Preferred Instruments PCC-IV Instruction Manual
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Preferred Instruments PCC-IV Instruction Manual

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PCC-IV Controller
Instruction Manual
Revision 0.2
Preferred Instruments
A Division of Preferred Utilities Mfg. Corp.
31-35 South St., Danbury, CT 06810
Ph: 203-743-6741 Fax: 203-798-7313
preferred-mfg.com

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Summary of Contents for Preferred Instruments PCC-IV

  • Page 1 PCC-IV Controller Instruction Manual Revision 0.2 Preferred Instruments A Division of Preferred Utilities Mfg. Corp. 31-35 South St., Danbury, CT 06810 Ph: 203-743-6741 Fax: 203-798-7313 preferred-mfg.com...
  • Page 2 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-IV 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-IV MEMORY.
  • Page 3 PCC-IV Instruction Manual (rev. 0.2) Page...
  • Page 4 PCC-IV Instruction Manual (rev. 0.2) Page...
  • Page 5 PCC-IV Instruction Manual (rev. 0.2) Page...
  • Page 6 PCC-IV Instruction Manual (rev. 0.2) Page...
  • Page 7 Minor grammar/format changes throughout • Corrected error in description of alarm annunciator screen Revision 0.2 – 01/22/2018 • Updated Section 5 to latest PC4_Draw • Stated that 24 Vdc power supply wiring should be shielded twisted pair. PCC-IV Instruction Manual (rev. 0.2) Page...
  • Page 8 24VDC power but still has the same PCC-III 120Vac I/O. So, as you read this manual, be sure that you are clear about the vast capabilities of the PCC-IV. It is simply not just another digital controller.

  • Page 9: Table Of Contents

    Input/output (Standard – no option cards): ..9 Triac Output for Electric Actuators (option cards) 5 Service Manual and Block Forcing ...... 5 Communications ..........9 Steam Flow Pressure Compensation ....5 PCC-IV Instruction Manual (rev. 0.1) Page 1-1 Section 1 - Product Overview...

  • Page 10: Product Description

    This section overviews the many PCC-IV features which address the requirements of both data acquisition and control applications. The PCC-IV 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.

  • Page 11: Distributed Control System Concepts

    I/O module (DCS-IV) for a data acquisition system, as a multi-loop controller, or as a traditional single loop controller. In all cases the PCC-IV will communicate on a network with a central operator’s station using the industry standard Modbus protocol.

  • Page 12: Blockware Concepts

    Library of Functions The PCC-IV 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, and other types of special PID Functions.

  • Page 13: Special Option Card And Special Function Block Capabilities

    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-IV has the capacity to use as many F(x) functions as are required by the application.

  • Page 14: Drum Level Pressure Vs. Density Compensation

    Relay Output Channels The PCC-IV 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”...

  • Page 15: Pcc Iv Loop Controller Model Number

    A J 0 0 Note: The examples given in no way reflect the number of possible option card possibilities. The PCC-IV 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.

  • Page 16: Spare Parts List

    Front Panel screw with integral O-ring 90415 Bezel w/ Gasket (Set) 90416 Touch Screen Retaining Plate 94309 TFT LCD 19708F Preferred Instruments nameplate for Front Panel, Alum 92492 Cable, 1.6 ft., USB-A to Micro USB-B Available Spare Parts: 190800 CPU board 92491 2 pt.

  • Page 17: Pcc-Iv Specifications

    Communications Network: Protocol: Modbus (ASCII, RTU, or TCP/IP mode) Speed: 4800-115,200 baud Type: RS-485 (optically isolated) or Ethernet Configuration: Type: Micro-USB connector Specifications subject to change without notice. PCC-IV Instruction Manual (rev. 0.1) Page 1-9 Section 1 - Product Overview...
  • Page 18 “J” Option Board Isolated Neutral Jumpers ... 10 Micro-USB Download Cable ........25 “S” Option Board 120 Vac Fuse ......10 Field Installation of Option Boards ......26 CPU Board Layout ..........11 PCC-IV Instruction Manual (rev. 0.2) Page 2-1 Section 2 - Installation...

  • Page 19: Option Board Descriptions

    Rear Access The PCC-IV case is 7 ¾ ̎ deep behind the mounting flange; therefore, PCC-IV 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 troubleshooting.

  • Page 20: Mounting

    Remove any burrs and loose metal chips. Remove the Panel Mounting Brackets from the PCC-IV case. Slide the PCC-IV into the hole. From the rear of the PCC-IV, slide the Mounting Brackets tabs into the slots in the PCC-IV case. Using a 1/8” Allen wrench, tighten each mounting bracket screw against the enclosure.

