functional design specification for seal a-d test · pdf filefunctional design specification...

Functional Design Specification for Seal A-D test rig.

- 1 – WetSealRigFDS Javelin Controls

Functional Design Specification for

Seal A-D test rig

Prepared by: Tony Whiting

Javelin Controls Ltd Prepared for Prospective Client.



Section 1 F.D.S....................................................................................................4 1.0 F.D.S Overview & Fundamentals....................................................................4 1.1 Test Rig Fundamentals...................................................................................4 Section 2 - Cimplicity System ............................................................................5 2.1 PC Requirements............................................................................................5 2.2 Communications. ............................................................................................5 2.3 Software..........................................................................................................5 2.3.1 Operating System ........................................................................................5 2.3.2 Utilities Norton Ghost ...................................................................................6 2.3.3 Utilities PC Anywhere ..................................................................................6 2.3.4 Cimplicity HMI Plant Edition .........................................................................6 2.3.5 Cimplicity Web View ....................................................................................6 2.4 Cimplicity Application ......................................................................................7 2.4.1 Supervisors set up screen............................................................................7 2.4.2 Operators set up screen ..............................................................................8 2.4.3 Operators Start Screen ..............................................................................11 2.4.4 Plant Graphic Screen with Alarm Banner...................................................11 2.4.5 Sensor & Transducer Screen.....................................................................13 2.4.7 Historic Data Compare...............................................................................15 Section 3 Loading Component and preparation for testing..........................16 3.1 Flood the System and Evacuate Air..............................................................16 3.2 Pressurising System. ....................................................................................16 3.3 Circulate Water. ............................................................................................16 3.4 Temperature Control. ....................................................................................16 3.5 DC Motor control...........................................................................................16 Section 4 Control Panel HMI (Human Machine Interface) .............................17 4.1 HMI. ..............................................................................................................17 Section 5 Water Temperature Control.............................................................18 5.1 Cooling Loop PID..........................................................................................18 5.2 Heating Loop PID..........................................................................................18 Section 6 Pneumatic components & water pressure Control .......................19 6.1 Pneumatic Components................................................................................19 6.2 Water Pressure Control ................................................................................20 Section 7 Water Usage .....................................................................................21 7.1 Water Usage Detection.................................................................................21 7.2 Terminal Connections ...................................................................................21 7.3 XT950 Field Connection Terminals...............................................................21 Section 8 Motor, Drive & Motor Speed Transducer ......................................22 8.1 Motor.............................................................................................................22 8.2 Drive .............................................................................................................22 8.3 Motor Speed Tacho ........................................ Error! Bookmark not defined. 8.4 Motor Speed Pulse .......................................................................................22 Section 9 Torque Transducer ..........................................................................23 9.1 Torque Transducer .......................................................................................23 Section 10 Flow Transducer ............................................................................24 10.1 Flow Transducers .......................................................................................24 Section 11 Program Logical Controller (PLC) ................................................29 11.1 PLC Overview.............................................................................................29 11.2 PLC Components........................................................................................29 11.3 PLC I/O Description. ...................................................................................31 Section 12 Safety Circuit ..................................................................................34



12.1 Safety Circuit...............................................................................................34 Section 13 Electrical drawings ........................................................................36 13.1 Electrical Drawings .....................................................................................36



Section 1 F.D.S 1.0 F.D.S Overview & Fundamentals

This F.D.S. is designed describe control philosophy of the A-D test rig as interpreted by Javelin Controls. The purpose of and F.D.S is to highlight and describe in detail each section of the test rig. Each section should then be debated and edited to the satisfaction of all interested parties. The finished document will describe the function and control philosophy of the test before material purchase and manufacture. 1.1 Test Rig Fundamentals The test rig described in this document is designed to test seals and record the information on a PC for further analysis. It is also designed to automatically protect against critical seal failure by stopping the test when test limits have been exceeded. The test rig is designed to control the environment of the test by controlling motor speed, water inlet temperature and water pressure. Various sensors and transducers monitor temperatures, pressures, speed, torque, flow water usage etc. All information from the sensors will be saved by a PC system at a sample rate dictated by the operator/supervisor.



