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IML (Industrial Multi Logic) ELECTRONIC CONTROL PANEL

1. GE Home page screen Ran cides WT kb 46 RS SY 2 5 Description of the HOME page and of the FUNC SETTINGS SERVICE AUTO PLC status LED STAND BY TIONS The HOME PAGE is displayed during normal operation of the C boiler 2 In the centre of the screen the steam generator is represented by a synoptic panel The main variables that regulate its operation are explained Q S WARM FILL S S Pressure Water level Burner power Automatic sediment drainage Count down Current time SAFE SERVICE Count down Pending alarms bar The variables are Pressure in boiler in bar Water level in boiler in value Burner operating status and power assigned Electrical con ductivity for TDS if enabled in uS cm Automatic Blow Down system status if enabled and count down to valve opening in min Active operating mode stand by mode auto mode fill mode warm up mode which are described below Current time Count down for safety services 24 72 hr Pending alarms bar The operating modes are displayed and can be selected on this page The modes available are STAND BY MODE FUNCTION NOT ACTIVE FUNCTION ACTIVE Press the icon to activate the function selected The enabling status of the function is displayed by the change in status of the image To disable the function another mode must be selected as the modes are alternative by
2. P SET AP 1STG value after which it will extinguish NOTE the AP 1STG value must be higher than the proportional band within which the PID function operates The page is shown as follows ENJ E P Sen Gel Ai a Se Gel E a e e Se e gi 55 setpoint P SET on PRESSURE PAGE and the statuses of the burner The page is as follows AUTO TUNING Oo aan E The red line represents the pressure setpoint P SET The green line the trend of pressure in the boiler from the pres sure transducer BURNER AUTOTUNING Burner autotuning is a function that allows the IML system to At top right are the START AUTOTUNING and ABORT perform adjustment cycles to find the best parameters for set ting the derivative integrative function managing flame modula AUTOTUNING tion commands The following statuses are displayed for the MODUL 3PNT mode opening and closing O of the air shutter CONTACT THE UNICAL TECHNICAL SER VICE FOR THE ABOVE AUTOTUNING OPER ATIONS B Power AUTO 100 TUNING p FAIL V S 2 V S d kel kel S T Q Zen Kal Se E Pm Se 2 lt lt g 25 3 4 LEVEL ADJUSTMENT LEVEL PAGE The LEVEL PAGE is dedicated to managing the level of water in the boiler and the loading pump that ensures its refilling The IML system for adjustment of the level relies on these sen sors e a level transducer capacitive electrode probe which trans mits a
3. pump s Safe Service boiler safety devices inspection service Login access key TI IK ae 3 toa User Ae GUEST USER SERVICE Zeen Only after authentication with USER 1 USER 4 and or ADMINISTRATOR login will the access fields to SERVICE and to SAFE SERVICE be enabled The page is shown graphically as follows 0 COM CPU PWR U i at ie s User Je USER 1 Qe SERVICE 16 18 l 0 ORDINARY SERVI access key 46 SAFE SERVICE access key ORDINARY SERVICE The SERVICE page displays the burner and water supply pump s operating meters The limit can also be set in hours to request maintenance of the burner and the differential limit between the operating hours of the two pumps when available The page is shown graphically as follows SERVICE EVICE A a 0 d Ns PUMPS AUTO SWITCH TIME 18 36 g 0 BURNER SERVICE During the burner s operating and control cycle there will be a check of the Flame Present logic Input that will activate the icon on the BURNER PAGE A partial time counter is reset at each service and which is con stantly compared with the limit set on the SERVICE SETTINGS PAGE after which the system will send a message reguesting service of the burner called BURNER SERVICE After the service has been completed the partial counter will be reset by pressing the reset key Both the partial counter and the
4. z MODUL V PUMP MODE Use the analogue signal 4 20 mA towards the opening con trol of a modulating valve to adjust the level As the valve is be variation in the water flow from the supply pipe tween the pump and the boiler its opening or closing creates a EE j 9 9 When you press cal the page becomes P Mode Selection DE SSES P Mode Modul V MAX CLOSE 0 Other than the fields already described in the ON OFF and 2 STG mode the following fields are enabled PR band within which the derivative function is ac tivated in level TD derivative function calculation time in seconds Tl integrative function calculation time in seconds DEATH ZONE dead band or rather insensitive zone around the L SET setpoint value in level RUN TIMEV valve run time in seconds Description of the function 1 With control in STANDBY MODE The level adjustment is disabled 2 With control in AUTO MODE If the ECONOMISER is disabled e Using a PID function the level control will maintain a value equal to L SET by using an analogue signal varying from 4 to 20 mA towards the opening control device of the flow modulating valve The value is calculated using the PID function integrate with function description and meaning of variables When the pump starts being controlled a timer starts counting the adjustment time to check wheth er the system is adjusting enough to increase the level such that the
5. 8 Sa Gel P Mode ON OFF mol Ki ji 20 sec AL MIN 2 30 min Above the figure of the pump there are two fields for control of the pulse operation The first field is the ON time the second is the OFF time ON TIME OFF TIME gt Mode ON OFF O OMK Leg Description of the function This mode must not be activated if the ECONOMISER function is enabled with economiser 1 With control in STANDBY MODE the level control is disa bled 2 With control in AUTO MODE when the level falls to touch L ON i e L lt L ON the pump is activated until the level returns to the setpoint i e L gt L SET With water level L gt L SET the pump is stopped 2 STG PUMP MODE Use the pump in 2 stage mode with inverter to adjust the level P Mode Selection P Mode 2 STG The speed of the pump s motor will vary from the set minimum speed e g 30 at the maximum speed e g 100 Other than the fields already described in the ON OFF mode the following fields are enabled e INV MAX inverter adjustment maximum limit for 2nd stage speed in e INV MIN inverter adjustment minimum limit for 2nd stage speed in Description of the function 1 With control in STANDBY MODE The level adjustment is disabled 3 With control in FILL MODE e with water level L lt L MIN on LEVEL PAGE AL P ON the pump is on e With water level L gt L MIN on LEVEL PAGE the pump is turned off and STANDBY MOD
6. 49 2 Aftera few seconds the following alarms should be triggered HP SAFE LWL SAFE1 LWL SAFE2 and HWL SAFE if available LE Se COM P OM CPU PWR m nical SAFE SERVICE 1 Safety device Tested Push Alarms Reset i OOO e Zeen After 10 seconds the PLC closes the DO7 digital input and 4 If all of the alarms are present there are two possibilities checks that the alarms are active a if the TDS is not enabled ADVANCED SETTINGS page HP SAFE the reset phase is activated LWL SAFE1 b if the TDS is enabled ADVANCED SETTINGS page LWL SAFE2 E HWL SAFE IML EXT or EXT type the key is enabled and If HWL is disabled if pressed causes interruption of the conductivity probe which in turn sends the safety device in alarm 3 If they are all present a dedicated bit is put on ON which we After a few seconds the TDS SAFE alarm will be triggered will call Safe service phase 1 used as a flag enabling you to continue with the SAFE SERVICE procedure E COM P l PWR Unical a Safety device Tested x Push Alarms Reset i V ke A OO 5 Now proceed with the reset phase by pressing the buttons on the front of the panel as shown in the image that appears on the right of the screen Each time reset is done the system puts the check symbol at the side of every safety device 50 6 If all are enabled you will continue with the SAFE SERVICE procedure An image appears as
7. 7 H LWL SAFE DIAGNOSTIC Level probe s anomaly detection alarm 9 B MODE POWER ON Burner power on 11 CP POWER ON Electrical control panel on 15 P2 MODE RUN Pump 2 in operation optional 16 P2 MODE OVERLOAD Pump 2 circuit breaker tripped optional 18 P1 MODE RUN Pump 1 in operation 19 P1 MODE OVERLOAD Pump 1 circuit breaker tripped 21 B MODE RUN Burner in operation 22 B MODE LOCK Burner locked O Selectors Switches 5 BLD MODE MAN 0 AUTO Boiler drain operating mode optional 8 MAIN SWITCH 10 EMERGENCY STOP BUTTON 14 P2 MODE MAN 0 AUTO Pump 2 operating mode op tional 17 P1 MODE MAN 0 AUTO Pump 1 operating mode 20 B MODE MAN 0 AUTO Burner operating mode 23 MODEM ROUTER POWER ON Router modem activa tion for remote connection optional 24 TDS MODE MAN 0 AUTO Salinity control unit operating mode optional 2 2 MAIN FEATURES OF THE IML CONTROL PANEL The IML control manages all adjustment devices and interfaces with the safety devices that are approved in accordance with the provisions of the regulations falling within the PED The electronic safety relays PED approved have secondary electromechanical relays in cascade compared to the cat IV prescribed for steam boilers The software functions are enabled in suitable settings menus depending on the devices installed and which may vary from case to Case The basic IML panel controls the following e working pressure switch s
8. is then sent by the UNICAL technical service to the cus tomer who will after having printed it store it with the technical documentation of the boiler as reguired by the regulations 3 12 ALARMS PAGE The alarms controlled by the system are displayed with appro On the home page the IDs of the pending alarms scroll on the priate IDs on the scroll bar at the bottom of the home page and bar so that multiple alarms are displayed simultaneously on a dedicated page eeeee A 43 03 FAULT INV 19 43 44 Scroll bar Access key to the ALARMS page On the bottom of the screen there is a descriptive zone of the Q alarms present with date of intervention and IDs The alarms Press to access the alarms page page is shown as follows The ALARMS page is a mosaic of squares each tile is a lamp associated with an alarm The on red square or off grey square status is updated in real time or rather the square re mains on while the alarm associated to it is active Alarm square present Access key to the page 7 P ALARMS ARCHIVE C R HP SAFE P1MOIDE OVER P2MODE OVER TDS SAFE HPE PI1MOIDE FAULT P2MODE FAULT TDS SAFE EXT CRL P1 TIME P2 TIME TIME TDS FAULT PT L NO AL INV INV SPEED B MODE LOCK FAULT INV B NO FLAME LWL SAFE2 11 53 54 zm LWL SAFE 1 BMODE FAULT HWL SAFE FAULT POS B FAULT POS V FAULT LT TIM ILSET 11 54 g 0 1 53 54 LWL SAFE1 Alarm square absent List of
9. Italy tel 39 0376 57001 telefax 39 0376 660556 info unical ag com export unical ag com www unical eu Unical shall not be held liable for any inaccuracies due to transcription or printing errors Furthermore it reserves the right to modify its products as deemed necessary or useful without affecting their essential features 1 Edition 10 15 00335655
