EPIC III Fläktbus O p era to r´s M a nua la nd Insta lla tio n Instructio ns
Power Pow er Service Service
Page 1 Preface
Preface EPIC EPIC III the ESP ESP controller controller of the the future This Operator’s and Installation Manual for EPIC III contains contains information for all groups of users from f rom the installation and commissioning to daily operation and tuning of the cleaning process. In addition this manulal has an appendix with the FläktBus Manual.
ALSTOM Power reserves the right to revise any publication and to make changes to its contents, at any time, without obligation to notify any person or entity of such revision or changes. Fur thermore, ALSTOM Power Power reserves the right to make changes to any and all parts of hardware and software, at any time, without obligation to notify any person or entity of such changes.
Page 1 Preface
Preface EPIC EPIC III the ESP ESP controller controller of the the future This Operator’s and Installation Manual for EPIC III contains contains information for all groups of users from f rom the installation and commissioning to daily operation and tuning of the cleaning process. In addition this manulal has an appendix with the FläktBus Manual.
ALSTOM Power reserves the right to revise any publication and to make changes to its contents, at any time, without obligation to notify any person or entity of such revision or changes. Fur thermore, ALSTOM Power Power reserves the right to make changes to any and all parts of hardware and software, at any time, without obligation to notify any person or entity of such changes.
Page 2 Preface
Page 1 Contents
Contents 1. Introduction ....................................................... 3 1.1. EPIC III system ........................................... 3 1.2. EPIC III controller ....................................... 3 2. The EPIC menu system .................................... 7 2.1. [Operation] .................................................. 8 2.2. [Readings] ................................................... 9 2.3. [Alarm Table] ............................................ 10 2.4. [Master] ..................................................... 11 2.5. [Process settings] ..................................... 12 2.6. [Set Up Menu] ........................................... 13 2.7. [Inputs] ...................................................... 17 2.8. [ESP] ......................................................... 17 2.9. [EPOQ] ..................................................... 17 2.10.[VI-curve] .................................................. 19 2.11.[Diagnostics] ............................................. 20 2.12.[Tests] ..................................................... .. 21 2.13.[Save settings] .......................................... 22 3. Installation ....................................................... 23 3.1. General ..................................................... 23 3.2. Assembly rules ......................................... 23 3.3. Connection ................................................ 23 4. First start up (including initial set up) ........... 25 4.1. General instructions .................................. 25 4.2. Initial checks to avoid damage .................. 25 4.3. Power up self test ..................................... 26 4.4. Set up of configuration parameters ........... 26 4.5. Digital alarm test ....................................... 30 4.6. Ignition phase test ..................................... 30 4.7. First start up .............................................. 32 4.8. T/R short circuit test .................................. 33 4.9. I/O groups etc. .......................................... 34 5. Tuning of ESP operation ................................ 35 5.1. Spark settings ........................................... 35 5.2. Process parameters .................................. 35 5.3. [Process settings] ..................................... 35 6. Daily operation ................................................ 37 6.1. ESP-Master operation .............................. 37 6.2. Operation of single T/Rs ........................... 37 7. Function descriptions .................................... 39 7.1. General measurements and control ......... 39 7.2. Spark detection and control ...................... 40 7.3. Password function .................................... 45
7.4. 7.5. 7.6. 7.7.
Copy settings ............................................ 46 [Save settings] .......................................... 47 ESP Master function ................................. 48 EPOQ - Electrostatic Precipitator Optimizing Q algorithm 49 7.8. OpOpt - Opacity optimization algorithm .... 52 7.9. VI-curve function ...................................... 55 7.10.I/O groups and auxiliary inputs ................. 60 7.11.Timer functions ......................................... 69 8. Variable list ..................................................... 81 9. Trouble shooting ............................................ 91 9.1. Alarm messages ....................................... 91 9.2. Alarm messages list ................................. 92 9.3. External alarms ........................................ 96 9.4. Other faults ............................................... 96 9.5. Diagnostics windows ................................ 97 9.6. Test windows ............................................ 98 9.7. Program update ...................................... 100 9.8. Warranty & Repair Service ..................... 101 10.Technical data .............................................. 103 10.1.General ................................................... 103 10.2.Analog inputs .......................................... 104 10.3.Analog outputs ....................................... 105 10.4.Digital inputs ........................................... 105 10.5.Digital outputs ......................................... 107 10.6.Power supply .......................................... 107 10.7.Communication ...................................... 107 10.8.Front panel LEDs ................................... 108 11.Word list ....................................................... 109 Appendices EPIC III settings ......................................... 1 page Mounting drawing EPIC III (V4 559 883) .... 1 page Mounting drawing ignition transformer (V3632136) ............................. 1 page Connection diagram, example (V3635661) 1 page Declaration of conformity ........................... 1 page FläktBus manual .......................................4 pages
Page 2 Contents
Page 3 1. Introduction
1. Introduction 1.1.
EPIC III system The EPIC III (Electrostatic Precipitator Integrated Controller) system is an ALSTOM Power third generation microprocessor based control system for electrostatic precipitators. With a separate control unit and display unit, a new degree of design freedom is achieved. The new EPIC III concept consists of two major components of which only one is needed for basic operation. •
EPIC III main unit, includes all processing power.
•
Remote Terminal Unit (RTU), needed only as an operator interface.
One RTU can serve as the operator interface for many EPIC s
ProMo, colour graphic software package, host computer gateways with software protocol is available as an option.
1.2.
EPIC III controller The EPIC III is a microprocessor based unit for regulation and control of the electric power input to electrostatic precipitators. The EPIC III maintains the spark rate at a suitable level for large variations of gas temperature, dust composition, gas flow, etc. It regulates the rectifier in such a way that the current through the electrostatic precipitator is corrected as t he conditions for sparking change. The whole operation can be monitored by the RTU , ProMo and host computers.
Page 4 1. Introduction
The EPIC III gives alarm messages to the operator when values are lower or higher than set, if one or several alarm contacts are activated etc. All alarm messages are displayed on and may be reset from RTU , ProMo, etc. Six operating modes can be predefined and then selected for each individual EPIC III . The EPIC III has a Master function which means that one EPIC III , defined as master unit, can control all EPIC III s in the FläktBus system and achieve greater total ESP performance. Operation together with the optional EPOQ algorithm, Electrostatic Precipitator Optimizing Q, optimizes the best collection efficiency at different load conditions. The EPIC III contains one circuit board mounted in the enclosure. The circuit board holds all functions needed for the complete controller: •Power Supply feed from 24V AC or DC. •One 16 bit Microprocessor with software. •Data acquisition analog and digital.
•Analogue outputs (kV, mA)
•Ignition circuits for the SCR.
•Non-Volatile Memory (EEPROM, no battery needed) for storing of system parameters.
•Non-Volatile Memory (FLASH) for storage of control software.
•Real Time Clock (capacitor backed, no battery needed). •Field Bus Communication (FläktBus) for communication with RTU , ProMo, Gateway and other connected EPIC III units. •Ethernet kit will be available.
1.2.1.
Front panel There are several LEDs on the front panel indicating the status of the EPIC III . Status information can also be obtained from other equipment like RTU (Remote Terminal Unit), ProMo etc.
Page 5 1. Introduction
POWER
Power from the +5 V power supply unit is OK
ALARM
Indicates during all alarm conditions Lit = tripping alarm Flicking = warning alarm
SPARK
One flicking for each detected spark
TOKEN
Flicking during communication over FläktBus No flicking = no communication
T/R ON
Indicates if the main contactor and T/R is ON.
SYNC
Indicates when EPIC is locked to line frequency.
RTU connector Service connector with power and FläktBus for one RTU used at first start-up and during trouble shooting. NETWORK
ON = (Normal position) EPIC connected to external FläktBus network and to the RTU connector above. OFF = (For test and maintenance) EPIC is only connected to the RTU connector.
All terminals on the left-hand side of EPIC III are made through plug-in terminals. This arrangement makes service fast by swapping a unit without having to unscrew all the wires. For all information about the hardware input/ output of both analog and digital signals, see section 10. Technical data on page 103.
Page 6 1. Introduction
Page 7 2. The EPIC menu system
2. The EPIC menu system The following pages describe all windows in EPIC III displayed by using an RTU. All names between brackets [ ] are menus containing parameters. At the beginning of this chapter there is a chart of all windows as they appear in the RTU . It is recommended to read the text below, as well as studying the “Window structure chart”. For detailed information about each parameters, see section 8. Variable list on page 81.
Operation
Process settings
Mode 1
Readings
Set Up Menu
Diagnostics
Master
Tests
T/R
Mode 2
System
Mode 3
Alarm
Mode 4
Alarm
I/O Groups
Mode 5 Inputs Mode 6 ESP Spark settings EPOQ
VI-curve
VI-Curve Set.
Figure 1. Explanation of EPIC III window structure
Page 8 2. The EPIC menu system
2.1.
[Operation] The [Operation] menu consists of the most important parameters for daily operation and control of EPIC III .
2.1.1.
[Operation] The left side of this window have parameters which controls the operation such as, T/R ON or OFF and selection of different control modes. The Limiter parameter informs the operator why EPIC III is unable to increase the power to the ESP. The Reset function will only be displayed when an alarm is active. The Active CL shows the present current limit and the Active CR shows the present charging ratio the EPIC III is using for the moment The right side of the window shows measured variables.
2.1.2.
[Active Settings] This window displays the parameters of the active mode selected in the [Operation] window above. All parameters in this window can be changed during operation. The actual mode will also be updated in [Mode Settings] at the same time.
Page 9 2. The EPIC menu system
2.2.
[Readings] The [Readings] menu displays measured values. The values are updated continually to give you the actual status of your system.
2.2.1.
[Prim. readings] The [Prim. Readings] window displays measured values on the primary side.
2.2.2.
[Sec. readings] The [Sec. readings] window shows all measured information on the secondary side.
2.2.3.
[Readings sparks] The [Readings sparks] window shows all measured information about sparks.
Page 10 2. The EPIC menu system
2.3.
[Alarm Table] The [Alarm Table] consists of the most common alarms EPIC III can indicate. It contains both W = warning and T = tripping alarm. The warning alarm informs that something is wrong and the tripping alarm turns t he T/R OFF. When there is an alarm situation an alarm message will be displayed on the RTU , see section 9. Trouble shooting on page 91 for explanation of each alarm. The alarm message must either be Acknowledged - which means that the alarm is noticed by the operator and the alarm message is turned off, but the alarm is still active - or Reset - which means that the alarm will disappear if the error has disappeared. See the RTU manual for further information about the alarm windows.
2.3.1.
[Alarm Table 1-5] In the [Alarm Table] all active alarms are marked with a black box (n) at the right. When all alarms have been thoroughly checked they must be Reset. The Reset function is placed under the [Operation] menu in [ Operation] window. Each alarm situation follows by an alarm message containing the most important information needed. See section 9. Trouble shooting on page 91 for an explanation of alarms.
IoGrp 1 IoGrp 2 IoGrp 3 IoGrp 4
DigAux1 DigAux2 DigAux3 DigAux4
Cont.
Page 11 2. The EPIC menu system
2.4.
[Master] The [Master] window is for Master function only. A Master EPIC can control and operate part of or all connected EPIC III units in a network.
2.4.1.
[ESP-Master] This window displays the total number of connected T/Rs and the total number of different alarm status. All EPIC III can be globally changed for example, all active alarm situations can be reset, the active mode can be globally changed, all EPIC III can be switched off, etc.
The Opacity Optimizing command activates or deactivates the Opacity optimizing algorithm, the OpOpt. Note! In each slave EPIC that shall be activated from the master unit the Opacity controlled in the [Process settings] [Mode #] RTU-window has to be set to ON .
In addition, this window shows the total power consumption. The ESP-Master must know the lowest and highest address of connected EPIC III units. The master will only control those EPICs within the limit. This limit decides also which units the OpOpt will optimize.
Page 12 2. The EPIC menu system
2.4.2.
[Opacity optim.] This window contains Opacity optimizing set-up parameters, see heading 7.8. OpOpt - Opacity optimization algorithm on page 52 for detailed information.
2.5.
[Process settings] [Process settings] contains six identical blocks of parameters. Each block is called a “Mode” since it gives EPIC III a certain mode of operation, when it is active. The modes have different numbers and need to be pre-set with optimal parameter settings for the actual T/R to be able to give correct operation. All parameters in each mode can be manually changed during normal operation or in advance to achieve the required operation after a mode change.
2.5.1.
[Settings Mode #] These modes can be set to different operating conditions such as different Semipulse® charging ratios and with EPOQ optimization on or off.
2.5.2.
[Spark settings] The [Spark settings] window contains settings of the parameters that define the spark detection, quenching and level following functions. These settings can be manually changed during operation to optimize the precipitator operation.
Page 13 2. The EPIC menu system
Three more parameters concerning sparks are available in each operation mode block.
2.5.3.
[Spark levels] The normal sensing method is voltage sensing but current sensing can be used if the kV-signal is not available.
2.6.
[Set Up Menu] The [Set Up Menu] is used mostly during the installation and first start-up of the EPIC III . All variables and other settings which define basic data of the T/R and the precipitator are collected here.
Page 14 2. The EPIC menu system
2.6.1. 2.6.1.1.
[T/R] [Set up T/R Limit] The [Set up T/R Limit] windows contain settings of different alarm and control limits that are set according to the T/R and ESP limitations
2.6.1.2.
[Set up T/R Ratio] The [Set up T/R Ratio] window informs EPIC III about the conversion ratios for primary and secondary values of voltage and current.
2.6.2.
[Set up system] In the [Set up system] menu all parameters are collected which are important for system set up such as, date, time, unit address etc.
2.6.2.1.
[Copy settings] This window restores the default values or copy values from other EPIC III controllers on the net. This means that all field made settings will be l ost. The restore function is supplied as a method to erase bad data in the parameter memory. After use of this restore function the set up part of the installation has to be made again.
Page 15 2. The EPIC menu system
A convenient and time saving function is the node copy function. This function allows you to transfer all parameter values from a specific EPIC III controller. Select the node address of an installed EPIC III that you will copy and press “Node”. Note! The copy function can only transfer parameters from other EPIC III controllers, see heading 7.4. Copy settings on page 46.
2.6.3.
[Set Up Alarms] This menu contains settings of the polarity of digital alarm input and output. Digital inputs number DI04-DI10 can be set individually to activate an alarm when they go high (24V) or low (0V).
2.6.4.
[Set up I/O Groups] This menu contains all parameters for control of I/O groups, see heading 7.10. I/O groups and auxiliary inputs on page 60.
Page 16 2. The EPIC menu system
2.6.4.1.
[Group configuration] This window contains configuration of I/O groups, see heading 7.10.2. Con trol description on page 60.
2.6.4.2.
[Timers 1-3], [Timers 4-6] These two window contains configuration of timers, see heading 7.10.13. [Timer1-6] on page 66.
2.6.4.3.
[Power control] This window contains settings for power change control, see heading 7.10.6.1. Power control Rapping (PCR) on page 64.
Page 17 2. The EPIC menu system
2.7.
[Inputs] This window contains settings for auxiliary digital inputs, see heading 7.10.14. Auxiliary Digital Inputs on page 66.
2.8.
[ESP] The [ESP] window informs EPIC III about the T/R location and the collecting plate area. These are used by EPIC III in calculations and in automatic procedures.
2.9.
[EPOQ] This menu contains the Electrostatic Precipitator Optimizing Q algorithm. (EPOQ) settings. It selects automatically the best possible intermittent energization (Semipulse ®) ratio and current based on on-line measurements of the ESP. For more information, see heading 7.7.3. EPOQ Set up on page 51.
Page 18 2. The EPIC menu system
The EPOQ function contains the following three RTU windows:
Page 19 2. The EPIC menu system
2.10. [VI-curve] The VI-curve window is used for analysing of Electrostatic Precipitator operation, see heading 7.9.2. Window structure overview on page 55.
2.10.0.1. [VI Curve] This window contains the control of the VI-curve function. It also shows information about the latest collection.
2.10.0.2. [VI-Curve Graph] This window presents graphs of the latest collection.
90.0
2.10.0.3. [Settings] This window contains different settings that affect the measurement.
Page 20 2. The EPIC menu system
2.11. [Diagnostics] 2.11.1. [Communication stats.] The [Communication stats.] window is used for monitoring of communication status, see heading 9.5.1. [Communication stats.] on page 97.
Page 21 2. The EPIC menu system
2.12. [Tests] The [Tests] menu is for trouble shooting, see heading 9.6. Test windows on page 98. The Test functions contains the following RTU windows:
Page 22 2. The EPIC menu system
2.13. [Save settings] All changes of parameters must be saved with this function if they should be remembered even after a power down. The function monitors if any changes have been made since last saving by showing “Changes” or “No changes”. See heading 7.5. [Save settings] on page 48. See section 8. Variable list on page 81 for indication of which parameter that is saved. Unit address and unit name is always automatically saved when changed.
Page 23 3. Installation
3. Installation 3.1.
General EPIC III is very simple to install since all electronic components are gathered in one box, even the SCR ignition circuits.
For mechanical mounting, dimensions and instructions see Appendix. One ignition transformer is delivered with every EPIC III unit. Measurement transformers for primary current and voltage is available as an option.
3.2.
Assembly rules There are a few simple rules for installation of EPIC III . 1. EPIC III must be installed close to the SCRs. 2.
Make sure that EPIC III is properly grounded directly in the mounting plate with the mounting screws.
3.
The pair of twisted cables from the ignition board must not be increased in length. See Appendix.
4.
The measuring cables for secondary current and secondary voltage must be pair twisted and shielded. The shield must be grounded at both ends.
3.3.
Connection For reference purposes one example drawing of the connection between EPIC III and T/R is supplied in the Appendix. This drawing is generally used as a basic drawing for the design of the actual plant drawings. For installation and trouble shooting, please refer to the actual plant drawings.
Page 24 3. Installation
For an explanation of all input and output terminals, see section 10. Techni cal data on page 103. All wires are connected to jackable terminal connectors. The terminals can take wires from 0,5 to 2,5 mm 2.
