INSTRUCTION MANUAL

FOR DD-01
DIGITAL DIVERT CONTROL SYSTEM VERSION 4.1.
WITH MAIN PROGRAM 8.5 OR HIGHER

WARNING
The process medium may be hot or otherwise hazardous. Precautions when removing the sensor from
the process line:
Make sure that the process line is not under pressure. Open a vent valve to the atmosphere. For a retractor/isolation valve the line pressure should be within specifications.
For a prism wash system, close a hand valve for the wash medium and disable the wash valve. Loosen the clamp or flange bolts cautiously, be prepared to tighten again. Be out of the way of any possible splash and ensure the possibility of escape.
Use shields and protective clothing adequate for the process medium. Do not rely on avoidance of contact with the process medium.
After removal of the sensor, it may be necessary to mount a blind flange for security reasons.

Document/Revision No. IMD 1/5

Effective: June 20, 2005

This product manual is delivered to the end-user with a K-Patents product. Information in this manual is
subject to change without notice. The latest manual version is freely available at http//www.kpatents.com/.
You can also contact manuals@kpatents.com.
THE PASSWORD FOR PR-01-S IS 7 8 4 5 1 2 IN PROGRAM VERSIONS 4.0 AND HIGHER.

K-PATENTS OY

K-PATENTS OY

K-PATENTS,INC.

Postal address:
P.O. Box 77
FIN-01511 Vantaa, Finland

Street address:
Elannontie 5
FIN-01510 Vantaa, Finland

1804 Centre Point Circle,

Suite 106,
Naperville, IL 60563

Tel. + 358-9-825 6640

Fax +358-9-825 66461
E-mail: info@kpatents.com
http://www.kpatents.com/

Tel. + 358-9-825 6640

Fax +358-9-825 66461

Tel. 630-955 1545

Fax 630-955 1585
E-mail: info@kpatents.com
http://www.kpatents.com/

1. TABLE OF CONTENTS

TABLE OF CONTENTS........................................................................................................................1

GENERAL INFORMATION .................................................................................................................2

2.1 Digital divert control system DD-01 .................................................................................................2
2.2 Operator panel...................................................................................................................................3
2.3 Alarms ...............................................................................................................................................4
2.4 Prism wash ........................................................................................................................................4
2.5 Master divert control unit..................................................................................................................5
2.6 Indicating transmitters.......................................................................................................................6
2.7 K-Patents digital divert control unit specifications............................................................................7

MOUNTING...........................................................................................................................................8
3.1 Wiring ...............................................................................................................................................8

START-UP ...........................................................................................................................................12
4.1 Divert control unit start-up ..............................................................................................................12
4.2 Divert control system trimming.......................................................................................................12

CALIBRATION....................................................................................................................................13
5.1 Refractometer concentration measurement .....................................................................................13
5.2 Refractometer activation for divert control .....................................................................................13
5.3 Signal difference alarm ...................................................................................................................14
5.4 Low alarms......................................................................................................................................14
5.5 Refractometer malfunction alarm ....................................................................................................14
5.6 Prism wash ......................................................................................................................................14
5.7 Divert decision rules........................................................................................................................15

MAINTENANCE .................................................................................................................................17
6.1 Information flow..............................................................................................................................17
6.2 Divert control circuit boards ...........................................................................................................18
6.3 Diagnostic messages........................................................................................................................23
6.4 Diagnostic lights..............................................................................................................................23
6.5 Push-button assembly......................................................................................................................24
6.6 Fuses................................................................................................................................................24

DIVERT CONTROL LOGIC ...............................................................................................................25

7.1 Block diagram .................................................................................................................................25
7.2 Logical diagrams .............................................................................................................................26
7.3 Safety Decision Logics....................................................................................................................28

OPTIONAL CONFIGURATIONS.......................................................................................................30
8.1 Remote divert control unit...............................................................................................................30
8.2 Equipment .......................................................................................................................................30
8.3 Remote divert control unit in the control room ...............................................................................31
8.4 Wiring and mounting.......................................................................................................................32
8.5 Serial output ....................................................................................................................................34
8.6 Current output signal .......................................................................................................................34
8.7 External DC power supply ..............................................................................................................34

DIVERT CONTROL UNIT PARTS LISTS.........................................................................................35

9.1 Divert control unit and optional remote divert control unit.............................................................35
9.2 Remote divert control unit...............................................................................................................36

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

2. GENERAL INFORMATION
The K-Patents Digital Black Liquor Divert Control System DD-01 provides a divert signal preventing black
liquor with dangerously low solids to reach the black liquor burners. The system is built strictly according to
the principles of Recommended Good Practice "Safe Firing of Black Liquor in Black Liquor Recovery Boilers" (BLRBAC August, 1982 and revisions April, 1991, and March, 2001).
2.1. DIGITAL DIVERT CONTROL SYSTEM DD-01

Figure 2.10

Complete Digital Divert Control System DD-01

The system consists of the following parts (Figure 2.10): Two K-Patents Process Refractometers PR-01-S (A
& B) are installed in series in the main black liquor line. Each refractometer is complete with a Sensor, an
Indicating transmitter and Interconnecting cables. Each refractometer provides also a 4-20 mA % solids output
signal not used by the divert control system.
The Divert Control Unit DD-01 is contained in one enclosure with the same dimensions as the refractometer
Indicating transmitter enclosure. The control unit includes:
an operator panel
control logics
contact outputs for prism wash, warnings, alarms and black liquor diversion
Two isolation valves HIMP-2 (optional) for the refractometers above to allow removal of
the refractometers from a pipe with full flow and pressure. The isolation valve includes a
prism wash nozzle and two check valves (one for prism wash, one for stuffing box flush).
A roofed mounting plate to mount the two Indicating transmitters and the Divert Control
Unit together.
Two steam valves with steam traps for prism wash (pneumatic + solenoid valves).
Two hand valves (one for prism wash, one for stuffing box flush).
One alarm horn (supplied by the customer).
Note. BLRBAC (The Black Liquor Recovery Boiler Advisory Committee) recommends a spare sensor to be
maintained in stock on-site.
INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

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2.2. OPERATOR PANEL

4
5

Figure 2.20

The operator panel.

