Attachment 4 Small Pulper Fabrication Inspection Procedures and Record.pdf

ATTACHMENT B – TESTING

B3 – Small Pulper

Small Pulper Fabrication Inspection Procedures and Record, SP001

Revision: - Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Small Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ __________________________

Vendor Approval: _________________________ __________________________

1.0 Introduction

1.1 The purpose of this inspection is to verify that critical dimensions of the small pulper have been met during fabrication.

2.0 Equipment

2.1 Calibrated measuring equipment is required to verify drawing dimensions. The precision of the equipment shall be one order of magnitude finer than the characteristic to be measured. The equipment calibration shall be current. The equipment required includes: gage blocks, scales, calipers, micrometers, surface plate with height gage, angle gage, adjustable protractor, depth micrometers, inside micrometers, and thread gages; a coordinate measurement machine may be used in lieu of many of the above.

2.2 Common tools and equipment (wrenches, screwdrivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment

3.1 Nomenclature: 1.250-7 UNRC-2A Left Hand Thread Ring

Purpose: For measuring threads on the drive shaft

3.2 Nomenclature: 1.250-7 UNC-2B Left Hand Thread Plug

Purpose: For measuring threads on the impeller disk

4.0 Services: None.

Small Pulper Fabrication Inspection Procedures and Record, SP001

Inspection Step

Number

Inspection Step Description Results

Initials/ Date

Sat

Unsat

— Direct measurement or record review methods may be used —

Inspector Record, Revision of Drawing Used Initials

Reference — Dwg. No. 593-6960500 (Control Enclosure) Rev _______ _______ Dwg. No. 593-6960584 (Piping Details) Rev _______ _______ Dwg. No. 593-6960585 (Feed Chute Assembly) Rev _______ _______ Dwg. No. 593-6960587 (Drive Housing Machining Rev _______ _______ Dwg. No. 593-6960589 (Drive Lip Seal Holder) Rev _______ _______ Dwg. No. 593-6960591 (Drive Shaft) Rev _______ _______ Dwg. No. 593-6960592 (Drive End Cap) Rev _______ _______ Dwg. No. 593-6960593 (Drive Mechanical Seal Plate) Rev _______ ______ Dwg. No. 593-6960594 (Tank Assembly) Rev _______ _______ Dwg. No 593-6960595 (Frame) Rev _______ _______ Dwg. No. 593-6960597 (Junk Box Flange) Rev _______ _______ Dwg. No. 593-6960598 (Impeller Assembly) Rev _______ _______ Dwg. No. 593-6960599 (Impeller Machining) Rev _______ _______ Dwg. No. 593-6960601 (Cutter Ears) Rev _______ _______ Dwg. No. 593-6960604 (Security Ring Assembly)Rev _______ _______ Dwg. No. 593-6960640 (Tank Bottom Machining) Rev _______ _______

1 Verify that the size and location (4x 0.541/0.531 diameter) and location of the electrical control enclosure mounting holes are in accordance with Dwg. No. 593-6960500, Sheet 5, Detail 39-C).

2 Verify that the proper brazing procedures have been followed per Dwg. No. 593-6960584, Note 3.

3 Verify the orifice plate diameter (Dwg. No. 593- 6960584 Pc. 15) is 0.344 diameter, do not break corners.

4 Verify the following piping assembly dimensions (Dwg. No. 593-6960584):

A) Outlet Piping Assembly 98: Detail 26-A; 28.00 B) Inlet Piping Assembly 93: Detail 39-A, 31.50 and 12.29.

5 Verify that the Inlet Piping Assembly (Assembly 93) has been pressure tested in accordance with Note 12 (Dwg. No. 593-6960584).

6 Verify that the following characteristics of the feed chute assembly (Dwg. No. 593-6960585, Detail 6- A) are within tolerance:

A) 48.25 dimension B) 50 degrees and 30 degrees dimensions C) Feed chute mounting hole size and locations

7 Verify that the following characteristics of the drive housing (Dwg. No. 593-6960587, Section 3-B) are within tolerance:

A) 4.7258/4.7244 diameter 32 surface (2 places)

B) 4.127/4.125 diameter

C) 6.548/6.546 diameter

D) 5.823 dimension; 2 X

E) 7.320 dimension

8 Verify that the following characteristics of the drive lip seal holder and flinger (Dwg. No. 593-6960589) are within tolerance:

A) 4.124/4.122 diameter

B) 2.783/2.781 diameter

C) 4.780 diameter

9 Verify that the following characteristics of the drive shaft (Dwg. No. 593-6960591, Detail 5-B) are within tolerance:

A) 2.1664/2.1659 diameter 32 surface (2 places)

B) 1.375/1.374 diameter

C) 3.225 dimension

D) 1.250-7 UNRC-2A left hand threads

E) 1.878/1.872 diameter 32 surface (2 places)

