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Lochinvar INS7141 Water System User Manual

1. OUT DSGN WWSD Occ WWSD UnOcc Supply Water Temperature ROOM Occ lt t ROOM UnOcc 60 40 20 16 5 7 Outdoor Air Temperature OuTDOOR DESIGN TEMPERATURE The outdoor design temperature is the outdoor air tempera ture that is the typical coldest temperature of the year where the building is located This temperature is used when doing the heat loss calculations for the building If a cold outdoor design temperature is selected the boiler supply tempera ture rises gradually as the outdoor temperature drops If a warm outdoor design temperature is selected the boiler supply temperature rises rapidly as the outdoor temperature drops BOILER DESIGN TEMPERATURE The design supply temperature is the supply water temper ature required to heat the building when the outdoor air tem perature is as cold as the outdoor design temperature WARM WEATHER SHUTDOWN When the outdoor air temperature rises above the WWSD setting the control turns on the WWSD pointer in the dis play When the control is in Warm Weather Shut Down the boiler demand pointer is displayed if there is a boiler demand However the control does not operate the heating system to satisfy this demand The control does respond to a DHW or set point demand and operates as described in sections E amp F ROOM The room is the desired room temperature for the building
2. Low Mass Radiant Fancoil Fin Tube Convector Radiator BOOST When the control changes from the UnOccupied mode to the Occupied mode it enters into a boosting mode In this mode the supply water temperature to the system is raised above its normal values for a period of time to provide a faster recovery from the setback temperature of the build ing The maximum length of the boost is selected using the BST setting Typical settings for the boost function vary between 30 min utes and two hours for buildings that have a fast responding heating system For buildings that have a slow responding heating system a setting between four hours and eight hours is typical After a boost time is selected the setback timer must be adjusted to come out of setback some time in advance of the desired occupied time This time in advance is normally the same as the BST setting If the building is not up to temperature at the correct time the BST setting should be lengthened and the setback timer should be adjusted accordingly If the building is up to tem perature before the required time the BST setting should be shortened and the setback timer should be adjusted accord ingly If the system is operating near its design conditions or if the supply water temperature is being limited by set tings made in the control the time required to bring the building up to temperature may be longer than expected SECTION E DOMEST
3. LN INSTALLATION INS7162 Rev INSTRUCTIONS INTRODUCTION The MP 15 capable of controlling the supply water tempera ture for up to nine ON OFF stages based on outdoor tem perature control for the Domestic Hot Water DHW gener ation a set point requirement or optionally an external input signal 0 10 V dc A large easy to read display provides current system temperatures and operating status FIG 1 The control has outputs for a primary pump and a combus tion air damper or alarm Based on the mode of operation selected the control can operate different combinations of boiler stages and boiler pumps Boiler Demand DHW Setpoint Demand WWSD External Input Signal Offset Menu ower Co Boil Boil Out Un Sup Ret Sw ADDITIONAL FUNCTIONS INCLUDE Installer and Advanced Access Levels Primary Pump Output Individual Boiler Pump Outputs in applicable modes Pump Exercising Pump Purging primary and boiler Boiler Demand for Space Heating Loads DHW Demand DHW Loads Set Point Demand for Set Point Loads Test Sequence to Ensure Proper Component Operation Setback Input for Energy Savings e 0 10 V dc Input Signal Rotate Fixed Last First On Last Off Exerci se First On First Stand Alone Modes Test 1 Up to 9 On Off Boilers 2 Up to 4 On Off Boilers amp 4 Pumps 3 Up to 4 Lo Hi Bo
4. Au Auto OFF Default Au 60 to 45 F 51 to 7 C Default 10 F 12 C 1 HRF1 2 HRF2 3 COIL 4 CONV 5 RAD 6 BASE Default 4 35 to 100 F 2 to 38 C Default 70 F 21 C 70 to 220 F 21 to 104 C Default 180 F 82 C Adjust Menu 3 of 4 Description Boiler Minimum The minimum allowed boiler target temperature BOIL Boiler Maximum The maximum allowed boiler target temperature Fire Delay 1 The time delay the control can expect between the time that the relay contact closes to fire the first stage of the boiler and the burner actually fires Fire Delay 2 The time delay the control can expect between the time that the relay contact closes to fire the third stage of the boiler and the burner actually fires This item is available in Modes 5 to 8 Combustion Air Damper Delay The time allowed for the combustion air damper to open before the first stage is fired This item is only available if the Alarm C A DIP switch is set to C A Boil Mass The thermal mass characteristics of the boilers that are being used Stage Delay The minimum time delay between the operation of stages Boiler Differential The temperature differential that the control is to use when it is operating the boiler s Staging Selects the firing sequence of the stages when using multi stage boilers This item is only available in Modes 3 to 7 MODE DHW Mode Selects the DHW mode of op
5. Combustion Air Alarm Contact C A Alarm The Combustion Air Alarm Contact C A Alarm terminals 12 and 13 FIG 29 are an isolated output in the control There is no power available on these terminals from the control These terminals are to be used as a switch to either make or break power to the combustion air damper or alarm Since this is an isolated contact it may switch a volt age between 24 V ac and 230 V ac 18 Relay 1 to Relay 9 The Relay 1 to Relay 9 terminals 14 and 15 to 30 and 31 FIG 30 are isolated outputs in the control There is no power available on these terminals from the control These terminals are to be used as a switch to either make or break power to a boiler stage or a boiler pump Since this is an isolated contact it may switch a voltage between 24 V ac and 230 V ac Relay 9 DHW If a DHW pump or DHW valve is connected to the Relay 9 DHW contact 30 and 31 FIG 30 make sure the power to the pump or valve circuit is off and install a jumper between those terminals When the DHW circuit is powered up the DHW pump should turn on or the DHW valve should open completely If the DHW pump or valve fails to operate check the wiring between the terminals and the pump or valve and refer to any installation or troubleshooting information sup plied with these devices If the DHW pump or valve oper ates correctly disconnect the power and remove the jumper SENSOR AND UN
6. If a combustion air damper or an alarm is connected to the C A Alarm terminals 12 and 13 make sure power to the damper or alarm circuit is off and install a jumper between terminals 12 and 13 FIG 38 When the circuit is powered up the combustion air damper should open or the alarm should activate If the damper or the alarm fails to operate check the wiring between the terminals and the damper or the alarm and refer to any installation or troubleshooting information supplied with these devices If the damper or the alarm operates properly disconnect the power and remove the jumper Relay 1 to Relay 9 If a boiler stage is connected to the Relay 1 terminals 14 and 15 FIG 39 make sure power to the boiler circuit is off and install a jumper between the terminals When the boiler circuit is powered up the boiler should fire If the boiler does not turn on refer to any installation or trou bleshooting information supplied with the boiler The boiler may have a flow switch that prevents firing until the primary pump P1 or boiler pump is running If the boiler operates properly disconnect the power and remove the jumper If a boiler pump is connected to the Relay 1 terminals 14 and 15 FIG 39 make sure that power to the terminal block is off and install a jumper between the terminals When power is applied to the circuit the boiler pump should start If the pump does not turn on check the wiring between the
7. TARG DSGN LLLI HORE HUNE E A gt r p 4 STG F DLY BST 1234 1 5 6789 gt MASS TERM Q gt OUT BOIL RQDM DHW SETP A SUP RETAT DIFFINDR gt min hr DHW BoilPmp 1234 Boiler Demand DHW Setpoint Demand WWSD External Input Signal Offset Menu j Buttons Selects Menus Items and adjust settings SYMBOL DESCRIPTION Stage Displays which stage relays are turned on Primary Pump Displays when the primary pump relay is turned on Boiler Pump Displays which boiler pump relays are turned on Combustion Air Damper Displays when the Combustion Air Damper relay is turned on Delta T The current difference between the supply and return temperatures F C min hr Units of measurement UnOccupied Schedule Displays when the control is in UnOccupied Mode Occupied Schedule Displays when the control is in Occupied Mode Installer Access Level Displays when the installer Advanced Dip switch is set to installer Pointer Displays the control operation as indicated by the text Warning Alarm Displays when an error exists or the alarm relay is turned on DHW Displays when the DHW relay is turned on DEFINITIONS The following defined terms and symbols are used through out this manual to bring attention to the presence of hazards of various risk levels or to bring attention to impo
8. This item is only available if the External Input Stand Alone DIP switch is set to External Input Boost The amount of morning boost This item is only available if the External Input Stand Alone DIP switch is set to Stand Alone Mode Selects the staging mode of operation Boiler 1 Selects whether or not boiler 1 is operational This item is available in all modes 25 0 to 1999 hr O to 1999 hr to 1999 hr Actual oetting 35 to 100 F 2 to 38 C Default 70 F 21 C 35 to 100 F 2 to 38 C Default 65 F 18 C Default 0 10 10 to 10 F 6 to 6 C Default 0 F 0 C OFF 0 20 to 8 00 hr 5 minute increment Default OFF 1 9 Boil 2 4 Boil 4 Pmp 3 4 LoHi 4 3 LoHi 3 Pmp 5 3 3 Stg 6 2 3 Stg 2 6 7 2 4 Stg 8 1 4 Stg 1 Pmp Default 1 Au Auto OFF Default Au Adjust Menu 2 of 4 BOIL BOIL ADJUST BOIL UJ BOIL UJ BOIL UJ ADJUST BOIL BOIL UJ BOIL UJ Description Boiler 2 Selects whether or not boiler 2 is operational This item is available in modes 1 to 7 Boiler 3 Selects whether or not boiler 3 is operational This item is available in modes 1 to 5 Boiler 4 Selects whether or not boiler 4 is operational This item is available in modes 1 to 3 Boiler 5 Selects whether or not boiler 5 is operational This item is available in mode
