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Improving life through heat transfer solutions SCOPE Sequencer Panel This manual must be made available to the boiler operator at all times

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Microsoft Word - SP-IOMM-2020-1 - SCOPE Sequencing Panel Installation, Operation & Maintenance Manual - Final.docxImproving life through heat transfer solutions
SCOPE Sequencer Panel This manual must be made available to the boiler operator at all times
SP-IOMM-2020-1 2
Table of Contents
I. Warning & Cautions Explained ...................................................................................................... 4 II. Warning & Cautions In Manual ..................................................................................................... 4 III. Safety ................................................................................................................................................. 5 IV. Regulations ....................................................................................................................................... 6
SECTION - 1 INTRODUCTION ........................................................................................................ 7 1.1 General .............................................................................................................................. 7 1.2 Technical Data ................................................................................................................. 7 1.3 Product Overview ........................................................................................................... 7
SECTION 2 - INSTALLATION ........................................................................................................... 9 2.1 General .............................................................................................................................. 9 2.2 Pre-Installation ................................................................................................................. 9 2.2.1 Receiving Inspection .................................................................................................... 9 2.2.2 Siting ............................................................................................................................... 9 2.3 Electrical Requirements ................................................................................................ 10 2.4 Standard Electrical Customer Connections ............................................................. 10 2.5 Enviromental Requirements ........................................................................................ 10
SECTION 3 – POST INSTALLATION ............................................................................................. 11 3.1 Electrical Installation Testing ...................................................................................... 11 3.2 Mechanical Installation Testing .................................................................................. 11
SECTION 4 - COMMISSIONING .................................................................................................... 12 4.1 Commissioning The Panel ........................................................................................... 12 4.2 Connecting To Boilers .................................................................................................. 12 4.3 Connecting To Slow Open Valves ............................................................................. 12 4.4 Connecting To Thermcouples .................................................................................... 12 4.5 Connecting To Steam Flow Rate Sensor .................................................................. 12 4.6 Connecting To BMS ...................................................................................................... 12
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SECTION 5 - OPERATION ............................................................................................................... 13 5.1 General ............................................................................................................................ 13 5.2 Controls ........................................................................................................................... 13 5.2.1 Scope Panel Controls ................................................................................................ 13 5.2.2 Start-Up ........................................................................................................................ 14 5.2.3 Main Screen ................................................................................................................ 16 5.2.3.1 Login .......................................................................................................................... 17 5.2.3.2 Individual Boiler Status .......................................................................................... 18 5.2.3 Status ............................................................................................................................ 19 5.2.4 I/O ................................................................................................................................. 20 5.2.5 Option ........................................................................................................................... 21 5.2.5.1 Logging ...................................................................................................................... 22 5.2.6 Lag / Lead .................................................................................................................... 23 5.2.7 Settings ......................................................................................................................... 24 5.2.7.1 Settings Screen One .............................................................................................. 25 5.2.7.2 Settings Screen Two .............................................................................................. 26 5.2.8 Engineer ....................................................................................................................... 27 5.2.8.1 Engineer Screen One ............................................................................................. 27 5.2.8.2 Engineer Screen Two ............................................................................................. 28 5.2.8.3 Engineer Screen Three .......................................................................................... 29 5.3 Scope Functions ............................................................................................................ 30 5.3.1 Setting Set Points ....................................................................................................... 30 5.3.2 Boiler Change Over ................................................................................................... 30 5.3.3 Slow Opening Valve Control ................................................................................... 30 5.3.3 Scope Shut Down In Emergency Situation .......................................................... 31 5.4 Scope Panel Monitoring ............................................................................................... 31
SECTION 6 - MAINTENANCE ........................................................................................................ 32 6.1 Cleaning ........................................................................................................................... 32 6.2 Weekly ............................................................................................................................. 32 6.3 Six-Monthly ..................................................................................................................... 32
SECTION 7 - TROUBLESHOOTING ............................................................................................. 33
APPENDIX A – SCOPE SPECIFICATION ..................................................................................... 34 Specification ........................................................................................................................... 34 Mechanical Drawing ............................................................................................................ 35 Electrical Drawing - Complete ........................................................................................... 36
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For your safety!
The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.
• WARNINGS must be observed to prevent serious injury or death to personnel. • CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating
effectiveness. • NOTES must be observed for essential and effective operating procedures, conditions and as a
statement to be highlighted.
It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS and NOTES by which hazards are to be eliminated or reduced.
Personnel must become familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment.
II. Warnings & Cautions in Manual
! WARNING !
This product is designed and constructed to withstand the forces encountered during normal use. Use of the product other than as a Sequencer, or failure to install the product in accordance with these
Instructions, product modifications or repair could:
• Cause personal injury or loss of life • Cause damage to the product and/or property
• Invalidate CE marking
These precautions must, at all times, be stored in a safe place near the product installation.
