization ensures that relevant documents are amended and that relevant personnel are made aware of the changed requirements.

7.2.3

Customer Communication Turblex, Inc. has determined and implemented effective arrangements for communicating with customers in relation to a) product information, b) inquiries, contracts or order handling, including amendments, and c) customer feedback, including customer complaints.

7.3

Design and Development 7.3.1

Design and Development Planning Turblex, Inc. plans and controls the design and development of product. During the design and development planning, the organization determines: a) the design and development stages, b) the review, verification and validation that are appropriate to each design and development stage, and c) the responsibilities and authorities for design and development. Turblex, Inc. manages the interface between different groups involved in design and development to ensure effective communication and clear assignment of responsibility. Planning output is updated, as appropriate, as the design and development progresses.

QMS 7 Product Realization Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

7.3.2

Design and Development Inputs Inputs relating to product requirements have been determined and records are maintained (see 4.2.4). These inputs include: a) functional and performance requirements, b) applicable statutory and regulatory requirements, c) where applicable, information derived from previous similar designs, and d) other requirements essential for design and development. These inputs are reviewed for adequacy. Requirements are complete, unambiguous and not in conflict with each other.

7.3.3

Design and Development Outputs The outputs of design and development are provided in a form that enables verification against the design and development input and is approved prior to release. Design and development outputs: a) meet the input requirements for design and development, b) provide appropriate information for purchasing, production and for service provision, c) contain or reference product acceptance criteria, and specify the characteristics of the product that are essential for its safe and proper use.

7.3.4

Design and Development Review At suitable stages, systematic reviews of design and development are performed in accordance with planned arrangements (see 7.3.1) a) to evaluate the ability of the results of design and development to meet requirements, and b) to identify any problems and propose necessary actions. Participants in such reviews include representatives of functions concerned with the design and development stage(s) being reviewed. Records of the results of the reviews and any necessary actions are maintained (see 4.2.4).

7.3.5

Design and Development Verification Verification is performed in accordance with planned arrangement (see 7.3.1) to ensure that the design and development outputs have met the design and development input requirements. Records of the results of the verification and any necessary actions are maintained (see 4.2.4).

7.3.6

Design and Development Validation Design and development validation is performed in accordance with planned arrangements (see 7.3.1) to ensure that the resulting product is capable of meeting the requirements for the specified application or intended use, where known. Wherever practicable, validation is completed prior to the delivery or implementation of the product. Records of the results of validation and any necessary actions are maintained (see 4.2.4).

QMS 7 Product Realization Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

7.3.7

Control of Design and Development Changes Design and development changes are identified and records maintained. The changes are reviewed, verified and validated, as appropriate, and approved before implementation. The reviews of design and development changes include evaluation of the effect of the changes on constituent parts and product already delivered. Records of the results of the review of changes and any necessary actions are maintained (see 4.2.4).

7.4

Purchasing 7.4.1

Purchasing Process Turblex, Inc. ensures that purchased product conforms to specified purchase requirements. The type and extent of control applied to the supplier and the purchased product is dependent upon the effect of the purchased product on subsequent product realization or the final product. Turblex, Inc. has evaluated and selected suppliers based on their ability to supply product in accordance with the organization’s requirements. Criteria for selection, evaluation and re-evaluation have been established. Records of the results of evaluations and any necessary actions arising from the evaluation are maintained (see 4.2.4).

7.4.2

Purchasing Information Purchasing information describes the product to be purchased, including where appropriate a) requirements for approval of product, procedures, processes and equipment, b) requirements for qualification of personnel, and c) quality management system requirements. Turblex, Inc. ensures the adequacy of specified purchase requirements prior to their communication to the supplier.

7.4.3

Verification of Purchased Product Turblex, Inc. has established and implemented inspections or other activities necessary for ensuring that purchased product meets specified purchase requirements. Where Turblex, Inc. or its customer intends to perform verification at the supplier’s premises, Turblex, Inc. shall state the intended verification arrangements and method of product release in the purchasing information.

QMS 7 Product Realization Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

7.5

Product and Service Provision 7.5.1

Control of Production and Service Provision Turblex, Inc. plans and carries out production and service provisions under controlled conditions. Controlled conditions include, as applicable a) the availability of information that describes the characteristics of the product, b) the availability of work instruction, as necessary, c) the use of suitable equipment, d) the availability and use of monitoring and measuring devices, e) the implementation of monitoring and measurement, and f) the implementation of release, delivery and post-delivery activities

7.5.2

Validation of Processes for Production and Service Provision Turblex, Inc. validates any processes for production and service provision where the resulting output cannot be verified by subsequent monitoring or measurement. This includes any processes where deficiencies become apparent only after the product is in use or the service has been delivered. Validation demonstrates the ability of these processes to achieve planned results. Turblex, Inc. has established arrangements for these processes including, as applicable a) defined criteria for review and approval of the processes, b) approval of equipment and qualification of personnel, c) use of specific methods and procedures, d) requirements for records (see 4.2.4), and e) revalidation

7.5.3

Identification and Traceability Turblex, Inc. identifies product from receipt and during all stages of production through a combination of our part number, vendor’s part number, description of the product, and/or placed in a job specific material-handling item. Turblex, Inc. assigns and records a unique serial number and attaches a Turblex, Inc. nameplate to each machine or job for product identification. Turblex, Inc. has established a quality plan for identifying the product by suitable means from receipt and during all stages of production, delivery and installation where and to the extent that traceability is a specified requirement.

7.5.4

Customer Property Turblex, Inc. exercises care with customer property while it is under the organization’s control or being used by the organization. Turblex, Inc. identifies, verifies, protects and safeguards customer property provided for use or incorporation into the product. If any customer property is lost, damaged or otherwise found to be unsuitable for use, this is reported to the customer and records maintained (see 4.2.4).

QMS 7 Product Realization Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

7.5.5

Preservation of Product Turblex, Inc. preserves the conformity of product during internal processing and delivery to the intended destination. This preservation includes identification, handling, packaging, storage and protection. Preservation also applies to the constituent parts of a product.

7.6

Control of Monitoring and Measuring Devices Turblex, Inc. has determined the monitoring and measurement to be undertaken and the monitoring and measuring devices needed to provide evidence of conformity of product to determined requirements (see 7.2.1). Turblex, Inc. has established processes to ensure that monitoring and measurement can be carried out and are carried out in a manner that is consistent with the monitoring and measurement requirements. Where necessary to ensure valid results, measuring equipment is: a) calibrated or verified at specified intervals, or prior to use, against measurement standards traceable to international or national measurement standards; where no such standards exist, the basis used for calibration or verification is recorded; b) adjusted or re-adjusted as necessary; c) identified to enable the calibration status to be determined; d) safeguarded from adjustments that would invalidate the measurement result; e) protected from damage and deterioration during handling, maintenance and storage In addition, Turblex, Inc. assesses and records the validity of the previous measuring results when the equipment is found not to conform to requirements. Turblex, Inc. takes appropriate action on the equipment and any product affected. Records of the results of calibration and verification are maintained (see 4.2.4). When used in the monitoring and measurement of specified requirements, the ability of computer software to satisfy the intended application is confirmed. This is undertaken prior to initial use and reconfirmed as necessary.

QMS 7 Product Realization Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

QMS 8 Measurement, Analysis, and Improvement 8.1

General Turblex, Inc. plans and implements the monitoring, measurement, analysis and improvement processes needed: a) to demonstrate conformity of the product, b) to ensure conformity of the quality management system, and c) to continually improve the effectiveness of the quality management system This includes determination of applicable methods, including statistical techniques, and the extent of their use.

8.2

Monitoring and Measurement 8.2.1

Customer Satisfaction As one of the measurements of the performance of the quality management system, Turblex, Inc. monitors information relating to customer perception as to whether the organization has met customer requirements. The methods for obtaining and using this information have been determined.

8.2.2

Internal Audit Turblex, Inc. conducts internal audits at planned intervals to determine whether the quality management system: a) conforms to the planned arrangements (see 7.1), to the requirements of ISO 9001: 2000 E and to the quality management system requirements established by Turblex, Inc. and b) is effectively implemented and maintained An audit program was planned, taking into consideration the status and importance of the processes and areas to be audited, as well as the results of previous audits. The audit criteria, scope, frequency and methods are defined. Selection of auditors and conduct of audits ensures objectivity and impartiality of the audit process. Auditors do not audit their own work.

QMS 8 Measurement, Analysis, and Improvement Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

The responsibilities and requirements for planning and conducting audits, and for reporting results and maintaining records (see 4.2.4) are defined in a documented procedure. The management responsible for the area being audited ensures that actions are taken without undue delay to eliminate detected nonconformities and their causes. Follow-up activities include the verification of the actions taken and the reporting of verification results (see 8.5.2). 8.2.3

Monitoring and Measurement of Processes Turblex, Inc. applies suitable methods for monitoring and, where applicable, measurement of the quality management system processes. These methods demonstrate the ability of the processes to achieve planned results. When planned results are not achieved, correction and corrective action is taken, as appropriate, to ensure conformity of the product.

8.2.4

Monitoring and Measurement of Product Turblex, Inc. monitors and measures the characteristics of the product to verify that product requirements have been met. This is carried out at appropriate stages of the product realization process in accordance with the planned arrangements (see 7.1). Evidence of conformity with the acceptance criteria is maintained. Records indicate the person(s) authorizing release of product (see 4.2.4). Product release and service delivery do not proceed until the planned arrangements (see 7.1) have been satisfactorily completed, unless otherwise approved by a relevant authority and, where applicable, by the customer.

8.3

Control of Nonconforming Product Turblex, Inc. ensures that product which does not conform to product requirements is identified and controlled to prevent its unintended use or delivery. The controls and related responsibilities and authorities for dealing with nonconforming product are defined in a documented procedure. Turblex, Inc. deals with nonconforming product by one or more of the following ways: a) by taking action to eliminate the detected nonconformity b) by authorizing its use, release or acceptance under concession by a relevant authority and, where applicable, by the customer c) by taking action to preclude its original intended use or application Records of the nature of nonconformities and any subsequent actions taken, including concessions obtained, are maintained (see 4.2.4). When nonconforming product is corrected it is subject to re-verification to demonstrate conformity to the requirements. When nonconforming product is detected after delivery or use has started, the organization takes action appropriate to the effects, or potential effects of the nonconformity.

QMS 8 Measurement, Analysis, and Improvement Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

8.4

Analysis of Data Turblex, Inc. determines, collects and analyzes appropriate data to demonstrate the suitability and effectiveness of the quality management system and to evaluate where continual improvement of the effectiveness of the quality management system can be made. This includes data generated as a result of monitoring and measurement and from other relevant sources. The analysis of data provides information relating to: a) customer satisfaction (see 8.2.1), b) conformity to product requirements (see 7.2.1), c) characteristics and trends of processes and products including opportunities for preventative action, and suppliers

8.5

Improvement 8.5.1

Continual Improvement Turblex, Inc. continually improves the effectiveness of the quality management system through the use of the quality policy, quality objectives, audit results, analysis of data, corrective and preventive actions and management review.

