Document Outline

• Telephone Support
• TABLE OF CONTENTS
  • FOREWARD A
  • Chapter 1 – SAFETY PRECAUTIONS 1-1
  • Chapter 2 – INSTALLATION PROCEDURES 2-1
  • Chapter 3 – CONTROL PANEL COMPONENTS AND
  • OPERATING PROCEDURES 3-1
  • Chapter 4 – INITIAL START-UP 4-1
  • Chapter 5 – MODE OF OPERATION 5-1
  • Chapter 6 – SAFETY DEVICE TESTING PROCEDURES 6-1
  • Chapter 7 – MAINTENANCE REQUIREMENTS 7-1
  • Chapter 8 – TROUBLESHOOTING GUIDE 8-1
  • APPENDICES
  • WARRANTIES W-1
• CHAPTER 1
  • SAFETY PRECAUTIONS
    • 1.1 WARNINGS & CAUTIONS
    • 1.2 EMERGENCY SHUTDOWN
    • 1.3 PROLONGED SHUTDOWN
• CHAPTER 2
  • INSTALLATION
    • 2.1 RECEIVING THE UNIT
    • 2.2 UNPACKING
      • • Figure 2.1
          • Boiler Clearances
    • 2.3 INSTALLATION
      • 2.3.1. SETTING THE UNIT
        • Figure 2.2
          • Lifting Lug Location
      • 2.3.2 SUPPLY AND RETURN PIPING
        • Figure 2.3
          • Supply and Return Location
      • 2.3.3 CONDENSATE PIPING
      • 2.4. GAS SUPPLY PIPING
        • • Condensate Drain Connection Location
      • 2.4.1 GAS SUPPLY SPECIFICATONS AND GAS SUPPLY REGULATORS
      • 2.4.2 MANUAL GAS SHUTOFF VALVE
      • 2.4.3 IRI GAS TRAIN KIT
        • Figure 2.5
          • Gas Supply Regulator and Manual Shut-Off Valve Location
    • 2.4 GAS SUPPLY PIPING
    • 2.5 ELECTRICAL SUPPLY
      • • Figure 2.6
          • AC Input Terminal Location
      • 2.5.1 ELECTRICAL REQUIREMENTS
        • Figure 2.7
    • 2.6 MODE OF OPERATION and FIELD CONTROL WIRING
      • • Figure 2.8
          • I/O Box Terminal Location
      • 2.6.1 CONSTANT SETPOINT MODE
      • 2.6.2 INDOOR/OUTDOOR RESET MODE
        • • Figure 2.9 I/O Box Terminal Strip
      • 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
      • 2.7.8 EXHAUST SWITCH IN
      • 2.7.9 INTERLOCKS
        • 2.7.9.1 REMOTE INTERLOCK IN
        • 2.7.9.2 DELAYED INTERLOCK IN
        • 2.7.10 FAULT RELAY
      • 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 FROM OUTSIDE THE BUILDING
      • 2.10.2 COMBUSTION AIR FROM INSIDE THE BUILDING
      • 2.10.3 SEALED COMBUSTION
• CHAPTER 3
  • CONTROL PANEL OPPERATING 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
• CHAPTER 4
  • INITIAL START-UP
    • 4.1 INITIAL START- UP REQUIREMENTS
    • 4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
      • 4.2.1 REQUIRED TOOLS AND INSTRUMENTATION
      • 4.2.2 INSTALLING THE SUPPLY GAS MANOMETER
    • 4.3 NATURAL GAS COMBUSTION CALIBRATION
    • 4.4 UNIT REASSEMBLY
    • 4.5 OVER-TEMPERATURE LIMIT SWITCH
• CHAPTER 5
  • - MODE OF OPERATION
    • 5.1 INDOOR/OUTDOOR RESET MODE
      • 5.1.1 RESET RATIO
      • 5.1.2. BUILDING REFERENCE TEMPERATURE
      • 5.1.3 OUTDOOR AIR TEMPERATURE SENSOR INSTALLATION
      • 5.1.4 INDOOR/ OUTDOOR STARTUP
    • 5.2 CONSTANT SETPOINT MODE
      • 5.2.1 SETTING THE SETPOINT
    • 5.3 REMOTE SETPOINT MODES
      • 5.3.1 REMOTE SETPOINT FIELD WIRING
      • 5.3.2 REMOTE SETPOINT STARTUP
    • 5.4 DIRECT DRIVE MODES
      • 5.4.1 DIRECT DRIVE FIELD WIRING
      • 5.4.2 DIRECT DRIVE STARTUP
    • 5.5 BOILER MANAGEMENT SYSTEM (BMS)
      • 5.5.1 BOILER MANAGEMENT SYSTEM EXTERNAL FIELD WIRING
      • 5.5.2 BOILER MANAGEMENT SYSTEM SETUP AND STARTUP
    • 5.6 COMBINATION CONTROL SYSTEM (CCS)
      • 5.6.1 COMBINATION CONTROL SYSTEM FIELD WIRING
      • 5.6.2 COMBINATION CONTROL SYSTEM SETUP AND STARTUP
• CHAPTER 6
  • SAFETY DEVICE TESTING PROCEDURES
    • 6.1 TESTING OF SAFETY DEVICES
    • 6.2 LOW GAS PRESSURE FAULT TEST
      • • Figure 6.1
          • 1/8” Pipe Plug Position for Manometer Installation & Low Gas Pressure Testing
    • 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
    • 6.8 AIR FLOW FAULT TEST
    • 6.9 SSOV PROOF OF CLOSURE SWITCH
      • • Figure 6.6
          • SSOV Actuator Set Screw Location
          • SSOV Terminal Connections
    • 6.10 PURGE SWITCH OPEN DURING PURGE
    • 6.11 IGNITION SWITCH OPEN DURING IGNITION
    • 6.12 SAFETY PRESSURE RELIEF VALVE TEST
• CHAPTER 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 BURNER
    • 7.7 EXHAUST MANIFOLD AND COMBUSTION CHAMBER
    • 7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
    • 7.9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN
• CHAPTER 8
  • TROUBLSHOOTING GUIDE
  • 8.1 INTRODUCTION
• APPENDIX A
• APPENDIX B
• APPENDIX C
• APPENDIX D
• APPENDIX E
• APPENDIX F
• APPENDIX G
• APPENDIX H
• APPENDIX I
• APPENDIX J
• STANDARD WARRANTY