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OPLC-2100 Operation Manual 

                                                                                                                                                                                  

CONFIDENTIAL

 

 

 

21 Harbor Park Dr. N, Port Washington Phone: 516.656.72211 Fax: 516.626.7201 

One Pipe Local Controller OPLC2100  

1. Introduction

 

The One Pipe Local Controller OPLC-2100 V3.26 (Fig 1) has been designed to provide control of the Steam Zone Valve in 
One Pipe Heating System to regulate the amount of heat (thermal energy) supplied to a building, as well to provide control a  
Steam Boiler. On the Steam Boiler application the OPLC-2100 is equipped an auxiliary

 

board to supply 4 – 20ma interface 

to control the Boiler’s actuator. On this document we will describe the Steam Boiler Control further called as “”. 
OPLC-2100  works  as  a  standalone  controller  or  can  be  connected  to  a  Local  Server,  which  furnishes  the  additional 
parameters adjustments to OPLC-2100 based on apartments real time temperature reading in order to improve the  heating 
supply efficiency and avoid apartment over/under-heating. When the OPLC-2100 is connected to the Local Server it can be 
monitored  and  controlled  from  the  local  Intranet  and/or  Internet  with  appropriate  authentications.  On  all  applications 
automatic  control  of  the  main  parameters  in  accordance  with  operation  settings  and  measured  temperatures/pressure  to 
achieve optimal heating delivery and reduce fuel losses.  

 

 

 

                         Figure 1.   OPLC2100. Front view 

The OPLC-2100 features: 

 

Adjustable Day and Night modes of operation.

 

 

 

Adjustable Winter and Summer modes of operation. 

 

Programmable Heat Up and Cool Down set points. 

 

Morning Boost period up to 120 min. 

 

Provides compensator control for unusual weather conditions 

 

Measures  and displays outdoor and heating system sensors temperature. 

 

Measures  and displays Boiler’s steam pressure. 

 

Sensors malfunction processing and indicating (open/short situation). 

 

Displays the control cycle parameters and valve status. 

 

Adaptable to different types of standard temperature and pressure sensors, and valve motors. 

 

Simple calibration procedure for the temperature and pressure sensors. 

 

Internal real-time clock/calendar with backup battery. 

 

Automatic storage of setup values. No loss of setup values or mode of operation if power is OFF for extended time. 

 

Automatic Daylight Saving Time clock adjustment. 

 

Locally controlled by the four-button keypad and convenient menu. 

 

Password protection for the critical settings. 

 

Remotely controlled and/or monitored through the RS485 interface. 

 

PID controlled analog output 4-20mA or digital potentiometer for flame modulations to maintain the 
required steam pressure during the boiler ON cycle.  

Summary of Contents for OPLC-2100

Page 1: ...ccordance with operation settings and measured temperatures pressure to achieve optimal heating delivery and reduce fuel losses Figure 1 OPLC2100 Front view The OPLC 2100 features Adjustable Day and Night modes of operation Adjustable Winter and Summer modes of operation Programmable Heat Up and Cool Down set points Morning Boost period up to 120 min Provides compensator control for unusual weathe...

Page 2: ...m the ON part of the cycle to the OFF part of the cycle required Post Purge period which includes time for moving Gas Valve from a point where it was during on the ON part to the LFR set point and shat down the boiler After Post Purge Delay the Valve returns to the zero position The PID control is active on the Heat Up state and D N Norm state of the Heating Cycle Fig 3 3 Controls The four button ...

Page 3: ... Boost Span NEW BoostSpn 0 N Stbk 15 F SET BoostAdvance NEW Boost Adv 0 D ICutOff 70 F SET In D CutOff NEW D CutOff 70 N ICutOff 60 F SET In N CutOff NEW N CutOff 60 D_Band 2 5 F SET D_Band NEW D_Band 2 5 F InDoorTemp 90 F SET Day Begin NEW Begin 5 00am Heat Gain 4 0 SET Day End NEW End 10 00pm Comp Snstvty 1 0 SET WntrBegin NEW WrBeg Oct 15 Heat Limit 100 SET WinterEnd NEW WrEnd May 15 MotorType ...

Page 4: ...D_I 0 5 CAL ValveCloseP NEW Cadj 572 SampleRate 12sec SET PID_D NEW PID_D 0 2 PurgeDelay 30sec SET PurgeDelay NEW PurgeD 30sec PsPurgeDly 15sec SET PsPurgeDly NEW PPurgeD 20sec PSen 4ma 15psi SET Pressure Stp New Pres 5 6psi PSen 20ma 15psi SET LowFlame LVL NewFlameLvl 15 Pressure 4 9psi SET SamplingRate NewSampleR 12sec SYS Temp 120 F OD Temp 42 F Com ID 1 Fig 3 Typical track of the Fuel Valve po...