8.5.2

Corrective Action Turblex, Inc. takes action to eliminate the cause of nonconformities in order to prevent recurrence. Corrective actions are appropriate to the effects of the nonconformities encountered. A documented procedure has been established to define requirements for: a) reviewing nonconformities (including customer complaints), b) determining the causes on nonconformities, c) evaluating the need for action to ensure that nonconformities do not recur, d) determining and implementing action needed, e) records of the results of action taken (see 4.2.4), and f) reviewing corrective action taken

8.5.3

Preventative Action Turblex, Inc. determines action to eliminate the causes of potential nonconformities in order to prevent their occurrence. Preventive actions are appropriate to the effects of the potential problems. A documented procedure has been established to define requirements for: a) determining potential nonconformities and their causes, b) evaluating the need for action to prevent occurrence of nonconformities, c) determining and implementing action needed, d) records of results of action taken (see 4.2.4), and e) reviewing preventative action taken

QMS 8 Measurement, Analysis, and Improvement Turblex, Inc. Quality Management System Revision: 02 Date: 4/24/09

Item D Procedures

www.turblex.com

Project Design Change Control Procedure 1.0

Purpose 1.1

2.0

Scope 2.1

3.0

Red Line - An approved change to a drawing.

Reference 4.1 4.2

5.0

This procedure covers all changes to standards, drawings or bills of material that have been released from Engineering.

Key Words 3.1

4.0

To establish and maintain documented procedures to insure that all design changes and modifications will be identified, documented, reviewed and approved by authorized personnel before their realization.

Please reference Flow Chart - Design Change Control Procedure. Please reference Engineering Work Instruction titled “Change Order”.

Procedure General: The two general ways to approve changes to information that has been released from Engineering are an ECO form or a Red Line that is followed up with an “As Built” drawing. As stated in QAP# 4.6-01: “The use of a component shall be approved by Engineering.” This means that any additions, deletions, or changes in type or quantity of material must be done through an Engineering Change Order (ECO), except as stated below. The Assembly Shop must follow the information released by Engineering or receive approval before any deviations are made, except for the following areas: 1. The Shop has authority to make clerical corrections to Electrical schematics such as wire labeling. These corrections will be made to the “As Built”. 2. The Process and Instrumentation Diagram (P&ID) is the guideline for skid electrical. Engineering and Shop personnel should meet to have a discussion for each specific job’s skid electrical layout. The shop has authority to add or delete quantity of components in the estimated Bill of Material to complete skid electrical. The shop cannot change type of material. 3. The Shop will be

Project Design Change Control Procedure Turblex, Inc. Design Change Control Procedure (QAP# 4.4-02) Revision: 009 Date: 4/27/09

given an oil/water piping layout to follow. As long as field connection points listed on the General Arrangement drawing are met, the Shop has authority to adjust length dimensions, and add or delete fittings as needed. The Shop does not have authority to change the sequence of components such as gauges, valves, filters, etc.

6.0

5.1

A potential change to a drawing or bill of material may be found at any time, or by anyone, after it has been released by Engineering.

5.2

The person identifying a potential change(s) should initiate an ECO (Form #95032401, printed on goldenrod paper). The Project Manager reviews the ECO changes and assesses the effect of the changes on parts or products that have already been approved, creating additional ECO’s, if necessary. The Project Manager assigns an ECO number and records the ECO on the ECO log. The Project Manager will make a copy of the ECO on white paper, and place the copy in the job file. All of these steps must be completed prior to releasing the ECO.

5.3

The original ECO with any revised drawings will be released to the Materials department for processing. To process the ECO, the Materials department will create the proper paperwork in accordance with the ECO. This paperwork may include, among other things, an inventory activity sheet, return goods form, purchase order, purchase order cancellation, or change. Materials will make the appropriate changes to the BOM in the computer.

5.4

Materials will issue the original ECO to either the Electrical or Mechanical Shop department to implement the change into the product.

5.5

After the change is completed, the Team Leader will inspect the product, sign-off on the original ECO, and place it in the production traveler.

5.6

Prior to the functional testing, the Project Manager will verify that all ECO's have been processed, and all changes have been made to the product. File all original ECO’s in the job file, complete the ECO log, and discard all ECO copies. The product cannot pass final inspection, and therefore is not shipped, until the above has been completed.

5.7

Prior to the completion of a product or process, minor changes to drawings can be documented by the Project Manager approving a red line correction without an ECO. The Project Manager is responsible for making the red line correction on the master drawing and all released copies in the Production Manager’s office, Buyer’s office, Shop and Warehouse. The Project Manager will initial and date all red line corrections.

5.8

During quality inspection, the Production Manager will verify that all red line corrections are implemented, initial and date each red lined drawing (shop copy only) next to the Project Manager’s initial.

5.9

Prior to the functional testing, the Project Manager will collect all the shop drawings and incorporate all red lines into “As Built” drawings.

Records, Reports, and Forms 6.1

ECO Form 95032401.QAS ECO Log Form 95041201.QAS

Project Design Change Control Procedure Turblex, Inc. Design Change Control Procedure (QAP# 4.4-02) Revision: 009 Date: 4/27/09

Project Design Control: Non-Standard Material Selection Process Project Engineering Review Customer’s Specifications Review Customer’s Approved Suppliers

RFQ’s to 3-5 Suppliers

Review Quotes Against Specs and Budget

Select Conforming Quote

Technical Review With Project Engineering Manager

Business Review With Material Selection Committee

Submittal To Customer For Approval

Approved Submittal From Customer

Material Requisition to Purchasing

Inspection and Testing Procedure

1.0

Purpose 1.1

2.0

Scope 2.1

3.0

Specified Requirements - The requirements by which a product or service must conform that have been contractually agreed upon between the customer and supplier which includes any exceptions taken and agreed upon modifications.

Reference 4.1 4.2 4.3 4.4 4.5

5.0

This procedure will cover the inspection, testing, and verification functions for all products produced by Turblex at the following points in production; incoming product, in-process, functional, and final visual inspection.

Key Words 3.1

4.0

To establish and maintain documented procedures for inspection and testing and for the coordination of these activities.

Please reference Procedure 4.13-01 Control of Nonconforming Product. Please reference Procedure 4.4-02 Design Change Control. Please reference the ASME PTC-10 test procedure performed on Turblex compressors by HV-Turbo. Please reference Procedure 4.20-01 Statistical Techniques. Please reference Flow Chart 4.10 Inspection and Testing Procedure.

Procedure General: A production traveler, which lists the inspection and test hold points, will be attached to a quality board as the product is being assembled and tested. The status of any inspection and test should be recorded on this traveler. 5.1

Turblex has determined that all incoming product to be used in production or as service parts will be inspected and verified. No incoming product will be issued to manufacturing until the incoming inspection has been performed.

Inspection and Testing Procedure Turblex, Inc. Inspection and Testing Procedure (QAP# 4.10-01) Revision: 07 Date: 4/27/09

A determination will be made on product that is shipped directly from the vendor to the customer on whether it will be inspected on a case by case basis that takes into consideration the value added work being done by the vendor and the quality reliability of the vendor. 5.2

Turblex has identified four categories of incoming product for the purpose of inspection and verification and shipments directly from the vendor to the customer. These categories and the associated inspection and verification procedures are as follows: A. Raw Material for fabrication. The initial inspection will be done by receiving according to the Non-fabricated parts procedure. (See category C.) Final inspection of raw material is done by the fabrication department as raw material is pulled into fabrication. Raw material will be compared to drawings and any applicable standards for all relevant data such as dimensions and correct material. Relevant data will be recorded and records maintained. B. Fabricated. This inspection will generally be done by receiving unless there is an inspection data sheet in the Traveler or the item is unusual, then the Project Manager or the CADD Manager will be involved. Fabricated parts will be compared to the following documents based on the sampling methods described in QAP# 4.20-01: 1. Drawing for all relevant data such as dimensions, welds, correct materials, tolerances, paint specifications, etc. 2. Packing list to determine if what was received is the same as the items listed as shipped. The inspector shall initial the packing list to verify that the appropriate review has been completed. 3. Purchase Order to determine if what was received is the same as the items listed as purchased. C. Non-fabricated. This inspection will generally be done by receiving unless the item is unusual, then the Project Manager will be involved. All non-fabricated parts will be compared to the following documents where appropriate: 1. Packing list to determine if what was received is the same as the items listed as shipped. The inspector shall initial the packing list to verify that the appropriate review has been completed. 2. Purchase Order to determine if what was received is the same as the items listed as purchased. 3. Bill of Material to determine if what was received is the same as the items called for on the Bill of Material.

Inspection and Testing Procedure Turblex, Inc. Inspection and Testing Procedure (QAP# 4.10-01) Revision: 07 Date: 4/27/09

D. Main drive motor, compressor, main motor starter, valves, and other special specified items. 1. Packing list to determine if what was received is the same as the items listed as shipped 2. Purchase Order to determine if what was received is the same as the items listed as purchased. 3. Inspection data sheets will be completed as applicable. E. Shipments directly from the vendor to the customer. If this inspection will be performed during start-up, then this will be listed on the Job Start-up Log form 99021802. 1. If a fabricated item, drawing for all relevant data such as dimensions, welds, correct materials, tolerances, paint specifications, etc. 2. Purchase Order to determine if what is to be shipped is the same as the items listed as purchased. All incoming product and product shipped directly from the vendor to the customer that is inspected will be visually inspected for damage. 5.3

If there is a nonconformance, a completed red tag should be attached to the product and the product placed in a segregated nonconformance area if possible. Please see Procedure 4.13 Control of Non-Conforming Product if there are any non-conformances. If no discrepancies, proceed to Step 5.4.

5.4

After all discrepancies have been resolved; the incoming product will be issued to the appropriate job or put into stock.

5.5

The in-process inspection and test procedures will be performed according to work instructions developed for each product line. The work instructions will identify at what stage each inspection or test should be performed, what each inspection or test will cover, and who has authority to perform and approve each inspection or test. The person having the authority to approve the inspection and test will record the inspection and test results on the production traveler.

5.6

If there is a non-conformance, a completed red tag should be attached to the product and the product placed in a segregated nonconformance area if possible. Please see Procedure 4.13 Control of Non-Conforming Product if there are any non-conformances. If no discrepancies, proceed to Step 5.7.

5.7

The functional test procedures will be performed according to work instructions developed for each product line. The work instructions will identify what the operational test will cover and who has authority to perform and approve each test. The person having the authority to approve the inspection and test will record the inspection and test results on the production traveler. Records of applicable vendor test reports shall be evaluated for conformance to specified requirements before check off of functional inspection and testing.

