INSTALLATION/OPERATING INSTRUCTIONS Hot Water Reset
Contents
1. WEIL McLAIN INSTALLATION OPERATING INSTRUCTIONS Hot Water Reset Control For up to 3 Boilers How the BCP 3 operates The BCP 3 establishes ambient comfort by varying the tempera ture of the heating system s circulating hot water in response to changes in the outdoor temperature In addition it provides an outdoor temperature based start stop and system pump control for systems with less than 3 boilers Two sensors are used one to monitor the outdoor temperature and one to monitor the temperature of the circulating hot water in the heating system When the outdoor temperature falls to the outdoor starter setting the heating system is activated and the hot water temperature is increased proportionally to meet the need for more heat Should it get warmer outdoors the hot water temperature is automatically lowered by the control If the outdoor temperature continues to rise to the outdoor starter setting then the heating system is turned off 1 4 1 3 Because of many physical characteristics and the type of even 4 degrees in order to gain the desired comfort level This is known as the reset ratio The middle chart shows the wide range of reset ratios available for the BCP 3 The installer fits the BCP 3 to a specific building by adjusting the reset ratio curve With a curve of 4 2 1 reset ratio a 2 degree change in outdoor temperature will change the circulat ing hot water temperature by 1 degree at an2. For new installations with standard baseboard heating begin with a Reset Ratio curve of 7 For new installations with radiant heat begin with a Reset Ratio curve of 4 or 5 Adjust the Reset Ratio value in cold weather If the ambient indoor temperatures are cold in the cold weather pick the next higher Reset Ratio that is go from 7 to 8 If the ambient building temperatures are warm in the cold weather pick the next lower Reset Ratio After adjusting the Reset Ratio curve wait at least 24 hours before making another adjustment The Reset Ratio can be set from 1 to 12 Default 2 0 Center button pressed six times The Reaction Time controls the minimum run time for any stage When a boiler stage has been added that stage can not be turned off until at least half the Reaction Time has elapsed The Reaction Time must be at least as long as the time it takes for a newly activated stage to start affecting the system If the Reaction Time is shorter than this the BCP 3 may activate additional stages before it can see the impact of each stage For cast iron boilers it is recommended to start with a Reaction Time of 5 0 minutes If the system temperature tends to fluctuate rapidly above and below the Calculated water temperature the Reaction Time may be set too short If the system temperature tends to remain always below the Calculated water temperature the Reaction Time may be set too long When making a change to the Reac
3. Not connected Boiler 2 Boiler 2 Hi Fire Boiler 1 OUTPUT 3 Black Wires System Pump System Pump Boiler 3 System Pum INITIAL CONTROL START UP For C Fahrenheit or Celsius Temperature Operation Default is F b_1 2 3 or 4 Output selection Default is b 3 Minimum Water Temperature Default is 140 F Whenever the BCP 3 is powered up it will display the software version number and then the current operating parameters Each display will remain on the screen approximately 5 seconds If the parameters are correct there is no need to make any adjust ments Once the parameters have been set for a particular application they will be retained in memory and will not need to be reset Note that if you do change an operating parameter you will need to reset all the settings shown on chart on next page An operating parameter can only be changed when it is being displayed in the start up sequence To restart the sequence it is necessary to remove power to the BCP 3 and then power it again Set the operating parameters as described in sequence below If the display shows F then the BCP 3 will operate in Fahrenheit degrees If the display shows C then the BCP 3 will operate in Celsius degrees To change the temperature operation hold down the center button while pushing either the UP or DOWN button to toggle between the displays of F and C When the correct temperature operation is selected release the b
4. energize any stages e The BCP 3 comes equipped with a factory installed jumper across the HEAT DEMAND terminals DO NOT remove this jumper unless it is being replaced by a dry contact switch e This input would typically be provided by a thermostat When the thermostat is satisfied there is no need for heat When the thermostat requires heat the BCP 3 will activate and stage the Outputs to hold the required set point e This input can also be used as a remote stop start for the BCP 3 e When the HEAT DEMAND terminals are first opened all active boiler outputs will immediately turned off However the System Pump output not available in the 3 boiler operating mode will continue to run on for 3 minutes before turning off SYSTEM PUMP OPERATION e The System Pump output is design to continuously circulate the heating water whenever heat is required e The System Pump relay will energize whenever the outdoor temperature is below the Outdoor Starter temperature and the HEAT DEMAND input is closed e When either the outdoor temperature rises above the Outdoor Starter or the HEAT DEMAND input is opened the System Pump will run on for 3 more minutes This removes heat from any boiler stages which were active and circulates it around the system e Ifthe System Pump output has not been activated for 7 days as might occur in the summer the relay will be energized for 15 seconds to exercise the pump e The System Pump output not available in the 3 b
