Harsco Industrial ENVI, Advanced User'S Manual

Page 1: ...r s Guide Installation Date _______________________ Harsco Industrial Patterson Kelley 155 Burson Street East Stroudsburg PA 18301 Telephone 877 728 5351 Facsimile 570 476 7247 www harscopk com ENVI C...

Page 2: ...ings 20 1 6 4 DHW Modes 21 1 6 5 Boiler Settings 22 1 6 6 OEM SETTINGS 23 1 7 Configuration Menu 23 1 8 CASCADE MENU 24 1 8 1 Cascade setup 24 1 8 2 Control Mode 24 1 8 3 Master Settings 25 1 8 4 Mast...

Page 3: ...Protocol converter which is also available separately from your Patterson Kelley representative ENVI APPLICATION Note The ENVI control is capable of running the boiler on its own without any external...

Page 4: ...ER UP DOWN and RESET as shown There are shortcut functions also associated with these buttons LIGHT SET PT DHW SVC and CANCEL The shortcut functions are available only when the default home screen is...

Page 5: ...ot up is complete This screen displays the date time boiler status supply temperature setpoint temperature error codes present operating mode CH or DHW CM cascade master or CS 01 24 cascade member als...

Page 6: ...ENVI CONTROL FLOW CHART Note Parameter ranges in flow chart reference a typical MACH boiler Parameter ranges will typically be different for a condensing vs non condensing boiler such as the Modufire...

Page 7: ...s beginning the ignition sequence purging the combustion chamber Ignition the igniter and gas valve are energized while flame is detected Run flame is established igniter is de energized gas valve is...

Page 8: ...s the value displayed when the control recognizes an open circuit This is common when a particular sensor such as the DHW sensor in the example above is not used but may also occur in the event of an...

Page 9: ...g in Analog Input N A Not Currently Used Analog out Analog Output N A Not Currently Used Ignitions Number of Ignitions 0 99999 Burn Hi HR Hours at High Fire 75 to 100 HRS 0 99999 Burn MD HR Hours at M...

Page 10: ...he cursor is on an error displays several lines of information about the status of the boiler during the error The error information recorded at the time of the error is shown in the table below Displ...

Page 11: ...lities Boiler Settings Boiler Operating Settings Boiler settings contain the primary settings for the boilers operation OEM Settings Original Equipment Manufacturer Settings These setting are non conf...

Page 12: ...S menu press at the CH SETTINGS menu to access the comfort heat parameters listed in the table below Alternatively pressing at the boiler status screen also accesses the CH SETTINGS menu You can now s...

Page 13: ...Temp Minimum Outdoor Air Temperature 18 59 F SVC1 Max ODA SetP Desired setpoint Lo ODA Temp See Appendix I F SVC1 ODA Shutdown Outdoor Air Shutdown Temperature 45 140 F SVC1 Night Setback Reduces CH...

Page 14: ...SIS OFF the boiler will shut off Once it shuts off it will not restart until the temperature drops below 150 F 160 F SETPOINT 10 F HYSTERESIS ON This is illustrated graphically below The MIN SETPOINT...

Page 15: ...point temperature increases until LO ODA TEMP is reached by the outdoor air temperature When the outside air temperature has dropped to meet the LO ODA TEMP setting the setpoint of the boiler will be...

Page 16: ...LV terminals 1 and 2 will reduce the CH setpoint by the value of the night setback setting Example Using the values CH SP 180 F and Night Setback 10 F when TB1 LV terminals 1 and 2 are open the CH set...

Page 17: ...3 Description This mode is a combination of CH Mode 2 Outdoor Control and CH Mode 4 Header Stat The temperature is maintained at the location of the header sensor and the setpoint is based on the ODA...

Page 18: ...ying 10 VDC sets the boiler setpoint to BOILER MAX SETPOINT Applying less than 5 VDC removes the heat request The Min and Max set points can be adjusted within the boiler settings menu NOTE When in an...

Page 19: ...ough the boiler may be receiving a 10 VDC signal high fire will not be achieved if certain parameters such as the boiler maximum temperature are exceeded NOTE When in analog control mode enable disabl...

Page 20: ...nt for Domestic Hot Water Output 86 185 F User Tank set Setpoint of Storage Tank DHW mode 1 104 162 F User ON different Boiler On Differential 0 36 F SVC1 OFF different Boiler Off Differential 0 36 F...

