Bryan Boilers Concert Instruction And Operation Manual

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Concert

Control

Instruction and Operation

Manual

Form 105975-01; Revision 7

April 15, 2016

Contents

Introduction

Quick Reference

Overview

Product Features

Boiler Sequence

Protection Features

Single Boiler Control

Multiple Boiler Control Sequencer

Front Panel

General Navigation

Status Screens

Installation

Quick Setup

Terminal Layout

Boiler-To-Boiler Network

Energy Management Interface

Setup & Tuning

Manual Operation

Parameter Adjustment

Response Tuning

Trouble Shooting

General Issues

Sensor Status

Limit String Status

Soft Lockouts (Holds)

Hard Lockouts

Using Archives

Specifications

General

Parameter Summary

Concert Boiler Control Instruction & Operation Manual

Boiler

783 N Chili Ave

Peru, IN 46970

Telephone 765-473-6651

Fax 765-473-3074

www.bryanboilers.com

Application

The Concert

Boiler Control (Control) has been

designed for commercial hot water boiler

applications.

Intent

This

instruction

functional, installation and setup information.

The intended users are application engineers,

I&O manual and brochure writers, development

and

specifying

contractors.

Figure 1: Control Front Panel

(Showing Home Screen)

Figure 2: Control

manual

includes

engineers

and

installing

Page 1 of 68

detailed

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Summary of Contents for Bryan Boilers Concert

