NUC-Magnum Controller

Quality - Integrity - Reliability

NUC-Magnum Chiller Digital Control System

The MCS NUC-Magnum Controller is a microprocessor based system specifically designed to provide primary control of chillers. The controller provides alarms, protective trips and control set points that are selected and configured prior to commissioning a system. Displays, alarms, lockouts (protective trips) and status information are continuously displayed on a Keypad/Display panel. The NUC-Magnum Controller is designed to be configurable without requiring base system software changes.

Basic NUC-Magnum Digital Control System

The NUC-Magnum controller consists of the following main components installed in a NEMA 4 enclosure:

  • NUC-Magnum Board (Master)
  • NUC-SI16 AO4 Input/Output (I/O) Expansion Board (Slave)
  • Display – 128x64 Pixels Monochrome LCD Display with 9 Button Membrane Keypad
  • NUC-Magtouch Color LCD Display (Optional)

NUC-Magnum Controller Hardware

Note: For illustrative purposes only. Actual installed enclosure may differ.

The NUC-Magnum and NUC-SI16 AO4 boards are mounted on the internal backplane of the enclosure. The Keypad/Display, NUC-Magtouch Color LCD, Chiller RUN/STOP Switch and WARNING and ALARM lights are mounted on an internal swing panel. The enclosure door has provisions for a lock as a cyber-security enhancement option. The enclosure door incorporates an integrated clear acrylic window so the Keypad/Display and WARNING and ALARM lights are viewable without opening the enclosure as well as the position of the Color LCD key-lock and RUN/STOP switches. The NEMA 4 enclosure acrylic window, NUC-Magtouch Color LCD and the Keypad/Display also incorporates a metallic screen mesh for enhanced EMI/RFI shielding.

NUC-Magnum Board

The NUC-Magnum board provides overall control functions for chiller operation. It processes input signals from sensors, I/O expansion boards and the keypad and provides information to the NUC-Magtouch and monochrome displays. The NUC-Magnum board also provides output signals to other chiller control devices and supports the following inputs and outputs:

  • Ten (10) Relay Outputs (6.3amps @ 120/230 VAC)
  • Twelve (12) Sensor Inputs (0-5vdc)
  • Four (4) Analog Outputs (0-10vdc)
  • Four (4) Digital inputs

NUC-Magnum Board

NUC-SI16 AO4 Board

The NUC-SI16 AO4 board is an I/O expansion board and functions in a slave configuration to the NUC-Magnum board. It provides an additional sixteen (16) analog sensor inputs and four (4) analog outputs. The NUC-SI16 AO4 board utilizes a 16-Bit Microchip PIC24HJ64GP206 microprocessor and that contains a small amount of software code to control on-board signal processing (A/D and D/A conversion). The microprocessor also incorporates a separate, discrete on-board hardware WDT. The major modules of the board are:

  • One 16-Bit Microchip PIC24HJ64GP206 microprocessor
  • Sixteen (16) Sensor Inputs (0-5 VDC)
  • Four (4) Digital Outputs (0-10 VDC)
  • One (1) 16-channel A/D converter
  • Four (4) D/A converters
  • One MCS I/O Communication Port (38,400 baud)
  • One Control Power Transformer

NUC-SI16 AO4 Board

NUC-KEYPAD Assembly (Keypad/Display)

The NUC-KEYPAD assembly consists of two major sub components and is referred to as the Keypad/Display:

  • Keypad
  • Monochrome LCD

The Keypad/Display is considered the safety related system display. The Keypad/Display is utilized to monitor chiller operating conditions and display system status messages, alarms and trending.

The Keypad/Display is the primary HMI for the NUC-Magnum control system. The Keypad/Display is also utilized as part of the cyber-security design of the system. The display is a 128 x 64 dot pixel STN monochrome graphics LCD with a 2.8-inch diagonal viewing area. The keypad and display are mounted onto a common backplane and is normally mounted within the NUC-Magnum system enclosure.

NUC-KEYPAD Assembly

 

Sensors

The NUC-Magnum controller utilizes various temperature, pressure, flow and current sensors to implement effective chiller control. Sensors may be analog or digital and may be supplied by MCS, the chiller manufacturer, PMT or the customer. Sensors are connected to the NUC-Magnum and NUC-SI16 AO4 boards with a 2/C or 3/C shielded-twisted pair, IEEE-383, Class 1E qualified cable.

Qualification and Dedication of the NUC-Magnum Chiller Digital Control System

The NUC-Magnum digital control system hardware has been qualified and dedicated for nuclear safety related applications per the following:

  • IEEE 323-1974/1983, “Qualifying Class 1E Equipment for Nuclear Power Generating Stations”
  • IEEE 344-1975/1987, “Recommended Practice for Seismic Qualification of Class 1E Equipment for Nuclear Power Generating Stations”
  • IEEE 7-4.3.2, 2003, “Criteria for Digital Computers in Safety Systems of Nuclear Generating Stations”
  • EPRI TR-102323, Rev. 2/3, “Guidelines for Electromagnetic Interference Testing of Power Plant Equipment” (USNRC RG 1.180)
  • EPRI TR-106439, “Evaluation and Acceptance of CG Digital Equipment for Nuclear SR Applications, 1996”

Verification and Validation of the NUC-Magnum Chiller Digital Control System

The NUC-Magnum digital control system software has been verified and validated for nuclear safety related applications per the following:

  • IEEE 7-4.3.2, 2003, “Criteria for Digital Computers in Safety Systems of Nuclear Generating Stations”
  • IEEE 1012, 1998, “Software Verification and Validation”
  • IEEE 730, 2002, “Software Quality Assurance Plans”
  • IEEE 830, 1993, “Software Requirements Specifications”
  • IEEE 1028, 1997, “Software Reviews”
  • USNRC Reg. Guide 1.152, Rev. 2, “Criteria for Use of Computers in Safety Systems of Nuclear Power Plants”
  • USNRC RG 1.168, Rev 1 – Verification, Validation, Reviews, and Audits for Digital Computer Software used in Safety Systems of Nuclear Power Plants – Feb 2004
  • EPRI TR-103291-CD, Handbook for Verification and Validation of Digital Systems, Final Report, December 1998
  • EPRI TR-106439, Evaluation and Acceptance of CG Digital Equipment for Nuclear SR Applications, 1996

The following documents provide objective evidence of the NUC-Magnum digital control system software V&V program and are available for customer submittal and review:

  • Software V&V Plan (SVVP)
  • Software Quality Assurance Plan (SQAP)
  • Software Requirements Spec (SRS)
  • Software Design Document (SDD)
  • Software V&V Report (SVVR)
  • Failure Modes & Effects Analysis (FMEA)
  • Hazards Analysis (HA)
  • Software Code Review Records
  • Software Validation Test Cases and Results
  • Software Bug List
  • Critical Digital Review (CDR)

 

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