Product complies with Low Voltage Directive (LVD) 2014/35/EU by meeting requirements found within BS EN 60204-1:2018
Product complies with Restriction of Hazardous Substances (RoHS) 2011/65/EU by meeting requirements found within EN IEC 63000:2018
Product complies with Electromagnetic Compatibility Directive (EMC) 2014/30/EU. This product is suitable for Industrial Class A environments. However, it may be exposed to interference
above the Heavy Industrial Immunity limits if:
• The product or wires to or from are near a radio transmitter • If excessive electrical noise is present on the mains supply.
• Cellular telephones and mobile radios could cause interference if used within 1 meter of the product or wires to or from it.
! CAUTION !
It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out the routine maintenance checks could result in a drastic reduction in the life expectancy of the system
and increase the possibility of fire, explosion, property damage, personal injury or loss of life.
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III. Safety
The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in damage to the boiler and serious personal injury.
! WARNING ! ! WARNING !
Do not try to do repairs or any other maintenance work you do not understand.
Obtain a service manual from Fulton Ltd or call a Fulton service engineer.
Key to gain access to the inside of the panel should be left with the senior member of staff responsible for the equipment, or one that has been empowered by this member and knowing
the risks within an electrical panel.
It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted in a
correct and safe manner
Adequate lighting should be provided when access the internals of panel before any work is
completed.
component. A wrong connection can cause injury and or damage.
Correct tools should be used for any work that is completed upon the panel; these should be listed
in a method statement before work is carried out.
A defective panel can injure you or others. Do not operate a panel which is defective or has missing parts. Make sure that all maintenance procedures are completed before using the
panel.
ALL Parts and cables before the Isolator may still be live even when this is turned to off, if work is
to be carried out on this section this must be isolated first.
LIFTING EQUIPMENT Make sure that lifting equipment complies with all local regulations and is suitable for the job. You can be injured if you
use faulty lifting equipment. Make sure the lifting equipment is in good condition.
Steam leaks should be frequently looked for within the facility, this panel can allow steam to enter the plant based on the program that has
been set up and thus personnel may not be present to view when this happens and locate
risks.
Operating the panel beyond its design limits can damage the panel, it can also be dangerous. Do not operate the panel outside its limits. Do not
try to upgrade the panel performance by unapproved modifications.
If slow opening valves are fitted these should be tested as frequently as possible, minimum of
monthly tests, this can be tested via the program.
Non-approved modifications can cause injury and damage. Contact your Fulton dealer before
modifying the boiler.
Panel has a mass of 23kg, care should be taken when handling and life risk assessments and method statements should be completed if
anything beyond the normal handling for the personnel involved is completed. All parties who should lift this needs to have access to the mass
of the unit and relevant PPE.
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! WARNING ! ! WARNING !
Never attempt to operate equipment that has failed to pass all the safety checks.
Panel in packaging will have a minimum mass of 25kg, care should be taken when handling and lift risk assessments and method statements should be completed if anything beyond the normal handling for the personnel involved is
completed. All parties who should lift this needs to have access to the mass of the unit.
If any “Manual Reset” limit device trips, DO NOT reset without determining and correcting the
cause. (Manual Reset Limits may include flame safeguard, high or low gas pressure, high
pressure limit.)
This equipment should only be used with Fulton VSRT boilers, unless specified in writing by
Fulton that this is not the case for an application.
Commissioning of the sequencer panel should only be completed by Fulton personnel or
supervised by Fulton personnel. ! CAUTION !
! CAUTION ! Do not try and amend, remove or change the program on the PLC.
Obey all laws and local regulations which affect you and your boiler.
Proper electrical power and type must be supplied to the panel as per the specification, if
unknown request information from Fulton.
IV. Regulations
Observe the following when working on this system:
• Work on gas equipment must only be carried out by a qualified gas engineer • Work on electrical equipment must only be carried out by a qualified electrician • All legal instructions regarding the prevention of accidents • All legal instructions regarding environmental protection • The Code of Practice of relevant trade associations • All current safety regulations as defined by PED, DIN, EN, DVGW, TRGI, TRF, VDE and all locally
applicable standards • Gas Safety (Installation & Use) Regulations - The appropriate Building Regulation either the Building
regulations, the Building Regulation (Scotland) or Building Regulations (Northern Ireland). - The Water Fittings Regulation or Water Bylaws in Scotland, - The current I.E.T. Wiring Regulations
! CAUTION !
In case of emergency this panel has been designed and constructed to meet all of the essential requirements of the applicable European Directives and subject to proper maintenance should not give
occasion to any hazardous conditions.
If such a condition should occur during commissioning or during subsequent operation of this product, whatever the cause, then the electrical supply to the panel should be isolated immediately, until the fault
has been investigated by a competent person and rectified.
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1.1 General
Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:
• Material inspections • Manufacturing process inspections • Electrical components inspection • Packing, inspection and final check
This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the staff responsible for the operation of the boiler. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.
Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, qualified installers and service personnel. Trained personnel are responsible for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are qualified and fully understand all requirements and procedures.
1.2 Technical Data
1.3 Product Overview
The sequencer panel is fitted into a metal industrial electrical cabinet, with a touch screen HMI on the outside. It is designed to monitor the functions of multiple boilers that are working on the same system, monitoring normal occurrences such as pressure and flow rate - also errors, faults and alarms.