Page 1 Manual Operation Parameter Adjustment Response Tuning Trouble Shooting General Issues Sensor Status Limit String Status Soft Lockouts (Holds) Hard Lockouts Using Archives Specifications Figure 2: Control General Parameter Summary Concert Boiler Control Instruction & Operation Manual Page 1 of 68...
Page 2: Introduction Quick Reference
Page 10 Page 20 Page 20 Page 20 Page 28 Information Table 1: Quick Reference * Both Peer-To-Peer Network and Modbus Remote Control may be used at the same time. Concert Boiler Control Instruction & Operation Manual Page 2 of 68...
Page 3: Introduction Overview
The boilers are modulated in “unison” (parallel) Built-in Safety Control The Control includes safety controls designed to modulation rate to ensure even heat distribution. ensure safe and reliable operation. In addition to Concert Boiler Control Instruction & Operation Manual Page 3 of 68...
Page 4 Header Temperature Sensor System Pump Return Water System Supply Water Domestic Hot Water Stack Temperature Sensor Domestic Hot or Switch Water Pump Domestic Hot Water Supply Stack Temperature Outside Air Boiler Pump Sensor Temperature Water Flow Sensor Switch Return Low Water Cutoff Switch Temperature Sensor High Limit Auto Reset Supply...
Page 5: Product Features Boiler Sequence
Product Features Boiler Sequence Figure 4: Home Screen Details Boiler “Priority” The Control accepts a call for heat (demand) from multiple places and responds according to the “Priority.” When more than 1 demand is present the higher priority demand is used to determine active boiler settings.
Page 6 Product Features Boiler Sequence Boiler Sequence Status is shown on both the Home screen and the Status Screen. Once limits have been established the boiler start/stop sequence progresses as show in the graph below; Boiler “Status” Shown on Display: Low Fire Slow Released Stabilization...
Page 7: Protection Features
Product Features Boiler Protection Features temperature for longer than a limit time delay, the Supply Water Temperature High Limit Control shuts down the boiler and delays restart. If the inverted temperature is detected more than The Control is equipped with internal operating control and high limit features.
Page 8 Product Features Boiler Sequence Temp >Setpoint CH Enabled & Termp < Setpoint (lead boiler demand active) Boiler “Status” Shown on Display: ILK OFF LCI OFF Warm Weather Shutdown Frost Protection CH Enabled DHW Enabled Blower Output Alarm Relay System Pump DHW Pump Lea d B oiler Isolation Valve...
Page 9 Product Features Boiler Protection Features Limit Devices The control monitors individual limit devices as shown in Figure 6 below. If any of these limits open the boiler will shut down and an open limit indication is provided. Additionally, the control monitors an air proving switch.
Page 10: Single Boiler Control
Product Features Single Boiler Control Control Options  Modulating Sensors Header Temperature 1. Supply 2. Header Return 3. Domestic Hot Water System Water  Modulation Setpoint Circulator Outdoor Air Reset Temperature Warm Weather Shutdown Sensor or Frost Protection Switch EMS interface Circulator Options ...
Page 11: Multiple Boiler Control Sequencer
Product Features Multiple Boiler Control Sequencer Control Options  Header Modulating Sensors Temperature 1. Header  Modulation Setpoint System Outdoor Air Reset Circulator Warm Weather Shutdown Temperature Frost Protection EMS interface Switch ONLY  Circulator Device Control Boiler, System & Domestic Connects to pumps Up to Eight...
Page 12: Product Features
Product Features Multiple Boiler Control Sequencer (continued) During low loads, the Sequence Master limits firing rates to a “Base Load Rate” to ensure modulating condensing boiler peak operating efficiency. Lower firing rates boost efficiency by helping increase the amount of flue gas water vapor condensation. The Control maintains a “Base Load Rate” until the last lag boiler is started.
Page 13 Product Features Multiple Boiler Control Sequencer (continued) Improved Availability - The following features help improve the heat availability: Backup Header Sensor In the event of a header sensor failure the lead boiler’s supply sensor is used by the Sequence Master to control firing rate.
Page 14: Front Panel General Navigation
Front Panel General Navigation Figure 10: Main Menu  Lockout History – provides data on up to 15 Main Menu The Main Menu provides access to all display manual reset Lockouts. Data collected functions. It is accessible from the Home includes cause of boiler trip, run hour and Screen.
Page 15: Status Screens
Front Panel Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” through boiler operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selecting the “status” button from the “Home” or “Menu” screens. Figure 11: Status Screen Navigation Sequencer Status Demand Status...
Page 16 Front Panel Status Screens The status screen shows data relevant to current boiler operation. All installed sensors are shown on this page as well as current modulation %, setpoint, active sensor, and much more. A detailed screen map is shown below. Manual Figure 12: Status Screen Detail Boiler Control Instruction &...
Page 17: Installation Quick Setup
Installation Quick Setup The Quick Setup Menu is accessed from the Main Menu Screen. The Quick Setup menu allows the user to review and adjust the most commonly adjusted parameters, such as Setpoints and pump output settings, from one location. Refer to Parameter Adjustment section for additional information. Setpoints Factory Range /...
Page 18: Terminal Layout
