$25.

00
CLEAVERmBROOKS MODEL

Computerized Boiler Management Control

Installation,
Operating and
Servicing
Manual

DIVISION OF AQUA-CHEM, INC.

Manual Part No. 750- I33 MILWAUKEE, WlSCONSlNU.S.A.
 CLEAVER-BROOKS MODEL

COMPUTERIZED BOILER MANAGEMENT CONTROL

INSTALLATION, OPERATING
and
SERVICING MANUAL

Cleave rooks
0 Aqua-Chem, Inc., I993

Please direct purchase orders for replacement manuals

to your local Cleaver-Brooks representative

Manual Part No. 750- I33

Printed in U.S.A.
 WARNIN6
DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESSYOU FULLY UNDERSTAND
ALL APPLICABLE SECTIONS OF THIS MANUAL.

DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THISEQUIPMENT UNLESS THEY

FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONSMAY RESULT IN SE-

VERE PERSONAL INJURY OR DEATH.

TO: Qwners, Operators andor Maintenance Personnel

This operating manual presents information that will help to properly operateand care for the equipment. Study its contents
carefully. The unit will provide good service and continued operationif proper operating and maintenance instructions are
followed. No attempt should be made to operate theunit until the principlesof operation and all of the componentsare
thoroughly understood. Failure to follow all applicable instructionsand warning may result in severepersonal injury ordeath.

It is the responsibility of the owner totrain and advise not onlyhis or her personnel, but the contractors personnel who
are
servicing, repairing or operating the equipment, inall safety aspects.

Cleaver-Brooks equipment is designed and engineeredto give long life and excellent serviceon the job. The electricaland
mechanical devicessupplied as part of the unit were chosen because of theirknow ability toperform; however, proper operating
techniques and maintenance procedures mustbe followed at all times. Although these componesnts afforda high degree of
protection and safety, operationof equipment isnot to be considered fieefrom all dangers and hazards inherent in handling and
finng of fuel.

Any automatic features includedin the design do not relieve the attendant of any responsibility. Such features merely free
himher of certain repetitive choresand give h i d e r more time tot devoteto the proper upkeep ofequipment.

It is solelythe operators responsibility to properly operate and maintain the equipment.No amount of written instructions can
replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of
the responsibility
for proper operation. On the other hand, a thorough understandingof this manual is required beforeattempting to operate,
maintain, service, or repair this equipment.

Because of state, local, or otherapplicable codes, there are a variety

of electric controlsand safety deviceswhich vary consider-
ably fromone boiler to another. This manual contains mformation designed toshow how a basic boiler operates.

Operating controls will normally functionfor long periodsof time and we have foundthat some operators become lax in their
daily or monthlytesing, assuming that normal operation will continue indefinitely. Malfunctions
of controls lead to
uneconomical operation and damage and, in mostcases, these conditionsca nbe traced directlyto carelessness and deficiencies
in testing and maintenance.

It is recommendedthat a boiler room log or record be maintained. Recording of daily, weekly, nonthlyand yearly maintenance
activities and recording of any unusual operation will serve as a valuable guide to any necessary
investigation.

Most instances of major boilerdamage are the resultof operation with low water.We cannot emphasize too strongly the need
for the operator to periodically check hisher low water controlsand to follow good maintenance and testing practices. Cross-
connecting piping to low water devices mustbe internally inspected periodically to guardagainst any stoppages which could
obstruct the fiee flow of water to the low water devices. Float bowlsof these controls mustbe inspected frequentlyto check for
the presence of foreign substances that would impede float ball movement.

The waterside condition of the pressure vessel isof extreme importance. Waterside surfaces shouldbe inspected frequentlyto
check for the presence of anymud, sludge, scale or corrosion.

The servicesof a qualified water treating company

or a water consultant to recommend the proper boiler water
treating practices
are essential.

The operation of this equipment by the ownerand hisher operating personnel must comply with all requirements or regulations
of hisher insurance company and/or other authority having jurisdiction. In the eventof any conflict or inconsistency between
such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.
lNSTRUCTlONS
C
DIVISION
-4
OF AQUA-CHEM, INC.

~ Computerized
Boiler
Controller

APPLICATION
The Cleaver Brooks Boiler Controller is a micropro-
cessor based integrated control system for gas,oil, or
combinationfuelsingleburnerapplication.TheBoiler
Controller consists of a Boiler Controller {Chassis,
Program Module, and Keyboard Display Module}, Flame
Amplifier,SolidStateSensors{FuelOilandWater
Temperature,Steam,Gas,andOilPressure},and
Damper Motor.
The Boiler Controller is programmed to provide levels
of safety, functional capability and features beyond the
capacity of conventional controls. The Boiler Controller
isUnderwritersLaboratoriesIncListed,Canadian
StandardsAssociationListed[pending],andFactory
Mutual approved[pending].
Functions provided by the Boiler Controller include
automatic burner sequencing, flame supervision, system
status indication, system and self diagnostics.

FEATURES
Dynamic self check logic
Circuit status monitoring
Dynamic amplifier check
Expanded safe start check
SPECIFICATIONS
Dynamic sensorcheck ELECTRICAL RATINGS
Closed loop logic test Voltage and Frequency
Dynamic safety relay test Chassis and Program Module
Tamper resistant.timing andlogic l2OVac (+lo/-15%)
Damper motor control tests 50 or 60 HZ +/- 10%
Dynamic input check Keyboard and Display Module
First out annunciation and systems diagnostics are 24Vac (+20/-15%)
provided by an 80 character liquid crystal display {LCD} 50160 Hz
located on the Keyboardand Display Module
LCD display of bailer operating parameters including Power Dissipation
steam pressure, oil pressure, gas pressure, firing rate, oil Chassis and Program Module
temperature, water temperature, flame signal strength, 10 Watts maximum
historical data, system diagnostics, and systemfaults. Keyboard andDisplay Module
Solid state pressure and temperatureinputs. 2 Waits maximum
Five functionRun/Test switch
Thermal shock protection Maximum Total Connected Load
Damper motor feedback Chassis and Program Module
Nonvolatile memory, Boiler Controller retains history 2000 Vh
files and sequence status after loss of power.
Interchangeable plug-in flame amplifiers Fusing
Microcomputer technology provides dependable, Boiler Controller (Total System)
long-term operation. 15A maximum, type FRN or equivalent
Communications Interface capability Chassis
Dynamic Motor Calibration 1OA, field replaceable

Form Number CB6834

TERMINAL RATINGS

Terminal No. Description Rating

L2 Line Voltage Common 12OVac +1 O/-15%

E Earth Ground 50 or 60 Hz +/- 1 l2

L1 Line Voltage Supply 2000 VA Maximum

4 Burner Motor Starter 12OVac, 9.8AFU58.8ALR

I I
5 I Preignition
Interlock I 12OVac,
Maximum
4mA (input)
I I
6 Recycle Limits 12OVac, 4mA Maximum (input)

7 Demand (Burner Switch) 12OVac, 4mA Maximum (input)

8 Lockout Interlocks 12OVac, 8A Maximum (input)

10 Pilot ValveAgnition Transformer 12OVac, 4.5A Ignition and 50VA Pilot Duty3
or 120Vac 2.5A Ignition and 75VA Pilot Duty

11 Oil Main Valve 12OVac, 250VA Pilot Duty4

12 I Gas Main
Valve/Gas
Pressure
Sensor Test
Valve 1 12OVac,
250VA Pilot Duty4

13 Alarm Normally Open, N.O.

14 Alarm Common 12OVac, 5A Resistive
15 Alarm Normally Closed, N.C. Isolated SPDT

16 Atomizing Air Proving Switch 12OVac, 4mA Maximum (input)

17 Unused

18 Load Demand Normally Open, N.0

19 Load Demand Common 12OVac, 5A Resistive
20 Load Demand Normally Closed, N.C. Isolated SPDT

21 Low Oil Pressure, Normally Open, N.O.

22 Low Oil Pressure, Common 12OVac, 5A Resistive
23 Low Oil Pressure, Normally Closed, N.C. Isolated SPDT

24 Damper Motor Close 24Vac, 1A Maximum, Common to

25 Damper Motor Common Open or Common to Close (triac output for
26 Damper Motor Open energizing motor)

27 Flame Detector Shutter 12OVac

28 Power Flame Sensor 60 to 220Vac, Current Limited

29 Ground Flame Sensor
30 F2 Flame Sensor
31 F1 Flame Sensor

32 Water Temperature Sensor,Signal 31 10Ohms @ O'F to 5413 Ohms @ 500'F.

33 Water Temperature Sensor,Common Approximately Linear.

34 Oil Temperature Sensor, Signal 3110 Ohms @ O'F to 5413 Ohms @ 500'F.
35 Oil Temperature Sensor, Common Approximately Linear.

36 Steam Pressure Sensor Power 8 +I- .05Vdc

37 Steam Pressure Sensor Signal 1.25 to 5.5 Vdc over rated range
Steam Pressure Sensor Common 38 Common (Negative of 8Vdc Supply)

2
 Terminal No. Description Rating

39 Damper Position Sensor Power 8 +I- .05Vdc

40 Damper Position Sensor Signal 1.5 to 5.5 Vdc over motor range
41 Common (Negative of 8Vdc Supply) Damper Position Se

42 Oil Pressure Sensor Power 8 +I- .05Vdc

43 Oil Pressure Sensor Signal 1.25 to 5.75 Vdc over rated range
44 Common (Negativeof 8Vdc Supply) Oil Pressure Sensor

45 Gas Pressure Sensor Power 8 +I- .05Vdc

46 Gas Pressure Sensor Signal 1 to 6 Vdc over rated range
47 Gas Pressure Sensor Common Common (Negativeof 8Vdc Supply)

48 Unused

49 Line Voltage Common 12OVac +lob1 5%, 50 or 60Hz +I- 10%2

50 Assured Low FireCutoff 12OVac, 4mA Maximum (input)

51 1- Heavy
Oil
Select I 12OVac, 4mAMaximum(input)

52 Light Oil Select 12OVac, 4mA Maximum (input)

53 Gas Select 12OVac, 4mA Maximum (input)

54 Oil Line Purge 12OVac, 1I4HP, 5.8AFL 34.8ALR

55 Voltage Supply 12OVac, +lo/-1 5%50 or 60Hz +I- 10%2 Line

56 Atomizing Air Compressor 12OVac, 1/4HP, 5.8AFL 34.8ALR

1 The earth ground provides for a connection between the Chassis Module and the control panel or the boiler. The
earth ground wire must be capable of conducting the current required to blow the 15A fuse (or breaker) in case of an
internal short circuit. The Boiler Controller, and its sensor leadwire shields, need a low-impedance ground connection to
theboilerframewhich, in turn,needsalowimpedanceconnectiontoearthground.Foragroundpathtobelow
impedance at RF frequencies, connections must be made with minimum length conductors having maximum surface
areas. Wide straps or brackets are preferred over leadwires. Care should be taken to insure that mechanically tightened
joints along the ground path, such as pipe or conduit threads or surfaces held together with fasteners, are free of non-
conductive coatings and have protection against corrosion on mating surfaces.
2 2000VA maximum connected loadto Chassis and Program ModuleAssembly.
3 Can also be12OVac, 2.5A ignition plus75VA pilot duty
4 Can alsobe 65VA pilot duty with
'a. Motorized valve, 1150VA inrush, 460VA open, 250Va hold.
'b. Motorized valve, 15OOVA inrush, 600VA open, 250VA hold.

ENVIRONMENTAL RATINGS: ACCESSORIES:

Ambient Temperature Chassis Module
Operating 32'F to 130'F 833-2507 Electrical Connector (TerminalsL2 - 8)
Storage -3O'F to 150'F 833-2510 Electrical Connector (Terminals 23-31 )
Humidity 833-2509 Electrical Connector (Terminals 16-22)
Operating 85% RH Continuous, Noncondensing 833-2506 Electrical Connector (TerminalsA - C)
Vibration 833-2508 Electrical Connector (Terminals 9- 15)
Continuous 0.5G environment
832-1 614Field Replaceable 1OA Fuse
Dimensions
See Figures 1, 2, 3, and 4. Program Module
Weight 833-2513 Electrical Connector (Terminals 48 - 56)
Chassis Module 3 pounds2 oz, unpacked 833-2511 Electrical Connector (Terminals 32-35)
Program Module 1 pound 10 02, unpacked 833-2512 Electrical Connector (Terminals 36-47)
Keyboard and DisplayModule 1 pound9 oz, 808-1 7 Replacement BatteryAssembly
unpacked 833-251 4 Battery Compartment Cover

3 CB68-34
 Keyboard and Display Module
833-2506 Electrical Connector (Terminals A- C)
833-251 5 ContrastPlug
853-1035 NEMA 12 Gasket I
APPROVAL BODIES: !
UNDERWRITERS LABORATORIES INC. LISTED:
! i 5 1

CANADIAN STANDARDS ASSOCIATION , pending

Factory Mutual Approved, pending
Federal Communications Commission
Part 15, Class A Emissions
I
I
!i ["i" I

1
It

FIG "KEYBOARD
. I

AND DISPLAY MODULE

DIMENSIONS
T

r
U1118

FIG 1-APPROXIMATE DIMENSIONS OF 833-2415 IN

in. [mm SHOWN IN BRACKETS].

_ .
:IG 4-COMBINAllON OF CHASIS AND PROGRAM
FIG 2-PROGRAM MODULE DIMENSIONS MODULE DEMENSIONS
4
 f. Oil temperature fault:
I HEAT BLOCK
I 1. 833-2417 Program Module; Lock out if
CELL MOUNT
I I high oil temperature limit exceeded, after 10
seconds into the ignition period.
2. 833-2418 Program Module; Lock out if
oil temperature is not within limit values, after
.SI 10 seconds intothe Prepurgeperiod.
g. Damper motor fault.
2 LEADS II
48 INCH
11.2 METRE]
FLEXIBLE
CONDUIT
A@
1
I APERTURE
& O L U R . 3 / & 1 4 NPSM
INTERNALTHREADS
I \ '
NPSM
\
i,4.14 3/4-14 NPSM
INTERNAL
I h. Pilot valvefignition terminal energized.
i. Main oil valve terminal energized.
BUSHING WITH
MAGNIFYING LENS
THREADS j. Main gas valve terminal energized.
E2177
k. Internalsystem fault.
1. Faultygaspressure sensor.
3. PILOT F U M E ESTABLISHING PERIOD
FIG H N F R A R E D DETECTOR
a. Incorrect fuel select input.
b. Preignition interlock open or shorted.
c. Lockout i n t e r i d open.
d. No flame established.
e. Gas pressure limit or sensor fault.
f. Oil pressure limit fault, heavy oil only.
g. Oil temperature limit fault.
h. Damper motor fault.
i. Pilot valve or ignition terminal not energized.
j. Mainoilvalve energized.
k. Main gas valve energized.
1. Internalsystemfault.
4. MAIN FLAME ESTABLISHING PERIOD
a Incorrect fuel select input.
b. Lockout interlock open.
FIG 64JLTRAVIOLET DETECTOR c. No flame present.
d. Gas pressure limit fault.
e. Oil pressure limit fault, heavy oil only.
PRINCIPAL TECHNICAL 1. Oil temperature limit fault.
g. Atomizing air pressure switch open, oil select-
FEATURES ed fuel.
h. Damper motor fault.
i. PiloVignitiontransformerterminalde-ener-
The Boiler Controller provides all customary flame safe- g ized.
guard functions while providing significant advancements j. Main oil valve de-energized, oil selected fuel.
in the areas of safety, annunciation, and system diagnos- k Maingasvalvede-energized,gasselected
tics. fuel.
1. Internal system fault.
SAFETY SHUTDOWN (LOCKOUT) OCCURS IF: 5. RUN PERIOD
1. STANDBY PERIOD a. Incorrect fuel select input.
a. Incorrect fuel selection input. b. No flame present.
b. Preignitioninterlockopen. c. Lockoutinterlocks open.
c. Flame signal is present continuously for more d. Gas pressure limit fault.
than 40 seconds. e. Oil pressure limit fault, heavy oil only.
d. Pilothgnitionterminal energized. f. Oil temperature limit fault.
e. Main oil valve terminal energized. g. Atomizing air de-energized, oil selected fuel.
1. Main gas valve terminal energized. h. Dampermotor fault.
g. Internal system fault. i. Pilothgnition terminal energized.
h. Damper Motor fault j. Mainvalveterminal-de-energized,selected
2. PREPURGE PERIOD fuel.
a. Incorrect fuel selection input. k.Mainvalveterminal energized, main valve of
b. Preignition interlock open. fuel series not selected.
c. Lockout interlock open (after 10 seconds into 1. Internalsystem fault.
the prepurge period). 6. POSTPURGE PERIOD
d. Flamepresent,after10secondsintothe a. Preignition interlock open after 5 seconds.
Prepurge period. b. Atomizing air terminal de-energized,oil select-
e. Oil pressure fault: ed fuel.
1. 833-2417 Program Module; Lock out if c. Pilothgnition terminal energized.
pressure is not within limit values, after 10 d. Main oil valve terminal energized.
seconds into the Prepurge period. e. Main gas valve terminal energized.
2. 833-2418 Program Module; Lock out if f. Internal system fault.
oil pressure is not within limits values. g. Damper motor fault.
5 CB68-34
SAFETY PROVISIONS
DYNAMIC SELF CHECK SAFETY CIRCUIT
The microcomputer tests itself and related hardware.
If a microcomputer or safety relay failure occurs, not
allowing proper execution of the selfcheck routine, safe-
ty shutdown will occur and all safety critical loads will be
de-energized.
CIRCUIT STATUS MONITORING
The Boiler Controller must react to input changes but
avoid the occurrence of "nuisance" shutdown events.
Signal conditioning is applied to the line voltage, optoiso-
latorcoupled, inputs to ensure proper operation in the
presenceof"normal"electricallinenoisesuchas tran-
sient high voltage spikes or short periods of line dropout.
Signal conditioning is tolerant of synchronous noise [line
noise events that occur at the same time during each line
cycle].
The Boiler Controller utilizes optoisolators for signal
conditioning as well as for Dynamic Input Checks, Closed
Loop Logic Checks and Dynamic Safety Relay Tests.
DYNAMIC INPUT CHECK
All system inputs circuits are examined to assure the
Boiler Controller is capable of recognizing the true status
of external controls, limits and interlocks. If anyinput
fails this test, a safety shutdown will occur, and the fault
will be annunciated.
CLOSED LOOP LOGIC TEST
Verifies the integrity of ail safety critical loads (termi-
nals 10, 11, and 12 ). If the loads are not energized prop-
erly,i.e. the main oil valveis powered duringprepurge,
the Boiler Controller will lockouton safety shutdown.
DYNAMIC SAFETY RELAY TEST
Checks the ability of the dynamic safety relay's con-
tact to open and close.Assuresthat the safetycritical
loads (terminals 10, 11, and 12) can be de-energized, as
required, by the Dynamic Self Check logic.
DYNAMIC FLAME AMPLIFIER CHECK
The Boiler Controller accepts one of two amplifiers,
833-2419 for infrared flame detectors or the 833-2420 for
ultraviolet flame detectors,.
The Boiler Controllers microcomputer checks the
amplifier at least once every 6 seconds. The microcom-
puter disables the amplifier for 1/2 second before the
flame signal amplifier must indicate NO FLAME. This
assures the flame amplifier can respond to a flame fail-
ure. If the amplifier fails thischeck Safety Shutdown
occurs.Dueto this dynamicamplifiercheck the flame
signal when read at a volt-ohm meter may momentarily
drop to zero.
EXPANDED SAFE START CHECK
The conventional safe start check, that prevents burn-
er start-up if flame is indicated at start-up, is expanded to
include a flame signal check during STANDBY and a
preignition interlock check.
OFF CYCLE (STANDBY) FLAME SIGNAL CHECK
The flame detection subsystem [flame detector and
amplifier] is monitored during STANDBY. If a flame simu-
6
lating condition or an actual flame exists a system HOLD
occurs andstart-up is prevented. If the flame signal
exists for more than 40 seconds, safety shutdown will
occur and be annunciated.
PREIGNITION OUTPUTCIRCUIT CHECK
At the end of prepurgethe Dynamic SafetyRelay
operation is checked. Also, all safety critical loads [termi-
nals 10, 11, and 121 are checked to assure the terminals
are not powered. If the Dynamic Safety Relay operation
is faulty or if any of the safety critical loads are powered,
safety shutdown will occur and be annunciated.
DYNAMIC SENSOR CHECK
The Boiler Controller interrogates the gas pressure
sensor. The gas pressure sensors provide a 6.0 Vdc out-
putindicating a 100% Full Scale Output (FSO) reading
and a 1.0 Vdc output indicating a 0% pressure reading,
i.e. with a 6.0 Vdc input a 15 psi sensor indicates 15 psi
is present at the sensor diaphragm.
The sensor is tested during the pilot flame establish-
ing period for its ability to detect zero gas pressure The
sensor is considered faulty if its output voltage signal is
greater than 1.26Vdc or less than 0.75Vdc, during this
check.
DAMPER MOTOR CONTROLTESTS
The Boiler Controller monitors the damper motor via a
feedback circuit. Four checksare performedonthe
dampermotortoassure proper operation . A failure to
operate properly is a "damper fault" and will be annunci-
ated via the Keyboard and Display Module.
1. The damper motor must reach the commanded
position within 60 seconds after a new positioning com-
mand is issued.
2. The damper motor must not slew too quickly during
prepurge. Checks are made to assure that the damper
motor does not exceed the speed required for proper air
changes during prepurge; a damper fault lockout occurs
if this requirement is not met.
3. The indicated damper motor position must be with-
in 0 to 90 degrees. A single or occasional indication of
out-of-range is tolerated. Repetitive and persistent occur-
rences result in a damper fault lockout.
4. The damper motor is dynamically calibrated during
every prepurge cycle. Out of tolerance calibration data
results in a damper motor fault lockout.
TAMPER RESISTANT TIMING ANDLOGIC
All safety and logic timings are inaccessible and can-
not be altered or defeated.
RATE LINEARIZATION
Rate Linearization is a user programmed configura-
tion parameter which defines the relationship between
motor position and firing rate and is also used to deter-
mine the rotation to whichthe damper motorwill drive
during Drive to Purge Rate. Table 1 summarizes the
Rate Linearization settings.
Low Fire Rate is the lowest rate at which satisfactory
combustion may be obtained andthe reciprocal of the
boiler turndown. I. E., a boiler with a turndown range of 4
to 1 has a firingrate range of 25% to 100%. Table 1
summarizes Low Fire Rate [turndown] settings.
 TABLE 1-TURNDOWN RANGE
3 - 4:l
0 70% of the operating setpoint, point P2. When the pres-
Competitive
M 207
ANTI-SWAP
The Boiler Controller Anti-Swap function assures that
programmable parameters must be re-programmed after
"swapping" the Chassis Module and/or Program Module
from one boilerto another.
NOTE: Reprogramming of the Boiler Controller must
bedonewhenswappingcontrolsbetweenboilers
because limit values of certain measured parameters are
stored in the Boiler Controller's Program Module.
Thermal Shock Protection
Thermal shock protection slowly increases the burner
firing rate on a cold start to limit mechanical stress on the
boiler dueto thermal differences. The thermal shockpro-
tection control requires two inputs, operating pressure
/temperature setpoint and actual pressurehemperature.
The output of the thermal shock protection control is a
commanded firing rate position. Thermal shock protec-
tion varies with boiler type [firetube or watertube] and
load type[hot water or steam].
NOTE: Thermal shock only functions during the Auto
Mode; Manual Mode overrides thermal shock.
STEAM FIRETUBE BOILER THERMAL SHOCK
PROTECTION
See figure 7
Thermal shock protectionis initiated if boiler pressure
at startup is less than 20% of the operating setpoint point
P1. Thermal shock protection is exited when operating
pressure reaches 70% of setpoint, point P2. When ther-
mal shock is initiated the span from 20?/0 to 70% of oper-
ating setpoint is equally segmented, into seven steps,
point P3. The firing rate span, from low fire to maximum
fire, also is segmented into seven equal parts.
When pressure increases to equal the next pressure
segment, firing rate is increased to the next firing rate
segment.Thisprocesscontinuesuntilthepressure
reaches 70% of the operating setpoint At this point con-
trol is releasedto the boiler rate control.
A timed override is provided if the pressure does not
build rapidly enough. The timed override will step the fir-
ing rate to thenext segment at a rate of one step per
hour. The timed override is limited to 50% of fire rate or
the programmed maximum firerate, whichever is less.
Thermal shock protection will not be entered again
unless the pressure drops below 50% of the operating
setpoint.
7 CB68-34
STEAM WATERTUBE THERMAL SHOCK PRO-
TECTION
See figure 9
In general watertube boilers are manually brought up
to setpoint. Thermal shock protection is initiated if pres-
sure at startup is less than 20% of the operating setpoint,
point P1. When thermal shock protection is initiated fir-
ing rate is held at low fire rate until pressure reaches
sure reaches 70% of the operating setpoint, control is
released to automatic firerate control.
Thermal shock protection will not be entered again
unless the pressurehemperature drops below 20% of
operating setpoint.
HOTWATER FIRETUBE BOILER THERMAL SHOCK
PROTECTION
See figure 8
Thermal shock protectionis initiated if boiler tempera-
ture at startup is less than 60% of the operating setpoint,
point T1. Thermal shock protection is exited when oper-
ating temperaturereaches 90% of setpoint,point T2.
When thermal shock is initiated the span from 60% to
90% of operatingsetpoint is equallysegmented, into
seven steps, point T3. The firing rate span, from low fire
to maximum fire,alsoissegmentedintosevenequal
parts.
When temperature increases to equal the next tem-
perature segment, firing rate is increased to the next fir-
ing rate segment. This process continues until the tem-
perature reaches 90% of the operating setpoint At this
point control is released to automatic fire ratecontrol.
A timed override is provided if the temperature does
not build rapidly enough. The timed override will step the
firing rate to the next segment at a rate of one step per
hour. The timed override is limitedto 50% of the fire rate
or the programmed maximum firerate, whichever is less.
Thermal shock protection will not be entered again
unless the temperature drops below 75% of the operating
setpoint
HOTWATERWATERTUBETHERMALSHOCK
PROTECTION
See figure 10
In general watertube boilers are manually brought up
to setpoint manually. Thermal shock protection is initiat-
ed if temperature at startup is less than 60% of the oper-
ating setpoint, point T1. When thermal shock protection
is initiated firing rate is held at low fire rate until tempera-
ture reaches 90% of the operating setpoint, point T2
When the temperature reaches90% of the operating set
Thermal shock protection will not be entered again
unless the temperature drops below 75% of operating
setpoint
 THERMAL SHOCK PROTECTIOKSTEAM RRETUBEBolLERS I THERMAL SHOCK PROTECTION-HOT
WATER
RRETUBE BOlLERS