Section 2 - Cimplicity System 2.1 PC Requirements PC Requirements For the Cimplicity platform to work reliably we suggest a minimum hardware specification for the PC:- 1 Intel 2.0 Ghz processor. 2 256Mb fast access RAM. 3 40 Gb IDE Hard Disk. & 1 x

Removable Caddies. 4 48 Speed CD/RW 5 1.44 Mb Floppy disk drive. 6 10/100 Network Card 7 56.6K Modem PCI Modem 8 64Mb ATI Radeon 7000 RTL

Graphics Card 9 PS2 Mouse & Keyboard. 2.2 Communications.

The Alan Bradley PLC communicates to the PC in RS232 using the DF1 Protocol. The effective range of RS232 commutations is limited to 50 feet. To communicate over larger distances we need to convert the RS232 to RS485 with a converter mounted local to the PLC. The RS485 will then need to be converted back to RS232 local to the PC. The converters we intend to use are ‘ADAM 4520 Isolated 232/485 Converter & Brainbox Velocity RS232 & RS485 Serial PCI Card.

2.3 Software 2.3.1 Operating System Windows XP professional.



2.3.2 Utilities Norton Ghost Norton Ghost

• This is recommended as it would allow complete system backups including the Operating System and Cimplicity System and Gathered data acquired into SQL.

• Windows-based Interface: Provides the ability to configure and execute imaging/backup sessions without relying on the traditional DOS shell and Boot Diskette.

• Expanded list of supported CD/RW device: Provides the ability to write Ghost Images for recovery directly to a broad range of devices supporting recordable CD.

• Partition Cloning: Allows you to clone one or more individual partitions rather than just the entire hard drive.

2.3.3 Utilities PC Anywhere Norton PC Anywhere. I believe you have non-Norton version of PC anywhere. I am sure this will suffice but I do not have any details on this product. We assume that we would have access to this particular software to allow us to remotely administer the system if required. 2.3.4 Cimplicity HMI Plant Edition Cimplicity is a SCADA (Supervisory Control and Data Acquisition) system developed by GE Fanuc. We suggest using the latest revision of this software, namely Cimplicity Plant Edition, Version 6.0 – 75 Tag Runtime / Development with Allen Bradley DF1 communications Protocol. – This is currently being released with Service Pack 2. The system has the ability to log data in a Microsoft SQL Compatible database format. The system can be scaled as needs arise, and is currently widely used in manufacturing industry, where reliability is a foremost priority 2.3.5 Cimplicity Web View Cimplicity Webview, is an additional license which can be purchased which allows all of the Cimplicity Graphics to be served up as web pages and viewed using internet explorer on any networked computer. The functionality can be restricted which would stop people from actually stopping and starting tests or adjusting set points – however you would get full real time information over the web as if you were sat at the test rig.



2.4 Cimplicity Application General The Cimplicity Application will be developed in such a way that it can always be modified or added to at a later date, using consistent looking graphics, point naming conventions and Scripting documentation. Every screen (Graphic) will have a common title bar and alarm banner at the bottom of the screen. Colour coding will be used to define certain states – e.g. red = alarm state, green = healthy. 2.4.1 Supervisors set up screen

The set up screen has two levels. The first level is password protected to restrict access to supervisors. The operators will be able to see the data, however they will not be able to change any of the inputted values. In the supervisor screen the system limits can be edited.

• The maximum permitted torque. • The maximum permitted seal outlet temperature. • The maximum permitted seat temperature. • The permitted deviation from set point pressure. • The permitted deviation from set point RPM. • Acceptable flow rate.



• Test duration. • Data sample rate (see Note 1).

