dd-01

INSTRUCTION MANUAL FOR DD-01

DIGITAL DIVERT CONTROL SYSTEM VERSION 4.1.

WITH MAIN PROGRAM 8.5 OR HIGHER

WARNING

The process medium may be hot or otherwise hazardous. Precautions when removing the sensor from the process line:

Make sure that the process line is not under pressure. Open a vent valve to the atmosphere. For a retractor/isolation valve the line pres-sure should be within specifications.

For a prism wash system, close a hand valve for the wash medium and disable the wash valve. Loosen the clamp or flange bolts cau-tiously, be prepared to tighten again. Be out of the way of any possible splash and ensure the possibility of escape.

Use shields and protective clothing adequate for the process medium. Do not rely on avoidance of contact with the process medium. After removal of the sensor, it may be necessary to mount a blind flange for security reasons.

Document/Revision No. IMD 1/5 Effective: June 20, 2005

This product manual is delivered to the end-user with a K-Patents product. Information in this manual is subject to change without notice. The latest manual version is freely available at http//www.kpatents.com/. You can also contact [email protected].

THE PASSWORD FOR PR-01-S IS 7 8 4 5 1 2 IN PROGRAM VERSIONS 4.0 AND HIGHER.

K-PATENTS OY

Postal address: P.O. Box 77 FIN-01511 Vantaa, Finland

Tel. + 358-9-825 6640 Fax +358-9-825 66461 E-mail: [email protected] http://www.kpatents.com/

K-PATENTS OY

Street address: Elannontie 5 FIN-01510 Vantaa, Finland

Tel. + 358-9-825 6640 Fax +358-9-825 66461

K-PATENTS,INC.

1804 Centre Point Circle, Suite 106, Naperville, IL 60563

Tel. 630-955 1545 Fax 630-955 1585 E-mail: [email protected] http://www.kpatents.com/

1

1. TABLE OF CONTENTS

1 TABLE OF CONTENTS........................................................................................................................1

2 GENERAL INFORMATION .................................................................................................................2 2.1 Digital divert control system DD-01 .................................................................................................2 2.2 Operator panel...................................................................................................................................3 2.3 Alarms...............................................................................................................................................4 2.4 Prism wash ........................................................................................................................................4 2.5 Master divert control unit ..................................................................................................................5 2.6 Indicating transmitters.......................................................................................................................6 2.7 K-Patents digital divert control unit specifications............................................................................7

3 MOUNTING...........................................................................................................................................8 3.1 Wiring ...............................................................................................................................................8

4 START-UP ...........................................................................................................................................12 4.1 Divert control unit start-up ..............................................................................................................12 4.2 Divert control system trimming.......................................................................................................12

5 CALIBRATION....................................................................................................................................13 5.1 Refractometer concentration measurement .....................................................................................13 5.2 Refractometer activation for divert control .....................................................................................13 5.3 Signal difference alarm ...................................................................................................................14 5.4 Low alarms......................................................................................................................................14 5.5 Refractometer malfunction alarm....................................................................................................14 5.6 Prism wash ......................................................................................................................................14 5.7 Divert decision rules........................................................................................................................15

6 MAINTENANCE .................................................................................................................................17 6.1 Information flow..............................................................................................................................17 6.2 Divert control circuit boards ...........................................................................................................18 6.3 Diagnostic messages........................................................................................................................23 6.4 Diagnostic lights..............................................................................................................................23 6.5 Push-button assembly......................................................................................................................24 6.6 Fuses................................................................................................................................................24

7 DIVERT CONTROL LOGIC ...............................................................................................................25 7.1 Block diagram .................................................................................................................................25 7.2 Logical diagrams .............................................................................................................................26 7.3 Safety Decision Logics....................................................................................................................28

8 OPTIONAL CONFIGURATIONS.......................................................................................................30 8.1 Remote divert control unit...............................................................................................................30 8.2 Equipment .......................................................................................................................................30 8.3 Remote divert control unit in the control room ...............................................................................31 8.4 Wiring and mounting.......................................................................................................................32 8.5 Serial output ....................................................................................................................................34 8.6 Current output signal .......................................................................................................................34 8.7 External DC power supply ..............................................................................................................34

9 DIVERT CONTROL UNIT PARTS LISTS.........................................................................................35 9.1 Divert control unit and optional remote divert control unit.............................................................35 9.2 Remote divert control unit...............................................................................................................36

INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

2

2. GENERAL INFORMATION

The K-Patents Digital Black Liquor Divert Control System DD-01 provides a divert signal preventing black liquor with dangerously low solids to reach the black liquor burners. The system is built strictly according to the principles of Recommended Good Practice "Safe Firing of Black Liquor in Black Liquor Recovery Boil-ers" (BLRBAC August, 1982 and revisions April, 1991, and March, 2001).

2.1. DIGITAL DIVERT CONTROL SYSTEM DD-01

Figure 2.10 Complete Digital Divert Control System DD-01

The system consists of the following parts (Figure 2.10): Two K-Patents Process Refractometers PR-01-S (A & B) are installed in series in the main black liquor line. Each refractometer is complete with a Sensor, an Indicating transmitter and Interconnecting cables. Each refractometer provides also a 4-20 mA % solids output signal not used by the divert control system.

The Divert Control Unit DD-01 is contained in one enclosure with the same dimensions as the refractometer Indicating transmitter enclosure. The control unit includes:

�� an operator panel �� control logics �� contact outputs for prism wash, warnings, alarms and black liquor diversion �� Two isolation valves HIMP-2 (optional) for the refractometers above to allow removal of

the refractometers from a pipe with full flow and pressure. The isolation valve includes a prism wash nozzle and two check valves (one for prism wash, one for stuffing box flush).

�� A roofed mounting plate to mount the two Indicating transmitters and the Divert Control Unit together.

�� Two steam valves with steam traps for prism wash (pneumatic + solenoid valves). �� Two hand valves (one for prism wash, one for stuffing box flush). �� One alarm horn (supplied by the customer).

Note. BLRBAC (The Black Liquor Recovery Boiler Advisory Committee) recommends a spare sensor to be maintained in stock on-site.



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2.2. OPERATOR PANEL

37

65

4

Figure 2.20 The operator panel.

The operator panel has a clear layout and the operator can see all information at one glance. The divert deci-sion is controlled from the operator panel which provides doubled security, since all information is simultane-ously shown both as LED indication in the Divert Control Unit and as a diagnostic messages in the Indicating Transmitters (Figure 2.20).

Each refractometer has a green OPERATING light (1), so the operator knows when he can rely on the refrac-tometer measurement. A refractometer will influence the divert decision only when the green OPERATING light is on. A malfunctioning refractometer is automatically taken out of operation. One green indicator light SAFE% SOLIDS (2) is based on the two refractometers and the divert decision rules (Section 5.7).

One red DIVERT light (3) that will be switched on when the SAFE% SOLIDS goes off. The DIVERT light indicates divert status of the divert relay. The divert relay has an output switch contact, for use in the Black Liquor Firing Tripping Logic. The relay is OFF in the DIVERT position, because a power failure will give a DIVERT decision.

