ProCon 16, 31, 47 & 75. RVA 63 Boiler and Circuit Controller Commissioning Data.

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1 ProCon 16, 31, 47 & 75. RVA 63 Boiler and Circuit Controller Commissioning Data. The RVA63 controller can be utilized to control the following system configurations via LPB communication. Equipment Required System Configuration Single Boiler. Two timed heating zones with independent pumps. Common flow temperature. Fixed temp / weather compensation. HWS Control. Single Boiler. Two timed heating zones with independent pumps. Independent flow temperatures. Fixed temp / weather compensation. HWS Control. Single Boiler. (Multiples of) Two timed heating zones with independent pumps. (Via multiple RVA63s) Independent flow temperatures. Fixed temp / weather compensation. HWS Control. OCI420 Com Clip One per boiler Outside sensor (QAC31/Q AC32 / *620 Ω to RVA63/47 or QAC34 to boiler) Mixing Valve/s supplie d by others one per zone Flow sensor/s (QAD21/ QAD26) One per zone Room Unit/s QAA70/ QAA50/ QAA10 directly to RVA63 Yes Yes No No Yes For pump control Yes Yes Up to 2 Up to 2 Up to 2 For valve and pump control Yes Yes Up to the number of zones Up to the number of zones Up to the number of zones As above) RVA47 Cascade manager To control up to 12 boilers No No No HWS Sensor or Volt fee enable. (QAZ21 direct to RVA63) Yes Yes Yes Multiple Boilers. Two timed heating zones with independent pumps. Common flow temperature. Fixed temp / weather compensation. HWS Control. Multiple Boilers. Two timed heating zones with independent pumps. Independent flow temperatures. Fixed temp / weather compensation. HWS Control. Multiple Boiler. (Multiples of) Two timed heating zones with independent pumps. (Via multiple RVA63s) Independent flow temperatures. Fixed temp / weather compensation. HWS Control. Yes Yes No No Yes For pump control Yes Yes Up to 2 Up to 2 Up to 2 For valve and pump control Yes Yes Up to the number of zones Up to the number of zones Up to the number of zones (As Above) Yes Yes Yes Yes Yes Yes The system configuration and sensor requirement information detailed above is not an exhaustive list, as many control options are available utilizing the Siemens Albatross control system in conjunction with the ProCon range. (*620 Ohms Substitute resister part # RES-620) Where the system configuration calls for the inclusion of a RVA47 controller, reference must be made to the specific quick reference guide for accurate parramatization. 1

2 To ensure that the ProCon can communicate with the RVA63/47 controllers the following hardware must be connected to each LMU64 controllers mounted in the rear of each ProCon boiler. 1x OCI420 Communication Clip. Clipped into the right hand space on the front of the LMU64 controller. 1x OCI420 Wiring loom to be connected to the exposed PCB at the base of the OCI420 Clip X40 and to the exposed PCB at the base of the LMU64 controller X40. Wiring Configuration and Type The interconnecting cascade wiring from the RVA 63 to RVA47 (if required) to the ProCon boilers must be connected as follows: In a parallel configuration using screened cable. (The screening must be earthed) When utilising the RVA47 as a cascade manager in conjunction with the RVA63 the following pump wiring changes must be undertaken. The pump supply wiring must be altered as follows. The boiler pump must be connected to the K1 terminals, and not the K2 terminals. RVA63 LPB Connections. MB Pink DB Purple RVA47 LPB Connections. MB Pink DB Purple LMU64 / OCI420 Clip ProCon Boiler Connections. X41 Connection Plug on front of OCI420. #1 left hand terminal. DB Purple #2 Right hand terminal. MB Pink 2

