Thermal Solutions Boiler Control TSBC, Instruction Manual

Page 1: ...nce 41 Security Menu 42 Specifications General 43 Component Description Repair Part Numbers 44 Appendix A Parameter Summary 45 B Customer Parameter Worksheet 47 Application The Thermal Solutions Boiler Control TSBC has been designed for commercial hot water boiler applications Intent This instruction manual includes detailed functional installation and setup information The intended users are appl...

Page 2: ...sed on Setpoints Based on Setpoints Based on Setpoints Based on Setpoints Input RO or Modbus Manually Set Modulation Rate Internal Boiler Control Based on Setpoint Based on Setpoint Based on Setpoint Based on Setpoint Ignored Ignored Lead Boiler Control Peer to Peer Connected With Peer to Peer Connected With Peer to Peer Connected With Peer to Peer Connected Ignored Ignored Remote EMS Control Igno...

Page 3: ...re Switches HL High Limit Aquastat HP High Pressure Gas Switch IN Boiler Inlet Water Temperature LC Low Water Cutoff Switch LL Lead Lag LO Lockout Indicator LR Local Remote M Electric Motor Mix 3 Way Mixing Valve OA Outside Air Temperature OL Operating Limit Aquastat OO Burner On Off Switch OUT Boiler Outlet Water Temperature RO Remote On Off RST Remote System Temperature SH Space Heating Demand S...

Page 4: ...sor failure the TSBC will automatically switch to boiler outlet temperature sensor based control Outdoor Air Reset When selected the modulation rate setpoint is automatically adjusted based on outside air temperature Outdoor air reset setpoint saves fuel by adjusting the water temperature of a heating boiler lower as the outside air temperature increases Warm Weather Shutdown WWSD Some boilers are...

Page 5: ...TSBC Instruction Manual Page 5 of 48 Introduction Overview Thermal Solutions Boiler Control ...

Page 6: ...stem Pump is On when the System Pump is set to yes and WWSD is set to either WWSD of Boiler or Off d Boiler pump is On during Prepurge and Post Purge when Boiler Pump is set to Purge or boiler is lead Boiler Pump is set to On Lead e Combustion Air Damper Spare Output is maintained On for 2 minutes after the Call For Heat is removed f Modulation rate is held at purge when low fire input is not prov...

Page 7: ... MODE LCD Display Description Pump Purge Any Mode Except Manual Mode Once a Call For Heat is initiated and Boiler Pump Purge is selected the pump output is energized until the Pump Prepurge Time is complete If the Call For Heat condition still exists at the end of the Prepurge Time the temperature of the water at the sensor may rise with boiler water flowing passed it the pump will continue to ope...

Page 8: ...en water temperature is above the setpoint by more than the Off Point differential for longer than the Boiler Off Delay parameter Lead Boiler Stop The last boiler remains on line until the water temperature is above the Off Point setpoint for longer than the time delay Notes The Boiler Address parameter assignment determines the boiler sequencing order The Lead Boiler automatically rotates when Ro...

Page 9: ...e Options Outside Air Reset If enabled the Outside Air Sensor will automatically adjusted the setpoint Warm Weather Shutdown WWSD If enabled the WWSD will disable a boiler start when outside air temperature is above a Warm Weather Shutdown WWSD setpoint Domestic Hot Water Priority DHWP If enabled the DHWP will adjust the setpoint to satisfy the DHWP setpoint when a DHWP input DP is energized Selec...

Page 10: ... is activated a Call for Heat is also initiated when the Lead boiler modulation rate is above an adjustable High Fire Rate Limit parameter 37 for too long a time Options Outside Air Reset If enabled the Outside Air Sensor will automatically adjusted the setpoint Warm Weather Shutdown WWSD If enabled the WWSD will disable a boiler start when temperature is above a Warm Weather Shutdown WWSD setpoin...