The operator panel has a clear layout and the operator can see all information at one glance. The divert decision is controlled from the operator panel which provides doubled security, since all information is simultaneously shown both as LED indication in the Divert Control Unit and as a diagnostic messages in the Indicating
Transmitters (Figure 2.20).
Each refractometer has a green OPERATING light (1), so the operator knows when he can rely on the refractometer measurement. A refractometer will influence the divert decision only when the green OPERATING
light is on. A malfunctioning refractometer is automatically taken out of operation. One green indicator light
SAFE% SOLIDS (2) is based on the two refractometers and the divert decision rules (Section 5.7).
One red DIVERT light (3) that will be switched on when the SAFE% SOLIDS goes off. The DIVERT light
indicates divert status of the divert relay. The divert relay has an output switch contact, for use in the Black
Liquor Firing Tripping Logic. The relay is OFF in the DIVERT position, because a power failure will give a
DIVERT decision.
A lockable OVERRIDE/AUTOMATIC switch (5) and a red OVERRIDE warning light (4) is ON always if
switch in OVERRIDE position. If the SAFE% SOLIDS goes OFF and this switch is in the OVERRIDE position, then the OVERRIDE light is lit instead of the DIVERT light. One RESET push-button (6) for the
DIVERT action. The DIVERT action always has to be manually reset. If the override switch is in Automatic
position and SAFE% SOLIDS is off, the DIVERT action cannot be reset.
One EMERGENCY DIVERT push-button (7) to manually initiate DIVERT in an OVERRIDE or emergency
situation. The DIVERT light is lit also after manual divert action. The EMERGENCY DIVERT button has a
protective hinged cover, to prevent inadvertent use.
Two indicator lights (8) for the divert valve status TO BY-PASS/TO BURNER from microswitches on the
valve. For intermediate valve positions both lights are off.
A row of four alarm lights (9) that indicate black liquor SOLIDS WARNING (at 60%), black liquor SOLIDS
ALARM (below 58%), refractometer reading more than 2% absolute difference and refractometer malfunction.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

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A light test button (10) switches all 11 lights on. An alarm reset button (11) resets the alarm lights. For normal
operation the operator panel has four green lights on (A OPERATING/B OPERATING/ VALVE TO
BURNER/SAFE% SOLIDS).
2.3. ALARMS
The divert control system has four alarms, audible and indicating:
1.
2.
3.
4.

Black liquor SOLIDS WARNING, yellow light (60% or below)

Black liquor SOLIDS ALARM, red light (58% or below)
Refractometers reading more than 2% absolute DIFFERENCE, yellow light
Refractometer MALFUNCTION, yellow light

The alarms 1, 2 and 4 are initiated by either refractometer. System contains also optional alarms, see wiring
drawing 3.11.
The operator panel contains four indicator lights and an ALARM RESET button. The reset button will silence
the audible alarm, but the visual indication will remain until the condition has returned to normal.
To avoid unnecessary alarms the following interlocks are implemented:
-

A refractometer can initiate an alarm only when it is operating.

Alarm 4 can be initiated only if both refractometers are operating.

The parameters (2%, 58% and 60%) are default settings, which can be changed from the Indicating transmitter
keyboard (Sections 5.3 and 5.4). The parameter for 2% can be decreased and the parameter for 58% and 60%
can be increased.
2.4. PRISM WASH
For K-Patents Process Refractometer, the need of prism wash is reduced and even in some cases eliminated.
The prism keeps clean due to the probe design features:
-

The prism is flush mounted in a surface deflecting the black liquor main flow, which causes
a strong mechanical cleaning action.

The prism has the same temperature as the black liquor.

In any case, however, an automatic regular prism wash provides an efficient check that the refractometer reacts. A steam wash of 3 seconds every half hour should be sufficient. Automatic single (one-of-two) diversion
will occur if either of the refractometers is in wash cycle.
The Divert Control Unit contains two relays for prism wash, WASH A and WASH B. To follow the BLRBAC
recommendation not to wash both prisms at the same time, there is an interlock. If both refractometers try to
wash simultaneously, one will display "WAIT" and perform the wash when the other has finished.
K-Patents recommends to use a steam trap instead of preconditioning valve to remove condensate from the
steam line. The wash times can be seen pressing soft keys "Display"/"System configuration"/"Wash times". To
change the wash times, see Section 5.6.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

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2.5. MASTER DIVERT CONTROL UNIT

Figure 2.50
indications.

Operators panel and functions of the master divert control unit in the field with LED

1. Black liquor SOLIDS WARNING (at

60%), Black liquor SOLIDS ALARM (below 58%), Refractometer reading more than
2% absolute difference, and Refractometer
malfunction).
2. Each refractometer A and B has an
OPERATING green light, A refractometer
will influence the divert decision only when
the green OPERATING light is on. A malfunctioning refractometer is automatically
taken out of operation.
3. One green indicator light SAFE%
SOLIDS, based on the two refractometers
and the divert decision rules.
4. A red OVERRIDE warning light is on
always if the override switch is switched on.

INSTRUCTION MANUAL FOR DD-01

5. One red DIVERT light that will be

switched on when the SAFE% SOLIDS
goes off. The DIVERT light indicates divert
status of the divert relay.
6. Two indicator lights for the divert valve
status. TO BY-PASS/TO BURNER from
microswitches on the valve. For intermediate valve positions both lights are off.
7. A lockable Override/Automatic divert
switch
8. A DIVERT RESET push-button.
9. An EMERGENCY DIVERT push-button.
10. A light test button switches all 11 lights
on.
11. An alarm reset button resets the alarm
lights.

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

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2.6. INDICATING TRANSMITTERS
An Indicating transmitter in a Divert Control System is identical (both hardware and software) to a standard
transmitter described in the PR-01-S Instruction manual.

3
2

C ONC

C
P R O C E S S T E M P E R A T U R22.1
E
T E S T 109.3
In d iv e r t c o n tr o l o p e r a tio n
R em oved
S ta r t
fr o m d iv
p r is m
C a lib r a te
c o n tr o l
wash

Figure 2.60

B
8

5
D is p la y

K -PT E N T S
P R O C E S S IN S T R U M E N T S

ENTER

RESET

The Indicating transmitter.

The display, Figure 2.60, will give the following additional information pertinent to the Divert system:
1. A or B in the upper right corner indicates that the
transmitter is OPERATING in the divert system as refractometer A or B, Figure 2.10. If a or b is displayed
instead, the refractometer is removed from divert control operation. (If the upper right corner is empty, see
Section 5.2). For A or B the corresponding green
OPERATING light, Figure 2.20, is on, for a or b it is
off.
If you see a ? in this corner, see Section 5.2.
2. A softkey (B) defined by "Remove from divert control"
or alternatively "Restore to divert control". The visible
effects of pressing "Remove" for refractometer A is
that the soft key changes to "Restore", A switches to a,
and the green OPERATING light goes off. Further the
"Remove" soft key disappears from refractometer B,
because B must not be removed if it is the only refractometer in operation.
Note. Always press "Remove" for a refractometer before making service or switching the power off.

INSTRUCTION MANUAL FOR DD-01

3. The "Normal operation" message is substituted by

"In divert control operation" or "Removed from divert control". Those messages may change to "Solids warning" or "Solids alarm" at low solids. An additional error message may occur: ** Divert control
fault ** combined with a ? in the upper right corner,
see Section 6.3.
4. The softkey "Display" (D) leads via "System configuration" (C) to "Divert control system" (D) which
gives the following information:
Refractometer difference alarm limit in % solids
Solids warning limit in % solids (default
value 60%)
solids alarm limit in % solids (default value 58%)
Divert rule and SW1/SW2 positions (Section 5.7)
5. The softkey "Calibrate" (C) gives possibilities to set
up for divert control and calibration, see Chapter 5.