Inspection and Testing Procedure Turblex, Inc. Inspection and Testing Procedure (QAP# 4.10-01) Revision: 07 Date: 4/27/09

6.0

5.8

If there is a non-conformance, a completed red tag should be attached to the product and the product placed in a segregated nonconformance area if possible. Please see Procedure 4.13 Control of Non-Conforming Product if there are any non-conformances. If no discrepancies, proceed to Step 5.9.

5.9

Before shipment of the completed product, a final visual inspection will be performed according to work instructions developed for each product line. The work instructions will identify what the final visual inspection will cover and who has authority to perform and approve the final visual inspection. The person having the authority to approve the inspection and test will record the inspection and test results on the production traveler.

5.10

If there is a non-conformance, a completed red tag should be attached to the product and the product placed in a segregated nonconformance area if possible. Please see Procedure 4.13 Control of Non-Conforming Product if there are any non-conformances. If no discrepancies, proceed to Step 5.11.

5.11

The product will be shipped after it has passed all inspections, tests, and verifications performed at incoming, in process, operational, and final inspection.

Records, Reports, and Forms 6.1 6.2

Production Traveler Inspection and Test Checklists

Inspection and Testing Procedure Turblex, Inc. Inspection and Testing Procedure (QAP# 4.10-01) Revision: 07 Date: 4/27/09

Control of Inspection, Measuring, and Test Equipment Procedure 1.0

Purpose 1.1

2.0

Scope 2.1

3.0

4.0

This procedure covers all inspection, measuring and test equipment affecting quality that is used for the purpose of final inspection, measurement, or test during inspection, production, quality control, testing, startup, and service.

Key Words 3.1

Calibration: Comparison of a measurement standard or instrument of known accuracy with another standard or instrument to detect, correlate, report, or eliminate by adjustment any variation in the accuracy of the item being compared.

3.2

Measuring and Test Equipment: All equipment used to measure, gauge, test, inspect, or otherwise examine items to determine compliance with specifications.

Reference 4.1 4.2

5.0

To provide a system to assure that all measurement and test equipment used for activities affecting quality is controlled, calibrated, and adjusted to maintain necessary accuracy.

Please reference Procedure 4.10-01 Inspection and Testing. Please reference Flow Chart 4.11 Control of Inspection, Measuring and Test Equipment.

Procedure 5.1

Engineering, in accordance with the specifications, will define on the drawing what measurements are to be made and the accuracy required; and, on the Production Traveler, what tests will be required.

5.2

Engineering and Manufacturing will identify the type of equipment needed to perform the necessary inspections, measurements and test equipment.

Control of Inspection, Measuring, and Test Equipment Procedure Turblex, Inc. Control of Inspection, Measuring, and Test Equipment Procedure (QAP# 4.11-01) Revision: 009 Date: 4/27/09

5.3

Receive all newly purchased or repaired inspection, measuring, and test equipment in accordance with Procedure 4.10-01. Send all equipment to the ISO department to be recorded in test equipment calibration certificate log.

5.4

Log the following information on the inspection, measuring and test equipment log sheet: A. B. C. D. E.

Description of instrument Serial number, if available Location to be used The unique number assigned to that instrument Frequency the instrument should be recalled to check calibration and re-calibrate if needed.

When size permits, place a calibration label on the instrument indicating the unique instrument number, date of calibration, and date next calibration is due. 5.5

The Chief Engineer or designee will determine if calibration certification has been issued with instrument. If certification has been issued, then file the certification and proceed to Step 5.6. If certification has not been issued, then proceed to Step 5.8.

5.6

The instrument can be placed in use. The person using an instrument has the responsibility of returning to the Chief Engineer or designee any instrument suspected of being damaged or out of calibration, has an expired label, or if the calibration label has been removed.

5.7

On a monthly basis, all equipment to be calibrated by the end of that month will be recalled from use by the Chief Engineer or designee.

5.8

All recalled equipment, new equipment without calibration evidence, and any equipment suspected of being damaged or out of calibration will be calibrated in accordance with approved work instructions. Detailed results of the calibration, along with date calibrated and by who will be recorded on the approved calibration form (see Quality Control including Calibration Work Instructions and Forms). If during re-calibration, the instrument is found to be outside the required calibration limits, corrective action will be taken. Evaluation will be made to determine the effects the instrument that is out of calibration may have had on completed or in-process work and to what extent reprocessing or retesting needs to be done.

5.9

The Chief Engineer or designee will verify that the instrument was calibrated. If the instrument is unable to be properly calibrated, go to Step 5.10. If it has been properly calibrated, go to Step 5.11.

5.10

All instruments in need of repair because of damage or inability to be calibrated will be sent for repairs or removed from service.

5.11

The results of the calibration or repair or disposal of the instrument should be recorded on the inspection, measuring and test equipment log sheet. Any calibration certificate will be filed by the Chief Engineer or designee.

5.12

Calibration may be extended or delayed on an emergency as needed basis if an instrument is in the field or is required to satisfy production.

Control of Inspection, Measuring, and Test Equipment Procedure Turblex, Inc. Control of Inspection, Measuring, and Test Equipment Procedure (QAP# 4.11-01) Revision: 009 Date: 4/27/09

6.0

Records, Reports, and Forms 6.1 6.2

Test Equipment Calibration Certificate Log, #95120502 Calibration Label

Control of Inspection, Measuring, and Test Equipment Procedure Turblex, Inc. Control of Inspection, Measuring, and Test Equipment Procedure (QAP# 4.11-01) Revision: 009 Date: 4/27/09

Control of Non-Conforming Product Procedure 1.0

Purpose 1.1

2.0

Scope 2.1

3.0

4.0

This procedure covers all components and completed units. This includes vendor and customer supplied items, as well as items that are assembled or fabricated by Turblex.

Key Words 3.1

Non-conforming Product - Product that does not meet the specified requirements.

3.2

Specified Requirements - The requirements by which a product or service must conform that have been contractually agreed upon between the customer and supplier which includes any exceptions taken and agreed upon modifications.

3.3

Corrective/Preventive Action Report - Report filed due to major or recurring nonconforming product or procedure.

Reference 4.1 4.2 4.3 4.4

5.0

To establish and maintain documented procedures for control and proper disposition of nonconforming product.

Please reference Procedure 4.10-01 Inspection and Testing. Please reference Procedure 4.18-01 Training. Please reference Flow Chart 4.13 Control of Non-Conforming Product. Please reference Procedure 4.14-01 Corrective and Preventive Action.

Procedure 5.1

Every employee has the inherent responsibility to look for and identify possible non-conforming product.

Control of Non-Conforming Product Procedure Turblex, Inc. Control of Non-Conforming Product Procedure (QAP# 4.13-01) Revision: 009 Date: 4/27/09

5.2

If a product or component requiring a technical inspection is received, a two part yellow tag is placed on the item identifying the need for inspection. One part of the yellow tag will be torn off and sent to the inspector as notification of inspection need.

5.3

Authorized personnel inspect the product or component.

5.4

5.3.1

If the product or component conforms to the requirements the authorized inspector signs the yellow tag and the item is made available for production.

5.3.2

If the product or component does not conform to the requirements the inspector will notify the Project Manager who will make an evaluation whether a true non-conformance exists.

5.3.3

If a non-conformance does not exist, the Project Manager signs the yellow tag and the item is made available for production.

If a non-conformance does exist, then the Project Manager will place a Red Tag on the item. The Project Manager will enter the red tag onto a red tag log. The Project Manager will inspect all similar components for the job and other jobs if appropriate. Feedback will be given to the authorized inspector of the yellow tag as to the determination of whether there is a non-conformance. 5.4.1

The red tag log will contain all pertinent information pertaining to the non-conformance, such as tag number, job number if applicable, and initiator of red tag, brief description of non-conformance, type of non-conformance (category), how the non-conformance was corrected, who corrected it and what date the correction was complete. If the nonconformance is recurring, a major problem, or the system possibly needs to be changed, then the non-conformance shall be recorded on a corrective/preventive action report. When completed, the original report should be filed with the assistant ISO Coordinator and copies distributed to any departments affected.

5.5

The Material Manager will confer with appropriate personnel to determine the disposition of the non-conforming product

5.6

The disposition has been made to return the component to the vendor for replacement or credit. 5.6.1

5.7

Purchasing shall complete a Returned Goods Authorization (RGA) form to effectively return the goods to the vendor.

The disposition has been made to rework or repair the item to meet the customer's specifications. 5.7.1

Purchasing, Engineering, and Manufacturing will determine whether to return the part to the vendor or rework/repair the part in house. Go to Step 5.6.1 if the part will be returned to the vendor, otherwise proceed to 5.7.2.

5.7.2

Manufacturing will rework or repair the part.

5.7.3

An item will be re-inspected by engineering once it has been reworked or repaired. If the item passes the inspection then proceed to Step 5.7.4. If the item fails the inspection, then return to Step 5.5.

Control of Non-Conforming Product Procedure Turblex, Inc. Control of Non-Conforming Product Procedure (QAP# 4.13-01) Revision: 009 Date: 4/27/09

5.7.4

6.0

The Red Tag will be removed and the part made available for production.

5.8

Once the customer's concession or waiver is obtained in writing, the Red Tag will be removed by Engineering and the part made available for production.

5.9

A re-graded item will be identified as such and used appropriately.

5.10

The item will be scrapped in the appropriate manner under the direction of the Manufacturing Manager.

5.11

The Project Manager is responsible for clearing Yellow and Red Tags before shipment.

Records, Reports, and Forms 6.1 6.2 6.3 6.4

Yellow Tag Red Tag Corrective/Preventative Action Report, No. 95050901.QAS Red Tag Log, No. 95111001.QAS

Control of Non-Conforming Product Procedure Turblex, Inc. Control of Non-Conforming Product Procedure (QAP# 4.13-01) Revision: 009 Date: 4/27/09

Corrective and Preventative Action Procedure 1.0

Purpose 1.1

2.0

Scope 2.1

3.0

4.0

This procedure covers the analysis to determine the root cause of a nonconformance and the corrective action to prevent future similar nonconformances. The procedure also covers the analysis of new or modified processes or procedures before being implemented to prevent potential nonconformances.

Key Words 3.1

Non-conformance - The non-fulfillment of a specified requirement.

3.2

Specified Requirements - The requirements by which a product or service must conform that have been contractually agreed upon between the customer and supplier which includes any exceptions taken and agreed upon modifications.

Reference 4.1 4.2 4.3

5.0

To establish and maintain documented procedures for corrective and preventive action.

Please reference Procedure 4.13-01 Control of Nonconforming Product. Please reference Procedure 4.19-01 Servicing Procedure. Please reference Flow Chart 4.14-01 Corrective and Preventive Action Procedure.

