VT.3® WATER BOILER INSTALLATION & MAINTENANCE MANUAL Models (400, 500, 650, 750, 850, 900 and 1000) WB 125A-IF Installation and service must be performed by a qualified service installer, service agency or the gas supplier. IMPORTANT: THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION, OPERATION AND MAINTENANCE OF THIS EQUIPMENT. READ AND FOLLOW THE INFORMATION IN THIS MANUAL AND ALL OTHER PROVIDED INSTRUCTIONS, LABELS AND MARKINGS BEFORE INSTALLING, OPERATING OR SERVICING THIS UNIT.
TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. Safety Considerations Product Description Boiler Installation 3.1. Checking Equipment Before You Install 3.2. Codes 3.3. Electrical Requirements 3.4. Location 3.5. Service Clearances 3.6. Clearances to Combustible Surfaces General Piping Guidelines 4.1. Inlet and Outlet Connections 4.2. Supply and Return Piping 4.3. Temperature Control Sensor (Install in system return piping) 4.4. Filling the Boiler Gas Supply Piping 5.1. Inlet Gas Pressure 5.2.
9. 10. 11. 12. 13. 14. 15. 16. TempTrac Controller Panel 9.1. Principle of Operation 9.2. Upper LED Readout 9.3. Lower LED Readout 9.4. Control Buttons 9.5. Modulation Firing Sequence 9.6. To View the Setpoint 9.7. To Change The Setpoint 9.8. To Change Other Parameters 9.9. LED Display Alarm Messages Boiler Control Interface 10.1. If BMS is to provide remote on/off control only 10.2. If BMS provides Modulation control through a 4 to 20 milliamp 10.3. Modbus Application for TempTrac 10.4.
1 SAFETY CONSIDERATIONS WARNING: If the information in the supplied manual(s) is not followed exactly, a fire, explosion or exposure to hazardous materials may result, causing property damage, personal injury or death. FOR YOUR SAFETY • Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building.
2 PRODUCT DESCRIPTION Component, Controls and Connection Locations (Locations May Vary) 5 34-55 08/14
3 BOILER INSTALLATION 3.1 Checking Equipment Before You Install Inspect the unit completely upon receipt from the freight carrier before signing the bill of lading. Inspect the appliance and all accompanying parts for signs of impact or mishandling. Verify the total number of pieces shown on packing slips with those actually received. Contact the freight carrier immediately if any damage or shortage is detected. 3.
4 GENERAL PIPING GUIDELINES Consult factory for piping of hybrid boiler systems that contain both condensing and non-condensing boilers. 4.1 Inlet and Outlet Connections The connection to the unit marked “Inlet” on the header connects to the return from the system (water to be heated). The connection on the header marked “Outlet” connects to the supply side of the system (hot water out of the unit). 4.
4.4 Filling The Boiler 1 Fill the system with water. To be sure that the unit is not “air bound,” open the relief valve. Leave the valve open until a steady flow of water is observed. Close valve and complete filling the system. 2 In hard water areas, water treatment should be used to reduce introduction of minerals into the system. Excessive buildup of minerals in the heat exchanger can cause a non-warrantable failure. 3 Make sure there are no system leaks.
5 GAS SUPPLY AND PIPING Verify that the type of gas specified on rating plate is supplied to the unit. This unit is orificed for operation up to 2000 feet altitude. Appliance btuh output derates 4% per 1000 feet elevation above sea level. Consult Factory for installations above 2000 feet elevation. 5.1 Inlet Pressure: Measured at the inlet pressure tap located at the main gas cock.
MULTIPLE UNIT INSTALLATIONS GAS PIPING SIZE CHART Maximum Capacity of Pipe in Thousands of BTU’s per hour for gas pressures of 14 Inches Water Column (0.5 PSIG) or less and a pressure drop of 0.05 Inch Water Column (Based on NAT GAS, 1025BTU’s per Cubic Foot of Gas and 0.60 Specific Gravity).
5.7 Gas Control Trains All models include gas control trains with the following components: main gas cock, a dual safety valve, proportionator regulator and a final manual shutoff valve with the manifold pressure tap on the side of the valve. CAUTION: Do not adjust or remove any screws or bolts on gas train control components which are sealed with a red or blue colored compound. Doing so will void all approvals and warranties.
the total equivalent length allowed in Maximum Air Inlet Duct Equivalent Length chart above. The sum of this calculation is the maximum length of straight duct allowed. If a longer length is required, repeat the calculation using a larger duct size. No additional deduction is required for the addition of the duct system terminal.
