Page 1: Table Of Contents
Parameter Adjustment (Showing Home Screen) Response Tuning Trouble Shooting General Issues Sensor Status Limit String Status Soft Lockouts (Holds) Hard Lockouts Using Archives Specifications General Parameter Summary Figure 2: Control Concert Control Instruction & Operation Manual Page 1 of 70...
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 Control Instruction & Operation Manual Page 2 of 70...
Page 3: Overview
Control includes supply water temperature, differential water temperature, and Control stack temperature safety limits, as well as stepped The Concert Control (Control) contains features and capabilities which help improve modulation responses. Unit modulation is adjusted heating system operation, and efficiency. By when required to help avoid loss of operation due to exceeding limits.
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 Primary Sensor Temperature pump Water Flow Sensor Switch Low Water Cutoff Switch Return Temperature High Limit Auto Reset Supply...
Page 5: Product Features Sequence
Sequencer Control if the Sequence Master has no active call for heat. Warm Weather WWSD is active and the unit will not respond to central heat demands. Shutdown (WWSD) DHW demand is not blocked by WWSD. Concert Control Instruction & Operation Page 5 of 70 Manual...
Page 6 When the call for heat ends the main fuel valve is closed and the blower is driven to the Post- fan post-purge speed. After the blower reaches the fan post-purge speed setting the 5 purge minute second combustion chamber purge is conducted. Concert Control Instruction & Operation Page 6 of 70 Manual...
Page 7 It is temperature sensors. the return water recommended that the unit be installed in a temperature exceeds supply water location that is not exposed to freezing temperatures. Concert Control Instruction & Operation Page 7 of 70 Manual...
Page 8 Opens if unit is a lead and when the unit has burner demand. Closes when the unit is locked out or in WWWSD. Primary pump: Runs when unit has burner demand. Stops when the unit is locked out or in WWSD. Concert Control Instruction & Operation Manual Page of 70...
Page 9: Protection Features
ON. Failure to close will cause a manual reset lockout • ILK OFF Lockout cause the Lockout Alarm contact to turn ON. Concert Control Instruction & Operation Manual Page of 70...
Page 10: Single Unit Control
Press Main Menu > EMS Interface > Remote Demand; User May select the Supply sensor or DHW Select Modulating Source = Local. Sensor as Modulation Sensor. Upon a DHW call for heat the setpoint is either the user Concert Control Instruction & Operation Manual Page of 70...
Page 11: Multiple Unit Control Sequencer
Under Adjust Menu, select Sequence Master and then select Sequence Master Enable. started without delay in response to a DHW call for heat. This feature allows rapid recovery of large IWH’s and multiple IWH’s. Concert Control Instruction & Operation Manual Page of 70...
Page 12 The last unit remains on line until the water features help reduce energy wasting temperature is above the setpoint more than the system temperature swings and the “Difference Above” for longer than the time delay. resulting unnecessary cycling. Concert Control Instruction & Operation Manual Page of 70...
Page 13 It may be required to wire the system pump to multiple units. Once the Sequence Master is restored to operation the individual units automatically resume their position as sequencer slaves. Concert Control Instruction & Operation Manual Page of 70...
Page 14: Front Panel General Navigation
A historical trend – Up to four (4) months of Each adjustable parameter is presented for data is collected and may be viewed on adjustment. Proper login is required. screen or saved to a Thumb Drive. Concert Control Instruction & Operation Manual Page of 70...
Page 15: Status Screens
Numeric values are also provided for accurate readings. issue with any of them. Additional information shown on this page includes current firing rate, priority, current status, and setpoint source. Concert Control Instruction & Operation Manual Page of 70...
Page 16 The status screen shows data relevant to current unit 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 Concert Control Instruction & Operation Manual Page of 70...
Page 17: Installation Quick Setup
Central Heat, Optional Priority Fresh Air Damper DHW Pump: Never DHW Pump Primary DHW Pump: Primary Loop Piped IWH Loop Piped IWH Spare Output J4, 6-7 DHW Pump: Boiler Piped IWH Fresh Air Damper Concert Control Instruction & Operation Manual Page of 70...
Page 18: Terminal Layout
Installation Terminal Layout Figure 13a: Control Terminal Layout and wiring note for units less than 1000 MBH Concert Control Instruction & Operation Manual Page of 70...
