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8

3 - COMPONENT LISTING

3 - COMPONENT LISTING

FIGURE 3-4  Boiler Components  (View from Front of Boiler)

GAS SHUTOFF 

GAS SHUTOFF 

VALVE

VALVE

(SHOWN IN OPEN 

POSITION)

VENT CONNECTOR 

COMBUSTION 

COMBUSTION 

AIR 

AIR 

BLOWER

BLOWER

GAS (CONTROL) 

GAS (CONTROL) 

VALVE

VALVE

LOW WATER 

LOW WATER 

CUTOFF

CUTOFF

HIGH TEMPERATURE 

SUPPLY SWITCH

SAFETY RELIEF VALVE  

SAFETY RELIEF VALVE  

AIR VENT

AIR VENT

COMBUSTION 

AIR INLET

  NOTE:                 

See Section 5 

For Piping 

Instructions

HEAT EXCHANGER 

HEAT EXCHANGER 

PUMP

PUMP

HEAT 

HEAT 

EXCHANGER        

EXCHANGER        

CONDENSATE 

COLLECTOR

RETURN WATER                                     

RETURN WATER                                     

FROM HEATING 

FROM HEATING 

SYSTEM (IN)  

SYSTEM (IN)  

SUPPLY WATER TO  

SUPPLY WATER TO  

HEATING SYSTEM 

HEATING SYSTEM 

(OUT)   

(OUT)   

LOW VOLTAGE 

LOW VOLTAGE 

TERMINAL STRIP

TERMINAL STRIP

CONTROL 

MODULE 

Fuse and 

Holder 

IGNITER        

IGNITER        

FLAME 

SENSOR

SIGHT 

SIGHT 

GLASS        

GLASS        

PRESSURE 

TEST PORT 

VENT 

TEMPERATURE 

SENSOR

GAS CONNECTION

GAS CONNECTION

CONDENSATE        

CONDENSATE        

DRAIN 

DRAIN 

COMBUSTION 

COMBUSTION 

ANALYSIS TEST 

ANALYSIS TEST 

PORT

PORT

TRANSFORMER

HIGH VOLTAGE 

HIGH VOLTAGE 

JUNCTION BOX

JUNCTION BOX

 HEAT EXCHANGER        

 HEAT EXCHANGER        

BALL VALVE

BALL VALVE

USER INTERFACE

USER INTERFACE

RETURN WATER 

SENSOR (Located 

behind piping)

Summary of Contents for BWMAAN000050

Page 1: ... CONDENSING GAS BOILER INSTALLATION OPERATION AND MAINTENANCE MANUAL P N IM BWMA 01 240009473 Rev A 06 2012 MODELS BWMAAN000050 BWMAAN000075 BWMAAN000100 BWMAAN000150 BWMAAN000200 CAC BDP 7310 West Morris St Indianapolis IN 48231 ...

Page 2: ...Data Models 050 075 100 150 200 Width A 20 508mm 23 584mm Height B 31 787mm 42 1092mm Depth C 14 356mm 16 0 406mm Bracket D 28 711mm 40 1016mm Water Connections Location I 2 51mm 2 51mm Size E 1 1 4 NPT 1 1 4 NPT Gas Connection Location J 4 1 2 114mm 4 1 2 114mm Size G 1 2 NPT 3 4 NPT Condensate Drain Connection H 3 4 NPT 3 4 NPT Weight Shipping 111 lb 50 kg 182 lb 83 kg Unit 91 lb 41 kg 157 lb 71...

Page 3: ...ctions 27 8 4 External Connections 27 9 Start Up Procedure 29 9 6 CSD 1 Compliance Test 32 10 Operating Instructions 33 11 General Maintenance And Cleaning 34 12 Ratings And Capacities 38 13 Troubleshooting 39 14 Wiring Diagram 53 15 Glossary 55 Appendix A Control Module 57 1 1 Introduction 57 1 2 Operation 57 1 3 Status Indication 57 1 4 Sequence of Operation 58 1 5 Theory of Operation 60 TABLE O...

Page 4: ...tly heat potable water Indirect heating is acceptable Heat water with non hydronic heating system chemicals present example swimming pool water Exceed 50 psig 344 kPa system pressure Exceed 195 F 90 5 C system design temperature 1 3 Operational Features Modulating 20 100 Integral Dual Limit Integral Low Water Cutoff with test button Outdoor Temperature Reset Integral Multiple Boiler Control 1 INTR...

