Dual Mixing Application

Transcription

1 HBX MIXING APPICATION The CPU-000 configured as a Mixing Control allows for mixing of hitemp boiler (supply) water with lower temp system water, bringing several benefits to a hydronic design and installation. When designed and controlled correctly, the two main benefits are boiler protection from condensing flue gases, and system efficiency from accurately controlled water temperature to match the thermal characteristics and limitations of the actual heat emitters. Figure Version.0 Product Note Dual Mixing Application In its simplest form the CPU-000, using no s and the Mixing Control can handle the following application(s): a) Single stage boiler control running off of indoor/outdoor reset boiler sensor system sensor outdoor sensor b) mixed temperature loop c) boiler side (hi-temp system) pump d) system (lo-temp/mixed system) pump e) Mixed injection via valve (PMIv) Or injection pump PMIp (up to 0Amps) f) Optional DHW control with or without priority Via an aquastat only g) DHW pump or DHW valve CR00533X Comfort Control Innovation HBX Control Systems Inc. 006 Mixing Control Page

2 Version.0 MIXING CONTRO FEATURES The Mixing Control Will:. Allow for multiple boiler(s) or stages to be operated when additional EXP-000 Modules are connected. The maximum number of total stages cannot exceed ( boiler stage only inside the CPU-000 and multiples of or greater must be wired via an EXP-000), E.g. 0 stages in the CPU-000 plus 6 x EXP- 000 = stages (See Application Drawing # MIX 000-).. Allow the pump relays (Terminals 0- & 3-5) to run continuously, E.g. programmed as s Always On -Y, accessed via, Mixing Options then Options menu under Options. * Injection pump relay (Terminals 6-8) will not run continuously as this is an undesirable condition for a mixing pump. However, this pump relay will run if selected to DHWp which has the potential to overheat the DHW tank under certain conditions, proceed with caution or disable s Always On - N. 3. The Post Purge feature is also available with terminals 0- & 3-5 and is selectable for between secs when selected in the Options menu. 4. Allow for optional setpoints to be added and controlled via the CPU-000. To use the setpoint features you must add either an EXP-000 or EXP-0300 depending on the device being controlled, E.g. a -wire 4VAC actuator or a 0VAC pump/fan. The position of the setpoint sensor relative to the device being controlled is very important in regards to the input wiring on the control. The setpoint sensor/thermistor will automatically trigger or activate the last relay in series within the overall controls wiring. For example; if programming the Control for Setpoint # within the Controls Menu; setpoint # looks for an input signal on the first unused thermistor terminal in the string of s and operates the next available relay in circuit that is not controlling either a boiler stage or connected boiler pump. In most cases the setpoint thermistor wires and the actuator/motor contact relay will not be wired into the same (see Application Drawing # MIX 000- to illustrate how this would be wired). The Mixing Control will NOT: 5. Allow for the pump sequencer option 6. Allow you to control individual boiler pumps 7. Allow you to access the flow proof option Mixing Control Page

