ALTRONIC RESEARCH, INC.

Transcription

1 ALTRONIC RESEARCH, INC. P.O. BOX 249 YELLVILLE, ARKANSAS U.S.A. MODEL SODA LOAD

2 MODEL SODA LOAD 1050 KW 41050/New/Mar Page 2 Altronic Research Inc.

3 LIMITED WARRANTY We take pride in manufacturing products of the highest quality and we warrant them to the original purchaser to be free from defects in material and workmanship for the period of one year from date of invoice. Additionally, products of our manufacture repaired by us are warranted against defects in material and workmanship for a period of 90 days from date of invoice, with the provisions described herein. Should a product, or a portion of a product of our manufacture prove faulty, in material or workmanship, during the life of this warranty, we hereby obligate ourselves, at our own discretion, to repair or replace such portions of the product as required to remedy such defect. If, in our judgment, such repair or replacement fails to be a satisfactory solution, our limit of obligation shall be no more than full refund of the purchase price. This warranty is limited to products of our own manufacture. Equipment and components originating from other manufacturers are warranted only to the limits of that manufacturer's warranty to us. Furthermore, we shall not be liable for any injury, loss or damage, direct or consequential, arising out of the use, or misuse (by operation above rated capacities, repairs not made by us, or any misapplication) of the equipment. Before using, the user shall determine the suitability of the product for the intended use; and the user assumes all risk and liability whatsoever in connection therewith. The foregoing is the only warranty of Altronic Research Incorporated and is in lieu of all other warranties expressed or implied. Warranty returns shall first be authorized by the Customer Service Department and shall be shipped prepaid. Warranty does not cover freight charges /New/Mar Page 3 Altronic Research Inc.

4 TABLE OF CONTENTS MODEL SECTION PAGE Warranty...3 Warnings/Precautions...6 Introduction...7 I. Description and Leading Particulars 1.1 Purpose and Application of Equipment Sequence & Theory of Operation Digital Calorimetry Resistive Components...8 II. Dry Cooler Installation 2.1 Inspection Unpacking Assembly Plumbing Electrical Wiring of Status Monitor Circuit Electrical Control Modification...11 III. Soda Load Installation 3.1. Inspection Unpacking Leveling Charging and Leak Test Interlock Connection...14 IV. Calibrations 4.1 Testing and Calibration Overtemp Switch Calibration Soda Pressure Switch Adjustment Water Coolant Pressure Switch Adjustment Soda Flow Switch Calibration/Adjustment Water Coolant Flow Switch Adjustment Emergency Stop Verification High and Low Liquid Level Switch Verification Soda Loop Sensor Adjustment Medium Power Testing High Power Testing Way Valve Initial Programming /New/Mar Page 4 Altronic Research Inc.

5 SECTION PAGE V. Water Coolant Charging and Leak Test 5.1 Water Coolant System Leak Check Water Coolant System Coolant Charging Soda System Drains Water Coolant Drains...19 VI. Resistor Repair VII. Program Instructions VIII. Control Component Replacement...35 Outline Drawings...36 Resistor Configuration...37 Schematic...38 Replacement Parts List...39 Technical Characteristics...40 Attachments A. Dry Cooler Mechanical Drawing B. Dry Cooler Electrical Schematic C. Material Safety Data Sheets Component Manufacturer Documents 41050/New/Mar Page 5 Altronic Research Inc.

6 PRECAUTIONS!!!DANGER!!! Do not attempt any service or parts replacement without first disconnecting all AC power and RF power. Failure to do so may result in serious or fatal electrical shock.!!!warning!!! Before operating equipment insure interlock is operating properly. Not doing so can result in a dangerous, possibly lethal condition. WARNING Do not expose open tank to flames or sparks. The contents of the tank might be explosive. WARNING Ethylene Glycol may cause permanent damage to the kidneys, liver and other organs if ingested. Avoid excessive contact with skin or eyes. See the Material Safety Data Sheet for the specific precautions and first aid measures prescribed by the manufacturer. CAUTION Operating without interlock will void the warranty /New/Mar Page 6 Altronic Research Inc.

