Trailblazing the future through the fusionof information technology

with MHPS's plant manufacturing experience

Head Office 12, Nishikicho, Naka-ku, Yokohama, Kanagawa, 231-8715, Japanhttp://www.mhi.co.jp/en/products/category/diasys.html

PS60-03IC1E1-A-0

01 General

03 System Overview and Feature System Devices System Suited for Remote Monitoring and Control (Protocol for Low-Load Traffic: Card Communication Technology) Sytem for Small Facilities: Compact Process Station (CPS) Coexistence of User-friendliness (OPS) and High Reliability (MPS and CPS)

07 Human-Machine Interface Overview OPS/MPS/ACS Role Allocation Function of OPS Function of ACS Control System Monitoring Functions Plant Operation Support Functions Other Functions Remote Monitoring and Operation Functions System Security Hardware Specifications

16 Multiple Process Station (MPS) Overview Hardware Architecture Hartdware Lineup System Reliability

23 Compact Process Station (CPS) Overview Specifications Hardware Architecture Hardware Lineup

24 Engineering & Maintenance Station (EMS) and DIASYS-IDOL++ Overview Features Functions Integrated Database (ObjectDatabase(ORCA)) Control and Processing Logic Description Language DIASYS-IDOL++ Hardware Specifications

29 DIASYS Netmation®- Related Products

CONTENTS

DIASYS Netmation® and DIASYS-IDOL++ are trademarks or registered trademarksof Mitsubishi Hitachi Power Systems, Ltd.

Windows is either trademark or a registered trademark of Microsoft Corporation in the United States and/or other countries.

Windows 95, Windows 98, Windows NT, Windows 2000, Windows XP, ActiveX, Excel, and Internet Explorer are either trademarks or registered trademarks of Microsoft Corporation

in the United States and/or other countries.

ControlNet is a trademark of ControlNet International, Ltd.pSOSystem is a registered trademark of Wind River Systems, Inc.

VISIO is a registered trademark of Microsoft Corporation.FLEX I/O are trademarks of the Allen-Bradley Corporation, Inc.

All other brand or product names appearing in this document are either trademarks or registered trademarks of their respective holders.

System specifications are subject to change without notice.

Copyright© 2009 by Mitsubishi Hitachi Power Systems, Ltd., Japan. All rights reserved.

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Mitsubishi Hitachi Power Systems is one of the largest plant manufacturers in the world. We manufacture the devices in a power plant such as boilers, turbines and gas turbines, and also engineer conventional plants consisting of boilers and turbines and combined cycle plants consisting of gas turbines, HRSGs (waste heat recovery boilers) and steam turbines. Additionally, we design and manufacture varied types of power generation facilities using gas engines, diesel engines, wind power, fuel cells and waste materials, and different types of facilities in a power plant (such as desulfurization facilities).

As a company that manufactures the devices in a power plant and engineers power plants, Mitsubishi Hitachi Power Systems started to create its own control system, DIASYS® , from 1970s to provide optimum control for these power generation facilities.

So far, we have released the DIASYS-UP series and the DIASYS-UP/V series employing the latest hardware of each era. For the software that controls each plant, we always use our original logic description language called DIASYS-IDOL that is best suited for plant control.

General

General

General

DIASYS Netmation® : finally, a control system that integrates the invaluable experience of a plant manufacturer with the latest information technology.

DIASYS Netmation® was released in 2000 and it is the latest control system of the DIASYS® series. DIASYS Netmation® actively incorporates the ever-developing IT technology and uses DIASYS-IDOL++ as the plant control software. DIASYS-IDOL++ is an enhanced version of DIASYS-IDOL which has many successful results and is optimized for plant control. The DIASYS Netmation® system is designed to achieve high reliability which we think, as a designer and manufacturer of plants, is the most important feature. DIASYS Netmation® differs from the old DIASYS® series in three points:

(1) Using the latest IT technology and maintaining the high reliability as before

・ We developed our original card communication technology based on the Internet technology with enhanced reliability and use it to monitor and control plants. The card communication technology is highly reliable and creates only a low traffic load, enabling control and monitoring of a remote place by radio with no need to prepare new infrastructures such as optical fiber.

・ By using Microsoft Windows as the user-machine interface, high operability is achieved. The important features such as data logging and alarm detection are equipped in the controller to maintain reliability.

・ The logic and graphics creation tools are based on VISIO, a CAD tool which is renowned for its user friendliness, so you can design systems by dragging and dropping. The logic diagrams you create by using VISIO are directly saved as formal drawings, allowing you to keep the consistency between the actual logic and drawings (self documentation).

・ There are many options based on the IT technology such as emailing alarms, monitoring and operations via the Web, mobile operator stations, and displaying the video recorded by cameras via the Web.

・ The latest technology is always used for external security.

・ Many interfaces are available to enable the connection with the systems of other companies.

(2) Easy maintenance using the fully integrated database

Before DIASYS Netmation®, the user needed to register items in a system and set up the system in each of different tools that were used to create and change logic, create graph-ics windows for monitoring, and perform other operations. The different sets of data in the tools needed to be related by using communication point numbers. Now DIASYS Netmation® centrally manages all the system data in the integrated database and you do not need to relate the data by using communication point numbers any more. Since you can reference and edit the same data in an easy-to-understand format from multiple tools, human errors such as incorrect relations of data can be prevented and efficient maintenance is possible.

(3) Broad line-up to accommodate systems of any size

The large controller (MPS) and the small controller (CPS) are available. The MPS is suitable for controlling a gas turbine or a gas engine which requires processing of large quantities of data at a fast cycle, or a plant which requires processing of many input and output points. The CPS is suitable for a small system consisting of such as a packaged boiler, enabling an optimum system with adequate cost and performance. The MPS and the CPS can be used together to operate, monitor, and maintain a plant.

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0403

CPU CPU

Router

Firewall

EMS

ACS

MPS

CPS Remote PI/O

OPS(Twin monitor type)OPS

TabletPC

FieldbusDeviceNetProfibusMODBUS(422/485)etc.

Interface to other productsMitsubishi MELSECYokogawa CENTUMCS/XLOpen standard TCP/IPMODBUSData can be provided using simple UDP

DMZ WebServer

SequencerLinking Device/Sequencer

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INTERNET

System Devices

■ Multiple Process Station (MPS)The Multiple Process Station (MPS) is used to perform automatic plant control and I/O processing. It features advanced arithmetic processing capabilities that enable it to support a wide range of applications that require high-speed processing, such as turbine governor control, as well as automatic boiler control and automatic plant start/stop control. In addition, since the MPS was successfully connected with the products of other companies in many occasions in the past and has interface software as standard, you can configure a seamless control and monitoring system for the entire plant. The system can also be configured to connect to fieldbuses via ControlNet. Moreover, since the Multiple Process Station supports a duplexed configuration and optical communications, remote-process I/O devices can be installed right next to plant equipment.The MPS is duplexed (CPUs, power supplies, I/O networks) to ensure the reliability as a controller.

■ Operator Station (OPS)The Operator Station (OPS) is a human-machine interface for monitoring and operating a plant. Since an OPS is a Windows-based system, it is easy to use and allows the plant operators to learn the operations easily.

■ Browser Operator Station (Browser WSM) DIASYS Netmation® also offers browser-based OPS software. Simply by installing and setting up this software on a browser-resident PC, operators can obtain the same functionality as provided by an OPS in the central control room.

■ Engineering & Maintenance Station (EMS)The Engineering & Maintenance Station (EMS) is used to maintain the entire DIASYS Netmation® system and register necessary elements, such as creating and changing the logic calculated on the MPS, and designing graphic displays, trends and control loop plates on OPSs , all the way up to and including configuring an entire system. All maintenance data is managed in the integrated database called ObjectDatabase (ORCA) and no complex specification of relationships is needed. You use DIASYS-IDOL++ software to write the logic. The EMS provides OPS elements and MPS elements such as control loop plates for operating the plant and alarms. The EMS is an extended function block and enables the seamless description and manage-ment of the relationships among those elements on the same sheet.

■ Accessory Station (ACS)The Accessory Station (ACS) stores and manages large amounts of plant data. Removable media such as magneto-optical drives for data storage can be easily connected. The ACS can also be used as an interface with external devices.

■ Compact Process Station (CPS)The Compact Process Station (CPS) is a controller containing a CPU (SmartCPU) that can be mounted on the bus (FLEX BUS) which is used for I/O modules. The CPS can be used more casually compared to the MPS, for example, in a small plant such as a packaged boiler, an additional facility for diagnosing the combustion vibration of a gas turbine, or any other place that requires input and output. The CPS uses the same I/O modules as the MPS. The CPS and the MPS can coexist in the same system.

Internet LevelOn the Internet Level, DIASYS Netmation® offers monitoring from home and remote diagnostic services from MHPS. Operation and monitoring can be performed by simply connecting to the Internet using the same Browser WSM as on the Office LAN Level.

Office LAN LevelOn the Office LAN Level, DIASYS Netmation® offers plant operations monitoring and control via a local LAN that extends throughout the entire power plant. Since all functions are available using just a Browser WSM, a business PC or similar computer can be used effectively without modification. What's more, by simply installing an in-house wireless LAN or PHS line, mobile OPSs that permit on-site operation checking and monitoring can be utilized.

