CB HAWK ICS BOILER MANAGEMENT CONTROL SYSTEM by pharmphresh28

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                    CB-HAWK ICS BOILER MANAGEMENT
                           CONTROL SYSTEM
The CB-HAWK ICS is a state-of-the-art boiler control system          • Assured low fire cut-off
that integrates the functions of a Programmable Controller and
                                                                     • Assured Start Permissive Safety Interlocking
Burner Management Controller, as well as other boiler
operating and ancillary controls. The CB-HAWK ICS system             • High Stack Temperature Alarm and Shutdown
incorporates a graphical Human Machine Interface (HMI),
                                                                     • Boiler Efficiency Calculations
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                   Optional Features:
complete boiler firing rate controls for steam or hot water          • Color Graphical HMI
boilers. The CB-HAWK ICS’s advanced technology features
utilize the latest communication methods, such as DeviceNet™,        • E-Mail and Pager Alarm/Fault Forwarding
Ethernet, and the Internet. The CB-HAWK ICS also has the             • Fuel-Air Ratio Control
capability of interfacing with various Building/Plant
Automation Systems. Additional features include lead/lag             • Building/Plant Automation System Interface
capability; e-mailing and paging of alarms, remote monitoring,       • Remote Internet Monitoring and Diagnostics
and HMI alarm history printing.
                                                                     • O2 Monitoring and Trim
The CB-HAWK ICS Integrated Control System may be used
on most types of steam or hot water boilers, including firetube,     • Internet Parts and Service Lookup
industrial watertube, and commercial watertube. It is designed       • Built-in two boiler lead/lag control
to operate with a gas, oil, or combination burner using a single-
point modulating control or a parallel-positioning fuel-air ratio    • Lead/Lag Capability for Multiple Boiler Systems
control system.                                                      • Variable Speed Drive on Combustion Air Fan
In addition to installation on new boilers, the CB-HAWK ICS          • Diagnostic Annunciator
can be added as a retrofit to existing boilers. Contact your local
authorized Cleaver-Brooks representative for details.                Safety Provisions and Diagnostics:
                                                                     A. Integrated Burner Management
KEY FEATURES AND BENEFITS
                                                                     • Utilizes the CB780 or CB100E Flame Safety Control
Advanced Technology
                                                                     • Communicates with the Programmable Controller via
Standard Features:                                                     DeviceNet™
• Integrates control function of burner sequencing and safety        • Burner Control Status, Faults, and Diagnostics displayed on
  with firing rate, fuel-air ratio, and operating limit controls       HMI
• Incorporates a Programmable Controller                             B. Integrated Boiler Controls
• Touch Screen Graphical Human Machine Interface (HMI)               • Operating and Modulating Controls
• Monitors and Displays Connected Boiler Parameters                  • Primary Low Water Cut-Off
• Optimizes Boiler Firing Rate Control                               • Variable Speed Drive fault shutdown – communicates via
• Alarm/Fault Indication and History                                   DeviceNet™ (optional)

• On-Screen Fault Diagnostics                                        • Password protection of Programmable Controller Logic

• Night/Day Setback Control                                          • Password protection of Parallel Positioning Control
                                                                       (optional)
• Thermal Shock Protection
• Remote Modulation
• Remote Setpoint