Page 5: ...onal State are permanently displayed in the upper line of the LCD as follows LCD Indicator Mode of Operation Upper line begins with Description Possible Operational States indicate on the right corner of the upper line OFF OFF PPrg Post Purge Auto AUTO hh AUTO max Calculated Target Heat Amount to be delivered hh in the range of 0 100 Summer D Mild N Mild D ICOFF N ICOFF N Stbk D Norm N Norm HeatUp...

Page 6: ... 1 Cyc 0 CL OFF CL 2 Cyc CL 0 ON CL Regular Cycle CL Cycle Length is A B in minutes A Calculated time amount the boiler must be On B CL A C Current minutes boiler is On or D Current minutes boiler is Off 0 heat to be delivered Boiler is OFF more then CL minutes 100 heat to be delivered Boiler is ON more then CL minutes sine shows that the boiler stays on On or Off more time then Cycle length AUTO ...

Page 7: ...ting season M_Set xx Purge aa a ps FR yy y ttsec LFR zz z Same as for the AUTO mode of operation see Purge description above PPrg aa a ps LFR yy y ttsec LFR zz z aa b ps FR 0 0 See PPrg on the OFF operation description Cyc A B ON E or Cyc A B OFF H Regular Cycle Same as for the AUTO mode of operation Manual OFF PPrg aa a ps LFR yy y ttsec LFR zz z aa b ps FR 0 0 see Post Purge description above Ma...

Page 8: ......

Page 9: ...nutes Pressure and Firing Rate 4 2ps FR 17 8 The pressure is represented in psi The Firing Rate FR is percent of the Gas Valve opening Compensator Compensator 1 Indicates the COMPENSATOR setting Time and Date 10 25am Sep10 08 Current time and date The am pm displayed with capital letters when Daylight Saving Time is in effect Outdoor Temperature OD Temp 52 F Temperature at the RTD outdoor sensor f...

Page 10: ... period as defined by the COLD NIGHT and NIGHT SETBACK settings Note If Out Door Temperature has been reached Day Mild or Cold Night Set Point the Boiler will be shut down via special procedure named Post Purge which is will be indicated on the right corner of the upper line of the LCD as PPrg operational state D Mild or N Mild operational state will be displayed for DAY NIGHT mild weather after P...

Page 11: ...Park Dr N Port Washington Phone 516 656 72211 Fax 516 626 7201 11 Fig 4 Heat Request vs Outdoor Temperature curves Mild Weather 55 Compensator 0 Fig 5 Heat Request vs Outdoor Temperature curves Mild Weather 55 Heat Gain 3 0 Compensator Sensitivity 3 0 ...

Page 12: ...s higher than this set point Range 40 to 80 F with 1 step Default value is 55 F N Mild NIGHT MILD WEATHER If the outdoor temperature is lower than this setpoint and the time is between 10PM and 5AM then the heat request value is corrected in accordance with the NIGHT SETBACK setting If the outdoor temperature is higher than this setpoint and the time is between 10PM and 5AM then the heat request i...

Page 13: ...culated ON period if ON bigger than Hit Limit Default value is 100 Motor Type Motorized valve nominal timing in seconds for 90 or 160 stroke Range 15 30 45 60 72 90 144 180 240 seconds Default 30seconds HeatUpStp New cycle will comment when the system temperature on the Cold Pipe Temperature Sensor reaches this set point please see diagram on Figures 5 7 red line Range 40 to 240 F Step 1 F Default...

Page 14: ...react on the High Pressure AUTO MAN SET and MAN ON In the AUTO and MAN SET mode of operations the controller will finish current operational Cycle and will not start the next until PRESSURE 2 PRESSURE_SP 0 2 psi hysteresis In the MAN ON mode the controller will close the fuel valve to 0 If the boiler was turned OFF before changing the operational mode to MAN ON it wouldn t turn the boiler ON until...

Page 15: ...Down key to make desired value then press Enter Set Pressure Sensor Value for maximum current 20ma 1 From Calibration Menu Select SetPSensor 20ma and press Enter 2 The upper line of the display indicates mode of operation CAL 3 The lower line of the display shows possible adjustment for example NewPSns 4ma 15psi 4 Press Up or Down key to make desired value then press Enter Pressure Sensor Calibrat...

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