Unit LevelConnected over a duplexed 100M Ethernet network, the Unit Level is a layer designed with emphasis on reliability. This level offers an interface to the upper layers and overall unit monitoring and operation. The ACS is equipped with large-scale storage devices, interfaces with the upper levels, and integrates printers and other peripheral devices. The OPS is placed in the central control room, and effectively provides the operator with a variety of displays and methods of operation. The EMS is used for editing the overall configuration and to control arithmetic operations. The MPS not only includes control functionality, but can also be used to perform arithmetic calculations and short-term data storage in 1-hour intervals.

Control LevelThe Control Level enables the arithmetic operations for control and the input and output with the field. If the Control Level fails or stops, the plant may be greatly affected. Therefore, the high reliability is mandatory for the Control Level. The MPS and the CPS perform varied types of calculations in addition to the arithme-tic operations for control, and collect data for a short period of time (one hour). The MPS and the CPS can be connected to a DCS and a sequencer (PLC) of other manufacturers via ControlNet, which is the I/O network, or Ethernet.

Field LevelThis level provides ports to field networks such as Fieldbus and DeviceNet by connec-tion through Linking Devices (LD) to a ControlNet network. Not only is seamless integration with the control system possible, but remote, batch maintenance of terminal field devices can be performed.

Fig. 1 : System Configuration

System Overview and Feature

System

Overview

and Feature

Below are outlined the main devices making up the DIASYS Netmation® system.

System

Overview

and Feature

When you use DIASYS Netmation®, you can easily create a remote monitoring and operation system that allows operations and monitoring at a place far from the plant or a field mobile terminal system that enables operations on the field outside the control room in the same manner you expand an ordinary system (security measures are required). You can create such systems since a protocol for low-load traffic, called the card communication technology, was developed and adopted in DIASYS Netmation® to enable the communications between the system components.

■ Low-load traffic is achieved by sending and receiving only required dataThe traditional control systems periodically sent all the process data collected by the controller to user-machine interface devices such as OPSs. Therefore, the larger the plant, the larger the traffic became. And an applicable infrastructure was required. The card communication technology is an outstanding communi-cations method since it queries the controller for the data to be displayed on the OPS, and compresses and sends or receives only the required data.

With the card communication technology, the traffic required for normal operations and monitoring can be 32 kbps or less per OPS. Therefore, a remote monitoring and operation system can be created using existing low-load infrastructures such as PHS and microwaves. You do not need to lay new optical fiber to create a remote monitoring and operation system. Data is not missed even if an unstable communications network might experience momentary lapses of data since the MPS logs and stores data. When the communications are restored, the OPS calls the MPS for data again. Therefore, trend data and alarms are not lost. Other functional degeneration does not occur, either.

■ Many applications are available for the control and monitoring systemMany applications are available such as a remote monitoring and operation system using existing microwave lines for security purposes or telephone lines, a tablet PC used as a field mobile terminal, and the email feature of a mobile phone used as an alarm reception feature.

Fig. 2 : Card Communication

System Suited for Remote Monitoring and Control　(Protocol for Low-Load Traffic: Card Communication Technology)

Browser WSM

BrowserWSM

BrowserWSM

BrowserWSM

BrowserWSM

MPS (Multiple Process Station)

② Card received : data parcel sent

① Client OPS data request enterd on card : card sent

③ Data parcel received : data displayed on OPS screen

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MPS (Plant Control System)

(Common Control System)(Turbine Governor Control System)

Geothermal PowerGeneration Facility

Company LAN

Company LAN

OPS(Plant Monitoring and Operation)

Web Server

NO.1 Proxy

NO.2 Proxy

Demilitarized Zone

64kps

VPN

About 100km

Firewall

OPS

OPSOPS OPS

MPS(I/O Device)

OPS

Diesel PowerGeneration Facility

Base Station(Control Station in Island A)

Island B

Island CIsland D

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When trend data is displayed,

the machine restarts

Past data is resent

if the machine freezes or is reset

MPS/CPS

Windows is convenient. But how about reliability?

System

Overview

and Feature

System

Overview

and Feature

In this example, an operator station was set up at the client's monitoring center over 100km from the plant, where the client carried out remote monitoring and control via a secure microwave link.

In this example, multiple power plants on separate islands were monitored and controlled from a single plant, for improved operating efficiency. Communication between the islands was carried out using the client's secure microwave link and an NTT (Nippon Telegraph and Telephone Corporation) dedicated phone line.

Fig. 4 : Remote Monitoring System for Island Power Plants

Compact Process Station (CPS)

Fig. 3 : Example Remote Monitoring and Operation System for a Geothermal Power Plant

System for Small Facilities: Compact Process Station (CPS)

Coexistence of User-friendliness (OPS) and High Reliability (MPS and CPS)

Not all applications involve large-scale systems like thermal power plants. The Compact Process Station (CPS) has the flexibility to adopt to smaller, dispersed power sources and other small-scale facilities. As a DCS, the CPS has the same operability, expandability, and reliability that characterize DIASYS Netmation®, with the size and cost performance comparable to a sequencer (PLC).

・Whereas in the MPS, the CPU chassis and I/O modules are completely independent in the cabinet, the CPS employs a simpler arrangement, with the CPU module located alongside the DIN rail with I/O modules.

・High-speed access is made possible by directly connecting the CPU module and the I/O module via a world-standard Allen Bradley FLEX I/O.

・In addition to the conventional DIASYS Netmation® I/O module, the Allen Bradley module can also be used on its own.

・A dual CPU configuration can also be used for even higher reliability.

・The system can be configured and maintained using the same Engineering & Maintenance Station software as with DIASYS Netmation®.

・Systems combining DIASYS Netmation® and the "Smart CPU" can be seamlessly configured, operated, and maintained.

・DIASYS Netmation®'s characteristic low-load communications allows the configuration of remote monitoring and control systems for unmanned facilities and so on.

For details, see the chapter on the Compact Process Station (CPS).

DIASYS Netmation® uses Microsoft's Windows as the operating system of the OPS. Since you can use the OPS to operate and monitor a plant by clicking the mouse or dragging and dropping items like you use Windows applications such as Word and Excel, the users who are accustomed to Windows can easily learn how to use the OPS. Some of you may worry that Windows is prone to freeze (a window suddenly stops and does not recover until the power is turned off and on again) and Windows may not be suitable for operating and monitoring a plant in terms of reliability.

DIASYS Netmation® was successful in gaining the operability of Windows and high reliability by designing the system based on a concept that totally differs from conventional control systems. Now the controller (MPS or CPS) has the data collection feature and the alarm detection feature which belonged to the OPS previously. Even if the OPS goes down, the required functionality is never lost. The MPS and the CPS are designed with reliability as the top priority. The operating systems of the MPS and the CPS are not Windows and each of the MPS and the CPS is duplexed (two CPUs, two power supplies, two networks) to achieve a high working ratio. In the OPS, only the DIASYS Netmation® graphics display software (Work Space Manager) is running and the OPS does not collect or store process data at all. When the OPS needs data, it asks the MPS, the CPS, or the ACS using the card communication technology each time. Therefore, even if the OPS freezes and is reset, functional degeneration such as missed alarm detection or missed trend data does not occur at all.

To achieve this level of reliability, DIASYS Netmation® knows the causes that might freeze Windows in advance and performs required measures on Windows applications for continued operation. That is why DIASYS Netmation® can run 24 hours a day, 365 days a year. If a memory leak that might cause a system freeze occurs, an appropriate circuit in DIASYS Netmation® detects it and reports it as an alarm to reset the PC before the freeze occurs and release the memory.

Fig.5 : Reliability of Windows

Since the duplexed controller (non-Windows) collects data and detectsalarms, the activation and deactivation of the higher-level PC have no influence on data collection.

Detected alarms, history of alarms, whether alarms are checked, and trend graphs are displayed without fail.Tagging status is also kept regardless of the status of this PC.

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Human-Machine Interface H

uman-M

achine Interface

Overview

Control, monitoring, and data management are carried out from OPSs , which are Windows PC-based systems. The human-machine in-terface was created with emphasis placed on similarity to Microsoft Office, to make the system easy to learn for operators familiar with the use of Word and Excel.

It is also possible to set up a central control room designed for people familiar with office-type environments that utilizes full-monitor op-eration combined with a user-friendly human-machine interface. Adding a large screen (optional) allows several people to share the lat-est plant information.

A Web-based OPS (browser OPS) has also been developed for DIASYS Netmation®. Simply by setting up the OPS on a Browser-active PC, operators can supervise plant operations via their intranet. Operators can also perform browser OPS opera-tions at home or on the road via public telephone lines.

Furthermore, by setting up a wireless LAN on their premises, operators can perform plant operations, monitoring and control in the field using a notebook or tablet PC, just as if they were in the central control room.

The OPS is a Windows personal computer installed with Work Space Manager which is the DIASYS Netmation® graphics display software. The OPS does not store process data. Each time a window needs to be displayed on the OPS, the OPS asks the MPS, the CPS, or the ACS to send the data required for the window (card communication technology). Therefore, operations and monitoring can be performed with low traffic load.

