CB-HAWK ICS Integrated Boiler Control System

Section D
CONTROLS
TABLE OF CONTENTS
HAWK ICS LEVEL COMPARISON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
CB-HAWK ICS BOILER MANAGEMENT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS - PARALLEL POSITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-5
D-7
D-7
D-8
D-12
CB-HAWK ICS COMBUSTION AIR FAN VARIABLE SPEED DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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D-15
D-15
D-16
D-17
CB-HAWK ICS OXYGEN MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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D-18
D-19
D-19
D-19
CB-HAWK ICS — ETHERNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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D-21
D-21
D-21
D-22
CB-HAWK ICS — PAGING and REMOTE DIAL-UP ACCESS with MODEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-23
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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D-23
D-23
D-23
D-23
CB-HAWK ICS — LEAD/LAG FOR TWO BOILER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-24
D-24
D-25
D-25
CB-HAWK ICS — LEAD/LAG for up to EIGHT BOILERS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-26
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPLICATION AND SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-26
D-27
D-27
D-28
D-1
09-09
Section D
CB780E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29
FEATURES AND BENEFITS . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATION . . . . . . . . . . . . .
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.D-29
.D-30
.D-30
.D-31
CB120-120E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
FEATURES AND BENEFITS . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATION . . . . . . . . . . . . .
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.D-32
.D-33
.D-33
.D-33
CB100E CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34
FEATURES AND BENEFITS . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATION . . . . . . . . . . . . .
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.D-34
.D-35
.D-35
.D-35
CB110 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-36
FEATURES AND BENEFITS . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATION . . . . . . . . . . . . .
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.D-36
.D-36
.D-37
.D-37
LEAD/LAG SYSTEMS (TWO BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-38
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-38
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-38
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-39
LEAD/LAG SYSTEMS (TWO THROUGH FOUR BOILER LEAD/LAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-41
FEATURES AND BENEFITS . . . . . . . . . . . .
PRODUCT OFFERING . . . . . . . . . . . . . . . .
ENGINEERING DATA . . . . . . . . . . . . . . . .
SAMPLE SPECIFICATIONS . . . . . . . . . . . .
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LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-44
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-44
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-44
MINIMUM TEMPERATURE — LOW FIRE HOLD CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-45
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-45
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-46
ASSURED LOW FIRE CUTOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-47
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-47
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-47
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-47
REMOTE MODULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-48
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-48
SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-48
D-2
09-09
Section D
AUTOMATIC FUEL CHANGEOVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
SAMPLE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
AccuTrim O2 TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-50
FEATURES AND BENEFITS . .
PRODUCT OFFERING . . . . . .
ENGINEERING DATA . . . . . .
SAMPLE SPECIFICATIONS . .
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D-50
D-51
D-51
D-52
CB-HAWK ICS ADAC ADVANCED DEAERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-55
FEATURES AND BENEFITS . .
PRODUCT OFFERING . . . . . .
ENGINEERING DATA . . . . . .
SAMPLE SPECIFICATIONS . .
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D-55
D-56
D-57
D-57
LCS-150E LEVEL CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-63
FEATURES AND BENEFITS . .
PRODUCT OFFERING . . . . . .
ENGINEERING DATA . . . . . .
SAMPLE SPECIFICATIONS . .
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D-63
D-63
D-63
D-64
CB-HAWK Compact ICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-65
FEATURES AND BENEFITS . .
PRODUCT OFFERING . . . . . .
ENGINEERING DATA . . . . . .
SAMPLE SPECIFICATIONS . .
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D-65
D-66
D-66
D-66
CB SysteMAX HYDRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-69
FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-69
ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-71
SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-72
D-3
09-09
Section D
HAWK ICS LEVEL COMPARISON
Table D-1. Hawk ICS Level Comparison
Feature
Processor
5.5" Monochrome Screen
6" Color Screen
10" Color Screen
Honeywell CB780E
Fireye CB120E
O2 Monitoring
O2 Trim & Programming
O2 Hardware
Variable Speed Drive Programming
Variable Speed Drive Hardware
Parallel Positioning Programming
Parallel Positioning Hardware
Additional 4 User Analog Inputs (Base 2 IN's Only)
Expanded Annunciation/3 User DI
Combustion Air/Ambient Temperature Monitoring
2 Boiler Lead/Lag Programming
2 Boiler Lead/Lag Hardware
Dual Set Points
Stack Temp with High Cutoff Set Point
Thermal Shock Protection
Assumed Boiler Efficiency Reading
Corrected Boiler Efficiency Reading
Hot Stand By
Ethernet Communications
E-Mail and Paging (text messaging only) via Internet
Paging Via Phone Line (Requires modem)
Lan/Wan Interfacing
Building Automation Interface
Remote Monitoring Software (Rs-View)
Level Master Interface (Level and Alarm Only)
Master Panel Lead/Lag 3-8 Boilers
Remote Modulation or Set Point Input (See Note 1)
Remote Stop/Start (See Note 1)
PLC Based Combustion Control
Alternate Fuel Capabilities
Flash Card Reader - Touch Screen
Flash Card Reader - Processor
Draft Control - Integrated in PLC
Alarm Bell
Alarm Silencer Button Via Touch Screen
Base L32B
L32E
Standard
N/A
N/A
Standard
Optional
External
External
N/A
N/A
N/A
N/A
N/A
Optional
Optional
N/A
Included
Optional
Included
Included
Included
Included
N/A
Included
Included
Optional
Optional
Optional
Optional
Optional
N/A
Optional
Included
Included
Included
Included
Included
Included
External
Included
Included
N/A = Not Available
Note 1: Not avaialble when either 2 boiler Lead/Lag or
Master Panel options are selected
D-4
09-09
Intermediate L32I
L32E
N/A
Standard
Optional
Standard
Optional
Optional
External
Optional
Included
Optional
External
Optional
Optional
Optional
Optional
Included
Optional
Included
Included
Included
Included
With O2 Option
Included
Included
Optional
Optional
Optional
Optional
Optional
Included
Optional
Included
Included
Included
Included
Included
Included
External
Included
Included
Advanced L35E
L35E
N/A
N/A
Standard
Standard
Optional
Optional
Integrated
Optional
Included
Optional
Integrated
Optional
Included
Included
Optional
Included
Optional
Included
Included
Included
Included
With O2 Option
Included
Included
Optional
Optional
Optional
Optional
Optional
Included
Optional
Included
Included
Included
Included
Included
Included
Included
Included
Included
Section D
CB-HAWK ICS Integrated Boiler Control System
The CB-HAWK ICS is a state-of-the-art boiler control system that integrates the
functions of a Programmable Controller and Burner Management Controller, as well
as other boiler operating and ancillary controls. The CB-HAWK ICS system
incorporates a graphical Human Machine Interface (HMI), which displays boiler
parameters, fault annunciation and alarm history, as well as providing access to
boiler configuration and control functions. The CB-HAWK ICS system includes
complete boiler firing rate controls for steam or hot water boilers. The CB-HAWK
ICS’s advanced technology features utilize the latest communication methods, such
as Modbus, Ethernet, and the Internet. The CB-HAWK ICS also has the capability of
interfacing with various building/plant automation systems. Additional features
include lead/lag capability; e-mailing and paging of alarms, remote monitoring, and
HMI alarm history printing.
The CB-HAWK ICS Integrated Control System may be used on most types of steam
or hot water boilers, including firetube, industrial watertube, and commercial
watertube. It is designed to operate with a gas, oil, or combination burner using a
single-point modulating control or a parallel-positioning fuel-air ratio control system.
In addition to installation on new boilers, the CB-HAWK ICS can be added as a
retrofit to existing boilers. Contact your local authorized Cleaver-Brooks
representative for details.
The CB-HAWK ICS system is offered in Advanced, Intermediate, and Base
packages. Table D-1 shows a feature comparison.
FEATURES AND BENEFITS
Advanced Technology
Standard Features:
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Integrates control function of burner sequencing and safety with firing rate, fuelair ratio, and operating limit controls
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Incorporates a programmable controller
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Touch screen graphical human machine interface (HMI)
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Monitors and displays connected boiler parameters
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Optimizes boiler firing rate control
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Alarm/fault indication and history
•
On-screen fault diagnostics
•
Built-in two boiler lead/lag control
•
Night/day setback control
•
Thermal shock protection
•
Remote modulation
•
Remote setpoint
•
Assured low fire cut-off
•
Assured start permissive safety interlocking
•
High stack temperature alarm and shutdown
•
Boiler efficiency calculations
D-5
09-09
Section D
Optional Features:
•
E-Mail and pager alarm/fault forwarding
•
Fuel-air ratio control
•
Display of boiler water level with optional CB Level Master (Advanced and
Intermediate systems only)
•
Building/plant automation system interface
•
Remote monitoring and diagnostics
•
O2 monitoring and trim
•
Internet parts and service lookup
•
Lead/lag capability for multiple boiler systems
•
Variable speed drive on combustion air fan
•
Expanded annunciation
Safety Provisions and Diagnostics:
A. Integrated Burner Management
•
Utilizes the CB780E or CB120E flame safety control
•
Communicates with the programmable controller via Modbus
•
Burner Control status, faults, and diagnostics displayed on HMI
B. Integrated Boiler Controls
•
Operating and modulating controls
•
Variable speed drive fault shutdown – communicates via Modbus (optional)
•
Password protection of programmable controller logic
•
Password protection of parallel positioning control (optional)
Powerful Display/Diagnostic Capabilities:
•
Touch screen graphical human machine interface (HMI).
Advanced system: 10” color touch screen
Intermediate system: 6” color touch screen standard - 10” color screen optional
Base system: 5.5” monochrome touch screen
•
HMI allows easy screen navigation to monitor various boiler parameters &
diagnostics and to configure boiler controls.
•
Displays alarms/faults, burner status, and flame signal from the flame safety
control.
•
Diagnostics in plain English and prioritized fault annunciation simplify
troubleshooting. Last 100 faults are stored.
•
Displays boiler steam pressure, water temperature, firing rate, Stack
temperature, boiler efficiency, combustion air temperature (optional), Flue
gas O2 concentration (optional), combustion air fan motor speed and kw
(vsd option), combustion air pressure (with VSD option), water level (CBLevel Master option), shell water temperature (steam boilers), and other
control points.
•
Displays boiler operating status (e.g. “Warm Up”, “Auto/Manual”, “Boiler
On”, fuel selection, etc.).
•
Displays boiler firing rate control parameters
D-6
09-09
Section D
and settings.
•
Provides remote monitoring and diagnostic capabilities (optional).
•
Touch screen controls simplify screen navigation and boiler configuration
•
Reliable and accurate controls using microprocessor-based programming
Simplified Servicing:
•
Diagnostics and fault history, up to 100 faults, through touch screen display
simplifies troubleshooting procedures
•
E-Mail forwarding and paging of system fault codes (optional)
•
Connection to user building automation system (optional)
PRODUCT OFFERING
Included in each CB-HAWK ICS system is the following:
•
Programmable controller
•
Touch screen HMI
•
Modbus communication interface to burner management or optional
Variable Speed Drive
•
Built-in Ethernet/IP capability via L35E (Advanced system) or L32E
(Intermediate and Base) processors
•
Various controller input/output modules
•
Flame safety controller (CB780E or CB120E)
•
Various temperature and pressure sensors
•
E-mailing via Ethernet
Optional Features and Equipment: (see individual specifications for these options)
•
OPC server software for interface with building/plant automation system
•
Lead/Lag control of multiple boilers
•
Fuel-Air Ratio Control system and actuators
•
Variable speed drive for combustion air fan motor
•
O2 analyzer and/or external O2 trim system
•
Combustion air temperature sensor
•
Economizer stack flue gas temperature, feed water temperature, oil
temperature, and gas & oil pressure sensors
•
Steam, water, and fuel flow monitoring
•
CB Level Master primary safety water level control
•
Paging via phone line with modem
ENGINEERING DATA
•
Supply voltage: 120 VAC (+10%/-15%) 50 or 60 Hz.
•
Maximum total connected load: 1200 VA
•
Operating temperature limits: 32 to 130°F
D-7
09-09
Section D
•
85% RH continuous, non-condensing, humidity
•
0.5G continuous vibration
Sample Specifications
CB-HAWK ICS Integrated Boiler Control System
PART 1 GENERAL
1.1
GENERAL
A. Each unit shall be factory equipped with a boiler control system
providing technology and functions equal to the CB-Hawk ICS boiler
control system.
B. Each Boiler Control System shall be factory equipped with a preconfigured Programmable Controller and Human Machine Interface
(HMI).
PART 2 PRODUCTS
2.1
MAJOR SYSTEM COMPONENTS
A. Major system components shall include:
1. Programmable controller
2. Touch screen HMI
3. Modbus communication interface to burner management or
optional Variable Speed Drive
4. Various controller input/output modules
5. One burner management controller and wiring sub-base
6. One flame scanner: Infrared, Ultra-Violet, or UV Self-Check
7. One flame amplifier, to correspond with the selected flame
scanner
8. Various temperature and pressure sensors
B. Major functions that the Boiler Control System shall provide:
1. Automatic sequencing of the boiler through standby,
pre-purge, pilot flame establishing period, main flame
establishing period, run and post purge
2. Flame proving and lockout on flame failure during pilot flame
proving, main flame proving, or run
3. Low fire damper/valve position for flame ignition trials
4. Full modulating control of fuel and combustion air
5. Utilize solid state controls and sensors to provide various
control functions, such as:
a. On/Off, and Modulating control
b. Modulating control algorithm shall be ProportionalIntegral-Derivative (PID) type
c. Thermal shock protection based on water temperature
and setpoint
d. Various high and low limit alarms and shutdowns
6. Touch screen graphical operator interface and monitoring
a. Manual control of the boiler-firing rate utilizing control
screens on the HMI to increment and decrement the firing
rate
D-8
09-09
Section D
b.
