BC-1 CONTROLLER MANUAL
Contents
1. BC 1 CONTROLLER MANUAL For use with Gas and Electric Boilers and Indirect Hot Water Tanks The BC 1 controllers are designed to be mounted on two or three stage boilers in order to provide accurate water temperature control in a variety of applications The controls may be used to provide a setpoint temperature outdoor reset with reset override or dedicated DHW generation with an indirect hot water tank Two relay contacts are included to operate the boiler pump and provide an alarm signal in case of a sensor failure Featuring 2 or 3 Stage Control PID Logic Sensor Alarm Outdoor Reset DHW Reset Override BOIL TARGET Boiler Controller Item A y a a a IMPORTANT e Read all instructions before operating e This manual must be left with owner and should be located adjacent to the boiler for reference Allied Engineering Company Division of E Z Rect Manufacturing Ltd Manufacturers of Gas and Electric Boilers Stainless Steel Tanks Tankless Coils Electric Boosters 94 Riverside Drive North Vancouver B C V7H 2M6 Telephone 604 929 1214 www alliedboilers com Cc US Branches Calgary Edmonton Toronto Denver PN8332757 Introduction This brochure is organized into four main sections They are 1 Sequence of Operation 2 Installation 3 Control Settings and 4 Troubleshooting The Sequence of Operation section has 5 sub sections We recommend reading Section A General o2. 24 V 10 50 60 Hz 75 VA 120 V ac 5 A 1 6 hp pilot duty 240 VA 120 V ac 3 A 1 6 hp 24 V ac 3 A 1 6 hp 20 to 130 V ac 2VA NTC thermistor 10 KQ 77 F 25 C 0 2 C B 3892 2 of Universal Sensor 071 Universal Sensor 071 Setp Dem E Boiler Controller Item A v s Sensor o ue n Cirasa ALLIED ENGINEERING COMPANY DIVISION OF E Z RECT MANUFACTURING LTD 94 Riverside Drive North Vancouver BC V7H 2M6 Tel 604 929 1214 Fax 604 929 5184 Web Site www alliedboilers com All specifications are subject to change without notice 16 of 16 Printed in Canada
3. MODE 1 2 3 4 5 The interstage differential that the control is to use 10 F 4 when it is operating the boiler ae ae MODE 1 2 3 4 5 and STGMODE P The interstage delay that the control is to use when an additional stage is required to turn on 1 00 to 8 00 2 MODE 1 2 3 4 5 and STGMODE P mindes IAES The interstage delay that the control is to use when a stage is required to turn off Off delay has been d djustable setti Nol Hire removed as an adjustable setting Applicable ninutes The thermal mass of the boiler used 1 light mass 2 medium mass MODE 1 2 3 4 5 and STGMODE Pid 3 heavy mass OFFDLY MODE 1 2 3 4 5 and STGMODE P F F The minimum on time for each stage when manual ce CT Min on has been removed as an Not 0 00 l 1 Applicable minutes MODE 1 2 3 4 5 and STGMODE P The minimum off time for each stage when manual f staging is selected 0 30 to 5 00 0 50 minutes minutes MODE 1 2 3 4 5 and STGMODE P OFF 0 20 to 9 55 min 0 30 Determines when to stop purging On The system s warm weather shut down 35 to 100 F OFF 70 F MODE 4 5 2 to 38 C OFF 21 C The units of measure that all of the temperatures are oF to be displayed in by the control 2 13 Error Displayed Description of Error The control was unable to read a piece of information from its EEPROM The control will stop operation until all settings in the Adjust menu have been checke
4. brochure Testing the Control s Outputs The BC 1 has a built in test routine which is used to the main control functions The test sequence is enabled when the A button is pressed and held while in the View menu The outputs are tested in the following sequence Step 1 After 1 second the pump is turned on Step 2 After 4 seconds Stage 1 is turned on Step 3 After 7 seconds Stage 2 is turned on Step 4 After 10 seconds Stage 3 is turned on Step 5 After 13 seconds the Alarm is turned on Step 6 After the A button is released the control continues normal operation 10 Control Settings DIP SWITCH SETTING Note DIP switches are located on the front of the control A Advanced Insialler The Advanced Installer DIP switch is used to select which items are available to be viewed and or adjusted in the user interface The Advanced Access Level includes all the settings available in the control The Installer Access Level includes the settings and items which are required for system setup B DIP s witch BAA The DIP switch B is used to select the stage mode In 2 stage mode the BC 1 will operate stages 1 and 2 to control the boiler temperature In 3 stage mode the BC 1 will operate stages 1 2 and 3 to control the boiler temperature For Electric Boilers set DIP switch B to 3 stage mode For Gas Boilers set DIP switch B to 2 stage mode View Menu 1 of 1 BOIL TARGET BO
