APEM APEM – – Fall 2011 Forum Fall 2011 Forum High Efficiency Burners and High Efficiency Burners and Linkageless Combustion Controls Linkageless Combustion Controls Presented By: Mechanical Sales, Inc. Presented By: Mechanical Sales, Inc. Peter Larro and Barry Jostol Peter Larro and Barry Jostol
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APEM APEM –– Fall 2011 ForumFall 2011 Forum
High Efficiency Burners and High Efficiency Burners and
--HoneywellHoneywell--Autoflame MM ControlsAutoflame MM Controls--Custom systems locallyCustom systems locally
Do they work well and are they Do they work well and are they reliable ?reliable ?
�� YES YES –– Most burner manufacturers are Most burner manufacturers are going to linkageless as their standardgoing to linkageless as their standard
�� Reliability is very good, systems work as Reliability is very good, systems work as they shouldthey should
�� Case studies have shown fuel savings to as Case studies have shown fuel savings to as much as 20% with the addition of much as 20% with the addition of linkageless control strategieslinkageless control strategies
�� Serviceability of the burner improvesServiceability of the burner improves
Linkageless Control Systems also Linkageless Control Systems also ProvideProvide…………
�� Full PID control of temp / pressure Full PID control of temp / pressure Setpoint by using temp / press Setpoint by using temp / press transmitterstransmitters
�� Setpoint control accurate to within 2 PSI Setpoint control accurate to within 2 PSI or +/or +/-- 22ºº F.F.
�� Enhanced diagnostics, communications, Enhanced diagnostics, communications, data collection and remote monitoring and data collection and remote monitoring and controlcontrol
With a programmable linkageless control system, it is possible to optimize combustion quality for
boiler/burner load requirements. A linkageless combustion-control unit can display positioning data for several individually controlled channels, such as fuel, air, flue-gas recirculation, and atomizing air. Most systems checks the relative positioning of these
channels 50 times per second, ensuring safety and accuracy. This enables the system to achieve “locked-on” near stoichiometric fuel/air mixing throughout a boiler's fuel-input range while maintaining exact
temperature or target pressure values.
Will they work for my boiler Will they work for my boiler ––In most casesIn most cases…….. YES !!.. YES !!
--Initial cost usually limits applicability to Initial cost usually limits applicability to boilers above 100 HP for boilers above 100 HP for ““standardstandard””
systemssystems
--Available as retrofit Available as retrofit ““kitskits”” or as part of or as part of new equipmentnew equipment
-- Applicable to most forced draft burnersApplicable to most forced draft burners
--Even available now on residentially sized Even available now on residentially sized boilersboilers
Major Manufacturers Include:Major Manufacturers Include:
•• Line Voltage & Low VoltageLine Voltage & Low Voltagewiring separationwiring separation
R7999R7999ControllerController
TerminalsTerminalsaccessible foraccessible for
troubleshootingtroubleshooting
Different sizeDifferent sizeterminal pinsterminal pins
prevents improperprevents impropermounting onmounting on
wiring subbasewiring subbase
R7999 ControllerR7999 Controller•• Two Model Numbers :Two Model Numbers :---- R7999AR7999A
100 to 120Vac, 100 to 120Vac, +10% +10% --15%, 15%, 50/60 Hz50/60 Hz---- R7999BR7999B
200 to 240Vac, +10% 200 to 240Vac, +10% --15%, 50/60 Hz15%, 50/60 Hz
•• Four Channel Output Control :Four Channel Output Control :---- Two FuelsTwo Fuels---- Combustion AirCombustion Air---- Flue Gas ReFlue Gas Re--circulationcirculation
•• Operating Temperature :Operating Temperature :-- 4040°°°°°°°°F to +140F to +140°°°°°°°°F F
R7999 ControllerR7999 Controller•• Two Independent Fuel ProfilesTwo Independent Fuel Profiles
-- (950 Positions)(950 Positions)