5. stages The Calculated water temperature will read OFF 80 70 60o 50 40 The Outdoor Starter has a built in 2 F differential When the outdoor temperature drops below the Outdoor Starter setting Outdoor Temperature minus the 2 F differential the BCP 3 will compute the Calculated water With a 20 Fine 5 130 1 3 11 temperature and sequence stages to hold that temperature Tune the ratio e If the building is too cold before the system starts raise the Outdoor Starter curves begin at 3 140 temperature 120 Water a aa The Outdoor Starter temperature can be set from 40 to 100 F Temperature 120 Reset Ratio Default is 7 O Ok DOn A Outdoor Temperature Center button pressed five times Reaction Time The Reset Ratio controls how much heat will be added based on outdoor temperature The Reset Ratios are shown as Outdoor Temperature Water Temperature A 1 1 Reset Ratio signifies for each degree it gets colder outside the Calculated water temperature will raise 1 degree The other Reset Ratios are shown on the first page The Reset Ratio curves start at 70 F At 70 F the BCP 3 will require 100 F water Note that this is not the point where the BCP 3 will begin giving heat That point is determined by the Outdoor Starter Also note this starting point can be changed by adjusting the Fine Tune as shown above Finally the Calculated water temperature can never be less than the Minimum Water temperature see pg 4
6. 11 curve 1 3 reset ratio an outdoor change of 1 degree will change the water temperature by 3 degrees Most buildings with baseboard radiation require a curve of 6 7 or 8 Radiant heat applications usually require a lower curve An optional external heat demand input can be connected to the BCP 3 This can be connected to a new or existing thermostat or switch to shut the heating system down when the thermostat is satisfied The BCP 3 can control all the following types of systems one radiation ie baseboard or radiant heat loss varies In one building a 1 degree temperature change outdoors may require a change of 1 degree in heating water temperature for another it may require a change of 2 3 or Water Temperature in F 70 60 50 40 30 20 Outdoor Temperature in F boiler with system pump one lo hi fire boiler with system pump two boilers with system pump or three boilers system pump output must be provided separately 10 0 10 20 WARNING This manual must only be used by a qualified heating installer service technician Failure to comply could result in severe personal injury death or substantial property damage Part Number 550 141 696 1200 1 DEFINITIONS The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product PAW se Be mee Indicates pre
7. Power HEAT SYS COM OUT COM DEMAND NOTE COM terminals are connected internally and are interchangeable Sensor Heat Demand Input Dry Contact Only 2 WIRING THE HEAT DEMAND INPUT e Ifthe HEAT DEMAND inputs are open the BCP 3 will not energize any output stages e The BCP 3 is shipped with a jumper across the HEAT DEMAND inputs DO NOT remove this jumper unless you replace it with a dry contact switch which is closed when heat is required in the system This type of contact is usually provided by a thermostat which activates the BCP 3 when it requires heat e When the HEAT DEMAND inputs are opened all boiler stages are immediately turned off If there is an active System Pump output it will run on for three minutes and then also turn off e The Heat Demand signal must be a dry contact only No voltage can be placed across the HEAT DEMAND terminals e Bring the two wires from the dry contact to the front terminals marked HEAT DEMAND CAUTION WIRING THE POWER INPUTS e Attach 120VAC line voltage to the two blue wires extending from the back of the BCP 3 e Use wire nuts or wrap the connections with electrical tape e Class 1 voltages must enter the enclosure through a different opening from any Class 2 wiring Do not remove the factory installed Heat Demand jumper without installing a Heat Demand switch WIRING THE OUTPUTS The output wires provide a dry contact closure only They do not source an
