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PCC-III Installation Manual - Preferred Utilities Manufacturing

1. PC3 Edit Personal Computer based software The PCC Ill Cover Blockware can be designed and entered using the PC3_Edit software on a Personal Computer and then downloaded into the PCC III via the RS232 Download Port behind the Front Panel PC3_Edit is a Windows 95 98 based point and click style program that is arranged in a spreadsheet format with a convenient fill in the blanks approach Each Block has an unlimited length Comments field for documentation and the Blockware data and comments can be printed to any Windows compatible printer PC3_Edit can also upload Blockware from a PCC III into PC3_Edit PC3_Edit can be used to do on line troubleshooting because it displays the real time outputs of every Block in the PCC III This manual does not cover the operation and use of PC3_Edit PC3 Draw Personal Computer based software PC3_Draw includes all of the features of PC3_Edit however the approach is CAD based rather than spreadsheet based PC3_Draw includes a menu with a pre drawn figure for each PCC III Blockware Function Type The user simply drags the desired Functions onto the Drawing Page and then uses Smart Connector lines to interconnect the Blocks Double Clicking on any block allows the user to edit data within the Block The resulting drawing can be printed on a plotter and the Blockware data can also be printed in the PC3_Edit tabular format This manual does not
2. Part Number Description Recommende d spares per 10 PCC Ill s PCC III 0000 Complete PCC III controller with case amp mounting brackets 0 5 92227 Main power fuse 0 3A slo blo 92233 Ribbon cable assy door to CPU board Available Spare Parts 190315 CPU board 99595 Backup Memory Module 8kx8 EEPROM 92204 8 pt field wiring connector 92223 14 pt field wiring connector 92076 Slide on jumper 250 ohm amp R W 2759 006A CPU to case retainer screw 6 32 x 1 2 08C 190349 Front Panel complete includes Bezel keyboard display board cable Edit keys door 90137 Front Panel screw with integral O ring 90140 Front Door gasket 190358 Front Panel with Keybord less display circuit board 190316 Front Panel display circuit board only 2759 006A Front Panel display circuit board mounting screws 03Z 6 32 x 3 16 90136 Blank engravable nameplate for Front Panel 190348 Case for panel mounting with rear cover 190347 panel mounting brackets not included 90134 Case to panel gasket 190347 Panel Mounting Bracket Kit 2 brackets kit 190319 1 pair Triac output option board slot 3 only 92245 5 pt field wiring connector 92247 fuse 3 A fast acting 190361 5ch 4 20 mA 0 5 Vdc AIN option board 92243 12 pt field wiring connector 190362 3 ch 4 20 mA 0 5 Vdc isolated AIN option board 92251 6 pt field wiring connector 190366 3 ch 4 20 mA 0 5 Vd
3. AO A1 DO D1 NOP NOP NOP NOP NOP NOP 0 100 0 1 0 1 2 3 4 O 5 7 8 9 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 10 11 12 13 4 I is IlL e 17 18 19 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 20 21 22 23 24 25 26 27 28 29 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 30 31 32 33 34 35 36 37 38 39 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 40 41 42 43 44 45 46 47 48 49 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 50 51 52 53 54 55 56 57 58 59 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 60 61 62 63 64 65 66 67 68 69 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 70 71 72 73 74 77 78 79 Figure 5 1 Note Blocks 0 through 3 are automatically configured by the firmware as Functions AO A100 DO and D1 as shown above These four Blocks can not be changed to a different Function Block 0 A0 is automatically Softwired to whenever the Function Type of a Block is changed Block 2 DO is likewise Softwired to all Block Inputs that require an discrete value PCC III Instruction Manual rev 2 3 Page 5 3 Section 5 Configuring Blockware PCC III Blocks continued NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 80 81 82 83 84 85 86 87 88 89 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 90 91 92 93 94 95 96 97 98 99 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 100 101 102 103 104 105 106 107 108 109 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 110 111 112 113 114 115 116 117 118 119 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 120 121 122 123 1
4. P8 Fail Mode Triac Response 0 STOP Both triacs are turned OFF 1 INC INCREASE triac is turned ON DECREASE triac is turned OFF 2 DEC DECREASE triac is turned ON INCREASE triac is turned OFF 3 DISABLE The Fault is ignored The triacs respond to the normal TOUT PV and SP logic During the P9 time delay the triacs respond to the normal TOUT PV and SP logic Wire the Feedback Pot as indicated below to achieve the desired response during the P9 time delay Desired Response Connect Pot Increase end to Connect Pot Decrease end to Fail Close 5 V Signal Common Fail Open Signal Common 5 V PCC III Gxx0 FEEDBACK PCC III Gxx0 FEEDBACK POT asa i POT een ee ee ee INCREASE a EEEE INCREASE PULL UP RESISTOR WIPER ne WIPER AIN SIGNAL ONY SIGNAL X40 PULL UP RESISTOR l S emcee O DECREASE ray Betas ci O DECREASE Fail Closed Pull up Wiring Fail Open Pull up Wiring If Wiper Opens If Wiper Opens AIN 5V gt 100 Decrease Triac turns ON AIN 5V lt 0 Increase Triac turns ON PULL UP WIRING FOR FAIL CLOSED AND FAIL OPEN SYSTEMS PCC III Instruction Manual ver 2 3 Page 6 32 Section 6 Blockware Functions Technical Reference Test Feedback Pot Fault Detection Install the actuator stroke it Calibrate the Scaled Position see above and then test the Feedback Pot Fault Detection The block outputs of TOUT TTRIP and TCODE must be monito
5. Terminals shown are for TOUT ch 3 1 Page 2 17 T1 Increase Solenoid Valve Section 2 Installation DC Commons and AC Neutrals Isolation The drawing on page 2 19 shows the relationships between the various Grounds and Commons within the PCC III A thorough understanding of these relationships will prevent unintended Ground Loops in the DC and AC field wiring Ground Loops is a general term to describe unintended current flows via AC Ground or DC Common circuits which generally are NOT drawn on a schematic as a distinct field wiring connection DC Ground Loops can cause lower than expected 4 20 mA values due to a portion of the current bypassing the intended circuit path and traveling through some unintended parallel path AC Ground Loops can cause Ground Fault Interrupter Circuit Breakers to trip if current returns via a Neutral that is not protected by the GFCI breaker Green Wire Ground The incoming AC power Ground the Green wire is only connected to Case Ground ie the metal enclosure Case Ground is isolated from all Neutrals and all DC Commons Case Ground should always be connected to the appropriate power supply Ground per NEC Line The CPU AC Power Line Input Terminal 2U is internally connected to CPU terminals 2L and 3L CPU Terminal 2U is NOT internally connected to any of the option boards If a connection is
6. o so O WW 0 TYPICAL FEEDBACK POT WITH PARTIAL STROKE SETUP FEEDBACK POT WITH FULL STROKE SETUP G BOARD INTERNAL PULL UP RESISTOR USED EXTERNAL BIAS RESISTORS FOR FAULT DETECTION FEEDBACK POT FAULT DETECTION WITH PULL UP AND BIAS RESISTORS PCC III Instruction Manual ver 2 3 Page 6 29 Section 6 Blockware Functions Technical Reference Scaled Position Positioner Mode The actuator position feedback signal must be connected to a PCC III Analog Input channel typically on a G Option Board The AIN Block for this channel is then connected to the TOUT Block Feedback Input For Potentiometer position feedback signals the AIN Block scaling Parameter values should be OV 0 and 5V 100 The AIN FILTER SECONDS Parameter 6 MUST be set to 0 0 seconds larger values will cause the actuator to hunt or oscillate TOUT Parm 4 amp 5 are used to convert the unscaled AIN Feedback Input to a 0 100 TOUT Scaled Position Example AIN 25 at minimum position AIN 75 at maximum position Set Parameter 4 0 feedback 25 and Parameter 5 100 feedback 75 When Feedback Input 25 TOUT Block Output 0 Feedback 35 TOUT 20 Feedback 45 TOUT 40 Feedback 75 TOUT 100 For fail open applications P4 Parameter 4 can be greater than P5 that is P4 0 feedback 75 and P5 100 feedback 25 Use S M for Initial Actuator Setup Positioner Mode After the actuator electri
7. Configure P17 Channel 4 message to read Plant Demand When you enter this parameter the first digit will flash Use the EDIT or EDIT arrows until the proper letter number character is displayed Press DIS button to advance to the next digit Press ENTER when finished Configure P18 Channel 5 decimal to 0 Configure P19 Channel 5 zero to 0 The Bias can go to 50 This parameter must be set to what the value would be when B25 is at 0 The PCC III will plot a straight line passing through the zero and span settings Configure P20 Channel 5 span to 100 The Bias can go to 50 This parameter must be set to what the value would be when B25 is at 100 even if it can never get there Configure P21 Channel 5 message to read BSM BIAS Configure P42 Channel 1 alarm message to read HIGH PSI Configure P43 Channel 2 alarm message to read LOW PSI PCC III Instruction Manual rev 2 3 Page 5 12 Section 5 Configuring Blockware Test the configuration Read Section 4 before testing This section explains how to use the Force and Examine features of the PCC III s Utility Menu The PCC III should not be performing any control Function while being tested Each Block that was added or was modified should be thoroughly checked prior to returning the PCC III to process control To test the configuration Exit Service Manual S M The PCC III will perform several types of error checks The cont
8. Use the EDIT A or EDIT V keys to scroll to the desired QUICK menu line then press ENTER EDIT will jump into the EDIT A BLOCK menu and attempt to display and edit the Parameter that was linked to the selected QUICK menu line item If the Password level is correct the Parameter value will be displayed the Edit Value LED will be ON and the EDIT A or EDIT V key can be used to change the value Press ENTER or ESC EDIT is now in the EDIT A BLOCK menu If the current Password is not at the correct level or if S M mode is required then the Parameter cannot be edited and an error message will be displayed Press ESC to clear the error message the Parameter value will then be displayed with the Edit Value LED turned OFF EDIT is now in the EDIT A BLOCK menu LAST PARAMETER This selection causes EDIT to jump to the last Parameter that was previously displayed EDIT saves the LAST PARAMETER linkage automatically and retains the link even after leaving the EDIT mode Example if you are tuning a PID Block and use the EDIT A BLOCK menu to change the PID Gain value ESCape out of the EDIT display mode into the Process display mode observe the process response and then re activate EDIT QUICK MENU will be the first MAIN menu line displayed press ENTER QUICK MENU LAST PARAMETER will be displayed press ENTER EDIT will then jump back to EDIT A BLOCK with the PID Gain displayed The LAST PARAMETER link is lost and will not be displayed in the QUIC
9. or the Release to Modulate Input B40 is not energized the selected Input to B144 is high 1 which results in selection of the B Input When the FSG Purge contact B42 is open the firing rate Output is at the position determined by B30 Light off position constant When the FSG calls for Purge B42 closes the firing rate demand is directed to 100 B Input of B130 or that rate which meets the Number of Air Changes requirement recommended by NFPA When the FSG establishes that the Purge period is complete the firing rate is returned to the Low fire light off position B42 opens After Main Flame Ignition the FSG will allow the control system to Release to Modulate via closure of B40 Process Signal FSG Modulate S On Manual Auto Man Closed DIN FPT H PB Invert 40 Light off Position A DIN AOUT Firing FSG Ch 3 Rate Purge 42 Closed Purge Figure 5 5 PCC III Instruction Manual rev 2 3 Page 5 15 Section 5 Configuring Blockware Add Day Night Pressure Setpoint Blockware Figure 5 6 is an example of a Day Night Setpoint select circuit Some facilities find it desirable to setback the steam pressure setpoint or hot water temperature setpoint at night to conserve fuel This is accomplished by adding a few Function Blocks Pushbutton 3 B57 and LED 3 B87 are labeled Day Night Setpoint A discrete Input can be used in lieu of the push
10. Invert Input By default a 1 Input energizes the Discrete Output and changes the Output to a 1 If Parameter 3 is changed to a 1 a 0 Input Energizes the Discrete Output and the Block Output FUNCTION 126 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 16 NAME DOUT SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D INPUT BLOCK 1 Parameter Description Default Max Min Code Notes 1 OPTION BOARD 0 CPU BOARD 0 2 0 3 2 OUTPUT CHANNEL 1 4 1 3 3 INVERT INPUT 0 NO 1 YES 0 1 0 2 1 Notes 1 See Invert Input above By default Relay energizes when Input 1 F127 NOP No Operation Dummy Function Function NOP does not do anything NOP is the default function that is placed in all Blocks when memory is erased A NOP Block is not a valid Input to any other Block and if used as an Input would cause a Type Mismatch error that would prevent the controller from leaving Service Manual mode FUNCTION 127 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 0 NAME NOP SINGLE USE FUNCTION N OUTPUT TYPE D No Inputs and No Parameters PCC III Instruction Manual ver 2 3 Page 6 58 Section 6 Blockware Functions Technical Reference
11. boards This example shows Pair 1 of a Triac Output on a G Option Board in Slot 2 The Triacs are protected by surge suppressing capacitors inductors and varistors 6 mA leakage typ The Triac Hot and Neutral supply are isolated from the PCC III 120 Vac Each Triac pair has a separate fuse Motors rated 24 120 Vac and 0 2 Amps are acceptable The G Board also includes two Analog Input channels If a Position Feedback signal is required by the control strategy See the potentiometer and 4 20 mA input examples above Triac Output Other AC Loads Typical for Q and S boards This example shows Pair 1 of a Triac Output on a S Option Board in Slot 3 The TOUT Blockware allows each Triac to be controlled as a separate Solid State AC Switch The Triacs are protected by surge suppressing capacitors inductors and varistors 6 mA leakage typ The Triac Hot and Neutral supply are isolated from the PCC III 120 Vac Each Triac pair has a separate fuse Loads rated 24 120 Vac and 0 2 Amps are acceptable PCC Ill Instruction Manual rev 2 3 to second F2 PCC IN 3A Fuses Fy ZA 2 40 H 24 120 Vac Baie See Power Input 2 N a Actuator oe AON a Increase Max Load 2 Amps FLA 2 4 Sa METTA VY Terminals shown are for TOUT ch 2 1 PCC M 24 120 Vac Power Input
12. on line fired equipment efficiency but as a result allows determination of changes in that efficiency and therefore the potential for maintenance Service Manual option card The optional Service Manual feature allows the operator to manually adjust the controller s output in the event of a failure of the controller s microprocessor power supply memory or any digital circuitry In the event of such a failure the output will remain at its last position until such time as the operator changes that position Triac Output for Electric Actuators option cards Many systems utilize electric actuators where a bi directional on off voltage signal is used to drive the actuator open or closed The PCC III has the optional interface electronics to accomplish this control action Additionally the Triac Output option card s include position feedback input provisions for optimizing control of actuator position Steam Flow Pressure Compensation Accurate steam flow measurements are very important to the control and monitoring of process systems Even though most control systems are designed to assure a constant pressure variations and or upsets can occur which if unaccounted for can render records erroneous and produce unacceptable instabilities in all control loops upon which this measurement depends Gas Flow Pressure Temperature Compensation Most gas flow measurements require some level of pressure and or temperature
13. 0 0 FUNCTION 110 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME XOR SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D A INPUT 2 D B INPUT Parameter Description Default Max Min Code Notes 1 INVERT OUTPUT O NO 1 YES 0 1 0 2 F111 NOT NOT Logic Function NOT logically inverts ie negates the Block Input FUNCTION 111 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME NOT SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D INPUT BLOCK No Parameters PCC Ill Instruction Manual ver 2 3 Page 6 49 Section 6 Blockware Functions Technical Reference F112 F F Flip Flop Logic Function F F behaves like a Latch relay The Block Output remains at it s last value 1 or 0 unless one of the three Inputs is activated The Block Output behaves according to the table below Parameter 1 Reset Toggle Output Inverted NS oT X ag Opposite the Output value from the previous scan 0 becomes 1 1 becomes 0 E ae No change same value from previous scan 1 gt 0 X means not used can be any value 1 means on the rising edge i e only once during the scan that the Input changes from 0 to 1 The Set and Reset Inputs have priority over the Toggle Input that is the Toggle Input is ignored unless both the Set and Reset Inputs 0 When Set Reset 1 the Block Output does not change and the Toggle Input is ignored The Toggle Input is only active for the single
14. Configuring Blockware Sketch each section Figure 5 3 below highlights each section that is to be added to the original configuration The Plant Master section will require an input Block AIN a Front Panel Constant Block FPCON for the Submaster bias and a weighted sum Block WSUM to calculate the bias The Plant Master Local PID selector requires a pushbutton Block PB an indicator Block LED and a switching Block ASW The alarm section requires a high alarm Block HIALM and a low alarm Block LOALM Drum PSI Plant i Transmitter Master i AIN i Ch 1 1 5v i sete SNe ner AGT eee Ny Sie act a i i l 3 Drum PSI Submaster i PV PV s PV_ Y Setpoint Bias 1 i LOALM d p HIALM TS PID SP FPCON je ve tl O lre T1 i 60 59 120 20 i L m n WAA la mm Hi Alarm B150 B40 i ens Sn PB LED ASW 1 La i Sy PES Invert i 55 85 125 PM On Local t Local PID i Alarm A Silence DIN ASW Ch 1 S gt 4 B Bo Invert 40 126 FSG Modulate S On Manual Auto Man FPT H LT H EA ca AOUT Burner Common 4 20 Firing Alarm Figure 53 B120 150 Rate PCC III Instruction Manual rev 2 3 Page 5 9 Section 5 Configuring Blockware Please read Section 4 which explains how to use the PCC IIl EDIT menus You must know how to modify a Block as well as how to copy the Primary Blockware memory to the Backup memory before proceeding Change the Function Type of a Block Change
15. FIND USAGE and QUICK menu setup FORCE BLOCK UN FORCE A BLOCK EXAMINE UN FORCE ALL BLOCKS The concept of Blockware and Softwiring the Output of one Block to the Input of DISPLAY SCAN TIME a second Block is the direct software equivalent of physically hardwiring from EDIT QUICK MENU one electronic signal processing module to another Trouble shooting a BLOCK TIMING hardwired system is done with a Voltage Current multi meter The EXAMINE menu item is the software equivalent of the physical multi meter The EXAMINE menu item allows you to select any Block and to display the real time Output of that Block In addition EXAMINE can display the real time value of each Input signal for that Block Analog signals from 199 99 to 199 99 can be displayed however Blockware is normally designed to use a 0 100 00 range Block Outputs are percentages The Block output values are not scaled in engineering units rather it is the PANEL Block that performs the engineering units scaling for the Front Panel displays Discrete signals are displayed as 1 or 0 A signal can easily be traced from the initial AIN Block to the next Block to the next and finally to the AOUT Block When an improper signal is found the preceding Blocks are then checked for incorrect Parameter values or incorrect Softwiring e g the Input should come from Block 17 but was accidentally entered as Block 18 Referring to a Blockware drawing that
16. flow measuring element Block 39 evaluates the square root of the steam density calculation The Output of B39 is the compensated corrected steam flow The corrected flow is sent to analog Output Block 151 perhaps to a recorder and to a totalizer B42 If a value of 1000 cph counts hr is entered into B42 each discrete Output B96 pulse represents 100 Ibs of steam flow Orifice Plate Steam Flow Transmitter Drum PSI Design PSI Transmitter Full Scale Transmitter AIN AIN Ch 3 Ch 1 1 5v 1 5v 6 4 A F x C Blocks 35 amp 36 are Steam Density vs Saturation Pressure 36 Curves Design Actual TOT 1000 CPH 1 count 100 Ibs Compensated Compensated Steam Flow Steam Flow Pulsed Output Analog Output Figure 5 4 PCC III Instruction Manual rev 2 3 Page 5 14 Section 5 Configuring Blockware Add Purge and Light off Positioning Blockware Figure 5 5is an example of the required Flame Safeguard System FSG interfaces for Boiler Burner Purge and Low fire light off positions Note there are cases when the Low fire light off firing rate is higher than the Burner s lowest attainable or minimum firing rate in operationThe logic we will develop will assure that there is sufficient fuel for Main Fuel Ignition while assuring that the full turndown capabilities of the burner are realized This same logic is also applied to combustion air flow and draft control When the FSG is off
17. Function of Time Generator 13 F X Function of X Generator with Learn Mode 15 L L Lead Lag with Gain Dynamic Compensation 18 SCALE Signal Scaling 19 AB C A B C Multiply Divide 20 WSUM Weighted Sum 21 INV Invert 21 CON Analog Constant 22 FRCON Front Panel Adjustable Constant 22 DEV Deviation Calculation for Bargraph Displays 22 COUNT Pulse Counter 23 SQRT Square Root 24 ABS Absolute Value 24 PID PID Control with GAP and ADAPTIVE gain 24 AOUT Analog 4 20 mA Output 28 TOUT Triac Output 28 TCODE TOUT Fault Code 34 F90 F91 F92 F93 F95 F96 F97 F98 F99 F100 F101 F102 F103 F104 F107 F110 F111 F112 F116 F117 F118 F119 F120 F121 F122 F123 F124 F125 F126 F127 DO Discrete 0 Constant 34 D1 Discrete 1 Constant 34 DIN Discrete Input 35 DCON Discrete Constant 35 S M Service Manual Status 35 PANEL Front Panel Display 36 RDIN RS485 Remote Discrete Input 41 PB Pushbutton 42 LED LED 43 TTRIP TOUT Fault Status 43 HIALM High Alarm 44 LOALM Low Alarm 45 DEVALM Deviation Alarm 46 RATE Rate of Change Alarm 47 LOGIC User Defined Logic 48 XOR Exclusive OR Logic 49 NOT NOT Logic 49 F F Flip Flop Logic 50 TOT Totalizer Integrator with Pulse Output 50 DSW Discrete Switch 51 DAETDR Delay After Energize Time Delay Relay On Delay 52 DADTDR Delay After De energize Time Delay Relay Off Delay 52 INTTDR Interval
18. If the Learn Enable Input 1 and Clear Input 0 Then During the first scan that the Learn Input changes from 0 to 1 the current X and Y Inputs are stored in a Xj Yj parameter pair The rules for selecting the Xj Yj parameter pair are as follows If less than 11 active X Parameters exist ie Xj gt 150 00 Is the current X Input within 2 00 of an existing X Parameter Yes Replace the existing X Y parameter values with the X and Y Inputs This allows you to Edit an existing Y value using Learn Mode No Store the current X and Y Inputs in a new Xj Yj parameter pair such that the X values remain in ascending order ie X1 lt X2 lt X3 lt X4 F X automatically moves all X Y parameter pairs above Xj up one position lf 11 active X Parameters exist Replace the existing breakpoint X Y parameter pair that is closest to the current X value with the current X and Y Inputs The above process only occurs during the first scan that the Learn Input changes from 0 to 1 If Learn 1 for more than one scan the subsequent scans do not Learn any additional values Clearing X Y Data If the Learn Enable Input 1 and Clear Input 1 Then During the first scan that the Learn Input changes from 0 to 1 all eleven Y parameters are set equal to Parameter 24 the Y VALUES AFTER CLEAR parameter All eleven
19. No Operation Dummy Function 58 F83 TOUT Triac Output 28 F84 TCODE TOUT Fault Code 34 Note See the ZP Oxygen Analyzer Instruction Manual for Functions Functions ZAIN AABO and DABO are only included in ROM version 3 0 or higher F4 AABO Analog Auxiliary Block Output F6 ZAIN ZP Oxygen Analyzer Analog Inputs F94 DABO Discrete Auxiliary Block Output Functions TTRIP and TCODE are only included in ROM version 3 04 or higher PCC III Instruction Manual ver 2 3 Page 6 1 Section 6 Blockware Functions Technical Reference Table of Contents Listed in Function Name Order Name Description Page A0 Analog Constant 0 00 4 A100 Analog Constant 100 00 4 AB C A B C Multiply Divide 20 ABS Absolute Value 24 AIN Analog Input 4 AOUT Analog 4 20 mA Output 28 ASW Analog Switch 10 BEFF Boiler Efficiency 7 COMM RS485 Communications Link Control 55 CON Analog Constant 22 COUNT Pulse Counter 23 DO Discrete 0 Constant 34 D1 Discrete 1 Constant 34 DADTDR Delay After De energize Time Delay Relay Off Delay 52 DAE DAD Delay After Energize Delay After De energize Timer 53 DAETDR Delay After Energize Time Delay Relay On Delay 52 DCON Discrete Constant 35 DEV Deviation Calculation for Bargraph Displays 22 DEVALM Deviation Alarm 46 DIN Discrete Input 35 DOUT Discrete Output Open Collector Sinking 58 DSW Discrete Switch 51 DUAL Dual Range Flow Transmitter Select
20. O ActiveLO 0 Disabled 0 Active LO Enabled PCC III Instruction Manual ver 2 3 Page 6 44 Section 6 Blockware Functions Technical Reference FUNCTION 101 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 32 NAME HIALM SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 A PV INPUT 2 A EXT SP INPUT Optional 1 3 D DISABLE INPUT 2 Parameter Description Default Max Min Code Notes 1 SP MODE 1 EXT 2 INT 2 2 1 2 1 2 DEADBAND 0 20 100 00 0 00 1 3 3 INTERNAL SETPOINT 50 00 199 99 199 99 1 1 4 ALARM DISABLE ACTIVE LO HI O LO 1 HI 1 1 0 2 2 5 ALARM DELAY SECONDS 0 600 0 1 4 Notes 1 See Internal vs External Setpoint above 2 See Alarm Disable above 3 See Deadband above 4 See Alarm Time Delay above F102 LOALM Low Alarm LOALM SP 40 DB 10 DELAY 0 100 Function LOALM compares the PV Process Variable Input to the SP Setpoint and changes the Block Output to a 1 when PV lt SP If LOALM is connected to the PANEL Block or directly to an ROUT DOUT or TOUT Block it can trigger audible visual alarms for the Operator LOALM can also be used as a trigger in Blockware to automate a control strategy See figure Deadband or _Hysterisis_ Parameter_2 When Deadband DB 0 0 Output 1 if PV lt SP Output 0 if PV gt SP When Deadband gt 0 Output 1 if PV lt SP and once the Output becomes a 1 it remains a 1 until PV gt SP DB and then it resets to 0 See fi
21. Qx Byyy Pzz followed by the Parameter Name will be displayed along with zz on the Numeric display The Edit Value light will be blinking Use EDIT 4 or EDIT Vv to display the desired Block Number press ENTER The display returns to the menu with Qx PARAM displayed along with the Parameter Number shown on the Numeric display NOTE zz is the Parameter number it is not the value stored in this Parameter location For example Repeats MIN is PID Parameter number 2 while the value stored might be 3 50 BLOCK TIMING This menu item displays the number of microseconds required to execute a particular Block Scroll to BLOCK TIMING press ENTER ENTER BLOCK NUMBER will be displayed Use EDIT 4 or EDIT v to display the desired Block Number press ENTER Bxx followed by the Function Name will be displayed and the Numeric display will show the execution time in microseconds Press ESC to return to the menu CALIBRATE Menu BOARD 0 INPUTS BOARD 1 INPUTS This menu item allows the user to calibrate the Analog Inputs 0 5 Vdc and the BOARD 2 INPUTS Analog Ouputs 4 20 mA All PCC Ill controller Analog Inputs and Analog BOARD 0 OUTPUT 1 Ouputs are factory calibrated per the chart below BOARD 0 OUTPUT 2 BOARD 1 OUTPUT 1 Board Type Input or Output Factory Calibration Tolerence All Input 0 0005 V or 0 013 of 4V All Output 0 003 mA or 0 019 of 16 mA When
22. and the ON timer starts Parameter 1 If the Input is still 1 and the ON timer times out the Output changes to 0 the OFF Input 7 t f 0 5 10 15 20 timer starts and the ON timer resets If the Input is still 1 s nan econds the Output changes to 1 and the cycle repeats until the Input changes to 0 FUNCTION 122 TEMP BYTES 8 RETENTIVE BYTES 0 DATA BYTES 16 NAME REPTDR SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D INPUT Parameter Description Default Max Min Code Notes 1 ON TIME SECONDS 1 19999 1 2 2 OFF TIME SECONDS 1 19999 1 2 3 INVERT OUTPUT O NO 1 YES 0 1 0 2 PCC III Instruction Manual ver 2 3 Page 6 54 Section 6 Blockware Functions Technical Reference F123 COMM RS485 Communications Link Control Function COMM and Function PLINK both provide Communications Link Comm Link status and control the ability of the Comm Link to write modify PCC III Block Outputs and parameters COMM and PLINK are mutually exclusive ie only one of these two functions can be used within a PCC III configuration Neither Block is required if the Comm Link does not have to write modify to any Block Outputs or parameters ie the Comm Link will be read only If the Comm Link only writes to ie modifies Block Outputs but not Block parameters the COMM function may be used If the Comm Link writes to Block parameters the PLINK function must be used COMM has no parameters and thu
23. boo0o0000000000l m00000000000 ie a iE E o 1 3 PREF INSTR DANBURY CT 06810 Neutrals are Isolated ch to ch Neutrals of Selected Channels can be Connected by Installing Jumpers J Option Board Isolated Neutral Jumpers Combination 120 Vac Isolated Discrete Inputs 4 Channels Relay Outputs 8A 1 2 HP 2 Channels TR2 a o R8 29 S x 30 a2 2 g 31 gg 32 oF PREFERRED INSTRUMENTS DANBURY CT 06810 a R6 E J RS v2 L2 4 Fuse for Pair 1 Term 30 amp 31 S Option Board 120 Vac Fuse Triac Output AC Solid State Switch 1 Pairs 2 Triacs n Manual rev 2 3 Page 2 9 Section 2 Installation CPU Board Field Wiring Terminals gt 2 amp O pas O 2 z fo D ka O amp o xe S O a z 2 Q O PCC III Instruction Manual rev 2 3 O DD gt gt gt 4r VUGVVVNO o NO RC lt 4 OURWNMY COONDORWN e lt 3 PO 0000000000000000 N EN lt 17 AIN 1 180 19 AIN 2 200 21 O AIN3 O 25 AINS 26 Q 27 O 24V 28 O 24 V 1 Preferred Instruments Danbury CT PCC III Field Wiring 120 Vac 22 VA 50 60 Hz ROUT 1 120 Vac 8A max A ROUT 2 ISOLATED RS 485 24 Vdc 200 mA SINKING 4 20 mA 800 ohms 50 mA max 0 5 Vde or 4 20 mA JP2 jumpers connect 250 oh
24. eiei aeai 3 Panel Cutout Dimensions ccceeeeeeeeeeneeeenes 3 Wiring Overview essseseeeseseeeseeessreeneeenertnernnrensreesenee 4 120 Vac Ground cccceeecceseeeeeeseteeeesseeeeesseeees 4 Terminal Blocks Wire LY Pe feet viscetiesyecceeestie errire ee et Shielded Cable ccccsccceeseeeeeteeeeeeessneeeesees 24 Vdc amp 5 Vdc Power Supply Load Calculations 5 FEUSCS iss scchpietatassateace dapfiscesesceeedtistanadstitisastastauacsateass 5 250 ohm Resistors for 4 20 mA Inputs eee 5 A Option Board 250 ohm Switches 6 CPU Board Layout ecceeecceeeceeeeeeeeeeeeeseeeeeneeeaes 7 F Option Board 250 ohm Switches 06 8 G Option Board Fuses and Pull ups 8 J Option Board Isolated Neutral Jumpers 9 S Option Board 120 Vac Fuse ceeeeeeeeeees 9 CPU Board Field Wiring Terminals cee 10 Option Board Descriptions Option Board Slot1 or Slot 2 Option Board Field Wiring Terminals 10 Option Board Field Wiring Terminals 11 Two Wire 4 20 mA Input Internal 24 Vdc 12 Two Wire 4 20 mA Input External 24 Vadc 12 Four Wire 4 20 MA Input seeen 12 Isolated 4 20 MA Input ceecee 13 1 6 Vde Inputs in ees 13 O 10 Vde Input sascivises ities a 13 Potentiometer INDUt seerne 14 Potentiometer Input G Board ceeeeeee 14 4 20 MA Outptt
25. ie copy Backup into Primary loads these changes the user must_copy the Primary memory into the Backup memory using the MEMORY COPY PRIMARY TO BACKUP menu item pg 4 16 FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH The user should always refer to a Blockware schematic drawing when attempting to modify any aspect of the Blockware The PCC III Blockware executes continuously including when the EDIT A BLOCK menu is being used Any changes that are made will affect the Blockware as soon as the ENTER key is pressed The Function Type of any Block the Input Softwiring of any Block and the parameters in any Block can be displayed at any time However if the Password system is enabled see pg 4 10 values can only be changed if the correct security password has been entered Section 6 Blockware Functions Technical Reference for the password level required to change each Parameter The Function Type of a Block and the Input Softwiring of a Block can NOT be modified unless the PCC III is in Service Manual mode see pg 4 8 The number of items ie lines in the EDIT A BLOCK menu depends on the Function Type in the Block that is being displayed This menu has up to three groups of line items Function Name one line for each Input and one line for each Parameter However some Functions AIN DIN CON have no softwired Inputs so the Input line items would not exist Other Functions don t have any Parameters HS
26. 0 1 2 Notes T See Alarm Disable above 2 See Alarm Time Delay above F107 LOGIC User Defined Logic Function LOGIC provides user configurable binary logic for up to three discrete Inputs Parameters 3 6 allow negating any Input or the Block Output Parameter 1 selects the logical function used to combine Inputs A and B Parameter 2 selects the logical function used to combine Input C with the result of A and B See figure below If only two Inputs are used Connect Inputs A and B leave Input C connected to the default Block 2 DO and change Parameter 2 to a 2 OR logic Inputs Result for each logical function AND OR NAND NOR PCC III Instruction Manual ver 2 3 Page 6 48 Section 6 Blockware Functions Technical Reference FUNCTION 107 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 36 NAME LOGIC SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D A INPUT 2 D B INPUT 3 D C INPUT Parameter Description Default Max Min Code Notes 1 A B LOGIC 1 AND 2 OR 3 NAND 4 NOR 1 4 1 2 2 AB C LOGIC 1 AND 2 OR 1 2 1 2 3 INVERT INPUT A O NO 1 YES 0 1 0 2 4 INVERT INPUT B O NO 1 YES 0 1 0 2 5 INVERT INPUT C 0 NO 1 YES 0 1 0 2 6 INVERT OUTPUT O NO 1 YES 0 1 0 2 F110 XOR Exclusive OR Logic Result Function XOR calculates the Exclusive OR logical function for two discrete Inputs XOR means If ONLY one Input is True Exclusively Then the Output is True See Truth Table
27. 00 ee eee eee eeeeeeteeeeeeeeeteaeeeeeeeteas 14 120 Vac Discrete Inputs CPU Board 15 120 Vac Discrete Inputs J Board 205 15 Relay Output kis ssri deena ees 16 Discrete Output Sinking Internal 24 Vdc 16 Discrete Output Sinking External 24 Vdc 16 Triac Output Other AC Loads ccceee 17 DC Commons and AC Neutrals Isolation 17 DC Commons and AC Neutrals Isolation 18 Pull Up Down Resistor for Voltage Inputs 19 RS485 Communications WiIring cceeeeeeeeeees 20 RS232 Blockware Download Cable ce 22 Field Installation of Option Boards eeeee 23 Installing Front Panel Legends eesseeeeeeees 24 A AIN 5ch 4 20 mA 0 5 Vdc B IAIN 3ch F AN 3ch Pa AOUT 2ch K TOUT 2 pair AIN 2ch Isolated 4 20 mA 0 5 Vdc 4 20 mA 0 5 Vdc 4 20 mA Triac Outputs 2A 24 120 Vac Pot 0 5 Vdc 4 20 mA 120 Vac Optically lsolated Relay Contact 8 A Inductive mV Optically lsolated Triac Outputs 2A 120 Vac J DN 4ch ea ROUT 2h Z AN 3ch TOUT 1ch Note The Z Option Board is described in the ZP Oxygen Analyzer Manual it is NOT covered by this Manual Option Board Slot 3 Combination Board Combination Board Combination Board ZP Oxygen Analyzer Combination Board S TOUT 1 pair Triac Outputs 2A 24 120 Vac PCC Ill Instruction Manual rev 2 3 Pag
28. 000 0 000 2 19 FUEL B MOLES OF H2O 0 000 5 000 0 000 1 20 FUEL B HEATING VALUE MILLIONS OF BTUS UNIT OF FUEL 0 409 2 500 0 100 2 Notes 1 All analog input signals must be zero based O Input 0 deg F 0 Oxygen 0 ppm CO 0 Btu Input Non zero based signals can be converted with a SCALE F45 Block 2 If the CO signal is not available connect Block 0 A0 to this Input 3 This Input is 0 100 Fuel Btu Input NOT 0 100 of operating range If a burner has an 8 1 turndown this Input should be 12 5 at low fire A SCALE F45 Block can be used to convert a 0 100 operating range to Fuel Input This Input only affects the Radiation ie boiler sheathing losses 4 0 Fuel A 2 Oil by default 1 Fuel B Natural Gas by default 5 Radiation boiler sheathing heat loss is a nearly constant Btu hr rate ie a fixed quantity but not a fixed percentage of Btu Input Enter as a Percentage of maximum firing rate Btu Input Radiation Loss Parm 5 100 Input 5 6 Typical Units of Fuel are Liquid and Solid Fuels Moles 100 lbs Fuel burned Million Btu 100 lbs Fuel burned Gaseous Fuels Moles Mole of Fuel burned Million Btu Mole of Fuel burned 7 Contact Preferred Instruments for Parameter values for other fuels Constants for any fuel can be calculated if the chemical analysis of the fuel is known PCC III Instruction Manual ver 2 3 Page 6 8 Section 6 Blockware Functions Technical Reference F31
29. 000 VOLT SIGNAL TO CHANNELS 1 x THEN PRESS ENTER will be displayed if the 2 5 V calibration was successful Set the Voltage Source to 5 0000 Vdc 0 0005 Vdc Press ENTER filter settling will be displayed for 10 sec to allow the hardware low pass filter capacitors to charge up busy will then be displayed for 15 sec while the 5 0 V calibration is attempted The error message CALIBRATION ABORTED CHANNEL x OUT OF RANGE yyyyyy will be displayed for one of the same reasons describd above Press ESC to return to the menu the original calibration will still be in effect input calibration is complete will be displayed if the 5 0 V calibration was successful Press ESC to return to the menu the new calibration will be in effect Repeat the above procedure for any other Boards that are going to be calibrated Then COPY PRIMARY TO BACKUP see pg 4 16 and then EXIT S M see pg 4 9 Analog Output Calibration Procedure This procedure requires a DC milliamp meter to measure the 4 20 mA output signal to within 0 002 mA This means that the DC milliamp meter must display at least 5 1 2 digits ie 20 001 However not all 5 digit Voltmeters have 0 002 mA accuracy depending on the accuracy specification of the meter a 6 digit meter may be required Most portable test meters and voltage calibrators have 4 digits or less of display resolution Calibrating the PCC III with a less than 5 digit DC milliamp m
30. 150 00 to 150 00 min max values A value of 110 05 would be transmitted via RS485 as 11005 Function F T F41 shows Parameter 3 with 0 0 to 1999 9 min max values A value of 60 0 minutes would be transmitted via RS485 as 600 Indirect Addressing Advanced Users PLINK can modify it s own Parameters to allow a remote Workstation access to ALL of the Parameters in ALL Blocks without configuring the desired PLINK register in advance Example Assign Register 41001 to PLINK Parameter 5 Assign Register 41002 to PLINK Parameter 6 Register 41001 and 41002 can now be used to assign Register 41003 to any Parameter in any Block in the PCC III FUNCTION 124 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 244 NAME PLINK SINGLE USE FUNCTION Y OUTPUT TYPE D Input Type Description Notes 1 D REMOTE LOCAL BLOCK x Parameter Description Default Max Min Code Notes 1 R41001 BLOCK 3 159 3 2 1 2 R41001 PARAMETER 1 70 1 2 3 R41002 BLOCK 3 159 3 2 1 4 R41002 PARAMETER 1 70 1 2 5 R41003 BLOCK 3 159 3 2 1 6 R41003 PARAMETER 1 70 1 2 7 R41004 BLOCK 3 159 3 2 1 8 R41004 PARAMETER 1 70 1 2 9 R41005 BLOCK 3 159 3 2 1 10 R41005 PARAMETER 1 70 1 2 11 R41006 BLOCK 3 159 3 2 1 12 R41006 PARAMETER 1 70 1 2 13 R41007 BLOCK 3 159 3 2 1 14 R41007 PARAMETER 1 70 1 2 15 R41008 BLOCK 3 159 3 2 1 16 R41008 PARAMETER 1 70 1 2 17 R41009 BLOCK 3 159 3 2 1 18 R41009 PARAMETER 1 70 1 2 19 R41010 BLOCK 3 159 3 2 1 20 R41010 PARAMETER 1 70 1 2 21 R410011 BLOCK 3 159 3 2
31. 4 mA or a 20 4 mA output 0 20 mA The AOUT milliamp output is proportional over the entire 25 to 125 Input range ie 0 24 mA and the D A converter has 16 bit resolution ie 0 0004 mA The AOUT Block Output is equal to the AOUT Block Input unless the Block Output is Forced or under Service Manual S M control see Section 4 When Forced the AOUT Block Output is equal to the percentage that the user entered when the Block was forced The 4 20 mA output is based on the Force Value and the Reverse Output parameter Example AOUT is forced to 25 and Reversed Output is set to 0 or 4 20 mA then the actual mA output would be 8 mA If Reversed Output is set to 1 or 20 4 mA then the actual mA output would be 16 mA when forced to 25 During Service Manual S M mode the Block Input is ignored and the user sets the hardware mA output directly from the Front Panel see Section 4 During S M the AOUT Block output will be the percentage that is equivalent to the mA output If Reverse Output is 1 the percentage will be scaled accordingly Example S M set output to 8 mA and Reverse Output is 0 4 20 then Block Ouput will be 25 If Reverse Output was 1 20 4 then the Block Ouput would be 75 The AOUT function interfaces to Analog Outputs on the CPU board and on option boards Parameter 1 specifies the board location the CPU board Board 0 Parameter 2 selects a par
32. 5 Vdc B IAIN 3ch Isolated 4 20 mA 0 5 Vdc F AIN 3ch 4 20 mA 0 5 Vdc AOUT 2ch 4 20 mA Combination Board G TOUT 2 pair Triac Outputs 2A 24 120 Vac AIN 2ch Pot 0 5 Vdc 4 20 mA Combination Board J DIN 4ch 120 Vac Optically lsolated ROUT 2ch Relay Contact 8 A Inductive Combination Board Z ZrO2 Oxygen Analyzer Amplifier and Temperature Controller R Redundant RS 485 Communications Optically isolated Slot 1 only Option Card Slot Number 2 a Select card type from the Slot 1 list above Option Card Slot Number 3 0 none S TOUT 1 pair Triac Outputs 2A 24 120 Vac Option Board Input Output Expansion Examples PCC II Model Number 8A 2A 200 mA relay triac pairs sinking Total ROUT TOUT DOUT 1 0 0 4 18 0 4 28 0 4 28 0 4 30 5 4 27 3 4 28 0 4 29 Note The examples given in no way reflect the number of possible option card possibilities The PCC III has a total of three 3 option card slots of which one is designated for use by the S card only The remaining two slots can house any of the remaining option cards in any desired combination Please referSection 5to establish the total 24 VDC power supply requirements as some combinations may require installation of an auxiliary power supply PCC III Instruction Manual rev 2 3 Page 1 7 Section 1 Product Overview Preferred Instruments PCC III Controller Spare Parts List