Fig. 6 : Conceptual Image of a Central Control Room

OPS/MPS/ACS Role AllocationThe human-machine interface functions are implemented using the three main elements making up DIASYS Netmation® : Operator Stations (OPS), Process Stations (MPS/CPS), and Accessory Stations (ACS). Their respective roles are apportioned as shown in Fig. 10. The OPS does not store process data of the plant; it fetches necessary data from the MPS/CPS or the ACS when necessary using the card communication technology.

Function of OPS

The OPS provides plant operation and monitoring functions.

■ Graphics (P&ID display)

Fig. 8 : Sample Graphic Screen Displayed with Other Screens Fig. 9 : Sample Graphic Screen

The OPS graphically displays the operating status of a plant. The OPS displays an overall or partial system diagram of the plant, and displays process status and process values in real time, using methods such as digital display, bar graphs, and color variations. Clicking on the screen-displayed graphical symbol of a plant device causes a control loop plate (operation frame) to appear, where it can then be manipulated. Further, more efficient status monitoring can be achieved by displaying trend components and other graphic components concurrently. Since the logic calculation status can also be displayed, a screen densely populated with integrated plant and control infor-mation can be configured.

Fig. 10 : Sample Graphic Screen Fig. 11 : Sample Graphic Screen

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Fig. 7 : OPS/MPS/CPS/ACS Role Allocation

The main functions are as follows:・Long-term storage of data (31 days by default)・Storage of event traces・Storage of logs・Process data reports・Other reports・Exporting data to Excel data sheets

The main functions are as follows:・Arithmetic calculations・Short-term storage of data (1 hour)・Performance calculations・Accumulation of process values・Alarm detection・Time stamping for alarm events

Process Station(MPS/CPS)

Accessory Station(ACS)

Operator Station(OPS)

The main functions are as follows:・Graphic display・Plant operation input (operation frame)・Modification of some settings such as logic

parameters・Alarm display・Trend display

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■ Control Loop PlatesA control loop plate component (equivalent to a conventional moni-toring and operation-type instrument) is provided with the system.Control loop types include analog operation loops and digital opera-tion loops. Analog operation loops are used for performing continu-ous operations (e.g. set value manipulation and valve lift opera-tions) and digital control loops are used for starting and stopping auxiliary equipment and for opening and closing motorized valves. The system is designed to prevent mishaps through the combined use of control loop operation and execute keys for initiating an oper-ation.The control loop's associated controllers and control logic are processed at a Multiple Process Station. It is possible to display a maximum of 12 control loops per OPS window.

■ TrendsA trend is a component that graphically displays the variance of process data over time. There are three types of trend components:

1) Trend Graph

The trend graph component graphically displays up to 16 points of process data as the data varies over time.

Functions・ Seamless display of both realtime & historical trends・ Pen recorder-style current value monitoring・ Easy scaling and scaling information summary・ Independent timing mark information・ Display of reference data such as ideal curves・ Collection time Recent mode : Display data within the last 24 hours Historical mode : Display data after the last 24 hours up to 31 days ago (standard)・ Collection cycle Recent mode : 1 sec Historical mode : 10 sec (standard), 1 sec, 5 sec, or 15 sec・ Display span : 3 min, 10 min, 30 min, 1 hr, 2 hr, 4 hr, 8 hr or 24 hr

2) Quick Trend

The quick trend allows ready display of trends in parameters the user wishes to monitor for a short time only. Simply right-click any analog data on the graphic window to display trend data.

Functions・ Vertical axis auto-scaling・ Drag-and-drop display of up to 4 parameters・ High/low (max/min) monitoring

Fig. 12 : Sample Loop Plate Window

Fig. 13 : Sample Trend Graphic

Fig. 14 : Sample Quick Trend

3) X-Y Trend

The X-Y trend graphically displays the correlation between multiple process data items that cannot be represented by the time-sequence components. The X-Y trend component supports operation and mon-itoring by the operator through display of saturation curves, NPSH characteristics, water-fuel ratio, cross limits, and a host of other data types.

Functions・Setting of actual data as a target curve・Drag & drop target curve setting・On-line or off-line target curve setting

■ Alarms

DIASYS Netmation® 's alarm function boasts a number of ways to quickly inform operators of plant and system abnormalities, and to help investigate their sources.The system comes with an alarm summary, two-line message, alarm group display, and event trace. It also includes an alarm setting function and alarm event printing function.

1) Alarm Summary

The alarm summary displays a list of alarms that have occurred. Alarms can be grouped according to categories set using the Engineering & Maintenance Station, and the classified alarms easily displayed with the look and feel of Explorer. Operations such as alarm suppression are also possible.

Functions・ Fifteen-class Color-Coded Display・ Alarm sorting by device and importance

using the alarm list view・ Sorting by priority (Fifteen-class)・ Display items: Occurrence time

(mm/dd hh:mm:ss), tag name, details, level, alarm setting value. The user can accessdetailed information on selected alarmsusing the View function.

2) Two-line Message

The two-line message displays the latest alarm messages on two lines. The latest alarm occurrences and their status can be checked while referring to graphic and trend win-dows.

3) Event Trace

The event trace displays in list form up to 160,000 events of various types (alarm occurrence and recovery, automatic manual switching, etc.). An event-type sorted display is also available.

Fig. 16 : Sample Alarm Summary

Fig. 15 : Sample X-Y Trend

Table 1 : Example of alarm type and display colorsAlarm Type Abnormal Restored

Major Red GreenMinor Yellow Green

System Red Green

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■ Operator Action LogsThe operator action log function stores operator actions such as control loop plate operation (on/off, increase/decrease) and alarm/data setting, and automatically prints them on demand. Display options are also available.

Functions・Number of actions stored: up to 160,000 (including event, trace)・Display options: operation-, tag-, and time-based display

■ Flight RecorderIf a main plant device is tripped, the flight recorder function collects the data about the pre-registered process values before and after the trip and displays the data as trend data on the OPS. The flight recorder helps you investigate and analyze the cause of trips by chronologically displaying the process data before and after a trip in high resolution.

Functions・Collection interval: Minimum calculation interval of logic・Collection period: 1 minute at maximum before and after a

trigger・Number of points collected: 32 points at maximum/group, up to

8 triggers can be set per group・Number of groups: 4 groups at maximum/MPS・Display method: Trend feature of the OPS・Amount of data stored: Data of past 10 collections is stored per

group.

■ Digital Group TrendsThe digital group trend function periodically stores the pre-registered data and chronologically displays it in a list format.

Functions・Number of data items registered: 20 points at maximum/group・Number of groups: 40 groups at maximum・Display update interval: Selectable from 1, 2, 3, 4, 5, 6, 10, 12,

15, 20, and 30 seconds, 1, 2, 3, 5, 10, 20, 30 minutes, and 1 hour

■ Maintenance LogsUsing bar graphics or numeric values, the maintenance log function displays the elapsed operation time or the total number of starts and stops of specified auxiliary plant equipment.

Functions・3200 items・Group Point List

■ Group Point ListThe group point list function displays the current values of pre-registered data in a table format in real time.

Functions・Number of data items registered: 64 points at maximum/group・Number of groups: 64 groups at maximum・Display update interval: 1 second

■ Sequence Event LogsIf a major device in the plant is tripped, the log collects data of the signals that are registered in the event DI module every millisec-ond.

Functions・Resolution: 1 msec・Collection period: 30 minutes at maximum before and after a

trigger・Number of trigger points: 128 points at maximum/group・Number of groups: 10 groups at maximum・Amount of data stored: Data of past 10 collections is stored per

group.

■ ReportsThe report function is used for printing process data managed by the Accessory Station database in the form of daily or monthly reports. To print, data is first obtained from the database and then a report is created by pasting the data into an Excel form. Because report screens are created using Excel, report formats can easily be created by customers.

Functions・Report types: daily, monthly, and the following optional types: hourly, shift, weekly, quarterly, and annual・Print request function for reprinting previously printed reports on demand・Ability to revise reports using Excel

■ Post-trip LogsWhen the plant power train is tripped, the post-trip log function collects data consisting of pre-registered analog and digital values from before and after it was tripped.

Functions・Collection period: 20 minutes at maximum before and after a

trigger・Standard: 5 minutes before and after a trigger・Collection cycle: 1 second・No. of data points collected: 64 points + 8 triggers/ group　× 40 groups・Amount of data stored: Data of past 10 collections is stored per

group.

Fig. 18 : Sample Report

Function of ACS

■ System Status IndicationThis window displays the status of each element making up the system. If an abnormality occurs, a message including its details (self-diagnosis results) and location (e.g., card/module address) is displayed.

Fig. 19 : Sample System Status

Control System Monitoring Functions

■ Logic MonitoringMonitoring of logic calculation executed on the MPS , parameter tuning, and collection of data with static characteristics can be performed from the OPS display.

Fig. 17 : Sample Logic Monitoring

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As a leading plant manufacturer, MHPS offers a variety of plant operation support software packages.

■ Operation Support Functions (optional)The following operation support functions are available to custom-ers upon request.

Functions (selected)・Plant start and stop curve display・Automatic plant start and stop control (APS)/sequence master display・Trip factor monitoring・Control schematic diagram display・Leak detection monitoring・Enthalpy diagrammatic drawing・Control balance・Trend monitoring

■ Plant Calculation (optional)MHPS offers a variety of calculation packages.