F) 1.305/1.303 diameter

G) 1.752/1.748 32 diameter surface

H) 1.090/1.088 32 diameter surface

I) 4.831 (2 places)

10 Verify that the following characteristics of the drive end cap (Dwg. No. 593-6960592) are within tolerance:

A) 4.722/4.720 diameter

B) 2.783/2.781 diameter 32 surface

C)

D) 0.135 dimension

11 Verify that the following characteristics of the drive mechanical seal plate (Dwg. No. 593-6960593) are

A) 2.501/2.499 diameter

B) 6.548/6.546 diameter

12 Verify that the following characteristics of the tank assembly (Dwg. No. 593-6960594) are within tolerance:

A) 50 degrees and 30 degrees dimensions, View 10-A

B) Feed chute mounting hole size and locations, View 10-A

C) 3.64 dimension, Partial Section 14-A

D) 3.15 dimension, Partial Section 14-A

E) 20 degrees dimension, Partial Section 14-A

13 Verify that the following characteristics of the frame (Dwg. No. 593-6960595) are within tolerance:

A) 25.00 hole spacing

B) 15.50 hole spacing

C) (17.00) flatness to 0.010

14 Verify the length of the junk box flange drain pipe (Dwg. No. 593-6960597, Pc. 2).

15 Verify that the impeller assembly has been balanced per Notes 5 and 6 of Dwg. No. 593-6960598.

16 Verify that the following characteristics of the impeller (Dwg. No. 593-6960599) are within tolerance:

A) 2.887/2.885 diameter

B) 1.250-7 UNC-2B left hand threads

C) 9.955/9.950 major diameter of external threads

D) 1.310/1.315 diameter

E) 2.756/2.752 diameter (2 places)

F) 0.402/0.398 dimension (2 places)

G) Cutter ear mounting hole size and locations per Detail 6-C

17 Verify the following characteristics of the cutter ears (Dwg. No. 593-6960601) are within tolerance:

A) 2.293 dimension

B) 0.375/0.345 dimension

C) 12 degrees

D) Cutter ear mounting hole size and locations

E) Cutter ear blade mounting hole size and locations

F) 65 degrees

18 Verify that the following characteristics of the security ring assembly (Dwg. No. 593-6960604) are

A) 10.000/10.002 diameter

B) Pc. 5 is flush or outward of Pc. 1 (10.000/10.002 diameter).

C) Pc. 4 and Pc. 5 are aligned within 0.000 (flush) +

0.025 (Pc. 4 outward).

19 Verify that the following characteristics of the tank bottom (Dwg. No. 593-6960640) are within tolerance:

A) 6.552/6.554 diameter and

B) 9.996/9.994 diameter

Inspection Complete.

Small Pulper Assembly Inspection Procedures and Record, SP002

Revision: - Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Small Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ __________________________

Vendor Approval: _________________________ __________________________

1.0 Introduction

1.1 The purpose of this inspection is to verify that critical components of the small pulper have been properly assembled.

2.0 Equipment

2.1 Calibrated measuring equipment is required to verify drawing dimensions. The precision of the equipment shall be one order of magnitude finer than the characteristic to be measured. The equipment calibration shall be current. The equipment required includes: gage blocks, scales, calipers, micrometers, surface plate with height gage, angle gage, adjustable protractor, depth micrometers, inside micrometers, and thread gages; a coordinate measurement machine may be used in lieu of many of the above.

2.2 Common tools and equipment (wrenches, screwdrivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment: None.

4.0 Services: None.

Small Pulper Assembly Inspection Procedures and Record, SP002

Inspection Step

Initials/Date

Sat Unsat

— Direct measurement or record review methods may be used —

Inspector Record, Revision of Drawing Used Initials

Reference — Dwg. No. 593-6960581 (Small Pulper Top Level Assembly) Rev _______ _______ Dwg. No. 593-6960584 (Piping Details) Rev _______ _______

Dwg. No. 593-6960586 (Drive Assembly) Rev _______ _______

1 Verify that the mechanical seal and O-ring (Dwg. No.

593-6960581, Pcs. 10 and 84) have been installed without damage per Note 1.3.9. Verify that antiseize compound has been applied.

Verify that the impeller assembly (Dwg. No. 593- 6960581, Pc. 12) has been installed in accordance with Note 1.3.10.

3 Verify that the gap between the security ring and the impeller is 0.020/0.026 inches all around per Dwg.

No. 593-6960581 Note 1.3.11.

4 Verify that both lid latch assemblies (Dwg. 593- 6960581, Pc. 51) have been assembled and adjusted in accordance with Detail 44-E and Note 1.17.

