Lochinvar Harmony User Manual

Lochinv

INSTALLATION & OPERATION MANUAL

HARMONY

ABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTS

ABLE OF CONTENTSABLE OF CONTENTS

Function Chart................................................pg. 2

Harmony Overview......................................pg. 3

Panel Installation.........................................pg. 4

Using the Menus.....................................pg. 10

System St artup ........................................pg. 11

Operating Settings.....................................pg. 14

System Settings...........................................pg. 17

Stage Settings............................................pg. 22

Reset Settings............................................pg. 25

Troubleshooting.......................................pg. 27

Appendix.....................................................pg. 28

Index..............................................................pg. 30

Specifications................................................pg. 32

This manual attempted to be complete and accurate at the time of publication. Additional upgrades and new features may change Harmony functions. Upgrades to this manual may occur at any time. Contact the factory for further details.

Harmony Function Chart

The digital display shows the system status, set point, lead stage <in brackets>, and status of each stage. To view and adjust settings, press the Adjust/Select button

FULL MODULATION

SEQUENCING CONTROL

Depress the knob to mov forward through the menus and to accept changes, rotate the knob to change a setting's value

Depress the button to go back through the menus, or to view a setting value without changing it

MENU FUNCTIONS

SELECT

enters menus or accepts changes

ADJUST

selects menu items or changes settings

BACK

returns to previous menu

STAGE

selects stage menus or next stage

PREV/NEXT

steps through stage settings

SAFETY GROUND MUST BE

CONNECTED

MADE IN U.S.A.

SIGNAL

BURNER

ACTIVE

SHIELD

DO NOT APPLY ANY VOLTAGE

TO SENSOR TERMINALS

INPUTS

A10

A11

A12

SYSTEM

TEMP

SHUTDOWN

NETWORK

SYSTEM

PROVE

OUTDOOR

TEMP

STAGE

To Temp sensor mounted in common header

When closed, all stages are turned off*

To network sensors** Checks status of system

components* Optional sensor enables

outdoor reset

If input is not made, the Harmony will not consider it an active stage*

Provides remote set

HARMONY

ADJUST

181

PRESS TO

<A> B C D

100 52 OFF STBY

PREV.

SYSTEM

ABCD

STAGEHELP NEXT

C1 C2 C3 C4 C5 C6 C7 C8C9C10 C11 C12

SELECT

BACK

EMS INPUT

point adjustment with

SYS

LINE

NEUTRAL

A B C D

OPERATING LIMIT

OUTPUTS

A B C D

MODULATION OUTPUTS

a 4-20mA signal

Green Ground screw must be connected to Earth Ground

System Output controls pumps, valves or other system components

120VAC

Power

One output relay is required for

Each N.O. output is wired in series with each unit's limit circuit

* DRY CONTACTS ONLY ** Only available with the Remote Communications package

each stage.

The modulation outputs can be 0-5V, 0-10V,

1-5V, 2-10V, or 4-20ma

Different output boards mount on the back of the Harmony and determine the type of output.

Harmony Overview

Sequences up to 4 Fully Modulating Stages

The Harmony is the perfect control whenever multiple fully modulating stages are required. The Harmony controls the on/ off and the modulation of each stage to maintain precise set point control.

PID T ype Logic

The Harmony's control algorithms allow it to look at the rate of change in the system. If the system temperature is changing quickly, the Harmony will react quickly to adjust the modulating stages' output. If the system temperature changes slowly , the Harmony will make slow and gradual adjustments. Therefore, the Harmony adapts to specific system requirements and minimizes fluctuations around the set point.

Controls 0-5 V , 0-10 V, 1-5V , 2-10V, or 4-20 mA modulating motors

The Harmony is designed to accurately control the output from 0 to 100% of modulation for each of these different types of motors. One Harmony can even control two different types of motors.

Only One Sensor

The Harmony requires only one sensor located in the common output header of all stages.

Digital Display of all System Settings

The Harmony's 80 character alphanumeric digital display names each system parameter in plain English and shows its precise value. The easy to follow menu system allows users to quickly make changes to any system setting without having to learn any specialized codes or keyboard commands. Password protection is available to prevent unauthorized users from making adjustments to control settings.

Automatic Rotation among Stages

Rotating the first stage to be activated on a call for output promotes even wear on each stage. The Harmony has three modes of rotation: Manual, First ON/First OFF , or automatically each time period which can be adjusted from every hour to every 7 days.

Outdoor Reset Control

The Harmony has an optional stand-alone hydronic outdoor temperature reset function.

