Spirax Sarco PLC Installation, Operation And Maintenance Manual
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Spirax Sarco PLC Installation, Operation And Maintenance Manual

Spirax Sarco PLC Installation, Operation And Maintenance Manual

Unit control for csm-k clean steam generators
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3.635.5275.253
Ed. 1 IT - 2010
PLC Unit Control
for CSM-K Clean Steam Generators
Installation, Operation and Maintenance Manual
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.
The ATEX Directive 94/9/EC is repealed and replaced by the new
ATEX Directive 2014/34/EU with effect from 20 April 2016.
© Copyright 2010
E X P E R T I S E
S O L U T I O N S
S U S T A I N A B I L I T Y

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Summary of Contents for Spirax Sarco PLC

  • Page 1 3.635.5275.253 Ed. 1 IT - 2010 PLC Unit Control for CSM-K Clean Steam Generators Installation, Operation and Maintenance Manual The PED Directive 97/23/EC is repealed and replaced by the new PED Directive 2014/68/EU with effect from 19 July 2016. The ATEX Directive 94/9/EC is repealed and replaced by the new ATEX Directive 2014/34/EU with effect from 20 April 2016.
  • Page 2 3.635.5275.253...
  • Page 3 ATTENZIONE Lavorare in sicurezza con apparecchiature in ghisa e vapore Working safely with cast iron products on steam Informazioni di sicurezza supplementari - Additional Informations for safety Lavorare in sicurezza con prodotti Working safely with cast iron in ghisa per linee vapore products on steam I prodotti di ghisa sono comunemente presenti Cast iron products are commonly found on steam...
  • Page 4 Prevenzione dai colpi d’ariete - Prevention of water hammer Scarico condensa nelle linee vapore - Steam trapping on steam mains: Intervalli di 30÷50 m. intervals Vapore Steam Gruppo di scarico Vapore Gruppo di scarico Trap set Steam Trap set Gruppo di scarico Trap set Condensa - Condasate Condensa - Condasate...
  • Page 5 Prevenzione delle sollecitazioni di trazione Prevention of tensile stressing Evitare il disallineamento delle tubazioni - Pipe misalignment: Installazione dei prodotti o loro rimontaggio post-manutenzione: Installing products or re-assembling after maintenance: Evitare l’eccessivo serraggio. Per garantire l’uniformità del carico e dell'allineamento, Utilizzare le coppie di serraggio i bulloni delle flange devono essere serrati in modo raccomandate.
  • Page 6 Dilatazioni termiche - Thermal expansion: Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione. Examples showing the use of expansion bellows. It is highly recommended that expert advise is sought from the bellows manufacturer.

  • Page 7: Table Of Contents

    Table of Contents Limits of Responsability Pag. 4 Control Unit Pag. 6 Location and identification of components Pag. 7 Control Features Pag. 8 External Connections Pag. 9 Display and Keyboard Pag. 10 Initial Screen Pag. 11 Manual Mode Pag. 13 Manual set-up of feed water Pag.

  • Page 8: Limits Of Responsability

    Limits of Responsability This manual covers the procedures for the Installation, Operation and Maintenance of the PLC unit for the control of indirect Steam Generator Systems. This manual is intended to be as complete and up to date as possible. SPIRAX SARCO reserves the right to update it at any time and without obligation to notify product owners of such changes.
  • Page 9 All procedures for the connections of main power supplies have to be performed by trained and qualified electrical personnel. The PLC unit for the control of SPIRAX SARCO Steam Generators are designed to be installed in covered locations, unless otherwise specified by the customer.

  • Page 10: Control Unit

    Control Unit Description The control and safety unit is a PLC type intelligent equipment designed to start-up, control and operate indirect steam generation systems, either in local mode or by ultimate means of a remote system. 3.635.5275.253...

  • Page 11: Location And Identification Of Components

    PRB: Pushbutton Manual reset pushbutton (after shutdown) L2: Led Indicator When lit (blinking red light) it indicates that the system is stopped due to intervention of one or more alarms. Measurement Unit of Total Dissolved Solids (TDS). PLC Control Unit 3.635.5275.253...

  • Page 12: Control Features

    Control Features The PLC based unit is designed to provide control of Pressure, Water Level, Discharge and operation of Blow-down function and of all Alarm limits of SPIRAX SARCO indirect steam generators. The control unit is equipped with a video interface displaying screens with graphics of the generator and also selective parts, e.g.

