Programming Manual The OnTrac® Boiler Management System Model CS4 Riverside Hydronics®, LLC – 990 Haltom Road - Fort Worth, Texas 76117 - Tel 1-800-990-5918 34-160 10/11 Page | 1
TABLE OF CONTENTS Caution ___________________________________________________________________ Overview and Main Menu Screen _______________________________________________ User Data Entry _____________________________________________________________ Assigning Boiler Addresses and Changing the Clock ________________________________ Single Tier Quick Setup _______________________________________________________ Outdoor Reset Function and Setup ______________________________________________ The Tier 1 Menu ___
OVERVIEW The OnTrac® Boiler Management System is designed to perform all of the function of a typical BMS. OnTrac® however is designed to work in concert with the individual boiler controls to maintain optimum load matching and balanced boiler runtime. OnTrac® will communicate with the boiler controls over an RS485 Serial Bus and through the Modbus RTU protocol.
MAIN MENU SCREEN CONTINUED The LEAD/LAG SETUP TIER 2 screen is structured much like the TIER 1 screen but will only be used for setting up a 2 TIER system. The TIER 1 SYSTEM STATUS is an information screen which allows the user to monitor important information about all TIER 1 boilers. The TIER 2 SYSTEM STATUS is an information screen which allows the user to monitor important information about all TIER 2 boilers.
USER DATA ENTRY The Numerical entry pad is the most common user interface for the OnTrac®. When a button is chosen which requires user input, the Numerical entry pad allows the user to select a value within the minimum and maximum vales indicated. Press Enter to lock in the value. The other interface point for the OnTrac® user is the Security Code entry pad. If you have chosen a screen which contains parameters which have been protected by password, it may be entered here.
ASSIGNING BOILER ADDRESSES The first step in commissioning an OnTrac® system will be the assignment of the address number for each boiler. The following instructions are specific to the TempTrac®. If your boiler uses a different control refer to the programming instruction for that control to set the control address. 1. Enter the Programming mode by pressing the Set and DOWN key for 3s. 2. Press the DOWN key. 3. Select “Pr2” – “PAS” parameter and press the “SET” key. 4.
QUICK SETUP OF A 1 OR 2 TIER SYSTEM This section will provide the necessary instructions for quickly commissioning a one or two Tier boiler system. 1. Once the boiler addresses have been assigned, add up the total number of boilers in your first Tier and enter that number in the FIRST TIER BOILERS box. If your boiler system only contains one type of boiler, condensing only or non‐condensing, skip step 2. 2. Enter the total number of boilers in your second Tier in the SECOND TIER BOILERS box.
SETUP OF THE OUTDOOR RESET FUNCTION This section will provide the necessary information to quickly set up the basic Outdoor Reset function. Once the boiler Tiers have been structured, the Outdoor Reset function can be added. 1. The outdoor sensor must be wired and turned on by pressing the TURN ON OUTDOOR SENSOR button. Note that the outdoor sensor location is boiler 2 sensor 3 by default. See the OnTrac Installation Guide (34‐151) for wiring details.
THE TIER 1 MENU The TIER 1 menu should be the first menu used. This menu will apply to single Tier boiler systems where all of the boilers are of the same type, such as all condensing or all non‐condensing. It will also be used to set up the first Tier of the two Tier (Front‐End Loaded System). The first entry button is titled FIRST TIER BOILERS. Press this button and you will be prompted to enter the number of first Tier boilers in your system.
THE TIER 2 MENU The TIER 2 menu will only be used when a “Front‐end Loaded” boiler system is applied. The 2 Tier system is designed to use high efficiency condensing boilers as the primary heat source for the majority of the heating season but use less efficient non‐condensing boilers for additional heat when the system load is exceptionally high. The OnTrac® does this by concentrating the distribution of load to the Tier 1 boilers while cycling the lead/lag priority.
TIER 1 SYSTEM STATUS The TIER 1 SYSTEM STATUS screen is provided to monitor the most commonly need system information for multiple boiler. The first screen display this information for up to eight boiler and a supplemental screen TIER 1 9‐12 displays the same information for boilers 9 to 12. SYSTEM TEMP displays the current system temperature. OUTDOOR TEMP displays current system temperature.
SCHEDULED SETBACK The SCHEDULED SYSTEM SETPOINT is a menu of programmable set point setbacks which give the user the ability to reduce the system temperatures during times which a building is not being occupied and the usual level of comfort is not needed. Scheduled setback can be provide significant energy saving and should be used as much as possible. The OnTrac® has four separate schedules which are explained below.
The WEEKEND SETBACK is a program structured initiate a setback each weekend in a facility which not occupied from Friday night until Monday morning. o The START HOUR is described by the 24 hour clock; 17hrs is 5:00pm. Choose the hour of the day Friday your setback will begin and enter it here. o The END HOUR is described by the 24 hour clock; 5hrs is 5:00am. Choose the hour of the day your setback will end Monday morning and enter it here.
