VERSA IC™ Control - Master Hydronics Inc

Transcription

INSTALLATION & OPERATING
INSTRUCTIONS
VERSA IC™ Control
Catalog No. 5000.72
Effective: 01-04-13
Replaces: NEW
P/N 241493 Rev. 1
2
Table of Contents
WARNINGS
WARNINGS ..............................................................3
VERSA Display Board ..............................................5
WARNING: Improper installation, adjustment,
alteration, service, or maintenance can cause
property damage, personal injury or loss of life.
Refer to the user's information manual provided with
the heater. Installation and service must be
performed by a qualified installer, service agency, or
the gas supplier.
Application & Modes .................................................9
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
Introduction ...............................................................4
VERSA Control Board ..............................................4
VERSA PIM™ Module...............................................6
Boiler Applications ...................................................10
WARNING: When servicing or replacing any
components of the control system within this unit, be
certain that:
• The gas is off.
• All electrical power is disconnected.
Water Heater Applications .......................................22
Control Menus .........................................................26
Control Settings .......................................................31
Sequence of Operation ...........................................37
Wiring Connections – PIM™ ...................................39
Wiring Connections – VERSA IC™ Control ............42
Energy Management System Setup .......................43
Cascade Set-up and Operation ...............................44
Stand-alone Operation of PIM™ .............................46
Troubleshooting .......................................................47
Technical Data .........................................................50
Quick Start Set-Up and Programming Tips .............51
Resetting PIM™ to Accept New ID Card ................52
Modbus Communication Values ..............................52
3
Introduction
In addition, the VERSA IC control system allows cascading control of multiple units up to 4 units total
without the need for an external sequencer. The
VERSA IC control system is Modbus ready for easy
external communication and control.
The Raypak VERSA IC is an appliance integrated control system consisting of the following components:
•
•
•
•
•
•
•
VERSA Control Board
VERSA IC Control Board
VERSA Display Board
VERSA IC Platform Ignition Module (PIM) in HSI,
DSI or Supervised Pilot Ignition
ID Card
Water Sensors (up to 6)
Vent Sensor
Outdoor Air Sensor
The VERSA Control Board provides high level functionality for the VERSA IC control system. It has field
interlock connections, cascading heater connections
and VERSA Display Board connections. The VERSA
IC control system allows “limp along” operation via the
PIM if the VERSA Control Board becomes inactive or
if the communications between the VERSA Control
Board and the PIM are terminated for any reason.
This “limp along” mode operation is outlined in more
detail starting on page 46. The VERSA Control Board
is ANSI Z21.23 certified.
F6018C
CN1
Remote LCD
S7
S6
CN7
Com
LED Out
Diagnostics
R
Mod +
CWS/CWR
GND
Power On
Call For Heat
Burner On
Service
Fig. 1: Water Sensor
GND
RS485-A
Raypak
VERSA
#013935F
CN6
RS485-B
GND
ModBus-A
Power: 24 V (ac) ± 10% 50/60 Hz 5.2 VA 215 mA
Relays: 240 V (ac) 5 A
CN5
ModBus-B
CN4
Condensate Switch
External
Valve
Vent Temp Limit
Auto High Limit
Fan /
Damper
Low Water
Blocked Vent
Low Gas Press
Extra
High Gas Press
CN2
(Extra)
PIM 2 A
Ft_Bus B
CN8
Water Flow Switch
PIM 3 A
Ft_Bus B
Blower Air Switch
Factory Option 1
PIM 4 A
Ft_Bus B
Factory Option 2
Factory Option 3
Fig. 2: Outdoor Air Sensor
The VERSA IC control system provides integrated
functions of automatic ignition control, thermostat control, high temperature limit control, diagnostic
enumeration, safety interlock, domestic hot water
(DHW) override and several options for external
heater control for Raypak commercial boilers, water
heaters and pool heaters. The VERSA IC control system controls the heater pump, system pump and
indirect DHW pump simultaneously as needed.
1049-01
4
12345678
GND
ON
158033
Designed and assembled in Canada
Fig. 3: VERSA Control Board
The VERSA Control Board includes connections for:
•
•
•
•
•
•
•
•
•
•
o
LED Indicator Lights (model specific)
o Green – POWER ON
o Amber – CALL FOR HEAT
o Blue – BURNER ON
o Red – SERVICE REQUIRED
Diagnostic Inputs
o Condensate Switch
o Vent Temperature Limit
o Auto High Limit
o Low Water Cutoff
o Blocked Vent
o Low Gas Pressure
o High Gas Pressure
o Extra – (future usage)
o Water Flow Switch
o Blower Air Switch (model specific)
o Factory Option 1 – Factory Defined
(3 second delay)
(10 second delay)
(90 second delay)
Cascade Communication Connections (Ft_bus
Communication)
o PIM 2 – A & B
o PIM 3 – A & B
o PIM 4 – A & B
External Device Triggers (dry contact)
o External Valve
o Fan/Damper
o Extra
Auxiliary Sensor Inputs
o Aux 1 – IND Supply Sensor (S6)
o Aux 2 – CWS/CWR (future usage)
0-10vdc Output (CWS/CWR)
o Mod+/Communication Connections
o RS485 (future usage)
o Modbus RS485 (RTU/ASCII)
VERSA IC Display Connection (Ribbon Cable)
PIM Connection (RJ45 Connection)
Dip Switches
o
o
o
o
o
o
o
#1 – Access Level
•
•
#2
•
•
#3
•
•
#4
•
•
#5
•
•
#6
•
•
#7
#8
OFF – Installer
ON - Advanced
– Cascading
OFF – Follower/Slave
ON – Master
– Cold Water Protection
OFF – None
ON – CWS/CWR
– Proportional Output Selection
OFF – 0-10 VDC
ON – 0-20mA (requires 500 ohm resistor)
– Remote Display (RS485)
OFF –
ON –
– Heater Rotation
OFF – No Rotation
ON – Enable Rotation
– TBD
– TBD
Fig. 4: VERSA IC Control DIP Switches
VERSA Display Board
The VERSA Display Board is the board with the LCD
display viewable from outside of the heater. All operation and settings of the VERSA IC control are
accomplished through the use of the 5 buttons of the
user interface. These buttons are labeled as follows:
•
•
•
•
•
5
MENU – Scroll through available menus
ITEM – Scroll items within the selected menu
UP – Increase values in the Adjust menu
DOWN – Decrease values in the Adjust menu
RESET – Clear lockout
Fig. 5: VERSA IC Display Board
The display uses a Liquid Crystal Display (LCD) as the
method for supplying information. Use the LCD to
setup and monitor the operation of your heater.
The PIM integrates the functions of Automatic Ignition
Control with temperature regulating and control functions. The PIM is designed for a range of boilers, water
heaters and pool heaters including ON/OFF, staged
and modulating types. The PIM is intended to provide
safe lighting and supervision of the burners in a heater.
If the membrane switch remains inactive for 180 seconds (3 minutes), the screen will revert to the VIEW
menu – Boil INLET unless some error/fault exists –
then the fault will be displayed. Touching any button
resets this timer (the timer can be seen in the bottom
right corner of the display) to keep the current view.
The PIM is also designed to connect to and receive
commands from the VERSA Control Board for higher
level functionality to include indirect DHW, outdoor
reset, diagnostic messaging, and other system capabilities. Communication is accomplished using a
proprietary protocol on the Ft_bus.
The PIM is CSA certified to the ANSI Z21.20 Standard
for Thermostats and Automatic Gas Ignition Systems
and Components and CAN/CSA C22.2 No. 199-M99.
The VERSA PIM also complies with the UL372
Primary Safety Controls for Gas and Oil Fire
Appliances (Harmonized version); UL 1998 Software
in Programmable Components, 2nd edition and UL
353 Limit Controls.
The PIM provides standard support for 10k ohm @
77°F NTC curve J Thermistor probes. The Inlet, Outlet,
Hi-Limit, and Vent (model dependent) sensors are
directly processed by the PIM. The optional System,
Fig. 6: Display
The VERSA Control Board has 2 access levels:
Installer and Advanced. Most settings are hidden in
the Installer mode. The Advanced mode can be
accessed by changing the VERSA dip switch #1 from
the “OFF” position (Installer) to the “ON” position
(Advanced).
J4
J3
WARNING: Return the VERSA control dip
switch #1 to the “OFF” (Installer) position after
heaters are fully set up and commissioned to prevent
inadvertent changes to program settings by unauthorized personnel.
9
J2
1
10
J1
OPERATOR
SET
POINT
J6
FIELD OPTIONS
SEE MANUAL
RESET
J7
POWER
ALARM/TEST
J8
FAULT
J15 REMOTE LED
The default menu displayed is the VIEW menu. If
there is an unresolved (active) error, then the default
menu is the TOOLBOX menu. The default item will be
the active error message. After 60 seconds of keypad
inactivity, the VERSA IC display will return to the
default menu and display the default item.
J9
F1
J10
T3
J11
J12
VERSA PIM™ Module
L1
15A
BLOWER
OPTION
FS
P2
FCFC+
The PIM™ (Platform Ignition Module) is available in
DSI (Direct Spark Ignition), HSI (Proven Hot Surface
Ignition), or IID (Intermittent Ignition Device Supervised Pilot) (Future) versions depending on
Raypak model type.
1
J5
GND
BLOWER
J14
6
Fig. 7: VERSA DSI PIM Module
Icon
When Displayed
Icon
When Displayed
VIEW
Menu = View
Pumps
Menu = View/Test
SETUP
Menu = Setup
BOILER
BOILER 1
BOILER 2
BOILER 3
BOILER 4
MONITOR
M
Boiler
Pump
Menu = Boiler View Menu of Boiler 1,
2, 3 or 4
System
Pump
DHW
Pump
Menu = Boiler View Menu of Boiler 1
Burner
1
2
Menu = Monitor
3
Single boiler or
Master Boiler in Cascade
4
(Burner
Rate) %
Menu = View, Solid if Installer Access
Level
Flashes at 1Hz if OEM Access Level
WWSD
Calls
Heat
DHW
Pool
Tank
Setpoint
(tN4)
Menu = Toolbox
ModBus
Warm Weather Shutdown is active
°C
Menu = View, Flashes at 1 Hz if one of
the connected PIMs is in Lockout
Menu = View, Solid if there is a known
active error on one of the connected
PIMs
°F
min
Menu = View/Test
hr
Menu = View/Test and Heat Call present
Menu = View/Test and DHW Call present
sec
Menu = View/Test and Pool Call present
µA
Menu = View/Test and Tank Call present
%
Menu = View/Test and Setpoint Call
present
RPM
Menu = View/Test and Boiler Pump is on
Menu = View/Test and System Pump is on
Menu = View/Test and DHW Pump is on
Menu = View/Test
Menu = View/Test and PIM 1 is on
Menu = View/Test and PIM is modulating. Displays current plant firing rate.
Menu = View and tN4 communication
is present
Menu = View and ModBus communication is present
Whenever the item displayed in the
number field is a temperature and
UNITS = degC
number field is a temperature and
UNITS = degF
number field is in minutes
number field is in hours
number field is in seconds
number field is in micro-amps
number field is in percent
number field is in RPM
Table A: VERSA Display Symbol Descriptions
7
VERSA IC Identification Card
Outdoor, and DHW tank sensors are also connected to
the PIM but are passed through to the VERSA Control
Board which is required to provide those additional
functions. Auxiliary sensors connect direct to the
VERSA Control Board for other enhanced functions
depending on the mode selected. Refer to the I&O
Manual for the product being installed for detailed
wiring information.
The VERSA IC Identification Card (ID Card) is a small
circuit card that determines the operating parameters
for each individual model by unlocking the correct program within the VERSA PIM module (referred to
simply as PIM throughout the rest of this manual). It is
permanently affixed to the chassis of the heater and
MUST be present for the heater to operate.
PIM Dip Switches
There is an 8-position dip switch on each PIM that can
be field configurable during commissioning. The UP
position is “ON” and the DOWN position of each dip
switch is “OFF”. The items in BOLD below represent
factory defaults settings.
Dip Switch #1 – Operator Differential
ON = Manual Differential
OFF = Auto Differential
Dip Switch #2 – Analog Input Type
ON = Direct Drive
OFF = Target Temperature
Dip Switch #3 – Pump Post Purge
ON = Pump Post Purge Active
OFF = Pump Post Purge Inactive
Dip Switch #4 – Pump Exercise Enable
ON = Pump Exercise Active
OFF = Pump Exercise Inactive
Dip Switch #5 – EMS/Demands
ON = EMS Analog Input Only
OFF = VERSA IC Demands Only
Dip Switch #6 – EMS Signal Type
ON = 4-20mA*
OFF = 0-10vdc
Dip Switch #7 – Freeze Protection
ON = Freeze Protection Active
OFF = Freeze Protection Inactive
Dip Switch #8 – Commission Test
ON = Commission Test Active
OFF = Commission Test Inactive
Fig. 8: VERSA PIM ID Card
WARNING: In the event of ID Card failure, replacement must be performed by a qualified technician
and must be replaced with an ID Card of the same
number.
If a PIM needs to be reconfigured for another ID Card
(such as during service or replacement), its internal ID
Card settings must be cleared before using on another heater. To clear these settings, follow the procedure
on page 52 – Resetting the PIM to Accept a New ID
Card.
Applications & Modes
The VERSA IC Control system is designed for a wide
range of applications. The installer/design engineer
should refer to the following drawings for configurations currently supported by the VERSA IC Control
System to determine which most closely resembles
the intended/installed system configuration. Refer to
the section(s) of this manual for instructions outlining
the piping layout, sensor locations and settings for
best operation of the specific configuration shown.
*NOTE: 4-20mA operation requires the use of an
external 500Ω, 1/2W resistor.
PIM Operator Set Point Dial
The PIM has a set point dial that is used to determine
the operator set point during standalone operation of
the VERSA IC Control System. The default position of
the operator set point dial is the maximum set point
which is defined by the PIM parameters defined by the
ID card. The dial can be adjusted down to a user
defined level between the minimum setting of 70°F or
the maximum allowed by the ID card. This function is
only active during standalone operation.
8
Hot water heating systems all have unique levels of
operating diversity that must be accounted for in the
system design. The system should always include
adequate system flow in excess of the connected boiler flow for proper operation. Where the system flow
may drop below the connected boiler flow, a
buffer/decoupler may be needed. Failure to design for
adequate flow (i.e. bypasses, 3 way control valves,
flow limiting balance devices, buffer tanks, etc.) will
result in boiler short cycling and may reduce boiler life.
Always contact your local Raypak representative for
system design assistance to avoid these issues.
H - Hydronic Heating
Applications
Single Boiler with Indirect DHW on
Boiler Loop – See Page 18
All Hydronic applications can be configured with or
without outdoor air reset functionality. The following
are the various system configurations discussed in further detail later in this manual.
Single Boiler – See Page 10
Multi-boiler Cascade with Indirect
DHW on Boiler Loop – See Page 20
Multi-boiler Cascade – See Page 12
WH - Direct DHW Applications
When a unit is ordered as a “WH” configuration the
only application available is direct Domestic Hot
Water. Systems can be configured for Single unit or up
to 4 heater Cascade systems as highlighted below.
Single Boiler with Indirect DHW on
System Loop – See Page 14
Single Heater – See Page 22
Multi-boiler Cascade with Indirect
DHW on System Loop – See Page 16
Multi-heater Cascade – See Page 24
9
Single Boiler Hydronic Heating - Mode 1
This section covers a single boiler used for hydronic heating. Primary/secondary piping is the only method supported by Raypak to ensure proper boiler and system functionality while achieving maximum system efficiency.
The piping configuration shown above can be used as fixed set point or set up to work in conjunction with an
Outdoor Air Reset Sensor (S4) to adjust the target water temperature as the outdoor air temperature changes.
The boiler firing rate will be controlled by the System Supply Sensor (S3). The VERSA IC™ will provide Max
Delta T (Differential Temperature) control and will cycle the burner in the event the Max Delta T is exceeded
between Boiler Outlet Sensor (S1) and Boiler Inlet Sensor (S2). The Boiler Pump (P1) runs during any call for
burner operation and is delayed “off” as user defined in the SETUP menu after the burner has shut down. The
System Pump (P2) runs whenever the system is enabled for heating and the outdoor air temperature is lower
than the WWSD temperature setting (if utilized). The System Pump is delayed “off” as user defined in the SETUP
menu. MODE 1 is used for this configuration. See SETUP menu items in Table B. This configuration supports
