HEAT-TIMER CORP. 20 NEW DUTCH LANE FAIRFIELD, NEW JERSEY TEL. (973) FAX (973) Model MPC OUTPUT LED'S OUTPUT RELAYS

Transcription

1 HEAT-TIMER CORP. 20 NEW DUTCH LANE FAIRFIELD, NEW JERSEY TEL. (973) FAX (973) INSTALLATION & OPERATION MANUAL MODEL MPC GOLD SERIES TABLE OF CONTENTS Control Panel... 2 Understanding the MPC... 4 Installation... 6 Control Settings Appendix Specifications Cycle Chart Vari-Boost and Early Shutdown Wiring Troubleshooting Interpreting Status Lights THIS HEAT-TIMER MODEL MPC HAS BEEN APPROVED BY UNDERWRITERS LABORATORIES E-60760(M) AND THE CANADIAN STANDARDS ASSOC. THIS MODEL IS APPROVED FOR INSTALLATION AND OPERATION IN THE CITY OF NEW YORK BY THE DIVISION OF PUBLIC STRUCTURES. THE CALENDAR NUMBER APPROVAL IS

2 HEAT-TIMER CORP. 20 NEW DUTCH LANE FAIRFIELD, NEW JERSEY TEL. (973) FAX (973) Model MPC OUTPUT LED'S OUTPUT RELAYS OUTPUT TERMINALS INPUT TERMINALS Functions To help simplify these instructions, sections of the control panel are keyed and referred to in the text by the above numbers Control Panel 2

3 Functions CURRENT STATUS INDICATORS Indicator lights show status of heating system at all times. OUTDOOR SENSOR SET POINTS Digital display of outdoor sensor set points SHIFT manual switch to change NORMAL (DAY) to SAVE (NIGHT) and reverse. RED LIGHT to show when unit is in NORMAL (DAY) mode. RED LIGHT to show when unit is in SAVE (NIGHT) mode. PROGRAM LOCK, BY- PASS SWITCH and WINTER / SUMMER SWITCH KEY locks program and outside set point settings. BY-PASS SWITCH puts unit in AUTO mode or BY-PASS. WINTER / SUMMER SWITCH auto / heat-off switch. HEAT ADJUSTMENT NORMAL (DAY) mode. SAVE (NIGHT) mode. CLOCK & OUTDOOR TEMPERATURE DISPLAY Clock displays PRESENT TIME while the unit is in AUTO mode. RED LIGHT indicates AM or PM. RED LIGHT indicates the day of the week. OUTSIDE TEMPERATURE displays current outdoor temperature. CLOCK PROGRAM CONTROLS Used to program 7-day clock for NORMAL (DAY) and SAVE (NIGHT) heat levels. BOOST RED LIGHT indicates unit is in BOOST and BOOST adjustment curve knob. PRESS TO DISPLAY HEATING SYSTEM SENSOR displays temperature of the system sensor. FAST CYCLE FOR TESTING rapidly advances unit through a cycle. HEATING SYSTEM SENSOR DIFFERENTIAL knob to adjust system differential. X-Y-Z Adjustment knob to adjust system set point. BOOST & THERMAL LOCKOUT BOOST switch to select type of morning boost and shutdown. THERMAL LOCKOUT switch to enable system differential. 3 Control Panel

4 Understanding the "Gold Series" Model MPC The Heat-Timer MPC is a microprocessor based control for steam heating systems. The control operates a steam boiler or valve, automatically providing the desired heat pattern for a building. The control operates on the CYCLE principle which was created specifically for steam heating systems. The CYCLE concept was developed by Heat-Timer to overcome the inabilities of standard thermostatic controls to cope with the erratic properties of steam. Steam heat can not be switched on and off instantaneously. Instead, it takes time to build up a "head of steam". And, once the system starts heating up, it has momentum which can not be quickly stopped. Operates in Continual Cycles Sample MILD Weather Cycle HEAT - ON HEAT - OFF 8 MINUTES 52 MINUTES HEAT - ON HEAT - OFF 21 MINUTES 39 MINUTES Sample COLD Weather Cycle By monitoring the outside temperature, the MPC is able to anticipate the heating needs of the building. Each fixed time CYCLE period (usually 60 minutes long but adjustable to 20, 30, or 90 minutes) is divided into a heat/on segment and a heat/off segment. The length of the ON segment will vary with the outside temperature. The colder it is outside, the longer the ON part of the cycle will be. HEATING PLANT INSIDE Heating System SENSOR B A Input OUTDOOR Temperature SENSOR C Instructions to HEATING PLANT Input The MPC constantly checks the outside temperature by means of a solid state sensor (A) located on the exterior of the building. At the same time it also monitors the heating system of the building by means of a heating system sensor (B). This heating system sensor is located where it will show that heat has reached to the furthest location in the building (or the hardest to heat area). On the basis of this combined data, the MPC sends instructions (C) to the heating plant to control the heat level in the building. In addition to adjusting the length of the ON part of a cycle, the outdoor temperature acts as a system cutoff. When the outdoor temperature rises above an adjustable set point, the MPC will not call for any heat. When the outdoor temperature drops below the set point, the MPC will automatically begin controlling the heating cycles. Once the heating system has been activated, the heating system sensor will register when heat has reached throughout the building. The effect of these two sensors combined is to provide an even, comfortable level of heat throughout the building. Understanding the MPC 4