5. E External Boiler Operation When mode 6 is selected the BC 1 allows for an external boiler control to operate the boiler stages In this mode the BC 1 oper ates the boiler pump in order to provide purging and exercising The staging operation is provided by an external device such as an Energy Management System EMS or Boiler Staging control HEAT DEMAND A heat demand is generated when a voltage of 24 V ac is applied across the CD common demand and the Ht D heat demand terminals Once voltage is applied the BC 1 turns on the Dem segment in the display The BC 1 closes the Pmp Pmp contact which starts the boiler pump and the control turns on the boiler pump segment in the display The BC 1 also closes the Stg 1 Stg 1 contact which turns on stage 1 of the boiler The Stg 1 Stg 1 contact is closed as long as the heat demand is present Installation ELECTRICAL CONNECTIONS TO THE CONTROL The installer should test to confirm that no voltage is present at any of the wires during installation The BC 1 includes a 24 pin connector for ease of installation r 24R 4 H23 Alarm 22 Stg4 L2 Stg4 r H20 Stg3 L19393 HE18 Stg2 L17 S92 r H16 Stg 1 L15 Sig 1 rk 14 Pmp 13 Pmp eG WARNING The BC 1 controller may be pre wired to the boiler at the factory Please refer to the appropriate boiler installation
6. and service manual for instructions on electrical connections If the BC 1 has been pre wired to the boiler please do NOT apply power to any of the connections described below Powered Input Connections Output Connec tions Sensor and Unpowered Input Connections Powered Input Connections 24 V ac Power Connect the 24 V ac power supply to the C and R terminals 12 and 24 This con nection provides power to the microprocessor and display of the control As well this R eo par connection provides power to the Alarm terminal 23 from the R terminal 24 Heat Demand 24 to 240 V ac To generate a heat demand a voltage of 24 V ac must be applied across the CD A E 2 ero common demand and the Ht D heat demand terminals 1 and 2 o D co Setpoint Demand To generate a setpoint demand a voltage of 24 V ac must be applied across the CD common demand and the Set D setpoint demand terminals 1 and 3 Caution The same power supply must be used for both the heat demand and setpoint demand circuits since they share the CD common demand terminal Output Connections Boiler Pump Contact The Pmp Pmp terminals 13 and 14 are an isolated output in the BC 1 There is no N ap power available on these terminals from the control These terminals are to be used L ty ere as a switch to either make or break power to the boiler pump Since this
7. temperature is determined from the mode of operation The control displays the temperature that it is currently trying to maintain at the operating sensor as BOIL TARGET in the View menu The operating sensor for modes 1 3 and 4 is the boiler outlet sensor and the operating sensor for modes 2 and 5 is the boiler supply sensor If the control does not presently have a requirement for heat it displays in the LCD There is no boiler target temperature generated in Mode 6 BOILER PUMP OPERATION The boiler pump contact Pmp Pmp operates based on the mode of operation selected During setpoint operation modes 1 and 2 the boiler pump contact closes whenever there is a heat demand During dedicated DHW operation mode 3 the boiler pump contact closes whenever there is an internal heat demand During outdoor reset modes 4 and 5 the boiler pump contact closes whenever there is either a heat demand and the BC 1 is not in Warm Weather Shut Down WWSD whenever there is a setpoint demand During Warm Weather Shut Down if the boiler pump has not operated at least once every 70 hours the control turns on the output for 10 seconds This minimizes the possibility of the pump seizing during a long period of inactivity During External Boiler Operation Mode 6 the boiler pump contact closes whenever there is a heat demand Boiler Purge PUMP DLY After a demand is satisfied the BC 1 continues to operate the boiler pump for a period of time Th
8. 4 5 Page 6 Page 7 Page 7 l Page 8 Section A General POWERING UP THE CONTROL When the BC 1 is powered up the control turns on all segments in the display for 2 seconds Next the software version is displayed for 2 seconds Finally the control enters into the normal operating mode MODES OF OPERATION MODE The BC 1 controller allows for six modes of operation in order to define the control operation and piping arrangement used The piping arrangement can be categorized into parallel and primary secondary The mode of operation is selected using the MODE item in the Adjust menu The temperature being controlled out to the heating system is measured by the operating sensor The piping arrangement determines which sensor the BC 1 uses as the operating sensor The operating sensor is either the boiler outlet sensor or the boiler supply sensor see page 15 and 16 for typical applications Boiler Outlet Parallel Sensor In parallel piping applications the boiler outlet temperature is typically the same tem perature that is being delivered out to the system Therefore the operating sensor in Boiler parallel piping applications is the boiler outlet sensor Boiler Outlet Primary Secondary In primary secondary applications the boiler outlet temperature is typically higher than the primary loop temperature Therefore the BC 1 uses an additional sensor boiler supply to measure the temperature delivered out to t