Page 21: ...tive for assistance on tank sizing 1 6 4 2 DHW Mode 2 Storage Stat Storage Tank with Thermostat Installer needs to supply a closure device aquastat thermostat flow switch etc to close the DHW Enable c...

Page 22: ...w fire Example 45 F MBD 5 F MBD Offset 50 F at which time the boiler will drop to low fire Inside of this 5 F range it will step modulate to buffer out an application where the boiler flow may dip jus...

Page 23: ...allows the user to select Fahrenheit or Celsius MODBUS ADDRESS configuration allows the user to set the Modbus device identification Each ENVI control defaults to Modbus address 1 In applications with...

Page 24: ...the MASTER position is away from the blue transformer while the MEMBER position is towards the blue transformer The orientation of the board may vary from the picture shown CAUTION Setting more than...

Page 25: ...1 8 4 5 2 Header Mode HDR Setpt Control See Below 1 8 4 6 3 Header Mode HDR Analog Setpt See Below 1 8 4 7 4 Hyst Start Blr See Below 1 8 4 8 1 0 36 F SVC2 Hyst Stop Blr See Below 1 8 4 8 2 0 36 F SVC...

Page 26: ...ault Setting In this mode the boilers modulate in parallel based on a signal from the master boiler This satisfies the load with the necessary number of boilers firing at the lowest fire rate possible...

Page 27: ...accessory choices for different applications is shown in section 1 0 on page 3 In this mode the temperature is maintained at the location of the header sensor based on a reset schedule that is determi...

Page 28: ...r This is the differential below header setpoint at which the master control will initiate the WAIT BOILER SWITCH ON timer to request the next member boiler to run When the HEADER TEMPERATURE drops be...

Page 29: ...l wait for the last started boiler to achieve before switching on the next boiler in the cascade system Set to 100 to deactivate 1 8 4 7 6 Wait blr sw off Wait boiler switch off This parameter is the...

Page 30: ...hange in the controlled variable required to drive the loop output from 0 to 100 For example With the proportional band left at the default setting of 20 and a header setpoint of 140 With the Derivati...

Page 31: ...ases the action towards setpoint Integral rate continues to adjust the control output in accordance with both the size of the deviation from setpoint and the time it lasts to bring the process to setp...

Page 32: ...ber boilers each member boiler control monitors its own supply temperature to detect if a low load condition exists This and additional low load settings are described in the Cascade Settings section...

Page 33: ...ad condition can be set inactive see note 3 4 0 255 Sec SVC2 Load detct dlt When supply temperature is above the header setpoint plus this setting the loload condition is set active 0 99 F SVC2 Csc Mi...

Page 34: ...p Restriction 1 Alarm Condition When a boiler is requested for cascade operation it must be free from alarms If the requested boiler is in an alarm state the master will attempt to request another boi...

Page 35: ...122 F HYST MIN RET T 9 F RET T MAX PWR 113 F RET T MIN PWR 127 F PREPUMP PERIOD 30 Sec 1 8 5 1 Master Setup The master boiler must be equipped with certain hardware to allow it to control the cascade...

Page 36: ...boiler will be disabled When the timer reaches 0 00 and a boiler is disabled the timer immediately resets and resumes counting down This timer pauses when the header temperature is between the HYST S...

Page 37: ...master boiler will begin the QUIC START TIME timer which will bypass the WAIT BLR SW ON timer Once QUIC START TIME timer expires and the temperature condition is still true a boiler will be requested...

Page 38: ...LOW allows the service technician to hold the boiler in high or low fire for ver 1043 20 40 60 and 80 selections are included during firing operation so that the combustion adjustment can be performed...

Page 39: ...hat text is present Replace display board 3 Turn S4 switch to the on position which is on the main board Display continuously shows CONNECT INIT Incorrect communication between control boards Check co...

Page 40: ...ains are reversed E19 E2PROM READ ERROR 0 Problems from reading from or writing to E2prom E20 FLAME ERROR 2 74 False flame detected E21 LOW FLOW ILK 73 Low flow or interlock error E22 WD 50HZ ERROR 45...

Page 41: ...A19 FLAME OUT TOO LATE ERROR 20 Flame still present 10 sec after closing the gas valve A20 FLAME ERROR I 21 Flame detected just before gas valve opened A30 HIGH GAS PRESSURE ERROR 32 Gas pressure is...