Page 5: ...hazards potential hazards 2 1 General Boiler installation shall be completed by qualified agency See glossary for additional information WARNING Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation 2 IMPORTANT SAFETY INFORMATION 2 3 Installation shall conf...

Page 6: ...lation Fuel supply isolation during servicing See section 7 3 page 26 during servicing See section 7 3 page 26 19 Combustion Air Blower Combustion Air Blower see page 8 Delivers Delivers proper quantity of combustion air receives fuel from proper quantity of combustion air receives fuel from gas valve mixes air and fuel sending mixture to burner gas valve mixes air and fuel sending mixture to burn...

Page 7: ... For Safety Relief Valve Piping Instructions COMBUSTION AIR INLET SAFETY RELIEF VALVE SAFETY RELIEF VALVE AIR VENT AIR VENT WALL HANGING WALL HANGING SUPPORT SUPPORT BRACKET BRACKET FIGURE 3 2 Upper and Lower Jacket Latch Viewed from front of boiler Jacket Latch Lift Jacket up engage jacket with chassis push down ...

Page 8: ...T HEAT EXCHANGER EXCHANGER CONDENSATE COLLECTOR RETURN WATER RETURN WATER FROM HEATING FROM HEATING SYSTEM IN SYSTEM IN SUPPLY WATER TO SUPPLY WATER TO HEATING SYSTEM HEATING SYSTEM OUT OUT LOW VOLTAGE LOW VOLTAGE TERMINAL STRIP TERMINAL STRIP CONTROL MODULE Fuse and Holder IGNITER IGNITER FLAME SENSOR SIGHT SIGHT GLASS GLASS PRESSURE TEST PORT VENT TEMPERATURE SENSOR GAS CONNECTION GAS CONNECTION...

Page 9: ...sate See section 6 Drainage of water or water antifreeze solution during boiler service or from safety relief valve discharge See section 5 Access to system water piping gas supply and electrical service See sections 5 7 and 8 Clearances to combustible materials and service clearances See Table 2 and figure 4 1 Multiple Boilers can be wall mounted placed side by side or back to back TABLE 2 BOILER...

Page 10: ...s and 4 washers for attaching wall mount bracket to wood studs Field source appropriate fasteners for other wall constructions masonry concrete Attach wall mount bracket level on wall Boiler must engage with wall mount bracket Avoid overhang on sides of wall mount bracket Verify boiler bracket is centered on wall bracket See figure 4 2 4 LOCATING BOILER FIGURE 4 2 Wall Mount Bracket Engaged with B...

Page 11: ... other automatic means to prevent gravity circulation of boiler water during cooling cycle 5 3 Safety Relief Valve and Air Vent NOTICE Boiler rated at 50 psig 345 kPa maximum allowable working pressure Boiler provided with 30 psig 206 kPa safety relief valve Field source safety relief valve for system pressures greater than 30 psig 206 kPa Temperature Pressure Gauge and Air Vent satisfactory for 3...

Page 12: ... back flow prevention device Single boiler system See figures 5 4 5 5 5 6 5 7 for general guidance Additional considerations Control system designed for single central heating pump Installer responsible for integration of multiple central heating pumps Control system allows domestic hot water prioritization Function could be lost if central heating pump not directly connected to control system Mul...

Page 13: ...ICE Illustrations are meant to show system piping concept only Installer responsible for all equipment and detailing required by authority having jurisdiction Check Local Codes For Maximum Distance To Floor System Return System Supply F L O O R Safety Relief Valve ...

Page 14: ...ONED SYSTEM WITH VALVES 5 6 TWO PIPE ZONED SYSTEM WITH PUMPS Heat exchanger ball valve open as shipped Heat exchanger ball valve open as shipped DHW Pump CH System Pump DHW Pump Zone Pump 3 8 10mm Open End Wrench 3 8 10mm Open End Wrench ...

Page 15: ...p Heat exchanger ball valve open Heat exchanger ball valves closed 3 8 10mm Open End Wrench 5 7B SINGLE BOILER USING PRIMARY SECONDAY PUMPING CH System Pump 12 305mm Max apart 12 305mm Max apart Existing closely spaced tees in primary system loop Limit length to 5 1 6 m 3 8 10mm Open End Wrench Existing closely spaced tees in primary system loop ...

Page 16: ...tiple Boiler Guide CH System Pump 12 305mm Max apart System Temperature Sensor Size common piping according to maximum heat capacity of entire system Up to 16 boilers All heat exchanger ball valves closed 3 8 10mm Open End Wrench DHW Pump See Multiple Boiler Guide ...

