Lochinvar SMP3014, SMP3000-3014 Installation Manual

General PProduct Information

The SMP3000 - 3005 Sequencing packages are an effective way to improve efficiency, reduce maintenance, and enhance the longevity of a hydronic system.

NOTE: This controller MUST be designed to operate with a primary/secondary full flow boiler loop. This is due to the fact that variable speed changes the operating characteristics.

Intelli-Fin boilers and water heaters give system designers “conventional” sequencing options such as first on/last off and first on/first off which are offered as part of this standard sequencing package, however, the Intelli-Fin also provides a whole host of optional sequencing packages on the SMP3003 SMP3005, SMP3009 - SMP3010 and the SMP3011 SMP3014.

Multiple sequencing options are available. The specific software programming required to sequence multiple boilers must be specified at the time the appliances are ordered. The sequencing options are used to control how multiple boilers or water heaters are cycled to meet system demand. The sequencing options are programmed into an Excel 10 controller at the factory based on the number of selectable sequencing algorithms ordered. The desired method of sequencing multiple boilers or water heaters may be selected from the screen of the Command Display.

There are up to five sequencing options that are selectable from the Command Display, based on the sequencing package purchased. One sequencer has the capability of handling up to 16 boilers or water heaters.

NOTE: Separate sequencers must be used if desired to control both boilers and water heaters simultaneously.

Intelli-Fin Sequencer

SMP3000 - 3014 Installation Manual

Table oof CContents

General Product Information . . . . . . . . . . . . . . . . . . . . . . .1

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Options Offered on the SMP3000-SMP3002 . . . . . . .2

Options Offered on the SMP3003-SMP3005 . . . . . . .2

Options Offered on the SMP3002, 3005, 3014 and

SMP3014 (Boilers Only) Outdoor Air Reset . . . . . . .3

Options Offerered on the SMP3009 - 3012 and

SMP3014 - 4-20 mAReset . . . . . . . . . . . . . . . . . . . . .4

Parts List (Items Included in the Kit) . . . . . . . . . . . . . . . . .5

Items to be Provided by the Installer . . . . . . . . . . . . .5

Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . .5

One Year Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . .6

Connecting to Electrical Supply . . . . . . . . . . . . . . . . .6

Sensor Location and Wiring Requirements . . . . . . . .7

E-Bus Communications Wiring . . . . . . . . . . . . . . . . .7

LonWorks® Termination Module . . . . . . . . . . . . . . . .8

System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Sequencer Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .10

Table oof FFigures

Figure 1 - Commissioning Label . . . . . . . . . . . . . . . . . . . .5

Figure 2 - Daisy Chain Connection . . . . . . . . . . . . . . . . . .6

Figure 3 - Rear E-Bus Connection . . . . . . . . . . . . . . . . . . .6

Figure 4 - Wire Termination for E-Bus Connection . . . . .6

Figure 5 - Sequencer - Rear View . . . . . . . . . . . . . . . . . . .6

Figure 6 - Sequencer - Inside View . . . . . . . . . . . . . . . . . .7

Figure 7 - Primary/Secondary Loop . . . . . . . . . . . . . . . . . .8

Figure 8 - Sequencer Wiring Diagram . . . . . . . . . . . . . . . .10

Save this manual for future reference.

IFS-i&s-02

LIMITATIONS

These installation instructions are for sequencer kits SMP3000 SMP3014. These kits are for use with Intelli-Fin Models IB/IW 1500-2000 and can be used for the sequencing of up to 16 units.

Options Offered on the SMP3000 - SMP 3002 Standard Sequencing Packages

SMP3000 – Standard Sequencing Package for Water Heaters SMP3001 – Standard Sequencing Package for Boilers SMP3002 – Standard Sequencing Package for Boilers with

Outdoor Air Reset

First On – First Off – This is a lead/lag control functionality. The sequencing of the boilers or water heaters is based on the total loop load with added units being brought ON when the units that are running are at 100% and the loop load is not being met. Boilers or water heaters are turned OFF when the loop load falls and the first boiler or water heater ON is at minimum load.

First On – Last Off – This is a simple first on / last off without rotation of the lead boiler or water heater.