Page 25 4. First start up (including initial set up)
4. First start up (including initial set up) This chapter is a step by step instruction of how to make the first start up of EPIC III .
4.1.
General instructions The EPIC III must have been correctly installed before start up, See section 3. Installation on page 23. In order to understand this chapter you must be familiar with the RTU , If you do not know how to use an RTU, please read the RTU manual. The necessary equipment for start up comprises: •
One hand held RTU , which has been correctly set up.
•
Voltage meter
•
Oscilloscope
•
Network node address list
•
Circuit diagram of the installation.
4.2. Initial checks to avoid damage Before you turn on the mains you must be sure that the EPIC III has been correctly installed. The following steps ensures that all voltage inputs are correct in order to prevent damage to EPIC III . Do as follows: 1.
Make sure that the mains power supply is switched off. Disconnect the six jackable terminal connectors terminal 1-72 where all the wires to the EPIC III are connected.
2.
Switch on the mains power supply.
3.
Measure the power supply between terminal 1 and 13. The Power supply must be 24 V AC or DC ±15% .
4.
Measure the Primary line voltage from the measuring transformer between terminal 10 and 22. The Primary line voltage is normally 5 V AC at nominal line voltage.
5.
Switch off the mains power supply.
6.
Reconnect all terminal connectors to EPIC III .
Page 26 4. First start up (including initial set up)
4.3.
Power up self te test 1.
Turn the NETWORK switch to OFF position and connect the RTU to to the front of EPIC III .
2.
Switc Switch h on the the mai mains ns po power wer supp supply ly.. The The POWER LED will light up and remain lit as long as the EPIC III is is in operation. Both EPIC III and and RTU commence commence operation with a self test. The self test on EPIC III starts starts to test all LEDs one by one on the front panel. The light will run from the ALARM LED the SYNC LED.
3.
Check that the TOKEN LED starts to blink when the RTU self test is ready. ready. If it doesn’t start to blink, check the node addresses (all nodes must have unique addresses).
4.
If an external external alarm is display displayed ed such such as “T “Temperature emperature high, high, T/R Tripped” just acknowledge acknowledge the alarm. This will be taken care of under “Digital alarm test” later in this chapter.
4.4. 4. 4. Set Set up up of of con confi figu gura rati tion on para parame mete ters rs The EPIC III has has to be set to t o correct values to ensure proper operation of the ESP. ESP. All parameters concerning the T/R operation and its it s location in the ESP must be set up before first start up. The following pages will guide you through the different parameters and explain its function. All names between brackets [ ] are menus displayed on the RTU which which contain the parameters. Note! A time saving function is the node copy function. This function lets EPIC III III . See heading you copy parameters from an already installed EPIC 7.4. Copy settings on page 46. 46.
You need to know the actual passwords for the hand-held RTU . Each unit are delivered with following password levels: Low= 0001, Medium = 0002 and High = 0470. You also need the Network node address list compiled by ALSTOM Power. For detailed information of each parameter, see section 8. Variable list on page 81. 81 .
4.4.1.
[Set Up] [System], [System], definin defining g the the position position in the the FläktBus FläktBus network network After the power up self test the RTU displays displays the [Node list]. This list contains two nodes, the home RTU and and the EPIC III . To display the [Set Up] [System] window do as follows: 1.
Select the EPIC III unit. unit.
2.
The [Main [Main menu menu]] is now now displa displaye yed. d. Sele Select ct “Set “Set up”. up”.
3.
The [Set [Set Up] menu menu is now now displa displayed yed.. Selec Selectt “Syst “System” em”..
4.
The The [Sys [Syste tem] m] wind windo ow is now now dis displ play ayed ed..
Page 27 4. First start up (including initial set up)
This window displays five parameters and the actual program version:
Only used if this unit is to serve as master for other EPI EPIC’ son the network.
Select “Date”. Set actual day, month and year. 5.
Sele Select ct “Tim “Time” e”.. Set Set actu actual al time time..
6.
Sele Select ct “Lan “Langu guag age” e” on the the EPIC III . This setting has to be made on the RTU first. If the language settings on the RTU and the EPIC III are are not the same, English will automatically be selected on both the RTU and the EPIC III . Language codes are shown below: Language
Code
(English
0)
Swedish
1
German
2
Danish
3
Spanish
4
Czech
5
Polish
6
Russian
7
Finnish
8
French
9
Japanese
10
Dutch
11
Portuguese
12
Bulgarian
13
Note! All languages are not implemented. If a not implemented language is selected, the following error message will appear: The parameter is temporarily blocked!
7.
Select “Name”. Enter the name of this EPIC from from the Network node address list.
8.
Select Select “Addres Address” s”.. Enter Enter the new new addre address ss from from Network node address list.
Note! When the address parameter is changed the RTU will will give an error
Page 28 4. First start up (including initial set up)
EPIC III III with message and return to the [Node list] and display the EPIC with its new address.
Shortly after pressing OK an error message is displayed. ************ERROR ************ The selected node is no longer present on the net! The error message is displayed because there is no longer a node with the old address. Press OK and the RTU returns returns to the [Node list]. After Aft er a short delay the EPIC III will will display its new name and address address in the node list.
4.4.2. 4.4 .2.
[Set [Set Up] Up] [T/R]: [T/R]: defini defining ng the T/R and ESP Further on from this point each parameter will only be indicated by its name as it appears in the RTU , and a short explanation of its function. However However all parameters have to be set to correct values to ensure proper operation of the ESP.
4.4. 4.4.2. 2.1. 1.
[Set [Set-u -up] p] [T/R [T/R]] [Lim [Limit it]] Pr. curr limit rms: Trip This is the maximum allowed primary current for the T/R. EPIC III will will try to keep the current below this value during all control situations, if this is not possible the T/R will trip. Voltage limit ave: Low warning This warning alarm will give an alarm message if the secondary voltage to the ESP stays below this limit for more than 30 sec. Voltage limit ave: Low trip This trip alarm will trip tr ip the T/R and give an alarm message if the secondary voltage stays below below this limit for more than 30 sec. Voltage limit ave: High trip This trip alarm will trip tr ip the T/R and give an alarm message if the secondary voltage stays above above this limit for more than 1 sec. Av. Curr. max. This is normally the rated value for the T/R. Ign. ang. lim. This should normally be 100 %. Lower values can, can, however, however, be used during start-up. Idle cur. lim. This should should normally normally be 0 mA.
Page 29 4. First start up (including initial set up)
4.4.2.2.
[Set Up] [T/R] [Ratio] Line volt. xformer This is the rated primary voltage of the measurement transformer actually in use. It normally converts the line nominal voltage to 5V. It is possible to use transformers that convert a higher voltage, than line voltage (mains input), to 5 V but it will degrade measurement accuracy. Prim curr. xformer This is the rated primary current of the actual used measurement transformer. It normally converts the T/R rated primary current to 1 A. It is possible to use transformers that convert a higher current, than T/R rated primary current, to 1 A, but it will degrade measurement accuracy. Sec. volt. ser. res. This is the T/R rated secondary average voltage at rated ESP load. Enter the voltage that gives 0.4 mA input to EPIC III . Sec. curr. shunt This is the rated secondary average current. Enter the current that gives 1V input to EPIC III . Prim Curr adjustm. An offset trim variable to get 0.0 A during High voltage OFF.
4.4.2.3.
[Set Up] [ESP] Position: Field/cell This is the T/R position in the ESP indicated by letters and numbers. The lengthwise position is indicated by a letter A,B......where A is closest to the dust inlet and the crosswise position is indicated by numbers 1,2,.....where 1 is to the left if you are facing the dust stream of the ESP.
Page 30 4. First start up (including initial set up)
3
61
62
63
64
65
2
51
52
53
54
55
Flow
1
41
42
43
44
45
A B Master
C
D
E
3
31
32
33
34
35
Recommended node addresses EPIC III 11-99 RTU 100-109 Gatewa Gateway y 110-1 110-119 19 ProMo 120-125
2
21
22
23
24
25
1
11
12
13
14
15
C
D
E
A B Master
Flow
Figure Figure 2. Node addresses addresses and field/cell position (in bold text)
Position: Collector area This is the collector area the T/R is connected to. The area includes both plate sides.
4.5.
Digital tal alarm test At this point during the start up of the EPIC III it it is important to test the digital alarm signals to the EPIC III . If they are wrong they may invalidate the rest of the start up and may also be unable to indicate alarm situations during start up. The digital alarms are connected to Digital Input DI 04 to DI 10, see section 10. Technical data on page 103. 103 . The actual installation may use all or some of these inputs. Check each input one by one by activating the alarm sensor and observe the alarm message on the RTU . If the default setting of an alarm input has the wrong active level it is possible to change the active level of the alarm input in window [SET UP][ALARM]. Note! If changes of parameters are made remember to save settings.
4.6.
Ignition ph phase te test To make sure that the t he installation is correct in phase it is absolutely necessary to do a phase check before normal T/R operation. This is done to ensure that each SCR (thyristor) is ignited in the t he correct phase, when it has higher voltage on the anode than on the cathode. Carry out the following test:
Page 31 4. First start up (including initial set up)
4.6.1 .6.1..
Lig Light bulb ulb te test 1.
Turn Turn off off power power to to the cubicle cubicle with with the the mains mains switch switch.. Follo Follow w the local local safety instructions of the plant!
2.
Disconnec Disconnectt the power power cable cabless betwee between n the control control cubicle cubicle and the T/R T/R and connect light bulbs in place of T/R. The light bulbs have have to withstand the full line voltage.
3.
Turn Turn on power power to the the cubicle. cubicle. Follow Follow the the local local safety safety instruction instructionss of the the plant!
4.
Set temporarily Voltage limit low warning = 0, Voltage limit low trip = 0 and Ignition angle limit = 30 % in [Set [Set Up] [T/R] [T/R]
5.
det. level = 0 in [Process Set temporarily Arc det. [Process settings] [Spark settings].
6.
Turn urn on the the ign ignit itio ion n by High voltage ON in in [Operation].
7.
Check Check that that the power power to to the light bulbs bulbs is controllab controllable le by by setting setting Ignition Ignition angle limit to values between 1 and 100%. If so the phase is okay, continue with point 10.
8.
If the light does not chang changee it is probab probably ly becaus becausee the phase phase referenc referencee is shifted 180 °. This can be corrected by by switching the reference voltage voltage to the EPIC III as follows: A. Turn off power power to the cubicle cubicle with the mains switch. switch. Follow local safety instructions! B. Swap Swap the the wires wires to EPIC III terminal terminal 10 and 22 (Primary line voltage transformer input). This is the phase reference to the EPIC III . C. Repeat from point 3 above.
9.
Turn Turn off off power power to to the cubicle cubicle with with the the mains mains switch switch.. Follo Follow w the local local safety instructions of the plant! The temporary settings in EPIC III are lost.
10. Disconnec Disconnectt the light bulbs bulbs and conne connect ct power power cables cables to the T/R. 11. Turn on power power to the cubicle. Follow the local safety instructions instructions of the plant!
Page 32 4. First start up (including initial set up)
4.7.
First start up It is recommended that during the first start up the readings are checked checked using a very low current. 1.
UP in [Operation]. Set Mode= START UP in
2.
Go to to [Opera [Operation tion]] [Acti [Active ve set] set] and make make the the follo followin wing g settin settings gs:: 30kV Volt peak limit = a low value compared to T/R ratings Current Current limit = 1:1 Charge ratio = OFF EPOQ = 1 Rapp Intens. OFF Rapp all 10 spm Spark rate limit = 15% Current step= 2 pls Short quenching = SHORT Quench mod. = OFF Opacity controlled =
3.
Go to [Se [Set up] up] [T/R [T/R]] and and set: set: 30% Ignition angle limit =
4.
voltage ON in Turn High voltage in [Operation]
5.
Obse Observ rvee the the cur curre rent nt rea readi ding ngss and and the the Limiter indicator in [Operation]. Current and voltage values should increase until this indicator shows a limit value.
6.
Increase Increase the limiting limiting paramet parameters ers one by one until normal normal operatio operation n is obtained.
7.
Make external external measureme measurements nts and compare compare the following following analog analog readreadings on RTU in in [Readings]: Line volt rms Primary current rms. (Be rms. (Be sure to use a true RMS meter). Secondary voltage Secondary current. Auxiliary (If used).
4.7. 4.7.1. 1.
Feed Feedba bac ck sign signal al qual qualit ity y The EPIC III performs performs very sophisticated sampling and calculations based on the analog signals input to the EPIC III . It is therefore essential that these signals represent the actual field signal with good accuracy and that the signals are free from distortion and transients. Use an oscilloscope, not grounded, battery powered and measure over the two input terminals for each signal to EPIC III . The signals should look as follows: (60 Hz line frequency) f requency)
Page 33 4. First start up (including initial set up)
Primary line voltage [Line volt rms]
Primary current [Pr.curr rms]
0
Terminal no: 10, 22
10 ms/ div
0
Terminal no: 9, 21
Secondary line voltage [Line volt rms]
10 ms/ div
Secondary current [Pr.curr rms]
0
0 Terminal no: 8, 20
4.8.
10 ms/ div
Terminal no: 6, 18
10 ms/ div
8.
Turn High voltage = OFF
9.
Turn off and on the power to the EPIC III to reset temporary test settings on parameters.
T/R short circuit test If the manufacturer of the T/R recommends carrying out a short circuit test of the T/R it is possible to do this using the following procedure. 1.
Set [Set Up] [T/R] [Limit] Voltage limit ave: Low warning and Low trip = 0 kV to avoid alarms. Do not save the settings.
2.
Set [Process settings] [Spark settings] Arc detection level = 0 kV to avoid false arc detection. Do not save the settings.
Page 34 4. First start up (including initial set up)
4.9.
3.
Perform short circuit test according to T/R manufacturers specification.
4.
Restore the Voltage limit ave: Low warning and Low trip and Arc detection level to the previous levels by disconnecting the voltage to the EPIC III .
I/O groups etc. It is recommended to control rappers from the EPIC III via the I/O:s in order to utilize the power change rapping function in EPIC III . For more information, see heading 7.10. I/O groups and auxiliary inputs on page 60. Note! If changes of parameters are made remember to save settings.
Page 35 5. Tuning of ESP operation
5. Tuning of ESP operation 5.1.
Spark settings See heading 7.2. Spark detection and control on page 40
5.2.
Process parameters EPIC III has six sets of parameters in [Process Settings] each one for use during different operating conditions. The default data of these modes at delivery provides an approximate value only. For proper operation of the actual process must these parameters be tuned at site.
All modes have an identical set of parameters. It is the selected value of the parameters that determine if the mode is useful for a certain process operation. It is however not necessary to set parameters for more modes than needed.
5.3.
[Process settings]
Each of the six mode blocks above have one set of the following parameters.
5.3.1.
Volt. peak lim. This parameter should be set to the maximum peak voltage that the precipitator is allowed to operate at during this mode. This is useful for example, to limit peak voltage below sparking level during start up of ESP.
5.3.2.
Current limit This parameter limits the pulse current. For charge ratio = 1:1 the same as the average value on the mA meter. For more information, see heading 7.1.1. Current measurements on page 39.
5.3.3.
Charging ratio This parameter controls the Semipulse® energization. For example, if the set value is 1:3 it means that one half period will be fired, but the following two are not. 1:1 means that each half period will be fired.
Page 36 5. Tuning of ESP operation
5.3.4.
EPOQ This is an algorithm for optimizing the ESP. See section 7. Function descrip tions on page 39.
5.3.5.
Rapp. Intens This parameter makes it possible to prolong the repetition time for the rappers. The rapping intensity parameter can be set from 1 to 10 and multiplies the repetition time with its assigned value.
5.3.6.
Rapp all This parameter starts all the rappers in EPIC III .
5.3.7.
Spark rate lim This parameter limits the number of sparks per minute.
5.3.8.
Current step This parameter reduces the secondary current after a sparkover. The reduction is in percent of the secondary current at the time of the spark.
5.3.9.
Short quenching This parameter determines the blocking time in half periods.
5.3.10. Quench mod. This parameter has three modes: SELF = No quenching after a spark SHORT = Short quenching time after a spark. SELF + SHORT = Short quenching only if a spark occurs on two consecutive half periods.
5.3.11. Opacity controlled The Opacity control for this unit can be activated or deactivated. This assumes that the Opacity optim. in window [Master] [Opacity] is set to ON and that this unit is within the ESP address limits for master control. Remember to save all settings. See heading 7.5. [Save settings] on page 48.
Page 37 6. Daily operation
6. Daily operation The daily operation assumes that setup has being performed correctly and also that correct mode settings have being set during tuning of the ESP. See section 2. The EPIC menu system on page 7 for an overview of all windows in EPIC III displayed by an RTU. Daily operation is mainly performed from the [ESP-Master] window, controlling all T/Rs at the same time using convenient group commands. If for some reason one T/R need to be controlled as a single unit this can be performed from the [Operation] window in the actual unit.
6.1.
6.2.
ESP-Master operation 1.
From the [Node List], that always can be reached by repeatedly pressing the key, select the EPIC III unit that is appointed master for the other nodes. This is shown by the indication MU to the right of the unit name in the [Node list]. If no master is appointed, the MU sign will not show.
2.
Select [Master] window in the master unit.
3.
Check that the Total corresponds to the actual No. of T/Rs for this ESP. This shows that the master unit has contact with all other EPIC/SIR controllers.
4.
Select required mode of operation, this will change all T/Rs to selected mode.
5.
Start all T/Rs with ESP mode = ON command. The T/Rs will start one by one and begin operation during control of the parameters in selected mode. Remember that different T/Rs can have different parameters set for a certain mode.
6.
If the process calls for a change of mode. For example, from Mode 1 to Mode 2 this is easily done by the Mode change command.
7.
The [ESP-Master] window shows how many units are running in the actual mode on the right.
8.
Stop of all T/R's is effected by ESP mode = OFF command. The T/Rs will stop one by one.
