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Page 1
Preface
Preface
EPIC III the ESP controller of the future
This Operator’s and Installation Manual for EPIC III contains information
for all groups of users from the installation and commissioning to daily oper-
ation and tuning of the cleaning process. In addition this manulal has an
appendix with the FläktBus Manual.
ALSTOM Power reserves the right to revise any publication and to make changes to its contents, at any time,
without obligation to notify any person or entity of such revision or changes. Furthermore, ALSTOM Power
reserves the right to make changes to any and all parts of hardware and software, at any time, without obliga-
tion to notify any person or entity of such changes.
Page 2
Preface
Page 1
Contents
Contents
1. Introduction ....................................................... 3 7.4. Copy settings ............................................ 46
1.1. EPIC III system ........................................... 3 7.5. [Save settings] .......................................... 47
1.2. EPIC III controller ....................................... 3 7.6. ESP Master function ................................. 48
7.7. EPOQ - Electrostatic Precipitator
Optimizing Q algorithm 49
2. The EPIC menu system .................................... 7
7.8. OpOpt - Opacity optimization algorithm .... 52
2.1. [Operation] .................................................. 8
7.9. VI-curve function ...................................... 55
2.2. [Readings] ................................................... 9
7.10.I/O groups and auxiliary inputs ................. 60
2.3. [Alarm Table] ............................................ 10
7.11.Timer functions ......................................... 69
2.4. [Master] ..................................................... 11
2.5. [Process settings] ..................................... 12
2.6. [Set Up Menu] ........................................... 13 8. Variable list ..................................................... 81
2.7. [Inputs] ...................................................... 17
2.8. [ESP] ......................................................... 17 9. Trouble shooting ............................................ 91
2.9. [EPOQ] ..................................................... 17 9.1. Alarm messages ....................................... 91
2.10.[VI-curve] .................................................. 19 9.2. Alarm messages list ................................. 92
2.11.[Diagnostics] ............................................. 20 9.3. External alarms ........................................ 96
2.12.[Tests] ....................................................... 21 9.4. Other faults ............................................... 96
2.13.[Save settings] .......................................... 22 9.5. Diagnostics windows ................................ 97
9.6. Test windows ............................................ 98
3. Installation ....................................................... 23 9.7. Program update ...................................... 100
3.1. General ..................................................... 23 9.8. Warranty & Repair Service ..................... 101
3.2. Assembly rules ......................................... 23
3.3. Connection ................................................ 23 10.Technical data .............................................. 103
10.1.General ................................................... 103
4. First start up (including initial set up) ........... 25 10.2.Analog inputs .......................................... 104
4.1. General instructions .................................. 25 10.3.Analog outputs ....................................... 105
4.2. Initial checks to avoid damage .................. 25 10.4.Digital inputs ........................................... 105
4.3. Power up self test ..................................... 26 10.5.Digital outputs ......................................... 107
4.4. Set up of configuration parameters ........... 26 10.6.Power supply .......................................... 107
4.5. Digital alarm test ....................................... 30 10.7.Communication ...................................... 107
4.6. Ignition phase test ..................................... 30 10.8.Front panel LEDs ................................... 108
4.7. First start up .............................................. 32
4.8. T/R short circuit test .................................. 33 11.Word list ....................................................... 109
4.9. I/O groups etc. .......................................... 34
Appendices
5. Tuning of ESP operation ................................ 35
EPIC III settings ......................................... 1 page
5.1. Spark settings ........................................... 35
Mounting drawing EPIC III (V4 559 883) .... 1 page
5.2. Process parameters .................................. 35
Mounting drawing ignition
5.3. [Process settings] ..................................... 35
transformer (V3632136) ............................. 1 page
Connection diagram, example (V3635661) 1 page
6. Daily operation ................................................ 37 Declaration of conformity ........................... 1 page
6.1. ESP-Master operation .............................. 37 FläktBus manual .......................................4 pages
6.2. Operation of single T/Rs ........................... 37
1. Introduction
1.1. EPIC III system
The EPIC III (Electrostatic Precipitator Integrated Controller) system is an
ALSTOM Power third generation microprocessor based control system for
electrostatic precipitators. With a separate control unit and display unit, a
new degree of design freedom is achieved.
The new EPIC III concept consists of two major components of which only
one is needed for basic operation.
• EPIC III main unit, includes all processing power.
• Remote Terminal Unit (RTU), needed only as an operator interface.
One RTU can serve as the operator interface for many EPICs
To host
computer
ProMo
RTU RTU Gateway II
Not to be used
with EFFIC
FläktBus
1 13 1 13 1 13 1 13 1 13 1 13
12 24 12 24 12 24 12 24 12 24 12 24
25 41 25 41 25 41 25 41 25 41 25 41
25 41 25 41 25 41 25 41 25 41 25 41
ON ON ON ON ON ON
NETWORK NETWORK NETWORK NETWORK NETWORK NETWORK
40 56 40 56 40 56 40 56 40 56 40 56
EPIC III Control unit for T/R\s EFFIC Control unit for Fabric filter
FF
ES
EFFIC Fabric Filter Control
EPICAB
Control of
T/R, rappers,
heaters etc. SIR
HV energization
and control of
appers, heaters etc
Conventional T/R
ProMo, colour graphic software package, host computer gateways with soft-
ware protocol is available as an option.
The EPIC III gives alarm messages to the operator when values are lower or
higher than set, if one or several alarm contacts are activated etc. All alarm
messages are displayed on and may be reset from RTU, ProMo, etc.
Six operating modes can be predefined and then selected for each individual
EPIC III.
The EPIC III has a Master function which means that one EPIC III, defined
as master unit, can control all EPIC IIIs in the FläktBus system and achieve
greater total ESP performance.
Operation together with the optional EPOQ algorithm, Electrostatic Precipi-
tator Optimizing Q, optimizes the best collection efficiency at different load
conditions.
