advanced control package furnace pass balance temperature ... · 03 /98 furnace pass balance 1...

Advanced Control Package

Furnace Pass BalanceTemperature Control

User’s Guide

TP-SWFPB1Revision 2.1

3/98

AP13-600

iv Furnace Pass Balance 03/98

Honeywell Inc.

Copyright, Notices, and Trademarks

© Copyright 1996 by Honeywell Inc.

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the impliedwarranties of merchantability and fitness for a particular purpose and makes no express warranties except asmay be stated in its written agreement with and for its customer.In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The informationand specifications in this document are subject to change without notice.

Robust Multivariable Predictive Control (RMPC) is a U. S. trademark, and TDC 3000 and TotalPlant are U. S.registered trademarks of Honeywell Inc.

Other product names are trademarks of their respective owners.

HoneywellIndustrial Automation and Control

Automation College2820 West Kelton Lane

Phoenix, AZ 85023

(602) 313-5669

03/98 Furnace Pass Balance v

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Table of Contents

COPYRIGHT, NOTICES, AND TRADEMARKS ................................................................................ IV

TABLE OF CONTENTS............................................................................................................... V

SECTION 1 -- OVERVIEW ..........................................................................................................11.1 About Furnace Pass Balancer............................................................................1

Definition .....................................................................................................1Application...................................................................................................1Calculation...................................................................................................1Incentives ....................................................................................................1Package Description ....................................................................................1

1.2 Process Diagram ...............................................................................................21.3 Functional Description .......................................................................................3

Equations Used............................................................................................31.4 Control Constraints ............................................................................................5

Overview .....................................................................................................5Minimum pass flow ......................................................................................5Maximum pass flow rate of change..............................................................5Maximum (percent) imbalance of any pass flow from the averagepass flow......................................................................................................5Pass flow controller not maintaining SP .......................................................6Individual pass flow controller windup ..........................................................6Individual pass flow controller setpoint limit..................................................6Individual pass flow controller RATIO limit ...................................................6

1.5 Skin Temperature Checking ..............................................................................7Furnace Pass Coking...................................................................................7Conditions....................................................................................................7

1.6 Hardware and Software Requirements..............................................................81.7 Instrumentation Requirements (Process Inputs).................................................9

SECTION 2 -- INSTALLATION PROCEDURE................................................................................ 112.1 Overview......................................................................................................... 112.2 Preparation for Installation............................................................................... 12

PBAL Directory .......................................................................................... 12Procedure .................................................................................................. 12

2.3 Custom Data Segment (CDS) and Parameter List (PL) Installation.................. 142.4 Building the Furnace Pass Balancing Points .................................................... 15

Procedure .................................................................................................. 15Notes for Building Points............................................................................ 16

2.5 Graphics Installation ........................................................................................ 17Procdure.................................................................................................... 17

2.6 Input Configuration .......................................................................................... 19Configure Inputs ....................................................................................... 19

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Note for input configuration ........................................................................202.7 Linking CL Programs .......................................................................................21

Procedure ..................................................................................................21

SECTION 3 -- DETAILED DESIGN.............................................................................................233.1 Overview ........................................................................................................233.2 Point Structures ...............................................................................................24

Points.........................................................................................................24Calculations ...............................................................................................24

3.3 Process Inputs .................................................................................................26Custom Parameter List...............................................................................26

3.4 Configuration Inputs.........................................................................................27User Inputs.................................................................................................27

3.5 Calculation Outputs .........................................................................................30Custom Parameter Outputs........................................................................30

3.6 Control Outputs................................................................................................34Control Outputs..........................................................................................34

3.7 Conversion of Engineering Units......................................................................353.8 Filtering ...........................................................................................................36

SECTION 4 -- STATUS CODES ...............................................................................................374.1 Overview .........................................................................................................37

Overview ...................................................................................................374.2 Pass-Specific Major Error Codes .....................................................................38

Major Error Codes......................................................................................384.3 Pass-Specific Limit Condition Codes................................................................39

Limit Condition Codes ................................................................................394.4 General Major Error Codes ..............................................................................41

Major Error Codes......................................................................................414.5 Minor Error Codes...........................................................................................42

Minor Error Codes......................................................................................424.6 Message Storage Point Error Codes ................................................................43

SECTION 5 - MESSAGING .....................................................................................................455.1 Overview .........................................................................................................455.2 Operator Messaging.........................................................................................465.3 User Schematic Messaging..............................................................................475.4 Engineer Log Messaging..................................................................................485.5 Configuration Inputs for Message Storage Point ..............................................495.6 Default Message Strings ..................................................................................50

Pass-specific Major Error Messages...........................................................50Pass-specific Limit Condition Messages.....................................................51General Major Error Messages...................................................................52

SECTION 6 -- TUNING PARAMETERS ........................................................................................556.1 Adjusting Tuning Parameters ...........................................................................55

SECTION 7 -- USER AND CONFIGURATION SCHEMATICS .............................................................577.1 Overview ........................................................................................................57

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Overview ................................................................................................... 577.2 User Schematic ............................................................................................... 58

Overall Status Message............................................................................. 58Button Targets ........................................................................................... 58Pass Flow Table ........................................................................................ 59Pass-specific Message Table..................................................................... 59

7.3 Help Schematic ............................................................................................... 617.4 Configuration Schematic ................................................................................. 627.5 Message Maintenance Schematics................................................................. 64

Non-Pass-specific Error Message Maintenance Schematic ........................ 64Pass-specific Error Message Maintenance Schematic................................ 65Pass-specific Limit Message Maintenance Schematic................................ 65Pass-specific Limit Message Maintenance Schematic................................ 66

7.6 Operator Message Maintenance Schematic..................................................... 67

SECTION 8 -- OPERATING INSTRUCTIONS ................................................................................ 698.1 Overview......................................................................................................... 698.2 Turning the Pass Balancer On .......................................................................... 708.3 Turning the Pass Balancer Off.......................................................................... 718.4 Miscellaneous Features .................................................................................. 72

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viii Furnace Pass Balance 03/98

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03/98 Furnace Pass Balance 1

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Section 1 -- Overview

1.1 About Furnace Pass BalancerDefinition A balanced furnace is defined as having equal outlet temperatures for all passes.Application A pass balancer adjusts the flow rate through each furnace pass, while

maintaining the total flow rate, to achieve equal pass outlet temperatures. Theseequal pass outlet temperatures are equal to the weighted average pass outlettemperature. This temperature remains unchanged by the act of pass balancing.

Calculation The Furnace Pass Outlet Temperature Balancer package calculates the RATIOparameters, for each individual furnace pass flow controller, required to achieveequal pass outlet temperatures.

Incentives A furnace performs most efficiently and cost effectively if all pass outlettemperatures are equal. Pass balancing a furnace:

1.Reduces cracking and coke laydown in a furnace by reducing the maximumpass outlet temperature.

2.Reduces furnace fuel consumption.3.Encourages operator acceptance of advanced control.

Package

Description

The furnace pass outlet temperature balancing package includes the following:

Object file code of the pass balancing program.Standard user and configuration schematics.Messaging feature to help configure and monitor a pass balancing application.

Overview

1.2 Process Diagram

2 Furnace Pass Balance 03/98

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1.2 Process DiagramThe following two figures show the same furnace, before and after passbalancing:

Un-Balanced Furnace

Balanced Furnace

TI

Flow: 100Ratio: 1.0

695

TI 665

TI 657

TI 683

Flow: 100Ratio: 1.0

Flow: 100Ratio: 1.0

Flow: 100Ratio: 1.0

Total Flow: 400 Weigted Average Outlet Temperature: 675

FC

TI

Flow: 105.0Ratio: 1.05

675

TI 675

TI 675

TI 675




Total Flow: 400

FC

FC

FC

FC

FC

FC

FC

FC

FC4-Pass Fired

Furnace

4-Pass Fired

Furnace

Weigted Average Outlet Temperature: 675

Overview

1.3 Functional Description


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1.3 Functional DescriptionThis section describes the following items of the Furnace Pass OutletTemperature Balancer package:

Equations UsedControl ConstraintsSkin Temperature Checking (Optional)

Equations Used The furnace's weighted outlet temperature is calculated using Equation 1:

TWA = _ (Fi • Tout,i) / _ FiWhere:

TWA = Furnace weighted average outlet temperature.

_ (Fi • Tout,i) = The sum of the products of each pass flow setpoint timesits outlet temperature.

_ Fi = The sum of all pass flow setpoints.

Equation 1

The individual pass flow controller ratio parameters are calculated from processinputs using the Honeywell Hi-Spec Solutions furnace pass outlet temperaturecalculation, as shown in Equation 2. This algorithm is essentially an integral-only control algorithm:

Ideal_chgi = KG • (Tout,i – TWA) • Fi / [(TWA – Tin) + (Kv • Hv / Cp)]

Where:

Ideal_chgi = Calculated ideal1 flow SP change for furnace pass i.

KG = Controller gain factor.

Tout,i = Outlet temperature for pass i.


