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INS7162 Rev-
TM
INSTALLATION INSTRUCTIONS
ADDITIONAL FUNCTIONS INCLUDE:
INTRODUCTION
• Installer and Advanced Access Levels
Primary Pump Output
2
The MP is capable of controlling the supply water tempera-
Individual Boiler Pump Outputs (in applicable
ture for up to nine ON / OFF stages based on outdoor tem-
modes)
perature, control for the Domestic Hot Water (DHW) gener-
Pump Exercising
ation, a set point requirement or optionally an external input
Pump Purging (primary and boiler)
sign
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This instruction manual is organized into four main sections: USER INTERFACE 1) Sequence of Operation, 2) Installation, 3) Control Settings, and 4) Testing and Troubleshooting. The The control uses a Liquid Crystal Display (LCD) as the Sequence of Operation section has seven sub-sections. We method of supplying information. The LCD is used in order recommend reading Section A: General Operation of the to setup and monitor the operation of your system. The con- Sequence of Operation, as this con
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DISPLAY Boiler Demand DHW / Setpoint Demand WWSD External Input Signal Offset FIG. 2 SYMBOL DESCRIPTION
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Set Point DEFINITIONS When a set point demand signal from a set point system is present, the control operates the boiler(s) to maintain the The following defined terms and symbols are used through- supply water temperature at least as hot as the SETP set- out this manual to bring attention to the presence of hazards ting. Refer to section F. of various risk levels, or to bring attention to important infor- mation concerning the life of the product, see Figure 4 External Input 0 - 10 V (dc) or 2
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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 fir
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Resetting the Rotation Sequence BOILER MAXIMUM To reset the rotation sequence, set the Rotate / Off DIP The boiler maximum is the highest temperature that the switch to the Off setting for 5 seconds and then return the control is allowed to use as a boiler target temperature. If DIP switch to the Rotate setting. the control does target the BOIL MAX setting, and the boil- er temperature is near the boiler maximum temperature, the maximum segment will be displayed in the LCD while either RUNNING T
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FIG. 9 FIRE DELAY LO / HIOR LO / LO The Fire Delay is the time delay that occurs between the When using multi-stage boilers, a selection must be made time that the control closes a stage contact to fire a stage regarding the staging order of the boile
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Fixed Differential STAGE DELAY If the user desires to have a fixed differential, this is set The stage delay is the minimum time delay between the fir- using the BOIL DIFF setting in the ADJUST menu (FIG. 11). ing of stages. After this delay has expired the control can fire the next stage if it is required. This setting can be adjust- Auto Differential ed manually or set to an automatic setting. When the auto- matic setting is used, the control determines the best stage If the Auto Differentia
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FIG. 12 FIG. 13 BOILER PUMP OPERATION In certain modes of operation, the control can operate the individual boiler pumps on each boiler in addition to the pri- mary pump. The boiler pump turns on prior to the boiler fir- ing 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 MA
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type of terminal unit. This improves the control of the air ROOM temperature in the building. The room is the desired room temperature for the building BOILER INDOOR DESIGN TEMPERATURE and provides a parallel shift of the heating curve. The room temperature desired by the occupants is often different from The indoor design temperature is the room temperature that the design indoor temperature. If the room temperature is was used in the original heat loss calculations for the build- not corre
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FIG. 16 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 space, or sandwiched between the sub-floor and the surface. This type of radiant system has a relatively low thermal mass and responds
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SECTION E: DOMESTIC HOT WATER OPERA- TION SECTION E1: DOMESTIC HOT WATER (DHW) DHW DEMAND A DHW Demand is required for the control to provide heat to the DHW system. A DHW aquastat or set point control is used as a switch in the DHW demand circuit. Once the con- trol detects a DHW demand, the DHW Demand pointer turns on in the LCD and the control operates the boiler to provide a sufficient boiler supply water temperature to the DHW tank. The control operates the pumps as described below. The
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DHW MODE 4 - DHW IN PRIMARY / SECONDARY WITH CONDITIONAL DHW PRIORITY PRIORITY The Conditional DHW Priority Override applies to DHW MODE 2 and 4. If the boiler supply temperature is main- When a DHW Demand is present, the Relay 9 / DHW con- tained at or above the required temperature during DHW tact (terminals 30 and 31) is closed and the primary pump generation, this indicates that the boiler(s) has enough contact is closed. Priority can only be obtained using exter- capacity for DHW and poss
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For correct operation, close attention must be paid to the NUMBER OF BOILERS USED FOR DHW GENERATION mechanical layout of the system. When the control turns off the primary pump (Prim P1), flow to the heating system The number of boilers used for DHW generation can be must stop. If flow is not stopped, the temperature in the selected from one to the maximum number of boilers using heating system can exceed the maximum desired tempera- the BOIL DHW setting. This applies when only a DHW ture an
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operates set point and heating simultaneously by turning on BOILER TARGET DURING SET POINT the primary pump (Prim P1). The boiler target temperature during a set point demand is CONDITIONAL SET POINT PRIORITY increased to at least the Set Point setting. This temperature is maintained as long as the control has a set point demand. If the boiler(s) supply temperature is maintained at or above the required temperature during set point generation, this SET POINT MODE indicates that the boiler(s) ha
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INPUT SIGNAL EXTERNAL INPUT SIGNAL CONVERSION TABLES The control can accept either a 0 - 10 V (dc) signal or a 2 - 10 V (dc) signal. The External Input Signal setting must be set to the proper setting based on the signal that is being sent to the control. 0 - 10 V (dc) or 0 - 20 mA When the 0 - 10 V (dc) signal is selected, an input voltage of 1 V (dc) corresponds to a boiler target temperature of 50°F (10°C). An input voltage of 10 V (dc) corresponds to a boiler target temperature of 210
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All wires are to be stripped to a length of 3/8" (9 mm) to INSTALLATION ensure proper connection to the control. CAUTION If an Outdoor Sensor TST2311 is used, install the sensor according to the installation instructions in the INS7141 and Improper installation and operation of this control could run the wiring back to the control. result in damage to the equipment and possibly even personal injury. It is your responsibility to ensure that this Install the TST2311 sensor according to
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Set Point Demand OUTPUT CONNECTIONS To generate a setpoint demand, a voltage between 24 V Primary Pump Contact (Prim P1) (ac) and 230 V (ac) must be applied across the Setp / DHW and Com Dem terminals (8 and 7) (FIG. 26). The DHW The Prim P1 output terminal (11) is a powered output. MODE must be set to OFF. When the relay in the control closes, 115 V (ac) is provided to the Prim P1 terminal (11) from the Power L terminal (10). To operate the primary pump, connect one side of the pri- mary pump
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Boiler Return Sensor If a boiler return sensor is used, connect the two wires from the TST2311 sensor to the Com - and Boil Ret terminals (1 and 3) (FIG. 31). The boiler return sensor is used by the control to measure the boiler return water temperature. FIG. 30 Relay 9 / DHW If a DHW pump or DHW valve is connected to the Relay 9 / DHW contact (30 and 31) (FIG. 30), make sure the power to the pump or valve circuit is off and install a jumper between those terminals. When the DHW circuit is powe
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V A good quality electrical test meter, capable of reading from DHW Demand at least 0 - 300 V (ac) and at least 0 - 2,000,000 ohm, is essential to properly test the wiring and sensors. If a DHW demand is used, measure the voltage between the Setp / DHW and the Com Dem terminals (8 and 7) (FIG. 35). When the DHW demand device calls for heat, a TEST THE SENSORS voltage between 20 and 260 V (ac) should be measured at the terminals. When the DHW demand device is off, less In order to test the se