A lockable OVERRIDE/AUTOMATIC switch (5) and a red OVERRIDE warning light (4) is ON always if switch in OVERRIDE position. If the SAFE% SOLIDS goes OFF and this switch is in the OVERRIDE posi-tion, then the OVERRIDE light is lit instead of the DIVERT light. One RESET push-button (6) for the DIVERT action. The DIVERT action always has to be manually reset. If the override switch is in Automatic position and SAFE% SOLIDS is off, the DIVERT action cannot be reset.

One EMERGENCY DIVERT push-button (7) to manually initiate DIVERT in an OVERRIDE or emergency situation. The DIVERT light is lit also after manual divert action. The EMERGENCY DIVERT button has a protective hinged cover, to prevent inadvertent use.

Two indicator lights (8) for the divert valve status TO BY-PASS/TO BURNER from microswitches on the valve. For intermediate valve positions both lights are off.

A row of four alarm lights (9) that indicate black liquor SOLIDS WARNING (at 60%), black liquor SOLIDS ALARM (below 58%), refractometer reading more than 2% absolute difference and refractometer malfunc-tion.



4

A light test button (10) switches all 11 lights on. An alarm reset button (11) resets the alarm lights. For normal operation the operator panel has four green lights on (A OPERATING/B OPERATING/ VALVE TO BURNER/SAFE% SOLIDS).

2.3. ALARMS

The divert control system has four alarms, audible and indicating:

1. Black liquor SOLIDS WARNING, yellow light (60% or below) 2. Black liquor SOLIDS ALARM, red light (58% or below) 3. Refractometers reading more than 2% absolute DIFFERENCE, yellow light 4. Refractometer MALFUNCTION, yellow light

The alarms 1, 2 and 4 are initiated by either refractometer. System contains also optional alarms, see wiring drawing 3.11.

The operator panel contains four indicator lights and an ALARM RESET button. The reset button will silence the audible alarm, but the visual indication will remain until the condition has returned to normal.

To avoid unnecessary alarms the following interlocks are implemented:

- A refractometer can initiate an alarm only when it is operating. - Alarm 4 can be initiated only if both refractometers are operating.

The parameters (2%, 58% and 60%) are default settings, which can be changed from the Indicating transmitter keyboard (Sections 5.3 and 5.4). The parameter for 2% can be decreased and the parameter for 58% and 60% can be increased.

2.4. PRISM WASH

For K-Patents Process Refractometer, the need of prism wash is reduced and even in some cases eliminated. The prism keeps clean due to the probe design features:

- The prism is flush mounted in a surface deflecting the black liquor main flow, which causes a strong mechanical cleaning action.

- The prism has the same temperature as the black liquor.

In any case, however, an automatic regular prism wash provides an efficient check that the refractometer re-acts. A steam wash of 3 seconds every half hour should be sufficient. Automatic single (one-of-two) diversion will occur if either of the refractometers is in wash cycle.

The Divert Control Unit contains two relays for prism wash, WASH A and WASH B. To follow the BLRBAC recommendation not to wash both prisms at the same time, there is an interlock. If both refractometers try to wash simultaneously, one will display "WAIT" and perform the wash when the other has finished.

K-Patents recommends to use a steam trap instead of preconditioning valve to remove condensate from the steam line. The wash times can be seen pressing soft keys "Display"/"System configuration"/"Wash times". To change the wash times, see Section 5.6.



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2.5. MASTER DIVERT CONTROL UNIT

Figure 2.50 Operator’s panel and functions of the master divert control unit in the field with LED indications.

1. Black liquor SOLIDS WARNING (at 60%), Black liquor SOLIDS ALARM (be-low 58%), Refractometer reading more than 2% absolute difference, and Refractometer malfunction).

2. Each refractometer A and B has an OPERATING green light, A refractometer will influence the divert decision only when the green OPERATING light is on. A mal-functioning refractometer is automatically taken out of operation.

3. One green indicator light SAFE% SOLIDS, based on the two refractometers and the divert decision rules.

4. A red OVERRIDE warning light is on always if the override switch is switched on.

5. One red DIVERT light that will be switched on when the SAFE% SOLIDS goes off. The DIVERT light indicates divert status of the divert relay.

6. Two indicator lights for the divert valve status. TO BY-PASS/TO BURNER from microswitches on the valve. For intermedi-ate valve positions both lights are off.

7. A lockable Override/Automatic divert switch

8. A DIVERT RESET push-button.

9. An EMERGENCY DIVERT push-button.

10. A light test button switches all 11 lights on.

11. An alarm reset button resets the alarm lights.



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2.6. INDICATING TRANSMITTERS

An Indicating transmitter in a Divert Control System is identical (both hardware and software) to a standard transmitter described in the PR-01-S Instruction manual.

A B C D

1 2 3

4 5 6

7 8 9

0 . - E N T E R R E S E T

P R O C E S S T E M P E R A T U R E22.1 ° C

AC O N C

T E S T 109.3In d iv e r t c o n tr o l o p e r a tio nS ta r tp r is mw a s h

R e m o v e dfr o m d ivc o n tr o l

C a lib r a te D is p la y

P R O C E S S IN S T R U M E N T SK -PT E N T S

4

52

3

1

Figure 2.60 The Indicating transmitter.

The display, Figure 2.60, will give the following additional information pertinent to the Divert system:

1. A or B in the upper right corner indicates that the transmitter is OPERATING in the divert system as re-fractometer A or B, Figure 2.10. If a or b is displayed instead, the refractometer is removed from divert con-trol operation. (If the upper right corner is empty, see Section 5.2). For A or B the corresponding green OPERATING light, Figure 2.20, is on, for a or b it is off. If you see a ? in this corner, see Section 5.2.

2. A softkey (B) defined by "Remove from divert control" or alternatively "Restore to divert control". The visible effects of pressing "Remove" for refractometer A is that the soft key changes to "Restore", A switches to a, and the green OPERATING light goes off. Further the "Remove" soft key disappears from refractometer B, because B must not be removed if it is the only refrac-tometer in operation.

Note. Always press "Remove" for a refractometer be-fore making service or switching the power off.

3. The "Normal operation" message is substituted by "In divert control operation" or "Removed from di-vert control". Those messages may change to "Sol-ids warning" or "Solids alarm" at low solids. An ad-ditional error message may occur: ** Divert control fault ** combined with a ? in the upper right corner, see Section 6.3.

4. The softkey "Display" (D) leads via "System con-figuration" (C) to "Divert control system" (D) which gives the following information:

Refractometer difference alarm limit in % solids Solids warning limit in % solids (default

value 60%) solids alarm limit in % solids (default value 58%) Divert rule and SW1/SW2 positions (Section 5.7)

5. The softkey "Calibrate" (C) gives possibilities to set up for divert control and calibration, see Chapter 5.



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2.7. K-PATENTS DIGITAL DIVERT CONTROL UNIT SPECIFICATIONS

Model: DD-01

Enclosure: IP66 Nema 4X, dimensions 226 x 267 mm (8.91 x 10.5 in)

Supply: 24 V DC, provided by the Indicating transmitters

Ambient temperature: max 45 °C (113 °F)

Accessory: Roofed mounting plate for the Divert Control Unit and 2 Indicating transmitters, Figure 2.60.