7 INTRODUCTION This handbook is for skilled technical personnel as an aid in understanding and performing installation, service and maintenance procedures for the OMEGALINE Model Soda Load. Personnel are considered to be skilled if they have the necessary knowledge and practical experience of electrical and radio engineering to appreciate the various hazards that can arise from working on radio transmitters, and to take appropriate precautions to ensure the safety of personnel. SECTION I DESCRIPTION AND LEADING PARTICULARS 1-1. Purpose and Application of Equipment. The OMEGALINE Model Soda Load is designed to safely dissipate a maximum of 1050 kw watts of electrical energy Sequence & Theory of Operation. In preparation for operation, the soda load system is powered up. A heater is switched on to warm the average temperature of the soda solution to a set point. This set point is usually 75ºC to allow the system to work at high ambient temperatures, but it may be altered in the field to compensate for different soda mixture concentrations and lower ambient temperatures. When the soda solution has reached the set point, RF power may be applied. There are two isolated liquid loops in this system. The soda solution loop is an open system that receives solute from the tank and directs it to the resistor, thence to the heat exchanger and back to the tank. The water coolant loop is a closed system that circulates water-based coolant from the heat exchanger through a dry cooler as necessary to maintain the set point. Temperature measurements are made on the inlet and outlet ports of the soda cell. The temperature difference between these points is mathematically combined with the flow and specific heat of the solutions and yields the applied power: Power in KW = Temperature Difference( C.)*Flow(GPM)*0.258 As the applied R.F. power heats the soda solution flowing through the resistor, the inlet temperature must decrease proportionally to maintain the average temperature in the load. Precise temperature control is achieved by using a 3- way valve controlled by a programmable logic controller. This valve mixes the hot water from the heat exchanger with colder water from the cooler and maintains the required temperature to the coolant side of the heat exchanger. The position of this valve is proportional to a zero to 10 VDC signal which is 41050/New/Mar Page 7 Altronic Research Inc.

8 generated by the calorimetry/controller module. This signal is based on a proportional integral, derivative equation calculating the cold-water inlet of the load. This control process is augmented by a look-ahead algorithm based on projected power Digital Calorimetry. Digital calorimetry is included in the soda load package. This operates at both high and low power block settings with accurate and repeatable measurements. A programmable logic controller utilizes this high-speed calorimetric data and provides totally automatic control of the soda load system. Additionally, it adapts to changing environmental conditions. The program continuously scans for fault conditions and protects the soda load and transmitter in fault conditions whenever transmitter power is applied to the load. Safety points monitored include soda flow, temperature and level Resistive Components. The resistive element is constructed using two nonconductive tubes; one smaller tube is placed inside a larger tube. The crosssectional area of these tubes is selected to provide the required fluid flow rates while minimizing pressure drops. The tubes are mounted on a dual sweep elbow. The soda solution flows into the smaller tube up to a housing cap at the top. It is diverted down through the cavity between the small OD and the large ID tubes. When it reaches the outlet elbow, it is directed to the system heat exchanger for heat removal. The top housing cap is metallic. The RF energy is applied at this point. The dual sweep elbow serves as ground and the termination point for RF signals. The complete resistive element assembly is enclosed in a semi-log tapered outer shield. The spacing at the RF end is dimensioned to match the source impedance. The shape tapers as it approaches the ground end. This matches the impedance of the solution as it approaches ground. There are many factors that determine the resistive component of the load. The liquid cross-sectional area, length and metal surface contact area are pre-determined and fixed by the design /New/Mar Page 8 Altronic Research Inc.

