265 Boiler Control - Three Modulating Boiler and DHW / Setpoint

8/8/2019 265 Boiler Control - Three Modulating Boiler and DHW / Setpoint

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- Data BrochureBoiler Control 265

D 26512/08

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The tekmar Boiler Control 265 can control the supply water temperature on up to three modulating boilers based on outdoor

temperature or setpoint requirements. The control can be set to control up to two modulating boilers based on outdoor temperatureor domestic hot water requirements. A large easy to read display provides current system temperatures and operating status. The

control has outputs for a primary pump, individual boiler pumps, and either a combustion air damper or an alarm.

Additional functions include:

Outdoor Reset

Sequential or Parallel Modulation

Installer and Advanced access levels

Primary pump output

Individual boiler pump outputs

Pump purging

Boiler demand for space heating loads

DHW demand for domestic hot water loads

Setpoint demand for setpoint loads

0 10 V (dc) BAS / EMS input

Test sequence to ensure proper component operation

Setback input for energy savings

CSA C US certified

Pump exercising

InputUniversalSensorIncluded

InputUniversalSensorIncluded

InputOutdoorSensorIncluded

or

Input0-10 V (dc)External Signal

InputBoiler

Demand

OutputModulating

Boiler

OutputBoiler

Enable

OutputPump

OutputBoiler

Enable

or

Pump

InputSetpointor DHWDemand

Input115 V (ac)

Power Supply

OutputPrimaryPump

InputTimer or Switch

Optional

OutputCombustion Air

or Alarm

1Com

2BoilSup

3BoilRet

4Out+

5UnOSw

6

+

7

+ +

8Mod2 mAMod1 mA

9 10 11 12 13PrimP1 L

14

N

15 16 17

1

18

1

19

2

20

2

21 22 23 24 25 26 27 28 29BoilDem

30ComDem

31Setp/DHW

Boiler Control 265Three Modulating Boiler & DHW / Setpoint

Do not apply power

Mod3 mA Power Boiler BoilerC.A./Alarm

Boiler 3 /DHW

BoilerPump 1

BoilerPump 2

BoilerPump 3

H2037B

Menu Item

Boiler Demand

DHW / Setpoint Demand

WWSD

Modulation

Boiler Output (x10,000 BTU/hr)

External Input Signal

Offset / Priority Override

Test

off not testingred testingred testing paused

For maximum heat,press & hold Test for3 seconds.

Meets Class B:

Canadian ICESFCC Part 15

DateCode

Made in Canada bytekmar Control Systems Ltd.

Power 115 V 10% 60 Hz 600 VARelays 230 V (ac) 5 A 1/3 hp, pilot duty 240 VADemands 20 to 260 V (ac) 2 VA

Stand Alone

AdvancedExternal Input

OffCA.

OffAlarm

Fixed LeadFirst On / Last Off

First On / First Off

S of t Stop RotateParallel

Installer

ExerciseSequential

OutputModulating

Boiler

OutputModulating

Boiler

or

Signal wiring must be rated at least 300 V.

Note:Boiler, DHW,or setpointdemand mustbe powered with20 to 260 V (ac)before the boiler

is able to fire.


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How To Use The Data Brochure

User Interface

Table of Contents

Installation .......................................................Pg 19

DIP Switch Settings ........................................Pg 26

Control Settings ..............................................Pg 28

View Menu..............................................Pg 28

Adjust Menu...........................................Pg 29

Testing the Control .........................................Pg 34

Error Messages ...............................................Pg 35

Technical Data .................................................Pg 36

Limited Warranty ............................................Pg 36

User Interface ..................................................Pg 2

Display .............................................................Pg 3

Sequence of Operation ..................................Pg 4

Section A: General Operation..............Pg 4

Section B: Boiler Operation..................Pg 6

Section C: Outdoor Reset.....................Pg 10

Section D: DHW Operation...................Pg 13

Section E: Setpoint Operation.............Pg 16Section F: External Input Operation....Pg 17

Section G: Pump Operation..................Pg 18

This brochure is organized into four main sections. They are: 1) Sequence of Operation, 2) Installation, 3) Control Settings, and4) Testing and Troubleshooting. The Sequence of Operation section has seven sub-sections. We recommend reading Section A:

General of the Sequence of Operation, as this contains important information on the overall operation of the control. Then read thesub sections that apply to your installation.

The Control Settings section (starting at DIP Switch Settings) of this brochure describes the various items that are adjusted and

displayed by the control. The control functions of each adjustable item are described in the Sequence of Operation.

The 265 uses a Liquid Crystal Display (LCD) as the method of supplying information. You use the LCD in order to setup and monitor

the operation of your system. The 265 has four push buttons (Menu, Item,, ) for selecting and adjusting settings. As you

program your control, record your settings in the ADJUST Menu table which is found in the second half of this brochure.

MenuAll of the items displayed by the control are organized into various menus. These menusare listed on the left hand side of the display (Menu Field). To select a menu, use the

Menubutton. By pressing and releasing the Menubutton, the display will advance tothe next available menu. Once a menu is selected, there will be a group of items that can

be viewed within the menu.

ItemThe abbreviated name of the selected item will be displayed in the item field of the

display. To view the next available item, press and release the Itembutton. Once youhave reached the last available item in a menu, pressing and releasing the Itembutton

will return the display to the first item in the selected menu.

The items can be quickly scrolled through by holding the Itembutton and then pressingthe button. To rapidly scroll through the items in the reverse order, hold the Itembutton

and press the button.

AdjustTo make an adjustment to a setting in the control, begin by selecting the appropriate

menu using the Menubutton. Then select the desired item using the Itembutton. Finally,use the and / or button to make the adjustment.

Additional information can be gained by observing the Status field of the LCD. The status

field will indicate which of the controls outputs are currently active. Most symbols in thestatus field are only visible when the VIEW Menu is selected.

Menu Item

Menu Item

Menu Item


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Display

Symbol Description

Boiler Demand

DHW / Setpoint Demand

WWSD

Modulation

Boiler Output (x10,000 BTU/hr)

External Input Signal

Offset / Priority Override

Menu FieldDisplays thecurrent menu

Item FieldDisplays anabbreviatedname of theselected item

Status FieldDisplays the

current statusof the control'sinputs, outputsand operation

Number FieldDisplays the current value of the selected item

ButtonsSelects Menus, Itemsand adjust settings

Stage

Displays which boiler relays are turned on.

UnOccupied Schedule

Displays when the control is in

UnOccupied Mode.

Primary PumpDisplays when the primary pump relay is

turned on.

Occupied Schedule

Displays when the control is in Occupied Mode.

Boiler Pump

Displays which boiler pump relays areturned on.

Installer Access Level

Displays when the Advanced / Installer Dip switchis set to Installer.

Combustion Air Damper

Displays when the Combustion Air Damper

relay is turned on.

Pointer

Displays the control operation as indicated by the

text.

Delta TThe current difference between the supply

and return temperatures.

Warning / AlarmDisplays when an error exists or the alarm relay

is turned on.

F, C, min, hr

Units of measurement.

Modulating Output Scale

Displays the total modulation output level of theboilers.

DHW

Displays when the DHW relay is turned

on.


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Section AGeneral

OperationPage 4 - 6

Section BBoiler

OperationPage 6 - 10

Section COutdoorReset

Page 10 - 12

Sequence of Operation

Section A: General Operation

The following defined terms and symbols are used throughout this manual to bring attention to the presence of hazards of various risklevels, or to important information concerning the life of the product.

- Warning Symbol: Indicates presence of hazards which can cause severe personal injury, death or

substantial property damage if ignored.

- Double insulated

- Local level, appliancesINSTALLATION

CATEGORY II

Definitions

Section DDHW

OperationPage 13 - 15

Section ESetpointOperationPage 16

Section FExternalInput Operation

Page 17 - 18

Section GPumpOperation

Page 18 - 19

POWERING UP THE CONTROLWhen the control is powered up, all segments in the LCD are turned on for 2 seconds. Next, the control displays the control typenumber in the LCD for 2 seconds. Next, the software version is displayed for 2 seconds. Finally, the control enters into the normal

operating mode.

BOILER TARGET TEMPERATUREThe control operates up to three modulating boilers to control the supply water temperature to a hydronic space heating system

or setpoint. When using the control to provide Domestic Hot Water (DHW) requirements, only two modulating boilers can beoperated. The supply water temperature is based on boiler reset, an external 0 10 V (dc) signal, DHW requirements, or a

setpoint temperature.

Boiler Reset(Stand Alone)When a boiler demand signal from the heating system is present,

the control operates the boiler(s) to maintain the supply temperaturebased on the outdoor air temperature and the Characterized Heating

Curve settings. Refer to section C.

DHW

When a DHW demand is present, the control operates the boiler(s)to maintain the supply water temperature at least as hot as the DHWexchange setting. Refer to section D.

SetpointWhen a setpoint demand signal is present, the control operates the boiler(s) to maintain the supply water temperature at least as

hot as the Setpoint setting. Refer to section E.

External Input 0 10 V (Dc) or 2 10 V (Dc)When an external input signal is present, the control converts the signal to a target supply temperature. The control operates theboiler(s) to maintain the required supply water temperature. Refer to section F.

