BURNERMATE TS BOILER CONTROL SYSTEM Overview

203.743.6741 • 203.798.7313www.preferred-mfg.com

Instruments & Controls

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BurnerMate TSisacustom-programmableboilercontrolandflamesafeguardsystemthatincludesoneortwoDCS-IIIloopcontrollersandaflamesafeguardmicroprocessorcommunicating viaModbuswitha10” or 15”OIT touchscreen. The system provided includes an industrialenclosurewithnecessarypushbuttons,selectorswitches,powersupplies,terminalblocks;factorywiredandtestedwith other field devices for a complete system. Eachsystemisprogrammedtothejobspecificrequirementsoftheproject.

Advanced Combustion Control Options• SinglePointPositioning(Jackshaft)control.Effective

controlwithremotemonitoringforsmallerboilers.• Parallel Positioning control with Oxygen Trim and

Variable Speed Fan Combustion Air Flow Control.Combined fuel and electrical savings for fastpayback.

• FullyMeteringcontrolwithOxygenTrimandvariablespeedfancombustionairflowcontrolcreatessuperiorcontrolforLowNOxburnerapplications.Essentialforsimultaneous dual fuel firing,multiple burner boilersandbalanceddraftapplications.

• Optional Drum Level, Draft and/ or Flue GasRecirculationControl

Integral Flame Safeguard• Independent,industrial-hardenedmicroprocessor.• Automaticsingleburner,dualfuel,gasoroilfiring,

sequencing,ignitionandflamemonitoringprotection.

Easy to Order, Stock and Field Upgrade • Factorywiredandtestedcontrolsystem.

Integrated Boiler ManagementTheBurnerMateTS is a combined combustion control,flame safeguard, and SCADAmonitoring and controlsystem. It incorporatesPreferred’s high qualityDCS-IIIMultiple LoopController for boiler control functions, anindustrial-hardenedmicroprocessor for flame safeguardfunctions,andaPC-basedSCADAworkstationforgraphicmonitoringandoperating.BurnerMateTS isa fullscopecontrolpackagethatassuressafeandefficientcontrolwithundividedsystemintegrationresponsibility.

Flexible & ExpandableAsecond,optionalDCS-IIIMultipleLoopControllercanbesuppliedtoprovidedraftanddrumlevelcontrolloopsandbalanceofplantmonitoringwithupto15analoginputs,6analogoutputs,5triacpairoutputs,6relayoutputs,13digital120VACinputs,orcombinationsofthese.BurnerMateTSisdesignedtobemonitoredandcontrolledbytheoptionalSCADA/FlexDistributedControlSystem.

BurnerMate TS Boiler ControlCombustion Control Shown with Optional Flame Safeguard, Drum Level, Draft and FGR Control, Flue Gas Oxygen Analyzer, Flame

Scanner, and SCADA/Flex Distributed Control System

Easy to Operate BurnerMateTSwithitslarge,industrial-gradecolortouchscreensprovidesanintuitive,easilyusedcontrolsystemthatdisplayscurrentboiler status,alarms,andhistoricallogging.The system is password protected for security.Historicaltrendingisstandard.AnoptionalflashcardallowshistoricaldatatobeexportedtoMSExcel.Scalableobjectsenableaccurateprocessdisplays.X/Yplotsareprovidedfor intuitiveFuel/AirCurvesdisplayandcommissioning.TheNEMA4Xfrontpaneleliminatestheneedforprotectiveviewing doors. Easily used OIT_Edit® configurationsoftwarecanbeusedtocustomizegraphicpages.

Integral Oxygen AnalyzerTheZPOxygenProbeisdirectlyconnectedtotheDCS-III controller (eliminating the need for a fieldmountedtransmitter),which simplifies installation.TheModel ZPwithDCS-III-Zxxxisafullfunctionanalyzerwhichincludesspecificanalyzerdiagnosticcodesforrapidtroubleshootingandcontinuousmonitoringofcellimpedanceforpredictingcellhealth.

Easy CommissioningUsing “LearnMode” –F(x) characterizer curvesare setbymanuallypositioningfuelandair forsafeandreliableoperation andoptimumOxygen level and thenpressingthe“STORE”button.Airandoxygensetpointcurvesaresimultaneouslysetup.Theprocesscanberepeatedforamaximumof11loadpoints.Independentcurvesforeachfuelareautomaticallyselected.

BURNERMATE TS BOILER CONTROL SYSTEMOverview



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SpecificationsMechanical

EnclosureType: WindboxMounted(optionalWallMounted)

Size: Typically-30"Hx30"Wx12"DElectrical InputPower: 120VACEnvironmental

OperatingTemp: 32°Fto122°F(0°to50°C)StorageTemp: -20°to150°F(-28°to65°C)HumidityLimits: 15to85%(noncondensing)FrontPanel: NEMA13/IP65

CommunicationNetwork:

Protocol: Modbus(ASCIIorRTUmode)Speed: 1200to38,400baudType: RS485,opticallyisolated

Configuration:Speed: 38,400baudType: RS232

Configuration, DCS-III ControllerLanguage: Functionblockstyle,

60functions,160blocksLaptop(optional): PC3_Edit™spreadsheetbased

editororPC3_Draw™graphical,object-orientededitor

OIT Touch ScreenMechanical 10.4”TFT256ColorVGA

640x480pixelLCDCommunication 10BaseT/100BaseTXEthernet

OneRS-485,SecondOptionalTwoRS-232PortsRemoteWebAccessIsolated,SimultaneousModbusMaster&Slave

Remote Control and MonitoringThe optional SCADA/FLEXDistributedControl Systemprovidesremoteoperation,graphicdisplayofinformation,alarmmessagedisplays,alarmprinting,andremoteboilertuningcapabilities.ThesystemisnetworkedtotheboilercontrolandFlameSafeguardSystems.

Typical Boiler Overview Screen is customized for the application

StandardFeatures• AdvancedCommunication- 10BaseT/100BaseTX

Ethernet- OneRS-485,SecondOptional- TwoRS-232Ports- RemoteWebAccess- Isolated,SimultaneousModbusMaster&Slave

• RealTimeandHistoricalTrendingStandard,optionalFlashCardallowshistoricaldatatobeexportedtoMSExcel.

• Scalableobjectsenableaccurateprocessdisplays• X/YPlots, for intuitiveFuel/AirCurves display and

commissioning• NEMA4XFrontPaneleliminatestheneedforprotective

viewingdoors.• EasilyusedOIT_Edit®ConfigurationSoftware

MajorBenefits• IntegrationwithDCS-IIIControllers enables intuitive

commissioningwithout theuseofLaptopsorPCC-IIIControllerFaceplate.

• BurnerMateTSSystemsmaybecommissionedwithouttheneedforblockwaretrainingorlaptops.

BURNERMATE TS BOILER CONTROL SYSTEMSpecifications

DCS-III Multiple Loop Controller



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BURNERMATE TS BOILER CONTROL SYSTEMOrderingInformation

Ordering Information1. SpecifyBurnerMateTSControlSystemfromthetable(seethefollowingpagesforsystemdescriptions)

Combustion Control Type CatalogNumber

SteamorHotWaterBoilerSteam ST

HotWater HW

SinglePointPositioningCombustionControlTriac** SPTCurrent* SPC

ParallelPositioningCombustionControl Triac PPTFullyMeteredCombustionControl Current FMC

Optional Features OutputType Catalog Number

VariableSpeedDrive(VSD)CombustionAirFanControl(PPTorFMCsystemsonly)

Current add“-VSD”suffix

OxygenTrimControl -- add“-ZP”suffixFlameSafeguard add“-FSG”suffix

DraftControlTriac add“-DRT”suffix

Current add“-DRC”suffix

DrumLevel(Feedwater)Control“X”-Feedwater(1,2,or3)Element

Triac add“-FWT”suffixCurrent add“-FWC”suffix

FlueGasRecirculation(FGR)ControlTriac add“-FGRT”suffix

Current add“-FGRC”suffixWallMountedstyleenclosure(insteadofBurnerWindboxMountedstyle)

add“-WM”suffix

* “Current”outputsprovidea4-20mADCsignaltodriveelectricorpneumaticactuators.** “Triac”outputsprovidedirectcontrolofelectricactuatorssuchastheSM-15Additional Ordering Information (when required)2. Specifyrequiredpressure,temperature,orflowsensorranges3. SpecifyVariableSpeedDrive(VSD)motordata4. SpecifyIn-SituOxygenSensorprobelengthandcablelength5. SpecifySCADA/FlexDistributedControlrequirements

Catalog Number Example:BMTS-HW-FMC-VSD-ZP-FSG-DRT-2-FWC-FGRT: BurnerMate TS for HotWaterGenerator with FullyMetered CombustionControlwithcurrentoutputs,VariableSpeedDrive(VSD)CombustionAirFanControl,OxygenTrimControl,FlameSafeguard,DraftControlwithtriacoutput,TwoElementFeedwaterControlwithcurrentoutput,andFlueGasRecirculationControlwithtriacoutput.

Consult factory for VSD bypass or additional monitoring and control requirements.