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

2.7. K-PATENTS DIGITAL DIVERT CONTROL UNIT SPECIFICATIONS

Model:

DD-01

Enclosure:

IP66 Nema 4X, dimensions 226 x 267 mm (8.91 x 10.5 in)

Supply:

24 V DC, provided by the Indicating transmitters

Ambient temperature:

max 45 C (113 F)

Accessory:

Roofed mounting plate for the Divert Control Unit and 2 Indicating
transmitters, Figure 2.60.

Material:

AISI 316, dimensions 916 x 488 mm (36 x 19.2 in)

Figure 2.70

Divert Control Unit Mounting Plate: Dimensions (mm/in)

Figure 2.71

Divert Control Unit and Indicating Transmitter Enclosures: Dimensions (mm/in)

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

3. MOUNTING
For mounting of the process refractometer and the isolation valve, consult the separate Refractometer
PR-01-S(-EX/FM) Manual.
3.1. WIRING
Wiring for the complete system, see Figure 3.10 and Figure 3.11 which describe also all cables and how each
cable is connected.
The cables 1 and 2 are included in the delivery. The terminal strip positions of the Divert Control Unit are
specified in Figure 3.11 and Figure 3.12.

Figure 3.10

Divert Control System Wiring Cables and Connections

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

Figure 3.11

Divert Control System Wiring and Connections

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

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Figure 3.12

Cable connections

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

11

RN2

SW
12345678

C16

X2

IC8

IC25

IC21
C38

IC27

D13

K2

8 9 10 11 12 13 14

8 9 10 11 12 13 14

15 16

SERIAL BUS A

SERIAL BUS B

EXT24V

D17
D18

D23

D24

D25
R23

D26
R24

C49

R21 R22

D27

1A

RE1

V1

18

LN

SGND

R28

D30
RE2

19

AC-POWER

RE3

RE4

V4
V3

K5

17

D28
C51
R27

C50
R25
R26
D29

TP4

D31
V2

K4

C41
R12
R13
C42

R16

D2

F2

C40

D14
K3

IC30
L1

R11

RN7

D12

D9

TP3

C26

IC22
R9

C36

SWGND

R15

R14

IC19

C25
D16

R10

D8

K1

IC16

F1

D11

D20
D21
D22
C48 D19
R17
R18
R19
R20

C47

IC23

D7

C35 C52

IC29

IC13

C21

RN5

C33
C34

IC26

D6
D10

1A

C46

D5

C22

D15

C43

C31

R8
C30

C37

C23
1

IC11

C29

IC14
C44

C32

IC18

R7

RN6

IC28

C24

IC12

C19
C20

D1
C45

J2

C27
X1IC17
C28

RN4

GND

IC24

IC5
IC15

D4

IC20

IC4

D3

IC9

C14
IC1

TP2

C13

IC7

IC10

J1

C7

C18

C1
R2
C2
R3
C3
R4
C4
R5
C5
R6
C6

R1

C15

IC6

RN1

+5V

C39

C11

C17
SW1

IC3

C10

TP1

CONTROL UNIT

C12

IC2

C9

C8

PR-7310 Rev.C DIVERT

RN3

K-PATENTS

K6

20 21

22 23

WASH
A

WASH
B

RE5
V6

K8

RE7

RE8

V8

V5
K7

RE6

V7
K9

V9
K10

K11

K12

D32
63mA

63mA

F3

F4
K13

K14

VALVE
35 36 POSITION37 38 39 40
BYPASS BURNER
HORN
SOLIDS SOLIDS NORM.
OVERRIDE
REF.DIFF.
WARN. ALARM
DIVERT
24 25

26 27

28 29 30

31 32

33 34

DANGER HIGH VOLTAGE

Figure 3.13

Divert control circuit board, layout.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

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4. START-UP
For refractometer start-up consult the separate Refractometer PR-01-S(-EX/FM) Manual and the Mounting
and start-up check list.
4.1. DIVERT CONTROL UNIT START-UP
1.

Check the wiring and supply voltage.

Note: Before the power is switched on, the DIVERT output relay is in DIVERT position.

2.

Switch the power on for both Indicating transmitters.

The control system is now in the DIVERT mode, and the red DIVERT light is on.

3.

Press the LIGHT TEST button. All eleven lights should switch on.

4.

The upper right corner of the Indicating transmitter displays should now state a or b respectively. If
not, see Section 5.2.
If the message is "Removed from divert control" the refractometer is ready to "Restore to
divert control", softkey B.
If the message is "Solids warning" or "Solids alarm" then "Restore" provokes an alarm.
Press the ALARM RESET button.
For any other message, see Section 6.3.

5.

Observe that the VALVE STATUS lights follow the position of the valve.
Now the Divert Control System is set for normal monitoring operation.

6.

Check that the prism wash is working. Press the "Start prism wash", softkey A.

7.

When the SAFE % SOLIDS has turned on and also the other conditions for safe boiler operation are
satisfied, the DIVERT can be turned off using the RESET button.

4.2. DIVERT CONTROL SYSTEM TRIMMING

During the trimming of a new system, it is recommended to keep the key in the OVERRIDE position.
When the key is in the OVERRIDE position, the DIVERT action has to be initiated manually using the
EMERGENCY DIVERT button. This should be done when the green SAFE %SOLIDS light turns off.
The trim procedures are described in Chapter 5, the measurement calibration in Section 5.1 and the prism
wash in Section 5.6.
The key should be turned to the AUTOMATIC position only after it has been decided that sufficient experience has been gained.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

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5. CALIBRATION
The K-Patents Divert Control System is calibrated by the manufacturer. This chapter contains instructions how
to make the fine adjustment of the system.
5.1. REFRACTOMETER CONCENTRATION MEASUREMENT
For refractometer calibration consult also the separate Refractometer PR-01-S(-EX/FM) Manual.
The CONC% displays of the two Indicating transmitters have to show the same value. If there is a difference,
this can be eliminated by changing the Bias for one of the refractometers. Key in the sequence Calibrate / Parameters / CONC(RI) / Parameters / Bias. Comparison with sample determination can decide which one
should be corrected.
Example: If the Indicating transmitter of A displays CONC% = 63.2% and B displays CONC% = 63.8%, the
difference can be eliminated e.g. by lowering B by 0.6%. Read bias from the display of refractometer B. If
bias = 52.923 then enter a new bias = 52.323.
Due to its digital measurement principle, the readings of the K-Patents Process Refractometer do not drift by
time. Frequent recalibrations based on off-line moisture analysis must be avoided, as they will introduce random fluctuations to the refractometer readings.
If the concentration reading is noisy, the damping can be increased. Enter Calibrate / Parameters / CONC(RI) /
Damping time. The Damping time is the time in seconds for the signal to reach half of its final value after a
step change. Increase the damping time in small steps, and wait for the result.
5.2. REFRACTOMETER ACTIVATION FOR DIVERT CONTROL
When a refractometer is activated for Divert control, the upper right corner of the display shows alternatively
A, a, B, b or ?. If the corner is blank the divert function must be activated by pressing the sequence Calibrate/Parameters/Divert control/Divert control and select "1 Activated".
The program has to be version 4.0 or higher, otherwise "8 Divert control" is missing from the CALIBRATE
menu. The program EPROM has then to be changed to an up-dated version.
The decision to display A (a) or alternatively B (b) is not programmed, it depends on to which SERIAL BUS
port in the Divert unit (Figure 3.13) the Indicating transmitter is connected.
If a Divert activated refractometer is used in another type of application, the divert function has to be deactivated by selecting "0 Not activated". After de-activation all references to Divert functions disappear except "8
Divert control" in the CALIBRATE menu.
Note. If a message DIVERT CONTROL FAULT and a ? appear on the IT-R display, the reason is one of the
following:
1.