9. ILSUP A Lieve Current outdoor air temperature as measured by the outdoor sensor This is the default display for the control MODE 4 5 Description 2 stage lt C 3 stage BK AJE OFF OFF Advanced I L Installer Range 60 to 190 F 51 to 88 C Target boiler supply is the temperature the control is currently trying to maintain at the boiler supply sensor or the boiler outlet sensor MODE 1 2 3 4 5 Current boiler supply water temperature as measured by the boiler supply sensor MODE 2 5 Current boiler outlet water temperature as measured by the boiler outlet sensor MODE 1 3 4 6 Installer Level MODE 2 5 Advanced Level Current boiler inlet water temperature as measured by the boiler inlet sensor Current AT temperature difference between the boiler outlet sensor and the boiler inlet sensor Current DHW tank temperature as measured by the DHW sensor MODE 3 The total number of running hours of the boiler since this item was last cleared 11 0 to 999 35 to 266 F 2 to 130 C 14 to 230 F 10 to 110 C 14 to 266 F 10 to 130 C 14 to 266 F 10 to 130 C 99 to 252 F 55 to 140 C 14 to 266 F 10 to 130 C Adjust Menu 1 of 2 STGMODE BOIL TARGET TARGET TANK OUTDR DSGN F F Description Sets the operat
10. OUTDR DSGN temperature WARM WEATHER SHUT DOWN WWSD When the outdoor air temperature rises above the WWSD setting the BC 1 turns on the WWSD segment in the display When the control is in Warm Weather Shut Down the Dem segment is displayed if there is a heat demand However the control does not oper ate the heating system to satisfy this demand The control does respond to a setpoint demand and operates as described below RESET OVERRIDE SETPOINT DEMAND A setpoint demand is required whenever heat is required for the setpoint load The setpoint demand overrides the reset water temperature A setpoint demand is generated when a voltage of 24 V ac is applied across the CD common demand and the Set D setpoint demand terminals Once voltage is applied the BC 1 turns on the Setp Dem pointer in the display The BC 1 closes the Pmp Pmp contact which starts the boiler pump and the control turns on the boiler pump segment in the display The BC 1 then operates the boiler stages to maintain the programmed boiler target temperature The reset override operation is not affected by WWSD If both Heat Demand and Setpoint Demand are present at the same time the controller targets the higher termperature of the two requirements A switching external pump relay e g tekmar Relay 003 should be used to stop hot water flow to the space heating loop e g radiant in floor and redirect it to the DHW heating loop during a setpoint demand 7 Section
11. an adjustment to a setting in the control begin by selecting the Adjust menu by pressing and holding simultaneously all three buttons Then select the desired item F using the Item button Finally use the A or VW 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 Description of Display Elements Item Field Number Field Displays an abbreviated Displays the current value name of the selected item of the selected item OUTDR DSGN DIFE Displays the STARTMINMAX ae m mc ioe TARGETMASS ATONOFFDLY WWSD Ci 34 TANK STGMODE g Dem BOILSUPINOUT j 7 DI c Menu Field L Setp Dem 2 Buttons I O A y Ta eg Selects Menus Items and tae ae ni ea adjusts settings status of the control s inputs outputs and operation Symbol Description Pump ae pe P Displays when the boiler pump is in F C Unii E operation SO 12 Stage Pointer E Displays when the stage 1 and or 2 3 4 p Displays the operation as indicated by 3 4 relay is turned on the text Sequence of Operation Section A Section B Section C Section D Section E General Setpoint Dedicated Outdoor External Boiler Operation Operation l DHW Reset Operation Page
12. at demand and a setpoint demand are present at the same time the control targets the higher of the two requirements Refer to section D for a description of outdoor reset operation Mode 5 MODE 5 Mode 5 is designed for outdoor reset and reset override operation using primary secondary piping Once a heat demand is present the control operates the boiler stages to maintain an outdoor reset temperature at the boiler supply sensor Once a setpoint demand reset override is present the control operates the boiler stages to maintain a setpoint temperature at the boiler supply sensor If both a heat demand and a setpoint demand are present at the same time the control targets the higher of the two requirements Refer to section D for a description of outdoor reset operation 4 Mode 6 MODE 6 Bojer Outlet Bojer Outlet Mode 6 is designed for external boiler control This mode of opera D tion allows for an external control to operate multiple boilers equipped with a BC 1 The BC 1 is used to provide boiler pump control Once a heat demand is present the control closes the Stg 1 Stg 1 contact and operates the boiler pump Refer to section E for a description of external boiler operation BOILER DIFFERENTIAL DIFF An on off heat source must be operated with a differential in order to prevent short cycling The boiler differential is divided around the boiler target temperature The first stage contact will clo