C.
On screen indication of burner management controller
status and diagnostics
c. On screen real-time display of all connected process
parameters
d. On screen display of system alarms and faults
e. On screen history of alarms and faults
f.
On screen water level indication (optional) and alarm(s)
g. Printing Alarm/Fault history
7. E-mail or paging of boiler alarms (with either Ethernet/IP or
modem option)
8. Building/plant automation system interface (with Ethernet/IP
option)
9. Ethernet communications (with Ethernet/IP option)
10. Tamper resistant control logic and password protection.
11. Night/day setback control
12. Stack flue gas, combustion air (optional), and shell (water)
temperatures
13. Boiler efficiency calculation (corrected efficiency with O2
option - Advanced and Intermediate systems)
14. Outdoor reset for hot water boilers
15. Remote modulation or firing rate setpoint control
16. Assured low fire cut-off (ALFCO)
17. Assured start permissive safety interlocking
The Boiler Control System shall provide the following safety
provisions for:
1. Integrated burner management
a. Examine all load terminals to assure it is capable of
recognizing the true status of the external controls, limits
and interlocks. If any input fails this test, the burner
management system should lockout on safety shutdown.
b. Closed-loop logic test verifies integrity of safety critical
loads (ignition, pilot, and main fuel valves) and must be
able to lockout on safety.
c. Pre-ignition interlocks (fuel valve proof of closure, etc.)
and flame signal checked during Standby and Pre-Purge.
d. Dynamic checking of the flame signal amplifier. The
control flame signal amplifier must be able to recognize a
no flame signal during this dynamic amplifier check.
e. Safe start check and expand check to include monitoring
flame signal during standby.
f.
High and Low fire switches checked for proper
sequencing.
g. Tamper-proof purge timing and safety logic.
2. Integrated boiler controls
a. Operating and Modulating control
b. Variable Speed Drive (if used) fault shutdown
D-9
09-09
Section D
c.
d.
D.
E.
F.
G.
Password protection of programmable controller Logic
Password protection of parallel positioning control (if
used)
The Boiler Control System shall provide annunciation and
diagnostics:
1. Active alarm annunciation
2. Provide historical alarm information for on screen display
3. Detects and isolates an alarm, and reports internal circuit
faults
4. Printer output capable for logging alarms
5. Capability of printing alarm history of date, time, cycle of
occurrence and date and time of acknowledgement up to the
most recent 100 faults
6. English text description of the system fault and troubleshooting
procedures
7. Water level indication and low water shutdown alarm
8. Dynamic self-checking
The Boiler Control System shall be able to operate in these
environmental conditions.
1. Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz
2. Maximum total connected load: 1200 VA
3. Operating temperature limits: 32 to 130°F
4. 85% RH continuous, non-condensing, humidity
5. 0.5G continuous vibration
All Boiler Control System wiring shall be in accordance with the
National Electrical Codes and local electrical codes.
Boiler Control System component functions shall be as follows:
1. Burner Management Controller: Provides burner sequencing
logic to meet FM/IRI/UL/cUL approval body requirements.
2. Touch Screen Graphical Interface: Provides user interface to
the control system, boiler overview screen with connected
boiler parameter readouts, burner management control status
screen, alarm banners, diagnostic screens for fault
troubleshooting, alarm history screen, system firing rate screen
and system configuration screens.
3. Modbus communication network: provides communication
between the programmable controller and burner management
system (and optional Variable Speed Drive).
4. Various programmable controller input/output modules:
Provides interface for discrete powered and/or isolated relay
signals, as well as for analog signals, from and/or to other
input/output devices.
D-10
09-09
Section D
5.
H.
Stack temperature sensor: measures and transmits a signal to
the programmable controller in relation to boiler exit flue gas
temperature. It is used for indication and in the calculation of
boiler efficiency; it can also be used for high stack temperature
alarm and shutdown.
6. Steam pressure transmitter (steam boiler): provides an analog
signal to the programmable controller for indication of boiler
steam pressure; utilized for on/off and modulating control of the
burner.
7. Water temperature transmitter (hot water boilers): provides an
analog signal to the programmable controller for indication of
boiler water temperature; utilized for thermal shock protection,
on/off, and modulating control of the burner.
8. Water (shell) temperature sensor (steam boilers): measures and
transmits a signal to the programmable controller in relation to
boiler water temperature; used for indication and thermal
shock protection.
Optional equipment/features (see also individual Boiler Book
sections below)
1. Lead/Lag Control for multiple boiler systems
2. Parallel Positioning hardware (Advanced and Intermediate
systems)
3. Variable Speed Drive for combustion air fan motor (Advanced
and Intermediate systems)
4. O2 analyzer and/or external O2 trim system
5. Combustion air temperature sensor (Advanced and
Intermediate systems): measures and transmits a signal to the
programmable controller in relation to the combustion inlet
temperature for indication and for use in the calculation of
boiler efficiency; also can be used for high combustion air
temperature alarm and shutdown, based on setpoint
6. Economizer flue gas inlet and outlet temperatures, feed water
temperature, economizer water in and out temperature (no
thermocouple inputs with Base system)
7. Steam, water & fuel flow monitoring
8. CB Level Master primary safety water level control
9. Email and paging (text messaging) via Ethernet
10. Paging via phone line (requires modem)
11. Building automation interface
12. Remote monitoring with RSView software
D-11
09-09
Section D
Sample Specifications
HAWK ICS Parallel Positioning System
PART 1 GENERAL
The purpose of the parallel positioning system is to control fuel, combustion air and
flue gas recirculation (FGR) if applicable. Individual actuators will be used to control
each of above functions.
PART 2 PRODUCTS
CONTROLLER - A/B COMPACT LOGIX PLC COMPRISING THE
FOLLOWING COMPONENTS
2.1
Row 1
Processor L35E
SM2 Modbus Module
Power Supply 1769-PA4
Discrete Input Module 1769-IA16
Discrete Output Module 1769-OW8I
Analog Input Module 1769-IF4
Analog Output Module 1769-OF2
Themocouple input module 1769-IT6
Discrete Input Module 1769-IA16
Analog Input Module 1769-IF4
Analog Output Module1769-OF2
Row 2
Power Supply 1769-PA2
Analog Output Module 1769-OA16
Analog Input Module 1769-IF4
Analog Input Module 1769-IF4
Expansion cable
Right hand terminator
2.2
HMI (HUMAN MACHINE INTERFACE)
10” color PanelView touch screen with serial communication.
2.3
ACTUATORS
Quantity up to 4.
Typical actuators arrangement:
Combustion air
Gas
Oil
FGR
D-12
09-09
Section D
ACTUATOR SPECIFICATIONS
General: Reversing Motor with Position Feedback
Application: Control of Dampers and Fuel Valves
Note- Position will be controlled by a PLC; no Servo-Positioning Module is required.
Rotary: 90 Degree Rotation
30 Second Timing (for 90 Degrees)
36 in-lb Torque
0.1% Resolution (over 90 Degrees)
Electrical:
120 VAC Preferred
Control Signal: Pulse position with 0-10 VDC feedback
Duty: Continuous
Enclosure: NEMA 1 Minimum; NEMA 3 or 4 Optional
Approvals:
UL Listed or Recognized and/or FM Approved
Environmental: Temperature 0-130°F.
Whenever possible design without linkages shall be used.
Control Description
Control shall be parallel positioning with cross limiting.
Note: System will not be capable for simultaneous fuel firing.
Air control
Firing rate control signal is compared with corrected fuel actuator position signal.
Highest of the two values is a control signal for the combustion air actuator. Velocity
limitter with adjustments in both directions (up and down) shall be provided.
Control signal to the actuator is compared with feedback signal. If unacceptable
error is detected for the preset amount of time, system will be shut down and fault
will be annunciated.
Fuel control
Firing rate control signal is compared with air actuator position signal. Lowest of the
two values is an input to the function generator. Output of the function generator is a
control signal for the fuel actuator. Function generator has to have a minimum of 10
break points. The X-axis and Y-axis parameters must follow the relationship:
X[1] < X[2] < X[3] <... < X[n]
Y[1] < Y[2] < Y[3] < … < Y[n]
Where n is the number of break points (20 maximum).
Velocity limiter with adjustments in both directions (up and down) shall be
provided.
D-13
09-09
Section D
Control signal to the actuator is compared with feedback signal. If unacceptable
error is detected for the preset amount of time, system will be shut down and fault
will be annunciated.
FGR control
Firing rate control signal is compared with air actuator position signal. Lowest of the
two values is an input to the function generator. Output of the function generator is
a control signal for the FGR actuator. Function generator has to have a minimum of
10 break points. The X-axis parameters must follow the relationship:
X[1] < X[2] < X[3] <... < X[n]
Where n is the number of break points (20 maximum).
Velocity limitter with adjustments in both directions (up and down) shall be
provided.
Control signal to the actuator is compared with feedback signal. If unacceptable
error is detected for the preset amount of time, system will be shut down and fault
will be annunciated.
D-14
09-09
Section D
CB-HAWK ICS COMBUSTION AIR FAN
VARIABLE SPEED DRIVE
Provides variable speed output to the burner’s Combustion Air Fan blower motor for
the purpose of improving boiler efficiency and reducing electrical energy
consumption.
FEATURES AND BENEFITS
Improved Efficiency:
Energy Savings:
•
Reduces electrical energy consumption
•
Soft starting reduces electrical and mechanical stress on the motor,
extending the life of the motor
•
Provides Substantial Savings from Mid to Low Fire modulation points
•
Average Payback in approximately 6 – 8 Months
Communication:
•
Communicates with the Boiler Controller via Modbus
•
Provides Drive process information on the Boiler Control Panel Display
•
Provides Drive faults and troubleshooting suggestions, in “Plain English”, on
Boiler Control Panel Display
•
Cleaver-Brooks shall supply the following equipment:
•
Adjustable Frequency Variable Speed Drive.
•
Modbus communications
•
VSD Compatible Combustion Air Fan Motor.
PRODUCT OFFERING
D-15
09-09
Section D
ENGINEERING DATA
Drive:
•
Ambient Operating Temperatures: 32 – 122°F
•
Altitude: 3300 Ft (1000 m) Max without derating
•
Shock: 15G peak for 11ms duration (±1.0 ms)
•
Vibration: 0.152 mm (0.0006 in.) displacement, 1G peak
•
Voltage Tolerance: -10% of minimum, +10% of Maximum
•
Frequency Tolerance: 47 – 63 Hz
•
Input Phases: Three-phase input provides full rating of all drives, Singlephase operation provides 50% of rated current
•
Frequency Accuracy: Digital Input – Within ±0.01% of set output
frequency, Analog Input – Within ±0.4% of maximum output frequency
•
Intermittent Overload: 110% Overload capability for up to
1 minute, 150% Overload capability for up to 3 seconds
•
Current Limit Capability: Proactive Current Limit programmable from 20 to
160% of rated output current; Independently programmable proportional
and integral gain
•
Line Transients: Up to 6000 volts peak per IEEE
C62.41-1991
•
Ground Fault Trip: Phase-to-ground on drive output
•
Short Circuit Trip: Phase-to-phase on drive output
•
Drive Overcurrent Trip: Software – 20 to 160% of rated current, Hardware –
200% of rated current (typical), Instantaneous – 220 to 300% of rated
current (dependent on drive rating)
•
Electronic Motor Overload Protection: Class 10 protection with speed
sensitive response. Investigated by U.L. to comply with N.E.C. Article 430,
UL File E59272 Volume 12
•
See Drive Manual for other, Model and Voltage Specific, specifications.
Motor:
•
Motor suitable for variable speed drive service
•
Variable Torque, 3 phase
•
Other specifications based on Specific Horsepower, Voltage, and Frequency
requirements. Contact your local Authorized Cleaver-Brooks Representative
for further details.
D-16
09-09
Section D
Sample Specifications
CB-HAWK ICS Combustion Air Fan Variable
Speed Drive
PART 1 GENERAL
A.
B.
C.
D.
E.
The Boiler Manufacturer shall provide a Variable Speed Drive
controller for use on the burner’s Combustion Air Fan blower motor
for the purpose of providing Improved Boiler Efficiency and Reduced
Electrical Energy consumption.
The Drive’s voltage, frequency, and current ratings shall be rated in
accordance with the electrical requirements as dictated by job site
specifics, and for the properly rated motor horsepower.
The Variable Speed Drive must be capable of communicating over
the Modbus protocol.
A Motor suitable for variable speed drive service must be supplied
for use in conjunction with the Variable Speed Drive, and sized to
match the motor requirements of the Combustion Air Fan Blower.
Variable Speed Drive shall be interlocked with boiler control to
ensure safe operation.
D-17
09-09
Section D
CB-HAWK ICS OXYGEN MONITORING SYSTEM
The CB-HAWK ICS Oxygen Monitoring System provides indication and monitoring
of the boiler’s exit flue gas O2 concentration. In conjunction with Stack Flue Gas
and Combustion Air Temperature measurements, the system also provides means
for a more accurate boiler efficiency calculation.
If O2 Trim is desired see page D-50 of the CB Boiler Book.