33. 9 F104 RATE Rate of Change Alarm 47 F35 H LLIM High Low Signal Limiter 10 F107 LOGIC User Defined Logic 48 F36 RLIM Rate Limiter 10 F110 XOR Exclusive OR Logic 49 F38 FPT H Front Panel Adjustable Track Hold F111 NOT NOT Logic 49 11 F112 F F Flip Flop Logic 50 F41 F T Function of Time Generator 13 F116 TOT Totalizer Integrator with Pulse F42 F X Function of X Generator with Learn Output 50 Mode 15 F117 DSW Discrete Switch 51 F43 L L Lead Lag with Gain Dynamic F118 DAETDR Delay After Energize Time Delay Compensation 18 Relay On Delay 52 F45 SCALE Signal Scaling 19 F119 DADTDR Delay After De energize Time F51 AB C A B C Multiply Divide 20 Delay Relay Off Delay 52 F52 WSUM Weighted Sum 21 F120 INTTDR Interval Time Delay Relay Non F53 INV Invert 21 Retriggerable One Shot 53 F54 CON Analog Constant 22 F121 DAE DAD Delay After Energize Delay F55 FPCON Front Panel Adjustable Constant After De energize Timer 53 22 F122 REPTDR Repeat Time Delay Relay 54 F56 DEV Deviation Calculation for Bargraph F123 COMM RS485 Communications Link Displays 22 Control 55 F58 COUNT Pulse Counter 23 F124 PLINK Block Parameter Links for F59 SQRT Square Root 24 Communications 55 F60 ABS Absolute Value 24 F125 ROUT Relay Output 57 F71 PID PID Control with GAP and F126 DOUT Discrete Output Open Collector ADAPTIVE gain 24 Sinking 58 F81 AOUT Analog 4 20 mA Output 28 F127 NOP
34. A default Parameters below are for 6 fuel oil Fuel B defaults are for Natural Gas Contact Preferred Instruments for Parameter values for other fuels FUNCTION 22 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 128 NAME BEFF SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A EXIT TEMPERATURE INPUT 1 2 A AMBIENT TEMP INPUT 1 2 3 A OXYGEN INPUT 1 4 A PPM CO INPUT 1 3 5 A FIRING RATE INPUT 1 6 D FUEL SELECT INPUT 0 FUEL A 1 FUEL B 4 Parameter Description Default Max Min Code Notes 1 02 FULL SCALE 10 00 25 00 10 00 2 2 PPM CO FULL SCALE 1000 5000 1000 2 3 EXIT TEMPERATURE FULL SCALE 1000 2000 300 2 4 AMBIENT TEMPERATURE FULL SCALE 100 1000 100 2 5 LOSS DUE TO RADIATION AT 100 FIRING RATE 0 75 5 00 0 00 2 5 6 LOSS DUE TO MISC FIXED LOSSES 1 00 5 00 0 00 1 Fuel A Components Moles Unit of Fuel Burned Default 6 Oil 6 7 FUEL A MOLES OF C 7 377 12 000 0 000 2 8 FUEL A MOLES OF H2 3 175 6 000 0 000 2 9 FUEL A MOLES OF S 0 027 6 000 0 000 2 10 FUEL A MOLES OF N2 0 011 2 000 0 000 2 11 FUEL A MOLES OF 02 0 022 2 000 0 000 2 12 FUEL A MOLES OF H20 0 011 5 000 0 000 1 13 FUEL A HEATING VALUE MILLIONS OF BTUS UNIT OF FUEL 1 812 2 500 0 100 2 Fuel B Components Moles Unit of Fuel Burned Default Nat Gas 6 14 FUEL B MOLES OF C 1 050 12 000 0 000 2 15 FUEL B MOLES OF H2 2 000 6 000 0 000 2 16 FUEL B MOLES OF S 0 000 6 000 0 000 2 17 FUEL B MOLES OF N2 0 050 2 000 0 000 2 18 FUEL B MOLES OF 02 0 000 2
35. B 60 59 37 n 26 Low Alarm Hi Alarm g ae Day PV Vv S Setpoint T PID SP ASW FPCON gt a lt TS T1 A E t ae PM B150 B40 Local PID B PE LED ASW 1 1 S A Invert 4 35 85 125 On Local s On Manual Auto Man FSG DIN FPT H LED PB Modulate Ch 1 H 2 2 Invert lt 40 143 86 56 Light off Position oe CON A ASW s asw eE B z Po B1 100 S DIN TOUT Firing Ch lt 3 Rate B120 4 20 42 ETE FSG Purge Figure 5 7 PCC III Instruction Manual rev 2 3 Page 5 17 Section 6 Blockware Functions Technical Reference Table of Contents Code Description Page Code Description Page Table of Contents Listed in Function Name Order 2 F90 DO Discrete 0 Constant 34 FO A0 Analog Constant 0 00 4 F91 D1 Discrete 1 Constant 34 F1 A100 Analog Constant 100 00 4 F92 DIN Discrete Input 35 F2 AIN Analog Input 4 F93 DCON Discrete Constant 35 F5 RAIN RS485 Remote Analog Input 5 F95 S M Service Manual Status 35 F11 DUAL Dual Range Flow Transmitter F96 PANEL Front Panel Display 35 Selector Scaler 6 F97 RDIN RS485 Remote Discrete Input 41 F20 OPLR Optical Path Length Ratio F98 PB Pushbutton 42 Correlation for Opacity Monitors 7 F99 LED LED 43 F22 BEFF Boiler Efficiency 7 F100 TTRIP TOUT Fault Status 43 F31 HSEL High Select 9 F101 HIALM High Alarm 44 F32 LSEL Low Select 9 F102 LOALM Low Alarm 45 F33 MSEL Median Selector 9 F103 DEVALM Deviation Alarm 46 F34 ASW Analog Switch
36. Block 5 from a NOP to an AIN Function Type Put the PCC III in the EDIT mode EDIT until you see ENTER S M in the bottom alpha numeric display then press ENTER two 2 times This puts all the Outputs into the Service Manual mode Note the PCC III requires that the controller be in Service Manual for some calibration and configuration tasks When configuring on line while in Service Manual you do not have to worry about the process jumping up or down during configuration However the process may need to be adjusted while in this manual condition EDIT to EDIT A BLOCK Press ENTER The previous Block edited is displayed in the top numeric display EDIT or until Block 5 appears on the numeric display Press ENTER The Alphanumeric LED should be flashing and the display will read BO5 NOP The numeric display should read Function 127 Press ENTER to access the numeric display top LED will flash EDIT until you reach Function 2 Lower display will read B05 AIN Press ENTER Refer to Section 6 and look at Function 2 AIN Softwire the Block Inputs This particular Function type AIN does not have any Blockware Inputs therefore no Softwiring is required See Block 26 below for the first example of Softwiring an Input Modify Parameters as required There are seven parameters that can be configured In many cases the default value that was loaded by
37. COPY PRIMARY TO BACKUP power down remove the Backup memory chip and install it in the second unit with power OFF COPY BACKUP TO PRIMARY and then start debugging and testing the second unit This saves time and can be accomplished without any special equipment COPY PRIMARY TO BACKUP This menu item copies the entire contents of the Primary memory into the Backup Memory This includes all Blockware Calibration COM PORT and Retentive Memory data Remove the Front Panel and move the Backup Memory Write Protect Jumper to the R W position see pg 2 7 Scroll to COPY PRIMARY TO BACKUP Press ENTER Press ENTER to save primary is displayed Press ENTER to proceed or ESC to return to the menu If ENTER was pressed busy will be displayed for several seconds followed by backup complete Press ESC to return to the menu and move the Backup Memory Write Protect Jumper to the WP position Re install the Front Panel The error message ERROR UNABLE TO UPDATE BACKUP will be displayed if the Write Protect Jumper is in the wrong position or the Backup memory is not properly inserted into the socket COPY BACKUP TO PRIMARY This menu item copies the Blockware and COM PORT data from the Backup into the Primary memory Calibration Retentive and Password data is NOT copied into the Primary because it is hardware specific and the Backup chip could contain Calibration data from a different set of hardware The
38. Continuous Normal OFF ON 95 Forced Block s OFF Blinks OFF once every second see Section 4 ON Blinks ON twice every second OFF 85 Service Manual ON OFF Continuous Not Operating Note S M Mode RUN light indication takes priority over FORCED Mode indication when both S M and FORCED Modes are active PV Bargraph Item 1 in fig 1 Typically bargraph provides a graphical display of the Process Variable PV over a range of from 0 100 Process Variable is control system slang for that specific system condition that the PCC III is trying to control Put another way if the PCC III is modulating a steam valve in order to control the burner fuel oil temperature then the oil temperature is the PV that is Process Variable If the PCC III is a boiler feedwater controller the boiler drum water level is the PV However the Blockware Designer is free to use this bargraph to display any other variable The bargraph has 50 segments individual lights plus one zero light therefore each segment represents 2 of the range of the signal being displayed SP Bargraph Item 2 in fig 1 Typically this bargraph provides a graphical display of the Setpoint SP over a range of from 0 100 Setpoint is control system slang for that specific value at which the PCC III should maintain the Process Variable PCC III Instruction Manual rev 2 3 Page 3 3 Section 3 Operation Put another way if the PCC III is
39. Controller Model Numbet 5 7 Option Board Input Output Expansion Examples 7 Spare Parts LiSt scscco cscayee irrar oversees 8 PCC III Specifications cccccceesseeeeeeee ceeeeeeeneeees 9 Mechanical 2 cs cct ate avai dee 9 Environmental speia er ananpi 9 Performan Cei ae ack ea at 9 Operator Control Panel cceeesceeeeeseeeeees 9 Electrical eein e E at 9 Input Output Standard no option cards 9 COMMUNICATIONS s sies ea 9 Option Board Field Wiring Terminals 008 10 Option Board Field Wiring Terminals 00 11 Two Wire 4 20 mA Input Internal 24 Vdc 12 Two Wire 4 20 mA Input External 24 Vdc 12 Four Wire 4 20 MA Input seeen 12 Isolated 4 20 MA INDUt eee eeeeeeeesteeeeneeeeee 13 125 VdeMNput tee eeaten leaking 0 1 0 Vde INpUt inssin Potentiometer Input Potentiometer Input Q Board c cee 14 4 20 MA Output oo ee eee ete eeeteeeteteeteeeeeneetaaee 14 120 Vac Discrete Inputs CPU Board 15 120 Vac Discrete Inputs J Board 00 15 Relay Outputiccets seecennte siete cee ieee 16 Discrete Output Sinking Internal 24 Vdc 16 Discrete Output Sinking External 24 Vdc 16 Triac Output Other AC Loads c eeeee 17 DC Commons and AC Neutrals Isolation 17 DC Commons and AC Neutrals Isolation 18 Pull Up Down Resistor for Voltage
40. ENTER THE 12 Blink you could scroll to a different Block number BLOCK NUMBER at this point ESC EDIT A BLOCK ESC DRUM PSI 149 EDIT light turns OFF Process mode displays re activate After tuning is complete COPY PRIMARY TO BACKUP PCC III Instruction Manual rev 2 3 Page 4 5 Section 4 EDIT Menus EDIT Menus Diagram MAIN Menu QUICK MENU ENTER S M or EXIT S M PASSWORD MENU EDIT A BLOCK MEMORY MENU UTILITIES MENU CALIBRATE O COM MENU PCC III Instruction Manual rev 2 3 QUICK Menu LAST PARAMETER QUICK 1 QUICK 2 QUICK 8 SERVICE MANUAL Menu ALL S M AO b0c1 AUTO or S M AO b0c2 AUTO or S M AO b1c1 AUTO or S M TO b1c1 AUTO or S M TO b2c1 AUTO or S M PASSWORD Menu ENTER PASSWORD SECURE CONTROLLER TIMEOUT CHANGE OPERATOR PASSWORD CHANGE TECHNICIAN PASSWORD EDIT A BLOCK Menu ENTER THE BLOCK NUMBER Bxx FUNCTION TYPE Bxx 101 description Bxx 102 description Bxx P01 description Bxx P02 description MEMORY Menu mim CALIBRATE Menu BOARD 0 INPUTS BOARD 1 INPUTS BOARD 2 INPUTS BOARD 0 OUTPUT 1 BOARD 0 OUTPUT 2 BOARD 1 OUTPUT 1 COPY PRIMARY TO BACKUP COPY BACKUP TO PRIMARY ERASE PRIMARY COMPARE MEMORIES REMAINING MEMORY REPORT CONFIG NAME EPROM VER UTILITIES Menu EXAMINE BLOCK FIND FUNCTION FIND USAGE FORCE BLOCK UN FORCE A BLO
41. HSEL High Select Function HSEL selects the greater of the three Inputs and copies that value to its Block Output If there are only two Inputs connect either one of the two active Input Block numbers to the third Input FUNCTION 31 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME HSEL SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A A INPUT 2 A B INPUT 3 A C INPUT No Parameters F32 LSEL Low Select Function LSEL selects the lowest i e smaller of the three Inputs and copies that value to it s Block Output If there are the only two Inputs connect either one of the two active Input Block numbers to the third Input FUNCTION 32 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME LSEL SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A A INPUT 2 A B INPUT 3 A C INPUT No Parameters F33 MSEL Median Selector Function MSEL selects the median ie middle of the three Inputs and copies that value to it s Block Output Examples Block Output If this function is configured with only two active Inputs the third Input will be the default Block 0 A0 In this case the Median selection would compare the two active Inputs to 0 FUNCTION 33 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME MSEL SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A A INPUT 2 A B INPUT 3 A C INPUT No Parameters F34 ASW Analog Switch Fun
42. Note Blown fuse 1 Any motor wire open circuit Motor winding burned out Motor limit switch opened within 5 95 Scaled Position Note 1 Check Scaled Positon calibration 4 Actuator moving Slower than Binding linkage damper or valve Same as Fail Closed 40 speed for more than P9 Low AC line voltage seconds Note 1 Stroke Time P6 set too low Note 1 TTRIP will NOT Fault due to Actuator Stopped or Actuator Slow if any of the following are true The TOUT channel is in S M mode Scaled Position is less than 5 or greater than 105 The Decrease Triac is ON and the Scaled Position is less than 5 The Increase Triac is ON and the Scaled Position is greater than 95 The last two prevent nuisance Faults due to inaccurate travel limit switch operation PCC III Instruction Manual ver 2 3 Page 6 31 Section 6 Blockware Functions Technical Reference All actuators that use Fault Detection require a pull up resistor 330k or less that is connected from the Feedback Pot wiper to 5V and it should be located inside the PCC III controller Review Pull Up Down Resistor for Voltage Inputs in Section 2 If the pot wiper circuit field wiring goes open circuit or if the wiper loses contact with the pot element due to wear or dirt the PCC III analog input will ramp to 5V within 3 seconds or less The PCC III G option board includes an internal 330k pull up resistor for each analog input The CPU A B and F
43. O expansion capabilities and the significant number of choices available for expansion that render the PCC IIl an unparalleled choice for any control application Consider that each PCC III CPU board has two expansion board slots each of which is able to harbor any of the available option cards Note a third spot is available but is dedicated for use with only one type of option card Consider further that there are option cards which can e Control the temperature of Oxygen Sensors and convert their millivolt outputs to signals useful for control and or monitoring applications e Accept as inputs or output analog signals in per option card combinations ranging from 5Al to 3AI 2AO to 4A0O to 2 Isolated Al e Accept as inputs or output discrete signals in per option card combinations ranging from 8DI to 4DI 2RO to 4RO e As noted the ability to install the PCC III CPU board alone i e less front panel DCS Ill with or without any of the combination boards mentioned above further enhancing Data Acquisition and control capabilities So as you read this manual be sure that you are clear about the vast capabilities of the PCC IIl It is simply not just another digital controller Section 1 PRODUCT OVERVIEW Table of Contents Product Description eee eeeseeeseteeeteeeteeeeeeteesteneeeee 2 Gas Flow Pressure Temperature F atuieS wis sit E A E E ETET 2 Compensation eeeeseeeeeeeeeeteeeeeeeeeeeteteseeeeeeeeeeees 5
44. Output can be changed with the front panel UP DOWN ye Hold Xfer Limiting Time arrows After the Operator completes the change the Block Output will remain at the last value until the next Operator change or until the Block goes into Track mode The FPT H Block must be configured as an Input to the PANEL Block in order to allow changes from the front panel In Hold mode the RS485 communications link can change the Block output by writing a new value to the Block Output see Section 7 PCC III Instruction Manual ver 2 3 Page 6 11 Section 6 Blockware Functions Technical Reference Mode Selection The Track Hold mode is normally determined by the Hold Select Input 0 Track mode 1 Hold mode However the optional Track Override Inputs can override the Hold Select Input If either Track Override Input is set to a discrete 1 the Hold Select Input is ignored and the Block is forced into the Track mode see below If no Blocks are connected to these Inputs the default Block 2 Discrete 0 Inputs disable the override feature TRACK OVERRIDE 2 TRACK OVERRIDE 1 Transfer Rate Limiting is OFF when Parameter 3 Transfer Rate Limit equals 100 sec and the transfer from Hold mode to Track Mode is instantaneous That is the Block Output is set equal to the Signal Input during the first scan of the mode change Remote Hot Water Transfer Rate Limiting is ON when the Transfer Rate Limit R
45. PCC III will not COPY BACKUP TO PRIMARY unless ALL of the 4 20 mA and Triac Output channels are in Service Manual mode see pg 4 9 WARNING The PCC IIl is commonly used to control potentially dangerous Combustion and Chemical Processes VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE PUTTING THE PCC II CONTROLLER INTO SERVICE MANUAL MODE FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH WHEN A PCC III OUTPUT IS IN THE SERVICE MANUAL MODE ALL BLOCKWARE IMPLEMENTED SAFETY LOGIC IS BYPASSED THE OPERATOR HAS TOTAL RESPONSIBILITY TO INSURE THAT ALL EQUIPMENT IS OPERATED SAFELY THIS OPERATION COMPLETELY OVERWRITES THE EXISTING BLOCKWARE LOGIC IN LESS THAN 1 10 SECOND AND WILL CAUSE RELAY AND SINKING DISCRETE OUTPUTS TO CHANGE STATE UNPREDICTABLY Scroll to COPY BACKUP TO PRIMARY Press ENTER Press ENTER to restore primary is displayed Press ENTER to proceed or ESC to return to the menu If ENTER was pressed busy will be displayed for several seconds followed by primary restored Press ESC to return to the menu The error message ERROR ALL OUTPUTS MUST BE IN S M will be displayed if this menu item is selected before putting all Outputs into S M mode Press ESC to return to the menu PCC III Instruction Manual rev 2 3 Page 4 16 Section 4 EDIT Menus The error message ERROR BAD BACKUP CHECKSUM will be di
46. PRIMARY ccsseeeseeees 16 EDIT Bight sei 8 ata cietesdshetitacte ies sath teak 3 ERASE PRIMARY aaraa ens 17 ESC EDIT Ke yen Rice e en ete Rie ee 3 COMPARE MEMORIES cccesceceseeeeseeeessneeens 17 Edit Value and Scroll Menu Lights cce 3 REMAINING MEMORY REPORT c0 ceeeees 17 EDIT A and EDIT W FOYS ennan 4 CONFIG NAME cccccccccssccessccssseess cesseesseeenseeens 17 EDIT A and EDIT Y Rate of Change e 4 EPROM VER 2 2 220 nto ede niat iin 17 ENTER key amen ni aA edna N 4 UTILITIES SUB MENU cecsesessesessesssseeessnessseess 18 EDIT Menu Scrolling Example ccscseseeeeee 5 EXAMINE vscvtsecscctesssis avesiseutveevearsecasdian tosnetis 18 EDIT Menus Diagram 0 c cccceseseseseeseseeesseseeeneeseeees 6 EXAMINE Block Outputs eee 18 MAA INS riUis ctsc ac iteertictcroestauss Sesiscnaeettactceswracteet 7 EXAMINE the Input Signals of a Block 18 QUICK Menu innein e aR 7 FIND FUNCTION ssssesssessesessesseestsanestnenesnnenens 18 LAST PARAMETER cccccccccccccccceccccccecececeececeeceeee 7 FIND USAGE wai ii eee 19 SERVICE MANUAL Menu ccccccccsececceeeceeceseeceeees 7 Forcing Block Outputs ccsccceseseeeeeeceeeneees 19 What is Service Manual S M Mode c0000 7 RUN light indicates Normal Forced or S M Mode RUN light indicates Normal Forced or S M Mode 8 wvsesssssesesseseesseessessesteeeeseeneesenee
47. Pi Fuse Supplies 10 16 27 mee 24 Vdc 215 mA 2U 2L 3L Signal Common for Ground O 12 14 18 are AIN ch 0 1 gt 0 5 Z No _ 22 24 26 AOUT ch 0 1 amp 0 2 Case Ground Connection Power Common X for DOUT ch 1 gt 4 to Option Cards 1 amp 2 Terminal Numbers Grounds Neutrals and DC Commons Schematic Pull Up Down Resistor for Voltage Inputs This Sub Section does NOT apply to 4 20 mA Inputs that is Inputs with the 250 ohm Resistor connected The 250 ohm resistor is never connected for 1 5 V 0 5 V 0 10 V and Potentiometer Inputs Typical Internal Circuitry for Analog Inputs 8 5 vac R1 lt Field x eek 0 5 Vdc Terminals JP2 x to A D es qJumper 68 uF 250 0 ORs o sc 0 6 Hz Filter Signal Common 63 db 60 Hz Each Analog Input has a low pass noise filter with high quality low leakage capacitors for 60 Hz noise rejection If the field wiring breaks a pot wiper gets dirty or is otherwise disconnected the A D Input Voltage will remain at the last value for several hours due to the capacitors in the filter In many applications it is desirable for the Input to fail to either OV or 5V after the Input becomes disconnected PCC III Instruction Manual rev 2 3 Page 2 19 Section 2 Installation A Pull Up Resistor R1 will force the Input to 5V after a wire break A Pull Down Resistor R2 will force the Input to OV
48. Pulse Counter Function COUNT adds 0 01 to the Block Output during the first scan that the Pulse Input changes from a 0 toa 1 ie on the rising edge assuming Parameter 1 the Pulse Divisor 1 If the Pulse Divisor 5 then 5 pulse rising edges will have to be received before the Output is incremented by 0 01 The Block Output rolls over from 99 99 to 0 00 after 10 000 pulses The Block output is forced to 0 00 when the Reset Input equals 1 A typical application would be to count flow totalizer pulses and then connect the COUNT Block Output to a PANEL Front Panel Display channel See TOT on pg 6 50 At power down the Block Output is saved in the Retentive Memory area of the EEPROM During the first scan after CPU start up the COUNT Block Output is set to the value stored in the Retentive Memory FUNCTION 58 TEMP BYTES 8 RETENTIVE BYTES 4 DATA BYTES 12 NAME COUNT SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 D PULSE INPUT 41 COUNT 1 2 D RESET INPUT 1 RESET Parameter Description Default Max Min Code Notes 1 PULSE DIVISOR 1 19999 1 2 Notes 1 Increments Output on the rising edge of the Input ie the first scan when Input becomes a 1 PCC III Instruction Manual ver 2 3 Page 6 23 Section 6 Blockware Functions Technical Reference F59 SQRT Square Root Function SQRT provides a 0 100 scaled square root of a 0 100 Input signal Negative Inputs result in a 0 00 Block Output Inputs u
49. Signal Common Terminals shown are for Al ch 0 3 Page 2 12 im 120 Vac or 24 Vdc Xmtr Power Input 4 20 mA Four Wire Xmitr Section 2 Installation Isolated 4 20 mA Input B Option Board Only This example shows Analog Input 2 on a B Option Board that is plugged into Slot 2 Turn ON switch 1 2 to connect the internal 250 0 ohm resistor The of each channel is isolated from all other channels and from the CPU Signal Common The External Power Supply and the B Board for this channel must be connected The shield connects to the External Power Supply 1 5 Vdc Input Typical for CPU A and F boards This example shows Analog Input 4 on the CPU Board Remove JP 2 4 to disconnect the internal 250 0 ohm resistor The 5 Mohms input impedance of each channel allows over 15 PCC IIIs to be connected to the same 1 5 V signal See Pull Up Down Resistors in this Section The External Power Supply and the PCC III Signal Common must be connected The shield connects to the External Power Supply 0 10 Vdc Input Typical for CPU A and F boards This example shows Analog Input 5 on the CPU Board Remove JP 2 5 to disconnect the internal 250 0 ohm resistor The two external precision resistors reduce the signal by exactly 50 Set the AIN Block for a 0 5V range instead of the default 1 5V ran
50. Time Delay Relay Non Retriggerable One Shot 53 DAE DAD Delay After Energize Delay After De energize Timer 53 REPTDR Repeat Time Delay Relay 54 COMM RS485 Communications Link Control 55 PLINK Block Parameter Links for Communications 55 ROUT Relay Output 57 DOUT Discrete Output Open Collector Sinking 58 NOP No Operation Dummy Function 58 INTRODUCTION The PCC IIl represents the next generation of digital controllers in that it maintains all of the advantages of single or multiple loop controllers while addressing many of the features of PLCs and DCS I O modules The substantially shorter mounting depth will fit in 8 deep panels NEMA 13 splashproof front panel standard RS 485 communications facility Modbus protocol and RS 232 laptop as well as front panel configuration capabilities are certainly readily apparent differences between itself its predecessor the PCC II and its competitors In addition we have retained and in fact enhanced many of the features that customers have come to appreciate about our digital controllers Service Manual Learn function Boiler Efficiency function OPLR Stack Exit Correlation for Opacity Monitors function new Oxygen Sensor Temperature Controller and O2 signal conversion option card new But It is the flexibility of the PCC III not simply as measured by its ability to function without its front panel but more importantly its I
51. V Rate of Change Ba deen ie 4 EPROM VER ea ate Seewec sensed hee iecuazee 17 ENTER K6y cie ne oie eto cnet EFi 4 UTILITIES SUB MENU se eseetee sees eeeeseeseeneenn 18 EDIT Menu Scrolling Example TESTLAR ELA 5 EXAMINE iaten etio iaiia 18 EDIT Menus Diagram 6 EXAMINE Block Outputs eee 18 MAIN Menu 2 ta ele a lnc alec tanta Datta 7 EXAMINE the Input Signals of a Block 18 QUICK Ment 2 020247 ciel et wt 7 FIND FUNCTION 0 0 ee eet eee teteee 18 LAST PARAMETER ooccccccececcccctcescececsecetcesececeeceteess 7 FIND USAGE e 2c2e een rete Siete 19 SERVICE MANUAL MenU ccscccscsssseeesseeseseesens 7 Forcing Block Outputs seceeeeeeeeeeeeeeeneees 19 What is Service Manual S M Mode s0 7 RUN light indicates Normal Forced or S M Mode RUN light indicates Normal Forced or SIM Mode 8 vessssssssssertttesee net nesttneneneneeee ete neneneneitnneneenaaeae 19 ENTER S M in MAIN Menu 8 FORCE BLOCK ceecceeeeeecceeeenneeeeeeneeeeenneeeeeaas 19 ALE SIM elo oie etl oe Seca orto et oe co Sd 9 UN FORCE A BLOCK eect eetesesssseetseenennens 20 EXIT S M in MAIN Menu ccccccceeeseeteneees 9 UN FORCE ALL BLOCKS se teeseteeieeeee 20 Changing an Output Value in S M Mode 9 DISPLAY SCAN TIME cccccccceeseeeeseeeeeeeeeees 20 PASSWORD MeMU scscscecscsesesesesetscseseseseeteesesees 10 EDIT QUICK MENU eens 20 Password Levels crc Mceh cate as Ate 10 Entering a Mess
52. a secondary variable using an F x Block see Error SP PV notes 3 and 12 FUNCTION 71 TEMP BYTES 44 RETENTIVE BYTES 0 DATA BYTES 108 NAME PID SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A PV INPUT 2 A SP INPUT 3 A TRACK SIGNAL INPUT 1 4 A FEED FORWARD INPUT 2 5 A ADAPTIVE GAIN INPUT 3 6 D TRACK MODE 1 INPUT 1 TRACK 4 7 D TRACK MODE 2 INPUT 1 TRACK 4 8 D TRACK MODE 3 INPUT 1 TRACK 4 9 D OVERRIDE MODE INPUT 1 OVERRIDE 4 Parameter Description Default Max Min Code Notes 1 GAIN 10 00 100 00 0 10 2 2 INTEGRAL REPEATS MIN O OFF 1 00 60 00 0 00 2 8 3 DERIVATIVE MINUTES 0 OFF 0 00 30 00 0 00 2 4 SETPOINT FILTER O OFF 1 00 MAX 0 00 1 00 0 00 2 6 5 MAX OUTPUT 100 00 150 00 0 00 2 7 8 6 MIN OUTPUT 0 00 50 00 50 00 2 7 8 7 CONTROL ACTION O REV 1 DIR 0 1 0 3 10 8 DERIVATIVE ACTION 0 PV 1 ERROR 0 1 0 3 11 9 PID TYPE 1 PID 2 GPID 3 APID 1 3 1 3 3 12 10 GAP BAND OF PV 0 25 50 00 0 05 2 12 11 GAP GAIN MULTIPLIER 0 00 1 00 0 00 2 12 12 OUTPUT BIAS 0 00 100 00 100 00 2 8 9 PCC III Instruction Manual Section 6 Page 6 26 Blockware Functions Technical Reference NOTES 1 2 10 11 12 The Track Input signal is used during Track or Override modes to force the value of the PID Integral term This Input is used to provide bumpless transfer See above for details The Feed Forward Input is added to the result of the PID calculation before the Output Min Max limiting logic This pre
53. adjustment range EDIT to Block 25 Press ENTER Using the skills you developed above in Block 5 make Block 25 a FPCON Block Function 55 Refer to Section 6 for details on the purpose of each Input and Parameter There are two parameters to setup Configure P01 as 50 00 min output Configure P02 as 50 00 max output PCC III Instruction Manual rev 2 3 Page 5 10 Section 5 Configuring Blockware Block 26 WSUM We want to apply the positive or negative Submaster Bias to the Plant Master signal We will setup the WSUM Function 52 as A B with Input A as the Plant Master signal and Input B as the Bias signal EDIT to Block 26 Press ENTER Make Block 26 a WSUM Function Function 52 There are three Inputs and 4 parameters to setup Configure 101 A to be from B5 Configure 102 B to be from B25 Configure 103 C to be from BO no Input Configure P01 2 amp 3 as 1 00 Configure P04 as 0 00 Block 55 PB We need to add a pushbutton to select Local PID or Plant Master control EDIT to Block 55 Press ENTER Make Block 55 a PB Function Function 98 There are three parameters to setup Configure P01 as 1 This is the top left pushbutton Configure P02 as 3 This is a toggle button Configure P03 as 3 We want the button to power up in its last mode of operation Block 59 HIALM We will assume the Plant Master has a high and low header pressure alarm We want high
54. applies to Industrial Control Panel wiring 120 Vac Ground Connect the incoming AC Power Ground ie Green Wire Ground to the screw and lug marked GROUND inside the rear of the case near the bottom of the terminal strips AC Ground is not connected to DC Common See DC Commons and AC Neutrals on page 2 18 Terminal Blocks A See Field Wiring Label on pg 2 10 All Field Wiring terminals are separable and plug in to the PC board This allows rapid board level replacement without disconnecting individual field wires Verify that Terminals are inserted properly before applying power The AC terminals on the CPU board are numbered 1L to 8L and 1U to 8U The terminals are arranged in two rows of eight L refers to the Lower row while U refers to the Upper row Terminals 1L to 8L 1U to 8U and 29 to 33 accept 24 12 ga wire and should be tightened to 4 5 in lb Terminals 1 to 28 and 40 to 51 accept 22 14 ga wire and should be tightened to 2 2 in lb Wire Type All wiring AC DC and shielded cable should be copper stranded 150 V min and 60 C minimum Shielded Cable All 4 20 mA 0 5 Vdc Input and Output wiring should be 22 gauge minimum 85 shield min and have twisted pairs Belden 8737 or equal 100 foil shielding is preferable if available The shields of all 4 20 mA 0 5 Vdc cables should be connected at one end only as shown on the drawings that follow Generally the shield is conne
55. as part number 190347 if the mounting brackets supplied with the PCC Ill are lost or damaged PCC III Instruction Manual rev 2 3 Page 2 2 Section 2 Installation Flange 3 4 conduit K O 11 8 hex socket Gasket Gasket g Ja D 3 8 4 Conduit K O Z i 1 2 Conduit K O i 7 75 PCC Ill Dimensions inches f 1 75 63 min e min A Q ite N 3 13 y Y Panel Cutout Dimensions and Minimum Spacings inches PCC III Instruction Manual rev 2 3 Page 2 3 Removable Rear Cover Field Wiring Terminal Blocks Located Section2 Installation Wiring Overview WARNING The PCC III is commonly used to control potentially dangerous Combustion and Chemical Processes VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE REMOVING POWER FROM THE PCC III CONTROLLER FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH WARNING It is very common to have multiple sources of power among the wires connected to a PCC III VERIFY THAT ALL SOURCES OF POWER HAVE BEEN DISCONNECTED BEFORE WORKING ON WIRING FAILURE TO DO SO CAN RESULT IN INJURY OR DEATH All Panel and Field wiring should conform to National and Local Electrical Codes Typically NEC National Electric Code applies to field wiring while NFPA 79 and UL508
56. block 22 HIALM Press ENTER Block 22 is now Softwired to Block 158 Input 20 Scroll Menu light will blink Edit Value light turns off Entering a Message Parameter in PANEL All of the Softwiring and Parameter editing involved changing Numeric values The PANEL Function has Parameters that are up to 16 character alphanumeric messages The Numeric display can not display A Z so a different editing technique is required to enter or modify a message Parameter Proceed as follows Continuing from the previous example B158 I20 ALM CH 1 is displayed S M mode is active and Technician Password Level is active Scroll Menu light should be blinking If Edit Value light is blinking Press ESC Scroll Menu light will then blink Scroll down to B158 P42 ALM CH 1 MESSAGE Press ENTER The Message display will change from B158 P42 ALM CH 1 MESSAGE to the existing message The cursor position is indicated by alternating between the existing character and an underline Use EDIT 4 or EDIT Vv to scroll through the available characters A Z 0 9 When the desired character is displayed DO NOT PRESS ENTER Press the DIS key to move the cursor one position to the right Repeat this process until up to 16 characters have been selected Press ENTER after the entire message has been composed The Message display returns to the menu ie B158 P42 ALM CH 1 MESSAGE MEMORY Menu COPY PRIMARY TO B
57. board analog inputs do NOT have internal pull up resistors and require external resistors Are Bias Resistors Required for Positioner mode Fault Detection If OV and 5V position feedback pot voltages correspond to a Scaled Position outside the 5 to 105 range Bias resistors are NOT required If OV and 5V correspond to a Scaled Position inside the 5 to 105 range Bias resistors ARE required Preferred Instruments model DM 1E P1 actuators 90 deg stroke do NOT require Bias resistors Preferred model R AL actuators DO require 75 ohm Bias resistors The best way to determine if Bias resistors are required with other actuators is to install the actuator stroke it Calibrate the Scaled Position see above and then test the actuator for proper Fault Detection see below for procedure When in doubt install Bias Resistors if Fault Detection is required See the schematic above for Bias resistor wiring Use metal film or wirewound Bias Resistors for low temperature drift carbon composition or carbon film resistors should be not be used if the ambient temperature changes substantially The Bias resistance should be approximately 7 or more of the feedback pot element s actual resistance some pots have a 20 tolerance Fail Mode STOP INC DEC DISABLE Parameter 8 If the Scaled Position is outside the 5 to 105 range for more than P9 seconds TOUT activates the triacs according to the mode selected by P8
58. cover the operation and use of PC3_Draw PCC III Instruction Manual rev 2 3 Page 4 2 Section 4 EDIT Menus EDIT Keys All data entry editing and diagnostics are accomplished with the four EDIT keys behind the hinged cover see pg 4 2 in conjunction with the numeric and alphanumeric digital displays The EDIT menus may be entered at any time and the PCC III Blockware will continue to execute normally However since the displays are showing EDIT Data none of the Front Panel Process Mode display channels can be displayed or modified i e Setpoint Controller Manual Output etc The EDIT menus can always be used to display any and all data in the PCC Ill memory regardless of the password or S M status However data can only be changed if the password and or S M mode restrictions are satisfied see Sections 4 and 6 The majority of the Blockware Parameters tuning alarm setpoints time delays characterizer breakpoints can be changed on line with the Blockware continuing to execute However changing the Function Type of a Block changing Softwiring and changing Input Ouput channel assignments can have a drastic affect on the controller Ouputs therefore PCC III must be in Service Manual Mode in order to make these changes pg 4 8 EDIT Light When the EDIT light is OFF The EDIT Menus and the ENTER EDIT 4 and EDIT keys are disabled A Process mode display channel or an Alarm Annunciator Message and the DIS ff 4 and AC
59. operator to view up to 10 process variables each with process tag descriptions Allows front panel Blockware configuration without the need for a special configurator or laptop computer Note a standard RS 232 port allows laptop configuration as an alternative Allows the operator to view the order of alarms and acknowledge each separately Allows for easy entry of complex function curves without prerequisite data collection Allows the controller to be used in any system and or with others hardware software which communicate via Modbus protocol Allows significant Discrete and Analog I O expansion capabilities within a single controller The controller s CPU board is fully functional without the front panel allowing for further I O expansion alternatives Page 1 2 Section 1 Product Overview Distributed Control System Concepts The PCC III represents the third generation of process controllers from Preferred Instruments This controller is designed to provide a true distributed approach to control applications The PCC III provides automation features that are self sufficient and will operate independently of the remainder of the control system The PCC IIl can be configured as a data collection I O module DCS III for a data acquisition system as a multi loop controller or as a traditional single loop controller In all cases the PCC III will communicate on a network with a central operator s station using the in
60. reduced Example Setpoint Filter 0 90 Repeats Min 0 75 therefore the filter time constant is 72 seconds Note If Parameter 2 0 01 repeats min and setpoint filter 1 00 the filter time constant is 6000 seconds Note When Parameter 2 0 00 i e Reset turned OFF the filter time constant is 60 seconds when the setpoint filter 1 00 Setpoint filter values less than 1 00 reduce the time constant proportionately The Setpoint filter must be turned OFF for full metering combustion fuel and airflow PID loops and for cascade control inner loops i e three element feedwater flow loop The Maximum Output limit must be greater than the Minimum Output limit Parameters 5 and 6 For P or PD modes ie Repeats min 0 0 I term is Off the PID Output equals the mid point of the Maximum and Minimum Output Parameters when PV SP For Example the mid point is 50 for 0 100 Output range 100 for 50 150 75 for 50 100 Neither Track Mode nor Override Mode will activate if Repeats Min 0 0 In applications when Repeats min 0 0 ie I term is Off it is not always desirable for the PID Output to be at the midpoint when PV SP see note 8 Examples some batch processing level control and pressure relief valves Output Bias adds subtracts to from the standard PID midpoint Output but the Output is still limited by the Min Max Output Parameters If Output Bias is non zero when Repeats min gt 0 serious system oscillations can occur due to Rese
61. scan after the Toggle Input changes from 0 to 1 and Set Reset 0 At power down the F F Block Output is saved in the Retentive Memory area of the EEPROM During the first scan after CPU start up the F F Block Output is set according to Parameter 2 LAST means use the value saved in Retentive Memory FUNCTION 112 TEMP BYTES 0 RETENTIVE BYTES 1 DATA BYTES 20 NAME F F SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D SET INPUT 2 D TOGGLE INPUT 3 D RESET INPUT Parameter Description Default Max Min Code Notes 1 INVERT OUTPUT 0 NO 1 YES 0 1 0 2 2 POWER UP 1 HI 2 LO 3 LAST 3 3 1 2 F116 TOT Totalizer Integrator with Pulse Output Function TOT is a signal integrator with a scaled pulse Output The primary application of the TOT Block is to drive a counter for flow totalization TOT can connect to a DOUT TOUT or ROUT Block to drive an external physical counter TOT can also be connected to a COUNT Block and the COUNT Block Output can be displayed via the PANEL Block 100 Input Counts Hr Parameter 2 determines the TOT Output pulse scaling as follows If the Input is a constant 100 Then TOT produces Parameter 2 Pulses or Counts per hour The TOT Block Output is normally 0 each Block Output pulse is a 1 for exactly one scan Example If the TOT Input is a 0 100 signal from a steam flow meter that is calibrated for 0 75 000 lb hr steam flow set Parameter 2 to 7500 to make every pulse equi
62. static protected mat Install the option cards as shown below Note that the Connector for Option Slot 2 will have pins that purposely do not plug into the Option Board plug in as shown Option Slots 1 and 3 do not have any extra pins Reassemble the instrument in reverse order Calibration may be required see Section 4 CALIBRATE Menu Wire the new Option Board s Re assemble in the reverse order Lt Plug in Field Option Board CPU Board a 7 Te Installation of Option Boards onto CPU Board Side View PCC III Instruction Manual rev 2 3 Page 2 23 Section 2 Installation Installing Front Panel Legends Power down the PCC III Controller WARNING un plugging or plugging in the front panel ribbon cable with power on can damage the controller or cause it to re boot and possibly upset the controller process in a Dangerous manner Remove the front door of the PCC II and un plug the ribbon cable from the door to the CPU Lay the door face down on a table to view the back of the front door Un plug the clear plastic ribbon cable from the keypad to the display board Remove the three screws that secure the display board and remove the display board The Legend insert slides into the keyboard pocket that is located just to the left of the short red bargraph window Re assemble the Front door and plug in all cables Apply Power to the PCC III Note Legends are typically made by crea
63. the 32 possible node addresses and displays the node address of each device that sends back a normal reply This test will verify the proper operation of the cabling system and the proper operation of each Modbus node Before starting the Cable Test Turn off any software drivers that continuously poll the cable such as SCADA or DCS workstations Make sure that all nodes are set to the same Baud Parity and RTU ASCII mode Make sure that each device is set to a unique Address Make sure that the COM PORT is set to MODBUS Scroll to TEST CABLE Press ENTER the Numeric display will start counting down from 5 to 1 and testing will be displayed If no other nodes are polling the cable the display changes to scanning and the Numeric display shows the address currently being tested If the addressed node does not reply the address increments and the next node is tested If a node replies properly the display changes to found The address of the node will be on the Numeric display and the address scanning sequence stops Press ENTER to resume the scanning for the remainder of the nodes Press ESC during the scanning to end the test or Press ESC after that scan sequence has completed to return to the menu If a node fails to communicate check all of the requirements in Before starting the Cable Test above and then check the wiring for reversed polarity PCC III Instruction Manual rev 2 3 Page 4 25 Section 4 ED
64. this controller The address can be any value from 1 to 32 The user must insure that each PCC III or other Modbus devices on the same cable have their own unique Address Scroll to ADDRESS Press ENTER Use the EDIT 4 or EDIT v key to set the Address on the Numeric display Press ENTER The display returns to the COM PORT menu BAUD This menu item determines the Baud rate for both Modbus and Download modes Available Baud rates are 1 2k i e 1200 2 4k 4 8k 9 6k 19 2 k and 38 4k Scroll to BAUD Press ENTER Use the EDIT 4 or EDIT v key to set the Baud Rate on the Numeric display Press ENTER The display returns to the COM PORT menu PARITY This menu item determines the parity for both Modbus and Download modes ODD or EVEN Parity is available PCC III does not support No Parity Scroll to PARITY Press ENTER PARITY ODD 1 EVEN 2 will be displayed Use the EDIT 4 or EDIT v key to choose either 1 or 2 on the Numeric display Press ENTER The display returns to the COM PORT menu PCC III Instruction Manual rev 2 3 Page 4 24 Section 4 EDIT Menus RTU ASCII This item is ignored when COM PORT is set to DOWNLOAD This menu item selects either Modbus RTU protocol or Modbus ASCII protocol Scroll to RTU ASCII Press ENTER RTU 0 ASCIl 1 will be displayed Use the EDIT 4 or EDIT v key to choose either 0 or 1 on the Numeric display Press ENTER The display returns to the COM PORT menu DATA This item is i
65. to Case Retainer Screw Option Board 250 ohm Switches PCC III Instruction Manual rev 2 3 CPU Board Layout Shown with 3 Option Boards Installed td avol R3 eS PREFERRED INSTRUMENTS DANBURY CT 06810 LRN 7 a R6 x 5X2 mm TTZ i R3 sx a 250 VAC TR2 R5 LO 3A SLO va J1 a B 29 5 U2 Ul 4 RI w Ae I R2 223 ag 32 F A mos c1 55 ort l R avon Fi N 84 AR 55 RSE T wuuiozxs a BE SSHL IWNYON VEO 2 z i a S v3 F uz RW 40 x E A cy xs Jle ie S Rap n 9 WP 32438 A 7 St ei 1 RBIS 2 zap ale 5 lle 5 Sl am C59 D3 2 3 44 eE g x gt A a 0 x 1 fa q 451 R6 g z 2 z iP J4 H aS asp pl rrr V Eio di s s amp P Ils 2475 Laaa orae c10 C12 Ze Bi w48 l j H II 49 RN1 oj ARISI g g i 0 RN1 O Hg Fj k so f RaR S co e1 Ila E te be u J1 C2 RN13 H as ca H3 al z 5 3 Ro Hi be H T aaen cee gl PREF INSTR DANBURY CT 06810 _ 3 al RU24 m RI OR2 PREF INSTR DANBURY CT 06810 PS gs es c22 c17 c23 cia c19 c24 c25 c2a c21 c26 C63 gt RNS O x 3 RNO i fe z RNG Q a 2 Si 3 N o 11 G5 Se Su2 Sur Qua aXe Site Be Sos us aW N i r z re R3 R56 le 79 IE 3 1D ll l k ei Swi Sw2 34 1s ra RN6 RN3 RN2RN7 C1 A soi a VA mnunjunnn BEFA ji l 8l km oe ee i L 2 8 12345 pm KRZ 6548 cig U8 C92 vie Page 2 7 Section 2 Inst