  • Page 13: External Connections

    External Connections All electrical connections have to be carried out by trained and qualified installation electricians. It is impor- tant to verify that the main power switch is in “OFF” position before connecting the line voltage. The installer has to route the power cables, reach the terminals located on the main power switch mounted on the panel and run the ground wire to the earth ground terminal.

  • Page 14: Display And Keyboard

    Display and Keyboard Nine keys are located on the lower part of the panel just below the display. Alarm Led Run Led Graphic Display START RESET STOP Screen 2 3.635.5275.253...

  • Page 15: Initial Screen

    Initial Screen Powering the unit the display will show this screen: Screen 3 Pressing the key Screen 4 will be displayed. Screen 4 Note: in this image is shown the firmware installed 3.635.5275.253...
  • Page 16 Pressing again the key the Screen 4 will be displayed where in sequence it is possible to select one out of four operation modes (Manual – Automatic – Historical alarms – Parameters). Press the and ^ keys to move down and up for selection of the desired operation mode. Press then the OK key to confirm and store the choice and enter the selected mode.

  • Page 17: Manual Mode

    "Manual" Mode Manual operation mode: general considerations Upon selection of the manual operation mode and by pressing ^ and keys, it is possible to scroll and access into subsequent pages in order to insert other functions, simultaneously maintaining in operating condition the previously selected functions.

  • Page 18: Manual Set-Up Of Feed Water

    Manual set-up of feed water The level transmitter fitted into the equipment has an employment field defined with the specification of each steam generator. It is essential that the employment field of the transmitter is the same of the one setted to the controller. There are different control typologies: 1) ON-OFF operation level (Sensilevel) and ON-OFF feedwater valve Select the next screen by setting the “automatic-manual”...
  • Page 19 2) ON-OFF operation level (Sensilevel) and water pump Select the next screen by setting the “automatic-manual” key in “manual” position: Screen 8 Press the + (ON) key to activate the pump and the – (OFF) key to stop it. During the manual operation the functioning level is displayed when achieved, but it doesn’t control the stop of the pump.
  • Page 20 5) Continuous operating level (4-20 Ma) and modulating water control valve Select the next screen by setting the “automatic-manual” key in “manual” position: Screen 9 To activate the valve opening push the button + (ON), and press – (OFF) to shutoff it. Repeatedly pushing the + button it is possible to choke the valve opening (in %) to obtain the continuative level control also in manual mode.

  • Page 21: Manual Control Of The Pressure

    Manual control of the Pressure The supplied pressure transmitter has a working range defined by the specifications of each generator. Normal ranges are 0 - 3, or 0 – 10 bar. It is important that the working range of the transmitter matches that programmed in the control unit.
  • Page 22 Select Screen 10 with ^ and keys. Press (+) (-) keys to increase or decrease the pressure of the generated steam. The display will indicate the opening value of the valve in % and the steam pressure value in bar. When the required value of the position exceeds the limit of “0”, the on-off solenoid valve of the primary steam will be open.

  • Page 23: Manual Control Of The Bottom Blowdown Valve

    Manual control of the Bottom Blowdown Valve For manual control of the bottom blowdown valve proceed with the following steps: Turn the “cycle” selector into position (manual control) and select Screen 14 (bottom blowdown control). If the selector is turned in position (Automatic control) an alarm status is obtained as displayed on Screen 15. In these situations switch the selector in position to reach the condition displayed on Screen 7.
  • Page 24 After a command to open or close the valve, the achievement of the travel limit is verified. If after few seconds the intervention of the travel limit does not occur (the valve has not reached the open or closed position after the correspondent command) the general alarm is generated (Screen 16) and its associated lamp will light up.
  • Page 25 (BC3150) installed inside the cabinet. In this case the value of the water conductivity is indicated on the PLC display. Two modes are provided: NORMAL mode during normal operation and ALARM mode when a condition of maximum TDS is verified (Screen 17).

  • Page 26: Automatic Mode

    "Automatic" Mode After a Start-up or after a Manual Mode press the key and access Screen 18 where in sequence one out of four operation modes can be selected. Press the and ^ keys to move down or up and select the Automatic Mode. Press then the OK key to confirm and store the choice and enter the selected mode.
  • Page 27 Pressing now the key Screens 19,20,21 and 22 are accessed in sequence. Pressing instead the ^ key the reverse selection is obtained. These four screens are used for local programming of set point values. Screen 19 Screen 20 Screen 21 Screen 22 3.635.5275.253...

  • Page 28: Pressure Control

    Pressure Control Setting of the desired value (Set-Point) The supplied pressure transmitter has a working range defined by the specifications of each generator. Normal ranges are 0 - 3, or 0 – 10 bar. It is important that the working range of the transmitter matches that programmed in the control unit.

