Plant Wide Controller (PWC)

The Plant Wide Controller is a state-of-the-art equipment sequencing, control and monitoring system. It combines innovative ease of operation, communication and expansion capabilities with boiler plant control application expertise. Off-the-shelf, standard applications for boiler modulating lead/lag, cooling towers and air compressors can be expanded to include additional monitoring or control additional pumps, variable speed drives and valves. Multiple communication protocols allow simultaneous communication to alphanumeric pagers, laptops via standard telephone lines and Building Automation System or SCADA Systems using a control network. The PWC is a complete plant monitoring, control and communication interface.

Overview
Application
Specifications
Documents

Overview

Easy Installation: The PWC integrates a powerful Programmable Function Controller (PFC), I/O boards, hardwired and LCD HMI, power distribution, 24VDC power supplies, external communications, isolation relays into a single wall mountable controller. No external control devices are required.

Easy to Operate: Large LCD Display, intuitive operation, setup, alarm / event summary and historical trend displays allow quick process assessment and maintenance monitoring.

Easy to Configure: PWC configuration tools maintain the look and feel of the PCC-III and offer advanced features. The PWC uses an intuitive “Blockware” configuration language with multiple block outputs and special purpose “Super” blocks that greatly simplify complex logic such as Outdoor Air Reset and boiler sequencing.

Configuration

Blockware: The PWC uses an intuitive “Blockware” configuration language.

Multiple Block Outputs: Using the Analog Input Block’s “BAD” data quality output a user may switch a loop to manual control or initiate an alarm.

Super Blocks: The PWC provides a collection of special function “Blockware” to enable simplified implementation of complex control strategies.

LCD Display Commissioning: Plant Wide Controller configurations are designed to allow commissioning to be accomplished from the controller mounted displays. Project specific tuning displays may be created to present and group key “Blockware” parameters for field tuning. Additionally, any block parameter may be edited from the front panel display using the “Parameter Edit” mode.

PWC_Edit™: The “point and click” simplicity of the PWC_Edit software makes “Blockware” configuration simple and intuitive.

PWC_Draw™: The powerful object-oriented CAD interface in PWC_Draw makes the program the ideal choice for rapid “Blockware” programming in a visual environment.

Historical Trend Display

Each Chart can display up to 4 traces, called ‘Pens’. The bottom of the screen shows the symbol and name of each Pen. Charts can be a mixture of analog and discrete data. A specific chart is displayed by selecting a Menu line that is linked to the chart. The PWC can save up to 32 analog values plus up to 32 discrete values every 1, 5, 15, or 60 seconds in the 32 Mb non-volatile memory. The 32 Mb Historical Memory can store up to 1-6 months of data (number of points monitored, sample interval, and data compression ratio affect duration).

Pen Selection: Each "Pen" trace has a unique name, chart scale, and engineering units. However, only one Pen Scale can be displayed at a time. The Up and Down Cursor Arrows may be used to display the desired Pen Scale.

Chart Cursor Readout: When a chart is first displayed, the Chart Cursor is located at the right hand edge of the screen. Using the Numeric keypad Arrows the operator may move the Chart Cursor. The number on the top line of the screen is the value of the currently selected Pen trace where it touches the Chart Cursor. Use the Cursor Up and Down Arrows to display the values for the other Pens.

Start Time Panning: Use the Cursor Left and Right Arrows to shift the Start Time backward or forward in time. The time is shifted 7/8 of the span to provide chart display overlap.

Changing Chart Span: Using the PAGE UP and PAGE DOWN keys, the operator may change the Chart Span between 8 minutes, 40 minutes, 2 hours, 8 hours, or 24 hours.

‘Span’, Start Time and Date Selection: When a Chart is selected, the first screen that appears is the “Setup Display.” This display allows the operator to easily select “Span” (width), Start Time and Date. This screen defaults to the current time and date with a 40 minute wide chart.

Application

The PWC can be configured for an unlimited number of control applications. These configurations are the most common:

Lead/Lag Controller for Improved Steam or Hot Water System Availability: Automatic Sequencing ensures that the number of boilers in service meets hot water or steam demand. Tripped equipment is automatically replaced with a standby unit.

Boiler Monitoring: Flue gas temperature, smoke opacity and boiler draft may be monitored and trended. Warning alarms and burner safety shutdown interlocks may be included.

Unmanned Boiler Plants: Provides for off-site monitoring and control using internal modem or RS485 interface. Serves as a single plant monitoring point for Building Automation Systems and personal alphanumeric pagers.

