Installation / Operation Instruction Manual

SECTION 8 (continued)
8.D.4 Cascade (Lead / Lag) ....................... 69
8.D.4.a Cascade CH (Central Heat) .............. 74
8.D.4.a.1 Cascade CH Lead Settings .............. 75
8.D.4.a.1.A Cascade Base / Drop Load............ 75
8.D.4.b Cascade DHW (Dom Hot Water) ....... 76
8.D.4.c Cascade Rotation .............................. 77
8.D.4.c.1 Cascade Rotation Setup .................. 77
8.D.4.d Cascade Redundancy ........................ 78
8.D.5 Hybrid ............................................... 78
8.D.6 Pumps ............................................... 80
8.D.6.a Variable Speed Pump Control ............ 80
8.D.7 Manual Firing Rate ............................ 81
8.D.8 Temp Limits ....................................... 81
8.D.8.a Delta T Parameters ............................ 82
8.D.8.b Flue Limitation Parameters ................ 82
8.D.8.c Outlet Limitation Parameters .............. 82
8.D.9 External ............................................. 83
8.D.9.a External – Remote Set Point .............. 84
8.D.9.b External Firing Rate............................ 85
8.D.10 Time & Date ...................................... 85
8.D.11 Miscellaneous Features .................. 86
8.D.11.a Demand Priority ................................ 87
8.D.11.b Anti-Short Cycle ................................ 87
8.D.11.c Warm Weather ................................. 88
8.D.11.d COM Port, BMS ................................. 89
8.D.11.e Temperature Conversion ................... 90
8.D.11.f Anti-Frost ........................................... 90
8.D.12 Login .................................................. 91
8.E Service Screens................................ 92
8.E.1 Burner................................................. 93
8.E.2 Digital I/O ( Input / Output ) ............... 93
8.E.3 Analog I/O .......................................... 94
8.E.4 Screen Settings Timeout .................... 95
8.E.5 History ................................................ 95
8.E.6 Restart Touchscreen & Recalibrate .... 96
8.E.7 Factory Reset ..................................... 96
8.E.8 HMI Model OEM only. ....................... 96
8.E.9 BIC Model OEM only ......................... 96
8.E.10 Both Model OEM only. ....................... 96
8.E.11 About About the Firmware ................. 96
8.F Messages and USB .......................... 97
8.F.1 Messages ........................................... 97
8.F.2 USB Functionality ............................... 97
8.G Active Demands ............................... 98
SECTION 9 Parameter Tables ................. 99
SECTION 10 Initial startup Instructions
10.A Filling the Boiler System ................... 105
10.B Initial Operation ................................ 106
10.B.1 Initial Burner Operation .................... 106
10.B.2 Combustion Setup Procedure .......... 107
10.C Shutting Down the Unit..................... 110
10.D Restarting the Unit............................ 110
10.E Sequence of Operation .....................111
10.E.1 Pre-purge Open.................................111
10.E.2 Pre-purge Closed ..............................111
10.E.3 Transition to Pre-Ignition ...................111
10.E.4 Pre-Ignition ........................................111
10.E.5 Pilot Ignition ....................................... 111
10.E.6 Main Ignition ......................................111
10.E.7 Run ................................................... 112
10.E.8 Inter-Purge ....................................... 112
10.E.9 Post-Purge ....................................... 112
10.E.10 Lock-out............................................ 112
SECTION 11 Maintenance
11.A System Maintenance ....................... 113
11.B Maintenance Notes .......................... 113
11.B.1 Burner............................................... 113
11.B.2 Modulating Gas Valve / Venturi ........ 113
11.B.3 Controller .......................................... 114
11.B.4 Spark Ignition Electrodes ................. 114
11.B.5 Flame Sensor ................................... 114
11.B.6 Blower 1600 ..................................... 114
11.B.7 Blower 2000-4000 ............................ 114
11.B.8 Heat Exchanger Tubes ..................... 115
11.B.9 Gas Pressure Switches .................... 115
SECTION 12 Troubleshooting .............. 117
SECTION 13 Replacement Parts
13.A General Information.......................... 119
13.B Component Illustrations, Parts Lists,
and Part Numbers ................... 119 - 134
ii
5.A.4 Suggested Boiler Piping Schematics
5.B Water Heaters .................................... 31
5.B.1 Water Quality ...................................... 31
5.B.2 Heater Water Connections ................. 31
5.B.3 Cold Water Make-Up .......................... 31
5.B.4 Freeze Protection ............................... 32
5.B.5 Suggested Piping Schematics ........... 32
SECTION 6 Condensate Drain Trap .......34
SECTION 7 Electrical Connections
7.A Installation Warnings .......................... 35
7.B Main Power Connections ................... 36
7.C Control Panel Layout .......................... 37
7.D Field Connections............................... 37
7.D.1 Power ................................................. 37
7.D.2 Dry Contacts ....................................... 37
7.D.3 Temperature Sensors ......................... 38
7.D.4 Heat Demands ................................... 39
7.D.5 Analog In and Analog Out .................. 39
7.D.6 Dry Contacts. Run & Alarm ................ 39
7.D.7 RS 485, for Cascade (Lead / Lag)...... 40
7.D.8 RS485 BMS........................................ 40
7.E Modbus and BACnet Memory Map .... 41
7.F Wiring Diagrams ................................. 44
7.G High Voltage Wiring Diagrams ........... 48
7.H Ladder Diagrams ................................ 55
SECTION 8 Control Operation
8.A The Home Screen ............................. 58
8.A.1 Home Screen Active Icons ................. 58
8.A.2 Keypad Operations............................. 59
8.B Login to Lock / Unlock ..................... 60
8.C Quick Start ........................................ 61
8.C.1 Quick Start CH (Central Heat) ............ 61
8.C.2.a Quick Start CH1 (Central Heat, One) . 62
8.C.2.b Quick Start CH2 (Central Heat, Two) . 62
8.C.2 Quick Start DHW (Domestic Hot Water) 62
8.C.3 Quick Start Outdoor Reset ................ 63
8.C.4 Quick Start Warm Weather Shut Down 63
8.C.5 Quick Start Anti-Short Cycle .............. 64
8.C.6 Time & Date ...................................... 64
8.D Conguration .................................... 65
8.D.1 CH (Central Heat) ............................... 66
8.D.1.a CH1 (Central Heat, One) .................... 66
8.D.1.a.1 PID Parameters ................................ 67
8.D.1.b CH2. (Central Heat, Two) ................... 67
8.D.2 DHW (Domestic Hot Water) ............... 67
8.D.3 Outdoor Reset ................................... 68