9. run the wiring back to the control Install the TST2311 sensor according to the installation instructions in the Data Brochure D 070 and run the wiring back to the control e If a TST2311 sensor is used install the sensor according to the installation instructions in the Data Brochure D 070 and run the wiring back to the control Run wire from other system components pumps boilers etc to the control Run wires from the 115 V ac power to the control Use a clean power source with a 15 A circuit to ensure proper operation Multi strand 16 AWG wire is recommended for all 115 V ac wiring due to its superior flexibility and ease of installation into the terminals STEP THREE ELECTRICAL CONNECTIONS TO THE CONTROL General The installer should test to confirm that no voltage is pres ent at any of the wires Push the control into the base and slide it down until it snaps firmly into place POWERED INPUT CONNECTIONS 115 V ac Power Connect the 115 V ac power supply to the Power L and Power N terminals 10 and 9 FIG 26 This connection provides power to the microprocessor and display of the control As well this connection provides power to the Prim P1 terminal 11 from the Power L terminal 10 Boiler Demand To generate a boiler demand a voltage between 24 V ac and 230 V ac must be applied across the Boil Dem and Com Dem terminals 6 and 7 FIG 26 DHW Demand To generate a DHW Demand a voltage
10. 1 Boiler 6 Selects whether not boiler 6 is operational This item is available in mode 1 Boiler 7 Selects whether or not boiler 7 is operational This item is available in mode 1 Boiler 8 Selects whether or not boiler 8 is operational This item is available in mode 1 Boiler 9 Selects whether or not boiler 9 is operational This item is available in mode 1 Outdoor Design The design outdoor air temperature used in the heat loss calculations for the heating system This item is only available if the External Input Stand Alone DIP switch is set to Stand Alone Terminal Unit The type of terminal units that are being used in the heating system This item is only available if the External Input Stand Alone DIP switch is set to Stand Alone Boiler Indoor The design indoor air temperature used in the heat loss calculation for the heating system The item is only available if the External Input Stand Alone DIP switch is set to Stand Alone Boiler Design The design supply water temperature used in the heat loss calculations for the heating system This item is only available if the External Input Stand Alone DIP switch is set to Stand Alone 26 Actual oetting Au Auto OFF Default Au Au Auto OFF Default Au Au Auto OFF Default Au Au Auto OFF Default Au Au Auto OFF Default Au Au Auto OFF Default Au Au Auto OFF Default Au
11. 32 TYPICAL BOILER INSTALLATION CONTINUED 3 zm BOILER 4 AC120 60Hz lt lt AC120 SSBHEM AC120 60Hz hcl ii 120 W SU EHE 43 BK AC120 60Hz ho lt lt 120 n 60Hz BR SYSTEM AC120 yw 60Hz BK BOILER 3 E BOILER 2 BOILER 1 BL P1 DWH m PUMP a BK SSS Slc COMBUSTION 1 TT AIR LOUVERS M miri 60Hz 33 TYPICAL DWH PRIORITY HEATING PACKAGE SYSTEM Minimum Retum of 120 F Minimum Supply of 140 F SYSTEM PIPING 3 Way Relay 5 120 C ACOM Minimum Reset of 140 F 3 WAY valve with spring return SETPOINT TT 24VAC 2 E SYSTEM SUPPLY SENSOR NON CONTROLLING RETURN SENSOR FOR DELTA T ONLY TOP UNIT 30GPM ContinuousPump aW 500 000 BTU Building Heating amp DWH BOILER 1 BOTTOM UNIT Intermittent Pump Tekmar 150 Controller PUMP 3 WA Y SETPOINT SENSOR Building Heating amp DWH BOILER 2 04 11 03 34 NOTES 35 9 04 Printed in U S A
12. a second stage is present the second stage is turned on and remains on e third stage is present the third stage is turned on and remains on If a fourth stage is 29 present the fourth stage is turned on After ten seconds all stages and the boiler pump are turned off Step 4 If DHW MODE is set to 1 or 2 and the last boiler in modes 1 4 and 5 are set to OFF the primary pump is shut off and the DHW contact is closed Step 5 If DHW MODE is set to 3 or 4 and the last boiler in modes 1 4 and 5 are set to OFF the primary pump stays on and the DHW contact is closed Step 6 All contacts are turned off MAX HEAT The control has a function called Max Heat see Figure 52 In this mode the control turns on and operates the system up to the maximum set temperatures as long as there is a demand for heat The control continues to operate in this mode for up to 24 hours or until the Item Menu or Test but ton is pressed This mode may be used for running all cir culators during system start up in order to purge air from the piping To enable the Max Heat feature use the following procedure 1 Press and hold the Test button for more than 3 seconds At this point the control flashes the MAX segment and dis plays the word OFF 2 Using the up or down arrow buttons select the word On After 3 seconds the control turns on all outputs However the max heat mode is still limited by the BOIL MAX setting 3 To cancel the M
13. and provides a parallel shift of the heating curve The room temperature desired by the occupants is often different from the design indoor temperature If the room temperature is not correct adjusting the ROOM setting increases or decreases the amount of heat available to the building A ROOM setting is available for both the occupied day and unoccupied night periods TERMINAL UNITS The control provides for a selection between six different terminal unit types two types of radiant floor heat fancoil fin tube convector radiator and baseboard When a termi nal unit is selected the control automatically loads the design supply temperature maximum supply temperature and minimum supply temperature FIG 16 The factory defaults are listed in Figure 16 These factory defaults can be changed to better match the installed system If a facto ry default has been changed refer to section A to reload the factory defaults 10 TERMINAL UNIT HIGH MASS RADIANTI LOW MASS RADIANT FANCOIL FIN TUBE RADIATOR BASEBOARD 1 2 3 CONVECTOR 4 5 6 BOIL DSGN 120 F e 140 F 190 F 88 C 180 F 82 C 160 F 71 C BOIL MAX are HIGH Mass RADIANT 1 This type of a hydronic radiant floor is embedded in either a thick concrete or gypsumpour This heating system has a large thermal mass and is slow acting FIG 17 Low Mass RADIANT 2 This type of radiant heating system is either attached to the bottom of a wood sub
14. between 24 V ac and 230 V ac must be applied across the Setp DHW and Com Dem terminals 8 and 7 FIG 26 If using DHW the last boiler in MODE 1 4 or 5 must be set to OFF and DHW MODE must also be set to 1 through 4 17 Set Point Demand To generate a setpoint demand a voltage between 24 V ac and 230 V ac must be applied across the Setp DHW and Com Dem terminals 8 and 7 FIG 26 The DHW MODE must be set to OFF External Input 0 10 V dc To generate an external input signal a voltage between 0 and 10 V dc must be applied to the Com and Out ter minals 1 and 4 FIG 27 A 0 20 mA signal can be converted to a 0 10 V dc sig nal by installing a 500 ohm resistor between the Com and terminals 1 and 4 FIG 27 A 4 20 mA signal can be converted to a 2 10 V dc sig nal by installing a 500 ohm resistor between the Com and terminals 1 and 4 FIG 27 Do Not Applyower Do Not Applyower mnie 0 10 V or 2 10V dc A OUTPUT CONNECTIONS Primary Pump Contact Prim P1 The Prim P1 output terminal 11 is a powered output When the relay in the control closes 115 V ac is provided to the Prim P1 terminal 11 from the Power L terminal 10 To operate the primary pump connect one side of the pri mary pump circuit to terminal 11 and the second side of the pump circuit to the neutral N side of the 115 V ac power supply see Figure 28 aes p
15. dc signal The External Input Signal setting must be set to the proper setting based on the signal that is being sent to the control 0 10 V dc or 0 20 mA When the 0 10 V signal is selected an input voltage of 1 V dc corresponds to a boiler target temperature of 50 F 10 C An input voltage of 10 V dc corresponds to a boiler target temperature of 210 F 99 C As the voltage varies between 1 V dc and 10 V dc the boiler target tem perature varies linearly between 50 F 10 C 210 99 C If a voltage below 0 5 V dc is received the boiler target temperature is displayed as indicating that there is no longer a call for heating A 0 20 mA signal can be converted to a 0 10 V dc sig nal by installing a 500 ohm resistor between the Out and Com terminals 4 and 1 2 10 V dc or 4 20 mA When the 2 10 V signal is selected an input voltage of 2 V dc corresponds to a boiler target temperature of 50 F 10 C An input voltage of 10 V dc corresponds to a boiler target temperature of 210 F 99 C As the voltage varies between 2 V dc and 10 V dc the boiler target tem perature varies linearly between 50 F 10 C 210 99 C If a voltage below 1 5 V dc is received the boiler target temperature is displayed as indicating that there is no longer a call for heating A 4 20 mA signal can be converted to a 2 10 V dc sig nal by installi
16. h hold Test for 3 seconds 943 01 Made in Canada by tekmar Control Systems Ltd Power 115 10 50 60 Hz 600 VA Relays 230V ac 5 A 1 3 hp pilot duty 240 VA g Demands 20 to 260 V ac 2 EE The installer must ensure that this control and its wiring are isolated and or shielded from strong sources of electromag netic noise Conversely this Class B digital apparatus com plies with Part 15 of the FCC Rules and meets all require ments of the Canadian Interference Causing Equipment Regulations However if this control does cause harmful interference to radio or television reception which is deter mined by turning the control off and on the user is encour aged to try to correct the interference by re orientating or relocating the receiving antenna relocating the receiver with respect to this control and or connecting the control to a different circuit from that to which the receiver is connect ed A CAUTION The nonmetallic enclosure does not provide grounding between conduit connections Use grounding type bush ings and jumper wires 31 TYPICAL BOILER INSTALLATION Boiler Demand Setpoint Demand 6686 QQ Menu Hem SENSOR COMMON OUTDOOR CONNECTIONS AIR e SENSOR T BOILER REI URN BOILER SENSOR SUPPLY 22 SENSOR STOP RUN Y SWITCH TRANSFORMER 115VAC COMBUSTI AIR LOUVER
