Bryan Boilers Concert, Instruction And Operation Manual

Page 1: ...iler To Boiler Network 19 Energy Management Interface 20 Setup Tuning Manual Operation 28 Parameter Adjustment 29 Response Tuning 42 Trouble Shooting General Issues 46 Sensor Status 48 Limit String Status 49 Soft Lockouts Holds 50 Hard Lockouts 52 Using Archives 55 Specifications General 60 Parameter Summary 62 Application The ConcertTM Boiler Control Control has been designed for commercial hot w...

Page 2: ... Priority DHWP Option Option Ignored Ignored Ignored Ignored Warm Weather Shutdown WWSD Option Option Option Option Option Ignored Call For Heat Call For Heat Based on Setpoints Based on Setpoints Based on Setpoints Based on Setpoints Input RO or Modbus Based on Setpoints Modulation Rate Firing Rate Demand Internal From Sequence Master Internal From Sequence Master Input 4 20mAdc or Modbus Ignored...

Page 3: ...le operation In addition to flame safety controls the Control includes supply water temperature differential water temperature and stack temperature safety limits as well as stepped modulation responses Boiler modulation is adjusted when required to help avoid loss of boiler operation due to exceeding limits Additionally the Control monitors the safety limits and displays cause of boiler alarm tri...

Page 4: ...dwired Connections Boiler On Off Switch Low Water Cutoff Switch High Limit Auto Reset Supply Supply Temperature Sensor Vestibule and Burner Thermal Fuses Min Max Air Press Switches Variable M Combustion Air Damper Fresh Air Supply Lockout Indicator Enable Disable Input Boiler Running Contact Optional Remote Firing Rate 4 20mAdc Remote Setpoint 4 20mAdc Flame Rod Ignition Transformer FAN Speed Fan ...

Page 5: ...ing to 1st Sequencer Control The boiler is connected to the peer to peer network The boiler accepts demand from the Sequencer Master 2nd Domestic Hot Water DHW call for heat is on and selected as the priority demand DHW is always higher priority than Central Heat It also has higher priority than the Sequencer Control when DHW priority is enabled and Boiler Piped IWH is selected 3rd Central Heat Ce...

Page 6: ...the Supply temperature is greater than setpoint minus the Diff Below Prepurge When supply temperature drops below setpoint minus the Diff Below burner demand continues with following Status shown Safe Startup Flame circuit is tested Drive purge The blower is driven to the fan purge speed Prepurge After the blower reaches the fan purge speed setting the 30 second combustion chamber purge is conduct...

Page 7: ...n times the boiler manual reset Hard Lockout is set Additionally if the supply temperature rises faster than the 4 F 2 C per second limit a soft lockout is activated Return Higher Than Supply Temperature The Control monitors the supply and return temperature sensors If the return water temperature exceeds the supply water temperature for longer than a limit time delay the Control shuts down the bo...

Page 8: ...Enabled Termp Setpoint lead boiler demand active ILK OFF LCI OFF Warm Weather Shutdown Frost Protection On CH Enabled DHW Enabled Blower Output Alarm Relay System Pump DHW Pump Isolation Valve Lea d Boiler Onl y Boiler Pump Notes System Pump Runs when boiler room has heat demand enabled Is shut off when boiler is in Warm Weather Shutdown WWSD DHW Pump Runs when there is a domestic demand Isolation...

Page 9: ...ture at setpoint Heat demand may be received from STAT terminal for Central Heat demand S6 terminal for Domestic Hot Water demand the Sequence Master or EMS Modbus Inputs A Heat Demand input ON initiates pumps and Fresh Air Damper outputs LCI Load Control Input The boiler will not start if the LCI is OFF when it is turned OFF during run the boiler shuts down Hold message is shown when LCI limit is...

Page 10: ... Outdoor air reset setpoint saves fuel by adjusting the active setpoint of a heating boiler lower as the outside air temperature increases Domestic Hot Water DHW Setpoint User May select the Supply sensor or DHW Sensor as Modulation Sensor Upon a DHW call for heat the setpoint is either the user entered DHW setpoint or the time of day input DHW setpoint The optimal value of this setpoint is establ...