RRlffi RATE Rmtu

D9

Y U ARE

+-(;I
L O W ARE

=
O F
p1

OPERATING
=OF
P2

OPERATINQ
t' PRESSURE

OPERATINO
sEWc4m
LOW FIRE

YP
&-
Ti
SWOF
OPERATING
OPERATING
SETP0ih-r

SETpO0h-T SETPOlM smam

FIG 7-STEAM FIRETUBE THERMAL SHOCK FIG "HOTWATER FIRENBE THERMAL SHOCK

THERMAL SHOCK PROTECTIOKSTEAM WATERTUBE BULER THERMAL SHOCK PROTECTION-HOT WATER WATERTUBE BOlLER

R m t s RATE R m m RATE

MAX ARE 4

FIG 9 4 T E A M WATERTUBE THERMAL SHOCK FIG 1 G H O T WATER WATERTUBE THERMAL

SHOCK

OPERATION
FIRING RATE CONTROL sure control is not maintained. Response bands of 1, 3,
an 5 are represented in figure 14 point P3.
The rate control determines what the firing rate of the
As pressure or temperature rises the burner will shut-
burner should be during Run. Water temperature or
down at point P4, Boiler Off.
Steam pressure is monitoredandprocessed by the
BoilerController's rate control determining a firingrate
which minimizes load temperature or pressure variations, SEQUENCE 833-2416 PROGRAM
reducing on-off cycling and minimizing Damper Motor MODULE
adjustments. The Boiler Controller's firing rate control for The 833-2416 has the following operating sequence,
steam or hot water boilers is the same except for the as shown in Figure 13.
sensor inputs. See figure 14.

RATE CONTROL
A burnersequence begins when operating pressure
or temperature reaches the BoilerOn Setting, point P1.
The burner is held in low fire until pressure or temper-
STANDBY-
The 833-2416 is ready to start an operating sequence
when the Boiler Controller's rate control determines a
"call for heat" is required. The burner switch, limits, inter-

- - -
ature drops to the Operating Setpoint. P2. The burner is locks, assured low firecutoff,andallmicrocomputer
nowallowedtomodulateundercontrol of the Boiler monitored circuits mustbe in the correct operating state.
Controller firing rateantrol.
The rate control will control the pressure or tempera- - STANDBY DISPLAY
turewithin a control band asdefined by the Response
factor. One of five response factors can be chosen to Demand Main Valve Alarm
determine the tightness of control. A response factor of 5
is very tight temperature/pressure control requiring f 3
Auto 12 PSI FlarneSignal 0.OOV
numerous Damper Motor repositions. A response factor
of 1 is loose control which does not require the numerous
Damper Motor repositions, but tight temperature/pres- \
Standby GAS OperSetPolnt 8 PSI
-
M203

8
 A

t '

FIG 11-WIRING DIAGRAM

9 CB68-34
 TEUPEMWREI
selected fuel; the atomizing air compressor is pow-
PRESSURE ered 1 second after the burner motorstarts pre-
purge . If heavy oil is the selected fuel; the Boiler
BULER OFF
Controller will recycle if high or low oil temperature
limits are exceeded.

BULER ON
\ I
---Demand
f I \ i-

AUto 9PSI

Prepurge 57%
-
D. After the Damper Motor reaches the purge rate
position it is driven to the low fire position.

,\I /, Mainvalve

OperSetPoint 8 PSI

Drive to Low Fire

Alarm

m t P d n l

E. When the Damper Motor reaches low fire position

the sequence is allowed to continue. Prior to the
ignition trial,a 1.5 second transition occurs to con-
duct a Dynamic Check of the gas pressure sensor
FIG 12-RATE CONTROL and safetyrelay. The gas sensor must indicate
zero gas pressure or safetyshutdown will occur.

NORMAL START-UP- IGNITION TRIAL'S

A. Pilot Flame Establishing Period
PREPURGE 1. With the Damper Motor at the low fire position
The Boiler Controller is configured specifically for a. The pilot valve and ignition transformer {ter-
CleaverBrooksboilers. To obtaintherequiredair minal 10) are energized.
changes the Boiler Controller will position the Damper
Motor to a selected purge rate position. This purge rate * PILOT IGNITION MSPLAY
position will provide the required volume of air to purge

1 1
the combustion chamber and flue passages; and it is a

z::::!":
function of the selected rate linearization curve and the
boiler type [firetube or watertube], see figure 17. A Purge
Extension Tmed Period can be added to prepurge; it will Auto 9PSI
begin when the Damper Motor reachesthe purge rate Pilot IGN 8
position.

With power applied and the Boiler Controller rate con-

trol requiring a "call for heat": b. Flame must be proven by the end of the 10
A. Recycle limits, preignition interlocks, burner switch, secondPilotflameestablishing periodto
Assured Low Fire Cutoff, Runnest switch, and all allow the sequencetocontinue. If flame is
microcomputer monitored circuitsmust be in the not proven by the end of Pilot flame estab-
correct operating state. If heavy oilis selected, lishing period, a safety shutdown will occur.
fuel oil temperature must be within programmed
high and low limit values. B. Main Flame Establishing Period
1. Ten {lo}seconds into the ignition trials, and with
Program Boiler . RateLinearization the presence of flame, the main fuel valve [ter-
minal 11 for oil or terminal 12 for gas] is pow-
Module Type 0 I 1 1 2 1 3
I ered. If a flame out occurs, the Boiler Controller
Firetube 5 5 " 61' 65" 75" will respond with a safety shutdown within four
033-2416
[4] seconds.
Watertube 900 900 900 goo

FIG 1P U R G E RATE
M208
I MAIN IGNITION DISPLAY

B. Damper Motor is driven to the purge rate position;

then the burner motor is powered.
Auto 9 PSI FlarneSignai 2.4CV
C. The lockout interlocks {proving combustion air and
Main IGN 4 OperSetPomt 8 PSI
burnermotorstart interlocks} mustcloseand no
flame can be presentafter 10 secondsinto pre-
MX)6
purge or a safety shutdown will occur. If oil is the

10
 5 833-2416 SEQUENCE DIAGRAM A YIlVUVE

TANDBY
PREPURGE PREPUffiE PREPURGE PILOTFLAME
MAIN FUME RUN POSTPURGE
DRVETO PURGE RATE DRVETO LOW RRE lWmON TRANSTON ESTABUSHWG ESTIBLWUG

8
c
10

-
11

R . M Y VALVE UL

'.UAIN VALVE- '24s

2951

3253

34.35 A

424344 A
454647 A
YI

24-2626

A THE C E X m SEOUMCE STATUS DIAGRAM PROVIDE WOlCATKm OF W E N THE

NOTEDClRCUlT~ACTNE(POWERED)ORIFlHECI~UTISASU(SORINPUTTEU
A OILTEYPERANREYUST BE WKWN PROGRAMMED VALUES FROM STANDBY
THROUGHRUN. IFULTEYPERATUREISOUTSIDEDFLlMlTVALUESTHE8ULER
l H E INPUT MVST BE m T n l N R L N G L C M R O L l E R WLLUOLD OR RECYCLE FROMSTANDBY TUROUW PREPURGE

A THE A U R M RELAY CAN BE POWERED ANITIME DURING A SEOUWCE FROM

STANDEYTHROUGU POSTPURGE l H E A U R YR E U Y WLL BE POWERED I F *
S A F m SHUTDOWN (LOCKOUT) OCCURS OR IF A STANDBY HOLD OCCURS DUETO
AN O P M RECYCLE LIMIT OIL PRESSURE OUTSDE OF LIMITS IF OIL IS THE
SELECTEDFUELORIFC~LTMPERATUREISOUTSDEOFLMITSIFOILISTHE
SELECTED FUEL W R N G A NORMAL OPERATING Y O U M C E T H E A U W R E U Y IS
DEENERIZED.
AND LOCKOUT (SAFETY ScIvTDow)IFA YGNAL OCCURS WICW IS OUTSIDE
OF THE UYT -NOS FROM PILOT 1t31111m
TnRoucu RUN.
A RR)WGR)ITEY)TORPOSITlONISMCUITOREDATAUTIYU I F T H E R R N C
RATE K l T O R IS NOT AT THE COY*UNDED POSTICU DURNG PREPURGE
THROUGH RUN LOCKOUT( S A F m SHUTDOWN) WLL OCCUR
A OIL PRESSURE IS NOT MONITORED WmC THE C B m .

A THE ATOMDNG U R PR)VlNG S m C U MUST BE CLOSED FROM 10 SECONDS lKT0

PREPURGE-DRVETOPURGERITElHROUGHRM. IFTHEATOMVJNGURSWKW
A G4S PRESSURE MUS7 BE W T H W W I T SElTNGS PILOT IGNIC
l UTRALS
muww RUN. IF GAS PRESSUREIS OUYDE OF UMK VALUES LOCKOUT
IS O P M AND IF OIL IS THE SELECTED FUELTUE SAFEPI SHUTDOWN (LOCKOW ( S A F m SHUTDOWN)WlLLOCCUR DURINGTHE PREPURGE-IGNITION
WLL OCCUR DuRmG PILOTm m w THROUGH RUN. 1R)INSISllQI THE G I s PRESSURE SENSOR MUST I N U U T E D PRESSURE THIS IS

A -
THE LOAD DEMANDR E U Y IS POWERED FROM PREPURGE DRVETO PURGE RATE
THROUCU RUN W E N A CALL FOR HEAT OCCUW AND THE aOlLER CCUTROLLER IS A
W E DYNAMJC SENSOR CUECC

l H E RUING RATE MOTOR IS DRlVM FR)M LOW RRETOTHE PURGE RATE

UOT LOCKED OUT ON S I F E P I SHUTDOWN. POSITWN DURING PREPURGE- DRVE TOPURGE RATE THE R R N G RLTE

A THE LOW U L PRESSURE R E U Y IS NORMALLY OFF.

YOTOR D DRlVM TO LOW FIRE POSKION FOR I U i I l l O N T R A L SAND RELEASED
TO M O D U U T W UNDER
DURING R M .
THE CWTROL OF THE RATE
CONTROL ALCORNIH
uxH6

RG 1-33-241 6 SEQUENCE

11 CB68-34
 2. Pilot valve and ignition transformer, terminal 10, NORMAL START-UP-
are de-energized at 20 seconds into ignition tri-
als if gas or light oil is selected fuel, or 25 sec- PREPURGE
onds if heavy oil is the selected fuel. This action TheBoilerController is configuredspecifically for
signals completion of theMain Flame CleaverBrooksboilers. To obtaintherequired air
Establishing Period. changes the Boiler Controller is programmed to position
the Damper Motor to a selected purge rate position. This
Run purge rate position will provide the required volume of air
A 10 second stabilization period occurs at the begin- to purge the combustion chamber and flue passages and
ning of the Run period before the Boiler Controller releas- is a function of the selected rate linearization curve and
es theDamperMotortomodulation.TheBoiler theboilertype[firetubeorwatertube]seefigure 15.
Controller is now in its Run period and will remain in Run A PurgeExtensionTimedPeriodcan be addedto pre-
until the rate control determines that the load is satisfied. purge; it will begin when the Damper Motor reaches the
Purge Rate position.
.RUN DISPLAY
1. Withpowerappliedand the BoilerControllerrate
control requiring a "call for heat":
Auto 9PSI FkmSignal 2.40V
a. Recyclelimits, preignition interlocks,burner
Run 25% Ram OperSetPoint 8 PSI switch,AssuredLowFireCutoff , Runnest
switch and all microcomputer monitored circuits
must be in the correct operating states. If oil is
selected the oil pressure limit and oil tempera-
POSTPURGE ture limits must be within programmed limit val-
1. When Runperiod is discontinuedthe main fuel ues.
valve, terminal 11 for oil and terminal 12 for gas, is de-
energized and a 15 second postpurge period begins. The
Damper Motor is commanded to its low fire position. The
Oil Line Purge Valve {terminal 54) is powered if oil was
the selected fuel; oil line purge will continue through the Firelube 62' 69O 77' 90'
833-2417
Postpurge period.
2. The preignition interlocks must be closed 5 sec- Watertube 900 900 goo 900

-
onds into Postpurge or safety shutdown will occur. MZQ

FIG 15-PURGE RATE

POSTPURGEDISPLAY

Demand = Main Valve = Alarm

I b. TheDamperMotoris driven to its purge rate
position and the blower motor is powered.
Auto 12 PSI

Postpurge
OperSetPoint

PurgeTim
8 PSI

10
I PREPURGE DRIVETO PURGE RATE DISPLAY

M x)1
-\ \ I I //
-=-Demand
'/ \'
I I \
= MainVaive = Alarm

SEQUENCE 833-2417 PROGRAM

MODULE
I (I Auto 9 PSI

Prepurge 21%
OperSerPolnt 8 PSI

Drive 10 Purge Rae

The 833-2417 provides the following operating

M20(
sequence, as shown in Figure 16.
c. The lockout interlocks, proving combustionair
STANDBY- andburner motor start interlocks, mustclose
The833-2417isreadytostarttheoperating and no flame can be present after 10 seconds
sequence when the Boiler Controllers rate control deter- into prepurge or a safety shutdown will occur.
minesa"callforheat"isrequired.Theburnerswitch,
limits, Runmest switch, assured low fire cutoff, interlocks, If oil is the selected fuel, the atomizing air com-

-
and all microcomputer monitored circuits are in the cor- pressor terminal 56, is powered. If oil pressure
rect operating state. limits are exceeded safety shutdown will occur.
STANDBY DISPLAY

Demand m Main Valve = Alarm

If heavyoilistheselectedfueltheBoiler
Controller will recycle if low oil temperature lim-
its are exceeded and lockout if high oil tempera-
r >
Auto 12PSI FlameSignai 0.WV ture limits are exceeded.
Srandby GAS OperSetPoint 8 PSI
k d d. After the Damper Motor reaches the purge rate
M2X
position it is commanded to the low fire position.
833-2418 SEQUENCE DIAGRAM A
DEYAYD YIYVUVE

TERYrnALJ TANDBY PREPURGE PREPURE PREPURGE PILOTFLAUE W N F U U E POSTPURGE

RUN
DRVETO PURGE RATE DRVETO LOW FIRE IoNrnoNTruwnoN ESTAIU*NG ESTABLISHING

t
Ll-u Powm

SUWWWTOR
I I I I I I
5

7 DDU

10

11

11

ll-14.15 Q
16 A
1ClPWI A
I I
21.22.n A

YO5 A

144blS A
--,. ....- ,

THE D Y N M C SENSOR O I K K
A IoynoN
THE A M G RATE M
OR IS DllVEN RKY LOW FIRETO THE PURGE R4TE
DURNC PREPURGE. DRIVETO PURGE RITE. THE FIRING RATE
WTOR ISDRIVDI TO LOW RRE PQVTION KHI lwnw TRALS AND RELEISED
TO WWUTKm UNDER TE CQlmOc OF THE U T E CCUTROL A L W R W Y
DURNC RUN. Y 2019

FIG 16-833-2417 SEQUENCE

13 C860-34
 PREPURGE DRIVE TO LOW FIRE DISPLAY
Run
A 10 second stabilization period occurs at the begin-
ning of the Run period before the Boiler Controller releas-
es the Damper Motor to modulation. The Boiler Controller
isnowinitsRun period andwill remainthere untilthe
OprSetPoint
Auto 9 PSI 8 PSI rate control determinesthat the load is satisfied.
Preprrge 57% Drive to Low Fire
IJ * RUN DISPLAY

-m
.\

' / I I \\'
I I/,
-Demand
\. \ I If/
---Win
0
r l I t\.
Valve m Alarm

e. When the Damper Motor reaches the low fire

position the sequence is allowed to continue. Auto 9 PSI
FIameSignai 2.40V
Prior to ignition trials a 1.5 second transition
Run 25% Rate OperSerPoinr 8 PSI
occurs to conduct a Dynamic Check of the gas
pressure sensor and safety relay. The gas pres- M a
sure sensor must indicate zero gas pressure or
safety shutdown will occur.
POSTPURGE
1. When the Run sequence is discontinued , the main
IGNITION TRIALS
fuel valve, terminal 11 for oil and terminal 12 for gas, is
A. Pilot Flame Establishing Period
de-energized and a 15 second postpurge period begins.
1. With the Damper Motor at the low fire position
The Damper Motor is commanded to its low fire position.

-
a. The pilot valve and ignition transformer {ter-
The Oil Line Purge Valve {terminal 54) is powered if oil
minal 10) are energized.
was the selected fuel; oil line purge will continue through
the Postpurgeperiod.
-
~

PILOT IGNITION MSPLAY 2. The preignition interlock must be closed 5 seconds

\\ \ I I /, into postpurge or safety shutdown will occur.
;--Demand Abnn
MainValve
/ I I \\-
t \
SEQUENCE 833-2418 PROGRAM
AUIO 9 PSI Flame Signal 24OV MODULE
Pilot IGN 8 OperSetPoinl 8 PSI The 833-2418 has the following operating sequence,
\ I as shown in Figure 17.
M202
STANDBY-
b. Flame must be proven by the end of the 10 The 833-2418 is ready to start an operating sequence
second pilot flame establishing period for the when the Boiler Controller's rate control determines a
sequence to continue. If flame is not proven "call for heat" is required. The burner switch, limits, inter-
by the end of the Pilot Flame Establishing locks, assured low fire cutoff, Run/Test switch and all
Period asafety shutdown will occur. microcomputer monitored circuits must be in the correct

-
operating state.
B. Main Flame Establishing Period
a. Ten 11 0} seconds into the ignitiontrials, and with - STANDBY DISPLAY
the presenceof flame the main fuel valve, termi-
nal 11 for oil or terminal 12 for gas, is powered.
If a flame-out occurs, the Boiler Controller will
Demand = Main Valve = Alarm

f 5
respond with a safety shutdown within 4 sec- Auto 12 PSI FlameSgnal 0.OOV
onds. Standby GAS OperSetPoint 8 PSI
v /

MXC
* MAIN IGNITION DISPLAY

NORMAL START-UP-

Aub 9PSI

MainlGN 4
FlameSignal

CperSetPoint
240V

8 PSI
I PREPURGE
MX6
b. The pilot valve and ignition transformer, terminal
10, are de-energized at 20 seconds of Ignition
Trials, if gas or light oil is selected fuel, or 25
seconds if heavy oil is the selectedfuel.This
actionsignalscompletion of theMainFlame
Establishing Period.
14
The Boiler Controller is configured specifically for
CleaverBrooksboilers. To obtaintherequired air
changes the Boiler Controller will position the Damper
Motor to a selected purge rate position. This purge rate
position will provide the required volume of air to purge
thecombustionchamberandfluepassagesand is a
function of the selected rate linearization curve and the
boiler type [firetube or watertube], see figure 18. A Purge
Extension Timed Period can be added to prepurge; will
begin when the DamperMotorreachesthe purge rate
position. A 20 second Purge Extensionisautomatically
added for watertube boilerapplications.
833-2417 SEQUENCE DIAGRAM A
IERUYALJ

.1 .u

I I i

I
I/ R M VALVE iYyrmow

I I
I I I I I I
A T W I N G AIR WTOR STARTER I

I I I
AOSUREO LOY RRECUTOFF
I I

I I I I
A THE C B m l SEWOlCE S A N S U A G R u l l PROVIDE I N D K A M OF W E N THE
NOTED aRUT 6ACTIVE (WWERED) OR IF THE a R W K IS A SENSOR YFW A On TDlPERATUREMUST BE W H I N PROGRIWED VALUESFROYSTANDBY
THROUCHRUN. IFOILTEUPERLTUREISOVrYDEOFLYnVALUESTHEBOILER
C W R O L L E R WlLL HOLDIN STANDBY AND LOCUOUT(UFETY SHUTDOWN) lF A
WOl THE I N W T WST BE WlTHN RANGE
SiCNAL OtcURS WWCH IS 0U"SDE OF THE UMlT SETflNCSFROY PREPURGE
1% A U R I RELAY U N BE WWERED ANTTIME W R N G A SEOUOlCE Hou THROUW RUN
STANDBY THROW m s P u R E THE AURI REUY WLL BE m w E r s o IF A
SAFETI SHUTOOWN (LocXovr) OCCURS OR IF A STANDBY HOLD OCCURS DUE
TO AN opm RECYCLE WIT.OIL PRESSURE OUTSIDE OF UYTSFI OILIS m E
SELECTED FUEL OR IF OILTENPERATURE IS DUTSlDE OFL M l S IF OIL IS THE
A RRHG RATE WTOR posmo~ ISMCWKORED AT ALL n w s IF
YOTORtSNOTATTHECQIY.NMD~IONDU~GPREPURETHR)UM
RUN LOCKOUT (YrFETY WUTWWN) WLLCCCUR.
RRNG RATE

SELECTED FUEL DURNGA NORUAL o p E t u n m c SEWO~CE THEAURI RELAY

A OIL PRESSURE MUST BEMWH P R K i R A W E D U Y KSlTMGS F R Q I STANDBY
THROUW WN IF a L PRESSURE IS OUTSDE OF u r n m STANDBYA HOLD
muoctuRRQImSECCWDSIHT0PREWRETHR)UCHRUNANDOILISTHE
P R E W R E - D R N E T O P U R O E R ~ T E T H ~ ~ W R U N IFWEATOWZINGAIR SELECTED FUEL THE BOILERODNTROUER W L L LOCUOUTIF OIL PRESSURE
S~CCIISO~ENANDIFOILBTHESELECTEDFUEL~ESAF~SHUTDOWN UMSAREUCEEDED.
(LOCUOUr) W L L OCCUR DURING PILOT l G H m C U T H R O W RUN.

