SIMULATION NO
DEVICE
1
AC
AIR CONDITIONER
UTM
NA
2
AHU
AIR HANDLER
UTM/TRANE
TROUBLE ALARM
UTM/TRANE
SUPPLY FAN 1 FAIL
3
DFF
DEWATERING FACILITY FAN
UTM
MOTOR OVERLOAD
4
TIT
TEMPERATURE TRANSMITTER
UTM
NA
5
TSHL
THERMOSTAT
UTM
NA
6
ULIT
ULTRASONIC LEVEL TRANSMITTER
HELIX/ZAK
TANK FULL LEVEL
Place a reflective surface at know distances from transmitter
6A
HELIX/ZAK
TROUBLE ALARM
Simulate it from the Transmitter or breaking the analog loop by disconnecting wire
6B
HELIX/ZAK
A PROCESS VARIABLE
6C
HELIX/ZAK
TANK HIGH HIGH LEVEL
CORTECH
VFD FAIL
CORTECH
MOTOR HIGH TEMP
Lower the setpoint trip temperature of the TSE relay module to below ambient temperature. Reset to 20-30 deg greater than ambient after test
complete.
CORTECH
LOW SUCTION PRESSURE
Option 1. If you can change trip pressure raise it to above the actual suction pressure until trips and then reset to desired trip pressure. Option
2. If you can't change (or won't), ensure there is liquid in the suction housing (can rig some flush water through cleanout port), run the pump at
low speed and close the suction valve. If doesn't trip in 1-2 min (without flush), then reopen valve and investigate pressure switch.
FACILITIES ENG
LONG TRAVEL VFD TROUBLE
2A
7
IBPMP
INDUSTRIAL WATER BOOSTER PMP
7A
7B
8
CRN
BRIDGE CRANE
PROVIDER
RECOMMENDED SIMULATION
ABBREV.
FOR
8A
FACILITIES ENG
CROSS TRAVEL VFD TROUBLE
8B
FACILITIES ENG
HOIST MOTOR CONTROLLER TROUBLE
SILO CAKE HANDLING
HART Communicator
Simulate using the transmitter or 4-20 ma loop generator or HART communicator
Simulate using 4-20 ma loop or HART
Simulate by removing the output wires from VFD
LOW OIL LEVEL HPU
HIGH OIL TEMP AT HPU
9B
SCHWING
SOFT START FAULT
9C
SCHWING
OIL HIGH PRESSURE AT HPU
Change the set point to a lower value
9D
SCHWING
24VDC TROUBLE
Pull the fuse for 24VDC power supply
9E
SCHWING
DIRTY OIL FILTER #1 AT HPU
Change the DP set point or simulate it with 4-20 ma loop
9F
SCHWING
DIRTY OIL FILTER #2 AT HPU
Change the DP set point or simulate it with 4-20 ma loop
9G
SCHWING
SCREW FEEDER HIGH PRESSURE (JAMMED)
Set the set point to a lower value
9H
SCHWING
SLIDE FRAME HIGH PRESSURE (JAMMED)
Set the limit switch out of range
9I
SCHWING
AUTOMATIC GREASER FAULT
Jumper the wires at Greaser
9J
SCHWING
PUMP S2 SPEED CHANGE
Change the speed from HMI
9K
SCHWING
PUMP S3 SPEED CHANGE
Change the speed from HMI
9L
SCHWING
0% PUMP SPEED
Change the speed from HMI
9M
SCHWING
0% SCREW FEEDER SPEED COMMAND
Change the speed from HMI
9N
SCHWING
0% SLIDE FRAME SPEED COMMAND
Change the speed from HMI
9O
SCHWING
SLIDE FRAME EXTENDED POSITION
Manualy extend from the panel
9P
SCHWING
SLIDE FRAME RETRACTED POSITION
Manulay Retract from the panel
9Q
SCHWING
SLIDE GATE OPENED
Remote open and wait for feedback
9R
SCHWING
SLIDE GATE CLOSED
Remote close and wait for feedback
9S
SCHWING
0% PUMP INLET PRESSURE (AT PRESSURE TRANSMITTER)
Use hand held programmer or transmitter itslef to simulate the displays
9T
SCHWING
0% LEVEL AT RADAR LEVEL TRANSMITTER 1
Use hand held programmer or transmitter itself to simulate the displays
9U
SCHWING
0% LEVEL AT RADAR LEVEL TRANSMITTER 2
Use hand held programmer or transmitter itself to simulate the displays
9V
SCHWING
RTD
CPMP
CENTRATE PUMP
10A
10B
XYLEM
VFD FAIL
XYLEM
MOTOR HIGH TEMP
XYLEM
LOW LOW WET WELL LEVEL
UTM
TROUBLE ALARM
Jumper the wires on sensor
Jumper the fault contact
Verify that all RTD'S are reading close to each other. If one is different there is an issue. If possible remove the probe and apply heat, if not
possible disconnect one wire and verify the loss of connection.