Options Offered on the SMP3003 SMP3005 Custom Sequencing Packages

In addition to the sequencing options listed above in the Standard Sequencing Packages, the Custom Sequencing Packages offer the following sequencing enhancements:

SMP3003 – Custom Sequencing Package for Water Heaters SMP3004 – Custom Sequencing Package for Boilers SMP3005 – Custom Sequencing Package for Boilers with

Outdoor Air Reset

Efficiency Optimized – The lead/lag will be based on first on/first off lead/lag. The overall efficiency will be optimized to run the boilers or water heaters at their highest efficiency. Highest efficiency occurs at the minimum loading for each boiler or water heater. Therefore, this option will add boilers or water heaters when the load reaches a point where the next boiler or water heater can run at minimum load.

Efficiency Optimized with Time Equalization – This is the same as “Efficiency Optimized” but the lead/lag is based on boiler or water heater run-times. The boilers or water heaters will be sequenced to equalize run-times to within 24 hours over a years time period. If no opportunity is given to cycle, the control will not interrupt action to equalize run-time.

Efficiency Optimized Control Algorithm Operation

The “efficiency optimized control algorithm” controls boilers to achieve maximum operating efficiency by having boilers firing at the lowest rate possible and still statisfying the load. Boiler efficiency is highest at the lowest firing rate and lowest at the maximum firing rate. At lower firing rates more heat is transferred from the combustion gases through the heat exchanger to the water inside the boiler. The combustion gases are flowing slower past the heat exchanger and give up more heat.

The efficiency algorithm works as follows: One firing rate is commanded to all boilers. As soon as the firing rate to all boilers ON exceeds that required to bring on a new boiler at the minimum firing rate, a new boiler is ignited and begins firing. Once the new boiler is operating and supplying heat, all boilers are modulated down to a new minimum to compensate for the new boiler being turned ON. Asimilar thing happens when a boiler is subtracted from operation. When all boilers are firing at the minimum and the load is decreasing, a boiler is shut OFF and the remaining boilers ON are modulated up to satisfy the load deficit.

The “efficiency optimized control algorithm operation” can best be illustrated with the following example:

Example: Assume we have a four boiler system, all boilers are initially OFF and a load change occurs resulting in an overall load of 20%. One boiler firing at maximum can satisfy only 25% of the load. The first boiler is ignited and modulates up to a 50% firing rate. At this point a second boiler is ignited. One boiler firing at 50% is equivalent to two boilers firing at 25%. Both boilers modulate to 37.5% and the third boiler is ignited. T wo boilers firng at 37.5% is equivalent to three boilers firing at 25%. All three boilers now modulate to a firing rate of 27% satisfying the overall load of 20% at maximum efficiency with no unnecessary cycling. Now assume the load changes to 15%. All three boilers are modulated down to 25% and temperature is still rising. One boiler is commanded OFF and the remaining two boilers modulate up to 30% and satisfy the load.

NOTE: This explanation has been idealized. In actuality, the control algorithm assumes the switching firing rate is 33%. This assumption prevents unnecessary cycling resulting from load fluctuations that would be associated with a 25% switching firing rate.

Efficiency Not Optimized Control Algorithm Operation

The “efficiency not optimized control algorithm” controls boilers to achieve the minimum number of boilers firing at one time. Before a new boiler can be commanded ON, all the boilers cur-

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Verify the correct sequencing package is used for the correct a pplication.

Model(s)

Boiler

IB 1500, 1700, & 2000

Water Heater IW 1500, 1700, & 2000

rently ON are at a firing rate of 100% and the load is not being satisfied. If the load can be satisfied with this new boiler modulating above the minimum, all the previously ON boilers are held at a firing rate of 100% and the new boiler modulates up and off, the boilers that are firing at the maximum are modulated back slightly so that the new boiler will modulate above the minimum and not cycle. For the “efficiency not optimized” case, all boilers are at or near the maximum firing and one boiler is modulating to satisfy the load fluctuations.

The previous example used to illustrate how “efficiency optimized” works is not a good example for the “efficiency not optimized” case. If it were applied to that example, only one boiler would ever come ON. For an overall load of 20%, one boiler would be ON and at a firing rate of 80% and for an overall load of 15% the firing rate would be 60%.