Note 1: High sample rates will produce large files that create their own problems in storage and can become unwieldy. By producing low sample rates the file can lack meaningful data. To help with this quandary we suggest that we have a second file that will continuously monitor the previous 30 min data at a very high sample rate. This file will only be saved if the seal fails during a test. This high resolution file can then be examined for clues to the seal failure. Should a test not last 30 min only the high resolution file will be saved. 2.4.2 Operators set up screen

When a new seal is to be tested the operator enters the test parameters and alarm values into the seal set-up screen. All parameters will have to be filled in to enable the test to start. Parameters. Description 1 Tester Name Selected from a drop down list box. When selected

the operator will be asked for a unique password.

2 Component No Unique number used to describe seal.

3 Text Box Free form text box for operator to describe special properties of the seal under test.



4 Direction of rotation This has to be entered and confirmed by the operator.

5 Maximum normal running torque & trip settings.

The system will be set up with max permitted torque limit set at 199 Nm. If this is exceed for more than 1 second the motor will shutdown. Their will also be an adjustable torque limit that can be set by the operator. This torque limit can be disabled when required. Note 1: With torque limit on the rig will adjusted the acceleration ramp to keep torque below set point. Note 2: There will be a window of time to achieve set speed without reaching torque limit. If this time is exceeded the test will be abandoned and an alarm raised.

6 Test Speed. Sets the motor R.P.M that the test is to be carried out at.

7 Inlet water temperature The operator sets the seal inlet water temperature. There will also be a maximum permitted temperature. Note 1: The water inlet temperature is monitored against the water outlet. Should the inlet water temperature be higher than the outlet the observation will be alarmed (probable incorrect flexible pipe connection) Note 2: To filter out nuisance trips the inlet water temperature will have to exceed the set point for one second.

8 Maximum outlet temperature.

The operator sets the maximum acceptable seal outlet temperature. Note1: Setting the maximum temperature takes into account temperature differentials between inlet and outlet. i.e. if maximum outlet temperature is 80º C with an inlet temperature of 25º C the temperature differential is of 55º C. Should the inlet temperature raise to 30º C the maximum outlet temperature set point will be raised to 85º C. Note 2: To filter out nuisance trips the outlet temperature will have to exceed the set point for one second.

9 Water Pressure set The water pressure will also have alarm points for



point & high low alarms.

high and low pressure. Note 1: To filter out nuisance trips the water pressure will have to reach an alarm set point for one second.

10 Seal circulation or pumped circulation.

When the type of circulation has been selected a text screen will display which valves should be open and which valves closed for the test to commence.

11 Left hand seat maximum permitted temperature.

Sets the maximum permitted temperature for the left hand seals. Note 1: To filter out nuisance trips the seat temperature will have to reach an alarm set point for one second.

12 Right hand seat maximum permitted temperature.

Sets the maximum permitted temperature for the right hand seals. Note 1: To filter out nuisance trips the seat temperature will have to reach an alarm set point for one second.

13 Test duration The operator sets the test duration within the limits set by the supervisor.



2.4.3 Operators Start Screen

The operator opens the “start up screen” in Cimplicity. This screen checks that the rig is ready to start the test. It will instruct the operator what actions are necessary to facilitate the test.

• Clear water usage load cell containers? • Add water to Haskel storage tank? • Is the factory air pressure OK? • Is chiller on and is cooling water at set temperature? • Is the circulation water pressure at set point? • Is the circulation water temperature at set point? • Is the heating loop working and is the inlet temperature at set point? • Is the drive healthy and is the motor at set speed? • Is water flow within acceptable range?

When all conditions have been met the “start button” will be made available on the start up page. Once the operator has selected the start button the Cimplicity test will begin and the data will start to be recorded. Once the test has started all control push-buttons mounted locally to the test rig will be disabled. The emergency stop buttons will remain active. 2.4.4 Plant Graphic Screen with Alarm Banner



When the test has been started the operator has a choice of running screens, the first is an animated graphic of the test rig. It will display the various pressures, temperatures, torque, speed, levels and flow rates etc in text boxes located in the appropriate position on the graphic. The hand and automatic valves will be displayed in their current positions. The level of the water on the load cells will be displayed graphically and a text box water usage in ml per hour. The flow rate will be displayed in litres per min. The PLC will calculate the energy produced by the seal by measuring the volume of water and the change of water temperature between inlet and outlet manifolds. The energy produced will be displayed in Watts. The colour of the text will change to red should the value be out of range. Any alarm will also appear in an alarm banner at the bottom of the screen. This text box will give a fuller description of the alarm, its likely causes and set points.



