CHART TRIFECTA 2K Service Manual Download Page 25

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Trifecta 2K

RODUCT

ELIVERY

ABLE

12 lists possible problems and causes.

Problem

Laser-Cyl’s
don’t fill

Gas not being
delivered

Controller
Continuously
Beeps

ABLE

12 - Troubleshooting

Possible Cause

Power not on

Bulk tank auxiliary liquid valve
not open

Laser-Cyl liquid valve not open

Fill solenoid valve not opening

No pressure in bulk tank

Vent to atmosphere
solenoid valve not opening

Leak in phase lines

Transmitters faulty

Power not on

Laser-Cyl gas use valve not open

Laser-Cyls empty

Gas use solenoid valves not
opening

Code has been displaced from
memory

Remedy

Turn power on

Open bulk tank auxiliary liquid
valve

Open Laser-Cyl liquid valve

Check relay

Repair solenoid

Build pressure in bulk tank

Check relay

Repair solenoid

Repair leaks

Replace transmitter

Turn power on

Open Laser-Cyl gas use valve

See above section

Check relay

Repair gas use solenoid valve

Turn power off, wait a minute

and turn it back on

Consult factory

Applies to T

RIFECTA

450 system.

Summary of Contents for TRIFECTA 2K

Page 1: ...Trifecta 2K Service Manual OPERATING INSTRUCTIONS TRIFECTA 2K TRIFECTA Gas Supply System Rev D ...

Page 2: ...Trifecta 2K ...

Page 3: ...2 AUTOMATIC MODE 12 PLC CONTROLLER INTERFACE 13 Changing Parameters 13 Typical Operating Cycle 14 Fill Mode 14 MANUAL MODE 15 REPLACEMENT PARTS 16 SOLENOID VALVES 17 PRESSURE DIFFERENTIAL PRESSURE TRANSMITTERS 17 LASER CYL PRESSURE SAFETY DEVICES 17 LINE RELIEF VALVES 17 FUSES 18 RESISTOR ELEMENTS 18 RELAYS 19 TROUBLESHOOTING 20 SENSOR ERROR CHECK 20 Sensor Error Solutions 20 PRODUCT DELIVERY 21 C...

Page 4: ...le Time 15 TABLE 3 Valve Identification 16 TABLE 4 Solenoid Valves 16 TABLE 5 Solenoid Valve Repair Kits 17 TABLE 6 Transmitters 17 TABLE 7 Pressure Safety Devices 17 TABLE 8 Line Relief Valves 17 TABLE 9 Fuses 18 TABLE 10 Resistor Elements 18 TABLE 11 Relays 19 TABLE 12 Troubleshooting 21 TABLE 13 PLC Input Channels 22 TABLE 14 Pressure Transmitter Formula Quick View 24 TABLE 15 Differential Pres...

Page 5: ... lbs 892 Kg FLOW The TRIFECTA gas supply system is capable of supplying a continuous nitrogen gas flow rate at higher pressures than standard cryogenic bulk storage tanks If the customer can tolerate lower delivery pressures the TRIFECTA system will deliver greater flow rates If the customer can tolerate lower flow rates the TRIFECTA system will deliver at higher pressures The following curve is a...

Page 6: ...rtain items considered non combustible in air might burn rapidly in such an environment Keep all organic materials and other flammable substances away from possible contact with oxygen particularly oil grease kerosene cloth wood paint tar coal dust and dirt which may contain oil or grease Do not permit smoking or open flame in any area where oxygen is stored handled or used Failure to comply with ...

Page 7: ...mphlet P 9 Write to Compressed Gas Association Inc 1235 Jefferson Davis Highway Arlington VA 22202 FROM CGA SAFETY BULLETIN Cryogenic containers stationary or portable are from time to time subjected to assorted environmental conditions of an unforeseen nature This safety bulletin is intended to call attention to the fact that whenever a cryogenic container is involved in any incident whereby the ...

Page 8: ... can be masked by a state of euphoria leaving the victim with a false sense of security and well being Human exposure to atmosphere containing 12 or less oxygen leads to rapid unconsciousness Unconsciousness can occur so rapidly that the user is rendered essentially helpless This can occur if the condition is reached by immediate change of environment or through the gradual depletion of oxygen Mos...

Page 9: ... stem packing or by adiabatic compression produced when oxygen at high pressure is rapidly introduced into a system initially at low pressure NITROGEN AND ARGON Nitrogen and argon inert gases are simple asphyxiants Neither gas will support or sustain life and can produce immediate hazardous conditions through the displacement of oxygen Under high pressure these gases may produce narcosis even thou...