FEATURES AND BENEFITS
Integrated Type In-Situ Zirconia Oxygen Analyzer:
•
Reduces wiring, piping and installation costs
•
Allows replacement of the zirconia cell on site
•
Built-in heater assembly of the probe can be replaced on site
•
Can be configured on site without opening the cover using an infrared
sensor
•
O2 measurement circuitry built into probe head electronics
•
O2 Level percentages displayed on the Boiler Control Panel Human Machine
Interface (HMI)
•
Provides accurate Boiler Efficiency Calculations with the CB-HAWK ICS
Programmable Controller
•
Separate analyzer/converter display panel not required
User Configurable Alarm Points
•
Low O2 Alarm
Analyzer Probe is Direct Insertion, In-situ Zirconia Type Which Provides:
•
High accuracy
•
Fast Response
•
Proven Reliability
D-18
09-09
Section D
PRODUCT OFFERING
•
In-Situ Zirconia Probe and Analyzer
•
Process Variable% O2 Readout on Control Panel HMI
•
Accurate Efficiency Calculations
Options:
•
Separate O2 Converter/Display Panel
•
Replacement Zirconia Cell
•
Auto Calibration Pneumatics
•
Replacement Heater Assembly
•
Remote Indicator/Alarm
•
Probe Stack Mounting Adapter
•
Calibration Gas Kit
ENGINEERING DATA
Ambient Temperature: -4 to 131°F (-20 to +55°C)
Sample Gas Temperature: 32 to 1292°F (0 – 700°C)
Sample Gas Pressure: -1.5 to 73.8 in Hg (-5 to +250 kPa)
Output Signal: 4 – 20mA DC, One Point, Maximum Load Resistance 550 Ohms
Digital Output (HART): 250 – 500 Ohms
Contact Output Signal: Two Points, 30 VDC 3A, 250 VAC 3A (one is fail safe
normally open)
Contact Input Signal: Two Points
Reference Air: Natural Convection, Instrument Air, pressure compensated
Instrument Air: 200 kPa plus the pressure in the furnace
Power Supply: 100 – 240 VAC, 50/60Hz
Power Consumption: Max 300 W, approx. 100 W for ordinary use
Sample Specifications
CB-Hawk ICS Oxygen Monitoring System
PART 1 GENERAL
A.
B.
This specification covers the hardware and monitoring functions of
the CB-HAWK ICS Oxygen monitoring system. The system monitors
and displays Oxygen concentration and is used, in conjunction with
combustion air and stack flue gas temperature sensors, to calculate
the overall efficiency of the boiler.
The system shall be completely configured from the factory requiring
only job specific data to be entered (or modified) in the field.
Note: O2 Sensor Requires calibration in the field!
D-19
09-09
Section D
PART 2 PRODUCTS
2.1
PART 3 EXECUTION
This system is applicable to modulating burners using the CB-HAWK ICS Integrated
Control System. This system shall monitor and display O2 concentration in the
boiler’s exit flue gas and provide overall boiler efficiency calculations.
HARDWARE
A. Hardware shall consist of the following:
1. Oxygen Sensor
2. Integrated type Zirconia Oxygen Analyzer
3. Direct Insertion Type
4. Built-in Heater Assembly
5. 4-20mA DC Process Variable Output
6. Heater to be of field replaceable construction
7. Cell to be of field replaceable construction
B. Analyzer
1. Shall be of the Integrated Type (in probe head)
2. Provide 4 – 20mA DC Signal output in relation to process
variable for remote display
C. Monitoring System
1. Indicate O2 Percentages
2. Provide Low O2 Alarm Indication
3. Perform Efficiency Calculations and display results using
O2 percentages
D-20
09-09
Section D
CB-HAWK ICS — ETHERNET COMMUNICATION
The CB-HAWK ICS Ethernet communication package provides Ethernet
communications between the CB-HAWK ICS programmable controller and other
Ethernet compatible devices such as the Boiler Room Master Lead/Lag Control
Panel, Building/Plant automation system, and the Internet.
FEATURES AND BENEFITS
•
Provides communication between the CB-HAWK ICS programmable controller
unit and other Ethernet Compatible Devices
•
Provides interface capability with many Building/Plant automation systems
when utilizing OPC server or protocol bridge
•
Provides interface with plants LAN/WAN
•
Provides interface to the Internet (requires static IP address)
•
E-mailing of boiler alarms/faults
•
Provides means of connection between various boiler room control systems,
such as the CB-HAWK ICS Master Panel for lead/lag control
•
Provides means of connection to a remote Personal Computer
•
Ethernet Industrial Protocol
•
IEEE 802.3 Physical and Data Link Standard
•
Ethernet TCP/IP protocol suite industry standard
•
Control and Information Protocol (CIP) Compliant
PRODUCT OFFERING
•
Optional Ethernet Communication Hub (necessary for stand-alone boiler (no
Master Panel) connection to LAN/WAN and/or Paging Modem option)
•
E-mail functionality — requires customer provided e-mail service and address
•
Modular connection to CB-HAWK ICS Programmable Controller unit
•
Ethernet Industrial Protocol (Allen-Bradley EPIC)
•
Follows Ethernet Rules and Practices
•
High Noise Rejection
•
Cabling: Category 5E rated twisted pair cable (solid core, PVC jacket with RJ45
connections).
•
Meets Open Industrial Network Standards
•
IEEE 802.3 Physical and Data Link Standard
•
Ethernet TCP/IP protocol suite industry standard
•
Control and Information Protocol (CIP) Compliant
•
OPC (OLE Process Control) communication compatibility with RSLinx OPC
Server software
ENGINEERING DATA
D-21
09-09
Section D
Sample Specifications
CB-HAWK ICS — Ethernet Communication
PART 1 GENERAL
The Boiler Manufacturer shall furnish and install a control module capable of
Ethernet communications between the boiler’s programmable logic control system
and other Ethernet compatible devices, as needed, and provide the following
minimum requirements:
A.
B.
C.
D.
E.
F.
G.
H.
Interface with the Compact Logix Programmable Controller Protocol
Ethernet Industrial Protocol (Allen-Bradley EPIC)
Follows Ethernet Rules and Practices
High Noise Rejection
Open Industrial Network Standards
IEEE 802.3 Physical and Data Link Standard
Ethernet TCP/IP protocol suite industry standard
Control and Information Protocol (CIP) Compliant
D-22
09-09
Section D
CB-HAWK ICS — PAGING and REMOTE
DIAL-UP ACCESS with MODEM
Provides Paging of Alarms Faults, via Modem, from the CB-HAWK ICS Control System to the
customer provided pager or a compatible cell phone.
FEATURES AND BENEFITS
•
Paging of boiler system alarms. (Paging Service and Pagers furnished by
customer)
•
Allows Remote Dial-Up Access for monitoring and troubleshooting.
•
Remote Access Paging Modem
•
Easy to use configuration software
•
Requires customer provided, dedicated phone line
•
Requires customer provided Paging Service and pagers (or paging
compatible cell phones)
•
Requires Pager Numbers and PINs supplied by customer
•
Configure up to 10 unique pagers
•
Voltage: 24 VDC
•
Baud Rate: 56K
•
Type: External, Serial
•
Paging functionality utilizes TAP Protocol
PRODUCT OFFERING
ENGINEERING DATA
Sample Specifications
CB-HAWK ICS — Paging and Remote Dial-up Access With Modem
PART 1 GENERAL
The boiler manufacturer shall provide a Paging and Remote Dial-Up Access Modem,
using customer provided paging systems for the purpose of paging boiler system
alarms and providing remote access to the control system.
Pager number(s) and PINs to be supplied by customer.
Dedicated telephone connection to be supplied by customer.
D-23
09-09
Section D
CB-HAWK ICS — LEAD/LAG FOR TWO
BOILER SYSTEMS
Provides Lead/Lag control for a two-boiler system when used in conjunction with the CBHAWK ICS integrated boiler control system.
FEATURES AND BENEFITS
Controls Header Pressure and Temperature:
•
Maintains steam pressure or hot water supply temperature based on system
load demand.
•
Compensates for varying losses between boiler and header.
Sequences of Operation for Two Boilers:
•
Provides maximum system efficiency.
•
Reduces cycling and boiler wear; thereby reducing maintenance and downtime
costs.
•
Optimizes fuel savings.
Lead/Lag Start with Lead/Lag Modulation:
•
Lead boiler operates at full capacity prior to starting lag boiler.
•
Lag boiler starts modulation when lead boiler reaches maximum firing rate
position.
•
Ideal for steam boilers.
Lead/Lag Start with Unison Modulation:
•
Lead boiler operates at full capacity prior to starting lag boiler.
•
Lag boiler operates at the same firing rate as a lead boiler.
•
Ideal for hot water boilers.
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment:
•
Boiler control for each boiler shall be CB-HAWK ICS.
•
Pressure (steam) or temperature (hot water) transmitter shipped loose for
mounting in the common header.
D-24
09-09
Section D
Sample Specifications
CB-HAWK ICS — Lead/lag For Two-Boiler Systems
PART 1 GENERAL
1.1
GENERAL
A. Lead/Lag Start with either Lead/Lag or Unison Modulation.
B. Boilers’ Start and Stop
1. Steam pressure, or hot water temperature, is compared with
the setpoint and controller’s processor executes PID algorithm.
Lead boiler is commanded to come on line first. Lag boiler is
commanded to come on line when a firing rate signal for the
lead boiler reaches lag boiler start point. Lag boiler is
commanded to stop when a firing rate signal for the lag boiler
reaches lag boiler stop point.
C. Lead/Lag Modulation - Lag boiler starts modulation after lead boiler
reaches maximum firing rate.
D. Unison Modulation - Firing rates for both boilers are equal.
E. Hot Standby - System shall have a provision for keeping lag boiler in
hot standby. Standby routine shall be based on a water temperature
signal.
1.2
APPLICATION AND SYSTEM REQUIREMENTS
A. This option is applicable to full modulation burners utilizing the CBHAWK ICS advanced boiler control system and modulating controls.
B. All logic for Lead/Lag Control shall reside in the boiler controller. No
additional control panels shall be required.
D-25
09-09
Section D
CB-HAWK ICS — LEAD/LAG for up to EIGHT
BOILERS SYSTEM
Provides Lead/Lag control for up to eight boilers when used in conjunction with the
CB-HAWK ICS integrated boiler control system.
FEATURES AND BENEFITS
Controls Header Pressure and Temperature:
•
Maintains steam pressure or hot water supply temperature based on system
load demand.
•
Compensates for varying losses between boiler and header.
Benefits:
•
Maximizes system efficiency.
•
Reduces cycling and boiler wear, thereby reducing maintenance and downtime
costs.
•
System shall be provided with a sequence to automatically rotate sequence in
which the boilers are fired. Rotation shall be based on the elapsed time.
•
Optimizes fuel savings.
Lead/Lag Start with Lead/Lag Modulation:
•
Lead boiler operates at full capacity prior to starting lag boiler #1.
•
Lag boiler #1 starts when the lead boiler’s firing rate is close to the maximum.
Operator can select this parameter via HMI.
•
Lag boiler #1 starts modulation when the lead boiler reaches the maximum
firing rate position.
•
Subsequent lag boilers operate in the same fashion.
•
Ideal for steam boilers.
Lead/Lag Start with Unison Modulation:
•
Lead boiler operates at full capacity prior to starting the lag boiler.
•
All boilers operate at the same firing rate as the lead boiler.
•
Ideal for Hot Water boiler systems.
D-26
09-09
Section D
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment:
•
Boiler control for each boiler shall be the CB-HAWK ICS.
•
Pressure (Steam) or temperature (Hot Water) transmitter shipped loose for
mounting in the common header.
•
Master Control Panel shipped loose for field mounting.
•
Requires Ethernet/IP Communication Option
Sample Specifications
CB-HAWK ICS — Lead/lag for up to Eight Boilers System
PART 1 GENERAL
1.1
GENERAL
A. Lead/Lag Start with either Lead/Lag or Unison Modulation.
B. Boilers’ Start and Stop
1. Steam pressure, or hot water temperature on hot water
systems, is compared with the setpoint and controller’s
processor executes PID algorithm. Lead boiler is commanded
to come on-line first. Lag boiler #1 is commanded to come online when a firing rate signal for the lead boiler reaches lag
boiler start point. Lag boiler #1 is commanded to stop when a
firing rate signal for the lead boiler reaches lag boiler stop
point.
2. Lag boiler #2 is commanded to come on-line when a firing rate
signal for the lag boiler #1 reaches lag boiler #2 start point.
Lag boiler #2 is commanded to stop when a firing rate signal
for the lag boiler #1 reaches lag boiler #2 stop point.
3. Subsequent boilers operate in a similar fashion.
C. Lead/Lag Modulation
1. Lag boiler #1 starts modulation after lead boiler reaches
maximum firing rate (or firing rate selected by the operator).
2. Lag boiler #2 starts modulation after lag boiler #1 reaches
maximum firing rate (or firing rate selected by the operator).
3. Subsequent boilers operate in a similar fashion.
D. Unison Modulation - Firing rates for all boilers are equal.
E. Hot Standby - System shall have a provision for keeping lag boilers
in hot standby. Standby routine shall be based on a water
temperature signal.
F.
Firing Sequence Selection - Sequence in which boilers come on-line
shall be selected via HMI. Adequate check shall be provided that
does not allow improper sequence selection.
G. Automatic Rotation of the Boilers - System shall be provided with a
sequence to automatically rotate sequence in which the boilers are
fired. Rotation shall be based on the elapsed time.
