Lochinvar INS7162, TST2313, INS7141, MP2 User Manual

The MP2is capable of controlling the supply water temperature for up to nine ON / OFF stages based on outdoor temperature, control for the Domestic Hot Water (DHW) generation, a set point requirement or optionally an external input signal (0 - 10 V (dc)). Alarge easy to read display provides current system temperatures and operating status (FIG. 1). The control has outputs for a primary pump and a combustion air damper or alarm. Based on the mode of operation selected, the control can operate different combinations of boiler stages and boiler pumps.

ADDITIONAL FUNCTIONS INCLUDE:

• Installer and Advanced Access Levels

• Primary Pump Output

• Individual Boiler Pump Outputs (in applicable modes)

• Pump Exercising

• Pump Purging (primary and boiler)

• Boiler Demand for Space Heating Loads

• DHW Demand for DHW Loads

• Set Point Demand for Set Point Loads

• Test Sequence to Ensure Proper Component Operation

• Setback Input for Energy Savings

• 0 - 10 V (dc) Input Signal

INSTALLATION INSTRUCTIONS

INS7162 Rev-

INTRODUCTION

FIG. 1

Modes 1 Up to 9 On/Off Boilers 2 Up to 4 On/Off Boilers & 4 Pumps 3 Up to 4 Lo/Hi Boilers 4 Up to 3 Lo/Hi Boilers & 3 Pumps 5 Up to 3 Three Stage Boilers 6 Up to 2 Three Stage Boilers & 2 Pumps 7 Up to 2 Four Stage Boilers 8 1 Four Stage Boiler & 1 Pump

This instruction manual is organized into four main sections:

1) Sequence of Operation, 2) Installation, 3) Control Settings, and 4) Testing and Troubleshooting. The Sequence of Operation section has seven sub-sections. We recommend reading Section A: General Operation of the Sequence of Operation, as this contains important information on the overall operation of the control. Followed by the sub-sections that apply to your installation. The Control Settings section (starting at DIP Switch Settings) of this instruction manual 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.

The control uses a Liquid Crystal Display (LCD) as the method of supplying information. The LCD is used in order to setup and monitor the operation of your system. The control has four push buttons ( FIG. 2) for selecting and adjusting settings. As you program your control, record your settings in the ADJUST menu table which is found in the second half of this instruction manual.

All of the items displayed by the control are organized into two menus. These menus are listed on the top left hand side of the display (Menu Field). To select a menu, use the Menu button. By pressing and releasing the Menu button, the display switches between the two menus. Once a menu is selected, there will be a group of items that can be viewed within the menu, see Figure 2.

ITEM

The abbreviated name of the selected item will be displayed in the item field of the display. 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. The items can be quickly scrolled through by holding the Item button and pressing the down arrow button. To rapidly scroll through the items in the reverse order, hold the Item button and press the up arrow button, see Figure 2.

ADJUST

To make an adjustment to a setting in the control, begin by selecting the ADJUST menu using the Menu button. Then select the desired item using the Item button. Finally, use the up arrow button, or down arrow 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, see Figure 2.

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Symbol Description . . . . . . . . . . . . . . . . . . . . . . . . .3

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . .4

Section A: General Operation . . . . . . . . . . .4

Section B: Staging . . . . . . . . . . . . . . . . . . . .6

Section C: Pump Operation . . . . . . . . . . . . .8

Section D: Boiler Reset . . . . . . . . . . . . . . . .9

Section E: DHW . . . . . . . . . . . . . . . . . . . . . .12

Section F: Set Point . . . . . . . . . . . . . . . . . . .14

Section G: External Input . . . . . . . . . . . . . . .15

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . .22

Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

View Menu . . . . . . . . . . . . . . . . . . . . . . . . . .24

Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . .25

Testing the Control . . . . . . . . . . . . . . . . . . . . . . . . .29

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Typical Boiler Installation . . . . . . . . . . . . . . . . . . . . .32

Typical DWH Priority Heating Package System . . .34

Notes Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

USER INTERFACE

DISPLAY

FIG. 2

SYMBOL DESCRIPTION

FIG. 3

Boiler Demand DHW / Setpoint Demand WWSD

External Input Signal Offset

The following defined terms and symbols are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to bring attention to important information concerning the life of the product, see Figure 4 below.

