203.743.6741 • 203.798.7313 www.preferred-mfg.com Instruments & Controls Catalog 25 Instruments & Controls 181 BURNERMATE UNIVERSAL INDUSTRIAL BOILER CONTROLLER System Overview System Overview Fully Metered combustion control is now available “off the shelf” in an economical, pre-engineered, parameter-driven control package. The BurnerMate Universal Industrial includes the following features: • Patented “Predictive Full Metering” fuel-air ratio control • Cross-limited Actuator, “Position Pacing” • Single PID fuel-air, ratio tuning • Air flow temperature compensation • Gas flow pressure compensation • Windbox O 2 FGR Trim + Flue O 2 Air Flow Trim The BurnerMate Universal Industrial also includes all of the features in the Basic and Expanded versions of BMU: • Precise high torque Servo Actuators ( 3 ft-lb -> 720 ft-lb, 8 sizes) • FD, ID & FGR Fan and BFW Pump VFD drive control • NFPA 85 compliant Burner Management System (BMS) • Individual Interlock Annunciation with advanced Lockout Data storage • Low Fire, Fuel Changeover • Firing Rate, Feedwater and Draft control • Oil Atomizing Pressure control with Setpoint Curve • Large 10” color Touch Screen OIT with pre-programmed graphics (Note: 15” also available on custom applications) • Modbus communications Typical Fully Metered BurnerMate Universal Industrial P & ID. S AE PT Gas FGR Draft Oxygen Draft S Boiler Windbox AT Oxygen VFD Motor S S Fresh Air TE FGR FD S Aux 1 FT TE S Gas Aux 2 S S FT PT** Oil Steam FE pulser PT** or dP Atomize Oil LT Drum Level S Drum Feedwater S Digester Gas FT Fuel3 INDUSTRIAL
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TheBurnerMateUniversal Industrial isavailableoff-the-shelf for immediate delivery, requires only wiring andparametersetuptobeoperationalandisNFPA85compliantandU.L.recognized.
Predictive Metering Combustion ControlThe BurnerMate Universal Industrial offers a patentedmeteringfuel-airratiocombustioncontroltechniqueusingauniquecontrolstrategyreferredtoas“predictivemetering”.The ideal combustion control strategymaintains a presetfuel-air ratioover theentire loadrangeofaboilerdespitechangesinfuelsupply,combustionairanddraftconditions,andalsoprovidesrapidloadchangeresponse.
Because “predictivemetering” combustion control usesboth the servo actuator position feedback and fuel andairflowmeterinputs,meteringcombustioncontrolcanbeselectively “turned” off at low firing rateswhereair flowmetersmaynotbeasaccurate.Mostimportantly,ifaflowmetermalfunctions,bysimpleparameterselectiontheBMUIndustrialcontrollercanbedirectedtooperateasaparallelpositioning combustion control systemwith oxygen trimuntiltheflowmeterisrepairedorreplaced.Traditionalfullymeteredsystemscanonlyberuninmanualwhenthereisaflowmetermalfunction.
BurnerMate Universal Industrial Predictive Metering Control Schematic
Because“predictivemetering”ispre-programmedandonlyapplication-specificparametersetup is required tomakethecontrollerfunction,BurnerMateUniversalIndustrialismucheasier tocommissionandoperate than traditionalfullymeteredcombustioncontrolsystems.ThesinglePIDblock(ratherthanthetworequiredfortraditionalsystems)requiresthatonlyonesetofPIDvaluesneedtobetunedduringcommissioning.
BMUIndustrialFuel-Air-FGRCrossLimitedPositionPacing“Positionpacing” is a unique featureof theBurnerMateUniversal Industrial thatassuresthepositionsofall fuel,air,andFGRServosandrelatedVSDspeedsremain“oncurve”duringloadswings.Positionpacinghelpsavoid:
• Periodsof lean combustion that can cause rumbling,vibration,orflame-outsduringfiringrateincreases
Withtraditionalfullymeteredcontrolsystems,thesolutiontotheseproblemsistoslowdowntheresponsetofiringrate changes, and to tighten “cross limiting lead-lag” toassurethatthefuelandairflowsremain“oncurve.”Forsuchsystems,itisnotunusualforlowtohighfireresponsetimestobe4-8minutes.
BMU Industrial “position pacing” assures that all servoactuatorsremain“oncurve”inthefollowingmanner:
• EachServo andVSDhas precise position or speedfeedbacktoinsurethatalldevicesarecrosslimited.
