Page 1: Table Of Contents
Thermal Solutions Boiler Control™ (TSBC™) Instruction Manual Contents Application The Thermal Solutions Boiler Control™ (TSBC™) has Introduction been designed for commercial hot water boiler Quick Reference applications. Overview Intent Product Features This instruction manual includes detailed functional, Boiler Sequence installation and setup information. The intended users Single Boiler Control Mode are application engineers, I&O manual and brochure...
Page 2: Introduction
Introduction Quick Reference CONTROL Outlet Sensor Outlet Sensor & Remote Sensor Remote Remote Sensor Manual MODE & Local SP Remote SP & Remote SP Control & Local SP Mode Mode LCD Display Mode Mode Mode Mode Energy Management System (EMS) Boiler Control Typical Manual Single Boiler...
Page 3 Introduction Quick Reference Abbreviation List Abbreviation Description Flame Safeguard Alarm Boiler Inlet Temperature Boiler Outlet Temperature Boiler Pump Blocked Vent Switch Common Termination Point Low Combustion Air Flow Call For Heat (CFH) Fuel Valve Energized Domestic Hot Water Heating Demand Domestic Hot Water Priority (DHWP) TSBC Sage Boiler Control...
Page 4: Overview
Overview Thermal Solutions Boiler Control Overview The Thermal Solutions Boiler Control (TSBC) is a complete boiler monitoring and automation system. The TSBC provides advanced boiler modulation, operating control, diagnostics, multiple boiler lead-lag and auxiliary device control. The TSBC provides advanced control features in an easy to use package.
Page 5 Introduction Overview TSBC Instruction Manual Page 5 of 48...
Page 6: Product Features
Product Features Boiler Sequence Notes Boiler Pump is “On” when the Boiler Pump is set to “On Always” or the boiler is lead boiler and Boiler Pump is set to “On Lead”. Boiler Pump is "On" when the Boiler Pump is set to "On Always" and WWSD is set to "WWSD of System Pump" or “Off”. System Pump is "On"...
Page 7 Product Features Boiler Sequence (Continued) Pre-Sequence States BOILER CONTROL MODE STATE Description LCD Display LCD Display Any Mode Boiler Boiler is prevented from starting, Remote On/Off (Enable) (Terminal RO) Input is not (Except for Disabled energized. Remote Control) Warm Any Mode Boiler is prevented from starting, Warm Weather Shutdown (WWSD) is enabled and Weather (Except for...
Page 8 Product Features Boiler Sequence (Continued) Multiple Boilers Boiler Start and Stop Peer-To-Peer Network Sequence Diagram (3 boiler system shown, typical for up to 8 boilers) Lead Boiler Start Water temperature is below the setpoint by more than the “On Point” differential. Temperature Based Lag Boiler Start Water temperature is below the setpoint by more than the “On Point”...
Page 9: Single Boiler Control Mode
Product Features Single Boiler Control Display Shows: Outlet Sensor & Local SP Mode Return Water Outside Air Temperature Boiler ( O + , O - ) Circulator Boiler Outlet Boiler Inlet Temperature EMS System Hardwired Connections Temperature ( BO , BC ) ( BI , BC ) Lockout Indicator ( LO ) Soft Alarm ( SO )
Page 10: Multiple Boiler Control Mode
Product Features Multiple Boiler Control Display Shows: Remote Sensor & Local SP Mode EMS System Hardwired Return Connections Water Wired to Each TSBC controller Lockout Indicator ( LO ) Soft Alarm ( SO ) Remote On / Off ( Enable ) ( RO ) Outside Air Temperature ( O + , O - )
Page 11: Ems Boiler Control Mode
Product Features Energy Management System (EMS) Boiler Control Display Shows: Outlet Sensor & Remote SP Mode Return Water Outside Air Temperature Boiler ( O + , O - ) Circulator Boiler Outlet Boiler Inlet EMS System Temperature Temperature Hardwired Connections ( BO , BC ) ( BI , BC ) Lockout Indicator ( LO )
Page 12 Product Features Energy Management System (EMS) Boiler Control (continued) Display Shows: Remote Sensor & Remote SP Mode EMS System Connections Return Water Lockout Indicator ( LO ) Wired to Each TSBC Controller Soft Alarm ( SO ) Remote On / Off ( Enable ) ( RO ) Remote Setpoint ( C + , C - ) Outside Air Temperature...