SECTION A: GENERAL OPERATION

OWERING UP THE CONTROL

When the control is powered up, all segments in the LCD are turned on for two seconds. The control displays the control type number in the LCD for two seconds. Next, the software version is displayed for two seconds. Finally, the control enters the normal operating mode.

OPERATION

The control operates up to nine on / off heat sources to control the supply water temperature to a hydronic system. The supply water temperature is based on either the current outdoor temperature, an external 0 - 10 V (dc) or 2 - 10 V (dc) signal, or a fixed set point.

Boiler Reset (Stand Alone)

When a boiler demand signal from the heating system is present, the control operates the boiler(s) to maintain a supply temperature based on the outdoor air temperature and Characterized Heating Curve settings, see Figure 5.

Domestic Hot Water

When a DHW demand signal from a DHW aquastat is present, the control operates the boiler(s) to maintain the supply water temperature at least as hot as the DHW XCHG setting. Refer to section E.

Set Point

When a set point demand signal from a set point system is present, the control operates the boiler(s) to maintain the supply water temperature at least as hot as the SETP setting. Refer to section F.

External Input 0 - 10 V (dc) or 2 - 10 V (dc)

When an external input signal is present, the control converts the signal to a target supply temperature. The control operates the boiler(s) to maintain the required supply water temperature.

SETBACK (UNOCCUPIED)

To provide greater energy savings, the control has a setback feature (FIG. 6). With setback, the supply water temperature in the system is reduced when the building is unoccupied. By reducing the supply water temperature, the air temperature in the space may be reduced even when thermostat(s) are not turned down. Any time the UnO Sw (5) and the Com - (1) are connected, the control operates in the UnOccupied mode. When in the UnOccupied mode, the UNOCC segment is displayed in the LCD. The control adjusts the supply water temperature based on the UNOCC settings made in the control. This feature has no effect when the control is used in the External Input mode.

DEFINITIONS

FIG. 4

SEQUENCE OF OPERATION

FIG. 5

COMBUSTION AIR OR ALARM CONTACT

The control has an isolated contact that can be used as either a combustion air damper contact or an alarm contact. This selection is made using the C. A. / Alarm DIP switch.

Combustion Air (C. A.)

When the DIP switch is set to C. A., terminals 12 and 13 can be used as a switch to operate a combustion air damper. This contact closes prior to the first stage operating on the control. The amount of time that the contact closes prior to the first stage operating is set using the combustion delay setting. The combustion air contact remains closed for a minimum of 15 seconds after the last stage is turned off.

Alarm

When the DIP switch is set to Alarm, terminals 12 and 13 can be used as a switch to operate an alarm circuit. This contact closes whenever an error message is present on the control. When the alarm contact is activated, refer to the Error Messages section of this manual to determine the cause of the alarm. Once the fault has been fixed, the alarm can be cleared by pressing either the Menu, Item, up arrow or down arrow button.

Boiler Alarm

The control can monitor the boiler supply temperature and provide an alarm if the temperature does not increase within a certain amount of time. The amount of time can be set using the Boiler Alarm setting. This alarm can be used to determine if the boilers have failed to fire. To reset the alarm, press and hold the up and down arrow buttons for 5 seconds while in the VIEW menu.

ROTATION

The control's Equal Run Time Rotation function is fixed at 48 hours. The firing order of the boilers change whenever one boiler accumulates 48 hours more running time than any other boiler. After each rotation, the boiler with the least running hours is the first to fire and the boiler with the most running hours is the last to fire. This function ensures that all the boilers being rotated receive equal amounts of use. When the Rotate / Off DIP switch is set to the Off position, the firing sequence always begins with the lowest boiler to the highest boiler, see Figure 7 below.