Cooling Tower Optimization: Multiple Tower Cells are sequenced and fan speed controlled with wet bulb optimization. Substantial fan and chiller electrical savings can be realized.

Improved E-Gen Fuel System Availability: Fuel pump standby sequencing, day tank level control and fuel storage tank level and leak monitoring.

Improved Steam System Availability: Condensate transfer and feed pump standby sequencing, Deaerator and Surge tank level monitoring, alarm and remote communications.

Coordinated Hot Water System Operation: Pumps, isolation valves, distribution pumps and temperature monitoring for reduced thermal stress and energy consumption.

Fresh Air Dampers, Air Compressors and Fans: Sequencing, monitoring, and control are based on the number of boilers online. A single damper failure will not prevent a boiler from firing.

Custom configurations are available to suit virtually any application.

Specifications

Mechanical

Case Size: 16½" H x 14½" W x 6¾" D

Enclosure Type: Wall Mounted

Case: 7 Slot, (CPU + 6 I/O Slots)

Weight: 55 lbs

Environmental

Operating Temp: 32° to 122° F (0° to 50° C)

Storage Temp: -20° to 150° F (-28° to 65° C)

Humidity Limits: 15 to 95% (non-condensing)

Enclosure: NEMA 1

Performance

Accuracy: 0.025% Analog I/O

Resolution: 16 bit input/12 bit output

Microprocessor: 32 bit, 128k EEPROM

Execution Cycle: Five per second

Time/Date Clock: (battery backed)

Operator Control Panel

LCD Graphic Display: 2.9" H x 5.1" W

Keyboard: Membrane, tactile feedback

Historial Data (Optional)

Displays: 8 or 40 minute; 2, 8 or 24 hour charts

Memory: Non-Volatile, 32 Mb. 48 points every 15 sec for 30 days, or greater with datacompression

Configuration

Standard Lead/Lag: Menu style, “Fill-In-The-Blanks” setup.

Control Language: Function block style, 60 functions, 600 Blocks

Security: 2 password levels

Custom Blockware Configuration Software: PWC_Edit™ spread sheet based or PWC_Draw™ graphical, editor (Windows PC Required).

Communication

Control Network

Protocol: Modbus (ASCII or RTU mode)

Speed: 1200 to 38,400 baud

Type: RS485, optically isolated

Telephone Modem: Internal Card 33,600 baud, RJ-11 Jack, Data and Pagers

Printer Port: Alarms/Logs, DB25F connector

Programming Port

Speed: 9600 to 38,400 baud

Type: RS232, DB9F connector

Electrical

Input Power: 120 VAC (+/- 15%), 12A total, 0.7A internal Built in surge suppressors

Internal Power Supply:24 VDC @ 300 mADC for external use

Input/Output Specifications

CPU Board

Analog Inputs: Quantity, 2; Type, 4-20 mADC or -20°F to +300°F Thermistor

Relay Output: Quantity, 5; Type, SPDT, 8A, ½ HP, 120VAC

Hand-Off-Auto Relay Output (HOA-ROUT) Board

Relay Output: Quantity, 5; Type, SPST, 8A, ½ HP, 120VAC

Toggle Switches: Quantity, 5 Type, Hand-Off-Auto (hard wired) SPDT, 8A, ½ HP, 120VAC

LED Indicators: Quantity, 10; Type, “Call for Operation” and “Output Status”

Auto/Manual Analog Output (A/M-AOUT) Board

Analog Output: Quantity, 5 Type, 4-20 mADC or 0-135 ohm (any combination)

Toggle Switches: Quantity, 5; Type, Auto-Manual

Control Dial: Quantity, 5; Type, 0-100% (Manual Potentiometer)

Bargraphs: Quantity, 5; Type, 0-100%, 10 segment

Discrete Input (DIN) Board

Digital Inputs: Quantity, 15; Type, 120 VAC, optically isolated

LED Indicators: Quantity, 15; Type, Status Indication

Analog Input (AIN) Board

Analog Input: Quantity, 8; Type, Universal, Switch Selectable as: 4-20 mADC, 2 wire Thermistor, -20°F to 300°F, Thermocouple Type J, 0-1200° F, 0-5 VDC, or Potentiometers Pulse, 0.01 – 4000 Hz, 0-15 VDC

LED Indicators: Quantity, 8; Type: Status Indication

Relay Output (ROUT) Board

Relay Output: Quantity, 8; Type, (2) SPDT, (6) SPST-NO, 8A, ½ HP, 120 VAC

LED Indicators: Quantity, 8; Type, Status Indication

Documents

Plant Wide Controller Specification