2.4.5 Sensor & Transducer Screen.

The second running screen displays actual values of the sensors and transducers along with alarm and set points. As with the first screen an alarm banner will also be displayed.



2.4.6 Current & Historic Trends

The third screen will show trends of all sensors and transducers. This screen will be generated in real time. The operator will be able to view the trends at different time intervals from two 2 minutes to the full term of the test.



2.4.7 Historic Data Compare.

The data from previous test or tests can be opened and compared against current trends. This tool can be useful for monitoring long term trends or comparing new designs against previous designs. The operator will be able to look at a list of previous tests and select the data accordingly.



Section 3 Loading Component and preparation for testing

3.1 Flood the System and Evacuate Air The operator mechanically fixes the seal onto the test rig. The flexible high pressure water tubes are connected to the seal input and output connections. The system is then flooded by opening water inlet and top bleed valves (hand valves 1 & 2). The remaining air can be evacuated by starting water pump with hand valve 2 open. While hand valve 2 remains open the pump starter will not latch and the pump will only run with the pump start button depressed. 3.2 Pressurising System. When the operator has evacuated the air and closed the water inlet and air bleed valves (hand valves 1 & 2) the system can be pressurised. To pressurise the system the operator presses the “pressurise system” push-button located on the control panel door. The system will now be pressurised by the Haskel pump to the value set in the set within the Cimplicity set up screen. Should the operator discover a leak the pressure can be removed by selecting the “de-pressurise” push-button. Once the leak has been repaired the system can be pressurised. The water pressure is displayed on the control panel HMI. 3.3 Circulate Water. With the system flooded and at pressure the water can be circulated using the circulation pump. The operator presses the circulation pump start button and pump will latch on. The water circulation rate is displayed on the HMI. 3.4 Temperature Control. With the system flooded, pressurised and the water circulating the water temperature can start to be controlled. The operator selects temperature control start button and the system will start to control water temperature through the cooling and heating loops. The water temperature of inlet and outlet manifolds will be displayed on the HMI. 3.5 DC Motor control. With the system flooded, pressurised, circulating water and at temperature set point. The drive can be started by operating the start drive push-button. The drive will accelerate to set speed. Seals fitted with impellers will generate their own circulation. Once the drive is up to speed the circulating pump will be stopped. The motor speed and flow rates are displayed on the HMI.



Section 4 Control Panel HMI (Human Machine Interface) 4.1 HMI. The HMI I have chosen is the Alan Bradley Panel View 550. It comes in various types i.e. touch-screen, key pad & key pad/touch-screen. It can also come with a printer port if required. The panel View 550 can handle text and limited graphics and can use alarm banners to display faults. If required, various screens can be password protected.

The right choice of HMI will depend on its intended use. If the HMI is only going to be used to display values the touch-screen version will be more than adequate. However, if you intend to have the facility to enter values into the PLC such as set points, alarm points speeds etc. the touch-screen with keypad would suit best. A printer port is available on both touch-screen and keypad. The printer capability is quite limited but could be used to print time stamped data if required.



Section 5 Water Temperature Control. Approximately 30 Litres of pressurised water is circulated by the seal in a closed loop system. The water will be presented to the seal inlet at 30º C +/- 1º C. The seal under test generates heat that the cooling loop needs to remove. 5.1 Cooling Loop PID

The cooling loop is controlled with a 3 way proportional valve. A temperature probe mounted at the outlet of the heat exchanger monitors the temperature and adjusts the cold water flow through the heat exchanger to maintain the outlet water temperature. The target temperature for the cooling loop will be approximately 25ºC. The proportional valve is controlled by an analogue 4 to 20ma output from the PLC. The analogue output will in turn be controlled by (Proportional / Integral / Derivative) Closed Loop Control PID. By controlling the cooling effect of the heat exchange we will improve the overall stability of the pressurised water circuit.