Remove the output wires to simulate fault
Unplug wire at controller
Manually actuate the switch
11
CHR
CHILLER
12
HTR
HEATER COIL
UTM
NA
13
CVY
CONVEYORS
SCHWING
VFD FAIL
SCHWING
MOTOR HIGH TEMP
HELIX/ZAK
GAS DETECTED ALARM
Use manufacturer gas test kit
HELIX/ZAK
NO GAS DETECTED
Use manufacturer gas test kit
13A
14
CGAT
COMBUSTIBLE GAS DETECTOR
14A
NO SIMULATION REQUIRED
Remove the outgoing wires to motor from VFD and turn on VFD
Disconnect the High Temp contact from MCC
Use a hand pump calibrator
15
PDIT
DIFFERENTIAL PRESSURE TRANSMITTER
METPRO
PROCESS VARIABLE (IF AVAILABLE)
16
ORPAIT
ORP ANALOG TRANSMITTER
METPRO
TRANSMITTER TROUBLE
Use ORP transmitter for simulation
METPRO
PROCESS VARIABLE (IF AVAILABLE)
Use ORP transmitter for simulation
METPRO
TRANSMITTER TROUBLE
Use ORP transmitter for simulation
METPRO
PROCESS VARIABLE (IF AVAILABLE)
USE ph Transmitter for simulation
MISCO
OVERLOAD
18A
MISCO
REMOTE CURRENT TRIP
18B
MISCO
MOTOR HIGH TEMP
16A
17
PHAIT
PH ANALOG TRANSMITTER
17A
18
GDR
GRINDER
By control panel manufacturer
Remove the sensor from oil and verify the change of state
SCHWING
SCHWING
10
SCH
Manually trip overload device in MCC bucket
9A
9
COMMENTS
Manually trip overload device in MCC bucket
Unplug wire at MCC
By control panel manufacturer
Lift L3 to create PHASE LOSS trouble.
19
MOVOC
MOTOR OPERATED VALVES
CSAMSCO
TROUBLE
20
IF
INLINE FAN
DANIEL CO
MOTOR OVERLOAD
Manually trip overload device in MCC bucket
20A
DANIEL CO
MOTOR HIGH TEMP
Unplug wire at controller
20B
DANIEL CO
LOW FLOW
If possible manually activate switch. Jumper switch terminals
Disconnect VFD output wires from terminal strip (current fail)
21
LPMP
LUBRICATION PUMP
SCHWING
VFD FAIL
22
BCH
BATTERY CHARGER
HELIX/ZAK
TROUBLE ALARM
HELIX/ZAK
LOW DC VOLTAGE
23
BSWI
BATTERY DISCONNECT SWITCH
HELIX/ZAK
NA
NO SIMULATION REQUIRED
24
MTS
MANUAL TRANSFER SWITCH
HELIX/ZAK
NA
NO SIMULATION REQUIRED
25
QC
SWITCHGEAR QC
HELIX/ZAK
LINE A/B NORMAL
25A
HELIX/ZAK
LOW VOLTAGE
25B
HELIX/ZAK
BUS A TRIP
25C
HELIX/ZAK
BUS B TRIP
25D
HELIX/ZAK
TIE TRIP
HELIX/ZAK
TROUBLE ALARM
26A
HELIX/ZAK
LOW BATTERY VOLTAGE
26B
HELIX/ZAK
BYPASS
22A
26
UPS
UNINTERRUPTABLE POWER SUPPLY
27
24F
24 VDC FAIL
HELIX/ZAK
NA
NO SIMULATION REQUIRED
28
120F
120 VAC FAIL
HELIX/ZAK
NA
NO SIMULATION REQUIRED
29
ATS
AUTOMATIC TRANSFER SWITCH
HELIX/ZAK
NA
NO SIMULATION REQUIRED
30
LT
D/P LEVEL TRANSMITTER
HELIX/ZAK
PROCESS VARIABLE (IF AVAILABLE)
31
NGT
NEUTROL GROUND TROUBLE
HELIX/ZAK
TROUBLE
32
RRA
RIO REMOTE AND ALARMS
HELIX/ZAK
NA
33
PPMP
T&D CAKE PISTON PUMP
SCHWING
LOW OIL LEVEL AT HPU
Remove the sensor from oil and verify the change of state
33A
SCHWING
HIGH OIL TEMP AT HPU
Jumper the wires on sensor
33B
SCHWING
SOFT START FAULT
33C
SCHWING
HIGH OIL PRESSURE
Change the set point to a lower value
33D
SCHWING
24 VDC TROUBLE
Pull the fuse for 24VDC power supply
33E
SCHWING
HPU DIRTY OIL FILTER 1
Change the DP set point or simulate it with 4-20 ma loop
33F
SCHWING
HPU DIRTY OIL FILTER 2
Change the DP set point or simulate it with 4-20 ma loop
33G
SCHWING
SCREW FEEDER HIGH PRESSURE (JAMMED)
Set the set point to a lower value
33H
SCHWING
AUTOMATIC GREASER FAULT
Set the limit switch out of range
33I
SCHWING
PUMP S2 SPEED CHANGE
Jumper the wires at Greaser
33J
SCHWING
PUMP S3 SPEED CHANGE
Change the speed from HMI
33K
SCHWING
0% PUMP SPEED COMMAND
