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UtilitySaver Boiler Retrofit Controller

Application | Overview | Features

The UtilitySaver Burner Control System is designed to minimize total energy consumption of a burner (both fuel and electricity usage). UtilitySaver combines the fuel savings of an Oxygen trim system with the electrical kWh savings of a Variable Speed Drive (VSD) FD fan. UtilitySaver is intended for installation on an existing burner with either a Jackshaft or parallel positioning combustion control system.

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Utility Saver
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Utility Saver

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The UtilitySaver is the ideal retrofit controller for customers that want to add oxygen trim and VSD control to their boiler control system, but want to retain their existing flame safeguard system. It installs quickly and easily, reducing installation cost and maximizing the payback from efficiency improvements.

Customers that want to modernize their flame safeguard controls as well should see the BurnerMate Universal, Preferred's new linkageless controller that combines flame safeguard, parallel positioning with oxygen trim control, and VSD control.

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  • Overview
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Our UtilitySaver Burner Control System is designed to minimize total energy consumption of a burner (both fuel and electricity usage). UtilitySaver combines the fuel savings of an Oxygen trim system with the electrical kWh savings of a Variable Speed Drive (VSD) FD fan. UtilitySaver is intended for installation on an existing burner with either a Jackshaft or parallel positioning combustion control system.

Standard Equipment:

  • UL Labeled, Wired and Tested Control Panel
  • PCC-III-ZG00 UtilitySaver Controller
  • 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

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.

Energy Efficient Burner Control: It is well known that VSD controlled variable speed fans provide significant electrical savings compared to fixed speed fans with a damper. In most cases, the annual electrical cost savings due to the VSD are approximately the same as the annual fuel cost savings due to the Oxygen Trim. Therefore, One UtilitySaver control system provides twice the annual savings, achievable with application of only O2 Trim or a VSD.

Internal Proportion Integral and Derivative (PID) Control Option: The firing rate is determined by a pressure or temperature transmitter, the setpoint (determined by the operator), and a PID control block. PID control ensures that the required setpoint is reached without “offset” (setpoint deviation).

Manual Air Trim Capability: Manual Air Trim Capability with automatic adaptive gain.

Integral Oxygen Analyzer Diagnostics: Specific diagnostic codes for rapid trouble shooting. Continuous cell impedance checking for cell health prediction.

Oxygen Trim Delayed: Oxygen trim is delayed for a period after light-off (adjustable) to allow stack Oxygen to stabilize.

Simple Auto/Manual Control: The Operator has a simple “Demand Auto/Manual” station on the front of the controller to allow Automatic or Manual control of the burner firing rate. In Automatic, UtilitySaver uses the existing 0-135 ohm (or 4-20 mAdc) firing rate control signal to modulate the burner firing rate. In Manual, the Operator uses the PCC-III “Up” and “Down” arrows to set the desired 0-100% firing rate.

Lightoff Position: Lightoff position is adjustable for wide turndown burners.

Fuel-Air Lead/Lag: The UtilitySaver’s “Electronic Jackshaft” control logic links the Fuel Valves, Damper, and VSD speed together. 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”: F(x) Characterizer curves are set up by manually positioning fuel and air for safe and reliable operation and optimum Oxygen level and then pressing the “STORE” button. Air and Oxygen Setpoint curves are simultaneously setup. This process can be repeated for a maximum of 11 load points. Independent curves for each fuel are automatically selected.

Automated Purge & Light-Off: The air and fuel automatically drive to purge and light-off positions under flame safeguard system direction. VSD “at speed” contact interlocks burner purge and light-off limits.

Modbus Communication Interface: An easy to setup RS485 MODBUS interface is available for off-site monitoring and control.

Commissioning Software: The PC3_Setup Commissioning Software is included with every UtilitySaver Burner Control. The PC3_Setup Commissioning Software is MS Windows compatible. The software uses an automated step-by-step procedure to assist the service technician with the setup of the fuel and air actuators, ZP Oxygen Sensor, variable speed drive and fuel/air profile. The Software is not required for operation, it is only required during commissioning, calibration and tuning. Using the PC3_Setup Commissioning Software is a step-by-step procedure.  Individual “Tasks” are selected and “Run” by “pressing” the “Run” pushbutton. When each task is initiated, a series of steps are carried out and the user is prompted as required.

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  • Features
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  • Minimum Fuel And Fan Power Usage
  • Improved  Availability with Full Speed Bypass
  • Real Time Boiler Efficiency Display

Enclosure

Controller: PCC-III-ZG00

Input Power: 120 VAC (+/- 15%)

Actuator Power: 24 VAC

Enclosure: 16” H x 14” W x 10“ D, NEMA 12 Wall Mounted

Inputs

Drum Pressure: 4-20 mADC (optional)

Flue Gas Temperature: T/C

Flue Gas Oxygen: ZP Probe

Plant Master: 4-20 mADC

Fuel Actuator Feedback: Potentiometer

Air Actuator Feedback: Potentiometer

VSD Speed Feedback: 4-20 mADC

Outputs

Boiler Efficiency: 4-20 mADC

Fuel Valve Actuator: Triac

Air Damper Actuator: Triac

VSD Speed Demand:  4-20 mADC

In-Situ Oxygen Sensor, Model ZP

Insertion Length: 20, 30, 45, 65, 90" Probe

Flange: 3" 125 lb

Mounting Kit (190680): Flanges, nipple, coupling, gasket, bolts, nuts and washers, calibration tubing, compression fittings and isolation valve 

Signal Cable Kit (190681)

ZP Cable: 70 ft of 7 conductor wire cable for ZP probe

T/C Cable: 70 ft of type J T/C shielded cable

Triac Output Cable: 100 ft of 3 wire shielded cable

Load Sensor Cable: 50 ft of 2 wire shielded cable

Boiler Efficiency Kit (104087C)

Efficiency: ASME “by losses” method efficiency configuration

T/C: Flue Gas Temperature Assembly, 104087D, with mounting flange

Actuators

Fuel: SM series

Air: SM series

Mounting Kit (190682): Right angle mounting bracket for Damper Actuator, (3) Lever Arms, (4) ball joints, (2) 12" threaded Links

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