Document Outline

• CHAPTER 1. SAFETY PRECAUTIONS
  • 1.1 WARNINGS & CAUTIONS
  • 1.2 EMERGENCY SHUTDOWN
  • 1.3 PROLONGED SHUTDOWN
• CHAPTER 2. INSTALLATION
  • 2.1 INTRODUCTION
  • 2.2 RECEIVING THE UNIT
  • 2.3 UNPACKING
  • 2.4 SITE PREPARATION
    • 2.4.1 Installation Clearances
    • 2.4.2 Setting the Unit
  • 2.5 WATER INLET AND OUTLET PIPING
  • 2.6 TEST HOSE BIB CONNECTION
  • 2.7 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION
  • 2.8 SYSTEM RECIRCULATION LOOP
  • 2.9 CONDENSATE DRAIN & PIPING
  • 2.10 GAS SUPPLY PIPING
    • 2.10.1 Gas Supply Specifications.
    • 2.10.2 Manual Gas Shutoff Valve
    • 2.10.3 External Gas Supply Regulator
  • 2.11 AC ELECTRICAL POWER WIRING
    • 2.11.1 Electrical Power Requirements
  • 2.12 FIELD CONTROL WIRING
    • 2.12.1 Outdoor Air Sensor
    • 2.12.2 AUX SENSOR IN
    • 2.12.3 ANALOG IN
    • 2.12.4 B.M.S. (PWM) IN
    • 2.12.5 SHIELD
    • 2.12.6 mA OUT
    • 2.12.7 EXHAUST SENSOR IN
    • 2.12.8 INTERLOCKS
      • 2.12.8.1 REMOTE INTERLOCK IN
      • 2.12.8.2 DELAYED INTERLOCK IN
    • 2.12.9 FAULT RELAY
    • 2.12.10 AUXILIARY RELAY CONTACTS
  • 2.13 FLUE GAS VENT INSTALLATION
  • 2.14 COMBUSTION AIR
    • 2.14.1 Combustion From Outside the Building
    • 2.14.2 Combustion Air from Inside the Building
  • 2.15 SEALED COMBUSTION
• CHAPTER 3. OPERATION
  • 3.1 INTRODUCTION
  • 3.2 CONTROL PANEL DESCRIPTION
  • 3.3 CONTROL PANEL MENUS
    • 3.3.1 Menu Processing Procedure
  • 3.4 OPERATING MENU
  • 3.5 SETUP MENU
  • 3.6 CONFIGURATION MENU
  • 3.7 TUNING MENU
  • 3.8 START SEQUENCE
  • 3.9 START/STOP LEVELS
• CHAPTER 4. INITIAL START-UP
  • 4.1 INITIAL START-UP REQUIREMENTS
  • 4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
    • 4.2.1 Required Tools & Instrumentation
    • 4.2.2 Installing Gas Supply Manometer
    • 4.2.3 Accessing the Analyzer Probe Port
  • 4.3 NATURAL GAS COMBUSTION CALIBRATION
  • 4.4 REASSEMBLY
  • 4.5 TEMPERATURE CONTROL CALIBRATION
    • 4.5.1 Setting the Outlet Water Temperature Setpoint
    • 4.5.2 Minimum Load Adjustment
    • 4.5.3 Maximum Load Adjustment
  • 4.6 OVER-TEMPERATURE LIMIT SWITCHES
• CHAPTER 5. SAFETY DEVICE TESTING
  • 5.1 TESTING OF SAFETY DEVICES
  • 5.2 LOW GAS PRESSURE FAULT TEST
  • 5.3 HIGH GAS PRESSURE TEST
  • 5.4 LOW WATER LEVEL FAULT TEST
  • 5.5 WATER TEMPERATURE FAULT TEST
  • 5.6 INTERLOCK TESTS
    • 5.6.1 Remote Interlock
    • 5.6.2 Delayed Interlock
  • 5.7 FLAME FAULT TESTS
  • 5.8 AIR FLOW FAULT TESTS
  • 5.9 SSOV PROOF OF CLOSURE SWITCH
  • 5.10 PURGE SWITCH OPEN DURING PURGE
  • 5.11 IGNITION SWITCH OPEN DURING IGNITION
  • 5.12 SAFETY PRESSURE RELIEF VALVE TEST
• CHAPTER 6. MAINTENANCE
  • 6.1 MAINTENANCE SCHEDULE
  • 6.2 IGNITER-INJECTOR
  • 6.3 FLAME DETECTOR
  • 6.4 COMBUSTION CALIBRATION
  • 6.5 SAFETY DEVICE TESTING
  • 6.6 FIRESIDE INSPECTION
  • 6.7 WATERSIDE INSPECTION
  • 6.8 HEAT EXCHANGER CLEANING
    • 6.8.1 Pumping System Set-Up Instructions
    • 6.8.2 Cleaning Procedure
    • 6.8.3 Testing HydroSkrub Effectiveness
  • 6.9 CONDENSATE DRAIN TRAP
  • 6.10 AIR FILTER REPLACEMENT
  • 6.11 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME
  • 6.12 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN
• CHAPTER 7. TROUBLESHOOTING GUIDE
  • 7.1 INTRODUCTION
  • 7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES
• CHAPTER 8. RS232 COMMUNICATION
  • 8.1 INTRODUCTION
  • 8.2 RS232 COMMUNICATION SETUP
  • 8.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION
  • 8.4 DATA LOGGING
    • 8.4.1 Fault Log
    • 8.4.2 Operation Time Log
    • 8.4.3 Sensor Log