5 Sequence of Operation Sequence of Operation The MPC activates the steam source when the outside temperature falls below the outdoor sensor set point (factory set at 55 F for day and 40 F for night, but fully adjustable). The MPC will continue to call for heat until the heating system sensor reaches the set point. This indicates that steam has gotten entirely through the system, or that "heat is established". Once "heat is established", the heat-on segment of the cycle will begin. During the ON part of the cycle, the MPC will keep the steam source activated. Once the ON part of the cycle has ended, the heat-off part of the cycle will begin. The MPC will turn off the boiler or close the steam valve. When the OFF part of the cycle is over, the MPC will once again activate the steam source unless either the outside temperature has risen above the set point, or the thermal lockout is active. With the thermal lockout, the heating system sensor temperature must fall through an adjustable differential before the heating source can be reactivated. HEAT-ON HEAT-ON HEAT-OFF HEAT-OFF HEAT-ON PRESSURE BEING ESTABLISHED 60 MINUTE CYCLE NEW CYCLE DELAYED (Thermal Lockout Active) When outdoor temperature drops to a set point chosen by you, the heating system goes ON to "establish" heat in the building... When heat is "established" (when heat has spread thru the entire building), a CYCLE begins... A CYCLE consists of a heat-on part and a heat-off part, both adding up to a fixed time (usually 60 minutes). The lower the outside temperature, the longer the heat-on part and more heat produced... At each CYCLE's end the control checks to see if more heat is needed. If so, the control makes sure heat is "established" first and then starts a new CYCLE. 5 Understanding the MPC

6 Getting the installation started The MPC may be used with any of the following systems: One pipe steam Two pipe steam Motorized valve operation Direct boiler operation Sketches for each of these systems are on the following two pages. Before proceeding with the installation, familiarize yourself with the details for your application. Installation of this control is relatively simple if you follow the instructions carefully. The installation consists of four basic steps: Locating and mounting the control, Locating and mounting the sensors, both the outside sensor and the heating system sensor, Wiring the power, input and output lines, Creating an initial pilot program of settings. Warning: The Heat-Timer Model MPC is strictly an operating control; under no circumstances should it be used as a primary limit or safety control. Each boiler must have its own certified limit and safety controls as required by local codes. These are the responsibility of the installing contractor who must verify proper operation and correct any safety problems prior to starting the MPC installation. Installation 6

7 Motorized Valve Guidelines MPC Installation Guidelines for Motorized Valve Operation One Pipe Steam - Motorized Valve Operation HEATING SYSTEM SENSOR (HSS) PREFERRED LOCATION TO ZONE "A" TO ZONE "B" TO ZONE "C" HEATING SYSTEM SENSOR OPTIONAL LOCATIONS TO TERM C-C MPC OUTDOOR SENSOR BOILER WATER LINE BURNER CONDENSATE RECEIVER TO ZONE "A" HSS PREFERRED LOCATION TO TERM TO TERM T-T TO TERM TO TERM T-T STEAM BOILER WITH OR WITHOUT TANKLESS COIL NEVER INSTALL HEATING SYSTEM SENSOR ON WET RETURN Two Pipe Steam - Motorized Valve Operation HEATING SYSTEM SENSOR OPTIONAL LOCATIONS OUTDOOR SENSOR TO ZONE "B" TO ZONE "C" TO TERM C-C MPC BOILER WATER LINE STEAM BOILER WITH OR WITHOUT TANKLESS COIL BURNER CONDENSATE RECEIVER NEVER INSTALL HEATING SYSTEM SENSOR ON WET RETURN 7 Installation

8 STEAM BOILER WITH OR WITHOUT TANKLESS COIL STEAM BOILER WITH OR WITHOUT TANKLESS COIL Direct Burner Guidelines MPC Installation Guideline for Direct Burner Operation One Pipe Steam - Direct Burner Operation HEATING SYSTEM SENSOR (HSS) PREFERRED LOCATION OUTDOOR SENSOR HEATING SYSTEM SENSOR OPTIONAL LOCATIONS TO TERM T-T TO TERM T-T BURNER BOILER WATER LINE TO TERM 7 & 8 CONDENSATE RECEIVER Two Pipe Steam - Direct Burner Operation NEVER INSTALL HEATING SYSTEM SENSOR ON WET RETURN HSS PREFERRED LOCATION TO TERM C-C MPC HEATING SYSTEM SENSOR OPTIONAL LOCATIONS TO TERM C-C MPC OUTDOOR SENSOR BOILER WATER LINE TO TERM 7 & 8 BURNER CONDENSATE RECEIVER NEVER INSTALL HEATING SYSTEM SENSOR ON WET RETURN Installation 8

9 Mount the Control First Step: Mount the Control Enclosure Control Panel Gutter Cover Locate an appropriate site Near the equipment to be controlled Away from excessively high or low temperatures At eye level, or where the display is easily visible The surface must be strong enough to hold the weight of the control and the metal enclosure. Remove the MPC from the yellow metal enclosure Take off the gutter cover by loosening the screws at its bottom Remove the top center screw holding the panel to the enclosure Loosen the two screws at the bottom of the enclosure Lift the panel from the enclosure Screw the enclosure to the mounting surface through the holes provided. Set the back of the panel: Activate the battery Turn the MPC panel over to reveal the piggyback circuit board (CPU board). Remove the insulating strip from the coin-type battery. Dip Switch CPU Board Battery CAUTION: Do not activate the battery unless you plan to power the control at once. If the control is not powered, the battery will lose its charge in 100 days. Set dip switch for appropriate cycle time (see chart on next page) With most cast iron radiation, choose a 60 minute cycle. If the radiators are very large or the system is oversized, choose a 90 minute cycle. For convector or baseboard radiation, choose a 30 minute cycle For air handlers or blower units, choose a 20 minute cycle If using district steam, or steam is being generated at a central boiler plant, you may set the dip switch for the District Steam option (see chart next page), With this option: The heating system sensor is not used The X-Y-Z knob changes function to become an adjustable time period (A free sticker is available to show the new function of the knob, HT# ) After a cycle has ended, the steam valve will open for the time period set by the X-Y-Z knob. Once this time period has elapsed, the MPC will start the ON part of a new cycle. 9 Installation