Decreasing Outdoor TemperatureIncrea

singWaterTemperatureTerminal UnitTerminal Unit

Indoor DesignIndoor Design Outdoor DesignOutdoor Design

Design SupplyDesign Supply


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SETBACK (OCC and UNOCC)To provide greater energy savings, the control has a setback feature. With setback, thesupply water temperature in the system is reduced when the building is unoccupied. By

reducing the supply water temperature, the air temperature in the space may be reducedeven when thermostat(s) are not turned down. Any time the UnO Sw(5) and the Com(1)

terminals are shorted together, the control operates in the unoccupied mode. When in the

unoccupied mode, the UNOCCsegment is displayed in the LCD. The control adjusts thesupply water temperature based on the UNOCCsettings in the control.

COMBUSTION AIR OR ALARM CONTACTThe control has an isolated contact that can be used as either a combustion air damper contact or an alarm contact. This selection

is made using the C.A. / Alarm DIP switch.

Combustion Air (C.A.)When the DIP switch is set to C.A., terminals 15 and 16 can be used as a switch to operate a combustion air damper. This contac

closes prior to the first boiler operating on the control. The amount of time that the contact closes prior to the first boiler firing isset using the combustion delay setting.

The combustion air contact remains closed for a minimum of 15 seconds after the last boiler is turned off.

AlarmWhen the DIP switch is set to Alarm, terminals 15 and 16 can be used as a switch to operate an alarm circuit. This contact closes

whenever an error message is present on the control display. When the alarm contact is activated, refer to the Error Messages

section of this brochure to determine the cause of the alarm. Once the fault has been fixed, pressing either the Menu, Item or button will clear the alarm.

Boiler AlarmThe control can monitor the boiler supply temperature and provide an alarm if the temperature does not increase within a

certain amount of time. The amount of time can be set using the Boiler Alarm setting. This alarm can be used to determine ithe boilers have failed to fire. To reset the alarm, press and hold the and buttons for 5 seconds while in the VIEW menu.

ROTATIONThe control includes an Equal Run Time feature which changes the firingorder of the boilers whenever one boiler accumulates 48 hours more

running time than any other boiler. After each rotation, the boiler with the

least running hours is the first to fire and the boiler with the most runninghours is the last to fire. This function ensures that all of the boilers that

are being rotated receive equal amounts of use. When the Rotate/OffDIP switch is set to the Offposition, the firing sequence always begins

with lowest boiler to the highest boiler.

Fixed Lead RotationIn some applications, it may be desirable to have the first boiler fire first

at all times while the firing sequence of the remaining boilers is changedusing Equal Run Time Rotation. This rotation option is selected by

setting the Fixed Lead/OffDIP switch to the Fixed Leadposition.

First On / Last Off or First On / First OffWhen using the Fixed Lead rotation option, a selection must be made between First On/LastOff and First On/FirstOf

using the DIP switch. When FirstOn/LastOff is selected, the lead boiler is always modulated first and shut off last. When

FirstOn/FirstOffis selected, the lead boiler is always modulated first and shut off first. This DIP switch is only read by the controwhen the FixedLead/OffDIP switch is set to Fixed Lead.

Resetting the Rotation SequenceTo reset the rotation sequence, set the Rotate/OffDIP switch to the Offsetting for 5 seconds and then return the DIP switch to

the Rotatesetting.

RUNNING TIMESThe control displays the accumulated running time of each boiler in the VIEW menu.

Resetting the Running TimesTo reset the running time for each boiler, select the appropriate running time in the VIEW menu. Next press the and buttons

simultaneously until CLris displayed.

1 2 3 45

Com

BoilSup

BoilRet

Out+

UnOSw

Timer Switch

1 2

720 hours 672 hours

2 1

672 hours 720 hours


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Section B1: Boiler Modulation

Section B: Boiler Operation

EXERCISINGThe control has a built-in exercising feature that is selected through the Exercise/Off DIPswitch. To enable the exercising feature set

the Exercise/OffDIP switch to Exercise. If exercising is enabled, the control ensures that each pump is operated at least once every

3 days. If a pump has not been operated at least once every 3 days, the control turns on the output for 10 seconds. This minimizesthe possibility of the pump seizing during a long period of inactivity. While the control is exercising, the TestLED flashes quickly.

Note:The exercising function does not work if power to the control or pumps is disconnected.

FACTORY DEFAULTSThe control comes preset with several factory defaults. These defaults are based on the terminal unit selection (see section C).

To fine-tune building requirements, these defaults may be changed.To reload the factory defaults listed in the ADJUST Menu, power down the control and wait for 10 seconds. Power up the controlwhile simultaneously holding the Menuand buttons. An E01 error occurs forcing the installer to go through the ADJUST menu

to ensure the settings are correct.

MODULATIONThe control provides three modulating output signals, three boiler enable contacts, and three boiler pumps contacts to operate up

to three modulating boilers. The boiler enable contact may not be required, depending on the make and model of the boiler(s).

The control operates a boiler by first closing the boiler pump contact. The boiler enable contact is closed next and then the control

provides a modulating output signal to the boiler.

The modulation output signal is then modulated from the minimum modulation using Proportional, Integral and Derivative (PID)logic in order to satisfy the boiler target temperature.

SEQUENTIAL MODULATION

Boiler 1 Boiler 2 Boiler 3

100% MOD OFF

PARALLEL MODULATION

Boiler 1 Boiler 2 Boiler 3

MOD MOD MOD

SEQUENTIAL MODULATIONThe control offers a sequential modulation option. This is selected by setting theSequential/ParallelDIP switch to Sequential. Sequential modulation should be used onboilers that are more efficient when operating at high fire.

In sequential modulation, the first boiler is turned on and is modulated to satisfy light loads.

Once the first boiler does not have enough capacity to satisfy the load, the first boilerreduces its modulation to provide a smooth transition when the second boiler fires at low

fire. The first boiler then modulates up to maximum modulation as the load increases. Only

then is the second boiler able to increase its output as the load continues to increase.When the third boiler is required, the second boiler reduces its modulation to allow the

third boiler to operate at low fire. As the load continues to increase, the second boiler ismodulated to its maximum and then the third boiler is modulated. The operation is reversed

when shutting off the boilers.

PARALLEL MODULATIONThe control offers a parallel modulation option. This is selected by setting the

Sequential/ParallelDIP switch to Parallel. Parallel modulation should be used on boilersthat are more efficient when operating at low fire.

In parallel modulation, the first boiler turns on at low fire and begins to increase its

modulation. Once the first boilers output is greater than the combined output of the firstand second boilers low fire, the first boiler is modulated down to low fire and the second

boiler is fired at low fire. The two boilers now modulate together. Once the two boilerscombined output is greater than the combined output of all three boilers operating at low

fire, the first and second boilers are modulated down to low fire, and all three boilers are

operated at low fire. The boilers are then modulated as the load increases. The operationis reversed when shutting off the boilers.

Section B1Boiler

Modulation


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To calculate the Minimum Modulation, use the following formulae:

For 4 to 20 mA:

Minimum Modulation = 4 mA Boilers Minimum Input Signal x 100%4 - 20 mA

For 0 to 10 V (dc):

Minimum Modulation = 0 V (dc) Boilers Minimum Input Signal x 100%0 10 V (dc)

For 2 to 10 V (dc):

Minimum Modulation = 2 V (dc) Boilers Minimum Input Signal x 100%2 10 V (dc)

Example 1:A boiler requires a 1.8 V (dc) signal to fire the boiler at low fire. The boiler can be modulated to 10 V (dc) where it reaches high fire.

This means the boilers input signal range is 1.8 to 10 V (dc). The 265 control has an output signal range of 0 to 20 mA which can beexternally converted to 0 to 10 V (dc) using a 500 resistor (Refer to Modulation Output section in Step 4 of the Installation section).

To make the two signal ranges the same, the Minimum Modulation required is:

Minimum Modulation = 0 V 1.8 V x 100% = 18%0 V 10 V

Example 2:If the boilers input signal range is 6 to 20 mA the required Minimum Modulation is:

Minimum Modulation= 4 mA 6 mA x 100% = 13%4 mA 20 mA

MAXIMUM MODULATIONThe maximum modulation defines the maximum output signal from the control to the boiler burner. It is based on a percentage of

the controls output signal range.

The maximum modulation setting for boilers with power burners is typically set to 100%.

For boilers with electronic operators, the boilers input signal range may not match the output signal range of the 265 control. The

Maximum Modulation setting limits the control output range in order to match the boilers input range.

To calculate the Maximum Modulation, use the following formulae:

For 4 to 20 mA:

Maximum Modulation = 4 mA Boilers Maximum Input Signal x 100%4 20 mA

For 0 to 10 V (dc):

Maximum Modulation = 0 V (dc) Boilers Maximum Input Signal x 100%0 10 V (dc)

For 2 to 10 V (dc):

Maximum Modulation = 2 V (dc) Boilers Maximum Input Signal x 100%2 10 V (dc)

MINIMUM MODULATION

18%

0%0 V (dc)

1.8 V (dc)

100%10 V (dc) 10 V (dc)

Control'sOutputSignalRange

MinimumModulation

Boiler's MinimumInput Signal

Boiler'sInputSignalRange

MODULATION RANGE (4 to 20 mA or 0 to 20 mA)The modulation output (Mod 1, Mod 2, and Mod 3) for each boiler can be adjusted from a 4 to 20 mA output range to a 0 to 20 mA

output range using the Boil Modulation 1, Boil Modulation 2, or Boil Modulation 3setting. The resulting modulation output signacan be converted to a 0 to 5 V (dc), 1 to 5 V (dc), 0 to 10 V (dc), and 2 to 10 V (dc) output using external resistors. The modulation

output signal can be converted to a 0 to 135 (W R B) output using a 0 - 135 Converter 005. Refer to the Modulation Outputsection in Step 4 of the Installation section.

