636514 . . . . . . . . . . . . . . Page 1 Of ECN

. . . . . . . . . . . . . 636514 . . . . . . . . . . . . . . . . . . . . . . . . . P'O,. ECN

ENGINEERING CHANGE NOTICE Page 1 Of r

3. O r i g i n a t o r ' s Name, Organ iza t ion , MSIN,

JD Robinson, 75230, S7-12, 376- 4777

and Telephone No.

6. P r o j e c t T i t le /Na. /Uork Order NO.

Rotary Mode Core Sampling

WHC-SD-WM-CSDD-020, Rev. 0

9. Docunent Numbers Changed by t h i s ECN ( i n c l u d e s sheet no. and rev.)

2. ECN Category (mark one)

4. US9 Required? 5. Date

[XI Yes [ I NO September 19, 1996

7. Bldg.lSys./Fac. No. 8. Approval Designator

2416 Q

N/A N/A

10. Re la ted ECN No(s). 11. Re la ted PO No.

Supplemental (1 D i r e c t Rev is ion [ X I Change ECN [I Temporary [I Standby 11 Supersedure [I Cancel /Void I1

12b. Uork Package No.

N/A

12a. M o d i f i c a t i o n Uork

[ ] Yes ( f i l l out Blk.

[XI No (NA B lks . 12b. 12b)

12c. 12d)

12c. M o d i f i c a t i o n Uork Complete 12d. Restored t o O r i g i n a l Condi- t i o n (Temp. o r Standby ECN only)

W A N/A

Design Authar i ty/Cog. Engineer S ignature & Date

Design Author i ty ICag. Engineer S ignature & Date

14a. J u s t i f i c a t i o n (mark one)

C r i t e r i a Change [XI Design Improvement [ ] Env i ro rmenta l [ ] F a c i l i t y D e a c t i v a t i o n [ ] k - F o u n d [ ] F a c i l i t a t e Const [ ] Const. Er ro r /Omiss ion [ ] Design Er ror /Omiss ion [ ] 14b. J u s t i f i c a t i o n D e t a i l s

These changes will allow easier daily functional checks and help operators differentiate between alarm types.

A-7900-013-2 (05/96) tEF095

1-7900-01 3-1

ENGINEERING CHANGE NOTICE Page 2 o f 2

SDDIDD

Functional Design Criteria

ope,at,ng spsciticat,on

Criticality Specification

Conceptual Daaign Rsporl

Equipment Spsc

const spec

Procurement Spec.

Vendor Information

OM Manual

FSARISAR

Safety Equipment List

Radiation Work Permit

Environmental impact Statement

Environmental Reporl

Environmental Permit

1. ECN (use no. f r w n pg. 1)

636514

SsismiciStrsrs Analysis

StrassIDssign Report

1ntsrtllce Control Drawing

Calibration Procedure

Installation Procedure

Maintenance Procedure

Enoinesring Procedure

opsrat,ng Instruction

Operating Procedure

Operational Safety Requirement

IEFD Drawing

Cell Arrangement Drawing

Essential Material Specification

Fsc Proc Samp Schedule

Inspection Plan

Inventory Adjustment Request

16. Des ign V e r i f i c a t i o n Required

[ I Yes [XI No

[ I [ I [ I [ I [ I [ I [ I [ I 11 [ I [ I [ I [I

Tickler File r i

Tank Calibration Manual

Health Physics Procedure

Spares Multiple Unit Listin0

Test ProcsduresiSpecitication

Component Index

ASME Coded Item

Human Factor Consideration

computer software

Electric Circuit Schedule

ICRS Procedure

Process Control ManualIPlan

Process Flaw Chart

Purchase Requimtion

17. Cost l n p a c t 18. Schedule Impact (days)

[ I [ I

4M ENGINEERING /?Id CONSTRUCTION

Improvement

De lay [ I $ [ I

A d d i t i o n a l

Savings [ I $ [ I

A d d i t i o n a l

Sav ings

L J t l

[ X I Not Applicable 11 [ I [ I

20. Other A f f e c t e d Documents: (NOTE: Docunents l i s t e d below u i l l n o t b e r e v i s e d by t h i s ECN.) S ignatures below i n d i c a t e t h a t t h e s i g n i n g o r g a n i z a t i o n has been n o t i f i e d o f o t h e r a f f e c t e d documents l i s t e d below.

Document Nurber /Rev is ion Docment Nunber/Revision Document Nunber R e v i s i o n

None

21. Approva ls

S i g n a t w e Des ign A u t h o r i t y OW Hami l ton

Cog. Eng. EJ Waldo &e cog. Mgr. OW H a m i I t o n L f j

QA ML M c E l r o y m . w C

S a f e t y

Environ.

Other

D a t e S i g n a t u r e Des ign Eng ineer JD Robinson ).a & PE

QA

S a f e t y

Des ign

Environ.

Other

DEPARTMENT OF ENERGY

S i g n a t u r e or a C o n t r o l Nunber t h a t t r a c k s t h e Approval S i g n a t u r e

ADDITIONAL

A-7900-013-3 (05/96) tEF096

s WHC-SD-WM-CSDD-020. Rev. 1

FLAMMABLE GAS TANK EXHAUSTER INTERLOCK (FGTEI) COMPUTER SOFTWARE DESIGN DESCRIPTION

SO Smith/RW Truitt Westinghouse Hanford Company, Richland, WA 99352 U.S. Department of Energy Contract DE-AC06-87RL10930

ECN: 636514 UC: 2070 Org Code: 75230 Charge Code: N4HBB B&R Code: EW3120074 Total Pages:-;lj

Key Words: Flammable gas tank exhauster interlock, (FGTEI), software design.

Abstract: Modicon Compact Programmable Logic Controller (PLC). The device configuration integrates the isolation and current- carrying capacities of mechanical relays with the logic and programming sophistication of the PLC.

This revised document provides descriptions of components and tasks involved in the PLC system for controlling and monitoring the FGTEI. All control functions required by the PLC, and how they are implemented, are described in detail.

TRADEMARK DISCLAIMER. Reference h e r e i n t o any s p e c i f i c comnercial product, process, or s e r v i c e by t r a d e name, trademark. manufacturer, or o theru ise , does no t n e c e s s a r i l y c o n s t i t u t e or imp ly i t s endorsement, r e c m n d a t i o n , o r f a v o r i n g by t h e Un i ted Sta tes Goverrunent o r any agency thereo f o r i t s c o n t r a c t o r s o r subcont rac tors .

P r i n t e d i n t h e Un i ted Sta tes of America. T O o b t a i n copies of t h i s document, con tac t : VHC/BCS D o c m n t Cont ro l Services, P.O. Box 1970, M a i l s t o p H6-08, R ich land UA 99352, Phone ( 5 0 9 ) 372-2420: Fax (509) 376-4989.

Recease pprova l Date/ Rele e Stamp

Approved for Public Release

A-6400-073 (10195) GEF321

RECORD OF REVISION

Flammable Gas l a n k Exhauster I n t e r l o c k (FGTEI) Computer Software Design Descr ip t ion

( 1 ) Document N h e r

WHC-SD-WM-CSDD- Page 1 070

CHANGE CONTROL RECORD Authorized f o r Release

( 5 ) Cog. Engr. (6 ) Cog. Mgr. Date (3) Revision ( 4 ) Descr ip t ion o f Change - Replace, Add, and De le te Pages

0 (7) I n i t i a l Release EDT #615408 8/96 JD Robinson DW ,Hamilton 1 RS Complete Revision per ECN #636514 90 L & 4/&91.

?

I I I I I

A-7320-005 (08/91) UEF168

WHC-SD-WM-CSDD-020, REV 1

FLAMMABLE GAS TANK EXHAUSTER INTERLOCK (FGTEI)

COMPUTER SOFTWARE DESIGN DESCRIPTION

September 12, 1996

Samuel 0. Smi th Ross W . T r u i t t

PLCS P l u s f o r

WESTINGHOUSE HANFORD COMPANY

WHC.SD.WM.CSDD.020, REV 1

TABLE OF CONTENTS

1.0 INTRODUCTION . . . . . . . 2

2.0 HARDWARE CONFIGURATION . . . . 2

3.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3.2 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . 3

4.0 PLC SOFTWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 9

4 . 1 GENERAL . . . . . . . . . . . . . . . . 9 4.2 LADDER LOGIC NETWORK DESCRIPTIONS . . . . . . . . . . . . . . 9

APPENDIXA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1/0 Channel L i s t . . . . . . . . . . . . . . . . . . . . . . 23

APPENDIXB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Reference Symbol Table . . . . . . . . . . . . . . . . . . . 27

APPENDIXC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 PLC System C o n f i g u r a t i o n . . . . . . . . . . . . . . . . . . 32

APPENDIXD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Ladder l o g i c Network Diagrams . . . . . . . . . . . . . . . . 36

APPENDIXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 C o i l / R e g i s t e r U t i l i z a t i o n Tables . . . . . . . . . . . . . . 55

APPENDIXF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ADU206 C o n t r o l R e g i s t e r Reference . . . . . . . . . . . . . . 68

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FLAMMABLE GAS TANK EXHAUSTER INTERLOCK (FGTEI) COMPUTER SOFTWARE DESIGN DESCRIPTION

1.0 INTRODUCTION

The Flammable Gas Tank Exhauster I n t e r l o c k (FGTEI) i s c o n t r o l l e d by a Modicon Compact Programmable Log ic C o n t r o l l e r (PLC). i n t e g r a t e s t h e i s o l a t i o n and c u r r e n t - c a r r y i n g c a p a c i t i e s o f mechanical r e l a y s w i t h t h e l o g i c and programming s o p h i s t i c a t i o n o f t h e PLC.

Th is document p rov ides d e s c r i p t i o n s o f components and t a s k s i n v o l v e d i n t h e PLC system f o r c o n t r o l l i n g and m o n i t o r i n g t h e FGTEI. f u n c t i o n s r e q u i r e d by t h e PLC, and how they a re implemented, a re desc r ibed i n d e t a i l .

The dev i ce c o n f i g u r a t i o n

A l l c o n t r o l

2.0 HARDWARE CONFIGURATION

As shown on drawings H-14-100519 and H-14-100520, t h e FGTEI PLC system

2 backplane housings (HDTA-200 and HDTA 201) 1 c o n t r o l l e r module (A984-145) 2 power supp l i es (P120) 1 120 VAC 16-channel d i s c r e t e i n p u t module (DEP218) 2 120 VAC 16-channel d i s c r e t e ou tpu t modules (DAP218) 2 4-20 mA 4-channel analog i n p u t modules (ADU206)

Appendix A l i s t s t h e s p e c i f i c backplane 1/0 s l o t s f o r each module.

Each component has been c a r e f u l l y chosen, based on i t s c a p a b i l i t i e s , t o pe r fo rm a s p e c i f i c t ask . The system i s designed t o c o l l e c t da ta f rom e x t e r n a l i n p u t s and sensors, and pe r fo rm programmed c o n t r o l t asks based on s p e c i f i e d i n p u t c r i t e r i a . The e x t e r n a l FGTEI l o g i c , us ing hard-wi red r e l a y s , works i n concer t w i t h t h e PLC l a d d e r l o g i c t o p rov ide safe o p e r a t i o n o f t h e p o r t a b l e exhauster .

i s comprised o f t h e f o l l o w i n g :

3 .0 OPERATION

3 . 1 GENERAL

The p r imary purpose o f t h e FGTEI i s t o t r i p t h e i n t e r l o c k t o t h e Rotary Mode Core Sampling (RMCS) t r u c k i f any a b o r t l i m i t s have been exceeded. These

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RMCS a b o r t s i g n a l s i n c l u d e t h e f o l l o w i n g :

High hydrogen c o n c e n t r a t i o n H igh r a t e o f change o f hydrogen (dH/dT) High combust ib le gas c o n c e n t r a t i o n High r a t e o f change o f combust ib le gas (dCG/dT) 2" W.C. above b a s e l i n e pressure alarm Emergency s top (E-STOP) s w i t c h a c t i v a t i o n Watch dog t i m e r (WDT) e x p i r a t i o n High t a n k pressure

I n a d d i t i o n , t h e FGTEI w i l l a l s o shut down t h e p o r t a b l e exhauster should t h e pressure drop below -3" W.C., o r i f t h e t a n k pressure ins t rument f a i l s .

The FGTEI samples gas from t h e r e s p e c t i v e t a n k f rom a spoo lp iece i n s t a l l e d between t h e t a n k exhaust header and t h e p o r t a b l e exhauster.