CatalogNumber:BMTS-ST-FMC



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ApplicationTheBurnerMateTSModel BMTS-STSP providesautomaticfiringratecontrolforneworexistingsteamboilersusingsinglepointpositioning,combustioncontrol.Inasinglepointpositioningsystemthefuelvalvesandaircontroldamperaremechanicallylinked,andaremodulatedbyasinglecontrolactuator.Generally, the fuel valvehasa characterizableflowversuspositionrelationshipthatisusedtoestablishthefuel/airratioovertherangeofmodulation.SinglepointpositioningcontrolisrecommendedwhentheboilersizeorservicehoursdonotjustifytheadditionofOxygentrimandvariablespeedfancontrollogic.

Model BMTS-STSP Combustion Control System

• SteamDrumPressure isMaintainedusing localPIDsetpointcontrol.PIDcontrolprovidesefficient,accuratecontrolbyeliminatingdrumpressure“offset”(error)

• RespondstoPlantMasterFiringRateandSequencingDemand

• WarmStandby and Low Fire Hold –The boiler isperiodicallystartedandheldatlowfireuntilitreturnstothewarmstandbytemperature.(Aquastatsuppliedbyfiredequipmentmanufacturer)

• OxygenTrim(optional)–UsingtheLinkTrimActuator(LTA)andZP In-SituOxygenSensor,OxygenTrimcanbeaddedtotheBMTS-STSP.

BURNERMATE TS MODEL BMTS-STSPSteamBoilerSinglePointPositioningCombustionControl

Warm Standby

Plant Master

DCS-III

(Aquastat)



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OrderingInformation

Description Catalog Number

SteamBoilerControlwithTriacOutput BMTS-STSPT

SteamBoilerControlwithCurrentOutput BMTS-STSPC

Order Sensors Separately(Optional)

Catalog Number

SteamPressureTransmitter,4-20mADC,0to200PSI,NEMA4,Smartwithsinglevalvemanifold

Consult Factory

SpecificationsBurnerMate TS Control Panel

Touchscreen: OIT-10orOIT-15Controller: DCS-III-0000 InputPower: 120VAC(+/-15%)

InputsDrumPressure: 4-20mADCPlantMaster: 4-20mADC*WarmStandby: 120VAC,opticallyisolated*

OutputsBoilerModulation: 4-20mADCorTriac

*Thesefeaturesarestandard,buttheiruseisselectableattimeofstart-up.

ConsultFactoryforInputsandOutputsincludedwith“-ZP”option.

Suggested Specification1. ApplicationSupplyaself-contained,BoilerControlSystemwith10”(or15”)colortouchscreentoprovideprocesscontrolofsteampressure,combustion air, and fuel flow. The control system shall bemicroprocessor-basedandsuitableforwallorwindboxmounting.Allthelogicrequiredtoensurethatpre-purge,post-purge,light-off,andburnermodulatecyclesareautomatic.2. Combustion ControlAPID-based single point positioning combustion control logicschemeshallbeusedtomaintainsteamdrumpressureatsetpoint.Thefuelflowcontrolvalveshallbemechanicallylinkedtotheairflowcontroldevicetoassureanairrichfuel/airratio.Mechanicallinkageadjustmentshallberequiredtoadjustthefuel/airratio.A combustion controlmicroprocessor failure shall not preventthecontinuedmanualoperationoftheboiler.Fuelvalveandairdampershallbemodulatedinresponsetoanexternalplantmasterdemandsignalormeasuredboilerdrumpressurecomparedtosetpoint.Atminimum,thecontrolsystemshalldisplaythefollowing:steampressure,steampressuresetpoint,boilerfiringrateandalarmmessagesforlowpressure,highpressure,andpressuresetpointdeviation.Thefollowingcolortouchscreengraphicpagesshall be provided: boiler overview, flame safeguard overview,controlpanelfaceplatewithrealtimeandhistoricaltrending,setupandcommissioningscreens,andboileralarm.

3. Boiler ControllersTo assure system integrity, a pre-wired and factory-tested,microprocessor-based,multiple loop controller systemshall beprovided.Thecontrollershallincludeprocessvariableand“first-out”annunciator,120VACdiscreteinputsandoutputs,and4-20mADCanaloginputsandoutputs.Configurationandcalibrationdatashallbestoredonredundantnon-volatileEEPROMmemorymodules.Thebackupmemorymoduleshallautomaticallydownloadintotheprimarymemoryifprimarymemorydataiscorrupted.Allcontrollogic,tuning,andfuel/airratiocurvesshallbefieldconfigurable.Ifrequiredtoallowfieldmodificationstothecontrollerlogic,provideoneconfigurationtoolorlaptopcomputerperfacility.4. CommunicationEachcontrollershallbeequippedwithanopticallyisolatedRS485modbuscommunicationsdatahighwayconnection to thecolortouchscreen.ThetouchscreenshallcommunicatewiththeplantBAS,EMS,orDCSbyaModbusoverEthernetcommunicationsdatahighwayandshallallow:auto/manualmodechange,setpointchange,variationofthemanualoutput,sensingandsilencingofalarms, changeof any configuration parameter (includingPIDtuningconstants),changeoftimers,etc.Provideallequipmentcapabilities specified in this paragraph, even if a connectingSCADAsystemisnotincludedinthisproject.5. Quality AssuranceThesystemshallbefactorymanufacturedandtestedaccordingtoUL508A requirements (CSAC22.2#14 for use inCanada).ThecontrolsystemshallbeaPreferred Instruments,Danbury,CT,BurnerMate TS Model BMTS-STSPx (‘x’=“C”or“T”todenoteaCurrentorTriacControlOutput).

BURNERMATE TS MODEL BMTS-STSPSuggestedSpecifications



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ApplicationTheBurnerMateTSModel BMTS-HWSP providesautomaticfiringratecontrolforneworexistinghotwaterboilersusingsinglepointpositioningcombustioncontrol.Inasinglepointpositioningsystemthefuelvalvesandaircontroldamperaremechanicallylinked,andaremodulatedbyasinglecontrolactuator.Generally, the fuel valvehasa characterizableflowversuspositionrelationshipthatisusedtoestablishthefuel/airratioovertherangeofmodulation.Singlepointpositioningcontrolisrecommendedwhentheboilersizeorservicehoursdonotjustifytheadditionofoxygenrimandvariablespeedfancontrollogic.

Model BMTS-HWSP Combustion Control System

• HotWaterTemperature isMaintainedusing localPIDsetpointcontrol.PIDcontrolprovidesefficient,accuratecontrolbyeliminatingtemperature“offset”(error)

• RespondstoPlantMasterFiringRateandSequencingDemand

• LowFireHold–Firingratemaybeheldatlowfireduringwarm-up,orbaseloadedatanoptimumlevelinresponsetothelead/lagcontroller

• OxygenTrim(optional)–UsingtheLinkTrimActuator(LTA)andZP In-SituOxygenSensor,OxygenTrimcanbeaddedtotheBMTS-HWSP.

BURNERMATE TS MODEL BMTS-HWSPHotWaterBoilerSinglePointPositioningCombustionControl

Warm Standby

DCS-III



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Suggested Specification1. ApplicationSupplyaself-containedBoilerControlSystemwith10”(or15”)colortouchscreentoprovideprocesscontrolofwatertemperature,combustion air and fuel flow. The control system shall bemicroprocessor-basedandsuitableforwallorwindboxmounting.Allthelogicrequiredtoensurethatpre-purge,post-purge,light-off,andburnermodulatecyclesareautomatedshallbeprovided.2. Combustion ControlAPIDbased single point positioning combustion control logicschemeshallbeusedtomaintainwatertemperatureatsetpoint.Thefuelflowcontrolvalveshallbemechanicallylinkedtotheairflowcontroldevicetoassureanairrichfuel/airratio.Mechanicallinkageadjustmentshallberequiredtoadjust thefuel/airratio.A combustion controlmicroprocessor failure shall not preventthe continuedmanual operation of the boiler. Fuel valve andairdampershallbemodulatedinresponsetoanexternalplantmasterdemandsignalormeasuredwatertemperaturecomparedto setpoint.Atminimum, the control system shall display thefollowing:water temperature, temperature setpoint, firing rateandalarmmessagesforlowtemperature,hightemperature,andtemperaturesetpointdeviation.Thefollowingcolortouchscreengraphicpagesshallbeprovided:boileroverview,flamesafeguardoverview, control panel faceplatewith real timeand historicaltrending,set-upandcommissioningscreens,andboileralarm.3. Hot Water Temperature SetpointWhenthecontrollerisintheautomaticmode,thecontrolsystemshallestablish thesetpointbasedonday-nightandoutsideairtemperature.When inmanualmode, theoperatormayset thesetpointviathefrontpaneldisplay.