Functions (selected)・Performance calculations・Life duration calculations・Stress calculations・User defined calculations

■ Archiving to External Storage Units (optional)This function archives data to large external storage units such as magneto-optical disks.

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DIASYS Netmation®'s security system is built on MHPS's proven track record in security technology.

・Special operating controls ensure solid security, including password-protected operation, over and above what is already provided by carefully-implemented hardware and software procedures.

・Firewalls are set up where necessary, to block unauthorized access from outside the system.

・The Operator Station can be set up with security levels to limit access either by operation or by area.

The hardware specifications for the Operator Station (OPS), the Browser OPS, and the Accessory Station (ACS) are listed below.

Table 2 : OPS Hardware Specifications

・Windows -based PC is employed.・An industrial personal computer for long-term maintenance (PCLTM01) is recommended.

・ Windows -based PC is employed.・An industrial personal computer for long-term maintenance (PCLTM01) is recommended.

・Recommended specifications. (Requirements for a Windows-based PC containing an applicable browser.) ・ An industrial personal computer for long-term maintenance (PCLTM01) is recommended.

Table 3 : Browser OPS Hardware Specifications

Table 4 : Accessory Station (ACS) Hardware

Fig. 21 : Sample Setting Screen for Security Level

■ Voice Guidance (optional)Voice guidance uses speech to convey the content of the plant auxiliaries operation guide and to alert operators to alarm occurrences.

■ Large Screen (optional)Connection and use of a large screen display allows several operators to monitor the plant and share plant operations at the same time.

■ Displaying Video Recorded by a Web Camera (optional)The video of Motion-JPEG (M-JPEG) can be displayed. The video recorded by an inexpensive Web camera can be displayed in the same manner graphics are displayed on the OPS. Any type of camera can be used.

■ Displaying Video Recorded by an NTSC Camera (optional)The video recorded by an existing NTSC camera can be displayed by installing an MPEG4 encoder. You can use an existing camera and display the recorded video on the OPS.

■ Browser OPS (optional)By installing and setting up this software on a browser-resident PC, operators can obtain the same functionality as provided in the central control room OPS. By connecting to the operator's intranet, plant operation and monitoring are possible from the home or office. What's more, by implementing this function over the Internet or a leased line, remote monitoring from MHPS and remote plant diagnosis are also possible.

■ Mobile OPS (optional)By setting up a wireless LAN, OPS functionality using a tablet PC can be realized from the field. Security from external tampering is achieved by setting up a firewall.

System Security

Hardware Specifications

Plant Operation Support Functions

Other Functions

Remote Monitoring and Operation Functions

Item SpecificationCPU Pentium 4 1.5GHz or higher

(latest model is employed)Memory 1 GB or moreHard disk 80 GB or moreResolution 1280 x

x

1024Network connection 100baseT 3ch

(2ch when networking printer not required)

OS Windows NT 4.0 workstation/2000/XP Professional

Item SpecificationCPU Pentium 4 2.4GHz or higher

(latest model is employed)Memory 1 GB or moreHard disk 80 GB or moreResolution 1280 x 1024Network connection 100baseT x 1chOS Windows NT 4.0 workstation/

2000/XP ProfessionalBrowser Internet Explorer 5.0 or higher

Item SpecificationCPU Pentium 4 1.5GHz or higher

(latest model is employed)Memory 1 GB or moreHard disk 80 GB or more Network connection 100baseT x 3ch

(2ch when network printer not required)

OS Windows NT 4.0 workstation/ 2000/XP Professional

Other CD - R/RW drive

Fig. 20 : Mobile OPS

FieldIn-plant PHS, wireless LAN, etc.

Same operation and monitoring screen as the OPSin the central operation room

■ Alarm Mail (optional)It is possible to register a critical alarm and deliver it in real time via e-mail. This function allows you to know immediately if a problem occurs in the plant and to take a quick, proper action.

Hum

an-Machine Interface

Multiple P

rocess Station (M

PS

)

1615

■ Multi-screen (optional)The multi-screen is an OPS consisting of one PC controller and multiple monitors. The multi-screen supports a one-person operation by allowing you to concurrently display and operate multiple windows more easily compared to usual monitors.

■ Liquid Crystal Panel (optional)OPSs with liquid crystal panels are available (with limited functions). You can incorporate this type of OPS in the control board if you do not require an independent personal computer as the OPS.

Multiple Process Station (MPS)

The Multiple Process Station (MPS) of DIASYS Netmation® is a controller that performs arithmetic operations for control and processes input and output with the field.The DIASYS Netmation® Multiple Process Station (MPS) gives full play to the plant manufacturer's basic philosophy of ensuring reliability and controllability. The key features of the MPS are as follows.

■ High ReliabilityDuplicated redundant functional processors, network and power supply units help ensure system reliability. Moreover, each CPU is provided with a complete set of self-diagnostic functions. This means that, in the event of failure, switchover can be made to the standby CPU of the duplex system without adversely affecting control.

■ High-Performance Control FunctionsDIASYS Netmation®'s MPS achieves excellent controllability, thanks to its powerful Intel Celeron/Pentium processor and high-speed process I/O scheme. Since it employs the latest high-speed CPU, the MPS is able to perform most any type of arithmetic computation, including efficiency calculations, soot calculations, and more.The MPS also detects alarms and logs data.

■ Flexible System ConfigurationA broadly-based hardware line-up makes it possible for the MPS to conform to a wide range of system configurations, from compact architecture systems to highly-complex systems. Since sequencers (PLCs), MCCs and fieldbuses can be connected directly to the system, the plant system designer can set up a total plant control and monitoring system, including control of proprietary systems within the plant.

■ Easy MaintenanceThe DIASYS-IDOL++ engineering software tools integrate total plant control logic designing, maintenance, monitoring and diagnostics. DIASYS-IDOL++ is a user-friendly system for the customer, which makes it a snap to perform system maintenance of anything from control logic modification to system configuration.

■ High Maintainability of HardwareEven in the unlikely event of system failure, the MPS's self-diagnostic functions and indication features make it easy to locate the failure and restore the system.

Overview

Table 5 : Specifications of the CPU in the MPS

Table 6 : Specifications of the MPS I/OItem Specifications

I/O network ControlNet Redundancy Duplex Standard IEC61158

Communication method CTDMA (Concurrent Time Domain Multiple Access)

Communication speed 5 Mbps Maximum number of distributions

5 ControlNet/ MPS

Maximum number ofControlNet nodes

Number of I/O modules

Data update interval

For arithmetic operations at 50 msec: 7 adapters/ControlNet, for arithmetic operations at 100 msec: 14 adapters/ControlNet8 modules/adapter5 msec

Duplex

Specifications

CompactPCI busUnnecessary (flash memory is used)

pSOS

ItemCPCPU01 CPCPU02 CPCPU11 CPCPU31

Intel Celeron 300 MHz Intel Pentium Ⅲ　700MHz

Intel Pentium 4-M 2.2GHz

Intel / ULV Celeron M 1.0GHzCPU

RedundancyCPU busBackup batteryOSMemory 128-MB ECC memory as standard 256-MB ECC memory as standardCompactFlash 64 MB as standard 128 MB as standard 128 MB as standard 256 MB as standardBattery Lithium battery (for calendar)

Remarks - - -Used for gas turbine control.

Multiple P

rocess Station (M

PS

)

Multiple P

rocess Station (M

PS

)

1817

Human-machine interface level (OPS, ACS, Browser OPS, etc.)

Fast Ethernet HUB/SWITCH

CPU card

System DI/O card

Adapter

Multiple ProcessStation (MPS)

Remote I/O

Plant

Adapter Adapter Adapter

OpticalConverter

OpticalConverter

TB

TB

TB

TB

TB

TB

TB

TB

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

TB

TB

TB

TB

TB

TB

TB

TB

TB

TB

TB

TB

TB

TB

TB

TB

Adapter PLC(sequencer)

LinkingDevice

FIELDBUSDeviceNet

MCC

ControlNet

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

TB

TB

TB

TB

TB

TB

TB

TB

SystemDI/O card

CPU card

C-PCI

Tracking

Communication

Optical fiber

C-PCI

Ethernetinterface

card

ControlNetinterface

card

ControlNetinterfacecard

Ethernetinterfacecard Engineering &

Maintenance Station(EMS)

SIDE (A-A)

2300

200229

1000

100300

FRONT A REAR

750

FG

A 250 250 250

2300

200229

1050

421100

300

FG

310.35

89.6 5

71

1000

282

P/S

CPU

PO

WE

R S

UP

PLY C

AB

LE S

PAC

E

206

482

265

CP

U-A

SY

STE

M I/O

P/S-B P/S-A INPUT +5.0V +3.3V +12V

INPUT +5.0V +3.3V +12V

CP

U-B

SY

STE

M I/O

ETH

ER

NE

T-Q

ETH

ER

NE

T-P

CO

NTR

OLN

ET I/F

ETH

ER

NE

T-QE

THE

RN

ET-P

CO

NTR

OLN

ET I/F

P/S-B P/S-A INPUT +5.0V +3.3V +12V

INPUT +5.0V +3.3V +12V

FRONT VIEW SIDE VIEW

The system configuration of the MPS is shown in Fig. 22.

