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AutoVREL

Sentry AutoVREL Installation, Operation And Maintenance Manual

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Page 1
Original Instructions
Installation, Operation &Maintenance Manual
Sentry AutoVREL Flow Controller
Sample Conditioning Automation
S-SW-IOM-00457-2 02-18
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understanding, and following the appropriate Sentry Equipment Corp instructions. Otherwise, injury, damage, or both may result.
Table of Contents
Safety Information ......................... 3
General Safety Precautions ................. 4
Specications .............................. 5
General Description ........................ 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation .................................. 14
Parts List ................................... 17
Accessories List ............................18
Standard Warranty ......................... 18
Customer Support .......................... 19
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Sentry AutoVREL Flow Controller 3
DANGER indicates a hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
 NOTE
Information that requires special emphasis.
 TIP
Alternate techniques or clarifying information.
This word is understood to be mandatory.
This word is understood to be advisory.
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Improper selection, installation, or use can cause personal injury or property damage. It is solely the responsibility of users, through their own analysis and testing, to select products suitable for their speci c application requirements, ensure they are properly maintained, and limit their use to their intended purpose.
Follow proper local, state, and federal regulations for proper installation and operational requirements.
Always use caution and common sense when working with any chemical. Read the product label and Material Safety Data Sheets (MSDS) carefully and follow the instructions exactly.
Hot surfaces! This equipment may have very hot surfaces. If an operator contacts a hot surface, injury may occur. Use protective clothing to prevent injury. If other equipment comes in contact with a hot surface, damage to the equipment may occur. Ensure the area around this equipment is kept clear to prevent this damage from occurring.
High pressures! This equipment may contain  uids at very high pressures. Prior to installing, removing, or maintaining this equipment, ensure that the equipment is isolated from all connecting piping, the equipment is depressurized, the contents have been drained, and the equipment is cool.
Moving parts! This equipment may contain moving parts. All drive guards and doors must be secured in place when this machine is being operated.
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Sentry AutoVREL Flow Controller 5
Specications
Specications are subject to change without notice.
Sample Ratings
Pressure: 500 to 3000 psi (35 to 207 bar) Temperature (calibrated): 60 to 95°F (15 to 35°C)* Range: 200 to 1500 cc/min** Accuracy: ± 100 cc/min**
Measurements
Sample Flow Rate
Alarm Relay Contact Rating
Max. operating voltage: 250 VAC, 220 VDC Max. switching capacity: 25 W, 55 VA Inductive
55 W, 110 VA Resistive
Display
Backlit LCD 2x8 character
Power
Input Voltage: 24VDC +/-10% Typical Operating Current: 0.5 A Absolute Max Current: 3 A (see parts list for power sizing recommendations) Wired Connections: 14-30 AWG Power supply needed (see Parts List)
Wiring
Min Current rating: 3A Wire Size: 14-30 AWG
Dimensions
4.25 in L x 4.25 in W x 6.93 in D
Mounting
Panel mount Factory mounting recommended Optional installation kit available (see Parts List)
Ambient Temperature
-4 to 140°F (-20 to 60°C)
Approximate Shipping Weight
15 lb (6.8 kg)
* The AutoVREL has been designed for optimum performance at EPRI recommended value of 25°C (77°F). If your normal
sample temperatures fall outside the sample temperature range, please contact Sentry Equipment to discuss options.
**Range and accuracy are dependent on ow meter selection. Numbers shown are based on the default ow meter.
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General Description
Flow control of water and steam sampling is important to help assure representative sampling, quality of the samples and, repeatability of the analytical results. During plant cycling, constant ow in the sample line minimizes the chance of altering the chemistry of the samples of high purity water through entrapment and/or release of soluble species from deposits in the system. Sample inlet temperature and ow are easily controlled under base load conditions. However, since sample pressures typically uctuate during varying load conditions, maintaining a representative sample can be dicult and labor intensive. The traditional manual sample conditioning system can require constant adjustment during startup or as plant conditions change. The Sentry® AutoVREL Flow Controller is designed to meet requirements for representative sampling by maintaining a constant ow rate with varying inlet conditions. Automated ow control is achieved by continuously monitoring the sample ow rate and controlling a Sentry VREL® valve. This helps to avoid nuisance analyzer alarms and continual operator intervention.