5 Verify that the tensioner arm (Dwg. No. 593-6960581, Pc. 16) has been oriented (at approximately 70 degrees) as shown in Detail 58-E and Note 1.3.14.

6 Verify that the impeller drive sheave(Dwg. No. 593- 6960581, Pc. 13) and the motor sheave (Pc. 20) are properly aligned with each other and with the tensioner idler pulley (Pc. 18) per Note 1.3.16 and View 61-A.

7 Verify that the drive belt (Dwg. No. 593-6960581, Pc.

19) has been installed as shown in Section 61-C and Note 1.3.17.

8 Verify that the tensioner arm (Dwg. No. 593-6960581, Pc. 16) is oriented at an approximate angle of 105 degrees in accordance with Section 61-C, after the drive belt has been installed.

9 Verify that the proximity switches (Dwg. No. 593- 6960581, Pc. 106) have been installed per Note 1.3.19.

10 Verify that the orifice plate (Dwg. No. 593-6960584, Pc. 15) has been installed.

11 Verify that the drive assembly has been assembled in accordance with Dwg. No. 593-6960586. Also verify the following characteristics after assembly:

A) Shaft torque value from Notes 2.12 and 2.15.

Inspection complete.

Small Pulper General Examination Procedures and Record, SP003

Revision: - Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Small Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ __________________________

Vendor Approval: _________________________ __________________________

1.0 Introduction

1.1 The purpose of this examination is to verify that the small pulper components are properly assembled and adjusted.

2.0 Equipment

2.1 Calibrated measuring equipment is required to verify drawing dimensions. The precision of the equipment shall be one order of magnitude finer than the characteristic to be measured. The equipment calibration shall be current. The equipment required includes: gage blocks, scales, calipers, micrometers, surface plate with height gage, angle gage, adjustable protractor, depth micrometers, inside micrometers, and thread gages; a coordinate measurement machine may be used in lieu of many of the above.

2.2 Common tools and equipment (wrenches, screwdrivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment: None.

4.0 Services: None.

Small Pulper General Examination Procedures and Record, SP003

Intials/Date

Sat Unsat

Inspector Record, Revision of Drawing Used Initials

Reference – Dwg. No. 593-6960500 (Control Enclosure) Rev _______ _______ Dwg. No. 593-6960502 (Local Status Indicator) Rev _______ _______ Dwg. No. 593-6960581 (Small Pulper

Top Level Assembly) Rev _______ _______ Dwg. No. 593-6960584 (Piping Details) Rev _______ _______ Dwg. No. 593-6960585 (Feed Chute Assembly) Rev _______ ______

1 Verify workmanship per Dwg. No. 593-6960581, Note 1.2.

2 Verify that the following nameplates are properly completed, are legible and attached:

A) Pulper (Dwg. No. 593-6960581, Pc. 32)

B) Control Enclosure (Dwg. No. 593-6960500, Pc.

62)

C) Local Status Indicator (Dwg. No. 593-6960502, Pc. 21)

3 Verify that all belt guards, danger labels, caution labels and rotation label (Dwg. No. 593-6960581;

Pcs 28, 29, 30, 31 and 98) are installed.

4 Verify that the drive belt and sheave surfaces are clean, dry and free from grease, dirt or other debris or damage.

DANGER: Ensure that no electrical connections have been made to the drive motor.

5 Verify that the impeller and drive components (Dwg.

No. 593-6960581, Pc. 12) rotate freely by hand.

6 Verify that a service loop is provided in cable W104 per Dwg. 593-6960581, Zone 70-C.

7 Verify that all cables are cut to the proper length and secured to the pulper in accordance with Dwg. No.

593-6960581.

8 Verify that all heat discoloration has been removed per Dwg. No. 593-6960584, Note 21.

9 Cycle the lid latch assemblies (Dwg. No. 593- 6960585, Pc. 51) and feed chute lid (Dwg. No. 593- 6960585, Detail 20-C) 5 times and verify smooth operation. Inspect chute cover gaskets for cracks, cuts or other damage.

Examination complete.

Small Pulper Static Leak Test Procedures and Record, SP004

Revision: - Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Small Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ __________________________

Vendor Approval: _________________________ __________________________

1.0 Introduction

1.1 The purpose of this test is to verify that the small pulper does not leak when subjected to a static head of water.

1.2 The small pulper shall be fully assembled.

2.0 Equipment

2.1 Common tools and equipment (wrenches, screwdrivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.2 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment

3.1 Nomenclature: 1.00 NPS MIL-F-20042 blind flange and gasket (or suitable alternative) Use of the Test Equipment: Seal the inlet piping assembly Material: Bronze Class: 150 lbs

3.2 Nomenclature: 2.50 NPS ANSI blind flange and gasket (or suitable alternative) Use of the Test Equipment: Seal the outlet piping assembly Material: 316 SST Class: 150 lbs

4.0 Services

4.1 Fresh Water (to fill the pulper, no flow and pressure requirements are specified)

4.2 Gravity Drain

Small Pulper Static Leak Test Procedures and Record, SP004

Sat Unsat

DANGER: Ensure that no electrical connections have been made to the drive motor.