C o n t i n u i t y o f t h e t r u c k shut down c i r c u i t i s i n t e r r u p t e d by normal ly open r e l a y c o n t a c t l o c a t e d on t h e exhauster. i n t e r r u p t e d by a motor c o n t a c t o r l o c a t e d i n each FGTEI u n i t . Two FGTEI u n i t s a re p rov ided f o r redundancy and are c o n t r o l l e d independent ly by t h e i r r e s p e c t i v e PLCs.

Power t o t h e exhauster i s

The "RMCS t r u c k enable" r e l a y c o n t a c t i s c losed when c o n d i t i o n s are w i t h i n s p e c i f i e d t o l e r a n c e s . use o f a ma in ta ined arming c i r c u i t , energized by an electro-mechanical r e l a y , enabled by t h e PLC. ( v i a t h e emergency s top b u t t o n ) , can t r i p t h e c i r c u i t and de-energize t h e A.C. power t o t h e p o r t a b l e exhauster.

3 . 2 SEQUENCE OF OPERATION

The p o r t a b l e exhauster i s c o n t r o l l e d w i t h t h e

When a shutdown c o n d i t i o n occurs, t h e PLC o r o p e r a t o r

NOTE: For the f o l l o w i n g d iscuss ion , r e f e r e n c e drawings H-14-100519 and H-14-100520 are necessary.

3.2.1 Analog I n p u t S i g n a l s

F i v e 4-20 mA s i g n a l s are connected t o t h e FGTEI.

I n s i d e c a b i n e t temperature Combust ib le gas c o n c e n t r a t i o n Hydrogen c o n c e n t r a t i o n Exhaust header p ressure Outs ide c a b i n e t temperature

The s i g n a l s are:

The f i r s t f o u r s i g n a l s are connected t o t h e AOU206 module i n s l o t 7, w i t h t h e l a s t s i g n a l connected t o t h e ADU206 module i n s l o t 8. Three channels a re a v a i l a b l e f o r f u t u r e use.

Page 3

These are t h e o n l y analog i n p u t s i g n a l s


prov ided t o t h e PLC system.

3.2.2 Power I n i t i a l i z a t i o n

The system i s s t a r t e d by t h e o p e r a t o r a c t i o n o f c l o s i n g t h e d isconnects , e n e r g i z i n g t h e u n i t s . The LOSS OF POWER r e l a y c o i l ( K l ) i s i n i t i a l l y energized, c l o s i n g two normal ly-open (N.O.) r e l a y c o n t a c t s , e n e r g i z i n g t h e c o n d i t i o n e d c o n t r o l power c i r c u i t . The power i n i t i a l i z a t i o n energ izes a l l ma jor components. T h i s i n c l u d e s t h e f o l l o w i n g dev ices :

Cabinet a i r c o n d i t i o n i n g ( A / C ) u n i t

Cont ro l power c o n d i t i o n i n g u n i t Transducer s i g n a l conditioning/transmitters Modicon PLC system

As soon as t h e PLC r e c e i v e s power, an au tomat ic i n i t i a l i z a t i o n sequence

I n s i d e and o u t s i d e u t i l i t y power r e c e p t a c l e s

i s s t a r t e d . However, i f t h e c a b i n e t temperature i s below t h e o p e r a t i n g temperature o f t h e PLC, i t w i l l n o t f u n c t i o n . The c a b i n e t w i l l be r e q u i r e d t o a t t a i n a minimum o p e r a t i n g temperature, i n i t i a t e d by t h e EXH FAN START P E R M I S S I V E b u t t o n , as descr ibed i n t h e f o l l o w i n g s e c t i o n .

When t h e PLC s t a r t s o p e r a t i o n a t power-up i t begins t o c o n t r o l t h e c a b i n e t temperature t o t h e p r e d e t e r m i n e d temperature range by a c t u a t i o n o f A I R CONDITIONER r e l a y c o i l (K7) and HEATER r e l a y c o i l (K8).

The a c t u a l temperature o f t h e c a b i n e t i s be ing read by t h e PLC from a

The PLC then commands a h e a t i n g o r c o o l i n g a c t i o n , as r e q u i r e d , 4-20 mA INSIDE CABINET TEMPERATURE s i g n a l be ing generated from t h e temperature t r a n s m i t t e r . t o m a i n t a i n t h e programmed temperature.

sensed, t h e WATCH DOG t i m e r o u t p u t i s pu lsed by t h e PLC every second. T h i s i n p u t v e r i f i e s t h a t t h e c o r r e c t jumper i s i n p l a c e i n t h e e x t e r n a l cab le , ensur ing c o r r e c t system c o n f i g u r a t i o n (see r e f e r e n c e drawings) . The t a n k pressure ins t rument must a l s o be connected and t h e PLC must measure g r e a t e r than 2mA on t h e i n p u t t o enable t h e watch dog t i m e r . OK lamp t o f l a s h on and o f f con t inuous ly . (VTP-HM-2205/6) r e q u i r e s a p u l s e t o be sent a t l e a s t every 2 seconds. I f t h e PLC f a i l s , t h i s t i m e de lay r e l a y w i l l shut o f f power t o t h e exhauster by de- e n e r g i z i n g t h e ENABLE POWER TO EXHAUSTER r e l a y c o i l (K3).

3.2.3 S t a r t

I f t h e FGWL (Flammable Gas Watch L i s t ) enable i n p u t ( s l o t 4 , i n p u t 7) i s

T h i s causes t h e SYSTEM A programmable t i m e d e l a y r e l a y

NOTE: Prev ious shutdown c o n d i t i o n s may be ind i ca ted on t h e o p e r a t o r ' s console. These l i g h t s are la tched on, and w i l l not e x t i n g u i s h u n t i l t h e KEYSWITCH i s turned o f f and back on (see 3 . 2 . 4 ) .

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The sequence i s i n i t i a t e d by t h e opera tors depress ing t h e EXH FAN START PERMISSIVE(S3) b u t t o n on each u n i t . r e l a y c o i l (K2) and energ izes t h e c a b i n e t heater . The CABINET TEMPERATURE OUT OF RANGE lamp i s i l l u m i n a t e d by a N.O. c o n t a c t f rom t h e p a r a l l e l HEATER BYPASS r e l a y c o i l (K12). i s o n - l i n e and r u n n i n g i t s l a d d e r l o g i c program. When t h e PLC senses t h e HEATER BYPASS N.O. r e l a y c o n t a c t c l o s u r e (K2) on, s i g n i f y i n g t h a t t h e HEATER BYPASS r e l a y c o i l (K2) has been energized, t h e PLC de-energizes t h e HEATER BYPASS r e l a y c o i l (K2) by t o g g l i n g t h e HEATER OFF r e l a y c o i l (K4) on and o f f . I f t h e PLC i s below o p e r a t i n g temperature, t h e HEATER OFF r e l a y c o i l (K4) w i l l n o t be t o g g l e d u n t i l t h e PLC has warmed s u f f i c i e n t l y t o beg in o p e r a t i o n .

I f t h e FGWL Enable i n p u t i s on (enab l ing t h e WDT c o n t a c t ) then t h e ENABLE POWER TO EXHAUSTER r e l a y c o i l (K3) i s energ ized and main ta ined ( l a t c h e d ) . The N.O. r e l a y c o n t a c t c l o s u r e (K3) i s c losed, and i f a l l r e q u i r e d c o n d i t i o n s are met i n t h e PLC, t h e PLC energ izes t h e MOTOR STARTER r e l a y c o i l (K6), p r o v i d i n g power t o t h e exhauster by e n e r g i z i n g t h e POWER CONTACTOR r e l a y c o i l (MS). A d d i t i o n a l l y , t h e PLC w i l l enable t h e RMCS t r u c k i n t e r l o c k i f t h e proper c o n d i t i o n s have been s a t i s f i e d .

RMCS t r u c k i n c l u d e t h e f o l l o w i n g :

The a c t i o n energ izes t h e HEATER BYPASS

Since t h e d isconnects have been p r e v i o u s l y c losed, t h e PLC

The r e q u i r e d c o n d i t i o n s t h a t need t o be met i n t h e PLC t o enable t h e

FGWL enable i n p u t ON KEYSWITCH i n ON p o s i t i o n Hydrogen c o n c e n t r a t i o n l e s s than alarm va lue

0 Rate o f change o f hydrogen (dH/dT) l e s s than a la rm va lue Combust ib le gas c o n c e n t r a t i o n l e s s than a la rm va lue Rate o f change o f combust ib le gas (dCG/dT) l e s s than a la rm va lue Pressure w i t h i n range (no more than 2" W.C. above b a s e l i n e , and l e s s than t h e h i g h pressure alarm s e t t i n g o f -0.1" W.C.)

The r e q u i r e d c o n d i t i o n s t h a t need t o be met i n t h e PLC t o enable t h e

FGWL enable i n p u t ON Pressure above low l i m i t (p ressure above -3" W.C.) Pressure s i g n a l OK (measured i n p u t g r e a t e r than 2mA)

When t h e PLC senses t h a t t h e POWER CONTACTOR r e l a y i s energized, t h e

p o r t a b l e exhauster i n c l u d e t h e f o l l o w i n g :

"POWER CONTACTOR" lamp i s then i l l u m i n a t e d under program c o n t r o l .

Page 5


3.2.4 Shutdown

1 i s t e d b e l ow: The RMCS INTERLOCK r e l a y (K10) can be de-energized by t h e c o n d i t i o n s

High hydrogen c o n c e n t r a t i o n High r a t e o f change o f hydrogen (dH/dT) 2 " W.C. above b a s e l i n e pressure alarm High combust ib le gas c o n c e n t r a t i o n High r a t e o f change o f combust ib le gas (dCG/dT) H igh t a n k pressure

The PLC w i l l l i g h t an i n d i c a t o r l i g h t , on t h e o p e r a t o r ' s console, i d e n t i f y i n g t h e c o n d i t i o n causing t h e shutdown f o r t h e above c o n d i t i o n s . l i g h t i s l a t c h e d on, and w i l l n o t e x t i n g u i s h u n t i l t h e KEYSWITCH i s tu rned o f f , which w i l l r e s e t any l a t c h e d alarms. Two a d d i t i o n a l events w i l l cause t h e RMCS INTERLOCK r e l a y t o de-energize:

T h i s

Loss o f A.C. Power KEYSWITCH i n OFF p o s i t i o n

The p o r t a b l e exhauster can be shut down by t h e f o l l o w i n g c o n d i t i o n :

0 Tank Low Pressure Alarm (-3" W.C. o r below)

Again, t h e PLC w i l l l i g h t an i n d i c a t o r l i g h t on t h e o p e r a t o r ' s console, i d e n t i f y i n g a PRESSURE alarm. T h i s l i g h t i s l a t c h e d on, and w i l l n o t e x t i n g u i s h u n t i l t h e KEYSWITCH i s t u r n e d o f f , which w i l l r e s e t any l a t c h e d alarms. FAN START PERMISSIVE(S3) b u t t o n . Four a d d i t i o n a l events w i l l cause t h e p o r t a b l e exhauster t o shut down:

The p o r t a b l e exhauster enable must be manual ly r e s t a r t e d from t h e EXH

.Tank pressure s i g n a l l e s s than 2mA (open c i r c u i t d e t e c t i o n ) Emergency s t o p (E-STOP) s w i t c h a c t i v a t i o n Loss o f A.C. Power Watch dog t i m e r e x p i r a t i o n

3.2.4.1 High Hydrogen Concent ra t ion

I f a h i g h hydrogen c o n c e n t r a t i o n (above 5000 ppm) i s de tec ted , t h e HYDROGEN lamp w i l l be energized, t h e STROBE LIGHT r e l a y c o i l (K11) w i l l energize, and t h e RMCS INTERLOCK r e l a y c o i l (K10) w i l l de-energize. T h i s w i l l cause t h e RMCS t r u c k t o shut down.

3.2.4.2 H igh Rate o f Change o f Hydrogen Concent ra t ion (dH/dT)

I f a h i g h r a t e o f change o f hydrogen c o n c e n t r a t i o n (above 100 ppm/sec f o r 10 seconds) i s de tec ted , t h e dH/dT lamp w i l l be energized, t h e STROBE

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LIGHT r e l a y c o i l (K11) w i l l energ ize , and t h e RMCS INTERLOCK r e l a y c o i l (K10) w i l l de-energize. T h i s w i l l cause t h e RMCS t r u c k t o shut down.

