UPAC™ Combustion Control

1

• UPAC Combustion Control
• Features and Capabilities

2
Company Background

• Present Organization
• Corporate Headquarters ManufacturingCleveland,
  Ohio.
• Air Switch Sales, Order Processing, Customer
  Service Cleveland, Ohio.
• Process SalesBoynton Beach, Florida,
  Cleveland, Ohio.
• Engineering DevelopmentCleveland, Ohio.
• Combustion Product Systems SalesBoynton
  Beach, Florida.
• Sales/Service Representatives111 offices in the
  USA, Canada, and Mexico.

3
Company Background

• Hays Corporation was founded in 1901 by Mr.
  Joseph Hays. Republic Corporation joined in 1972.
  Thereafter, the company was known as Hays
  Republic Corporation.
• Cleveland Fuel Equipment Company was founded in
  1942 by Mr. Norman Hahn. During the 1950's, the
  company moved to it's present location at 1111
  Brookpark Road, and its name was changed to
  Cleveland Controls in 1958.
• Cleveland Controls Hays Republic consolidated
  under Optimum Controls in 1984.
• The two corporations sold assets to UniControl
  Inc. during 1994.
• The combustion control product lines of the Hays
  Republic division and the Cleveland Controls
  division were further consolidated as Hays
  Cleveland during October 1996. The air switch
  product line remained as Cleveland Controls.

4
Company Background Significant Achievements

• Hays Cleveland is a pioneer developer of in-situ
  flue gas O2 analyzers, parallel positioning and
  metering systems, O2 trim systems, cross-limiting
  and deviation limiting strategies, and SCADA
  workstations.
• Industries Served Combustion Products
• Fire tube and Water tube Boiler Applications
• Federal State Institutions.
• Utilities analyzers, recorders, indicator.
• Process mechanical, automotive, all private
  industry.

5
Combustion Control Product Lines

• Controller Lines
• UPAC Universal Programmable Automation
  Controller
• DirectLink
• Dedicated purpose
• C-07720 Draft Control System.
• C-07200 Manual/Auto Station.
• R-09500 Draft Regulator (CDR)
• Single-loop controllers.
• Multiple loop controllers (C-07000AC Station
  Series).

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UPAC - Introduction

• The new Hays Cleveland UPAC package provides
  complete facility control, monitoring and
  communications with the accuracy, speed and
  advanced capabilities expected in high-end PLC
  and PC automation products--at a much lower than
  expected investment! With UPAC, boiler plant
  operations and other facility operations are
  fully integrated in one platform. UPAC's modular
  approach provides almost unlimited capability.
  Components include a touch screen, control unit
  and modules for analog and digital I/O.

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System Overview Hardware

• UPAC Controller CPU
• P/N 42026
• Multi-function platform
• Modular open architecture, both for industrial
  applications and for process system automation
  units.
• Maximum connectivity guaranteed by various
  interface ports RS-232, 485, Ethernet,
  Fieldbus
• Add Analog, Digital RTD Modules to configure
  system.

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System Overview Hardware

• UPAC Controller CPU Specifications
• ARM 32 bit processor
• 4 Mb flash memory, 16 Mb RAM
• 16Mbyte DRAM
• 128Kbyte SRAM with Battery Backup
• 1 CANopen master port
• 1 RS232 service port
• 1 Ethernet 10Mb programming and supervision port
  (Modbus TCP, OPC server)
• Optional Port configurations
• 1 RS485 port (Modbus RTU protocol, Master or
  Slave conf.)
• 1 RS232 port (with Modbus RTU protocol, Master or
  Slave conf.)
• 1 Profibus DP port (Slave)
• 1 CANopen port (Slave)

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System Overview Hardware

• UPAC I/O Modules
• Used With UPAC CPU for System Applications
• 8-Channel Analog Input
• P/N 42008
• 8-Channel Analog Output
• P/N 42014
• 16 Channel Digital Input
• P/N 42012
• 16 Channel Digital Output
• P/N 42016
• 4 Channel RTD or T/C input
• P/N 42010

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UPAC Mini ControllerP/N 42062