1 Inspect the pulper tank and junk box for any loose hardware or miscellaneous debris.

2 Close and latch the feed chute lid.

3 Close the drain valve.

4 Secure an ANSI 1.00 NPS blind flange to the tank inlet piping assembly inlet flange.

5 Secure an ANSI 2.50 NPS blind flange to the outlet piping assembly discharge flange.

6 Fill the pulper tank with fresh water to a level approximately at or touching the tank gasket (Dwg.

No. 593-6960594 Piece 15).

Note: It is not necessary to vent piping and hose assemblies.

7 If signs of surface sweating occur, wipe the external surface of the pulper dry before proceeding with the test.

8 Allow the water to set in the pulper for 30 minutes and observe all external pulper surfaces for signs of leakage. Zero leakage is permitted. If any leaks are present, stop the test, resolve the leak, and reconduct the test.

9 Upon successful completion of the static leak test, drain the pulper.

10 Wipe down the interior of the pulper. The interior surfaces may be damp to the touch. There should be no puddled water.

Test Complete.

Small Pulper Run Test Procedures and Record, SP005

Revision: - Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Small Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ __________________________

Vendor Approval: _________________________ __________________________

1.0 Introduction

1.1 The purpose of this test is to verify that the small pulper operates smoothly, and that no leaks occur while running.

1.2 The small pulper shall be fully assembled .

2.0 Equipment

2.1 Common tools and equipment (wrenches, screwdrivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.2 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment

3.1 Nomenclature: 1.00 NPS MIL-F-20042 flange and adapter (or suitable alternative) Use of the Test Equipment: Connect the supply water to the inlet piping assembly Material: Bronze Class: 150 lbs

3.2 Nomenclature: 2.50 NPS ANSI flange and adapter (or suitable alternative) Use of the Test Equipment: Connect the outlet piping assembly to the gravity drain Material: 316 SST Class: 150 lbs

3.3 Nomenclature: #12 AWG single conductor cable

Use of the Test Equipment: Grounding Range: Length as required for ground.

3.4 Nomenclature: #12 AWG 4-conductor cable

Use of the Test Equipment: Power Leads Range: Length as required.

4.0 Services

4.1 Fresh Water, 30 gpm at 10 psig

4.2 Gravity Drain

4.3 440 Vac, 3 Phase, 60 Hz, 20 Amp supply (minimum) with circuit breaker element of 20 Amp

Small Pulper Run Test, SP005

Test Step

Sat Unsat

DANGER: Electrical safety precautions shall be carefully followed since test personnel are exposed to 440 Vac that is required to operate the drive motor.

1 Secure the unit to prevent movement during the run test.

2 Inspect the pulper tank and junkbox for any loose hardware or miscellaneous debris.

3 Verify that the impeller assembly rotates freely (by hand).

4 Close and latch the feed chute lid.

5 Place the 20A circuit breaker at the 440 Vac power panel in the open position and tag it out.

6 Ground the drive motor frame to the electrical ground of the 440 Vac power source using a single-conductor #12 AWG cable.

7 Connect the 440 Vac load side of the 20A circuit breaker to the drive motor using a #12 AWG 4-conductor cable, length as required.

8 Close the drain valve.

9 Connect a drain line to the 2.50 NPS outlet piping assembly discharge flange to drain the pulper at the same rate (30 gpm) as the supply.

10 Connect water supply to the inlet piping assembly inlet flange (30 gpm at 10 psig) and fill the pulper to a level 2 to 4 inches above the uppermost edge of the tank bottom weldment (motor end).

11 Remove the tagout tag and close the 20A circuit breaker for just long enough to initiate rotation. Carefully observe impeller rotation to ensure it is rotating clockwise. (Looking down through the feed chute lid window). If rotation is counterclockwise, open the 20A circuit breaker and switch two of the motor end 3-phase leads and retest for proper rotation.

CAUTION: Never run the pulper without 30 gpm of water flowing into the impeller flush hose.

12 Turn on water supply and close the 20A circuit breaker.

The drive motor should start and achieve full speed within approximately 2 seconds.

13 Run the pulper continuously for 30 minutes. Observe the pulper during startup, run and shutdown.

A) Observe the height of the water vortex in the pulper after the motor has achieved full speed. Note that the water vortex will appear higher than when the pulper was initially filled. It may be necessary to adjust the flow being discharged from the pulper during the test to maintain a constant water level.