Change the speed from HMI
33L
SCHWING
0% SCREW FEEDER SPEED COMMAND
Change the speed from HMI
33M
SCHWING
DIVERTER GATE OPENED
Simullate from HMI by open command
33N
SCHWING
DIVERTER GATE CLOSED
Simulate from HMI by close command
33O
SCHWING
0% PUMP INLET PRESSURE (AT PRESSURE TRANSMITTER)
33P
SCHWING
0% LEVEL AT RADAR LEVEL TRANSMITTER 1
simulate using 4-20 ma loop generator or HART communicator or instrument
33Q
SCHWING
0% LEVEL AT RADAR LEVEL TRANSMITTER 2
simulate using 4-20 ma loop generator or HART communicator or instrument
WESTFALIA
PROCESS VARIABLE (IF AVAILABLE)
WESTFALIA
TROUBLE
34
DAIT
DENSITY ANALOG TRANSMITTER
34A
Preferably use hand pump for pressure or Simulate from transmitter OR 4-20 ma loop simulator or HART
NO SIMULATION REQUIRED
Jumper the fault contact
Use manual pressure source or simulate using HART
Remote close and wait for feedback
Use hand held programmer or transmitter itslef to simulate the displays
Jumper flow switch contacts in field
35
FS
FLOW SWITCH
CORTECH & HELIX/ZAK
FLOW SWITCH/CONTACT ON
36
PS
PRESSURE SWITCH
CORTECH & HELIX/ZAK
PRESSURE SWITCH/CONTACT ON
Use hand pump calibrator to raise pressure
37
PCPMP
PROGRESSIVE CAVITY PUMPS
CORTECH
VFD TROUBLE
Remove the output wires to simulate fault
37A
CORTECH
PRV FAIL TO CLOSE
Prevent switch contact from being activated
37B
CORTECH
HIGH MOTOR TEMP
Unplug wire at controller
NO SIMULATION REQUIRED
38
ELP
EMERGENCY LOADOUT PANEL
HELIX/ZAK
NA
39
DSPMP
DUPLEX SUMP PUMP
XYLEM
OVERLOAD TRIP
39A
XYLEM
SEAL LEAK
39B
XYLEM
MOTOR HIGH TEMP
Unplug wire at controller
UTM
MOTOR OVERLOAD
Manually trip overload device in MCC bucket
UTM
LOW FLOW
40
OCF
ODOR CONTROL FAN
40A
if not available us a 4-20mA loop generator to simulate the signal from the field device wiring to the PLC module
Join neutral with ground
Manually trip overload device in MCC bucket
Jumper contacts
If possible manually activate switch. Jumper switch terminals
NO SIMULATION REQUIRED
41
PSTFP
POLYMER STORAGE TANK FILL PANEL
HELIX/ZAK
NA
42
PREF
PUMP ROOM EXHAUST FAN
OCSD FANS, HELIX TUB
MOTOR OVERLOAD
Manually trip overload device in MCC bucket
EXISTING FANS, NEW TUB
43
PRSF
PUMP ROOM SUPPLY FAN
OCSD FANS, HELIX TUB
MOTOR OVERLOAD
Manually trip overload device in MCC bucket
EXISTING FANS, NEW TUB
44
SD
SMOKE DETECTOR
HELIX/ZAK
SMOKE DETECTION CONTACT ON
Use spray can of smoke detector test aerosol
45
SFY
SOLENOID OPERATED VALVE (OPEN/CLOSE)
CSAMSCO
NA
46
ULS
ULTRASONIC LEVEL SWITCH
HELIX/ZAK
START LEAD PUMP LEVEL
47
BK
BREAKER
HELIX/ZAK
TROUBLE
48
CPL
CONTROL POWER LOST
HELIX/ZAK
CONTROL POWER LOST AT SW
49
ESL
LOW VOLTAGE
HELIX/ZAK
LOW VOLTAGE AT SWITCHGEAR
50
XFMR
TRANSFORMER
HELIX/ZAK
LOW OIL LEVEL
HELIX/ZAK
HIGH TEMP
50A
Place a reflective surface at know distances from transmitter
50B
HELIX/ZAK
HIGH PRESSURE
Use a hand pump calibrator
50C
HELIX/ZAK
SUDDEN PRESSURE
Use a hand pump calibrator
OCSD
VFD FAULT
OCSD
LEAK DETECTION (IF APPLICABLE)
51
BPMP
BLEACH PUMP
51A
52
LSL
LEVEL SWITCH
HELIX/ZAK
SWITCH/CONTACT ON
53
MAG
MAGNETIC FLOW METER
HELIX/ZAK
TROUBLE ALARM
HELIX/ZAK
PROCESS VARIABLE (IF AVAILABLE)
53A
Disconnect VFD output wires from terminal strip (current fail)
If possible add water in leak detection chamber to activate Level switch or Jumper contacts in the field
Manually actuate the switch
simulate from Flowmeter OR Disconnect 4-20 ma wires.