The EPIC III contains one circuit board mounted in the enclosure. The cir-
cuit board holds all functions needed for the complete controller:
•Power Supply feed from 24V AC or DC.
•One 16 bit Microprocessor with software.
•Data acquisition analog and digital.
1 13
25 41
•Non-Volatile Memory (EEPROM, no battery
needed) for storing of system parameters.
•Non-Volatile Memory (FLASH) for storage of
40 56
control software.
POWER
ALARM
SPARK
TOKE
TRON
SYNC
N
40 56
munication with RTU, ProMo, Gateway and other
connected EPIC III units.
•Ethernet kit will be available.
25 41
POWER
ALARM
SPARK
TOKEN
TRON
quency.
SYNC
25 41
ON RK
NETWO
40 56
All terminals on the left-hand side of EPIC III are made through plug-in ter-
minals. This arrangement makes service fast by swapping a unit without hav-
ing to unscrew all the wires. For all information about the hardware input/
output of both analog and digital signals, see section 10. Technical data on
page 103.
Page 6
1. Introduction
Page 7
2. The EPIC menu system
Mode 1 T/R
Mode 2 System
Mode 3 Alarm
Mode 5
Inputs
Mode 6
ESP
Spark
settings
EPOQ
VI-curve
VI-Curve Set.
2.1. [Operation]
The [Operation] menu consists of the most important parameters for daily
operation and control of EPIC III.
2.1.1. [Operation]
The left side of this window have parameters which controls the operation
such as, T/R ON or OFF and selection of different control modes. The Lim-
iter parameter informs the operator why EPIC III is unable to increase the
power to the ESP. The Reset function will only be displayed when an alarm
is active. The Active CL shows the present current limit and the Active CR
shows the present charging ratio the EPIC III is using for the moment
The right side of the window shows measured variables.
2.2. [Readings]
The [Readings] menu displays measured values. The values are updated con-
tinually to give you the actual status of your system.
IoGrp 1
IoGrp 2
IoGrp 3
IoGrp 4
DigAux1
DigAux2
DigAux3
DigAux4
Cont.
Page 11
2. The EPIC menu system
2.4. [Master]
The [Master] window is for Master function only. A Master EPIC can con-
trol and operate part of or all connected EPIC III units in a network.
2.4.1. [ESP-Master]
This window displays the total number of connected T/Rs and the total
number of different alarm status. All EPIC III can be globally changed for
example, all active alarm situations can be reset, the active mode can be glo-
bally changed, all EPIC III can be switched off, etc.
2.6.1. [T/R]
A convenient and time saving function is the node copy function. This func-
tion allows you to transfer all parameter values from a specific EPIC III con-
troller. Select the node address of an installed EPIC III that you will copy
and press “Node”.
Note!
The copy function can only transfer parameters from other EPIC III
controllers, see heading 7.4. Copy settings on page 46.
2.7. [Inputs]
This window contains settings for auxiliary digital inputs, see heading
7.10.14. Auxiliary Digital Inputs on page 66.
2.8. [ESP]
The [ESP] window informs EPIC III about the T/R location and the collect-
ing plate area. These are used by EPIC III in calculations and in automatic
procedures.
2.9. [EPOQ]
This menu contains the Electrostatic Precipitator Optimizing Q algorithm.
(EPOQ) settings. It selects automatically the best possible intermittent ener-
gization (Semipulse ®) ratio and current based on on-line measurements of
the ESP. For more information, see heading 7.7.3. EPOQ Set up on page 51.
Page 18
2. The EPIC menu system
2.10. [VI-curve]
The VI-curve window is used for analysing of Electrostatic Precipitator
operation, see heading 7.9.2. Window structure overview on page 55.
90.0
2.10.0.3. [Settings]
This window contains different settings that affect the measurement.
Page 20
2. The EPIC menu system
2.11. [Diagnostics]
2.12. [Tests]
The [Tests] menu is for trouble shooting, see heading 9.6. Test windows on
page 98.
The Test functions contains the following RTU windows:
Page 22
2. The EPIC menu system
3. Installation
3.1. General
EPIC III is very simple to install since all electronic components are gath-
ered in one box, even the SCR ignition circuits.
For mechanical mounting, dimensions and instructions see Appendix.
One ignition transformer is delivered with every EPIC III unit. Measurement
transformers for primary current and voltage is available as an option.
1 13
12 24
25 41
40 56
POWER
ALARM
SPARK
TOKEN
TRON
SYNC
RTU
25 41 ON K
NETWOR
40 56
3.3. Connection
For reference purposes one example drawing of the connection between
EPIC III and T/R is supplied in the Appendix. This drawing is generally used
as a basic drawing for the design of the actual plant drawings.
For installation and trouble shooting, please refer to the actual plant draw-
ings.
Page 24
3. Installation
For an explanation of all input and output terminals, see section 10. Techni-
cal data on page 103. All wires are connected to jackable terminal connec-
tors.
The terminals can take wires from 0,5 to 2,5 mm2.
Page 25
4. First start up (including initial set up)
The self test on EPIC III starts to test all LEDs one by one on the front
panel. The light will run from the ALARM LED the SYNC LED.
3. Check that the TOKEN LED starts to blink when the RTU self test is
ready. If it doesn’t start to blink, check the node addresses (all nodes
must have unique addresses).
4. If an external alarm is displayed such as “Temperature high, T/R
Tripped” just acknowledge the alarm. This will be taken care of under
“Digital alarm test” later in this chapter.
4.4.1. [Set Up] [System], defining the position in the FläktBus network
After the power up self test the RTU displays the [Node list]. This list con-
tains two nodes, the home RTU and the EPIC III.