Page 17: ...so they will operate at maximum speed Do not operate summer exhaust fan Close fireplace dampers Turn on appliance being inspected Follow lighting instructions Adjust thermostat so appliances will operate continuously Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use flame of match or candle smoke from cigarette cigar or pipe Determine each appliance remain...

Page 18: ...tion of pipe Combustion air and vent piping must be air tight and water tight Certified vent system components must NOT be inter changed with other vent systems or unlisted pipe fittings 6 5 Termination Terminate combustion air and vent pipes with fittings or concentric vent kit See Parts Kits and Optional Accessories manual for concentric vent kit part numbers Use horizontal pipe for vent and 90 ...

Page 19: ...combustion air intake and vent of same appliance 8 21 cm Minimum vertical separation between combustion air intake and vent of different appliances 15 38 cm Maximum horizontal length of vent Maximum vent intake between different appliances 12 30cm Maximum allowable total vertical vent length with outside exposure is 10 ft 3 05m Abandoned unused masonry chimney may be used as chaseway for combustio...

Page 20: ... or 7 6cm Diameter PVC intake combustion air Elbow field supplied Combustion Air Note Securing strap must be field installed to prevent movement of termination kit in side wall 2 5 0cm Diameter 41 Length 1 0m 3 7 6cm Diameter 47 Length 1 2m Note Overall length may be modified by cutting or extending both combustion air and vent pipes 12 is minimum allowable length and 60 is maximum allowable lengt...

Page 21: ...ve roof Concentric Vent Roof Terminations Glue inner vent pipe to prevent recirculation Maintain 12 30 cm minimum clearance above highest anticipated snow level Maximum of 24 0 61m above roof Support must be field installed to secure termination kit to structure Elbow roof boot flashing field supplied Allowed Wall Roof thickness 1 2 30 1 2 76cm Vertical concentric vent system can be installed in u...

Page 22: ...minimum 12 300 mm above highest anticipated snow level Avoid locations where snow may drift and block vent and combustion air Ice or snow may cause boiler to shut down if vent or combustion air becomes obstructed Condensate Vent gas may condense forming moisture may be corrosive Protect building materials at vent from exhaust of vent gas 6 COMBUSTION AIR AND VENT PIPING Termination must be 12 30 5...

Page 23: ...ecirculated vent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable 6 COMBUSTION AIR AND VENT PIPING Walkways Locate vent termination minimum 7 2 1 m above any public walkway with consideration to condensate 7 2 1 m Minimum 3 0 9 cm Minimum Termination Meters Regulators deck porch Vent termin...

Page 24: ...iler and field sourced piping to condensate drain at bottom of boiler See figure 6 1 Slope condensate drain pipe minimum 1 4 per foot 21mm m away from boiler Use field source condensate pump if boiler located below disposal point Field source condensate neutralizing kit as required by authority having jurisdiction or for environmentally friendly condensate disposal FIGURE 6 1 Condensate Drain Cond...

Page 25: ...d with Boiler CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switches do not use any phones in your building Immediately call your gas supplier from a neighbor s phone Follow gas supplier s instructions If you cannot reach your gas supplier call the fire department 7 GAS SUPPLY PIPING TABLE 5 GAS SUPPLY PRESSURE MODEL Natural Gas Propane Min Max M...

Page 26: ...gas shutoff valve See figure 7 3 Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods providing ignition source Correct leaks immediately and retest Manual Main Gas Shutoff Valve 7 GAS SUPPLY PIPING 7 3 Gas Shutoff Valve Gas shutoff valve shown in closed posi...

Page 27: ...de individual 120V 15 amp circuit recommended with fused disconnect or service switch as required by authority having jurisdiction B Open High Voltage Junction Box see figure 3 4 to access line voltage terminal strip C Connect 120 VAC circuit to line voltage terminal strip 120 VAC L N G Central Heating Pump if used A Isolate pump from control module if pump FLA Full Load Amps exceeds 2 amps or 1 a...

Page 28: ...Use temperature control with dry contacts rated at 0 5 amps 120 VAC Boiler control does not provide power to DHW temperature control NOTICE IMPORTANT Do not apply power to DHW T T terminals Dry contact only use of isolation relay may be necessary B Maximum wire length is 330 ft 100 m 22 gauge wire C Connect wires interchangeable to DHW T T terminals Wires are interchangeable Central Heating Thermo...