•• Programmable Positioning for :Programmable Positioning for :-- StandbyStandby-- PurgePurge-- NonNon--Selected FuelSelected Fuel-- Light OffLight Off-- Minimum ModulationMinimum Modulation
Activate & Setup ZM7999AActivate & Setup ZM7999ADefine Burner System ParametersDefine Burner System ParametersEstablish End PointsEstablish End PointsConfigure Profile CurveConfigure Profile CurveVerify (walk) the Profile CurveVerify (walk) the Profile CurveSave the Profile CurveSave the Profile Curve
Two Versions : Open and Enclosed UL & UL RecognizedContains Terminal StripsMain FuseVoltage Selection LinksPressure / Temperature Selection LinksPotentiometer Voltage Selection LinksRS485 Communications Selection Link
Nexus MMI / DisplayNexus MMI / Display
Display NX550
Two Line 20 Character Vacuum Fluorescent Display
Key Pad w/ Multi Purpose Keys
Engineer’s Key
Nexus Servo Motors Nexus Servo Motors
Three Servo Configurations
36 in. lbs. 4 Nm
180 in. lbs. 20Nm
420 in. lbs. 50Nm
Nexus Servo Motor RequirementsNexus Servo Motor Requirements
Servo Motor Control
Type of Motor - AC Up/Down with Feedback PotentiometerNumber of Motors - 3 or 4 Depending on Controller24 Setpoints per ProfilePosition Accuracy 0.1°Response time to Positioning Error
15s for +/- 1.0°1s for +/- 5.0 °
Number of Fuel Motors 1 or 2Number of Air Motors 1 or 2
Optional EquipmentOptional Equipment
–– Pressure SensorsPressure Sensors
–– Temperature SensorTemperature Sensor
–– SequencingSequencing
–– Communication SoftwareCommunication Software
–– O2 TrimO2 Trim
AUTOFLAMEAUTOFLAME
AUTOFLAME FEATURESAUTOFLAME FEATURES
�� Fuel/Air Ratio Controller Fuel/Air Ratio Controller
–– Controls Servo Motors for up to 3 FuelsControls Servo Motors for up to 3 Fuels
Temp (NO and SO are optional)Temp (NO and SO are optional)
Mini M.M. Facia
AUTOFLAMEM.M./E.G.A. Technical Manual
Multiple Systems OptionsMultiple Systems Options
�� ““MMMM”” –– Mark SeriesMark Series
�� Mini Mark V Mini Mark V –– Two fuel channels and FGRTwo fuel channels and FGR
�� Mark VI Evolution Mark VI Evolution –– Six dedicated channelsSix dedicated channels
�� Mini Mark VII Mini Mark VII –– Three channels Three channels –– two fuel and one two fuel and one
VFDVFD
�� Mark VII Evolution Mark VII Evolution –– Six dedicated channels Six dedicated channels –– four four
fuels and two VFDfuels and two VFD
AUTOFLAME MK.6 FEATURESAUTOFLAME MK.6 FEATURES
�� 4 Fuel Curves 4 Fuel Curves
�� Integral Flame SafeguardIntegral Flame Safeguard
�� Gas and Oil Pressure SupervisionGas and Oil Pressure Supervision
�� Combustion Air SupervisionCombustion Air Supervision
�� Integral VFD InterfaceIntegral VFD Interface
�� Quarter VGA ScreenQuarter VGA Screen
AUTOFLAMEM.M./E.G.A. Technical Manual
Optional Exhaust Gas AnalyzerOptional Exhaust Gas Analyzer
Use of an exhaustUse of an exhaust--gas analyzer expands the benefits of gas analyzer expands the benefits of linkageless combustion control. An exhaustlinkageless combustion control. An exhaust--gas gas analyzer measures and displays O2, CO2, carbonanalyzer measures and displays O2, CO2, carbon--monoxide (CO), nitricmonoxide (CO), nitric--oxide (NO), nitrogenoxide (NO), nitrogen--dioxide dioxide (NO2), NOx, and sulfur(NO2), NOx, and sulfur--dioxide (SO2) exhaust dioxide (SO2) exhaust
temperature and combustion efficiency. An exhausttemperature and combustion efficiency. An exhaust--gas analyzer's builtgas analyzer's built--in continuousin continuous--emissionsemissions--monitoring monitoring
software monitors instantaneous and totalized software monitors instantaneous and totalized emission output for each fuel as a weight (cubic feet) emission output for each fuel as a weight (cubic feet) and mass (pounds or tons). Because of the software, and mass (pounds or tons). Because of the software, data collected from the exhaustdata collected from the exhaust--gas analyzer can be gas analyzer can be submitted as an emissions report for a boiler and/or submitted as an emissions report for a boiler and/or
plant annually, quarterly, or monthly.plant annually, quarterly, or monthly.