8. allations After the start up routine has completed the display will show the system water temperature To display the other settings see chart next page repeatedly press the center PRESS TO READ button A setting can only be adjusted when it is being displayed Use the UP and DOWN buttons to adjust the setting The display will always revert back to the actual system water temperature after 30 seconds The default Fine Tune is 0 This means the system target temperature will be 100 F at an outdoor temperature of 70 F as shown on the reset curves on the front page The default Outdoor Starter setting is 60 F When the outdoor temperature is above the Outdoor Starter setting the BCP 3 will not give heat The default Reset Ratio is curve 7 or 1 1 see chart on first page This ratio should be a good Default Display starting point for applications with baseboard or lt lt System Water radiators If the application has radiant heat a Temperature lower numbered reset ratio curve should be selected output The default Reaction Time is 5 minutes This B rf makes the minimum run time for any stage 2 or _ UP P d half the reaction time Press to scroll O gt seLecrsering P eSS and through settings 7 SY A hold to adjust t _ DOWN d AY Q 4 OPERATION DISPLAY SETTINGS Calculated water temperature Center button pressed once Fine Tune Default is 0 This is the water
9. he Calculated water temperature is above the actual Stages should begin to fire No Heat No Outputs Output Light ON All other modes TEMPERATURE VALUE in degrees F in Ohms 0 42683 10 31215 20 23089 25 19939 30 17264 35 14985 40 13040 45 11374 50 9944 55 8714 60 7653 70 5941 80 4649 90 3667 100 2914 110 2332 120 1879 130 1524 140 1243 150 1021 160 842 170 699 180 583 190 489 200 412 Remove any connections to the Black System Pump wires Test for continuity across the System Pump output If the wires are continuous the BCP 3 is calling for the System Pump to run Check the pump to determine why it is not circulating One or more of the Boiler Stages does not fire Lo Hi Fire mode If the red OUTPUT light is not on no stages should be firing If the actual water temperature is above the Calculated water temperature no stages should be firing Otherwise remove all connections to the Red and the Orange output wires and test for continuity If the Red wires are continuous the Lo fire stage should have been running If it wasn t check the boiler It may be off on a boiler limit If the Red and the Orange wires are continuous and the Lo stage was firing check the boiler to determine the fault with the Hi fire circuit One or more of the Boiler Stages does not fire All other boiler modes If the red OUTPUT light is not on no stages should be firing If the actual water temperature is above the Calc
10. n header where it will register the output of all the boiler stages If the sensor can not read the output of all the stages the control will not be able to sequence properly e The sensor wires can be extended up to 500 by splicing with 18 gauge shielded wire e Do notrun sensor wire in conduit with line voltage e The sensor has no polarity Connect either sensor wire to the front terminal marked SYS e Connect the other sensor wire and the shield where needed to a front terminal marked COM INSTALL THE OUTDOOR SENSOR e Locate the sensor in the shade on the north side of the building e Be sure the location is away from doors windows exhaust fans vents or other possible heat sources e The sensor should be mounted at least 4 inches away from the building wall and approximately 10 feet above ground level e The sensor wires can be extended up to 500 by splicing with 18 gauge shielded wire e Do not run sensor wire in conduit with line voltage e The sensor has no polarity Connect either sensor wire to the front terminal marked OUT e Connect the other sensor wire and the shield where needed to a front terminal marked Heating System Outdoor Sensor Output 473 BLACK Output ORANGE C Computed Temp DY Output O Outdoor Temp d UP N r F Fine Tune a SA O SELECT SETTING G Outdoor Starter XY G l N C 2own RSA r Reset Ratio rel Reaction Time NS 120VAC
11. nt For example if the Calculated water temperature were 150 F based on the specific outdoor temperature and Reset Ratio then increasing the Fine Tune from 0 F to 10 F would increase the Calculated water temperature to 160 F oe DISPLAY Press and hold either the UP or DOWN button to adjust the value E This is the water temperature the BCP 3 will control boilers to hold Itis based on Once c ted the outdoor temperature reset ratio and the fine tune value If ON is shown there pute is a sensor fault If OFF is shown there is no call for heat gt k 0 ka Twice Outdoor Temp This is the outdoor sensor temperature value J The Fine Tune moves the reset curves vertically up or down For example 3 Times F changing the offset from 0 to 10 will decrease the water temperature 10 Fine Tune regardless of outdoor temperature or the reset curve selected The Fine Tune is adjustable from 40 to 40 F 5 When the outdoor temperature falls below the Outdoor Starter setting the BCP 3 will 4 Times Outd give heat When the outdoor temperature is above the Outdoor Starter the ae SEA Calculated value will be OFF and no stages will be activated The Outdoor Starter aner is adjustable from 40 to 100 F The Reset Ratio controls the amount of heat which enters the heating system based 5 Times Ir on the outdoor temperature A higher numbered Reset Ratio will result in a higher Reset Ratio Calculated water temperature See the cha