3.2 .4 .3 Cabine t Temperature Out of Range

s e t p o i n t (95 degrees F . ) by t h e PLC, t h e CABINET TEMPERATURE OUT OF RANGE lamp w i l l be energized. T h i s lamp w i l l a l s o be i l l u m i n a t e d whenever t h e p a r a l l e l HEATER BYPASS r e l a y c o i l (K12) i s energized, i n d i c a t i n g t h e c a b i n e t temperature i s t o o l o w f o r PLC o p e r a t i o n .

3 . 2 . 4 . 4 2" W.C. Above B a s e l i n e Pressure Alarm

I f t h e pressure i s observed t o be 2 " W . C . above t h e b a s e l i n e pressure, t h e PRESSURE lamp w i l l be energized, the STROBE LIGHT r e l a y c o i l (K11) w i l l energize, and t h e RMCS INTERLOCK r e l a y c o i l (K10) w i l l de-energize. T h i s w i l l cause t h e RMCS t r u c k t o shut down.

NOTE: A t power-up, a tank pressure r e a d i n g i s taken, and t h e high

I f t h e c a b i n e t temperature i s sensed t o be o u t s i d e o f t h e h i g h alarm

p r e s s u r e a la rm i s s e t t o 2" W.C. above t h i s background l e v e l . A s soon as t h e exhauster beg ins o p e r a t i n g , a d r o p i n p r e s s u r e w i l l occur, and 3 minutes l a t e r t h e h i g h p r e s s u r e a la rm i s s e t t o 2" W . C . above t h i s new pressure . Every 5 minu tes d u r i n g exhauster opera t ion , t h e h i g h pressure alarm i s updated t o 2" W . C . above t h e c u r r e n t tank pressure read ing . T h i s a l l o w s f o r normal t a n k p r e s s u r e f l u c t u a t i o n s .

3 . 2 . 4 . 5 High Combust ib le Gas Concent ra t ion

ppm), t h e COMBUSTIBLE GASSES lamp w i l l be energized, t h e STROBE LIGHT r e l a y c o i l (K11) w i l l energize, and t h e RMCS INTERLOCK r e l a y c o i l (K10) w i l l de- energ ize . T h i s w i l l cause t h e RMCS t r u c k t o shut down.

3.2 .4 .6 High Rate o f Change of Combust ib le Gas (dCG/dT)

I f a h i g h r a t e o f change o f combust ib le gas c o n c e n t r a t i o n (above 100 ppm/sec f o r 10 seconds) i s de tec ted , t h e dCG/dT lamp w i l l be energized, t h e STROBE LIGHT r e l a y c o i l (K11) w i l l energize, and t h e RMCS INTERLOCK r e l a y c o i l (K10) w i l l de-energize. T h i s w i l l cause t h e RMCS t r u c k t o shut down.

3.2 .4 .7 Tank Pressure Alarm

I f t h e pressure i s observed t o be below -3" W.C., t h e PRESSURE lamp w i l l be energized, t h e MOTOR STARTER r e l a y c o i l (K6) w i l l be de-energized, and t h e E-STOP r e l a y c o i l (K5) w i l l be togg led . T h i s de-energizes t h e ENABLE POWER TO EXHAUSTER r e l a y c o i l (K3 ) .

I f t h e combust ib le gas c o n c e n t r a t i o n reaches t h e a la rm l i m i t (above 5000

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I f t h e t a n k pressure i s observed t o be above -0.1" W.C. , t h e STROBE LIGHT r e l a y c o i l (K11) w i l l energize, and t h e RMCS INTERLOCK r e l a y c o i l (K10) w i l l de-energize. Th is w i l l cause t h e RMCS t r u c k t o shut down.

3 . 2 . 4 . 8 E-STOP

The depress ion o f t h e EMER STOP (S2) b u t t o n d i r e c t l y de-energizes t h e POWER CONTACTOR and i s sensed by t h e PLC by t h e EMER STOP pushbutton s w i t c h p o l e . The PLC then ac tua tes t h e E-STOP r e l a y c o i l (K5), redundant ly de- e n e r g i z i n g t h e POWER CONTACTOR r e l a y c o i l (MS), which shuts down t h e exhauster.

3 . 2 . 4 . 9 Watch Dog Timer

A watch dog t i m e r (WDT) must be p e r i o d i c a l l y r e s e t by t h e PLC any t i m e t h e PLC i s runn ing . T h i s i s accomplished by e n e r g i z i n g and de-energ iz ing t h e WATCH DOG r e l a y c o i l (K9) every second. The r e s e t command w i l l be e v i d e n t t o t h e o p e r a t o r by t h e f l a s h i n g o f t h e SYSTEM OK lamp (DS2) a t t h e o p e r a t o r ' s console. Togg l ing a N.O. r e l a y c o n t a c t c l o s u r e (K9) r e s e t s t h e WDT. The WDT m a i n t a i n s a N.O. r e l a y c o n t a c t c l o s u r e i n t h e arming c i r c u i t . begins o p e r a t i n g on power-up, t h e WDT N.O. r e l a y c o n t a c t i s i n i t i a l l y c losed. I f t h e WDT f a i l s t o g e t r e s e t by t h e PLC, t h e t i m e r w i l l e x p i r e and open t h e N.O. c o n t a c t , de-energ iz ing t h e POWER CONTACTOR (MS) . T h i s w i l l be e v i d e n t on t h e o p e r a t o r ' s panel by t h e c e s s a t i o n o f t h e f l a s h i n g o f t h e SYSTEM OK lamp, a shutdown o f power t o t h e exhauster, and t h e l o s s o f t h e POWER TO EXHAUSTER lamp (DS3). A d d i t i o n a l l y , i f power f a i l s , t h e N.O. c o n t a c t c l o s u r e w i l l r e t u r n t o t h e N.O. s t a t e .

When t h e PLC

NOTE: I f t h e FGWL ENABLE input ( s l o t 4 , input 7) i s n o t sensed by the PLC, then t h e SYSTEM OK lamp w i l l n o t f l a s h and t h e watch dog t i m e r w i l l n o t be r e s e t . The c o r r e c t cab les must be connected t o the FGTEI c a r t s a t J5A ( c a r t 2205) and J12A ( c a r t 2206) t o a l l o w p r o p e r FGTEI o p e r a t i o n .

A d d i t i o n a l l y , i f t h e tank pressure s i g n a l input i s l e s s than 2mA, the SYSTEM OK lamp w i l l n o t f l a s h and t h e watch dog t i m e r w i l l n o t be r e s e t . T h i s i n d i c a t e s an open c i r c u i t f r o m t h e tank p r e s s u r e s i g n a l , o r a f a i l e d pressure ins t rument .

3 . 2 . 4 . 1 0 Loss o f A . C . Power

A l o s s o f A.C. power w i l l drop o u t a l l hard-wired r e l a y c o i l s , as w e l l as de-energize t h e PLC. RMCS t r u c k and s t a r t t h e p o r t a b l e exhauster again.

The s t a r t - u p sequence must be performed t o enable t h e

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3.2 .4 .11 Keyswitch

alarm r e s e t . t h e ON p o s i t i o n t o s t a r t , b u t t h e RMCS t r u c k DOES r e q u i r e i t ' s use. KEYSWITCH must be i n t h e ON p o s i t i o n f o r alarms t o be l a t c h e d . l a t c h e d alarms, s imp ly t u r n t h e KEYSWITCH t o t h e OFF p o s i t i o n and then back t o t h e ON p o s i t i o n .

The KEYSWITCH i s used as a "Truck Enable" i n p u t , as w e l l as a l a t c h e d The p o r t a b l e exhauster does n o t r e q u i r e t h e keyswi tch t o be i n

The To r e s e t

4 . 0 PLC SOFTWARE DESCRIPTION

4 . 1 GENERAL

Ladder l o g i c f o r t h e FGTEI has been developed u t i l i z i n g FGTEI elementary

Programming t h e PLC i s accomplished w i t h a MS-DOS based 486 PC runn ing

diagrams and o p e r a t i o n a l des ign i n f o r m a t i o n .

Modsoft , a so f tware package prov ided by Modicon, I n c . The l a d d e r l o g i c i s downloaded t o t h e PLC v i a an RS-232 l i n k , r e f e r r e d t o by Modicon as Modbus. T h i s RS-232 connect ion w i l l a l s o p r o v i d e t h e communication p a t h when t h e FGTEI i s connected t o a l a p t o p PC i n t h e f i e l d ( o r d u r i n g t e s t i n g ) . C a r t 2205 u t i l i z e s JlOA as t h e l a p t o p i n t e r f a c e connector, w h i l e c a r t 2206 uses J16A.

I n c l u d e d i n t h e appendices o f t h i s document are:

1/0 channel l i s t (Appendix A) Reference symbol t a b l e (Appendix B) PLC system c o n f i g u r a t i o n (Appendix C ) Ladder l o g i c network diagrams (Appendix D) C o i l / r e g i s t e r u t i l i z a t i o n t a b l e s (Appendix E) ADU206 c o n t r o l r e g i s t e r r e f e r e n c e (Appendix F)

4.2 LADDER LOGIC NETWORK DESCRIPTIONS

The f o l l o w i n g s e c t i o n s d e s c r i b e t h e i n d i v i d u a l networks t h a t c o l l e c t i v e l y make up t h e l a d d e r l o g i c o f t h e FGTEI PLC system. Refer t o Appendix D f o r t h e a p p r o p r i a t e l a d d e r l o g i c network diagram.

4 . 2 . 1

watch dog t i m e r and t o p r o v i d e a 10-second power-up de lay t i m e r f o r use w i t h a1 arms.

Network 1 - Watch Dog / Powerup Delay Timers

T h i s network has two f u n c t i o n s -- t o c o n t r o l t h e p u l s e t r a i n t o t h e

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WHC-SD-WM-CSOD-020, REV 1

4 . 2 . 1 . 1 Watch Dog Timer

second t i m e r b l o c k , w i t h a m u l t i p l i e r o f 10, t o p r o v i d e a p u l s e every 1.0 seconds.

A N.C. c o n t a c t 204 (WDTCOUNT) c o n t r o l s t h e r e s e t o f t h e t i m e r .

The watch dog t i m e r (WDT) p o r t i o n o f t h i s network uses an i n t e r n a l 0 . 1

Output c o i l WDTCOUNT energ izes a f t e r 1 second, which r e s e t s t h e t i m e r by opening t h e N.C. c o n t a c t on t h e r e s e t i n p u t . The t i m e r o u t p u t then de-energizes WDTCOUNT, which s t a r t s t h e t i m e r again. T h i s process i s repeated c o n t i n u a l l y w h i l e t h e PLC i s i n o p e r a t i o n .

A SUB b l o c k uses t h e t i m e r r e g i s t e r 41200 (WDTTIMR) t o p r o v i d e a square- wave o u t p u t t o c o i l 12 (WDTO). Whenever WOTTIMR i s l e s s than 5, t h e WDTO c o i l i s energized, and remains energized f o r 0 .5 seconds.

NOTE: A N.O. c o n t a c t 10007 (FGWLEI) i s i n s e r i e s b e f o r e WDTO. T h i s r e q u i r e s FGWLEI t o be energ ized f o r the WDTO c o i l t o t o g g l e as d e s c r i b e d above. T h i s input i s t h e FGWL ENABLE input ( s l o t 4, input 7). See s e c t i o n 3.2.4.9.

An a d d i t i o n a l N.C. c o n t a c t 402 i s i n s e r i e s b e f o r e WDTO. T h i s c o n t a c t i s c o n t r o l l e d b y the s t a t u s b i t f o r t h e t a n k p r e s s u r e s i g n a l input (see Network 4 - s e c t i o n 4 . 2 . 4 ) . I f t h e s i g n a l i s measured t o be tZmA, then c o i l 402 i s energized, and the N.C. c o n t a c t 402 opens up, d i s a b l i n g WDTO.

The WDTO c o i l i s hardware-mapped t o the WATCH DOG o u t p u t r e l a y c o i l ( K 9 ) . The p u l s e o u t p u t w i l l cause f l a s h i n g o f t h e SYSTEM OK lamp a t t h e o p e r a t o r ' s console. (N.O.) r e l a y c o n t a c t c l o s u r e i n t h e arming c i r c u i t . f a i l s t o g e t r e s e t b y t h e PLC, t h e t i m e r w i l l e x p i r e and open the N . O . c o n t a c t c losure , de-energ iz ing t h e POWER CONTACTOR (MS). T h i s w i l l be e v i d e n t on t h e o p e r a t o r ' s pane l b y t h e c e s s a t i o n o f t h e f l a s h i n g o f t h e SYSTEM OK lamp, a shutdown o f power t o t h e exhauster, and t h e loss o f the POWER TO EXHAUSTER lamp.

