JC 5383A System Simulator and Calibration Kit for Room Thermostats, Receiver-Controllers and Most Pneumatic Devices and JC 5383B System Simulator

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1 Pneumatic Control Manual Receiver-Controllers Section Product/Technical Bulletin JC 5383 Issue Date 0198 JC 5383A System Simulator and Calibration Kit for Room Thermostats, Receiver-Controllers and Most Pneumatic Devices and JC 5383B System Simulator The JC 5383A System Simulator and Calibration Kit is a portable, prepiped test panel to check out pneumatic controls. The kit also simulates a real system for field calibration of receiver-controllers and low-pressure controllers (within 0 to 15 psi). The air connections, pressure regulators, and gauges are numbered with lines drawn between them to show the internal circuitry of the panel. The panel is constructed so that the case can be hung by the handle on the wall next to the control panel for hookup convenience. The JC 5383B Simulator is designed for installation into an existing JC 5383 (X ) Calibration Kit to create a JC5383A System Simulator and Calibration Kit, as mentioned throughout this bulletin. Figure 1: JC 5383A Simulator and Calibration Kit Features and Benefits Precision Regulators and Gauges System Simulator T-4000 and H-4000 Series Mounting Bracket Provides accurate pressure values Simulates an actual system for field calibration of most pneumatic devices Allows calibration and checkout of Johnson Controls T-4000 and H-4000 series controllers 1998 Johnson Controls, Inc. 1 Code No. LIT x

2 Application Overview The JC 5383A System Simulator and Calibration Kit can be used to check out and calibrate room thermostats and receiver-controllers. The kit can also be used to simulate a building environment. Figures 2, 3, and 4 illustrate thermostat connections for checkout. Other controllers can be connected in a similar manner. A corresponding list of steps for checkout and calibration of the T-5800 Series Receiver-Controller is also provided, as an example. For more detailed calibration procedures on these and other pneumatic devices, refer to the corresponding product literature available for these devices. For additional information on how to check out and calibrate various older Johnson Controls pneumatic devices, refer to the Pneumatic Operator's Manual (Publication 2054) and the related product literature. For more detailed simulation procedures, refer to the Pneumatic Control Systems Series of Training Modules (LM40 - LM47). Contact the Johnson Controls Training Institute in Milwaukee to obtain Publication 2054, or training modules LM40 - LM47. Operation: Calibration Kit IMPORTANT: Use the rubber caps furnished with the JC 5383A Calibration Kit on all unused fittings on the kit to prevent leakage. T-4000 Series Pneumatic Room Thermostat Initial Setup (for Checkout) Install any type of room thermostat to check for operation. This piping configuration can also be used to check out or reset the switchover point on Dual T-4000 and T-3300 Series Thermostats. Checkout of a 3-pipe room controller is not possible using the mounting bracket furnished on the JC 5383A System Simulator and Calibration Kit. 1. Furnish supply air (20 to 90 psig) to the MAIN AIR IN connection of the calibration kit. 2. Set regulator S-5 to furnish 20 psig, as read on gauge G Using tubing furnished with the kit, connect the supply line to the controller input located above the mounting bracket (see Figure 3). 4. Install the furnished rubber caps on all unused fittings on the calibration kit to prevent leakage. Tubing Supply Supply G6 Output thermo2 Tubing Figure 3: T-4000 Series Mounting Bracket Continue by following the detailed calibration procedures provided in the product literature for the device. Figure 2: Thermostat Initial Setup 2 JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin

3 T-5800 Series Receiver-Controllers Initial Setup (for Checkout) T and T Single-Input Receiver-Controllers (Calibration) Set Point Adjustment 1. Select the proper gauge on the calibration kit to match the range of the Controlled Variable CV transmitter. Connect the gauge chosen to the CV spigot on the T Determine the set point required and rotate the gradual switch (for the gauge chosen in Step 1) to this required value. 3. Adjust the set point (local or remote) until the output pressure of the T-5800 is at the mid-spring-range of the controlled device. Figure 4: T-5800 Receiver-Controller Initial Setup 1. Furnish supply air (20 to 90 psig) to the MAIN AIR IN connection of the calibration kit. 2. Set regulator S-5 to furnish 20 psig as read on gauge G Using the O/S/F connector and tubing furnished with the kit, connect the supply line to the Supply fitting and connect the output line to fitting G-6. (The fan F line is not used.) 4. Using the M/CV/SP connector and tubing, connect the input lines to the gauge connections that match the ranges of the transmitters. Do not connect input M for single-input receiver-controllers. Vent the SP input for units with local set point. 5. Install the furnished rubber caps on all unused fittings on the calibration kit to prevent leakage. 6. Remove the Orifice jumper on the T-5800 (if connected) and cap these spigots with the black rubber caps provided with the T-5800 (see Figure 5). 7. Position the Action Side jumper and, if present, Set Point Readjustment Side jumper on the T for the proper action and readjustment per the job requirements. 8. For Proportional plus Integral (PI) models, disconnect the PI jumper from one of its spigots since the PI function, as well as the gain, can only be checked and adjusted during actual system operation (see Figure 5). Pulling the PI jumper off of one of its spigots causes the receiver-controller to operate as a proportional-only controller. Gain Adjustment The Set Point Adjustment section must be completed before moving to these steps. 1. The T-5800 must be connected to the actual control system to adjust the gain. Remove the receiver-controller from the calibration kit and reconnect the Orifice jumper if previously removed. 2. Connect the T-5800 to the system, allow the system to come into control, and note the output pressure. 3. If the gain setting is specified on the control drawing, set the gain to this value. If not specified, increase the gain setting until the system becomes unstable and begins to cycle. Then decrease the gain setting slightly to remove the cycling effect. Integral Time Adjustment (T Only) The Gain Adjustment section must be completed before moving to these steps. 1. Reconnect the PI jumper previously removed, in order to restore the PI function to the T If the system response toward the set point is too slow, decrease the integral time and/or increase the Gain Adjustment dial settings by small increments each. If cycling occurs, increase the integral time and/or decrease the Gain Adjustment dial settings by small increments each. JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin 3