5.2 Heating Loop PID

With the water being presented to the heater at a nearly constant temperature the heater will only require small modulations to maintain 30º C at the seal inlet. We have chosen a United Automation BM2 burst firing module. This burst firing module incorporates the unique MONO -LINKtm Gate to Gate firing feature which eliminates cathode firing connections. Phase timing problems are eliminated and the burst firing circuit prevents fast changes in load current thus inhibiting Radio Frequency Interference.

The BM2 burst firing module is controlled an analogue 4 to 20ma output from the PLC. The analogue output will in turn be controlled by Closed Loop Control PID.



Section 6 Pneumatic components & water pressure Control

6.1 Pneumatic Components Pneumatics used on this test rig varies the pressure of the circulating water. The component parts of the pneumatics are: 1 Lockable Shut off valve. Festo

183002 HEA-M1-G1/4. Used to isolate pneumatic supply during times of maintenance.

2 Component connector. Festo 183873 LV-M2/M3. Uses to connect modules together.

3 Pressure build-up and dump

valve. Festo183096 HEM-M2-N1/4-10110

4 Pressure switch Festo 152704

PENV-PS/O-S-L-GH. Used to check factory air pressure.

5 Filter Festo LF-M1-G1/8-CS.

Used to filter factory air to 5um.

6 Proportional pressure regulator

Festo MPPES-3-1/4-10-420. This controller will vary pneumatic pressure in response to analogue out.

7 Angled plug socket Festo

161839. Used to connect analogue output to control valve.



6.2 Water Pressure Control The seal will be pressurised to approximately 150 Bar by a Haskel pump. The Haskel pump uses variable pneumatic pressure “0 to 8 bar” to produce variable water pressure. A pressure transducer will be mounted in the high pressure water pipe work to monitor the water pressure. The water pressure is maintained by adjustments in air pressure controlled by the proportional pressure regulator. The proportional pressure regulator is controlled by an analogue 4 to 20ma output from the PLC. The analogue out put will in turn be controlled by Closed Loop PID. The proportional pressure regulator has an analogue output that could be used to compare the relationship between water pressure and valve opening. Pressure transducer. Gem general purpose. RS 348-8201. Used to monitor water pressure.



Section 7 Water Usage 7.1 Water Usage Detection Two Load cells weigh the collected water from each side of the seal to monitor the water usage of the seals. At the start of the test both values are zeroed so only newly collected water is recorded. If the water weighed is above a set point the operator will be instructed to empty the containers and if weighed value is too low the operator will be informed to replace container. This instruction will appear on the Cimplicity start screen. Any large anomalies in water usage will be alarmed on the Cimplicity running screens but will not halt the test. The load cells require new amplifiers part No XT950 to interface with the PLC. The Cimplicity system will display water levels in litres and usage in ml per minutes. Cimplicity will only recognise positive increases in water weight, so that if the container is empted during test cycle it will not affect the ml per minute’s total. The HMI will only display the ml per hour total.

7.2 Terminal Connections Connection between the XT950 unit and input/output signals, including power supplies, are made via 2.5mm field terminal blocks inside the unit. Access to the terminals is made through glands in the bottom of the case. 7.3 XT950 Field Connection Terminals