10 Dip Switches Activate Aux clock if desired (see below for configuration) The Auxiliary clock provides separate time clock functions for the MPC (see pg. 25) Set the dip switch Locate the dip switch on the rear of the MPC next to the battery Set the switches as shown below. The OPEN position is away from the circuit board, and the CLOSE position is down toward the circuit board DIP SWITCH CHART - OPEN- - OPEN Minute Cycle 30 Minute Cycle - OPEN- - OPEN Minute Cycle 90 Minute Cycle - OPEN- - OPEN Boiler or Standard Valve Operation District Steam Operation - OPEN- Installation Aux Clock Enabled 10

11 Installing Outdoor Sensor Second Step: Install the Sensors Installing the outdoor sensor Only use a Gold Series sensor. If you are replacing an earlier model Heat-Timer, it is necessary to upgrade the sensor. Locate the sensor in the shade on the north side of the building Be sure the location is away from doors, windows, exhaust fans, vents, or other possible heat sources The sensor should be mounted at least 4 inches away from the building wall and approximately 10 feet above ground level The sensor wires can be extended up to 500' using shielded 2 conductor cable (Belden #8760 or equivalent). Do not run sensor wires in conduit with line voltage wiring. CAUTION: Determining the proper location for the outdoor sensor is very important. The MPC will base the heat on the outdoor temperature information it receives from this location. If the sensor is in the sun, or covered with ice, its reading will be different from the actual outdoor temperature. "Gold Series" OUTDOOR SENSOR 4" Building Material 10' - 0" 1/2" Conduit 7/8" Dia. Hole Outdoor Ground Level Putty or other suitable filler material Wood or other mounting surface 1/2" Pipe Clamps Low Voltage wiring to T T Terminals 11 Installation

12 Installing Heating System Sensor Heating System Sensor The Heating System Sensor (HSS) must be located where it will indicate that the entire system is full of steam. Locating the HSS The ideal location for the HSS is on the last radiator in the system to get warm. This radiator is usually the one with the furthest piping distance from the boiler. With a one or two-pipe system, the sensor may also be located high up on the furthest supply riser (see diagrams pg. 7 and 8) With a two-pipe system, the sensor may be located on the furthest return riser. However, the sensor must be above the water line of the boiler (on a dry return). Never install the sensor between a condensate receiver and the boiler. System Pipe CAUTION: If the HSS can not sense the system is full of steam, the MPC will not provide comfortable heat levels. Be sure the HSS is located on a properly vented pipe which can not easily be isolated from the system. Heating System Sensor If none of the above locations can be accessed, a pressure switch may be used instead of the HSS Install the pressure sensor in the main steam header. Fuel will be wasted since the Thermal Lockout feature (see pg. 25) will not be active Use a direct acting switch with the pressure setting less than the boiler's operating pressure control Pipe Clamp Installing the HSS Only use a Gold Series sensor. If you are replacing an earlier model Heat-Timer, it is necessary to upgrade the sensor. Strap the HSS to the pipe with the pipe clamp provided The sensor wires can be extended up to 500' using shielded 2 conductor cable (Belden #8760 or equivalent). Do not run sensor wires in conduit with line voltage wiring Installation 12

13 Power and Output Terminals Third Step: Wire the Power and Output Terminals Wire the power terminals Bring the power wires through the bottom left hand KO of the enclosure. Do not bring wires through sides or the top as this will interfere with servicing the control. Attach 120V 60 Hz to terminals 2 LINE, and 3 NEUTRAL. Terminal 1, power ground, must be connected. Class 1 copper wire is required by UL. Wiring directly to a boiler Wire the rmally Open (N.O.) contacts, Terminals 7 and 8, in series with the limit controls of the boiler. Wiring to a motorized valve The valve outputs are for a 3-wire RWB connection. Wire the Common (Red) to Terminal 5. Wire the Open (Black) to Terminal 4. Wire the Close (White) to Terminal 3. For information on wiring the AUX clock, see page 22. Bring all wires through the bottom KOs of the enclosure. WARNING: The MPC is an operating control only. The boiler must have all safety and limit controls required by code. It is the responsibility of the installer to verify that all the safety and limits are working properly before the MPC is installed. 120V 60Hz power line goes to terminals #2 and #3 For direct 2-wire boiler control connect to terminals #7 and #8 Be sure to connect terminal #1 to earth ground If installation uses a motorized valve, use terminals #4, #5 and #6 13 Installation

14 Wiring Input Terminals Fourth Step: Wire the Input Terminals Wiring the outdoor sensor Bring outdoor sensor wires through the bottom right hand KO in the enclosure (see pg. 11 on running the wires). Attach the sensor wires to the T-T terminals. Connect the shield to the right hand T terminal with a circle around it. Wiring the heating system sensor (HSS) Bring HSS wires through the bottom right hand KO in the enclosure (see pg. 12 on running the wires). Attach the sensor wires to the C-C terminals. Connect the shield to the right hand C terminal with a circle around it. Connect to outdoor sensor wires Connect to heating system sensor wires WARNING: Never apply external voltage to the input terminals. Permanent damage will occur, voiding the warranty. Testing the Sensor Installation Testing the sensors Power up the MPC. The control will go through a countdown, and then the small rightmost three digit display marked OUTSIDE TEMP will show the temperature read by the outdoor sensor. If the display reads OPN, SHT, or an incorrect temperature, see pg. 39 to determine the source of the problem. Press the button marked HEATING SYSTEM SENSOR. The small rightmost display will now show the temperature read by the HSS. If the display reads OPN, SHT, or an incorrect temperature, see pg. 39 to determine the source of the problem. Installation 14

