PCC-III MULTIPLE LOOP CONTROLLER Overview the assessment of existing piping, burner and boiler ... ,...
Transcript of PCC-III MULTIPLE LOOP CONTROLLER Overview the assessment of existing piping, burner and boiler ... ,...
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PCC-III MULTIPLE LOOP CONTROLLEROverview
• MultipleloopcontrollerLarge 160 block memory and 18 I/O points as astandard with three (3) additional I/O card slots foravailableexpansionupto31I/O.
• HighlyVisibleLEDDisplays- 10ProcessVariablesdisplayedwithEnglishlanguagedescription
- 10 Point (“first-out”) annunciator with Englishlanguage messages
- Large5.1",51segmentbargraphs
• Intuitive“Blockware”configurationlanguageCompletely configurable from controller front panel.Noexternalkeypadsorterminalsarerequiredforanyreason
• DualredundantmemorymodulesProtects configuration data, tuning parameters andoperatingstatusinformation
• OpticallyIsolatedRS485ModbusdatahighwayEnsuressafeandreliablecommunications
• 120VACDiscreteInput,RelayandTriacOutputBoilersystemcompatibilityand24VDCinternalpowersupply
• FlushMountedNEMA13FrontPanel
PCC-III Multiple Loop Controller
Reliable, FlexibleControl and Monitoring
The PCC-III Multiple Loop Controller is a boiler ormultiple loopprocess controller. The large I/Oquantity,integralOxygensensor,highlyvisiblefrontpanel,intuitive“Blockware”,redundantmemories,4-20mADCinputandoutputs, 120VACdiscrete contact inputs, isolated relayoutputs, 24VDC transmitter power supply, the ability tocontrol electric positioners directly and built-in industrystandard communications allows the PCC-III to be integratedintocomplexsystemswithaminimumnumberofexternalcomponents.ThePCC-IIIisacompletecontrolsolutionforindividualboilersormultiplecontrolloops.
User Friendly• EasyInstallation–ThePCC-IIIintegratesaflexible,
highly visible HMI, up to 31 I/O points (includingisolateddiscreteandanaloginputs,relayoutputsandtriacand4-20mADCoutputs),24VDCpowersuppliesand network communications into a single panelmountedNEMA13controller.
• Easy to operate - The PCC-III comes with largenumericandEnglishlanguagedisplays,pushbuttonsand intuitive bargraphswhich provide clear processinformation.A flexible display allows the operator toviewup to10different process variables, eachwithup to a 16 character English language descriptionmessage.The“first-in-first-out”annunciatorallowstheoperatortoviewtheorderofalarmsandacknowledgeeach separately. Configurable “lights and buttons”allow incorporation of auxiliary functions into thecontrollerwithouttheadditionofexternalhardware.
• Easy to configure - The PCC-III uses an intuitive“Blockware”configurationlanguage.Functions(AIN,PID, LOALM, F(x), etc) are simply copied into aconfiguration,andthenthecontrolsignalsare“wired”from block to block. Preferred’s innovative PC3_Draw™ forMSWindows®usesagraphical,“draganddrop”interface.BlockwarecanalsobeediteddirectlyfromthePCC-IIIfrontpanelorthespreadsheetstylePC3_Edit™. The PCC-III includes automated setuptoolstohelpreducecommissioningtimeandimprovecontrolsystemtuning.