4. Boiler ControllersTo assure system integrity, a pre-wired and factory-tested,microprocessor-based,multiple loop controller systemshall beprovided.Thecontrollershallincludeprocessvariableand“first-out”annunciator,120VACdiscreteinputsandoutputs,and4-20mADCanaloginputsandoutputs.Configurationandcalibrationdatashallbestoredonredundantnon-volatileEEPROMmemorymodules.Thebackupmemorymoduleshallautomaticallydownloadintotheprimarymemoryifaprimarymemorydataiscorrupted.Allcontrollogic,tuning,andfuel/airratiocurvesshallbefieldconfigurable.Ifrequiredtoallowfieldmodificationstothecontrollerlogic,provideoneconfigurationtoolorlaptopcomputerperfacility.5. CommunicationEachcontrollershallbeequippedwithanopticallyisolatedRS485modbuscommunicationsdatahighwayconnection to thecolortouchscreen.ThetouchscreenshallcommunicatewiththeplantBAS,EMS,orDCSbyaModbusoverEthernetcommunicationsdatahighwayandshallallow:auto/manualmodechange,setpointchange,variationofthemanualoutput,sensingandsilencingofalarms, changeof any configuration parameter (includingPIDtuningconstants),changeoftimers,etc.Provideallequipmentcapabilities specified in this paragraph, even if a connectingSCADAsystemisnotincludedinthisproject.6. Quality AssuranceThesystemshallbefactorymanufacturedandtestedaccordingtoUL508A requirements (CSAC22.2#14 for use inCanada).Thesystemshallbedesignedtoinsurethesafestart-up,on-lineoperation and shutdownof fuel firing equipment.The controlsystemshallbeaPreferredInstruments,Danbury,CT,BurnerMateTS Model BMTS-HWSPx(‘x’=“C”or“T”todenoteaCurrentorTriacControlOutput).


Touchscreen: OIT-10orOIT-15Controller: DCS-III-0000 InputPower: 120VAC(+/-15%)

InputsWaterTemperature: 4-20mADCPlantMaster: 4-20mADC*WarmStandby: 120VAC,opticallyisolated

(Optional)*

OutputsBoilerModulation: 4-20mADCorTriac


ConsultFactoryforInputsandOutputsincludedwith“-ZP”option.


Catalog Number

HotWaterTransmitter,4-20mADC, 0to500°F,NEMA4,with4.5"depth Consult Factory

Thermowell,SS,4.5"x½NPT Consult Factory

Ordering Information


HotWaterBoilerControlwithTriacOutput BMTS-HWSPT

HotWaterBoilerControlwithCurrentOutput BMTS-HWSPC

BURNERMATE TS MODEL BMTS-HWSPSuggestedSpecifications



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ApplicationTheBurnerMateTSModel BMTS-STPPT providesautomaticfiring rate control forneworexistingsteamorhotwaterboilersusingparallel positioning combustion controlwithbothoxygentrimandvariablespeedfancombustionairflowcontrol.Separatecontrolleroutputsareprovidedforeachfuelflowcontrolvalve,aircontroldamperandVariableSpeedDrive(VSD).Fuel/airratioisestablishedandadjustedbyuseofa“soft”functioncurveoffuelvalvepositionvs.airfanspeedanddamperposition.CrosslimitingusingVSDandactuatorpositionfeedbacks isemployedforsafetyandtopreventcombustionorsmokeduringloadchanges.

Model BMTS-STPPT Combustion Control System

• SteamDrumPressure IsMaintained using localPIDsetpointcontrol.PIDcontrolprovidesefficient,accuratecontrolbyeliminatingdrumpressure“offset”(error).Italsorespondstoplantmasterdemand.

• MinimumFuelUsage–FluegasOxygen is used tocontinuouslyadjust(trim)thefuel/airratio.Oxygentrimsavesfuelbyfinetuningtheburnertooperatesafelyandreliably,reducingexcessairlevelsthroughouttheburnerfiringrange

• MinimumFanPowerUsage–Fanspeedcontrolminimizesdamperpressuredroprelatedtofanpowerusage

• RealTimeBoilerEfficiencyDisplay–Allows theboileroperator to instantly identify inefficienciesandpotentialoperatingproblems

• Safety–Fluegastemperatureandoxygenaremonitored.Warningalarmsandburnersafetyshutdowninterlocksareavailable.VSDspeedandactuatorpositionfeedbacksarecontinuouslymonitoredandtheburnertripsifanyareoutofposition.

BURNERMATE TS MODEL BMTS-STPPTSteamBoilerParallelPositioningCombustionControl

DCS-III



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Catalog Number


Consult Factory

OrderingInformation


SteamBoilerControl BMTS-STPPT

AdditionalOrderingInformationandSuggestedSpecifications1. Model ZPIn-SituOxygenSensor2. VariableSpeedDrive(VSD)3. RotaryActuator(SMorUM)4. Consult factory for low fire changeover, VSD bypass or

pneumaticactuators


Touchscreen: OIT-10orOIT-15Controller: DCS-III-GZS0 InputPower: 120VAC(+/-15%)

InputsDrumPressure: 4-20mADCFlueGasTemperature: T/C(Option“-ZP”)FlueGasOxygen: ZP Probe(Option“-ZP”)PlantMaster: 4-20mADC*FuelGasActuatorFeedback:PotentiometerFuelOilActuatorFeedback: PotentiometerAirActuatorFeedback: PotentiometerVSDSpeedFeedback: 4-20mADC

(Option“-VSD”)Outputs

BoilerEfficiency: 4-20mADCFuelGasValveActuator: TriacFuelOilValveActuator: TriacAirDamperActuator: TriacVSDSpeedDemand: 4-20mADC

(Optional“-VSD”)


BURNERMATE TS MODEL BMTS-STPPTSteamBoilerParallelPositioningCombustionControl



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1. ApplicationSupplyaself-containedBoilerControlSystemwith10”(or15”)colortouchscreentoprovidebothelectricityandfuelsavingswithinthe limitsofstableburneroperation.Thecontrolsystemshallbemicroprocessor-basedandsuitableforwallorwindboxmounting.Provideallthelogicrequiredtoensureautomatedpre-purge,post-purge,light-off,andburnermodulatecycles.2. Combustion ControlAPID-based,parallelpositioningcontrolstrategyshallpositionthefuelvalve(s),combustionairdamper,and forceddraft fanspeedforminimumfankWhusage,andshallcontinuouslytrimthefuel/airratiobasedonmeasuredfluegasoxygenlevelsforminimumfuelconsumption.Systemsthatcontrolforceddraftfanspeedbasedsimplyonburnerwindboxpressurearenotacceptable.Thesystemshallpositionthefuelandcombustionairfinalcontrolelements’movementandVSDspeedwith“positioncross-limiting”toensurethatasafefuel/airratioismaintainedunderallloadchangeconditions.Fuel/airratioshallbeestablishedandadjustedbytheuseofa“soft”functioncurverelatingfuelvalvepositiontoairdamperposition.ProvideaPIDbasedoxygentrimcontrolstrategywithautomaticadaptivegainforstableoperation.Fluegasoxygensetpointshallvaryautomaticallybasedonfiringrate.Fuelvalveandairdampershallmodulateinresponsetoanexternalplantmasterdemandsignalormeasuredboilerdrumpressurecomparedtosetpoint.Atminimum,thecontrolsystemshalldisplaythefollowing:boilerfiringrate,steampressure,steampressuresetpoint,boilerefficiency,trimpercent,fluegasoxygensetpoint,fluegasoxygen,fluegas temperature, fuelvalveposition,airdamperposition,andVSDspeedandalarmmessagesforlowpressure,highpressure,highfluegastemperature,lowoxygen,lowoxygentrip,fueltrip,dampertrip,VSDtrip,andoxygencellfault.Thefollowingcolortouchscreengraphicpagesshallbeprovided:boileroverview,flamesafeguardoverview,controlpanelfaceplatewithrealtimeandhistoricaltrending,set-upandcommissioningscreens,andboileralarm.Thecontrolsystemshallincludeadedicated,normallyenergized,failsaferelayoutputcontactinthe“running”interlockcircuitoftheflamesafeguardthatwillcauseafiredequipmentshutdownintheeventof:lowoxygen,airdamperactuatorfault,fuelvalveactuatorfault,VSDfault,orcontrollerfault.3. Boiler Efficiency DisplayRealtimeboilerefficiencyshallbecalculatedanddisplayed,therebyallowing theboileroperator to instantly identify inefficienciesandpotentialoperationalproblems.ThecalculationshallbebasedontheASME“bylosses”methodandmustutilizerealtimeinputsofboilerfiring rate,fluegasoxygen,fluegas temperatureand fuelselected.Twosetsofadjustablefuelchemistrydataparametersshallbeincluded,andfiringratescaledradiationlossesshallbeusedformaximumaccuracy.Calculations that relyonfixedconstants,ormanuallyinputtedvaluesfortheseconditions,arenotacceptable.NOTE:Fluegas temperature transmittersmustbeprovidedandinstalledateachboileroutlet.