10. field point set P SET PRESSURE PAGE AP 1STG 1st stage of flame delta ignition pressure in bar The page is as follows EJ E d et A Ad Selection p SE r p e B Mode ON OFF ISTG 0 1 bar Operating logic With P lt P SET AP 1STG pressure detected the control will Also see Common Functions of Single Stage 2 Stage and ignite the 1st stage of flame until it reaches a P gt P SET value 3 Stage Burner Control chapter after which it will extinguish 2 STAGE BURNER MODE 2 STG With activation of the control mode for 2 stage burners named DELAY 2STG 2nd stage of flame ignition delay in minutes 2STG two new fields are displayed and activated AP 2STG 2nd stage of flame delta ignition pressure in bar The page is shown as follows SE EE Selection B Mode 25TG AP ISTG 0 1 bar OSTG O 2 bar DELAY 2STG 6 mn Operating logic The burner s 1st and 2nd stages of flame are ignited as follows the 1st stage of flame is always ignited based on the P SET and on the AP 1STG as previously described for the single stage burner the 2nd stage of flame is ignited as follows when the pressure value read is P lt P SET AP 1STG AP 2STG a DELAY 2STG timer delay is started When the DELAY 2STG has timed out if the pressure P lt P SET AP 1STG AP 2STG was maintained then the control will ignite the 2nd stage of flame The DELAY 2STG time is reset 3 STAGE BURNER MODE
11. gt L MIN the pump is kept off to allow expansion of the water when the temperature rises If the ECONOMISER is enabled with water level lower than L MIN i e L lt L MIN the pump speed is maximum acting on the inverter with the maximum percentage INV MAX with water level higher than L MIN and lower than L MAX Le L MIN lt L lt L MAX the pump is pulse activated at a minimum speed acting on the inverter with the minimum percentage INV MIN with ON OFF cycles to protect the ECONOMISER and ensure there is no boiling in it with water level higher than L MAX i e L gt L MAX the pump is kept off 2STG mode summary table The NO ECONOMISER columns are to be read with descend ing level NO INV MAX INV MAX INV MAX INV MAX INV MAX MODUL INV PUMP MODE Use the rotation speed of the pump with the inverter in modulat ing mode to adjust the level P Mode Selection P Mode Modul INV The value of the level continuously detected by the transducer allows you to modulate the rotation speed of the pump s electric motor by means of an inverter The frequency values for correcting the level are calculated by the integrative derivative function Other than the fields already described in the ON OFF and 2 STG mode the following fields are enabled PR band within which the derivative function is activated in level TD derivative function calculation time in seconds TI integrative function calculatio
12. level lower than L MIN the valve is completely opened and the pump is activated to restore the level until it is higher than L MIN i e L gt L MIN e with water level higher than L MIN i e L gt L MIN the pump is kept off and the valve is stopped STANDBY MODE is activated 4 With control in WARM UP MODE burner ON If the ECONOMISER is disabled e with water level lower than L MIN the valve is completely opened and the pump is activated to restore the level until it is higher than L MIN i e L gt L MIN e with water level higher than L MIN i e L gt L MIN the pump is kept off and the valve stops to allow expansion of the water when the temperature rises If the ECONOMISER is enabled water boiling in it with water level lower than L MIN i e L lt L MIN the e with water level higher than L MAX i e L gt L MAX the valve is completely opened and the pump is activated to pump is kept off restore the level until it is higher than L MIN i e L gt L MIN with water level higher than L MIN and lower than L MAX Le L MIN lt L lt L MAX the pump is pulse activated with the valve open with value 1 4 from closure 8 MA to ensure minimum movement of the ECONOMISER at intervals and to protect it from overheating and from the MODUL INV mode summary table AUTO MODE WARMUP MODE NO ECONOMISER NO ECONOMISER HWL ECONOMISER BURN ON BURN ON ECONOMISER BURN ON L MAX une V 1 4 PULSES v1 4 P
13. parameters values The page is shown as follows Selection keys B Mode oa Selection f B Mode ON OFF ISTG Ol bar Active mode At the top are the burner s operating mode selection keys which are Type of Selection B MODE operation key Ce ee KS es A Electronic control is managed by a pressure transducer with The pressure transducer continuously controls the pressure scale field 0 1 6 bar for boilers operating at 1 bar 0 or scale status field 0 16 bar for boilers operating at 12 or 15 bar BURNER ADJUSTMENT The selector on the front of the panel has three positions l e MAN the burner is adjusted only by consent of the working pressure switch which gives consent for ON OFF oper ation or 1st Flame OFF for 2 stage 3 stage modulat ing burners It is considered as an emergency operating Ei EA 7 NV NA 0 neither the PLC nor the pressure switch have given consent to the burner AUTO consent and flame adjustment occurs via the PLC out puts based on the various adjustment algorithms avail able It is considered as the normal operating mode P2 MODE P SAFE RUN MAN 0 AUTO Push to Reset H AN RI EN KI K A V V ke ke e e xa S eed S 2 GG gt lt e Ki B MODE MAN 0 AUTO 20 SINGLE STAGE BURNER MODE ON OFF The power of the burner is controlled based on the pressure set On the page is the
14. the height value of the SET POINT PROBE with respect to ZERO of the level transducer must be entered in the L SET field This value is then adjusted once the boiler has been filled for the first time using the procedure described in the following par agraph In this way a consistent percentage value will be calculated which will be the real SETPOINT for the control system Any corrections can be made using the ADJUSTMENT function on the LEVEL PAGE The status of the physical probe is displayed with an indicator on the LEVEL PAGE 3 7 MAXIMUM WATER LEVEL SAFETY LEVEL SWITCH HWL HIGH WATER LEVEL The HWL function is the protection against excessive water fill ing defined as High Level Water It can operate in two different modes e In standard mode relying on the value sent by the capaci tive probe as set on the LEVEL PROBE SETTINGS PAGE and equivalent to 100 generators not equipped with HIGH LEVEL safety level switch e In optional mode relying on a high level safety electrode probe the same type as that used for the LWL function This mode is activated on the ADVANCED SETTINGS page ac cessible only with ADMINISTRATOR login and is a default setting The level height of the HWL probe is at about 30 mm higher than the SETPOINT PROBE If the water reaches this level and touches the electrode of the probe with a delay of about 10 sec the relay of the relative safe ty device PED approved and with fail safe logi
15. there is no steady flame present signal If during the DELAY FLAME time the flame present signal re turns then the DELAY FLAME resets and the CTRL FLAME delay restarts if the active flame present signal remains stable for the entire CTRL FLAME time then the system again controls the air shutter via calculation of the PID function otherwise con trol is recalculated with the DELAY FLAME CTRL FLAME time 23 V lt E ke ke e e te S skas Q 2 Se 2 lt lt e 24 EXTERNAL MODULATING BURNER MODUL EXT The MODUL EXT control mode is specific for modulating burn ers managed with electronic control external to the PLC and specific normally provided by the burner manufacturer The adjustment made by the IML system behaves so as to ena ble the 1st stage of flame with P lt P SET AP 1STG pressure detected the control will ignite the 1st stage of flame and will B Mode Selection B Mode 1STG Modul EXT 0 1 bar The operating parameters are adjusted on the external control ler by following the manufacturer s operating instructions taking care to match the P SET pressure setpoint on the PLC to the setpoint on the external controller ADJUSTMENT PARAMETERS SETTINGS PAGE The ADJUSTMENT PARAMETERS SETTINGS PAGE can be accessed from the burner setting page and which displays the trend chart of the pressure with respect to assigned pressure maintain it until it reaches a P gt
16. 0 bar Virtual pressure transducer The pressure transducer is set by the man ufacturer The P MAX WORK value is set by the man ufacturer SETTING THE P SET and P WARM UP val ues USER 1 4 login Proceed as follows to correctly set the values Press the P WARM UP field A numerical keypad will be displayed indicating the previously entered PMAX WORK value as the maximum limit to be en tered Enter the value that will define the limit below which the system will activate the cold start mode Press the P SET field A numerical keypad will be displayed indicating the previously entered PMAX WORK value as the maximum limit to be en tered and the P WARM UP value as the minimum limit to be entered V lt GA ke ke e e te S Kal Q Pm Se 2 lt lt CORRECTING THE TRANSDUCER READING USER 1 4 login Between the pressure gauge and the transducer is the field for correcting the transducer reading with respect to the real pres sure gauge on the boiler P MAX WORK 11 50 bar P SET 6 00 bar P WARM UP 3 00 bar Ge P 5 47 bar 17 35 0 Use the up PR and down RA keys to slightly correct the value read by the transducer to make it consistent with that indicated by the boiler s physical pressure gauge 3 3 BURNER PAGE The BURNER PAGE is dedicated to displaying the operating statuses of the burner The page is show
17. 3 STG With activation of the control mode for 3 stage burners named 3STG in addition to the single and 2 stage fields two new ones are displayed and activated B Mode Selection B Mode 3 STG DELAY 3STG ou 0 1 bar AP 2STG ISTO 6 min AP 3STG 0 2 bar ISTG o bar DELAY amp 18 29 g 0 Operating logic The 1st 2nd and 3rd stages of flame are ignited as follows the ist and 2nd stages of flame are managed as described above for the single stage and 2 stage burner when the pres sure value read is P lt P SET AP 1STG AP 2STG AP 3STG then a DELAY 3STG time delay is started When the DELAY 3STG has timed out if the pressure P lt P SET AP 1STG AP 2STG AP 3STG was maintained then the control will ignite the 3rd stage of flame The DELAY 3STG time is reset If during the DELAY 3STG time the pressure rises to a P gt P SET AP 1STG AP 2STG AP 3STG value then the DELAY If during the DELAY 2STG time the pressure rises to a P gt P SET AP 1STG AP 2STG value then the DELAY 2STG time is reset and the 2nd stage of flame remains off The DELAY 2STG timer will restart for the pressure status P lt P SET AP 1STG AP 2STG When it has been ignited the 2nd stage of flame will extinguish when the pressure rises to a value of P gt P SET AP 1STG whilst the 1st stage relay will extinguish for P gt P SET pressure The new fields are AP 3STG 3rd stage of flame delta ign