There are two, duplexed CPU cards, each of which monitors the other in a redundant configuration. If one of the CPUs fails, the control functions are seamlessly handed over to the standby CPU. Process I/O modules that provide plant interfaces also provide the interface to the CPUs via ControlNet, which is an open, state-of-the-art control network advanced by Allen Bradley specifically for real-time, high-throughput industrial applications.

Ready I/O module extensibility is provided by adding I/O modules to ControlNet. Similarly, specialized function modules such as turbine interlock modules and valve interface modules are also connected to ControlNet, just like a regular I/O module.

Allen Bradley's PLC can also be connected directly to ControlNet. This allows one to configure a total plant control and monitoring system that includes proprietary PLCs for auxiliary systems such as water treatment facilities, desulfurization facilities and ash treatment facilities. For the sequencers (PLCs) that are manufactured by companies other than Allen Bradley, the interface is enabled by MODBUS or Ethernet. Moreover, by connecting linking devices to ControlNet, the system can also be set up to interface fieldbuses, DeviceNet networks, or MCCs.

Fig. 23 shows a typical arrangement of modules in a cabinet; Fig. 24 is a sketch of a CPU chassis; and Figure 25 is power distribution diagrams of the CPU and I/O systems.

Hardware Architecture

Fig. 22 : System Configuration of Multiple Process

Fig. 24 : Outside View of CPU Chassis

Fig. 23 : Typical Arrangement within Cabinet

Multiple P

rocess Station (M

PS

)

2019

Multiple P

rocess Station (M

PS

)

Fig. 25 : Power Distribution Diagram

DC POWER SUPPLY

Adjacent BoardTable 7 : DIASYS Netmation® Original Card and Module Lineup (1/2)

Hardware Lineup

DIASYS Netmation®'s card line-up is shown in Table 7. In addition to the DIASYS Netmation® cards, the FLEX I/O cards manufactured by the Allen Bradley company can also be used.

TYP E N A M E N U M B E R S P E C IF IC AT IO N C P C P U 31 C O M PA C T P C I C P U C A R D (U LV C e leron M ) M B C P U 03 M U LT IB U S C P U C A R D

C P U card

D 0C P U 05 U P /V C P U C A R D C P E TH 01 10M /100M E therne t IN TE R FA C E C A R D C P E TH 02 10M /100M E therne t IN TE R FA C E C A R D (2 P O RTS ) C P E TH 03 10M /100M E therne t IN TE R FA C E C A R D (2 P O RTS )

N etw ork inte rface card

C P C N T01 C ontro lN et IN TE R FA C E C A R D D U A L P O RT R A M 16K B C P D IO 01/02 C O M PA C T P C I S Y S TE M I/O C A R D

C P U chassis s to rage com patib le card

S ystem D IO card C P D IO 03 C O M PA C T P C I S Y S TE M I/O C A R D TA C T S IG N A L O U TP U T FXA IM 01 A I M O D U LE (C o ntro lN et FLE X A N A LO G IN P U T 4 -20m A , 8 P O IN TS ) FXA IM 01C A I M O D U LE (C o ntro lN et FLE X A N A LO G IN P U T 4 -20m A , 8 P O IN TS ) [A D C O N V E R TE R R E D U N D A N C Y ] FXA IM 02 A I M O D U LE (C o ntro lN et FLE X TR A N S M ITTE R IN P U T, 8 P O IN TS ) FXA IM 02C A I M O D U LE (C o ntro lN et FLE X TR A N S M ITTE R IN P U T, 8 P O IN TS ) [A D C O N V E RT E R R E D U N D A N C Y ] FXA IM 03 A I M O D U LE (C o ntro lN et FLE X D C 1～5V IN P U T, 8 P O IN TS ) FXA IM 03C A I M O D U LE (C o ntro lN et FLE X D C 1～5V IN P U T, 8 P O IN TS ) [A D C O N V E RTE R R E D U N D A N C Y] FXA IM 04 A -U P A I M O D U LE (C o ntro lN et FLE X TH E R M O C O U P LE IN P U T, 7 P O IN TS B U R N -U P ) FXA IM 04 A -DW A I M O D U LE (C o ntro lN et FLE X TH E R M O C O U P LE IN P U T, 7 P O IN TS B U R N -D O W N ) FXA IM 04 B -U P A I M O D U LE (C o ntro lN et FLE X TH E R M O C O U P LE IN P U T, 7 P O IN TS B U R N -U P ) FXA IM 04 B -DW A I M O D U LE (C o ntro lN et FLE X TH E R M O C O U P LE IN P U T, 7 P O IN TS B U R N -D O W N ) FXA IM 04 C -U P A I M O D U LE (C o ntro lN et FLE X TH E R M O C O U P LE IN P U T, 7 P O IN TS B U R N -U P ) [A D C O N V E RTE R

R E D U N D A N C Y] FXA IM 04 C -DW A I M O D U LE (C o ntro lN et FLE X TH E R M O C O U P LE IN P U T, 7 P O IN TS B U R N -D O W N ) [A D C O N V E RT E R

R E D U N D A N C Y]

FXA IM 04 D -DW A I M O D U LE (C o ntro lN et FLE X TH E R M O C O U P LE IN P U T, 7 P O IN TS B U R N -D O W N ) [A D C O N V E RT E R

R E D U N D A N C Y]FXA IM 05A A I M O D U LE (C o ntro lN et FLE X RTD IN P U T, P t100Ω -1 00～650℃ 5 P O IN TS ) FXA IM 05B A I M O D U LE (C o ntro lN et FLE X RTD IN P U T, P t100Ω -4 0～60℃ 5 P O IN TS ) FXA IM 05C A I M O D U LE (C o ntro lN et FLE X RTD IN P U T P t100Ω -10 0～650℃ 5 P O IN TS ) [A D C O N V E RTE R

R E D U N D A N C Y] FXA IM 05E

A I M O D U LE (C o ntro lN et FLE X RTD IN P U T Cu10Ω 5 P O IN TS )

A I m od ule

A I M O D U LE RTD IN P U T P t10 0Ω -200～200℃ 5 P O IN TS

FXA O M 01A A O M O D U LE (C o ntro lN et FLE X 4～20m A /0～20m A O U TP U T, 8P O IN TS ) FXA O M 01B A O M O D U LE (C o ntro lN et FLE X 4～20m A /0～20m A O U TP U T, 4P O IN TS ) FXA O M 01A D A O M O D U LE (C o ntro lN et FLE X 4～20m A /0～20m A O U TP U T, 8P O IN TS , R E D U N D A N C Y)

A O m od ule

FXA O M 01B D A O M O D U LE (C o ntro lN et FLE X 4～20m A /0～20m A O U TP U T, 4P O IN TS , R E D U N D A N C Y) FXD IM 01 D I M O D U LE (C o ntro lN et FLE X 24V D C D IG ITA L IN P U T, 16 P O IN TS ) FXD IM 02 D I M O D U LE (C o ntro lN et FLE X 48V D C D IG ITA L IN P U T, 16 P O IN TS ) FXD IM 11 D I M O D U LE (C o ntro lN et FLE X 24V D C D IG ITA L IN P U T, 8 P O IN TS )

D I m od ule

FXD IM 12 D I M O D U LE (C o ntro lN et FLE X 48V D C D IG ITA L IN P U T, 8 P O IN TS ) FXD O M 01 D O M O D U LE (C o ntro lN et FLE X D IG ITA L O U TP U T, 8 P O IN T S ) FXD O M 01D D O M O D U LE (C o ntro lN et FLE X D IG ITA L O U TP U T, 8 P O IN T S , R E D U N D A N C Y) FXD O M 02 D O M O D U LE (C o ntro lN et FLE X D IG ITA L O U TP U T, 16 P O IN TS )

I/O m od ule

D O m od ule

FXD O T01 D O M O D U LE (C o ntro lN et FLE X TA C T S IG N A L O U TP U T, 8 P O IN TS ) FXE D I01A C ontro lN et FLE X I/O E V E N T D I M O D U LE , 24V D C , 8 P O IN TS FXE D I01B C ontro lN et FLE X I/O E V E N T D I M O D U LE , 48V D C , 8 P O IN TS FXE D I02A C ontro lN et FLE X I/O E V E N T D I M O D U LE , 24V D C , 16 P O IN TS FXE D I02B C ontro lN et FLE X I/O E V E N T D I M O D U LE , 48V D C , 16 P O IN TS FXP IM 01A C ontro lN et FLE X P U LS E IN P U T M O D U L E , 24V D C , 8 P O IN TS FXP IM 01B C ontro lN et FLE X P U LS E IN P U T M O D U L E , 48V D C , 8 P O IN TS FXP IM 02A C ontro lN et FLE X P U LS E IN P U T M O D U L E , 24V D C , 16 P O IN TS FXP IM 02B C ontro lN et FLE X P U LS E IN P U T M O D U L E , 48V D C , 16 P O IN TS FXP O M 01 C ontro lN et FLE X P U LS E O U TP U T M O D U LE , 8 P O IN TS FXV IF 01 C ontro lN et FLE X I/O I/P VA LV E IN TE R FA C E M O D U LE

FXV IF 02B C ontro lN et FLE X I/O I/P VA LV E IN TE R FA C E M O D U LE FXP D M 01 P U LS E D IS TR IB U TIO N M O D U LE FXR Y M 01 R E LAY IN TE R LO C K M O D U L E

Functio n m od ule

FXIR S 01 IN FR A R E D FLA M E D E TE C TO R M O D U L E (FLE X )

FXA IM 06A

FXV IF 02 C ontro lN et FLE X I/O I/P VA LV E IN TE R FA C E M O D U LE

Multiple P

rocess Station (M

PS

)

Multiple P

rocess Station (M

PS

)

2221

Table 9 : Self-Diagnostic Items

System Reliability

To help ensure the highest system reliability, a stringent quality control system is rigorously applied to both the hardware and the software of the MPS. Even so, as a basic rule, MHPS embraces a redundant configuration to maintain automatic control and operation monitoring functions, even in the rare event a system failure occurs.