The sequencer panels purpose is to ensure the boilers are ready for process normally when left overnight so they don’t fully cool down and can be safely and gradually brought to temperature/pressure. This is because in normal operation, the boilers be will be powered up quickly when required, if this is done it can cause fatigue on the boilers and will also cost more money due to the added energy of start-up.
Optional slow opening steam valves can also be installed after the boilers, these will gradually open when slowly powering up, this will allow the steam system to slowly re-pressurise. This is an advantage because in a lot of cases as many boiler locations being quickly powered up, the pressure is released very quickly from the boilers, this causes the condensate within the system’s pipework to be transported through it very quickly (water hammer) which can lead to significant damage to the system, potentially health and safety risks and very loud and uncomfortable noises within the system.
The sequencer also automatically switches which boiler(s) (depending on how many are fitted and steam demand) are taking the lead, which are assisting, and which are in reserve (banked); this will help to ensure that they are evenly utilised over their life. The SCOPE sequencer panel will also automatically change a boiler from assist or reserve up to lead or assist with an increased steam demand, so manual intervention is not required. It will do the opposite in a low demand situation from a high demand. It can also change a boiler over to a new lead or assist if the current lead or assist is in an alarm situation to ensure seamless supply of steam, providing of course, that the remaining boilers can cope.
The SCOPE Sequencing panel has optional extras that can be utilised such as controlling of valves after boilers, hotwell and boiler room temperature monitoring and feedback to BMS central system.
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SECTION 2 - INSTALLATION 2.1 General The installation of a SCOPE Sequencer Panel should be carried out by competent personnel in accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that these regulations are complied with. 2.2 Pre-Installation Prior to delivery, consideration should be given to the following: (planning regulations may call for more consents than those listed below, always check with your Local Planning Authority).
A. Local Planning consents where appropriate B. Consideration given to access for delivery and positioning of the panel C. Preparation of a suitable structure to fit to (see mechanical drawing in 1.3), which must be able to
support the total weight (max 23kg) of the panel under operating conditions. The locations of services to the site required for the system, under operating conditions. The entirety of the Panel must be located between 0.6m and 1.7m from the level at which the user will stand on, the boilers should be visible from the panel location without moving
D. Electricity supply check the loading required/available E. Suitable access for delivery and off-loading F. Safe access to the plant when installation is complete. Appropriate front, side and top clearances
must be maintained (see mechanical drawing in 1.3). This will allow access around the equipment to facilitate maintenance and a safe work environment
2.2.1 Receiving Inspection The customer should examine the equipment for any damage. It is the responsibility of the installer to ensure all parts supplied with the equipment are fitted in a correct and safe manner. 2.2.2 Siting
! WARNING !
Failure to provide required and safe access to the equipment could impede commissioning and maintenance. Service technicians are instructed not to commence commissioning if hazardous conditions
exist.
The panel must be kept closed at all times unless maintenance, installation or commissioning work is being carried out.
! CAUTION !
The Panel must only be fitted in the orientation shown in Appendix A.
(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1 Communication 1676, and in particular to Section 5, Location of Appliances). The boiler house should be sufficiently sized to allow easy and safe access to all parts of the panel for operational and maintenance purposes. Reference should be made to Appendix A – SCOPE Specification and data product submittals to ascertain the relevant dimensions and weights.
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! CAUTION !
Any electrical work should be undertaken by a qualified electrician to current local regulations.
! WARNING !
Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the equipment.
An individual wiring diagram for the boiler is sent with the panel (also in Appendix A). Make sure the information on the electrical drawing corresponds to your voltage and frequency. Check the supply voltage and make sure that there is no over-or under-voltage exceeding 10% of the nominal value. Note: The power ratings and requirements are given in Appendix A - SCOPE Specification and affixed to the CE plate. 2.4 Standard Electrical Customer Connections Steam flow rate - Input Connect the steam flow rate as per the electrical drawing. This will then receive the 4-20mA signal from the sensor and log the steam flow rate after the steam header if the sensor is fitted. Thermocouple plant room temperature - Input Connect the thermocouple plant room as per the electrical drawing. This will then receive the k-type thermocouple input signal from the sensor and log the plant room temperature if the sensor is fitted. Common alarm out - Output Connect the common alarm out as per the electrical drawing. This will then feedback to the BMS if a common alarm has occurred on any of the boilers. Steam pressure re-transmission - Output Connect the Steam pressure re-transmission as per the electrical drawing. This will then provide an analogue output to the BMS of the header steam pressure. 2.5 Environmental Requirements The effects of heat, vibration, shock and electrical interference need to be minimised to as low as possible, for further information read the safety precautions at the start of the manual.
! CAUTION !
Do not install outdoors without contacting Fulton first and adding further weather protection.
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SECTION 3 – POST INSTALLATION 3.1 Electrical Installation Testing Earth bonding should be tested. Electric terminals should be tightened. Cables should be inspected to ensure no exposed conductors are accessible by a small screwdriver or larger. Internally and externally. 3.2 Mechanical Installation Testing Supports for the panel must be tested to ensure they can cope with any vibration in the environment. Any external cable trunking used must be fit for purpose and properly supported.