Cables between the IT-R and the terminals 8-14 on the DD-01 are not properly connected. Reconnect to fix.

2.

Communication 485 component IC 17 (A) or IC 19 C (B) is broken on the PR-7310 board inside
the DD-01. Replace board.

3.

Communication 485 component IC 1r is broken on the PR-7010 board inside the IT-R. Replace
board.

4.

Dip switch 3. is in the up position which means that the PR-7310 card is configured to work in
the remote mode. Change the dip switch back to low (=off) position.

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Effective: June 20, 2005

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5.3. SIGNAL DIFFERENCE ALARM
According to BLRBAC, if a difference of 2% solids (absolute value) or greater exists between refractometer
readings, an alarm shall be activated.
The alarm limit 2% can be changed from the keyboard using the sequence Calibrate/Parameters/Divert control/Ref. difference limit. If the deviation alarm trips seem too frequent, it may help to increase the signal
damping, Section 5.1.
Note. If the two refractometers have different limit values, the lower value is used by alarm system.
5.4. LOW ALARMS
The low alarm limits are set from the keyboard of the Indicating transmitter. Enter sequence Calibrate/Parameters/Divert control. The menu will show 3 Low conc warning limit and 4 Low conc divert
limit. The latter has a double function: Both LOW SOLIDS ALARM and DIVERT limit.
The Indicating transmitter display will carry the messages Solids warning and Solids alarm when the corresponding alarms occur.
Note. The alarm limits are set separately for the two refractometers. Each refractometer gives an alarm according to its own settings.
5.5. REFRACTOMETER MALFUNCTION ALARM
The built-in intelligent diagnostics of K-Patents Process Refractometer provides a tight control of the operation. A full test cycle is completed with an interval less than one second. A description of the microprocessor
implemented diagnostics is given below. For details consult the Instruction Manual of the refractometer PR01-S. Only errors classified as Equipment malfunctions will cause alarm and removal from the Divert control system. Process related faults will only cause a message in the Indicating transmitter display. See also
Section 6.3 for additional diagnostics.
The most important test is to check the signal coming from the digital image sensor during measurement. Improper function of light source, optical components, image sensor and sensor driver are recognized by this
test.
The compensation for temperature measurement is checked, both the temperature element and the A/D converter.
The cable between Sensor and Indicating transmitter is checked using a check sum method, thus recognizing
short circuits, open circuits and excessive disturbances.
The microprocessor system has also a self-checking test program to ensure the proper operation of the CPU
and the memories. The constants in the EEPROM memory are tested to be within strict limits of acceptance.
The performance of the microprocessor is of critical importance for the measurement control. A separate
hardware watch-dog circuit ensures the proper microprocessor operation by checking that the microprocessor
regularly sends out a predetermined pulse sequence. Another hardware circuit checks that the supply voltage
to the microprocessor is within safe limits, to prevent any brownout stray output pulses.
5.6. PRISM WASH
A prerequisite for a proper function of the divert system, is that the prism wash works. The TEST value in the
display should increase at least 20 steps during WASH, provided TEST is not close to its maximum value 248.
See Sections 8.1, 8.5 and 9.2 in PR-01-S Instruction Manual.

INSTRUCTION MANUAL FOR DD-01

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WASH TIMES
The wash times can be seen by pressing Display/System configuration/Wash times. The values set at delivery
are the following:
Preconditioning = 0 seconds
Wash time = 3 seconds
Recovery time = 30 seconds
Interval = 20 min
The wash times are changed by pressing the sequence Calibrate/Parameters/Prism wash.
Note maximum wash time is 30 seconds and maximum recovery time 30 seconds.
WASH CHECK
This function can be defined from the prism wash menu: Calibrate/Parameters/Prism wash/Wash test. A prism
wash is accepted if:
a.

TEST exceeds TEST limit

b.

TEST increases more than TEST difference

The default values of TEST limit and TEST difference are zero (0), which makes the wash check inactive.
If the wash is not accepted, the diagnostic message will be Prism wash failure.
A Wash retries parameter can also be set to repeat the wash if the wash check fails. The default value is zero
(0).
WASH STOP
Wash stop function can be defined from the prism wash menu. Wash can be prevented when the process temperature is below the set limit, thus indicating that the pipe is not in use. To activate the wash stop key sequence: Calibrate/Parameters/1. Prism wash/Wash stop/1. Active and set the temperature limit.
The default value for wash stop is inactivate. When the wash is not accepted the diagnostics message is Wash
stop/temp. limit.
EXTERNAL WASH STOP
An input switch can be configurated to an external wash stop to prevent the prism wash when the corresponding input switch is connected. External wash stop-message will show when automatic wash is activated from
the soft keys. The input switch can be set to protect the refractometer e.g. if the process is stopped.
AUTOMATIC SINGLE DIVERSION CONTROL DURING PRISM WASH CYCLE
Automatic single (one-of-two) diversion control will take place if either of sensors are in prism WASH cycle.
5.7. DIVERT DECISION RULES
TWO REFRACTOMETERS IN OPERATION:
BLRBAC states the following: For the solids measurements, two refractometers in series must be used. When
both refractometers are in service, the requirement for an automatic black liquor diversion can be satisfied by
either of the following options:
1.

If either refractometer reads dissolved solids content 58% (default) or below, an automatic
black liquor diversion must take place.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

16
2.

When both refractometers read dissolved solids content 58% (default) or below, an automatic black liquor diversion must take place.

Either option is satisfactory.

The rules are listed in decreasing order of security. Only rule 1 satisfies the high safety requirements set by
BLRBAC, August, 1982. On the other hand, the probability of false trips decreases with decreasing safety. It
means that if false trips are too frequent, the rule 2 may be preferred at the cost of safety. The rule 2 has later
been accepted by BLRBAC.
A third conceivable alternative is to base the decision on only one refractometer (the master) and use the other
refractometer (the slave) for comparison only (and difference alarm). Concerning security and false trips, this
rule is a compromise between rules 1 and 2.
The divert decision rule is selected by the switch SW on the divert control board (Figure 3.13). ON position is
upwards.

Switch SW
SW1
SW2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
Table 5.70

Rule
One-of-two (BLRBAC)
A master, B slave
B master, A slave
Two-of-Two

Rule 1
Rule 2

Divert decision rule selection.

ONLY ONE REFRACTOMETER IN OPERATION:

When only one instrument is IN OPERATION the divert action takes place if this instrument reads 58 % or
below. The status of SW (Table 5.70) has no influence on the divert decision in this case.
NO REFRACTOMETER IN OPERATION:
If both instruments are out of operation (due to malfunction or maintenance), then according to BLRBAC
divert action must take place. See also Section 8.7 about external DC supply.
REMOTE DIVERT SWITCH CONFIGURATION
Switch SW
SW 3
OFF
ON

Rule
DD-01 normal operation
Remote divert card activated
See Section 8.8.