Fi = Flow controller set point for pass i.

Tin = Furnace inlet temperature.

Kv = Weight fraction of the fluid vaporized in the furnace.

Hv / Cp = Ratio of the heat of vaporization of the fluid vaporized divided bythe heat capacity of the fluid.

Equation 2These ideal pass flow moves are then checked against various limits (see

1 Ideal refers to the flow change calculated prior to limit checking.

Overview1.3 Functional Description


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"Control Constraints", below), and clamped as is appropriate, so that no limitsare violated. The flow moves are then re-normalized (so that the sum of themoves is zero), and then converted to new pass flow ratio values prior tooutputting.The process gain factor for the furnace, defined below, is output (as customparameter KMF) for the user's information. It is useful in that when divided bythe value for a given pass flow, the process gain of the system (the change inpass outlet temperature per unit change in pass flow) is produced.The process gain factor is estimated as shown in Equation 3:

KMF = [(TWA – Tin) + (Kv • Hv / Cp)]

Where:

KMF = Estimated process gain factor for the furnace.


Tin = Furnace inlet temperature.

Kv = Weight fraction of the fluid vaporized in the furnace.

Hv / Cp = Ratio of the heat of vaporization of the fluid vaporized divided bythe heat capacity of the fluid.

Equation 3

Overview

1.4 Control Constraints


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1.4 Control ConstraintsOverview The pass flow moves produced by the pass balancer are checked to ensure that

they do not violate any process constraints, and that the result of implementingthe moves is a reasonable course of action.It is noted that all constraints take priority over trying to balance the furnace. Ifmultiple constraints exist for a given pass, then the most limiting constraint isobserved. In complying with constraints, it is still necessary that the net effectof all pass moves is to maintain a constant total furnace flow.Following is a list of constraints and conditions that are checked:

Minimum pass

flow

This constraint is user-specified. Moves are clamped such that this limit is notviolated.If a given pass is below the low limit, then any positive move calculated isaccepted. Negatives moves are zeroed-out.This check is made to ensure that the pass balancer does not drive the pass flowsbeyond a reasonable condition. This could possibly occur if a thermocouple isgiving a false reading. A pass with a low flow is most susceptible to coking.

Maximum pass

flow rate of

change

This constraint is user-specified. Moves are clamped such that this limit is notviolated.

Maximum

(percent)

imbalance of any

pass flow from

the average pass

flow

This constraint is user-specified.

The following condition is checked for each pass flow controller: 100 • (SP – SPavg) / SPavg . Moves are clamped such that the condition for any pass doesnot violate the user-specified limit. Both positive and negative directions arechecked.

If a given pass is beyond the limit, then any move calculated towards theaverage pass flow is accepted. Moves away from the average are zeroed-out.

Again, this check is made to ensure that the pass balancer does not drive thepass flows beyond a reasonable condition. This could possibly occur if athermocouple is giving a false reading.

Overview

1.4 Control Constraints


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Pass flow

controller not

maintaining SP

This constraint is user-specified. Only one limit is provided; it must be used foreach pass flow controller

The following condition is checked for each pass: 100 • (PV – SP) / SP . Bothpositive and negative directions are checked. If a given pass is beyond the user-specified limit, then any move calculated towards the pass flow PV is accepted.Moves away from the PV (that would worsen the condition) are zeroed-outThis check is made to see if any pass flow controller, for whatever reason, ishaving trouble maintaining setpoint. It is treated just as if the system hadflagged a windup condition. This will often occur as a valve begins to saturate,for example. It may be some time before the system flags a wind-up condition.

Individual pass

flow controller

windup

If any of the individual passes have reached a set point or output windupcondition and the calculated ideal move for that pass would worsen the windupcondition, then the move for that pass is zeroed-out. If a move is calculated thatwould improve the windup condition, then it is accepted.

Individual pass

flow controller

setpoint limit

All moves generated by the pass balancer are checked to make sure that theyrespect the setpoint limits on the individual pass flow controllers. If the setpointlimit for a given pass flow would be violated, the move is clamped at the limit.

Individual pass

flow controller

RATIO limit

All moves generated by the pass balancer are checked to make sure that theyrespect the RATIO limits on the individual pass flow controllers. If the RATIOlimit for a given pass flow would be violated, the move is clamped at the limit.

.

Overview

1.5 Skin Temperature Checking


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1.5 Skin Temperature CheckingFurnace Pass

Coking

An optional check has been included in the pass balancing package in order tohelp detect furnace pass coking. This check requires that a complete, symmetric

set2 of pass skin temperatures be available.Coking service is typically defined as a furnace operating at a combined outlettemperature of 600 to 650 °F (or greater). Coking is an important issue toconsider in pass balancing, because pass balancing can make matters worse in apass that is coked. This is because a pass that is coked will tend to have arelatively low outlet temperature. Pass balancing will tend to reduce the cokedpass' flow, thereby causing an increase in coking rate.The skin temperature check involves comparing a given pass' outlet and skintemperatures with their respective furnace averages. For example, if a givenpass' outlet temperature is lower than the average, but its skin temperature ishigher than the average, this can be taken as a sign of coking, and passbalancing should be suspended.

Conditions Specifically, a given pass is flagged as apparently coking if the following threeconditions are all true:1) Its skin temperature is hotter than the furnace average skin temperature.

2) Its outlet temperature is cooler than the furnace average outlet temperature.

3) The difference between its skin temperature and its outlet temperature is'significantly' greater than the average temperature difference for thefurnace.

'Significantly' is defined by the user, using the "skin temperature deadband"displayed on the Configuration Schematic. This "skin temperaturedeadband" defines the margin by which the pass' temperature difference hasto exceed the average temperature difference.

If any pass is flagged as apparently coking, then the pass balancing routine isstopped (no control moves output).

2 A symmetric set refers to the fact that, in order for the skin temperature check to

be reasonable, all pass skin temperatures used should be located near the sametube position.

Overview

1.6 Hardware and Software Requirements


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1.6 Hardware and Software RequirementsThe following table describes the hardware and software requirements for thefurnace pass balancing package:

Requirement Description

Hardware Platform TDC 3000 AM

Special Boards None

Other Computing Systems None

LCN Release 400 or greater

AM Load Modules None

US Load Modules None

Other Packages Required None

Other Related Control Applications Master Flow Controller

Overview

1.7 Instrumentation Requirements (Process Inputs)


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1.7 Instrumentation Requirements (Process Inputs)The following table describes the hardware and software requirements for thefurnace pass balancing package:

The following table shows all of the instrumentation inputs used by the FurnacePass Outlet Temperature Balancer package:

Process Input3 Required Optional Comments

Pass flow controllers X These inputs are required per furnacepass. Pass flow controllers should beconfigured using PID control algorithm,with a Ratio/Bias Option (RBOPT) of

AutoRatio.Pass outlet temperatures X These inputs are required per furnace

pass.Pass skin temperatures X Skin temperature checking is an

optional feature of the package. Ifused, the skin temperatures are

required per furnace pass, and theymust be a symmetric set.

Furnace inlet temperature X This input is only used to calculate theprocess gain of the system. If not

available as an instrument, the usershould configure a Numeric point to

manually enter a typical value.Total (Master) Furnace

Feed Flow controllerX This input is not used by the pass

balancing routine. It is only displayedon the supplied user schematic.

3 . The Furnace outlet temperature balancer can be configured for up to eight passes

Overview

1.7 Instrumentation Requirements (Process Inputs)


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Section 2 -- Installation Procedure

2.1 Overview

This section describes the installation procedure for this package on the TPSSystem.

The following topics are covered:

Topic See Page

Preparation for Installation 2

Custom Data Segment (CDS) and Parameter List (PL) Installation 3

Building the Furnace Pass Balancing Points 5

Graphics Installation 7

Input Configuration 9

Linking CL Programs 10

Note that, for a successful installation, it is recommended that the installationtopics be followed in the order listed above.

The instructions that follow are intended to be for someone who has some basicknowledge of the TDC3000. The instructions also assume that this is a firsttime installation, and not a re-installation or upgrade.

If you are reinstalling or upgrading this software, previous implementations ofthe furnace pass balancer may need to be rebuilt. Consult your resident systemexpert prior to installation. The main area of concern is overwriting thepreviously installed custom data segments (CDS’s) that may be used by currentapplications.

Installation Procedure

2.2 Preparation for Installation


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The furnace pass outlet temperature balancing package is composed of thefollowing files located in the PBAL directory.

PBAL Directory

File Name Description

HSS_DDB.DF Display Database Definition file

PBAL.AO Pass balancing object code.

PBAL_SK.AO Skin temperature check object code

PBAL_CDS.CL Pass balancing point CDS

PBALMCDS.CL Message point CDS

PBAL.DS User schematic

PBAL_CFG.DS Configuration schematic

PBAL_HLP.DS Pass balancing operator help schematic

PBAL_MSG.DS Message configuration schematic

PBAL.EB Sample point data

BC_CONFG.EB Optional EB for configuration of Basic Controllers(BC’s)

Procedure To prepare for the installation of this package, follow these steps:

1) Gather removable media (Bernoulli or floppy disk) containing thedirectory PBAL and the files listed above.