The WDT m a i n t a i n s a n o r m a l l y open I f t h e WDT

4 . 2 . 1 . 2 Powerup De lay Timer

The purpose o f t h i s t i m e r i s t o generate a c o n t a c t c l o s u r e f o r i n t e r n a l c o i l 205 (PWRUPTMR) 10 seconds a f t e r i n i t i a l power up o f t h e PLC. Using an i n t e r n a l 1.0 second t i m e r b l o c k , w i t h a m u l t i p l i e r o f 10, c o i l PWRUPTMR goes h i g h 10 seconds a f t e r i n i t i a l power up v i a i n t e r n a l c o i l 101 (POWERUP). C o i l POWERUP i s d iscussed i n s e c t i o n 4.2.2.

T h i s 10-second de lay i s used f o r two purposes. The f i r s t i s t o l o a d t h e h i g h pressure a la rm l i m i t t o 2" W . C . above t h e background pressure . d iscussed i n s e c t i o n 4.2.3.

Th is i s

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The second use f o r PWRUPTMR i s t o d i s a b l e any a la rm c o n d i t i o n s f o r 10 T h i s i s seconds a f t e r power up, t o ensure t h e ins t ruments have s t a b i l i z e d .

discussed i n s e c t i o n s 4.2.10 and 4.2.11.

4.2.2 Network 2 - Toggle HEATOFFO Relay (K4) / Set HIPRABVAL

T h i s network has two f u n c t i o n s -- t o t o g g l e t h e Heater Bypass r e l a y (K2) a l l o w i n g t h e PLC t o t a k e c o n t r o l o f t h e HVAC o f t h e FGTEI c a r t and t o s e t t h e pressure a la rm l i m i t f o r t h e exhauster d u r i n g i t s o p e r a t i o n .

4.2.2.1 Toggle HEATOFFO Relay (K4)

c o n t a c t s f rom t h i s c o i l a re used th roughout t h e FGTEI l a d d e r l o g i c , p r i m a r i l y t o i n i t i a l i z e values on power up o f t h e PLC.

I n t h i s network, POWERUP, i n s e r i e s w i t h a N.C. c o n t a c t 10003 (HBYPASSI), c o n t r o l s t h e r e s e t i n p u t f o r a 2 second t i m e r . t i m e r b lock , w i t h a m u l t i p l i e r o f 20, ho lds t h e o u t p u t o f c o i l 7 (HEATOFFO) h i g h f o r 2 seconds, then de-energizes it.

HEATOFFO i s hardware-mapped t o t h e HEATER OFF o u t p u t r e l a y c o i l (K4), which w i l l drop o u t r e l a y c o i l K2 (and p a r a l l e l r e l a y c o i l K12), t u r n i n g o f f t h e HEATER BYPASS.

When HBYPASSI i s c losed, t h i s a l s o opens t h e N.C. c o n t a c t f rom HBYPASSI and energ izes HEATOFFO f o r two seconds. up, a 2-second e n e r g i z a t i o n o f HEATOFFO occurs, as w e l l as any t i m e t h e EXH FAN START P E R M I S S I V E b u t t o n i s pressed (which causes HBYPASSI t o energ ize K2).

4.2.2.2 Set HIPRABVAL

an o u t p u t 180 seconds (3 minutes) a f t e r t h e exhauster i s s t a r t e d . generated by a p o s i t i v e - t r a n s i t i o n f rom i n t e r n a l c o i l 206 (BKGNDTMRl). p u l s e i s used t o perform an a d d i t i o n f u n c t i o n when t h e exhauster i s r u n n i n g t o e s t a b l i s h a new h i g h pressure alarm l i m i t ( r e g i s t e r 41013 - HIPRABVAL) t o 2" W.C. above t h e " runn ing" b a s e l i n e pressure l e v e l ( r e g i s t e r 30005 - PRESSVAL).

An a d d i t i o n a l p o s i t i v e - t r a n s i t i o n c o n t a c t fro! c o i l 207 (BKGNDTMRZ) a l s o causes HIPRABVAL t o be updated w i t h PRESSVAL p l u s 2 T h i s occurs every 5 minutes w h i l e t h e exhauster i s runn ing , and i s discussed i n network 6 ( s e c t i o n 4.2.6.2).

On power-up, i n t e r n a l c o i l 101 (POWERUP) i s energized. I n t e r n a l

The 0.1 second

A N.O. c o n t a c t f rom K2 i s hardware-mapped t o c o i l 10003 (HBYPASSI).

There fore , when t h e PLC i s f i r s t powered

A 1.0 second t i m e r b l o c k , w i t h a m u l t i p l i e r o f 180, i s used t o generate A p u l s e i s

The

W.C.

If t h e r e s u l t o f t h e SUB b l o c k i s determined t o be above 0 "W.C. , then

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t h e f o l l o w i n g BLKM b l o c k moves ZERO (41003) i n t o 41013 (HIPRABVAL). T h i s


ensures t h a t t h e h i g h pressure alarm l i m i t never exceeds 0" W,C.

4 .2 .3 Network 3 - Alarm and Abor t I n i t i a l i z a t i o n

D u r i n g power-up, t h e pos i t i ve-edge r e c o g n i t i o n o f POWERUP causes t h e N.O. c o n t a c t 101 (POWERUP) t o c l o s e . T h i s enables t h e ADD b l o c k s t o per fo rm t h e a d d i t i o n shown, b u t o n l y one t i m e due t o t h e n a t u r e o f a p o s i t i v e - e d g e t r i g g e r e d c o n t a c t . The r e s u l t o f t h e ADD i s t r a n s f e r r e d t o t h e des ignated r e g i s t e r used f o r s e t p o i n t s f o r alarms, abor ts , and temperature c o n t r o l .

r e s p e c t i v e s e t p o i n t va lue t r a n s f e r s . Two MUL ( m u l t i p l y ) b l o c k s are used t o c r e a t e cons tan ts above t h e l i m i t a t i o n number o f 999 f o r d i r e c t cons tan t use. The f i r s t MUL b l o c k c r e a t e s t h e number 2000 by p l a c i n g (500 x 4) i n t h e r e a i s t e r o a i r a t address 41300. T h i s o laces t h e number 2000 i n t o r e q i s t e r

The ADD b l o c k s use cons tan ts added t o o t h e r cons tan ts t o accompl ish t h e

-_I - - 41301 (TWiTHOUSAND). r e g i s t e r 41303 (THREETHOUSAND).

The remaining M U i b l o c k c r e a t e s t h e number 3006 i n t o

The f i r s t ADD b l o c k adds 2000 t o zero (#OOOO), p l a c i n g t h e r e s u l t i n t o r e g i s t e r 41006 (HHZABVAL). va lue one t ime, a t s t a r t - u p .

T h i s i n i t i a l i z e s t h e HIGH HYDROGEN ABORT s e t p o i n t

The remain ing ADD b l o c k s i n i t i a l i z e t h e f o l l o w i n g :

41001 (TCLOVAL) TEMPERATURE CONTROL LOW = 1125 (45°F.) 41002 (TCHIVAL) 41004 (TAHIVAL)

TEMPERATURE CONTROL HIGH = 2125 (85°F.) TEMPERATURE ALARM HIGH = 2375 (95'F.)

41005 (CGABVAL) 41006 (HHZABVAL) 41008 (DHDTABVAL)

41508 (DCGDTABVAL) dCG/dT ABORT = 40 (100 ppm/sec.)

COMBUSTIBLE GAS ABORT = 2000 (5000 ppm) H I G H HYDROGEN ABORT = 2000 (5000 ppm) dH/dT ABORT = 40 (100 ppm/sec.)

41012 (LOPRABVAL) LOW PRESSURE ABORT = 1200 (-3" W.C. )

A l l analog i n p u t s a re 4-20 mA. The ADU206 modules are c o n f i g u r e d t o read 0 a t 4 mA, and 4000 a t 20 mA (see s e c t i o n 4 .2 .4 ) . f o r a l l i n p u t s a re as f o l l o w s :

Hydrogen: Combust ib le Gas: Pressure: 0 - 4000 = 0 t o -10 "W.C. (.0025 "W.C./count) Temperatures: 0 - 4000 = 0 t o 160 degrees F. ( .04"F /count )

The c a l i b r a t i o n s used

0 - 4000 = 0 t o 10,000 ppm (2.5 ppm/count) 0 - 4000 = 0 t o 10,000 ppm (2.5 ppm/count)

4 .2 .4 Network 4 - ADU206 I n i t i a l i z a t i o n

The ADU206 modules r e q u i r e an i n i t i a l i z a t i o n r e g i s t e r t o be loaded p r i o r t o use. T h i s network i n i t i a l i z e s t h e ADU206 4-channel analog i n p u t modules i n s l o t s 7 and 8. One t i m e o n l y , upon power-up, a N.O. p o s i t i v e - e d g e t r i g g e r e d c o n t a c t 101 (POWERUP) i s c losed.

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The s i n g l e c l o s u r e o f POWERUP enables t h e ADD b l o c k s t o per fo rm t h e a d d i t i o n shown. s e t t h e mode o f o p e r a t i o n f o r t h e ADU206 modules. i s used f o r t h e module i n s l o t 7, and r e g i s t e r 40002 (MODZMODE) i s used f o r t h e module i n s l o t 8.

ADD b l o c k s are used t o add cons tan ts t o zero t o accompl ish t h i s . For example, t h e f i r s t ADD b l o c k adds 112 (#0112) t o zero (#OOOO), p l a c i n g t h e r e s u l t i n t o r e g i s t e r 40001 (MODIMODE). T h i s i n i t i a l i z e s t h e ADU206 module t o u n i p o l a r mode w i t h o f f s e t and extended r e s o l u t i o n (see Appendix F ) . I n t h i s mode, a l l 4-20 mA i n p u t s a re read as 0000 when 4 mA i s i n p u t , and 4000 a t 20 mA .

T h i s network a l s o i n i t i a l i z e s t h e system cons tan t ZERO t o 0. accomplished by adding 0 t o 0 ( u s i n g an ADD b l o c k ) w i t h t h e r e s u l t p laced i n t o r e g i s t e r 41003 (ZERO).

T h i s t r a n s f e r s t h e r e s u l t t o t h e des ignated r e g i s t e r s used t o R e g i s t e r 40001 (MODlMODE)

T h i s i s

T h i s cons tan t i s used i n networks 2, 13, and 15.

R e g i s t e r 41401 (HITANKPRESSVAL) i s i n i t i a l i z e d t o 40 (-0.1 "W.C. ) i n t h i s network by u s i n g an ADD b l o c k t o add 0 t o 40, s t o r i n g t h e r e s u l t i n t o r e g i s t e r 41401.

T e s t i n g o f t h e pressure s i g n a l i n p u t i s a l s o performed i n t h i s network B i t 13 i n r e g i s t e r 30001 ( t h e ADU206 w i t h t h e use o f a SENS (sense) blo;k.

s t a t u s r e g i s t e r ) w i l l be s e t t o a 1" i f t h e i n p u t i s sensed t o be l e s s than 2 mA. Should t h i s happen, i n t e r n a l c o i l 402 w i l l energ ize and t h e N.C. c o n t a c t 402 used i n Network 1 w i l l open, causing t h e WDTO c o i l t o s top p u l s i n g (see s e c t i o n 4 .2 .1 .1 ) .

4 . 2 . 5 Network 5 - Exhauster k RMCS Truck Shutdown

p o r t a b l e exhauster (K6), t o e n a b l e / d i s a b l e t h e RMCS t r u c k i n t e r l o c k (KlO), and t o c o n t r o l t h e ESTOP r e l a y (K5) .

4.2.5.1 Exhauster (Motor S t a r t e r ) Enable Output

(MOTSTRTO). W.C. (N.C. c o n t a c t 300 - see s e c t i o n 4 .2 .11 .1 ) , t h e E-Stop s w i t c h i s n o t pressed (N.O. b u t n o r m a l l y energized c o n t a c t l O O O l ) , and t h e FGWL i n p u t i s enabled ( N . O . c o n t a c t 10007), and t h e EXH FAN START P E R M I S S I V E s w i t c h i s de tec ted v i a t h e HEATER BYPASS (K2) N.O. con tac t , hardware-mapped t o 10003 (HBYPASSI).