13. ceceenveteeeseecesesterernade Pg 8 User Interface The BC 1 uses a Liquid Crystal Display LCD as a method of supplying information You use the LCD in order to setup and monitor the operation of your system The BC 1 uses three push buttons Item A W for selecting and adjusting settings As you program your control record your settings for future reference A table showing default settings is found in the second half of this brochure Menu All of the items displayed by the control are organized into two menus These menus are listed on the upper right hand side of the display Menu Field The default menu for the BC 1 is the View menu While in the View menu the VIEW segment is displayed To ltem A Vv select the Adjust menu press and hold simultaneously all three buttons for 1 second F The display then advances to the Adjust menu and the ADJUST segment is turned on in F the display The display will automatically revert back to the View menu after 20 seconds of keypad inactivity Once in a menu there will be a group of items that can be viewed within that menu Item ltem y The abbreviated name of the selected item will be displayed in the item field of the dis F play To view the next available item press and release the Item 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 Adjust ltem A y To make
14. d by the user or installer The control is no longer able to read the boiler outlet sensor due to a short circuit In this case if the boiler inlet sensor is present and operational the control will operate using the boiler inlet sensor Oth erwise the control will not operate the boiler stages The control is no longer able to read the boiler outlet sensor due to an open circuit In this case if the boiler inlet sensor is present and operational the control will operate using the boiler inlet sensor Oth erwise the control will not operate the boiler stages The control is no longer able to read the boiler inlet sensor due to a short circuit In this case the con trol will continue operation The control is no longer able to read the boiler inlet sensor due to an open circuit In this case the control will continue operation pana The control is no longer able to read the boiler supply sensor due to a short circuit In this case if the boiler outlet sensor is present and operational the control will operate based on the boiler outlet sensor If the boiler outlet sensor is not available and the boiler inlet sensor is present and operational the con trol will operate using the boiler inlet sensor Otherwise the control will not operate the boiler stages ROISUP The control is no longer able to read the boiler supply sensor due to an open circuit In this case if the boiler outlet sensor is present and operational the contr
15. e length of time that the boiler pump continues to run is based on the pump DLY setting Once the last stage of the boiler turns off the control keeps the boiler pump running for the time selected This setting allows purging of any excess heat out of the boiler after the boiler is shut off This also helps to prevent the water in the boiler from flashing into steam after the boiler is shut off When OFF is selected there is no purging When ON is selected pump operation is continuous Also during outdoor reset and the pump DLY is set to ON the pump continues to run even during Warm Weather Shut Down Section B Setpoint Operation When either mode 1 or 2 is selected the BC 1 controls the water temperature based on a fixed setpoint The setpoint temperature is set using the BOIL TARGET item in the Adjust menu HEAT DEMAND A heat demand is required whenever heat is required for the setpoint load A heat demand is generated when a voltage of 24 V ac is applied across the CD common demand and the Hf D heat demand terminals Once voltage is applied the BC 1 turns on the Dem segment in the display The BC 1 closes the Pmp Pmp contacts which starts the boiler pump and the control turns on the boiler pump segment in the display The BC 1 then operates the boiler stages to maintain the setpoint temperature Section C Dedicated Domestic Hot Water DHW Operation When mode 3 is selected the BC 1 provides dedicated DHW operation An indirect ho