Operation of single T/Rs If more information about a single T/R is needed or there is a need to control a T/R separately, this can be done by selecting the actual unit f rom the [Node list] and then selecting the appropriate window for the task. The most common windows for daily operation are,
Page 38 6. Daily operation
6.2.1.
[Operation] In this window alarms can be reset. The T/R can be individually turned ON and OFF. The active mode can be individually selected. The reason for any limitation of current is displayed. The most important measurements are displayed.
6.2.2.
[Operation] [Oper. active set.] In this window is it possible to change parameters for the mode that is in operation.
6.2.3.
[Readings] and [Readings spark] In this window more detailed readings are available.
6.2.4.
[Alarm Table 1-5] This windows are used to find out which alarms are active - if this has been forgotten since the alarm message was displayed.
Page 39 7. Function descriptions
7. Function descriptions 7.1. General measurements and control The measurements are synchronized to the line frequency and all presented values are averaged over approximately one second. This means that for instance 100 peak values are averaged in the kVp value at 50Hz and Charging ratio (CR)=1:1, but only 2 values at CR 1:51. For CR values lower than 1:101 the update and average frequency will be equal to the firing frequency for those values that depend on CR.
7.1.1.
Current measurements Measurement of secondary current includes Peak, Pulse and Average. These values are measured as follows: CR = 1:1
Pulse
Peak
CR = 1:3
Pulse Average
Peak
Average
Theoretical pulse value is equal the CR rate multiplied with the measured average value
7.1.2.
Voltage measurement Measurement of secondary voltage includes Average, Peak, and Valley values. These values are measured as follows:
Page 40 7. Function descriptions
Peak
Average
Valley
“No” load
Normal load
7.1.3.
ON-OFF control The T/R can easily be switched on and off over the FläktBus using an RTU or a ProMo. If power is lost for longer than 200 ms the EPIC III s restart routine will switch High voltage = OFF. This routine prevents unwanted restarts when power is restored after dropouts > 200 ms. By using an RTU , the High voltage can be switched ON again.
7.1.4.
Current limitation One of the set up parameters in [Set Up] [T/R] [Set up T/R Limit] is called Pr. curr. limit rms (Primary Line Current Limit rms [Arms]). It is set to the T/R rated primary current, using an RTU , during first start up of the T/R. If primary current tends to rise above this value the EPIC III will first try to keep it below the limit by reducing the SCR firing angle. If the primary current still stays above the limit for more than 5 seconds the EPIC III will trip the T/R and display an alarm message. The delay-time is fixed because all short over-current situations will be handled by the control of ignition angle. When this limit control fails (when the EPIC III loses control of the SCRs) the EPIC III will trip the contactor.
7.2. Spark detection and control Sparks are handled by the EPIC III by three different software functions:
7.2.1.
•
Spark detecting
•
Spark quenching
•
Spark level following function:
Spark and arch detecting function A. Sparks are normally detected from the kV measurement samples (Voltage Method), they are continuously analyzed for slopes that indicates sparkover. If found, a signal is given to the quenching function to actu-
Page 41 7. Function descriptions
ate proper action. The Spark sensitivity detector determines how steep the current has to rise in order to detected as a spark situation. The variable is adjustable and is defined in kV/ms. It is located under [Process settings] [Spark settings] [Spark levels] window. B.
Arcs are detected by analyzing the kVv values. Arching is defined as kVv < Arc detection level continuously for 10 fired periods. (During Semipulse, one period means one total semipulse cycle.) If arc is detected, a signal is given to the quenching function to actuate proper action.
T/R units which only have secondary current measurement feedback can be controlled by using the Current method instead of the Voltage method. By doing so only sparks can be detected (no Arcs).
7.2.2.
Spark quenching function Four methods of quenching are used.
7.2.2.1.
Quench mode = SELF This method is useful when the spark does not need any explicit quenching period except the normal time to next firing. Nothing is done by the quenching function. The T/R decreases the current according to settings in Step act. curr. Be careful while using this mode since it may cause severe arcing conditions. The arcs can be studied by the arc counter.
7.2.2.2.
Quench mode = SHORT This method is useful when the spark always needs a short blocking time. This quenching time is selectable in half periods from 2 to 9. During semipulse® operation, the next fired pulse will start immediately after the quenching period. The spark level follower decreases the current according to settings in Step act. curr.
7.2.2.3.
Quench mode = SELF + SHORT (recommended for general use) This method is useful when the spark does not normally need any explicit quenching period, except for the normal time to next firing, but if two sparks occur on consecutive half periods then short quenching is needed and actuated. The T/R decreases the current according to settings in Step act. curr. While used, this function should not cause more than 1/10 of double sparks compared to sparks, else use quench mode = Short.
7.2.2.4.
Arc quenching=1-99 This function takes place when arcs are detected. The quench time is adjustable in half periods from 1 to 99. The Arc quenching function is always active.
Page 42 7. Function descriptions
7.2.3.
Spark level following The spark level follower is a function that has factory set parameters. Its purpose is to maintain maximum voltage in the ESP. These factory settings can very often be used without any change at all, but they can be adjusted to suit the process. The figure below shows that the spark level follower in the EPIC III raises the current to the ESP. Consequently the voltage in the ESP will rise and at a certain level there will be a spark in the ESP. Spark quenching ( Short quenching ) then brings the current down to 0 for a short time. The spark level following function will then re-apply the current again. The current will, however, not be restored to the same level immediately, but to one step lower (called current step). Current mA
Spark detection Current step
Spark level
Spark quenching (Short quenching)
1
2
t (s)
From this level the current is set to rise and follow three slopes (slope A, B and C), see figure below. The slope parameters Slope Rise A, Slope Time A and Slope Rise C can be changed. Slope Time A determines the time for slope A as a percentage of the average time between sparks. Slope Rise A determines the increase in current during slope A as a percentage of the current step. The parameters for slope B cannot directly be changed by the user. The time and rise parameters are calculated as follows: after a spark the EPIC III seeks to establish the same current level as before the spark and in a time equal to the average time between sparks (Slope Time A + Slope Time B). Most likely a new spark will occur here (marked with a second spark symbol). If no spark occurs, slope B continues for a period equal to the period before the assumed spark. If still no spark occurs, slope B will be succeed by Slope C. Slope C (Slope Rise C can be set) will raise the current until a spark occurs or the voltage or current limit for the EPIC III is reached.
Page 43 7. Function descriptions
Limited Slope rise C
Slope rise A Current mA
Slope rise B
Step
t (s) 1
2
3
4
5
6
7
Slope time A
8
9
10
Slope time B
11
12
13
Slope time B
Sparks are normally detected from the kV measurement which is continuously analysed for negative slopes, indicating sparks. If found, the output is quenched for a set time ( Spark Quenching - 2-9 half-periods). Spark sensitivity determines how steep the slope must be in order to be detected as a spark. The spark sensitivity detector is adjustable and is defined in kV/ms. Arcs are detected by analysing the kV measurement. Arcing is defined when the ESP voltage is continuously lower than the Arc Detection Level for more than 10 half-periods. If an arc is detected, the output is quenched for a set time ( Arc Quenching 1-99 half-periods in steps of one half-period).
7.2.4.
Spark detection sensitivity tuning Spark sensitivity can only be adjusted if the precipitator produces sparks. If the operation conditions are so that maximum T/R output voltage does not reach the break over voltage, and no sparks are produced, it is possible to temporarily decrease the distance between emitting and collecting electrode by insertion of some metal object. Be sure then to follow ESP safety regulations. The EPIC III can use the secondary voltage or the secondary current for detecting of sparks. The voltage sensing is selected as default. This is the safest sensing method and shall be used if the T/R provides a kV measuring signal. Normally the ESP will function using the “delivery” default setting of spark sensitivity. If any adjustment is needed, find correct setting as follows: 1.
Select
Quench mode= SHORT .
2.
Set
Ignition angle limit = 100% Volt peak limit = MAX Current limit = MAX Charging ratio = 1:11
3.
Start T/R and observe that the Limiter = SPARK .
Page 44 7. Function descriptions
4.
Make the spark detector more and more sensitive by setting lower and lower values on Spark sensitivity* (kV/ms) until normal voltage shapes are falsely detected as sparks. This is the situation when the spark level in kV or mA is decreasing and dependent on the setting of Spark sensitivity.
5.
Write down the value of Spark sensitivity* (false det.) where false detection starts.
6.
Set
7.
Make the spark detector less and less sensitive by setting higher and higher values on Spark sensitivity* (kV/ms) until the sparks in the ESP are not detected. This is the situation when the primary and secondary current makes abrupt increasing jumps for short periods. Easiest to see on analog panel meters.
8.
Write down the value on Spark sensitivity* (kV/ms) (no det.) where no detection starts.
9.
Set Spark sensitivity to the average between Spark sensitivity* (false det.) and Spark sensitivity (no det.) achieved above.
Charging ratio = 1:1
10. Restore the previous settings except Spark sensitivity* and then remember to save the changes in window [Save settings]. * or Level (0-32) if current sensing method is used.
7.2.5.
Spark quenching tuning Which quench mode is best for a certain application has to be found with process tests, but can be generally ascertained by: Quench mode = SHORT is the safest mode to use because it always actuate a blocking period. On the other hand it also gives a loss of current input to the ESP during the blocking. Quench mode = SELF+SHORT is useful if the majority of the sparks are of the self quenching type. This mode then produce a smoother operation and higher current input. Try with this mode first and observe the spark counters.
If a majority of double sparks is detected or if arcs are detected, Quench mode = SHORT should be selected. Quench mode = SELF is the mode that may force the highest average current into the ESP, but it is not generally recommended. Because there is no quenching action like blocking inserted it can easily cause arcing in most processes. However, it is easy to test by observing the arc counter during a test period.
7.2.6.
Tuning of other spark parameters The tuning of other spark parameters as Spark rate limit , Step actual current and Slope is totally process related. Please ask ALSTOM Power for the latest data available for these settings on the actual process.
Page 45 7. Function descriptions
7.3.
Password function The password function is a shell function within the FläktBus system. All units (nodes), connected to the FläktBus, that can accept data input from operators or from external communication lines via gateways, are protected against unauthorised manipulation of data by a three level password function. (The Password check routines are placed in ProMo and RTU ).
7.3.1.
Password location The password function resides in the interface nodes themselves. All other executing nodes on the FläktBus network only indicate to the interface nodes the actual password level for the requested parameter. The interface unit requires the correct password from the operator before alteration of data is possible.
7.3.2.
Default password settings The passwords levels are preset at delivery. Low=1, Medium=2 and High=0470.
7.3.3.
Interference avoidance To avoid different password levels being used in the interface nodes connected to the same FläktBus network, a new unit connected to the network will adopt the password levels from the nodes already connected to the network.
7.3.4.
Setting of password Using one of the interface nodes, a password can be changed for all connected interface nodes. However, this is only possible if the highest password level is known by the operator. Setting a password to “0000” turns off the password protection for the actual password level. (The highest password level is however not possible to turn off.)
7.3.5.
The last chance If the highest level of password has been forgotten it is still possible to enter the system using the following procedure: 1.
Disconnect all interface nodes from power supply and/or from the network.
2.
Connect one RTU to the network and power and simultaneously depress the keys until all internal start-up tests are completed.
3.
Set the new password by using the [Password] function in RTU-menu.
4.
Disconnect the RTU from the power supply and connect it again to restart the communication.
5.
Wait one minute and connect all other interface nodes to power supply and the network.
Page 46 7. Function descriptions
7.3.6.
Parameter alteration The RTU requires a password entry when you wish to alter a parameter. When you have given the correct password it will remain as long as you use the RTU but if you do not use the RTU for 4 minutes you must give the password once again. This means that you do not have to give the password every time you make an alteration.
7.4.
Copy settings This window restores the default values or copy values from other EPIC III controllers on the net. This means that all field made settings will be l ost. The [Copy settings] RTU window is reached by [Set up] [System] [!].
7.4.1.
Restore to default settings The Restore to default function is supplied as a method to erase bad data in the parameter memory. After use of this restore function the set up part of the installation has to be made again. This function is only active when you have changed the default settings with the “Save settings” parameter. Note! Write down all settings before execution of the “Default” parameter.
Do as follows:
7.4.2.
1.
Highlight “DEFAULT” and press OK.
2.
Enter your Password and press OK.
3.
Press OK to confirm the selection. Press “Page up” to cancel the operation.
Copy settings from a selected node A convenient and time saving function is the node copy function. This function allows you to transfer all parameter values that are saved to the non-volatile memory from a specific EPIC III controller. Do as follows: 1.
Highlight the area to the right of “NODE” and press OK.
2.
Enter your password and press OK.
Page 47 7. Function descriptions
3.
Enter an address of an installed EPIC III that you will copy.
4.
Highlight “NODE” and press OK.
5.
Press OK to confirm the selection. Press “Page up” to cancel the operation.
Note! The copy function may only transfer parameters from other EPIC III controllers.
7.4.3.
Restore/Copy messages Following messages comes from EPIC III when using the Restore/Copy function. “Error. Check all params! Operation cancelled” Cause: The source or destination node has been disconnected during the copy function. Solution: Check the nodes. Check all parameters or execute the copy function again. “Incompatible revision! Operation cancelled” Cause: The database version differs between the nodes. The copy function cannot transfer parameter values. Solution: Enter the values by hand or upgrade the old EPIC III . No unit on specified address! Operation cancelled! Cause: There is no EPIC III on specified address in the network. Solution: Locate the node address and execute the copy function again. “Please wait... Transferring parameters” “Ready. All parameters transferred” “Ready. All parameters restored to factory settings” “Ready. Version difference. Check all parameters” Cause: The database version differs between the nodes. The copy function could not transfer all parameter values. Solution: Check all parameters and change bad or incorrect parameter values manually. “Ready. XXX parameters transfer error” Cause: The specified number of parameters has bad or incorrect data. Solution: Check the parameters and change them manually.
Page 48 7. Function descriptions
7.5.
[Save settings] When parameters have been entered it is very important to save these settings to the non-volatile memory so they will remain even after a power loss. In the [Main menu] it is a selection called [Save settings]. After the text is a small box. It is filled (black) if there has been changes that is not saved. Select “Save Settings” and in the following window press “OK”. The changes are now saved. This save procedure has to be repeated each time there has been changes made that is needed to save for longer time. See section Variable list on page 79 to see which parameters can be saved.
7.6.
ESP Master function The daily operation is mainly performed from a Master EPIC in the menu [ESP-Master]. All connected T/R units are controlled with convenient group commands. Any EPIC III can be assigned to be Master, but only one unit must act as Master for one group of EPIC III units. The group the Master controls are decided by the parameter ESP address limits: in window [Master] [!]. The units within a group can be controlled by group commands e.g. ESP OFF, ESP ON, change operating mode etc. The Master controls the Opacity optimizing if Opacity optim. (MU) is set to ON. Each EPIC III with parameter Opacity controlled set to “ON” are optimized. The Master controls also the EPOQ. Each EPIC III with parameter EPOQ set to “ON” are optimized.
Page 49 7. Function descriptions
7.7.
EPOQ - Electrostatic Precipitator Optimizing Q algorithm
7.7.1.
Function description
7.7.1.1.
EPOQ minimizes the ESP emission It is a well known fact, that the conditions in an ESP vary from bus section to bus section. Every ESP bus section must therefore be individually optimized. The conditions in an ESP also vary greatly from process to process, and also with the fluctuations in the process itself (e.g. dust concentration, dust resistivity, gas velocity, gas temperature, gas composition, etc.). All process variations alter the electrical characteristics of the ESP bus section. The electrical characteristics (and their variations) are continuously adaptively surveilled by each EPIC III . The EPOQ software analyzes the electrical characteristics, and EPOQ’s inherent expertise is then able to selects the optimal current and charging ratio that will minimize the emission from the bus section in question. Note! Note, that the emission optimization uses “only” electrical data mainly wave form analysis of primary and secondary T/R signals from EPIC III . Readings of emissions from opacity meters are not utilized at all during EPOQ’s emission minimizing.
EPOQ maximizes the precipitation in each bus section, and thereby actually maximizes the collection efficiency of the overall ESP.
7.7.1.2. EPOQ start and adaption to ESP process After initial set-up and starting the EPOQ function, EPOQ is self adaptive. The individual bus section’s basic information that EPOQ needs for correct continuous optimizing, is determined during an automatic reference measurement sequence. The reference is automatically obtained on a regular time basis. At ESP start-up, EPOQ will start with a reference measurement sequence, and will then - step by step - tune the ESP to minimal emission.
7.7.1.3. EPOQ minimizes emission continuously During normal ESP operation, EPOQ that resides in every single EPIC III unit continuously analyzes the sampled electrical values. The fast and accurate sampling of voltage and current, both on the primary and secondary side of each T/R, produces a detailed ESP performance analysis - independent of opacity meters. EPOQs analysis results in a “relative operation efficiency” for the bus section in question. EPOQ then adjusts secondary current and charging ratio with the aim to feed as much effective charge (Q) into the bus section as possible. EPOQ considers - by the way it is designed - all individual field differ-
Page 50 7. Function descriptions
ences, and is thus able to optimize the whole ESP operation very rapidly and very flexibly. EPOQ will continuously adjust every ESP bus section to operate at optimum current and charging ratio - bringing the ESP to continuously operation at peak performance capability - minimal emission.
7.7.1.4. EPOQ still optimizes ESP operation even at T/R or field drop out Sometimes a short circuit occurs in a bus section, or a T/R trips due to some fault. This will increase the dust load on the following bus sections, and will also increase the emission from the overall ESP. EPOQ will - unaffected by the trip - continue to keep all the other bus sections at optimum operation efficiency, and is in this way capable of minimizing emissions - irrespective of the cause of the alteration in electrical characteristics.
7.7.1.5. EPOQ minimizes emission - may save majority of T/R energy EPOQ will always adjust operation to optimum current and charging ratio which produces minimized emissions. In ESP processes where EPOQ decides that Semipulse operation is the most emission effective way of energizing the ESP, EPOQ will also save a very high percentage of the T/R power consumption. Semipulse operation always reduces power consumption by a minimum of 50%, but figures between 80% and 95% of power saving are quite common - at minimized emission!
