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CleaverBrooks Master Panel 4 Operation Manual
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CleaverBrooks Master Panel 4 Operation Manual

CleaverBrooks Master Panel 4 Operation Manual

Four boiler lead lag control
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Master Panel 4
Four Boiler Lead Lag Control
Operation Manual
750-383
06/16

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Summary of Contents for CleaverBrooks Master Panel 4

  • Page 1 Master Panel 4 Four Boiler Lead Lag Control Operation Manual 750-383 06/16...
  • 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 Cleaver-Brooks Master Panel 4 Four Boiler Lead Lag Control Operation Manual Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative Manual Part No. 750-383 06/16 P rinte d in U.S .A.
  • Page 5 TABLE OF CONTENTS Section 1 — Overview A. FEATURES......... 1-2 B.
  • Page 7 Section 1 Overview A. Features................1-2 B. Components ..............1-2 C. Inputs/Outputs ..............1-3 D. Specifications ..............1-4 E. Wiring Diagram..............1-5 www.cleaverbrooks.com...
  • Page 8 Section 1 — Overview Master Panel 4 The Cleaver-Brooks Master Panel 4 master boiler room control system provides lead/lag control for up to four boilers when used in conjunction with CB integrated boiler controls. A. FEATURES • Lead/lag control for up to four boilers.
  • Page 9 Master Panel 4 Section 1 — Overview 2. Pressure (steam system) or temperature (hot water system) transmitter with well (shipped loose). Transmitter must be mounted in a common outlet header. C. INPUTS/OUTPUTS Processor - Slot 0 Analog Output Embedded I/O - Slot 1-3...
  • Page 10 Section 1 — Overview Master Panel 4 D. SPECIFICATIONS Cleaver-Brooks Master Panel 4 operational and environmental specifications are as follows: Table 1-1. Operational and Environmental Specifications Description Specification Maximum connecting units 4 boilers Power Supply Voltage 120 VAC (+10%/-15%) Power Supply Frequency...
  • Page 11 Master Panel 4 Section 1 — Overview E. WIRING DIAGRAM p 1 of 5 Part No. 750-383...
  • Page 12 Section 1 — Overview Master Panel 4 p 2 of 5 Part No. 750-383...
  • Page 13 Master Panel 4 Section 1 — Overview p 3 of 5 Part No. 750-383...
  • Page 14 Section 1 — Overview Master Panel 4 p 4 of 5 Part No. 750-383...
  • Page 15 Master Panel 4 Section 1 — Overview p 5 of 5 Part No. 750-383...
  • Page 16 Section 1 — Overview Master Panel 4 1-10 Part No. 750-383...
  • Page 17 Warm-Up Sequence (hot water units) ....2-27 Unison Modulation (hot water and steam boilers) ..2-27 www.cleaverbrooks.com...
  • Page 18 Section 2 — Commissioning Master Panel 4 A. INITIAL SETUP Note: Prior to the commissioning of the lead/lag system all boilers have to be started and combustion set. 1. 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 each boiler panel.
  • Page 19 Master Panel 4 Section 2 — Commissioning Note: These settings are made at the boiler control panel, not at the Master Panel. Figure 2-2 Lead lag boiler On the boiler Firing Rate Screen, <Remote> must be selected for the firing rate control mode.
  • Page 20 Section 2 — Commissioning Master Panel 4 3. 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 21 Master Panel 4 Section 2 — Commissioning Figure 2-6 Confirm IP address 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 22 Section 2 — Commissioning Master Panel 4 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 23 Master Panel 4 Section 2 — Commissioning Table 1: Steam System Set Points and Sequence Screen Settings Factory Actual Minimum Maximum Parameter Name Description Units Default Limit Limit Setting Setting Number of Units* Number of boilers Max Pressure* Maximum design pressure...
  • Page 24 Section 2 — Commissioning Master Panel 4 Table 2: Hot Water System Set Points and Sequence Screen Settings Factory Minimum Parameter Name Description Units Maximum Limit Default Actual Setting Limit Setting Number of Units* Number of Boilers Max Temp* Design water temperature...
  • Page 25 Master Panel 4 Section 2 — Commissioning Table 3: Set Up 1 Screen Parameters Settings Factory Actual Parameter Name Description Units Minimum Limit Maximum Limit Default Setting Setting Lag Boiler 1 Boiler Start Control signal to lead boiler at which Lag...
  • Page 26 Section 2 — Commissioning Master Panel 4 Table 4: Set Up 2 Screen Parameters Settings Minimum Maximum Factory Default Actual Parameter Name Description Units Limit Limit Setting Setting Boiler A Shutdown Delay Time delay for Boiler A start output to be...
  • Page 27 Master Panel 4 Section 2 — Commissioning B. DISPLAY NAVIGATION AND PARAMETER ENTRY 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 28 Section 2 — Commissioning Master Panel 4 2. Overview Screen Figure 2-8 Overview Screen Press (Temp) — indicates supply pressure (steam) or temperature (hot water). Set Point — Operating set point indicator. Under each boiler name are indicators of the boiler’s working status: •...
