CleaverBrooks Master Panel 8 Operation Manual
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CleaverBrooks Master Panel 8 Operation Manual

CleaverBrooks Master Panel 8 Operation Manual

Eight boiler lead lag control
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Master Panel 8
Eight Boiler Lead Lag Control
Operation Manual
750-375
10/16

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Summary of Contents for CleaverBrooks Master Panel 8

  • Page 1 Master Panel 8 Eight Boiler Lead Lag Control Operation Manual 750-375 10/16...
  • Page 2 TO: Owners, Operators and/or Maintenance Personnel This operating manual presents information that will help to properly operate and care for the equipment. Study its con- tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc- tions are followed.
  • Page 3 Cle ave r-Bro o ks Master Panel 8 Operation Manual P le a s e dire ct purcha s e orde rs for re pla ce me nt ma nua ls to your loca l Cle a ve r-Brooks a uthorize d re pre s e nta tive Ma nua l P a rt No.

  • Page 5: Table Of Contents

    E. SYSTEM WIRING...............3-18 Section 4 — Troubleshooting A. GENERAL ................ 4-2 B. ETHERNET TROUBLESHOOTING ........4-2 C. LOADING PLC PROGRAM ..........4-6 D. WEB SERVER ..............4-10 Section 5 — Parts A. PARTS LIST..............5-3 Appendix — Master Panel 8 I/O List...

  • Page 7: Section 1 - Overview

    Section 1 Overview A. Features................1-2 B. Components ..............1-2 C. Specifications ..............1-4 www.cleaverbrooks.com...

  • Page 8: Features

    Section 1 — Overview Master Panel 8 The Cleaver-Brooks Master Panel 8 master boiler room control system provides lead/lag control for up to eight boilers when used in conjunction with CB integrated boiler controls. A. FEATURES • Lead/lag control for up to eight boilers.
  • Page 9 Master Panel 8 Section 1 — Overview PLC and I/O modules: 1. Slot 0 - PLC: L30ER Processor 2. Power Supply 3. Slot 1 - Digital Inputs: Boiler A, B, C, D Ready Power to Boiler A, B, C, D 4.

  • Page 10: Specifications

    Section 1 — Overview Master Panel 8 C. SPECIFICATIONS Cleaver-Brooks Master Panel 8 boiler control operational and environmental specifications are as follows: Table 1-1. Operational and Environmental Specifications Description Specification Maximum connecting units 8 boilers Power Supply Voltage 120 VAC (+10%/-15%)
  • Page 11 5. Set-Up 2 Screen ..........2-10 6. Firing Rate ............. 2-11 7. Elapsed Time Screen ........2-12 8. Alarm History Screen ........2-13 9. Configuration (Config) Screen ......2-13 10. PanelView Configuration (PV Conf) Screen ..2-15 11. Individual Boiler Overview Screen ....2-16 www.cleaverbrooks.com...

  • Page 12: Section 2 - Operation

    Section 2 — Operation Master Panel 8 A. SEQUENCE OF OPERATION 1. Boiler Start and Stop Header water temperature (steam pressure) is compared with the set point and the Master Panel PLC processor executes PID (Proportional, Integral, and Derivative) control algorithm. The lead boiler is commanded to come on line first.
  • Page 13 Master Panel 8 Section 2 — Operation Control output to the boilers is calculated using the following equation: 0 O CV = (CV x N) – ((n-1) x 100) + (100 - ModShift) O 100 MAIN Where = control output to boiler #n (For lead boiler n = 1, for lag #1 n = 2, etc.)
  • Page 14 Section 2 — Operation Master Panel 8 Figure 2-1 Lead/Lag Modulation (8 boilers available, ModShift = 100) Seq Number (n) ModShift PID Out CONTROL OUTPUT (CV MAIN -100 -200 -300 -400 -500 -600 -700 -160 -260 -360 -460 -560 -660...

  • Page 15: Display Screens And Parameter Settings

    Master Panel 8 Section 2 — Operation B. DISPLAY SCREENS AND PARAMETER SETTINGS The following appear on all screens: • Day and time • Current alarm • Cleaver-Brooks logo • Screen selection buttons 1. Screen Select This is a navigational screen from which all other screens can be accessed.

  • Page 16: Boiler Overview Screen

    Section 2 — Operation Master Panel 8 2. Boiler Overview Screen Figure 2-3 Boiler Overview Screen (steam system with 8 boilers shown) Press (Temp) — indicates supply pressure (steam) or temperature (hot water). Set Point — Operating set point indicator.