12. oiler operation mode TROUBLESHOOTING No Display or Display of 888 Check the power to the BCP 3 The BCP 3 requires 120VAC power to the blue wires Turn the power off and back on to restore display Actual or Outdoor Display shows OPN Check that the wires from the sensor are continuous to the BCP 3 Then follow the procedure for Incorrect Temperature Display Actual or Outdoor Display shows SHT The BCP 3 sees a short across the input terminals Remove the wires from the input terminals The display should change to read OPN If it doesn t the BCP 3 may be damaged Actual or Outdoor Display shows an Incorrect Temperature Display Remove the wires from the input terminals The display should change to read OPN If it doesn t the BCP 3 may be damaged Take an ohm reading across the detached sensor wires The ohm reading should correspond to the chart at right If it doesn t the sensor may be damaged No Heat No Outputs Output Light OFF Check the outdoor temperature and Outdoor Starter readings If the outdoor tempera ture is above the Outdoor Starter the BCP 3 will not give heat Then check the HEAT DEMAND terminals If the HEAT DEMAND terminals are not jumped together the BCP 3 will not give heat No Heat No Outputs Output Light ON 3 Boiler Mode Check if the actual water temperature is above the Calculated water temperature If it is wait until the actual water temperature falls or increase the Fine Tune value until t
13. rt on the first page for the reset curves The Reset Ratio is adjustable from 1 to 12 6 Times rC The Reaction Time controls the minimum run time for a stage Itis adjustable from Reaction Time half a minute 0 5 to 8 0 minutes 7 Times Default The BCP 3 returns to the default display of actual system water temperature These values can not be adjusted 5 In a new installation start with a Fine Tune value of 0 Adjust the Fine Tune value in mild weather If the ambient indoor tempera l 130 1 3 1 1 tures are warm in the warm weather decrease the Fine Tune If the ambient With a 0 Fine building temperatures are cold in the mild weather increase the Fine Tune une Sue ratio 120 The rule of thumb for baseboard radiation is to change the Fine Tune by 4 SRR or for every degree you wish to change the building temperatures For radiant Temperature ne 4 1 heat applications change the Fine Tune by 1 or 2 for every degree you 100 wish to change the building temperature 70 60 50 40 The Fine Tune can be set from 40 to 40 F g i 1 1 Outdoor Starter Default is 60 F With a 20 Fine 5110 1 Center button pressed four times Tune the ratio a oi e The Outdoor Starter sets at what outdoor temperature the BCP 3 will begin curves begin at s heating 80 Water 5 9 Temperature 4 1 e When the outdoor temperature is above the Outdoor Starter setting the BCP 3 will not activate
14. sence of hazard which can cause severe personal injury death or substantial property damage if ignored Indicates presence of hazard which will or can cause minor personal injury or property damage if ignored CAUTION WARNING The Weil McLain BCP 3 is strictly an operating control do not use as limit s or safety control s Each boiler must have its own certified limit and safety controls as required by codes These controls are the responsibility of the installing contractor He must verify proper operation and correct any safety problems before installing the BCP 3 Failure to follow all instructions in proper order can cause severe personal injury death or substantial property damage Read all instructions before installing Weil McLain BCP 3 INSTALLATION MOUNTING THE CONTROLLER e The BCP 3 is designed to mount on a standard 1900 4 x4 electrical box not supplied e If panel mounting or if additional room is needed for wiring an extension skirt is available e Locate the BCP 3 in a convenient location near the unit to be controlled e Mount the unit away from excessive heat or cold Ambient operating temperature is from 20 to 120 F e After completing all the wiring connections see below use the two screws provided to mount the BCP 3 to the 1900 box INSTALL THE HEATING SYSTEM SENSOR e The BCP 3 heating system sensor is designed to be installed in a 3 8 ID well e Locate the sensor in the commo
15. temperature the BCP 3 will stage units to hold It is based on outdoor temperature and the Fine Tune and Reset Ratio values described in the following sections The Calculated water temperature can not be less than the Minimum Water temperature setting see opposite page If either sensor is reading a fault condition all stages will immediately turn on The Calculated display will show ON to indicate this condition If the outdoor temperature is above the Outdoor Starter setting the BCP 3 will not activate stages The Calculated display will show OFF to indicate this condition The BCP 3 will either add stages subtract stages or maintain the same number of stages to hold the system temperature around the Calculated temperature The Calculated temperature is the average temperature the BCP 3 will maintain The system can be expected to fluctuate above and below this temperature The size of the fluctuation depends on the number of stages the size of each stage the system load and the Reaction Time The Calculated temperature is based on all the settings described above The temperature value can not be changed by pressing the UP or DOWN button while it is displayed Center button pressed three times The Fine Tune value moves the starting point of the Reset Ratio curves see charts on the next page Therefore any change made to the Fine Tune will immediately change the value of the Calculated water temperature by the same amou