3 Version.0 WIRING TERMINAS OPTIONS AND FACTORY DEFAUTS The purpose of the Mixing Control is to allow the installer access to the parameter selections imbedded within the CPU-000. The Mixing Control will configure the CPU-000 to be used for a variety of commonly used hydronic heating applications that utilize mixed radiant injection. An added feature with the Mixing Control is that the Control can stage multiple boilers as well as provide pump or valve injection to a mixed temperature loop. Part of the parameter selections unlocked also set up the default values and functions for the terminal block connections (See Figure and the corresponding notes). TERMINA DESIGNATIONS: 0-40V 0-40V 0-40V 0A Do Not Connect Power Here 0A 0A 0A 0A N G 0 0 N G N G N G Figure Terminals - Terminals - can be used to create an external heat demand, E.g. a 4VAC -wire thermostat. This signal, when closed, will trigger the boiler(s) to turn on (fire) and maintain an output target temperature that is programmed as the maximum boiler temperature or lower; as is calculated by the indoor/outdoor reset algorithm as long as the control is not in warm weather shut down (WWSD). If these conditions exist the CPU-000 display will show the letters HD for heat demand in the top left part of the Controls display System Status screen. Terminals 3-4 Terminals 3-4 can be used to create a high temperature heat demand from a remote switching device powered by any 0-40VAC source. E.g. a make-up air unit, high temperature heat emitters (fan coil baseboard heaters) controlled via a thermostatic switch etc. This signal will trigger (fire) the boiler(s) and maintain an output target temperature set to be the maximum boiler temp as programmed in the control menu. This function will be overridden by the WWSD and the boiler temperature is tied to the indoor/outdoor reset. If these conditions exist the CPU-000 display will show the letters HTD for high temp demand in the top left part of the Controls display System Status screen. A hi-temp heat demand would normally be piped from the high temperature loop of your mixing system. Terminals 5-6 Terminals 5-6 can be used as an external demand signal, designed to be controlled via an aquastat powered from a 0-40VAC source, and supplying an indirect DHW storage tank where the heat exchanger coil is heated via either an actuator valve (terminals 5-6) or inline circulating pump (terminals 6-8). output target temperature will be staged to the maximum boiler temp as programmed within the Control. In DHW priority, the priority demand will only last for a maximum of 60 mins before going back to satisfy the new or existing HD (heat demand). To function correctly the DHW parameter selections need to be programmed through the Domestic Options in the CPU-000 menu. The letters DHW will appear in the 3rd column from the top left part of the controls display when a DHW HBX Control Systems Inc. 006 Mixing Control Page 3

4 demand exists. DHW overrides WWSD and can be programmed to be either in a priority or nonpriority mode within the Control. * The DHW choice for valve or pump is limited or governed by the radiant mixing device used, if you are mixing using PMIp you cannot choose to supply your DHW with a pump and conversely if you are mixing with PMIv you cannot heat your DHW with a valve. The Control will display an error message if a conflict exists and advise you to make a different selection for either mixing or DHW valve/pump. This will be discussed again under Terminals 5-6 and 6-8. Terminals 7-8 Terminals 7-8 are designed to be used as the boiler supply water sensor inputs. The resistance change across the thermistor provides feedback to the control, and is used as part of the indoor/outdoor reset control calculation which will be critical to the reliable operation of the boiler staging sequence. * It is important to also note that this part of the Control is not regarded or to be used as a safety/limit device. The measured value will be displayed on the controls screen as either ºC or ºF, visible in the centre column as a large font along side the word. Terminals 7-8 are dedicated to be 0K Ohm thermistor inputs. * Any external power applied to this terminal may result in permanent damage. Terminals 9-0 Terminals 9-0 are designed to be used as the mixed loop System inputs. The resistance change across the thermistor provides feedback to the Control and is used as part of the indoor/outdoor reset control calculation which will be critical to the reliable operation of the mixing device (pump or valve). This sensor provides a Version.0 feedback signal to the control and must be in place for the controls PID algorithm to function and maintain the desired temperature to the heat emitters in the heating system. The measured value will be displayed on the Controls screen, as either ºC or ºF, visible in the centre column as a large font along side the word System. Terminals 9-0 are dedicated to be 0K Ohm thermistor inputs * Any external power applied to this terminal may result in permanent damage. Terminals - Terminals - are the default inputs for the outdoor sensor (thermistor). The resistance change across the thermistor provides feedback to the control and is used as part of the indoor/outdoor reset control calculation which will be critical to the reliable operation of the boiler staging sequence. The measured value will be displayed on the controls screen, as either ºC or ºF, visible in the centre column as a large font along side the word Outdoor. Terminals - are dedicated to be 0K Ohm Thermistor inputs. * Any external power applied to this terminal may result in permanent damage. Terminals 3-4 Terminals 3-4 are dry contacts (rated for up to 0Amps) and default to be boiler (stage) #. Wire in the boilers staging contacts in series with this -wire terminal. The logic within the CPU- 000 will open and close this contact to control the firing sequence for the boiler(s). * It is very important to note that this function and operation only works for a single boiler stage. As soon as a second stage and higher is added to the system, all of the staging contacts must be wired through the EXP- 000, including the first stage (please see Application Drawing # MIX 000-). Mixing Control Page 4