B) Observe pulper connections for any leaks. If any leaks are present, stop the test, resolve the leak, and reconduct test.

C) Monitor the operation of the pulper for any abnormal condition. Abnormal conditions include: excessive vibration, unusual noises, water leaks, and signs of excessive heating. If any abnormal conditions are noted resolve the condition and reconduct the test.

D) Verify that no mechanical seal leakage has occurred by checking beneath pulper for water. If the mechanical seal shows signs of leakage, stop the test, resolve the leakage, and reconduct the test.

14 After 30 minutes of continuous operation, open the 20A circuit breaker at the 440 Vac power panel and tag it out.

Disconnect the 440 Vac power cable and ground cable from the drive motor and the 20A circuit breaker.

15 Drain the contents of the pulper and perform a general examination of the interior and exterior of the pulper.

Inspect for any abnormal conditions such as loose hardware or debris, drive belt loosening, and for water or grease leakage from the drive housing.

16 Wipe down the interior of the pulper. The interior surfaces may be damp to the touch. There should be no puddled water.

Small Pulper Inspection Procedures and Record for the PLC Based Controller, SP006

Revision: - Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Small Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ ______________________________

Vendor Approval: _________________________ ______________________________

1.0 Introduction

1.1 The purposed of this inspection is to verify the electrical performance of the controller.

2.0 Equipment

2.1 Common tools and equipment (wrenches, screwdrivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.2 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment

3.1 Nomenclature: #12 AWG single conductor cable

Use of the Test Equipment: Grounding Range: Length as required for ground.

3.2 Nomenclature: #12 AWG 4-conductor cable

Use of the Test Equipment: Power Leads Range: Length as required.

3.3 Nomenclature: Multimeter

Use of the Test Equipment: Continuity checks Accuracy: +/- 2% of scale, Calibration within 12 months Range: Low Ohms and 500 Vac

3.4 Nomenclature: Jumper

Quantity: 3 Use of the Test Equipment: #16 AWG Wire Minimum

3.5 Nomenclature: Single-phase Variac capable of supplying 10 Amps Use of the Test Equipment: Simulate current through the C-T

3.6 Nomenclature: Clamp on Ammeter

Use of the Test Equipment: Current simulation of current transducer verification and alarms checkout Accuracy: +/- 2% of scale, Calibration within 12 months Range: 0 - 10 Amps

4.0 Services

4.1 440 Vac, 3 Phase, 60 Hz, 20 Amp supply (minimum) with circuit breaker element of 20 Amp

4.2 100 Vac, 60 Hz, single-phase, 15 Amp supply

Small Pulper Inspection Procedures and Record for the PLC Based Controller, SP006

Test Step

Test Step Description

Results

Sat Unsat Inspector Record, Revision of Drawing Used Initials

Reference – Dwgs. No. 593-6960500 Rev ________ ________ Dwgs. No. 593-6960501 Rev ________ ________ Dwgs. No. 593-6960879 Rev ________ ________

Small Pulper (specific):

Dwgs. No. 593-6960581 Rev ________ ________ Dwgs. No. 593-6960502 Rev ________ ________ Dwgs. No. 593-6960504 Rev ________ ________

Assumptions

- Before initiating any testing, verify that point-to-point wiring checks have been made to verify correct wiring.

- Pulper is not attached, therefore, differential pressure switch, conductivity switches, and remote E-stop actions are simulated at terminal board TB1 and TB3.

- The correct Programmable Read Only Memory (PROM) version is installed in the Programmable Logic Controller (PLC) and Display Unit (DU1).

- The electrical enclosure (Dwg. No. 593-6960500, sheet 3) door is open for access to electrical components and observation of PLC indicators.

The retaining screws (Dwg. No. 593-6960500, sheet 3, pc 114) on the display unit cover are loose so that the function keys on the display unit can be operated. The local status indicator is installed at terminal board TB1 (Dwg. No. 593-6960504).

DANGER: Electrical safety precautions shall be observed since the test person is exposed to both 440 Vac and 110 Vac.

If any of the following verifications cannot be made as described, troubleshoot as required to isolate the cause and/or failed component.