17. into the control circuit Do not open the con trol Refer to qualified personnel for servicing Opening voids warranty and could result in damage to the equip ment and possibly even personal injury STEP ONE GETTING READY Check the contents of this package If any of the contents listed are missing or damaged please contact your whole saler or Lochinvar sales representative for assistance MP includes One Boiler Control MP One Outdoor Sensor TST2311 Two Temperature Sensors TST2313 Instruction Manuals INS7141 and INS7162 Note Carefully read the details of the Sequence of Operation to ensure that you have chosen the proper con trol for your application A STEP Two ROUGH IN WIRING All electrical wiring terminates in the control base wiring chamber The base has standard 7 8 22 mm knockouts which accept common wiring hardware and conduit fittings Before removing the knockouts check the wiring diagram and select those sections of the chamber with common volt ages Do not allow the wiring to cross between sections as the wires will interfere with safety dividers which should be installed at a later time Power must not be applied to any of the wires during the rough in wiring stage All wires are to be stripped to a length of 3 8 9 mm to ensure proper connection to the control If an Outdoor Sensor TST2311 is used install the sensor according to the installation instructions in the INS7141 and
18. the menu see Figure 2 ITEM The abbreviated name of the selected item will be displayed in the item field of the display To view the next available item press and release the button Once you have reached the last available item in a menu pressing and releasing the Item button will return the display to the first item in the selected menu The items can be quickly scrolled through by holding the Item button and pressing the down arrow button To rapidly scroll through the items in the reverse order hold the Item button and press the up arrow button see Figure 2 ADJUST To make an adjustment to a setting in the control begin by selecting the ADJUST menu using the Menu button Then select the desired item using the Item button Finally use the up arrow button or down arrow button to make the adjustment Additional information can be gained by observing the Status field of the LCD The status field will indicate which of the control s outputs are currently active Most symbols in the status field are only visible when the VIEW menu is selected see Figure 2 Menu Field Displays the current menu Item Field Displays an abbreviated name of the selected item Status Field Displays the current status of the control s inputs outputs and operation ue 21490 56789 Boil Pmp 1234 min hr DISPLAY Number Field Displays the current value of the selected item ma ADJUST
19. to 266 F 10 to 130 C 0 to 252 F 0 to 140 C View Menu 2 of 2 Adjust Menu 1 of 4 MODE BOIL Description Boiler 7 Hours The total running time of boiler 7 since this item was last cleared To clear this item press the A and v arrow button simultanously while viewing this item This item is available in mode 1 only Boiler 8 Hours The total running time of boiler 8 since this item was last cleared To clear this item press the A and v arrow button simultanously while viewing this item This item is available in mode 1 only Boiler 9 Hours The total running time of boiler 9 since this item was last cleared To clear this item press the A and v arrow button simultanously while viewing this item This item is available in mode 1 only Description Room Occupied The desired room air temperature during the occupied period This item is only available if the External Input Stand Alone DIP switch is set to Stand Alone Room Unoccupied The desired room air temperature during the unoccupied period This item is only available if the External Input Stand Alone DIP switch is set to Stand Alone External Input Signal Selects the range of the external input signal This item is only available if the External Input Stand Alone DIP switch is set to External Input Offset Sets the temperature offset used in calculating the boiler target temperature with an external input signal
20. 1 EXTERNAL INPUT EXTERNAL INPUT The control can accept an external DC signal in place of the outdoor sensor The control converts the DC signal into the appropriate boiler target temperature between 50 F 10 C and 210 F 99 C based on the External Input Signal and Offset settings To use the external input signal the External Input Stand Alone DIP switch must be set to External Input When operating in the external input mode an external sig nal is required in order for the control to provide heat to the heating system An external signal is generated by apply ing a voltage between 0 V dc and 10 V dc across the Out and Com terminals 4 and 1 FIG 25 Once voltage is applied the External Input Signal pointer is displayed in the LCD and the control closes the primary pump contact The control calculates a boiler target supply temperature based on the external input signal and the settings made in the control The control then fires the boiler s if required to maintain the target supply temperature If the external sig nal goes below the minimum voltage the External Input Signal pointer is turned off in the display The boiler target temperature is displayed as to indicate that there is no longer a call for heating The primary pump and boiler pumps operate as described in section C Do Not Apply Power 0 10 V dc or INPUT SIGNAL The control can accept either a 0 10 V dc signal or 2 10 V
21. F DHW Mope 1 DHW iN PARALLEL NO PRIORITY When a DHW Demand is present the Relay 9 DHW con tact terminals 30 and 31 closes and the primary pump con tact is opened It is assumed that the DHW pump will provide adequate flow through the heat exchanger and the boiler DHW 2 DHW iN PARALLEL NO PRIORITY When a DHW Demand is present the Relay 9 DHW con tact terminals 30 and 31 closes with the DHW demand The primary pump does not turn on but may operate based on a Boiler Demand or External Input Signal Refer to sec tions E and G It is assumed that the DHW pump will pro vide adequate flow through the heat exchanger and the boiler DHW 3 DHW iN PRIMARY SECONDARY NO PRIORITY When a DHW Demand is present the Relay 9 DHW con tact terminals 30 and 31 is closed and the primary pump contact is closed This mode can be used if a DHW tank Is piped in direct return and a DHW valve is installed 12 DHW 4 DHW iN PRIMARY SECONDARY WITH PRIORITY When a DHW Demand is present the Relay 9 DHW con tact terminals 30 and 31 is closed and the primary pump contact is closed Priority can only be obtained using exter nal wiring During a priority override the Relay 9 DHW contact is opened until the heating system has recovered before returning to DHW operation see Figure 19 This mode can be used if a DHW tank is piped in direct return and a DHW
22. IC HOT WATER TION SECTION E1 DOMESTIC Hor WATER DHW DHW DEMAND A DHW Demand is required for the control to provide heat to the DHW system A DHW aquastat or set point control is used as a switch in the DHW demand circuit Once the con trol detects a DHW demand the DHW Demand pointer turns on in the LCD and the control operates the boiler to provide a sufficient boiler supply water temperature to the DHW tank The control operates the pumps as described below The control registers a DHW Demand when a voltage between 24 and 230 V ac is applied across the Setp DHW and Com Dem terminals 8 and 7 BOILER TARGET DURING DHW GENERATION The boiler target temperature is at least as hot as the DHW exchange setting DHW XCHG The DHW demand over rides the boiler reset target temperature except when the boiler reset target is higher than that of the DHW exchange setting DHW amp PRIORITY OPERATION The control has five different settings available for DHW MODE The required DHW MODE setting will depend on the piping arrangement of the DHW tank It is often desirable to have a priority for the DHW allowing for quick recovery of the DHW tank temperature This is achieved by limiting or even stopping the flow of heat to the heating system when the DHW tank calls for heat see Figure 18 DHW Orr DHW The DHW feature is not selected This allows for Set Point operation as described in section
23. POWERED INPUT CONNECTIONS Do not apply power to these terminals as this will dam age the control Outdoor Sensor If an outdoor sensor is used connect the two wires from the Outdoor Sensor TST2311 to the Com and Out terminals 1 and 4 FIG 31 The outdoor sensor is used by the con trol to measure the outdoor air temperature Boiler Supply Sensor Connect the two wires from the TST2311 sensor to the Com and Boil Sup terminals 1 and 2 FIG 31 The boiler sup ply sensor is used by the control to measure the boiler sup ply water temperature Boiler Return Sensor If a boiler return sensor is used connect the two wires from the TST2311 sensor to the Com and Boil Ret terminals 1 and 3 FIG 31 The boiler return sensor is used by the control to measure the boiler return water temperature UnOccupied Switch If an external timer or switch is used connect the two wires from the external switch to the Com and UnO Sw terminals 1 and 5 FIG 32 When these two terminals are shorted together the control registers an UnOccupied signal 19 TESTING THE WIRING STEP FOUR Z GENERAL Each terminal block must be unplugged from its header on the control before power is applied for testing To remove the terminal block pull straight down from the control The following tests are to be performed using standard test ing practices and procedures and should only be carried out by properly trained and exper