MINIMUM MODULATIONThe minimum modulation defines the minimum output signal from the control to the boiler burner. It is based on a percentage o

the controls output signal range.

The minimum modulation setting for boilers with power burners is typically set to 0%.

For boilers with electronic operators, the boilers input signal range may not match the output signal range of the 265 control. TheMinimum Modulation setting limits the control output range in order to match the boilers input range.

MAXIMUM MODULATION

88%

0%2 V (dc) 2 V (dc)

100%10 V (dc)

9 V (dc)

Control'sOutputSignalRangeMaximum

ModulationBoiler's

MaximumInput Signa

Boiler'sInputSignalRange


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BOILER MASSThe boiler mass setting allows the installer to adjust the control to the thermal mass of the type of heat sources used in the

application. There is a boiler mass setting for each boiler. The modulation of the boiler can become unstable if the incorrect BoilerMass setting is chosen. A key sign of the boiler modulation being unstable is the flame will continue to increase and then decrease

in short periods of time. By choosing a lower boiler mass setting, the boiler response will become more stable.

Lo (1)The Lo setting is selected if the boiler that is used has a low thermal mass. This means that the boiler has a very small water

content and has very little metal in the heat exchanger. A boiler that has a low thermal mass comes up to temperature quiterapidly when fired. This is typical of many copper fin-tube boilers.

The Lo mass setting provides a fast response to the heating system.

number into the Maximum Boiler Output setting.

For example, if a boiler has a maximum output of 100 MBH:

Maximum Boiler Output = 100,000 BTU/hr = 10 x 10,000 BTU/hr10,000

MOTOR SPEEDThe Motor Speed is the amount of time the boiler requires to go from 0%modulation to 100% modulation. The control includes a Motor Speed

setting for each individual boiler.

Gas valve actuating motors have a design time from fully closed to fullyopened which can be found in the manufacturers manual. The Motor

Speed should be set to this time.

The Motor Speed setting for a Variable Frequency Drive (VFD) is theamount of time required to go from a stopped position to 100% fan

speed. Since a VFD has a very quick response rate, it may be necessaryto increase the Motor Speed setting in order to increase the stability of

the boiler modulation.

Example 1:A boilers input signal range is 2 to 9 V (dc). The 265 control has an output signal range of 2 to 10 V (dc). To make the two signal

ranges the same, the Maximum Modulation required is:

Maximum Modulation = 2 V 9 V x 100% = 88%2 V 10 V

Example 2:If the boilers input signal range is 6 to 19 mA the required Maximum Modulation is:

Maximum Modulation = 4 mA 19 mA x 100% = 94%

4 mA 20 mA

MINIMUM BOILER OUTPUTIn order to accommodate different boiler capacities in the same system, a minimum boiler output for each boiler can be set. This

allows the control to properly operate the boilers using either sequential or parallel modulation. The minimum boiler output rangeis from 10,000 BTU / hour to 19,990,000 BTU / hour.

Each boiler typically has a rating plate that specifies the minimum output. This information is also available in the boiler manual. The

Minimum Boiler Output setting has units of 10,000 BTU / hour. Divide the minimum output rating by 10,000 and enter the numberas the Minimum Boiler Output setting.

For example, if a boiler has a minimum output of 20 MBH:

Minimum Boiler Output = 20,000 BTU/hr = 2 x 10,000 BTU/hr10,000

MAXIMUM BOILER OUTPUTIn order to accommodate different boiler capacities in the same system, there is a maximum boiler output for each boiler. This

allows the control to properly operate the boilers using either sequential or parallel modulation. The maximum boiler output rangeis from 10,000 BTU / hour to 19,990,000 BTU / hour.

Each boiler typically has a rating plate that specifies the maximum output. This information is also available in the boiler manual.

The Maximum Boiler Output setting has units of 10,000 BTU / hour. Divide the maximum output rating by 10,000 and enter the


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MIN Segment On

Med (2)The Med setting is selected if the boiler that is used has a medium thermal mass. This means that the boiler either has a largewater content and a low metal content or a low water content and a high metal content. This is typical of many modern residentia

cast iron boilers or steel tube boilers.

The Med mass setting provides a moderate response to the heating system.

Hi (3)The Hi setting is selected if the boiler that is used has a high thermal mass. This means that the boiler has both a large water

content and a large metal content. A boiler that has a high thermal mass is relatively slow in coming up to temperature. This is

typical of many commercial cast iron and steel tube boilers.

The Hi mass setting provides a slow response to the heating system.

DIFFERENTIALA modulating boiler must be operated with a differential while operating in low fire. The boiler differential is divided around the boiletarget temperature. The boiler starts at low fire when the supply water temperature is of the differential setting below the boiler

target temperature. The boiler is shut off in low fire as the supply temperature reaches at least of the differential above the boilertarget temperature. With the control, either a fixed or an auto differential may be selected.

When the boiler is modulating above low fire, the differential does not apply. Instead, the modulation output signal is determined

using Proportional, Integral and Derivative (PID) logic in order to satisfy the boiler target temperature.

Fixed DifferentialIf the user desires to have a fixed differential, this is set using theboiler differential setting in the ADJUST menu.

Auto DifferentialIf the Auto Differential is selected, the control automatically determines

the best differential as the load changes. This reduces potential shortcycling during light load conditions.

BOILER MINIMUMThe boiler minimum is the lowest temperature that the control is allowed

to use as a boiler target temperature. During mild conditions, if the control

calculates a boiler target temperature that is below the boiler minimumsetting, the boiler target temperature is adjusted to at least the boiler

minimum setting. During this condition, if the boiler(s) is operating, theminimum segment is turned on in the display when viewing either the

boiler supply temperature or the boiler target temperature. Set the boiler

minimum setting to the boiler manufacturers recommended temperature.

BOILER MAXIMUMThe boiler maximum is the highest temperature that the control is

allowed to use as a boiler target temperature. If the control does target

the boiler maximum setting, and the boiler temperature is near the boilermaximum temperature, the maximum segment will be turned on in the

display while either the boiler target temperature or the boiler supplytemperature is being viewed. At no time does the control operate the

boiler(s) above 248F (120C).MAX Segment

OnMAX Segment

On

Tem

pera

turefa

llTe

mpe

ratu

rerise

Time

Desired temperature160F (71C)

Differential10F (6C)Boiler Off

Boiler On

155F (68C)

165F (74C)

IncreasingL

o

ad

Time

Differential On

Off


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Section C1: Boiler Reset (Stand Alone)

FIRE DELAYThe Fire Delay is the time delay that occurs between the time that the

control closes a boiler enable contact to fire a boiler and when the boilerfires at low fire.

STAGE DELAYThe stage delay is the minimum time delay between the firing of stages.

After this delay has expired the control can fire the next stage if it isrequired. This setting can be adjusted manually or set to an automatic

setting. When the automatic setting is used, the control determines the

best stage delay based on the operation of the system.

Boiler Reset operation only applies when the Stand Alone/External InputDIP switch is set toStand Alone.

BOILER DEMANDA boiler demand is required in order for the control to provide heat to the heating system. A boiler

demand is generated by applying a voltage between 24 and 230 V (ac) across the BoilDem

and ComDemterminals (29 and 30). Once voltage is applied, the BoilerDemandpointer isdisplayed in the LCD. If the control is not in Warm Weather Shut Down (WWSD), the control

closes the primary pump contact. The control calculates a boiler target supply temperaturebased on the outdoor air temperature and the characterized heating curve settings. The control

then fires the boiler(s), if required, to maintain the target supply temperature.

29 30Boil

DemComDem

24 to 230 V (ac)

Stage Delay

Stage Delay

Boiler 1Contact Closes

Boiler 1Fires

FireDelay 1

FireDelay 3

FireDelay 2


Boiler 2Fires


Boiler 3Fires

Time

SOFT STOPIt is possible to thermally shock a boiler when it is shut off at high fire. The Soft Stopfeature forces the boiler to modulate down to

minimum before turning off. This is designed to prevent large volumes of cold air being introduced into the combustion chamber ofthe boiler when it is shut off. This can occur in applications where the burner includes a fan.

Once all demands are removed, the control allows for the firing rate to be modulated down to the MIN Modulationsetting prior to

turning off the burner. This feature is enabled by setting the Soft Stop/OffDIP switch to the Soft Stopposition. If the Soft Stop/OffDIP switch is in the Offposition, the control turns off the boiler at the current firing rate once all demands are removed.