To display the [Set Up] [System] window do as follows:
1. Select the EPIC III unit.
2. The [Main menu] is now displayed. Select “Set up”.
3. The [Set Up] menu is now displayed. Select “System”.
4. The [System] window is now displayed.
Page 27
4. First start up (including initial set up)
This window displays five parameters and the actual program version:
Language Code
(English 0)
Swedish 1
German 2
Danish 3
Spanish 4
Czech 5
Polish 6
Russian 7
Finnish 8
French 9
Japanese 10
Dutch 11
Portuguese 12
Bulgarian 13
Note!
All languages are not implemented. If a not implemented language is
selected, the following error message will appear: The parameter is
temporarily blocked!
7. Select “Name”.
Enter the name of this EPIC from the Network node address list.
8. Select “Address”. Enter the new address from Network node address
list.
Note!
When the address parameter is changed the RTU will give an error
Page 28
4. First start up (including initial set up)
message and return to the [Node list] and display the EPIC III with its
new address.
************ERROR ************
The selected node is no longer
present on the net!
The error message is displayed because there is no longer a node with the old
address. Press OK and the RTU returns to the [Node list]. After a short delay
the EPIC III will display its new name and address in the node list.
3 61 62 63 64 65
2 51 52 53 54 55 Flow
1 41 42 43 44 45 Recommended
node addresses
A B C D E EPIC III 11-99
Master RTU 100-109
Gateway 110-119
ProMo 120-125
3 31 32 33 34 35
2 21 22 23 24 25 Flow
1 11 12 13 14 15
A B C D E
Master
0 0
0
Terminal no: 8, 20 10 ms/ div Terminal no: 6, 18 10 ms/ div
Each of the six mode blocks above have one set of the following parameters.
5.3.4. EPOQ
This is an algorithm for optimizing the ESP. See section 7. Function descrip-
tions on page 39.
6. Daily operation
The daily operation assumes that setup has being performed correctly and
also that correct mode settings have being set during tuning of the ESP.
See section 2. The EPIC menu system on page 7 for an overview of all win-
dows in EPIC III displayed by an RTU.
Daily operation is mainly performed from the [ESP-Master] window, con-
trolling all T/Rs at the same time using convenient group commands. If for
some reason one T/R need to be controlled as a single unit this can be per-
formed from the [Operation] window in the actual unit.
6.2.1. [Operation]
In this window alarms can be reset. The T/R can be individually turned ON
and OFF. The active mode can be individually selected. The reason for any
limitation of current is displayed. The most important measurements are dis-
played.
7. Function descriptions
7.1. General measurements and control
The measurements are synchronized to the line frequency and all presented
values are averaged over approximately one second. This means that for
instance 100 peak values are averaged in the kVp value at 50Hz and Charg-
ing ratio (CR)=1:1, but only 2 values at CR 1:51. For CR values lower than
1:101 the update and average frequency will be equal to the firing frequency
for those values that depend on CR.
Peak
Pulse CR = 1:3
Average
“No” load
Normal load
Current
mA Spark detection
Current step
Spark level
Spark quenching
(Short quenching)
1 2
t (s)
From this level the current is set to rise and follow three slopes (slope A, B
and C), see figure below. The slope parameters Slope Rise A, Slope Time A
and Slope Rise C can be changed. Slope Time A determines the time for
slope A as a percentage of the average time between sparks. Slope Rise A
determines the increase in current during slope A as a percentage of the cur-
rent step.
The parameters for slope B cannot directly be changed by the user. The time
and rise parameters are calculated as follows: after a spark the EPIC III seeks
to establish the same current level as before the spark and in a time equal to
the average time between sparks (Slope Time A + Slope Time B). Most
likely a new spark will occur here (marked with a second spark symbol). If
no spark occurs, slope B continues for a period equal to the period before the
assumed spark. If still no spark occurs, slope B will be succeed by Slope C.
Slope C (Slope Rise C can be set) will raise the current until a spark occurs
or the voltage or current limit for the EPIC III is reached.
Page 43
7. Function descriptions
Limited
Slope rise A Slope rise C
Current
mA Slope rise B
Step
t (s)
1 2 3 4 5 6 7 8 9 10 11 12 13
4. Make the spark detector more and more sensitive by setting lower and
lower values on Spark sensitivity* (kV/ms) until normal voltage shapes
are falsely detected as sparks. This is the situation when the spark level
in kV or mA is decreasing and dependent on the setting of Spark sensi-
tivity.
5. Write down the value of Spark sensitivity* (false det.) where false detec-
tion starts.
6. Set Charging ratio = 1:1
7. Make the spark detector less and less sensitive by setting higher and
higher values on Spark sensitivity* (kV/ms) until the sparks in the ESP
are not detected. This is the situation when the primary and secondary
current makes abrupt increasing jumps for short periods. Easiest to see
on analog panel meters.
8. Write down the value on Spark sensitivity* (kV/ms) (no det.) where no
detection starts.
9. Set Spark sensitivity to the average between Spark sensitivity* (false
det.) and Spark sensitivity (no det.) achieved above.
10. Restore the previous settings except Spark sensitivity* and then remem-
ber to save the changes in window [Save settings].
* or Level (0-32) if current sensing method is used.
Do as follows:
1. Highlight “DEFAULT” and press OK.
2. Enter your Password and press OK.
3. Press OK to confirm the selection. Press “Page up” to cancel the opera-
tion.
EPOQ maximizes the precipitation in each bus section, and thereby actually
maximizes the collection efficiency of the overall ESP.
ences, and is thus able to optimize the whole ESP operation very rapidly and
very flexibly. EPOQ will continuously adjust every ESP bus section to oper-
ate at optimum current and charging ratio - bringing the ESP to continuously
operation at peak performance capability - minimal emission.
7.7.1.4. EPOQ still optimizes ESP operation even at T/R or field drop out
Sometimes a short circuit occurs in a bus section, or a T/R trips due to some
fault. This will increase the dust load on the following bus sections, and will
also increase the emission from the overall ESP. EPOQ will - unaffected by
the trip - continue to keep all the other bus sections at optimum operation
efficiency, and is in this way capable of minimizing emissions - irrespective
of the cause of the alteration in electrical characteristics.