Material: AISI 316, dimensions 916 x 488 mm (36 x 19.2 in)

Figure 2.70 Divert Control Unit Mounting Plate: Dimensions (mm/in)

Figure 2.71 Divert Control Unit and Indicating Transmitter Enclosures: Dimensions (mm/in)



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3. MOUNTING

For mounting of the process refractometer and the isolation valve, consult the separate Refractometer PR-01-S(-EX/FM) Manual.

3.1. WIRING

Wiring for the complete system, see Figure 3.10 and Figure 3.11 which describe also all cables and how each cable is connected.

The cables 1 and 2 are included in the delivery. The terminal strip positions of the Divert Control Unit are specified in Figure 3.11 and Figure 3.12.

Figure 3.10 Divert Control System Wiring Cables and Connections



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Figure 3.11 Divert Control System Wiring and Connections


10

Figure 3.12 Cable connections



11

F1

F3 F4

X1

F2

D10 D12

D26D25D24D23D22D21D20D19

D13D11

D3

D4

D27 D28

IC8

D17

D16

D29

D31

D32

D30

D7

D9

D1

IC30

IC26

IC29

IC24

K4

IC25

TP4

D5

D15

D8

L1

IC27

IC28

RE1 RE8RE7RE6RE5RE4RE3RE2

IC2

IC16

IC13

IC22

IC12

IC23

K11K10

J1

TP1

V6

V5 V9

V8

V7

V4

V3

V2

V1

1

IC15 IC17

IC19

IC6

IC1

TP2

IC14

IC20

IC21

IC11

IC10

IC3

IC7

D6

C27

C30

R10

SW1

IC18

X2

C44

C52

C48

C43

C45R16

R8

R1

R2

R3

R4

R5

R6

R7

R26

R27R25

R28

R13R12

R11

R24R23R22R21R20R19R18R17

R15

R14

R9

C8

C26

C23

C24

C22

C25

C40

C50C51

C41

C42

C7

C12

C28

C6

C9

C5

C4

C3

C2

C1

C17

C16

C15

C37

C38

C13

C39

C31 C33C35

C36C34

C32

C18

C49

C47

C46

C29

C19

C20

C14

C21

C11C10

RN6

RN4

RN5

RN2

RN3

RN1

RN7

IC9

IC5IC4 J2

K12K9

D14

K8 K13

K3

K7K6K5 K14

K1 K2

D2

TP3

D18

DIVERT CONTROL UNIT

DANGER HIGH VOLTAGE

K-PATENTS PR-7310 Rev.C

37 403938363534333231302928

AC-POWER

27191817 26252423222120

1615

87654321SW

NL

14 1413 1312 1211 1110 109 98 8

SWGND

SGND

+5V

GND

OVERRIDEALARMSOLIDS

WARN.SOLIDS

REF.DIFF.NORM.

DIVERT

POSITIONVALVE

B

63mA 63mA

1A

1A

EXT24VSERIAL BUS BSERIAL BUS A

BURNERBYPASSHORNWASH WASH

A

Figure 3.13 Divert control circuit board, layout.



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4. START-UP

For refractometer start-up consult the separate Refractometer PR-01-S(-EX/FM) Manual and the Mounting and start-up check list.

4.1. DIVERT CONTROL UNIT START-UP

1. Check the wiring and supply voltage. Note: Before the power is switched on, the DIVERT output relay is in DIVERT position.

2. Switch the power on for both Indicating transmitters. The control system is now in the DIVERT mode, and the red DIVERT light is on.

3. Press the LIGHT TEST button. All eleven lights should switch on.

4. The upper right corner of the Indicating transmitter displays should now state a or b respectively. If not, see Section 5.2.

If the message is "Removed from divert control" the refractometer is ready to "Restore to divert control", softkey B.

If the message is "Solids warning" or "Solids alarm" then "Restore" provokes an alarm. Press the ALARM RESET button.

For any other message, see Section 6.3.

5. Observe that the VALVE STATUS lights follow the position of the valve.

Now the Divert Control System is set for normal monitoring operation.

6. Check that the prism wash is working. Press the "Start prism wash", softkey A.

7. When the SAFE % SOLIDS has turned on and also the other conditions for safe boiler operation are satisfied, the DIVERT can be turned off using the RESET button.

4.2. DIVERT CONTROL SYSTEM TRIMMING

During the trimming of a new system, it is recommended to keep the key in the OVERRIDE position.

When the key is in the OVERRIDE position, the DIVERT action has to be initiated manually using the EMERGENCY DIVERT button. This should be done when the green SAFE %SOLIDS light turns off.

The trim procedures are described in Chapter 5, the measurement calibration in Section 5.1 and the prism wash in Section 5.6.

The key should be turned to the AUTOMATIC position only after it has been decided that sufficient experi-ence has been gained.



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5. CALIBRATION

The K-Patents Divert Control System is calibrated by the manufacturer. This chapter contains instructions how to make the fine adjustment of the system.

5.1. REFRACTOMETER CONCENTRATION MEASUREMENT

For refractometer calibration consult also the separate Refractometer PR-01-S(-EX/FM) Manual.

The CONC% displays of the two Indicating transmitters have to show the same value. If there is a difference, this can be eliminated by changing the Bias for one of the refractometers. Key in the sequence Calibrate / Pa-rameters / CONC(RI) / Parameters / Bias. Comparison with sample determination can decide which one should be corrected.

Example: If the Indicating transmitter of A displays CONC% = 63.2% and B displays CONC% = 63.8%, the difference can be eliminated e.g. by lowering B by 0.6%. Read bias from the display of refractometer B. If bias = 52.923 then enter a new bias = 52.323.

Due to its digital measurement principle, the readings of the K-Patents Process Refractometer do not drift by time. Frequent recalibrations based on off-line moisture analysis must be avoided, as they will introduce ran-dom fluctuations to the refractometer readings.

If the concentration reading is noisy, the damping can be increased. Enter Calibrate / Parameters / CONC(RI) / Damping time. The Damping time is the time in seconds for the signal to reach half of its final value after a step change. Increase the damping time in small steps, and wait for the result.

5.2. REFRACTOMETER ACTIVATION FOR DIVERT CONTROL

When a refractometer is activated for Divert control, the upper right corner of the display shows alternatively A, a, B, b or ?. If the corner is blank the divert function must be activated by pressing the sequence Cali-brate/Parameters/Divert control/Divert control and select "1 Activated".

The program has to be version 4.0 or higher, otherwise "8 Divert control" is missing from the CALIBRATE menu. The program EPROM has then to be changed to an up-dated version.