Page 11: ...elected to run first during winter months and then selected to run last for the remainder of the year DHW Two boiler Start When the Indirect Water Heater IWH parameter is set to Primary Piped and the DHW Two Boiler Start parameter is set to Enabled two boilers are started without delay in response to a DHW call for heat This feature allows rapid recovery of large IWH s and multiple IWH s Figure 8 ...

Page 12: ...n the water temperature is outside the user selected Difference Above and Difference Below settings Also in order to minimize temperature deviations the control adjusts the number of boilers running based on the firing rate This combination allows the boilers to anticipate slow load changes before they disrupt water temperature yet still respond quickly to sudden load changes These special sequenc...

Page 13: ...e Sequence Master Control is powered down disabled or Boiler to boiler communication is lost The following are design considerations for backup Stand Alone operation Enable Disable Upon loss of the Sequence Master each boiler will automatically begin local control This means it will operate only if it has a call for heat For this reason slave boilers should have their External Enable Disable J8 te...

Page 14: ... fast or slow system load changes ARCHIVES The Archives collect the history of how the boiler has operated and provides tools to review and improve system operation A historical trend Up to four 4 months of data is collected and may be viewed on screen or saved to a Thumb Drive Lockout History provides data on up to 15 manual reset Lockouts Data collected includes cause of boiler trip run hour and...

Page 15: ...he active setpoint and sensor which the boiler is currently modulating based on are displayed using a bar graph numeric values Also displayed are all current sensors installed in the boiler These sensors will display red if there is an issue with any of them Additional information shown on this page includes current firing rate boiler priority current status and setpoint source Demand Status This ...

Page 16: ...l Status Screens The status screen shows data relevant to current boiler operation All installed sensors are shown on this page as well as current modulation setpoint active sensor and much more A detailed screen map is shown below Manual Figure 12 Status Screen Detail ...

Page 17: ...ºF Stop All Boilers Comfort Factory Setting Range Choices Parameter and Description 30 ºF 50 to 32 ºF Minimum Outdoor Temperature 70 ºF 35 to 100 ºF Maximum Outdoor Temperature 110 ºF 70 to 180 ºF Low Water Temperature 130 ºF 50 to 185 ºF Minimum Boiler Water Temperature Response Factory Setting Range Choices Parameter and Description 3 1 to 5 Central Heat Response Speed 0 0 to 30 Minutes Central ...

Page 18: ...Boiler Control Instruction Operation Manual Page 18 of 68 Installation Terminal Layout Figure 13 Control Terminal Layout and wiring notes ...

Page 19: ...Boiler Control Instruction Operation Manual Page 19 of 68 Installation Terminal Layout Figure 14 Display Terminal Layout and wiring notes ...

Page 20: ...t be enabled unless a Header Sensor is installed 2 Install Ethernet Cables between boilers Use standard Ethernet type cables to make connection between boilers When more than two boilers are connected an RJ45 splitter may be used to connect the boilers Refer to Figure 15 4 Set Unique Boiler Addresses Assign all boilers a unique Boiler Address using any number from 1 through 8 Found in Main Menu Ad...

Page 21: ...quencer enabled Control The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master Refer to boiler manual s piping diagram for installation location and Figure 15a or 15b for installation detail Figure 15a Direct Immersion Type Header Sensor Installation Detail Figure 15b Thermowell type Header Sensor Installation Detail ...

Page 22: ...nt 4 20mA Input wired to J8 terminals 6 and 7 is used as setpoint Modbus Modbus signal is used as setpoint Local Local Modbus CH Demand Switch The Central Heat demand Central Heat Enable Disable can be directly wired to the Control or provide by the Modbus interface Local Central Heat demand is present when a contact closure is received between J8 terminals 1 and 3 Modbus Modbus signal provides de...

Page 23: ...ter may be used to connect the boilers Refer to Figure 15 NOTE The same Ethernet cable that connects the Boiler To Boiler Sequence Master also connects the EMS Modbus signals Refer to Figure 14 for detail 2 Enable EMS Communication Communication must be enabled Go to Modbus menu Press Menu EMS Interface Modbus Setup and Press EMS Enable Disable to Enable 3 Set Unique Modbus Addresses Comm HMI Stat...