Page 42: ...ON DEMAND QUIC STOP TIME DHW Parameters DHW MODE LOLOAD WAITING DHW TYPE START ROTATION DHW SETPOINT NO BLR ON WAIT TANK SET ANTI WINDUP ON DIFFERENT LEAD BOILER OFF DIFFERENT CASCADE SETTINGS MAX SU...

Page 43: ...r RS485 two wire MODBUS REGISTER MAP Address Byte Type Parameter Name Formula Data 0 HIGH State See State Table 0 LOW Supply Temperature Normal Temperature 2 HIGH Return Temperature Normal Temperature...

Page 44: ...d the holding register addressing range starts either at 0x0000 or at 0x0001 If your MODBUS software starts at 0x0000 you can use the holding register addresses shown in the tables above If your MODBU...

Page 45: ...0x0C PUMP_CH_0 Post pumping for CH 13 0x0D PUMP_CH_1 Pumping for CH 14 0x0E PUMP_HW_0 Post pumping for DHW 15 0x0F PUMP_HW_1 Pumping for DHW 16 0x10 ALARM_1 Error handling locking 17 0x11 ERROR_CHECK...

Page 46: ...MODBUS RTU Supported MODBUS Commands Read Holding Register 0x03 Write Single Holding Register 0x06 Baud rate 9600 bps Data Length 8 Parity None Stop Bits 1 Register Request 1 Physical Layer RS485 two...

Page 47: ...on there are several procedures which require integer division These particular operations are indicated by Integer and two examples of standard division vs integer division are shown below Standard D...

Page 48: ...08 IGNIT_1 Ignition with gas valve open 9 0x09 BURN_0 Burning 10 0x0A POST_PURGE_0 Post purging 11 0x0B POST_PURGE_1 Post purging 12 0x0C PUMP_CH_0 Post pumping for CH 13 0x0D PUMP_CH_1 Pumping for CH...

Page 49: ...ader Temperature 40006 Firing Rate 40007 Flue Gas Temperature 40008 HX Temperature 40009 Outside Temperature 256 255 100 Integer 256 2 32 F 1 8 10 C Integer 256 2 32 F 1 8 10 C Integer 256 2 32 F 1 8...

Page 50: ...W Setpoint 40013 Boiler Operation Decimal Hex Description 0 0x00 Boiler OFF Pump OFF 1 0x01 Boiler ON Pump ON 2 0x02 Boiler OFF Pump ON 3 0x03 Boiler ON Pump ON ON indicates pump is on constantly 4001...

Page 51: ...Night Setback 40020 Error Code Decimal Hex 01BD BD71 49A7 6999 79F2 1 0x01 IGNITION FAILURE 4 0x04 MAX DT EXCEEDED 5 0x05 INT ERR GAS VLV RLY 6 0x06 INT ERR SAFETY RLY 7 0x07 RAPID RISE OUT TEMP Cont...

Page 52: ...0x2B N A NO GROUND 60 HZ ERR 44 0x2C NO GROUND 60 HZ ERR LINE NEUTRAL REV 45 0x2D LINE NEUTRAL REV LINE FREQUENCY ERR 46 0x2E LINE FREQUENCY ERR FAULTY GROUND 47 0x2F FAULTY GROUND INTERNAL ERROR 47 4...

Page 53: ...oll to Code and press ENTER 40021 Analog In 40022 Analog Out 40023 Ignitions 40025 Burner High Hours Hours spent between 75 and 100 firing rate 40027 Burner Medium Hours Hours spent between 45 and 75...

Page 54: ...mperature 40035 ET DHW Temperature 40036 ET Flue Gas Temperature 40037 ET HX Temperature 40038 ET Outside Temperature 256 2 32 F 1 8 10 C Integer 256 2 32 F 1 8 40 C Integer 256 2 32 F 1 8 10 C Intege...

Page 55: ...the error Bit 6 indicates if the boiler was operating in DHW mode at the time of the error Bit 7 indicates if the boiler was operating in CH mode at the time of the error 40040 ET Month 40041 ET Day...

Page 56: ...e decimal value to be written is 35840 184 36024 Refer to the M 104 MODBUS Calculator xls spreadsheet to help with these calculations MODBUS WRITE ONLY REGISTER MAP 40011 CH Setpoint DHW Setpoint 4001...

Page 57: ...Temperature Outdoor Air Shutdown Temperature 40018 Outdoor Air Shutdown Temperature Night Setback Integer 10 32 1 8 512 Integer 40 32 1 8 2 OA Shutdown Temperature F Max OA Temperature F Integer 40 32...