CONTROL THE LEVEL INA TANK USING ON/OFF CONTROL Procedure Overview In this procedure, you will use the control relays on the T5552 to control the level in the process tank using on/off control. é © 1, Perform a lockout/tagout. @ 2, Perform the following substeps to set up the T5552, as shown in figure 12. NOTE Pow The appearance of the electrical outlet will differ based on the electrical ES power supplied at your location. |PROCESS CONTROL SYSTEM = "R57 To =) / ELECTRICAL OUTLET CCITT ] = PRESSURE REGULATOR vi ue = SET TO ZERO ‘MANUAL a _ DRAIN VALVES r , CLOSED = 7 AIR SUPPLY CONNECTION HAND VALVES ayy OPEN MANUAL FLOW CONTROL VALVE Figure 12. T5552 Setup A. Plug the power cord into an electrical outlet. B. Connect the air supply line to the T5552, 88270-XDO7DEN LIQUID LEVEL CONTROL Copyright © 2012 Amattol, Inc.C. Set the pressure regulator to 0 psi. You will not control flow with the diaphragm-actuated control valve in thi D. Fill the reservoir tank with water. E. Close the two manual process tank drain valves (fully clockwise). F. Open flow hand valves HV1 and HV2. G. Fully close the manual flow control valve. © 3. Connect the on/off control circuit according to the ladder diagram in figure 13. Figure 14 shows a pictorial diagram, 24v Or GND stor ‘sm to courno. on POWER ist 1s LoWteveL HIGH LeveL ArT a ru ‘ =YorAN Figure 13. On/Off Control Ladder Diagram feo eine Figure 14. On/Off Control Circuit Pictorial (88270-XDO7DEN LIQUID LEVEL CONTROL, = Copyright © 2012 Amatra, Ine.© 4, Determine if the float switches are in the normally closed or normally open position. Figure 15, Float Switches in the Process Tank ‘Amatrol supplies the float switches on the T5552 in the normally open configuration. However, for this circuit, the float switches must be normally closed. You can quickly determine which state the float device is in by looking att from the top. If you look down on the float device and see writing (e.g. manufacturer's name), as shown in figure 16, the float device is in the normally open state. Figure 16. Float Device with Writing Side Up NOTE n , ce ___ Another method used to quickly check the configuration of a level switch is to place an ohmmeter across the contacts. The meter will read a small resistance if the switch is normally closed and an infinite resistance if it is normally open. a BB270-XD07DEN LIQUID LEVEL CONTROL a Copyright © 2012 Amatrol, Inc.Q 5, Perform the following substeps to change the float switches on the T5552 from normally open to normally closed if they are normally open. If they are already in the normally closed state, skip to step 6. A. Locate and remove the retaining clip by pulling it off, as shown in figure 17, with needle nose pliers. STEP 1: SHAFT WRITING. ONTOP FLOAT DEVICE RETAINING cuP (PULL OFF TO REMOVE) Figure 17. Location of Retaining Clip B. Slide the float device off the shaft, as shown in figure 18. STEP 2: ‘SLIDE FLOAT DEVICE Figure 18. Remove Float Device BB270-XDO7DEN LIQUID LEVEL CONTROL Copyright © 2012 Amatrol, Inc. 15C. Rotate the float device 180° (end over end), as shown in figure 19. STEP 3: [bow a ue q 5 Figure 19, Rotate Float Device D. Slide the float device back on the shaft and replace the retaining clip, as shown in figure 20. STEP 4: SLIDE FLOAT DEVICE warring oneorrom = SSREPLACE Figure 20. Replace Float Device and Retaining Clip 38270-XDO7DEN LIQUID LEVEL CONTROL 5 opyright © 2012 Amatrol, Inc.© 6, Perform the following substeps to set the float switches at the desired lower and upper levels. The float switch shafts, shown in figure 21, are mounted so you can slide the shafis up and down by loosening the adjustment screws. A. Loosen LS1’s adjustment screw by turning it counter-clockwise one or ‘two turns so that the shaft can be moved up or down. vsismer LJ UJ tsesuser ust tse wouNTING ouNTING RACKET SrACKET ADWUSTMENT oq 1} “Sstrens 9 ofp 74 Figure 21, Float Switch Mounting Brackets B. Move LSI’s shaft so that the bottom of the switch is even with the 1-inch mark, as shown in figure 22. Then tighten the adjustment screw to lock it in position. This is the lower level. Figure 22. Level Switch at 1-Inch Mark BB270-XDO7DEN LIQUID LEVEL CONTROL. = Copyright © 2012 Amatrol, Inc.C. Reposition L$2 to the 2-inch level using the same procedure as substeps Aand B. This is the high level. Setting the low level switch to 1-inch and the high level switch to 2-inches creates a dead band of 1 inch. © 7, Remove the lockout/tagout. 