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2) Set the Universal Station to Engineer Personality or Universal Personality.

3) Call up the Engineer Main Menu display and select "Command Processor"

4) From the Command Processor display, make a back-up copy of thedirectory and files using a US with drives 'm' and 'n' used as follows:

To create a PBAL directory on the back-up type the following:

CD $Fn>vol_dir> PBAL [ENTER]

To copy the pass balancing files to the back-up:

COPY $Fm>PBAL>*.* $Fn>PBAL>= -V -D [ENTER]

'vol_dir' is the volume name assigned to the back-up media.'$Fm' is the drive with the source media and '$Fn' is the drivewith the target media. Remember that the target media mustnot have the write protection tab in the protect position.

5) Set the volume pathnames. From the Command Processordisplay, type 'SP [ENTER]' to access the Modify Volume Pathsdisplay. From the this display, enter the following:

CL SOURCE/OBJ: $Fn>PBAL>

CL CUSTOM GDF: NET>CDSG> (or user's choice)

CL PARAM LISTS: NET>CL> (or user's choice)

USER DEFLT PATH: $Fn>PBAL>

When finished, press [ENTER] and then select 'EXIT' to return to theCommand Processor display.


2.3 Custom Data Segment (CDS) and Parameter List (PL) Installation


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2.3 Custom Data Segment (CDS) and Parameter List (PL)Installation

To install the Custom Data Segments and Parameter Lists for this package, dothe following:

Compile source files. From the Command Processor display, compile theCDS files, PBALMCDS.CL and PBAL_CDS.CL:

CL PBALMCDS -UL [ENTER]

CL PBAL_CDS -UL [ENTER]

NOTE: If you are upgrading this package the -OCD option will also berequired. However, DO NOT USE this option unless you know what you aredoing.


2.4 Building the Furnace Pass Balancing Points


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2.4 Building the Furnace Pass Balancing PointsProcedure To build the furnace pass balancing points, follow these steps:

1) Modify the Exception Build file, PBAL.EB. PBAL.EB includes three points,named, PBAL_TIN (furnace inlet temperature as a Numeric point), PBAL_MSG(message point), and PBAL (pass balancer point). Note that if furnace inlettemperature point already exists, you do not need to configure the PBAL_TINnumeric point. From the Command Processor display:

ED PBAL.EB [ENTER]

For each point, edit the template as follows. Refer to the AM Parameter ReferenceDictionary for valid entries:

&N point_name (required for all)

UNIT = unit_number (required for all)

PTDESC = "point descriptor text" (required for all)

KEYWORD = "keyword" (required for all)

EUDESC = "eng unit" (not required for PBAL_MSG)

PERIOD = as desired (required only for PBAL)

These parameters cannot be changed from a point detail display.

Notes regarding setting PERIOD (pass balancing execution frequency):

• The furnace pass balancing package should be executed no moreoften than it takes the process to reach steady state. Time to steadystate is defined as the time it takes a pass outlet temperature tocome to a new steady state value after that pass's flow has beenchanged.

If the furnace pass balancing is executed faster than this, it is likely that theprocess will become unstable. Either increase the execution period of the passbalancer, or reduce the controller gain factor (K).

• The master flow controller for the system should be run faster than the pass


2.4 Building the Furnace Pass Balancing Points


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balancing routine. The pass flow controller setpoint calculation, whichinvolves using the RATIO values determined by the pass balancer, is onlyexecuted as often as the master flow controller is executed.

2) From the Engineering Main Menu, select the Builder Commands target.From the Builder Commands display, select the Exception Build target.

Fill in ports as:

REFERENCE PATH NAME: $Fn>PBAL

Load Entities (select target)

Pathname for SOURCE file: PBAL.EB

Pathname for IDF file: PBAL

Selection List: (To load all three points, leave blank; otherwise,enter the desired point names here, asedited in the EB file, above. If a furnaceinlet temperature exists, enter only the passbalancer and message points).

Optional pathname forTEMPLATE

(leave blank)

[ENTER]

Depending on your LCN software release, you may get "ENTITY DOESN'TEXIST" errors for the pass flow, outlet temperature, and skin temperaturetagnames, but the points will load:

Notes for

Building PointsNotes for Building the Furnace Pass Balancing Points:

• Each furnace to be balanced requires its own pass balancingpoint.

• Only one message point is required per LCN.

• Each furnace for which an inlet temperature measurement is notavailable requires a Numeric inlet temperature point.


2.5 Graphics Installation


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2.5 Graphics InstallationProcdure To build the furnace pass balancing graphics, follow these steps:

1) Go to the Picture Editor. Enter the Picture Editor in one of two ways:a. From the Engineering Main Menu select the Picture Editor target, orb. From the Command Processor command line type 'PE' [ENTER].

2) Load the Global variable definition file, HSS_DDB:

L HSS_DDB [ENTER]

3) Read in the picture file, PBAL_CFG.DS:

R PBAL_CFG [ENTER]

4) Compile the picture:

a. COM [ENTER]

b. ("overwrite existing file" when asked)

5) Repeat steps 3) and 4) for the schematics, PBAL.DS, andPBAL_MSG.DS.

6) For the schematic PBAL_HLP.DS, follow these steps:

There is room in PBAL_HLP for 20 available fields, each using the samesup-picture, to accommodate up to 20 installations of the pass balancingpackage. PBAL_HLP is configured with just one of these fields.

a. Read in the picture file, PBAL_HLP.DS:

R PBAL_HLP [ENTER]

b. Select the sub-picture that has been supplied, next to the magentanumeral '1'.

c. Copy the sub-picture as many times as you need, to accommodate asmany pass balancing installations as necessary.

d. Select and modify each field (sub-picture) to enter the point_names ofeach installation. Modify the picture by typing 'M' [ENTER].

e. Verify the picture by typing 'V' [ENTER].

f. Compile the picture by typing 'COM' [ENTER].

("overwrite existing file" when asked)

7) To exit the Picture Editor, type 'END' [ENTER]


2.5 Graphics Installation


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8) Copy PBAL_CFG.DO, PBAL.DO, PBAL_MSG.DO, and PBAL_HLP.DOto an operator graphics directory. From the Command Processor displaytype:

COPY PBAL*.DO NET>pic_dir>= -D [ENTER].

'pic_dir' is the picture object directory specified in the Schematic Search Path.To view the defined picture directories defined to the system, one must be ineither Operator Personality or Universal Personality. Call up the SystemMenu. From there, select the Organization Summary target, and then theSchematic Titles target. Select 'display', and the picture directories(pathnames for schematic search) will be displayed.


2.6 Input Configuration


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IMPORTANT NOTE FOR BASIC CONTROLLER INSTALLATIONS

If you are installing the furnace pass balancer with basic controller pass flow inputs,you must configure the pass balancer with dummy Application Module AUTORATIOconfiguration points in order for the software to link properly. This occurs becausebasic controller AUTORATIO points do not have all of the parameters referenced bythe furnace pass balancer software.

An EB file (BC_CONFG.EB) was included with the pass balancer software whichcontains 2 dummy points which can be used to link the pass balancer software priorto final application configuration. One point (RC_CONFG) acts as a dummyregulatory control point. The other point (PF_CONFG) is a dummy autoratio point.Two points are required since the dummy AUTORATIO point outputs to the dummyregulatory control point.

Exception build these points in the same manner as was outlined in A-5 and A-6.However, in this case, only an appropriate &UNIT number needs to be specified. Allthe other parameters should already be configured appropriately.

After these points have been built, activate them both and then use PF_CONFG inplace of the basic controller pass flow controllers until the pass balancer softwarehas been successfully linked. Then replace the dummy configuration with the actualbasic controller configuration.

Configure Inputs Prior to linking the CL blocks to the furnace pass balancing point, all inputsshould be configured.From the Configuration Schematic (SCHEM PBAL_CFG), enter the following:

• Furnace Pass Balancer point_name.

• Furnace description for this application.

• Number of furnace passes.

• Tagnames for all furnace pass flow controllers and pass outlettemperatures. (For BC installations, input PF_CONFG for each of thepasses (See Note Above))

• Tagname for all pass skin temperatures (only if the pass skin temperaturechecking feature is desired).

• Tagname for the master flow controller. If a master flow controller doesnot exist, you can use an AM Summer PV point to add up the sum of the




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individual pass flows.

• Tagname for the furnace inlet temperature. If this is a Numeric point,enter a reasonable value for it.

• Enter reasonable values for all engineering inputs and limit values.

• If desired, a related group number and a related process graphic name.A default message storage point tagname (custom parameter MSG_CONF) isautomatically loaded in the procedure described under the "Building the FurnacePass Balancing Points" section, above in this document. The default namesupplied is PBAL_MSG. If desired, the user may change this name to suit hisown purposes. This can be done via any Message Maintenance schematic.