BMS 0-10vdc input for temperature or rate control and can be configured for connectivity to BMS via the onboard
Modbus port covered later in this manual.
10
Item
BOILER 1
Range
ON <> OFF
Default
ON
Access
Level
Installer
TARGET
RSET <> SETP
SETP
Installer
EMS
When is it Displayed
Ft_Bus 1 is connected or “NO
PIM™1” Error
PIM™ Identity is H
Description
Selects whether PIM™ 1 is
operational
RSET = Outdoor Reset
SETP = Setpoint
EMS=TEMP/RATE
EMS = Energy Management
System (Analog Target
Temperature)
MODBUS=TEMP/RATE
MODB = ModBus
Piping and application
configuration (see pages
12-20 for descriptions of
applications and modes)
Target setpoint boiler
temperature while a heat
demand is present for
setpoint operation
Outdoor reset starting
temperature
MODE
MODB
1, 2, 3
1
Installer
SETPOINT
50 to PIM™ Value
180°F
Installer
TARGET = SETP
OUT START
35 TO 85°F
70°F
Advanced
OUT DESIGN
-60 to 45°F
10°F
Installer
TARGET = RSET
Boil START
35 to 150°F
70°F
Advanced
Boil DESIGN
70 to 200°F
180°F
Installer
TARGET = RSET
Boil MASS
1 <> 2 <> 3
1
Installer
Always
TARGET MAX
PIM™
value**
Installer
TARGET MIN
100°F to PIM™
Operating Limit
50 TO 180°F
50°F
Installer
TARGET DIFF
2 to 42°F
10°F
Installer
BOIL PURGE
OFF, 0:20 TO 10:00 min
0:20 min
Advanced
PIM™ DIP = Manual Diff
PIM™ DIP = Purge On
SYS PURGE
OFF, 0:20 TO 20:00 min
0:20 min
Advanced
tN4 CYCLE
Au, 5 to 30 min
Au
Advanced
tN4 SCHD
OFF, <> Mb1
OFF
Installer
WWSD
40 - 100°F, OFF
70°F
Installer
UNITS
°F <> °C
°F
Installer
tN4 Bus Detected
tN4 Schedule #1
TARGET = RSET
Always
MODE
Modbus
OFF <> MNTR <> TEMP
<> RATE
OFF
Advanced
Always
1 to 247
1
Advanced
RTU <> ASCI
RTU
Advanced
2400 <> 9600 <> 19K2
19K2
Advanced
<> 57K6 <> 115K
PARITY
NONE <> EVEN <> ODD
EVEN
Advanced
** Check the Installation & Operating Manual for each specific product.
Always
Always
Always
Minimum target boiler
temperature
Differential for target boiler
temperature
Sets the length of the boiler
pump purge
Sets the length of the
system pump purge
Cycle length which all tN4
devices synchronize to
Selects if control will follow
Master Schedule #1
The system warm weather
shut down temperature
Show units using icons in
display
ModBus Operating Mode:
Off, Monitor, Temp Control,
Rate Control
ModBus slave address
ModBus data type
Modbus baud rate
Always
Modbus parity
ADDRESS
DATA TYPE
BAUD RATE
TARGET = RSET
TARGET = RSET
Table B: Mode 1 Setup Menu
11
Outdoor reset design
temperature
Starting boiler target
temperature when the
outdoor temperature is at
outdoor start
Design boiler target
temperature when the
outdoor temperature is at
outdoor design
Thermal mass of boiler – 1
= low mass boiler and 3 =
high mass boiler
Maximum target boiler
temperature
Multi-Boiler Cascade Hydronic Heating - Mode 1
This section covers a cascade of boilers (up to 4 boilers maximum) in a hydronic heating system. Reverse/return
piping is shown and is recommended to ensure balanced flow through each of the connected boilers.
Primary/secondary piping is the only method supported by Raypak to ensure proper boiler and system functionality while achieving maximum system efficiency.
The piping configuration shown can be used with a fixed set point or in conjunction with an Outdoor Air Reset
Sensor (S4a) to adjust the target water temperature as the outdoor air temperature changes. The system will be
controlled by the System Supply Sensor (S3a). The system will provide Max Delta T control to cycle the burner to ensure that the Delta T is not exceeded (between Boiler Outlet Sensors (S1a-b-c-d) and Boiler Inlet Sensors
(S2a-b-c-d)). The Boiler Pumps (P1a-b-c-d) run during any call for that pumps associated boilers burner and is
delayed “off” as user defined in the SETUP menu after the associated boilers burner has shut down. The System
Pump (P2a) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the
WWSD temperature setting (if utilized). The System Pump is delayed “off” as user defined in the SETUP menu.
Each Follower boiler connects back to the Master boiler via a two wire connection for communication within the
cascade. All sensors (Supply (S3a) and Outdoor Air (S4a)) connect to the Master boiler. Each boiler in the cascade connects to and controls its own respective Boiler Pump (P1a-b-c-d). The System Pump (P2a) gets its
enable signal from the Master boiler. It is important to remember to enable a boiler to be a follower in the cascade by turning dip switch #2 on the VERSA Control Board to the “OFF” position for each of the followers. Once
the followers have been configured correctly you must then enable the followers within the SETUP menu of the
Master boiler by turning them from “OFF” to “ON”. MODE 1 is used for this configuration. See SETUP menu
items in Table C. This configuration supports BMS 0-10vdc input for temperature control (rate not supported)
and can be configured for connectivity to BMS via the onboard Modbus port covered later in this manual.
To enable Follower boilers, scroll to the SETUP menu and, using the item button, scroll to the individual boilers
and toggle from “OFF” to “ON” to allow them to operate when commanded by the Master to run.
12
Item
BOILER 1
Range
ON <> OFF
Default
ON
Access
Level
Installer
BOILER 2
ON <> OFF
OFF
Installer
BOILER 3
ON <> OFF
OFF
Installer
BOILER 4
ON <> OFF
OFF
Installer
TARGET
RSET <> SETP
SETP
Installer
EMS
Ft_Bus 1 is connected or
“NO PIM™1” Error
Description
Selects whether PIM™ 1 is operational
EMS=TEMP/RATE
EMS = Energy Management System (Analog Target Temperature)
MODBUS=TEMP/RATE
MODB = ModBus
Piping and application configuration (see pages 12-20 for
descriptions of applications and modes)
Target setpoint boiler temperature while a heat demand is present
for setpoint operation
Outdoor reset starting temperature
MODE
MODB
1, 2, 3
1
Installer
SETPOINT
50 to PIM™ Value
180°F
Installer
OUT
START
OUT
DESIGN
Boil START
35 to 85°F
70°F
Advanced
-60 to 45°F
10°F
Installer
35 to 150°F
70°F
Advanced
Boil
DESIGN
Boil MASS
TARGET
MAX
70 to 200°F
180°F
Installer
1 <> 2 <> 3
100°F to PIM™
Operating Limit
1
PIM™
value**
Installer
Installer
TARGET
MIN
50 to 180°F
OFF
Installer
TARGET
DIFF
2 to 42°F
10°F
Installer
BOIL
PURGE
SYS
PURGE
OFF,
0:20 to 10:00 min
OFF,
0:20 to 20:00 min
0:20
min
0:20
min
Advanced
tN4 CYCLE
Au, 5 to 30 min
Au
Advanced
tN4 SCHD
OFF, <> Mb1
OFF
Installer
WWSD
40 - 100°F, OFF
70°F
Installer
UNITS
°F <> °C
°F
Installer
TARGET = SETP
TARGET = RSET
TARGET = RSET
TARGET = RSET
TARGET = RSET
Always
MODBUS RATE
EMS RATE
Ft_Bus 1 is connected
MODBUS RATE
EMS RATE
MODBUS RATE
EMS RATE
MODBUS RATE
MODBUS
TEMP/RATE
tN4 Bus Detected
tN4 Schedule #1
TARGET = RSET
Always
MODE
Modbus
ADDRESS
DATA
TYPE
BAUD
RATE
PARITY
Advanced
Advanced
TARGET = RSET or SETP
OFF <> MNTR <>
TEMP <> RATE
1 to 247
RTU <> ASCI
OFF
Always
1
RTU
Advanced
Advanced
MODBUS OFF
MODBUS OFF
2400 <> 9600 <>
19K2 <> 57K6 <>
115K
19K2
Advanced
MODBUS OFF
SETP = Setpoint
Outdoor reset design temperature
Starting boiler target temperature when the outdoor temperature is
at outdoor start
Design boiler target temperature when the outdoor temperature is at
outdoor design
Thermal mass of boiler – 1 = low mass boiler and 3 = high mass boiler
Maximum target boiler temperature
Minimum target boiler temperature
Differential for target boiler temperature
Sets the length of the boiler pump purge
Sets the length of the system pump purge
Cycle length which all tN4 devices synchronize to
Selects if control will follow Master Schedule #1
The system warm weather shut down temperature
Show units using icons in display
ModBus Operating Mode: Off, Monitor, Temp Control, Rate Control
ModBus data type
NONE <> EVEN
EVEN
Advanced MODBUS OFF
<> ODD
Table C: Mode 1 Cascade Setup Menu
13
Single Boiler with Indirect DHW on System
Loop – Mode 2
This section covers a single boiler used for hydronic heating in conjunction with an indirect DHW demand located on the system loop. Primary/secondary piping is the only method supported by Raypak to ensure proper
boiler and system functionality while achieving maximum system efficiency.
The piping configuration shown can be used as fixed set point or set up to work in conjunction with an Outdoor
Air Reset Sensor (S4) to adjust the target water temperature as the outdoor air temperature changes. The system can also be set to operate the indirect DHW call with or without priority. The boiler firing rate will be controlled
by the System Supply Sensor (S3). The Indirect Sensor (S5) determines the indirect call/tank setpoint. The
VERSA IC™ control system also allows for a thermostat controller (tank-stat) to be mounted in the indirect tank
and provide a call for indirect operation via contact closure in lieu of the tank sensor. The thermostat wiring connection is at the PIM™ J1 terminal block at terminals 8 and 10. When using an indirect DHW sensor to control
tank temperature contact closure is required across the indirect override connections for proper operation (see
IND Sensor, page 32 for further details).
The VERSA IC™ will provide Max Delta T (Differential Temperature) control and will cycle the burner in the event
the Max Delta T is exceeded between Boiler Outlet Sensor (S1) and Boiler Inlet Sensor (S2). The Boiler Pump
(P1) runs during any call for burner operation and is delayed “off” as user defined in the SETUP menu after the
burner has shut down. The System Pump (P2) runs whenever the system is enabled for heating and the outdoor
air temperature is lower than the WWSD temperature setting (if utilized). Priority mode toggles the System Pump
(P2) off during an indirect call-for-heat. The Indirect Pump (P3) runs during an indirect call-for-heat with no “off”
delay. The System Pump is delayed “off” as user defined in the SETUP menu.
Mode 2 is used for this configuration. Ensure dip switch #1 on the VERSA Control Board is in the ON position
to make programming changes.
14
Item
Range
Default
Access
Level
BOILER 1
ON <> OFF
ON
Installer
TARGET
RSET <> SETP
SETP
Installer
EMS
EMS=TEMP/RATE
EMS = Energy Management System (Analog Target
Temperature)
MODBUS=TEMP/RATE
TARGET = RSET or
SETP
TARGET = SETP
TARGET = RSET
TARGET = RSET
TARGET = RSET
TARGET = RSET
Always
MODB = ModBus
MODE
MODB
1, 2, 3
2
Installer
SETPOINT
70 to PIM™ Value
180°F
Installer
OUT START
35 TO 85°F
70°F
Advanced
OUT DESIGN
-60 to 45°F
10°F
Installer
Boil START
35 to 150°F
70°F
Advanced
Boil DESIGN
50 to 200°F
180°F
Installer
Boil MASS
1 <> 2 <> 3
1
Installer
TARGET MAX
100°F to PIM™ Operating
Limit
PIM™
value**
Installer
50°F
Installer
TARGET DIFF
2 to 42°F
Auto
Installer
IND SENSOR
OFF <> ON
OFF
Installer
IND SETP
OFF, 50 TO 180°F
140°F
Installer
IND DIFF
2 to 10°F
6°F
Advanced
IND SUPPLY
OFF, 70 to 200°F
180°F
Advanced
IND PRIORITY
OFF <> ON
OFF
Advanced
PRI OVR
Au, 0:10 to 2:00 hr
1:00 hr
Advanced
BOIL PURGE
OFF, 0:20 TO 10:00 min
0:20 min Advanced
SYS PURGE
OFF, 0:20 TO 20:00 min
0:20 min Advanced
tN4 CYCLE
Au, 5 to 30 min
Au
Advanced
tN4 SCHD
OFF, <> Mb1
OFF
Installer
WWSD
40 - 100°F, OFF
70°F
Installer
UNITS
°F <> °C
°F
Installer
MODE = 2 or 3
DHW SENSOR = OFF
MODE = 2 or 3
DHW SENS = ON
MODE = 2 or 3
DHW SENS = ON
MODE = 2 or 3
DHW SENS = OFF
MODE = 2
tN4 Bus Detected OR
DHW PRIORITY = ON
MODBUS RATE
MODBUS
TEMP/RATE
tN4 Bus Detected
tN4 Schedule #1
TARGET = RSET
Always
1
RTU
19K2
Advanced
Advanced
Advanced
MODBUS OFF
MODBUS OFF
MODBUS OFF
EVEN
Advanced
MODBUS OFF
TARGET MIN
MODE
Modbus
ADDRESS
DATA TYPE
BAUD RATE
PARITY
50 TO 180°F
OFF <> MNTR <> TEMP
<> RATE
1 to 247
RTU <> ASCI
2400 <> 9600 <> 19K2 <>
57K6 <> 115K
NONE <> EVEN <> ODD
OFF
Advanced
Description
Always
SETP = Setpoint
Target setpoint boiler temperature while a heat demand is
present for setpoint operation
Starting boiler target temperature when the outdoor
temperature is at outdoor start
Design boiler target temperature when the outdoor
temperature is at outdoor design
Thermal mass of boiler – 1 = low mass boiler and 3 = high
mass boiler
Selects whether a DHW sensor is used in lieu of tankstat
Target indirect DHW temperature when a DHW sensor is
selected
Differential for the target indirect DHW tank temperature
Target boiler temperature for the DHW heat exchanger
during indirect DHW operation
Selects whether or not indirect DHW priority is active during
indirect DHW operation
Sets the length of the priority override time
ModBus Operating Mode: Off, Monitor, Temp Control, Rate
Control
ModBus data type
Table D: Mode 2 Setup Menu
15
Multi-boiler Cascade with Indirect on the System
Loop – Mode 2
This section covers a cascade of up to 4 boilers used for hydronic heating in conjunction with an indirect DHW
demand located on the system loop. Reverse/return piping is shown and is recommended to ensure balanced
flow through each of the connected boilers. Primary/secondary piping is the only method supported by Raypak
to ensure proper boiler and system functionality while achieving maximum system efficiency.
Air Reset Sensor (S4a) to adjust the target water temperature as the outdoor air temperature changes. The system can also be set to operate the indirect DHW call with or without priority. The system temperature will be
controlled by the System Supply Sensor (S3a) during a call for hydronic heat or an indirect call. The Indirect
DHW Sensor (S5a) determines the indirect call based on the user defined set point. The VERSA IC™ control
system also allows for a thermostat controller (tank-stat) to be mounted in the indirect tank and provide a call for
indirect operation via contact closure in lieu of the tank sensor. The thermostat wiring connection is at the Master
PIM™ J1 terminal block at terminals 8 and 10. When using an indirect DHW sensor to control tank temperature
contact closure is required across the indirect override connections for proper operation (see IND Sensor, page
32 for further details).
During an indirect call-for-heat with or without priority selected, the cascade firing rate is determined by the
System Supply Sensor (S3a) temperature. The system will provide Max Delta T control to cycle the burner in
the event the Max Delta T is exceeded between Boiler Outlet Sensors (S1a-b-c-d) and Boiler Inlet Sensors
(S2a-b-c-d). Priority mode toggles off the System Pump (P2a) when an indirect call-for-heat is present. Boiler
Pumps (P1a-b-c-d) run in conjunction with their associated burner during all heat calls regardless of priority. The
Indirect DHW pump (P3a) runs during an indirect call-for-heat with no “off” delay. The Boiler Pumps (P1a-b-c-d)
and System Pump (P2a) delay “off” as user defined in the ADJUST menu. The System Pump (P2a) runs whenever the system is enabled for heating and the outdoor air temperature is lower than the WWSD temperature
setting (if utilized) unless an indirect call-for-heat is present with priority.
Mode 2 is used for this configuration. Ensure dip switch #1 on the Master VERSA Control Board is in the ON
position to make programming changes. It is important to remember to enable a boiler to be a follower in the
cascade by turning dip switch #2 on the VERSA Control Board to the "OFF" position for each of the followers.
and toggle from OFF to ON to allow them to operate when commanded by the Master to run.
16
Item
Range
Default
Access
Level
BOILER 1
ON <> OFF
ON
Installer
BOILER 2
ON <> OFF
OFF
Installer
BOILER 3
ON <> OFF
OFF
Installer
BOILER 4
ON <> OFF
OFF
Installer
TARGET
RSET <> SETP
SETP
Installer
Description
SETP = Setpoint
EMS
EMS=TEMP/RATE
MODE
MODB
1, 2, 3
2
Installer
MODBUS=TEMP/RATE
SETPOINT
50 to PIM™ Value
180°F
Installer
OUT START
35 TO 85°F
70°F
Advanced
MODB = ModBus
Target setpoint boiler temperature while a heat demand is present
for setpoint operation
OUT DESIGN
-60 to 45°F
10°F
Installer
Boil START
35 to 150°F
70°F
Advanced
Boil DESIGN
70 to 200°F
180°F
Installer
TARGET = RSET
Boil MASS
TARGET MAX
1 <> 2 <> 3
100°F to PIM™
Operating Limit
1
Installer
Installer
TARGET MIN
50 TO 180°F
OFF
Installer
Always
MODBUS RATE
EMS RATE
TARGET
DIFF
IND SENSOR
2 to 42°F
10°F
Installer
OFF <> ON
OFF
Installer
IND SETP
OFF, 50 TO 180°F
140°F
Installer
IND DIFF
2 to 10°F
6°F
Advanced
IND SUPPLY
OFF, 70 to 200°F
180°F
Advanced
IND
PRIORITY
PRI OVR
OFF <> ON
OFF
Advanced
Au, 0:10 to 2:00 hr
1:00 hr
Advanced
BOIL PURGE
SYS PURGE
tN4 CYCLE
tN4 SCHD
OFF, 0:20 TO 10:00 min
Au, 5 to 30 min
OFF, <> Mb1
0:20 min
0:20 min
Au
OFF
Advanced
Advanced
Advanced
Installer
WWSD
40 - 100°F, OFF
70°F
Installer
UNITS
°F <> °C
°F
MODE
Modbus
ADDRESS
DATA TYPE
BAUD RATE
PARITY
OFF, 0:20 TO 20:00 min
OFF <> MNTR <>
TEMP <> RATE
1 to 247
RTU <> ASCI
2400 <> 9600 <> 19K2
<> 57K6 <> 115K
NONE <> EVEN <> ODD
PIM™
value**
TARGET = SETP
TARGET = RSET
TARGET = RSET
TARGET = RSET
MODBUS RATE
EMS RATE
MODE = 2 or 3
MODE = 2 or 3
DHW SENS = ON
MODE = 2 or 3
DHW SENS = ON
MODE = 2 or 3