The decision to display A (a) or alternatively B (b) is not programmed, it depends on to which SERIAL BUS port in the Divert unit (Figure 3.13) the Indicating transmitter is connected.

If a Divert activated refractometer is used in another type of application, the divert function has to be deacti-vated by selecting "0 Not activated". After de-activation all references to Divert functions disappear except "8 Divert control" in the CALIBRATE menu.

Note. If a message DIVERT CONTROL FAULT and a ? appear on the IT-R display, the reason is one of the following:

1. Cables between the IT-R and the terminals 8-14 on the DD-01 are not properly connected. Re-connect to fix.

2. Communication 485 component IC 17 (A) or IC 19 C (B) is broken on the PR-7310 board inside the DD-01. Replace board.

3. Communication 485 component IC 1r is broken on the PR-7010 board inside the IT-R. Replace board.

4. Dip switch 3. is in the “up” position which means that the PR-7310 card is configured to work in the remote mode. Change the dip switch back to low (=off) position.



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5.3. SIGNAL DIFFERENCE ALARM

According to BLRBAC, if a difference of 2% solids (absolute value) or greater exists between refractometer readings, an alarm shall be activated.

The alarm limit 2% can be changed from the keyboard using the sequence Calibrate/Parameters/Divert con-trol/Ref. difference limit. If the deviation alarm trips seem too frequent, it may help to increase the signal damping, Section 5.1.

Note. If the two refractometers have different limit values, the lower value is used by alarm system.

5.4. LOW ALARMS

The low alarm limits are set from the keyboard of the Indicating transmitter. Enter sequence Cali-brate/Parameters/Divert control. The menu will show “3 Low conc warning limit” and “4 Low conc divert limit”. The latter has a double function: Both LOW SOLIDS ALARM and DIVERT limit.

The Indicating transmitter display will carry the messages “Solids warning” and “Solids alarm” when the cor-responding alarms occur.

Note. The alarm limits are set separately for the two refractometers. Each refractometer gives an alarm accord-ing to its own settings.

5.5. REFRACTOMETER MALFUNCTION ALARM

The built-in intelligent diagnostics of K-Patents Process Refractometer provides a tight control of the opera-tion. A full test cycle is completed with an interval less than one second. A description of the microprocessor implemented diagnostics is given below. For details consult the Instruction Manual of the refractometer PR-01-S. Only errors classified as Equipment malfunctions will cause alarm and removal from the Divert con-trol system. Process related faults will only cause a message in the Indicating transmitter display. See also Section 6.3 for additional diagnostics.

The most important test is to check the signal coming from the digital image sensor during measurement. Im-proper function of light source, optical components, image sensor and sensor driver are recognized by this test.

The compensation for temperature measurement is checked, both the temperature element and the A/D con-verter.

The cable between Sensor and Indicating transmitter is checked using a check sum method, thus recognizing short circuits, open circuits and excessive disturbances.

The microprocessor system has also a self-checking test program to ensure the proper operation of the CPU and the memories. The constants in the EEPROM memory are tested to be within strict limits of acceptance.

The performance of the microprocessor is of critical importance for the measurement control. A separate hardware watch-dog circuit ensures the proper microprocessor operation by checking that the microprocessor regularly sends out a predetermined pulse sequence. Another hardware circuit checks that the supply voltage to the microprocessor is within safe limits, to prevent any brownout stray output pulses.

5.6. PRISM WASH

A prerequisite for a proper function of the divert system, is that the prism wash works. The TEST value in the display should increase at least 20 steps during WASH, provided TEST is not close to its maximum value 248. See Sections 8.1, 8.5 and 9.2 in PR-01-S Instruction Manual.



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WASH TIMES

The wash times can be seen by pressing Display/System configuration/Wash times. The values set at delivery are the following:

Preconditioning = 0 seconds Wash time = 3 seconds Recovery time = 30 seconds Interval = 20 min

The wash times are changed by pressing the sequence Calibrate/Parameters/Prism wash. Note maximum wash time is 30 seconds and maximum recovery time 30 seconds.

WASH CHECK

This function can be defined from the prism wash menu: Calibrate/Parameters/Prism wash/Wash test. A prism wash is accepted if:

a. TEST exceeds “TEST limit”

b. TEST increases more than “TEST difference”

The default values of “TEST limit” and “TEST difference” are zero (0), which makes the wash check inactive.

If the wash is not accepted, the diagnostic message will be “Prism wash failure”.

A “Wash retries” parameter can also be set to repeat the wash if the wash check fails. The default value is zero (0).

WASH STOP

Wash stop function can be defined from the prism wash menu. Wash can be prevented when the process tem-perature is below the set limit, thus indicating that the pipe is not in use. To activate the “wash stop” key se-quence: Calibrate/Parameters/1. Prism wash/Wash stop/1. Active and set the temperature limit.

The default value for wash stop is inactivate. When the wash is not accepted the diagnostics message is “Wash stop/temp. limit”.

EXTERNAL WASH STOP

An input switch can be configurated to an external wash stop to prevent the prism wash when the correspond-ing input switch is connected. “External wash stop”-message will show when automatic wash is activated from the soft keys. The input switch can be set to protect the refractometer e.g. if the process is stopped.

AUTOMATIC SINGLE DIVERSION CONTROL DURING PRISM WASH CYCLE

Automatic single (one-of-two) diversion control will take place if either of sensors are in prism WASH cycle.

5.7. DIVERT DECISION RULES

TWO REFRACTOMETERS IN OPERATION:

BLRBAC states the following: For the solids measurements, two refractometers in series must be used. When both refractometers are in service, the requirement for an automatic black liquor diversion can be satisfied by either of the following options:

1. If either refractometer reads dissolved solids content 58% (default) or below, an automatic black liquor diversion must take place.



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2. When both refractometers read dissolved solids content 58% (default) or below, an auto-matic black liquor diversion must take place.

Either option is satisfactory.

The rules are listed in decreasing order of security. Only rule 1 satisfies the high safety requirements set by BLRBAC, August, 1982. On the other hand, the probability of false trips decreases with decreasing safety. It means that if false trips are too frequent, the rule 2 may be preferred at the cost of safety. The rule 2 has later been accepted by BLRBAC.

A third conceivable alternative is to base the decision on only one refractometer (the master) and use the other refractometer (the slave) for comparison only (and difference alarm). Concerning security and false trips, this rule is a compromise between rules 1 and 2.

The divert decision rule is selected by the switch SW on the divert control board (Figure 3.13). ON position is upwards.

Switch SW SW1 SW2

Rule

OFF OFF One-of-two (BLRBAC) Rule 1 ON OFF A master, B slave - OFF ON B master, A slave - ON ON Two-of-Two Rule 2

Table 5.70 Divert decision rule selection.

ONLY ONE REFRACTOMETER IN OPERATION:

When only one instrument is IN OPERATION the divert action takes place if this instrument reads 58 % or below. The status of SW (Table 5.70) has no influence on the divert decision in this case.