18. E GENERATOR ATTENTION Incorrect installation inadequate use and maintenance of the appliance can cause damage to persons or property for which the MANUFACTURER is not liable These design limits are given on the CE data plate applied on the appliance on the CE declaration of conformity supplied with the generator CAREFULLY READ AND FOLLOW THE IN STRUCTIONS CONTAINED IN THIS MANUAL ATTENTION This manual is an integral and essential part of the supply and must be delivered to the user In the event that the generator is transferred in use or sold to other Users change of desti nation or move make sure that the appliance is transferred together with this installation use and maintenance manual so that it can be consulted by the entrusted installer the maintenance technician and the new owner Before starting installation fill the system start the ignition process or undertake any maintenance carefully read the instructions and procedures contained in this manual they provide important information regard ing the safety of the system and the safety of persons The installation operation and maintenance must be carried out in compliance with the BEFORE CARRYING OUT ANY OPERATION ATTENTION THE GENERATOR IS NOT DESIGNED TO BE INSTALLED OUTDOORS BUT MUST BE LO CATED WITHIN THE APPROPRIATE PREM ISES BOILER ROOM OUTDOOR OPERATION CAN DAMAGE THE SET THUS RESULTING IN SERIOUS DAN GER DUE TO e
19. E is activated 4 With control in WARM UP mode with water level L lt L MIN on LEVEL PAGE the pump is turned on until the water level is L gt L MIN on LEVEL PAGE or rather when the pump is turned off ON OFF mode summary table Statuses to be considered with the level lowering and rising AUTOMODE WARMUP MODE OFF OFF OFF OFF OFF ON When you press the key the page becomes 2 With control in AUTO MODE If the ECONOMISER is disabled when the water level falls below the setpoint until it touches L ON i e L lt L ON the speed of the pump is minimum meaning the percentage of the inverter is INV MIN and this speed is maintained until it touches the setpoint i e L gt L SET If instead the level falls further until it touches L MIN i e L lt LMIN the speed ofthe pump is maximum meaning the percentage of the inverter is INV MAX until it touches L ON i e L gt L ON after which the speed returns INV MIN until it touches L SET i e L gt L SET e With water level L gt L SET the pump is stopped 33 V lt GA ke ke e e tee S shkas Q 2 Se 2 lt lt 34 If the ECONOMISER is enabled the status of the burner be comes involved With burner off 1st stage of flame OFF e If the water level falls below the setpoint until it touches L MIN i e L lt L MIN the speed of the pump is maximum meaning the percentage of the invert
20. ET THE SAFETY LEVEL SWITCH TO REACH LWL SAFE 1 THE MINIMUM SAFETY LEVEL OF WATER IN THE BOILER MANUALLY RESET THE SAFETY LEVEL SWITCH TO REACH LWL SAFE 2 THE MINIMUM SAFETY LEVEL OF WATER IN THE BOILER MANUALLY RESET THE SAFETY LEVEL SWITCH TO REACH THE MAXIMUM SAFE HWL SAFE TY LEVEL OF WATER IN THE BOILER PRESSURE ALARM ALARM ID DESCRIPTION ALARM MANUALLY RESET THE SAFETY PRESSURE SWITCH TO REACH HP SAFE THE MAXIMUM PRES SURE IN THE BOILER SYSTEM SAFETY INTER VENTION BURNER LOCKED BURNER LOCKED BURNER LOCKED SYSTEM SAFETY INTER VENTION BURNER LOCKED Luminous button on panel and buzzer Luminous button on panel and buzzer Luminous button on panel and buzzer Luminous button on panel and buzzer RESET ALARM Physical reset of the alarm status can be done ONLY by hand and directly by the system maintenance technician who will FIRST ensure that the water level has been taken above the safety limit and THEN will press the LWL SAFE1 alarm reset button indicator on the front panel of the Electrical control panel Once the alarm condition has been physically removed this alarm will automatically reset Physical reset of the alarm status can be done ONLY by hand and directly by the system maintenance technician who will FIRST ensure that the water level has been taken above the safety limit and THEN will press the LWL SAFE2 alarm reset button indicator on
21. ET 30 dd 31 32 With INVERTER With an INVERTER the system applies the following procedure for automatic or manual switch e interruption of 4 20 mA signal to the inverter e interruption of command to pump 1 contactor e activation of pump 2 contactor signal e reactivation of 4 20 mA signal to the inverter For details on automatic switch between pump 1 and pump 2 based on the load operating hours see ORDINARY SERVICE chapter P Mode Selection TIME ESE Osm The control thresholds are e L SET upon reaching going up from the bottom the pump is turned OFF e L MIN upon reaching going down from the top the pump is turned ON as set on the LEVEL PAGE The following parameters can be set on the page e TIME AL maximum time to restore a value equal to AL MIN described in the next step after which the TIME MIN P1 alarm is triggered see ALARMS chapter e AL MIN minimum value to be exceeded in the time set in TIME AL described in the next step e TIMELSET maximum time to reach the L SET in sec onds after which the TIME LSET alarm is triggered see ALARMS chapter Use the selector on the front of the panel to override operation of the pumps released from the PLC control logic See PUMP S MANUAL OPERATION chapter PUMP ON OFF MODE Use the ON and OFF of the water feeding pump to adjust the level When you press rth the page becomes e R i e Espl n Mar i z Pine 2e 2 ae Z
22. Modul 3 PNT SE O Ger ISTG PR TD WI DT E e weg z i di 5 6 1 9 sec TI 38 sec The new fields are RANGE field for derivative integrative adjustment in bar TIME D derivative time in seconds TIME I integrative time in seconds DEAD ZONE dead zone around which adjustment is not made in bar TIME AIR GATE burner air shutter opening time in seconds DELAY FLAME no flame delay time in sec CTRL FLAME delay time for controlling flame stability for modulation consent in sec The page is shown as follows R DEAD ZONE SS TAIR GATE DELAY FLAME CTRL FLAME 30 E 30 _30_ 30 sl ec sec sec Operating logic The burner s 1st stage of flame is ignited and the Primary Com bustion Air Shutter is modulated as follows the 1st stage of flame is put on ON depending on the pressure setpoint P SET on PRESSURE PAGE and on the pressure differential AP 1STG With P lt P SET AP 1STG pressure detected the control will ignite the 1st stage of flame and will maintain it until it reaches a P gt P SET AP 1STG value after which it will extinguish NOTE the AP 1STG value must be higher than the proportional band within which the PID function operates When the ist stage of flame is ignited a flame stability control time CTRL FLAME is activated within which if the no flame sig nal occurs the air shutter is closed and the no flame time delay DELAY FLAME is started
23. N BURNER LOCKED Luminous button on panel and buzzer Luminous indicator on panel Luminous indicator on panel RESET ALARM Luminous button on the panel and buzzer The Physical reset of the alarm status can be done ONLY by hand and directly by the system maintenance technician who will FIRST manually reset the level of salinity in the boiler water including using proce dures assisted by PLC and made available on own PLC upon occurrence of this warning THEN when the level of water salinity has been taken to below the safety threshold set by the TDS unit exter nal controller will press the TDS SAFE alarm reset button indicator on the front panel of the electrical control panel Once the alarm condition has been physically re moved this alarm will automatically reset RESET ALARM Physical reset of the alarm status can be done ONLY by hand and directly by the system maintenance technician who will access the unlock button indicator on the burner itself Once the alarm condition has been physi cally removed this alarm will automatically reset This alarm is reset only by the User Termi nal of the PLC The position of the reset buttons on the front of the control panel TDS SAFE HWL SAFE LWL SAFE2 LWL SAFE1 Push to Reset Push to Reset Push to Reset Push to Reset for alarms LWL SAFE1 LWL SAFE2 HWL SAFE HP SAFE TDS SAFE is as follows STEAMER WY WY MODEM ROU
24. TER POWER ON AN WY Hr rN TN aN d SA KIEM FA KA GA VN CN AN d SA KIEM os Ce Me e VN AN E SS WEA The burner locked alarm reset button BMODE LOCK is on the burner itself HP SAFE Push to Reset 59 60 Alarms log page All alarms that can be activated are archived and controlled by The alarms on the list can have three different colours according the system on a specific page which is as follows to their status The archive is structured and displayed with a list of alarms e Active alarm showing these properties These are alarms that are still active either because the causes that triggered them are still present or because they e Alarm name are considered by the system in order to allow only manual e Activation date reset e Activation time e Alarm withdrawn but not acknowledged These are alarms that are no longer active and are without retaining system The causes that triggered the alarms have disappeared e Alarm acknowledged Historical alarms which have been acknowledged with the 42 DALE EROZII BAT ALTE Hi 5 GFE 11 15 04 07 12 10 11 15 04 07 12 10 11 15 04 07 12 10 11 12 40 07 12 10 11 12 40 07 12 10 11 12 40 07 12 10 HAL SAFE LIL SAFE 2S o Lt SAFEST HWL SAFE LWL SAFE 2 LWL SAFE1 LWL SAFE 1 LWL SAFE 2 HWL SAFE 2 2 3 FF FF S B f 6 5 4 3 2 1 Unical www unical eu Unical ac S p A 46033 casteldario mantova
25. ULSES IMN V OPEN V OPEN V OPEN LWL 39 PUMP S MANUAL OPERATION There is also the possibility of manually forcing operation of the pumps by bypassing the PLC and using the selectors on the front of the panel The procedure is as follows Put the P 1 or 2 MODE MAN O AUTO selector on MAN B MODE LOGK d Pi MODE OVERLOAD P1 MODE RUN Pi MODE MAN 0 AUTO P2 MODE OVERLOAD P2 MODE RUN P2 MODE MAN 0 AUTO If the INVERTER kit is used proceed as follows a gt Put the P MODE selector on the IML panel on 0 b gt Put the selector on the INVERTER panel on 0 c gt Put the P MODE selector on the IML panel on MAN d gt Put the selector on the INVERTER panel on MAN In the event of manual override with two pumps activate one pump at a time 40 HP SAFE Push to Reset 3 9 TDS PAGE TDS is the abbreviation of Total Dissolved Solids i e the total amount of dissolved salts The amount of salts dissolved in the water is measured indirect ly by a probe that feels the electrical conductivity of the water The probe has an integrated temperature sensor since the value of conductivity varies when the water temperature changes the combination of the two values interpreted by the electronics on the probe generates a consistent 4 20 mA signal By enabling the TDS function the system activates to adjust the value of conductivity by comparing the value read by the probe wi