DHW SENS = OFF
Starting boiler target temperature when the outdoor temperature is
at outdoor start
Design boiler target temperature when the outdoor temperature is at
outdoor design
Thermal mass of boiler – 1 = low mass boiler and 3 = high mass boiler
Selects whether a DHW sensor is used
Target indirect DHW temperature when a DHW sensor is selected
Target boiler temperature for the DHW heat exchanger during
MODE = 2
Selects whether or not indirect DHW priority is active during indirect
DHW operation
Installer
tN4 Bus Detected
tN4 Schedule #1
TARGET = RSET
Always
1
RTU
19K2
Advanced
Advanced
Advanced
MODBUS OFF
MODBUS OFF
MODBUS OFF
ModBus data type
EVEN
Advanced
MODBUS OFF
OFF
Advanced
tN4 Bus Detected OR DHW
PRIORITY = ON
Always
ModBus Operating Mode: Off, Monitor, Temp Control, Rate Control
Table E: Mode 2 Cascade Setup Menu
17
Single Boiler with Indirect DHW on Boiler Loop –
Mode 3
This section covers a single boiler used for hydronic heating in conjunction with an indirect DHW demand located on the boiler loop. Primary/secondary piping is the only method supported by Raypak to ensure proper boiler
and system functionality while achieving maximum system efficiency.
Air Reset Sensor (S4) to adjust the target water temperature as the outdoor air temperature changes. The system will operate the indirect DHW call with priority function only. The system will be controlled by the System
Supply Sensor (S3) whenever the indirect call-for-heat is not active. The Indirect Sensor (S5) determines the
indirect call/tank set point. The VERSA IC™ control system also allows for a thermostat controller (tank-stat) to
be mounted in the indirect tank and provide a call for indirect operation via contact closure in lieu of the tank sensor. The thermostat controller wiring connection is at the PIM™ J1 terminal block at terminals 8 and 10. When
using an indirect DHW sensor to control tank temperature contact closure is required across the indirect override connections for proper operation (see IND Sensor, page 32 for further details). During an indirect
call-for-heat the firing rate is determined by the Indirect Setpoint or Max Target at the water temperature to the
Indirect System Sensor (S6). The VERSA IC™ will provide Max Delta T (Differential Temperature) control and
will cycle the burner in the event the Max Delta T is exceeded between Boiler Outlet Sensor (S1) and Boiler Inlet
Sensor (S2). The Boiler Pump (P1) runs during any call for burner operation and is delayed “off” as user defined
in the SETUP menu after the burner has shut down. The System Pump (P2) runs whenever the system is
enabled for heating and the outdoor air temperature is lower than the WWSD temperature setting (if utilized). An
indirect DHW call-for-heat will toggle the System Pump (P2) off until the indirect call-for-heat is satisfied or the
priority timer has elapsed allowing the system to return to heating mode. The Indirect DHW Pump (P3) runs during an indirect call-for-heat with no “off” delay. The System Pump is delayed “off” as user defined in the SETUP
menu.
Mode 3 is used for this configuration. Ensure dip switch #1 on the VERSA Control Board is in the ON position
to make programming changes.
18
Item
BOILER 1
Range
ON <> OFF
Default
ON
Access
Level
Installer
TARGET
RSET <> SETP
SETP
Installer
EMS
or “NO PIM™1” Error
Description
EMS=TEMP/RATE
EMS = Energy Management System (Analog Target
Temperature)
MODBUS=TEMP/RATE
MODB = ModBus
Piping and application configuration (see pages 12-20
for descriptions of applications and modes)
Target setpoint boiler temperature while a heat demand
is present for setpoint operation
MODE
MODB
1, 2, 3
3
Installer
SETPOINT
70 to PIM™ Value
180°F
Installer
OUT START
35 TO 85°F
70°F
Advanced
OUT
DESIGN
Boil START
-60 to 45°F
10°F
Installer
35 to 150°F
70°F
Advanced
Boil DESIGN
50 to 200°F
180°F
Installer
Boil MASS
1 <> 2 <> 3
1
Installer
TARGET
MAX
100°F to PIM™
Operating Limit
50 TO 180°F
PIM™
value**
Installer
50°F
Installer
2 to 42°F
Auto
Installer
OFF <> ON
OFF
Installer
OFF, 50 TO 180°F
140°F
Installer
IND DIFF
2 to 10°F
6°F
Advanced
IND SUPPLY
OFF, 70 to 200°F
180°F
Advanced
PRI OVR
Au, 0:10 to 2:00 hr
1:00 hr
Advanced
BOIL
PURGE
SYS PURGE
OFF,
0:20 TO 10:00 min
OFF,
0:20 TO 20:00 min
0:20 min
Advanced
0:20 min
Advanced
tN4 CYCLE
Au, 5 to 30 min
Au
Advanced
tN4 SCHD
OFF, <> Mb1
OFF
Installer
WWSD
40 - 100°F, OFF
70°F
Installer
UNITS
°F <> °C
°F
Installer
MODE = 2 or 3
DHW SENSOR = OFF
MODE = 2 or 3
DHW SENS = ON
MODE = 2 or 3
DHW SENS = ON
MODE = 2 or 3
DHW SENS = OFF
tN4 Bus Detected OR
DHW PRIORITY = ON
MODBUS RATE
MODBUS
TEMP/RATE
tN4 Bus Detected
tN4 Schedule #1
TARGET = RSET
Always
Advanced
Advanced
Advanced
MODBUS OFF
MODBUS OFF
MODBUS OFF
TARGET
MIN
TARGET
DIFF
IND
SENSOR
IND SETP
MODE
Modbus
ADDRESS
DATA TYPE
BAUD RATE
PARITY
OFF <> MNTR <>
TEMP <> RATE
1 to 247
RTU <> ASCI
2400 <> 9600 <>
19K2 <> 57K6 <>
115K
OFF
1
RTU
19K2
Advanced
TARGET = SETP
TARGET = RSET
TARGET = RSET
TARGET = RSET
TARGET = RSET
Always
Always
SETP = Setpoint
Design boiler target temperature when the outdoor
temperature is at outdoor design
Thermal mass of boiler – 1 = low mass boiler and 3 =
high mass boiler
Target indirect DHW temperature when a DHW sensor
is selected
Target boiler temperature for the DHW heat exchanger
during indirect DHW operation
ModBus Operating Mode: Off, Monitor, Temp Control,
Rate Control
ModBus data type
NONE <> EVEN <>
EVEN
Advanced
MODBUS OFF
ODD
Table F: Mode 3 Setup Menu
19
Multi-boiler Cascade with Indirect DHW on Boiler
Loop – Mode 3
This section covers a cascade of up to 4 boilers used for hydronic heating in conjunction with an indirect DHW
demand located on the boiler loop. Reverse/return piping is shown and is recommended to ensure balanced flow
through each of the connected boilers. Primary/secondary piping is the only method supported by Raypak to
ensure proper boiler and system functionality while achieving maximum system efficiency.
Air Reset Sensor (S4a) to adjust the target water temperature as the outdoor air temperature changes. The system will operate the indirect DHW call with priority only. The cascade firing rate will be controlled by the System
Supply Sensor (S3a) whenever the indirect call-for-heat is not active. The Indirect Sensor (S5) determines the
indirect call/tank set point. When using an indirect DHW sensor to control tank temperature contact closure is
required across the indirect override connections for proper operation. During an indirect call-for-heat the firing
rate is determined by the Indirect Setpoint or Max Target at the water temperature to the Indirect System Sensor
(S6). The system will provide Max Delta T control to cycle the burner in the event the Max Delta T is exceeded
between Boiler Outlet Sensors (S1a-b-c-d) and Boiler Inlet Sensors (S2a-b-c-d). Priority mode toggles off the
System Pump (P2a) when an indirect call-for-heat is present. Boiler Pumps (P1a-b-c-d) run in conjunction with
their associated burner during all heat calls regardless of priority. The Indirect DHW Pump (P3a) runs during an
indirect call-for-heat with no “off” delay. The Boiler Pumps (P1a-b-c-d) and System Pump (P2a) delay “off” as
user defined in the ADJUST menu. The System Pump (P2a) runs whenever the system is enabled for heating
and the outdoor air temperature is lower than the WWSD temperature setting (if utilized) unless an indirect callfor-heat is present with priority.
Mode 3 is used for this configuration. Ensure dip switch #1 on the Master VERSA Control Board is in the ON
position to make programming changes. It is important to remember to enable a boiler to be a follower in the
cascade by turning dip switch #2 on the VERSA Control Board to the "OFF" position for each of the followers.
and toggle from OFF to ON to allow them to operate when commanded by the Master to run.
20
Item
Range
Default
Access
Level
BOILER 1
ON <> OFF
ON
Installer
BOILER 2
ON <> OFF
OFF
Installer
BOILER 3
ON <> OFF
OFF
Installer
BOILER 4
ON <> OFF
OFF
Installer
TARGET
RSET <> SETP
SETP
Installer
EMS
Description
EMS=TEMP/RATE
SETP = Setpoint
MODBUS=TEMP/RATE
MODB = ModBus
MODE
1, 2, 3
3
Installer
SETPOINT
50 to PIM™ Value
180°F
Installer
OUT START
35 to 85°F
70°F
Advanced
OUT
DESIGN
Boil START
-60 to 45°F
10°F
Installer
35 to 150°F
70°F
Advanced
Boil DESIGN
70 to 200°F
180°F
Installer
Boil MASS
1 <> 2 <> 3
1
Installer
TARGET = SETP
TARGET = RSET
TARGET = RSET
TARGET = RSET
TARGET = RSET
Always
Target setpoint boiler temperature while a heat demand is
present for setpoint operation
TARGET
MAX
100°F to PIM™
Operating Limit
PIM™
value**
Installer
50°F
Installer
2 to 42°F
Auto
Installer
OFF <> ON
OFF
Installer
OFF, 50 TO 180°F
140°F
Installer
IND DIFF
2 to 10°F
6°F
Advanced
IND
SUPPLY
PRI OVR
OFF, 70 to 200°F
180°F
Advanced
Au, 0:10 to 2:00 hr
1:00 hr
Advanced
MODE = 2 or 3
DHW SENSOR = OFF
MODE = 2 or 3
DHW SENS = ON
MODE = 2 or 3
DHW SENS = ON
MODE = 2 or 3
DHW SENS = OFF
BOIL
PURGE
SYS PURGE
OFF, 0:20 to 10:00 min
0:20 min
Advanced
OFF, 0:20 to 20:00 min
0:20 min
Advanced
MODBUS RATE
tN4 CYCLE
Au, 5 to 30 min
Au
Advanced
tN4 SCHD
OFF, <> Mb1
OFF
Installer
WWSD
40 - 100°F, OFF
70°F
Installer
UNITS
°F <> °C
°F
Installer
tN4 Bus Detected
tN4 Schedule #1
TARGET = RSET
Always
1
RTU
19K2
Advanced
Advanced
Advanced
MODBUS OFF
MODBUS OFF
MODBUS OFF
EVEN
Advanced
MODBUS OFF
MODB
TARGET
MIN
TARGET
DIFF
IND
SENSOR
IND SETP
MODE
Modbus
ADDRESS
DATA TYPE
BAUD RATE
PARITY
50 to 180°F
OFF <> MNTR <>
TEMP <> RATE
1 to 247
RTU <> ASCI
2400 <> 9600 <> 19K2
<> 57K6 <> 115K
NONE <> EVEN <>
ODD
OFF
Advanced
tN4 Bus Detected OR
DHW PRIORITY = ON
MODBUS
TEMP/RATE
Always
Design boiler target temperature when the outdoor temperature
is at outdoor design
Thermal mass of boiler – 1 = low mass boiler and 3 = high
mass boiler
Target indirect DHW temperature when a DHW sensor is
selected
Target boiler temperature for the DHW heat exchanger during
ModBus Operating Mode: Off, Monitor, Temp Control, Rate
Control
ModBus data type
Table G: Mode 3 Cascade Setup Menu
21
WH – Direct DHW Applications – Single Heater
This section covers a single WH model for use on direct Domestic Hot Water heating systems used in conjunction with a storage tank. The piping configuration above is representative of a condensing heater and shows the
makeup water on the supply side of the heater. Piping for noncondensing heaters have the cold water connection between the heater outlet and the storage tank to prevent condensation in the heater.
The tank temperature will be controlled by the Supply Sensor (S3). The VERSA IC™ will provide Max Delta T
(Differential Temperature) control and will cycle the burner in the event the Max Delta T is exceeded between
Heater Outlet Sensor (S1) and Heater Inlet Sensor (S2). The Heater Pump (P1) runs during any call for burner
operation and is delayed “off” as user defined in the SETUP menu after the burner has shut down. The System
Pump output (P2) is enabled to run whenever the heater is enabled for operation. The Heater Pump (P1) runs
during any call-for-heat. The Heater Pump (P1) is delayed “off” as user defined in the ADJUST menu. The
System Pump output (P2) is delayed “off” only when the heater is disabled by opening the connection across
the enable/disable at the PIM™.
There is no mode to configure for WH operation as this is the only mode available when built as a WH model
unit. The Supply Sensor (S3) must be installed in the storage tank and functional for heater operation.
22
Item
BOILER 1
Range
ON <> OFF
TARGET
EMS
Default
ON
Access
Level
Installer
Description
Installer
EMS=TEMP/RATE
MODBUS=TEMP/RATE
PIM™ Identity is WH
MODB = ModBus
Tank setpoint temperature
Tank differential temperature
MODB
OFF, 50 to PIM™ value
125°F
Installer
2 to 10°F
5°F
Installer
BOIL
PURGE
SYS
PURGE
OFF, 0:20 to 10:00 min
0:20 min
Advanced
OFF, 0:20 to 20:00 min
0:20 min
Advanced
UNITS
°F <> °C
°F
Installer
MODBUS
TEMP/RATE
EMS TEMP/RATE
MODBUS RATE
MODBUS
TEMP/RATE
Always
TANK
SETP
TANK DIFF
MODE
Modbus
ADDRESS
DATA
TYPE
BAUD
RATE
PARITY
OFF <> MNTR <>
TEMP <> RATE
1 to 247
RTU <> ASCI
OFF
Advanced
Always
1
RTU
Advanced
Advanced
MODBUS OFF
MODBUS OFF
2400 <> 9600 <> 19K2
<> 57K6 <> 115K
NONE <> EVEN <>
ODD
19K2
Advanced
MODBUS OFF
EVEN
Advanced
MODBUS OFF
Table H: Direct DHW Setup Menu
23
EMS = Energy Management System (Analog
Target Temperature)
ModBus Operating Mode: Off, Monitor, Temp
Control, Rate Control
ModBus data type
WH – Direct DHW Applications – Multi-heater
Cascade
This section covers a cascade of up to 4 WH models for use on direct Domestic Hot Water heating systems used
in conjunction with a storage tank. The piping configuration above is representative of a cascade of condensing
heaters and shows the makeup water on the supply side of the heaters. Piping for noncondensing heaters have
the cold water connection between the heater outlet and the storage tank to prevent condensation in the heater.
The tank temperature will be controlled by the Supply Sensor (S3). The VERSA IC™ control system will provide Max Delta T control to cycle the burner in the event the Max Delta T is exceeded between Heater Outlet
Sensors (S1a-b-c-d) and Heater Inlet Sensors (S2a-b-c-d). The Heater Pumps (P1a-b-c-d) run during any call
for the associated heaters burner operation and is delayed “off” as user defined in the SETUP menu after the
associated heater burner has shut down. The System Pump output (P2a) is enabled to run whenever the heater
is enabled for operation. The System Pump output (P2a) is delayed “off” only when the heater is disabled by
opening the connection across the enable/disable at the PIM™.
There is no mode to configure for WH operation as this is the only mode available when built as a WH model
unit. Ensure dip switch #1 on the VERSA Control Board is in the ON position to make programming changes. It
is important to remember to enable a heater to be a follower in the cascade by turning dip switch #2 on the
VERSA Control Board to the "OFF" position for each of the followers. To enable Follower heaters, scroll to the
SETUP menu and, using the item button, scroll to the individual heaters and toggle from OFF to ON to allow
them to operate when commanded by the Master to run.
24
Item
BOILER 1
Range
ON <> OFF
Default
ON
Access
Level
Installer
BOILER 2
ON <> OFF
OFF
Installer
BOILER 3
ON <> OFF
OFF
Installer
BOILER 4
ON <> OFF
OFF
Installer
TARGET
EMS
TANK
SETP
TANK DIFF
MODB
OFF, 50ºF to PIM™
Value
2 to 10°F
Description
Installer
EMS=TEMP/RATE
125°F
Installer
MODBUS=TEMP/RATE
MODB = ModBus
Tank setpoint temperature
5°F
Installer
Tank differential temperature
BOIL
PURGE
SYS
PURGE
OFF, 0:20 to 10:00 min
0:20 min
Advanced
OFF, 0:20 to 20:00 min
0:20 min
Advanced
UNITS
°F <> °C
°F
Installer
MODBUS
TEMP/RATE
EMS TEMP/RATE
MODBUS RATE
MODBUS
TEMP/RATE
Always
MODE
Modbus
ADDRESS
DATA
TYPE
BAUD
RATE
PARITY
OFF <> MNTR <>
TEMP <> RATE
1 to 247
RTU <> ASCI
OFF
Advanced
Always
1
RTU
Advanced
Advanced
MODBUS OFF
MODBUS OFF
2400 <> 9600 <> 19K2
<> 57K6 <> 115K
NONE <> EVEN <>
ODD
19K2
Advanced
MODBUS OFF
EVEN
Advanced
MODBUS OFF
EMS = Energy Management System (Analog
Target Temperature)
ModBus Operating Mode: Off, Monitor, Temp
Control, Rate Control
ModBus data type
Table I: Direct DHW Cascade Setup Menu
25
VERSA IC™ Control Menus
The user interface consists of several Menu options.
Press the MENU button to scroll through the different menus in the interface. Press the ITEM button to select a
specific menu to scroll through available items within a selected menu. The UP and DOWN buttons allow for setting changes to items in the SETUP menu. The available menus are VIEW, SETUP, BOILER, MONITOR and
TOOLBOX. The RESET button is used to reset the control when a hard lockout condition has occurred. See
specific heater I&O for instructions regarding resetting the control.
User Interface Menus
The following menus are available in the control by hitting the MENU button on the membrane switch and then
pushing the ITEM button to scroll through the menus. Some menus are model specific and not available on all
equipment types.
26
VIEW Menu
The “VIEW” icon is turned on. BOILER and 1 segment are turned on if BOILER 2, 3 or 4 are set to ON.
Item
OUTDOOR
Range
---, -76 to 149°F
Access
Installer
Boil TARGET
---, -22 to 266°F
Installer
SUPPLY
---, -22 to 266°F
Installer
DHW SUPPLY
---, -22 to 266°F
Installer
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
TARGET = RSET
MASTER
MODBUS RATE
EMS RATE
MASTER
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
Boil OUTLET
---. -22 to 266°F
Installer
Mode = 3
Always
Boil INLET
---, -22 to 266°F
Installer
Always
Boil T
0 to 252°F
Installer
Always
INDIR DHW
---, -22 to 266°F
Installer
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