7 VENTING 7.1 Venting the unit using Category I, III or IV Venting Materials The following instructions can be used to install the VT3 using UL, ULC, ETL or CSA listed, Category I, negative pressure, non-condensing vent materials, like type B venting or it can be installed using smaller diameter UL, ULC, ETL or CSA listed, stainless steel, Category III, positive pressure, non-condensing venting materials.
WARNING: Do not combine appliances utilizing Category I or Category II venting into the same vent system with appliances utilizing Category III or Category IV venting. This could cause unsafe operation and the potential for poisonous carbon monoxide to enter occupied areas. Such improper installation can cause property damage, personal injury, exposure to hazardous materials or death. Conventional Venting Through the Wall Venting 7.
7.3.1 Maximum Category III or Category IV Vent Length (Equivalent Length) If a vertical or horizontal Category III or Category IV vent system is used with this appliance, the maximum length of field supplied venting is shown in the chart below titled Maximum Category III – Category IV Vent Equivalent Length.
9. A vertical vent must exhaust outside the building at least 3 feet (0.91m) above the point of the exit and at least 2 feet (0.61 m) above the highest point of the roof within a 10-foot (3.05 m) radius of the termination. 10. A vertical termination less than 10 feet (0.91 m) from a parapet wall must be a minimum of 2 feet (0.61 m) higher than the parapet wall 7.3.
CAUTION: Do not install a reducing coupling, valve or other restriction in the relief valve(s) discharge line. The discharge line shall allow complete drainage of the valve and line. Relief valves should be manually operated at least once a year. WARNING: To prevent burns caused by hot water discharge and water damage, pipe the discharge from the relief valve to a suitable floor drain for disposal when relief occurs. Avoid contact with hot discharge water.
9 TEMPTRAC™ ELECTRONIC CONTROLLER PANEL 9.1 Principle Of Operation The boiler operates to satisfy the setpoint of the TempTrac digital control whose sensor is located in the return line of a Hydronic system. Demand (flow) will typically create a drop in temperature, thus activating the Centauri to add heat to the system. This setpoint is the highest temperature the appliance permits any firing to occur. 9.
9.5 Modulating Firing Sequence The boiler is fully modulating and initiates combustion at the lowest firing rate. It will modulate between this lowest possible rate and full rate as the boiler loop temperature rises and falls in relation to the operating set point. The Parameters involved with the modulation control sequence are St1, Hy1 St4, and SR.
• C to D: Once modulation is established, the sensed loop temperature can fluctuate between 155°F and 145°F (between St4 and SR). The firing rate increases or decreases proportionately between 100% and low fire, depending upon the temperature sensed in the return loop. Temperature rise in the heat exchanger varies accordingly, 45° to 15° depending upon the firing rate. • D: The unit will remain in modulation until the sensed temperature rises above 155°F (St4). The firing rate returns to low fire.
9.9 LED Display Alarm Messages Alarm messages are displayed in t upper LED readout and alternate with the default display. An alarm LED ICON is also illuminated. (See TempTrac User Manual 34-80 for full description.) ALARM MESSAGE CAUSE RESULTS OF ALARM CONDITION RECOMMENDED ACTION “P1” TP1 probe failure Inlet temperature sensor is not connected or is reading incorrectly. Call for heat and burner modulation output signal will revert to low fire.
10 BOILER CONTROL INTERFACE A terminal strip for the remote connection is located behind the hinged control panel at the top of the cabinet and is accessed by removing the bottom cover and then removing the screws at the top of the hinged cover. 10.1 If BMS/BAS provides remote on/off control directly to each boiler but allows boiler to control modulation on its own: • Remove the jumper connecting terminals R1 and R2. • Connect the BMS output leads for the enable/disable function to terminals R1 and R2.
A1-A2: Used to activate a remote alarm signaling shutdown of combustion control. Provides a maximum 10 amp relay contact closure when the flame safeguard terminates combustion due to a tripped safety interlock (i.e.: air proving switch high limit switch, low water flow switch or flame sensor, etc.). Options Required - Consult Factory. P1-P2: Activates remote equipment and requires confirmation signal back to the appliance. Provides a maximum 10-amp relay contact closure to activate a remote device (i.e.
− In hybrid systems, prioritizes and rotates through up to 12 condensing boilers before energizing and rotating through up to 8 non-condensing boilers. − Communicates with boilers by Modbus RTU protocol over 485 serial connection (2-wire, shielded daisy chain). − Connects to Building Automation Systems through either a 4-20mA analog signal for remote set point or over the non-proprietary Modbus TCP/IP network protocol. Gateways are available for other protocols.
a. The Delay-On (Low Fire Hold) Relay and the Gas Safety Valves are energized. b. During TFI the flame safeguard control will monitor the flame using flame rectification through the hot surface igniter. c. If the flame control senses the presence of flame before the end of the TFI period, the igniter will be deenergized and the flame control will continue to monitor the flame, through the igniter, until the operating thermostat ends the call for heat condition. 7. Loss of Flame Signal a.