3 Communication Operation Indications The RED LED on the OCI420 flashes to indicate the detected operational status of the ProCon boiler dictated by the LPB communication from the RVA47. LED FLASH STATUS LED ON Constantly LED OFF Constantly LED ON 93% OFF 7% LED ON 5% OFF 95% LED ON 5% OFF 20% ON 5% OFF70% INTERPRETATION OPTIONS OCI420 not configured to operate with LMU64 OCI420 Configured. LPB Short Circuit / No Power. OCI420 and LUM64 Not Compatible / LPB Address inadmissible. Boiler being controlled via LPB and required to be not operating. Boiler being controlled via LPB and required to be operating. Boiler and RVA63 Parameter Configuration A number of parameters within each boiler must be altered to ensure correct operation of the system cascade communications. Press and Hold the UP and DOWN PROG buttons on the facial of the boiler until H90 appears on the display. Press the UP PROG button until the following parameters are displayed. Alter the parameters as detailed using the PLUS and MINUS button. Following the alteration of the final parameter press the INFO button to confirm the final alteration. All previous alterations will be stored into the memory by pressing the UP PROG button to pass to the next parameter for alteration. LMU64 ProCon Controller Parameter Alterations. PARAMETER EXISTING REQUIRED (Single Boiler Installation.) REQUIRED (Multiple Boiler Installations Via RVA47) System Dependant Do Not Alter from Standard Setting for Normal Operation 604 Bit Fist boiler in cascade = 2 Second boiler in cascade = 3 Third boiler in cascade = 4 80 To the maximum number of boilers allowable in cascade boiler # 12 = 13 3

4 RVA63 Controller Parameter Alterations. PARAMETER EXISTING REQUIRED (Single Boiler Installation.) REQUIRED (Multiple Boiler Installations Via RVA47) * For the first RVA63 then for subsequent RVA63s. 1* For the first RVA63 then for subsequent RVA63s * (Heat consumer not heat generator) 1* (Heat consumer not heat generator) * If LPB communication difficulties are experienced using these settings please adjust 140 to the last consecutive unused addresses up to 14 and 141 to 0. (Heat Generator) RVA 63 Fault Indication If the sensors or ProCons connected to the RVA63 controller fail or are removed from circuit, an error message will be displayed on the left of the LCD screen. Error Message Notation Er. Once an error message is present the cause of the error can be traced by accessing function [50]. To access function [50], Open the flap of the controller and press the DOWN PROG button twice. [50] Should appear in the left-hand side of the LCD display. The figure shown in the center of the screen is the fault identification number. The display can hold a number of faults but will only display 2 at any one time. The second error can be accessed by pressing the + or buttons. Once a fault has been rectified the error number will disappear or be replaced with another fault number if further attention is required. ProCon Fault Indication. The following codes will be displayed on both the Boiler control panel and all RVA controllers. Boiler Control Panel: If the Boiler LMU64 Controller or RVA63 Unit detects an operational fault a relevant code is flashed alternately with the Time of Day display. If the fault prevents the boiler from operating the appears at the lower left corners of the display. By pressing the INFO button on the display a full screen display will indicate the fault code. By opening the opening the side-hinged cover / flap on the RVA63 unit and pressing the PROG button twice Line # 50 will indicate the fault code and give a brief description of the fault. Faults can only be rest at the boiler by pressing the RESET button. Prior to pressing the RESET button a note should be made of the fault code for future reference. 4

