Basic Electricity Principles & Boiler Wiring Fundamentals. Presented by Steve Connor April 20, 2016
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1 Basic Electricity Principles & Boiler Wiring Fundamentals Presented by Steve Connor April 20, 2016
2 Today s Topics 1 Some basics & historical background Electricity and its current types The advantages and disadvantages 2 Terms and definitions you need to know 3 Basic Circuits and control devices; then applied to a boiler wiring circuit 4 Importance of Training Summary and Q&A 2
3 First law of Thermodynamics First Law: The energy of the universe is constant; it can be neither created or destroyed, but only transferred and transformed. The energy can be harnessed to produce work. 3
4 The Atom Elements Free Electron 4
5 Illuminating America 1878 Thomas Edison Nikola Tesla 5
6 Direct Current Power Electric light bulb Phonograph Motion pictures Vote Recorder Iron ore separator All DC powered 6
7 DC power Generator Steam Boiler DC Generator 7
8 Alternating Current Power 8
9 Steam Boiler AC Generator 9
10 The Investor Sharks 1878/79 JP Morgan Edison Cornelius Vanderbilt 10
11 Edison electrifies Menlo Park 11
12 Edison electrifies the Columbia 12
13 Investment Shark 1884 Tesla George Westinghouse 13
14 14 War of the Currents
15 Chicago Worlds Fair,
16 16 Hydro Electric Power
17 Electrical reach AC vs DC DC Power 17
18 AC Power 18
19 Kerosene Oil lighting JD Rockefeller 19
20 What is AC & DC Current? 20
21 Old steam turbine & Hydro power 21
22 22 DC Power Generator
23 Alternating Current Sinusoidal Flow 23
24 Alternating Current 60 Cycles per Sec. 24
25 Advantage vs Disadvantage 25
26 Transforming AC Power High Voltage Boosting Transformer Power Reducing Transformer Line to house 26
27 27 Converting AC to DC
28 AC vs DC Voltage DC AC 28
29 Terminology Ampere: The flow of an electrical charge through 1 ohm by force of 1 volt Current: Electrical flow measured in Amperes (Amps) Watt: The total power of a circuit at any given moment. [Volts X Amps = Watts] Kilowatt: One thousand Watts Hertz: Unit of frequency equaling one cycle per second (Hz) Voltage: Electrical potential difference between two points: Electromotive Force (EMF) Ohm: Resistance overcome by 1 volt pushing1 Amp. Ohm s Law: The electric potential difference between 2 points (Voltage) is the product of the current (Amps) X Resistance [E = I. R] Single Phase: The distribution of alternating current where voltages vary in unison Three Phase: A polyphase system for large loads; voltages reaching peak values sequentially Ground: A direct physical connection to earth for safety purposes. Should not carry current. Neutral: Known as common, completes the circuit, allowing current to flow back and forth within both neutral and hot wires. 29
30 3 phase vs single phase 3 phase Single phase Polyphase 30
31 Basic circuits Common devices 31
32 Series circuit Ohm s Law for voltage solving V = I.R Finding amperage I = V/R [9/450 =.02 Amps] [.02 X 450 = 9 Volts] 450 Ohms total 32
33 Parallel Circuit Rules for Parallel circuits: Total current = sum of all circuits Voltage across each path is the same Total resistance always less than any individual circuit Solving for amperage I = V/R Total the 3 circuits Solving for Resistance R = V/I Solving for Voltage V = I.R EMF 9/14.4 = Ohms 14.4 Amps 9/10 = 9/2 = 9/1 = 0.9A 4.5A 9.0A = 13 Ohms 33
34 Starters & Contactors Starter Contactor 34
35 Relays & Timers Timer Relays 35
36 Transformers 220/120V 120/24V 10,000V 36
37 The Burner Management System (BMS) 37
38 38 Switchman
39 Burner Management System Switchman Train engineer 39
40 Schematic wiring diagram, AC voltage Hot side Neutral Side Top 40 Bottom
41 Flame Safeguard System Sequence The Switchman Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
42 Schematic wiring diagram, AC voltage 440/3/60 Power in CCT 220/120/3/60 Top 42 Bottom
43 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
44 Schematic wiring diagram, AC voltage Limit circuit Top 44 Bottom
45 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