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Powerful Display/Diagnostic Capabilities:                          PRODUCT OFFERING
• Touch Screen Graphical Human Machine Interface (HMI).
  Color (optional).                                                Included in each CB-HAWK ICS system is the following:
• HMI allows easy screen navigation to monitor various boiler      • Programmable Controller
  parameters & diagnostics and to configure boiler controls.
                                                                   • Touch Screen HMI
• Displays alarms/faults, burner status, and flame signal from
                                                                   • DeviceNet™ Communication Network
  the Flame Safety Control.
                                                                   • Various Controller Input/Output Modules
• Diagnostics in plain English and prioritized fault
  annunciation simplify troubleshooting.                           • Flame Safety Controller
• Displays Boiler Steam Pressure, Water Temperature, Firing        • Various Temperature and Pressure Sensors
  Rate, Stack Temperature, Boiler Efficiency, Combustion Air
  Temperature (optional), Flue Gas O2 Concentration                Optional Features and Equipment: (see individual specifica-
  (optional), Combustion Air Fan Motor Speed and kW (VSD           tions for these options)
  option), Combustion Air Pressure (with VSD option), Water
  Level (CB-Level Master option), Shell Water Temperature          • Ethernet/IP Module to provide communication between the
  (Steam Boilers), and other control points.                         Programmable Controller and other Ethernet compatible
                                                                     devices
• Displays Boiler Operating Status (e.g. “Warm Up”, “Auto/
  Manual”, “Boiler On”, fuel selection, etc.).                     • OPC Server software for interface with Building/Plant
                                                                     Automation System
• Displays Boiler Firing Rate control parameters and settings.
                                                                   • Lead/Lag Control of Multiple Boilers
• Provides Remote Monitoring and Diagnostic capabilities via
  the Internet or Modem (optional).                                • Fuel-Air Ratio Control System and Actuators
                                                                   • Variable Speed Drive for Combustion Air Fan Motor
• Provides E-mail Forwarding and Paging of Alarm/Fault
  Codes (optional).                                                • O2 Analyzer and/or External O2 Trim System
• Touch Screen controls simplify screen navigation and boiler      • Combustion Air Temperature Sensor
  configuration
                                                                   • Economizer Stack Flue Gas Temperature, Feed Water
• Reliable and accurate controls using microprocessor-based          Temperature, Oil Temperature, and Gas & Oil Pressure
  programming                                                        Sensors
                                                                   • Steam, Water, and Fuel Flow Monitoring
Simplified Servicing:
                                                                   • CB-Level Master primary safety water level control
• Diagnostics and fault history, up to 100 faults, through touch
  screen display simplifies troubleshooting procedures             • Internet Web Site Monitoring Package
• E-Mail Forwarding and Paging of System Fault Codes when          • Paging and Remote Dial-Up Access with Modem
  applicable (optional)                                              communication
• Connection to user Building Automation System when               • E-mailing with Ethernet/IP option
  applicable (optional)




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ENGINEERING DATA                                                    • Thermal Shock Protection based on water temperature
                                                                      and setpoint
Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz.
                                                                    • Various High and Low limit alarms and shutdowns
Maximum total connected load: 2000 VA
                                                                • Touch Screen graphical operator interface and monitoring
Operating temperature limits: 32 to 130°F
                                                                    • Manual control of the boiler-firing rate utilizing control
85% RH continuous, non-condensing, humidity                           screens on the HMI to increment and decrement the
0.5G continuous vibration                                             firing rate
                                                                    • On screen indication of burner management controller
SAMPLE SPECIFICATIONS                                                 status and diagnostics

1.0 Each unit shall be factory equipped with a Boiler Control       • On screen real-time display of all connected process
System providing technology and functions equal to the                parameters
CB-HAWK ICS Boiler Control system.                                  • On screen display of system alarms and faults
2.0 Each Boiler Control System shall be factory equipped with       • On screen history of alarms and faults
a pre-configured Programmable Controller and Human
Machine Interface (HMI).                                            • On screen recommendation for troubleshooting fault
                                                                      conditions
3.0 Major system components shall include:
                                                                    • On screen water level indication (optional) and alarm(s)
• Programmable Controller
                                                                    • Printing Alarm/Fault history
• Touch Screen HMI
                                                                • E-Mail or Paging of boiler alarms (with either Ethernet/IP or
• DeviceNet™ Communication Network                                Modem Option)
• Various Controller Input/Output Modules                       • Building/Plant Automation System interface (with Ethernet/
• One Burner Management Controller and Wiring Sub-Base            IP Option)

• One Flame Scanner: Infrared, Ultra-Violet, or UV              • Ethernet and Internet communications (with Ethernet/IP
  Self-Check                                                      Option)

• One Flame Amplifier, to correspond with the selected Flame    • Tamper resistant control logic and password protection.
  Scanner                                                       • Night/Day Setback control
• Various Temperature and Pressure Sensors                      • Stack Flue Gas, Combustion Air (optional), and Shell (water)
4.0 Major functions that the Boiler Control System shall          temperatures
provide:                                                        • Boiler Efficiency calculation
• Automatic sequencing of the boiler through standby,           • Outdoor Reset for Hot Water Boilers
  pre-purge, pilot flame establishing period, main flame
  establishing period, run and post purge                       • Remote Modulation or Firing Rate Setpoint control

