UtilitySaver Burner Control

UtilitySaver Package SystemBenefits

[Technical Information]

The UtilitySaver combines the fuel savings of an Oxygen trim system with the electrical kWh savings of a variable speed drive (VSD) FD fan.  The UtilitySaver is intended for installation on an existing burner with either a jackshaft or parallel positioning combustion control system.

Typical Energy Savings

Typical Energy Savings Chart

About the Example: conservative $13,700 per year. This calculation is based on:
  • ASME "by losses" boiler efficiency calculations
  • Industry leading manufacturer motor energy data
  • 600 Bhp boiler
  • 125 psi steam
  • Natural gas fired
  • Operating 365 days/year & 24 hours/day
  • Electric cost - 7.7 cents/kWh
  • Fuel cost - $4.5/k ft3
  • Oxygen reduction - 1.5% wet

Minimum Fuel Usage

  • Flue gas Oxygen is used to continuously adjust (trim) the fuel/air ratio
  • Oxygen trim saves fuel by fine tuning the burner to operate safely and reliably at reduced excess air levels throughout the burner firing range

Minimum Fan Power Usage

  • Fan speed control minimizes damper pressure drop related fan power usage

Maximum Electrical Savings

  • UtilitySaver maximizes VSD electrical energy savings by keeping the FD fan damper(s) 100% open from high fire down to approximately 30% firing rate (field adjustable)
  • From 30% firing rate down to minimum fire, the damper ramps from full open to partially closed to assure maximum burner turndown is achieved

Improved Availability with Full Speed Bypass

  • “Flip-a-Switch” to change over from variable speed to constant speed control with pre-set full speed air damper curve

Real Time Boiler Efficiency Display

  • Allows the boiler operator to instantly identify inefficiencies and potential operational problems

Direct Interface

  • Directly Interfaces with 135 ohm or 4-20 mAdc Boiler or Plant Master firing rate controllers 
  • Optional transmitter adds local PID firing rate control

Safety

  • Flue gas temperature and Oxygen are monitored
  • Low flue gas Oxygen trips the burner after an adjustable time delay
  • VSD speed and actuator position feedbacks are continuously monitored and the burner trips if any are out of position

New or Existing Flame Safety System Interface

  • It permits automatic operation at a reduced cost of installation

Features

UtilitySaver Control System Diagram
Click to view larger image. (Zoom) (View larger image...)

  • Manual air trim capability with automatic adaptive gain
  • Integral Oxygen Analyzer diagnostics provides continuous cell impedance checking for cell health prediction
  • Oxygen trim delayed after light-off (adjustable) to allow stack oxygen to stabilize
  • Simple Auto/Manual station on the front of the controller to allow automatic or manual control of the burner firing rate
  • Light off position is adjustable for wide turndown burners
  • Fuel-air lead/lag to provide low CO (gas) and smokeless (oil) load changes.  The air increases before the fuel on a load increase, and the fuel decreases before the air on a load decrease
  • Easy commissioning using “Learn Mode”
  • Automated purge & light-off under flame safeguard system direction. VSD "at speed" contact interlocks burner purge and light-off limits
  • RS485 Modbus interface is available for off-site monitoring and control

Commissioning

The PC3_Setup Commissioning Software is included with every UtilitySaver Burner Control:

  • MS Windows compatible
  • Automated step-by-step procedure to assist the service technician with the setup of the fuel and air actuators, ZP oxygen sensor, VSD, and fuel/air profile
  • Software is only required during commissioning, calibration and tuning
  • User friendly interface Content

Main Menu Screen
PC3_Setup Main Menu
When Task 5 is selected and the "Run" button is "pressed", the
screens to the right are shown

User Prompts

PC3_Setup Sample User Prompts
Input verification and equipment calibration is automated to
ensure a thorough and fast burner setup

 

Profile Setup Screen
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PC3_Setup Air/Fuel Profile Setup Screen
A Single Screen is provided to enter setup data and inspect the resulting fuel/air profile

Specifications

Cabinet Dimension

UtilitySaver Panel Enclosure

Controller:

Input Power:

Actuator Power:

Enclosure:

PCC-III-ZG00 (Click here for a complete hardware specifications)

120 Vac (+/- 15%)

24 Vac

16h x 14w x 10d NEMA 12, wall mounted

Inputs

Drum Pressure*:

Flue Gas Temperature:

Flue Gas Oxygen:

Plant Master:

Fuel Actuator Feedback:

Air Actuator Feedback:

VSD Speed Feedback:

4-20 mAdc (optional)

T/C

ZP Probe

4-20 mAdc

Potentiometer

Potentiometer

4-20 mAdc

Outputs

Boiler Efficiency:

Fuel Valve Actuator:

Air Damper Actuator:

VSD Speed Demand:

4-20 mAdc

Triac

Triac

4-20 mAdc

In-Situ Oxygen Sensor, Model ZP

Insertion Length:

Flange:

Mounting Kit (190680):

20, 30, 45, 65, 90" Probe

3" 125 lb

flanges, nipple, coupling, gasket, bolts, nuts and washers, calibration tubing, compression fittings and isolation valve

Signal Cable Kit (190681)

ZP Cable:

T/C Cable:

Triac Output Cable:

Load Sensor Cable:

70 ft of 7 conductor wire cable for ZP probe

70 ft of type J T/C shielded cable

100 ft of 3 wire shielded cable

50 ft of 2 wire shielded cable

Boiler Efficiency Kit (104087D)

Efficiency:

T/C:

ASME “by losses” method efficiency configuration

Flue Gas Temperature Assembly, 104087D, with mounting flange
Actuators

Fuel:

Air:

Mounting Kit (190682):

DM-1E-P1A-S2

DM-1E-P1A-S2

Right angle mounting bracket for Damper Actuator, (3) Lever Arms, (4) ball joints, (2) 12" threaded Links

Note: When "ST" or "HW" ooption selected, Pressure shown, Temperature for Hot Water Applications

Standard Equipment

  • UL Labeled, Wired and Tested Control Panel
  • PCC-III-ZG00 UtilitySaver Controller
  • 24Vac Actuator Power Supply
  • VSD – FSG Interface Relays
  • ZP-20 Oxygen Probe
  • ZP Oxygen Probe Mounting Kit
  • Flue Gas T/C Assembly
  • Air Damper Actuator
  • Air Damper Mounting Kit
  • Fuel Valve Actuator
  • Variable Speed Drive
  • VSD Fuses
  • Field Wiring Kit
  • Instruction Manual

Optional Equipment

  • VSD Full Speed Bypass
  • Pressure Transmitter
  • Temperature Transmitter

Ordering Information

Ordering table

Variable Speed Drive (VSD) Ordering Information

Order Sensors Separately
(Optional)		 Catalog Number
Hot Water Temperature Transmitter, 4-20 mAdc,
0 to 500 F, NEMA 4, Smart with 4.5" depth		 Consult Factory
Steam Pressure Transmitter, 4-20 mAdc,
0 to 200 psi, NEMA 4, Smart with single valve manifold		 Consult Factory
Thermowell, SS, 4.5" x 1/2 NPT Consult Factory