- Installation & Maintenance Manual RTC/Return Temperature Control The Burnham Return Temperature Control (RTC) is designed to operate a 3-way or a 4-way valve to protect the boiler against flue gas condensation and thermal shock. The RTC can also optionally control the supply water temperature to the system based on a setpoint temperature or an outdoor reset strategy. A boiler post purge is provided by keeping the boiler recirculating pump running after the call for heat is removed.
How To Use This Manual This manual is organized into four main sections. They are: 1) Sequence of Operation, 2) Installation, 3) Control Settings, and 4) Testing and Troubleshooting. The Sequence of Operation section has four sub-sections. We recommend reading Section A: General Operation of the Sequence of Operation section, as this contains important information on the overall operation of the control. Then read the sub sections that apply to your installation.
Display Displays the current value of the selected item Displays an abbreviated name of the selected item Monitor Delay Open Close Demand Displays the current menu Item Displays the current status of the control's inputs, outputs and operation Selects Menus, Items and adjusts settings Symbol Description Pump Displays when the boiler recirculating pump is in operation. °F, °C Displays the unit of measure that all of the temperatures are to be displayed in the control.
Outdoor Reset When the outdoor design (OUTDR DSGN) setting is set to a temperature, the control calculates a mix supply temperature based on the outdoor air temperature and the programmed reset ratio. An outdoor sensor and a mix supply sensor must be installed. Setpoint Control When the outdoor design (OUTDR DSGN) setting is set to OFF, and there is a mix supply sensor installed, the control supplies a fixed mix supply temperature equal to the MIX TARGET setting.
MIX TARGET When used as a mixing reset control, the MIX TARGET temperature is calculated from the reset ratio and outdoor air temperature. When used as a setpoint control, the installer sets the MIX TARGET temperature. The control displays the temperature that it is currently trying to maintain as the mix supply temperature. If the control does not have a heat demand,”– – –” is displayed as the MIX TARGET.
SETPOINT OPERATION Mix Target For setpoint control, set the OUTDR DSGN to OFF. The mix target becomes the setpoint supply temperature that the control is to maintain. The mix target temperature is set by the installer in the ADJUST menu. An outdoor sensor is not required during this mode of operation. COMMON SETTINGS The following settings are common to both the outdoor reset and setpoint operations.
Installation Caution Improper installation and operation of this control could result in damage to the equipment and possibly even personal injury. It is the installer’s responsibility to ensure that this control is safely installed according to all applicable codes and standards. This electronic control is not intended for uses as a primary limit control. Other controls that are intended and certified as safety limits must be placed into the control circuit. Do not open the control.
Figure 1: Typical Boiler Wiring With RTC (Front) of 60
Figure 2: Typical Boiler Wiring With RTC Return Sensor (Rear) of 60
Figure 3: V9A Series Boiler Recommended Minimum Piping - RTC With 3-Way Diverting Valve 10 of 60
Figure 4: V11 Series Boiler Recommended Minimum Piping - RTC With 3-Way Diverting Valve 11 of 60
Figure 5: Typical Burnham Boiler Loop w/3-Way Diverting Valve 12 of 60
Figure 6: Typical Burnham Boiler Loop w/4-Way Diverting Valve 13 of 60
On multiple boiler applications, each boiler is installed in the same arrangement as a single boiler application. Each boiler loop contains its own boiler circulator, diverting valve and actuator, RTC control, and return sensor. A number of different boiler sequencers can be used in conjunction with the RTC by energizing the control’s heat demand circuit. The RTC control’s outdoor reset feature cannot be used on multiple boiler installations.
Diverting Valve Actuator 24 Volt Output Terminals 9, 10 and 11 are powered with 24 V (ac) from the control. There is no need to provide a separate 24 V (ac) power source for the diverting valve actuator. R (9) is connected to the open terminal of the actuating motor and R (10) is connected to the close terminal of the actuating motor. N (11) is then connected to the common terminal of the actuating motor.
Boiler Enable Contact 7 r8 The Boiler Enable terminals (7 and 8) are an isolated output in the control. There is no power available on these terminals from the control. These terminals are to be used as a switch to either make or break the boiler limit circuit. When the control requires the boiler to fire, it closes the contact between terminals 7 and 8. Boile Enable Sensor and Unpowered Input Connections Do not apply power to these terminals, as this will damage the control.