Once MOTSTRTO i s energized, i t i s l a t c h e d i n p l a c e w i t h a N.O. c o n t a c t c o n t r o l l e d by MDTSTRTO. The MOTSTRTO c o i l w i l l de-energize o n l y i f t h e t a n k pressure drops below -3" W.C., t h e FGWL enable i n p u t i s removed, o r t h e E-STOP b u t t o n c o i l 10001 (ESTOPI) i s energized.

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T h i s network has t h r e e f u n c t i o n s -- t o c o n t r o l t h e power o u t p u t t o t h e

The MOTOR STARTER o u t p u t r e l a y (K6) i s hardware-mapped t o o u t p u t c o i l , , 9 T h i s c o i l i s energized o n l y when t h e t a n k pressure i s above -3

WHC-SO-WM-CSOO-020, REV 1

4.2.5.2 RMCS I n t e r l o c k (K10)

The RMCS INTERLOCK o u t p u t r e l a y (K10) i s hardware-mapped t o o u t p u t c o i l 13 (RMCSO). T h i s c o i l i s energized o n l y when no a b o r t c o n d i t i o n s e x i s t ( w i t h t h e N.O. c o n t a c t l o o ) , t h e FGWL i n p u t i s enabled (N.O. c o n t a c t 10007), and t h e KEYSWITCH i s enabled ( w i t h t h e N.0 c o n t a c t 10006).

FGWL enable i n p u t i s removed, o r t h e KEYSWITCH i s d i s a b l e d .

f o l l owing:

The RMCSO c o i l w i l l de-energize o n l y i f an a b o r t c o n d i t i o n occurs, t h e

The composi te a b o r t ( c o i l 100) i s made up w i t h N.C. c o n t a c t s f rom t h e

00001 (HIGHHLO) H I G H HYDROGEN CONCENTRATION 00005 (OHOTO) dH/dT OUT 00301 (OELTAPRESS) DELTA PRESSURE ALARM 00004 (COMBGALO) COMBUSTIBLE GAS ALARM 00006 (OCGOTO) dCG/dT OUT

and a N.0 c o n t a c t from: 10001 (ESTOPI) E-STOP BUTTON INPUT

E n e r g i z i n g any o f t h e f i r s t f i v e c o i l s l i s t e d above ( o r de-energ iz ing 10001 w i t h t h e E-Stop b u t t o n ) w i l l cause t h e composite c o i l 100 (COMPABORT) t o de-energize. I f RMCSO (which enables t h e RMCS t r u c k i n t e r l o c k ) i s energ ized when t h i s occurs, RMCSO w i l l de-energize.

00005, 00301, 00004, and 00006) energ ize c o i l 208 (NOTSTROBE). T h i s i s t h e i n v e r t e d s t r o b e c o n t r o l ou tpu t , and w i l l be discussed i n t h e f o l l o w i n g network (network 6 ) .

4.2.6

A d d i t i o n a l l y , t h e N.C. c o n t a c t s f rom t h e f i r s t f i v e c o i l s above (00001,

Network 6 - St robe / Background Pressure

T h i s network has two d i s t i n c t f u n c t i o n s - t o c o n t r o l t h e s t r o b e l i g h t ou tpu t , and t o update t h e h igh-pressure a b o r t l e v e l (2 " W . C . above b a s e l i n e pressure) .

4.2.6.1 S t robe L i g h t C o n t r o l

LIGHT (K11). T h i s o u t p u t goes on when t h e c o i l t o N.C. c o n t a c t 208 (NOTSTROBE) i s de-energized. s e c t i o n 4.2.5.2).

4.2.6.2 Background Pressure Timer

C o i l 207 (BKGNOTMR2) i s used t o update t h e 2" W . C . above b a s e l i n e pressure a b o r t (HIPRABVAL - as discussed i n s e c t i o n 4.2.2.2) every f i v e

Page 14

Output c o i l 14 (STROBEO) i s hardware-mapped t o e x t e r n a l r e l a y STROBE

T h i s occurs under RMCS a b o r t c o n d i t i o n s (see


minutes w h i l e t h e exhauster i s runn ing . The N.O. c o n t a c t 206 (BKGNDTMRl) i s used as an i n d i c a t o r t h a t t h e exhauster i s r u n n i n g - i t a l s o serves as t h e s t a r t t i m e a f t e r t h e i n i t i a l 3-minute update.

The N.C. c o n t a c t 207 ( i n s e r i e s w i t h t h e N.O. c o n t a c t 206) i s used as a r e s e t c o n t r o l f o r t h e 300 second t i m e r b l o c k t h a t c o n t r o l s c o i l 207. T h i s t i m e r b l o c k c o n t i n u a l l y counts 300 seconds ( f i v e minu tes) , r e s e t s , and counts aga in w h i l e t h e exhauster i s runn ing . I f t h e exhauster i s stopped, then c o i l 206 w i l l de-energize, caus ing t h e updates t o d i s c o n t i n u e (see s e c t i o n 4.2.2.2).

The SUB b l o c k i s used t o compare t h e r e a l - t i m e t a n k pressure ( r e g i s t e r 30001 - PRESSVAL) w i t h t h e 2 " W.C. above b a s e l i n e pressure a b o r t l i m i t ( r e g i s t e r 41013 - HIPRABVAL). I f t h e t a n k pressure i s above t h e l i m i t , then t h e a la rm c o i l 301 (DELTAPRESS) i s energized. However, t h e N.O. c o i l 206 (BKGNDTMRl) i n s e r i e s w i t h c o i l 301 ensures t h a t t h e a la rm o n l y occurs i f t h e exhauster i s r u n n i n g ( c o i l 301 o n l y a b o r t s t h e p o r t a b l e exhauster, and s i n c e t h e 2 " W.C. above b a s e l i n e background pressure a b o r t l i m i t i s updated o n l y when t h e exhauster i s runn ing , HIPRABVAL w i l l n o t have c u r r e n t i n f o r m a t i o n i n i t un less t h e exhauster i s runn ing) .

The N.O. c o i l 10006 (KBYPASSI) i s t h e keyswi tch i n p u t . I f i t i s energ ized (KEYSWITCH ON), then i f c o i l 301 i s energized, t h e c o i l i s s e l f - l a t c h i n g ( w i t h t h e use o f t h e N.O. c o n t a c t 301) . The KEYSWITCH must be tu rned OFF t o r e s e t t h e alarm c o n d i t i o n .

N.O. c o i l 401 (HITANKPRESS) w i l l a l s o energ ize c o i l 301. T h i s c o i l i s c o n t r o l l e d by t h e h i g h t a n k pressure alarm o f -0.1 " W . C . ( s e e Network 9 - s e c t i o n 4.2.9.4).

4 .2 .7 Network 7 - Low Temperature Cont ro l (HEAT)

Output c o i l 11 (HEATONO) i s hardware-mapped t o e x t e r n a l r e l a y HEATER

R e g i s t e r 30002 (ICBTEVAL) i s t h e I n s i d e Cabinet Temperature. It i s

(K8).

compared t o t h e l o w temperature c o n t r o l s e t p o i n t (TCLOVAL) u s i n g a SUB b l o c k t o p e r f o r m a s u b t r a c t i o n . a p p l i e d t o t h e ad jacent ADD b l o c k and c o i l 200 (HEATCONTl) i s energized. The f u n c t i o n of t h e ADD b l o c k i s t o s e t t h e deadband f o r temperature c o n t r o l . ADD b l o c k adds 125 (5 degrees F.) t o t h e low temperature s e t p o i n t , TCLOVAL, and p laces i t i n t o r e g i s t e r 41102 (HTCONDVAL), t h e h e a t i n g c o n t r o l d e l t a Val ue.

energized. T h i s a l l o w s t h e N.O. c o n t a c t f rom HEATCONTL t o pass power t o t h e f i n a l SUB b l o c k , which performs t h e a c t u a l c o n t r o l t o t h e h e a t e r . HTCONDVAL i s s u b t r a c t e d from ICBTEVAL, and HEATONO i s energized w h i l e ICBTEVAL i s l e s s

When t h e HEATER r e l a y i s energized, t h e heater i s on.

I f ICBTEVAL i s l e s s than TCLOVAL, then power i s

The

When c o i l 200 (HEATCONTl) i s energized, c o i l 201 (HEATCONTE) i s a l s o

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WHC-SD-WM-CSDD-020. REV 1

than HTCONDVAL.

t h e temperature r i s e s 5 degrees F. above t h e low temperature s e t p o i n t .

4.2.8 Network 8 - High Temperature Cont ro l (COOL)

CONDITIONER ( K 7 ) . When r e l a y A I R CONDITIONER i s energized, t h e a i r c o n d i t i o n e r i s on.

compared t o t h e h i g h temperature c o n t r o l s e t p o i n t (TCHIVAL) u s i n g a SUB b l o c k t o per fo rm a s u b t r a c t i o n . I f ICBTEVAL i s g r e a t e r than TCHIVAL, then power i s a p p l i e d t o t h e ad jacent SUB b l o c k and c o i l 202 (COOLCONTl) i s energ ized. The f u n c t i o n o f t h i s second SUB b l o c k i s t o s e t t h e deadband f o r temperature c o n t r o l . The SUB b l o c k s u b t r a c t s 125 (5 degrees F . ) f rom t h e h i g h temperature s e t p o i n t , TCHIVAL, and p laces i t i n t o r e g i s t e r 41103 (CTCONDVAL), t h e c o o l i n g c o n t r o l d e l t a va lue .

As HEATONO i s energized, t h e N.O. c o n t a c t w i l l l a t c h HEATCONT2 on u n t i l

Output c o i l 10 (COOLONO) i s hardware-mapped t o e x t e r n a l r e l a y A I R

R e g i s t e r 30002 (ICBTEVAL) i s t h e I n s i d e Cabinet Temperature. I t i s

When c o i l 202 (COOLCONTl) i s energized, c o i l 203 (COOLCONTE) i s a l s o energ ized. f i n a l SUB b lock , which performs t h e a c t u a l c o n t r o l t o t h e a i r c o n d i t i o n e r . CTCONDVAL i s s u b t r a c t e d from ICBTEVAL, and COOLONO i s energ ized w h i l e ICBTEVAL i s g r e a t e r than CTCONDVAL.

t h e temperature drops 5 degrees below t h e h i g h temperature s e t p o i n t .

4.2.9

T h i s a l l o w s t h e N.O. c o n t a c t f rom COOLCONTZ t o pass power t o t h e

As COOLONO i s energized, t h e N.O. c o n t a c t w i l l l a t c h COOLCONTE on u n t i l

Network 9 - Temp. Out o f Range/Power t o Exhauster/E-STOP/High Tank Pressure

4.2.9.1 Temperature Out O f Range

temperature i s o u t o f range ( h i g h ) f o r o p e r a t i n g t h e PLC. The h i g h a la rm p o i n t (95 degrees F . ) i s 10 degrees F . above t h e h i g h temperature c o n t r o l s e t p o i n t (85 degrees F . ) .

E n e r g i z i n g i n t e r n a l c o i l 2 (CABTEMPO) i n d i c a t e s t h a t t h e c a b i n e t

NOTE: E x t e r n a l r e l a y c o i l K I P (HEATER BYPASS - i n p a r a l l e l w i th K 2 ) a l s o w i l l i l l u m i n a t e the CABINET TEMPERATURE OUT OF RANGE lamp, i n d i c a t i n g t h a t t h e temperature i s too low t o opera te t h e P L C .

T h i s network c o n t i n u a l l y checks f o r an o u t o f range c o n d i t i o n , th rough R e g i s t e r 41004 (TAHIVAL) i s s u b t r a c t e d f rom r e g i s t e r t h e use o f a SUB b l o c k .

30002 (ICBTEVAL), and c o i l 2 (CABTEMPO) i s energ ized i f ICBTEVAL i s above TAHIVAL.

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WHC-SO-WM-CSDD-020, REV 1

CABTEMPO i s hardware-mapped t o t h e CABINET TEMPERATURE OUT OF RANGE lamp.

4.2.9.2 Power To Exhauster Lamp

C o i l 15 (PWRLEXHSTRO) i s hardware-mapped t o t h e POWER TO EXHAUSTER lamp on t h e console (DS3). When t h e N.O. c o n t a c t 10004 (MOTSTRTI) c loses , c o i l 15 i s energized, i l l u m i n a t i n g t h e POWER TO EXHAUSTER lamp. C o i l 10004 i s t h e i n p u t f rom t h e motor s t a r t e r (MS) power c o n t a c t o r . When t h e power c o n t a c t o r i s energized, a N.O. c o n t a c t f rom t h e c o n t a c t o r c loses , e n a b l i n g i n p u t c o i l 10004.