4. Boiler ControllersTo assure system integrity, a pre-wired and factory-tested,microprocessor-based,multiple loop controller systemshall beprovided.Thecontroller shall includeprocessvariableand “first-out”annunciatordisplays.Configurationandcalibrationdatashallbestoredonredundantnon-volatileEEPROMmemorymodules.Thebackupmemorymoduleshallautomaticallydownloadintotheprimarymemory ifprimarymemorydata iscorrupted. Allcontrollogic,tuning,andfuel/airratiocurvesshallbefieldconfigurable.Ifrequiredtoallowfieldmodificationstothecontrollerlogic,provideoneconfigurationtoolorlaptopcomputerperfacility.5. Flue Gas Oxygen AnalyzerProvideaboilerbreechingmountedin-situ,zirconiumoxideOxygenanalyzerforeachboiler.Extractiveor“wetcell”typeoxygenanalyzersarenotacceptable.Theprobeshallbeofasuitablelengthforsensingtheoxygenlevelinthemiddle⅓ofthebreeching.Allwettedpartsshallbestainlesssteel.Theoxygenanalyzershallincludeadigitalcontrollerthatperformscontinuousself-diagnosticswithdiagnosticcodesforatleast10commonfaults.Thesystemshallautomaticallysend the trimactuator to the ‘null’positionand trigger thealarmdrycontactsintheeventofanoxygenanalyzerfault.Thedetectorshallbefieldreplaceablewithoutremovingtheprobefromthestackandshallnotrequirespecialtools.Theanalyzershallautomaticallyperformperiodicdetectorcell impedancetests tobeusedbytheoperatorasanindicationofcalibrationshift.Analyzercalibrationshallbepushbuttonsemi-automatic(notrimpots),withEnglishlanguagepromptsanddiagnosticmessages.Analyzeroutputshallbefieldselectableas0-10%or0-21%withoutfieldrecalibration.6. CommunicationEachcontrollershallbeequippedwithanopticallyisolatedRS485modbuscommunicationsdatahighwayconnection to thecolortouchscreen.ThetouchscreenshallcommunicatewiththeplantBAS,EMS,orDCSbyaModbusoverEthernetcommunicationsdatahighwayandshallallow:auto/manualmodechange,setpointchange,variationof themanualoutput,sensingandsilencingofalarms,changeofanyconfigurationparameter(includingPIDtuningconstants),changeoftimers,etc.Provideallequipmentcapabilitiesspecifiedinthisparagraph,evenifaconnectingSCADAsystemisnotincludedinthisproject.7. Quality AssuranceThesystemshallbe factorymanufacturedand testedaccordingtoUL508Arequirements(CSAC22.2#14foruseinCanada).Thecontrol systemshall beaPreferred Instruments,Danbury,CT,BurnerMate Model BMTS-STPPT-ZP-VSD.

BURNERMATE TS MODEL BMTS-STPPTSuggestedSpecifications



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ApplicationTheBurnerMateTSModel BMTS-HWPPT providesautomaticfiringratecontrolforneworexistinghotwaterboilersusingparallel positioning combustion controlwith bothoxygentrimand variable speed fan combustionair flowcontrol.Separatecontrolleroutputsareprovidedforeachfuelflowcontrolvalve,aircontroldamperandvariablespeeddrive(VSD).Fuel/airratioisestablishedandadjustedbyuseofa“soft”functioncurveoffuelvalvepositionvs.airfanspeedanddamperposition.CrosslimitingusingVSDandactuatorposition feedbacks isemployed for safetyand topreventcombustiblesorsmokeduringloadchanges.

Model BMTS-HWPPT Combustion Control System

• HotWaterTemperature isMaintainedusing localPIDsetpointcontrol.PIDcontrolprovidesefficient,accuratecontrolbyeliminatingdrumpressure“offset”(error).AlsorespondstoPlantMasterdemand

• MinimumFuelUsage –Flue gas oxygen is used tocontinuouslyadjust(trim)thefuel/airratio.oxygentrimsavesfuelbyfinetuningtheburnertooperatesafelyandreliablyatreducedexcessairlevelsthroughouttheburnerfiringrange

• MinimumFanPowerUsage–Fanspeedcontrolminimizesdamperpressuredroprelatedtofanpowerusage

• RealTimeBoilerEfficiencyDisplay–Allows theboileroperator to instantly identify inefficienciesandpotentialoperationalproblems

• Safety–Fluegastemperatureandoxygenaremonitored.Warningalarmsandburnersafetyshutdowninterlocksareavailable.VSDspeedandactuatorpositionfeedbacksarecontinuouslymonitored,andtheburnertripsifanyareoutofposition.

BURNERMATE TS MODEL BMTS-HWPPTHotWaterBoilerParallelPositioningCombustionControl

DCS-III



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Catalog Number

HotWaterTemperatureTransmitter,4-20mADC, 0to500°F,NEMA4,Smartwith4½"depth

Consult Factory

Thermowell,SS,4½"x½NPT Consult Factory

OrderingInformation


HotWaterBoilerControl BMTS-HWPPT

AdditionalOrderingInformationandSuggestedSpecifications1. Model ZPIn-SituOxygenSensor2. VariableSpeedDrive(VSD)3. Actuator(SMorUM)4. ConsultfactoryforlowfirechangeoverandVSDbypass

SpecificationsBurnerMate TS Panel

Touchscreen: OIT-10-orOIT-15Controller: DCS-III-GZS0 InputPower: 120VAC(+/-15%)

InputsWaterTemperature: 4-20mADCFlueGasTemperature: T/C(Option“-ZP”)FlueGasOxygen: ZP Probe(Option“-ZP”)PlantMaster: 4-20mADC*FuelGasActuatorFeedback:PotentiometerFuelOilActuatorFeedback: PotentiometerAirActuatorFeedback: PotentiometerVSDSpeedFeedback: 4-20mADC

(Option“-VSD”)Outputs

BoilerEfficiency: 4-20mADCFuelGasValveActuator: TriacFuelOilValveActuator: TriacAirDamperActuator: TriacVSDSpeedDemand: 4-20mADC

(Option“-VSD”)


BURNERMATE TS MODEL BMTS-HWPPTHotWaterBoilerParallelPositioningCombustionControl



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1. ApplicationSupplyaself-containedBoilerControlSystemwith10”(or15”)colortouchscreentoprovidebothelectricityandfuelsavingswithinthe limitsofstableburneroperation.Thecontrolsystemshallbemicroprocessor-basedandsuitableforwallorwindboxmounting.Provideallthelogicrequiredtoensureautomatedpre-purge,post-purge,light-off,andburnermodulatecycles.2. Combustion ControlAPIDbased,parallelpositioningcontrolstrategyshallpositionthefuelvalve(s),combustionairdamper,and forceddraft fanspeedforminimumfankWhusage,andshallcontinuouslytrimthefuel/airratiobasedonmeasuredfluegasoxygenlevelstominimizefuelconsumption.Systems thatcontrol forceddraft fanspeedbasedsimplyonburnerwindboxpressurearenotacceptable.Thesystemshallposition the fuelandcombustionair final controlelements’movementandVSDspeedwith“positioncross-limiting”toinsurethatasafefuel/airratioismaintainedunderallloadchangeconditions.Fuel/airratioshallbeestablishedandadjustedbytheuseofa“soft”functioncurve relating fuel valveposition toairdamperposition.ProvideaPIDbasedoxygen trimcontrolstrategywithautomaticadaptivegainforstableoperation.Fluegasoxygensetpointshallvaryautomaticallybasedonfiringrate.Fuelvalveandairdampershallmodulate in response toanexternalplantmasterdemandsignalormeasuredhotwatertemperaturecomparedtosetpoint.Atminimum,thecontrolsystemshalldisplaythefollowing:boilerfiringrate,hotwatertemperature,hotwatertemperaturesetpoint,boilerefficiency,trimpercent,fluegasoxygensetpoint,fluegasoxygen,fluegastemperature,fuelvalveposition,airdamperposition,andVSDSpeedandalarmmessagesforlowtemperature,hightemperature,highfluegas temperature, lowoxygen, lowoxygen trip, fuel trip,damper trip,VSD trip,andoxygencell fault.The following colortouchscreengraphicpagesshallbeprovided:boileroverview,flamesafeguardoverview,controlpanelfaceplatewithrealtimeandhistoricaltrending,set-upandcommissioningscreens,andboileralarm.Thecontrolsystemshallincludeadedicated,normallyenergized,failsaferelayoutputcontactinthe“running”interlockcircuitoftheflamesafeguardthatwillcauseafiredequipmentshutdownintheeventof:lowoxygen,airdamperactuatorfault,fuelvalveactuatorfault,VSDfault,orcontrollerfault.3. Hot Water Temperature SetpointWhenthecontrollersetpointisinautomaticmodethecontrolsystemshallestablishthesetpointbasedonoutsideairtemperature.Wheninmanualmode,theoperatormayadjustthesetpointviathefrontpaneldisplay.4. Boiler Efficiency DisplayRealtimeboilerefficiencyshallbecalculatedanddisplayed,therebyallowing theboileroperator to instantly identify inefficienciesandpotentialoperatingproblems.ThecalculationshallbebasedontheASME“bylosses”methodandmustutilizerealtimeinputsofboilerfiringrate,fluegasOxygen,fluegastemperatureandfuelselected.Twosetsofadjustable fuel chemistrydataparameters shall be