High limit 10
Set value 5
Time
Current limit %
Start 100
80
60
40
20
Time
Figure 3. Sample of average opacity signal and the reflected current limit. We
assume that the current limit starts at 100%
7.8.2.1. [ESP-Master]
The first [ESP-Master] window contains parameters for control of the Master
function of EPIC III. It also contains start and stop of the Opacity optimiza-
tion algorithm.
7.9.1. Introduction
When tuning an electrostatic precipitator (ESP) it is important to know its
operating condition. It depends on many different factors such as the
mechanical design, the electrical design and the actual process in use.
The VI-curve function is a new feature in EPIC III. It is a tool to analyze the
operating condition and the process of an electrostatic precipitator. It enables
fast and accurate data collection of the secondary voltage as a function of dif-
ferent calculated current density values. The result of the collection is pre-
sented both in graphs and as numerical values.
The VI-curve function in EPIC III interacts closely with the VI-curve soft-
ware in ProMo II which is a customized tool for the analysis of collected VI-
curves. It is also possible to transfer the values manually to a spreadsheet
program, for analysis and print out of the graphs.
90.0
Page 56
7. Function descriptions
7.9.2.3. [Settings]
This window contains different settings that affect the measurement.
7.9.3.1. General
There are some actions that must be followed to obtain the best VI-curve
results.
• Make sure that rappers and/or optimizing algorithms are not running
while the VI-curve function is active. If possible turn EPOQ and OpOpt
to OFF in [Active] [Settings] during the acquisition of the VI-curve.
• Perform two VI-curve collections. One in air load before start-up and
thereafter during the most representative operating condition, normally
full load. These curves will provide considerable amount of information
concerning the ESP’s mechanical, electrical and process operating con-
ditions.
• Always start to collect the VI-curve values in the rear field and work
your way up to the first field. This ensures that you have a representa-
tive dust layer on the collecting plates during the measurement.
• When a new VI-curve is collected the previous collection is lost in EPIC
III. For comparison between different collections, the numeric values
can be copied (manually) to a spreadsheet program or ProMo II can be
used. Each VI-collection is saved for comparison.
90.0
Page 58
7. Function descriptions
7.9.4.1. General
The VI-curve function is a tool for analyzing the operating conditions of an
electrostatic precipitator. It presents the secondary voltage as a function of
the current density. The current density scale is adjusted for root linearity
facilitate the reading.
7.9.4.2. Overview
The VI-curve function measures the average, peak and valley voltage at
seven different pulse currents. The measurement is performed twice (except
at the lowest value).
5 9
6
8
7
Time
the previous operating level when the VI-curve function is ready or has been
cancelled.
It can also be executed from ProMo.
7.10.1. Introduction
The “I/O Groups” function is a versatile firmware for control of external
devices such as rappers, heaters, ash handling etc. The “I/O Groups” com-
prises four I/O groups with different control categories. An I/O group is a
specific Digital Input that from an operational point of view is grouped
together with a specific Digital Output.
The “I/O Groups” can be set up to control the following:
• Up to four rappers of the tumbling hammer type
• Ash transport
• Heaters
• Digital outputs for external control with or without confirmation of the
feedback (CON.DO = Confirmed Digital output and
UNCON.DO = Unconfirmed Digital output).
• External control of ESP On on an ESP-Master unit (ESP-ctrl).
• External control of individual T/R (T/R-ctrl).
In addition there are four additional digital inputs called Digital Inputs Aux-
iliary (DigAux1-4). Each of these inputs have eight different predefined con-
trol categories.
Name
This column contains the name of connected devices. The name of the device
will then be used in all actual windows, even in the alarm messages. Enter
the name (max 7 characters).
Type
There are eight different selections of connected devices: RAPPER,
HEATER, TRANSPORT, CONF. DO, UNCONF. DO, ESP CTRL,
T/R CTRL or NOT CONN. Each selection will be explained separately in this
chapter.
Mode
There are five different modes of operation: ON, OFF, AUTO, CONT and
----. Each selection will be explained later in this chapter. Some of the Mode
settings combined with a Type may not have a function. All positions on the
next page that are marked with N/A are such combination. The RTU displays
“The parameter is temporarily blocked” if one of these combinations is
selected.
The “----” mode is automatically selected when NOT CONN, ESPCTRL,
T/R CTRL is selected in Type. This mode will change to OFF when Type is
changed to other selections.
Page 62
7. Function descriptions
RAPPER Follow the set- Follow the set- No rapping is Continuous rap-
tings in [Set Up] tings in [Set Up] performed. Alarm ping. Alarm after
[Config IO [Config IO after 30 minutes 30 minutes.
groups] and acti- groups] inde- if ESP is ON/High
vates with pendent of the voltage ON.
ESP ON/High ESP ON/OFF-
voltage ON and position or High
deactivates with voltage ON/OFF.
ESP OFF/High
voltage OFF.
TRANSPORT The output goes The output is The output is low. N/A
high at ESP ON/ high. Alarm after 30
High voltage ON minutes if ESP is
and low at ESP ON.
OFF/High volt-
age OFF.
switches OFF, rappers are stopped (if not set to conduct oth-
erwise by Timers 1-6).
ON The rapping is performed according to the time parameters
independent of commands like High voltage or ESP ON/OFF.
OFF No rapping is performed. If this mode is OFF for more than
30 minutes while High voltage or ESP is ON, EPIC III indi-
cates an alarm.
CONT Continuous rapping. If this mode is CONT for more than 30
minutes, EPIC III will indicate an alarm.