Page 13 Product Features Energy Management System (EMS) Boiler Control (continued) Display Shows: Remote Control Mode Return Water Boiler Circulator Boiler Outlet Boiler Inlet EMS System Temperature Temperature Hardwired Connections ( BO , BC ) ( BI , BC ) Lockout Indicator ( LO ) Soft Alarm ( SO ) Remote On / Off ( Enable ) ( RO ) POWER...
Page 14: Manual Boiler Control Mode
Product Features Manual Boiler Control Mode Display Shows: Manual Operation Mode and Lost Sensor Blind Mode Return Water Boiler Circulator Boiler Outlet Boiler Inlet Temperature Temperature EMS System Hardwired Connections ( BO , BC ) ( BI , BC ) Lockout Indicator ( LO ) Soft Alarm ( SO ) POWER...
Page 15: Auxiliary Device
Product Features Auxiliary Device Control Standby System Pump Start / Stop ( SO ) System Pump Feedback ( SI ) Return System Water Supply Water System Pump Start / Stop ( SP ) Mixing Valve Control ( MR , MS ) Boiler Pump Start / Stop ( BP ) Energy Management...
Page 16: Front Panel Features
Front Panel Features POWER LED [Steady On Green LED] indicates power is available down stream of the TSBC’s on board fuse. [Flashing On Green LED] indicates manual mode operation for boiler modulation, Call For Heat and/or mixing valve modulation. ALARM LED [Steady On Red LED] indicates an alarm is active. [Flashing On Red LED] indicates a lockout alarm is active and a manual reset may be required.
Page 17: Display Mode
Front Panel Display Mode All values shown in Display Mode are for display only and can not be adjusted by the operator. The keys scroll through the Display Mode screens: Boiler State Standby boiler state shown, refer to the top of pages 6 &...
Page 18: Menu Navigation
Front Panel Display Navigation Press and hold the key to leave the Display Mode and access the Main Menu: MENU Display Mode Displays: Boiler operating status, Display Only, Values Are Not Editable from this display Configuration and Setup Menus: Sensor, boiler and system options selections (refer to pages 28 through 34) Setpoints Menu: Operational, On, Off, Min &...
Page 19: Setpoints Menu
Front Panel Setpoint Menu Water Temperature Off Point Operational SP On Point Time Call For Heat Relay (CH) Call For Heat Settings Range / Choices Parameter and Description Operational Setpoint 60 F to 230 F Setpoint used in Local Setpoint Mode when not servicing a Domestic Hot Water Priority (DHWP) request.
Page 20: Installation
Installation Terminal Layout Label 101175-04 ™ Thermal Solutions Boiler Control Alternate Connection For ™ (TSBC Outside Air Temperature and RJ-45 Remote System Temperature (8 pin) Boiler Peer-To-Peer TERMINAL LAYOUT GUIDE RJ-11 Communication (10k ohm Thermister, 5 Vdc) (6 pin) (Terminal connections as viewed from front of boiler)
Page 21: External Connections
Installation External Connections System Water Temperature Sensor Mount the sensor in the common header downstream of all boiler connections. Locate the sensor a minimum distance of 10 straight pipe diameters from the flow disturbing fittings. Outdoor Air Temperature Sensor Mount the temperature sensor on an outside wall out of direct sunlight, preferably on a north facing wall. Do not mount sensor near exhaust of any kind, as this may affect readings.
Page 22 Installation External Connections (Continued) Outside Air and Remote System Temperature Sensor RJ45 Connection All boilers may be connected to the remote system temperature (RST) and the outdoor air temperature (OAT) sensors. Only one of each type sensor is needed for connections with up to eight boilers. The lead boiler is automatically enabled to monitor the sensors.
Page 23: Communication
Installation Communication The Peer-To-Peer or Modbus networks allow boiler information, including modulation rate and on/off commands, to be sent via a standard phone cable thus avoiding the cost, time and complexity of wiring multiple signals. When Wiring Modbus Communication to a Building Automation System (BAS) The Modbus communication connects to the same RJ11 port that is used by the peer-to-peer communication.