24. TION SECTION F1 SET POINT Set point operation is only available when DHW MODE is set to OFF SET POINT The control can operate to satisfy the requirements of a set point load in addition to a space heating load A set point load overrides the current outdoor reset temperature and WWSD setting in order to provide heat to the set point load SET PoiNT DEMAND A set point demand is required for the control to provide heat to the set point load The control registers a set point demand when a voltage between 24 and 230 V ac is applied across the Setp DHW and Com Dem terminals 8 and 7 23 Once voltage is applied the Set Point Demand pointer turns on in the LCD The control operates the boiler s to main tain at least the set point setting 14 BoiLER TARGET DuniNG SET POINT The boiler target temperature during a set point demand is increased to at least the Set Point setting This temperature is maintained as long as the control has a set point demand SET PoiNT MODE SETP MODE 1 Setpoint in Parallel Whenever a set point demand is present the boiler s is operated to maintain the set point target The primary pump does not turn on but may operate based on a Boiler Demand or an External Input Signal see Figure 24 It is assumed that the Set Point pump will provide ade quate flow through the heat exchanger and the boiler SETP MODE 2 Set Point in Parallel with Priority Whenever a set point demand
25. above 248 120 C SECTION B STAGING OPERATION SECTION B1 STAGING Mode The control is capable of staging single stage two stage three stage or four stage on off heat sources In certain modes of operation the control is capable of controlling the individual boiler pumps The control has 8 modes of opera tion based on the type of staging and pump operation that is desired The following describes the modes of operation Mode 1 9 Single Stage Boilers and a primary pump Mode 2 4 Single Stage Boilers with individual boiler pumps and a primary pump Mode 3 4 Lo Hi boilers and a primary pump Mode 4 3 Lo Hi boilers with individual boiler pumps and a primary pump Mode 5 3 Three Stage Boilers and a primary pump Mode 6 2 Three Stage Boilers with individual boiler pumps and a primary pump Mode 7 2 Four Stage Boilers and a primary pump Mode 8 1 Four Stage Boiler with a boiler pump and a pri mary pump Boiler m Pumps Sensor RELAY 1 RELAY 2 RELAY 3 RELAY 4 RELAY 5 RELAY 6 RELAY 7 RELAY 8 RELAY 9 MODE 1 Boiler 1 Boiler 2 Boiler 3 Boiler 4 Boiler 5 Boiler 6 Boiler 7 Boiler 8 Boiler 9 Boiler 1 Boiler 2 Boiler 3 Boiler 4 MODE 2 1 Pump Boiler 2 3 Boiler 4 ui MODE 3 Boiler 1 Boiler 1 Boiler 2 Boiler 2 Boiler 3 Boiler 3 Boiler 4 Boiler 4 E Stage 1 Stage 2 Stage 1 Stage 2 Stage 1 Sta
26. ax Heat mode press the Item Menu or Test button 4 Once the Max Heat mode has either ended or is can celled the control resumes normal operation v Item ERROR MESSAGES The control was unable to read a piece of information stored in its memory FIG 53 Because of this the control was required to reload the factory settings into all of the items in the ADJUST menu The control will stop operation until all of the items in the ADJUST menu of the control have been checked by the user or installer Note The Installer Adv DIP Switch must be set to Adv in order to clear the error The control is no longer able to read the outdoor sensor due to a short circuit FIG 54 In this case the controlassumes an outdoor temperature of 32 F 0 C and continues opera tion Locate and repair the problem as described in INS7141 To clear the error message from the control after the sensor has been repaired press either the Menu or Item button This error message only occurs if the External Input Stand Alone DIP switch is set to Stand Alone The control is no longer able to read the outdoor sensor due to an open circuit FIG 55 n this case the control assumes an outdoor temperature of 32 F 0 C and contin ues operation Locate and repair the problem as described in INS7141 To clear the error message from the control after the sensor has been repaired press either the Menu or Item button This e
27. e DIP switch is set to Stand Alone WWSD UnOccupied The system s warm weather down temperature during the UnOccupied period This item is only available if the External Input Stand Alone DIP switch is set to Stand Alone OFF 35 to 100 F OFF 2 to 38 C Default 70 F 21 C OFF 35 to 100 F OFF 2 to 38 C Default 60 F 15 5 C Primary Pump Purge The maximum length of time that the primary pump will continue to operate after the boiler demand has been removed OFF 0 10 to 19 55 min Default 0 20 min Boiler Pump Purge The length of time that the boiler pump will continue to run after the last stage in the boiler has turned off This item is only available in modes 2 4 6 and 8 OFF 0 10 to 19 55 min Default 0 20 min BOIL Boiler Alarm The alarm signal will be activated if the boiler supply temperature does not increase within the selected time This item is only available when the Alarm C A DIP switch is set to Alarm OFF 3 to 40 min 1 minute increments Default 20 min F C Default F Units The units of measure that all of the temperatures are to be displayed in by the control 28 TESTING THE CONTROL The control has a built in test routine that is used to test the main control functions The control continually monitors the sensors and displays an error message whenever a fault is found See the following pages for a list of the control s error message
28. e Fixed Lead Off DIP switch is set to Fixed Lead FIG 49 Orr EXERCISE First On Last Off First On First The Off Exercise DIP switch selects whether not the control is to exercise the primary pump and boiler pumps FIG 50 If the DIP switch is set to Exercise the pumps are operated for 10 seconds after every three days of inactivity EE HE o View Menu 1 of 2 Description US Q S Outdoor Current outdoor air temperature as measured by the outdoor sensor This item is only available if the External Input Stand Alone DIP switch is set to Stand Alone This item is available in all modes Boiler Supply Current boiler supply water temperature as measured by the boiler supply sensor This item is available in all modes Boiler Target Boiler target temperature is the temperature the control is currently trying to maintain at the boiler supply sensor 1 2 of the differential This item is available in all modes Boiler Return Current boiler return water temperature as measured by the boiler return sensor A boiler return sensor must be installed to view this item This item is available in all modes Delta T Current difference in temperature between the boiler supply sensor and the boiler return sensor temperatures A boiler return sensor must be installed to view this item This item is available in all modes Boiler 1 Hours The total running time of boi
29. emand device calls for heat a voltage between 20 and 260 V ac should be measured at the terminals When the DHW demand device is off less than 5 V ac should be measured Set Point Demand If a set point demand is used measure the voltage between the Setp DHW and the Com Dem terminals 8 and 7 FIG 35 When the set point demand device calls for heat you should measure between 20 and 260 V ac at the termi nals When the set point demand device is off you should measure less than 5 V ac 6 Boil Con el 20 to 260 V ac 20 to 260 V ac External Input If an external input is used measure the voltage between the Com and the terminals 1 and 4 When the external input device calls for heat you should measure between 0 and 10 V dc at the terminals 20 TEST THE OUTPUTS Primary Pump Prim P1 If a primary pump is connected to the Prim P1 terminal 11 make sure that power to the terminal block is off and install a jumper between the Power L and Prim P1 terminals 10 and 11 FIG 37 When power is applied to the Power N and Power L terminals 9 and 10 FIG 37 the primary pump should start If the pump does not turn on check the wiring between the terminal block and pump and refer to any installation or troubleshooting information supplied with the pump If the pump operates properly disconnect the power and remove the jumper Combustion Air or Alarm C A Alarm
30. er or alarm device is to be connected to the C A Alarm terminals 12 and 13 FIG 45 ROTATE OFF SEE The Rotate Off DIP switch selects whether or not the con trol is to provide Equal Run Time Rotation of the boiler stages If the switch is set to Rotate the stages will be rotat ed accordingly If the switch is set to Off the firing sequence is fixed starting with the lowest stage to the highest stage FIG 46 FIXED LAsT Hotate The Fixed Last Off DIP switch selects whether or not the last boiler is to be included in the rotation sequence If the DIP switch is set to Fixed Last the last boiler is always the last to fire FIG 47 This DIP switch is only active when the Rotate Off DIP switch is set to Rotate FIXED LEAD OFF JGEOMEGE The Fixed Lead Off DIP switch selects whether or not the first boiler is to be included in the rotation sequence If the DIP switch is set to Fixed Lead the first boiler is always the first to fire FIG 48 This DIP switch is only active when the Rotate Off DIP switch is set to Rotate FIRST ON LAST Orr OR FIRST ON FIRST OFF The First On Last Off or First On First Off DIP switch selects whether the first boiler is the first to stage on and the last to stage off or the first to stage on and the first to stage off This DIP switch is only active when the Rotate Off DIP switch is set to Rotate and th
31. eration This item is only available when the last boiler in MODES 1 4 and 5 is set to OFF DHW pa LIF DHW Exchange Occupied The minimum boiler supply temperature to the DHW heat exchanger during the Occupied period This item is only available when the last boiler in MODES 1 4 and 5 is set to OFF and DHW MODE is set to 1 through 4 DHW Exchange Unoccupied Selects whether or not a DHW demand will be responded to during the UnOccupied period This item is only available when the last boiler in MODES 1 4 and 5 is set to OFF and DHW MODE is set to 1 through 4 Actual oetting OFF 80 to 180 F OFF 27 to 82 C Default 140 F 60 C 120 to 225 F OFF 49 to 107 C OFF Default 200 F 93 C 0 00 to 3 00 minutes 1 sec increment Default 0 10 min 0 00 to 3 00 minutes 1 sec increment Default 0 10 min 0 00 to 3 00 minutes 1 sec increment Default 1 00 min 1 Lo 2 Med 3 Hi Default 2 Au Auto 0 30 to 19 55 min 5 second increment Default Au Au Auto 2 to 42 F Au 1 to 23 C Default Au lohi lolo Default lohi OFF 1 parallel no priority 2 parallel priority 3 pri sec no priority 4 pri sec priority Default OFF OFF 100 to 220 F OFF 38 to 104 C Default 180 F 82 C OFF On Default OFF Adjust Menu 4 of 4 Actual Description oetting BOIL 1 to Max number of DHW B