Note for input

configuration

Typical values for ENGPAR(3), the ratio of the heat of vaporization divided by

the heat capacity of the furnace fluid, are in the range of 200 to 300 °F-1.


2.7 Linking CL Programs


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2.7 Linking CL ProgramsProcedure To complete building the furnace pass balancing point, follow these steps:

1) Link PBAL to the furnace pass balancing point. From the CommandProcessor display:

LK PBAL point_name [ENTER]2) If the pass skin temperature checking feature is desired, then link PBAL_SKto the furnace pass balancing point as well:

LK PBAL_SK point_name [ENTER]When linking PBAL_SK, it is noted that the skin temperature checkautomatically defaults to 'ACTive' -- inactivate if desired.3) If the basic controller BC implementation was followed, replace the dummyAUTORATIO controller tagnames (PF_CONFG) with the actual basiccontroller tagnames.4) Activate the pass balancer point from the PBAL_CFG graphic, or call up thepoint detail and activate it.5) Verify operation. Verify that the pass balancing point is running without anyCL errors.


2.7 Linking CL Programs


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Section 3 -- Detailed Design

3.1 OverviewThis section describes the following:

• Point Structure• Process Inputs• Configuration Inputs• Calculation Outputs• Control Outputs• Conversion of Engineering Units• Filtering

Detailed Design

3.2 Point Structures


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3.2 Point StructuresPoints The furnace pass balancing package can use up to three points:

• Furnace Pass Balancing Point

• Message Storage Point

• Furnace Inlet Temperature Point

Calculations The furnace pass balancing point performs all of the necessary pass balancingcalculations:

Furnace Pass Balancing Point

Point Type Application Module Regulatory Data

PV Algorithm CL

Control Algorithm CL

Custom Data Segment PBAL_CDS

Compiled CL Code File PBAL.AO (main pass balancing program)

Block PBAL1 PBAL2 PBAL3

Insertion Point PV_ALG CTL_ALG

CTL_ALG

Slot 5 5 8

Compiled CL Code File PBAL_SK.AO (optional skin temperature check)

Block PBAL_SK

Insertion Point PV_ALG

Slot 8

Outputs The maximum difference between any pass outlet temperatureand the weighted average outlet temperature is displayed as thepoint's PV.

The calculated ratio values needed to drive all outlet temperaturestowards the weighted average outlet temperature is sent to theRATIO parameter of the pass flow controllers. A maximum of 8passes can be specified.

Detailed Design

3.2 Point Structures


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A common message storage point is used to hold the text of messagesreferenced by the furnace pass balancing point and displayed on theuser schematic. Only one message storage point (per LCN) isrequired per any number of pass balancing applications:

Message Storage Point

Point Type Application Module Custom

Custom Data Segment PBALMCDS

Outputs None.

The furnace inlet temperature point shown below is required if no instrument isavailable. It is used to provide a value for the furnace inlet temperature:

Furnace Inlet Temperature Point

Point Type Application Module Numeric

Outputs None.

Detailed Design

3.3 Process Inputs


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3.3 Process InputsCustom

Parameter List

The following table lists and describes the custom parameters related toinstrument measurement inputs:

Process InputsParameter Description Units Validation Checking4

FLOW_PT(1) Tagname of source for thefirst pass flow controller.

Any flowunits

All pass flows are:

• • • Critical inputs.FLOW_PT(n) Tagname of source for the

nth pass flow controller.The units ofFLOW_PT(1)

NULL tagname checked.BAD value checked.

• • • Value must be > 0.FLOW_PT(8) Tagname of source for the

eighth pass flow controller.The units ofFLOW_PT(1)

TEMP_PT(0) Tagname of source for thefurnace inlet temperature.

Anytemperatureunits

Not critical.5 NULL tagname checked.BAD value checked.

TEMP_PT(1) Tagname of source for thefirst pass outlet temperature.

The units ofTEMP_PT(0)

All outlet temperaturesare:

• • • Critical inputs.TEMP_PT(n) Tagname of source for the nth

pass outlet temperature.The units ofTEMP_PT(0)


TEMP_PT(8) Tagname of source for theeighth pass outlet temperature.


TEMP_PT(9)Tagname of source for the firstpass skin temperature.


If used, all skin temperaturesare:

• • • Critical inputs.

TEMP_PT(n)Tagname of source for the nthpass skin temperature.



TEMP_PT(16)Tagname of source for theeighth pass skin temperature.


4 Critical indicates that a non-valid input will result in the package's outputs not being updated.5 If the furnace inlet temperature value goes bad, then the last good value will be used

indefinitely, until a good value is restored. This value is stored in custom parameter 'T'.

Detailed Design

3.4 Configuration Inputs


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3.4 Configuration InputsUser Inputs The following table lists and describes inputs that require user input:

Configuration InputsParameter Description Units Validation Checking

DESCRIPT Name (description) of specificfurnace to be balanced, used formessages. Must be 25characters.

N/A No checking done.

ENGPAR(1) Flag to stop routine. N/A If = 0.0, the routine willfunction normally. If < 0.0, orif BAD, no outputs arecalculated.

ENGPAR(2) Number of input furnace passes. N/A Must be between 2 and 8,inclusively. If not, or if BAD,no outputs are calculated.

ENGPAR(3) Ratio of the heat of vaporizationof the furnace fluid divided bythe heat capacity of the fluid.

This value is used in thecalculation of a process gain forthe pass balancer. The valueshould be reasonable, but doesnot need to be absolutelyaccurate.

The units of

TEMP_PT(1)-1See note, following table.

ENGPAR(4) Weight percent of the fluidvaporized in the furnace.

This value is used in thecalculation of a process gain forthe pass balancer. The valueshould be reasonable, but doesnot need to be absolutelyaccurate.

Percent See note, following table.

ENGPAR(5) Minimum allowable individualpass flow rate limit.

The units ofFLOW_PT(1)

If BAD, limit is ignored.

ENGPAR(6) Maximum pass flow rate ofchange limit for individual passper balancer execution.

The units ofFLOW_PT(1)

If BAD, limit is ignored.

ENGPAR(7) Maximum allowable percentimbalance limit of an individualpass flow rate from the averagepass flow rate.

Percent If BAD, limit is ignored.

Detailed Design



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Configuration Inputs (continued)

Parameter Description Units Validation Checking

ENGPAR(8) Tolerance for individual pass flowcontroller holding setpoint (basis:100•(PV-SP)/SP).

Treated as wind-up; checked inboth directions.

Percent If BAD, limit is ignored.

ENGPAR(9) Temperature deadband for skintemperature check.


If BAD, skin temperaturecheck is not done, and passbalancing continues.

ENGPAR(10) Elapsed time (timeout period)before control is turned off (putinto manual) after a major errorhas been detected.

Value is internally rounded to thenearest value for the PERIOD ofthe pass balancing point.

To turn off immediately, enter avalue > 0.0, and less than half thevalue for the PERIOD of the passbalancing point.

MINUTES If 0.0 or BAD, the timeoutperiod is ignored (controlleris never automatically turnedoff).

ENGPAR(11) Tolerance for the sum of themoves, the sum of the movesmust be less than this number.

Flow units If 0.0000, the controller willfail on the initial run.

GRPNUM Related Group Display number . N/A No checking done. Usedonly on user schematic.

K Controller gain factor (typically,0.0 < K < 1.0).

N/A See note, following table.

MES(1-2) Text strings to be sent to theoperator via the TDC3000message system, in the event ofcertain status changes.

The message is sent in twoseparate messages. The first isMES(1) followed by the furnacename (as defined by theparameter DESCRIPT on thepass balancer point). The secondis MES(2) followed by the passbalancer point tagname.

N/A Default values are:

MES(1): "Pass balancerstopped working: "

MES(2): "....See schematicPBAL, point: "

The length of each messagecannot exceed 65characters.

Detailed Design



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Configuration Inputs (continued)

Parameter Description Units Validation Checking

MSG_CONF Tagname of point containing textstrings for user notification andschematic messages.

N/A If not specified, no usermessages are generated.The same point can be usedfor all pass balancingapplications.

SCHEMNAM Related process schematic. N/A No checking done. Usedonly on user schematic.

TFL Tagname of source for the total(master) furnace feed flowcontroller.

Any flowunits

Not critical.No checking done. Usedonly on user schematic.

Note: if the resulting term "K/KMF" is negative or BAD, no outputsare calculated.

Detailed Design

3.5 Calculation Outputs


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3.5 Calculation OutputsCustom

Parameter

Outputs

The following table lists and describes all custom parameter outputs of the passbalancer package.

Regarding the 'Use' column, this is intended to note which calculations have beenoutput stircitly due to a programming need (denoted by PRG), and whichcalculations may be of interest to the user (no notation).

Calculation Outputs

Parameter Description Units Use

PVCALC The maximum difference between any pass outlettemperature and the weighted average outlet temperature.

Inputtemperature units

CALC_VAL(1) Calculated final RATIO parameter for pass 1 flowcontroller.