COPY BOILER 1 SETTINGSMany boiler installations will have multiple identical boilers. To reduce the number of settings required, the settings of boiler 1(Fire Delay, Boiler Mass, Motor Speed, Minimum Boiler Output, Maximum Boiler Output, Boiler Modulation, Minimum Modulation,

Maximum Modulation, and Purge Boiler Pump) are copied to boiler 2 by setting the Boiler 2 setting to CP1. Likewise, setting Boiler 3to CP1 copies the settings of boiler 1 to boiler 3. Boiler 2 and Boiler 3 settings are set to CP1 by default.

The setting of CP1 allows the control to enable the boiler similar to the set ting of Au (automatic). If a boiler is set to OFF, the control

disables that boiler.

If required, each of the three modulating boilers can have individual boiler settings. This allows for three different type, size,and make of modulating boilers. To select individual boiler settings for boiler 2, set Boiler 2 to Au (automatic). Likewise, to select

individual boiler settings for boiler 3, set Boiler 3 to Au (automatic).

Section C: Outdoor Reset

Section C1Boiler Reset

(Stand Alone)


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BOILER DESIGN TEMPERATUREThe boiler design supply temperature is the supply water temperaturerequired to heat the building when the outdoor air temperature is as cold

as the outdoor design temperature.

BOILER INDOOR DESIGN TEMPERATUREThe indoor design temperature is the room temperature that was used in the original heat loss calculations for the building. This

setting establishes the beginning of the characterized heating curve.

ROOMThe ROOMsetting is the desired room temperature for the building and provides a parallel shift of the heating curve. The room

temperature desired by the occupants is often different from the design indoor temperature. If the room temperature is not correct,adjusting the room setting increases or decreases the amount of heat available to the building. A room setting is available for both

the occupied (day) and unoccupied (night) periods.

BOILER TARGET TEMPERATUREThe boiler target temperature is determined from the characterized heating curve settings and the outdoor air temperature. The

control displays the temperature that it is currently trying to maintain as the boiler supply temperature. If the control does notpresently have a requirement for heat, it does not show a boiler target temperature. Instead, is displayed in the LCD.

TERMINAL UNITSThe control provides for a selection between six different terminal unit types: two types of radiant floor heat, fancoil, fin-tube

convector, radiator and baseboard. When a terminal unit is selected, the control automatical ly loads the design supply temperaturemaximum supply temperature, and minimum supply temperature. The factory defaults are listed below. These factory defaults can

be changed to better match the installed system.

Terminal Unit High Mass

Radiant (1)

Low Mass

Radiant (2)

Fancoil

(3)

Fin-Tube

Convector (4)

Radiator

(5)

Baseboard

(6)

BOIL DSGN 120F (49C) 140F (60C) 190F (88C) 180F (82C) 160F (71C) 150F (66C)

BOIL MAX 140F (60C) 160F (71C) 210F (99C) 200F (93C) 180F (82C) 170F (77C)

BOIL MIN OFF OFF 140F (60C) 140F (60C) 140F (60C) 140F (60C)

High Mass Radiant (1)

This type of a hydronic radiant floor is embedded in either a thick concrete or gypsum

pour. This heating system has a large thermal mass and is slow acting.

Low Mass Radiant (2)

This type of radiant heating system is either attached to the bottom of a wood sub-floor,suspended in the joist space, or sandwiched between the sub-floor and the surface.

This type of radiant system has a relatively low thermal mass and responds faster thana high mass system.

CHARACTERIZED HEATING CURVEThe control varies the supply water temperature based on the outdoor air

temperature. The control takes into account the type of terminal unit thatthe system is using. Since different types of terminal units transfer heat

to a space using different proportions of radiation, natural convectionand forced convection, the supply water temperature must be controlled

differently. Once a terminal unit is selected, the control varies the supplywater temperature according to the type of terminal unit. This improves

the control of the air temperature in the building.

OUTDOOR DESIGN TEMPERATUREThe outdoor design temperature is the outdoor air temperature that is

the typical coldest temperature of the year where the building is located.This temperature is used when doing the heat loss calculations for the

building. If a cold outdoor design temperature is selected, the boiler

supply temperature rises gradually as the outdoor temperature drops.If a warm outdoor design temperature is selected, the boiler supply

temperature rises rapidly as the outdoor temperature drops.

BOIL MAXBOIL DSGN

OUT DSGN

ROOM OCC

ROOM UNOCC

210(99)

190(88)

170(77)

150(66)

130(54)

110(43)

90(32)

70(21)

50F(10C)

-20(-29)

0(-18)

20(-7)

40(5)

60(16)

80(27)

Outdoor Air Temperature

SupplyWaterTemperature

Boiler CharacterizedHeating Curve

Boiler CharacterizedHeating Curve

BOIL MIN

BOIL INDR

WWSD OCC

WWSD UNOCC


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2008 D 265 - 12/08 12 of 36

Self AdjustingWater Temperature

Boil Target (Occupied)

Boost

Boil Target (UnOccupied)

Boost setting - 20 minutes to 8 hours

Time

Fancoil (3)

A fancoil terminal unit or Air Handling Unit (AHU) consists of a hydronic heating coil andeither a fan or blower. Air is forced across the coil at a constant velocity by the fan or

blower, and is then delivered into the building space.

Fin-Tube Convector (4)

A convector terminal unit is made up of a heating element with fins on it. This type of

terminal unit relies on the natural convection of air across the heating element to deliver

heated air into the space. The amount of natural convection to the space is dependanton the supply water temperature to the heating element and the room air temperature.

Radiator (5)

A radiator terminal unit has a large heated surface that is exposed to the room. A radiator

provides heat to the room through radiant heat transfer and natural convection.

Baseboard (6)

A baseboard terminal unit is similar to a radiator, but has a low profile and is installed at

the base of the wall. The proportion of heat transferred by radiation from a baseboard is

greater than that from a fin-tube convector.

WARM WEATHER SHUT DOWN (OCC and UNOCC)The Warm Weather Shut Down (WWSD) disables the space heating system during warm outdoor weather. There is a separate WWSDfor both the occupied and the unoccupied periods. When the outdoor air temperature rises above the WWSD setting, the control turns

on the WWSDpointer in the display. When the control is in WWSD, the Boiler Demandpointer is displayed if there is a boiler demand.

However, the control does not operate the heating system to satisfy this demand. The control does respond to a DHW demand or asetpoint demand and operates as described in sections D and E. WWSD is not active when using an external input signal.

BOOSTWhen the control changes from the unoccupied mode to the occupied mode,

it enters into a boosting mode. In this mode, the supply water temperature to

the system is raised above its normal values for a period of time to provide a

faster recovery from the setback temperature of the building. The maximumlength of the boost is selected using the BSTsetting.

Typical settings for the boost function vary between 30 minutes andtwo hours for buildings that have a fast responding heating system. For

buildings that have a slow responding heating system, a setting betweenfour hours and eight hours is typical. After a boost time is selected, the

setback timer must be adjusted to come out of setback some time in

advance of the desired occupied time. This time in advance is normallythe same as the BSTsetting.

If the building is not up to temperature at the correct time, the BSTsetting should be lengthened and the setback timer should beadjusted accordingly. If the building is up to temperature before the required time, the BSTsetting should be shortened and the setback

timer should be adjusted accordingly. If the system is operating near its design conditions or if the supply water temperatures are being

limited by settings made in the control, the time required to bring the building up to temperature may be longer than expected.


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Section D1Domestic HotWater (DHW)

Section D2DHW w/ LowTemp Boilers

Section D: Domestic Hot Water Operation

Section D1: Domestic Hot Water (DHW)

DHW operation is available during Boiler Reset (Stand Alone) and External Input operation.

The DHW operation requires the use of the Boiler 3/DHWcontact; therefore, only 2 boilers can be connected to the control. The

BOIL 3 setting must be set to OFFbefore the DHW MODE item will be available.

DHW DEMANDA DHW Demandis required in order for the control to provide heat to the DHW system. A

DHW aquastat or setpoint control is used as a switch in the DHW demand circuit. Oncethe control detects a DHW demand, the DHW Demandpointer turns on in the LCD and the

control operates the boiler to provide a sufficient boiler supply water temperature to theDHW tank. The control operates the pumps as described below.

The control registers a DHWDemandwhen a voltage between 24 and 230 V (ac) is appliedacross the Setp/DHWand ComDemterminals (31 and 30).

BOILER TARGET DURING DHW GENERATIONThe boiler target temperature is at least as hot as the DHW exchange setting (DHWXCHG). The DHW demand overrides the boilereset target temperature, except when the boiler reset target is higher than the DHW Exchange setting.

DHW MODE AND PRIORITY OPERATIONThe control has five different settings available for DHW MODE. The required DHW MODE setting will depend on the pipingarrangement of the DHW tank.

It is often desirable to have a priority for the DHW allowing for quick recovery of the DHW tank temperature. This is achieved by

limiting or even stopping the flow of heat to the heating system when the DHW tank calls for heat.

DHW Mode Off No DHWThe DHW feature is not selected.

30 31ComDem

Setp/DHW

24 to 230 V (ac)

Aquastat

DHWPump

PrimaryPump Boiler

Pump

DHWPump

PrimaryPump Boiler

Pump

DHW MODE 1 - DHW in Parallel no PriorityWhen a DHW Demand is present, the Boiler3/DHW contact

(terminals 21 and 22) closes with the DHW demand. The primary

pump contact does not turn on, but may operate based on a BoilerDemand, or an External Input Signal.