• Flame proving and lockout on flame failure during pilot       • Assured Low Fire Cut-Off (ALFCO)
  flame proving, main flame proving, or run                     • Assured Start Permissive Safety Interlocking
• Low fire damper/valve position for flame ignition trials
• Full modulating control of fuel and combustion air
• Utilize solid state controls and sensors to provide various
  control functions, such as:
    • On/Off, and Modulating Control
    • Modulating Control algorithm shall be Proportional-
      Integral-Derivative (PID) type




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5.0 The Boiler Control System shall provide the following              • English text description of the system fault and
safety provisions for:                                                   troubleshooting procedures
A. Integrated Burner Management                                        • Water Level indication and low water Shutdown Alarm
      • Examine all load terminals to assure it is capable of          • Dynamic Self Checking
        recognizing the true status of the external controls, limits
                                                                       7.0 The Boiler Control System shall be able to operate in these
        and interlocks. If any input fails this test, the burner
                                                                       environmental conditions.
        management system should lockout on safety shutdown.
                                                                       • Supply Voltage: 120 VAC (+10%/-15%) 50 or 60 Hz
      • Closed-loop logic test verifies integrity of safety critical
        loads (ignition, pilot, and main fuel valves) and must be      • Maximum total connected load: 2000 VA
        able to lockout on safety.
                                                                       • Operating temperature limits: 32 to 130°F
      • Pre-ignition interlocks (fuel valve proof of closure, etc.)
                                                                       • 85% RH continuous, non-condensing, humidity
        and flame signal checked during Standby and Pre-Purge.
                                                                       • 0.5G continuous vibration
      • Dynamic checking of the flame signal amplifier. The
        control flame signal amplifier must be able to recognize       8.0 All Boiler Control System wiring shall be in accordance
        a no flame signal during this dynamic amplifier check.         with the National Electrical Codes and local electrical codes.
      • Safe start check and expand check to include monitoring        9.0 Boiler Control System component functions shall be as
        flame signal during standby.                                   follows:
      • High and Low fire switches checked for proper                  • Burner Management Controller: Provides boiler sequencing
        sequencing.                                                      logic to meet FM/IRI/UL/cUL approval body requirements.
      • Tamper-proof Purge Timing and safety logic.                    • Touch Screen Graphical Interface: Provides user interface to
                                                                         the control system, boiler overview screen with connected
B. Integrated Boiler Controls
                                                                         boiler parameter readouts, Burner Management Control
      • Operating and Modulating Control                                 status screen, alarm banners, diagnostic screens for fault
                                                                         troubleshooting, alarm history screen, system firing rate
      • Primary Low Water Cut-Off
                                                                         screen and system configuration screens.
      • Variable Speed Drive (if used) fault shutdown
                                                                       • DeviceNet™ Communication Network: Provides
      • Password protection of Programmable Controller Logic             communication between the Programmable Controller and
                                                                         other peripheral devices.
      • Password protection of Parallel Positioning Control
        (if used)                                                      • Various Programmable Controller Input/Output modules:
                                                                         Provides interface for discrete powered and/or isolated relay
6.0 The Boiler Control System shall provide annunciation and
                                                                         signals, as well as for analog signals, from and/or to other
diagnostics:
                                                                         input/output devices.
• Active alarm annunciation
                                                                       • Stack Temperature Sensor: Measures and transmits a signal
• Provide historical alarm information for on screen display             to the Programmable Controller in relation to boiler exit flue
                                                                         gas temperature. It is used for indication and in the
• Detects and isolates an alarm, and reports internal circuit
                                                                         calculation of boiler efficiency; it can also be used for high
  faults
                                                                         stack temperature alarm and shutdown.
• Printer output capable for logging alarms
                                                                       • Steam Pressure Transmitter (Steam Boiler): Provides an
• Capability of printing alarm history of date, time, cycle of           analog signal to the Programmable Controller for indication
  occurrence and date and time of acknowledgement up to the              of boiler steam pressure; utilized for on/off and modulating
  most recent 100 faults                                                 control of the burner.




