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intech 21 OPLC-2100 Operation Manual

intech 21 OPLC-2100 Operation Manual

One pipe local controller

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The One Pipe Local Controller OPLC-2100 V3.26 (Fig 1) has been designed to provide control of the Steam Zone Valve in
One Pipe Heating System to regulate the amount of heat (thermal energy) supplied to a building, as well to provide control a
Steam Boiler. On the Steam Boiler application the OPLC-2100 is equipped an auxiliary board to supply 4 – 20ma interface
to control the Boiler's actuator. On this document we will describe the Steam Boiler Control further called as "Boiler+".
OPLC-2100 works as a standalone controller or can be connected to a Local Server, which furnishes the additional
parameters adjustments to OPLC-2100 based on apartments real time temperature reading in order to improve the heating
supply efficiency and avoid apartment over/under-heating. When the OPLC-2100 is connected to the Local Server it can be
monitored and controlled from the local Intranet and/or Internet with appropriate authentications. On all applications
automatic control of the main parameters in accordance with operation settings and measured temperatures/pressure to
achieve optimal heating delivery and reduce fuel losses.
The OPLC-2100 features:
Adjustable Day and Night modes of operation.
Adjustable Winter and Summer modes of operation.
Programmable Heat Up and Cool Down set points.
Morning Boost period up to 120 min.
Provides compensator control for unusual weather conditions
Measures and displays outdoor and heating system sensors temperature.
Measures and displays Boiler's steam pressure.
Sensors malfunction processing and indicating (open/short situation).
Displays the control cycle parameters and valve status.
Adaptable to different types of standard temperature and pressure sensors, and valve motors.
Simple calibration procedure for the temperature and pressure sensors.
Internal real-time clock/calendar with backup battery.
Automatic storage of setup values. No loss of setup values or mode of operation if power is OFF for extended time.
Automatic Daylight Saving Time clock adjustment.
Locally controlled by the four-button keypad and convenient menu.
Password protection for the critical settings.
Remotely controlled and/or monitored through the RS485 interface.
PID controlled analog output 4-20mA or digital potentiometer for flame modulations to maintain the
required steam pressure during the boiler ON cycle.
21 Harbor Park Dr. N, Port Washington Phone: 516.656.72211 Fax: 516.626.7201
One Pipe Local Controller OPLC2100
1. Introduction
Figure 1. OPLC2100. Front view
OPLC-2100 Operation Manual
CONFIDENTIAL
1

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Summary of Contents for intech 21 OPLC-2100

  • Page 1 1. Introduction The One Pipe Local Controller OPLC-2100 V3.26 (Fig 1) has been designed to provide control of the Steam Zone Valve in One Pipe Heating System to regulate the amount of heat (thermal energy) supplied to a building, as well to provide control a Steam Boiler.
  • Page 2 The four-button keypad and 16 characters by 2 lines LCD backlit display can be found on the front panel of the OPLC-2100. These controls provide full local management of the system. Operator can read system status information (e.g. temperatures, pressure, cycle parameters, and alerts), set the operational modes, and change settings. The control keypad consists of four pushbuttons: Escape (Esc), Down (), Up (), Enter (Enter).
  • Page 3: Set Time And Date