It is assumed that the DHW pump will provide adequate flowthrough the heat exchanger and the boiler.

DHW MODE 2 - DHW in Parallel with Priority

When a DHW Demandis present, the Boiler 3 /DHWcontact (terminals21 and 22) closes and the primary pump contact is opened.

It is assumed that the DHW pump will provide adequate flow

through the heat exchanger and the boiler.


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2008 D 265 - 12/08 14 of 36

DHWPump

PrimaryPump Boiler

Pump

DHWPump

PrimaryPump Boiler

Pump

DHW MODE 3 - DHW in Primary / Secondary no PriorityWhen a DHW Demandis present, the Boiler3/DHWcontact (terminals

21 and 22) is closed and the primary pump contact is closed.

This mode can be used if a DHW tank is piped in direct return and

a DHW valve is installed.

DHW PRIORITY OVERRIDEThe DHW Priority Overrideapplies to DHW MODE2and 4. To prevent the building from cooling off too much or the possibility ofa potential freeze up during DHW priority, the control limits the amount of time for DHW priority. The length of DHW priority time

is determined using the Priority Overridesetting. Once the allowed time for priority has elapsed, the control overrides the DHWpriority and resumes space heating.

To provide external DHW priority, the space heating zones must be interlocked with the Boiler 3 / DHW contact. During DHW

demands, the Boiler 3 / DHW contact must remove any power to all space heating zone valves or zone pumps.

CONDITIONAL DHW PRIORITYThe Conditional DHW Priority Override applies to DHW MODE 2and 4. If the boiler supply temperature is maintained at or abovethe required temperature during DHW generation, this indicates that the boiler(s) has enough capacity for DHW and possibly

heating as well. As long as the boiler supply temperature is maintained near its target and the heating and DHW targets are similar,DHW and heating occurs simultaneously.

DHW POST PURGEAfter the DHW Demand is removed, the control performs a purge (PURG) on the boiler(s). The control shuts off the boiler(s) andcontinues to operate either the DHW pump or the DHW valve and the system and boiler pump if applicable. This purges the residual

heat from the boiler(s) into the DHW tank. The control continues this purge for a maximum of two minutes or until the boiler supply

water temperature drops 20F (11C) below the boiler target temperature during the DHW operation. The control also stops thepurge if the boiler supply temperature is close to the current boiler target temperature.

DHW MIXING PURGEAfter DHW operation, the boiler(s) is extremely hot. At the same time,

the heating zones may have cooled off considerably after being off fora period of time. To avoid thermally shocking the boiler(s) after DHW in

parallel with priority (DHW MODE 2), the control shuts off the boiler(s), butcontinues to operate the DHW while restarting the heating system. This

allows some of the DHW return water to mix with the cool return water

from the zones and temper the boiler return water.

DHWPump

PrimaryPump Boiler

Pump

DisableUsing External

Wiring

DHW MODE 4 - DHW in Primary / Secondary with Priority

When a DHW Demandis present, the Boiler3/DHWcontact (terminals 21 and 22) is closed and the primary pump contact isclosed. Priority can only be obtained using external wiring. During a priority override, the Boiler3/DHWcontact is opened until

the heating system has recovered before returning to DHW operation.

This mode can be used if a DHW tank is piped in direct return and a DHW valve is installed.

DHW MODE 4External PrioritInterlock

Power to ExternalBoiler Zones

N.C.

L

DHWPump

N

N.O.

L

N

COIL

Power fromDHW Pump / Vlv

Contact

DHW DURING UNOCCUPIEDIf the control receives a DHW Demandduring an unoccupied period, the control can either continue operation of the DHW systemas it would during the occupied period or the control can ignore a DHW Demand for the duration of the unoccupied period.

NUMBER OF BOILERS USED FOR DHW GENERATIONThe number of boilers used for DHW generation can be selected to either one or two using the BOIL DHW setting. This applies whenonly a DHW Demand is present. If there are other demands present, the control does not limit the number of boilers operated.


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If DHW is to be incorporated into a low temperature system such as aradiant heating system, a mixing device is often installed to isolate the high

DHW supply temperature from the lower system temperature. If a mixing

device is not installed, high temperature water could be supplied to thelow temperature system while trying to satisfy the DHW demand. This may

result in damage to the low temperature heating system. The control iscapable of providing DHW in such a system while maximizing the chance

that the temperature in the heating system does not exceed its allowedmaximum setting.

To prevent high temperature water from being introduced into the heating

system, the primary pump (Prim P1) must be turned off during a call forDHW. To do this, the control must be set to DHW MODE 2 or DHW MODE 4

and Boil MIN must be set to OFF.

DHWPump

PrimaryPump BoilerPump

Section D2: DHW with Low Temperature Boilers

DHW MODE 2 OPERATION

On a call for DHW, the control provides DHW priority by shutting off the primary pump (Prim P1) for a period of time. This time is

based on the DHW Priority Override setting. However, if the DHW Demand is not satisfied within the allotted time, the boiler(s) shuts

off and the heat of the boiler is purged into the DHW tank.

Once the boiler supply temperature is sufficiently reduced, the Boiler 3 / DHW contact shuts off. The heating system is turned on

for a period of time to prevent the building from cooling off. After a period of heating, and if the DHW Demand is still present, the

control shuts off the heating system and provides heat to the DHW tank once again.

For correct operation, close attention must be paid to the mechanical layout of the system. When the control turns off the primary

pump (Prim P1), flow to the heating system must stop. If flow is not stopped, the temperature in the heating system can exceed the

maximum desired temperature and can result in damage to the heating system.

DHW MODE 4 OPERATION

In DHW MODE 4, the space heating zones must be prevented from coming on during DHW demands using external wiring. This

can be done using an external relay to remove power from zone pumps or zone valves while a DHW Demand is present. Thisexternal relay is interlocked with the Boiler3/DHW contact.

During a DHW Demand, the control closes the primary pump (Prim P1) contact and the Boiler 3 / DHW contact. Once the DHW

Demand is removed, or during a DHW priority override, the Boiler 3 / DHW contact is opened, and the external wiring should allowthe space heating zones to operate.

There is no mixing purge available in DHWMODE4. After DHW priority, the boiler supply water temperature may exceed the designwater temperature of the space heating system and can result in damage to the heating system.


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Section E1: Setpoint

Note:Setpoint operation is only available when DHW MODE is set to OFF.

SETPOINTThe control can operate to satisfy the requirements of a setpoint load in addition to a space heating load. A setpoint load overridesthe current outdoor reset temperature and WWSD setting in order to provide heat to the setpoint load.

SETPOINT DEMANDA Setpoint Demand is required in order for the control to provide heat to the setpoint load.

The control registers a setpoint demand when a voltage between 24 and 230 V (ac) is

applied across the Setp/DHW Demand Com Demterminals (31 and 30). Once voltageis applied, the Setpoint Demand pointer turns on in the LCD. The control operates the

boiler(s) to maintain at least the setpoint setting.

BOILER TARGET DURING SETPOINTThe boiler target temperature during a setpoint demand is increased to at least the Setpointsetting. This temperature is maintained as long as the control has a setpoint demand.

SETPOINT MODE

SETP MODE 1 - Setpoint in ParallelWhenever a setpoint demand is present, the boiler(s) is operated to maintain the setpoint target. The primary pump contact does not

close, but may operate based on a Boiler Demand or on an external input system.

It is assumed that the Setpoint pump will provide adequate flow through the heat exchanger and the boiler.

SETP MODE 2 - Setpoint in Parallel with PriorityWhenever a setpoint demand is present, the boiler(s) is operated tomaintain the setpoint target and the primary pump (Prim P1) contact

is opened.

It is assumed that the Setpoint pump will provide adequate flowthrough the heat exchanger and the boiler.

SETP MODE 3 Primary Pump during SetpointWhenever a setpoint demand is present, the primary pump (Prim P1) is turned on and the boiler(s) is operated to maintain thesetpoint target.

SETPOINT PRIORITY OVERRIDEThe setpoint has a Priority Override while in SETP MODE 2. In order to prevent the building from cooling off too much or thepossibility of a potential freeze up during setpoint priority, the control limits the amount of time for setpoint priority. The length of

Setpoint priority is determined by the Priority Override setting. Once the allowed time for priority has elapsed, the control overridesthe setpoint priority and operates setpoint and heating simultaneously by turning on the primary pump (Prim P1).

CONDITIONAL SETPOINT PRIORITYIf the boiler(s) supply temperature is maintained at or above the required temperature during setpoint generation, this indicates thatthe boiler(s) has enough capacity for setpoint and possibly heating as well. As long as the boiler target temperature is maintained

and the heating and setpoint targets are similar, setpoint and heating occur at the same time.

30ComDem

31Setp/Dem

24 to 230 V (ac)

Setpoint Device

BoilerPumps

PrimaryPump

Section E1Setpoint

Section E: Setpoint Operation


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Section F1: External Input

DHW or Setpoint operation is available during External Input operation. Boiler Demands are not active when the Stand Alone/ExternaInput DIP switch is set to External Input.

EXTERNAL INPUTThe control can accept an external DC signal in place of the outdoor sensor. The control converts the DC signal into the appropriateboiler target temperature between 50F (10C) and 210F (99C) based on the External Input Signal and Offset settings. To use

the external input signal, the External Input / Stand Alone DIP switch must be set to External Input.