16. f the Sequence of Operation as this contains important information on the overall operation of the control Then read the sub sections that apply to your installation The Control Settings section starting at DIP Switch Settings of this brochure 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 Table of Content cssccsssssseessesseeserneeees Pg 2 User Inte rfacCe ccccccececececececcenscecececeuecncecsuances Pg 2 Testing PRP EEE REECE EERE EEE EEE EE Cee Ee CE OES Se Eee eee EE Tee Pg 9 Description of Display Elements Pg 3 Control SettingS cs ceecesssseeeeeeeseeneees Pg 11 Sequence of Operation s scsssseesseeseeees Pg 4 DIP Switch Setting Pg 11 Section A General cecccccccececcccceccccececececes Pg 4 View Menu 1 1scccecceeneneeneneeeeeeeenesnsenenenes Pg 11 Section B Setpoint sseeeeeeeeeeeeees Pg6 Adjust Menu cccecceecceeeeeeseeeeeeenenes Pg 12 Section C Dedicated DHW ecececcccceceeeeee Pg7 Error M SSaQes scecceeceeeeeeseeeenneneneeeeees Pg 14 Section D Outdoor R SChexenccccoccceceeneee Pg7 Typical Applications ccccccessesseeseeeeereee Pg 15 Section E External Boiler 22 2 lt 0 0000 Pg 8 Technical Data 2 ccccccccsieccsccccsseeeeccesseeeee ste Pg 16 InSta lation ie lt ccsscnscccidseeecede
17. ge of 24 V ac is applied across the CD common demand and the Ht D heat demand terminals Once voltage is applied the BC 1 turns on the Dem segment in the display If the BC 1 is not in warm weather shut down WWSD it closes the Pmp Pmp contact which starts the boiler pump and the control turns on the boiler pump segment in the display The BC 1 then operates the boiler stages to maintain the boiler target temperature BOILER START BOIL START The BOIL START temperature is the theoretical boiler supply water temperature that the ese o heating system requires when the outdoor air temperature equals the OUTDR START tem perature setting The BOIL START is typically set to the desired building temperature OUTDR 8 OUTDOOR START OUTDR START DSGN 2 The OUTDR START temperature is the outdoor air temperature at which the control pro vides the BOIL START water temperature to the system The OUTDR START is typically H a set to the desired building temperature F OUTDOOR DESIGN OUTDR DSGN START a The OUTDR DSGN is the outdoor air temperature that is the typical coldest temperature Decreasing Outdoor Temperature of the year where the building is located This temperature is used when doing heat loss calculations for the building BOILER DESIGN BOIL DSGN The BOIL DSGN temperature is the water temperature required to heat the boiler zones when the outdoor air is as cold as the
18. hat system and to ensure compliance with building and safety code requirements Outdoor m Sensor Gl Thermostat 7 He HEE n i R i a F Boil Out Boil Out Sensor Sensor Boil In Sensor i Boil In Sensor i EEEEECEEEEELIT feretrerret te a CELECEEEE TI A a T MODE 2 MODE 5 Outdoor E Sensor a n z Boiler Boil Out j 7 a Boil Out j Supply Sensor Sensor P Supply Sensor Sensor a A d i Boil In Sensor Boil In Sensor Tekmar Controller Outdoor m Sensor Boiler Out F Boiler Out Sensor S F Boil Out Sensor Boil In Sensor _ mi Sensor Boiler Supply Sensor Boiler In Boiler In H a Sensor Sensor snnnonnunnnnnnnnnnnnn anshnnnnnnnonnnnnnnnN Technical Data BC 1 Control Microprocessor PID control This is not a safety limit control Enclosure Enclosure D black Noryl plastic Dimensions 4 3 4 H x 2 7 8 W x 1 7 8 D 120 x 74 x 48 mm Approvals CSA C US meets ICES amp FCC regulations for EMI RFI Ambient conditions Power supply Pump Stage relay Stage 2 Stage 3 relays Alarm relay Demands Sensors included Optional devices Indoor use only 40 to 140 F 40 to 60 C lt 90 RH non condensing
19. he system The operating sensor in primary secondary piping applications is the boiler supply sensor ensor Mode 1 MODE 1 Mode 1 is designed for setpoint operation using parallel piping Once a heat demand signal is present the control operates the boiler stages to maintain a fixed temperature at the boiler outlet sensor Refer to section B for a description of setpoint opera tion Mode 2 MODE 2 Mode 2 is designed for setpoint operation using primary secondary piping Once a heat demand signal is present the control operates the boiler stages to maintain a fixed temperature at the boiler supply sensor Refer to section B for a description of setpoint operation Boiler Outlet Sensor Mode 3 MODE 3 Mode 3 is designed for dedicated DHW operation using parallel piping The control oper ates the boiler stages based on the boiler outlet sensor to maintain a tank temperature at the DHW sensor Refer to section C for a description of dedicated DHW operation To mH M Boiler Inlet Mode 4 MODE 4 Mode 4 is designed for outdoor reset and reset override operation using parallel piping Once a heat demand is present the control operates the boiler stages to maintain an outdoor reset temperature at the boiler outlet sensor Once a setpoint demand reset override is present the control operates the boiler stages to maintain a setpoint temperature at the boiler outlet sensor If both a he