  • Page 29 Master Panel 4 Section 2 — Commissioning 3. PLC Hardware Overview Figure 2-10 PLC Hardware Overview This screen shows the installed hardware devices and displays the PLC firmware number and serial number. 4. I/O Status Screen On/Off status is shown for digital inputs. Analog inputs show Raw (mA) and Value (engineering units) Part No.
  • Page 30 Section 2 — Commissioning Master Panel 4 5. Set Points and Sequence Screen Figure 2-11 Setpoints and Sequence Screen 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 31 Master Panel 4 Section 2 — Commissioning “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 32 Section 2 — Commissioning Master Panel 4 6. Set-Up 1 Screen Figure 2-12 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 33 Master Panel 4 Section 2 — Commissioning 7. Set-Up 2 Screen Figure 2-13 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 34 Section 2 — Commissioning Master Panel 4 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 35 Master Panel 4 Section 2 — Commissioning P — Proportional gain (unitless) I — Integral gain (1/minutes) D — Derivative gain (minutes) 9. Elapsed Time Screen Figure 2-16 Elapsed Time Screen This screen is informational only. The following parameters are displayed: •...
  • Page 36 Section 2 — Commissioning Master Panel 4 10.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 Description...
  • Page 37 Master Panel 4 Section 2 — Commissioning Boiler ID Figure 2-18 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 38 Section 2 — Commissioning Master Panel 4 12.Change Date and Time To set the date and time, press <Update Date/Time> from the Screen Select menu. Figure 2-19 Date/Time Screen 13.PanelView Configuration Certain PanelView internal settings can be accessed through PanelView Configuration. Press <PV+ Config> from the Screen Select menu.
  • Page 39 Master Panel 4 Section 2 — Commissioning Figure 2-20 PV Configuration Main Screen Press <Terminal Settings> to see the Terminal Settings menu. These are settings specific to the PanelView device and are independent of the currently loaded application. Figure 2-21 Terminal Settings Select “Time/Date/Regional Settings”...
  • Page 40 Section 2 — Commissioning Master Panel 4 Figure 2-22 Boiler Overview 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 41 Master Panel 4 Section 2 — Commissioning Input range, high/low alarm points, and engineering units are configured here. The units selected should be appropriate for the input device used. Once an input is configured, a bar graph and numeric totalizer will appear on the Analog Input screen.
  • Page 42 Section 2 — Commissioning Master Panel 4 C. CONTACT INFO Figure 2-26 Contact Info Screen The Contact Info screen can be filled in by the C-B representative with the appropriate contact information. 2-26 Part No. 750-383...
  • Page 43 Master Panel 4 Section 2 — Commissioning D. SEQUENCE OF OPERATION 1. Boiler Start and Stop Header steam pressure (water temperature) 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 44 Section 2 — Commissioning Master Panel 4 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 45 Master Panel 4 Section 2 — Commissioning Figure 2-27 Lead/Lag Modulation (4 boilers available) Seq Number Mod Shift PID Out CONTROL OUTPUT NO LIMITS -100 -160 -200 -240 -300 -140 -180 -220 -280 -120 -160 -200 -260 -100 -140 -180...
  • Page 46 Section 2 — Commissioning Master Panel 4 2-30 Part No. 750-383...
  • Page 47 D. Web Server ........3-10 www.cleaverbrooks.com...
  • Page 48 Section 3 — Troubleshooting Master Panel 4 A. GENERAL Table 3-1. 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 49 Master Panel 4 Section 3 — Troubleshooting 3. Select “Local Area Connection” 4. Select “Internet Protocol (TCP/IP)” Part No. 750-383...
  • Page 50 Section 3 — Troubleshooting Master Panel 4 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 51 Master Panel 4 Section 3 — 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 52 Section 3 — Troubleshooting Master Panel 4 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 53 Master Panel 4 Section 3 — 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 54 Section 3 — Troubleshooting Master Panel 4 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 55 Master Panel 4 Section 3 — Troubleshooting 2. Loading program from SD card to PLC 1. Insert SD card into the card slot of the processor. Take care to insert card in the correct orientation. 2. The PLC mode selection switch must be in PROG or RUN mode.
  • Page 56 Section 3 — Troubleshooting Master Panel 4 3-10 Part No. 750-383...
  • Page 57 Section 4 Parts Master Panel 4 Parts List ............4-3 www.cleaverbrooks.com...
  • Page 58 Section 4 — Parts Master Panel 4 Part No. 750-383...
  • Page 59 Master Panel 4 Section 4 — Parts Master Panel 4 Boiler Parts List Description CB Part # Processor L24ER 833-10039 Display, 7 inch Touch Screen 817-04863 Analog Output Module 2 Ch. 833-02844 End Cap 833-02838 Ethernet Switch 5 Port 833-09181...
  • Page 60 Web Address: http://www.cleaverbrooks.com...