included,andfiringratescaledradiation lossesshallbeused formaximumaccuracy.Calculations that relyonfixedconstants,ormanuallyenteredvaluesfortheseconditions,arenotacceptable.NOTE:Fluegas temperature transmittersmustbeprovidedandinstalledateachboileroutlet.5. Boiler ControllersTo assure system integrity, a pre-wired and factory-tested,microprocessor-based,multiple loop controller systemshall beprovided.Thecontrollershall includeprocessvariableand “first-out”annunciatordisplays.Configurationandcalibrationdatashallbestoredonredundantnon-volatileEEPROMmemorymodules.Thebackupmemorymoduleshallautomaticallydownloadintotheprimarymemoryifaprimarymemorydataiscorrupted.Allcontrollogic,tuning,andfuel/airratiocurvesshallbefieldconfigurable.Ifrequiredtoallowfieldmodificationstothecontrollerlogic,provideoneconfigurationtoolorlaptopcomputerperfacility.6. Flue Gas Oxygen AnalyzerProvideaboilerbreechingmountedin-situ,zirconiumoxideoxygenanalyzerforeachboiler.Extractiveor“wetcell”typeoxygenanalyzersarenotacceptable.Theprobeshallbeofasuitablelengthforsensingtheoxygenlevelinthemiddle⅓ofthebreeching.Allwettedpartsshallbestainlesssteel.Theoxygenanalyzershallincludeadigitalcontrollerthatperformscontinuousself-diagnosticswithdiagnosticcodesforatleast10commonfaults.Thesystemshallautomaticallysendthetrimactuatortothe‘null’positionandtriggerthealarmdrycontactsintheeventofanoxygenanalyzerfault.Thedetectorshallbefieldreplaceablewithoutremovingtheprobefromthestackandshallnotrequirespecialtools.Theanalyzershallautomaticallyperformperiodicdetectorcellimpedanceteststobeusedbytheoperatorasanindicationofcalibrationshift.Analyzercalibrationshallbepush-buttonsemi-automatic(notrimpots),withEnglishlanguagepromptsanddiagnosticmessages.Analyzeroutputshallbefieldselectableas0-10%or0-21%withoutfieldrecalibration.7. CommunicationEachcontrollershallbeequippedwithanopticallyisolatedRS485modbuscommunicationsdatahighwayconnection to thecolortouchscreen.ThetouchscreenshallcommunicatewiththeplantBAS,EMS,orDCSbyaModbusoverEthernetcommunicationsdatahighwayandshallallow:auto/manualmodechange,setpointchange,variationof themanualoutput,sensingandsilencingofalarms,changeofanyconfigurationparameter(includingPIDtuningconstants),changeoftimers,etc.Provideallequipmentcapabilitiesspecifiedinthisparagraph,evenifaconnectingSCADAsystemisnotincludedinthisproject.8. Quality AssuranceThesystemshallbe factorymanufacturedand testedaccordingtoUL508Arequirements(CSAC22.2#14foruseinCanada).Thecontrol systemshall beaPreferred Instruments,Danbury,CT,BurnerMate Model BMTS-HWPPT-ZP-VSD.

BURNERMATE TS MODEL BMTS-HWPPTSuggestedSpecifications



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ApplicationTheBurnerMateTSModel BMTS-STFMC providesautomaticfiringratecontrolforneworexistingsteamboilersusingfullymeteredcombustioncontrol.Boththefuelflowandtheairflowareaccuratelymeasured.Measuredtemperatureorpressureisusedtogenerateasetpointforfuelflowandairflow.Thefuelflowsetpointiscomparedagainstactualfuelflowtocontrolthefuelmeteringvalvesandtheactualairflowiscomparedagainsttheairflowsetpointtocontroltheaircontroldamper.Crosslimitingusingmeasuredfuelandcombustionairflowisemployedforsafetyandtopreventcombustiblesorsmokeduringloadchanges.Fullymeteredcontrolwithoxygentrimminimizesexcessair.

Model BMTS-STFMC Combustion Control System

• SteamDrumPressure isMaintainedusing localPIDsetpointcontrol.PIDcontrolprovidesefficient,accuratecontrolbyeliminatingdrumpressure“offset”(error).Alsorespondstoplantmasterdemand.

• MinimumFuelUsage–Measuredfuel,airflowandfluegasoxygenisusedtocontinuouslyadjust(trim)thefuel/airratio.Oxygentrimsavesfuelbyfinetuningtheburnertooperatesafelyandreliablyatreducedexcessairlevelsthroughouttheburnerfiringrange.

• MinimumFanPowerUsage–Fanspeedcontrolminimizesdamperpressuredroprelatedtofanpowerusage.

• RealTimeBoilerEfficiencyDisplay–Allows theboileroperator to instantly identify inefficienciesandpotentialoperationalproblems.

• Safe and Dependable Boiler Control – Flue gastemperatureandoxygenaremonitored.Warningalarmsandburnersafetyshutdowninterlocksareavailable.

BURNERMATE TS MODEL BMTS-STFMCSteamBoilerFullyMeteredCombustionControl

DCS-III



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OrderingInformation


SteamBoilerControl BMTS-STFMC

Additional Ordering Information and Suggested Specifications1. Model ZPIn-SituOxygenSensor2. VariableSpeedDrive(VSD)3. Actuator4. ConsultfactoryforlowfirefuelchangeoverandVSDbypass


Catalog Number


Consult Factory

OilFlow,OvalGeartype,4-20mADC,NEMA4 Consult Factory

GasFlow,ThermalInsertionMassFlow,4-20mADC,NEMA4

Consult Factory

AirFlow,differentialpressuretransmitter,4-20mADC,NEMA4,Smartwith3valvemanifold

Consult Factory

SpecificationsBurnerMate TS Panel

Touchscreen: OIT-10orOIT-15Controller: DCS-III-FZ00 InputPower: 120VAC(+/-15%)

InputsDrumPressure: 4-20mADCFlueGasTemperature: T/C(Option“-ZP”)FlueGasOxygen: ZP Probe(Option“-ZP”)PlantMaster: 4-20mADC*FuelGasFlow: 4-20mADC*FuelOilFlow: 4-20mADC*AirFlow: 4-20mADCVSDSpeedFeedback: 4-20mADC(Option“-VSD”)

OutputsFuelOilValveActuator: 4-20mADC*FuelGasValveActuator:4-20mADC*AirDamperActuator: 4-20mADCVSDSpeedDemand: 4-20mADC(Option“-VSD”)


BURNERMATE TS MODEL BMTS-STFMCSteamBoilerFullyMeteredCombustionControl



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1. ApplicationSupplyaself-containedBoilerControlSystemwith10”(or15”)colortouchscreentominimizeconsumptionofbothelectricityandfuelwithin the limitsofstableburneroperation.Thesystemshallusea flowmeter cross-limited fullmeteringcombustioncontrollogicschemewithoxygentrimandvariablespeedcombustionairfancontroltomaintainmainsteamheaderpressureattheselectedvalue.Positioningsystemsthatdependonactuatorfeedbackpotsforcross limitingarenotacceptable.Thecontrolsystemshallbemicroprocessor-basedandsuitableforwallorwindboxmounting.All the logicprovidespre-purge,post-purge, light-off,andburnermodulatecyclesareautomatedshallbeprovided.2. Combustion ControlThe fuelflowcontrol loopshallbecross-limitedwith theair flowcontrol loopsothatfueldemandcannotbeincreaseduntilanairflowincreaseisprovenbytheairflowmeasurementloopandairdemandcannotbedecreaseduntilafuelflowdecreaseisprovenbythefuelflowmeasurementloop.Inaddition,fueldemandcannotbeincreasedbeyondacertainamountabovethemeasuredairflow,andairdemandcannotbedecreasedbeyondacertainamountbelowthemeasuredfuelflow.Fuel/airratioshallbeestablishedandadjustedbytheuseofa“soft”functioncurve,relatingfuelflowsetpointtoairflowsetpoint.Oxygentrimshallbeaccomplishedbyvaryingthefuel/airratioandshallincludeseparatecharacterizableoxygensetpointcurvesforbothoilandgasfuels.Fuelvalveandairdampershallbemodulatedinresponsetoanexternalplantmasterdemandsignalormeasuredsteampressurecomparedtosetpoint.Provisionshallbemadetoautomaticallyswitchthecontrolmodefrommeteringtopositioningcontroloftheaircontroldamperwheneverthefiringrateoftheunitisbelowtheturndownrangeoftheairflowtransmitter.Thiscontrolsystemshallrequiretheburnertobeshutdowntochangefuels.Atminimum,thecontrolsystemshalldisplaythefollowing:boilerfiringrate,steampressure,steampressuresetpoint,gasflow,oil flow,fluegasoxygen, fuelvalveposition,airflow,airdamperpositionandVSDspeed.Thefollowingcolortouchscreengraphicpages shall be provided: boiler overview, FlameSafeguardoverview, control panel faceplatewith real timeand historicaltrending,set-upandcommissioningscreens,andboileralarm.Thecontrolsystemshallincludeadedicated,normallyenergized,failsaferelayoutputcontactinthe“running”interlockcircuitoftheflamesafeguardthatwillcauseafiredequipmentshutdownintheeventof:lowoxygen,lowfuelflow,highfluegastemperature,VSDfault,orcontrollerfault.3. Boiler Efficiency CalculationRealtimeboilerefficiencyshallbecalculated.ThecalculationshallbebasedontheASME“bylosses”methodandmustutilizerealtimeinputsofboilerfiringrate,fluegasoxygen,fluegastemperatureandfuelselected.Twosetsofadjustablefuelchemistrydataparametersshallbeincluded,andfiringratescaledradiationlossesshallbeusedformaximumaccuracy.NOTE:Fluegastemperaturetransmittersmustbeprovidedandinstalledateachboileroutlet.