N/A

CALC_VAL(n)Calculated final RATIO parameter for pass n flowcontroller.

N/A

CALC_VAL(8) Calculated final RATIO parameter for pass 8 flowcontroller.

N/A

CALC_VAL(9) The calculated furnace pass weighted outlettemperature.

Inputunits

CALC_VAL(10) The calculated furnace pass weighted skintemperature.

Inputunits

ERRCODE Saved CL error status on block PBAL2. N/A PRG

F(1) Current value of pass 1 flow controller setpoint. Inputunits

PRG

F(n)Current value of pass n flow controller setpoint. Input

unitsPRG

Detailed Design



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Calculation Outputs


F(8) Current value of pass 8 flow controller setpoint. Inputunits

PRG

F(9) Calculated total of all pass flow controller setpoints. Inputunits

PRG

F(10) Calculated average pass flow controller setpoint. Inputunits

INT_VAL1(1) Calculated temperature difference between pass 1 and theweighted outlet temperature.

Inputunits

PRG

INT_VAL1(n) Calculated temperature difference between pass n andweighted outlet temperature.

Inputunits

PRG

INT_VAL1(8) Calculated temperature difference between pass 8 andweighted outlet temperature.

Inputunits

PRG

INT_VAL1(9) Current pass 1 outlet temperature. Inputunits

PRG

INT_VAL1(n) Current pass n outlet temperature. Inputunits

PRG

INT_VAL1(16) Current pass 8 outlet temperature. Inputunits

PRG

INT_VAL2(1) Calculated ideal flow change for pass 1. Inputunits

INT_VAL2(n) Calculated ideal flow change for pass n. Inputunits

INT_VAL2(8) Calculated ideal flow change for pass 8. Inputunits

INT_VAL2(9) Calculated limited flow change for pass 1. Inputunits

Detailed Design



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Calculation Outputs


INT_VAL2(n) Calculated limited flow change for pass n. Inputunits

INT_VAL2(16) Calculated limited flow change for pass 8. Inputunits

INT_VAL2(17) Calculated final flow change for pass 1 Inputunits

• • •

INT_VAL2(n) Calculated final flow change for pass n Inputunits

• • •

INT_VAL2(24) Calculated final flow change for pass 8 Inputunits

INT_VAL2(25) Calculated sum of negative flow changes after limitingmoves

Inputunits

INT_VAL2(26) Calculated sum of positive flow changes after limitingmoves

Inputunits

INT_VAL2(27) Calculated sum of negative flow changes after normalizingmoves

Inputunits

INT_VAL2(28) Calculated sum of positive flow changes after normalizingmoves

Inputunits

KMF6 Calculated process gain factor for the furnace; equal tothe term "any pass flow" times "the estimated change inpass outlet temperature per unit pass flow change".Output for the user's information.

Inputunits

RT(1) Calculated sum of current ratio parameters N/A

RT(2) Calculated sum of final ratio parameters N/A

RT(3) Ratio factor for normalizing moves N/A

REV_NO Program revision number. N/A

STATE(1)7 Error code for pass 1. N/A

STATE(n) Error code for pass n. N/A

STATE(8) Error code for pass 8. N/A

6 If "set bad" flag, ENGPAR(1), is set, the last good value of KMF is retained.7 See "Status Codes" section (following) for detailed information about STATEs.

Detailed Design



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Calculation Outputs


STATE(9) Limit condition status code for pass 1. N/A

STATE(n) Limit condition status code for pass n. N/A

STATE(16) Limit condition status code for pass 8. N/A

STATE(17) Saved error code for pass 1 from previous execution. N/A PRG

STATE(n) Saved error code for pass n from previous execution. N/A PRG

STATE(24) Saved error code for pass 8 from previous execution. N/A PRG

STATUS(1)8 Non-pass-specific, major (no moves output as a result)error status.

N/A

STATUS(2)9 Minor (moves still output) error status. N/A

STATUS(3) Message point error status. N/A

STATUS(4) Saved, composite error status from last execution. N/A PRG

STATUS(5) Saved, pass balancer point MODE from last execution.1.0: AUTO or CAS; 0.0: MAN; -1.0: just downgraded toMAN.

N/A PRG

T Furnace inlet temperature. Inputunits

PRG

TIMEDESC Date and time of last 'successful' (control moves output)program execution.

Time PRG

8 See "Status Codes" section (following) for detailed information about STATUSs.9 If "set bad" flag, ENGPAR(1), is set, the last good value of STATUS(2) is retained.

Detailed Design

3.6 Control Outputs


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3.6 Control OutputsControl Outputs The following table lists and describes all control outputs generated by the

furnace pass balancing package:

Calculation Outputs

Parameter Description Units

FLOW_PT(1).RATIO Calculated pass 1 flow controller RATIO parameterrequired for pass 1 temperature to reach weightedaverage outlet temperature.

N/A

FLOW_PT(n).RATIO Calculated pass n flow controller RATIO parameterrequired for pass n temperature to reach weightedaverage outlet temperature.

N/A

FLOW_PT(8).RATIO Calculated pass 8 flow controller RATIO parameterrequired for pass 8 temperature to reach weightedaverage outlet temperature.

N/A

Detailed Design

3.7 Conversion of Engineering Units


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3.7 Conversion of Engineering UnitsNo engineering unit conversions are performed in the Furnace Pass OutletTemperature Balancer.

The user must ensure that, for all inputs, the same engineering units are used forsimilar variables. For example, one pass temperature cannot be input in units of°F and another in °C. By definition, outputs are calculated in the same units asthose input.

Detailed Design

3.8 Filtering


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3.8 FilteringNo filtering is performed in or provided by the Furnace Pass Outlet TemperatureBalancer.

Notes:

• Temperature values generally do not exhibit a significant amount of noise,and therefore filtering of temperature inputs should not be necessary.

• The control calculation uses pass flow setpoints (not PVs), which areinherently not noisy.

• The value of "100 • (PV – SP) / SP" for each pass, which is checked againsta user-specified limit, may exhibit some noise due to PV variability. Theuser is advised to set the limit above the typical noise level.


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Section 4 -- Status Codes

4.1 OverviewOverview The tables in this section describe the following program status codes:

• Pass-specific Major Error Code

This code indicates when a major error has been encountered, and which passhas the error. As a result, no new output moves have been calculated.

• Pass-specific Limit Condition Code

This code indicates when a constraint has been encountered, and which pass hasencountered the constraint. Output moves are still calculated, but, as a result,the RATIOs output to the pass flow controllers have been at least partiallylimited.

• General Major Error Code

This code indicates when a major error that is non-pass-specific has beenencountered. As a result, no new output moves have been calculated.

• Minor Error Code

This code indicates when a minor error has been encountered. This is just forthe user's information. The program has worked around the error, and newRATIOs have been calculated.

• Message Storage Point Error Code

This code indicates that the message storage point has not been defined. Thepass balancing routine will continue, but operator messages will not beavailable, and status displays on schematics may be incomplete.

Status Codes

4.2 Pass Specific Major Error Codes


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4.2 Pass-Specific Major Error CodesMajor Error

Codes

The pass-specific major error codes are stored in the custom parameter arraySTATE(1:8). The array element number (1 through 8) in the parameter STATEcorresponds to the pass number. For example, the value of STATE(2)corresponds to the major error detected for pass #2.

Major Error Codes

Parameter Value Meaning

STATE(1-8) 0.0 No errors.

1.0 Null pass flow controller point entered.

2.0 A flow controller point has been specified for a pass number greaterthan the number of passes.

3.0 Pass flow controller setpoint is bad or below zero.

4.0 Null outlet temperature point entered.

5.0 An outlet temperature point has been specified for a pass numbergreater than the number of passes.

6.0 Outlet temperature is bad.

7.0 Null skin temperature point entered.

8.0 A skin temperature point has been specified for a pass numbergreater than the number of passes.

9.0 Skin temperature is bad.

10.0 Skin temperature check has found apparent coking.

11.0 Pass flow controller PV is bad.

12.0 Communication error for pass flow controller MODE, MODATTR, orARWNET.

13.0 Pass flow controller is not in P-CAS mode.

14.0 Bad RATIO read from pass flow controller.

15.0 Bad ratio limit or setpoint limit read from pass flow controller.

Note that STATE values 1.0 through 6.0 are generated from the pass balancingPV block. STATE values 7.0 through 10.0 are generated from the passbalancing skin temperature block. STATE values 11.0 and 15.0 are generatedfrom the control block.

Status Codes

4.3 Pass-Specific Limit Condition Codes


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4.3 Pass-Specific Limit Condition CodesLimit Condition

Codes

The pass-specific limit condition codes are stored in the custom parameter arraySTATE(9:16). The array element number (9 through 16) in the parameterSTATE corresponds to the pass number, plus '8'. For example, the value ofSTATE(11) corresponds to the limit condition detected for pass #3.

Limit Condition Codes


STATE(9-16) -1.0 Limits were not checked due to other problems.