Page 24: ... Port Configure For Not Used Control EMS Port Type Not Used Modbus Master Modbus Slave Special Notes n a Caution Do not change any of these settings Loss of communication to control could result Note This is the port to adjust settings to suit the EMS System Comm HMI Station This is Modbus Slave Address n a 0 not used 1 COM Mode n a RS 485 RS 485 Baud Rate n a 38400 38400 Stop Rate n a 1 bit 1 bit...

Page 25: ...s default 30 seconds CH Modbus Stat is reverted to 0 no demand W 203 Burner on off Burner On Off burner 1 on 0 off R 6 Demand source 0 Unknown 1 No source demand 2 Central heat 3 Domestic hot water 4 Lead Lag slave 5 Lead Lag master 6 Central heat frost protection 7 Domestic hot water frost protection 8 No demand due to burner switch turned off 9 Domestic hot water storage 11 Warm weather shutdown...

Page 26: ... master setpoint source 0 Unknown 1 CH setpoint 2 CH TOD setpoint 3 Outdoor reset 4 Remote control 4 20mA 5 DHW setpoint 6 DHW TOD setpoint 7 Outdoor reset time of day 8 Mix setpoint R 10 018 Active LL setpoint 40 F 40 C to 266 F 130 C Setpoint determined by LL setpoint source register 162 R 10 643 Low Temperature setpoint Setpoint entered on the local user interface valid range 79 F 26 1 C to 191...

Page 27: ...l boiler firing rates This register is used when firing rate control is performed by an external building automation system Firing rate reverts to local control when register is not written every Modbus Command Time Out parameter seconds default 30 seconds Range is 0 to 200 provides 0 100 firing rate W 8 Fan Speed Measured Speed of the combustion air blower in rpm R 9 Fan Speed Commanded Speed of ...

Page 28: ...en 3 Boiler Safety Limit Open ILK Off 7 Return sensor fault 8 Supply sensor fault 9 DHW sensor fault 10 Stack sensor fault 11 Ignition failure 13 Flame rod shorted to ground 14 Delta T inlet outlet high 15 Return temp higher than supply 16 Supply temp has risen too quickly 17 Fan speed not proved 23 24VAC voltage low high 25 Hardware Fault 27 Ignition Failure R Statistics 763 Modbus command timeou...

Page 29: ...tatus See Table 9 R 128 129 Burner cycle count 0 999 999 U32 R W 130 131 Burner run time Hours U32 R W 132 133 System pump cycle count 0 999 999 U32 R W 134 135 DHW pump cycle count 0 999 999 U32 R W 400 138 400 139 Boiler pump cycle count 0 999 999 U32 R W Status Description 92 Forced On from manual pump control 93 Forced On due to Outlet high limit is active 94 Forced On from burner demand 95 Fo...

Page 30: ... Low After selecting Manual Mode the High or Low buttons drives firing rate to High and Low fire position for combustion testing Service Trend Service Trend screen shows boiler temps firing rate demand statuses Tune Tune screen allows for adjustment of parameters related to the rate of boiler response This includes PID settings Ramp rates and more For more details on the Tune Screen see Tune Scree...

Page 31: ...to review and adjust all parameters Parameters are password protected to discourage unauthorized or accidental changes to settings User login is required to adjust these settings Parameters are locked and login requirement is shown when the padlock icon is not green Press the Lock icon to access password screen Use keypad to enter Password Press Enter Key when complete Figure 18 Security System Ad...

Page 32: ...tion allows a single point adjustment of the outdoor sensor reading This adjustment is a correction offset added to or subtracted from the outdoor temperature sensor reading It is recommended to make any calibration when outdoor air temperature is at or near the most common operating point For example when necessary calibrate the sensor when outdoor air is halfway between Minimum and a Maximum Out...

Page 33: ...erature is greater than the WWSD setpoint WWSD is initiated as soon as outside air temperature is above WWSD Setpoint The control does not require call for heat to be satisfied before entering WWSD The boiler will still start in response to a Domestic Hot Water call for heat 70 F 20 to100 ºF Warm Weather Shutdown Setpoint The Warm Weather Shutdown WWSD Setpoint used to shutdown the boiler when ena...

Page 34: ...rate the Control will go to during a central heat call for heat If the rated input of the installed radiation is less than the maximum output of the boiler change the Central Heat Maximum Modulation fan speed setting to limit the boiler output accordingly 100 Minimum to Maximum Modulation Domestic Hot Water DHW Max Modulation Speed This parameter defines the highest modulation rate the Control wil...