In a redundant configuration, reliable self-diagnostic functions and a thorough backup transfer function constitute the two most critical elements. These self-diagnostic functions are shown in Table 11.

1) Self-diagnostic Functions

Since the CPU card of an MPS assigns its highest priority to maintaining continued control as the plant control system, it is equipped with the ability to perform reliable self-diagnostics.

2) System Switching Procedure

Two CPUs are used for redundancy. One CPU is the control CPU and the other is the standby CPU. The control CPU issues output permissions to the output modules and the calculations of this CPU control the plant. The standby CPU periodically fetches necessary data from the control CPU to maintain the same calculations as the control CPU in case of emergency switchover. The CPUs monitor each other. If an abnormality occurs in the control CPU, the standby CPU detects it immediately and takes over the control CPU bumplessly. The system I/O card in each system monitors whether the status of the other CPU is normal or abnormal.

Item SpecificationHardware WDT error

PCI bus errorMaster abortTarget abortAddress parity errorData parity error

CPU power supply errorSoftware Division by zero

Incorrect addressOverflowAlignment over accessInvalid opcodeDouble faultInvalid TTSSegment not presentStack faultGeneral protection errorFloating point errorSheet data errorSheet data expansion errorSheet data mismatchSystem configuration data errorSystem I/O connector errorTracking receive errorEthernet transmission errorControlNetTM communication errorEthernet transmission fault (minor error)ControlNetTM communication fault (minor error)

Table 8 : Allen Bradley FLEX IO Module Lineup

Table 7 : DIASYS Netmation® Original Card and Module Lineup (2/2)

TYP E S P E C IF IC AT IO N TYP E S P E C IF IC AT IO N

1794-1B 16 24V D C 16 S IN K IN P U T M O D U LE 1794-O W 8 8 R E LAY S IN K S O U R C E O U TP U T M O D U LE

1794-IV 16 24V D C S O U R C E IN P U T M O D U LE 1794-IE 24V D C S E LE C TA B LE A N A LO G 8 IN P U T M O D U LE

1794-O B 16 24V D C 16 S IN K O U TP U T M O D U LE 1794-IF4 I 24V D C S O U R C E IS O LATE D A N A LO G 4 IN P U T M O D U LE

1786-R PA M O D U LA R R E P E ATE R A D A P TE R 1794-O F4I 24V D C S O U R C E IS O LATE D A N A LO G 4 O U TP U T M O D U L E

1794-O A 8 120V A C 8 O U T P U T 1794-IT 24V D C TH E R M O C O U P LE IN P U T M O D U LE

1794-O E 4 24V D C 4 O U TP U T 1794-A C N 24 V D C C o ntro lN et M E D IA A D A P TE R

TYP E N A M E N U M B E R S P E C IF IC AT IO N

FXS V L01A S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, ±20 m A /4-20m A O U T/LV D T IN )

FXS V L01B S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, ±20 m A /4-20m A O U T/LV D T IN )

FXS V L02A S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, ±50 m A O U T/LV D T IN )

FXS V L02B S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, ±50 m A O U T/LV D T IN )

FXS V L02B -8V-1 K S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, ±50 m A O U T/LV D T IN )

FXS V L02C S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, ±50 m A O U T/LV D T IN )

FXS V T01 S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, ±20 m A /4-20m A O U T/Tra nsm itte r IN )

FXS V T02 S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, ±50 m A O U T/Tra nsm itte r IN )

FXS V T03 S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, 0 -250m A O U T/Tra nsm itte r IN )

FXS V T04 S E RV O VA LV E IN TE R FA C E M O D U LE（C ontro lN et FLE X, 0 -500m A O U T/Tra nsm itte r IN )

FXO P C 01 C ontro lN et FLE X I/O O V E R S P E E D P R O T E C TIO N C O N TR O L M O D U LE

FXE O S 01 C ontro lN et FLE X I/O TU R B IN E E O S T C O N TR O L M O D U LE

FXTC L01 C ontro lN et FLE X I/O TU R B IN E IN TE R LO C K LO G IC M O D U LE

FXTC L02 C ontro lN et FLE X I/O TU R B IN E IN TE R LO C K LO G IC M O D U LE

FXG TI01 C ontro lN et FLE X I/O TU R B IN E IN TE R FA C E LO G IC M O D U LE

FXV IM 01 C ontro lN et FLE X I/O V IB R ATIO N IN TE R L O C K M O D U LE

FXV IM 02 C ontro lN et FLE X I/O V IB R ATIO N IN TE R FA C E M O D U LE

Turb ine co ntro l m od ule

FXV IM 02B C ontro lN et FLE X I/O V IB R ATIO N IN TE R FA C E M O D U LE

FXD C C 02 P O W E R S U P P LY U N IT (24V D C O U TP U T 10W ×1ch, 40W ×3C h)

FXD C C 03 P O W E R S U P P LY U N IT (24V D C O U TP U T 10W ×1ch, 40W ×1C h)

FXD C C 05 P O W E R S U P P LY U N IT (24V D C O U TP U T 100W ×1C h)

FXD C G 01 P O W E R S U P P LY U N IT (24V D C 100W ×1ch, 40W ×2ch, 48V D C 4 0W ×1)

C P D D A 01 P O W E R S U P P LY U N IT FO R C P U U N IT C H A S S IS

C P D D A 11 P O W E R S U P P LY U N IT FO R C P U U N IT C H A S S IS

C P D D A 21 P O W E R S U P P LY U N IT FO R C P U U N IT C H A S S IS

C P D D A 31 P O W E R S U P P LY U N IT FO R C P U U N IT C H A S S IS

P ow er supp ly unit

C P D D A 41 P O W E R S U P P LY U N IT FO R C P U U N IT C H A S S IS （24V D C IN）

C P C H S 01 C O M PA C T P C I D U P LIC ATE D C P U U N IT C H A S S IS

C P C H S 02 C O M PA C T P C I D U P LIC ATE D C P U U N IT C H A S S IS

C P C H S 11 C O M PA C T P C I D U P LIC ATE D C P U U N IT C H A S S IS , 6U

C P C H S 21 C O M PA C T P C I D U P LIC ATE D C P U U N IT C H A S S IS

R C K -FA N -N 1 C P C H S 21 C O O LIN G FA N U N IT

R S 232H U B 8ch D TU (D ATA TR A N S FE R U N IT )

FXD T B 01 TE R M IN A L B A S E U N IT W ITH D IS C O N N E C TIN G SW ITC H

O ther periphera l m od ule

C R IS E -P D FLA M E D E TE C TO R

Long-te rm m ainte na nce P C P C LTM 01 IN D U S TR IA L P C E N A B LIN G LO N G -TE R M M A IN TE N A N C E

1794-A C N R 15 D C 24V C o ntro lN et R E D U N D A N T M E D IA A D A P TE R

1794-TB N TE R M IN A L B A S E U N IT

1794-TB 3 3-W IR E S C R EW C LA M P TE R M IN A L B A S E U N IT

A llen B rad ley ’s O rigina l p roduc ts

1794-TB N F FU S E D TE R M IN A L B A S E U N IT

C ontro lN et C O A X IA L C A B LE C ab le

C ontro lN et F IB E R O P TIC C A B LE

Engineering &

Maintenance S

tation (EM

S) and D

IAS

YS

-IDO

L++

Com

pact Process S

tation (MP

S)

2423

Smart CPU

Smart CPU

FLEX I/O

OPS/EMS

Relay circuit (blue section)

Characeristics and specifications of auxiliary devices

■ Features　(1)The CAD feature of Visio allows you to enter information that is similar to traditional CAD diagrams.(2)Information acquired outside control systems can also be entered as doagrams.(3)The sequence of signals from the field to the graphical user interface can be written in one sheet.

■ Advantages　・The circuits of the relay sequence can also be written in the same diagram (the MPS/CPS ignoresthem during operations).・The specifications of auxiliary devices such as the rated current can be written in the same diagram.・Confirmation of operations is easy at test runs and maintenance inspections.

The Compact Process Station (CPS) of DIASYS Netmation® is a controller that handles input and output with the instruments and devices installed in the field of the plant. The CPS automatically controls the plant and performs varied calculations. The CPS contains a CPU that can be mounted on a FLEX I/O module bus.Since the CPS requires no CPU chassis unlike the MPS and may be used in a single configuration, it can be used more casually, for example, in a small-scale system such as a packaged boiler, an additional facility for diagnosing combustion vibration of a gas turbine, or any other place that requires input and output. The CPS can be duplexed if necessary.

