Operating instructions

ManualsBrandsWeil-McLain ManualsBoilerBCP-8S

INSTALLATION/OPERATING INSTRUCTIONS

BCP-6 and BCP-12

Lead-Lag System for up to 12 Stages of Output

Operates as either an Outdoor Reset Control or as a Set

Point Control for Water Temperature or Steam Pressure

Table of Contents

Installation.........................................................................................................................pg. 2

Dip Switch Chart..........................................................................................................pg. 3

Initial Settings................................................................................................................pg. 8

Display Settings and Adjustments.............................................................................pg. 10

Operation...........................................................................................................................pg. 12

Outdoor Reset Control Settings................................................................................pg. 12

Set Point Control Settings.......................................................................................pg. 14

Lead Stage................................................................................................................pg. 15

Output Controls.........................................................................................................pg. 16

Optional External Set Point........................................................................................pg. 16

Interface Mode..........................................................................................................pg. 17

Heat Demand...............................................................................................................pg. 17

DHW Call....................................................................................................................pg. 17

Troubleshooting..............................................................................................................pg. 18

Sensor Selection.............................................................................................pg. 20

Part Number 550-141-695/1200

This manual must only be used by a qualified heating installer/service

technician. Failure to comply could result in severe personal injury, death

or substantial property damage.

W A R N I N G

Summary of content (20 pages)