32. exercising function does not work if power to the control or pumps is disconnected RELOADING FACTORY DEFAULTS To reload the factory defaults power down the control for 10 seconds Power up the control while simultaneously hold ing the Menu and down arrow buttons The control will now display the E01 error message To clear this error message follow the procedure in the Error Messages section of this manual MINIMUM The boiler minimum is the lowest temperature that the con trol is allowed to use as a boiler target temperature During mild conditions if the control calculates a boiler target tem perature that is below the BOIL MIN setting the boiler tar get temperature is adjusted to at least the BOIL MIN setting During this condition if the boiler s is operating the mini mum segment is turned on in the display when viewing either the boiler supply temperature or the boiler target tem perature Set the BOIL MIN setting to the boiler manufac turer s recommended temperature MAXIMUM The boiler maximum is the highest temperature that the control is allowed to use as a boiler target temperature If the control does target the BOIL MAX setting and the boil er temperature is near the boiler maximum temperature the maximum segment will be displayed in the LCD while either the boiler target temperature or the boiler supply tempera ture is being viewed At no time does the control operate the boiler s
33. floor suspended in the joist space or sandwiched between the sub floor and the surface This type of radiant system has a relatively low thermal mass and responds faster than a high mass system FIG 17 FANCOIL 3 A fancoil terminal unit or air handling unit AHU consists of a hydronic heating coil and either a fan or blower Air is forced across the coil at a constant velocity by the fan or blower and is then delivered into the building space FIG 17 FiN TUBE CONVECTOR 4 A convector terminal unit is made up of a heating element with fins on it This type of terminal unit relies on the natu ral convection of air across the heating element to deliver heated air into the space The amount of natural convection to the space is dependant on the supply water temperature to the heating element and the room air temperature FIG 17 RADIATOR 5 A radiator terminal unit has a large heated surface that is exposed to the room A radiator provides heat to the room through radiant heat transfer and natural convection FIG 17 BASEBOARD 6 A baseboard terminal unit is similar to a radiator but has a low profile and is installed at the base of the wall The pro portion of heat transferred by radiation from a baseboard is greater than that from a fin tube convector FIG 17 11 150 F 66 C 210 F 99 C 200 F 93 C 180 F 82 C 170 F 77 C 140 F 60 C 140 F 60 C zj
34. ge 2 Stage 1 Stage 2 Boiler 1 Boiler 1 Boiler 1 Boiler 2 Boiler 2 Boiler 2 Boiler 3 Boiler 3 Boiler 3 MODE 4 Stage 1 Stage 2 Pump Stage 1 Stage 2 Pump Stage 1 Stage 2 Pump Boiler 1 Boiler 1 Boiler 1 Boiler 2 Boiler 2 Boiler 2 Boiler 3 Boiler 3 Boiler 3 MODE 5 Stage 1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Stage 1 Stage 2 Stage 3 Boiler 1 Boiler 1 Boiler 1 Boiler 1 Boiler 2 Boiler 2 Boiler 2 Boiler 2 m MODE 6 Stage 1 Stage 2 Stage 3 Pump Stage 1 Stage 2 Stage 3 uim Boiler 1 Boiler 1 Boiler 1 Boiler 1 Boiler 2 Boiler 2 Boiler 2 Boiler 2 u MODE 7 Stage 1 Stage 2 Stage 3 Stage 4 Stage 1 Stage 2 Stage 3 Stage 4 Boiler 1 Boiler 1 Boiler 1 Boiler 1 Boiler 1 MODE 8 Stage 1 Stage 2 Stage 3 Stage 4 Pump iid m FIG 9 Lo Hi or Lo Lo FiRE DELAY When using multi stage boilers a selection must be made regarding the staging order of the boiler s This adjustment is made in the ADJUST menu of the control Lo Hi If the Lo Hi staging option is selected the control stages in sequence all of the stages in a single boiler Once all of the stages are turned on the control then stages in sequence all of the stages in the next boiler in the rotation sequence Lo Lo If the Lo Lo staging option is selected the control stages all of the Lo stage outputs in all of the boilers first Once all of the boilers are operating on their Lo stages the control then operates the second stage in each boiler in the same order STAGING The control operates up
35. he firing order of the boilers change whenever one boiler accumulates 48 hours more running time than any other boiler After each rotation the boiler with the least running hours is the first to fire and the boiler with the most running hours is the last to fire This function ensures that all the boilers being rotated receive equal amounts of use When the Rotate Off DIP switch is set to the Off position the firing sequence always begins with the lowest boiler to the highest boiler see Figure 7 below 690 hours 672 hours Fixed Lead Rotation In some applications it may be desirable to have the first boiler fire first at all times while the firing sequence of the remaining boilers is changed using Equal Run Time Rotation This rotation option is selected by setting the Fixed Lead Off DIP switch to the Fixed Lead position First On Last Off or First On First Off When using the Fixed Lead rotation option a selection must be made between First On Last Off and First On First Off using the DIP switch When First On Last Off is selected the lead boiler is always staged on first and staged off last When First On First Off is selected the lead boiler is always staged on first and staged off first This DIP switch is only read by the control when the Fixed Lead Off DIP switch is set to Fixed Lead Fixed Last In some applications it may be desirable to have the last boiler fire last at all times while the firing seq
36. ienced persons A good quality electrical test meter capable of reading from at least 0 300 V ac and at least 0 2 000 000 ohm is essential to properly test the wiring and sensors AN TEST THE SENSORS In order to test the sensors the actual temperature at each sensor location must be measured A good quality digital thermometer with a surface temperature probe is recom mended for ease of use and accuracy FIG 33 Where a digital thermometer is not available a spare sensor can be strapped alongside the one to be tested and the readings compared Test the sensors according to the instructions in INS7141 TEST THE POWER SUPPLY Make sure exposed wires and bare terminals are not in con tact with other wires or grounded surfaces Turn on the power and measure the voltage between the Power L and Power N terminals 10 and 9 FIG 34 using an AC volt meter the reading should be between 103 5 and 126 5 V ac 103 5 to 126 5 V ac AN TEST THE POWERED INPUTS Boiler Demand If a boiler demand is used measure the voltage between the Boil Dem and the Com Dem terminals 6 and 7 FIG 35 When the boiler demand device calls for heat you should measure between 20 and 260 V ac at the ter minals When the boiler demand device is off you should measure less than 5 V ac DHW Demand If a DHW demand is used measure the voltage between the Setp DHW and the Com Dem terminals 8 and 7 FIG 35 When the DHW d
37. ilers red 4 Up to 3 Lo Hi Boilers amp 3 Pumps 5 Up to 3 Three Stage Boilers Eora 6 Up to 2 Three Stage Boilers amp 2 PUMPS heat press 8 7 Up to 2 Four Stage Boilers hold Test for 8 1 Four Stage Boiler amp 1 Pump seconds not testing testing testing ximu Power 115 V 10 50 60 Hz 600 VA o Relays 230 V ac 5A 1 3 hp pilot duty 240 VAS Demands 20 to 260 V ac 2 VA o Signal wiring must be rated at least a S D N 1 2 5 CORINEX ee ee p KO NI Output n DHW Pump Or Input DHW Valve Universal Sensor Included Output Input Boiler Universal Sensor Included E EN nd NN NN Input Output Outdoor Pump Sensor Included Input 0 10 V dc External Signal 4 a p 2 4 V 7 Input Input Input Input Output Output Timer or Switch Boiler Setpoint DHW 115 V ac Primary Combustion Air Optional Demand Demand Power Supply Pump Or Alarm This instruction manual is organized into four main sections 1 Sequence of Operation 2 Installation 3 Control Settings and 4 Testing and Troubleshooting The Sequence of Operation section has seven sub sections We recommend reading Section A General Operation of the Sequence of Operation as this contains important informa tion on the overall operation of the control Followed by the sub sections that apply to your installation The Control Settings section starting at DIP Switch Settings of th
38. individual boiler pumps on each boiler in addition to the pri mary pump The boiler pump turns on prior to the boiler fir ing and continues to run after the boiler is turned off The amount of time that the boiler pump turns on prior to the boiler firing is determined by the BOIL MASS setting lf a BOIL MASS of Lo is selected the boiler pump turns on 15 seconds prior to the boiler If BOIL MASS of Medium is selected the boiler pump turns on 22 seconds prior to the boiler If a BOIL MASS of Hi is selected the boiler pump turns on 30 seconds prior to the boiler However if the con trol is operating based on a set point demand the boiler pump turns on 5 seconds prior to the boiler see Figure 13 Boiler Pump Purge The amount of time that the boiler pump continues to run after the boiler turns off is adjustable using the boiler pump purge setting PURG Boil Pmp SECTION D BOILER RESET OPERATION SECTION D1 BOILER RESET STAND ALONE DEMAND When operating in the stand alone mode a boiler demand is required in order for the control to provide heat to the heating system A boiler demand is generated by applying a voltage between 24 and 230 V ac across the Boiler Demand and Common Demand terminals 6 and 7 FIG 14 Once voltage is applied the Boiler Demand pointer is displayed in the LCD If the control is not in WWSD the control closes the primary pump contact The control calculates a boiler target supply tempera
