Bryan Boilers 250 User Manual

Date:

Revision:

Form:

8-4-2010

2396

Bryan Steam LLC

Installation and Operating Service Manual

Triple-Flex

High Efficiency Boilers

Date:

Revision:

Form:

8-4-2010

2396

Table of Contents

Bryan Steam LLC ..............................................................................................................................i

Installation and Operating Service Manual........................................................................................i

Table of Contents ............................................................................................................................i ii

Table s ...............................................................................................................................................v

Figures..............................................................................................................................................v

Section 1 Installation Instructions– Triple-Flex High Efficiency Boilers........................................... 1

1.1 Boiler Foundation................................................................................................................... 2

1.2 Clearance s ............................................................................................................................. 2

1.2.1 Minimum Clearances to Combustible Surface s ............................................................... 2

1.3 Receiving The Boiler.............................................................................................................. 2

1.4 Boiler Connections................................................................................................................. 3

1.4.1 Flow Connection .............................................................................................................. 3

1.4.2 Safety Relief Valve s ......................................................................................................... 3

1.4.3 Expansion Tank Connections .......................................................................................... 3

1.4.4 Drain Connection ............................................................................................................. 3

1.4.5 Condensate Drain Connection......................................................................................... 3

1.4.6 Gas Supply Connection ................................................................................................... 3

1.4.7 Drip Leg............................................................................................................................ 3

1.4.8 Gas Piping Leak Test....................................................................................................... 3

1.4.9 Venting Of Gas Train Components.................................................................................. 4

1.5 Electrical Requirement s ......................................................................................................... 4

1.6 Combustion Air Supply .......................................................................................................... 4

1.6.1 Combustion Air Openings :............................................................................................... 5

1.6.2 Louvers, Grilles, and Screens.......................................................................................... 5

1.7 Flue Gas Venting System ...................................................................................................... 6

1.7.1 Design & Installation ........................................................................................................ 6

1.7.2 Combustion Air and Venting Requirements for Canada.................................................. 7

1.7.3 Marking Of Gas Vents...................................................................................................... 8

1.8 Before Placing Boiler In Operation ........................................................................................ 8

1.8.1 Hydrostatic Test Of Boilers And System.......................................................................... 9

1.8.2 Test Of Gas Piping........................................................................................................... 9

Section 2 Start-Up and Operation Triple-Flex High Efficiency Boilers .......................................... 10

2.1 Boiler Assembly ................................................................................................................... 11

2.1.1 Triple-Flex Front Vie w .................................................................................................... 11

2.1.2 Triple-Flex Rear View .................................................................................................... 12

2.1.3 Triple-Flex Left Side Vie w .............................................................................................. 13

2.1.4 Triple-Flex Right Side View............................................................................................ 13

2.1.5 Triple-Flex Behind the Cabinet Door.............................................................................. 13

2.1.6 Pilot Spark Igniter Assembl y .......................................................................................... 15

2.1.7 Triple-Flex Left Flue Collector Vie w ............................................................................... 15

2.1.8 Triple-Flex Right Flue Collector View............................................................................. 16

2.2 SOLA Hydronic Control System .......................................................................................... 16

2.2.1 Power-up Validatio n ....................................................................................................... 16

2.2.2 Home Page .................................................................................................................... 16

2.2.3 Page Navigation............................................................................................................. 17

2.2.4 Keyboard........................................................................................................................ 17

2.2.5 Status Page.................................................................................................................... 18

2.2.6 Configuration Page ........................................................................................................ 18

2.2.7 Configuration Passwor d ................................................................................................. 19

2.2.8 Change Parameter Settings........................................................................................... 20

2.2.9 Safety Verificatio n .......................................................................................................... 20

2.2.10 Fault/Alarm Handling ................................................................................................... 21

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2.2.11 Operation Pag e ............................................................................................................ 22

2.2.12 Annunciation Pag e ....................................................................................................... 23

2.2.13 Modulation Configuratio n ............................................................................................. 23

2.2.14 Firing Rate Control Page ............................................................................................. 23

2.2.15 Advanced Setup........................................................................................................... 24

2.2.16 System Time ................................................................................................................ 24

2.2.17 Calibrate Touch Screen ............................................................................................... 24

2.2.18 Reset / Reboot Display ................................................................................................ 25

2.2.19 Outdoor Reset.............................................................................................................. 25

2.2.20 Remote Setpoint (4 – 20 mA) ...................................................................................... 26

2.2.21 Central Heat Configuration .......................................................................................... 27

2.2.22 Sound Pressure Levels................................................................................................ 27

2.2.23 Modbus Communication .............................................................................................. 29

2.2.24 Alert Codes .................................................................................................................. 29

2.3 Boiler Commissioning .......................................................................................................... 35

2.3.1 Modulation...................................................................................................................... 35

2.3.2 Test Setup...................................................................................................................... 35

2.3.3 Pre Checks And Setup................................................................................................... 35

2.3.4 Dry Ru n .......................................................................................................................... 36

2.3.5 Pilot Adjustmen t ............................................................................................................. 36

2.3.6 Initial Light Off ................................................................................................................ 37

2.3.7 Adjusting Boiler Maximum Input .................................................................................... 37

2.3.8 Adjusting Boiler Minimum Input ..................................................................................... 37

2.3.9 Gas Meter Reading s ...................................................................................................... 38

2.4 Troubleshooting ................................................................................................................... 39

Section 3 Care and Maintenanc e .................................................................................................. 50

3.1 Cleaning The Boiler And System – New Systems............................................................... 51

3.1.1 Pre-Boil Out Flushing Of Syste m ................................................................................... 51

3.1.2 Boil Out Procedure......................................................................................................... 51

3.1.3 Draining The System ..................................................................................................... 52

3.2 Replacement Boiler Installations: Protection Against Corrosion And Sediment.................. 52

3.3 Boiler Water Treatment........................................................................................................ 52

3.4 External “Fire-Side” Cleaning............................................................................................... 53

Section 4 Lead Lag........................................................................................................................ 55

4.1 General Description Of The Lead Lag Application .............................................................. 56

4.2 Lead Lag (Ll) Master General Operatio n ............................................................................. 56

4.3 System Wiring Hookup ........................................................................................................ 58

4.4 Lead-Lag Operatio n ............................................................................................................. 59

4.5 Slave Operation And Setup ................................................................................................. 60

4.6 Slave Parameters ................................................................................................................ 60

4.7 Ll Master Operation And Setup ........................................................................................... 61

4.7.1 Overall Control ............................................................................................................... 61

4.7.2 Periodic Data Polling messages .................................................................................... 62

4.7.3 Slave Status Manager.................................................................................................... 62

4.7.4 Master Active Service .................................................................................................... 65

4.7.5 Modulation Senso r ......................................................................................................... 65

4.7.6 Demand and Rat e .......................................................................................................... 66

4.7.7 Rate Adjustment............................................................................................................. 67

4.7.8 Implementation............................................................................................................... 67

4.7.9 Rate Allocatio n ............................................................................................................... 68

4.7.10 Burner Demand............................................................................................................ 70

4.7.11 Lead Drop-Stage On Error - LDSE: ............................................................................. 73

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Tables

Table 1 Minimum Clearance............................................................................................................ 2

Table 2 Electrical Requirements...................................................................................................... 4

Table 3 Boiler Draft.......................................................................................................................... 7

Table 4 Water Flow Switch Settings.............................................................................................. 14

Table 5 Gas Limiting Orifice Rough Settings ................................................................................ 15

Table 6 Sound Pressure Readings................................................................................................ 28

Table 7 Modbus Terminal s ............................................................................................................ 29

Table 8 Alert Code s ....................................................................................................................... 29

Table 9 Approximate Boiler Setting s ............................................................................................. 38

Table 10 Gas Pressure Correctio n ................................................................................................ 38

Table 11 Gas Temperature Correction.......................................................................................... 38

Table 12 R7910A Lockout and Hold Code s .................................................................................. 39

Figures

Figure 1 Minimum Clearances......................................................................................................... 2

Figure 2 Main Gas Inlet Connectio n ................................................................................................ 4

Figure 3 Triple-Flex Front View ..................................................................................................... 11

Figure 4 Triple-Flex Rear View...................................................................................................... 12

Figure 5 Triple-Flex Left Side View ............................................................................................... 13

Figure 6 Triple-Flex Right Side Vie w ............................................................................................. 13

Figure 7 Triple-Flex Behind the Cabinet Door............................................................................... 13

Figure 8 Air Flow Switc h ................................................................................................................ 14

Figure 9 Pilot Spark Igniter Assembly ........................................................................................... 15

Figure 10 Triple-Flex Left Flue Collector View .............................................................................. 15

Figure 11 Triple-Flex Right Flue Collector View............................................................................ 16

Figure 12 Home Page ................................................................................................................... 16

Figure 13 Keyboar d ....................................................................................................................... 17

Figure 14 Status Page................................................................................................................... 18

Figure 15 Configuration Menu Page.............................................................................................. 18

Figure 16 Sample Configuration Page .......................................................................................... 19

Figure 17 Change Parameter Dialog............................................................................................. 20

Figure 18 Safety Parameter Verification ....................................................................................... 20

Figure 19 Safety Parameter User Confirmation ............................................................................ 21

Figure 20 Safety Parameter Rese t ................................................................................................ 21

Figure 21 Home Page Lockout...................................................................................................... 22

Figure 22 Status Page Lockou t ..................................................................................................... 22

Figure 23 History Dialo g ................................................................................................................ 22

Figure 24 Lockout History Page .................................................................................................... 22

Figure 25 Operation Page ............................................................................................................. 22

Figure 26 Annunciation Page ........................................................................................................ 23

Figure 27 Modulation Configuration .............................................................................................. 23

Figure 28 Firing Rate Control Page............................................................................................... 23

Figure 29 Advanced Setu p ............................................................................................................ 24

Figure 30 System Time ................................................................................................................. 24

Figure 31 Display Diagnostic s ....................................................................................................... 24

Figure 32 Reset / Reboot Display.................................................................................................. 25

Figure 33 Outdoor Rese t ............................................................................................................... 25

Figure 34 Outdoor Reset Curve .................................................................................................... 26

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Figure 35 Outdoor Reset Sensor Configuratio n ............................................................................ 26

Figure 36 Air / Gas Ratio Tapping s ............................................................................................... 35

Figure 37 LL / Multi-Boiler Field Wiring ......................................................................................... 58

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Section 1 Installation Instructions–

Triple-Flex High Efficiency Boilers

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Note:

1.2.1 MINIMUM CLEARANCES TO

COMBUSTIBLE SURFACES

Please read and save for future reference the

entire instruction manual before attempting

installation of or starting the unit. Insurance and

local or state regulatory codes may contain

additional or more stringent requirements than

those contained in this manual. Installation must

conform to these codes and any other authority

having jurisdiction. This instruction manual shall

be posted and maintained in a legible condition.

1.1 BOILER FOUNDATION

Before uncrating, the boiler location should be

prepared. The boiler should set upon a good

level concrete floor. If the boiler is not level or

the floor is not in good condition, a concrete

foundation should be built, the dimensions being

larger than the outside dimensions of the boiler

base.

4” high housekeeping pad is

suggested.

Figure 1 Minimum Clearances

WARNING:

Triple-Flex

150 - 300

Do not install boiler on combustible

flooring.

DIM. Description

Clearance Above Top of

18”

Boiler

Right Side

18”

From Chimney or Vent

1.2 CLEARANCES

Collector

Measured 18”

Horizontally

Left Side – Tube Access

See Table 1 for minimum clearances to walls,

ceilings, or obstructions. The clearances in

Side

Construction

From Chimney or Vent

Standard 27”

Table

are intended as

general

recommendation only. Local codes must be

applied to specific installations and the minimum

clearances established accordingly. Provisions

must also be made for service, accessibility and

clearance for piping and electrical connections.

Do not obstruct combustion air and ventilation

openings with piping or any other construction.

All boilers must be installed in a space that is

large compared to the boiler.

Collector

Measured 18”

Vertically

Front of Boiler – Gas Train

& Control Panel End

Rear of Boiler Opposite

48”

Gas Train & Control Panel 18”

End

Table 1 Minimum Clearance

NOTE:

These boilers should be installed in a room that

is large compared to the size of the boiler. They

are not intended for alcove installation and are

suitable for installation on non-combustible

flooring only. Adhere to all applicable local

codes regarding boiler installation and

clearances.

1.3 RECEIVING THE BOILER

The boiler is shipped from the factory with (4)

shipping feet/legs bolted to the skids. These are

provided to facilitate unloading/moving with a

forklift. Lifting lugs are also provided to enable

over-head lifting. The shipping feet/legs MUST

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BE REMOVED after the boiler is set in-place on

1.4.5 CONDENSATE DRAIN

CONNECTION

its

concrete

foundation

before

any

piping/electrical connections are made.

It is

recommended that the plastic protective cover

be left on as long as possible to reduce finish

damage from the installation.

A 1” MPT connection is provided to drain the

condensed products of combustion from a trap

located beneath the boiler. This must be run to

a drain using stainless steel or PVC piping. The

condensate temperature should never exceed

212^oF and the pH of the condensate should

never be greater than 3.5. NO VALVE is to be

installed in this line from the boiler to point of

discharge.

1.4 BOILER CONNECTIONS

Do not run any pipes along the tube access

panel side of the boiler. Maintain clearances as

shown on the dimensional drawing for servicing

of the boiler tubes. Provide at least 48" from the

front of the boiler, unless a larger dimension is

indicated on the dimensional. All piping should

be designed and installed to avoid any loadings

on the boiler connections or piping.

1.4.6 GAS SUPPLY CONNECTION

The installation must conform completely to the

requirements of the authority having jurisdiction,

or in the absence of such, requirements shall

conform in the U.S. to the current National Fuel

Gas Code, ANSI Z223.1-1984, or in Canada to

the current Natural gas and propane installation

code (CAN/CSA B149.1-05), and applicable

regional regulations for the class; which should

be followed carefully in all cases. Authorities

having jurisdiction should be consulted before

installations are made.

1.4.1 FLOW CONNECTION

The system supply and return flow connections

are shown on Figure

and Figure

respectively. A gate valve should be installed on

the boiler outlet and inlet lines. This allows the

boiler to be isolated from the heating system for

draining and servicing.

1.4.2 SAFETY RELIEF VALVES

1.4.7 DRIP LEG

Safety relief valve(s) are shipped loose.

Connections are provided in the top of the boiler

for the safety relief valve(s). The safety relief

valve discharge piping must be the same size as

the safety relief valve discharge opening and run

to a point of safe discharge. Avoid over-

tightening as this can distort valve seats. All

piping from the safety relief valve(s) must be

independently supported with no weight carried

by the valve.

A drip leg, or sediment trap, must be installed in

the gas supply line. See Fig. 1.5A. The gas line

must be connected to a supply main at least as

large as the gas train connection at the boiler.

This connection should be made with a union so

that the boiler gas train components and burner

may be easily removed for service.

1.4.8 GAS PIPING LEAK TEST

1.4.3 EXPANSION TANK

CONNECTIONS

Leaks shall be checked using a soap and water

solution.

Connection(s) to an expansion tank are to be

provided by others in the system piping separate

from the boiler.

After completion of the gas-piping hookup, the

installation must be checked for leaks. All joints

up to the main motorized gas valve shall be

checked. A pressure gauge shall be installed

down stream of the main motorized gas valve

and up stream of the manual gas shutoff valve in

the closed position to ensure the main motorized

1.4.4 DRAIN CONNECTION

valves are not leaking by.

commissioning, the remainder of the gas train

joints down stream of the main motorized gas

During

A drain valve must be installed on the boiler

drain connection, the same pipe size as this

connection, to allow draining of the boiler.

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valve shall be tested for leaks.

Model

TF300/250

TF200/150

200 V – 240 V / 60 Hz / 3 Ph

Blower Motor

3 (4.02)

N/A

KW (HP)

Full Load

Amps¹

1.4.9 VENTING OF GAS TRAIN

COMPONENTS

15.6

N/A

Service Fuse

(3) 20 Amp

400 V – 480V / 60 Hz / 3 Ph

Blower Motor

N/A

KW (HP)

Full Load

Amps¹

N/A

Service Fuse

200 V – 240 V / 60 Hz / 1 Ph

Blower Motor

KW (HP)

N/A

1.05 (1.41)

Full Load

N/A

Amps¹

Service Fuse

(2) 7 Amp

Table 2 Electrical Requirements

Figure 2 Main Gas Inlet Connection

Equipment Grounding

The boiler must be grounded in accordance with

the current American National Standard

Electrical Code, ANSI/NFPA #70.

Normally open vent valves (when supplied) -

These valves must be piped to outdoors using

pipe no smaller than that of the valve.

1.6 COMBUSTION AIR SUPPLY

Gas pressure switches – All gas pressure

switches provided are of the VENTLESS type

and do not require venting to atmosphere.

Combustion Air:

For proper combustion it is necessary to provide

the boiler room with appropriate openings for

fresh air supply. Temporary air intakes such as

windows and doors should be avoided since

they may be closed. In addition to air needed

for combustion, sufficient air must be supplied

for ventilation as well as other air consuming

equipment that may be present in the boiler

room. Often when personnel are working in the

boiler room, combustion air openings are closed

due to the temperature of the outside air. THIS

MUST BE AVOIDED AT ALL COSTS!

Provisions should be made to heat the outside

combustion air, if necessary, for personnel

comfort.

Gas pilot pressure regulator – A vent limiter for

the pilot pressure regulator is provided

eliminating the need to run a vent line to

atmosphere.

NOTE:

Do not use Teflon tape for threaded joints in gas

piping.

1.5 ELECTRICAL REQUIREMENTS

WARNING:

All electrical connections must

conform to the National Electrical

Code and to all other applicable State

and Local Codes. See boiler wiring

diagram and equipment list for specific

voltage requirements.

Positive means for supplying an ample amount

of outside air, allowing for the complete

combustion of the gas, must be provided.

Movable combustion air dampers, automatic or

manually adjustable, must be electrically

Full load Amps include blower and control

circuit.

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interlocked with the boiler to prevent boiler

operation if the dampers are closed.

One Permanent Opening Method

One opening commencing within 12” of the top

of the room shall be provided. The opening

shall be directly to the outside or shall be ducted

to the outside with a horizontal or vertical duct.

Combustion air openings must never be blocked

or obstructed in any manner.

The boiler room must be at a positive or neutral

pressure relative to the outdoors. A negative in

the boiler room will result in downdraft problems

and incomplete combustion due to the lack of

air.

The opening or duct shall have a minimum free

area of:

1 in²/ 3000 BTU /hour of the total input ratting of

all appliances (boilers) in the room.

WARNING!

Not less than the sum of the areas of all vent

connectors in the room. A “vent connector” is

defined as the pipe or duct that connects a fuel

burning appliance to a vent or chimney.

Failure to provide an adequate air

supply will result in boiler damage and

hazardous conditions in the building

(fire and asphyxiation hazard as well

as equipment damage).

Additional area must be provided for other air

consuming equipment in the room.

Mechanical Air Supply Systems

1.6.1 COMBUSTION AIR OPENINGS:

The combustion air supply may be provided by a

mechanical air supply system. If utilized, the

combustion air must be provided from the

outside at a minimum rate of 0.35 ft³/min. for

every 1000 Btu/hr. input for all appliances

located in the space.

The design of combustion air openings MUST

comply with local and/or State codes or the

authority having jurisdiction. As a minimum,

combustion air openings to the boiler room shall

be provided as follows:

Note:

If exhaust fans are utilized, additional air shall be

provided to replace the exhausted air.

Combustion air provided solely from an indoor

source is discouraged. No dimension for a

round or rectangular opening shall be less than

3”.

Each boiler and other appliance must be

interlocked to prevent operation when the

mechanical air supply system is not in operation.

Two Permanent Opening Method

If the combustion air is provided by a buildings

mechanical ventilation system, the system shall

be sized to provide the specified combustion air

in addition to the ventilation air requirements.

One opening starting within 12” of the top of the

boiler room and one starting within 12” of the

bottom of the boiler room shall be provided. The

openings shall be open directly to the outside or

ducted directly to the outside.

1.6.2 LOUVERS, GRILLES, AND

SCREENS

When directly open to the outside or ducted to

the outside by vertical ducts, each opening or

duct shall have a minimum fee open area of 1

in²per 4000 BTU total input rating of the

boiler(s) in the room.

Louvers and Grilles:

The required size of openings for combustion,

ventilation, and dilution air shall e based on the

net free area of each opening. Where the free

area through a design of louver, grille, or screen

is know, it shall be used in calculating the size

opening required to provide the free area

If ducted to the outside through horizontal

ducts, each opening or duct shall have a

minimum free area of 1 in²per 2000 BTU total

input rating of the boiler(s) in the room.

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specified. Where the louver and grille design

and free area are not know, it shall be assumed

that wood louvers have a 25 percent free area,

and met louvers and grilles have 75 percent free

area. Non-motorized louvers and grilles shall be

fixed in the open position.

BOCA, National Mechanical Code

WARNING:

Do not locate air intakes where

petroleum distillates, CFC’s,

detergents, volatile vapors or any

other chemicals are present. Severe

boiler corrosion and failure will result.

Screens

Minimum Screen Mesh Size:

Screens shall not be smaller than 1/4 “ mesh.

Motorized Louvers:

Motorized louvers shall be interlocked with the

appliance so they are proven in the full open

position prior to main burner ignition and during

main burner operation. Means shall be provided

to prevent the main burner from igniting should

the louver fail to opening during burner startup

and to shut down the main burner if the louver

close during burner operation.

1.7 FLUE GAS VENTING SYSTEM

Triple-Flex boilers are Category IV appliances

that vent with a positive exhaust vent pressure

and with a temperature that is likely to cause

condensation. Any venting system used with

the Triple-Flex boiler must comply with the

requirements for Special Gas Vents per UL

Category Code (CCN) DGSH, which are UL

Listed per UL 1738 or UL Category Code

DGSH7, which are cUL Listed (Canada) per UL

1738.