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Safe Boiler OperationThePreferredPCC-IIIcontroller,joinedwithproperfuelandcombustionairflowregulatingelements,assuresaccurateandrepeatablecombustioncontrol.Fuelandairflowsarematchedinordertomaintainproperfueltoairratioatalltimes.Too littleaircausesunburned fuel lossesand toomuchair causesexcessive stack losses. Improper fuelair ratio can beDANGEROUS.Any combustion projectrequirestheassessmentofexistingpiping,burnerandboilerconditions, processmeasurements, analyzers, linkages,actuators,controlvalves,controldampersandoperationalrequirements.Preferred’sfocusoncombustionapplications,withthousandsofboilercontrolsysteminstallations,bringsthe required experience to the evaluation, developmentand commissioning of each project.With its redundantnon-volatilememories and “servicemanual”mode, thePCC-IIIControlleriscapableof“self-recovery”intheeventofasevere120VACelectricalpowerdisturbanceorsomeotheroccurrencethataltersdatainitsmemory.Moreover,an integraloptically isolatedRS485DataHighwayhelpspreventasinglecontrollerfailurefromdisruptinganentirenetwork.Lower Installed Cost Whenconsideringanycontroller,itisimportanttoconsiderthe total “installed” cost.ThePCC-III offers the lowestinstalled cost in the industry.Other controllers routinelyrequire external hardware such as interfacing relays,communicationisolators,24Vpowersupplies, laptopsorconfigurators and possibly extra controllers tomanagea specific application.ThePCC-III overcomesmany oftheseissuesbyincorporatingthesefeaturesintothebasiccontroller.ThePCC-III “Z” option card, as an example,eliminatestheneedforanexternalfluegasexcessoxygentransmitter,whilestandard120VACinputsand8Amprelayoutputs eliminate the need for interposing relays.Whilemostothercontrollersarewellover15"long,thecompactPCC-IIIfitseasilyintolessexpensive8"deepcabinetsorenclosures.
PCC-III MULTIPLE LOOP CONTROLLEROverview
Multiple Loops Duetoitsabilitytohandleseveralcontrolloops,applicationofasinglePCC-IIImayallowareductioninthetotalnumberofcontrollersnecessaryforaninstallation.Thelarge160functionblockconfigurationmemoryallowsanyfunctiontobeassignedtoeachblock,providingunequalledflexibilityandenoughpowertohandlejustaboutanyboilercontrolstrategy.Expandable I/OThewide variety ofPCC-III option boards allowone toexpandtheI/Ocapabilitiesofagivencontrollertofitanyapplication.Refertothespecificationspageforexpansioncardpossibilities.Upto15analoginputscanbeusedtosupportcomplexcontrolstrategiesorsatisfydataacquisitionneeds.ThePCC-III canbeequippedwith up to 6 relayoutputs.Theseoutputs are rated for up to 8A inductiveloadsandcanbeusedonmostapplicationswithoutexternal“helper”relays.Additionally,thePCC-IIIoffersTriacoutputstodrivereversibleACelectricactuators,solenoids,hornsandotherdevices.The“G”TriacOutputoptioncardincludesa“positionfeedback”potentiometeror4-20mADCinputsforclosedloopservopositioning.
3.75”
Panel Cutout Dimensionsand Minimum Spacings
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PCC-III MULTIPLE LOOP CONTROLLERApplications
RefertoEngineeringDataSectionforfeaturesandBenefitsofSinglePointPositioning,ParallelPositioningandFullyMeteredCombustionControlSystem.
PCC-III Multiple Loop Controller Example Applications:
Boiler Monitoring• FlueGasOxygenMonitoringwithASME“ByLosses”EfficiencyCalculationforOne(1)orTwo(2)Boilers• DataAcquisitionwithupto15AnalogInputsor13DigitalInputs
Header Temperature or Pressure Control• Two(2)orThree(3)BoilerModulatingLead/LagControl• PlantMasterModulatingControl
Single Point Positioning Combustion Control• FiringRateControl• FiringRateControlwithOxygenTrimControlusingLinkTrimActuator(LTA)orFuelTrimOutput• FiringRateControlwithDraftorDrumLevelControl
Parallel Positioning Combustion Control• FiringRateControl• FiringRateControlwithOxygenTrimControl• FiringRateControlwithOxygenTrimControlandVariableSpeedDrive(VSD)CombustionAirFanControl
Fully Metered Combustion Control• FiringRateControl• FiringRateControlwithOxygenTrimControl• FiringRateControlwithOxygenTrimControlandVariableSpeedDrive(VSD)CombustionAirFanControl
2ConfigurableLEDLights
4ConfigurablePushbuttonswithLEDLights
10ProcessVariableDisplayswith16CharacterEnglishLanguageDescription
10Point("first-out")Annunciatorwith16CharacterEnglishLanguageDescription
ACK-AcknowledgePushbuttonDIS -DisplaySelectionPushbutton
Increase,DecreasePushbuttons
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Combustion Control FeaturesCombustion isademandingprocesscontrolapplication.ThefollowingaresomeofthePCC-III featuresdevelopedtomeetthosedemands.
