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
123
45678910

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

www.cleaverbrooks.com
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 Parameters 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 (PV Conf) Screen ....... 2-15
11. Individual Boiler Overview Screen ................... 2-16

Section 2 — Operation Master Panel 8
2-2 Part No. 750-375
A. SEQUENCE OF OPERATION
1. Boiler Start and Stop
Header water temperature (steam pressure) is compared with the set
point and the Master Panel PLC processor executes PID
(Proportional, Integral, and Derivative) control algorithm. The lead
boiler is commanded to come on line first. The lag boiler #1 is
commanded to come on line when firing rate signal for the lead boiler
reaches the lag boiler #1 start point and the time delay is expired.
Subsequent lag boilers are commanded to start in a similar manner.
Lag boilers are commanded to shut down in reverse order. If one of
the boilers is unavailable, it will be replaced by the next available unit
in the firing sequence.
When the previous boiler in selected firing sequence becomes
available, and is required, the boiler will be started and inserted back
into the proper sequence. The last boiler in the sequence will be shut
down as required by the load.
Once the firing rate for the previous-in-sequence boiler reaches this
boiler stop point and time delay expired, boiler will be shut down.
The lead boiler is shut down when the water temperature (steam
pressure) in a header exceeds the setting of the lead boiler off point.
2. Warm-Up Sequence (hot water units only)
If the boiler was off (fuel valve deenergized) for the duration of the
setting for “Warm-Up Boiler Off” timer, the boiler will start and stay
at low fire for the duration of the “Warm-Up Boiler On” timer. If during
this period there is a demand for this boiler, the boiler will be released
for modulation after the “Warm-Up Boiler On” timer expires. If there
is more than one boiler in standby, only one can be fired in the warm-
up cycle at the same time.
3. Unison Modulation (hot water and steam boilers)
The control signals to all boilers on line are equal to the lead lag PID
output.
4. Lead Lag Modulation (steam systems only)
Control output of the firing rate controller is divided into equal
segments according to the number of boilers available. For example:
with the number of boilers available equal to 4, firing rate control
signal for lead boiler of 0 – 100% corresponds to the control output
from the lead/lag controller of 0 – 25%. Firing rate control signal to
the lag boiler 1 of 0 –100% corresponds to the control output from
the lead/lag controller 25 – 50%. Firing rate control signal for the lag
boiler 2 of 0 –100% corresponds to the control output from lead/lag
controller of 50 – 75%. Firing rate control signal to the lag boiler 3 of
0 –100% corresponds to control output 75 – 100%. Values can be
shifted depending on the ModShift parameter.

Master Panel 8 Section 2 — Operation
Part No. 750-375 2-3
Control output to the boilers is calculated using the following
equation:
0 OCVn= (CVMAIN x N) – ((n-1) x 100) + (100 - ModShift) O100
Where CVn= control output to boiler #n
(For lead boiler n = 1, for lag #1 n = 2, etc.)
CVMAIN = lead/lag PID control output (0-100%)
N = number of boilers available
ModShift = percent of previous-in-sequence boiler’s firing
rate control signal at which current boiler starts
to modulate (ModShift not applicable to lead boiler)
Example: CVMAIN = 35%
ModShift = 100 for all boilers
Number of boilers available N = 4
Control output to the lead boiler
For Lead boiler n = 1
Using above equation,
CV1 = 35x4-((1-1)x100) = 140%
Since firing rate cannot exceed 100%, CV1=100%
For the first lag boiler n = 2.
CV2 = 35x4-((2-1)x100)+(100-100) = 40%
For the second lag boiler n = 3
CV3 = 35x4-((3-1)x100)+(100-100) = -60%
Since firing rate cannot be below 0%, CV3 = 0%
Note: Second lag may be off depending on the setting of start
and stop points
For the third lag boiler n = 4.
Third lag boiler will not be commanded to fire, since firing rate
of second lag boiler is 0% and start point cannot be set at 0%.
CV4 = 0%

