Spirax Sarco PLC User manual

3.635.5275.253 Ed. 1 IT - 2010
© Copyright 2010
EXPER
TISE SOLUTIONS SUST
AINABILITY
PLC Unit Control
for CSM-K Clean Steam Generators
Installation, Operation and Maintenance Manual
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.
The ATEX Directive 94/9/EC is repealed and replaced by the new
ATEX Directive 2014/34/EU with effect from 20 April 2016.

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ATTENZIONE
Lavorare in sicurezza con apparecchiature
in ghisa e vapore
Working safely with cast iron products on steam
Informazioni di sicurezza supplementari - Additional Informations for safety
Lavorare insicurezza conprodotti
in ghisa per linee vapore
I prodotti di ghisa sono comunemente presenti
in molti sistemi a vapore.
Se installati correttamente, in accordo alle
migliori pratiche ingegneristiche, sono dispositivi
totalmente sicuri.
Tuttavia la ghisa, a causa delle sue proprietà
meccaniche, è meno malleabile di altri materiali
come la ghisa sferoidale o l’acciaio al carbonio.
Di seguito sono indicate le migliori pratiche
ingegneristiche necessarie per evitare i colpi
d'ariete e garantire condizioni di lavoro sicure
sui sistemi a vapore.
Movimentazione in sicurezza
La ghisa è un materiale fragile: in caso di
caduta accidentale il prodotto in ghisa non è
più utilizzabile. Per informazioni più dettagliate
consultare il manuale d'istruzioni del prodotto.
Rimuovere la targhetta prima di effettuare la
messa in servizio.
Working safely with cast iron
products on steam
Cast iron products are commonly found on steam
and condensate systems.
If installed correctly using good steam
engineering practices, it is perfectly safe.
However, because of its mechanical properties,
it is less forgiving compared to other materials
such as SG iron or carbon steel.
The following are the good engineering practi-
ces required to prevent waterhammer and ensu-
re safe working conditions on a steam system.
Safe Handling
CastIronisa brittlematerial.If theproduct isdropped
during installation and there is any risk of damage
the product should not be used unless it is fully
inspectedand pressuretested bythe manufacturer.
Please remove label before commissioning

Vapore
Steam
Flusso
Flow
Esempi di esecuzioni corrette ( ) ed errate ( ) sulle linee vapore:
Steam Mains - Do's and Dont's:
Flusso
Flow
Prevenzione dai colpi d’ariete - Prevention of water hammer
Scarico condensa nelle linee vapore - Steam trapping on steam mains:
Intervalli di 30÷50 m. intervals
Pendenza - Gradient 1:100
Vapore
Steam Gruppo di scarico
Trap set
Condensa - Condasate
Pendenza - Gradient 1:100
Gruppo di scarico
Trap set
Gruppo di scarico
Trap set
Condensa - Condasate
Condensa - Condasate
Vapore
Steam

Prevenzione delle sollecitazioni di trazione
Prevention of tensile stressing
Evitare il disallineamento delle tubazioni - Pipe misalignment:
Installazione dei prodotti o loro rimontaggio post-manutenzione:
Installing products or re-assembling after maintenance:
Evitare l’eccessivo serraggio.
Utilizzare le coppie di serraggio
raccomandate.
Do not over tighten.
Use correct torque gures.
Per garantire l’uniformità del carico e dell'allineamento,
i bulloni delle ange devono essere serrati in modo
graduale e in sequenza, come indicato in gura.
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.

Dilatazioni termiche - Thermal expansion:
Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una
consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.
Guide
Guides
Distanza breve
Short distance
Punto di ssaggio
Fixing point
Movimento assiale
Axial movement
Distanza
media
Medium
distance
Tiranti limitatori
Limit rods
Piccolo
movimento
laterale
Small
lateral
movement
Piccolo
movimento
laterale
Small
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Guide
Guides
Guide
Guides
Guide
Guides
Punto di ssaggio
Fixing point
Tiranti limitatori
Limit rods
Movimento assiale
Axial movement

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Table of Contents
Limits of Responsability Pag. 4
Control Unit Pag. 6
Location and identication of components Pag. 7
Control Features Pag. 8
External Connections Pag. 9
Display and Keyboard Pag. 10
Initial Screen Pag. 11
Manual Mode Pag. 13
Manual set-up of feed water Pag. 14
Manual control of the Pressure Pag. 17
Manual control of the Bottom Blowdown Valve Pag. 21
Automatic mode Pag. 22
Pressure control Pag. 24
Level setup Pag. 25
Set-up of the bottom blowdown period Pag. 26
General considerations in Automatic Operation Pag. 28
Alarms and Blocks Pag. 29
Conguration Pag. 31
Parameters protected by a password Pag. 34
Repairs Pag. 39