When operating in the external input mode, an external signal is required in order for the control to provide heat to the heatingsystem. An external signal is generated by applying a voltage between 0V(dc) and 10V(dc) across the Out +and Com terminals

(4 and 1). Voltages that exceed 10V(dc) will still be considered a 10V(dc) signal. Once voltage is applied, the control closes theprimary pump contact and the control calculates a boiler target supply temperature based on the external input signal and the

settings made in the control. The control then fires the boiler(s), if required, to maintain the target supply temperature. If the externa

signal goes below the minimum voltage, the boiler target temperature is displayed as to indicate that there is no longer a calfor heating. The primary pump and boiler pumps operate as described in section G.

INPUT SIGNALThe control can accept either a 0 - 10 V (dc) signal or a 2 - 10 V (dc) signal. The External Input Signal setting must be set to the

proper setting based on the signal that is being sent to the control.

0 - 10 V (dc) or 0 - 20 mAWhen the 0 - 10 V (dc) signal is selected, an input voltage of 1V(dc) corresponds to a boiler target temperature of 50F (10C)

An input voltage of 10 V (dc) corresponds to a boiler target temperature of 210F (99C). As the voltage varies between 1 V(dcand 10 V (dc) the boiler target temperature varies linearly between 50F (10C) and 210F (99C). If a voltage below 0.5V(dc) is

received the boiler target temperature is displayed as indicating that there is no longer a call for heating.

A 0 - 20 mA signal can be converted to a 0 - 10 V (dc) signal by installing a 500

W resistor between the Out +and Com terminals (4 and 1).

2 - 10 V (dc) or 4 - 20 mAWhen the 2 - 10 V (dc) signal is selected, an input voltage of 2V(dc) corresponds to a boiler target temperature of 50F (10C)

An input voltage of 10 V (dc) corresponds to a boiler target temperature of 210F (99C). As the voltage varies between 2 V(dc

and 10 V (dc) the boi ler target temperature varies linearly between 50F (10C) and 210F (99C). If a voltage below 1.5V(dc) isreceived the boiler target temperature is displayed as indicating that there is no longer a call for heating.

A 4 - 20 mA signal can be converted to a 2 - 10 V (dc) signal by installing a 500 resistor between the Out +and Com

terminals (4 and 1).

Section F1External

Input

Section F: External Input Operation


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2008 D 265 - 12/08 18 of 36

Section G1: Pump Operation

PRIMARY PUMP OPERATIONThe primary pump operates under the following conditions:

A boiler demand is present and the control is not in Warm Weather Shut Down (WWSD). An external input signal is present.

A DHW demand is present and DHW MODE is set to 3 or 4. A setpoint demand is present and Setpoint MODE is set to 3.

Primary Pump PurgeAfter all demands are removed, the control continues to operate the primary pump for a period of time. The maximum length of time

that the primary pump continues to run is adjustable using the Purge setting. The primary pump continues to run until either thepurging time has elapsed or the boiler supply temperature drops more than of the differential below the boiler minimum setting.

PrimaryPump

BoilerPumps

PrimaryPump

BoilerPumps

PrimaryPump

BoilerPumps

OR

Example Range = 0 - 10 V (dc)

Input = 7 V (dc) 157F (69C)

Offset = +5F (3C) +5F (3C)

Boiler Target = 162F (72C)

CONVERSION TABLE 0 - 10

0 - 20 mA* 0 - 10 V (dc) Boiler Target

0 0 (OFF)

2 1 50F (10C)

4 2 68F (20C)

6 3 86F (30C)

8 4 103F (39C)

10 5 121F (49C)

12 6 139F (59C)

14 7 157F (69C)

16 8 174F (79C)

18 9 192F (89C

20 10 210F (99C)

*Requires 500 Resistor in Parallel

*Requires 500 Resistor in Parallel

CONVERSION TABLE 2 - 10

4 - 20 mA* 2 - 10 V (dc) Boiler Target

0 0 (OFF)

4 2 50F (10C)

6 3 70F (21C)

8 4 90F (32C)

10 5 110F (43C)

12 6 130F (54C)

14 7 150F (66C)

16 8 170F (77C)

18 9 190F (88C)

20 10 210F (99C)

OFFSETThe Offset setting allows the boiler target temperature to be fine tuned to the external input signal. The control reads the external

input signal and converts this to a boiler target temperature. The Offset setting is then added to the boiler target temperature

Section G1Pump

Operation

Section G: Pump Operation


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CAUTIONImproper installation and operation of this control could result in damage to the equipment and possibly even personal injury. It is

your responsibility to ensure that this control is safely installed according to all applicable codes and standards. This electroniccontrol is not intended for uses as a primary limit control. Other controls that are intended and certified as safety limits must be

placed into the control circuit. Do not open the control. Refer to qualified personnel for servicing. Opening voids warranty and could

result in damage to the equipment and possibly even personal injury.

STEP ONEGETTING READYCheck the contents of this package. If any of the contents listed are missing or damaged, please contact your wholesaler or tekmarsales representative for assistance.

Type 265 includes: One Boiler Control 265, One Outdoor Sensor 070, Two Universal Sensors 071, Data Brochures D 265, D 070

D 001, Application Brochure A 265, Four 500 resistors.

Note: Carefully read the details of the Sequence of Operat ion to ensure that you have chosen the proper control foyour application.

STEP TWOMOUNTING THE BASERemove the control from its base by pressing down on the release clip in the wiring chamber and sliding the control away from it

The base is then mounted in accordance with the instructions in the Data Brochure D 001.

STEP THREE ROUGH-IN WIRINGAll electrical wiring terminates in the control base wiring chamber. The base has standard 7/8 (22 mm) knockouts which accep

common wiring hardware and conduit fittings. Before removing the knockouts, check the wiring diagram and select those sections

of the chamber with common voltages. Do not allow the wiring to cross between sections as the wires will interfere with safetydividers which should be installed at a later time.

Power must not be applied to any of the wires during the rough-in wiring stage.

All wires are to be stripped to a length of 3/8 (9 mm) to ensure proper connection to the control. If an Outdoor Sensor 070 is used, install the sensor according to the installation instructions in the Data Brochure D 070 and run

the wiring back to the control.

Install the Boiler Supply Sensor 071 according to the installation instructions in the Data Brochure D 070 and run the wiring backto the control.

If a Boiler Return Sensor 071 is used, install the sensor according to the installation instructions in the Data Brochure D 070 andrun the wiring back to the control.

Run wire from other system components (pumps, boilers, etc.) to the control. Run wires from the 115 V (ac) power to the control. Use a clean power source with a 15 A circuit to ensure proper operation

Multi-strand 16 AWG wire is recommended for all 115 V (ac) wiring due to its superior flexibility and ease of installation into

the terminals.

Installation

BOILER PUMP OPERATIONThe control can operate a boiler pump on each boiler in addition to the primary pump. The boiler pump turns on prior to the boiler

firing and continues to run after the boiler is turned off. The amount of time that the boiler pump turns on prior to the boiler firing isdetermined by the boiler mass setting. As the boiler mass setting is increased, the boiler pump pre-purge time of the also increases

However, if the control is operating only on a setpoint demand, the boiler pump turns on immediately before the boiler fires.

Boiler Pump PurgeThe amount of time that the boiler pump continues to run after the boiler turns off is adjustable using the boiler pump purge setting(PURG Boil Pmp).

PrimaryPump Boiler

Pump

PrimaryPump Boiler

Pump

PrimaryPump Boiler

Pump


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2008 D 265 - 12/08 20 of 36

29 30Boil

DemComDem

24 to 230 V (ac)

30 31ComDem

Setp/DHW

24 to 230 V (ac)

Aquastat

STEP FOURELECTRICAL CONNECTIONS TO THE CONTROL

GeneralThe installer should test to confirm that no voltage is present at any of the wires. Push the control into the base and slide it downuntil it snaps firmly into place.

115 V (dc)

PrimP1

PowerL

14

N

12 13

N

L

Powered Input Connections

115 V (ac) PowerConnect the 115 V (ac) power supply to the PowerL and PowerNterminals (13 and 14).

This connection provides power to the microprocessor and display of the control. Aswell, this connection provides power to the PrimP1 terminal (12) from the PowerL

terminal (13).

Boiler DemandTo generate a Boiler Demand, a voltage between 24 V (ac) and 230 V (ac) must beapplied across the BoilDemand ComDemterminals (29 and 30).

DHW DemandTo generate a DHW Demand, a voltage between 24 V (ac) and 230 V (ac) must be

applied across the Setp/DHW Demand Com Demterminals (31 and 30). The Boil 3setting must be set to OFF and DHW MODE must also be set to 1 through 4.

Setpoint DemandTo generate a Setpoint Demand, a voltage between 24 V (ac) and 230 V (ac) mustbe applied across the Setp/DHWDem and ComDem terminals (31 and 30). The

DHW MODE must also be set to OFF.

External Input (0 -10 V dc)To generate an external input signal, a voltage between 0 and 10 V (dc) must beapplied to the Com and Out +terminals (1 and 4).

A 0 - 20 mA signal can be converted to a 0 - 10 V (dc) signal by installing a 500 resistor between the Com and Out +terminals (1 and 4).