Installation Terminal Layout Figure 13: Control Terminal Layout and wiring notes Boiler Control Instruction & Operation Manual Page of 68...
Page 19 Installation Terminal Layout Figure 14: Display Terminal Layout and wiring notes Page 19 of 68 Boiler Control Instruction & Operation Manual...
Page 20: Boiler-To-Boiler Network
Installation Boiler-To-Boiler Network The Boiler-To-Boiler Network allows the Control’s Internal Sequence Master to communicate boiler information, including modulation rate and on/off commands, using a standard Ethernet cable. FREE FLEX FREE FLEX Splitter (when more than 2 boilers) (Sold Seperately) PN: 109032-01 FREE FLEX RJ45 Connection Ethernet Cable...
Page 21 Installation External Sensors Header Sensor (P/N 101935-01 or 103104-01) A header sensor must be installed and wired to the Master Sequencer “enabled” Control. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master. Refer to boiler manual’s piping diagram for installation location and Figure 15a or 15b for installation detail.
Page 22: Energy Management Interface
Installation Energy Management Interface The control system has a full featured ability to interface with an Energy Management System (EMS). The control system allows remote control and monitoring via RS485 Modbus or through direct wiring. Figure 16: Remote Demand Setup Screens (From Display “Press”...
Page 23: Installation
Installation Energy Management Interface Remote Demand Setup Screens Continued: Parameter and Description Factory Range / Setting Choices Analog Input Hysteresis This parameter adjusts the amount of hysteresis applied remote control input when 0 - 10 modulation source is set to 4-20mA. A zero value disables this feature. Analog output hysteresis This parameter adjusts the amount of hysteresis applied to the PID output when a non-PWM modulation is selected.
Page 24 Installation Energy Management Interface The following Parameters are adjustable within the System menu of the display. Access System menu by going to the Main Menu > EMS Interface > Modbus Setup. Select EMS Modbus Parameters for directions on how to edit EMS Parameters. READ ALL DIRECTIONS before entering the System Menu. Display Communication Port Setup;...
Page 25 Installation Energy Management Interface Table 8: Modbus Signal List The following is the list of available Modbus signals; Register addresses start at 0 (zero) based on the Modbus-IDA protocol specification. For more traditional addressing scheme (starting at 40001) a value of 40001 should be added to the decimal address for each register.
Page 26 Installation Energy Management Interface Table 8: Modbus Signal List (continued) Modbus Protocol Read (R)/ Description Register Name Write (W) 10,211 CH setpoint Status of local setpoint 10,453 DHW setpoint Status of local setpoint 10,546 Lead Lag setpoint Status of local setpoint 10,212 CH TOD setpoint Status of local setpoint...
Page 27 Installation Energy Management Interface Table 8: Modbus Signal List (continued) Modbus Protocol Read (R)/ Description Register Name Write (W) Building Automation may send the controller the outdoor air temperature. Use this register to change the outdoor temperature. When this register is not written every “Modbus Command Time Out”...
Page 28 Installation Energy Management Interface Table 8: Modbus Signal List (continued) Modbus Protocol Read (R)/ Description Register Name Write (W) Trouble Shooting Reasons for burner lockout No lockout, Supply high limit DHW high limit Stack High limit Flame detected out of sequence Lightoff rate proving failed Purge rate proving failed 10,034...
Page 29 Installation Energy Management Interface Table 8: Modbus Signal List (continued) Modbus Protocol Read (R)/ Description Register Name Write (W) Pump Status See Table 9 CH pump status See Table 9 DHW pump status See Table 9 Boiler pump status 128- Burner cycle count 0-999,999 (U32) 130-...
Page 30: Setup & Tuning Manual Operation
Setup & Tuning Manual Operation The Firing rate may be adjusted manually using the Operation screen. The user may select Low or High speeds, or adjust firing rate anywhere between low and high; Figure 17: Operating Screens Bar Graph & Trend Service Trend Active Sensor, Active Setpoint &...
Page 31: Parameter Adjustment
Setup & Tuning Parameter Adjustment Login to Adjust Parameters Control operation may be tailored to suit the application by adjusting parameters. To adjust parameters select the ADJUST icon located throughout the display. Press ADJUST icon to review and adjust all parameters. Parameters are password protected to discourage unauthorized or accidental changes to settings.
Page 32 Setup & Tuning Parameter Adjustment From the ADJUST menu select the following buttons to view and adjust parameters. Press System to adjust the following parameters. Range / Factory Parameter and Description Setting Choices Temperature Units Fahrenheit Fahrenheit The Temperature Units parameter determines whether temperature is represented in Celsius units of Fahrenheit or Celsius degrees.
Page 33 Setup & Tuning Parameter Adjustment System Menu Continued Factory Range / Setting Choices Parameter and Description Supervisor Password Allows for custom password to be set. Must be 9 characters or less. Only allows adjustment of supervisor password (supervisor default: 76). Cannot change Factory password.
Page 34 Setup & Tuning Parameter Adjustment WARNING Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
