2 BHEL Rapping Controller PDF
2 BHEL Rapping Controller PDF
2 BHEL Rapping Controller PDF
RAPCON - 24
2004.05.20 1:10,30
ALIVE ACTIVE
ERROR 7 8 9 SET
FUNCTION
1 2 `3 4 5 6 7 8 9 10 11 12 MOTOR
RUNNING 4 5 6 STANDBY
ERROR
1
ON
2 3 LOCAL
13 14 15 16 17 18 19 20 21 22 23 24 MOTOR
RUNNING
CLEAR
OFF
0 ENTER
YES
REMOTE
RAPCON-24
3.0 Controls
4.0 Function
5.0 Operation
5.1 Function Selection
5.1.1 Using Password
5.1.2 Setting Rapper Times
5.1.3 Setting Real Time
5.1.4 Starting and stopping a Rapper
5.1.5 Starting and stopping a rapper manually
5.1.6 Setting Program set no.
5.1.7 Checking the Rapper Times
5.1.8 Checking the Real Time
5.1.9 Checking the RAPCON-24 Address
5.1.10 Checking the Program set NO.
5.1.11 Alarm Action
6.0 Standby
APPENDIX-A
APPENDIX-B
1.0 Introduction
RAPCON-24 (Rapper Controller) is a microprocessor-based unit that controls and
surveys the operation of rapping motors in Electrostatic Precipitators. One RAPCON-
24 unit can control up to 24 rapping motors. RAPCON-24 starts and stops the rapping
motors as programmed and will give an alarm if a rapping motor fails.
From RAPCON-24 each rapping motor can be manually started or stopped during
operation, without interfering with other rapping motors. The operation state of each
rapping motor is indicated with light emitting diodes on the RAPCON-24 panel.
Cutout
Width 255mm Panel Protection IP 54
Height 180mm
All RAPCON-24 inputs & outputs are brought to screw type terminal strips via short
(2.5m) Flat Ribbon cables
Inputs :One for each rapping motor: (Opto coupled that acknowledge
Rapping motor ON/OFF status.)
Outputs : One for each rapping motor.(A relay contact. Closure operates the
Contactor of the rapping motor.)
2004.05.20 08:10,30
13
ALIVE ACTIVE
12
01 ERROR 7 8 9 SET
11
FUNCTION
02 1 2 `3 4 5 6 7 8 9 10 11 12 MOTOR
10
03
RUNNING
4 5 6 STANDBY
1 09
ERROR
ON
2 3 LOCAL
13 14 15 16 17 18 19 20 21 22 23 24 MOTOR
RAPCON-24
04 05 06 07
1. ERROR - RED LED that lights if the rapping motor does not start within 3 secs. After start order, or
if the rapping motor stops during operation or rapping motor runs more than 10 mnts. continuously in manual
mode.
2. MOTOR - Rapping motor No. Appropriate number lights when rapping is in programmed running
mode.
3. RUNNING - Green LED that lights when the rapping motor is running.
5. CLEAR(OFF) - Pushbutton for clearing the display e.g. after typing errors, or before entering new values
and for OFF commands
6. Numerical Pushbuttons - for entering times, rapping motor numbers, password etc.,
12. DISPLAY - Alphanumeric display that presents the functions, set value etc., during setting and
control of process times, alarm resets, rappers on and off and password entries.
13. ACTIVE - RED LED indicator to show the unit is controlling the rapping motors
14. ALIVE - RED LED indicator to BLINK to show healthiness of the controller
Page No. 02
4.0 Function
RAPCON-24 controls and monitors the operation of up to 24 rapping motors. RAPCON-
24 has three timers for each rapping motor, so that start time, repetition time run time can
be independently set for each rapper.
The start time is set in actual clock time (hour, minutes). The repetition time is set in
hours and minutes and the run time is set in minutes and seconds.