Procedure 5.1

A Corrective/Preventive Action can be initiated by: A. B. C. D. E. F.

Internal or External Quality Audits Contact Notes / Customer Complaints Field Reports / Service Reports Vendor Analysis Log Red Tag Log A major problem, a recurring problem, or the system possibly needs to be changed.

Corrective and Preventative Action Procedure Turblex, Inc. Corrective and Preventative Action Procedure (QAP# 4.14-01) Revision: 010 Date: 4/27/09

The Corrective/Preventive Action will be logged. The corrective/preventive actions will be identified by a consecutive numbering system. A Corrective/Preventive Action Report will be completed, which clearly describes in detail the verified non-conformance or problem being corrected. 5.2

The ISO department, and/or any other necessary personnel, will perform an analysis to determine the root cause of the non-conformance. This analysis will examine the applicable processes, procedures, work instructions, quality records, customer complaints, service reports, work operations, and/or any other related items to the non-conformance. Any new or modified process or procedure will be reviewed by the ISO department and any other necessary personnel, to detect, analyze and eliminate potential causes of nonconformities before implementation.

6.0

5.3

The ISO department, and/or any other necessary personnel, will evaluate the Corrective/Preventive Action Report documenting a summary of the analysis performed, root cause, review of the potential impact on past product, action assigned to, action completed by and the date corrective action is required. The ISO department will file the original report and distribute copies to the appropriate areas listed in the distribution box.

5.4

Initiate measures to correct the root cause of the non-conformance.

5.5

Monitor the situation to determine if the actions taken have corrected the non-conformance and that no other non-conformances were created. If actions taken were effective, then close the Corrective/ Preventive Action Report; otherwise, return to Step 5.2.

5.6

Supplier non-conformances will be handled internally utilizing a Corrective/Preventive Action Report; however, completion of the report detailing root cause and corrective action to prevent reoccurrence is beyond our control and may not be attainable in some situations.

Records, Reports, and Forms 6.1 6.2

Corrective/Preventative Action Report, Form 95050901.QAS Corrective/Preventative Action Report Log, Form 95110901.QAS

Corrective and Preventative Action Procedure Turblex, Inc. Corrective and Preventative Action Procedure (QAP# 4.14-01) Revision: 010 Date: 4/27/09

Statistical Techniques Procedure

1.0

Purpose 1.1

2.0

Scope 2.1

3.0

None.

Reference 4.1

5.0

This procedure outlines statistical techniques criteria that Turblex must identify and address in order to comply with ISO 9001.

Key Words 3.1

4.0

To establish and maintain documented procedures to identify the need for statistical techniques required for establishing, controlling, and verifying process capability and product characteristics.

Please reference Procedure 4.10-01 Inspection and Testing Procedure.

Procedure 5.1

Turblex Field Service Surveys retuned from the customer are kept in a binder; the administrative assistant does a summary of the reports each quarter.

5.2

Turblex Engineering/Start up Surveys returned from the customer are kept in a binder, the administrative assistant does a summary of the reports each quarter.

5.3

Customer Complaints are documented on Contact Notes and kept in a file to be reviewed by the Operations Manager who determines if the Customer Complaint should be recorded on a Corrective/Preventive Action Report. (See 5.6)

5.4

Field Reports and Service Reports are given to the Operations Manager who determines if any issues encountered should be recorded on a Corrective/Preventive Action Report. (See 5.6)

Statistical Techniques Procedure Turblex, Inc. Statistical Techniques Procedure (QAP# 4.20-01) Revision: 006 Date: 4/27/09

5.5

Contact Notes used in the area of Field Service and/or Customer Service are kept in a file to be reviewed by the Operations Manager who determines if any issues documented should be recorded on a Corrective/Preventive Action Report. (See 5.6)

5.6

Corrective/Preventive Action Reports are summarized and reviewed in the Management Review Board Meetings.

5.7

Job Costs - Assembly labor and engineering hours, material costs, and start-up costs are collected and monitored to measure product cost trends and quality trends (i.e., warranty).

5.8

Warranty - Warranty costs are tracked and compared to budget and previous years. Information is reviewed in Management Review Board Meeting.

5.9

Red Tag Log - The red tag log is summarized by category and results are reviewed in the Management Review Board Meeting.

5.10

Engineering Change Orders - ECO's are grouped into categories and summarized, results are reviewed in the Management Review Board Meeting.

5.11

Vendor problem log - Vendor problems are grouped into categories and summarized, results are reviewed in the Management Review Board Meeting.

5.12

The following are guidelines for sampling and inspecting incoming fabricated items: 1. 10 pieces or less: Inspect all items. 2. 11 to 100 pieces: A sample of ten percent of the items shall be randomly chosen for inspection. If two of the pieces are rejected, then an additional ten percent of the items shall be inspected. If more than a total of 2 rejections are made, then 100% of the delivery shall be inspected. 3. 101 to 1000 pieces or more: A sample of five percent of the items shall be randomly chosen for inspection. If two of the pieces are rejected, then an additional five percent of the items shall be inspected. If more than a total of 2 rejections are made, then 100% of the delivery shall be inspected.

6.0

Records, Reports, and Forms 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

Turblex Field Service Surveys Turblex Engineering/Start up Surveys Field Reports and Service Reports Contact Notes Corrective/Preventive Actions Reports Red Tag Log Engineering Change Orders Vendor Problem Log

Statistical Techniques Procedure Turblex, Inc. Statistical Techniques Procedure (QAP# 4.20-01) Revision: 006 Date: 4/27/09

QUALITY MANAGEMENT PROCESS Servicing

Requirements

Control of NonConforming Product

Quote/Proposal

C U S T O M E R

Contract Review

Purchase Order

Job File to Engineering

Acceptance Letter to Customer

Design Change Control Submittal to Customer

Approved Submittal

Inspection & Testing

Incoming Product

Design Type

Submittal Changes

Product Shipment

Purchase Order to Vendor

Purchasing

Project Design Control

Shop Package to Materials & Manufacturing

Control of Inspection & Test Equipment

Customer Supplied Product

C U S T O M E R

Servicing Procedure

1.0

Purpose 1.1

2.0

Scope 2.1

3.0

4.0

This procedure covers all equipment commissioning, warranty needs, after sales servicing activities, as specified in the contract and customer complaints.

Key Words 3.1

Job file - A file made up of several books containing information concerning the job at various stages of completion.

3.2

Jobsite file - A file made up of several books containing information, correspondence, records, reports and various other documents concerning the job after, but not limited to, start-up.

Reference 4.1 4.2 4.3

5.0

To establish and maintain documented procedures for equipment commissioning (start-up including customer training), satisfying warranty needs, and after sales servicing activities.

Please reference Procedure 4.3-01 Contract Review. Please reference Procedure 4.14-01 Corrective and Preventive Action. Please reference Procedure 4.18-01 Training.

Procedure General Statement: Only qualified individuals will perform start-up, service, and warranty work. The goal of Turblex is to meet or exceed customer requirements and achieve a high level of customer satisfaction at a reasonable cost. 5.1

If this is a service or warranty activity, then proceed to Step 5.2. If this is a startup activity, then proceed to Step 5.3.

Servicing Procedure Turblex, Inc. Servicing Procedure (QAP# 4.19-01) Revision: 009 Date: 4/27/09

5.2

Determine the needs of the customer. Determine if it is a warranty issue, a billable service, or parts job. Discuss the billable or warranty determination with the customer. If a billable job, then give quote to the customer. The terms of the purchase order from the customer will be reviewed by the Service or Parts Manager, and the other information contained in the purchase order will be compared to the quote. Once purchase order details have been finalized with the customer, then proceed to Step 5.4.

5.3

The customer should complete a Compressor (Blower) Pre-Startup Inspection Checklist and send to Turblex before Turblex personnel or representatives travel to the jobsite.

5.4

The start-up, warranty, billable service, or spare parts work is completed by qualified individuals. The person performing the work shall fill out the appropriate documentation applicable to the situation. The documentation and instructions on use and application shall be found in the department work instruction books. Documentation such as Field Reports serve, not only as final product validation, but will also determine billable service work; which if billable, the customer should sign-off on billable hours.

5.5

When the service, warranty, or start-up work is complete, the customer should sign a field service/start-up form and/or any other appropriate forms. These forms should signify the beginning date of the warranty period.

5.6

The field reports and service reports will be given to the Vice-President who will review the reports to determine if a Corrective/Preventive Action Report is required. (See Procedure 4.19-02 Sec. 5.2) Copies will be distributed to the appropriate individuals if necessary. 5.6.1

5.7 6.0

The signed original is then filed in the job file until warranty is up, and the jobsite file after that.

The customer will be invoiced for billable service or parts jobs.

Records, Reports, and Forms 6.1 6.2 6.3 6.4

Compressor (Blower) Pre-Startup Inspection Checklist Form, No. 98012802.QAS Field Report Form, No. 98011601.QAS Field Service/Start-up Sign-off Sheet Form, No. 98011602.QAS Contact Notes Form, No. 96040301.QAS

Servicing Procedure Turblex, Inc. Servicing Procedure (QAP# 4.19-01) Revision: 009 Date: 4/27/09

Item E Production Traveler Quality Assurance

www.turblex.com

QUALITY ASSURANCE PRODUCTION TRAVELER

PAGE: 1 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

INSPECTION FORMS COMPRESSOR INSPECTION FORM

COMPLETED BY PROJ. MGR.

MOTOR INSPECTION FORM

PROJ. MGR.

ENGINE INSPECTION FORM

PROJ. MGR.

BASE INSPECTION FORM

INSPECTOR

CONE AND BLOW-OFF SILENCER INSPECTION FORM

INSPECTOR

INLET FILTER SILENCER ASSEMBLY INSPECTION FORM

INSPECTOR

BLOW-OFF VALVE INSPECTION FORM

PROJ. MGR.

DISCHARGE VALVE INSPECTION FORM

PROJ. MGR.

HEADER BLOW-OFF VALVE INSPECTION FORM

PROJ. MGR.

FLOW CONTROL VALVE INSPECTION FORM

PROJ. MGR.

SHOP COUPLING ALIGNMENT RECORD FORM

MFG. MGR.

LUBE OIL PIPING SYSTEM INSPECITON FORM

MFG. & PROJ. MGR.

SKID ASSEMBLY SUFACE FINISH INSPECTION FORM

MFG. MGR.

LOCAL CONTROL PANEL SYSTEM TEST FORM

E. ENG. & PROJ. MGR.

MASTER CONTROL PANEL SYSTEM TEST FORM

E. ENG. & PROJ. MGR.

LABELS INSTALLATION RECORD FORM

MFG. or PROJ. MGR.

FINAL INSPECTION FORM

MFG. & PROJ. MGR.