Page 24 Installation Communication (Continued) The TSBC communication selections are found on the Communication Menu. Press and hold the MENU key to leave the Display Mode and access the Main Menu: Use the keys scroll down to the Communication Menu and push the key: ENTER Communication Menu...
Page 25: Peer-To-Peer Network
Installation Peer-To-Peer Network The TSBC includes a dependable Peer-To-Peer communication network. This network allows multiple boiler modulating lead/lag control and status signals to be transferred between boilers. In order to successful use this network certain requirements must be followed. Network Relevant & Updated Parameters When using the Peer-To-Peer network certain “Network Relevant”...
Page 26: Rs485 Modbus Network
Installation RS485 Modbus Network The TSBC includes a dependable Modbus communication network. This network allows boilers to be controlled and/or monitored by a remote system via a RS485 Modbus communication network. Each TSBC is a Modbus slave with the following available boiler information: Modbus Addresses Coil Address Description...
Page 27 Installation RS485 Modbus Network Modbus Addresses (continued) Coil Address Description Read/Write coil = 0 coil = 1 Notes 00043 Annunciator Remote Temp Fail 00044 Annunciator Remote In Fail 00045 Annunciator Comm Fail 00046 Annunciator Low Inlet Temp Annunciator Memory Failure 00047 Engineering Engineering...
Page 28: Boiler Configuration Menu
Configuration & Tuning Boiler Configuration Menu Boiler operating behavior is adjusted using the configuration & tuning menus. Press and hold the MENU key to leave the Display Mode and access the Main Menu. Use the keys scroll down to the required Menu and push the key.
Page 29: System Configuration Menu
Configuration & Tuning System Configuration Menu Range / Choices Parameter and Description DHWP Enables Domestic Hot Water Priority (DHWP) control feature. When input (DP) is energized DHWP becomes active as selected: No DHWP. Isolated Demand Boiler that receives the input (DP) drops off the Peer-To-Peer network and it’s temperature setpoint is adjusted above the DHWP Setpoint.
Page 30: Setup Menu
Configuration & Tuning Setup Menu Range / Choices Parameter and Description WWSD Specifies Warm Weather Shut-Down (WWSD) control of boiler and/or system pump: Off: Ignores Warm Weather setpoint. WWSD of Boiler WWSD of boiler: When Outside Air Temperature (OAT) is higher than WWSD of Sys Pump the WWSD setpoint, inhibits boiler start.
Page 31 Configuration & Tuning Setup Menu (Continued) Range / Choices Parameter and Description Net Start Dwell The Net Start Dwell Time Delay specifies the length of time the peer-to- peer network will wait for the Main Fuel Valve Energized input (CS) to be 16 to 420 energized after a boiler Call for Heat.
Page 32 Configuration & Tuning Setup Menu (Continued) Outdoor Reset Graph Energy used by the hot water heating system can be greatly reduced by adjusting (resetting) the operating temperature setpoint as the outdoor temperature changes. Using this approach, the heat lost from the building is matched by the heat input to the building.
Page 33 Configuration & Tuning Setup Menu (Continued) Faster Response Slower Response Factory Setting PID (I) PID (P) ½ Repeats/Minute Repeats/Minute Repeats/Minute Faster Response Local PID Factory Setting Slower Response Typical TSBC PID Gain and Integral Settings Range / Choices Parameter and Description Local PID P Proportional Gain value for boiler outlet temperature sensor control Modes.
Page 34 Configuration & Tuning Setup Menu (Continued) Range / Choices Parameter and Description Mixing Valve P Proportional Gain value for boiler Inlet temperature sensor control mode. A larger gain value results in tighter, more active, PID control. Gain is the primary PID modulation rate tuning adjustment and provides the 0 to 10000 immediate mixing valve modulation response.
Page 35: Manual Mode
Configuration & Tuning Manual Mode Menu Manual mode allows the boiler modulation rate, boiler call for head output and mixing valve position to be directly positioned by the user. These are valuable tools for trouble shooting and setup. Range / Choices Parameter and Description Boiler Man/Auto Man: Remain in Manual Mode.
Page 36: Trouble Shooting
Trouble Shooting Alarm Messages Alarm Messages are shown one at a time in priority order. The message closest to the top of this List is displayed first. Following messages are not shown until the higher priority message has cleared. All alarm messages are also stored in the Fault History.