See Section 5.2 if you have on the screen the message DIVERT CONTROL FAULT.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

17

6. MAINTENANCE
As the Divert Control System is a pure digital system, no special maintenance is needed. The LIGHT TEST
button on the operator panel (Figure 2.50) sends a signal to the microprocessor, and the microprocessor
switches all 11 LED lights on as long as the button is pressed. This way not only the lights but also the processing system is checked.
To assist the identification of a faulty component, the information flow and the circuit diagrams are given in
Sections 6.1 and 6.2. Also the logic diagrams of Chapter 7 may be of help.
6.1. INFORMATION FLOW
The power and information flow of the total Divert system is shown by Figure 6.10. Additional information
about the cable connections is found in Figures 3.10, 3.11 and 3.12.

Figure 6.10

Information and power flow.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

18

6.2. DIVERT CONTROL CIRCUIT BOARDS

The component lay-out of the divert control circuit board is shown by Figure 3.12 and the circuit diagram by
Figures 6.20 to 6.25.

Figure 6.20

Operator panel board, component layout.

Figure 6.21

Operator panel PR-7311 circuit diagram, page 2 of 2

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

19

Figure 6.22

Operator panel PR-7311 circuit diagram, page 1 of 2.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

TXD0
RXD0

TXD1
RXD1

INT1

+5V

R8

3K32

10R0

6
WDI
1
2 VCC

+5V

GND
3 48

RESET

C25

2 100n

10K0

R7

IC18
MAX699

RN1 1

+5V

32.0MHz

X1

C26

RN4

1
1
1
1
1

2 100n

C24

6
8
7
9
5

C22

2 100n 2 100n

10K0

RN5
RN5
RN5
RN5
RN5

RN5 2

10K0

RN5

1
RN5 4
1
3

10K0
1
RN4 4
1
6
1 RN4 5
RN4 3
1

C23

+5V

2 100n

14
VCC Osc.
1 N.C. OUT 8
7
GND

+5V

P2.7
P2.6
P2.5
P2.4
P2.3
P2.2
P2.1
P2.0

INT4
INT3
INT2
INT1
INT0

T0IN
T0OUT
T1IN
T1OUT

HOLD
HOLDA
NCS
ERROR
PEREQ

RESIN
PDTMR
NMI
TEST
READY

2 22
43 63
VSS
65 84

1 23 VCC
42 64

A19
A18
A17
A16
AD15
AD14
AD13
AD12
AD11
AD10
AD9
AD8
AD7
AD6
AD5
AD4
AD3
AD2
AD1
AD0

UCS
LCS
P1.7
P1.6
P1.5
P1.4
P1.3
P1.2
P1.1
P1.0

RESOUT
S2
S1
S0
ALE
BHE
RD
WR
DEN
DT
LOCK

83
82
81
80
79
77
75
73
71
69
67
62
78
76
74
72
70
68
66
61

30
29
19
20
21
24
25
26
27
28

38
8
9
10
6
7
4
5
11
16
15

CLOCKOUT 44

80C186EB

51
52 CTS0
TXD0
53
RXD0

49
50
54
56
55
59
58
57

35
34
33
32
31

46
45
48
47

13
12
60
3
39

37
36
17
14
18

41 CLKIN
40
OSCOUT

IC15

16bit MICROPROCESSOR

+5V

AD19
AD18
AD17
AD16
AD15
AD14
AD13
AD12
AD11
AD10
AD9
AD8
AD7
AD6
AD5
AD4
AD3
AD2
AD1
AD0

SRLY
ISOSW
SSER2
SDISP

RESOUT

RESET

AD7
AD6
AD5
AD4
AD3
AD2
AD1
AD0

AD15
AD14
AD13
AD12
AD11
AD10
AD9
AD8

AD19
AD18
AD17
AD16

1Q
2Q
3Q
4Q
5Q
6Q
7Q
8Q

1Q
2Q
3Q
4Q
5Q
6Q
7Q
8Q

1Q
2Q
3Q
4Q
5Q
6Q
7Q
8Q

74HC573

1 OC
11
C
2
1D
3
4 2D
3D
5
4D
6 5D
7
6D
8 7D
9
8D

IC10

74HC573

1
OC
11 C
2
1D
3 2D
4
5 3D
4D
6
5D
7 6D
8
7D
9 8D

IC7

74HC573

1 OC
11
C
2
1D
3
2D
4 3D
5
6 4D
5D
7
6D
8 7D
9
8D

IC3

19
18
17
16
15
14
13
12

20
10

19
18
17
16
15
14
13
12

20
10

19
18
17
16
15
14
13
12

20
10

C9

C13

C18

A7
A6
A5
A4
A3
A2
A1
A0

2 100n

+5V

A15
A14
A13
A12
A11
A10
A9
A8

2 100n

+5V

A18
A17
A16

2 100n

+5V

A17
A16
A15
A14
A13
A12
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1

A18

A0

C8
14

HC32

IC2

38
37
36
35
34
33
32
31
29
28
27
26
25
24
23
22
21

3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19

11
30

40

11

O15
O14
O13
O12
O11
O10
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0

27C210

NC
A15
A14
A13
A12
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
A0

2
20 CE
OE
39 PGM

IC8
+5V
1 VPP

13

HC32

12

IC2

HC32

IC2

10

5
7

2 100n
4

64K x 16bit EPROM

INSTRUCTION MANUAL FOR DD-01

C14

AD15
AD14
AD13
AD12
AD11
AD10
AD9
AD8
AD7
AD6
AD5
AD4
AD3
AD2
AD1
AD0

2 100n

+5V

A15
A14
A13
A12
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1

A15
A14
A13
A12
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1

1
26
2
23
21
24
25
3
4
5
6
7
8
9
10

IO8
IO7
IO6
IO5
IO4
IO3
IO2
IO1

55257

A14
A13
A12
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
A0

IC4

55257

IO8
IO7
IO6
IO5
IO4
IO3
IO2
IO1

IC5

A14
A13
A12
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
A0

20 CE
22
OE
27
W

1
26
2
23
21
24
25
3
4
5
6
7
8
9
10

20 CE
22
OE
27
W

32K x 8bit SRAM

Figure 6.23
32K x 8bit SRAM

+5V

AD7
AD6
AD5
AD4
AD3
AD2
AD1
AD0

100n

C10

+5V

AD15
AD14
AD13
AD12
AD11
AD10
AD9
AD8

2 100n

C11

+5V
1

AD0-15

A0-9

19
18
17
16
15
13
12
11

14

28

19
18
17
16
15
13
12
11

14

28

RD
WR

20

Divert control board PR-7310 circuit diagram. Page 1 of 3.