66. water level After the boiler trips the feedwater pressure returns to normal pressure The displays would respond as follows Condition ALARM Message Numeric ACK Comment light pushbutton Low feedwater Blink Process Control Process Control Operator not present supply pressure Display Display Low Drum Level Blink Process Control Process Control Display Display Low Low Drum Blink Process Control Process Control Level trip Display Display Feedwater Supply Blink Process Control Process Control Pressure returns to Display Display normal Blink LOW WATER PSI 1 3 Press Operator returns Blink LOW DRUM 2 3 Press LEVEL Blink LO LO DRUM 3 3 Press LEVEL Low Low Level trip ON LOW DRUM 1 2 Press returns to normal LEVEL ON LO LO DRUM 2 2 Press LEVEL Low Level returns OFF LO LO DRUM 2 2 to normal LEVEL OFF NO MORE Press ALARMS OFF Process Control Process Control Press DIS Display Display pushbutton When one wishes the displays to stop showing Alarm Annunciator messages and return to showing normal Process Control display channels press DIS Item 7 The operation of the ACK pushbutton can not be changed by the Blockware designer However alarm s can be disabled by Blockware Typically this is done to prevent nuisance alarms when a process is shutdown User Defined Pushbuttons Items 12 14 16 and 18 in fig 1 These four pushbuttons are configured by the Blockware designer The Pu
67. when editing a numerical value the EDIT 4 and EDIT Y keys change the value shown on the Numeric display When BOTH the Message and Numeric displays are showing data ONE of the two lights Edit Value or Scroll Menu will blink to indicate which display the EDIT 4 and EDIT Y keys are going to change PCC III Instruction Manual rev 2 3 Page 4 3 Section 4 EDIT Menus EDIT 4 and EDIT v keys The EDIT 4 and EDIT VY keys are used to scroll up or down through the line items of any of the EDIT menus see next page The menu line item scrolling does not wrap around That is if the MAIN menu is active and PASSWORD MENU is displayed pressing EDIT 4 moves up one line to ENTER S M pressing EDIT 4 again displays QUICK MENU pressing EDIT 4 again will not change the display because QUICK MENU is the top of the menu The EDIT 4 and EDIT Y keys are also used to change the value of the number shown on the Numeric display Edit Value light must be blinking These keys can also be edit messages in the PANEL Block see pg 4 15 any EDIT men and to increase the value of displayed parameters When used in conjunction with the various Menus and Sub Menus depressing EDIT 4 will move up the page to the previous line in the menu When used to change parameter values during configuration numeric display flashing depressing EDIT A will increase the value or in the case of message generation alphanumeric display character flashing EDIT 4 will sc
68. 0 19999 19999 2 3 25 CH 6 MESSAGE CH 6 2 5 26 CH 7 DEC PT 0 4 0 2 3 27 CH 7 ZERO 0 19999 19999 2 3 28 CH 7 SPAN 100 19999 19999 2 3 29 CH 7 MESSAGE CH 7 2 5 30 CH 8 DEC PT 0 4 0 2 3 31 CH 8 ZERO 0 19999 19999 2 3 32 CH 8 SPAN 100 19999 19999 2 3 33 CH 8 MESSAGE CH 8 2 5 34 CH 9 DEC PT 0 4 0 2 3 35 CH 9 ZERO 0 19999 19999 2 3 36 CH 9 SPAN 100 19999 19999 2 3 37 CH 9 MESSAGE CH 9 2 5 38 CH 10 DEC PT 0 4 0 2 3 39 CH 10 ZERO 0 19999 19999 2 3 40 CH 10 SPAN 100 19999 19999 2 3 41 CH 10 MESSAGE CH 10 2 5 42 ALM CH 1 MESSAGE ALM 1 2 5 43 ALM CH 2 MESSAGE ALM 2 2 5 44 ALM CH 3 MESSAGE ALM 3 2 5 45 ALM CH 4 MESSAGE ALM 4 2 5 46 ALM CH 5 MESSAGE ALM 5 2 5 47 ALM CH 6 MESSAGE ALM 6 2 5 48 ALM CH 7 MESSAGE ALM 7 2 5 49 ALM CH 8 MESSAGE ALM 8 2 5 50 ALM CH 9 MESSAGE ALM 9 2 5 51 ALM CH 10 MESSAGE ALM 10 2 5 Notes 1 See Annunciator Mode and Annunciator Logic above 2 See Bargraph Control above 3 See Display Scaling Examples above 4 See Automatic Display Channel Selection above 5 See Section 4 When modifying from Edit Menus DIS moves cursor right EDIT EDITw change the character at the blinking cursor PCC Ill Instruction Manual ver 2 3 Page 6 40 Section 6 Blockware Functions Technical Reference F97 RDIN RS485 Remote Discrete Input When the PCC III RS485 communications link Comm Link is in Local Mode the Comm Link can read all Block Outputs however the Comm Link is prevented f
69. 0 6 Hz 63 db 60 Hz is included for each analog Input for noise reduction and high frequency aliasing prevention The AIN function interfaces to Analog Inputs on the CPU board and on option boards Parameter 1 specifies the board location the CPU board board 0 Parameter 2 selects a particular Input on the specified board Any portion of the 0 5 100 Vdc Input range 0 5 Vdc min span may be selected and scaled to the 0 100 00 Block Output using parameters 3 amp 4 Voltages outside the configured 0 100 00 range produce proportional Block Outputs within the limitations of 0 5 100 Vdc measurement range and 327 Block Output range Parameters 3 amp 4 may be configured for reverse Inputs 0 5 Vdc 100 1 Vdc for 20 4 mA transmitters Scaling Example Parameter 3 0 1 000 Vdc Parameter 4 100 5 000 Vdc Outputs for other voltages 0 000 Vdc 25 1 000 Vdc or 4 mA 0 4 000 Vdc or 20 mA 75 00 5 100 Vdc in 102 50 The square root option is scaled for 0 100 Input 0 100 Output that is Block Output 10 sq root Input Square Root Example 100 Input 100 Output 49 Input 70 Output 4 Input 20 Output Negative Inputs yield a 0 Output The Low Flow Cutoff parameter forces the Block Output to 0 00 if the Block Output would be less than Parameter 7 This feature is bypassed if the Cutout is 0 0 PCC III Instruction Manual ver 2 3 Page 6 4 Section 6 Blockware Functions Tech
70. 1 22 R410011 PARAMETER 1 70 1 2 23 R41012 BLOCK 3 159 3 2 1 24 R41012 PARAMETER 1 70 1 2 25 R41013 BLOCK 3 159 3 2 1 26 R41013 PARAMETER 1 70 1 2 27 R41014 BLOCK 3 159 3 2 1 28 R41014 PARAMETER 1 70 1 2 29 R41015 BLOCK 3 159 3 2 1 30 R41015 PARAMETER 1 70 1 2 31 R41016 BLOCK 3 159 3 2 1 32 R41016 PARAMETER 1 70 1 2 33 R41017 BLOCK 3 159 3 2 1 34 R41017 PARAMETER 1 70 1 2 35 R41018 BLOCK 3 159 3 2 1 36 R41018 PARAMETER 1 70 1 2 37 R41019 BLOCK 3 159 3 2 1 38 R41019 PARAMETER 1 70 1 2 39 R41020 BLOCK 3 159 3 2 1 40 R41020 PARAMETER 1 70 1 2 41 R41021 BLOCK 3 159 3 2 1 PCC III Instruction Manual ver 2 3 Page 6 56 Section 6 Blockware Functions Technical Reference 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Note R41021 PARAMETER R41022 BLOCK R41022 PARAMETER R41023 BLOCK R41023 PARAMETER R41024 BLOCK R41024 PARAMETER R41025 BLOCK R41025 PARAMETER R41026 BLOCK R41026 PARAMETER R41027 BLOCK R41027 PARAMETER R41028 BLOCK R41028 PARAMETER R41029 BLOCK R41029 PARAMETER R41030 BLOCK R41030 PARAMETER PWRPWREWPWRPWRPWPWPWPWweR 70 1 2 159 3 2 1 70 1 2 159 3 2 1 70 1 2 159 3 2 1 70 1 2 159 3 2 1 70 1 2 159 3 2 1 70 1 2 159 3 2 1 70 1 2 159 3 2 1 70 1 2 159 3 2 1 70 1 2 159 3 2 1 70 1 2 1 Assigning Block 3 D1 to any register disables the register If a disabled register is the first register in a multiple register read or write command a bad address error is Disabled re
71. 24 125 126 127 128 129 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 130 131 132 133 134 135 136 137 138 139 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 140 141 142 143 144 145 146 147 148 149 NOP NOP NOP NOP NOP NOP NOP NOP NOP NOP 150 151 152 153 154 155 156 157 158 159 PCC III Instruction Manual rev 2 3 Figure 5 1 continued Page 5 4 Section 5 Configuring Blockware PCC III Terminology Glossary Block The memory of the PCC III is divided into 160 groups Each group or Block can be set up by the user to perform a specific task such as A B A B square root PID control etc The task that a Block performs is determined by the Function type that we assign to the Block Function type is explained below NOTE Blocks are often referred to as B1 BLK 1 or simply by the Block s number All Blocks are identified by a number 0 thru 159 This number determines the sequence in which the Block tasks are carried out PCC III computes each Block in sequence from 0 thru 159 and computes all 160 Blocks 10 times per second All 160 Blocks are always present those Blocks which are not in use are simply assigned a No Operation NOP Function type Blockware Configuration This refers to the process of entering information into the Blocks such as the Function type ie the task that each Block will perform the specification of which of the 4 field Inputs a parti
72. 4 5 A DIS CH 5 lt PV 2 gt 4 6 A DIS CH 6 lt SP 2 gt 4 7 A DIS CH 7 8 A DIS CH 8 9 A DIS CH 9 10 A DIS CH 10 11 A PV BARGRAPH 1 2 12 A SP BARGRAPH 1 2 13 A OUT BARGRAPH 1 2 14 D AUTO MAN PB 1 OPTIONAL O AUTO 1 MAN 4 15 A PV BARGRAPH 2 2 16 A SP BARGRAPH 2 2 17 A OUT BARGRAPH 2 2 18 D AUTO MAN PB 2 OPTIONAL O AUTO 1 MAN 4 19 D LOOP 2 SELECT OPTIONAL O LOOP 1 1 LOOP 2 4 20 D ALM CH 1 1 21 D ALM CH 2 1 22 D ALM CH 3 1 23 D ALM CH 4 1 24 D ALM CH 5 1 25 D ALM CH 6 1 26 D ALM CH 7 1 27 D ALM CH 8 1 28 D ALM CH 9 1 29 D ALM CH 10 1 30 D RMT ALM SILENCE BLOCK 1 31 D ANNUCIATOR ENABLE BLOCK 1 PCC III Instruction Manual ver 2 3 Page 6 39 Section 6 Blockware Functions Technical Reference Parameter Description Default Max Min Code Notes 1 BARGRAPH FLASH O NO 1 YES 1 1 0 2 1 2 CH 1 DEC PT 0 4 0 2 3 3 CH 1 ZERO 0 19999 19999 2 3 4 CH 1 SPAN 100 19999 19999 2 3 5 CH 1 MESSAGE CH 1 2 5 6 CH 2 DEC PT 0 4 0 2 3 7 CH 2 ZERO 0 19999 19999 2 3 8 CH 2 SPAN 100 19999 19999 2 3 9 CH 2 MESSAGE CH 2 2 5 10 CH 3 DEC PT 0 4 0 2 3 11 CH 3 ZERO 0 19999 19999 2 3 12 CH 3 SPAN 100 19999 19999 2 3 13 CH 3 MESSAGE CH 3 2 5 14 CH 4 DEC PT 0 4 0 2 3 15 CH 4 ZERO 0 19999 19999 2 3 16 CH 4 SPAN 100 19999 19999 2 3 17 CH 4 MESSAGE CH 4 2 5 18 CH 5 DEC PT 0 4 0 2 3 19 CH 5 ZERO 0 19999 19999 2 3 20 CH 5 SPAN 100 19999 19999 2 3 21 CH 5 MESSAGE CH 5 2 5 22 CH 6 DEC PT 0 4 0 2 3 23 CH 6 ZERO 0 19999 19999 2 3 24 CH 6 SPAN 10
73. 55 mA regardless of how many Input channels are being used 3 Example a PCC III BFOO that is configured to use three 4 20 mA Outputs and 1 Relay Output draws 155 mA internally Therefore 60 mA is available for field loads typically transmitters 4 A direct short across the 24 Vdc will blow the PCC III 120 Vac power fuse An external 300 mA fast acting fuse for field 24 Vdc loads is recommended 5 The CPU has a 5 Vdc 50 mA power supply for field devives feedback pots etc Each G option board also has a separate 5 Vdc 50 mA power supply Note the G board 5Vdc current usage subtracts from the available 24 Vdc current Fuses Every PC board in the PCC Ill that uses a fuse is shipped with one spare fuse attached to the PC board see drawings on pages 2 7 thru 2 9 for fuse locations Fuses used in the PCC III include Board Service Amps Type Preferred Littleftuse Part Number Part Number CPU 120 Vac power to 0 3A Slo Blo 92227 239 300 5 and 24 Vdc supplies 250 V 5x20 mm G and S Triac 24 120 Vac power to Triacs 3 0A_ Normal Blow 92247 235 003 option boards 250 V 5x20 mm 250 ohm Resistors for 4 20 mA Inputs Except for the G Option Board every PCC III Analog Input channel has an internal 250 0 ohm precision resistor that the user can connect to the Input If connected the 250 ohm resistor converts a 4 20 mA signal into a 1 5 Vdc signal The CPU Board utilizes j
74. ACKUP COPY BACKUP TO PRIMARY The CPU board has two separate non volatile EEPROM memories we refer ERASE PRIMARY to as Primary and Backup Each memory contains Blockware data COMPARE MEMORIES Calibration data and Communications setup data Normally the Primary REMAINING MEMORY REPORT and Backup memories contain duplicate copies of this data CONFIG NAME EPROM VER AutoLoad During normal operation the CPU uses the Primary memory In the unlikely event that a large electrical surge corrupts the Primary memory the CPU will automatically re boot and attempt to AutoLoad the entire contents of the Backup memory into the Primary memory If the Backup memory is OK the controller will automatically resume operation AutoLoad copies all Blockware Calibration COM PORT and Retentive Memory data from the Backup into the Primary memory WARNING Data changes that are made during the use of the EDIT A BLOCK CALIBRATE and COM PORT menus are saved in the Primary memory However these changes are NOT saved in the Backup memory To insure that a future AutoLoad ie copy Backup into Primary loads these changes the user must copy the Primary memory into the Backup memory using the MEMORY COPY PRIMARY TO BACKUP menu item pg 4 16 FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH When changes are being made to existing operational Blockware logic the changes should be completely debugg
75. AMAGE INJURY OR DEATH WARNING Data changes that are made during the use of the EDIT A BLOCK CALIBRATE and COM PORT menu items are saved in the Primary memory however these changes are NOT saved in the Backup memory To insure that a future AutoLoad ie copy Backup into Primary loads these changes the user must_copy the Primary memory into the Backup memory using the MEMORY COPY PRIMARY TO BACKUP menu item pg 4 16 FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH Analog Input Calibration Procedure This procedure requires a low noise voltage source that can produce 2 500 Vdc and 5 000 Vdc and a DC Voltmeter to measure the calibration voltages to within 0 4 mV This means that the DC Voltmeter must display at least 5 digits ie 19 9999 However not all 5 digit Voltmeters have 0 4 mV accuracy depending on the accuracy specification of the meter a 6 digit meter may be required Most portable test meters and voltage calibrators have 4 digits or less of display resolution Calibrating the PCC III with a less than 5 digit DC Voltmeter will result in lower PCC III accuracy This procedure applies to the CPU Board Board 0 Option Board 1 and Option Board 2 Using the CPU Board will be used as an example the procedure is as follows ENTER S M for ALL Outputs see pg 4 9 Remove all field wiring from all of the Analog Input channels on the Board to be calibrated Alternatively un pl
76. ARE MEMORIES This menu item compares the Blockware Calibration and COM PORT data in the Primary and Backup memories and indicates if the two memories match i e are the same or are mismatched i e are different Scroll to COMPARE MEMORIES Press ENTER Either memories match or memories mismatch will be displayed Press ESC to return to the menu REMAINING MEMORY REPORT This menu item displays the amounts of FREE ie unused Blockware memory in three categories DATA TEMP and RETENTIVE Section 6 details the quantity of each type of memory that each Blockware Function requires Press EDIT V succesively to display the current values for each of the following catagories Message Maximum Available REMAINING RETENTIVE WRITES x1000 570 000 displayed as 0 570 FREE DATA BYTES 5120 FREE TEMP BYTES 1280 FREE RETENTIVE BYTES 58 Press ESC to return to the MEMORY menu CONFIG NAME This menu feature has not been activated at this time EPROM VER This menu item displays the software version of the ROM firmware the date that the version was released and an EEPROM memory map structure code Scroll to EPROM VER Press ENTER The Version information will be displayed Press ESC to return to the menu PCC III Instruction Manual rev 2 3 Page 4 17 Section 4 EDIT Menus UTILITIES SUB MENU EXAMINE BLOCK FIND FUNCTION This menu provides a variety of tools for trouble shooting information display
77. Application Desired Actual equation K1 K2 K3 K4 equation a A 1 000 B 1 000 0 1 000 0 00_ 1 000 1 000 n al _0 00 A 1 000 B 1 000 C 1 000 0 00 000 1 000 1 000 _0 00 A 1 000 B 1 00 0 1 000 0 00 000 1 000 _m a _0 00 0 00 0 00 Oo A B 2_ A 0 500 B 0 500 0 1 000 0 00 0 50 A B C 3_ A 0 333 B 0 333 C 0 333 0 00 3 Scaling 0 25A 50 A 0 25 B 1 00 0 1 00 50 00 250 n a n a 50 00 0 100 xmtr Input is equivalent to 50 75 setpoint Addition with Scaling A 0 125 B 0 375 C 0 500 0 00 0 125 0 375 0 500 Weighted Sum A 0 100 0 50 gpm B 0 100 0 150 gpm C 0 100 0 200 gpm Output 0 100 0 400 FUNCTION 52 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 28 NAME WSUM SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A A INPUT 2 A B INPUT 3 A C INPUT Parameter Description Default Max Min Code Notes 1 K1 1 000 10 000 10 000 2 2 K2 1 000 10 000 10 000 2 3 K3 1 000 10 000 10 000 2 4 K4 0 00 199 99 199 99 2 F53 INV Invert Function INV negates its analog Input that is Output Input 1 For example a 21 Input is converted to a 21 Output FUNCTION 53 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME INV SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A INPUT No Parameters PCC III Instruction Manual ver 2 3 Page 6 21 Section 6 Blockware Function
78. B1 is high Configure P05 as 60 Sixty second delay before the alarm sounds Block 85 LED We need a light to tell us whether we have selected Local PID or Plant Master control The pushbutton legend will be setup as PM Local PID Thus when the LED is on we are in Local PID control mode EDIT to Block 85 Press ENTER Make Block 85 an LED Function Function 99 There is one Input and two parameters to setup Configure 101 from B55 Configure P01 as 1 This is the top left LED Configure P02 as 1 We need to invert the Input When PB1 is low 0 the LED is on Local PID PCC III Instruction Manual rev 2 3 Page 5 11 Section 5 Configuring Blockware Block 125 ASW EDIT to Block 125 Press ENTER Make Block 125 an ASW Function Function 34 There are three Inputs and three parameters to setup Configure 101 A to be from B26 Configure 102 B to be from B120 Configure 103 Select to be from B85 High Local mode selects Input B Configure P01 as 1 We want transfer rate limiting to avoid any bumps when switching modes Configure P02 as 1 00 This gives us a 1 per second transfer rate going from Plant Master to Local PID mode Configure P03 as 1 00 This gives us a1 per second transfer rate going from Local PID to Plant Master mode Modify Block 120 PID When adding or deleting Blocks we must remember to review all of the existing Blocks to see if any their Inputs ar
79. Benefits iania aa 2 High Temperature Hot Water HTHW BTU Hr Distributed Control System Concepts ee 3 Comp tatiomMr ispan 6 Analog and PLC Control Functions cee 3 Drum Level Pressure Vs Density Configuration CONCe pts se eececseseeseseseseseeeeeeeeeeeeees 3 COMPENSATION eeeseeeeeeeeeeeeeeeeeeeeeeeeteeeeeteeeeeeees 6 Com Link Data Highway Concepts n s 3 Oxygen Sensor Control Signal Conversion Blockware Concepts ssssseesscteteeeteteteteteteeeeteteeeees 4 Option Card seaciceden ce eniiistdeadeneet 6 BIOCKS 2 2 ccfiiit btiind TETE 4 Relay Output Channels 0 0 cece 6 Library Of FUNCTIONS 0 ccceeeeeeeeeeeeeteeeeeeeeeees 4 OPLR Stack Exit Correlation for EPA Opacity Any Function Any Block eccsseseeeeeeeeenees 4 MONITORS estes seve eerste ree easton tae deeded 6 Reusable Functions essnee 4 Flow TotaliZation seses 6 SOfWINING ties chee 4 PCC III Loop Controller Model Numbet 7 Special Option Card and Special Function Block Option Board Input Output Expansion Examples 7 Capabilities teins esactranenwadetecars aries nets 5 Spare Parts Uistw scicicn cteahewheeees Multiple F x s scccstiau deinen eanneaen 5 PCC III Specifications Learn Mode waist ainsi eee 5 Mechanical cciik nee einen Boiler Efficiency ccecscececeeesseseceseeseneeneeseeeneees 5 Environmental arenis 10 Service Manual Option card sees 5 Performance sees Triac Output for Electr
80. CK UN FORCE ALL BLOCKS DISPLAY SCAN TIME EDIT QUICK MENU BLOCK TIMING COM PORT Menu COM PORT ADDRESS BAUD PARITY RTU ASCII DATA TIME OUT TEST CABLE Page 4 6 PCC III EDIT Menus Section 4 EDIT Menus MAIN Menu QUICK MENU ENTER S M or EXIT S M The Main Menu simply displays the names of all the other Menus contained in PASSWORD MENU PCC III EDIT The Main Menu provides the means to access the other Menus EDIT A BLOCK MEMORY MENU As described above the EDIT A and EDIT Y keys scroll the message display up UTILITIES MENU and down within this Menu The ENTER key activates the Menu that is currently CALIBRATE I O being displayed on the message display The ESC key terminates the EDIT GoM MENU Menus and returns the Front Panel displays to the Process Mode See the SERVICE MANUAL menu pg 4 7 for details on ENTER S M or EXIT S M QUICK Menu LAST PARAMETER QUICK 1 The purpose of QUICK menu is to provide the user with rapid access to QUICK2 frequently used Blockware Parameters Examples PID Gain High and Low alarm setpoints equipment startup delay time and warm up ramp rate of QUICK8 change The Quick Menu can have up to 9 lines LAST PARAMETER and up to 8 QUICK selection line items The QUICK menu line item descriptions Block Numbers and Parameter numbers are field configurable via UTILITIES MENU EDIT QUICK MENU see pg 4 20
81. D 0 2 4 5 digit LED 0 48 51 segments LED 5 1 20 segment LED 2 1 Membrane tactile feedback Mylar splashproof 10 Point First out 6 LED Configurable 4 Configurable 120 Vac 15 22 VA 24 Vdc 215 mA and 5 Vdc 50 mA Input Output Standard no option cards Analog Inputs Quantity Type Analog Outputs Quantity Type Discrete Inputs Quantity Type Discrete Outputs Quantity Type I O Expansion Communications 5 4 20 maDC 0 5 VDC 2 4 20 maDC 800 ohm load 5 120 VAC opto isolated 6 2 SPDT relay contact 8A 120V 12 HP 120 VAC 4 Open Collector sinking 24 VDC 200mA See Table Below Network Protocol Modbus ASCII or RTU mode Speed 1200 38 400 baud Type RS 485 optically isolated Speed 1200 38 400 baud Type RS 232 with telephone modular handset connector Configuration Specifications subject to change without notice PCC III Instruction Manual rev 2 3 Page 1 9 Section 1 Product Overview Section 2 Installation Table of contents Option Board Descriptions ceeeeeeeeeeeeeteeeeeeees 1 Mounting OVerview cesceeeeeeeeeeeeeneeeeeeeeeneeeeeneeeaes 2 Mounting OVerview ccesceeeseeeeeeeeeeeeeeeeeeeseeeeneeeeaes 2 NEMA 13 IP65 Environment ccccseeeeeeeeees 2 Ambient Temperature eeseesesseeeeesneeeeseneeerenaees 2 Rear ACC SS iiiji ee etec dit ie a a 2 MOUNTING wise AA tie ee a 2 PCC III Dimensions
82. DIT A Press EDIT 4 or EDIT VY to re display the Block Inputs that were found Press ESC to return to the MAIN menu If no Block Inputs were found NOT USED will be displayed Press ESC to return to the MAIN menu Forcing Block Outputs As an aid to trouble shooting and field wiring check out PCC III Block Outputs can be temporarily FORCED to remain at a user selected fixed value When AOUT TOUT DOUT or ROUT Block Outputs are FORCED the hardware Outputs will be set to the equivalent value see also Forcing TOUT in Dual Triacs Mode WARNING The PCC III is commonly used to control potentially dangerous Combustion and Chemical Processes Block Outputs should only be FORCED on a short term temporary basis under the direct continuous supervision of a qualified technician who is familiar with the operation of the entire control system FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH The FORCE data ie FORCED Block number s and the Output value s is stored in RAM it is NOT stored in the Blockware EEPROM memories Therefore after every power interruption or any other PCC Ill CPU re start all FORCED blocks will revert to UN FORCED RUN light indicates Normal Forced or S M Mode Green RUN Light ON OFF Cycle Operating Mode ON Continuous Normal OFF ON 95 Forced Block s pg 4 19 OFF Blinks OFF once every second ON Blinks ON twice every second OFF 85 Service M
83. Disable signal is Active HI or Active LO as follows Disable Input 1 Active HI 0 Enabled 1 Active HI Disabled O ActiveLO 0 Disabled 0 Active LO Enabled Inverted Output Parameter 6 When Parameter 6 1 The Block Output is opposite the normal value Or when INVERTED 1 Output 1 if PV SP lt Deviation PCC III Instruction Manual ver 2 3 Page 6 46 Section 6 Blockware Functions Technical Reference FUNCTION 103 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 40 NAME DEVALM SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 A PV INPUT 2 A EXT SP INPUT 1 3 D DISABLE INPUT 2 Parameter Description Default Max Min Code Notes 1 SP MODE 1 EXT 2 INT 1 2 1 2 1 2 DEVIATION THRESHOLD 2 00 199 99 0 10 1 3 DEADBAND 0 10 100 00 0 00 1 3 4 INT SP 50 00 199 99 199 99 1 1 5 ALARM DISABLE ACTIVE LO HI O LO 1 HI 1 1 0 2 2 6 INVERT OUTPUT O NO 1 YES 0 1 0 2 5 7 ALARM DELAY SECONDS 0 600 0 1 4 Notes 1 See Internal vs External Setpoint above 2 See Alarm Disable above 3 See Deadband above 4 See Alarm Time Delay above 5 See Inverted Output above F104 RATE Rate of Change Alarm RATE Limits 2 sec 5 sec Function RATE calculates the per second sec rate of change of the Input signal every scan RATE also saves the sec values from the previous 5 scans in memory RATE then computes the average sec rate of change over the last 5 scans and compa
84. EDIT will be used However some parameters need to be modified to suit the needs of the desired Control Strategy EDIT to Parameter 1 P01 This tells the PCC III what board the Input resides on We are using AIN ch 2 on the CPU board Thus P01 should be left as 0 EDIT to P02 The Plant Master input will be directed tAIN ch 2 Press ENTER to access the numeric display EDIT up until 2 is displayed Press ENTER again EDIT to P03 The numeric display should read 1 000 when the input from the Plant Master is 0 there will be a 4 ma signal dropped across a 250 ohm resistor creating a 1 000 volt drop across the input EDIT to P04 The top display should read 5 000 when the input from the Plant Master is 100 there will be a 20 ma signal dropped across a 250 ohm resistor creating a 5 000 volt drop across the input EDIT to P05 The top display should read 0 We will not need to square root this input EDIT to P06 The top display should read 1 0 This represents a 1 second filter for the input which should help to eliminate noise or sharp spikes EDIT to P07 The top display should read 0 00 This corresponds to a low flow cut off limit which is not required for this application Press EDIT ESC Block 5 should reappear on the numeric display Block 25 FPCON We need a Front Panel Constant to adjust display our Submaster Bias We will setup a 50 bias
85. EL LSEL AB C so the Parameter line items would not exist Section 6 Blockware Functions Technical Reference provides a detailed description of each Function Type PCC III Instruction Manual rev 2 3 Page 4 12 Section 4 EDIT Menus Three sample EDIT A BLOCK menus are shown below At left is the menu for an AIN Function in Block 4 in the center is the menu for an AB C Function in Block 5 and at right is the menu for an ASW Function in Block 6 B04 AIN B05 AB C B06 ASW B04 P01 OPTION BOARD B05 101 A INPUT BO6 101 A INPUT B04 P02 INPUT CHANNEL B05 102 B INPUT B06 102 B INPUT B04 P03 VOLTS INPUT FOR 0 B05 103 C INPUT B06 103 SELECT INPUT B06 P01 XFER RATE LIMIT B06 P02 A TO B SEC B06 P03 B TO A SEC B04 P04 VOLTS INPUT FOR 100 B04 P05 SQ ROOT O NO How to use EDIT A BLOCK an Example Assume that the Blockware shown at right already exists in memory The designer wants to add a HIALM Function with a Setpoint of 75 in Block 22 Block 22 is currently a NOP Function whick means this Block is not being used The designer wants the message HI PSI to appear on the Annunciator when a high alarm is acknowledged The Ouput of Block 22 HIALM will be Softwired to Input 20 Alarm Channel 1 of the PANEL Function in Block 158 and the HI PSI message will be entered into PANEL Parameter 42 Alarm Channel 1 Message Change Block 22 from a NOP to a HIALM Function ENTER
86. EMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 52 NAME TOUT SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A SETPOINT INPUT 1 8 2 A FEEDBACK INPUT 3 D TRIAC 1 INPUT INCREASE 2 4 D TRIAC 2 INPUT DECREASE 2 Parameter Description Default Max Min Code Notes 1 OPTION BOARD 1 3 3 3 1 7 2 TRIAC PAIR 1 2 1 3 3 7 3 MODE O POSITIONER 1 DUAL TRIACS 0 1 0 3 4 FEEDBACK AT 0 POSITION 0 0 150 0 50 0 3 4 5 5 FEEDBACK AT 100 POSITION 100 0 250 0 50 0 3 4 5 6 STROKE TIME SEC 15 0 300 0 4 0 3 6 7 DEADBAND 0 7 15 0 0 1 3 8 FAIL MODE 0 STOP 1 INC 3 3 0 3 2 DEC 3 DISABLE 9 FAIL TRIP DELAY 3 0 90 0 2 0 3 Notes 1 Ignored in Dual Triac mode 2 Ignored in Positioner mode 3 The G option board has two pairs of Triacs 4 The difference between Parameters 4 amp 5 must be greater or equal to 10 5 Reverse Input scaling is valid i e 0 POSITION 100 Feedback 100 POSITION 0 Feedback 6 Stroke time is from 0 to 100 POSITION ie Scaled Feedback NOT 0 100 Feedback Input 7 The quantity of Outputs available is dependent on the type of option board installed An error message is displayed during EXIT S M if sufficient Outputs are not available 8 Internally limited to 0 100 range PCC III Instruction Manual ver 2 3 Page 6 33 Section 6 Blockware Functions Technical Reference F84 TCODE TOUT Fault Code Function TCODE indicates the Fault code of a particular TOUT Block The TCODE Block Outp
87. Editor menus under password protection via RS232 Blockware download or via the RS485 communications link using PLINK F124 This value cannot be changed from the PCC Ill front panel Operator displays during normal operation FUNCTION 93 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME DCON SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes NONE Parameter Description Default Max Min Code Notes 1 DISCRETE CONSTANT VALUE 0 1 0 2 F95 S M Service Manual Status Function S M indicates the current Service Manual S M status of a particular AOUT or TOUT Block The S M Block Output 1 if the monitored AOUT or TOUT Block is in S M mode The analog Input to the S M Block is a dummy Input that is used to indicate which AOUT or TOUT Output Block is to be monitored This Block is primarily used to activate FPT H and PID Track Mode when a loop is in S M mode This can provide bumpless transfer when exiting S M mode FUNCTION 95 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME S M SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 A BLOCK TO BE MONITORED 1 No Parameters Notes 1 The BLOCK TO BE MONITORED must be an AOUT or TOUT Block F96 PANEL Front Panel Display PCC III Instruction Manual ver 2 3 Page 6 35 Section 6 Blockware Functions Technical Reference Function PANEL is the Operator s interface to the PCC Ill Blockware logic The Blockware designer uses PANEL to determine
88. IT Menus SUPPORTED MODBUS FUNCTIONS The PCC III includes both Modbus ASCII and RTU protocols and supports the following Modbus Functions Function Modbus Description PCC III Description Notes 01 Read Coil Status Read Discrete Block Output 03 Read Holding Registers Read Analog Block Output 05 Force Single Coil Write Single Discrete Block Output 1 06 Preset Single Register Write Single Analog Block Output 2 08 00 Loopback Diagnostic 3 15 Force Multiple Coils Write Multiple Discrete Block Output 1 16 Preset Multiple Registers Write Multiple Analog Block Output 2 Notes 1 Only RDIN and PB Blocks may be written to 2 Only RAIN FPT H FPCON Blocks and PLINK mapped Parameters may be written to 3 Only the Loopback diagnostic subfunction Code 00 is supported Addressing Each PCC III is field configurable therefore the User must have the PCC IIIl Blockware Documentation or Drawing for the particular Controller that is going to be queried in order to know which Function Types are in which Blocks and to know the significance of each signal The Controller Station Address is within the range 1 32 as described above Coil ie Discrete Block addresses are simply the PCC III Block Number Example Block 27 is a PB Block Use coil address 00027 to read or write to the PB Block Holding Register ie Analog Block addresses 40xxx for Analog Block Outputs and 41xxx for PLINK Parameters See F124 in Sec
89. Inputs 19 RS485 Communications Wiring ccceeeeeeeeee 20 RS232 Blockware Download Cable 00 22 Field Installation of Option Boards ceeeee 23 Installing Front Panel Legends s e 24 Section 3 Operation Operator Controls and Front Panel Usage 2 T and Rate of Change uo 5 General EEE E E 2 AUTO MAN Pushbutton and Light 000 5 Front Panel Displays and Pushbuttons 3 Auto Manual Example ccccccccccccssssesesses errereen 6 RUN Light ote teeeeeeeeeeeeeeeecneeteeeeeeeeneeneeeereeaey 3 ALARM Light c c cccccceseseseseseses sessecssecesscseeteeeeees 6 SP Bargraph RoGincasiaceswatauaeaacueseetcimimesenenecnetavaatamarncs 4 ACK Pushbutton and the Alarm Annunciator 6 OUT Bargraph ccccsccceeeeeeeeessseeeeseseeessneeeeenes 4 User Defined PUSHDUIONS cccccccccececcccccccceceeee 7 Numeric Display seeeeeeeseneeeemeneieteeeeenetees 4 User Defined Lights c0cccccccccccsseeeesseeeeesens 8 Message Display ccssceseseeeeseeseeeetesetieeees 4 Multiple LOODS ccccccccceesesesescssseessseeseeeeeeeees 8 DIS Pushbutton eiesesctcssccevesseccsdeedenevepinssecsceveceeseness 4 T and Pushbuttons ccssecssesseesseesseeesseeeseesees 5 Section 4 EDIT Menu Operations Introductions si hehe oh a Lh 2 2 COPY PRIMARY TO BACKUP ccscceeseeees 16 DIA AEA A E eee E A oe See nS 3 COPY BACKUP TO
90. K keys will all be enabled Press the EDIT key to turn ON the EDIT light and to activate the EDIT menus When the EDIT light is ON The EDIT Menus and the ENTER EDIT 4 and EDIT Y keys are all enabled The Process mode display channels Alarm Annunciator Messages and the DIS f 4 and ACK keys will all be disabled However the Blockware the bargraphs the other 4 pushbuttons AUTO MAN REM LOC and two more User defined keys and the 6 User defined Lights will all continue to operate normally See ESC below for details on how to turn OFF the EDIT light and exit the EDIT menus ESC EDIT key When the EDIT light is OFF Pressing ESC EDIT turns ON the EDIT light and activates the EDIT menus When the EDIT light is ON The EDIT menus are active and the ESC EDIT key is only used as an ESC Escape key Therefore throughout the remainder of this Section this key will simply be called the ESC key Pressing ESC when a menu item is displayed will cause the display to jump back to the previous menu If any MAIN menu line item is being displayed pressing ESC will exit the EDIT menus and activate the Process mode display channels If the ESC key is pressed while a Numeric value is being changed the new value will not be saved and the origianl value will continue to be used by the Blockware Edit Value and Scroll Menu Lights Generally the EDIT 4 and EDIT V keys are used to scroll through menus on the Message display however
91. K menu after the PCC III powers down or re boots The LAST PARAMETER link is automatically re established and will again be in the QUICK menu after a Parameter is displayed via either EDIT A BLOCK or another QUICK menu line item SERVICE MANUAL Menu ALL S M AO b0c1 AUTO or S M What is Service Manual S M Mode AO b0c2 AUTO or S M Normal Operation During Normal Operation an AOUT or TOUT Block 4O b1c1 AUTO or S M converts a Blockware 0 100 Input signal into a proportional 4 20 mA or Triac hardware output every scan 1 10 second Normal Operation continues TO b1c1 AUTO or S M uninterrupted regardless of the Front Panel Display mode Process mode TO b2c1 AUTO or S M Annunciator mode or EDIT mode Most PCC Ill controller Blockware control strategies have an Auto Manual station on the Front Panel During Normal Operation BOTH Auto AND Manual modes rely on the field configurable Blockware to regulate the PCC III Instruction Manual rev 2 3 Page 4 7 Section 4 EDIT Menus 4 20 mA or Triac Output channels Manual mode does NOT bypass the Output Channel Blockware ie AOUT or TOUT and does NOT directly regulate the Output hardware Service Manual S M During S M mode a 4 20 mA or Triac Output channel is directly controlled using the permanently programmed firmware ROM instead of the field configurable Blockware logic In fact both the Primary and Backup Blockware memories can be e
92. Most PCC III Block Outputs are NOT limited to the 0 00 100 00 range and can use all or part of the full PCC III 327 00 range Since the scaling of each signal is Blockware dependent the User must consult the PCC III Blockware to determine the engineering units 41xxx Registers ie PLINK mapped Block Parameters See F124 in Section 6 for Data Format Information Modbus Write Enable Local Remote Mode Modbus Writes are only enabled for PCC III functions FPCON FPT H and PB when the PCC III is in Remote Mode However Modbus may write data to PCC III functions RAIN and RDIN at any time The Remote Local Mode input of either F123 COMM or F124 PLINK determines the PCC IIl Remote Local Status Typically this input is linked to a PCC III Front Panel Pushbutton labeled Remote Local or to an external physical switch Consult the PCC III Blockware for each controller to determine how the Remote Local Status is controlled PCC III Instruction Manual rev 2 3 Page 4 26 Section 4 EDIT Menus Section 5 CONFIGURING BLOCKWARE Table of Contents Blockware Basics cesessesesseeeeseeseeeeeeeeeeeeeateeeeteeaeenees 1 Configuring Blockware Control LOGIC 7 BlOCKS 422i ei ts eke eo eal Sel Bell 1 Modifying a Boiler Master Blockware Configuration9 Library Of FUNCTIONS esesessessesseseeseeseesteseeseesens 1 Define the requirem Sisuu 9 Any Function Any Bl0ock ccssessessessesssesseeseessees 2 Check the I O count R
93. OUT 11 or right turn ON one LED when it s Input is 0 turn ON all LED s when it s Input is 100 and a proportional quantity between 0 and 100 A SCALE or DEV Block can be used to convert non 0 100 Block Outputs to 0 100 bargraph Inputs Inputs 11 13 control the bargraphs when Input 19 Loop 2 0 and Inputs 15 17 control the bargraphs when Input 19 Loop 2 1 Display Channel Scaling Examples Block Calibration Desired ZERO SPAN Output Display Display for Display for Format Input 0 Input 100 0 100 oio oopa 00200 1 iore oare ooo H ana o 15 to 15 level 15 0 15 0 1 50 150 2o20 e010 ianao osora f e 0 00 f 10 0 100 800 1200 psig 800 1200 1200 0 100 0 70 kib hr 0 00 70 00 a 70 00 Automatic Display Channel Selection Auto DIS If Inputs 14 A M PB 1 and 19 Loop 2 Sel are left at the default of Block 2 DO then the DIS key 4 is the only method to change the selected display channel If Inputs 1 6 14 18 and 19 are configured as shown the display will jump to the Process Variable when entering AUTO and will jump to the Controller Output ie Valve Damper FPT H when entering Manual If dual Loops are configured the display jumps to the selected Loop when the Loop2 Input changes The descriptions of Inputs 1 6 OUT 1 PV 1 are provided to assist in configuring PANEL for Auto DIS However any variable can be assigned to any display channel Recom
94. Operator puts the loop in Auto and the Valve Damper when the Loop is put into Manual Auto DIS can also coordinate the displays of a dual loop controller However the DIS key 4 can still be used to manually select a display channel when Auto DIS is utilized See Automatic Display Channel Selection below for details Annunciator mode Annunciator mode allows the Operator to view up to 10 user defined alarm messages 16 characters max each stored in a sequential first out memory stack Alarms are saved in the order that the alarms occurred and are displayed oldest alarm first most recent alarm last Press the ACK 3 key to activate Annunciator mode and view the first alarm message Once activated press ACK 8 repeatedly to view additional alarm messages Press DIS 4 to leave Annunciator mode and return to Process mode The Message display shows the alarm message as entered in Parameters 42 51 The Numeric display shows the sequential position of the alarm Example 1 3 means first of three alarms stored in the stack ie the oldest See Annunciator Logic below for further details PCC III Instruction Manual ver 2 3 Page 6 36 Section 6 Blockware Functions Technical Reference BRE 10 11 d id PREFERRED INSTRUMENTS PCC IH PCC III Instruction Manual ver 2 3 Page 6 37 Section 6 Blockware Functions Technical Reference Bargraph Control All three bargraphs PV 9 or left SP 10 or middle and
95. Output of Block 20 NOTE At this point pressing ESC would return EDIT A BLOCK to Scroll Menu mode and the Softwiring would remain as it was before any changes were attempted For this example do not press ESC lt i Press ENTER Block 20 is now Softwired to Block 22 Input 1 Scroll Menu light will blink Edit Value light turns off PV Change the HIALM Setpoint Parameter Change Parameter 3 the Internal Setpoint from the default value of 50 to the desired 75 as follows Continuing from the previous example B22 101 PV INPUT is displayed S M mode is active and Technician Password Level is active Scroll Menu light should be 5 blinking If Edit Value light is blinking Press ESC Scroll Menu light will then blink This particular Parameter can modified at Password Level 1 Operator Level without S M mode however it is good practice to stay in S M mode and the higher Technician Level can be used for the lower Operator Level Scroll down to B22 P03 INT SP B22 means Block 22 P03 means Parameter 3 and INT SP describes the purpose of this Parameter The Numeric display will indicate the current value of this Parameter Press ENTER to change from Scroll Menu to Edit Value mode Scroll Menu light turns off Edit Value light will blink Use EDIT 4 or EDIT Y to set the Numeric display to 75 00 75 00 NOTE At this point pressing ESC would return EDIT A BLOCK to Scroll Menu mod
96. PCC III Controller Instruction Manual Instruction Manual Part Number 90082 Revision 2 3 1 13 03 Preferred Instruments A Division of Preferred Utilities Mfg Corp 31 35 South St Danbury CT 06810 Ph 203 748 6741 Fax 203 798 7313 preferred mfg com WARNING The PCC IIl is commonly used to control potentially dangerous Combustion and Chemical Processes Only qualified Instrument Engineers or Senior Technicians that have read this entire manual and are familiar with all aspects of the Process being controlled should attempt to re configure the Blockware Control Logic contained in the memory of a PCC Ill Controller VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE MODIFYING ANY OF THE BLOCKWARE DATA IN ANY BLOCK IN THE PCC III MEMORY FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH Note Rev 2 3 Instruction Manual changes are indicated by a vertical line in the left margin Summary of Rev 2 2 Changes Added UL508 screw tightening Caution Note Enhanced the Retentive Memory Comments and Specifications Corrected Spare Parts part number errors Revised OPLR Function description to reflect ROM changes Added Installing Front Panel Legends section Added Supported Modbus Functions section Summary of Rev 2 3 Changes F83 TOUT revised per ROM 3 04 F84 TCODE added per ROM 3 04 F100 TTRIP added per ROM 3 04 Tab