Page 35: ...ll be forced off if there is a DHW call for heat and Domestic Hot Water Priority is active DHW Pump Pump Runs during domestic hot water call for heat Domestic Hot Water Priority enable disable does not affect pump operation Any Demand Never Any Demand Contact C Boiler Pump Activates the Boiler Pump Combustion Air Damper and or Standby Loss Damper output according to selected function Never Output ...

Page 36: ...atisfied Used to dissipate heat within the system 1 Min 10 seconds to 60 Min Overrun Time Boiler Pump Combustion Air Damper and Standby Loss Damper Time that pump runs after demand is satisfied Used to dissipate heat within the system 7 Days 0 to 40 Days Pump Exercise Interval The number of days the pump is inactive before the pump will be activated for the Pump Exercise Time 20 Sec 0 to 10 Min Pu...

Page 37: ... number Enter email Contractor Select the line of information to edit Use key pad to input data and press ENT to enter data into Contractor Info Enter name Enter address line 1 Enter address line 2 Enter phone number Enter email Service Company Select the line of information to edit Use key pad to input data and press ENT to enter data into Service Company Info Enter name Enter address line 1 Ente...

Page 38: ...r setback cost savings 10 ºF 3 to 29 ºF Central Heat Difference Above The boiler stops when the water temperature rises Difference Above degrees above the setpoint 5 ºF 3 to 29 ºF Central Heat Heat Diff Below The boiler starts when the water temperature drops Difference Below degrees below the setpoint 3 1 to 5 Central Heat Response Speed This parameter adjusts the Central Heat temperature control...

Page 39: ...de 10 ºF 3 to 29 ºF Domestic Hot Water Difference Above The boiler stops when the water temperature rises Difference Above degrees above the setpoint 5 ºF 3 to 29 ºF Domestic Hot Water Diff Below The boiler starts when the water temperature drops Difference Below degrees below the setpoint Factory Setting Range Choices Parameter and Description Outlet Sensor Outlet Sensor Header Sensor Central Hea...

Page 40: ...delay allows heat to travel out to the system and provide system feedback prior to the control modulating firing rate 1200 RPM 1200 to 1300 RPM Domestic Hot Water Low Fire Hold Rate Low Fire Hold Rate is the modulation rate the boiler will fire at for the duration of the Low Fire Hold Time before being released to modulate After ignition and flame stabilization periods the firing rate is held at L...

Page 41: ...perature is supplied This parameter is typically set to the desired building temperature 110 ºF 70 to 180 ºF Low Water Temperature The Low Boiler Water Temperature parameter is the operating setpoint when the High Outdoor Temperature is measured If the occupied space feels cool during warm outdoor conditions the Low Boiler Water Temperature parameter should be increased 130 ºF 50 to 185 ºF Minimum...

Page 42: ...etpoint plus Difference Above setpoint Longer time delay will prevent nuisance stops due to short temperature swings 195 ºF 50 to 195 ºF Stop All Boilers Setpoint When this temperature is reached all Networked boilers are stopped at once without any stop boiler time delays This setpoint allows the Sequencer to respond to rapid load increases 40 25 to 100 Base Load Common Rate To maximize condensin...

Page 43: ...mperature Stack Limit 230 F Note This feature is not active for Supply temperature when it is the modulation sensor For example this feature is active when Header Sensor is selected as modulation sensor when a boiler is a slave when a boiler is responding to a remote modulation demand 4 20mAdc or Modbus 10 ºF 10 to Stepped Modulation Start Offset 6 Stepped Modulation Recycle Offset This feature he...

Page 44: ...e The burner modulation rate can oscillate if the Proportional Gain is too large 45 0 to 400 Integral Rate Integral gain value For Central Heat control Modes A larger value makes the Integral ramp in less time i e faster Integral is a secondary PID modulation rate tuning adjustment that ramps the output over time typically minutes Based on the selected Local PID P select the corresponding from abo...

