peter larro mechanical sales

APEM APEM –– Fall 2011 ForumFall 2011 Forum

High Efficiency Burners and High Efficiency Burners and

Linkageless Combustion ControlsLinkageless Combustion ControlsPresented By: Mechanical Sales, Inc.Presented By: Mechanical Sales, Inc.

Peter Larro and Barry JostolPeter Larro and Barry Jostol

•Optimization strategies using high efficiency burners and combustion controls

•Burners and burner controls options

•Linkageless Combustion Controls

Topics weTopics we’’ll discussll discuss………………....

In all cases, what are we trying In all cases, what are we trying to doto do…………………………..

�� Improve thermal or combustion efficiency to Improve thermal or combustion efficiency to the best level availablethe best level available

�� Maintain reliable operationMaintain reliable operation

�� Maintain absolute level of safety in operationMaintain absolute level of safety in operation

�� Attempt to minimize maintenance requirements Attempt to minimize maintenance requirements if possibleif possible

�� Extend operational life of existing equipmentExtend operational life of existing equipment

Perfect Combustion

Fuel (C, H2)

Air (O2, N2)Air (O2,N2)

Burner

CO2

N2

H2O

Complete Combustion by todays standards……

Fuel (C, H2)

Air (O2, N2)Air (O2,N2)

Burner

CO2 CO (< 50 PPM)

NO (as low as possible)

H2O

O2 (as low as 3%)

0

2

4

6

8

10

12

14

16

0 50 100 150 200 250

% B

y V

loum

e in

dry

flue

gas

% Theoretical Air

Stoichiometric

Fuel Rich Excess Air

%CO

%CO2 %CO2

%O2

O2 Effect on EfficiencyEffect on Efficiency

The graph below shows the savings realized with a 100 horsepower load at various efficiencies caused by different excess air levels.

Burner Controls Burner Controls –– Where is Where is the industry now ?the industry now ?

Microprocessor based, Microprocessor based, linkageless combustion linkageless combustion

controls, often utilizing VFDcontrols, often utilizing VFD’’s s on blower motorson blower motors

HereHere’’s the type of system we s the type of system we are used to..are used to..

Modulating BurnerModulating BurnerWith Single Point PositioningWith Single Point Positioning

Single modulating motor, driving fuel and air, through a system of mechanical linkages, user adjustable for fuel / air ratio control

Linkageless ControlsLinkageless Controls………………....

Individual servo motors attached to fuel valves and air damper, no linkage…infinite adjustability – parallel positioning

PARALLEL PARALLEL

POSITIONINGPOSITIONING

LINKAGELESS BURNER CONTROLLINKAGELESS BURNER CONTROL

What is Parallel PositioningWhat is Parallel Positioning

�� Parallel positioning is the use of Parallel positioning is the use of

multiple positioning motors to set the multiple positioning motors to set the

position of the fuel valves and air position of the fuel valves and air

damper throughout the firing range.damper throughout the firing range.

�� Traditional modulating burners use Traditional modulating burners use

single point positioning. Using one single point positioning. Using one

motor and linkage to position the fuel motor and linkage to position the fuel

valves and air damper.valves and air damper.

Advantages of Parallel Advantages of Parallel

PositioningPositioning

�� No HysterisisNo Hysterisis

�� Accurate Characterization of Fuel/Air Accurate Characterization of Fuel/Air

RatioRatio

�� Optimal Firing of Each FuelOptimal Firing of Each Fuel

�� Accurate Control of Firing RateAccurate Control of Firing Rate

�� TamperTamper--resistant Burner Settingsresistant Burner Settings

�� Remote Monitoring of Burner Remote Monitoring of Burner

PerformancePerformance

Typical Fuel CurveTypical Fuel Curve

Parallel Positioning

0

10

20

30

40

50

60

0 10 20 30 40 50 60 70 80 80 90

Fuel/Air

Fuel

Air

Many manufacturers now sell Many manufacturers now sell linkageless controlslinkageless controls……..

--Siemans CorporationSiemans Corporation--Fireye Fireye ““NexusNexus”” systemsystem

--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:

�� Honeywell Honeywell –– ““Control LinksControl Links””

�� Fireye Fireye –– ““NexusNexus””

�� Siemens Siemens –– ““LMVLMV””

�� Autoflame Autoflame –– ““MMMM””

HONEYWELLHONEYWELL

---- The Application The Application ----Fuel Air Ratio Control SystemFuel Air Ratio Control System

Natural GasNatural Gas

Fuel OilFuel Oil

Limits & Operating Control4-20mA Firing Rate Control

WIN 95WIN 95

Limits

Q7999A Wiring SubbaseQ7999A Wiring Subbase

•• Panel mount wiring subbasePanel mount wiring subbase

•• 40 terminal wiring subbase40 terminal wiring subbase

•• Short circuit proof terminalsShort circuit proof terminals

•• 7 terminal grounding strip7 terminal grounding strip

•• 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

•• Auto / Manual Firing Rate InputAuto / Manual Firing Rate Input

•• 7 to 24 Point Profiles7 to 24 Point Profiles

•• Floating Control OutputFloating Control Output

R7999 ControllerR7999 Controller•• Fast Burner Setup via PC or LaptopFast Burner Setup via PC or Laptop

•• Step by Step, Menu DrivenStep by Step, Menu DrivenCommissioning ProcessCommissioning Process

•• File Backup of Commissioning DataFile Backup of Commissioning Data

•• Diagnostic / Historical DataDiagnostic / Historical Data

•• Password ProtectedPassword Protected

•• Remote Reset CapabilityRemote Reset Capability

•• Alarm OutputAlarm Output

R7999 ControllerR7999 Controller•• Configurable Sensor Interface Configurable Sensor Interface (4(4--20mA):20mA):

