CleaverBrooks Master Panel 8 User manual

750-375
10/16
Master Panel 8
Eight Boiler Lead Lag Control
Operation Manual

TO: Owners, Operators and/or Maintenance Personnel
This operating manual presents information that will help to properly operate and care for the equipment. Study its con-
tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc-
tions are followed. No attempt should be made to operate the unit until the principles of operation and all of the
components are thoroughly understood.
It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who
are servicing, repairing, or operating the equipment, in all safety aspects.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical
and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however,
proper operating techniques and maintenance procedures must be followed at all times.
Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely
free him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment.
It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instruc-
tions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of
the responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before
attempting to operate, maintain, service, or repair this equipment.
Operating controls will normally function for long periods of time and we have found that some operators become lax in
their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to
uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and
deficiencies in testing and maintenance.
The operation of this equipment by the owner and his operating personnel must comply with all requirements or regula-
tions of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency
between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before pro-
ceeding.

Cleaver-Brooks
Master Panel 8
Operation Manual
ManualPart No. 750-375
10/16
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized
representative
Printed in U.S.A.

TABLE OF CONTENTS
Section 1 — Overview
A. FEATURES........................................................................1-2
B. COMPONENTS .................................................................1-2
C. SPECIFICATIONS ..............................................................1-4
Section 2 — Operation
A. SEQUENCE OF OPERATION .............................................. 2-2
1. Boiler Start and Stop ......................................... 2-2
2. Warm-Up Sequence .......................................... 2-2
3. Unison Modulation ........................................... 2-2
4. Lead Lag Modulation.......................................... 2-2
B. DISPLAY SCREENS AND PARAMETER SETTINGS ............... 2-5
1. Screen Select ................................................... 2-5
2. Boiler Overview Screen ..................................... 2-6
3. Set Points and Sequence Screen ........................ 2-7
4. Set-Up 1 Screen .............................................. 2-9
5. Set-Up 2 Screen .............................................. 2-10
6. Firing Rate ......................................................2-11
7. Elapsed Time Screen ........................................2-12
8. Alarm History Screen ........................................2-13
9. Configuration (Config) Screen .............................2-13
10. PanelView Configuration ..................................2-15
11. Individual Boiler Overview Screen .....................2-16
Section 3 — Commissioning
A. I/P ADDRESSING (INDIVIDUAL BOILERS)............................3-2
B. BOILER CONFIGURATION..................................................3-3
C. I/P ADDRESSING (MASTER PANEL)....................................3-4
D. SETPOINTS AND SET-UP PARAMETERS ............................3-4
E. SYSTEM WIRING...............................................................3-18
Section 4 — Troubleshooting
A. GENERAL ........................................................................ 4-2
B. ETHERNET TROUBLESHOOTING ....................................... 4-2
C. LOADING PLC PROGRAM ................................................. 4-6
D. WEB SERVER ................................................................... 4-10
Section 5 — Parts
A. PARTS LIST......................................................................5-3
Appendix — Master Panel 8 I/O List

www.cleaverbrooks.com
Section 1
Overview
A. Features........................................................................... 1-2
B. Components ..................................................................... 1-2
C. Specifications ................................................................... 1-4

Section 1 — Overview Master Panel 8
1-2 Part No. 750-375
The Cleaver-Brooks Master Panel 8 master boiler room control system
provides lead/lag control for up to eight boilers when used in
conjunction with CB integrated boiler controls.
A. FEATURES
• Lead/lag control for up to eight boilers.
• Warm-up routine for hot standby (hot water units only).
• Ethernet I/P communication with individual boilers.
• Boilers’ parameters are available from the master panel to
customer BMS.
• Individual boiler indicating screens.
• Web server for remote monitoring through a web browser.
B. COMPONENTS
1. Control panel, which houses the following components:
A. Programmable Logic Controller
B. Input/Output for up to 8 boilers
C. 24 VDC power supply
D. Ethernet switch
E. Display (Allen Bradley PanelView Plus) — displays various
data and allows input of the configurable parameters.
2. Pressure (steam system) or temperature (hot water system)
transmitter with well (shipped loose). Transmitter must be
mounted in a common outlet header.
Figure 1-1 Master Panel Components
E

Master Panel 8 Section 1 — Overview
Part No. 750-375 1-3
PLC and I/O modules:
1. Slot 0 - PLC: L30ER Processor
2. Power Supply
3. Slot 1 - Digital Inputs: Boiler A, B, C, D Ready
Power to Boiler A, B, C, D
4. Slot 2 - Digital Outputs: Boiler A-H Start
5. Slot 3 - Analog Input: Header Pressure (Temperature)
6. Slot 4 - Analog Outputs: Control Signal Boiler A, B
7. Slot 5 - Analog Outputs: Control Signal Boiler C, D
8. Slot 6 - Digital Inputs: Boiler E, F, G, H Ready
Power to boiler E, F, G, H
9. Slot 7 - Analog Outputs: Control Signal Boiler E, F
10. Slot 8 - Analog Outputs: Control Signal Boiler G, H
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Section 1 — Overview Master Panel 8
1-4 Part No. 750-375
C. SPECIFICATIONS
Cleaver-Brooks Master Panel 8 boiler control operational and
environmental specifications are as follows:
1. Enclosure
Type: NEMA 4/12
Dimensions: 24” x 24” x 10”
Table 1-1. Operational and Environmental Specifications
Description Specification
Maximum connecting units 8 boilers
Power Supply Voltage 120 VAC (+10%/-15%)
Power Supply Frequency 50 or 60 Hz
Fusing:
Touch Screen HMI (10") 2A
Analog Power Supply 2.1A
PLC Power Supply 2A
Ambient Operating
Temperature Limits
32° to 130°F (0° to 54°C)
Humidity 85% RH continuous, non-condensing
Vibration Continuous to 0.5 G
Communication Protocol EtherNet I/P