Fixed Lead Rotation

In some applications, it may be desirable to have the first boiler fire first at all times while the firing sequence of the remaining boilers is changed using Equal Run Time Rotation. This rotation option is selected by setting the Fixed Lead / Off DIP switch to the Fixed Lead position.

First On / Last Off or First On / First Off

When using the Fixed Lead rotation option, a selection must be made between First On / Last Off and First On / First Off using the DIP switch. When First On / Last Off is selected, the lead boiler is always staged on first and staged off last. When First On / First Off is selected, the lead boiler is always staged on first and staged off first. This DIPswitch is only read by the control when the Fixed Lead / Off DIP switch is set to Fixed Lead.

Fixed Last

In some applications, it may be desirable to have the last boiler fire last at all times while the firing sequence of the remaining boilers is changed using Equal Run Time Rotation. This rotation option is selected by setting the Fixed Last / Off DIP switch to Fixed Last. With a fixed last rotation, the last boiler is the last to stage on and the first to stage off.

FIG. 6

FIG. 7

Resetting the Rotation Sequence

To reset the rotation sequence, set the Rotate / Off DIP switch to the Off setting for 5 seconds and then return the DIP switch to the Rotate setting.

RUNNING TIMES

The control displays the accumulated running time of each boiler in the VIEW menu. When using a multi-stage boiler, the running time that is displayed is the total number of running hours of the Lo stage of the boiler.

Resetting the Running Times

To reset the running time for each boiler, select the appropriate running time in the VIEW menu. Next, press the up and down arrow buttons simultaneously until CLR is displayed.

EXERCISING

The control has a built-in exercising feature that is selected through the Exercise / Off DIP switch. To enable the exercising feature set the Exercise / Off DIP switch to Exercise. If exercising is enabled, the control ensures that each pump is operated at least once every 3 days. If a pump has not been operated at least once every 3 days, the control turns on the output for 10 seconds. This minimizes the possibility of the pump seizing during a long period of inactivity. While the control is exercising, the Test LED flashes quickly.

Note: The exercising function does not work if power to the control or pumps is disconnected.

RELOADING FACTORY DEFAULTS

To reload the factory defaults, power down the control for 10 seconds. Power up the control while simultaneously holding the Menu and down arrow buttons. The control will now display the E01 error message. To clear this error message, follow the procedure in the Error Messages section of this manual.

BOILER MINIMUM

The boiler minimum is the lowest temperature that the control is allowed to use as a boiler target temperature. During mild conditions, if the control 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(s) is operating, the minimum segment is turned on in the display when viewing either the boiler supply temperature or the boiler target temperature. Set the BOIL MIN setting to the boiler manufacturer's recommended temperature.

BOILER MAXIMUM

The boiler maximum is the highest temperature that the control is allowed to use as a boiler target temperature. If the control does target the BOIL MAX setting, and the boiler temperature is near the boiler maximum temperature, the maximum segment will be displayed in the LCD while either the boiler target temperature or the boiler supply temperature is being viewed. At no time does the control operate the boiler(s) above 248°F (120°C).

SECTION B: STAGING OPERATION

ECTION B1: STAGING

Mode

The control is capable of staging single stage, two stage, three stage or four stage on / off heat sources. In certain modes of operation the control is capable of controlling the individual boiler pumps. The control has 8 modes of operation based on the type of staging and pump operation that is desired. The following describes the modes of operation:

Mode 1: 9 Single Stage Boilers and a primary pump. Mode 2: 4 Single Stage Boilers with individual boiler pumps

and a primary pump.

Mode 3: 4 Lo/Hi boilers and a primary pump. Mode 4: 3 Lo/Hi boilers with individual boiler pumps and a

primary pump.

Mode 5: 3 Three Stage Boilers and a primary pump. Mode 6: 2 Three Stage Boilers with individual boiler pumps

and a primary pump.