RATE wmuw RUN WEN A CALL WR HEATOCCURS AND THE B a L m

A as PRESSURE MUST BE m u UIT ~ N C PILOT
THROUW RUN IF G * S P RW R
S tmmw TRALS
EIS OUTYDE DF U M n VALUES LOCKOUT
(SAFETI YIUTDOWN) W U OCCUR. W R H G THE PREPURGE-IGNmON
CONTROUERISHQTLOCKEDOUTON5*FETYSHUTWWK TRANSISTION THE O I S PR5SURE SMSOR MUST H D I U T E 0 PRESSURE TWS IS
A THE DTNIYLC SENSOR CHECK

FIG 17433-2418 SEQUENCE

15 CB68-34
I 1 IGNITION TRIALS
A. Pilot Flame Establishing Period
1. With the Damper Motor at the low fire position

-
a. Thepilotvalveandignitiontransformer {ter-
Firetube 90 90' 90" 90' minal 10) are energized.
833-2418
WatertubeA 90" 90" 90" 90"
PILOT IGNITION DISPLAY
A M210
/,
PIUS 20 second pmtpurge ertenaion

FIG 1&PURGE RATE

\\

;---Demand
\ I I

/ I I \\.
= Main Valve Alarm

f T
1. Withpowerapplied and the BoilerControllerrate Auto 9 PSI Flame Signal 2.4CV
control requiring a "call for heat" Pilot IGN 8 CperSetPoint 8 PSI
a. Recyclelimits,preignitioninterlocks,burner \ ;
switch , RunlTestswitch,AssuredLow Fire M 202
Cutoff and all microcomputer monitored circuits
must be in the correctoperatingstate. If oil is
the selected fuel the oil pressure and oil temper- b.Flamemust be proven by the end of the 10
ature must be within selected limits. second pilot flame establishing period for the
sequence to continue. If flame is not proven
b. Damper Motor is driven to the purge rate posi- by the end of the Pilot Flame Establishing
tion and the burner motor is powered. Period safety shutdown will occur.
* PREPURGE DRIVE TO PURGE RATE DISPLAY
B. Main Flame Establishing Period
-=
.\I I I //
-Demand = Main Valve = Alarm
a.Ten {lo} seconds into the ignition trials, and
I \.
f. \ with the presence of flame the main fuel valve,
Auto 9 PSI OperSetPolnt 8 PSI terminal 11 for oil or terminal 12 for gas, is pow-
Prepurge 21 % Drive to Purge Rate
ered. If a flame-outoccurs,theBoiler
Controller will respond with a safety shutdown

-
L J

MZW within four [4] seconds.

-.\
c. The lockoutinterlocks {proving combustionair * MAIN IGNITION DISPLAY
and burner motor start interlocks} must close \ I I //
and no flame can be present after 10 seconds --Damand
/I I I \ \'
-',\\/ I II ,/\\- --Main Valve m Alarm
into prepurge or safety shutdown will occur.
f \
If oil is the selected fuel the atomizing air com- Auto 9 PSI 2.4CV
Flamesignal
pressor terminal, 56, is powered and oil pres- Main IGN 4 OperSetPoint 8 PSI
sure must be within programmed limit values or \ d
safety shutdown will occur. M2-S

If heavy oil is the selected fuel, oil temperature

must be within programmed limit values or safe- b.Thepilotvalveandignitiontransformer,termi-
ty shutdown will occur. nal 10, are de-energized at 20 seconds of igni-
tion trials, if gas or light oil is selected fuel, or
d. When the Damper Motor reaches the purge rate 25 seconds if heavy oil is the selected fuel.
position plus 20 seconds purge extension for Thisactionsignalscompletion of theMain

-
watertube boilers the Damper Motor is driven to Flame Establishing Period.
the low fire position.
Run
* PREPURGE DRIVE TO LOW FIRE DISPLAY
A 10 second stabilization period occurs at the begin-
\.
- =
' i f I \\.
I I//
-Demand Main Valve = Alarm
ning of the Run period before the Boiler Controller releas-
es the Damper Motor to modulation. The Boiler Controller

-
is now in its Run period and will remain in Run until the

-
f 3
Auto 9 PSI OperSelPoint 8 PSI rate control determines that the loadis satisfied.
Prepurge 57% Drive to Low Fire
\ J RUN DISPLAY
MZm

e. When the DamperMotor reaches low fire the

-
.\\

//I
I I/,

I \\'
-Damand
\\ \ I I I/
;--Man
I /
i
I I\.
Valva Alarm

sequence is allowedtocontinue.Priorto the

ignition trials a 1.5 second transition occurs to I fi Auto 9 PSI FlameSignai 2.4CV 1
conduct a Dynamiccheckof the gas pressure Run 25% Rate OperSetPoint 8 PSI
sensor and safety relay. The gas pressure sen-
sor must indicate zero gas pressure or a safety MZ@S

shutdown will occur.

16
POSTPURGE
1. When the Run sequence is discontinued the main
fuel valve, terminal 11 for oil or terminal 12 for gas, is de-
energized and a 15 second postpurge period begins.
The Damper Motor is commanded to the low fire posi-
tion. The Oil Line Purge Valve {terminal 54) is powered if
oilwas theselectedfuel;oillinepurgewillcontinue
through the Postpurge period.
2. The preignition interlocks must be closed 5 sec-
onds into postpurge periodor safety shutdown will occur.
INSTALLATION
When installing this product...
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazardous
condition.
2. Check the ratings given in the instructions and on
the product to make sure the product is suitable for you
application.
3. Installer must be a trained, experienced flame safe-
guard technician.
4. After installation, checkout the product as provided
in these instructions.
1. Disconnect power supply before beginning instal-
lation to prevent electrical shock and equipment
damage.Morethanonepower supply discon-
nect may be involved.
2. Wiringmustcomplywithallapplicablecodes,
ordinances and regulations.
3. WiringwhererequiredmustcomplywithNEC
Class 1 {Line Voltage}.
4. Refer to figure11 for proper systemwiring.
L I
IMPORTANT
Thisequipmentgenerates,usesandcanradiate
radio frequency energy andif not installed and used
in accordance with the instructions may cause inter-
ference to radio communications. It has been tested
and found to comply with the limits for a Class A
computing device of part 15 of FCC rules which are
designed to provide reasonable protection against
suchinterferencewhenoperated in a commercial
environment. Operation of this equipment in a resi-
dential area may cause interference; in which case,
the user at hisownexpensemayberequiredto
take whatever measures thatare required to correct
this interference.
HUMIDITY
Install theBoilerController where therelativehumidity
neverreachesthedewpoint.TheBoilerController is
designed to operate in a maximum 85% RH continuous
noncondensing,moisture,environment.Condensing
moisture may cause a safety shutdown.
17
VIBRATION
Do not install the Boiler Controller where it could be sub-
jected to vibration accelerations greater than0.5G.
WEATHER
If the Boiler Controller is installed outdoors, it must be
protected by a weather-tight [NEMA41 enclosure.
MOUNTING THE BOILER CONTROLLER
NOTE: For installation dimensions see figures1, 2, 3,
and 4 in this specification sheet.
CHASSIS MODULE MOUNTING {FIGURE19)
1. The Chassis Module c a r b e mounted vertically as
shown in figure 1 it may alsobemountedhorizontally
base down. The Chassis Module must be mounted in an
electrical enclosure.
2. Selectthelocation in theelectricalenclosure. Be
sure to allow clearances for servicing, installation and
removal of theProgramModule,flameamplifiersignal
voltage probes, and electrical field connectors.
a. Allowforanadditional 2 inches below the
Chassis Module for Program Module mounting.
b. Allow for an additional 1.5 inches minimum on
each side of the Chassis Module for electrical
field connectors.
3. Using the Chassis module as a template mark the
4 screw locations. Drill the pilot holes.
4. Insert the mounting screws, use
4 #8 screws.
5 . Mount the ChassisModule by aligning its "foot"
mounts over the screws sliding the chassisso the narrow
portion of the mounting foot slots are under the screw
heads,andtighteningthescrewssecurelywithout
deforming the plastic.
ELECTRICAL ALARM
READY
AND LED'S
CONNECTOR
. .- - - . .. .-
E2191 'TERMINAL BLOCK
AND DISPLAY
~
FIG 19-ELECTRICAL PANEL INSTALLATION
CB68-34
PROGRAM MODULE MOUNTING{FIGURE 20)
1. Align the 4 mating slots with the 4 interlocking ears
on the Chassis Module. Assure the 37 pin electrical con-
nector is aligned.
2. Mount the Program Module to the Chassis Module
bypushingthe37pinmaleandfemaleconnectors
together.
3. Once in place secure the Program Module to the
Chassis Module by tightening the spring loaded retaining
screw.

PROGRAM MODULE RESET

37 PIN MALE CONNECTOR
I BUrroN \ >
CHASSIS MODULE
37 PIN FEMALE CONNECTOR

CHASSIS

FOOTMOUNT

\'
. - - ....- -. .. FIG 21-KEYBOARD AND DISPLAY MODULE
PROGRAMMODULE
ELECTRICAL
CONNECTORS / MOUNTING C9R MOUNTING SLOT
3. Remove and replacethe 1OA fuse.
E2437
4. Reposition the fuse cap and Program Module and
reconfigure the Boiler Controller.
FIG 2O-PROGRAM MODULE MOUNTING
WIRING
1. Referto figure 11 for proper wiring.
KEYBOARDAND DISPLAY MODULE MOUNTING 2. Before beginning wiring to the electrical connectors
assure power is removed from the control panel by open-
{FIG. 19and 21 }
1. TheKeyboard andDisplayModuleshouldbe ing the main disconnect. More than one disconnect may
mounted on thedoor panel ofthe electrical enclosure. be involved.
2. Select the location on the door panel, pay attention 3. All wiring must comply with all applicable electrical
to the insertion dimension of the Keyboard and Display codes, ordinances, and regulations.
Module to allow sufficient clearance,1.4inches mini- 4. Recommended Wire Size and Type, terminal num-
mum. bers noted in brackets {}.
3. Using the Keyboard and Display Module as a tem- a. WaterTemperature 132 and33}andOil
plate mark the 4screwlocations. Drill the pilotholes. Temperature Sensor (34 and 35}.
Provide for an opening on the panel door for mounting Belden 9341, Rating 600V service 9OC, or
see fig 3. equivalent.
4. Mount the Keyboard and Display Module by secur- Belden9318,Rating 300V service 105C,or
ing the 4 #6 screws. equivalent.

INSTALLINGTHEFLAMESIGNAL b. Steam Pressure 136, 37, and 38}, Gas Pressure

{45, 46,and47},DamperPosition139,40,and
AMPLIFIER 41}, and Oil Pressure {42. 43, and 44} sensors
1. Disconnect power supply before beginning installa- Beldens9365,Rating300Vservice105C,or
tion to prevent electrical shock and equipment damage. equivalent.
2. Align the amplifier circuit board with the receptacle Beldens8770, Rating 300Vservice60C,or
on the Boiler Controller Chassis Module.Assure the equivalent.
amplifier's name plate is on the outside.
3.Pushintheamplifieruntilitscircuitboardisfully c. Line VoltageTerminals:heavy oil select {51},
inserted into the receptacle and then cam its top edge light oil select {52}, gas select {53} demand {7},
beneath the Chassis Module retaining clasp. atomizing air provingswitch{16},preignition
4. Assure the amplifier is firmly in place. interlocks {5},assuredlowfirecutoff {50}, line
voltage common {L2 and 48}, line voltage supply
REPLACING THE CHASSIS MODULE {Ll and 55}, recycle limits {6}, lockout interlocks
{8}, pilot valve/ignition transformer {lo}, oil main
FUSE valve {ll}, gas main valve/gas sensor test valve
1. Remove the Program Module. {12}, alarm {13, 14,and 15}, loaddemand 118,
2. Remove the fuse cap. 19, and 20},low oil pressure (21, 22, and 23}, oil
18
 line purge {54}, atomizing air compressor {56},
burner motor starter {4}, flame sensor shutter
{27,and earth ground {E}.
#14 Copper conductors TW60C or THW75C
or THHNSOC.
Energy Limited Terminals; Damper Motor {24,
25, and 26) and flamesensor input (30 and 31).
9 #18 Copper conductors TW60C or THW75C
or THHNSOC.
TheKeyboardandDisplayModuleshouldbe
wired with Belden 9829 cable [or equivalent] for
RS485 circuits.
5. Recommended Grounding Practices
a. Chassis Module-The ChassisModuleEarth
Ground terminal that must be grounded to the
metal control panel withas short a wire as prac-
tical. The ground wire must be capable of car-
rying a fault current equal to the rating of the
protective fuse, 15A. A #14 copper conductoris
recommended.
b. Keyboard and Display Modul-The Keyboard
and Display Module can be connected to any
convenientearthground.TheControlBus
shield should be connected to the C terminal of
the RS485 connector at the Keyboard Display
Module andat theChassisModule.Failureto
terminatetheshield may resultinimproper
Keyboard and Display Module operation.
c. Shielded Cables, Temperature sensors, Gas Oil
andSteamPressuresensors,andDamper
Position.
The shield must NOT be connected at the sen-
sor end; it should be taped to avoid unintended
contact with the sensor housing. At the Boiler
Controller end the shield MUST be groundedto
the control panel with as short a lead length as
practical.
6. Recommended Wire Routing
a. Sensor Leadwires
1. Sensorleadwiresshouldnotberoutedin
conduit with line voltage circuits.
2. Avoid routing sensor leadwires close to the
ignition transformer leadwires.
3. Sensor leadwires are low voltage and can be
routed outside of conduit if properly support-
ed and protected from damage.
b. Flame Detector Leadwires
1. Do notrun high voltage ignition transformer
wires in the same conduit with the flame
detection wiring.
2.Followdirectionsgiven in flamedetector;s
instruction sheet.
c. Keyboard and Display Module
-TheControlBus-RS485shieldedcable
should not be routed in conduit with line volt-
age circuits.
Avoid routing the ControlBus RS485 shield-
ed cable close to the ignition transformer
leadwires.
The ControlBus RS485 shielded cable is low
voltage and can be routed outside of conduit
if properlysupportedandprotectedfrom
damage.
The ControlBus requires termination with a
120R [1/4 minimum] wattresistor on the
19
module furthest from the Chassis Module.
The Keyboard and Display Module requires
placing this 120R resistor across !he A and
B terminals of the electrical connector if it is
the furthest controller from the Chassis on
the RS485 ControlBus.
7. Maximum Wire Lengths
a. Sensors.-Themaximumcablelengthfor
Pressure and Temperature sensors is 100 feet.
b. FlameDetectorLeadwires-Themaximum
flamesensorleadwirelength is limited by the
flame signal strength.
c. KeyboardandDisplay Module-Themaximum
ControlBus RS485 shielded cable length under
ideal conditions is 1000 feet.
8. Fusing
BoilerController-The total connected Boiler
Controller load plus its power consumption,
muststaybelow 2000 VA. TheSystemfuse
must NOT exceed 15A [a 15 ampere type FRN
or equivalent is recommended].
Chassis Module-The ChassisModulehasa
field replaceable 1OA fuse in series with the fuel
valves and ignition transformer.
9. Make sure the loads donot exceed the terminalrat-
ings. Refer to the labels on the Program Module, Chassis
Module,motor,Sensors,and/ortotheratingsinthe
Specification sectionof this sheet.
10. Check all wiring against figure 11 before installing
the electrical connectors and powering the Boiler
Controller.
11. Install all electrical connectors.
12. Restore powerto the panel.
RUNiTEST SWITCHOPERATION
The Runnest switch is locatedontheside of the
Program Module. The Runnest switch performs the fol-
lowing functionsin an operating sequence:
1. In Standby the Runnest switch, when placed in the
Test position, will cause a hold condition, preventing
burner start-up, and allow manual control of the damper
motor from low fire through high fire using the Keyboard
and Display Module.
2. InPrepurgeDrive To PurgeRate theRunnest
switch,whenplacedinthe Test position,willhold in
Prepurge Drive to Purge Rate and will drive the damper
motor to high fire.
3. In Prepurge,MeasuredPurgeTimethe Runnest
switch, when placed in the Test position, will hold the dis-
playedtimeandburnersequence,Prepurgeinthe
Measured Purge Time, and will drive the damper motor
to high fire. When the Runnest switch is returned to the
Run position the purge timer will resume immediately.
4. In Drive to Low Fire the Runnest switch, when
placed in the Test position, will hold the burner sequence
in Prepurge at the end of the Drive to Low Fire when the
damper motoris in the low fire position.
5. In Pilot Flame Establishing the Runnest switch,
when placed in the Test position, will hold the timer dur-
ing the first 8 seconds of Pilot Flame Establishing Period
allowing for pilot-turndown test and other burner adjust-
ments . It activates a 30 second flame-out timer that per-
mits pilot flame adjustment without nuisance safety shut-
down.
CB68-34
CHECKOUT
Do not allow fuel to accumulate in the combustion
chamber. if fuel is allowed to enter the chamber for
longer than a few seconds without igniting, an
explosivemixturecould result. It is recommended
you limit the trial for pilot to 10 seconds, and limit
the attempt to light the main burner to 2 seconds
from the time the fuel has reached the burner noz-
zle. in any case, do not exceed the normal lightoff
time specified by Cleaver Brooks; close the manual
fuel shutoff valves if the flame is not burning at the
end of the specifiedtime.
L I
1. Use utmost care while testing the system. Line
voltage is present on most terminal connections
when power is on.
2. Openthemasterswitchbeforeremovingor
installing the BoilerController.
3. Make sure all manual fuel shutoff valves are
closed before starting the Initial LightoffCheck,
and the PilotTurndown Tests.
4. Do not put the system into service until you have
satisfactorily completed all applicable tests in this
sectionandanyothersrequired byCleaver
Brooks.
I LIQUID CRYSTAL DISPLAY
KEYBOARD DISPLAY MODULE
FIG 1 7 4 O I L E R CONTROLLER
20
IMPORTANT
a.If the system fails to perform properly, note the
fault code, fault message, burnerhiler status,
and sequence time on the display. Refer to the
troubleshooting section of this sheet.
b. Repeat ALL required Checkout tests after all
adjustments have been made.ALL tests must
be satisfied with the flame detector{s} in its
FINAL position.
EQUIPMENT REQUIRED
1. Volt-Ohm meter [20,000ohm/volt minimum sensi-
t ivity]
0-300V
capability
AC
0-6000 Ohm capability
0-1OV dc capability
2. Thermometer or thermocouple - to measure tem-
perature at the flame detector.
3 Orifice plates {aperture disc} or filters as necessary
to adjust sensitivity of flame detector.
CHECKOUT SUMMARY
Preliminary Checkout - all installations
initial Lightoff Check for ProvedPilot - all installa-
tions using a pilot
Pilot Turndown Test - all installations using a pilot
Hot Refractory Saturation Test - all installation using
infrared {lead sulfide} flame detectors
Hot Refractory Hold-in Test - all installations
ignition Spark Pickup - all installations using ultravi-
olet flame detectors
Refer to figure 22 for locationof component parts and
to figure 11 for terminal locations.
,CHASSIS
MODULE
RUN/TEST
SWITCH
I
FLAME SIGNAL MEASUREMENT 4. With the burner running check the temperature at
the detector. If it exceeds the detectors maximum rated
(All installations) temperature:
(Figure 23) add a heat block to stop conducted heat traveling
up thesight-pipe.
add a shield or screen to reflect radiated heat
addcooling (refer to sighting pipe ventilation in
the detector instruction sheet)

TABLE I I FLAME SIGNAL

Minimum
Acceptable Maximum
Flame Flame Signal Steady DC Expected
Detector Amplifier [b] Voltage [a] DC Voltage

817-1 743 833-2420 2..2 Vdc 4.98 Vdc at the

Keyboard
Module

81 7-1
742[C] 833-2421 5.9 Vdc at a
\ CHASS1JE.LE FOOTMOUNT E2439 Volt-ohm meter

[a]. Thisminimum or strongersignalshouldeasilybe

FIG 23-FLAME SIGNAL MEASUREMENT
Measuretheflamesignal at theappropriatetime
defined in the following checkout tests. Read the flame
signal in DC volts at the flame amplifier test jacks (posi-
tiveandnegative)or at theKeyboardandDisplay
Module.
1. Use a voIt/ohm meter with a 0 to 1OVdc capability.
2. Set the volWohm meter to the 0 to 10 Vdc range.
3. Insert the positive (red) volt/ohmmeter probe into
the positive jack of the flame amplifier. Insert the nega-
tive (black) volt/ohm meter probe into the negative jack of
the flame amplifier.
4. Allow a few seconds for the meter reading to stabi-
lize.
5. Readtheaveragestable voltage,disregard the
peaks dueto self-checking operation.
6. The meter reading must be as specified in Table II
after all tests are completed and all adjustments made.
As an option the flame signal can be checked via the
Keyboard and Display Module.
If the signal isunstable or less than the minimum
acceptable voltage, check the flame detector installation
and circuitry.
1 . Check thesupplyvoltages at terminals ( L l ) and
(L2). Make sure the master switch is closed, connections
are correct, and the sinusoidal power supply is of the cor-
rect voltage and frequency.
2. Check the detector wiring for defects including;
incorrect connections
* wrong type of wire
-- deteriorated wire
open circuits
short circuits
leakage paths caused by moisture, soot, or accu-
mulated dirt
3. For all optical detectors, clean the detector viewing
window and inside of the sighting pipe as applicable.
obtalnedifthedetectoriscorrectlyinstalledandpositioned to
senseflameproperly. This voltagemustbeobtained before
completing checkout.
[b]. The flame signal amplifier circultry is tested ai least 10
times a minuteduringburneroperationandshutsdownthe
burner if the amplifier fails.
[c]. The lead sulfide cells are available in 4 ranges of sensi-
tivity104662A (red marking) lowest, 1046628 (yellow marking)
medium,104662C(greenmarking)high,and104662D(white
marking) highest sensitivity. If a sufficiently strong signal cannot
otherwise be obtained try a different cell of the same range. If
necessary, substitutea cell of higher sensitivity.
INITIAL LIGHTOFF CHECK
FOR PROVED PILOT
Perform this check immediately following the prelimi-
nary inspection.
1. Open the master switch.
2. Makesuremanualmainfuelshutoffvalvesare
closed. Open the manual pilot shutoffvalve (if the pilot
takeoff is downstream from the manual main fuel shutoff
valve, just barely open the manual main valve to supply
pilot gasflow).Makesurethemainfuel isshutoffjust
upstream from the burner inlet, or disconnect power from
the automatic main fuel valve.
3. Close the master switch and start the system with a
call for heat (lower the - Boiler On- setting of the steam or
hot water sensor), The burner sequence should start.
NOTE: The' Boiler Controller can be shutdown by open
ing theburnerswitch and/or loweringthe Boiler Off
setpoint.
4. Let thesequenceadvancethroughPrepurge.
When the Pilot Ign status is displayed on the Keyboard
and DisplayModule's Liquid Crystal Display (LCD) igni-
tion spark shouldoccurand the pilotshould light. If the
pilot ignites, proceed to step 7.
5. If the pilot flame is not established in 10 seconds,
safety shutdown will occur. Let the sequence complete
its cycle. Consult the burner operating manual.