D-27
09-09
Section D
1.2
HMI (HUMAN MACHINE INTERFACE)
A. Master panel shall include HMI for display and selection of the
following parameters:
B. Display
1. Available boilers
2. Number of boilers required
3. Selected sequence of firing
4. Control output to each boiler
5. Header steam pressure or water temperature on hot water
systems
6. Setpoint
7. Elapsed time from last rotation
C. Selection
1. Number of boilers
2. Sequence of firing
3. Automatic or manual rotation
4. Individual boiler start and stop points with timers
5. Setpoint
6. Proportional, integral and derivative gains for control algorithm
1.3
APPLICATION AND SYSTEM REQUIREMENTS
A. This option is applicable to full modulation burners utilizing the CBHAWK ICS advanced boiler control system and modulating controls.
B. Logic for Lead/Lag control shall reside in the Master Control Panel.
Communication between the Master Panel and the individual Boiler
Control Panels shall be via Ethernet communication or hard wiring.
D-28
09-09
Section D
CB780E CONTROL
The CB 780E is a microprocessor-based flame safeguard control used to monitor the
presence of a flame inside a boiler, and to sequence the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for safe
operation.
FEATURES AND BENEFITS
Dynamic self-check logic and diagnostics:
•
Dynamic self-check safety circuit checks microprocessor and safety relay to
ensure safe and proper operation.
•
Dynamic input check verifies controls ability to recognize the true status of
external controls, limits and interlocks.
•
Closed-loop logic test verifies integrity of safety critical loads (ignition, pilot, and
main fuel valves) for proper operation.
•
Pre-ignition interlocks and flame signal checked during Standby and Pre-Purge.
•
High and Low fire switches checked for proper sequencing.
•
Tamper-proof Purge Timer Card.
Valve Proving System
•
Programmable valve proving system provides fuel valve proof-of-closure.
Powerful Display/Diagnostic Capabilities:
•
2 line x 20 character Vacuum Fluorescent Display is easy to read under all
lighting conditions.
•
Status and diagnostic messages displayed in English Language with no scrolling
necessary (Spanish also available).
•
Displays flame signal in Volts dc, eliminating need for separate meter.
•
Displays burner hours and numbers of cycles.
•
Diagnostic displays include on/off status of inputs and outputs, RUN/TEST
switch status, selected purge time, amplifier type and configuration data.
•
Fault history (retained in non-volatile memory) displays the cycle, hours, code,
description, and condition for the last six fault occurrences.
•
Capability to mount display on front of Control Panel for improved access, or
remotely, in separate control room. (Optional)
•
5 LEDs on base provide at-a-glance status of Power On, Pilot, Flame, Main
D-29
09-09
Section D
Valves, and Alarm conditions (Power LED blinks periodically to indicate proper
control operation).
•
Diagnostic display capabilities are further enhanced by the optional CB783
Expanded Annunciator which provides 36 additional specific HOLD and Fault
messages, as well as 26 LEDs to indicate current status or first-out alarm
indication (user-selectable).
•
Communication capabilities to a local or remote Personal Computer, with
optional CB-LINKcommunications module and Combustion System Manager™
software (runs under Microsoft Windows®).
Application Flexibility:
•
Purge Timing Cards available in 30, 60, 90 seconds or 2-1/2 minutes cover a
wide range of applications, while eliminating need for a separate purge timer.
•
Separate output for ignition transformer simplifies applications requiring early
spark termination.
•
Selectable configuration jumpers allow application-specific configuration.
•
Communication interface capability.
Simplified Servicing:
•
Diagnostic and fault history information available through display simplifies
troubleshooting procedures.
•
Removable access covers for checking voltage at terminals.
•
5-function RUN/TEST switch eases start-up procedure.
•
Flame signal display facilitates pilot/light-off test procedures.
PRODUCT OFFERING
Included in each CB 780E system is the following:
•
One CB780E chassis, including display module.
•
One Purge Timer Card.
•
One wiring sub-base.
•
One flame scanner, either Infrared, Ultra-Violet, or UV Self-Check.
•
One flame amplifier, to correspond with the selected flame scanner.
Included with the optional CB783 Expanded Annunciator:
•
One CB783 Annunciator.
•
One wiring sub-base.
•
All limits and interlocks are wired into wiring sub-base to provide individual
hold/fault indication on LEDs of Expanded Annunciator, as well as on display
module of CB 780E control.
•
Supply voltage: 120 Vac (+10%/-15%) 50 or 60 Hz.
•
Maximum total load: 2000 VA.
ENGINEERING DATA
D-30
09-09
Section D
•
Load rating-fuel valve output: 65 VA pilot duty plus 1150 VA inrush, 460 VA
opening, 250 VA holding.
•
Operating temperature limits: -40 to 140 °F.
•
Maximum ambient humidity: 85% non-condensing.
Sample Specification
CB780E Control
PART 1 GENERAL
Flame safeguard shall be a Cleaver-Brooks Model CB 780E microprocessor-based
control to monitor all critical boiler and burner interlocks, control and supervise
burner light off sequence, and initiate an orderly safety procedure in the event of
interlock or flame failure. The system shall provide status, fault history, and
diagnostic information by means of a two-line alpha-numeric display and alarm/
status LEDs. The system shall be approved by UL, FM, and CSA, and shall be
acceptable by IRI.
D-31
09-09
Section D
CB120/120E CONTROLS
The CB120 is a microprocessor-based burner management control system designed
to provide the proper burner sequencing, ignition, and flame monitoring protection
on automatically ignited oil, gas , and combination fuel burners. In conjunction with
limit and operating controls, it programs the burner/blower motor, ignition, and fuel
valves to provide for proper and safe burner operation
The CB120E includes all of the features of the CB120 with the addition of an
alphanumeric display.
FEATURES AND BENEFITS
Display and Diagnostic Capabilities:
•
(CB120E) 2 x 16 character display with keypad. Available display types are
vacuum fluorescent (VFD) and liquid crystal (LCD). VFD has increased
brightness and extended operating temperature range to -40°F. Messages are
spelled out in English (optional Spanish version is also available). Provides
indication of flame signal during operation.
•
Lockout history stores last 10 lockouts with burner cycle and burner hour when
occurred.
•
Display module can be mounted remotely from the CB120 for external
indication (optional).
•
Optional expanded annunciator provides increased messaging and diagnostic
capabilities.
•
Optional communication via Modbus with local or remote PC.
Modular Design:
•
Interchangeable program modules in English or Spanish.
•
Adjustable purge time programmable via display.
•
Chassis available for infrared, ultra-violet, or UV self-check flame scanners.
•
Reduces part replacement costs.
D-32
09-09
Section D
PRODUCT OFFERING
Included in each CB120 System is the following:
•
Chassis with corresponding flame ampliifier
•
Plug-In Programmer Module.
•
Wiring base.
•
Flame scanner - either infrared, ultra-violet, or UV self-check.
Included in each CB120E System is the following:
•
All of the above
•
Alphanumeric display
Display is required for Modbus communication or to access special functions.
ENGINEERING DATA
•
Supply voltage: 120 Vac (+10%/-15%) 50/60 Hz.
•
Fuel valve output load rating: 65 VA pilot duty plus 3850 VA inrush, 700 VA
open, 250 VA hold.
•
Operating temperature limits: -40°C (-40°F) to 60°C (140 °F). LCD display min.
temp. limit -20°C (-4°F).
•
Maximum ambient humidity: 90% non-condensing.
Sample Specification
CB120/120E Control
PART 1 GENERAL
Flame safeguard shall be a Cleaver-Brooks Model CB120/120E microprocessorbased control to monitor all critical boiler and burner interlocks, control and
supervise burner light-off sequence, and initiate an orderly safety procedure in the
event of interlock or flame failure. CB120E system shall provide status, fault history,
and diagnostic information by means of a 2 x 16 VFD or LCD display. The system
shall be approved by UL, FM, and CSA, and shall be acceptable by IRI.
D-33
09-09
Section D
CB100E CONTROL
The CB100E is a microprocessor-based, flame safeguard control used to monitor
the presence of a flame inside a boiler, and include various interlocks to ensure safe
operation. The flame safeguard also sequences the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for
safe operation.
FEATURES AND BENEFITS
Display and Diagnostic Capabilities:
•
2 x 16 Backlit LCD display with a 3-key tactile dome keypad indicates 38
different messages regarding status and fault indication. Messages are spelled
out in English. (Optional Spanish version is also available.) Provides indication
of flame signal during operation.
•
Provides indication of burner cycles and run time.
•
Non-volatile memory retains last 6 fault/lockout conditions on power failure.
•
Display module can be mounted in cabinet door for external indication.
(Optional)
•
Optional E300 expansion module provides additional 31 messages pertaining
to fault or “hold” status indication.
•
Communication with local or remote PC by means of an optional E500
communication module.
Modular Design:
•
Interchangeable program modules in English or Spanish.
•
Purge time is selected via dip switches.
•
Interchangeable amplifiers for infrared, ultra-violet, or UV self-check flame
scanners.
•
Reduces part replacement costs.
D-34
09-09
Section D
PRODUCT OFFERING
Included in each CB100E System is the following:
•
One chassis, including a dust cover.
•
One 2-line display module.
•
One Programmer Module.
•
One wiring sub-base.
•
One flame scanner, either infrared, ultra-violet, or UV self-check.
•
One flame amplifier — to correspond with the selected flame scanner.
Included with optional E300 Expansion Module is:
•
One E300 expansion module.
•
One wiring subbase.
•
One interconnection cable to E100E.
•
All interlocks are wired into wiring sub base to provide individual hold/fault
indication on display of CB100E control.
•
Supply voltage: 120 Vac (+10%/-15%) 50/60 Hz.
•
Maximum total load: 2000 VA.
•
Fuel valve output load rating: 1250 VA opening, 500 VA holding.
•
Operating temperature limits:32 °F to 125 °F.
•
Maximum ambient humidity: 85% non-condensing.
ENGINEERING DATA
Sample Specification
CB100E Control
PART 1 GENERAL
Flame safeguard shall be a Cleaver-Brooks Model CB100E microprocessor-based
control to monitor all critical boiler and burner interlocks, control and supervise
burner light-off sequence, and initiate an orderly safety procedure in the event of
interlock or flame failure. The system shall provide status, fault history, and
diagnostic information by means of a 2 x 16 backlit LCD display. The system shall
be approved by UL, FM, and CSA, and shall be acceptable by IRI.
D-35
09-09
Section D
CB110 CONTROL
The CB 110 is a micro-processor-based, flame safeguard control used to monitor
the presence of a flame inside a boiler, and include various interlocks to ensure safe
operation. The flame safeguard also sequences the burner through several stages of
operation to provide proper air purge, ignition, normal operation and shut down for
safe operation.
FEATURES AND BENEFITS
Self Diagnostics:
•
Seven LED display provided to indicate: Fan, High Fire, Low Fire, Ignition,
Flame detected, Auto and Alarm.
•
23 Fault indications.
Modular Design:
•
Interchangeable amplifiers for infrared, ultra violet, or UV self-check flame
scanners.
•
Reduces part replacement costs.
•
Easily upgradeable to a CB 100E by replacing programmer and display
modules.
PRODUCT OFFERING
Included in each CB 110 System is the following:
•
One CB 110 chassis, including dust cover.
•
One Programmer/Display Module.
•
One wiring subbase.
•
One flame scanner, either infrared, ultra-violet, or UV self-check.
D-36
09-09
Section D
•
One flame amplifier — to correspond with the selected flame scanner.
•
Supply voltage: 120Vac (+10%/-15%) 50/60 Hz.
•
Maximum total load: 2000 VA.
•
Fuel valve output load rating: 1250 VA opening, 500 VA holding.
•
Operating temperature limits: -40 °F to 125 °F
•
Maximum ambient humidity: 85% non-condensing.
ENGINEERING DATA
Sample Specification
CB110 CONTROL
PART 1 GENERAL
Flame safeguard shall be a Cleaver-Brooks Model CB 110 microprocessor-based control to
monitor all critical boiler and burner interlocks, control and supervise burner light-off
sequence, and initiate an orderly safety procedure in the event of interlock or flame failure.
The system shall provide status, fault history, and diagnostic information by means of an
LED display. The system shall be approved by UL, FM, and CSA, and shall be acceptable by
IRI.
D-37
09-09
Section D
LEAD/LAG SYSTEMS (TWO BOILER LEAD/
LAG)
This section contains information on Multiple Boiler Lead/Lag systems. For Lead/
Lag systems used with boilers equipped with the CB-HAWK ICS system, refer to the
CB-HAWK ICS Two Boiler Lead/Lag and Eight Boiler Lead/Lag sections.
FEATURES AND BENEFITS
Controls Actual Header Pressure and Temperature:
•
Maintains steam or hot water supply to system load.
•
Compensates for varying losses between boiler and header.
Sequences Operation of Two Boilers:
•
Maximum system efficiency.
•
Reduces cycling and boiler wear reducing maintenance and downtime costs.
•
Optimizes fuel savings.
Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag High-Low Fire:
•
Lead boiler operates at full capacity prior to starting lag boiler.
•
Ideal where load swings are infrequent and small such as heating applications.
Lead/Lag Start with either Unison Modulation or Unison High-Low Fire:
•
Boilers operate in unison when both are on line.
•
Ideal where load swings are frequent and large, such as process applications.
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment:
•
Lead/Lag selector switch mounted on one boiler.
•
On-off and firing rate controls shipped loose for mounting in common
header piping.
•
Minimum temperature low-fire-hold control — steam boilers.
•
Low-fire-hold control — hot water boilers.
•
Components shall be Underwriters Laboratories’ approved for intended
service.