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Limits of Responsability
This manual covers the procedures for the Installation, Operation and Maintenance of the PLC unit for the
control of indirect Steam Generator Systems. This manual is intended to be as complete and up to date as
possible. SPIRAX SARCO reserves the right to update it at any time and without obligation to notify product
owners of such changes.
Responsabilities
SPIRAX SARCO is not responsible for inaccuracies in specications, procedures and / or the content of
other product literature supplied by the manufacturers of components used on SPIRAX Steam Generators.
For manufacturing and control of Steam Generators SPIRAX SARCO utilizes only high quality components.
In case of a complete supply of a system SPIRAX SARCO will take full system responsibility. Where instead
SPIRAX SARCO has no direct control on other manufacturers and their quality level the responsibility will
be assumed only for the supplied parts.
Note: the symbol points out the “Warnings”
SPIRAX SARCO is not responsible for injury to personnel or product damage due to improper
actions and procedures used for installation, operation and maintenance.
These procedures should only be performed by trained and certied personnel. Prior to attempt these proce-
dures the personnel should completely and carefully read and understand this manual and other applicable
manuals for all supplied products. All personnel should also pay strict attention to all Notes, Cautions and
Warnings described in this manual.
In case SPIRAX SARCO supplies a Steam Generator without any auxiliary control equipment,
this manual is applicable only for the Generator part. The main contractor of the system will then
assume the responsibility for the supplied components, for their relevant manuals and for the com-
plete generation system.

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Information
This manual has been conceived as an operating guide for the control unit of SPIRAX SARCO Steam
Generators. Since every unit is built according to customer specications, the manual instructions might
sometimes appear too general and incomplete. Additional specic notes will be supplied when the proce-
dures substantially differ from those included in the standard manual.
Should this manual not respond to all questions or the procedures are not clearly comprehensive,
the user is invited to contact SPIRAX SARCO for any clarication.
Warnings
In the following pages several points with specic warnings are listed. Warnings are moreover repeated
when the procedures refer to areas of potential hazard.
All warnings and relevant precautions have to be carefully studied and followed to reduce the risk of injury
during operations of Installation, Start-up and Maintenance.
Every product or system using steam, diathermic oil, superheated water under pressure or
electric power can represent a potential hazard to personal injury when procedures are not properly
followed.
The simultaneous presence of water and electric power can generate hazardous conditions.
Areas with potential hazard
1. All connections and electric cables
2. All steam lines, valves, joints and pressure controllers
3. All steam lines, diathermic oil or superheated water, valves, joints and pressure controllers
Connections of main power supplies
All procedures for the connections of main power supplies have to be performed by trained and qualied
electrical personnel. The PLC unit for the control of SPIRAX SARCO Steam Generators are designed to be
installed in covered locations, unless otherwise specied by the customer.
Make sure to disconnect power before starting any operation of installation or maintenance.

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Control Unit
Description
The control and safety unit is a PLC type intelligent equipment designed to start-up, control and operate
indirect steam generation systems, either in local mode or by ultimate means of a remote system.
PLC
S1
L1
PE IG
BC
L2
PRB

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Location and identication of components
Front Panel
IG: Main power switch
This power disconnect device is equipped with a door locking handle that breaks the three phases of the
input voltage and allows to open the cabinet door only when is in “OFF” position.
Attention: the user must provide an external stop circuit outside of the drive circuitry. The circuit
must disable the system in case of improper operation or for unit maintenance. Failure to observe
this precaution could result in a hazardous situation or in body injury for employed personnel.
PE: Pushbutton
Emergency stop pushbutton.
L1: Led Indicator
When lit (white light) it indicates that the unit is powered.
S1: Selector
Two (lockable) position selector to select:
- Manual Control
- Automatic Control
PRB: Pushbutton
Manual reset pushbutton (after shutdown)
L2: Led Indicator
When lit (blinking red light) it indicates that the system is stopped due to intervention of one or more alarms.
BC
Measurement Unit of Total Dissolved Solids (TDS).
PLC
PLC Control Unit

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Control Features
The PLC based unit is designed to provide control of Pressure, Water Level, Discharge and operation of
Blow-down function and of all Alarm limits of SPIRAX SARCO indirect steam generators.
The control unit is equipped with a video interface displaying screens with graphics of the generator and
also selective parts, e.g. error and functional messages, etc.
Set point values can be displayed and modied during operation using functional keys.
Two LED’s respectively indicate the RUN status of the program (Green light) and the presence of one alarm
at least (Red light). The control unit enables the setting of all operating parameters by means of different
display screens. The PLC also provides a visual alarm signal.
In addition to the automation of a single generator, the system allows the achievement of computerized
networks with PC’s, PLC’s and microprocessor based systems thus permitting a high level of integration
among automation systems applied to the various units present in the plant. The supervision system can
be considered in terms of visualization of data relevant to equipment, conguration and production control.
The control unit is equipped with a main power switch and is housed in a metal cabinet with protection degree
IP54 and with dimensions of 700x500x250mm.
Screen 1