Connects to Energy Management Systems

The Harmony can accept a 4-20 mA input signal from an EMS to adjust the temperature set point according to outdoor temperature, system requirements, or other factors. In addition, Harmony can be disabled by an Energy Management System (EMS) or other controller when there is no output requirement.

Monitors Stage Status

The Harmony is designed to accept a lockout signal from each stage. If any stage requires a manual reset, the Harmony will automatically skip it when adding more capacity . If a stage goes into lockout during normal operation, the next stage will be activated immediately to maintain the desired output capacity .

System Output is Active when Any Stage is Active

This output can be used to activate a system pump, combustion air damper, or perform any other function that is required when any stage is active. A System Prove input checks the status of components activated by the System output before stages can be activated.

Remote Communication Upgrade Available

The Harmony can be upgraded to the V isual Gold system to monitor and control all Harmony functions from a remote location. The Visual Gold upgrade also allows the Harmony to accept additional sensors, to monitor their status, and to provide alarms if the sensor values are not in the correct range.

Additional features include: A purge timer, a low fire adjustment, a firing point setting for the next stage based on the firing rate of the current stage, a lag stage timer, a last stage hold adjustment, and many others.

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INPUT WIRING

INPUT WIRINGINPUT WIRING

SAFETY GROUND MUST BE

CONNECTED

Mounting Holes

LINE

SYS

NEUTRAL

INSTALLATION

MOUNTING THE ENCLOSURE

• Select a location near the equipment to be controlled.

• The surface should be flat, and be sufficiently wide and strong to hold the Harmony.

• Keep the Harmony panel away from extreme heat, cold, or humidity. Ambient operating temperature is from 20 to 120°F .

• Remove the panel from the metal enclosure by removing the top center screw and loosening the two bottom screws. Lift the panel out.

• Screw the enclosure to the surface through the mounting holes in the back of the enclosure.

• Return the panel to the enclosure, replace the top screw, and tighten the bottom two screws.

WIRING THE POWER

• Bring the 120V AC 60Hz power wires through a bottom Knockout

(KO) of the enclosure. The left front KO is preferred.

• Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring.

• Connect the hot line to terminal marked LINE.

• Connect the neutral line to the terminal marked NEUT.

• The green ground screw MUST be connected to earth ground.

INPUTS

A10

Ground

Earth

TEMP

SHUTDOWN

NETWORK

SYSTEM

PROVE

120VAC

60 Hz

To Temperature Sensor Mounted in Common Header

INPUT WIRING

CONNECTING THE SYSTEM SENSOR

• The Harmony is designed to be connected to a temperature sensor for immersion in a 3/8ID well. Contact the factory for additional temperature sensor options.

• Locate the sensor in a common header where it will register the output of all the stages in the flow and after all stages have fed the header. If the sensor can not read the output of all the stages, it will not be able to control the system properly.

• T emperature sensor wires can be extended up to 500’ by splicing with 18 gauge shielded wire (Belden #8760 or equivalent).

• Do not run sensor wire in conduit with line voltage.

• T emperature sensors have no polarity. Connect the wires from the sensor to the Harmony terminals marked TEMP- A1, A2.

• Connect the shield to the circled terminal TEMP-A2 with one of the sensor wires.

Note: Cut the shield wire at the sensor end.

Harmony Sources Curren

24VDC Excitation Voltage

EMS INPUT

(-)

(+)

EMS

Input

SIGNAL

SHIELD

EMS Sourcing Current

EMS INPUT

(-)

(+)

EMS

Input

SIGNAL

SHIELD

CONNECTING AN EXTERNAL SET POINT

(4-20mA EMS-CONTROL)

• The Harmony can take a 4-20mA signal from an Energy Management System (EMS) or other signal source to change the set point remotely (see pg. 28 for additional details).

• The signal must be a two-wire 4-20mA.

• A system sensor must be installed as described in the previous section.

• The External Set Point must be set up correctly (see pg. 12). These settings will allow the Harmony to read and monitor the system temperature and also monitor the 4-20mA input to remotely adjust the Harmony set point to the desired value.

• The Harmony can source the current for the 4-20mA input. It provides an excitation voltage of 24VDC. If using the Harmony to source the power, attach the (+) side of the 4-20mA input to the Harmony EMS terminal marked +. Attach the (-) side of the 4-20mA signal to the EMS terminal marked SIGNAL.

• If the EMS or other signal sources the current (provides the excitation voltage), attach the (+) side of the 4-20mA input to the Harmony EMS terminal marked SIGNAL. Attach the (-) side of the 4-20mA input to the EMS terminal marked SHIELD.