20. iler outlet sensor is required for every mode of operation Boiler Inlet Sensor Connect the two wires from the Boiler Inlet Sensor 071 to the Com common sensor and Boil in boiler inlet sensor terminals 9 and 8 The boiler inlet sensor is used by the BC 1 to measure the boiler inlet water temperature to the boiler Note The boiler inlet sensor is required for every mode of operation Boiler Supply DHW Sensor Boiler Outlet Sensor 22 21 20 Stg3 19 Stg 3 18 Stg 2 17 Stg 2 16 Stg 1 15 Stg 1 9 Com 7 Boil O SPE 8 Boil in Boiler Inlet Sensor Either a Boiler Supply Sensor 071 or DHW Sensor 071 may be connected to the BC 1 If a sensor is used connect the two wires from the sensor to the Com common sensor and Sup D boiler supply DHW sensor terminals 4 and 6 6 Sup D 4 Com Boiler Outlet Sensor Sensor Sensor Inlet Sensor TESTING Boiler Outlet Supply Boiler Inlet 6 Sup D Boiler Sensor 4 Com The wiring harness must be unplugged from the connector on the control before testing To remove the wiring harness push down on the tab which fits over the tab on the connector from the control and pull away form the control The following tests are performed using standard testing practices a
21. ing mode for the control Selects the staging operation to be either automatic or manual MODE 1 2 3 4 5 Minimum boiler target temperature during reset over ride setpoint or DHW operation MODE 1 2 3 4 5 Sets the DHW storage tank s temperature MODE 3 Sets the differential for the DHW storage tank MODE 3 The outdoor starting temperature used in the reset ratio for the heating system MODE 4 5 The design outdoor air temperature used in the heat loss calculations for the heating system MODE 4 5 The starting water temperature used in the reset ratio calculation for the heating system MODE 4 5 The design water temperature used in the heat loss calculations for the heating system MODE 4 5 The maximum boiler target water temperature MODE 1 2 3 4 5 The minimum temperature allowed for the boiler target temperature MODE 1 2 3 4 5 12 Default Setting PID automatic staging P manual staging OFF 70 to 210 F OFF 21 to 99 C OFF 70 to 210 F OFF 21 to 99 C 2 to 10 F 1 to 6 C 35 to 85 F 2 to 29 C 60 to 32 F 51 to 0 C 35 to 150 F 2 to 66 C 70 to 210 F 21 to 99 C 120 to 210 F 49 to 99 C OFF 80 to 180 F OFF 27 to 82 C Adjust Menu 2 of 2 Default D b gi escription Setting The differential that the control is to use when it is 2 to 42 F operating the boiler oe 1 to 23 C 20
22. interstage delay off minimum on time and minimum off time of the stages when PID staging is used A higher thermal mass setting provides slower staging while a lower thermal mass provides faster staging T BOIL MAX BOILER MINIMUM BOIL MIN The BOIL MIN is the lowest water temperature that the control is allowed to use as a boiler target temperature During mild condi tions if the BC 1 calculates a boiler target temperature that is below the BOIL MIN setting the boiler target temperature is adjusted to at least the BOIL MIN setting During this condition if the boiler is operating the MIN segment turns on in the LCD while the boiler target temperature or boiler operating sensor temperature is viewed Increasing Water Temperature i Decreasing Outdoor Temperature gt BOILER MAXIMUM BOIL MAX The BOIL MAX is the highest water temperature that the control is allowed to use as a boiler target temperature If the control does target BOIL MAX and the boiler outlet sensor is near the BOIL MAX temperature the MAX segment turns on in the LCD while the boiler target boiler inlet boiler outlet or boiler supply temperature is viewed The control sequentially shuts off stages in advance of the boiler outlet temperature reaching the boiler maximum Boiler maximum overrides operational and time delays BOILER TARGET TEMPERATURE BOIL TARGET The boiler target
23. is an isolated contact it may switch a voltage between 24 V ac and 120 V ac Boiler Contacts The Sig 1 Stg 1 Stg 2 Stg 2 and Stg 3 Stg 3 terminals 15 and 16 17 and 18 19 and 20 are isolated outputs in the BC 1 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 the boiler circuit When the BC 1 requires boiler stages to energize fire it closes the contact between the appropriate terminals Alarm Contact The Alarm terminal 23 on the BC 1 is a powered output When the relay contact in the BC 1 closes 24 V ac from the R terminal 24 is provided to the Alarm terminal 23 To operate the alarm connect one side of the alarm circuit to the Alarm terminal 23 and the second side of the alarm circuit to the common C side of the 24 V ac power supply Sensor and Unpowered Input Connections Do not apply power to these terminals as this damages the control Outdoor Sensor Connect the two wires from the Outdoor Sensor 070 to the Com common sensor and Os outdoor sensor terminals 4 and 5 The outdoor sensor is used by the BC 1 to measure the outdoor air temperature Boiler Outlet Sensor Connect the two wires from the Boiler Outlet Sensor 071 to the Com common sensor and Boil O boiler outlet sensor terminals 9 and 7 The boiler outlet sensor is used by the BC 1 to measure the boiler outlet water temperature from the boiler Note The bo