Combustion Air Ducts

Combustion air ducts shall comply with the

following:

Ducts shall be constructed of galvanized steel or

WARNING:

material having equivalent corrosion

resistance, strength and rigidity.

The Triple-Flex boiler is NOT certified

for use with other types of venting

excepting Special Gas Vents. Use of

any other types of venting may cause

vent failure resulting in serious injury

or death.

Ducts shall terminate in an unobstructed space,

allowing free movement of combustion air to the

appliances.

Ducts shall serve a single space.

Ducts shall not serve both upper and lower

combustion air openings where both such

openings are used. The separation between

ducts serving the upper and lower combustion

air openings shall be maintained to the source of

combustion air.

1.7.1 DESIGN & INSTALLATION

Ducts shall not be screened where terminating

in an attic space.

Horizontal upper combustion air ducts shall not

slope downward toward the source of

combustion air.

A qualified venting professional experienced in

venting system designs should design the boiler

vent system. The vent size must be NO LESS

THAN 8” IN DIAMETER and sized such that the

pressure drop between the boiler and the point

of discharge does not exceed 0.20” WC. While

the vent must be UL Listed Special Gas Vent

per Category Code DGSH or DGSH7 for

Canada, Bryan Steam, LLC recommends the

use of venting components fabricated from

AL29-4C® material. The vent installation must

be in strict compliance with the vent

For informational purposes, there are several

codes that address the amount of air and/or size

of the opening(s) in walls for combustion air.

NFPA 54, National Fuel Gas Code (ANSI

Z223.1)

ASME CSD-1, Controls and Safety Devices for

Automatically Fired Boilers

manufacturers requirements.

combustible materials and

Clearances to

supporting

ASME Section VI, Recommended Rules for

Care and Operation of Heating Boilers

requirements, per the vent manufacturers

installation instructions, must be maintained.

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Horizontal sections of the flue vent system must

be pitched back towards the boiler at ¼ inch per

foot to avoid condensate pooling and allow for

proper drainage. Venting may be horizontal,

through the wall installation or vertical, through

the roof installation. The vent system, including

terminus, must be sized in accordance with the

flue gas flow(s) and pressure drop(s) per Table 3 .

Note:

An existing masonry chimney may be utilized

PROVIDING that the existing chimney is lined

with Special Gas Vent material(s), primarily

AL29-4C®. There are venting manufacturers

that have these products available.

1.7.2 COMBUSTION AIR AND VENTING

REQUIREMENTS FOR CANADA

Flue Gas

Comb Air

Flow,

Req.

SCFM

Permissible

∆P Thru

Venting

ACFM

@40%X

Boiler Model

Canadian

Standard

CAN/CSA-B149.1-05,

@40%XS

Natural gas and propane installation code

specifies venting systems and air supply for

appliances in Section 8. Paragraph 8.1.4 states

“Air supply shall be provided in accordance with

Clause 8.4 when either an appliance or a

combination of appliances has a total input

exceeding 400,000 Btuh”. Air supply is defined

as combustion air, excess air, flue gas dilution

air, primary air, secondary air, and ventilation

air. The air supply requirements below are a

summation of Clause 8.4 specific to the Triple-

Flex boiler.

A60^oF

200^oF

0.2” WC

(Max)

0.2” WC

(Max)

0.2” WC

(Max)

0.2” WC

(Max)

TF-150

TF-200

TF-250

TF-300

452

603

753

904

330

441

550

661

Table 3 Boiler Draft

Note:

Air Supply Requirements per CAN/CSA-

B149.1-05 for Appliances having an input

exceeding 400 MBH.

NFPA 54-2009 (ANSI Z223.1-2009) paragraph

12.7.3.3 states, “The sizing of gas vents for

Category II, Category III, and Category IV

Appliances shall be in accordance with the

appliance manufacturers instructions.”

Ventilation Air: an opening for ventilation air at

the highest point that opens to the outdoors shall

provide Ventilation of the space. The cross

sectional area of this opening shall be at least

10% of the area required for combustion air, but

in no case shall the cross-sectional area be less

that 10 in²(6500mm²).

Combustion Air: For combustion air where the

air supply is provided by natural airflow from

outdoors, in addition to the opening for

ventilation air, there shall be permanent opening

having a total cross-sectional free area of not

less than 1 in²for each 30,000 BTU/hr. (70 mm²

for each kW) of the total rated input of the

boiler(s). The location of the opening(s) shall

not interfere with the openings for ventilation air.

Please refer to CAN/CSA-B149.1-05, Para.

8.4.4, for combustion air openings if there are

natural draft, fan assisted or power draft

assisted equipment in the space.

WARNING:

Do not use a barometric damper with

this boiler. This is a positive pressure

system. The use of a barometric

damper may cause flue gases to leak

into the boiler room.

The boiler vent must not be connected to any

portion of another vent system without

consulting the vent manufacturer. The boiler

shall not be connected to any part of a vent

system serving a Category I or Category II

appliance, nor shall a Category I or Category II

appliance be connected to the vent system

serving this boiler. Improper connection of

venting systems may result in leakage of flue

gases into building spaces.

When an air supply duct is used to supply

combustion air, it’s discharge opening shall be

located where there is no possibility of cold air

affecting steam or water lines or other

temperature sensitive equipment.

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shaft used for return air, hot air,

ventilating air, or combustion air.

An appliance that operates at a positive

vent pressure shall not be connected to

a venting system serving any other

Combustion Air Supply Dampers, Louvers,

and Grilles

•

The free area of the combustion air supply

opening shall be calculated by subtracting the

blockage area of all fixed louvers, grilles or

screens from the gross area of the opening.

Openings in a fixed louver, grille, or screen shall

have no dimension smaller than ¼” (6 mm).

No manually operated damper or manually

operated adjustable louvers are permitted.

appliance.

The Triple-Flex boiler

operates at a positive vent pressure.

A factory-built chimney used for venting

an appliance shall be certified.

Vent Sizing

motorized damper or louvers shall be

•

A vent or chimney serving a single

interlocked so the burner(s) cannot operate

unless the damper or louver is in the fully open

position.

appliance shall provide effecting venting

and shall be sized so that it’s effective

area is not less than that of the flue

outlet diameter of the boiler and in

accordance with engineering venting

tables acceptable to the authority having

jurisdiction.

A vent or chimney serving more than

one appliance shall provide effective

venting and shall be sized in

accordance with good engineering

practice, such as by the use of

engineering venting tables acceptable to

the authority having jurisdiction.

Mechanical Combustion Air Supply

When combustion air is supplied by mechanical

means, an airflow sensing device shall be

installed and wired into the safety limit circuit of

the primary safety control to shut off the gas in

the even a an air supply failure.

•

Appliance Venting per CAN/CSA-B149.1-

Paragraph 8.9 of CAN/CSA-B149.1-05 addresses

“Appliance Venting”. Paragraphs 8.9 through 8.31

address many facets of flue gas vents, many of which

do not apply to the Triple-Flex boiler, which is a

Category IV listed appliance requiring the use of

special venting systems as previously described.

1.7.3 MARKING OF GAS VENTS

Where solid and liquid fuels are used, gas vents,

must be plainly and permanently identified by a

label. The label should read, "This gas vent is

for appliances that burn gas only. Do not

connect to incinerators or solid or liquid fuel

burning appliances."

This label must be attached to the wall or ceiling

at a point near where the gas vent connector

enters the wall, ceiling or chimney.

NOTE:

Please note that the information provided in this

manual relative to the Canadian Standard is not

meant to be all-inclusive. Reading the entire

Standard is strongly suggested.

approval of all system designs must be

acceptable to the authority having jurisdiction.

The final

The authority having jurisdiction must determine

whether their area constitutes such a locality.

•

Venting for Category IV appliances shall

be as specified or furnished by the

manufacturer of the listed appliance.

The Triple-Flex boiler is a Category IV

appliance requiring the use of special

vent that is certified.

Solid Fuel Appliance Vents

Gas appliances shall not be vented to a vent or

a chimney that serves a solid-fuel burning

appliance.

•

A special venting system shall be

installed in accordance with the terms of

it’s listing and the vent manufacturers

certified installation manual.

A flue gas vent or a vent connector shall

not be installed in either a duct or a

1.8 BEFORE PLACING BOILER IN

OPERATION

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1.8.1 HYDROSTATIC TEST OF

BOILERS AND SYSTEM

After completing the boiler and burner

installation, the boiler connections, fittings,

attachments and adjacent piping must be

inspected for leaks by filling the unit with water.

The pressure should be gradually increased to a

pressure just below the setting of boiler safety

relief valve(s).

Remove the boiler tube access panels (see

dimensional drawing in the boiler manual).

Inspect the tube to header joints to be certain

that all tube fittings are sealed.

This is

necessary because, although the boiler is

hydrostatically tested at the factory, minor leaks

in fittings and at attachments can develop from

shipping

vibration

from

installation

procedures. It is often necessary to retighten

such fittings after installation and after the boiler

has been operated for some time. Replace tube

access panels before proceeding to start boiler.

1.8.2 TEST OF GAS PIPING

Reference the gas system test under paragraph

Gas Supply Connection, in this manual.

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Section 2 Start-Up and Operation

Triple-Flex High Efficiency Boilers

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2.1.1 TRIPLE-FLEX FRONT VIEW

WARNING:

Improper servicing and start-up of this

equipment may create a potential

hazard to equipment, operators, or

persons in the building.

Only fully trained and qualified

personnel should do servicing and

start-up.

WARNING:

Before disconnecting or opening any

fuel line, cleaning or replacing parts of

any kind take the following

precautions.

Turn OFF the main fuel shutoff valves,

including the pilot gas cock if

applicable.

Turn OFF all of the electrical

disconnects to the burner, boiler and

any other equipment or systems

electrically interlocked with the burner

or boiler.

Figure 3 Triple-Flex Front View

1. The boiler cabinet door provides easy

access to boiler and burner components.

This door should remain closed during

normal operation to ensure proper flow of air

around the boiler flue collector.

All cover plates, enclosures, and

guards must be in place at all times

except during maintenance and

servicing.

2. The boiler supply water connection provides

heated water to the system.

connection is a standard ANSI 150# class 3”

flange.

This

3. The boiler water pressure gauge is 2”

diameter and will have a range not less than

1-1/2 nor more than 3-1/2 times the

pressure setting of the boiler safety relief

valve.

4. The boiler water temperature gauge is 2”

diameter and is located so that it will indicate

the boiler water temperature at the supply

water connection of the boiler.

5. The boiler touch panel display provides a

human interface for controlling the boiler.

Controlling the boiler with the touch panel

display will be explained in section 2.2.

6. The boiler on / off switch will turn on or off

the 120 volt ac control voltage for every

electrically connected device. This includes

2.1 BOILER ASSEMBLY

The Triple-Flex boiler is a fully integrated

assembly consisting of a Metal Fiber Pre-Mix

Burner Head and the necessary fittings, valves,

and safety devices. The boiler equipment list

provided in the boiler manual lists the

components supplied for the boiler assembly.

Refer to the boiler dimensional for location

dimensions.

description of the major

components follows. For additional information

refer to the manufactures literature provided in

the boiler manual.

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the touch panel display. There is a soft

switch (paragraph 2.2.11) provided with the

SOLA hydronic control that will put the boiler

into standby for an indefinite period of time.

2.1.2 TRIPLE-FLEX REAR VIEW

WARNING:

The boiler on / off switch will not turn

off the 3 phase high voltage power to

the motor.

7. The boiler lockout reset button is a push

button used to reset the hydronic control

after a boiler failure.

8. The power on light will be white in color and

indicates that there is 120 volts ac being

supplied to electrically connected devices.

9. The enabled light will be green in color and

indicates that the boiler is enabled. Enabled

is a state in which the boiler is allowed to

operate within the boiler’s predefined

parameters.

10. The fuel on light will be amber in color and

indicates that the boiler is firing and

producing heated water.

11. The boiler lockout light will be red in color

and indicates that the boiler has failed. The

Figure 4 Triple-Flex Rear View

SOLA

control

will

have

additional

1. The flue gas vent is 8” diameter and

exhausts products of combustion. Refer to

section 1.7 for installation details.

information displayed on the touch panel

display. These failures will be explained in

section 2.3.9.

2. The rear jacket access panel provides

access to the combustion air blower for

servicing.

3. The boiler return water connection receives

cooled water from the system.

This

connection is a standard ANSI 150# class 3”

flange.

4. The drain connection is 1” NPT and provides

a means for draining water from the boiler.

For installation details refer to paragraph

1.4.4.

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1. Main gas inlet connection. This connection

is a 2” male national pipe thread.

2.1.3 TRIPLE-FLEX LEFT SIDE VIEW

2. Condensate Drain Connection.

This

connection is a 1” male national pipe thread.

For installation details refer to paragraph

1.4.5.

3. This jacket access panel will permit access

to the majority of the boiler devices.

4. These jacket access panels will permit

access to the flue collector. There is no

practical reason for the removal of these

panels.

5. This jacket access panel will permit access

to the condensate trap. The condensate

trap is provided with a ½” NPT plugged

connection for cleanout purposes.

6. This jacket access panel will permit access

to the primary air-to-air exchanger.

Figure 5 Triple-Flex Left Side View

1. This jacket access panel will permit access

to the primary air-to-air exchanger.

2. This jacket access panel will permit access

to the primary air-to-air exchanger and the

boiler convection tube access panels.

3. These jacket access panels will permit

access to the convection and furnace tube

access.

2.1.5 TRIPLE-FLEX BEHIND THE

CABINET DOOR

4. Flame observation port. This port provides

visual access to observe the pilot and main

flame during operation and service.

5. This jacket access panel will permit access

to the majority of the boiler devices.

WARNING:

The flame observation port will

become very hot during normal

operation. Burn injuries can occur if

come in contact with the skin.

2.1.4 TRIPLE-FLEX RIGHT SIDE VIEW

Figure 7 Triple-Flex Behind the Cabinet Door

1. Auxiliary gas shutoff valve actuator.

2. Low fire displacement adjustment that can

be adjusted by removing the cap and

rotating the slotted screw clockwise to

increase gas flow and counter-clockwise to

decrease gas flow.

Fig. 2.1.2 Triple-Flex Rear View

Figure 6 Triple-Flex Right Side View

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port is also used to record the furnace

pressure.

NOTE:

15. Boiler water flow switch. The boiler water

flow switch is adjustable within the

parameters listed in the table.

The low fire displacement final adjustment

should be made at low fire only.

3. Main gas pressure regulating and shutoff

valve actuator. The pressure regulating

actuator provides slow opening fast closing

safety shutoff and air/gas ratio control. The

actuator controls the pressure difference

across the gas limiting orifice valve (Figure 7

item 26) as a function of the pressure

difference across the furnace section so that

the air to gas ratio remains constant

irrespective of air volume changes. There is

no need for an upstream constant pressure

regulator when the supply gas pressure

does not exceed 56 inches of water column.

A minimum of 14 inches of water column

must be supplied at the gas inlet connection

(Figure 6 item 1). The supply pressure can

be measured at the test port (Figure 7 item

28).

Mode Of Operation

Settings

Switch

Closed

30 gpm

52.1

Switch

Open

12 gpm

46.1

Minimum

Maximum

gpm

Table 4 Water Flow Switch Settings

16. Low Water Cutoff (Manual Reset Probe

Type).

17. Combustion air-flow switch.

An airflow

switch is provided to prove that air is being

provided to the burners before main flame

can be established. The airflow switch can

be adjusted by turning the screw (Figure 8

item A) clockwise to increase the pressure

setting and counter-clockwise to decrease

the pressure setting. The switch will open

on pressure drop. When the blower is

running there should be continuity between

the common and the normally open contacts

(Figure 8 item B and C). When the blower is

interrupted the switch should open and

cause a safety shutdown.

NOTE:

The supply pressure is not static. The supply

pressure is at the maximum full flow of gas

through the burner.

4. Manual main gas shutoff valve.

5. Pilot ignition transformer.

6. Manual pilot gas shutoff valve.

7. Pilot gas pressure regulator. This regulator

provides a constant gas pressure to the pilot

when the solenoid valve is energized. The

pressure can be adjusted by removing the

cap and adjusting the slotted screw

clockwise to increase the pressure and

counter-clockwise to decrease the pressure.

The pilot gas supply is taken upstream of

the main gas cock so the pilot may be

lighted and adjusted with the main gas cock

closed.

8. Low pilot gas pressure switch (Manual

Reset)

9. Pilot spark igniter assembly. For further

detail see Figure 9.

10. Pilot gas solenoid valve.

Figure 8 Air Flow Switch

11. Flame scanner.

12. Main gas manifold pressure test port (1/4”

NPT).

13. Main high gas pressure switch (Manual

Reset). This switch should be set 1” of

water column above the maximum gas

manifold pressure.

18. High burner air pressure switch manual

reset. This switch will trip when the air

pressure in the burner rises above the set-

point, indicating that the burner has become

plugged with dust or other foreign matter.

19. Gas and air mixer assembly.

20. Main 3-phase power connection and fuse

14. Pilot gas pressure test port (1/4” NPT). This

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block.

2.1.6 PILOT SPARK IGNITER

ASSEMBLY

21. Control circuit transformer.

22. 24 volt ac transformer.

23. 12 volt dc power supply.

24. SOLA hydronic and flame supervision

control.

25. Repeat cycle timer. This timer will ensure

that a forced shut down and pre-start safety

check is performed at least once in a 24

hour period.

This timer has been

incorporated into the SOLA control for newer

boilers.

Figure 9 Pilot Spark Igniter Assembly

26. Gas limiting orifice valve. This valve is used

to increase or decrease the gas / air ratio for

1. Spark grounding screw.

2. Pilot igniter gas orifice (#49 Drill)

3. Shell body ¾”.

4. Gland nut.

5. Igniter electrode.

6. Brass bushing.

combustion.

Adjustments are made by

removing the cap and using a flathead

screwdriver. Clockwise rotation will increase

the flue outlet % O2 levels and counter-

clockwise will decrease the flue outlet % O2

level. Starting point adjustments are listed

in the table. This vale is factory set and the

number of turns out is written in black

adjacent to the adjustment cap.

7. Gas inlet fitting.

2.1.7 TRIPLE-FLEX LEFT FLUE

COLLECTOR VIEW

Turns Out From

Boiler Model

Bottom

TF300

TF250

TF200

TF150

8-1/2 to 9

6-1/2 to 7

Table 5 Gas Limiting Orifice Rough Settings

27. Main low gas pressure switch (Manual

Reset). This switch should be set 2 – 3

inches of water column below the minimum

required supply gas pressure.

28. Supply gas pressure test port (1/4” NPT).

29. (-) Air pressure sensing line connection.

30. (+) Air pressure sensing line connection.

31. (-) Gas pressure sensing line connection.

32. (+) Gas pressure sensing line connection.

33. Burner internal temperature fuse. This fuse

senses the internal burner temperature and

will open at a temperature greater than

425^oF.

Figure 10 Triple-Flex Left Flue Collector View

1. 3” Lower drum cleanout and inspection

opening.

2. Furnace tube access panel.

3. Convection tube access panel.

4. Primary air-to-air exchanger access cover.

5. ASME name-plate stamping.

6. Combustion air blower.

7. 3” Upper drum cleanout and inspection.

8. ASME Safety relief valve.

9. Air filter 20” x 25”. This filter is a polyester

coated fiberglass. The frame is made of

fiberboard and has two tin-plated steel grills

(one bonded to each side) as well as sealed

corners to prevent dust leakage. Filters are

marked with size and airflow direction.

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Actual length and width are 3⁄8” less than

trade size shown. Filters meet UL Class 2

flame retardance requirements. Maximum

temperature is 180° F.

2.2.2 HOME PAGE

Make sure a screen similar to Figure 12 appears

after the system is completely powered up. The

directional map shown before each page

description in this manual will start with this

2.1.8 TRIPLE-FLEX RIGHT FLUE

COLLECTOR VIEW

symbol

Pressing this symbol will return

you to the home page.

Figure 11 Triple-Flex Right Flue Collector View

Figure 12 Home Page

1. High primary air-to-air exchanger pressure.

This switch will trip when the air pressure in

the primary air-to-air exchanger rises above

the set-point, indicating that the primary air-

to-air exchanger has become plugged with

dust or other foreign matter.

2. Condensate trap cleanout. This connection

is ½” NPT.

3. Condensate trap. The condensate trap is

welded and fixed into place.

On multi-boiler applications, each boiler in the

hydronic system is represented on the Home

page by an icon and name. Pressing the boiler

icon allows the user to zoom in on that boiler

and see specific details about it. These details

are provided on a new page, which can include

additional buttons that display additional detail

and operation information, which itself leads to

other pages. The pages are traversed in a tree

structure method. The boiler icon button will

appear in one of four colors indicating the boiler

status.

4. Flue vent temperature sensor.

2.2 SOLA HYDRONIC CONTROL

SYSTEM

•

Blue: Normal operation

Red: Lockout condition

Gray: Standby mode (burner switch off)

Gray and crossed out: Hydronic control

The Triple-Flex is equipped with a Honeywell

SOLA control system (Figure 3 item 5). This

section will explain navigation, configuration,

history, and diagnostics.

communication error (disconnected or powered

off)

Up to 8 boilers can be displayed on the System

Home page.

2.2.1 POWER-UP VALIDATION

The name of each boiler is displayed next to the

boiler icon. When Lead Lag is enabled, the

system header temperature and firing rate are

displayed for each boiler. When the burner is in

standby or not firing the firing rate is not

displayed.

Flip the power button, (Figure 3 item 6), to the

on position. After a few seconds the Home page

will appear and the POWER LED will be blinking

when the device is properly powered. Select the

Setup button to adjust the contrast as desired.

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NOTE:

2.2.4 KEYBOARD

The boiler name may be cut off on the Home

page when all boilers are present for the

hydronic system.

The Home page also includes a System

Analysis button that allows the user to view

status information on a system-wide (that is,

multiple boiler) basis. The user can choose

which status information to compare from the

boilers in the system. Pressing the Setup button

on the Home page displays miscellaneous

display setup and diagnostic functions.