Mode 7: 2 Four Stage Boilers and a primary pump. Mode 8: 1 Four Stage Boiler with a boiler pump and a pri-

mary pump.

FIG. 8

LO / HIORLO / LO

When using multi-stage boilers, a selection must be made regarding the staging order of the boiler(s). This adjustment is made in the ADJUST menu of the control.

Lo / Hi

If the Lo/Hi staging option is selected the control stages in sequence all of the stages in a single boiler. Once all of the stages are turned on, the control then stages in sequence all of the stages in the next boiler in the rotation sequence.

Lo / Lo

If the Lo/Lo staging option is selected, the control stages all of the Lo stage outputs in all of the boilers first. Once all of the boilers are operating on their Lo stages, the control then operates the second stage in each boiler in the same order.

STAGING

The control operates up to nine stages to supply the required temperature. After a stage is turned on in the firing sequence, the control waits for the minimum time delay. After the minimum time delay between stages has expired, the control examines the control error to determine when the next stage is to fire. The control error is determined using Proportional, Integral and Derivative (PID) logic.

Proportional compares the actual supply temperature to the boiler target temperature. The colder the supply water temperature, the sooner the next stage is turned on.

Integral compares the actual supply temperature to the boiler target temperature over a period of time.

Derivative compares how fast or slow the supply water temperature is changing. If the supply temperature is increasing slowly, the next stage is turned on sooner. If the supply temperature is increasing quickly, the next stage is turned on later, if at all.

FIRE DELAY

The Fire Delay is the time delay that occurs between the time that the control closes a stage contact to fire a stage and the burner fires for that stage. The fire delays for the first and third stages in a boiler are adjustable using the F DLY 1 and F DLY 2 settings. The fire delay for the second and the fourth stages is fixed at 10 seconds, see Figure 10 below.

Fire Delay 1

Fire Delay 1 is available in all modes of operation. Fire Delay 1 is the fire delay of the first stage of the boiler.

Fire Delay 2

Fire Delay 2 is only available in the modes of operation for Three and Four Stage Boilers. Fire Delay 2 is the fire delay of the third stage of the boiler.

FIG. 9

FIG. 10

STAGE DELAY

The stage delay is the minimum time delay between the firing of stages. After this delay has expired the control can fire the next stage if it is required. This setting can be adjusted manually or set to an automatic setting. When the automatic setting is used, the control determines the best stage delay based on the operation of the system.

BOILER MASS

The BOIL MASS setting allows the installer to adjust the control to the thermal mass of the type of heat sources used in the application. The BOIL MASS setting also adjusts the minimum inter-stage delay time when operating with an automatic differential.

Lo (1)

The Lo setting is selected if the boiler(s) that is used has a low thermal mass. This means that the boiler(s) has a very small water content and has very little metal in the heat exchanger. A boiler that has a low thermal mass comes up to temperature quite rapidly when fired. This is typical of many copper fin-tube boilers. The Lo MASS setting provides the quickest staging on of boilers.

Med (2)

The Med setting is selected if the boiler(s) that is used has a medium thermal mass. This means that the boiler(s) either has a large water content and a low metal content or a low water content and a high metal content. This is typical of many modern residential cast iron boilers or steel tube boilers. The Med MASS setting stages on additional boilers at a slower rate than the Lo MASS setting.

Hi (3)

The Hi setting is selected if the boiler(s) that is used has a high thermal mass. This means that the boiler(s) has both a large water content and a large metal content. Aboiler that has a high thermal mass is relatively slow in coming up to temperature. This is typical of many commercial cast iron and steel tube boilers. The HI MASS setting stages on additional boilers at the slowest rate.

DIFFERENTIAL

An on / off heat source must be operated with a differential to prevent short cycling. With the control, either a fixed or an auto differential may be selected. The boiler differential is divided around the boiler target temperature. The first stage contact closes when the supply water temperature is ½ of the differential setting below the boiler target temperature. Additional stages operate if the first stage is unable to bring the supply water temperature up to the boiler target temperature at a reasonable rate. As the supply temperature reaches ½ of the differential above the boiler target temperature, stages are staged off.