Multiple Function Generator F(x) blocksThe F(x) block is used to “characterize”or “curve fit” an analog signal by allowingeach value of the input to be assigned anindependentoutputvalue. ThePCC-III’s F(x)blockallows11breakpointstodefinetheinputvs.outputprofile.Theblocksareusedtosetupfeedforwardandremotesetpointsignalsaswellaslinearizerelationships.Forexample,incombustionairflowcontrolapplications,F(x)blocksareusedto“characterize”theAirFlowDemandsignal tocreateAirFlowControllerandOxygenTrimController setpoints.TheexampleshowntotherightusesseparateF(x)blocksto“characterize”differentsetpointsforgasandoilfiring.ThePCC-III hasthecapacitytouseasmanyF(x)functionsasarerequiredbytheapplication.
“Learn Mode” The PCC-III “Learn Mode” feature allowsmultipleF(x)blockinputvs.outputprofilestobe entered simultaneously.This capacity isbestdescribedwithanexample(refertotheexampleblockwarediagramatright).Duringcommissioning,thecontroltechnicianadjustsairandfuelflowsmanuallytoestablishoptimalfiring conditions for a particular load point.Withtheconditionsset,thetechniciansimplypressesthe“store”buttonforthePCC-III to store (learn) the current firing rate, oxygen valueandburnerair flow rate into theappropriateF(x) blocks simultaneously. This causesconsiderable time incommissioning,aswellasanoptimally“characterized”process.
Boiler Efficiency Function BlockTheboilerefficiencyfunctionallowsrealtimecalculationoftheboiler’sefficiencywithresultsdisplayedonthecontroller’sfrontpanel,recorderand/ordata acquisition system. Boiler efficiency is calculatedusingtheASME“bylosses”method.Thisfunctionrequiresinputsoffluegas temperature,combustion(ambient)airtemperature,percentoxygeninthefluegas,andpercentfiring rate toevaluate theefficiency. Notonlydoes thisfunctionhelpestablish“on-line”firedequipmentefficiency,but it also helps detect changes in efficiency, alertingoperating personnel of potentialmaintenance concernsbefore theybecomeaproblem.The resultsofefficiencycalculations can also be used in advanced controlapplications.
Simplified Blockware Diagram Exampleshowing the combustion air flow control and Oxygen trim portion of a full metering combustion control application
PCC-III MULTIPLE LOOP CONTROLLERConfiguration
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PCC-III MULTIPLE LOOP CONTROLLERConfiguration
Programmingconfigurationsisachallengingtaskformostprogrammablecontrollers.ThePCC-III multipleloopcontrolleristheexceptiontothisrulewiththreedifferentwaystocreateconfigurations.Configurationscanalwaysbemadedirectlyfromthefaceplateofthecontroller,usingthebuilt-ineditbuttons,butthetaskismadeeveneasierwithPreferred’sPC3_Edit™ and PC3_Draw™ software.BothprogramsallowtheusertodesignBlockwareconfigurationsandupload/download them to thePCC-III controller through thePC3-Link™ cable connecting the serial port of your computertoastandardRS232connectiononthePCC-III controller.PC3_Edit™ provides a straightforward spreadsheet styleinterfacewhilePC3_Draw™ usesapowerfulobject-orientedvisualinterface.BothprogramsarebuiltforMSWindows®.