26. Unical STEAMER a IML Industrial Multi Logic ELECTRONIC CONTROL PANEL 3 OPERATING INSTRUCTIONS 1 GENERAL INFORMATION e5 isn nata esinaiseks ateena EES 4 t BENUN EE 4 le aey MON te DE 4 1 3 User obligations pursuant to the legislation in force Au 5 UNICAL BOILER IML Industrial Multi Logic CONTROL PANEL rnsenannnnnnannnanannnannnnanannennnnnnnnnnannnnnanannnnana anna 6 BV NEE 7 2 2 Main features of the IML control panel EE 7 E Een 7 a NV ee 8 2 5 Description of the HOME page and of feEUNTIONG nn nnnanennnnen enn nnenen nn nann enn enne 9 Oe EE die EE 12 PROCEDURES pepe eon ee eee ee ee eer ee ee ene ne ere ne eee ne cree an eee ee ee ear 13 3 1 Accreditation procedure and gualifications nnvrnvevnnnevnvennnnenennnennennnnnenenannnnn enn nnanennnnnannennnnnn nen nnnan annan nene 13 22 FE SWO PAGE samsa E ai aial na lit amaan aplaasia eua aata lats ee 15 3o EE PIO AE PEAD A E DT a ma eee eer tree ee 17 Burner settings page USER 1 4 and ADMINISTRATOR login Ak 18 edela geet 19 Single stage burner mode ON OFF E 20 2 stage burner Mode 2 SUG isata pita atika tits kallata kinaasi haaku m eks akka 20 SE Le Ne doosi e KE peer nner ener en AAA ter ner e ee ee een a en ee ee 21 3 point modulating burner MODUL 2DNT vanana nnnnnnennnnnnnennnnanennnnnanennnnaneeennnanennnnnnenennnnnnennnnnenea 22 IML modulating burner MODUL IML serre com ecteseecotneaseaeuione
27. active alarms 55 The IDs of the alarms controlled by the IML system are B NO FLAME Permanent Overpressure Level reached Permanent Low Pressure Level reached FAULT PT Pressure Probe Fault No Flame LWL Permanent Minimum Water Level reached TIME LSET Time Out maximum time to reach the water setpoint level P1MODE FAULT Pump 1 Not Started P2MODE FAULT Pump 2 Not Started P1MODE OVER Pump 1 Circuit Breaker Tripped P2MODE OVER Pump 2 Circuit Breaker Tripped TIME MIN P1 Time Out maximum time for minimum increase of the water level for Pump 1 TIME MIN P2 Time Out maximum time for minimum increase of the water level for Pump 2 FAULT INV Inverter Fault NO AL INV No Inverter Power TIME TDS Time Out maximum time to reset TDS Setpoint The alarms highlighted in Eege alarms associated with the safety devices external to the PLC and have electromechanical retaining systems They are reactivated on the PLC automatical ly with timed control The alarms highlighted in yellow have software self retaining systems therefore they will be reset on the operator panel with appropriate unlock keys The alarms highlighted f tpn do not have software self re taining systems therefore they will be active only during contin uation of the root cause but will remain archived in the alarms log 56 Alarms associated with safety devices LEVEL ALARMS ALARM ID DESCRIPTION ALARM MANUALLY RES
28. afety pressure switch PED pressure transducer setpoint probe 2 probes safety controller for low water level PED 2 3 SOFTWARE The software constituting the IML is the software on the PLC to gether with the one on the operator panel HMI Data input from the control devices on the boiler and data input as data entered by the operator on the panel are processed by the PLC software The data resulting from the processes are output to the control devices burner pump valves etc and to the panel that graph ically shows them on the display in a user friendly tree menu e capacitive probe level transducer e burner ON OFF 2 stage 3 stage 3 point modulating modu lating with proportional signal e 1 water supply pump As an option the following can be added e 1 high level probe PED e probe safety controller for control and bleeding due to high salinity level TDS e timer valve for sediment drainage with dirt separator func tions e 1 water supply pump as a second safety pump e kit for remote installation of alarms 2 Send o s 2 lt o O 2 4 SYSTEM ACCESS START PROCEDURE Access the control panel by turning the main yellow red switch 8 to The HMI panel touch screen turns on immediately and the PLC start up cycle starts lasting for about 30 seconds The following screens will be shown Starting screen Access screen rey TTT ttt AADA JAKA GK wr
29. after which a B NO FLAME alarm is triggered if during the no flame DELAY FLAME time the no flame signal stops the time calculation CTRL FLAME restarts at the end of which consent is given to the modulation via PID calculation NOTE to improve efficiency of the adjustment the DELAY FLAME and CTRL FLAME times must be reduced as much as possible and be consistent with the type of burner installed The electronic control calculates the derivative integrative func tion which aims at reaching the pressure setpoint P SET de tecting the pressure transducer value and activating the air shut ter opening and closing outlets with modulated pulses so as to obtain an approximation of the P SET pressure setpoint This must be done without the pressure exceeding the P SET clearly there are some tolerances as quickly as possible and using the ON OFF relays as little as possible The Flame Present signal must however be monitored contin uously since if it is missing in addition to immediately closing the air shutter the DELAY FLAME will be activated again after which the system signals the B NO FLAME alarm if there is no steady flame present signal If during the DELAY FLAME time the flame present signal re turns then the DELAY FLAME resets and the CTRL FLAME delay restarts if the active flame present signal remains stable for the entire CTRL FLAME time then the system again controls the air shutter via calculation of the PID func
30. ation to communicate commissioning to the local ISPESL and ASL as defined in art 6 of the Italian Ministerial Decree 1st Decem ber 2004 no 329 e obligation to submit the steam generator to the periodic inspections required by Law set forth in Italian Ministerial Decree 1st Decem ber 2004 no 329 in the Table in Annex B namely e Internal visit and operation verification every 2 years e Integrity check every 10 years BOILER IML Industrial Multi Logic CONTROL PANEL A A A A a s Alas OBR TDS MODE MAN 0 AUTO P1 MODE OVERLOAD LC3050 ALARM OK STEAMER S B MODE SS P1 MODE RU SS F EES CG O 20 Sm IX ei Zz P 23 CH P2 MODE MAN 0 AUTO Es iN POWER ON 3 CP MODE POWER ON d HP MODE POWER ON MAN 0 AUTO Ww H LWL SAFE DIAGNOSTIC we SKS E ZH e e 12 Sg 2 1 PANEL KEY 6 Touch Screen operator pnel 12 Alarm buzzer 30 USB HMI Output N Luminous alarm buttons 1 TDS SAFE Push to Reset Salinity control unit alarm indicator optional 2 LWL SAFE 1 Push to Reset Low level probe 1 alarm indicator 3 LWL SAFE 2 Push to Reset Low level probe 2 alarm indicator 4 HWL SAFE Push to Reset High level probe alarm indi cator optional 13 HP SAFE Push to Reset Safety pressure switch alarm indicator DW Luminous indicators
31. c is triggered interrupting with 4 secondary relays the chain of consents to the burner thus interrupting operation The indicator off means that the level of water is below L SET The indicator on means that the water touches the probe elec trode Indicator on level reached Intervention of the high level probe HWL is noted by e The alarm buzzer e The HWL SAFE luminous button lights up on the front door of the panel only with physical probe present e HWL SAFE alarm on the operator panel The relative luminous indicator lights up at top right on the LEV EL PAGE V V S 3 E ke ke z e e ses S Keel 2 Pm GG gt lt e 29 30 3 8 LEVEL SETTINGS WATER LEVEL CONTROL With USER 1 4 and ADMINISTRATOR login The access key to the LEVEL SETTINGS PAGE is activated The LEVEL SETTINGS PAGE is dedicated to managing the water level in the boiler this allows you to select the operating mode and to enter the operating parameters values The page is shown as follows Active mode Selection keys P Mode Selection oi Sa BN Soa Se P Mode ON OFF po e Bac VO ESG AL MIN 2 wem TIME CS ESE 30 HA Atthe top are the water loading pump operating mode selection keys which are 2 STG 2 stage with inverter MODUL INV Modulating with inverter MODUL 3 PNT Modulating with 3 way valve MODUL V Modulating with proportional control valv
32. che seweast mune tatdaueewner aqmcnc cla steed aenieeenin a teuseced aeecteamennaSaeeweeeeeaanoaat 23 External modulating burner MODUL EST 24 Adjustment parameters settings page 1 sa aata a a A a ma acca custadeuautencadsneclultetonacosauuennts 24 IIIS AION CITING E E E E meem E E AT T 25 3 4 Level adjustment Level page E 26 3 5 Minimum water level safety level switches LWL Low Water Level 28 30 SETPOINT el 29 3 7 Maximum water level safety level switch HWL High Water Level 29 3 8 Level settings Water level control EE 30 PUMP ON OFF nee 32 SEET a MANA E E Terme te renee ee eer eee 33 MODULE INY I WMO CS ose cs caesar sa es ase inaenda a ae rie son eeetcencacaiedotas beeace odeaseeaaeuesumeeadiergocesddacesaneesbere 35 MODUL S PNT PHD MOGAE EN 36 Moduly pump nee EE 38 Pump S Manudl OO GUO EE 40 39 TDS e E 41 Eemal DS OCS EX TE E 43 210 BLOW DOWN Men 44 ITE ONICO oe E A E E stead ease eenasormeneatad 46 le Dale 47 Edel 47 Metering of pumps operating e 47 EE Eege 48 NEE de encerro Mamma M a n 55 Alarms associated with safety devices EE 56 Alarms associated with service devices NEEN 58 Nee Ree 60 D GENERAL INFORMATION This document is the Technical Manual of the electronic control certified as a SET in compliance with the Essential Safety Re panel installed on Unical 24 hr 72 hr series steam generators quirements of Directive 97 23 EC PE D Pressure Equipment equipped to Operate without c
33. collapse burst of framework aimed at the pressure containment for embrittlement of the metal parts ofthe framework making up the pressurised body e collapse burst for failed operation inhibition of the safety and adjustment accessories e damage due to impairment of safety equipment adjustment due to the action of rainwater e minimum temperature not compatible with the minimum allowable for the set components during the expected life e impairment of the IP protection of electrical parts not suitable for oper ating the set outdoors under the action of atmospheric agents 1 3 USER OBLIGATIONS PURSUANT TO THE LEG ISLATION IN FORCE ATTENTION PURSUANT TO THE LEGISLATION IN FORCE IT IS NOT PERMITTED TO OPER ATE THIS GENERATOR BEFORE YOU HAVE COMMUNICATED COMMISSIONING TO THE NATIONAL CONTROL BODIES AS PRE SCRIBED IN DECREE 1 December 2004 no 329 Regulation with standards for the commissioning and use of pressure equip ment and assemblies referred to in article 19 of the Legislative Decree 25 February 2000 no 93 to which the equipment User must strictly adhere because RESPONSIBILITY of the same The set is excluded from commissioning verifi cation as it meets art 5 paragraph d of the Ital ian Ministerial Decree 1st December 2004 no 329 Nevertheless the User MUST COM MUNICATE COMMISSIONING TO THE LOCAL AUTHORITIES USING THE METHOD DE SCRIBED IN ART 6 OF THE SAME AS SPEC IFIED BELOW e oblig