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External Connections
All electrical connections have to be carried out by trained and qualied installation electricians. It is impor-
tant to verify that the main power switch is in “OFF” position before connecting the line voltage. The installer
has to route the power cables, reach the terminals located on the main power switch mounted on the panel
and run the ground wire to the earth ground terminal. For the feed voltage see the electric diagram inside
the control board.
Attention: Prior to drilling a hole in the panel for the connection of power cables, carefully open the
panel door and verify there are no impediments inside the panel. Make sure to avoid contacts with drilling
residuals or with any mechanical part left on the base or on the transformer or on the switch.
Main Power Supply
Input voltage: 220 V ac – 50 Hz
Output contacts: 3 A – 220 V for inductive loads
Output contacts: 6 A – 220 V for resistive loads
Operational ambient temperature: Min –20°C, Max 55 °C
Relative Humidity (RH): from 5% to 95% non condensing
LCD Display with energy saving dimmer function: 4 lines each with 16 characters

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Display and Keyboard
Nine keys are located on the lower part of the panel just below the display.
Graphic Display
RESET
ESC
Alarm Led
Run Led
START
STOP
^
^
^ ^
Screen 2

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Initial Screen
Powering the unit the display will show this screen:
Pressing the
^
key Screen 4 will be displayed.
Note: in this image is shown the rmware installed
Screen 3
Screen 4

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Pressing again the
^
key the Screen 4 will be displayed where in sequence it is possible to select one out
of four operation modes (Manual – Automatic – Historical alarms – Parameters).
Press the
^
and
^
keys to move down and up for selection of the desired operation mode. Press then the
OK key to conrm and store the choice and enter the selected mode.
Screen 5

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Reactivate the previously pressed emergency key to restart the normal operation.
"Manual" Mode
Manual operation mode: general considerations
Upon selection of the manual operation mode and by pressing
^
and
^
keys, it is possible to scroll and
access into subsequent pages in order to insert other functions, simultaneously maintaining in operating
condition the previously selected functions.
Otherwise, when it is necessary to disable the selected function before enter others, press the
^
-(OFF)
^
key till the achievement the "0" value of the dened set.
Press ESC key to clear all operating functions with a single operation, and to return to the screen displayed
in Screen 5 (operating mode).
During manual operations the block (latching) alarm devices (safety) are active and operating.
All the working functions can be resetted by pressing the emergency key, and the alarm condition is displayed.
Screen 6

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Screen 7
Manual set-up of feed water
The level transmitter tted into the equipment has an employment eld dened with the
specication of each steam generator. It is essential that the employment eld of the transmitter is
the same of the one setted to the controller.
There are different control typologies:
1) ON-OFF operation level (Sensilevel) and ON-OFF feedwater valve
Select the next screen by setting the “automatic-manual” key in “manual” position
To activate the valve opening, push the button + (ON), and press – (OFF) to shut it.
During the manual operating, when the functioning level is achieved is displayed on the screen but it doesn’t
control the valve shutting. The isolated valve condition is achieved by pressing the – (OFF) button.
The open valve condition is identiable on the screen by the valve’s image fully pointed out and the notice
“feed water” in reverse.
In any case, manual operation is provided with block (latching) alarm devices. These alarms will close the
valve while on the screen will be displayed the typology of the anomaly and the lighting of the warning light.
For latching alarms, before opening the valve it is necessary to eliminate the cause of the alarm, then push
the button in reset blocks front panel.

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Press the + (ON) key to activate the pump and the – (OFF) key to stop it.
During the manual operation the functioning level is displayed when achieved, but it doesn’t control the stop
of the pump. The stop pump condition is obtained by pushing the – (OFF) key. The motion pump condition
is identiable on the screen by the pump’s image outlined and the notice is without reverse.
In any case, manual operation is provided with block (latching) alarm devices. These alarms will provide the
stop of the pump while the screen will display the typology of the anomaly and the lighting of the warning light.
For latching alarms, before activating the pump it is necessary to eliminate the cause of the alarm, then
push the reset blocks button.
3) Continuous operating level (4-20 mA) and ON-OFF water control valve
Act as step 1).
4) Continuous operating level (4-20 mA) and water pump
Act as step 2).
2) ON-OFF operation level (Sensilevel) and water pump
Select the next screen by setting the “automatic-manual” key in “manual” position:
Screen 8

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5) Continuous operating level (4-20 Ma) and modulating water control valve
Select the next screen by setting the “automatic-manual” key in “manual” position:
To activate the valve opening push the button + (ON), and press – (OFF) to shutoff it.
Repeatedly pushing the + button it is possible to choke the valve opening (in %) to obtain the continuative
level control also in manual mode.
During manual operation, the functioning level, when reached, is displayed (in mm) but it doesn’t control
the shutoff of the valve. The shutoff valve condition is obtained by pushing the button – (OFF) up to the “0”
percentage. The open valve condition is observable on the screen by the valve’s image fully pointed out
and the notice “feed water” in reverse.
The shutoff valve condition is identiable on the screen by the valve’s image contour outlined, and the notice
is without reverse.
In any case, manual operation is provided with block (latching) alarm devices. These alarms will close the
valve while on the screen will be displayed the typology of the anomaly and the lighting of the warning light.
For latching alarms, before opening the valve it is necessary to eliminate the cause of the alarm, then push
the button in reset blocks front panel.
Screen 9