PC3_Edit™The“pointandclick”simplicityofthePC3_Edit™softwaremakes“Blockware”configurationsimpleandintuitive.Theprogramusesastraightforwardspreadsheetformatwithaconvenientfill-in-the-blanksapproach.EachBlockhasanunlimitedlength“comments”fieldforcleardocumentation.The “Blockware” data and comments can be printed toanyMSWindows® compatible printer. The generatedconfigurationsaretheneasilydownloadedtothecontrollerthroughthePC3-Link™cable.
PC3_Draw™Thepowerfulobject-orientedCADinterfaceinPC3_Draw™makestheprogramtheidealchoiceforrapid“Blockware”programming in a visual environment. The program isbuilt on a Visio® platformwith extensive Visual Basicautomation.Standardfunctionsareincludedinmenusofpre-drawnfiguresforeachPCC-IIIBlockwarefunctiontype.Functionsaresimplydraggedontothedrawingpageandconnectedwith“smartconnector”linestointerconnecttheblocks.Blockinputsareautomaticallygeneratedbyplacingtheblockconnections.Doubleclickingonanyblockallowstheuser to edit datawithin theblock.Drawings canbeprintedonanyMSWindows®compatibleprinterorplotter.“Blockware”datacanalsobeprinted in thePC3_Edit™tabularformat.
Whatevertheconfigurationneeds,PreferredInstrumentshasaneasysolutionforyou.Whetherit’sthestraightforwardapproach of PC3_Edit™ or themore robust graphicalabilitiesofPC3_Draw™,configurationswillneverbethechoretheyusedtobe.
The PCC-III can be configured directly from the front panel or with Preferred’s PC3_Edit™ or PC3_Draw™ Software.
PC3_Draw™ uses a visual, “drag and drop” approach to “Blockware” design.
PC3_Edit™ Allows easy uploading, editing, and downloading of “Blockware” configurations.
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MechanicalCaseSize: 7.38"HX3.00"WX7.75"DEnclosureType: FlushpanelmountedFrontPanelSize: 8.00"HX3.75"WPanelCutout: 7.50"HX3.13"W(+/-.062)Weight: 6lbs.(excludingoptionboards)
EnvironmentalOperatingTemp: 32°to122°F(0°to50°C)StorageTemp: -20°to150°F(-28°to65°C)HumidityLimits: 15to95%(noncondensing)FrontPanel: NEMA13/IP65
PerformanceAccuracy: 0.025%AnalogInputsand
Outputs,70°FResolution: 16bitinput/16bitoutputMicroprocessor: 32bit,256kRAMExecutionCycle: TenpersecondNon-VolitaleMemoryLife: 10.8-30years,Blockware
dependent
Operator Control PanelDisplays:Alphanumeric: 8characterLED(0.2")
Numeric: 4.5digitLED(0.43")Bargraphs:PV&SP: 51segmentLED(5.1")Output: 21segmentLED(2.1")
Pushbuttons: Membrane,tactilefeedbackFaceplate: Mylar,splashproofAlarmAnnunciator: 10point,firstoutStatusIndicators: 6LED,configurableUserDefinedPushbuttons: 4configurable
ConfigurationLanguage: Functionblockstyle,
60functions,160BlocksSecurity: 4passwordlevels
RedundantmemoriesUserInterface:Faceplate: Fullyfrontfaceconfigurable
4dedicatedEDITkeyslocatedunderhingedcover
Laptop(optional): PC3_Edit™spreadsheetbasededitororPC3_Draw™graphical,object-orientededitor
CommunicationNetwork:Protocol: Modbus(ASCIIorRTUmode)Speed: 1200to38,400baudType: RS485,opticallyisolated
Configuration:Speed: 1200to38,400baudType: RS232withtelephonemodular
handsetconnector