• TheBMUIndustrial“knows”howfareachservoactuatorandVSD canmove in 0.5 seconds and uses “self-adaptive”positionpacing toensure that loadchangesnevercauseanyservoorVSDtolagbehindtheothers.
1. Quality AssuranceTheboilercontrolsystemshallbemanufacturedandsupportedintheUnitedStatesbyPreferredInstruments.Theburnerfuel-air-FGR ratio control systemand the burner flame safeguardsystemshallbemanufacturedand labelled inaccordancewithU.L.372,U.L.1998,andCSAC22.2#199.SimplysupplyingULrecognizedindividualcomponentsisnotsufficient.Theassembledcontrolcabinetasawholemustbeinspectedforproperwiringmethods, fusing, etc., andmust be labeled as conforming toUL508AandCSAC22.1#14.InspectionandlabelingshallbesupervisedanOSHAapprovedNationallyRecognizedTestLab(NRTL).ThesystemshallcomplywithNFPA85“RequirementforIndependence,”theflamesafeguardsystemshallbeprovidedwithindependenthardware,andshallbephysicallyseparatedfromthecombustioncontrollogic.2. Predictive Metering Combustion ControlA fully metered combustion control system with oxygencompensationand(optional)VSDcontrolshallbeprovided foreachboiler.Eachsystemshallbedesignedtoprovidecontinuousboiler operationwithin boiler design limitswith a high level ofsafetyandenergyefficiency.Fuelflow,airflow,andservopositionforuptoeightservoswillbecontinuallymonitoredandheld“oncurve” during boiler load changes. For convenient setup andfasterresponseto loadchanges, thefullymeteredcombustioncontrol logic shall contain only one PID loop.As required thesystemshallprovidecontinuousmonitoringandcontrolofsteampressure(orwatertemperature),andwaterlevel.Ifaflowmeterisoutofrangeorinoperative,thecontrolstrategycanbeswitchedtoparallelpositioning,byparameterselection.Thesystemshallbefullyintegratedtotheburnermanagementsystemtoprovidefullyautomatic,safeandreliablestartupandshutdown.3. Oxygen Compensation SystemProvide a boiler breeching mounted in-situ, zirconium oxideoxygenanalyzerforeachboiler.Extractivetypeoxygenanalyzersarenotacceptableforcombustioncontrol.Theprobeshallbeofasuitable length tosense theoxygen level in themiddle thirdof thebreeching.Allwettedparts shall bestainlesssteel.Theoxygenanalyzershall:• Includecontinuousself-diagnosticswithdiagnosticcodesfor
atleast10commonfaults.• Automaticallysendthe trimcontrol to the ‘null’positionand
trigger the alarmdry contacts in the if an oxygen analyzerfaults.
• Analyzercalibrationshallbepushbuttonsemi-automatic(notrim pots) with English language prompts and diagnosticmessages.Analyzeroutputshallbefieldselectableas0-10%or0-21%withoutfieldre-calibration.
5. Atomizing Media Pressure ControlThe controller shall accept an input for atomizing steampressure or atomizing steam/ oil differential pressure. Duringcommissioning, an atomizing steam pressure (or atomizingsteam/oil differential pressure) curveshall beestablished.Thecontrollerwillmodulateanatomizingsteamflowcontrolvalvetokeeptheatomizingsteampressureoncurveatallfiringrates.6. Flame Safeguard System (FSG)Integral to the control system furnished shall be a BurnerManagement System (BMS)/ FlameSafeguardSystem (FSG)controller.Thesystemshallbedesignedtoensurethesafestart-up, on-line operation, and shutdown of fuel firing equipment.Burner management system components shall be located inthe combustion control cabinet and shall be fully integratedforautomaticsequencingof lightoffandshutdown.For safetytheBMSmicroprocessorandBMSVDshallbeonaphysicallyseparatecircuitboard.