5 Fault Code Description E-0 No Error Detected E-10 Outside Air Sensor Fault / Not Detected E-20 Flow Water Sensor Fault / Not Detected E-26 System Flow Sensor Faulty / Not Detected E-28 Flue Gas Sensor Fault / Not Detected E-40 Return Water Sensor Fault / Not Detected E-46 System Return Water Sensor Fault / Not Detected E-50 HWS Sensor Short Circuit 1 E-52 HWS Sensor Short Circuit 2 (Not Used) E-58 HWS Volt Free Switch Fault / Not Detected E-60 Faulty Room Sensor E-61 Faulty Room Sensor E-62 Incorrect Room Unit Connected E-77 Air Pressure Sensor Not Detected (Not Used) E-78 Water Pressure Sensor Defective (Not Used) E-81 LPB Short Circuit (Boiler Cascade Wiring) E-82 LPB Address Conflict (Boiler Cascade Settings) E-86 Short Circuit on PPS Connection (Not Used in ProCon Configuration) E-91 EEPROM E-92 Hardware Malfunction E-100 Conflict Between Time of Day Master Control (Boiler / QAA73 / RVA47) E-110 Boiler Water Temperature Overheat. Internal Fuse failure. X3:03 wiring error. E-111 Boiler Temperature Too High (Auto Resetting) E-113 Flue Gas Temperature overheat (Not Used) E-117 High System Water Pressure Sensor (Not Used) E-118 Low System Water Pressure Sensor (Not Used) E-119 System Water Pressure Switch Activated (Below 0.8 bar) E-124 Boiler Temperature Too High (Auto Resetting) E-128 No Flame Detected After Final Ignition Attempt (version D LMUs) E-129 Flame Extinguished During Operation (Version D LMUs) E-130 Flue Temperature Too High (Auto Resetting) E-131 Fault With Burner E-132 External Safety Interlock Activated (Open Circuit) E-133 No Flame Detected After Final Ignition Attempt E-134 Flame Extinguished During Operation E-135 Air Supply Error (Not Used) E-140 LPB Segment / Address Not Recognized (Boiler Cascade Settings) E-142 LPB Missing Partner (Boiler Cascade Settings) E-145 Wrong Device Connected to PPS Circuit (Not Used in ProCon Configuration) E-146 Unrecognized Plant Configuration E-147 Burner Modules Not Connected (PPS Circuit Not Used in ProCon Configuration ) E-148 LPB Interface Not Configured (Boiler Cascade Settings) E-150 General Boiler Fault E-151 Boiler LMU64 Controller Malfunction E-152 Boiler LMU64 Controller Parameter Programming Error E-153 Boiler Control Interlocked E-154 Boiler Operating Outside of Predefined Parameters. (System Hydraulic Error.) E-160 Fan Not Reaching Set Point E-161 Combustion Fan Speed Too High E-162 Air Pressure Switch Fault (Not Used) E-164 Flow Switch / Pressure Switch Open (Not Used) E-166 Air Pressure Switch Fault (Not Used) E-180 Boiler Operating in Chimney Mode 100% Output E-181 Boiler Operating in Commissioning Mode E-183 Boiler Controller / QAA73 Room Unit in Parameter Setting Mode 5

6 Complete RVA63 Boiler and Multi zone Controller End User Parameter Setting. To enter the End User Parameter Program, the door must be opened and one of the UP or DOWN Prog buttons must be depressed. A number between 1 & 50. Will appear in a bracket on the left of the display window. These can be paged through by using the UP or DOWN buttons. To alter or input the required data in the selected program line # use the + or - buttons. To leave the End User Parameter Setting Menu press the AUTO button. The defaults indicated below are for standard systems. If additional control features are required alteration will have to be made. Please refer to the RVA63 manual for additional details. #, -, --- Indicates where an input can be made if required. -- Indicates where an input can not be made and a sensed / attenuated figure is displayed. OFF will be displayed if the +/- buttons are used. [Prog #] Description of Prog # Range Inputs Standard Time of Day. 1 Time of day 0-23:59 Hr/Min 00:00 2 Weekday 1 7 Day 1 3 Date Day / Month Date Year 0000 Year 2005 Time Switch Program Heating Zone 1 5 Every day the same. 1-7 Day - Every day different. 1 7 Day 6 1 st On time :00 Hr/Min 06: st Off time :00 Hr/Min 22: nd On time 00-24:00 Hr/Min - 6

7 9 2 nd Off time 00-24:00 Hr/Min rd On time 00-24:00 Hr/Min rd Off time 00-24:00 Hr/Min - Time Switch Program Heating Zone 2 5 Every day the same. 1-7 Day - Every day different. 1 7 Day 6 1 st On time :00 Hr/Min 06: st Off time :00 Hr/Min 22: nd On time 00-24:00 Hr/Min nd Off time 00-24:00 Hr/Min rd On time 00-24:00 Hr/Min rd Off time 00-24:00 Hr/Min - Time Switch Program HWS 19 Every day the same. 1-7 Day - Every day different. 1 7 Day 20 1 st On time :00 Hr/Min 06: st Off time :00 Hr/Min 22: nd On time 00-24:00 Hr/Min nd Off time 00-24:00 Hr/Min rd On time 00-24:00 Hr/Min rd Off time 00-24:00 Hr/Min - Hot Water Service 26 Required HWS temperature C 55 Heating Circuit 27 Night set back temperature C Frost Protection temp 4-15 C 10 7

