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2004.05.20 1:10,30
ALIVE ERROR 1 ACTIVE
7 4 1
ON CLEAR OFF
8 5 2 0
9 6 3
ENTER YES
SET FUNCTION
`3
10
11
12
MOTOR RUNNING
STANDBY
ERROR
13 14 15 16 17 18 19 20 21 22 23 24
LOCAL
MOTOR RUNNING
REMOTE
RAPCON-24
BHARAT HEAVY ELECTRICALS LIMITED BOILER AUXILIARIES PROJECT RANIPET - 632 406
CONTENTS
1.0 2.0 3.0 4.0 5.0 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.1.9 5.1.10 5.1.11 6.0 7.0 7.1 7.2 7.3 7.4 8.0 Introduction Technical Data Controls Function Operation Function Selection Using Password Setting Rapper Times Setting Real Time Starting and stopping a Rapper Starting and stopping a rapper manually Setting Program set no. Checking the Rapper Times Checking the Real Time Checking the RAPCON-24 Address Checking the Program set NO. Alarm Action Standby System Messages RAPCON-24:MASTER Key Board Timeout 2004.04.25 09:10,40 Input Out of Range! Fault Finding
APPENDIX-A APPENDIX-B
1.0
Introduction
RAPCON-24 (Rapper Controller) is a microprocessor-based unit that controls and surveys the operation of rapping motors in Electrostatic Precipitators. One RAPCON24 unit can control up to 24 rapping motors. RAPCON-24 starts and stops the rapping motors as programmed and will give an alarm if a rapping motor fails. RAPCON-24 is a component of BHELs Integrated Operating System (IOS), but can also be used as a stand alone unit. In BHELs Integrated Operating System a maximum of eight RAPCON-24s will communicate on a data link with other control units. From RAPCON-24 each rapping motor can be manually started or stopped during operation, without interfering with other rapping motors. The operation state of each rapping motor is indicated with light emitting diodes on the RAPCON-24 panel. The RAPCON-24 is pre-programmed with number of Rapping Sequences, any of which can be selected depending on the field failure condition of the Electrostatic Precipitator.
2.0
Technical data
280mm 180mm 210mm Weight Operation Temperature Storage Temperature ~8kg +5 to+50C 0 to +70C
255mm 180mm
Panel Protection
IP 54
Mains Requirement 24V10% (RAPCON-24 only) 50Hz 5%, 50VA All RAPCON-24 inputs & outputs are brought to screw type terminal strips via short (2.5m) Flat Ribbon cables
Inputs Outputs
:One for each rapping motor: (Opto coupled that acknowledge Rapping motor ON/OFF status.) : One for each rapping motor.(A relay contact. Closure operates the Contactor of the rapping motor.) Page. No.: 01
3.0 Controls
2004.05.20 08:10,30
ALIVE ACTIVE
01 02 03
ERROR 1
7 4 1
ON OFF
8 5 2 0
9 6 3
ENTER YES
SET FUNCTION
`3
10
11
12
MOTOR RUNNING
STANDBY
13 12 11 10 09 08
ERROR
13 14 15 16 17 18 19 20 21 22 23 24
LOCAL
MOTOR RUNNINGCLEAR
REMOTE
RAPCON-24
04 05 06 07
1. ERROR - RED LED that lights if the rapping motor does not start within 3 secs. After start order, or if the rapping motor stops during operation or rapping motor runs more than 10 mnts. continuously in manual mode. 2. MOTOR mode. 3. RUNNING - Rapping motor No. Appropriate number lights when rapping is in programmed running - Green LED that lights when the rapping motor is running.
4. 1(ON) - Numeric pushbutton also used for ON commands 5. CLEAR(OFF) - Pushbutton for clearing the display e.g. after typing errors, or before entering new values and for OFF commands 6. Numerical Pushbuttons - for entering times, rapping motor numbers, password etc., 7. ENTER(YES) - Pushbutton for confirming commands and data entered 8. REMOTE 9. LOCAL 10. STANDBY - Pushbutton for selection of control by Integrated Operating System - Pushbutton for selecting of LOCAL control - Pushbutton ON/OFF selection of standby - Pushbutton for displaying the desired value.