D-38
09-09
Section D
Sample Specifications
Lead/Lag Systems (Two-boiler Lead/lag)
PART 1 GENERAL
1.1
GENERAL
A. Lead/Lag Start with either Lead/Lag Modulation or Lead/Lag HighLow Fire.
B. The boiler manufacturer shall supply a control system to lead and
lag two boilers. The system shall start, stop, and control the firing
rate of both boilers.
C. Upon system demand, the lead boiler shall start and operate to full
capacity prior to starting the lag boiler. When both boilers are on
line, the lead shall always operate to full capacity and the lag shall
operate between minimum and maximum output to satisfy demand
requirements.
D. When system demand decreases, the lag boiler shall return to the
minimum firing rate position and shut off. A further decrease shall
cause the lead boiler to reduce its firing rate to minimum and shut
off.
E. A switch shall be provided to rotate the lead position between both
boilers.
F.
For steam boilers, a means shall be provided to maintain minimum
boiler water temperature at low-fire when the boilers are off line.
G. For hot water boilers, a means shall be provided to keep the boilers
at low-fire rate until a predetermined minimum temperature is
reached. This releases the boiler to automatic operation from the
firing rate control.
H. All components shall be Underwriters Laboratories approved for
intended service.
I.
Lead/Lag Start with either Unison Modulation or Unison High-LowFire.
J. The boiler manufacturer shall supply a control system to lead and
lag start of two boilers. The system shall start, stop, and control the
firing rate of both boilers.
K. Upon system demand, the lead boiler shall start and operate to full
capacity prior to starting the lag boiler. When both boilers are on
line, they shall operate in unison between minimum and maximum
output to satisfy demand requirements.
L. When system demand decreases, both boilers shall reduce their
firing rate, in unison, to minimum. The lag boiler shall shut off and
the lead boiler shall operate between minimum and maximum until
demand is satisfied, and then shut off. A switch shall be provided to
rotate the lead position between both boilers.
M. For steam boilers, means shall be provided to maintain minimum
boiler water temperature at low-fire when boilers are off line.
N. For hot water boilers, means shall be provided to keep boilers in a
low-fire-hold mode until a predetermined minimum temperature is
reached. This shall then release the boiler to automatic operation
from firing rate control.
D-39
09-09
Section D
O.
P.
1.2
All components shall be Underwriters Laboratories approved for
intended service.
The lead/lag system is a specialized digital control that sequences
the starting, stopping, and controls modulation firing rate for two
boilers. It can be used for either steam or hot water applications.
APPLICATION
This option is applicable to full modulation burners utilizing standard Cleaver-Brooks modulating controls.
D-40
09-09
Section D
LEAD/LAG SYSTEMS (TWO THROUGH
FOUR BOILER LEAD/LAG)
The lead-lag system is a specialized digital control that sequences the starting,
stopping, and controls modulation firing rate for two through four boilers. It can be
used for either steam or hot water applications.
FEATURES AND BENEFITS
PID Control Logic:
•
Precise control.
•
Monitors rate of change to anticipate needs of system, turning boilers on or off
as needed.
Lead/Lag Start and Modulation:
•
Provides optimal control action for different applications.
•
Lead boiler rotates automatically every 24 hours or manually selected for fixed
lead position.
Boilers Controlled From Header Pressure or Temperature:
•
Maintain constant steam or hot water supply to system load.
•
Compensate for varying losses between boiler and header.
Sequences Optimal Number of Boilers on Line:
•
Maximum system efficiency.
•
Reduces cycling and boiler wear reducing maintenance and downtime costs.
•
Optimizes fuel savings.
PRODUCT OFFERING
Cleaver-Brooks shall supply the following equipment:
•
Lead/lag sequencing control system for full modulating boilers (four boilers
maximum).
•
Relays on control system panel for start-stop control of boilers.
•
Pressure or temperature sensor and immersion well.
•
Assured low-fire cutoff upon boiler shut off (steam and hot water boilers).
•
Minimum temperature low-fire-hold control (steam boilers).
•
Low-fire-hold control (hot water boilers).
D-41
09-09
Section D
ENGINEERING DATA
Voltage input: 115 V, 60 Hz
Power consumption: 30 VA maximum
Output rating:
Relays: 1 amp inductive, 10 amp resistive at 115 V, 60 Hz. (up to 4 relays used,
plug in type).
•
Firing rate signal: 0 to 135 ohm resistive.
•
Sensor ranges:
•
Temperature: -30 °F to 250 °F accuracy plus or minimum 1°F.
•
Pressure: 0-30 psig, 0-100 psig, 0-200 psig accuracy 1% full scale.
Standby battery: Operates for 100 days minimum with overall average life of 5
years.
Maximum ambient temperature: 120 °F.
Sample Specifications
Lead/lag Systems (Two Through Four Boiler Lead/lag)
PART 1 GENERAL
1.1
GENERAL
A. The boiler manufacturer shall furnish a microprocessor based
control system. The control shall be engineered and programmed
exclusively for the operation of multiple steam or hot water full
modulation boilers. It shall incorporate the following integrated
functions:
1. Manual or automatic lead stage rotation; boiler sequencing and
burner firing rate (modulation control). The control shall be of
modular construction to facilitate field modification, upgrading
or repair. It shall include the following features.
B. The control shall have the capability of operating in a temperature
or pressure mode. Temperature sensors shall be of the thermistor
type, suitable for insertion into a 3/8” ID well. Standard operating
range shall be -30 °F to +250 °F. Pressure sensors shall be of the
4-20 ma type. Standard operating range shall be 0-30, 0-100, 0150 or 0-200 psig.
C. The control shall provide an integral sensor set point adjustment.
The set point shall be adjustable in 1 °F or 1 psig increments (1/10
psig increments for 0-30 psig units) via a multi-turn knob. The
setting value shall be stored in EEPROM indefinitely.
D. The control shall provide a LED bar graph display of each boiler’s
approximate percent modulation. The control shall also provide a
digital LED display of actual temperature or pressure, set point
temperature or pressure, gain adjustment and each boilers exact
percent modulation. In addition, the digital display shall be used to
indicate the following four control settings as they are being
adjusted:
1. Modulation start point shall be adjustable from 50 to 100%.
This setting determines the percent modulation a stage must
achieve before the next stage is activated. There shall be
D-42
09-09
Section D
E.
F.
G.
H.
I.
J.
independent adjustment of this setting for each burner.
2. Purge timer shall be adjustable from 0-9.9 minutes. This
setting determines the delay time between a burner being
started and the beginning of modulation.
3. Set back (additional set point) shall be adjustable from 0-75
°F/psig (0-7.5 psig on 0-30 psig units). This setting determines
the °F/psig drop from the primary set point whenever the
setback mode is activated. An “off” setting shall also be
included for complete burner shutdown. The set back mode
shall be activated by an external switch closure.
4. Standby timer shall be adjustable from 1-60 minutes. This
setting determines the delay period which must elapse before
any designated standby boilers are activated. The timing
sequence shall begin when all active boilers reach 100% firing
rate.
LEDs shall be provided to indicate the lead stage and all activated
stages.
A lithium “coin” type battery shall be included to maintain the
correct lead stage and lead stage rotation timer in the event of power
failure. Storage capacity shall be 100 days.
A four position selector switch shall be provided to set the operating
mode of each stage. Positions include on, auto, off and standby.
The control shall have the capability of operating up to four full
modulation boilers. Each stage shall have the following outputs:
1. A normally open contact to start/stop the burner.
2. A 0-135 ohm output to independently control each burner’s
firing rate.
The control shall be UL listed, tested per Standard 873.
Temperature Indicating and Regulating Equipment. It shall be CSA
listed, tested per Standard C22.2 Number 24-1987 Temperature
Indicating and Regulating Equipment. It shall also be approved for
use in NYC by the City of New York; Department of Buildings,
Bureau of Electrical Control and Department of Environmental
Protection, Bureau of Air Resources.
A surface mounted, locking steel, NEMA 1 type, minimum 18 gauge
enclosure shall be provided.
1.2
APPLICATION
This option is applicable to full modulation burners utilizing standard Cleaver-Brooks
modulating controls.
D-43
09-09
Section D
LOW FIRE HOLD CONTROL
FEATURES AND BENEFITS
Prevents Automatic Control of Burner Firing Rate Until Pre- Determined Boiler
Water Temperature is Reached:
•
Equalizes water temperature in boiler.
•
Reduces possibility of thermal shock to pressure vessel and refractory.
PRODUCT OFFERING
Cleaver-Brooks shall provide a boiler water temperature control with sensor and
immersion well. The control is Underwriters Laboratories approved for intended
service and shall be mounted and wired on the boiler.
RECOMMENDED USE
The use of this control is recommended where a minimum temperature control has
not been installed and where operating personnel may not be diligent in manually
placing the boiler at low fire until the boiler shell is of equal temperature
throughout.
Note: In an emergency one can override this control by placing the “Manual-Auto” switch in the
Manual position.
Sample Specifications
Low Fire Hold Control
PART 1 GENERAL
1.1
GENERAL
The boiler manufacturer shall furnish and install a control to sense boiler water
temperature. The control shall maintain burner in a low-fire hold mode until a preset temperature is satisfied. This shall then release boiler to automatic control of
system demand. Control shall be Underwriters Laboratories approved for intended
service.
1.2
APPLICATION
This option is applicable to full modulation and high-low fire burners.
D-44
BB_D-03-06
09-09
Section D
MINIMUM TEMPERATURE — LOW FIRE
HOLD CONTROL
FEATURES AND BENEFITS
Maintains Minimum Boiler Water Temperature in Steam Boilers at Low-Fire Mode
of Operation During Off Periods:
•
Reduces lag-time to steaming rate.
•
Reduces possibility of thermal shock to pressure vessel and refractory.
•
Operational mode-manual or automatic.
PRODUCT OFFERING
Cleaver-Brooks shall supply:
•
Boiler water temperature control and immersion well.
•
Interface relay.
•
Operation mode.
•
•
Manual — selector switch.
•
Automatic — activated by remote on-off boiler control device.
Components Underwriters Laboratories’ approved for intended service.
RECOMMENDED USE
A common procedure at many steam boiler installations is to shut the boiler off
overnight, during weekends, or during holidays. During this “off” period boiler water
temperature decreases. This can effectively decrease boiler metal and refractory
temperatures to near room temperature. After this “off” period the boiler is placed
back into operation. Due to low boiler water temperature and a steam pressure
demand the boiler will immediately position itself at high fire. The important factors
to remember are that metals expand when heated; contract when cooled. This is
also true of boiler refractory. With repeated heating and cooling of any boiler,
premature deterioration of boiler refractory, metals, and resultant tube leakage can
occur. To minimize these effects, the installation of a combination minimum
temperature-low fire hold control is recommended.
Occasionally there are objections to the use of a combination minimum
temperature-low fire hold control. If the “off” period will be of prolonged duration
maintaining minimum temperature could represent a considerable waste of fuel.
Under this condition it is recommended that a low fire hold control be installed.
D-45
06-08
09-09
Section D
Sample Specifications
Minimum Temperature — Low Fire Hold Control
PART 1 GENERAL
1.1
GENERAL
The boiler manufacturer shall furnish and install a control to sense boiler water
temperature. The control shall have an adjustable set point to maintain a minimum
temperature at a pre-set level when the boiler is off line. This shall be accomplished
at the burners minimum firing rate. The function can be activated either manually
or automatically. Components shall be Underwriters Laboratories approved for
intended service.
1.2
APPLICATION
This option is applicable to full modulation and high-low fire burners.
D-46
09-09
Section D
ASSURED LOW FIRE CUTOFF
FEATURES AND BENEFITS
Assures that the burner shuts off at minimum firing rate when signaled from remote
disable source:
•
Prevents shutoff at firing rates above low fire.
•
Reduces possibility of thermal shock to pressure vessel and refractory.
PRODUCT OFFERING
Cleaver-Brooks shall provide terminal connection points for remote disable/enable
signals, and internally wire additional electrical components necessary to perform
this function.
Sample Specifications
Assured Low Fire Cutoff
PART 1 GENERAL
1.1
GENERAL
The boiler manufacturer shall make provisions to accept remote enable/disable
signal contact. Any disable signal shall cause the burner to return to minimum low
fire position prior to shutting off the main fuel.
1.2
APPLICATION
This option is applicable to full modulation and high-low fire burners.
D-47
09-09
Section D
REMOTE MODULATION
FEATURES AND BENEFITS
•
Provides burner modulation from a customer supplied 4-20 ma control signal.
•
Ties boiler firing rate control with customer control system (for example,
building management, boiler room master, lead-lag control).
PRODUCT OFFERING
Standard Equipment
•
Resistor kit to allow standard firing rate motor to operate from a 4-20 ma
control signal.
•
Relay with gold flashed contacts to switch between automatic and manual
operation.
•
Manual firing rate potentiometer to allow local manual operation.
Optional Equipment
Local — remote firing rate control selector switch.
•
Allows control of firing rate from standard local firing rate controller or
remote 4-20 ma signal.
Sample Specification
Remote Modulation
1.1
GENERAL
Furnish and install components to allow burner to modulate from a remote 4-20 ma
control signal. Provisions shall be made for local manual firing rate control.
1.2
APPLICATION
This option is applicable to full modulation burners utilizing standard CleaverBrooks modulating controls.
D-48
09-09
Section D
AUTOMATIC FUEL CHANGEOVER
FEATURES AND BENEFITS
•
Provides sequence to allow burner to automatically change fuel.
•
Interfaces boiler-burner control with customer control system and avoids
premium charges for fuel.