Microprocessor-based FSG shall provide: safety interlocks,flamemonitoringprotection,and timedsequences.Sequencesshall include forced draft fan start and stop, furnace purge,burnerlightoffandshutdownandpost-purge.TheFSGshallbecapableoffiringuptothreefuels(twogasfuels,oneoilfuel),onefuelatatime.Fuelchangeovershallbefromoiltogas,orgastooilfiringshallbeaccomplishedatlowfirewithoutboilershutdownperNFPA.A front-mountedpanelwithEnglish language, four line, twentycharacter LCD message display shall be provided to displayflame signal strength, startup and shutdown sequence status,alarm, system diagnostic, first-out messages and burnerhistorical information. Historical information shall include thestatusofalllimitsandservosforthelasttenlockouts.To ensure boiler low water cutouts are working correctly, thecontrollershallbecapableofperformingadailyautomaticwatercolumnblow-downtest.Theusershallselectthetimeofdayanddurationofthewatercolumnblow-downtest.Thecontrollershallensure the lowwater cutoff switches are functioning correctly,andalarmtheoperatororlockouttheboilerifitdetectsaswitchmalfunction.To prevent nuisance trips, the flame safeguard system shallaccommodate two flame scanners with one required toprove flame.The controller shall provide120VACor 24VDCscannerpower,andaccepttwoanaloginputsforflamestrengthindications.Flamesafeguardsystemshall includeoilgunpostpurgeforoilfiring.Reliablelowfirecutoffshallbeprovided.For additional nuisance trip protection, field adjustable timedelays shall be provided for F.D. fan start, fresh air damper,minimumairflow,lowdraftcutout,andfuelpressurelimits.Fivefield selectable auxiliary relays shall be included for commonalarm,auxiliaryfanstart,blow-down,flameon,fuelvalveopen,hotwaterpumporvalve.Toprotectagainstdryfiring,anoptionshallbeavailableforhighfluegastemperaturelockout.Toensureairswitchesarefunctioning,minimumairflowpressureswitchandpurgeairflowpressureswitchshallbetestedforsafestarting.
7. Feedwater ControlProvideaboilerwaterlevelcontrollercapableofsingle-,two-,orthree-elementfeedwatercontrolwiththeabilitytoautomaticallyswitch between control strategies dependent on systemdemands.8. Draft ControlThe controller shall provide two-element draft control using aPreferred Instruments JC-22XMTR draft transmitter. Burnerfiringrateshallbeusedasafeedforwardforimprovedresponseto loadchanges.Thecontrolshallprovidebothautomaticandmanualdampercontrol.Alladjustmentsshallbemadefromthefrontpaneldisplayinengineeringunits.9. Flue Gas Recirculation Valve ControlThe controller shall have a characterizable setpoint curve fordamperorvariablespeedfanoutputsignal.Allthelogicrequiredtoverifythatpre-purge,postpurge,light-off,andburnermodulatecycles are automated shall be provided within the controller.Alternatively,thecontrolwillregulateFGRaccordingtoapresetwindboxoxygensetpointcurve.10. Additional Control Requirements:• Minimumnumberoff(x)curvestobeprovidedperservo:6• Minimumnumberofpointsperf(x)curvetobeprovided:11• ColdFGR lowfirecutbackshallbeprovidedwhenFGR is
utilizedforNOxreduction.• Separate curves shall be provided for FD fan full speed
bypassofVSDincaseofVSDfailure.• Controllershall include thecapabilityof receivingaremote
firingrateinputandremotesetpointinput.• Controller shall include dual outdoor reset setpoint curves
• Thecontrollershallacceptstandard4-20mA,1-5VDC,orRTD inputs for analog inputs.No special sensors shall berequired.
11. OIT Color Touch ScreenProvideasanoptionaten(10)inchOperatorInterfaceTerminal(OIT) designed to provide local operation, graphic display ofinformation, alarm message display, historical and real timetrending, remote controller tuning, x/y plots of fuel-air curvedata for intuitive commissioning, Ethernet connectivity andstandardinternetbrowserremotecommunication.TheOITshallcontainaminimumof75graphicpagesandbenetworkedtotheboilercontrolandburnermanagementsystems.TheOITshallprovidegraphicpagesallowing step-by-step commissioningofthecontrollerparametersusingEnglish languagepromptsandselections.The systemshall be an industrial hardenedoperator interfaceterminal.The terminal shallbewebenabledandallow remotemonitoringviaastandardinternetbrowserandsupportModbusTCP/IPMaster,TCP/IPSlave,RS-485ModbusMaster,BacNetIP,andEthernetcommunications.
12. High Torque Servo Features:• Easy pushbutton set-up, not requiring the adjustment of
• Noservofeedbackadjustmentsshallberequiredwithpush-button zero setup.Adjustable travel limit switches shall beintegral, with re-adjustment not requiring new fuel air ratiocurvere-entry.
• Servos shall be cycled during each light-off cycle, and thefeedbackfromeachservoshallbemonitoredtoensuresafeactuatoroperation.
• Servos shall be Preferred Instruments,model BMU-SM orBMU-UM(hightorque).