9 SECTION II DRY COOLER INSTALLATION WARNING: THE DRY COOLER WEIGHS 5,285 pounds/ 2,397 kilograms. Use caution when unpacking and lifting Inspection. Inspect outer carton for evidence of damage during shipment. Claims for damage in shipment must be filed promptly with the transportation company involved. Collect all documentation. The units should be handled and unpacked with care. The dry cooler is pressurized to 30 psi/207kpa at the time of shipment. This pressure should be checked prior to unpacking. If the pressure is below 20 psi/138kpa, the dry cooler may be damaged. Appropriate investigation of the condition of the unit should be initiated at once Unpacking. Remove crating. The cooler and leg assemblies are mounted to the shipping platform with lag bolts. All of these bolts must be removed. The expansion tank has to be removed from the shipping platform and installed after the dry cooler is assembled and placed in position. Special Equipment Required: Crane Adequate capacity with lifting slings. Site Plan. The final plan for this installation must be developed on-site and is beyond the scope of this manual. Common hand tools in SAE and metric sizes are assumed to be available to installing personnel Assembly. The manufacturer of the dry cooler has prepared detailed plans for assembly and installation of the dry cooler. They are included in this manual as Attachment 1. The basic steps are summarized below: 1. Prepare footing for placement. Refer to Attachment 1 for dimensions. 2. Lift cooler coil assembly and install mounting legs. 3. Position dry cooler in installation spot and lower cooler into position. 4. Install expansion tank shipped with unit. The required fittings are provided to plumb the tank to the dry cooler Plumbing Installation Tasks. Equipment Required: Steel Pipe Threading machine with 3-inch dies. 1. Connect 3-inch source and drain lines. a. Fabricate pipe and assemble to fittings. b. Install in accordance with site plan /New/Mar Page 9 Altronic Research Inc.

10 MATERIALS LIST QTY ITEM 2 4 Flange seal sets 2 3 Flange seal sets 2 4 to 3 Threaded reducers steel 8 3 Elbows steel 2 3 Flange 150lb threaded w/nuts & bolts 2 4 Flange 150lb threaded w/nuts & bolts As required 3 steel pipe - Schedule 40 As required Thread sealer As required Pipe wrenches As required Large socket set to connect flanges Charging of the water coolant fluid system and leak tests will be performed after installation of soda load. See Section V for instructions Electrical Installation Tasks. 1. Route high voltage wiring from AC Mains service to dry cooler. 2. One roll (100 feet) of 8-conductor control cable is provided by Altronic Research. Route control wiring from dry cooler to soda load. Check motor rotation by momentarily starting fans. The proper airflow direction is bottom to top. If the airflow is incorrect, reverse two wires of the input power at the AC Mains connection Wiring of Status Monitor Circuit. ITEMS REQUIRED QTY ITEM 1 Terminal Strip 2 Mounting screws 1 Drill 1 Tap Control Cable The terminal strip is mounted in the lower left section of the dry cooler junction box. Mark the hole placement, drill holes, and tap holes. Attach the terminal strip with attachment screws using a section of stripped-back control cable wire in the terminal strip to the dry cooler circuitry /New/Mar Page 10 Altronic Research Inc.

11 2.7. Electrical Control Modification. Dry cooler terminal strip. An 8-position terminal strip has been added to the dry cooler electrical panel by the factory. This is wired into the control circuitry. The added terminal block will be referred to as DCTB1. 1) Run wire from/to 002 to DCTB1-1 Cooler 24 VAC 005 to DCTB1-2 Cooler fan bank 1 enable 006 to DCTB1-3 Cooler fan bank 2 enable 011 to DCTB1-4 Cooler fan bank 3 enable 014 to DCTB1-4 Cooler fan bank 4 enable 017 to DCTB1-4 Cooler fan bank 5 enable 004 to DCTB1-4 Cooler enable 03 to DCTB1-4 Cooler AC common 2) Remove jumper between ) Install cable from DCTB1 to Terminal strip 3 in the soda load control panel. The connections are 1 to 1, 2 to 2, 8 to /New/Mar Page 11 Altronic Research Inc.

12 SECTION III SODA LOAD INSTALLATION 3.1. Inspection. Inspect for damage. Compare Bill of Materials with shipment Unpacking. The soda load is shipped partially assembled. It is necessary to remove wrapping materials and segregate and identify the loose parts and accessories that are packed in cartons Leveling. Four leveling bolts are built into the soda frame assembly. They must be adjusted to level the soda load assembly Charging and Leak Test. a. Connect the wires in the dry cooler status cable to the soda load junction box if this has not been done. b. Connect to electrical power. c. Prime the pumps. d. Verify phase rotation of pumps by: (1) Momentarily applying power to the pump while observing the pump rotation. [Manually depress the contactor armature.] (2) The proper direction of rotation is shown on the top of the pumps. If the rotation is wrong, exchange two of the mains supply wires. This should correct the rotation for all pumps on the load. e. Apply power to the soda load and verify operational performance. f. Start the water coolant pump with the valve fully open. Inspect for leaks. g. Turn the water coolant pump off. h. Fill the soda tank with potable water to the 250 gallon mark. NOTE: This level is above the lower level switch in the tank. NOTE: Bleed the soda pump air bleed port after the tank is filled and before starting the pump. The pump will be air-locked. Failure to accomplish this will result in damage to the pump. i. Start the soda pump. j. Inspect for leaks. NOTE: Liquid-proof safety glasses and gloves should be used for the following steps in the commissioning procedure. The addition of sodium carbonate to water may cause vigorous bubbling and splashing of the very hot solution. k. Turn on the heaters and the soda pump. l. Allow sufficient time for the water to heat up. The temperature will increase 18 C per hour using heaters /New/Mar Page 12 Altronic Research Inc.