8 29 Summer/Winter switching 8-30 C Slope of heating curve -/ If a 0-10 volt signal is the required heat generation control method for the RVA63 / 47 / boiler installation this setting must be adjusted to -- on all RVA63s /47s present in the boiler cascade installation. This will result in the Auto, On/Off and Frost lights becoming inactive. Alteration to parameter #170 and #172 will also be required. Actual Values 33 Actual Room temperature 0-50 C Actual outside temperature C -- (Pressing the +&- buttons simultaneously until the display stops flashing will reset the averaged value.) Maintenance 35 Burner Hours run Stage 1 or LMU enabled Burner Hours run Stage Number of burner starts Stage Number of burner starts Stage Time switch factory presets reset. 0/1-0 Press +&- together for 3 seconds Holidays 40 Holiday Period (up to 8 preprogrammed holiday periods can be stored) 41 Start date for holiday period. Month/Day --:-- Holiday period setting factory reset. Press +&- together for 3 seconds 42 End date for holiday period. Month/Day --:-- Holiday period setting factory reset. Press +&- together for 3 seconds Service Indications 49 Module Error Code 1..4/ (Not always displayed) 50 Indication of faults

9 Heating Engineer Parameter Setting. To enter the Heating Engineer Parameter Program, the door must be opened and the UP & DOWN Prog buttons must be depressed for at least 3 seconds until # 51 appears in the window. A # between 51 & 173. will appear in a bracket on the left of the display window. These can be paged through by using the UP or DOWN buttons. To alter or input the required data in the selected program line # use the + or - buttons. To leave the Heating Engineer Parameter Setting Menu press the AUTO button. [Prog #] Description of Prog # Range Standard Service Values 51 Output Test 0 Automatic control All outputs Off 2 Burner stage 1 on (K4) 3 Burner stages 1 & 2 On (K4 & K5) 4 HWS pump/valve on (Q3 / Y3) 5 Heating Circulating pump 1 On (Q2) 6 Mixing Valve 1 Open (Y1) 7 Mixing Valve 1 Close (Y2) 8 Heating Circulating pump 2 On (Q6) 9 Mixing Valve 2 Open (Y5) 10 Mixing Valve 2 Close (Y6) 52 Input Test 0 Boiler Sensor (B2) HWS 1 Sensor (B3) 2 Display of input of H2 (H2/B31) 3 Flow sensor Heating zone 1 (B1) 4 Flow sensor Heating zone 2 (B12) 5 Outside air sensor (B9) 6 Room sensor heating zone 1 (RG1,A6) 7 Room sensor heating zone 2 (RG2,A7) 8 Flue gas sensor (B8) 9 Display of input of H1 (H1) 53 Plant Type # refer to drawings at rear of manual (System Specific) Actual Values 55 Actual value of Zone flow temperatures

10 56 Actual value of Boiler flow temperature Actual value of common flow temperature Actual value of HWS 1 temperature Actual value of HWS 2 temperature Maximum value flue gas temperature Press +&- together for 3 seconds to reset setting 65 Attenuated outside air temperature Comp outside air temperature --/ Outside air temperature source 00.01/ RVA63 Dictated Set Points 68 Display of boiler temperature set point Affected by external inputs 69 Display of common flow temperature set points Affected by external inputs Display of HWS temperature set point 0.0/ Nominal Room temperature set point 0.0/ Display of Set point of room temperature 0.0/ Display of flow temperature set point Underfloor heating control 77 Floor curing data. Day Temperature set point Heat Generation Equipment 80 Type of heat source Via LPB or PPS 1. Single Stage burner 2. 2 stage burner 10