12. DISPLAY - Alphanumeric display that presents the functions, set value etc., during setting and control of process times, alarm resets, rappers on and off and password entries. 13. ACTIVE - RED LED indicator to show the unit is controlling the rapping motors 14. ALIVE - RED LED indicator to BLINK to show healthiness of the controller Page No. 02
4.0 Function
RAPCON-24 controls and monitors the operation of up to 24 rapping motors. RAPCON24 has three timers for each rapping motor, so that start time, repetition time run time can be independently set for each rapper. The start time is set in actual clock time (hour, minutes). The repetition time is set in hours and minutes and the run time is set in minutes and seconds. RAPCON-24 gives a relay contact closure to order a rapping motor start. If the rapping motor has not acknowledged the start order within 3 secs, an ERROR alarm will be obtained and the rapping motor will be switched off. This will also occur if the rapping motor should stop during the set run time.
Page No. 03
5.0 5.1
Function selection and settings are both made interactively using the RAPCON-24 pushbuttons and the display. Some function can be used during operation, while others require the RAPCON-24 to be in LOCAL mode. The first event operation from (no.2 to 6) Only permits access if the password is answered correctly.
EVENT/OPERATION
PUSHBUTTON
DISPLAY
SET FUNCTION
And you will get NEXT FUNCTION NO = where you can select the function you went to use. The following are available, and will appear as text on the display. PASSWORD? SET RAPPER TIMES?
1.
NEXT FUNCTION NO =
1.
PASSWORD?
2.
4.
Page No. 04
6.
DISPLAY TIMES?
7.
DISPLAY TIMES?
8.
PROGRAMSET NO?
9.
PROGRAMSET NO?
RAPCON-24 ADDRESS?
10.
RAPCON-24 ADDRESS?
RESET ALARM?
12.
There are two methods to reach a function, when you are at NEXT FUNCTION No.=. Method A: Jump directly to a specific Function by entering the Number of the function you Want NEXT FUNCTION NO = 7 NEXT FUNCTION NO =7
ENTER YES
Step from function to Function by pushing The SET FUNCTION Pushbutton repeatedly Until desired function Is obtained.
NOTE: To reach a function with Function no. 1 to 6 the RAPCON-24 must be in LOCAL mode. LOCAL Push the pushbutton LOCAL so that the Light Emitting Diode In the pushbutton light.
LOCAL
NOTE: To reach function no. 2 to 6 also have to answer the password. You will automatically Get function No.2 after Answering the password.
Page No.06
EVENT/OPERATION
PUSHBUTTON
DISPLAY
PASSWORD?
ENTER YES
Give the Password code, Consisting of 4 numbers, On the numerical pushButton, e,g,
PASSWORD =
4 Confirm by pushing the ENTER (YES) pushbutton. ENTER YES Page No. 07
PASSWORD = ****
2 SET RAPPER TIMES? Push the ENTER (YES) Pushbutton. ENTER YES RAPPER NO Give the desired rapper no. (1-24) On the numerical pushbuttons.
2
RAPPER NO: 2 . And push the ENTER (YES) pushbutton. The display answers with START TIME =hh:mm.
CLEAR OFF
Give the new time by The numerical pushbuttons. Valid value is 00:00 to 23:59
7
Confirm by pushing ENTER (YES) Pushbutton. ENTER Repeat time Will appear on the Display. If you want to change the Repeat time(hh:mm), do the same As for the setting time. Valid value Is 00:01 to 24:00 Otherwise push ENTER (YES) Pushbutton and.. YES START TIME = 09:27
.run time (mm:ss) will appear on the display. To change the run time do the same as for setting time Valid value is 00:01 to 59:59 To leave the SET RAPPER TIMES Press SET FUNCTION pushbutton Until next function appears.
3. Push the ENTER (YES) push Button and the display shows The real date and time. ENTER YES
1995.01.15 If you want to change date push The ENTER (YES) push button Again. ENTER YES
10:23,45
Press CLEAR (OFF) to erase The old date and CLEAR OFF
SET DATE:
Page No.10
9 2
7
SET DATE 1995.01.27
Confirm by pushing ENTER (YES) Pushbutton. If you dont want to change The date push ENTER (YES) pushButton for the next function. ENTER YES
Set time will appear on the display. If you want to change the time, do The same as for setting date.
SET TIME
10:24,12
To leave the SET REAL TIME press SET FUNCTION pushbutton until next function appears.
SET FUNCTION
Page No.11
2
RAPPER NO 2 .and push the ENTER (YES) Pushbutton. The display now Replies with ON or OFF.
Push the 1(ON) Pushbutton for ON. The rapper will now stop & Start according to set new times & The MOTOR NO on RAPCON-24 Panel ligts.
1 ON RAPPER NO 2 ON
Push the CLEAR (OFF) PushButton for OFF. The rapper will Not any longer operate according To set times i,e., the rapper has been shut off.
Page No.12
To have the SET AUTO ON/OFF Press the SET FUNCTION pushButton until next function appears.