13 m. When the solution has reached 40 degrees C., slowly pour the sodium carbonate (soda) into the water through the top of the tank. Pouring 1-liter size portions and distributing the soda across the boundaries of the tank prevents the mixture from clotting and dropping to the bottom of the tank. The soda is shipped in five-gallon containers. 5 ½ liters of soda powder should bring the impedance to 50 ohms. Begin by mixing about 5 liters of the soda into the water. The end mixture will vary with the type of water used, so start with less soda than you think will be needed. NOTE: The impedance will change about 1 ohm per degree C. increase in temperature. The approximate impedance at this point will be about 55 ohms. n. See Table 1 for additional information about different impedance values that may be achieved by changing soda concentration. TABLE 1 The tank holds 250 gallons at the low switch level. The required soda at this level is 5.5 L. 5.5L Soda / 946 L water * 2.5 SG Soda = ~.015% solution Sodium Carbonate NaCO3 20 deg C % mmohm/cm ohm/sq ohm/sq The impedance of the mixture is determined by both the conductivity of the water + the solution set point temperature. o. The final adjustment will be made later when RF is applied and the mixture is heated to 75º C by the applied RF. Low level RF power may be applied until the set point of 75º C is reached. At this time, additional soda may be added as the reflected power is observed. The time delay between adding soda and the impedance changing is about 1 minute. Add small amounts of soda, i.e., less than a cup, as the mixture approaches the desired level as indicated by a low reflected signal. The reflected power will drop to zero when the proper impedance is achieved. NOTE: The exact impedance of the load is temperature sensitive. The required RF conductance is degrees C /New/Mar Page 13 Altronic Research Inc.

14 p. If too much soda is added to the tank, it is a simple matter to drain ~2% of the soda solution or simply to add additional water to the tank, but care must be taken not to overfill the tank. q. Once the system is charged, turn off the soda pump Interlock Connection. Remove all power to the load. Connect the 6-1/8 EIA RF line. Connect the safety copper ground to the soda load frame at the provided connection. Connect the transmitter interlock. Dry verify operation of interlock /New/Mar Page 14 Altronic Research Inc.

15 SECTION IV CALIBRATIONS 4.1. Testing and Calibration. To start soda load verification, calibrate the soda flow meter as follows: With low power (<200kW) out of the transmitter, adjust the flow gain parameter in the offsets screen of the program until the displayed power matches the applied RF power. This parameter will be adjusted at high power levels for final calibration Overtemp Switch Calibration. This adjustment was accomplished at the factory. If a switch is replaced, the following procedure may be used for adjustment: a. The load must be excited with RF energy until the mean temperature reaches the set point temperature. b. Remove one wire of the three-way valve control signal. c. Tape the free wire to prevent shorting. Apply low level RF power. d. The hot temperature will slowly increase. As the temperature approaches 90 degrees C., adjust the screw of the overheat sensor until the transmitter is shut down. e. Remove RF power and reconnect the removed 3-way valve control wire. The valve will reposition and cool the mean temperature to set point Soda Pressure Switch Adjustment. The switch is adjusted to close at the standard flow and open if the pressure drops. a. Start the soda pump. b. Turn the adjustment screw until the switch opens when the pump is running and then turn it the reverse direction one full turn. c. Stop the soda pump and restart to check for proper operation of the switch Water Coolant Pressure Switch Adjustment. The switch is adjusted to open at the standard flow and close if the pressure drops. Adjust as the soda loop pressure switch described in Soda Flow Switch Calibration/Adjustment. The flow switch is set by the factory and no adjustment is required. If adjustment should be required, there is a screw to increase the tension Water Coolant Flow Switch Adjustment. The flow switch is set from the factory and no adjustment is required. If adjustment should be required, there is a screw to increase the tension Emergency Stop Verification. When the system is operating, press the E- Stop Button. All heaters, valves and pumps should stop and transmitter enable signal must be automatically removed /New/Mar Page 15 Altronic Research Inc.