Test the Sensors A good quality test meter capable of measuring up to 2,000,000 Ω (1kΩ = 1000 Ω) is required to measure the sensor resistance. In addition to this, the actual temperature should be measured with a good quality digital thermometer. First measure the temperature using the thermometer. Then measure the resistance of the sensor at the control. The wires from the sensor must not be connected to the control while the test is performed.
Test the Outputs Boiler Recirculating Pump (Boil Pmp) The boiler recirculating pump is connected to the Boil Pmp terminal (5). Make sure that power to the terminal block is off, and install a jumper between the Power L and the Boil Pmp terminals (3 and 5). Install a second jumper between Power N and N terminals (4 and 6). When power is applied to the Power L and Power N terminals (3 and 4), the boiler recirculating pump should start.
E. WWSD (Warm Weather Shut Down) – This feature is only used when the outdoor reset feature is selected. Set the WWSD as desired, keeping in mind that, when the outdoor air temperature rises above the WWSD setting, the control will not operate the boiler to satisfy any demands for heat. F. MIX MIN (Mixing Minimum) – When the outdoor reset feature is selected, this setting represents the minimum mix target supply water temperature. Set as desired. G.
Display Se ct io n View Menu (1 of 1) Description Range D BOIL Current boiler return temperature as measured by the boiler sensor. 14 to 266°F (-10 to 130°C) D MIX TARGET Target mixed supply is the temperature the control is currently trying to maintain at the mixing sensor. (Mix sensor is present or OUTDR DSGN = OFF) – – –, 14 to 266°F (– – –,-10 to 130°C) D MIX Current mixed supply water temperature as measured by the mixing sensor.
Display Delay Se ct io n Adjust Menu (1 of 1) Description Range C ROOM The desired room air temperature. (OUTDR DSGN ≠ OFF) 35 to 100°F (2 to 38°C) Default = 70°F (21°C) C MIX TARGET Mixing setpoint temperature. (OUTDR DSGN = OFF) 60 to 200°F (16 to 93°C) Default = 180°F (82°C) C MIX DSGN The design supply water temperature used in the heat loss calculation for the heating system.
Testing the Control The control has a built-in test routine, which is used to test the main control functions. The control continually monitors the sensors, and displays an error message whenever a fault is found. See the following pages for a list of the control’s error messages and possible causes. When the Test button is pressed, the test light is turned on. The individual outputs and relays are tested in the following test sequence.
Isolate the Problem Isolate the problem between the control and the system. Now that the sequence of operation is known and the system is sketched, is the control operating the proper pumps and valves at the correct times? Is the control receiving the correct signals from the system as to when it should be operating? Are the proper items selected in the menus of the control for the device that is to be operated? Test the Contacts, Voltages and Sensors Test the contacts, voltages and sensors.
Repair Parts Q t y /B o i l e r P a rt N u mb e r Re turn Te mp e ra ture C o ntro l (RTC ) wi th b o i le r s e ns o r a nd mo unti ng s c re ws 1 80160916 C o ntro l Mo to r, E S B E 9 2 M, 2 4 V, 5 0 S e c o nd mo to r, D a nfo s s # 0 6 5 F 8 9 5 3 .
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Appendix A: Application Drawings A1. 3-way RTC in Primary/Secondary - Heating Only/No DHW; with/without Outdoor Reset (Mechanical) C1 = Diverting Valve Actuator M1 = By-Pass Mix Point P1 = Boiler Circulator P2 = System Pump (runs on call for heat) S1 = Boiler Return Sensor S2 = Mix Supply Sensor 071 (Required for Reset or Set-point Control) S3 = Outdoor Sensor 070 (Required for Reset Control) V1 = 3-Way Diverting Valve V2 = Ball Valve, Balancing Valve Z1...
A1. 3-way RTC in Primary/Secondary - Heating Only/No DHW; with/without Outdoor Reset (Electrical) C1 = Mixing Valve Actuating Motor P1 = Boiler Circulator S1 = Boiler Return Sensor S2 = Mix Supply Sensor 071 S3 = Outdoor Sensor 070 Z1...
A2.