34. e The various modes work differently on the pump also in relation to other variables which are e Burner ON OFF e With or without economiser e Active boiler operating status Stand By AUTO Warm Up Fill If two water loading pumps kit upon request are set the LEVEL SETTINGS PAGE is P Mode ON OFF P active P1 P Switch MANUAL 0 M O sec pea 20 sec ALMIN 2 TIME L SET _30 bale The IML control can automatically switch between the two At the top is the O key to enable disable the automatic pumps in consideration of switch function e operating load if the limit set on the SERVICE PAGE is ex The active status is indicated with P Switch which has two al ceeded the control changes the active pump to balance the ternative statuses AUTO and MANUAL The active pump is in wear of both pumps dicated with P active that can indicated P1 or P2 e possible faults in the event of faults during operation of the active pump the system will activate the other pump see If the automatic switch is disabled the user must choose the ALARMS PAGE paragraph pump Next to the pumps the pump selection key is active so touch the required pump to se lect the active pump DER P Mode gt Selection e e ji S P Mode ON OFF P active P1 P Switch MANUAL o msec pos 20 sec V S 2 0 S d kel kel S x Q Bee Kal Se E Pm GG 2 lt lt g ALMIN 2 TIME L S
35. e pressure differential AP 1STG with P lt P SET pressure detected the control will ignite the 1st stage of flame and will maintain it until it reaches a P gt P SET AP 1STG value after which it will extinguish NOTE the AP 1STG value must be higher than the proportional band within which the PID function operates When the ist stage of flame is ignited a flame stability control time CTRL FLAME is activated within which if the no flame sig nal occurs the air shutter is closed and the no flame time delay DELAY FLAME is started after which a B NO FLAME alarm is triggered if during the no flame DELAY FLAME time the no flame signal stops the time calculation CTRL FLAME restarts at the end of which consent is given to the modulation via PID calculation The electronic control calculates the derivative integrative func tion which aims at reaching the pressure setpoint set P SET detecting the pressure transducer value and setting the 4 20 mA output value so as to obtain an approximation of the P SET pres sure setpoint This must be done without the pressure exceed ing the P SET clearly there are some tolerances as quickly as possible and with the least signal variations as possible The Flame Present signal must however be monitored contin uously since if it is missing in addition to immediately closing the air shutter the DELAY FLAME will be activated again after which the system signals the B NO FLAME alarm if
36. e correct passwords which are PROTECTED Password meem 6 23 48 g 0 if the password entered is correct the LOGIN key is activated press to access Press LOGIN to confirm 3 2 PRESSURE PAGE The Pressure page is dedicated to managing the boiler s steam pressure The page is as follows irtual analogue pressure gauge m a P 5 47 bar GP 17 35 Current pressure value The instrument holder tube of the boiler on which the pressure control instruments are mounted is represented virtually on the screen On the left there is a virtual analogue pressure gauge which makes reading of the optimal operating zone green zone fast and intuitive The scale field of the pressure gauge is divided into three coloured zones that identify blue zone zone in which the WARM UP MODE is activat ed green zone generator s optimal working zone red zone safety zone The current P pressure value in bar is shown in the field at the bottom of the pressure gauge On the other side of the tube the pressure transducer is repre sented on the right of which there are three fields for setting P MAX WORK pressure at beginning of red zone maximum working pressure P SET working pressure P WARM UP pressure at end of green zone pressure that defines the limit below which the cold start mode or WARM UP MODE activates R 258 P MAX WORK 11 50 bar P SET 6 00 bar P WARM UP 3 0
37. e mode input by the probe TDS Mode Selection TDS operating mode selection buttons R IML EXT SET A ON 1500 uS cm 100 uS cm TIME OFF TIME ON A sec 0 sec MAX SET TIME TDS MAX 0 min 5000 uS cm Bleed valve operating status The conductivity control system consisting of probe and water bleed valve is shown on the TDS page The current conductivity value value read by the probe is displayed in a box and ex pressed in uS cm The status of the bleed valve is displayed by the output spray valve open or by no spray valve closed valve open valve closed 42 Sensitive zone for probe settings access page only ADMINISTRATOR External TDS mode EXT For the EXT mode the conductivity probe is connected to an electronic device external to the PLC Control and safety is assigned to an external device Fields are not displayed for setting the parameters as they are all set by the external controller All settings are done on the external device In this mode the TDS SAFE alarm is disabled due to no probe signal Description of operating mode The functions are disabled on the IML system and are carried out by the external device If the safety threshold of the external device is exceeded said device triggers the alarm which is read by the IML system as a TDS SAFE EXT alarm and the STAND BY status is activated A contact of the device acts directly on the chain of consents to T
38. e of the test ALKALINITY 0026 0 ppm TIME Value read Time of the test HARDNESS 043 emn HP Value read Safety device result from the pre TDS 1520 0 320 0 1520 0 uS cm vious page Ph Value to be entered Ph of the boiler water LWL 1 Value read Safety device result from the pre vious page ALKALINITY Value to be entered Alkalinity of the boiler wa ter LWL2 Value read Safety device result from the pre vious page HARDNESS Value to be entered Total hardness of the boil er water HWL Value read Safety device result from the pre vious page TDS Value to be entered Electrical conductivity of the boiler water TDS Value read Safety device result from the pre vious page 10 When the data relative to the water have been entered 11 When all of the check symbols are present the saving key press Q next to each single field to confirm which will will be enabled occur with the change in status of the key in Q SAFE SERVICE 2 P R SERVICE N ID 1 SICH fF fs USER N ID 0 TIME Ff H up pH TO F HARDNESS 23 DB pH 8 0 bi ALKALINITY 26 gt MAA HARDNESS 043 1 TDs 1520 143 usicm oo C 12 Press to save all of the just completed SAFE SER VICE data in the internal memory of the operator panel On the SERVICE page press Q to access the service ar chive 13 If the ID number is already taken by a position in the ar chive the system will request confirmation to overw
39. el o lt V o O ENTERING VALUES Alphanumerical value fields For alohanumerical values touch the field to display the keypad The numerical and alphanumerical values on all of the IML sys tem s pages are entered by touching the field in which you want to enter and or edit the value Numerical value fields For numerical values touch the field to display a numerical key pad MAX 000000 MIN 000000 Press Enter to confirm the value At the top any limits MAX and MIN are shown for the value to be entered Press Enter to confirm the value 2 6 DEFAULT SETTINGS GENERATOR IDENTIFICATION BOILER TYPE O O BOILER POWER 01363 kW STEAM POWER 02000 kg h P MAX 12 0 NI A10UXXXXX S E ed g o a o EER Oo GENERATOR CONFIGURATION System boiler configuration Page can be accessed and modified only by the ADMINISTRA TOR D PROCEDURES 3 1 ACCREDITATION PROCEDURE AND QUALIFI CATIONS USER LOGIN The IML system is structured to manage three different user levels GUEST guest user allowed to browse the displayed pages it is the user to be used during normal operation of the generator USER x users from USER 1 4 are intended for operators authorised to control the generator password protected The USERS are allowed to modify the generator s adjustment parameters ADMINISTRATOR system administrator intended for the installer and or UNICAL service centre personnel and i
40. enabling one mode the others are dis abled A fourth icon represents WARM UP MODE which is an au tomatic mode meaning it automatically activates during cold starts until AUTOMODE is activated FUNCTION FUNCTION ACTIVE NOT ACTIVE WARM UP MODE STAND BY MODE The control at each switch on activates the STAND BY MODE by default With this mode the PLC is on standby all settings burner pres sure pump s level TDS valve bleed blow down dirt separator valve are disabled Control remains activated of the alarm statuses input from the safety devices and referral of the values read by the transducers pressure level TDS etc The key is also used as a STOP button AUTO MODE Automatic power supply operation Press Gi to activate AUTO MODE i e automatic operation shown with the change in status of the icon The boiler is completely controlled by the IML system All transducers that send signals detected to the boiler are ac tive the PLC processes the input signals with the logic that is described in the following chapters to adjust the boiler s control devices The controls are active on the alarm statuses input from the safety devices which when activated cause the forced stop of the steam generator Management of the pump is explained in detail in the LEVEL SETTINGS PAGE chapter FILL MODE Press T to activate FILL MODE i e controlled water filling of the boiler function during w
41. er is INV MAX and this speed is maintained until it touches L ON i e L gt L ON e When the water level is higher than L ON i e L gt L ON the pump is kept at a standstill while waiting for the burner to ignite With burner on 1st stage of flame ON e f the water level is higher than the setpoint but not higher than L MAX i e L SET lt L lt L MAX the pump is pulse activated at the minimum speed ON and OFF intervals e f the level is higher than L MAX i e L gt L MAX the pump is stopped e f the water level is lower than the setpoint but higher than L MIN i e L MIN lt L lt L SET the pump is activated at the minimum speed acting on the inverter at the frequency INV MIN e If the level falls below L MIN i e L MIN the pump is activated at the maximum speed acting on the inverter with the maximum percentage INV MAX 3 With control in FILL MODE e with water level lower than L MIN i e L lt MIN on LEV EL PAGE the pump speed is maximum acting on the inverter with the maximum percentage INV MAX e with water level higher than L MIN i e L gt L MIN the pump is kept off and the STANDBY MODE is activated 4 With control in WARM UP MODE burner ON If the ECONOMISER is disabled with water level lower than L MIN i e L lt MIN on LEV EL PAGE the pump speed is maximum acting on the inverter with the maximum percentage INV MAX with water level higher than L MIN i e L
42. essage requesting service this remains active on the home page up to operator intervention When the time has passed the generator enters STANDBY mode thus interrupting operation of the burner but not operation of the pumps In this phase activation of the AUTO mode is prevented The operator can restart the AUTO mode only after having run the programmed controls cycle First he she must be authenticated with USER 1 4 on the SERVICE page When authenticated a key will be enabled for access to the SAFE SERVICE Archive access key SERVICE User authenticated USER 1 4 48 Start key SAFE SERVICE The first screen of the SAFE SERVICE is shown initially as fol lows SAFE SERVICE start key phase 1 co M CPU PWR Unical A Safety device Tested HP SAFE x LWL SAFE1 LWL SAFE2 HWL SAFE TDS SAFE EXT os oo as Zeen Optional Available only if the HWL SAFE and TDS SAFE EXT functions are enabled 1 Press E to start the first phase which causes the self re High level safety level switch HWL SAFE if provided and taining relay to open enabled Safety pressure switch HP SAFE Low level water safety level switch no 1 LWL SAFE1 If HWL is disabled the relative alarm will not be displayed Low level water safety level switch no 2 LWL SAFE2 GEN M COM CPU PWR Unical d R Safety device Tested HP SAFE x LWL SAFE1 LWL SAFE2