4 Figure 5: Typical T-5800 Series Instrument T and T Dual-Input Receiver-Controllers 1. From the control drawing and reset schedule (Form #561), determine the minimum and maximum values of the Master M and Controlled Variable CV transmitters. An example of a typical reset schedule is illustrated in Figure Position the Ratio Selection jumper in the proper position, as determined on the control drawing (Example: A ratio of.83:1 means install the jumper in the 1:1 position). 3. Connect the T-5800 to the calibration kit, matching the gauge ranges on the kit to the corresponding Master M and Controlled Variable CV transmitters (Example: 0 to 100 F and 40 to 240 F, respectively). Master Input Balance Adjustment ( R Test Point) The previous section of this document must be completed before moving to these steps. 1. Apply a simulated Master M input pressure, equal to the midpoint of the working range according to the reset schedule (Example: 40 F). 2. Connect the hypodermic needle test probe assembly to test gauge G-4 on the calibration kit and insert the needle test probe into the R test point on the T Adjust the Master Input Balance screw to 9 psig. 3. Remove the needle test probe from the R test point and insert it into the SP test point location. 4. Set the Set Point dial (local or remote) to provide a 9 psig reading on test gauge G-4. Remove the test probe from the T JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin

5 Figure 6: Typical Reset Schedule Ratio Adjustment The Master Input Balance Adjustment ( R Test Point) section must be completed before moving to these steps. 1. With the Master M input pressure still at the midpoint of the working range of the controlled device (Example: 40 F), apply a simulated Controlled Variable CV input pressure equal to the midpoint of its working range according to the reset schedule (Example: 130 F). 2. With the Ratio Selection jumper and Ratio Adjustment dial in the 1:1 position, rotate the dial to the calculated ratio value for the specific application (Example: Ratio of.83:1). 3. Adjust the set point (local or remote) to produce an output pressure equal to the mid-spring-range of the controlled device(s). 4. Apply a simulated Master M input pressure, starting at the minimum value of the working range according to the reset schedule (Example: 10 F). 5. Apply a simulated Controlled Variable CV input pressure which corresponds to the minimum Master value in Step 4 (Example: 180 F). 6. Determine what valve position on the operating system would be necessary to produce the desired CV value in Step 5. Rotate the Ratio Adjustment dial to produce this output pressure (Example: Approximately 6.5 psig assuming a Normally Open [N.O.] valve for this application). 7. Adjust the simulated input values to the other end of the reset schedule (Example: Master M = 70 F, Controlled Variable CV = 80 F). 8. Determine what valve position on the operating system would be necessary to produce the CV value in Step 7. Adjust the set point (local or remote) to produce this output pressure (Example: Approximately 10.5 psig). To determine if this controller will operate as desired when installed on the job site, go to the Operation: Simulator section and observe controller operation. JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin 5

