Furnace Setup


The Furnace Setup menu option is an administrative access only option.  Do not make any adjustments on the screen without first contacting Super Systems, Inc. at (513) 772-0060.  Note for controllers with Cascade control: When in cascade mode, the 9xxx treats loop 2 as the furnace loop and loop 3 as the load loop.  It feeds the output of the load loop into the set point of the furnace loop.

 

PVT Type

There are nine PVT choices for the 9125:

 

%Carbon    Cascade

Dew Point    % Carbon + Redundant TC

Millivolts    Dew Point + Redundant TC

Multi-loop    Millivolts + Redundant TC

% Carbon + Dual Temp

 

%Carbon:  Process variable will calculate for carbon potential along with a temperature loop.  Loop 1 is based off of Input 1 (terminals 31, 32 probe sensor millivolts) and Input 2 (terminals  29, 30 probe TC).  These two inputs together constitute loop 1.  Loop 2 comes from Input 3 (terminals 27, 28) which is temperature control.

 

Cascade:  Three loops of temperature control work together in a cascade setting.

 

Dew Point:  Control will be for dew point along with a temperature loop.  Loop 1 is based off of Input 1 (terminals 31, 32 probe sensor millivolts) and Input 2 (terminals  29, 30 probe TC).  These two inputs together constitute loop 1.  Loop 2 comes from Input 3 (terminals 27, 28) which is temperature control.

 

%Carbon + Redundant TC:  This functions the same way as the %Carbon option with an additional thermocouple for Loop 3.  The two thermocouples are used to control carbon, and the operator can choose the setting that will be used. 

 

Millivolts:  Control is based on what the millivolt reading is and also reads temperature.

 

Dew Point + Redundant TC:  This functions the same way as the Dew Point option with an additional thermocouple for Loop 3.  The two thermocouples are used to control dew point, and the operator can choose the setting that will be used. 

 

Multiloop:  Three loops of control can be assigned as selected.

 

Millivolts + Redundant TC:  Control is based off of the millivolt reading and also reads temperature.  Loop 3 is another thermocouple.

 

%Carbon + Dual Temp:  This functions similarly to %Carbon.  Input 2 is the control TC.  IT is not used to calculate carbon potential with input one and to control furnace temperature.  Input 3 in the third loop and is another TC. 

 

IMPORTANT: If the 9125 is controlling % Carbon or Dew Point, control will be disabled if either or both of the following are true:

  • Millivolts registered by probe are below 500 mV or above 1300 mV.

  • Temperature registered by probe is below 900°F or above 2100°F.

 

Temperature Mode

This allows the operator to choose either degree Fahrenheit or Celsius for the temperature.  The options are °C or °F.  Pressing OK will set the choice.

 

Loop 1 Instrument

 

Internal Loop 1    (typical)    Instrument 5        Instrument 12        Instrument 19

Internal Loop 2        Instrument 6        Instrument 13        Instrument 20

Internal Loop 3        Instrument 7        Instrument 14        Instrument 21

Instrument 1        Instrument 8        Instrument 15        Instrument 22

Instrument 2        Instrument 9        Instrument 16        Instrument 23

Instrument 3        Instrument 10        Instrument 17        Instrument 24

Instrument 4        Instrument 11        Instrument 18        Instrument 25

 

 

Loop 2 Instrument

 

Internal Loop 1        Instrument 5        Instrument 12        Instrument 19

Internal Loop 2    (typical)    Instrument 6        Instrument 13        Instrument 20

Internal Loop 3        Instrument 7        Instrument 14        Instrument 21

Instrument 1        Instrument 8        Instrument 15        Instrument 22

Instrument 2        Instrument 9        Instrument 16        Instrument 23

Instrument 3        Instrument 10        Instrument 17        Instrument 24

Instrument 4        Instrument 11        Instrument 18        Instrument 25

 

Event Instrument

Allows for a client instrument (or internal) to be the defined event control device.  The types of instruments are:  Internal, Instrument 1 – Instrument 25. Internal is typical.

 

Quench  Instrument

Allows for client instrument (or internal) to be the defined quench control device.  The types of instruments are:  Internal Loop 1 – Internal Loop 3, Instrument 1 – Instrument 25.