7.7.1.6. EPOQ combined with OpOpt (Opacity optimizing software) At low process load, minimized emission may sometimes lead to unnecessary high power consumption. A typical example is an ESP that operates with low resistive dust, and at (for the moment) a low process load (a low dust load or low gas flow or both). EPOQ will strive to maintain ESP at optimum, which in this case means full power. The ESP will however not be able to perform significantly better with the max current, than with a current which is sometimes only 10% of max. Above a certain “knee current” a further emission reduction is barely noticeable with increased current - above a certain current level the ESP field becomes “saturated”. The optional software for EPIC III , is the OpOpt (Opacity Optimizing) software which is designed to handle such situations. Even with OpOpt operating and reducing the available current in order to reduce the T/R power consumption, EPOQ will still be in full emission optimizing mode, however now limited by a reduced available current range.
7.7.2.
Window structure In the EPIC III window structure, all EPOQ parameters are reached in the [Set Up] [EPOQ] window.
Page 51 7. Function descriptions
7.7.2.1.
[Set Up EPOQ] The [Set Up EPOQ] window contains the parameters for EPOQ set-up. The parameters should normally not be changed. See section Variable list on page 79 for explanation of each variable.
7.7.3.
EPOQ Set up There are no set up parameters for EPOQ. The reference measurement that EPOQ makes after start gives the needed data about the ESP condition. Note! Be sure to have the Field/Cell and the collector area , in the [Set Up] [ESP] window, correctly set since EPOQ uses this parameter to make its operations not to coincide with EPOQ in other EPIC III .
7.7.4.
Starting EPOQ The EPOQ is started in the [Operation] [Oper. active set.] window by setting the EPOQ to ON . When EPOQ is turned ON, optimization is started immediately but full effect is not reached until a reference measurement is made. Consequently there will be a varying delay from the time when EPOQ is turned on to full optimization, depending on the T/R position in the ESP and the time of day when EPOQ turned on.
Page 52 7. Function descriptions
7.8.
OpOpt - Opacity optimization algorithm
7.8.1.
Function description A Master EPIC with an opacity signal connected to its auxiliary input terminal has the ability to control the current limit of selected slave EPIC’s. The algorithm’s target is to find an optimal current which reflects a given opacity set value. The algorithm calculates the new optimal current limit using an average value of the opacity. The interval for the average is alterable between 1-30 minutes. The average value is compared to a set value once per minute. A 0100 % part (alterable gain value) of the error is then used to calculate the new current limit. The optimal current is sent as a limit to all slaves simultaneously and will depend on the difference between an average and a set value of the opacity.
Opacity % High limit
10
Set value
5
If process change makes one minute opacity mean value > HIGH LIMIT
Time Current limit % Start
100 80 60 40 20 Time
Figure 3. Sample of average opacity signal and the reflected current limit. We assume that the current limit starts at 100%
7.8.2.
Window structure The following windows are used for the opacity optimization algorithm displayed by using an RTU . For detailed information about each parameter, see section 8. Variable list on page 81.
Page 53 7. Function descriptions
7.8.2.1.
[ESP-Master] The first [ESP-Master] window contains parameters for control of the Master function of EPIC III . It also contains start and stop of the Opacity optimization algorithm.
7.8.2.2.
[Opacity optim] This window contains all parameters for control of the Opacity optimizing algorithm.
7.8.3. 7.8.3.1.
OpOpt Set up Connection of the opacity monitor signals The 4-20 mA signal from the opacity monitor is connected to the auxiliary analog input terminal AI 05 (terminal number 11, 23). The 4-20 mA signal will be converted to a 0-100 % value. Two additional opacity monitors connected to other slaves can be viewed by choosing a position for each one of them. The opacity is shown as a 10 s average signal. If the opacity meter performs an automatic calibration procedure, the OpOpt algorithm must be informed by a 24 V signal applied to one of the digital inputs DI1, 2, 14 or 16 configurated in [Set up] [Inputs] RTU-window. During the time of the calibration the OpOpt will freeze it's calculations and thereby avoid wrong corrections based on calibration spikes.
7.8.3.2.
Using the opacity optimization in the slaves In order to let the slaves and the master react upon the current limit sent from the Master, an appropriate mode must be selected in each slave. The selected mode must have the option Opacity controlled set to ON in the [Operation][!] window.
Page 54 7. Function descriptions
7.8.4. 7.8.4.1.
Starting OpOpt Preparation in slave EPICs In each slave EPIC that shall be activated from the master unit the Opacity controlled in the [Process settings] [Mode #] RTU-window has to be set to ON .
7.8.4.2.
Starting the algorithm in the Master EPIC The algorithm is started in the master EPIC by setting the Opacity optim. in the [MASTER] RTU -window to ON . After being started the algorithm function begin with a 100 % current limit to all slaves (which practically means: no limit). When the limit is received, the slave will calculate a current limit according to the rated secondary current. If this limit is lower than any other current limit, it will be used and the text “OPACITY_OPT” will be shown at the Limiter -position in the [Operation] RTU-window. If no current limit has been received within 2,5 minutes the slave in question will assume that a 100 % limit is to be used.
Page 55 7. Function descriptions
7.9.
VI-curve function
7.9.1.
Introduction When tuning an electrostatic precipitator (ESP) it is important to know its operating condition. It depends on many different factors such as the mechanical design, the electrical design and the actual process in use. The VI-curve function is a new feature in EPIC III. It is a tool to analyze the operating condition and the process of an electrostatic precipitator. It enables fast and accurate data collection of the secondary voltage as a function of different calculated current density values. The result of the collection is presented both in graphs and as numerical values. The VI-curve function in EPIC III interacts closely with the VI-curve software in ProMo II which is a customized tool for the analysis of collected VIcurves. It is also possible to transfer the values manually to a spreadsheet program, for analysis and print out of the graphs.
7.9.2.
Window structure overview In the EPIC III window structure, all parameters for control of the VI-curve function are gathered under the [Set Up] [VI-curve] menu. For a detailed explanation of each parameter, see section 8. Variable list on page 81.
7.9.2.1.
[VI Curve] This window contains the control of the VI-curve function. It also shows information about the latest collection.
7.9.2.2.
[VI-Curve Graph] This window presents graphs of the latest collection.
90.0
Page 56 7. Function descriptions
7.9.2.3.
[Settings] This window contains different settings that affect the measurement.
7.9.3. 7.9.3.1.
Using the VI-curve function General There are some actions that must be followed to obtain the best VI-curve results.
7.9.3.2.
•
Make sure that rappers and/or optimizing algorithms are not running while the VI-curve function is active. If possible turn EPOQ and OpOpt to OFF in [Active] [Settings] during the acquisition of the VI-curve.
•
Perform two VI-curve collections. One in air load before start-up and thereafter during the most representative operating condition, normally full load. These curves will provide considerable amount of information concerning the ESP’s mechanical, electrical and process operating conditions.
•
Always start to collect the VI-curve values in the rear field and work your way up to the first field. This ensures that you have a representative dust layer on the collecting plates during the measurement.
•
When a new VI-curve is collected the previous collection is lost in EPIC III. For comparison between different collections, the numeric values can be copied (manually) to a spreadsheet program or ProMo II can be used. Each VI-collection is saved for comparison.
VI-curve function set-up There are some parameters that must be set before starting the function. In window [Set Up] [VI-curve] [Settings] four parameters are located. The first parameter is Sample Interval, this parameter affects the time before each measurement. The time length is process related. A high resistive process needs a longer time than a plant with a low resistive process. The Charging ratio parameter is the active CR during the operation of the VI-curve function. The actual charging ratio is restored as soon as the VI-collection is completed. Min. current density is the lowest point of the current measurement. Step at spark, the current is reduced the specified percentage value when it is limited by a sparkover.
Page 57 7. Function descriptions
7.9.3.3.
Starting the VI-curve function Start the VI-curve function when the operation of the ESP is stable. The starting parameter is located in window [Set Up] [VI-Curve]. The latest VIcollection will be erased when a new collection is started. Do as follows: 1.
Select “Start VI-collection” and press OK (requires the high priority password).
2.
The parameter on the right hand side will display READY when the V-I collection is completed.
The VI-curve function can be stopped at any time during its operation by pressing “Cancel VI-collection” (requires only the low password priority).
7.9.3.4.
Presentation of the VI-collection result The VI-curve function is successfully completed when it displays “Ready”. The collected values are presented as graphs in window [Set Up] [VI-curve] [!]. The numerical values are presented in the [Set Up] [VI-curve] [! !] and [Set Up] [VI-curve] [! ! ! ]. The Limit parameter informs the type of limiter that was active when the VI-curve function was determining the maximum current for the VI-curve. If “Stopped by” is displayed the VI-curve function has been disturbed or manually stopped.
90.0
Page 58 7. Function descriptions
7.9.4. 7.9.4.1.
Functional description General The VI-curve function is a tool for analyzing the operating conditions of an electrostatic precipitator. It presents the secondary voltage as a function of the current density. The current density scale is adjusted for root linearity facilitate the reading.
7.9.4.2.
Overview The VI-curve function measures the average, peak and valley voltage at seven different pulse currents. The measurement is performed twice (except at the lowest value). Current
Point of Measuring
1
13 2
12
Sample interval
3
11
4
10 5
9 6 8 7 Time
Figure 4. VI-curve function
When activated, the function determines its maximum current by increasing the pulse current to a point below the sparkover level or the rated current on the T/R. The VI-curve function calculates seven different pulse current values. Each value is divided equidistant to its root value on a scale from the highest to the lowest current (the lowest current density is preset in the [VICurve] [Settings] window). At each current value the VI-curve function measures the average, peak and valley voltage. Totally 3*13 values will be measured. See Figure 4 above. Each voltage type with the same current density is then averaged and saved. The result is seven different current density values with peak, average and valley voltage values. The collection of values is presented in the RTU window as a VI-curve graph with the voltage as a function of the current density or in a table where all the measured values can are presented. The VI-curve function must be activated manually by an operator with the highest priority password as this may affect the outlet dust emission temporarily. The function can however be stopped by a user with low priority password. The operation of the ESP will return to
Page 59 7. Function descriptions
the previous operating level when the VI-curve function is ready or has been cancelled. It can also be executed from ProMo.
7.9.5.
Initial checks performed by the VI-curve function When the VI-curve function is executed by the operator it starts by checking that no other function is active e.g. rapping and EPOQ that can block and disturb the collection. The function awaits these blocking factors before starting and if it has not been executed after 5 minutes, it will stop all attempts and display an alarm message.
7.9.6.
Checks performed during operation of the VI-curve function The function constantly monitors all factors that can affect the result of the collection and give unreliable information concerning the ESP. When this occurs it will immediately stop the collection of data and display the cause of termination. Typical causes are rapping, manual stop by operator or, if the current limit could not be reached, stoppage due to e.g. sparks.
7.9.7.
Current measurement The highest current is determined by increasing the VI-collection current limit to maximum. Another function will then limit the current and determine the highest current limit. The VI-collection current limit is then set to a percentage step below this current. This step is the same as “Step at spark” if the current is limited by sparkover otherwise the step is one percent of the highest current limit. The current level is now controlled from the VI-curve function Each measuring point is set by two steps. The first step is a hysteresis that has a characteristic curve. The second step is then adjusted up or down to the calculated pulse current. See Figure 4. The function will wait for the specified time to elapse (specified in Sample interval) before the collection of the secondary voltage is made.
Page 60 7. Function descriptions
7.10. I/O groups and auxiliary inputs 7.10.1. Introduction The “I/O Groups” function is a versatile firmware for control of external devices such as rappers, heaters, ash handling etc. The “I/O Groups” comprises four I/O groups with different control categories. An I/O group is a specific Digital Input that from an operational point of view is grouped together with a specific Digital Output. The “I/O Groups” can be set up to control the following: •
Up to four rappers of the tumbling hammer type
•
Ash transport
•
Heaters
•
Digital outputs for external control with or without confirmation of the feedback (CON.DO = Confirmed Digital output and UNCON.DO = Unconfirmed Digital output).
•
External control of ESP On on an ESP-Master unit (ESP-ctrl).
•
External control of individual T/R (T/R-ctrl).
In addition there are four additional digital inputs called Digital Inputs Auxiliary (DigAux1-4). Each of these inputs have eight different predefined control categories.
7.10.2. Control description The “I/O Groups” function is based on four I/O groups. Each I/O group can be set to seven different control categories. The main window below is located under [Set Up] [I/O Groups].
Name: 7 characters
Type: RAPPER HEATER TRANSPORT CONF. DO UNCONF. DO ESP-CTRL T/R-CTRL NOT CONN.
Mode: ON OFF AUTO CONT ----
This window contains parameters to define the type of connected devices, their names and the mode of operation. The function of this window is depending of which “Type:” of device you chose and “Mode” of operation.
Page 61 7. Function descriptions
Name This column contains the name of connected devices. The name of the device will then be used in all actual windows, even in the alarm messages. Enter the name (max 7 characters). Type There are eight different selections of connected devices: RAPPER, HEATER, TRANSPORT, CONF. DO, UNCONF. DO, ESP CTRL, T/R CTRL or NOT CONN . Each selection will be explained separately in this chapter. Mode There are five different modes of operation: ON, OFF, AUTO, CONT and ----. Each selection will be explained later in this chapter. Some of the Mode settings combined with a Type may not have a function. All positions on the next page that are marked with N/A are such combination. The RTU displays “The parameter is temporarily blocked” if one of these combinations is selected.
The “----” mode is automatically selected when NOT CONN, ESPCTRL, T/R CTRL is selected in Type. This mode will change to OFF when Type is changed to other selections.
Page 62 7. Function descriptions
7.10.3. Mode/Type function view Type/Mode
AUTO
ON
OFF
CONT
NOT CONN
N/A
N/A
N/A
N/A
RAPPER
Follow the settings in [Set Up] [Config IO groups] and activates with ESP ON/High voltage ON and deactivates with ESP OFF/High voltage OFF.
Follow the settings in [Set Up] [Config IO groups] independent of the ESP ON/OFFposition or High voltage ON/OFF.
No rapping is performed. Alarm after 30 minutes if ESP is ON/High voltage ON.
Continuous rapping. Alarm after 30 minutes.
TRANSPORT
The output goes high at ESP ON/ High voltage ON and low at ESP OFF/High voltage OFF.
The output is high.
The output is low. Alarm after 30 minutes if ESP is ON.
N/A
HEATER
N/A
The output is high.
The output i s low.
N/A
CONF.DO (Dig. Output)
N/A
The output is high. The feedback is checked every minute.
The output is low. The feedback is checked every minute.
N/A
UNCONF. DO (Dig. Output)
N/A
The output is high. No feedback check.
The output is low. No feedback check.
N/A
ESP CTRL
N/A
N/A
N/A
N/A
T/R CTRL
N/A
N/A
N/A
N/A
The different types are explained as follows:
7.10.4. Type: RAPPER Each of the four rapper can basically be programmed for “Start time”, “Repetition time” and “Run time” individually. In addition a network of gates (Boolean algebra) can be set up to control the rappers. For more information on timers, see heading 7.11.5.1. Example 1 - Different timers for collector and emitter rapping on page 75.
7.10.5. Mode of operation The rapper motor is controlled by the Mode parameter. This parameter can be changed manually from the RTU . It has four modes: AUTO
This is the normal position of the Mode parameter for rapper. When High voltage or ESP is ON , rapping is performed according to the time parameters in window [Set Up] [I/O Group] [Timers 1-6]. When the High voltage or ESP is
Page 63 7. Function descriptions
ON OFF
CONT
switches OFF , rappers are stopped (if not set to conduct otherwise by Timers 1-6). The rapping is performed according to the time parameters independent of commands like High voltage or ESP ON/OFF . No rapping is performed. If this mode is OFF for more than 30 minutes while High voltage or ESP is ON , EPIC III indicates an alarm. Continuous rapping. If this mode is CONT for more than 30 minutes, EPIC III will indicate an alarm.
It is possible to set continuous rapping in an other way too. In RTU window [Process settings] [Mode 1-6] select Rapp All. When the Mode parameter or any of the time parameters are changed, the rapping will immediately follow the new setting. When rapping is performed according to the time parameters, rapping will always recommence directly at the start time, regardless of the current rapper output state.
7.10.6. Rapper control via timers Each of the four rapper can basically be programmed for “Start time”, “Repetition time” and “Run time” individually. In addition a network of gates (Boolean algebra) can be set up to control the rappers. For more information on timers, see heading 7.11.5.1. Example 1 - Different timers for collector and emitter rapping on page 75. EPIC III has one output and one input connection for each rapper motor. The output is used to control the motor contactor. The input is used to sense the feedback that indicates that the rapper is operating as ordered, if not an alarm message will be given. The alarm is activated if the status of the feedback and the output does not compare just before each start or stop, see below. For more information concerning the connections, see section 10. Technical data on page 103.
The feedback is checked immediately before the status of the output is changed.
Page 64 7. Function descriptions
Run time
Process delay
EPIC III rapper motor output Rapper motor feedback
EPIC III alarm function sensing the feedback
Alarm will be given here if motor is running. (Alarm if feedback = ON)
Alarm will be given here if motor is n ot running. (Alarm if feedback is n ot = ON)
Figure 5. State diagram, rapper sequence with rotary switch feedback
7.10.6.1. Power control Rapping (PCR) The Power Control Rapping function constitutes a limitation of the power to the ESP during rapping (power = current). The reduction of the electric field during rapping makes the rapping (in most cases) more effective. The limitation of the current is set in parameter Rapping current limit in window [Set UP] [I/O Groups] [Power control]
7.10.6.2. Set up of rapper parameters The EPIC III rapper function has to be set to correct values to ensure proper operation of the ESP. All parameters concerning rapper operation must be setup before start-up. In the EPIC III window structure, all parameters for control of the rappers are reached through the menu [Set Up] [I/O Groups] The set up is done in the following order: [Set Up] [I/O Groups] [Group configuration], defining the I/O Groups. [Set Up] [I/O Groups] [Connection], connects the output of the timers with the rappers. [Set Up] [I/O Groups] [Timers 1-3] and [Timers 4-6], defining the rapping times.