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• Water Temperature Transmitter (Hot Water Boilers):            • O2 Analyzer and/or External O2 Trim System
  Provides an analog signal to the Programmable Controller
                                                                • Combustion Air Temperature Sensor: Measures and
  for indication of boiler water temperature; utilized for
                                                                  transmits a signal to the Programmable Controller in relation
  thermal shock protection, on/off, and modulating control of
                                                                  to the combustion inlet temperature for indication and for use
  the burner.
                                                                  in the calculation of boiler efficiency; also can be used for
• Water (shell) Temperature Sensor: Measures and transmits a      high combustion air temperature alarm and shutdown, based
  signal to the Programmable Controller in relation to boiler     on setpoint
  water temperature; used for indication and thermal shock
                                                                • Economizer Flue Gas Inlet and Outlet Temperatures, Feed
  protection.
                                                                  Water Temperature, Oil Temperature, and Gas & Oil
10.0 Optional Equipment (see individual data sheets for these     Pressure Sensors
options)
                                                                • Steam, Water & Fuel Flow Monitoring
• Ethernet/IP Module: Provides communication between the
                                                                • CB-Level Master primary safety water level control
  Programmable Controller and other Ethernet Compatible
  devices (e.g. Boiler Room Master Control, Building/Plant      • Internet Web Site Monitoring Package
  Automation system, and the Internet) and E-mail
                                                                • Paging and Remote Dial-Up Access with Modem
  functionality
• Lead/Lag Control for Multiple Boiler Systems
• Fuel-Air Ratio Control System and Actuators
• Variable Speed Drive for Combustion Air Fan Motor




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                     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 Boiler Efficiency:
• Maintains consistent Wind Box Pressure throughout the
  Modulating Firing Range of the Boiler

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                                               ENGINEERING DATA
• Average Payback in approximately 6 – 8 Months
                                                                  Drive:
PI Control Logic:                                                 • Ambient Operating Temperatures: 32 – 122°F
• Precise control.                                                • Altitude: 3300 Ft (1000 m) Max without derating
• Monitors rate of change to anticipate needs of system,          • Shock: 15G peak for 11ms duration (±1.0 ms)
  increasing and decreasing the output speed (frequency) to the
                                                                  • Vibration: 0.152 mm (0.0006 in.) displacement, 1G peak
  blower motor as needed
                                                                  • Voltage Tolerance: -10% of minimum, +10% of Maximum
• Maintains Wind Box Pressure at the Setpoint
                                                                  • Frequency Tolerance: 47 – 63 Hz
Communication:                                                    • Input Phases: Three-phase input provides full rating of all
• Communicates with the Boiler Controller through                   drives, Single-phase operation provides 50% of rated current
  DeviceNet™
                                                                  • Displacement Power Factor:
• Provides Drive process information on the Boiler Control          PF70 – C & D Frames – 0.92 lagging (entire speed range),
  Panel Display                                                     PF70 – A&B Frames – 0.64 lagging,
                                                                    PF700 – TBD
• Provides Drive faults and troubleshooting suggestions, in
  “Plain English”, on Boiler Control Panel Display                • Output Voltage: 0 to rated motor voltage
                                                                  • Output Frequency Range: 0 – 400 Hz
PRODUCT OFFERING                                                  • Frequency Accuracy: Digital Input – Within ±0.01% of set
Cleaver-Brooks shall supply the following equipment:                output frequency, Analog Input – Within ±0.4% of maximum
                                                                    output frequency
• Adjustable Frequency Variable Speed Drive.
                                                                  • Intermittent Overload: 110% Overload capability for up to
• Wind Box Pressure Transmitter.
                                                                    1 minute, 150% Overload capability for up to 3 seconds
• VSD Compatible Combustion Air Fan Motor.




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• Current Limit Capability: Proactive Current Limit             SAMPLE SPECIFICATIONS
  programmable from 20 to 160% of rated output current;
  Independently programmable proportional and integral gain     The Boiler Manufacturer shall provide a Variable Speed Drive
                                                                controller for use on the burner’s Combustion Air Fan blower
• Line Transients: Up to 6000 volts peak per IEEE               motor for the purpose of providing Improved Boiler Efficiency
  C62.41-1991                                                   and Reduced Electrical Energy consumption.
• Ground Fault Trip: Phase-to-ground on drive output            The Drive’s voltage, frequency, and current ratings shall be
• Short Circuit Trip: Phase-to-phase on drive output            rated in accordance with the electrical requirements as dictated
                                                                by job site specifics, and for the properly rated motor
• Drive Overcurrent Trip: Software – 20 to 160% of rated        horsepower.
  current, Hardware – 200% of rated current (typical),
  Instantaneous – 220 to 300% of rated current (dependent on    The Variable Speed Drive must be capable of communicating
  drive rating)                                                 over the DeviceNet™ protocol.