1 PLC Configuration Record the following information A) PLC Baseplate Part and Revision Number

B) System PROM Serial Number Installed on the PLC Baseplate _______

C) Serial Number of the Electrical Enclosure

2 Set overload relay for automatic reset and 10A.

3 Check fuses – Continuity check with ohmmeter:

4 Connect local status indicator enclosure via cable W102 (Dwg. No.593-6960581 and 593-6960504).

5 Connect proximity switches on TB3 in local status indicator (Dwg. No. 593-6960502) and place metal flag on both switches:

TB3-5 to PX1-1 (Brown Lead) TB3-6 to PX1-2 (Blue Lead) TB3-6 to PX2-1 (Brown Lead) TB3-7 to PX2-2 (Blue Lead)

6 Connect 110 Vac lamps to V1 and V2 circuit to allow observation of circuit energization:

V1 → TB1-24 and TB1-25 V2 → TB1-27 and TB1-28

7 Hook-up a jumper to the following terminals to simulate differential pressure switch (DP1):

TB1-20 → TB1-21

8 Hook up a jumper to the following terminals to simulate remote emergency stop pushbutton (PB2) See Dwg. No. 593-6960501 Sheet 5:

TB3-9 → TB3-10 and

TB3-11 → TB3-12

9 Install jumper from TB1-12 - TB1-13. (Dwg. No.

6960501 Sheet 3)

10 Connect 440 Vac Power Leads.

11 Close circuit breaker, pull out EMERGENCY STOP pushbutton (PB1) and observe:

- After initializing, the Display Unit (DU1) momentarily displays program version numbers

Record DU1 Ver No. PDU _______

Record PLC Ver No. SWP _______

- Display Unit (DU1) then displays message "A)

PRESS TIMED-START".

- Motor Current Meter (A1) should indicate in the green "MOTOR OFF" region.

- Verify with voltmeter 440 Vac at TXFMR primary H1 → H4

Record measured voltage ________

- Verify with voltmeter 110 Vac at TXFMR secondary X1 → X2

Record measured voltage ________

- POWER ON light (DS1, White) is lit.

12 Safety checks: Press EMERGENCY STOP pushbutton (PB1) and verify:

- The POWER ON light (DS1, White) remains lit.

The DU1 display should indicate:

11) Reset PB1 ESTOP, push TIMED START.

- After safety check, reset EMERGENCY STOP (pull out pushbutton).

13 Press Display Unit (DU1) function key F7 "LAMP TEST" and observe on local status indicator while pressed:

- FEED light (DS2, Green) is lit.

- WAIT light (DS3, Amber) is lit.

- DON'T FEED light (DS4, Red) is lit.

Also, on the controller observe:

- Alarm Horn (H1) sounds.

- PLC slot 3 LEDs A3, A4, A5 and A6 are lit.

- Motor Current Meter A1 reads full scale.

- All segments of Display Unit (DU1) are lit.

14 Press Display Unit (DU1) function key F4 "HALT PULPER" and observe while pressed:

- Message Display Unit (DU1) should display F4)

PULPER HALTED.

15 Press Display Unit (DU1) function key F5 "ADVANCE TIMERS" and observe while pressed:

- Message Display Unit (DU1) should display F5)

TIMERS ADVANCED.

16 Press Display Unit (DU1) function key F6 "DISPLAY MOTOR CURRENT" and observe while pressed:

- Message Display Unit (DU1) should display

MOTOR I_in I_out PCT 0A 4mA 4mA 0%

17 Remove metal flag from proximity switch (PX1) to simulate the Access Door/Feed Chute being open, observe LED on PX2 is lit and LED on PX1 is out, the DON'T FEED light (DS4) is lit, and observe Message Display Unit says "05) DOOR/COVER OPEN or UNLATCHED."

Press the TIMED START pushbutton (PB3) to attempt to pick up the Master Control Relay (MCR).

Press Display Unit (DU1) function key F1 "JOG MOTOR ON" and observe while pressed:

- Motor Contactor (M1) should not operate.

- Message Display Unit (DU1) "99) F1 - F3 NOT

ACTIVE WHEN SHUTDOWN."

18 Replace metal flag on Proximity Switch PX1, remove metal flag from Proximity Switch PX2 to simulate junkbox door/feed chute being open, observe LED on PX1 is lit and LED on PX2 is out, the DON'T FEED light (DS4) is lit, and observe Message Display Unit says "05) DOOR/COVER OPEN or UNLATCHED."

19 Press the TIMED START pushbutton (PB3) to attempt to pick up the Master Control Relay (MCR), and immediately press Display Unit (DU1) function key F4 "HALT PULPER" and observe Message Display Unit says "F4) PULPER HALTED." When released, Message Display Unit says "05) DOOR/COVER OPEN or UNLATCHED."

20 Press Display Unit (DU1) function key F1 "JOG MOTOR" and observe while pressed:

- Motor Contactor (M1) should not operate.

- Message Display Unit (DU1) "99) F1 - F3 NOT

ACTIVE WHEN SHUTDOWN."

Replace metal flag on Proximity Switch PX2.

Press the TIMED START pushbutton (PB3) to pick up the Master Control Relay (MCR), and immediately press Display Unit (DU1) function key F4 "HALT PULPER" and observe Message Display Unit says "F4) PULPER HALTED." When released, Message Display Unit says "A) PRESS TIMED-

START."

22 Press Display Unit (DU1) function key F1 "JOG MOTOR" and observe while pressed:

- Motor Contactor (M1) should operate.