97. PLC due to its purely logical basis The combination of integral analog discrete and timing functions renders the PCC III a very powerful control solution Configuration Concepts In most applications the PCC III is shipped with a factory configuration but it is designed to permit easy modification or development of control strategies in the field The PCC III can be completely configured using front panel keys and the digital and alphanumeric displays The configuration is managed using easy to follow menus that are controlled by keys on the front panel Note these keys are normally locked out with switches that are located behind the front panel to prevent unauthorized use The keys allow for field modification or development of configurations without the use of any other devices such as special configurators or laptop computers that may not be readily available An RS 232 port is however available to allow the use of a PC computer as a configuration tool The PC also permits the downloading and retrieval of stored configurations and full documentation of same Com Link Data Highway Concepts The PCC III can be networked together over an industry standard Modbus network Modbus is an open architecture format to allow flexibility for future system expansion and or modification This network is optically isolated and makes use of a single pair of wires The network allows controllers to be located up to 4000 feet part and up to 31 contro
98. Parameter 1 seconds When the INTTDR Input changes from a 0 in the previous scan to a 1 in the current scan the timer starts counting down and the Output changes to 1 When the Timer counts 0 5 10 15 20 down to 0 the Output changes to 0 While the timer is Seconds counting down the Input is ignored and has no effect on the timer or Output Input If the Delay Seconds is set to 0 seconds the INTTDR Output will be 1 for exactly one scan FUNCTION 120 TEMP BYTES 8 RETENTIVE BYTES 0 DATA BYTES 12 NAME INTTDR SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D INPUT 1 Parameter Description Default Max Min Code Notes 1 SECONDS DELAY 0 1 SCAN 1 19999 0 2 2 2 INVERT OUTPUT O NO 1 YES 0 1 0 2 Notes 1 An Input transition from 0 to 1 starts the timing sequence 2 Delay Seconds 0 means the Output will go active for exactly one scan and then return to the inactive Output state F121 DAE DAD Delay After Energize Delay After De energize Timer Function DAE DAD combines DAETDR F118 and DADTDR F119 into a single function DAE DAD behaves as though DAEDAD A SECON PESEE OTE DENY the Output of a DAETDR Block was the Input to a DADTDR 3 Block DAE DAD provides an initial ON Delay and then a provides an OFF Delay when the Input returns to 0 The Output may be inverted see Parameter 3 The timing diagram shows the default non inverted logic 2 For non Inverted Output Wh
99. S M mode see pg 4 8 ENTER PASSWORD Technician Level if enabled see pg 4 11 Scroll to EDIT A BLOCK in the MAIN menu press ENTER ENTER THE BLOCK NUMBER TO BE EDITIED will be displayed PANEL Use EDIT 4 or EDIT V to set the Numeric display to 22 ie Block a number 22 press ENTER B22 NOP and 127 will be displayed B22 means Block 22 NOP is the Function Name currently in this Block 127 is the Function Code Number for a NOP Function The Scroll Menu light will blink see pg 4 1 Press ENTER to change from Scroll Menu to Edit Value mode Scroll Menu light turns off Edit Value light will blink NOTE If ENTER is accidently pressed a second time 5 REPLACE f127 WITH f127 ENTER YES will be displayed Press ESC then press ENTER Use EDIT to scroll down through the available Function Code Numbers until B22 HIALM and 101 are displayed 18 NOTE While the scrolling is changing the Function Code Number on the Numeric display it is simultaneously changing the Function Name on the Message display In fact the Function Number can almost be ignored and the Function Name display can be used as the primary indicator NOTE At this point pressing ESC would return the display to B22 NOP and Block 22 would remain as it was before any changes were attempted For this example do not press ESC When B22 HIALM and 101 are displayed press ENTER Block 22 is now a HIALM F
100. S232 levels and can be directly connected to a standard Personal Computer Serial Port The RS232 Port DC Common pin is connected to the PCC III Power and Signal Commons The connector on the CPU board is a standard 4 pin telephone handset modular jack The wiring to connect a PCC III to a Personal Computer is shown below A pre fabricated Download Cable with 4 pin modular to 9 pin DB 9 RS232 connector adapter is available as Preferred part number 190355 Assembly 190355 is also included with each PC3_Edit and PC3_Draw software package 5 Download a 1 sense bit 2 2 gt Tx 3 Tx 4 lt R 3 2 Rx gt 4 4 5 NV VY Ft a S O ___d PCC III Standard Telephone Handset PCC III Personal RS232 coiled cord with modular Download Computer Download connectors Adapter 9 pin male Connector p n 190355 serial port connector 14 Front View Download Connector Pin out PCC III Instruction Manual rev 2 3 Page 2 22 Section 2 Installation Field Installation of Option Boards WARNING The PCC III is commonly used to control potentially dangerous Combustion and Chemical Processes VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE REMOVING POWER FROM THE PCC III CONTROLLER FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH WARNING It is very common to have multiple sources of power among the wires connected to a PCC III
101. TES 0 DATA BYTES 36 NAME RAIN SINGLE USE FUNCTION N OUTPUT TYPE A No Inputs Parameter Description Default Max Min Code Notes 1 MIN OUTPUT 0 00 199 99 199 99 2 1 2 MAX OUTPUT 100 00 199 99 199 99 2 1 3 SEC RATE LIMITER 100 0FF 100 00 100 00 0 10 2 2 4 FILTER SECONDS 0 00 3 00 0 00 2 x 5 COMM FAIL DELAY SEC 5 3600 1 2 x 6 FAIL ACTION O LAST 1 DEFAULT 0 1 0 2 x 7 FAIL DEFAULT 0 00 199 99 199 99 2 x Notes 1 MIN must be less than MAX 2 100 00 sec rate limit turns off Rate Limiting F11 DUAL Dual Range Flow Transmitter Selector Scaler Function DUAL is used to automatically select and scale one of two flow transmitters in a dual range arrangement This allows greater measurement accuracy over a wider flow range Example An orifice plate with two differential pressure transmitters piped in parallel The High range transmitter is calibrated 0 100 WC the Low range transmitter is calibrated 0 9 WC The DUAL Block should be set to a 9 switch point with the square root option selected the transmitters should NOT have internal square root selected From 100 9 WC the High range Input would be selected square rooted and sent to the DUAL Block Output as a 100 30 signal Below 9 WC the Low range would be selected the transmitter signal would be scaled square rooted and sent to the DUAL Block Output as a 30 0 signal Formula shown with optional square root being taken If High Range Input great
102. TES 4 RETENTIVE BYTES 0 DATA BYTES 116 NAME F X SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A X INPUT 2 D LEARN ENABLE INPUT 1 ENABLE 1 3 D LEARN INPUT 41 LEARN 2 3 4 D CLEAR INPUT 41 CLEAR 2 4 5 A Y INPUT 5 Parameter Description Default Max Min Code Notes 1 FIRST LAST SEGMENT O0 HOLD 1 LINEAR 0 1 0 2 2 X1 0 00 150 00 150 00 2 6 3 Y1 0 00 150 00 150 00 2 4 X2 100 00 150 00 150 00 2 6 5 Y2 100 00 150 00 150 00 2 6 X3 150 00 150 00 150 00 2 6 7 Y3 50 00 150 00 150 00 2 8 x4 150 00 150 00 150 00 2 6 9 Y4 50 00 150 00 150 00 2 10 x5 150 00 150 00 150 00 2 6 11 Y5 50 00 150 00 150 00 2 12 X6 150 00 150 00 150 00 2 6 13 Y6 50 00 150 00 150 00 2 14 X7 150 00 150 00 150 00 2 6 15 Y7 50 00 150 00 150 00 2 16 x8 150 00 150 00 150 00 2 6 17 Y8 50 00 150 00 150 00 2 18 x9 150 00 150 00 150 00 2 6 19 Y9 50 00 150 00 150 00 2 20 X10 150 00 150 00 150 00 2 6 21 Y10 50 00 150 00 150 00 2 22 X11 150 00 150 00 150 00 2 6 23 Y11 50 00 150 00 150 00 2 24 Y VALUE AFTER CLEAR 100 00 150 00 150 00 2 Notes 1 1 Learn Mode enabled 0 disabled 2 This Input is ignored if LEARN ENABLE Input 0 3 The Learn Event is active during the single scan when the LEARN Input changes from 0 to oO F43 1 AND LEARN ENABLE Input equals 1 and CLEAR Input equals 0 The Clear Event is active during the single scan when the LEARN Input changes from 0 to 1 AND LEARN ENABLE Input equa
103. TO B SEC RATE LIMIT 1 00 100 00 0 10 2 3 B TO A SEC RATE LIMIT 1 00 100 00 0 10 2 Notes 1 Output A Input when Select 0 Output B Input when Select 1 2 When Xfer Rate Limiting 0 the Output changes instantaneously when Select changes F35 H LLIM High Low Signal Limiter Function H LLIM passes the Input to the Block Output if the value is less than Parameter 1 Hi Limit and greater than Parameter 2 Low Limit If the Input is outside of these limits the Block Output is held at the appropriate limit value The limits can be positive positive positive negative or negative negative however the Hi Limit must be greater than the Low Limit FUNCTION 35 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME H LLIM SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A INPUT Parameter Description Default Max Min Code Notes 1 HI LIMIT 100 00 199 99 199 98 2 1 2 LOW LIMIT 0 00 199 98 199 99 2 1 Notes 1 The Hi Limit MUST be greater than the Low Limit F36 RLIM Rate Limiter o PEM Limits 2 sec 5 sec Function RLIM compares the sec rate of change of the 25 Input analog signal to Parameter 1 increasing amp 2 decreasing rate of change limits Whenever the Input rate of change is between the two limits the Input is passed to L15 the Block Output If the Input rate of change exceeds either 240 limit the Output will ramp at the appropriate rate li
104. TOUT Block Enter this value into Parameter 5 Feedback at 100 Position Deadband Parameter 7 Positioner mode This value must be adjusted individually for each actuator to minimize hunting due to the connected load and the effectiveness of the actuator s brake Use either Force mode see Section 4 or the Blockware s Manual mode if provided to vary the actuator s position in 5 10 steps do not use S M mode Then observe the actuator response If the actuator hunts increase the Deadband If the actuator doesn t hunt decrease the deadband in increments until it does hunt after a move and then increase the deadband until the actuator doesn t hunt Stroke Time Parameter 6 Positioner mode TOUT uses Parameter 6 in an anticipator calculation to minimize actuator undershoot and overshoot during each move This parameter should be set to the approximate time in seconds that it takes to move the actuator from 0 to 100 Scaled Position Typically 85 of the actuator nameplate stroke time is used Values above 100 of the actual stroke time can cause overshooting and subsequent hunting Values below 45 of the actual stroke time can cause false TTRIP Block trips due to Slow Moving After the Deadband has been adjusted if the actuator continues to overshoot or undershoots excessively adjust the Stroke Time can help to reduce this If the actuator undershoots increase Stroke Time if the actuator overshoots decrease the Stroke
105. Time PCC III Instruction Manual ver 2 3 Page 6 30 Section 6 Blockware Functions Technical Reference Actuator Fault Detection Positioner Mode Some Hazardous applications monitor the actuators for faults in order to cause an alarm or safety shutdown An example is parallel positioning of separate fuel and air actuators for burner fuel air ratio control TOUT provides internal fault monitoring logic that is made available to other Blocks via the F100 TTRIP and F84 TCODE auxiliary Output Blocks This logic is designed for actuators with position feedback potentiometers pots that are wired directly to a PCC III analog input This logic is NOT designed to work with 4 20 mA or other types of position feedback signals This logic is designed to detect an open circuit in any of the Pot field wires or the Pot element stalled or burned out motors that are not moving and overloaded motors that are moving very slowly WARNING The TOUT Fault Detection logic may require external Pull up and Bias resistors for proper operation Failure to provide these parts and to test the installed system can result in EQUIPMENT DAMAGE INJURY OR DEATH The Fault Detection logic in TOUT is NOT sufficient for ALL applications Each application must be individually assessed and the control logic and external safety shutdown systems must be individually designed for the application Many applications require additional independent monitoring for example a Low Ox
106. VERIFY THAT ALL SOURCES OF POWER HAVE BEEN DISCONNECTED BEFORE WORKING ON WIRING FAILURE TO DO SO CAN RESULT IN INJURY OR DEATH The quantity of PCC III Input and Output channels can be expanded by adding up to three plug in Option Boards These Option Boards can be field installed by competent Instrument Technicians Refer to the procedure below the Drawing below and the CPU Board Layout drawing on page 2 7 If the PCC III is controlling a process it must be safely taken out of the control loop before attempting to install any option cards Remove the Front Panel From the PCC III Remove the screw on the top of the Front Panel Grasp the top corners of the Front Panel and move it forward away from the case about 12 Move the Front Panel Upwards and away from the case about 1 2 The Front Panel should now be free Depress the two retainer clips on each side of the ribbon cable connector on the CPU Board and remove the Ribbon Cable Connector Remove the rear cover from the PCC III Note where each field wiring Terminal Strip Connector is plugged in Unplug the field wiring Terminal Strip Connectors at the rear of the circuit boards Unscrew the Board to Case Retainer Screw see CPU Layout pg 2 7 It is located in the lower rear area of the CPU Board next to the JP2 250 ohm jumper header Prepare a static free work area and protect all circuit boards from a static discharge Slide the main PCB out of the PCC Ill and place on a
107. Vdc Typical for CPU A and F boards This example shows Analog Input 1 on the CPU Board Install JP 2 1 to connect the internal 250 0 ohm resistor The shield connects to the PCC III Signal Common Two Wire 4 20 mA Input External 24 Vdc Typical for CPU A and F boards This example shows Analog Input 2 on the CPU Board Install JP 2 2 to connect the internal 250 0 ohm resistor The External Power Supply and the PCC III Signal Common must be connected The shield connects to the External Power Supply Four Wire 4 20 mA Input Typical for CPU A and F boards This example shows Analog Input 3 on the CPU Board Install JP 2 3 to connect the internal 250 0 ohm resistor The Transmitter and the PCC III Signal Common must be connected The shield connects to the Transmitter PCC Ill Instruction Manual rev 2 3 PCC M 24 Vdc 1 5 Vde 4 20 mA Two Wire Xmtr to A D 250 0 ohms WH SC Signal Common Terminals shown are for Al ch 0 1 PCC M 24 Vdc Insulate Shield Insulate Shield 1 5 Vdc to A D 4 20 mA Two g JP2 2 ls Wire Xmtr Jumper lt P 250 0 gt I ohms 20 _ L 20 24 Vde SC Power Signal Common Supply Terminals shown are for Al ch 0 2 PCC M 24 Vdc 1 5 Vde Insulate Shield to A D
108. X Parameters are set equal to 150 00 ie inactive This allows the Block Output to be set to a defined value until a new curve is entered Blockware Example The Blockware on the next page shows a simplified parallel positioning combustion control application that uses two F x Blocks The F x in Block 55 holds the fuel to air characterizing curves for one fuel The F x in Block 62 holds the Oxygen Setpoint versus Load le Firing Rate characterizing curves for one fuel A second or third fuel could be accomodated by adding additional F x Blocks and ASW Blocks to select the correct F x Block based on the fuel currently being fired WARNING This simplified example does not show all of the required safety features that would be included in a real combustion control strategy Do not use the Blockware example shown for an actual application The Blockware is configured to use Learn Mode for simultaneous entry of the fuel air and Oxygen Setpoint Load F x curves The gerneral procedure a Burner Technician would follow is 1 Enable Learn Mode 2 Put BOTH the Fuel and Air Acutaors in Manual Manually position the Fual and Air at Minimum Firing Rate for best combustion Allow the Oxygen Analyzer signal to stabilize Press the front panel pushbutton that is configured as the STORE button Block 55 will add an X Y breakpoint for the current fuel X and air Y positions Block 62 will add an X Y breakpoint for the current fuel X and Oxy
109. ach other CPU 9 12 14 18 20 22 24 26 Ae x 41 x 43 x 45 x 47 x 49 x 51 FP x 41 x 43 x 45 x 46 x 47 x 49 x 51 G x 51 Power Common PC Terminal 9 on the CPU Board is reserved for noisy electrical loads such as external relay coils and solenoids Signal Common SC Except for Terminal 9 Power Common all other DC Commons are referred to as Signal Common and should be connected to low noise 0 5 Vdc and 4 20 mA circuits Isolated Signal Commons The terminal of each channel of a B Option Board is isolated from all other channels on that Option Board and from the CPU Board The terminals are also isolated channel to channel and from the CPU Isolated RS485 Terminal 3 COM is the isolated DC Common of the isolated power supply that powers the field wiring portion of the Isolated RS485 Communications Link The RS485 Data and terminals 1 amp 2 are also isolated from the CPU Board PCC III Instruction Manual rev 2 3 Page 2 18 Section 2 Installation CPU Board AC to DC and DC to DC Isolation To DIN ch 1 3 Optical rt RS485 is a D A Isolators Xmtr to from 4 __ D Isolated 7L Serial Port Revr 2 120 Vac TAS PE Discrete O RS485 Inputs DC DC u 3 Isolated Common L Loud y K Isolator AM O 5 Vdc 50 mA 1U 1L 15 T DC Power
110. after a wire break If Required install only one 1 Resistor either R1 or R2 Do NOT install BOTH resistors The value of Ri or R2 depends on the impedance of the field device the desired response time and the acceptable level of error introduced by the resistor Each application should be analyzed separately Example An Input for a 1k Position Feedback Pot on an electric actuator with an R1 Pull Up Resistor equal to 330k This combination adds less than 0 05 error and has a 3 sec response time If the pot is wired such that approx 5 V is 100 Open then TOUT will drive the actuator fully closed if the feedback pot wiper circuit becomes disconnected If the desired effect is to make the actuator fail open then reverse the 5 and Common wires to the pot and re calibrate TOUT The CPU A B and F boards do not include pull up or pull down resistors If desired the user must mount them externally The G option board includes an integral 330k Pull Up Resistor on each Input channel RS485 Communications Wiring RS 485 communications wiring terminals 1 3 is optically isolated and is not electrically connected to any other circuits within the PCC III This means that an accidental short to the RS485 cable will not affect the operation of the other controllers up to 31 units connected to the cable RS 485 cabling may be up to 4000 feet in length Longer distances can be accommodated by using RS 485 re
111. age ecseeeeeeeeee teens 20 Enabling the Password System bette otter Andes ane 10 Entering the Block Numbet cccccceeceseeeeeees 20 ENTER PASSWORD scscscsessssesssesesceteteteteeesees 11 Entering the Parameter Numbet c eee 21 SECURE CONTROLLER 0 oc ecccceccccccccccceceececececcesece 11 BLOCK TIMIN Gives csccceecese ceezeacs cathoeesesueecesstiptevnecie TIME QUT a r ete n E 11 CALIBRATE Menu 0 0 eee eee eee CHANGE OPERATOR PASSWORD cscccc0c00 11 When is Calibration Required CHANGE TECHNICIAN PASSWORD c 0000 11 Analog Inputs Calibration Status Display 22 Disabling the Password System c ccccccteeeees 11 Analog Input Calibration Procedure 22 EDIT A BLOCK MGI eiesccot 0502 82 peccenacetsaeasiradevece 12 Analog Output Calibration Procedure 23 GONG Pals e ican ae aa e eve 12 COM PORT MeNU ccccesesseesesteseetesteseetesneseeesne 24 How to use EDIT A BLOCK an Example 13 COM PORT siesena iia 24 Softwire the HIALM Block PV Input 0 005 14 ADDRESS 2 c 2chigeceneteciantvanee neh channseuexersesteetnviees 24 Change the HIALM Setpoint Parameter 14 BAW D irictececee a a a a 24 Softwire the PANEL Alarm Channel 1 Input 14 ata E E EE EE EEE EE 24 Entering a Message Parameter in PANEL 15 RTU ASCl sinen ea a deveniate 25 MEMORY Me cecececccccccccccccccceceecccceceesecce
112. allation D INSTRUMENTS DANBURY CT 06810 Option Board 3 Terminals RS232 Blockware Download Port Backup Memory Write Protect Jumper Front Panel Cable Connector Backup Memory Socket 40 a R2 25K D4 q 9 oes ee na ntlo c5 c6 K___D2 __KDS5 I I Shaloqr R1 IE 5 c1 C14 X R8 ER R3 1D y eed he 2 sabodo e c SANUS SUMIL Z 44 fe RN2 Ie eae F a C18 Wl wilo o I S i 5 C3 i TE Js o 4 gt DW Al ko co D 47L 0 ol 5 D Sahod e o3 tt a ys Be c10 U eS 2 C25 C33 BE 0 cacy jf 51 LO dopo _F Wed a 2 Pres a 250 1 zl Re i 250 2 af R6 moo oC ooo OO O08 i ee eee 250 3 PREF INSTR DANBURY CT 681 RN3 RN4 RNS RNG RN7 RNB AIN ch 1 To Connect 250 ohm Resistor AIN ch 3 Turn Switch ON F Option Board 250 ohm Switches Combination 4 20 mA 0 5Vdc Analog Inputs 3 Channels 4 20 mA An
113. alog Outputs 2 Channels Fuse for Pair 1 Term 42 amp 43 Fuse for Pair 2 Term 45 amp 46 J2 V3 C8 RIZ 3A NORMAL R3 LARIS R1 pa z ts a D an TR1 TRS 8B INE LOA a amp 3A NORMAL 5 nte g pal toca 23 250 VAC Test T Be a mp R9 L2 R6 1 at x LINEC 1 9F2 x1 i V es 21 085 124 eres Troe poe aie ga z Fi oa s Sia T JD3 gt p o nonU orm goes Uh ii ps JP I Cg ct D 7 R12 c170c14 c20 Ep Gi ait R18 genea CSSSSOSEOSSOE by aRN2 RN4 gN3 RNS RNG RNB Ss AJIN Sa jor H polos Ho99999999999 T T T TTT RZ2 2RZ4 C19 PREF INSTR DANBURY CT 06810 AIN ch 2 330k Pull Up Resistor Remove if External Pull Down Resistor AIN ch 1 or External 250 ohm Resistor is in use G Option Board Fuses and Pull ups Combination 0 5Vdc Analog Input 2 Channels Triac Output AC Solid State Switch 2 Pairs 4 Triacs PCC III Instruction Manual rev 2 3 Page 2 8 Section 2 Installation NOILdO f E cuvo PCC III Instructio 40 xe tH het a a D 42 m N 2 43 R5 or ar D a L all s oll s Ole ca S 45h 9 d re oe one Sehol aly gr jee 8 5 eee U8 C10 C12 Z aboe qs oy a ea a p NLS HIII is or 7 Pte ea gee 51 Src S Ch E o a a DIN ch 4 Neutral DIN ch 1 Neutral
114. an Analog Output 4 20 mA TO means this is a Triac Output Scroll to the desired channel of the desired Board then Press ENTER to toggle between AUTO or S M At power up this menu is automatically re configured to show only the Output types channels and boards that are actually installed Press ESC to return to the MAIN menu The MAIN menu display will automatically change to EXIT S M The RUN light will start blinking EXIT S M in MAIN Menu Pressing ENTER starts the Blockware error check routine If no errors are detected all of the 4 20 mA and Triac Output channels are put into Normal Operation mode The MAIN menu display will automatically change to ENTER S M The RUN light will stop blinking If the Blockware error check detects an error the message display will indicate the nature of the error and the Block that is causing the error Press EDIT v to see if there are any additional errors Press ESC when review of the error list is complete in order to return to the MAIN menu The RUN light will continue to blink Changing an Output Value in S M Mode When an Output channel enters S M mode the Output is held at the last value The Output will remain at the last value until the Operator changes the Output from the Front Panel Use ESC to exit the EDIT menus EDIT light is OFF Use the DIS key to scroll through the display channels until the desired S M Output channel is displayed S M Output channel messages have the followin
115. and SP bargraphs to blink and if supplied activate a panel mounted or remote alarm horn bell and or light Pressing ACK will cause the Message display to show the first of up to 10 alarm messages and it will silence any optional alarm horns or bells If the ALARM light continues to blink then there are additional alarm messages that have not been displayed Press ACK again to allow the next alarm message to appear on the Message display The Annunciator records and plays back alarm messages in the same sequence as the alarms actually occurred The Numeric display is used to indicate the sequence number of the alarm message currently being displayed and the total quantity of alarm messages in the alarm memory The Numeric display shows two numbers separated by a blank space The left digit is the sequence number 1 is the first to occur and the right digit is the total quantity of alarm messages in memory Alarms that are no longer in the alarm state are deleted from the list after all message have been displayed at least once Example A feedwater controller monitors and has alarm channels for Low Feedwater Supply Pressure High Drum Level Low Drum Level and Low Low Drum Level Assume that a boiler modulates up to maximum rate but the PCC III Instruction Manual rev 2 3 Page 3 6 Section 3 Operation feedwater pump capacity is inadequate the feedwater pressure drops the drum level drops and the boiler eventually trips due to low low
116. and low drum pressure alarms only when in Local PID mode EDIT to Block 59 Press ENTER Make Block 59 a HIALM Function Function 101 There are three Inputs and five parameters to setup Configure 101 PV to be from B4 Configure 102 External SP to be from BO We will use an internal setpoint Configure 103 Disable Input to be from B55 We want no alarm if in the Plant Master mode Configure P01 as 2 We want internal Setpoint mode Configure P02 as 1 00 1 of the Drum Pressure transmitter s full scale range gives us a deadband of 2 psig Configure P03 as 70 00 70 of the Drum Pressure transmitter s full scale range gives us a high alarm setpoint of 140 psig Configure P04 as 1 Alarm is disabled when PB1 is high Configure P05 as 60 We want a 60 second delay before the alarm sounds to prevent nuisance alarming Block 60 LOALM EDIT to Block 60 Press ENTER Make Block 60 a LOALM Function Function 102 There are three Inputs and five parameters to setup Configure 101 PV to be from B4 Configure 102 External SP to be from BO We will use an internal setpoint Configure 103 Disable Input to be from B55 We want no alarm if in the Plant Master mode Configure P01 as 2 We want internal Setpoint mode Configure P02 as 1 00 This gives us a deadband of 2 psig Configure P03 as 40 00 This gives us a low alarm setpoint of 80 psig Configure P04 as 1 Alarm is disabled when P
117. annels causes both the Numeric and Message displays to change to the next display channel at the same time A typical display channel example would be boiler drum steam pressure the variable After scrolling to this display channel with the DIS pushbutton the Numeric display item 4 might show 149 for 149 psig while the Message display item 5 simultaneously showed DRUM PSI If the displays are currently showing an Alarm Annunciator message press DIS to return to the display of the Process Control display channels The operation of the DIS pushbutton can not be changed by the Blockware designer In normal operation the DIS pushbutton can always be used to scroll through the display channels There are only three reasons why depressing the DIS pushbutton would not cause a change in the display channel If the EDIT light item 22 is ON See Section 4 for instructions on how to exit the EDIT mode The Blockware loaded in the PCC III memory does not have any display channels PCC III Instruction Manual rev 2 3 Page 3 4 Section 3 Operation If the green RUN light is OFF or blinking indicating that the controller may need to be serviced ft and Pushbuttons Item 10 and 11 in fig 1 These pushbuttons are used to increase or decrease the value that is currently being displayed on the Numeric display These pushbuttons can only be used to change values that the Blockware Designer has configured to be modifiab
118. anual ON OFF Continuous Not Operating Note S M Mode RUN light indication takes priority over FORCED Mode indication when both S M and FORCED Modes are active FORCE BLOCK Scroll to FORCE BLOCK press ENTER ENTER BLOCK NUMBER will be displayed Use EDIT 4 or EDIT v to display the desired Block Number press ENTER Bxx followed by the Function Name will be displayed and the Edit Value light will be blinking Use EDIT 4 or EDIT v to set the desired Block Output Value press ENTER The display returns to the menu The RUN light will start blinking as noted above unless S M mode is active Repeat the above for each Block to be FORCED Multiple Block Outputs can be simultaneously FORCED PCC III Instruction Manual rev 2 3 Page 4 19 Section 4 EDIT Menus UN FORCE A BLOCK This menu item returns a single Block to Normal Operation ie UN FORCED Scroll to UN FORCE A BLOCK press ENTER ENTER BLOCK NUMBER will be displayed Use EDIT 4 or EDIT v to display the desired Block Number press ENTER Block Released will be displayed and the Block will be UN FORCED Press ESC to return to the menu UN FORCE ALL BLOCKS This menu item returns ALL Blocks to Normal Operation ie UN FORCED Scroll to UN FORCE ALL BLOCKS press ENTER PRESS ENTER TO RELEASE OUTPUTS will be displayed press ENTER to continue The display returns to the UN FORCE ALL BLOCKS menu item DISPLAY SCAN TIME This menu item displays
119. ary memory that is erased every time power is lost RAM is where the configuration Blockware is processed EEPROM EEPROM stands for Electrically Erasable Programmable Read Only Memory The PCC III has one Primary and one backup EEPROM chip The Primary EEPROM is soldered to the board The backup EEPROM is in a removable socket Upon power up the PCC III copies the contents of the Primary EEPROM to RAM The controller then operates from this RAM When the user makes a configuration change he she is writing to RAM The PCC III automatically copies RAM to the Primary EEPROM after leaving EDIT mode if any changes are made to RAM Thus any change the user makes to the program is saved in the non volatile Primary EEPROM Using the MEMORY menu in EDIT the user may copy Primary EEPROM into the backup EEPROM All Microprocessors are susceptible to severe electrical noise Though the PCC III is well protected it is possible for the contents of memory to be lost or scrambled If this happens the PCC III will Autoload the contents of the backup EEPROM to the Primary EEPROM and RAM and the system will continue to operate see Section 4 Retentive Memory Retentive memory is a special area of the EEPROM used to automatically save and restore specific Block Output values at power down and power up Typically Setpoints Ratios flow totals and pushbutton status s are saved and restored to from Retentive Memory Retentive Memory allows a controller to re
120. ass digital smoothing filter The result of the digital filter becomes the RAIN Block Output By setting parameters 1 4 any or all of these signal conditioners can be turned off The Comm Link scaling is Block Output 100 That is when Comm Link writes 5047 PCC III interprets the value as 50 47 A RAIN Block Output of 17 01 is reported to the Comm Link as 1701 The limiting and filtering discussed above can cause the value written by Comm Link to be different from the RAIN Block Output that is read by Comm Link RAIN will not indicate an error to the Comm Link if Comm Link writes a value outside of the min max limits Timeout The value written by Comm Link remains in effect until a new value is written or until a Comm Link time out Upon Comm Link time out ie no new message received within x sec parameter 5 RAIN can either remain at the last value or switch to the default value parameters 6 and 7 If RAIN switches to the default the signal conditioning is applied to smooth the transition At power down the Block Output is saved in the Retentive Memory area of the EEPROM During the first scan after CPU start up the RAIN Block Output is set to the value stored in the Retentive Memory If Retentive Memory is invalid the Block Output initializes to the Default Output value upon CPU start up PCC III Instruction Manual ver 2 3 Page 6 5 Section 6 Blockware Functions Technical Reference FUNCTION 5 TEMP BYTES 8 RETENTIVE BY
121. button for remote setback The control is in setback mode Night Setpoint when the LED is on When the LED is on its Output is high 1 This selects the B Input of B22 which is the Night Setpoint Day and Night Setpoints can be adjusted from the front panel Day Night Select Night Setpoint Day Setpoint Figure 5 6 Revised Overall Boiler Master Blockware Figure 5 7 on the next page shows how the individual control enhancements discussed in this section figures 5 4 5 5 amp 5 6 can be incorporated into our original scheme Figure 5 3 to produce a revised overall control strategy PCC III Instruction Manual rev 2 3 Page 5 16 Section 5 Configuring Blockware Submaster Bias FPCON Orifice Plate Steam Flow Drum Xmtr Transmitter Full Scale Design PSI AIN Ch g 1 5v Drum PSI B4 Blocks 35 amp 36 are Steam Density vs Saturation 36 Pressure Curves Actual 37 Design SQRT 39 Alarm Silence DIN Ch 2 Corrected Corrected Steam Flow Steam Flow Pulsed Output Analog Output Common Alarm Section 5 Configuring Blockware Drum PSI Day Night Plant Transmitter Select Master PB AIN 3 Che 2 1 5v 5a 5 Night PV PV Setpoint A LOALM HIALM B32 On LED FPCON WSUM Night 3 A
122. c A larger value provides a larger response to a signal change FUNCTION 43 TEMP BYTES 20 RETENTIVE BYTES 0 DATA BYTES 24 NAME L L SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A PV INPUT Parameter Description Default Max Min Code Notes 1 LAG SECONDS 0 1800 0 2 1 2 3 2 LEAD SECONDS 0 1800 0 2 1 2 3 3 GAIN 1 00 20 00 0 01 2 Notes I 0 Off 2 Lag seconds must be greater than 0 if Lead is greater than 0 3 The ratio Lead Seconds Lag Seconds must be less than 15 F4 ALE ignal lin 5 SC Signal Scaling Function SCALE generates a Block Output based on two X Y scaling points X is the Block Input and Y is the Block 100 Output The straight line defined by scaling points X1 Y1 and X2 Y2 continues beyond the two defined points and generates a Block Output within the 327 limitations of 50 the Input and Output See examples below O o Graph of Example 3 50 p p 50 0 50 100 150 Input X Example 1 Example 2 Example 3 Input x X 0 Output Y Yi 0 Yi _90 FUNCTION 45 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 20 NAME SCALE SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A SIGNAL INPUT Parameter Description Default Max Min Code Notes 1 X1 0 00 150 00 150 00 2 2 Y1 0 00 150 00 150 00 2 3 X2 100 00 150 00 150 00 2 4 Y2 100 00 150 00 150 00 2 PCC III Instruction Manual ver 2 3 Pa
123. c AIN 2 ch 4 20 mA AOUT combination option board 92243 12 pt field wiring connector 190367 2 ch 0 5 Vdc pot AIN 2 pair 3A 24 120 Vac TOUT Triac combination option board 92243 12 pt field wiring connector 190370 4 ch 120 Vac opto isolated DIN 2 ch 8 A ROUT Relay combination option board 92243 12 pt field wiring connector 190355 PC3_Edit _ Draw RS232 download cable with DB9 adapter 25250 0B25 250 0 Ohm Precision Resistor 3 4MF PCC III Instruction Manu al rev 2 3 Page 1 8 Section 1 Product Overview PCC III Specifications Mechanical Case Size Enclosure Type Front Panel Size Panel Cutout Weight Environmental Operating Temp Storage Temp Humidity Limits Front Panel Performance Accuracy Resolution Execution Cycle Non Volitale Memory Life Operator Control Panel Displays Alphanumeric Numeric Bargraph Left Right Output Pushbuttons Faceplate Alarm Annunciator Status Indicators User Defined Pushbuttons Electrical Input Power Requirements Power Supplies Height 7 38 Width 3 00 Depth 7 75 Flush panel mounted 8 00 H X 3 75 W 7 50 H X 3 13 W 4 062 6 Ibs excluding option boards 32 to 122 F 0 to 50T 20 to 150 F 28 to 65 15 to 95 non condensing NEMA 13 IP65 0 025 Analog Inputs and Outputs 70 F 16 bit input 16 bit output Ten per second 10 8 30 yrs Blockware dependent 8 character LE
124. cal installation is completed put the PCC III into S M mode Service Manual see Section 4 and exit the EDIT display mode Then press DIS repeatedly until TO bxcy Triac Output Board x Channel y is displayed for the desired Triac Output channel Press the front panel ff key to open increase the actuator then press and hold the front panel key to close decrease the actuator Calibrating the Scaled Position Positioner Mode Read Scaled Position Initial Actuator Setup and Are Bias Resistors Required sections of TOUT before Calibrating Consult the Blockware to determine the Block Number of the TOUT function that drives the actuator being calibrated Use S M mode to move the actuator during this procedure see Actuator Setup above The Scaled Position must be calibrated whenever the actuator is initially installed changed out re stroked or if the feedback pot is changed Using the TO bxcy S M mode front panel display press and hold the front panel key until the actuator is fully closed 0 position Use the Utilities Examine menu see Section 4 to display the unscaled FEEDBACK INPUT 102 value of this TOUT Block Enter this value into Parameter 4 Feedback at 0 Position Using the TO bxcy S M mode front panel display press and hold the front panel ff key until the actuator is fully open 100 position Use the Utilities Examine menu see Section 4 to display the un scaled FEEDBACK INPUT 102 value of this
125. cations ports and require an external RS232 RS485 converter RS232 RS485 converters are available from Telebyte Technology 516 423 3232 Model 8324 The RS485 Cable must have exactly one set of Pull Up Pull Down resistors installed to insure that the cable is biased to greater than 0 2 Vdc differential in the Idle state ie no nodes are transmitting The Model 8324 has internal Pull Up Pull Down resistors that are activated by setting DIP switches PCC III Instruction Manual rev 2 3 Page 2 20 Section 2 Installation D Cee D eve a aera a re sy Belden 3106A no substitutes PCC Il PCC M PCC II 4000 ft cable length max Use Repeaters if greater than 4000 ft Daisy Chained Bus Layout OK PCC III PCC I PCCHI PCCM PCCM PCCM PCCM ScadaFlex Workstation Daisy Chained Bus Layout OK PCC III PCCHI PCCW PCCM PCCIIT PCCHI PCCM ScadaF lex Workstation Daisy Chained Bus Layout OK PCC HI PCCW PCCII ScadaFlex PCC UI PCCW PCCHI Workstation Bus with Stubs Layout Not Acceptable PCC III PCC PCC PCCII PCCM PCCM PCC HI ScadaFlex Workstation Star Layout Not Acceptable PCC III PCCIN PCC PCCII PCCIN PCCIN PCCI ScadaF lex Workstation PCC III Instruction Manual rev 2 3 Page 2 21 Section 2 Installation RS232 Blockware Download Cable The PCC IIl is capable of uploading and downloading Blockware Configurations and other diagnostic information via the RS 232 port on the CPU board The signals are standard R
126. ckage while coincidentally allowing for the automatic integration of that variable into any planned control or monitoring strategy Relay Output Channels The PCC III can be equipped with up to 6 Relay Outputs The Relay contacts are rated for up to 8A inductive loads and include integral surge suppressors for extended contact life These outputs can be directly wired into most burner limit circuits without external helper relays OPLR Stack Exit Correlation for EPA Opacity Monitors EPA certified stack Opacity monitors are required to display the Opacity as would be viewed at the Stack Exit However the Opacity Transmissometer ie the sensor is never mounted at that location The PCC III includes a function type that will calculate the complex EPA mathematical equation to convert ie correlate the Opacity measured at the sensor s actual location to that at the Stack Exit Flow Totalization The PCC III is equipped with a Pulse Counter function type to permit output and subsequent totalization of flow rates on digital displays This can eliminate the need for local counters on flow meters in those instances when they already transmit an analog flow signal to the PCC III PCC III Instruction Manual rev 2 3 Page 1 6 Section 1 Product Overview PCC Ill Loop Controller Model Number PCCIIl a b 0 Option Card Slot Number 1 0 none A AIN 5ch 4 20 mA 0
127. cludes an RS232 port to allow a Personal Computer ie PC to be used as a configuration tool The PC also allows the downloading and retrieval of stored configurations along with the ability to fully document the configuration Preferred Instruments PC3_Edit or PC3_Draw software is required to upload or download Blockware data via the RS232 port Development of good control strategy starts with a well conceived game plan These few steps will help the user to configure the PCC III in a timely manner Define the user s requirements Check the system Input Output I O count Break the configuration down into manageable sections Sketch each section Assign ie change the Function Types in each Block Softwire the Block Inputs Modify Parameters as required Configure the front panel displays and alarms Test the configuration Place controller into operation The remainder of this Section will be a detailed example of how to enhance a simple Boiler Master Blockware Control Strategy by adding features in small manageable sections PCC III Instruction Manual rev 2 3 Page 5 7 Section 5 Configuring Blockware Modifying a Boiler Master Blockware Configuration Let s suppose a customer has developed a simple Boiler Master configuration as shown in Figure 5 2 The configuration consists of a steam drum pressure transmitter Input drum pressure setpoint a PID control loop a 4 20 ma firing rate demand Output wired
128. compensation This becomes of particular importance when the flow measurement is a significant process control variable as it is in a fully metered combustion control strategy High Temperature Hot Water HTHW BTU Hr Computation An important characteristic of any High Temperature Hot Water Generator is the quantity of BTU s produced per interval of time With inputs of the generator s inlet and outlet water temperatures and the water s flow rate this value can be easily calculated The resultant figure is typically compared to that from the aforementioned Boiler Efficiency calculation to determine if possible problems have arisen PCC III Instruction Manual rev 2 3 Page 1 5 Section 1 Product Overview Drum Level Pressure Vs Density Compensation In applications where there are large swings in steam demand the steam generator s drum level can be subjected to significant shrink and swell Density compensation is an important tool in assuring optimum drum level control despite these conditions Oxygen Sensor Control Signal Conversion option card Zirconium oxide in situ oxygen analyzers include a basic electronics package that maintains sensor temperatures at exacting levels and as well converts the millivolt output of the sensor into a linear O2 vs milliamp function 4 20 madc When equipped with the appropriate option card the PCC III performs the same function as the manufacture s electronics pa
129. cted to the DC common of the Power Supply that is powering the signal All shield foils and shield wires should be insulated taped or heat shrink to prevent accidental connection to earth or power ground Shields connected at both ends or unintentional second grounds can actually add extra noise to a signal instead of reducing noise To prevent noise pick up shielded cables should never be run in conduits or trays with AC wiring any voltage Ignition transformer and variable frequency drive AC wiring is particularly noisy and should be kept separated from all DC signal wiring PCC III Instruction Manual rev 2 3 Page 2 4 Section 2 Installation 24 Vdc amp 5 Vdc Power Supply Load Calculations The PCC III CPU board has a built in 24 Vdc power supply that is rated for 215 mA continuous output at 138 Vac and 125 F The 215 mA current limit is based on the sum of all 24 Vdc loads CPU board Option boards and field terminals 10 16 27 28 Below is a worksheet to calculate total 24 Vdc current load Item mA Qty Total each 2 wire 4 20 mA xmtrs 20 that are powered by PCC III 4 20 mA Outputs 20 CPU F board s Relays 25 CPU J board s B Isolated Input board s 55 G Triac Board 24V powers 5Vdc 50 max Field wiring load dependent Total mA Load Notes 1 Only count 4 20 mA Outputs and Relays that are actually being used 2 Each B board draws
