Fairway Farms Swim Club

Pool Boiler Temperature Controller: Difference between revisions

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* The controller functionality shall help improve boiler function and longevity without adding unnecessary complexity.
* The controller functionality shall help improve boiler function and longevity without adding unnecessary complexity.
* The core function (temperature control) shall be performed by a proven, durable controller.  In this case, a Euroterm 3504 was chosen due to its enhanced logic control capabilities.
* The core function (temperature control) shall be performed by a proven, durable controller.  In this case, a Euroterm 3508 was chosen due to its enhanced logic control capabilities.
* The [[Pool_Systems_Automation|automation system]] shall not be required for operation.  Failure of other components should have minimal impact upon its operation.
* The [[Pool_Systems_Automation|automation system]] shall not be required for operation.  Failure of other components should have minimal impact upon its operation.


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=== LCD Display ===
=== LCD Display ===


An LCD display on the front of the controller indicates the measured temperature of the boiler manifold (top-most value).  A graphical bar shows the value relative to the typical minimum and maximum operating thresholds.  Temperature thresholds for a [[#Low Temperature Fault|Low Temperature Fault]], [[#Stage 2|Stage 2]] operation, and a [[#High Temperature Fault|High Temperature Fault]] are displayed on the subsequent lines.  All temperatures are displayed in degrees Fahrenheit.
An LCD display on the front of the controller indicates the measured temperature of the boiler manifold (top-most value).  A graphical bar shows the value relative to the typical minimum and maximum operating bounds.  Temperature thresholds for a [[#Low Temperature Fault|Low Temperature Fault]], [[#Stage 2|Stage 2]] operation, and a [[#High Temperature Fault|High Temperature Fault]] are displayed on the subsequent lines.  All temperatures are displayed in degrees Fahrenheit.


The <tt>OP1</tt> and <tt>OP2</tt> indicators (beacons) indicate that [[#Stage 1|Stage 1]] and/or [[#Stage 2|Stage 2]] operation is active, respectively.  An <tt>ALM</tt> indicator is associated with a fault condition; user intervention may be required to restore boiler operation.  Blinking <tt>H</tt> and/or <tt>J</tt> indicators indicate communication port activity.
The <tt>OP1</tt> and <tt>OP2</tt> indicators (beacons) indicate that [[#Stage 1|Stage 1]] and/or [[#Stage 2|Stage 2]] operation is active, respectively.  An <tt>ALM</tt> indicator is associated with a fault condition; user intervention may be required to restore boiler operation.  Blinking <tt>H</tt> and/or <tt>J</tt> indicators indicate communication port activity.
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The boiler temperature is greater than the [[#Stage 2|Stage 2]] threshold, and [[#Stage 2| Stage 2]] is disabled as a result.  This is not a fault condition, though it may indicate sub-optimal operation.  Only [[#Stage 1|Stage 1]] heating is enabled.
The boiler temperature is greater than the [[#Stage 2|Stage 2]] threshold, and [[#Stage 2| Stage 2]] is disabled as a result.  This is not a fault condition, though it may indicate sub-optimal operation.  Only [[#Stage 1|Stage 1]] heating is enabled.


The [[#Stage 2| Stage 2]] threshold is the temperature value to the right of the <tt>Stg2</tt> identifier on the display, and should typically be set to TBD.  To adjust this threshold, see the [[#Threshold Adjustment|Threshold Adjustment]] section below.
The [[#Stage 2| Stage 2]] threshold is the temperature value to the right of the <tt>Stg2</tt> identifier on the display, and should typically be set to <span style="background:yellow">TBD</span>.  To adjust this threshold, see the [[#Threshold Adjustment|Threshold Adjustment]] section below.


