MOYNO Section: ACCESSORIES Page: 1 of 8 Date: May 1, 1998 SERVICE MANUAL FLUID DETECTION CONTROL GENERAL The Moyno Fluid Detection Control prevents unnecessary loss of production time or repair costs to positive displacement pumps or other fluid process equipment when they are subjected to run dry conditions or high-pressure conditions. The control works equally well on high and low viscosity fluids, suspended solids, abrasive, corrosive and volatile liquids. The product consists of three basic components: a sensor, a pressure switch and a control box. The sensor, available from 1" to 14", fits between two standard ANSI pipe flanges and allows complete fluid flow without obstruction. There are no drilling, tapping, special tools or sealants required for installation. Pressure transmission over the entire pipe circumference ensures that coating, settled material or bridging in the pipe line does not affect pressure readings. As an added feature, a liquid-filled gauge allows visual monitoring of pressure conditions. This control will also control and monitor seal flush water.
Page 2 PRINCIPLES OF OPERATION The Fluid Detection Control ensures that pumps operate within design parameters, protecting them from overpressure, run dry conditions and loss of seal water. Although designed primarily for use with progressing cavity pumps, the Control may be used with other equipment as well. The pump starter is wired directly to the control box. A double pressure switch is installed in the discharge line of the pump. The high-pressure switch must be set to the highest safe operating pressure for the process system. If the pump discharge pressure exceeds the setting of the high-pressure switch, the pump will stop and the HIGH lamp on the front of the control box will illuminate. The pump will remain stopped until the Stop/Reset or External Stop pushbutton is pressed. The pump can be restarted if the pressure has been relieved. The control box protects the pump against run dry conditions by using a low pressure switch. This ensures that a certain minimum pressure is maintained in the system. It is very important that this switch be properly set. In order to set this switch, it is necessary to understand the difference between static, friction and total pressure. Static pressure is the pressure which results from the pipe being filled with liquid, and is present even when the pump is idle. Static pressure is not influenced by pipe size, number of fittings, or viscosity. Static pressure is determined by the difference in height between the pressure switch and the outlet of the piping. Friction pressure is the pressure which results from the flow of liquid through a pipe, and is present only when the pump is actually operating. It is dependent on the flow rate, the size of pipe, the length of pipe, the number of fittings, and the viscosity of the fluid. Total pressure is the combination of the static and friction pressures. In an existing installation, these pressures can be obtained by observing the gauge on the pump discharge. When the pump is idle, the gauge shows static pressure. When the pump is operating and there is flow present, the gauge shows total pressure. For run dry protection, the low pressure switch is set between the static and the total pressure. When the pump runs, the switch signals the control box that flow is present. If the pump runs dry and flow stops, the pressure falls back to the static pressure. This causes the low pressure switch to signal the control box that flow has stopped. The pump will stop and the lamp on the front of the control box will illuminate. The pump will remain stopped until the STOP/RESET or External Stop pushbutton is pressed. The pump can be restarted after the cause of the run dry has been identified. Typical Example: If the pressure gauge in the discharge line reads 22 psi when the pump is idle, and the gauge reads 32 psi when the pump is running, set the low switch to 27 psi (half way between low and high) and set the high switch to 37 (high pressure +5 psi). Pumps that require seal water, a flow switch can be installed to monitor loss of flow. The pump will stop and the SEAL WATER lamp on the front of the control box will illuminate. The pump will remain stopped until the STOP/RESET button is pressed. SWITCH SELECTION The unit consists of two separate snap action switches, each with an independently adjustable set point and nonadjustable reset point. The difference between the set and reset points of each switch is the deadband as listed below; the minimum difference to which the two switches may be set is the separation. Determine the pressure range needed. Check that rated overrange pressure is sufficient. Separation Maximum - Full Range Rated Fixed Adjustable Overrange Deadband Minimum - Operating Pressure As Listed As Listed Range (PSIG) Below Below 1.0-18 PSIG 100 0.6 PSIG 1.8 PSIG 1.5-36 PSIG 150 1.4 PSIG 3.6 PSIG 2-60 PSIG 150 2.2 PSIG 6 PSIG 3-100 PSIG 200 3.5 PSIG 10 PSIG 6-200 PSIG 400 7.0 PSIG 20 PSIG 13-300 PSIG 600 10 PSIG 30 PSIG 15-400 PSIG 600 14 PSIG 40 PSIG SIMPLE CALIBRATION The pressure sensor is supplied with sensing liquid and requires no calibration. The pressure switch is preset for the operating conditions. Final field calibration of the pressure switches is recommended, and can be performed with 7/16" open end wrench.