Page 11: ... off points and boiler outlet temperature Options Warm Weather Shutdown WWSD If enabled the WWSD will disable a boiler start when temperature is above a Warm Weather Shutdown WWSD setpoint Outside Air Temperature may be displayed only Outside Air Reset and Domestic Hot Water Priority input DP are ignored Selecting This Control Mode To select Outlet Sensor Remote SP Mode set the following parameter...

Page 12: ... determined by setpoint on and off points and Remote System Temperature If a Peer To Peer network is activated a Call for Heat is also initiated when the Lead boiler modulation rate is above an adjustable High Fire Rate Limit Parameter 37 for too long a time Options Warm Weather Shutdown WWSD If enabled the WWSD will disable a boiler start when temperature is above a Warm Weather Shutdown WWSD set...

Page 13: ...nts are ignored The boiler will turn off if the water temperature increases past the temperature set on the Operational Temperature Limit Options Outside Air Reset and Domestic Hot Water Priority input DP and Warm Weather Shutdown are ignored Selecting This Control Mode To select Remote Control Mode set the following parameters System Configuration Menu Remote Control Remote Mod Remote System Temp...

Page 14: ...perature increases past the temperature set on the High Temperature Stop parameter Options Outside Air Reset Warm Weather Shutdown and Domestic Hot Water Priority are ignored The Spare Output VI and Combustion Air Damper SO outputs are energized when the operator starts the boiler in manual mode Selecting This Control Mode Manual Mode is activated from the Manual Mode menu when Supervisor password...

Page 15: ...ed Simply set the Mixing Valve M A parameter to Man and adjust the Mixing Valve as required Once activated the green LED flashes To leave manual mode set the Mixing Valve M A parameter to Auto Combustion Air Damper and Vent Inducer When the Relay CH is closed the Combustion Air Damper CAD and Vent Inducer outputs are energized If the CAD open position is needed to be proven a limit switch may be w...

Page 16: ... no function in display mode The ENTER key is used to select menus menu items and save edited parameters as follows Select Mode steady text Press ENTER to change into Edit Mode or select a menu or menu item Edit Mode blinking text Press ENTER to save the current value Press MENU to cancel the current editing operation UP DOWN Select Mode steady text Press UP DOWN to change the selected display and...

Page 17: ...en Remote Sensor Control SP Active Setpoint MOD RATE Modulation Rate SH Space Heating active when DH is not DH Domestic Hot Water Priority visible when DHWP Yes and DP input is true In Boiler Inlet Temperature SP Min In H2O Temp MIX VALVE Modulation Rate Control Mode Outlet Sensor Local SP Mode message shown refer to page 2 for an overview of each control mode LEAD BOILER 0 8 Lead Boiler when zero...

Page 18: ...4 Setpoints Menu Operational On Off Min Max Setpoints Editable Values refer to page 19 Communication Menu Modbus and Peer To Peer Network Selections refer to pages 23 24 Diagnostic Menu Fault and Low Inlet Temp history Input Output Status refer to pages 38 through 40 System Menu Software revision parameter code and sensor calibration refer to page 40 Security Menu Supervisor and Factory access ref...

Page 19: ...nput DP closes and DHWP parameter is set to yes and Local SP Mode is selected When the contact is closed the boiler outlet is maintained at or above the DHW Setpoint 75 40 to 90 F WWSD Setpoint The Warm Weather Shutdown WWSD Setpoint used to disable boiler and or system pump operation when enabled by setting the WWSD parameter to WWSD of Boiler WWSD of Sys Pump or Both 76 140 F to 230 F Max SP The...

Page 20: ...er 5 Vdc Common Boiler Inlet Temperature Boiler Peer To Peer Communication Network V V P P GP WF HL Power Common 24 Vac Power Supply 24 Vac Flame Safeguard Alarm 24 Vac Fuel Valve Energized 24 Vac P P Firing Rate Demand 0 10 Vdc PWM V V Firing Rate Demand 0 10 Vdc OO Burner On Off Switch WF Low Water Flow Switch GP Gas Pressure Switch HL Operating or High Limit CA Low Combustion Air Flow Thermal S...