2.2.3 PAGE NAVIGATION

Figure 13 Keyboard

The System Display, (Figure 3 item 5), presents

information and options in a paged manner.

Pages are displayed in a tree structure in which

the user navigates up and down to arrive at the

desired function. The page descriptions are

provided below so that you can understand the

purpose of each and view the selections,

parameters, and information that are available or

required on each. Most pages have a Home

Some pages request user entry of characters.

When this type of input is required, a keyboard

page appears, as shown in Figure 13.

The text box at the top of the screen displays the

current (or default) setting of the user input. The

user can add to this text, clear it, or change it.

The Shift key on the left side of the screen shifts

between upper- and lowercase characters.

Pressing the Shift key toggles the keyboard from

one mode to the other (continuous pressing of

the Shift button is not required). The OK button

should be pressed when the user is done

entering the text input. The Cancel button on the

bottom of the screen allows the user to ignore

any text changes that have been made and

keep the original text value. Pressing the OK or

Cancel buttons returns the user to the page

displayed prior to the keyboard page.

button

in the top-left corner of the screen

and a Back button in the top-right corner of the

screen. The Home button returns the user to the

Home page and terminates any operation in

progress. The Back button

returns the user

to the previous page. Two other icons may be

noticed near the boiler name. A bell will be

displayed if the system is in lockout that reset

will be required. A padlock will be shown on

screens that a password is needed to change

the parameter. An unlocked padlock

indicates the password has been entered to

change the parameter (either the installer or

OEM), depending on the security level entered.

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2.2.5 STATUS PAGE

Details:

Used to view boiler detail status information.

►

History:

Used to view R7910 history.

Modulation:

Used to toggle between two different status

displays: modulation, and setpoints.

2.2.6 CONFIGURATION PAGE

►

►CONFIGURE

Figure 14 Status Page

The status page (Figure 14) is displayed when a

boiler is selected on the Home page. The status

page displays the current condition of the boiler

and displays some of the more important

configuration settings.

The boiler name is

displayed in the title bar of the status page.

NOTE:

When the boiler has no name defined, the

display will use the Modbus address to identify

the boiler.

Figure 15 Configuration Menu Page

The standard status page displayed for the

Triple-flex boiler contains summary status

information as shown in Figure 14. Any status

information not applicable for the installation is

blanked out on the screen. Buttons on this

screen include:

The configuration page allows the user to view

and set parameters that define how the boiler

functions in the hydronic heating system.

Configuration parameters for any boiler

connected in the Global Modbus™ network can

be accessed from the display. Press the boiler’s

button on the Home page to acess the Status

page. Pressing the Configure button on the

status page starts a configuration session. The

Configure:

Used to configure the R7910 (see “Configuration

Page” 2.2.6 page 18 for more details).

configuration page contains

menu of

parameters grouped into functional areas that

the user selects for configuration (see Figure

15).

Operation:

Used to perform daily/frequent functions with the

R7910, such as setpoint adjustment, etc. (See

“Operation Page” 2.2.11 page 22 for more

details.)

No specific order for configuring the boiler is

required. All parameters are enabled for editing,

though some may not be applicable (e.g., a

configuration parameter may disable a boiler

feature). Selecting a parameter group from the

Diagnostic:

Used to view R7910 diagnostic information.

displays

parameters

exclusively

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applicable for the functional group on the page

(Figure 16).

for a parameter that has a lower access level

than the access level achieved by an earlier

password entry for any configuration group (as

long as the user stays in the configuration

pages). The user only needs to enter a

password once until a parameter that has a

higher access level is selected.

The user enters the password from a keyboard

as shown in Figure 13. After the password is

entered, select the OK button. The Cancel

button aborts the password login.

WARNING:

Explosion Hazard.

Figure 16 Sample Configuration Page

Improper configuration can cause fuel

buildup and explosion. Improper user

operation may result in PROPERTY

LOSS, PHYSICAL INJURY or DEATH.

Changing parameters, must be

attempted by only experienced and/or

licensed burner / boiler operators and

mechanics.

These parameters can be edited, and when the

user is finished, control returns back to the

configuration menu page. Each parameter is

displayed in its group. If there are more

parameters than will fit on the screen, a vertical

scroll bar allows the user to scroll up and down

to view all parameters. The parameter name is

displayed on the left and the current setting is

displayed in the text box on the right.

Three levels of write access to boiler parameters

are permitted. Each access level has defined

rights when interfacing with configuration and

status parameters in the Boiler.

2.2.7 CONFIGURATION PASSWORD

Any user can view the configuration parameters

(default mode). No access-level password is

• End user:

The lowest access rights (no

required to view the parameters.

A valid

password login). The end user can, in most

cases, only read or view boiler parameters. In

some instances the end user can change boiler

parameters, e.g., change the CH, central heat,

setpoint.

configuration password for the parameter’s level

must be entered before the parameter can be

changed. The password need only be entered

once while the user remains on the configuration

pages. Leaving the configuration pages ends

the scope of the password entry. The user is

notified that a new password is needed upon the

first attempt to change a parameter (or until a

password is entered successfully). The user can

continue viewing the configuration parameters

regardless of whether a password is entered

successfully.

• Installer: The next highest level. The installer

can read all boiler parameters and change most

boiler parameters. This access level is used to

customize the boiler for a particular installation.

The default installer password is ‘bryan’.

• OEM: The highest access level. The OEM can

read and change all R7910 parameters, as well

as change sensor limits and burner control

safety parameters.

The boiler also maintains a password timeout

that limits the scope of the password entry.

Once a password is successfully entered the

boiler starts an internal timer that expires after

10 minutes of inactivity. After the timer expires,

the user is required to re-enter a password

before a parameter can be changed. The user

is not required to enter a configuration password

Different passwords exist in the boiler for each

access level. The end user level requires no

password, but the installer and OEM levels have

unique passwords defined for them. The display

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validates all password entry attempts with the

boiler, but doesn’t conduct the validation itself.

The boiler has sole responsibility to accept a

password entry.

There are two classes of parameters.

Non-Safety: Non-safety parameters can be

changed without placing the boiler in

dangerous state. These parameters typically do

not require a password to modify.

The display gets information from each boiler

about the access level settings for the status

and configuration parameters.

Safety: Safety parameters can be viewed the

same way non-safety parameters can be

viewed. If the user makes no attempt to change

a safety parameter, the user isn’t required to

enter safety verification mode.

The installer and OEM passwords can be

changed in the boiler after logging in with the

current password. When the password is

changed at the S7999B1026 it is saved in the

R7910 and effective for all future logins.

Safety parameters are grouped into blocks that

include only safety parameters, not a mixture of

safety data and non-safety data. All parameters

within the safety group undergo a verification

NOTE:

Each boiler in a multi-boiler configuration has its

own set of installer and OEM passwords. To

avoid user confusion the passwords should be

changed to the same setting in all the boilers,

but there is no requirement to do so.

process,

(see

paragraph

2.2.9

Safety

Verification).

A safety parameter group is

identified on the display to indicate when the

configuration parameters are safety-related.

2.2.9 SAFETY VERIFICATION

2.2.8 CHANGE PARAMETER SETTINGS

►

► CONFIGURE ►VERIFY

Figure 17 Change Parameter Dialog

Figure 18 Safety Parameter Verification

Change parameter settings by selecting the

parameter on the page. A dialog box displays

for the parameter with controls allowing the user

to change the value (Figure 17).

For safety configuration parameters, safety

verification is required to commit the changes.

All safety configuration parameters in the group

should have the same access level. If this

condition isn’t so, the user is asked to enter

another password when a higher access level is

needed.

After changing the setting to a new value, press

the OK button. Pressing the Cancel button

leaves the parameter unchanged.

The changed setting is reflected on the screen

and sent to the boiler when the OK button is

pressed.

Each safety parameter group is verified one at a

time until all have been verified (Figure 18).

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A verification step is required for each safety

parameter block that is changed. The verification

steps do not have to be completed immediately;

the user can traverse between parameter

groups before the verifications are done. If the

user is logged in with the appropriate password

After all safety parameter blocks have been

confirmed, the user is asked to press and hold

the reset button, (Figure 3 item 7), on the boiler

to complete the safety configuration session

(Figure 20).

and has changed

safety configuration

parameter, a verify button is enabled that allows

the user to conduct verification sessions.

If the user terminates the safety configuration

session after it has started, the boiler is left in an

un-configured (boiler will not operate) state.

The user can terminate the session by pressing

the Menu button or by attempting to leave the

Verification page with the Home or Back buttons

(top-left and -right screen corners, respectively).

The user is warned that leaving the session at

this point leaves the boiler in an un-configured

state and confirms whether the user still wants

to do so.

Figure 20 Safety Parameter Reset

When the Reset button is pressed and held for 3

seconds the confirmed safety parameters are

committed in the boiler. The above reset dialog

box automatically closes when this step is

completed.

The settings of all parameters in each safety

block must be confirmed to commit them to the

boiler.

Selecting the begin button will start the

verification process. The settings for all safety

parameters in each changed block are

presented and confirmed by the user (Figure

19).

NOTE:

If the user doesn’t perform this step, the boiler

remains in a locked state until the user resolves

the unconfirmed safety parameters.

Press the Yes button to confirm each safety

parameter block. If the user selects the No

button, the safety parameter block remains

unconfirmed and the configuration menu page is

2.2.10 FAULT/ALARM HANDLING

Each boiler reports a fault code when a lockout

condition occurs for one of the following

annunciations:

displayed.

The boiler remains in an un-

configured state in this case.

• Burner control

• Lockout

• Lead/Lag control

A less serious alarm condition may also occur

that is treated as a warning instead of a fault.

Each boiler can report active fault and warning

codes for each annunciation.

Any new fault code detected in a boiler is

indicated as a lockout condition at the display.

The notification method used depends on the

page that is displayed. On the Home page the

button for the boiler with the fault turns red

(Figure 21). On a boiler status page the History

Figure 19 Safety Parameter User Confirmation

Date:

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2396

Figure 23 History Dialog

button turns red (Figure 22). On all other pages

and when the user is looking at a different boiler,

a notification dialog box displays indicating

which boiler just locked out.

The lockout history can be displayed for each

boiler. The state information about each lockout

is displayed along with the date/time that the

lockout occurred.

Figure 21 Home Page Lockout

Figure 24 Lockout History Page

Use the following to clear a lockout and reset the

boiler.

►

► INFO BAR ► LOCKOUTS ►

CLEAR LOCKOUT

2.2.11 OPERATION PAGE

►

►OPERATION

Figure 22 Status Page Lockout

Selecting the info bar will display the history

dialog. If none of the buttons are selected the

dialog box closes after 30 seconds.

Figure 25 Operation Page

The operation page displays the boiler running

operation, including set point and firing rate

values expressed in rpm. From this page the

user can change set points, manually control the

boiler’s firing rate, manually turn pumps on, view

Date:

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2396

annunciation information, and switch between

heating loops (Central Heat and Domestic Hot

Water), as shown in Figure 25. If a password is

required to change any of the settings on this

page, the user can press the Login button to

enter the password.

2.2.13 MODULATION CONFIGURATION

►

► CONFIGURE ► MODULATION

CONFIGURATION

2.2.12 ANNUNCIATION PAGE

►

►OPERATION►

ANNUNCIATION

Figure 27 Modulation Configuration

The modulation configuration page is used to set

the modulation range of the boiler.

The

recommended maximum and minimum rpm

values can be found in

Figure 26 Annunciation Page

2.2.14 FIRING RATE CONTROL PAGE

The annunciation page shows the status of the

load control input (call for heat), pre-ignition

interlock (proof of gas valve closure), and the

running interlock strings. The components are

listed in the order they are wired. This page can

be called up at any time from the operation page

(Figure 25). This page is very helpful for

troubleshooting a lockout 67 (ILK off). All

components for a given string are wired in

series. The first component that indicates off will

be the safety device to check.

►

► OPERATION ► FIRING RATE

FIELD

Figure 28 Firing Rate Control Page

The firing rate control page enables the user to

change how the firing rate is controlled. The first

option is for automatic control based on the

current set point. The second option enables

Date:

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2396

the user to manually control the firing rate while

the boiler is firing. The third option can be

selected to change the rpm of the blower while

the boiler is off or in standby. The manual firing

rate can be changed by pressing the clear

button and entering the new value or by using

the up and down arrows. To accept the new

value press the ok button and the boiler will

change the firing rate to the new value. An error

message will display if the value entered

exceeds the maximum firing rate or falls below

the minimum firing rate.

2.2.16 SYSTEM TIME

► 1234 SETUP ► ADVANCED

SETUP ► DATE & TIME

Note:

The firing rate control should come from the

factory set to ‘Manual in Run’ with the manual

firing rate value set to the light off rpm.

2.2.15 ADVANCED SETUP

Figure 30 System Time

► 1234 SETUP ►ADVANCED SETUP

Set the date and time by adjusting the

appropriate boxes using the up and down arrow

keys. Select the OK button when finished.

Note:

Currently the date and time will need to be reset

when a loss of power to the display occurs.

2.2.17 CALIBRATE TOUCH SCREEN

► 1234 SETUP ► ADVANCED

SETUP ► DIAGNOSTICS

Figure 29 Advanced Setup

The advanced setup page displays many more

options that can be changed by the user.

Figure 31 Display Diagnostics

Occasionally the touch screen will need to be

Date:

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2396

calibrated. When the screen is touched in a

spot and unexpected results occur this is a good

indication that the display needs to be

calibrated. To calibrate the touch screen select

the ‘Calibrate’ button and follow the on screen

directions. Try using a stylus of some kind if the

problem persists. The eraser end of a pencil or

the blunt end of a pen can be used as a good

stylus.

2.2.19 OUTDOOR RESET

►

► CONFIGURE

► OUTDOOR RESET

► (page) CENTRAL HEAT

2.2.18 RESET / REBOOT DISPLAY

► 1234 SETUP

► ADVANCED SETUP

► DISPLAY RESET

Figure 33 Outdoor Reset

When the outdoor

temperature is equal

or greater than this

value the boiler

setpoint will be set to

the low water

Max outdoor temp

(x₂)

temperature.

When the outdoor

temperature is equal

or less than this value

the boiler setpoint will

be set to the Central

Heat Setpoint value

(y₂) see 2.2.21.

This value represents

the water temperature

setpoint when the

maximum outdoor

temperature is

Figure 32 Reset / Reboot Display

Min outdoor temp

(x₁)

The display can be reset or rebooted without

powering down the boiler. Select the ‘OK’

button and the display will reboot as shown in

paragraph Power-up Validation 2.2.1.

Low water temp

(y₂)

reached.

This value is used to

override the low water

temperature of the

curve created with the

above points without

changing the slope.

Undefined / Not Used

Min water temp

Max off point

Select the ‘Show Line’ button to display a

graphical representation for the inputted data

Date:

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2396

(Figure 34). The normal reset curve is shown in

green and the time of day is red.

►

► CONFIGURE

► CH - CENTRAL HEAT

CONFIGURATION

► (page) CENTRAL HEAT

► (Outdoor Reset) ENABLED

Note:

y1 is the maximum water setpoint value found in

‘CH – Central heat Configuration’ on the

‘Setpoint’ page.

2.2.20 REMOTE SETPOINT (4 – 20

MA)

Figure 34 Outdoor Reset Curve

►

► CONFIGURE

►

► CONFIGURE

► SENSOR CONFIGURATION

► (Sensor) S2 (J8-6) sensor

► (Connector type) 4-20mA

► SAFETY VERIFICATION 2.2.9

► (Sensor) S5 (J8-11) sensor

► (Connector type) 10K NTC single

non-safety

► (Outdoor temperature source) S5

(J8-11) sensor

►

► CONFIGURE

► CH - CENTRAL HEAT

CONFIGURATION

► (page) SETPOINT

► (Setpoint Source) S2 (J8-6) 4-20mA

► (4 mA water temperature) MIN

► (20 mA water temperature) MAX

Figure 35 Outdoor Reset Sensor Configuration

Note:

Update the sensor name to ‘Outdoor Sensor’ by

selecting a different sensor then reselecting the

S5 (J8-11) sensor.

Date:

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2396

Setpoint source

Setpoint

Local

S2 (J8-6) 4-20mA

Setpoint for normal

Central Heat modulation:

50 °F to 190 °F

2.2.21 CENTRAL HEAT

CONFIGURATION

Time of day setpoint

Off hysteresis

Setpoint when Time Of

Day switch is on. 50 °F to

190 °F

►

► CONFIGURE

► CH - CENTRAL HEAT

Differential above

setpoint when boiler is

turned off. 2 °F to 5 °F

Differential from setpoint

when boiler is turned on.

2 °F to 30 °F

CONFIGURATION

On hysteresis

4 mA water temperature

50 °F to 190 °F

20 mA water temperature 50 °F to 190 °F

Figure 36 Central Heat Configuration (Central Heat Page)

CH enable

Disable or Enable Central

Heating Loop

Demand switch

Sensor for Central Heat

demand:

Figure 38 Central Heat Configuration (Modulation Page)

Sensor only

Modulation sensor

Outlet

sensor, S5 (J8-11)

Local

applied for the P portion

of the PID equation 0-400

applied for the I portion of

the PID equation 0-400

Gain applied for the D

portion of the PID

equation 0-400

sensor,

Inlet

Sensor & STAT terminal

Sensor & Remote Stat

LCI & Sensor

Enabled

Disabled

Modulation Rate Source

P-gain Gain

Outdoor reset

I-gain Gain

D-gain

CH has priority over Lead Yes, No, Cancel

Lag

Hysteresis step time Time between hysteresis

(0=Disable

stepping)

hysteresis step changes: 0-600

seconds

2.2.22 SOUND PRESSURE LEVELS

Sound pressure levels were measured at 4-1/2’

above the floor and 3’ from the boiler at the

front, rear and two sides. See Table 6 for

decibel readings.

Decibel Readings

Figure 37 Central Heat Configuration (Setpoint Page)

Tube

Side

Right

Side

Model

Front

Rear

Date:

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2396

Decibel Readings

Tube

Side

59.5

66.3

82.7

Right

Side

58.5

65.4

82.8

Model

Front

Rear

TF150

TF200

TF250

TF300

55.5

62.1

77.7

58.0

65.1

82.8

Table 6 Sound Pressure Readings

Date:

Revision:

Form:

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2396

Annunciation

restored from backup

Safety group verification table was

restored from factory defaults

Safety group verification table was

updated

configuration

was

2.2.23 MODBUS COMMUNICATION

The hydronic control Global Modbus port is a 3-

pin connector that interfaces to the following RS-

485 signals:

Invalid Parameter PCB was detected

Invalid Range PCB was detected

Table 7 Modbus Terminals

Signal

Terminal

Alarm

silence

time

exceeded

Data +

Data -

Common

maximum

Invalid safety group verification table

was detected

20-26 RESERVED

Modbus connections can be made at the display

(Figure 3 item 5) or the hydronic control (Figure

7 item 24).

Safety processor was reset

Application processor was reset

Burner switch was turned OFF

Burner switch was turned ON

Program Module (PM) was inserted

into socket

For the modbus register map and other related

information please download Honeywell’s

R7910A product manual at:

Program Module (PM) was removed

from socket

http://customer.honeywell.com/TechLit/pdf/66-

0000s/66-1171.pdf

Alert PCB was configured

Parameter PCB was configured

35 Range PCB was configured

Program Module (PM) incompatible

with product was inserted into socket

2.2.24 ALERT CODES

Program

Module

application

Table 8 Alert Codes

parameter revision differs from

application processor

Code Description

None (No alert)

Program Module safety parameter

revision differs from safety processor

PCB incompatible with product

contained in Program Module

Parameter PCB in Program Module is

too large for product

Range PCB in Program Module was

too large for product

Alert PCB in Program Module was

too large for product

Alert PCB was restored from factory

defaults

Safety configuration parameters were

restored from factory defaults

Configuration

restored from factory defaults

parameters

were

Invalid Factory Invisibility PCB was

detected

Invalid Factory Range PCB was

detected

IAS start check was forced on due to

IAS enabled

Low voltage was detected in safety

processor

Invalid range PCB record has been

dropped

EEPROM

initialized

lockout

history

was

High line frequency occurred

Low line frequency occurred

Invalid subsystem reset request

occurred

Write large enumerated Modbus

Maximum cycle count was reached

Maximum hours count was reached

Illegal Modbus write was attempted

Modbus write attempt was rejected

(NOT ALLOWED)

Switched application annunciation

data blocks

Switched application configuration

data blocks

Configuration was restored from

factory defaults

Backup configuration settings was

restored from active configuration

Annunciation

configuration

was

restored from factory defaults

Date:

Revision:

Form:

8-4-2010

2396

Illegal Modbus read was attempted

Safety processor brown-out reset

occurred

Application processor watchdog reset

occurred

Application processor brown-out reset

occurred

Safety processor watchdog reset

occurred

Alarm was reset by the user at the

control

Burner control firing rate was >

absolute max rate

Burner control firing rate was <

absolute min rate

Burner control firing rate was invalid,

% vs. RPM

Burner control was firing with no fan

request

Burner control rate (nonfiring) was >

absolute max rate

Burner control rate (nonfiring) was <

absolute min rate

Burner control rate (nonfiring) was

absent

Burner control rate (nonfiring) was

invalid, % vs. RPM

Fan off cycle rate was invalid, % vs.