Fixed Differential

If the user desires to have a fixed differential, this is set using the BOIL DIFF setting in the ADJUST menu (FIG. 11).

Auto Differential

If the Auto Differential is selected, the control automatically determines the best differential as the load changes. This reduces potential short cycling during light load conditions (FIG. 11).

SECTION C: PUMP OPERATION

SECTION C1: PUMP OPERATION PRIMARY PUMP OPERATION

The primary pump operates under the following conditions:

• The control receives a boiler demand and is not in warm weather shut down (WWSD).

• The control receives a DHW demand when DHW MODE is set to 3 or 4.

• The control receives a set point demand and set point MODE is set to 3.

Primary Pump Purge

After a demand is removed, the control continues to operate the primary pump for a period of time. The maximum length of time that the primary pump continues to run is adjustable using the Purge setting. The primary pump continues to run until either the purging time has elapsed or the boiler supply temperature drops more than a differential below the boiler minimum setting, see Figure 12.

FIG. 11

BOILER PUMP OPERATION

In certain modes of operation, the control can operate the individual boiler pumps on each boiler in addition to the primary pump. The boiler pump turns on prior to the boiler firing and continues to run after the boiler is turned off. The amount of time that the boiler pump turns on prior to the boiler firing is determined by the BOIL MASS setting. If a BOIL MASS of Lo is selected, the boiler pump turns on 15 seconds prior to the boiler. If a BOIL MASS of Medium is selected, the boiler pump turns on 22 seconds prior to the boiler. If a BOIL MASS of Hi is selected, the boiler pump turns on 30 seconds prior to the boiler. However, if the control is operating based on a set point demand, the boiler pump turns on 5 seconds prior to the boiler, see Figure 13.

Boiler Pump Purge

The amount of time that the boiler pump continues to run after the boiler turns off is adjustable using the boiler pump purge setting (PURG Boil Pmp).

SECTION D: BOILER RESET OPERATION

ECTION D1: BOILER RESET (STAND ALONE)

BOILER DEMAND

When operating in the stand-alone mode, a boiler demand is required in order for the control to provide heat to the heating system. Aboiler demand is generated by applying a voltage between 24 and 230 V (ac) across the Boiler Demand and Common Demand terminals (6 and 7) (FIG. 14). Once voltage is applied, the Boiler Demand pointer is displayed in the LCD. If the control is not in WWSD, the control closes the primary pump contact. The control calculates a boiler target supply temperature based on the outdoor air temperature and the characterized heating curve settings.

BOILER TARGET TEMPERATURE

The boiler target temperature is determined from the characterized heating curve settings and the outdoor air temperature. The control displays the temperature that it is currently trying to maintain as the boiler supply temperature. If the control does not presently have a requirement for heat, it does not show a boiler target temperature. Instead, "- - -" is displayed in the LCD.

CHARACTERIZED HEATING CURVE

The control varies the supply water temperature based on the outdoor air temperature. The control takes into account the type of terminal unit that the system is using. Since different types of terminal units transfer heat to a space using different proportions of radiation, natural convection and forced convection, the supply water temperature must be controlled differently. Once a terminal unit is selected, the control varies the supply water temperature according to the

FIG. 12

FIG. 13

FIG. 14

type of terminal unit. This improves the control of the air temperature in the building.

BOILER INDOOR DESIGN TEMPERATURE

The indoor design temperature is the room temperature that was used in the original heat loss calculations for the building. This setting establishes the beginning of the characterized heating curve, see Figure 15 below.

OUTDOOR

DESIGN TEMPERATURE

The outdoor design temperature is the outdoor air temperature that is the typical coldest temperature of the year where the building is located. This temperature is used when doing the heat loss calculations for the building. If a cold outdoor design temperature is selected, the boiler supply temperature rises gradually as the outdoor temperature drops. If a warm outdoor design temperature is selected, the boiler supply temperature rises rapidly as the outdoor temperature drops.

