Harsco Industrial ENVI Instrucciones de montaje

ENVI®Boiler Controller

Advanced User’s Guide

Installation Date: _______________________

Harsco Industrial, Patterson-Kelley

155 Burson Street

East Stroudsburg, PA 18301

Telephone: (877) 728-5351

Facsimile: (570) 476-7247

www.harscopk.com

ENVI®Control

Rev. 2.(12/19/2014)

Software versions 112E, BD71,

49A7, 79F2, 8C51,1043, 9820

ENVI®Control

1.0 ENVI®BOILER CONTROL ...................................................................................................................... 3

1.0 Operation of the ENVI Control......................................................................................................................................5

1.1 ENVI®control flow chart................................................................................................................................................ 6

1.2 Menu Screen................................................................................................................................................................. 7

1.3 Boiler Status Screen .....................................................................................................................................................7

1.4 Information Menu..........................................................................................................................................................8

1.5 Errors Menu ................................................................................................................................................................10

1.6 Program Parameters Menu.........................................................................................................................................11

1.6.1 Initial Setup of the Control ..................................................................................................................................11

1.6.2 CH Settings .......................................................................................................................................................... 12

1.6.2 CH Modes...........................................................................................................................................................14

1.6.3 DHW Settings ..................................................................................................................................................... 20

1.6.4 DHW Modes........................................................................................................................................................21

1.6.5 Boiler Settings.....................................................................................................................................................22

1.6.6 OEM SETTINGS................................................................................................................................................. 23

1.7 Configuration Menu:....................................................................................................................................................23

1.8 CASCADE MENU:......................................................................................................................................................24

1.8.1 Cascade setup....................................................................................................................................................24

1.8.2 Control Mode ...................................................................................................................................................... 24

1.8.3 Master Settings...................................................................................................................................................25

1.8.4 Master Modes..................................................................................................................................................... 26

1.8.5 Cascade Settings................................................................................................................................................33

1.9 Service Menu:.............................................................................................................................................................38

2.0 TROUBLESHOOTING........................................................................................................................... 39

2.0.1 Troubleshooting Table........................................................................................................................................ 39

2.0.1 The Loss of Power..............................................................................................................................................39

3.0 APPENDIX –MODBUS®INTERFACE.................................................................................................... 43

3.0.1 Descriptions of MODBUS®Register Map...........................................................................................................44

3.0.2 Boiler State .........................................................................................................................................................45

3.0.3 Information Byte..................................................................................................................................................45

3.0.4 Sequence Byte....................................................................................................................................................45

4.0 MODBUS CONFIGURATION................................................................................................................. 48

ENVI®Control

1.0 ENVI®BOILER CONTROL

The ENVI® boiler control consists of 3 components and is an intelligent control system with advanced features such as text-

based display, MODBUS® communication capabilities, and boiler sequencing. Firing rate and setpoint can be controlled

via an external 0-10VDC analog control signal. Errors are date and time stamped, and the control records burner run time

at various operating points. A single integral control for temperature control, flame safeguard, firing rate control, blocked

flue protection, outdoor air reset, freeze protection, built-in cascade sequencing and more. Throughout this manual and in

the ENVI®controller the term “Hysteresis” is used with the meaning of “Differential”.

The ENVI®control is capable of accepting building management control via 0-10VDC and MODBUS®. Other languages

require the use of a Protocol converter which is also available separately from your Patterson-Kelley representative.

ENVI®APPLICATION

Note: The ENVI®control is capable of running the boiler on its own without any external control hardware or accessories.

However, certain applications warrant the purchase and installation of separate sensors such as:

26-0000-0507

Outdoor air sensor

BP-0000-0279

Well and sensor for header and DHW applications ENVI®Control

23-0000-0539

Surface mount strap on sensor kit for header or DHW applications ENVI®Control

BP-0000-0480

Kit, 12” brass thermowell, tank temperature sensor, DHW applications ENVI®Control

10-0510-0642

Dual element immersion sensor

Optional flow switch: (necessary in some DHW applications)

86-8350-0800

Switch, flow switch

Optional aquastat: (necessary in some DHW applications)

10-0000-1209

SW,THERMO,100-200F,HONEYWELL_L6008A1242

23-0000-0233

THERMOWELL, ½” NPT

These optional sensors will enhance the performance of the ENVI® control and may be necessary to sense the locations

needed for some applications to perform properly.

ENVI®Control

This chart represents the temperature/resistance relationship of the 12K ohm thermistor mentioned above.

The user should become thoroughly familiar with the operation of the boiler and

controls before attempting to make any adjustments.

The display panel is used to setup and monitor boiler

operation by means of six push buttons; MENU, BACK,

ENTER, UP, DOWN, and RESET as shown.