Page 65 7. Function descriptions
[Set Up] [I/O Groups] [Power control] defines which timers who have power control. Remember to save all your settings with function [Save settings] in the [Main menu].
7.10.7. Type: TRANSPORT This selection is mainly for ash transport devices. The status of the feedback is checked 2 seconds after a status change and repeatedly checked every minute.
7.10.7.1. Mode of operation The transport motors as a group are controlled by the Mode parameter. This parameter can be changed manually from the RTU . It has two modes: ON OFF
The transport starts to operate. The transport stops.
7.10.8. Type: HEATER This selection is mainly for heater devices. The status of the feedback is checked 2 seconds after a status change and repeatedly checked every minute.
7.10.8.1. Mode of operation The Heater is controlled by the Mode parameter. This parameter can be changed manually from the RTU . It has two modes: ON OFF
The heater is turned on. The heater is turned off.
7.10.9. Type: CONF. DO (Confirmed Digital output) This selection is for additional devices such as an electrical fan. The status of the feedback is checked 2 seconds after a status change and repeatedly checked every minute.
7.10.9.1. Mode of operation The output is controlled by the Mode parameter. This parameter can be changed manually from the RTU . It has two modes: ON OFF
The output goes high. The output goes low.
Page 66 7. Function descriptions
7.10.10.Type: UNCONF. DO (Unconfirmed Digital output) This selection is for additional devices such as an electrical fan. The status of the feedback is not checked.
7.10.10.1.Mode of operation The output is controlled by the Mode parameter. This parameter can be changed manually from the RTU . It has two modes: ON OFF
The output goes high. The output goes low.
7.10.11.Type: ESP-CTRL This function is only for the master unit. ESP-ctrl is a flank triggered input which toggles between ESP ON and ESP OFF . The function can be used together with a button or a switch to stop and start the ESP. The output follows the ESP status and goes high when ESP is ON and low when ESP is OFF .
7.10.12.Type: T/R-CTRL T/R-ctrl is a flank triggered input which toggles between High voltage ON and High voltage OFF . The function can be used together with a button or a switch to stop and start the T/R unit. The output follows the T/R unit status and goes high when High voltage is ON and low when High voltage is OFF .
7.10.13.[Timer1-6] See section Timer functions on page 69.
7.10.14.Auxiliary Digital Inputs This is four additional digital inputs for different control. The window Set up inputs is located under [Set Up] [Inputs].
Name: 7 characters
•
Type: See below
Alarm reset - Possibility to make a sum alarm reset by using a signal from e.g. a PLC.
Page 67 7. Function descriptions
• • •
•
• • •
ALARM -T- This external alarm will trip the EPIC III and display an alarm message on the RTU. ALARM-W- This external alarm will display an alarm message on the RTU. MODE TOGGLE - This external input can be used to toggle the EPIC III between two or four different operational profiles (only possible for input DI 14 and/or DI 16). MU M TOGGLE - This external input can be used to toggle the master EPIC III (and consequently all slave EPIC III s) between two or four different operational profiles (only possible for input DI 14 and/or DI 16). OPAC. CAL- This input is used to block the opacity algorithm during calibration of an opacity meter (if used). RAPPER - This input runs the EPIC III with PCR limit and can be used if the EPIC III not controls the rapper. NOT CONN- When the input is not used.
Type: Alarm reset A flank gives a sum alarm reset. Type: RAPPER This input runs the EPIC III with PCR limit and can be used if the EPIC III not controls the rapper. Type: OPAC. CAL If the opacity meter performs an automatic calibration procedure, the OpOpt algorithm must be informed by a 24V signal applied to the input. During the time of the calibration the OpOpt will freeze it's calculations and thereby avoid wrong corrections based on calibration spikes. Type: MU M TOGGLE (only for Master Unit) This selection toggles between mode 1-4 or mode 1-2 as the Master mode (depending on if one or two inputs are used, see table below). The function changes all connected EPIC III that has these modes as active modes. Type: MODE TOGGLE This selection toggles between mode 1-4 or mode 1-2 as the active mode on single units (depending on if one or two inputs are used, see table below). The function does not work if the active mode is other than this two modes. DI 14
DI 16
Mode
DI 14 or DI16
Mode
0
0
1
0
1
1
0
2
1
2
0
1
3
1
1
4
If tw o inputs are used
If on e input is used
Page 68 7. Function descriptions
Type: ALARM-W External warning alarm. A high or low signal, depending of settings in [Set Up] [Inputs], activates an alarm message “XXXXXXX, external alarm, Warning” on the RTU . The “XXXXXXX” is the name of the connected input. Type: ALARM-T External tripping alarm. A high or low signal, depending of settings in [Set Up] [Inputs], will trip the T/R and display an alarm message “XXXXXXX, external alarm, Trip” on the RTU . The “XXXXXXX” is the name of the connected input. Type: NOT CONN. The input is not used. Normally closed: Filled box inverts the input.
Page 69 7. Function descriptions
7.11. Timer functions EPIC III has a number of software functions, often called timers (since they are based on a timer function). The timer function was basically aimed for control of rapper mechanisms. In EPIC III the timer function can be used in many different ways and fill a variety of purposes.
There are 6 individual and identical timers containing: •
A timer function
•
A coupling function (with Boolean algebra)
•
A function for reducing power during rapping Power Control Rapping (PCR)
The 6 timers are connected in cascade and common for all 6 timers there is a connection selector to the I/O.
7.11.1. The timer function The timer has three different time settings: •
Start time - defines the day, hour, minute and second when the event shall start. Day number 1 is defined as the first Monday of the New Year. It is not the day number you can find in your calendar. At the next New Year synchronization to the same working day will take place. The result is when you specify the start of an event to e.g. a Friday; the event will always start on this day (every year, even a leap year).
•
Repetition time - defines the time in days, hours, minutes and seconds between the first start of the event until it shall start again. The working day synchronization mentioned above is valid here too. The Repetition time is effected by the rapping intensity, see heading 5.3.5. Rapp. Intens on page 36.
•
Run time - defines the duration of the event . The run time can be specified in hours, minutes and seconds. The example shows:
Run time
00:00
02:00
04:00
06:00
Start time Repetition time Run time
08:00
10:00
12:00
14:00
16:00
003:04:00 ddd:hh:mm:ss 000:07:00 ddd:hh:mm 00:30:00 hh:mm:ss
18:00
20:00
22:00
00:00 (24:00)
Repetition time Start time
Figure 6. One of 6 timers (the time setting function). The event will start on the first Wednesday of the year and run for 30 minutes and will be repeated every 7th hour
Page 70 7. Function descriptions
Note! There is no monitoring of the ratio between run time and repetition time. You can specify a run time nearly as long as the repetition time. The result of this will be an ongoing event with a short brake just before it starts over.
7.11.2. Couplings The output from the timer function is fed to a certain coupling function with 4 alternatives: •
NO - no coupling at all, an active timer output will result in an active output from the coupling section.
•
AND - the timer signal and the input have to be active at the same time, to get an active output.
•
AND NOT - the timer signal has to be active and the input has to be inactive, to get an active output.
•
OR - one of the timer signal or the input has to be active in order to get an active output.
Timer 1 - Start time - Repetition time - Run time
Coupling (in this case AND)
NO
Input
& & >1
AND AND NOT OR Output
Figure 7. The coupling function of the timer
The RTU window [Set Up Timer 1-3] has the path Set up, I/O Groups, Timer 1-3.
Page 71 7. Function descriptions
7.11.3. The Power control rapping (PCR) The output from the coupling function is fed to the Power Control Rapping function (PCR). This function constitutes a limitation of the power to the ESP during rapping (power = current). The reduction of the electric field during rapping makes the rapping (in many cases) more efficient. The PCR can be selected in the RTU window [Set up Power Ctrl]. Select ON to activate the PCR function and insert a value for the reduced current (the value specifies which level the current will be reduced to). When the PCR is selected, an active output from the coupling function will result in a reduction of power during rapping.
& & >1
PCR ON/OFF
Reduction of current to this level
Output
Figure 8. The PCR function
The RTU window [Set Up Power Ctrl] has the path Set up , Power control.
Page 72 7. Function descriptions
7.11.4. Cascade coupling of timers and connection to I/O The output from timer No. 1 is connected to the input of timer No. 2. And this output is connected to the input of timer No. 3 and so on (all timers are connected in cascade). For timer No. 1 the input is external, see heading 7.11.4.1. The input to timer 1 on page 73. Further more the output from all 6 timers is connected to an output connection. In this connection any of the 6 outputs can be directed to one of 4 different I/O groups. Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
Timer 6
&
&
&
&
&
&
&
&
&
&
&
&
>1
>1
>1
>1
>1
>1
PCR
PCR
PCR
PCR
PCR
Input for timer 1 is external
Connection to I/O Group
I/O 1
I/O 2
I/O 3
I/O 4
Figure 9. Cascade coupling of all 6 timers
PCR
Page 73 7. Function descriptions
7.11.4.1. The input to timer 1 The input can be retrieved from any of the four digital inputs (DI 1-2, 14,16) by selecting the Type: to RAPPER. Select the RTU window [Set up inputs] by using the path Set up, Inputs Timer 1
The external input to timer 1 40
Timer 3
&
&
&
&
&
&
>1
>1
>1
Timer
DI14
56
26
Timer 2
PCR
PCR
PCR
>1 DI02
42 Connection
I/O 1
I/O 2
RAPPER
Figure 10. Input to timer 1
The digital inputs DI 1-2, 14, 16 will, in the RAPPER case, have an OR coupling. Therefore if you select e.g. two RAPPERs an active signal from any of these inputs will result in an active input to timer No. 1.
Page 74 7. Function descriptions
7.11.4.2. The connection to I/O Group and activating of I/O The connection between the output of the timers and the I/O groups 1-4 is made in the RTU window [I/O Group Connection] found by using the path Set up, I/O Groups, Connection. By selecting a timer number for one I/O Group the output of this timer is connected to the I/O Group. If you specify 0, no timer will be connected to the I/O group in question. . &
&
&
&
&
&
>1
>1
>1
>1
>1
>1
PCR
PCR
PCR
PCR
PCR
PCR Timer 6
Connection to I/O Group
I/O 2
I/O 3
I/O 4
6
I/O Group 1
IoGrp 1
RAPPER
AUTO
02 03 04 05
58 DO02
66
Figure 11. Connection timer to an I/O Group (I/O Group 1 is more detailed than the other I/O Groups)
Next step is to activate the connected I/O Group. This is made in the RTU window [Config I/O groups] found by using the path Set up, Group configuration. Set the Type: for I/O Group 1 to RAPPER and the MODE: to AUTO.
Page 75 7. Function descriptions
7.11.5. How to use the timers etc. There are almost endless ways to use the timer functions that just have been explained to you. When you have studied the timer functions and maybe one or two of the examples you will be ready to make your own settings.
7.11.5.1. Example 1 - Different timers for collector and emitter rapping In this example one timer is controlling the rapping of collector electrodes and another timer is controlling rapping of the emitting electrodes (there is often need for more intensive rapping on the collector electrodes than on the emitting electrodes). 1.
Start time for collector rapping - Set timer No. 1 to start on the first Monday of the year at midnight ( 001:00:00:00), see heading 7.11.1. The timer function on page 69.
2.
Repetition time for collector rapping - Set the repetition time for timer No. 1 to 12 minutes ( 000:00:12).
3.
Run time for collector rapping - Set the run time for timer No. 1 to 1 minute (00:01:00). (You must of course set the run time in accordance to your process.)
4.
Start time for emitter rapping - Set the timer No. 2 to start at midnight the first Monday of the year ( 001:00:00:00).
5.
Repetition time for emitter rapping - Set the repetition time for timer No. 2 to 5 minutes ( 000:00:05).
6.
Run time for emitter rapping - Set the run time for timer No. 2 to e.g. 2 minutes (00:02:00). (You must of course set the run time in accordance to your process.)
7.
Coupling - Set the Coupling for timer No. 1 and No. 2 to NO. Use the RTU window [Set Up Timer 1-3] reached by using the path Set up, I/O Groups, Timer 1-3.
8.
PCR - Check that the power control for timer No. 1 and No. 2 is OFF. Use the RTU window [Set Up Power Ctrl] reached by using the path Set up, Power control .
9.
I/O Group - Connect I/O group 1 to timer No. 1 and I/O Group 2 to timer No. 2 in the RTU window [I/O Group Connection] reached by using the path Set up, I/O Groups, Connection.
10. Type - For I/O group 1 and 2, set the Type: to RAPPER. Use the RTU window [Config IO groups] reached by using the path Set up, I/O Groups, Group configuration. Timer No. 1 will now generate output every 12 th minute (with duration of 1 minutes). And timer No. 2 will generate output every half-hour (with duration of 2 minutes).
Page 76 7. Function descriptions
7.11.5.2. Example 2 - A four hour rapping cycle that is blocked at midnight In this example rapping shall start 4 o’clock in the morning and be repeated every 4th hour of the day, except at midnight. 1.
Start time for rapping - Set timer No. 2 to start on the first Monday of the year at 4 o’clock in the morning ( 001:04:00:00), see heading 7.11.1. The timer function on page 69.
2.
Repetition time for rapping - Set the repetition time for timer No. 2 to 4 hours (000:04:00).
3.
Run time for rapping - Set the run time for timer No. 2 to 15 minutes (00:15:00). (You must of course set the run time in accordance to your process.)
4.
Start time for blocking - Set the timer No. 1 to start at midnight the first Tuesday of the year ( 002:00:00:00).
5.
Repetition time for blocking - Set the repetition time for timer No. 1 to 24 hours ( 000:24:00).
6.
Run time for blocking - Set the run time for timer No. 1 to e.g. 16 minutes or at least longer than the run time for timer No. 2 (00:16:00).
7.
PCR - Set the power control to ON and specify the current. Use the RTU window [Set Up Power Ctrl] reached by using the path Set up, Power control .
8.
Coupling - Set the Coupling for timer No. 2 to AND NOT and NO for timer No. 1. Use the RTU window [Set Up Timer 1-3] reached by using the path Set up, I/O Groups , Timer 1-3.
Note! In figure No. 12 you can see that it is the output from timer No. 2 that shall be used (output from timer No. 1 is not relevant in this example).
9.
I/O Group - Set I/O group 1 to timer No. 2 in the RTU window [I/O Group Connection] reached by using the path Set up, I/O Groups, Connection.
10. Type - For I/O group 1, set the Type: to RAPPER. Use the RTU window [Config IO groups] reached by using the path Set up, I/O Groups, Group configuration.
Page 77 7. Function descriptions
Since the output from timer No. 1 is low on the first day, the rapping will start 4 o’clock in the morning and last for 15 minutes. The same thing will happen at 8:00, at 12:00 (noon), at 16:00 (4 PM) and at 20:00 (8 PM). At midnight the output of timer No. 1 will be activated and since the coupling AND NOT is selected there will be no output from timer No. 2 (t he midnight rapping is omitted). Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
&
&
&
&
&
&
&
&
&
&
>1
>1
>1
>1
>1
PCR
PCR
PCR
PCR
PCR
External input
Connection to I/O Group
I/O 1
I/O 2
I/O 3
I/O 4
Figure 12. Output every forth hour except for midnight
7.11.5.3. Example 3 - A timer controlled rapping with externally forced rapping In example 3 a rapper output is controlled by timer No. 1. In certain cases extra rapping can be needed and using the external input can solve that. The output is connected directly to the I/O group 1 without any influence from the PCR. 1.
Start time - Set timer No. 1 to start on the first Monday of the year at 1 o’clock in the morning ( 001:01:00:00), see heading 7.11.1. The timer function on page 69.
2.
Repetition time - Set the repetition time for timer No. 1 to 2 hours (000:02:00).
3.
Run time - Set the run time for timer No. 1 to 6 minutes ( 00:06:00). (You must of course set the run time in accordance to your process.)
4.
Type - Set the Type : to RAPPER. Use the RTU window [Set up inputs] reached by using the path Set up, Inputs.
5.
PCR - Set the power control to OFF. Use the RTU window [Set Up Power Ctrl] reached by using the path Set up , Power control.
Page 78 7. Function descriptions
6.
Coupling - Set the Coupling for timer No. 1 to OR. Use the RTU window [Set Up Timer 1-3] reached by using the path Set up , I/O Groups, Timer 1-3.
7.
I/O Group - Set I/O group 1 to timer No. 1 in the RTU window [I/O Group Connection] reached by using the path Set up, I/O Groups, Connection.
8.
Type - For I/O group 1, set the Type: to RAPPER. Use the RTU window [Config IO groups] reached by using the path Set up, I/O Groups, Group configuration.
The rappers connected to I/O Group 1 will operate during 6 minutes every second hour. When an external signal is received the OR coupling will feed this signal to the connection to I/O Groups. Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
&
&
&
&
&
&
&
&
&
&
>1
>1
>1
>1
>1
PCR
PCR
PCR
PCR
PCR
External input
Connection to I/O Group
I/O 1
I/O 2
I/O 3
I/O 4
Figure 13. Output every second hour and during forced rapping via the external input
7.11.5.4. Example 4 - Utilization of the PCR function from an external source In this example rapping is controlled from an external source (e.g. PLC) but the PCR function in EPIC III is utilized. In this case timer No. 1 is involved but shall not be active at all. The easiest way to block the timer is to set the run time to 0. 1.
Run time - Check that the run time for timer No. 1 is set to 0 (00:00:00:00). For more information on timers, see heading 7.11.1. The timer function on page 69.
Note! When the Run time is set to 0 there will not be any output at all from this timer (no matter what the Start time or the Repetition time is set to).
Page 79 7. Function descriptions
2.