Rapper motor
feedback
EPIC III alarm func- Alarm will be given here Alarm will be given here if motor
tion sensing the feed- if motor is running. is not running.
back (Alarm if feedback = ON) (Alarm if feedback is not = ON)
[Set Up] [I/O Groups] [Power control] defines which timers who have power
control.
Remember to save all your settings with function [Save settings] in the
[Main menu].
7.10.10.1.Mode of operation
The output is controlled by the Mode parameter. This parameter can be
changed manually from the RTU.
It has two modes:
ON The output goes high.
OFF The output goes low.
7.10.11.Type: ESP-CTRL
This function is only for the master unit. ESP-ctrl is a flank triggered input
which toggles between ESP ON and ESP OFF. The function can be used
together with a button or a switch to stop and start the ESP. The output fol-
lows the ESP status and goes high when ESP is ON and low when ESP is
OFF.
7.10.12.Type: T/R-CTRL
T/R-ctrl is a flank triggered input which toggles between High voltage ON
and High voltage OFF. The function can be used together with a button or a
switch to stop and start the T/R unit. The output follows the T/R unit status
and goes high when High voltage is ON and low when High voltage is OFF.
7.10.13.[Timer1-6]
See section Timer functions on page 69.
• ALARM -T- This external alarm will trip the EPIC III and display an
alarm message on the RTU.
• ALARM-W- This external alarm will display an alarm message on the
RTU.
• MODE TOGGLE- This external input can be used to toggle the
EPIC III between two or four different operational profiles (only possi-
ble for input DI 14 and/or DI 16).
• MU M TOGGLE - This external input can be used to toggle the master
EPIC III (and consequently all slave EPIC IIIs) between two or four dif-
ferent operational profiles (only possible for input DI 14 and/or DI 16).
• OPAC. CAL- This input is used to block the opacity algorithm during
calibration of an opacity meter (if used).
• RAPPER - This input runs the EPIC III with PCR limit and can be used
if the EPIC III not controls the rapper.
• NOT CONN- When the input is not used.
0 0 1 0 1
1 0 2 1 2
1 1 4
Type: ALARM-W
External warning alarm. A high or low signal, depending of settings in
[Set Up] [Inputs], activates an alarm message “XXXXXXX, external alarm,
Warning” on the RTU. The “XXXXXXX” is the name of the connected
input.
Type: ALARM-T
External tripping alarm. A high or low signal, depending of settings in
[Set Up] [Inputs], will trip the T/R and display an alarm message
“XXXXXXX, external alarm, Trip” on the RTU. The “XXXXXXX” is the
name of the connected input.
Type: NOT CONN.
The input is not used.
Normally closed:
Filled box inverts the input.
Page 69
7. Function descriptions
00:00 02:00 04:00 06:00 08:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 00:00
(24:00)
Repetition time
Start time
Figure 6. One of 6 timers (the time setting function). The event will start on the first
Wednesday of the year and run for 30 minutes and will be repeated every 7th hour
Page 70
7. Function descriptions
Note!
There is no monitoring of the ratio between run time and repetition
time. You can specify a run time nearly as long as the repetition time.
The result of this will be an ongoing event with a short brake just
before it starts over.
7.11.2. Couplings
The output from the timer function is fed to a certain coupling function with
4 alternatives:
• NO - no coupling at all, an active timer output will result in an active
output from the coupling section.
• AND - the timer signal and the input have to be active at the same time,
to get an active output.
• AND NOT - the timer signal has to be active and the input has to be
inactive, to get an active output.
• OR - one of the timer signal or the input has to be active in order to get
an active output.
Timer 1
- Start time Coupling (in this
- Repetition time case AND)
- Run time
NO
Input AND
&
AND
NOT
&
OR
>1
Output
The RTU window [Set Up Timer 1-3] has the path Set up, I/O Groups,
Timer 1-3.
Page 71
7. Function descriptions
&
&
>1
PCR
ON/OFF Reduction
of current to Output
this level
The RTU window [Set Up Power Ctrl] has the path Set up, Power control.
Page 72
7. Function descriptions
The external
& & &
input to timer 1
& & &
>1
26
DI02
42
Connection
I/O 1 I/O 2
RAPPER
The digital inputs DI 1-2, 14, 16 will, in the RAPPER case, have an OR
coupling. Therefore if you select e.g. two RAPPERs an active signal from
any of these inputs will result in an active input to timer No. 1.
Page 74
7. Function descriptions
58
DO02 66
Next step is to activate the connected I/O Group. This is made in the RTU
window [Config I/O groups] found by using the path Set up, Group configu-
ration. Set the Type: for I/O Group 1 to RAPPER and the MODE: to
AUTO.
Page 75
7. Function descriptions
9. I/O Group - Set I/O group 1 to timer No. 2 in the RTU window [I/O
Group Connection] reached by using the path Set up, I/O Groups, Con-
nection.
10. Type - For I/O group 1, set the Type: to RAPPER.
Use the RTU window [Config IO groups] reached by using the path
Set up, I/O Groups, Group configuration.
Page 77
7. Function descriptions
Since the output from timer No. 1 is low on the first day, the rapping will
start 4 o’clock in the morning and last for 15 minutes. The same thing will
happen at 8:00, at 12:00 (noon), at 16:00 (4 PM) and at 20:00 (8 PM). At
midnight the output of timer No. 1 will be activated and since the coupling
AND NOT is selected there will be no output from timer No. 2 (the midnight
rapping is omitted).
External input
External input
Figure 13. Output every second hour and during forced rapping
via the external input
8. Variable list
This list contains standard default values and description of each variable
and parameter in alphabetical order. The actual installation may have cus-
tomized default settings and they may differ from the list below. All parame-
ters marked with S are saved to the non-volatile memory when using [Save
settings]. The password levels are marked with L = low, M = middle and
H = high. Master function, marked with MU is only valid when set from the
master unit.