Page 29: ...ondensate Trap with Water Disconnect collet clip from condensate hose barb See figure 9 1 Disconnect tubing below from hose barb Pour approximately 2 cups 473 ml of water into condensate drain Reconnect tubing to hose barb with collet clip See figure 9 1 9 START UP PROCEDURE NOTICE IMPORTANT Condensate trap must be manually filled with water at initial start up 9 1 Condensate Drain Assembly 1 Disc...

Page 30: ...0 F 82 C 104 195 F 40 91 C Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Low Water Cutoff Enabled Enable Disabled Pump Mode 0 0 4 Service Reminder Status On ON OFF Service Reminder Days 365 Days 1 999 Days CH Settings CH Mode 1 0 1 2 3 Warm Weather Shutdown 70 F 21 C 35 100 F 2 38 C Reset Curve Design Temperature Boiler 180 F 82 C 60 195 F 40 91 C Reset Curve De...

Page 31: ...cu ft dial on gas meter Measure time required for one or more complete revolutions Measure time for 1 2 minutes Calculate input Input MBH 3600 x cu ft seconds Example Gas flow from Meter 2 cu ft Measured time 72 seconds Rate MBH 3600 x 2 cu ft 100 MBH 72 seconds Metric See Glossary Most propane systems do not have gas flow meters 2 Compare measured input to table Adjust input rate 9 START UP PROCE...

Page 32: ...em 4 Establish call for heat Jump CHW T T terminals on low voltage terminal block Turn on boiler using boiler service switch 5 Boiler will fire Based on natural convection within boiler boiler will either A Lockout A 06 Safety Relay Error Requires manual reset of control module Press reset button on User interface See 9 3 Program Boiler Control page 30 OR B Shut off burner E40 Return Water Temp Th...

Page 33: ...ructions TO TURN OFF GAS TO APPLIANCE if boiler is not being placed into immediate operation 3 Enter installer information on Warranty Registration Card 4 Gather all instructions manuals wiring diagrams warranty registration card and other supporting information Review with user and or affix in conspicuous location adjacent to boiler 9 6 Control Module J7 Connector ...

Page 34: ...ice which automatically lights the burner Do not try to light burner by hand Remove upper front jacket panel Turn gas shutoff valve clockwise to closed position Handle should be perpendicular to gas pipe Wait 5 minutes for any gas to clear Smell for gas including near floor If you smell gas STOP Follow instructions on this page What To Do If You Smell Gas If you do not smell gas go to next step Tu...

Page 35: ...e of blockages or obstructions air vent check venturi air inlet for blockage and clean as required verify pressure test port cap and combustion test port are in place return temperature sensor clip must be securely seated on pipe Check boiler for any sign of leaks Check low water cutoff using user interface Check operation by pressing test button on low water cutoff Low Water LED should illuminate...

Page 36: ...ner opening to dislodge any debris in burner ports Inspect burner for foreign matter in flame ports or inside burner Remove foreign matter by blowing with compressed air or vacuuming Replace burner if it cannot be cleaned or is showing deterioration Clean heat exchanger with low pressure water spray Use flexible handle nylon brush to loosen sediment and oxide on all accessible heating surfaces of ...

Page 37: ...ensate collector to heat exchanger using 7 16 deep well socket See figure 11 2 Remove condensate collector assembly from heat exchanger and flue pipe Flush collector and condensate trap with water Follow Burner Inspection Kit instructions to reassemble boiler and resume operation ...

Page 38: ...put rate 4 for each 1000 ft 300m above sea level TABLE 12 1 SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate MBH 1 Heating Capacity MBH 1 2 Net AHRI Rating Water MBH 1 3 AFUE 2 Maximum Minimum 050 50 10 46 40 96 0 075 75 15 69 60 96 0 100 100 20 91 79 96 0 150 150 30 139 121 96 0 200 200 40 185 161 96 0 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AFUE Annu...

Page 39: ...re Harness NO YES Replace Power Light YES NO Remove User Interface from base Using Digital Voltmeter check for 25 to 30 Vdc Is voltage present Locate fuse holder on front of control and pull to check fuse Spare fuse located on controller Make sure all wire harness plugs are properly pushed in Release plug lock with finger remove and reconnect all 7 plugs Check wiring from User Interface to Low Vol...

Page 40: ...47 Go to Page 48 Go to Page 49 Go to Page 49 Go to Page 50 Go to Page 51 Go to Page 51 Go to Page 52 Go to Page 52 Replace Control Module Replace Control Module Replace Gas Valve Replace Control Module Replace Gas Valve Replace Control Module Replace Control Module Replace Control Module Replace Control Module Error Clears in 1 2 minutes Replace Control Module ...