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INPUT WIRING

INPUT WIRINGINPUT WIRING

INPUTS

A10

TEMP

SHUTDOWN

NETWORK

SYSTEM

PROVE

Dry Contact Shutdown Signal

WIRING THE SHUTDOWN

• This feature can be used whenever it is desirable to turn off the Harmony from a remote location or another controller.

• A typical use for this feature would be to turn off all boiler stages when an EMS panel no longer requires heat in the system.

• When the Shutdown feature is enabled by closing a dry contact, all active stages will immediately modulate down to low . They will remain in low for 45 seconds and then turn off.

• If the System Output relay was active, it will remain active until the System Delay is over, then it will also turn off .

• The Shutdown signal must be a dry contact only. No voltage can be placed across the SHUTDOWN terminals.

• Bring the two wires from the dry contact to the terminals marked SHUTDOWN- A3, A4.

WIRING THE SYSTEM PROVE

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INPUT WIRING

INPUT WIRINGINPUT WIRING

INPUTS

A10

TEMP

SHUTDOWN

NETWORK

SYSTEM

PROVE

WARNING: The SYSTEM PROVE

input can not be used as a safety limit. All equipment must have its own certified limit and safety controls as required by local codes.

Dry Contact System Prove Signal

• The System Prove feature is provided to check system component operation.

• A typical use of this feature is to check for flow before firing any boiler stages. When there is a call for heat, the System Output activates the system pump starter. When the pump establishes flow, a flow switch closes together the SYSTEM PROVE input. Only then can the Harmony activate boilers and modulate them as required to hold the temperature set point.

• If the SYSTEM PROVE input is open on a call, the Harmony will enable only the System Output. All Stage outputs will be off when the SYSTEM PROVE input is open.

• A factory installed jumper provides the System Prove signal. Do not remove the jumper unless it will be replaced by a System Prove signal.

• The System Prove signal must be a dry contact only. No voltage can be placed across the SYSTEM PROVE - A9, A10 terminals.

• Bring the two wires from the dry contact to the terminals marked SYSTEM PROVE - A9, A10.

IMPORT ANT : Do not remove the factory installed System Prove

jumper unless it is replaced by a System Prove signal. If the SYSTEM PROVE input is not closed, the Harmony will NOT activate stages.

BOILER

ACTVE

INPUTS

STAGE

Dry Contact Active Signal

WARNING: The BOILER ACTIVE IN-

PUTS can not be used as a safety limits. All equipment must have its own certified limit and safety controls as required by local codes.

WIRING THE BOILER ACTIVE INPUTS

• A closure across the BOILER ACTIVE terminals informs the Harmony that a boiler is running normally. If the BOILER ACTIVE terminals open, the Harmony registers that the Stage has encountered a safety limit and can not be restarted without a manual reset. The Harmony will not reactivate or modulate a Stage which is not Active.

• The Boiler Active signal is not a safety, but use of these inputs will significantly improve the Harmony's set point control performance in the event of a Stage encountering a safety limit.

• A pair of BOILER ACTIVE terminals is provided for each stage.

• The Boiler Active signal must be a dry contact closure from the boiler controlled by that Stage's output. For example, the Boiler Active signal wired into terminals ST AGE A (Terminals B1 and B2) must come from the unit whose operating limits are connected to terminals OPERA TING LIMIT OUTPUTS A (Terminals 5 and 6).

• The BOILER ACTIVE terminals are dry contacts only . No voltage can be placed across the them.

• Wire the Boiler Active signals to their respective STAGE terminals:

- ST AGE A to Boiler Active Input terminals B1&B2

- ST AGE B to Boiler Active Input terminals B3&B4

- ST AGE C to Boiler Active Input terminals B5&B6

- ST AGE D to Boiler Active Input terminals B7&B8

EMS INPUT

SIGNAL

Dry Contact

Setback

Signal

SHIELD

WIRING A SETBACK

• The Setback feature can be used to provide the Harmony with a lower temperature Set Point when less load is required.

• A typical use for Setback is to lower the system temperature during the night or on the weekends when a building is unoccupied, but a minimum level of heat is still required.

• The Setback feature can not be used with External Set Point (4-20mA EMS-control) or Reset operation (see Startup Settings, pg. 11).

• T o adjust the amount of Setback see pg. 19.

• The Setback signal is wired into the EMS terminals (T erminals SIGNAL and SHIELD) .

• The Setback signal must be a dry contact only. No voltage can be placed across the EMS SIGNAL and SHIELD terminals.