39. is instruction manual describes the various items that are adjusted and displayed by the control The control functions of each adjustable item are described in the Sequence of Operation TABLE OF CONTENTS Introduction User Interface Display Symbol Description Sequence of Operation Section A Section B Section C Section D Section E Section F Set Point Section G External Input General Operation Staging Pump Operation Boiler Reset Installation DIP Switch Settings Control Settings View Menu Adjust Menu Testing the Control Error Messages Technical Data Typical Boiler Installation Typical DWH Priority Heating Package System Notes Page USER INTERFACE The control uses a Liquid Crystal Display LCD as the method of supplying information The LCD is used in order to setup and monitor the operation of your system The con trol has four push buttons FIG 2 for selecting and adjust ing settings As you program your control record your set tings in the ADJUST menu table which is found in the sec ond half of this instruction manual MENU All of the items displayed by the control are organized into two menus These menus are listed on the top left hand side of the display Menu Field To select a menu use the Menu button By pressing and releasing the Menu button the display switches between the two menus Once a menu is selected there will be a group of items that can be viewed within
40. is present the boiler s is operated to maintain the set point target and the primary pump Prim P1 contact is opened It is assumed that the Set Point pump will provide ade quate flow through the heat exchanger and the boiler SETP MODE 3 Primary Pump during Set Point Whenever a set point demand is present the primary pump Prim P1 is turned on and the boiler s is operated to main tain the set point target E Boiler Pumps SET PoiNT PRIORITY OVERRIDE The set point has a Priority Override while in SETP MODE 2 In order to prevent the building from cooling off too much or the possibility of a potential freeze up during set point pri ority the control limits the amount of time for set point prior ity The length of Set Point priority is determined by the Priority Override setting Once the allowed time for priority has elapsed the control overrides the set point priority and operates set point and heating simultaneously by turning on the primary pump Prim P1 CONDITIONAL SET PoiNT PRIORITY If the boiler s supply temperature is maintained at or above the required temperature during set point generation this indicates that the boiler s has enough capacity for set point and possibly heating as well As long as the boiler target temperature is maintained and the heating and set point targets are similar set point and heating occur at the same time SECTION G EXTERNAL INPUT OPERATION SECTION G
41. ler 1 since this item was last cleared To clear this item press the A and v arrow button simultaneously while viewing this item This item is available in all modes Boiler 2 Hours The total running time of boiler 2 since this item was last cleared To clear this item press the A and v arrow button simultanously while viewing this item This item is available in modes 1 to 3 Boiler 3 Hours The total running time of boiler 3 since this item was last cleared To clear this item press the A and v arrow button simultanously while viewing this item This item is available in mode 1 Boiler 4 Hours The total running time of boiler 4 since this item was last cleared To clear this item press the A and v arrow button simultanously while viewing this item This item is available in mode 1 Boiler 5 Hours The total running time of boiler 5 since this item was last cleared To clear this item press the A and v arrow button simultanously while viewing this item This item is available in mode 1 Boiler 6 Hours The total running time of boiler 6 since this item was last cleared To clear this item press the A and v arrow button simultanously while viewing this item This item is available in mode 1 only __ gt gt gt gt gt e e Jo o 24 67 to 149 F 55 to 65 C 14 to 266 F 10 to 130 C 14 to 266 F 10 to 130 C 14
42. ler s that is used has a medium thermal mass This means that the boiler s either has a large water content and a low metal content or a low water content and a high metal content This is typical of many modern residential cast iron boilers or steel tube boil ers The Med MASS setting stages on additional boilers at a slower rate than the Lo MASS setting Hi 3 The Hi setting is selected if the boiler s that is used has a high thermal mass This means that the boiler s has both a large water content and a large metal content A boiler that has a high thermal mass is relatively slow in coming up to temperature This is typical of many commercial cast iron and steel tube boilers The HI MASS setting stages on additional boilers at the slowest rate DIFFERENTIAL An on off heat source must be operated with a differential to prevent short cycling With the control either a fixed or an auto differential may be selected The boiler differential is divided around the boiler target temperature The first stage contact closes when the supply water temperature is Y of the differential setting below the boiler target tempera ture Additional stages operate if the first stage is unable to bring the supply water temperature up to the boiler target temperature at a reasonable rate As the supply tempera ture reaches 1 2 of the differential above the boiler target temperature stages are staged off Fixed Differential If the user desires
43. n a set point demand signal from a set point system is present the control operates the boiler s to maintain the supply water temperature at least as hot as the SETP set ting Refer to section F External Input 0 10 V dc or 2 10 V dc When an external input signal is present the control con verts the signal to a target supply temperature The control operates the boiler s to maintain the required supply water temperature EB Indoor Design JA Outdoor Design pum 25 i 5 i O amp N O cc Decreasing Outdoor Temperature UNOCCUPIED To provide greater energy savings the control has a set back feature FIG 6 With setback the supply water tem perature in the system is reduced when the building is unoc cupied By reducing the supply water temperature the air temperature in the space may be reduced even when ther mostat s are not turned down Any time the UnO Sw 5 and the Com 1 are connected the control operates in the UnOccupied mode When in the UnOccupied mode the UNOCC segment is displayed in the LCD The control adjusts the supply water temperature based on the UNOCC settings made in the control This feature has no effect when the control is used in the External Input mode SA Timer Switch COMBUSTION AIR OR ALARM CONTACT The control has an isolated contact that can be used as either a combusti
44. ng a 500 ohm resistor between the Out and Com terminals 4 and 1 OFFSET The Offset setting allows the boiler target temperature to be fine tuned to the external input signal The control reads the external input signal and converts this to a boiler target tem perature The Offset setting is then added to the boiler tar get temperature EXTERNAL INPUT SIGNAL CONVERSION TABLES CONVERSION TABLE 0 10 0 10 Boiler Target 86 F 30 C 103 F 39 C 121 F 49 C CO NEN Requires 500 2 Resistor in Parallel CONVERSION TABLE 2 10 4 20 2 10 V dc Boiler Target 0 OFF 6 0 2 50 F 10 C 3 4 5 6 21 C o Hor re 12 130 F 54 C 6 8 170 F 77 C 20 10 210 F 99 C Requires 500 Resistor in Parallel 1 Example Range 0 10V dc Input 7V dc pae 157 F 69 C cesse BHO e Boiler Target 162 F 72 C INSTALLATION A CAUTION Improper installation and operation of this control could result in damage to the equipment and possibly even personal injury It is your responsibility to ensure that this control is safely installed according to all applicable codes and standards This electronic control is not intended for uses as a primary limit control Other con trols that are intended and certified as safety limits must be placed
45. of boilers using the BOIL DHW setting This applies when only a DHW Demand is present If there are other demands present the control does not limit the number of boilers operated SECTION E2 DHW witH Low TEMPERATURE BOILERS If DHW is to be incorporated into a low temperature system such as a radiant heating system a mixing device is often installed to isolate the DHW supply temperature from the lower system temperature If a mixing device is not installed high temperature water could be supplied to the low temperature system while trying to satisfy the DHW demand This may result in damage to the low temperature heating system The control is capable of providing DHW in such a system while maximizing the chance that the tem perature in the heating system does not exceed its allowed maximum setting To prevent high temperature water from being introduced into the heating system the primary pump Prim P1 must be turned off during a call for DHW To do this the control must be set to DHW MODE 2 or DHW MODE 4 and Boil MIN must be set to OFF see Figure 22 below DHW 2 OPERATION On a call for DHW the control provides DHW priority by shutting off the primary pump Prim P1 for a period of time This time is based on the DHW Priority Override setting However if the DHW Demand is not satisfied within the allotted time the boiler s shuts off and the heat of the boiler is purged into the DHW tank Once the boiler
46. oilers Selects how many boilers are to be operated during DHW generation This item is only boilers available when the last boiler in MODES 1 4 and 5 is set Default Maximum to OFF and DHW MODE is set to 1 through 4 number of boilers MODE Set Point Mode Selects the Set Point Mode of operation This item is only available when DHW MODE is set to OFF 1 parallel no priority 2 parallel priority 3 primary pump Default 1 OFF 60 to 220 F OFF 16 to 104 C Default 180 F 82 C OFF On Default OFF SETP H Lio Set Point Occupied The minimum supply temperature when a set point demand is present during the Occupied period This item is only available when DHW MODE is set to OFF TI Set Point Unoccupied Selects whether or not a set point demand will be responded to during the Unoccupied period This item is only available when DHW MODE is set to OFF Priority Override Sets the maximum amount of time the control provides DHW or Set Point priority before resuming space heating This item is only available when Set Point MODE is set to 2 or when DHW MODE is set to 2 or 4 and the last boiler in MODES 1 4 and 5 are set to OFF TI OFF 0 20 to 4 00 hr 10 minute increments Default OFF WWSD Occupied The system s warm weather shut down temperature during the Occupied period This item is only available if the External Input Stand Alon
