Attachment 7 Small Pulper Fabrication Inspection Procedures and Record for PLC.pdf

ATTACHMENT B – TESTING

B3 – Small Pulper

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 Number

Test Step Description

Results

Initials/ Date

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.

Test Complete.