PRODUCT OFFERING
•
A selector switch. With selector switch in the “AUTO” position, burner shall fire
primary fuel when auxiliary contact governing fuel selection (for an example, gas
pressure switch or outdoor thermostat) is closed. Upon opening of the above
contact: a burner shall modulate to the minimum firing rate position, shutdown
and restart firing stand by fuel.
•
Fuel auto changeover switch (a low gas pressure switch or outdoor thermostat).
This switch may be furnished by the boiler supplier, customer, or utility.
Sample Specification
Automatic Fuel Changeover
PART 1 GENERAL
1.1
GENERAL
The boiler manufacturer shall furnish sequence to allow an automatic changeover
from primary to stand by fuel and back. An automatic fuel changeover shall be
initiated by gas pressure, outdoor temperature or other dry contact.
1.2
APPLICATION
This option is applicable to dual-fuel (i.e., gas-oil fired) boilers with exception of
Model LE Boilers.
D-49
09-09
Section D
Accu-Trim O2TRIM SYSTEM
The C-B Accu-Trim O2 Trim System is a stand-alone PLC-based control system
designed to maintain the proper fuel-air ratio of a boiler/burner. The system will
automatically compensate for changes in temperature, barometric pressure, or fuel
characteristics, as well as correcting for normal hystereses. The system is intended
for use on a Cleaver-Brooks boiler or burner with single point positioning, or
jackshaft-type, combustion controls; however, it may be customized for special
applications such as parallel positioning or alternate fuel firing. A complete system
includes oxygen and firing rate sensors, a control panel which houses the PLC, and
an actuator or VSD system which trims either the fuel or air flow.
FEATURES AND BENEFITS
•
Single unit PLC / HMI with 6” color touchscreen
•
Modular DIN rail mounted I/O - 8 analog inputs, 8 analog outputs, 4 digital
inputs, 4 relay outputs
•
Analog signals are 0-10 VDC, digital inputs are 24 VDC
•
Modbus RTU communication
•
Quick overview of O2 setpoint and actual value
Real time data trending for visual confirmation of system operation
•
•
Displays stack temperature, variable speed drive output, excess air, and fuel
selection
•
•
Uses CB O2 probe, Yokogawa probe, or any 4-20 mA probe
Compatible with natural gas, propane, and #2 oil using the CB O2 probe and
with heavy oils using the Yokogawa probe
•
Password protected operating parameter values
•
12-point setup for up to three fuel curves
•
Independent PID loops for each trim device/fuel
D-50
09-09
Section D
•
Ability to integrate with Base and Intermediate Hawk ICS packages
•
Active and historical alarms
•
Flash card available for data logging
PRODUCT OFFERING
Basic configurations:
The Accu-Trim system can be supplied for either fuel trim or air trim in the following
configurations:
•
•
•
•
Fuel trim - electric actuators only
Fuel trim - pneumatic actuators only
Fuel trim - electric and pneumatic actuators combined
Air trim with VSD
Analyzer:
Yokogawa integrated type Zirconia oxygen analyzer
OR
Cleaver-Brooks model oxygen analyzer
Controller:
• Integrated PLC/touchscreen HMI
• Discrete input/output module
• Analog input module
• Analog output module
Actuators:
Electric, pneumatic, or combination
Options:
O2 process value retransmission
ENGINEERING DATA
Electrical
120 VAC, 60 Hz, or 110 VAC 50 Hz 6 Amp 3-wire
grounded system.
Environmental
Temperature:
Control Panel 32-122 °F
Firing Rate Sensor 0-180 °F
Air Supply (For
pneumatic actuators only)
25-125 PSIG, 2 SCFM
CLEAN, DRY instrument quality air
Oil content 1 ppm maximum
Dew point 35 °F or less at line pressure.
D-51
09-09
Section D
Sample Specifications
Accu-Trim
PART 1 GENERAL
1.1
PART 2 PRODUCTS
2.1
GENERAL
A. This specification covers the hardware and control of the C-B AccuTrim O2 Trim System. The system adjusts the fuel-to-air ratio in
order to maintain maximum efficiency and features reliable
monitoring and control of oxygen concentrations.
B. The system shall be completely configured from factory, requiring
only job-specific data to be entered (or modified) in the field.
Controller/analyzer shall be shipped with “default” values and have
a limit on the range of adjustments where applicable.
C. Oil fuel trim available on integral head boiler applications only.
HARDWARE
A. Analyzer - choose one of the following:
Yokogawa integrated type Zirconia oxygen analyzer
OR
Cleaver-Brooks model oxygen analyzer
B.
Actuator – Siemens electric actuator for gas pressure, Controlair or
Bellofram mounted on the oil pressure regulator (system without air
trim via VSD).
C.
Controller
1. Integrated PLC/HMI touchscreen (6” color screen standard)
2. HMI shows bar graph and ‘moving pen’ data value indication
3. Overview of O2 setpoint and process value
4. Display of stack temperature, VSD output, excess air, and fuel
selection
5. 8 Analog Inputs, 8 Analog Outputs
6. 4 Digital Inputs and 4 Relay Outputs
7. Modbus RTU
8. Password protection of operating parameters.
9. Active and historical alarms
Control algorithm shall be PID (Proportional, Integral, and Derivative) type.
Proportional action shall be applied to the process variable and not to the deviation.
PV (Process Variable) is oxygen concentration in flue gases. This is a 4-20 mA or
0-10 VDC signal from the oxygen analyzer. The O2 input is scaled from 0 to 25%
O2. When analyzer is not measuring O2 in flue gas (warm-up, calibration, fault)
control output shall be at 50%. The oxygen setpoint shall be based on the burner
firing rate. Set point curve shall have 12 adjustable break points. The setpoint
shall have independent settings for up to 3 fuels.
•
Systems with Fuel Trim - Correction to the fuel air ratio is accomplished by
changing fuel pressure. In the case of natural gas this is done via an
D-52
09-09
Section D
electric or pneumatic actuator mounted on the gas pressure regulator. In the
case of oil fuel, this is done by applying air pressure to the top side of the
PRV diaphragm.
•
Systems with Air Trim - Applying adjustment to the calculated combustion
air blower speed performs the correction to the fuel-air ratio.
2.2
APPLICATION
This system is intended for use on a Cleaver-Brooks boiler or burner with single
point positioning, or jackshaft-type, combustion controls; however, it may be
customized for special applications such as parallel positioning or alternate fuel
firing. System is compatible with natural gas, propane, and #2 oil using the CB O2
probe and with heavy oils using the Yokogawa probe.
D-53
09-09
Section D
D-54
09-09
Section D
CB-HAWK ICS ADAC ADVANCED DEAERATOR CONTROL
The CB ADAC Advanced Deaerator Control provides a PLC based control system for
a deaerator, surge tank, two tank deaerator-and-surge, or Duo-tank installations.
The system is capable of controlling operation of boiler feed and/or transfer pumps,
maintaining tank levels, monitoring and responding to system demands, and
recording/annunciating alarm conditions.
The ADAC can run as a stand-alone system or tie into a CB-HAWK ICS Master Panel
or customer building automation system.
FEATURES AND BENEFITS
Standard Features:
•
Integration of various deaerator and surge tank devices in a common control
system
•
Touch screen graphical Human Machine Interface (HMI)
•
Deaerator and surge tank water level modulating controls
•
Chemical feed pump control
•
Boiler feed pump control - up to 6 pumps via variable speed drive, soft starters,
combination starters, or contactors
•
Surge tank feed pump control (transfer pumps) - up to 3 pumps
•
Pump alternating, lead/lag, and automatic rotation
•
Serial, Ethernet, BAS, web server communications capability
•
Control of remote devices (valves, etc.)
•
Alarm/fault annunciation and history with audible alarm
•
Red/Yellow/Green stack light for visual status indication
•
Cumulative pump run time totals for maintenance purposes
Optional Features:
•
10” PanelView in lieu of 6” (10” is standard on two tank systems)
•
Dial-up paging modem (selecting this option and Ethernet communication
requires Ethernet PanelView and 5 port Ethernet hub)
•
Alarm bell, horn, or electric sounder
•
GEMS Mini Sure Site level indicator with 4-20 mA transmitter or discrete level
switches
•
Steam or water flow transmitters
•
Manual hard wired controls for any 4-20 mA controlled valve
•
Siemens motorized make-up valve
•
RSLinx OPC compliant remote monitoring software
•
Recirculation bypass (tank one only)
•
NEMA 4/12 entrance panel
•
NEMA 4x electrical panel
D-55
09-09
Section D
PRODUCT OFFERING
Standard Features, Single Tank System:
•
Compact Logix L32E processor
•
6” color touch screen HMI
•
Stack light
Programming and I/O cards for the following:
•
I/O for 1-6 pumps using contactors, soft starters, or combination starters
•
Hard wired fixed location level inputs for Hi and Low water alarms
•
Low water pump cutoff audible alarm output
•
Stack light outputs
•
Recirculation bypass output
•
Chemical feed relay
•
Boiler 1-6 ‘Feed Water Required’ inputs
•
Analog inputs for tank pressure, temperature, level, and discharge header
pressure
Optional Features, Single Tank System:
NOTE: Options must be selected in order; each option requires all of the preceding
ones.
Option 1
Feedwater make up valve analog output
Option 2
1-6 pump proving flow switch inputs
Option 3
Single tank system emergency make up valve
Option 4
1-3 VSD driven pumps I/O
Option 5
4-6 VSD driven pumps I/O
Option 6
1-6 feed pump (1 pump per boiler) VSD driven pump analog inputs
Standard Features, Duo Tank or DA-and-Surge System:
•
Compact Logix L32E processor
•
10” color touch screen HMI
•
Stack light
Programming and I/O cards for the following:
•
I/O for 1-6 boiler feed pumps and 1-3 transfer pumps using contactors, soft
starters, or combination starters
•
Hard wired fixed location level inputs for HI and LO water alarms, and low
water pump cutoff for 2 tanks
•
Audible alarm output
•
Stack light outputs
D-56
09-09
Section D
•
Recirc bypass output
•
Chemical feed relay
•
Boiler 1-6 ‘Feed Water Required’ inputs
•
Pump proving switch inputs for up to 6 feed pumps and 3 transfer pumps
•
DA tank pressure analog input
•
Tank temperature, level, discharge header pressure inputs for 2 tanks
•
1 customer configured analog input (future)
Optional Features, Duo Tank or DA-and-Surge System:
NOTE: Options must be selected in order; each option requires all of the preceding
ones.
Option 1
Feedwater make up valve analog output Tank 2
Option 2
Tank 1 Emergency make up valve analog output for 2 Tank systems
Option 3
Tank 2 Emergency make up valve analog output for 2 Tank systems
Option 4
I/O for 1-3 feed pumps and 1 transfer pump VSD driven
Option 5
I/O for 4-6 feed pumps and 2-3 transfer pump VSD driven
ENGINEERING DATA
•
Supply voltage: 120 VAC (102 VAC - 132 VAC), 50 or 60 Hz
•
Maximum total connected load: 500 VA
•
Operating temperature limits: 32 to 130°F
•
Humidity: 85% relative humidity continuous, non-condensing
•
0.5G continuous vibration
Sample Specifications
CB ADAC Advanced Deaerator Control
PART 1 GENERAL
1.1
GENERAL
A. Each ADAC system shall be factory equipped with a pre-configured
Programmable Controller and Human Machine Interface.
B. System shall provide control logic for the following:
1. 1-6 feed pumps and 1-3 transfer pumps
2. Make up water level control for DA tank or DA and Surge
3. Low Water, Hi Water, and Aux Low Water alarms
4. Chemical feed control
D-57
09-09
Section D
PART 2 PRODUCTS
2.1
STANDARD SYSTEM AND OPTIONS
A. Hardware Platform - Standard System
1. Compact Logix L32E Processor
2. Power Supply
3. Discrete Input Module
4. Discrete Output Module
5. Analog Input Module 4 Channel
6. Analog Input Module 8 Channel
7. Analog Output Module 2 Channel
8. Analog Output Module 8 Channel
9. Right Termination End Cap
10. HMI Display, 6” Serial Color - Standard on single tank systems
11. HMI Display, 10” Serial Color Standard on two tank systems,
optional on single tank systems
B.
Optional Components
1. Remote Access Paging Modem
2. Veris Current Switch - sized for pump
3. Electric actuators for pump water recirculation bypass - sized
for system
4. PowerFlex 70, 400, or 700 Variable Speed Drive
2.2
SENSORS AND TRANSMITTERS
A. Tank level indication
1. Standard
a. DA tank - GEMS Mini Sure Site with transmitter
b. Surge tank - GEMS Mini Sure Site with transmitter
2. Optional
a. DA tank - Differential pressure level transmitter
Rosemount 3051CD
b. Surge tank - Differential pressure level transmitter
Rosemount 3051CD
B. Tank Pressure and Temperature (see table)
Tank Pressure/Temperature Transmitters
Standard
Optional
DA tank pressure transmitter
Setra-256
Rosemount-3051
DA pump discharge pressure transmitter
Setra-256
Rosemount-3051
Surge tank transfer pump pressure transmitter Setra-256
Rosemount-3051
DA tank temperature transmitter
ARI
Rosemount-3144
Surge tank temperature transmitter
ARI
Rosemount-3144
C.
D.
Pump flow proving sensors
1. Pressure switch mounted after each pump or differential
pressure switch across pump. Monitor pump running status
with Veris current switch.