Page 19 Installation Terminal Layout Figure 13b: Control Terminal Layout and wiring note for units greater than 1000 MBH Concert Control Instruction & Operation Manual Page of 70...
Page 20 RS485 (+) MB2 A --- Pin 8 LOW VOLTAGE RS485 (-) MB2 B --- Pin 7 CONNECTIONS PCB Ground MB2 C --- Pin 2 Figure 14a: Display Terminal Layout and wiring notes Concert Control Instruction & Operation Manual Page of 70...
Page 21 Installation Terminal Layout Figure 14b: Display Terminal Layout and wiring notes Concert Control Instruction & Operation Manual Page of 70...
Page 22: Unit-To-Unit Network
Sequence Master Enabled Control’s Home Screen “press” the Status button. Confirm The Sequencer display shows the unit address of the communicating units. Communication If a unit is not shown, check Ethernet cable connections and confirm all units have unique addresses. Concert Control Instruction & Operation Manual Page of 70...
Page 23 Sequence Master. Refer to unit manual’s piping diagram for installation location and Figure 15a or 15b for installation detail. Figure 15a, Direct Immersion Type Header Sensor Installation Detail Figure 15b, Thermowell type Header Sensor Installation Detail Concert Control Instruction & Operation Manual Page of 70...
Page 24: Energy Management Interface
LL Rate to 4-20mA LL Rate to 4-20mA Sequence Master demand is provided using 4-20mA signal LL Rate to 0-10V LL Rate to 0-10V Sequence Master demand is provided using 0-10V signal Concert Control Instruction & Operation Manual Page of 70...
Page 25 The display provides a list of all EMS signals. Go to Modbus menu (Press Confirm Menu > EMS Interface) and select Points List. Use the list to verify signals Communication sent and received from the EMS. Concert Control Instruction & Operation Manual Page of 70...
Page 26 Comm Delay 10 ms 10 ms Comm Timeout 1000 ms 1000 ms Comm Retry Times PLC Default Station This is address Modbus Master is reading. (not used) Baud Rate Fine Tuning Concert Control Instruction & Operation Manual Page of 70...
Page 27 When this register is not written every “Modbus CH Sequencer Command Time Out” parameter seconds (default 30 10,562 Modbus Setpoint seconds), setpoint reverts to local setpoint valid range 60 F to 190 F Concert Control Instruction & Operation Manual Page of 70...
Page 28 10,170 Outdoor sensor -40 F (-40°C) to 266 F (130°C) 4 - 20 mA remote mA value for S2 (J8-6) parameter selectable as control input (remote set point) & (remote modulation) Concert Control Instruction & Operation Manual Page of 70...
Page 29 Prepurge – Measured Purge Time Prepurge – Drive to Lightoff Rate Preignition Test Burner control state Preignition Time Pilot Flame Establishing Period Main Flame Establishing Period Direct Burner Ignition Postpurge Lockout Concert Control Instruction & Operation Manual Page of 70...
Page 30 30 – 120, Default 30 seconds Other R/W registers should only be written when a value is needed to be changed. Only the above listed registers are stored in non-volatile registers. Concert Control Instruction & Operation Manual Page of 70...
Page 31 On from Lead Lag Central Heat demand On from local DHW demand On from local Lead Lag service On from Lead Lag DHW demand On from local Lead Lag pump demand Table 9: Pump Status Codes Concert Control Instruction & Operation Manual Page of 70...
Page 32: Setup & Tuning Manual Operation
High and Low fire position for combustion Adjust Menu. testing. NOTE: Manual control mode locks firing rate to a fixed speed. The control stays in manual even through a power cycle. Select Automatic when commissioning is complete. Concert Control Instruction & Operation Manual Page of 70...
Page 33: Parameter Adjustment
Press the Lock icon to access password screen. • Use keypad to enter Password. • Press Enter Key when complete. Figure 18: Security System Adjusting Parameters Editing parameters is accomplished as follows: Figure 19: Adjusting Parameters Concert Control Instruction & Operation Manual Page of 70...
Page 34 Supply Water > 50°F Burner Supply Water < 38°F Supply Water > 50°F Frost Protection Setpoint Outdoor Temperature at which pumps are started for frost protection. 32 (ºF) -50 to 50 (ºF) Concert Control Instruction & Operation Manual Page of 70...
Page 35 Solutions, Brand displayed on Home screen banner and unit model name. This can only be Brand Bryan Steam, changed with the factory fire test password. Dependent U.S. Boiler, Velocity Boiler Works Concert Control Instruction & Operation Manual Page of 70...
Page 36 2000 ft. 6001-8000 ft, 8001-10100 ft NOTE: Maximum Modulation Rates are designed for 100% nameplate rate at 0°F (-18°C) combustion air. Contact factory before attempting to increase the Maximum Modulation Rate Concert Control Instruction & Operation Manual Page of 70...