4.2.9.3 E-STOP

C o i l 8 i s hardware-mapped t o t h e E-STOP r e l a y (K5) . Under normal c o n d i t i o n s , t h e N.C. c o n t a c t 300 (PRESSABRT) and t h e N.O. c o n t a c t 10001 (ESTOPI) keep c o i l 8 energized. Whenever t h e low pressure a b o r t ( -3" W.C.) i s de tec ted , t h e N.C. c o n t a c t 300 w i l l open, causing c o i l 8 t o de-energize, which causes K5 t o de-energize. r e q u i r i n g t h e EXH FAN START P E R M I S S I V E s w i t c h t o be pressed t o r e s t a r t t h e exhauster.

T h i s w i l l remove t h e power t o t h e exhauster,

S i m i l a r l y , t h e N.O. c o n t a c t 10001 i s c losed when t h e E-STOP b u t t o n i s I f an o p e r a t o r presses t h e E-STOP b u t t o n , t h i s w i l l cause t h e n o t pressed.

N.O. c o n t a c t 10001 t o open, removing power t o t h e exhauster by de-energ iz ing K5.

4.2.9.4 H igh Tank Pressure

t r u c k t o shut down w i t h t h e use o f c o i l 401 (HITANKPRESS). Network 6 uses a N.O. c o n t a c t f rom c o i l 401 t o generate a p ressure alarm (see s e c t i o n 4.2.6.2) The pressure s i g n a l i n r e g i s t e r 30005 i s compared w i t h t h e h i g h t a n k pressure a la rm va lue ( r e g i s t e r 41401 - HITANKPRESSVAL). I f t h e pressure i s above t h i s value, AND N.O. c o n t a c t 206 i s c losed ( i n d i c a t i n g t h a t t h e exhauster i s runn ing) , t h e n c o i l 401 i s energized.

4.2.10 Network 10 - Combust ib le Gas, Hydrogen Abor ts

combust ib le gas c o n c e n t r a t i o n l e v e l e x i s t s o r a high-hydrogen l e v e l l i m i t i s detected.

A h i g h t a n k pressure alarm s e t t i n g o f -0 .1 "W.C. w i l l cause t h e RMCS

T h i s network has two d i s t i n c t f u n c t i o n s - t o generate an a b o r t i f a h i g h

4.2.10.1 Combust ib le Gas Abor t

Output c o i l 4 (COMBGALO) i s energized whenever t h e combust ib le gas c o n c e n t r a t i o n exceeds a p r e s e t s e t p o i n t . o f a SUB b l o c k , where r e g i s t e r 41005 (CGABVAL), t h e combust ib le gas a b o r t

T h i s i s accomplished th rough t h e use

Page 17


value, i s s u b t r a c t e d f rom r e g i s t e r 30003 (COMBGVAL), t h e combust ib le gas c o n c e n t r a t i o n . I f COMBGVAL i s g r e a t e r than CGABVAL, COMBGALO i s energized, causing an a b o r t (see 4.2.5.2). c losed, i n d i c a t i n g t h a t a t l e a s t 10 seconds have elapsed s i n c e power up o f t h e PLC (see s e c t i o n 4.2.1.2). COMBGALO i s hardware-mapped t o t h e COMBUSTIBLE GASSES lamp.

c o i l 10006 (KBYPASSI) t o l a t c h t h e alarm. OFF, de-energ iz ing KBYPASSI, t h e alarm i s r e s e t .

However, N.O. c o n t a c t 205 (PWRUPTMR) must be

A N.O. c o n t a c t f rom COMBGALO i s used i n s e r i e s w i t h a N.O. c o n t a c t f rom Whenever t h e KEYSWITCH i s t u r n e d

4.2.10.2 Hydrogen Abor t

Output c o i l 1 (HIGHHEO) energ izes whenever a hydrogen c o n c e n t r a t i o n l e v e l exceeds t h e alarm s e t p o i n t . T h i s i s accomplished th rough t h e use o f a SUB b lock , where r e g i s t e r 41006 (HH2ABVAL), t h e h i g h hydrogen a b o r t value, i s sub t rac ted from r e g i s t e r 30004 (HZVAL), t h e hydrogen c o n c e n t r a t i o n . I f H2VAL is g r e a t e r than HHZABVAL, HIGHHEO i s energized, causing an a b o r t (see 4.2.5.2). However, N.O. c o n t a c t 205 (PWRUPTMR) must be closed, i n d i c a t i n g t h a t a t l e a s t 10 seconds have elapsed s i n c e power up o f t h e PLC (see s e c t i o n 4.2.1.2). HIGHH2O i s hardware-mapped t o t h e HYDROGEN 1 amp.

A N.O. c o n t a c t f rom HIGHHE0 i s used i n s e r i e s w i t h a N.O. c o n t a c t f rom c o i l 10006 (KBYPASSI) t o l a t c h t h e alarm. OFF, de-energ iz ing KBYPASSI, t h e alarm i s r e s e t .

Whenever t h e KEYSWITCH i s tu rned

4.2.11 Network 11 - Low Pressure Abor t / Pressure Alarm Lamp

T h i s network has two purposes - t o generate t h e l o w pressure (-3" W.C.) a b o r t o f t h e p o r t a b l e exhauster, and t o i l l u m i n a t e t h e PRESSURE lamp on t h e consol e .

.4.2.11.1 Low Pressure Abor t

To handle t h e low pressure abor t , r e g i s t e r 41012 (LOPRABVAL), t h e low pressure a b o r t value, i s sub t rac ted from r e g i s t e r 30005 (PRESSVAL), t h e pressure s i g n a l . energized, causing an a b o r t ( see 4.2.5.1). (PWRUPTMR) must be c losed, i n d i c a t i n g t h a t a t l e a s t 10 seconds have elapsed s i n c e power up o f t h e PLC (see s e c t i o n 4 .2 .1 .2 ) .

I f PRESSVAL i s l e s s than LOPRABVAL, c o i l 300 (PRESSABRT) i s However, N.O. c o n t a c t 205

A N.O. c o n t a c t f rom PRESSABRT i s used i n s e r i e s w i t h a N.O. c o n t a c t f rom c o i l 10006 (KBYPASSI) t o l a t c h t h e alarm. OFF, de-energ iz ing KBYPASSI, t h e alarm is r e s e t .

Whenever t h e KEYSWITCH i s t u r n e d

4.2.11.2 Pressure Alarm Lamp

Output c o i l 3 (PRESSALO) energ izes whenever t h e 2" W . C . above b a s e l i n e

Page 18


c o n d i t i o n occurs (N.O. c o n t a c t 301 - see 4.2.6.2), t h e h i g h t a n k pressure alarm v a l u e i s exceeded ( c o i l 401 c o n t r o l l i n g c o i l 301 - see 4.2.9.4), o r t h e l o w pressure a b o r t e x i s t s (N.O. c o n t a c t 300 - see 4.2.11.1). PRESSALO i s hardware-mapped t o t h e PRESSURE lamp.

4.2 .12

r e g i s t e r s c o n t a i n i n g r e a l - t i m e hydrogen c o n c e n t r a t i o n data, separated by a p r e s e t t i m e de lay . i n network 13 (see 4.2.13).

r e g i s t e r 41201 (DHDTTIMR) and ou tpu ts a p u l s e t o c o i l 102 (DHDTTIMER), which r e s e t s i t s e l f and counts t o 200 again, p r o v i d i n g a p u l s e every 2 seconds.

i s g r e a t e r than 100, c o i l 103 (DHDTCAP), t h e dH/dT capture c o n t r o l c o i l , i s energ ized. r i s i n g edge i s always 1 second from t h e nex t f a l l i n g edge, and v ice-versa . Therefore, a p o s i t i v e edge t r i g g e r i n g one da ta capture r e g i s t e r and a n e g a t i v e edge t r i g g e r i n g another da ta capture r e g i s t e r r e s u l t s i n t h e two r e g i s t e r s c o n t a i n i n g da ta p o i n t s 1 second a p a r t .

P r e c i s i o n da ta capture i s accomplished by u s i n g r e g i s t e r s 41009 (DHDTVALl) and 41010 (DHDTVALL). Zero i s s u b t r a c t e d from r e g i s t e r 30004 (HZVAL) and p laced i n these r e g i s t e r s , c o n t r o l l e d by a p o s i t i v e edge o f DHDTCAP ( i n t o DHDTVALl) and a n e g a t i v e edge o f DHDTCAP ( i n t o DHDTVALL), as exp la ined above.

w h i l e t h e PLC i s o p e r a t i n g . Network 13 ( s e e 4.2.13) uses these r e g i s t e r s t o determine t h e dH/dT ( r a t e o f change o f hydrogen c o n c e n t r a t i o n ) and t o t e s t f o r an a b o r t c o n d i t i o n .

4.2 .13

s u b t r a c t s r e g i s t e r 41010 (DHDTVALZ) f rom r e g i s t e r 41009 (DHDTVALI). The r e s u l t i s p laced i n t o r e g i s t e r 41007 (DHDTRAW), t h e dH/dT r a t e raw va lue . pos i t i ve-edge t r i g g e r i n g i s r e q u i r e d t o ensure t h a t every t i m e t h e s u b t r a c t occurs, DHDTVALl i s cap tured 1 second a f t e r DHDTVAL2.

p o s i t i v e ) , then t h e va lue i n r e g i s t e r 41007 (OHDTRAW) i s p laced i n t o r e g i s t e r 41011 (DHDTRVAL) v i a a BLKM b l o c k .

Network 12 - dH/dT Data Capture

The purpose o f t h e dH/dT da ta capture network i s t o p r o v i d e two

T h i s a l l o w s t h e hydrogen r a t e o f change t o be determined

A 0.01 second t i m e r b l o c k , w i t h a m u l t i p l i e r o f 200, counts t o 200 i n

The f i r s t SUB b l o c k i s used t o s u b t r a c t 100 from DHDTTIMR. I f DHDTTIMR

T h i s p r o v i d e s a square wave w i t h a p e r i o d o f 2 seconds. Any

These two r e g i s t e r s , DHDTVALl and DHDTVALL, are c o n t i n u a l l y updated

Network 13 - dH/dT Alarm and Abor t

A r i s i n g edge o f c o i l 103 (DHDTCAP) i s used t o c o n t r o l a SUB b l o c k t h a t

T h i s

I f DHDTVALl i s g r e a t e r than DHDTVALL ( i m p l y i n g t h e r a t e o f change i s

Page 19


When DHDTVALl i s l e s s than o r equal t o DHDTVALZ ( i m p l y i n g t h e dH/dT r a t e i s n o n - p o s i t i v e ) , then r e g i s t e r 41003 (ZERO) i s p laced i n t o r e g i s t e r DHDTRVAL w i t h another BLKM b l o c k .

R e g i s t e r 41008 (DHDTABVAL), t h e dH/dT a b o r t va lue , i s s u b t r a c t e d from I f DHDTRVAL i s g r e a t e r than DHDTABVAL, DHDTRVAL i n t h e f o l l o w i n g SUB b l o c k .

then c o i l 104 (DHDTALARM) i s energized, i n d i c a t i n g t h e r a t e o f change i s g r e a t e r than t h e a b o r t s e t p o i n t .

The 0.1 second t i m e r b l o c k , w i t h a m u l t i p l i e r o f 100, i s used t o f i l t e r t h e dH/dT va lue . cause a dH/dT a b o r t c o n d i t i o n . When DHDTALARM i s h igh , t h e N.O. c o n t a c t f rom DHDTALARM c l o s e s and t h e t i m e r s t a r t s t o count. 10 seconds, t h e t i m e r o u t p u t energizes c o i l 105 (DHDTABORT), t h e a b o r t c o i l f o r t h e dH/dT hydrogen r a t e . 4.2.5.2). DHDTABORT i s a l s o de-energized.