15 Initial Settings Final Step: Make these Initial Settings Once the control is mounted and wired, set up an initial program. The list below acts as a check list and provides typical settings. The settings may have to be adjusted later based on actual building conditions. The list numbers correspond to the detailed descriptions of each setting in the following section THE CONTROL SETTINGS. 1. Set the Winter/Summer switch to WINTER. 2. Set the Outdoor Sensor Set Points to 55 F for NORMAL and 40 F for SAVE. 3. Set the Heat Adjustment Knobs to F for both NORMAL and SAVE. 4. Set the Bypass switch to AUTO 5. Set the present time.* 6. Day/Night program is factory set for the normal heat level from 6AM to 10PM, and the save heat level from 10PM to 6AM for the entire week.* 7. Cycle time is factory set at 60 minutes.* 8. Heating System Sensor Adjustment (XYZ knob) must be set to indicate when steam has gotten through the system.* 9. Set Thermal Lockout to ON. 10. Set the Heating System Sensor Differential to the halfway position (12 noon on the dial). 11. Morning Boost - Set the Boost switch to VARI. Set the Morning Boost knob to 4. * To adjust, see the next section CONTROL SETTINGS 15 Installation

16 As you start up the control, learn each setting and how it operates The start-up list on the opposite page serves to get the MPC up and running. To adjust the MPC to run optimally in your system, additional adjustments will probably have to be made. The following pages provide complete descriptions of the MPC functions. All the settings are keyed by number to the list of Initial Settings for easy reference. Control Settings 16

17 Winter/Summer Switch 1. Winter/Summer switch The MPC will not call for any heat when this switch is in SUMMER. When the switch is in the Winter position, the MPC will call for heat whenever the outdoor temperature falls below the Outdoor Sensor Set Points. In the SUMMER position, the MPC will not give heat Therefore, during the heating season, this switch must be in the WINTER position. When the heating season is over, it is a good practice to move the switch into the SUMMER position. CAUTION: Do not turn the power off to the MPC when the heating season is over. If you do so, the battery will run down and have to be replaced. Instead, switch to SUMMER. 2. Outdoor Sensor Set Points Turn key to UNLOCK to program set points The Outdoor Sensor Set Points determine when the MPC will call for heat. When the outside temperature is above the Set Points, the MPC will not call for heat. When the temperature falls below the Set Points, the MPC will begin running cycles. The MPC has two heating modes, a rmal (Day) mode and a Save (Night) mode. The rmal mode is set for times when the building is occupied and people are active. The Save mode holds a lower ambient temperature, and is for when the building is unoccupied, or people are sleeping. Therefore, the MPC comes factory set with a rmal Set Point of 55 F and a Save Set Point of 40 F. To change the Outdoor Sensor Set Point, you must first unlock the Program Lock. This is to prevent the settings from being changed by unauthorized users. Simply insert the program key and rotate it clockwise to the Unlock position. Then rotate the knobs under the Outdoor Sensor Set Points until the desired temperature is displayed. Knobs rotate to change set point settings on display The range of the rmal Outdoor Sensor Set Point is from 20 F to 70 F. The range of the Save Set Point is from 1 F to 70 F and OFF. The OFF will be shown on the display by (--). If the Set Point is OFF, the MPC will not call for heat during the programmed Save period. 17 Control Settings

18 Heat Adjustment 3. Heat Adjustment The Heat Adjustment knobs adjust the amount of heat given based on outdoor temperature. An A setting gives the least amount of heat at any given outside temperature, and a P setting gives the most heat (see chart pg. 29). An A setting provides the least amount of heat, a P setting the most heat te: The length of the ON part of the cycle is based on the Outdoor Sensor Set Points. This means if you set both the rmal and Save Heat Adjustments to the same value, you will get less heat at night. For instance, with both Heat Adjustments to F and the factory set Outdoor Sensor Set Points of 55 F for rmal and 40 F for Save, if the outdoor temperature is 25 F the On part of the cycle will last for 15 minutes in rmal, and only 7 minutes at Save. A good starting point for both Heat Adjustment knobs is F. If the building is too cold in cold weather, adjust the appropriate knob (rmal if it is too cold in the Day program, and Save if it is too cold in the Night program) clockwise up a letter. That is, from F to G. Then wait at least 24 hours before evaluating if the adjustment was sufficient. Similarly, if it is too hot in the cold weather, adjust the knob counterclockwise one letter and wait. In AUTO, the MPC will give heating cycles. In BYPASS, the boiler will run on its limits or the valve will be fully open and Total hours and minutes on BY-PASS will be recorded and displayed. Shown is 125 hours and 38 minutes. 4. By-Pass switch The By-Pass switch must be in the AUTO position for the MPC to cycle heat. In BY-PASS, the control will run the boiler on its limits, or fully open a motorized valve. Switch to BY-PASS to override the panel or to test the equipment. When the MPC is in the BY-PASS position, none of the normal functions will be executed. The display will change to read the total amount of time the control has been in BY-PASS. The large central display will show the number of hours in BY-PASS, and the smaller right hand display will show the number of minutes. When switched to BY-PASS, the boiler will run, or the valve will open, even if the MPC has no display. The By-pass switch directly connects the rmally Open contacts 4 to 5, and 7 to 8. Therefore, if there is no heat, test the boiler or valve by putting the control in BY-PASS. If the boiler does not come on, or the valve does not open, the problem is not with the MPC panel. Control Settings 18

19 AM or PM Press to increment Hours Minutes Day Switch to Run Day of week Time displayed is 1:25 AM on Friday, the outside temperature is 38 F 5. Setting the Present Time Setting the Time When an MPC is first powered up, the central display will show NONE. This may also occur if the control has been turned off for an extended period of time and the battery has drained down. (See Winter/Summer switch pg. 17 on how to avoid this.) To set the present time, use the following procedure: Use the programming key to turn the Program Lock switch to the UNLOCK position. Switch the Run/Program switch to Run. This will cause the display to show the present time and outside temperature. Press the Hours button until the correct hour and AM or PM is shown. It is very important to note the AM and PM lights directly under the central display. If the time is 4:35 PM, keep pressing the hours button until the hour shows 4 and the red PM light is lit. Press the Minutes button until the correct number of minutes is shown. Press the Day button until the correct day of week, MON, TUE, WED, THU, FRI, SAT, or SUN is lit. 6. Setting the rmal (Day) and Save (Night) Program Schedules The first rmal (day) setting for FRI is 6:00 AM, the first Save (night) setting for FRI is 10:00 PM The MPC has two levels of control. The rmal (Day) level is used when a building is occupied, and people are active. The Save (Night) level is used when a building is not occupied, or when people are sleeping. The MPC can have up to four rmal and four Save periods for each day of the week. When in the programming mode, a rmal level is shown with the small right-hand display of 1d, 2d, 3d, or 4d and the Save levels are shown by 1n, 2n, 3n, and 4n. If there is a time shown, then that is the time when the heat level will begin. If the display shows NONE, that means this heat level is not programmed. Every time the MPC updates the time, it looks at the program. If there is a setting for this time, it sets the heat level accordingly, otherwise it leaves the heat level where it is. This means you do not have to program every day of the week. If an office building is unoccupied all weekend, simply set the last programmed n setting (8:00 2n PM for example) on FRI. Set all the SAT and SUN programs to NONE. The control will stay off until it reaches a d setting (6:00 1d AM for example) on MON morning. 19 Control Settings