• Combines CPU with Analog Digital I/O
• CPU
• 32bit processor, ARM architecture
• 4mb Flash (2mb for programs)
• 16mb RAM, 64kb for retentive redundant variable
  memory.
• On-board I/O
• 8 Analog Inputs
• 4 Analog Outputs
• 8 Digital Inputs (24v) w/ counter function (80hz
  max.)
• 8 Digital Outputs (24v, .5A)
• Interface Ports
• RS232/485 Modbus RTU or ASCII
• RS485 Modbus RTU
• Ethernet port with Modbus TCP Server
• Other Mini controller units available

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System Overview Hardware

• UPAC Touch Screen HMI
• 12.1 color TFT screen Standard
• Other sizes available
• 800x600 pixel resolution
• Cirrus Logic 32-bit processor
• 6001 Contrast Ratio
• 128kb SRAM w/ battery backup
• NEMA 4 rated.

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Software OpenPCS

• IEC 61131-3 Programming
• Instruction List
• Structured Text
• Sequential Function Chart
• Function Block diagram
• Ladder diagram
• Standard IEC Function library
• Hays Cleveland Custom library
• Online Debugging
• Offline Simulation

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Software Indusoft Webstudio

• HMI software package
• Web interface that allows you to visualize
  screens in a Web browser
• Platform-independent application
• Online, remote application management and
  configuration (download/upload, commands, system
  and network diagnostics, and debugging)
• Screen and object password-protected run-time
  security
• Full-featured objects and dynamics with
  customizable object properties such as bar
  graphs, color, resizing, position, rotation,
  hide/unhide, commands, hyperlinks, and text
  input/output

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Connectivity
Ethernet modbus TCP/IP communications between
HMI, Controller and SCADA
CanOpen protocol to modules
RS232 serial RS485 modbus
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Connectivity
Network Switch or Gateway
Modbus TCP/IP Communications
Plant Master

• Standard Communications to SCADA is through
  Modbus TCP/IP. Other solutions such as gateways
  can be provided for interfacing with building
  management systems such as LonWorks, BacNet and
  Metasys

SCADA or Building Management System
Modbus TCP/IP Communications
Boiler 1
Boiler 2
Boiler 3
Boiler 4
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Applications - Combustion Control

• UPAC enhances operator awareness, improving
  efficiency and safety throughout the facility. It
  can control more than 10 devices for applications
  ranging from boiler combustion control to DA tank
  and condensate tank control. For example, in a
  typical parallel positioning application with O2
  trim and boiler efficiency monitoring, UPAC
  would control the gas and oil valves FD damper
  and FD damper VFD with by-pass FGR, feed water
  control valve, draft damper and boiler feed water
  pump VFD.

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Applications

• Single Package Plant Automation Control
• Linkageless Servomotor Control
• Single Point to Full Metering Combustion Control
• O2 Trim Control
• Advanced PID Control
• Boiler Lead-Lag Sequencing
• Pump Sequencing
• Feedwater Control
• Surge Tank control
• BMS Interface
• Flow Efficiency Computations
• Economizer Bypass Control

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Plant Wide Control

• Enhanced Plant wide control with the UPAC can
  include
• Plant master operations
• DA Condensate Tank level control
• Feedwater pump sequencing
• Fuel Oil Tank level monitoring
• and provide one central location for operator
  viewing and control.

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Boiler Combustion Control

• A typical parallel positioning application with
  O2 trim and boiler efficiency monitoring, UPAC
  controls the gas and oil valves FD damper and FD
  damper VFD with by-pass FGR, feed water control
  valve, draft damper and boiler feed water pump
  VFD, all while monitoring the economizer IN and
  OUT temperatures and calculating overall boiler
  efficiency.

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Boiler Control Operations (cont.)

• UPAC parallel positioning and metering
  applications use the same Hays Cleveland UL 1998
  Certified Strategies as our AC Station hardware
  platforms. For safety, both cross-limiting and
  deviation-limiting logic as well as actuator
  failure detection are employed in these
  strategies to prevent the occurrence of low
  excess air.