SET FUNCTION
Push the ENTER (YES) pushbutton. ENTER YES Give the desired rapper number (1 24) on the numerical push-button
2
.and push the ENTER (YES) Pushbutton. The display now Replies with ON or OFF.
RAPPER NO 2
Push the 1(ON) Pushbutton for ON.(start) The rapper will now Start running continuously until you push the CLEAR (OFF) push button for OFF (stop) . Now the rapper is set to AUTO ON , the rapper continues to operate according to set times
RAPPER NO 2 ON
Page No.13
Push the CLEAR (OFF) PushButton for OFF. The rapper will Not any longer operate according To set times i,e., the rapper has been shut off.
To have the SET MANUAL ON/OFF Press the SET FUNCTION pushButton until next function appears.
SET FUNCTION
EVENT/OPERATION
PUSHBUTTON
DISPALY
PROGRAMSET NO = 1
Push the CLEAR(OFF) PUSHButton to erase old program set On. And.give new program set no., By pressing the numerical pushbutton. Valid value is 1 to X. (for X ref. Maximum Set Nos., in Appendix-B.)
CLEAR OFF
2 PROGRAMSET NO . = 2
Page No.14
ENTER YES
SET FUNCTION
EVENT/OPERATION
PUSHBUTTON
DISPLAY
7 DISPLAY TMES?
and push the ENTER(YES) pushbutton. The display now replies with START TIME= hh:mm.
The display now replies with REPEAT RIME =hh:mm ENTER YES RUN TIME = 01: 00 The display now replies with N RIME =mm:ss SET FUNCTION
To leave the DISPLAY TIMES Press SET FUNCTION pushButton until next function appears.
EVENT/OPERATION
PUSHBUTTON
DISPLAY
8 DISPLAY REAL TIME? Push the ENTER(YES) pushbutton ENTER YES 1995.01.15 10:35,15
To leave DISPLAY REAL TIME press SET FUNCTION Pushbutton until next function Appears.
SET FUNCTION
Page No. 16
9 RAPCON-24 ADDRESS? Push the ENTER(YES) pushbutton ENTER YES RAPCON-24 ADDRESS = 1
To leave the RAPCON-24 ADDRESS Press SET FUNCTION until next Function appears.
SET FUNCTION
NOTE: RAPCON-24 address is required to be set when the RAPCON-24 is communicating with BHELs Integrated Operating System. The RAPCON-24 Address is set using DIP switch (SWI) provided in the CPU card of the RAPCON-24. The following table shows the switch position for various addresses. Address set at factory - 1
Maximum Address Acceptable =16 1 2 3 4 OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF Address Set at factory 1 ON ON OFF = OFF OFF OFF ON OFF ON OFF ON OFF OFF ON ON OFF ON ON ON OFF OFF OFF OFF ON ON OFF OFF ON OFF ON OFF ON ON ON OFF ON OFF OFF ON ON ON OFF ON ON OFF ON ON ON ON ON ON ON
ADDRESS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Page No.17
To leave the PROGRAMSET NO. press SET FUNCTION pushbutton until next Function appears.
SET FUNCTION
The display then changes from ALARM to------------- and the Summation alarm are reset.
To leave the RESET ALARM Press SET FUNCTION push Button until the NEXT FUNCTION =appears on the Display. 5.1.12
SET FUNCTION
To VIEW Press ENTER(YES) Pushbutton. ENTER YES MOTOR No:1 PASS-A CERM-1
Page No. 19
Press ENTER(YES) to see next motors assignment (For every ENTER(YES) key press, next motor label will be shown)
ENTER YES
CLEAR OFF
Press 1 to change PASS information. The built-in pass names are PASS-A, PASS-B PASS-C & PASS-D. 1 key can be pressed repeatedly to select one of those pass labels.
1 ON
2 Press 2 to change RAPPER TYPE information. The built-in rapper types CERM, EERM & EEGD. 2 key can be pressed repeatedly to select one of those rapper type labels. MOTOR No:1 PASS-A CERM- ( 3 )
3 Press 3 to change RAPPER No information. The built-in motor numbers are 1,2,3,4,5,6,7, 8,9,10,11 & 12. 3 key can be pressed repeatedly to select one of those rapper number labels.
Page No.20
After setting all three individual labels, Press ENTER (YES) to save the change. The labels are saved in NVRAM to retain values even during power-off.
ENTER YES
6.0 Standby
This operation requires password to be answered.