20 Programming the Heat Levels Switch to Program MON TUE WED THU FRI SAT SUN 1d 6:00AM 6:00AM 6:00AM 6:00AM 6:00AM 6:00AM 6:00AM 1n 10:00PM 10:00PM 10:00PM 10:00PM 10:00PM 10:00PM 10:00PM 2d NONE NONE NONE NONE NONE NONE NONE 2n NONE NONE NONE NONE NONE NONE NONE 3d NONE NONE NONE NONE NONE NONE NONE 3n NONE NONE NONE NONE NONE NONE NONE 4d NONE NONE NONE NONE NONE NONE NONE 4n NONE NONE NONE NONE NONE NONE NONE DAY This button advances you to the next day of the week Press Advance to move through the day/night program DAY COPY This copies the complete program from one day to the next ERASE PAIR SHOWN Erases a complete pair (both d and n) of the setting being displayed. Use the following procedure to program the MPC: Use the programming key to turn the Program Lock switch clockwise to the UNLOCK position. Switch the Run/Program switch to Program. This will cause the display to show the first program time. If it is at the factory default the display will show 6:00 1d and the AM light will be lit. Also note the day of the week which is lit. If MON is lit, this means the rmal heat level will begin on Monday at 6:00 AM. To adjust this time, push the Hours and Minutes button until the desired time is shown. For example, to change the time to 7:00 AM, simply press the Hours button once. Be sure the AM and PM lights below the time are correct. w press the Review/Advance Button. If at the factory default times, the display will change to 10:00 1n and the PM and MON light will be lit. This means the Save heat level will begin on Monday at 10:00 PM. Adjust the time with the Hours and Minutes button. Continue to press the Review Advance button. The small display will change to 2d, 2n, 3d, 3n, 4d, and 4n. Set any of these by pressing the Hours and Minutes buttons. When you continue to press the Review Advance button past 4n, the small display will read 1o, 1c, 2o, 2c, 3o, 3c, 4o, 4c, and then advance on to 1d for the next day of the week. The o and c settings are for the auxiliary clock, are set with the Hours and Minutes button as above, and the functions are explained on pg. 25. To advance on to the next day at any point, press the Day button. This will move you on to the 1d for the next day of the week. To clear any of the programmed times simply press the Erase Pair Shown button. This will clear the pair (a matching d and n for that weekday) to NONE. To save time, you can copy one days program to the next. If you have set up MON as you like it, press the Day button until TUE is lit. Then press the Day Copy button. Tuesday will now have the same program as Monday. When you are finished programming, be sure to move the Run/ Program switch back to the Run position. Control Settings 20

21 7. Cycle time Cycle Time The length of the cycle time depends on the type of radiation. For most cast iron radiation, choose a 60 minute cycle. If the radiators are very large or the system is oversized, choose a 90 minute cycle. If the building has convector or baseboard radiation, choose a 30 minute cycle. If the building has air handlers or blower units, choose a 20 minute cycle. To set the cycle time, you must set the dip switch on the rear of the MPC. Follow the instructions on pg. 9 and 10 to set the switch. Heating System Sensor Adjustment or XYZ knob X is 70 F Y is 160 F Z is 250 F When this green light comes on, the temperature at the Heating System Sensor has risen above the temperature value of the XYZ knob. All the radiators in the building should be receiving heat. 8. Heating System Sensor Adjustment (XYZ knob) The XYZ knob is used to prove that heat has gotten all the way through the buildings radiation system. The knob sets a temperature for the heating system sensor. Above this temperature, all the radiators in the building should be receiving heat. The XYZ knob can be set from 70 F (fully counterclockwise) to 250 F (fully clockwise). To set the XYZ knob, use the following procedure: 1. Turn the heating system off and wait until the radiators are cool when touched. 2. Turn the XYZ knob fully clockwise to Z. 3. Start the heating system. 4. Go to the furthest radiator (in terms of longest piping distance) or to a radiator in a location known to get heat last. 5. Wait until the radiator begins to get warm. This may take up to half an hour, or even more, depending on the steam distribution in the building. 6. Return to the MPC panel and very slowly rotate the XYZ knob counterclockwise until the green Heat Circulation Established light comes on. The point on the dial when the green light comes on is the correct temperature set point for your system. CAUTION: The System Sensor Set Point must be set correctly, as described above. Otherwise, the MPC may consistently under or overheat the building, especially in mild weather when fuel savings should be the greatest. WARNING: If the Heating System Sensor does not register a rise in temperature above the XYZ knob adjustment, the system will never start a cycle. The boiler will run on its limits, or the steam valve will constantly be open. If this occurs, check that the Heating System Sensor is reading correctly (see pg. 39) and is located appropriately (see pg. 12). 21 Control Settings