Fig. 26 shows a typical system configuration for a CPS.SmartCPU can be directly connected to an OPS or an EMS as shown in Fig. 26 since SmartCPU has an Ethernet interface. Up to eight I/O modules can be mounted under SmartCPU. To mount more than eight I/O modules, you can use the FXADP01 to extend the I/O bus.To duplex the CPS, connect two SmartCPUs by using a tracking cable.

Table 11 shows the module line-up of the DIASYS Netmation® CPS. In addition to DIASYS Netmation®'s original modules, you can use the FLEX I/O modules manufactured by Allen Bradley.

Overview

Specifications

Hardware Architecture

Hardware Lineup

Compact Process Station

Fig. 26 : CPS System Configuration Example

Table 11 : Hardware Lineup

Compact Process Station (CPS)

The EMS, which is a maintenance tool of DIASYS Netmation®, is used to make system settings and perform maintenance procedures ranging from modification and creation of logic on the MPS and design of graphic displays, trends and control loop plates on OPSs , all the way up to and including configuring an entire system.

・ Easy maintenance using the fully integrated database・ Engineering by dragging and dropping・ No conversion of logic to POL (logic diagrams are directly used

as arithmetic operation data)・ DIASYS-IDOL++ logic description language added with data

processing and OPS elements in addition to the logic language.

■ Logic Data Management and Creation (LOGIC WINDOW/LogicCreator)For a traditional control system, the instrumentation control engineer creates logic diagrams and the maintenance tool of the control system converts the logic diagrams to POL diagrams to create the logic to be calculated on the controller. For DIASYS Netmation®, the conversion to POL diagrams is totally abolished.The instrumentation control engineer uses LogicCreator, which is based on a Microsoft CAD tool, VISIO, to create function block diagrams (control logic diagrams) by drag and drop operations only. When the data is built and downloaded to the MPS or the CPS, only the logic elements that need to be calculated are extracted and calculated. The created diagrams can be directly submitted to your customers or maintained properly. For the traditional system, if logic is changed in the system, the diagrams need to be re-written afterward. For DIASYS Netmation®, since the calculated logic and the diagrams are the same, the diagrams are automatically updated when logic is changed.

■ System Configuration Function (SYSTEM WINDOW)This function is used to arrange elements making up the system such as MPSs , OPSs , and ACSs connected to the unit network, and to set the I/O configuration of the MPSs . This function can also be used to compress logic data drawn using LOGIC WINDOW into numeric data known as sheet data and download it to an MPS.

■ Human Machine Interface Setting Function (HMI WINDOW)This function is used for constructing OPS displays, including control loop plates and alarm summaries, as well as data logging function setting. It is used to perform not only placement of display components such as valves and pumps, but also placement of JPEG and bitmap data, logic data, and setting of log trend data.

■ Plant System Diagram Management and Creation Function (GRAPHIC WINDOW)This function is used for managing and creating the graphics displayed on the OPS.

■ ObjectDatabase (ORCA) Modification Function (DOCUMENT WINDOW)This function is used to interface with ObjectDatabase (ORCA). Since Excel can be used for this interface, modification or revision of data can be performed using various easy-to-learn functions of Excel.

■ Drawing Management Function (DRAWING WINDOW)This function is used to manage drawings such as function block diagrams, IO lists and instrument lists as PDF files.

Overview

Features

Functions

Engineering & Maintenance Station (EMS) and DIASYS-IDOL++

Fig. 27 : Feature of Logic Creator

Table 10 : DIASYS Netmation® CPS SpecificationsItemCPUMemoryOSInterface

Max. number of I/O module connectionsOperating cycleData logging function

Power

EthernetControlNet

FXCPU0132-bit high speed RISC CPU 266 MHz128 MBLinux (realtime compatible)

3 ch216 modules

More than 10 msec CPS internal logging capacity: 800 points per hour (1 sec cycle), up to 1,600 alarms total (Separate ACS required for long-time storage)24V DC

40 modules

TYPE NUMBER SPECIFICATIONFXCPU01B FLEX I/O TYPE CPU MODULE (Ethernet 3 ch / 16 modules)FXCPU03 FLEX I/O TYPE CPU MODULE (Ethernet 3 ch / 40 modules)FXADP01B FLEX I/O REDUNDANT ADAPTER MODULE(FXCPU01B)

CPU module

FXADP02 FLEX I/O REDUNDANT ADAPTER MODULE(FXCPU03)I/O module FX type modules listed Table 7 can be used.

Engineering &

Maintenance S

tation (EM

S) and D

IAS

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-IDO

L++

Engineering &

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L++

2625

Fig. 29 : Previous Control System's Method (Example of Pump Color Change)

Fig. 30 : ObjectDatabase (ORCA)'s Method (Example of Pump Color Change)

ＤＩ　１

２

３

４

５

ＡＩ　１

ORCA

Object-oriented databaseObjectbase(ORCA)

Number Setting LD0001 1 when active LD0002 1 when inactive LD0003 1 for failure … .

The logic for establishing each state is written.Graphic components do not exist.

Logic creation tool

Same state of the same pump since the number is the

same

Number Setting LD0001 Red for 1 LD0002 Yellow for 1 LD0003 Red and flicking for 1 ….

The color for each state is set.

Graphic creation tool

Logic for definingcolor changepatterns

Same object with different

appearances

The logic for establishing each state is written.Graphic components can coexist with logic.

Logic creation tool:LogicCreator

The color for each state is set (this setting is also possible using LogicCreator).

Graphic creation tool:GraphicCreator

Fig. 28 : Conceptual Rendering of ObjectDatabase (ORCA)

One of the main features of DIASYS Netmation® is an integrated database called ObjectDatabase (ORCA). The control system performs varied functions including the graphic display on an OPS, creating logic for defining arithmetic processing for control, and assignment of input and output signals to I/O modules. ObjectDatabase (ORCA) managed each piece of data that is shared by different functions as a single component (object). Objects appear differently depending on the function that uses them. However, objects do not change. Figure 28 shows the concept.

　

In previous systems, when different functions required the same data, each function created the data and gave the same number to the data to show that they were actually using the same data. Let's take a pump for example.

Suppose there is logic that defines a pump that changes its color depending on its status. Also suppose there is a graphic window that displays the pump which changes its color. In previous systems, the logic creation tool was used to create the color change logic and the pump was given a number for each piece of that logic. Then the graphic creation tool was used to create a graphic that displayed the pump. To the colors of the pump, the numbers defined in the color change logic were assigned.

Figure 29 shows the concept of the previous number assignment method. Figure 30 shows the ObjectDatabase (ORCA) method used in DIASYS Netmation®.

Integrated Database（Object Database(ORCA)）

Engineering &

Maintenance S

tation (EM

S) and D

IAS

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-IDO

L++

Engineering &

Maintenance S

tation (EM

S) and D

IAS

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-IDO

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2827

<L

001Input 1

Input 2

Input 1

Input 2

i nput 3

Output

Output

Intput i

Example of element having three Input

The lowest value of three i nput s ignals is output

Behavior

V001

Behavior

InputInput

Rate of change

Rate of change

Tracking

TrackingOutput

OutputAM001

Behavior

Tracking

Tracking

Trackingvalue

Tracking value

Increasedemand

Increase demand

Decreasedemand

Decrease demandOutput

Output

Fx001

Y1

Y2

Y 3

Y4

Y 5 Y 6

Y7

Y8

Y 9

Y10

X 2 X 3 X 4X 1 X 5 X 6 X 8 X 9 X10X 7

Behavior

Input Output

Output

Input

PI001

Element Behavior

Input

Input

Output

Tracking

TrackingTracking value

Tracking value

Output

AND001

Input 1

Input 2

Input 1

Input 2

i nput 3

Output

Output

Intput i

Example of three Input

Three input s ignals are ANDed.

Behavior

ORCA-View

ORCA:Object Relation Control Architecture

・You can write operation controls in control logic.

・You can write lamps in control logic.

Element

Element

ElementElement

Element

Fig. 31 : Typical DIASYS-IDOL++ Elements

Control and processing logic is described using DIASYS-IDOL++, the logic description language exclusive to DIASYS®. Conventional digital controllers require programming technology to build up the control logic, making them difficult for control engineers to handle. With DIASYS-IDOL++, however, the program code is formed simply by drawing a conventional control system diagram on the VDU screen.

This control and processing logic description software, originally developed by MHPS for power plants, has earned a solid reputation among customers for its easy description of control algorithms. Since it was first developed in 1980, DIASYS-IDOL++ has become faster and more compact in terms of arithmetic processing, while maintaining the same interchangeability of expression.

The DIASYS-IDOL++ contains more than 100 standard logic elements, with the typical 6 elements shown in Fig. 31. The elements are displayed for selection on the LogicCreator of the EMS. The standard elements can also be combined to form a new element using the "user definition macro function."

Control and Processing Logic Description Language DIASYS-IDOL++

Fig. 32 : Logic of DIASYS Netmation®

The DIASYS-IDOL++ software installed in the EMS includes not just elements for logic description language, but for operating screens,

OPS control monitoring elements including alarms and lamps, and plant status as well, allowing various linked conditions to be entered on

a single logic sheet. Previously, links between control logic, OPS, and other functions were created by assigning an ID number, but

DIASYS-IDOL++ eliminates the need to assign and manage ID numbers.