Electrical InputPower: 120VAC(+/-15%)
BuiltinsurgesuppressorsInternalPowerSupplies: 24VDC@215mADC
(for2wiretransmitters)5VDC@50mADC(forpotentiometers)
Input/Output (Standard - no option cards)AnalogInputs: Quantity: 5
Type: 4-20mADC,0-5VDCAnalogOutputs: Quantity: 2
Type: 4-20mADC,750ohmloadDiscreteInputs: Quantity: 5
Type: 120VACopto-isolatedDiscreteOutputs:Quantity: 6
Type: (2) SPDTrelay,8A,120V(4) 24VDC,(sinking),100mA
Input/Output Option Cards OptionBoardA:AnalogInputs: Quantity: 5
Type: 4-20mADC,0-5VDC
OptionBoardF:AnalogInputs: Quantity: 3
Type: 4-20mADC,0-5VDCAnalogOutputs: Quantity: 2
Type: 4-20mADCOptionBoardG:TriacOutput: Quantity: 2pair
Type: 2A24-120VACAnalogInputs: Quantity: 2
Type: Pot/0-5VDC/4-20mADCOptionBoardJ:DigitalInputs: Quantity: 4
Type: 120VAC,Optically-IsolatedRelayOutputs: Quantity: 2
Type: Relaycontact,8AinductiveOptionBoardS:TriacOutput: Quantity: 1pair
Type: 2A24-120VACOptionBoardZ:AnalogInput: Quantity: 3
Type: 120VAC,Optically-IsolatedTriacOutput: Quantity: 1pair
Type: 2A-120VAC
PCC-III MULTIPLE LOOP CONTROLLERSpecifications
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Title Description CatalogNumber
PCC-IIIModelNumber
Plant Master (current outputs)
Includessteamheaderpressurecontrol.ThiscontrollermaybecombinedwithanyboilerSubmastercontrollertoformacompletesystem.
PC3-00003C PCC-III-0000
Plant Master with 3 Steam Boiler Lead/Lag
Includessteamheaderpressurecontrolandlead/lagsequencingforthreeboilers.ExternalleadboilerselectorswitchandBoilerSubmasterControllersarerequired.
PC3-10013C PCC-III-J000
Anumberofcommoncontrollerconfigurationscanbeorderedpre-programmedintothePCC-IIItoperformavarietyofdifferentcontrolfunctionsincluding:• PlantMaster• SinglePointPositioning(Jackshaft)BoilerMaster• ParallelPositioningBoilerMaster• FullyMeteredBoilerMaster• FeedwaterControl• Condensate Level Control• Stand-AloneOxygenAnalyzer
Note:althoughthecontrollersareprovidedpre-programmed,therewillstillbeadditionalfieldprogrammingrequiredtoentersite-specificdataintothecontrollersincluding:transmitterranges,customizedtextdescriptions,tuningparameters,etc.
Plant Master Configuration Options:
Title Description CatalogNumber
PCC-IIIModelNumber
Steam Boiler Submaster Jackshaft (current outputs)
Includesboilersteampressurecontrolforaboilerequippedwithajackshaft.Thisisacompletesystem. PC3-10103C PCC-III-0000
Steam Boiler Submaster Jackshaft (triac outputs)
Includesboilersteampressurecontrolforaboilerequippedwithajackshaft.Thisisacompletesystem. PC3-10013C PCC-III-G000
Hot Water Boiler Submaster Jackshaft
Includeshotwatergeneratortemperaturecontrolforahotwatergeneratorequippedwithajackshaft.Thisisacompletesystem.
PC3-10153C PCC-III-Z000
Oxygen Trim w/Efficiency Jackshaft (Z-board)
Includesoxygentrimlogicforajackshaft-equippedboiler.FueltrimequippedpressureregulatorandI/Pconverterarerequired.ConfigurationissetupforusewithPreferred’sZPOxygenAnalyzer.ThiscontrollermaybeusedasastandalonesystemorcombinedwithPC3-10103orPC3-10153toformacompletesystem.