A2. 3-way RTC in Primary/Secondary - Heating and DHW using Tankless Coil; with/without Outdoor Reset (Electrical) A1 = Tankless Coil or Storage Tank Aquastat C1 = Mixing Valve Actuating Motor P1 = Boiler Circulator P2 = Tankless Coil System Circulator R1 = Relay (Required with and without priority) R2 = Relay (Required for priority) S1 = Boiler Return Sensor S2 = Mix Supply Sensor 071 S3 = Outdoor Sensor 070 Z1...
A3.
A3. 3-way RTC in Primary/Secondary - Heating and DHW using Indirect Water Heater; with/without Outdoor Reset (Mechanical) A1 = Indirect Hot Water Aquastat C1 = Mixing Valve Actuating Motor P1 = Boiler Circulator P2 = Indirect Circulator R1 = Relay (Required with and without priority) R2 = Relay (Required for priority) S1 = Boiler Return Sensor S2 = Mix Supply Sensor 071 S3 = Outdoor Sensor 070 Z1...
A4. 3-way RTC in Primary/Secondary - Heating and DHW using Indirect Water Heater on Primary Loop; without Outdoor Reset (Mechanical) A1 = Indirect Hot Water Aquastat C1 = Diverting Valve Actuating Motor M1 = By-Pass Mix Point P1 = Boiler Circulator P2 = Indirect Circulator P3 = System Pump (runs on call for heat) R1 = Relay S1 = Boiler Return Sensor V1 = 3-Way Diverting Valve V2 = Ball Valve, Balancing Valve V3 = Ball Valve, System Balancing Z1...
A4. 3-way RTC in Primary/Secondary - Heating and DHW using Indirect Water Heater on Primary Loop; without Outdoor Reset (Electrical) A1 = Indirect Hot Water Aquastat C1 = Mixing Valve Actuating Motor P1 = Boiler Circulator P2 = Indirect Circulator R1 = Relay S1 = Boiler Return Sensor Z1...
A5. 4-way RTC in Primary/Secondary - Heating Only/No DHW; with/without Outdoor Reset (Mechanical) C1 = Diverting Valve Actuating Motor M1 = By-Pass Mix Point P1 = Boiler Circulator P2 = System Pump (runs on call for heat) S1 = Boiler Return Sensor S2 = Mix Supply Sensor 071 (Required for Reset Control) S3 = Outdoor Sensor 070 (Required for Reset Control) V1 = 4-Way Diverting Valve V2 = Ball Valve, Balancing Valve Z1...
A5. 4-way RTC in Primary/Secondary - Heating Only/No DHW; with/without Outdoor Reset (Electrical) C1 = Mixing Valve Actuating Motor P1 = Boiler Circulator S1 = Boiler Return Sensor S2 = Mix Supply Sensor 071 S3 = Outdoor Sensor 070 Z1...
A6.
A6. 4-way RTC in Primary/Secondary - Heating and DHW using Tankless Coil; with/without Outdoor Reset (Electrical) A1 = Tankless Coil or Storage Tank Aquastat C1 = Mixing Valve Actuating Motor P1 = Boiler Circulator P2 = Tankless Coil System Circulator R1 = Relay (Required with and without priority) R2 = Relay (Required for priority) S1 = Boiler Return Sensor S2 = Mix Supply Sensor 071 S3 = Outdoor Sensor 070 Z1...
A7.
A7. 4-way RTC in Primary/Secondary - Heating and DHW using Indirect Water Heater; with/without Outdoor Reset (Electrical) A1 = Indirect Hot Water Aquastat C1 = Mixing Valve Actuating Motor P1 = Boiler Circulator P2 = Indirect Circulator R1 = Relay (Required with and without priority) R2 = Relay (Required for priority) S1 = Boiler Return Sensor S2 = Mix Supply Sensor 071 S3 = Outdoor Sensor 070 Z1...
A8. 4-way RTC in Primary/Secondary - Heating and DHW using Indirect Water Heater on Primary Loop; without Outdoor Reset (Mechanical) A1 = Indirect Hot Water Aquastat C1 = Diverting Valve Actuating Motor M1 = By-Pass Mix Point P1 = Boiler Circulator P2 = Indirect Circulator P3 = System Pump (runs on call for heat) R1 = Relay S1 = Boiler Return Sensor V1 = 3-Way Diverting Valve V2 = Ball Valve, Balancing Valve V3 = Ball Valve, System Balancing Z1...