16 4.8. High and Low Liquid Level Switch Verification. There are no adjustments for these items. If either fails to work, remove and replace. NOTE: The transmitter will have to be reset when an interlock trip condition has existed. Apply minimum power. Verify calorimetry in accordance with Para Soda Loop Sensor Adjustment. a. Adjust soda flow meter calibration settings to match power. b. Vary the flow control valve to verify tracking. c. Lower the flow until the soda flow switch set point. If the switch does not shut down the transmitter adjust, adjust the soda pressure switch to the set point. Reference the dial pressure gauge. d. Verify electrical actuation below set point. e. Open the soda flow control valve fully open. f. Remove RF power Medium Power Testing. a. Apply medium RF power, high setting, no modulation. b. Monitor calorimetry indications for accuracy. c. Using a stop watch, record the time from power application until the temperature stabilizes. d. Record the VSWR as displayed by the transmitter control panel. e. Remove RF power and record the time required for the coolant temperature stabilization. Record these times High Power Testing. a. Apply about 2/3 full power. b. Note VSWR and calorimetry reading. c. After the temperature control loop has stabilized, the power may be increased slowly to full power. The hot temperature must not exceed 90 degrees C. or the transmitter will shut down. d. If VSWR and calorimetry are within acceptable limits, the RF may be applied in ramp or stepped operation. A full on, i.e. 1050KW may shut down the transmitter because the temperature exceeded 90 degrees C. e. Full power without modulation may be applied for about 30 seconds. This allows the coolant loop to lower the cold inlet temperature. After it is lowered, the full modulation may be applied Way Valve Initial Programming. The valve controller is programmed from the factory to operate in the analog mode. If this program is lost or changed, the controller will need to be programmed before operation /New/Mar Page 16 Altronic Research Inc.

17 The settings for the dip switches are located in the 3-way valve control box and are 1,3 ON and 2, OFF. This sets the direction of operation and speed. These are set after all other operations are completed and should be considered the default settings for 3-way valve operation. See diagram below. a. Mode programming: Remove power and put all dip switches OFF, reapply AC power to the valve controller. This may be accomplished by cycling circuit breaker 4 (lower left) in the power control box. Within 10 seconds of power application, press and release the reset button. The LED should be blinking. Switch dip switch #3 ON, then OFF. b. Valve travel programming: This is set to the default and would not normally be changed. To calibrate, apply power and wait at least 10 seconds. Press and release the reset button. The LED should be illuminated. First Option: the actuator will travel in both directions to find its limit and position itself according to the demand. The LED will extinguish, completing the process. Second Option: When the desired end position is reached, press and release the reset button. The actuator will now return to the original position. You can also press and release the reset button when it reaches the original position. The LED will extinguish, completing the process /New/Mar Page 17 Altronic Research Inc.