A 4 - 20 mA signal can be converted to a 2 - 10 V (dc) signal by installing a 500

resistor between the Com and Out +terminals (1 and 4).

Output Connections

Primary Pump Contact (Prim P1)The PrimP1 output terminal (12) is a powered output. When the relay in the control

closes, 115 V (ac) is provided to the PrimP1 terminal (12) from thePowerL terminal (13).

To operate the primary pump, connect one side of the primary pump circuit to terminal(12) and the second side of the pump circuit to the neutral (Power N) side of the

115 V (ac) power supply.

1Com

2

DoNotApplyPower

BoilSup

3BoilRet

4Out+

0 - 10 V (dc)or

2 - 10 V (dc)

+

1Com

2

DoNotApplyPower

BoilSup

3BoilRet

4Out+

0 - 20 mA

or4 - 20 mA

500

+

13 14

115 V (ac)

L

N

PowerL N


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15 16

M

24 to 230 V (ac)

or Low Voltage Alarm

C.A./

Alarm

23 24

BoilerPump1

24 to 230 V (ac)

2122

Boiler3/DHW

24 to 230 V (ac)

17 18Boiler

1 1

Connection to Operatea 4 - 20 or 0-20 mA Device

+

4-20or0-20mA

ActuatingMotor

6

+

7

Mod1mA

Combustion Air / Alarm Contact (C.A./Alarm)The Combustion Air / Alarm Contact (C.A./Alarm) terminals (15 and 16) are an iso-lated output in the control. There is no power available on these terminals from the

control. These terminals are to be used as a switch to either make or break power to

the combustion air damper or alarm. Since this is an isolated contact, it may switch avoltage between 24 V (ac) and 230 V (ac).

Boiler 1 and Boiler 2 ContactsThe Boiler1 and Boiler2 terminals (17 and 18, 19 and 20) are isolated outputs in

the control. There is no power available on these terminals from the control. Theseterminals are to be used as a switch to enable the modulating boiler. Since this is an

isolated contact, it may switch a voltage between 24 V (ac) and 230 V (ac).

Boiler 3 / DHW Contact

Boiler OperationThe Boiler3/DHWterminals (21 and 22) are isolated outputs in the control. There

is no power available on these terminals from the control. These terminals are to beused as a switch to enable the modulating boiler. Since this is an isolated contact, itmay switch a voltage between 24 V (ac) and 230 V (ac).

DHW OperationThe Boiler3/DHWterminals (21 and 22) are an isolated output. There is no poweravailable on these terminals from the control. These terminals are to be used as a

switch to either make or break power to the DHW pump or the DHW valve. Since this

is an isolated contact, it may switch a voltage between 24 V (ac) and 230 V (ac).

Boiler Pump 1 to Boiler Pump 3 Contacts

The BoilerPump1 to BoilerPump3terminals (23 and 24, 25 and 26, 27 and 28) areisolated outputs in the control. There is no power available on these terminals from the

control. These terminals are to be used as a switch to either make or break power toa boiler pump. Since these are isolated contacts, they may switch a voltage between

24 V (ac) and 230 V (ac).

Note:When a Boiler is set to OFF, the Boiler Pump contact becomes inactive.

Mod 1 to Mod 3 Outputs

The Mod 1 to Mod 3 outputs (Mod1, Mod2, Mod3) on terminals (6 and 7, 8 and 9, 10 and11) provide a 4 to 20 mA or a 0 to 20 mA output to each boiler. The modulating outputsreplace any mechanical operator such as a T991. Observe polarity when connecting the

control to the boiler.


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2008 D 265 - 12/08 22 of 36

Converting the 0 - 20 mAOutput to Operate a0 - 10 V (dc) Device

6

+

7

Mod1mA

0-10Vdc

ActuatingMotor

500 resistor0 - 20 mA converted

to 0 - 10 V (dc) outputOR

250 resistor0 - 20 mA convertedto 0 - 5 V (dc) output

The 4 to 20 mA output can be converted to 1 to 5 V (dc) using anexternal 250 resistor across the Mod1 (Mod 2, Mod 3) terminals.

The 4 to 20 mA output can be converted to 2 to 10 V (dc) using an

external 500 resistor across the Mod1 (Mod 2, Mod 3) terminals.





The 4 to 20 mA output can be converted to a 0 - 135 output for

a Modutrol IV gas valve actuating motor using a 0 - 135 tekmarConverter 005 (sold separately).

The 4 to 20 mA output can be converted to a 0 - 135 output for

a V9055 gas valve actuating motor using a 0 - 135 tekmarConverter 005 (sold separately).

6

+

7

Mod1mA

500 resistor4 - 20 mA converted

to 2 - 10 V (dc) outputOR

250 resistor4 - 20 mA convertedto 1 - 5 V (dc) output

Converting the 4 - 20 mAOutput to Operate a

1 - 5 or 2 - 10 V (dc) Device

+

1-5or2-10Vdc

ActuatingMotor

Modutrol IV

tekmar

B

R

W

+

-

tekmar

V9055

+

-

B

R

W

Modutrol IV0 - 135 Actuating

Motor

B

R

W

6Mod1mA+

7

Modutrol IV

tekmar

B

R

W

+

-

tekmar

V9055

+

-

B

R

W

6

+

7

Mod1mA

B

R

W

V90550 - 135 ActuatingMotor

Modutrol IV and V9055 are trademarks of Honeywell, Inc.


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SENSOR AND UNPOWERED INPUT CONNECTIONSDo not apply power to these terminals as this will damage the control.

Outdoor SensorConnect the two wires from the Outdoor Sensor 070 to theComandOutterminals (1 and 4).

The outdoor sensor is used by the control to measure the outdoor air temperature.

Boiler Supply SensorConnect the two wires from the Boiler Supply Sensor 071 to the Com and BoilSup

terminals (1 and 2). The boiler supply sensor is used by the control to measure the boilersupply water temperature.

Boiler Return SensorConnect the two wires from the Boiler Return Sensor 071 to the Comand Boilterminals

(1 and 3). The boiler return sensor is used by the control to measure the boiler returnwater temperature.

UnOccupied SwitchIf an external timer (tekmar Timer 032) or switch is used, connect the two wires from the

external switch to the Comand UnO Swterminals (1 and 5). When these two terminalsare shorted together, the control registers an unoccupied (UNOCC) signal.

2BoilSup

3BoilRet

4Out+

1Com

2BoilSup

1Com

1Com

2BoilSup

3BoilRet

1 2 34 5

Com

BoilSup

BoilRet

Out+

UnOSw

Timer Switch


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2008 D 265 - 12/08 24 of 36

STEP FIVETESTING THE WIRING

General

Each terminal block must be unplugged from its header on the control before power is applied for testing. To remove the terminalblock, pull straight down from the control.

The following tests are to be performed using standard testing practices and procedures and should only be carried out by

properly trained and experienced persons.

A good quality electrical test meter, capable of reading from at least 0 300 V (ac) and at least 0 2,000,000 Ohms, is essential

to properly test the wiring and sensors.

2Boil

Sup

1Com

Test the SensorsIn order to test the sensors, the actual temperature at each sensor

location must be measured. A good quality digital thermometer witha surface temperature probe is recommended for ease of use and

accuracy. Where a digital thermometer is not available, a spare sensorcan be strapped alongside the one to be tested and the readings

compared. Test the sensors according to the instructions in the DataBrochure D 070.

Test the Power SupplyMake sure exposed wires and bare terminals are not in contact with otherwires or grounded surfaces. Turn on the power and measure the voltage

between the PowerL and PowerN terminals (13 and 14) using an ACvoltmeter, the reading should be between 103.5 and 126.5 V (ac).

Test the Powered Inputs

Boiler DemandIf a boiler demand is used, measure the voltage between the

BoilDem and ComDem terminals (29 and 30). When the boilerdemand device calls for heat, a voltage between 20 and 260 V (ac)

should be measured at the terminals. When the boiler demanddevice is off, less than 5 V (ac) should be measured.

DHW DemandIf a DHW demand is used, measure the voltage between the

Setp/DHW and the ComDem terminals (31 and 30). When theDHW demand device calls for heat, a voltage between 20 and

260 V (ac) should be measured at the terminals. When the DHWdemand device is off, less than 5 V (ac) should be measured.

Setpoint DemandIf a setpoint demand is used, measure the voltage between the

Setp/DHW and the ComDem terminals (31 and 30). When thesetpoint demand device calls for heat, a voltage between 20 and

260 V (ac) should be measured at the terminals. When the setpointdemand device is off, less than 5 V (ac) should be measured.

External InputIf an external input is used, measure the voltage between theCom and the Out +terminals (1 and 4). When the external input

device calls for heat, a voltage between 0 and 10 V (dc) should bemeasured at the terminals.