21 CB68-34
 6. When the pilot ignites measure the flame signal If
the pilot flame signal is unsteady or approaching the 2.2
Vdc minimum value, adjust the pilot flame size or detec-
tor sighting to provide a maximum and steady flame sig-
nal.
7. Recycle the system to recheck lightoff and pilot
flame signal.
8. When the Main Flame Establishing Period status is
displayed on the LCD make sure the automatic main fuel
valve is open; then smoothly open the manual main fuel
shutoff valve and watch for main burner flame ignition.
When the main burner flame is established, proceed to
step 14.
NOTE: This step may require 2 people - one to open the
manual fuel valve and one to watch for ignition.
9. If the mainburner flame isnotestablishedwithin
the normal lightoff time specified by Cleaver Brooks close
the manual main fuel shutoff valve(s).
10. Let the Boiler Controller recycle to the Main
Ignitionperiod.Smoothlyopen the manual fuel shutoff
valve(s) and try lightoff again (thefirst reattempt may
have been required to purge the lines and bring sufficient
fuel to the burner)
11. If the main burner flame is not established within
the normal lightoff time specified by Cleaver Brooks close
the manual main fuel shutoff valve(s). Check all burner
adjustments.
12. If the mainburnerflame is notestablishedafter
two attempts
a. Check for improper pilot size.
b. Check for excess combustion air at low fire.
c.Checklowfire fuel flow,isthefuelflowade-
quate.
d. Check for proper gas supply pressure
e. Check for proper valve operation.
f. Check for proper pilot flame positioning.
13. When the main burner flame is established the
sequence will advance to Run. Make burner adjustments
for flame stability and input rating.
14. Shut down the system by opening the burner
switch or by lowering the Boiler Off setpoint of the steam
or hot water sensor Make sure the main flame goes out,
may delay due to gas trapped between the valve and
burner. Make sure all automatic fuel valves close.
15.Restart the systembyclosingtheburnerswitch
and/or raising the Boiler On setpoint of the system sen-
sor, see the programming specificationsheet.Observe
that the pilot is established during Pilot lgn and the main
burner flame is established during Main Ign within the
normal lightoff time.
16. Measure the flame signal, it should be above 2.2
Vdc andhave less than1 voltinstability. Continue to
check for the proper signal (Table II) through the Run
period. Check the signal at both high and low firing rate
positions and while modulating.
NOTE: The flame signal read at the amplifier test jacks
will dip once every six [6]seconds for the amplifier
selftest. This dip isnotseen at theKeyboardand
Display Module because theBoilerControllermicro
computer processes it out.
22
17.Runtheburnerthroughanothersequence,
observing the flame signal for pilot flame alone, pilot and
mainflametogether,andmainflamealone. Also
observe the time it takes to light the main flame, ignition
of main flame should be smooth.
18. Make sure all readings are in the required ranges
before proceeding.
19. Return the system to normal operation.
PILOT TURNDOWN TEST
Performthis check on allinstallations.Thepurpose
of this test is to ensure the main flame can be lit by the
smallest pilot flame that will hold-in the Boiler Controller
flamerelay. Clean the flame detectortoensureitwill
detect the smallest acceptable pilot flame.
1. Connect a manometer or pressure gauge to mea-
sure pilot gas pressure during the turndown test.
2. Open the manual pilot shutoff valve.
3. Start the system with a call for heat, raise the Boiler
On setpoint of the steamorhotwatersensorfromthe
Keyboard and Display Module, refer to the Programming
specification sheet form CB68-42. The burner sequence
should start, and prepurge should begin.
4. When the Pilot Ign trial is displayed on the LCD, set
the Runnest switchtothe Test position to stop the
sequence, during the first 8 seconds of Pilot Ign trial.
Flame signal should be monitored via the LCD.
NOTE: If the sequence does not stop, reset the system
and make sure you set the Runnest switch as soon
as Pilot Ign sequence is displayed on the LCD.
IMPORTANT
You have 8 seconds to position the Run/Test switch
in the Test position to stop the sequence after the
start of the pilot flame establishing period.
5. Turnthepilot pressure downveryslowly,reading
themanometer(or gauge) asitdrops. Stop when the
flame signal drops to 1.8 - 2.2 Vdc. Note the pressure at
the Boiler Controller flame relay dropout point. The pilot
is at its minimum position.
6. Set the Runnest switch to the Run position and let
the sequence proceed. At 10 seconds into the trial peri-
od, LCD will show 10 seconds in Field 2 of the LCD dur-
ing the Operate mode, make sure the automatic main
fuel valve opens; then smoothly open the manual fuel
shutoffvalveandwatch for mainburnerignition. If the
main burner flame is established, proceed to step 17.
NOTE: This step may require 2 people - one to open the
manual fuel valve(s) and one to watch for ignition.
7. If the mainburnerflame isnotestablishedwithin
thenormallightoff time specifiedbyCleaverBrooks, or
lightoffisrough,closethe manual fuelshutoffvalve(s).
Consult the burner operating manual.
8. If main flame did not light within the normal lightoff
time established by Cleaver Brooks, or if thls lightoff was
also rough, the pilot flame sizeis too small.
9. Increase pilot flame size by increasing its fuel flow
until a smoothmainflamelightoff is accomplished.
 10. Recycletheburner and stop sequence in pilot
flame establishing period using the Runnest switch.
11. Reposition the flame scanner sight tube or use ori-
fices until the pilot flames signal voltage hovers in region
Of 1.8 - 2.2 VdC.
12. Turn pilot gas flow up to that recommended by
Cleaver Brooks.
13. Remove manometer/gauge.
14. Run the system through another cycle to check for
normal operation.
HOT REFRACTORY SATURATION TEST
(All Infrared Detectors)
Test to make certain that radiation from hot refractory
does not .mask the flickering radiation of the flame itself.
Start the burner and monitor the flame signal during
the warm-up period. A decrease in flame signal strength
as the refractory heats up indicates hot refractory satura-
tion. If saturation is extreme the flame signal will drop
below 1.8V dc and the system will shut down as though a
flame failure has occurred.
If hot refractory saturation occurs, the condition must
be corrected.Add an orifice plate ahead of the cell to
restrict the viewing area. You can also try lengthening the
sightingpipe or decreasing the pipe size (diameter).
Continueadjustmelltsuntil hot refractory saturation is
eliminated.
HOT REFRACTORY HOLD-IN TEST
(All Infrared Detectors)
Test to make certain hot refractory will not delay the
flame detection systems response to a flame-out.This
condition may delay response to flame failure and also
can prevent a system restart as long as hot refractory is
detected.
Infrared(leadsulfide)detectorscanrespondto
infrared rays emitted by a hot refractory, even when the
refractory's visible glowhasceased. Infrared radiation
from hot refractory is steady, whereas radiation from a
flame has a flickering characteristic. The infrared detec-
tion system responds only to a flickering infrared radia-
tion; it can reject a steady signal from hot refractory. The
refractory's steady signal can be made to fluctuate if it is
reflected, bent, or blocked by smoke or fuel mist within
thecombustion chamber. Care mustbe taken when
applying an infrared system to ensure its response to
flame only.
To checkinfrared(leadsulfide)detectorsforhot
refractory hold-in, operate the burner until the refractory
reaches its maximum temperature. If the installation has
a multi-fuel burner, burn the heavier fuel, which is most
likely to reflect, bend or obscure the hot refractory steady
infrared radiation. When the maximum refractory tem-
perature is reached, close the manual fuel shutoff valve,
or open the electrical circuits of the automatic fuel valves.
Visually observe when the burner flame goes out. If this
takes more than 4 seconds, the infrared detector is sens-
ing hot refractory. Terminate the firing cycle. (Lower the
Boiler Off setting the steam or hot water sensor or set the
Burner Switch to the off position. Do not open the master
switch).
23
If the detector is sensing hot refractory, the condition
must be corrected. Add an orifice plate ahead of the cell
to restrict the viewing area of the detector or choose a
lower sensitivity cell grade. For an infrared detector, you
can also try lengthening the sighting pipe or decreasing
the pipe size (diameter). For details, refer to the detector
instructionsheetandtheburneroperatingmanual
Continue adjustments until hot refractory hold-in is elimi-
nated.
ULTRA-VIOLET SENSOR, IGNITION
SPARK RESPONSE TEST
(All Ultra-violet Detectors)
Test to make certain that the system is not responding
to ignition spark.
1. Close the pilot and main burner manual fuel shutoff
valves.
2. Start the burner and use the Runfiest switch to
stop the sequence in the Pilot Flame Establishing Period.
Ignition spark should occur, but the flame signal should
not be more than 1.OV dc.
3. If the flame signalishigher than 1.OV dc consult
the burner operating manual. Continue adjustments until
the flame signal due to ignition spark is less than 1.OV
dc.
RESPONSE TO OTHER
ULTRA-VIOLET SOURCES
Some sources of artificial light produce small amounts
of ultra-violetradiation,incandescentorfluorescent
bulbs, mercury andsodium vapor lamps, daylight etc..
Undercertainconditionsanultra-violetdetectorwill
respond to these sources as if itis sensing a flame. To
check for proper detector operation, flame failure
responsetests,SafetyShutdown Tests 4, 5 , and 6,
should be conducted under all operating conditions.
FLAME SIGNAL WITH HOT
COMBUSTION CHAMBER
(All Installations)
With all start-up tests and burner adjustments com-
pleted, operate the burner until the combustion chamber
isatthemaximumexpectedtemperature,Observe
Cleaver Brooks warm-up instructions. Recycle the burn-
er under these hot conditions and measure the flame sig-
nal. Check flame signal with the pilot alone, the main
flame alone, and both the pilot and main flame together.
Check the flame signal at both high and low firing rate
and while modulating.
Also check the flame failure response time. Lower
the BoilerOffsetting of the steam orhotwatersensor,
see the programming specification sheet form CB68-42,
and observe the time it takes for the flame signal to drop
below 1.8V dc. This must be 4 seconds maximum aRer
the flame is extinguished.
If the flame signal is too lowor unsteady, check the
temperature at the flame detector. If the temperature is
too high refer to the burner operating manual for recom-
mended actions.
CB68-34
SAFETY SHUTDOWN TESTS
(All Installations)
Perform these tests at the end of Checkout after all
other tests have been completed. If used, the external
alarmshouldturn on. TheBoilerController'slockout
switch must be manually reset to restart the system.
1. OpeningaPreignitioninterlockduringStandby,
Prepurge or Pilot Ignperiod.
a. Fault will be displayed "Pre-ign interlock" in the
Keyboard Display Modules LCD Fault code 38
will be displayed to denote thefault;
b. Safety shutdown will occur.
2. Opening a Lockout interlock during Prepurge, Pilot
Ign, Main Ign, or Run period.
a. Fault will be displayed "Lockout Interlock" in the
Keyboard and Display Modules LCD Fault code
37 will be displayed to denote thefault;
b. Safety shutdown will occur.
3. Detection of flame 40 seconds after entry to
Standby and Prepurge 10 seconds after Drive to Purge
Rate or if during MeasuredPurged Time.
a. Simulate a flame to cause the flame signal volt-
age level to be at least 2.2 V dc (actuate the
flame detector with a flame) during Standby for
40 seconds continuous and during Prepurge 10
seconds or after the burner motor starts..
b. The fault will be displayed, "Flame Detected" in
the Keyboard and Display modules LCD. Fault
code 11 will be displayedto denote thefault;
c. Safety shutdown will occur.
4. Failure to ignite pilot
a. Closethepilotandmainfuelmanual shutoff
valves
b. Depress the reset burton
c. Start the system
d. The automatic pilot valve should be energized
but thepilot cannot ignite
e. The fault will be displayed "PilotFlameFautt"
and fault code "Fault 14". 10 seconds after the
pilot valve is energized.
f. Safety shutdown will occur.
TROUBLESHOOTING
BOILER CONTROLLER SYSTEMS
FAULT DIAGNOSTICS
Troubleshooting of boiler control system failures is
made easier with the Cleaver Brooks Boiler Controllers
selfdiagnostics and first out annunciation. In addition an
isolated SPDT alarm relay {audible annunciation} the
Boiler Controller provides visual annunciation by display-
ing a3 digitfaultcodeandfaultmessage at the
Keyboard and Display Module's 2 rowby 40 character
LCD. The Boiler Controller provides 73 diagnostic mes-
sages for troubleshooting the boiler system.
Selfdiagnostics of the Boiler Controller detect and
annunciate both externaland internal systemproblems.
External faults such as interlock failures, flame failure,
false flame signals, Damper Motor faults, gas pressure
limits and sensor faults, oil pressure limits and sensor
faults, oil temperature limits and sensor faults, steam
pressure sensor faults, hot water sensor faults, and inter-
nalfaultsarereported at theKeyboardandDisplay
5. Failure to ignite main
a. Open the manual pilot shutoffvalve:leave the
manual main fuel shutoff valve(s) closed.
b. Depress the reset button
c. Start the system
d. Thepilotshouldigniteandtheflamesignal
should be at least 2.2 V dc but the main burner
cannot light
e. The flame signal should drop below 1.8 V dc
within 4 seconds after thepilot goes out.
f. The fault "Main Flame Failure" will be displayed
in the Keyboard and Display Modules LCD and
FauhCode"Fault 13" will be displayed in the
Keyboard Display Modules LCD.
g. Safety shutdown will occur.
6. Loss of flame during Run
a. Open the manual main fuel shutoff valve(s); the
manual pilot shutoff valve must also be opened.
b. Depress the reset button
c. Start the system. Start-up should be normal and
the main burner should light normally.
d. Afterthesequencestops in the normal Run
position with the burner firing, close the manual
main fuel shutoff valve(s) to extinguish the main
burner flame.
e. The flame signal should drop below 1.8 V dc
within 4 seconds after the main flame goes out.
f. The fault "Main Flame Failure" will be displayed
in the Keyboard Display Modules LCD and fault
code "Fault 13" will bedisplayed in Field 3.
g. Safety Shutdown will occur.
- 1 IMPORTANT
1. tl the Boiler Controller fails to shutdown on any of
these tests, take corrective action based on the
enclosedtroubleshootingguideandBoiler
Controller diagnostics and rerun all Checkout
tests from the beginning.
2. WhenallCheckout tests have beencompleted
reset all Boiler Controller setpointsto the desired
values.
Module LCD.
First out annunciation is also achieved with the 2 row
by 40 character LCD. The cause of the safety shutdown
is displayed with a fault message and a 3 digit fault code.
The cause of a failuretocontinuewiththeburner
sequence is displayed with a Hold message. In addition
the LCD displays a sequence status message to provide
visual indicationof the program sequence status Standby
{poweron},Prepurge,Pilot Ign, Main Ign, Run,and
Postpurge. Safety shutdown {lockout}de-energizes all
loads and requires reset of the system using the reset
button locatedon the ProgramModule.With this infor-
mation most problems can be diagnosed without exten-
sive trial and error testing.
Table VI provides a summary of all Boiler Controller
fault and hold messages, the meaning of the fault and
holdcodes,theinterpretation and recommendedtrou-
bleshooting checks.In additionDiagnosticInformation
andHistoryData files areavailable to assist in trou-
bleshooting of the Boiler Controller Boiler Controller
24
 The Boiler Controller has expanded annunciation and
diagnostic information.Oneimportant feature of the
Boiler Controller diagnostics is theability to read voltages
and pressures from the 833-2419 Keyboard and Display
Module'sLCD. TheDiagnosticInformationfiles are
accessed through the Keyboardand Display module, see
figure 22.
The Boiler Controller provides diagnostic information
to aid the service mechanic in obtaining information when
troubleshootingthe system. Thefollowing items are
available in the diagnostic information file; fuel selected,
pressure sensor voltages, and temperature sensor resis-
tance in ohms, as measured at the terminals of the Boiler
Controller.
The Diagnostic Information parameter can accessed
only in the Operatemode.
Table IV lists all possible points the diagnostic files
cancheckwithabriefdescription. Itis necessary to
become familiar with the operation of the Keyboard and
DisplayModule as wellas the DiagnosticInformation
files.
terminals. If a 1 is displayed voltage is detected at the
terminal. tf a 0 is displayed no voltage is detected at the
terminal. Contained in this index will be the abbreviation
of the terminal as it is displayed on the Keyboard and
Display Module. A complete terminal description is also
provided.
HISTORICAL INFORMATION INDEX
The Boiler Controller retains historical information for
the total hours of operation, total number of cycles, and
fault history for the last 6 lockouts. Each of the 6 lockout
files retain the cycle when the fault occurred, the hour of
operation when the fault occurred, the 3 digit fault code,
the actualfault message, the burner status when the fault
occurred{whatisontheLCD of theKeyboardand
Display Module referencing LCD Fields 2 and 4j. The
Historical Information Index can be viewed only in the
Operate Mode.
SERVICE NOTE: tf thekeyboard and Display Module
LCD is "scrambled"reset the Boiler Controller.

DIAGNOSTIC INFORMATION INDEX SERVICENOTE:ForDamperMoterFaultsorwhen

The Boiler Controller monitors terminals and can dis- replacing theDamper Motor or Boiler Controllermanu-
play the status of a terminal at the Keyboard and Display ally drive the motor from Low to Max Fire to electroni-
Module. The display will be the actual voltage or resis- cally calibrate the moter stroke.
tance for sensor and motor inputs or a 1 or 0 for other
TABLE IICACCESS DIAGNOSTICTABLE

Step Operation Press Display Comments

1. Place
cursor [>] Auto: 8.0 psi OperSetpoint 7.7 psi Assure cursor is in Field3 or 4 to
to access Run Fire LoFireRate
80% 25 YO access
Diagnostic Information.
this ForInformation example field 4 will be used
Diagnostic to display Diagnostic data.
parameter

2. Access [VI Auto: 8.0OperSetpoint

psi 7.7Use
psi [VIkey to access the Diagnostic
Diagnostic- Run Fire
Qiagnostic
80%
Info? No parameter.
parameter.

3. Select [>I Auto: 8.0 psi OperSetpoint 7.7Move

psi
cursor
to Yes No, Plus
[>I. [+]
diagnostic Run
[+I Fire 80% Diagnostic Info? Yes key will select Yes option and ENTER
parameter. [ENTER] to open the Diagnostic Information file.

4. Continue [VI Auto: 8.0 OperSetpoint

psi 7.7 The
psi
[v] key will
scroll to the next
display of- Run Fire 80% I: GasPressSensor 5V diagnostic file parameter.this
In
the case Diagnostic sensor is
signaling 5Vdc. Field 3 could be
accessed to display the actual
gas pressure alongwith the
voltage signal as a check to assure
proper gas pressuresensor operation.

5. Continuethroughremainingdiagnosticinformation displays following step 4 asrequired.

6. Returnthe
to
[CLEAR] Auto:
8.0 psi OperSetpoint 7.7 psi Another display parameter or
first level of Run Fire Diagnosticlnfo?
80% No discontinue accessing Diagnostic
Diagnostic review.
Information
data prompt.

25 CB68-34
 TABLE IV-DIAGNOSTIC INDEX
Diagnostic
Point / Description
Possible StatesIRange Comments
Display {Terminals}

Flame Signal Flame signal 0 - 4.98V DC Flame relay pull-in and dropout
strength. Flame amp + and - valuel.8Vdc.

GasPressSensor Gas pressure 1 -6Vdc Voltage must be within

sensor
signal {46 and
47) range or sensor is bad.
voltage.

OilPressSensor Oil pressure sensor

1.25 - 5.75
Vdc Voltage must be within
signal
voltage I43 and 44j range or sensor is bad.

OilTempSensor Oil temperature

1031 - 5413 ohms Resistances
must be within
sensor
resistance {34 and 35) range or sensor is bad.
signal.
~~

Steampresssensor Steam
pressure 1.25 - 5.75Vdc Voltage must be within range or
sensor
signal. {37 and 38) voltage sensor is bad.

WaterTempSensor
Water
temperature
3110 - 5413 ohms
Resistances
must be within
sensor
resistance {32 and 33) range or sensor
is bad.
signal

DampMotor
1.5
motor
rate
Firing - 5.5Voltage
Vdc
must be within
range
feedback poten- 140 41)
and or the firing
rate motorbad.
is
tiometer signal.

GAS LTO HVO GAS, gas fuel 1 or 0 These points indicate

what the fuel
inputs (531
selection terminals.
select
are to fuel

LTO, light oil 1 or0

selection
I521
fuel

HVO, heavyoil 1 or 0
fuel selection. {51I

PI1 RLIM LO1 * PI1 preignition 1 or 0 These points monitor theand

limit
interlocks. I51 strings. interlock

RLIM, recycle limits 1 or 0

I61
LOI,
lockout 1 or0
interlocks { 8)

GMV
PV OMV AAPS PV, pilot valve/ 1 or 0 These points monitor
valve
fuel
the
transformer
ignition {lo} atomizing
airand terminal status.

GMV,gas main/ 1 or 0
valvegassensor { 12j
test valve

OMV, oil main 1 or 0

valve 1111

AAPS,atomizing 1 or 0
airprovingswitch { 16j

DMD ALFC DMD, demand/ 1 or 0

burner switch 17)
ALFC,assured 1 or 0
cutoff
fire
(501
low

Revision CB2OOxxx.xx Program module and software revision information.

26
 TABLE V-HISTORY INDEX

peration Step Ress

Comments Display

1. Access
historical [>] Auto: 8.0 psi
OperSetPoint 7.7 psi Assure cursor is in Field 3 or
data [VI Run8O% Rate History
Data? No to 4 access history data. For this
example the History file will be
accessed in Field 4.

2. Select history [>] Auto: 8.0 psi OperSetPoint 7.7psi Move cursor to No. Plus [+I key
data. [+I Run80%
Rate History Data? Yes will select Yes option to open
the History Data file.

3. Select Yes [ENTER] Auto: 8.0psiOperSetPoint 7.7psi The

[ENTER]
key
will
open
Run 80% Rate H: Iota1 Hours 12345 the history data files. The first
parameter providedis the total hours
of operation, 12345 hoursfor this
example.
~~~~ ~ ~ ~~~~~~~~

4. Access
the [vl Auto: 8.0psi OperSetPoint 7.7psi The [qkey willscroll
Total Cycle Run 80% Rate H: Iota1 Cycles 23456 the history files.
value
~~~~ ~~

5. Access the [Vj Auto: 8.0psi OperSetPoint 7.7psi The [Vj key
will
scroll the history files.
H1 Fault Cycle Run 80% Rate HI: EaultCycles 23456
value.
~ _ _ _ _ _ ~ ~ ~

6. Access
the [vl Auto: 8.0 psi OperSetPoint 7.7psi The [Vj key will
scroll the history files.
H1 Fault Hours
Run 80% Rate
EaultHoursl2345
H1:
value.
~

7. Access the [Vj Auto: 8.0 psi OperSetPoint 7.7psi The [v key
will scroll the history files.
H I Fault Code Run 80% Rate H1: EauttCode 33

8. Access the Ivl Auto: 8.0 psi

OperSetPoint 7.7psi The [Vj key will
scroll the history files.
H1 Fault Message
Run 80% Rate H1 :SteamPressureSensw

9. Access
the [vl Auto: 8.0 psi
OperSetPoint 7.7psi The [Vj key will
scroll the history files.
H1 Fault Burner
Run 80% Rate H1 :BUN LF-Cutoff
status, Field 2
display.

10. Access
the [vl Auto: 8.0 psi
OperSetPoint 7.7psi The [Vj key will
scroll the history files.
H1 Fault Burner Run 80% Rate:Drive
H1 To LowFire
status, Field
4 display.

11. Return to first

[CLEAR] Auto: 8.0 psi OperSetPoint 7.7 psi Select anotherlevel of History
prompt
file to Run80% Rate
History
Data? No File or discontinue history search
exit history file. point. at this

27 CB68-34
 TABLE VI-HOLD AND FAULT MESSAGE SUMMARY

Annunciation RecommendedTroubleshooting
m Code and

Fault 1 Pilotvalve/ignitiontransformer 1 . UtilizeDiagnostic Information to determine

"Call CB Service" was
de-energizedwhen if terminal 10de-energized.
is
the terminal { 10) should have
energized.
been 2. Reset the Controller.
Boiler

3. Sequence the Boiler Controller and check

for power at terminal 10 - L2, correct any
errors.

4. Check wiring, correct any errors.

5. Reset the Boiler Controller

6. If code reappears replace Chassis Module.

Fault 2 Pilotvalve/ignitiontransformer 1. UtilizeDiagnostic Information to

"Call CB Service" was
energized when the determine if terminal 10 is energized.
terminal {lo}should have been
de-energized. errors.
2.any
correct
wiring,
Check

3. Ensure the pilot valve is not externally

powered or shorted, correct any errors.

4. Reset the Boiler Controller.

5. If code reappears replace Chassis Module.

Fault 3 valve/ignition
Pilot trans- 1.Diagnostic
Utilize Information to determine
"Call CB Service" former terminal 110) if terminalde-energized.
10 is
momentarily was
de-energizedwhen should
it 2. Reset the Boiler
Controller.
have been energized.
3. Sequence the Boiler Controller and
check for power at terminal 10 - L2,
correct any errors.

4. Check wiring, correct any errors.

5. Reset the Boiler Controller.

6. If code reappears replace Chassis Module.

Fault 4 Oil mainvalvewasde-energized 1. UtilizeDiagnosticInformation to determine

"Call CB Service" when the terminal { 1 I } should if terminal 11 is de-energized.
have been energized.
2. Reset the Boiler Controller.

3. Sequence the Boiler Controller and check for

power at terminal 11 - L2,correct any errors.

4. Check wiring, correct any errors.

5. Reset the Boiler Controller.

6. If code reappears replace Chassis Module.

Fault 5 Oil mainvalvewasenergized 1 . UtilizeDiagnostic Information to determine

"Call CB Service" when the terminal { 1 I } should if terminal 11 is energized.
have been de-enersized.

28
Annunciation Message Recornrnendedlroubieshooting
and Code System Failure Fault Checks

2. Check wiring, correctany errors.

3. Ensure the oil main valve is not externally

powered or shorted, correct any errors.

4. Reset the Boiler Controller.

5. tf code reappears replace the Chassis

Module.

Fault 6 terminal
valve
main
Oil {ll} 1. Utilize
Diagnostic
information to determine
"Call
Service"
CB momentarily was de-energized if terminal 11 is de-energized.
when it should have been
energized. 2. Reset
Controller.
Boiler the

3. Sequence the Boiler Controller and

check for powerat terminal 11 - E,
correct any errors.

4. Check wiring, correctany errors.

5. Reset the BoilerController.

6. tf code reappears replace Chassis Module.

Fault 7 Gas main

valve
de-energized
was 1. Utilize
Diagnostic
information to determine
"Call
CB
Service" when the
terminal {12} should if terminal 12 is de-energized.
have been energized.
2. Reset the Boiler Controller.

3. Sequence the Boiler Controller and

check for powerat terminal 12 - L2,
correct any errors.

4. Check wiring, correctany errors.

5. Reset the Boiler Controller.

6. If code reappears replace Chassis Module.

~

Fault 8 Gas mainvalvewasenergized 1. UtilizeDiagnostic.Information to determine

"Call CB Service" when theterminal {12} should if terminal 12 is energized.
have been de-energized.
2. Check wiring, correct any errors.