PC3-10313C PCC-III-Z000
Oxygen Trim w/Efficiency Jackshaft (Z-board)
Includesoxygentrimlogicforajackshaft-equippedboiler.Differentiallinktrimactuatorisrequired.ConfigurationissetupforusewithPreferred’sZPOxygenAnalyzer.Thiscontrollermaybeusedasastand-alonesystemorcombinedwithPC3-10103orPC3-10153toformacompletesystem.
PC3-10363TA PCC-III-ZG00
Boiler Submaster/ Draft, Jackshaft
Includesboilersteampressurecontrolanddraftdampercontrolforajackshaft-equippedboiler.Thisisacompletesystem.
PC3-12043C PCC-III-0G00
Single Point Positioning Boiler Master Configuration Options:
PCC-III MULTIPLE LOOP CONTROLLERStandardConfiguration
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PCC-III MULTIPLE LOOP CONTROLLERStandardConfiguration
Title Description CatalogNumber
PCC-IIIModelNumber
Boiler Submaster/ Fuel/Air Ratio, Parallel Positioning (no Oxygen Trim)
Includesboilersteampressurecontrolwithfuelvalve,air-fuelratiologicandairdampercontrolconfigurationforparallelpositioningfieldequipment.Thisisacompletesystem.
PC3-12053C PCC-III-0000
Parallel Positioning Boiler Master Configuration Options:
Title Description CatalogNumber
PCC-IIIModelNumber
Steam Boiler Submaster/ Fuel Flow, Full Metering
Includesboilersteampressurecontrolandone(1)fuelvalvecontrolconfiguredforfullymeteredfieldequipment.ThisconfigurationisusedwithPC3-12073C.
PC3-12033C PCC-III-0000
Air Flow/ Oxygen Trim, Full Metering
Includesair-fuelratiologic,airdampercontrolandoxygentrimlogicconfigurationforfullymeteredfieldequipment.ConfigurationissetupforusewithPreferred’sZPOxygenAnalyzer.ThisconfigurationisusedwithPC3-12033CorPC3-12493C.
PC3-12073C PCC-III-Z000
Fully Metered Boiler Master Configuration Options:
Title Description CatalogNumber
PCC-IIIModelNumber
One Element Drum Level Feedwatervalvecontrolusingdrumlevelmeasurement. PC3-10213C PCC-III-0000
Two Element Drum Level Feedwatervalvecontrolusingsteamflowanddrumlevelmeasurements. PC3-10203C PCC-III-0000
Three Element Drum Level
Feedwatervalvecontrolusingsteamflow,drumlevelandfeedwaterflowmeasurements. PC3-10223C PCC-III-0000
Condensate Tank Level Condensatevalvecontrolwithcondensatelevelmeasurement. PC3-10263C PCC-III-0000
Deaerator Tank Level CondensateflowvalvecontrolwithDeaeratorlevelmeasurement. PC3-10273C PCC-III-0000
Oxygen Analyzer w/ Efficiency
Standaloneoxygenanalyzerconfiguration.ConfigurationissetupforusewithPreferred’sZPOxygenAnalyzer.
PC3-11033C PCC-III-Z000
Standard PID Controller StandardPIDlogicwithhighandlowalarm. PC3-STDPID PCC-III-0000
Auxilliary Configuration Options:
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specifications subject to change without notice
PCC-III MULTIPLE LOOP CONTROLLEROrderingInformation
Option Card Slot #1:0 noneA AIN 5ch. 4-20mADC/0-5VDC
F AIN 3ch. 4-20mADC/0-5VDCAOUT 2ch. 4-20mADC CombinationBoard
G TOUT 2pair TriacOutputs,2A24-120VACAIN 2ch. Pot/0-5VDC/4-20mADC CombinationBoard
J DIN 4ch. 120VAC,OpticallyIsolatedDIN 2ch. RelayContact,8AInductive CombinationBoard
Z ZPOxygenAnalyzerAmplifierandStackTemperatureController
Option Card Slot #2Selectcardtypefromthe"Slot1"listabove
Option Card Slot #3
0 none
S TOUT 1pair TriacOutputs,2A24-120VAC
OptionalInput/OutputBoardExpansionExamples:
CatalogNumber:PCCIIIa b c 0
1. SpecifythePCC-IIIcatalognumberasshownbelow.2. Consultfactoryforpre-configuredcombustioncontrolstrategiesthatmaybeincludedforanadditionalcost.3. OptionallyspecifyPC3_Edit™orPC3_Draw™programmingpackages.4. Optionallyspecifythe“DCS-III”Controllerformonitoringapplications.The“DCS-III”isaPCC-IIIControllerwithout
faceplateandcase.Itissuppliedwithabracketformountingonanenclosuresubpanel.