46 Schematic wiring diagram, AC voltage Top 46 Bottom
47 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
48 Schematic wiring diagram, AC voltage Top 48 Bottom
49 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
50 Schematic wiring diagram, AC voltage Top 50 Bottom
51 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
52 Schematic wiring diagram, AC voltage 120/24V Top 52 Bottom
53 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
54 Schematic wiring diagram, AC voltage Top 54 Bottom
55 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
56 Schematic wiring diagram, AC voltage Top 56 Bottom
57 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
58 Schematic wiring diagram, AC voltage Top 58 Bottom
59 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
60 Schematic wiring diagram, AC voltage Top 60 Bottom
61 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
62 Schematic wiring diagram, AC voltage Top 62 Bottom
63 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
64 Schematic wiring diagram, AC voltage Top 64 Bottom
65 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
66 Schematic wiring diagram, AC voltage Top 66 Bottom
67 Burner Management System Sequence Control circuit power applied....circuits 4 & 5 Power enters....4,l2 Limit circuit 4,6 Pre-ignition interlock.....4,20 Blower motor coil energized.5 Modulating damper motor closed proof..13,14 Drive damper full open..13,12 Combustion air proof..7 Drive damper to low fire position.13,14 Ignition pilot. 8 Flame proven (10 sec proof)...f,g Open main gas valve(s)..9 Release to modulation..13,15 Alarms.3
68 Schematic wiring diagram, AC voltage Top 68 Bottom
69 LW/FFA with Alarm Silencing Switch Boiler On Line 4 4 OLC 24 HLC MR 48 (2) LWCO (1) (5) (6) 34 (4) CONN S FOR FEED WATER SYSTEM CR-1 (B) (A) (9) CR-1 (6) 17 LWL R LDL W 3 (3) CR-1 (9) (9) CR-2 (3) 16 FFL AB R (9) CR-2 (6) CR-2 (B) (A) ASS 55 (mom)
70 LW/FFA with Alarm Silencing Switch Boiler Off Line 4 4 OLC 24 HLC MR 48 (2) LWCO (1) (5) (6) 34 (4) CONN S FOR FEED WATER SYSTEM CR-1 (B) (A) (9) CR-1 (6) 17 LWL R LDL W 3 (3) CR-1 (9) (9) CR-2 (3) 16 FFL AB R (9) CR-2 (6) CR-2 (B) (A) ASS 55 (mom)
71 24 (5) LW Alarm 4 4 FFL LWL AB R LDL W R CR-1 (6) (9) CR-1 (9) (3) OLC HLC MR (2) (1) (4) (6) 48 LWCO CONN S FOR FEED WATER SYSTEM CR-1 (B) (A) 55 CR-2 (3) (9) CR-2 (6) (9) CR-2 (B) (A) ASS (mom) Relay
72 24 (5) LW with Alarm 4 4 FFL LWL AB R LDL W R CR-1 (6) (9) CR-1 (9) (3) OLC HLC MR (2) (1) (4) (6) 48 LWCO CONN S FOR FEED WATER SYSTEM CR-1 (B) (A) 55 CR-2 (3) (9) CR-2 (6) (9) CR-2 (B) (A) ASS (mom) Relay
73 Schematic wiring diagram, AC voltage Hot side Neutral Side Top 73 Bottom
74 Knowledge is Power Boiler outage & Un$cheduled downtime!
75 Knowledge is Power! 75
76 76 At our facility At your facility On-line
77 77
78 78
79 79
80 80
81 Summary Electricity is the flow of electrons from more to less potential. Direct current is unidirectional and cannot be transformed. Alternating current moves in both directions above and below the zero volt horizontal in a sinusoidal curve. AC can be transformed to increase and decrease voltage. Voltage is the electrical potential difference between two points and also referred to as Electromotive Force (EMF). An ampere is the measurement unit used to determine the flow of current. Watt is the standard of unit power where a current of 1 ampere flows across a potential difference of 1 volt. Ohm s law for voltage is E = I.R Neutral is also known as the common which completes the circuit. Ground is a direct physical connection to earth for safety purposes and should not carry current. Three phase power is also known as polyphase with 3 separate current supplies coming into one connector. A schematic wiring diagram shows point to point connections, but not the logic of the sequencing. The BMS provides the sequence for energizing the proper circuits for safe and reliable boiler operation. Electricity is complicated, and requires training for adequate understanding. 81
82 Patrick Gore Electrical engineering cleaverbrooks.com 82
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