  • Page 21: Wiring Overview

    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-IV. VERIFY THAT ALL SOURCES OF POWER HAVE BEEN DISCONNECTED BEFORE WORKING ON WIRING. FAILURE TO DO SO CAN RESULT IN INJURY OR DEATH.

  • Page 22: Connecting And Powering The Front Panel

    2-3, to pins 1-2. If, in the future, a separate power supply is no longer necessary, move the jumper J9, on the back of the front panel, from pins 1-2, back to pins 2-3. The power supply connection may come from the same power supply used for the PCC-IV. PCC-IV Instruction Manual (rev. 0.2)

  • Page 23: 24 Vdc & 5 Vdc Power Supply Load Calculations

    24 Vdc & 5 Vdc Power Supply Load Calculations The PCC-IV CPU board is powered by an external 24 Vdc power supply that must be rated as a minimum for (450 mA + field loads + option board loads). 450 mA is the load for the CPU Board + the face plate + a 25% safety factor.

  • Page 24: 250-Ohm Resistors For 4-20 Ma Inputs

    250-ohm Resistors for 4-20 mA Inputs Except for the “G” Option Board, every PCC-IV 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.

  • Page 25: A" Option Board 250-Ohm Switches

    AIN ch.1 Turn Switch 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) PCC-IV Instruction Manual (rev. 0.2) Page 2-8 Section 2 - Installation...

  • Page 26: F" Option Board 250-Ohm Switches

    External 250-ohm Resistor is in use. AIN ch. 1 “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-IV Instruction Manual (rev. 0.2) Page 2-9 Section 2 - Installation...

  • Page 27: J" Option Board Isolated Neutral Jumpers

    Relay Outputs, 8A, ½ HP, 2 Channels Fuse for Pair 1 (Term. 30 & 31) “S” Option Board 120 Vac Fuse Triac Output (AC Solid State Switch), 1 Pairs (2 Triacs) PCC-IV Instruction Manual (rev. 0.2) Page 2-10 Section 2 - Installation...

  • Page 28: Cpu Board Layout

    Select Jumpers J2 Option Board 1 Right pins are 1-3/2-4 Connector Left pins are 3-5/4-6 Option Board 2 Front USB Connector Programming Port (PCC-IV) CPU Board 250- ohm jumpers PCC-IV Instruction Manual (rev. 0.2) Page 2-11 Section 2 - Installation...

  • Page 29: Cpu Board Field Wiring Terminals

    120 Vac Line “L” and “N” terminals: The PCC-IV is not powered by 120Vac. Terminals 2U, 2L, 3L are connected to each other but not to any other internal PCC circuitry. These terminals are provided for compatibility with PCC-III controllers. 120 Vac does not need to be connected to these terminals for new PCC-IV installations.

  • Page 30: Option Board Field Wiring Terminals

    " 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-IV Instruction Manual (rev. 0.2) Page 2-13 Section 2 - Installation...

  • Page 31: Wiring Examples

    JP1-2 JP1-2 Board. Install JP 1-2 to connect the internal Jumper Jumper 250.0-ohm resistor. 250.0 250.0 The External Power Supply “-” and the PCC-IV ohms ohms Signal Common “-” must be connected. 24 Vdc Power 24 Vdc Power Supply Supply...

  • Page 32: Isolated 4-20 Ma Input

    See “Pull-Up/Down Resistors” in this Section (Signal Common) (Signal Common) The External Power Supply “-” and the PCC-IV Signal Common “-” must be connected. Terminals shown are Terminals shown are for: AI ch. 0-4 for: AI ch. 0-4 The shield connects to the External Power Supply “-”.

  • Page 33: Potentiometer Input

    4-20 mA 4-20 mA 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-IV is 800 ohms. 4-20 mA 4-20 mA shield connects Signal Common “-”.

  • Page 34: 120 Vac Discrete Inputs, Cpu Board

    CPU board AC Neutral. channels. The CPU AC Neutral (terminal 1U) does not connect to the “J” board. An external wire must be run if these isolated Neutrals need to be connected. PCC-IV Instruction Manual (rev. 0.2) Page 2-17 Section 2 - Installation...

  • Page 35: Relay Output

    Mount Clamp Diode on Coil to Terminals shown are Terminals shown are Prevent Electrical Noise Prevent Electrical Noise for: DOUT ch. 0-1 for: DOUT ch. 0-1 NOTE POLARITY!! NOTE POLARITY!! PCC-IV Instruction Manual (rev. 0.2) Page 2-18 Section 2 - Installation...