Page 10: ...he control box at any time Consideration should also be given to where the optional external vaporizer will be placed on the pad PLUMBING TO BULK TANK The TRIFECTA skid needs to have a line plumbed to the bulk storage tank This line will serve two functions The first function is to allow the transfer of liquid from the bulk tank to the Laser Cyl s in the filling process The second function is to a...

Page 11: ...izer should be plumbed to the customer house line When looking at the back of the system skid there are four open ended lines Two of these lines are the vent to atmosphere lines for either tank and the other two are the bulk tank connector and the gas use These are labeled Excluding the two vent lines the connection point on the right is the one that should be plumbed to the vaporizer This is the ...

Page 12: ...rical signal back to the controller Transmitter Rosemont Connection is 1 2 inch 1 27cm FPT Plumbing to Bulk Tank Pressure Transmitter The bulk tank pressure transmitter is installed at the control box and the vapor pressure of the bulk tank must be piped to the transmitter A convenient place to connect to the pressure source is with the vapor phase line of the differential pressure gauge installed...

Page 13: ...should also be taken to not install the system on a circuit that regularly gets shut on and off to provide power to another piece of equipment lights heaters cooling systems etc It should be recognized that a PLC computer controls the TRIFECTA system and a circuit similar to that which would be used to power a personal computer should be used to power the TRIFECTA system It is recommended that the...

Page 14: ...ter the vaporizer for draining or testing of the system It also can be used as a liquid cylinder emergency supply port if needed Be sure the vaporizer has a maximum working pressure of at least 550 psig 37 92 bar 7 On initial start up prior to powering the unit manually open all the solenoid valves by turning the red hand wheels on the solenoid valves clockwise This will allow you to purge the sys...

Page 15: ...ifferential between it and the operating pressure Operating pressure at 425 29 3 bar overpressure at 480 33 1 bar Bulk tank critical should be set to 150 psi 10 3 bar To exit the menu press menu and the controller will again be in the run mode Remember when you access the menu all solenoid valves close interrupting any process in use 11 Bleed off product after the vaporizer until the cylinder in u...

Page 16: ... back on the controller will go through the initialization routine and begin controlling Nothing is lost when the controller is turned off The system does not have to be turned off in periods of non use over night weekends etc Turning the system off will de energize the solenoids and may be advantageous if the system is not going to be used for an extended period of time greater than four days How...

Page 17: ...ressure Tank Choice This should be set to indicate if your system is using Laser Cyl 450L or Laser Cyl 200L Bulk Tank Critical At the start of the filling process the Laser Cyl will vent its gas into the bulk tank to conserve product if the pressure in the bulk tank is less than this value If the pressure in the bulk tank is greater than this value it will vent to atmosphere This also applies to t...

Page 18: ... on Typical Operating Cycle Tank 1 in use gas use valve is open and pressure building valve open on demand to maintain pressure Tank 2 is on standby full of product and pressure building valve opens on demand to maintain pressure at set point Tank 1 liquid level drops to 18 of full volume After a short time delay tank 1 switches to the fill mode and tank 2 switches to the gas delivery mode The cyc...

Page 19: ...ulk tank liquid will flow into the tank through the check valve The Laser Cyls should be filled to 27 inches 68 6 cm of water as shown on the liquid level gauges The manual by pass feature of the solenoids is operated such that turning the valve handle in closer to the valve body will open the valve and allow flow Turning the valve handle out away from the valve body will close the valve and stop ...

Page 20: ...e solenoid valves that are used in this system have very long life and valve failure or replacement is highly unlikely In the unlikely event that a valve needs to be repaired the following table gives the part number of the valve It is generally not necessary to remove the valve body but only replace the top works of the valve When replacing or inspecting the piston assembly 4 bolts are removed ho...

Page 21: ...wo valves with trapped liquid between them The line relief valves are installed on candy canes to help keep the valve at warmer temperatures TABLE 8 lists the specifications of the line relief valves used TABLE 6 Transmitters Transmitter Type Service Span Output Chart Inc Part Number Differential Pressure Inert 0 100 WC 0 254 cm 4 20 mA 11043751 Pressure Inert 0 500 psig 0 34 5 bar 4 20 mA 1104374...

Page 22: ...ms a new resistor should be installed TABLE 10 lists the resistor information TABLE 9 Fuses Fuse Type Size Capacity Chart Inc Part Number AGC 10 x 1 0 7 x 2 54 cm 10 Amperes AAA0205 AGC 5 x 1 0 7 x 2 54 cm 5 Amperes AAA0204 114 114 114 114 114 114 114 114 114 114 114 114 SH SH SH SH SH SH SH SH SH SH SH SH 114 114 114 114 114 114 114 114 114 114 114 114 201 113 202 113 203 113 204 113 205 113 206 ...