Page 35 Setup & Tuning Parameter Adjustment Press Pumps to adjust the following parameters. Parameter and Description Factory Range / Setting Choices Contact A: System Pump Activates the system pump output according to selected function. Never: Pump is disabled and not shown on status screen. Any Demand: Pump Runs during any call for heat.
Page 36 Setup & Tuning Parameter Adjustment Press Pumps to adjust the following parameters. Parameter and Description Factory Range / Setting Choices Overrun Time: System Pump 0 Min 0 to 60 Min Time that pump runs after demand is satisfied. Used to dissipate heat within the system.
Page 37 Setup & Tuning Parameter Adjustment Service Contacts Press to adjust the following parameters. This information may be entered from a USB thumb drive or from the screen. Refer to Using Archives section for thumb drive instructions. Factory Parameter and Description Setting Enter name Contractor...
Page 38 Setup & Tuning Parameter Adjustment Table 11: Response Speed Adjustment Guidelines Press Central Heat to adjust the following parameters. Range / Factory Parameter and Description Choices Setting Central Heat Setpoint 50 to 190 (ºF) Target temperature for the central heat priority. Value also used by the outdoor air reset function.
Page 39 Setup & Tuning Parameter Adjustment Factory Range / Setting Choices Parameter and Description Central Heat Modulation Sensor Heat Demand may respond to the boiler’s Supply Temperature or Header Outlet Sensor Outlet Temperature sensors. When Header Sensor is selected the boiler is fired in response Header Sensor Sensor...
Page 40 Setup & Tuning Parameter Adjustment Factory Range / Setting Choices Parameter and Description Domestic Hot Water Response Speed This parameter adjusts the Domestic Hot Water temperature controller Proportion Integral Derivative (PID) values. Higher values cause a larger firing rate change for each degree of temperature change.
Page 41 Setup & Tuning Parameter Adjustment Factory Range / Parameter and Description Setting Choices Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating set point temperature based on the outdoor reset curve in (see Figure 20).
Page 42 Setup & Tuning Parameter Adjustment Master Press to adjust the following parameters. Sequencer Range / Factory Parameter and Description Choices Setting Master Enable/Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Lead- Enable Lag Control. Disabled Disable WARNING: Enable ONLY one Sequence Master in the boiler to boiler network.
Page 43 Setup & Tuning Parameter Adjustment Slave Press to adjust the following parameters. Sequencer Range / Factory Parameter and Description Choices Setting Boiler Address Each boiler must be given a unique address. When “Normal” slave selection order is used, the None 1 to 8 boiler address is used by the Sequence Master as the boiler start order.
Page 44 Setup & Tuning Press Tune to access the following menus. Central Heat Press within the Tune menu to adjust the following parameters Tuning Factory Range / Parameter and Description Setting Choices Response Speed parameter This adjusts the Central Heat temperature controller Proportion Integral Derivative (PID) values.
Page 45 Setup & Tuning Domestic Hot Water Press within the Tune menu to adjust the following parameters Tuning Factory Range / Parameter and Description Setting Choices Response Speed This parameter adjusts the Domestic Hot Water temperature controller Proportion Integral Derivative (PID) values. Higher values cause a larger firing rate change for each degree of temperature change.
Page 46 Setup & Tuning Press Lead-Lag Tuning within the Tune menu to adjust the following parameters Factory Range / Parameter and Description Setting Choices Response Speed This parameter adjusts the Sequence Master temperature controller Proportion Integral Derivative (PID) values. Higher values cause a larger firing rate change for each degree of temperature change.
Page 47 Setup & Tuning Press Fan Tuning within the Tune menu to adjust the following parameters Factory Range / Parameter and Description Setting Choices Fan Speed-Up Ramp 0 to 12000 Whenever the burner is firing it will be commanded to increase its RPM no faster rpm/sec.
Page 48: Trouble- Shooting General Issues
Trouble- Shooting General Issues WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. This boiler must only be serviced by skilled and experienced service technician. Troubleshooting when “Help” icon NOT flashing; Indication Condition Possible Cause Boiler is not seeing Enable/Disable of Domestic Demand Boiler not responding to call for Demand Not Input.
Page 49 Trouble- Shooting General Issues (continued) Faults are investigated by selecting the “Help” button from the “Home” screen. When a fault is active the “Help” button flashes red. Continue selecting the flashing buttons to be directed to the Fault cause. Figure 21: General Alarms Indication Condition Possible Cause...
Page 50 Trouble- Shooting General Issues (continued) Flashing Red Condition Possible Cause Outline The following messages appear when the firing rate is limited or reduced to help avoid unnecessary cycling or lockout. Refer to Soft and Hard Lockout sections for potential corrective action. - High Stack Temperature Rate Limit (Temp >...
Page 51: Troubleshooting
Trouble- Shooting Sensors Status Supply -768 F Shorted Figure 22: Sensor Screen shown with Shorted Supply Sensor The sensor status screen is selected from the MAIN or HELP menus. A failed sensor is shown with a red background. By selecting on the individual sensors a larger display “gauge’ with applicable limits is provided. When a sensor fails “opened”...
Page 52: Limit String Status