4.2.14

DHDTALARM must be energ ized f o r a minimum o f 10 seconds t o

I f DHDTALARM remains h i g h f o r

I f a t any t i m e DHDTALARM i s de-energized, t h e t i m e r r e s e t s and I f DHDTABORT i s energ ized an a b o r t occurs ( s e e

Network 14 - dCG/dT D a t a Capture

The purpose o f t h e dCG/dT data capture network i s t o p r o v i d e two r e g i s t e r s c o n t a i n i n g r e a l - t i m e combust ib le gas (CG) c o n c e n t r a t i o n da ta , separated by a p r e s e t t i m e de lay . determined i n network 15 (see 4.2.15).

r e g i s t e r 41501 (DCGDTTIMR) and o u t p u t s a pu lse t o c o i l 502 (DCGDTTIMER), which r e s e t s i t s e l f and counts t o Z O O again, p r o v i d i n g a p u l s e every 2 seconds.

T h i s a l l o w s t h e CG r a t e o f change t o be

A 0.01 second t i m e r b l o c k , w i t h a m u l t i p l i e r o f 200, counts t o 200 i n

The f i r s t SUB b l o c k i s used t o s u b t r a c t 100 f rom DCGDTTIMR. I f DCGDTTIMR i s g r e a t e r than 100, c o i l 503 (DCGDTCAP), t h e dCG/dT capture c o n t r o l c o i l , i s energ ized. Any r i s i n g edge i s always 1 second from t h e nex t f a l l i n g edge, and v ice-versa . Therefore, a p o s i t i v e edge t r i g g e r i n g one da ta capture r e g i s t e r and a n e g a t i v e edge t r i g g e r i n g another d a t a capture r e g i s t e r r e s u l t s i n t h e two r e g i s t e r s c o n t a i n i n g da ta p o i n t s 1 second a p a r t .

P r e c i s i o n da ta capture i s accomplished by u s i n g r e g i s t e r s 41509 (DCGDTVALl) and 41510 (DCGDTVALZ). Zero i s sub t rac ted from r e g i s t e r 30003 (COMBGVAL) and p laced i n these r e g i s t e r s , c o n t r o l l e d by a p o s i t i v e edge o f DCGDTCAP ( i n t o DCGDTVALl) and a n e g a t i v e edge o f DCGDTCAP ( i n t o DCGDTVALZ), as exp l a i ned above.

These two r e g i s t e r s , DCGDTVALl and DCGDTVALZ, a re c o n t i n u a l l y updated w h i l e t h e PLC i s o p e r a t i n g . determine t h e dCG/dT ( r a t e o f change o f combust ib le gas c o n c e n t r a t i o n ) and t o t e s t f o r an a b o r t c o n d i t i o n .

T h i s p rov ides a square wave w i t h a p e r i o d o f 2 seconds.

Network 15 ( s e e 4.2.15) uses these r e g i s t e r s t o

Page 20


4.2.15

A r i s i n g edge o f c o i l 503 (DCGDTCAP) i s used t o c o n t r o l a SUB b l o c k t h a t s u b t r a c t s r e g i s t e r 41510 (DCGDTVALZ) from r e g i s t e r 41509 (DCGDTVALl). The r e s u l t i s p laced i n t o r e g i s t e r 41507 (DCGDTRAW), t h e dCG/dT r a t e raw va lue . T h i s p o s i t i v e - e d g e t r i g g e r i n g i s r e q u i r e d t o ensure t h a t every t i m e t h e s u b t r a c t occurs, DCGDTVALl i s captured 1 second a f t e r DCGDTVAL2.

I f DCGDTVALl i s g r e a t e r than DCGDTVALZ ( i m p l y i n g t h e r a t e o f change i s p o s i t i v e ) , then t h e va lue i n r e g i s t e r 41507 (DCGDTRAW) i s p laced i n t o r e g i s t e r 41511 (DCGDTRVAL) v i a a BLKM b l o c k .

r a t e i s n o n - p o s i t i v e ) , then r e g i s t e r 41003 (ZERO) i s p laced i n t o r e g i s t e r DCGDTRVAL w i t h another BLKM b l o c k .

Network 15 - dCG/dT Alarm and Abor t

When DCGDTVALl i s l e s s than o r equal t o DCGDTVAL2 ( i m p l y i n g t h e dCG/dT

R e g i s t e r 41508 (DCGDTABVAL), t h e dCG/dT a b o r t va lue , i s s u b t r a c t e d from DCGDTRVAL i n t h e f o l l o w i n g SUB b l o c k . DCGDTABVAL, then c o i l 504 (DCGDTALARM) i s energized, i n d i c a t i n g t h e r a t e o f change i s g r e a t e r than t h e a b o r t s e t p o i n t .

I f DCGDTRVAL i s g r e a t e r than

The 0.1 second t i m e r b l o c k , w i t h a m u l t i p l i e r o f 100, i s used t o f i l t e r t h e dCG/dT va lue . cause a dCG/dT a b o r t c o n d i t i o n . When DCGDTALARM i s h igh , t h e N.O. c o n t a c t f rom DCGDTALARM c loses and t h e t i m e r s t a r t s t o count. I f DCGDTALARM remains h i g h f o r 10 seconds, t h e t i m e r o u t p u t energ izes c o i l 505 (DCGDTABORT), t h e a b o r t c o i l f o r t h e dCG/dT combust ib le gas r a t e . I f DCGDTABORT i s energ ized an a b o r t occurs (see 4.2.5.2). I f a t any t i m e DCGDTALARM i s de-energized, t h e t i m e r r e s e t s and DCGDTABORT i s a l s o de-energized.

DCGDTALARM must be energ ized f o r a minimum o f 10 seconds t o

4.2.16 Network 16 - dH/dT and dCG/dT Alarm Outputs

T h i s network has two f u n c t i o n s - t o generate an a b o r t i f a h i g h hydrogen c o n c e n t r a t i o n r a t e o f r i s e (dH/dT) e x i s t s , o r a h i g h combust ib le gas c o n c e n t r a t i o n r a t e o f r i s e i s de tec ted .

4.2.16.1 dH/dT Alarm Output

Output c o i l 5 (DHDTO) energ izes whenever a dH/dT hydrogen r a t e a b o r t occurs. T h i s i s accomplished through t h e use o f a N.O. c o n t a c t 105 (see 4.2.13), which w i l l c l o s e when a dH/dT alarm occurs. When t h e N.O. c o n t a c t 105 c loses , c o i l 5 (DHDTO) w i l l energ ize , causing an a b o r t (see 4.2.5.2). However, N.O. c o n t a c t 205 (PWRUPTMR) must be c losed, i n d i c a t i n g t h a t a t l e a s t 10 seconds have elapsed s i n c e power up o f t h e PLC (see s e c t i o n 4.2.1.2). DHDTO i s hardware-mapped t o t h e dH/dT lamp.

Page 21


A N.O. c o n t a c t f rom DHDTO i s used i n s e r i e s w i t h a N.O. c o n t a c t f rom c o i l 10006 (KBYPASSI) t o l a t c h t h e alarm. Whenever t h e KEYSWITCH i s t u r n e d OFF, de-energ iz ing KBYPASSI, t h e a la rm i s r e s e t .

4.2 .16 .2 dCG/dT Alarm Output

Output c o i l 6 (DCGDTO) energ izes whenever a dCG/dT hydrogen r a t e a b o r t occurs. 4.2.15), which w i l l c l o s e when a dCG/dT a la rm occurs. When t h e N.O. c o n t a c t 505 c loses , c o i l 6 (DCGDTO) w i l l energ ize , causing an a b o r t (see 4.2.5.2). However, N.O. c o n t a c t 205 (PWRUPTMR) must be c losed, i n d i c a t i n g t h a t a t l e a s t 10 seconds have elapsed s i n c e power up o f t h e PLC (see s e c t i o n 4.2.1.2). DCGDTO i s hardware-mapped t o t h e dCG/dT lamp.

A N.O. c o n t a c t f rom DCGDTO i s used i n s e r i e s w i t h a N.O. c o n t a c t f rom c o i l 10006 (KBYPASSI) t o l a t c h t h e alarm. Whenever t h e KEYSWITCH i s tu rned OFF, de-energ iz ing KBYPASSI , t h e alarm i s r e s e t .

T h i s i s accomplished th rough t h e use o f a N.O. c o n t a c t 505 (see

Page 22


APPENDIX A

1/0 Channel L i s t

Page 23


Page 24


1 2

1 2

2 N/A 3x/4x AS-BADU-206

2 N/A 30001 MODlSTAT ADU206 Op. S t a t u s

Page 25


Page 26


APPENDIX B

Reference Symbol Tab1 e

Page 27

WHC-SD-WM-CSDD-020, REV I

D i s c r e t e Output C o i l s

00001 HIGHH20 1 .1 .5 .1 00002 CABTEMPO 1.1.5.2 00003 PRESSALO 1 .1 .5 .3 00004 COMBGALO 1 .1 .5 .4 00005 DHDTO 1 .1 .5 .5 00006 DCGDTO 1.1.5.6 00007 HEATOFFO 1.1.5.7 00008 ESTOP0 1.1.5.8 00009 MOTSTRTO 1.1.5.9 00010 COOLONO 1.1.5.10 00011 HEATONO 1.1.5.11 00012 WDTO 1.1.5.12 00013 RMCSO 1.1.5.13 00014 STROBE0 1.1.5.14 00015 PWRZEXHSTRO 1 .1 .5 .15 00016 1.1.5.16 00017 1 .2 .1 .1 00018 1 .2 .1 .2 00019 1 .2 .1 .3 ~ ~ . . .

00020 00021 00022 00023 00024

1.2.1.4 1 .2 .1 .5 1 .2 .1 .6 1 .2 .1 .7 1 .2 .1 .8 1 .2 .1 .9 i . 2 .1 .10 1.2.1.11 1.2.1.12 1.2.1.13 1.2.1.14

00029 00030 00031 1.2.1.15 00032 1.2.1.16

High Hydrogen Out Cabinet Temp. Out Of Range Out Pressure Alarm Out Combustible Gas Alarm Out dHjdT Out dCG/dT Out Heater O f f Out Exhauster ESTOP Out Motor S t a r t e r Out A i r Cond i t i on ing On Out Heater On Out Watch Dog Timer Out RMCS I n t e r l o c k Out St robe L i g h t Out Power To Exhauster Lamp Out Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

Page 28


D i s c r e t e I n t e r n a l C o i l s

00100 COMPABDRT 00101 POWERUP 00102 DHDTTIMER 00103 DHDTCAP 00104 DHDTALARM 0 0 i 0 5 DHDTABORT 00200 HEATCONTl 00201 HEATCONTZ 00202 COOLCONTl 00203 COOLCONTL 00204 WDTCOUNT 00205 PWRUPTMR 00206 BCKGNDTMRI 00207 BCKGNDTMRZ 00208 NOTSTROBE 00209 NDTRMCSO 00300 PRESSABRT 00401 HITANKPRESS 00402 PRESSUREBAD 00301 DELTAPRESS 00502 DCGDTTIMER 00503 DCGDTCAP 00504 DCGDTALARM 00505 DCGDTABORT

D i s c r e t e I n p u t R e g i s t e r s

10001 ESTOP1 10002 EXHSTRI 10003 HBYPASSI 10004 MOTSTRTI 10005 ESTOPFI 10006 KBYPASSI 10007 FGWLEI 10008 EXFANRUNI 10009 10010 10011 10012 10013 10014 10015 10016

1.1.4.1 1.1.4.2 1.1.4.3 1.1.4.4 1.1.4.5 1.1.4.6 1.1.4.7 1.1.4.8 1.1.4.9 1.1.4.10 1.1.4.11 1.1.4.12 1.1.4.13 1.1.4.14 1.1.4.15 1.1.4.16

COMPOSITE ABORT POWER UP dH/dT Data Capture Timer Reset dH/dT Data Capture C o n t r o l dH/dT A1 arm ( u n f i 1 t e r e d ) dH/dT Alarm & Abor t Heat ing Cont ro l 1 Heat ing C o n t r o l 2 Cool ing Cont ro l 1 Coo l ing Cont ro l 2 WDT Counter Power Up Timer Background Pressure Timer 1 Background Pressure Timer 2 S t robe Output NOT enabled RMCS t r u c k o u t p u t NOT enabled l a n k Pressure Abor t H igh Tank Pressure Alarm Pressure Transducer Bad (t2mA measured) 6 Minu te D e l t a Pressure Abor t dCG/dT d a t a Capture Timer Reset dCG/dT Data Capture Cont ro l dCG/dT A1 arm ( u n f i 1 t e r e d ) dCG/dT Alarm & Abor t

Exhauster ESTOP I n Exhauster Running I n Heater Bypass I n Motor S t a r t e r I n ESTOP Feedback I n Keyswitch Bypass I n FGWL Enable I n Exhauster Fan Running Spare Spare Spare Spare Spare Spare Spare Spare