  • Page 36: Triac Output, Reversible Actuator

    Increase varistors (6 mA leakage, type). Max. Load Max. Load 2 Amps 2 Amps The Triac Hot and Neutral supply are isolated from the PCC-IV 120 Vac. Each Triac pair has (FLA) (FLA) a separate fuse. 2-43 2-43 Decrease Decrease Motors rated 24 –...

  • Page 37: Dc Commons And Ac Neutrals Isolation

    Interrupter Circuit Breakers to trip if current returns via a neutral that is not protected by the GFCI breaker. The PCC-IV is not powered by 120Vac. Terminals 2U, 2L, 3L are connected to each other but not to any other internal PCC-IV circuitry. These terminals are provided for compatibility with PCC-III controllers. 120 Vac does NOT need to be connected to these terminals for new PCC-IV installations.
  • Page 38 Option Cards 1 & 2 Terminal Numbers * 2U, 2L, and 3L are connected to each other but have no connection to any other PCC-IV internals. They are provided for PCC-III backwards compatibility only. PCC-IV Instruction Manual (rev. 0.2)

  • Page 39: Pull-Up/Down Resistor For Voltage Inputs

    .68 uF .68 uF typ. 2 typ. 2 250.0 250.0 0.6 Hz Filter 0.6 Hz Filter (Signal Common) (Signal Common) (-63 db @ 60 Hz) (-63 db @ 60 Hz) PCC-IV Instruction Manual (rev. 0.2) Page 2-22 Section 2 - Installation...

  • Page 40: 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-IV. 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.
  • Page 41 Workstation Star Layout: Not Acceptable Star Layout: Not Acceptable ScadaFlex ScadaFlex Workstation Workstation Bus with Stubs Layout: Not Acceptable Bus with Stubs Layout: Not Acceptable ScadaFlex ScadaFlex Workstation Workstation PCC-IV Instruction Manual (rev. 0.2) Page 2-24 Section 2 - Installation...

  • Page 42: Ethernet Cables

    USB port. There is (1) USB port, but (2) physical USB jack locations. Jumpers on the CPU board select the front or rear jack. The rear jack is used for PCC-IV applications, and the front jack is used for DCS-IV applications.

  • Page 43: Field Installation Of Option Boards

    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-IV. VERIFY THAT ALL SOURCES OF POWER HAVE BEEN DISCONNECTED BEFORE WORKING ON WIRING. FAILURE TO DO SO CAN RESULT IN INJURY OR DEATH.
  • Page 44 ACK Soft-button and the Alarm Annunciator ..6 Numeric Display............. 4 User Defined Soft-buttons ........6 Message Display ........... 4 User Defined Lights ..........6 DIS Soft-button ............4 Multiple Loops ............6 PCC-IV Instruction Manual (rev. 0.1) Page 3-1 Section 3 - Operation...

  • Page 45: Operator Controls And Front Panel Usage

    By design, the PCC-IV is exceedingly flexible, and very adaptable. For convenience, this section will use specific examples to explain how to operate the PCC-IV. However, the reader should remember that each PCC-IV will be programmed differently to suit the needs of an application. For this reason, one must consult the documentation for the blockware loaded in the memory of your specific PCC and become familiar with your installation before attempting to operate the PCC-IV controller.

  • Page 46: Front Panel Displays And Soft-Buttons

    “Process Variable” is control system slang for: “that specific system condition that the PCC-IV is trying to control.” Put another way, if the PCC-IV is modulating a steam valve to control the burner fuel oil temperature, then the oil temperature is the Process Variable (PV). If the PCC-IV is a boiler feedwater controller, the boiler drum water level is the PV.

  • Page 47: Numeric Display

    Put another way, if the PCC-IV is modulating a steam valve 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.

  • Page 48: Auto/Manual Soft-Button And Light

    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. PCC-IV Instruction Manual (rev. 0.1) Page 3-5 Section 3 - Operation...

  • Page 49: Alarm Light

    Multiple Loops PCC-IV 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 with your specific controller’s blockware to determine the requirements specific to your application.
  • Page 50 LEVEL loop AUTO/MAN soft-button would toggle the Auto-Manual status as expected. The text at the bottom of the screen would display which loop is currently being displayed on the bargraphs. PCC-IV Instruction Manual (rev. 0.1) Page 3-7 Section 3 - Operation...
  • Page 51 Section 4: Menu Operations Table of Contents Introduction ............... 2 Memory Menu ............11 Entering the Main Menu ..........3 Save Config Changes: ......... 11 Menu Tree ..............3 Calibrate I/O Menu ..........11 Main Menu ..............4 When is Calibration Required? ......11 Quick Parameters Menu ..........