24. n 165 F 74 C until the temperature drops the interstage differential below the tem 163 F 73 c perature at which the previous stage turned on The interstage differ ential is adjustable through the STG DIFF setting in the Adjust menu 160F 71 C Interstage Delay On ON DLY The interstage delay on is the amount of time that must elapse before turning on the next stage Once a stage turns on the next 153 F 67 0 7 7 as po nnn nnn nm stage cannot turn on until the interstage delay on time elapses The interstage delay on is adjustable through the ON DLY setting in the Adjust menu Interstage Delay Off OFF DLY The interstage delay off is the amount of time that must elapse before turning off the next stage Once a stage turns off the next stage cannot turn off until the interstage delay off time elapses The interstage delay off is adjustable through the OFF DLY setting in the Adjust menu Minimum On Time MIN ON The minimum on time is the minimum amount of time that a stage must be on before it is allowed to turn off Once a stage turns on it cannotturn off until a minimum on time elapses The minimum on time is adjustable through the MIN ON setting in the Adjust menu Minimum Off Time MIN OFF The minimum off time is the minimum amount of time that a stage must be off before it is allowed to turn on Once a stage turns off it cannot turn on until a minimum off time elapses The minimum off time is adjustable through
25. nd procedures and should only be carried out by properly trained and experienced persons A good quality electrical test meter capable of reading from at least 0 300 V ac and at least 0 2 000 000 Ohms is essential to properly test the wiring and sensors 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 rec ommended for ease of use and accuracy First measure the temperature using the ther mometer and then measure the resistance of the sensor at the control Using the chart below estimate the temperature measured by the sensor The sensor and the thermom eter readings should be close If the meter reads a very high resistance there may be a broken wire a poor wiring connection or a defective sensor If the resistance is very low the wiring may be shorted there may be moisture in the sensor or the sensor may be defec tive To test for a defective sensor measure the resistance directly at the sensor location 9 if Af 9 Com 8 Boil in Resistance Temperature Resistance Temperature Resistance Temperature Resistance Q 490 813 336 606 234 196 165 180 118 018 85 362 62 465 Test the Power Supply ILV Make sure exposed wires and bare terminals are not in contact A with other wires or grounded surfaces Tu
26. ol will operate based on the boiler outlet sensor If the boiler outlet sensor is not available and the boiler inlet sensor is present and operational the con trol will operate using the boiler inlet sensor Otherwise the control will not operate the boiler stages The control is no longer able to read the outdoor sensor due to a short circuit In this case the control assumes an outdoor temperature of 32 F and continues operation The control is no longer able to read the outdoor sensor due to an open circuit In this case the control assumes an outdoor temperature of 32 F and continues operation The control is no longer able to read the tank sensor due to a short circuit In this case the control will not operate the boiler stages The control is no longer able to read the tank sensor due to an open circuit In this case the control will not operate the boiler stages Applications Mechanical The following are only mechanical and electrical concept drawings not engineered drawings They are not intended to describe a complete system nor any particular system It is up to the designer to determine the necessary components for and configura tion of the particular system being designed including additional equipment isolation relays for loads greater than the control s specified output ratings and any safety devices which in the judgement of the designer are appropriate in order to properly size configure and design t
27. rn on the power and mea VJ 2 sure the voltage between the C and R terminals 12 and 24 using ry an AC voltmeter the reading should be between 22 and 26 V ac aw 22 to 26 V ac Test the Powered Inputs Heat Demand _ _ If a heat demand is used measure the voltage between the CD V common demand and the Ht D heat demand terminals 1 and 2 When the heat demand device calls for heat you should measure vo Q between 20 and 260 V ac at the terminals When the heat demand device is off you should measure less than 5 V ac a Setpoint Demand 20 to 260 V ac If a setpoint demand is used measure the voltage between the CD common demand and the Set D setpoint demand terminals 1 and 3 When the setpoint demand device calls for heat you should 2 HtD measure between 20 and 260 V ac at the terminals When the cD setpoint demand device is off you should measure less than 5 V ac Connecting the Control Make sure all power to the devices and wiring harness is off Reconnect the wiring harness to the connector on the control by aligning the tab on the wiring harness to the tab on the connector on the control and then pushing the wiring harness into the connector on the control The tab on the wiring harness should snap over the tab on the connector of the control Apply power to the control The operation of the control on power up is described in the Sequence of Operation section of the