 NOTE
The Sentry AutoVREL ow controller is designed to be used in conjunction with the Sentry TSV (thermal shut-o valve) with alarm switch.
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Sentry AutoVREL Flow Controller 7
Sample
In
2
V-2C
SC-2
Flush Water
3 2
* MT-5V
Mag Trap
F-1
To Sink
4
1
VREL
TSV-1
SC-1
Alarm to Customer DCS
ZS­310
R
M AutoVREL
FE­307
FI
1
PI
1
TI
1
F-2
MT-1
(option)
To Analyzers
To Sink
BPR/RV
* MT-5V recommended in applications with high magnetite loading
Example P&ID
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AVREL-300
AutoVREL
Alarm PWR Flow Meter
Optional
Alarm Out
Default Flow Meter
Power for AutoVREL
BLK
BLU
BRN
4-20mA
-VDC
+24V
ZS-310
NO
NC
C
COMNCNO
TSV IN
RESERVE
GND
+24 VDC
GND
MOD +
MOD -
+24 VDC
+12 VDC
GND
4-20mA IN
0-5VDC IN
EWD - AutoVREL
ZS-310
ZS-207
From DCS
To DCS
Replaced with AutoVREL
AVREL-300
AutoVREL
Alarm PWR Flow Meter
Default Flow Meter
Power for AutoVREL
BLK
BLU
BRN
ZS-310
TSV Connections
moved to AutoVREL
COMNCNO
TSV IN
RESERVE
GND
+24 VDC
GND
MOD +
MOD -
+24 VDC
+12 VDC
GND
4-20mA IN
0-5VDC IN
Alarm to
Customer
DCS
Example TSV Alarm Conguration
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Sentry AutoVREL Flow Controller 9
Installation
Unpacking
After carefully removing the Sentry AutoVREL ow controller and ow meter from its shipping carton, inspect it for any damage. Report damages to the shipper immediately.
Mounting
 NOTE
Installation by a Sentry authorized service representative is recommended due to the complex mechanical and electrical assembly needed.
Equipment Needed
 Sentry AutoVREL ow controller
– controller and drive unit – ow meter – wire harnesses – DC power (4-pin connector) and I/O harness (8-pin connector) – shaft adapter, set screw and locking nut
 Corded power drill  Cutting oil  Loctite Blue 242 or equivalent  Hammer  1/8-inch, 3/16-inch and 9/64-inch Allen wrenches  7/16-inch and 1/2-inch open-end, crescent or socket wrench or equivalent  Sentry AutoVREL mounting kit  Sentry TSV thermal shuto valve and TSV switch (may already be on panel)  24 VDC power supply (only required if not available on existing panel)
AutoVREL
control unit
AutoVREL drive unit
Mounted after secondary cooling
Flow meter
TSV
TSV Switch
VREL control valve
Wire to ow meter
ow controller
Wire to AutoVREL TSV input and GND (Alarm Conn pins 4 & 6)
Optional Alarm wiring can be routed to the AutoVREL ow controller
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Installation Instructions
To avoid potential safety concerns, isolate the sample stream before beginning installation.
1. Using a 3/16-inch Allen wrench, loosen and remove the Sentry VREL control valve handle.
 NOTE
Do not mark holes with punch until transfer plate is level.
2. Place the transfer plate (2) from the Sentry AutoVREL mounting kit over the Sentry VREL, with the LEVEL indicator at the top of the plate. Once the plate is horizontally level, mark the ve (5) holes using the transfer punch and hammer.
 NOTE
Stainless steel is a challenge to drill/punch through, so make sure to constantly keep the drill wet with the cutting oil and do not rush drilling.