• Electronic Motor Overload Protection: Class 10 protection     A pressure transmitter shall be supplied to measure the Wind
  with speed sensitive response. Investigated by U.L. to        Box Pressure of the Burner and shall be capable of supplying a
  comply with N.E.C. Article 430, UL File E59272 Volume 12      4 – 20mA process variable input signal to the VSD.

• See Drive Manual for other, Model and Voltage Specific,       A Motor suitable for variable speed drive service must be
  specifications.                                               supplied for use in conjunction with the Variable Speed Drive,
                                                                and sized to match the motor requirements of the Combustion
                                                                Air Fan Blower.
Pressure Transmitter:
• Pressure Range: 0 – 2 psig                                    Variable Speed Drive shall be interlocked with boiler control to
                                                                ensure safe operation.
• Output: 4 – 20mA DC
• Connection: 1/4" NPT
• Enclosure: NEMA 4
• Accuracy: ±0.25% FS
• Compensated Range: -4 to +176°F

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.




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        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-33, Oxygen Trim, 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
                                                                  Analyzer Probe is Direct Insertion, In-situ Zirconia Type
• Can be configured on site without opening the cover using an    Which Provides:
  infrared sensor
                                                                  • High accuracy
• O2 measurement circuitry built into probe head electronics
                                                                  • Fast Response
• O2 Level percentages displayed on the Boiler Control Panel
  Human Machine Interface (HMI)                                   • Proven Reliability

• Provides accurate Boiler Efficiency Calculations with the
  CB-HAWK ICS Programmable Controller
                                                                  PRODUCT OFFERING
                                                                  • In-Situ Zirconia Probe and Analyzer
• Separate analyzer/converter display panel not required
                                                                  • Process Variable % O2 Readout on Control Panel HMI
Combustion Air Temperature:
                                                                  • Combustion Air Temperature measurement and indication
• Provides temperature measurement of boiler’s combustion
                                                                  • Accurate Efficiency Calculations
  air
• Indication on HMI display                                       Options:
• Used in overall boiler efficiency calculations                  • Separate O2 Converter/Display Panel
                                                                  • Replacement Zirconia Cell
Stack Flue Gas Temperature (included in standard offering):
                                                                  • Auto Calibration Pneumatics
• Provides temperature measurement of boiler’s stack flue gas
                                                                  • Replacement Heater Assembly
• Indication on HMI display
                                                                  • Remote Indicator/Alarm
• Used in overall boiler efficiency calculations
                                                                  • Probe Stack Mounting Adapter
User Configurable Alarm Points                                    • Calibration Gas Kit
• Low O2 Alarm




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ENGINEERING DATA                                                    2.0 Combustion Air Temperature Probe

• Ambient Temperature: -4 to 131°F (-20 to +55°C)                   • Type J thermocouple

• Sample Gas Temperature: 32 to 1292°F (0 – 700°C)                  3.0 Analyzer

• Sample Gas Pressure: -1.5 to 73.8 in Hg (-5 to +250 kPa)          • Shall be of the Integrated Type (in probe head)

• Output Signal: 4 – 20mA DC, One Point, Maximum Load               • Provide 4 – 20mA DC Signal output in relation to process
  Resistance 550 Ohms                                                 variable for remote display

• Digital Output (HART): 250 – 500 Ohms                             4.0 Monitoring System

• Contact Output Signal: Two Points, 30 VDC 3A, 250 VAC 3A          • Indicate O2 Percentages
  (one is fail safe normally open)                                  • Provide Low O2 Alarm Indication
• Contact Input Signal: Two Points                                  • Perform Efficiency Calculations and display results using
• Reference Air: Natural Convection, Instrument Air, pressure         O2 percentages
  compensated                                                       5.0 Combustion Air Thermocouple to be Type J
• Instrument Air: 200 kPa plus the pressure in the furnace          6.0 The system shall continuously monitor oxygen
• Power Supply: 100 – 240 VAC, 50/60Hz                              concentration in the boiler’s exit flue gas and provide
                                                                    indication of O2 percentages and alarm points on a Human
• Power Consumption: Max 300 W, approx. 100 W for                   Machine Interface (HMI) type display.
  ordinary use
• Combustion Air Thermocouple: Type J                               APPLICATION
                                                                    This system is applicable to modulating burners using the
SAMPLE SPECIFICATIONS                                               CB-HAWK ICS Integrated Control System. This system shall
• This specification covers the hardware and monitoring             monitor and display O2 concentration in the boiler’s exit flue
  functions of the CB-HAWK ICS Oxygen monitoring system.            gas and provide overall boiler efficiency calculations.
  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.
O2 Sensor Requires calibration in the field!