Type - Set the Type : to RAPPER. Use the RTU window [Set up inputs] reached by using the path Set up, Inputs.
3.
PCR - Set the power control to ON and specify the current. Use the RTU window [Set Up Power Ctrl] has the path Set up, Power control .
4.
Coupling - Set the Coupling for timer No. 1 to OR. Use the RTU window [Set Up Timer 1-3] reached by using the path Set up, I/O Groups, Timer 1-3.
Selection of RAPPER connects the external input to timer No. 1. And since the Run time for timer No. 1 is 0, this timer will not be active at any time. When an external signal is received the OR coupling will feed this signal to the PCR. Since the PCR function is activated, the power will be reduced to the set value when the external signal is active.
Page 80 7. Function descriptions
Page 81 8. Variable list
8. Variable list This list contains standard default values and description of each variable and parameter in alphabetical order. The actual installation may have customized default settings and they may differ from the list below. All parameters marked with S are saved to the non-volatile memory when using [Save settings]. The password levels are marked with L = low, M = middle and H = high. Master function, marked with MU is only valid when set from the master unit.
Name in RTU windows
The complete name & description
Accumulated: Sparks
Total detected sparks Double sparks increment this by 1. (Saves to memory every midnight)
Accumulated: Arcs
Passw. Range etc.
Def. value
Unit of measurement
Path to the RTU window
0 - 4x109
Read only
Counts
Readings +!+!
Total detected arcs. (Saves to memory every midnight)
0 - 4x109
Read only
Counts
Readings +!+!
Accumulated: Double
Total detected double sparks (Saves to memory every midnight)
0 - 4x109
Read only
Counts
Readings +!+!
Act. power
Active power consumption
0 - 999
Read only
kW
Operation or Readings
Active CL
Active pulse current limit
0 - 999
Read only
mA
Operation !
Active CR
Active charging ratio
1/1 - 1/999 or 2/4 - 2/998
Read only
Number/ number
Operation
An. out 1
Analog out 1 set value
4 - 20
4
mA
Tests+!+!+!
An. out 2
Analog out 2 set value
4 - 20
4
mA
Tests+!+!+!
App. power
Apparent power consumption
0 - 999
Read only
kVA
Readings
Arc det. level
Arc detection level S, M An arc is detected if the kVv, after a fired half cycle, is lower than detection level for more than 10 consecutive Semipulse cycles.
0-9
5
kV
Process settings / Spark settings
Arc quenching
Arc quenching Number of quenching pulses
S, M
1 - 99
10
Pulses
Process settings / Spark settings
Auxiliary
Auxiliary input For opacity, boiler load etc.
-
00.0 - 25.0
Read only
mA
Readings or Tests+!
Av. Curr. max
Secondary Current Average Max
M
0 - T/R rating
1000
mA
Set up / T/R
Average
Average 1-30 min average of the opacity signal.
0 - 100
Read only
%
Master +!
Calibrating
Calibrating Lit when the calibration is active and the algorithm is frozen.
!=ON
Read only
Text string
Master +!
"=OFF
-
H
Cancel VI-collection Cancel the VI-collection
L
---
---
---
Set up / VI-curve
Charge ratio
S, M
1/1 - 1/999 or 2/4 - 2/998
1/1
Number/ number
Operation+! or Process settings / Mode #
Charging Ratio The control parameter for Semipulse Fired/Total, No of half periods
Page 82 8. Variable list
Name in RTU windows
The complete name & description
Passw. Range etc.
Charging ratio
Charging ratio S, M The control parameter for Semipulse used during the VI-curve collection.
Collector area
Collector area Collector are for this field/cell
S, M
Def. value
Unit of measurement
Path to the RTU window
1:1 - 1:999
1:1
Number/ number
Set up / VI-curve / Settings
1 - 9999
1
m2
Set up / ESP
Cor time
Setup / EPOQ+!
Cor time rel
Setup / EPOQ+!
Cor time step
Setup / EPOQ+!
Coupl.
Coupling of Timers to output
S, M
NO AND OR AND NOT
NO
-
Set up / I/O Groups / Timers Setup / EPOQ+!
CR wait 0 - 4x10 9
Read only
Current limit Resulting current limit of OpOpt
1 - 100
Read only
%
Master +!
Current limit
Actual Pulse Current Limit
0 - T/R rating
Read only
mA
Operation
Current limit
Pulse Current Limit Ave. of all ignited current pulses
S, M
0 - T/R rating x 2
1000
mA
Operation+! or Process settings / Mode #
Current limit min
Current limit minimal for opacity opt.
S, M, MU
0 - 50
10
%
Master +!+!
Current Step
Current step after spark
S, M
1 - 98
15
% of actual secondary current.
Operation+! or Process settings / Mode #
Date
Date
S, M
YYYY-MM-DD 1980-01-012079-12-31
Year, Month, Day
Set up / System
DI Name:
The name of the input
S, H
7 letters
DigAux 1-4
Text string
Set up / Inputs
DI Type:
Type of connected input signal
S, H
Not con., Alarm-T, Alarm-W, Mode toggle, MU M toggle, Opac. cal. Rapper, Alarm Reset
Not con
Text string
Set up / Inputs
DI01-DI16
Read the digital inputs
CRC error
No. of CRC errors to Fläktbus
Current limit
DI4 - 10
Polarity of alarm
-
Read only
Tests+!+!
"=OFF !=NO
o
Set up / Alarm
o
Tests+!+!+!
!=ON
S, H
Diagnostics
"=NC
DO01-DO07
Digital Output Only possible to change if Test Mode is active
H
Duration
Duration The total time length of the VIcurve collection.
S
E2Prom
Test of E2PROM
H
!=ON "=OFF
0 - 999
Read only
Seconds
Set up / VI-curve
Command
Tests+!+!+!+!
Page 83 8. Variable list
Name in RTU windows
The complete name & description
EPOQ
EPOQ S, M Electrostatic Precipitator Optimizing Q Algorithm. Optimizing Charging Ratio and current limit.
EPOQ state
EPOQ Monitoring the progress of the EPOQ software
ESP address limits: ESP address limits: High High The Highest address on the network which will be controlled by the Master.
Passw. Range etc. ON OFF
Def. value
Unit of measurement
Path to the RTU window
OFF
Operation+! or Process settings / Mode #
Read only
Set up / EPOQ
S, H, MU
5 - 125
125
Numbers
Set up / System
ESP address limits: ESP address limits: Low S, H, Low The lowest address on the network MU which will be controlled by the Master.
5 - 125
5
Numbers
Set up / System
ESP mode
ESP control Controls the whole ESP operation in the address limits.
L, M U
On, Off
Off
Text string
Master
First ign. angle
First Ignition angle Determines the start current for the first fired pulse after a sparkover with short quenching.
S, M
0 - 100 100%=180°
40
%
Process settings / Spark settings
Gain
Gain
S, M, MU
0 - 200
20
%
Master +!
Get parameter from Reset of all settings in non-volatile Default memory to initial factory settings.
H
-
-
Command
Set up / System+!
Get parameter from Copy parameters from a specified Nod node
H
-
-
Command
Set up / System+!
HCR
EPOQ Highest allowed changing ratio.
H
1:1 - 1:999
1:61
High limit
High limit Opacity high limit.
S, M, MU
0 - 99
10
High voltage
Start/Stop of the T/R operation
L
ON/OFF
OFF
Idle cur. lim.
Idling Current Limit S, M Determines how much current that will be inserted between the normal Semipulse pulses.
0 - 10 mA
0
mA Ave. of idling pulses
Set up / T/R
Ign. ang. lim.
Ignition angle limit Limits the maximum firing angle for the SCRs.
S, M
100%= 180° 0.0 - 100.0
100.0
%
Set up / T/R
Language
Language in the RTU windows
S, M
1
Number
Setup / System
Last collection
Last collection Of VI Curve
S
Last ref meas OK
Last reference measurement OK Shows NO if a reference measurement never is performed
LCR
Lowest allowed changing ratio for EPOQ
Level (0-32)
Spark levels Determines the Spark detection level when Method is set to Current.
yyyy-mm-dd hh:mm
Read only
YES NO
Read only
H
1:1 - 1:999
1:1
H
1 - 32
16
Set up / EPOQ+! Master +!
%
Operation
Set up / VI-curve YES/NO
Set up / EPOQ
Set up / EPOQ+! Number
Process settings / Spark settings
Page 84 8. Variable list
Name in RTU windows
The complete name & description
Passw. Range etc.
Limit
Limit S This parameter informs the operator the type of limiter that was active when the VI-curve function was determining the maximum current.
Limiter
Limiter Shows the limit that is active for the moment.
Loop gain
Control Loop Gain Damping factor for regulation
S, M
Def. value
Unit of measurement
Path to the RTU window
OFF, None, Sec Current, Prim current, Peak volt, Ign angle, Spark, Rapping, Pulse curr., EPOQ, Opacity opt., Pulse current, ARC
Read only
---
Set up / VI-curve
Off, None, Sec Current, Prim current, Peak volt, Ign angle, Spark, Rapping, VI curve, Pulse curr. EPOQ, Opacity-opt., ARC
Read only
1 - 50
10
Operation
%
Setup / EPOQ+!
Max sec curr Method
Process settings / Spark settings
Determines what method to be used for spark detection.
S, H
Voltage Current
Voltage
Text string
Process settings / Spark settings Setup / EPOQ+!
Min curr dens Min. current density Minimum current density This value is the lowest current density the VI-collection will use
S, M
0 - 9999
10
# A/m2
Set up / VI-curve / Settings
Mode
Mode All modes contain the same set of parameters.
L
Mode 1 - 6
Mode 1
Text string
Operation
Mode:
Mode of operation for the I/O groups
S, H
Auto, On, Off, ----Cont.
-----
Text string
Set up / I/O Groups / Group configuration
Modes:
Mode change (global command) Changes mode in all units controlled by the master unit.
L, MU
Mode 1 - 6
Mode 1
Text string
Master
Momentary
Opacity Momentary value 1 second average of the opacity signal
0 - 100%
Read only
%
Master +!
Monitors, 1st
1st Opacity monitor cell
A01 - L20
B01
-
Master +!
Monitors, 1st
Returned value of 1 st opacity monitor. The opacity is shown as a 10 s average signal.
1 - 100
Read only
%
Master +!
Monitors, 2nd
2nd Opacity monitor cell
A01 - L20
B01
-
Master +!
Monitors, 2nd
Returned value of 2 nd opacity monitor. The opacity is shown as a 10 s average signal.
1 - 100
Read only
%
Master +!
Name:
The name of the I/O group
7 letters
Iogrp 1-4
Text string
Set up / I/O Groups / Group configuration
M
M
S, H
Page 85 8. Variable list
Name in RTU windows
The complete name & description
Passw. Range etc.
Def. value
Unit of measurement
New Q
Path to the RTU window Setup / EPOQ+!+!
NIC
NIC Next in change
-
0 - 127
Read only
Diagnostics
Normally closed
Polarity of operation of DI14, DI16, DI1, DI2
S, H
" =
" =
Set up / Inputs
Off
! =
Total number of T/Rs in off position
Yes No
0 - 999
Yes
Read only
Count
Old Q
Master Setup / EPOQ+!+!
On
Total number of T/Rs in on position
0 - 999
Read only
Opac. controlled
Opacity controlled
Opacity optim.
Opacity optimization Starts or stops the Opacity optimization.
OpOpt Clim>
M
ON OFF
OFF
S, M, MU
ON OFF
OFF
ON OFF
Master
Opacity optimization pulse S, M current limit minimum If the current is limited to a lower level by the opacity algorithm, no EPOQ reference measurement will be performed.
0.0 - 100.0
15
%
Set up / EPOQ
Optimal Clim
EPOQ Optimal Pulse Current Limit
0 - T/R rating
Read only
mA
Set up / EPOQ
Optimal CR
EPOQ Optimal Charging Ratio
1/1 - 1/999
Read only
Number/ number
Set up / EPOQ
Position: Field/Cell
Position: Field/Cell T/R position in ESP
S, M
A01 - L20
A01
Text string
Set up / ESP
Power Control
Power Control for Timer 1-6
M
On, Off
Off
Power Control
Power Control pulse current for Timer 1-6
M
0 - T/R rating x 2
400
mA
Set up / I/O Groups / Power control
Pr. cur. ave
Primary Current Average
1.0 - 999.9
Read only
A
Readings
Pr. cur. limit rms Trip
Primary Line Current Limit Trip Alarm Operation above this limit is prevented by ignition angle reduction. The T/R is tripped if current stays above this limit > 5 seconds.
0 - 999.9
250
A rms
Set up / T/R
Pr. cur. rms
Primary Line Current RMS
0.0 - 999.9
Read only
Arms
Operation or Readings
Pr. volt rms
Primary Line Voltage Rms
0 - 999
Read only
V
Operation or Readings
Prim Curr adjustm.
Primary current adjustment zero
0 - 20
10
Number
Setup / T/R +!
Primary current (RMS)
Primary current signal
Read only
mA
Tests+!
Primary voltage (RMS)
Primary voltage
Read only
V
Tests+!
S, M
S, H
Count
Master Operation+! or Process settings / Mode #
Set up / I/O Groups / Power control
Page 86 8. Variable list
Name in RTU windows
The complete name & description
Passw. Range etc.
Program version
Program Version
Quench mod.
Spark Quench Mode
RAM
RAM Test H Only possible if Test Mode is active
Rapp all
Run all Rapper outputs
M
ON/OFF
OFF
Operation+!
Rapp. Intens.
Rapping Intensity The number of times that the repetition time is prolonged.
M
1 - 10
1
Operation+! or Process settings / Mode #
Ratio for Line volt. xformer
Primary Line Voltage Transformer Ratio
S, H
100 - 700
500
V/5V
Set up / T/R +!
Ratio for Prim. curr. Primary Line Current Transxformer former Ratio
S, H
10.0 - 900.0
250
A/1A
Set up / T/R +!
Ratio for Sec. curr. shunt
Secondary Current Shunt Ratio
S, H
10.0 - 3000.0
1000.0
Ratio mA/1V
Set up / T/R +!
Ratio for Sec. volt. ser. res.
Secondary Voltage Divider Ratio Standard.
S, H
Ratio kV/0.4 mA
Set up / T/R +!
S, M
Def. value
Unit of measurement
Path to the RTU window
-
Read only
-
Set up / System
SELF SHORT SELF+SHORT
SHORT
Text string
Operation+! or Process settings / Mode #
Command
Tests+!+!+!+!
20.0kV/0.4 200.0kV/0.4 90
By removing jumpers R142 and R144
20.0kV/0.1 200.0kV/0.1
kV/0.1mA
0 - 4x1099
Read only
Repetition time for charging ratio optimization
00:00 - 23:59
Read only
Hours, Minutes
Set up / EPOQ
Rep ref meas
Repetition time for reference measurement
00:00 - 23:59
Read only
Hours, Minutes
Set up / EPOQ
Repet. Time
Repetition time for Rapper outputs
0:00:00 365:23:59
0:00:00
Days Hours Minutes
Setup / I/O Groups / Timers #
Reset alarm
Sum alarm reset
L
Command
Reset NIC <>0
Number of Reset NIC <>0
-
0 - 4x1099
Read only
Diagnostics
Run time
Run time for timer 1-6
S, M
hh:mm:ss
00:00:00 Hours Minutes Seconds
Set up / I/O Groups / Timers
Sampl. interv
Sampling interval for average signal calculation
S, M, MU
1 - 30
5
Minutes
Master +!
Sample interval
Sample interval A specified waiting time before measuring each current value.
S, M
0 - 255
2
Seconds
Set up / VI-curve / Settings
Save settings
Save settings Save all active settings in non-volatile memory
H
-
Command
Save settings
Sec. curr. Average
Secondary Current Average
0 - 9999
Read only
mA
Readings +!
Sec. curr. Density
Secondary Pulse Current Density
0 - 1000
Read only
µA/m2
Operation or Readings+ !
Sec. curr. Peak
Secondary Current Peak
0 - 9999
Read only
mA
Readings +!
Receive errors
Receive error counter
Rep Opt CR
-
Diagnostics
Operation
Page 87 8. Variable list
Name in RTU windows
The complete name & description
Passw. Range etc.
Def. value
Unit of measurement
Path to the RTU window
Sec. curr. Pulse
Secondary Pulse Current
-
0 - 9999
Read only
mA
Readings +! or Operation
Sec. volt. Average
Secondary Voltage Average
0.0 - 999.9
Read only
kV
Operation or Readings +!
Sec. volt. Peak
Secondary Voltage Peak
0.0 - 999.9
Read only
kV
Readings +!
Sec. volt. Valley
Secondary Voltage Valley
0.0 - 999.9
Read only
kV
Readings +!
Secondary current
Secondary Current Signal
Read only
mA
Tests+!
Secondary voltage
Secondary Voltage Signal
Read only
V
Tests+!
Set
Set Opacity set value
S, M, MU
1 - 99
5
%
Master +!
Short quenching
Short Quenching Number of half periods
S, M
2-9
2
Pulses
Operation+! or Process settings / Mode #
Slope Rise A
Slope Rise A
S, M
0.0 - 100.0
80.0
%
Process settings / Spark settings
Slope Rise B
Slope Rise B
Read only
%
Process settings / Spark settings
Slope Rise C
Slope Rise C
S, M
High Medium Low
High
Slope Time A
Slope Time A
S, M
0 - 100
5
%
Process settings / Spark settings
Slope Time B
Slope Time B
Read only
%
Process settings / Spark settings
Spark rate
Spark Rate, Detected Sparks Per Minute (Double are counted as 1)
0 - 999
Read only
spm (sparks per minute)
Operation or Readings +!+!
Spark rate lim.
Spark Rate Limit Limitation of sparks
S, M
0 - 450
10
spm (sparks per minute)
Operation+! or Process settings / Mode #
Spark sens.
Spark Sensitivity High value= low sensitivity Low value= high sensitivity
S, H
1.0 - 99.9
40.0
kV/ms
Process settings / Spark settings +!