3. Ensure gas main valveis not externally

powered or shorted, correct any errors.

4. Reset the Boiler Controller.

5. If code reappears replace the Chassis

Module.

Fault 9 Gasmain valve terminal { 12) 1. UtilizeDiagnosticInformationtodetermine

"Call CB Service" momentarily was de-energized if terminal 12 is energized.
when it should have been
energized. 2. Reset
Boiler the Controller.

3. Sequence the Boiler Controller and check

for power at terminal 12 - L2,correct any errors

4. Check wiring, correct any errors.

29 CB68-34
 Annunciation Message RecommendedTroubleshooting
and CodeChecks Fault Failure System

5. Reset the Boiler Controller.

6. If code reappears replace Chassis

Module.
~ ~ ~~ ~~

Fault 10 A flame signalwas detected 1. Reset the Boiler

"Flame
Amp/Sensor"
when the shutter
mechanism Controller.
of the "Dynamic Selfcheck"
flame detector was closed, 2. Sequence the BoilerController.

3. If code reappears replace the flame

detector and reset the BoilerController.

4. Sequence the BoilerController.

5. If code reappears replace the flame

amplifier.

6. Sequence the BoilerController.

7. If code reappears replace the

Chassis
Module.

Fault 11 A false flamesignal was detected
"Flame Detected' when the shutter mechanism
of the "Dynamic Selfcheck
flame detector was open, but
no flame should have been
present.
1. Check that flameis not present in the
combustion chamber, correct any errors.
2. Reset the BoilerController.
3. If code reappears replace the flame
detector and reset the BoilerController.

4. Sequence the BoilerController.

5. If code reappears replace the flame

amplifier, reset the BoilerController.

6. Sequence the BoilerController.

7. If code reappears replace theChassis

Module.

Fault 12 With the R u d e s t switch in the 1. Check the position of the Test switch.
"Flame Out Timer Test position and conducting a
a pilot turndown test the Boiler 2. Check the flame sensor and sensor wiring.
Controller allows30 seconds to
establishaflame. If 30 seconds 3. Check the Flame Amplifier.
elapses with no flame being
estabiished the Boiler Controller 4.Purge the combustion chamber prior to
lockout. will continuing pilot adjustments.

Main
flame
Fault
13 ignite
failed
to 1. Check main
fuel supply and valve
wiring.
"Main
Flame Failure"
during period.
Main
Ign
2. Check that thepilot can light the main
flame {conductpilot turndown test}.
3. Check flame sensorsability to sense and
respond to main flame.
4. Check operationof flame signalamplifier.
5. Check pilot operation as main fuelvalve
opens.

30
 Annunciation RecommendedTroubleshooting
Code and Checks System Failure
Fault

Fault 14 Pilot flame

failed to ignite
during 1. Check pilot valve
wiring
and
operation.
Flame
"Pilot
Failure" Pilot
period.
Ign
2. Check fuel supply.

3. Check pilot pressure and repeatpilot

turndown test.

4. Check ignition transformer electrode, flame

detector, flame detector sighting, and
flame signal amplifier.

Fault 15 The gas pressuresensor 1. Utilize Diagnostic Information and check

"Gas Pressure Sensor" voltage signal is underrange, the gas pressure voltagesignal.
.75Vdc MINIMUM.
2. Reset and sequence the Boiler Controller
Check the gas pressure sensor voltage signal

3. Check wiring, correctany errors.

4. If code reappears replace the gas

pressure sensor.

5. Reset the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 16 sensor
pressure
gas The 1. Utilize Diagnostic Information and check
"Gas
Pressure
Sensor"
indicated
pressure
gas the gas pressure voltage signal
was present during the
"Dynamic Sensor Check" 2. Reset and sequence the Boiler Controller.
prior to ignition trials. The Check the gas pressure sensor voltage signal.
gas pressure sensor must
indicate zero gas pressure 3. Check wiring, correctany errors.
during the "Dynamic
Sensor Check" 4. Check operation and wiringof the
three way Gas Pressure SensorTest
Valve, correct any errors.

5. Reset the Boiler Controller.

6. If code reappears replace the Gas

Pressure Sensor.

7. If code reappears replace the Program

Module.

Fault 17 Gas pressure dropped below
"Low Gas Press/Sensor" the low gas pressure limit
setting.
1. Utilizing Diagnostic Information check gas
pressure.
2. Check fuel supply, fuel piping, pressure
regulating valve operation, gas pressure
sensor wiring, correctany errors.

3. Reset and sequence the Boiler Controller

4. If code reappears replace theGas

Pressure Sensor.

5 . Reset and sequence the Boiler Controller.

31 CB68-34
 Annunciation RecommendedTroubleshooting
Code and Checks

6. If code reappears replace the Program

Module.

Fault 18 Gas pressure exceeded the high 1. Utilizing Diagnostic Information check gas
"High Gas Press/Sensor" gas pressure limit setting. pressure.

2. Check fuel supply, fuel piping, pressure

regulating valve operation, gas pressure
sensor wiring, correct any errors.

3. Reset and sequence the Boiler Controller.

4. If code reappears replace the Gas

Pressure Sensor.

5. Reset and sequence the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 19 The gas pressure sensor
"Gas Pressure Sensor" voltage signal is overrange,
6.30Vdc MAXIMUM.
1. Utilize Diagnostic Information and check
the gas pressure voltage signal.
2. Reset and sequence the Boiler Controller.
Check the gas pressure sensor voltage signal.

3. Check wiring, correct any errors.

4. If code reappears replace the gas

pressure sensor.

5. Reset the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 20 The fuel selection input 1. Utilizing

Diagnostic
Information check the
"Fuel Selection" wasinvalid,withoutregardfuelselectioninputpoints, GAS{gas} or
to the fuelseriesprogrammedHVO {heavy oil}, or LTO {light oil}.
in the Boiler Model Number,
i.e. heavy
andlight oil 2. Check fuel
selector
switch operation and
selected
simultaneously.
wiring,
correct
errors.
any
3. Reset and sequence the Boiler Controller.

4. If code reappears replace the Program

Module.
Fault 21 The fuel selectioninputwas 1. UtilizingDiagnosticInformation check the
"Fuel Selection" invalidforthefuelseries fuel selectioninputpoints; GAS {gas} , or
programmed in the Boiler Model HVO {heavy oil}, or LTO {light oil}.
Number.
2. Check fuel selector switch operation and
wiring, correct any errors.
3. Reset and sequence the Boiler Controller.
4. If code reappears replace the Program
Module.

Fault 22 The flame interlock circuit failure. 1. Reset the boiler controller.
"Call CB Service"
2. Check the flame signal strength, must
be 2.2V dc minimum.

32
 Annunciation RecornrnendedTroubleshooting
stem Code and

3. If flame signal problemcheck flame

detector circuitryand operation.

4. Reset the boilercontroller.

5. If the problem persists replace the

program module.

Fault 23 interlock
Flame
circuit fault. boiler
1.the
Reset
"Call CB
controller.
Service"
2. Check the flame signal strength,
must
be 2.2V dc minimum.

3. If flame signal problem check flame

detector circuitryand operation.

4. Reset the boiler controller.

5. If the problem persists replace the

program module.

Fault 24 Atomizing air provingswitch 1. UtilizingDiagnosticInformationcheckthe

"Atomizing Air Off" inputwas open when it shouldAtomizing Air ProvingSwitchinput.
have been closed, terminal 16.
2. Check wiringand atomizing air switch
operation, correctany errors.

3. Reset and sequence the Boiler

Controller.

4. If code reappears replace the Chassis

Module.

Fault 25 The steam pressure sensor 1. Utilizing Diagnostic Informationcheck the

"Steam Presssensor" voltage signal is underrange,
O.9Vdc MINIMUM.
steam pressure voltage signal
2. Reset and sequence the Boiler
Controller
and check steam pressure voltagesignal.

3. Check wiring, correctany errors.

4. If code reappears replace steam

pressure sensor.

5. Reset and sequence the Boiler Controller

and check steam pressuresignal.

6. If code reappears replace Program Module.

Fault 26 The steam pressure sensor 1. Utilizing Diagnostic Informationcheck the

"Steam Press Sensor" voltage signalis overrange,
6.05Vdc MAXIMUM.
steam pressure voltage signal
2. Reset and sequence the BoilerController
and check the steam pressure voltagesignal.
3. Check wiring, correct any errors.
4. If code reappears replace steam
pressure sensor.
5 . Reset and sequence theBoiler Controller
and check steam pressure sensor signal.

33 CB68-34
Annunciation Message
and Code System Failure
Fault 27 The water temperature sensor
"Water Temp Sensor" resistace signal is underrange,
31 83R MINIMUM, 300'F sensor
3232R MINIMUM 500'F sensor
Fault 28 Thewatertemperaturesensor
"Water TempSensor"
resistance
signal is overrange,
water
4595R MAXIMUM, 300'F sensor
5521R MAXIMUM, 500'F sensor
Fault 29 The oil pressure sensor
"Oil Pressure Sensor" voltage signal is underrange,
1.OVdc MINIMUM.
Fault 30 Oil pressure dropped below
"Low Oil Press/Sensor" the low oil pressure limit
setting.
34
RecommendedTroubleshooting
Fault Checks
6. If code reappears replace Program Module.
1. Utilizing Diagnostic Informationcheck
the water temperature resistance signal.
2. Resetand sequence the BoilerController,
check the water temperature resistance signal.
3. Check wiring, correct any errors.
4. if code reappears replacewater
temperature sensor.
5. Reset and sequence theBoiler Controller
and check the water temperature sensor signal.
6. I f code reappears replace the
Program
Module.
1. UtilizingDiagnosticInformation check
temperature
resistance
signal.
2. Reset and sequence the Boiler Controller,
check water temperature sensor resistance
signal.
3. Check wiring, correctany errors.
4. If code reappears replacewater
temperature sensor.
5. Reset and sequence theBoiler Controller
and check the water temperature sensor signal.
6. If code reappears replace theProgram
Module.
1. Utilizing Diagnostic Information check the
oil pressure sensor voltage signal.
2. Reset and sequence theBoiler Controller,
check the oil pressure sensor voltage signal.
3. Check wiring, correct any errors.
4. If code reappears replace oil pressure sensor.
5. Reset and sequence the Boiler Controller
and check theoil pressure sensor signal.
6. If code reappears replace the Program
Module.
1. Utilizing Diagnostic Information check the
oil pressure.
2. Check the fuel supply, piping, supply
pump, correct any errors.
3. Reset and sequence the Boiler Controller.
4. If code reappearsreplace oil pressure
sensor.
Annunciation Message RecommendedTroubleshooting
and Code System Failure Fault Checks

5. Reset and sequence the BoilerController.

6. tf code reappears replace the Program

Module.

Fault 31 Oil pressure exceeded the high 1. Utilizing Diagnostic Information check the
"High Oil Press/Sensor" oil pressurelimit setting. oil pressure.

2. Check the fuelsupply, piping, supply pump,

correct any errors.

3. Reset and sequence the Boiler Controller.

4. If code reappears replace oil pressure

sensor.

5. Reset and sequence the BoilerController.

6. If code reappears replace the Program

Module.

Fault 32 The oil pressure sensor voltage
"Oil Pressure Sensor" signal is overrange, 6.05Vdc
MAXIMUM.
1. Utilizing Diagnostic Information check the
oil pressure voltagesignal.
2. Reset and sequence the Boiler Controller,
check oil pressure sensor voltagesignal.

3. Check sensor wiring, correct any errors.

4. If code reappears replace oil pressure

sensor.

5. Reset and Sequence the Boiler Controller,

check oil pressure sensor signal.

6. If code reappears replace Program Module.

Fault 33 The
oil
temperature sensor 1. Utilizing
Diagnostic
Information
check
"Oil Temp Sensor" resistancesignal is underrange, oiltemperaturesensorresistance si,gnat.
3183R MINIMUM.
2. Reset and sequence the Boiler Controller.

3. Check wiring, correct any errors.

4. If code reappears replace oil temperature

sensor.

5. Reset and sequence the BoilerController.

6. ll code reappears replace ProgramModule.

Fault 34 Oil temperature dropped 1. Utilizing Diagnostic information determine

"Low OilTemp/Sensor" below thelow oil temperature
limit setting.
fuel oil temperature.
2. Check the fuelsupply, fuel oil temperature
controller, fueloil heater, oil temperature sensor
wiring, correctany errors.

3. Reset and sequence the BoilerController.

4. If code reappears replace the oil

temperature sensor.

35 CB68-34
 Annunciation Recommendediroubleshooting
Code and

5. Reset and sequence theBoiler Controller.

6. If code reappears replace the

Program
Module.

Fault 35 Oil temperature exceeded 1. Utilizing DiagnosticInformation check

"Hiqh OilTemp/Sensor"
the highoil temperature
limit setting.
fuel oil temperature.
2. Check the fuel supply, fuel oil temperature
controller, fuel oil heater, oil temperature sensor
wiring, correct any errors.

3. Reset and sequence theBoiler Controller.

4. If code reappears replace theoil

temperature sensor.

5. Reset and sequence the Boiler Controller.

6. If code reappears replace the Program

Module.

Fautt 36 The oil temperaturesensor 1. Utilizing Diagnostic Informationcheck oil

"Oil Temperature Sensor"
resistance signal
wasoverrange,
temperature
sensor resistance signal.
4595R MAXIMUM.
2, Reset and sequence theBoiler Controller,
check oil temperature resistancesignal.

3. Check wiring, correct any errors.

4. If code reappearsreplace oil

temperature sensor.

5. Reset and sequence the Boiler Controller,

check oil temperature signal.

6. If code reappears replace theProgram

Module.

Fault 37 Thelockoutinterlockwas open 1. UtilizingDiagnosticInformation determine

"Lockout Interlock" lockout interlock status.

2. Reset and sequence the Boiler Controller,

check the lockout interlock status.

3. Check lockout interlocksand wiring,

correct any errors.

4. Check combustion air flow etc.

5. Reset and sequence the Boiler

Controller.

6. If code reappears replace Chassis Module.

Fault 38 The pre-ignition interlock was 1. Utilizing Diagnostic Information

determine
"Pre-ign. Interlock" open pre-ignition interlock status.

2. Reset and sequence the Boiler Controller,

check the preignition interlockstatus.

36
 Annunciation RecommendedTroubleshooting
tem Code and Checks

3. Check pre-ignition interlocksand wiring,

correct any errors.

4. Check fuel valve operation.

5 . Reset and sequence the Boiler Controller.

6. If code reappears replace theChassis

Module.

Fault 39 Internal
system fault, 1. Reset and sequence
the
Boiler
Controller.
"Call CB Service"
2. Assure Program Module and Chassis
Module connector is seated properly.

3. If code reappears replace the Chassis

Module.

Fault 40 Internal
system
fault 1. Reset and
Controller.
Boiler
sequence
the
"Call CB Service"
2. Assure Program Module and Chassis
Module connector is seated properly.

3. If code reappears replace the Chassis

Module.

Fault 41 Internal system fault 1 Reset and sequence the Boiler Controller.
"Call CB Service"
2. Check electrical connector wiring,
correct any errors.

3. Assure Program Module and Chassis

Module connectoris seated properly.

4. If code reappears replace the Program

Module.

Internal
system
42Fault fault 1 Reset and
Controller.
Boiler
sequence
the
"Call CB Service"
2. Check electrical connector wiring,
correct any errors.

3. Assure Program Moduleand Chassis

Module connectoris seated properly.

4. If code reappears replace the Program

Module.

Fault 43 Internal
system fault 1 Reset andBoiler
sequence
the Controller.
"Call CB Service"
2. Check electrical connector wiring,
correct any errors.

3. Assure Program Moduleand Chassis

Module connectoris seated properly.

4. If code reappears replace the Program

Module.

37 CB68-34
Annunciation Message RecommendedTroubleshooting
and Code System Failure Fault Checks

Fault 44 Internal
system
fault 1 Reset
and sequence the
Boiler
Controller.
"Call CB Service"
2. Check electrical connector wiring,
correct any errors.

3. Assure Program Module and Chassis

Module connector isseated properly.

4. If code reappears replace the Program

Module.

Fault 45 Internal system fault 1 Reset and sequence the Boiler Controller.
"Call CB Service"
2. Check electrical connector wiring,
correct any errors.

3. Assure Program Module and Chassis

Module connector is seated properly.

4. If code reappears replace the Program

Module.

Fault 46 Internal fault

system 1 Reset
sequence
and theController.
Boiler
"Call CB Service"
2. Check electrical connector wiring,
correct any errors.

3. Assure Program Module and Chassis

Module connector is seated properly.

4. If code reappears replacethe Program

Module.

Fault 47 Internal system fault 1 Reset and sequence the Boiler Controller.
"Call CB Service"
2. Check electrical connector wiring,
correct any errors.

3. Assure Program Module and Chassis

Module connector isseated properly.

4. If code reappears replace the Program

Module.

Fault 48 Internal system fault 1 Reset and sequence the Boiler Controller.
"Call CBService"
2. Check electrical connector wiring,
correct any errors.
3. Assure Program Module and Chassis
Module connector isseated properly.
4. If code reappear replace theProgram
Module.

Fault 49 Optoisolator
coupled 1. Reset the Boiler
Controller.
"Call CB Service" circuit monitored indicate
improper circuit operation. 2. Check
electrical
connector
wiring,
ensure there are no externalshorts or
that no Boiler Controller loads are
externally powered, correct any errors.
Annunciation Message RecommendedTroubleshooting
and Code System Failure Fault Checks

3. Assure Program Module and Chassis

Module connector is seated properly.

4. Sequence the Boiler Controller.

5. If code reappears replace Chassis Module.

6. Reset and sequence the Boiler Controller.

7. If code reappears replace the Program

Module.

Fault 50 AC
The line frequency is 1. sequence
Reset
and
Boiler
the Controller.
"AC
Line
Frequency"
outside of rated
specification.
2. Check that supply frequency meets Boiler
Controller frequency specification.

3. Check main and auxiliary powersupply

line frequency, correct any errors.

Fault 51 Controller
Boiler
The has 1. controller
Check
boiler
power supply.
"Excess AC
Line
Noise"
has
identified
AC line
variationswhichmay result2. Checkboilercontrollerpower supply
in improper
Boiler
Controller wiring.
operation.
3. Check backup powersupply as
appropriate.

4. Check chassis and program module

connections.

5. Reset the boiler controller.

6. If problem persits replace chassis module.

Fault 52 The damper motorwas not 1. Utilizing Diagnostic Information check

"Damper Fault" to the commanded position motor feedback signal
in 60 seconds.
2. Check damper motorwiring, correct any
errors

3. Reset the Boiler Controller.

4. Open the Burner Switchto place the

Boiler Controllerin the Standby mode.

5. Place the Runmest switch in the Test

position.

6. Using the [e]or [>] keys on the

Keyboard and Display Module, position the
cursor under the Fire Rate parameter.

7. Using the [+I and [-I keys on the

Keyboard and Display Module manuallydrive
the damper motor through its complete
stroke.

39 CB68-34
 Annunciation RecommendedTroubleshooting
Code and Checks Fault
System Failure

8. If damper motor will not drive through its

complete stroke in 60 seconds check for
voltage at terminals 24, 25 and 26.
If correct replace thedamper motor.
If incorrect voltage replace the Chassis Module.
9. Reset and automatically sequence the Boiler
Controller.

10. If code reappears replace the Program

Module

completed
Damper
motor53 Fault 1. Reset the
Controller.
Boiler
prepurge
Fault"
"Damper too quickly.
2. Automatically sequence the Boiler
Controller.

3. If fault reoccurs replace the Damper Motor.

4. Reset and sequence the Boiler Controller.

5. If fault reoccurs replace the Program Module.

Fault 54 The damper motor is calibrated 1. Utilizing Diagnostic Information check

"D.amper Motor" by driving the motor to Damper Motor feedback voltage.
the end of its stroke and a
voltagereadingismade. An 2. Checkfeedbackcircuitwiring,connections
excessiveamount of electricalandrouting,correctanyerrors.
noise in the feedback circuit
prevented this check from
being made.

Fault 55 Thedamper motorfeedback 1. UtilizingDiagnosticInformation check

"Damper Motor" voltagewas too
highduringDamper Motorfeedbackvoltage.
closed dynamic motor
calibration,
range . 2. Check
feedback
circuit
connections
1.5 - 5.5Vdc.Themotoris
and
routing,
correct
any
errors.
driven 100% closed and a voltage
checkismadetocalibratethe 3. Resetandsequence the BoilerController
closedpoint in the Boiler
and
check Damper Motor
feedback voltage.
Controllers microcomputer.
During this checkthevoltage 4. If code reappearsreplace the damper
feedback signal
was too high.
motor.

5. Reset and sequence the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 56 The damper motor feedback 1. Utilizing Diagnostic Information check

"Damper Motor" voltage was too low during Damper Motor feedback voltage.
closed dynamic motor
calibration,
range . 2. Check
feedback
circuit
connections
1.5 - 5.5Vdc. Themotor is
and
routing,
correct
any
errors.
driven 100/o closed and a voltage
checkismadetocalibrate the 3. Resetand sequence the BoilerController
closedpoint
in
the
Boiler
andcheck Damper Motorfeedback voltage.
Controllers microcomputer.
During this check the voltage 4. If code reappearsreplacethedampermotor.
feedback signal wastoo low.

40
 Annunciation RecommendedTroubleshooting
m Code and

5. Reset and sequence the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 57 The damper motor feedback 1.Utilizing Diagnostic Information check

"Damper Motor" voltage wastoo high during
open dynamic motor calibration,
range .1.5 - 5.5Vdc. The
motor is driven 100% open
and a voltage checkis made
to calibrate the open pointin
the Boiler Controllers
microcomputer. During this
check the voltage feedback
signal was too high.
Damper Motor feedbackvoltage.
2. Check feedback circuit connections
and routing, correct any errors.
3. Reset and sequence the Boiler Controller
and check DamperMotor feedback voltages.
4. If code reappears replace the dampermotor.
5. Reset and sequence the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 58 The damper motor feedback 1. Utilizing Diagnostic Informationcheck

"Damper Motor" voltage wastoo low during
open dynamic motor
calibration, range 1.5 - 5.5Vdc.
The motor is driven 100%
open and a voltage check is
made to calibrate the open
p i n t in the Boiler Controllers
microcomputer. During this
check thevoltage feedback
signal was too low.
Damper Motor feedback voltage.
2. Check feedback circuit connections
and routing, correctany errors.
3. Reset and sequence the Boiler Controller
and check damper motor feedbackvoltage.
4. If code reappears replace the dampermotor.
5. Reset and sequence the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 59 Thefeedback voltage fromthe 1. UtilizingDiagnosticInformation check

"Damper Motor" damper motorwas too high, out dampermotorfeedbackvoltage.
of range, 1.5 - 5.5Vdc.
2. Check feedback circuit connections
and routing, correct any errors. Check for
an open ground at the Boiler Controller
terminal 41 or damper mctor terminal.
3. Reset and sequence the Boiler Controller
and check damper motor feedback voltage.
4. If code reappears replace thedamper motor

5. Reset and sequence the Boiler Controller.

6. If code reappears replace the Program
Module.

Fault 60 Thefeedbackvoltagefromthe1.UtilizingDiagnosticInformationcheck
"Damper Motor" dampermotorwas too low,out dampermotorfeedbackvoltage.
of range, 1.5 - 5.5Vdc.
2. Check feedback circuit connections
and routing, correct any errors. Check for
open supply feedback wire at the Boiler
Controller terminal39 and 40 or damper
motor.

41 CB68-34
Annunciation Message RecommendedTroubleshooting
and Code System Failure Fault Checks

3. Reset and sequencethe Boiler Controller

and check damper motor feedback voltage.

4. If code reappears replace the damper motor.

5. Reset and sequencethe Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 61 The damper motor cannot 1. Utilizing Diagnostic Information check

"Damper Motor" travel over the entire 90' damper motor feedbackvoltage
stroke of the motor.
The
and
position.
damper motor is ableto travel
over e75' of stroke. 2. Check
damper
motor
wiring,
correct
any
errors

3. Reset the Boiler Controller.

4. Open the Burner Switch to place the

Boiler Controller in theStandby mode.

5. Place the Runnest switch in the Test

position.

6. Using the [<] and [ 5 ]keys on the

Keyboard and Display Module place the
cursor beneath the Fire Rate parameter.

7. Using the [+I

and [-I keys onthe
Keyboard and Display Module manually drive
the damper motor through its complete
stroke.

8. If damper motor will not drive through

its complete stroke check for voltage at
terminals 24, 25, and 26 when manually
driving the motor open and closed and any
physical obstruction or binding of the
motor. If voltage is correct replace the
damper motor. If voltage is incorrect
check damper motor power wiring and
24Vac supply transformer, correct any errors.