There are shortcut functions also associated with these

buttons; LIGHT, SET PT, DHW, SVC and CANCEL. The

shortcut functions are available only when the default

(home) screen is displayed.

The four line screen shows boiler operating information

on various screens. The display screen is backlit for

ease of viewing. The display panel will turn off its

backlight after a period of inactivity. Press the BACK

button to illuminate the screen.

In a cascade system it will be necessary to make control

adjustments to every boiler display panel.

ENVI®Control

1.0 OPERATION OF THE ENVI CONTROL

The control displays the initial boot screen (above) when first powered.

The second line of text indicates one of three possible operating configurations:

Boiler Control indicates the boiler is set up as a standalone (SA) operation (Factory default)

Master Control indicates the boiler is set up as the master in a cascade system.

Member 1 (or 2, 3, 4…) indicates the boiler is set up as a member 1 thru 24 within a cascade system.

The value shown on the fourth line of text inside the brackets [8C51] is the software version or code installed on the ENVI®

boiler controls.

There are several versions of the ENVI® control. These include 112E, BD71, 49A7, 79F2, 8C51,1043 and 9820. Not all

features are available with all versions. Parameters which are only applicable to certain release versions will be designated

accordingly. If there is no mention of versions with the parameter, then it is valid for all versions.

The control displays the default (home) screen shown above once boot up is complete.

This screen displays; the date, time, boiler status, supply temperature, setpoint temperature, error codes, present operating

mode (CH or DHW), CM=cascade master, or CS 01-24=cascade member (also referred to as subordinate or slave).

Also, firing rate, FP (freeze protection), CL (cycle limit) and firing rate (Power) may be displayed. Cycle limit & freeze

protection settings are explained later in the manual.

The control has multiple menu levels to provide set-up and operating information. Navigation through the various menus

may be performed using the buttons beneath the display. The function of the buttons may be two-fold as shown below.

The shortcut functions are available only when the default (home) screen is displayed.

Buttons

Function

Shortcut

Accesses the menu

None

Back / Light

Returns to the previous screen

Turns on backlight

Enter / Set Pt

Accepts the value

Accesses CH Settings

Up / DHW

Increases the value/moves cursor

Accesses DHW Settings

Down / SVC

Decreases the value/moves cursor

Accesses Service Mode

Reset / Cancel

Resets the control

Cancels Service Mode

Version 1.0 [8C51]

Patterson Kelley

Boiler Control

Run Power 65%

Supply 130

Setpt

146

Supply 130

Setpt

146

Feb 17 2013 04:27

ENVI®Control

1.1 ENVI®CONTROL FLOW CHART

Note: Parameter ranges in flow chart reference a typical MACH boiler. Parameter ranges will typically be different

for a condensing vs. non-condensing boiler such as the Modufire Forced Draft boiler.

ENVI®Control

1.2 MENU SCREEN

From the main screen, pressing the button provides access to the following sub-menus, shown below:

Standby

Information

Errors

Program Parameters

Configuration

Cascade Menu

Service

Use the and buttons to scroll to the desired sub menu and the button to select that sub menu.

1.3 BOILER STATUS SCREEN

Pressing while in the menu screen returns the boiler status (default) screen described in Section 1.0.

The default screen displays the current operating status. A list of possible operating statuses is shown below:

Standby –boiler waiting for a call for heat or for temperature conditions to require heat

Checking Air Switch –boiler is in its pre-ignition sequence, verifying the air switch is open prior to proceeding

Pre Purge - boiler is beginning the ignition sequence, purging the combustion chamber

Ignition - the igniter and gas valve are energized while flame is detected

Run –flame is established, igniter is de-energized, gas valve is controlled to satisfy heat load

Post Purge - boiler has completed the burn sequence and is purging the combustion chamber

Post Pumping –circulator pump is energized for a specified period to remove residual heat from the boiler

Reset –the ENVI® control has detected an error and locked out the boiler. (DO NOT reset the control without

determining and correcting the cause)

Blocking (Alarm)-Auto reset- automatic reset lockouts that will self reset when the error condition clears.

Locking (Alarm)-Manual reset- manual reset lockouts requiring an operator to press the reset button.

If the ignition sequence is started it will be finished. Even if the demand is taken away, the sequence up to the burn state is

completed.

Standby

Information

Errors

Standby

Errors

ENVI®Control

1.4 INFORMATION MENU

Pressing at the INFORMATION menu displays the following information.

Use the and buttons to scroll through the INFORMATION menu.

Below is a list of values within the Information screen. This screen is very useful for obtaining values as it displays real time

changes.

NOTE: Observe the 14°F value in the information screen above. This is the value displayed when the control recognizes an

open circuit. This is common when a particular sensor such as the DHW sensor in the example above is not used, but may

also occur in the event of an electrically open sensor or sensor circuit. The value displayed in the event of a shorted

sensor or sensor circuit is 244°F. The values will be defined further in the following table.