43. he valve control is enabled by activating the PLC output named TDS CONTROL B7 terminal When the EXT mode has been enabled the page is shown as follows TDS Mode Selection the burner thus blocking operation In STAND BY mode the control disables the PLC output named TDS CONTROL B7 terminal to interrupt the bleed valve control by the external device which could cause the water level to lower thus becoming non restorable by the pump s Approved devices Devices that can be used are 1 GESTRA system consisting of mod LRGT 16 1 probe and mod KS90 controller 2 SPIRAX SARCO system consisting of mod CP32 probe and mod BC3150 controller The controller settings are done by the manufacturer 43 3 10 BLOW DOWN PAGE Blow Down is a timed discharge system that ensures expulsion of the heavy particles dissolved in the water that create sludge which being heavier sinks to the bottom of the boiler The BLOW DOWNTDS function is optional and can be selected on the ADVANCED SETTINGS page accessible only by the ADMINISTRATOR When the function has been enabled on the home page the dirt separator valve associated with control of the BLOW DOWN is shown on the boiler s synoptic panel and the access keys to the specific function control page are enabled The following is displayed on the main page time remaining until the next sludge discharge the status of the bleed valve closed open The acce
44. hich operation of the burner is disabled Activation of the fill function is displayed with the change in sta tus of the icon Filling is done to take the water level to the setpoint level that is up to when the water touches the setpoint probe electrode When the water touches the electrode the fill function stops Allows the first filling controlled by the setpoint probe and then allows the first adjustment operations of the capacitive level probe which will support the adjustment The fill function is also used for recalibration and periodic con trols required in the boiler s user manual WARM UP MODE The WARM UP MODE activates when after the AUTO MODE has been activated the system detects pressure lower than the P WARM UP minimum pressure set see PRESSURE PAGE lts activation is automatic With this mode active management of the supply pump and level control system varies Management of the pump is explained in detail in the LEVEL SETTINGS PAGE chapter ACCESS TO THE PAGES The specific pages of the individual control devices are ac cessed from this page by pressing the dedicated zone on the synoptic panel Access zones to the pages TDS PAGE Optional PRESSURE PAGE BURNER PAGE PRESSURE PAGE BURNER PAGE TDS PAGE optional SERVICE PAGE SETTINGS PAGE LEVEL PAGE BLOW DOWN PAGE ALARMS PAGE LEVEL PAGE BLOW DOWN PAGE SERVICE PAGE SETTINGS PAGE ALARMS PAGE 2 Kas
45. ition pressure in bar DELAY 3STG 3rd stage of flame ignition delay in minutes The page is shown as follows EN E Sa Gei ef Gei Ra Gei r Ze Zei Sat Gei Sa Gei 6 min 3STG time is reset and the 3rd stage of flame remains off The DELAY 3STG timer will restart for the pressure status P lt P SET AP 1STG AP 2STG AP 3STG When it has been ignited the 3rd stage of flame will extinguish when the pressure rises to a value of P gt P SET AP 1STG AP 2STG Common Functions of Single Stage 2 Stage and 3 Stage Burner Control During the entire management cycle of the burner the Burn er Lock logic input control must be enabled and if this signal is shown then there must be an alarm warning displayed as BMODE LOCK See the ALARMS PAGE chapter for more details 21 lt GA ke ke e e te S Kal Q Pm Se 2 lt lt 22 3 POINT MODULATING BURNER MODUL 3PNT With activation of the control mode for 3 point modulating burners named MODUL 3PNT the burners are managed that control opening of the combustion air adjustment shutter with 3 point mode or rather with open stop close commands The 3 status are adjusted with a derivative integrative function With this mode enabled on the page the fields relative to the 2 STG and 3 STG modes are disabled whilst new fields for man agement of the flame modulation are displayed and activated B Mode Selection B Mode
46. king the user to reset the alarms by pressing the buttons on the front of the control panel cc N mM CPU PWR Unical a Safety device Tested HP SAFE LWL SAFE1 LWL SAFE2 HWL SAFE Push Alarms Reset TDS SAFE GC RER KR 00 HP SAFE 12 2307 Lw Ki Ascon 7 After having reset the alarms the warnings turn off and you On the second SERVICE DATA SAVING PAGE there are fields should then press for entering the analysis values of the supply water and of the boiler water Flags light up indicating that the tests were carried out successfully The analyses are to be carried as prescribed by the regulations in force or as described in the boiler s use and maintenance manual with the use of specific water analysis tools 8 The key is enabled press to go to the SERVICE DATA SAVING page EE Se COM CPU PWR i Unical SAFE SERVICE 2 SERVICE N ID 1 DATE USER MN ID 0 TIME CHE COEUR pH 0 0 0 gt O LWL2 HARDNESS HW pH 0 0 ONS ALKALINITY D PB oom HARDNESS 000 Tos O HS cm 12 26 0 ASCON 51 The following information is shown on the screen Ph Value to be entered Ph of the supply water SERVICE N ID Incremental value proposed by the system HARDNESS Value to be entered Total hardness of the sup Possibility of entering a different value Identi ply water fication number for saving USER N ID Value read User who ran the test pH 08 0 DATE Value read Dat
47. n analogue signal 4 20 mA e asecond ON OFF electrode probe which defines the height of the level setpoint called SETPOINT PROBE e two safety probes for low level e a possible safety probe for high level e a pressure transducer Adjustment is performed with The following is displayed on the main page the current level value in percentage as described in the fol lowing paragraphs the status of the pump on i 26 e 1 or 2 water supply pump s e possible three way or proportional flow control valve or pos sible inverter for speed adjustment of the motor pump There are five adjustment modes which vary according to the following statuses e burner operation e economiser boiler operating status STANDBY AUTO WARM UP FILL The level of water detected by the capacitive probe is displayed on the HOME PAGE and on the LEVEL PAGE Press the key on the HOME PAGE defined by the loading pump zone to access the LEVEL PAGE Sensitive zone key to access the LEVEL PAGE dk AK From the other pages on the first level press the following key to access ES P 547 bar 17 35 0 The LEVEL PAGE is as follows COM CPU PWR KA 57 SO P MAX WORK 11 50 bar Poel 6 00 bar P WARM UP 3 00 bar P MODE ON OFF The page shows the status of the level control devices pumps and probes and the settings of the intervention limits for adjust ments The operating s
48. n as follows gt ei EI e 8 F B Power 42 Rd B Mode Modul 3 PNT The burner in operation is shown on the BURNER PAGE as a percentage from 0 to 100 The operating status is displayed by a flame of variable length The name B Mode indicates the active operating mode which and shape in relation to the power assigned by the control to canbe selected on the next page as per the following table the burner The power value assigned is shown with the name B POWER B Mode burner TYPE OF BURNER operating mode 2STG 2 STAGE 3STG 3 STAGE Modul 3 PNT 3 POINT MODULATING Modul IML MODULATING WITH SHUTTER MOTOR CONTROL WITH 4 20 mA ANALOGUE SIGNAL Modulation via IML Modul EXT MODULATING WITH EXTERNAL CONTROLLER TO THE PLC V lt GA E ke ke e e te S shkas Q Pm Se 2 lt lt e By activating the different operating modes available the cor responding luminous indicators are activated that identify the operating status of Enabled status Disabled status Status display display Displayed FLAME ri et KEE AA see TO O s TO TT With USER 1 4 and ADMINISTRATOR login the virtual key next to the burner is activated this allows access to the BURNER SETTINGS PAGE BURNER SETTINGS PAGE USER 1 4 and ADMINISTRATOR login The BURNER SETTINGS PAGE is dedicated to managing operation of the burner this allows you to select the operating mode and to enter the operating
49. n time in seconds Description of the function 1 With control in STANDBY MODE The level adjustment is disabled 2 With control in AUTO MODE If the ECONOMISER is disabled then e Using a PID function the level control will maintain a value equal to L SET by varying the frequency value assigned to the pump by means of an inverter integrate with function description and meaning of variables The minimum INV MIN and maximum INV MAX ad justment percentages set limits to the signal output from the PLC to the inverter and consequently to the frequency assigned by the inverter to the pump s motor When the pump starts being controlled a timer starts counting the adjustment time to check whether the system is adjusting enough to increase the level such that there is a level gain equal to AL MIN in the TIME AL but no later than the ab solute time equal to TIME L SET If instead the level falls until it touches L MIN i e L lt L MIN then the speed of the pump is maximum meaning the percentage of the inverter is INV MAX until it ex When you press Saal the page becomes R E Ba Ke E Sue lt a Se Ke z ap s m 2e INV MAX INV MIN 50 TD 30 sec 60 sec TI ceeds L MIN beyond which the PID function becomes involved again With the logic described in the previous paragraph If the ECONOMISER is enabled the status of the burner be comes involved In this condition the paramete
50. nd with fail safe logic are triggered interrupting with secondary relays 4 for each probe controller the chain of consents to the burner thus interrupting operation Intervention of the low level probes LWL is noted by e The alarm buzzer e The LWL SAFE1 or LWL SAFE2 luminous button lights up on the front door of the panel e LWL SAFE1 or LWL SAFE2 alarm on the operator panel Use the two UP and DOWN keys to increase and decrease the value sent by the probe with 1 resolution as described on the LEVEL PROBE SETTINGS PAGE With ADMINISTRATOR login The virtual key is activated next to the level probe al lowing access to the LEVEL PROBE SETTINGS PAGE Default setting The relative luminous indicator lights up at bottom right on the LEVEL PAGE Indicators off no alarms Indicator 1 on LWL SAFE1 alarms present Ifa LWL SAFE alarm is triggered first understand and eliminate what caused excessive lowering of the level then restore the water level To reset the alarm restore the level until the water touches the probes then press the flashing luminous button 3 6 SETPOINT PROBE The SETPOINT PROBE physically identifies the normal level of water in the boiler to which adjustment is aimed It consists of an electrode probe connected to an electronic re lay which in turn is connected to a PLC input It is set at 70 mm above the threshold of the LWL probes The exact value corresponding to