Hardware:
Hardware shall consist of the following:
1.0 Oxygen Sensor
• Integrated type Zirconia Oxygen Analyzer
• Direct Insertion Type
• Built-in Heater Assembly
• 4-20mA DC Process Variable Output
• Heater to be of field replaceable construction
• Cell to be of field replaceable construction




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        CB-HAWK ICS — ETHERNET COMMUNICATION

The CB-HAWK ICS Ethernet communication package                      ENGINEERING DATA
provides Ethernet communications between the CB-HAWK
ICS programmable controller and other Ethernet compatible           • Modular connection to CB-HAWK ICS Programmable
devices such as the Boiler Room Master Lead/Lag Control               Controller unit
Panel, Building/Plant automation system, and the Internet.          • Ethernet Industrial Protocol (Allen-Bradley EPIC)
                                                                    • Follows Ethernet Rules and Practices
FEATURES AND BENEFITS
                                                                    • High Noise Rejection
• Provides communication between the CB-HAWK ICS
  programmable controller unit and other Ethernet Compatible        • Cabling: Category 5E rated twisted pair cable (solid core,
  Devices                                                             PVC jacket with RJ45 connections).

• Provides interface capability with many Building/Plant            • Meets Open Industrial Network Standards
  automation systems when utilizing OPC server or protocol          • IEEE 802.3 Physical and Data Link Standard
  bridge
                                                                    • Ethernet TCP/IP protocol suite industry standard
• Provides interface with plants LAN/WAN
                                                                    • Control and Information Protocol (CIP) Compliant
• Provides interface to the Internet (requires static IP address)
                                                                    • OPC (OLE Process Control) communication compatibility
• E-mailing of boiler alarms/faults                                   with RSLinx OPC Server software
• Provides means of connection between various boiler room
  control systems, such as the CB-HAWK ICS Master Panel             SAMPLE SPECIFICATIONS
  for lead/lag control
                                                                    The Boiler Manufacturer shall furnish and install a control
• Provides means of connection to a remote Personal                 module capable of Ethernet communications between the
  Computer                                                          boiler’s programmable logic control system and other Ethernet
• Ethernet Industrial Protocol                                      compatible devices, as needed, and provide the following
                                                                    minimum requirements:
• IEEE 802.3 Physical and Data Link Standard
                                                                    • Interface with the Compact Logix Programmable Controller
• Ethernet TCP/IP protocol suite industry standard                    Protocol
• Control and Information Protocol (CIP) Compliant                  • Ethernet Industrial Protocol (Allen-Bradley EPIC)
                                                                    • Follows Ethernet Rules and Practices
PRODUCT OFFERING
                                                                    • High Noise Rejection
• Ethernet/IP Module
                                                                    • Open Industrial Network Standards
• Optional Ethernet Communication Hub (necessary for stand-
  alone boiler (no Master Panel) connection to LAN/WAN              • IEEE 802.3 Physical and Data Link Standard
  and/or Paging Modem option)                                       • Ethernet TCP/IP protocol suite industry standard
• E-mail functionality — requires customer provided e-mail          • Control and Information Protocol (CIP) Compliant
  service and address




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      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.