Sierra flow transmitters - sized per application
D-58
09-09
Section D
2.3
VALVES
A. Make-up water valves - all sized per application
1. DA tank make-up valve - Siemens SK electronic actuator with
optional 3 valve bypass and strainer
2. DA tank emergency or raw water make-up valve - Siemens SK
electronic actuator with optional 3 valve bypass and strainer
3. Surge tank make-up valve - Siemens SK electronic actuator
with optional 3 valve bypass and strainer
2.4
PUMPS
A. Feed water pumps - Grundfos
B. Transfer pumps - Grundfos
2.5
SOFTWARE DEVELOPMENT PLATFORM
(software not required - for informational purposes only)
A.
B.
C.
D.
2.6
RSLogix 5000 (controller logic programming)
Allen-Bradley Panel Builder (HMI programming)
RSView32 (control room display and data acquisition)
RSLinx OEM version (OPC server - Building Automation System)
MAJOR FUNCTIONS THAT THE ADAC SYSTEM SHALL PROVIDE:
(controller functions based on customer configuration and purchase of options)
A.
B.
Feed water pump control
1. System will be able to support up to 6 pumps, selected using
the HMI (no PC or additional software required). Upon
selection, graphics and control logic will be activated
automatically.
2. Pumps may be part of a common header or may feed individual
boilers. If part of a common header pumps may be configured
to operate in a lead/lag sequence based on system demand.
3. Order of pump alternation can be automatically rotated to share
running time and wear equally between pumps.
4. For a common boiler feedwater pump discharge system, PLC
monitors 4-20 mA pressure/flow signal from boiler feedwater
header to determine when to command pumps to start/stop. In
a VSD system the 4-20 mA pressure/flow signal will determine
VSD output.
5. If the pumps are feeding individual boilers, pumps will be
turned on/off based on individual boiler feed water pressure
(when using VSDs) or discrete 110 VAC signals from each
boiler.
6. PLC/VSDs can only control pumps that are in AUTO mode.
Pumps in manual will run continuously. The hard wired Aux
Low Water pump cutoff will prevent pumps from running in any
mode if water level drops below set point.
Transfer pump control
1. System will be able to support up to 3 pumps for transferring
water from the Surge tank to the DA. Pumps are selected using
the HMI; no PC or additional software required. Upon
selection, graphics and control logic will be activated
automatically.
D-59
09-09
Section D
2.
C.
D.
E.
F.
Pumps may be configured to operate in a lead/lag sequence
based on system demand. In addition, order of pump
alternation can be automatically rotated to share running time
and wear equally between pumps.
DA make-up water level control
1. The lead pump runs continuously. If DA tank level falls below
set point, make up valve is already fully open, and condensate
tank discharge pressure falls below set point, the PLC will
command the lag pump to start.
2. When surge tank discharge pressure falls below set point, the
PLC will sound an alarm. Operator must respond to the alarm
condition and reset the alarm.
3. When level control is in manual mode, the make up valve can
be opened or closed from the HMI screen, or optionally by a
manual potentiometer. Either method will allow the operator to
manually adjust the valve between fully open and fully closed
to control the incoming flow of make up water.
Surge tank make up water level control
1. The PLC receives a 4-20 mA signal indicating surge tank water
level. Signal is compared to the operator input set point and
valve modulates accordingly to control the incoming flow of
make-up water.
2. When the valve is in manual mode the HMI or optional manual
potentiometers will allow the operator to manually adjust the
valve between fully open and fully closed.
Pump Lead/Lag and Alternating Control
1. Selection of pumps and rotation schedule are configurable
from the HMI. PLC will monitor all pumps and determine
availability; pumps may be taken out of rotation for
maintenance.
2. When system is in auto rotation, if a pump is not available the
PLC will alternate to the next available one. If no pumps are
available an alarm will sound, requiring manual reset. PLC will
maintain equal run time between all pumps.
3. If Lead/Lag option is selected, pump start/stop set points are
set from the HMI. Start point is based on percentage of set
point achieved by previous pump in sequence. PLC internal
timers will maintain minimum load fluctuations.
4. If Lead/Lag and VSD options are selected, VSD% to start/stop
lag pump is set from the HMI. When lag function is activated,
VSDs function in unison modulation until the speed reaches
VSD stop point; then lag pump shuts off.
5. When pump alternation is selected, alternation schedule is
configured from the HMI. When current pump run time is met,
next pump will start and come up to speed; previous pump will
then stop.
Chemical Feed Control
1. One set of dry contacts wired to terminal blocks will be
provided to change state when any boiler feed pump is
D-60
09-09
Section D
running, enabling customer chemical feed pump.
2.7
ADDITIONAL ADAC SYSTEM FUNCTIONS:
A. A pressure sensor mounted in steam space monitors Deaerator
pressure.
B. A set of contacts on each pump’s overload relay provides indication
of pump failure. If VSDs or soft starters are used, a fault contact is
monitored by the PLC to indicate pump failure.
C. A set of contacts on each pump starter indicates pump running. If
VSDs or soft starters are used, a contact is monitored by the PLC to
indicate run status.
D. A selector switch is mounted at each pump starter to allow HandOff-Auto switching. ‘Hand’ ignores all external signals except Aux
Low Water Cutoff, ‘Off’ ignores all signals and prevents pump from
running, ‘Auto’ allows pump to run based on commands from the
PLC.
2.8
ALARM FEATURES
A. DA Tank water level alarms
1. Low Water — If water level as indicated by the tank level
device falls to a pre-set point, the PLC will sound an alarm,
display a message on the HMI, log a message to the alarm
history file, and turn on the appropriate stack light.
2. Low Low Water — If water level falls further to the pre-set Low
Low Water point, the PLC will sound an alarm, display a
message on the HMI, log a message to the alarm history file,
and turn on the appropriate stack light.
3. Hi Water — If water level as indicated by the tank level device
rises to a pre-set point, the PLC will sound an alarm, display a
message on the HMI, log a message to the alarm history file,
and turn on the appropriate stack light.
4. Aux Low Water — If water level falls to the pre-set Aux Low
Water point, the hard wired Aux Low Water device will open,
signalling the PLC and shutting down all pumps for that tank.
The PLC will sound an alarm, display a message on the HMI,
log a message to the alarm history file, and turn on the
appropriate stack light.
B. Surge Tank water level alarms (same as above)
2.9
ADAC COMMUNICATION OPTIONS
A. Ethernet connectivity
1. PLC features an OPC compliant Ethernet/IP port for connection
to a Building/Plant Automation System or Local Area Network.
2. Remote monitoring/data logging available using RSView
software.
3. Connection to CB HAWK ICS Master Panel (Note: Existing
Master Panels would require a program upgrade and possibly
a processor upgrade to use this option).
4. Compliance with IEEE 802.3 Physical and Data Link, TCP/IP
protocol, and Control and Information Protocol (CIP) standards.
D-61
09-09
Section D
B.
Other communication options
1. Communication to most major building management system
interfaces such as Johnson Controls Metasys, ASHRAE
Bacnet, LON, and Siemens will be available via a CleaverBrooks protocol translator bridge. Check with Cleaver-Brooks
for specific information.
2. Data can be transferred by Ethernet through a CB Master Panel
to a customer BAS. If a Master Panel is unavailable, the
protocol translator can be configured to communicate directly
between the ADAC and the customer BAS.
D-62
09-09
Section D
CB LCS-150E LEVEL CONTROL SYSTEM
The Cleaver-Brooks LCS-150E Level Control System utilizes a level transmitter and
a programmable controller to control water level and water level alarms. System
includes modulating make-up valve with user-selectable manual or automatic
control.
FEATURES AND BENEFITS
Standard Features
•
Programmable controller with display
•
Set points, alarm points, transmitter span, and PI controls configurable using
controller keypad
•
Manual or automatic control of make-up valve
•
Easy-to-read level indication
•
No sight glass - water is contained in a pressure-tight housing
PRODUCT OFFERING
The following are included as standard in each LCS-150E control system:
•
Programmable controller
•
Controller display with keypad
•
I/O module
•
Level sensor and transmitter
•
Modulating feed water valve and actuator
•
Alarm horn and silence button
•
High, Low, and Low Water Cut-Off alarm lights
ENGINEERING DATA
•
Supply voltage 120 VAC
•
Max load 3 amps
•
Ambient temperature range 32 - 130 deg F
•
Humidity, non condensing 5-95%
•
Degree of protection
-
Display/keypad: IP65, Type 3R, Type 12R
Panel Nema 4/12
Lights and switches IP66
Level indicator / transmitter Nema 4
Siemens valve Nema 1; optional weather shield will change it to Nema 3R
D-63
09-09
Section D
Sample Specifications
CB LCS-150E Level Control System
PART 1 GENERAL
1.1
GENERAL
A. Each LCS-150E system shall be factory equipped with controller
including display and I/O, NEMA 12 cabinet, and GEMS magnetic
level sensor with transmitter.
B. System shall provide the following functions:
1. Adjustable transmitter span
2. Adjustable water level set point
3. Adjustable high water alarm point (with differential)
4. Adjustable low water alarm point (with differential)
5. Adjustable low water cutoff point (with differential)
6. Adjustable P and I (proportional and integral gain) parameters
7. Manual or automatic make-up valve operation
8. On-screen alarm indication and relay outputs for high water,
low water, low water cutoff, and general alarms
9. Alarm Silence input
PART 2 PRODUCTS
2.1
STANDARD SYSTEM
A. Hardware Platform
1. Pico GFX Controller with backlit graphic display
2. Power Supply 115VA/24VDC 30 Watts
3. I/O module:
(12) 24VDC inputs
(4) relay outputs
(1) 0-10 VDC analog output for make-up valve
(1) 0-10 VDC input for level transmitter
B.
C.
D.
Level sensor and transmitter
1. GEMS Mini Sure Site magnetic level indicator
2. Level transmitter 4-20 mA
Make-up valve
1. Siemens modulating feed water valve - sized per application
2. Electronic actuator 0-10 VDC
Alarms
1. Panel mounted alarm horn
2. Alarm silence switch
3. LED alarm lights for High and Low Water and Low Water CutOff
D-64
09-09
Section D
CB-HAWK Compact ICS
The CB-HAWK Compact ICS is a microprocessor based burner management and
single point combustion control system combining the CB120Z burner management
control/boiler controller with a 6” color touchscreen HMI. The CB120Z expands
upon the CB120/120E by adding firing rate control to burner sequencing/flame
supervision functions.
FEATURES AND BENEFITS
Standard Features:
•
6” color touchscreen HMI
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Configurable overview screens
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Solid state sensing of steam and water demand
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Operating control functions for start/stop of boiler operating sequence
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Full modulation control of fuel and combustion air
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Solid state sensor inputs for steam pressure, water temperature, stack
temperature, boiler water temperature, outdoor temperature
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Hot standby
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Day/night setback
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Cold start thermal protection
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Programmable maximum high fire position (limits boiler firing rate)
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Auto/Manual control with bumpless transfer
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Lead/Lag for two or three boilers
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Alarm history, data logging, and trending
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E-mail capability
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Password protection of system configuration, auto/manual functions
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Optional Features:
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Protocol translator for Modbus, Bacnet IP and Ethernet, Johnson Metasys
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Remote monitoring
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Internet web server
PRODUCT OFFERING
CB120Z:
• Chassis with corresponding flame amplifier
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Plug-in programmer module
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Wiring base
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UV, IR, or UV self-check flame scanner
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Pressure (temperature) transducer
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Communicates with HMI by Modbus
HMI:
• 2 line, 16 character, 4 button display
Misc.:
• Additional equipment includes cable, 24VDC power supply, fuse, and DIN rail
mounted fuse holder
ENGINEERING DATA
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Supply voltage: 120 VAC (+10%/-15%) 50 or 60 Hz.
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Power consumption: 25 VA
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Operating temperature limits: -40°F to 130°F
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Pressure sensors: 0-15, 0-30, 0-200, or 0-300 psig
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Temperature sensors: RTD type, 32°F-350°F or 32°F-752°F
Sample Specifications
CB-HAWK Compact ICS
PART 1 GENERAL
Burner management control/firing rate control shall be a Cleaver-Brooks Model
CB120Z microprocessor-based burner management control with integrated boiler
control operation. Status, fault history, diagnostic information, and operator
interface shall be provided by a 6” color touchscreen HMI. HMI shall be panel
mounted with 2 line x 16 character, 4 button display allowing access to all CB120Z
functions.
PART 2 PRODUCTS
A. Major system components shall include:
1. Touch screen HMI
2. Integrated burner management control/firing rate controller with wiring subbase
3. One flame scanner: Infrared, Ultraviolet, or UV self-check
4. One flame amplifier, to correspond with the selected scanner
5. Pressure/temperature sensors
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Section D
B. Major functions that the boiler control system shall provide:
1. Automatic sequencing of the boiler through standby, pre-purge, pilot flame
establishing period, main flame establishing period, run, and post-purge
2. Flame proving and lockout on flame failure during pilot proving, main flame
proving, or run
3. Full modulating control of fuel and combustion air
4. Various high and low limit alarms
5. Manual control of boiler firing rate using touchscreen HMI
6. Lockout history
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Section D
CB SysteMAX Hydronic Control System
The CB SysteMAX hydronic system controller is a microprocessor based boiler
sequencing and modulation control. This control is designed for controlling multiple
boilers of different or similar sizes. Additionally it can control and optimize the use of
condensing boilers, non-condensing boilers or hybrid boiler systems that integrate
condensing and non-condensing boilers.
Cleaver-Brooks recognizes the need for new and better controls that allow for greater
flexibility in the configuration of boiler operating parameters to take advantage of
high efficiency boiler designs and system designs. As often is the case, the advances
in system and boiler heat exchanger design have created a greater opportunity for
efficiency savings in hydronic heating systems. Further, we recognize that future
advances will require increased control over thermodynamic processes.