18 SECTION V WATER COOLANT CHARGING AND LEAK TEST 5-1. Water Coolant System Leak Check. a. Close the valve to the surge tank at the dry cooler outlet port. [The pressure relief cap on this tank vents at 16psi/110kPa.] Pressure may be applied at any accessible point on the system. b. Apply 80psi/552kPa dry air pressure to the water coolant system. Close off the valve and allow 30 minutes for leaks to appear. The system has a large volume. After the prescribed time, observe the pressure reading. If there is a drop in pressure, leak isolation must be performed. A spray bottle filled with a soap mixture aids in isolating leaks. c. After a leak-free system is verified, the pressure can be vented. The surge tank isolation valve must be opened. CAUTION: This valve must be left in the open position when the system is filled. Failure to comply with this precaution will result in the water coolant pressure relief valve discharging soda solution when the soda load is operational Water coolant System Coolant Charging. The water coolant system may be charged at the valve assembly located just prior to the upper port of the heat exchanger. The vent valve located at the top manifold of the dry cooler may be opened to vent air from the system. NOTE: The system volume is determined by the length of connecting pipe. a. Using a mixing container, prepare a 30% solution of inhibited ethylene glycol and potable water. The coolant mixture is pumped into the system at the water coolant charging port. Connect water + glycol source to dry cooler liquid lines. Pump this mixture into the cooling system. Charge to proper level. NOTE: Bleed the water coolant pump vent port after the water coolant system is charged. It will be air-locked. Failure to accomplish this will result in damage to the pump. b. The air will have to be bled at the dry cooler vent port. c. As the system approaches the proper level, the air will have to be bled at the water coolant charging port. d. The water coolant pump will have to be bled and allowed to prime the pump cavity. e. Close the water coolant charging port valve. f. Momentarily press the water coolant motor starter to verify proper pump rotation. The pumps were synchronized at the time of manufacture. g. If the rotation is wrong, swap (2) two-phase wires. The initial start up of the pump is a repeated process. The pump is run until there is a pressure drop. The vent plug on the pump has to be bled until the air is out, closed, and the pump run again using the motor starter 41050/New/Mar Page 18 Altronic Research Inc.

19 contact. This has to be repeated several times along with the air vented at the dry cooler vent port. When the system is free from air, the pump will run evenly and the pressure will be constant at about 60 psi Soda System Drains. The soda system may be drained at the valve located near the bottom of the tank. There is a hose connection located below the AC control box. This connection is plumbed to the low points of the soda system. There are 3 valves that must be repositioned to drain the soda side. NOTE: After the system is drained, these valves must be closed prior to recharging the system Water coolant Drains. The water coolant side of the system may be partially drained at the fill port. There is a valve located on the water coolant strainer. There are valves located at the low points of the water coolant plumbing. These valves direct the remaining fluid to a common drain point. NOTE: Close these valves prior to recharging the system. HEATER WARNING OPERATION OF THE HEATERS WHEN THEY ARE NOT COMPLETELY COVERED IN LIQUID WILL RESULT IN IMMEDIATE FAILURE! 41050/New/Mar Page 19 Altronic Research Inc.

20 SECTION VI RESISTOR REPAIR The Altronic 1050 KW Soda Load Resistor consists of three sections combined to absorb RF power and to act as a cooling medium for removal of heat from the load. Section one is a four-inch diameter segment of polypropylene tube. Section two is a six-inch piece of polypropylene tube, with the same length and position inside the housing as section one. The last section is the outer conductor, which is a tapered sheet metal housing. Water enters from the flanged connection at the bottom of the load, and flows up through the center of the four-inch tube. After reaching the top of the four-inch tube, water flows down between the four-inch and six-inch tube. Water leaves the resistor through the flanged connection on side two of the load. The shape of the outer conductor is used to set the V S W R of the dummy load. The resistor is positioned inside of an aluminum housing. The housing is used to prevent injuries and contain the liquid inside the resistor. The housing panels should only be removed for periodic maintenance and visual inspection of the resistor. The resistor housing is fitted with leak detectors. WARNING!!! OPERATION OF THE DUMMY LOAD WITHOUT THE RESISTOR HOUSING IN PLACE COULD CAUSE FATAL INJURIES AND DAMAGE THE LOAD. RESISTOR INSPECTION AND MAINTENANCE The following instructions and diagrams are written as a best practice for inspecting and making repairs to the resistor. Minor repairs can be accomplished without removing the resistor from the load. If it is found that the four-inch polypropylene tube has to be replaced, the resistor must be removed from the load. The following page shows the resistor and housing as an assembly and section view /New/Mar Page 20 Altronic Research Inc.

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22 Remove the side one panel and set it in a rack. A 3/16 inch Allen wrench can be used to remove the bolts around the outside of the panel. Before the six-inch tube can be removed or the o-rings replaced, the resistor transition must be detached from the resistor. Do not separate the RF input flange from the top panel of the resistor. This would create unnecessary time and difficulty during reassembly. Remove the side one transition panel from the transition and set it in the rack. This panel is attached to the transitions with fourteen ¼-20 Allen head bolts /New/Mar Page 22 Altronic Research Inc.

23 Remove the eight ¼-20 bolts holding the strap to the center conductor. (Strap shown elevated but will flatten when the bolts are removed.) Remove the ¼-20 bolts that fasten the transition at its base to the resistor housing. Remove the transition and store it /New/Mar Page 23 Altronic Research Inc.