ELECTRICAL PANEL LAYOUT/CT LOCATION LOCAL CONTROL PANEL BACK PANEL LAYOUT APPROVAL

E. ENG

LOCAL CONTROL PANEL SIDE PANEL LAYOUT APPROVAL

E. ENG

LOCAL CONTROL PANEL DOOR LAYOUT APPR0VAL

E. ENG

MASTER CONTROL PANEL BACK PANEL LAYOUT APPROVAL

E. ENG

MASTER CONTROL PANEL SIDE PANEL LAYOUT APPROVAL

E. ENG

MASTER CONTROL PANEL DOOR LAYOUT APPROVAL CT LOCATION APPROVAL

REMARKS:

RED TAGS:

G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

E. ENG PROJ. MGR.

DATE COMPLETED

INITIAL

COMPRESSOR INSPECTION FORM

PAGE: 2 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

RECORD AND VERIFY THE FOLLOWING DATA: SERIAL NO. MECHANICAL OIL PUMP MODEL NO. IGV ACTUATOR MODEL NO. IGV ACTUATOR SERIAL NO. IGV ACTUATOR VOLT., FREQ. & PHASE

V,

IGV ACTUATOR SPEED & STROKE LENGTH

Hz,

ph

V,

Hz,

ph

V,

Hz,

ph

V,

Hz,

ph

mm/s,

mm

mm/s,

mm

mm/s,

mm

mm/s,

mm

IGV ACTUATOR FORCE & AMP.

N,

Amp

N,

Amp

N,

Amp

N,

Amp

IGV ACTUATOR CAPACITOR IS OK / SIZE

/

mfd

/

mfd

/

mfd

/

mfd

VD ACTUATOR MODEL NO. VD ACTUATOR SERIAL NO. VD ACTUATOR VOLT., FREQ. & PHASE VD ACTUATOR SPEED & STROKE LENGTH VD ACTUATOR FORCE & AMP. VD ACTUATOR CAPACITOR IS OK / SIZE VERIFY/INSPECT THE FOLLOWING: UNIT IS CONSISTENT WITH HVT PO UNIT IS CONSISTENT WITH P&ID AND GA IGV ACTUATOR IGV LIMIT SWITCHES VD ACTUATOR VD LIMIT SWITCHES SHAFT & KEY MECHANICAL OIL PUMP BEARING RTDS BEARING RTD FITTINGS D&T HOLES FOR PROX. PROBES D&T HOLE FOR ACCELEROMETER BLOWER DISCHARGE ORIENTATION DISCHARGE FLANGE ADAPTER DISCHARGE FLANGE BOLT PATTERN SPECIAL TOOLS AS RECEIVED SPARE PARTS AS RECEIVED NO OIL LEAKAGE AT THE LABYRINTH SEAL VENT COVERS REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

V,

Hz,

ph

V,

Hz,

ph

V,

Hz,

ph

V,

Hz,

ph

mm/s,

mm

mm/s,

mm

mm/s,

mm

mm/s,

mm

N,

Amp

N,

Amp

N,

Amp

N,

Amp

/

mfd

/

mfd

/

mfd

/

mfd

100% INSPECTION OF ALL MACHINES REQUIRED BEFORE CHECKED OFF EXCEPTIONS & RED TAG NOS:

MOTOR INSPECTION FORM

PAGE: 3 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

RECORD AND VERIFY THE FOLLOWING DATA: SERIAL NO. HORSE POWER

HP

SERVICE FACTOR RPM VOLTAGE, FREQUENCY & PHASE

V,

Hz,

HP

HP

HP

SF

SF

SF

SF

rpm

rpm

rpm

rpm

ph

V,

Hz,

ph

V,

Hz,

ph

V,

Hz,

ph

ENCLOSURE FRAME INSULATION CLASS MAXIMUM AMBIENT TEMPERATURE

ºC

ºC

ºC

ºC

TEMPERATURE RISE

ºC

ºC

ºC

ºC

%

%

%

%

NEMA DESIGN NEMA CODE EFFICIENCY POWER FACTOR FULL LOAD AMPS

%

%

%

%

Amp

Amp

Amp

Amp

ROTATION @ ODE SPACE HEATER VOLTAGE & WATTS VERIFY/INSPECT THE FOLLOWING: UNIT IS CONSISTENT WITH DATA SHEET & PRINT UNIT IS CONSISTENT WITH P&ID SHAFT AND KEY BEARING RTDS WINDING RTDS TEMPERATURE SWITCH VIBRATION SWITCH D&T HOLES FOR VIBRATION SENSORS SUPPLIED VIBRATION SENSORS OVERSIZED CONDUIT BOX SURGE CAPACITORS LIGHTNING ARRESTORS PF CORRECTION CAPACITORS DIFFERENTIAL CT'S SPARE BEARINGS REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

V,

W

V,

W

V,

100% INSPECTION OF ALL MACHINES REQUIRED BEFORE CHECKED OFF EXCEPTIONS & RED TAG NOS:

W

V,

W

ENGINE INSPECTION FORM

PAGE: 4 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

RECORD AND VERIFY THE FOLLOWING DATA: SERIAL NO. NAMEPLATE DATA: RECORD ALL DATA SHOWN ON THE NAMEPLATE IN THE SPACE BELOW. THERE MAY BE MORE THAN ONE NAMEPLATE.

VERIFY NAMEPLATE DATA IS CONSITENT WITH

EXCEPTIONS & RED TAG NOS:

DESIGN SPECIFICATION VERIFY THE FOLLOWING USING THE ENGINE INSTALLATION DRAWINGS: ENGINE ROTATION

EXCEPTIONS & RED TAG NOS:

ENGINE MOUNTING HOLE SIZES & LOCATIONS GENARAL LOCATIONS OF ENGINE COMPONENTS SIZES AND LOCATIONS OF ALL ENGINE CONNECTIONS VERIFY ALL SHIP LOOSE COMPONENTS AND ASSEMBLIES. RECORD THE DESCRIPTION OF EACH ITEM IN THE SPACE BELOW. EXCEPTIONS & RED TAG NOS:

REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

BASE INSPECTION FORM

PAGE: 5 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

NOTE: VERIFY ALL DIMENSIONS TO TAPE MEASURE ACCURACY OF +/- 1/8". UNIT NO.

EXCEPTIONS & RED TAG NOS.

VERIFY/INSPECT THE FOLLOWING: OVERALL HxLxW VIBRATION ISOLATOR ANCHOR HOLES LIFTING LUB STAMPED WITH THE JOB NO. OIL DRAIN COUPLING IS 1 1/2" NPT SIGHT GLASS COUPLING IS VERTICAL LCP & COOLER BRACKETS ARE LEVEL & SQUARE MOTOR MOUNTS ARE WELDED INSIDE & OUT ALL WELDS ARE CLEAN & UNIFORM ALL BURRS, TACK WELDS, & JAGGED EDGES ARE GROUND SMOOTH PHYSICALLY & DIMENSIONALLY CORRECT PER PRINT DATE INSPECTED: INSPECTOR INITIALS:

NOTE: VERIFY THE OIL RESERVOIRS ARE WATER TIGHT UNIT NO.

EXCEPTIONS & RED TAG NOS.

VERIFY/INSPECT THE FOLLOWING: NO LEAKS AFTER 12 HRS DATE INSPECTED: MFG MANAGER INITIALS:

NOTE: VERIFY ALL MACHINING DIMENSIONS TO TAPE MEASURE ACCURACY OF +/- 1/16" UNIT NO. VERIFY/INSPECT THE FOLLOWING: MACHINED DIMENSIONS MATCH THE PRINT RESERVOIR COATING (FREE OF HOLIDAY RUNS & UNIFORM IN COLOR) EXTERNAL PRIMER (FREE OF HOLIDAY RUNS & UNIFORM IN COLOR THREADED HOLES (FREE OF DEBRIS & THREADS APPEAR UNIFORM) MATING SURFACES FREE OF DEFECTS/RUST FLANGE GASKETS & PLUGS INSTALLED

DATE INSPECTED: INSPECTOR INITIALS:

G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

EXCEPTIONS & RED TAG NOS.

CONE AND BLOW-OFF SILENCER INSPECTION FORM

PAGE: 6 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

CONE INSPECTION: NOTE: VERIFY ALL DIMENSIONS TO TAPE MEASURE ACCURACY OF +/- 1/16". UNIT NO. VERIFY/INSPECT THE FOLLOWING: OVERALL LENGTH

EXCEPTIONS & RED TAG NOS:

BLOW-OFF PIPE LOCATION INLET FLANGE DISCHARGE FLANGE BLOW-OFF FLANGE PITOT TUBE HOLES ORIENTATION INLET FLANGE ORIENTATION DISCHARGE FLANGE ORIENTATION BLOW-OFF FLANGE ORIENTATION MATING SURFACES (FREE OF DEFECTS/RUST) FLANGE TO FLANGE SQUARENESS WELDS (CONFORM TO DRAWING SPECIFICATION, CLEAN AND UNIFORM) CONE INTERIOR (CLEAN & FREE OF DEFECT) COUPLINGS & PLUGS INSTALLED THREADED HOLES (FREE OF DEBRIS AND THREADS APPEAR UNIFORM) PRESSURE TEST COMPLETED BY VENDOR REMARKS:

DATE INSPECTED INSPECTOR INITIAL

BLOW-OFF SILENCER INSPECTION: NOTE: VERIFY ALL DIMENSIONS TO TAPE MEASURE ACCURACY OF +/- 1/16". UNIT NO. VERIFY/INSPECT THE FOLLOWING: OVERALL HEIGHT SILENCER DIAMETER CONNECTING FLANGE MATING SURFACES (FREE OF DEFECTS/RUST) INTERIOR (CLEAN & FREE OF DEFECT) WELDS (CONFORM TO DRAWING SPECIFICATION, CLEAN AND UNIFORM) REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

EXCEPTIONS & RED TAG NOS:

INLET FILTER SILENCER ASSEMBLY INSPECTION FORM

PAGE: 7 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

NOTE: VERIFY ALL DIMENSIONS TO TAPE MEASURE ACCURACY OF +/- 1/16". UNIT NO. VERIFY/INSPECT THE FOLLOWING: OVERALL HxLxW VERTICAL CENTERLINE HORIZONTAL CENTERLINE INLET CONNECTING FLANGE OUTLET CONNECTING PIPE INLET FLANGE (FREE OF DEFECTS) OUTLET PIPE (FREE OF DEFECTS) FILTER HOUSING (FREE OF DEFECTS) FILTER/SILENCER INTERFACE (PROPERLY SEALED AND ALL FASTENERS TIGHTENED) SILENCER WALL PANELS (PROPERLY SEALED AND ALL FASTENERS TIGHTENED) SILENCER/SHROUD INTERFACE (PROPERLY SEALED AND ALL FASTENERS TIGHTENED) LIFTING LUGS AND FEET INSTALLED PRESSURE SENSING PORT (COUPLING AND PIPE INSTALLED) ALL EXPOSED SURFACES (FREE DEFECT AND PROPERLY GALVANIZED) INTERIOR (CLEAN AND FREE OF FOREIGN OBJECTS LAMELLAS (CLEAN AND FREE OF TEARS) ANY FOAM DAMAGED MUST BE REPAIRED. REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