Hardware Specifications

The hardware specifications for the EMS are listed below.

・Windows -based PC is employed.・An industrial personal computer for long-term maintenance (PCLTM01) is recommended.

Table 12: EMS Hardware SpecificationsItem SpecificationCPU Pentium 4 2.4 GHz or higher

(latest model is employed)Memory 1 GB or moreHard disk 80 GB or moreResolution 1280 x 1024Network connection 100baseT x 3ch

(2ch when network printer not required)

OS Windows NT 4.0 workstation/ 2000/XP Professional

3029

http://www.diasysnetmation.com/solutions

Thermal Power PlantControl System DIASYS Solutions

　Flame Detector ・IR-S Infrared Flame Detector ・Net IR-S Infrared Flame Detector ・Infrared Flame Detector Rail Mounting Net IR-S

● ●

　Analyzer/Simulator・Tube Leak Detector ・Training Simulator

●

● 　Self-learning Training Simulator ・SimTRAC

　Optimization/Operation support ・Trip Analysis System・Plant Optimization System・Condenser Water Quality Monitor・Multi-Coal Fired Boiler Optimum Control ・Joint Operation System・Modernization of Power Plants for Local Use・Automated Plant Start/Stop System・Remote Turbine Vibration Diagnostics Service ・Operation Support System・Approach for Renovation of DCS DIASYS

Normal operation

After optimization

Total power generated

90 MW 87 MW

Purchased 10 MW 13 MW

Consumed 8.1 t/h 7.1 t/h

Consumed coal

29.8 t/h 29.8 t/h

Power gen. cost

48.3 k US$/h

47.4 k US$/h

As a plant manufacturer, Mitsubishi Hitachi Power Systems (MHPS) provides total solutions for operating plant including design, manufacture, and operation of boilers and turbines. We also integrate the component parts of the plant such as boilers, turbines, and auxiliary units using our thermal plant control system, DIASYS®. This provides the measurement, control and required information to operate the plant. In addition MHPS offers other products to cover every aspect of plant operation: high sensitivity monitoring devices, high efficiency operation control support applications, and operation training assistance systems.

DIASYS Netmation®-Related ProductsMeasurement and Control Products for Thermal Power Plant : DIASYS SOLUTIONS

　A part of these products is presented from the following page.

DIA

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DIA

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Training Simulator

Joint Operation System (JOS)

Setting (input) Operation plan, cost calculation

Dataconversion

Convert toCSV file

Device operation

plan" Load rate" Amount of electricity" Purchased" Amount of stored electricity" Amount of stored heat

" Electricity supply charge" Gas charge" CO2" Maintenance fee

As a world-renowned plant manufacturer, Mitsubishi Hitachi Power Systems has delivered a variety of plants ranging from plants with boilers and turbines for small industries to large-scale plants consisting of monotube boilers and steam turbines. Our operation training simulator, SimTRAC is the essence of our accumulated design know-how and operation technologies, realized in the form of user-friendly simulation technology.■ Advantages of introducing SimTRAC 1) Operators can easily learn how to start and stop a plant or change load by themselves.2) Simulated operations provide a varied types of abnormalities including device failures and system changes, allowing operators to　　　

　improve their skills effectively. 3) Simulations for changing the control logic and adjusting parameters allow operators to understand plants better.4) Simulations include special types of operations such as coal-fired boilers.

■ Training simulatorPrecise and compactHighly sophisticated design technologies of Mitsubishi Hitachi Power Systems as a plant manufacturer are incorporated including know-hows for designing boiler heat surfaces and turbine blades, heat transfer equations, and consideration for the heat balance of plants.

Database methodPlant models are easy to create since they consist of device components registered in the database (DBSS） and devices are represented as symbols.

Operation graphics and control logic based on actual devicesControl plate display, warning display, and graphic display are the same as those used in actual devices. The renowned control software of Mitsubishi Hitachi Power Systems, DIASYS-IDOL, is implemented for control.

As parameters, you can specify (or enter signals for) 1): plant system information, such as characteristics of boilers and turbines or pressure loss in pipes, 2): electricity supply charge, fuel cost, 3): energy demand patterns of steam and electricity and 4): operation conditions. By doing so, JOS calculates the economical operation in real time using n-order polynomial expressions considering the task as a nonlinear constrained optimization problem and displays the result as a reference for the actual operation.■ Example of Calculating the Advantages of Introducing JOS

The typical cost improvement of a mill of a paper manufacturer is described here.You can calculate the advantages of introducing JOS based on the following data:

■ System OverviewJOS enables the optimal operation of power plants with multiple boilers and turbines in factories. It uses the system characteristics and fuel costs of the plant as parameters and finds the optimal solution that minimizes the fuel and electricity to be purchased while satisfying the demands for electricity and steam in the factory. When combined with online control, JOS also enables real-time optimal operation.

(1)Systems in the target plant (steam, fuel, electricity) (2)Whether electricity is purchased, unit price of electricity (for each season and time zone) (3)Rating and structures of boilers and turbines (4)Boilers: Rated capacity, type of fuel, operation range (5)Turbines: Type (such as 2-stage extraction back-pressure), rated capacity, and operation range of steam in each stage

Setting on the block diagram/Web screen" Device configuration " Device operation " Specifications of each device" System information" Energy demands

" Cost" Amount of electricity generated and purchased" Amount of gas used" Activity status of devices" Amount of CO2

Cost calculation

Data conversion

Convert to CSV file

Result display (output)

3231

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Remote Operation and Monitoring System

Net IR-S Infrared Flame Detector

　

Ethernet VPN

Power plant A thatremotely runs plant B

Power plant B at a remotelocation

Customerprivate

line

Customerprivate line

Ethernet VPNconnector

Ethernet VPNconnector

Controlsystem

Remoteoperationsystem

Localnetwork

Localnetwork

The recent monitoring and control systems for therminal power plants require the communications technology such as the Internet and intranet, powerful databases, high-performance yet low-cost hardware including personal computers, and easy-to-use user-machine interface software.To fulfill these needs, DIASYS Netmation IR-S (Net IR-S) is created. The Net IR-S is a flame detector that is created as a feature of the burner control system by combining DIASYS Netmation , which is latest control system of Mitsubishi Hitachi Power Systems, and the renowned IR-S Infrared Flame Detector.The sensor unit of the Net IR-S inherits the detection reliability, maintainability, and economy of the conventional IR-S. The detection circuit board is now a module of DIASYS Netmation . The board is connected to the higher levels of Netmation, enabling easy-to-use user-machine interface.The Net IR-S can be detached from the burner control unit and used as an independent flame detector as well.

Features

Fast EthernetHUB/SWITCH

IRS Sensor

Net IR-S

Ｓ

Control Net

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

Adapter

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

Adapter

TB

TB

TB

TB

TB

TB

TB

TB IRSmodule

IRSmodule

IRSmodule

IRSmodule

IRSmodule

IRSmodule

IRSmodule

IRSmodule

Adapter

TB

TB

TB

TB

TB

TB

TB

TB

Adapter

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

TB I/O

Adapter

IRSmodule

IRSmodule

IRSmodule

IRSmodule

IRSmodule

IRSmodule

IRSmodule

IRSmodule

CPU-A CPU-B

Nowadays, remote systems are introduced to allow operations of a power plant from a different remote power plant or operations and monitoring from a customer's headquarters. MHPS has provided remote systems in more than 30 power plants worldwide. Some remote systems are connected to MHPS's remote center to allow our plant engineers to support efficient operations.

To introduce a remote system, the following points must be noted:

１） Security precautions against network intruders and information leakage must be provided.２） The processing of the control system must not be affected.３） There should be no response bottlenecks that may cause communication overload on the data transmission route such as VPN lines and Internet lines.４） Expandability must be taken into account to allow adding features in the future such as video transmission.

MHPS has delivered remote systems that require high reliability such as remote systems in far islands and remote geothermal turbines.

Example of the burner controlsystem with the built-in Net IR-S

■High Reliability　　　High-sensitivity designThe newly designed sensor enables the detection of burner flames, reliably. Flames are detected through the non-ignition zone.

Greater detection rangeThe detector allows better and more reliable detection from high-luminance flames to slow combution. Besides providing a much better detection sensitivity-100 times that of the existing product, the new detector eliminates the need for sensitivity adjustments.

■Excellent Maintenanability　　　Manitenance-free designThe spherical lens eliminates the need for cleaning the sensor window.

Long-life sensorLong-life semiconductors used in the infrared sensor element makes it unnecessary to carry out replacement at normally frequent intervals.

■Excellent EconomyFewer number of panelsDue to the space-saving design of the detector module, each panel is capable of housing 40 corners.

Uses existing boiler equipmentFor replacement work, it is unnecessary to modify the boiler.

Uses existing equipmentIt is unnecessary to replace the sensor-to-panel cable.

＜Features＞By combing burner control and flame monitoring, the following advantages can be achieved; ・The maintenance tools of the burner control system can perform monitoring, adjustment, and maintenance. ・Easy maintenance using the common line ・Compact size ・No need to replace the control cable