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Commissioning by qualified persons only.
4.1 Commissioning the Panel It is essential that the commissioning procedures listed below are carried out by a Fulton service engineer who will have the necessary experience and testing equipment to ensure that the installation is not only correct but is operating safely and at optimum efficiency. 4.2 Connecting to Boilers Connect as per electrical drawing. 4.3 Connecting to Slow Open Valves Connect as per electrical drawing and SOV installation manual. Please note the SOV will need their own power source and will not be powered via the SCOPE sequencer panel. 4.4 Connecting to Thermocouples Connect as per electrical drawing and thermocouple installation manual. 4.5 Connecting to Steam Flow Rate Sensor Connect as per electrical drawing and steam flow rate sensor installation manual. 4.6 Connecting to BMS Modbus can be connected into the communication port of the HMI screen inside the panel. This feature must be turned on and enabled in order to use. Contact your service engineer to ensure this can be used.
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! CAUTION !
The following instructions are given for the guidance of the operator in the use of the Fulton steam boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored.
5.1 General The following instructions are given for the guidance of the competent operator in the use of the SCOPE Sequencing panel and to provide adequate information to ensure that when the panel is put into use it will be done safely and without risk to health. Where original equipment service manuals are supplied, they must be read and understood in conjunction with this manual. All warnings and cautions must be observed. 5.2 Controls The following description of the controls used on the SCOPE Sequencing panel is intended to provide the operator with a basic understanding of the operating principles, which is essential for the continued efficient operation of the panel. 5.2.1 Scope Panel Controls Common alarm input This is an input from the boiler to say the common alarm has triggered. If the sequencing panel receives this and the boiler that sends it is the lead it will, after a short delay, switch a boiler in lag/standby to lead. If the alarm is reset, which requires manual intervention at the boiler, the lead will be switched back to the original boiler. Up to 4 Inputs. Digital input. Boiler firing input Send a signal to the sequencer. Will show on the sequencer HMI that the boiler is running, it will count the run time of the boiler for records and display purposes. Up to 4 Inputs. Digital input. Fully opened valve input Fitted if SOV are fitted. Signal received from the valve that will tell the sequencer panel a valve is fully open; the sequencer panel will stop sending the signal to open the valve. Up to 4 Inputs. Digital input. Fully closed valve input Fitted if SOV are fitted. Signal received from the valve that will tell the sequencer panel a valve is fully closed; the sequencer panel will stop sending the signal to close the valve. Up to 4 Inputs. Digital input.
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Low water indication input Signal received that the boiler has low water. Will display that it has occurred and count occurrences. Sequencer panel will not action from this as common alarm will also be received in this circumstance and the program will take action from this. Up to 4 Inputs. Digital input. Boiler pressure input A 4-20mA Input, representing the boiler pressure. Sequencer panel will display this data. If a boiler can’t maintain the pressure set point for a nominal time (usually 30 minutes) then a further boiler will have its set point increase to help maintain the demand. Up to 4 Inputs. Analogue input. Boiler demand input A 4-20mA Input, representing the demand on the boiler. This is a signal received from the boiler and based off the burner duty. If the boiler shows a demand of 80% or over for a customer set time, then a further boiler will have its set point increased to help with the demand. If demand changes back and is considerably more than needed it will drop the set point of the secondary boilers. Up to 4 Inputs. Analogue input. Steam header pressure input A 4-20mA Input, that will be set from 0-100%, fitted at the steam header after all valves join that will display and record on the panel the pressure going to the plant (if steam header pressure sensor is fitted). Analogue input. Steam flow rate input A 4-20mA Input, that will be set from 0-100%, set based on input upon commissioning. Will be used if a flow rate monitor is fitted after a boiler. Logged and displayed visually on the sequencer panel Analogue input. Thermocouple plant room temperature input A K-type thermocouple, based on min to max temperature set on site. Always set in a high position which is above the boiler(s), must be fitted near the boilers. Will visually show the temperature on the sequencer panel and log it (if plant room thermocouple is fitted). 5.2.2 Start-Up
! CAUTION !
It is recommended that the first power up is completed by a Fulton Engineer.
Steam leaks within the overall system should be thoroughly checked for and prevented before powering up the SCOPE system.
If Slow Opening Valves are installed, they should be checked to be in good operation and condition before being brought into service.
Before the SCOPE panel is switched on all boilers should be turned on and brought up to normal operating pressure/temperature as per the boiler instruction manual. The initial set up must be completed by a trained Fulton engineer to ensure that the Control methodology in place matches that of the steam generation and distribution system. Once this initial set up has taken place, it will be safe to power up the SCOPE system and put it online. The SCOPE start-up routine can vary depending on what equipment is installed. The longest will be if slow opening steam distribution control valves are installed as these must home themselves, so the SCOPE panel knows their location.
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After approximately 60 seconds the SCOPE animated logo will appear on screen and a push button as indicated below.
At this point further checks should be made that the Steam System is both safe and ready to be put into operation.