Page 21: ...ownstream of all boiler connections Locate the sensor a minimum distance of 10 straight pipe diameters from the flow disturbing fittings Outdoor Air Temperature Sensor Mount the temperature sensor on an outside wall out of direct sunlight preferably on a north facing wall Do not mount sensor near exhaust of any kind as this may affect readings ...

Page 22: ...the Outside Air and Remote System Temperature sensors should use low impedance shielded twisted pair wire and go directly to the terminals on any one boiler Signal wiring should not be run in the same conduit with power wiring Wire shields may be connected to the common terminal C located on the same terminal block with the outside air and remote system temperature connections 3 The RJ45 sensor ca...

Page 23: ...re the A represents the active transmission state of the RS485 transmitter as opposed to the line idle state You need only to wire to one of the A terminals and one of the B terminals Phone cable signals 4 wire connect to pin black or yellow and red or green Wire Color Slot Number Connection Black 1 A Red 2 B Green 3 B Yellow 4 A Notes 1 Use standard phone cables although ones that have all six wi...

Page 24: ...uals Modbus 93 Odd Even None Parity Only visible when Protocol equals Modbus 94 1 120 Seconds Timeout Only visible when Protocol equals Modbus 95 Messages Rcvd Diagnostic tool used to confirm wiring and Modbus master configuration Only visible when Protocol equals Modbus 96 Messages Sent Diagnostic tool used to confirm wiring and Modbus master configuration Only visible when Protocol equals Modbus...

Page 25: ... all boilers a unique Boiler Address between 1 and 8 and set the Protocol to Peer to Peer 2 Connect all boilers using a RJ11 ended telephone cable 3 Configure all Network Relevant parameters identically on all boilers Unexpected boiler behavior may result if these parameter values differ among boilers on the network When Network Relevant parameters are identical the Param Code parameter will be id...

Page 26: ...gized Off On 00013 Flame Safeguard Alarm Off On 00014 Call For Heat CFH Off On 00015 General Alarm Off On 4 00016 Vent Inducer Off On 00017 Boiler Pump Off On 00018 System Pump Off On 00019 Spare Output Programmable Off On 00020 State Boiler Disabled Off On 3 00021 State Weather Shutdown Off On 3 00022 State Lockout Off On 3 00023 State Pump Purge Off On 3 00024 State Limit Hold Off On 3 00025 Sta...

Page 27: ... monitor or control the boilers the Comm Failure alarm is not cleared until a successful write to both the Remote On Off Modbus Command 00004 and Remote Firing Rate or Remote Setpoint 40006 points have been completed power is cycled or the Protocol parameter is changed from Modbus to Peer to Peer and back again 2 The limit string points 00006 00011 are only monitored when there is a Call For Heat ...

Page 28: ...ute month day year Set Time Date Displays and sets the time and date of the boiler s real time clock 8 No Yes Fuel Limit Specifies a Fuel Limit such as high and low fuel gas pressure switches are connected to input GP Enables Fuel Limit Hold and alarm messages 9 Off Sys Pump Feedback Low Fire Spare Input Sets the function of the Spare Input Terminal SI Off Ignore Sys Pump Feedback Input SI should ...

Page 29: ...range Modbus SP RS485 Modbus 40006 is used as the temperature setpoint Remote Mod Remote Input C C is used as the modulation rate Modbus Mod RS485 Modbus 40006 is used as the modulation rate 22 60 F to 140 F Remote 1 0 Volt Sets the temperature corresponding to input C C 1Volts Voltage below 1V is considered invalid failed or incorrect wired sensor 23 150 F to 220 F Remote 9 0 Volt Sets the temper...