  • Page 52: Introduction

    The resulting drawing can be printed on a printer. PC4_Draw is used to upload or download software to and from the PCC-IV and can be used to do on-line troubleshooting using the real-time block output value display of every lock in the PCC-IV.

  • Page 53: Entering The Main Menu

    (i.e. Setpoint, Controller Manual Output, etc.). The menus can always be used to display all data in the PCC-IV 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.

  • Page 54: Main Menu

    PID Gain value that was just changed. The Last Parameter link is lost when the PCC-IV powers down or re-boots, and the words “Last Parameter” will be displayed with no associated soft-button. The Last Parameter link is established and will again be in the Quick Parameters menu after a Parameter is displayed via the Browse Blocks menu.

  • Page 55: Service Manual Menu

    “Change One Output” submenu. The output channels can all be in Auto operation mode, all in S/M mode, or in any combination of modes. However, PCC-IV will automatically put all output channels into the S/M mode if any of the self-diagnostic tests detect a problem.

  • Page 56: Entering Service Manual (S/M)

    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. Section 4 – Menu Operations PCC-IV Instruction Manual (rev. 0.1) Page 4-6...

  • Page 57: Password Menu

    However, the Browse Blocks menu will not allow the user to modify blockware parameters unless the active Password Level is acceptable. As shipped from the factory, the PCC-IV password system is disabled; therefore, the user can modify any item in the PCC-IV.

  • Page 58: Disabling The Password System

    The user should always refer to a blockware schematic drawing when attempting to modify any aspect of the blockware. The PCC-IV blockware executes continuously, including when the Browse Blocks menu is being used. Any changes that are made will affect the blockware as soon as the ENTER key is pressed.

  • Page 59: How To Use Browse Blocks

    Forcing Block Outputs As an aid to trouble-shooting and field wiring check-out, PCC-IV 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”).

  • Page 60: Utilities Menu

    (forced or unforced). Press this button to toggle between forced and unforced. Multiple blocks may be forced simultaneously. The Unforce All soft-button will unforce all blocks in the PCC-IV. If any block is forced, the RUN light will blink on the operator display page.

  • Page 61: Memory Menu

    Typically, a PCC-IV will not require field calibration for the life of the controller. There are two reasons to field calibrate all or part of the PCC-IV: An Option Board is installed in the field, or the factory calibration data is corrupted.

  • Page 62: Analog Input Calibration Procedure

    Factory calibration data is corrupted: While unlikely, it is possible to corrupt the Blockware or Calibration data. If the calibration data does not pass the validation tests performed at start-up, the PCC-IV will use default calibration data and continue operating with the reduced accuracy as described above.

  • Page 63: Analog Output Calibration Procedure

    Most portable test meters and voltage calibrators have 4 ½ digits or less of display resolution. “Calibrating” the PCC-IV with a less than 5 ½ digit DC milliamp meter will result in lower PCC-IV accuracy. This procedure applies to the CPU Board (Board 0), Option Board 1, and Option Board 2.

  • Page 64: Screen Utilities Menu

    12. Using the INC or DEC keys, and observing the milliamp meter, set the 4-20 mA Output to 20.000 mAdc, +/-0.003. The Channel Value displayed on the PCC-IV front panel is a percentage of output. 100.000 = 100% = 20 mA.

  • Page 65: Choose Theme

    M4 Messages Menu This screen displays the last few internal messages of the PCC-IV blockware and is useful in troubleshooting and general info about the last thing to happen. The user will not normally need to view this screen.

  • Page 66: Rs485 Port

    This is the Isolated RS-485 Modbus communication port which is wired to terminals 1 thru 3 at the back of the PCC-IV CPU card. See Section 2 for wiring. After making all changes described below, press the Confirm soft-button to make the changes.

  • Page 67: Ipv4 Gateway

    2. Only the Loopback diagnostic sub-function (Code 00) is supported. Addressing: Each PCC-IV is field configurable; therefore, the User must have the PCC-IV Blockware Documentation or Drawing for the Controller that is going to be queried to know which Function Types are in which Blocks, and to know the significance of each signal.
  • Page 68 Search and Replace ........... 8 Any-Function-Any-Block ........2 Modifying the Front Panel Settings ..... 9 Reusable Functions ..........2 Writing a Configuration to the PCC-IV ....10 Softwiring ............2 Reading a Configuration from the PCC-IV ..11 PCC-IV Blocks ............3 Viewing Live Values ..........