Trouble- Shooting Limit String The Limit String Status screen shows the safety limit status. A contact icon, either “ON” or “OFF”, graphically represents each safety limit. The “ON” contact icon with normal text; the “OFF” contact icon is shown in red. “ON” means that the contact is closed and there is no issue.
Page 53: Soft Lockouts (Holds)
Trouble- Shooting Soft Lockouts (Holds) Display Faults When a soft lockout occurs, the boiler will shut down and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the soft lockout. The boiler will automatically restart once the condition that caused the lockout is corrected.
Page 54: Hard Lockouts
Trouble- Shooting Soft Lockouts (Holds) Continued Lockout Condition Number Possible Cause Shorted or miswired flame rod wiring. Flame rod shorted to ground Defective flame rod. Flame rod shorted to ground Inadequate boiler water flow. Verify that circulator is Temperature rise between supply operating and that circulator and piping are sized per Delta T and return is too high.
Page 55 Trouble- Shooting Hard Lockouts Display Faults When a fault is active the “Help” button flashes red. The “Help” button will lead you to the Help menu, which will flash to indicate the issue with the boiler. If “Hard Lockout” is flashing select that button to investigate further. Figure 25: Hard Lockout Example The Hard Lockout screen will display the Lockout number, name of the lockout, the condition that caused the lockout, possible causes, and a basic description of corrective actions that may be taken to fix the problem.
Page 56 Trouble- Shooting Hard Lockouts (continued) Condition Possible Cause Lockout Number - Inadequate boiler water flow The difference between the inlet/return and the Delta T Inlet/Outlet High outlet/supply temperature is too large. - Water flow reversed The temperature of the - No flow, sensor reversed, sensor bad return/inlet is higher than the Return Temp Higher Than temperature of the...
Page 57 Trouble- Shooting Hard Lockouts (continued) Condition Possible Cause Lockout Number - No gas pressure. - Gas pressure under minimum value shown on rating plate. - Gas line not completely purged of air. - Defective Electrode. - Loose burner ground connection. Flame failure Ignition failure - Defective Ignition Cable.
Page 58: Using Archives
Trouble Shooting Using Archives The archives are a fundamental resource for the users interested in commissioning, optimizing and trouble shooting an issue with the boiler. Using the archives a user may review up to 4 months of sensor values, up to 3000 alarms, lockout history or cycle and run history. Data may be simply viewed on screen or exported to a thumb drive for detailed analysis.
Page 59 Trouble Shooting Using Archives Alarm History The alarm history is a powerful tool that will record up to 3000 alarms. These alarms include Lockouts, Holds, Sensor Faults, EMS Communication Error or Loss, Boiler-to-Boiler Network Communication Loss, 4-20mA Errors, and Limit String Cycling. The alarms are recorded in a list with the most recent appearing at the bottom.
Page 60 Trouble Shooting Using Archives USB Thumb Drive Requirements The Thumb Drive must be formatted as a FAT32 for use with the display. In order to check the format of a USB Thumb Drive, follow these instructions:  Plug the USB Drive into a computer ...
Page 61 Trouble Shooting Using Archives An example of the Trend1-20141022.csv file follows: Table 12, Boiler State Boiler State Initiate Standby delay Standby Safe Startup Drive Purge Prepurge Drive Lightoff Preignition Test Preignition PFEP MFEP Direct Ignition Running Postpurge Lockout Page 61 of 68 Boiler Control Instruction &...
Page 62 Trouble Shooting Using Archives An example of the Alarm-20141022.csv file follows: Save Parameters to USB “Save Parameters” saves the current parameter settings of the boiler, including the contact information of the contractor, Service Company, and sales representative, to a USB Drive. This allows for easy transfer of boiler parameters from one boiler to another.
Page 63: Specifications General
Specifications General Control Display Dimensions: 9 21/64” x 6 21/64” Dimensions:  Bezel: 8.46” x 6.33” x 1.96”  Electrical Ratings: Panel Cutout: 7.75” x 5.62”  Operating voltage: 24Vac (20 to 30 Vac, 60 Hz ±5%) Electrical Ratings:  Operating voltage: DC +24V（-10% ~+15%）...
Page 64 Control (ABC), Thermal Solutions Boiler Control (TSBC), Sage2.1 & manual) Control. Energy Management Systems (EMS) Universal Gateway translates LonWorks Universal Modbus 485 to LonW orks. Compatible with Concert Boiler Control, 106433-02 Gateway Kit (includes Apex Boiler Control (ABC), Thermal Solutions Boiler Control (TSBC), gateway & manual) Sage2.1 Control.
Page 65: Parameter Summary
Specifications Parameter Summary Parameter Range Security Page System Menu Temperature Units F / C Basic Outdoor Sensor Source Not Installed / Modbus / Wired / Wireless Basic Outdoor Sensor Calibration - 50 to 50 ° Basic Antishort Cycle Time 0 - 20 minutes Basic CH Frost Protection Enable / Disable...
Page 66 Specifications Parameter Summary Parameter Range Security Page Boost Time 0 to 30 minutes Basic ° Basic Central Heat ODR Max Off Point 50 to 190 ° Basic Lead Lag CH ODR Max Off Point 50 to 190 Sequence Master Menu Supervisor Master Enable/Disable Disable / Enabled...
Page 67 Notes Page 67 of 68 Boiler Control Instruction & Operation Manual...
Page 68: Peru, In
783 N Chili Ave Peru, IN 46970 Telephone 765-473-6651 Fax 765-473-3074 www.bryanboilers.com Page 68 of 68 Boiler Control Instruction & Operation Manual...

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