Page 30: ...emperature and modulation rate swings 35 1 to 30 Minutes FR On Delay Time Delay after the modulation rate is above the LL Start Trigger before starting the next boiler Long time delay to avoid temperature going below setpoint as a result of a slow process change 36 1 to 30 Minutes FR Off Delay Time Delay after the modulation rate is below the LL Stop Trigger before stopping the next boiler Long ti...

Page 31: ...d on the following page 49 0 to 100 Full Scale Blower Spd High Linkage Max Position Percent of 0 10 Vdc output V V output that represents a 100 modulation rate This scaling factor allows the TSBC to display 100 when the linkage is at rated boiler output Please Note The Burner input rate adjustment must be completed before this parameter can be set After maximum boiler firing rate is established th...

Page 32: ...or temperature Display Outside Air Temperature Outdoor Reset Calculate the temperature setpoint based on outdoor temperature using a reset curve defined by Outdoor Set Up Boiler Set Up Outdoor Design and Boiler Design parameters 45 40 F to 100 F Outdoor Set Up The Outdoor Set Up temperature is the outdoor temperature at which the Boiler Set Up temperature is supplied 46 140 F to 180 F Boiler Set U...

Page 33: ...ure sensor control Modes A smaller 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 between 0 5 and 2 0 are typical The burner modulation rate can oscillate if the Integral ...

Page 34: ... selected Mixing Valve P select the corresponding from table on previous page Integral value The mixing valve can oscillate if the Integral time is too small 63 0 to 10000 Mixing Valve D The Derivative gain value for boiler inlet temperature sensor control mode A larger Derivative gain value produces a larger PID output contribution proportional to the rate of change of the error Setpoint Boiler I...

Page 35: ...ate Sets the modulation rate to be used for boiler when in Manual Mode Activated only when in Supervisor Mode and Boiler Man Auto Man 103 On Off Boiler On Off Sets the boiler start stop status when in Manual Mode No Turn off boiler if running otherwise remain off Yes Turn on boiler if off otherwise remain on Activated only when in Supervisor Mode and Boiler Man Auto Man 104 Man Auto Mixing Valve M...

Page 36: ...receive power and the Call For Heat output CH is powered the High Temp Limit Message is displayed Low Air Flow Flashing Red Alarm Light Check combustion air blower and air pressure switch settings and wiring Low Air Flow or Blocked Vent Switch Not Made The air flow and blocked vent switch when provided is preventing a boiler start If terminal CA does not receive power and the Call For Heat output ...

Page 37: ...nd a successful writes to both the Remote On Off Modbus Command 00004 and Remote Firing Rate or Remote Setpoint 40006 points have been completed power is cycled or the protocol parameter is changed to Peer To Peer and then back to Modbus When a Peer To Peer network has failed the boilers begin operation as stand alone boilers using the selected parameters After a Peer To Peer communication failure...

Page 38: ...red in memory Each time the boiler inlet temperature is less than the Min In H2O Temp parameter a low temperature event is recorded The BIT History screen automatically toggles between the lowest temperature for the event and Duration Below Setpoint displays and provides time and date of each event SYSTEM Items provided by this menu are shown on page 40 DISCRETE INPUTS These screens provide a conv...

Page 39: ...Discrete Output ANALOG INPUTS These screens provide a convenient way to trouble shoot wiring during the installation phase Each screen provides the status of a controller analog input These displays show the status of the corresponding Analog Input ANALOG OUTPUTS These screens provide a convenient way to trouble shoot wiring during the installation phase Each screen provides the status of a contro...

Page 40: ...ory calibrated However it may become necessary to field calibrate due to measuring errors resulting from long wire lengths or third party sensor use This is a single point calibration tool To gain the greatest benefit it is recommended to calibrate as close as possible to the expected operating temperature and measure the temperature at the sensor location Remote System Temperature RST Outside Air...