  • Page 69: Blockware Basics

    Reusable Functions Almost all PCC-IV function types can be used as many times as required, within the 265 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.

  • Page 70: Pcc-Iv Blocks

    PCC-IV Blocks … Figure 5.1 PCC-IV Instruction Manual (rev. 0.2) Page 5-3 Section 5 – Configuring Blockware...

  • Page 71: Pcc-Iv Terminology / Glossary

    Block The memory of the PCC-IV is divided into 256 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.

  • Page 72: Analog

    Discrete Block outputs within the PCC-IV that can only have values of 0 or 1 (i.e. ON / OFF, TRUE / FALSE, HI / LOW) are called discrete values. Discrete and analog values cannot be intermixed. That is, if a function type calls for one of its inputs to be an analog value, then the user cannot assign discrete value to this input.

  • Page 73: Configuring Blockware Control Logic

    Configuring Blockware Control Logic In some applications, the PCC-IV blockware is pre-configured at the factory. In other cases, it is desirable to modify that configuration in the field because the end user may want to add features due to process changes. Yet in other cases, the customer may prefer configuring their own system from scratch.

  • Page 74: Anatomy Of A Block

    An InOutScreen pop-up will appear asking you which output and input you are trying to connect. Select the correct points and click OK. Connection Points Softwire Connector Function Block InOutScreen PCC-IV Instruction Manual (rev. 0.2) Page 5-7 Section 5 – Configuring Blockware...

  • Page 75: Connectors

    By right clicking on any Tag or Off-Page, you can search for, and jump to, all “destination” and/or “source” usages. Search and Replace operations can also be done. For example, all Tag Names that contain “Blr 1” can be replaced with “Blr 2”. PCC-IV Instruction Manual (rev. 0.2) Page 5-8 Section 5 – Configuring Blockware...

  • Page 76: Modifying The Front Panel Settings

    Loop Names – These specify the text that will be displayed at the bottom of the operator screen depending • on which control loop is selected. This ensures the operator knows which control function is currently being PCC-IV Instruction Manual (rev. 0.2) Page 5-9 Section 5 – Configuring Blockware...

  • Page 77: Writing A Configuration To The Pcc-Iv

    (NVRAM) SUCH AS SETPOINTS, FLOWS, TOTALS, PUSHBUTTON STATES, AND BLOCK OUTPUTS WILL BE ERASED BY THE NEW PROGRAM. To send the blockware to a PCC-IV, secure, isolate, or bypass the process being controlled, and/or place the controller into Service Manual to hold all outputs at their current value.

  • Page 78: Reading A Configuration From The Pcc-Iv

    Reading a Configuration from the PCC-IV Connect a USB cable between the computer and the PCC-IV – see section 2 if assistance is needed. Click on the Data tab on the Tool Bar and then click on Read on the Ribbon.

  • Page 79: Flashing/Updating Firmware

    On the CPU board, set the startup select switch (SW1) to 11110 (A=ON, B=ON, C=ON, D=ON, E=OFF). Insert SD card into the SD card slot (J10), on the PCC-IV, by sliding it in until it clicks. SD Card Slot with...
  • Page 80 11. Remove the SD card by pressing it in until it clicks. It will then slide out of the SD card slot. 12. On the CPU, set the startup select switch (SW1) to 11001 (A=ON, B=ON, C=OFF, D=OFF, E=ON). 13. Reinstall the PCC-IV back to its correct location and apply power by plugging in the 24 Vdc power supply plug(s).

  • Page 81: Modifying A Blockware Configuration

    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-IV Instruction Manual (rev. 0.2) Page 5-14 Section 5 – Configuring Blockware...

  • Page 82: Drag The Blocks Needed For Each Section To The Canvas, Assign Block Numbers, And "Softwire" The Block Inputs

    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). They are softwired as shown. Figure 5.3 PCC-IV Instruction Manual (rev. 0.2) Page 5-15 Section 5 – Configuring Blockware...

  • Page 83: Modify Parameters As Required

    P1 – Xfer rate Enable is 1 – we want transfer rate limiting to avoid and “bumps” when switching modes • P2 – A to B %/Sec is 1.00. This gives us a 1% per second transfer rate going from Plant Master to Local • PID mode. PCC-IV Instruction Manual (rev. 0.2) Page 5-16 Section 5 – Configuring Blockware...

  • Page 84: Add Tags Necessary For Setting Up The Panel Data Screen And/Or Oit & Scada Communication

    For Quick Parameter 1, select High Alarm SP as the Source Tag, Description = “High PSI SP” For Quick Parameter 2, select Low Alarm SP as the Source Tag, Description = “Low PSI SP” PCC-IV Instruction Manual (rev. 0.2) Page 5-17...