PRODUCT OFFERING
• Remote Access Paging Modem
• Easy to use configuration software
• Requires customer provided, dedicated phone line
• Requires customer provided Paging Service and pagers (or     SAMPLE SPECIFICATIONS
  paging compatible cell phones)                               The boiler manufacturer shall provide a Paging and Remote
• Requires Pager Numbers and PINs supplied by customer         Dial-Up Access Modem, using customer provided paging
                                                               systems for the purpose of paging boiler system alarms and
• Configure up to 10 unique pagers                             providing remote access to the control system.
                                                               Pager number(s) and PINs to be supplied by customer.
ENGINEERING DATA
                                                               Dedicated telephone connection to be supplied by customer.
• Voltage: 24 VDC
• Baud Rate: 56K
• Type: External, Serial
• Paging functionality utilizes TAP Protocol




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                  CB-HAWK ICS — INTERNET WEB SITE
                            MONITORING
Provides customer with a secure connection for monitoring site
specific, Cleaver-Brooks Boiler(s) operating parameters and
alarm conditions via the Internet. Website will also include
links to boiler-serial-number based parts lookup and ordering.
(Requires CB-HAWK ICS Ethernet Communication Option)

FEATURES AND BENEFITS
• Provides monitoring of boiler on remote PC via the Internet
• Provides parts lookup and ordering via the Internet
• Provides remote troubleshooting capabilities by the customer
  and by Authorized Cleaver-Brooks Representatives and/or
  service personnel (with customer allowed password
  protected access) via the Internet
• E-Mail and Paging of boiler alarms. (A Modem may be
  required for some E-Mail and Paging system). E-Mail
  addresses and Pagers furnished by customer.                    SAMPLE SPECIFICATIONS
                                                                 The boiler manufacturer shall provide an Internet Monitoring
PRODUCT OFFERING                                                 package for the purpose of monitoring the boiler system
                                                                 operating parameters and alarm conditions via the Internet. The
• Internet Communication Access                                  offering shall supply at a minimum:
• Requires CB-HAWK ICS Ethernet Communication Option             1.   Provide monitoring of boiler on remote PC via the Internet.
• Monthly/Quarterly/Annual monitoring subscription               2.   Provide parts lookup and ordering via the Internet.
• Requires customer provided, dedicated boiler room              3.   Provide remote troubleshooting capabilities by the
  connection, which requires a global static IP address               customer and by Authorized Boiler Manufacturer
                                                                      Representatives and/or service personnel (with customer
                                                                      allowed password protected access) via the Internet.
                                                                 4.   E-Mail and Paging of boiler alarms, understanding that a
                                                                      Modem and a dedicated phone line may be required for
                                                                      some e-mail and paging systems.




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                    CB-HAWK ICS — LEAD/LAG FOR TWO
                           BOILER SYSTEMS
Provides Lead/Lag control for a two-boiler system 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.

Sequences of Operation for Two Boilers:
Provides maximum system efficiency.
                                                                      Boilers’ Start and Stop
Reduces cycling and boiler wear; thereby reducing
maintenance and downtime costs.                                       Steam pressure, or hot water temperature, is compared with the
                                                                      setpoint and controller’s processor executes PID algorithm.
Optimizes fuel savings.                                               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/Lag Start with Lead/Lag Modulation:                              lead boiler reaches lag boiler start point. Lag boiler is
                                                                      commanded to stop when a firing rate signal for the lag boiler
Lead boiler operates at full capacity prior to starting lag boiler.
                                                                      reaches lag boiler stop point.
Lag boiler starts modulation when lead boiler reaches
maximum firing rate position.                                         Lead/Lag Modulation
Ideal for steam boilers.                                              Lag boiler starts modulation after lead boiler reaches
                                                                      maximum firing rate.
Lead/Lag Start with Unison Modulation:
Lead boiler operates at full capacity prior to starting lag boiler.   Unison Modulation

Lag boiler operates at the same firing rate as a lead boiler.         Firing rates for both boilers are equal.

Ideal for hot water boilers.                                          Hot Standby
                                                                      System shall have a provision for keeping lag boiler in hot
PRODUCT OFFERING                                                      standby. Standby routine shall be based on a water temperature
Cleaver-Brooks shall supply the following equipment:                  signal.

• Boiler control for each boiler shall be CB-HAWK ICS.
                                                                      APPLICATION AND SYSTEM
• Pressure (steam) or temperature (hot water) transmitter
  shipped loose for mounting in the common header.
                                                                      REQUIREMENTS
                                                                      This option is applicable to full modulation burners utilizing
SAMPLE SPECIFICATIONS                                                 the CB-HAWK ICS advanced boiler control system and
                                                                      modulating controls.
Lead/Lag Start with either Lead/Lag or Unison Modulation.
                                                                      All logic for Lead/Lag Control shall reside in the boiler
                                                                      controller. No additional control panels shall be required.