47. on air damper contact or an alarm contact This selection is made using the C A Alarm DIP switch Combustion Air C A When the DIP switch is set to C A terminals 12 and 13 can be used as a switch to operate a combustion air damper This contact closes prior to the first stage operating on the control The amount of time that the contact closes prior to the first stage operating is set using the combustion delay setting The combustion air contact remains closed for a minimum of 15 seconds after the last stage is turned off Alarm When the DIP switch is set to Alarm terminals 12 and 13 can be used as a switch to operate an alarm circuit This contact closes whenever an error message is present on the control When the alarm contact is activated refer to the Error Messages section of this manual to determine the cause of the alarm Once the fault has been fixed the alarm can be cleared by pressing either the Menu Item up arrow or down arrow button Boiler Alarm The control can monitor the boiler supply temperature and provide an alarm if the temperature does not increase with in a certain amount of time The amount of time can be set using the Boiler Alarm setting This alarm can be used to determine if the boilers have failed to fire To reset the alarm press and hold the up and down arrow buttons for 5 seconds while in the VIEW menu ROTATION The control s Equal Run Time Rotation function is fixed at 48 hours T
48. on section of this instruction manual CLEANING THE CONTROL The control s exterior can be cleaned using a damp cloth Moisten the cloth with water and wring out prior to wiping the control Do not use solvents or cleaning solutions DIP SWITCH SETTINGS GENERAL The DIP switch settings on the control are very important and should be set to the appropriate settings prior to mak ing any adjustments to the control through the User Interface The DIP switch settings change the items that are available to be viewed and or adjusted in the User Interface If a DIP switch is changed while the control is powered up the control responds to the change in setting by returning the display to the VIEW menu see Figure 42 DIP Switches EXTERNAL INPUT STAND ALONE The External Input Stand Alone DIP switch selects whether a Lochinvar Outdoor Sensor TST2311 or an external 0 10 V dc input signal is to be connected to the Com and the Out terminals 1 and 4 FIG 43 External Input b IEE EI EH ERES Stand Alone ADVANCED INSTALLER The Adv Installer DIP switch selects the access level of the control FIG 44 In the Installer access level a limited number of items may be viewed and or adjusted In the Advanced access level all items may be viewed and or adjusted ALARM COMBUSTION AIR Ea Ee The Alarm C A DIP switch selects whether a combustion air damp
49. rol shuts off the boiler s and continues to operate either the DHW pump or the DHW valve and the system and boiler pump if applicable This purges the residual heat from the boiler s into the DHW tank The control continues this purge for a maximum of two minutes or until the boiler supply water temperature drops 20 F 11 C below the boiler target temperature during the DHW operation The control also stops the purge if the boil er supply temperature is close to the current boiler target temperature DHW MixiNG PURGE After DHW operation the boiler s is extremely hot At the same time the heating zones may have cooled off consid erably after being off for a period of time To avoid thermal ly shocking the boiler s after DHW in parallel with priority DHW MODE 2 the control shuts off the boiler s but con tinues to operate the DHW while restarting the heating sys tem This allows some of the DHW return water to mix with the cool return water from the zones and temper the boiler return water FIG 21 DHW DuRING UNOCCUPIED If the control receives a DHW Demand during an unoccu pied period the control can either continue operation of the DHW system as it would during the occupied period or the control can ignore a DHW Demand for the duration of the unoccupied period NUMBER OF BoiLERS USED FoR DHW GENERATION The number of boilers used for DHW generation can be selected from one to the maximum number
50. rror message only occurs if the External Input Stand Alone DIP switch is set to Stand Alone 30 The control is no longer able to read the boiler supply sen sor due to a short circuit FIG 56 The control will not oper ate the boiler s until the sensor is repaired Locate and repair the problem as described in INS7141 To clear the error message from the control after the sensor has been repaired press either the Menu or Item button The control is no longer able to read the boiler supply sen sor due to an open circuit FIG 57 The control will not operate the boiler s until the sensor is repaired Locate and repair the problem as described in INS7141 To clear the error message from the control after the sensor has been repaired press either the Menu or Item button The control is no longer able to read the boiler return sen sor due to a short circuit FIG 58 The control will continue to operate normally Locate and repair the problem as described in INS7141 To clear the error message from the control after the sensor has been repaired press either the Menu or button The control is no longer able to read the boiler return sen sor due to an open circuit FIG 59 The control will contin ue to operate normally Locate and repair the problem as described in INS7141 To clear the error message from the control after the sensor has been repaired press either the Menu or Item button If the boiler re
51. rtant infor mation concerning the life of the product see Figure 4 below Warning Symbol Indicates presence of hazards which can cause severe personal injury death or substantial property damage if ignored A Double insulated INSTALLATION CATEGORY II SEQUENCE OF OPERATION SECTION A GENERAL OPERATION Local level appliances POWERING UP THE CONTROL When the control is powered up all segments in the LCD are turned on for two seconds The control displays the control type number in the LCD for two seconds Next the software version is displayed for two seconds Finally the control enters the normal operating mode OPERATION The control operates up to nine on off heat sources to con trol the supply water temperature to a hydronic system The supply water temperature is based on either the current out door temperature an external 0 10 V dc or 2 10 V dc signal or a fixed set point Boiler Reset Stand Alone When a boiler demand signal from the heating system is present the control operates the boiler s to maintain a sup ply temperature based on the outdoor air temperature and Characterized Heating Curve settings see Figure 5 Domestic Hot Water When a DHW demand signal from a DHW aquastat is pres ent the control operates the boiler s to maintain the supply water temperature at least as hot as the DHW XCHG set ting Refer to section E Set Point Whe
52. s and possible causes When the Test but ton is pressed the test light is turned on The individual out puts and relays are tested in the following test sequence Test off testing red testing 3red testing paused TEST SEQUENCE Each step in the test sequence lasts 10 seconds During the test routine if a demand from the system is pres ent the test sequence may be paused by pressing the Test button If the Test button is not pressed again for 5 minutes while the test sequence is paused the control exits the entire test routine If the test sequence is paused the Test button can be pressed again to advance to the next step This can also be used to rapidly advance through the test sequence To reach the desired step repeatedly press and release the Test button until the appropriate device and seg ment in the display turn on Step 1 The primary pump is turned on and remains on for the entire test routine Step 2 If the Alarm C A DIP switch is set to Alarm the Alarm contact is turned on for 10 seconds and then shuts off If the Alarm C A DIP switch is set to C A the com bustion Air Damper contact is turned on and remains on for the entire test routine Step 3 For each boiler that is set to Auto the following test sequence is used f the mode indicates that a boiler pump is used the boiler pump is turned on and remains on Next the first stage of the boiler is turned on and remains on e f
53. supply temperature is sufficiently reduced the Relay 9 DHW contact shuts off The heating system is turned on for a period of time to prevent the building from cooling off After a period of heating and if the DHW Demand is still present the control shuts off the heating sys tem and provides heat to the DHW tank once again For correct operation close attention must be paid to the mechanical layout of the system When the control turns off the primary pump Prim P1 flow to the heating system must stop If flow is not stopped the temperature in the heating system can exceed the maximum desired tempera ture and can result in damage to the heating system DHW MODE 4 OPERATION In DHW MODE 4 the space heating zones must be pre vented from coming on during DHW demands using exter nal wiring This can be done using an external relay to remove power from zone pumps or zone valves while a DHW Demand is present During a DHW Demand the con trol closes the primary pump Prim P1 contact and the Relay 9 DHW contact Once the DHW Demand is removed or during a DHW Priority Override the Relay 9 DHW contact is opened and the external wiring should allow the space heating zones to operate There is no mixing purge available in DHW MODE 4 After DHW priority the boiler supply water temperature may exceed the design water temperature of the space heating system and can result in damage to the heating system SECTION F SET POINT OPERA
54. terminal block and pump and refer to any installation or troubleshooting information supplied with the pump If the pump operates properly disconnect the power and remove the jumper Repeat the above procedure for Relay 2 to Relay 9 Relay 9 DHW If a DHW pump or DHW valve is connected to the Relay 9 DHW contact 30 and 31 FIG 40 make sure the power to the pump or valve circuit is off and install a jumper between those terminals When the DHW circuit is powered up the DHW pump should turn on or the DHW valve should open completely If the DHW pump or valve fails to operate check the wiring between the terminals and the pump or valve and refer to any installation or troubleshooting information sup plied with these devices If the DHW pump or valve oper ates correctly disconnect the power and remove the jumper 21 AN CONNECTING THE CONTROL Make sure all power to the devices and terminal blocks is off and remove any remaining jumpers from the terminals Reconnect the terminal blocks to the control by carefully aligning them with their respective headers on the control and then pushing the terminal blocks into the headers The terminal blocks should snap firmly into place see Figure 41 Install the supplied safety dividers between the unpowered sensor inputs and the powered or 115 V ac wiring cham bers Apply power to the control The operation of the control on power up is described in the Sequence of Operati