11 81 Minimum limitation of boiler flow temperature Bathroom circuit heating supply pump overrun Inactive 1. Active Space Heating 100 Displacement of heating curve Gain factor for room temperature influence Active 1. Inactive 102 Room temperature pump switching differential Higher = Less stable temperature ---/ Lower = More stable temperature Inactive. 103 Operating / Control mode of Room unit Parallel action. Room unit 1 on Heating Zone 1 Room unit 2 on Heating Zone 2 1. Crossed action Room unit 1 on Heating Zone 2 Room unit 2 on Heating Zone 1 2. Serial action Room unit 1 on Heating Zones 1 & Room unit values Parallel action. Room unit 1 on Heating Zone 1 Room unit 2 on Heating Zone 2 1. Crossed action Room unit 1 on Heating Zone 2 Room unit 2 on Heating Zone 1 2. Serial action Room unit 1 on Heating Zones 1 & Minimum limitation of flow temperature Maximum limitation of system flow temperature. 109 Optimum Start Maximum Forward Shift 00-06:00 00:00 00:00 Inactive 11

12 110 Optimum Stop Maximum Forward Shift 00-06:00 00:00 00:00 Inactive 113 Type of build construction 0/1 1 0 Heavy 1 Light 114 Adaptation of heating curve. 0/1 0 0 Inactive 1 Active 115 Gain of locking signal % 100 Effect of HWS priority on mixing valves 116 Floor curing activation setting Off 1. Functional Heating 2. Floor curing 3. Functional and floor curing HWS 120 Reduced HWS temperature set point HWS time control hours per day. 1. As heating times with 1 hour shift. 2. As HWS time settings. 123 HWS control system Controlled via local circuit 1. Controlled via all segment 2. Controlled via all in LPB system 124 HWS charging cycles per 24 hour period One per day with 2.5 hour forward shift. 1. Several per day with 1 hour forward shift. 125 HWS sensor type Sensor. 1. Thermostat switch. 126 Flow temperature boost in HWS mode

13 127 HWS Priority / Shifting Absolute priority. 1. Shifting priority heating reduced to increase recovery on HWS. 2. No priority HWS and Heating operate. 3. Shifting / Absolute Pump circuit switched off, mixing circuit decreased to increase recovery of HWS. 128 HWS Charging option Charging pump 1. Diverter valve LPB Communication Setting 140 LPB control device address Standalone single RVA Master RVA63 cascade manager with sensors attached Slave RVA63 / 47s operating from master RVA63.(House Number.) (Each subsequent RVA47 should be given consecutive numbers.) 141 LPB control segment address Heat generator. (Street Name.) 1.14 Heat consumer. 142 LPB Bus power supply Off. 1. On. 143 Operation of LPB power supply. On / Off Change over via LPB connections All controller in same segment. 1. All controllers in LPB system. 146 Auto Summer / Winter change over function Local control only. 1. Entire control via LPB. 147 Central Standby switching Deactivated. 1. Activated. 148 Clock mode Autonomous Clock Individual controller can have different times. 1. System time, time will match system can not be adjusted. 2. System time with adjustment. 3. System Clock, master. There can be only one master on system. 13