Section 2 — Operation Master Panel 8
2-4 Part No. 750-375
Figure 2-1 Lead/Lag Modulation (8 boilers available, ModShift = 100)
CVn= (CVMAIN x N) - ((n-1) x 100) + (100 - ModShift)
Seq Number (n) 12345678
ModShift 100 100 100 100 100 100 100
PID Out
(CVMAIN)CONTROL OUTPUT (CVn)
0 0 -100 -200 -300 -400 -500 -600 -700
5 40 -60 -160 -260 -360 -460 -560 -660
10 80 -20 -120 -220 -320 -420 -520 -620
15 120 20 -80 -180 -280 -380 -480 -580
20 160 60 -40 -140 -240 -340 -440 -540
25 200 100 0 -100 -200 -300 -400 -500
30 240 140 40 -60 -160 -260 -360 -460
35 280 180 80 -20 -120 -220 -320 -420
40 320 220 120 20 -80 -180 -280 -380
45 360 260 160 60 -40 -140 -240 -340
50 400 300 200 100 0 -100 -200 -300
55 440 340 240 140 40 -60 -160 -260
60 480 380 280 180 80 -20 -120 -220
65 520 420 320 220 120 20 -80 -180
70 560 460 360 260 160 60 -40 -140
75 600 500 400 300 200 100 0 -100
80 640 540 440 340 240 140 40 -60
85 680 580 480 380 280 180 80 -20
90 720 620 520 420 320 220 120 20
95 760 660 560 460 360 260 160 60
100 800 700 600 500 400 300 200 100

Master Panel 8 Section 2 — Operation
Part No. 750-375 2-5
B. DISPLAY SCREENS AND PARAMETER SETTINGS
The following appear on all screens:
• Day and time
• Current alarm
• Cleaver-Brooks logo
• Screen selection buttons
1. Screen Select
This is a navigational screen from which all other screens can be
accessed.
Figure 2-2 Screen Select

Section 2 — Operation Master Panel 8
2-6 Part No. 750-375
2. Boiler Overview Screen
Press (Temp) — indicates supply pressure (steam) or temperature
(hot water).
Set Point — Operating set point indicator.
Under each boiler name are indicators of the boiler’s working status:
•Idle — boiler is not called to start from lead/lag panel.
•Warm-Up — boiler is in warm-up cycle (hot water only).
•Running — boiler is running at the indicated control rate.
•Unavailable — boiler is not available and is not part of lead/lag
sequence.
Working — Indicates current sequence in which boilers are brought
on line (1 = Lead Boiler, 2 = Lag Boiler 1, 3 = Lag Boiler 2, etc.).
Entered — indicates the sequence of firing selected by the operator.
Working and entered numbers will be identical if all boilers are
available. If one or more of the boilers are not available, the sequence
will be shifted by the number of units which are not available (see
Figure 2-4).
Control — Indicates the firing rate control signal to each boiler (from
0 to 100%).
Auto Sequence Rotation In — Indicates the time remaining until
automatic rotation (if selected).
Psig (Bar) or Deg F (C) — indicates units used for pressure (steam)
or temperature (hot water) measurement.
Figure 2-3 Boiler Overview Screen (steam system with 8 boilers shown)
Figure 2-4 Example Working
Sequence

Master Panel 8 Section 2 — Operation
Part No. 750-375 2-7
3. Set Points and Sequence Screen
Lead Boiler On and Off Point — This is the water temperature (steam
pressure) at the header for the lead boiler to start and stop. These
values are calculated based on the values entered for set point and
On/Off dp (see below).
ON and OFF dp — these are differentials expressed as a % of set
point. Valid entries for “ON dp” are from -50 to “Off dp”. Valid entries
for “Off dp” are from “On dp” to:
Example: Max Pressure = 250 psig
SP = 200 psig
“Off dp” maximum setting = 25
Operating Set Point — This button allows changing of the water
temperature (steam pressure) set point. This is the value at which
controller will try to maintain water temperature (steam pressure) at
the header. Valid entries for hot water system are from 170
° F
(76.7 ° C) to the “Off” point setting. Valid entries for steam system are
from 0 PSI (0 Bar) to the “Off” point setting. Set point setting is also
limited by the low and high limits that can be set on this screen.
Remote Set Point if enabled can also be entered on this screen.
Remote Set Point is enabled using “Select Set Point” on the Firing
Rate screen (see below).
Water Temp (Steam Press) — Displays water temperature (steam
pressure) at the common header.
SP Limit — These keys are used for setting of the high and low
operating set point limits.
Hot Water System: Valid entries for the “Low Limit” are from
170°F (76.7°C) to the “High Limit” setting. Valid entries for
Figure 2-5 Set Points and Sequence
maxpressure
SP
---------------------------------- 100