9. Reset and sequencethe Boiler Controller.

10. If code reappears replace the Chassis

Module.

11. Reset and sequence the Boiler Controller.

12. If code reappears replace the Program

Module.

Fault 62 The damper motor moved 1. Utilizing Diagnostic Information check

"Damper not at Lowfire" away from the Low Fire the damper motor position indication.
position during Main Flame
Establishing
Period. 2. Reset
and
sequence the Boiler
Controller,
check to assure the damper motor can
reach and hold low fire position.

3. Check feedback wiring and routing,

correct any errors.

4L
 ~~ ~

Annunciation Message RecommendedTroubleshooting

and Code System Failure Fault Checks

4. If code reappears replace dampermotor.

5. Reset and sequence theBoiler Controller.

6. If code reappears replace theProgram

Module.
~ _____~

Fault 63 Internal fault. 1 Reset and sequence the BoilerController.

"Call CB Service"
2. Check electrical connector wiring,
correct any errors.

3. Assure Program Moduleand Chassis

Module connectoris seated properly.

4. tf code reappears replace the Program

Module.

Fault 64 The "anti-swap" circuit

was 1. Reset
boiler
controller.
"Call CB Service" engaged indicating the
ProgramModule or Chassis 2. Checkanti-swapbatteryconnection.
Module had been removed
from
the
control
panel. 3. Check
mating of chassis and program
module connector.

4. Reset boiler controller asrequired.

5. If problem reoccurs replace the program

module.

6. Reset the boiler controller.

7. If problem reoccurs replace the chassis

module.
~ ~~

Fault 65 The
battery voltage
is 1. Replace
battery.
"Replace Battery" low and the battery should
be replaced. 2. Reset
and sequence
the Boiler Controller.

Note: If power is removed with low battery voltage the Boiler Controller may require reconfiguration or programming.
~~

HOLD CONDITIONS

Fault 66 Two fuel inputs arepresent, 1. Utilizing Diagnostic Information determine

"Hold Fuel Selection" the Boiler Controller will hold the statusof the fuel selectioninputs.
until one fuel input is present.
2. Check fuel input wiring and selector switch
operation, correctany errors.

3. Sequence the Boiler Controller.

4. If code reappears replace Program Module.

67Fault The recycle limits opened 1. Utilizing

Diagnostic
Information
determine
s" Recycle "Hold:

2. Sequence the Boiler Controller, check

the recycle limits status.

3. Check recycle limits and wiring,

correct any errors.

43 CB68-34
 ~~~ ~

Annunciation Message RecommendedTroubleshooting

em Code and

4. Check low cutoff etc.

5. Sequence the Boiler Controller.

6. If code reappears replace Chassis Module.

Fault 68 Oil pressure exceeded 1. Utilizing Diagnostic Information check the

"Hold Oil Pressure"
programmed pressure
limit settings in Standby.
The Boiler Controller will
hold/stop the sequence
until oil pressure returns
to a value withinprogrammed
limit settings.
oil pressure.
2. Check the fuel supply, piping, supply pump,
correct any errors.
3. Sequence the Boiler Controller.
4. If code reappears replace oil pressur-!
sensor.

5.Sequence the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 69 Oil temperature exceeded 1. Utilizing Diagnostic Information check

"Hold Oil Temperature programmed temperature fuel oil temperature
limit settings in Standby.
TheBoilerController
will 2. Check the fuel supply, fuel oil
hold/stop
the
sequence
temperature
controler, fuel oil heater,
until the oil temperature oil temperature
sensor
wiring,
correct
any
value
within
returns
errors.
a to
programmed limit settings
3. Sequence the Boiler Controller.

4. If code reappears replace the oil

temperature sensor.

5. Sequence the Boiler Controller.

6. If code reappears replace the Program

Module.

Fault 70 The lockout interlock 1. Utilizing Diagnostic Information determine

"Hold: Lockout Interlock" opened. lockout interlock status.

2. Sequence the Boiler Controller, check

the lockout interlock status.

3. Check lockout interlocks and wiring,

correct any errors.

4. Check combustion air flow etc.

5. Sequence the Boiler Controller.

6. If code reappears replace Chassis

Module.
~~

Fault 71 No fuel selection input 1. Utilizing Diagnostic Information determine

"Hold Open Oil Drawer" IS present. The Boiler the status of the fuel selection inputs.
Controller will hold until
a single fuel selection input 2. Check fuel input wiring and selector
is present. switch operation, correct any errors.
Annunciation Message
and Code System Failure
Fautt 72 The oil pressure sensor
"Oil Pressure Sensor" voltage signal is underrange,
1.OVdc MINIMUM, oil is not
the selected fuel.
Fautt 73 The oil pressure sensor
"Oil Pressure Sensor" voltage signal is overrange,
6.05Vdc MAXIMUM, oil is not
the selected fuel.
DIVISION OF AQUA-CHEM. I N C
Recommendedlroubleshooting
Fault Checks
3. Sequence the Boiler Controller.
4. if code reappears replace Program Module.
1. Utilizing Diagnostic Information check the
oil pressure sensorvoltage signal.
2. Reset
and
sequence the Boiler Controller,
check the oil pressure sensor voltage
signal.
3. Check wiring, correct any errors.
4. if code reappears replace oil
pressure sensor.
5. Reset and sequencethe Boiler Controller
and check the oil pressure sensorsignal.
6. if code reappears replace the Program
Module.
1. Utilizing Diagnostic Information check the
oil pressure sensorvoltage signal.
2. Reset
and
sequence the Boiler Controller,
check oil pressure sensor voltagesignal.
3. Check sensorwiring, correct any errors.
4. if code reappears replace oil pressure
sensor.
5. Reset and Sequencethe Boiler
Controller, check oil pressure sensor
signal.
6. If code reappears replace Program
Module.
Form No. 63-216811-89
 DIVISION O F AQUA-CHEM, INC.

PROGRAMMING
THE BOILER CONTROLLER BOILER ROOM CONTROL REQUIRES CONFIGURATION OF A NUMBER OF PARAM
ETERS FOR PROPER SYSTEM OPERATION. THE KEYBOARD AND DISPLAY MODULE PROVIDES THE USER
INTERFACE FOR PROGRAMMING THE BOILER ROOM CONTROL. THE KEYBOARD AND DISPLAYMODULE,
PART 833-2419, HAS BEEN DESIGNED IN SUCH AWAY TO MAKE INTERFACING WITH THE SYSTEM EASY. THE
KEYBOARD AND DISPLAY MODULE CONSISTS OF 11 KEYS USED TO ENTER AND REVIEW DATA AND A
LIQUID CRYSTAL DISPLAY {LCD}USED TO DISPLAY DATA AND BURNEWBOILER SYSTEMSTATUS.

BOILER CONTROLLER
PROGRAMMING BASICS
Run 3
0%Rate PperSetPoint 185 PSI
833-241 9 KEYBOARD FUNCTIONS CURSOR
The keyboard contains 11 key pads each having sep- MOVE CURSOR TO PARAMmR VALUE,W KFY
arate function.
Auto190 PSI
1. Cursor Keys { A/V and &}
The cursor is a one segment wide flashing horizontal
line in the Liquid Crystal Display [LCD]. The cursor keys
provide the same function in the Operate and Program MOVE CURSOR TO PARAMmR VALUE,-
modes. f \
Auto 190 PSI FiameSignaJ 2.5V
a. A /v key scrolls through the available parame-
ters noted in tables 2 and 3. The /v key can Run 3
0% Rate
i
be pressed to list the parameters one at a time
or held down to scroll through the parameters
at a rate of once per second,see fig 1. FIGURE 2--f<]l[>] KEY
b. The cb key moves the cursor around the LCD
field. In the program mode the cb key moves b. Switch to operate mode from program mode.
the cursor to the adjusted value, eg 100 psi, or 1. The ENTER key should be pressed to assure
to the parameter description, eg OperSetpoint, the displayed parameter value is stored in the
see figure2. boiler controllers micro-computer prior to
pressing the MODE key. The boiler controller
I 5
than can be switched to the operate mode.
Auto 190 PSI ElameSignal 2.5V
IN OPERATE MODE
Run 30% Rate OperSetPoint 185 PSI
i I A m 19oPSI FlameSignal 2.5V

M TO SELECT NUCT PARAMEER Standby Gas QperSetPoint 185 PSI

I \
Auto 190 PSI flame Amplifier 833-2421 PLACE BOILER CONTROLLERIN PROGRAMMODE NODE] KEY

L
Run 30% Rate

FIGURE 1-i
OperSefPoinf

A ] KEY
185 PSI
#
Mllll
BLC
Program System is configured

[VIto set parameters MODE]to OPERATE 1

CHANGE MODE FROM PROGRAM TO OPERATE
IN PROGRAM MODE
3. Mode Key
The Mode key is used to toggle the Boiler Controller
QperSetPoint
ProgramBLC 20OoF I
between the Operate and Program Modes,see figure 3.
a. Switching to program mode from operatemode.
1. Programmodecanbeentered ONLY when PLACE BOILER CONTROLLERIN OPERATE MODE WODEI KEY
the system is in Standby or if the boiler con- AU(o 19OPSI FlameSlpnai 2.5V
\

troller is locked out. The Boiler Controller will

not allow entry to the Program mode while the Standby Gas QparSe!Po~nt 185 PSI
d
burner is firing. Y111'

FIGURE 3--[MODE] KEY

Form NumberCB68-42
 4. AUTOIMANUAL Key
The AUTO/MANUAL key places the Boiler Controller IN OPERATEMODE
in an automatic {AUTO} sequence operation or a manual 190 Auto PSI Flamesignal 2.5V
{MANUAL} sequence operation. The AUTOIMANUAL
key function has control of the Boiler Controller only I I Standby
Gas QperSetPoint 185 PSI II
when in the Operate Mode. When in the Program Mode
the AUTO/MANUAL key has no function. PLACE BOILER CONTROLLER IN PROGRAMMODE, (MODE] KEY
AUTO{automatic}controlallowstheBoiler r- BLC Program System
configured
is
\
Controller to sequence the burner based on safety
sequencelogicandratecontrol of theBoiler [VIto set parameters [MODE] to OPERATE
b- /
Controller. The system starts and stops the burner
automatically, see figure 4. ACCESS PARAMETERS, [VIKEY
MANUAL {manual} control allows manual adjust- BLCQperSetPolnt
Program 200 PSI
mentof the firing rate motor position. The cursor
must be placed beneath % Rate to allow manual II [>I to set value Ivl for next II
adjustment of firing rate using the [+I or [-I keys.
Firingratecontrolisremoved from theBoiler ACCESS PARAMETER VALUE, [>] KEY
Controller's rate control and given to manual firing BLC Program
OperSetPoint 2CQPSI
ratecontrol,see figure 4. The manual firingrate
canbesetintheStandbymode.TheBoiler
Controllerwilldrive the DamperMotortothefir-
[+] to set value [VIfor next
IJ
ing rate position the Damper Motor was driven to ALTER PARAMETER VALUE (INCREASE BY 3 PSI), [+I KEY
3 TIMES
in the Manual Mode duringthepreviousManual f I
Firing sequence. BLCOperSetPoint
Program 2a PSI

[+I to s e t value [ENTER] when dOM

I N " A U T OAND OPERATE MODE \

t \ ENTER AND STORE ADJUSTED PARAMETER VALUE IN

Auto
190 PSI Flamesignal 2.54 MEMORY, [ENTER] KEY

Run 30% Rate QperSetPoint 185PSI BLCQperSetPoint

Program 203 PSI
\ A
PLACE BOILER CONTROLLER IN MANUAL CONTROL, I I [>I to s e t vdue [VIdone
when II
[AUTOlMANUAL] KEY
M1115
f I
Man:
190 PSI FlameSignal 2.5V
FIGURE 5+ENTER] KEY
Run 30% Rate QperSetPoint 185 PSI
i
MOVE CURSOR TO %RATE TO ADJUSTFIRING RATE, 1.1 in the Program mode the Keyboard and Display Module
f \ will prompt the user to ENTER the data. In the Operate
Man:
190 PSI Flamesignal 2.5V
mode no prompting is provided
Run ~ 0 Rate
% OperSetPoint 185 PSI
L 6. CLEAR Key
The CLEAR key is used to clear a fault message from
CHANGE FROM MANUAL CONTROL TO the display {the BoilerControllermuststill be manually
AUTOMATIC CONTROL reset for automatic operation}, move the parameter dis-
IN "MAW AND OPERATE MODE play to the home position of the parameter list {front end
f \ of the scroll see figure 12, return the display to the previ-
Man:
Flamesignal
190 PSI 2.5V
ously displayed parameter, i.e. to exit the history or diag-
Run 30% Rate QpeSetPoint 185 PSI nostic file, or to clear changesto a parameter value prior
to using the ENTER key. The CLEAR key can be used in
PLACE BOILER CONTROLLER IN AUTOMATIC MODE, the Program or Operate mode.
[AUTO/MANUAL] KEY

Auto
190 PSI FlameSigml 2.5V 7.+,FAST, Keys -
The +, FAST, - keys are used to adjust the value of a
Run 30% Rate QperSetPoint 185PSI displayedparameter. With thecursorbeneaththe
L 1
M1114 parameter value, see figure 7, the +, FAST, - keys can be
used in increase or decrease a numerical value or scroll
throughavailableoptions, e.g. historicalinformation
FIGURE 4+AUTO]/[MANUAL] KEY
Yes/No, diagnostic information Yes/No, or amplifier selec-
tion etc. The FAST key can be pressed along with the +
5. ENTER Key or - key to increase or decrease the value at a greater
The ENTER key is used to store a parameter value in rate, see figure 7.
theBoilerControllermicrocomputer memory. The
ENTER keymust be usedin the Program or Operate Thedisplay has beenformattedconsistentlyto dis-
modes when a valueis changed, see figure 5. If the play data and operating parameters. Two display formats
ENTER key isnot pressed the new value willnotbe are possible depending if the system is in the Program or
stored, the previous value will remain in memory. When Operate mode.
2
 IN OPERATE MODE, DIAGNOSTIC INFORMATION PARAMETER
ACCESSED
3
190 Auto PSI Qagnosticlnfo? No

PSI OperSetPolnt
185 GasStandbv

ACCESS Diagnosticlnfo VALUE, NO, [>I KEY

f
190 Auto
Diagnosticlnfo?
PSI NQ
PSI
Standby
OperSetPoint
185 Gas
\

SELECT Diagnosticlnfo FILES, [+I KEY

f
Diagnostlclnfo?
PSI
Auto 190 YQ

PSI OperSetPoint
185 GasStandby
i

ENTER Diagnosticlnfo FILES, [ENTER] KEY

I \
Auto 190 PSI Slgnal
I:Elame 0.OOV

PSI
Standby
OperSetPoint
185 Gas
L- 1

ACCESS GasPressSensor VOLTAGE VALUE, [VI

KEY I J

FIGURE &KEYBOARD AND DISPLAY

Auto 190PSI IGasPressSensor 0.OOV

Standby Gas OperSetPolnt

185 PSI
i d
833-2419 LCD FORMAT
EXIT Diagnosticlnfo FILE, [CLEAR] KEY
f \ 833-2419 LCDFormattingDuringProgram Mode
PSI
Auto 190 plagnosticlnfo? No Operation
OperSetPoint
185 Gas
Standby PSI The Keyboard and Display Modules LCD is a two row
\ / by 40 character LCD. The LCD during the Program mode
M1117
is separated into three fields. Figures 10, 11, 12, and 13
indicate the location and information available in these
FIGURE &[CLEAR] KEY fields,each displaying different information All parame-
ters can be viewed and values adjusted in the Program
Mode. The Boiler Controller requires specific parameters
IN OPERATE MODE
(configuration parameters) to be programmed by the
PSIAuto

Standby
190

Gas
Flamesignal

QperSetPomt
185
2.5V

PSI
I user.Theconfigurationparameters(BoilerModel
Number,SteamPressureSensorRange,Water
TemperatureSensorRange,SetbackCapable,Gas
Pressure Sensor Range, and Operating Setpoints) must
ACCESS OPERSETPOINT VALUE, 11. KEY be programmed to identify application specific informa-
t \
Auto 190 PSI Signal
Flame 2.5 V tionto assurepropersystem operation. Configuration
parameters must be programmed by the user for proper
OperSetPolnt
GasStandby 1 6 PSI
Boiler Controller operation. The Boiler Controller assigns
L /
default values to non-configuration parameter values,
INCREASE OPERSETPOINT ADJUSTMENT BY 5 PSI, [+I KEY, ~~
see Table I. These non-configuration parameters can be
5 PRESSES OR HOLD AND SLEW TO 190 PSI
r 7 altered by the user. The Program Mode provides prompts
Auto 190PSI Flame
Slgnal 2.5V to aid in the programming (information displayed in Field
2 indicates what keys should be pressed to proceed with
Standby Gas OperSetPoint 19o_PSI
i J programming).

ENTER ADJUSTED OPERSETPOINT VALUE, [ENTER] KEY

190 Auto
Slgnal
Flame PSI 2.5V IMPORTANT
PSI QoerSetPolnt
190 Gas
Standby
When changing a limit or configuration parameter
the Keyboard Display Module will provide warning
M1116
prompts, see figure 9. The Boiler Controller must be
configured properly for safe system operation.
FIGURE 7++] [FAST} [-I KEYS

3 CB68-42
 TABLE I-DEFAULT VALUE TABLE

Adjustment
Parameter/Description Range Default Comments

Boiler Model Number Program the boiler model number as

taken from the boiler identification plate.
Do not vary from the combination on the
boiler identification plate.

Boiler Type CB or WT None CB identifies firetube boilers.

WT identifies watertube boilers

Fuels Series 100,200,300 None Fuel series identifies what fuel options
400, 500, 600, are available to burn, gas, light oil, heavy
700,800, or 900 oil, or a combination.

Boiler/Burner Size A-1 A-2, A-3, A-4, A-5,

~

Watertube Boilers A-6,A-7, A-8, BR-1 ,BR-2,

BR3,CN-l, CN-2,CN-3, None
CN-4, CN-5, CN-6,
or CN-7

Firetube Boilers 015, 020, 030,040,

050, 060, 070, 080, None
100,125, 150, 175,
200,225, 250, 300,
350,400, 500, 600,
700,750, w 800

I
~~~ ~