14 150 Automatic Seasonal Time Adjustment. Date.Month Spring, time adjustment Date and Month of the last Sunday in the month of March 151 Automatic Seasonal Time Adjustment. Date.Month Autumn, time adjustment Date and Month of the last Sunday in the month of October 156 Display of PPS to Room unit for zone Input H1 170 Operation of H1 terminals Changeover of operation all Heating and HWS systems 1. Changeover of operation all heating only. (HWS released) 2. Minimum flow temperature maintained (Set at 171.) 3. Heat generation stooped when switch is made. (Frost Active) Volt control to vary flow temperature. (Curve set at 172) (Terminal # volt. Terminal #2. Ground.) 5. Changeover of operation of heating zone Changeover of operation of heating zone 2. If a 0-10 volt signal is the required heat generation control method for the RVA47 / boiler installation this setting must be adjusted to 4. Alterations must also be made to parameter #17. The setting must be adjusted from 32 to on all RVA63 / 47s present in the boiler cascade installation. This will result in the Auto, On/Off and Frost lights becoming inactive. Possible alterations to parameter #172 may also be required. 171 Minimum temperature set point for H Maximum temperature set point for H (For 0-10 Volt control) 173 Operating action of H1 and H2 contacts The contact is Normally Closed. 1. The contact is Normally Open. The RVA47 will operate according to its internal time switches and presets. If a remote BMS is controlling the RVA47 via a Volt Free switch across H1 0 should be inserted. This will allow the boilers operate when the Volt Free switch is made and stopped (Blocked.) when the switch is opened. If you are controlling the lead (master) RVA/Boiler via a volt free switch across H1, all slave modules should be left with 1 as the input. This will allow the AUTO light and the OFF light to indicate their operational mode dictated by the lead (master) RVA/Boiler. 14

15 174 Operating function of H2/B31 terminal HWS Sensor #2 1. Minimum flow set point 2. Heat Generation lock 3. Changeover of operation of heating zone 1 4. Changeover of operation of heating zone 2 OEM Parameter Setting. To enter the OEM Parameter Program, the door must be opened and the UP & DOWN Prog buttons must be depressed for at least 10 seconds until appears in the window. The display must be changed to by inputting a password. The password for the RVA 63 is DOWN, DOWN, PLUS, MINUS, PLUS. A # between 1 & 92. will appear in a bracket on the left of the display window. These can be paged through by using the UP or DOWN buttons. To alter or input the required data in the selected program line # use the + or - buttons. To leave the OEM Parameter Setting Menu press the AUTO button. [Prog #] Description of Prog # Range. Standard Setting Heat Source OEM 1 Minimum limitation of boiler flow temperature (Manual operation.) 2 Maximum module temperature (Manual operation.) 3 Switching differential of boiler temperature Minimum run time of boiler. 5 Release limit (Integral) of burner stage Reset limit (integral) of burner stage Pump overrun timer following burner off

16 9 Operating mode of boiler To maintain min temperature 0. Continuous. Burner operates to maintain minimum flow temperature regardless of control signal (#81) 1. Automatic. Burner operates to maintain minimum flow temperature outside of automatic controlled on modes. (#81) 2. Automatic. Burner operate only when required dependant upon automatic controlled on modes. 10 Condensation reduced startup Heat load not restricted during start up to promote condensing. 1. Heat load restricted during start up to reduce condensing. 12 Boiler pump control Mixed temperature operation. 1. Parallel to burner operation Space Heating OEM 30 Flow temperature set point boost mixing valves Room influence gain factor Constant for quick setback and optimum start Boost of room temperature set point (Room sensor dependant) Increase. Heat up time reduced. Decreased. Heat up time increased. 34 Frost protection program Frost protection program switched. Off 1. Frost protection program switched. On 35 Control Mode of actuators Zone 1 and position (Y1 / Y5) (see # 36) 1. 3 position (Y1,Y2 / Y5,Y6) 36 Switching differential of 2 position valves

17 37 Over temperature protection for pump heating circuits 0. Inactive 1. Active. 38 Heat gains Increase. If gains are high. Decrease If gains are low. 39 Curve Adaptation 1 sensitivity Outside air range between C 40 Curve Adaptation 2 sensitivity Outside air range below 4 0 C 41 Proportional band for heating zone mixing Valves 42 Integral action time for heating zone mixing Valves 43 Actuator running time for heating zone mixing Valves HWS OEM 50 Maximum HWS set point HWS switching differential.(sensor Only) Legionella function Inactive 1. Active 53 Set point of Legionella function Discharge protection during HWS heating No 1. Continuously 2. Partly 17

18 Configuration of Plant OEM 90 Continuous Display Option Weekday / Time of day 1. Actual flow temperature 91 Software Version RVA47 controller operating hours ,