4. Boiler ControllersTo assure system integrity, a pre-wired and factory-tested,microprocessor-based,multiple loop controller systemshall beprovided.Thecontrollershallincludeprocessvariableand“first-out”annunciatordisplays.Configurationandcalibrationdatashallbestoredonredundantnon-volatileEEPROMmemorymodules.Thebackupmemorymoduleshallautomaticallydownloadintotheprimarymemoryifprimarymemorydataiscorrupted.Allcontrollogic,tuning,andfuel/airratiocurvesshallbefieldconfigurable.Ifrequiredtoallowfieldmodificationstothecontrollerlogic,provideoneconfigurationtoolorlaptopcomputerperfacility.5. Flue Gas Oxygen AnalyzerProvideaboilerbreechingmountedin-situ,zirconiumoxideoxygenanalyzerforeachboiler.Extractiveor“wetcell”typeoxygenanalyzersarenotacceptable.Theprobeshallbeofasuitablelengthforsensingtheoxygenlevelinthemiddle⅓ofthebreeching.Allwettedpartsshallbestainlesssteel.Theoxygenanalyzershallincludeadigitalcontrollerthatperformscontinuousself-diagnosticswithdiagnosticcodesforatleast10commonfaults.Thesystemshallautomaticallysendthetrimactuatortothe‘null’positionandtriggerthealarmdrycontactsintheeventofanoxygenanalyzerfault.Thedetectorshallbefieldreplaceablewithoutremovingtheprobefromthestackandshallnotrequirespecialtools.Theanalyzershallautomaticallyperformperiodicdetectorcellimpedanceteststobeusedbytheoperatorasanindicationofcalibrationshift.Analyzercalibrationshallbepush-buttonsemi-automatic(notrimpots),withEnglishlanguagepromptsanddiagnosticmessages.Analyzeroutputshallbefieldselectableas0-10%or0-21%withoutfieldrecalibration.6. CommunicationEachcontrollershallbeequippedwithanopticallyisolatedRS485modbuscommunicationsdatahighwayconnection to thecolortouchscreen.ThetouchscreenshallcommunicatewiththeplantBAS,EMS,orDCSbyaModbusoverEthernetcommunicationsdatahighwayandshallallow:Auto/Manualmodechange,setpointchange,variationof themanualoutput,sensingandsilencingofalarms,changeofanyconfigurationparameter(includingPIDtuningconstants),changeoftimers,etc.Provideallequipmentcapabilitiesspecifiedinthisparagraph,evenifaconnectingSCADAsystemisnotincludedinthisproject.7. Quality AssuranceThesystemshallbe factorymanufacturedand testedaccordingtoUL508Arequirements(CSAC22.2#14foruseinCanada).Thecontrol systemshall beaPreferred Instruments,Danbury,CT,BurnerMate TS Model BMTS-STFMC-ZP-VSD.

BURNERMATE TS MODEL BMTS-STFMCSuggestedSpecifications



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ApplicationTheBurnerMateTSModel BMTS-HWFMC providesautomaticfiringratecontrolsforneworexistinghotwaterboilersusingfullymeteredcombustioncontrol.Boththefuelflowandtheairflowareaccuratelymeasured.Measuredtemperatureorpressureisusedtogenerateasetpointforfuelflowandairflow.Thefuelflowsetpointiscomparedagainstactualfuelflowtocontrol the fuelmeteringvalvesandtheactualairflowiscomparedagainsttheairflowsetpointtocontroltheaircontroldamper.Crosslimitingusingmeasuredfuelandcombustionairflowisemployedforsafetyandtopreventcombustiblesorsmokeduringloadchanges.Fullymeteredcontrolwithoxygentrimminimizesextraexcessair.

Model BMTS-HWFMC Combustion Control System

• HotWaterTemperature isMaintainedusing localPIDsetpointcontrol.PIDcontrolprovidesefficient,accuratecontrolbyeliminatingdrumpressure“offset”(error).Alsorespondstoplantmasterdemand.

• MinimumFuelUsage–Measuredfuel,airflowandfluegasoxygenisusedtocontinuouslyadjust(trim)thefuel/airratio.Oxygentrimsavesfuelbyfinetuningtheburnertooperatesafelyandreliablyatreducedexcessairlevelsthroughouttheburnerfiringrange.

• MinimumFanPowerUsage–Fanspeedcontrolminimizesdamperpressuredroprelatedtofanpowerusage.

• RealTimeBoilerEfficiencyDisplay–Allows theboileroperator to instantly identify inefficienciesandpotentialoperationalproblems.

• Safe and Dependable Boiler Control – Flue gastemperatureandoxygenaremonitored.Warningalarmsandburnersafetyshutdowninterlocksareavailable.

BURNERMATE TS MODEL BMTS-HWFMCHotWaterBoilerFullyMeteredCombustionControl

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OrderingInformation


HotWaterBoilerControl BMTS-HWFMC

Additional Ordering Information and Suggested Specifications1. Model ZPIn-SituOxygenSensor2. VariableSpeedDrive(VSD)3. Actuator4. ConsultfactoryforlowfirefuelchangeoverandVSDbypass


Catalog Number

HotWaterTemperatureTransmitter,4-20mADC,0to500°F,NEMA4,Smartwith4½"depth Consult Factory

Thermowell,SS,4½"x½NPT Consult Factory

OilFlow,OvalGeartype,4-20mADC,NEMA4 Consult Factory

GasFlow,ThermalInsertionMassFlow, 4-20mADC,NEMA4 Consult Factory

AirFlow,DifferentialPressureTransmitter,4-20mADC,NEMA4,Smartwith3valvemanifold Consult Factory


Touchscreen: OIT-10orOIT-15Controller: DCS-III-FZ00 InputPower: 120VAC(+/-15%)

InputsWaterTemperature: 4-20mADCFlueGasTemperature: T/C(Option“-ZP”)FlueGasOxygen: ZP Probe(Option“-ZP”)PlantMaster: 4-20mADC*FuelGasFlow: 4-20mADC*FuelOilFlow: 4-20mADC*AirFlow: 4-20mADC

VSDSpeedFeedback: 4-20mADC(Option“-VSD”)Outputs

FuelOilValveActuator: 4-20mADC*FuelGasValveActuator: 4-20mADC*AirDamperActuator: 4-20mADCVSDSpeedDemand: 4-20mADC(Option“-VSD”)


BURNERMATE TS MODEL BMTS-HWFMCHotWaterBoilerFullyMeteredCombustionControl



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1. ApplicationSupplyaself-containedBoilerControlSystemwith10”(or15”)colortouchscreentominimizeconsumptionofbothelectricityandfuelwithinthelimitsofstableburneroperation.Thesystemshalluseaflowmetercross-limitedfullmeteringcombustioncontrollogicschemewithoxygentrimandvariablespeedcombustionairfancontroltomaintainwatertemperatureattheselectedvalue.Positioningsystemsthatdependonactuator feedbackpots forcross limitingarenotacceptable.Thecontrolsystemshallbemicroprocessor-basedandsuitableforwallorwindboxmounting.Allthelogicrequiredtoensurethatpre-purge,post-purge,light-off,andburnermodulatecyclesareautomatedshallbeprovided.2. Combustion ControlThe fuelflowcontrol loopshallbecross-limitedwith theair flowcontrol loopsothatfueldemandcannotbeincreaseduntilanairflowincreaseisprovenbytheairflowmeasurementloopandairdemandcannotbedecreaseduntilafuelflowdecreaseisprovenbythefuelflowmeasurementloop.Additionally,fueldemandcannotbeincreasedbeyondacertainamountabovethemeasuredairflowandairdemandcannotbedecreasedbeyondacertainamountbelowthemeasuredfuelflow.Fuel/airratioshallbeestablishedandadjustedbytheuseofa“soft”functioncurverelatingfuelflowsetpointtoairflowsetpoint.Oxygentrimshallbeaccomplishedbyvaryingthefuel/airratioandshallincludeseparatecharacterizableoxygensetpointcurves forbothoilandgas fuelsbasedonfiring rate.Fuelvalveandairdampershallbemodulatedinresponsetoanexternalplantmasterdemandsignalormeasuredsteampressurecomparedtosetpoint.Provisionshallbemadetoautomaticallyswitchthecontrolmodefrommeteringtopositioningcontroloftheaircontroldamperwheneverthefiringrateoftheunitisbelowtheturndownrangeoftheairflowtransmitter.Thiscontrolsystemshallrequiretheburnertobeshutdowntochangefuels.Atminimum,thecontrolsystemshalldisplaythefollowing:boilerfiringrate,hotwatertemperature,hotwatertemperaturesetpoint,gasflow,oilflow,airflow,fluegasoxygen, fuelvalveposition,airdamperpositionandVSDSpeed.Thefollowingcolortouchscreengraphicpagesshallbeprovided:boileroverview,flamesafeguardoverview,controlpanelfaceplatewithrealtimeandhistoricaltrending,set-upandcommissioningscreens,andboileralarm.Thecontrolsystemshallincludeadedicated,normallyenergized,failsaferelayoutputcontactinthe“running”interlockcircuitoftheflamesafeguardthatwillcauseafiredequipmentshutdownintheeventof:lowoxygen,lowfuelflow,highfluegastemperature,VSDfault,orcontrollerfault.3. Boiler Efficiency CalculationRealtimeboilerefficiencyshallbecalculated.ThecalculationshallbebasedontheASME“bylosses”methodandmustutilizerealtimeinputsofboilerfiringrate,fluegasOxygen,fluegastemperatureandfuelselected.Twosetsofadjustablefuelchemistrydataparametersshallbeincluded,andfiringratescaledradiationlossesshallbeusedformaximumaccuracy.NOTE:Fluegastemperaturetransmittersmustbeprovidedandinstalledateachboileroutlet.