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

10
12
14
40
44
46

SSER2
RESOUT

RD
WR

A1-3

1
2
3
4
5
6
7
8

16
15
14
13
12
11
10
9

R25

EMERGENCY DIVERT

DIVERT RESET

OVERRIDE

100n 2

D30

ALARM RESET

C50

R28

3K3

3K3

SA5.0

LAMP TEST

SW8

SW1

R27 2

500R

SA5.0 2

D31

1 1N4007

D29

1 F4

C51

R6

1
TP4
2

2 100n

D28

D27

SWGND
TEST POINT

R5

R4

C6

+5V

R3

C5

C4

C2

R1

2 100R1
1

C3

R2

C42

2 100n

C41

2 100n

+5V

C1

KN6

KN5

KN4

KN3

KN2

KN1

RD

ISOSW

2
2
2
2
2
2
100n 100n 100n 100n 100n 100n

+5V

VO2 6
GND 5

VO1

VCC

HCPL2731

3
4 22+

1
1+
2
1-

IC29
8

4
VCC
1
GND

NME0505D

5
VOUT
7
0V

KN1
KN2
KN3
KN4
KN5
KN6

AD0
AD1
AD2
AD3
AD4
AD5
AD6
AD7
A1
A2
A3

DIP8
DIP7
DIP6
DIP5
DIP4
DIP3
DIP2
DIP1

D0
D1
D2
D3
D4
D5
D6
D7

1
74HC05

21

X2
15
DTR
16
RTS
6
TXD
5
INT 13
RXD
RI 10
CTS 14
11
DSR 12
DCD

X1

VSS

VCC

IC23

20 RD
19
18 WR
CS
17
RESET

22
A0
23
24 A1
A2

25
26
27
28
1
2
3
4

IC9

20
1
&
G1
EN
19
10
G2
18
2
Y1
A1
17
3
Y2
A2
16
4
A3
Y3
15
5
A4
Y4
14
6
A5
Y5
13
7
A6
Y6
12
8
A7
Y7
11
9
A8
Y8
HC541

IC6

1
20
&
G1
EN
19
10
G2
18
2
Y1
A1
17
3
Y2
A2
16
4
A3
Y3
15
5
A4
Y4
14
6
A5
Y5
13
7
A6
Y6
12
8
A7
Y7
11
9
A8
Y8
HC541

IC1

82510

AD0-15

J1
J1
J1
J1
J1
J1

1N4007
2
D32
1

X14 2

X14 1

BURNER

X13 2

X13 1

R26 2
1

C40

2 100n

RN2

RN1 1
7

RN2 1

500R
3K32

RN2 1
9

RN1 1
6

7 RN2 1
1

RN1 1

RN2 1

5 RN1 1

Opto-isol.

RN2 1

RN1 1

RN2 1

RN2

1 F3

2
1
3K32

2
1 1K

BYPASS

1K

R13
2
R12
1

IC28
DC/DC
conv.
C7

C12

C17

1
74HC05

IC23

INT1

2 100n

+5V

AD15
AD14
AD13
AD12
AD11
AD10
AD9
AD8

2 100n

+5V

AD0-18

AD0
AD1
AD2
AD3
AD4
AD5
AD6
AD7

2 100n

+5V

C16

11

C15

1
74HC05

IC23

CTS

RXD

TXD

RTS

13
7

100n 2
10

C38

9
12
6
15
5
16
2
19

20
10

2 100n

+5V

C31

2 33pF

18.432MHz
1
2

X2

C37

1Q
2Q
3Q
4Q
5Q
6Q
7Q
8Q
HC273

2 100n

+5V

1D
2D
3D
4D
5D
6D
7D
8D

IC20

1
R
CLR
11
C1
CP

AD0 8
AD113
AD2 7
AD314
AD4 4
AD517
AD6 3
AD718

2 33pF

HC32

C28
D4

12

HCPL2731

GND

VO2

VO1

VCC

IC26

3
24
2+

HCPL2731

GND

VO2

VO1

1
74HC05

IC23

IC23
1
74HC05

5
VOUT
7
0V

1
1+
2
1-

IC24
VCC

3
24
2+

IC23
14

NME0505D

1 1+
2 1-

+5V

D3

+5V

1k00

IC27
DC/DC
conv.

4
VCC
1
GND

2 100n

1
74HC05

RN7

1K0

RN1

Opto-isol.

WR

5
1
RN7 1
4
RN7 1
3
RN7 1
2

RN3 1
3

RN3 1
2

Opto-isol.

RN6

1K0
2
1
RN6 1
4

IC2

C52
2 100u

TP3

C33

TXDI

RXDI

11

10

12

13

C35

RTSI

2 100n

5VSER

2 100n
CTSI

SA5.0

D9

LTC485

C30

C1+

C2-

C2+

C1-

VCC
+9V
-9V
OFF
GND

15

14

17
3
7
18
16

2 100n

2 100n

IC25
LT1180

DO
GND

DE

DO

VCC

C27

D6

C34

SGND

SD

RD

UARTS

UACTS

2 100n 2 100n

3 K2A

4 J2

1 J2

2 J2

3 J2

6 J2

5 J2

(10)

1 K2A (8)

2 K2A (9)

3 K1A (10)

1 K1A (8)

2 100n

A
2 K1A (9)

C32

SER1+

D5
2
SA5.0 SA5.0

D8

SER1-

2
SA5.0 SA5.0

C36

D7

SER0+

SER0-

+5V

+5V

GND

DO

DO

VCC

LTC485

IC17

IC19

DI

DE

RE

RO

4 DI

RE

RO

1
SGND
2
TEST POINT

2 100n

TXD1

TXD0

RXD0

RTS

D12

C39
1

5 RN3 1
1k00

2 D10

RN6

2 10R0 1

1
4

RN3
3 RN6 1
5
1

INSTRUCTION MANUAL FOR DD-01

R11

Figure 6.24
POWER

RESET

21

Divert control board PR-7310 circuit diagram. Page 2 of 3.

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

J1 47
J1 49

A (14) K1C 2
B (14) K2C 2

(16) K3 2

(15) K3 1

(11) K2B 1
B (12) K2B 2
(13) K2C 1

GND

EXT24V

SR224V

VIO24V

11

SR124V

HC32

IC16

13

HC32

IC16

14

HC32

IC16

12

10
7

(11) K1B 1
A (12) K1B 2
(13) K1C 1

2 100n

1 C21

WR

+5V

SDISP

RESET

HC32

IC16

AD8
AD9
AD10
AD11
AD12
AD13
AD14
AD15

AD0
AD1
AD2
AD3
AD4
AD5
AD6
AD7

AD0
AD1
AD2
AD3
AD4
AD5
AD6
AD7

D17

D16
2 1
1N4007

IC14

1
CLR
11
CP
3
1Q
1D
4
2Q
2D
7
3Q
3D
8
4Q
4D
13
5Q
5D
14
6Q
6D
17
7Q
7D
18
8Q
8D
HC273

1
CLR
11
CP
3
1D
1Q
4
2D
2Q
7
3D
3Q
8
4D
4Q
13
5D
5Q
14
6D
6Q
17
7D
7Q
18
8D
8Q
HC273

IC11

IC21

1
CLR
11
CP
3
1D
1Q
4
2D
2Q
7
3D
3Q
8
4D
4Q
13
5D
5Q
14
6D
6Q
17
7D
7Q
18
8D
8Q
HC273

D11 D13 D14

R16
4K7

SRLY

R9
4K7

.
.