51. ng the adjustment time to check whether the system is adjusting enough to increase the level such that there is a level gain equal to AL MIN in the TIME AL but no later than the absolute time equal to TIME L SET If the level falls until it touches L MIN i e L lt L MIN then the valve is opened until it exceeds L MIN beyond which the PID function becomes involved again With the logic described in the previous paragraph If the ECONOMISER is enabled the status of the burner becomes involved In this condition the parameters for counting the level restore time AL MIN TIME AL TIME L SET are not taken into account With burner off 1st stage of flame OFF e the control does not maintain the setpoint level assigned equal to L SET but allows it to be lowered until it reaches L MIN i e L lt L MIN When L MIN has been touched the valve is completely opened and the pump is activated to restore the level up to L ON i e L gt L ON With burner on 1st stage of flame ON e The PID function is activated to calculate the valve mod ulation aiming for L SET thus calculating the times to be assigned to the three statuses open stopped closed e Ifthe level falls below L MIN i e L lt L MIN the valve is completely opened and the pump is activated to restore the level up to L ON i e L gt L ON 3 With control in WARM UP MODE burner ON e with water level lower than L MIN the valve is completely opened and the pum
52. obes LWL 0 and the intervention threshold of the high level safety probe HWL if present or software threshold 100 The setpoint probe usually requires that the difference in mm between the LWL and HWL is 100 mm which leads to a corre spondence of 1 mm 1 A coloured bar indicates the adjustment field and the safety zones the range identified by the green zone between L MAX and L MIN is the field in which the level is adjusted during auto matic operation AUTO MODE see explanations on the HOME PAGE The yellow fields are temporary fields the level touches these fields only during temporary operating phases such as cold start WARM UP MODE and FILL MODE The red zones are the intervention bands of the high level safety probes HWL and the low level ones LWL The lamps associ ated with the HWL and LWL alarms are in the red zones With USER 1 4 and ADMINISTRATOR login The zone is displayed for adjustment fine cali bration of the level probe 3 5 MINIMUM WATER LEVEL SAFETY LEVEL SWITCHES LWL LOW WATER LEVEL Two low level safety electrode probes are installed on the boiler They are set atthe same length and are double for back up of the safety devices The level height of the LWL probes is at about 70 mm lower than the SETPOINT PROBE If the water reaches this level and uncovers the electrode of the probe s with a delay of about 10 sec the relays of the rela tive safety devices PED approved a
53. ontinuous supervision by a per Directive according to the B F conformity assessment modules son authorised to run it up to a maximum of 24 hr 72 hr These series of steam generators are manufactured tested and 1 1 DEFINITIONS ATTENTION Information or procedure which if not strictly followed can cause dangerous situations NOTE Information or procedure which can facilitate and simplify maintenance operations or part of the text of particular importance that you want to point out WARNING Information or procedure which if not strictly followed can cause damage to the system or to the single components 1 2 SAFETY INFORMATION regulations in force following the instructions described in this manual also any operation must be carried out by ATTENTION professionally qualified and authorised personnel THE BAHR 24 hr 72 hr GENERATOR IS EQUIPPED AND CERTIFIED TO OPERATE WITHOUT CONTINUOUS SUPERVISION BY ATTENTION THE RUNNING OF THE STEAM GENERATOR A PERSON AUTHORISED TO RUN IT UP TO A MAXIMUM OF 24 72 hr ATTENTION The BAHR 24 hr 72 hr series steam gen erators must be operated within the limits for which they were designed any other use must be considered improper and therefore dangerous MUST BE ASSIGNED TO QUALIFIED PER SONNEL AS DEFINED BY ITALIAN LEGIS LATIVE DECREE 1 MARCH 1974 IT IS STRICTLY FORBIDDEN FOR PERSONS NOT SPECIFICALLY ENABLED TO USE RUN MAINTENANCE TH
54. p is activated to restore the level until it is higher than L MIN i e L gt L MIN e with water level higher than L MIN i e L gt L MIN the pump is kept off and the valve is stopped STANDBY MODE is activated 4 With control in WARM UP MODE burner ON If the ECONOMISER is disabled e with water level lower than L MIN the valve is completely MODUL INV mode summary table AUTO MODE opened and the pump is activated to restore the level until itis higher than L MIN i e L gt L MIN e with water level higher than L MIN i e L gt MIN the pump is kept off and the valve stops to allow expansion of the water when the temperature rises If the ECONOMISER is enabled e with water level lower than L MIN i e L lt L MIN the valve is completely opened and the pump is activated to restore the level until it is higher than L MIN i e L gt L MIN e with water level higher than L MIN and lower than L MAX Le L MIN lt L lt L MAX the pump is pulse activated with the valve open for 1 4 ofthe valve run time RUN TIME V to ensure minimum movement of the ECONOMISER at intervals and to protect it from overheating and from the water boiling in it e with water level higher than L MAX i e L gt L MAX the pumpis kept off WARMUP MODE NO ECONOMISER NO ECONOMISER ECONOMISER HWL ECONOMISER BURN ON BURN ON ECONOMISER BURN ON O L voren J i LMAX S Sheed S GA S Y Q x o o 9
55. re is a level gain equal to AL MIN in the TIME AL but no later than the absolute time equal to TIME L SET e lf the level falls until it touches L MIN i e L lt L MIN then the valve is opened 20 mA until it exceeds L MIN be yond which the PID function becomes involved again With the logic described in the previous paragraph If the ECONOMISER is enabled the status of the burner be 38 E SIE a R ze mp pe e mm ne e DEATH ZONE KM RUN TIME V TI 0 0 sec TD 0 sec 0 sec comes involved In this condition the parameters for counting the level restore time AL MIN TIME AL TIME L SET are not taken into ac count With burner off 1st stage of flame OFF e the control does not maintain the setpoint level assigned equal to L SET but allows it to be lowered until it reaches L MIN i e L lt L MIN When L MIN has been touched the valve is completely opened 20 mA and the pump is activated to restore the level up to L ON i e L gt L ON With burner on 1st stage of flame ON e The PID function is activated to calculate the valve mod ulation aiming for L SET thus calculating the analogue value between 4 and 20 mA to be transmitted to the mod ulating valve control device e lf the level falls below L MIN i e L lt L MIN the valve is completely opened and the pump is activated to restore the level up to L ON i e L gt L ON 3 With control in FILL MODE burner ON e with water
56. rite The SERVICE ARCHIVE page is as follows Unical R 0 XN00 100 0000 fa 00 100 00 0 XN00 100 0000 fa 00 g oo F 00 0 RI 0000 9 goo 100 2 mme DE Zeen Each page displays four tests Next to each line are the keys that Use Q and to change the page for scrolling through display the single service OPEN and to delete the archive A service display page is OP Unical R SERVICEN ID 001 DATE gt ON 0 TIME S B pH 07 0 HARDNESS 023 dr 08 0 ALKALINITY 0026 0 ppm HARDNESS 043 53 The maximum number of tests that can be saved is 400 When the memory is full the data archive must be exported onto a mass storage device via the USB port on the front of the panel next to the main display On the SERVICE page press to export the data The file recipe_a rcp has been downloaded onto the USB device After having downloaded the file the customer can press The formatted file sent to the customer LEGENDA Unical STEAMER Boiler BAHR 12 1500 HP NF A09U01256 STAMPA ARCHIVIO SAFE SERVICE Periodo dal 1 12 2009 al 1 12 2009 NOTE Il presente documento costituisce archivio storico dei test sui dispositivi di sicurezza SAFE SERVICE e deve essere conservato insieme al manuale d uso libretto di centrale e docomentazione accessoria Al ricevimento del documento consentito la cancellazione dell archivio elettronico a bordo del quadro controllo IML il presente documento stato format
57. rs for count ing the level restore time AL MIN TIME AL TIME L SET are not taken into account With burner off 1st stage of flame OFF then e With burner off the control does not maintain the setpoint level assigned equal to L SET but allows it to be lowered until it touches L MIN i e L lt L MIN the speed of the pump is maximum meaning the percentage of the in verter is INV MAX and this speed is maintained until it touches L ON i e L gt L ON With burner on 1st stage of flame ON then e The PID function is activated to calculate the pump speed modulation aiming for L SET thus calculating the percent age to be assigned to the inverter between the minimum and maximum limits set e Ifthe level falls below L MIN i e L MIN the pump is activated at the maximum speed acting on the inverter with the maximum percentage INV MAX until it touches LON With control in FILL MODE e see that described for 2 STG mode 3 4 With control in WARM UP MODE burner ON e see that described for 2 STG mode MODUL INV mode summary table V lt GA ke ke e e te S Kal Q Pm Se 2 lt lt 35 36 AUTO MODE WARMUP MODE NO ECONOMISER ECONOMISER ECONOMISER BURN ON BURN ON ECONOMISER BURN ON DL oFF oFF fO oF GE t tpi eo poo oe or Puses eo poo oe or puises MODUL 3 PNT PUMP MODE Use the open stop close 3 ways of the modulating
58. s pass word protected The ADMINISTRATOR is allowed access to all of the pages and complete modification of the entire system The IML upon start up enables access as a GUEST LOGOUT key LOGIN access key 3 fowl e ei D User Za GUEST USER For every modification authentication as a different user is re quired Press 43 on the home page to access the SERVICE page for user authentication The SERVICE page is as follows The login and logout keys are on the right e Zen Kal Q 2 GG 2 lt TEL Db Jae A OL N User enabled Lock unlock user Press the login key to access the user selection window and enter the password LOGIN User ID GUEST USER Password The top zone of the SERVICE page is dedicated to managing users User GUEST USER FS tian Se EF Press on the User ID field to activate the drop down menu to select the user A padlock is displayed on the far left its unlocked or locked status depends on the user connected itis also displayed on the near right The UNLOCK status corresponds to a GUEST as access for this user is not password protected The LOCK status corresponds to a USER 1 4 and ADMINIS TRATOR as they are password protected Once you have made your selection the user selected will be User USER 1 Al written in the User ID field then for USER 1 4 and ADMINIS TRATOR you need to enter th