5 Terminals 5-6 Terminals 5-6 are dry contacts (rated for up to 0Amps) and default to be the injection valve terminals. The CPU-000 uses a unique mixing strategy called PMIv (Pulsed Modulated Injection, to learn more study the PMI Technical Bulletin or the PMI section of the CPU-000 Installation Manual). An option or alternative use for this relay is to operate an actuator valve supplying the heat exchanger coil of an indirect fired DHW tank. Within the Domestic Options menu you must change the default value from DHW to DHW Valve. Terminals 7-9 Terminals 7-9 are the 3-wire inputs for 0VAC power supply to control the pump (or fan) motors that follow next. Note; each input on the terminal block is silk screened to indicate which wire is the ine, Neutral and Ground (see Figure 3). The remaining 3 outputs (to be discussed next) can carry a maximum of 0Amps each, depending on the number of motors and size of motors connected this input should be protected by a 30Amp fuse or breaker. Terminals 0- Terminals 0- are used to supply power (, N & Gnd) to the main system pump (hi-temp) which is part of the pumping circuit being fed from the boiler or boilers. In the CPU-000 display this would read as. Terminals 3-5 Terminals 3-5 are used to supply power (, N & Gnd) to the Mixed system pump (reduced temperature side of the system). Version.0 Terminals 6-8 Terminals 6-8 are used to supply power (, N & Gnd) to either an injection pump (PMIp) or to a DHW pump circulating hot water through the heat exchanger coil inside an indirect DHW storage tank. When programmed for this application the words DHW are visible on the lower part of the controls display when viewing the, System Function screen. * The default designation for this terminal is for a DHW pump. The alternative function for this terminal is to control an injection pump using the PMIp injection strategy (Pulsed Modulated Injection, to learn more study the PMI Technical Bulletin or the PMI section of the CPU 000 Installation Manual). Application Drawing # MIX 000- illustrates the use and default designations for the Terminal # s thru 8. Figure 3 * If pumps always on Y is selected, proceed with caution. This feature will run all pumps continuously, with the exception of instances where terminals 6-8 are programmed for PMIp. However, if terminals 6-8 are programmed as a DHW pump, this pump will also run continuously. Running the DHW pump all of the time increases the risk of overheating the DHW storage / buffer tank. HBX Control Systems Inc. 006 Mixing ID Control Page 5

6 Input: 0VAC 60Hz 5A Relays: 40VAC 0A Demand Signal: 0-40V Model: CPU CAUTION, RISK OF EECTRICA SHOCK - DIS PRIOR TO SERVICING Certified to CSA C. No 4 Conforms to U Standard 873 Control Systems Inc. Version.0 MIXING CONTRO 000- Single stage boiler, showing mixed injection using a valve (PMIv) main boiler pump (hi-temp) and main system pump (lo-temp) Optional DHW capabilities showing an aquastat and DHW supplying an indirect DHW tank. EECTRICA HBX CPU v 0-40 v 0-40 v 0 A 0 A CENTRA PROCESSING UNIT 0 A 0 A 0 A N GR N GR N GR N GR TH A BOIER BOI SEN SUPY SEN OUT SEN 4 V AC C R V PMIv Injection Mixing Valve P System P DHW P3 0 V AC N MECHANICA Application: Mixing Utilized 000 Central Processing Unit B C D egend: P - Hi-Temp System ( Circuit) P - o-temp System (Mixed Circuit) P3 - DHW 0 vac P H E A T O A D System Balancing Valve Inj. Valve P A P3 Check Valve Mixing Control Page 6