LOCAL REMOTE STOP/ RESET POWER ON HIGH SEAL WATER Page 3 Fluid Detection Control APPLICATION REQUIREMENTS* SWITCH SWITCH SENSOR SENSOR ENCLOSURE RANGE ELASTOMER HOUSING MATERIAL NEMA 4 0-36 PSIG NITRILE CARBON NEMA 7/9 0-60 PSIG EPDM STEEL 0-100 PSIG NEOPRENE STAINLESS 0-200 PSIG HYPALON STEEL 0-300 PSIG FLUORO CUSTOMER: FOR: CUSTOMER NO: DATE: CERTIFIED: MOYNO SENSOR SIZE 1 1 1 /2 2 2 1 /2 3 4 6 8 10 12 14 OPTIONAL ALARM SWITCH SETTING () (HIGH) *All the above requested information is necessary for the completion of your order. A copy of this page may be submitted with your order. 7.50 3/4 N.P.T. CONDUIT CONNECTION (BOTH ENDS) ACCURACY: ANSI GRADE B 4 X Ø.31 THRU (8) SENSOR DIMENSIONS SIZE A-DIA. B THICKNESS 1 2-1/2 1-7/8 1-1/2 3-1/4 2-3/4 1-7/8 2 4 1-7/8 2-1/2 4-3/4 1-7/8 3 5-1/4 1-7/8 4 6-3/4 2-1/8 6 8-5/8 3-3/4 2-1/4 8 10-7/8 2-1/4 10 13-1/4 2-13/16 12 16 3-1/8 14 17-5/8 3-1/8 6.00 (152) ALL DIMENSIONS IN INCHES FLUID DETECTION CONTROL B 10.75 (273) SENSOR FITS INSIDE BOLT PATTERN OF MATING FLANGES MOYNO A TUBE I.D. MATCHES SCH. 40 CARBON STEEL PIPE UNIT HAS GASKETS MOLDED IN. NO ADDITIONAL GASKET REQUIRED 8.91 (226) CONTROLS: NEMA 4 ENCLOSURE STANDARD SIGNAL LIGHTS ADJUSTABLE TIME DELAY 0-60 SEC 1/60/115 VOLT POWER REQUIRED TERMINAL STRIPS FOR WIRING ALARM OPTIONAL BOX DEPTH: 6.87 (2) 3/4 NPT CONDUIT CONNECTIONS
Page 4 Typical Wiring Diagram (OPTIONAL) ADDITIONAL STOP/RESET PUSH BUTTON N/C (REMOVE JUMPER IF ADDITIONAL SWITCH IS USED). JUMPER OR N/C SWITCH MUST BE USED OR STOP/RESET LIGHT WILL BLINK (OPTIONAL) REMOTE /STOP (PLC OR DCS) TWO SELECTIONS (SEE SET-UP) 1. HI-N/O -N/C SEAL WATER-N/O *2. HI-N/C -N/O SEAL WATER-N/C * SWITCHES UTILIZE BROKEN WIRE DETECTION. IF SEAL WATER F SWITCH IS USED, REMOVE JUMPER AT TB2-9 AND 10. NOTE: ELECTRICAL INSTALLATION SHOULD BE PERFORMED BY QUALIFIED PERSONNEL. INSTALLATION MUST CONFORM TO LOCAL AND NATIONAL CODE. { HI SWITCH SWITCH (OPTIONAL) SEAL WATER F SWITCH (OPTIONAL) EXTERNAL ADDITIONAL LOCAL PUSH BUTTON N/O (OPTIONAL) SEAL WATER SOLENOID VALVE 120 VAC PUMP MOTOR (OPTIONAL) ALARM HORN 120 VAC 120 VAC FIELD WIRING TBI L1 N TB2 1 2 3 4 5 6 7 8 9 10 11 12 TB3 13 14 15 16 17 18 19 20 21 22 23 24 25 TB4 26 27 PUMP RUN CONTACT HIGH RELAY RELAY SEAL WATER RELAY FLUID DETECTION CONTROL CIRCUIT BOARD INPUTS CONTACTS OUTPUTS CONTACTS SPECIFICATIONS ENCLOSURE RATING: SUPPLY VOLTAGE: AC LINE VOLTAGE VARIATION: OUTPUT CONTACTS: INPUT CONTACTS: WIRE SIZE: AMBIENT TEMPERATURE: RELATIVE HUMIDITY: ALTITUDE: NEMA 4 115 VAC 50/60 HZ 1PH +10 TO -5% 5A 250 VAC DRY CONTACTS 14 AWG MAXIMUM -20 TO 120 F -5 TO 95% (WITHOUT CONDENSATION) TO 5160 FT.