Page 37 - Isolation Valve Loop Piped - DHW Pump boiler. (IWH) DHW Pump: Pump Runs during domestic hot water call for heat. Domestic Hot Water Priority enable/disable does not affect pump operation. Concert Control Instruction & Operation Manual Page of 70...
Page 38 Pump Exercise Time. Pump Exercise Time 20 Sec 0 to 10 Min The amount of time the pump runs for exercise. This feature helps prevent pump seizing due to inactivity periods. Concert Control Instruction & Operation Manual Page of 70...
Page 39 Select the line of information to edit. Use key pad to Enter address line 1 input data and press ENT to enter data into Sales Enter address line 2 Representative Info. Enter phone number Enter email Concert Control Instruction & Operation Manual Page of 70...
Page 40 If set too low, the firing rate response will be sluggish and temperature will wander away from setpoint. Refer to Table 11 for PID values used by these selections. Concert Control Instruction & Operation Manual Page of 70...
Page 41 3 to 29 (ºF) 10 (ºF) the setpoint. Domestic Hot Water Diff Below The unit starts when the water temperature drops ‘Difference Below’ degrees below 5 (ºF) 3 to 29 (ºF) the setpoint. Concert Control Instruction & Operation Manual Page of 70...
Page 42 & 2 is below the “DHW Setpoint” less “Difference Below” and is fired in response to DHW Sensor the DHW Sensor. Outdoor Reset Press to adjust the following parameters. BOILER ONLY Figure 20: Reset Curve Concert Control Instruction & Operation Manual Page of 70...
Page 43 Lead Lag Outdoor Air Maximum Off Point 50 to 190 187 (ºF) Maximum value the setpoint can reach due to boost function. Should be set to match (ºF) Central Heat Setpoint. Concert Control Instruction & Operation Manual Page of 70...
Page 44 If set too low, the firing rate response will be sluggish and temperature will wander away from setpoint. Refer to Table 11 for PID values used by these selections. Concert Control Instruction & Operation Manual Page of 70...
Page 45 High Limit in the control. Preferred Stack High Limit 230 (ºF) 150 to 230 (ºF) Adjustable high limit for the stack temperature. Only adjustable to a number below the maximum Stack Limit in the control. Concert Control Instruction & Operation Manual Page of 70...
Page 46 “Low Fire Hold Rate” for “Low Fire Hold Time”. This delay allows heat to travel out to the system and provide system feedback prior to the control modulating firing rate. Concert Control Instruction & Operation Manual Page of 70...
Page 47 “Low Fire Hold Rate” for “Low Fire Hold Time”. This delay allows heat to travel out to the system and provide system feedback prior to the control modulating firing rate. Concert Control Instruction & Operation Manual Page of 70...
Page 48 Local PID P, select the corresponding (from above table) Integral value. Repeats per minute between 0.5 and 2.0 are typical. The burner modulation rate can oscillate if the Integral time is too large. Concert Control Instruction & Operation Manual Page of 70...
Page 49 Although provided as a per-minute %/min. value, the Control will calculate and apply this as a stepped function using step duration of 10 seconds. Concert Control Instruction & Operation Manual Page of 70...
Page 50: Troubleshooting General Issues
The green light should be steady. If it is not, then the control is Fault defective. If steady, start plugging in all the connectors while watching the green light. When faulty wiring reconnected, green light will begin to flash. Concert Control Instruction & Operation Manual Page of 70...
Page 51 In this case replace control. Communication Error Communication Display has lost communication with controller. - Loose or defective display harness Fault - Defective Display - Defective Control - Incorrect Communication Parameters (See page 22) Concert Control Instruction & Operation Manual Page of 70...
Page 52 35 for data entry instructions When the lockout condition has been cleared, manual reset hard Lockouts Reset Control Reset maybe reset here or on the top of the control. Control Concert Control Instruction & Operation Manual Page of 70...
Page 53: Sensor Status
Sensor input is out of range. Sensor is defective or is being subjected to electrical noise. Outside high range Sensor is unreliable. Sensor is defective or is being subjected to electrical noise. Not reliable Concert Control Instruction & Operation Manual Page of 70...
Page 54: Limit String Status
NOTE: Some Limits cycle normally based on the function of the unit. For example, the Low Air Pressure limit will cycle to “OFF” after the unit post purge is complete. The “Help” icon only indicates a fault (flashes) when the limit string is not behaving normally. Concert Control Instruction & Operation Manual Page of 70...