  • Page 85: Test The Configuration

    Each Block that was added or was modified should be thoroughly checked prior to returning the PCC-IV to process control. To test the configuration: Write the new Blockware to the PCC-IV and verify there are no errors. The green RUN LED should • be solid green after sending the configuration Display “PM Demand.”...
  • Page 86 [AOUT] Analog (4-20 mA) Output .... 28 F127 [NOP] No Operation Dummy Function ..50 [TOUT] Triac Output ........ 28 Note: See the ZP Oxygen Analyzer Instruction Manual for Function F6 [ZAIN] Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-1 Technical Reference...
  • Page 87 [F(T)] Function of Time Generator ....... 13 [TOUT] Triac Output ..........28 [F(X)] Function of X Generator with Learn [WSUM] Weighted Sum ........21 Mode..........15 [XOR] Exclusive OR Logic ........43 Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-2 Technical Reference...
  • Page 88 Default Block Inputs: There are 256 blocks in the PCC-IV (numbered 0 to 255). Think of a block as a receptacle, or socket into which the user inserts a PCC-IV blockware function. Any PCC-IV blockware function can be inserted into any available block.

  • Page 89: F0 [A0] Analog Constant, 0.00

    [AIN] Analog Input Function AIN is the blockware interface to the PCC-IV 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.

  • Page 90: F5 [Rain] (Modbus) Remote Analog Input

    [RAIN] (Modbus) Remote Analog Input When the PCC-IV Modbus 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 (i.e. changing) all Block Outputs, except for the RAIN and RDIN Blocks.

  • Page 91: [Dual] Dual Range Flow Transmitter Selector-Scaler

    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-IV, If the Switch point is 10%, the Low range transmitter MUST be calibrated 0–12.0” wc for 0- 100%.

  • Page 92: F22 [Beff] Boiler Efficiency

    Therefore, most portable combustion analyzers will indicate a higher efficiency than the BEFF (and ASME) method. Default Fuels: The "Fuel 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. --------------------------------------------------------------------------------------------- NAME:...

  • Page 93: F31 [Hsel] High Select

    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. [HSEL] High Select Function HSEL selects the greater of the three Inputs and copies that value to its Block Output.

  • Page 94: F33 [Msel] Median Selector

    Output = “A” Input when “Select” = 0, Output = “B” Input when “Select” = 1 When “Xfer Rate Limiting” = 0, the Output changes instantaneously when “Select” changes. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-9 Technical Reference...

  • Page 95: F35 [H/Llim] High / Low Signal Limiter

    OUTPUT TYPE: --------------------------------------------------------------------------------------------- Input Type Description Notes _____________________________________________________________________________________________ INPUT Parameter Description Default Code Notes _____________________________________________________________________________________________ + %/SEC LIMIT 10.00 100.00 0.10 - %/SEC LIMIT -10.00 -0.10 -100.00 Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-10 Technical Reference...

  • Page 96: [Fpt/H] Front Panel Adjustable Track / Hold

    At power down, the Block Output is saved in the Retentive Memory area of the NVRAM. During the first scan after CPU start-up, the FPT/H Block Output is set to the value stored in the Retentive Memory. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-11 Technical Reference...
  • Page 97 The Transfer Rate Limiting would be used to prevent a rapid setpoint change when transferring from Local Setpoint mode back to Remote Setpoint mode. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-12 Technical Reference...

  • Page 98: F41 [F(T)] Function Of Time Generator

    T = 0.0 is encountered. Breakpoints 4 through 10 (inclusive) would be ignored in this example: Y0=10%; (Y1=20%, T1=10.0); (Y2=20%, T2=20.0); (Y3=30%, T3=30.0); (Y4=0%, T4=0.0). Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-13 Technical Reference...
  • Page 99 See chart above for REST and HOLD Input operation. Times must be entered in ascending order. Starting from T0 and scanning toward T10, all breakpoints after the first Ti = 0.0 will be ignored. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-14 Technical Reference...

  • Page 100: [F(X)] Function Of X Generator With Learn Mode

    Learn Mode X and Y coordinates may be entered or modified at any time from the PCC-IV front panel editor, the USB port, or the MODBUS communications port (via PLINK). F(X) also has a Learn mode for automated entry and editing of characterizing curves.
  • Page 101 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 Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-16 Technical Reference...
  • Page 102 WARNING: This simplified example does not show all 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. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-17 Technical Reference...
  • Page 103 (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. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-18 Technical Reference...