If this state is active, [[Pool_Boiler#Recirculation_Valve|adjustment of the recirculation valve position]] should be considered.  Since operating only in [[#Stage 1| Stage 1]] produces less heat, the ability to heat the pool is reduced.  This is primarily an issue where the amount of heat loss in the pool exceeds the capability of [[#Stage 1| Stage 1]] heating (i.e. the pool cools faster than it can be heated).
If this state is active, [[Pool_Boiler#Recirculation_Valve|adjustment of the recirculation valve position]] should be considered.  Since operating only in [[#Stage 1| Stage 1]] produces less heat, the ability to heat the pool is reduced.  This is primarily an issue where the amount of heat loss in the pool exceeds the capability of [[#Stage 1| Stage 1]] heating (i.e. the pool cools faster than it can be heated).
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==== Low Temperature Fault ====
==== Low Temperature Fault ====


The boiler temperature is less than the low-temperature threshold and both stages are disabled as a result.  The low-temperature threshold should typically be set to TBD.
The boiler temperature is less than the low temperature threshold and both stages are disabled as a result.  The low-temperature threshold should typically be set to <span style="background:yellow">TBD</span>.  This is a latching fault and must be cleared via the front panel before the boiler will operate.


This is a latching fault and must be cleared via the front panel before the boiler will operate.
Before attempting to clear the fault, the source of the fault should be cleared.  See the [[Pool_Boiler#Low_Temperature_Fault|Pool Boiler Low Temperature Fault]] section for further information ([[Pool_Boiler#Recirculation_Valve|recirculation valve adjustment]] may be needed).


==== High Temperature Fault ====
==== High Temperature Fault ====


The boiler temperature is greater than the high-temperature threshold and both stages are disabled as a result.
The boiler temperature is greater than the high-temperature threshold and both stages are disabled as a result.  The high temperature threshold should typically be set to <span style="background:yellow">TBD</span>.  This is a latching fault and must be cleared via the front panel before the boiler will operate.


This is a latching fault and must be cleared via the front panel before the boiler will operate.
=== Threshold Adjustment ===


=== Threshold Adjustment ===
Threshold adjustment is typically not necessary or recommended.  Instead, it is recommended that the system be evaluated for deficiencies.
 
If a parameter must be adjusted, press the scroll button (left of the down arrow) to move the up/down cursor to the desired parameter.  Press the up/down keys to adjust the temperature.  Internal bounds limit how high or low a parameter may be adjusted.  Use extreme caution in adjusting each parameter, as each could have significant impacts upon boiler operation.


=== Other Buttons ===
=== Other Buttons ===
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=== Low Operator ===
=== Low Operator ===


The low operator is activated when the following conditions are true:
The low operator is activated (the relay contact is closed) when the following conditions are true:


* A call for heat is present.
* The RTD is producing valid feedback (not shorted or open-circuit).
* The RTD is producing valid feedback (not shorted or open-circuit).
* The boiler temperature is below the over-temperature shutdown threshold (timing rules apply).
* The boiler temperature is below the high temperature fault threshold (timing rules apply).


The low operator may be released when any of the prior conditions are no longer met.  In addition, it may be released when:
The low operator may be released when any of the prior conditions are no longer met.  In addition, it may be released when:
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=== High Operator ===
=== High Operator ===


The high operator is activated when the following conditions are true:
The high operator is activated (the relay contact is closed) when the following conditions are true:


* All conditions for the low operator are met.
* All conditions for the [[#Low Operator|low operator]] are met.
* The main valve (MV) is active.
* The boiler temperature is below the second stage threshold (timing rules apply).
* The boiler temperature is below the second stage threshold (timing rules apply).


== Controller Hardware ==
== Controller Hardware ==


=== As Shipped Configuration ===
=== As-Shipped Configuration ===
 
When shipped from the factory, a long configuration code is printed on the side of the controller to identify the configuration.  The code on the installed controller is decoded below:


{| class="wikitable"
{| class="wikitable"
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|LO
|LO
|Isolated Single Logic Output
|Isolated Single Logic Output
|
|May not be used.
|-
|-
!IO Slot 2
!IO Slot 2
|D4
|D4
|DC Control
|DC Control
|Will not be used.
|Will not be used; see modifications below.
|-
|-
!IO Slot 3
!IO Slot 3
|TK
|TK
|Triple Contact Input
|Triple Contact Input
|
|May not be used.
|-
|-
!H Comms Slot
!H Comms Slot
|PD
|PD
|Profibus with D-type Connector
|Profibus with D-type Connector
|Module is an AH026222U002.
|Module is an AH026222U002 (visually identified).
|-
|-
!J Comms Slot
!J Comms Slot
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