3. Remove the transfer plate and, using the 3/8-inch drill bit, drill the ve (5) holes through the panel.
4. The four (4) holes around the periphery of the transfer plate should be deburred with a standard le.
5. Using the hole punch provided in the Sentry AutoVREL installation kit, punch out the 1-7/64-inch hole just to the right and below the Sentry VREL control valve. This hole will be used for the cable gland, and therefore MUST be free of burrs. The cable gland will serve as a channel way for the electrical connections to the AutoVREL ow controller.
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Sentry AutoVREL Flow Controller 11
6. Open the AutoVREL ow controller packaging and remove the front shaft adapter, set screw and lock nut. Place the shaft adapter on the VREL control valve shaft so that the height from the panel to the top of the adapter is approximately 3.5 inches.
7. Place Loctite on the set screw and tighten the set screw MAKING SURE IT MAKES CONTACT WITH THE FLAT OF THE VREL SHAFT, and tighten.
8. Apply Loctite on the set screw shaft and tighten the set screw using the 1/8-inch Allen wrench.
Ensuring the lock nut is tight is critical to the operation of the Sentry AutoVREL ow controller.
9. Place and tighten the lock nut using the 7/16-inch wrench.
10. Using the 9/64-inch Allen wrench, remove the control unit and disconnect the electrical connectors; place the control unit aside.
11. Slide the drive unit over the Sentry VREL control valve shaft. To engage the shaft adapter with the hex drive shaft, rotate the VREL gear by hand until the AutoVREL ow controller is seated against the panel.
12. While holding the drive unit ush against the front of the panel, place the included nuts and washers over the four (4) threaded studs behind the panel and tighten the AutoVREL control valve to the panel using the 1/2-inch wrench. This operation may require two people.
VREL flow controller
Tighten set screw on flat of VREL shaft
(shipped w/ shaft adapter)
Set Screw Lock Nut
(shipped w/ shaft adapter)
Shaft Adapter
(shipped loose)
Shaft, w/ hex drive
Cotter Pin Hole
VREL Gear
Cable Way
Cotter Pin
(to retain gear)
Screw (2X)
#8-32 X 1.75
AutoVREL
Control Unit
AutoVREL Drive Unit
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12 Sentry Equipment Corp
 NOTE
Default ow meter is pictured below; installation may dier for other ow meters.
13. Identify a location downstream of the VREL control valve after secondary cooling.
14. Once the tubing is cut, deburr all cut edges to prevent shavings from entering sample lines.
15. Paying attention to the direction of ow listed on the ow meter (if listed), install the ow meter.
 NOTE
Since each panel is unique, the complexity of ow meter installation will vary.
16. Install the provided cable gland in the 1-7/64-inch hole.
17. Once the ow meter is mounted, carefully route wires over to the back of the AutoVREL ow controller and slide them through the cable gland and wire channel until they are exposed to the front of the drive unit. This will be connected to the controller.
Take care when installing connectors. They are delicate and can be damaged easily.
18. With the AutoVREL ow controller in one hand, carefully connect the wire harnesses to the connectors on the back side of the controller. The TSV switch wiring should be made to the Alarm Conn header pins 4 and 6.
E
9.90
4.95
NOTE: Comes with 1/4” ttings
Detail E
Brown wire (+24 VDC)
Blue wire (GND)
Black wire (4-20 mA sig)
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Sentry AutoVREL Flow Controller 13
Carefully route wire harnesses into wireways, making sure that they do not interfere with gears during normal operation.
19. Feed the customer I/O harness and DC power supply harness through the cable gland and cableway in the drive unit until they are exposed on the back side of the panel.
20. Optional plant control system alarm: The AutoVREL ow controller features a relay output that can be used to alarm the plant control system with a hard failure alarm. During Alarm condition, the normally open contact will be open and the normally closed contact will be closed. One wire from the DCS must be connected to RELAY COM and the othe rwire either to RELAY NC or RELAY NO. (See detail C above.)
21. With all of the harnesses connected, reinstall the AutoVREL ow controller and tighten in place using the 9/64-inch Allen wrench.
22. Wire the TSV IN connection (Alarm Conn: Detail C pin 4) to the TSV switch “normally closed” and the GND (Alarm Conn: Detail C pin 6) to the TSV switch “common.”