14

Power13

V

103.5 to 126.5 V (ac)

NL

20 to 260 V (ac)3029BoilDem

ComDem

20 to 260 V (ac)3130ComDem

Setp/Dem

1 23 4

Com

BoilRet

Out+Bo

ilSup

500

0 - 10 V (dc) 0 - 20 mAOR

V


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25 of 36 2008 D 265 - 12/08

1412 13

PrimP1

PowerL N

N

L

115 V (ac)

1615C.A./

Alarm

M

24 to 230 V (ac)

or Low Voltage Alarm

Test the Outputs

Primary Pump (Prim P1)If a primary pump is connected to the PrimP1 terminal (12), make sure that power to theterminal block is off and install a jumper between the PowerL and PrimP1 terminals (13

and 12). When power is applied to the PowerL and PowerNterminals (13 and 14), theprimary pump should start. If the pump does not turn on, check the wiring between the

terminal block and pump and refer to any installation or troubleshooting information

supplied with the pump. If the pump operates properly, disconnect the power andremove the jumper.

Combustion Air or Alarm (C.A./Alarm)If a combustion air damper or an alarm is connected to the C.A./Alarm

terminals (15 and 16), make sure power to the damper or alarm circuit is off andinstall a jumper between terminals (15 and 16). When the circuit is powered up, the

combustion air damper should open or the alarm should activate. If the damper orthe alarm fails to operate, check the wiring between the terminals and the damper

or the alarm and refer to any installation or troubleshooting information supplied with

these devices. If the damper or the alarm operates properly, disconnect the power andremove the jumper.

Boiler 1 and Boiler 2 ContactsIf a boiler is connected to the Boiler1 and / or Boiler2contacts (17 and 18, 19 and

20), make sure power to the boiler circuit(s) is off, and install a jumper between theterminals. When the boiler circuit is powered up, the boiler should fire. If the boiler does

not turn on, refer to any installation or troubleshooting information supplied with theboiler. (The boiler may have a flow switch that prevents firing until the primary pump

(Prim P1) or boiler pumps (Boiler Pump 1, 2) are running). If the boiler(s) operates

properly, disconnect the power and remove the jumper.

Boiler 3 / DHW Contact

Boiler OperationIf a boiler is connected to the Boiler3/ DHW contact (21 and 22), make sure power

to the boiler circuit is off, and install a jumper between the terminals. When the boilercircuit is powered up, the boiler should fire. If the boiler does not turn on, refer to any

installation or troubleshooting information supplied with the boiler. (The boiler may

have a flow switch that prevents firing until the primary pump (PrimP1) or boiler pump(BoilerPump3) is running). If the boiler operates properly, disconnect the power and

remove the jumper.

DHW OperationIf a DHW pump or DHW valve is connected to the Boiler3/DHWcontact (21 and 22),

make sure the power to the pump or valve circuit is off and install a jumper between

those terminals. When the DHW circuit is powered up, the DHW pump should turnon or the DHW valve should open completely. If the DHW pump or valve fails to

operate, check the wiring between the terminals and the pump or valve and refer toany installation or troubleshooting information supplied with these devices. If the DHW

pump or valve operates correctly, disconnect the power and remove the jumper.

Boiler Pump 1 to Boiler Pump 3 ContactsIf a boiler pump is connected to BoilerPump1 contact (23 and 24), make sure thatpower to the terminal block is off and install a jumper between the terminals. When

power is applied to circuit, the boiler pump should start. If the pump does not turn on,check the wiring between the terminal block and pump and refer to any installation

or troubleshooting information supplied with the pump. If the pump operates properly,disconnect the power and remove the jumper.

Repeat the same procedure for Boiler Pump 2contacts (25 and 26) and for Boiler Pump 3

contacts (27 and 28) as necessary.

2221Boiler3/DHW

24 to 230 V (ac)

Mor

L

N

1817

Boiler

1 1

2221Boiler3/

DHW

Boiler 3

2423Boiler

Pump1

24 to 230 V (ac)

L

N


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2008 D 265 - 12/08 26 of 36

Connecting the ControlMake sure all power to the devices and terminal blocks is off, and remove any remaining

jumpers from the terminals.

Reconnect the terminal blocks to the control by carefully aligning them with their

respective headers on the control, and then pushing the terminal blocks into the headers.The terminal blocks should snap firmly into place.

Install the supplied safety dividers between the unpowered sensor inputs and the

powered or 115 V (ac) wiring chambers.

Apply power to the control. The operation of the control on power up is described in the

Sequence of Operation section of the brochure.

32 415

Com-

BoilSup

BoilRet

Out+

UnOSw

Test the Modulating OutputsConnect an ammeter to the modulating output Mod1 terminals (6 and 7)and observe the current reading during operation or during the Test

Sequence in the Test the Control section. For example, when using

a 4 - 20 mA output, the initial percentage output is zero and themeter should read 4 mA. As the Boiler 1 Modulation increases in the

VIEW menu, the meter reading should increase until 100% Boiler 1Modulation is reached at which point the meter should read 20 mA.

When the 4 - 20 mA modulation decreases, the meter should start at

20 mA and eventually reach 4 mA when the display shows 0% Boiler 1Modulation.

Repeat the same procedure for modulating output Mod2terminals (8 and 9) and Mod3terminals (10 and 11).

mA

76

Mod1mA-+

The controls exterior can be cleaned using a damp cloth. Moisten the cloth with water and wring out prior to wiping the control. Do

not use solvents or cleaning solutions.

Cleaning The Control

Dip Switch Settings

GENERAL

The DIP switch settings on the control are very important and shouldbe set to the appropriate settings prior to making any adjustmentsto the control through the User Interface. The DIP switch settings

change the items that are available to be viewed and / or adjusted inthe User Interface.

If a DIP switch is changed while the control is powered up, the

control responds to the change in setting by returning the display tothe VIEW menu.

Advanced / Installer

The Advanced / Installer DIP switch selects the access level of thecontrol. In the Installer access level, a limited number of items may beviewed and / or adjusted. In the Advanced access level, all items may

be viewed and / or adjusted.

External Input / Stand AloneThe External Input / Stand Alone DIP switch selects whether a tekmarOutdoor Sensor 070 or an external 0 - 10 V (dc) input signal is to be

connected to the Com and the Out +terminals (1 and 4).

DIP Switches

Boiler Control 265

Men u I te m

BoilerDemand

DHW/ SetpointDemand

WWSD

Modulation

BoilerOutput(x10,000 BTU/hr)

External InputSignal

Offset/Priority Override

Test

off not testingred testingred testingpa used

Formaximumheat, press&holdTest f or3

seconds.

MadeinCanadabytekmarControl SystemsLtd.

Power 115V 10%50/60Hz600VARelays 230V (ac)5A 1 /3hp , p ilo t du ty240VADem ands 20 to260V (ac)2VA

StandAlone


OffCA.

OffAlarm



S o f tS to p Ro ta teParallel

Installer

ExerciseSequential

ol 265Boiler Co

Item

oilerDemand

HW/ SetpointDemand

WWSD

Modulation

oilerOutput(x10,000 BTU/hr)

External InputSignal

Offset/Priority Overrideff not testingred testingred testingpaused

Formaximumheat, press&

holdTest for3

Made in Canada bytekmarControl SystemsLtd.

Power 115 V 10%50/60Hz600VARelays 230V (ac)5A 1 /3hp , p ilo t duty240 VADem ands 20 to260V (ac)2VA

xed Leadt On / Last Off

n / First Off

otate

)

ffre

xet O

n

Ro

Stand Alone

Advanced

External Input

OffCA.

OffAlarm



Sof t S top RotateParallel

Installer

ExerciseSequential

Stand Alone


OffC.A.

OffAlarm




Installer

ExerciseSequential


27/36

27 of 36 2008 D 265 - 12/08

Stand Alone


OffC.A.

OffAlarm




Installer

ExerciseSequential

Stand Alone

Advanced

External Input

OffC.A.

OffAlarm




Installer

ExerciseSequential

Stand Alone


OffC.A.

OffAlarm




Installer

ExerciseSequential

Stand Alone


OffC.A.

OffAlarm



Soft Stop RotateParallel

Installer

ExerciseSequential

Stand Alone


OffC.A.

OffAlarm

Fixed Lead

First On / Last Off


Soft Stop RotateParallel

Installer

ExerciseSequential

Stand Alone


OffC.A.

OffAlarm




Installer

ExerciseSequential

Stand Alone


OffC.A.

OffAlarm




Installer

ExerciseSequential

Alarm / Combustion AirThe Alarm / Combustion Air DIP switch selects whether a combustion

air damper or alarm device is to be connected to the C.A./Alarmterminals (15 and 16).

Off / Exercise

The Off / Exercise DIP switch selects whether or not the control is toexercise the primary pump and boiler pumps. If the DIP switch is setto Exercise, the pumps are operated for 10 seconds after every three

days of inactivity.

Parallel / SequentialThe Parallel / Sequential DIP switch selects whether to modulate

the boilers using parallel modulation or sequential modulation when

operating multiple boilers.

Soft Stop / OffThe Soft Stop / Off DIP switch selects whether or not to provide

the boiler with a Soft Stop. If the switch is set Soft Stop, the controlmodulates the burner down to minimum and holds it at the minimum

for an amount of time before shutting off the burner. If the switch is setto Off, the control turns off the burner at the current firing rate once a

demand is removed.

Rotate / OffThe Rotate / Off DIP switch selects whether or not the control is to

provide Equal Run Time Rotation of the boilers. If the switch is set

265 Boiler Control - Three Modulating Boiler and DHW / Setpoint

Documents

Transcript of 265 Boiler Control - Three Modulating Boiler and DHW / Setpoint