Page 41: ...Gas Valve Is harness connected to Control Module J13 NO YES _ P _ _ _ Lockout Alarm A 0 5 GV relay error Replace Control Module Connect harness Disconnect harness from Control Module J13 Measure resistance across J13 3 and J13 4 Is resistance between 1 0 and 1 2 kohms Replace Gas Valve YES NO Disconnect harness from Gas Valve Does each wire have continuity between Gas Valve and Control Module YES ...

Page 42: ...ides of the baffle near the coil for blockages Is there any apparent debris or obstruction of the flue way YES NO Reset the boiler by pressing the Reset button When the boiler tries to ignite is there a strong consistent spark evident throught the sight glass YES NO Does the boiler ignite and stay running YES NO Enter the Installer Menu and place the boiler into test mode in high fire Once the boi...

Page 43: ...from Control Module J9 Measure voltage between J9 2 and J9 3 Is voltage 120 Vac 10 Disconnect 3 wire harness from Combustion Air Blower Measure continuity in each wire Continuity in each wire Replace harness Connect harness Replace Combustion Air Blower Disconnect harness from Control Module J9 Continuity in each wire of 4 wire harness yellow red white black Replace Control Module Replace harness ...

Page 44: ... 6 to Switch 3 YES NO YES NO Replace wire s YES NO Is High Temperature Supply Switch open no continuity between terminals 1 and 3 YES NO 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 High Temperature Supply Switch Resistance Chart Replace Control Module Replace High Temperature Supply Switch Is H...

Page 45: ...ection clean and secure NO Replace Flame Sensor or harness Remove Flame Sensor Is rod free of contamination Clean or replace Flame Sensor Replace Control Module Replace Flame Sensor and Burner YES YES YES NO NO Inspect burner through sight glass Is flame present NO YES _ P _ _ _ Blocking Error E 3 5 False flame detect Replace Control Module Turn Gas Shutoff Valve clockwise to closed position Follo...

Page 46: ...46 13 TROUBLE SHOOTING ...

Page 47: ... Temp Disconnect harness from Return Water Sensor Measure resistance using digital ohm meter Is resistance between 950 to 33 000 ohms Is Heat Exchanger Pump oriented properly Pump Arrow pointing down YES NO YES NO Correct wiring Install Heat Exchanger Pump in proper orientation Replace Control Module Replace Return Water Sensor ...

Page 48: ...48 13 TROUBLE SHOOTING ...

Page 49: ...with digital meter Estimate Sensor temperature Does it fall in the range of the Resistance Chart Replace Wires 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 Supply Water Sensor Resistance Chart Disconnect field wiring Is continuity between field wiring neutral and ground less than 10 ohms Is fiel...

Page 50: ...urn Temperature Sensor and Control Module J5 4 and J5 12 Continuity Measure Return Temperature Sensor resistance with digital meter Estimate Sensor temperature Do temperature and resistance fall within ranges shown in chart Replace Wires 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 Return Temper...

Page 51: ...e Replace Vent Temperature Sensor Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Do temperature and resistance fall within ranges shown in chart NO YES _ P _ _ _ Blocking Error E 5 9 Supply Sensor Shorted Disconnect J5 from Control Module Continuity between J5 11 and Switch 2 Continuity between J5 3 and Switch 4 YES NO 50 to 90 10 to 32 9K t...

Page 52: ... Replace Return Water Sensor Replace Control Module Disconnect wire harness from Vent Temperature Sensor Measure Sensor resistance Does resistance match estimated flue temperature NO YES _ P _ _ _ Blocking Error E 6 5 Flue Sens Shorted Replace Vent Temperature Sensor 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 3...

Page 53: ...53 14 WIRING DIAGRAM 14 1 Connection Diagram ...

Page 54: ...54 14 WIRING DIAGRAM 14 2 Schematic Diagram of Ladder Form ...

Page 55: ...ompanied by production of heat or heat and light Complete combustion of fuel is possible only in presence of adequate supply of Oxygen COMBUSTIBLE MATERIAL Materials made of or surfaced with wood compressed paper plant fibers or other materials capable of being ignited and burned Such material shall be considered combustible even though flame proofed fire retardant treated or plastered CONDENSATE ...