 

Date and Time

This value is the current date and time on the 9125 controller only (not the local computer or the touch screen, if applicable).  The time on the controller is displayed in the 24-hour format, so 8 = 8 AM, and 14 = 2 PM.  Note: The date and time of the touch screen can be changed (if necessary) by selecting the date and time in the lower right corner on the touch screen, once the screen software has been shut down and the Windows™ desktop is visible.  Then, at the CE screen the date and time can be changed by double taping the time in the bottom right corner and setting it, then select “apply”. For this to take effect the screen needs to be rebooted; on the older TPC 642 displays the registry needs to be saved under TPC Configuration icon, the Misc Tab and then reboot the touch screen. The date and time that is recorded on the flash card (and therefore the datalog data) is the date and time of the Advantech display, not the controller.

 

Cascade Inhibit

Note: This field is only applicable if the controller is in Cascade mode.  This will turn cascade control on or off.  When inhibit = enabled, the 9125 functions as a multi-loop controller with three control loops.  The options are: enabled or disabled.

 

PV Difference Cutback

Note: This field is only applicable if the controller is in Cascade Mode.  This is used with the Cascade Lower Range EOPV and Cascade Upper Range EOPV to limit the absolute % output of the furnace loop.  This will turn the PV difference cutback feature on or off.  The options are: enabled or disabled.

    

Cascade Lower Range EOPV

Note: This field is only applicable if the controller is in Cascade Mode.  This is the cascade lower range end of PV difference.  This is used with the PV Difference Cutback and Cascade Upper Range EOPV to limit the absolute % output of the furnace loop.  Between the lower range EPOV and the upper range EOPV, there is a linear interpolation from 0 to the loop 2 output maximum (usually 100 %) that determines the maximum % output for the furnace loop.  The range is -300 to 10000.

 

Cascade Upper Range EOPV

Note: This field is only applicable if the controller is in Cascade Mode.  This is the cascade upper range end of PV difference.  This is used with the Cascade Lower Range EOPV and PV Difference Cutback to limit the absolute % output of the furnace loop.  Between the lower range EPOV and the upper range EOPV, there is a linear interpolation from 0 to the loop 2 output maximum (usually 100 %) that determines the maximum % output for the furnace loop.  The range is -300 to 10000.

 

Example: With the Lower EOPV set to 10 and the Upper EOPV set to 110, if the load PV is 1700 and the furnace PV is 1710, the full 100% output is available.  If the load PV is 1600 and the furnace PV is 1710, the furnace output will not go above 0%.  If the load PV is 1655 and the furnace PV is 1710, the maximum output for the furnace loop will be limited to 55%: (1710 – 1655)/(110-10) * (1.0).

 

Furnace Name

This will allow the user to give the controller a display name.

 

PV1 Name

This will allow the user to give the first process variable a display name.

 

PV2 Name

This will allow the user to give the second process variable a display name

 

PV3 Name

This will allow the user to give the third process variable a display name

 

client Event Boards

This is the number of clientd boards connected to the 9125. Examples of compatible devices would be a 9015 event module or digital I/O boards connected via an SSi SR box.

 

CO Factor

Displays the current CO Factor. When selected, this setting allows you to set the current CO Factor. The range is 0 - 1000. NOTE: A CO Factor of 200 represents approximately 20.0% CO in the furnace. 

 

COF is the sole adjustable variable that can be used to influence the calculated carbon potential; with other parameters (Probe mV and Temperature) being fixed. As such COF can be increased/decreased to compensate for differences with a furnace, atmosphere composition, etc. The table below shows how changes to COF will result in different calculated carbon potentials. 

 

Note: Default COF is set to 200.

 

 

COF

Prove mV

Probe Temp

Carbon

190

1100 mV

1700°F

0.44

200

1100 mV

1700°F

0.46

210

1100 mV

1700°F

0.48

 

This example assumes a controller atmosphere set point of 0.46%c. By decreasing the COF to 190, the calculated carbon potential is lowered from 0.46- to 0.44%c. As such the furnace's control system will respond by increasing the volume of enrichment gas to return the atmosphere to equilibrium of 0.46%c. Contrary by increasing the COF to 210, the calculated carbon potential is increased from 0.46- to 0.48%c. As such the furnace's control system will respond by increasing the volume of dilution air to return the atmosphere to equilibrium of 0.46%c.

 

 

H Factor

Displays the current H Factor. When selected, this setting allows you to set the current H Factor. The range is 0 - 1000. NOTE: An H Factor of 400 represents approximately 40.0 % H2 in the furnace.