59. ss key is enabled also from the other specific pages BURNER PRESSURE etc 44 Sensitive zone key to access the BLOW DOWN page The TDS page can also be accessed from the other pages BURNER PRESSURE etc by pressing the relative access key The BLOW DOWN page is as follows TIME TO BLOW DOWN 23 min It consists of a guick opening valve controlled by the IML system as regards opening and closing times Expulsion of the sludge is effective when after quick opening of the valve there follow moments of opening that are not exces sively long prolonged opening does not allow the sludge to be continuously dredged from the bottom towards the pipe and as a result only water would be expelled with consequent disper sion of useful energy There are three fields on the page for displaying entering values The fields are TIME TO BLOW DOWN display of time remaining until next bleed TIME OFF entering the interval time between the bleeds TIME ON entering the opening time of the dirt separator valve The values can be entered and edited only with USER 1 USER 4 login 45 3 11 SERVICE The SERVICE page is dedicated to all of the IML system s main tenance operations The following operations are managed from this page User authentication via Login The page is shown graphically as follows Kd PWR Unical Ordinary Service planned maintenance service of the burner and water supply
60. tato e realizzato dal servizio tecnico UNICAL sull base dell archivio elettronico ricevuto a mezzo Inviato al cliente a mezzo che ne costituiscono prova di autenticit Servizio tecnico UNICAL Data stampa 02 12 2009 Archivio controlli SAFE SERVICE TEST Jun __ RISULTATO_ SEZIONE Unical STEAMER Service nr 1 Data 1 12 2009 HP SAFE 16260 0 Ora 14 18 20 Utente nr 3 LWL SAFE1 16260 0 LWL SAFE2 16260 0 SAFE HWL SAFE 16260 0 TDS SAFE 16260 0 Ph DUREZZA Ph ALCALINITA ppm 68 0 DUREZZA sj CONDUCIBILITA uS cm 1500 0 Service nr 2 EST U m ___ RisuLTATO sezione Data 1 12 2009 16260 0 Ora 14 19 53 16260 0 Utente nr 1 16260 0 SAFE 16260 0 16260 0 7 6 H20 i 30 0 AUMENTA 7 8 ppm 65 0 H20 T 34 0 CALDAIA CONDUCIBILITA HS cm 1520 0 rest u m ___ RisuLTATO SEZIONE HP SAFE 16260 0 LWL SAFE1 16260 0 LWL SAFE2 16260 0 SAFE HWL SAFE 16260 0 TDS SAFE 16260 0 Ph 7 6 H20 DUREZZA nl 32 0 ALIMENTA Ph 7 7 ALCALINITA ppm 62 0 H20 DUREZZA T 32 0 CALDAIA CONDUCIBILITA uS cm 1580 0 Service nr 3 Data 1 12 2009 Ora 14 21 36 Utente nr 4 DEL to empty the electronic archive passing all of the in dividual lines of the archiv E rerwriting the existing records restarting from the service with NR ID 1 The file must be sent to the UNICAL technical service who will format it and transform it into a printable file The file in pdf for mat
61. tatus of the water loading pump is displayed by the pump s rotary movement pump working and green and the static image pump stopped and grey On the left a filling bar represents the level and above a field with the numerical value with a scale from 0 to 100 whose meaning is described later in this section On the right of the screen there are the indication entering fields of the level limits in order of height which are e HWL high level safety value calculated which cannot be edited always 100 e L MAX maximum value required for overflow value can be edited e LSET setpoint level to which adjustment is aimed value calculated which cannot be edited e LON hysteresis threshold for adjustment activation val ue can be edited minimum adjustment threshold value can be edit ed low level safety value calculated which cannot be edited always 0 e L MIN e LWL The only fields which can be edited on this page are L MAX L ON and L MIN The other values are calculated by the system and depend on that set on the next page called LEVEL PROBE SETTINGS PAGE accessible only by the ADMINISTRATOR lt GA ke ke e e te S Kal Q 2 Se 2 lt lt 27 28 Therefore the measuring field of 0 100 corresponds to the height of the level that varies from the value corresponding to the intervention threshold of the low level safety pr
62. th the SETPOINT value set in the system When the setpoint value is exceeded the control acts by com manding the water bleed valve to open which by causing the level in the boiler to lower will actuate the loading pump thus filling the boiler with new water water with low level of TDS conductivity Sensitive zone key to access the TDS page The valve has ON OFF control modes with a time interval on opening and closing for the entire time the TDS value is being requested to lower A second conductivity threshold is set as a limit value for safe ty block of the entire generator if this threshold is exceeded the high TDS alarm is triggered and operation of the burner is locked The TDS function is optional and can be selected on the AD VANCED SETTINGS page accessible only by the ADMINIS TRATOR When the function has been enabled on the home page the bleed valve associated with control of the TDS is shown on the boiler s synoptic panel and the access keys to the specific func tion control page are enabled The following is displayed on the main page e the current conductivity value read by the probe in the field above the sensitive zone e the status of the bleed valve closed ja va and open ple The TDS page can also be accessed from the other pages BURNER PRESSURE etc by pressing the relative access key 41 The TDS page is as follows Active operating Current conductivity valu
63. the front panel of the Electrical control panel Once the alarm condition has been physically removed this alarm will automatically reset Physical reset of the alarm status can be done ONLY by hand and directly by the system maintenance technician who will FIRST ensure that the water level has been taken below the safety limit and THEN will press the HWL SAFE alarm reset but ton indicator on the front panel of the Elec trical control panel Once the alarm con dition has been physically removed this alarm will automatically reset RESET ALARM Physical reset of the alarm status can be done ONLY by hand and directly by the system maintenance technician who will FIRST manually reset the safety pressure switch after the pressure level has been taken below the safety limit and THEN will press the HP SAFE alarm reset button in dicator on the front panel of the Electrical control panel Once the alarm condition has been physically removed this alarm will automatically reset 57 TDS ALARM 58 ALARM ID TDS SAFE EXT DESCRIPTION ID SALINITY CONTROL UNIT INTERVENTION TDS Total Dissolved Solids FOR EXCEED ING THE TDS SAFETY VALUES IN THE BOILER WATER SYSTEM SAFETY INTER VENTION BURNER LOCKED ALARMS ASSOCIATED WITH SERVICE DEVICES ALARM ID B NO FLAME DESCRIPTION ALARM Burner control equip ment operating lock signal Burner lock signal SYSTEM SAFETY INTER VENTIO
64. tion otherwise con trol is recalculated with the DELAY FLAME CTRL FLAME time IML MODULATING BURNER MODUL IML The MODUL IML control mode is specific for modulating burn ers with position sensor of the combustion air shutter or of the fan motor speed variation inverter therefore with analogue output signal 4 20 mA The output signal value is adjusted with a derivative integrative function With this mode enabled on the page the fields relative to the 2 STG and 3 STG modes are disabled whilst new fields for man agement of the flame modulation are displayed and activated B Mode Selection B Mode Modu mi as 0 1 bar Laf PR TD TI 38 sec kB The new fields are RANGE field for derivative integrative ad justment in bar TIMED derivative time in seconds TIME integrative time in seconds DEAD ZONE dead zone around which adjustment is not made in bar TIME AIR GATE burner air shutter opening time in second2 DELAY FLAME no flame delay time in sec CTRL FLAME delay time for controlling flame stability for mod ulation consent in sec The page is shown as follows eR DEAD ZONE LE T AIR GATE x DELAY FLAME CTRL Sir RE 9 30 Te sec sec The burner s 1st stage of flame is ignited and the Primary Com bustion Air Shutter is modulated as follows the 1st stage of flame is put on ON always depending on the pressure setpoint P SET on PRESSURE PAGE and on th
65. total counter 1st flame can be reset from the keypad display RUN TIME hr hr hr hr hr 0 PRESET TIME 0 hr O hr 0 hr O hr 0 br RESET Da 0 hr PUMPS OPERATING TIMES METER During the burner s operating cycle there will be a check of the status of the P1 and P2 if available pumps contactors Detection of these activated inputs determines increase of the timers PUMP 1 COUNTER and PUMP 2 COUNTER The difference in hours between PUMP 1 COUNTER and PUMP 2 COUNTER is compared with a settable value on the SERVICE SETTINGS PAGE which defines the limit in hours between Pump 1 and Pump 2 operating hours after which the system switches between the pumps 47 SAFE SERVICE Safe service is dedicated to control and maintenance of the safety devices that oversee the steam generator and must be run every 24 or 72 hr of operation The controls are carried out as prescribed by the regulations in force SAFE SERVICE is a function that can be set on the ADVANCED SETTINGS paged Setting only with ADMINISTRATOR login The logic of the SAFE SERVICE function is that the system counts the operating hours of the generator comparing them to the set limit that can be 24 or 72 hours The countdown is displayed in the bar at the bottom of the home page next to the clock USB archive export key Alarms page access key Ge When the countdown counter reaches the value 1 hr the system displays a m
66. valve to ad just the level As the valve is between the pump and the boiler its opening or closing creates a variation in the water flow from the supply pipe P Mode Selection P Mode Modul 3 PNT MAX CLOSE Other than the fields already described in the ON OFF and 2 STG mode the following fields are enabled PR band within which the derivative function is activated in level TD derivative function calculation time in sec onds Tl integrative function calculation time in seconds DEATH ZONE dead band or rather insensitive zone around the L SET setpoint value in level RUN TIME V valve run time in seconds Description of the function 1 With control in STANDBY MODE The level adjustment is disabled 2 With control in AUTO MODE If the ECONOMISER is disabled e Using a PID function the level control will maintain a val 20 The variation in flow in relation to the collection of steam power read also as water consumption will also maintain it constant When you press the page becomes a E Ka n ay K z be Ma be wt s Ba Ger DEATH ZONE RUN TIME V o Bite TD ue equal to L SET by using the open stop close 3 ways of a modulating flow valve The times to be assigned to the three statuses open stop close are calculated with the PID function integrate with function description and meaning of variables When the pump starts being controlled a timer starts counti

IML (Industrial Multi Logic) ELECTRONIC CONTROL PANEL

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