! CAUTION !
Before the SCOPE system is brought online ensure all boilers and associated equipment’s safety checks according to their respective operation manual have been completed, only then can SCOPE be started, if
in doubt do not enable.
The start button can now be pressed. If the Slow opening valve system is being employed, then at this point the steam valves will all be driven to the closed position if they are not already. Once this action has been completed the SCOPE system will either commence automatically sequenced operation of the steam boilers or if the sequencing has not been set up the panel will await the inputs in order to begin sequencing. The “Main Screen will then be shown (Figure 5.1). This shows a graphical representation of the boilers connected to scope. The picture will be representative of the boiler that is installed.
Figure 5.1 - SCOPE
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5.2.3 Main Screen Below (figure 5.2) is the main screen for SCOPE.
• Menu – Left hand side o The “Main” button returns to the Main/Home page seen in figure 5.2 o The “Status” button takes the user to a screen giving information on the boilers o The “I/O” button takes the user to a breakdown of what options are available and on o The “Option” button allows the viewing of data relating to the installed options o The “Lag/Lead” button allows the change of set-points o The “Settings” button allows the user to change basic configurations o The “Engineer” button allows the engineer to change advanced configurations
• Middle Section
o Along the top of the screen there is the Fulton logo, date and time o If the Fulton logo is pressed it will provide the contact details of Fulton o At the top right is the date and time, if this is pressed access can be gained to the login o Below this is the readouts there are two system overviews displayed: o Header pressure after the boilers o Total demand as a percent o Below this is the boiler read outs which shows the following o A graphical representation of the boiler – if pressed takes to the individual boiler status –
5.2.5 o Demand on boiler - bar chart o Pressure of boiler from 0-13.8 bar g for VSRT - bar chart o Position of slow opening valve if fitted, fully blue means fully open - bar chart o Four indicators: o Highest one indicates setpoint Lead (green), Banked (yellow), Lag (yellow), off (red) o Middle one is Valve position open or closed; Open (green), Shut (red), Opening or Closing o Bottom one is whether this boiler is being sequenced; SEQON – green, SEQOFF red
Figure - 5.2 Main Screen
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5.2.3.1 Login To access the login screen to gain further functionality the date and time can be pressed. There are four login statuses:
• Operator o Very limited functionality, predominantly a viewing login
• Manager o Can change functionality
• Service o Can change functionality as to how the SCOPE sequencer panel works within the
“Engineer” section • Admin
o Full functionality
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5.2.3.2 Individual Boiler Status If a boiler is pressed on the “Main” screen the individual boiler status will be shown. To return to the original screen press “Main” on the left-hand side.
There are a number of statuses:
• The screen shows the boiler type, serial number and date of manufacture • The time since last service (set during service engineer visit) • Whether the boiler is powered up or off (status) • Whether the burner is on or off • The total hours the boiler has run for and its pressure • Whether a service is due soon, immediately or not at all
It is also possible to change to next or previous boiler by pressing the respective buttons.
Figure 5.3 – Individual Boiler
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5.2.3 Status This screen shows the current functionality of all boilers connected to the SCOPE sequencer panel. It will be split down per boiler.
From top to bottom the screen shows:
• Current status of the boiler with respect to its setpoint: o Lead o Assist o Lag o Banked o Off
• Steam pressure inside the boiler • The total hours the boiler has run while connected to the panel • Total number of common alarm occurrences • Total number of low water occurrences • Total number of boiler lockouts occurrences • Individual boiler demand on each individual boiler • Slow open valve position, can be:
o Open o Closed o Fault
Figure 5.4 - Status
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5.2.4 I/O The I/O screen is for fault finding and shows the current status of all I/O functions to and from the sequencer panel. For info on each see electrical drawing in appendix. The ones in the middle section are inputs and outputs and will either be on or off. The ones on the right-hand side are analogue inputs and outputs.
Figure 5.5 – I/O
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5.2.5 Option The “Option” lists the items or options that are currently enabled or connected to the sequencer panel. This will include the following:
• Slow opening valves • Modbus • Logging
The images can be pressed to take to a screen with further information or functionality.
Figure 5.6 - Options
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5.2.5.1 Logging If the logging image is pressed it will show graphical representations of the sensors readings that are currently employed, such as steam pressures and steam demand.
Navigate using the arrows at the bottom right, the logging available is as follows:
• Pressure logging o Header pressure o Individual boiler pressures
• Demand o Individual boiler demand o Average Demand
• Steam flow header (option) o Flow rate at header
Figure 5.7 – Options Logging
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5.2.6 Lag / Lead This screen allows for the viewing of the set points, with information at the top with regards pressure set point and header set point. Then below this it gives an indication as to which boiler is on which set point, if boiler 4 is currently the lead it will say “4” on the right of Lead Boiler. The setpoint this boiler will then be working towards is on the right of its corresponding setpoint. This page is for indication purposes only.
Figure 5.8 – Lead/Lag
! CAUTION !
Ensure the setpoints on the Yokogowa UT32A match with the setpoints in the first settings screen, contact Fulton if unsure how to do.