  • Page 17: Set Points And Sequence Screen

    Master Panel 8 Section 2 — Operation 3. Set Points and Sequence Screen Figure 2-5 Set Points and Sequence Lead Boiler On and Off Point — This is the water temperature (steam pressure) at the header for the lead boiler to start and stop. These values are calculated based on the values entered for set point and On/Off dp (see below).
  • Page 18 Section 2 — Operation Master Panel 8 “High Limit” setting are from the “Low Limit” to 95% of the maximum temperature. Steam System: Valid entries for the “Low Limit” are from 5 PSI (0.3 Bar) to the “High Limit” setting. Valid entries for “High Limit”...

  • Page 19: Set-Up 1 Screen

    Master Panel 8 Section 2 — Operation 4. Set-Up 1 Screen Figure 2-6 Set-Up 1 Screen This screen is used to enter boiler timers’ start and stop points. Start Point — Control signal to the previous-in-sequence boiler at which this boiler will start. Valid entry is from Boiler Stop Point to 100.

  • Page 20: Set-Up 2 Screen

    Section 2 — Operation Master Panel 8 5. Set-Up 2 Screen Figure 2-7 Set-Up 2 Screen (steam) Shut Down Delay — Time delay for boiler shut down after the stop command is received. Valid entry is from 0 to 1200 seconds.

  • Page 21: Firing Rate

    Master Panel 8 Section 2 — Operation Warm-up Blr Off (hot water only) — This timer is activated when the main fuel valves for the specific boiler are de-energized. Upon expiration of this timer, the boiler enters the warm-up sequence.

  • Page 22: Elapsed Time Screen

    Section 2 — Operation Master Panel 8 P — Proportional gain (unitless). I — Integral gain (1/min.). D — Derivative gain (Minutes). 7. Elapsed Time Screen Figure 2-10 Elapsed Time Screen This screen is informational only. The following parameters are displayed: •...

  • Page 23: Alarm History Screen

    Master Panel 8 Section 2 — Operation 8. Alarm History Screen This screen is information-only. The PanelView display stores up to 100 alarms. The Alarm history table contains the following information. Table 2-1. Alarm History Column # from the Left...
  • Page 24 Section 2 — Operation Master Panel 8 Figure 2-12 System Configuration Screen Boiler ID — These buttons allow changing boiler name. To assign a name to a boiler, touch Boiler ID display for the specific boiler. The keypad display will appear. Type new boiler name (up to 8 characters) and press enter key.

  • Page 25: Panelview Configuration

    Master Panel 8 Section 2 — Operation 10.PanelView Configuration Certain PanelView internal settings, including date and time, screen saver settings, etc., can be accessed through PanelView Configuration. Most of these settings should not require user configuration. For more information refer to the Allen-Bradley PanelView Plus manual.

  • Page 26: Individual Boiler Overview Screen

    Section 2 — Operation Master Panel 8 11.Individual Boiler Overview Screen This is an information-only screen. It displays parameters pertaining to an individual boiler. To select a boiler press the appropriate button (<Boiler A> etc.) from the Screen Select menu. Overview screens for the Deaerator/Surge will also be available for systems so equipped.
  • Page 27 Setpoints And Set-up Parameters ....3-6 System Wiring ....... . 3-18 www.cleaverbrooks.com...

  • Page 28: Section 3 - Commissioning

    Section 3 — Commissioning Master Panel 8 Note: Prior to the commissioning of the lead/lag system all boilers have to be started and combustion set. A. I/P ADDRESSING (INDIVIDUAL BOILERS) Addresses have to be assigned to the individual boilers. This can be done using the Ethernet Set Up screen on the boiler panel.

  • Page 29: Boiler Configuration

    Master Panel 8 Section 3 — Commissioning B. BOILER CONFIGURATION On the Configuration Screen (#2) of the boiler panel make selections as follows (refer to the Hawk controls manual for configuration help). Note: These settings are made at the boiler control panel, not at the Master Panel.

  • Page 30: I/P Addressing (Master Panel)

    Section 3 — Commissioning Master Panel 8 C. I/P ADDRESSING (MASTER PANEL) To set the Master Panel Ethernet configuration, first go to System Configuration. Observe the screen warning: Lead/Lag control will not function while in system configuration and the master panel firing rate control will be forced to manual.
  • Page 31 Master Panel 8 Section 3 — Commissioning After confirming a new IP address for the PLC, this address must be entered into the PanelView configuration settings. 1. Go to <PanelView Configuration> and from the PV Config main screen select <Terminal Settings>.