12 INITIAL STARTUP 12.1 Initial Startup Requirements Installation should be complete prior to performing initial startup; and the startup must be complete prior to placing the boiler into service. Starting the boiler without proper piping, combustion air, venting or electrical systems can be dangerous and may void the product warranty. The following startup instructions should be followed precisely in order to achieve safe and efficient operation to assure trouble-free service life.
c. Reattach the manometer to the gas train manual shutoff valve at the burner and record the measured gas pressure in inches of water column (W.C.). Measure gas pressure again after 15 minutes. If gas pressure has increased 0.5" W.C. or more, the gas leak must be isolated to one or more of the operating gas valves. (For example, a solenoid actuated gas shutoff valve.) After any leaking valve is replaced, the reassembled gas train must be leak tested again before start-up is attempted. 5.
20. After the pre-purge, the flame control energizes the HSI for the heat up period, approximately 30 seconds. At the end of that period the gas valve is opened for approximately 4 seconds. After the burner has lit and the primary safety control senses a flame, the burner will remain on until the call for heat is satisfied or operation is interrupted by a safety device. 21. If the burner fails to light, the flame control will lockout.
VALVE ORIFICE ADJUSTMENT DUAL SAFETY SHUTOFF VALVE AND REGULATOR REGULATOR ADJUSTMENT MANIFOLD PRESSURE Gas Train Illustration for Centauri Models 250 through 500 REGULATOR ADJUSTMENT VALVE ORIFICE ADJUSTMENT LOW PRESSURE GAS SWITCH DUAL SAFETY SHUTOFF VALVE HIGH GAS PRESSURE SWITCH MANIFOLD PRESSURE Gas Train Illustration for Centauri Models 650 through 2200 29 34-55 08/14
13 TROUBLESHOOTING GUIDE Problem Probable Cause Corrective Action Power Supply Check fuse and/or circuit breaker. Check voltage at 120/24V step-down transformer. On-Off Switch Check if On-Off switch is lighted Check that the operating temperature control is set higher than the temperature of the boiler. Temperature Control Flame Safeguard Control Check for bad ground or bad control. Replace if necessary. Remote enable/disable open Enable boiler or place jumper between terminals R1-R2.
14 REPLACEMENT PARTS REPLACEMENT PARTS 31 34-55 08/14
14.
14.2 Control Panel Components (Optional components may not be included) Key No. Part No. 1 101947 2 Description Qty.
14.
14.4 Burner Assembly Components Optional components may not be included) Key No. Qty. Part No. Description 1 1 111876 2 1 SEE BOM ASSY, BULKHEAD REFRACTORY 3 1 SEE BOM BURNER, METAL PUNCHED 4 6 114513 SPACER, NYLON 1/4 ID X 1/2 OD X 11/16 MCMASTER C 5 1 115248 ASSY, INTAKE GAS AIR 7 OD X 1 NPT 6 14 3494 7 6 111912 BOLT, 1/4 X 20 NC X 1 1/4 PLT HEX HEAD GR 5 8 16 64326 SCREW, M5 X 0.
15 PERIODIC MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations. Maintenance must be performed by a qualified service or maintenance provider. To ensure proper maintenance, the following instructions should be posted near the appliance and maintained in legible condition. Verify proper operation after servicing. WARNING: When servicing the controls, use exact, Factory authorized, replacement parts and label all wires prior to disconnection.
6. The combustion air filter should be replaced every six months. If filter blockage becomes excessive the filter safety switch will not allow the burner to fire. To avoid nuisance shutdown in dirty environments, check and replace filter more frequently. 7. Inspect low water cutoffs and relief valves for proper operation at every six months, or more often if indicated by inspection. 8. Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids. 9.
16 RECOMMENDED MAINTENANCE SCHEDULE 1. Annual Maintenance a. b. c. d. e. f. g. h. i. 2. Semi-Annually a. b. c. d. e. f. g. h. 3. Recalibrate all indicating and recording gauges. Check flame failure detection system components. Check firing rate control. Check piping and wiring of all interlocks and shutoff valves. Inspect burner components. Check igniter. Test high and low gas pressure interlocks. Check air filter and replace if required Monthly Maintenance a. b. c. d. e. f. 4.
NOTES: 39 34-55 08/14
MODEL NUMBER: SERIAL NUMBER: INSTALLATION DATE: Riverside Hydronics, LLC • 990 Haltom Road • Ft. Worth, TX 76117 • 1‐800‐990‐5918 • www.riversidehydronics.