NO REFRACTOMETER IN OPERATION:

If both instruments are out of operation (due to malfunction or maintenance), then according to BLRBAC divert action must take place. See also Section 8.7 about external DC supply.

REMOTE DIVERT SWITCH CONFIGURATION

Switch SW Rule SW 3 OFF DD-01 normal operation ON Remote divert card activated

See Section 8.8.

See Section 5.2 if you have on the screen the message DIVERT CONTROL FAULT.



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6. MAINTENANCE

As the Divert Control System is a pure digital system, no special maintenance is needed. The LIGHT TEST button on the operator panel (Figure 2.50) sends a signal to the microprocessor, and the microprocessor switches all 11 LED lights on as long as the button is pressed. This way not only the lights but also the proc-essing system is checked.

To assist the identification of a faulty component, the information flow and the circuit diagrams are given in Sections 6.1 and 6.2. Also the logic diagrams of Chapter 7 may be of help.

6.1. INFORMATION FLOW

The power and information flow of the total Divert system is shown by Figure 6.10. Additional information about the cable connections is found in Figures 3.10, 3.11 and 3.12.

Figure 6.10 Information and power flow.



18

6.2. DIVERT CONTROL CIRCUIT BOARDS

The component lay-out of the divert control circuit board is shown by Figure 3.12 and the circuit diagram by Figures 6.20 to 6.25.

Figure 6.20 Operator panel board, component layout.

Figure 6.21 Operator panel PR-7311 circuit diagram, page 2 of 2



19

Figure 6.22 Operator panel PR-7311 circuit diagram, page 1 of 2.



20

A14

A13

A12

A11

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

A0

IO8

IO7

IO6

IO5

IO4

IO3

IO2

IO1

WCE

OE 5525732K x 8bit SRAM

IC4

1 2 3 4 5 6 7 8 9 10

11

12

13

15

16

17

18

19

20

21

22

23

24

25

26

27

A14

A13

A12

A11

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

A0

IO8

IO7

IO6

IO5

IO4

IO3

IO2

IO1

WCE

OE 5525732K x 8bit SRAM

IC5

1 2 3 4 5 6 7 8 9 10

11

12

13

15

16

17

18

19

20

21

22

23

24

25

26

27

8Q

7Q

6Q

5Q

4Q

3Q

2Q

1Q

8D

7D

6D

5D

4D

3D

2D

1D

COC

74HC573

IC3

1 2 3 4 5 6 7 8 911

12

13

14

15

16

17

18

19

8Q

7Q

6Q

5Q

4Q

3Q

2Q

1Q

8D

7D

6D

5D

4D

3D

2D

1D

COC

74HC573

IC7

1 2 3 4 5 6 7 8 911

12

13

14

15

16

17

18

19

100n

1 2

C25

100n

1 2

C14

1 2100n

C26

100n

1 2

C9

100n

1 2

C13

100n

1 2

C18

100n

C10

100n

1 2

C11

8Q

7Q

6Q

5Q

4Q

3Q

2Q

1Q

8D

7D

6D

5D

4D

3D

2D

1D

COC

74HC573

IC10

1 2 3 4 5 6 7 8 911

12

13

14

15

16

17

18

19

1HC32

IC2

9 10

8

1HC32

IC2

4 56

100n

1 2

C8

1HC32

IC2

12

13

11

100n

1 2

C22

MAX699

GNDRESET

WDI

VCCIC18

1 2

34

67

8

CTS0

TXD0

RXD0

P1.7

P1.6

P1.5

P1.4

P1.3

P1.2

P1.1

P1.0

T0IN

T1IN

T0OUT

T1OUT

INT4

INT1

INT0

INT3

INT2

P2.7

P2.6

P2.0

P2.4

P2.5

P2.2

P2.1

P2.3

UCS

LCS

PEREQ

ERROR

ALE

BHE

RD

WR

READY

DEN

DT

LOCK

HOLD

HOLDA

NCS

S0

S1

S2

RESIN

RESOUT

PDTMR

NMI

TEST

AD0

AD1

AD2

AD3

AD4

AD5

AD6

AD7

AD8

AD9

AD10

AD11

AD12

AD13

AD14

AD15

A16

A17

A18

A19

CLOCKOUT

CLKIN

OSCOUT

80C186EB

16bit MICROPROCESSOR

IC15

3

4 56 78 9 10

11

12

13

14

1516

17

18

1920212425262728

2930

31

32

33

34

35

36

37

38

39

40

41

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

66

67

68

69

70

71

72

73

74

75

76

77

78

7980818283

10K0

RN5

15

RN5

13

10K0RN11 2

RN5

18

RN5

14

RN4

15

10K0

RN4

1410K0

RN5

12

RN5

16

RN4

13

RN4

16

RN5

17

RN5

19

10R0R8

12

3K32R7

12

100n

1 2

C24

100n

1 2

C23

O8O9

O10

O11

O12

O13

O14

O15

PGM

VPP

NC

OECE

A15

A14

A13

A12

A11

A10

A9A8A7A6A5A4A3A2A1A0

O7O6O5O4O3O2O1O0

64K x 16bit EPROM

27C210

IC8

1 2

3 4 5 6 7 8 9 10

12

13

14

15

16

17

18

19

20

2122232425262728293132333435363738

39

OUT

VCC

N.C.

GND

Osc.

32.0MHz

X1

1 78

14

RD

WR

RESET

AD11

AD11

AD11

AD11

AD10

AD10

AD10

AD10

AD8

AD8

AD8

AD8

AD5

AD5

AD5

AD5

AD2

AD2

AD2

AD2

AD1

AD1

AD1

AD1

AD0

AD0

AD0

AD0

A13

A13

A13

A13

AD4

AD4

AD4

AD4

A18

A18

AD12

AD12

AD12

AD12

A17

A17

AD7

AD7

AD7

AD7

A9

A9

A9

A9

A8

A8

A8

A8

A7

A7

A7

A7

A6

A6

A6

A6

A5

A5

A5

A5

A4

A4

A4

A4

A3

A3

A3

A3

A2

A2

A2

A2

A1

A1

A1

A1

A0

A0

A15

A15

A15

A15

SDISP

AD13

AD13

AD13

AD13

A16

A16

AD3

AD3

AD3

AD3

A14

A14

A14

A14

AD6

AD6

AD6

AD6

AD14

AD14

AD14

AD14

AD9

AD9

AD9

AD9

AD15

AD15

AD15

AD15

A11

A11

A11

A11

A10

A10

A10

A10

A12

A12

A12

A12

RXD0

RESOUT

SRLY

ISOSW

ISOSW

SSER2

SSER2

TXD0

AD16

AD16

RXD1

TXD1

INT1

AD17

AD17

AD18

AD18

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

AD19

AD19

AD0-15

A0-9

14

28

14

28

30

11

14

7

84

65

63

43

22

64

42

23

21

40

10

10

10

20

20

20

VSS

VCC

Figure 6.23 Divert control board PR-7310 circuit diagram. Page 1 of 3.