EXCEPTIONS & RED TAG NOS:

BLOW-OFF VALVE INSPECTION FORM

PAGE: 8 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

RECORD AND VERIFY THE FOLLOWING: VALVE SERIAL NO. ('S) VALVE SIZE VALVE TYPE VALVE MODEL ACTUATOR SERIAL NO. ('S) ACTUATOR TYPE ACTUATOR MODEL ACTUATOR VOLTAGE ACTUATOR MOTOR CURRENT ACTUATOR TRAVEL TIME VERIFY/INSPECT THE FOLLOWING: VALVE BODY

EXCEPTIONS & RED TAG NOS:

VALVE SEAT VALVE DISC ACTUATOR HOUSING LOCAL CONTROL STATION PAINT ACTUATOR ORIENTATION MATCHES PIPING CONFIGURATION ACTUATOR ORIENTATION WON'T INTERFERE WITH NEARBY PIPING COMPONENTS REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

DISCHARGE VALVE INSPECTION FORM

PAGE: 9 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

RECORD AND VERIFY THE FOLLOWING: VALVE SERIAL NO. ('S) VALVE SIZE VALVE TYPE VALVE MODEL ACTUATOR SERIAL NO. ('S) ACTUATOR TYPE ACTUATOR MODEL ACTUATOR VOLTAGE ACTUATOR MOTOR CURRENT ACTUATOR TRAVEL TIME VERIFY/INSPECT THE FOLLOWING: VALVE BODY

EXCEPTIONS & RED TAG NOS:

VALVE SEAT VALVE DISC ACTUATOR HOUSING LOCAL CONTROL STATION PAINT ACTUATOR ORIENTATION MATCHES PIPING CONFIGURATION ACTUATOR ORIENTATION WON'T INTERFERE WITH NEARBY PIPING COMPONENTS REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

HEADER BLOW-OFF VALVE INSPECTION FORM

PAGE: 10 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

RECORD AND VERIFY THE FOLLOWING: VALVE SERIAL NO. ('S) VALVE SIZE VALVE TYPE VALVE MODEL ACTUATOR SERIAL NO. ('S) ACTUATOR TYPE ACTUATOR MODEL ACTUATOR VOLTAGE ACTUATOR MOTOR CURRENT ACTUATOR TRAVEL TIME VERIFY/INSPECT THE FOLLOWING: VALVE BODY

EXCEPTIONS & RED TAG NOS:

VALVE SEAT VALVE DISC ACTUATOR HOUSING LOCAL CONTROL STATION PAINT ACTUATOR ORIENTATION MATCHES PIPING CONFIGURATION ACTUATOR ORIENTATION WON'T INTERFERE WITH NEARBY PIPING COMPONENTS REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

FLOW CONTROL VALVE INSPECTION FORM

PAGE: 11 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

RECORD AND VERIFY THE FOLLOWING: VALVE SERIAL NO. ('S) VALVE SIZE VALVE TYPE VALVE MODEL ACTUATOR SERIAL NO. ('S) ACTUATOR TYPE ACTUATOR MODEL ACTUATOR VOLTAGE ACTUATOR MOTOR CURRENT ACTUATOR TRAVEL TIME VERIFY/INSPECT THE FOLLOWING: VALVE BODY

EXCEPTIONS & RED TAG NOS:

VALVE SEAT VALVE DISC ACTUATOR HOUSING LOCAL CONTROL STATION PAINT ACTUATOR ORIENTATION MATCHES PIPING CONFIGURATION ACTUATOR ORIENTATION WON'T INTERFERE WITH NEARBY PIPING COMPONENTS REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

SHOP COUPLING ALIGNMENT RECORD FORM

PAGE: 12 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

ALIGNMENT RECORD (BY SHOP PERSONNEL): COMPRESSOR SERIAL NO. MOTOR SERIAL NO. DATE ALIGNED NOTES: SPACER TOLERANCE: 9 IN +1/32" - 0"

0 DEG.

MAX. ALLOWABLE MISALIGNMENT: 0.002 IN MAX. ALLOWABLE SOFT FOOT: 0.002 IN 270 DEG. 90 DEG.

180 DEG.

LOOKING AT THE COMPRESSOR SHAFT.

ALIGNMENT READINGS: SPACER DISTANCE 0 DEG. RADIAL 0 DEG. AXIAL 90 DEG. RADIAL 90 DEG. AXIAL 180 DEG. RADIAL 180 DEG. AXIAL 270 DEG. RADIAL 270 DEG. AXIAL SOFT FOOT READINGS: (LOOKING AT NDE OF MOTOR) @ 0 DEG RADIAL LEFT NDE LEFT DE RIGHT NDE RIGHT DE REMARKS:

ALIGNED BY APPROVED BY (MFG MGR OR PROJ. MGR) G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

LUBE OIL PIPING SYSTEM INSPECTION FORM

PAGE: 13 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

WATER PIPING ASSEMBLY INSPECTION AND TESTING (BY MFG MGR): VERIFY THE FOLLOWING UNIT ASSEMBLED PER DRAWINGS AND ECOS

EXCEPTIONS & RED TAG NOS:

COMPONENT FLOW DIRECTION CORRECT UNIT PASSED PRESSURE TEST (CERTIFIED THAT ALL PIPE CONNECTIONS ARE LEAK FREE) REMARKS:

DATE INSPECTED / TESTED INSPECTOR INITIAL

OIL PIPING ASSEMBLY INSPECTION (BY MFG MGR): VERIFY THE FOLLOWING UNIT ASSEMBLED PER DRAWINGS AND ECOS

EXCEPTIONS & RED TAG NOS:

FILTER DIFFERENTIAL SWITCHES ARE INSTALLED CORRECTLY (Per manufacture instructions) DIPSTICK IS CORRECTLY MARKED UNIT PASSED 225 PSI DRY NITROGEN PRESSURE TEST IF AIR COOLED, AMOT VALVE CONNECTIONS ARE CORRECT FOR MIXING APPLICATION REMARKS:

DATE INSPECTED INSPECTOR INITIAL

OIL PIPING ASSEMBLY TESTING (BY PROJ. MGR): VERIFY THE FOLLOWING: UNIT PASSED 24 HOURS TEST (CERTIFIED THAT

EXCEPTIONS & RED TAG NOS:

ALL FLANGE & PIPE CONNECTIONS, ALL RTDS & PROX PROBES, MOTOR BEARING HOUSINGS & & BLOWER GEARBOX, AND ALL PLUGS ARE LEAK FREE) NO OIL LEAKAGE AT THE LABYRINTH SEAL VENT COVERS REMARKS:

DATE TESTED INSPECTOR INITIAL

COUPLING GUARD (BY PROJ. MGR): VERIFY THE FOLLOWING: COUPLING GUARD DRAWING HAS BEEN ISSUED AND RELEASED TO PURCHASING. REMARKS:

DATE COMPLETED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

EXCEPTIONS & RED TAG NOS:

SURFACE FINISH INSPECTION FORM

PAGE: 14 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

SERIAL NO. BEFORE PAINTING: VERIFY ALL SURFACES ARE PREPARED PER

EXCEPTIONS & RED TAG NOS:

TURBLEX COATING SYSTEM SPECIFICATION RECORD THE THICKNESSES (MILS DFT) OF THE ORIGINAL COATINGS ON THE COMPRESSOR, MOTOR, BASE, CONE & BLOW-OFF SILENCER IN THE SPACE BELOW. RECORD THREE DIFFERENT POINTS ON EACH COMPONENT. COMPRESSOR

/

/

/

/

/

/

/

/

MOTOR

/

/

/

/

/

/

/

/

BASE

/

/

/

/

/

/

/

/

CONE

/

/

/

/

/

/

/

/

BLOW-OFF SILENCER

/

/

/

/

/

/

/

/

AFTER APPLICATION OF PRIMER COAT: RECORD THE COMBINED THICKNESSES (MILS DFT) OF THE ORIGINAL AND PRIMER COATINGS ON THE COMPRESSOR, MOTOR, BASE, CONE & BLOW-OFF SILENCER IN THE SPACE BELOW. RECORD THREE DIFFERENT POINTS ON EACH COMPONENT. COMPRESSOR

/

/

/

/

/

/

/

/

MOTOR

/

/

/

/

/

/

/

/

BASE

/

/

/

/

/

/

/

/

CONE

/

/

/

/

/

/

/

/

BLOW-OFF SILENCER

/

/

/

/

/

/

/

/

VERIFY PRIMER THICKNESS CONFORMS TO

EXCEPTIONS & RED TAG NOS:

TURBLEX COATING SYSTEM SPECIFICATION AFTER APPLICATION OF FINISH COAT: RECORD THE COMBINED THICKNESSES (MILS DFT) OF THE ORIGINAL, PRIMER AND FIHISH COATINGS ON THE COMPRESSOR, MOTOR, BASE, CONE & BLOW-OFF SILENCER IN THE SPACE BELOW. RECORD THREE DIFFERENT POINTS ON EACH COMPONENT. COMPRESSOR

/

/

/

/

/

/

/

/

MOTOR

/

/

/

/

/

/

/

/

BASE

/

/

/

/

/

/

/

/

CONE

/

/

/

/

/

/

/

/

BLOW-OFF SILENCER

/

/

/

/

/

/

/

/

VERIFY FINISH COAT THICKNESS CONFORMS TO TURBLEX COATING SYSTEM SPECIFICATION VERIFY SURFACE FINISH IS FREE OF HOLIDAYS AND RUNS VERIFY COLOR AND TEXTURE ARE UNIFORM REMARKS:

DATE INSPECTED INSPECTOR INITIAL G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

EXCEPTIONS & RED TAG NOS:

LOCAL CONTROL PANEL SYSTEM TEST FORM

PAGE: 15 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

SYSTEM INSTALLATION CHECK (BY ELEC. ENG.): UNIT NO. VERIFY / PERFORM THE FOLLOWING: CONTROL PANEL IS WIRED PER SCHEMATICS

REMARKS:

J-BOXES ARE WIRED PER SCHEMATICS SKID COMPONENTS ARE WIRED TO J-BOXES AND LCP PER SCHEMATICS VALVES ARE WIRED TO LCP PER SCHEMATICS VOLTAGE CHECK AC AND DC POWERS SET OVERLOADS ON MOTOR STARTERS PER SCHEMATICS (VERIFY ACTUAL DEVICE RATING) TRIP TEST AND RESET GFCI LOAD SOFTWARES CONFIRM ALL DIGITAL & ANALOG SIGNALS ARE ACTIVE AND CORRECT PER SCHEMATICS VERIFY BLOWER AND MOTOR BEARING RTDS BY DISCONNECTING WIRE AT TRANSMITTER SET BOV OPEN/CLOSE LIMIT SWITCHES SET DV OPEN/CLOSE LIMIT SWITCHES SET IGV / VD LIMIT SWITCHES PER PRC-4 VERIFY AUTO CALIBRATION FOR IGV AND VD (RANGE OF R/I UNIT IS 100 OHMS TO 900 OHMS) AUTOMATIC VANE EXERCISE - EVERY 12HRS COMPLETE PRC-4 TABLE AND ATTACH TO THIS DOCUMENT WHEN COMPLETED DATE COMPLETED ABOVE CHECKS CHECKED BY (ELEC. ENG.)