Information

Supply Temp 122

Return Temp 119

DHW Temp 14

Information

Supply Temp 122

Return Temp 119

DHW Temp 14

Information

Supply Temp 122

Return Temp 119

DHW Temp 14

ENVI®Control

Display

Description

Units

Open/Shorted

Sensor Indication

Supply Temp

Outlet / Supply Temperature

°F

14°F (Open) / 244°F(Shorted)

Return Temp

Inlet / Return Temperature

°F

14°F (Open) / 244°F(Shorted)

DHW Temp

Domestic Hot Water Temperature at the location of the

sensor(field installed)

°F

14°F (Open) / 244°F(Shorted)

Flue gas Temp

Flue Gas Temperature

FD boiler - thermal disc switch breaks the display will

indicate 50F

°F

50°F (Open) / 280°F(Shorted)

HX Temp

Heat Exchanger Temperature available on the MACH line

C1500 thru to the C4000

°F

14°F (Open) / 244°F(Shorted)

Outside Temp

Outside Air Temperature at the location of the sensor

(field installed)

°F

-40°F / 176°F

CH set Temp

Comfort Heat Setpoint Temperature

°F

N/A

DHW set Temp

Domestic Hot Water Setpoint Temperature

°F

N/A

Header Temp

Header Temperature at the location of the sensor(field

installed)

°F

244°F / 244°F

Flame signal

Flame Signal (versions 49A7 and earlier were “YES/NO”)

μA

< 1.7 μA = Flame Not Detected

> 1.7 μA = Flame Detected 0-10

Fan speed

Fan Speed

RPM

0-9999

Analog in

Analog Input

N/A

Not Currently Used

Analog out

Analog Output

N/A

Not Currently Used

Ignitions

Number of Ignitions

0-99999

Burn Hi HR

Hours at High Fire (75% to 100%)

HRS

0-99999

Burn MD HR

Hours at Medium Fire (45% to 75%)

HRS

0-99999

Burn LO HR

Hours at Low Fire (20% to 45%)

HRS

0-99999

Water press

Water Pressure

N/A

Not Currently Used

Water level

Water Level Sensor Status

Aux LWCO status on FD boilers (if installed)

Off/On

0 = Low Water Cutoff

1 = Low Water Cutoff Detects Water

Low gas press

Low Gas Pressure Sensor Status

Off/On

0 = Low Gas Pressure Switch Open

1 = Low Gas Pressure Switch Closed

Air pressure

Air Pressure Switch Status

Off/On

0 = Air Pressure Switch Open

1 = Air Pressure Switch Closed

Blocked flue

Blocked Flue Switch Status

Off/On

0 = High Exhaust Back Pressure

Switch Open

1 = High Exhaust Back Pressure

Switch Closed

CH pump

Comfort Heat Pump Relay Status

Off/On

0 = CH Pump relay Off

1 = CH Pump relay On

DHW pump

Domestic Hot Water Pump Relay Status

Off/On

0 = DHW Pump relay Off

1 = DHW Pump relay On

Air damper

Air Damper Relay Status

Off/On

0 = Air Damper relay Off

1 = Air Damper relay On

Hi gas pressure

Hi Gas Pressure Switch Status

Off/On

0 = Hi Gas Pressure Switch Open

1 = Hi Gas Pressure Switch Closed

ENVI®Control

1.5 ERRORS MENU

Apr 20 2009 14:20

Locking

IGNITION FAILURE

Err:A01

Apr 20 2009 14:20

Locking

IGNITION FAILURE

Err:A01

Version [8C51] and earlier Versions [1043] and [9820]

The ENVI® control stores the most recent error. Version 1043 and after store the last 6 errors. These errors may be

locking or blocking errors.

Pressing while in the menu screen with the cursor on Errors, the ERROR menu displays a list of the last 6

errors as shown.). Pressing and scrolls through the list of errors. Pressing while the cursor is

on an error displays several lines of information about the status of the boiler during the error.

The error information recorded at the time of the error is shown in the table below.

Display

Description

Units

Varies

Error Description

N/A

Error code

Error Code

Date

Date Error Occurred

DD-MM-YY

Time

Time Error Occurred

24:00

Supply Temp

Outlet Temperature

°F

Return Temp

Inlet Temperature

°F

DHW Temp

Domestic Hot Water Temperature

°F

Flue gas Temp

Flue Gas Temperature

°F

HX Temp

Heat Exchanger Temperature

°F

Outside Temp

Outside Air Temperature

°F

Operation Mode

Boiler Operation Mode (CH/DHW)

°F

Days run

Accumulated Days Runtime

State

State at time of error

ERRORS

Error 0 A03

Error 1 E01

Error 2 00

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