Design
Pressure 001 - 999

Boiler Medium ST or HW 1 None ST identifies a steam boiler

~~

HW identifies a hot water boiler.

~~~~~
~ ~~

Steam Pressure Sensor

Range 300 psior
15 psi or 750psipsi
150 or 1 None
Select the sensor range value.

Water Temperature Sensor

Range

Gas Pressure Sensor Range

300 F or 500" F

1 psi or 2 psi
1 None
None 15"wc or
Select the sensor range value.

Select the sensor range value.

or 5 psior 15 psi.

Low Fire Rate 1OYOI Low Firetube The low fire rate setting must be within
Fire Rates 40% 30% a minimum of 10% of the firing rate to a
Watertube maximum of 40% of the firing rate.
25%

Maximum Fire Rate Low Fire RateI Maximum
Fire Rate I 100%
I I
Flame Amplifier Identif- 833-2420 (Ultraviolet)
ication 833-2421 (Infrared)
833-2462 (UV selfcheck)
I I
100% The maximum fire rate must be within
the range of the LowFire Rate setting
and 100% fire rate.
833-2421 Select the number for the amplifier
installed.

A

Adjustment
ParameterlDescription Range
Nominal Gas Pressure 10% Gas Pressure
Sensor Range snominal
gas pressure I100%
of the gas pressure
sensor range
Low Gas Pressure Limit 1OY0 of the gas pressure
sensor range I low gas
limit Inominal gas
pressure.
High Gas Pressure Limit Nominal gas pressureI
high gas limit Igas
pressure sensor range.
Nominal Oil Pressure 30 psi Inominal oil
pressure 5 135 psi
Low Oil Pressure Limit 80% of nominal oil
pressure 5 low oil pressure
lirnit.193% of nominal oil
High Oil PressureLimit 107% of nominal oil
pressur& high oil
pressure limit 5 120%
of nominal oil pressure
I 145 psi.
~
Nominal OilTemperature 60 'F Inominal oil
temperature I265 'F
~
Low Oil Temperature Limit 85% of nominal oil
temperature Ilow oil
temperature limit I92% of
nominal oil temperature.
5 CB68-42
~~ ~
Default Comments
25% of gas The nominal gas pressuresensor
pressure range must be within the value of 10%
sensor range to 100% of the gas pressuresensor
range, e.g. for a 15 psi sensor the
nominal gas pressure setting has a
range of 1.5 psi to 15psi. The default
value for this example would be 3.75 psi,
25%.
50% of the The low gas pressurelimit setting must
nominal gas be within the valueof 10% of the sensor
pressure range up to the nominal gas pressure
setting, eg if the sensor rangeis 15psi
and the nominal settingis 7.5 psi the low
gas pressure limit has a rangeof 1.5 psi
minimum to 7.5 psi maximum.
150% of the The high gas pressure limit setting must
nominal gas be within the value of the nominal gas
pressure pressure and the gas pressure sensor
range, e.g. if the sensor rangeis 15 psi
and the nominal gas pressure settingis
7.5 psi the high gas pressurelimit has a
range of 7.5psi minimum to 15 psi
maximum.
None The nominal oil pressure mustbe within
the values of 30 psi minimum to 135 psi
maximum.
87% Of The low oil pressure limit setting must be
nominal oil within the valueof 80% of the nominal
pressure oil pressureand of thenominal oil
pressure setting,e.g. if the nominal oil
pressure is 85 psi the low oil pressure
limit has a range of 68 psi minimum to
79 psi maximurn.
113% of The high oil pressurelimit setting must
nominal oil be within the valueof 107% of the
pressure nominal oil pressure and 120%of the
setting nominal oil pressure without the
exceeding 145 psi absolute maximum,
e.g. if the nominal oil pressureis 120
psi the high oil pressure limit has an
adjustable range of 128 psi minimum
to 144 psi maximum.
None The nominal oil temperature must be
within the valuesof 60 'F minimum and
and 265'F maximum.
92YO of The low oil temperature limit setting
nominal oil must be within the valueof 85% to 92%
temperature of nominal oil temperature setting,eg
if the nominal oil temperature settingis
170'F the low oil temperature limit has a
range of 144'F minimum to 156'F
maximum.
 Adjustment
Parameter/Description Range
High Oil Temperature Limit 108% of nominal oil
temperature Ihigh oil
temperature limit
I 115% of nominal
oil temperature I 290' F.
Operating Setpint
Steam System 5% of steam pressure
sensor range I operating
setpoint I97% of steam
pressure sensor range.
Hot Water System 160 'F minimum s operating
setpoint I97% of water
temperature sensor
range.
BoilerOn
Steam System 5% of steam pressure
sensor range IBoilerOn
setpoints 97% of steam
pressure sensor range
I 150 psisteam pressure sensor the
Hot Water System 160 'F minimum 5
BoilerOn setpoint 5
97% of water temperature
sensor range
Boileroff
I
Steam System 5% of steam pressure
sensor range I Boileroff
setpoints 97% of steam
pressure sensor range
~ ~~
Hot Water System 160 'F minimum s Boileroff
setpoint I 97% of water
temperature sensor range
6
Default Comments
108% of The high oil temperature limit setting
nominal oil must be within the value of 108%
temperature of the nominal oil temperature and 115%
setting of the nominal oil temperature without
exceeding 290'F absolute maximum,
e.g. if the nominal oil temperature setting
is 170'F the high oil temperature limit
has a range of 180 'F minimum to 195'F
maximum.
None The operating setpoint setting
must be within the value of 5% of the
steam pressure sensor range and 97%
of the steam pressure sensor range, eg
with a 150 psi steam pressure sensor
the operating setpoint has a range of
7.5 psi minimum to 145 psi maximum.
None The operating setpoint setting must be
within the value of 160'F and 97% of
water temperature sensor range, eg with
a 500'F water temperture sensor range
the operating setpoint has a range of
160'F minimum to 485'F maximum.
None The BoilerOn setpoint setting must be
within the value of 5%of the steam
pressure sensor range and 97%of the
steam pressure sensor range, eg with a
BoilerOn setpoint has a range of 7.5 psi
minimum to 145 psi maximum.
None The BoilerOn setpoint setting must be
within the value of 160'F and 97% of
water temperature sensor range, eg with
a 500'F water temperature sensor range
the BoilerOn setpoint has a range of
160'F minimum to 485'F maximum.
None The Boileroff setpoint setting must be
within the value of 5% of the steam
pressure sensor range and97% of the
steam pressure sensor range, eg, with a
150 psi steam pressure sensorthe
BoilerOff setpoint has a range of 7.5 psi
minimum to 145 psi maximum.
None The BoilerOff setpoint setting must be
within the value of 160'F and 97% of
water temperature sensor range, eg with
a 500'F water temperature sensor range
the Boileroff setpoint has a range of
160'F minimum to 485'F maximum.
Default Range
Parameter/Description
Adjustment
Setback Setpoint
I I
Steam System 5% of steam pressure
sensor range I setback
setpoints 97% of steam
pressure sensor range
I I
Hot Water System 160 'F minimum I setback
setpoint s 97% of water
temperature sensor range
Setback BoilerOn
I I
Steam System 5% of steam pressure
sensor range s BoilerOn
set back setpoints 97%
of steam pressure
sensor range
I I
I I
Hot Water System 160 'F minimum s
BoilerOn set back
setpoint I 97% of water
temperature sensor
range.
Setback Boileroff
Steam System 5% of steam pressure
sensor range I Boileroff
set back setpaints 97%
I I
Hot Water System 160 'F minimum I BoilerOfl
setback setpoint I 97% of
water temperature sensor
range.
7 CB68-42
I Comments
I
OperSetpoint The setback setpoint setting
must be within the value of 5% of the
steam pressure sensor range and 97%
of the steam pressure sensor range, eg
with a 150 psi steam pressure sensor
the setback setpoint has a rangeof
7.5 psi minimum to 145 psi maximum.
I
I
OperSetpoint The setback setpoint setting
must be within the value of 160'F and
97% of water temperaturesensor
range, eg with a 500'F water
temperature sensor range the setback
setpoint has a rangeof 160'F minimum
to 485'F maximum.
BoilerOn TheBoilerOn setback setpoint setting
must be within the value of 5% of the
steam pressure sensor range and 97%
of the steam pressure sensor range, eg
with a 150 psi steam pressure sensor
the BoilerOn setback setpoint has a
range of 7.5 psi minimum to 145 psi
maximum.
I
BoiierOn The BoilerOn setback setpoint setting
must be within the value of 160'F and
97% of water temperaturesensor
range, e.g. with a 500'F water
temperature sensor range the Boileron
setback setpoint has a rangeof 160'F
minimum to 485'F maximum.
Boileroff The high BoilerOff setback setpoint
setting must be within the value of 5% of
the steam pressure sensor range and
97% of the steam pressuresensor
range, eg with a 150 psisteam pressure
sensor the Boileroff setbacksetpint
has a range of 7.5 psi minimum to 145
psi maximum pressuresensor range
I
BoilerOff The high BoilerOff setback setpoint
setting must be within the value of 160F
and 97% of water temperature sensor
range, e.g. with a 500'F water tempera
ture sensor range the high Boileroff
setback setpoint has a rangeof 160'F
minimum to 485'F maximum.
 Adjustment
Parameter/Description Range Comments

Response Factor The response factor must fall within the

I5 range of 1 minimum to 5 maximum.

PrepurgeTimeExtension 0 I Prepurge
Extension The prepurge can be extended within
I 9000 seconds. the range of 1 second minimum to 9000
seconds (150 minutes) maximum.

PostpurgeTimeExtension 0 I Post-purgeExtension The postpurge can be extended within

I9000 seconds. the range of 1 second minimum to 9000
seconds (150 minutes) maximum.
I
I

Rate Linearization 0 5 Rate The rate linearization parameter must

Linearization I 3 fall within the range of 0 minimum to
3 maximurn.

History Data Yes or No To enter the history files, selectYes.

If History files are not tobe entered,
select No. Then press ENTER.
To exit, press CLEAR.

Diagnostic
Info No
Yes or To enter the diagnostic files selectYes.
If diagnostic files are not to be entered,
select No. Then press ENTER.
To exit, press CLEAR

Different
Module? Yes
No or As future enhancement modules are
added to the Boiler Room Control
System ControlBus, the Keyboard and
Display Module can be used by these
different modules for programming and
review of the Different Modules
parameters. The Different Module
selection will allow accessing these
modules. To use select Yes then ENTER.

Setback Capable? Yes or No The Boiler Controller will allowthe

user to select if the Boiler Controller
can be placed in a setback mode.
If No is selected the setback values
will not be displayed. If Yes is
selected the setback values will
be made available for programming

Setback Mode? Yes or No Setback mode switchesthe Boiler

Controller between the Setback set
points and Operating setpoints.
Selecting Yes will place the Boiler
Controller in a Setback condition
(unoccupied). Selecting No will Place
the Boiler Controller in an Operate
condition (occupied).
 Field 2 Display, +] to set value [VI
for next
f. 3 Field 2 contains this display when the cursor is
Warning: Improper configuration or limit
positioned under the parameter value to be
values may allow hazardous operation [v] changed when the parameteris not mutti-value. To
\ /
adjust the value use the [+I or [-I key. If another
parameter is desired use the [VI key to view other
parameters.
t \
Warning: Refer to instwction manual
Field 2 Display, [+Ito set value [Enter] when done
for proper configuration procedure [VI Field 2 contains this display when the value is
& #
u 19o being adjusted using the [+I or [-I key. This is also
displayed when a configuration parameteris to be
FIGURE %WARNING PROMPTS adjusted and the cursor is located beneath the
configuration parameter name. When the proper
EXAMPLE DISPLAY PROGRAM MODE parameter value is displayed the [Enter] key must
/ 5 be pressed to store the value into the microcom-
BLC Program QmrSetPoint 2

F puters memory.
[>] tu set value [VIfor next
L Field 2 Display, [VI to set parameters [Mode] to
M 101
operate
Field 2 contains this display when all parameters
FIGURE IO-PROGRAM MODEDISPLAY
have been adjusted and configured. To return to
1. Field 1 indicatespresentBoilerController mode, the normal Operate mode the [Mode] key must be
Program or Operate. When in the Program Mode field 1 pressed. If a value isto be changed itmust be
contains the description BLC Program, see Figure
11. accessed with the [v]key.

EXAMPLE PROGRAM MODE FIELD 1
BLC Progrsm
[>Ito set value
- Field 2 Display, [VIto enter new code to v e r i
Field 2 contains this display when setting the one,
QmrSetPdnt 200nF t w o , or three digit access code. After the code is
entered the [VIkey must be depressed to veriiy the
[v] for next entered code.

Field 2 Display, [VI to enter Model # again to verify

FIGURE 11-fROGRAM MODE, FIELD 1
2. Field 2, provides prompt information to assist in
configuringtheBoilerController.BoilerController
prompts are provided only in the Program mode, see fig-
ure 12.
Field 2 Display, [VIto set configuration parameters
Field 2 contains this prompt whenthe system is ini-
tially powered and parameters have not yet been
set. To continue programming the system the [VI
cursor key must bepressed.
Field 2 contains this display.whensetting the Boiler
Modelnumberconfigurationparameter.Itisa
requirement that the model number be verified
after initial entry. Use the [VI key to access the
model number again for veriiication.
Field 2 Display, [VI
to continue
Field 2 contains this display when the Access
Code or Boiler Model Number have been entered
and veriiied. To continue programming the [VI key
must be depressed.

Field 2 Display, [>I to set value

-
EXAMPLE PROGRAM MODE FIELD 2

Field 2 contains this prompt when the cursor is BLC Program QmSetPoint 200F
located beneath a configuration parameter identifi-
cation andnovaluehas been set. The [>] cursor [>I to set value [VIfor next
key should be pressed to access the configuration
parameter value to make an adjustment.
FIGURE 12-PROGRAM MODE, flELD 2
Field 2 Display, [>]to set value [VIfor next
Field 2 contains this prompt when a parameter is 3. Field 3 provides parameter identification and value
displayed and the value can be adjusted. The cur- indication. Asan exampleOperSetpoint 100 psiidenti-
fies the parameter to be the Operating Setpoint which is

~ . ; : :
sor islocatedbeneaththeparametername. To
adjust the parameter value depress the [>I key. If currently set at 100 psi, see Figure 13.
another parameter isdesired use the [VIkey.
* EXAMPLE PROGRAM MODE -FIELD3
Field 2 Display, [+I
to set value [>] for next
BLC Program
Field 2 contains this prompt when a multi-value
parameter, ie BoilerModelNumber, is being [>] to set d u e [v] for next
adjusted. The [+] or [-I
keys are used to setthe \ /
value.The [>] key is used to accessthe next
parameter value to the right of the cursor. FIGURE 13-PROGRAM MODE, FIELD 3
9 CB68-42
 All parameters can be viewed in Field 3. Parameters 833-2419 LCD Formatting During Operate Mode
are displayed inorderas if on a scroll, see figure14. Operation
Table I I is a complete listing of available parameters and The Keyboard and Display Modules LCD is a two row
the order displayed when in the Program mode. by 40 character LCD. The LCD during the Operate Mode
is separatedintofourfields.Figure 15, 16, 17, and 18
TABLE II-PROGRAM MODE PARAMETER LIST highlightthelocationandinformationavailable in these
fields each displaying different information during opera-
tion.All parameters except for Model Number, Steam
Model xx-xxx-xxx-xxx-xx Pressure SensorRange, Water Temperature Sensor
SteamSensRange xxx PSI Range, Setback Capable, Erase History, Change Access
WaterSensRange xxx F Code,RateLinearization, Flame AmplifierIdentification
GasSensRange xxx "WC or PSI Number, and Gas Pressure Sensor Range can be adjust-
OperSetPoint xxx PSI or F ed in the Operate Mode. All parameters can be viewed in
BoilerOn xxx PSI or F the Operate mode. The Operate Mode does not include
BoilerOff xxx PSI or F prompts to assist in programming the Boiler Controller.
Setback Capable? xxx
Setback Mode? xxx 1. Field 1 indicatesthepresentBoilerController
SetbackSetpt xxx PSI or F mode,ProgramorOperate.IntheOperatemode,the
SetbackBoilerOn xxx PSI or F LCD indicates if the burner is firing "Auto" [automatic] or
SetbackBoilerOff xxx PSI or F "Man" [manual] and the actual boiler steam pressure [psi]
FlameAmplifier xxx-xxx or temperature ['F]., see figure 15.
NomGasPress xxx "WC or PSI
LoGasLimit xxx "WC or PSI
HiGasLimit xxx "WC or PSI
-
!EXAMPLE OPERATE MODE FIELD 1

NomOilPress xxx PSI ~ Auto 190 PSI

LoOilPressLimit xxx PSI
HiOilPressLimit xxx PSI Run 30% Rate QerSetPolnt 185 PSI
NornOilTemp xxx F \ I
LoOilTempLimit xxx F
HiOilTempLimit xxx F FIGURE 15-OPERATE MODE, FIELD 1
Response X
2. Field 2 displays present burner sequence status
LoFire xx % Rate
indication. Forty six different display types are possible
RateLinearization X
depending upon the present burner status. Sequence
MawFire xxx % Rate
status does overwrite Field 4 to indicate burner status,
PrepurgeExtend xxxx
whenever the cursor is not positioned in field four. See
PostpurgeExtend xxxx
figure 16 for an exampleofanOperatingModedisplay
Change access code? xxx
with Field 2 highlighted.
Erase History Data? xxx
Different Module? xxx
Standby Oil
Field 2 indicates the burner status, Standby, and
the fuel series selected, Oil. The burner can be
placed in Standby by opening the Burner Switch
or based on the cyclingratecontrolindicating
the setpoint has been satisfied.

Standby Gas
Field 2 indicates the burner status, Standby, and
the fuel series selected, Gas. The burner can be
placed in Standby by opening the Burner Switch
or based on thecyclingratecontrolindicating
the setpoint has been satisfied.

Standby Both
Field 2 indicates the burner status, Standby, and
the fuel series selected, is both Oil and Gas.
The burner can be placed in Standby by open-
ingtheBurnerSwitchor based onthecycling
rate control indicating the setpoint has been sat-
isfied.

Standby
Field 2 indicates the burner status, Standby, and
no fuel seriesisselected. The burner canbe
M 195
placed in Standby by opening the Burner Switch
~~
or based on the cyclingratecontrolindicating
FIGURE 1 G C R O L L DIAGRAM the setpoint has been satisfied.
10
Standby Both
Hold:
Fuel
Selection
Field 2 indicates the burner status, Standby, and
thefuelseriesselected,bothOilandGas. A no fuel series is selected. A Demand is present
Demand is present for burner operation. The
burner sequence will not advance to Prepurge
until a valid Fuel Selectionis made.
StandbyGas Hold: Recycle
Limits
Field 2 indicates the burner status,Standby, and
the fuel series selected, Gas. A Demand is pre-
sent for burner operation. The burner sequence
will not advance to Prepurge until the Recycle
Limits prove closed.
Standby
Oil
Hold:
RecycleLimits
Field 2 indicates the burner status,Standby, and
the fuel series selected, Oil. A Demand is pre-
sent for burner operation. The burner sequence
will not advance to Prepurge until the Recycle
Limits prove closed.
Standby Both
Hold:
Recycle
Limits
Field 2 indicates the burner status,Standby, and
thefuelseriesselected,bothGasandOil.A
Demand is presentforburneroperation.The
burner sequence will not advance to Prepurge
until the Recycle Limits prove closedand a valid
fuel selection is made.
Standby - - - - Hold:RecycleLimits
Field 2 indicates the burner status,Standby, and
no fuel series is selected. A Demand is present
for burner operation. The burner sequence will
not advance to Prepurge until the Recycle Limits
prove closed and a valid fuel selectionis made.
Standby GasHold:
LowFire Cutoff
Field 2 indicates the burner status,Standby, and
the fuel series selected, Gas. A Demand is pre-
sent for burner operation. The burner sequence
will not advance to Prepurge until the Assured
Low Fire Cutoff input (usually a time clock or
combustion air damper auxiliary switch is ener-
gized).
StandbyOil
Hold: Low Fire Cutoff
Field 2 indicates the burner status,Standby, and
the fuel series selected, Oil. A Demand is pre-
sent for burner operation. The burner sequence
will not advance to Prepurge until the Assured
Low Fire Cutoff input (usually a time clock or
combustion air damper auxiliary switch is ener-
gized).
Standby Both
Hold: Low Fire Cutoff
Field 2 indicates the burner status,Standby, and
thefuelseriesselected,bothGas and Oil. A
Demand is present for burner operation. The
burner sequence will not advance to Prepurge
until the Assured Low Fire Cutoff input (usually a
time clock or combustion air damper auxiliary
switch is energized).
11
Standby - - - - Hold: Low Fire Cutoff
Field 2 indicates the burner status,Standby, and
for burner operation. The burner sequence will
not advance to Prepurge until the Assured Low
Fire Cutoff input (usually a time clock or com-
bustionairdamperauxiliaryswitchisener-
gized).
StandbyGasHold:
FlameDetected
Field 2 indicates the burnerstatus, Standby, and
the fuel series selected, Gas. A Demand is pre-
sent for burner operation. The burner sequence
willnotadvance to Prepurgeasaflame is
detected as being present.The sequencewill not
advance to Prepurgeuntiltheflamesignal
clears. If the flame signal does not clear within
40 seconds the Boiler Controller will lockout.
StandbyOil
Hold:
Flame
Detected
Field 2 indicates the burner status,Standby, and
the fuel series selected, Oil. A Demand is pre-
sent for burner operation. The burner sequence
will not advancetoPrepurge asa flame is
detected as being present. The sequence will
not advance to Prepurge until the flame signal
clears. If the flame signal does not clear within
40 seconds the Boiler Controllerwill lockout.
Standby Both
Hold:
FlameDetected
Field 2 indicates the burnerstatus, Standby, and
the fuel series selected, both Gas and Oil. A
Demand is presentforburneroperation.The
burnersequence willnot advancetoPrepurge
as aflame is detected as beingpresent.The
sequence will not advance to Prepurge until the
flame signal clears. If the flame signal does not
clear within 40 seconds the Boiler Controllerwill
lockout.
Standby - - - - Hold:FlameDetected
Field 2 indicates the burner status,Standby, and
no fuel series is selected. A Demand is present
for burner operation. The burner sequence will
not advance to Prepurge as a flame is detected
asbeingpresent.Thesequencewillnot
advancetoPrepurgeuntiltheflamesignal
clears. If the flame signal does not clear within
40 seconds the Boiler Controller will lockout.
StandbyOil
Hold:
Oil
Pressure
Field 2 indicates the burner status,Standby, and
the fuel series selected, HeavyOil. A Demand is
present for burner operation. The burner
sequence will not advance to Prepurge as oil
pressureisoutside of programmedlimits
(Program Module 833-2417 and 833-2418).The
burner sequence will not advance until the oil
pressure is within the programmedlimit values.
9 Standby OilHold:
Oil Temperature
Field 2 indicates the burner status,
Standby, and
CB68-42
 the fuel series selected, Heavy Oil. A Demand is
present for burner operation. The burner
sequence will not advance to Prepurge as tem-
perature is outside of programmed limits. The
burnersequence will not advance until the oil
temperature is within the programmed limit val-
ues.
- Standby Gas Hold:
Damper
Motor
Field 2 indicates the burner status, Standby, and
the fuel series selected, Gas. A Demand is pre-
sent for burner operation. The burner sequence
willnotadvance to Prepurge as the Damper
Motor is not in the correct position. The seq-
uence will advance to Prepurge when the motor
advances to the correct position.
Standby Oil Hold:
DamperMotor
Field 2 indicates the burner status, Standby, and
the fuel seriesselected,Oil. A Demandis pre-
sent for burner operation. The burner sequence
will not advance to Prepurge as the Damper
Motorisnotinthecorrectposition.The
sequence will advance to Prepurge when the
motor advancesto thecorrect position.
Standby Gas Hold:
Lockout
Interlocks
Field 2 indicates the burner status, Standby, and
the fuel series selected, Gas. A Demand is pre-
sent for burner operation. The burner sequence
will not advance to Prepurge until the Lockout
Interlocks prove closed.
Standby Oil Hold:
Lockout
Interlocks
Field 2 indicates the burner status, Standby, and
the fuel series selected, Oil. A Demand is pre-
sent for burner operation. The burner sequence
will not advance to Prepurge until the Lockout
Interlocks prove closed.
Standby Both
Hold:
Lockout
Interlocks
Field 2 indicates the burner status, Standby, and
the fuel series selected, both Gas andOil. A
Demand is present for burner operation. The
burnersequencewillnotadvanceto Prepuge
until the Lockout Interlocks prove closed.
Standby - - - - Hold:LockoutInterlocks
Field 2 indicates the burner status, Standby, and
no fuel series is selected. A Demand is present
for burner operation. The burner sequence will
notadvancetoPrepurgeuntiltheLockout
Interlocks prove closed.
Standby - - - - Hold:
Open Oil Drawer
Field 2 indicates the burner status, Standby, and
no fuel series is selected. A Demand is present
for burner operation. The burner sequence will
not advance to Prepurge until the Oil Drawer
Switch proves closed.
- Standby x x x o/o Hold:TestSwitch
Field 2 indicates the burnerstatus,Standby. A
Demand may or may not be present for burner
operation.Theburnersequencewillnot
advance to Prepurge as the Runirest switch is
in the Test position. The sequence will continue
12
when the Runnest switch is placed in the Run
position if a Demand exists.
Prepurgexxx% Drive to PurgeRate
Field 2 indicates the burner status, Prepurge,
the fraction of high fire air flow in o/o and that the
firing rate motor is driving to its purge rate posi-
-
tion (maximum degree of rotation during purge)
Prepurgexxx%PurgeTime xxxx
Field 2 indicates the burner status, Prepurge,
the fraction of high fire air flow in %, and count-
ing of the prepurge timer in seconds.
Prepurgexxx%ExtensionTime xxxx
Field 2 indicates the burner status, Prepurge,
the fraction of high fire air flow in Yo and count-
ing of the prepurge extension timer in seconds.
Prepurgexxx% Drive to Low Fire
Field 2 indicates the burner status, Prepurge,
the fraction of high fire air flow in %, and that the
firing rate motor is driving to the low fire position
in preparation for ignition trials.
Prepurge xxx% Hold TestSwitch
Field 2 indicates the burner status, Prepurge,
the fraction of high fire air flow in % and that the
Runnestswitch is inthe Test position. The
sequence will not continueuntilthe Runnest
switch is placed in the Run position.
Prepurge xxx% Hold: Damper Motor
Field 2 indicates theburner status, Prepurge,
the fraction of high fire air flow in %, and that the
Damper Motor (firing rate motor) isnotin the
proper position. The sequence will not continue
until the Damper Motor reaches the Low Fire
position.
PilotIGN xxx
Field 2 indicates the burner status, Pilot IGN,
which is the period of time the Boiler Controller
permits the pilot valve to be open and during
which pilot flame should be established, and the
timing of the Pilot IGN trial, in seconds.
Pilot
IGNxxx
Hold:
Test
Switch
Field 2 indicates the burner status, Pilot IGN,
which is the period of time the Boiler Controller
permits the pilot valve to be open and during
which pilot flame should be established, and the
timing of the Pilot IGN trial, in seconds and that
the Runnest switchisplacedin the Test posi-
tion. The sequence will not continue until the
Runnest switch is placed in the Run position.
IGN xxx
Pilot Hold:
Damper Motor
Field 2 indicates the burner status, Pilot IGN,
which is the period of time the Boiler Controller
permits the pilot valve to be open andduring
which pilot flame should be established, and the
timing of the Pilot IGN trial, in seconds, and that
the Damper Motor (firing rate motor) is not in the
proper position. The sequence will not continue
until the Damper Motor reaches the Low Fire
position.
 Main IGN xxxx
Field 2 indicates the burner status, Main IGN,
which is the period of time the Boiler Cantroller
permits the main valve to be open and during
which main flame should be established, and
the timing of the Main IGN trial, in seconds.
Run xxx% Rate
Field 2 indicates the burner status, Run, which
is the period of time after the ignition trials and
beforethehighoperating limit (BoilerOff)set-
point is reached during which time the burner is
firing under the control of the Boiler Controllers
rate control, and the fraction of high fire air flow,
in %.
Run LF-Cutoff Drive To Low Fire
Field 2 indicates the burner status, Run, which
is the period of time after the ignition trials and
beforethehighoperating limit (BoilerOff)set-
point is reached during which time the burner is
firing under the control of the Boiler Controllers
rate control, and that the DamperMotor (firing
rate motor) is driving to lowfire in preparation for
entering Postpurge.
parameters can be viewed in Fields 3 and 4. All parame-
ters can be adjusted in the Operate Mode except Boiler
ModelNumber,SteamSensorRange, WaterSensor
Range, Setback Capable, Erase History, Change Access
Code,RateLinearization,FlameAmplifierIdentification
number, and Gas Sensor Range which can be adjusted
only in theProgramMode.Parametersaredisplayed
one at a time in a specific order as if on a scroll, see fig-
ure 14. Table Ill contains a complete listing of available
parameters and the order they will be displayed when in
the Operate Mode.
Figure 17 is an example of a complete Operate Mode
display with Field 3 highlighted. Figure 18 is an example
of a complete Operate Mode display with Field 4 high-
lighted.
-
* EXAMPLE OPERATE MODE FIELD 3
f. \
AUro 1 9 0 PSI FlsrneSignal 2.5V
Run 30% Rate QperSetPoint 185 PSI
\ J
M 189

- Run Test Sw Low Fire Commanded

Field 2 indicates the burner status, Run, which
FIGURE 17-OPERATE MODE, FIELD 3

is the period of time after the ignition trials and

beforethehighoperating limit (BoilerOff)set- . -
EXAMPLE OPERATE MODE FIELD 4

point is reached during which time the burner is f

Auto 190 PSI FhrneSignal 2.5V
firing under the control of the Boiler Controllers
rate control, and that the Runnest switch isin Run 30% Rate PparSetPoint 185 PSI
the Test position and the Damper Motor (firing L J
M 189
rate motor) is in the Test position.
FIGURE 18-OPERATE MODE, FIELD 4
Postpurge
Purge
Time xxxx
Field 2 indicates the burner status, Postpurge,
which is the period of time after the Run period
during which time the blowermotor continues to ACCESS CONTROL
run, and the timing of the Postpurge period in The Boiler Controller provides an access code which
seconds, 1-15. restricts system access to set or modify parameter val-
ues.
Postpurge
Extension Tme xxxx
Field 2 indicates the burner status, Postpurge, Optional 3 Digit Code
which is the period of time after the Run period This code can be programmed to control access to
during which time the blower motor continues to the Program mode and to control modification of param-
run, and the timing of the Postpurge Extension etervaluesintheOperatemode.Thiscode hasa
T m e in seconds. default value of 000. When the value of the code is 000
no code entry is required to change values.
. -
EXAMPLE OPERATE MODE flELD 2
6 \ FAULT MESSAGES
Auto 190 PSI FlameSignal 2.5V ,Fault message will temporarily overwrite fields 3 and
Run 30% Ral QoerSerPoinr 185 PSI 4 intheevent of asafetyshutdown.Information will
L i remain until the CLEAR key is pressed.
M 187

FIGURE 1C P E R A T E MODE, FIELD 2 DISPLAY ON POWER UP

The Boiler Controller will retain the status of boiler
3. Fields 3 and 4 display operating parameters, histor- operation and upon power up will display any fault mes-
ical data, and diagnostic information. All Boiler Controller sages and the operating status.

13 CB68-42
 TABLE III-OPERATE MODE PARAMETER LIST

flamesignal xxxx v H4: Fault Cycle XXXXX

FlarneArnplifier xxx-xxxx H4: Fault Hours xxxxx

xxx "WC or PSI H4: Fault Code xxx
Gaspressure
NomGasPress xxx "WC or PSI H4: xxxxxxxxxx
xxx "WC or PSI H4 xxxxxxxxxx
LoGasLimit
xxx "WC or PSI H4: xxxxxxxxxx
HiGastirnit
H5: Fault Cycle xxxxx
OilPress xxx PSI
H5: Fault Hours xxxxx
NomOilPress xxx PSI
H5: Fault Code XXX
LoOilPressLirnit xxx PSI
H5: xxxxxxxxxx
HiOilPressLimit xxx PSI
H5: xxxxxxxxxx
OilTemperature xxx F
H5: xxxxxxxxxx
NornOilTernp xxx F
H6: Fault Cycle xxxxx
LoOilTernptimit xxx F
H6: Fault Hours xxxxx
HiOilTernpLimit xxx F
H6: Fault Code xxx
Response X
H6: xxxxxxxxxx
LoFire xx O h Rate
H6: XXXXXxxXxx
Ratelinearization X
H6: xxxxxxxxxx
MaxFire xxx YoRate
Diagnostic Info? xxx
PrepurgeExtend xxxx
I: Flamesignal xxxx v
PostpurgeExtend xxxx
I: GasPressSensor xxxx v
History Data? xxx
I: OilPressSensor xxxx v
H: Total Cycles xxxxx
I: OilTernpSensor xxxx Ohm
H: Total Hours xxxxx
I: StmPressSensor xxxx v
H1:Fault Cycle XXXXX
I: WtrTempSensor xxxx Ohm
H1:Fault Hours xxxxx
I: DampMotor XxxX v
H1: Fault Code XXX
I: GAS LTO HVO xxx
H1: xxxxxxxxxx I: PI1 GMV OMV AAPS xxxx
H1: XxxXXxxXxx I: DMD ALFC xx
Hi : xxxxxxxxxx I: Revision CB-200~XX.XX
H2: Fault Cycle XXXXX
Different Module? xxx
H2: Fault Hours xxxxx Model xx-xxx-xxx-xxx-xx
H2: Fault Code xxx SteamSensRange xxx PSI
H2: xxxxxxxxxx WaterSensRange xxx F
H2: xxxxxxxxxx GasSensRange xxx "WC or PSI
H2: xxxxxxxxxx CperSetPoint xxx PSI or F
H3: Fault Cycle xxxxx BoilerOff xxx PSI or F
H3: Fault Hours xxxxx BoilerOn xxx PSI or F
H3: Fault Code xxx Setback Mode? xxx
H3: xxxxxxxxxx Setback Capable? xxx
SetbackSetPt xxx PSI or F
H3: xxxxxxxxxx SetbackBoilerOn xxx PSI or F
H3: xxxxxxxxxx SetbackBailerQff xxx PSI or F

14
 BOILER ROOM CONTROLSTEP BY STEP PROGRAMMING INDEX
Item Pages
1 Gaining Access To Program Mode .................................................................................................................. 15
2 Gaining Access To Operate Mode ................................................................................................................... 15
3. Use of Clear Key .............................................................................................................................................. 15
4 . Use of AutolManual Key .................................................................................................................................. 16
5 . Changing The Access Code............................................................................................................................ 16-17
6. Flame Amplifer Part Number........................................................................................................................... 17
7 . Nominal Gas Pressure..................................................................................................................................... 17-18
8. Low Gas Pressure Limit................................................................................................................................... 18-19
9 . High Gas Pressure Limit.................................................................................................................................. 19
10. Nominal Oil Pressure....................................................................................................................................... 20
11. Low Oil Pressure Limit..................................................................................................................................... 20-21
12. High Oil Pressure Limit.................................................................................................................................... 21-22
13. Nominal Oil Temperature................................................................................................................................. 22-23
14. Low Oil Temperature Limit ............................................................................................................................... 23
15. High Oil Temperature Limit .............................................................................................................................. 24
16. Response Factor.............................................................................................................................................. 24-25
17. Low Fire Rate................................................................................................................................................... 25-26
18. Rate Linearization............................................................................................................................................ 26
19. Maximum Fire Rate.......................................................................................................................................... 26-27
20 Prepurge Extend .............................................................................................................................................. 27-28
21 Postpurge Extend ............................................................................................................................................ 28-29
22 Accessing Historical information...................................................................................................................... 29
23 Accessing Diagnostic Information.................................................................................................................... 29-30
24 Different Module? ............................................................................................................................................. 30
25 Boiler Model Number ....................................................................................................................................... 30-31
26 Steam Pressure Sensor ................................................................................................................................... 32-34
26A Steam Sensor Range............................................................................................................................... 32
26B Steam Sensor Operating Setpoint ............................................................................................................ 32-33
26C Steam Sensor BoilerOn........................................................................................................................... 33-34
26D Steam SensorBoilerm............................................................................................................................ 34
27 Hot Water Temperature Sensor....................................................................................................................... 34-37
27A Hot Water Sensor Range......................................................................................................................... 34-35
27B Hot Water Sensor Operating Setpoint ...................................................................................................... 35
27C HotWater Sensor BoilerOn...................................................................................................................... 36
27D HotWater Sensor Boileroff...................................................................................................................... 36-37

28 Gas Pressure Sensor Range........................................................................................................................... 37

29 Setback Control ............................................................................................................................................... 38-41
29A Setback Capable?.................................................................................................................................... 38-39
29B Setback Mode? ......................................................................................................................................... 39
29C Setback Operating Setpoint..................................................................................................................... 39
29D SetbackBoilerOn...................................................................................................................................... 39-40
29E SetbackBoilerOff.........,............................................................................................................................. 40-41
30 Erasing Historical Data .................................................................................................................................... 41

15 CB68-42
 Step By Step Programming
1. Gaining Access To The Program Mode
The Boiler Controller is initially powered on a new installation in the Program mode. The following sequenceis neces-
sary if the Program mode is to be entered after initial power-up and the Boiler Controllers Access Code has been config-
ured. If an Access Code has not been entered the Mode key toggles the Boiler Controller tothe Proaram mode.

ion Step

1. Gain access [MODE] Program

BLCAccess
Code 0
programming
to [>] to select
digits [ENTER] When
done
mode.

2. Enter
your
code, a. [>] BLC Program AccessCode 9 Code
numbers will increment
911 usedasanWhen 9 [>] to selectdigits [ENTER] whendoneat one digitper second
appears. example.
b. [>I BLC PROGRAM Access Code 1
When 1 [>] toselectdigits[ENTER] when done
appears.
c- [>I BLC PROGRAM Access Code 1
When 1 [>]to selectdigits[ENTER] when done
appears.
~~ ~

3. Enter
code
[ENTER] BLC PROGRAM Access
Code 1 Access code accepted. Return to
[>]to
valueset operate mode or select next
parameter with [VIkey

4. Reentercode to validate thecode number.

5. Return
to [MODE] Auto: 0.0 psi QperSetPoint 8.0 psi The Boiler Controlleris returned
operate mode Standby
Flame Signal OV to normal Operatemode.

2. Gaining Access To The Operate Mode

The MODEkey toggles theBoiler Controller to the Program or Operate mode. For normal operationthe Boiler
Controller must bein the Operatemode.

tion Step

1. Assure
any [ENTER] BLC PROGRAM Model WT400BR3400ST For this example boiler
a model
values set [>]tovalue
set [ENTER] when done
number has been stored.
during pro-
gramming
are stored,
[ENTER}.

2. Return to [MODE] Auto: 10.0 psi Flame Signal 0 V The

Boiler
Controller is returned
Operate
mode Standby Flamesignal 0 V to normal
Operate mode.

3. U s e of the Clear Key.

The CLEAR key clears asafety shutdown diagnostic message fromthe LCD [the BoilerController must still be manual-
ly reset for proper operation]and used to reselect a previous level of display information. An example is provided for use
in the Program mode to prompt information.

Step operation Press

Comments Display

rogram
BLC 1. BoilerOffExample
8.8 psi of displayed information
[>] to set
value [v] for next
while
the
in Program mode.

2. Clear display
[CLEAR] BLC
Program
System is configured
Use of [CLEAR] key
for prompt
for prompt [VIset parameters[MODE]to operate
information how
on continue
to
information. programming or changing mode
selection.

3. Return to [Mode] Auto: 10.0 psi &ilerOff 8.8 psi Boiler Controller is returned to
Operate mode. Standby Oil FlameSignal 0V normal Operate mode.

16
 4. Use of the AutoIManual Key.
The AUTO/MANUAL key toggles the burner firing between automatic and manual firing modes. In the Automatic and
Operate mode the burnerwill sequence normally basedon demand {load on the boiler}. In the Manual and Operate
mode burner firing rate can be manually adjusted using the[+I and [-I keys.

Operation Step

1 Auto: 8.0 psi QperSetpoint 8.0 psiBurner is firing inRun at 80%.

Run
Fire 80% LoFire
Rate
25%

2. Toggle
[AUTO]
Man:
to 8.0 psi QperSetpoint 8.0 psi
manual firing. [MANUAL]
Run
Fire 80% LoFire
Rate
25%

3. Move
cursor
Man:
[<I 8.0OperSetpoint
psi 8.0Cursor
psi is placed under percent
Fire
to x%. Run Fire 8Q0/0 LoFire
Rate
25% of firing rate to allow
manual
for
adjustment of firing rate motor.

4. Adjust burner [-I ... Man: 8.0 OperSetpoint

psi 8.0 Minus
psi [-] key will decrement
firing rate, 50% Run
Fire 50% LoFireRate 25% firing
single
arate
by digit.
for this example.

5. Return to [AUTO]
Auto: 8.0 psi QperSetpoint 8.0 Firing
psi rate will modulate as
Automatic
[MANUAL]
Run Fire 50% LoFire
Rate
25%
required by boiler
load.
mode.

5. Changing Your Access Code

A 3 digit access code can be programmed. tf an access code is programmed the code must be entered to make any
changes to the Boiler Controller parameterseither from the Program or Operate mode. The access code can be
changed only when in the Program Mode.
~~

Display
Press
Operation
Step Comments

1. Gainaccess to theProgrammode, see of thisprogrammingsection.

~~

2. Access
the [VI BLCProgram Change Access Code?No
Assure
cursor is in Field 3 to
access
mode [>]to set value [VIfor next Access
access
mode
the
parameter. parameter.

3. Access
change [>] BLC ProgramChangeAccessCode?No Move
cursor to value,[>] key.
access
code
[+I tovalue
set [VI
next
for
value.

4. Select
change [+I BLC ProgramChangeAccessCode?YeS Select Yes [+I key
access
code [+]to set [Enter]
value when done

5. Create
access [>] BLC ProgramChangeAccessCode? 9 Use
[>] key to select
new access
code. [Enter] [>]to select digits
[Enter] when
done code when desired
the number(s1
appear on the display, then press
[Enter] to store number.

6. Verify access [v] BLC Program New code selected Verify access code use [VIkey to
code. [VI
to enter new code againto verify access verification screen.

7. Verify acc- 1.1 BLC ProgramChangeAccessCode? 9 Use [>] key to select new access
ess code. [>] to select digits[Enter] when done code when the desired number[s]
appears on the display

8. Enter new [Enter]

BLC Program New
code
verified
New
code
number
stored.
code.
access continue
[VIto

9. Return to [MODE]
Auto: 10 psi NomOilTemp 1OO'F Boiler
Controller is returned to
Operate Standby Oil Fame Signal 0 V Operate
mode.
normal
mode.

17 CB68-42
 Note: An access codeis only active when the code
is not0. If an access codeis not desiredkequired program-
ming the access code 0towill allow direct access to changing parameters
in the Program orOperate mode.

Note: If you happent o forget your access code contact your local
Cleaver Brooks sales/service agent for assis
tance.
~~~ ~~~ ~ ~~