Page 5 Typical Block Diagram 120VAC STOP LOGIC BOARD DCS OR PLC HI PUSHBUTTONS LOCAL REMOTE ALARM HORN STOP/ RESET ALARM LIGHTS HI SEAL WATER SEAL WATER F FLUID DETECTION CONTROL FIELD SWITCHES SEAL WATER SOLENOID VALVE 3 Ø POWER PUMP MOTOR ER OR VFD MOTOR PUMP
Page 6 SYSTEMS ADAPTABILITY The system can be adapted to meet a variety of system requirements: temperature ranges from -20 F to +300 F, elastomers to provide the best combination of chemical and abrasion resistance characteristics, operating pressures from 5 to 300 PSI. There are certain situations where it is impractical to install the low-pressure switch on the discharge side of the pump. An example would be several pumps that discharge into a common header. Here, the discharge pressure from one pump creates an erroneous reading at the low-pressure switch of the adjacent pump. Other installations not suitable for low pressure detection are pumps that discharge into the bottom of a tank, systems that generate little or no friction pressure, and systems with excessively long discharge piping. Progressing cavity pumps are capable of compressing air after it is empty. The pressure will not drop until after the discharge piping is empty. SET-UP Connect the Fluid Detection Control Box as shown on the Typical Wiring Diagram. The HIGH,, and SEAL WATER flow switches can be connected two ways. (See Typical Wiring Diagram) 1. HIGH -N/O -N/C SEAL WATER F -N/O 2. HI -N/C -N/O SEAL WATER F -N/C While Method One is most often used, Method Two will activate the fault lights, while the pump is running, if a wire is broken between the pressure switches and The Fluid Detection Control Box. See Table 4 of Setup. The Fluid Detection Control box has three setable timers. 1. Pressure Fault Timer - This timer is adjustable from 10-60 seconds. When the pump is started, the timer allows a set period to elapse before checking for low pressure/run dry conditions. During this time period, the light will blink. After this timeout period, if the pressure falls below the setting of the low-pressure switch, the pump stops and the light is lit. The factory setting is 30 seconds. 2. HI Pressure Fault Timer - This timer is adjustable from 0-0.2 seconds. In some instances a pump is capable of generating high-pressure spikes at startup. When the pump is started, the timer allows a very short period to elapse before checking for high-pressure conditions. The factory setting is 0 seconds. After this time-out period, if the pressure rises above the setting of the HI pressure switch, the pump stops and the HI light is lit. 3. SEAL WATER F Timer - This timer is adjustable from 5-30 seconds. When the pump is started, the timer allows a set period to elapse before checking for Seal Water Flow. During this time period, the SEAL WATER light will blink. After this timeout period, if Seal Water Flow is not established, the pump stops and the SEAL WATER light is lit. The factory setting is 5 seconds. To reset timers for other than factory settings and switches connections for, HIGH and SEAL WATER Faults see Tables 1, 2, 3 and 4 and follow the seven steps listed below. 1. Stop the pump by pressing STOP/RESET button. CAUTION 115 VOLTS INSIDE CONTROL BOX 2. Open door of Fluid Detection Control box and locate DIP switch on the inside of the door. This small switch has four rockers. 3. Set the DIP switches to match either Table 1, 2, 3 or 4. Table 1: Low-Pressure Timer Table 2: High-Pressure Timer Table 3: Seal Water Timer Table 4: Switch Connections 4. Match the three red fault lights to the table to determine current settings that the Fluid Detection Control box is currently set. Table One - Example, if all three lights are off, the low-pressure fault timer is set at 10 seconds. 5. Press the LOCAL pushbutton to change settings if desired. 6. Repeatedly press LOCAL until the fault lights match the desired settings. 7. After the correct setting has been selected, turn all DIP switches OFF before restarting the pump. If another setting needs to be changed, set the DIP switches to the next table and repeat steps 4 through 7. The Alarm Test Mode enables the Fluid Detection Control alarm output relays to be operated without starting the pump and jumping around the pressure or flow switches. To operate the Alarm Test Mode, follow the steps listed below: 1. Stop the pump by pressing STOP/RESET button. 2. Open door of the Fluid Detection Control box and locate the DIP switches on the inside of the door. 3. Set the DIP switches to match Table 5. 4. Press the associated buttons to perform the listed functions on Table 5. 5. Turn all DIP switches OFF to return the Fluid Detection Control box to normal operating mode.