RPM

Setpoint was overridden due to

sensor fault

Modulation was overridden due to

sensor fault

Slow start was end due to reference

setpoint fault

CH max modulation rate was invalid,

% vs. RPM

CH max modulation rate was >

absolute max rate

CH modulation range (max minus

min) was too small (< 4% or 40 RPM)

DHW max modulation rate was

invalid, % vs. RPM

DHW max modulation rate was >

absolute max rate

DHW modulation range (max minus

min) was too small (< 4% or 40 RPM)

Min modulation rate was < absolute

min rate

Min modulation rate was invalid, %

vs. RPM

Manual rate was invalid, % vs. RPM

Slow start enabled, but forced rate

was invalid

100

101

102

103

104

105

106

107

108

109

Analog output hysteresis was invalid

Analog modulation output type was

invalid

IAS open rate differential was invalid

IAS open step rate was invalid

110

111

112-

114

RESERVED

Fan was limited to its minimum duty

cycle

115

116

117

118

119

120

121

122

123

124

125

Manual rate was

modulation rate

CH max

Manual rate was

modulation rate

DHW max

70-74 RESERVED

Absolute max fan speed was out of

range

Absolute min fan speed was out of

range

Fan gain down was invalid

Fan gain up was invalid

Fan minimum duty cycle was invalid

Fan pulses per revolution was invalid

Fan PWM frequency was invalid

Manual rate was < min modulation

rate

Manual rate in Standby was

absolute max rate

Modulation commanded rate was >

CH max modulation rate

Modulation commanded rate was >

DHW max modulation rate

Modulation commanded rate was <

min modulation rate

Modulation rate was limited due to

outlet limit

Modulation rate was limited due to

Delta-T limit

Modulation rate was limited due to

stack limit

Modulation rate was limited due to

anti- condensation

Fan Speed out of range in RUN

Modulation rate was limited due to

IAS was open

82-89 RESERVED

Modulation output type was invalid

Firing rate control parameter was

invalid

Forced rate was out of range vs.

min/max modulation

Forced rate was invalid, % vs. RPM

Slow start ramp value was invalid

Slow start degrees value was invalid

Slow start was ended due to outlet

sensor fault

126

127

128

Date:

Revision:

Form:

8-4-2010

2396

Slow start ramp setting of zero will

result in no modulation rate change

RESERVED

CH demand source was invalid

CH P-gain was invalid

Lead Lag master was suspended due

to fault

Lead Lag slave was suspended due

to fault

Lead Lag header temperature was

invalid

Lead Lag was suspended due to no

enabled Program Module installed

Lead Lag slave session has timed out

129

204

205

206

207

130

131

132

133

134

135

136

137

138

CH I-gain was invalid

CH D-gain was invalid

CH OFF hysteresis was invalid

CH ON hysteresis was invalid

CH sensor type was invalid

CH hysteresis step time was invalid

CH remote control parameter was

invalid

208

209-

221

RESERVED

CH frost protection temperature was

invalid

CH frost protection inlet temperature

was invalid

DHW frost protection temperature

was invalid

222

223

224

139

140

CH ODR not allowed with remote

control

141-

145

RESERVED

225-

230

231

232

233

CH control was suspended due to

fault

CH header temperature was invalid

CH outlet temperature was invalid

CH steam pressure was invalid

RESERVED

146

LL setpoint was invalid

147

148

149

150-

156

157

158

159

160

161

162

163

164

165

LL time of day setpoint was invalid

LL outdoor temperature was invalid

LL ODR time of day setpoint was

invalid

LL ODR time of day setpoint

exceeded normal setpoint

LL max outdoor setpoint was invalid

LL min outdoor setpoint was invalid

LL min water setpoint was invalid

LL outdoor temperature range was

too small (minimum 12 C / 22 F)

LL water temperature range was too

small (minimum 12 C / 22 F)

234

235

RESERVED

DHW demand source was invalid

DHW P-gain was invalid

DHW I-gain was invalid

236

237

238

DHW D-gain was invalid

DHW OFF hysteresis was invalid

DHW ON hysteresis was invalid

DHW hysteresis step time was invalid

DHW sensor type was invalid

Inlet sensor type was invalid for DHW

Outlet sensor type was invalid for

DHW

239

240

241-

245

246

247

248

RESERVED

166

CH setpoint was invalid

167-

170

RESERVED

CH time of day setpoint was invalid

CH outdoor temperature was invalid

CH ODR time of day setpoint was

invalid

CH ODR time of day setpoint

exceeds normal setpoint

CH max outdoor setpoint was invalid

CH min outdoor setpoint was invalid

CH min water setpoint was invalid

CH outdoor temperature range was

too small (minimum 12 C / 22 F)

CH water temperature range was too

small (minimum 12 C / 22 F)

RESERVED

DHW control was suspended due to

fault

DHW temperature was invalid

DHW inlet temperature was invalid

DHW outlet temperature was invalid

171

249

250

172

173

174

175-

182

183

184

185

186

187

188

251

252

253

RESERVED

Lead Lag P-gain was invalid

Lead Lag I-gain was invalid

Lead Lag D-gain was invalid

Lead Lag OFF hysteresis was invalid

Lead Lag ON hysteresis was invalid

Lead Lag slave enable was invalid

Lead Lag hysteresis step time was

invalid

254

255

256-

260

261

262

189

DHW setpoint was invalid

DHW time of day setpoint was invalid

190-

203

RESERVED

Date:

Revision:

Form:

8-4-2010

2396

263-

271

Abnormal Recycle: Interrupted air

flow switch was off during Measured

Purge Time

Abnormal Recycle: Interrupted air

flow switch was off during Drive to

Lightoff Rate

Abnormal Recycle: Interrupted air

flow switch was off during Pre-Ignition

test

Abnormal Recycle: Interrupted air

flow switch was off during Pre-Ignition

time

Abnormal Recycle: Interrupted air

flow switch was off during Main

Flame Establishing Period

Abnormal Recycle: Ignition failed due

to interrupted air flow switch was off

Abnormal Recycle: ILK off during

Drive to Purge Rate

Abnormal Recycle: ILK off during

Measured Purge Time

Abnormal Recycle: ILK off during

Drive to Lightoff Rate

Abnormal Recycle: ILK off during Pre-

Ignition test

Abnormal Recycle: ILK off during Pre-

Ignition time

Abnormal Recycle: ILK off during

Main Flame Establishing Period

Abnormal Recycle: ILK off during

Ignition period

Run was terminated due to ILK was

off

Run was terminated due to

interrupted air flow switch was off

Stuck reset switch

Run was terminated due to fan failure

Abnormal Recycle: Fan failed during

Drive to Purge Rate

Abnormal Recycle: Fan failed during

Measured Purge Time

Abnormal Recycle: Fan failed during

Drive to Lightoff Rate

RESERVED

297

298

299

300

301

Abnormal Recycle: Pressure sensor

fault

Abnormal Recycle: Safety relay drive

test failed

Abnormal Recycle: Demand off

during Pilot Flame Establishing

Period

Abnormal Recycle: LCI off during

Drive to Purge Rate

Abnormal Recycle: LCI off during

Measured Purge Time

Abnormal Recycle: LCI off during

Drive to Lightoff Rate

Abnormal Recycle: LCI off during

Pre-Ignition test

Abnormal Recycle: LCI off during

Pre-Ignition time

Abnormal Recycle: LCI off during

Main Flame Establishing Period

Abnormal Recycle: LCI off during

Ignition period

Abnormal Recycle: Demand off

during Drive to Purge Rate

Abnormal Recycle: Demand off

during Measured Purge Time

Abnormal Recycle: Demand off

during Drive to Lightoff Rate

Abnormal Recycle: Demand off

during Pre-Ignition test

Abnormal Recycle: Demand off

during Pre-Ignition time

Abnormal Recycle: Flame was on

during Safe Start check

Abnormal Recycle: Flame was on

during Drive to Purge Rate

Abnormal Recycle: Flame was on

during Measured Purge Time

Abnormal Recycle: Flame was on

during Drive to Lightoff Rate

Abnormal Recycle: Flame was not on

at end of Ignition period

272

273

274

275

276

277

278

279

280

281

282

283

284

285

286

287

288

289

290

291

302

303

304

305

306

307

308

309

310

311

312

313

314

315

316

317

318

319

320

321

322

Abnormal Recycle: Fan failed during

Pre-Ignition test

Abnormal Recycle: Fan failed during

Pre-Ignition time

Abnormal Recycle: Fan failed during

Ignition period

Abnormal Recycle: Fan failed during

Main Flame Establishing Period

Abnormal Recycle: Main Valve off

after 10 seconds of RUN

Abnormal Recycle: Flame was lost

during Main Flame Establishing

Period

Abnormal Recycle: Flame was lost

early in Run

Abnormal Recycle: Flame was lost

during Run

Abnormal Recycle: Leakage test

failed

292

293

294

295

Abnormal Recycle: Interrupted air

flow switch was off during Drive to

Purge Rate

296

Abnormal Recycle: Pilot Valve off

after 10 seconds of RUN

Date:

Revision:

Form:

8-4-2010

2396

Abnormal Recycle: Safety Relay off

after 10 seconds of RUN

Abnormal Recycle: Hardware flame

bias

Abnormal Recycle: Hardware static

flame

Abnormal Recycle: Hardware flame

current invalid

Abnormal Recycle: Hardware flame

rod short

Abnormal Recycle: Hardware invalid

power

Abnormal Recycle: Hardware invalid

AC line

Abnormal Recycle: Hardware SLO

flame ripple

Abnormal Recycle: Hardware SLO

flame sample

Abnormal Recycle: Hardware SLO

flame bias range

Abnormal Recycle: Hardware SLO

flame bias heat

Abnormal Recycle: Hardware SLO

spark stuck

Abnormal Recycle: Hardware SLO

spark changed

Abnormal Recycle: Hardware SLO

static flame

Abnormal Recycle: Hardware SLO

rod shorted

Abnormal Recycle: Hardware SLO

AD linearity

Abnormal Recycle: Hardware SLO

bias not set

Abnormal Recycle: Hardware HFS

LFS shorted

Abnormal Recycle: Invalid zero

crossing

Abnormal Recycle: fault stack sensor

Abnormal Recycle: stack limit

Abnormal Recycle: delta T limit

Abnormal Recycle: fault outlet sensor

Abnormal Recycle: outlet high limit

Abnormal Recycle: fault DHW sensor

Abnormal Recycle: DHW high limit

Abnormal Recycle: fault inlet sensor

323

324

325

326

327

328

329

330

331

332

333

334

335

336

337

338

339

340

341

342

343

344

345

346

347

348

349

350

351

352

353

354

355

356

357

358

359

Abnormal

Recycle:

Check

360

361

362

363

364

365

366

367

368

369

370

371

372

373

Parameters Failed

Internal error: No factory parameters

were detected in control

Internal error: PID iteration frequency

was invalid

Internal error: Demand-Rate interval

time was invalid

Internal error: Factory calibration

parameter for modulation was invalid

Internal error: CH PID P-scaler was

invalid

Internal error: CH PID I-scaler was

invalid

Internal error: CH PID D-scaler was

invalid

Internal error: DHW PID P-scaler was

invalid

Internal error: DHW PID I-scaler was

invalid

Internal error: DHW PID D-scaler was

invalid

Abnormal Recycle: Hardware SLO

bias shorted

Abnormal Recycle: Hardware SLO

electronics

Internal error: Lead Lag master PID

P-scaler was invalid

Internal error: Lead Lag master PID I-

scaler was invalid

Internal error: Lead Lag master PID

D-scaler was invalid

Abnormal

Recycle:

Hardware

processor clock

Abnormal Recycle: Hardware AC

phase

Abnormal Recycle: Hardware A2D

mismatch

Abnormal Recycle: Hardware VSNSR

A2D

Abnormal Recycle: Hardware 28V

A2D

Abnormal Recycle: Hardware HFS

IAS shorted

Abnormal Recycle: Hardware PII

INTLK shorted

Abnormal Recycle: Hardware HFS

LCI shorted

374-

459

460

461

462

463

464-

466

RESERVED

LCI demand lost in run

Demand lost in run

STAT demand lost in run

Demand lost in run due to no flame

RESERVED

Internal error: EEPROM write was

attempted before EEPROM was

initialized

Internal error: EEPROM cycle count

address was invalid

467

468

Date:

Revision:

Form:

8-4-2010

2396

Internal error: EEPROM days count

address was invalid

Internal error: EEPROM hours count

address was invalid

Internal error: Safety timer was

corrupt

Internal error: Safety timer was

expired

Internal error: Safety timings

Internal error: Safety shutdown

469

470

471

472

473

474

475

476

477

478

479

480

497

498

Internal

error:

Lockout

record

499

500

EEPROM index was invalid

Internal error: Request to write PM

status was invalid

Internal error: PM parameter address

was invalid

Internal error: PM safety parameter

address was invalid

Internal error: Invalid record in lockout

history was removed

Internal error: EEPROM write buffer

was full

Internal error: Data too large was not

written to EEPROM

Internal error: Safety key bit 0 was

incorrect

Internal error: Safety key bit 1 was

incorrect

Internal error: Safety key bit 2 was

incorrect

481 Internal error: Safety key bit 3

was incorrect

482 Internal error: Safety key bit 4

was incorrect

Internal error: Safety key bit 5 was

incorrect

Internal error: Safety key bit 6 was

incorrect

Internal error: Safety key bit 7 was

incorrect

Internal error: Safety key bit 8 was

incorrect

Internal error: Safety key bit 9 was

incorrect

Internal error: Safety key bit 10 was

incorrect

Internal error: Safety key bit 11 was

incorrect

Internal error: Safety key bit 12 was

incorrect

483

484

485

486

487

488

489

490

491

492

Internal error: Safety key bit 13 was

incorrect

Internal error: Safety key bit 14 was

incorrect

Internal error: Safety key bit 15 was

incorrect

Internal error: Safety relay timeout

493

494

495

Internal

error:

Safety

relay

commanded off

Internal error: Unknown safety error

occurred

496

Date:

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Form:

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2396

The regulating gas valve is a 1:1 differential

pressure air / gas ratio controller. This means

that the control adjusts the same pressure

difference on the gas side as it senses on the

airside. The airside pressure is the difference

between the pressure in the burner housing and

the pressure downstream of the furnace section.

The gas side pressure is the difference between

the pressure upstream and downstream of the

gas limiting orifice valve. For the locations of the

+/- gas and air connections see (Figure 39). Air

to gas ratios are adjusted with the gas limiting

orifice valve (Figure 7 item 26).

2.3 BOILER COMMISSIONING

NOTE:

All of the installation instructions found in section

1 must be completed before commissioning the

boiler.

WARNING:

The following procedures must be

followed carefully before putting the

boiler in operation. Failure to do so

will present severe hazards to

equipment, operating personnel and

building occupants.

During the burner pre-purge period, when the

gas valve is closed, only the air pressure

difference acts on the regulator causing the air

diaphragm to move to the left and closes the

regulating hydraulic bypass valve. When the

actuator is powered, the gas valve begins to

open. The downstream gas pressure difference

immediately begins to increase until the gas

pressure difference is in balance with the air

pressure difference.

2.3.1 MODULATION

2.3.2 TEST SETUP

Connect a u-tube manometer to the gas

manifold pressure tapping (Figure 7 item 12).

Connect a 0 – 5 psi gauge in the port provided in

the low gas pressure switch connection (Figure

7 item 28).

Connect a u-tube manometer to the pilot gas

pressure port provided (Figure 7 item 14).

A suitable combustion analyzer shall be used for

measuring O2, CO, and Nox levels.

The

analyzer probe should be inserted in the stack

above the boiler outlet and before any draft

controls. Calibration is required for the Nox and

CO cells at the time of commissioning.

Figure 39 Air / Gas Ratio Tappings

2.3.3 PRE CHECKS AND SETUP

Modulation on the Triple-flex boiler is

accomplished with air / gas ratio control. The

system consists of two major components, a

blower (Figure 10 item 6) and a regulating gas

valve (Figure 7 item 3). The blower is variable

speed and provides combustion air to the

burner. The blower rpm is controlled by a PWM

(pulse width modulation) signal. The PWM

signal increases or decreases as the load

increases or decreases in the hydronic system.

Close the manual gas cock (Figure 7 item 4).

Date:

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seconds the purge timer will start and count to

30. After 30 seconds the fan speed is reduced

to the light off rate. When the fan speed is with

in +/- 3% of the firing rate for 3 seconds the

ignition transformer and the pilot valve are

energized. The pilot will light and can be

observed from the observation port (Figure 5

item 4). After a duration of 5 seconds the

ignition transformer will de-energize. The pilot

valve will stay energized for another 5 seconds

before the main gas valves are energized.

During this 10 second period the pilot should be

adjusted according to paragraph 2.3.5.

WARNING:

Do not open the manual main gas cock

(Figure 7 item 4) before all pre checks,

setups, and dry runs have been

successfully completed.

With a voltmeter check for the proper incoming

main voltage and the proper control voltage from

the control circuit transformer. Refer to the

electrical wiring diagram and boiler-rating label

for proper voltages.

The main gas valves will energize for 10

seconds. After this 10 second duration the pilot

valve is de-energized. The control will lockout

with a code of 106, Flame lost in Main Flame

Establishing Period.

Make sure the boiler is full of water and proper

flow has been established.

Power up the boiler see (paragraph 2.2.1).

Navigate to the ‘Operation Screen’ (paragraph

2.2.11). Select the burner switch to toggle the

burner to the off state.

WARNING:

During the first 10 seconds of this

process the automatic gas valves

should not have opened or been

energized. If any of the automatic gas

valves are energized or open at this

point correct the problem immediately.

Navigate to the ‘Firing Rate Control Page’

(paragraph 2.2.14). Select the ‘Manual in Run”

option and enter the light off RPM from (Table 9

Approximate Boiler Settings) in the Manual

Firing Rate box. This will prevent the burner

from ramping up to high fire after the flame

stabilization period.

Navigate to the ‘Annunciation Page” (paragraph

2.2.12). All load control inputs and interlocks

should be in the on state with the exception of

the air flow switch. The air flow switch will close

when the burner is commanded to start. Correct

any problem indicated. Refer to trouble shooting

(paragraph 0) for further help.

2.3.5 PILOT ADJUSTMENT

Adjust the pilot gas pressure between 3.5 iwc

and 4 iwc. The pilot flame signal can be

observed from the status page (paragraph

2.2.5). The minimum flame signal is .8 volts.

The flame signal can vary between 4 volts and

15 volts. A flame signal closer to 15 volts is

preferred. Observe the pilot flame through the

flame observation port (Figure 5 item 4). The

pilot should appear stable. A stable pilot will not

flicker on and off. Recycle the boiler as many

times as needed to establish a good pilot. If the

pilot fails to light refer to trouble shooting

(paragraph 1.1.1) for further help.

Navigate to the ‘Operation Screen’ (paragraph

2.2.11). The boiler is now prepared to be placed

in the on state by toggling the burner switch to

on.

2.3.4 DRY RUN

Navigate to the ‘Operation Screen’ (paragraph

2.2.11). Toggle the burner switch to on.

Navigate to the ‘Status Page’ (paragraph 2.2.5).

If there is demand for hot water the burner state

will display driving to purge. When the fan

speed is within +/- 3% of the firing rate for 3

Date:

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for NOx, O2, and CO should be made at the

maximum firing rate. No further adjustments are

required of the gas limiting orifice valve. Return

to the minimum low fire rate (paragraph 2.2.13)

in increments of 500 rpm. For each increment

verify combustion readings. Refer to trouble

shooting (paragraph 0) for further help.

WARNING:

During pilot adjustment leave the

manual main gas cock (Figure 7 item

4) closed.

NOTE:

Use rpm values that fall between the rpm values

used going to high fire. This will give more

points to verify on the modulation curve.

Pilot gas pressures in excess of the

recommended will lead to the formation of

carbon hairs that will ground out the pilot igniter

causing a safety shutdown.

2.3.8 ADJUSTING BOILER MINIMUM

INPUT

2.3.6 INITIAL LIGHT OFF

NOTE:

The boiler maximum input must be adjusted

before final adjustments can be made for

minimum input.

Open the manual main gas cock (Figure 7 item

4). Clear the lockout fault (paragraph 2.2.10)

and allow the burner to cycle and attempt to light

off. If the main flame fails to light, the low fire

displacement of the pressure regulating actuator

(Figure 7 item 2) may need to be increased.

Decrease the boiler firing rate to the minimum

modulation rate (paragraph 2.2.13). Adjust the

O2 level to obtain Nox levels desired by

adjusting the low fire displacement on the gas

WARNING:

pressure

regulating

actuator

obtain

appropriate NOx, O2, and CO levels. Allow

sufficient time for combustion to stabilize after

each ¼ to ½ turn of the low fire displacement

(Figure 7 item 2).

Do not adjust the low fire displacement

more than 1/4 to 1/2 turn for each main

flame-establishing period.

The boiler will light off at approximately 1.5 times

the minimum firing rate rpm. The boiler will hold

in this position for no less than 5 minutes to

establish a stable flame before releasing the

boiler to full modulation. Observe combustion

readings and make small adjustments to the low

fire displacement of the pressure regulating

actuator (Figure 7 item 2) when the O2 is not

within 6% to 10%. Allow sufficient time for

combustion to stabilize after each ¼ to ½ turn of

the low fire displacement (Figure 7 item 2).

WARNING:

O2 levels below 6% will overheat the

metal fiber burner and cause the fuel /

air mixture to ignite inside the burner.

An internal temperature fuse is

provided to open when the internal

burner temperature reaches 425 ^oF.

Boiler Model

TF300 TF250 TF200 TF150

2.3.7 ADJUSTING BOILER MAXIMUM

INPUT

Pilot Gas

Pressure

(IWC)

Light Off

RPM

High Fire

3.5 - 4 3.5 - 4 3.5 - 4 3.5 - 4

1800 1800 1200 1200

After the flame stabilization period increase the

firing rate in 500 rpm increments until the

maximum modulation rate (paragraph 2.2.13) is

reached. For each 500 rpm increment observe

combustion readings and make adjustments to

the gas limiting orifice (Figure 7 item 26) if the

O2 is not within 6% to 10%. Final adjustments

Date:

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cubic feet per hour). Consult the National Fuel

Gas Code (ANSI Z223.1, NFPA 54) or the local

gas utility for further information. Refer to Table

10 for correction factors for the gas pressure at

the meter. Refer to Table 11 for the gas

temperature correction factors.