22 Displaying the XYZ value When the Run/Program switch is in Program, pressing this will show the XYZ knob temperature Displaying the XYZ value To display the temperature value of the XYZ knob do the following: 1. Switch the Run/Program switch to the Program position. 2. Press the Heating System Sensor button. 3. As long as the button is being pressed, the small right-hand display will show the actual value of the XYZ knob. If you rotate the knob you will see the display change value. 4. Be sure to return the Run/Program switch back to run when done. This display should only be used for information. Do not adjust the XYZ knob based on the displayed value, instead use the procedure described in the previous section. 9. Thermal Lockout Thermal Lockout Switch should be ON to prevent overheating The thermal lockout prevents another cycle from starting when the system is still hot. When a cycle is over, the pipes and radiators may still be heating the space. If more steam were immediately added to the system, the space may begin to overheat. The thermal lockout prevents this from occurring as it allows the system pipe temperatures to fall through the adjustable Heating System Sensor Differential (see next page) before reactivating the heat source. The Thermal Lockout switch should be ON unless the system dissipates heat very quickly, as might occur with air handling units. Thermal Lockout and Differential Example Heating System Sensor Adjustment (XYZ) Heating System Sensor Differential Thermal Lockout Cycle Minutes 150 F -25 F ON 60 HEAT - ON HEAT - OFF HEAT - OFF HEAT - ON 60 MINUTE CYCLE THERMAL LOCKOUT ACTIVE Heating System Sensor (HSS) reaches 150 F HSS greater than 150 F HSS temperature begins to fall HSS temperature continues to fall, possibly below 150 F HSS falls below 125 F (XYZ less Differential) Control Settings 22

23 Displaying Thermal Lockout Display when MPC is in Thermal Lockout When the MPC is in Thermal Lockout, the cycle is over, the outdoor temperature calls for heat, and yet the heat source is not activated. This might cause confusion as it would appear the control is malfunctioning. However, the MPC is simply waiting for the system to cool down. If ONLY this green light is on, the MPC is in thermal lockout. To quickly tell if the MPC is in thermal lockout, simply look at the Current Status Indicator lights. If only the green Heat Circulation Established light is lit, then the MPC is in thermal lockout. As soon as the Heating System Sensor temperature falls below the XYZ setting less the Differential (see below), the heat source will be turned on. With the XYZ knob set to Y or 150 F Heat Source re-activated at 125 F 25 Differential middle 10. Heating System Sensor Differential The Differential knob only affects the MPC operation if the Thermal Lockout switch is ON (see previous page). The Differential is the temperature range through which the Heating System Sensor must fall (below the temperature set by the XYZ knob) before another cycle can begin. The differential is adjustable from 0 F when fully counterclockwise to 50 F when fully clockwise. 0 Differential Heat Source re-activated at 150 F fully left 50 Differential Heat Source re-activated at 100 F fully right A good starting point for the Differential is to turn the knob to the 12 o'clock position, which is a 25 differential. This means a new cycle can not start until the Heating System Sensor registers a fall of 25 below the XYZ knob temperature. If the space temperature becomes too cold between cycles, reduce the amount of the Differential (turn the knob counterclockwise). If the building is overheating, especially in mild weather, first check the XYZ setting (see pg. 21). If the XYZ setting is correct, then increase the Differential (turn the knob clockwise). 11. Morning Boost The Morning Boost is designed to return the building to comfortable ambient temperatures after the cooler Save (Night) period. The MPC will accomplish this by either running the boiler on its limits or opening the steam valve for a given time period based on the 1d time for that day. If you do not want a boost on a day of the week, simply program the 1d to NONE, and use the 2d 23 Control Settings

24 Morning Boost The length of the Vari-Boost changes with outside temperature The Manual Boost is the same length every morning Shutdown is used to switch to Save early based on outside temperature The inner dial shows the minutes of Manual Boost The outer dial sets the Vari- Boost curve program for any rmal (Day) settings. To set up the Morning Boost, you must set the type of Boost you need (3-way Boost switch) and the amount of Boost (Morning Boost knob). There are three types of Boost: 1. Manual - This Boost begins at the 1d time, and lasts for as many minutes as set by the Boost knob. The Boost time can be adjusted from 0 to 120 minutes. This Boost does not adjust with outside temperature. 2. Vari-Boost - This boost begins earlier than the 1d time. The time depends on the outside temperature and the selected Vari-Boost curve. A Vari-Boost curve of 1 gives the shortest Boost period, and a curve of 6 gives the longest Boost period (for actual times, see chart pg. 31). The Vari-Boost has a built in self-adjusting Warm-up time. This accounts for how long it takes for the boilers to reach the System Sensor Set Point, and is added to the Boost time. 3. Vari-Boost with Shutdown - This should be used in commercial buildings where the building will be unoccupied in the Save (Night) times. A Vari-Boost as described above is run. In addition, the MPC will switch into the Save mode earlier than the latest n setting for that day. The warmer it is outside, the earlier the MPC will shift into Save. The chart below compares the three types of Boost for an MPC set up as follows: Program settings of 1d 6:00 AM, 1n 10:00 PM, and all other settings are NONE Manual Boost time 75 minutes Vari-Boost curve of 3, Warm-up-time 15 minutes Heating System Sensor Adjustment (XYZ knob) 150 F When either Boost begins, the heat source will be activated. The Heating System Sensor will reach 150 F in approximately 15 minutes. The MPC will leave the heat source activated until the Boost time ends. After the Boost the MPC will begin running normal cycles. With the Shutdown, the MPC will switch to the Save (Night) settings at the time shown before the actual night setting of 10:00 PM. OUTDOOR TEMP MANUAL BOOST START MANUAL BOOST END VARI-BOOST START VARI-BOOST END SHUTDOWN START SHUTDOWN END 50 F 6:00 AM 7:15 AM 5:44 AM 6:00 AM 8:30 PM 10:00 PM 30 F 6:00 AM 7:15 AM 5:10 AM 6:00 AM 8:15 PM 10:00 PM 10 F 6:00 AM 7:15 AM 4:40 AM 6:00 AM 9:18 PM 10:00 PM Control Settings 24