  • Page 104: F43 [L/L] Lead - Lag With Gain (Dynamic Compensation)

    --------------------------------------------------------------------------------------------- Input Type Description Notes _____________________________________________________________________________________________ SIGNAL INPUT Parameter Description Default Code Notes _____________________________________________________________________________________________ 0.00 150.00 -150.00 0.00 150.00 -150.00 100.00 150.00 -150.00 100.00 150.00 -150.00 Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-19 Technical Reference...

  • Page 105: F51 [Ab/C] ( A*B ) / C Multiply - Divide

    AB/C can be used for A/C division (without multiplying) by connecting Input B to dummy Block 1 (A100 function, or 100%). --------------------------------------------------------------------------------------------- NAME: AB/C SINGLE USE FUNCTION: OUTPUT TYPE: --------------------------------------------------------------------------------------------- Input Type Description Notes _____________________________________________________________________________________________ A INPUT B INPUT C INPUT No Parameters Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-20 Technical Reference...

  • Page 106: F52 [Wsum] Weighted Sum

    Notes _____________________________________________________________________________________________ A INPUT B INPUT C INPUT Parameter Description Default Code Notes _____________________________________________________________________________________________ 1.000 10.000 -10.000 1.000 10.000 -10.000 1.000 10.000 -10.000 0.00 199.99 -199.99 Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-21 Technical Reference...

  • Page 107: F53 [Inv] Invert

    No Parameters [CON] Analog Constant Function CON Outputs a user defined analog constant. This value can be changed via: the PCC-IV Editor menus (under password protection), via USB Blockware download, or via the MODBUS communications link (using PLINK F124). This value cannot be changed from the PCC-IV front panel Operator displays during normal operation.

  • Page 108: F56 [Dev] Deviation Calculation (For Bargraph Displays)

    Code Notes _____________________________________________________________________________________________ PULSE DIVISOR 19999 Notes: 1. Increments Output on the rising edge of the Input (i.e., the first scan when Input becomes a 1) Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-23 Technical Reference...

  • Page 109: F59 [Sqrt] Square Root

    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). Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-24 Technical Reference...
  • Page 110 Ki *  P dt Limit: AG > 0 G=[(G*AG)/100] Out_Mid Anti-Reset Windup Logic I = TSIG – (P+D+FF) TSIG I = TSIG Internal Schematic of PID (F71) Function Block Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-25 Technical Reference...
  • Page 111 DERIVATIVE ACTION 0=PV 1=ERROR PID TYPE 1=PID,2=GPID,3=APID 3,12 GAP BAND (+/-% OF PV) 0.25 50.00 0.05 GAP GAIN MULTIPLIER 0.00 1.00 0.00 OUTPUT BIAS 0.00 100.00 -100.00 Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-26 Technical Reference...
  • Page 112 (see figure above). Gap Parameters 11 and 12 are ignored for PID types 1 and 3 (see Parameter 9). Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-27 Technical Reference...

  • Page 113: F81 [Aout] Analog (4-20 Ma) Output

    [AOUT] Analog (4-20 mA) Output Function AOUT is the Blockware interface to the PCC-IV 4-20 mA output hardware. AOUT converts a 0-100% Input into either a 4-20 mA output (0% = 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 (i.e.
  • Page 114 Use S/M for Initial Actuator Setup (Positioner Mode): After the actuator electrical installation is completed, put the PCC-IV into S/M mode (Service Manual, see Section 4), and go to the Service Manual submenu for Change one output. Select the applicable TOUT channel (Triac Output, Board x, Channel y). Press the INC key to open/increase the actuator;...
  • Page 115 TCODE auxiliary Outputs. This logic is designed for actuators with position feedback potentiometers (pots) that are wired directly to a PCC-IV 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.
  • Page 116 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-IV analog input will ramp to +5V within 3 seconds. The PCC-IV "G" option board includes an internal 330k pull-up resistor for each analog input.
  • Page 117 Scaled Position outside the -5% to +105% range, Bias resistors are NOT required. If 0V 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.
  • Page 118 6. Stroke time is from 0% to 100% POSITION (i.e. 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 when writing Blockware to the PCC-IV if sufficient Outputs are not available.

  • Page 119: [D0] Discrete 0 Constant

    No Inputs and No Parameters [DIN] Discrete Input Function DIN is the Blockware interface to the PCC-IV’s 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.

  • Page 120: [Dcon] Discrete Constant

    See Section 3 for further details. Note: If there are multiple PCC-IV's, all 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-IV.