A8. 4-way RTC in Primary/Secondary - Heating and DHW using Indirect Water Heater on Primary Loop; without Outdoor Reset (Electrical) A1 = Indirect Hot Water Aquastat C1 = Mixing Valve Actuating Motor P1 = Boiler Circulator P2 = Indirect Circulator R1 = Relay S1 = Boiler Return Sensor Z1...
A9.
A9. 3-way Multiple Boiler RTC in Primary/Secondary - Heating and DHW using Indirect Water Heater on Primary Loop; Using Sequencer with & without Outdoor Reset (Electrical) A1 = Indirect Hot Water Aquastat C1,C2 = Mixing Valve Actuating Motor P1,P2 = Boiler Circulator P3 = System Pump (runs on call for heat) P4 = Indirect Circulator R1 = Relay S1,S2 = Boiler Return Sensor S3 = Mix Supply Sensor 071 S4 = Outdoor Sensor 070 Z1...
A10.
A10. 4-way Multiple Boiler RTC in Primary/Secondary - Heating and DHW using Indirect Water Heater on Primary Loop; Using Sequencer with & without Outdoor Reset (Electrical) A1 = Indirect Hot Water Aquastat C1,C2 = Mixing Valve Actuating Motor P1,P2 = Boiler Circulator P3 = System Pump (runs on call for heat) P4 = Indirect Circulator R1 = Relay S1,S2 = Boiler Return Sensor S3 = Mix Supply Sensor 071 S4 = Outdoor Sensor 070 Z1...
Appendix B: Boiler Circulator and Diverting Valve Selection Charts Appendix B1 V9A Boiler Circulator and Diverting Valve Selection Chart, 20°F & 40°F DT, TACO V 9 B o i le r C i r c ula to r S e le c ti o n - TA C O ( 4 0 ∞F D i ffe r e nti a l) S IZE IB R G RO S S O U TP U T ( M B H) TOTA L GP M Pi pe S i ze V 903A 346 17 V 904A 483 V 905A B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y TA C O C i r c ula ti ng P um p Va lve S i ze Va lve P a rt Num b
Appendix B2 V9A Boiler Circulator and Diverting Valve Selection Chart, 20°F & 40°F DT, Grundfos V 9 B o i le r C i r c ula to r S e le c ti o n - Gr und fo s ( 2 0 ∞F D i ffe r e nti a l) S IZE IB R GROS S TOTA L O U TP U T G P M ( M B H) Pi pe S i ze B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Gr und fo s C i r c ula ti ng P um p Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No .
Appendix B3 V9A Boiler Circulator and Diverting Valve Selection Chart, 20°F & 40°F DT, Bell and Gossett V 9 B o i le r C i r c ula to r S e le c ti o n - B e ll a nd Go s s e tt ( 2 0 ∞F D i ffe r e nti a l) S IZE IB R GROS S TOTA L P i p e OUTP UT GP M S i ze ( M B H) B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y B e ll a nd Go s s e tt C i r c ula ti ng P um p Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No .
Appendix B4 V9A Boiler Circulator and Diverting Valve Selection Chart, 20°F & 40°F DT, Armstrong V 9 B o i le r C i r c ula to r S e le c ti o n - A r m s tr o ng ( 2 0 ∞F D i ffe r e nti a l) S IZE IB R GROS S TOTA L P i p e OUTP UT GP M S i ze ( M B H) B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y A r m s tr o ng C i r c ula ti ng P um p Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No .
Appendix B5 V11 Boiler Circulator and Diverting Valve Selection Chart, 20°F & 40°F DT, TACO V 11 B o i le r C i r c ula to r S e le c ti o n - TA C O ( 2 0 ∞F D i ffe r e nti a l) S IZE IB R GROS S TOTA L O U TP U T G P M ( M B H) Pi pe S i ze B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r Mo d e l No . Im p " HP RP M V 11 0 4 667 67 2 .5 " 2 .0 " NP T 80160358 2 .
V 11 B o i le r C i r c ula to r S e le c ti o n - TA C O ( 4 0 ∞F D i ffe r e nti a l) S IZE IB R G RO S S O U TP U T ( M B H) TOTA L GP M Pi pe S i ze V 11 0 4 667 33 V 11 0 5 857 V 11 0 6 B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r Mo d e l No . Im p " HP RP M 2 .0 " 1 .5 " NP T 80160357 1 .5 " NP T 80149024 111 N/A 1 /8 1725 43 2 .0 " 1 .