Ensure all set points on the Yokogowa are the same and are the same setpoint number, if not the SCOPE panel will not operate the boilers correctly.
The settings screens are used to configure the SCOPE system. Everything in here needs manager level login or above in order to make changes.
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5.2.7.1 Settings Screen One
At the top of the screen there are demand monitoring and fault changeover buttons.
• Demand Monitoring – This monitors the demand from the boiler. Next to it is the indication that will show on or off. If over 80% for an allotted time it will raise another boiler’s set point if possible
• Fault Changeover – If one of the boilers is locked out for more than the lag time (default 180 seconds) this will allow another boiler to start up and reach lead set point. If the original lead boiler comes back online, it will retake the lead position. Next to it is the indication that will show on or off
Below the demand monitoring is the setpoints the boilers are currently working towards; this will be a list corresponding to the number of boilers. On the right where the numbers are, the set points can be inputted by pressing them, it brings up a keyboard to edit. These must correspond to what has been inputted on the Yokogowa UT32A, contact Fulton if unsure how to do. On the right-hand side below fault changer over is further settings.
• Header low alarm will show up an indication on the screen that the pressure that is inputted is not being achieved. After the header delay time is reached it will start up another boiler. If the numbers on the right are pressed it brings up a keyboard where the pressure can be changed
• Header delay is the time the SCOPE panel will wait before starting up another boiler because the header pressure is too low (default 180 seconds). If the numbers on the right are pressed it brings up a keyboard where the pressure can be changed
• Demand delay brings a further boiler to lead pressure if the demand from the Yokogowa on the lead boiler(s) is above 80% for this time (default 180 seconds). If the numbers on the right are pressed it brings up a keyboard where the pressure can be changed
• Fault delay is the amount of time a boiler will be in fault before another will start up to take its set point. If the numbers on the right are pressed it brings up a keyboard where the pressure can be changed
• Right at the bottom is where the time and date can be changed • Further settings can then be reached by pressing arrows at the bottom
Figure 5.9 – Settings
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5.2.7.2 Settings Screen Two The second settings screen is below (figure 5.10). This screen allows the user to change which boiler is lead and whether they are on.
It is split into increments of 2 hours and by days of the week. For example, if it shows “one” then boiler one will be the lead. To change, each button can be manually pressed, and it will dial through the options. It is advised to not change the lead of the boiler every two hours and give each boiler a reasonable amount of time as lead. At the bottom there is an indication as to which boiler is currently lead.
Figure 5.10 – Settings
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5.2.8 Engineer The engineer screen can only be accessed with a Service login or above. 5.2.8.1 Engineer Screen One
The first screen allows the engineer to change span the inputs from high to low inputs corresponds to what numbers. Each goes from left to right, where the first numerical input is the number at which 4mA is set to and the high number next is set to what the 20mA will be. This should be set at the extremes of the equipment and will only be used for logging purposes. After that there is the operational values these numbers will correspond to what the user can change. These must always be within the 4-20mA scaling range. These are then scaled linearly from 4-20mA. First on the list from top to bottom is:
• Boiler (number) PTD, this relates to each individual boiler’s pressure transducer. This is a pressure scale in bar.
• Header PTD, this relates to the header pressure transducer. This is a pressure scale in bar. • B(number) demand relates to each boiler’s demand from the Yokogowa. This is a percentage scale
from 0-100%. The 4-20mA scaling will nearly always be the same as the operational values. • Boilers present, this allows the engineer to set the number of boilers connected. • At the bottom is an arrow to access the next engineer’s screen.
Figure 5.11 – Engineer
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5.2.8.2 Engineer Screen Two The second engineer screen is below (figure 5.12). This one tells the SCOPE sequencing panel what is connected and details about what is connected. This screen allows the engineer to change the currently selected options and configure the boiler details.
On the left-hand side from top to bottom.
• SOV Option is whether the Slow opening valve(s) are connected or not. • Modbus Option is whether the Modbus is connected or not. • Boiler (#) Type is what boiler type is connected. • Boiler (#) Date is the date of manufacture of boiler, found on the name plate.
On the right-hand side from top to bottom.
• Logging is to enable or disable this facility • Boiler (#) Serial is the serial number of the boiler, found on the name plate • Boiler (#) Hours is the length of time the boiler has ran for in hours • At the bottom there is arrows to go to engineer screen 1 or 3
Figure 5.12 – Engineer
! WARNING !
Do not use auto valve calibration when boilers are online or under pressure.
Do not use Auto valve Calibration when maintenance or persons are within the vicinity of the valves.
Engineer screen three is below (figure 5.13).
The SOV modes allow valves to open and close based on the header pressure If the header pressure is below the pressure on the right-hand side, it will cause a boiler that is being brought online to open at the rate in the boxes on the right of “Pulse Open”. If the pressure is higher than that shown in the “Pressure” box and a boiler is being taken offline it will cause it to close at the rate on the right of “Pulse Close”. The pulse open or close is the amount of time in seconds that the SCOPE will drive the valve for and the delay how long it will then wait for. Valve low limit indicates the nominal number that signifies the low position for the valve(s). This will be set by the auto valve calibration below. The valve high limit will work in reverse to the low limit. This should be completed upon every service and record any significant deviation, as this could indicate issues with the valve(s).