4. Boiler ControllersTo assure system integrity, a pre-wired and factory-tested,microprocessor-based,multiple loop controller systemshall beprovided.Thecontrollershallincludeprocessvariableand“first-out”annunciatordisplays.Configurationandcalibrationdatashallbestoredonredundantnon-volatileEEPROMmemorymodules.Thebackupmemorymoduleshallautomaticallydownloadintotheprimarymemoryifprimarymemorydataiscorrupted.Allcontrollogic,tuning,andfuel/airratiocurvesshallbefieldconfigurable.Ifrequiredtoallowfieldmodificationstothecontrollerlogic,provideoneconfigurationtoolorlaptopcomputerperfacility.5. Flue Gas Oxygen AnalyzerProvideaboilerbreechingmountedin-situ,zirconiumoxideoxygenanalyzerforeachboiler.Extractiveor“wetcell”typeoxygenanalyzersarenotacceptable.Theprobeshallbeofasuitablelengthforsensingtheoxygenlevelinthemiddle⅓ofthebreeching.Allwettedpartsshallbestainlesssteel.Theoxygenanalyzershallincludeadigitalcontrollerthatperformscontinuousself-diagnosticswithdiagnosticcodesforatleast10commonfaults.Thesystemshallautomaticallysendthetrimactuatortothe‘null’positionandtriggerthealarmdrycontacts in theeventofanoxygenanalyzer fault. Thedetectorshallbefieldreplaceablewithoutremovingtheprobefromthestackandshallnotrequirespecialtools.Theanalyzershallautomaticallyperformperiodicdetectorcell impedancetests tobeusedbytheoperatorasanindicationofcalibrationshift.Analyzercalibrationshallbepushbuttonsemi-automatic(notrimpots),withEnglishlanguagepromptsanddiagnosticmessages.Analyzeroutputshallbefieldselectableas0-10%or0-21%withoutfieldrecalibration.6. CommunicationEachcontrollershallbeequippedwithanopticallyisolatedRS485modbuscommunicationsdatahighwayconnection to thecolortouchscreen.ThetouchscreenshallcommunicatewiththeplantBAS,EMS,orDCSbyaModbusoverEthernetcommunicationsdatahighwayandshallallow:auto/manualmodechange,setpointchange,variationof themanualoutput,sensingandsilencingofalarms,changeofanyconfigurationparameter(includingPIDtuningconstants),changeoftimers,etc.Provideallequipmentcapabilitiesspecifiedinthisparagraph,evenifaconnectingSCADAsystemisnotincludedinthisproject.7. Quality AssuranceThesystemshallbefactorymanufacturedandtestedaccordingtoUL508Arequirements (CSAC22.2#14 foruse inCanada). Thecontrol systemshall beaPreferred Instruments,Danbury,CT,BurnerMate TS Model BMTS-HWFMC-ZP-VSD.

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ApplicationTheBurnerMateTSModel BMTS-AC provides automaticcontrolfordrumlevel,boilerdraftandfluegasrecirculation(FGR)forneworexistingboilers.Afeedwatervalvethatisswingingfromclosedtoopenwillcausethesteamheaderpressuretoswingupanddown,evenwhentheplantloadisabsolutelyconstant.Thiswill in turncause theburnerfiringratetoswingupanddown.Burnerloadswingscausecombustion control systems to operate the burnerwithextraexcessair,thusloweringefficiency.Draftcontrollersmodulate theboileroutletdamper inorder tomaintainaconstantpressureinthecombustionchamber.Anyboilerthatwill be operated at a negative draft should have adraft control system.Positioningburner control systemscanoperatewithlessexcessairifthefurnacepressureisconstant.AtagivenF.D.faninletdamperposition,theairflow throughaburnerwill increasewhen theboilerdraftgoesmorenegative.

Key Features

• PreciseDraftControl - “GAP”PIDDraftControl andfiringratefeedforwardassurestabledraftevenduringloadchanges.Thisisespeciallyimportantforoutletdraftcontrol on boilerswith induced fluegas recirculation(FGR)NOxreduction.

• SingleElementDrumLevelControl-Adrumlevelsensorcausesthefeedwatervalvetoopenorcloseinproportionto thedeviation fromdesireddrum level.Suitable forfiretubeboilerswithmoderateloadswingsandwatertubeboilerswith slowly changing loads.Variations in thefeedwatersupplypressurewillcausethedrumleveltochangewhentheloadissteady.Thiscontrolstrategydoesnotrespondwelltoshrinkandswell.

• TwoElementDrumLevelControl-Adrumlevelsensoristheprimarycontroller input,asteamflowsensor isa feedforward controller input.Thesteamflowsignalallowsthecontrollertorespondproperlyduringshrinkandswell.Feedwaterpressurevariationsalsoupsetthedrumlevel.Suitableforwatertubeboilerswithsubstantialloadswingsifthefeedwaterpressureisconsistent.

• ThreeElementDrumLevelControl-Afeedwaterflowsensorisaddedtoallowthecontrollertocompensatefor variations in feedwater supply pressure.Suitableforwatertubeboilerswithsubstantialloadswingsandinconsistentfeedwaterpressure.

• FlueGasRecirculation(FGR)Control-FGRflowrateiscontrollerinresponsetoboilerload.


Catalog Number

E-linkDraftDamperAssembly Consult Factory

DraftTransmitter,4-20mADC,NEMA4,Smartwiththreevalvemanifold

Consult Factory

DrumLevelTransmitter,4-20mADC,NEMA4,Smartwiththreevalvemanifold

Consult Factory

SteamFlow,VortexSheddingtype,4-20mADC Consult Factory

FeedwaterFlowMeter,Turbinetype Consult Factory


Optional FeaturesAdd Suffix to

BurnerMate TS Catalog Number

DraftControl add"-DR*"suffix

DrumLevel(Feedwater)Control"X"=Feedwater(1,2,or3)Element add"-x-FW*"suffix

FlueGasRecirculation(FGR)Control add"-FGR*"suffix

*Add"C"or"T"todenoteaCurrent(4-20mADC)orTriacControl Output

RefertothePlantEngineeringDatasectionforthe“ControlSignal”diagrams

BURNERMATE TS MODEL BMTS-ACDrumLevel(Feedwater)Control,DraftControl,and/orFlueGasRecirculationControl



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1. ApplicationSupplyaself-containedBoilerControlSystemwith10”(or15”)colortouchscreentoprovidedrumlevel,boileroutletdraftandfluegasrecirculationcontrol.Thecontrolcomponentsshallbelocatedinthecombustioncontrolcabinetandshallbefullyintegratedforautomaticsequencingoflight-offandshutdown.2. Drum Level (Feedwater) Control (when required)TheDrumLevel control systemshall bedesigned tomaintainboilerdrumlevel.Drumlevelshallbecontrolledbymodulatingthefeedwatercontrolvalveineitherasingleelementorthreeelementmode.Inthesingleelementmodeonlydrumlevelmeasurementisused.Inthethreeelementmodedrumlevel,steamflowandfeedwaterflowmeasurementsareused.3. Draft Control (when required)BoilerDraftshallbecontrolledinresponsetochangingfurnacepressure,andafeed-forwardsignalofboilerload.Thecontrollershallhaveacharacterizableset-pointcurveforthefeed-forwardsignal.Alarmshallbeprovidedforlowdraft.Allthelogicrequiredtoinsurethatpre-purge,postpurge,light-off,andburnermodulatecyclesareautomatedshallbeprovidedwithinthecontroller.4. Flue Gas Recirculation Control (when required)Flue gas recirculation (FGR) flow rate shall be controlled inresponsetoboilerload.Thecontrollershallhaveacharacterizablesetpointcurvefordamperoutputsignal.Allthelogicrequiredtoinsurethatpre-purge,postpurge,light-off,andburnermodulatecyclesareautomatedshallbeprovidedwithinthecontroller.5. Boiler ControllersTo assure system integrity, a pre-wired and factory-tested,microprocessor-based,multiple loopcontrollersystemshallbeprovided.Thecontrollershallincludeprocessvariableand“first-out”annunciatordisplays.Configurationandcalibrationdatashallbestoredonredundantnon-volatileEEPROMmemorymodules.Thebackupmemorymoduleshallautomaticallydownloadintotheprimarymemoryintheeventofprimarymemorydatacorruption.Allcontrol logic, tuning,and fuel/air ratiocurvesshallbefieldconfigurable.Ifrequiredtoallowfieldmodificationstothecontrollerlogic,provideoneconfigurationtoolorlaptoppersonalcomputerperfacility.Thefollowingcolortouchscreengraphicpagesshallbededicatedtoeachboilercontrolloopincludingdrumlevelcontrol,draftcontrol,andFGRcontrol,whenapplicable.6. CommunicationEachcontrollershallbeequippedwithanopticallyisolatedRS485modbuscommunicationsdatahighwayconnection to thecolortouchscreen.ThetouchscreenshallcommunicatewiththeplantBAS,EMS,orDCSbyaModbusoverEthernetcommunicationsdatahighwayandshallallow:auto/manualmodechange,setpointchange,variationofthemanualoutput,sensingandsilencingofalarms, changeof any configuration parameter (includingPIDtuningconstants),changeoftimers,etc.Provideallequipmentcapabilities specified in this paragraph, even if a connectingSCADAsystemisnotincludedinthisproject.