28. se when the water 160 F 71 C Target temperature Differential 10 F all temperature at the operating sensor is 1 2 of the differential setting 165 F 74 C 7 aa a EEE below the boiler target temperature and will open when the water tem Supply Water Temperature perature at the operating sensor is 1 2 of the differential setting above F CTO the boiler target temperature The remaining stages will operate sequen 455 F 68 c 3 tially based on the staging mode selected Time T STAGING MODE STGMODE The BC 1 controls can operate up to four stages in order to supply the required target temperature The method of staging used by the control is either P proportional or PID proportional amp Integral amp Derivative and is selected using the STGMODE item in the Adjust menu PID is recommended and it is the default setting Proportional P Proportional staging also known as step staging is based on manually adjusted settings which determine when the next stage is required to turn on These manual settings are based on temperature and time The interstage differential sets the temperature drop at which the next stage turns on However in order for a stage to fire the interstage delay on and minimum off times must first elapse Interstage Differential STG DIFF ea The interstage differential is the temperature drop at which the next stage will turn on Once a stage turns on thenextstage cannotturno
29. t water tank must be used INTERNAL DHW DEMAND Asensor is required to be connected on the Comand the Sup D terminals An internal demand for DHW is generated when the tem perature at the DHW sensor drops 1 2 of the tank differential setting below the desired DHW tank temperature The TANK TARGET setting is used to set the desired DHW tank temperature Once an internal demand is generated the Dem segment turns on in the LCD The BC 1 then closes the Pmp Pmp contact which starts the boiler pump and the control turns on the boiler pump segment in the display The BC 1 then operates the boiler stages to maintain the programmed boiler target temperature at the boiler outlet sensor The boiler target temperature is set using the BOIL TARGET item in the Adjust menu Note An external demand is not required in this mode of operation TANK DIFFERENTIAL TANK DIFF Adifferential setting that operates 1 2 above and below the TANK TARGET is selectable using the TANK DIFF item in the Adjust menu Section D Outdoor Reset Operation When either mode 4 or 5 is selected the BC 1 uses outdoor reset to control the water temperature Outdoor reset adjusts the target temperature based on the outdoor air temperature and reset ratio The reset ratio is determined from the Boiler Start Boiler Design Outdoor Start and Outdoor Design settings HEAT DEMAND A heat demand is required whenever heat is required in the system A heat demand is generated when a volta
30. the MIN OFF setting in the Adjust menu Boiler Differential 155 F 68 C Interstage Differential 2F Proportional amp Integral amp Derivative PID PID staging allows the control to determine when the next stage is required to turn on The BC 1 automatically determines the settings that are manually selected in proportional staging mode After each stage is turned on in the firing sequence the control waits a minimum amount of time before turning on the next stage After the minimum time delay between stages has expired the BC 1 examines the control error to determine when the next stage is to fire The control error is determined using PID logic Proportional compares the actual operating sensor temperature to the boiler target temperature The colder the temperature the sooner the next stage is turned on Integral compares the actual operating sensor temperature to the boiler target temperature over a period of time Derivative determines how fast or slow the operating sensor temperature is changing If the temperature is increasing slowly the next stage is turned on sooner If the temperature is increasing quickly the next stage is turned on later if at all 5 Boiler Mass BOIL MASS The boiler mass setting allows the installer to adjust the control to the thermal mass of different types of heat sources used The boiler mass setting automatically determines the interstage differential interstage delay on
Download Pdf Manuals
Related Search