Use a hart communicator OR simulate from Flowmeter itslef
NO SIMULATION REQUIRED
54
MOVLOCFCP
MOTOR OPERATED VALVE (LOCAL-OPEN-CLOSE-FCP)
DANIEL CO
NA
55
MOVOC-R
MOTOR OPERATED VALVE (OPEN-CLOSE W/ REMOTE)
CSAMSCO
TROUBLE
56
PT
PRESSURE TRANSMITTER
SOME SCHWING AND SOME ZAK
PROCESS VARIABLE (IF AVAILABLE)
Use a hand pump calibrator
57
RLIT
RADAR LEVEL TRANSMITTER
SOME SCHWING AND SOME ZAK
PROCESS VARIABLE (IF AVAILABLE)
Place a reflective surface at know distances from transmitter
58
SFV
SOLENOID OPERATED PNEUMATIC VALVE (O-C)
SCHWING
NA
NO SIMULATION REQUIRED
59
ZS
LIMIT SWITCH (OPEN-CLOSED)
HELIX/ZAK
CLOSE FIELD SWITCH/CONTACT ON
Manually actuate the switch
60
CMAT
CARBON MONOXIDE DETECTOR
HELIX/ZAK
NA
NO SIMULATION REQUIRED
61
HGAT
SOLENOID OPERATED PNEUMATIC HOPPER GATE
SCHWING
NA
NO SIMULATION REQUIRED
62
TLC
TRUCK LOADING CONSOLE
HELIX/ZAK
NA
NO SIMULATION REQUIRED
63
SRPMP
SCRUBBER RECIRCULATION PUMP
METPRO
MOTOR OVERLOAD
Manually trip overload device in MCC bucket
METPRO
MOTOR HIGH TEMP
Simulate High Temp alarm by disconnecting the high temp contact
METPRO
MOTOR OVERLOAD
Manually trip overload device in MCC bucket
METPRO
MOTOR HIGH TEMP
Simulate High Temp alarm by disconnecting the high temp contact
HIGHLAND TANK
PROCESS VARIABLE (IF AVAILABLE)
63A
64
FAEF
FOUL AIR EXHAUST FAN
64A
65
FTLT
FUEL TANK D/P LEVEL TRANSMITTER
66
DSFV
DUAL SOLENOID PNEUMTIC VALVE
67
MTM
MIXING TANK MIXERS (POLYMER)
NA
Philadelphia Mixing
67A
68
STM
SLUDGE TANK MIXERS (BLEND TANKS)
Philadelphia Mixing
Simulate High Temp alarm by bdisconnecting the high temp contact
VFD FAIL
OVERTORQUE CONDITION
00
MAG
EXISTING MAGNETIC FLOWMETER
OCSD
NO SIMULATION REQUIRED
Simulate motor overload from MCC
68B
SOLENOID OPERATED VALVE (CURRENT TO PRESSURE)
Simulate from transmitter OR 4-20 ma loop simulator or HART
MOTOR HIGH TEMP
MOTOR HIGH TEMP
SFVIP
MAY BE OTHER SUPPLIERS
MOTOR OVERLOAD
68A
69
Lift L3 to create PHASE LOSS trouble.
Simulate the VFD trouble by disconnecting the outgoing power from VFD drive
Simulate the High temp alarm by disconnecting the High temp contact.
Simulate overtorque condition by changing overload current set point at vendor PLC/HMI
TROUBLE ALARM
PROCESS VARIABLE
SUPPLIER RECOMMENDATION
RECOMMENDATION STILL NEEDED