16. tion Time wait at least 5 reaction times before making another change The system will need time to settle out The Reaction Time can be set from 0 5 to 8 0 minutes LEAD STAGE ROTATION e For the single boiler and lo hi boiler operating mode when heat is required the first stage brought on is Output 1 see output chart pg 3 e For the 2 and 3 boiler operating modes the lead stage will rotate among the boilers to promote even wear on each unit e The Lead Stage will always be the first stage brought on when there is a call for output e As more output is needed additional stages are added e When less output is needed the additional stages are turned off in the reverse order of how they were added For instance if the stages were added in the sequence 1 2 and 3 then they will be turned off in the sequence 3 2 and finally 1 e Onpower up the lead boiler will always be Output 1 e The Lead Stage will rotate every 24 hours either between Output 1 and 2 for 2 boilers or between Output 1 2 and 3 for 3 boilers OUTPUT LIGHT DISPLAY e The red LED marked OUTPUT indicates when the BCP 3 is in the heating mode The red LED will be off when the outdoor temperature is above the Outdoor Starter or when the HEAT DEMAND input is open e When the outdoor temperature is below the Outdoor Starter and the HEAT DEMAND input is closed the red LED will be on HEAT DEMAND e When the HEAT DEMAND input terminals are open the BCP 3 will not
17. ulated water temperature no stages should be firing Otherwise remember the lead stage will rotate every 24 hours If one boiler is sufficient to hold the actual temperature at or above the Calculated water temperature then the other boiler stages will not be active until the lead changes If no boilers are firing remove all connections to the output wires and check for continuity If any set of wires were continuous that boiler should have been firing Check that boiler REPAIR PARTS 389 900 177 3 8 Brass sensor with plastic wall mount clip This sensor can be used for either system temperature or outdoor temperature
18. uttons and wait approximately 5 seconds If the display shows b_ then the BCP 3 will control 1 On Off Boiler and a System Pump If the display shows b_2 then the BCP 3 will control 2 On Off Boilers and a System Pump If the display shows b_3 then the BCP 3 will control 3 On Off Boilers If the display shows b_4 then the BCP 3 will control 1 Lo Hi Boiler and a System Pump To change the boiler output selection hold down the center button while pushing either the UP or DOWN button to toggle between the displays the boiler outputs When the correct boiler output is selected release the buttons and wait approximately 5 seconds The display will next show the minimum water temperature setting The BCP 3 can not compute a calculated water temperature below this setting and can not have a set point value below this DO NOT lower this below the default setting of 140 F without contacting your Weil McLain representative To change the minimum water temperature hold down the center button while pushing either the UP button to increase the value or the DOWN button to decrease the value When the desired minimum water temperature is selected release the buttons and wait approximately 5 seconds DEFAULT SETTINGS Settings shown in instructions have been selected by Weil McLain and will provide proper operation for many installations The BCP 3 comes equipped with default settings which are a good starting point for most inst
19. y power Each pair of same colored wires are connected internally to a N O relay which is rated at 8 Amp max Total output of all stages must not exceed 15A Class 1 voltages must enter the enclosure through a different opening from any Class 2 wiring For on off single stage boilers wire the appropriate pair of wires in series with the boiler s limit circuit or thermostat wire terminals TT as shown in the chart below e For lo hi fire boilers connect the Red output wires in series with the boiler s limit circuit Connect the Orange output wires to the Hi fire control circuit e Fora System Pump connect the Black output wires to the pump starter Note if there are three boilers the System Pump must be energized by another controller Typical Limit Circuit for ON OFF Boilers Typical Limit Circuit for Lo Hi Boilers ia Internal ols Limit Circuit or pp N O Rel ois TT if available Internal Limit U Relay T on boiler N O Relay Bm Circuit Red Refer to Specific Boiler Wiring Diagram 2322 a inie Internal Hi Fire N O Relay Circuit System Pump C Orahge Refer to Specific Boiler Wiring Diagram Internal N O Relay SYTEM TYPE 1 Boiler amp Pump 2 Boilers amp Pump 3 Boilers 1 Lo Hi Boiler amp Pum To Pump Starter OUTPUT 1 Red Wires Boiler 1 Boiler 1 Boiler 1 Lo Fire Boiler 1 OUTPUT 2 Orange Wires
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