BOILER DESIGN TEMPERATURE

The design supply temperature is the supply water temperature required to heat the building when the outdoor air temperature is as cold as the outdoor design temperature.

ARM WEATHER SHUTDOWN

When the outdoor air temperature rises above the WWSD setting, the control turns on the WWSD pointer in the display. When the control is in Warm Weather Shut Down, the boiler demand pointer is displayed if there is a boiler demand. However, the control does not operate the heating system to satisfy this demand. The control does respond to a DHW or set point demand and operates as described in sections E & F.

ROOM

The room is the desired room temperature for the building and provides a parallel shift of the heating curve. The room temperature desired by the occupants is often different from the design indoor temperature. If the room temperature is not correct, adjusting the ROOM setting increases or decreases the amount of heat available to the building. A ROOM setting is available for both the occupied (day) and unoccupied (night) periods.

TERMINAL UNITS

The control provides for a selection between six different terminal unit types: two types of radiant floor heat, fancoil, fin-tube convector, radiator and baseboard. When a terminal unit is selected, the control automatically loads the design supply temperature, maximum supply temperature, and minimum supply temperature (FIG. 16). The factory defaults are listed in Figure 16. These factory defaults can be changed to better match the installed system. If a factory default has been changed, refer to section Ato reload the factory defaults.

FIG. 15

BOIL DSGN

BOIL IND

HIGH MASS RADIANT (1)

This type of a hydronic radiant floor is embedded in either a thick concrete or gypsumpour. This heating system has a large thermal mass and is slow acting (FIG. 17).

LOW MASS

RADIANT (2)

This type of radiant heating system is either attached to the bottom of a wood sub-floor, suspended in the joist sp ace, or sandwiched between the sub-floor and the surface. This type of radiant system has a relatively low thermal mass and responds faster than a high mass system (FIG. 17).

FANCOIL (3)

A fancoil terminal unit or air handling unit (AHU) consists of a hydronic heating coil and either a fan or blower. Air is forced across the coil at a constant velocity by the fan or blower, and is then delivered into the building space (FIG. 17).

FIN-TUBE CONVECTOR (4)

A convector terminal unit is made up of a heating element with fins on it. This type of terminal unit relies on the natural convection of air across the heating element to deliver heated air into the space. The amount of natural convection to the space is dependant on the supply water temperature to the heating element and the room air temperature (FIG. 17).

RADIATOR (5)

A radiator terminal unit has a large heated surface that is exposed to the room. A radiator provides heat to the room through radiant heat transfer and natural convection (FIG. 17).

BASEBOARD (6)

A baseboard terminal unit is similar to a radiator, but has a low profile and is installed at the base of the wall. The proportion of heat transferred by radiation from a baseboard is greater than that from a fin-tube convector (FIG. 17).

BOOST

When the control changes from the UnOccupied mode to the Occupied mode, it enters into a boosting mode. In this mode, the supply water temperature to the system is raised above its normal values for a period of time to provide a faster recovery from the setback temperature of the building. The maximum length of the boost is selected using the BST setting.

Typical settings for the boost function vary between 30 minutes and two hours for buildings that have a fast responding heating system. For buildings that have a slow responding heating system, a setting between four hours and eight hours is typical. After a boost time is selected, the setback timer must be adjusted to come out of setback some time in advance of the desired occupied time. This time in advance is normally the same as the BST setting.

If the building is not up to temperature at the correct time, the BST setting should be lengthened and the setback timer should be adjusted accordingly. If the building is up to temperature before the required time, the BST setting should be shortened and the setback timer should be adjusted accordingly. If the system is operating near its design conditions or if the supply water temperature is being limited by settings made in the control, the time required to bring the building up to temperature may be longer than expected.

FIG. 16

FIG. 17

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