6 Gain Adjustment The Ratio Adjustment section must be completed before moving to these steps. 1. The T-5800 must be connected to the actual control system to adjust the gain. Remove the receiver-controller from the calibration kit and reconnect the Orifice jumper if previously removed. 2. Connect the T-5800 to the system, allow the system to come into control, and note the output pressure. 3. If the gain setting is specified on the control drawing, set the gain to this value. If not specified, increase the gain setting until the system becomes unstable and begins to cycle. Then decrease the gain setting slightly to remove the cycling effect. Integral Time Adjustment (T Only) The Gain Adjustment section must be completed before moving to these steps. 1. Reconnect the PI jumper previously removed, in order to restore the PI function to the T If the system response toward the set point is too slow, decrease the integral time and/or increase the Gain Adjustment dial settings by small increments each. If cycling occurs, increase the integral time and/or decrease the Gain Adjustment dial settings by small increments each. Operation: Simulator The simulator can produce a system speed reaction in a Fast or Slow mode. The system speed is accomplished by setting the Gain Adjustment dial of the T test kit above (increase response) and below (decrease response) a setting of 10:1. (See Figure 7.) The System Load Change knob is turned to cause the controller being checked to reposition the controlled device to a more open or closed position, simulating system offset. The output change will be different depending on the action (Direct Acting [D.A.] or Reverse Acting [R.A.]) of the controller being checked. IMPORTANT: The Action Side jumper of the T test kit must match the action of the controller being tested. Simulator Initial Setup 1. Set the Gain Adjustment dial on the T test kit to 10:1, to simulate a normal system response. 2. Center the System Load Change knob. 3. Set the Action Side jumper on the T test kit to match the action of the controller being tested. Testing a Receiver or Pressure Controller The Simulator Initial Setup section must be completed before moving to these steps. 1. Furnish supply air (20 to 90 psig) to the MAIN AIR IN connection of the calibration kit. 2. Connect the supply air connection from the test kit to the Supply connection of the controller. 3. Connect the output of the controller to the Controller Output to System connection. If the controller does not have an output gauge, connect a jumper tube to G-6. Figure 7: Simulator Application 4. Connect G-7 to the CV or pressure connection on the controller. Identify proper scale on gauge G If not at the desired set point, turn the Set Point dial to the desired set point. 6. Set the Gain Adjustment or sensitivity dial and/or slider to the desired setting. The controller should now be trying to reach the set point. If the controller cycles, adjust gain, sensitivity, or throttling range. On dual-input controllers, slightly adjust the Ratio Adjustment (authority) and Set Point dials to bring the CV temperature values to the desired values. 7. Once the controller has settled out, note temperature and output values. 6 JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin

7 JC 5383B Simulator Installation The following instructions are used to install a system simulator into an existing JC 5383 (X ) Calibration Kit, thus creating a JC 5383A Simulator and Calibration Kit: 1. Remove everything from the side compartment of the JC 5383 (X ). 2. Remove the calibration kit face plate. Depending on the age of the kit, four to five screws hold the plate on the kit. 3. Attach the supply air line S of the T test kit to the calibration kit Supply air circuit by drilling a 3/8 in. diameter hole into the compartment of the kit, as shown in Figure 8. This hole is 4 in. from the back of the inside of the kit and approximately 2 in. from the top edge of the kit. 4. Insert the simulator supply air tubing through the 3/8 in. diameter hole and attach the tubing to the calibration kit pneumatic circuit, as indicated in Figure 8 (after the PRV regulator). Cut tubing and attach with the tee fitting provided with the simulator. Figure 8: JC 5383B Simulator Installation JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin 7

8 5. Reattach the face plate and secure the holding screws. 6. Place simulator into side compartment of calibration kit with T near handle of kit. 7. The simulator is permanently attached to the kit using two mounting holes that are provided in the simulator plate. The location of these holes is indicated in Figure 8. The holes are approximately 1 in. and 3-3/4 in. from the outer edge of the kit. Use the pretapped holes in the simulator plate for a template. Use a No. 18 drill bit to create matching holes in the kit. The holes in the plate are tapped for a in. screw. Servicing the JC 5383 Calibration Kit Periodically check the accuracy of all gauges on the JC 5383A kit, utilizing a good master test gauge. Johnson Controls recommends a 4 to 6 in. test gauge with an accuracy of 0.1 psi be used. 8 JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin

9 Repairs and Replacements A E E H I D K F G B E E C J boxcallot Figure 9: JC 5383A Repair Parts Table 1: Repair Parts Item Product Code Number Description A JC 5385 Multi-Scale Transmission Gauge 50 to 150 F, 0 to 100 F 20 to 120 F, -40 to 160 F B JC 5386 Multi-Scale Transmission Gauge 60 to 85 F, 40 to 240 F 50 to 65 F, 50 to 100 F C JC 5391 Multi-Scale Transmission Gauge 40 to 240 F, 50 to 100 F 0 to 100 F, 60 to 85 F D G to 30 psig Gauge E R Miniature Pressure Regulator F R Pressure Reducing Valve G T Stat Mounting Equipment: Mounting Bracket T Terminal Connector with Two Straight Fittings H T Controller I T Air Tank J T Input/Output Connector Kit K F Blue 1/4 in. O.D. Urethane Tubing (Order in multiples of 100 ft.) JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin 9

10 Notes 10 JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin

11 Notes JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin 11

12 S pecifications Product Power Requirements Ambient Operating Conditions Ambient Storage Conditions Dimensions (H x W x D) Shipping Weight JC 5383A Simulator / Calibration Kit 20 to 90 psig Clean, Dry Air 50 to 104 F (10 to 40 C) -40 to 158 F (-40 to 70 C) 12-1/4 x 5-1/2 x 19-1/4 in. (311 x 140 x 489 mm) 15-1/2 lb (7 kg) The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products. Controls Group FAN E. Michigan Street Pneumatic Control Manual P.O. Box 423 Printed in U.S.A. Milwaukee, WI JC 5383A System Simulator and Calibration Kit Product/Technical Bulletin