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Technical Document 12 September 2012 Dewatering System Controller™ (DSC™) Technical Document 12 September 2012 Table of Contents 1 DEWATERING SYSTEM CONTROLLER™ (DSC™) Technical Document 12 September 2012 1 DEWATERING SYSTEM CONTROLLER™ (DSC™) 1.1 Basic System Design This controller is designed for international low voltage of 220VAC. The standard DSC™ (Dewatering System Controller™) is based around a design that uses a stand-alone Logic Control Panel to monitor and control the entire dewatering system. The DSC™ contains an Allen-Bradley SLC-500 processor and all the associated I/O to control one Thickener, one Belt Filter Press and various ancillary pumps and field devices. The DSC™ will also contain a PC with an industrial panel mount color monitor for operator interface. The operator interface PC shall provide a graphical representation of the system with bed mass, underflow density, center well flocculation, and pump speeds actively displayed. Manual control of each pump will be through the operator interface PC HMI software or remotely using the remote control panels, RCP1 and RCP2 respectively. The DSC™ shall be designed to control an external motor control package. The external motor package (by others) can take any form from either a Motor Control Center (MCC) or a Motor Control Panel (MCP). 1.2 Hardware to include: NEMA 12 Free Standing PC Enclosure Industrial PC Graphics Display in Door Lockable Keyboard and mouse drawer Circuit Breaker and Surge Suppressor protected main 220VAC power supply from external source. 230V to 24VDC Power supply built in. Allen-Bradley SLC-500 Series PLC, Power Supply and Rack Hardware 24VDC Discrete I/O 24VDC Analog I/O 4-20mA Dry Contact Closures for motor starter, variable frequency drives, solenoid valve control, and various ancillary equipment and field devices for the dewatering system. The customers MCC or MCP that houses the switchgear shall provide power for these devices. Field Wiring Terminals located in the rear door for ease of wiring to MCC, MCP and other plant equipment. Technical Document 12 September 2012 Typical DSC™ Control Panel 1.3 DSC™ Layout The figure above shows the basic layout of the DSC™ enclosure. The upper front portion of the NEMA 12 enclosure contains the ELO Industrial monitor, the Allen-Bradley SLC-500 series processor and I/O rack, and all power connections. The PLC is accessible through the upper door on the front of the enclosure. The middle section shows a standard keyboard/mouse drawer with a lockable slide out shelf. System power on, power off and emergency stop buttons are provided on the front of the enclosure above the keyboard. The lower front portion of the enclosure contains the PC. All field terminations are located on the rear mount sub-panel and are accessible through the back door. Technical Document 12 September 2012 1.4 REMOTE CONTROL Included in this package are two (2) RCP (Remote Control) Panels to allow remote operator control of the thickener/press area and the polymer Area. 1.5 Hardware to Include: NEMA 4X Fiberglass Enclosure 30mm Allen-Bradley Push Buttons, Selector Switches, and potentiometers Terminal Strip for field wiring Typical Belt Press RCP Technical Document 12 September 2012 1.6 Dewatering System Electrical Engineering and Programming 1.6.1 Electrical Engineering This control system will include a PC/PLC master control enclosure, remote operator control stations, and field device / instrumentation wiring interface. The control system design will include the supply of CAD drawings developed with AutoCAD 2007 software. The drawing package will include the following: Filed Device layouts Process & Instrumentation Diagram Instrumentation Wiring Diagram Controls Wiring Diagram PLC Wiring Diagram Enclosure(s) Layout drawings. 1.6.2 PLC Programming Extensive testing and past experience has allowed us to develop a fully functional and tested PLC ladder logic code for a DSC. The program has been written using Rockwell Software’s RSLogix 500 latest revision and has been 100% tested and finalized in our shop prior to releasing the DSC for shipment. Included with the PLC programming service is a complete and comprehensive O&M manual. 1.6.3 Operator Interface Programming The PC and industrial monitor will provide a real time graphical representation of the dewatering system. Additional screens will allow for manual override controls, parameter/speed adjustment settings, and fault annunciation with alarm history and date time stamp for record keeping. The Human-Machine Interface (HMI) will be developed using Microsoft’s Visual Basic program development language. This is a PHOENIX Process Equipment Co developed application and is sold to the customer license free. PHOENIX Process Equipment Co retains all rights to the developed code which is maintained as a proprietary developed software program. The basic function of the HMI can be controlled with the mouse or keyboard or utilizing the touch screen capabilities of the industrial monitor. Popup dialog boxes and alerts assist the operator in ease of controlling the system and provide instant information.
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