READ INSTRUCTION MANUAL BEFORE INSTALLATION



Section 8 Motor, Drive & Motor Speed Transducer

8.1 Motor The motor fitted to the rig is a Thrige-Scott GB160-17BF, 70.9kW 400V DC. The motor is no longer manufactured and has been superseded in recent years. The motor is in good condition, and has been worked relatively lightly since its purchase. It is believed that the motor has several years’ service ahead of it and replacement will not be necessary. 8.2 Drive The Thorn EMI Star Drive is no longer manufactured or supported. Should it fail in service it is unlikely replacement parts will be obtainable. But like the motor it has done very little work in service and it is believed that it has years of service ahead of it. The speed is controlled by a 0 to 10v analogue output from the PLC. The analogue output is in turn controlled by Closed Loop PID. The speed loop is closed by a speed transducer driven from the motor. The drive however is unlikely to conform to current electrical noise regulations and we suggest that we fit a Controls Techniques mains infeed line reactor type M210 D-3308. This will reduce or remove RFI and mains notching. 8.3 Motor Speed Pulse The analogue tacho described above may be hard to install. A simpler solution would be to fit a proximity sensor, unfortunately the potential speed of the drive means that more than one pulse could arrive during the program scan. PLC scan time is 20 to 40ms 4000 RPM / 60sec = 66.66 pulses per second. 1 sec / 66.66 pulses = 15ms per pulse. To overcome this problem we will require a pulse divider. This can count pulses at very high speeds and output a pulse when the preset value has been reached. If we set the divider to 10:1 we would generate 1 pulse approximately every 150ms and that one pulse would represent 10 revolutions. With this information the speed can be calculated.



Section 9 Torque Transducer 9.1 Torque Transducer Motor torque is measured by a HMB T5/200Nm torque transducer. The torque transducer is connected to an amplifier and visual display unit A0104. Terminals 1 & 2 can be configured to output a 4 to 20mA signal to the PLC. The PLC will monitor Torque through the test. Should the torque exceed an adjustable set point the test will be abandoned. During the initial start up high torques can be generated, to avoid nuisance tripping we intend monitor and if necessary adjust the acceleration the motor. The set point speed will still have to be achieved within a given window of time for the test to continue.



Section 10 Flow Transducer 10.1 Flow Transducers There are various types of flow transducers available in the market place. They vary in type accuracy and price. I have listed a selection of flow transducers to choose from. By identifying the flow rate we can calculate the energy generated by the seal under test. We can also check the efficiency seal impellers.



Section 11 Program Logical Controller (PLC)

11.1 PLC Overview The PLC will be used to monitor digital and analogue inputs from the test rig and output analogue and digital information in response. It will be used to control the various PID loops, and calculate values used or set by the Cimplicity system. The test rig is in essence controlled by the PLC and monitored by Cimplicity. The choice of PLC is not cast in stone and can be changed to suit company or site standards. We have selected Allen Bradley SLC500 range PLC for availability and flexibility. It is modular in design and can be easily expanded if required. The Allen Bradley SLC500 range has an extensive existing range cards to suit most test rig and industrial applications. 11.2 PLC Components. 1 Power supply

1746P2 Produces 5 Amps at 5VDC to feed the back plane that supplies the cards and processor. It also 0.96 Amps at 24VDC.

2 Processor

1747L531 503 processor 4K user & 4K data memory.

3 10 Slot Rack

1746A10 The dimensions of 10 slot rack with a P2 power W455mm x H171mm x D145mm.

4 1746IB32

32 Way Digital Input Card

32 way digital input card. 10 to 30VDC. inputs



5 1746OB16 16 Way Digital Output Card

16 way digital output card. 10 to 50VDC outputs

6 1746NT8

8 Way Thermocouple Input Module

8 way Thermocouple Input Module. Type: J,K,T,E,NR,S,B,Mv Temperature re-scale resolution 1ºC and 0.1ºC.

7 1746NR4

4 Way Thermocouple Input Module

4 way Thermocouple Input Module. Type: J,K,T,E,NR,S,B,Mv Temperature re-scale resolution 1ºC and 0.1ºC.