• When the EMS SIGNAL and SHIELD are closed, the Setback is enabled and the Harmony will hold the lower Set Point. The lower Set Point will appear on the main display indicating this condition.

• When the closure is removed, the Harmony will revert to the higher saved Set Point.

Note: The Setback is not equivalent to the 4-20mA input, even though

both wire into the EMS terminals. The 4-20mA input requires a 420mA source which changes the Set Point in one degree increments. The Setback provides a single lower Set Point.

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INPUT WIRING

INPUT WIRINGINPUT WIRING

A10

A11

A12

NETWORK

SYSTEM

PROVE

OUT

TEMP

To Outdoor Sensor Mounted in Shade

CONNECTING AN OUTDOOR SENSOR

For Reset Operation

• To enable the reset function, see System Startup settings, pg. 11.

For Outdoor Cutoff

• The Harmony will disable all stages when the outdoor temperature is above the adjustable Outdoor Cutoff temperature.

• This feature will automatically be activated when an outdoor sensor is connected.

• T o adjust the Outdoor Cutof f temperature see pg. 26.

Installing the sensor

• For outdoor sensor use the outdoor sensor.

• Locate the sensor in the shade on the north side of the building

• Be sure the location is out of direct sunlight, and away from doors, windows, exhaust fans, vents, or other possible heat sources

• The sensor should be mounted at least 4 inches away from the building wall and approximately 10 feet above ground level

• The sensor wires can be extended up to 500' using shielded 2 conductor cable (Belden #8760 or equivalent).

• Do not run sensor wires in conduit with line voltage wiring.

• T emperature sensors have no polarity. Connect either wire from the outdoor sensor to one of the Harmony terminals marked OUTDOOR (T erminals A11&A12).

• Connect the other sensor wire to the other OUTDOOR terminal.

• Connect the shield to the circled terminal OUTDOOR (Terminal A12) with one of the sensor wires.

OUTPUT WIRING

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OUTPUT WIRING

OUTPUT WIRINGOUTPUT WIRING

N.O. contacts to activate a pump, valve or other system componen

SYS A B C

NEUTRAL

WIRING THE SYSTEM OUTPUT

System Output Operation in Set Point Mode

• The SYS output relay will energize whenever there is a call for output and the Shutdown feature is not active.

• Until the SYSTEM PROVE input is shorted, no Stages will be activated. If a Prove is not required, the factory installed jumper

should remain.

• The SYS will remain energized while any Stage is active.

• When the last Stage relay turns off, the SYS output can remain energized for the period of time set by the System Run-On (see pg.

19)

• A typical use of the SYS output is to activate a system pump starter. The pump can run whenever there is a call for heat. When heat is no longer required, the pump will stay active for a few more minutes to remove the residual heat from the boilers.

System Output Operation in Reset Mode

• The SYS output relay will energize whenever the outdoor temperature is below the Outdoor Cutoff.

• The SYS will remain constantly energized while the outdoor temperature is below the Outdoor Cutoff.

• When the outdoor temperature rises 2°F above the Outdoor Cutoff, the SYS output will remain energized for the period of time set by the System Run-On (see pg. 19).

Wiring the SYS Output

• The SYS output has one Normally Open (N.O.) relay contact.

• The N.O. contacts are dry contacts only. They do not source any voltage.

• Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring.

• Each N.O. contact is capable of switching 6A resistive at 120VAC.

• T otal output SYS and the OPERATING LIMIT OUTPUTS must not exceed 15A.

WIRING THE STAGE OUTPUTS

Installing the Output Relays

• Each output stage (A through D) which is to be used must have a relay installed in the socket. The SYS relay is included with the Harmony.

• To install a relay, orient the pins and then press it gently into the appropriate socket.

• Any stage output which does not have a relay must have its Mode set to Off (see Stage Settings pg. 22).

SYS A B C D

OPERATING LIMIT

OUTPUTS

Limit Circuit

Wiring the Stage Outputs

• Each Stage output (A through D) has one Normally Open (N.O.)

relay contact.

• The N.O. contacts are dry contacts only. They do not source any voltage.

• Each N.O. contact is capable of switching 6A resistive at 120VAC.

• T otal output of all stages, including the SYS, must not exceed 15A.

• Wire the N.O. relay contacts in series with the boiler’s limit circuit.

• Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring.

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Typical for each stage

4-20 mA

MODULATION OUTPUTS

CommonmACommonmACommonmACommon

C1 C2 C3

- +

4 - 20mA

Motor

C5 C6 C7 C8 C9 C10 C11 C12

C D

WIRING TO 4-20 MA MODULATING MOTORS

• The Harmony can be equipped to operate up to four 4-20 mA modulating motors.