I n

Page 29


Analog I n p u t Reg is te rs

30001 MODlSTAT Module 1 (ADU206) Operat ion S ta tus R e g i s t e r 30002 ICBTEVAL 1.2.2.1 I n s i d e Cabinet Temperature 30003 COMBGVAL 1.2.2.2 Combustible Gasses 30004 HZVAL 1.2.2.3 Wh i t take r H2 Signal 30005 PRESSVAL 1.2.2.4 Pressure 30006 MODLSTAT Module 2 (ADU206) Opera t i on S ta tus R e g i s t e r 30007 OCBTEVAL 1.2.3.1 Outs ide Cabinet Temperature 30008 1.2.3.2 Spare 30009 1.2.3.3 Spare 30010 1.2.3.4 Spare

Output Reg is te rs

40001 MODlMODE 40002 MODZMODE

Module 1 (ADU206) Mode/Range R e g i s t e r Module 2 (ADU206) Mode/Range R e g i s t e r

Page 30


H o l d i n g R e g i s t e r s

41001 TCLOVAL 41002 TCHIVAL 41003 ZERO 41004 TAHIVAL 41005 CGABVAL 41006 HHZABVAL 41007 DHDTRAW 41008 DHDTABVAL 41009 DHDTVALl 41010 DHDTVALL 41011 DHDTRVAL 41012 LOPRABVAL 41013 HIPRABVAL 41101 SCRATCH 41102 HTCDNDVAL 41103 CTCONDVAL 41200 WDTTIMR 41201 DHDTTIMR 41202 DHDTFTIMR 41203 HZDLYTIMR 41204 PWRUPTIMR 41205 HTOFFTMR 41207 EXHSTRTMR 41208 BCKGNDTMR 41301 TWOTHOUSAND 41303 THREETHOUSAND 41401 HITANKPRESSVAL 41501 DCGDTTIMR 41502 DCGTFTIMR 41507 DCGDTRAW 41508 DCGDTABVAL 41509 DCGDTVALl 41510 DCGDTVALL 41511 DCGDTRVAL

Temperature Cont ro l Low Value Temperature Cont ro l H igh Value System Zero Temperature Alarm High Value Combust ib le Gas Abor t Value H igh Hydrogen Abor t Value dH/dT Raw Unsigned Value dH/dT Abor t Value dH/dT Value 1 dH/dT Value 2 dH/dT Rate Value Low Pressure Abor t Value H igh Pressure Abor t Value

Heat ing Cont ro l D e l t a Value Coo l ing Cont ro l D e l t a Value WDT Timer R e g i s t e r dH/dT Timer R e g i s t e r dH/dT F i l t e r Timer R e g i s t e r Hydrogen S t a r t u p Delay Timer R e g i s t e r Power Up Delay Timer R e g i s t e r Heat O f f Pulse Timer R e g i s t e r Exhauster Running Delay Timer R e g i s t e r Background Pressure Update Timer System Constant (2000) System Constant (3000) H i Tank Pressure Alarm p o i n t (-0.1"W.C.) dCG/dT Timer R e g i s t e r dCG/dT F i l t e r Timer R e g i s t e r dCG/dT Raw Unsigned Value dCG/dT Abor t Value dCG/dT Value 1 dCG/dT Value 2 dCG/dT Rate Value

Page 31

WHC-SO-WM-CSDD-020, REV I

APPENDIX C

PLC System Conf igurat ion

Page 32


FGTEI Ladder Log ic - J u l y 2, 1996

C o n f i g u r a t i o n

CONFIGURATION O V E R V I E W I S i ze o f F u l l Log ic Area 07277

PLC : I No. o f 1 /0 Map Words 00073

Model A145 I 1 /0 : PLC Type 984 -COMPACT +----------------------------------

Memory 8.OK / Number o f Segments 12 Extended Memory K / 1 /0 Drops 1

I 1/0 Modules 8

Ranges : O X X X X 00001 - 01536 l X X X X 10001 - 10512 JXXXX 30001 - 30048 ~ X X X X 40001 - 41872 ~ X X X X <-> SFC None

-+ Spec ia l s . I B a t t e r y C o i l I Timer Reg is te r I Time o f Day Clock I Con f ig Extens ion S i z e

01536 41864

0 41865 - 41872

. - - - - - - - -

I

CONFIGURATION EXTENSION BLOCKS

No C o n f i g u r a t i o n Extens ions found

PORTS

Number Mode Data B i t s P a r i t y Stop B i t s Baud Keyboard Address Delay

MODBUS 01 RTU 02 RTU

8 8

EVEN EVEN

1 1

9600 9600

1/0 MAP 984-120/130/145 CONTROLLERS

PLC COMPACT A145 Rack Number I n p u t s : 176 Number Outputs :

1 1

10 ms 10 ms

1 64


S l o t Type I n p u t

101 984 102 984 103 P120 104 DEP218 10001 -10016

ou tpu t

105 DAP218 00001 -00016

t ype D e s c r i p t i o n

PLC-COMPACT PLC-COMPACT

16-1 115VAC 16-0 115VAC

POWER SUPPLY

PLC COMPACT A145 Rack __________________-_____________________---------_---

Module Reference Numbers Data S l o t Type I n p u t ou tpu t t ype

201 DAP218 00017 -00032 202 ADU206 30001 -30005 40001 -40001 BIN 203 ADU206 30006 -30010 40002 -40002 BIN 204 P120 205 ** AVAILABLE SLOT **

2 ------_____-__---

Module D e s c r i p t i o n

16-0 ll5VAC 4 CHN A / D 4 CHN A / D POWER SUPPLY

Page 34


APPENDIX D

Ladder l o g i c Network Diagrams

Page 35


FGTEI Ladder L o g i c - September 12, 1996 Network L i s t Segment: 01

WATCH DOG / POWERUP DELAY TIMERS

TOGGLE HEATOFFO / SET HIPRABVAL

ALARM & ABORT INITS

ADU206 I N I T - UNI/OFFSET EXT RES

EXHSTR. & RMCS SHUTDOWN

STROBE / BACKGROUND PRESSURE

LOW TEMPERATURE CONTROL (HEAT)

HIGH TEMPERATURE CONTROL (COOL)

TEMP OUT OF RNGE/PWRZEXSTR/ESTOP

COMBUSTIBLE GAS, HYDROGEN ABORTS

LOW PRESS. ABORT/PRESS. ALARM

dH/dT DATA CAPTURE

dH/dT ALARM & ABORT

dCG/dT DATA CAPTURE

dCG/dT ALARM & ABORT

dH/dT & dCG/dT A larm Outputs

Page 36


THIS PAGE INTENTIONALLY LEFT BLANK

Page 37


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I wo20

+/H HTU.1-[ I- 10003 0I l lOl 41205- 00007

Page 39

0 * W

a m


EMODSOFT ma€ Seg. 1 rt4 1 4 ROU206 INIT - UHIAWSET EXT RES -(P

-(P

-[ 1-

40002 41003- Wool-

Reference Data

Fornat :Decinal Off line Range : 1

Page 41


I t -[ 1- 00208

Ref erence Data

Fornat :Oecina 1 Range : 1 1

Page 4 2

WHC-SD-CSDD-020, REV 1

THIS PAGE INTENTIONALLY LEFT BLANK

43


:MODSOFT mmE

leg. 1 #6 I 6 STROBE I’ BACKGROUND PRESSURE

00208 00014 +I+[ 1-

-iH 10006 00301

Reference Oata

Fornat :Oecina 1 Off l i n e Range : 1

Page 4 4


Page 45


Fornat : Dec ina 1

Page 46


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Seg. 1 M I 1 11 LOU PRESS. AEORTIPRESS. ALARH I 30005

41012 -1SUE - 41101-

10006 00300 00205 00300

-I

-IHH t--+ 1-

-

dooL [ I - 00301 00003

Reference Oat a

Fornat : Dec ina 1 Range : Ii

Page 48


I 1- #0200 00102

I [ 1- 41201 00103 I #0100 lsUB - 41101-

+/ H T . 0 1 - 00102 41201-

-

00103

Page 49


Page 50


Page 51

WHC-SD-WM-CSDD-020, REV I

Seg. 1 #15 1 15 dCGldT ALARH & ABORT I [ 1- W100 00505

1 HTiJ.1- 00504 41502-

I 1- 41511 00504

I BLKH

I Reference Data

- Format :Decimal Off l i n e Range : 1

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I

Reference Oat a

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APPENDIX E

Coil/Register Utilization Tables

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FGTEI Ladder Log ic - September 12, 1996

Used OX References

00000 00020 00040 00060 00080

00160 00180 00200 00220 00240 00260 00280 00300 00320 00340 00360 00380 00400 00420 00440 00460 00480 00500 00520 00540 00560 00580 00600 00620 00640 00660 00680 00700 00720 00740

00800 00820 00840

B M


00860 00880 00900 00920 00940 00960 00980 01000 01020 01040 01060

Key : UPPER CASE LETTER = DOCUMENTED; lower case l e t t e r = un-documented B = In b o t h Log ic and 1/0 - = A v a i l a b l e L = I n Log ic o n l y ? = Documented, b u t n o t used M = I n 1/0 o n l y

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FGTEI Ladder Logic - July 2, 1996

Used O X References

0 1080 01100 01120

01200 01220

01300 01320

01400 01420 01440 01460 0 1480 01500 01520

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Key : UPPER CASE LETTER = DOCUMENTED; lower case l e t t e r = un-documented B = I n both Log ic and 1/0 - = A v a i l a b l e L = I n Log ic o n l y ? = Documented, b u t n o t used M = I n 1/0 o n l y

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FGTEI adder o g i c - Ju ly 2, 1996

Used 1X References

10000 10020 10040 10060 10080 10100 10120 10140 10160 10180 10200 10220 10240 10260 10280 10300 10320 10340 10360 10380 10400 10420 10440 10460 10480 10500

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Key : UPPER CASE LETTER = DOCUMENTED; lower case l e t t e r = un-documented B = I n bo th Log ic and 1/0 - = A v a i l a b l e L = I n Log ic o n l y ? = Documented, b u t n o t used M = I n 1/0 o n l y

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FGTEI Ladder Log ic - July 2, 1996

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Key : UPPER CASE LETTER = DOCUMENTED; lower case l e t t e r = un-documented B = I n bo th Log ic and 1/0 - = A v a i l a b l e L = I n Log ic o n l y ? = Documented, b u t n o t used M = I n 1/0 o n l y

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FGTEI Ladder Log ic -

40000 40020 40040 40060 40080 40100 40120 40140 40160 40180 40200 40220 40240 40260 40280 40300 40320 40340 40360 40380 40400 40420 40440 40460 40480 40500 40520 40540 40560 40580 40600 40620 40640 40660 40680 40700 40720 40740 40760 40780 40800 40820 40840

Ju ly 2, 1996

Used 4X Reg is te rs


40860 40880 40900 40920 40940 40960 40980 41000 41020 41040 41060

Key : UPPER CASE LETTER = DOCUMENTED; lower case letter = un-documented 8 = In both Logic and 1/0 - = Available L = In Logic only ? = Documented, but not used M = In 1/0 only

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FGTEI Ladder Log ic -

41080 41100 41120 41140 41160 41180 41200

41280 41300 41320 41340 41360 41380 41400 41420 41440 41460 4 1480 41500 41520 41540 41560 4 1580 41600 41620 41640 41660 4 1680 41700 41720 41740 41760 41780 41800 41820 41840 41860

Ju ly 2, 1996

Used 4X Registers

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Key : UPPER CASE LETTER = DOCUMENTED; lower case letter = un-documented B = In both Logic and 1/0 - = Available L = In Logic only M = In 1/0 only

? = Documented, but not used

41864 Timer Register 41865 - 41872 Time/Date Register

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APPENDIX F

ADU206 Control Register Reference

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1 5 1 4 1 3 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 0

ADU 206 4OXXX Control Register Quick Reference

EXPANDED RANGE SELECT (Chs 1-4; set to a "I 'I if over

1 V will be input.) F;H4CH

0 0 Bipolar 0 1 Unipolar 1 0 Bipolar w/Offset and

Ext Res 1 1 Unipolar w/Offset -t and Ext Res

MODULE MODE SELECT

1 Add this bit for overrange conditions to be displayed in the common BOXXX Stat Register

EXAMPLE: 000000000

NOT USED Q 9

- CH 3 and CH 4 Expanded Ranges

- Module set to Unipolar Mode

- Overrange Indication Requested

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