-- Low Fire HoldLow Fire Hold-- FGR HoldFGR Hold-- FGR & Low Fire HoldFGR & Low Fire Hold

•• Maximum Modulation Limit InputMaximum Modulation Limit Input

•• Dynamic Safety Checks:Dynamic Safety Checks:-- Fail Safe Potentiometer ChecksFail Safe Potentiometer Checks-- Anti Swap of ActuatorsAnti Swap of Actuators-- Curve Tracking TestsCurve Tracking Tests

•• Global Approval Body CompliantGlobal Approval Body Compliant

Universal Parallel Positioning ActuatorUniversal Parallel Positioning Actuator

ML7999ML7999•• External Indication of PositionExternal Indication of Position

•• Floating Control InputFloating Control Input

•• I.D. Number ProtectedI.D. Number Protected

•• Power IndicatorPower Indicator

•• Operating Temperature:Operating Temperature:

-- 4400°°°°°°°°F to +140F to +140°°°°°°°°FF

•• Universal Power Input:Universal Power Input:

100 to 240Vac, +10%, 100 to 240Vac, +10%, --15%, 50/60Hz15%, 50/60Hz

ML7999ML7999•• Direct Coupled OutputDirect Coupled Output

•• High Torque & Fast Speed:High Torque & Fast Speed:-- 100 in. lb.,100 in. lb.,-- 30 Sec,30 Sec,-- 9595°°°°°°°° StrokeStroke

•• Compact Size Compact Size

•• NEMA 3 / IP54NEMA 3 / IP54-- Requires Weatherproofing KitRequires Weatherproofing Kit

Universal Parallel Positioning ActuatorUniversal Parallel Positioning Actuator

Honeywell S7999Honeywell S7999Honeywell S7999

Controlinks ™ Displayand commissioning

interface

Allows you to set up Controlinks ™ system

without a laptop computer.

• 3.5” x 4.625” Color Touch Screen• RS-485 Communication port• Audio feed back• Flush mounts on panel See Sales Release # 610

Install Commissioning SoftwareInstall Commissioning Software

ZM7999AZM7999A

R7999R7999 -- System SetupSystem Setup

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

WIN 95WIN 95

3 conductor shielded cable3 conductor shielded cable

RS485 to RS232 converterRS485 to RS232 converter

FIREYEFIREYE

Nexus OverviewNexus Overview

Servo Motors

Controller and Base

Flame ScannerMMI/ Display

Remote Station

ControllerController

NX 3000 / 4000

Contains the CPU and PSU Boards

LED Indication of Status/Fault ConditionAuto, Boiler Status, Pre-Purge,Ignition, Normal Run, Flame, Air Pressure, Fault

Nexus Flame SafeguardNexus Flame Safeguard

Timing Sequences Similar to E110 / E210

Non-Recycling Running Interlocks

Supervised Purge

Open Damper Purge Position Proving, Ignition Low Fire Start Position Proving

Proof of Closure - Main Fuel Valve orValve Gas Pressure Test Proving Sequence Available

Nexus Combustion ControlNexus Combustion Control

Parallel Positioning

Individual Servo Positioning MotorsDrive shaft mounted Feedback Potentiometers

24 Programming Positions for each motor

Approved Safety Checking on all Electronics

Three, Four Channel Options

Accuracy to 0.1 angular degrees

Nexus Wiring BaseNexus Wiring Base

Wiring Module NX1386, NX1466

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

–– P.I.D. Load ControllerP.I.D. Load Controller

–– Intelligent Boiler SequencingIntelligent Boiler Sequencing

–– Computer CompatibleComputer Compatible

�� Exhaust Gas AnalysisExhaust Gas Analysis

–– 3 Parameter Trim of O2, CO, CO23 Parameter Trim of O2, CO, CO2

–– Displays O2, CO, CO2, Efficiency, Exhaust Displays O2, CO, CO2, Efficiency, Exhaust

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

�� Heavy duty constructionHeavy duty construction

Webster HDRMBWebster HDRMB

RielloRiello

WeishauptWeishaupt

Weishaupt Head DetailWeishaupt Head Detail

New non-traditional burner designs such as:

Ceramic infrared / radiant burner

- Extended warranties

- Minimal moving

parts

- Minimal service

- Ultra low NOx

Alzeda TechnologyAlzeda Technology

PREMIXED SURFACEPREMIXED SURFACE--STABILIZED STABILIZED

COMBUSTIONCOMBUSTION

�� Fully preFully pre--mixed design similar to what we mixed design similar to what we

see on todaysee on today’’s condensing boilers but s condensing boilers but

available for retrofitavailable for retrofit

�� UltraUltra--low NOx of 12 ppm, 9 ppm or even low NOx of 12 ppm, 9 ppm or even

lower without FGRlower without FGR

�� Parallel positioning and fully metered fuelParallel positioning and fully metered fuel--air air

ratio controlratio control available as optionavailable as option

Burners Burners -- Communications Communications –– Major Major

AdvancesAdvances

�� Ability to gather and transmit incredible amounts of Ability to gather and transmit incredible amounts of

datadata

�� Integrated multi boiler and systems controlIntegrated multi boiler and systems control

�� Interface to building management systemsInterface to building management systems

�� Wireless / Smartphone monitoring and controlWireless / Smartphone monitoring and control

QUESTIONS QUESTIONS –– THOUGHTS THOUGHTS ––

COMMENTS ?COMMENTS ?

Thank You For The Opportunity Thank You For The Opportunity

and Good Luck With Your Boiler and Good Luck With Your Boiler

Systems !!Systems !!