SYSTEM HISTORY The SYSTEM HISTORY screen will provide the user with a real time and historical log of four preselected system temperatures as well as two additional temperatures the user can select. The function is also preprogrammed to record data every five minutes and store up to 10000 scans. The preselected temperatures are as follows: System Temperature, Outdoor Temperature, Boiler 1 Return and Boiler 2 Return.
BOILER STATUS DISPLAY The BOILER STATUS DISPLAY screen is designed to allow the user to get more detailed information about a particular boiler. The BOILER ADDRESS is a data entry button. Press this button and enter the desired boiler. Once the boiler address has been entered it may take up to 30 seconds to compile the screen data. LEAD BOILER displays the current lead boiler address. BOILER STATE is a color coded display indicating the On/Off status of the boiler.
REMOTE EQUIPMENT AND PROVING INTERLOCKS The REMOTE EQUIPMENT ENABLE AND PROVING INTERLOCKS screen gives the user the ability to monitor the status of Remote Equipment outputs and the Remote Proving inputs. Additionally the user can temporarily override the action of these inputs and outputs while commissioning or troubleshooting the system. The Remote Equipment outputs are switched contacts which will activate equipment such as louvers, active ventilation or pumps when one or more boilers are operating.
REMOTE EQUIPMENT CONTINUED The WATER VALVE CONTROL switch will activate OnTrac® control of a hydronic isolation valve. This function is useful when boilers which can be installed in a single pipe, variable flow loop, are flow isolated when not used. This function will insure that a minimum water flow is maintained though the system, even when the call for heat has ended. The valve control contacts are rated for (3 Amps) and are located on the field access terminal strip of the boiler.
OPTION MENU The OPTIONS SCREEN contains links to other screens and parameters which will be rarely used. A trained technician should be consulted before any changes are made. SENSOR SELECTION allows the user to change the default sensor locations as required. TIER 1 LEAD/LAG and TIER 2 LEAD/LAG is a time delay parameter adjustable from 5 to 30 minutes. This delay occurs between the drop in loop temperature and the call for additional boilers to be enabled.
OPTION MENU 2 OPTION SCREEN 2 contains adjustments for the real Time Clock, Screen Contrast, Screen Saver and the Audible Alarm switch. The SCREEN SAVER button, when pushed, will immediately activate the panel screen saver. If left inactive the screen saver will automatically engage after 30 minutes. The AUDIBLE ALARM ENABLE switch comes from the factory in the off position. If you wish to have audible notification of alarms, move the switch to the on position.
TIER 2 INDEPENDENT OPERATION The TIER 2 INDEPENDENT OPERATION, when activated, separates the function of Tier 1 and Tier 2. This effectively allows the user to control two separate hydronic systems with one OnTrac®. Tier 2 is assigned its own loop sensor, which can be connected to any boiler in the Tier 2 system. Assign the TIER 2 SENSOR ADDRESS. The default address is 13 but can be any address in the Tier 2 boiler system (13‐20). Push the button TURN ON T2 SYSTEM SENSOR to activate the sensor.
TIER 2 CONTROL FUNCTION FOR NON-RH BOILERS When non‐Riverside Hydronics boilers are operated as the Tier‐2 boilers, the optional TempTrac Boiler Control module can be applied as a fully functional operating control or used to enable and disable only. This screen allows that functional selection to be chosen for each boiler. The enable/disable (ON/OFF ONLY) button, when pushed, will program the TempTrac Control Module to turn the boiler on or off only.
BAS CONNECTIVITY The OnTrac can be connected to a Building Automation System via Ethernet and the Modbus TCP/IP protocol. This feature comes standard with all OnTrac models. The RJ45 connector is located in the control enclosure on the side of the PLC as shown below. The default IP setting are as follows: IP Address 192.168.1.100 Subnet Mask 255.255.255.0 Gateway Address 192.168.1.
ALTERNATE PROTOCOL GATEWAY When a BAS interface with OnTrac® requires a protocol other than Modbus TCP/IP, Riverside Hydronics offers a premapped gateway from FieldServer Technologies. The ProtoCessor ProtoNode RER. Currently BACnet IP/MSTP is supported. Consult factory for other protocols. The ProtoNode is an external protocol gateway and should be powered and located external to the OnTrac®. Communication with the OnTrac® is over TCP/IP.
BATTERY BACKUP The OnTrac® has backup batteries to maintain the program when the system is without power. One is a built-in 3V Lithium ion cell battery to maintain the PLC system RAM. The other is a ½ AA, 3.6V Lithium ion cell battery to maintain the Panel. Typical battery life is 5 years, inclusive of PLC runtime and normal shutdown periods. A Low Battery LED indicator gives a low battery voltage warning.
CLEANING TOUCHSCREEN The OnTrac® touchscreen has a scratch resistant coating. This adds a slight chemical barrier to the screen, but the coating’s primary purpose is to protect the screen from abrasion. The OnTrac® touchscreen should be cleaned as needed with warm, soapy water. FUSES The internal fuse does not require replacement. It is reset by removing power for 5 minutes and then reapplying power to the unit. The external fuse is a MDA 1.0 amp/250V.