ECO CLOSE OUT (BY PROJ MGR) ALL ECO'S RELEASED TO PRODUCTION ARE COMPLETED, SIGNED-OFF, AND RETURNED TO PRODUCTION TRAVELER

REMARKS

ALL SIGNED-OFF ECO'S TRANSFERRED TO JOB FILE ECO LOG COMPLETED PROJECT MGR INITIAL/DATE

AS BUILT CLOSE OUT (BY PROJ MGR) ALL RED LINED SHOP DRAWINGS COLLECTED AND CHANGES TRANSFERRED TO AS BUILT DRAWINGS

REMARKS

GA, LUBE OIL PIPING, AND BASE DRAWINGS UPDATED TO REFLECT FINISHED SKID ASSEMBLY PROJECT MGR INTIAL/DATE

RED TAG CLOSE OUT (BY PROJ MGR) VERIFY ALL RED TAGS ARE REMOVED VERIFY ALL CORRECTIONS ARE RECORDED ON RED TAG LOG PROJECT MGR INTIAL/DATE

REMARKS

LOCAL CONTROL PANEL SYSTEM TEST FORM

PAGE: 16 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

SYSTEM FUNCTIONAL CHECK (BY ELEC. ENG. & VERIFIED BY PROJ. MGR) NORMAL/SERVICE/TEST MODES: SWITCH BETWEEN NORMAL/SERVICE/TEST/ MODES SEVERAL TIMES AND VERIFY THE FOLLOWING. PAY CLOSE ATTENTION TO THE STATUS MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. VERIFY THE MODE SELECTION

REMARKS:

BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT EACH MODE STATUS IS CORRECTLY DISPLAYED ON MAIN OPERATING SCREEN ALARM IS ACTIVATED AND STAYS ACTIVATED WHEN IN SERVICE MODE START IS INHIBITED WHEN IN SERVICE MODE SERVICE MODE OPERATIONS CHECK: PLACE LCP IN THE SERVICE MODE, VERIFY THE FOLLOWING DEVICES OPERATE AS DECRIBED IN THE LCP PROCEDURE AND CONFIRM ALL STATUS INFORMATION IS CORRECTLY DISPLAYED ON THE SCREEN(S). PAY CLOSE ATTENTION TO THE STATUS MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. AUX. OIL PUMP AND ON/OFF BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE IGV AND OPEN/CLOSE BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE IGV GRAPHIC AND/OR NUMERIC VALUE ARE DISPLAYED CORRECTLY VD AND OPEN/CLOSE BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE VD GRAPHIC AND/OR NUMERIC VALUE ARE DISPLAYED CORRECTLY BOV AND OPEN/CLOSE BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE DV AND OPEN/CLOSE BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE OIL COOLER FAN AND ON/OFF BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE COOLING WATER SOL. VALVE AND ON/OFF BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE SOUND ENCLOSURE FAN AND ON/OFF BUTTON FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE OIL HEATER AND ON/OFF BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE AUTO CALIBRATE IGV & VD BUTTON TO FUNCTION PROPERLY AND DISPLAY CORRECT TEST & COLOR CHANGE. BUTTON IS DISABLED WHEN ON-LINE OR DURING START-UP SEQUENCE

REMARKS:

LOCAL CONTROL PANEL SYSTEM TEST FORM

PAGE: 17 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

START SEQUENCE CHECK: PLACE LCP IN THE TEST MODE, VERIFY THE START SEQUENCE OPERATES AS DESCRIBED IN THE LCP PROCEDURE AND CONFIRM ALL STATUS INFORMATION IS CORRECTLY DISPLAYED ON THE SCREEN. PAY CLOSE ATTENTION TO THE SEQUENCE MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. BLOWER START BUTTON AND START

REMARKS:

SEQUENCE FUNCTION PROPERLY AND STATUS MESSAGES ARE CORRECTLY DISPLAYED ON THE MESSAGE CENTER VD AND OPEN/CLOSE BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE VD/AMPS GRAPHICS AND NUMERIC VALUES ARE DISPLAYED CORRECTLY IGV AUTOMATICALLY RESPONSE TO PRC-4 CONTROL AS BLOWER CAPACITY VARIES LOCAL/REMOTE SELECTION SWITCH FUNCTION PROPERLY AND DISPLAY CORRECT TEXT AND COLOR CHANGE VERIFY CR1 DOES NOT ENERGIZE IN TEST MODE STOP SEQUENCE CHECK: PLACE LCP IN THE TEST MODE, VERIFY THE STOP SEQUENCE OPERATES AS DESCRIBED IN THE LCP PROCECURE AND CONFIRM ALL STATUS INFORMATION IS PROPERLY DISPLAYED ON THE SCREEN. PAY CLOSE ATTENTION TO THE SEQUENCE MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. BLOWER STOP BUTTON AND NORMAL STOP

REMARKS:

SEQUENCE FUNCTION PROPERLY AND STATUS MESSAGES ARE CORRECTLY DISPLAYED ON THE MESSAGE CENTER E-STOP BUTTON AND E-STOP SEQUENCE FUNCTION PROPERLY AND STATUS MESSAGES ARE CORRECTLY DISPLAYED ON THE MESSAGE CENTER, AND THE ALARM WINDOW SIMULATE A SOFT STOP - SOFT STOP SEQUENCE FUNCTION PROPERLY AND STATUS MESSAGES ARE CORRECTLY DISPLAYED ON THE MESSAGE CENTER, AND THE ALARM WINDOW ALARM / TRIP FUNCTIONAL CHECK: PLACE LCP IN THE TEST OR NORMAL MODE, SIMULATE THE FOLLOWING ABNORMAL CONDITIONS AND VERIFY THEIR ALARM / TRIP FUNCTIONS OPERATE AS DESCRIBED IN THE LCP PROCEDURE, CONFIRM ALL ALARM MESSAGES ARE CORRECTLY DISPLAYED ON THE ALARM WINDOWAND HORN/BEACON ARE ENERGIZED. PAY CLOSE ATTENTION TO THE ALARM MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. SOFT STOP IS INITIATED BY: HIGH OIL TEMPERATURE HIGH INLET AIR TEMERATURE HIGH BLOWER BEARING TEMPERATURE HIGH MOTOR BEARING TEMPERATURE HIGH MOTOR WINDING TEMPERATURE SURGE HIGH MOTOR AMPERAGE

REMARKS:

LOCAL CONTROL PANEL SYSTEM TEST FORM

PAGE: 18 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

E-STOP IS INITIATED BY: LOW OIL PRESSURE

REMARKS:

LOW/LOW OIL PRESSURE

REMARKS:

HIGH BLOWER VIBRATION HIGH MOTOR VIBRATION BOV NOT CLOSED AT START SEQUENCE BOV NOT OPEN AT STOP SEQUENCE

CHECK THE NEXT THREE IN NORMAL MODE NO MOTOR FEEDBACK AT START SEQUENCE LOSS OF MOTOR FEEDBACK MOTOR NOT STOPPED AT STOP SEQUENCE CONFIRM ALARM ACKNOWLEDGE BUTTON FUNCTIONS PROPERLY

AUTOMATIC PLC SAFETY OPERATIONS CHECK: PLACE LCP IN THE TEST MODE, VERIFY THE FOLLOWING PLC OPERATIONS AS DESCRIBED IN THE LCP PROCEDURE AND CONFIRM ALL ALARM MESSAGES ARE CORRECTLY DISPLAYED ON ON THE ALARM WINDOW, AND HORN/BEACON ARE ENERGIZED. PAY CLOSE ATTENTION TO THE ALARM MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. LOW OIL TEMPERATURE ALARM - AUX.

REMARKS:

OIL PUMP ENERGIZED UNTIL 2 MINUTES AFTER ALARM IS CLEARED LOW-LOW OIL TEMPERATURE ALARM START INHIBIT UNTIL ALARM IS CLEARED HIGH MOTOR AMPS ALARMS - VD LIMIT @ 98% FLA, REDUCE VD @ 102% FLA AND TRIP @ 105% FLA AFTER 45 SECS WATCH DOG REVERSE ROTATION ALARM - AUX. OIL PUMP ENERGIZED UNTIL 2 MINUTES AFTER ALARM IS CLEARED DIRTY OIL FILTER ALARM - ALARM ONLY DIRTY INLET FILTER ALARM - ALARM ONLY LOW OIL LEVEL ALARM - ALARM ONLY RESTART BLOCKING - START INHIBIT UNTIL ALARM IS CLEARED

AUTO/REMOTE MODE OPERATIONS CHECK: PLACE LCP IN AUTO/REMOTE MODE, VERIFY THE FOLLOWING OPERATIONS AS DESCRIBED IN THE LCP PROCEDURE AND CONFIRM ALL STATUS INFORMATION IS CORRECTLY DISPLAYED ON SCREEN. PAY CLOSE ATTENTION TO THE STATUS MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. REMOTE START/STOP (IF MCP IS NOT PROVIDED) REMOTE INCREASE/DECREASE (IF MCP IS NOT PROVIDED) ALL SPECIAL REMOTE SIGNALS AND CONTROLS (IF MCP IS NOT PROVIDED)

REMARKS:

LOCAL CONTROL PANEL SYSTEM TEST FORM

PAGE: 19 OF 26

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA JOB NUMBER: 4607T MODEL NUMBER: KA10S-GL400

OPERATOR INTERFACE SCREENS CHECK: GO THROUGH EACH SCREEN AND VERIFY THE FOLLOWING. MAIN OPERATOINS SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT SERVICE SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE, AND ANALOG SCALES ARE CORRECT AIR MONITOR SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT OIL SYSTEM MONITOR SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT BLOWER BRG TEMP SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT BLWR VIBRATION SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT MTR TEMP/AMP SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT MTR VIBRATION SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT TRANS MONITOR SCREENS: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, AND ANALOG SCALES ARE CORRECT ALARM/TRIP COUNTER SCREENS: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING AND COLOR CODE ARE CORRECT ALARM/TRIP DISPLAY SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING AND COLOR CODE ARE CORRECT TRANS SCALE SETUP SCREENS: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, AND ANALOG SCALES ARE CORRECT