Gas

Manifold

Pressure

(IWC)

4.4

3.6

4.0

2.0

6000-

7000

5100-

5500

3550-

4200

2700-

2850

Max RPM

Low Fire

Gas

Manifold

Pressure

(IWC)

Gas Pressure at Meter Corr. Factor

14" w.c.

21" w.c.

1 psig

1.034

1.051

1.061

1.136

2 psig

1200-

1600

1200-

1600

800-

950

800-

950

Min RPM

5 psig

1.340

Table 10 Gas Pressure Correction

Table 9 Approximate Boiler Settings

Gas Temp. at Meter

Corr. Factor

1.04

1.02

1.0

.981

2.3.9 GAS METER READINGS

40 °F

50 °F

60 °F

70 °F

80 °F

90 °F

Burner input rate can be checked by taking

readings from the gas meter. Please note

checking the rate with a meter is the only way to

be sure of input. Manifold readings are only an

approximate value and may vary from unit to

unit.

.963

.945

Table 11 Gas Temperature Correction

In order to obtain accurate data, there must be

no other appliances using gas from the same

meter while the burner input rate is being

checked.

To correct for pressure and temperature use the

following formula.

Q_c= Qt_pt_t

t_p= pressure correction table 2.2A

t_t= temperature correction table 2.2B

A stopwatch or a watch with a second hand is

required to obtain a meter reading. Clock the

amount of time it takes for the smallest dial to

complete one revolution in seconds. Use the

following formula to obtain the cubic feet per

hour throughput of the unit.

3600V_c

CFH =

g_c

CFH = ft³hr⁻¹of gas

V_c= ft clocked

g_c= time in seconds

To obtain the Btu per hour throughput of the unit

use the following formula.

Q = CFH

(

h_v

)

h_v= heating value of fuelin Btu ft^-3

If the meter is not calibrated for gas temperature

and pressure, correction factors must be applied

to determine correct rate in SCFH (standard

Date:

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2.4 TROUBLESHOOTING

To support the recommended Troubleshooting, the R7910 has an Alert File. Review the Alert history for

possible trends that may have been occurring prior to the actual lockout.

Note Column:

H = Hold message

L = Lockout message

H or L = either Hold or Lockout depending on Parameter Configuration

Table 12 R7910A Lockout and Hold Codes

Code Description

Recommended Troubleshooting of Lockout Codes

1.New Device, complete device configuration and safety

verification.

Code

Unconfigured

safety data

2. If fault repeats, replace module.

Waiting for safety 1. Device in Configuration mode and safety parameters need

data verification

verification and a device needs reset to complete verification.

2. Configuration ended without verification, re enter

configuration, verify safety

parameters and reset device to complete verification.

3. If fault repeats, replace module

Internal

Hardware fault

Internal

fault: Internal fault

1. Reset module

2. If fault repeats, replace module.

fault:

Safety Relay key

feedback error

Internal

Unstable

(DCDC) output

Internal

Invalid

clock

Internal

Safety relay drive

error

Internal fault: Zero

crossing

detected

Internal

Flame bias out of

range

Internal

Invalid

control state

Internal

Invalid

fault:

power

fault:

processor

fault:

not

fault:

Burner

fault:

Burner

control state flag

Internal

fault:

Safety relay drive

cap short

Internal fault: PII

shorted to ILK

Internal fault: HFS

shorted to LCI

H OR L

Date:

Revision:

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Code Description

Recommended Troubleshooting of Lockout Codes

Code

Internal

Safety relay test

failed

feedback ON

fault:

due

Internal

fault:

Safety relay test

failed due to safety

relay OFF

Internal

fault:

Safety relay test

failed due to safety

relay not OFF

Internal

Safety relay test

failed due to

feedback not ON

Internal fault:

Safety RAM write

fault:

Internal

fault:

Flame ripple and

overflow

Internal

Flame number of

sample mismatch

Internal

Flame bias out of

range

Internal fault: Bias

changed

heating cycle starts

Internal fault: Spark

voltage stuck low or

high

fault:

since

Internal fault: Spark

voltage

changed

too much during

flame sensing time

Internal fault: Static

flame ripple

Internal

fault:

Flame rod shorted

to ground detected

Internal fault: A/D

linearity test fails

Internal

fault:

Flame bias cannot

be set in range

Internal

fault:

Flame bias shorted

to adjacent pin

Internal fault: SLO

electronics

unknown error

Date:

Revision:

Form:

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Code Description

32-46 Internal

Recommended Troubleshooting of Lockout Codes

Code

fault:

Key 0

Safety

through 14

Flame

Rod

ground leakage

Static flame (not

flickering)

24VAC voltage low/ 1. Check the Module and display connections.

high

2. Check the Module power supply and make sure that both

frequency, voltage and VA meet the specifications.

Internal sub-system fault.

1. Review alert messages for possible trends.

2. Correct possible problems.

Modulation fault

Pump fault

Motor tachometer

fault

AC inputs phase 1. Check the Module and display connections.

reversed 2. Check the Module power supply and make sure that both

frequency and voltagemeet the specifications.

3. On 24Vac applications, assure that J4 terminal 10 and J8

terminal 2 are connected together.

54-57 RESERVED

Internal fault: HFS Internal Fault.

shorted to IAS

Internal Fault: Mux

pin shorted

1. Reset Module.

2. If fault repeats, replace module

Internal Fault: HFS

shorted to LFS

Anti short cycle

Fan speed not

proved

Will not be a lockout fault. Hold Only.

LCI OFF

1. Check wiring and correct any faults.

2. Check Interlocks connected to the LCI to assure proper

function.

3. Reset and sequence the module; monitor the LCI status.

4. If code persists, replace the module

1. Check wiring and correct any faults.

2. Check Preignition Interlock switches to assure proper

functioning.

PII OFF

3. Check the valve operation.

4. Reset and sequence the module; monitor the PII status.

5. If code persists, replace the module.

Interrupted Airflow 1. Check wiring and correct any possible shorts.

H or L

Switch OFF

Interrupted Airflow

Switch ON

2. Check airflow switches to assure proper functioning.

3. Check the fan/blower operation.

4. Reset and sequence the module; monitor the airflow status.

5. If code persists, replace the module.

ILK OFF

1. Check wiring and correct any possible shorts.

2. Check Interlock (ILK) switches to assure proper function.

3. Verify voltage through the interlock string to the interlock input

with a voltmeter.

4. If steps 1-3 are correct and the fault persists, replace the

module.

Date:

Revision:

Form:

8-4-2010

2396

Code Description

Recommended Troubleshooting of Lockout Codes

Code

ILK ON

This lockout occurs when the interlock string is closed before the

blower starts. The airflow switch is the only device in the

interlock string that will open when in standby. Probable causes

are.

1. Air pressure in the boiler room has become negative.

2. Excessive downdraft in the stack.

3. Blower is spinning before being commanded by the

hydronic control. Make sure blower is not running in

standby.

4. Airflow switch is stuck closed.

Pilot test hold

1. Verify Run/Test is changed to Run.

2. Reset Module.

3. If fault repeats, replace module.

Wait for leakage 1. Internal Fault. Reset Module.

test completion 2. If fault repeats, replace module.

71-77 RESERVED

Demand Lost in 1. Check wiring and correct any possible errors.

Run

2. If previous steps are correct and fault persists, replace the

module.

Outlet high limit

1. Check wiring and correct any possible errors.

2. Replace the Outlet high limit.

H or L

3. If previous steps are correct and fault persists, replace the

module.

DHW high limit

Delta T limit

1. Check wiring and correct any possible errors.

2. Replace the DHW high limit.

3. If previous steps are correct and fault persists, replace the

module.

H or L

1. Check Inlet and Outlet sensors and pump circuits for proper H or L

operation.

2. Recheck the Delta T Limit to confirm proper setting.

3. If previous steps are correct and fault persists, replace the

module.

Stack limit

1. Check wiring and correct any possible errors.

2. Replace the Stack high limit.

H or L

3. If previous steps are correct and fault persists, replace the

module.

83-90 RESERVED

Inlet sensor fault

Outlet sensor fault

DHW sensor fault

1. Check wiring and correct any possible errors.

2. Replace the Inlet sensor.

3. If previous steps are correct and fault persists, replace the

module.

1. Check wiring and correct any possible errors.

2. Replace the Outlet sensor.

3. If previous steps are correct and fault persists, replace the

module.

1. Check wiring and correct any possible errors.

2. Replace the DHW sensor.

3. If previous steps are correct and fault persists, replace the

module.

Header sensor fault 1. Check wiring and correct any possible errors.

2. Replace the header sensor.

3. If previous steps are correct and fault persists, replace the

module.

1. Check wiring and correct any possible errors.

Stack sensor fault

Date:

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Form:

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2396

Code Description

Recommended Troubleshooting of Lockout Codes

2. Replace the stack sensor.

Code

3. If previous steps are correct and fault persists, replace the

module

Outdoor

fault

sensor 1. Check wiring and correct any possible errors.

2. Replace the outdoor sensor.

3. If previous steps are correct and fault persists, replace the

module.

Internal Fault: A2D Internal Fault.

mismatch.

1. Reset Module.

2. If fault repeats, replace module.

Internal

Fault:

Exceeded VSNSR

voltage tolerance

Internal

Exceeded

Fault:

28V

voltage tolerance

100

Pressure

Fault

Sensor 1. Verify the Pressure Sensor is a 4-20ma source.

2. Check wiring and correct any possible errors.

3. Test Pressure Sensor for correct operation.

4. Replace the Pressure sensor.

5. If previous steps are correct and fault persists, replace the

module.

101-

104

105

RESERVED

Flame detected out 1. Check that flame is not present in the combustion chamber. H or L

of sequence

Correct any errors.

2. Make sure that the flame detector is wired to the correct

terminal.

3. Make sure the F & G wires are protected from stray noise

pickup.

4. Reset and sequence the module, if code reappears, replace

the flame detector.

5. Reset and sequence the module, if code reappears, replace

the module.

106

107

Flame lost in MFEP 1. Check pilot valve (Main Valve for DSI) wiring and operation -

correct any errors.

Flame lost early in

run

2. Check the fuel supply.

3. Check fuel pressure and repeat turndown tests.

4. Check ignition transformer electrode, flame detector, flame

detector setting or flame rod position.

5. If steps 1 through 4 are correct and the fault persists, replace

the module.

108

109

Flame lost in run

Ignition failed

110

111

Ignition

occurred

Flame

failure Hold time of recycle and hold option. Will not be a lockout fault.

Hold Only. Internal hardware test. Not a lockout.

current

lower than WEAK

threshold

112

113

Pilot test flame Interrupted Pilot or DSI application and flame lost when system

timeout

in “test” mode.

1. Reset the module to restart.

Flame

timeout

circuit Flame sensed during Initiate or off cycle, hold 240 seconds, if

present after 240 seconds, lockout.

114-

121

RESERVED

Date:

Revision:

Form:

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2396

Code Description

Recommended Troubleshooting of Lockout Codes

Code

122

Lightoff

rate 1. Check wiring and correct any potential wiring errors.

2. Check VFDs ability to change speeds.

proving failed

Purge rate proving

failed

3. Change the VFD

4. If the fault persists, replace the module.

123

124

125

126

127

128

129

130

131

High fire switch 1. Check wiring and correct any potential wiring errors.

OFF

2. Check High Fire Switch to assure proper function (not welded

or jumpered).

High fire switch

stuck ON

Low fire switch

OFF

Low fire switch

stuck ON

3. Manually drive the motor to the High Fire position and adjust

the HF switch while in this position and verify voltage through

the switch to the HFS input with a voltmeter.

4. If steps 1-3 are correct and the fault persists, replace the

module.

H or L

Fan speed failed 1. Check wiring and correct any potential wiring errors.

during prepurge

Fan speed failed

during preignition

Fan speed failed

during ignition

2. Check VFDs ability to change speeds.

3. Change the VFD

4. If the fault persists, replace the module.

Fan

detected

standby

movement

during

132

Fan speed failed

during run

RESERVED

133-

135

136

Interrupted Airflow 1. Check wiring and correct any possible wiring errors.

Switch failed to 2. Check Interrupted Airflow switch(es) to assure proper

function.

3. Verify voltage through the airflow switch to the IAS input with

a voltmeter.

4. If steps 1-3 are correct and the fault persists, replace the

module.

137

ILK failed to close

1. Check wiring and correct any possible shorts.

2. Check Interlock (ILK) switches to assure proper function.

3. Verify voltage through the interlock string to the interlock input

with a voltmeter.

4. If steps 1-3 are correct and the fault persists, replace the

module.

138-

148

RESERVED

FAULT

149

CODES

THROUGH

165 ARE OEM

SPECIFIC FAULT

CODES.

149

150

Flame detected

OEM Specific

H or L

1. Holds if flame detected during Safe Start check up to Flame

Establishing period.

Flame not detected OEM Specific

1. Sequence returns to standby and restarts sequence at the

beginning of Purge after the HF switch opens. if flame detected

during Safe Start check up to Flame Establishing period.

151

High fire switch ON OEM Specific

H or L

Date:

Revision:

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2396

Code Description

Recommended Troubleshooting of Lockout Codes

1. Check wiring and correct any potential wiring errors.

Code

2. Check High Fire Switch to assure proper function (not welded

or jumpered).

3.Manually drive the motor to the High Fire position and adjust

the HF switch while in this position and verify voltage through

the switch to the HFS input with a voltmeter.

4. If steps 1-3 are correct and the fault persists, replace the

module.

152

153

Combustion

pressure ON

Combustion

Pressure Off

OEM Specific

1. Check wiring and correct any errors.

2. Inspect the Combustion Pressure Switch to make sure it is

working correctly.

H or L

3. Reset and sequence the relay module.

4. During STANDBY and PREPURGE, measure the voltage

between J6 terminal 5 and L2 (N). Supply voltage should be

present. If not, the lockout switch is defective and needs

replacing.

5. If the fault persists, replace the relay module.

154

155

Purge Fan switch OEM Specific

H or L

1. Purge fan switch is on when it should be off.

2. Check wiring and correct any errors.

3. Inspect the Purge Fan switch J6 terminal 3 and its

connections. Make sure the switch is working correctly and is

not jumpered or welded.

Purge fan switch

OFF

4. Reset and sequence the relay module.

5. If the fault persists, replace the relay module.

OEM Specific

156

157

Combustion

pressure

Flame ON

Combustion

pressure

H or L

and 1. Check that flame is not present in the combustion chamber.

Correct any errors.

2. Make sure that the flame detector is wired to the correct

terminal.

and

3. Make sure the F & G wires are protected from stray noise

Flame OFF

pickup.

4. Reset and sequence the module, if code reappears, replace

the flame detector.

5. Reset and sequence the module, if code reappears, replace

the module.

158

159

Main valve ON

Main valve OFF

OEM Specific

1. Check Main Valve terminal wiring and correct any errors.

2. Reset and sequence the module. If fault persist, replace the

module.

160

161

Ignition ON

Ignition OFF

OEM Specific

1. Check Ignition terminal wiring and correct any errors.

2. Reset and sequence the module. If fault persist, replace the

module.

162

163

Pilot valve ON

Pilot valve OFF

OEM Specific

1. Check Pilot Valve terminal wiring and correct any errors.

2. Reset and sequence the module. If fault persist, replace the

module.

164

Block intake ON

OEM Specific

Date:

Revision:

Form:

8-4-2010

2396

Code Description

Recommended Troubleshooting of Lockout Codes

1. Check wiring and correct any errors.

Code

165

Block intake OFF

2. Inspect the Block Intake Switch to make sure it is working

correctly.

3. Reset and sequence the module.

4. During Standby and Purge, measure the voltage across the

switch. Supply voltage should be present. If not, the Block Intake

Switch is defective and needs replacing.

5. If the fault persists, replace the relay module.

166-

171

172

RESERVED

Main

relay Internal Fault.

feedback incorrect

Pilot relay feedback

incorrect

1. Reset Module.

2. If fault repeats, replace module.

173

174

Safety

relay

feedback incorrect

Safety relay open

Main relay ON at

safe start check

Pilot relay ON at

safe start check

Safety relay ON at

safe start check

RESERVED

175

176

177

178

179-

183

184

Invalid BLOWER / 1. Return to Configuration mode and recheck selected

HSI output setting

Invalid Delta T limit

enable setting

Invalid Delta T limit

response setting

Invalid DHW high

limit enable setting

Invalid DHW high

parameters, reverify and reset module.

2. If fault repeats, verify electrical grounding.

3. If fault repeats, replace module.

185

186

187

188

limit

response

setting

189

190

Invalid

Flame

sensor type setting

Invalid interrupted

air switch enable

setting

191

Invalid interrupted

air switch start

check

enable

setting

192

193

194

195

Invalid igniter on

during setting

Invalid ignite failure

delay setting

Invalid ignite failure

response setting

Invalid ignite failure

retries setting

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Code Description

Recommended Troubleshooting of Lockout Codes

Code

196

Invalid

ignition

source setting

197

Invalid

open

interlock

response

setting

198

199

200

201

202

Invalid

interlock

start check setting

Invalid LCI enable

setting

Invalid lightoff rate

setting

Invalid lightoff rate

proving setting

Invalid Main Flame

Establishing Period

time setting

203

Invalid MFEP flame

failure

setting

response

204

205

Invalid NTC sensor

type setting

Invalid Outlet high

limit

response

setting

206

Invalid Pilot Flame

Establishing Period

setting

207

208

209

210

211

212

213

214

215

216

Invalid PII enable

setting

Invalid pilot test

hold setting

Invalid Pilot type

setting

Invalid Postpurge

time setting

Invalid Power up

with lockout setting

Invalid Preignition

time setting

Invalid

Prepurge

rate setting

Invalid

Prepurge

time setting

Invalid Purge rate

proving setting

Invalid Run flame

failure

setting

Invalid

stabilization

setting

response

217

218

Run

time

Invalid Stack limit

enable setting

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Code Description

Recommended Troubleshooting of Lockout Codes

Code

219

Invalid Stack limit

response setting

220

Unconfigured Delta

limit setpoint

setting

221

222

Unconfigured DHW

high limit setpoint

setting

Unconfigured

Outlet high limit

setpoint setting

Unconfigured Stack

limit setpoint setting

223

224

Invalid

demand

setting

Invalid

DHW

source

225

226

227

228

229

230

231

232

233

234

235

Flame

threshold setting

Invalid Outlet high

limit setpoint setting

Invalid DHW high

limit setpoint setting

Invalid Stack limit

setpoint setting

Invalid Modulation

output setting

Invalid CH demand

source setting

Invalid Delta T limit

delay setting

Invalid

Pressure

sensor type setting

Invalid IAS closed

response setting

Invalid Outlet high

limit enable setting

Invalid

connector

setting

Outlet

type

236

237

238

239

240

Invalid

connector

setting

Invalid

connector

setting

Invalid

connector

setting

Invalid

connector

setting

Inlet

type

DHW

type

Stack

type

Header

type

Invalid

connector

setting

Outdoor

type

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Code Description

Recommended Troubleshooting of Lockout Codes

Code

241-

255

RESERVED

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Section 3 Care and Maintenance

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important to keep these fumes from air intakes

that would distribute them throughout the

building.

WARNING:

The boiler area should be kept free of

combustible materials, gasoline and

other flammable liquids.

3.1.2 BOIL OUT PROCEDURE

The boil out of the boiler and system is neither

difficult nor expensive. The chemicals needed

for cleaning are readily available. Tri-sodium

phosphate, and sodium hydroxide (lye) are the

most commonly used chemicals. Be certain the

chemicals used contain NO CHLORIDES. Use

only one type of solution in the system. The

amount of chemical required will vary according

to conditions, but one pound per fifty gallons of

water is suggested.

The boiler and venting system must be

kept free of obstructions of the air

louvers.

The following procedures must be

conducted as outlined to prevent

damage to and assure safe operation

of the boiler.

Fill the system with this solution, venting all air.

Then, with the circulating pump running, bring

the system to design or operating temperature.

After circulating water for two to three hours, the

system should be drained completely, and

All cover plates, enclosures, and

guards must be in place at all times,

except during maintenance and

servicing.

refilled with fresh, softened water.

Usually

enough of the cleaning solution will adhere to

the piping to result in an alkaline solution

3.1 CLEANING THE BOILER AND

SYSTEM – NEW SYSTEMS

satisfactory for operation.

A pH reading

between 7 and 8 is preferred. If necessary, to

increase the pH, a small amount of cleaner may

be added.

3.1.1 PRE-BOIL OUT FLUSHING OF

SYSTEM

WARNING:

The boil out procedure outlined must

be performed by, or under the direct

supervision of, a qualified technician.

The chemicals used present a hazard

of burns and physical injury if

mishandled. Always use a suitable

facemask, goggles, protective gloves,

and garments when handling caustic

chemicals. Do not permit the chemical

to come into contact with skin or

clothing. Always follow the safety

precautions on the container's label.

Add chemicals slowly and in small

amounts to prevent excessive heat

and agitation.

Much of the dirt and contamination in a new hot

water system can be flushed out before the boil

out of the system. First, flush the system of

waste with clear water.

The boiler and

circulating pumps must be isolated through the

successive zones of the system to waste,

carrying metal shavings, dirt, pipe joint

compound, etc. with it. Follow with a chemical

flush. NOTE! Be CERTAIN that the chemicals

used to flush and boil-out the boiler and system

contain NO CHLORIDES.

The boiler is

fabricated with austenitic stainless steels that

can be severely damaged when exposed to

chlorides. The removal of pipe chips and other

debris from the system before opening the

isolation valves to the boiler and pumps will help

to protect this equipment from damage by such

debris.

In combination with system contamination,

bacteria from ground water boiler water may

produce objectionable odors, sometimes

resembling the odorant used in natural gas. It is

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the tank.

3.1.3 DRAINING THE SYSTEM

Install a strainer in the boiler return piping.

A clean neutral hot water system should not be

drained, except for an emergency or when

unavoidable for servicing of equipment. See

Section 3.3 for water treatment required when

refilling.