0.0 No limits were encountered.

1.0 Pass flow controller is wound-up HI.

2.0 Pass flow controller is wound-up LO.

3.0 Pass flow controller not holding SP; PV is too low.

4.0 Pass flow controller not holding SP; PV is too high.

5.0 Ideal ratio limited by ratio high limit on pass flow controller.

6.0 Ideal ratio limited by ratio low limit on pass flow controller.

7.0 Ideal ratio limited by setpoint high limit on pass flow controller.

8.0 Ideal ratio limited by setpoint low limit on pass flow controller.

9.0 Not used.

10.0 Ideal ratio limited by user-specified minimum pass flow limit.

11.0 Ideal ratio limited by user-specified positive percent imbalance limit.

12.0 Ideal ratio limited by user-specified negative percent imbalance limit.

13.0 Ideal ratio limited by user-specified positive rate of change limit.

14.0 Ideal ratio limited by user-specified negative rate of change limit.

15.0 - 24.0 Not used.

Status Codes

4.3 Pass-Specific Limit Condition Codes


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Limit Condition Codes


STATE(9-16) 25.0 Currently violating ratio high limit on pass flow controller, and passflow move is positive. Move limited to zero.

26.0 Currently violating ratio low limit on pass flow controller, and passflow move is negative. Move limited to zero.

27.0 Currently violating setpoint high limit on pass flow controller, andpass flow move is positive. Move limited to zero.

28.0 Currently violating setpoint low limit on pass flow controller, and passflow move is negative. Move limited to zero.

29.0 Not used.

30.0 Currently violating minimum pass flow limit, and pass flow move isnegative. Move limited to zero.

31.0 Currently violating positive percent imbalance limit, and pass flowmove is positive. Move limited to zero.

32.0 Currently violating negative percent imbalance limit, and pass flowmove is negative. Move limited to zero.

Note that odd code values relate to limits on positive moves, and even codevalues to limits on negative moves.

Status Codes

4.4 General Major Error Codes


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4.4 General Major Error CodesMajor Error Codes General (non-pass-specific) major error codes are stored in the custom

parameter array STATUS(1).

Major Error Codes


STATUS(1) 0.0 No errors.

1.0 Set calculation BAD flag is on.

2.0 Input number of furnace passes is outside the range 2 to 8.

3.0 Not used.

4.0 Not used.

5.0 Null inlet temperature point entered.

6.0 Calculated gain ratio (K/KMF) is bad or negative.

7.0 Pass Balancer turned OFF (MANual mode).

8.0 All moves limited to zero. For example, the pass flow rate-of-change limit, or the imbalance limit have been set to 0.0.

9.0 Total of flow changes is outside the tolerance of zero.

10.0 - 16.0 Not used.

17.0 Minor CL error occurred in control algorithm; likely means thatAM was unable to write out RATIOs to pass flow controllers(for example, due to being in BASIC control state).

18.0 Other CL error occurred in control algorithm.

19.0 Pass-specific error occurred; see STATE(1-8).

Note that STATUS values 1.0 and 2.0 are generated from the pass balancing PValgorithm block. STATUS values 5.0 through 9.0 are generated from the passbalancing control algorithm block. STATUS values 17.0 and 18.0 are generatedfrom the pass balancing messaging block. STATUS value 19.0 can begenerated from either the pass balancing PV or control blocks.

Status Codes

4.5 Minor Error Codes


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4.5 Minor Error CodesMinor Error Codes Minor error codes are stored in the custom parameter array STATUS(2).

Minor Error Codes


STATUS(2) 0.0 No errors

1.0 Furnace inlet temperature is bad. The last good value willbe used indefinitely, until a good value is restored.

Status Codes

4.6 Message Storage Point Error Codes


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4.6 Message Storage Point Error CodesThe error codes for the message storage point are stored in the customparameter array STATUS(3).

Message Storage Point Error Codes


STATUS(3) 0.0 No errors

1.0 Null message point has been specified. The pass balancingroutine will continue, but no operator messaging will occur,and the schematics will be incomplete.

Status Codes

4.6 Message Storage Point Error Codes


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Section 5 - Messaging

5.1 Overview

The pass balancing package contains messaging features, designed to help theuser configure and monitor the routine.

The messaging is accomplished via the pass balancing point and a separate,common 'message storage point'. The message storage point name is specifiedby the parameter MSG_CONF on the pass balancer point. Only one messagestorage point is necessary per LCN -- all pass balancers on the LCN can accessthe same message storage point.

Described following in this section are:

• Operator Messaging

• User Schematic Messaging

• Engineer Log Messaging

• Configuration Inputs required for the Message Storage Point

• Default Message Strings supplied with the pass balancing package

Messaging

5.2 Operator Messaging


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5.2 Operator Messaging

On a user-specified, case-by-case basis, the operator can be notified whenever thepass balancer stops working (stops outputting flow moves), but is still 'on'.

The operator is notified, using two message strings, via the TDC3000 MessageSystem. These two strings are configured through the pass balancer point'scustom parameter MES(1-2), as described above the "Configuration Input"section. The operator notification indicates only that the pass balancer hasstopped, and that the User Schematic should be viewed for details as to why ithas stopped.

These two strings, MES(1) and MES(2), can be user-modified via one of theMessage Maintenance schematics (see "User and Configuration Graphics"section, below). Whether or not the operator is notified in the event of certainstatus changes is user-specified. This is specified via the message storage point'scustom parameters OPOUT1 and OPOUT2. The value of OPOUT1 andOPOUT2 can also be user-modified by one of the Message Maintenanceschematics.

The operator messaging is suspended after the pass balancer has been turned off(is in manual mode).

Messaging

5.3 User Schematic Messaging


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5.3 User Schematic MessagingAll pass-specific errors, pass-specific limit conditions, and the overall error areeach displayed on the User Schematic using an appropriate message.

Messaging

5.4 Engineer Log Messaging


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5.4 Engineer Log MessagingAn engineer log message is sent to the TDC3000 Operator Message Journalwhenever a pass balancer status changes; in other words, when there is achange in STATUS(1), STATUS(2), STATUS(3), or STATE(1-8). Thismessage includes the new values for the above parameters. It appears as (withthe italicized parameters being replaced with their actual values):

PASS BALANCER LOG FOR , DESCRIPT

STATUS CHANGE TO: STATUS(1), :Major, STATUS(2),:Minor, STATUS(3), :Msg

PASS STATUSES:

STATE(1), STATE(2), STATE(3), ...., STATE(8)

In addition, if a CL error was detected on the control block, the messageincludes the ordinal value of the CLBLKERR on that block (CLERRSTSenumeration). This message, and the closing line, appear as:

CL control block error , ORD(cl_err)

END, DESCRIPT

Messaging

5.5 Configuration Inputs for Message Storage Point


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5.5 Configuration Inputs for Message Storage PointThe following table lists and describes inputs that require user input. Defaultstrings are described in the section immediately following:

Configuration Inputs

Parameter Description Comments

MSGTXT(0-36) Text strings used todescribe pass-specificlimit conditions, asdefined by STATE(9-16).

Example: if STATE(10) = 11, then MSGTXT(11)is displayed for pass number 2.

OPOUT1(0-18) Flag used to determinewhether or not theoperator should bealerted (via theTDC3000 MessageSummary display) whenSTATUS(1) haschanged to a certainvalue.

If = 0: Don't send message

If = 1: Send message

Example: if OPOUT1(5) = 1, then a message issent to the operator whenever STATUS(1)changes to a value of 5.0.

OPOUT2(0-16) Flag used to determinewhether or not theoperator should bealerted (via theTDC3000 messagesystem) when STATE(1-8) has changed to acertain value.

If = 0: Don't send message

If = 1: Send message

Example: if OPOUT2(7) = 1, then a message issent to the operator whenever STATE(1-8)changes to a value of 7.0.

STATETXT(0-16) Text strings used todescribe pass-specificerrors, as defined bySTATE(1-8).

Example: if STATE(4) = 6, then STATETXT(6)is displayed for pass number 4.

STS_MSG(0-19) Text strings used onschematics to describethe major, non-pass-specific error as definedby STATUS(1).

Example: if STATUS(1) is equal to 5.0, thenSTS_MSG(5) is displayed.