24 With a 1-1/16 inch wrench, remove the hex nut from the recess in the center conductor. Remove the set screws on the ring that locks the center conductor to the anchor insulator. The center conductor can now be removed. If needed, use the bolt pattern to remove the center conductor. Care should be used to prevent damaging this part. It conducts high voltage; sharp edges will allow arcing between the center conductor and ground. If charring has been found, replace the six-inch tube, center conductor, plated washer and nut. Continue with the following instructions for resistor removal. If the four-inch tube has not been damaged, then replace worn or damaged parts and reassemble /New/Mar Page 24 Altronic Research Inc.

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28 SECTION VII PROGRAM INSTRUCTIONS When power is applied this screen is displayed. Each of the squares are touch switches and will advance to the selected screen. The Hard key located in the lower left of the screen area will cause the program to always return to this menu screen. Power switch to small monitor screen. Test switch to large monitor screen. Control switch to manual control screen. Status switch to status display screen. Image switch to picture control screen. Offset switch to system constants screen. Gage switch to Gage view power indicator. Dry Cooler switch to dry cooler indicators. All Start will turn on the pumps,heaters and the dry cooler. All Stop will turn off the pumps,heaters,and the dry cooler. Alarm Status will display the alarms and allow reset of manual alarms /New/Mar Page 28 Altronic Research Inc.

29 The Power 1 screen displays the applied power. The temperature of the soda solution exiting the load. The temperature of the cold soda solution entering the load. The difference between the Hot and Cold Ports. The flow in Gallon per Minute of the soda system. The temperature of the Cold solution from the Dry Cooler. The Power 2 screen displays the applied power. The temperature of the soda solution exiting the load. The temperature of the cold soda solution entering the load. The difference between the Hot and Cold Ports. The flow in Gallon per Minute of the soda system. The temperature of the Cold solution from the Dry Cooler. This screen displays the same information as the Power 1 screen with the power portion of the display being enlarged for distant viewing /New/Mar Page 29 Altronic Research Inc.

30 The control screen allows the switches for power control. The soda pump may be started or stopped. The water coolant pump may be started or stopped. The Heaters may be turned on or off. The Dry Cooler may be enabled or disabled /New/Mar Page 30 Altronic Research Inc.

31 The status display shows the real time operation of the monitored points. The indicators will be green if conditions are acceptable. They will be red if a fault exists. Automatic faults will clear when the required condition is met. Manual faults will flash the letters until the condition is accepted on the reset screen. Soda pressure indicates that sufficient pressure is not present in the soda system. Sec pressure indicates that sufficient pressure is not present in the water coolant system. Temp switch soda indicates the outlet solution has exceeded 90 deg C. Soda Pump Hot indicates the soda pump motor has overheated. Sec Pump Hot indicates the water coolant pump motor has overheated. The Flow Switch soda indicates that the soda flow is low. The Flow Switch water coolant indicates that the water coolant flow is low. The soda over current switch indicates that the soda motor starter has tripped from overload. The water coolant over current switch indicates that the water coolant motor starter has tripped from overload. The Tank low switch indicates the soda solution in the tank is low. The Tank high switch indicates the soda solution in the tank is high. The e-stop indicates that the e-stop is pressed. The Dry Cooler power indicates the main power for the dry cooler is off. The Leak Switch indicates that there is a leak in the resistor cavity /New/Mar Page 31 Altronic Research Inc.

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33 The picture screen shows a schematic view of the Soda load. Pressing the color squares will display the information at the top of the screen. Dry Cooler operation is not included in this screen /New/Mar Page 33 Altronic Research Inc.

34 Note: the values in this slide are not valid; The following calibration table indicates the as-shipped data: THE PROGRAM CONSTANTS LOADED AT CALIBRATION HOFF HGAIN COFF CGAIN FOFF.85 FGAIN 775 IOFF IGAIN SETPOINT /16/08 FINAL CALIBRATION SERIAL # 101, /New/Mar Page 34 Altronic Research Inc.