- Message Display Unit (DU1) "F1) MOTOR JOG

ON."

23 Press Display Unit (DU1) function key F2 "OPEN INLET VALVE" and observe while pressed:

- V1 is lit.

- Message Display Unit (DU1) should display F2) INLET VALVE V1 Forced OPEN.

24 Press Display Unit (DU1) function key F3 "OPEN

EDUCTOR VALVE" and observe while pressed:

- V2 is lit.

- Message Display Unit (DU1) should display F3) EDUCTOR VALVE V2 Forced OPEN.

25 Timed Start Verification

- Display unit (DU1) displays message "A) PRESS

TIMED-START."

Push TIMED START pushbutton (PB3) and observe:

- PLC slot 3 LEDs A7 and A8 are lit.

- 110 Vac lights are lit ... V1 and V2 from Step 5

- DON'T FEED light (DS4, Red) is lit

- Display Unit (DU1) displays message "B) FILLING, DON'T FEED 00:00" and displays the count down from 40 seconds.

After 40 seconds observe:

- DON'T FEED light (DS4, Red) goes off and FEED light (DS2, Green) is lit.

- Motor contactor (M1) also operates.

- Hour meter is operating.

- Display Unit (DU1) displays message "C) FEED, when done press TIMED-STOP".

Verify:

- That controller properly sequences to the FEED mode and remains stable in this mode (1 minute minimum).

- V1, V2 should remain on.

26 Timed Stop Verification:

Push the TIMED STOP pushbutton (PB4) and observe:

- Display Unit (DU1) displays message "D) CLEANING, DON'T FEED 00:00" and displays the count down from 7 minutes.

- FEED light (DS2, Green) is not lit and DON'T FEED light (DS4, Red) is lit.

Press Display Unit (DU1) function key F5 "ADVANCE TIMERS" and observe:

- While pressed, DU1 message is "F5 TIMERS

ADVANCED"

- V1 light is not lit and V2 light remains lit

- Motor contactor (M1) drops out

- DON'T FEED light (DS4, Red) is lit

- Display Unit (DU1) displays message "E) DRAINING, DON'T FEED" and counts down from 60 seconds.

After 1 minute observe:

- V2 light is not lit

- DON'T FEED light (DS4, Red) is not lit

- Display Unit (DU1) displays message "A) PRESS

TIMED-START."

27 Verify operation of current transducer XDCR1 and overcurrent alarms.

Remove 440 Vac Power.

Connect Vac current source through CT1 (use variac with 5 turns through CT1).

Install the clamp-on ammeter on one of the variac output leads.

Provide 440 Vac Power.

Press the TIMED START pushbutton (PB3) and allow pulper to sequence to FEED mode.

Adjust the variac output as follows and observe:

- Slowly increase variac so that the motor current meter (A1) is observed to deflect to the right and near the top of the green "normal operation" band.

- Press the display unit (DU1) function key F6 "DISPLAY MOTOR CURRENT" and record the observed readings.

MOTOR I_in I_out PCT

_______A _______mA _______mA _______%

- Also record the clamp-on ammeter current reading ______A.

- When pressing F6 the MOTOR current should read approximately 10A while the clamp-on ammeter reads 4A.

- Adjust the variac so that the motor current meter (A1) deflects further to the right and into the red "OVERCURRENT" region.

Deenergize variac by unplugging (Do not adjust knob from this setting).

28 Short time overload simulation:

- Reapply power to variac by plugging it in for no longer than 5 seconds to simulate a short time overload.

Observe during applied power to variac:

- WAIT light (DS3, Amber) is lit.

- Display Unit (DU1) displays message "01) HIGH CURRENT, WAIT 00:00" and counts down from 5 seconds.

After variac is unplugged and after 5 seconds has expired, observe:

- WAIT light (DS3, Amber) is not lit.

- FEED light (DS2, Green) is lit.

- Display Unit (DU1) displays message "C) FEED, when done press TIMED-STOP."

29 Long time overload simulation:

Reapply power to variac for longer than 5 seconds.

After 5 seconds, observe:

- WAIT light (DS3, Amber) is not lit

- DON'T FEED light (DS4, Red) is lit

- ALARM HORN (H1) sounds

- Display Unit (DU1) displays message "02) OVERCURRENT, DON'T FEED 00:00" and maintains a countdown time of 00:60.

Press ALARM ACKNOWLEDGE (PB5) to silence alarm. Allow controller to operate in this mode for several minutes. Observe:

- Alarm should not sound again and DON'T FEED light (DS4, Red) should remain lit.

30 Long time overload restore simulation:

Unplug the variac.

Observe:

- DON'T FEED light (DS4, Red) should remain lit for 1 minute.