  • Page 32: Setpoints And Set-Up Parameters

    Section 3 — Commissioning Master Panel 8 Enter each path according to the IP address set on the individual boiler/ADAC control panel. Note: the settings on this screen do not change the IP address of the associated boiler or ADAC; they only specify the path used by the Master Panel to communicate with each unit.

  • Page 44: System Wiring

    Section 3 — Commissioning Master Panel 8 E. SYSTEM WIRING NOTE: Refer to wiring diagram supplied with unit for job specific information and terminal designations. 3-18 Part No. 750-375...
  • Page 45 D. Web Server ........4-10 www.cleaverbrooks.com...

  • Page 46: Section 4 - Troubleshooting

    Section 4 — Troubleshooting Master Panel 8 A. GENERAL Table 4-1. Troubleshooting Problem Possible Cause Recommended Action Boiler unavailable on the CB Master Lead/Lag not selected On Configuration Screen #2 toggle CB Master Lead/ Master Panel overview screen. Lag to YES (green)
  • Page 47 Master Panel 8 Section 4 — Troubleshooting 3. Select “Local Area Connection” 4. Select “Internet Protocol (TCP/IP)” Part No. 750-375...
  • Page 48 Section 4 — Troubleshooting Master Panel 8 Write down the current TCP/IP properties. 5. Change properties to the following: • IP address: 192.168.1.50 • Subnet mask: 255.255.255.0 • Default gateway:192.168.1.1 It is not necessary to change DNS server parameters. 6. Click OK, then OK again to return to desk top.
  • Page 49 Master Panel 8 Section 4 — Troubleshooting 11.Type ping <IP address>, then press Enter. Example: To “ping” Boiler 1, type • ping 192.168.1.101 • The computer screen should resemble the following: If computer display is as above, proceed to Step 12.

  • Page 50: Loading Plc Program

    Section 4 — Troubleshooting Master Panel 8 If computer shows no reply, as below: then there may be a problem with processor ethernet. Check I/P address. 12.Using straight Ethernet cable connect computer to Ethernet switch in master panel. 13.Repeat Steps 10 and 11. If there is no reply from the processor the problem is with the Ethernet cable connection from the master panel to the boiler.
  • Page 51 Master Panel 8 Section 4 — Troubleshooting 3. Double click on Extract. 4. Choose the drive where the SD card is located and click on Extract button. Close WinZip window. 5. Browse to the drive where SD card is located and make sure it contains the “Logix”...
  • Page 52 Section 4 — Troubleshooting Master Panel 8 6. Using “Unplug and Eject Hardware” on your computer select the USB device. A screen prompt will indicate that the device can be removed: 7. Remove card reader and remove SD card from reader.
  • Page 53 Master Panel 8 Section 4 — Troubleshooting 8. Insert SD card into the card slot of the processor. Take care to insert card in the correct orientation. 9. Put mode selection switch in RUN mode. 10.Cycle power to the controller.

  • Page 54: Web Server

    Section 4 — Troubleshooting Master Panel 8 D. WEB SERVER It is possible to access the Master Panel HMI remotely from a PC for diagnostic/informational purposes. From a computer on the same network as the Master Panel, enter the IP address of the PanelView Plus HMI in the computer’s web browser.

  • Page 55: Section 5 - Parts

    Section 5 Parts Master Panel 8 Parts List ............5-3 www.cleaverbrooks.com...
  • Page 56 Section 5 — Parts Master Panel 8 Part No. 750-375...

  • Page 57: Parts List

    Master Panel 8 Section 5 — Parts Master Panel 8 Parts List Description CB Part # Display, PanelView Plus 1000 833-03512 Cable Ethernet Patch, Cat 5 826-00111 Circuit Breaker 10 Amp 983-00081 Fuse Block 848-01321 Fuse, 2 Amp 832-02051 Terminal Block, AB, 1492-J4...
  • Page 58 Section 5 — Parts Master Panel 8 Part No. 750-375...

  • Page 59: Appendix - Master Panel 8 I/O List

    APPENDIX A — MASTER PANEL 8 I/O LIST...
  • Page 60 Web Address: http://www.cleaverbrooks.com...

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