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
Charging ratio Charging ratio S, M 1:1 - 1:999 1:1 Number/ Set up / VI-curve
The control parameter for Semi- number / Settings
pulse used during the VI-curve col-
lection.
Collector area Collector area S, M 1 - 9999 1 m2 Set up / ESP
Collector are for this field/cell
Cor time Setup / EPOQ+↓
Cor time rel Setup / EPOQ+↓
Cor time step Setup / EPOQ+↓
Coupl. Coupling of Timers to output S, M NO NO - Set up /
AND I/O Groups /
OR Timers
AND NOT
CR wait Setup / EPOQ+↓
CRC error No. of CRC errors to Fläktbus - 0- 4x109 Read Diagnostics
only
Current limit Current limit 1 - 100 Read % Master+↓
Resulting current limit of OpOpt only
Current limit Actual Pulse Current Limit 0 - T/R rating Read mA Operation
only
Current limit Pulse Current Limit S, M 0 - T/R rating x 2 1000 mA Operation+↓
Ave. of all ignited current pulses or
Process settings
/ Mode #
Current limit min Current limit minimal for opacity S, M, 0 - 50 10 % Master+↓+↓
opt. MU
Current Step Current step after spark S, M 1 - 98 15 % of actual Operation+↓
secondary or
current. Process settings
/ Mode #
Date Date S, M YYYY-MM-DD Year, Set up / System
1980-01-01- Month,
2079-12-31 Day
DI Name: The name of the input S, H 7 letters DigAux Text string Set up / Inputs
1-4
DI Type: Type of connected input signal S, H Not con., Not con Text string Set up / Inputs
Alarm-T,
Alarm-W,
Mode toggle,
MU M toggle,
Opac. cal.
Rapper,
Alarm Reset
DI01-DI16 Read the digital inputs !=ON Read Tests+↓+↓
"=OFF only
DI4 - 10 Polarity of alarm S, H !=NO o Set up / Alarm
"=NC
DO01-DO07 Digital Output H !=ON o Tests+↓+↓+↓
Only possible to change if Test "=OFF
Mode is active
Duration Duration S 0 - 999 Read Seconds Set up / VI-curve
The total time length of the VI- only
curve collection.
E2Prom Test of E2PROM H Command Tests+↓+↓+↓+↓
Page 83
8. Variable list
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
New Q Setup /
EPOQ+↓+↓
NIC NIC - 0 - 127 Read Diagnostics
Next in change only
Normally closed Polarity of operation of S, H " = Yes " = Yes Set up / Inputs
DI14, DI16, DI1, DI2 ! = No
Off Total number of T/Rs in off 0 - 999 Read Count Master
position only
Old Q Setup /
EPOQ+↓+↓
On Total number of T/Rs in on 0 - 999 Read Count Master
position only
Opac. controlled Opacity controlled M ON OFF Operation+↓
OFF or
Process settings
/ Mode #
Opacity optim. Opacity optimization S, M, ON OFF ON Master
Starts or stops the Opacity optimi- MU OFF OFF
zation.
OpOpt Clim> Opacity optimization pulse S, M 0.0 - 100.0 15 % Set up / EPOQ
current limit minimum
If the current is limited to a lower
level by the opacity algorithm, no
EPOQ reference measurement will
be performed.
Optimal Clim EPOQ Optimal Pulse Current 0 - T/R rating Read mA Set up / EPOQ
Limit only
Optimal CR EPOQ Optimal Charging Ratio 1/1 - 1/999 Read Number/ Set up / EPOQ
only number
Position: Position: Field/Cell S, M A01 - L20 A01 Text string Set up / ESP
Field/Cell T/R position in ESP
Power Control Power Control for Timer 1-6 M On, Off Off Set up /
I/O Groups /
Power control
Power Control Power Control pulse current for M 0 - T/R rating x 2 400 mA Set up /
Timer 1-6 I/O Groups /
Power control
Pr. cur. ave Primary Current Average 1.0 - 999.9 Read A Readings
only
Pr. cur. limit rms Primary Line Current Limit S, M 0 - 999.9 250 Arms Set up / T/R
Trip Trip Alarm
Operation above this limit is pre-
vented by ignition angle reduction.
The T/R is tripped if current stays
above this limit > 5 seconds.
Pr. cur. rms Primary Line Current RMS 0.0 - 999.9 Read Arms Operation
only or
Readings
Pr. volt rms Primary Line Voltage Rms 0 - 999 Read V Operation
only or
Readings
Prim Curr adjustm. Primary current adjustment zero S, H 0 - 20 10 Number Setup / T/R+↓
Primary current Primary current signal Read mA Tests+↓
(RMS) only
Primary voltage Primary voltage Read V Tests+↓
(RMS) only
Page 86
8. Variable list
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
Name in RTU The complete name & Passw. Range Def. Unit of Path to the RTU
windows description etc. value measurement window
Voltage limit ave. Secondary Voltage High Trip S, M 0.0 - 999.9 90.0 kV Set up / T/R
High trip Alarm Average
Alarm delay 1 s
Voltage limit ave. Secondary Voltage Low Trip S, M 0 - 999 5.0 kV Set up / T/R
Low trip Alarm Average
Alarm delay 20 s
Voltage limit ave. Secondary Voltage Low Warn- S, M 0 - 999 10.0 kV Set up / T/R
Low warning ing Alarm Average
Alarm delay 20 s
Vref Setup / EPOQ+↓
Vref wait Setup / EPOQ+↓
Page 90
8. Variable list
Page 91
9. Trouble shooting
9. Trouble shooting
This chapter tells you what to do when there is a malfunction. It is of great
importance that you read the following instructions before trying to do any-
thing yourself.
Warning!
Do not unscrew the enclosure and expose the circuit
board.
When sending the EPIC III for service, please send the
whole unit to ALSTOM Power. Do not remove the circuit
board from the enclosure.