    OPLC-2100 Operation Manual CONFIDENTIAL Fig 2. OPLC-2100 Menu Chart (Boiler+ Configuration) Cyc:29/61 ON:12 SET OPER MODE NEW Mode=AUTO 2.8psi FR=17% NEW Mode=MAN ON Compensator=+1 NEW Mode=MAN OFF 10:25am Aug10'07 NEW Mode=MAN SET NEW HeatSet=56% OD Temp = 42°F NEW Mode=OFF SYS Temp=120°F...
  • Page 4 OPLC-2100 Operation Manual CONFIDENTIAL PID_I = 0.7 DDBBCBA Password2:******* PID_D = 0.0 SET CALIBRATE CAL OUTDoorTemp NEW ODTAdj=0. CAL SYStemTemp IntSumErr=-7.1 NEW SYSTAdj=0 Correction=-6.6 SET Com.ID NEW Com.ID=3 SetPSenser@4ma NEWPSes@4ma= FiringRate=64.3% SetPSenser@20ma NEWPSes@20ma= MAINTENANCE Password1:******* CAL PRESSURE LowFlameRate=15% SET PID_P NEW PID_P= 0.7...
  • Page 5 OPLC-2100 Operation Manual CONFIDENTIAL LFR–Low Flame Rate. Sign ‘~’ shows that PID control of the Gas Valve movement is altering. 5. Operational States and System Information 5.1. Upper Line of the Display The OPLC has five Modes of Operation: AUTO, SET, MANUAL ON, MANUAL OFF and OFF.
  • Page 6 OPLC-2100 Operation Manual CONFIDENTIAL 5.2. Operational States and Bottom Line of the Display Upper Line of LCD Bottom line of LCD Description: Operational Operational State Mode When mode is changed to ‘OFF’ operation Gas Valve moves to Close position. Where: PPrg (Post Purge) aa.a ps FR=yy.y%...
  • Page 7 OPLC-2100 Operation Manual CONFIDENTIAL AUTO:xx% HeatUp ExtCycle ON:E Appear after Purge state if SYSTemp < HeatUpSP. Controller will be on HeatUp state either SYSTemp > HeatUpSP or HeatUpTime is expired. E = Current minutes boiler is ‘On’. Appear after ‘OFF’ part of Cycle (on D/N:Norm state) if SYSTemp > CoolDwnSP.
  • Page 9 OPLC-2100 Operation Manual CONFIDENTIAL 5.3 System Status Information All operational parameters and useful information can be seen on the low line of the LCD display by using Up/Down and Enter keys (see Fig.2 left corner). The following information can be selected (by pressing Up or Down key)
  • Page 10 OFF), indicates amount of heat (thermal energy) to be supplied during AUTO or SET operation. The right corner of the upper line indicates the current Operational State. (Please refer to the detailed description on section 10). The OPLC-2100 operates in one of the following modes: Operation...
  • Page 11 OPLC-2100 Operation Manual CONFIDENTIAL Fig 4. Heat Request vs. Outdoor Temperature curves. (Mild Weather=55, Compensator=0) Fig 5. Heat Request vs. Outdoor Temperature curves. (Mild Weather=55, Heat Gain=3.0, Compensator Sensitivity=3.0) 21 Harbor Park Dr. N, Port Washington Phone: 516.656.72211 Fax: 516.626.7201...
  • Page 12 This is the only setting, which is not protected by the password 8. Operation Settings To provide correct and reliable operation of the OPLC-2100 the operational parameters must be set properly. The parameter section of the menu is divided in two parts (SETUP and MAINTENANCE ). Each part protected with a password.
  • Page 13: Time And Date

    Submenu for Calibration of Temperature and Pressure Sensors. Uses to calibrate a current for CALIBRATE motorized valve. (Please see chapter #10) Each OPLC-2100 connected to the local server via the RS485 bus. To establish proper connection the controller should have a unique communication address (ID). Com.ID Range: 1 to 99.
  • Page 14 The temperature sensor, pressure sensor, and motor current loop interface must be calibrated after the initial system installations or after the parts replacement. The OPLC-2100 facilitates the calibration procedure. To enter the calibration section of the menu, select SET CALIBRATE and then enter password. Following table provides explanations for the calibration procedure.
  • Page 15 OPLC-2100 Operation Manual CONFIDENTIAL shows actual reading of the temperature sensor: " ODT=xx.y° ". Outdoor Temperature Sensor Calibration The lower line of the display shows possible adjustment for example “NewODTAdj=0.1°” Press Up or Down key to make the ODTemp equal to the real outdoor temperature, measured by the reference thermometer.