Messaging

5.6 Default Message Strings


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5.6 Default Message StringsThe following tables show the default message strings that have been suppliedwith the pass balancing package. These message strings scan be easily modifiedvia a provided set of Message Maintenance Schematics (PBAL_MSG), accessedfrom the Configuration Schematic (PBAL_CFG).It is noted that the messages have a one-to-one correspondence with the valuesof the custom parameters STATUS and STATE, the error and limit codesdescribed in the "Status Codes" section of this document.The following messages are provided and described:

• Pass-specific Major Error Messages• Pass-specific Limit Condition Messages• General Major Error Messages

Pass-specific

Major Error

Messages

These messages are generated whenever a pass-specific error has beenencountered. The pass balancer is either not working, or has stopped, due to theerror:

STATE(1-9)Values Parameter Default Message Text

0.0 STATETXT(0) " "

1.0 STATETXT(1) "NO PASS FLOW SPECIFIED "

2.0 STATETXT(2) "DON'T SPECIFY A FLOW CONTROLLER "

3.0 STATETXT(3) "PASS FLOW SP IS BAD OR NEGATIVE "

4.0 STATETXT(4) "NO PASS OUTLET TEMPERATURE SPECIFIED "

5.0 STATETXT(5) "DON'T SPECIFY AN OUTLET TEMP. "

6.0 STATETXT(6) "OUTLET TEMPERATURE IS BAD "

7.0 STATETXT(7) "NO SKIN TEMPERATURE SPECIFIED "

8.0 STATETXT(8) "DON'T SPECIFY A SKIN TEMPERATURE "

9.0 STATETXT(9) "SKIN TEMPERATURE IS BAD "

10.0 STATETXT(10) "PASS APPEARS TO BE COKING "

11.0 STATETXT(11) "PASS FLOW PV IS BAD "

12.0 STATETXT(12) "COMM. ERROR FOR PASS FLOW CONTROLLER "

13.0 STATETXT(13) "PASS FLOW CONTROLLER NOT IN P-CAS "

14.0 STATETXT(14) "PASS FLOW RATIO IS BAD "

Messaging



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STATE(1-9)

Values Parameter Default Message Text

15.0 STATETXT(15) "BAD RATIO OR SETPOINT LIMIT IN PASS FC "

16.0 STATETXT(16) "Shouldn't get this message STATETXT(16)"

Pass-specific

Limit Condition

Messages

These messages are generated whenever a pass-specific limit has beenencountered. The pass balancer is still working, but one or more moves havebeen at least partially limited:

STATE(1-9)Values Parameter Default Message Text

-1.0 ----------------- (No message is generated for this condition)

0.0 MSGTXT(0) " "

1.0 MSGTXT(1) "CAN'T INCREASE: PASS FC WOUND-UP "

2.0 MSGTXT(2) "CAN'T DECREASE: PASS FC WOUND-UP "

3.0 MSGTXT(3) "CAN'T INCREASE: FC NOT HOLDING SETPOINT "

4.0 MSGTXT(4) "CAN'T DECREASE: FC NOT HOLDING SETPOINT "

5.0 MSGTXT(5) "LIMIT INCREASE: PASS CONTROLLER RTHILM "

6.0 MSGTXT(6) "LIMIT DECREASE: PASS CONTROLLER RTLOLM "

7.0 MSGTXT(7) "LIMIT INCREASE: PASS CONTROLLER SPHILM "

8.0 MSGTXT(8) "LIMIT DECREASE: PASS CONTROLLER SPLOLM "

9.0 MSGTXT(9) "Shouldn't get this message MSG_TXT(9) "

10.0 MSGTXT(10) "LIMIT DECREASE: LOW FLOW LIMIT "

11.0 MSGTXT(11) "LIMIT INCREASE: AVERAGE FLOW IMBALNCE "

12.0 MSGTXT(12) "LIMIT DECREASE: AVERAGE FLOW IMBALNCE "

13.0 MSGTXT(13) "LIMIT INCREASE: RATE-OF-CHANGE LIMIT "

14.0 MSGTXT(14) "LIMIT DECREASE: RATE-OF-CHANGE LIMIT "







Messaging



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STATE(1-9)

Values Parameter Default Message Text





25.0 MSGTXT(25) "CAN'T INCREASE: ABOVE PASS RTHILM "

26.0 MSGTXT(26) "CAN'T DECREASE: BELOW PASS RTLOLM "

27.0 MSGTXT(27) "CAN'T INCREASE: ABOVE PASS SPHILM "

28.0 MSGTXT(28) "CAN'T DECREASE: BELOW PASS SPLOLM "


30.0 MSGTXT(30) "CAN'T DECREASE: BELOW LOW FLOW LIMIT "

31.0 MSGTXT(31) "CAN'T INCREASE: ABOVE IMBALANCE LIMIT "

32.0 MSGTXT(32) "CAN'T DECREASE: BELOW IMBALANCE LIMIT "





General Major

Error Messages

These messages are generated whenever a non-pass-specific error has beenencountered. The pass balancer is either not working, or has stopped, due to theerror:

STATUS(1)Value Parameter Default Message Text

0.0 STS_MSG(0) " "

1.0 STS_MSG(1) "BAD FLAG HAS BEEN TURNED ON "

2.0 STS_MSG(2) "NUMBER OF PASSES SPECIFIED NOT 2-8 "

3.0 STS_MSG(3) "Shouldn't get this message STS_MSG(3) "


5.0 STS_MSG(5) "INLET TEMPERATURE POINT NOT SPECIFIED "

6.0 STS_MSG(6) "CALCULATED GAIN RATIO IS BAD OR NEGATIVE"

Messaging



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STATUS(1)

Value Parameter Default Message Text

7.0 STS_MSG(7) "PASS BALANCER IS OFF "

8.0 STS_MSG(8) "ALL MOVES LIMITED TO ZERO "

9.0 STS_MSG(9) "CALCULATED TOTAL FLOW CHANGE NOT ZERO "








17.0 STS_MSG(17) "CAN'T ADJUST: PM IN BASIC CONTROL MODE? "

18.0 STS_MSG(18) "PROGRAM ERROR: CONTACT CONTROL ENGINEER "

19.0 STS_MSG(19) "ERROR FOR ONE OR MORE PASSES "

Messaging



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Section 6 -- Tuning Parameters

6.1 Adjusting Tuning ParametersIf the Furnace Pass Outlet Temperature Balancer is not performing in asatisfactory manner, adjusting one of the following parameters may help:Parameter SignificanceENGPAR(6) Pass Flow ROC Limit:

Increasing the maximum allowable pass flow change per execution may increasethe speed of the individual passes reaching the weighted average outlettemperature.

ENGPAR(8) Pass Flow Not Holding SP:The tolerance for an individual pass flow controller holding setpoint (basis:100•(PV-SP)/SP) should be specified such that pass flow controller outputsaturation may be detected as early as possible.This tolerance should be set greater than the typical noise level of the pass flows.

K Controller Gain:Increasing the controller gain will increase the speed of the individual passesreaching the weighted average outlet temperature.Typically: (0.0 < K < 1.0)Entering 'K=0.0' will result in pass flow changes of 0.0.As K approaches a value of 1.0, the pass balancer moves may becomeexcessively large, resulting in instability. This depends on modeling andconfiguration input value accuracy, and how fast the pass balancer is run.Also see 'Installation Procedures' section.

Tuning Parameters

6.1 Adjusting Tuning Parameters


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Section 7 -- User and Configuration Schematics

7.1 OverviewOverview The furnace pass balancing package includes both user and configuration

graphics. The intent of these graphics is to make the installation andconfiguration of a pass balancing application relatively simple, and to provide theuser with the capability of maintaining an installed application.There are four schematics provided with the furnace pass balancing package:

• User Schematic• Help Schematic• Configuration Schematic• Message Maintenance Schematics (5 pages)

These schematics are described in the following sections.

User and Configuration Schematics

7.2 User Schematic


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7.2 User SchematicShown below is the User Schematic for the furnace pass balancing package:

From this schematic, the user can turn an application on and off, and monitorhow the application is performing.The User Schematic is designed to automatically accommodate furnaces having2 to 8 passes. The particular example above shows a 4-pass application.To call up a particular Pass Balancing User Schematic, enter the desired pointin the "Furnace Pass Balancer Pt:" field. The user-configured furnacedescription automatically is displayed next to the point name.

Overall Status

Message

An Overall Status message is displayed below the pass balancing point field.This message pertains to non-pass-specific error messages, described in the"General Major Error Codes" section above.

Button Targets A set of five button targets allows the user to turn the application on and off, tocall up a standard help schematic (described below), to go to a user-configuredgroup display, to go to a user-configured process schematic, or to go to thestandard configuration schematic (described below).When the pass balancing application is on, its button target is displayed in low-intensity blue, and the 'off' button target is displayed in low-intensity white(gray). The buttons switch colors if the application is off.


7.2 User Schematic


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Pass Flow Table The table appearing near the top of the schematic displays values for the furnacepasses and the master flow controller:The MST/AVG row pertains to information for either the master flow controller(MODE, SP, PV, and OP), or the average furnace pass conditions (RATIO,Outlet, and Skin).The MODE column heading refers to the TDC controller mode of the master orpass flow controllers.The RATIO column heading refers to the average or specific value of the passflow controllers' RATIO parameters.The SP column heading refers to the value of a given flow controller's setpointparameter.The PV column heading refers to the value of a given flow controller's PVparameter.The OP column heading refers to the value of a given flow controller's outputparameter.The Outlet column heading refers to the average or specific value of the passoutlet temperatures.The Skin column heading refers to the average or specific value of the pass skintemperatures.Selecting any of the value fields will bring up the standard 'change zone' for theappropriate point.