21


&EN

A5

A3A4

A6A7A8

Y1Y2Y3Y4Y5Y6Y7Y8

A1A2

G1G2

HC541

1817161514131211

1 19 2 3 4 5 6 7 8 9

IC1

100n

1 2

C35

100n

1 2

C33

100n

1 2

C36

1+

1-

2-

2+

VO1

VO2

GND

VCC

Opto-isol.

HCPL2731

1 2 3 4

7 6 58IC29

100n

1 2

C38

1+

1-

2-

2+

VO1

VO2

GND

VCC

Opto-isol.

HCPL2731

IC24

1 2 3 4

7 6 58

1

23K3

R28 3K32

RN11 2

VCC

RD

WR

CS

RESET

DTR

RTS

X1

X2

TXD

INT

RXD

RI

CTS

DSR

DCD

VSS

D0

D1

D2

D3

D4

D5

D6

D7

A0

A1

A2

82510IC9

25262728 1 2 3 4 222324

20191817

1516

9 8 6 5 1310141112

721

RN11 3

RN11 6

VCC

GND

VOUT

0V

conv.

DC/DC

NME0505D

IC27

145 7

RN61 21K0

RN61 4

1+1-

2-2+

VO1

VO2

GND

VCC

Opto-isol.

HCPL2731

IC26

1 2 3 4

7 6 58

100u

1 2

C52

RN71 2

RN61 5RN61 3

RN71 3

33pF

1 2

C16

TP31 2

100n

1 2

C17

100n

1 2

C32

VCC

GND

VOUT

0V

conv.

DC/DC

NME0505D

145 7

IC28

1K0

RN71 4

100n

1 2

C34

100n

1 2

C42

12

500RR27

100n

1 2

C41

100n

1 2C6

100n

1 2

C37

D10

12

10R01 2R11

1HC32

IC2

1 23

D4

12

12D12

D3

12

SA5.0

1 2

D9

RO

RE

DE

DI

VCC

DO

DO

GND

LTC485

IC19

1 2 3 45678

100n

1 2

C39

J2

4

J2

1

R 1D

C1

HC2731Q

2Q

3Q

4Q

5Q

6Q

7Q

8Q

1D

2D

3D

4D

5D

6D

7D

8D

CLR

CPIC20

9 126 155 162 19

1 11 8 13 7 14 4 17 3 18

RN71 5

SA5.0

1 2

D5

RO

RE

DE

DI

VCC

DO

DO

GND

LTC485

IC17

1 2 3 45678

SA5.0

1 2

D8

SA5.0

1 2

D7

SA5.0

D6

1 2

K1A

2

K1A

1

RN21 9

3K32RN21 2

RN21 3

RN21 6

RN21 8

RN21 7

RN21 5

RN21 4

100n

C28

1 2

J146

J144

J140

J114

J112

J110

100n

1 2C1

100n

1 2C2

100n

1 2C3

12

R6

100n

1 2C4

12

R5

100n

1 2C5

12

R4

12

R3

K2A

2

K2A

1

J2

6

J2

2

J2

3

J2

5

12

R2

100R 1

2R1

100n

1 2

C31

X142

X132

X141

X131

1 2TP4

SA5.0

1 2D29

100n

1 2

C40

100n1

2

C50

12

D28

12

D27

SA5.0

1 2D30

100n

1 2

C51

12 1KR13

12

1KR12

RN11 7

100n

1 2

C12

&EN

A5

A3A4

A6A7A8

Y1Y2Y3Y4Y5Y6Y7Y8

A1A2

G1G2

HC541

IC6

1817161514131211

1 19 2 3 4 5 6 7 8 9

RN11 5

12

500RR26

1

23K3

R25

RN11 4

18.432MHz

X2

12

RR

T T

POWER

OFF

VCC

GND

+9V

-9V

C1+

C1-

C2+

C2-

LT1180

IC25

23

4 5 6

7 8910

11

12

13

14

15

16

17

18

K2A

3100n

1 2

C30

RN31 5

1k00RN31 3

RN31 2

1k00

RN31 4

100n

1 2

C27

SW8

SW1

1 2 3 4 5 6 7 8910

11

12

13

14

15

16

11

74HC05

IC23 1

213

11

74HC05

IC23

10

11

11

74HC05

IC23

89

11

74HC05

IC23

65

11

74HC05

IC23

43

K1A

3

1N4007

12D31

1N4007 12

D32

12

F3

12

F4

11

74HC05

IC23

21

33pF

1 2

C15

100n

1 2

C7

INT1

SGND

SGND

SER1+

TXD1

RTS

RTS

SER0-

KN2

KN2

A1

AD7

AD7

AD7

AD6

AD6

AD6

AD5

AD5

AD5

AD2

AD2

AD2

A2

KN1

KN1

ISOSW

RXD0

5VSER

AD1

AD1

AD1

WR

WR

DIP1

CTSI

DIP2

DIP3

DIP4

DIP5

AD4

AD4

AD4

DIP6

DIP7

RXD

RD

DIP8

SD

RXDI

TXDI

UARTS

UACTS

AD15

AD14

AD13

AD12

AD11

RTSI

TXD

AD10

KN6

KN6

KN5

KN5

RESET

KN4

KN4

KN3

KN3

AD9

TXD0

SER0+

AD8

SWGND

SER1-

CTS

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

+5V

BURNER

BYPASS

AD0

AD0

AD0

AD3

AD3

AD3

A3

RD

RD

SSER2

RESOUT

A1-3

AD0-15

EMERGENCY DIVERT

DIVERT RESET

OVERRIDE

ALARM RESET

LAMP TEST

BA

AD0-18

TEST POINT

TEST POINT

(10)

(10)

(8)

(8)

(9)

(9)

2010

7

14

2010

2010

Figure 6.24 Divert control board PR-7310 circuit diagram. Page 2 of 3.


22

HC2731Q2Q3Q4Q5Q6Q7Q8Q

1D2D3D4D5D6D7D8D

CLR

CPIC11

2 5 6 9 12151619

1 11 3 4 7 8 13

14

17

18

1HC32

IC16

4 56


1D2D3D4D5D6D7D8D

CLR

CPIC21

2 5 6 9 12151619

1 11 3 4 7 8 13

14

17

18

+

. .

100u

1 2

C48

+

. .

2u2

1 2

C43

OSC

FB

VOUT

GND

VIN

SS

FRC

L4962

7

15

11

4 5121310

2

14IC30

4K64

1 2R14.

.

150uH

12

L1

. .

33n

1 2

C47

. .

2n2

1 2

C46

+

. .

220u

1 2

C44

K4

2

. .

BYV27/50

1 2

D2

+

. .

220u

1 2

C45

12

D23

.. 1A

12

F1

1 2

D1

.

.