EVENT/OPERATION
PUSHBUTTON
DISPLAY
STANDBY
(Those rappers that for the moment run according to set run time will continue to operate until actual runtime is over and then they will stop) STANDBY Push the STANDBY pushbutton Once more to override the STANDBY mode.
(All rappers that have been set to AUTO ON will now continue to operate according to set times.)
Page No.21
EVENT/OPERATION
PUSHBUTTON
DISPLAY
RAPCON-24 : MASTER
ALIVE LED will start blinking & ACTIVE LED will glow if controller is active ( meant for redundancy) RAPCON-24 will start functioning based on default values (company set values) for the first time it is switched-on. All operating parameters are stored in NVRAM (Non-Volatile RAM) to preserve the system status. For subsequent resets, RAPCON-24 will start functioning only from stored set values. The following are the list of parameters stored in NVRAM 1. Manual Mode 2. Auto Mode 3. Program Set Number 4. Real Time 5. User entered rapper times 6. Rapper Labels
Push the SET FUNCTION pushbutton and you will get NEXTFUNCTION No= in the display.
Page No. 22
7.2
KEYBOARD TIMEOUT
EVENT/OPERATION
PUSHBUTTON
DISPLAY
If no action has been performed by The operator during the last 2 minutes, The RAPCON-24 gives a timeout warning By the text KEYBORD TIMEOUT In the display. By pushing any key you will return To the previous display.
KEYBOARD TIMEOUT
7.3
1995.01.20
10:15,17
EVENT/OPERATION
If no action has been performed During the last 2 minutes, the RAPCON-24 times out with the Display KEYBORD TIMEOUT And operator doesnt respond for the Next 2 minutes display shows the Real time and date.
PUSHBUTTON
DISPLAY
1995.01.20
10:15,17
By pushing the SET FUNCTION Pushbutton you will get the display NEXT FUNCTION No=
SET FUNCTION
Page No. 23
7.4
EVENT/OPERATION
PUSHBUTTON
DISPLAY
All invalid values that are entered Via the keyboard will be indicated By the text INPUT OUT OF RANGET! falashing on the display. Reset by pushing any key
4
Note: Key 4 is an example only.
Page No.24
8.0 Faultfinding
S.No 01 FAULT Front panel Dark CAUSE a. Mains power failure b. Power supply & Digital I/O card faulty. 02 Key board LEDS Are blinking Faulty CPU card REMEDY a. Check & correct the Mains power b. Change the card Change the CPU card
03
VF display faulty
04
05
Rapper ERROR LED (s) are glowing permanently thought the commands are acknowledged by the respective motor Modules. Motor ON command Is not excetended
a. Digital Buffer Card faulty b. Power supply and Dig. I/O card faulty.
a. Change Digital buffer Card b. Change power supply and Dig. I/O Card
a. Relay Card faulty b. Power supply and DIG. I/O Card faulty
a. Change the relay Card b. Change the power supply and DIG. I/O Card. a. Check the loop and polarity, if there is any problem correct it. Check the Dats Communication card cable. If faulty change it. b. Change the CPU card.
06
Page No.25
APPENDIX - A
DATA ADDRESS.I/O, CONTROL BUS FLAT RIBBON CABLE
DISPLAY CARD
CPU CARD
DATA COMMUNICATION
1 2
5. Pontential free NO contact To extend commands to Rapping Motors (Max 24) 6. Digital Inputs - To receive ack. from Rapping Motors (Max 24) (FOR DETAILED SCHEME REFER TO THE RAPCON-24 PANEL WIRING DRAWING) Page No. 26
APPENDIX-A
RAPCON-24 DATA PROJECT: UNIT: PASS/BUS SECTION:
NO.OF COLLECTING RAPPING MOTORS (CERM) NO. OF EMTTING RAPPING MOTORS (EERM) NO. OF CERM CONTROLLED BY ONE RELAY:
MOTOR NO 1 2 3 4 5 6 7 8 9 10 11 12
MOTOR
FIELD
MOTOR NO 13 14 15 16 17 18 19 20 21 22 23 24
MOTOR
FIELD
APPENDIX-B RAPPING FREQUENCY CHART 1. Rapping frequency for emitting rapping :__raps/hr
2. Rapping frequency for last field collecting rapping motor : __raps/___ hr. 3. Rapping frequency for GD rapping motor :___raps/hr
PROGRAM SETS WITH RESPECT TO FIELD AVILABLITY 0=Field ON: 1=Field OFF. F1,F2,F3Indicates Field No
Prg.Se t No 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
FIELD STATUS F1 F2 F3
F4
F5
RAPPING FREQUENCY F6 F1 F2 F3 F4
F5
F6
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64