Page 55: Soft Lockouts (Holds)
Water (DHW) temperature sensor. DHW sensor fault - Shorted or miswired flue temperature sensor wiring. Shorted or open flue gas (stack) - Defective flue temperature sensor. temperature sensor. Stack sensor fault Concert Control Instruction & Operation Manual Page of 70...
Page 56 Interrupted Airflow Switch Failed to Blocked vent, blocked inlet, blocked or disconnected inlet Interrupted Close air switch tube, blocked heat exchanger or burner. Airflow Something is blocking air/flue gas flow through unit Switch Off Concert Control Instruction & Operation Manual Page of 70...
Page 57: Hard Lockouts
A flame signal was present - Defective gas valve - make sure inlet pressure is Flame detected out of when there should be no below maximum on rating plate before replacing sequence flame. valve. Concert Control Instruction & Operation Manual Page of 70...
Page 58 - Reset the control. If problem reoccurs, replace (See display for details) Hardware Fault the Control. Internal control failure. - Reset the control. If problem reoccurs, replace Internal Fault the Control. Concert Control Instruction & Operation Manual Page of 70...
Page 59 - Loose ground Flam Lost in RUN - Air/fuel mix out of adjustment - Controller Failure - Consult Factory OEM Memory Lost, Honeywell Memory Reset To Default Default Memory Restored - Replace Control Concert Control Instruction & Operation Manual Page of 70...
Page 60: Using Archives
Cycle and Run time data is provided for control, unit and pumps. Additionally, a load profile is collected. Graphs are provided that show amount of time the unit operated at each load point. Data may be reset. Concert Control Instruction & Operation Manual Page of 70...
Page 61 The alarms are given a date and time stamp which allows for better troubleshooting capability. The alarm list may be downloaded to a USB in the form of a spreadsheet by using the Save to Historical Data function in the Archives Menu. Concert Control Instruction & Operation Manual Page of 70...
Page 62 The 20140612 is the date code of whenever the data was retrieved from the unit. In the example shown it was the year 2014, the 6 month of the year, 12 day of that month. Concert Control Instruction & Operation Manual Page of 70...
Page 63 An example of the Trend1-20141022.csv file follows: Table 12, Unit State Unit State Initiate Standby delay Standby Safe Startup Drive Purge Prepurge Drive Lightoff Preignition Test Preignition PFEP MFEP Direct Ignition Running Postpurge Lockout Concert Control Instruction & Operation Manual Page of 70...
Page 64 1. Plug USB thumb drive into USB Port on Unit 2. Select Main Menu > Archives > Load Parameters to USB Confirm or Cancel Load of Parameters. Confirm or Cancel Load of Contact Information. Concert Control Instruction & Operation Manual Page of 70...
Page 65: Specifications General
Enclosure: NEMA 4/IP65. 30 (86) 8.06 40 (104) 5.32 50 (122) 60 (140) 2.49 70 (158) 1.75 80 (176) 1.26 90 (194) 0.92 100 (212) 0.68 110 (230) 0.51 120 (248) 0.39 Concert Control Instruction & Operation Manual Page of 70...
Page 66 Apex Boiler Control (ABC), Thermal Solutions Boiler Control (TSBC), gateway & manual) Sage2.1 Control. CR2032 Display Battery 3V Lithium Battery. Used to maintain time and date clock. Table 13: Repair Parts Concert Control Instruction & Operation Manual Page of 70...
Page 67: Parameter Summary
Basic System Date Basic System Time Basic Auto Jump To Home Page Enable / Disable Basic Thermal Solutions / Bryan Steam / U.S. Boiler / Velocity Unit Brand Factory Boiler Works Modulation Menu Unit Type Factory CH Max Modulation Rate...
Page 68 F to 180 NOTES “Load Parameters” loads the current saved parameter settings off a USB Drive. This allows for easy transfer of unit parameters and contact information from one unit to another. Page 68 of 70 Concert Control Instruction & Operation Manual...
Page 69 Notes Concert Control Instruction & Operation Manual Page 69 of 70...
Page 70 2930 Old Tree Drive 3633 I Street Peru IN 46970 Lancaster PA 17603 Philadelphia PA 19134 Telephone 765-473-6651 Telephone 717-397-4701 Telephone 215-535-8900 Fax 765-473-3074 Fax 866-855-6078 Fax 215-535-9736 www.bryanboilers.com www.usboiler.net www.velocityboilerworks.com Concert Control Instruction & Operation Manual Page 70 of 70...

Velocity Concert Control Instruction And Operation Manual

Contents

Introduction Quick Reference

Product Features Sequence

Front Panel General Navigation

Installation Quick Setup

Setup & Tuning Manual Operation

Troubleshooting General Issues

Using Archives

Specifications General

Quick Links

Need help?

Questions and answers

Summary of Contents for Velocity Concert Control

Table of Contents