130. ction ASW is used to switch the Block Output between one of two analog Input signals under control of a discrete on off Select signal The concept is very similar to a SPDT relay or 3 PCC III Instruction Manual ver 2 3 Page 6 9 Section 6 E 1ckw ions nical Refegsg 0 1 Xter Limiting 0 Time port solenoid valve When the Select signal is 0 low the A analog Input is selected and passed to the ASW Block Output When Select 1 high the B signal is passed to the Output Transfer Rate Limiting When Parameter 1 O Transfer Rate Limiting is OFF the Block Output changes instantaneously when the Select Input changes When Parameter 1 1 Transfer Rate Limiting is ON the rate of change of the Block Output signal is limited for the duration of the transfer After the Block Output becomes equal to the selected Input the rate limiting is disabled and the Output will track the selected Input with no rate of change limiting Independent rate of change limits are provided for A to B and B to A transfers The Transfer Rate of Change feature can be used to provide bumpless transfer and for ramp generators FUNCTION 34 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 32 NAME ASW SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A A INPUT 2 A B INPUT 3 D SELECT INPUT 0 A Input 1 B Input 1 Parameter Description Default Max Min Code Notes 1 XFER RATE LIMITING O OFF 1 ON 0 1 0 2 2 2 A
131. cular Block will use the gain of a specific PID control Function etc A controller s configuration as a whole determines how the overall controller will function Multiple PCC IIls can be equipped with identical hardware circuit boards etc but each can be configured to Function completely differently Function Type Or Function Code Number The Function Code Number is a number that identifies the type of computation or the type of action that a Block will perform Examples are 2 get an analog Input from the field terminal strip 51 calculate A B C 71 calculate a PID controller Output 118 x seconds after Input turns on turn on Output Numbers are hard to remember so normally we refer to each of the Functions by using an abbreviation or Function Name such as 2 AIN Analog INput 51 AB C A B C 71 PID PID controller 118 DAETDR Delay After Energize Time Delay Relay When setting up a PCC III you must enter the Function Code Number All of the Functions available in the PCC III are listed in numerical order in Section 6 Blockware Technical Reference of the instruction manual and the task that each type performs is described in detail as well Section 6 provides two Table of Contents the first is in Function Code Number order the second is in Function Name order Input There are two types of inputs electrical signals that are physically wired to the rear terminal strip of the controller and imaginary connections in
132. d Position if the difference is outside of the Deadband Parmameter 7 one of the two Triac outputs is turned ON to drive the actuator toward the Setpoint position When the actuator position is within the range of Setpoint Deadband both Triacs are turned OFF In Positioner Mode the Triac 1 and Triac 2 Inputs are ignored The Block Output of TOUT is the 0 100 Scaled Position of the actuator See the diagram below for a typical Positioner Mode application PCC III Instruction Manual ver 2 3 Page 6 28 Section 6 Blockware Functions Technical Reference 0 NORMAL 1 FAULT DESIRED SCALED ACTUAL POSITION 0 100 POSITION 0 100 A 0 NONE AIN FILTER 1 POS gt 105 MUST BE 2 POS lt 5 ALED 3 NOT MOVING 0 0 SEC SC 4 SLOW MOVING UNSCALED POSITION r 1 0 NORMAL 1 S M MODE I l HOT PCC IIl BLOCKWARE NEUTRAL POSITION FEEDBACK POT REVERSIBLE ELECTRIC ACTUATOR TYPICAL F83 TOUT POSITIONER MODE APPLICATION z 5 BIAS RESISTORS z 5 Re APPROX 7 OF FEEDBACK zo a POT OHMS A to B a 7 eres METAL FILM OR WIREWOUND aera o 4 5 4 2 3 2 PCC III Gxx0 FEEDBACK 5 9 PCC III Gxx0 FEEDBACK D POT POT OIN A 100 150 5 R 100 AIN 94 100 330k 107 TOUT PULL UP 75 100 in BOARD AIN SIGNAL Boe Ne NTA nee 25 0 0 AIN SIGNAL 4 7 TOUT 6 0 aaO
133. d can be used to enter new passwords however this may require a billable service call to your site PCC III Instruction Manual rev 2 3 Page 4 10 Section 4 EDIT Menus ENTER PASSWORD This menu item is used to activate a Password Level Scroll to ENTER PASSWORD press ENTER Use EDIT 4 or EDIT V to change the Numeric display to the Password Number for the Level that you wish to activate then press ENTER Password Enabled will be displayed press ESC to clear the message and return to the PASSWORD menu If an incorrect password is entered ERROR INVALID PASSWORD WILL BE DISPLAYED Press ESC to clear the message and return to the PASSWORD menu SECURE CONTROLLER Once a Password Level is activated it will automatically deactivate after a Timeout period However the current Password Level can be de activated before the Timeout by scrolling to SECURE CONTROLLER and pressing ENTER Controller Secured will be displayed press ESC to return to the menu TIMEOUT Once a Password Level is activated it will automatically deactivate after a Timeout period The default Timeout is 30 minutes The Timeout can be changed to any value between 1 and 240 minutes The Timeout is reset to 30 minutes every time the Password Level is deactivated i e Secured To change the Timeout Scroll to TIMEOUT press ENTER Use EDIT 4 or EDIT V_ to change the Numeric display to the desired number of minutes then press ENTER Press ESC
134. desired external wiring is required Hot The Hot Power Inputs to the G and S Triac Output Option Boards are isolated from the CPU Line Input Each Option Board Hot is Isolated from the Hot of the other Option Boards If a connection is desired external wiring is required The Hot Input for a particular Triac Option Board is a common input that feeds all Triacs on that board Neutral The CPU AC Power Neutral Input Terminal 1U is internally connected to CPU terminal 1L CPU Terminal 1U is NOT internally connected to any of the option boards If a connection is desired run a field wire from the CPU board to the Option Board CPU Terminal 1U is the return path or Neutral for all current that enters any of the CPU 120 Vac Discrete Input channels Terminals 4L 8L The Hots and Neutral of all J Option Board 120 Vac Discrete Input channels are isolated from the CPU Board Line and Neutral Each J Board Input channel is isolated from each other J board channel The J Board is provided with jumpers to allow connecting the Neutrals of the channels together if desired DC Common The DC commons are isolated from case ground All Signal Commons on the CPU board are interconnected and are also connected to the Signal Commons on the A F and QG Option Boards Specifically the following terminals are all internally connected to e
135. dustry standard Modbus protocol Because the PCC III is self sufficient control will be maintained even if for any reason the operator s station s or network are completely disabled Further even if the internal microprocessor or digital electronics of the PCC III fail a hard manual option card will allow the process to be manually operated Lastly much like a DCS or PLC I O card a complete PCC III or DCS III failure affects a relatively small percentage of the overall system s I O Considering all the above the need for redundant power supplies microprocessor cards or I O cards is all but eliminated The backbone of the system is the network The network used between controllers is based upon the industry standard Modbus protocol using the controller s integral RS 485 communications facility This network communications is optically isolated and can be made redundant optional Analog and PLC Control Functions The PCC III includes all the control functions needed for your application The controller includes not only traditional analog functions but also many discrete logical and timing functions The controller can handle many tasks that would normally require the use of a PLC and the use of option cards permits expansion of those discrete I O capabilities up to 13 DI and 10 RO DO Discrete functions can also be readily integrated with analog functions which has been traditionally difficult to accomplish with a
136. e 2 1 Section 2 Installation Mounting Overview PCC III is designed for flush mounting in an enclosure in a NEMA 13 IP65 indoor environment Continuous operation is guaranteed over the 32 125 F 0 52 C ambient temperature range without derating The controller should not be subjected to excessive vibration The PCC III is UL508 recognized for NEMA 1 dry indoor applications The NEMA 13 rating is based on Preferred Instruments testing and is not third party UL508 recognized NEMA 13 IP65 Environment A NEMA 13 environment is generally defined as Intended for indoor use primarily to provide a degree of protection against dust and splashed or sprayed water oil or non corrosive coolant NEMA 13 is generally equivalent to the European IEC standard IP65 The PCC III front panel and case gasketing will provide NEMA 13 protection if the enclosure to which the PCC III is mounted itself is designed for NEMA 13 minimum protection PCC III can be installed in more severe environments if the user provides additional protection that is consistent with and or required for the area s rating Ambient Temperature PCC III is rated for continuous operation over the 32 125 F 0 52 C ambient temperature range without derating A typical PCC III installation in a control cabinet mounted next to an industrial packaged boiler would not require cabinet cooling However each installation should be evaluated individually to determine if the PCC III a
137. e affected EDIT to Block 120 Configure 107 Track mode 2 to be from B55 This forces the PID Block Output to track the Firing Rate when in the Plant Master mode Modify Block 126 ASW EDIT to Block 126 Configure 101 A to be from B125 Configure the front panel displays and alarms Modify Block 159 PANEL This is the PANEL Block Function 96 We must add display channels for the Plant Master Demand and Submaster Bias We must also put the high and low drum pressure alarms in the annunciator We will also change the bargraphs to display Plant Master Demand and Firing Rate demand when in the Plant Master mode Configure 104 Display Channel 4 to be from B5 Configure 105 Display Channel 5 to be from B25 Configure 115 PV Bargraph 2 to be from B5 Displays Plant Master Demand Configure 116 SP Bargraph 2 to be from B26 Displays Firing Rate demand User can visually compare to Plant Demand bargraph and detect if there is any bias Configure 117 Output Bargraph 2 to be from B150 Displays Firing Rate Configure 120 Alarm Channel 1 to be from B59 Configure 121 Alarm Channel 2 to be from B60 Check that 130 Alarm Silence is set to B41 Check that 131 Annunciator Enable is set to B3 This is always active Configure P14 Channel 4 decimal to 0 no decimal Configure P15 Channel 4 zero to 0 Configure P16 Channel 4 span to 100 Plant Demand spans from 0 100
138. e and the Parameter value would remain as it was before any changes were attempted For this example do not press ESC Press ENTER Block 2 Parameter 3 the Internal Setpoint is now set to 75 00 Scroll Menu light will blink Edit Value light turns off Softwire the PANEL Alarm Channel 1 Input The Alarm Channel 1 Input Input channel 20 see Section 6 of the PANEL Function in Block 158 will be Softwired ie configured to monitor the Block Ouput signal of the HIALM Function in Block 22 in this example See Softwire the HIALM Block PV Input above for more detailed comments the instructions below are shortened fro brevity Continuing from the previous example B22 P03 INT SP is displayed S M mode is active and Technician Password Level is active Scroll Menu light should be blinking If Edit Value light is blinking Press ESC Scroll Menu light will then blink Press ESC to exit the EDIT A BLOCK menu for Block 22 ENTER THE BLOCK NUMBER TO BE EDITIED will be displayed Use EDIT 4 or EDIT V to set the Numeric display to 158 ie Block number 158 press ENTER B158 PANEL and 96 will be displayed PCC III Instruction Manual rev 2 3 Page 4 14 Section 4 EDIT Menus Scroll down to B158 120 ALM CH 1 Press ENTER to change from Scroll Menu to Edit Value mode Scroll Menu light turns off Edit Value light will blink Use EDIT 4 or EDIT V to set the Numeric display to 22 ie
139. ed and tested before they are copied to the Backup memory If the changes do not work as desired the COPY BACKUP TO PRIMARY menu item can be used to load the original logic back into the Primary memory Backup Memory Write Protect Jumper In order to prevent corruption of the Backup memory the Backup has a Write Protect jumper on the CPU board see pg 2 7 The Write Protect jumper should be in the WP ie Write Protect position at all times during normal operation However the Write Protect Jumper must be moved to the R W ie Read Write position before using the COPY PRIMARY TO BACKUP menu item The jumper must then be moved back to the WP position after completing the Copy process PCC III Instruction Manual rev 2 3 Page 4 15 Section 4 EDIT Menus Backup Memory Socket Both the Primary and Backup memories are non volatile EEPROM memory chips that will retain their contents for over 20 years without power and they do not rely on batteries The Backup memory is plugged into a lever operated Zero Insertion Force ZIF socket The Backup memory chip can be easily removed from the PCC IIl and it will retain it s contents DO NOT REMOVE OR INSTALL THE BACKUP MEMORY CHIP WHEN POWER IS APPLIED TO THE PCC Ill These features can be used in several ways Copy Blockware from one PCC Ill into a second PCC Ill If you have two boilers or process units that are identical after the start up of the first unit is completed
140. ed value to change rapidly release the tort pushbutton after the displayed value has changed by 8 or 9 counts AUTO MAN Pushbutton and Light Items 14 and 15 in fig 1 This pushbutton and light are both User defined However it would be very unusual for a Blockware designer to use this pushbutton light pair for anything besides selecting the Automatic or Manual mode for the controller s Output Typically when the light is ON the controller is in Manual MAN When the light is OFF the controller is in Automatic AUTO The pushbutton is typically configured as a toggle type That is every time the pushbutton is pressed the status toggles to the opposite status MAN to AUTO AUTO to MAN MAN to AUTO Auto DIS Automatic Display Channel Selection Auto DIS is an optional feature that most Blockware designers utilize Auto DIS connects the AUTO MAN pushbutton to the display channel selection logic as follows When AUTO MAN changes from MANual to AUTO display ch 2 typically the PV is automatically selected When AUTO MAN changes from AUTO to MANual display ch 1 typically the OUT is automatically selected However after Auto DIS has changed the display channel the Operator can still use DIS to select a different display channel Without Auto DIS the Operator would have to first change the AUTO MAN pushbutton and then manually change the display channel with the DIS pushbutton Auto Manual Example This example wo
141. emote Local Temperature Supply is less than 100 sec The rate of change of the Block Setpoint Select Setpoint Temperature Output signal is limited to Parameter 3 sec for the duration of the transfer from the last Hold mode Block an ia Output to the current Signal Input When the Block Output becomes equal to the Signal Input the rate limiting is Toggle disabled and the Output will track the Signal Input with no rate of change limiting The Transfer Rate of Change D feature is used primarily to provide bumpless transfer i In ALL cases the Block Output is limited to the Min and n FPTH Max Output values set in Parameters 1 amp 2 LED4 H Setpoint For applications that only require a simple Track Hold Signal function without any Operator adjustment capability simply use FPT H without connecting FPT H to a front z panel display channel ON Local At power down the Block Output is saved in the Retentive Auto Man Memory area of the EEPROM During the first scan after CPU start up the FPT H Block Output is set to the value ci FPTH stored in the Retentive Memory PB R e at ate Auto Man The Blockware Example shows typical applications of the Toggle Station FPT H function Block 14 is the FPT H Manual Auto 32 station for the control loop Before the burner releases to modulation the FPT H TO Input and the PID TM Input S force both Blocks to Track the Firing Rate Output Block m 20 This ins
142. en the DAE DAD Output is 0 AND the Input is 0 the ON and OFF timers are reset to 0 5 10 15 20 Parameter 1 and Parameter 2 seconds respectively When the Input 1 the ON Delay timer starts counting down and the Output changes to 1 when the ON Delay timer counts down to 0 seconds Seconds When the DAE DAD Output is 1 and the Input changes from 1 to 0 the OFF Delay timer starts counting down and the Output changes to 0 when the timer counts down to 0 seconds If the Input changes back to 1 while the Output is still 1 the OFF Delay timer is reset PCC III Instruction Manual ver 2 3 Page 6 53 Section 6 Blockware Functions Technical Reference FUNCTION 121 TEMP BYTES 12 RETENTIVE BYTES 0 DATA BYTES 16 NAME DAE DAD SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D INPUT Parameter Description Default Max Min Code Notes 1 ON DELAY SECONDS 1 19999 1 2 2 OFF DELAY SECONDS 1 19999 1 2 3 INVERT OUTPUT O NO 1 YES 0 1 0 2 F122 REPTDR Repeat Time Delay Relay Function REPTDR provides repetitive Block Output cycling 1 0 1 0 with defined ON and OFF times The Output may be inverted see Parameter 2 The timing diagram shows the default non inverted logic REPTDR 3sec ON 1 sec OFF Outpui For non Inverted Output When the Input is 0 the Output is 0 and both ON and OFF timers reset When the Input changes from 0 to 1 the Output changes to 1
143. enable the Password system for the first time First change the Technicians Password Scroll to CHANGE TECHNICIAN PASSWORD press ENTER Use EDIT 4 or EDIT V to change the Numeric display to the desired Password Write down the number that is being displayed then press ENTER Password Changed will be displayed Press ESC to clear the message and return to the PASSWORD menu EDIT is now Secured that is there is no active Password Enter the Technician Password Scroll up to ENTER PASSWORD press ENTER Use EDIT 4 or EDIT V to change the Numeric display to the Technician Password that was entered in the previous step then press ENTER Password Enabled will be displayed press ESC to clear the message and return to the PASSWORD menu The Technician Password Level is now active Change the Operator Password Scroll to CHANGE OPERATOR PASSWORD press ENTER Use EDIT 4 or EDIT V to change the Numeric display to the desired Password Write down the number that is being displayed then press ENTER Password Changed will be displayed press ESC to clear the message and return to the PASSWORD menu EDIT is now Secured that is there is no active Password CAUTION It is very important to write down the Technician and Operator Password numbers and keep this record in a convenient location DO NOT LOSE THE PASSWORDS If the passwords are lost or forgotten you will not be able to modify any of the Blockware data The Factory Passwor
144. enu allows the user to display or modify all of the Blockware data in Bxx 101 description all 160 Blocks of the PCC III memory This menu is used to Change the Function Type of a Block PID AOUT Connect Block Inputs to Block Outputs ie Softwiring Modify Parameters ie PID Gain Alarm Setpoint Bxx 102 description Bxx P01 description Bxx P02 description General Do not attempt to use the EDIT A BLOCK menu until after you have read the complete Instruction Manual The concepts in the following Sections are particularly important and should be fully understood before modifying the Blockware Section 4 SERVICE MANUAL Menu Section 4 PASSWORD Menu Section 4 MEMORY Menu Section 5 Configuring Blockware Control Strategies the entire Section Section 6 Blockware Functions Technical Reference the entire Section WARNING The PCC III is commonly used to control potentially dangerous Combustion and Chemical Processes VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE MODIFYING ANY OF THE BLOCKWARE DATA IN ANY BLOCK IN THE PCC III MEMORY FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH WARNING Data changes that_are made during the use of the EDIT A BLOCK CALIBRATE and COM PORT menu items are saved in the Primary memory however these changes are NOT saved in the Backup memory To insure that a future AutoLoad
145. er than Switch Point Output 10 square root High Range Input Else Output 10 square root Low Range Input Switch Point 100 FUNCTION 11 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 16 NAME DUAL SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A HI RANGE INPUT 2 A LOW RANGE INPUT 1 Parameter Description Default Max Min Code Notes 1 SWITCHING POINT OF HIGH RANGE 10 00 50 00 1 00 2 2 2 SQUARE ROOT 0 NO 1 YES 1 1 0 2 Notes 1 Low Range Input MUST be scaled to match the Switch Point and the High Range transmitter Example High Range transmitter is 0 120 WC for 4 20 mA or 0 100 inside the PCC III If the Switch point is 10 the Low range transmitter MUST be calibrated 0 12 0 we for 0 1005 2 Percent of High Range Input PCC III Instruction Manual ver 2 3 Page 6 6 Section 6 Blockware Functions Technical Reference F20 OPLR Optical Path Length Ratio Correlation for Opacity Monitors with Opacity Output Optical Density Output Mode Selection ROM 2 23 and 3 01 and higher Function OPLR is a special purpose function that is used to convert a double pass opacity monitor s T Transmittance signal to a stack exit diameter corrected Opacity signal The Block Input signal must be 0 100 Transmittance The 0 100 Block Output can represent either OPLR corrected 0 100 Opacity or OPLR corrected 0 000 1 000 Optical Density If the duct inside diameter at the Opacity
146. erefore each segment represents 5 of the range of the signal being displayed Numeric Display Item 4 in fig 1 This display is used to show numbers Typically the values shown are shown in the correct engineering units That is the numbers are usually not in units of from 0 100 See ACK and DIS for more details Message Display Item 5 in fig 1 This display is used to show messages that can be displayed using the characters A Z 0 9 and most of the recognized symbols lt The message display can show up to 8 fixed characters at a time or longer messages which simply scroll across the display See ACK and DIS for more details All of the Process Display channel messages and all of the Alarm Annunciator messages can be modified by the user in the field without any special programming hardware see section 4 DIS Pushbutton Item 7 in fig 1 The PCC IIl is capable of displaying up to 10 channels of Process Control information Pressing the DIS pushbutton causes the next display channel to appear on the Message and Numeric displays The display channel sequence repeats after the last channel is displayed Repeatedly pressing the DIS pushbutton in order to cycle through the display channels is called scrolling through the display channels Each display channel consists of a Numeric display and a Message display working as a matched pair to display one variable Pressing DIS to scroll through the display ch
147. eter will result in lower PCC III accuracy This procedure applies to the CPU Board Board 0 Option Board 1 and Option Board 2 While a group of Analog Inputs are calibrated all at the same time each 4 20 mA Ouput must be calibrated individually Using the CPU Board will be used as an example the procedure is as follows ENTER S M for ALL Outputs see pg 4 9 Remove all field wiring from the Analog Output channel to be calibrated Alternatively un plug the field wiring connector and plug in a spare field wiring connector Wire the terminal to the milliamp meter see Section 2 for terminal numbers Wire the terminal to the milliamp meter Scroll to BOARD x OUTPUT y x is the Board number CPU 0 y is the channel on that board Press ENTER SET OUTPUT TO 4 00 MILLIAMPS THEN PRESS ENTER will be displayed The error message MUST BE IN S M TO CALIBRATE will be displayed if ALL of the Outputs are NOT in S M mode see pg 4 9 The error message CALIBRATION ABORTED DEVICE OUT OF COMPLIANCE will be displayed if the actual current output is not aprroximately 4 mA This can be caused by milliamp loop is open circuit the test meter is set to Volts instead of Amps there is too much resistance in the loop or an external voltage or current source is connected to the field wiring Press ESC to return to the menu the original calibration will still be in effect Using the EDIT 4 or EDIT v keys and observing the milliam
148. eusable FUnctions c ccccccsssscsscscessssesssteseeneseeseaes 2 Break the configuration down into manageable SOPtWITING nenem SECTIONS ATERPEA 9 PCC III Terminology Glossary Sketch each section cccesessseccsesesseesereeseseteeesees 10 lea loto eE E EE AE AAE ESE Change the Function Type of a Block 11 Blockware Configuration ssssesessseseseseessrerressesee Softwire the Block Inputs 0 0 0 11 Function Type Or Function Code Number 5 Configure the front panel displays and alarms 13 Mpita neee AERES Rs 3 Test the configuration sssssssessereseessierrersrreerse 14 Parameter s22 s iccsssdesedseseres scroxsesnenessnacesssecsesessersessengeses 6 Place the controller into operation 14 Amal S riera EE ee deceit seeded 6 Add Pressure Compensated Steam Flow Blockware Disce fe thee ett et ee ee te Att Bee Do D Seaktivaavin ten ichaeac amie haan 14 ROME r RE 6 Add Purge and Light off Positioning Blockware 16 RAM Pia isi Ghali Mia eee AS eas 6 Add Day Night Pressure Setpoint Blockware 17 EEPROM vnnenancorninre inaenea a 6 Revised Overall Boiler Master Blockware 17 Retentive Memory ou eeceeeseseeteseeeeeeeees 6 Blockware Basics PCC III uses Blockware to implement the control strategies that are contained in the memory of the PCC III The word Blockware is derived from the words Block diagram and software The use of Blockware results in a clearly docu
149. f B40 DIN to zero This will allow you to adjust be analog Output A 1 entered here would force the Output to 0 Place the controller in Auto Auto Man light off Select the Plant Master mode PM Local PID light off Set the Bias to zero Adjust the Plant Demand Input B5 by using the Plant Master a 4 20 ma simulator or forcing the Block to a value The Output of the controller B150 should follow the Plant Master demand Input The PV and SP bargraphs should be equal and should also follow the Plant Master demand Add or subtract from the Plant Master demand by using the Bias The Output should follow accordingly The SP bargraph should be offset by the Bias value Select the Local PID mode PM Local PID light on Adjust the Drum Pressure Setpoint to a desired value The SP Bargraph should follow accordingly 0 100 bargraph represents 0 200 psig Using a 4 20 ma simulator you may also force the Block to a value adjust the Drum PSI Input B4 above and below setpoint The Output should react inversely That is as you go above setpoint the Output will decrease and as you go below setpoint the Output will increase The PV bargraph should follow the Drum Pressure Input accordingly Place the controller into operation If all the above tests were successful you are ready for operation You should backup the configuration before doing so See Section 4 Once in operation you should check the tuning Gain Integral etc of the Drum P
150. fter CPU start up the FPCON Block Output is set to the value stored in the Retentive Memory FUNCTION 55 TEMP BYTES 0 RETENTIVE BYTES 4 DATA BYTES 8 NAME FPCON SINGLE USE FUNCTION N OUTPUT TYPE A No Inputs Parameter Description Default Max Min Code Notes 1 MIN OUTPUT 0 00 199 99 199 99 2 2 MAX OUTPUT 100 00 199 99 199 99 2 F56 DEV Deviation Calculation for Bargraph Displays Function DEV subtracts the two Inputs Process Variable PV and Setpoint SP multiplies the difference by a gain and then adds a 50 bias to the result When used as a PANEL Input to control one of the front panel Bargraphs the bargraph will be at 50 when the two signals are equal will be gt 50 when PV gt SP and will be lt 50 when PV lt SP Parameter 1 is the Proportional Band that is the deviation required to drive the Output from 50 to 100 The DEV formula is Block Output PV SP 50 Parameter 1 50 PCC III Instruction Manual ver 2 3 Page 6 22 Section 6 Blockware Functions Technical Reference DEV Examples 100 00 50 00 48 50o 200 000 80 00 FUNCTION 56 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME DEV SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A PV INPUT 2 A SP INPUT Parameter Description Default Max Min Code Notes 1 OF PV MAX DEVIATION 2 00 50 00 0 20 2 1 Notes 1 PV SP error is limited to 300 internally F58 COUNT
151. g format AO b_c_ TO b_c c1 c2 Channel number or Triac Pair number bO b1 b2 Board number bO CPU b1 Option Slot 1 b2 Option Slot 2 AO means this is an Analog Output 4 20 mA TO means this is a Triac Output Use the ft U keys to change the displayed S M Output as follows AO ie 4 20 mA channels The numeric display is 0 100 of 4 20 mA 0 4 mA 100 20 mA The 4 20 vs 20 4 Parameter in the AOUT Block does NOT change this scaling 0 is always 4 mA TO ie Triac channels The ff key turns ON the T1 i e Increase Triac of the selected pair The U key turns ON the T2 i e Decrease Triac of the selected pair If the Triacs are driving an actuator do not depend on the S M logic to indicate the actuator s position on the Numeric display The Operator must independently observe the actuators position and respond accordingly The S M logic will attempt to find a TOUT Block that is assigned to the Triac channel being displayed and display that assigned TOUT Block Output on the Numeric display However the displayed position is Blockware based not S M firmware based therefore it can display an incorrect position if there are Blockware errors PCC III Instruction Manual rev 2 3 Page 4 9 Section 4 EDIT Menus PASSWORD Menu ENTER PASSWORD SECURE CONTROLLER The EDIT A BLOCK menu will display any and all data regardless of TIMEOUT the Password system status However
152. ge The External Power Supply and the PCC III Signal Common must be connected The shield connects to the External Power Supply PCC Ill Instruction Manual rev 2 3 PCC M elem yo 4 20 mA Isolator Indicator 4 20 mA Two i to A D Isolated ch to ch and from SC Terminals shown are for Al ch 2 2 PCC M 24 Vdc Wire Xmtr 24 Vdc Insulate Power Shield Supply Insulate Shield 250 0 ohm 1 5 Vde 4 23 to A D Eos JP2 4 Jumper 250 0 Four Wire Xmtr or PCC Ill ohms 24 pe SC Signal Common Terminals shown are for Al ch 0 4 PCC M 24 Vdc 7 0 5 Vdc Voltage Divider Two 10k 0 1 resistors P N 25100 2B50 1 4F Not Included to A D cs JP25 Jumper 250 0 ohms Insulate Shield Four Wire Xmtr 7 SC Signal Common Terminals shown are for Al ch 0 5 Page 2 13 Section2 Installation Potentiometer Input Typical for CPU A and F boards This example shows Analog Input 1 on the CPU Board Remove JP 2 4 to disconnect the internal 250 0 ohm resistor The 5 Vdc power supply term 15 is rated at 50 mA The shield connects to the Signal Common Note For Actuator Feedback Pots See Pull Up Down Resistors in Section 2 and F83 TOUT in Section 6 for Fault Mode wiring considerat
153. ge 6 19 Section 6 Blockware Functions Technical Reference F51 AB C A B C Multiply Divide Function AB C multiplies Input A by Input B and then divides by Input C AB C then updates the Block Output with the result Inputs within 327 are acceptable the Block Output is limited to 327 Divide by Zero If the C Input equals 0 00 the Output will be set to 327 00 with the sign determined by the result A times B For Example AB C can be used for A B multiplication without dividing by connecting Input C to dummy Block 1 A100 function or 100 AB C can be used for A C division without multiplying by connecting Input B to dummy Block 1 A100 function or 100 FUNCTION 51 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME AB C SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A A INPUT 2 A B INPUT 3 A C INPUT No Parameters PCC III Instruction Manual ver 2 3 Page 6 20 Section 6 Blockware Functions Technical Reference F52 WSUM Weighted Sum Function WSUM computes the following Weighted Sum equation Output Input A K1 Input B K2 Input C K3 K4 Configured with three Inputs and using the default parameters WSUM adds the three Inputs WSUM does not require three active Inputs connect un used Inputs to dummy Block 0 A0 function or 0 Constants K1 through K4 allow WSUM to be used for addition subtraction averaging and scaling WSUM Examples
154. gen Y Levels 3 Repeat the above 4 steps at 10 additional firing rates less if applicable Make sure that the Maximum firing rate is Stored 4 Disable Learn Mode PCC III Instruction Manual ver 2 3 Page 6 16 Section 6 Blockware Functions Technical Reference WARNING In a combustion application it is not safe to leave the Learn Mode enabled during normal operation An accidental Store operation would instantly change the fuel air ratio The Blockware should include sufficient logic and interlocks to prevent unsafe conditions The example below requires an external Learn Enable input to be a 1 DIN Block 25 and both the fuel and air must be in Manual before Learn Mode is enabled A DCON could also be used as a permissive DCON requires a Technician level password to enable changing it s Parameter PB DIN AIN PB2 Ch 0 5 Ch 0 2 Learn Auto Man Enable Oxygen Input Analyzer F x Clear 1 Clear Oxygen Fuel Air Setpoint Ratio vs Load Curve Curve Fuel Air Auto Man Auto Man Station Station AOUT AOUT Fuel Valve Air Actuator Damper Actuator WARNING This simplified example does not show all of the required safety features that would be included in a real combustion control strategy Do not use the Blockware example shown for an actual application PCC III Instruction Manual ver 2 3 Page 6 17 Section 6 Blockware Functions Technical Reference FUNCTION 42 TEMP BY
155. gisters in the middle of a multiple register read request will return a value of 0 returned F125 ROUT Relay Output Function ROUT is the Blockware interface to the PCC Ill Relay Output hardware ROUT interfaces to Relay Outputs on the CPU board and on option boards Parameter 1 specifies the board location the CPU board board 0 Parameter 2 selects a particular Relay on the specified board Invert Input By default a 1 Input energizes the Relay and changes the Output to a 1 If Parameter 3 is changed to a 1 a 0 Input Energizes the Relay and the Block Output FUNCTION TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 16 NAME ROUT SINGLE USE FUNCTION N OUTPUT TYPE D Input Description Notes 1 INPUT BLOCK 1 Parameter Description Default Max Min Code Notes 1 OPTION BOARD 0 CPU BOARD 0 2 0 3 2 OUTPUT CHANNEL 1 2 1 3 3 INVERT INPUT O NO 1 YES 0 1 0 2 1 Notes 1 See Invert Input above By default Relay energizes when Input 1 PCC Ill Instruction Manual ver 2 3 Page 6 57 Section 6 Blockware Functions Technical Reference F126 DOUT Discrete Output Open Collector Sinking Function DOUT is the Blockware interface to the PCC III 24 Vdc Open Collector Discrete Output hardware DOUT interfaces to Discrete Outputs on the CPU board and on option boards Parameter 1 specifies the board location the CPU board board 0 Parameter 2 selects a particular Discrete Output channel on the specified board
156. gnored when COM PORT is set to DOWNLOAD This menu item directs the PCC III Modbus software to reply with either positive integers only or signed integers positive and negative Some SCADA and DCS I O driver software do not support signed integers PCC III Block Outputs can range from 32700 to 32700 Set this parameter to UNSIGNED unless the SCADA or DCS system specifically supports signed integers Scroll to DATA Press ENTER SIGNED 0 UNSIGNED 1 will be displayed Use the EDIT 4 or EDIT v key to choose either 0 or 1 on the Numeric display Press ENTER The display returns to the COM PORT menu TIME OUT This item is ignored when COM PORT is set to DOWNLOAD When a valid Modbus message that is addressed to this node Address is received the Communications status is set to Normal and the Time Out timer is started The Time Out timer is reset and restarted every time a new valid Modbus message is received If PCC Ill stops receiving Modbus messages the Time Out timer will expire and the communications status will change to Failed The Time Out can be from 1 to 120 seconds Scroll to TIME OUT Press ENTER Use the EDIT 4 or EDIT v key to set the desired seconds on the Numeric display Press ENTER The display returns to the COM PORT menu TEST CABLE This item is ignored when COM PORT is set to DOWNLOAD This item tests the RS485 Modbus communications network The PCC IIl sends an individual Loopback Test message to each of
157. gral constant is expressed as Repeats per Minute A numerically larger Repeats min results in a greater PID output per minute ramp change for the same Process Variable PV versus Setpoint SP difference The Derivative constant is expressed as Rate Minutes A numerically larger Rate Minutes results in a greater PID output step change for the same Process Variable PV versus Setpoint SP percent per minute rate of change The Derivative Input is low pass filtered at 1 10 of Rate Minutes to limit the Derivative Kick magnitude The optional Setpoint Filter Parameter 4 can be used to reduce system upsets due to inadvertent rapid Setpoint changes by the Operator see note 6 PCC III Instruction Manual ver 2 3 Page 6 24 Section 6 Blockware Functions Technical Reference Limit to Out_Min lt FF lt Out_Max FF FF Out_Min Output Bias Limit O Out_Min lt Out lt Out_Max uput P 6 P 5 SAGON TM or OM T TSIG P D FF Internal Schematic of PID F71 Function Block PCC III Instruction Manual Section 6 Page 6 25 Blockware Functions Technical Reference A Feedforward Input is provided that is summed with the P I D values prior to the Output Min Max limiting logic This prevents Integral term Reset Windup when feedforward control strategies are used For control logic that does not use Integral action an Output Bias Parameter 12 is provided to allow changing the PID Output mid point ie the Outpu
158. gure at right 9 Seconds 10 See HIALM F101 above for details on Inputs 2 3 and Pv SP Parameters 1 and 3 5 e SP DB Output FUNCTION 102 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 32 NAME LOALM SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 A PV INPUT 2 A EXT SP INPUT 1 3 D DISABLE INPUT 1 Parameter Description Default Max Min Code Notes 1 SP MODE 1 EXT 2 INT 2 2 1 2 1 2 DEADBAND 0 20 100 00 0 00 1 3 3 INT SP 50 00 199 99 199 99 1 1 4 ALARM DISABLE ACTIVE LO HI O LO 1 HI 1 1 0 2 2 5 ALARM DELAY SECONDS 0 600 0 1 4 Notes 1 See Internal vs External Setpoint in HIALM F101 above Notes PCC III Instruction Manual ver 2 3 Page 6 45 Section 6 Blockware Functions Technical Reference 2 See Alarm Disable in HIALM F101 above 3 See Deadband above 4 See Alarm Time Delay in HIALM F101 above F103 DEVALM Deviation Alarm DEVALM DEV SP 10 DB 5 Delay 0 Function DEVALM subtracts the PV Process Variable Input from the SP Setpoint and changes the Block Output to a 1 if the absolute value of the difference is greater than the allowable Deviation Parameter 2 Or in equation form If PV SP gt Deviation Then Block Output 1 Note PV SP means If PV SP is negative multiply by 1 If DEVALM is connected to the PANEL Block or directly to an ROUT DOUT or TOUT Block it can trigger audible visual alarm
159. hat a future AutoLoad ie copy Backup into Primary loads these changes the user must _copy the Primary memory into the Backup memory using the MEMORY COPY PRIMARY TO BACKUP menu item pg 4 16 FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH COM PORT The PCC III CPU board has two communications modes and connections RS485 at the rear terminal strip for Modbus Protocol Process Control Communications RS232 jack behind the Front Panel for Blockware Downloads Uploads and Diagnostics Modbus is an ANSI standard communications protocol that is used extensively for DCS SCADA and RTU applications See Section 2 for wiring Section 6 for PLINK Blockware interface and Modbus Functions below for the supported Modbus functions The Download connection is designed specifically for use with either PC3_Edit or PC3_Draw Personal Computer based software This software can be used for Blockware design documentation and diagnostics The CPU has one communications port Com Port The CPU Com Port can only be routed to one of the two connections at a time Modbus RS485 or Download RS232 Scroll to COM PORT Press ENTER O DOWNLOAD 1 MODBUS will be displayed Use the EDIT 4 or EDIT v key to choose either 0 or 1 on the Numeric display Press ENTER The display returns to the COM PORT menu ADDRESS This item is ignored when COM PORT is set to DOWNLOAD This menu item determines the Modbus node address for
160. he TOUT block that drives the TTRIP Block output TTRIP will remain active for at least 5 seconds This Block is primarily used to activate an alarm or a safety shutdown system FUNCTION 100 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME TTRIP SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 A TOUT BLOCK TO BE MONITORED 1 No Parameters Notes 1 The BLOCK TO BE MONITORED must be a TOUT Block PCC III Instruction Manual ver 2 3 Page 6 43 Section 6 Blockware Functions Technical Reference F101 HIALM High Alarm HIALM SP 50 DB 10 DELAY 0 Function HIALM compares the PV Process Variable Input to the SP Setpoint and changes the Block Output to a 1 when PV gt SP If HIALM is connected to the PANEL Block or directly to an ROUT DOUT or TOUT Block it can trigger audible visual alarms HIALM can also be used as a trigger in Blockware to automate a control strategy Example Trigger an ASW to select PID B instead of PID A when steam flow exceeds 20 See top figure at right Percent Inputs 2 3 and Parameters 1 5 modify the basic behavior as follows Deadband or Hysterisis Parameter 2 When Deadband DB 0 5 0 0 Output 1 if PV gt SP or Output 0 if PV lt SP When Seconds Deadband gt 0 Output 1 if PV gt SP and once the Output PV SP becomes a 1 it remains a1 until PV lt SP DB and then it SP DB Output resets to 0 Internal vs Exter
161. hematic drawing or the Blockware tabular data print out is not available it can be time consuming to EXAMINE every Block to locate a Function Type Using FIND FUNCTION any particular Function Type can be rapidly located Scroll to FIND FUNCTION press ENTER 127 and ENTER FUNCTION NUMBER will be displayed Use EDIT v to scroll down to the Function Number Function Name that you want to locate press ENTER FIND FUNCTION starts searching at Block 4 and scans up to Block 159 If the Function is found in a Block Bxxx followed by the Function Name will be shown on the Message display The Numeric display is not meaningful and should be ignored PCC III Instruction Manual rev 2 3 Page 4 18 Section 4 EDIT Menus FIND USAGE Softwiring is accomplished by scrolling to the Input channel of a Block ie the signal Destination and entering the Block number of the signal Source Said in another way Softwiring is accomplished by scrolling to the Destination and selecting a Source for the Input FIND USAGE will locate every Destination ie Block Input that is using a particular Source Block s Output Scroll to FIND USAGE press ENTER ENTER BLOCK NUMBER will be displayed Use EDIT 4 or EDIT v to display the desired Source Block Number press ENTER Searching begins at Block 4 and scans up Bxxx Iyy followed by the Input Name will be displayed To continue searching the remainder of the Blocks press E
