MODEL FIII-SERIES CONTROL INSTALLATION ... - Agencespl.com

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REV 1.1 FIII SERIES CONTROL Introduction The FIII-SERIES Control The FIII-series boiler control is designed to provide the FIII-series of boilers with an integrated boiler management system on every boiler. Designed for the Air-Fuel coupled FIII-series boilers, the FIII-series control provides for optimized heating efficiency without the need for a “wall mount control”. This also eliminates the need for analog control signals such as 4- 20ma control loops and 0-10vdc control voltages, since the FIII-series control method is based on digital communications. Although the use of analog control signals is still supported, a higher level of control precision /repeatability/feedback is gained with digital communications control. Optimized heating efficiency is accomplished by setting the Modulation Maximum (Mod-Max) setting to exploit the inverse efficiency curve. This value can be adjusted so that as each boiler is added, it operates at its maximum turndown. This allows the maximum number of boilers to operate at their lowest inputs until all boilers are firing. Once all boilers are firing, full range modulation control is allowed. An outdoor reset function is also provided to assist in the optimized heating efficiency of the FIII series boilers. The FIII-series boiler with the FIII-series control, can be operated in multiple ways: A. As a stand-alone boiler. B. A boiler in a Boiler Network using the Heat Net (H-Net ) protocol. C. A member boiler to a boiler management system with multiple input control methods. D. Or as a member in a system with up to (3) boilers using relay control. The primary purpose of the control is to maintain the boiler water temperature at the supply or the header sensor using a target setpoint. While performing this task, the control also monitors dedicated external limits in a limit string and provides an orderly shutdown and fault indication in the event of a tripped limit. The monitored limits include a HIGH LIMIT AQUASTAT, LOW WATER CUTOFF, GAS PRESSURE, FLOW, IGNITION CONTROL fault, GAS VALVE alarm, VARIABLE FREQUENCY DRIVE alarm, and other optional or user selectable limits. NOTE: The HIGH LIMIT circuit is independent of the control and shuts down the ignition control and the boiler if the control board or other component of the boiler was to malfunction. The control will continue to function and report the fault, but its ability to control the boiler will end. Each FIII-series boiler employing this control can function as either a master or a member. This allows one boiler (master) to be in control of target temperature. The other boilers (members) only respond to the commands issued by the boiler in control of the target temperature (master). If using an external control, all boilers can be setup as members. The following will define the roles of master and member. Master A boiler becomes a master when a temperature sensor is connected to the J10 “SYS/DHW HEADER” terminals. The sensor is auto-detected. The master senses and controls the header/loop water temperature using a system setpoint. It uses any boilers it finds (H-Net), or that are defined in the setup menus to accomplish this. It also monitors the Outside Air (OA) temperature to provide outdoor reset functionality. Only one master is allowed in a system. When operating as a master, the boiler control provides a stand-alone method using a PID algorithm to regulate water temperature. This algorithm allows a single boiler (Master), or multiple (Master + Member) boilers. The control algorithm is based upon a control band, at the center of which is the setpoint. While below the control band, boilers are staged on and modulated up until the control band is entered. Once in the control band, modulation is used to maintain setpoint. Boilers are shut down only when the top of the band is breached, or before the top of the band, if the control anticipates that there is a light load. Timers are also used to prevent short cycling. While staging the boilers on, a modulation clamp MOD MAX – LAST FIRE is used to hold the boilers at a lower fire rate until the last boiler is fired. Once the last boiler fires, the modulation clamp is removed and all boilers are allowed to fire above this clamped percentage up to 100%. This “boiler efficiency” clamp is defaulted to 80% and thus limits all of the boilers individual outputs to 80% until the last boiler fires. All boilers modulate up and down together always at the same modulation rate. MEMBER A boiler always defaults to the role of member. The lack of a “SYS/DHW HEADER” sensor (not) connected to J10 ensures this. The member senses its supply water, and modulates based on signals from an external control or master boiler. When operating as a member, starting, stopping, Page 2
REV 1.1 FIII SERIES CONTROL and the firing rate are controlled by an external control or by the master boiler. If using the H-Net protocol, the system setpoint is sent from the master, along with the modulation value to control firing rate. It also receives its command to start or stop over the H-Net cable. The member also continuously monitors its supply temperature against its operating limit. If the supply temperature approaches the operating limit temperature (adjustable), the boilers input control rate is limited and its modulation value decreases to minimize short cycling. If the operating limit is exceeded, the boiler shuts off. If not using the H-Net protocol, the master or an external boiler control can send a 4-20ma signal along with a 4-20ma enable signal to control the firing rate. The boiler may also be treated as a 4-stage boiler or an ON-OFF boiler using the dedicated T-inputs. Page 3
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MODEL FIII-SERIES CONTROL INSTALLATION ... - Agencespl.com

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