PCC-III Model #4-20mADC0-5VDCAIN
4-20mADCAOUT
120VACDIN
8A(relay)ROUT
2A(triacpairs)TOUT
200mADC(sinking)DOUT
TotalI/O
PCC-III- 0 0 0 0 5 2 5 2 0 4 18PCC-III- A A 0 0 15 2 5 2 0 4 28PCC-III- F F 0 0 11 6 5 2 0 4 28PCC-III- J J 0 0 5 2 13 6 0 4 30PCC-III- G G S 0 9 2 5 2 5 4 27PCC-III- F G S 0 10 4 5 2 3 4 28PCC-III- A J 0 0 10 2 9 4 0 4 29
Note:Theexamplesgiveninnowayreflectthenumberofoptioncardpossibilities.ThePCC-III hasatotalofthree(3)optioncardslots,ofwhichoneisdesignatedforusebythe"S"cardonly.Theremainingtwoslotscanhouseanyoftheremainingoptioncardsinanydesiredcombination.
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PCC-III MULTIPLE LOOP CONTROLLERSuggestedSpecifications
1. GeneralSupplyamicroprocessor-basedmultipleloopcontrollersuitableforflushmountingonthefaceofacontrolpanel.Thecontrollershallprovideforbalanceless-bumplesstransfer.Innormaloperation,thisunitreceivesanaloginputs,calculatestheoutputandpositionstheassociatedfinalcontrolelement.Theoperatorcanmanuallyoverridethisfunctionbyselectingthemanualmodeofoperationandadjustingthefinalcontrolelement.Primaryoperatingvoltageshallbe120volts,60Hz,singlephase.Plug-infieldwiringshallallowremovalofthecontrollercircuitboardswithoutdisconnectinganypanelorfieldwiringfromtheterminalstrips.Thecontrollershall includeall necessary24VDCpower tosupply inputandoutputcircuits.2. EnclosureControllers shall be flushmountedon the control cabinet andshallhaveNEMA13rated(oil/waterspray)frontpaneldisplays,keyboard, cabinet to case and case to front panel gasketing.Controllersshallbeabletooperateindefinitelyin120°Flocationswithnocoolingfans.Controllertuningandconfigurationmenusshallbeconcealedbehindapanelfrontlocateddoor.3. Operator InterfaceDigitaldisplaysandkeypadshallbeprovidedon thecontrollerfrontpanel.Thecontrollershallbecapableofdisplayingupto10processvariableswithEnglishlanguagedescriptions.Additionally,controllersshallhavea tenpointEnglish language “first -out”annunciator.Controllers shall have two 50 segment red LEDbargraphs to locally display the process variable and setpointandone20segmentredLEDbargraphtodisplaytheoutput.Alloperatorpushbuttonsshallbeof themembranetypeandshallhavetactilefeedback.StatusindicationsshallbelonglifeLEDs.4. ConfigurationControl strategy shall not use“blockware” type language.Thecontrollershallbesuppliedwithanonboardlibraryof61analoganddiscretefunctionsandhaveaminimum160blockmemory.Anyquantityorcombinationoffunctionblocks(AIN,PID,LOALM,F(x),etc.)shallbeeasilycopiedintoacontrolstrategyand“wired”fromblocktoblock.ThecontrollershallbecapableofcalculatingrealtimeboilerefficiencybasedontheASME“bylosses”method.Thecalculationmustuserealtimeinputsofboilerfiringrate,fluegasoxygen, fluegas temperatureand fuel selected.Twosetsofadjustablefuelchemistrydataparametersshallbeincluded,andfiringratescaledradiationlossesshallbeusedformaximumaccuracy.Calculationsthatrelyonfixedconstantsormanuallyentered values for these conditions are not acceptable. Fuel/Airratiocurveandoxygentrimsetpointcurveadjustmentshallbeautomated for rapid, error-free burner setup.Only a singleoperator action shall be required to store commissioningdataintomultiple characterizer curves for a particular load point.“examine”and“blockforce”modesshallbeprovidedtoallowrapidsystemtroubleshooting.Eachcontrollershallbecompletelyfieldconfigurablefromthefrontpanelkeypadwithouttheuseofexternal