TANK DHW
---, -22 to 266°F
Installer
POOL
---, -22 to 266°F
Installer
MOD RATE 1
0 to 100%
Installer
MOD RATE 2
0 to 100%
Installer
MOD RATE 3
0 to 100%
Installer
MOD RATE 4
0 to 100%
Installer
STATUS
Installer
MODE = 2 or 3
DHW SENSOR = ON
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
PIM™ Identity is P
MASTER
MODBUS RATE
EMS RATE
BOILER 1 = ON
MASTER
MODBUS RATE
EMS RATE
BOILER 2 = ON
MASTER
MODBUS RATE
EMS RATE
BOILER 3 = ON
MASTER
MODBUS RATE
EMS RATE
BOILER 4 = ON
Always
Description
Local or tN4 remote outdoor air temperature, the number field displays “----“ if the
OUTDOOR sensor has a fault.
Current target water temperature, the number field displays “----“ when there is no
current target.
Current system supply temperature, the number field displays “----“ if the SUPPLY
sensor has a fault.
Current system DHW Supply temperature, the number field displays “----“ if the
DHW sensor has a fault.
Current boiler outlet temperature as communicated from the PIM™, the number
field displays “----“ if the outlet sensor fails.
Current boiler inlet temperature as communicated from the PIM™, the number
field displays “----“ if the inlet sensor fails.
Current temperature difference between the boiler outlet and boiler inlet, the
number field displays “----“ if the inlet and/or outlet sensor fails.
Current temperature being supplied to the indirect, the number field displays “----“
if the indirect DHW sensor fails.
Current tank temperature, the number field displays “----“ if the tank sensor fails.
Current pool temperature, the number field displays “----“ if the pool sensor fails.
Target firing rate for Boiler 1
Shows the operational status of Boiler 1
Table J: View Menu
27
BOILER View Menu
The “BOILER 1” icon is turned on. Boiler 1, 2, 3 or 4 are displayed for their respective boilers.
Item
IGNITION
VENT WALL
LIMIT TEMP
AUX TEMP
FLOW RATE
EMS Vdc
FIRE RATE
SPEEDX 1000
HIGH LIMIT
H L OFFSET
OPERATOR
AUTO DIFF
PUMP PREP
BLOW PREP
BLOW PREP
BLOW POST
BLOW POST
MIN RATE
START RATE
MAX RATE
FLAME CUR
MASS
IDENTITY
IGN TYPE
ID CARD
PIM™ ID
SW ID
Range
IDLE, PREP, IGN,
BURN, POST,
HARD, SOFT
---, 22 TO 266°F
---, 22 TO 266°F
---, 22 TO 266°F
0.0 to 10.0
0 – 100%
0.0 to 20.00
Model dependent
Model dependent
70 to 210°F
2 to 42°F
5 sec
Model dependent
Model dependent
Model dependent
Model dependent
0 – 50%
0 – 50%
100%
0 - 25
LO,
H, WH, P
1STG, 2STG, MOD
0 – 255
0 – 255
0 - 65535
Access
Level
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Advanced
Always
Always, model dependent
Always
Aux sensor present
Flow meter present
Always
Always
PIM™ Identity Modulating
Always
Always
Always
PIM™ Differential DIP set to Auto
Always
Always
Always
Always
Always
Always
Always
Always
Always
Always
Description
IDLE=no CFH; PREP=pre-purge or inter-purge between
trials for ignition; IGN=trial for ignition; BURN=burner
operating; POST=post purge; HARD=a hard lockout fault
has occurred requiring manual reset (Ignition Lockout or
manual high limit); and SOFT=a soft lockout fault has
occurred which interrupts the heating cycle (any safety
other than ignition or manual high limit).
The CFH will resume after the soft lockout fault has been
corrected and a 15 min. waiting period has expired.
Current Vent temperature
Current Outlet -Limit temperature
Auxiliary temperature sensor
Flow rate in liters per min (lpm)
Current EMS signal in Volts DC
PIM™ firing rate
Blower speed in revolutions per minute (rpm) x 1000
High Limit setting
High Limit offset for max setpoint
Operator Limit Potentiometer setting
Current auto differential
Duration of Pump Prepurge
Duration of Blower Prepurge
Blower % during Prepurge
Duration of Blower Postpurge
Blower % during Postpurge
Minimum modulation rate (%) during operation
Start modulation rate (%) during ignition
Maximum modulation rate (%) during operation
Flame current in micro-amps ( A)
Identifies the unit as boiler, water heater or pool heater
PIM™ Board type
Identifies Raypak Identity Card
Identifies Raypak PIM™ PCB
PIM™ Software identification number
Table K: BOILER View Menu
28
MONITOR Menu
The “MONITOR” icon is turned on.
Item
RUN TIME
Range
0 to 9999 hr
Access Level
Installer
Always
CYCLES
0 to 9999
Installer
Always
RUN TIME
0 to 9999 hr
Installer
Always
RUN TIME
0 to 9999 hr
Installer
Always
RUN TIME
0 to 9999 hr
Installer
OUTLET HI
-22to 266°F
Installer
MODBUS
TEMP/RATE
EMS TEMP/RATE
MODE = 2 or 3
Always
OUTLET LO
-22to 266°F
Installer
Always
INLET HI
-22to 266°F
Installer
Always
INLET LO
-22to 266°F
Installer
Always
DELTA HI
-22to 266°F
Installer
Always
OUTDOOR HI
-76 to 149°F
Installer
OUTDOOR LO
-76 to 149°F
Installer
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
TARGET = RSET
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
TARGET = RSET
SYS HI
-22to 266°F
Installer
SYS LO
-22to 266°F
Installer
DHW HI
-22to 266°F
Installer
DHW LO
-22to 266°F
Installer
TANK HI
-22to 266°F
Installer
TANK LO
-22to 266°F
Installer
POOL HI
-22to 266°F
Installer
POOL LO
-22to 266°F
Installer
Burner
Burner
Pumps – Boiler
PUMPS – System
PUMPS – DHW
Description
Burner runtime (hours). Press UP & DOWN buttons for 3 sec to
clear
Number of boiler cycles. Press UP & DOWN buttons for 3 sec to
clear
Boiler pump runtime (hours). Press UP & DOWN buttons for 3
sec to clear
System pump runtime (hours). Press UP & DOWN buttons for 3
sec to clear
DHW pump runtime (hours). Press UP & DOWN buttons for 3
sec to clear
Captures the highest Boiler Outlet Temperature recorded. Press
UP & DOWN buttons for 3 sec to clear
Captures the lowest Boiler Outlet Temperature recorded. Press
Captures the highest Boiler Inlet Temperature recorded. Press
Captures the lowest Boiler Inlet Temperature recorded. Press UP
& DOWN buttons for 3 sec to clear
Captures the highest Delta T Temperature recorded. Press UP &
DOWN buttons for 3 sec to clear
Captures the highest Outdoor Temperature recorded. Press UP &
Captures the lowest Outdoor Temperature recorded. Press UP &
MASTER
MODBUS RATE
EMS RATE
PIM™ Identity is H or P
MASTER
MODBUS RATE
EMS RATE
PIM™ Identity is H or P
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
MODE = 2 or 3
DHW SENS = ON
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
MODE = 2 or 3
DHW SENS = ON
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
Captures the highest System Supply Temperature recorded.
Press UP & DOWN buttons for 3 sec to clear
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
MASTER
MODBUS
TEMP/RATE
EMS TEMP/RATE
Captures the highest Pool Temperature recorded. Press UP &
Captures the lowest System Supply Temperature recorded. Press
Captures the highest indirect DHW Temperature recorded. Press
Captures the lowest indirect DHW Temperature recorded. Press
Captures the highest Tank Temperature recorded. Press UP &
Captures the lowest Tank Temperature recorded. Press UP &
Captures the lowest Pool Temperature recorded. Press UP &
Table L: MONITOR Menu
29
TOOLBOX Menu
The “TOOLBOX” icon is turned on.
Item
Range
Default
USER TEST
OFF <> ON
OFF
Advanced
When is it
Displayed
Active Error
Present
Advanced
MAX HEAT
OFF <> ON
OFF
Advanced
Advanced
P/N 104901
Installer
Always
DEFAULTS
(JXX <>
XXA)
----
Advanced
Always
tN4 DEVICE
1 to 24
Lookup Active Error
Access
Level
Installer
Advanced
Always
HISTORY-1 <->
Advanced
Logged error
present
HISTORY-2 <->
Advanced
Logged error
present
HISTORY-3 <->
Advanced
Logged error
present
HISTORY-4 <->
Advanced
Logged error
present
HISTORY-5 <->
Advanced
Logged error
present
HISTORY-6 <->
Advanced
Logged error
present
HISTORY-7 <->
Advanced
Logged error
present
HISTORY-8 <->
Advanced
Logged error
present
HISTORY-9 <->
Advanced
Logged error
present
HISTORY-10 <->
Advanced
Logged error
present
HISTORY-11<->
Advanced
Logged error
present
HISTORY-12<->
Advanced
Logged error
present
HISTORY-13<->
Advanced
Logged error
present
HISTORY-14<->
Advanced
Logged error
present
HISTORY-15<->
Advanced
Logged error
present
Table M: TOOLBOX Menu
30
Description
Lookup and display the active error information
Select ON to start the function, setting returns to OFF
after running the test.
Select ON to start the function, the setting will time out to
OFF after 24 hrs or can be set to OFF again by the user
Software number of VERSA IC™ Control. The number
field alternate Jxx <> xxA when the item is entered
Press UP & DOWN for 3 seconds to show CLR and load
factory defaults to all settings
Show the number of devices on the boiler bus
Alternate “HISTORY 1” with lookup and display the most
recent error information if less than 24 days old. Press
Control Settings
gize the heater when the tank temperature drops
to 124°F and then will shut the heater off at 130°F.
The Tank Differential defaults to 5°F with a range
of 2°F to 10°F. This value is only available to
set/change when the PIM™ identity is “WH”.
Boiler System (BOILER 1,2,3,4)
These settings inform the control how many units are
part of a cascaded system. Each heater in the cascade must have this setting adjusted to “ON” to be
recognized. In addition, dip switch #2 on the MASTER
heater VERSA Control Board should be set to “ON”
(Master) while the same dip switch for the remaining
heaters should be set to “OFF” (Follower/Slave).
Connections between the additional heaters must be
made between the respective heater PIM™ and the
Master heater VERSA Control Board (see Wiring
Connections on pages 39-41 for details).
3. Pool Differential (POOL DIFF)
Pool Differential is subtractive to the set point. For
example, in the case of a POOL SETP set point of
80°F with a 2°F differential, the control will energize the heater when the pool temperature drops
to 78°F and then will shut the heater off at 80°F.
The Pool Differential defaults to 2°F with a range
of 1°F to 5°F. This value is only available to
set/change when the PIM™ identity is “P”.
4. Indirect Differential (IND DIFF)
Indirect Differential is the differential for the indirect DHW tank temperature. It is subtractive to the
set point. For example, in the case of an IND
SETP set point of 130°F with a 6°F differential, the
control will energize the heater when the tank temperature drops to 124°F and then will shut the
heater off at 130°F. The Indirect Differential
defaults to 6°F with a range of 2°F to 10°F. This
value is only available to set/change when the
PIM™ identity is “H” and MODE = 2 or 3 and DHW
SENS = ON.
NOTE: During service or if it is determined that a
heater should NOT be operational, this value can be
set to OFF to disable a heater so the system will not
use it or calculate it in the system operation.
Target Configuration (TARGET)
This setting is used to define if the control will operate
based on Outdoor Air Reset (RSET), setpoint control
(SETP), or an Energy Management System through
the ModBus communication protocol (MODB). The
default setting is SETP.
Heater Mass (BOIL MASS)
Differential Settings
The heater mass setting (1, 2 or 3) allows the installer
to adjust the VERSA IC™ Control to the thermal mass
of the system. The heater mass setting automatically
determines the minimum “on time” and minimum “off
time” of the heater, and the PID modulation parameters. A higher thermal mass setting provides slower
modulation, while a lower thermal mass provides
faster modulation.
A heat source must be operated with a differential in
order to prevent short cycling. The heater differential is
divided around the heater target temperature.
1. Target Differential (TARGET DIFF)
Target Differential is split equally above and below
the target set point (SETPOINT). For example, in
the case of a 180°F set point with a 10°F differential, the control will energize the boiler when the
controlled temperature drops to 175°F and then
will shut the boiler off at 185°F. The Target
Differential defaults to 10°F with a range of 2°F to
42°F. This value is only available to set/change
when the PIM™ identity is “H” and the PIM™ dip
switch #1 (Operator Differential) is set to ON
(Manual Differential).
Mass = 1
Mass = 2
Mass = 3
Heater Mass Definitions
Low Volume, High Recovery
Medium Volume, Medium Recovery
High Volume, Low Recovery
NOTE: Always start with a heater mass setting of 1.
If the Control responds too rapidly, look to increase
the BOIL MASS setting.
2. Tank Differential (TANK DIFF)
Tank Differential is subtractive to the set point. For
example, in the case of a TANK SETP set point of
130°F with a 6°F differential, the control will ener-
31
Boiler Pump Purge (BOIL PURGE)
Setpoint Temperature (SETPOINT)
The VERSA IC™ Control continues to operate the
boiler pump after the burner shuts down for the time
selected. When BOIL PURGE is set to OFF, there is
no boiler pump post purge. The default timing is 20
sec, but can be adjusted from 20 sec to 10 minutes.
This is the target setpoint heater temperature when a
call-for-heat is present while operating in setpoint
operation. This value is only available to set/change
when the PIM™ identity is “H” and the TARGET =
SETP. The range of adjustments is from 50°F to the
maximum value programmed into the PIM™. The
default value is 180°F.
System Pump Purge (SYS PURGE)
The VERSA IC™ Control continues to operate the system pump after the system is shut down, either by
removing the enable closure or by warm weather shut
down (when used). When SYS PURGE is set to OFF,
there is no system pump post purge. The default timing is 20 sec, but can be adjusted from 20 sec to 20
minutes.
Maximum Target Boiler Temperature
(TARGET MAX)
This is the set point temperature for the storage tank.
It is only available to set/change when the PIM™ identity is “WH”. A range of 50°F to 150°F or 160°F (model
dependent) is available with a default of 125°F. For
temperatures in excess of this range, use an H model
boiler configured in Mode 1 for process application.
Minimum Target Boiler Temperature
(TARGET MIN)
This is the maximum target temperature that the boiler can be set to. This value is only available to
set/change when the PIM™ identity is “H”. The range
of adjustments is from 100°F to the PIM™ value.
Refer to the specific product I&O Manual for this information.
Tank Setpoint (TANK SETP)
This is the minimum target temperature that the boiler
can be set to. This value is only available to
set/change when the PIM™ identity is “H”. The range
of adjustments is from 50°F to 180°F.
Pool Setpoint (POOL SETP)
Indirect Sensor Selection
(IND SENSOR)
This is the set point temperature for the pool. This
value is only available to set/change when the PIM™
identity is “P”. A range of 50°F to 104°F is available
with a default of 80°F.
This setting determines whether a DHW sensor or an
aquastat will control the indirect DHW tank temperature for pool heating. This value is only available for
set/change when the PIM™ identity is “H”, the MODE
= 2 or 3 and the DHW SENSOR = OFF. The setting
can be “ON” or “OFF”. The default value is “OFF.”
Contact closure is required for operation across the
IND Override at the PIM™ J1 terminal block at terminals 8 and 10 when using the IND Sensor option.
Pool Maximum Supply
(SUPPLY MAX)
This is the maximum supply temperature to the pool.
This value is only available to set/change when the
PIM™ identity is “P”. The heater will shut down if the
temperature exceeds this maximum value. The range
of adjustment is 100°F to 110°F.
CAUTION: When using the IND Sensor it is recommended that the operator setpoint dial on the PIM be
set for 140°F max or an aquastat be installed on the
discharge pipe of the indirect tank to act as a secondary limit during stand alone operation to prevent
an over-temperature condition from occurring.
Mode Selection (MODE)
This MODE selection determines the operational characteristics of the system. MODE = 1 relates to
hydronic heating or process heating applications.
Mode = 2 relates to conventional heating with an indirect heating need located in the system loop piping.
Mode = 3 relates to conventional heating with an indirect heating needs located within the boiler loop
piping. Refer to the Application diagrams and descriptions on pages 10-25 for more details of how your
specific system should be configured.
32
Target Indirect DHW Temperature
(IND SETP)
Modbus Operating Mode Selection
(MODBUS)
This is the target indirect DHW water temperature setting when a DHW sensor is selected. This value is
only available for set/change when the PIM™ identity
is “H”, the MODE = 2 or 3 and the DHW SENSOR =
ON. The range of settings is 50°F to 180°F. The
default value is 140°F.
This allows the system integrator to select the Modbus
operating mode. The choices are “OFF”, monitor
(MNTR), temperature control (TEMP) and rate control
(RATE). The default setting is “OFF”.
Modbus Component Address
(ADDRESS)
Target Boiler Temperature for DHW
Heat Exchanger (IND SUPPLY)