Figure 5.13 – Engineer
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5.3 Scope Functions This chapter describes the functions of the SCOPE system. 5.3.1 Setting Set Points Up to four boilers can have their “Set-points” controlled by the SCOPE Sequencing Panel. Setpoints are the user defined pressure levels that a boilers pressure will try to maintain whether there is steam demand or not. Each boiler can be placed into up to four different set-points, these set-points are normally a combination of the below:
• Lead – normally the highest pressure required of the boiler • Assist – normally at the highest pressure required of the boiler or just below • Lag – normally pressure below the highest pressure so the boiler can power up quickly if required • Banked – normally a pressure around half the required pressure, set so the boilers do not have to
heat up quickly damaging them and can responds quicker to demand The setpoints must be first setup on the Yokogowa UT32A and recorded. All boilers must have the same setpoints set in the same location. Once the Yokogowa has been setup correctly these figures must be duplicated into the SCOPE Sequencer panel, this is one using “Settings Screen One”, refer to this to complete this process 5.2.7.1. 5.3.2 Boiler Change Over This will normally be completed automatically for the following reasons:
• When a fault occurs • When steam demand on a boiler is too high for the current boiler(s) to handle • When the pre-set time inputted has completed for the current boiler(s)
If the steam demand caused another boiler to increase its set-point when the steam demand, then drops it will after a set time change the set-point back down one level. To affect a boiler changeover “Settings Screen One” and “Settings Screen Two” can be used. 5.3.3 Slow Opening Valve Control
! CAUTION ! If the panel is switched off at the isolator the slow opening valves will remain in the position they were in
until the panel reset function has been activated.
Only if the Slow Opening Valve option is fitted. This will be completed automatically with its primary function to slowly pulse open on start up to prevent a sudden pressurisation of a cold steam system that will cause serious water hammer, which can be a significant safety risk. Valves will be opened based on the boiler set-points or on start-up to home. Only within the Engineer section can changes be made to the SOV.
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5.3.3 Scope Shut Down In Emergency Situation SCOPE itself has been risk assessed and designed to not need an in-built e-stop. In the extremely unlikely event of an emergency occurring the isolator on the panel should be turned off. 5.4 Scope Panel Monitoring The SCOPE panel can monitor and log different functions of the boilers it is connected with, some of which can be fed back to the central “Building Management System” – BMS. This can be viewed in the “Option”, “Main” and “Individual Boiler Status” Section.
• Low water alarm facility - will monitor and log the amount of times boiler’s low alarms are triggered • Boiler Firing - will monitor and log when the boiler is firing to help record the “hours run” • Common Alarm - will monitor and log the number of occurrences the boiler’s common alarm is
triggered • Boiler Demand - will monitor and log the boilers burners duty from 0-100%, if over 80% for a
sustained period of time the SCOPE system raises the set point of another boiler if possible. • Steam header Pressure monitor - This will monitor and log the pressure in the header after the
boiler(s) • Boiler plant room temperature - if fitted this will monitor and log the boiler plant room temperature • Header Steam flow rate - if fitted this will monitor and log the header steam flow rate
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! WARNING !
Read the safety precautions at the start of this manual before starting any maintenance.
! CAUTION !
It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out the daily, weekly, monthly and six-monthly checks could result in a drastic
reduction in the life expectancy of the SCOPE system.
Tests should be carried out by a competent person trained to perform such tests. If any test shows that the equipment is not operating correctly, the fault should be investigated and corrected before the boiler is used. Any rectification or repairs should be carried out by trained, competent service personnel. 6.1 Cleaning If the SCOPE panel requires cleaning, a damp cloth (tap or deionised water; or isopropyl alcohol) must be used only. Any other cleaning materials could lead to damage on the product and invalidate the warranty. 6.2 Weekly Visually inspect the internals and externals of the panel for any damage, or sign of ingress. If any parts seem damage turn off panel and contact Fulton immediately. 6.3 Six-Monthly If fitted, Slow opening valves must be tested by Fulton engineers to ensure good running. Fulton service engineers should check internals and test the panel to ensure it is operating correctly, if not parts will be replaced. This can be organised by contacting your Fulton representative and is advised to completed alongside the boiler six monthly and annual maintenance.
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! WARNING !
Read the safety precautions at the start of this manual before starting any troubleshooting.
To confirm whether a fault has occurred enter the I/O menu and view whether the correct statues are showing.