PAGE 1
INSTALLATION/OPERATING INSTRUCTIONS BCP-6 and BCP-12 Lead-Lag System for up to 12 Stages of Output Operates as either an Outdoor Reset Control or as a Set Point Control for Water Temperature or Steam Pressure Table of Contents Installation.........................................................................................................................pg. 2 Dip Switch Chart..........................................................................................................pg.
PAGE 2
DEFINITIONS WARNING W A R N I N G Indicates presence of hazard The Weil-McLain BCP-6/12 is strictly an operating control; do not use as limit(s) or safety control(s). Each boiler must have its own certified limit and safety controls as required by codes. These controls are the responsibility of the installing contractor. He must verify proper operation and correct any safety problems before installing the BCP-6/12.
PAGE 3
DIP SWITCH CHART Combustion Air Damper SYSTEM relay is on when any OUTPUT is on * ON 1 ON 1 ON 5 System Pump SYSTEM relay is on based on outside temp and Heat Demand terminal ON 5 First On/First Off First stage on is the first stage turned off 8 Outdoor Reset Hydronic heating control with outdoor reset ON Switch 5 Rotation Switch 1 System Output 8 Set Point Set Point control for temperature or pressure ON First On/Last Off Lead stage rotates every 24 hours Switch 8 Set Point or Reset ON
PAGE 4
WIRING THE POWER INPUTS POWER NEUTRAL • Bring the 120VAC 60Hz power wires through a bottom knock out of the enclosure. Class 1 voltages must enter the enclosure through a different opening from any Class 2 wiring. • Connect the hot line to terminal marked LINE. • Connect the neutral line to the terminal marked NEUTRAL. • The green ground screw must be connected to earth ground.
PAGE 5
• Pressure sensors have polarity. If the sensor has a green wire, a white wire, or a clear tube, none of those should be connected. Simply cut them off. Only the red and black wires should be connected. • Connect the red wire from the pressure transducer to terminal 4 +. • Connect the black wire from the pressure transducer to terminal 5 SENSOR. • Connect shield (when needed) to terminal 3 SHIELD. • Pressure sensor set point range is 0 to 15 psi.
PAGE 6
BCP-6/12 Input Terminals INTERFACING TO A BCP-4 OUTDOOR RESET CONTROL INPUTS PRESSURE 4-20mA TEMP • The BCP-4 is a commercial outdoor reset control for heat which can directly control up to four output stages. • The BCP-6/12 can be used to expand the number of output stages of this control from 4 to 6 or 12. Check the I/O manual for the BCP-4 to be sure it is set up correctly to interface to the BCP-6/12. • When being used in the interface mode, the BCP-6/12 does not require a sensor.
PAGE 7
2 Stage (Lo/Hi) Units Typical Limit Circuit for 2 Stage Units (Refer to Chart below) • Each unit has two relays and two OUTPUTS associated with it. • Check the chart for the Lo and Hi stage output positions. • Connect the Lo N.O. relay contacts in series with the unit’s limit circuit. • Connect the Hi N.O. relay contacts to the Hi control circuit.
PAGE 8
System Pump operation • Dip switch 1 must be ON. • If an outdoor sensor is not connected or registers a fault condition: - The SYSTEM output will be energized when any OUTPUT stage is energized. - After the last OUTPUT is turned off, the SYSTEM output will remain energized for the period of time set by the System Delay and then turn off. • When the control is set for “no DHW priority” (see pg.
PAGE 9
dno or d_P - NO DHW Priority or DHW Priority (System Pump operation ONLY) • If the display shows dno then the BCP-6/12 will not have a DHW priority. • If the display shows d_P then the BCP-6/12 will disable the SYSTEM output for the first hour of a DHW call. • To change the priority, hold down the center button while pushing either the UP or DOWN button to toggle between the displays of dno and d_P. • When the correct priority is selected, release the buttons and wait approximately 5 seconds.
PAGE 10
OUTDOOR RESET CONTROL Dip Switch 6 and 7 - OFF and 8 - ON Press SELECT Button DISPLAY Once * Calculated Twice * Outdoor Temp 3 Times 4 Times 5 Times 6 Times 7 Times 8 Times 9 Times * Fine Tune Outdoor Starter Reset Ratio Press and hold either the UP or DOWN button to adjust the value This is the water temperature the BCP-6/12 will stage outputs to hold. It is based on outdoor temperature, reset ratio, and the fine tune value. If ON is shown, there is a sensor fault.
PAGE 11
TEMPERATURE SET POINT CONTROL Dip Switch 6 and 8 - OFF Press SELECT Button Once Twice * 3 Times 4 Times 5 Times 6 Times 7 Times ** 7 (or 8) Times* DISPLAY Press and hold either the UP or DOWN button to adjust the value Set Point The Set Point is the temperature which the BCP-6/12 will stage units to hold. Note that if you are using the External Set Point, you will not be able to change the Set Point unless you adjust the 4-20mA input. Outdoor Temp This is the outdoor sensor temperature value.
PAGE 12
OPERATION OUTDOOR RESET DISPLAY SETTINGS (WATER) CALCULATED Select button pressed ONCE • This is the water temperature the BCP-6/12 will stage units to hold. It is based on outdoor temperature and the Fine Tune and Reset Ratio values (described below and on the following page). • The Calculated water temperature can not be less than the minimum water temperature setting (see pg. 9). • If either sensor is reading a fault condition, all stages will immediately turn on.
PAGE 13
DEFAULT is 7 Select button pressed 5 Times • The Reset Ratio controls how much heat will be added based on outdoor temperature. The Reset Ratios are shown as Outdoor Temperature:Water Temperature. • A 1:1 Reset Ratio signifies for each degree it gets colder outside, the Calculated water temperature will raise 1 degree. • The other Reset Ratios available are shown on the right. • The Reset Ratio curves start at 70°F. At 70°F the BCP-6/12 will require 100°F water.
PAGE 14
SET POINT DISPLAY SETTINGS (WATER or STEAM) SET POINT Select button pressed ONCE • The Set Point is the temperature or pressure value the BCP-6/12 will use to control the system. • The BCP-6/12 will either add stages, subtract stages, or maintain the same number of stages to hold the system temperature or pressure around the Set Point. • The Set Point is the average temperature or pressure the BCP-6/12 will maintain. The system can be expected to fluctuate above and below the Set Point.
PAGE 15
PURGE TIME DEFAULT is 0 Select button pressed 6 Times • Many units must go through a purge cycle before they are brought on line and can begin generating heat or cooling. • The Purge Time should be set to the time of the unit’s purge cycle. • The Purge Time applies to every stage with ON/OFF units. • The Purge Time applies only to the Lo stages of multiple stage units. • When an ON/OFF stage, or a Lo stage, is turned on, the BCP-6/12 will begin counting down the Purge Time.
PAGE 16
OUTPUT CONTROLS MANUAL OVERRIDES • Each OUTPUT and the SYSTEM has an OFF/AUTO/ON switch. • The BCP-6/12 only controls units which are switched to AUTO. • In lo/hi applications, if any stage of the multistage unit is not switched to AUTO, then the whole unit will not be considered in the normal sequencing. • If an output is switched ON, then the output relay will always be energized. Any stage will run on its own limits. This switch position can be used for testing individual outputs.
PAGE 17
INTERFACE MODE • • • • The BCP-6/12 can be connected to the BCP-4 for commercial hot water heat applications. The BCP-4 can directly control up to 4 output stages. The BCP-6/12 can be used to expand the number of output stages from 4 to 6 or 12. When in the Interface mode, the BCP-6/12 determines when heat is needed, how much heat is needed, and how often stages will be added or subtracted. Therefore, if the reset control is not set up properly, the BCP-6/12 will not output correctly.
PAGE 18
TROUBLESHOOTING No Display, or Display of 888 Check the 120VAC power input to the BCP-6/12. Turn power to the panel off and back on. TEMPERATURE INPUTS Display shows OPN First check the dip switch (see pg. 3) to be sure the BCP-6/12 is configured to read a temperature input. If the dip switch is correct, then the BCP-6/12 does not register that a sensor is connected. Check that the wires from the sensor are continuous to the BCP-6/12. Then follow the procedure for Incorrect Temperature Display.
PAGE 19
EXTERNAL SET POINT INPUT Set Point changes when the knob is rotated Check the dip switch (pg. 3). Set Point always reads OFF Check the wiring is appropriate for the application (see pg. 16). Then use an ampmeter to measure the 4-20mA input. If the input is below 3.9mA or above 20.1mA, the Set Point will always be OFF. INTERFACE INPUT Display does not show INF Check the dip switch (see pg. 3).
PAGE 20
Red stage light is not lit, but the System Combustion Air Damper or Pump is on The BCP-6/12 is not calling for the unit to run. Remove any wires attached to the BCP-6/12 SYSTEM output terminals. Check the N.O. terminals are open. Then check the N.C. terminals are closed. If both conditions are true, the BCP-6/12 output is working correctly. Check the unit for any other operating controls which may be causing it to energize. SET POINT CAN NOT BE ADJUSTED Set Point reads ON There is a sensor fault.