Page 23: ...the specifications for the relays 19 TABLE 11 Relays 114 114 114 114 114 114 114 114 114 114 114 114 SH SH SH SH SH SH SH SH SH SH SH SH 114 114 114 114 114 114 114 114 114 114 114 114 201 113 202 113 203 113 204 113 205 113 206 113 SH SH SH SH SH SH SH SH SH SH SH SH 309 310 XI N N N N N GND CR302 CR304 CR306 CR308 CR310 CR312 CR314 CR316 FU104 FU112 FU120 103 104 105 106 108 109 110 111 102 102 ...

Page 24: ...or Solutions The sensor error check function is designed to find problems such as a wire coming disconnected or a short in the transmitter This feature will not determine if the transmitter reading is off by any amount If a Sensor Connection Error occurs check the wire junctions at the transmitter end and inside the control box Confirm that all connections are made If all connections are made and ...

Page 25: ...ng Leak in phase lines Transmitters faulty Power not on Laser Cyl gas use valve not open5 Laser Cyls empty Gas use solenoid valves not opening Code has been displaced from memory Remedy Turn power on Open bulk tank auxiliary liquid valve Open Laser Cyl liquid valve Check relay Repair solenoid Build pressure in bulk tank Check relay Repair solenoid Repair leaks Replace transmitter Turn power on Ope...

Page 26: ...Liquid Level Tank 1 U2 Liquid Level Tank 2 U3 Pressure Tank 1 U4 Pressure Tank 2 U5 Pressure Bulk Tank U6 Not Used TABLE 13 PLC Input Channels FIGURE 8 Input Channel Location on the PLC 6 This can also be done by pressing the menu button on the PLC keypad and toggling through the readings with the F1 button This is described in the PLC Controller Interface section RG 10V 5V GND U1 U2 U3 U4 U5 U6 G...

Page 27: ... Pressure Transmitter To check a differential pressure transmitter measure the voltage from the appropriate input channel to GND The probes of the voltmeter can be placed directly on the terminal screw heads Either of the two GND terminals can be used as they are common internally to the PLC With the measured voltage calculate the differential pressure by the following equation For example if the ...

Page 28: ... 500 343 75 7 5 x 2 4 16 x 500 350 7 6 x 2 4 16 x 500 356 25 7 7 x 2 4 16 x 500 362 5 7 8 x 2 4 16 x 500 368 75 7 9 x 2 4 16 x 500 375 8 x 2 4 16 x 500 381 25 8 1 x 2 4 16 x 500 387 5 8 2 x 2 4 16 x 500 393 75 8 3 x 2 4 16 x 500 400 8 4 x 2 4 16 x 500 406 25 8 5 x 2 4 16 x 500 412 5 8 6 x 2 4 16 x 500 418 75 8 7 x 2 4 16 x 500 425 8 8 x 2 4 16 x 500 431 25 8 9 x 2 4 16 x 500 437 5 9 x 2 4 16 x 500...

Page 29: ...tiple terminals labeled 114 Use the 114 terminal that is directly below terminal 1 as shown in the above table For example if testing the resistor for the liquid level sensor of Tank 2 loosen screw terminals 202 and 114 directly below 202 This will allow the resistor to be removed The resistor can then be measured for its value It is obviously extremely important that the resistor be returned to i...

Page 30: ...VEL GAUGE ___________ IN H2O PRESSURE GAUGE ___________ PSIG PRESSURE MENU ___________ PSIG VOLTAGE U 5 ___________ VOLTS TANK 1 PRESSURE GAUGE ___________ PSIG PRESSURE MENU ___________ PSIG VOLTAGE U 3 ___________ VOLTS LIQUID LEVEL GAUGE ___________ IN H2O LIQUID LEVEL MENU ___________ IN H2O VOLTAGE U 1 ___________ VOLTS TANK 2 PRESSURE GAUGE ___________ PSIG PRESSURE MENU ___________ PSIG VOL...

Page 31: ...Vaporizer Customer Supplied LT 1A B Level Transmitter Tank 1 2 C1 Connection Bulk Tank PI 1A B Pressure Indicator Tank 1 2 C2 Connection Gas Use PBC 1A B PB Coil Tank 1 2 TSV 1 Thermal Safety Relief Customer Supplied PT 1A B Pressure Transmitter Tank 1 2 PSE 1A Rupture Disc Safety Relief Tank 1 SOL 1 Solenoid Valve Vent to Bulk Tank 1 PSE 1B Rupture Disc Safety Relief Tank 2 SOL 2 Solenoid Valve V...

Page 32: ......

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