162. ic Actuators option Operator Control Panel Card 2 cicadas tet ead 5 Electrical ninian n Steam Flow Pressure Compensation 5 Input Output Standard no option cards 10 COMMUNICATIONS 0 eee eeeeeeeeeeeeeteteeeteteeeeeeeeees 10 PCC III Instruction Manual rev 2 3 Page 1 1 Section1 Product Overview Product Description This section overviews the PCC III features which address the requirements of both Data Acquisition and control applications The PCC IIl is designed to address the needs of most process control applications and that design has been further optimized to meet the exacting needs of combustion control systems Features Multiple Loops Service Manual Redundant Memories Optically Isolated Data Highway Engineering Units Display Flexibility Local Blockware Configuration Ten point first in first out Alarming Learn Function Industry standard communications Optional I O Cards Self supporting CPU Board PCC III Instruction Manual rev 2 3 Benefits Allows cost effective control of more than one process loop in a single controller Allows Manual control in the event of memory CPU or digital circuitry failure Allows for self recovery in the event of a primary memory error Safe reliable communication that prevents a single controller failure from disrupting an entire network Redundant RS 485 communications are available as an option Allows the
163. ient Temperature cceescceeseneeeeene rererere 2 Rear ACCESS ciictetace edie NR 2 MOUNTING tect iistaeee 2 PCC III Dimensions cesccceeeeceeeeeeeeeesteeteneees 3 Panel Cutout Dimensions ccecceeeeeeeeeeeeereees 3 Wiring Overview eeeeeeceeeeeeeneeeeeaeeeseeeteeeeteeeeeeeeeaes 4 120 Vae Ground i iii ieiet niit 4 Terminal BIOCKS isoce 4 Wire Type t eoa a ai 4 Shielded Cable asusti ieai ereire iaiia 4 24 Vdc amp 5 Vdc Power Supply Load Calculations 5 FUSE SH A nies eda aaa 5 250 ohm Resistors for 4 20 MA Inputs s 5 A Option Board 250 ohm Switches 6 CPU Board Layout ececceeceeeeeeeeeeeeeeeeneeeeeeeteaes 7 F Option Board 250 ohm Switches 05 8 G Option Board Fuses and Pull ups 00 8 J Option Board Isolated Neutral Jumpers 9 S Option Board 120 Vac FUSEC ceeeseeeeeees 9 CPU Board Field Wiring Terminals 10 Gas Flow Pressure Temperature Compensation5 High Temperature Hot Water HTHW BTU Hr Computatio Masern ahve ie i ied 5 Drum Level Pressure Vs Density Compensation dou evaded egcie dat cast EE AE A E E 6 Oxygen Sensor Control Signal Conversion OPTION Car ccceeeeeeceeceeeeeeee A anna Relay Output Channels OPLR Stack Exit Correlation for EPA Opacity MONIOFS gaene eel sek wie 6 Flow TotaliZation ccccccececeeeeeeeeneeeeeeeeeseeeees 6 PCC III Loop
164. if the Password system is CHANGE OPERATOR PASSWORD enabled the EDIT A BLOCK menu will not allow the user to modify CHANGE TECHNICIAN PASSWORD Blockware data unless the active Password Level is acceptable As shipped from the factory the PCC III Password system is disabled therefore the user can modify any data item in the PCC III Once a Password Level is activated it will automatically deactivate after a Timeout period 30 minutes by default 240 minutes max see TIMEOUT menu item Password Levels Level Active Password Service Manual S M Mode 4 Factory required 3 Technician required 2 Technician not required 1 Operator not required Section 6 Blockware Functions Technical Reference specifies the minimum password level required to modify each individual Parameter of each Function Block available in the PCC III If Passwords are enabled there are two generic EDIT A BLOCK editing tasks that require Password Level 3 or 4 Modifying the Function Type of any Block Modifying an Input Block Number ie the Softwiring within any Block Note The above tasks still require S M mode when Passwords are disabled Enabling the Password System A Password is any number except 0 between 19999 and 19999 To enable the Password system a Technician Password must be configured however the Operator Password is optional The Technician and Operator Passwords may be the same number To
165. ight indication takes priority over FORCED Mode indication when both S M and FORCED Modes are active WARNING The PCC III is commonly used to control potentially dangerous Combustion and Chemical Processes VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE PUTTING THE PCC III CONTROLLER INTO SERVICE MANUAL MODE FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH WHEN A PCC III_ OUTPUT IS IN THE SERVICE MANUAL MODE ALL BLOCKWARE IMPLEMENTED SAFETY LOGIC IS BYPASSED THE OPERATOR HAS TOTAL RESPONSIBILITY TO INSURE THAT ALL EQUIPMENT IS OPERATED SAFELY ENTER S M in MAIN Menu The MAIN menu will display ENTER S M if none of the Output channels are in S M mode Press ENTER if you want to put some or all of the Output channels into S M mode PCC III Instruction Manual rev 2 3 Page 4 8 Section 4 EDIT Menus ALL S M Pressing ENTER puts all of the 4 20 mA and Triac Output channels into S M mode and then automatically returns to the MAIN menu The MAIN menu display will automatically change to EXIT S M The RUN light will start blinking AO b_c_ AUTO or S M TO b_c_ AUTO or S M AUTO means this channel is currently in Normal Operation mode S M means this channel is currently in S M mode c1 c2 Channel number or Triac Pair number bO b1 b2 Board number bO CPU b1 Option Slot 1 b2 Option Slot 2 AO means this is
166. ion AO provides a constant Output of 0 00 PCC Ill automatically configures Block O to be function AO Block O analog 0 00 is the default Input for all analog Inputs for all functions Block 0 cannot be changed to any other function However other Blocks may be configured as AO No Inputs or parameters are required for AO FUNCTION 0 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 0 NAME AO SINGLE USE FUNCTION N OUTPUT TYPE A No Inputs and No Parameters F1 A100 Analog Constant 100 00 Function A100 provides a constant Output of 100 00 PCC III automatically configures Block 1 to be function A100 Block 1 analog 100 00 is useful as a dummy Input to many other functions ASW AB C Block 1 cannot be changed to any other function However other Blocks may be configured as A100 No Inputs or parameters are required for A100 FUNCTION 1 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 0 NAME A100 SINGLE USE FUNCTION N OUTPUT TYPE A No Inputs and No Parameters F2 AIN Analog Input Function AIN is the Blockware interface to the PCC III Analog Inputs A D converter hardware AIN retrieves the 0 000 5 100 Vdc signal from the selected field terminals applies a digital low pass filter scales the voltage to a 0 100 00 Block Output and optionally takes the square root A jumper selectable 250 ohm 0 1 resistor on the circuit board is used to convert a 4 20 mA Input to 1 5 Vdc Input A hardware based low pass filter 3db
167. ions Potentiometer Input G Board Q Option Board Only This example shows Analog Input 1 on a G Option Board that is plugged into Slot 1 There are no 250 0 ohm resistors on the G board The 5 Vdc power supply term 1 48 is rated at 50 mA total If two pots are connected to the 5 Vdc then the smallest value is 200 ohms each The G board has a built in pull up resistor It must be removed if an external 250 0 ohm resistor is required The shield connects to the Signal Common 4 20 mA Output Typical for CPU and F boards This example shows Analog Output 1 on the CPU Board The maximum 4 20 mA total loop resistance external to the PCC III is 800 ohms The shield connects to the Signal Common PCC Ill Instruction Manual rev 2 3 PCC M Potentiometer lt 100 ohms min 10k ohms max Wiper ohms BA SC Signal Common Note R1 R2 are optional external resistors See Pull Up Down Terminals shown Resistors in this section for details are for Al ch 0 1 Note Internal Pull Up only PCC M included on G Option Board Potentiometer lt 100 ohms min 10k ohms max Wiper Signal Common Terminals shown are for Al ch 1 1 Insulate Shields 7G 4 20 mA t JIO I P PCC m 24 V Ga IO 4 20 mA S I P SCY Signal Com
168. is Calibration Required Typically a PCC III will not require field calibration for the life of the controller There are two reasons to field calibrate all or part of the PCC III An Option Board is installed in the field or the factory calibration data is corrupted Option Board installed in the field Because factory calibration data is not in the CPU Board EEPROM memory the PCC III uses default calibration data to allow operating the new option board without factory calibration data The default data reduces the gauranteed accuracy as shown below If this accuracy is acceptable the new Option Board does not have to be calibrated Board Type Input or Output Worst Case Accuracy when using Default Calibration Data CPU A F or G Input 10 mV or 0 25 of 4V B Input 50mV_ or 1 25 of 4V CPU or F Output 0 05 mA or 0 3 of 16 mA NOTE This chart only applies to field installed Option Boards that have NOT been calibrated Factory installed Option Boards are calibrated as noted above The above chart reflects thoretical worst case accuracy data Typically the default data provides much higher accuracy than the chart shows Input voltage accuracy can be checked by measuring the input voltage converting it to a percentage based on AIN Block scaling and comparing the result to the AIN Block Output value as shown by the EXAMINE menu item see pg 4 18 Output accuracy can be checked by putting the Output in
169. l of a discrete Select signal Output The concept is very similar to a SPDT relay or 3 port solenoid B O valve When the Select signal is 0 the A Input is selected and passed to the DSW Block Output When Select 1 the B signal Select is passed to the Output The Block Output changes 0 A 1 B instantaneously when the Select Input changes FUNCTION 117 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME DSW SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D A INPUT 2 D B INPUT 3 D SELECT INPUT 0 A 1 B No Parameters PCC III Instruction Manual ver 2 3 Page 6 51 Section 6 Blockware Functions Technical Reference F118 DAETDR Delay After Energize Time Delay Relay On Delay Function DAETDR simulates a Delay After Energize Time DAETDR 5 sec ON Delay Delay Relay also known as an ON Delay function The Output may be inverted see Parameter 2 The timing 3 diagram shows the default non inverted logic 6 For non Inverted Output When the Input 0 the Output a is 0 and the timer is reset to Parameter 1 seconds a When the Input 1 the timer starts counting down and the Output changes to 1 when the timer counts down to 0 seconds 0 5 10 15 20 Seconds FUNCTION 118 TEMP BYTES 4 RETENTIVE BYTES 0 DATA BYTES 12 NAME DAETDR SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D INPUT Parameter Description Default Max Min Code N
170. le from the Front Panel Typically the Setpoint the Controller Output when in Manual Ratio Bias and other values can be changed with these pushbuttons The Blockware Designer can also limit the amount of adjustment that is possible For example if The Setpoint is normally 150 psig the Blockware designer can internally limit the range of adjustment to 125 175 psig ft and Rate of Change When the Operator presses and holds down either the ff or U pushbutton the displayed value will initially ramp slowly However after every 10 counts the display ramp speed increases by a factor of ten Therefore the longer the ft or pushbutton is pressed the faster the displayed value will change Example Assume the Numeric display initially shows 0 00 The Operator presses and continuously holds down the ff pushbutton The Numeric display would change as follows 0 00 0 01 0 02 0 03 0 04 0 05 0 06 0 07 0 08 0 09 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 2 00 3 00 4 00 5 00 6 00 7 00 8 00 9 00 Note the ramping sequence does not have to start with the right hand digit equaling O as shown in the above example If the initial display value had been 0 03 the ramp rate would change after 0 13 1 03 10 03 100 03 that is after every 10 display value changes Whenever the ft or U pushbutton is released the ramping rate is reset to the slowest rate Therefore if you don t want the display
171. le of Contents Introduction Section 1 Product Overview Product Description ee eeeeeeeseeeeeenee rreren 2 FOAlUIGS i Medena eiae eeaeee hence eet 2 Benefits cond Mian tach atten sik 2 Distributed Control System Concepts 3 Analog and PLC Control Functions 006 3 Configuration Concepts ccceescceeeseeeeteeeeeetneeees 3 Com Link Data Highway Concepts cseeeeee 3 Blockware COncepts cccecccesseeeeseeesesneeeeeeeereeees 4 BlOCKSiedesndtus E E i teeenvencnned eeeane 4 Library Of Functions 4 Any Function Any Block e cecssceseneeeee ees 4 Reusable Fun ctions eeceeesseereseeeeeeneereees 4 SOMWINING 2 esthetic nayaetntniie detest 4 Special Option Card and Special Function Block Capabilities i arsi a suni reier krasen riinan 5 Multiple F X renndi aaro 5 kearn Mode mei eriri meen aee aar anena Saone 5 Boiler Efficiency ecceececeeeeeeeneeeeeeneeeneeeneeeaees 5 Service Manual option Card cceeeeeeeees 5 Triac Output for Electric Actuators option cards Ee A A EE agin E deat ichat puphid eee sta sat 5 Steam Flow Pressure Compensation 5 Section 2 Installation Option Board Descriptions ccceeeeeeeeeeteeeeneeeee 1 Mounting OVErViCW ecceeeeeeeeeeeeeeteeeeneeteneeseaeeeeees 2 Mounting OVErVieW ecceeeeeeseeseeeeeeeeeeeeeeeeeseaeeeneees 2 NEMA 13 IP65 Environment 2 eceeeeeeeeeeees 2 Amb
172. llers plus the Master can be coincidentally networked The use of Modbus as a communications protocol allows the PCC III to be integrated with other s equipment and on networks supplied by ourselves or others The Modbus communications facility is the industry standard RS 485 PCC III Instruction Manual rev 2 3 Page 1 3 Section 1 Product Overview Blockware Concepts The PCC III makes use of Blockware which we believe makes control strategy configuration easier In Section 5 we will discuss Blockware and configuration in greater detail but the basic elements that make up Blockware are as follows Blocks The PCC IIl memory has 160 Blocks Each Block is a container that a Blockware Function is put into Think of a Block as a cell in an Excel or Lotus 1 2 3 spreadsheet you put a formula or a function into a cell and the formula uses the values from other cells as Inputs for the formulas Another analogy would be physical relay sockets that have signal processing modules plugged into each socket ie Block The controller includes sufficient memory to handle 160 Blocks Library of Functions The PCC III has an extensive library of Functions to handle any type of control task These Functions are identified and described in detail in Section 6 of this manual The library includes Functions for the conversion of Inputs to engineering values mathematical operations logical operations timing ope
173. lock Output will remain at Yj when the clock reaches the last valid Tj If Parameter 1 Auto Recycle 1 when the clock reaches the last valid T4 the clock resets to 0 0 min and repeats the ramp sequence At power down the clock run time is saved in the Retentive Memory area of the EEPROM During the first scan after CPU start up the clock run time is set to the value stored in Retentive Memory This feature can be bypassed by forcing the Block logic to set the Reset Input 1 at power up FUNCTION 41 TEMP BYTES 16 RETENTIVE BYTES 3 DATA BYTES 96 NAME F T SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 D HOLD INPUT 1 HOLD 1 2 D RESET INPUT 1 RESET 1 Parameter Description Default Max Min Code Notes 1 AUTO RECYCLE O NO 1 YES 0 1 0 2 2 YO 0 00 150 00 150 00 2 3 T1 MINUTES 0 0 1999 9 0 0 2 2 4 Y1 0 00 150 00 150 00 2 5 T2 MINUTES 0 0 1999 9 0 0 2 2 6 Y2 0 00 150 00 150 00 2 7 T3 MINUTES 0 0 1999 9 0 0 2 2 8 Y3 0 00 150 00 150 00 2 9 T4 MINUTES 0 0 1999 9 0 0 2 2 10 Y4 0 00 150 00 150 00 2 11 T5 MINUTES 0 0 1999 9 0 0 2 2 12 Y5 0 00 150 00 150 00 2 13 T6 MINUTES 0 0 1999 9 0 0 2 2 14 Y6 0 00 150 00 150 00 2 15 T7 MINUTES 0 0 1999 9 0 0 2 2 16 Y7 0 00 150 00 150 00 2 17 T8 MINUTES 0 0 1999 9 0 0 2 2 18 Y8 0 00 150 00 150 00 2 19 T9 MINUTES 0 0 1999 9 0 0 2 2 20 Y9 0 00 150 00 150 00 2 21 T10 MINUTES 0 0 1999 9 0 0 2 2 22 Y10 0 00 150 00 150 00 2 Notes 1 See chart abo
174. locks are calculated In the example below at left Block number 22 is not being used so it has the default NOP or No OPeration Function in it At Right Block 22 was changed from a NOP to a HIALM high alarm Function type Reusable Functions Almost all PCC III Function types can be used as many times as required within the 160 Block limit There are some Functions that are directly linked to the hardware that can only be used as many times as there is mating hardware For example only one PANEL Function Front Panel Display Interface can be used because there is only one Front Panel While those related to PID Functions curve fitting Functions etc can be used as many times as is deemed necessary for the application Softwiring Most Function Types like HIALM need information from other sources ie Blocks in order to calculate a result Softwiring is the term used to describe how the Blocks are interconnected within the software Softwiring allows the Input of a Block to monitor the Output of any other Block At right below the PV Process Variable Input of Block 22 HIALM is monitoring the Output of Block 20 AIN via a Softwiring connection AIN AIN NOT HIALM 20 20 NOP PV 2 2 PID PID 25 25 PCC III Instruction Manual rev 2 3 Page 5 2 Section 5 Configuring Blockware PCC III Blocks
175. ls 1 and CLEAR Input equals 1 The Y Input value is only used during the single scan of a Learn Event The Input is limited to 150 00 The X coordinates MUST be in ascending order that is X1 lt X2 lt X3 lt X4 lt X11 Xi 150 00 indicates that the X Y pair is inactive ie not being used All inactive X Y pairs must be the upper X s i e X11 X10 X9 F x determines how many of the eleven X Y breakpoints to use by starting at X1 and scanning up looking for the first Xi 150 00 That pair and all pairs above it are ignored L L Lead Lag with Gain Dynamic Compensation Function L L provides Lag Lead and Gain compensation in a single Block Lag is a digital filter operation and is the first operation performed on the Input Lead is a Derivative or Rate operation and is performed on the result of the Lag filter Gain is a simple multiplier that acts on the result of the Lead operation Lag and Gain operations can be used alone or in combination with any other operation Lead requires Lag to be non z PCC ero and the ratio Lead seconds Lag seconds must be less than 15 Ill Instruction Manual ver 2 3 Page 6 18 Section 6 Blockware Functions Technical Reference The Lag seconds is the time it takes for a step Input to drive the Output to 63 of the Input change A larger value provides more damping The Lead Seconds is the derivative gain that is Rate Sec Lead Se
176. lt the documentation for the Blockware loaded in the memory of your specific PCC and become familiar with your particular installation before attempting to operate the PCC III controller In particular the operation of the 4 pushbuttons and 6 lights items 12 21 shown in Figure 1 changes depending on the Blockware ie Control Logic that has been loaded into the memory of the PCC Ill Throughout this Section the words Typically Optionally Configurable and User defined will be used to indicate that the operation of a pushbutton or display may in fact vary from that described in the examples given in this section Front Panel Displays and Pushbuttons RUN Light Item 9 in fig 1 The green RUN light indicates the health of the hardware and indicates if the Blockware is being over ridden ie FORCED or S M or has errors S M The RUN light should be ON continuously If the RUN light is Blinking or it is OFF the PCC Ill Blockware is not operating properly A Technician should be called immediately to determine the cause of the problem It is normal for a Technician to purposely put the PCC III into either S M or FORCE mode during various maintenance procedures However the PCC III should not be in S M or FORCE mode during normal operation See Section 4 for details on S M and FORCE modes The RUN light indicates Normal Forced or S M Mode Green RUN Light ON OFF Cycle Operating Mode ON
177. ly are considered to be parameters Later in this section the purpose of each Function s parameter will be identified in detail Parameters are referred to by their name or by P1 P2 etc Analog Block Outputs within the PCC III that can be varied continuously and in small increments are called analog values A 4 20 ma or 3 15 psi field signal are examples of external analog signals Analog values inside the PCC IIl are normally considered to be 0 00 100 00 values However Block Outputs can actually range from 327 67 to 327 67 and all computations are carried out to 0 001 internal resolution Discrete Block Outputs within the PCC III that can only have values of O or 1 i e ON OFF HI LOW are called discrete values Discrete and analog values cannot be intermixed That is if a particular Function type calls for one of it s Inputs to be an analog value then the user cannot assign a Block with a discrete Output to this Input ROM ROM stands for Read Only Memory ROM memory is the non volatile permanent memory that stores all the firmware ie non changeable software that makes the PCC III work This memory is not lost when the power is turned off The user can not modify the ROM firmware The PCC III Function types menu editor Modbus protocol front panel version number etc are stored in ROM RAM RAM stands for Random Access Memory RAM can be read from and written to RAM is volatile tempor
178. m resistors AIN 250 ohm resistor jumpers Page 2 10 Section 2 Installation Option Board Field Wiring Terminals PCC Ill Option Board Field Wiring Terminal Numbers for Option Board Slots 1 or 2 Model A B F Analog Input Analog Output Analog Input Isolated Analog Input G Analog Input Triac Output J Discrete Input 120 Vac Relay Output Any Combination of the above Option Cards can be used in Slots 1 or 2 x indicates the PC Board Number in the above channel descriptors 29 HT 0 CPU board 1 Option Slot 1 2 Option Slot 2 40 HT TRIAC HOT Al x 1 41 NT NEUTRAL i INC 1 Al x 2 TO x 1 pair 1 DEC 1 NEUTRAL Al x 3 x INC 2 TO x 2 pair 2 DEC 2 Al x 4 gt NEUTRAL 48 5 Vde Al x 5 49 Al x 1 SC 50 Al x 2 SC 51 SC PCC III S Option Board Field Wiring Terminal Numbers Option Board Slot 3 Only TRIAC HOT INC 1 All of the above Option Cards use the same Terminal Numbers TO x 1 pair 1 31 D1 DEC 1 When wiring schematics are created label Terminals as x term no x is the option card slot number Examples 32 NT NEUTRAL 1 46 means Option Card 1 terminal number 46 Tie Point 2 46 means Option Card 2 terminal number 46 33 NT NEUTRAL PCC Ill Instruction Manual rev 2 3 Page 2 11 Section 2 Installation Wiring Examples Two Wire 4 20 mA Input Internal 24
179. m message is viewed ie acknowledged PANEL will NOT put a second copy of the same message on the stack When Input 31 Annunciator Enable equals 1 the annunciator functions normally When the Annunciator Enable Input equal 0 the default Input no new alarms are stored in the stack However all existing alarms on the stack remain until cleared and acknowledged Annunciator Enable can be used to prevent nuisance alarms during process startup or shutdown When a new alarm occurs the PANEL Block Output changes to a 1 The ALARM LED 5 starts flashing and optionally see Parameter 1 the bargraphs start flashing Typically the PANEL Block Output is connected to a ROUT DOUT or TOUT Block and then physically wired to an external audible alarm To silence an alarm Press ACK or change Input 30 Remote Alarm Silence from a 0 to a 1 to change PANEL s Block Output back to 0 and to stop the optional bargraph flashing See Section 3 for further details Note If there are multiple PCC Ill s all of the configured alarm horn outputs can be wired in parallel to a single audible alarm A single external Alarm Silence pushbutton can then be wired in parallel to a DIN on each PCC III FUNCTION 96 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 328 NAME PANEL SINGLE USE FUNCTION Y OUTPUT TYPE D Input Type Description Notes 1 A DIS CH 1 lt OUT 1 gt 4 2 A DIS CH 2 lt PV 1 gt 4 3 A DIS CH 3 lt SP 1 gt 4 4 A DIS CH 4 lt OUT 2 gt
180. mbient temperature ie the control cabinet internal temperature will exceed 125 F The control cabinet internal temperature is a function of the outside air temperature the surface area of the control cabinet and the amount of heat released by other components inside the cabinet A PCC III consumes 22 VA worst case therefore it releases a maximum of 75 Btu hr The major control cabinet manufacturers Hoffman Hammond include information in their catalogs to help calculate cabinet internal temperature rise with and without various cooling methods Rear Access The PCC III case is 7 deep behind the mounting flange therefore PCC III can be mounted in 8 or deeper control cabinets All field wiring connections are located behind a cover plate in the rear of the controller Rear access is required for installation calibration and trouble shooting Routine operation and control strategy Blockware downloading is accomplished from the front of the controller Mounting Refer to the PCC III Mounting and Panel Cutout Dimension drawings that follow Cut the hole in the enclosure Remove any burrs and loose metal chips Remove the Panel Mounting Brackets from the PCC III case Slide the PCC III into the hole From the rear of the PCC III slide the Mounting Brackets tabs into the slots in the PCC III case Using a 1 8 Allen wrench tighten each mounting bracket screw against the enclosure Additional Mounting Brackets can be ordered
181. mbustion air damper position will likely not be a linear function An F X block can be used to effectively linearize the combustion air flow vs firing rate relationship F X blocks will likely be required for the fuel valve degree of opening demand signal and the Oxygen Setpoint as well if O2 Trim is provided The clear benefit of the Learn Mode is that at each of the 10 available F X Block data points after optimum conditions are set by the technician he she simply presses the Learn button for the PCC III to remember Learn the current firing rate vs valve and damper positions and Oxygen Setpoint relationships simultaneously The technician then proceeds in a similar fashion up to full firing rate repeating this procedure at each point This results in a considerable savings in commissioning time as well as an optimally characterized process Boiler Efficiency The Boiler Efficiency function allows the controller to calculate in real time the boiler s efficiency and display that result on the controller s front panel and or a recorder or a Data Acquisition terminal Boiler Efficiency is calculated using the ASME by losses method This function requires inputs of flue gas temperature combustion ambient air temperature percent oxygen in the flue gas and percent firing rate for Radiation Loss determination to evaluate the efficiency This function is not only useful for establishing
182. mended PANEL Inputs configuration for Single Loop Auto DIS display control AUTO MAN 1 CHANNEL O AUTO DISPLAYED 1 MAN and Input Input 14 Number 1 OUT 1 2 PV1 NOTES Input 19 Block 2 DO ie Loop2 0 AMAN means on the rising edge of MAN i e only once during the scan that the Input changes to MAN Dual Loop Auto DIS display control LOOP 2 SELECT AUTO MAN 1 AUTO MAN 2 CHANNEL O Loop1 O AUTO O AUTO DISPLAYED 1 MAN and Input Input 14 NOTES AMAN means on the rising edge of MAN i e only once during the scan that the Input changes to MAN X means This Input is ignored Typical PANEL Input Descriptions OUT x The FPT H Block that drives the controller AOUT or TOUT Output PCC III Instruction Manual ver 2 3 Page 6 38 Section 6 Blockware Functions Technical Reference PV x The AIN or other Math Block being used as the Process Variable for this Loop SP x The FPCON or FPT H Block that generates the Loop Setpoint PID loops only AUTO MAN x The PB Block that the Operator uses to select the Auto Manual mode LOOP2 The PB DIN or other Block that the Operator uses to Select which Loop to view Annunciator Logic Inputs 20 29 determine which Blocks will be annunciated The first scan that an alarm Input changes from a 0 to a 1 ie on the rising edge the matching alarm channel message is stored at the end of the sequential memory stack If an alarm clears and re alarms before the alar
183. mented easy to understand and easy to configure a system The basic elements of Blockware are as follows Blocks The PCC III memory has 160 Blocks Each Block is a container that a Blockware Function is put into Think of a Block as a cell in an Excel or Lotus 1 2 3 spreadsheet you put a formula or a function into a cell and the formula uses the values from other cells as Inputs for the formulas Another analogy would be physical relay sockets that have signal processing modules plugged into each socket ie Block The controller includes sufficient memory to handle 160 Blocks See figure 5 1 Library of Functions The PCC IIl has an extensive library of Functions to handle any type of control task These Functions are identified and described in detail in Section 6 of this manual The library includes Functions for the conversion of Inputs to engineering values mathematical operations logical operations timing operations the traditional PID algorithm as well as other types of special PID Functions Additional special Functions such as Learn Boiler Efficiency etc are also included and are described in depth in Section 6 PCC III Instruction Manual rev 2 3 Page 5 1 Section 5 Configuring Blockware Any Function Any Block Each Block is assigned a Function type during configuration Any Function type can be used in any Block number The Block number only determines the order in which the B
184. mit until xe the Output becomes equal to the Input es The Input rate of change is ignored during the output rate limiting mode Therefore if the Input rate of change briefly 10 exceeds one of the limits and then returns to a moderate 0 5 10 15 20 Seconds PCC III Instruction Manual ver 2 3 Page 6 10 Sect Input Sec Output nce rate the Block Output will lag behind the Input until the Output becomes equal to the Input again FUNCTION 36 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 20 NAME RLIM SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A INPUT Parameter Description Default Max Min Code Notes 1 SEC LIMIT 10 00 100 00 0 10 2 2 SEC LIMIT 10 00 0 10 100 00 2 F38 FPT H Front Panel Adjustable Track Hold Function FPT H is a Track Hold that allows the Operator to adjust the Block Output from the Front Panel display when the Block is in Hold mode It s function is equivalent_to an Auto Manual or Remote Local station Track Mode When the Block is in Track mode similar to Auto or Remote the Block Output is set equal to the Signal Input That is the Block Output tracks the Block Input Hold Mode When the Block is in Hold mode similar to Manual or Local the Block Output remains at the last value unless changed by the Operator or the RS485 communications link In Hold mode if the Operator selects a FPT H Block for display on the front panel the Block
185. modulating a steam valve in order to control the burner fuel oil temperature then as noted above the oil temperature is the PV that is Process Variable If you want to keep the oil temperature at a constant 220 deg F then the Setpoint would be 220 deg F Typically when the two bargraphs are setup to display PV and SP simultaneously both bargraphs will be at the same height when the PCC III is in AUTO and the controller is maintaining the desired Setpoint However the Blockware Designer is free to use this bargraph to display any other variable The bargraph has 50 segments individual lights plus one zero light therefore each segment represents 2 of the range of the signal being displayed OUT Bargraph Item 3 in fig 1 Typically this bargraph provides a graphical display of the OUTput of the PCC III over a range of from 0 100 Output is control system slang for whatever the PCC III is changing in an effort to maintain the process at the desired setpoint Put another way if the PCC III is modulating a steam valve in order to control the burner fuel oil temperature then the 4 20 mA signal being sent to the steam valve positioner is the Output In this case the OUT bargraph would indicate 0 100 of the steam control valve s opening demand signal However the Blockware Designer is free to use this bargraph to display any other variable The bargraph has 20 segments individual lights plus one zero light th
186. mon Total Loop 800 ohms max Terminals shown are for AO ch 0 1 Page 2 14 Section 2 Installation 120 Vac Discrete Inputs CPU Board CPU Board Only This example shows Discrete Input 1 on the CPU Board The Neutral for the 5 Discrete Input channels on the CPU board is connected internally to the PCC III 120 Vac incoming power supply Neutral Provided that all Discrete Input power source Neutrals are Grounded as required by NEC then the Discrete Inputs and PCC III Hot can be from different phases Specifications gt 90 Vac ON lt 3mA OFF Input Impedance 8 k 20 Typical Input Current 15 mA 120 Vac Discrete Inputs J Board Isolated Neutrals J Board Only This example shows Discrete Input 1 on a J Option Board that is plugged into Slot 1 Each Discrete Input has a separate isolated Neutral which is isolated from all other channels and from the CPU Neutral If Isolation is not desired jumpers on the JP1 jumper block interconnect the channel Neutrals Each jumper connects an individual channel Neutral to an isolated inter channel tie bus Therefore two jumpers would have to be installed to connect the Neutrals of two different channels PCC M Field Hot and a ee PCC III Hot can be different Optical 33 uF 120 Vaci phases Isolator Hot AC J 120 Neutral Neutrals aL nono nana nana ene nn nana n
187. monitor location is the same as the stack exit inside diameter set OPLR 0 500 If the monitor and stack exit diameters are different use the following formulas to find OPLR corrected Opacity Lm The inside diameter or width of the flue at the Opacity Monitor location in inches Lx The inside diameter or width of the stack at the outlet in inches OPLR 0 5 Lx Lm Ox Opacity at the stack exit 1 T OP T and Ox are expressed as decimal percentages i e 0 92 instead of 92 in the above equations In Opacity Output Mode Parameter 1 1 the Block Output is scaled 0 100 for Ox 0 00 1 00 Opacity can not be less than 0 or greater than 100 However values greater than 100 and less than 0 are calculated to allow system trouble shooting Pursuant to Federal EPA regulations the OPLR constant can not be altered in the field The OPLR constant can only be adjusted by the transmissometer manufacturer and is protected by a level 4 Factory password Optical Density Od is calculated based on OPLR corrected Opacity Ox Od log 1 Ox In Optical Density Output Mode Parameter 1 0 the Block Output is scaled 0 100 for Ox 0 00 1 00 Optical Density Block Output values greater than 100 are calculated to allow system trouble shooting Optical Density is proportional to particulate emissions grft or mg mm Using EPA certified methods measure particulate emissions and note the Optical Densit
188. n Example The Blockware designer wants QUICK Menu line 2 to display PID Repeats Min and line 2 to Point to the PID Function in Block 32 Repeats Min is Parameter number 2 of the PID function Use EDIT QUICK MENU to enter the following data Q2 MSG PID REPEATS MIN Q2 BLK 32 Q2 PARAM 2 Entering a Message Scroll to Qx MSG Press ENTER The Message display will change from Qx MSG to the existing message The cursor position is indicated by alternating between the existing character and the underlined character Use EDIT 4 or EDIT Vv to scroll through the available characters A Z 0 9 When the desired character is displayed DO NOT PRESS ENTER press the DIS key to move the cursor one position to the right Repeat this process until up to 16 characters have been selected Press ENTER after the entire message has been composed The display will return to the menu Entering the Block Number Scroll to Qx BLK Press ENTER Qx Byyy followed by the Function Name will be displayed along with yyy on the Numeric display The Edit Value light will be blinking Use EDIT 4 or EDIT v to display the desired Block PCC III Instruction Manual rev 2 3 Page 4 20 Section 4 EDIT Menus Number press ENTER The display returns to the menu with Qx BLK displayed along with the Block Number shown on the Numeric display Entering the Parameter Number Scroll to Qx PARAM Press ENTER
189. n from DI ch PCC III 120 Vac Grounded 0 2 gt 0 5 Power Supply Neutral to PS xfmr lt Neutral Per NEC Code Terminals shown are for DI ch 0 1 PCC III eae eee eae eee Beet Optical _ 120 Vac Isolator Hot AC Neutral Isolated from ch lt gt ch and CPU AC Neutral JP1 Jumpers can be used to interconnect Nx Terminals N1 lt gt N4 are always isolated from CPU board AC Neutral Terminals shown are for DI ch 1 1 The CPU AC Neutral terminal 1U does not connect to the J board An external wire must be run if the these isolated Neutrals need to be connected PCC III Instruction Manual rev 2 3 Page 2 15 Section 2 Installation Relay Output Typical for CPU and J boards This example shows Relay Output 1 on the CPU Board The Relay contacts are protected from damage due to inductive loads by a capacitor and a 150 V Varistor To prevent damaging the Varistor do not apply voltages greater than 145 Vac across the Relay contacts When the Relay Contacts are Open less than 1 8 mA of leakage current is applied to the load through the snubber cap and Varistor Discrete Output Sinking Internal 24 Vdc CPU Board Only This example shows Discrete Output 1 on the CPU Board DOUT channels are Open Collector Transistors ie Sinking with internal clamping diodes When active the DOUT conducts DC current to Power Common Coil loads relays
190. n Linear mode Parameter 1 First last Segment 0 holds the Output Parameter 1 1 varies the Output linearly The figure above illustrates Linear mode At least two points must be entered to activate Linear Mode Learn Mode X and Y coordinates may be entered or modified at any time from the PCC III front panel editor the RS232 port or the RS485 communications port via PLINK F X also has a Learn mode for automated entry and editing of characterizing curves Learn mode is particularly useful for setting up the various curves associated with combustion applications fuel air ratio oxygen setpoint flue gas recirculation curves furnace draft feedforward and feedwater valve characterizer curves When Input 2 Learn Enable 1 the Learn mode is activated and Inputs 3 4 and 5 determine how Learn mode operates Inputs 3 5 are ignored when Input 2 Learn Enable 0 The Block Output continues to be calculated based on the X input and the current parameters throughout Learn mode See the truth table below ot Learn mode is disabled p protse _ not sed No X Y data is stored in the parameters a re ee The current X and Y Input values are stored in a pair of parameters see below NOTE 1 means on the rising edge i e only once during the scan that the Input changes from 0 to 1 PCC III Instruction Manual ver 2 3 Page 6 15 Section 6 Blockware Functions Technical Reference Automated Storing of X Y Data in Learn Mode
191. nal Setpoint Parameters 1 and 3 and Input 2 By default Parameter 1 2 and HIALM uses the HIALM SP 50 DB 10 DELAY 4 INTERNAL SETPOINT stored in Parameter 3 as the SP 100 Changing Parameter 1 to 1 causes HIALM to use the EXT sy Crp SP External Setpoint Input Input 2 as the SP 80 10 In EXT SP mode A FPCON F55 Input to EXT SP allows the Operator to adjust an alarm setpoint from the front panel Process mode display channels and FPCON s Min Max parameters can limit the range of adjustment If the PID setpoint FPCON Block feeds a WSUM F52 Block and WSUM connects to the EXT SP the HIALM setpoint can be a constant percentage above the Operator adjusted PID setpoint Percent 20 Alarm Time Delay Parameter 5 PV must be continuously 0 5 10 15 greater than SP for Parameter 5 seconds before the HIALM Seconds Block Output will change to a 1 See bottom figure at right Alarm Disable Parameter 4 and Input 3 By default HIALM is Enabled and responds to alarms because the defaults are Input 3 is Block 2 DO or Low and Alarm Disable is ACTIVE HI Parameter 4 1 However Blockware can use the Disable Input Input 3 to selectively Disable individual alarm Blocks that is force the alarm Block Output to be a 0 Parameter 4 determines if the Disable signal is Active HI or Active LO as follows Disable Input 1 Active Hl 0 Enabled 1 Active HI Disabled
192. nctions PANEL LOGIC Block 3 can not be changed to any other function However other Blocks may be configured as D1 No Inputs or parameters are required for D1 FUNCTION 91 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 0 NAME D1 SINGLE USE FUNCTION N OUTPUT TYPE D No Inputs and No Parameters PCC III Instruction Manual ver 2 3 Page 6 34 Section 6 Blockware Functions Technical Reference F92 DIN Discrete Input Function DIN is the Blockware interface to the PCC III 120 Vac optically isolated Discrete Inputs hardware The DIN function interfaces to Discrete Inputs on the CPU board and on option boards Parameter 1 specifies the board location the CPU board board 0 Parameter 2 selects a particular Discrete Input on the specified board When 120 Vac is applied to the selected Input the Block Output equals discrete 1 Optionally Parameter 3 Invert Output can be used to invert the Output ie 120 Vac Input equals discrete 0 Output FUNCTION 92 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME DIN SINGLE USE FUNCTION N OUTPUT TYPE D No Inputs Parameter Description Default Max Min Code Notes 1 OPTION BOARD 0 CPU BOARD 0 2 0 3 2 INPUT CHANNEL 1 5 1 3 1 3 INVERT OUTPUT O NO 1 YES 0 1 0 2 Notes 1 Maximum quantity depends on type of option board that is currently installed F93 DCON Discrete Constant Function CON outputs a user defined discrete constant This value can be changed via the PCC III