This control system was created with these advances in mind. By using a flow
measuring device along with an outdoor air sensor, system supply and system return
sensors, we have developed a control that is distinctly different from the typical
single or dual temperature sensor control. By allowing and accounting for boilers of
different sizes, we have enabled the system designer to easily include part load
operation of heating equipment into the design. These designs along with a CB
SysteMAX ISD allow the designer to manage a heating load as the control calculates
real time load needs, and using this data, selects and operates the appropriate
boiler or boilers. This approach eliminates the many detrimental effects on efficiency
(boiler and system) and equipment life reduction due to the unnoticed short cycling
of boilers.
The CB SysteMAX ISD control also offers as a main feature the ability to reset and
control both condensing and non condensing boilers within the same heating
system. With two unique and user definable reset temperature slopes, both types of
boilers can be utilized seamlessly. In short, condensing boilers can condense as
designed and non condensing boilers will be protected from the effects of
condensing. This advancement allows the designer the freedom to specify hybrid
boiler systems. These hybrid boiler systems can dramatically decrease fuel usage in
traditionally designed building comfort heating systems at a fraction of initial
equipment and installation costs.
FEATURES AND BENEFITS
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7" LCD full color touch screen Graphical User Interface.
USB port for graphical and code based updates.
Wireless network configuration with 128 bit signal encryption.
Hardwire network back-up.
RTC = Real Time Clock.
User selectable modulation signal, 0 - 10VDC, 4 - 20 mA.
External system enable contact.
External system reset analog input.
Boiler modes are: Auto/Manual/Off/Standby (Auto and Standby based on condensing/
non-condensing priority).
Outdoor Reset: (3) reset slopes; 2 winter, 1 summer.
Summer/Winter modes; summer allows DHW (Domestic Hot Water; future) and reheat.
User defined summer reheat enable and reset.
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DHW priority (future).
DHW supply set-point (future).
DHW priority override (future).
Condensing and non-condensing priority set-point.
Chooses boilers relative to priority of condensing or non-condensing (hybrid system).
Condensing protection program ensures non-condensing boilers see minimum water
return temperatures above 130 F.
Patent pending process calculates Real Time Load (measures supply, return, and
system flow to determine Real Time Load). Modulates boilers based on Real Time Load,
not supply temperature.
Utilizes/selects correct boiler based on base data of the min and max outputs of the
connected boilers in the system.
Intelligent load selection relative to the load required with intelligent load sharing.
Intelligent shutdown; uses load, size, type, priority, hours of operation for shut down of
boilers.
Occupied space set-point utilized in load calculations and predictions.
Controls boiler delta T.
Optimum Stop setback.
Optimum Start Boost.
Warm weather shutdown.
Soft stop.
Boiler minimum inlet temperature (per boiler).
Boiler maximum outlet temperature (per boiler).
Post cycle pump purge based on run time % with max limit (boost to 100%).
Process Acceleration Control for boiler modulation output. Uses boiler manufacturer's
unique product data in Acceleration Control Algorithm for modulation tuning.
Process Acceleration Control for boiler pump modulation output.
System pumps rotation (lead/lag).
Sequential/Parallel/Optimized modulation (boiler run time rotation with respect to size,
type, load, efficiency in range, and hours of operation).
Boiler alarm inputs remove boilers from rotation.
Fixed lead with respect to size, type, and load.
Fixed last with respect to size, type, and load.
Flame activation delay (seconds).
Low fire hold relative to load and occupied space temperatures.
User defined low fire hold with respect to set-point and outdoor conditions.
Event scheduling for occupancy used for start and stop.
Ignition start output percent.
Next stage delay based on user defined output percent.
Standby delay based on boiler failures and time below set-point.
Minimum stage delay at any percentage of boiler output.
Boiler Max. cycle time between one hour and 24 hours.
Damper prove circuits linked to ignition sequence.
Damper prove alarm for damper failure.
3-way valve control.
All points Alarm.
Minimum modulation signal during run cycle.
Internal load predictions based on outdoor air, redundancy factor, and history.
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Section D
ENGINEERING DATA
POWER
Input Voltage……………………..
24 - 130 VAC/DC
ENVIRONMENTAL
Operating Temperature………….
Storage Temperature……………
Relative Humidity…………………..
00 C to 700 C; 320 F to 1580 F
minus 200 C to 700 C; minus 40 F to 1580 F
0 to 95% Non-condensing
GENERAL
Display………………………………
Power Center…………………….
Status Indicators…………………..
LED Backlit 8" TFT LCD aspect (15/9) pixels (800/480)
Interface for navigation and data entry.
On/Off Switch
Red/Amber/Green LED for status. Blue LED blinks
with communication rate.
ENCLOSURES
Rating……………………………….
Construction………………………..
NEMA 1
ABS Plastic
INPUTS
Digital………………………………..
RTD's………………………………..
Flow………………………………….
Boiler Delta T……………………….
Up to 128 power supplied field dry contacts
(3) - return, supply, outdoor air temp. Type II 10K
Thermistors
(1) PFM or 4 - 20 mA
Up to (32) Type II 10K Thermistors or PT1000 RTD
inputs.
OUTPUTS
Contacts…………………………….
Signal………………………………..
Up to (128) SPDT 8A resistive, 1/4 HP
Up to (128) 0 - 10V or 4 - 20 mA standard
SELECTION GUIDE
CB SysteMax Wireless……………….
1 - 16 Boilers, 1 - 16 system pumps, 1 - 16 boiler
secondary pumps, 1 - 16 combustion air or draft
inducer controls.
STANDARD PERIPHERALS
Main System Temperature…………….
Outdoor Air………………………………
Flow………………………………………
(2) Temperature Sensors with wells.
(1) Temperature Sensor w/sunlight shield
(1) Flow device w/2" NPT Hot Tap.
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Section D
SPECIFICATIONS
Sample Specifications
CB SysteMAX Hydronic Control System
PART 1 GENERAL
The CB SysteMAX hydronic system controller is a microprocessor based boiler
sequencing and modulation control. This control is designed for controlling multiple
boilers of different or similar sizes. Additionally it can control and optimize the use
of condensing boilers, non-condensing boilers or hybrid boiler systems that
integrate condensing and non-condensing boilers.
PART 2 PRODUCTS
The boiler room system control shall consist of a Master Panel, to be located within
the mechanical equipment room, (3) thermistors for outside air, supply water
temperature, return water temperature, and a water flow measuring device.
The thermistors and flow device shall be field wired to a System Intelligence
Device (SID).
Each boiler within the heating system shall be equipped with a Boiler I/O Module
(BIM; up to 16 boilers on a single Master Panel). Each BIM shall be hard wired into
the boiler control circuit and mounted in a suitable location, preferably on the boiler
control panel.
If system pumps are to be controlled by the Master Panel, then an Auxiliary I/O
Module (AIM) shall be provided (up to two pumps per AIM), and field wired by the
installing contractor. Additionally, if fresh air dampers are to be interlocked with the
Master Panel, an AIM shall be installed (up to two damper drives per AIM) and field
hard-wired to the specific device.
The Master Panel shall include a high resolution (800 x 480 pixels) seven inch,
graphical touch screen interface. The touch screen shall be LED backlit and shall be
wide-screen format (15 x 9).
Through the use of the graphical user interface, the Master Panel shall provide all
functionality required for parameterization of the entire network and shall transmit
data wirelessly to the I/O modules for local storage or as an option may be
hardwired and communicate via the Live Fire ConnectTM communication protocol.
The Master Panel shall include the following:
USB Port for on screen "mouse" interaction with Graphical User Interface.
USB Port for updating/upgrading to new levels of functionality and interactivity.
Determination of all on/off states of equipment, all output rates of equipment and
communicate that data to the individual I/O devices wirelessly for the purpose of
boiler room control and heating operations.
All wireless communication shall be protected from other wireless signals through
the use of 128 bit encryption.
Switch to shutdown all wireless communication.
Alarm Output for notification of a boiler failure.
Capability of individually controlling up to sixteen boiler secondary pumps, with
timing off delays for post on cycle purge.
Capability to individually operate up to sixteen main system or zone pumps.
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(System pumps can be individually identified as on, off, or lead lag.
Capability of individually operating up to sixteen combustion make-up air dampers,
mechanical combustion air make-up enable circuits, or mechanical draft enable
circuits, linked to the firing sequence of the boiler for which it operates.
Input/Output (I/O) Devices shall include:
Two single pole double throw output contacts rated for 8 amps @ 120 VAC.
Operation at 22 - 130 VAC/DC on the same power input post. The power supply on
board both devices shall recognize the power provided and transform appropriately
for printed circuit operation.
Each boiler I/O module shall be factory configured for the purpose of optimum boiler
operation and error free network parameterization.
Each boiler I/O module shall, when enabled, contact the Master Panel and
automatically parameterize the network with all necessary information on proper
boiler selection, operation, and modulation based on the boiler’s model number.
Each I/O module shall individually communicate confirmation of on/off status,
output rate status, and alarm status to the Master Panel for the purpose of boiler
room control and heating operations.
Each I/O module shall have a physical switch capable of shutting down all wireless
transmissions.
PART 3 EXECUTION
Functionality
The boiler controller shall be capable to individually operate between one (1) and
sixteen (16) boilers with full modulation burners, on/off burners, or two stage (high
low) burners. When a fixed firing rate (on/off) boiler is enabled, the controller shall
account for this occurrence by assigning the entire load in MBH required to meet the
rated output of the boiler to that boiler. The balance of the load, if any, will then be
assigned to either two stage or modulating boilers in the system. The control shall
have the capability of selectable parallel sequential modulation, and shall provide
parallel modulation at any percentage of rated output.
The boiler controller shall be enabled on outdoor air and via contact closure,
indicating a call for heat, enable one of three resets for supply temperature; two (2)
for winter operation, one (1) for summer operation, allowing changes in building
loop temperature based on outdoor air. A warm weather shut down option shall be
included.
The boiler controller shall have the capability of individually controlling up to sixteen
(16) boiler output temperatures; the target output temperatures for each boiler can
differ one from the other.
The boiler controller shall have the capability of choosing any boiler on the network
for operation according to outdoor air temperature, Real Time Load, load
predictions, alarm status, minimum output rating, maximum output rating,
minimum return temperature, maximum outlet temperature, condensing, noncondensing, winter priority, standby status, hot water priority, efficiency in a given
range, and hours of operation.
The boiler controller shall have the capability of calculating the required heating
load utilizing supply water temperature, return water temperature, and water flow
rate of the main supply header. Based on the load requirement, the control shall
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assign all or part of any load to a condensing or non-condensing boiler at any
outdoor temperature, as required to meet the needs of the system, boiler, and the
building. It shall have the capability of overcoming burner output rate tuning issues
in order to meet the building load.
The boiler controller shall have the capability of determining individual minimum
return temperatures for the operation of non-condensing boilers according to the
manufacturers published guidelines. It shall be able to overcome minimum return
temperature errors by increasing boiler output or increasing system supply water
setpoint temperature or both. The control shall also have the capability of
determining individual maximum output temperatures for each system boiler
according to the manufacturers published guidelines.
The control shall be equipped to read both the inlet and outlet temperature of each
boiler on the system.
The control shall have the capability to control both boiler inlet temperature and
outlet temperature differential (Delta T) of each boiler by sending a modulating
signal to a customer supplied pump and appropriately sized frequency drive for this
purpose. The control shall adapt to temperature overshoot above the maximum
outlet temperature by assigning part of the load to another boiler during boiler delta
T operations. As the outlet temperature of a boiler approaches maximum
temperature, the boiler controller shall be able to respond by increasing the output
signal to the frequency drive attached to the boiler pump in order to reduce boiler
delta T and maintain compliance with the manufacturer's published maximum
boiler outlet temperature.
The boiler controller shall have the capability of an adjustable night and weekend
optimum stop/setback of building supply loop temperature. The optimum stop
shall allow a gradual setback beginning in advance of unoccupied times through the
use of customer input data and collected data.
The control shall have the capability of pre-occupancy system temperature
optimum start return and system boost. The optimum start shall allow a gradual
return and boost from setback beginning in advance of occupied times through the
use of customer input data and collected data. The control shall gradually ramp
down loading of boilers from boost setpoint operations.
The boiler controller shall utilize patent pending Live Fire ConnectTM "Load
Acceleration Control Algorithm" in meeting heating load through an analog signal to
the boilers which in turn affect the outputs of the selected boilers.
The boiler controller shall have the capability of a user definable summer reheat
mode, reset loop temperature based on outdoor air.
The boiler controller shall have a user definable low fire hold (1 - 60 minutes) time
period based on a system differential temperature during low load demands. The
controller shall determine if the building is warming up fast enough and if it is,
delay release of the boiler to modulation by maintaining low fire to increase
efficiency of operation.
The boiler controller shall have freeze protection programming that will overcome
heat being disabled in order to protect the building equipment and boilers from the
effects of freezing.
The boiler controller shall have the capability for individual boiler alarm inputs that
will ascertain if a boiler is available for operational rotation and shall share this
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Section D
information with the network traffic, either wirelessly or as an option, hard wired.
Field Parameterization
It shall be the boiler manufacturer's authorized field service representation
responsibility to ensure that all I/O modules are field programmed for the specific
heating load application. Each I/O module will be tested to ensure system network
functionality and interface functionality of the Master Panel and temperature sensors
and flow modules that interface with the Administrator. The field service
representative shall demonstrate the functionality to the authorized boiler operator
and or owner, and demonstrate the method needed to obtain data information.
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