1N4007

12

D16

K4

3

K4

1

K5

2

K5

1

.. 12

V1

RE2

K6

1

Q0

Q1

Q2

Q3

Q4

Q5

Q6

Q7

D7D6D5D4D3D2D1D0

GND

DCOM

ULN2803A

IC22

1 2 3 4 5 6 7 81112131415161718

10 9

12

D20

12

D26

K6

2

.. 12

V2

RE1

K7

1

K7

2

.. 12

V3

.. 12

V4

RE4

K8

1

K8

2

RE3

K10

2

.

.

1N4007

12

D18

K10

1

TP1

12

TP2

12

12 D14

4K7 12 R10

K2C2

K1C2

RE5

K2C1

K1C1

K2B2

4K7

12 R1712

D21

.. 12

V7

4K7

12 R22

K11

1

K11

2

.. 12

V8

12

D22

K12

1

K12

2

..

V9

.. 12

V5

12 D11

4K7

12 R23

12 D13

K9

1K9

3

..

12

V6

4K7

12 R24

..

1A

12

F2

4K7

12

R16

4K7

12

R9

12

D19

4K7

12 R18

. .

100n

1 2

C21

RE6RE7

1HC32

IC16

12

13

11

4K7

12 R19

RE8

12

D25

1HC32

IC16

9 10

8

4K7

12 R20

K9

2

12

D24

. .

100n

1 2

C20

15K0

1 2R15

. .

33nF

1 2

C49

. .

100n

1 2

C19

SA26

1 2

D15

.

.

1N4007

12

D17

K1B1

K3

1

K2B1

K3

2

J149

J147

K1B2

. .

100n

1 2

C29

4K7

12 R21

Q0

Q1

Q2

Q3

Q4

Q5

Q6

Q7

D7D6D5D4D3D2D1D0

GND

DCOM

ULN2803A

IC12

1 2 3 4 5 6 7 81112131415161718

109


1D2D3D4D5D6D7D8D

CLR

CPIC14

2 5 6 9 12151619

1 11 3 4 7 8 13

14

17

18

J1

30

J1

28

J1

32

J1

35

J1

37

J1

36

J1

38

J1

39

J1

25

J1

19

J1

21

J1

20

J1

22

J1

26

J1

27

J1

29

Q0

Q1

Q2

Q3

Q4

Q5

Q6

Q7

D7D6D5D4D3D2D1D0

GND

DCOM

ULN2803A

IC13

1 2 3 4 5 6 7 81112131415161718

10

9

1HC32

IC16

1 23

AD0

AD0

AD5

AD5

AD6

AD6

AD7

AD7

AD1

AD1

AD3

AD3

AD2

AD2

AD4

AD4

DIVERT

VBYPASS

SRLY

WARN

BURNER

OUT4

OUT5

OUT6

OUT8

EXT24V

BOPER

SAFE

OVERRIDE

SR224V

ALARM

REFRDIF

MALFUNC

L N

AOPER

VIO24V

VIO24V

VIO24V

VIO24V

VIO24V

VIO24V

GND

GND

RE6

RE6

RE5

RE5

RE2

RE2

RE1

RE1

SR124V

RE3

RE3

RE4

RE4

RE8

RE8

RE7

RE7

SDISP

WR

OUT7

P

P

AD11

AD10

AD8

+5V

+5V

+5V

+5V

+5V

+5V

AD12

RESET

AD13

AD14

AD9

AD15

RE1-8

LINE

AD0-18

(16)

(15)

BABA

(14)

(14)

(13)

(13)

(12)

(12)

(11)

(11)

912

8 8 8 8 8 8 8 85 5 5 5 5 5 5 5

16

16

16

16

16

16

16

161 1 1 1 1 1 1 1

7

14

1020

1020

1020

SOLIDS WARN.

SOLIDS ALARM

DIVERT/NORM

REF. DIFF

NO MALF.

B WASH

A WASH

HORN

SA5.0TEST POINT

TEST POINT

Figure 6.25 Divert Control board PR-7310 circuit diagram. Page 3 of 3. INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5


23

6.3. DIAGNOSTIC MESSAGES

For diagnostic messages in the Indicating transmitter display, see the PR-01-S manual. The following mes-sages appear only in divert systems:

- "In divert control operation" or "Removed from divert control", Section 2.6.

- "Solids warning" and "Solids alarm", Section 5.4.

- ** Divert control fault **

This message indicates that there is no communication to the divert control unit, probably cable error, Figure 3.12, cable 2.

If the instrument is not applied in a divert control system, de-activate the divert function, see end of Section 5.2.

Further the message ** Relay unit fault ** may appear. This indicates that the Relay unit PR-7080 functions are defined, but no Relay unit is connected. Normally a Relay unit is not used in a Divert system because the wash contacts are in the Divert control unit. Clear the relay functions by the key sequence Calibrate/Relay unit and select an "0 Not Defined" for all four relays. For using an optional relay unit, see PR-01-S Manual, sec-tion 9.1.

6.4. DIAGNOSTIC LIGHTS

The Divert circuit board, Figure 3.12, contains the following diagnostic LEDS:

D3 Processor cycles: should flash

D4 Processor reads serial bus: should flash

D10 Serial bus A input: should flash

D11 On if 24 V DC supply from A is OK

D12 Serial bus B input: should flash

D13 On if 24 V DC supply from B is OK

D14 On if external 24 V DC is applied

D19 Wash relay A on

D20 Wash relay B on

D21 Solids warning relay on

D22 Solids alarm relay on

D23 Divert relay on = not DIVERT (Section 2.2)

D24 Horn on

D25 Refractometer difference relay on = difference alarm

D26 Override

D27 Valve to bypass

D28 Valve to burner



24

6.5. PUSH-BUTTON ASSEMBLY

Before removing the push button or the lockable Override/Automatic switch from the front panel turn the screw 1/4 to the left, Figure 6.50. This will release the contact element.

Figure 6.50 Securing and removal of the contact element.

6.6. FUSES

The following fuses are printed on circuit board PR-7130:

Fuse F1: Microfuse IEC 127-3/1 DC Power (24 VDC) main fuse. Protects UL 198G 1A, fast divert electronics againts wrong voltages especially from exter-nal DC supply.

Fuse F2: 5 x 20 mm fuse IEC 60127, 1A, fast

AC supply to solenoid valves. Protects cable and coil, if faults appear.

Fuses F3, F4: Microfuse IEC 127-3/1, Fuses protect switch of divert valve position UL 198G 63 mA, fast feedback. Any external voltage connected to these circuits causes fuse blow.



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7. DIVERT CONTROL LOGIC

A logical description of the system is provided as a complement to the previous information about the elec-tronics.

7.1. BLOCK DIAGRAM

The block diagram Figure 7.10 shows the connections between the different logical subsystems.

Figure 7.10 Block diagram of the divert control system



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7.2. LOGICAL DIAGRAMS

Figure 7.20 The operation logics.

Figure 7.21 The divert decision logics.



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Figure 7.22 The alarm decision logics.



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Figure 7.23 The alarm system.

7.3. SAFETY DECISION LOGICS

The logical description of the Safety Decision Logics in Figure 7.10 is given by the following tables:

- Table 7.30 One - of - two

- Table 7.31 A master, B slave

- Table 7.32 Two - of - two

Note. NOT OPERATING includes the wash cycle.