193. neral This section will explain the Front Panel displays and the operation of the Front Panel pushbuttons This section is intended as an aid to the every day user of the PCC III controller The PCC III is a general purpose software configurable microprocessor based controller Typical applications High school heating plant firing rate controller with time of day clock start time logic and outside air temperature reset Multiple burner high pressure steam boiler fuel flow and air flow controller Boiler furnace pressure ie draft controller Electric generator steam turbine throttle valve controller Waste water pH controller Pump and Fan variable speed drive flow pressure controller Batch reactor temperature controller Paper stock consistency controller Chemical additive ratio blending controller Heat treating temperature controller The same physical PCC III controller hardware is used in every case What differentiates one controller from another is the application specific Blockware ie control strategy software in the memory of the PCC III PCC III Instruction Manual rev 2 3 Page 3 2 Section 3 Operation By design the PCC III is exceedingly flexible and very adaptable For convenience this section will use specific examples to explain how to operate the PCC III However the reader should remember that each PCC III will be programmed differently to suit the needs of a particular application For this reason one must consu
194. nical Reference FUNCTION 2 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 40 NAME AIN SINGLE USE FUNCTION N OUTPUT TYPE A No Inputs Parameter Description Default Max Min Code Notes 1 OPTION BOARD 0 CPU BOARD 0 2 0 3 2 INPUT CHANNEL 1 5 1 3 1 3 VOLTS INPUT FOR 0 OUTPUT 1 000 5 100 0 000 2 2 3 4 VOLTS INPUT FOR 100 OUTPUT 5 000 5 100 0 000 2 2 3 5 SQ ROOT O NO 1 YES 0 1 0 2 4 6 FILTER SECONDS 1 0 300 0 0 0 1 7 LOW FLOW CUTOFF 0 OFF 0 00 30 00 0 00 2 Notes 1 The quantity of Inputs available is dependent on the type of option board installed An error message is displayed during EXIT S M if sufficient Inputs are not available 2 The difference between Parameters 3 amp 4 must be greater or equal to 0 500 Volts 3 Reverse Input scaling is valid i e 0 Output 5 000 Volts 100 Output 0 000 Volts 4 Negative Inputs after 0 and 100 scaling yield a 0 Output if Square Root mode is selected F5 RAIN RS485 Remote Analog Input When the PCC III RS485 communications link Comm Link is in Local Mode the Comm Link can read all Block Outputs however the Comm Link is prevented from writing data to ie changing all Block Outputs with the exception of the RAIN and RDIN Blocks The Comm Link is permitted to write data to RAIN and RDIN Block Outputs at all times Signal Conditioning The value written by the Comm Link first passes through a min max limiter followed by a sec rate limiter and then a first order low p
195. ockware Functions included in the PCC III firmware See Section 5 for details on designing and configuring Blockware control strategies Each Function has a Name and a Function Code Number which are interchangable The Function Name is a mnemonic or abbreviation of the Function s description Function Name AIN Analog Input The Function Code is the number that the PCC IM internal firmware uses to reference a Function Function Code F2 AIN Typically users refer to Functions by Function Name not Function Code Functions are arranged in Function Code order in this Section Each Function has a verbal description technical data Header Inputs and Parameters and when appropriate an application example A glossary of the terminology used in the Technical Data area of each Function follows FUNCTION The Function Code Number NAME The Function Name ie mnemonic or abbreviation TEMP BYTES Bytes of Temporary RAM used per Block 1280 Bytes total are available RETENTIVE BYTES Bytes of Retentive Memory EEPROM used per Block 58 Bytes total are available DATA BYTES Bytes of Data EEPROM used per Block 5120 Bytes total are available SINGLE USE FUNCTION N Function can be used in multiple Blocks Y Function can only be used in one Block OUTPUT TYPE A The Block Output is Analog a 327 00 to 327 00 value D The Block Output is Discrete a Logical 0 or Logical 1 value Input Type A The Block Outpu
196. on Procedure 4 23 Generales seie nese oe hols Davee tee et 12 COM PORT Menu cette tenets eeeeeeentees 24 How to use EDIT A BLOCK an Example 13 COM PORT EE 24 Softwire the HIALM Block PV Input 14 ADDRESS h aT aTa RE aen E EEES 24 Change the HIALM Setpoint Parameter 14 aya D EE E E EA AAA EET T 24 Softwire the PANEL Alarm Channel 1 Input 14 PARITY ci icbccesieseecesdeesndctsiccaste aeie ao heihi arat 24 Entering a Message Parameter in PANEL 15 RTU ASCII ote Shel ae Zam Mates tesa Sc elect es E ETTE E TEST A 25 MEMORY Me ntheeecccccccccccccccceeecceccecce cececececsestttteeeeees 15 4 IDA P es shee 2 E nocce 8 22 O 25 A toload herena a i 15 TIME QUT nen ni 25 Backup Memory Write Protect Jumper AAA EP 15 TEST CABLE ELER TEE EEEE E A E TEETE 25 Backup Memory Socket a 16 SUPPORTED MODBUS FUNCTIONS 26 Section 5 Configuring Blockware Library of Functions Any Function Any Block ceeeeeeseeseeeeeeees Reusable Functions 0 cccccccccecesssseceeeeenseees Softwiring PCC Ill Terminology Glossary cceeeeeeeees Blockware Configuration cece Function Type Or Function Code Number INPUt nenii EEPROM Retentive Memory Configuring Blockware Control Logic 0e1 7 Modifying a Boiler Master Blockware Configuration8 Define the requirements eee eee ee 8 Check the I O Co
197. or Scaler 6 F T Function of Time Generator 13 F X Function of X Generator with Learn Mode 15 F F Flip Flop Logic 50 FRCON Front Panel Adjustable Constant 22 FPT H Front Panel Adjustable Track Hold 11 H LLIM High Low Signal Limiter 10 PCC III Instruction Manual ver 2 3 Page 6 2 Section 6 Blockware Functions Technical Reference Name Description Page HIALM High Alarm 44 HSEL High Select 9 INTTDR Interval Time Delay Relay Non Retriggerable One Shot 53 INV Invert 21 L L Lead Lag with Gain 18 LED LED 43 LOALM Low Alarm 45 LOGIC User Defined Logic 48 LSEL Low Select 9 MSEL Median Selector 9 NOP No Operation Dummy Function 58 NOT NOT Logic 49 OPLR Optical Path Length Ratio Correlation for Opacity Monitors 7 PANEL Front Panel Display 36 PB Pushbutton 42 PID PID Control with GAP and ADAPTIVE gain 24 PLINK Block Parameter Links for Communications 55 RAIN RS485 Remote Analog Input 5 RATE Rate of Change Alarm 47 RDIN RS485 Remote Discrete Input 41 REPTDR Repeat Time Delay Relay 54 RLIM Rate Limiter 11 ROUT Relay Output 57 S M Service Manual Status 35 SCALE Signal Scaling 19 SQRT Square Root 24 TCODE TOUT Fault Code 34 TOT Totalizer Integrator with Pulse Output 50 TOUT Triac Output 28 TTRIP TOUT Fault Status 43 WSUM Weighted Sum 21 XOR Exclusive OR Logic 49 Introduction Section 6 provides detailed information on each of the Bl
198. otes 1 SECONDS DELAY 1 19999 1 2 2 INVERT OUTPUT O NO 1 YES 0 1 0 2 F119 DADTDR Delay After De energize Time Delay Relay Off Delay Function DADTDR simulates a Delay After De energize Time Delay Relay also known as an OFF Delay function lt PADTOR soso OF DER The Output may be inverted see Parameter 2 The timing 2 diagram shows the default non inverted logic 5 For non Inverted Output When the Input 1 the Output is 1 and the timer is reset to Parameter 1 seconds 2 When the Input changes from 1 to 0 the timer starts counting down and the Output changes to 0 when the timer counts down to 0 seconds 0 5 10 15 20 Seconds FUNCTION 119 TEMP BYTES 4 RETENTIVE BYTES 0 DATA BYTES 12 NAME DADTDR SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D INPUT Parameter Description Default Max Min Code Notes 1 SECONDS DELAY 1 19999 1 2 2 INVERT OUTPUT O NO 1 YES 0 1 0 2 PCC Ill Instruction Manual ver 2 3 Page 6 52 Section 6 Blockware Functions Technical Reference F120 INTTDR Interval Time Delay Relay Non Retriggerable One Shot Function INTTDR simulates a Interval Time Delay INTTDR 3sec ON Interval Relay also known as an Non Retriggerable One Shot function The Output may be inverted see Parameter 2 The timing diagram shows the default non inverted logic Output For non Inverted Output When the INTTDR Output is 0 the timer is reset to
199. other Block At right below the PV Process Variable Input of Block 22 HIALM is monitoring the Output of Block 20 AIN via a Softwiring connection AIN AIN NOT HIALM T 20 NOP PV 22 22 PID PID 5 5 PCC III Instruction Manual rev 2 3 Page 1 4 Section 1 Product Overview Special Option Card and Special Function Block Capabilities The following are applications features of the PCC III which extend its capabilities considerably Multiple F x The F X function type allows for characterizing or curve fitting of a relationship when that relationship is non linear In combustion control applications as an example it is desirable to have the fuel input to a burner follow a linear relation with firing rate demand Even with a properly selected valve trim the relationship will not be perfectly linear But with the application of an F X block this objective can be realized The PCC III has the capacity to use as many F x functions as are required by the application In some complex combustion applications a single controller may use up to 6 to 8 F x functions Learn Mode The Learn Mode allows for easy commissioning of applications involving single or multiple non linear functions This capability is best described with an example in combustion control applications as the firing rate is increased the best co
200. ows the Blockware designer to assign up to 30 different individual Block Parameters to the Modbus Holding Register addresses 41001 thru 41030 The assignments do not have to be in any particular order and register addresses may be skipped if desired Example To allow PID tuning from a workstation configure PLINK to map the PID Gain and PID Repeats Min Parameters to two Modbus Holding Register addresses Pick any two available Registers 41003 for Gain and 41004 for Repeats Min in this Example Consult the PID description above Section 6 to determine that Gain is Parameter 1 and Repeats Min is Parameter 2 Assume for this Example that PID is in Block number 32 The PLINK Parameters should be configured as follows PLINK PLINK Parameter PLINK Comment Parameter Description Parameter Value 5 R41003 Block Number 32 PID Block Number 6 R41003 Parameter Number 1 PID Gain Parameter Number 7 R41004 Block Number 32 PID Block Number 8 R41004 Parameter Number 2 PID Repeats Min Parameter Number PCC III Instruction Manual ver 2 3 Page 6 55 Section 6 Blockware Functions Technical Reference Values are reported to the RS485 Comm Link as 16 bit signed integers The assumed decimal point location that is the scaling of each parameter is determined by consulting the parameter description min max values shown in each of the function descriptions above Section 6 Some Examples Function F T F41 shows Parameter 2 with
201. p meter set the 4 20 mA Output to 4 000 mAdc 0 003 The number shown on the Numeric display is used by factory technicians for diagnostics Press ENTER SET OUTPUT TO 20 00 MILLIAMPS THEN PRESS ENTER will be displayed The error message CALIBRATION ABORTED can be displayed for the same reasons described above Press ESC to return to the menu the original calibration will still be in effect Using the EDIT 4 or EDIT Vv keys and observing the milliamp meter set the 4 20 mA Output to 20 000 mAdc 0 003 Press ENTER output calibration complete will be displayed if the calibration was successful Press ESC to return to the menu the new calibration will be in effect Repeat the above procedure for any other Ouput channels that are going to be calibrated Then COPY PRIMARY TO BACKUP see pg 4 16 and then EXIT S M see pg 4 9 PCC III Instruction Manual rev 2 3 Page 4 23 Section 4 EDIT Menus COM PORT Menu COM PORT ADDRESS This menu is used to setup the communications parameters port select the BAUD communications mode and to test the RS485 cabling system All PARITY Communications setup data is stored in the non volatile EEPROM Blockware RTU ASCII memory DATA TIME OUT TEST CABLE WARNING Data changes that are made during the use of the EDIT A BLOCK CALIBRATE and COM PORT menu items are saved in the Primary memory however these changes are NOT saved in the Backup memory To insure t
202. p to 327 are acceptable For positive Inputs the scaling formula is Output 10 square root Input Examples 256 in 160 out 49 in 70 out 16 in 40 out 4 in 20 out 0 in 0 out 1 in 0 out FUNCTION 59 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME SQRT SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A INPUT BLOCK No Parameters F60 ABS Absolute Value Function ABS outputs the absolute value of the Input That is for Input gt 0 the Output Input for Input lt 0 the Output Input 1 FUNCTION 60 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME ABS SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A INPUT No Parameters F71 PID PID Control with GAP and ADAPTIVE gain Function PID is a Proportional Integral Derivative control algorithm The PID equation used is called the Parallel form by the ISA Instrument Society of America others have used the terms Non Interactive or Ideal form See figure below for PID logic schematic see Appendix for PID tuning suggestions The Proportional constant is expressed as Gain as opposed to Proportional Band To convert Proportional Band ie PB into Gain Gain 100 PB or 5 PB is equal to a Gain of 20 00 A numerically larger Gain results in a larger PID output change for the same Process Variable PV versus Setpoint SP difference The Inte
203. peaters RS 485 Network cabling should always be arranged in a bus Do not wire cabling in a star or with stub connections See Drawings below for examples of bus and stub wiring layouts Belden P N 3106A Preferred part number 16284 is the recommended shielded cable for all PCC Ill RS 485 communications data highways Belden 3106A is specifically designed for RS485 applications and is 3 wire shielded cable arranged as 1 twisted pair with a foil shield plus a separate single insulated conductor that is not twisted into the main pair The 3 wires are surrounded by a second braided shield and an overall PVC insulation Belden 3106A has a characteristic impedance of 120 ohms has 22 Ga conductors and is rated 300V 60C Shielding and RS 485 Commons The shield should be connected to the RS 485 common terminal at the master station At each PCC PLC RS 485 232 converter and any other devices on the network the shields should NOT be connected to each controller s RS 485 common The shields of the network cables should be wired together so as to continue the shield to the next controller The single wire ie not part of the twisted pair in the cable should be connected to all the Communications DC Commons on the RS 485 network Cut off the foil and braided shields insulate the bare shield wire and any exposed shield and connect as shown below RS232 RS485 Converters Typical DCS and SCADA workstations have RS232 communi
204. profile The parameters provide an initial yo Block Output value at time 0 0 min plus 10 additional y t breakpoint pairs Between each breakpoint pair the function ramps in a straight line fashion from breakpoint to breakpoint see the figure below Individual segment slopes from 600 min to 0 01 min can be generated A typical application is temperature setpoint generation for Heating or Cooling Ramp Soak cycles oo Oo Q Oo D O Output Y Percent No Oo 12 14 16 18 20 8 10 Minutes Less than 10 Breakpoints All ten breakpoints do not have to be used the F T function ignores all breakpoints after the first Tj 0 0 is encountered Breakpoints 4 through 10 inclusive would be ignored in this example YO 10 Y1 20 T1 10 0 Y2 20 T2 20 0 Y3 30 T3 30 0 Y4 0 T4 0 0 PCC III Instruction Manual ver 2 3 Page 6 13 Section 6 Blockware Functions Technical Reference Reset and Hold Inputs The Reset Input sets and holds the clock at 0 0 minutes whenever the Reset Input is 1 If the Hold Input is 0 the clock will start to run when the Reset Input is 0 Setting the Hold Input to 1 stops the clock and the time will remain at that value until the Hold Input returns to 0 at that point the clock resumes running from the held value onward see chart Reset Input Hold Input Clock Run Resume Stop and Hold Auto Recycle If Parameter 1 Auto Recycle 0 the B
205. rased or corrupted and the Operator will still be able to manually regulate the PCC III 4 20 mA and Triac Outputs The firmware ROM is factory programmed and cannot be erased or corrupted by the user Relay Outputs and Sinking Discrete Outputs are always controlled by the Blockware S M mode has no effect on these When an Output channel enters S M mode the Output remains at the last value unless the Operator uses the special S M Front Panel display channels to change the Output The primary reason for using the Service Manual mode is to prevent the 4 20 mA and or Triac Outputs from changing when the user is modifying the Blockware S M mode can be activated from the SERVICE MANUAL menu on an individual Output channel by Output channel basis The Output channels can all be in Normal Operation mode all in S M mode or in any combination of modes However PCC III will automatically put ALL Output channels into the S M mode if any of the self diagnostic tests detect a problem PCC Ill will not de activate S M mode automatically The user must manually de activate S M mode from the SERVICE MANUAL menu or from PC3_ Edit RUN light indicates Normal Forced or S M Mode Green RUN Light ON OFF Cycle Operating Mode ON Continuous Normal OFF ON 95 Forced Block s pg 4 19 OFF Blinks OFF once every second ON Blinks ON twice every second OFF 85 Service Manual ON OFF Continuous Not Operating Note S M Mode RUN l
206. rations the traditional PID algorithm as well as other types of special PID Functions Additional special Functions such as Learn Boiler Efficiency etc are also included and are described in depth in Section 6 Any Function Any Block Each Block is assigned a Function type during configuration Any Function type can be used in any Block number The Block number only determines the order in which the Blocks are calculated In the example below at left Block number 22 is not being used so it has the default NOP or No OPeration Function in it At Right Block 22 was changed from a NOP to a HIALM high alarm Function type Reusable Functions Almost all PCC III Function types can be used as many times as required within the 160 Block limit There are some Functions that are directly linked to the hardware that can only be used as many times as there is mating hardware For example only one PANEL Function Front Panel Display Interface can be used because there is only one Front Panel While those related to PID Functions curve fitting Functions etc can be used as many times as is deemed necessary for the application Softwiring Most Function Types like HIALM need information from other sources ie Blocks in order to calculate a result Softwiring is the term used to describe how the Blocks are interconnected within the software Softwiring allows the Input of a Block to monitor the Output of any
207. rd see Section 8 for details Legends can be made by with a word processor clear plastic overhead transparency material and a laser printer Parameter 2 specifies how the PB Block Output responds when the Operator presses a pushbutton MOM HI Momentary High means the Output 1 for as long as the button is depressed and returns to a 0 when released MOM LO Momentary Low is the opposite of MOM HI not pressed 1 depressed 0 TOGGLE means that the Output changes to the opposite of the previous Block Output during the first scan of every new button press At power down the PB Block Output is saved in the Retentive Memory area of the EEPROM During the first scan after CPU start up the PB Block Output is set according to Parameter 3 LAST means use the value saved in Retentive Memory FUNCTION 98 TEMP BYTES 0 RETENTIVE BYTES 1 DATA BYTES 12 NAME PB SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes NONE Parameter Description Default Max Min Code Notes 1 SELECT 1 TOP 2 A M 3 BOT 4 R L 1 4 1 3 1 2 TYPE 1 MOM HI 2 MOM LO 3 TOGGLE 3 3 1 2 1 3 POWER UP 1 HI 2 LO 3 LAST 3 3 1 2 1 Notes 1 See the description above PCC III Instruction Manual ver 2 3 Page 6 42 Section 6 Blockware Functions Technical Reference F99 LED LED Function LED is the Blockware interface to the 6 user configurable LED indicators on the front panel The LED s loca
208. red during the test Frequently these are Front Panel Display channels if not consult the Blockware drawing to find the block numbers and use the Utilities Examine menu see Section 4 to display the values Disconnect one feedback pot wire at a time leaving the other two wires connected Verify the following Open Pot Wire TOUT for Fail Closed Wiring 5 V Increase TCODE for Fail Closed Wiring 5 V Increase TOUT for Fail Open Wiring TCODE for Fail Open Wiring Increase less than 5 2 00 less than 5 2 00 Wiper greater than 105 1 00 less than 5 2 00 Decrease __ greater than 105 1 00 greater than 105 1 00 Forcing TOUT Blocks see Section 4 Positioner mode The Forced Block Output becomes the Setpoint and the Setpoint Input signal is ignored That is when Forced triacs activate based on the Scaled Feedback as compared to the Forced Block Output TOUT uses the normal Positioner logic when Forced and therefore requires the Position Feedback Input to be active and Scaling Parameters 4 amp 5 to be setup for proper operation Dual Triacs mode 199 99 activates Triac 1 199 99 activates Triac 2 S M Mode Dual Triacs mode See Section 4 Using the TO bxcy S M mode front panel display pressing the ft key will activate Triac 1 Increase for as long as the ff key is depressed The key similarly activates Triac 2 Decrease FUNCTION 83 T
209. res the average to the two alarm thresholds in Parameters 1 and 2 Alarm Time Delay Parameter 4 If the average sec rate exceeds either threshold continuously for more than Parameter 5 seconds the RATE Output changes to a 1 As soon as the average sec rate returns below both thresholds the RATE Output returns to a 0 See Figure 0 5 10 15 Alarm Disable Parameter 3 and Input 2 By default RATE Seconds is Enabled and responds to alarms because the defaults Input Sec Output are Input 3 is Block 2 DO or Low and Alarm Disable is ACTIVE HI Parameter 3 1 However Blockware can use the Disable Input Input 2 to selectively Disable individual alarm Blocks that is force the alarm Block Output to be a 0 Parameter 3 determines if the Disable signal is Active HI or Active LO as follows Disable Input 1 ActiveHl 0 Enabled 1 Active HI Disabled 0 ActiveLO 0 Disabled 0 Active LO Enabled PCC III Instruction Manual ver 2 3 Page 6 47 Section 6 Blockware Functions Technical Reference FUNCTION 104 TEMP BYTES 4 RETENTIVE BYTES 0 DATA BYTES 24 NAME RATE SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 A INPUT 2 D DISABLE INPUT 1 Parameter Description Default Max Min Code Notes 1 SEC LIMIT 10 0 100 0 0 1 1 2 SEC LIMIT 10 0 0 1 100 0 1 3 ALARM DISABLE ACTIVE LO HI O LO 1 HI 1 1 0 2 1 4 ALARM DELAY SECONDS 0 600
210. ressure PID control loop and adjust if necessarNMote it is good practice to place the controller and therefore the process in Manual before switching control modes Add Pressure Compensated Steam Flow Blockware Any type of control strategy can be configured in the PCC III Figure 5 4 is an example of a logic for pressure compensation of steam flow with subsequent totalization of that flow Steam flow and other compressible fluids transmitters are subject to inaccuracies unless the inlet pressure is maintained constant If the pressure fluctuates up or down the indicated steam flow will be higher or lower due to changes in the steam s density A steam density compensation strategy based on changes in steam pressure is depicted in Figure 5 4 Block 37 compares the actual steam density B36 to the design steam density B35 Blocks 35 and 36 are Steam Density vs Saturation Pressure curves Inputs to B35 and B36 must be in a percentage of 1000 psig Thus if the orifice plate was designed for 100 000 Ibs hr at 100 psig a value of 10 is entered into B34 Also PCC III Instruction Manual rev 2 3 Page 5 13 Section 5 Configuring Blockware if the drum pressure transmitter has a 0 200 psig span a value of 20 is entered into B31 Block 32 converts the drum pressure transmitter B4 to a value corresponding to of 1000 psig Steam flow is proportional to a constant times the square root of the delta P differential pressure across the
211. roll forward through the alpha numeric and symbol strings EDIT 4 and EDIT v Rate of Change When the User presses and holds down either the EDIT 4 or EDIT v key the displayed value will initially ramp slowly However after every 10 counts the display ramp speed increases by a factor of ten Therefore the longer the EDIT 4 or EDIT v key is pressed the faster the displayed value will change Example Assume the Numeric display initially shows 0 00 The User presses and continuously holds down the EDIT 4 key The Numeric display would change as follows 0 00 0 01 0 02 0 03 0 04 0 05 0 06 0 07 0 08 0 09 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 1 00 2 00 3 00 4 00 5 00 6 00 7 00 8 00 9 00 Note the ramping sequence does not have to start with the right hand digit equaling 0 as shown in the above example If the initial display value had been 0 03 the ramp rate would change after 0 13 1 03 10 03 100 03 that is after every 10 display value changes Whenever the EDIT 4 or EDIT Y key is released the ramping rate is reset to the slowest rate Therefore if you don t want the displayed value to change rapidly release the EDIT 4 or EDIT v key after the displayed value has changed by 8 or 9 counts ENTER key When the Scroll Menu light is Blinking or when both display lights are OFF The ENTER key activates the displayed EDIT Menu line item When the Edit Value light is blinking The ENTER ke
212. roller will display any errors The RUN light will become solid when all Outputs are out of S M Display Plant Demand Compare the numeric display to that of the Plant Master Output If they do not match check engineering units in B159 PANEL and check parameters of B5 AIN Display BSM BIAS Using the UP and DOWN arrows run the Bias all the way up and all the way down to verify the display ranges from 50 to 50 Set the Bias to 10 Using the PCC III s Utility Menu force the Plant Master Input B5 to 50 or if possible base load the Plant Master at 50 Examine B26 It should read 40 If not check the Inputs and parameters of Blocks 5 25 and 26 Press the PM LOCAL PID pushbutton on and off The LED PV and SP bargraphs should toggle accordingly If not check the Inputs and or parameters of Blocks 55 PB amp 85 LED Place in Local PID mode Place the controller in the Local PID mode Force the Drum Pressure Input B4 to 0 Exit the EDIT mode A LOW ALARM should annunciate Acknowledge the alarm press ACK and check the verbiage on the display Correct if necessary Note A 4 20 ma simulator can be used as the Input in lieu of forcing the Block Go back into theEDIT mode and force B4 to 100 Exit th DIT mode A HIGH ALARM should annunciate Acknowledge the alarm and check the verbiage on the display Correct if necessary Using the Utility Menu unforce all Blocks Force the Output o
213. rom writing data to ie changing all Block Outputs with the exception of the RAIN and RDIN Blocks The Comm Link is permitted to write data to RAIN and RDIN Block Outputs at all times Pulse Mode Off ie Parameter 1 3600 sec The value written by Comm Link remains in effect until a new value is written by Comm Link or until a Comm Link time out Upon Comm Link time out ie no new Comm Link writes within Parameter 2 seconds the Comm Link value can either remain at the last value received or switch to the default value see parameters 3 amp 4 Pulse Mode On ie Parameter 1 lt 3600 sec The RDIN Block Output becomes a re triggerable one shot pulse with Parameter 1 seconds minimum duration If Parameter 1 0 seconds RDIN creates a one scan long pulse Pulse mode is useful as a Comm Link Watchdog timer or for logic that requires momentary pulses 0 5 Comlink Writes 10 15 20 25 Seconds RDIN Output A Comm Link write of 0 followed by a Comm Link write of 1 is the trigger to change the RDIN Output to a 1 and start the Pulse timer If no additional Comm Link triggers occur the RDIN Output changes to a 0 after the Pulse timer expires If another Comm Link trigger occurs when RDIN s Output 1 the timer restarts If no further Comm Link writes occur or if Comm Link continuously writes either a 1 or a 0 the Pulse timer will expire and the RDIN output changes back to a 0 See P
214. rpose and Operation of each of these pushbuttons is determined by the Blockware designer Review the documentation provided with the Blockware for your specific controller to determine the purpose of each pushbutton Items 12 and 16 can be labeled by the user to indicate the purpose of each pushbutton Items 14 and 18 are permanently labeled User Defined Lights Items 13 15 17 19 20 and 21 in fig 1 These six lights are configured by the Blockware designer The Purpose and Operation of each of these lights is determined by the Blockware designer Review the documentation provided with your specific controller s Blockware to determine the purpose of each light Items 13 17 20 and 21 can be labeled by the user to indicate the purpose of each light Items 15 and 19 are permanently labeled The four lights that are located within the outline of a pushbutton are all actually controlled by Blockware that is independent of the operation of the pushbutton itself While it is very common for these four lights to be used to indicate when the pushbutton is ON it is not unusual for some of these lights to be used as simple indicators that are not affected by the operation of the mating pushbutton PCC III Instruction Manual rev 2 3 Page 3 7 Section 3 Operation Multiple Loops PCC Ill can control more than one loop at the same time The method used to accomplish this is selected by the Blockware Designer Review the documentation provided
215. s Technical Reference F54 CON Analog Constant Function CON Outputs a user defined analog constant This value can be changed via the PCC III Editor menus under password protection via RS232 Blockware download or via the RS485 communications link using PLINK F124 This value cannot be changed from the PCC Ill front panel Operator displays during normal operation FUNCTION 54 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME CON SINGLE USE FUNCTION N OUTPUT TYPE A N 70 0 t sts eee ceececets sare st es 04 s 8 lt 0 c 4 fanet tearerdie 4 Parameter Description Default Max Min Code Notes 1 ANALOG CONSTANT VALUE 0 00 199 99 199 99 2 F55 FPCON Front Panel Adjustable Constant Function FPCON outputs a user defined analog constant This value can be changed via the PCC III front panel Operator displays during normal operation or via the R8485 communications link This value can not be changed from the PCC IIl Editor menus nor via the RS232 Blockware download This function is used for Operator adjustable setpoints ratios channel selections etc A FPCON Block must be one of the 10 display channel Inputs to the PANEL F96 Block in order to allow the Operator to be able to change the value from the front panel Operator displays The MIN and MAX parameters limit the range of adjustment that can be made At power down the Block Output is saved in the Retentive Memory area of the EEPROM During the first scan a
216. s 4 20 mA 0 5Vdc Analog Inputs 5 Channels NOILdO 8 AJY Z99061 ASSY WM cxvo 29 C31 wc8 40 F R4 I u10 C179 C16 c15 U7 es iy Sh i s 42 1 RNTI c18 iam lt S81 Pa gre _ ot gI 45 ew c14 5l rm g i a 2x gh o U6 U4 e RN8 es CE os te n m ja g TZT y Hoe RN10 uu C19 c U2 U1 boooo0o00000000 m U3 mo90990099999909 e I gj J1 PREF INSTR DANBURY CT 26810 RN12 RN2 RN3RN4 o NOILdO E ZBEBEL ASSY PCC III Instruction Manual rev 2 3 T1 AIN ch 3 To Connect 250 ohm Resistor Turn Switch ON Rev 0 B Option Board 250 ohm Switches 4 20 mA 0 5Vdc Isolated Analog Inputs 3 Channels Isolated Ch to Ch and from CPU Signal Common sco l H I 2 3 gore fi L 24 ye 4 CD e g Let sC AIN AIN ch 1 1 To a e clin eee 250 ohm Resistor Turn a e clin eee ON Rev A B Option Board 250 ohm Switches 4 20 mA 0 5Vdc Isolated Analog Inputs 3 Channels Isolated Ch to Ch and from CPU Signal Common Page 2 6 Section 2 CPU Board 120 Vac Fuse CPU Board Terminals 1U 8U CPU Board Terminals 1L 8L Option Board 1 Terminals CPU Board Terminals 1 28 Option Board 2 Terminals CPU Board 250 ohm jumpers Al1 Al5 CPU Board
217. s consumes negligible memory while PLINK consumes a considerable amount of memory The Block Output is 1 if RS485 communications is enabled See Section 7 and a valid message addressed to this particular PCC Ill has been received within the Communications Time Out period The TIME OUT seconds are set in the COM MENU TIME OUT Edit Menus See Sections 4 and 7 Remote Local R L Input When the R L Input is 1 Remote the Comm Link is allowed to write modify FPT H F38 FRCON F55 PB F98 RAIN F5 and RDIN F97 Block Outputs In Remote mode the Operator can also modify from the PCC III front panel the FPT H FPCON or PB Blocks When the R L Input is 0 Local the Comm Link can not modify FPT H FPCON or PB Blocks However Comm Link can write to RAIN and RDIN Blocks in Local mode At power up If RS485 is Enabled in the COM MENU COM Block Output 1 The Time Out count down re starts at power up FUNCTION 123 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME COMM SINGLE USE FUNCTION Y OUTPUT TYPE D Input Type Description Notes 1 D REMOTE LOCAL BLOCK 1 REMOTE WRITES ENABLED O LOCAL ONLY No Parameters F124 PLINK Block Parameter Links for Communications Function PLINK provides all of the features of COMM F123 described above and adds the feature of allowing Comm Link to read or write Parameters into individual Blocks Without PLINK Comm Link can only read and write PCC Ill Block Outputs PLINK all
218. s for the Operator DEVALM can also be used as a trigger in Blockware to automate a control strategy Opie cence py Inputs 2 3 and Parameters 1 and 3 7 modify the basic SP PV SP behavior as follows ____DEVSP DEV SP DB Deadband_or Hysterisis Parameter 3 When Deadband DB 0 0 Output 1 if PV SP gt Deviation or Output 0 if PV SP lt Deviation When Deadband gt 0 Output 1 if PV SP gt Deviation and once the Output becomes a 1 it remains a 1 until PV SP lt Deviation DB and then it resets to 0 See figure above Internal vs External Setpoint Parameters 1 and 4 and Input 2 By default Parameter 1 1 and DEVALM uses the EXT SP External Setpoint Input Input 2 as the SP Changing Parameter 1 to 2 causes DEVALM to use the INTERNAL SETPOINT stored in Parameter 4 as the SP Alarm Time Delay Parameter 7 PV SP must be continuously greater than the Deviation threshold for Parameter 7 seconds before the DEVALM Block Output will change to a 1 Alarm Disable Parameter 5 and Input 3 By default DEVALM is Enabled and responds to alarms because the defaults are Input 2 is Block 2 DO or Low and Alarm Disable is ACTIVE HI Parameter 5 1 However Blockware can use the Disable Input Input 3 to selectively Disable individual alarm Blocks that is force the alarm Block Output to be a 0 Parameter 5 determines if the
219. s the display channel Each channel also has 4 Parameters Parameters 2 41 for formatting the displayed value Fixed Decimal Point Location Zero 0 Input Display Scaling Span 100 Input Display Scaling and a Channel Descriptor Message 16 characters max A Z 0 9 and symbols See Display Channel Scaling Examples below Messages can be entered or edited from the Edit Menus or via RS232 download PANEL also allows the Operator to modify FPCON F55 and FPT H F38 Block Outputs using the front panel ff and keys 6 Typically this is used for Operator adjustment of Setpoints Ratios Valve and Damper positions and other values PANEL bi directionally translates between the displayed scaled value and the FPCON or FPT H Block s Output based on the scaling Parameters of the channel PANEL limits the Operator s adjustment range to the scaled range determined by the MIN and MAX Output Parameters in each FPCON and FPT H Block PANEL will not allow Operator adjustment of a FPT H Block unless it is in Hold mode See F38 FPT H The scaled Numeric value and the Channel Descriptor Message are always displayed as a matched pair Pressing the DIS key 4 selects the next display channel DIS wraps around to the first channel after the last active channel is displayed Optionally a more powerful Operator friendly automatic display channel selector system Auto DIS is available Auto DIS can automatically display the Process Variable when the
220. seenennesneseensas eeseeeeenees 19 ENTER SM in MAIN Menu 0 0 cc0eeeeeeee 8 FORGE BEOGK s wedrvied tes iria as deret renters 19 PLES Mech E A E Breit et achat ae eo 9 UN FORCE A BLOCK sscsssesseesesteeeesenenseeens 20 EXIT SM in MAIN Menu ccccccccsecereseee coon 9 UN FORCE ALL BLOCKS 0 eee 20 Changing an Output Value in S M Mode 9 DISPLAY SCAN TIME cccceeseseeeeseeeneeeeeees 20 PASSWORD MeMU c scccsceeccesceccsesseceecserecsrsesseres 10 EDIT QUICK MENU essssessseeseeseseteseesansseenenns 20 Password LeVEIS ss ssssscsessessesscsesssssessccseasenss 10 Entering a Message secseseeeeseeeste coeeseeseenes 20 Enabling the Password System cccccceeeeeee 10 Entering the Block Numbet 2 eeeeeeeee es 20 ENTER PASSWORD siseses 11 Entering the Parameter Number sseeee 21 SECURE CONTROLLER ooece ccccccccceccccececececceceteees 11 BLOCK TIMING kroin cei ipia eect 21 TIMEOUT p nara i 11 CALIBRATE Menu sessssessssesstssnsses esses 21 CHANGE OPERATOR PASSWORD 11 When is Calibration Required cccseeeeeee 21 CHANGE TECHNICIAN PASSWORD 11 Analog Inputs Calibration Status Display 22 Disabling the Password System cccccccceeee 11 Analog Input Calibration Procedure 0 22 EDIT A BLOCK Menu scscsssssssessssssesssessscssssscesees 12 Analog Output Calibrati
221. seesecceteceecs 15 t DAWA coctevocsccccon test aa 25 AutoLoad emer ae te ae ee ener a er ET 15 TIME OUT 0 esesseseeeeseeeeseeseeeeseeneeneeeeneaneseeneanenes 25 Backup Memory Write Protect Jumper OTTEET NA 15 EIEN E E E E EAE 25 Backup Memory Socket sc essssesesseeeeeteeeees 16 SUPPORTED MODBUS FUNCTIONG 26 PCC III Instruction Manual rev 2 3 Page 4 1 Section 4 EDIT Menus Introduction Edit E a The PCC IIl Blockware ie the control strategy is software Value based and is totally field configurable The PCC II Blockware 1 9999 light on line diagnostics and other controller configuration data can Scroll be viewed or modified using any one of the three methods that MESSAGE 2 Menu follow light Front Panel EDIT Menus Using the EDIT keys see figure and the Front Panel displays any and all possible configurations can be accomplished without the use of a Personal Computer Some examples of what can be accomplished from the EDIT Moves keys Message Cursor Assigning Function Types to Blocks Softwiring from Block to Block Blockware data entry PID tuning Alarm setpoint adjustment Enter Edit Alarm messages Blockware debugging Copy Primary Memory to Backup and vice versa Service Manual Mode Control On line diagnostics Passwords Miscellaneous Setup li Ss EDIT Keys This Section will describe the purpose and operation of every EDIT menu item and every EDIT key
222. shows all of the Block Softwiring ie interconnections for the controller is strongly recommended EXAMINE Block Outputs Scroll to the EXAMINE menu item press ENTER Scanning up from Block number 4 EXAMINE will display the Output of the first Block that is not a NOP Use the EDIT 4 or EDIT Vv keys to scroll to the Output of any other Block EXAMINE will skip over any Blocks that contain a NOP The Numeric display will show the current Output Value The Message display will show the Block number as Bxxx and will show the Name of the Function contained in that Block EXAMINE the Input Signals of a Block First display the Block Output of the desired Block as described above in EXAMINING Block Outputs Press ENTER to display the current value of the first Input The Numeric display will show the Input value The Message display will show Bxxx Iyy followed by the Input Name xxx will be the Block Number yy will be the Input Number Use EDIT Y to scroll down to display any other Input channels that might be present Press ESC to return to the Block Output display mode Bxxx Function Name is displayed instead of Bxxx lyy Input Name Use EDIT 4 to scroll up through the available Input channels Scrolling up past the first Input channel will return EXAMINE to the Output display mode FIND FUNCTION The Blockware designer has the freedom to put any Function Type into any Block number If the Blockware Sc
223. side the PCC III that Softwire a signal from the Output of one Block to the Input of another Block Normally when we talk about Inputs we will be talking about the Softwire connections internal to the PCC III Every Block produces a single Output The Function type determines the Output value Some Functions do not require any Input from any other Blocks for example the AIN Block receives it s 0 5 Vdc input from the PCC IIl s field terminal strip while other Functions require multiple Inputs for example the AB C Block requires that three values be inputted A B amp Inputs can be referred to by a meaningful abbreviation such as A or PV Process Variable or by an Input number 11 12 etc Section 6 describes the purpose of each Input for each Function type Note The Input value for one Block is always the Output value of some other Block PCC III Instruction Manual rev 2 3 Page 5 5 Section 5 Configuring Blockware Parameter Many Functions require setup information to work properly We call these values parameters A parameter can be used to make a selection such as do you want to take the square root of this field 1 yes 0 no The reset rate of a PID Function would be considered a parameter The setpoint of a high alarm would be a parameter Basically any value that needs to be established when the controller is first configured or those values that the user will change rare
224. solenoids require an additional field mounted clamp diode on the actual coil to prevent noise induction in adjacent field wiring NOTE Incorrect clamp diode Polarity causes a direct short Each DOUT channel is rated 200 mA max load See 24 Vdc Power Supply on page 2 5 to calculate the mA current available from the 24 Vdc Power Supply The shield connects to the Power Common Discrete Output Sinking External 24 Vdc CPU Board Only The same comments noted above apply This example shows an External Power supply being used to power the load The shield connects to the External Power Supply PCC Ill Instruction Manual rev 2 3 PCC M 120 Vac max 8A Inductive 1 2 HP 120 Vac Note J Option Boards do not have NC Terminals Terminals shown are for ROUT ch 0 2 PCC M J a Clamp Diodes a Insulate 4 Shield Power Common Mount Clamp Diode on Coil Terminals shown are to Prevent Electrical Noise for DOUT ch 0 1 NOTE POLARITY PCC III 0 36 Vdc Insulate Power 24 V 10 Shield Supply Clamp Diodes 4 ch 0 2 ch 0 3 2 ch 0 4 EO PC Power Common Fo eee eee oe Ah o Mount Clamp Diode on Coil to Prevent Electrical Noise NOTE POLARITY al Terminals shown are for DOUT ch 0 1 Page 2 16 Section 2 Installation Triac Output Reversible Actuator Typical for QG and S
225. splayed if the Backup Memory is bad The Backup data will not be copied into the Primary memory Press ESC to return to the menu After completing the COPY BACKUP TO PRIMARY operation it is necessary to use the COPY PRIMARY TO BACKUP menu item to insure that the Backup Memory contains the Calibration data that is specific to this particular set of hardware After the new Blockware has been debugged and tested EXIT S M ERASE PRIMARY This menu item erases all of the Blockware It does this by setting every Block to a NOP Function The PCC III will not ERASE PRIMARY unless ALL of the 4 20 mA and Triac Output channels are in Service Manual mode see pg 4 9 WARNING The PCC IIl is commonly used to control potentially dangerous Combustion and Chemical Processes VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE ERASING THE PRIMARY MEMORY FAILURE TO DO SO CAN RESULT IN EQUIPMENT DAMAGE INJURY OR DEATH Scroll to ERASE PRIMARY Press ENTER Press ENTER to erase primary is displayed Press ENTER to proceed or ESC to return to the menu If ENTER was pressed busy will be displayed for several seconds followed by primary erased Press ESC to return to the menu The error message ERROR ALL OUTPUTS MUST BE IN S M will be displayed if this menu item is selected before putting all Outputs into S M mode Press ESC to return to the menu COMP