7. Quality AssuranceAsinglecontrolsystemmanufacturerwithaminimumof10yearsexperiencemanufacturing similar combustion control systemsshallprovidethespecifiedcontrolsystemcompletewithoxygenanalyzers, variable speed drive, transmitters, and actuators.Themanufacturer’s authorized representative shall provideexperienced combustion control technicians that have beentrainedbythemanufacturerforvariablespeedfanoxygentrimsystemsstart-upandoperatortraining.ThesystemshallbefactorymanufacturedandtestedaccordingtoUL508Arequirements(CSAC22.2#14 foruse inCanada). ThecontrolsystemshallbeaPreferredInstruments,Danbury,CT,BurnerMate TS Model BMTS-AC[-DRx] [-1, -2, or -3] [-FWx] [-FGRx](‘x’=“C”or“T”todenoteaCurrentorTriacControlOutput).


Touchscreen: OIT-10orOIT-15Controller: DCS-III InputPower: 120VAC(+/-15%)

InputsDraft 4-20mADC(optional)FiringRate 4-20mADC(optional)DrumLevel 4-20mADC(optional)DrumPressure 4-20mADC(optional)FeedwaterFlow 4-20mADC(optional)SteamFlow 4-20mADC(optional)OutletDamperFeedback Potentiometer(optional)*FGRDamperFeedback Potentiometer(optional)*FeedwaterValveFeedback Potentiometer(optional)*

OutputsOutletDamper Triacor4-20mADC

(optional)FGRDamper Triacor4-20mADC

(optional)FeedwaterValve Triacor4-20mADC

(optional)

* ThesesignalsareonlyrequiredifTriacoutputisselected.

BURNERMATE TS MODEL BMTS-ACSuggestedSpecifications



Catalog 25

Instruments &

Controls

207

ApplicationTheBurnerMateTSModelBMTS-FSG FlameSafeguardSystemprovidesautomatic flamesafetymonitoringandcontrolforneworexistingsteamorhotwaterboilers.ThesystemisengineeredtobeincompliancewiththelatestfactorymutualandNFPA85standards.Thesystemsaremanufactured, tested and labeled according toUL508Astandards.

Key Features

• Microprocessor-based Controller – The FlameSafeguardSystemismicroprocessor-based,withself-diagnosticsandnon-volatilememory.

• FlameScanners –An infrared (IR) flamescanner isprovided as a standard forwater-wall furnaces.Anultraviolet (UV) self checking flame scanner is anavailable option for refractory lined furnaces. TheFlameSafeguardSystemprovidestheproperburnersequencing, ignitionand flamemonitoringprotectiononsingleburner,automaticallyignitedoilorgasfiredboilers.

• Thesystemusesafail-safe“de-energize”totripdesign.Uponthelossofsystempowerthefuelsafetyshutoffvalvesareautomaticallyclosedandignitioncomponentsarede-energized.

• MessageDisplay–Anexternally-mountedLCDbacklitdisplayhastwolinesofsixteencharacterseach.Thedisplayprovidesburnerstatusandhistoricalinformation.Operation,troubleshootingandmaintenanceinformationisat theboiler front,where it isneeded.Onasafetyshutdown,themessagedisplaywilladvisetheoperatorthat the control is in “lockout” andwill indicate thespecificcauseandthestateintheoperatingsequencewheretheshutdownoccurred.

• CombustionControlSequenceInterlocks–Combustioncontrolsysteminterfacesareprovidedtoensuresafeautomatic fuelandairsequencing forpurge, light-offandshutdown.

• Drumlevelconductivityproberelaysareincorporatedforanauxiliary lowwatercutoutsafety interlock, lowwateralarmandhighwateralarm.

Specifications

Operator Control PanelTouchscreen: OIT-10orOIT-15Display: 2linex16characterLCDdisplayPushbutton: Membrane,tactilefeedback

IR Flame Scanner: Infrared,½"90°anglemount,96"cable

UV Flame Scanner: Ultraviolet1"NPTmount,72"lead


Optional FeaturesAdd Suffix to

BurnerMate TS Catalog Number

FlameSafeguard Add“-FSG”suffix

Consult Factory for suggested specifications and ordering information for Low Fire Fuel Change Over “LFCO,” Simultaneous Dual Fuel Firing, and Automatic Atomizer Post Purge functions.

BURNERMATE TS MODEL BMTS-FSGFlameSafeguardSystem



Catalog 25

Inst

rum

ents

& C

ontro

ls

208

1. ApplicationIntegral to the control systemshall be aBurnerManagementSystem (BMS) / FlameSafeguardSystem (FSG)with 10” (or15”)colortouchscreen.Thesystemshallbedesignedtoensurethesafestart-up,on-lineoperationandshutdownof fuel firingequipment.Burnermanagement systemcomponents shall belocated in the combustion control cabinet and shall be fullyintegrated for automatic sequencingof light-off and shutdown.Numbered terminal strips shall also be provided to permitterminationofallfieldwiring.2. MicroprocessorAnindustrialdutymicroprocessor-basedFSGshallprovide:safetyinterlocks, flamemonitoring protection and timed sequences.Sequencesshallincludeforceddraftfanstartandstop,furnacepurge,burnerlight-offandshutdownandpost-purge.TheFSGshall be capable of firing two fuels, one fuel at a time. Fuelchangeovershallrequireboilershutdown.FSGcomponentsshallbelocatedinthecombustioncontrolenclosureandshallbefullyintegrated for automatic sequencingof light-off and shutdown.Thefollowingcolortouchscreengraphicpagesshallbeprovided:boileroverview,flamesafeguardoverview,controlpanelfaceplatewithrealtimeandhistoricaltrending,set-upandcommissioningscreens,andboileralarm.Graphicpagesshalldisplayflamesignalstrength,startupandshutdownsequencestatus,alarm,systemdiagnostic,first-outmessagesandburnerhistoricalinformation.Historicalinformationshallincludethelastsixlockoutconditions,number of burner cycles and burner hours.The system shallincludea“systemreset”pushbuttonand“FDfan“hand-off-auto”,“burneroff-fuelselectgas-oil”controlswitchesandalarmhorn.Drumlevelconductivityproberelaysforlowlevelcutout,lowlevelandhighlevelalarmsshallbeprovided.Provisionshallbemadetoallowforwatercolumnblowdownwithout tripping theboiler.Provideone(1)flamescannerforeachburner.3. CommunicationsTheflamesafeguardcontrollershallbeequippedwithanopticallyisolatedRS485modbuscommunicationsdatahighwayconnectiontothecolortouchscreen.Thetouchscreenshallcommunicatewith theplantBAS,EMS,orDCSbyaModbusoverEthernetcommunications data highway and shall allow reading of thefollowinginformation:flamesignalintensity,sequenceofoperationmessages, diagnosticmessages, “first out” cause of lockoutmessages,lastsixlockoutconditions,numberofburnercyclesandburneroperatinghours.Provideallequipmentcapabilitiesspecifiedinthisparagraph,evenifaconnectingSCADAsystemisnotincludedinthisproject.4. Quality AssuranceThesystemshallbefactorymanufacturedandtestedaccordingtoUL508Arequirements.Thesystemshallbedesignedtoensurethesafestart-up,on-lineoperationandshutdownof fuel firingequipment.ThesystemshallcomplywithNFPA85.PerNFPA85“1.9.3.2.3RequirementforIndependence”,theflamesafeguardsystem shall be providedwith independent logic and powersuppliesandshallbephysicallyseparatedfromthecombustioncontrollogic.ThecontrolsystemshallbeaPreferredInstruments,Danbury,CT,BurnerMate TS Model BMTS-FSG.


Touchscreen: OIT-10orOIT-15 InputPower: 120VAC(+/-15%)Inputs

RecyclingHighSteamPressure DryContactFlameScanner ScannerInput*HighDrumLevel WaterProbe*LowWaterLevel DryContactEmergencyStopPushbutton DryContactLowDraftSwitch DryContactLowWaterCutout DryContactAuxiliaryLowWaterCutout DryContactBlowdownPushbutton DryContactExcessiveHighSteamPressure DryContactPurgeAirFlowSwitch DryContactMinimumAirFlowSwitch DryContact*LowInstrumentAirPressure DryContactFanMotorStarted DryContact*VSDRunningandNoAlarms DryContactFuelOilTemperatureLow DryContact*FuelOilTemperatureHigh DryContactFuelOilPressureLow DryContactLowAtomizingMediumFlow DryContactLowAtomizingMediumPressure DryContactFuelGasPressureHigh DryContactFuelGasPressureLow DryContactLowFireAirSwitch DryContactAirDamperProofofOpen DryContact*DraftDamperProofofOpen DryContact*FGRDamperProofofClosure DryContactFuelGasSSOVProofofClosure DryContactFuelOilSSOVProofofClosure DryContactFuelGasControlValveLowFire DryContactFuelOilControlValveLowFire DryContact

OutputsEnergizeIgniter 120VACOpen/CloseIgniterSSOV 120VACOpen/CloseGasSSOV 120VACOpen/CloseOilSSOV 120VACOpen/CloseAtomizingValve 120VACLimits(toLead/Lag) 120VACLockout(toLead/Lag) 120VAC


BURNERMATE TS MODEL BMTS-FSGSuggestedSpecifications

Documents

BURNERMATE TS BOILER CONTROL SYSTEM Overview