Page 41: ...1 212 10 14 55 301 27 80 9 298 82 180 1 169 9 16 52 069 28 82 8 862 83 182 1 129 8 18 49 047 29 84 8 448 84 184 1 089 7 20 46 220 30 86 8 056 86 186 1 052 6 22 43 574 31 88 7 685 87 188 1 016 4 24 41 097 32 90 7 333 88 190 981 2 3 26 38 776 33 92 6 999 89 192 947 9 2 28 36 601 34 94 6 682 90 194 915 9 1 30 34 562 36 96 6 382 91 196 885 2 0 32 32 650 37 98 6 097 92 198 855 7 1 34 30 856 38 100 5 82...

Page 42: ...er Password parameter The Factory Access Level can be reached by entering the factory password in the Enter Password parameter and holding the Enter key for at least two seconds when accepting the value entered The display will jump to the Access Level parameter menu when the system has entered the Factory Access Level Note that the Access Level parameters value will indicate Supervisor To exit ei...

Page 43: ...d Low Gas Pressure Switches 24 Vac 1mA HL Operating or High Limit 24 Vac 1mA CA Low Combustion Air Flow 24 Vac 1mA CS Fuel Valve Energized 24 Vac 1mA AL Flame Safeguard Alarm 24 Vac 1mA Discrete Outputs Terminal Description Rating CH Call For Heat CFH 24 Vac 10A LO Lockout Indicator 12 Vdc 100mA VI Spare Output 12 Vdc 100mA BP Boiler Pump 12 Vdc 100mA SP System Pump 12 Vdc 100mA SO Spare Output Pr...

Page 44: ...tery is NOT used to retain this memory The battery is located at the back of the TSBC for easy replacement Component Description Repair Part Number 1 Thermal Solutions Boiler Control Assembly 101171 03 Individual boiler operating and modulation rate control and modulating lead lag controller Built to UL and CSA standards 2 Replacement Fuse Busman GMC 5A 3 Immersion Temperature Sensor 101935 01 NPT...

Page 45: ...t Trigger 50 to100 of Modulation Rate Supervisor 30 Yes LL Stop Trigger 0 to 50 of Modulation Rate Supervisor 30 Yes Boiler On Delay 0 to 900 seconds Supervisor 30 Yes Boiler Off Delay 0 to 900 seconds Supervisor 30 Yes FR On Delay 1 to 30 minutes Factory 30 Yes FR Off Delay 1 to 30 minutes Factory 30 Yes High Fire Limit 40 100 Modulation Rate Supervisor 30 Yes Deg Min Hold Off 1 10 Degrees Minute...

Page 46: ...F Basic 19 Yes Off Point 0 F to 99 F Basic 19 Yes High Temp Stop 60 F to 230 F Basic 19 Yes DHWP setpoint 140 F to 230 F Basic 19 Yes WWSD setpoint 40 F 90 F Basic 19 Yes Max SP 140 F to 230 F Supervisor 19 Yes Min SP 60 F to 230 F Supervisor 19 Yes Min BIT 110 F to 235 F Factory 19 Update Min Inlet H2O Temp 110 F to 180 F Supervisor 19 Update Max H2O Delta T 20F to 50 F Supervisor 19 Update Max D...

Page 47: ...ntrol Circle one No Remote SP Modbus SP Remote Mod Modbus Mod Remote 1 volts F Remote 9 volts F Remote Sensor Circle one No Display Only Control System Pump Circle one Yes No LWC or CAD Circle one Yes No Alarm Message Setup Menu WWSD Circle one Off WWSD of Boiler WWSD of Sys Pump Both LL Start Trigger LL Stop Trigger Boiler On Delay Seconds Boiler Off Delay Seconds High Fire Limit Rotation Circle ...

Page 48: ...rational Setpoint F On point F Off Point F High Temp Stop F DHWP setpoint F WWSD setpoint F Max SP F Min SP F Min Inlet H2O Temp F Max H2O Delta T F Max Delta T Hold F Communication Menu Protocol Circle one Peer to Peer Modbus Modbus Address Baud Rate Circle one 9 6 19 2 38 4 Parity Circle one Odd Even None Timeout Seconds Boiler Address ...