Page 7 OPERATIONAL DETAILS When the pump is off and the STOP/RESET light is on, the pump is ready to be started. Start or stop the pump by pressing the LOCAL or STOP/RESET buttons on the front panel. A green light at the LOCAL button will light after pressing LOCAL. In the event of a malfunction, the STOP/RESET button is used to clear any fault condition indicated by three fault lights on the front panel. REMOTE is used for operating the pump using a Programmable Logic Controller (PLC) or Distribution Control System (DCS). Terminals 3 and 4 of TB2 must be connected to either a PLC or DCS for REMOTE to be functional. Press the REMOTE button. A yellow light at the REMOTE button will light indicating that the system is being controlled by a PLC or DCS. While the REMOTE light is on, the pump cannot be started with the LOCAL button or any additional start pushbuttons connected to terminal 11 and 12 of TB2. All STOP buttons can be used to stop the pump while running with REMOTE. The STOP/RESET light will be lit when the pump is off. If a fault occurs while the pump is controlled by a DCS or PLC, the REMOTE light will go off, the STOP/RESET will light and 1 of 3 fault lights will be illuminated. Press the STOP/RESET button to clear the fault and restart the pump using LOCAL or REMOTE. TABLE 1 TABLE 2 TABLE 3 - TIME LIGHTS SW1 SW2 SW3 SW4 TIME HIGH SEAL (SECONDS) WATER 10 OFF OFF OFF 20 ON OFF OFF OFF ON OFF OFF 30 OFF ON OFF 40 ON ON OFF 50 OFF ON ON 60 ON ON ON HIGH- TIME LIGHTS SW1 SW2 SW3 SW4 TIME HIGH SEAL (SECONDS) WATER.0 OFF OFF OFF 0.1 ON OFF OFF ON ON OFF OFF 0.2 OFF ON OFF 0.2 ON ON OFF 0.2 OFF ON ON 0.2 ON ON ON SEAL WATER TIMER LIGHTS SW1 SW2 SW3 SW4 TIME HIGH SEAL (SECONDS) WATER 5 OFF OFF OFF 10 ON OFF OFF OFF ON OFF ON 15 OFF ON OFF 20 ON ON OFF 25 OFF ON ON 30 ON ON ON
Page 8 TABLE 4, HIGH AND SEAL WATER F SWITCH CONNECTIONS LIGHTS SW1 SW2 SW3 SW4 SWITCH CONNECTIONS HIGH SEAL WATER HIGH - N/O - N/C OFF OFF OFF OFF OFF ON OFF SEAL WATER F - N/O HIGH - N/C - N/O ON OFF OFF SEAL WATER F - N/C TABLE 5 PRESS SW1 SW2 SW3 SW4 TEST BUTTON LOCAL ALARM TEST MODE FUNCTION FORCES ON HIGH RELAY AND LIGHT ON OFF OFF OFF REMOTE FORCES ON PRESURE RELAY AND LIGHT LOCAL AND REMOTE AT THE SAME TIME FORCES ON SEAL WATER RELAY AND LIGHT For information about Moyno Fluid Detection Control or progressing cavity pumps, write or call: Moyno, Inc. P.O. Box 960 Springfield, Ohio 45501-0960 U.S.A. Telephone:......1-877-4UMOYNO (Municipal):.........937-327-3510 Facsimile:..........937-327-3572 (Municipal):.........937-327-3064 Website: www.moyno.com Robbins & Myers Limited School Lane Chandlers Ford, Hampshire SO53 3DG ENGLAND Telephone:............02380/252528 Facsimile:.............02380/252529 Your Moyno Authorized Distributor is: Robbins & Myers Singapore Pte, Ltd. Singapore Branch No. 130 Gul Circle SINGAPORE 629596 Telephone:...........861-3877/8.....................& 861-6954 Facsimile:.............861-1642 Moyno de México, S.A. de C.V. Av. Encarnación Ortiz No. 1860 Col. Cosmopolita C.P. 02670 Mexico, D.F. Telephone...............5556-7842 Facsimile................5556-2044 MOYNO 1998 by Moyno, Inc. Moyno is a registered trademark of Moyno, Inc. Moyno, Inc. is a Unit of Robbins & Myers, Inc. Printed in U.S.A.