computersorhand-heldterminals.Configurationchanges,tuning,andoxygentrimsetpointcurveadjustmentshallbeaccomplishedviaakeypadonthecontrollerfrontpanel.Eachcontrollershallhaveseveral levelsofaccesssecurity topreventunauthorizedconfiguration.Provide laptopcomputer,software,andcables ifall formsof controllerconfigurationcannotbeperformed fromthecontrollerfaceplate.5. Input/ Output Signal TypesTheControllershalluse120VACfordiscreteinputsandoutputsforsystemcompatibility. Analoginputsshallbe1-5Vor4-20mADC.Analoginputandoutputsignalsshallbeisolatedfromearthground forground loopprevention.Thecontrollershall includeoptionalTRIAC,24-120VACsolidstateswitchoutputboardstodirectlyinterfacewithelectricactuators.ControllerI/Oquantitiesshallbeexpandablewithplug-inI/Ooptioncards.6. ReliabilityControl signals that are sharedbymultiple boilers (e.g.Plantmasterdemand,andRS485communicationslinks)shallhavesignal isolators in each boiler section. This is to prevent anequipmentorwiringfailureinoneboilerfromshuttingdownanyotherboiler.Eachtransmitterandsensorinputchannelshallhaveindividualpowersupplyshortcircuitprotection.Configurationandcalibrationdatashallbestoredinanon-volatileEEPROMplug-inmemorymodule.Inaddition,aredundantplug-inbackupmemorymoduleshallbefurnishedthatwillautomaticallydownload intothe primarymemory if primarymemory data is corrupted.Asanalternate toredundantplug-inmemorymodules,provideallnecessaryportablecomputers,softwareandhardwaretoallowconfigurationdownloadingandarchival.7. CommunicationEach controller shall be equipped with an isolated RS485communications data highway that communicates inModbusprotocol.IsolationisrequiredtopreventdamagetoallcontrollersonthesameRS485cableshoulda120VACshortoccuranywhereinthesystem.TheRS485protocolshallallow:Auto/Manualmodechange,setpointchange,variationofthemanualoutput,sensingandsilencingofalarms,changeofanyconfigurationparameter(includingPIDtuningconstants),changeoftimers,etc.Controllersshallnotdependonaserialcommunicationslinktosendsensordatarequiredfromcontrollertocontrollerunlessthelinkisfullyredundant.Provide all equipment capabilities specified in thisparagraph,evenifaconnectingSCADAsystemisnotincludedinthisproject.8. Quality AssuranceThecontrollersshallbemanufacturedandlabeledinaccordancewithUL508A (CSAC22.2#14 foruse inCanada). InspectionandlabelingshallbesupervisedbyULorotherOSHAapprovedNationallyRecognizedTestLab(NRTL).LackofanNRTLcertifiedUL508Awiringmethodsinspectionandlabelingwillbegroundsforcontrollerrejection.