Page 45: ...oportional Gain is too large 45 0 to 400 Integral Rate Integral gain value For Domestic Hot Water control Modes A larger value makes the Integral ramp in less time i e faster Integral is a secondary PID modulation rate tuning adjustment that ramps the output over time typically minutes Based on the selected Local PID P select the corresponding from above table Integral value Repeats per minute bet...

Page 46: ...nse will be sluggish and temperature will wander away from setpoint 22 0 to 400 Proportional Rate Proportional Gain value for Sequencer control modes A larger gain value results in tighter more active PID control Gain is the primary PID modulation rate tuning adjustment and provides the immediate modulation rate response Pick a gain based on the desired initial response The burner modulation rate ...

Page 47: ... function for Central Heat and Sequence Master demand sources It uses the CH Low Fire Hold Rate parameter as the starting point for the slow start Disabled Enable Disable DHW Slow Start Enable Disable This parameter enables or disables the slow start limit function for DHW demand source It uses the DHW Low Fire Hold Rate parameter as the starting point for the slow start 20 degrees 0 to 180 Slow S...

Page 48: ...s set to Central heat off DHW demand or Central Heat Optional Priority This has been set to allow all of the heat to be provided for fast indirect water heater recovery After priority protection time or the end of the Domestic Hot Water Heat Request the system and boiler pumps will be free to run Display Completely Dark Fan off LWCO lights off no green power light on Control No 120Vac Power at Boi...

Page 49: ...isplay boot up once you establish communication reboot display to read controller and setup display properly Communication Error 2 Communication Fault The display write attempt has failed Possible causes are that the password level is too low for the parameter being changed the controller is un configured or has a memory failure Lockout 20 Safety Data Verification will be displayed if control is n...

Page 50: ...ax and light off blower speeds Incorrect boiler size can cause hazardous burner conditions and improper operation that may result in PROPERTY LOSS PHYSICAL INJURY OR DEATH Sequencer Fault This alarm is active if the slave boiler has lost communication with the Sequence Master Check the following RJ 45 peer to peer network disconnected Sequencer Master was Enabled and then Disabled Master s Boiler ...

Page 51: ...s a fault with the sensor Each Sensor is provided with the following diagnostic information Indication Possible Cause Not Installed The sensor has not been selected As shown in Figure 22 above the Header sensor has not been selected Refer to the Parameter Adjustment section for additional information Open Check sensor wiring Sensor open will show if the sensor has not yet been wired to the boiler ...

Page 52: ...120 Vac positive to neutral When a limit is OFF all other contacts below or downstream that limit will also show as OFF When troubleshooting the first Limit in the string of OFF Limits is the contact to inspect ON limits indicating the limits are closed Figure 23 Limit String Status OFF limits indicating the limits are open In this case the contact at A6 ILK Thermal Fuse Limit is open The status o...

Page 53: ...o avoid excessive cycles Faulty contact provided by the EMS system 2 Boiler Recycling Limits Open LCI OFF The LCI input is not energized Limit Control Input LCI is not ON Refer to limit string screen for list of limits A wire is loose 3 Boiler Safety Limit Open Boiler Safety Limit Interlock ILK is OFF Lockout input ILK is not ON Refer to limit string screen for list of limits Loose wiring to limit...

Page 54: ...flow Verify that system is purged of air and that appropriate valves are open Sensor wiring reversed Supply or return sensor defective 16 Supply temp has risen too quickly Supply water temperature has risen too quickly See possible causes for Hard Lockout 4 Inadequate boiler water flow Verify that circulator is operating and that circulator and piping are sized per Installation Instructions Manual...

Page 55: ... 4 Supply high limit Supply sensor detected temperatures exceeding High Limit Heating load at time of error was far below the minimum firing rate of the boiler Defective system circulator or no flow in primary loop Defective boiler circulator no flow or insufficient flow in boiler loop Control system miswired so that the boiler operation is permitted when no zones are calling 5 DHW high limit DHW ...

Page 56: ...nfiguration Fault Unacceptable Control Safety related parameter detected See display for details Safety Parameter verification required Contact factory 21 Invalid Modulation Parameter Unacceptable Control Modulation related parameter detected Reset the control 22 Safety data verification needed Safety related parameter change has been detected and verification has not been completed Safety related...