25 Additional MPC Functions The Auxiliary Clock Auxiliary Clock The Auxiliary Clock provides extra outputs which switch based only on the time of day. They are not affected by outdoor temperature, but act as a separate time clock which can be used to turn on lights, fans, dampers, or other equipment. To activate the Auxiliary clock, set the appropriate dip switch (see chart pg. 10). The Auxiliary Clock has rmally Open and rmally Closed contacts. To program the Auxiliary Clock, keep pressing the Review/Advance button past 4n to get 1o, 1c, 2o, 2c, 3o, 3c, 4o, and 4c. With the o settings, the Auxiliary Clock relay will be open (de-energized), with c settings, the relay will be closed (energized). The Auxiliary Clock is separate from the program settings except for the Day Copy button (see pg. 20). If you use the Day Copy button, the auxiliary clock settings will be copied from one day to the next along with the program settings. This light indicates the control is in the rmal mode Press this button to shift from rmal to Save or vice versa This light indicates the control is in the Save mode When the rmal mode light is flashing, this means the control has been manually shifted from Save. In 90 minutes from the shift time, the rmal light will stop flashing, and the Save light will come on. Shift Button The Shift button allows you to manually shift from rmal (Day) settings into Save (Night) settings or vice versa. This can be used to temporarily override the program. A typical example where the shift would be used is in a school where an event has gone into overtime. Instead of reprogramming the control to keep it from going into the Save mode, simply press the Shift button and the MPC will run the rmal program. The amount of time the MPC will hold the shift is: Shifting from rmal to Save - The control will stay in the Save mode until either the control is shifted again, or until the next programmed rmal mode time Shifting from Save to rmal - The control will stay in the rmal mode for 90 minutes, and then revert back to the program. This prevents a user (without a programming key) from putting the MPC in rmal mode for an extended period of time when it is programmed for Save. When the control is manually shifted to rmal, the red light indicating the control is in the rmal mode will flash. 25 Control Settings

26 Fast Cycle Pressing this button fast forwards through a heating cycle. When pressed, the small right-hand display will show the number of minutes into the cycle. This red light will be on during the ON part of a cycle. Fast Cycle The Fast Cycle button changes cycle minutes to cycle seconds, so a 60 minute cycle can be reviewed in 60 seconds. This can be used to check the ON time of the cycle. Simply watch the red Heat Source Activated light (for details see pg. 41). The On part of the cycle lasts as long as the red light stays on. The Fast Cycle can also be used to test the boiler or valve. If the control is in the Off part of a cycle, press the Fast Cycle button until the cycle is over. At that point, as long as the thermal lockout is OFF, the MPC will bring on the boiler or open the valve. When the Fast Cycle button is pressed, the small right-hand display will change from reading outside temperature to the number of minutes in the cycle. If the display shows 00 and does not change, the MPC is not yet in cycle and the button will have no effect. You must wait until pressure is established and the yellow System in Cycle light (for details see pg. 41) comes on. This yellow light indicates the MPC is in a cycle Control Settings 26

27 Appendix This section contains detailed technical information on the MPC. All of the following are included: Specifications Cycle Chart Vari-Boost and Early Shutdown Curves Wiring Diagrams Troubleshooting Guide The Cycle and Vari-Boost charts allow you to quickly determine how much heat the MPC is putting into a building. You can also use the Fast Cycle button (previous page) to check the On part of the cycle. The Troubleshooting Guide has three charts. One for no heat, the second for not enough heat, and the third for too much heat. By using the correct chart, you should be able to quickly isolate any errors and make adjustments to solve the problem. 27 Appendix

28 Specifications General Specifications MPC Voltage Input: 120 VAC 60 Hz Power Consumption: 30 VA Max Heating Output: 1 S.P.D.T. and 1 N.O. Auxiliary Output: 1 S.P.D.T. Output Relay Ratings: 1 Amp inductive, 6Amp resistive at 120 VAC 60 Hz Ambient Temp: Min 20 F, Max 130 F Sensor Indicating Ranges: Outdoor temperature sensor - minus 35 F to 250 F Heating system sensor - minus 35 F to 250 F Sensor Set Point Ranges: Outside temperature sensor - NORMAL 30 F to 70 F, SAVE 1 F to 70 F and OFF Heating system sensor 70 F to 250 F Heat Adjustment Settings: 16 settings, A through P Cycle Duration: 20, 30, 60, or 90 minutes Heating Clock: 4 NORMAL and 4 SAVE settings Auxiliary Clock: 4 open and 4 closed settings per day Morning Boost: Manual - Off to 120 minutes Vari-Boost - Self-adjusting from 0 to 180 minutes Power Backup: Lithium coin battery, 100 days minimum 5 year replacement Enclosure: NEMA 1 Dimensions: 4-5/8" x 12-1/4" x 12-3/8" Weight: 14 pounds Appendix 28

29 Cycle Chart Cycle Chart The duration of the On part of a cycle (when the heat source is activated) depends on the following three factors: 1. Outside temperature 2. Outdoor Sensor Set Points (see pg. 17) and 3. Heat Adjustment Settings (see pg. 18) When the outside temperature is above the Outdoor Sensor Set Points, the MPC will not call for heat. Below the Set Points, the length of ON time is adjusted by the Heat Adjustment Settings. A gives the least amount of heat, and P gives the most amount of heat as shown by the chart below. Outdoor Sensor Set Point Minus Outdoor Temperature Heat Adjustment Settings A B C C D C C C E C C C C F C C C C C G C C C C C C H C C C C C C C I C C C C C C C J C C C C C C C C K C C C C C C C C C L C C C C C C C C C C M C C C C C C C C C C N C C C C C C C C C C C O C C C C C C C C C C C C P C C C C C C C C C C C C Minutes On (60 Minute Cycle) Example: Heat Adjustment: G Outside temp: 30 F Outdoor sensor set point: 55 F Outdoor sensor set point subtract Outdoor temp Vertical Column 55 F 30 F 25 F Cycle On time 60 Minute cycle: 14 min 30 Minute cycle: 7 min 20 Minute cycle: 4.7min 90 Minute cycle: 21 min The body of the chart shows the length in minutes of the On part of a cycle for a 60 minute cycle. C lasts the entire 60 minutes. For a 30 minute cycle: Divide all times by 2. For a 20 minute cycle: Divide all times by 3. For a 90 minute cycle: Multiply all times by Appendix