See also Section 5.7.

A

<58

OPERATING

NOT OP

>58

OPERATING

NOT OP

B

<58 OPERATING

NOT OP

Unsafe

Unsafe

Unsafe

Unsafe

Unsafe

Safe

Unsafe

Unsafe

>58 OPERATING

NOT OP

Unsafe Unsafe

Safe

Unsafe

Safe

Safe

Safe

Unsafe

Table 7.30 One-of-two decision rule



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A

<58

OPERATING

NOT OP

>58

OPERATING

NOT OP

B

<58 OPERATING

NOT OP

Unsafe

Unsafe

Unsafe

Unsafe

Safe

Safe

Unsafe

Unsafe

>58 OPERATING

NOT OP

Unsafe

Unsafe

Safe

Unsafe

Safe

Safe

Safe

Unsafe

Table 7.31 A master, B slave

A

<58

OPERATING

NOT OP

>58

OPERATING

NOT OP

B

<58 OPERATING

NOT OP

Unsafe

Unsafe

Unsafe

Unsafe

Safe

Safe

Unsafe

Unsafe

>58 OPERATING

NOT OP

Safe

Unsafe

Safe

Unsafe

Safe

Safe

Safe

Unsafe

Table 7.32 Two-of-two decision rule



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8. OPTIONAL CONFIGURATIONS

8.1. REMOTE DIVERT CONTROL UNIT

The remote divert control unit is an option of the digital divert control system DD-01, see Figure 8.20.

The remote divert control unit operates as a main unit, which means that the master divert unit is for indication only. If the remote divert control unit is not in operation, the master divert unit in the field operates as a main unit.

The remote control unit communicates with the master divert unit in the field through a modem. Connection and wiring is made according to Figure 8.40.

For contact terminals see Figure 8.41. Contact terminals 24 and 25 are for communication OK signal.

8.2. EQUIPMENT

Figure 8.20 Complete remote divert control system.



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8.3. REMOTE DIVERT CONTROL UNIT IN THE CONTROL ROOM

Figure 8.30 Operator’s panel and functions of the remote divert control in the control room.

The remote divert control unit contains all information for the deviation decision. The operation is clearly indicated with LED lights as follows:

1. A row of four alarms (indicating Black liq-uor SOLIDS WARNING (at 60%), Black liq-uor SOLIDS ALARM (below 58%), Refrac-tometer reading more than 2% absolute differ-ence, and Refractometer malfunction).

2. Each refractometer A and B has an OPERATING green light, so the operator knows when he can rely on the refractometer measurement.

A refractometer will influence the divert deci-sion only when the green OPERATING light is on. A malfunctioning refractometer is auto-matically taken out of operation.

3. One green indicator light SAFE% SOLIDS, based on the two refractometers and the divert decision rules.

4. A red OVERRIDE warning light.

5. One red DIVERT light that will be switched on when the SAFE% SOLIDS goes off, pro-viding OVERRIDE is off. The DIVERT light indicates divert status of the divert relay.

6. Two indicator lights for the divert valve status. TO BY-PASS/TO BURNER from mi-croswitches on the valve. For intermediate valve positions both lights are off.

7. A lockable Override/Automatic switch.

8. One RESET push-button for the DIVERT action. The DIVERT action always has to be manually reset. If the override swithc is in automatic position and SAFE% SOLIDS is off, the DIVERT cannot be reset.

9. EMERGENCY DIVERT push-button.

10. A light test button switches all 11 lights on.

11. An alarm reset button resets the alarm lights.

12. Communication to MASTER DIVERT ok, indication light blinking.

13. Power supply ok, indication light on.

Note when remote divert in use, master di-vert unit in the field is for indication only!



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8.4. WIRING AND MOUNTING

For wiring of the complete system, see Figure 8.40, which also specifies the cables and connections.

Figure 8.40 Digital Divert Control System with Remote Divert Control Unit Wiring.



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Figure 8.41 Remote Divert Control Unit terminals.

Figure 8.42 Digital Divert Control System: Remote Divert Control Unit mounting.



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8.5. SERIAL OUTPUT

Each Indicating transmitter has a serial output not used by the Divert Control unit. This serial output is select-able RS-232/RS-485 (see PR-01-S Manual) and contains concentration, temperature and error data. It contains also information whether the refractometer is in divert operation or not.

Possible uses of the Serial output: To communicate with a computer substituting the Divert Control unit.

8.6. CURRENT OUTPUT SIGNAL

Each Indicating transmitter provides a 4-20 mA output concentration signal not used by the Divert system. To calibrate this signal for suitable %Solids range, press Calibrate/Output signal/Current output, see PR-01-S Manual.

8.7. EXTERNAL DC POWER SUPPLY

The Divert Control unit may be connected to a DC power supply as a back-up. At AC power failure the refrac-tometers will black-out, but the Divert Control unit will still work. In this case the DIVERT signal can be pre-vented by turning the key to OVERRIDE. Terminals are 15 (+24VDC) and 16 (ground).

The power requirement is 24 VDC, 500 mA.

8.8. DIVERT CONTROL UNIT CARD IN THE REMOTE UNIT

In the remote unit the divert control card the third dip switch SW3 must be in the ON position (“up”).

See Figure 3.13 and Sections 5.2. and 5.7.



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9. DIVERT CONTROL UNIT PARTS LISTS

9.1. DIVERT CONTROL UNIT AND OPTIONAL REMOTE DIVERT CONTROL UNIT

ltem Pcs. Part No. Description Item Pcs. Part No. Description 1 1 Enclosure 6.1 2 PR-6551 Switch unit, green 1.1 7 Conduit hubs 1/2”

NPT-Type ST-1 (US) 6.2 1 PR-6551 Switch unit, red for Emer-

gency divert 2. 3.1 3.2 3.3

1 1 1 1

PR-7310 Divert Control Unit Card Modem transformer Modem card Modem cable

4 1 PR-7028 Ribbon cable 5 1 PR-7311 LED Display card

6.3 6.4 7.

1 1 1

PR-6551 PR-6552 PR-6501

Switch unit, green for Emer-gency divert reset Lock unit for Auto-matic/Override divert opera-tion Divert Fuse set: 9 fuses (3 x Microfuse 1A, fast IEC 127-3/1, UL 198G; 3 x 5x20mm Fuse 1A, fast; 3 x Microfuse 63 mA, fast IEC 127-3/1, UL 198G)



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9.2. REMOTE DIVERT CONTROL UNIT

ltem Pcs. Part No. Description 6.1 2 PR-6551 Switch unit, green 6.2 1 PR-6551 Switch unit, red for Emergency divert 6.3 1 PR-6551 Switch unit, green for Emergency divert

reset 6.4 1 PR-6552 Lock unit for Automatic/Override divert

operation 8.1 1 PR-7310-RACK 8.2 RACK-modem 8.3 1 RACK Power 24V



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