                                                                                                                                    D-17
                                                                                12-02
Controls


                     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.
                                                                     • Master Control Panel shipped loose for field mounting.
• Reduces cycling and boiler wear, thereby reducing
  maintenance and downtime costs.                                    • Requires Ethernet/IP Communication Option

• System shall be provided with a sequence to automatically
  rotate sequence in which the boilers are fired. Rotation shall
                                                                     SAMPLE SPECIFICATIONS
  be based on the elapsed time.                                      Lead/Lag Start with either Lead/Lag or Unison Modulation.
• Optimizes fuel savings.
                                                                     Boilers’ Start and Stop
Lead/Lag Start with Lead/Lag Modulation:                             Steam pressure, or hot water temperature on hot water systems,
• Lead boiler operates at full capacity prior to starting lag        is compared with the setpoint and controller’s processor
  boiler #1.                                                         executes PID algorithm. Lead boiler is commanded to come
                                                                     on-line first. Lag boiler #1 is commanded to come on-line
• Lag boiler #1 starts when the lead boiler’s firing rate is close   when a firing rate signal for the lead boiler reaches lag boiler
  to the maximum. Operator can select this parameter via HMI.        start point. Lag boiler #1 is commanded to stop when a firing
• Lag boiler #1 starts modulation when the lead boiler reaches       rate signal for the lead boiler reaches lag boiler stop point.
  the maximum firing rate position.
                                                                     Lag boiler #2 is commanded to come on-line when a firing rate
• Subsequent lag boilers operate in the same fashion.                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
• Ideal for steam boilers.
                                                                     lag boiler #1 reaches lag boiler #2 stop point.
Lead/Lag Start with Unison Modulation:                               Subsequent boilers operate in a similar fashion.
• Lead boiler operates at full capacity prior to starting the lag
  boiler.                                                            Lead/Lag Modulation

• All boilers operate at the same firing rate as the lead boiler.    Lag boiler #1 starts modulation after lead boiler reaches
                                                                     maximum firing rate (or firing rate selected by the operator).
• Ideal for Hot Water boiler systems.
                                                                     Lag boiler #2 starts modulation after lag boiler #1 reaches
                                                                     maximum firing rate (or firing rate selected by the operator).
PRODUCT OFFERING
                                                                     Subsequent boilers operate in a similar fashion.
Cleaver-Brooks shall supply the following equipment:
• Boiler control for each boiler shall be the CB-HAWK ICS.           Unison Modulation
• Pressure (Steam) or temperature (Hot Water) transmitter            Firing rates for all boilers are equal.
  shipped loose for mounting in the common header.


D-18
                                                  12-02
                                                                                                                        Controls

Hot Standby                                                         Selection
System shall have a provision for keeping lag boilers in hot        • Number of boilers
standby. Standby routine shall be based on a water temperature
signal.                                                             • Sequence of firing
                                                                    • Automatic or manual rotation
Firing Sequence Selection
                                                                    • Individual boiler start and stop points with timers
Sequence in which boilers come on-line shall be selected via
                                                                    • Setpoint
HMI. Adequate check shall be provided that does not allow
improper sequence selection.                                        • Proportional, integral and derivative gains for control
                                                                      algorithm
Automatic Rotation of the Boilers
System shall be provided with a sequence to automatically           APPLICATION AND SYSTEM
rotate sequence in which the boilers are fired. Rotation shall be   REQUIREMENTS
based on the elapsed time.
                                                                    This option is applicable to full modulation burners utilizing
                                                                    the CB-HAWK ICS advanced boiler control system and
HMI (HUMAN MACHINE INTERFACE)
                                                                    modulating controls.
Master panel shall include HMI for display and selection of the
following parameters:                                               Logic for Lead/Lag control shall reside in the Master Control
                                                                    Panel. Communication between the Master Panel and the
Display                                                             individual Boiler Control Panels shall be via Ethernet
                                                                    communication or hard wiring.
• Available boilers
• Number of boilers required
• Selected sequence of firing
• Control output to each boiler
• Header steam pressure or water temperature on hot water
  systems
• Setpoint
• Elapsed time from last rotation




                                                                                                                                D-19
                                                                                12-02

								
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