A better example would be to assume that we have a four boiler system, all boilers are initially OFF and a load change occurs resulting in an overall load of 60%. The first boiler is turned ON and modulates to 100%. The second boiler is turned ON and the boiler is modulated to 100% and the load is still not being satisfied. The third boiler is turned ON and modulates to 40% satisfying the load. Now assume the overall load changes to 40%. The third boiler is turned OFF, the second boiler is modulated down from 100% to 60% and the first boiler remains at 100%.

Notes for Both Approaches: In the previous examples, the boiler that would be turned OFF was based on first on/last off for simplicity. Also in this explanation, the term boiler was used, but the same holds true for a water heater.

Options Offered on the SMP3002, SMP3005, SMP3013,

and SMP3014 (Boilers Only) Outdoor Air Reset

Sequencer panels have the option of being equipped with Outdoor Air Reset, which automatically readjusts the temperature of the boiler loop to provide additional heat during cold days and provide for shutdown of the system on warmer days when heating is not required.

INTELLI-FIN SEQUENCER OUTDOOR AIR RESET VALUES

SMP3002, SMP3005, SMP3013 & SMP3014 - BOILERS ONLY

180°F

Max.

Reset Temp.

Water Temp. °F

Maximum Reset Temperature

Field Adjustable

Using Command

Display

Typical Values Shown

Calculated Setpoint

Outdoor Air Temp. °F

Item Description

Setpoint Temperature

O.A. Minimum

Setpoint Temp.

130°F

60°FO.A. Max.-10°FO.A. Min.

Factory

Defaults

180°F

130°F

-10°F

Shutdown

70°F

Special Factory/

Field

Lockout

Factory Set (1)

O.A. Maximum

O.A. Lockout

60°F

70°F

NOTE: 4-20mA RESET HAS PRIORITY OVER OUTDOOR AIR RESET.

LBL2226 REV-

Sequencer

+ +

+ + +

Boiler Interface

Controller

CONNECTIONS "SEE ACTUAL WIRING DIAGRAM FOR DETAILS" ON PAGE 10 OF THIS MANUAL.

+ + +

SENSOR

Field Provided Sensor Wiring

Polarity Insensitive

Mounting

Bracket

Outdoor

Air Sensor

Sequencer panels have the option of being equipped to handle a 4-20mA reset signal from a Building Management System. When equipped as such, the sequencer has the ability to respond to variations in the 4-20mA signal by either raising or lowering the water temperature or shutting down the units.

Options Offered on the SMP3009, SMP3010, SMP3011,

SMP3012, and SMP3014 4-20mA Reset

INTELLI-FIN SEQUENCER 4-20mA VALUES

SMP3009, SMP3010,SMP3011, SMP3012, SMP3013 & SMP3014

Not connected or 0mA signal.

Setpoint Temp.

130°F

mA VALUE TO SEQUENCER SEQUENCER ACTION TAKEN

Typical Values Shown

ShutDown

Off

Setpoint

Te mp .

130°F

Calculated Setpoint

6mA3-5mA0-3mA

External 0mA to 20mA Signal

0-3mA USE SETPOINT

3-5mA SHUTDOWN ALL UNITS

6mA RUN AT SETPOINT

7-19mA

LINEARLY RUN BETWEEN

SETPOINT AND MAX. RESET TEMP

20mA RUN AT MAXIMUM RESET TEMP.

Item Description

Factory

Defaults

Special-

Field Values

180°F

Max. Reset.

Te mp .

20mA7 - 19mA

Field Adjustable

Using Command

Display

Maximum Reset Temperature

Setpoint Temperature

180°F

130°F

NOTE: 4-20mA RESET HAS PRIORITY OVER OUTDOOR AIR RESET.

LBL2225 REV-

Boiler Interface

Controller

+ +

Negative Input (-) # 11

Positive Input (+) # 10

+ +

Sequencer

OPTIONAL

4-20ma INPUT

CONNECTIONS "SEE ACTUAL WIRING DIAGRAM FOR DETAILS" ON PAGE 10 OF THIS MANUAL.

Black

Red

4-20mA Output

From BMS

Polarity

Sensitive

Com

0-20mA

Building

Management

System

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