This assigns a slave address to components on the
Modbus communication network. The range of adjustments is 1 to 247. The default value is 1.
This is the target boiler temperature for the DHW heat
exchanger during indirect DHW operation. This value
is only available to set/change when the PIM™ identity is “H”, the MODE = 2 or 3 and the DHW SENSOR =
OFF. The range of settings is 70°F to PIM™ value.
The default value is 180°F. This setting is only available when using an aquastat in the indirect tank in lieu
of a 10k Ohm sensor. When using a sensor this setting
is defaulted to the Target Max setting.
Modbus Data Type (DATA TYPE)
This assigns the Modbus data type. The options
include “RTU” and “ASCI”. The default is “RTU”.
Modbus Communication Baud Rate
(BAUD RATE)
Selection of Indirect Priority
(IND PRIORITY)
This assigns the communication speed for the Modbus
communication network. The choices include: 2400,
9600, 19K2, 57K6 and 115K. The default value is
19K2.
This selects whether or not indirect DHW priority is
active during indirect DHW operation. This value is
only available to set/change when the PIM™ identity is
“H”, the MODE = 2. The setting can be “ON” or “OFF”.
The default value is “OFF”. Mode 3 requires priority
functionality due to the piping configuration.
Modbus Parity (PARITY)
The choices are “NONE”, “EVEN” and “ODD”. The
default is “EVEN”. 1 stop bit is used for “EVEN” or
“ODD”. 2 stop bits are used for “NONE”
Priority Override Time (PRI OVR)
Tank Operation - Unoccupied
Periods (TANK UNOCC)
This selects the length of time for the priority override.
This value is only available for set/change when the
PIM™ identity is “H” and the tN4 bus is detected OR
DHW PRIORITY = ON. The settings can be “Au” or
from 10 sec to 2.0 hours. The default value is
“1:00 hr”. This will maintain the priority override until
the call-for-heat in this system is satisfied. When in set
point “Au” is not selectable.
This value determines whether a tank call-for-heat will
be addressed during unoccupied or sleep periods.
PIM™ identity is “WH” and the network is operating
under tN4 Schedule #1. The choices are “ON” or
“OFF”. The default value is “ON” meaning that a tank
CFH will be honored at anytime.
Temperature Units of Measure
(°F or °C)
Pool Operation - Unoccupied Periods
(POOL UNOCC)
This selects the units of measure to show on the display. The choices are degrees Fahrenheit (°F) and
degrees Celsius (°C). The default is degrees
Fahrenheit (°F).
33
This value determines whether a pool call-for-heat will
be addressed during unoccupied or sleep periods.
PIM™ identity is “P” and the network is operating
under tN4 Schedule #1. The choices are “ON” or
“OFF”. The default value is “ON” meaning that a pool
CFH will be honored at any time.
outdoor temperature. The heating water temperature
is controlled through the modulation and/or sequencing of the cascade.
Indirect Operation - Unoccupied
Periods (IND UNOCC)
The VERSA control can also control the system circulating pump with an adjustable Outdoor Cutoff
(WWSD). When the outdoor temperature is above the
WWSD Cutoff, the pump is turned off and no heating
water is circulated through the system. When the outdoor temperature drops below the Outdoor Cutoff, the
system pump relay is activated and the heating water
circulates through the system. The temperature of the
heating water is controlled by the Reset Ratio, Water
Offset, and changes with the outdoor temperature.
This value determines whether a DHW call-for-heat
will be addressed during unoccupied or sleep periods.
PIM™ identity is “H”, the mode = 2 or 3 and the network is operating under tN4 Schedule #1. The choices
are “ON” or “OFF”. The default value is “ON” meaning
that a DHW CFH will be honored at anytime.
WWSD Operation - Unoccupied
Periods (WWSD UNOCC)
Reset Ratio/Outdoor Reset
This value determines the WWSD temperature setting
during Master Schedule #1 Unocc/Sleep periods. This
value is only available to set/change when the PIM™
identity is “H” and the network is operating under tN4
Schedule #1. The range of values is from 40°F to
100°F. The default value is 70°F.
The starting point for most systems is the 1.00
(OD):1.00 (SYS) (Outdoor Temperature: Heating
Water Temperature) ratio. This means that for every
degree the outdoor temperature drops, the temperature of the heating water will increase one degree.
With the VERSA, both ends of the slope are
adjustable. It is factory set at 70°F water temperature
(Boil START) at 70°F outdoor air (OUT START), and
180°F water temperature (Boil DESIGN) at 10°F outdoor air (OUT DESIGN). Each building has different
heat loss characteristics. A very well insulated building
will not lose much heat to the outside air, and may
need a Reset Ratio of 2.00 (OD):1.00 (SYS) (Outdoor:
Water). This means the outdoor temperature would
have to drop 2 degrees to increase the water temperature 1 degree. On the other hand, a poorly insulated
building may need a Reset Ratio of 1.00 (OD):2.00
(SYS). This means that for each degree the outdoor
temperature dropped the water temperature will
increase 2 degrees. The VERSA control Reset Ratio
allows for full customization to match any buildings
heat loss characteristics.
tN4 Schedule Selection (tN4 SCHD)
This selects if the control will follow Master Schedule
#1. This value is only available to set/change when
the PIM™ identity is “H”. The choices are “OFF” and
“Mb1”. The default value is “OFF”.
tN4 Cycle Length (tN4 CYCLE)
This selects the cycle length which all tN4 devices synchronize to. This value is only available to set/change
when the PIM™ identity is “H” and the tN4 bus has
been detected. The choices are “Au” and 5 to 30 min-
Additional Operational
Features
A heating curve that relies not only on Outdoor temperature but also on the type of radiation will improve heat
comfort. The user can fine tune these adjustments
based on the specific building need.
Outdoor Reset Operation
When a building is being heated, heat escapes
through the walls, doors, and windows to the colder
outside air. The colder the outside temperature, the
more heat escapes. If you can input heat into the building at the same rate that it is lost out of the building,
then the building temperatures will remain constant.
The Reset Ratio is an adjustment that lets you achieve
this equilibrium between heat input and heat loss.
The VERSA control can change the System Set Point
based on outdoor temperature (Outdoor Reset). The
VERSA control varies the temperature of the circulating heating water in response to changes in the
Reset Ratio
The control uses the four following settings to determine the reset ratio:
Outdoor Starting Temperature (OUT START)
This is the outdoor temperature at which the control
starts to calculate a reset when Outdoor Reset is
active. This value is only available for set/change
when the PIM™ identity is “H” and the TARGET =
34
RSET. The range of adjustment is 35°F to 85°F. The
default value is 70°F. See Figure 9 for Outdoor Reset
curve information.
WWSD segment in the display. When the Control is in
Warm Weather Shut Down, the Control does not operate the heating system to satisfy any heating demand
– however, any water heating or indirect heating load
will override the WWSD function until such call-forheat is satisfied. This value is only available to
set/change when the PIM™ identity is “H” and the
TARGET = SETP. The range of adjustments is from
40°F to 100°F or OFF. The default value is 70°F.
Outdoor Design Temperature (OUT DESIGN)
This is the outdoor temperature that is typically the
coldest temperature of the year where the building is
located. This temperature is used when doing heat
loss calculations for the building. This value is only
available for set/change when the PIM™ identity is “H”
and the TARGET = RSET. The range of adjustment is
-60°F to 45°F. The default value is 10°F. See Figure 9
for Outdoor Reset curve information.
Reset Ratio
The VERSA control uses the following four settings as
shown to calculate the Reset Ratio (RR):
Boiler Design temperature (Boil DESIGN)
This is the water temperature required to heat the system when the outdoor air temperature is as cold as the
OUT DESIGN temperature. This value is only available for set/change when the PIM™ identity is “H” and
the TARGET = RSET. The range of adjustment is 70°F
to TARGET MAX. The default value is 180°F. See
Figure 9 for Outdoor Reset curve information.
RESET RATIO (RR) =
RR = (70 - 10) / (180 - 70) = 0.55
Pump Exercise
This feature (when enabled via dip switch #4 on the
PIM™ being set to ON) will cycle the pumps for 10
seconds every 72 hours, even with no heat demand, to
help extend the life of the pumps. During this operation, the word “EXERCISE” will display on the VERSA
IC™ Display.
Freeze Protection
This feature (when enabled via dip switch #7 on the
PIM™ being set to ON) will cycle the boiler pump on if
either the inlet or outlet heater sensors drops below
45°F. The pump will continue to operate until the temperature rises above 50°F at both sensors. If the
temperature continues to drop below 38°F as noted on
either sensor, the heater will enable a heating cycle to
operate at minimum firing rate to raise the water temperature in the boiler to avoid freezing. The heating
cycle will terminate when both the Inlet and Outlet temperatures rise above 42°F.
180°F
Should the heater be in a soft lockout condition, the
Freeze Protection operation will over-ride all soft lockout timers to operate – however, it will NOT override a
hard lockout.
135°F
-10°F
Decreasing Outdoor Temperature
Freeze protection is functional with the VERSA IC™
Control operator, but will also function in Stand-alone
mode should the VERSA IC™ Control not be functioning as long as the PIM™ dip switch #7 is enabled as
noted above.
Fig. 9: Outdoor Air Reset Curve
Warm Weather Shut Down (WWSD)
When the outdoor air temperature rises above the
WWSD setting, the VERSA IC™ Control turns on the
BOILER DESIGN — BOILER START
For example, when using the default values, the RR is:
Boiler Start Temperature (Boil START)
This is the starting boiler target temperature that the
system requires when the outdoor air temperature
equals the OUT START temperature setting. The Boil
START is typically set to the desired building temperature. This value is only available for set/change when
the PIM™ identity is “H” and the TARGET = RSET.
The range of adjustment is TARGET MIN to 150°F.
The default value is 70°F. See Figure 9 for Outdoor
Reset curve information.
70°F
OUTDOOR START — OUTDOOR DESIGN
35
Target Differential – Auto/Manual
reset button on the heater membrane switch – if present) for a period of 5 seconds shall initiate a field test
mode. The PIM™ will light the amber Alarm/Test LED
indicator and sequentially turn on the pump outputs for
a minimum of 10 seconds each. Pressing and holding
the test button (or reset button) for at least one second
will cancel the field test and the PIM™ Alarm/Test LED
shall be turned off.
The VERSA IC™ control system is configured as standard with an “Auto Differential” feature. This function
serves as part of how the controller attempts to
achieve a minimum ON time to ensure maximum system and boiler operating efficiency. The VERSA IC™
will automatically adjust the target differential during
each cycle as needed to prevent short cycling of the
burner while also trying to maintain the system supply
temperature as close to target as is possible. The user
can select via dip switch #1 on the PIM™ to disable
the auto differential function and set a fixed differential.
Typically a manual differential is suggested when
operating at elevated temperatures near the limit of
the appliance. This is done to prevent overshooting the
temperature so as not to trip the manual reset high
limit. The manual differential is adjustable from 2°F to
42°F and is split equally above and below the target
temperature.
User Test
This test is accessible from the TOOLBOX menu on
the VERSA IC™ Display. “USER TEST” is displayed
on the first line of the display and “OFF” is shown on
the 2nd line. “USER TEST” remains on the first line of
the display throughout this testing mode. Only the 2nd
line of the display changes to show the state of operation. When this functionality is enabled (push the UP
button on the membrane switch), the system begins a
system wide test of the heater. “STRT” appears on the
display, then the system pump is enabled (and the display shows “SYS”).
Minimum Run Time
After approx. 10 seconds, the DHW pump is enabled
(and the system pump disabled) and the display
shows “DHW”. After approx. 10 seconds, the boiler
pump is enabled along with the system pump (the display shows “PMP1”). After approx. 10 seconds, the
display will show “Boil 1” which initiates a CFH for this
User Test.
The VERSA IC™ Control system attempts to maintain
a minimum run time of 210 seconds for each heater.
This is accomplished several ways automatically by
the control system. One method is by automatically
adjusting the differential used around the target temperature and another is by extending the OFF time of
the burner to achieve longer ON times. However,
should the temperature exceed the full differential
above the target temperature, the heater will shut
down. Conversely, if the system temperature exceeds
the full differential below the target temperature, the
heater will fire to achieve the set point.
If the heater is enabled to run, the heater will go
through a normal trial for ignition and light. If ignition is
successful, the display will show “MIN1” and the
heater will operate at minimum firing rate. Pushing
the UP button on the membrane switch will hold the firing rate at this level as long as desired and the display
will flash “HOLD” at 1 second intervals during this period of time.
Outdoor Sensor Fault Operation
If the Outdoor Sensor is open (OPN) or shorted (SHT),
the alarm will signify the fault, but the boiler will continue operation and set the TARGET temperature based
on an outdoor temperature of 32°F.
NOTE: If the heater outlet temperature approaches
the PIM™ Hi-Limit value, the heater will ramp down
the firing rate to keep the temperature in a safe operating range.
System Sensor Fault Operation
Pressing the UP button again will step the program to
ramp up the firing rate to maximum input and “MAX1”
will display. Pressing the UP button again will hold this
firing rate for as long as desired and the display will
flash “HOLD” at 1 second intervals during this period
of time.
If the System Sensor is not functioning, the heater will
alarm to signify the fault but will still operate to achieve
target based on the Outlet Sensor. The boiler pump
will be enabled to run continuously during this fault to
ensure water flow is moving past the active outlet sensor.
Field Test
Whenever the heater is IDLE or in lockout, pressing
and holding the test/reset button on the PIM™ (or the
36
Sequence of Operation
Any CFH received from the system during this User
Test will be ignored until the test is completed.
1. Upon initial application of 24VAC power, the PIM™
resets with all outputs in the “OFF” state.
Number
Output Action
Field
SYS
DHW
PMP 1
Boil 1
Min 1
Max 1
System Pump relay turns on.
2. The PIM™ and VERSA IC™ Control perform a
processor and memory self-test to ensure proper
operation.
DHW Pump relay turns on.
System and Boiler Pump relays turn on.
3. The PIM™ confirms the presence of a valid ID
Card which matches the configuration stored in
memory at the factory. If a valid ID Card is NOT
present, the PIM™ generates a diagnostic fault
and will shut down waiting for this fault to be
addressed.
Ignite Boiler Burner.
Hold Boiler at Min Fire.
Ramp Boiler to Max Fire and hold.
Commission Test Mode
4. The PIM™ reads the dip switch settings and configures itself for the desired operation.
When the PIM™ dip switch #8 is turned to the ON
position, a Commission Test Mode is activated. The
PIM™ lights the amber Alarm/Test LED. This mode
activates certain functions to assist initial commission
testing of the system. The configured high limit temperature is overridden to match the setpoint
potentiometer position. The high limit can then be
adjusted by the potentiometer to assist commission
testing and verification. The operating setpoint is automatically set to 20°F above the high limit (stand alone
mode), or it can be controlled by the VERSA IC™
Control.
5. The PIM™ scans the Ft_bus communications for
the VERSA IC™ Control and if found, system
operation is controlled by the VERSA IC™
Control.
6. Non-volatile memory is checked for any active
lockout conditions. If any exist, they must be
addressed before the PIM™ will allow a new trial
for ignition to start.