This command confirms This command resets the This command sup- This key cancels the
that you have registered alarm. If the error still presses all alarm mes- alarm message and
the alarm. The alarm remains the alarm will be sages for 1 minute. returns to the previous
message will disappear reactivated. window without taking
and will not be displayed any action. The alarm
again. The alarm is how- message will disappear,
ever still active. but the alarm will be dis-
played again if active.
Cause: The primary line current has exceeded the trip alarm limit in
[Set-up] [T/R].
Solution: Check all analog input signals by setting a low value on the
Ignition angle limit and compare EPIC III readings with
external measurements, if they are okay, check the T/R.
Alarm # 10 “DC-voltage low, T/R tripped”
Cause: The secondary voltage has stayed below the low trip alarm
limit in [Set-up] [T/R] for more than 30 sec.
Solution: Check the Electrostatic Precipitator for short circuits. If it is
okay check the kV measurement signal and the alarm level.
Alarm # 11 “DC-voltage low, Warning”
Cause: The secondary voltage has stayed below the low warning
alarm limit in [Set-up] [T/R] for more than 30 sec.
Solution: Check the Electrostatic Precipitator for short circuits. If it is
okay check the kV measurement signal and the alarm level.
Alarm # 12 “DC-voltage high, T/R tripped”
Cause: The secondary voltage has exceeded the high trip alarm limit
in [Set-up] [T/R].
Solution: Check the T/R and its connection to the Electrostatic Precipi-
tator. If it is okay check the kV measurement signal and the
alarm level.
Alarm # 18 “Contactor error, T/R tripped”
Cause: The feedback from the main contactor is missing during T/R
ON condition.
Solution: Check the contactor and its connections.
9.5.1.4. NIC
NIC = Next in chain displays the token destination address for this node
(only used for advanced troubleshooting).
The controller
without top cover P4
Serial adapter
V4 555 779
CPU
Laptop
24 V AC or DC RS-232
to 1 and 13
Note!
Use the program loading tool ProgCon.exe. This program can be run in
a DOS window in any of the following operating systems: OS2, Win3.x,
Win95, Win98 or Win NT. The operation is described in the ProgCon
Manual.
Page 101
9. Trouble shooting
9.8.1. General
In order to make the ALSTOM Power Service electronic service as efficient
as possible, all units / components are handled according to the following
routine(s):
Field service is undertaken, either by the purchaser or by ALSTOM Power
Service local representative, from fault location down to unit level in compli-
ance with the instructions in the EPIC III manuals.
The faulty unit is then sent to ALSTOM Power Service for repair. Remember
to label the unit with the return address and invoice address and include a
brief description of the fault symptoms.
ALSTOM Power Service will return either a new or a exchanged unit that
has been fully tested and configurated according to the application. A service
report accompanies each returned unit.
ALSTOM Power Service maintains a record of all repair information on
faults for statistical analysis.
9.8.2. Warranty
Our products will continue to meet the demands of our customers for maxi-
mum quality and reliability both today and in the future.
ALSTOM Power Service electronic products carry the following warranty:
AI1, SECCUR, 0-1 V DC, From T/ 1 V average corresponds to T/R rated 6+, 18-
Current to ESP R shunt. average secondary current.
AI2, SECVOLT, 0-400 µA DC, From 400 µA average corresponds to T/R rated 8+, 20-
Voltage at ESP series resistor. average secondary voltage.
Ri=11.2 kΩ
0-100 µA DC if Note!
jumpers R142 and Will not change the RTU-ratio window.
R144 are removed.
Ri=41.3 kΩ
AI3, PRICUR 0-1 A AC, Ri=0.5 Ω 1 A corresponds to the rated primary cur- 9, 21
Primary current From current trans- rent of the measuring transformer.
former
AI4, PRIVOLT 0-5 V AC, Ri=ca 10 5 V corresponds to the converted rated pri- 10,22
Primary line kΩ From voltage mary voltage of the measuring trans-
voltage transformer former. EPIC uses this value for phase
reference, for calculating of consumed
power and to avoid operation on too low
line voltage.
AI5, AUX 4-20 mA, Ri=124 Ω Auxiliary input for measurement of any 11+, 23-
Auxiliary input Common mode application specific variable. The use of
input resist- this input is determined by the actual
ance=400 kΩ installed program.
Page 105
10. Technical data
AO1, Second- 4-20 mA A sec current of 0 mA will give an output of 4+, 16-
ary current 4 mA and a sec current equal to the rated
current (max allowed) will give an output of
20 mA.
Load 0-600Ω
AO2, Second- 4-20 mA A sec voltage of 0 kV will give an output of 5+, 17-
ary voltage 4 mA and a sec voltage equal to the rated
voltage (max allowed) will give an output
of 20 mA.
Load 0-600Ω
* Active status of this input can be changed at the site by selecting the
[Set up] [Alarm] RTU window.
** Active status of this input can be changed at the site by [Set up] [Inputs].
Page 107
10. Technical data
DO02, Max 50VAC/DC,1A Potential free contact for control of I/O 58, 66
I/O GROUP 1 or 230V AC, 0.5 A. group 1
DO03, Max 50VAC/DC,1A Potential free contact for control of I/O 59, 67
I/O GROUP 2 or 230V AC, 0.5 A. group 2
DO04, Max 50VAC/DC,1A Potential free contact for control of I/O 60, 68
I/O GROUP 3 or 230V AC, 0.5 A. group 3
DO05, Max 50VAC/DC,1A Potential free contact for control of I/O 61, 69
I/O GROUP 4 or 230V AC, 0.5 A. group 4
Power supply 24 V AC or DC 1, 13
±15%
10.7. Communication
NAME & descr. SIGNAL/LOAD T#
L1, ALARM Indicates during all alarm conditions. ON=tripping alarm. Flickering
lamp=warning alarm.
L5, SYNC ON when AI04-PRIVOLT is present and EPIC is locked to line frequency.