Data Transfer and Data Transfer and
CommunicationsCommunications
M.M./E.G.A. Technical Manual AUTOFLAMEAUTOFLAME
SiemensSiemens
LMV51 Application
V1DualDual --fuel burnerfuel burner
LMV Basic Unit
�� Real dual fuel burner Real dual fuel burner control control Separate inputs and Separate inputs and outputs for oil and gasoutputs for oil and gas
�� Adjustable timing and Adjustable timing and programmingprogramming
�� Configurable inputs Configurable inputs and outputsand outputs
�� Continuous operation Continuous operation with IR detectionwith IR detection
�� Flexible test timingFlexible test timing�� No additional wiringNo additional wiring�� Only one additional pressure switchOnly one additional pressure switch�� Accuracy via timing adjustableAccuracy via timing adjustable�� Detectable which valve is leakingDetectable which valve is leaking�� Sequence for the test adjustable Sequence for the test adjustable (pre purge, post purge or during both (pre purge, post purge or during both phases)phases)
Gas valve proving system
Electronic air / fuel ratio Electronic air / fuel ratio
controlcontrol
�� Easy wiring of the actuatorsEasy wiring of the actuators�� Easy adjustment of the burnerEasy adjustment of the burner�� Ignition position independent of the Ignition position independent of the curvescurves
�� High adjustment accuracyHigh adjustment accuracy�� Up to 4 actuators:Up to 4 actuators:air, 2 x fuel, auxiliaryair, 2 x fuel, auxiliary
AZLAZLProgramming
• Burner control
• Electronic air/fuel ratio control
• Gas valve proofing
• Load controller
Display burner operation
Diagnosis
Interface communication
Display and programming unit Display and programming unit
(AZL)(AZL)
�� Separate housing removableSeparate housing removable�� Easy menu structure Easy menu structure �� Clear text display (4 x 16 characters)Clear text display (4 x 16 characters)�� 3 languages / other languages possible3 languages / other languages possible�� Functions protected with passwordsFunctions protected with passwords�� 4 different levels: End4 different levels: End--user, Installer, user, Installer, Burner manufacturer, L&SBurner manufacturer, L&S
�� UpUp--load and download and down--load functionality for load functionality for exchangeexchange
�� CommunicationCommunication
Actuator SQM45 / 48Actuator SQM45 / 48
�� High positioning accuracy High positioning accuracy over over the life time and torquethe life time and torque
�� Easy exchangeabilityEasy exchangeability�� Several torque ratingsSeveral torque ratings
�� 25 in. lb.25 in. lb.
�� 175 in. lb.175 in. lb.
�� 350 in. lb.350 in. lb.
QRI...QRI...
�� Infrared flame Infrared flame detector for gas detector for gas and oiland oil
�� Sensor and Sensor and amplifier are amplifier are integratedintegrated
�� Side or frontal Side or frontal scanningscanning
�� Flame signal Flame signal shown on AZL shown on AZL displaydisplay
Parallel PositioningParallel Positioning
Sales ToolsSales ToolsRun
Efficiency calculator can help you sell the customer on fuel savings.
Parallel PositioningParallel Positioning
Possible ApplicationPossible Application
� Hospitals / large health care facilities
� Schools / Institutions
� Prisons
� Federal and State Buildings
� Industrial Steam Generation plants
� Process applications
� Best return on investments for large industrial user
� Any applications that have varying loads
� <20 PPM Low NOx applications
� HTD applications with single fuel and especially on dual fuel
The next optimization stepThe next optimization step……
A burner conversion on A burner conversion on your existing boiler, or the your existing boiler, or the
specification of a specification of a currentcurrent””statestate--ofof--thethe--artart””burner on your new boilerburner on your new boiler
But how are new burners But how are new burners differentdifferent
Integrated burners by the boiler manufacturer…….
• Modulating firing with VFD and air/gas ratio valve
•Maintains same efficiency at all operating points
•Safety and ease of set-up using integral linear air/gas valves (negative ratio)
•Usually not available as a retrofit to other boiler manufacturers
What can new burners do for What can new burners do for meme…………
�� Provide significant fuel savings through better Provide significant fuel savings through better control of combustioncontrol of combustion
�� Provide for reduced emissionsProvide for reduced emissions
�� Offer much better servicabilityOffer much better servicability
�� Run at much more quiet sound levelsRun at much more quiet sound levels
�� Provide for more repeatable operationProvide for more repeatable operation
�� Increase turndown while maintaining incredibly Increase turndown while maintaining incredibly good combustion performancegood combustion performance
�� Enhanced communication ability to DDC systemsEnhanced communication ability to DDC systems
Typical Traditional Burners By:Typical Traditional Burners By:
�� PowerflamePowerflame
�� WebsterWebster
�� RielloRiello
�� WeishauptWeishaupt
Powerflame CPowerflame CMAXMAX BurnerBurner
�� Introduced in 2004Introduced in 2004
�� Over 500 burners sold (All Over 500 burners sold (All Applications)Applications)
�� Capacities from 12 MMBH to Capacities from 12 MMBH to 95 MMBH95 MMBH
�� Fires all gaseous fuels, light Fires all gaseous fuels, light & heavy oil& heavy oil
�� Sub 60 PPM NOx without Sub 60 PPM NOx without IFGR on Natural GasIFGR on Natural Gas
�� Sub 30 PPM with IFGRSub 30 PPM with IFGR
�� Sub 20 PPM on water tubeSub 20 PPM on water tube
�� Energy efficient Energy efficient -- reduced reduced blower motor HPblower motor HP