Appendix B6 V11 Boiler Circulator and Diverting Valve Selection Chart, 20°F & 40°F DT, Grundfos V 11 B o i le r C i r c ula to r S e le c ti o n - Gr und fo s ( 2 0 ∞F D i ffe r e nti a l) S IZE IB R G RO S S O U TP U T ( M B H) TOTA L GP M P i p e S i ze V 11 0 4 667 67 V 11 0 5 857 V 11 0 6 B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No . Im p " HP RP M 2 .
V 11 B o i le r C i r c ula to r S e le c ti o n - Gr und fo s ( 4 0 ∞F D i ffe r e nti a l) S IZE IB R G RO S S O U TP U T ( M B H) TOTA L GP M Pi pe S i ze V 11 0 4 667 33 V 11 0 5 857 V 11 0 6 B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No . Im p " HP RP M 2 .0 " 1 .5 " NP T 80160357 1 .5 " NP T 80149024 UP S 3 2 -4 0 /4 3 .3 9 1 /3 1667 43 2 .
Appendix B7 V11 Boiler Circulator and Diverting Valve Selection Chart, 20°F & 40°F DT, Bell and Gossett V 11 B o i le r C i r c ula to r S e le c ti o n - B e ll a nd Go s s e tt ( 2 0 ∞F D i ffe r e nti a l) S IZE IB R GROS S TOTA L Pi pe O U TP U T G P M S i ze ( M B H) B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No . Im p " HP RP M 80160358 2 .
V 11 B o i le r C i r c ula to r S e le c ti o n - B e ll a nd Go s s e tt ( 4 0 ∞F D i ffe r e nti a l) S IZE IB R GROS S TOTA L O U TP U T G P M ( M B H) Pi pe S i ze B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No . Im p " HP RP M V 11 0 4 667 33 2 .0 " 1 .5 " NP T 80160357 1 .5 " NP T 80149024 P L - 3 6 - 1 - 1 /2 " Std . 1 /6 3300 V 11 0 5 857 43 2 .
Appendix B8 V11 Boiler Circulator and Diverting Valve Selection Chart, 20°F & 40°F DT, Armstrong V 11 B o i le r C i r c ula to r S e le c ti o n - A r m s tr o ng ( 2 0 ∞F D i ffe r e nti a l) S IZE IB R GROS S TOTA L Pi pe O U TP U T G P M S i ze ( M B H) B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No . Im p " HP RP M 80160358 2 .0 " NP T 80149025 S -4 5 3 .
V 11 B o i le r C i r c ula to r S e le c ti o n - A r m s tr o ng ( 4 0 ∞F D i ffe r e nti a l) S IZE IB R GROS S TOTA L O U TP U T G P M ( M B H) Pi pe S i ze B o i le r Re c i r c ula ti o n 3 - Wa y B o i le r Re c i r c ula ti o n 4 - Wa y Va lve S i ze Va lve P a rt Num b e r Va lve S i ze Va lve P a rt Num b e r M o d e l No . Im p " HP RP M V 11 0 4 667 33 2 .0 " 1 .5 " NP T 80160357 1 .5 " NP T 80149024 E -8 F ull 1 /6 3600 V 11 0 5 857 43 2 .0 " 1 .
Appendix C: Valve and Actuator Mounting Instructions 58 of 60
Technical Data RTC Return Temperature Control Optional devices Monitor Delay Open Close Demand Item Test RTC/Return Temperature Control 158033 24 Volt Output — Outdoor Sensor 070, Universal Sensor 071. 1 2 3 4 5 6 Use supply wires Heat suitable for 120°F (50°C) above ambient Demand Power L N Boil Pmp N Power: 120 V ±10% 50/60 Hz 1300 VA Floating Output: 24 V (ac) 0.
Burnham Commercial P.O. Box 3939 Lancaster, PA. 17604-3939 (888) 791-3790 Fax. (877) 501-5211 © 2003 by tekmar Control Systems Ltd. All rights reserved. Used with permission of tekmar Control Systems Ltd. 60 of 60 All specifications are subject to change without notice. Printed in Canada. - 06/03.