3.3 BOILER WATER TREATMENT

Purpose of water treatment

Water treatment is required for satisfactory

operation of the boiler. It must be devised to

prevent depositing of scale and corrosion from

acids, oxygen and other such harmful elements

that may be in the water supply. A qualified

water treatment chemist should be consulted

and the water systematically treated.

3.2 REPLACEMENT BOILER

INSTALLATIONS: PROTECTION

AGAINST CORROSION AND SEDIMENT

Clean or replace all system piping and

heating units

Arrange for chemical or mechanical cleaning of

Objectives

the entire system.

A chemical treatment

The basic objectives of water treatment are:

Prevent the accumulation of scale and deposits

in the boiler.

company should be consulted for the proper

means of any chemical cleaning.

Replace any piping that is deteriorated beyond

safe or cleanable condition.

Flush the system clean, being certain to isolate

the boiler.

Remove dissolved gases from the water.

Protect the boiler against corrosion.

Maintain the highest possible boiler fuel

efficiency.

Decrease the amount of boiler down time from

cleaning.

WARNING:

Water softener

DO NOT FLUSH THE SYSTEM

THROUGH THE BOILER.

It is highly recommended that a zeolite water

softener be used for all make-up to the boiler. It

is intended that this be used in addition to the

For some old systems, there is a reluctance to

clean the piping because of possible leaks

occurring in badly corroded lines. Should the

customer refuse cleaning, it is necessary to

chemical treatment of the boiler.

softening removes calcium and magnesium, the

primary causes of hard boiler scale.

Water

install filtration equipment.

Install either a

Continuous monitoring required

fibrous filter or a centrifugal filter in the boiler

return piping. This will collect and remove

sediment from the system. A booster pump may

be required to overcome the additional pressure

drop introduced in the line by the filter. When

filling the system, provide chemical treatment as

outlined in Section 3.3.

Water treatment should be checked and

maintained whenever the boiler is operating.

The boiler operator should be sure that the

boiler is not operating for long periods without

proper water treatment.

Water treatment may vary from season to

season or over a period of time. Therefore, the

water treatment procedure should be checked

not less than four times a year, and possibly

more frequently as the local water conditions

may indicate.

Failure to properly clean the system or to install

mechanical sediment removal equipment can

result in tube blockage and severe corrosion

plus damage to pumps, controls, and air

removal devices.

It should be noted that water boilers may well

need chemical treatment for the first filling plus

additional

periodic

chemical

treatment,

Inspect, repair as necessary, or replace system

air control devices.

depending on system water losses and the

makeup requirements.

Water treatment may vary from season to

season or over a period of time. Therefore, the

water treatment procedure should be checked

Install gauge glasses on air expansion tanks and

install a tank fitting in the system connection to

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not less than four times a year, and possibly

more frequently as the local water conditions

may indicate. All water introduced into the boiler

should be softened and should include an

oxygen scavenger like sodium sulfite. This is

required to remove dissolved oxygen from the

water. Dissolved oxygen will cause severe

boiler tube corrosion.

WARNING:

If soot or condensation is apparent, a

boiler service technician should be

consulted. The presence of soot

indicates poor combustion and

possibly hazardous boiler operation.

Failure to do so may result in fire,

explosion potential, or asphyxiation. A

combustion test and burner

Draining and refilling the boiler & system

If the system is drained and then refilled,

chemical treatment is essential to treat the raw

water. Use only clean, softened water.

adjustments should be undertaken at

once.

3.4 EXTERNAL “FIRE-SIDE”

CLEANING

Purpose

3.5 SUGGESTED MAINTENANCE

SCHEDULE

Carbon (soot) is an insulator and corrosive. The

heating surfaces of a boiler must be kept free

from soot accumulation to keep the boiler

operating at its highest efficiency and to avoid

damage from corrosion.

Daily

1. Make visual inspection of gauges,

monitors, and indicators and record

readings in boiler log.

2. Make visual check of instrument and

equipment settings against factory

recommended specifications.

Soot removal

If the yearly inspection of the boiler tube

surfaces reveals a build-up of soot or rust

(usually due to condensation), the tubes should

be thoroughly brushed. (Tube cleaning brushes

are available from Bryan Steam) To inspect

and, if necessary, clean the tube surfaces and

flue collector, first remove the tube access

panels. Examine the exterior of the tubes for

evidence of soot or rust. Using a flashlight,

carefully look between the tubes. There should

be an unobstructed opening between all tubes,

and the top surfaces of the tube must be free

from soot accumulation. Also inspect the interior

of the flue collector. Brush or vacuum the soot

from all surfaces. Be sure to cover Triple-Flex

burner with a protective cover during cleaning to

prevent soot from falling onto it.

3. Check operation of probe type low water

cutoff(s) to ensure control is functioning.

Weekly

1. Confirm boiler area is free of

combustible materials and that there is

nothing obstructing air openings, draft

hood relief openings, etc.

2. Check combustion safety controls for

flame failure and flame signal strength

specified

manufacturer's

instructions located at the back of this

manual.

3. Check all limit controls.

4. Check low water cutoff as described

above.

If the buildup of soot is appreciable, the flue gas

venting system must be thoroughly inspected

internally as well, and cleaned as necessary.

Monthly

1. Check high and low gas pressure

interlocks. Refer to manufacturer's

instructions for correct procedure.

Annually

1. The flue gas passages and the exterior

surfaces of the boiler tubes should be

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inspected at least annually.

Any

accumulation of soot or debris should be

thoroughly cleaned out.

2. If the yearly inspection of the boiler tube

surfaces reveals a build-up of soot

(carbon), the tubes surfaces should be

thoroughly brushed. Failure to do so

may result in fire or asphyxiation

hazards.

3. The boiler pressure vessel and piping

should be checked annually.

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Section 4 Lead Lag

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There are parameters that are available to set

the features for Lead Lag.

The LL master turns the first stage on and

eventually turns the last stage off using the

same criteria as for any modulation control loop.

When the operating point reaches the Setpoint

minus the On hysteresis, then the first Sola is

turned on. When the operating point reaches

the Setpoint plus the Off hysteresis then the last

slave Sola (or all slave Solas) are turned off.

Many of the descriptions used are internal

functions or tables. The names help define the

functions but are not controlled or selectable

outside Sola, unless noted as a parameter.

The LL master PID operates using a percent

rate that is, 0% is a request for no heat at all,

and 100% means firing at the maximum

modulation rate.

4.1 GENERAL DESCRIPTION OF THE

LEAD LAG APPLICATION

Sola devices contain the ability to be a stand

alone control, operate as a Lead Lag Master

control which also uses the Sola control function

as one of the slaves or to operate solely as a

slave to the lead lag system. Conceptually it is

not a part of that specific control, but is an entity

that is "above" all of the individual Sola controls

(including the one that hosts it). The master

sees each slave (including the one that hosts it)

as a set of Modbus devices, each having certain

registers, and in this regard it is entirely a

communications bus device, talking to the slave

Sola controls via Modbus.

This firing rate sent to the slaves as a

percentage, but this is apportioned to the slave

Solas according to the rate allocation algorithm

selected by the Rate allocation method

parameter.

For some algorithms this rate might be common

to all slave Solas that are firing. For others it

might represent the total system capacity and be

allocated proportionally.

For example, if there are 4 slaves and the LL

master's percent rate is 30%, then it might

satisfy this by firing all four slaves at 30%,

by operating the first slave at 80% (20% of the

system’s capacity) and a second slave at 40%

(10% of the system’s capacity).

Sola devices utilize two ‘ModBus™’ ports (MB1

and MB2) for communications. One port will be

designated to support a system S7999B display

and the other port will support communications

from the LL Master with its slaves. The diagram

on page 4 shows a simplified wiring diagram

connecting the system display with a 4 system

Lead Lag arrangement.

The LL master may be aware of slave Sola’s

minimum firing rate and use this information for

some of its algorithms, but when apportioning

rate it may also assign rates that are less than

this. In fact the add-stage and drop-stage

algorithms may assume this and be defined in

terms of theoretical rates that are possibly lower

than the actual minimum rate of the Sola control.

In any case a Sola that is firing and is being

commanded to fire at less than its minimum

modulation rate will operate at its minimum rate:

this is a standard behavior for a Sola control in

stand-alone (non-slave) mode.

The Lead Lag master is a software service that

is hosted by a Sola control.

The LL master uses a few of the host Sola's

sensors (header temperature and outdoor

temperature) and also the STAT electrical inputs

in a configurable way, to provide control

information.

4.2 LEAD LAG (LL) MASTER GENERAL

OPERATION

If any slave under LL Master control is in a Run-

Limited condition, then for some algorithms the

LL master can apportion to that stage the rate

that it is actually firing at.

The LL master coordinates the firing of its slave

Solas. To do this it must add stages and drop

them to meet changes in load, and it sends firing

rate commands to those that are firing.

Additionally when a slave imposes its own Run-

limited rate this may trigger the LL

Master to add a stage, if it needs more capacity,

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or drop a stage if the run-limiting is providing too

much heat (for example if a stage is running at a

higher-than commanded rate due to anti-

condensation).

three groups: "Use First", "Equalize Runtime", or

"Use Last". If one or more Solas are in the "Use

First" category, then one of these (the one with

the lowest sequence number) will always be the

first boiler to fire. If there is no Sola in the "Use

First" category and one or more are in the

"Equalize Runtime" category, then the First

boiler is also the Lead boiler.

By adjusting the parameters in an extreme way

it is possible to define add-stage and drop-stage

conditions that overlap or even cross over each

other. Certainly it is incorrect to do this, and it

would take a very deliberate and non-accidental

act to accomplish it. But there are two points in

this:

Add-stage method

Add-stage detection timing

LL master does not prevent it, and more

important;

it will not confuse the LL master because it is

implemented as a state machine that is in only

one state at a time; for example:

• if its add-stage action has been triggered, it will

remain in this condition until either a stage has

been added, or

• the criteria for its being in an add-stage

condition is no longer met; only then will it take

another look around to see what state it should

go to next.

Add-stage request An Add-stage method

implements the criteria for adding another stage.

Criteria that may apply are the firing rate of a

stage or stages vs. a threshold, the amount of

operating point versus setpoint error seen by the

master, the rate at which setpoint error is

developing, and the rate at which a stage or

stages are approaching their maximum or

baseload firing rate.

Typically these use Add-stage detection

timing to determine how long these things have

persisted. When all criteria have been met for a

sufficient time, then an Add-stage request is

active.

Assumptions:

Modulating stage The modulating stage is the

Sola that is receiving varying firing rate requests

to track the load.

Drop-stage method

First stage This is the Sola that was turned on

Drop-stage detection timing

first, when no slave Solas were firing.

Drop-stage request A Drop-stage method

implements the criteria for dropping a stage.

Criteria that may apply are the firing rate of a

stage (or stages) vs. a threshold, the amount of

operating point versus setpoint error seen by the

master, the rate at which setpoint error is

developing, and the rate at which a stage or

stages are approaching their minimum firing

rate.

Previous stage The Sola that was added to

those stages that are firing. Just prior to the

adding of the Sola that is under discussion.

Next stage The Sola that will or might be added

as the next Sola to fire.

Last stage The Sola that is firing and that was

added the most recently to the group of slaves

that are firing. Typically this is also the

modulating stage, however as the load

decreases then the last-added stage will be at

its minimum rate and the previous stage will be

modulating.

Typically these use Drop-stage detection

timing to determine how long these things have

persisted. When all criteria have been met for a

sufficient time, then an Drop-stage request is

active.

Lead boiler The Lead boiler is the Sola that is

the first stage to fire among those stages which

are in the equalize runtime (Lead/Lag) group. If

a boiler is in the "Use first" group it may fire

before the Lead boiler fires.

First boiler A Sola may be assigned to any of

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4.3 SYSTEM WIRING HOOKUP

Figure 40 LL / Multi-Boiler Field Wiring

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be used (a)Lead Outlet - Outlet temperature of

the lead boiler will be used as the backup during

firing (i) Slave Outlet Average - Average of the

outlet temperatures of all slave boilers that are

firing will be used as a backup (b) If the sensor

chosen by the above parameter is faulty then

the backup sensor provided may be used. When

burner demand is off and no burners are firing

then, for either "Lead Outlet" or "Slave Outlet

Average", the lead boiler's outlet temperature is

used to monitor for burner demand. 4. Local

Display Configuration and Operation a. The

configuration parameters available on the local

display are edited in the Service Mode b. Access

to the Service Mode is accomplished by

pressing both up/down buttons for 3 seconds. c.

Status and Operation (1) Slave status (a) “Rmt”

and “Adr” icons are on to show slave (follower)

has been enabled. (b)Current burner status is

shown (c) To show slave CFH (i) Alternate “%”

firing rate and actual (slave) Outlet temp to

indicate slave CFH otherwise show the Home

screen. (2) Master status (a)Rmt icon is on, Adr

icon is off to show Master (Leader) has been

enabled. (b)Current burner status is shown (c)

Actual temperature LL (Header) temperature is

shown as described in 4e below. (d)Pressing the

up/down buttons allows setpoint adjustment for

LL-CH only (not LL-DHW or LL-Mix or others). (i)

All pump configurations must be done using the

PC Configuration tool in the OEM factories.

(e)To show Master CFH (i) Alternate “CH” or

“LL” or “Hdr” in numbers field with the actual

temperature to indicate LL CH CFH. d.

Configuration (1) Continue scrolling through set-

up screens until “Remote Firing Control” screen

is reached. (2) Rmt On/Off selection chooses to

navigate the user through the Master/Slave

configuration as existing today (3) Set

master/slave remote address as is done on

currently on the local display. (4) The following

parameters are mapped to Modbus addresses.

LEAD LAG ^{5 66—A1171}(a) “LL” = LL Operation (3

user selections available) (i) “Ldr” (i-a)Master

Enable (i-b)Slave Enable (ii)“SLA” (ii-a)Slave

Only Enable (ii-b)Master Disable (i) “OFF” (iii-

a)Master Disable (iii-b)Slave Disable (b)HS =

On/Off Hysteresis (One value used for all LL

boilers) (i) “HS” for on and off hysteresis values.

(i-a)Only allow 1 setting for both on and off

hysteresis values. (a-1)Must adhere to the

strictest of either the HS On or Off limits. •

Highest value of the “low” range limit in Sola

control • Lowest value of the “high” range limit in

Sola control (a-2)See Sola Modbus specification

for details. • Typical values: 2-15 (c) BL =

4.4 LEAD-LAG OPERATION

This is a summary of the functional capability of

the embedded lead-lag on the Sola control.

OEM Configurable parameters may be adjusted

as part of the OEM factory configuration and in

the field using the System Display with

appropriate password permissions. Specific

parameters may also be configured in the field

by the local display 1. Field Installation

Configuration a. The master and slave

controllers are enabled via the S7910 or S7999

display. b. All Sola controllers are programmed

with a default address of 1. Assuming the

Master Sola controller remains address 1, the

address of the slave controllers in the system

must have a unique address (1..8) via the local

display. 2. Basic Operation a. Firing rate

determination – Parallel common-base limited

(1) All boilers have a single assignable base

load firing rate. (2) Allocation (a)As load

increases: (i) Until all stages are Firing - No

stage is requested to exceed the common base

load rate. (ii)After all stages are Firing - There is

no restriction on the slave's commanded firing

rate. (b)As load decreases: (i) As long as all

available stages are firing - There is no

restriction on the slave's commanded firing rate.

(ii)When at least one stage has been dropped -

No stage is requested to exceed the common

base load rate. b. Rotation (1) The lead boiler is

rotated based sequence order. The lead boiler

rotation time is a configurable OEM assigned

parameter. Rotation is sequential by address (1-

2-3-4; 2-3-4-1; etc.) (2) Rotation trigger occurs at

the start of each new heat cycle. c. Source of

heat for call – The call for heat originates at the

master boiler. This source may be configured to

be an external thermostat or via EnviraCOM

Remote Stat. d. Slave boiler lockout – If any

slave is in lockout the master boiler will cause it

to be skipped and all system load setting

calculation settings will be based only on

available boilers. e. Master boiler lockout – If the

master boiler is in lockout then its burner control

function will be skipped in the rotation the same

as the slave controllers. However, the master

boiler function will continue to operate. 3.

System Component Failure Responses a. If the

system header sensor becomes disconnected

from the master boiler then the master boiler will

control off of one of the following OEM

configurable actions (1) Disable - No backup will

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Baseload common (i) “BL” for baseload (ii)User

selection 0 – 100 % (d)Use existing timeout,

Done button, and Next button functionality to

enter these parameters. (e)User selections will

be selected by MMI. (i) The local display does

not adhere to the PCB (OEM parameter

selections used by S7999). (5) In normal display

operation the display allows a user to scroll

through a list of temperatures with associated

icons (CH, Inlet, Delta, DHW, Stack, Outdoor)

using the Next button. With LL active the display

will show the header temperature at the end of

the list of temperatures as follows: (a)The

characters “LL” are displayed in the number field

(b)When the next button is pressed again the

temperature is displayed. (c) If the Up or Down

buttons are pressed then the LL set-point is

changed. 5. System Display Configuration – The

following parameters are available for OEM

configuration and may be adjusted through a

System Display or programmed at the OEM

production facility. Master Sola Slave Sola LL

frost protection enable Slave mode LL frost

protection rate Base load rate Base load rate

Slave sequence order LL CH demand switch LL

Demand to firing delay LL CH set point source

LL Modulation sensor LL Base load common LL

Modulation backup sensor LL CH 4mA water

temperature LL Lead selection method LL CH

20mA water temperature LL Lag selection

method LL Add stage method 1 LL Add stage

detection time 1 LL Add stage error threshold LL

Add stage rate offset LL Add stage inter-stage

delay LL Drop stage method 1 LL Drop stage

detection time 1 LL Drop stage error threshold

LL Drop stage rate offset LL Lead rotation time

LL Force lead rotation time LL Drop stage inter-

stage delay

diagram below:

Frost protection requests

The frost protection in this status register will be

set or cleared to match the status generated by

the frost protection detection functions.

Firing for local frost protection This

provides indication to the LL master that

although the burner is firing independently, it is

doing so for frost protection and thus is still

available as a lead/lag slave. This is set when 1)

frost protection is controlling the Sola per the

priority scheme (which occurs only if frost

protection is enabled), and 2) burner demand is

true and the burner is currently firing or

preparing to fire to serve that demand.

Otherwise it will be clear.

Aux Pump X, Y, and Z The pump control in

the Slave can be used by previously existing

command devices to create the same behavior.

However before these bits controlled actions is

specific pump blocks, they are now more

general. The pump X, Y, and Z bits control

actions in any pump block defined to handle

them (see the pump control block definition).

4.6 SLAVE PARAMETERS

SLAVE ENABLE: DISABLE, ENABLE VIA

MODBUS, ENABLE FOR SOLA MASTER

It enables or disables the "LL Slave" Demand

and Rate module. If the slave mode is set to

Disable then: none of the slave functions are

active, Slave Status register is zero, the LL –

Master Service Status register is not writable

and is held at zero (this is important for pump

control which might otherwise use values in this

location). The Slave Command register is

writable but it is mostly ignored, however the

Aux pump X, Y, and Z are effective for any

setting of the Slave enable parameter. The

Enable for Sola Master option Slave write and

Slave read parameters; if "Enable for Sola

Master" is not selected, then these parameters

are disabled.

4.5 SLAVE OPERATION AND SETUP

Slave Data Supporting Lead Lag

This data is provided by each slave Sola control

to support operation when a LL master exists.

The illustration below summarizes the slave's

registers and data:

SLAVE MODE: USE FIRST, EQUALIZE

RUNTIME, USE LAST

If set to Use First, then this Sola will be used

prior to using other Solas with other values. If

set to Equalize Runtime, then this Sola will be

staged according to a run time equalization

LL Slave

Some slave changes relate to pump control,

frost protection, and also are available to 3rd

party (non Sola) LL master devices. The generic

LL slave is updated to operate as shown by the

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algorithm. (Any Solas set to Use First will

precede any that are set to Equalize Run time.)

If set to Use Last, then this burner will be used

only after all Use First and Equalize Runtime

Solas have been brought online.

parameters that enable and disable its

operation.

• Periodic data polling - The LL master uses

polling to discover new slave Sola devices and

to periodically refresh the information it has

about a known slave Sola devices.

SLAVE SEQUENCE ORDER: 0-255

• Slave control - the LL master sends each

active slave a command and also performs a

slave status read for each known slave device. It

also sends a Master status broadcast that is

heard by all slaves.

• Slave status manager - The LL master keeps

track of slave status for each Sola that is

enabled as a slave device.

• Demand and priority - different sources of

demand can cause the LL master to operate in

different ways. These sources have a priority

relationship.

• Modulation - each demand source has one or

more setpoints that may be active and an

operation sensor. These are used to detect turn-

on and turn-off conditions. The difference

Slave sequence order is used to determine the

order in which Solas will be used (staged on) for

those Solas which the same Slave mode setting.

Numbers may be skipped, that is 3 will be first if

there is no 1 or 2. Note: For Equalize Runtime

purposes, 1 does not mean the Sola will be used

first every time; that will vary over time based on

the master's run time equalization scheme. In

this case the sequence number determines the

relative order in which Sola controls will be used

in a round-robin scheme. If the slave sequence

number value is zero, then the slave Sola's

ModBus address will be used instead. If two

Solas which are set the same mode both have

the same sequence number then an alert will

occur and the order in which they are used will

be arbitrary and is not guaranteed to be

repeatable.

between

operating

point

and

setpoint

determines the LL master's firing rate.

• Stager - the stager determines when slave

Solas should turn on as the need for heat

increases, and when they should turn off as the

need for heat decreases.

DEMAND-TO-FIRING DELAY: MM:SS OR

NONE

This delay time is needed by the LL master to

determine the length of time to wait between

requesting a slave Sola to fire and detecting that

it has failed to start. It should be set to the total

time normally needed for the burner to transition

from Standby to Run, including such things as

transition to purge rate, prepurge time, transition

to lightoff rate, all ignition timings, and some

extra margin.