Page 37 Trouble Shooting Alarm Messages (continued) LCD Display Recommended Action Explanation Alarm Message Remote Input Check wiring and Remote Control Input Fail Fail Remote System The Remote Control Input is configured and is not connected or is above or below a valid range. When the remote control input fails the following control mode changes are taken automatically: Selected Modes Resulting Control Mode...
Page 38: Diagnostics Menu
Trouble Shooting Diagnostic Menu All values shown in Diagnostic Menu are for display only and cannot be adjusted by the operator. Press and hold the key to leave the Display Mode and access the Main Menu. MENU Use the keys scroll down to the Diagnostic Menu and push the key.
Page 39 Trouble Shooting Diagnostic Menu (Continued) Display Description DISCRETE OUTPUTS These screens provide a convenient way to trouble shoot wiring during the installation phase. Each screen provides the status of a controller output. These displays show the status of the corresponding Discrete Output. ANALOG INPUTS These screens provide a convenient way to trouble shoot wiring during the installation phase.
Page 40 Trouble Shooting Diagnostic Menu (Continued) System Menu Display Description Software Revision Software Rev. S 3.24 Displays current Software Revision. PCB Board Temperature PCB Temperature 70 F The operating range for the control is 32 to 140 F. Clear Boiler Inlet Temperature (BIT) Memory No Action History remains unchanged.
Page 41: Sensor Temperature Vs. Resistance
Trouble Shooting Sensor Temperature vs. Resistance Water Temperature Ohms of Water Temperature Ohms of Water Temperature Ohms of °C °F Resistance °C °F Resistance °C °F Resistance 110,460 16,126 3,453 103,486 15,313 3,311 96,999 14,546 3,176 90,962 13,822 1,565 85,340 13,139 1,508 80,103...
Page 42: Security Menu
Trouble Shooting Security Menu Passwords There are three Access Levels in the system; Basic, Supervisor, and Factory.  At the BASIC Access Level, the user can view many parameters, but is only allowed to edit a small sub-set of the parameters that are visible. ...
Page 43: Specifications
Specifications General Mechanical: Panel Assembly: 8 inches wide x 6 inches tall Message Display: 2 x 16 Character, 8.06 mm characters Environmental: Operating Temp: 32 to 140 F (0 to 60 C) Storage Temp: -20 to 150 F (-28 to 65 C) Humidity Limits: 15 to 95% (non-condensing) Front Panel:...
Page 44: Component Description & Repair Part Numbers
The battery is located at the back of the TSBC for easy replacement. Component Description Repair Part Number 1. Thermal Solutions Boiler Control Assembly ....................101171-03 Individual boiler operating and modulation rate control and modulating lead-lag controller. Built to UL and CSA standards.
Page 45: Appendix A Parameter Summary
Appendix A Parameter Summary Network Security Parameter Range / Choices Page Relevant* Level** Boiler Configuration Menu Update Display Units Deg F / Deg C Basic Boiler Pump None / On Always / Purge / On Lead Supervisor Update If Purge, set Pump Prepurge 0 to 600 seconds Supervisor Update...
Page 46 Appendix A Parameter Summary (continued) Network Security Parameter Range/Choices Page Relevant* Level** Setup Menu (continued) Blower Spd High 0 to100 % of full scale Factory Blower Spd Low 0 to100 % of full scale Factory Low Fire Spd 0 to100 % Modulation Rate Factory Fan Purge Spd 0 to100 % Modulation Rate...
Page 47: Customer Parameter Worksheet
Appendix B Supervisor Parameter Worksheet Parameter Range / Choices Units Boiler Configuration Menu Display Units Circle one: Deg F Deg C Boiler Pump Circle one: None On Always Purge On Lead Pump Prepurge Seconds Postpurge Delta Inlet Sensor Circle one: Mixing Valve Circle one: Spare Input...
Page 48 Appendix B Supervisor Parameter Worksheet (continued) Parameter Range / Choices Units Setpoint Menu Operational Setpoint On point Off Point High Temp Stop DHWP setpoint WWSD setpoint Max SP Min SP Min Inlet H2O Temp Max H2O Delta T Max Delta T Hold Communication Menu Protocol Circle one:...

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