8, Perform the following substeps to operate the circuit. ‘A. Open the manual flow control valve (HFV2) by turing it fully counterclockwise. B. Make sure that SS1 is in the OFF (up) position. C. Tum on the main circuit breaker. D. Place SS1 in the ON position and observe the operation of the circuit. NOTE a Alll solenoid valves on the T5552 are normally closed. Therefore, they S remain closed until their solenoid coil is energized. When the solenoid coil is energized, the valve opens. E. Allow the process to go through a complete cycle (i.e. water level rises from the low level limit to the high level limit and drops back to the low limit) and record how long it takes to complete the cycle. Time to complete cycle: (seconds) F. Remove control power by placing SS1 in the OFF position. G. Drain the process tank using the manual drain valves until the water is below the low-level switch (LS1). Then, close the manual drain valves. 2 9, Perform the following substeps to operate the circuit and observe the effects of widening the dead band. A, Slide the high-level float switch (LS2) up to the 4-inch level. This will effectively triple the dead band (from 1 inch to 3 inches). Place SS1 in the ON position and observe the operation of the circuit. on Allow the process to go through another cycle and record how long it takes to complete the cycle. Time to complete cycle: ||| (seconds) D. Determine if the circuit cycles more or less frequently than in step 8? Cycle Frequency (higher/lower) You should find that the circuit cycles less frequently. This is due to the increased dead band. E, Remove control power by placing SS1 in the OFF position. + }XDO7DEN LIQUID LEVEL CONTROL 18 ight © 2012 Amatrol, Inc.910. Perform the following substeps to shut down the T5552. A. Open both of the manual drain valves on the process tank to completely drain the tank, When the tank is empty, close both valves. B. Tum off the main circuit breaker. C. Disconnect the control circuit. DESIGN AN ON/OFF LEVEL CONTROL SYSTEM Procedure Overview In this procedure, you will design an On/Off level control system. The purpose of this system is to maintain the liquid level between two points. 7 Q 1. Review the following design parameters. These parameters contain the information you need to design the circuit. *Selector switch S$1 will be used to simulate a pushbutton that energizes the circuit. *Selector switch SS2 will be used to simulate a “stop” pushbutton. +Use a high-level float switch set at 7 inches. *Use a low-level float switch set at 2 inches. +The pump will be controlled by one control relay contact. +The solenoid valve will be controlled by a second control relay contact. “The pump should start when selector switch SSI is turned on and should continue to run when the switch is turned off (simulated start pushbutton). +The pump should continue to run and fill the tank until the high-level float switch is reached. At this point, the pump should stop and the solenoid valve should open and begin draining the tank. «The tank should drain until the low-level float switch is reached. At this point, the solenoid valve should close and the pump should turn on and begin filling the tank. «Both float switches will be NC switches. NOTE This GS This circuit will require the use of a third relay to provide the seal-in contact for the start switch (SS1).8270-XDO7DEN LIQUID LE\ opyright © 2012 Amatrol, Inc. © 2, Design your circuit on a sheet of paper. © 3. Ask your instructor to verify your circuit and give you permission to connect the circuit, © 4, Perform a lockout/tagout. 5, Perform the following substeps to set up the T5552. A. Connect the air supply line to the T5552. B. Set the pressure regulator to 0 psi. C. Fill the reservoir tank with water. D. Close (fully clockwise) the two manual process tank drain. E. Close (fully clockwise) the manual flow control valve. F, Place selector switch SS1 in the OFF position. G. Place selector switch $S2 in the ON position. © 6 After receiving permission, connect your circuit. © 7. Notify your instructor that you are ready to operate the circuit. ‘Your instructor must check and approve your setup before you can continue, Q 8. Remove the tagout tag and lockout device. Q 9. Tum on the main circuit breaker. 910. Tum selector switch $S1 on and then off immediately to simulate the pressing of a start pushbutton. The pump should start and begin to fill the process tank with water. The solenoid drain valve should be closed. The tank should continue to fill past the low level switch. When the level reaches the high-level float switch (7- inch mark), the pump should stop and the solenoid drain valve should open and begin to drain the tank. When the level reaches the low-level float switch (2-inch mark), the solenoid valve should close and the pump should restart and begin filling the tank. The circuit should continue to cycle in this manner until selector switch SS2 is turned off (stop button pressed). 211. Perform the following substeps to shut down the T5552. A. Tum off selector switch SS2 to stop the circuit. B. Close the manual flow control valve. C. Open both manual drain valves to drain the process tank. When the tank is completely drained, close the valves. D. Tum off the main circuit breaker, E, Disconnect the circuit VEL CONTROL 2