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Control Screen Examples Overview screen (
Home button)

• The Home button will display the Boiler Overview
  screen which gives the operator the current
  status of
• Temperatures
• Flows
• Firing rates
• Flame safeguard status
• Servo positions

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Control Screen Examples LOCAL BOILER MASTER

• The Local pressure master screen is present on
  both boiler controls and allows for either manual
  control from the operator, or automatic control
  based on boiler pressure.
• This loop is only active when LOCAL MASTER is
  highlighted below the bargraph. This is normally
  due to a plant master signal failure.

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Control Screen Examples BOILER SUB-MASTER

• From the Pop-up control, touching the OIL
  button brings up the boiler submaster screen.
• This screen gives the operator an overview of the
  fuel/air position of the boiler.
• By touching the Auto/Man button on either the
  Submaster or Oxygen trim loop allows the
  operator to take manual control of that
  particular loop.
• The Fuel /Air auto/manual buttons are disabled
  while logged in as operator.

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Control Screen Examples FEEDWATER CONTROL

• Touching the FEEDWATER button on the pop-up
  menu will display the feedwater control loop.
• This screen provides the operator with the
  current status of the
• Boiler drum level
• Steam flow
• Feedwater flow
• Actuator position
• The operator can also take manual control of the
  feedwater by touching the auto/man button and
  specifying a valve percentage.

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Control Screen Examples DRAFT CONTROL

• Pressing the DRAFT button on the operator
  pop-up menu will display the Draft Control
  screen. On this screen you will find
• Draft control setpoint
• Actual/current Draft value
• Draft Actuator Position
• Auto/Manual Status
• While logged in as Operator, you can place the
  draft control loop in either auto or manual.
  While in manual mode, the operator can select the
  position of draft actuator to be held at.

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Control Screen Examples TREND SCREENS (
)

• The Trend icon on the main menu will bring up a
  list of available trends for display. The format
  for each trend screen is the same, with the large
  trend graphic, ranges to the left side, and the
  legend for each line at the bottom of the screen.
  The check boxes in the legend area will turn on
  or off that particular line.

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Control Screen Examples HISTORICAL ALARMS (
)

• The historical alarm icon will display all the
  alarms from the last seven days that the UPAC has
  monitored. This screen will give you the date and
  time of the alarm as well as the current status.
  The legend at the bottom of the screen is the
  color legend to help identify the state of the
  alarm, whether it has been acknowledged (green)
  or has returned to normal (blue). This color
  code also applies to the Alarm Pop-up display.

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Control Screen Examples Plant Master Control
loop

• The Plant Master Screen is the main screen that
  should be displayed most of the time. At a
  glance, the user can see the header pressure,
  master loading demand signal to all the boilers,
  header steam flow, and the outside air temp.

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Control Screen Examples Feedwater Pump
Sequencers

• The Feedwater Pump screen provides the user with
  information regarding the two-pump sequencer for
  boiler 4 feedwater, and the three pump sequencer
  for boilers 1,2, 3. Included for each set of
  sequencer controls are
• Auto/Manual for each pump
• Lead pump select
• Lead and lag pumps cut-in (On) and cut-out (Off)
  points.

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Control Screen Examples DA Tank Control

• There are individual screens for each DA Tank.
  The corresponding screen will give the user the
  current tank level, tank water temperature, and
  the fill valve position.

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Control Screen Examples Condensate Tank Control

• The Condensate tank screen accessible from the
  operator pop-up menu gives the user an overview
  of condensate system. This consists of
• Makeup water flow
• Return water flow
• Transfer pumps and sequencer status
• Tank level, and
• Fill valve position (If installed).

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Control Screen Examples Fuel Oil Tank Screen

• The control system monitors the status of each
  fuel oil storage tank. The individual tank
  levels, high and low level alarms are provided
  from the Omntec fuel oil monitoring system and
  are displayed on the Master UPAC control. Access
  to this screen is from the operator pop-up menu,
  FUEL OIL TANKS button.

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Engineering Services

• We program each UPAC system for a specific
  application. Typical packages include the
  auxiliary instrumentation necessary for a
  complete system level and pressure transmitters,
  flow meters and actuators, and an optional SCADA
  workstation. Complete wiring and system
  schematics are provided.

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•  
• SUMMARY
• We greatly appreciate the opportunity to present
  this material to you. Please contact the Sales
  Department (561-734-9400) or your local Hays
  Cleveland Representative for quotations,
  specifications and sales support.