LOC. PWR Conn
1 +24 VDC 2 GND 3 MODBUS + 4 MODBUS -
LOC. Alarm Conn
1 RELAY COM 2 RELAY NC 3 RELAY NO 4 TSV IN
LOC. Flow Meter Conn
1 +24 VDC 2 +12 VDC 3 GND 4 4-20 mA in 5 0-5 VDC in
C
D
E
5 RESERVE 6 GND
Detail C
Scale 3:1
Detail D
Scale 3:1
Detail E
Scale 3:1
1
2
3 4
5
6
1
1
2
2
3
3
4
4
5
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14 Sentry Equipment Corp
23. With the 24 VDC power supply turned o, connect 24 VDC to +24 VDC pin (PWR Conn: Detail D pin 1) on the AutoVREL controller and the return to GND (PWR Conn: Detail D pin 2) on the AutoVREL controller.
Improper connection of these two wiring harnesses could cause damage to the unit, or cause it not to operate as designed.
24. Apply power to the AutoVREL ow controller and verify it initializes its calibration and start-up sequence.
25. Once the start-up sequence is complete, open the sample isolation valve and check connections for leaks. Pay particular attention to the piping between the VREL control valve, ow meter and TSV thermal shuto valve.
If no leaks are found, the AutoVREL ow controller is ready for operation.
Factory Settings
The settings below are factory settings for AutoVREL units. These values are adjustable and can be changed according to customer requirements.
Flow rate Setpoint: 1000 cc/min
Operation
Electrical Shock Hazard – All input and output wiring should be installed in such a manner that access to bare copper is prohibited during normal operation.
If cotter pin was removed, a new pin should be ordered from Sentry Equipment to replace it. Using a cotter pin from any other manufacturer will void warranty.
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Sentry AutoVREL Flow Controller 15
1. Operation LED
 illuminated: ow within
specied limits
 o: ow not within
specied limits
2. 2 x 8 LCD display
3. ESCAPE button
4. ENTER button
5. UP and DOWN buttons
Power on Sequence
The following sequence should be followed during initial power up of the AutoVREL ow controller or after power interruption.
1. Ensure the sample inlet isolation valve is closed so that sample is not owing.
2. Introduce power to the AutoVREL ow controller. Once powered up, the unit begins an initialization sequence. During initialization, the display reads “VREL CAL” until initial calibration is complete.
3. Open the sample inlet isolation valve. When ow is detected, the unit begins automatic ow management to the preset ow rate.
Setting Flow Rate
1. The AutoVREL ow controller has two screens available during operation. The user may toggle between these screens by pressing the ENTER button on the keypad. a. Set point (in cc/min ) VREL % open b. Flow Rate (actual) and VREL % open
2. Toggle through the display screens until “Set point (in cc/min ) VREL % open” is displayed. Adjust the ow rate set point by pressing the UP or DOWN button on the keypad until the desired ow rate is displayed. The AutoVREL ow controller actively manages ow to the newly set position.
Set Up/Stand By
1. The AutoVREL ow controller requires very little setup, with only the following features available:
a. Cal VREL – recalibrates VREL valve to ensure accurate ow control b. AutoCAL Freq - sets the time between auto-calibrations in months. This can be
set from 1 to 6 months with an option to disable. Default frequency is 1 month.
 NOTE
The AutoVREL controller does not include a real time clock so the time between AutoCAL occurrences assumes a 30-day month.
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16 Sentry Equipment Corp
c. FACTORY SETTING – This is available for factory personnel only and requires a
password
2. Enter Standby mode by pressing the ESCAPE button. “STANDBY MODE” is displayed on the LCD display. While in Standby mode the unit does not actively manage ow. a. VREL Calibration sequence:
 From Standby mode, press the ENTER button to enter Set Up mode; “CAL VREL”
is displayed on the LCD display.
 To calibrate the VREL press ENTER again. A message prompts you to ensure the
sample inlet isolation valve is closed.