• T o program the control for 4-20 mA output, see System S tartup settings, pg. 12.

• Apply the supplied label marked 4-20 mA below the output terminals.

• The output boards are connected on the rear of the panel.

• The pair of outputs A and B are controlled by a one output board. The pair of outputs C and D are controlled by a second output board.

• The Harmony sources 24VDC excitation voltage for the 4-20mA signal.

• Wire as shown below:

mA Source (+)Common

Harmony

Sources

Current

Stage A Stage B Stage C Stage D

C1 C4 C7

C10

C2 C5 C8

C11

OUTPUT WIRING

OUTPUT WIRINGOUTPUT WIRING

Voltage

MODULATION OUTPUTS

V+

C5 C6 C7 C8 C9 C10 C11 C12

0- 5 V

or 0-10V Motor

BCD

GND

C1 C2 C3

0- 5 V

0-10V

Motor

V+

GND

0- 5 V

or 0-10V Motor

V+

GND

0- 5 V

or 0-10V Motor

WIRING TO VOL TAGE MODULA TING MOTORS

• The Harmony can be equipped to operate up to four 0-5 V, 0-10V, 15V , or 2-10V modulating motors.

• Apply the supplied label marked Voltage below the output terminals.

• The output boards are connected on the rear of the panel.

V+

• To select the range, 0-5V, 0-10V , 1-5V or 1-10V, see pg. 12.

• The pair of outputs A and B are controlled by a one output board. The pair of outputs C and D are controlled by another output board.

• Wire as shown below:

V+GND Stage A Stage B Stage C Stage D

C1 C4 C7

C10

C12

USING MENUS

USING MENUSUSING MENUS

MAKING SELECTIONS

USING THE MENUS

--- LEAD STAGE ---- >A

This pointer shows the currently

B C

BACK

ADJUST

PRESS TO

SELECT

ADJUST

PRESS TO

SELECT

selected item

The BACK button returns to a previous

menu without changing the selection

Pressing

The ADJUST/SELECT knob saves the selection to memory and returns to a previous menu

Rotating

The ADJUST/SELECT knob moves the pointer up and down selections

Example: CHANGING VALUES

--- PURGE DELAY ---

1.0 min

selected item

The Purge Delay is currently 1 minute

The BACK button returns to a previous

BACK

menu without changing the value

MENU TYPES

System Startup Settings - determines the type of system. For example,

the system is a hot water heating system with 0-10V modulating motors. If the Startup Settings are not correct, the Harmony can not operate the system correctly.

Set Point/Gain/Lead Stage Settings - These settings might need

occasional adjustment by operating personnel. These are the only settings which may require changes after the Harmony has been successfully initialized for your specific type of system.

Stage Settings - determine how the individual Stage outputs are

controlled. When installing the panel, each Stage must be set correctly , or the Harmony either will not control the Stage or will control them erratically.

System Settings - determine how the system will operate. These are

general settings which affect all Stages. The default settings will generally work in most applications, but adjustments should be made to fine-tune the performance of your system.

MENU BASICS

• The menus are in English and will guide you through the settings.

• T o change a selection, rotate the black knob marked ADJUST and PRESS TO SELECT (ADJUST/SELECT). Rotating the knob clock- wise will move down the list of possible selections. Rotating the knob counterclockwise will move up the list.

• A pointer in front of a menu line indicates that it is the one currently selected.

• When the pointer is on the same line as the item to be selected, press the black ADJUST/SELECT knob. This will either save the selection, or bring up a new screen to make further changes to that menu item.

• The BACK button will return you to the previous screen without saving any changes made.

ADJUST

The ADJUST/SELECT knob

PRESS TO

SELECT

The screen shows the old and new value

ADJUST

PRESS TO

SELECT

BACK

changes the value - this is indicated by a pointer from the old value to a new value

--- PURGE DELAY ---

1.0 min -> 2.0 min

The ADJUST/SELECT knob saves the new value (2.0 min) to memory and returns to a previous menu

The BACK button returns to a previous

menu without changing the value

Rotating

Pressing

CHANGING SETTINGS

• Some settings require a number, such as time or temperature to be adjusted.

• These screens will be indicated with the title on top and then the current numerical value for that setting.

• To change a selection, rotate the A DJUST/SELECT knob. Rotating the knob will cause a pointer to appear. Both the old and new value will be displayed.

• The BACK button will return you to the previous screen without saving any changes made.

• When the new value (the one being pointed to) is correct, press the ADJUST/SELECT knob. This will save the selection to memory and return you to the previous menu.

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