55. the modes of operation for Three and Four Stage Boilers Fire Delay 2 is the fire delay of the third stage of the boiler Stage 3 Contact Closes Stage 3 Stage 1 Contact Closes Stage 1 Fires stage 2 Contact Closes stage 2 Fires Interstage Delay Interstage Delay Fire Delay 1 S us J iV us Q 5 T un m STAGE DELAY The stage delay is the minimum time delay between the fir ing of stages After this delay has expired the control can fire the next stage if it is required This setting can be adjust ed manually or set to an automatic setting When the auto matic setting is used the control determines the best stage delay based on the operation of the system BoiLER MASS The BOIL MASS setting allows the installer to adjust the control to the thermal mass of the type of heat sources used in the application The BOIL MASS setting also adjusts the minimum inter stage delay time when operating with an automatic differential Lo 1 The Lo setting is selected if the boiler s that is used has a low thermal mass This means that the boiler s has a very small water content and has very little metal in the heat exchanger A boiler that has a low thermal mass comes up to temperature quite rapidly when fired This is typical of many copper fin tube boilers The Lo MASS setting pro vides the quickest staging on of boilers Med 2 The Med setting is selected if the boi
56. to have a fixed differential this is set using the BOIL DIFF setting in the ADJUST menu FIG 11 Auto Differential If the Auto Differential is selected the control automatically determines the best differential as the load changes This reduces potential short cycling during light load conditions FIG 11 Desired temperature 160 F 71 C Differential Boiler Off Cooler Temperature Warmer Boiler On Time gt FIXED DIFFERENTIAL Heating Load gt Time gt gt AUTO DIFFERENTIAL SECTION C PUMP OPERATION SECTION C1 PUMP OPERATION PRIMARY PUMP OPERATION The primary pump operates under the following conditions he control receives a boiler demand and is not in warm weather shut down WWSD The control receives a DHW demand when DHW is set to 3 or 4 The control receives a set point demand and set point MODE is set to 3 Primary Pump Purge After a demand is removed the control continues to operate the primary pump for a period of time The maximum length of time that the primary pump continues to run is adjustable using the Purge setting The primary pump continues to run until either the purging time has elapsed or the boiler supply temperature drops more than a differential below the boiler minimum setting see Figure 12 BoiLER PUMP OPERATION In certain modes of operation the control can operate the
57. to nine stages to supply the required temperature After a stage is turned on in the firing sequence the control waits for the minimum time delay After the minimum time delay between stages has expired the control examines the control error to determine when the next stage is to fire The control error is determined using Proportional Integral and Derivative PID logic Proportional compares the actual supply temperature to the boiler target temperature The colder the supply water temperature the sooner the next stage is turned on Integral compares the actual supply temperature to the boiler target temperature over a period of time Derivative compares how fast or slow the supply water temperature is changing If the supply temperature is increasing slowly the next stage is turned on sooner If the supply temperature is increasing quickly the next stage is turned on later if at all The Fire Delay is the time delay that occurs between the time that the control closes a stage contact to fire a stage and the burner fires for that stage The fire delays for the first and third stages in a boiler are adjustable using the F DLY 1 and F DLY 2 settings The fire delay for the sec ond and the fourth stages is fixed at 10 seconds see Figure 10 below Fire Delay 1 Fire Delay 1 is available in all modes of operation Fire Delay 1 is the fire delay of the first stage of the boiler Fire Delay 2 Fire Delay 2 is only available in
58. ture based on the outdoor air temperature and the characterized heat ing curve settings BoiLER TARGET TEMPERATURE The boiler target temperature is determined from the char acterized heating curve settings and the outdoor air tem perature The control displays the temperature that it is cur rently trying to maintain as the boiler supply temperature the control does not presently have a requirement for heat it does not show a boiler target temperature Instead is displayed in the LCD CHARACTERIZED HEATING CURVE The control varies the supply water temperature based on the outdoor air temperature The control takes into account the type of terminal unit that the system is using Since dif ferent types of terminal units transfer heat to a space using different proportions of radiation natural convection and forced convection the supply water temperature must be controlled differently Once a terminal unit is selected the control varies the supply water temperature according to the type of terminal unit This improves the control of the air temperature in the building BOILER INDOOR DESIGN TEMPERATURE The indoor design temperature is the room temperature that was used in the original heat loss calculations for the build ing This setting establishes the beginning of the character ized heating curve see Figure 15 below Boiler Characterized BOIL DSGN BOIL __ Curve
59. turn sensor was deliberately removed from the control remove power from the control and repower the control to clear the error message The control has detected no increase in the supply water temperature within the BOIL Alarm time setting Check to see if the boilers are operating properly using the Test but ton To reset the alarm press and hold the up and down arrow buttons for 5 seconds while in the VIEW menu TECHNICAL DATA MP NINE STAGE BoiLER amp DHW SET POINT Microprocessor PID control This is not a safety limit control Control Packaged Weight 3 3 Ib 1500 g Enclosure A blue modified PPO plastic Dimensions 6 5 8 H x 7 9 16 W x 2 13 16 D 170 x 193 x 72 mm Approvals CSA C US meets ICES amp FCC regulations for EMI RFI Ambient Conditions Indoor use only 30 to 120 F 0 to 50 C lt 95 RH non condensing 115 V ac 10 50 60 Hz 600 Va Power Supply 230 V ac 5A 1 3 hp pilot duty 230 VA Relay Capacity Demands 20 to 260 V ac 2 VA NTC thermistor 10 77 F 25 C 0 2 B 3892 Sensors Included DHW Setpoint Demand WWSD Priority Override External Input Signal not testin Offset 2 Up to 4 On Off Boilers amp 4 Pumps testin to 4 Lo Hi Boilers i 4 Up to 3 Lo Hi Boilers amp 3 Pumps 5 Up to 3 Three Stage Boilers 6 Up to 2 Three Stage Boilers amp 2 Pumps 7 Up to 2 Four Stage Boilers 8 1 Four Stage Boiler amp 1 Pump
60. uence of the remaining boilers is changed using Equal Run Time Rotation This rotation option is selected by setting the Fixed Last Off DIP switch to Fixed Last With a fixed last rotation the last boiler is the last to stage on and the first to stage off Resetting the Rotation Sequence To reset the rotation sequence set the Rotate Off DIP switch to the Off setting for 5 seconds and then return the DIP switch to the Rotate setting RUNNING TIMES The control displays the accumulated running time of each boiler in the VIEW menu When using a multi stage boiler the running time that is displayed is the total number of run ning hours of the Lo stage of the boiler Resetting the Running Times To reset the running time for each boiler select the appro priate running time in the VIEW menu Next press the up and down arrow buttons simultaneously until CLR is dis played EXERCISING The control has a built in exercising feature that is selected through the Exercise Off DIP switch To enable the exer cising feature set the Exercise Off DIP switch to Exercise If exercising is enabled the control ensures that each pump is operated at least once every 3 days If a pump has not been operated at least once every 3 days the control turns on the output for 10 seconds This minimizes the possibility of the pump seizing during a long period of inactivity While the control is exercising the Test LED flashes quickly Note The
61. valve is installed Disable Using External Wiring Primary Pump DHW PRIORITY OVERRIDE The DHW Priority Override applies to DHW MODE 2 and 4 To prevent the building from cooling off too much or the pos sibility of a potential freeze up during DHW priority the con trol limits the amount of time for DHW priority The length of DHW priority time is determined using the Priority Override setting Once the a llowed t ime for priority has elapsed the control overrides the DHW priority and resumes space heating To provide external DHW priority in DHW Mode 4 the space heating zones must be interlocked with the Relay 9 DHW contact Figure 20 During DHW demands the Relay 9 DHW contact must remove any power to all space heating zone valves or zone pumps Power from Relay 9 DHW contact DHW MODE 4 External Priority Interlock Power to External Boiler Zones CONDITIONAL DHW PRIORITY The Conditional DHW Priority Override applies to DHW MODE 2 and 4 If the boiler supply temperature is main tained at or above the required temperature during DHW generation this indicates that the boiler s has enough capacity for DHW and possibly heating as well As long as the boiler supply temperature is maintained near its target and the heating and DHW targets are similar DHW and heating occurs simultaneously DHW Post PURGE After the DHW Demand is removed the control performs a purge on the boiler s The cont

Lochinvar INS7141 Water System User Manual

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