 Once veried, press ENTER again and the unit executes VREL calibration.  Once calibration is complete, press ESCAPE once to go back to Standby mode.  To resume normal operation press ESCAPE again.
b. Factory Setting
 This option is not available for users and is restricted to factory authorized
personnel.
 If you accidentally enter this menu option, press ESCAPE once to go back to
Standby mode and ESCAPE again to resume normal operation.
Alarms
Local alarm
Operation LED is not lit when ow is outside of preset control limits.
External Alarm
External alarm is triggered on 2 events:
1. VREL valve error: VREL valve either does not turn or turns continuously without control of ow.
2. TSV error: Limit switch on TSV trips, indicating an over temperature condition.
Manual Operation
There are two methods of manual operation available: physical operation of the VREL valve and manual operation through the AutoVREL controller.
Physical Operation of the VREL Valve
If the AutoVREL ow controller becomes unavailable for any reason (e.g., stops working or is returned to the factory for calibration), the VREL valve can be operated manually.
1. Place the unit in Standby mode or disconnect power.
2. Remove the two (2) Allen screws on the face of the control unit.
3. Pull o the control unit and disconnect the cables.
4. Remove the cotter pin from the VREL gear and then remove the gear.
5. Mount a VREL handle on the shaft and tighten the set screw.
6. Rotate the VREL valve until desired ow rate is achieved.
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Sentry AutoVREL Flow Controller 17
Manual Operation through AutoVREL Controller
In the AutoVREL menu there is a manual control option. In this menu you can use the up and down arrows to change the desired percent open of the VREL.
To get to the menu:
1. Place the unit in standby mode.
2. Press up or down until ‘MANUAL CONTROL’ is visible on the controller screen.
3. Press enter to proceed to manual control mode.
4. Pressing up or down will cause ‘Seek XX’ to appear where xx is the desired percent open.
5. The controller will proceed to move the VREL to the desired position where ‘Seek XX’ will disappear.
6. To exit press the back key
7. The controller will return the VREL to the default position before exiting to the main menu.
Parts List
Description Part Number
AutoVREL control unit 6-05790J
AutoVREL drive unit 6-05790B
Flow meter 6-05790G
Cotter pin 4-06595P
DC power cord 4-01981G
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18 Sentry Equipment Corp
Accessories List
Description Part Number Comment
TSV 7-01137E
TSV switch 4-05144A
AC power cord 4-03624B
Installation kit 6-05790C
Retrot kit 6-05889A use when upgrading**
Seal kit 6-05889B use when replacing seals
Power supply* 4-05938H 80 W for up to 1 unit
Power supply* 4-05938F 240 W for up to 3 units
Power supply* 4-05938P 480 W for up to 8 units
* When sizing power supplies, use 72 W for a single AutoVREL controller. Use (n + 1) x 50 W for any number
(n)>1.
** Use the retrot kit to upgrade an existing VREL valve from a 7-00744A to 7-00744K. This is necessary for proper
AutoVREL ow controller function.
Product Line Product Category Warranty Period
Sentry® 1. Automatic Sampling
2. Corrosion Monitoring
3. Manual Sampling
4. Sample Conditioning
5. Sampling & Analysis Systems
6. Replacement Parts (without expiration dates)
Eighteen months from date of shipment or twelve months from startup, whichever occurs  rst
Waters Equipment
1. Sampling & Analysis Systems
2. Replacement Parts (without expiration dates)
Twelve months from date of shipment
www.sentry-equip.com/warranty.
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Sentry AutoVREL Flow Controller 19
Customer Service—General information, warranty claims, order management.
Installation Service—For systems that require specialized expertise upon installation.
Technical Support—Troubleshooting, training, and technical manuals.
Field Service & Retro ts—When a problem needs immediate attention.
Sentry ProShield Services—Select from four ProShield Guardian service plans
providing di erent levels of support to protect your large system investments with regularly scheduled maintenance.
www.sentry-equip.com/support.
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sentry-equip.com
966 Blue Ribbon Circle North, Oconomowoc, WI 53066 U.S.A. | +1-262-567-7256 | support@sentry-equip.com
Serving customers in more than 50 countries across six continents worldwide.
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