100–

Section 2 — Operation Master Panel 8
2-8 Part No. 750-375
“High Limit” setting are from the “Low Limit” to 95% of the
maximum temperature.
Steam System: Valid entries for the “Low Limit” are from 5 PSI
(0.3 Bar) to the “High Limit” setting. Valid entries for “High
Limit” setting are from the “Low Limit” to 90% of the maximum
pressure.
Remote Set Point Range — sets the range of the remote 4-20 mA
signal when using remote set point. <Minimum> sets the set point
corresponding to a 4 mA signal and <Maximum> the set point
corresponding to a 20 mA signal.
Set Point Ramp Rate — limits the rate of change of the remote set
point signal.
Boiler ID — Shows the boiler name as entered on the Configuration
screen.
Boiler Seq.
New — Allows the selection of a new firing sequence for the
boilers. To select the appropriate sequence: press the button
corresponding to the specific boiler. The numeric keypad will
appear. Select one of the following numbers:
(1 = Lead Boiler, 2 = Lag Boiler 1, 3 = Lag Boiler 2, 4 = Lag
Boiler 3, etc.).
Make a selection for each boiler (duplicate numbers are not
allowed)). When finished, press the <Enter New Order>
button. If the order is valid, the numbers in the existing column
will change. If the order is invalid, an “Invalid Order” message
is displayed.
Current — Displays the existing firing sequence.
Auto Rotation Days — With auto rotation selection “On” boiler firing
sequence will rotate automatically. When auto rotation time expires,
each boiler sequence number will be shifted to the left by one. Valid
entry is from 1 to 60 days.
(Example: Sequence before rotation – 12345678; Sequence after
rotation – 81234567. Auto rotation timer is reset every time
sequence is changed.)
Auto Rotation On/Off — “On” enables auto sequence rotation.
Units — This button toggles between English and Metric units of
measure.
Low Steam Pressure (Water Temp.) Alarm — This push button is
used to set the alarm activation point for low steam pressure (water
temperature).
Changing Parameter Values
In order to change a value, Press the <Change> button. The numeric
keypad display will appear. Select desired number. Press <enter>
key and then push the button corresponding to the number to be
changed. If the entry is invalid, the display will show “Out of Range”.

Master Panel 8 Section 2 — Operation
Part No. 750-375 2-9
4. Set-Up 1 Screen
This screen is used to enter boiler timers’ start and stop points.
Start Point — Control signal to the previous-in-sequence boiler at
which this boiler will start. Valid entry is from Boiler Stop Point to
100.
Start Delay — Time delay before the boiler will start. The time delay
is initiated when the Start Point is reached. A valid entry is from 0 to
900 seconds.
Stop Point — Firing rate of the boiler at which this boiler will stop.
Valid entry is from 0 to the Boiler Start Point.
Stop Delay — Time delay before the boiler is commanded to stop.
The time delay is initiated when the Stop Point is reached. A valid
entry is from 0 to 900 seconds.
Mod Start — This selection is available only on a steam system when
lead/lag modulation is selected. This is the firing rate for the previous
boiler at which this boiler will start modulation.
Modulation — On steam systems unison or lead/lag modulation can
be selected. Note: hot water systems are unison modulation only.
(Example: Boiler #1 is the lead boiler, Boiler #2 is Lag Boiler 1, and
Boiler #3 is Lag Boiler 2. Boiler Start point is set to 80%. Boiler start
delay is set to 90 seconds. Boiler stop point is set to 20%. Boiler stop
delay is set to 60%. The Shut Down delay for all units are set to 180
seconds. When the control signal to the boiler #1 is greater or equal
to 80% for more than 90 seconds, run command will be given to the
boiler #2. If control signal to the boiler #2 drops below 20% for more
than 60 seconds, stop command will be given to the boiler #2. Boiler
will stay on for another 180 seconds and then shuts down.)
Figure 2-6 Set-Up 1 Screen

Section 2 — Operation Master Panel 8
2-10 Part No. 750-375
5. Set-Up 2 Screen
Figure 2-7 Set-Up 2 Screen (steam)
Shut Down Delay — Time delay for boiler shut down after the stop
command is received. Valid entry is from 0 to 1200 seconds.
Boiler In Sequence — Valid selections are “Yes” or “No”. “Yes”
indicates that the unit is part of the lead/lag sequence.
Figure 2-8 Set-Up 2 Screen (hot water)