Pass-specific

Message Table

The table appearing near the bottom of the schematic displays messages that arepass-specific.Each pass row is made up of a pair of half-height rows. The top row of eachpair displays pass-specific error messages. The bottom row of each pair displayspass-specific limit condition messages.Also displayed on the User Schematic are the PERIOD of the pass balancingapplication, the last time that the application successfully ran, and the PVCALCof the pass balancing application, the difference between the maximum passoutlet temperature and the average pass outlet temperature.


7.2 User Schematic


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It is suggested to the user to include a target on an appropriate furnace processschematic that, when selected, calls up the User Schematic for that furnace. Ifthe target is implemented, the following notes are offered:The target actions should include the following:

S_ENT($_PBAL, point_name);

SCHEM('PBAL');where 'point_name' is the point name of the pass balancing point.Prior to adding this actor, load the global variable definition file HSS_DDB asfollows:

LOAD HSS_DDB [ENTER]

If a data definition file is already being used, add the following two lines to theend of it:

DDB = HONEYWELL;

$_PBAL:ENT, 11027, G;

If desired, conditions can be added to the target to indicate the state of the passbalancer. For example, if 'point_name.STATUS(1)' is not equal to zero,an error condition is preventing the pass balancer from functioning correctly.


7.3 Help Schematic


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7.3 Help SchematicThe "HELP" button target on the User Schematic calls up a standard HelpSchematic, shown below:

The Help Schematic is intended to be customized based on the specific passbalancing applications installed on site. This customization is described underthe 'Installation Instructions' section of this document.The Help Schematic is not intended to be pass balancing application-specific .By selecting a specific pass balancing application target from the right side ofthe Help Schematic, one can go to any application's user schematic.


7.4 Configuration Schematic


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7.4 Configuration SchematicThe [Confgtn Schemtc] button target on the User Schematic calls up theConfiguration Schematic for that application, shown below:

From this schematic, the user can configure an application, enter and changeparameter values, and activate/inactivate the application. To set the PV of theapplication bad, and stop the routine, enter a '1' in the "Set Bad?" field.

All changeable target fields are surrounded by a low-intensity yellow box.

The Configuration Schematic is designed to automatically accommodate from 2to 8 pass applications. The particular example above shows a 4-passapplication.

To call up a particular Pass Balancing Configuration Schematic, enter thedesired point in the "Furnace Pass Balancer Point:" field.

Once the "No. of Passes" has been entered for a particular application, theFurnace Pass Points table must be filled out for that number of passes, or anerror is flagged and the pass balancing application will not function. No 'holes'can be left in the table (except for pass skin temperatures, which are optional),and no points may be entered in the table beyond the configured pass number.

The optional pass skin temperature check may be activated/inactivated from theConfiguration Schematic.


7.4 Configuration Schematic


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The furnace inlet temperature point name is configured and displayed from theConfiguration Schematic. If this point is a Numeric point, then its value can bechanged from the schematic as well.To go to the Message Maintenance schematics, select the "Message Maint"target.To go to the User Schematic, select the "User Schem" target.The Configuration Schematic is shown again below, with the custom parameternames shown instead of their values:

DESCRIPT

ENGPAR(2)

ENGPAR(1)

ENGPAR(4)

ENGPAR(3)

ENGPAR(5)

ENGPAR(6)

ENGPAR(7)

ENGPAR(11)

ENGPAR(8)

ENGPAR(3)

ENGPAR(10)

ENGPAR(9)

GRPNUM

K

FLOW_PT(1)

FLOW_PT(2)

FLOW_PT(3)

FLOW_PT(4)

FLOW_PT(5)

FLOW_PT(6)

FLOW_PT(7)

FLOW_PT(8)

TEMP_PT(1)

TEMP_PT(2)

TEMP_PT(3)

TEMP_PT(4)

TEMP_PT(5)

TEMP_PT(6)

TEMP_PT(7)

TEMP_PT(8)

TEMP_PT(9)

TEMP_PT(10)

TEMP_PT(11)

TEMP_PT(12)

TEMP_PT(13)

TEMP_PT(14)

TEMP_PT(15)

TEMP_PT(16)

TFL

TEMP_PT(0) TEMP_PT(0).PV

INACTACT


7.5 Message Maintenance Schematic


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7.5 Message Maintenance SchematicsTheir are five pages of message maintenance schematics which are generallycommon in nature.Each of the five can be called up from the other. The schematic page target thatyou are on will be back-lit in low-intensity blue; the others are back-lit in low-intensity white (gray).The message storage point (custom parameter MSG_CONF) can be configuredfrom any of the message maintenance schematics.Each message string can be modified by the user to best fit his needs. Tocompletely clear a message, select the 'CLEAR' target from the appropriatecolumn.The "Message Maint" button target on the Configuration Schematic calls up thecommon "Non-Pass-specific Error Message" schematic, shown below:

Non-Pass-

specific Error

Message

Maintenance

Schematic

If it is desired to inform the operator when one of these messages is encountered,input 'YES' in the appropriate "Inform Operator" column. The exception to thisis the "Error for one or more passes" message. See the next messagemaintenance schematic for pass-specific error messages.




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Pass-specific

Error Message

Maintenance

Schematic

If it is desired to inform the operator when one of these messages is encountered,input 'YES' in the appropriate "Inform Operator" column.

Pass-specific

Limit Message

Maintenance

Schematic




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The limit messages have not been designed to allow the operator to be informedwhen one is encountered. The "Inform Operator" column is not relevant for thisschematic.

Pass-specific

Limit Message

Maintenance

Schematic

The limit messages have not been designed to allow the operator to be informedwhen one is encountered. The "Inform Operator" column is not relevant for thisschematic.


7.6 Operator Message Maintenance Schematic


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7.6 Operator Message Maintenance Schematic

The following message schematic pertains to the messages that will be sent to theTDC3000 Message System to alert the operator when a certain condition hasbeen encountered. When to and when not to alert the operator is user-configurable on a condition-by-condition basis, using the "inform operator"selections on the message schematics described previously.

The "Inform Operator" column is not relevant for this schematic.




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Section 8 -- Operating Instructions

8.1 Overview

The following message schematic pertains to the messages that will be sent to theTDC3000 Message System to alert the operator when a certain condition hasbeen encountered. When to and when not to alert the operator is user-configurable on a condition-by-condition basis, using the "inform operator"selections on the message schematics described previously.

This section describes the following:

• Turning the Pass Balancer ON

• Turning the Pass Balancer OFF

• Miscellaneous Features

Operating Instructions

8.2 Turning the Pass Balancer On


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8.2 Turning the Pass Balancer On

The following message schematic pertains to the messages that will be sent tothe TDC3000 Message System to alert the operator when a certain condition hasbeen encountered. When to and when not to alert the operator is user-configurable on a condition-by-condition basis, using the "inform operator"selections on the message schematics described previously.

All furnace pass flow controllers must be in CAScade mode and thecorresponding control box settings must be in FULL CONTROL for the passbalancer to operate.

Make sure all configuration inputs have reasonable values entered.

To turn the Pass balancer on, select the 'ON/OFF' button on the User Schematic.(If the application is OFF, the button will indicate so, and be displayed in red).

Turning the pass balancer ON changes the Normal Mode Attribute(NMODATTR) of all pass flow controllers to Program (P-), and sets the passbalancer point mode to AUTOmatic. The pass balancer routine will now beginto function.

If, when turning the pass balancer on, a major error status already exists, thepass balancer will immediately turn itself off.

If the pass balancer encounters a major error status during normal operation, itwill turn itself off after a certain period of time. This period of time is definedby the custom parameter ENGPAR(10), and is displayed as the "Timeoutperiod" on the standard Configuration Schematic.

NOTE: The pass balancer does not reset the NMODATTR when it turns OFF.This operation must be manually performed by the operators.


8.3 Turning the Pass Balancer Off


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8.3 Turning the Pass Balancer Off

To turn the Pass balancer off, select the 'ON/OFF' button on the UserSchematic. (If the application is on, the button will indicate so, and bedisplayed in green).

Turning the pass balancer OFF sets the pass balancer point mode to MANual.The pass balancer routine will now stop functioning.

NOTE: Pass balancing requires that the pass flow controllers be in P-CAScademode. The “P” identifies that the controllers have been configured to allow anAM based PROGRAM to access point parameters. When pass balancing isturned off, the normal mode attributes of the pass flow controllers should bemanually reset to their previous settings (normally OPERATOR modeattribute.)


8.4 Miscellaneous Features


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8.4 Miscellaneous Features

If the furnace pass balancing point is point processed (PPS), the logic is such thatthe controller gain (custom parameter K) and the rate-of-change limit (customparameter ENGPAR(6)), are reduced such that the application will not makeadjustments that are too large. This reduction is done internal to the programand is only temporary.

The current time is compared to the last time the application ran. Thisdifference is divided by the normal PERIOD of the application. This ratio is thefactor by which the parameters are reduced.


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