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APPENDIX A – SCOPE SPECIFICATION Specification General information:
• Mains Supply - Basic unit o AC input Voltage – 230V, +10%/-15%; 110V, +10%/-15% - 47-63Hz o AC Current Consumption - 1.23A @ 230VAC / 2.47A @ 110VAC
• Mains Supply - Powering SOV o AC input Voltage – 230V, +10%/-15%; 110V, +10%/-15% - 47-63Hz o AC Current Consumption – 2.37 @ 230VAC / 5.2A @ 110VAC
• Operating temperature o +5oC to 40oC
• Transportation and storage temperature o -25oC to 70oC o Up 70oC for periods not exceeding 24h
• Altitude o Can operate up to 1000m above sea level
• Contaminates o IP22 (EN60204)
• Weight o Max 23kg
• Dimensions o W – 500mm o H – 500mm o D – 210mm
• Location o Panel must be placed between 0.6 to 1.7m off the ground o Panel door must be allowed to open to 110o o Panel must not be placed on or around hazards o Panel musts be placed with good access o Water or steam pipes should not be placed above
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Mechanical Drawing
SP-IOMM-2020-1 36
MCB 1
HMI + CPU USP-104-B10
OPTIONS 1. SLOW OPENING VALVE OPTIONS
a) 2 SOV - OPTION 1 b) 3 SOV - OPTION 2* c) 4 SOV - OPTION 3**
2. THERMO COUPLES a) HOTWELL - OPTION 4 b) PLANTROOM - OPTION 5
3. BOILER QUANTITY (TWO - STANDARD) a) THIRD BOILER - OPTION 6 b) FOURTH BOILERS - OPTION 7***
4. HEADER STEAM FLOW a) STEAM FLOW - OPTION 8
5. HEADER PRESSURE RE-TRANSMIT - BMS a) PRESS RE-TRANSMIT - OPTION 9
6. VOLT FREE CONTACTS a) ADDED VOLT FREE CONTACTS
*MUST HAVE OPTION 1,6 **MUST HAVE OPTION 1,2,6 AND 7 ***MUST HAVE OPTION 6
OP1 OP2
OP7 OP6
OP6 OP7
OP8 OP9
A-0001-0200- OPTIONS
12345 896
3
18
T1 T2 T3 T4 T5 T6 T7 T8 T9 T1 0
T1 1
T1 2
T1 3
T1 4
T1 5
T1 6
4133 34
35 36
37 38
39 40
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
57
58
59
60
62
64
66
68
70
72
74
76
61
63
65
67
69
71
73
75
77
79
78
80
OP1
OP6
OP1 OP1 OP2OP2
PART NUMBER AND OPTIONS:____________________
SIGNING THIS CONFIRMS THE PANEL HAS BEEN BUILT AS PER THIS DRAWING. SCAN THIS SIGNED DRAWING AND KEEP IN MANUFACTURING
DOSSIER, ORIGINAL DRAWING TO GO WITH PANEL.
83 84
85 86
T4 2
24 .2
24 VD
C O
U T
- 2 4.
Mc3 2/21
+
+
+
+
PC PC
2527
OPTION 1 - SOV 1 AND 2 OPTION 2 - SOV 3 OPTION 3 - SOV 4
HEADER PRESSURE
49 Sc5
50 Sc5
THERMOCOUPLE
CABLES Mc1 - 8 REQUIRED - 1, 9, 17, 20, 73, 74, 81, 96 Mc2 - 8 REQUIRED - 3, 11, 19, 22, 75, 76, 82, 97
OPTION 8 - FLOW RATE SENSOR
OPTION 9 - BMS PRESSURE RE-TRANSMIT
OPTION 4 - HOTWELL THERMOCOUPLE
OPTION 5 - PLANT ROOM THERMOCOUPLE
Mc3 - 8 REQUIRED - 5, 13, 21, 24, 77, 78, 83, 98 Mc4 - 8 REQUIRED - 7, 15, 26, 26, 79, 80, 84, 99 Mc5 - 4 REQUIRED - 28, 30, 61, 63 Mc6 - 4 REQUIRED - 65, 66, 67, 68 Mc7 - 4 REQUIRED - 69, 70, 71, 72 Mc8 - 4 REQUIRED - 6, 8, 25, 27 Mc9 - 2 REQUIRED - 81,82 Sc1 - 4 REQUIRED - 33, 34, 41, 42 Sc2 - 4 REQUIRED - 35, 36, 43, 44 Sc3 - 4 REQUIRED - 37, 38, 45, 46 Sc4 - 4 REQUIRED - 39, 40, 47, 48
Sc6 - 2 REQUIRED - 51, 52 Sc5 - 2 REQUIRED - 49, 50
Sc7 - 2 REQUIRED - 53, 54 Sc8 - 2 REQUIRED - 57, 58 Sc9 - 2 REQUIRED - 59, 60
DOC START
REVISION DATA
PART NUMBER AND OPTIONS:____________________
SIGNING THIS CONFIRMS THE PANEL HAS BEEN BUILT AS PER THIS DRAWING. SCAN THIS SIGNED DRAWING AND KEEP IN MANUFACTURING
DOSSIER, ORIGINAL DRAWING TO GO WITH PANEL.
30/10/20
DATE
CHANGED COMMON ALARM TO VOLT FREE. MOVED ALONG 24VDC AND 0VDC TERMINALS. ADJUSTED THE BOILER PANEL ELECTRICAL DESIGN, SIMPLYFYING. VOLT FREE OPTION ADDED.
02 10/11/20
81 Mc9
82 Mc9
03 01/02/21
04 08/03/21
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