7. The PIM™ continually monitors the flame status to
ensure that no flame is present during Standby. If
an erroneous flame is detected, the PIM™ generates a False Flame error fault.
Max Heat Function
This function sets the target temperature equal to
Boiler Maximum value whenever any demand is present. In addition, the DHW priority is disabled and
WWSD is disabled. The Max Heat function will be
aborted if 24 hours has elapsed since it was initiated
or if the user sets MAX HEAT = OFF in the TOOLBOX
menu.
8. The PIM™ verifies that the vent sensor (some
models) is below the vent limit temperature before
burner operation. If the vent temperature is
exceeded, the PIM™ performs a Post-purge and
proceeds to a hard lockout.
Max Delta T Control
9. A Call-for-heat is initiated by the presence of any
one or more of the 4 sources below:
a. A heat demand (contact closure) on the TH
field wiring terminals
b. A voltage greater than 0.5vdc on the analog 010vdc EMS signal input
c. A heat demand present on the DHW field
wiring terminals
d. A heat demand from the VERSA IC™ control
based on the DHW sensor temperature
The VERSA IC™ system is capable of controlling the
operation of the heaters so that a maximum value of
Delta T is not exceeded in an attempt to protect the
heaters from flashing to steam or damaging the heat
exchanger due to scale which can form at high temperatures.
If the Maximum Delta T value is exceeded, the heater
will shutdown (pumps will continue to operate), the
alarm light will turn on and the display will show
“DELTA T ERR”. Once the Delta T drops below half
the maximum value, the alarm light will turn off and the
heater will return to IDLE state until a CFH is present.
10. The PIM™ initiates a trial for ignition counter to the
programmed number of trials for ignition (1 or multiple) and proceeds to Pump Purge mode.
37
11. The VERSA IC™ Control will turn on the system,
boiler and/or DHW pump as necessary to address
the call-for-heat. This is dependent on the Mode
of operation selected. The pumps will proceed
through their purge period before the control will
move into a Trial for Ignition (TFI).
The gas valve output is energized for the trialfor-ignition time to light the burner.
d. The HSI is de-energized during the last second of the trial-for-ignition period to sense for
the burner flame.
e. The flame sense is checked for successful
lighting of the burner. If a valid flame is detected, the main gas valve, operating pumps and
blower relay remain energized and the PIM™
proceeds to the Heating mode.
c.
12. The VERSA Control Board and PIM™ check the
safety circuit and will stop from going into a trial for
ignition if any of the safety devices is in an
error/fault condition.
24. On heaters equipped with a Direct Spark Igniter:
a. The DSI igniter (high voltage spark output) is
energized.
b. The gas valve output is energized for the trialfor-ignition time to light the burner.
c. The flame sense is checked for successful
lighting of the burner. If a valid flame is detected, the sparking is terminated, the main gas
valve, operating pumps and blower relay
remain energized and the PIM™ proceeds to
the Heating mode.
13. If no fault condition is found, the air pressure
switch (if equipped) is verified to be in the open
position before the blower is energized.
14. The blower(s) are energized and set to pre-purge
speed (if modulating).
15. The air pressure switch is verified to close within
60 seconds to prove air flow.
16. Once the air pressure switch closes (or the blower
speed is acknowledged as operating at the prepurge speed by the tachometer output), the blower
proceeds to pre-purge for the specified duration.
25. If flame is not detected during the trial-for-ignition
period, the gas valve output is disabled immediately and the blower goes to a post-purge.
17. The voltage level of the 24VAC supply input is
confirmed to be above 18.0VAC – if not, a Low
Voltage fault will be recorded and the heater will
go into a soft lockout condition until the voltage
rises above 18.0VAC consistently.
26. On single trial-for-ignition models, the PIM™
enters ignition lockout and the LED on the PIM™
indicates the fault code for ignition lockout. The
VERSA IC™ Display should also state Ignition
Lockout.
18. If all checks have passed, the system proceeds to
ignition.
27. On multi-trial-for-ignition models, the control goes
through an interpurge delay before additional ignition attempts are started. If no flame is detected
after the final trial-for-ignition, the PIM™ enters
ignition lockout and the LED on the PIM™ indicates the fault code for ignition lockout. The
VERSA IC™ Display should also state Ignition
Lockout.
19. The PIM™ re-initializes the ignition counter to the
configured number of trials (typically 1 or 3).
20. The Hi Limit sensor is confirmed to read below the
Hi Limit setpoint.
21. The blower light-off RPM speed (modulating blowers only) is verified.
NOTE: On CSD-1 controls, recovery from ignition
lockout requires a manual reset by either pushing
the RESET button on the membrane switch (if the
heater is so equipped) or pushing the reset button on
the PIM (located next to the LEDs) on lockout controls. Recovery from ignition lockout on auto reset
controls can be accomplished by recycling the callfor-heat, removing 24VAC (turning the power off to
the heater) from the PIM for a minimum of 5 seconds
or the control will automatically reset and start a new
heating cycle if the call-for-heat is still active and the
configured reset time has elapsed.
22. The gas valve relay contacts are verified open – if
closed, a fault code will be issued and the heater
will post-purge and go into a hard lockout condition.
23. On heaters equipped with a Hot Surface Igniter:
a. The control turns on the HSI and the HSI proving current is verified to be above the
configured value.
b. The configured heat-up delay takes place to
allow the HSI element to reach ignition temperature.
38
Wiring Connections PIM™
28. During heating the flame status, air pressure
switch, LWCO, water pressure switch and other
safety switches are continually monitored for proper state.
The following information relates to the wiring connections on the PIM™, VERSA IC™ Control and VERSA
IC™ Display boards. Refer to each product specific
I&O manual for specific connections for specific models.
29. The boiler operating temperature is monitored
against the target temperature to determine the
proper firing rate or staging level.
30. The PIM™ remains in heating mode until the staging reaches 0% or the firing rate drops below the
configured minimum value for the heater.
31. When the call-for-heat is satisfied the gas
valves(s) are immediately disabled and a blower
post-purge is completed and the controls proceed
to IDLE mode.
32. The pumps complete a purge period as set in the
ADJUST menu.
33. Should a loss of flame occur on Direct Spark
Ignition models during a heating cycle, the control
will energize the high voltage spark igniter within
0.8 seconds for the configured trial-for-ignition
period in an effort to relight the burner (multi-try
models allow 3 tries for ignition with inter-purges).
If the burner relights, normal operation is resumed.
If the burner does not relight, the gas valve is deenergized immediately and the control will go into
ignition lockout.
34. Should a loss of flame occur on Hot Surface
Ignition models during a heating cycle, the gas
valve is de-energized within 0.8 seconds and the
blower goes through a post-purge. After the flame
recycle delay, the control attempts to relight the
burner (multi-try models allow 3 tries for ignition
with inter-purges). If the burner relights, normal
operation is resumed. If the burner does not
relight, the gas valve is de-energized immediately
and the control will go into ignition lockout.
Fig. 10: PIM™ Connections – DSI Control
39
PIM™ Low-Voltage Field Wiring Connections (30VAC Max)
Connector
J1
Pin #
1
J1
2
J1
3
J1
4
J1
5
J1
6
J1
7
J1
8
J1
9
J1
10
J2
1
J2
2
Function
Alarm
Contacts
Alarm
Contacts
N/A
Type & Rating
0-30VAC, 2.0A Max
– Dry contact
0-30VAC, 2.0A Max
– Dry contact
0-30VAC, 2.0A Max
Connector
J2
Pin #
3
24VAC Out
(R)
Remote
Reset
N/A
18-30VAC, 2.0A
Max
0-30VAC, 2.0A Max
24VAC Out
(R)
DHW Call
(DHW)
Heat Call
(TH)
24VAC Out
(R)
18-30VAC, 2.0A
Max
0-30VAC, 2.0A Max
DHW
Sensor
DHW
Sensor
Common
Type & Rating
10K Thermister – J
Curve
9
Function
System
Supply
Sensor
System
Sensor
Common
Outdoor
Sensor
Outdoor
Sensor
Common
tN4
Communicat
ions
0-10VDC
Analog EMS
Input
Common
J2
4
J2
5
J2
6
J2
7
J2
8
18-30VAC, 2.0A
Max
J2
J3
1
Ft_bus B
J3
2
Ft_bus A
22AWG Twisted
Pair
22AWG Twisted
Pair
Curve
Curve
J4
1
PIM™ to
VERSA IC™
Control
0-30VAC, 2.0A Max
0-30VAC, 2.0A Max
40
Curve
Curve
Curve
Communications
Network Signal
0-10 VDC or 420mA
Ground
RJ45
PIM™ Factory Low-Voltage Wiring Connections
Connector
Pin #
Function
J5
1
J5
2
Ft_bus B (PIM™ to
PIM™)
Ft_bus A (PIM™ to
PIM™)
J6
1
ID Card
J6
2
ID Card
J6
3
ID Card
J7
1
Hi-Limit Sensor
J7
2
Hi-Limit Sensor
Common
J7
3
Outlet Sensor
Common
J7
4
Outlet Sensor
J8
J8
1
2
J8
J8
3
4
J8
5
NOT USED
Air Pressure
Switch (model
specific)
NOT USED
Air Pressure
Switch (model
specific) Return
Safety loop
J8
6
Safety loop
J9
1
Inlet Sensor
J9
2
Vent Sensor
J9
3
Inlet Sensor
Common
J9
4
Vent Sensor
Common
J10
J10
1
2
J10
J10
3
4
FUTURE
PWM Out
(Modulation %)
FUTURE
Tachometer Input
J10
5
J10
6
Fan Power
(18VDC)
Fan Ground
Type &
Rating
20-30AWG,
2.0A
20-30AWG,
2.0A
20-30AWG,
2.0A
20-30AWG,
2.0A
20-30AWG,
2.0A
10K
Thermister –
J Curve
10K
Thermister –
J Curve
10K
Thermister –
J Curve
10K
Thermister –
J Curve
20-30AWG,
2.0A
Connector
Pin #
Function
J10
J10
7
8
FUTURE
FUTURE
J11
J11
1
2
24VAC Power
24VAC Common
30VAC, 8A
30VAC, 8A
J12
1
120/240VAC,
8A
J12
2
J12
3
Gas Valve
Common (Isolated
Relay)
nd
2 Stage Gas
Valve
Gas Valve Return
J12
4
J12
5
J12
6
J13
1
J13
2
J13
3
Blower Output
(L1)
Blower Output
(L2)
Blower Ground
J13
4
L1 Supply Input
K5 Relay
20-30AWG,
2.0A
20-30AWG,
2.0A
20-30AWG,
2.0A
10K
Thermister –
J Curve
10K
Thermister –
J Curve
10K
Thermister –
J Curve
10K
Thermister –
J Curve
20-30AWG,
2.0A
20-30AWG,
2.0A
20-30AWG,
2.0A
41
120/240VAC,
5A
120/240VAC,
5A
120/240VAC,
8A
120/240VAC,
5A
120/240VAC,
8A
DHW Pump
J14
2
Boiler Pump
J14
3
J14
4
L1s – System
Pump Supply
System Pump
J14
5
L1 Supply Power
J14
J14
6
7
NOT USED
L2 (Neutral)
J14
8
Pumps Ground
FC+
P2
FC-
120/240VAC,
5A
120/240VAC,
5A
120/240VAC,
8A
120/240VAC,
8A
120/240VAC,
15A
1
GND
S1
S1/FS
FS
P2
120/240VAC,
5A
120/240VAC,
5A
120/240VAC,
5A
120/240VAC,
8A
120/240VAC,
8A
F1 & F2 Terminals
J14
HV
20-30AWG,
2.0A
nd
2 Stage Gas
Valve Return
Gas Valve
(MV/PV)
Valve Power
(Isolated Contact)
Type &
Rating
Spark Output (T3
Coil)
Burner Ground
Hot Surface Igniter
Hot Surface Igniter
Flame Sense Rod
Flame Current
Measurement
Flame Current
Measurement
120/240VAC,
8A
120/240VAC,
8A
25kV
5.0A Max
5.0A Max
Wiring Connections – VERSA IC™ Control
*
* CAN BE MODIFIED TO ACCEPT 4-20mA
CONSULT VERSA IC MANUAL
ALARM
Fig. 11: VERSA IC™ Control Connections
Connector
CN1
CN1
CN1
Pin #
1
2
3
Function
Aux 2
Aux 1
Common
CN1
CN1
CN1
CN1
CN1
CN1
4
5
6
7
8
9
CN1
CN1
10
11
Mod +
Mod RS485 Ground
RS485-A
RS485-B
Modbus
Ground
ModBus-A
ModBus-B
CN2
1
CN2
2
CN2
3
CN2
4
CN2
5
CN2
6
CN2
7
CN3
PIM™2 Ft-Bus
A
PIM™2 Ft-Bus
B
PIM™3 Ft-Bus
A
PIM™3 Ft-Bus
B
PIM™4 Ft-Bus
A
PIM™4 Ft-Bus
B
Ground
Field Wiring
CWS/CWR (S7)
S6 – IND Sensor
Aux 1 & 2
Common
CWS/CWR
FUTURE
ModBus
Communication
link
Cascade
Connections
from Master
VERSA IC™
Control to
Follower/Slave
PIM™s
Communication
Cable to PIM™
CN4
1
External Valve
CN4
2
External Valve
CN4
3
Fan/Damper
CN4
4
Fan/Damper
CN4
5
Extra
CN4
6
Extra
Dry contact
closure with call
for burner
Dry contact
closure with call
for burner
Dry contact
closure with call
for burner
42
Connector
Pin #
Function
CN5
1
CN5
2
CN5
CN5
3
4
CN5
CN5
5
6
CN5
7
CN5
8
Condensate
Switch
Vent Temp
Limit
Auto High Limit
Low Water
Cutoff
Blocked Vent
Low Gas
Pressure
High Gas
Pressure
Extra
CN6
Communication
cable to
Diagnostic
LEDs (model
specific)
CN7
Communication
cable to
VERSA IC™
Display Board
CN8
1
Flow Switch
CN8
2
CN8
3
CN8
4
CN8
5
Air Press
Switch
Factory Option
#1
Factory Option
#2
Factory Option
#3
Diagnostic
Wiring
Green – Power
On; Amber – Call
for Heat; Blue –
Burner ON; Red
- Service
Wiring the Thermostat
3. Connect the indirect tank sensor to the terminals
marked INDIRECT DHW SENSOR (see wiring
diagram). Caution should be used to ensure neither of these terminals becomes connected to
ground.
Connect the Enable/Disable terminals to the PIM™
(shown in Fig. 11). Alternately, any dry contact closure
(including a remote thermostat) across these terminals
will enable the unit to run. Caution should be used to
ensure neither of the terminals becomes connected to
ground.
Energy Mangement
System Setup
Wiring the Outdoor Sensor
Temperature or Rate Control using
an external 0–10VDC or 4-20mA
control signal
1. There is no connection required if an outdoor sensor is not used in this installation.
2. If using an Outdoor Sensor, connect the sensor
wires to the terminals marked OUTDOOR SENSOR (see wiring diagram). Caution should be
used to ensure neither of these terminals
becomes connected to ground.
1. A signal from an energy management system can
be used to control either the setpoint temperature
or the firing rate of the heater.
2. To enable this remote control function, set dip
switch #5 on the PIM™ to the UP position. Dip
switch #5 Toggles between an EMS (UP) signal or
a demand signal from the VERSA IC™ Control
(DOWN). Using dip switch #2 on the PIM™, select
between Direct Drive (UP) or Target Temperature
(DOWN) setpoint.
3. Use a minimum 18 AWG wire for runs of up to 150
feet.
4. Mount the outdoor sensor on an exterior surface of
the building, preferably on the north side of the
building in an area that will not be affected by
direct sunlight and that will be exposed to varying
weather conditions.
3. For use of a 4-20mA signal, dip switch #6 must be
in the ON (UP) position and a 500 OHM 1/2 watt
resistor wired in parallel across the input wires.
Wiring the Indirect Sensor
4. Connect an Energy Management system or other
auxiliary control signal to the terminals marked
0-10V (+/-) on the PIM™ (see Fig. 11). Caution
should be used to ensure that the +0-10V connection does not create a short to ground.
1. There is no indirect sensor connection required if
an indirect water heater is not used in the installation.
2. When the Indirect DHW call-for-heat is active, the
PIM™ communicates this to the VERSA IC™
Control. The VERSA IC™ Control calculates the
optimal operation and sends the firing rate and
pump output requests to the PIM™ so it can activate the Indirect DHW pump and Boiler pump if
needed. If an optional Indirect DHW sensor is connected to J2-1 and J2-2, the PIM™ will pass this
signal to the VERSA IC™ Control. This allows the
VERSA IC™ Control to optimize the Indirect DHW
demand to maintain the Indirect DHW setpoint.
The Indirect DHW thermostat must be closed for
proper operation when using the Indirect DHW
sensor. It is recommended that a tankstat be used
as a limiting device in conjunction with a tank sensor and wired to the Indirect DHW connections at
the PIM. If a VERSA IC™ Control is not present
the PIM™ shall activate the Indirect DHW pump
whenever the Indirect DHW call is active. The
Boiler pump may also be activated based on the
Indirect DHW piping configuration setting.
•
43
Temperature Control: Remote target temperature can be used in both single boiler
applications as well as to provide target temperature to a multi-boiler cascade. When
configured to allow an energy management system to provide a target temperature input to the
VERSA IC™ Control, the control requires both a
contact closure across the enable/disable connection as well as a DC voltage input to allow
the boiler to fire. The minimum voltage required
to operate the burner is 1.0vdc and equates to a
target temperature equal to the TARGET MIN
setting in the SETUP menu of the VERSA IC™
Control. An input voltage of 10vdc equates to a
target temperature equal to the TARGET MAX
setting in the SETUP menu. The VERSA IC™
Control will determine the firing rate required to
achieve the designated target temperature provided from the EMS.
•
Wiring the Cascade System
Communication Bus
Rate Control: Firing rate control will not work
with a multi-boiler cascade arrangement.
Multi-boiler systems require each boiler to be
driven individually when wanting to provide firing
rate control from an EMS or multi-boiler
sequencer
such
as
our
Raypak
TempTrackerMOD+ Hybrid. When configured to
allow an energy management system to provide
a burner firing rate input to the VERSA IC™
