Document Outline

• CONTENTS
  • FOREWARD A
  • SECTION 1 – SAFETY PRECAUTIONS 1-1
  • SECTION 2 – INSTALLATION PROCEDURES 2-1
  • SECTION 3 – CONTROL PANEL OPERATING PROCEDURES 3-1
  • SECTION 4 – INITIAL START-UP 4-1
  • Section 5 – MODE OF OPERATION 5-1
  • SECTION 6 – SAFETY DEVICE TESTING PROCEDURES 6-1
  • SECTION 7 – MAINTENANCE 7-1
  • SECTION 8 – TROUBLESHOOTING 8-1
  • APPENDICES
  • WARRANTIES W-1
• SECTION 1 - SAFETY PRECAUTIONS
• SECTION 2 - INSTALLATION PROCEDURES
  • 2.1 RECEIVING THE UNIT
  • 2.2 UNPACKING
  • 2.3 INSTALLATION
    • 2.3.1 SETTING THE UNIT
    • 2.3.2 SUPPLY AND RETURN PIPING
    • 2.3.3 PRESSURE RELIEF AND DRAIN VALVE INSTALLATION
    • 2.3.4 TEMPERATURE/PRESSURE INDICATOR
    • 2.3.5 CONDENSATE PIPING
  • 2.4 GAS SUPPLY PIPING
    • 2.4.1 GAS SUPPLY PRESSURE REGULATOR
    • 2.4.2 MANUAL GAS SHUTOFF VALVE
    • 2.4.3 IRI GAS TRAIN
  • 2.5 ELECTRICAL SUPPLY
    • 2.5.1 ELECTRICAL REQUIREMENTS
  • 2.6 MODE OF OPERATION AND FIELD CONTROL WIRING
    • 2.6.1 CONSTANT SETPOINT MODE
    • 2.6.2 INDOOR/OUTDOOR RESET MODE
    • 2.6.3 BOILER MANAGEMENT SYSTEM MODE
    • 2.6.4 REMOTE SETPOINT and DIRECT DRIVE MODES
    • 2.6.5 COMBINATION MODE
  • 2.7 I/O BOX CONNECTIONS
    • 2.7.1 OUTDOOR SENSOR IN
    • 2.7.2 AUX SENSOR IN
    • 2.7.3 ANALOG IN
    • 2.7.4 B.M.S. (PWM) IN
    • 2.7.5 SHIELD
    • 2.7.6 mA OUT
    • 2.7.7 RS-485 COMM
    • 2.7.8 EXHAUST SWITCH IN
    • 2.7.9 INTERLOCKS
    • 2.7.10 FAULT RELAY
  • 2.8 AUXILIARY RELAY CONTACTS
  • 2.9 FLUE GAS VENT INSTALLATION
  • 2.10 COMBUSTION AIR
    • 2.10.1 COMBUSTION AIR FROMOUTSIDE THE BUILDING
    • COMBUSTION AIR FROM INSIDE THE BUILDING
    • 2.10.3 SEALED COMBUSTION
• SECTION 3 - CONTROL PANEL OPERATING PROCEDURES
  • 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
• SECTION 4 - INITIAL STARTUP
  • 4.1 INITIAL START- UP REQUIREMENTS
  • 4.2 TOOLS AND INSTRUMENTATION REQUIRED FOR COMBUSTION CALIBRATION
    • 4.2.1 REQUIRED TOOLS AND INSTRUMENTATION
    • 4.2.2 INSTALLING THE SUPPLY GAS MANOMETER
    • 4.2.3 PREPARING THE FLUE VENT PROBE HOLE
  • 4.3 COMBUSTION CALIBRATION
  • 4.4 PROPANE COMBUSTION CALIBRATION
  • 4.5 UNIT REASSEMBLY
  • 4.6 OVER TEMPERATURE LIMIT SWITCH ADJUSTMENTS
• SECTION 5 - MODE OF OPERATION
  • 5.1 INTRODUCTION