Spark sensing method
Spark Sensing Method
S, H
Voltage/Current
Voltage
Process settings / Spark settings
Process settings / Spark settings
Start ref meas, hour Start hour for reference measurement. Consists of an hour variable.
S, H, M 00 - 23
00
Hours
Set up / EPOQ
Start ref meas, min- Start minutes for reference utes measurement. Consists of an minute variable.
S, H, M 0 - 60
dep. Minutes field/cell
Set up / EPOQ
Start Time
Start Time for Rapper outputs
S, M
0:00:00 365:23:59:59
0:00:00
Days Hours Minutes Seconds
Setup / I/O Groups / Timers #
Start VI-collection
Start VI-collection Starts the collection and stores the values.
M
-
-
Command
Set up / VI-curve
Page 88 8. Variable list
Name in RTU windows
The complete name & description
Passw. Range etc.
Def. value
Unit of measurement
Path to the RTU window
Step at spark
Step at spark Current reduction when VI curve is limited by sparkover.
S, M
1 - 25
5
%
Set up / VI-curve / Settings
Supervisor active
This node is Flaktbus supervisor -
0-1
Read only
Diagnostics
Test mode
Test mode is active
H
Yes, No
No
Tests
Time
Time The actual real time. Used for time synchronized functions like Rapping.
L, M
HH,MM,SS
00:00:00 Hours, Minutes, Seconds
Set up / System
Total
Total T/R:s The total number of connected T/R:s controlled by ESP-Master
MU
0 - 999
Read only
Counts
Master
Total number of EPIC in mode 1-6
Total number of E PIC:s in mode 1-6 controlled by ESP-master
MU
0 - 999
Read only
Counts
Master
Total power
Total active power for the EPIC:s controlled by ESPmaster
MU
0 - 999999
Read only
kW
Master
Total sum alarm
Total sum alarm reset
L
Command
Trip
Total Tripping units
Type:
Type of device connected to I/O group
Unit: Address
Master
0 - 999
Read only
Counts
Master
S, H
Rapper, Transport, Heater, Conf.DO., Unconf. Do., ESP-ctrl, T/R status, Not conn.
Not conn.
Text string
Set up / I/O Groups / Group configuration
FläktBus address
S, H
5 - 125
2
number
Set up / System
Unit: Master unit
Master Assigns an EPIC II to a Master EPIC
S, H
YES NO
NO
Unit: Name
Unit Name The name that appears in all windows.
S, H
Max 12 characters
EPIC-III
Set up / System
Text string
Upeak
Set up / System
Setup / EPOQ+!+!
Used EPOQ Clim
Used EPOQ Current Limit
0 - T/R rating
Read only
mA
Set up / EPOQ
Used EPOQ CR
Used EPOQ Charging Ratio Decides Charging Ratio if EPOQ is ON
1/1 - 1/999
Read only
Number/ number
Set up / EPOQ
Uval
Setup / EPOQ+!+!
Warn.
Total warning units
0 - 999
Read only
VI state
VI state The status and progress of the VI curve collection. 1-2 = initiation 1022= collection of data.
0 - 22 OFF ON
Read only
Volt.peak lim.
Voltage Peak Limit
0.0 - 999.9
15
S, M
Counts
Master Set up / VI-curve
kV p
Operation+! or Process settings / Mode #
Page 89 8. Variable list
Name in RTU windows
The complete name & description
Passw. Range etc.
Def. value
Unit of measurement
Path to the RTU window
Voltage limit ave. High trip
Secondary Voltage High Trip Alarm Average Alarm delay 1 s
S, M
0.0 - 999.9
90.0
kV
Set up / T/R
Voltage limit ave. Low trip
Secondary Voltage Low Trip Alarm Average Alarm delay 20 s
S, M
0 - 999
5.0
kV
Set up / T/R
Voltage limit ave. Low warning
Secondary Voltage Low Warning Alarm Average Alarm delay 20 s
S, M
0 - 999
10.0
kV
Set up / T/R
Vref
Setup / EPOQ+!
Vref wait
Setup / EPOQ+!
Page 90 8. Variable list
Page 91 9. Trouble shooting
9. Trouble shooting This chapter tells you what to do when there is a malfunction. It is of great importance that you read the following instructions before trying to do anything yourself.
Warning! Do not unscrew the enclosure and expose the circuit board. The warranty is void if the enclosure has been open by unauthorized personnel. Static electricity (ESD) may destroy the integrated circuits on EPIC III circuit board if the enclosure is opened. When sending the EPIC III for service, please send the whole unit to ALSTOM Power. Do not remove the circuit board from the enclosure.
9.1.
Alarm messages This is a description of alarm messages from EPIC III displayed on the RTU . The same alarm code number and similar text are used at alarm situations on other FläktBus units.
Alarm code
Date and time when the alarm occurred.
The name of the alarming node ALARM #19
2002 June 18 11:20 # 6
From node EPIC III LV isolation switch, T/R tripped
Alarm message
Acknowledge
This command confirms that you have registered the alarm. The alarm message will disappear and will not be displayed again. The alarm is however still active.
Node address
Reset Block alarm 1 min
This command resets the alarm. If the error still remains the alarm will be reactivated.
This command suppresses all alarm messages for 1 minute.
This key cancels the alarm message and returns to the previous window without taking any action. The alarm message will disappear, but the alarm will be displayed again if active.
There are three ways to locate an alarm: 1.
An alarm message is displayed on the RTU as the above.
Page 92 9. Trouble shooting
2.
The [Alarm Table] shows all acknowledged and blocked alarms.
3.
The [Node list] shows an alarm clock icon beside the alarming node.
When an alarm message is displayed the following steps must be taken:
9.2.
1.
Register the alarm and write down the alarm code number. This is very important especially for those alarms that need external service assistance.
2.
Check [Alarm Table] menu and see if more alarms are active and write them down.
3.
Remedy the fault or faults according to the priority of the alarm and follow the instructions in the “Alarm messages list”.
4.
Reset all alarms in the [Operation] menu.
Alarm messages list This is a list of all alarm messages from EPIC III . The alarm messages are in alarm code number order. The alarm code number is located at the top of the alarming window.
9.2.1.
External alarm messages Alarm # 1 Cause: Solution:
“Temperature high, Warning” The temperature of the T/R is high. Check the T/R and the temperature indicator.
Alarm # 2 Cause: Solution:
“Temperature high, T/R tripped” The temperature of the T/R is too high. Check the T/R and the temperature indicator.
Alarm # 3 Cause: Solution:
“Check oil, Warning” The oil warning indicator is activated. Check the T/R and the oil indicator.
Alarm # 4 Cause: Solution:
“Check oil, T/R tripped” The oil trip indicator is activated. Check the T/R and the oil indicator.
Alarm # 5 Cause: Solution:
“LV isolation switch, T/R tripped” The switch is open and has disconnected the power to the T/R. Check the switch.
Alarm # 6 Cause: Solution:
“HV safety breaker, T/R tripped” The breaker does not allow the T/R to operate. Check the breaker.
Alarm # 7 Cause: Solution:
“SCR temperature high, T/R tripped” The temperature of the SCRs (thyristors) are too high. Check the SCRs.
Alarm # 9
“AC-current high, T/R tripped”
Page 93 9. Trouble shooting
Cause: Solution:
Alarm # 10 Cause: Solution:
Alarm # 11 Cause: Solution:
Alarm # 12 Cause: Solution:
The primary line current has exceeded the trip alarm limit in [Set-up] [T/R]. Check all analog input signals by setting a low value on the Ignition angle limit and compare EPIC III readings with external measurements, if they are okay, check the T/R. “DC-voltage low, T/R tripped” The secondary voltage has stayed below the low trip alarm limit in [Set-up] [T/R] for more than 30 sec. Check the Electrostatic Precipitator for short circuits. If it is okay check the kV measurement signal and the alarm level. “DC-voltage low, Warning” The secondary voltage has stayed below the low warning alarm limit in [Set-up] [T/R] for more than 30 sec. Check the Electrostatic Precipitator for short circuits. If it is okay check the kV measurement signal and the alarm level. “DC-voltage high, T/R tripped” The secondary voltage has exceeded the high trip alarm limit in [Set-up] [T/R]. Check the T/R and its connection to the Electrostatic Precipitator. If it is okay check the kV measurement signal and the alarm level.
Solution:
“Contactor error, T/R tripped” The feedback from the main contactor is missing during T/R ON condition. Check the contactor and its connections.
Alarm # 50 Cause: Solution:
“XXXXXXX, I/O Group 1 error, Warning The feedback from the I/O Group 1 contactor is missing. Check the contactor and its connections.
Alarm # 51 Cause: Solution:
XXXXXXX, I/O Group 2 error, Warning The feedback from the I/O Group 2 contactor is missing. Check the contactor and its connections.
Alarm # 52 Cause: Solution:
XXXXXXX, I/O Group 3 error, Warning The feedback from the I/O Group 3 contactor is missing. Check the contactor and its connections.
Alarm # 53 Cause: Solution:
Rapping OFF when T/R ON > 30 min. The Rappers are not in operation when T/R is ON. Change the mode to auto. Check that the Rapping sequence is correct set. Check connections and the contactor.
Alarm # 54 Cause: Solution:
Rapping continuously > 30 min, warning. When Rapping sequence is CONT > 30 min. This message is always displayed when the rapper sequence has been working continuously in position CONT. for more than 30 minutes.
Alarm # 18 Cause:
Page 94 9. Trouble shooting
Alarm # 55 Cause: Solution:
XXXXXXX, I/O Group 4 error, Warning The feedback from the I/O Group 4 contactor is missing. Check the contactor and its connections.
Alarm # 56 Cause: Solution:
Transp. OFF when T/R ON > 30 min, Warning The Transport are not in operation when T/R is ON. Change the Transport mode to auto. Check connections and the contactor.
Alarm # 58 Cause: Solution:
XXXXXXX, External input, Warning The digital input Aux 2 T#40, 56 has been activated. Check the connections.
Alarm # 59 Cause: Solution:
XXXXXXX, External input, Trip The digital input Aux 2 T#40, 56 has been activated. Check the connections.
Alarm # 60 Cause: Solution:
XXXXXXX, External input, Warning The digital input Aux 1 T#38, 54 has been activated. Check the connections.
Alarm # 61 Cause: Solution:
XXXXXXX, External input, Trip The digital input Aux 1 T#38, 54 has been activated. Check the connections.
Alarm # 62 Cause: Solution:
XXXXXXX, External input, Warning The digital input Aux 3 T#25 41 has been activated. Check the connections.
Alarm # 63 Cause: Solution:
XXXXXXX, External input, Trip The digital input Aux 3 T#25 41 has been activated. Check the connections.
Alarm # 70 Cause:
Solution:
Sparks at low voltage > 1 hour, warning. The EPOQ optimizing has been prevented for more than 1 hour due to sparks at peak voltage < 20 kV Check the condition of the actual ESP bus section. Epoq ref.meas prevented 3 times, warning. The EPOQ reference measurement has been prevented the last three times. This occurs if the possibilities to change the secondary current are strongly limited, or if very frequent sparks are disturbing the measurement. Check the condition of the actual ESP bus section.
Alarm # 86 Cause: Solution:
XXXXXXX, External input, Warning The digital input Aux 4 T#26 42 has been activated. Check the connections.
Alarm # 87 Cause: Solution:
XXXXXXX, External input, Trip The digital input Aux 4 T#26 42 has been activated. Check the connections.
Solution: Alarm # 71 Cause: Probable cause:
Page 95 9. Trouble shooting
Alarm # 93 Cause: Solution:
9.2.2.
VI curve prevented EPOQ and/or rapping prevents the VI-curve function to run for more than 5 minutes. Synchronize the VI-curve with the rappers and/or the EPOQ or switch of the EPOQ and/or the rappers during the VI-curve configuration. Also see heading 7.9. VI-curve function on page 55.
Internal alarm messages Alarm # 210 Controller restarted, Trip The Controller has restarted. Cause: Action: Check the 24 V supply voltage. Alarm # 212 “All settings reset by operator, Warning” Cause: The message is displayed when the operator has restored settings to default in [Set Up] [System] [Restore]. Solution: Continue the operation with the default values or re-enter new values. Alarm # 213 “Watchdog reset, Trip” Internal error inside EPIC III . Cause: Solution: See heading 9.2.3. Remedy of internal alarm messages on page 95. Alarm # 215 Successful program update, Trip Cause: The message is displayed when the EPIC has restarted after program re-load. Action: Alarm # 221 “Real time clock re-initiated, Warning” Cause: Internal error inside EPIC III or the internal backup capacitor is discharged. Power has been down for more than 2 weeks. Set correct time again in [Set Up] [System]. If this does not Solution: help, see heading 9.2.3. Remedy of internal alarm messages on page 95.
9.2.3.
Remedy of internal alarm messages When an alarm message with alarm code number #200 or higher is displayed proceed as follows: 1.
Restart EPIC III by switching off the 24 V power and turning it on again.
2.
If the same alarm message is displayed once again, replace the EPIC III unit with a spare unit. Write down the alarm message and label the faulty EPIC III unit with this message.
3.
Contact nearest service center, see section 9.8. Warranty & Repair Service on page 101.
Page 96 9. Trouble shooting
9.3.
External alarms External alarms are input signals to EPIC III such as, Check oil, DC-Voltage low, etc. EPIC III gives alarm message at a certain level dependent of settings in [Set Up]. It is of great importance that all inputs have been tested during first start-up so that EPIC III gives the right alarm message for each event. See heading 9.2. Alarm messages list on page 92 for further information of each alarm.
9.4.
Other faults Symptom Solution
All LEDs on the front panel are dark. Check the 24 V supply to the EPIC III .
Symptom Solution
The alarms cannot be reset from RTU . The alarm may still be active. If not check input signal with [Field Test]. (Replace alarm contacts (indicators) if alarm is wrongly given).
Symptom Solution
The T/R cannot be switched to “ON” from RTU . Check that all trip alarms have been reset. If the T/R still cannot be switched to “ON”, check the main T/R contactor. Check also that the Test mode is not active (See [Field Test]).
Symptom
The operating values in [Readings] are low and not normal. A limit has a too low value for the operation. See [Operation] window and check if any Limiter is active. Increase the parameter which limits the operation, if it is to low.
Probably cause Solution
Page 97 9. Trouble shooting
9.5.
Diagnostics windows
9.5.1.
[Communication stats.]
9.5.1.1.
Receiver error Displays the accumulated number of hardware detected FläktBus communication errors sensed by this unit. Errors may be caused by interference from other electrical equipment, or by connecting or disconnecting units to the bus. The ideal state for a network is a stable figure. A slow increase in number is however acceptable as maximum error rate is dependent on the current configuration of the network. For example a small network containing a few EPICs and an RTU is less sensitive to high error rate than a network using a gateway. In general, the error rate should be kept as low as possible. Network design parameters such as cable routing, bus terminators, etc. considerably influence the network error rate.
9.5.1.2.
CRC error This is also an error counter that displays the accumulated number of communication errors detected by the software.
9.5.1.3.
Reset NIC <> 0 This figure is incriminated when a unit is logically attached to the bus. The ideal state for a network is a stable figure.
9.5.1.4.
NIC NIC = Next in chain displays the token destination address for this node (only used for advanced troubleshooting).
9.5.1.5.
Supervisor active The figure 1 denotes that this node is in FläktBus supervisor mode. Only one node may be current supervisor.
Page 98 9. Trouble shooting
9.6.
Test windows The [Tests] windows assumed for trouble shooting only. There are two ways to use the [Tests]. Test mode The Test mode is in off position and the status of inputs and outputs can be checked during operation. Test mode This mode does not change or destroy any settings. The Test mode is activated and digital outputs can be directly controlled and there is a possibility to run the non-volatile memory and the control circuit (Watchdog) test. All digital outputs and LEDs can also be manually tested. Note! Disconnect EPIC III from network with the network switch at front of EPIC III before activating the Test mode and connect the RTU at the front of EPIC III .
9.6.1.
Analog inputs [Test mode 1] This window shows measured values of the analog inputs. Check that all inputs have input signals. Note! These values are measured at the inputs of the screw terminal. Use a universal meter and check that all values are OK.
Page 99 9. Trouble shooting
9.6.2.
Digital Input [Test mode 2] This window shows all digital inputs. A digital input is activated and the box to the right of the input is filled when it receives an input signal. See section 10. Technical data on page 103 for detailed information of each input.
9.6.3.
Digital and analog outputs [Test mode 3] This window shows all digital outputs as well as the two analog outputs. The box to the right of each output is filled when the output relay is active (closed). When the Test mode is activated the digital outputs can be manually controlled. By activating or deactivating the relay contact each output can be checked and tested. Select for example one inactive output and press OK. The output will be active and the box will be filled. See section 10. Technical data on page 103 for detailed information of each output. The analog outputs can be checked in a similar way, by measuring the voltage indicated in the window. Note! Before activating an output make sure that you know what you are doing because if you activate e.g. DO01 (TR ON) the contactor will be activated.
9.6.4.
E2PROM and RAM [Test mode 4] In this window an E2PROM and an RAM test can be performed.
Page 100 9. Trouble shooting
9.7.
Program update The company is continuously updating the EPIC III software with new features for precipitator tuning and control. New program versions can be loaded in this way. Loading via RS 232 serial port - The EPIC III program can be loaded by using a standard PC and a serial adaptor (V4 555 779) connected directly to the controller (PCB), see figure 14. Remove the top cover from the EPIC III . Handle the printed circuit board with care and protect it from electrostatic discharge.
.
Figure 14. Updating RS 232 serial bus
Note! Use the program loading tool ProgCon.exe . This program can be run in a DOS window in any of the following operating systems: OS2, Win3.x, Win95, Win98 or Win NT. The operation is described in the ProgCon Manual.