Control, the control requires both a contact closure at the enable/disable connection as well as
a DC voltage input to allow the boiler to fire. The
minimum voltage required to fire the burner is
1.0vdc which also equates to low fire. A voltage
of 10vdc equates to a call for full fire. To turn off
the burner the EMS will need to open the contact
across the enable/disable. Reducing the voltage
input signal below .88vdc will also shut off the
active burner call. When operating in response
to a firing rate input from an EMS the VERSA
IC™ Control does not provide temperature control of the system, however will still provide Max
Delta T functionality as well as Manual High
Limit operation. The EMS system is now fully
responsible for supply water temperature control
as well as managing minimum cycle times to
prevent short cycling of the equipment.
Designate the primary boiler as the master boiler/boiler1 by leaving dip switch #2 on the VERSA IC™
Control board in the ON position. All other VERSA
IC™ Controls require dip switch #2 to be toggled OFF,
designating them as followers. Follower VERSA IC™
Controls are ignored by their corresponding PIM™
Modules. Use standard 22 AWG wire to connect the
master VERSA IC™ Control to the PIM™ on the followers. A total of 3 followers can be connected to the
VERSA IC™ Control on the master. For systems
requiring more than 4 connected boilers, an external
sequencer such as the Raypak TempTrackerMOD+
Hybrid can be used.
It is recommended that the shortest length cable possible be used to reach between the boilers. Do not run
unprotected cables across the floor or where they will
become wet or damaged. Do not run communication
cables parallel with, or close to or against, high voltage
(120 volt or greater) wiring. Raypak recommends that
the total maximum length of each set of communication bus cables not exceed 200 feet.
Route the Cascade Ft_bus wires out the back of the
cabinets and connect as shown in Fig. 13. Connect
the Cascade Ft_bus wires to the PIM™ by pressing
down on the slots with a small screwdriver and then
inserting the wires into the holes. See Fig. 12.
Cascade Set-up and Operation
The VERSA IC™ system has the capability of controlling the operation of up to 4 heaters without the
addition of any external sequencing controller. In order
to establish a cascade system, the first heater needs
to have the VERSA IC™ Control dip switch #2 set to
the ON position to be recognized as the Master heater
in the system. The remaining heaters need to have
their VERSA IC™ Control dip switch #2 set to the OFF
position to be recognized as Followers/Slaves on the
system. In addition, communication wire needs to run
from the J3 connections on each heater PIM™ (minimum 22AWG twisted pair wire) to the CN2 terminals
on the VERSA IC™ Control on the Master heater.
Once the field wiring is installed as per the instructions
below it is important to remember to enable each of
the Follower boilers within the SETUP menu on the
Master boiler. Once enabled within the VERSA IC™
control system it is now possible to view the individual
boiler data at the Master boiler as well as now possible for the Master boiler to begin using the Followers
to answer any heat requests from the system.
Fig. 12: Ft_bus Wire Connection
44
VERSA
MASTER
Fig. 13: Cascade System Wiring
Cascade System Pump and Sensor
Wiring
Cascade Follower Pump and Sensor
Wiring
1. On the boiler designated as the Master, connect
the system pump wiring to the terminal block at the
rear of the unit. The output is rated for pilot duty
only (2A maximum).
1. Once the primary boiler has been identified, additional boilers will be designated as follower boilers.
Ensure dip switch #2 on each follower VERSA
IC™ Control is set to the OFF/Down position.
2. Connect the boiler pump wires to the terminal
block at the rear of their unit. Connect to terminals
4, 5, and 6.
2. For each follower boiler, connect the boiler pump
wires to the terminal block at the rear of each unit.
Connect to terminals 4, 5, and 6.
3. Connect the system supply sensor to terminals 3
and 4 on the J2 connector located on the Master
PIM™.
3. The System and DHW pump outputs are not used
on the Cascade Follower.
Alarm Connection
4. Connect the Outdoor Sensor (if used) to terminals
5 and 6 on the J2 connector located on the Master
PIM™.
An alarm bell or light may be connected to the alarm
contacts on the boiler PIM™. The Alarm Contacts are
3A rated dry contacts on a normally-open relay that
closes during fault or lockout conditions, and the maximum voltage across the contacts is 30 VAC or
30 VDC.
5. Connect the Enable/Disable wiring to terminals 9
and 10 on the J1 connector located on the Master
PIM™. This connection must be provided through
dry contacts closure.
Connections are made at J1 pins 1 and 2 on the boiler PIM™. In a cascade system, the alarm output of the
master boiler will be active if either the master boiler or
follower(s) have a lockout condition. The alarm output
of the follower boilers will only energize if a lockout
condition occurs on that specific boiler.
NOTE: This dry contacts closure can come from a
room thermostat or a remote relay. No power of any
kind should be applied to either of these terminals.
45
Stand-alone Operation
of PIM™
POTENTIOMETER
The VERSA IC™ PIM™ is fully capable of stand-alone
operation of the heater should anything happen to the
VERSA IC™ Control board or the communications
between the PIM™ and VERSA IC™ Control board.
NOTE: The PIM reverts to Stand-alone operation
mode whenever communication with the VERSA
IC™ Control Board is lost for more than 30 seconds
or if the VERSA IC™ Control is not found on the
communications bus during power up.
Fig. 14: PIM™ Potentiometer Location
The potentiometer on the PIM™ (see Figure 14) is
used to control the Operating Setpoint. This is the target outlet temperature used in the firing rate
calculations. The maximum target setpoint will be limited to the high-limit setting less the operator
safeguard, regardless of the potentiometer position.
The PIM™ calculates the required firing rate or stage
demand using a PID-based algorithm. This algorithm
uses the heater inlet and outlet sensor inputs and the
target setpoint from the operator potentiometer setting.
The algorithm uses the boiler mass and other parameter settings to refine the firing rate for optimal setpoint
control. Full auto-differential capability is retained
when enabled using the dip switch #1 on the PIM™.
The PIM™ will respond to a DHW call signal on the
field wiring terminals. The DHW pump is activated and
the temperature is controlled to the operating setpoint
of the potentiometer. The boiler pump may also be
activated based on the DHW piping configuration and
dip switch setting.
Limitations During PIM™
Stand-alone Operation
1. Diagnostic information is limited to the alarm relay
and red LED flash codes on the PIM™.
2. System Sensor operation is NOT supported.
3. DHW Sensor operation is NOT supported.
4. Outdoor Sensor and Outdoor Reset functions are
NOT supported.
5. tN4 networking support is disabled.
6. Pump purge timings are controlled by parameter
settings factory determined and are nonadjustable.
46
Troubleshooting
The PIM™ is equipped with an onboard buss type fuse
(T8AL250VP) to protect the 24VAC circuits and the
24VAC relay outputs to the gas valves. ONLY use a
type GMA fuse (8 Amp max) as a replacement for
proper operation.
Before troubleshooting the system, ensure that:
•
•
•
•
All mechanical and electrical connections are
secure and tight
All system wiring is correct
A system ground is properly connected to the
heater (The igniter, flame sensor and ignition
module must share a common ground with the
burner. Nuisance shutdowns are often caused
by a poor or erratic ground.)
The system is powered and the thermostat is
calling for heat
Fault codes are displayed on the VERSA IC™ Display.
Many of these fault codes are also displayed by a
flashing red LED on the PIM™ module. The number
of flashes indicates the fault – see Table N below for
explanation of the flash codes and troubleshooting
recommendations.
The PIM™ is equipped with an Alarm LED which flashes in response to a noted error/fault. Table N below
outlines the flash codes and recommended troubleshooting tasks to address each fault.
If the VERSA IC™ Display is showing an error/fault
code, troubleshoot as noted in Tables O and P.
Error Mode
Normal Operation
ID Card Fault
Internal Control Fault
LED Flash Code on PIM™
Red LED OFF
Red LED Steady ON, Green Power
LED OFF
Red LED Steady ON
Airflow Fault
False Flame Error
Ignition Lockout Fault
Red LED – 1 Flash
Red LED – 2 Flashes
Ignition Proving Current Fault
Low Voltage Fault
Vent Temperature Fault
Hi-Limit Fault
Sensor Fault
Low Gas Pressure Fault
Water Pressure Fault
Blower Speed Fault
LWCO Fault
Hi-Temperature Delta Fault
Ft_bus Communications Fault
General limit circuit fault
Recommended Troubleshooting
Check that the proper ID Card is securely connected. Perform a power
and system reset.
Perform a power and system reset. If the fault remains, replace the
PIM™.
Check blower operation and air flow switch.
Check for proper gas valve closure. Clean burner and electrodes.
Check the gas supply. Check transformer. Check igniters. Check wiring.
Press reset button on PIM™/membrane switch. Recycle power.
Check HSI element (for those models equipped with a hot surface
igniter). Replace as necessary.
Check the 24VAC input voltage – the voltage must be above 18.0VAC for
proper operation. Replace transformer as necessary.
Check for a blocked flue. Check the vent sensor and wiring. Check vent
connections and vent system. If damage is observed, contact a qualified
installer to have the vent system properly inspected and repaired as
necessary.
Check for proper water flow. Check hi-limit setting and outlet sensor.
Check the VERSA IC™ Control for fault identification. Check sensor and
wiring.
Check gas pressure. Verify proper low gas pressure switch operation and
setting. Check wiring.
Check system piping for leaks. Check water pressure switch (if
equipped) and connections.
Verify the tachometer signal and the connections at terminals J5 on the
PIM™.
Check the LWCO switch. Checking wiring connections. Check for
proper pump operation. Check isolation valves to ensure that they are
fully open for proper operation.
Check pump operation. Confirm proper water flow across heat
exchangers (Delta T).
Verify that the VERSA IC™ Control is connected and operating properly.
Check the cable between the PIM™ and the VERSA IC™ Control.
Check the VERSA IC™ for fault indication and troubleshooting
information.
Table N: LED Flash Codes on PIM™
47
Error Message
OUTLET SEN
Description
Heater outlet sensor fault
LIMIT SEN
High limit sensor fault
INLET SEN
Heater inlet sensor fault
VENT SEN
Vent sensor fault
INTERLOCK
Factory installed jumper in place if not shipped with
water pressure switch
WATER PRESS
Water pressure switch fault (if equipped) – Raypak
factory installed jumper in place if not shipped with
water pressure switch
Air pressure switch fault (if equipped) – Raypak factory
installed jumper in place if not shipped with air
pressure switch
Gas pressure switch fault (if equipped) – Raypak
factory installed jumper in place if not shipped with high
pressure switch and/or low gas pressure switch
AIR PRESS
GAS PRESS
IGNITION
Ignition fault
LIMIT TRIP
Boiler outlet temperature tripped the high limit
FLAME
Flame detected without call for heat
ID CARD
Invalid/missing ID Card
IGN CTRL
DELTA T
Internal PIM™ control fault
Threshold Delta T temperature exceeded
LO HSI CUR
Low HSI current at PIM™ control
LOW 24VAC
Low 24VAC power at PIM™ control
BLOW SPEED
Blower speed (rpm) out of range
SAFETY INPUT
Additional factory installed safety fault – see Product
I&O manual for specific information relating to this
Recommended Troubleshooting
Check outlet sensor
Check outlet sensor wiring
Check limit sensor
Check limit sensor wiring
Check inlet sensor
Check inlet sensor wiring
Check vent sensor
Check vent sensor wiring
Check louver end switch & wiring
Check combustion air damper end switch & wiring
Check extractor & wiring
Verify wiring at J4 terminals 6 & 7
Check heater pump
Check isolation valves
Check blower(s)
Check air pressure switch tubing
Check gas pressure switches
Check gas pressure
Check gas pressure switch tubing
Reset ignition control – Push either RESET button on membrane
switch or reset button on PIM™ or recycle power
Push reset button on high limit control if Manual Reset High Limit
tripped
Wait for water temperature to drop and auto reset high limit will reset
Check pump operation
Check bypass (if equipped) for too much water flow
Shut off gas supply
Recycle power
Check gas valve leakage
Connect ID Card mounted in heater
Contact the factory if “Invalid ID Card” is noted
Recycle power – if error continues to occur, replace PIM™
Check pump operation
Check Delta T setting
Check HSI current
Replace HSI
Replace PIM™ control
Check power supply
Check transformer
Check power supply
Check blower wiring to PIM™
Check blower type
Verify wiring at J9 – terminals 5 & 6
Table O: Error messages generated from the PIM™ but displayed on the VERSA IC™ Display
48
Error Message
CTRL SETUP
Timeout
3 sec
SUPPLY ERR
3 sec
DHWSUP ERR
3 sec
OUTDOOR ERR
3 sec
DHW ERR
3 sec
TANK ERR
3 sec
POOL ERR
3 sec
DEV LOST
3 sec
DEV ERR
3 sec
Description
EEPROM setup block read error at power up. Factory
defaults are reloaded. Operation stops until all
adjustments are checked.
System supply sensor is shorted or has an open circuit.
The control will cease operation.
Plant sensor is shorted or has an open circuit. The
control will cease operation.
Outdoor air sensor is shorted or has an open circuit.
The control will continue to operate assuming an
outdoor temperature of 32°F
Indirect DHW sensor is shorted or has an open circuit.
The control will cease operation for indirect DHW, but
will continue to operate as required for system heating.
Tank sensor is shorted or has an open circuit. The
Pool sensor is shorted or has an open circuit. The
Device xx on heater bus is lost, if device is on the tN4
bus, the zone is displayed as well.
Troubleshooting
Check all SETUP items
Check supply sensor
Check supply sensor wiring
Check Aux1 sensor
Check Aux 1 sensor wiring
Check outdoor air sensor
Check outdoor air sensor wiring
Check DHW sensor
Check DHW sensor wiring
but then
Check tank sensor
Check tank sensor wiring
Check pool sensor
Check pool sensor wiring
Check wiring between VERSA IC™ control board and all
PIM™s on the network
Check communication wiring for BMS system
Check dip switches on cascaded heaters to make sure only
1 unit is set to Master while the others are set to
Followers/Slave.
Check communication wiring at heater with noted address
Use the functionality provided for in the VERSA IC™ control
board and disable the mixing module from heater control
Check cabling and dip switch settings for Master/Follower
configuration.
Confirm cabling and dip switch settings.
but then
but then
More than 1 master detected on tN4 bus.
tN4 device at displayed address (B:xx) has an error
MIX MOD
3 sec
A mixing module has been connected to the heater bus.
PIM 1 ERR
3 sec
PIM 2 ERR
3 sec
PIM 3 ERR
3 sec
PIM 4 ERR
3 sec
CONDENSATE
3 sec
Communications with PIM™1 were established
lost.
lost.
lost.
lost.
Condensate switch has tripped
VENT TEMP
1 sec
Vent temperature switch has tripped
AUTO LIMIT
3 sec
Automatic high limit has tripped
LOW WATER
1 sec
Low water cut-off has tripped
VENT BLOCK
3 sec
Blocked vent switch has tripped
LOW GAS
1 sec
Low gas pressure switch has tripped
HIGH GAS
1 sec
High gas pressure switch has tripped
EXTRA
1 sec
WATER FLOW
3 sec
Extra limit switch has tripped – see product I&O manual
for more detail if this limit is used and how to
troubleshoot it.
Water flow switch has tripped
BLOWER
10 sec
Blower air pressure switch has tripped
OPTION 1
3 sec
OPTION 2
10 sec
OPTION 3
90 sec
Factory option #1 switch has tripped. This switch uses a
3 sec delay on initial CFH before reporting the fault
but then
Check for blockage of condensate drain
Check condensate switch
Check condensate switch wiring
Check for heat exchanger leak which might overwhelm the
capacity of the condensate drain causing this error
Check vent temperature switch
Check vent temperature switch wiring
Check PVC/CPVC/Polypropylene vent for any damage due
to excessive temperatures
Check vent for leaks near vent temperature switch
Check the automatic high limit switch
Check the automatic high limit switch wiring
Check for proper pump operation
Push reset button on LWCO control
Check LWCO probe & wiring
Check venting
Check vent pressure switch & wiring
Check vent pressure switch tubing