  • 5.2 INDOOR/OUTDOOR RESET MODE
    • 5.2.1 RESET RATIO
    • 5.2.2. BUILDING REFERENCE TEMPERATURE
    • 5.2.3 OUTDOOR AIR TEMPERATURE SENSOR INSTALLATION
    • 5.2.4 INDOOR/OUTDOOR STARTUP
  • 5.3 CONSTANT SETPOINT MODE
    • 5.3.1 SETTING THE SETPOINT
  • 5.4 REMOTE SETPOINT MODES
    • 5.4.1 REMOTE SETPOINT FIELD WIRING
    • 5.4.2 REMOTE SETPOINT STARTUP
  • 5.5 DIRECT DRIVE MODES
    • 5.5.1 DIRECT DRIVE FIELD WIRING
    • 5.5.2 DIRECT DRIVE STARTUP
  • 5.6 BOILER MANAGEMENT SYSTEM (BMS)
    • 5.6.1 BOILER MANAGEMENT SYSTEM EXTERNAL FIELD WIRING
    • 5.6.2 BOILER MANAGEMENT SYSTEM SETUP AND STARTUP
  • 5.7 COMBINATION CONTROL SYSTEM (CCS)
    • 5.7.1 COMBINATION CONTROL SYSTEM FIELD WIRING
    • 5.7.2 COMBINATION CONTROL SYSTEM SETUP AND STARTUP
• SECTION 6 - SAFETY DEVICE TESTING PROCEDURES
  • 6.1 TESTING OF SAFETY DEVICES
  • 6.2 LOW GAS PRESSURE TEST
  • 6.3 HIGH GAS PRESSURE TEST
  • 6.4 LOW WATER LEVEL FAULT TEST
  • 6.5 WATER TEMPERATURE FAULT TEST
  • 6.6 INTERLOCK TESTS
    • 6.6.1 REMOTE INTERLOCK
    • 6.6.2 DELAYED INTERLOCK
  • 6.7 FLAME FAULT TEST
    • • Figure 6.4
        • Manual Leak Detection Valve
  • 6.8 AIR FLOW FAULT TEST
  • 6.9 SSOV PROOF OF CLOSURE SWITCH
  • 6.10 PURGE SWITCH OPEN DURING PURGE
  • 6.11 IGNITION SWITCH OPEN DURING IGNITION
    • • Figure 6.9
        • Air/Fuel Valve Purge and Ignition Switch Locations
  • 6.12 SAFETY PRESSURE RELIEF VALVE TEST
• SECTION 7 - MAINTENANCE
  • 7.1 MAINTENANCE SCHEDULE
  • 7.2 SPARK IGNITOR
  • 7.3 FLAME DETECTOR
  • 7.4 COMBUSTION CALIBRATION
  • 7.5 SAFETY DEVICE TESTING
  • 7.6 MANIFOLD AND EXHAUST TUBES
  • 7.7 HEAT EXCHANGER WATER SIDE INSPECTION
    • • Figure 7.10
        • Heat Exchanger Supply and Return Locations
      • Figure 7.11
        • Heat Exchanger 2 ½ Inch Inspection Plug Location
• SECTION 8 - TROUBLESHOOTING GUIDE
  • 8.1 INTRODUCTION
• SECTION 9 - RS232 COMMUNICATION
  • 9.1 INTRODUCTION
  • 9.2 RS232 COMMUNICATION SETUP
  • 9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION
  • 9.4 DATA LOGGING
    • 9.4.1 Fault Log
    • 9.4.2 Operation Time Log
    • 9.4.3 Sensor Log
• APPENDIX A
• APPENDIX B
• APPENDIX C
• APPENDIX D
• APPENDIX E
• APPENDIX F
• APPENDIX G
• APPENDIX H
• APPENDIX I
• APPPENDIX J
• STANDARD WARRANTY