2 1
1N4007
1N4007
D18

1
.

1A

F1

2
5
6
9
12
15
16
19

20
10

2
5
6
9
12
15
16
19

20
10

2
5
6
9
12
15
16
19

20
10

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

1 C48

Q0
Q1
Q2
Q3
Q4
Q5
Q6
Q7

Q0
Q1
Q2
Q3
Q4
Q5
Q6
Q7

Q0
Q1
Q2
Q3
Q4
Q5
Q6
Q7

1 C49

18
17
16
15
14
13
12
11

18
17
16
15
14
13
12
11

2 2u2
.

SS FRC OSC
15 11 14

1 C43

IC30

15K0
1 C46

GND

13
12

FB 10

VOUT 2

2 33n 2 2n2

1 C47

4
5

L4962

7 VIN

ULN2803A

D0
D1
D2
D3
D4
D5
D6
D7

RE1
RE2
RE3
RE4
RE5
RE6
RE7
RE8

10 VIO24V
DCOM
GND 9

IC13

ULN2803A

D0
D1
D2
D3
D4
D5
D6
D7

18
17
16
15
14
13
12
11

VIO24V

DCOM 10 VIO24V
GND 9

IC12

ULN2803A

D0
D1
D2
D3
D4
D5
D6
D7

DCOM 10
GND 9

IC22

2 SA26 2 100u 2 33nF

1 D15

VIO24V

2 100n

1 C20

+5V

2 100n

1 C19

+5V

2 100n

1 C29

L1
150uH

4K64

2 BYV27/50

1 D2

C45
2 220u

WARN

C44
2 220u

OUT8

OUT7

OUT6

OUT5

OUT4

TP1
+5V

D1

TEST POINT

1 2

TP2
GND

TEST POINT

1 2

39 J1

38 J1

36 J1

37 J1

35 J1

32 J1

30 J1

28 J1

29 J1

27 J1

26 J1

25 J1

22 J1

20 J1

21 J1

19 J1

SA5.0

+5V

BURNER

VBYPASS

DIVERT

OVERRIDE

SAFE

BOPER

AOPER

MALFUNC

REFRDIF

ALARM

RE1-8

RE8

RE7

RE6

RE5

RE4

RE3

RE2

RE1

VIO24V

2
2 1
R24
4K7

AD0-18

1
R15
2

.
.

R10
2
4K7
1

1
R14
2

D19

D20

D21

D22

D23

D24

D25

D26
1

12 5

9 8

16

16

16

16

16

16

16

16

.
.
.
.

1
2
2 1
R23
4K7
1
2
2 1
R22
4K7
1
2
2 1
R21
4K7
1
2
2 1
R20
4K7
1
2
2 1
R19
4K7
1
2
2 1
R18
4K7
1
2
2 1
R17
4K7
1

V9
V8
V7

RE8
RE7
RE6
RE5
RE4
RE3
RE2
RE1

2
1
2
1
2

.
.
.
.
.
.

1
2
1
2
1
2

.
.
.
.
.
.

1
2
1

V5
V4
V3
V2
P

V1

INSTRUCTION MANUAL FOR DD-01

.
.

Figure 6.25
2
1

+5V

F2
1A

V6
2

3 K4

2 K4

1 K4

2 K5

A WASH

2 K6
1 K5

B WASH

2 K7
1 K6

LINE

SOLIDS WARN.

2 K8
1 K7

SOLIDS ALARM

2 K9
1 K8

DIVERT/NORM

2 K10
1 K9
3 K9

HORN

2 K11
1 K10

REF. DIFF

2 K12
1 K11

NO MALF.

1 K12

22

Divert Control board PR-7310 circuit diagram. Page 3 of 3.

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

23
6.3. DIAGNOSTIC MESSAGES
For diagnostic messages in the Indicating transmitter display, see the PR-01-S manual. The following messages appear only in divert systems:
-

"In divert control operation" or "Removed from divert control", Section 2.6.

"Solids warning" and "Solids alarm", Section 5.4.

** Divert control fault **

This message indicates that there is no communication to the divert control unit, probably cable error, Figure
3.12, cable 2.
If the instrument is not applied in a divert control system, de-activate the divert function, see end of Section
5.2.
Further the message ** Relay unit fault ** may appear. This indicates that the Relay unit PR-7080 functions
are defined, but no Relay unit is connected. Normally a Relay unit is not used in a Divert system because the
wash contacts are in the Divert control unit. Clear the relay functions by the key sequence Calibrate/Relay unit
and select an "0 Not Defined" for all four relays. For using an optional relay unit, see PR-01-S Manual, section 9.1.
6.4. DIAGNOSTIC LIGHTS
The Divert circuit board, Figure 3.12, contains the following diagnostic LEDS:
D3

Processor cycles: should flash

D4

Processor reads serial bus: should flash

D10

Serial bus A input: should flash

D11

On if 24 V DC supply from A is OK

D12

Serial bus B input: should flash

D13

On if 24 V DC supply from B is OK

D14

On if external 24 V DC is applied

D19

Wash relay A on

D20

Wash relay B on

D21

Solids warning relay on

D22

Solids alarm relay on

D23

Divert relay on = not DIVERT (Section 2.2)

D24

Horn on

D25

Refractometer difference relay on = difference alarm

D26

Override

D27

Valve to bypass

D28

Valve to burner

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

24

6.5. PUSH-BUTTON ASSEMBLY

Before removing the push button or the lockable Override/Automatic switch from the front panel turn the
screw 1/4 to the left, Figure 6.50. This will release the contact element.

Figure 6.50

Securing and removal of the contact element.

6.6. FUSES
The following fuses are printed on circuit board PR-7130:
Fuse F1:

Microfuse IEC 127-3/1

DC Power (24 VDC) main fuse. Protects UL 198G 1A, fast

divert electronics againts wrong voltages especially from external DC supply.

Fuse F2:

5 x 20 mm fuse
IEC 60127, 1A, fast

AC supply to solenoid valves. Protects cable and coil, if faults

appear.

Fuses F3, F4:

Microfuse IEC 127-3/1,

Fuses protect switch of divert valve position UL 198G 63 mA,

fast feedback. Any external voltage connected to these circuits
causes fuse blow.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

25

7. DIVERT CONTROL LOGIC

A logical description of the system is provided as a complement to the previous information about the electronics.
7.1. BLOCK DIAGRAM
The block diagram Figure 7.10 shows the connections between the different logical subsystems.

Figure 7.10

Block diagram of the divert control system

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

26
7.2. LOGICAL DIAGRAMS

Figure 7.20

The operation logics.

Figure 7.21

The divert decision logics.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

27

Figure 7.22

The alarm decision logics.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

28

Figure 7.23

The alarm system.