Page 56: ...Y RELIEF VALVE Valve designed to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY SHUTOFF DEVICE Device that will shut off gas supply to controlled burner in event source of ignition fails SEDIMENT TRAP Gas piping arrangement designed to collect any liquid or solid contaminant before reaching gas valve VENT Passageway used to convey flue gas...

Page 57: ...item Increase value Scroll down to next menu item Decrease value Key Boiler Status Indicator F Flame Detected P Central Heating System pump On B Combustion Air Blower On S Safety Relay Check G Gas Valve Open D DHW Pump On Service Reminder Indicator Boiler in Standby Mode Boiler Supply Water Temperature Indicator Boiler Running in Central Heat mode Combustion Air Blower Speed Indicator Boiler Runni...

Page 58: ...ump is turned on based on type of heating demand CH call is illustrated Control Module compares sup ply temperature to set point Boiler proceeds to ignition if supply temperature is less than set point Combustion Air Blower speed modulates to prepurge setting for 15 seconds Sparking initiated sequence Heat Demand DHW CH Pump on Supply Temperature Setpoint 15 Second Prepurge Ignition Sparking No Ye...

Page 59: ...ing rate according to heating demand When Boiler detects demand met will enter post purge mode then standby mode If simultaneous demand for Central Heat and DHW boiler will enter DHW Priority Mode Priority mode limits amount of time boiler can run in DHW mode to meet CH demand Max DHW Priority Time setting determines maximum time allowed for DHW heating mode Please refer to section Appendix A sect...

Page 60: ...60 APPENDIX A CONTROL MODULE ...

Page 61: ...61 APPENDIX A CONTROL MODULE ...

Page 62: ...r to Multiple Boiler Manual System Test Tool aids setup of boiler installation or diagnosis of common problems Boiler Status S T A T U S F a n S p e e d A c t u a l 4 0 0 0 R P M L o w P o w e r 1 5 6 0 R P M Combustion air Blower provides airflow through Combustion and Vent systems Fan speed status screen indicates actual and operational fan speeds in RPM high low and ignition power speed setting...

Page 63: ...cted at end of pre spark period Ignit_0 than lockout will occur Re ignition If at end of safety period no flame detected control will go to post purge removing unburned gas Re ignition attempt started following same cycle Number of re ignition attempts limited to 4 after which lockout occurs Intermittent Operation Boiler can be firing continuously for 24 hours Burner switched off and restart seque...

Page 64: ...64 APPENDIX A CONTROL MODULE ...

Page 65: ... the CH System Pump electrical terminal block See page 56 for diagram The DHW pump terminal does not function This is typical of a hydronic system design which utilizes zone valves for all CH zones and an DHW indirect tank Note Pump Mode selection depends on electrical and hydronic system design Please refer to sections 5 and 8 for recommended hydronic piping and electrical configurations Internal...

Page 66: ...set curve See figure A 2 CH Mode 2 CH with Full Outdoor Reset Boiler will permanently attempt to satisfy CH demand CH thermostat input is ignored CH set point calculated as function of outdoor temperature using outdoor reset curve See figure A 2 CH Mode 3 CH with Permanent Demand Boiler will permanently attempt to satisfy CH demand CH thermostat input is ignored CH set point is adjusted in Setting...

Page 67: ...ather reference temperatures See points A B of Reset Curve below Calculated CH set point always limited between Reset Curve Boiler Minimum Maximum temperatures See points C D of Reset Curve below Figure A 2 Outdoor Reset Curve Note Modes only function when outdoor temperature sensor connected If Open outdoor sensor detected CH set point equal to Boiler Reset Curve Design temperature Outdoor temper...

Page 68: ...his value while operating in CH Mode Allowable Range 1 100 Default Setting 100 DHW Settings D H W S E T T I N G S D H W m o d e M O D E 1 D H W s t o r e w i t h s e n s o r Two DHW modes are available DHW Mode 0 No DHW DHW Mode is disabled The DHW thermostat input is ignored and the DHW pump is not used DHW Mode 2 DHW Store with Thermostat Boiler reacts to DHW demand when DHW thermostat input clo...

Page 69: ...CH or DHW demand being present System Test has priority over any system demand while test mode activated System test mode automatically ends after 30 minutes boiler resumes normal operation The following modes are available Disabled Low power Burner starts After ignition period has finished the burner stays at low power Ignition power Burner starts Stays at ignition power High power Burner starts ...

Page 70: ...70 NOTES ...

Page 71: ...71 Date Service Performed Company Name Tech Initials Company Address Phone ...

Page 72: ...CAC BDP 7310 West Morris St Indianapolis IN 48231 ...

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