8 1747N18

8 Way Analogue Input Module.

8 Way Analogue Input Module, input types. 0-20mA, 4-20mA, +/-20mA +/-10VDC, 0-5VDC 1-5VDC, 0-10VDC

9 1746NO4I

4 Way Analogue Output Module.

4 Way Analogue Output Module. 0-21mA, +/-10VDC



11.3 PLC I/O Description. Card 1 (32 way digital input card). Address Description I:1/0 Reset Button I:1/1 Emergency Stop Button 1 I:1/2 Emergency Stop Button 2 I:1/3 Safety Relay Healthy I:1/4 Factory Air Pressure OK I:1/5 Coolmation CA26 Healthy I:1/6 Drive Healthy I:1/7 Valve 1 open I:1/8 Valve 1 closed I:1/9 Valve 2 open I:1/10 Valve 2 closed I:1/11 Water Pump Start Button I:1/12 Water Pump Stop Button I:1/13 Pressurise Water System I:1/14 De-Pressurise Water System I:1/15 Heat control on button I:1/16 Heat control off button I:1/17 Main drive start button I:1/18 Main drive stop button I:1/19 Pump motor runnable/running I:1/20 Pump motor overload I:1/21 Haskel pump water level OK I:1/22 Motor speed Input Pulse I:1/23 Spare I:1/24 Spare I:1/25 Spare I:1/26 Spare I:1/27 Spare I:1/28 Spare I:1/29 Spare I:1/30 Spare I:1/31 Spare



Card 2 (16 way digital output Card). Address Description O:2/0 Start Chillier. (Isolated with emergency stop). O:2/1 Enable Drive. (Isolated with emergency stop). O:2/2 Energise safety relay. (Isolated with emergency stop). O:2/3 Pneumatic Dump Valve. (Isolated with emergency stop). O:2/4 Run pump Motor. (Isolated with emergency stop). O:2/5 Spare O:2/6 Spare O:2/7 Spare O:2/8 Alarm Beacon O:2/9 Spare O:2/10 Spare O:2/11 Spare O:2/12 Spare O:2/13 Spare O:2/14 Spare O:2/15 Spare Card 3 (8 Way Thermocouple Input Module). Address Description I:3/0 Chillier water temperature. (Used for information & alarm) I:3/1 Seal outlet left temperature. (Used for information & to stop

test if too high). I:3/2 Seal outlet right temperature. (Used for information & to stop

test if too high). I:3/3 Seal inlet left temperature. (Used for information and water

heater PID loop). I:3/4 Seal inlet right temperature. (Used for information and water

heater PID loop). I:3/5 Heat exchanger temperature. (Used for 3 way proportional

valve PID loop). I:3/6 Spare I:3/7 Spare Card 4 (4 Way Thermocouple Input Module). Address Description I:4/0 Right Hand Seat temperature Probe 1 (Used for information

and alarm). I:4/1 Right Hand Seat temperature Probe 2 (Used for information

and alarm). I:4/2 Left Hand Seat temperature Probe 1 (Used for information

and alarm). I:4/3 Left Hand Seat temperature Probe 2 (Used for information

and alarm).



Card 5 (8 Way Analogue Input Module). Address Description I:5/0 Torque Transducer. (Used for information & to stop test when

out of acceptable range). I:5/1 Water Pressure Transducer. (Used for information, pressure

loop, and to stop test if pressure can not be maintained). I:4/2 Left Seal Water Usage. (Used for information only). I:5/3 Right Seal Water Usage. (Used for information only). I:5/4 Water Flow Transducer (Used for information and to calculate

energy) I:5/5 Spare I:5/6 Spare I:5/7 Spare Card 6 (4 Way Analogue Output Module). Address Description I:6/0 3 Way Proportional Valve. (Used for cooling Loop PID). I:6/1 Modulating Pressure Valve. (Used for high water pressure

loop). I:6/2 Heater Thyristors Output. (Used in water heating PID loop). I:6/3 Motor Speed Output. (Used for speed Loop).



Section 12 Safety Circuit

12.1 Safety Circuit Two emergency stop buttons will be mounted local to the test rig. They will be monitored by a Pilz relay. When the Pilz relay is operated it will stop the main drive, remove pressure from system and close the heating and cooling loops. By removing the enable from the drive the motor will coast to a stop. This may take tens of seconds for the test rig to reach a zero speed. By holding the enable on for a second with a timed safety relay, the main drive could be driven to a stop. With this method the rig can achieve zero speed within two seconds. A risk assessment of the test rig should identify the correct safety philosophy for the test rig.



Section 13 Electrical drawings

13.1 Electrical Drawings The electrical drawings have made assumptions on completed design. The templates will remain largely untouched but the contents will change to mirror completed design.

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