30 Vari-Boost and Early Shutdown Vari-Boost and Early Shutdown Graphs The morning Vari-Boost allows a building to recover comfortable ambient temperatures after cooler Save periods. During the Boost period, the boiler runs on its limits, or the steam valve remains open. The Vari-Boost begins a variable time before the 1d setting. This variable time depends on three items: 1. The outside temperature 2. The setting of the Morning Boost Curve knob, which is adjustable from 1, the least amount of Boost, to 6, the most amount of Boost, and 3. The Warm-Up time. Three hours before the 1d setting, the MPC will start calculating the Vari-Boost time. If it is very cold outside, or the Boost curve is turned high, a full three hours of Vari-Boost may be given. Otherwise the MPC will continue updating the calculation until the time when the Vari-Boost begins. The Warm-Up time is a running average of how long it takes for the heating system sensor to reach the XYZ knob adjustment (see pg. 21). Each morning when there is a Vari-Boost from a cold start, the MPC counts how long it takes before this point is reached. This time is calculated with the times for the previous days, but can not change the total Warm-Up time by more than 25%. In this fashion, the MPC learns how long the Warm-up time needs to be, and the Warm-up time will change with any system or seasonal change. To adjust the Vari-Boost, simply change the Morning Boost Curve knob by one number. If there is too much heat in the morning, reduce the Boost by one number. If there is too little heat, increase the Boost. Since the Vari-Boost automatically changes with the outdoor temperature, once the appropriate setting for your building has been found, it should not have to changed. Early Shutdown The Early Shutdown should be used in commercial buildings, or where the building will be unoccupied during the Save periods. The Early Shutdown shifts the control into Save mode before the last n setting. The Early Shutdown time is adjusted with the Morning Boost Curve knob but works in the opposite fashion (see chart next page). The warmer it is outside, the earlier the MPC will shift to night. As it gets colder, the time between early shutdown and the last n setting diminishes. The maximum amount of Early Shutdown is 90 minutes. Appendix 30

31 Vari-Boost and Early Shutdown These six curves, infinitely adjustable, are programmed into the computer s memory to determine the duration of the morning boost in accordance with changes in outside temperature. The vertical axis represents the time span from zero to 3 hours; the horizontal axis represents the outdoor temperature in degrees F. SECTION X (just below ZERO) represents a variable period of up to 45 minutes during which time the heating system is warmed up prior to the morning boost. The number of warm-up minutes needed by a specific building comes from the computer s averaging out the experiences of that building in establishing heat. Total A.M. start-up time is equal to boost time plus X minutes. VARI - BOOST Duration of Morning Boost in Minutes X WARM-UP PRIOR TO MORNING BOOST - ZERO TO 45 MINUTES Outdoor Temperature EARLY SHUTDOWN 90 The same curves that influence the VARI- BOOST also determine the Early Shutdown operation, but in a reciprocal pattern. The time spans for the Early Shutdown are half as long - ranging from 0 to 90 minutes instead of 0 to 180 minutes (compare vertical axis of the two graphs). Once the setting (1 to 6) is chosen for the VARI-BOOST, it operates for the Early Shutdown as well. It cannot be set separately. Duration of Early Shutdown in Minutes Outdoor Temperature 2 31 Appendix

32 Wiring - MPC to Boiler T T C C Earth Ground Line Neutral Aux Clock Functions Limit Controls BOILER To Outdoor Sensor To Heating System Sensor Limit Circuit Appendix 32

33 Wiring - MPC to Valve T T C C Earth Ground Line Neutral Aux Clock Functions Open Common Close To Outdoor Sensor To Heating System Sensor MOTORIZED VALVE 33 Appendix

34 Troubleshooting Troubleshooting Guide When there is a problem with heat in a building, the first place people look is at the heating control. And the heating control may be the problem, but so may be other system components, or perhaps the heating control is not adjusted properly. To help determine and correct the problem, simply follow the troubleshooting guide that best describes your heating situation: Heat - pg. 35 Too Little Heat - pg. 36 Too Much Heat - pg. 37 In addition to these basic problems, you may have intermittent problems. If you IMPORTANT This is a cycle control. The boiler is ON part of the cycle, and OFF part of the cycle. Even in cold weather, the heat source may be OFF. Sometimes have Heat, too Little Heat or too Much Heat, the control may not be programmed correctly. Check through all the settings of the clock (see pg. 19) to make sure the rmal and Save modes are when you want them to be. Go through all four settings for each day of the week, making sure any unused settings display NONE. Pay special attention to the AM and PM lights below the times, since if these are incorrect, the program will be 12 hours off. HEAT - ON 8 MINUTES HEAT - ON 21 MINUTES HEAT - OFF 52 MINUTES HEAT - OFF 39 MINUTES Have too Little Heat or too Much Heat Only at the 1d Time, adjust your Boost. The Vari-Boost changes with outdoor temperature, and is therefore recommended over the fixed Manual boost. If there is too little heat, adjust the Vari-Boost curve up one number, it there is too much heat, adjust the curve down (see pg. 30). Have too Little Heat Before the Last Save Program, you may not wish to use the Shutdown feature. Simply move the Boost switch to the middle VARI position (see pg. 24). Have too Little Heat or too Little Heat Only in Parts of the Building, then check the Heating System Sensor Adjustment (see pg. 21). The last radiator in the system should begin to get warm before the control goes into cycle. If the Adjustment is set appropriately, then the problem is with the steam distribution of the system, not the MPC. Check the sections of the building in question for defective air vents, steam traps, and other components which may be affecting steam delivery. Appendix 34