FORM: 95063001.QAS REV.: 17 REV. DATE: 08/15/07 APPRV. BY: _________

LOCAL CONTROL PANEL SYSTEM TEST FORM

PAGE: 20 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

ALARM AND TRIP SETPOINT SCREENS: VERIFY ALL

APPRV. BY: _________

REMARKS:

TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, AND COLORS ARE CORRECT PASSWORD ENTRY SCREEN: VERIFY ALL

REMARKS:

TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, AND COLORS ARE CORRECT PASSWORD CHANGE SCREEN: VERIFY ALL

REMARKS:

TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, AND COLORS ARE CORRECT SET POINTS AND DEFAULT MODES FINAL CHECK: COMPLETE THE FOLLOWING CHECKS PRIOR TO SHIPPING. ALL ALARM/TRIP SETPOINTS ARE CORRECTLY SET PER THE STANDARD SETTINGS ALL ANALOG UPPER/LOWER RANGES ARE CORRECTLY SET PER EACH INSTRUMENTS ACTUAL CALIBRATED RANGE ALL TIMERS AND DEFAULTS ARE PROPERLY SET PER STANDARD DEFAULTS

DATE COMPLETED ABOVE CHECKS CHECKED BY (EE) / SIGN-OFF BY (PM) G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

REMARKS:

MASTER CONTROL PANEL SYSTEM TEST FORM

PAGE: 21 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

SYSTEM INSTALLATION CHECK (BY ELEC. ENG.): VERIFY THE FOLLOWING: CONTROL PANEL IS WIRED PER SCHEMATICS

REMARKS:

INTERCONNECT CABLES TO/FROM LCPS AND FIELD DEVICES ARE CONNECTED CONNECT ONE OF EACH DEVICE (DO, FLOW, TEMP) TO VERIFY WIRING SCHEMATICS ARE CORRECT ALL VALVES ARE WIRED PER SCHEMATICS PERFORM THE FOLLOWING: VOLTAGE CHECK AC AND DC POWERS SET OVERLOADS ON MOTOR STARTERS PER SCHEMATICS (VERIFY ACTUAL DEVICE RATING) TRIP TEST AND RESET GFCI LOAD SOFTWARES CONFIRM ALL DIGITAL & ANALOG SIGNALS ARE ACTIVE AND CORRECT PER SCHEMATICS ZERO / SPAN R/I TRANSMITTERS CONFIRM ALL COMMUNICATIONS WITH LCPS AND FIELD DEVICES ARE ACTIVE AND CORRECT SET BASIN VALVE OPEN/CLOSE LIMIT SWITCHES CALIBRATE BASIN VALVE POSITIONING AND POSITION FEEDBACK SET HBOV OPEN/CLOSE LIMIT SWITCHES CALIBRATE HBOV POSITIONING AND POSITION FEEDBACK DATE COMPLETED ABOVE CHECKS CHECKED BY (ELEC. ENG.)

SYSTEM FUNCTIONAL CHECK (BY ELEC. ENG. & VERIFIED BY PROJ. MGR) SERVICE MODE OPERATIONS CHECK: PLACE FOLLOWING DEVICES IN THE SERVICE MODE, VERIFY THEIR OPERATIONS AS DECRIBED IN THE MCP PROCEDURE AND CONFIRM ALL STATUS INFORMATION ARE CORRECTLY DISPLAYED ON THE SCREEN(S). PAY CLOSE ATTENTION TO THE STATUS MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. HBOV, MODE SELECTION AND OPEN/CLOSE BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT POSITION, TEXT AND COLOR CHANGE CONTROL VALVE, MODE SELECTION AND OPEN/CLOSE BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT POSITION, TEXT AND COLOR CHANGE

REMARKS:

MASTER CONTROL PANEL SYSTEM TEST FORM

PAGE: 22 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

MCP CONTROL LOOPS CHECK: VERIFY THE FOLLOWING MCP OPERATIONS AS DESCRIBE IN THE MCP PROCECURE AND CONFIRM ALL STATUS INFORMATION ARE PROPERLY DISPLAYED ON THE SCREENS. PAY CLOSE ATTENTION TO THE STATUS MESSAGES, CHECK FOR CORRECT DESCRIPTION AND SPELLING. BLOWER LEAD/LAG OPERATION, LEAD/LAG

REMARKS:

SELECTION AND BLOWER MODE SELECTION BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT BLOWER STATUS, TEXT AND COLOR CHANGE PRESSURE CONTROL SELECTION AND SETPOINT BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT STATUS, TEXT AND COLOR CHANGE CASCADE (PARALLEL) CONTROL ON INCREASING DEMAND FUNCTION PROPERLY AND DISPLAY CORRECT BLOWER STATUS CASCADE (PARALLEL) CONTROL ON DCREASING DEMAND FUNCTION PROPERLY AND DISPLAY CORRECT BLOWER STATUS FLOW CONTROL SETPOINT BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT STATUS AND TEXT DO CONTROL SETPOINT BUTTONS FUNCTION PROPERLY AND DISPLAY CORRECT STATUS AND TEXT

OPERATOR INTERFACE SCREENS CHECK: GO THROUGH EACH SCREEN AND VERIFY THE FOLLOWING. MENU SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS AND SPELLING ARE CORRECT BLWR CONTROL & SEQUENCE SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT BASIN/TANK CONTROL SCREENS: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, COLOR CODE AND ANALOG SCALES ARE CORRECT

REMARKS:

MASTER CONTROL PANEL SYSTEM TEST FORM

PAGE: 23 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

TRANS MONITOR SCREENS: VERIFY ALL

REMARKS:

TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS, SPELLING, AND ANALOG SCALES ARE CORRECT TIMING/SCALING SET UP SCREENS: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY ALL TEXT LABELS, SPELLING, AND ANALOG SCALES ARE CORRECT MOV CALIBRATION SCREEN: VERIFY ALL TOUCH COMMANDS FUNCTION PROPERLY, ALL TEXT LABELS AND SPELLING ARE CORRECT

DEFAULT MODES FINAL CHECK: COMPLETE THE FOLLOWING CHECKS PRIOR TO SHIPPING. ALL ANALOG UPPER/LOWER RANGES ARE CORRECTLY SET PER EACH INSTRUMENT'S ACTUAL CALIBRATED RANGE ALL TIMERS AND DEFAULTS ARE PROPERLY SET PER STANDARD DEFAULTS DATE COMPLETED ABOVE CHECKS CHECKED BY (EE) / SIGN-OFF BY (PM) G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

REMARKS:

LABELS INSTALLATION RECORD FORM

PAGE: 24 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

LABELS INSTALLATION RECORD (BY MFG MGR OR PROJ. MGR): SERIAL NO. CAUTION: DO NOT OPERATE WITHOUT GUARDS. THIS MACHINE MAY START AND STOP AUTOMATICALLY (ON COUPLING GUARD) CAUTION: THIS EQUIPMENT STARTS AND STOPS AUTOMATICALLY (ON COUPLING GUARD) CAUTION: DO NOT OPERATE WITHOUT GUARDS. THIS MACHINE MAY START AND STOP AUTOMATICALLY (ON CONTROL PANEL DOOR) DANGER: ELECTRICAL HAZARD AUTHORIZED PERSONNEL ONLY (ON CONTROL PANEL DOOR) DIECAST TURBLEX LOGO, 13" X 3" (ON COUPLING GUARD -KA44 &UP) DIECAST TURBLEX LOGO, 7" X 2" (ON CONTROL PANEL FRONT AND COUPLING GUARD - KA22 & DOWN) SS COMPRESSOR NAMEPLATE (ON COMPRESSOR GEARBOX) SET @ 15 PSIG LABEL (ON LLPS BRACKET) SET @ 29 PSIG LABEL (ON LPS BRACKET SET @ 5.5 " W.C. LABEL TOTAL IF PDS SHOWS 0.2 PSI DROP (LOCATE LABEL ON DPISH BRACKET) SET @ 4.125 " W.C. LABEL TOTAL IF PDS SHOWS 0.15 PSI DROP(LOCATE LABEL ON DPISH BRACKET) SET @ 1 " W.C. LABEL ON PRE-FILTER, (LOCATE LABEL ON DPISH BRACKET) SET @ 4" W.C. LABEL ON THE FINAL FILTER (ON DPISH BRACKET) SCALE __________ TO ___________ (MECAHNICAL LIMIT SWITCH LABELS ON IGV BRACKET) SCALE __________ TO ___________ (MECAHNICAL LIMIT SWITCH LABELS ON VD BRACKET) UL CONTACTOR RATINGS LABEL (ON CONTROL PANEL DOOR) UL APPROVED LABEL (INSIDE CONTROL PANEL DOOR) UL FUSE LIST (BEHIND CONTROL PANEL DOOR) G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

REMARKS:

LABELS INSTALLATION RECORD FORM

PAGE: 25 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

LABELS INSTALLATION RECORD (CONTINUE) TEST GFCI MONTHLY LABEL (ON GFCI) TERMINAL TIGHTENING TORQUES LABELS (NEXT TO TERMINAL BLOCKS) EMERGENCY STOP LABEL (E-STOP BUTTON) HOUR METER LABEL (ABOVE HOUR METER) UNIT NUMBER LABEL (ON CONTROL PANEL) BUILT BY LABEL (INSIDE CONTROL PANEL) TESTED BY LABEL (INSIDE CONTROL PANEL) ACCEPTED BY LABEL (INSIDE CONTROL PANEL) DATE COMPLETED INSPECTED BY G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

REMARKS:

FINAL INSPECTION FORM

PAGE: 26 OF 26

FORM: 95063001.QAS

JOB NAME: Vallourec & Sumitomo Tubos Do Brasil LTDA

REV.: 17

JOB NUMBER: 4607T

REV. DATE: 08/15/07

MODEL NUMBER: KA10S-GL400

APPRV. BY: _________

FINAL INSPECTION RECORD (BY MFG MGR & PROJ. MGR): NOTE: EQUIPMENT CANNOT BE DISPATCHED BEFORE THIS FORM IS COMPLETED. DATED COMPLETED ELECTRICAL "AS BUILT" DRAWINGS FINISHED AND INSERTED IN CONTROL PANELS SHIP LOOSE ITEMS INSPECTED ALL INSPECTION FORMS COMPLETED FINAL VISUAL INSPECTION OF ALL EQUIPMENT COMPLETED EQUIPMENT APPROPRIATELY PACKAGED FOR SHIPMENT DIAGRAM OF LOAD LOCATIONS ON TRUCK COMPLETED PICTURES OF LOADED TRUCK TAKEN SHIPPING LIST RECORD COMPLETED

G:\LIB\ISO9000\WI-FORMS\ENGR-SVC\95063001

COMPLETED BY

REMARKS: