Subject: RE: Trouble at BCS start up
Date: Wed, 14 Nov 2001 14:14:30 -0600
From: "Kaufman, Tom" <Tom.Kaufman@mts.com>
To: "'pcastald@atc.army.mil'" <pcastald@atc.army.mil>, "Larson, Rod"
     <Rod.Larson@mts.com>

Pat:
I will fax you a copy of the temperature switch data sheet.  The
temperature switch is a Fenwal, Model 228 00.
I talked to Rod, and we believe that one of the switches is connected in
the NO condition, when it was suppose to be connected in the NC
condition.  And then, when the unit was initially started-up, the
temperature switch adjustment was adjusted to a "cold setting" to allow
the pump to start.
To correct, these are the steps:
1.  Look at the Fenwal temperature switches on the pump.  You have two
round covers, with switches inside.  Each of these Fenwal round
controllers, have two separate switches inside.  Each switch has a
separate adjustment screw.
2. The Fenwal unit that is the farthest from the door, is the switch to
turn on the air fan coolers.   This unit should have the wire to the
solenoid.  Don't do anything to that unit. This unit has one additional
switch, with its own adjustment, that is not used.  Don't do anything to
that unit.
3.  The Fenwal unit that is closet to the door on the east, easier to
get at, contains the Oil Warning Signal from one of the switches, and
the Oil Over Temperature signal from the other switch.    Both of these
should be connected as NC.
4.  When the system is happy, the light should be "on", in the Opto
Modules, the white input module.  Channel #2 Opto module, is the E-Stop.
Channel #3, is the warning signal.
5.  If the light is "off", you should be able to jumper the signal out
at the pump, and determine which cable is which.  (If the light is "on",
I guess you could do this by removing a wire out at pump as well.)
6.  If one of the switches out at the pump is connected to NO, then
change that wire to NC.  That wire should be the E-Stop chain, since it
has been shutting you down.  Now, it appears that the adjustment screw
for this switch has been turned so that it switches at 27 F.  To
readjust the switch from 27 F to 150 F,  you will need to turn the screw
clockwise about 5 turns.  Each turn of the screw clockwise, increases
the setting by 23 F.
7.  Rod, if I have messed up with my email, will you help by making
corrections.

Let us know if this works.  Tom Kaufman
> -----Original Message-----
> From: pcastald@atc.army.mil [SMTP:pcastald@atc.army.mil]
> Sent: Wednesday, November 14, 2001 10:40 AM
> To:   Larson, Rod; Kaufman, Tom
> Subject:      RE: Trouble at BCS start up
>
> Tom or Rod,
> I was checking this out again today.  Over night low was 27 deg F and
> temp
> dial gage  on reservoir reads 45 deg F.  Without starting the pump - I
> reset
> interlocks and turned on pilots and the system immediately aborted on
> the
> oil over temp.  I also noticed in the message log that it aborted on
> Sat at
> 4:00 am, I had left the program running.  Is it possible that the
> connections to the thermostatic switch are some how inverted and I
> just need
> to physically switch something? I noticed there are two thermostatic
> switches on the reservoir one seems to be connected to the coolers and
> the
> other I assume is the interlock.
> -Pat
>
> -----Original Message-----
> From: Rod Larson [mailto:rod.larson@mts.com]
> Sent: Wednesday, November 07, 2001 5:42 PM
> To: pcastald@atc.army.mil
> Cc: Tom Kaufman
> Subject: Re: Trouble at BCS start up
>
>
> Pat,
> There is NO low limit in the software.  What is happening is for some
> strange
> reason, the temperature switch that normally indicates overtemp is
> somehow
> firing when you turn on the pump cold.  I can tell you how to cheat
> this;
> however, you MUST reset the condition after it runs or it will shut
> off
> later.
> If this really is a problem, we must do something to disable this
> during
> cold
> weather.
>
> What is happening is that the digital input for over-temp is switching
> after
> you
> start the pump.  It can be disabled in the following fashion:
>
> 1. Go to the listener panel:  (Found under Service Menu Bar on top of
> main
> panel).
>
> 2. In the service window, type the following and hit the enter key:
>
>     vm.overtempDI.setPolarity[high];
>
> 3. This will flip the polarity of the overtemp switch and might enable
> the
> machine to start.  Of course, when the signal becomes ok, then it will
> estop
> and
> you will have to set the polarity back to low:
>
>     vm.overtempDI.setPolarity[low];
>
> I think the polarity is now low on start-up, but I am NOT 100% sure.
> You
> might
> have to try low 1st then high.  You can determine this by typing the
> following
> BEFORE you change polarity:
>
>     vm.overtempDI.value.writeln;
>
> The system will answer TRUE or NIL.  If TRUE, then the input is low,
> if NIL,
> then the input is high and you know the normal state.  So, you 1st
> have to
> set
> the abnormal state to get started and then revert later.
>
> I don't like this that the pump is doing this - it should NOT happen.
> I
> know
> the filters will do this as pressure is applied, but we don't have an
> e-stop
> condition from that.  Overtemp is a real bad thing if it is REAL.  I
> will
> research the temperature sensor and see what is going on.
> Rod Larson
>
>
> pcastald@atc.army.mil wrote:
>
> > Tom, Rod,
> >
> > I had a little trouble getting started yesterday morning. When I
> tried to
> > turn on pilots I would get a system shutdown on "HPS oil over temp
> (estop)".
> > I was trying to go to pilots right away because of drift problem
> when we
> > don't.  The overnight temperature was about 35 deg F and the ambient
> > temperature was 45 deg F. I finally got it to work after 16 tries
> and once
> > it warmed up it ran fine.  Is there a low temperature limit in the
> software
> > and can we adjust it?
> >
> > -Pat