Rate allocation - the PID block's output is used

to determine the firing rate of each slave Sola

using various rate allocation techniques.

• Add-stage methods - various methods can be

used to determine when a new stage should be

added.

• Drop-stage methods - various methods can

be used to determine when a stage should be

dropped

• Sequencer - the Sola sequencer determines

which Sola will be the next one to turn on or turn

off.

BASE LOAD RATE: RPM OR %

This specifies the preferred firing rate of a

burner, which is used for some types of control

algorithms.

FAN DURING OFF-CYCLE RATE: RPM OR %

(0=DISABLE)

4.7.1 OVERALL CONTROL

This determines if or where the fan is to be

operating during the standby period.

LL MASTER ENABLE: DISABLE, ENABLE, LL

MASTER MODBUS PORT: MB1, MB2 If

Disable is selected then all LL master functions

are inactive. If Enable is selected then it acts as

the active bus master on the ModBus port it is

assigned. LL OPERATION SWITCH: OFF, ON

This controls the LL master in the same way that

the Burner switch controls a stand-alone Sola. If

"On" then the LL master is enabled to operate. If

this parameter is "Off" then the LL master turns

4.7 LL MASTER OPERATION AND

SETUP

LL master operation is subdivided into the

following functions:

• Overall control - The LL master has

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off all slaves and enters an idle or standby

condition.

discover what happened in a subsequent status

response). The LL master also sends this

message to a slave that is OnLeave. (This

ensures that if the slave is firing when it returns

to LL master control, it will stay that way until the

master has decided whether to use it; or

conversely, if the slave stops firing for some

reason that it will not start up again until the LL

master has requested this. In either case, the

command will be to turn on the off cycle fan if

any other slave burners are firing, or to turn the

fan off if the slave is the only slave that might (or

might not) be firing.

• The LL master sends message to turn the

burner on and to assign the burner’s firing rate.

If the commanded modulation rate is less than

the burner’s minimum modulation rate, then the

burner should always operate at its minimum

rate.

4.7.2 PERIODIC DATA POLLING

MESSAGES

The LL master uses polling to discover new

slave Sola devices and to periodically refresh

the information it has about a known slave Sola

devices. Thereafter it polls the known devices to

make sure they are still present and to obtain

updated status information. It also periodically

polls the entire slave address range to discover

any new slave devices. A polled Sola is read to

determine the values of the following data items:

a. The slave's type (compatibility) as indicated

by the Slave type b. The slave enable status

Slave enable c. The slave mode as set in Slave

mode d. The slave sequence order as set in

Slave sequence order e. Demand-to-firing

delay: mm:ss or None This delay time is

needed by the LL master to determine the length

of time to wait between requesting a slave Sola

to fire and detecting that it has failed to start. It

should be set to the total time normally needed

for the burner to transition from Standby to Run,

including such things as transition to purge rate,

prepurge time, transition to lightoff rate, all

ignition timings, and some extra margin. f. CT -

Burner run time This parameter will be needed

if measured run-time equalization is being used.

4.7.3 SLAVE STATUS MANAGER

The LL master keeps track of slave status for

each Sola that is enabled as a slave device. The

slave status manager operates internally for

each slave Sola devices (up to 8). There is a

table entry for each device containing the

following data:

• SlaveState:

Unknown - indicates the table entry is unused

and empty

Available - indicates the slave is OK and ready

to use, but is not

currently firing as a slave

Slave Control

The LL master sends each active slave a

command and also performs a slave status read

for each known slave device. It also sends a

Master status broadcast that is heard by all

slaves. There are 5 commands that might be

sent:

• All slaves are commanded to turn off and

remain off.

• The LL master sends message to Solas that

are off, to turn their fans on.

• The LL master suspends operation which

request a burner to recycle and remain in

Standby if it has not yet opened its main valve

(e.g. it is in Prepurge or PFEP) but to keep firing

if it has reached MFEP or Run. This suspend

may be for the fan to be on or off in standby.

This message is used to abort the startup of a

slave that is not yet firing (because demand

went away just before it was firing), but to keep it

on if it actually is firing (the LL master will

AddStage - stage is getting ready to fire

SuspendStage - stage was getting ready but is

not needed

Firing - indicates the slave is currently firing

OnLeave - indicates the slave is operating for

some other demand source within it that has

higher priority than slave demand.

Disabled - indicates the slave is locked out or

disabled in some way

Recovering - indicates the slave is in a time

delay to ensure that it is OK before it is again

considered to be available.

• RecoveryTime: Saves how long the slave

must be OK to recover.

• RecoveryTimer: Used to measure the slaves

recovery time

• RecoveryLimitTimer: Enforces a maximum

slave recovery time

•

DataPollFaultCounter: Used to tolerate

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momentary communication problems and to act

on these if they are excessive.

INVALID RESPONSE OR NO RESPONSE

•

StatusReadFaultCounter: Used to tolerate

momentary communication problems and to act

on these if they are excessive.

• AbnormalFaultCounter: Used to tolerate

momentary abnormality

• StagingOrder: Used to record the stage-on

order, for use by the sequencer when it needs to

drop a stage.

When a Sola responds to a data poll with an

improperly formatted message or it does not

respond then the slave status table is checked

and: If the polled slave device is in the table then

the Data Poll Fault is noted. If this causes a

fault counter to exceed the fault value then the

SetRecovering handling is invoked.

• Storage for each item described in the Periodic

data polling section • Storage for each item

described in the Slave status read response

section • Slave Command - the command word

from the master to the slave.

SlaveState states

Recovering A slave that is recovering is

checked once per second. If the slave has

recovered the SlaveState table is changed to

Available. If the slave has not yet recovered

when its recovery timer reaches the

RecoveryTimeLimit then: If the slave is not

enabled for the Sola LL master its SlaveState

table is Set to Unknown (which logically

removes it from the slave table). Otherwise the

Recovery- LimitTimer is cleared which starts a

new recovery measurement and the slave

remains in recovery (indefinitely).

Features common to all states

• Whenever a slave Sola device is not in an

expected condition then a recovery function is

used to set up timers to give a faulty slave: —

minimum time that it must appear to be OK, and

— limit how long a slave has to recover from any

error.

• If the slave status read was bad then the

slave's FaultCounter is incremented and if it to

reaches the fault value tries, then a recovery

action is invoked. This action does nothing else

if the status read was Bad. If the slave status

read was OK then the status function puts the

slave read response data in a slave status table.

If a transition to another state is indicated then

the SlaveState is simply set to the indicated

state.

Available A slave in the Available state remains

that way until the Stager moves it into the

AddStage state or the ProcessSlaveStatus

action moves it to some other state.

AddStage A slave in the AddStage state

remains that way until the ProcessSlaveStatus

moves it to Firing or some other state, or the

Stager times out and moves it into the

Recovering state if it fails to fire.

Data poll response handling

Valid Response Message

SuspendStage A slave in the SuspendStage

state

remains

that

way

until

the

ProcessSlaveStatus moves it to some other

state, or the Stager times out and moves it into

either the Firing or the Available state.

Firing A slave in the Firing state remains that

way until the ProcessSlaveStatus moves it to

some other state, or the Stager drops the stage

and moves it into the Available state.

OnLeave A slave in the OnLeave state remains

that way until the ProcessSlaveStatus moves it

to some other state.

Disabled A slave in the Disabled state remains

that way until the ProcessSlaveStatus moves it

to Recovering.

When a slave Sola responds with a properly

formatted message it is examined to see if

Slave enable value is "Enable for Sola Master".

• If the "Enable for Sola Master" value is not

present then the slave status table is checked

and if the slave is not in the table then the

message is ignored (this is normal). However if

the slave is in the table then the message is

stored as usual and the slave will invoke the

action as a disabled slave and cause recovery

action to occur.

• If the "Enable for Sola Master" value is present

then the slave status table is checked and if the

slave is not in the table then the slave data is

stored in an empty position in the table.

However if the slave is in the table then the

message is stored as usual (this is the normal

case).

Demand and Priority

Different sources of demand can cause the LL

master to operate in different ways. These

sources have a priority relationship.

CH Demand

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New occurrences of CH demand is inhibited.

DHW demand is not affected.

LL CH DEMAND SWITCH: DISABLE, STAT,

ENVIRONCOM REMOTE STAT

The inputs that can function as the CH demand

switch are: STAT, EnvironCOM Remote Stat. If

the CH demand switch value is Disable, the LL

master does not respond to CH demand.

Warm Weather Shutdown

Frost protection

LL master frost protection is enabled with Frost

protection enable: Disable, Enable

WARM WEATHER SHUTDOWN ENABLE:

DISABLE, SHUTDOWN AFTER DEMANDS

The need for frost protection is actually detected

independently by each slave which notifies the

master whether frost detection occurred in CH

frost detection, and/or its DHW frost detection,

and whether it is severe enough to require

burner firing as well as pump operation. This is

done via its Slave status parameter.

HAVE ENDED, SHUTDOWN IMMEDIATELY

WARM WEATHER SHUTDOWN SETPOINT:

TEMPERATURE OR NONE

When warm weather shutdown is Disabled then

it has no effect (i.e. the Warm Weather

Shutdown (WWSD) status shown on the priority

diagram is false).

If Frost protection enable is Enable then the

master's Slave write message, will indicate CH

or DHW frost protection or both as read from

each slave's Slave Status. This will cause any

slave pumps which are enabled to follow this

status to turn on without any other action

required from the master.

These two parameters are shared by the stand-

alone Sola control and the LL master and have

the same effect for either control.

This function requires the outdoor temperature.

This temperature may be obtained from either a

local sensor or a LL slave. If WWSD is enabled

but the outdoor temperature is invalid and

unknown, then the WWSD function acts as if it is

disabled and has no effect and an alert is issued

indicating an invalid outdoor temperature.

If any slave is indicating CH or DHW frost

protection, and additionally that slave's Slave

status register indicates burner firing is

requested then the LL master's frost protection

burner demand will be true.

If the priority scheme allows the master to honor

this demand, then it will fire a single burner (the

current lead burner as specified by the

sequencer) at the rate indicated by Frost

protection rate: 0-100%. (100% represents

100% firing of this boiler, and where 0% or any

value less than the boiler's minimum firing rate

represents the minimum firing rate).

If it is enabled then it uses a 4°F (2.2°C)

hysteresis:

If WWSD is false, then when the Outdoor

temperature is above the value provided by

Warm weather shutdown setpoint then:

If "Shutdown after demands have ended" is

selected then any current CH demand that is

present prevents WWSD from becoming true;

that is if CH demand is false then WWSD

becomes true.

Priority Control

CH heat demand is a simple signal such as

STAT, Enviro- COM remote stat, or Warm

Weather Shutdown.

Otherwise if "Shutdown immediately" is

selected then WWSD becomes true, it

immediatetly causes CH demand to end.

Frost protection input to the priority logic is not a

heat demand, it is a burner demand (because

frost protection always turns on pumps without

regard to the priority control - it is a priority item

only if it also wants to fire).

If WWSD is true, then when the Outdoor

temperature is below the value provided by

Warm weather shutdown setpoint minus 4°F

(2.2°C) then WWSD becomes false.

Master Status

MASTER HEAT DEMAND

When warm weather shutdown is true then:

Is a data item which contains the status for the

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following sources of demand. All sources that

are currently calling for heat will be true (multiple

items may be true at the same time) except

when WWSD is active, then CH demand is

inhibited.

These are used to detect turn-on and turn-off

conditions. The difference between operating

point and setpoint determines the LL master's

firing rate

CH Demand

4.7.5 MODULATION SENSOR

CH Frost demand – true if any slave is calling for

CH frost protection and Frost protection

enable is true.

LL MODULATION SENSOR: S5

The LL master's modulation sensor uses the S5

sensor (connector J8 terminal 11 and 12). If the

LL master is enabled and its sensor is faulty

then an alert will be issued.

4.7.4 MASTER ACTIVE SERVICE

Is a data item which contains the identity of a

single source of demand that the LL Master is

currently serving according to its priority:

• None – no active service, LL master is idle

• CH

MODULATION

BACKUP

SENSOR:

DISABLE, LEAD OUTLET, SLAVE OUTLET

AVERAGE

If the sensor chosen by the LL Modulation

sensor is faulty then the backup sensor

provided here may be used.

• Frost – burner demand is true for frost

protection

• WWSD – no high priority demand is active, and

WWSD is inhibiting CH demand (if any).

If Disable is selected then no backup will be

used.

MASTER SERVICE STATUS

If Lead Outlet is selected then the outlet

temperature of the lead boiler will be used as the

backup during firing.

Is a data item used by pump control logic that

combines the Master Heat Demand and Master

Active Service data. It is implemented as

described by the Pump Control Block diagram.

If Slave Outlet Average is selected then

average of the outlet temperatures of all slave

boilers that are firing will be used as a backup.

When the burner demand is off and no burners

are firing then, for either Lead Outlet or Slave

Outlet Average, the lead boiler's outlet

temperature is used to monitor for burner

demand.

Outdoor Temperature

For a Sola that hosts a LL master, the outdoor

temperature may be known from either of two

sources. If the host Sola has an outdoor sensor

that is reporting a valid temperature then this

sensor reading is used. Otherwise, if any slave

Sola is reporting a valid temperature as part of

its Data Poll message, then this temperature is

used.

Setpoints

LL CH SETPOINT SOURCE: LOCAL, S2 4-

20MA

If the setpoint source is Local then the Sola

control's local setpoint system is used. This

setting enables the normal use of the CH

setpoint, CH TOD setpoint, and the CH outdoor

reset parameters and functions.

The resulting outdoor temperature provides all

outdoor temperature needs for both stand-alone

and LL master purposes. If neither source has a

valid temperature then the outdoor temperature

is simply invalid and unknown, and the functions

which need this information handle it accordingly

per their individual definitions.

If the setpoint source is S2 4-20mA then the

setpoint is determined by the 4-20mA input on

S2, and the two parameters described below. If

the 4-20mA signal goes out of range or is

invalid, and this persists for a specified time,

then the setpoint source reverts to "Local". In

this case once it has gone to "Local", it remains

Modulation

Each demand source has one or more setpoints

that may be active and an operation sensor.

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that way until the 4- 20mA signal is stable again.

None

• LL CH ODR boost step: degrees or None

• LL CH ODR boost recovery step time:mm:ss or

None

LL CH 20MA WATER TEMPERATURE:

TEMPERATURE OR NONE

4MA

WATER

TEMPERATURE:

The outdoor reset function requires the outdoor

temperature. This temperature may be obtained

from either a local sensor or a LL slave as

described earlier. If the outdoor temperature is

invalid and unknown, then no outdoor reset

action occurs and an alert is issued indicating an

invalid outdoor temperature.

TEMPERATURE OR NONE

These provide the 20mA and 4mA temperatures

for the interpolation curve. If either of these have

the None value, are invalid, are out of range, or

are too close for interpolation, an alert is issued

and the setpoint reverts to "Local" when it is

selected as 4-20mA.

ODR

MINIMUM

WATER

LL CH SETPOINT: DEGREES OR NONE

This setpoint is used when the time-of-day input

is off. If the ODR function is inactive then the

setpoint is used as-is. If the ODR function is

active then this setpoint provides one coordinate

for the outdoor reset curve.

TEMPERATURE: DEGREES OR NONE

This specifies the minimum outdoor reset

setpoint for the LL master. If the outdoor reset

function calculates a temperature that is below

the temperature specified here, then this

parameter's temperature will be used. If this

parameter is invalid or None then the outdoor

reset function will be inhibited and will not run: if

it is enabled then an alert is issued.

LL CH TOD SETPOINT: DEGREES OR NONE

This setpoint is used when the time-of-day input

is on. If the ODR function is inactive then the

setpoint is used as-is.

If the ODR function is active then this setpoint

provides one coordinate for the shifted (because

TOD is on) outdoor reset curve.

4.7.6 DEMAND AND RATE

On/Off Hysteresis Includes hysteresis shifting

at turn-on, turn-off

TIME OF DAY

The Time of Day has one sources of control: a

switch contact. Closed TOD is an on condition;

open, then TOD is off.

LL OFF HYSTERESIS: DEGREES OR NONE

LL ON HYSTERESIS: DEGREES OR NONE

OUTDOOR RESET AND BOOST (BOOST IS

FUTURE)

The outdoor reset and boost functions for the LL

CH functions will be implemented as described

for a stand-alone CH loop.

The LL hysteresis values apply to all setpoint

sources. The behavior of the hysteresis function

is identical to the behavior of the stand-alone CH

hysteresis function, except:

Each of the loops which implements outdoor

reset and boost has its own parameters. The

parameters used by the LL master are:

• LL setpoint

• where stand-alone CH hysteresis uses the

on/off status of a single burner, the LL hysteresis

uses the on/off status of all slave burners: this

status is true if any slave burner is on, and false

only if all are off.

• where stand-alone CH hysteresis uses time of

turn-on and turn-off of a single burner, the LL

hysteresis uses the turn-on of the first slave

burners and the turn-off of the last slave burner.

• LL CH TOD Setpoint

• LL Outdoor reset enable: Disable, enable

• LL CH ODR minimum outdoor degrees or

None

• temperature:

• LL CH ODR maximum outdoor degrees or

None temperature:

• LL CH ODR low water temperature: degrees or

None

• LL CH ODR boost time: mm:ss or None

• LL CH ODR boost max setpoint: degrees or

LEAD LAG PID

The behavior of the Lead Lag PID function is

identical to the behavior of the stand-alone CH

PID function. The same gain scalars and

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algorithms are used. Additionally:

of step 1 are no longer true (demand has

decreased) then it clears the flag.

Whenever the rate allocator completes an

execution pass and detects both conditions of

step 1 are true, and it also detects that the total

rate potentially absorbed by the system (the

commands have not yet been sent) has

increased from the value that was saved when

the flag was set, then it re-computes the

integrator value based on the old commanded

maximum, clears the flag, and actually allocates

the old rate that was saved when the flag was

set.

4.7.7 RATE ADJUSTMENT

When the Slave dropout/return compensation

parameter specifies a rate adjustment and a rate

compensation event occurs (a slave leaves

while firing, or a slave returns) then rate

adjustment will alter the integrator value so that

the commanded rate compensates for the added

or lost capacity.

INTEGRATOR COMPENSATION

Examples include:

A stand-alone Sola includes a feature to smooth

the response when a rate override has occurred

(such as delta-T rate limit) causing the PID

output to be ignored.

• The rate allocator has encountered a limit such

as base load (for a "limited" rate allocation

scheme) and this limit is released.

Whenever an override has occurred then, at the

moment the override ends, the integrator is

loaded with a value that causes the PID output

to match the current rate, whenever this is

possible within the integrator’s limits. The Lead

Lag PID will implement similar behavior: The

rate allocator will provide a trigger that causes

the integrator's value to be recomputed and this

trigger will activate whenever a rate allocation

limit is released; that is, this event will occur any

time the system transitions from the condition in

which it is not free to increase the total

modulation rate, to the condition where this rate

may increase.

• All stages are at their maximum (base load, or

max modulation) and one or more stages are

rate-limited (such as due to slow-start or

stepped modulation limiting due to high stack

temperature, etc.) and the rate limited stage

recovers, changing from rate-limited to free to

modulate.

(This is indicated by the Slave Status "slave is

modulating": the changing from false to true is

not, itself, a trigger, but while it is true the rate

allocator can assign to the slave only the firing

rate that it is reporting; thus the release of this

might allow more rate to be absorbed by the

system. It also might not do this, if for example

the slave was in anticondensation and thus the

rate limit was maximum modulation rate.)

4.7.8 IMPLEMENTATION

• All firing stages are at their maximum (base

load, or max modulation) and a stage which was

OnLeave returns in the firing state and is

available for modulation.

The examples below are ways in which this may

occur, but in implementation what is necessary,

first of all, is to use a rate allocator that assigns

rate to each slave and can detect when all of the

assigned rate is absorbed, or if there is excess

requested rate that the firing stages could not

absorb.

• An add-stage is in-progress and all firing

burners are at their limits (max modulation rate

or base load) and then the new stage becomes

available.

Then:

Whenever the system is rate limited, that is,

when A) all firing stages are commanded to their

respective maximums and also B) the PID is

asking for more heat than that, note that this has

occurred by setting a flag and also record total

rate that the system absorbed (the total of the

commanded maximums, not the PID's requested

rate which might include excess).

This also applies when the system is first

starting up, that is, all firing burners are at their

limits (zero) because non are firing, and thus

when the add-stage is finished the system

transitions from no modulation at all, to

modulating the first stage.

Whenever the rate allocator completes an

execution pass and detects that both conditions

Lead Lag Burner Demand

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Lead Lag burner demand will be present when

Frost protection burner demand is true, as

described in the section on Frost protection. For

the CH, and DHW demand sources, Lead Lag

burner demand will be true when one of these is

true and also setpoint demand from the

hysteresis block is true.

each slave. Some rate allocation algorithms may

specify the use of this parameter, and that the

slave base load settings are ignored.

RATE ALLOCATION METHOD: PARALLEL

COMMONBASE LIMITED

This selects the rate allocation method. This

performs three purposes:

it determines how the LL master allocates firing

rate to each active stage,

4.7.9 RATE ALLOCATION

the modulating stage and last stage are

determined for the Add-stage and Drop-stage

methods,

it determines the overflow rate and underflow

rate and can provide this to staging algorithms.

The PID block's output is used to determine the

firing rate of each slave Sola using various rate

allocation techniques.

Common Features

OVERFLOW RATE AND UNDERFLOW RATE

The rate allocator knows the rate assigned to

each stage, and the requested rate, and thus

can determine the difference between these.

All rate allocation methods share certain

features. The rate allocator first generates the

Slave Command. Except for the Firing state,

the value ultimately depends only upon the

SlaveState. The values are:

This difference has two forms: overflow (used by

Addstage methods), underflow (used by Drop-

stage methods).