RAPCON-24 gives a relay contact closure to order a rapping motor start. If the rapping
motor has not acknowledged the start order within 3 secs, an ERROR alarm will be
obtained and the rapping motor will be switched off. This will also occur if the rapping
motor should stop during the set run time.
R R R S
G G G G G G
Page No. 03
5.0 Operation
Page No. 04
SET PROGRAMSET NO? 6. SET PROGRAMSET NO?
There are two methods to reach a function, when you are at “NEXT FUNCTION No.=”.
Method A:
7 DISPLAY TIMES?
Page No. 03
Page No.05
Method B:
SET
NOTE:
To reach a function with
Function no. 1 to 6 the
RAPCON-24 must be in
LOCAL mode.
LOCAL
NOTE:
To reach function no.
2 to 6 also have to
answer the password.
Page No.06
5.1.1 Using Password
This function will only appear if the RAPPER is in LOCAL mode. The Password is
factory set and there is on provision to set a new Password. To know the set Password
refer Appendix-A Password is required to reach the set function of no.2 to 6.
1 PASSWORD?
ENTER
YES
Page No. 07
5.1.2 Setting Rapper Times
Refer the function “Using Password” also.
In this function you set the different times for each motor. During Power ON, all the
times will be set as per the Program Set No.01 as default. Set times will be valid until
you set new times or charge the Program Set No.(Ref. The function SET
PROGRAMSET NO.). The rapper motor will not start to operate according to set time if
the rapper is not selected in AUTO ON.
ENTER
YES
RAPPER NO
RAPPER NO: 2
…. And push the “ENTER (YES)”
pushbutton. The display answers
with START TIME =hh:mm.
ENTER
YES
Page No. 08
Give the new time by
The numerical pushbuttons.
Valid value is 00:00 to
23:59
0
1995.01.15 10:23,45
ENTER
YES
SET DATE: . .
Page No.10
….give new date by the
numerical pushbuttons.
1
7
SET DATE 1995.01.27
Page No.11
5.1.4 Starting and stopping a rapper
Refer the function “Using Password” also. This function allows the operator to set the
required rapping motors in auto sequencing (as per the rapping program set) mode.
During power ON, the motors As per the project configuration will be set ON, as default.
(Refer Appendix-A.)
ENTER
YES
Give the desired rapper number
(1 – 24) on the numerical push-button…… RAPPER NO
2
RAPPER NO 2
….and push the “ENTER (YES)”
Pushbutton. The display now
Replies with ON or OFF.
ENTER
YES
RAPPER NO 2 OFF
Page No.12
To have the SET AUTO ON/OFF SET
Press the “SET FUNCTION” push- FUNCTION
Button until next function appears.
Refer to the function “Using Password” also. In this function you can start a rapper
manually, independent of set times. After start the Rapper will run continuously until it
is shut off and if the Rapper is set to AUTO ON it continues to operate according to ser
time. If manual runtime exceeds 10 minutes an alarm will appear as warning.
RAPPER NO
ENTER
YES
Give the desired rapper number
(1 – 24) on the numerical push-button……
2 RAPPER NO 2
….and push the “ENTER (YES)”
Pushbutton. The display now
Replies with ON or OFF.
ENTER
YES
RAPPER NO 2 OFF
Push the “1(ON)” Pushbutton for
ON.(start) The rapper will now Start
running continuously until you push 1
the CLEAR (OFF) push button for ON
OFF (stop) . Now the rapper is set
to AUTO ON , the rapper continues
to operate according to set times
RAPPER NO 2 ON
Page No.13
Push the “ CLEAR (OFF)” Push-
Button for OFF. The rapper will CLEAR
Not any longer operate according OFF
To set times i,e., the rapper has
been shut off.
RAPPER NO 2 OFF
Refer the function Using Password also The RAPCON is pre- programmed with number
of program sets to operate the RAPCON depending upon the ESP field availability. Any
desired program set among the available program sets can be selected. The existing start
time , repeat time and run time of all the rappers are replaced with the set of new times
as per the selected program set. According the rappers are switched over to new timings
with out any disturbance to the ESP operation, During power ON the PROGRAM SET
No. 01 is loaded as default set number.
