TSBC Instruction Manual
Page 4 of 48
Introduction
Overview
Thermal Solutions Boiler Control Overview
The Thermal Solutions Boiler Control (TSBC) is a complete boiler monitoring and automation system. The TSBC provides
advanced boiler modulation, operating control, diagnostics, multiple boiler lead-lag and auxiliary device control. The TSBC
provides advanced control features in an easy to use package.
Flexible, Field Selectable Control
Control modes, water system, boiler auxiliary and
modulating lead/lag control features are menu selectable
without the need for external programmers, laptops or
down loads. Every boiler is shipped with factory defaults
that make field menu selections unnecessary unless you
are applying additional control features.
Boiler Monitoring and Diagnostic Displays
The TSBC’s two line by sixteen character LCD display
may be used for monitoring boiler inlet and outlet,
remote system and outside air temperatures, modulation
rate setpoint and modulating percent and mixing valve
demand percent. Additionally, the display automatically
presents boiler sequence messages, alarms, hold and
lockout messages. A diagnostic menu is included that
provides the last 10 alarm messages and boiler inlet
temperature alarm history. Boiler inlet temperature
alarm history includes time and date, the lowest inlet
temperature reached and the amount of time the water
temperature dropped below the alarm setpoint.
Modulation Rate and On/Off Modes
The TSBC may simply control boiler modulation and
on/off output based on the boiler water outlet
temperature and an operator adjusted setpoint.
However, using parameter selections, the TSBC allows
the boiler modulation and on/off output to respond to
remote system water and outside air temperatures,
Domestic Hot Water Priority (DHWP) input or Energy
Management System (EMS) modulation rate demand,
remote setpoint or remote start/stop commands.
Parameter selections of remote system water
temperature and remote mode determine the choice of
one of six different control modes.
Advanced Availability
The above control modes are menu selectable options.
However, if a selected sensor fails, the TSBC
automatically changes to a control mode that will allow
continued automatic operation of the boiler. For
example, in the event of a remote system temperature
sensor failure, the TSBC will automatically switch to
boiler outlet temperature sensor based control.
Outdoor Air Reset
When selected the modulation rate setpoint is
automatically adjusted based on outside air temperature.
Outdoor air “reset” setpoint saves fuel by adjusting the
water temperature of a heating boiler lower as the
outside air temperature increases.
Warm Weather Shutdown (WWSD)
Some boilers are used primarily for heating buildings,
and the boilers can be automatically shutdown when the
outdoor air temperature is warm. When outside air
temperature is above the WWSD setpoint, this function
will prevent the boiler, boiler pump and/or the system
pump from starting.
Domestic Hot Water Priority (DHWP)
Some boilers are used primarily for building space
heating, but also provide heat for the domestic hot water
users. When the outdoor temperature is warm, the
outdoor reset setpoint may drop lower than a desirable
domestic hot water temperature. When enabled and a
DHWP contact input is detected, the hot water setpoint
is adjusted to be greater than a field adjustable DHWP
Setpoint.
Water Side Control Outputs
In order to maximize the life and availability of a hot
water systems it may be desirable to automate mixing
valves, boiler pumps, system pumps, and standby
system pumps. The TSBC makes this type of
automation totally integrated and cost effective. The
control of these devices is field selectable through
simple yes/no menu selections.
Combustion Air Side Control Outputs
Boiler room Combustion air dampers (fresh air dampers)
and Vent Inducer control outputs are field selectable
options.
Peer-To-Peer Network
The TSBC includes state-of-the-art modulating lead-lag
sequencer for up to eight (8) boilers capable of auto
rotation, outdoor reset and peer-to-peer communication.
The peer-peer network is truly “plug and play”.
Communication is activated by simply connecting a
RJ11 telephone line between boilers. The TSBC
provides precise boiler coordination by sequencing
boilers based on both remote system water temperature
and boiler modulation rate. For example, the lead boiler
can be configured to start a lag boiler after operating
above 90% modulation rate for longer than an adjustable
time. The boilers are modulated in “unison” (parallel)
modulation rate to ensure even heat distribution
Modbus Communication Interface
A factory configured RS485 Modbus interface is
available for Energy Management System (EMS) or
SCADA system monitoring and control. Modbus is not
available when using Peer-to-Peer.