7 Input: 0VAC 60Hz 5A Relays: 40VAC 0A Demand Signal: 0-40V Central Processing Unit Model: CPU CAUTION, RISK OF EECTRICA SHOCK - DIS PRIOR TO SERVICING B C D Certified to CSA C. No 4 Conforms to U Standard 873 Input: 0VAC 60Hz 5A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-000 Input: 0VAC 60Hz 5A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-000 Input: 0VAC 60Hz 5A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-000 Input: 0VAC 60Hz 5A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-000 Input: 0VAC 60Hz 5A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-000 Input: 0VAC 60Hz 5A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-000 Control Systems Inc. Version.0 MIXING CONTRO 000- stage boiler control, with injection mixing using a pump (PMIp) Individual boiler pumps can only be controlled by each boilers staging contacts main boiler pump (hi-temp system pump) and main system pump (lo-temp system pump) controlled via the CPU-000, plus injection mixing via P3 All staging is controlled via s EECTRICA CPU-000 CENTRA PROCESSING UNIT EXP-000 EXP-000 EXP-000 EXP-000 EXP-000 EXP v 0-40 v 0-40 v 0 A 0 A 0 A 0 A 0 A 0-40 v 0 A 0 A 0-40 v 0 A 0 A 0-40 v 0 A 0 A 0-40 v 0 A 0 A 0-40 v 0 A 0 A 0-40 v 0 A 0 A N GR N GR N GR N GR TH Stage Stage Stage 3 Stage 4 Apply Control Signal or Program for Permanent Heat Demand Supply Outdoor 4VAC N C R P P Sys. Side Sys. (Hi Temp) (Hi Temp) P3 Inj. (PMIp) 3 3 Stage 5 Stage Stage 7 Stage Stage 9 Stage Stage Stage 0VAC MECHANICA Application: Mixing Utilized 0VAC 000 EXP-000 EXP EXP-000 EXP-000 EXP-000 EXP-000 egend: P - Hi-Temp System ( Circuit) P - o-temp System (Mixed Circuit) P3 - Injection (PMIp) BP3 BP4 BP5 BP BP6 BP P Side System oad Heat P3 Inj. P System System HBX Control Systems Inc. 006 Mixing Control Page 7

8 Input: 0VAC 60Hz 5A Relays: 40VAC 0A Demand Signal: 0-40V Central Processing Unit Model: CPU CAUTION, RISK OF EECTRICA SHOCK - DIS PRIOR TO SERVICING B C D Certified to CSA C. No 4 Conforms to U Standard 873 Input: 0VAC 60Hz 5A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-000 Input: 0VAC 60Hz 5A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-000 Input: 0VAC 60Hz A Demand Signal: 0-40V Relays: 40VAC 0A Model: EXP-0300 Control Systems Inc. Version.0 MIXING CONTRO stage boiler control, with injection mixing using a pump (PMIp) Individual boiler pumps can only be controlled via each boilers staging contacts main boiler circuit pump (hi-temp) and main system pump (mixed circuit) are controlled via the CPU-000, plus injection mixing via P3 Setpoint load shown as a hot tub/pool demand using a setpoint sensor and controlling pumps piped into either side of a heat exchanger EECTRICA CPU-000 CENTRA PROCESSING UNIT EXP-000 EXP-000 EXP v 0-40 v 0-40 v 0 A 0 A 0 A 0 A 0 A 0-40 v 0 A 0 A 0-40 v 0 A 0 A 0-40 v 0 A 0 A DS DS R R R R N GR N GR N GR N GR N GR N GR N GR TH Apply Control Signal or Program for Permanent Heat Demand System Outdoor 4VAC P P System P3 PMIp Inj. Setpoint Stage Stage Stage 3 Stage 4 P4 Heat P5 Heat Exchanger Exchanger Side Hot P/S Tub Side C R 0VAC G MECHANICA Application: Mixing Utilized EXP-000 EXP-000 EXP-0300 egend: P - Hi-Temp System ( Circuit) P - o-temp System (Mixed Circuit) P3 - Injection (PMIp) P4 - Hot Side of Heat Exchanger P5 - Cold Side of Heat Exchanger Heat oad 0VAC System P System VAC P6 Hot Tub / Pool Setpoint P P5 Heat Exchanger P7 Hot Tub Side P3 PMIp Inj. Heat Exchanger P4 Heat Exchanger Side P/S Mixing Control Page 8