  • Page 29: Level Setup

    Level Setup Push key to enter the screen shown in screen 20 Definition of the required value (set point). Depending on the actual level, there are different control typologies: 1) ON-OFF level with ON-OFF Control valve No level to be set. 2) ON-OFF level with ON-OFF Control pump No level to be set.

  • Page 30: Set-Up Of The Bottom Blowdown Period

    Set-up of the bottom blowdown period In “automatic” mode, press the key to enter the screen shown on Screen 22. Press key to set the interval duration (seconds) until the screen displays the blowdown time required value. The interval is selectable from 3 to 60 seconds with one-second increments. Press ^ and keys to enter the required value.
  • Page 31 Screen 23B Screen 23C 3.635.5275.253...

  • Page 32: General Considerations In Automatic Operation

    General considerations in Automatic Operation During automatic operation if the STOP key is pressed the cycle is interrupted. All active outputs are cleared and RUN Led is switched off. Set point values are however stored in memory. With the STOP action Screen 24 will be displayed to allow the selection of different operation modes.

  • Page 33: Alarms And Blocks

    Alarms and Blocks As described in the manual operation mode all the block alarms are active during the automatic cycle. In detail they are: - Block of the feed water control when one of the following alarms occurs: • stoppage of water pump •...

  • Page 34: Configuration

    Configuration 1. Parameters non protected by a password Actions of the pressure controller To set the controller actions proceed as follows: Step 1 – Access Screen 5 (operation mode selection). Press the e ^ keys to select the item “PARAMETERS”. Pressing then the OK key Screen 26 will be displayed: Screen 26 Enter the desired value of the proportional band (gain) constant (0 to100%) using the...
  • Page 35 Screen 27 Enter the desired value of the integral action constant (0 to 10) using the - and + keys. Note: the entered value will be stored until a successive modification. For values set near to “0” or to “10” this action will be fast or slow respectively. Step 3 –...
  • Page 36 Step 4 – Press the key to access next Screen 29. Screen 29 Enter the desired value of the proportional band (gain) constant (0 to100%) using the - and + keys. Note: the entered value will be stored until a successive modification. Action of the level controller (except ON-OFF control).
  • Page 37 Step 2 - Push the button to shift to the next screen. Screen 31 Push the - and + to set the low level alert (pre-alarm) value. The definition value is absolute (zero and full scale value of the level transmitter). When this alarm occurs, the cycle doesn’t stop.

  • Page 38: Parameters Protected By A Password

    2. Parameters protected by a password Once the setting of the parameters not protected by a password is terminated, press the key to access next Screen 32. Screen 32 To enter the three digit password proceed as follows: - press the ^ key (the value 3 is entered in the first digit) Note: if the cycle is in run, it is stopped.
  • Page 39 To enter the pressure/level value: Press the OK key twice. The digit of the full scale value in decimal will blink. Press the ^ o keys to enter the desired value. Press then the key and move the cursor on the digit with the value in units. The value in units of the full scale will blink.
  • Page 40 To enter the level value: Screen 35 This screen is to enter the level control zero and full scale values. Repeat the same procedure used to enter the pressure value. Note: in case of continuous level measurement (4-20 mA) with water control ON-OFF the screen will display the level of delta (related to the START-STOP control set of the water).
  • Page 41 1) TDS with BC3150 Screen 37 In BC3150 (internal frame) are entered the values of zero and full scale relevant to the reading of water conductivity. Enter the conductivity values using the same method used for pressure and level setting. 3.635.5275.253...
  • Page 42 2) Modbus protocol It is activated by pressing the key. Screen 38A Screen 38B Any parameters screen is displayed it is possible to revert to the screen shown in Screen 22 by pushing ESC key. 3.635.5275.253...
  • Page 43 REPAIRS Should it be necessary to return the equipment for repairs please contact our nearest Branch Office or Agent or directly: Spirax Sarco S.r.l., Via per Cinisello, 18, 20054 Nova Milanese (MI) Tel.: 0362 49 17.1 Fax: 0362 49 17 307 Loss of Guarantee Total or partial disregard of above instructions involves loss of any right of guarantee.
  • Page 44 Spirax Sarco S.r.l. - Via per Cinisello, 18 - 20054 Nova Milanese (MI) - Tel.: 0362 49 17.1 - Fax: 0362 49 17 307 3.635.5275.253 Ed. 1 - 2010.03...

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