6 SET PROGRAMEST NO ?
CLEAR
Push the “CLEAR(OFF)” PUSH- OFF
Button to erase old program set
On. And.give new program set no.,
By pressing the numerical push-
button. Valid value is 1 to X.
(for X ref. Maximum Set Nos., 2
in Appendix-B.) PROGRAMSET NO . = 2
Page No.14
ENTER
YES
Confirm by pushing “ENTER(YES)”
Pushbutton.
7 DISPLAY TMES?
Page No. 15
The display now replies with
REPEAT RIME =hh:mm
ENTER
To continue push the “ENTER
YES
(YES)” pushbutton.
RUN TIME = 01: 00
SET
To leave the DISPLAY TIMES
FUNCTION
Press ”SET FUNCTION” push-
Button until next function appears.
1995.01.15 10:35,15
The display then shows the
Real date and time.
Page No. 16
5.1.9 Checking the RAPCON-24 address
This function does not require any password
9 RAPCON-24 ADDRESS?
Push the “ENTER(YES)” pushbutton ENTER
YES
RAPCON-24 ADDRESS = 1
NOTE:
RAPCON-24 address is required to be set when the RAPCON-24 is communicating
with BHEL’s Integrated Operating System. The RAPCON-24 Address is set using DIP
switch (SWI) provided in the CPU card of the RAPCON-24. The following table shows
the switch position for various addresses.
Address set at factory - 1
PROGRAM SET NO = 1
Page No.18
ENTER
Push the “ENTER(YES)” YES
Pushbutton.
RAPPER NO 2 ALARM
CLEAR
To reset the alarm push OFF
“CLEAR (OFF)” pushbutton.
RAPPER NO 2 ------------
To VIEW
Page No. 19
Press “ENTER(YES)”
to see next motor’s assignment ENTER MOTOR No:2
YES PASS-A CERM-2
(For every ENTER(YES) key
press, next motor label will be
shown)
To SET
2
Press “2” to change ‘RAPPER
TYPE’ information. The built-in MOTOR No:1
rapper types CERM, EERM & EEGD. PASS-A CERM- ( 3 )
“2” key can be pressed repeatedly to
select one of those rapper type labels.
3
Press “3” to change ‘RAPPER MOTOR No:1
No’ information. The built-in PASS-A CERM- 1
motor numbers are 1,2,3,4,5,6,7,
8,9,10,11 & 12. “3” key
can be pressed repeatedly to
select one of those rapper number labels.
Page No.20
After setting all three individual labels,
Press “ENTER (YES)“ to save the change. ENTER
The labels are saved in NVRAM to retain YES
values even during power-off.
6.0 Standby
STANDBY
Push the STANDBY pushbutton
Once more to override the STAND-
BY mode.
Page No.21
7.0 System Messages
Page No. 22
7.2 KEYBOARD TIMEOUT
1995.01.20 10:15,17
7.3
Page No. 23
7.4 INPUT OUT OF RANGE!
Note:
Key 4 is an example only.
Page No.24
8.0 Faultfinding
02 Key board LEDS Faulty CPU card Change the CPU card
Are blinking
Page No.25
9.0 RAPCON-24 General Scheme
1. Serial Communication -Receive
RAPCON-24
APPENDIX - A
P.S.& I/O
DISPLAY CPU CARD
CARD CARD
DATA DIGITAL
RAPPER-24 BUFFER CARD
COMMUNICATION REALY CARD
1 2 3 4 6
5
1. Serial Communication - Receive
4. 24V AC(INPUT)
RAPCON-24 DATA
RAPCON-24 SL.NO :
PROGRAM VERSION:
RAPCON-24 PASSWORD:
Page No. 27
APPENDIX-B
2. Rapping frequency for last field collecting rapping motor : __raps/___ hr.