  • Page 121: [Rdin] (Modbus) Remote Discrete Input

    [RDIN] (MODBUS) Remote Discrete Input When the PCC-IV MODBUS 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 (i.e. changing) all Block Outputs, except for the RAIN and RDIN Blocks.

  • Page 122: [Pb] Pushbutton

    If Param. 1 (INVERT INPUT) = 0: When Input = 1, LED is On, Output = 1 If Param. 1 (INVERT INPUT) = 1: When Input = 1, LED is Off, Output = 0 Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-37 Technical Reference...

  • Page 123: [Hialm] High Alarm

    Example: Trigger an ASW to select PID "B" instead of PID "A", when steam flow exceeds 20%. See top figure at right Inputs 2-3, and Parameters 1-5 modify the basic behavior as follows: Seconds SP-DB Output Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-38 Technical Reference...
  • Page 124 ALARM DISABLE ACTIVE LO/HI 0=LO, 1=HI ALARM DELAY SECONDS Notes: See "Internal vs External Setpoint" above. See "Alarm Disable" above. See "Deadband" above. See "Alarm Time Delay" above. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-39 Technical Reference...

  • Page 125: [Devalm] Deviation Alarm

    Operator. DEVALM can also be used as a trigger in Blockware to automate a control strategy. Figure xx Seconds Inputs 2-3, and Parameters 1, and 3-7 modify the basic behavior as follows: Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-40 Technical Reference...
  • Page 126 ALARM DELAY SECONDS Notes: See "Internal vs External Setpoint" above. See "Alarm Disable" above. See "Deadband" above. See "Alarm Time Delay" above. See "Inverted Output" above Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-41 Technical Reference...

  • Page 127: [Rate] Rate Of Change Alarm

    - % /SEC LIMIT -10.0 -0.1 -100.0 ALARM DISABLE ACTIVE LO/HI 0=LO, 1=HI ALARM DELAY SECONDS Notes: See "Alarm Disable" above. See "Alarm Time Delay" above. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-42 Technical Reference...

  • Page 128: [Logic] User Defined Logic

    NAME: SINGLE USE FUNCTION: OUTPUT TYPE: --------------------------------------------------------------------------------------------- Input Type Description Notes _____________________________________________________________________________________________ A INPUT B INPUT Parameter Description Default Code Notes _____________________________________________________________________________________________ INVERT OUTPUT? 0=NO 1=YES Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-43 Technical Reference...

  • Page 129: [F/F] Flip Flop Logic

    Input Type Description Notes _____________________________________________________________________________________________ SET INPUT TOGGLE INPUT RESET INPUT Parameter Description Default Code Notes _____________________________________________________________________________________________ INVERT OUTPUT 0=NO 1=YES POWER UP 1=HI 2=LO 3=LAST Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-44 Technical Reference...

  • Page 130: [Dsw] Discrete Switch

    NAME: SINGLE USE FUNCTION: OUTPUT TYPE: --------------------------------------------------------------------------------------------- Input Type Description Notes _____________________________________________________________________________________________ A INPUT B INPUT SELECT INPUT (0 = A, 1 = B) No Parameters Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-45 Technical Reference...

  • Page 131: Delay Relay (Off Delay)

    DADTDR SINGLE USE FUNCTION: OUTPUT TYPE: --------------------------------------------------------------------------------------------- Input Type Description Notes _____________________________________________________________________________________________ INPUT Parameter Description Default Code Notes _____________________________________________________________________________________________ SECONDS DELAY 19999 INVERT OUTPUT 0=NO 1=YES Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-46 Technical Reference...

  • Page 132: After De-Energize Timer

    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. Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-47 Technical Reference...

  • Page 133: [Reptdr] Repeat Time Delay Relay

    OUTPUT TYPE: --------------------------------------------------------------------------------------------- Input Type Description Notes _____________________________________________________________________________________________ INPUT Parameter Description Default Code Notes _____________________________________________________________________________________________ ON TIME SECONDS 19999 OFF TIME SECONDS 19999 INVERT OUTPUT 0=NO 1=YES Section 6 – Blockware Functions PCC-IV Instruction Manual (Rev. 0.1) Page 6-48 Technical Reference...

  • Page 134: Control

    Function COMM provides Communications Link (Comm Link) status and controls the ability of Modbus to write (modify) PCC-IV Block Outputs and parameters. The Block is not required if the Comm Link does not have to write (modify) to any Block Outputs or parameters (i.e., the Comm Link will be read-only).

  • Page 135: Sinking )

    F126 [DOUT] Discrete Output (Open Collector - Sinking) Function DOUT is the Blockware interface to the PCC-IV’s 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).

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