Push reset button on low gas pressure switch
Verify proper gas pressure
Open manual gas valves fully
Clean out drip leg
Push reset button on high gas pressure switch
Verify proper gas pressures
See product specific I&O manual troubleshooting section
Check heater pump operation
Purge air from system
Replace flow switch as necessary
Check air filter
Check blower
Check air pressure switch hose
Check wiring
Check wiring diagram to determine what is connected here
Check field interlocks such as combustion air damper
proving switch
Table P: Error messages generated from the VERSA IC™ Control Board
49
Technical Data
VERSA IC™ Control Board Ratings
Enclosure
Bare board with stand-offs
Control Load
TBD
Power Supply
Safety/Fan/Extra Relays
Modulating Output
Demands
Ambient Conditions
24 VAC +/- 10%, 60Hz
240VAC, 5A
0-10vdc, 3K min. load impedance / 0-20mA
Connect to 24VAC return to initiate demand
Inside enclosure use ONLY; 32°F to 122°F (0°C to 60°C), <90% relative humidity
non-condensing
PIM™ Ratings
Input Power
18-30 VAC 50/60Hz (Class 2 transformer)
Gas Valve Relays
5.0A max (continuous)
Input Current Drain
Combustion Blower
Hot Surface Igniter
Pump Relays
Alarm Relay
Operating Temperature
Storage Temperature
Flame Sensitivity
Flame Failure Response or
Reignition Time
Flame Detector Self-Check
Rate
Flame Failure Lockout Time
Spark Rate
Moisture Resistance
400mA @ 24VAC with gas and blower relays energized
5.0A max for standard (J2) connection
15.0A max for heavy duty (K5 relay) terminals
5.0A max, 120/240VAC
5.0A max (continuous)
2.0A, 30VDC or 30VAC max
-40°F to +176°F (-40°C to +80°C)
-40°F to +185°F (-40°C to +85°C)
0.7 µA minimum
0.8 seconds minimum
Once per second minimum
Varies by model
Remote sense – 50/60Hz; Local sense – 25/30Hz
Conformal coated to operate non-condensing to 95% relative humidity
50
Quick Start Set-up &
Programming Tips
10K Sensor Resistance Values
Temperature (°F)
Resistance (Ω)
41
25340
32
50
59
68
77
86
95
104
113
122
131
140
149
158
167
176
185
194
203
212
32550
1. Determine the piping arrangement for your particular application by referencing the Application
drawings and descriptions on pages 10 to 25.
19870
2. Install System Sensor, Outdoor Sensor, Indirect
Sensor and DHW Sensor as necessary as depicted in the appropriate Application drawing.
15700
12490
3. Wire the sensors to the VERSA IC™ system as
described on the wiring diagram of the respective
model (see model I&O wiring diagrams). Sensor
wires should be routed to the heater in separate
conduit.
10000
8059
6535
5330
4. Ensure that the entire system is ready for operation.
4372
a.
b.
c.
d.
Water piping properly filled and purged of air?
Gas pipe properly installed and purged?
Electrical connections properly installed?
For cascading systems:
i. Are communication wires properly
installed between Follower/Slave PIM™s
and the Master VERSA IC™ Control?
ii. Are the dip switches properly set for
Master/Slave operation?
e. Vent properly installed and terminated?
f. Sensor wires properly routed in separate conduit?
g. External interlocks properly installed and
wired to VERSA IC™ Control (louver interlock,
extractor, external gas valve, etc.)?
3605
2989
2490
2084
1753
1481
1256
1070
915
5. Turn on system electricity to allow programming
the VERSA IC™ Control.
786
667
6. For H models go to the ADJUST menu and set the
heater MODE as indicated on the Application
drawing – 1, 2 or 3. (Mode 1 is for stand-alone or
cascade heaters with no DHW or Indirect needs;
Mode 2 includes DHW or Indirect needs in the system loop; and Mode 3 includes DHW or Indirect
needs in the boiler loop). WH models do not
require a mode selection as they are configured
only for direct DHW operation.
7. Use the Application drawings and descriptions as
a guide to set up the control.
51
8. A change to a value will be made as soon as you
push the ITEM button, change the MENU screen
or wait until the 180 second timer expires.
12. Repeat this procedure again.
13. If reset was successful, remove power and reset
dip switches for desired operation and return the
unit to operation.
9. Should any error be displayed, check the
Troubleshooting Section to identify the source of
the error and recommended troubleshooting
ideas.
Modbus Communication
Values
Resetting PIM™ to
Accept New ID Card
The VERSA IC™ Control has a setting called Modbus
that determines how it operates when modbus is connected, as follows:
Should it be necessary to move a PIM™ control to
another dissimilar model heater, the PIM™ has to be
reset to allow the new ID Card to unlock the appropriate program parameters and to load them into the
PIM™ memory.
1. MODBUS = OFF
a. Modbus messages are ignored.
2. MODBUS = MNTR (Monitor Mode)
WARNING: DO NOT swap a PIM from 1 heater to
another heater without resetting the PIM as outlined
below.
a. The VERSA IC™ Control operates as usual,
however the modbus connection allows for
remote viewing and adjustment of selected
VERSA IC™ Control parameters.
Follow these steps for a hard reset of the PIM™ to
clear program parameters:
3. MODBUS = TEMP (Temperature Control Mode)
1. Remove power from the PIM™ control.
a. The VERSA IC™ Control operates as a slave
to a Modbus master control.
2. Set all dip switches on the PIM™ to their OFF
position.
i.
3. Unplug the current ID Card from connector J12 on
the PIM™ control.
ii.
4. Press and hold the reset/test button (located next
to the LEDs on the right side of the PIM™ board)
while powering the controller for 5 seconds.
Boiler pumps are operated as per usual
by the VERSA IC™ Control.
iii. The boiler system is operated at the target
temperature sent by the Modbus master
control.
5. The red diagnostic LED will flash indicating a successful reset. The PIM™ board’s memory is now
clear of any ID Card parameters.
1. A non-zero target temperature is
taken to be a call-for-heat.
6. Release the reset/test button.
4. MODBUS = RATE (Rate Control Mode)
7. Remove power from the PIM™ control.
a. The VERSA IC™ Control operates as a slave
to a Modbus master control.
8. Connect the new ID Card to connector J12 on the
PIM™ control.
i.
9. Power up the PIM™ control.
10. If the reset was successful, the green LED shows
steady ON.
11. If the red and yellow LEDs are ON and the green
LED is OFF, the reset was NOT successful.
DHW and System Pumps are turned on
and off according to the pump operation
sent by the Modbus master control.
ii.
52
Operates as a single boiler only (no cascade)
Pumps are turned on and off according to
the pump operation sent by the Modbus
master control
iii. The boiler is operated at the target rate
sent by the Modbus master control
Board to the “ON” position to access the Advanced
menus. The lock icon on the upper right hand corner
of the VIEW menu will disappear when configured correctly. From the VIEW menu press the MENU button
once to reach the SETUP menu. Using the ITEM button scroll to the Modbus MODE screen and select
either MNTR, TEMP or RATE for the functionality
desired. From there press the ITEM button to move to
the ADDRESS screen, DATA TYPE screen, BAUD
RATE screen and then PARITY screen to complete
setup for Modbus.
1. A non-zero target rate is taken to be a
call-for-heat
2. Target rates of 1 - 100 will translate to
boiler outputs of (min mod) - (max
mod)
To enable Modbus with the VERSA IC™ Control, you
must first turn dip switch #1 on the VERSA Control
ITEM
RANGE
DEFAULT
OFF – MNTR – TEMP
– RATE
MODBUS
ACCESS
LEVEL
WHEN
DISPLAYED
DESCRIPTION
OFF
Advanced
Always
ModBus Operating Mode: Off,
Monitor, Temp Control, Rate
Control
1
Advanced
MODBUS ON
ModBus data type
ADDRESS
1 to 247
DATA
TYPE
RTU <> ASCI
RTU
Advanced
MODBUS ON
BAUD
RATE
2400 <> 9600 <> 19K2
<> 57K6 <> 115K
19K2
Advanced
MODBUS ON
PARITY
NONE - EVEN - ODD
EVEN
Advanced
MODBUS ON
Even/Odd=1 stop bit,
None=2 stop bits
Table Q: Modbus Screens
Register
System Status
Registers
Parameter
MODBUS
Read/Write
Format
Note
R
S16
R
System Supply
Temperature
Outdoor
R
Temperature
DHW Temperature R
S16
1
S16
2
S16
3
R
S16
4
R
S16
5
R
R
S16
S16
6
7
R
R
S16
S16
8
9
R
S16
Aux 1
Temperature
Aux 2
Temperature
System Pump
System Pump
Runtime
DHW Pump
DHW Pump
Runtime
Setback
reserved
"0 = Off, 1 =
Monitor, 2 =
Temp, 3 = Rate"
Register Address
Only relevant if
MODBUS =
MNTR
Table R: Modbus System Status Registers
53
0
10
Register
Boiler 1 Status
Registers
Parameter
Read/Write
Format
Note
Register Address
16
Boiler1 detected
R
S16
Boiler1 On/Off
R/W
S16
Boiler1 Outlet
temperature
Boiler1 Inlet
temperature
Boiler1 Vent
temperature
Boiler1 High Limit
temperature
R
S16
R
S16
18
R
S16
19
R
S16
20
Boiler1 Operator
temperature
Boiler1 Mod
Rate
Boiler1 Mix Rate
R
S16
21
R
S16
22
R
S16
Boiler1 Ignition
Status
Boiler1 Runtime
Boiler1 Cycles
Boiler1 Pump
Boiler1 Pump
Runtime
Boiler1 Error
Code
Boiler1 Error
History 1
Boiler1 Error
History 2
Boiler1 Error
History 3
Boiler1 Error
History 4
Boiler1 Error
History 5
Boiler1 Error
History 6
Boiler1 Error
History 7
Boiler1 Error
History 8
Boiler1 Error
History 9
Boiler1 Error
History 10
Boiler1 Error
History 11
Boiler1 Error
History 12
Boiler1 Error
History 13
Boiler1 Error
History 14
Boiler1 Error
History 15
reserved
R
S16
R
R
R
R
S16
S16
S16
S16
25
26
27
28
R
S16
29
R
S16
30
R
S16
31
R
S16
32
R
S16
33
R
S16
34
R
S16
35
R
S16
36
R
S16
37
R
S16
38
R
S16
39
R
S16
40
R
S16
41
R
S16
42
R
S16
43
R
S16
44
"0 = boiler not
detected, 1 =
boiler detected"
"0 = offline, 1 =
online"
not available in
initial release
Table S: Boiler 1 Status Registers
54
1028
17
23
24
Register
Boiler 2 Status
Registers
Parameter
.
Read/Write
Format
Note
MODBUS =
MNTR or TEMP
"0 = boiler not
detected, 1 =
boiler detected"
"0 = offline, 1 =
online"
Register Address
45
Boiler2 detected
R
S16
Boiler2 On/Off
R/W
S16
Boiler2 Outlet
temperature
Boiler2 Inlet
temperature
Boiler2 Vent
temperature
Boiler2 High Limit
temperature
R
S16
R
S16
47
R
S16
48
R
S16
49
Boiler2 Operator
temperature
Boiler2 Mod
Rate
Boiler2 Mix Rate
R
S16
50
R
S16
51
R
S16
Boiler2 Ignition
Status
Boiler2 Runtime
Boiler2 Cycles
Boiler2 Pump
Boiler2 Pump
Runtime
Boiler2 Error
Code
Boiler2 Error
History 1
Boiler2 Error
History 2
Boiler2 Error
History 3
Boiler2 Error
History 4
Boiler2 Error
History 5
Boiler2 Error
History 6
Boiler2 Error
History 7
Boiler2 Error
History 8
Boiler2 Error
History 9
Boiler2 Error
History 10
Boiler2 Error
History 11
Boiler2 Error
History 12
Boiler2 Error
History 13
Boiler2 Error
History 14
Boiler2 Error
History 15
reserved
R
S16
R
R
R
R
S16
S16
S16
S16
54
55
56
57
R
S16
58
R
S16
59
R
S16
60
R
S16
61
R
S16
62
R
S16
63
R
S16
64
R
S16
65
R
S16
66
R
S16
67
R
S16
68
R
S16
69
R
S16
70
R
S16
71
R
S16
72
R
S16
73
not available in
initial release
Table T: Boiler 2 Status Registers
55
1029
46
52
53
Register
Boiler 3 Status
Registers
Parameter
.
Read/Write
Format
Note
MODBUS =
MNTR or TEMP
"0 = boiler not
detected, 1 =
boiler detected"
"0 = offline, 1 =
online"
Register Address
74
Boiler3 detected
R
S16
Boiler3 On/Off
R/W
S16
Boiler3 Outlet
temperature
Boiler3 Inlet
temperature
Boiler3 Vent
temperature
Boiler3 High Limit
temperature
R
S16
R
S16
76
R
S16
77
R
S16
78
Boiler3 Operator
temperature
Boiler3 Mod
Rate
Boiler3 Mix Rate
R
S16
79
R
S16
80
R
S16
Boiler3 Ignition
Status
Boiler3 Runtime
Boiler3 Cycles
Boiler3 Pump
Boiler3 Pump
Runtime
Boiler3 Error
Code
Boiler3 Error
History 1
Boiler3 Error
History 2
Boiler3 Error
History 3
Boiler3 Error
History 4
Boiler3 Error
History 5
Boiler3 Error
History 6
Boiler3 Error
History 7
Boiler3 Error
History 8
Boiler3 Error
History 9
Boiler3 Error
History 10
Boiler3 Error
History 11
Boiler3 Error
History 12
Boiler3 Error
History 13
Boiler3 Error
History 14
Boiler3 Error
History 15
reserved
R
S16
R
R
R
R
S16
S16
S16
S16
83
84
85
86
R
S16
87
R
S16
88
R
S16
89
R
S16
90
R
S16
91
R
S16
92
R
S16
93
R
S16
94
R
S16
95
R
S16
96
R
S16
97
R
S16
98
R
S16
99
R
S16
100
R
S16
101
R
S16
102
not available in
initial release
Table U: Boiler 3 Status Registers
56
1030
75
81
82
Register
Boiler 4 Status
Registers
Parameter
Read/Write
Format
Note
MODBUS =
MNTR or TEMP
"0 = boiler not
detected, 1 =
boiler detected"
"0 = offline, 1 =
online"
Register Address
103
Boiler4 detected
R
S16
Boiler4 On/Off
R/W
S16
Boiler4 Outlet
temperature
Boiler4 Inlet
temperature
Boiler4 Vent
temperature
Boiler4 High Limit
temperature
R
S16
R
S16
105
R
S16
106
R
S16
107
Boiler4 Operator
temperature
Boiler4 Mod
Rate
Boiler4 Mix Rate
R
S16
108
R
S16
109
R
S16
Boiler4 Ignition
Status
Boiler4 Runtime
Boiler4 Cycles
Boiler4 Pump
Boiler4 Pump
Runtime
Boiler4 Error
Code
Boiler4 Error
History 1
Boiler4 Error
History 2
Boiler4 Error
History 3
Boiler4 Error
History 4
Boiler4 Error
History 5
Boiler4 Error
History 6
Boiler4 Error
History 7
Boiler4 Error
History 8
Boiler4 Error
History 9
Boiler4 Error
History 10
Boiler4 Error
History 11
Boiler4 Error
History 12
Boiler4 Error
History 13
Boiler4 Error
History 14
Boiler4 Error
History 15
reserved
R
S16
R
R
R
R
S16
S16
S16
S16
112
113
114
115
R
S16
116
R
S16
117
R
S16
118
R
S16
119
R
S16
120
R
S16
121
R
S16
122
R
S16
123
R
S16
124
R
S16
125
R
S16
126
R
S16
127
R
S16
128
R
S16
129
R
S16
130
R
S16
131
not available in
initial release
Table V: Boiler 4 Status Registers
57
1031
104
110
111
Register
Monitor Mode
Parameter
Registers
Parameter
Read/Write
Format
Register Address
CH Call
R
DHW Call
R
Target temperature R
S16
S16
S16
Target rate
R
S16
Auto Diff
R
S16
Manual
Differential
R/W
S16
5 to 50F (only
1006
relevant when
auto diff is off)
MODBUS =
MNTR and Space
Heating Mode
Target Mode
R/W
S16
Setpoint Target
Outdoor Start
Outdoor Design
Boil Start
Boil Design
DHW Exchange
DHW Tank
DHW Differential
DHW Priority
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
S16
S16
S16
S16
S16
S16
S16
S16
S16
DHW During
UnOcc
R/W
S16
" 0 = Reset, 1 =
Setpoint"
70 to 200F
35 to 85F
-60 to 45F
35 to 150F
70 to 200F
70 to 200F
70 to 190F
2 to 10F
"0 = no DHW
priority, 1 = DHW
priority"
"0 = No DHW
during UnOcc, 1
= DHW during
UnOcc "
WWSD During
Occ
WWSD During
UnOcc
R/W
S16
40 to 100F
1012
R/W
S16
40 to 100F
1013
S16
S16
S16
MODBUS =
MNTR and Tank
Mode
50 to 180F
2 to 10F
"0 = No heating
during UnOcc, 1
= heating during
UnOcc"
1014
1015
1016
Monitor Mode
Space Heating
Monitor Mode
Tank
Note
MODBUS =
MNTR
Tank Setpoint
Tank Differential
Tank During
UnOcc
R/W
R/W
R/W
Monitor Mode
Pool
Pool Setpoint
Pool Differential
Pool Supply
Max
Pool During
UnOcc
reserved
R/W
R/W
R/W
S16
S16
S16
R/W
S16
degF
Plant target output 14
(%)
" 0 = off, 1 = on" 15
MODBUS =
MNTR and Pool
Mode
50 to 180F
2 to 10F
100 to 140F
"0 = No heating
during UnOcc, 1
= heating during
UnOcc"
Table W: Modbus Monitor Modes
58
11
12
13
1000
1001
1002
1003
1004
1005
1007
1008
1009
1010
1011
1017
1018
1019
1020
Register
Pump Control
Mode
Parameters
Temperature
Control Mode
Parameters
Rate Control
Mode
Parameters
Parameter
Read/Write
System Pump
DHW Pump
Boiler Pump
R/W
R/W
R/W
Format
S16
S16
S16
Note
MODBUS =
TEMP or RATE
Only relevant
when "MODBUS
= RATE"
reserved
Register Address
1021
1022
1023
MODBUS =
TEMP
Target temperature R/W
S16
70 to 200F
1024
Auto Diff
R
S16
" 0 = off, 1 = on"
132
Manual
Differential
R/W
S16
5 to 50F (only
relevant when
auto diff is off)
1025
reserved
MODBUS = RATE
Target Mod
Rate
Target Mix Rate
R/W
S16
0 - 100%
1026
R/W
S16
0 - 100% (not
available in initial
release)
1027
reserved
Table X: Modbus Control Mode Parameters
Code
0
VERSA
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Description
No Error
Errors
EEPROM
Outdoor Sensor
Supply Sensor
Plant Sensor
Mix Sensor
DHW Sensor
Tank Sensor
Pool Sensor
No PIM1
No PIM2
No PIM3
No PIM4
Condensate
Vent Temperature
Auto Hi-Limit
Low Water
Vent Blocked
Low Gas Pressure
High Gas Pressure
Extra
Flow Switch
Air Pressure
Option 1
Option 2
Option 3
Error Codes
Code
PIM
26
27
28
29
PIM
30
31
32
33
PIM
34
PIM
35
36
37
38
39
40
41
42
43
44
tN4
45
46
47
Description
Jumpers
LWCO (Jumper)
Water Pressure (Jumper)
Air Pressure (Jumper)
Gas Pressure (Jumper)
Sensors
Boiler Outlet Sensor
Boiler Inlet Sensor
Vent Sensor
High Limit Sensor
Ignition
Ignition Failure
Errors
Vent Hi-Limit
Boiler Hi-Limit
False Flame
OEM ID Card
Internal fault
Delta T Max
HSI Proof
Low Voltage
Blower Speed
Safety Input
Errors
Duplicate Master
Device Error
Device Lost
Table Y: Modbus Error Table
59
www.raypak.com
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-9725
Litho in U.S.A.
60

VERSA IC™ Control - Master Hydronics Inc

Transcription

Similar documents

pdf 4 MB | January 20, 2016

Receive a Crown Boiler Visa® Prepaid Card* with Every Mega

G M X ON LINE FLUID CONDEIONING

Bonus Plus

MOSO Boiler Fitting Squirrel

You Said You Want Training?

View brochure - Riverside Hydronics

New Technology for Multifamily_Pesce

Groenhoevelaan #S/M 0ong € 2.500,

Selected sample questions from actual licensing - Cleaver