Available

AddStage

When asked for rate overflow the threshold that

is used is the upper limit of the modulating stage

per the current rate allocation rules. Additionally

this threshold may be shifted if the Add-stage

method is using a dRate/dt behavior. Rate

overflow is a positive or negative percentage

offset from the threshold. For example:

SuspendStage depending on whether any other

slave stage is firing, no matter what SlaveState it

is in.

Firing

OnLeave - same as SuspendStage

This ensures that when a slave returns and is

already firing, it will remain firing until the master

decides what to do about that, or if it is not firing

it will remain off.

If the modulating stage is at the staging

threshold position but the

Disabled - same as Available

Recovering - same as Available

It next runs a rate allocator that depends upon

the rate allocation method. This routine fills in

the modulation rate for all Firing boilers.

LL master is not asking for more heat than this,

then the overflow rate is 0%. If it is at this

location (limited) or above this location

(unlimited) and the LL master is asking for 10%

more than the threshold value, then the overflow

rate is 10%. If it is below the staging threshold

position by 5%, then the overflow rate is -5%.

Each rate allocation method also provides

functions to return identification of the

modulating stage and the last stage, for use by

the Add-stage and Drop-stage methods.

When asked for rate underflow the threshold

that is used is the minimum modulation rate of

the last stage. Additionally this threshold may be

shifted if the Dropstage method is using a

dRate/dt behavior.

Rate Allocation Parameters

BASE LOAD COMMON: 0-100%

If set to zero, this parameter is disabled. For any

non-zero value, it uses the individual base load

rates of each slave to be ignored by the LL

master's routines and this common value to be

used instead. It is an easy way to set all base

loads to the same value, without having to set

Rate underflow is a positive or negative

percentage offset from the threshold. For

example:

If the last stage is at the threshold position but

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the LL master is not asking for less heat than

this, then the underflow rate is 0%. If it is at this

location and the LL master is asking for 10%

less than the threshold value, then the underflow

rate is -10%. If the last stage is 5% above the

threshold then the underflow rate is 5%.

For the Parallel common-base limited the

minimum modulation rate provides the underflow

threshold.

Stager

The Stager is an internal program that

determines when slave Solas should turn on as

the need for heat increases, and when they

should turn off as the need for heat decreases.

Rate allocation methods

PARALLEL

Allocation

COMMON

BASE

LIMITED

In all cases:

• The first burner turns on due to the

combination of heat demand (call for heat) and

setpoint demand (operating point falls below the

setpoint minus the on hysteresis).

All stages that are Firing receive the same firing

rate.

Only the Base load common parameter is used

for base loading, the individual slave's base load

values are ignored.

• The last burner (or all burners) turn off due to

the loss of burner demand which is caused by

either the loss of heat demand (no call for heat)

or the loss of setpoint demand (the operating

point climbs above the setpoint plus the off

hysteresis).

• In between those two extremes the Add-stage

and Dropstage methods determine when staging

occurs. The stager handles burner on and

burner off events. It operates according to this

state transition diagram.

As load increases:

Until all stages are Firing:

No stage is requested to exceed the common

base load rate.

After all stages are Firing:

There is no restriction on the slave's

commanded firing rate.

The stager has the following variables:

StagerState: encodes the current state of the

stager.

StagerTimer: multipurpose 1 second timer used

by states which measure time.

StagerTimeLimit: the timeout value for the

StagerTimer

As load decreases:

As long as all available stages are Firing There

is no restriction on the slave's commanded firing

rate.

When at least one stage has been dropped:

No stage is requested to exceed the common

base load rate.

LeadStartup: flag indicating the lead boiler is

starting

AddStageA: the stage being added to those

already firing

MODULATING STAGE

Since all Firing stages receive the same rate,

any stage can be considered to be the

modulating stage. The one with the highest

StagingOrder number is considered to be the

modulating stage.

Stager Parameters

ADD-STAGE INTERSTAGE DELAY: MM:SS

This specifies the minimum time that the Stager

waits after adding one stage before adding

another stage or dropping a stage.

Last stage

DROP-STAGE INTERSTAGE DELAY: MM:SS

This parameter specifies the minimum time that

the Stager waits after dropping one stage before

dropping another stage or adding a stage.

The stage with the highest StagingOrder

number is the last stage.

OVERFLOW AND UNDERFLOW

Functions common to all stager states

These functions handle overall burner demand

responsibility, and take care of cleaning up any

anomalous conditions.

For the Parallel common-base limited the

Base load common parameter provides the

overflow threshold.

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4.7.10 BURNER DEMAND

If so then the stager: Changes the SlaveState to

Suspend- Stage, resets and starts its

StagerTimer, sets the StagerTimeLimit to

T_StagerSuspend. This allows additional time

for the slave to reach its firing condition.

The stager checks the Master’s LL burner

demand. If this demand is off all slaves with

SlaveStates of AddStage, SuspendStage, or

Firing are set to Available by the Rate Allocator

turning them all off and the StagerState is set to

be Idle.

STAGERSTATE = ADDSTAGESUSPEND

During this state the stager is waiting to see if

the slave has transitioned to Firing or Available.

STAGERSTATE = IDLE WITH SLAVES ACTIVE

If the stager runs and its state is Idle, it checks

the status of all slaves. If any of these have

SlaveState=AddStage, SuspendStage, or Firing

then these are set to Available (this will cause

the Rate Allocator to turn them all off).

If the identified boiler has a SlaveState=Firing

then the stager:

Resets and starts its StagerTimer, sets the

StagerTime- Limit to Add-stage interstage

delay, it changes the StagerState to

InterstageDelay.

Stager States

The stager's operation is defined for each of its

states:

STAGERSTATE = IDLE

The stager checks to see if the StagerTimer

has reached the StagerTimeLimit.

Burner demand means that a demand source is

calling for heat and there is also setpoint

demand.

If so then:

If the boiler's SlaveState is set to Available.

If any slave boiler is firing then StagerState =

Active

Otherwise StagerState = Idle

When there is no burner demand the stager is

forced to be Idle.

When burner demand becomes true (Call for

Heat) the stager checks the sequencer to

identify the lead boiler. That boiler is given a

command to start.

STAGERSTATE = ACTIVE

During this state the stager is ready to manage

add-stage and drop-stage requests.

If AddStageRequest is true

The stager resets (to verify it is at 0) and starts

its

Stager-

Timer,

and

sets

the

The Stager ask the Sequencer for an available

slave.

When an available slave is found the stager

repeats the above steps to bring this stage to

Active.

StagerTimeLimit to the value of the slave's

Demand-to-firing delay time.

If the Stager fails to get even one boiler from the

Sequencer, it issues an alert and suspends until

it runs again.

If DropStageRequest is true and more than 1

slave burner is firing, the stager:

STAGERSTATE = ADDSTAGERESPONSE

During this state the stager is waiting for slave to

transition to Firing. If the identified boiler has a

SlaveState=Firing then the stager:

Resets and starts it’s StagerTimer, sets the

StagerTime- Limit to Add-stage interstage

delay, and changes the StagerState to

InterstageDelay.

Invokes SetRecovering for the stage identified

by DropStageRequest. This will turn the stage

off and put it into the recovering state until it has

finished its postpurge (if any).

Resets and starts its StagerTimer, sets

StagerTime- Limit to Drop-stage interstage

delay,

changes

the

StagerState

If the boiler's SlaveState is still AddStage then:

InterstageDelay, invokes an action to reset the

Add/Drop detection timers.

The stager checks to see if the StagerTimer

has reached the StagerTimeLimit.

When the Interstage time has elapsed, the

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Stager can execute an AddStage or DropStage

request.

amount greater than or equal to Add-stage

error threshold

Add Stage Methods

When the Add-stage condition is false then

AddStage- DetectTimerN is set to zero. (If the

condition is true then AddStageDetectTimerN

is not zeroed and thus allowed to run.) If this

timer reaches or exceeds LLAdd- stage

detection timeN then AddStageRequestN is

true.

Various methods can be used to determine

when a new stage should be added. The internal

algorithms that generate AddStageRequests

are called Add-stage methods.

All methods work by observing various criteria

such as the Firing stages, the commanded rate,

or setpoint error.

RATE THRESHOLD For rate based staging, a

stage is added based on the rate of the

modulating stage.

Adding Stages Parameters:

ADD-STAGE CONDITION:

ADD-STAGE DETECTION TIME1: MM:SS

This provides time thresholds.

The modulating burner is at a rate that is at or

above the rate which is calculated by adding the

Add-stage rate offset to the maximum position

per the rate allocation rules.

In the descriptions below, the relevant

parameter is referred to as Add-Stage

detection timeN.

Examples: rate offset = 20% The add-stage

condition will occur if the modulating stage is

20% above base load for unlimited allocations,

or, if limited, when there is 20% more rate to

distribute than can be absorbed by firing the

stages at base load.

Add-Stage method1:

Disable,

Error threshold,

Rate threshold,

dError/dt and threshold,

dRate/dt and threshold }

rate offset = -20% The add-stage condition will

be as described just above, but the threshold is

now 20% below the modulating stage's base

load rate.

In the descriptions below, the relevant

AddStageDetect- Timer is referred to as

AddStageDetectTimerN.

To support this, the current Rate Allocation

method asks for the current "Overflow rate" -

see the Rate Allocator section.

ADD-STAGE

DEGREES

ERROR

THRESHOLD:

This provides the error threshold as defined by

the methods below.

Drop Stage Methods

Various methods can be used to determine

when a stage should be dropped. The internal

algorithms that generate DropStageRequests

are called Drop-stage methods.

ADD-STAGE RATE OFFSET: -100% TO +100%

This provides the rate offset threshold as

defined by the methods below.

One or two methods may be active at any time.

If two are active then their requests are OR'd

together.

Add-stage methods

ERROR THRESHOLD

For error threshold staging, a stage is added

when the error becomes excessive based on

degrees away from setpoint, and time.

All methods work by observing various criteria

such as the Firing stages, the commanded rate,

or Setpoint.

ADD-STAGE CONDITION:

Dropping Stages Parameters:

- The modulating burner(s) is at its (their)

maximum position per the rate allocation rules,

- The operating point is below the setpoint by an

DROP-STAGE DETECTION TIME: MM:SS

This provides time thresholds. They differ only in

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that:

DropStageDetectTimerN is set to zero. (If the

condition is true then DropStageDetectTimerN

is not zeroed and thus allowed to run.) If this

timer reaches or exceeds Dropstage detection

timeN then DropStageRequestN is true.

Drop-Stage detection time is used with

DropStageDetectTimer

In the descriptions below, the relevant

parameter is referred to as LL – Drop Stage

detection timeN}.

Drop-Stage method:

RATE THRESHOLD

Disable,

Error threshold,

For rate based staging, a stage is dropped

based on the rate of the last stage.

Rate threshold,

dError/dt and threshold,

dRate/dt and threshold

DROP-STAGE CONDITION:

-The modulating burner(s) is at a rate that is at

or below the minimum modulation rate plus a

rate offset.

DROP-STAGE

DEGREES

ERROR

THRESHOLD:

Examples:

This provides the error threshold as defined by

the methods below.

rate offset = 20% The Drop-stage condition will

occur when the last stage is less than a

threshold that is the minimum modulation rate

plus another 20%.

DROP-STAGE RATE OFFSET: -100% TO

+100%

This provides the rate offset threshold as

defined by the methods below.

rate offset = 0% The Drop-stage condition will

occur when the last stage is at the minimum

modulation rate.

LL boiler off options:

Options disabled,

rate offset = -20% The Drop-stage condition will

occur if the last stage is at minimum modulation

and there is 20% less rate to distribute than can

be absorbed; that is, the rate allocator would like

the minimum modulation rate to be lower than it

is.

Enable all boilers off (ABO)

Enable lead drop-stage on error (LDSE)

Enable both ABO and LDSE

This provides options for customizing the way

stages are dropped, as described below.

To support this, the current Rate Alloction

method asks for the current "Underflow rate" -

see the Rate Allocator section.

LL ALL BOILERS OFF THRESHOLD:

TEMPERATURE OR NONE

When the LL boiler off options specifies "Enable

all boilers off (ABO)" or "Enable both ABO and

LDSE" then this parameter provides the boiler

off threshold temperature that is used. In this

case, if the temperature is the None value then a

parameter error lockout occurs.

Boiler off options

The LL boiler off option controls two optional

behaviors. One option is to enable the use of the

LL all boilers off threshold and is abbreviated

"ABO", and the other controls whether a lead

boiler is affected by a drop-stage method based

upon error, and is abbreviated as "LDSE".

Drop-stage methods Error threshold

For error threshold staging, a stage is dropped

when the error becomes excessive based on

degrees away from setpoint and time.

ALL BOILERS OFF - ABO:

The ABO temperature provides a Burner Off

threshold that essentially replaces the normal

Burner Off threshold as given by the LL off

hysteresis parameter; it is processed by the

same logic block using some additional rules.

DROP-STAGE CONDITION:

- The modulating burner(s) is at its (their)

minimum position per the rate allocation rules,

- The operating point is above the setpoint by an

amount greater than or equal to Drop-stage

error threshold

If ABO is enabled then:

• When the LL master operating point reaches or

exceeds the ABO threshold this turns off LL

master burner demand.

When the Drop-stage condition is false then

• The Burner Off threshold provided by LL off

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hysteresis is ignored if one or more lag boilers

are firing.

• If LDSE is enabled:

The Burner Off threshold provided by LL off

hysteresis is ignored also for the lead boiler

when it is firing solo (i.e. when no lag boilers are

firing).

modulation rate. When LDSE is enabled and the

lead is firing solo, then simply reaching the drop-

stage threshold causes a dropstage event that

causes the lead to turn off and [rf3259] which thus

ends LL master demand until the operating point

again falls to the Burner On threshold.

• If LDSE is disabled:

Sequencer

When the lead is firing solo and the operating

point reaches the Burner Off threshold specified

by LL off hysteresis turns off LL master burner

demand (and thus the lead boiler).

The Sola sequencer determines which Sola will

be the next one to turn on or turn off whenever

an Add-stage event occurs. It maintains the

following variables:

As usual, whenever LL master burner demand is

turned off by its hysteresis block, it does not

recur until the operating point falls below the

Burner On threshold.

LeadBoilerSeqNum - sequence number of the

current lead boiler in the Slave Status table.

Lead BoilerRunTime - the cumulative time that

the current lead boiler has been running.

Summary of the burner-off thresholds that are

used:

In all cases, if a boiler sequence number is

needed and Slave sequence order is 0, then

the boiler's ModBus address is used as its

sequence number.

4.7.11 LEAD DROP-STAGE ON ERROR

- LDSE:

In all cases, if two boilers being compared have

the same effective sequence number, then the

one that is selected is undefined (either may

prevail).

If LDSE is enabled then either Drop-stage

method1 must be enabled to provide staging

based on "Error threshold"; otherwise

parameter error lockout occurs.

Sequencer Parameters

LEAD SELECTION METHOD: ROTATE IN

SEQUENCE ORDER, MEASURED RUN TIME

This determines the selection method for lead

selection and sequencing, as described below.

Normally, for a lag boiler, dropping a stage

based on error involves meeting three criteria: 1)

the operating point temperature must exceed an

offset from setpoint, 2) this condition must

persist for a period of time, and 3) the measured

time starts only when the modulating boilers are

firing at the minimum modulation rate. And

normally when LDSE is not enabled, the lead

boiler is special case that is not affected by a

drop-stage event: it shuts down only when the

operating point reaches the burner-off threshold

(or ABO threshold, if that is enabled).

LAG SELECTON METHOD: SEQUENCE

ORDER, MEASURED RUN TIME

This determines the selection method for lag

selection and sequencing, as described below.

LEAD ROTATION TIME: HH:MM OR NONE

This determines the lead rotation time as

defined below.

If LDSE is enabled:

FORCE LEAD ROTATION TIME: HH:MM OR

NONE

If this parameter is a non-zero time, then it is

used to force the rotation of the lead boiler if it

stays on longer than the time specified.

• Enabling (or disabling) LDSE has no effect on

the dropstage behavior for a lag boiler; however

• When only the lead boiler is firing then an error

based drop-stage event does act to drop the

lead boiler, and moreover, only one of the three

criteria above are considered by the method in

this case: the operating point temperature. Thus

dropping the lead does not depend on

exceeding this temperature for a period of time,

nor does it require the lead to be at minimum

Sequencer Add Boiler Selection

The sequencer selects the next boiler to be

added according to a sorted order. This

description assumes this is implemented by

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assigning an ordering number and that the

lowest numbers are the first to be added.

a sequence number greater than this number is

used, or

• Any Available slaves that have a mode of Use

First will have the lowest ordering numbers. If

two or more Use First boilers exist, they are

numbered according to their assigned Slave

sequence order or Modbus address if this value

is zero, as descibed above.

• Next are slaves that have the mode of Equalize

Runtime. When the add boiler routine gets to

this group it first invokes the Voluntary Lead

Rotation routine (to make sure this is done, but

only once) and then selects an Available boiler,

if any, ordered according to:

— If no boiler has a greater sequence number,

then the one that has the smallest sequence

number is used (wrap around).

Otherwise when the Lead selection method is

"Measured run time", then the lead boiler is the

one having the lowest Measured run time value.

If two have the same measured run time, then

either may be selected.

The LeadBoilerRunTime value is then set to

zero to give the new lead boiler a fresh

allotment. Note: if the old lead boiler is the only

one, then this process may end up re-

designating this as the "new" lead with a fresh

time allotment.

—

The first is the lead boiler per the

LeadBoilerSeqNum parameter.

— The rest are the other slaves ordered

according to the LL –Lag selection method}

parameter:

• If this parameter is "Rotate in sequence order",

then they are ordered according to their LL –

Slave sequence order or Modbus address if

this value is zero, as descibed above.

• If this parameter is "Measured run time" then

they are ordered according to their reported run

time. If two have the same measured run time,

then either may be selected.

Sequencer ordering function

Part of the sequencer is called by the stager just

before the stager runs, to give the sequencer a

chance to assign order numbers to stages that

very recently turned on, and to maintain these in

a sequence. It uses the StagingOrder item in

the Slave Status table for this purpose.

• Last are any Available slaves that have a mode

of Use Last. These will have the highest

numbers. If two or more Use Last boilers exist,

they are numbered according to their assigned

Slave sequence order or Modbus address if

this value is zero, as described above.

The sequencer ordering function examines all

slaves and sets to zero the StagingOrder of any

stage that is not Firing.

This ensures that any stage that has left the

Firing condition recently is no longer in the

number sequence.

Voluntary Lead Rotation

Next, skipping all of those that have 0 values in

StagingOrder it finds the lowest numbered

StagingOrder and gives it the value 1, the next

receive 2, etc.

The current lead boiler is identified by the

LeadBoilerSeqNum value. This value will

change when the stager has asked the

sequencer for a boiler to add and either:

• the boiler identified by LeadBoilerSeqNum is

neither Available nor Firing (i.e. it has a fault or

is OnLeave), or

Thus if gaps have developed due to a slave

dropping out these are filled in.

• the LeadBoilerRunTime value exceeds Lead

rotation time.

Finally, the ordering function continues on,

giving the next numbers to and Firing stages

which have a 0 StagingOrder values (i.e. they

recently were added, or they recently returned

from OnLeave).

In either of these cases, the algorithm performed

is: If the Lead selection method is "Rotate in

sequence order", then LeadBoilerSeqNum is

incremented, and then new lead boiler is the one

that is a slave in Equalize Runtime mode that is

responding to the LL master (i.e. not OnLeave or

Recovering, but it might be Firing), and:

Example: Before After Notfiring 3 0 Notfiring 0 0

Firing 2 1 Firing 5 3 Firing 0 4 Firing 4 2

Sequencer Drop Lag boiler selection

—

has

sequence number equal to

LeadBoilerSeqNum, or.

— If no boiler has this then the closest one with

When the stager asks the sequencer for a lag

boiler to drop the sequencer looks at the

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StagingOrder numbers of all Firing boilers. If

only one Firing boiler is found, or none are

found, then this selection function returns a

value that indicates no boiler may be dropped.

Otherwise it returns an identifier for the boiler

having the highest StagingOrder number.

3 will be first if there is no 1 or 2.

NOTE: For Equalize Runtime purposes, 1 does

not mean the Sola will be used first every time;

that will vary over time based on the master's

run time equalization scheme. In this case the

sequence number determines the relative order

in which Sola controls will be used in a round-

robin scheme.

SEQUENCER 1 MINUTE EVENT

Part of the sequencer is called by the timing

service at a 1 minute rate to implement lead

rotation.

If the slave sequence number value is zero, then

the slave Sola's ModBus address will be used

instead.

The 1 minute event checks the boiler identified

by Lead- BoilerSeqNum. If it is Firing then the

LeadBoilerRunTime is incremented.

If two Solas are set the same mode and both

have the same sequence number then an alert

will occur and the order in which they are used

will be arbitrary and is not guaranteed to be

repeatable.

FORCED LEAD ROTATION:

When

the

boiler

identified

LeadBoilerSeqNum is firing and also

LeadBoilerRunTime reaches the Force lead

rotation time parameter time then:

1. The current lead boiler is noted.

2. Lead rotation occurs as described above

under Voluntary Lead Rotation (this changes the

designation, but does not change the actual

firing status).

SLAVE WRITE: DATA

This allows the slave to accept command

messages from a Sola master

SLAVE READ: DATA

This provides the slave status message to be

read by a Sola Master. It includes all of the data

that is read from a slave.

SLAVE MODE: USE FIRST, EQUALIZE

RUNTIME, USE LAST

• If set to Use First, then this slave Sola will be

used prior to using other slave Solas with other

values.

• If this parameter is set to Equalize Runtime,

then this slave Sola will be staged according to a

run time equalization. (Any Solas set to Use

First will precede any that are set to Equalize

Runtime.)

• If this parameter is set to Use Last, then this

slave Sola will be used only after

• all Use First and Equalize Runtime Solas have

been brought online.

SLAVE PRIORITY SEQUENCE ORDER: 0-255

Slave sequence order is used to determine the

order in which the slave Solas will be used

(staged on) for those Solas with the same Slave

mode setting. Numbers may be skipped, that is

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