- Display Unit (DU1) displays message "02) OVERCURRENT, DON'T FEED 00:00" and counts down from 60 seconds.

After 1 minute observe:

- DON'T FEED light (DS4, Red) is not lit, FEED light (DS2, Green) is lit

- Controller should now be back to the FEED mode.

- Display Unit (DU1) displays message "C) FEED, when done press TIMED-STOP."

31 Differential pressure (DP1) circuit verification:

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Remove the jumper from TB1-20 → TB1-21.

After 5 seconds, observe:

- Motor contactor (M1) drops out

- V1 and V2 lights go out

- DON'T FEED light (DS4, Red) is lit

- Display Unit (DU1) displays message "04) LOW WATER FLOW, Correct & Restart."

32 Proximity sensor verification:

Reset DP1 by hooking up the jumper from TB1-20

→ TB1-21.

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Remove metal flag from proximity switch PX1.

Observe:

- Motor contactor (M1) drops out

- V1 and V2 lights go out

- DON'T FEED light (DS4, Red) is lit.

- Display Unit (DU1) displays message "05) DOOR/COVER OPEN or UNLATCHED."

- Replace metal flag on PX1.

Allow controller to sequence to the FEED mode by pressing the TIMED START PUSHBUTTON.

Remove metal flag from proximity switch (PX2).

Observe:

- Motor contactor (M1) drops out

- V1 and V2 lights go out

- DON'T FEED light (DS4, Red) is lit.

- Display Unit (DU1) displays message "05) DOOR/COVER OPEN or UNLATCHED."

- Replace metal flag on PX2.

33 E-Stop Circuit Verification:

a) Controller E-STOP (PB1)

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Push in E-Stop PB1.

Observe:

- Controller should shut down. The POWER ON light (DS1, White) should remain lit.

- The Display Unit (DU1) should display:

11) Reset PB1 ESTOP, push TIMED START

Reset E-Stop (PB1).

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

b) Pulper remote E-Stop (PB2) (if pulper not connected)

Simulate remote E-Stop switch being pushed in by removing jumper TB3-9 → TB3-10.

Observe:

- Controller should shut down. The POWER ON light (DS1, White) should remain lit.

- The Display Unit (DU1) should display:

08) RMT ESTOP pushed, press TIMED START

- Replace jumper TB3-9 → TB3-10.

- Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

34 Conductivity Sensor Circuit Verification:

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Install jumper across CONDUCTIVITY SENSOR circuit

TB1-17 → TB1-18

Observe:

- Controller should shut down after 2.0 seconds.

- Motor contactor (M1) drops out.

- V1 and V2 lights go out.

- DON'T FEED light (DS4, Red) is lit.

- Display Unit (DU1) displays message "03) HIGH

WATER LEVEL."

Remove jumper TB1-17 → TB1-18.

35 Solenoid Fuse Blown Simulation:

Press the EMERGENCY STOP PUSHBUTTON

(PB1).

Remove fuse F5 from the fuse holder.

Pull out the EMERGENCY STOP PUSHBUTTON

(PB1):

- After the message display (DU1) initializes, the display message should be:

10) FUSE F5 BLOWN.

- Press the EMERGENCY STOP PUSHBUTTON

(PB1).

- Replace Fuse F5.

36 OverLoad Tripped Simulation:

- Press the TEST BUTTON on the overload relay.

- Display Unit (DU1) displays message "12)

MOTOR OVERLOAD TRIPPED.”

- Reset the overload by pressing the RESET

BUTTON

37 Current Sensor Failure Simulation:

- Depress the EMERGENCY STOP PUSHBUTTON

(PB1).

- Remove the lead from the CURRENT TRANSDUCER (XDCR1), Terminal 6.

- Tape the ring terminal to insulate.

- Pull out the EMERGENCY STOP PUSHBUTTON

(PB1).

- Display Unit (DU1) displays message "6)

CURRENT SENSOR FAILED”

- The motor current meter should be indicating in the red “SENSOR FAILED” region.

- Depress the EMERGENCY STOP PUSHBUTTON

(PB1).

- Remove the tape and reconnect the ring terminal that was removed from the CURRENT TRANSDUCER (XDCR1), Terminal 6.

- Pull out the EMERGENCY STOP PUSHBUTTON

(PB1).

- Display Unit (DU1) displays message "A) PRESS

TIMED START.”

38 Disconnect 440 Vac power leads, variac leads, 110 Vac lamps (V1 → TB1-24 to TB1-25, and V2 → TB2-27 to TB2-28), differential pressure switch jumper (TB2-20 to TB2-21), local status indicator jumpers (TB3-9 to TB3-10, and TB3-11 to TB3-12), proximity switches on TB3.

The pulper select jumper TB1-12 to TB1-13 should remain in control enclosure.