35 SECTION VIII CONTROL COMPONENT REPLACEMENT The control electronics consist of two major components: (1) the PLC and (2) the Display. A row of LED indicators located on the right upper section of the PLC housing indicates communications are occurring. The Display provides all the decision-making capabilities of the system. If there is a failure in either of these components, they will have to be replaced with programmed replacements. (1) The PLC may be replaced by loosing the screws attaching the terminal strip top and bottom. The terminal strips will unplug from the PLC. The PLC is affixed to the back panel with DIN rail hardware. The release point is located on the bottom and may be snapped down to release. The plug-in circuit assemblies on the PLC may be removed and replaced individually. This must be accomplished when the power is off. These devices are slot-specific and must be installed in their respective slot positions. The PLC has two add-on circuit assemblies that provide I/O interface. The voltage output card is located in slot two (2). This card provides a 0 to 10 VDC signal controlling the position of the three-way valve. The input card located in slot three (3) provides 4-20MA interface to the temperature and flow sensors. There is a 3-position switch located on the right side of the PLC. This switch must be in the middle position for normal operation. (2) The Display may be changed by removing the attaching wiring and cables and the mounting screws located around the edge of the display /New/Mar Page 35 Altronic Research Inc.

36 OUTLINE DRAWINGS 41050/New/Mar Page 36 Altronic Research Inc.

37 RESISTOR CONFIGURATION 41050/New/Mar Page 37 Altronic Research Inc.

38 SCHEMATIC DIAGRAM 41050/New/Mar Page 38 Altronic Research Inc.

39 REPLACEMENT PARTS LIST MODEL Item Qty. Description 1 1 Pump 2 1 Motor Starter Way Valve Control 4 1 PLC Programmed 5 1 I/O Card Input 6 1 I/O Card Output 7 1 Display Programmed 8 3 Heater Element 9 2 Relay Control 10 1 Relay Transmitter Enable 11 1 Power Supply DC 12 1 Power Supply AC 13 1 Breaker 18 Amp 14 1 Breaker 3 Amp 15 1 Pressure Switch 16 1 Flow Switch 17 1 Flow Meter 18 1 Switch, Overheat 19 2 Temperature Sensor 20 2 Temperature Transmitter 21 1 Switch, Level Way Valve Repair Kit 23 1 Dry Cooler Fan 24 1 Dry Cooler Fan Hub 25 1 Dry Cooler Motor Starter 26 1 Flange Kit 2-1/ Flange Kit Flange Kit /New/Mar Page 39 Altronic Research Inc.

40 Impedance: TECHNICAL CHARACTERISTICS: Model Frequency Range: Resistive Type: Max Power: RF Input: Stabilized VSWR: 1.05:1 Accurate Power Measurement: Dimensions: (Nominal) Weight: AC Power Requirements: System Protection: 50 ohms nominal 60 Hz to 2 MHz (including full load for harmonics 2 and 3) Soda Solution (Sodium carbonate + Water) 1050 KW 600 KW Carrier Power + 125% Peak Modulation Coaxial Connector 9-3/16 EIA Digital Calorimetric Range 10 to 100% FSR Error ±< 4% FSR 60 in. W x 108 L x 108 H Configuration dependent VAC, 3 Phase, 50/60 Hz MECHANICAL: LOW FLOW OVER TEMPERATURE LOW LEVEL OVER CURRENT: fans, pumps and control COMPUTER CONTROLLED: LOW FLOW OVER TEMPERATURE SYSTEM PERFORMANCE Water coolant Circuit: Dissipation: Cooling medium: Flow rate of cooling medium: Cooling air temperature: 1050 KW Glycol 30% + potable water 193 GPM -10ºC to 40ºC Load temperatures above 40ºC RF module must remain above freezing temp. Serial No. 101, 102 Frequency MW Resistance 50 Ω Model Inspected by GLJ Date 10 June 2008 CRAFTED WITH PRIDE IN ARKANSAS, U.S.A /New/Mar Page 40 Altronic Research Inc.

41 ATTACHMENTS A. DRY COOLER MECHANICAL DRAWING B. DRY COOLER ELECTRICAL SCHEMATIC C. MATERIAL SAFETY DATA SHEETS 41050/New/Mar Page 41 Altronic Research Inc.

42 COMPONENT MANUFACTURER'S DOCUMENTS 41050/New/Mar Page 42 Altronic Research Inc.