Page 101 9. Trouble shooting
9.8. Warranty & Repair Service 9.8.1.
General In order to make the ALSTOM Power Service electronic service as efficient as possible, all units / components are handled according to the following routine(s): Field service is undertaken, either by the purchaser or by ALSTOM Power Service local representative, from fault location down to unit level in compliance with the instructions in the EPIC III manuals. The faulty unit is then sent to ALSTOM Power Service for repair. Remember to label the unit with the return address and invoice address and include a brief description of the fault symptoms. ALSTOM Power Service will return either a new or a exchanged unit that has been fully tested and configurated according to the application. A service report accompanies each returned unit. ALSTOM Power Service maintains a record of all repair information on faults for statistical analysis.
9.8.2.
Warranty Our products will continue to meet the demands of our customers for maximum quality and reliability both today and in the future. ALSTOM Power Service electronic products carry the following warranty:
9.8.2.1.
ALSTOM Power Service hardware products The warranty for ALSTOM Power Service hardware products includes guarantees against defects in materials and workmanship. If notice of such defects is received by ALSTOM Power Service during the warranty period, ALSTOM Power Service shall elect to either repair at an Alstom location or replace such defective hardware.
9.8.2.2.
ALSTOM Power Service software products The warranty for ALSTOM Power Service software products designated by ALSTOM Power Service as suitable for use together with a hardware product when properly installed covers material defects and production defects affecting the functioning of the software. If such a defect should arise during the warranty period ALSTOM Power Service shall elect to either repair / make good the defect or replace the defective software. ALSTOM Power Service does not guarantee that the operation of software, hardware or programming is free from defects or free from operational disruptions.
Page 102 9. Trouble shooting
9.8.3.
Limitation of warranty The aforementioned warranty does not apply to defects r esulting from:
9.8.4.
•
Improper or inadequate maintenance by the purchaser.
•
Software furnished by the purchaser himself.
•
Unauthorized modification or misuse.
•
Transportation or operation outside the specifications of the product.
•
Improper installation and maintenance.
Warranty period The warranty period is valid for one (1) year from the date of dispatch from ALSTOM Power Service, if nothing else has been agreed in writing. The purchaser shall prepay freight charges (including all customs duties and taxes) for products that are returned to ALSTOM Power Service for repair under this warranty. ALSTOM Power Service shall pay for the return of products to the purchaser.
9.8.5.
Repair and service address: All defective equipment / units / components should be sent to the nearest service centre or to: ALSTOM Power Service Kvarnvägen SE-352 41 Växjö SWEDEN
Page 103 10. Technical data
10. Technical data 10.1. General Size (W x D x H)
64 x 185 x 370 mm
Enclosure
Steel casing.
Mounting holes
2 holes, 6.5 mm diam. See Appendix.
Weight:
2.2 kg
Permissible ambient +5 °C to +60 °C operation temperature Permissible ambient storage temperature
-40 °C to +85 °C
Fuse
1.6 A slow.
Mains requirement
24 VAC or DC ±15%
Power consumption
<15VA
EMC protection Emission
EN 61000-6-4:2001 EN 55011:1998 class A FCC part15 subpart B class A CISPR 11:1997 class A
Immunity
EN 61000-6-2:2001 industrial ESD EN 61000-4-2:1995+A1 8 kV air-, 4kV contact discharge IEC 61000-4-2:1995+A1 Radio frequency Electromagnetic field EN 61000-4-3:1996 10 V/m, 80-1000MHz IEC1000-4-3:1995+A1 Electrical fast transients (burst) EN 61000-4-4:1995 2kV IEC 61000-4-4:1995 Surge transients EN 61000-4-5:1995 2kV 12$, 1.2/50#s IEC 61000-4-5:1995+corr1:1995 Conducted radio frequency interference EN 61000-4-6:1996 10Vrms, 0.15-80MHz IEC 61000-4-6:1996+corr1:1996 Immunity to voltage dips and interruptions EN 61000-4-11:1994 -60% 1s IEC 61000-4-11:1994
Connections
2 screw terminals with 8 terminals in each. 2 screw terminals with 12 terminals in each 2 screw terminals with 16 terminals in each
Page 104 10. Technical data
10.2. Analog inputs Analog signals are sampled at a high speed with a 10 bit A/D converter preceded with anti aliasing filter. Analog inputs are balanced and capable of making measurements during disturbances of up to ±100V of common mode signals. All inputs are protected against voltage transients. Primary and secondary signals are sampled 32 times/half period. NAME & descr.
INPUT SIGNAL
COMMENTS
T#
AI1, SECCUR, Current to ESP
0-1 V DC, From T/ R shunt.
1 V average corresponds to T/R rated average secondary current.
6+, 18-
AI2, SECVOLT, Voltage at ESP
0-400 µA DC, From series resistor. Ri=11.2 k$
400 µA average corresponds to T/R rated average secondary voltage.
8+, 20-
0-100 µA DC if jumpers R142 and R144 are removed. Ri=41.3 k$
Note! Will not change the RTU-ratio window.
AI3, PRICUR Primary current
0-1 A AC, Ri=0.5 $ From current transformer
1 A corresponds to the rated primary current of the measuring transformer.
9, 21
AI4, PRIVOLT Primary line voltage
0-5 V AC, Ri=ca 10 k$ From voltage transformer
5 V corresponds to the converted rated primary voltage of the measuring transformer. EPIC uses this value for phase reference, for calculating of consumed power and to avoid operation on too low line voltage.
10,22
AI5, AUX Auxiliary input
4-20 mA, Ri=124 $ Common mode input resistance=400 k$
Auxiliary input for measurement of any application specific variable. The use of this input is determined by the actual installed program.
11+, 23-
Page 105 10. Technical data
10.3. Analog outputs NAME & descr.
OUTPUT SIGNAL
COMMENTS
T#
AO1, Secondary current
4-20 mA
A sec current of 0 mA will give an output of 4 mA and a sec current equal to the rated current (max allowed) will give an output of 20 mA. Load 0-600 $
4+, 16-
AO2, Secondary voltage
4-20 mA
A sec voltage of 0 kV will give an output of 4 mA and a sec voltage equal to the rated voltage (max allowed) will give an output of 20 mA. Load 0-600 $
5+, 17-
10.4. Digital inputs NAME & descr.
INPUT SIGNAL
ACTIVE status
ACTIVE function/ ALARM MESSAGE
T#
DI01, DIGAUX3
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V **
Auxiliary input for signal according to the application.
25, 41
DI02, DIGAUX4
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V **
Auxiliary input for signal according to the application.
26, 42
DI03, CONT-ON
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V
Gives information to EPIC that the main contactor is ON. Gives alarm if NOT present when DO02, TR-ON is active. ALARM, CONTACTOR ERROR, TRIP
27, 43
DI04, TR-TEMP-W
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V*
The T/R overtemp switch is activated.
28, 44
DI05, TR-TEMP-T
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V*
The T/R overtemp switch is activated. ALARM, T/R TEMP HIGH, TRIP
29, 45
DI06, OIL-W
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V*
The oil sensor is activated. ALARM, T/R OIL,WARNING
30, 46
DI07, OIL-T
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V*
The oil sensor is activated. ALARM, T/R OIL, TRIP
31, 47
ALARM, T/R TEMP HIGH, WARNING
Page 106 10. Technical data
NAME & descr.
INPUT SIGNAL
ACTIVE status
ACTIVE function/ ALARM MESSAGE
T#
DI08, LVSAFETY-T
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V*
The low voltage is ol ati on switch is open. ALARM, LOW VOLTAGE ISOLATION SWITCH, TRIP
32, 48
DI09, HVSAFETY-T
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V*
The high voltage safety breaker is open. ALARM, HIGH VOLTAGE SAFETY BREAKER, TRIP
33, 49
DI10, SCRTEMP-T
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V*
The SCR over temperature switch is activated. ALARM, SCR TEMPERATURE HIGH, TRIP
34, 50
DI11, I/O GROUP 1
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V
Signals I/O-group 1 in operation.
35, 51
DI12, I/O GROUP 2
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V
Signals I/O-group 2 in operation.
36, 52
DI13, I/O GROUP 3
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V
Signals I/O-group 3 in operation.
37, 53
DI14, Dig AUX 1
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V**
Auxiliary input for signal according to the application.
38, 54
DI15, I/O GROUP 4
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V
Signals I/O-group 4 in operation.
39, 55
DI16, Dig AUX 2
24 V DC or 24 V AC, load approx. 20 mA, floating optocoupler input.
24V**
Auxiliary input for signal according to the application.
40, 56
*
Active status of this input can be changed at the site by selecting the [Set up] [Alarm] RTU window.
** Active status of this input can be changed at the site by [Set up] [Inputs].
Page 107 10. Technical data
10.5. Digital outputs NAME & descr.
SIGNAL/LOAD
COMMENTS
T#
SCR-A SCR ignition
Special for Alstom ignition board
Ignition signal for connection to the A-SCRs ignition transformer.
2, 14
SCR-B SCR ignition
Special for Alstom ignition board
Ignition signal for connection to the B-SCRs ignition transformer.
3, 15
DO01, TR-ON
Max 50VAC/DC,1A or 230V AC, 0.5 A.
Potential free contact, for control of an external contactor.
57, 65
DO02, I/O GROUP 1
Max 50VAC/DC,1A or 230V AC, 0.5 A.
Potential free contact for control of I/O group 1
58, 66
DO03, I/O GROUP 2
Max 50VAC/DC,1A or 230V AC, 0.5 A.
Potential free contact for control of I/O group 2
59, 67
DO04, I/O GROUP 3
Max 50VAC/DC,1A or 230V AC, 0.5 A.
Potential free contact for control of I/O group 3
60, 68
DO05, I/O GROUP 4
Max 50VAC/DC,1A or 230V AC, 0.5 A.
Potential free contact for control of I/O group 4
61, 69
DO06, Sumalarm Trip
Max 50VAC/DC,1A or 230V AC, 0.5 A.
Tripping relay Potential free contact, both normally closed and conducting during all alarm, and mains power off, conditions.
62 NC 70 NO 63 Common
DO07, Sumalarm Warning
Max 50VAC/DC,1A or 230V AC, 0.5 A.
Warning relay Potential free contact, both normally closed and conducting during all alarm, and mains power off, conditions.
64 NC 72 NO 71 Common
10.6. Power supply NAME & descr.
SIGNAL/LOAD
T#
Power supply
24 V AC or DC ±15%
1, 13
10.7. Communication NAME & descr.
SIGNAL/LOAD
FläktBus communication
Special for FläktBus communication
T# See FläktBus installation instructions at the end of this manual.
12, 24
Page 108 10. Technical data
10.8. Front panel LEDs NAME & descr.
COMMENTS
L0, POWER
Power On, 5 V internally generated
L1, ALARM
Indicates during all alarm conditions. ON=tripping alarm. Flickering lamp=warning alarm.
L2, SPARK
One flickering for each detected spark
L3, TOKEN
Flickering lamp during communication.
L4, TR-ON
ON if input DI03 is ON.
L5, SYNC
ON when AI04-PRIVOLT is present and EPIC is locked to line frequency.
L6
Spare
Page 109 11. Word list
11. Word list FläktBus
Field bus with token passing concept.
Gateway
Communication protocol translator.
Network node address list
A list of all nodes with name and addresses made by ALSTOM Power
Node
A node (unit) is a single addressable entity on FläktBus
Node list
A window in RTU containing all nodes connected to net.
ProMo
A colour graphic software package for process control.
RTU
The Remote Terminal Unit gives operators an alpha numerical and graphical interface to ESP parameters.
Page 110 11. Word list
Page 111 Appendices
Appendices EPIC III settings Mounting drawing EPIC III Mounting drawing ignition transformer Connection diagram, example Declaration of conformity FläktBus manual
Page 112 Appendices
E PI C I I I SE T TI N G
Plant name Unit No.
ESP
Date
Set up system Date Time Program version:
Set Up Alarms
Unit: Address Name Master Address limi ts: Low High
MODE SETTINGS PARAMETERS UNITS MODE 1 Volt. peak lim kV Current limit mA Charge ratio -:EPOQ On/Off Rapp intensity Rapp all On/Off Spark rate lim spm Current step % Short quenching pls Quench mod. Opac. controlled On/Off Spark settings/levels Slope: Rise A Rise B Rice C Time A Time B Spark sens
+
+
Method % Arc det.level < % Arc quenching First ign.angle % % Loop gain kV/ms Level
Set Up T/R Limit Pr.curr.limit rms: Voltage limit ave: Trip A Low warning Low trip High trip Ign.ang.limit %
Idle cur.limit
mA
Av.Curr max
DI 04 DI 05 DI 06 DI 07 DI 08 DI 09 MODE 2
DI 10
MODE 3
MODE 4
DI: 14 16 1 2
Name:
Set up inputs Type:
Used node numbers: EPIC III Master unit (MU) RTU
Normal 0V 24V
MODE 5
Alarm 24V 0V
MODE 6
Config I/O groups Name:
Type:
Mode:
kV pls %
DI 11 12 13 15
/ DO 02 03 04 05
% %
kV kV kV
mA
Set up Timer 1-6 Repet. Run time (d:hh:mm) (hh:mm:ss)
Start (d:hh:mm:ss) T1 T2 T3 T4 T5 T6
Set up T/R Ratio Ratio for: Line volt. xformer Prim.curr. xformer Sec. volt. ser.res Sec. curr. shunt Prim.curr. adjustm
DIxx = =
Set up Power Ctrl V = 5V A = 1A kV = 0.4 mA mA = 1 V 0-20
Timer 1 Timer 2 Timer 3 Timer 4 Timer 5 Timer 6
mA mA mA mA mA mA I/O Group connection
Norm. closed: Connect Connect Connect Connect
I/O I/O I/O I/O
-group -group -group -group
1 2 3 4
to to to to
Timer Timer Timer Timer
Set up ESP Position: Field/Cell Collector area
m²
Coupl.
Intentionelly blank
Intentionelly blank
Intentionelly blank
Intentionelly blank
Intentionelly blank
Fläkt Bu s -Process I/O bus ALSTOM Power reserves the right to revise any publication and to make changes to its contents, at any time, without obligation to notify any person or entity of such revision or changes, further, ALSTOM Power reserves the right to make improvements and changes to any and all parts of hardware and software, at any time, without obligation to notify any person or entity of such changes.
General The FläktBus is a general I/O communication bus for ALSTOM Power process control systems. This installation instruction is general for all applications of the FläktBus. For specific application instructions please refer to the specific unit manual.
IMPORTANT The guarantee of undisturbedFläktBus operation is valid only if all points in this installation instruction are followed.
Installation requirements There are a few simple rules for configuring (installation of) FläktBus; They are all derived from certain limits that are imposed on the physical channel to ensure optimum performance of the network.
Bus cable As bus cable, an unshielded twisted pair cable of 80 to 150 ohms characteristic impedance is used. An unshielded cable is used because the use of shielding will cause degeneration of signal level and appearance at longer distances due to higher attenuation. The twisted pair is the lowest cost option for medium size local area networks. A balanced twisted pair circuit is less susceptible to noise ingress from environment and generates less radiated energy. Minimum conductor area is 0.5 mm2 AVG 20 to fit into the type of terminals used by ALSTOM Power.
Approved cables The following cables are tested and fulfils the requirements for use in a FläktBus network: LiYY,2 * 0.5mm2 RKKB , 2 * 0.5 mm2 Belden 8442, 2 * 0.76 mm2 (Belden 8444, 4 * 0.76 mm2 , connect the unused pair to ground
at one end point) SHINAGAWA ELECTRIC, AWM STYLE 2868, 20 AWG/2 Radox 125, 2 * 0.75 mm2 (Huber & Suhner, CH)
IMPORTANT Use exactly the same type and dimension of cable throughout the whole installation, even in short distances such as from terminal to connector. Different cable types will give reflections of pulses and thereby loss of information.
Fläkt Bu s -Process I/O bus
Cable length Maximum of total cable length allowed in a single network, including connection taps, is 1000 m. If longer cables are required please contact ALSTOM Power, Dept. ME for latest available information about expansions. Taps should be as short as possible, preferably less than 0.4 m. FläktBus allows up to 115 taps of maximum 2 m, 3 taps up to 10 m and 2 taps up to 30 m.
Connection The cable is connected to all units by screw terminals.
Termination The bus must be terminated with 120 ohms at both ends, at which point transmitted signals stop. Termination is very important also for short bus cable lengths. It is of the greatest importance to install the terminating resistors at the two furthest points of the bus, encompassing the longest distance of the bus trunk cable which may be placed at the end of a longer tap.
} 0,4 m Termination 120 Ω
Termination 120 Ω
Example of termination position
Node requirements and connection Up to 120 nodes can be tapped on to the bus cable. There is no requirement for minimum distance between nodes. A node is a single addressable entity on FläktBus. Each node shall have a unique address on the bus between 5 and 125. #
Addresses 1 to 4 and 126 to 127 are reserved for service equipment.
#
Two nodes with the same address will not cause the communication to cease for the other nodes connected to the bus, but lower the performance of the system as a whole. It will not be possible to establish communication with two nodes with same address.
#
Operation is not interrupted during installation or removal of nodes unless the cable is cut.
#
Nodes are automatically included/disconnected when installed or at failure.
#
A node can be powered off without interrupting network operation.
Fläkt Bu s -Process I/O bus
Protection from noise Try to separate the FläktBus cable as much as possible from high voltage cables, motors etc. surrounded by high electromagnet fields. Even though FläktBus is tolerant to different types of noise, increasing noise will cause performance to decrease.
FläktBus impedance test before start-up It is important to measure the impedance of the bus installation before it's put into operation. Follow the instructions below: 1. Disconnect all EPIC , SIR, MTU and RTU from the FläktBus network eg. unplug connector 17-32 on all EPICs and unplug the cable to all RTUs. 2. Disconnect the termination resistors. 3. Measure the wire resistance while shorting the two conductors in the far opposite end. The resistance should be R
R
4. Measure the insulation resistance with an ohm meter* at no load. The resistance should be R> 100k ohm.
R
5. Reconnect termination resistors and plug in EPIC , RTU etc.. Make sure that all connectors are pulled tightly to ensure good connections.
* Do not use Megger type of insulation tester.