Page 57: ...check speed 32 ILK ON This lockout occurs when the interlock string is closed before the blower starts The airflow switch is the only device in the interlock string that will open when in standby Air pressure in the boiler room has become negative Excessive downdraft in the stack Blower is spinning before being commanded by the hydronic control Make sure blower is not running in standby Airflow sw...

Page 58: ...ly backed up to a thumb drive Historical data values are viewed by scrolling left and right the further left the older the data By touching the trend at any location the exact data points will display as well as the Date and Time at which they were recorded Lockout History Lockout History is stored in a first in first out basis Each lockout file is stored with boiler run hour of when the lockout o...

Page 59: ...iler Network Communication Loss 4 20mA Errors and Limit String Cycling The alarms are recorded in a list with the most recent appearing at the bottom The alarm list can be scrolled through to investigate past alarms and most current alarms The alarms are given a date and time stamp which allows for better troubleshooting capability The alarm list may be downloaded to a USB in the form of a spreads...

Page 60: ...The USB Thumb Drive is now FAT32 format Save Historical Data Save Historical Data will save historical parameter data and the current alarm list as spreadsheets to the USB Drive that is plugged into the Boiler Display The files will have a date code in the file name year month date of when they were saved from the boiler That CSV files will be saved to the USB thumb drive under the following path ...

Page 61: ...ives An example of the Trend1 20141022 csv file follows Table 12 Boiler State Boiler State Initiate 0 Standby delay 1 Standby 2 Safe Startup 3 Drive Purge 4 Prepurge 5 Drive Lightoff 6 Preignition Test 7 Preignition 8 PFEP 9 MFEP 10 Direct Ignition 11 Running 12 Postpurge 13 Lockout 14 ...

Page 62: ...rameters Once procedure is complete the display saves two files in a directory as follows My Computer Removable Disk USB Drive HMI HMI000 Parameter File Recipe csv Contact Information Recipe32 csv Load Parameters from USB Load Parameters loads the current saved parameter settings off a USB Drive This allows for easy transfer of boiler parameters and contact information from one boiler to another R...

Page 63: ...umidity noncondensing at 104 F for 14 days Condensing moisture may cause safety shutdown Vibration to 0 5g Continuous V2 level Sensors All temperature sensors 10k NTC NTC Sensors temperature versus resistance Display Dimensions Bezel 8 46 x 6 33 x 1 96 Panel Cutout 7 75 x 5 62 Electrical Ratings Operating voltage DC 24V 10 15 please use isolated power supply Power Consumption 5W Backup Battery 3V ...

Page 64: ...pe Direct Immersion temperature sensor Insertion is NPT 105685 01 Thermowell Type DHW Sensor Header Sensor 10K ohm single element two wire thermistor type temperature sensor suitable for insertion into thermowells Thermowell not included 105684 01 Thermowell NPT Brass Immersion Well 106035 01 Wireless Outdoor Sensor Kit Wireless outdoor air reset adapter includes wireless receiver module and wirel...

Page 65: ...Piped IWH Boiler Piped IWH Fresh Air Damper Supervisor 34 X CH pump overrun time 0 to 60 minutes Supervisor 34 X DHW pump overrun time 0 to 60 minutes Supervisor 34 X Boiler pump overrun time 0 to 60 minutes Supervisor 34 X Pump exercise interval 0 to 40 days Supervisor 34 X Pump exercise time 0 to 600 seconds Supervisor 34 Central Heat Menu X CH Setpoint 50 to 190 F Basic 36 X CH TOD Setback Setp...

Page 66: ... to Stack Default Limit Factory 41 X Preferred Outlet Limit Setpoint 60 F to Outlet Default Limit Factory 41 EMS Remote Demand Menu Modulation Source Local 4 20mAdc Modbus Supervisor 20 CH Demand Switch Local Modbus Supervisor 20 LL Demand Switch Local Modbus Supervisor 20 4mA Water Temp 50 to 185 F Supervisor 20 Lead Lag Setpoint Source Local 4 20mAdc Modbus Supervisor 20 Central Heat Setpoint So...

Page 67: ...Boiler Control Instruction Operation Manual Page 67 of 68 Notes ...

Page 68: ...Boiler Control Instruction Operation Manual Page 68 of 68 783 N Chili Ave Peru IN 46970 Telephone 765 473 6651 Fax 765 473 3074 www bryanboilers com ...