7.3. SAFETY DECISION LOGICS

The logical description of the Safety Decision Logics in Figure 7.10 is given by the following tables:
- Table 7.30 One - of - two
- Table 7.31 A master, B slave
- Table 7.32 Two - of - two
Note. NOT OPERATING includes the wash cycle.
See also Section 5.7.
A
<58

OPERATING

NOT OP

OPERATING

NOT OP

<58 OPERATING

Unsafe

Unsafe

Unsafe

Unsafe

NOT OP

Unsafe

Unsafe

Safe

Unsafe

>58 OPERATING

Unsafe
Unsafe

Safe

Safe

Safe

Unsafe

Safe

Unsafe

NOT OP

Table 7.30

>58

One-of-two decision rule

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

29

A
<58

Table 7.31

>58

OPERATING

NOT OP

OPERATING

NOT OP

<58 OPERATING

Unsafe

Unsafe

Safe

Unsafe

NOT OP

Unsafe

Unsafe

Safe

Unsafe

>58 OPERATING

Unsafe

Safe

Safe

Safe

NOT OP

Unsafe

Unsafe

Safe

Unsafe

A master, B slave
A
<58

Table 7.32

>58

OPERATING

NOT OP

OPERATING

NOT OP

<58 OPERATING

Unsafe

Unsafe

Safe

Unsafe

NOT OP

Unsafe

Unsafe

Safe

Unsafe

>58 OPERATING

Safe

Safe

Safe

Safe

NOT OP

Unsafe

Unsafe

Safe

Unsafe

Two-of-two decision rule

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

30

8. OPTIONAL CONFIGURATIONS

8.1. REMOTE DIVERT CONTROL UNIT

The remote divert control unit is an option of the digital divert control system DD-01, see Figure 8.20.
The remote divert control unit operates as a main unit, which means that the master divert unit is for indication
only. If the remote divert control unit is not in operation, the master divert unit in the field operates as a main
unit.
The remote control unit communicates with the master divert unit in the field through a modem. Connection
and wiring is made according to Figure 8.40.
For contact terminals see Figure 8.41. Contact terminals 24 and 25 are for communication OK signal.
8.2. EQUIPMENT

Figure 8.20

Complete remote divert control system.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

31
8.3. REMOTE DIVERT CONTROL UNIT IN THE CONTROL ROOM

Figure 8.30

Operators panel and functions of the remote divert control in the control room.

The remote divert control unit contains all information for the deviation decision. The operation is clearly
indicated with LED lights as follows:

1. A row of four alarms (indicating Black liquor SOLIDS WARNING (at 60%), Black liquor SOLIDS ALARM (below 58%), Refractometer reading more than 2% absolute difference, and Refractometer malfunction).
2. Each refractometer A and B has an
OPERATING green light, so the operator
knows when he can rely on the refractometer
measurement.
A refractometer will influence the divert decision only when the green OPERATING light is
on. A malfunctioning refractometer is automatically taken out of operation.
3. One green indicator light SAFE% SOLIDS,
based on the two refractometers and the divert
decision rules.
4. A red OVERRIDE warning light.
5. One red DIVERT light that will be switched
on when the SAFE% SOLIDS goes off, providing OVERRIDE is off. The DIVERT light
indicates divert status of the divert relay.

INSTRUCTION MANUAL FOR DD-01

6. Two indicator lights for the divert valve

status. TO BY-PASS/TO BURNER from microswitches on the valve. For intermediate
valve positions both lights are off.
7. A lockable Override/Automatic switch.
8. One RESET push-button for the DIVERT
action. The DIVERT action always has to be
manually reset. If the override swithc is in
automatic position and SAFE% SOLIDS is off,
the DIVERT cannot be reset.
9. EMERGENCY DIVERT push-button.
10. A light test button switches all 11 lights on.
11. An alarm reset button resets the alarm
lights.
12. Communication to MASTER DIVERT ok,
indication light blinking.
13. Power supply ok, indication light on.
Note when remote divert in use, master divert unit in the field is for indication only!

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

32
8.4. WIRING AND MOUNTING
For wiring of the complete system, see Figure 8.40, which also specifies the cables and connections.

Figure 8.40

Digital Divert Control System with Remote Divert Control Unit Wiring.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

33

Figure 8.41

Remote Divert Control Unit terminals.

Figure 8.42

Digital Divert Control System: Remote Divert Control Unit mounting.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

34
8.5. SERIAL OUTPUT
Each Indicating transmitter has a serial output not used by the Divert Control unit. This serial output is selectable RS-232/RS-485 (see PR-01-S Manual) and contains concentration, temperature and error data. It contains
also information whether the refractometer is in divert operation or not.
Possible uses of the Serial output: To communicate with a computer substituting the Divert Control unit.
8.6. CURRENT OUTPUT SIGNAL
Each Indicating transmitter provides a 4-20 mA output concentration signal not used by the Divert system. To
calibrate this signal for suitable %Solids range, press Calibrate/Output signal/Current output, see PR-01-S
Manual.
8.7. EXTERNAL DC POWER SUPPLY
The Divert Control unit may be connected to a DC power supply as a back-up. At AC power failure the refractometers will black-out, but the Divert Control unit will still work. In this case the DIVERT signal can be prevented by turning the key to OVERRIDE. Terminals are 15 (+24VDC) and 16 (ground).
The power requirement is 24 VDC, 500 mA.
8.8. DIVERT CONTROL UNIT CARD IN THE REMOTE UNIT
In the remote unit the divert control card the third dip switch SW3 must be in the ON position (up).
See Figure 3.13 and Sections 5.2. and 5.7.

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005

35

9. DIVERT CONTROL UNIT PARTS LISTS

9.1. DIVERT CONTROL UNIT AND OPTIONAL REMOTE DIVERT CONTROL UNIT

ltem
1
1.1

Pcs.
1
7

Part No.

2.
3.1
3.2
3.3

1
1
1
1

PR-7310

4
5

1
1

PR-7028
PR-7311

Description
Enclosure
Conduit hubs 1/2
NPT-Type ST-1 (US)
Divert Control Unit
Card
Modem transformer
Modem card
Modem cable
Ribbon cable
LED Display card

INSTRUCTION MANUAL FOR DD-01

Item
6.1
6.2

Pcs.
2
1

Part No.
PR-6551
PR-6551

6.3

PR-6551

6.4

PR-6552

7.

PR-6501

Description
Switch unit, green
Switch unit, red for Emergency divert
Switch unit, green for Emergency divert reset
Lock unit for Automatic/Override divert operation
Divert Fuse set: 9 fuses (3 x
Microfuse 1A, fast IEC 1273/1, UL 198G; 3 x 5x20mm
Fuse 1A, fast; 3 x Microfuse
63 mA, fast IEC 127-3/1, UL
198G)
DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005

36
9.2. REMOTE DIVERT CONTROL UNIT

ltem

Pcs.

Part No.

Description

6.1
6.2
6.3

2
1
1

PR-6551
PR-6551
PR-6551

6.4

PR-6552

8.1
8.2
8.3

Switch unit, green

Switch unit, red for Emergency divert
Switch unit, green for Emergency divert
reset
Lock unit for Automatic/Override divert
operation
PR-7310-RACK
RACK-modem
RACK Power 24V

INSTRUCTION MANUAL FOR DD-01

DOCUMENT/REVISION: IMD 1/5

Effective: June 20, 2005