L6 Spare
Page 109
11. Word list
Appendices
EPIC III settings
Declaration of conformity
FläktBus manual
Page 112
Appendices
EPIC III SETTINGS
Plant name
Unit No. ESP Date
Set up system Set Up Alarms
Date Unit: DI 04 DI 10 DIxx Normal Alarm
Time Address DI 05 = 0V 24V
Name DI 06 = 24V 0V
Program version: Master DI 07
Address limits: DI 08
Low High DI 09
MODE SETTINGS
PARAMETERS UNITS MODE 1 MODE 2 MODE 3 MODE 4 MODE 5 MODE 6
Volt. peak lim kV
Current limit mA
Charge ratio -:-
EPOQ On/Off
Rapp intensity
Rapp all On/Off
Spark rate lim spm
Current step %
Short quenching pls
Quench mod.
Opac. controlled On/Off
Spark settings/levels Config I/O groups
Slope: Method Name: Type: Mode: DI / DO
Rise A % Arc det.level < kV 11 02
Rise B + % Arc quenching pls 12 03
Rice C First ign.angle % 13 04
Time A % 15 05
Time B + % Loop gain %
Spark sens kV/ms Level %
Set Up T/R Limit Set up Timer 1-6
Pr.curr.limit rms: Voltage limit ave: Start Repet. Run time Coupl.
Trip A Low warning kV (d:hh:mm:ss) (d:hh:mm) (hh:mm:ss)
Low trip kV T1
High trip kV T2
Ign.ang.limit % T3
T4
T5
Idle cur.limit mA Av.Curr max mA T6
Set up T/R Ratio Set up Power Ctrl
Ratio for: Timer 1 mA
Line volt. xformer V = 5V Timer 2 mA
Prim.curr. xformer A = 1A Timer 3 mA
Sec. volt. ser.res kV = 0.4 mA Timer 4 mA
Sec. curr. shunt mA = 1 V Timer 5 mA
Prim.curr. adjustm 0-20 Timer 6 mA
Set up inputs I/O Group connection
DI: Name: Type: Norm. closed:
14 Connect I/O -group 1 to Timer
16 Connect I/O -group 2 to Timer
1 Connect I/O -group 3 to Timer
2 Connect I/O -group 4 to Timer
Used node numbers: Set up ESP
EPIC III Position:
Master unit (MU) Field/Cell
RTU Collector area m²
Intentionelly blank
Intentionelly blank
Intentionelly blank
Intentionelly blank
Intentionelly blank
FläktBus
Process I/O bus
Based on the token passing concept.
Installation Instructions
ALSTOM Power reserves the right to revise any publication and to make changes to its contents, at
any time, without obligation to notify any person or entity of such revision or changes, further, ALSTOM
Power reserves the right to make improvements and changes to any and all parts of hardware and
software, at any time, without obligation to notify any person or entity of such changes.
General
The FläktBus is a general I/O communication bus for ALSTOM Power process
control systems.
This installation instruction is general for all applications of the FläktBus. For
specific application instructions please refer to the specific unit manual.
IMPORTANT
The guarantee of undisturbedFläktBus operation is valid only if all points in this
installation instruction are followed.
Installation requirements
There are a few simple rules for configuring (installation of) FläktBus;
They are all derived from certain limits that are imposed on the physical channel
to ensure optimum performance of the network.
Bus cable
As bus cable, an unshielded twisted pair cable of 80 to 150 ohms characteristic
impedance is used. An unshielded cable is used because the use of shielding will
cause degeneration of signal level and appearance at longer distances due to higher
attenuation.
The twisted pair is the lowest cost option for medium size local area networks.
A balanced twisted pair circuit is less susceptible to noise ingress from environment
and generates less radiated energy.
Minimum conductor area is 0.5 mm2 AVG 20 to fit into the type of terminals used
by ALSTOM Power.
Approved cables
The following cables are tested and fulfils the requirements for use in a FläktBus
network:
LiYY,2 * 0.5mm2
RKKB, 2 * 0.5 mm2
Belden 8442, 2 * 0.76 mm2
(Belden 8444, 4 * 0.76 mm2 , connect the unused pair to ground
at one end point)
SHINAGAWA ELECTRIC, AWM STYLE 2868, 20 AWG/2
Radox 125, 2 * 0.75 mm2 (Huber & Suhner, CH)
IMPORTANT
Use exactly the same type and dimension of cable throughout the whole
installation, even in short distances such as from terminal to connector.
Different cable types will give reflections of pulses and thereby loss of
information.
Cable length
Maximum of total cable length allowed in a single network, including connection
taps, is 1000 m. If longer cables are required please contact ALSTOM Power,
Dept. ME for latest available information about expansions.
Taps should be as short as possible, preferably less than 0.4 m. FläktBus allows up
to 115 taps of maximum 2 m, 3 taps up to 10 m and 2 taps up to 30 m.
Connection
The cable is connected to all units by screw terminals.
Termination
The bus must be terminated with 120 ohms at both ends, at which point transmitted
signals stop. Termination is very important also for short bus cable lengths. It is of
the greatest importance to install the terminating resistors at the two furthest points
of the bus, encompassing the longest distance of the bus trunk cable which may be
placed at the end of a longer tap.
} 0,4 m
Termination
120 Ω
Termination
120 Ω
1. Disconnect all EPIC, SIR, MTU and RTU from the FläktBus network eg.
unplug connector 17-32 on all EPICs and unplug the cable to all RTUs.
3. Measure the wire resistance while shorting the two conductors in the far opposite
end. The resistance should be R<L x 0.1 [ohm]. L= cable length in meters.
Make sure that all connectors are pulled tightly to ensure good connections.
ABCD
ALSTOM Power Service - Box 1233, SE-351 12 Växjö
Tel.: +46 (0) 470-76 20 00 - www.environmental.powerservice.alstom.com