226. sume controlling in the same state following power up as it was prior to shutdown The Block Output values of the following Function Types are saved to and restored from Retentive Memory FPT H Front Panel Track and Hold F T Function of Time ramp generator FPCON Front Panel Constant COUNT Pulse Counter RDIN Remote Discrete Input PB Pushbutton and F F Flip Flop All other Function Type Outputs are re calculated every scan based on the current Inputs and are not restored at power up PCC III Instruction Manual rev 2 3 Page 5 6 Section 5 Configuring Blockware Note All Block Parameters and Input Softwiring data of all Function Types are always saved in EEPROM As extra insurance The PCC III also automatically updates Retentive memory whenever any Retentive Block Output value changes during normal operation not to exceed once every 10 minutes Each PCC III provides 56 bytes of Retentive memory which is sufficient most complex control strategies Section 6 details how many bytes each Retentive Function utilizes EDIT will not allow you to use more memory than is available and will display an error message EEPROM memory is conservatively limited to 95 000 individual byte updates before potentially losing data EEPROM s will retain data for approximately 100 years when powered down PCC IIl provides 6 Retentive memory areas with auto selection based on usage Therefore PCC III Retentive memory is limited to 570 000
227. t Windup Reverse action means that the PID Output decreases when the process variable Input increases above setpoint Direct action causes the Output to increase when the process variable increases above setpoint Derivative Action PV Parameter 10 0 avoids abrupt PID Output changes due to setpoint changes since the derivative only responds to changes of the PV Input Derivative Action Error Parameter 10 1 is generally only used in the inner loop of cascaded PID loops Gap PID provides an error zone on either side of the setpoint with reduced or zero gain This feature is useful with noisy signals such as boiler furnace pressure and with non linear processes such as pH control loops Gap Band Parameter 11 determines setpoint deviation band within which the reduced gain is applied The Gap Gain Multiplier Parameter 12 numerically multiplies the normal PID Gain Parameter 1 within the Gap Band Gap Gain can be set equal to 0 Outside the Gap band the normal PID Gain remains the same but the error is automatically biased down for a smooth transition see figure above Gap Parameters 11 and 12 are ignored for PID types 1 and 3 see Parameter 9 PCC III Instruction Manual ver 2 3 Page 6 27 Section 6 Blockware Functions Technical Reference F81 AOUT Analog 4 20 mA Output Function AOUT is the Blockware interface to the PCC Ill 4 20 mA output hardware AOUT converts a 0 100 Input into either a 4 20 mA output 0
228. t is Analog a 327 00 to 327 00 value D The Block Output is Discrete a Logical 0 or Logical 1 value T Parameter Default The value assigned to this Parameter when a Function is initially assigned to a Block Parameter Max The maximum value that the Parameter can be changed to Parameter Min The minimum value that the Parameter can be changed to Parameter Code The minimum password level required to change a Parameter if Passwords are enabled Default Block Inputs There are 160 Blocks in the PCC III numbered 0 to 159 Think of a Block as a receptacle or socket into which the user inserts a PCC III Blockware Function Any PCC III BlockWare Function can be inserted into any available Block Blocks 0 thru 3 are not avalibale to the user and are permanently assigned the following Functions Block Function Comment 0 AO Analog 0 Default Analog Input 1 A100 Analog 0 2 DO Discrete 0 Default Discrete Input 3 D1 Discrete 1 When a Function is initially assigned to a Block the Block Inputs are automatically connected to the Default Blocks as follows Block 0 AO or 0 is connected to all of the Analog Inputs in the Block if any Block 2 DO or Logic 0 is connected to all of the Discrete Inputs in the Block if any PCC III Instruction Manual ver 2 3 Page 6 3 Section 6 Blockware Functions Technical Reference FO A0 Analog Constant 0 00 Funct
229. t when PV SP see notes 8 and 9 Track Mode Multiple Track Mode Inputs are provided to allow Blockware based bumpless transfer during Manual to Auto and Process Startup to Auto mode changes see note 4 Track Mode causes the PID Output to be equal to the Track Signal Input by forcing the I Integral term of P D See FPT H F38 for a bumpless transfer Bockware example An Qverride Mode Input is provided to allow automatic Blockware based bumpless transfer in Constraint based control strategies see note 5 Override Mode forces the woe 1 H l term to be equal to the Track Signal Input Override GAP PID GAP 2 Gap Gain 33 Gain 3 Mode will not be enabled unless Repeats min is greater 10 than 0 An example of a Constraint based control logic is One of several boilers on a header is burning a process 8 off gas modulate the burner s firing rate based on Plant iu 6 Master firing rate unless the off gas supply pressure Z 4 drops then reduce firing rate to maintain a minimum off 2 92 gas supply pressure Q 0 5 2 Non linear systems such as pH and furnace draft can be E controlled more effectively by using the Gap PID or Do A Adaptive gain PID modes Parameter 9 Gap PID 6 provides a simple dual gain strategy ie lower gain near 8 setpoint higher gain farther away from setpoint Adaptive 10 gain PID allows the gain to be changed continuously as a 5 4 3 2 1 0 1 2 3 4 5 function of
230. ted on the pushbuttons are controlled separately by function LED Function PB does not control these LED s directly However in many applications a PB Block Output is used as the Input to the mating LED Block Parameter 1 selects the LED to be used see the figure in PB F98 for locations By default the LED is On when the Input 1 and the LED Block Output the Block Input Parameter 2 allows the LED and LED Block Outputs to be inverted FUNCTION 99 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME LED SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 D INPUT BLOCK 1 Parameter Description Default Max Min Code Notes 1 SELECT 1 THRU 6 1 6 1 2 2 2 INVERT INPUT 0 NO 1 YES 0 1 0 2 1 Notes 1 If Parm 2 INVERT INPUT 0 When Input 1 LED is On Output 1 If Parm 2 INVERT INPUT 1 When Input 1 LED is Off Output 0 2 LED 1 top left pushbutton LED 2 A M pushbutton LED 3 bottom left pushbutton LED 4 R L pushbutton LED 5 middle left LED LED 6 middle right LED F100 TTRIP TOUT Fault Status Function TTRIP indicates the current Fault status of a particular TOUT Block The TTRIP Block Output 1 if the monitored TOUT Block has detected a Fault and the Block Output 0 when no Faults are present The analog Input to the TTRIP Block is a dummy Input that is used to indicate which TOUT Output Block is to be monitored See F83 TOUT for details on the Fault Detection logic in t
231. the Blockware variables that the Operator can view the variables the Operator can modify and the alarms to be annunciated The PANEL Block Output is controlled by the Annunciator Logic see below x refers to the items called out on the front panel drawing PANEL controls the front panel Bargraphs 9 10 11 the 4 12 digit Numeric display 1 the 8 character alphanumeric Message display 2 the Alarm LED 5 and PANEL s Alarm Horn Block Output PANEL responds to the front panel pushbuttons ACK 3 ACKnowledge DIS 4 DISplay channel select ft U 6 and optionally the AUTO MAN key s 7 PANEL can be configured for one loop or multiple loops See Section 3 for details on how to operate the front panel display control pushbuttons and for further details on the annunciator The front panel Numeric and Message displays have three operating modes Edit Process and Annunciator Edit mode Edit mode has priority over Process and Annunciator modes and overrides the PANEL s control of the Numeric and Message displays Edit mode is active when the ESC EDIT LED 8 behind the lower front door is ON see Section 4 Edit Menus To exit Edit mode and return to Process mode press the ESC EDIT key 8 several times until the ESC EDIT LED 8 turns OFF Process mode Process mode allows the Operator to view any of the 10 configured display channels Each channel has an Input Inputs 1 10 to determine the Block Output that drive
232. the Output will remain at 20 even though a different display channel may be displayed If an alarm occurs you can press the ACK button to view the alarm message and to silence the alarm horn if supplied The Output will remain at 20 Press DIS to return to the display channels No matter which display channel is currently being displayed when the AUTO MAN button is pressed again the Output will return to that corresponding with the Automatic control mode ALARM Light Item 8 in fig 1 The Alarm Light operates as follows Alarm Status Light Blinking One or more alarm messages have NOT been displayed Press ACK to display the next alarm message ON All alarm messages have been displayed 1 or more alarm inputs are still in the alarm condition OFF All alarm messages have been displayed No alarm inputs are in the alarm condition The operation of the ALARM light can not be changed by the Blockware designer However alarm s can be disabled by Blockware Typically this is done to prevent nuisance alarms when a process is shutdown ACK Pushbutton and the Alarm Annunciator Item 6 in fig 1 The PCC III can monitor up to 10 different alarm conditions This pushbutton is used to ACKnowledge new alarms and typically to silence an optional panel mounted or remote alarm horn or bell When a new alarm condition occurs the ALARM light item 8 will start blinking Optionally the Blockware designer can cause the PV
233. the loop select Pushbutton This method is used when there is no Loop pushbutton If the LEVEL loop is currently being displayed pressing the PSI AUTO MAN pushbutton would change the displays from the LEVEL loop to the PSI loop but the PSI AUTO MAN status would not change After the PSI loop has been selected for display pressing the PSI loop AUTO MAN pushbutton would toggle the Auto Manual status as expected One of the two lights PSI or LEVEL items 20 and 21 would be ON to indicate which loop is being displayed When the PSI loop is currently being displayed pressing the LEVEL AUTO MAN pushbutton would change the displays from the PSI loop to the LEVEL loop but the LEVEL AUTO MAN status would not change After the LEVEL loop has been selected for display pressing the LEVEL loop AUTO MAN pushbutton would toggle the Auto Manual status as expected PCC III Instruction Manual rev 2 3 Page 3 8 Section 3 Operation Section 4 EDIT Menu Operations Table of Contents INMODUCHION sienien e 2 COPY PRIMARY TO BACKUP oaeee 16 EDIT KEYS riot raara aer neesan tE 3 COPY BACKUP TO PRIMARY ooeec 16 EDIT LIOR eee ie eeraa sea eE aiaei 3 ERASE PRIMARY cecceeeeeeceeeeeeeeeereeeeaeeeeeees 17 ESC EDIT Key icorisindo iirst 3 COMPARE MEMORIES 17 Edit Value and Scroll Menu Lights ceee 3 REMAINING MEMORY REPORT eiee 17 EDIT amp and EDIT W keYS o oo cccceeteeseneeteeeees 4 CONFIG NAME iiia an 17 EDIT A and EDIT
234. the number of milliseconds required to execute the Blocks The PCC Ill executes all of the Blocks in no less more than 10 times per second 100 ms The Block SCAN TIME is typically 10 50 ms and the PCC III fills the remaining time with a delay loop In the unlikely event that the SCAN TIME is greater than 100 ms the PCC III will always complete the execution of all blocks Scroll to DISPLAY SCAN TIME press ENTER The milliseconds will be displayed Press ESC to return to the menu EDIT QUICK MENU Q1 MSG This menu item provides the means to enter and edit the QUICK menu Q1 BLK messages Block number pointers and Parameter number pointers See Q1 PARAM page 4 7 for an explanation of how to use the QUICK menu Q2 MSG Scroll to EDIT QUICK MENU press ENTER The sub menu shown at the Q BLK right is activated This menu has 24 line items Qx MSG Qx BLK and Qx PARAM for each of the eight QUICK menu items j EDIT QUICK MENU Line Items Qx MSG is the 1 16 character message that will be displayed when the user scrolls to line x of the QUICK menu If the user presses ENTER in the QUICK menu the QUICK menu display will change to the EDIT A BLOCK menu and will be pre positioned at the Block number specified by Qx BLK at the Parameter number specified by Qx PARAM Refer to Section 6 Blockware Functions Technical Reference to find the Parameter numbers for each Functio
235. ticular Analog Output on the specified board FUNCTION 81 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 16 NAME AOUT SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A INPUT BLOCK Parameter Description Default Max Min Code Notes 1 OPTION BOARD 0 CPU BOARD 0 2 0 3 1 2 SELECT CH 1 OR CH 2 1 2 1 3 1 3 REVERSE OUTPUT 0 4 20 1 20 4 0 1 0 3 Notes 1 The quantity of Outputs available is dependent on the type of option board installed An error message is displayed during EXIT S M if sufficient Outputs are not available F83 TOUT Triac Output NOTE This description is for ROM ver 3 04 or higher See previous Manuals for earlier ROM versions Function TOUT is the Blockware interface to the PCC III Triac output option board hardware Triacs are solid state switches for use with 24 120 Vac 0 2 Amp inductive loads TOUT can be used in one of two modes Positioner mode OR Dual Triacs mode see Parameter 3 Dual Triacs Mode allows direct Blockware control of each of the individual Triacs Triac 1 is turned on when Triac 1 Input equals 1 Triac 2 is turned on when Triac 2 Input equals 1 In Dual Triacs Mode the Setpoint Input is ignored The Block Output is equal to the Scaled Position as described below in Positioner mode Positioner Mode is used to position a reversible electric actuator that is equipped with a position feedback signal potentiometer 0 5 Vdc or 4 20 mA TOUT compares the Setpoint Input to the Scale
236. ting a MS Word or MS Excel document and then printing the legend on an 8 x 11 piece clear plastic The legend is then cut down to the 2 1 H x 1 75 W pocket size Contact Preferred Instruments Service department for a free MS Excel file that is a pre formatted template for PCC III Legend Inserts PCC III Instruction Manual rev 2 3 Page 2 24 Section 2 Installation Section3 Operation Table of Contents Operator Controls and Front Panel Usage 2 ft and Rate of Change uo General vet dete nutes a tines nari ald 2 AUTO MAN Pushbutton and Light 05 Front Panel Displays and Pushbuttons 3 Auto Manual Example ccsccccsesceeeeesteeeeeeees PUNO M Es EAEE stent eceeetecass 3 ALARM Light c c5 00 ae eh aol deen aes SP Bargraphsi c cs etek teed ea vee 3 ACK Pushbutton and the Alarm Annunciator OUT Bargraphi siihen ei eea 4 User Defined Pushbuttons ec eeeeeeeeeeseeeeeeees Numeric Display ccscceseseeeeeeneeeeesneeeeeeneeeeeee 4 User Defined Lights cccccccscesseesseeeseeeseeees Message Display c eee eee rennet 4 Multiple Loops sssri ananena e ease DIS Pushbutton srei iniaiaiai 4 ft and Y Pushbuttons ecceccecscsceteeteesescetetenens 5 PCC III Instruction Manual rev 2 3 Page 3 1 Section 3 Operation Operator Controls and Front Panel Usage PREFERRED INSTRUN PCC DANSURY CT USA 22 Figure 1 Ge
237. tion 6 For Analog Block Outputs Use 40000 the PCC III Block Number Example Block 6 is an AIN Block Use address 40006 to read the AIN Block Output data For PLINK Parameters Use 41001 41030 Note that some Modbus 1 O driver software uses the 4000 series addresses when emulating smaller Modbus PLC s and 400000 when emulating larger Modbus PLC s Consult your I O driver documentation to determine if 4000 40000 or 400000 series addresses should be used A Poll group can be set up to query multiple coils or registers for a range of addresses that includes a mixture of Analog and Discrete Blocks The only condition is that the first address of the Group must be the correct Analog or Discrete data type The User should simply ignore the data from the addresses for invalid data types Example The User wants to use one Modbus Multiple Register Read instead of several Modbus Single Register Read s to minimize Modbus Communication traffic If B4 is AIN B5 is DIN B6 is AIN B7 is DIN If the User wants to read the first two analog points then read addresses 40004 40006 but ignore the data returned for 40005 If the User wants to read the first two discrete points then read addresses 40005 40007 but ignore the data returned for 40006 Data Formats Coils ie Discrete Output Blocks 0 0 1 1 40xxx Registers ie Analog Output Blocks PCC III 100 00 Modbus 10000 PCC III 0 00 Modbus 0 ina 16 bit signed integer format
238. to S M mode see pg 4 9 and comparing the measured mA output to the percentage displayed by the EXAMINE menu item Factory calibration data is corrupted While unlikely it is possible for an electrical surge to corrupt the Blockware or Calibration data If the Primary memory was copied to backup then the calibration data would AutoLoad from PCC III Instruction Manual rev 2 3 Page 4 21 Section 4 EDIT Menus the Backup memory see pg 4 15 However if the Backup memory was not a duplicate of the Primary then the calibration data may not pass the validation tests preformed at start up If neither the Priamary nor the Backup contains valid calibration data then the PCC III will use default calibration data and continue operating with the reduced accuracy as described above Analog Inputs Calibration Status Display The Analog to Digital A D ead calibration status of each Board is displayed during the Power Up Self Test messages as A D x yy x indicates the Board number CPU displays as a blank 1 Option Board 1 2 Option Board 2 yy will B either OK or SC SC stands for Self Calibration ie defaut calibration data WARNING The PCC III is commonly used to control potentially dangerous Combustion and Chemical Processes VERIFY THAT THE PROCESS BEING CONTROLLED HAS BEEN SAFELY SECURED ISOLATED OR BYPASSED AS REQUIRED BY THE SITE CONDITIONS BEFORE CALIBRATING THE PCC Ill FAILURE TO DO SO CAN RESULT IN EQUIPMENT D
239. to a control actuator or valve logic to send the Output to low fire via a discrete Input from the Flame Safeguard System FSG and Auto Manual control logic The customer has decided to add an Input from a Plant Master controller and add high and low boiler drum pressure alarms Drum PSI Transmitter Drum PSI Setpoint B150 Alarm Silence DIN Ch 1 Invert 40 FSG Modulate On Manual Auto Man AOUT Burner Common 4 20 Firing Alarm B120 Rate id Figure 5 2 Following the recommended approach Define the requirements We will need to add an input for the Plant Master Demand a Submaster bias station to load balance the boilers a pushbutton to switch between Plant Master or Local PID control an LED to show the user which of these modes the controller is in and high and low pressure alarms The front panel display must also be modified Check the I O count The controller has four extra inputs available If the user wants the Plant Master input to be electrically isolated an option card will be required Isolating the Plant Master is not required but it is a more robust system design that prevents a single wiring problem from affecting multiple boilers Break the configuration down into manageable sections This is a relatively small change We will add an alarm section a Submaster bias section and a control mode section PCC III Instruction Manual rev 2 3 Page 5 8 Section 5
240. to return to the PASSWORD menu CHANGE OPERATOR PASSWORD The Operator Password number can only be changed if the Password System is disabled or if the active Password Level is at Operator or higher Scroll to CHANGE OPERATOR PASSWORD press ENTER Use EDIT 4 or EDIT V to change the Numeric display to the new Operator Password Number Write down the number that is being displayed then press ENTER Password Changed will be displayed press ESC to clear the message and return to the PASSWORD menu CHANGE TECHNICIAN PASSWORD The Technician Password number can only be changed if the Password System is disabled or if the active Password Level is at Technician or higher Scroll to CHANGE TECHNICIAN PASSWORD press ENTER Use EDIT 4 or EDIT V_ to change the Numeric display to the new Operator Password Number Write down the number that is being displayed then press ENTER Password Changed will be displayed press ESC to clear the message and return to the PASSWORD menu Disabling the Password System Activate the Technician Password follow the ENTER PASSWORD procedure above Change the Technician Password to the number 0 follow the CHANGE TECHNICIAN PASSWORD procedure above Change the Operator Password to the number 0 follow the CHANGE OPERATOR PASSWORD procedure above PCC III Instruction Manual rev 2 3 Page 4 11 Section 4 EDIT Menus EDIT A BLOCK Menu ENTER THE BLOCK NUMBER Bxx FUNCTION TYPE This m
241. ug the field wiring connector and plug in a spare field wiring connector Wire all of the terminals of all of the channels together to the Voltage Source and to the Voltmeter see Section 2 for terminal numbers Wire all of the terminals of all of the channels together to the Voltage Source and to the Voltmeter Disconnect ie switch OFF or remove the jumper all 250 ohm resistors Scroll to BOARD 0 INPUTS Press ENTER APPLY 2 500 VOLTS SIGNAL TO CHANNELS 1 x THEN PRESS ENTER will be displayed The error message MUST BE IN S M TO CALIBRATE will be displayed if ALL of the Outputs are NOT in S M mode see pg 4 9 Set the Voltage Source to 2 5000 Vdc 0 0005 Vdc Press ENTER filter settling will be displayed for 10 sec to allow the hardware low pass filter capacitors to charge up busy will then be displayed for 15 sec while the 2 5 V calibration is attempted The error message CALIBRATION ABORTED CHANNEL x OUT OF RANGE yyyyyy will be displayed if the Voltage Source is not at the correct voltage a 250 ohm resistor is connected to the input the Voltage Source is noisy or the A D has out of tolerance parts yyyy indicates the magnitude of the error and is used by factory technicians for PCC III Instruction Manual rev 2 3 Page 4 22 Section 4 EDIT Menus diagnostics values can be 6000 and higher Press ESC to return to the menu the original calibration will still be in effect APPLY 5
242. uld cover a typical Blockware control logic case However your Blockware may be different Review the documentation provided with the Blockware for your specific controller to determine the purpose of each pushbutton PCC III Instruction Manual rev 2 3 Page 3 5 Section 3 Operation Assume that the controller has the AUTO MAN pushbutton configured to allow selection of either the automatic or manual mode Auto DIS is in use there is NO Blockware that overrides MAN mode the Output is currently in AUTO and the Output is initially set to 4 To put the controller Output into Manual and then set the Output ie the valve or damper or to 20 open Press the AUTO MAN pushbutton The AUTO MAN light will come ON indicating that the Output is in Manual mode The Display channel will automatically change to the Output channel VALVE or DAMPER or a similar message will be displayed on the Message display Press and hold the ft pushbutton The Numeric display will start ramping up from 4 Momentarily release and then press and hold the ff pushbutton when the Numeric display shows 12 or 13 This resets the ramp rate change logic and keeps the ramp rate at the slowest ramp rate When the Numeric display shows 20 release the ft pushbutton If desired you can now press the DIS pushbutton to scroll through ie change the display channels As long as the AUTO MAN pushbutton remains in Manual the light will be ON
243. ulse Mode timing diagram below Power Down The Block Output is saved in the Retentive Memory area of the EEPROM CPU start up If Pulse Mode Off The Block Output and the Comm Link value are set to the value in Retentive Memory during the first scan If Retentive Memory is invalid the Block Output initializes to the Default Output upon CPU start up If Pulse Mode On The Block output is set to 0 and Comm Link must write a 0 followed by a 1 to change the RDIN Output to a 1 FUNCTION 97 TEMP BYTES 4 RETENTIVE BYTES DATA BYTES 16 NAME RDIN SINGLE USE FUNCTION OUTPUT TYPE D No Inputs Parameter Description Default Max Min Code Notes 1 PULSE SECONDS 3600 CONTINUOUS 3600 3600 0 2 1 2 COMM FAIL DELAY SEC 5 3600 1 2 x 3 FAIL ACTION O LAST 1 DEFAULT 0 1 0 2 x 4 FAIL DEFAULT 0 1 0 2 x Notes 1 If Pulse Seconds less than 3600 Fail delay must be greater than Pulse seconds PCC III Instruction Manual ver 2 3 Page 6 41 Section 6 Blockware Functions Technical Reference F98 PB Pushbutton Function PB is the Blockware interface to the 4 user configurable pushbuttons on the front panel Each pushbutton has an LED indicator that is controlled separately by an LED F99 Block Parameter 1 selects the pushbutton see adjacent figure for locations The AUTO MAN and REM LOC pushbuttons are permanently labeled Pushbuttons 1 and 3 can be labeled by the user by sliding a clear plastic legend in behind the keyboa
244. umpers that slide onto header pins to connect the 250 ohm resistors to the Inputs The A B and F Option Boards have DIP switches See the drawings on pages 2 6 through 2 9 for the locations of the 250 ohm resistor switches and jumpers The Q Option Board is used primarily to drive electric actuators with position feedback potentiometers The G Option Board does not have internal 250 ohm resistors for the two Analog input channels on this board Externally mounted 250 ohm resistors are required if these Analog Inputs are connected to 4 20 mA signals Precision 250 0 ohm resistors are available separately as part number 25250 0B25 3 4 PCC III Instruction Manual rev 2 3 Page 2 5 Section 2 Installation Vj J2 RI OR2 PREF INSTR DANBURY CT 06810 J 40 0 c22 c17 c23 Ecis Sci9 c24 C25 Uc2 Uc21 C26 gt alo RNB 3 R42 0 ij 33a h o RN9 z s 44 D fe I S451 0 g RNS z Q 46 h O T a wz 2 47 0 N Clio ES o Ci3os gaap U7 48h O Qu2 u4 U3 p e R3 R5 Rel lE o J lleg A Got ll 5l k 50 0 Swi Sw2 gt z Ts 7 a neo RN6 RN3 RN2RN7 C1 z i R D a al a ee jTSO00000000000 k Ol I mooo0000000000 U5 Kpr4 ict eee NG U6 2 us c9 250 1234 5 pi R Z Js 38 c12 5 AIN ch 5 ch 5 To Connect 250 ohm Resistor AIN ch 1 Turn Switch ON A Option Board 250 ohm Switche
245. unction Scroll Menu light will blink Edit Value light turns off NOTE When EDIT A BLOCK changes the Function Type of a Block it automatically does the following Softwires Block 0 Function AO the 0 constant to all Analog Inputs Softwires Block 2 Function DO the Discrete 0 constant to all Discrete Inputs Sets each Parameter to it s Default value as defined in Section 6 PCC III Instruction Manual rev 2 3 Page 4 13 Section 4 EDIT Menus Softwire the HIALM Block PV Input The PV Input Input channel 1 see Section 6 will be Softwired ie configured to monitor the Block Ouput signal of the AIN Function in Block 20 in this example Continuing from the previous example B22 HIALM is displayed S M mode is active and Technician Password Level is active Scroll Menu light should be blinking If Edit Value light is blinking Press ESC Scroll Menu light will then blink Press EDIT Y to scroll to B22 101 PV INPUT B22 means Block 22 I01 means Input Channel 1 and PV INPUT describes the purpose of this Input Channel The Numeric display will indicate the Block number that is currently Softwired to this Input Channel Press ENTER to change from Scroll Menu to Edit Value mode Scroll Menu light turns off Edit Value light will blink 2 Use EDIT 4 or EDIT V to set the Numeric display to 20 20 means that Input Channel 1 is going to be Softwired to the
246. unt ce eeeceeeeeeeseeeeeeneeeeeenes 8 Break the configuration down into manageable SOCU OMS e scssds coess sides ceansvssctceaceeisscasedva E 8 Sketch each Section 0 0 eesceseeeeseceeeeececeeeeeees 9 Change the Function Type of a Block 10 Softwire the Block Inputs ee 10 Configure the front panel displays and alarms 12 Test the configuration cece eee eseeeees 13 Place the controller into operation 13 Add Pressure Compensated Steam Flow Blockware E EE E E S ins evita E 13 Add Purge and Light off Positioning Blockware 15 Add Day Night Pressure Setpoint Blockware 16 Revised Overall Boiler Master Blockware 16 Section 6 Blockware Functions Technical Reference Table of Contents Listed in Function Name Order 2 FO F1 F2 F5 F11 F20 F22 F31 F32 F33 F34 F35 F36 F38 F41 F42 F43 F45 F51 F52 F53 F54 F55 F56 F58 F59 F60 F71 F81 F83 F84 A0 Analog Constant 0 00 4 A100 Analog Constant 100 00 4 AIN Analog Input 4 RAIN RS485 Remote Analog Input 5 DUAL Dual Range Flow Transmitter Selector Scaler 6 OPLR Optical Path Length Ratio Correlation for Opacity Monitors 7 BEFF Boiler Efficiency 7 HSEL High Select 9 LSEL Low Select 9 MSEL Median Selector 9 ASW Analog Switch 10 H LLIM High Low Signal Limiter 10 RLIM Rate Limiter 11 FPT H Front Panel Adjustable Track Hold 11 F T
247. updates If updated continuously at once per 10 minutes the Primary EEPROM will have to be replaced after 10 8 years If Retentive Memory is only saving infrequently updated Blockware the Retentive memory will probably never have to be replaced The EDIT MEMORY REMAINING MEMORY REPORT menu ROM 2 23 or 3 01 or higher can be used to view the REMAINING MEMORY WRITES At power up PCC III will not leave Service Manual mode if the REMAINING MEMORY WRITES equals zero and an error message will be displayed Configuring Blockware Control Logic In many applications the PCC III Blockware is pre configured at the factory In some cases it is desirable to modify that configuration in the field In other cases the customer may want to add features due to process changes Yet in other cases the customer may have a preference for configuring their own system The PCC III allows for easy modification or complete development of a configuration in the field The PCC III can be completely configured using the front panel EDIT keys along with the digital and alphanumeric displays The configuration is handled via easy to follow menus that are controlled by four keys on the flip down door on front panel A Password system can be enabled to prevent unauthorized use The configuration keys allow modification of All PCC Ill data in the field without the use of any other devices such as special hand held configurators or laptop computers Note The CPU board in
248. ures a bumpless balanceless transfer from Ch0 1 light off to modulate Release Purge to vs The second FPT H Block 10 is used to implement a Modulate Low Fire remote setpoint with local manual override strategy In 2a 100 Remote mode the PID setpoint will be the Remote setpoint When the Operator presses the pushbutton to put the controller in Local setpoint mode the setpoint will DN initially be held at the most recent remote setpoint and the cho2 fo Operator can then adjust it to any desired value The Transfer Rate Limiting would be used to prevent a rapid Purge setpoint change when transferring from Local Setpoint 2 mode back to Remote Setpoint mode FUNCTION 38 TEMP BYTES 0 RETENTIVE BYTES 4 DATA BYTES 32 PCC Ill Instruction Manual ver 2 3 Page 6 12 Section 6 Blockware Functions Technical Reference NAME FPT H SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A SIGNAL INPUT 2 D HOLD SELECT INPUT 1 HOLD 1 3 D TRACK OVERRIDE INPUT 1 TRACK 1 4 D TRACK OVERRIDE INPUT 1 TRACK 1 Parameter Description Default Max Min Code Notes 1 MIN OUTPUT 0 00 199 99 199 99 2 2 2 MAX OUTPUT 100 00 199 99 199 99 2 2 3 SEC TRANSFER LIMIT 100 0FF 100 00 100 00 0 10 2 Notes 1 See Track Hold truth table above 2 Max Output MUST be larger than Min Output limit F41 F T Function of Time Generator Function F T generates a Block Output based on a user generated output vs time
249. ut 0 1 2 3 or 4 See F83 TOUT for details on the Fault Detection logic and descriptions of the Codes in the TOUT block that drives the TCODE Block output The analog Input to the TCODE Block is a dummy Input that is used to indicate which TOUT Output Block is to be monitored TCODE outputs the last Fault Code that occurred and the Code will not change until a different Fault occurs The Code resets to 0 when PCC III powers down FUNCTION 84 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 4 NAME TCODE SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A TOUT BLOCK TO BE MONITORED 1 No Parameters Notes 1 The BLOCK TO BE MONITORED must be a TOUT Block F90 D0 Discrete 0 Constant Function DO provides a constant Output of a discrete 0 ie logic Low PCC III automatically configures Block 2 to be function DO Block 2 discrete 0 is the default Input for all discrete Inputs for all functions Block 2 cannot be changed to any other function However other Blocks may be configured as DO No Inputs or parameters are required for DO FUNCTION 90 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 0 NAME DO SINGLE USE FUNCTION N OUTPUT TYPE D No Inputs and No Parameters F91 D1 Discrete 1 Constant Function D1 provides a constant Output of a discrete 1 ie logic High PCC III automatically configures Block 3 to be function D1 Block 3 discrete 1 is useful as a dummy Input to many other fu
250. valent to 10 lbs of steam PCC III Instruction Manual ver 2 3 Page 6 50 Section 6 Blockware Functions Technical Reference Input Cutoff Parameter 1 The calibration of some flowmeters tend to drift near 4 mA 0 This can cause false flow totalization when there is actually no flow Inputs less than Parameter 1 are ignored and no pulse Outputs are generated Negative Inputs do not generate a pulse Output Disable Input Parameter 3 and Input 2 By default TOT is Enabled and totalizes because the defaults are Input 2 is Block 2 DO or Low and Alarm Disable is ACTIVE HI Parameter 3 1 However Blockware can use the Disable Input Input 2 to selectively Disable totalization that is force the TOT Block Output to be a 0 Parameter 3 determines if the Disable signal is Active HI or Active LO as follows Disable Input 1 ActiveHl 0 Enabled 1 Active HI 1 Disabled 0 ActiveLO 0 Disabled 0 Active LO Enabled FUNCTION 116 TEMP BYTES 4 RETENTIVE BYTES 0 DATA BYTES 24 NAME TOT SINGLE USE FUNCTION N OUTPUT TYPE D Input Type Description Notes 1 A INPUT BLOCK 2 D DISABLE BLOCK Parameter Description Default Max Min Code Notes 1 INPUT CUTOFF 0 00 100 00 0 00 2 2 100 INPUT COUNTS HOUR 1000 18000 60 2 3 DISABLE INPUT ACTIVE LO HI O LO 1 HI 1 1 0 2 F117 DSW Discrete Switch Function DSW is used to switch the Block Output between one of A two discrete Input signals under contro
251. ve for REST and HOLD Input operation 2 Times must be entered in ascending order Starting from TO and scanning toward T10 all breakpoints after the first Ti 0 0 will be ignored PCC III Instruction Manual ver 2 3 Page 6 14 Section 6 Blockware Functions Technical Reference F42 F X Function of X Generator with Learn Mode Function F X generates a Block Output based on a user generated Output vs Input profile ie y f x The parameters provide 11 X Y breakpoint pairs Between adjacent breakpoints F X draws a straight line from breakpoint to breakpoint see the figure below F x 10 Breakpoints Entered First Last Linear 120 100 80 60 40 Output Y 20 0 20 20 0 20 40 Input X 60 80 100 120 Less than 11 breakpoints All eleven breakpoints do not have to be used Starting from X1 F X ignores all breakpoints after the first Xj 150 00 is encountered Example Y1 10 X1 0 00 Y2 22 X2 20 00 Y3 29 X3 30 0 Y4 0 X4 150 00 Breakpoints 4 through 11 inclusive would be ignored in this example The X coordinates can be any value however the X values must be entered in ascending order ie X1 lt X2 lt X3 lt X4 First Last Seqments For X Inputs below the first or above the last defined breakpoints the Block Output can be held at the last valid Y value Hold mode or the Block Output can vary according to the last valid line segment equatio
252. vents Integral Term Reset Windup The Adaptive gain Input is ignored for PID types 1 and 2 see Parameter 10 Negative Input values are set equal to 0 00 Inputs greater than 327 00 are set equal to 327 00 The PID Gain Parameter 1 is multiplied by the Adaptive Gain Input divided by 100 00 Example Gain 15 0 and the Adaptive Gain Input 25 00 the effective PID gain would be 3 75 The three Track Mode Inputs are logically OR d together If any one of the three Inputs equals 1 AND Repeats Min gt 0 Then the Block Output is forced to equal the Track Signal Input This is accomplished by forcing the PID Integral term to counteract the Proportional Derivative and Feed Forward terms If all three Track Mode Inputs equal 0 the normal PID calculation determines the Output When the Override Input 1 AND the PID is NOT in Track Mode AND Repeats Min gt 0 the PID Integral term is set equal to the Track Signal Input This feature is used to provide bumpless transfer when Override i e Constraint control strategies are utilized See Example in the Configuration section Track mode has priority over Override mode The Setpoint Filter is used to prevent abrupt PID Output changes due to setpoint changes When the filter 1 000 the filter time constant in seconds is 60 Integral Repeats Min Parameter 2 determines the Repeats Min The filtering effect is proportionately less as the Setpoint Filter parameter is
253. with your specific controller s Blockware to determine the requirements specific to your application Two different loop select methods are described below Only one of the two methods will be used LOOP Pushbutton Loop Select Method As shown in figure 1 one PCC IIl can simultaneously control Boiler Firing rate based on Drum pressure the first loop and the Feedwater Control Valve based on Drum Level and Steam Flow the second loop However the Front Panel displays will display only one of the two loops at a time The Operator will Select which loop is to be displayed by pressing the LOOP pushbutton In this example the PSI and LEVEL lights indicate which loop LEVEL or PSI is currently being displayed on the bargraphs and which loop Auto DIS is using to select a display channel see pg 3 5 for Auto DIS Pressing the LOOP pushbutton causes the selected loop to toggle back and forth LEVEL to PSI PSI to LEVEL LEVEL to PSl Once a loop is selected Auto DIS works as described above for the currently selected loop If PSI is the selected loop Auto DIS would display PSI when the PSI AUTO MAN button is put into AUTO and FIRING RATE when put into MAN If LEVEL was the currently selected loop Auto DIS displays DRUM LEVEL in AUTO and FEEDWATER VALVE in MAN AUTO MAN Pushbuttons Loop Select Method An Alternative method for selecting the currently displayed loop is to use one of the two AUTO MAN pushbuttons for each loop as the as
254. y during the measurement Then use a SCALE Block to convert Optical Density to Particulates X1 Y1 0 0 X2 Ox 100 Y2 measured Particualtes in FUNCTION 20 TEMP BYTES 0 RETENTIVE BYTES 0 DATA BYTES 12 NAME OPLR SINGLE USE FUNCTION N OUTPUT TYPE A Input Type Description Notes 1 A T 2 INPUT Parameter Description Default Max Min Code Notes 1 MODE 1 OPACITY 0O OPTICAL DENSITY 1 1 0 3 2 OPLR 0 500 3 000 0 200 4 F22 BEFF Boiler Efficiency Function BEFF calculates Boiler or Process Heater Efficiency based upon the ASME Efficiency Test using the Losses Method For fuels with a known chemical composition Natural Gas Oils this method is a more reliable means of calculating efficiency than Input Output based calculations This method also applies to solid fuels wood coal however more frequent fuel analysis and resultant parameter corrections are required to account for moisture and chemical changes BEFF and ASME takes into account boiler casing radiation losses and miscellaneous fixed percentage losses blowdown unburned fuel Most portable combustion analyzers do not account for these losses and will typically indicate combustion efficiency not boiler efficiency Therefore most portable combustion analyzers will indicate a higher efficiency than the BEFF and ASME method PCC III Instruction Manual ver 2 3 Page 6 7 Section 6 Blockware Functions Technical Reference Default Fuels The Fuel
255. y stores the displayed number in the RAM and in the Primary Blockware EEPROM memories PCC III Instruction Manual rev 2 3 Page 4 4 Section 4 EDIT Menus EDIT Menu Scrolling Example Starting from Process display mode activate the EDIT menus and change the AIN digital filter in Block 12 ENTER the value and then exit the EDIT menus to re activate the Process display channels Asume Passwords are disabled Key Message Display Scroll Numeric Edit Comment Press after pressing key Menu Display Value Light Light DRUM PSI 149 EDIT QUICK MENU EDIT light turns ON EDIT v EXIT S M EDIT v PASSWORD EDIT v EDIT A BLOCK ENTER ENTER THE 4 Blink Leave MAIN menu BLOCK NUMBER Enter EDIT A BLOCK menu EDIT A ENTER THE 12 Blink Press and hold release when BLOCK NUMBER display shows 12 ENTER B12 AIN Blink 2 2 means Function Code Number 2 which is an AIN Function EDIT v B12 P01 OPTION Blink 0 B12 P01 means Block number 12 BOARD Parameter number 01 followed by a description EDIT v B12 P02 INPUT Blink 2 CHANNEL EDIT v Blink Scroll down through Parameters 03 thru 05 EDIT v B12 P06 FILTER Blink 1 0 SECONDS ENTER B12 P06 FILTER 1 0 Blink ENTER activates Edit Value SECONDS EDIT v B12 P06 FILTER 0 9 Blink Change Value SECONDS EDIT v B12 P06 FILTER 0 8 Blink SECONDS ENTER B12 P06 FILTER Blink 0 8 Save new value in RAM and Primary SECONDS EEPROM ESC
256. ygen burner trip Typical actuator faults include blown actuator power fuses open field wiring burned out motor windings dirty feedback pots that cause the wiper to go open circuit and worn feedback pot resistance elements that break and go open circuit The internal TOUT Fault Detection logic monitors the actuator A Fault is indicated by a TTRIP Block 0 Normal 1 Fault and the type of Fault is indicated by a TCODE 0 4 analog Block output as shown below The Inputs of the TTRIP and TCODE Blocks must be wired to the TOUT Block Output see figure above Conditions that cause TTRIP to change to a 1 Fault and the resulting TCODE Output Potential Reason with Potential Reason with TCODE Condition Fail Closed Wiring Fail Open Wiring 5 V wired to Pot Increase 5 V wired to Pot Decrease 0 PCC III Reset or Power up No Code in Memory 1 Scaled Position Pot wiper wiring is open circuit Pot 5V wiring is open circuit greater than 105 Pot wiring is open circuit Pot element is open circuit for more than P9 seconds Pot element is open circuit 2 Scaled Position Pot 5V wiring is open circuit Pot wiper wiring is open circuit less than 5 Pot element is open circuit Pot wiring is open circuit for more than P9 seconds Pot element is open circuit 3 _ Actuator stopped moving Stalled torque overload jammed Same as Fail Closed for more than P9 seconds

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