UPAC™ Combustion Control Features and Capabilities. Company Background. Present Organization Corporate Headquarters & Manufacturing: Cleveland, Ohio. Air Switch Sales, Order Processing, Customer Service: Cleveland, Ohio. Process Sales: Boynton Beach, Florida, & Cleveland, Ohio.
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Features and Capabilities
Hays Corporation was founded in 1901 by Mr. Joseph Hays. Republic Corporation joined in 1972. Thereafter, the company was known as Hays Republic Corporation.
Cleveland Fuel Equipment Company was founded in 1942 by Mr. Norman Hahn. During the 1950's, the company moved to it's present location at 1111 Brookpark Road, and its name was changed to Cleveland Controls in 1958.
Cleveland Controls & Hays Republic consolidated under Optimum Controls in 1984.
The two corporations sold assets to UniControl Inc. during 1994.
The combustion control product lines of the Hays Republic division and the Cleveland Controls division were further consolidated as Hays Cleveland during October 1996. The air switch product line remained as Cleveland Controls.
The new Hays Cleveland UPAC™ package provides complete facility control, monitoring and communications with the accuracy, speed and advanced capabilities expected in high-end PLC and PC automation products--at a much lower than expected investment! With UPAC™, boiler plant operations and other facility operations are fully integrated in one platform. UPAC™'s modular approach provides almost unlimited capability. Components include a touch screen, control unit and modules for analog and digital I/O.
UPAC™ Controller CPU
UPAC™ Controller CPU Specifications
Optional Port configurations:
UPAC™ I/O Modules
Combines CPU with Analog & Digital I/O
UPAC™ Touch Screen HMI
HMI software package
Ethernet modbus TCP/IP communications between HMI, Controller and SCADA
CanOpen protocol to modules
RS232 serial &
Standard Communications to SCADA is through Modbus TCP/IP. Other solutions such as gateways can be provided for interfacing with building management systems such as LonWorks, BacNet and Metasys
SCADA or Building Management System
Modbus TCP/IP Communications
UPAC™ enhances operator awareness, improving efficiency and safety throughout the facility. It can control more than 10 devices for applications ranging from boiler combustion control to DA tank and condensate tank control. For example, in a typical parallel positioning application with O2 trim and boiler efficiency monitoring, UPAC™ would control the gas and oil valves; FD damper and FD damper VFD with by-pass; FGR, feed water control valve, draft damper and boiler feed water pump VFD.
Enhanced Plant wide control with the UPAC™ can include:
and provide one central location for operator viewing and control.
A typical parallel positioning application with O2 trim and boiler efficiency monitoring, UPAC™ controls the gas and oil valves; FD damper and FD damper VFD with by-pass; FGR, feed water control valve, draft damper and boiler feed water pump VFD, all while monitoring the economizer IN and OUT temperatures and calculating overall boiler efficiency.
UPAC™ parallel positioning and metering applications use the same Hays Cleveland UL 1998 Certified Strategies as our AC Station™ hardware platforms. For safety, both cross-limiting and deviation-limiting logic as well as actuator failure detection are employed in these strategies to prevent the occurrence of low excess air.
The Home button will display the Boiler Overview screen which gives the operator the current status of:
The Local pressure master screen is present on both boiler controls and allows for either manual control from the operator, or automatic control based on boiler pressure.
This loop is only active when “LOCAL MASTER” is highlighted below the bargraph. This is normally due to a plant master signal failure.
From the Pop-up control, touching the “OIL” button brings up the boiler submaster screen.
This screen gives the operator an overview of the fuel/air position of the boiler.
By touching the “Auto/Man” button on either the “Submaster” or “Oxygen trim” loop allows the operator to take manual control of that particular loop.
The Fuel /Air auto/manual buttons are disabled while logged in as operator.
Touching the “FEEDWATER” button on the pop-up menu will display the feedwater control loop.
This screen provides the operator with the current status of the:
The operator can also take manual control of the feedwater by touching the auto/man button and specifying a valve percentage.
Pressing the “DRAFT” button on the operator pop-up menu will display the Draft Control screen. On this screen you will find
While logged in as Operator, you can place the draft control loop in either auto or manual. While in manual mode, the operator can select the position of draft actuator to be held at.
The “Trend” icon on the main menu will bring up a list of available trends for display. The format for each trend screen is the same, with the large trend graphic, ranges to the left side, and the legend for each line at the bottom of the screen. The check boxes in the legend area will turn on or off that particular line.
The historical alarm icon will display all the alarms from the last seven days that the UPAC has monitored. This screen will give you the date and time of the alarm as well as the current status. The legend at the bottom of the screen is the color legend to help identify the state of the alarm, whether it has been acknowledged (green) or has returned to normal (blue). This color code also applies to the Alarm Pop-up display.
The Plant Master Screen is the main screen that should be displayed most of the time. At a glance, the user can see the header pressure, master loading demand signal to all the boilers, header steam flow, and the outside air temp.
The Feedwater Pump screen provides the user with information regarding the two-pump sequencer for boiler #4 feedwater, and the three pump sequencer for boilers #1,2,& 3. Included for each set of sequencer controls are:
There are individual screens for each DA Tank. The corresponding screen will give the user the current tank level, tank water temperature, and the fill valve position.
The Condensate tank screen accessible from the operator pop-up menu gives the user an overview of condensate system. This consists of:
The control system monitors the status of each fuel oil storage tank. The individual tank levels, high and low level alarms are provided from the Omntec fuel oil monitoring system and are displayed on the Master UPAC control. Access to this screen is from the operator pop-up menu, “FUEL OIL TANKS” button.
We program each UPAC™ system for a specific application. Typical packages include the auxiliary instrumentation necessary for a complete system: level and pressure transmitters, flow meters and actuators, and an optional SCADA workstation. Complete wiring and system schematics are provided.
We greatly appreciate the opportunity to present this material to you. Please contact the Sales Department (561-734-9400) or your local Hays Cleveland Representative for quotations, specifications and sales support.