6. Programming Flame Amplifier Number

The Boiler Controller requires the Flame Signal Amplifier part number be programmed into system memory. Three
flame amplifier options are available.. Assure you correctly identify the amplifier installed in the Chassis Module. The
options available are part number 833-2420 Ultra violet Dynamic Ampli-check, 833-2421 Infrared Dynamic Ampli-check,
and 833-2462 Ultra violet Dynamic Self-check. The amplifier selection is required for proper system operation. The
amplifier can be selected only in the Program mode.

Press Step Operation

1. Gain access to the Programmode,see 1 of thisprogrammingsection.

Access
2. the flame [VI BLC ProgramElame Amplifier833-2421
Assure
cursor inis Field 3 to
amplifier [>]to set value
next
[VIfor access the Flame amplifier
parameter. parameter.

Access
3. the [>I BLC ProgramFlame Ampiifier833-2421 Move cursor
value,
to [>] key.
flame
amplifier
[+I tovalue
set [VI
next
for
number

Select
4. a flame [+I BLC
ProgramFlame
Amplifier833-2420
Select
flame
amplifier
type.
amplifier type [+Ito set value
[Enter]
when
done
The [+] key
scroll
will
through
numbers. number, desired the Stop when
833-2420 for number part amplifier is displayed.
this example.

5. Enter flame [Enter] BLC ProgramElame

AmpIifier833-2420
Amplifier type number
stored.
amplifier type [>] to
value
set [VI
next
for

6. Return
to Operate [MODE] Auto: 10 psi NomOilTemp 1OO'F Boiler
Controller is returned
to
Standby
mode. OilSignal
&me 0V normal Operate mode.

7.Programming NominalGas Pressure Setpoint.

The nominal gas pressure setpoint is programmed to the regulated gas pressure setting. The Boiler Controller auto-
matically calculates the maximum and minimum rangesof the high and low gas pressure limits based on the Nominal
Gas Pressure Setpoint.
The nominal gas pressure setpointcan be adjusted in the Programor Operate mode.

a. From ProgramMode.

Press Step Operation

1a. Gain access to the Program mode, see 1 of this programming section.

2a. Access the gas [VI BLC Program NomGasPress x Assure

cursor isField
in 3 to
pressure setpoint [>] tovalue
set [VI
access
next
for
nominal
pressure
gas
parameter. setpoint
~~

Access
3a. gas [>I BLC ProgramNomGasPress
Move
cursor to value, [>] key.
pressure set- [+] to
value
set [VI
next
for
point

4a. Set the gas [+I. BLC

ProgramNomGasPress 2.5
psi Move
cursor to value, [>] key.
pressure set- [+]value
set
to [ENTER] when
done Plus [+] key
will
increment
setting
2.5 point, psi and [FAST] the Withby .01 psi.
for this
example. increment will pressure gas [+] keys
by .2 psi.

Enter
[ENTER]
5a.
gas BLC
Program NomGasPress 2.5 psi Gas pressure
pressure set- [>]value
to set setpoint
stored
next
[VIfor
point.

18
 Return
6a to [MODE] Auto: 99 NomGasPress
psi 2.5 psi Boiler
Controller is returned
to
Operate
mode. Standby
Flame
Signal
Oil 0V normal
Operate
mode.

b. From Operate Mode.

1b. Access
gas [VI Auto: NomGasPress
psi
10 x Assure
psi cursor is in Field 3 or
pressure
setpoint
Standby
Flame
OilSignal 0V 4access
togas
pressure
the
parameter. setpoint

2b.
Set
gas
pressure [>] Auto: 10
psi
NomGasPress
2.5
psi
Move
cursor to value, [>] key.
setpoint
parameter, [+I ... Standby
Oil Flame Signal 0 V Plus [+] key will increment
2.5
pressure
psi is used bythe
.01 psi. With
and [FAST] example. in this pressure[+I keys
will increment by .2 psi.

3b. Enter
gas
[ENTER] Auto:UomGasPress
psi
10 2.5 Gas
psi
pressure
setpoint
stored
Signal
Flame
Standby
pressure
Oil
set- 0V
point value.

Note: Thisexample indicates no value was previously entered. Values can be changed using steps1b through
3b If value previously set.

8. Programming Low Gas Pressure Limit Setting

The gas pressure low limit setting provides alow pressure limit point which if exceeded would resultin unsafe burner
operation. The low gas pressure limit locksout the Boiler Controllerif a condition exists resultingin gas pressure below
the low limit setting.
The gas pressurelow limit can be set in the Program or Operate mode.

a. From Program Mode.

Press Step Operation Display Comments

1a. Gain access to the Program mode, see 1 of this programming section.

2a. Access low gas [VI BLC

ProgramLoGasLimit x Assure
psi cursor is in Field 3 to
pressure limit [>]to set value [VIfor next pressure
access
gas
low limit
parameter. parameter.
~~ ~

3a. Accessgas
low [>I BLC Program LoGasLimit x Move
psi
cursor to
pressure limit. [+] value
to set next
[VIfor value,
[>] key.

4a.
Set
low gas [+I ... BLC Program LoGasLimit 1.25 psi
Movecursor to value, [>] key.
pressure limit [+I to value
set [ENTER]
when
done
Plus
[+I key will increment
pressure this for 1.25 psi .01 by the psi. With
[FAST] example.
will increment by .2 psi.

5a.
Enter low gas
[ENTER]
BLC Program LoGasLimit 1.25 psi
Gas
pressure low
limit
stored.
pressure limit [>] to
value
set for[VI next

6a. Return
to
Operate
[MODE] Auto: 10
psi
LoGasLimit 1.25 psi
Boiler
Controller is returned to
Standby
Oilmode. Flame Signal 0 V Operate
mode.
normal

b. From Operate Mode.

1b. Access
gas [VI LoGasLimit
psiAuto:
10 x psi Assure
cursor
pressureStandby
low Flame
Oil
Signal 0V is in Field 3 or 4 to
access limit parameter. gas low
pressure limit.
~~ ~~

2b.
Set gas
pressure [>] Auto: psi
10
LoGasLimit 1.25 psi
Movecursor
value,
to [>] key
low
limit parameter,[+I ... Standby Oil FlameSignal 0V Plus [+I key will increment
1.25pressure
psi is used by .01 psi. With the
example in this [FAST]
pressure
and keys[+I
will increment by .2 psi.

CB68-42
 3b.
Enter
gas pressure [ENTER]
Auto: 10 psi LoGasLimit 1.25 psi Low
gas
pressure
limit
stored.
lowvalue.
Standby
limit Oil Flame
Signal 0V

Note: This example indicatesno value was previouslyentered. Values can be changed using stepsl b through
3b if value previously
set.

9. Programming HighGas Pressure Limit

The gas pressure high limit setting provides a high pressure limit which if exceeded would result in unsafe burner oper-
ation. The high gas pressure limit setting locksoutthe Boiler Controller if a condition exists resulting in gas pressure
above the high limit setting.
The gas pressure high limit can be adjusted in the Program or Operate mode.

a. From Program Mode.

Step
Display
Press
Operation Comments

1a. Gain access to the Program mode, see 1 of this programming section.

2a. Access
high [VI BLC Program
HiGasLimit x psi Assure
cursor is
Field
3in to
pressure
gas [>I
pressure
access
gas
to
[vj-for
value
next
high
limit
set
limit

Access
3a. high
gas [>] BLC Program
HiGasLimit & psi Move cursor to value, [>] key.
pressure
[+I
limit value
to set [VI
next
for
value.

4a. Set
high gas [+I BLC Program
HiGasLimit 1.30 psi Move
cursor to value, [>] key.
pressure
limit
[+I to value
set
[ENTER]
when
done Pluskey
increment
will
[+]
1 by pressure
1.30 psi for the
T] example. this pressure [+I keys
will increment by .2psi.

5a.
Enter
high
gas
[ENTER] BLC Program
HiGasLimit
1.30 psi Gas pressure
high
limit
stored.
pressure
limit [>]to
value
set next
[VIfor

Return
6a. to [MODE] Auto: 10 psi HiGasLimit 1.30 psi Boiler
Controller is returned to
Operate
Standby Oil Game Signal 0V normal Operate mode.
mode.
~~~ ~ ~ ~ ~ ~~~~~~

b. From Operate Mode.

1b. Access gas [VI Auto: 10 psi HiGasLimit x psi Assure

cursor
pressure
high
Standby Oil Flame
Signal 0V is in Field
or 3 4 to
limit para- gas high access
meter. pressure

2b. Set
gas
pressure [>] Auto: 10 psi HiGasLimit1.30 psi Movecursortovalue, [>] key.
[+I limit high Standby Oil FlameSignal 0V Plus [+] key
will
increment
parameter, pressure by .01 psi. With the
1.30 psi is [FAST] and [+I keys pressure
used in this will increment by .2 psi.
example.

[ENTER]
gasEnter3b. Auto: 10 psi HiGasLimit 1.30 psi High
gas
pressure limit stored.
pressure high Standby
Oil
FlameSignal 0V
limit value.

entered. Values can be changedusing steps 1b through

Note: This example indicates no value was previously
3b if value previously
set.

20
 10. Programming Nominal Oil Pressure Setpoint.
The nominal oil pressure setpoint should be programmed to theoil pressure required for proper burner operation.
With this setting the Boiler Controller calculates the maximum and minimum ranges for the high
and low oil pressure lim-
its.
The oil pressure setpoint can be adjusted in the Program or Operate mode.

a. From Program Mode.

Operation Step

1a. Gain access to the Program mode, see section 1 of this programming section.

2a. Access
the [VI BLC
ProgramNomOilPress xx Assure
psi cursor is into
Field
3
oil pressure [VI
[>] to set value access
next
nominal
for oil pressure
setpoint setpoint
parameter.

3a Access
the oil [>] BLC
Program
NomOilPress xx Move
psicursor
value,
to [>] key.
pressure value
[+] to set
next
for
value
[v]

Set
4a
the oil [+]... BLC
ProgramNomOilPress 100 psi
Move
cursor
value,
to [>] key.
pressure
set- [+] to value
set [ENTER] when done
Plus [+] key will increment
by point, 100 psi
setting 1[FAST]
psi. With the
and example. this for will
increment by 20 psi.

Enter
5a. oil [ENTER]
BLC
Program
NomOilPress
pressure
Oil
100
psi setpoint
stored
pressure
setpoint. [>]tovalue
set [VIfor next

Return
6a to [MODE] Auto: 10 NornOilPressl
psi 00 Boiler
psiController is returned
to
Operate mode.
Standby Flame
Signal
Oil 0V normal
Operate mode.

b. From Operate Mode.

1b. Access
oil [VI Auto: 10 NomOilPress
psi xx Assure
psi cursor is in to
Field
3
pressure
Standby
set-Oil Flame Signal 0V access
the oil pressure setpoint
point

2b.
Set
pressure
oil [>] Auto: 10
psi
NomOilPress 100 psi
Movecursor
value,
to [>] key.
setpoint [+I Standby Oil Flame Signal 0V Plus [+] key will increment
pressure parameter, the by 1 psi. With
[FAST]
100 psi is used and [+] keys
pressure
example. in this will increment by 20 psi.

3b. Enter
pressure
oil [ENTER] Auto: 10 psi
NomOilPress
100
psi
Oil
pressure
setpoint
value. Standby Oil Flame Signal 0 V setpoint
stored

can be changed using steps 1b through

Note: This example indicates no value was previously entered. Values
3b if value previouslyset.
~ ~~

11. Programming LowOil Pressure Limit.

The oil pressure low limit setting provides alow pressure limit point which if exceeded would result in unsafe burner
operation. The low oil pressure limit setting will stop the Boiler Controller sequenceor locksout the Boiler Controllerif oil
pressure is below the lowlimit setting.
The oil pressure low limit can be adjustedin the Program or Operate mode.

a. From Program Mode.

Operation Step

la. Gain access to the Program mode, see 1 of this programming section.

2a. Access low oil [VI BLC ProgramCoOilPressLimit x psi

Assure
cursor is in Field 3 to
pressure limit [>] to
value
set [v] for next access
low oil pressure limit
parameter. parameter.

21 CB68-42
 3a.
Access
low oil [>] BLC ProgramLoOilPressLimit 1( psi Move
cursor to value, [>] key.
pressure
limit [+] to
value
set [VI
next
for
value, [>] key.

4a. low
Set oil [+]... BLC Program LoOilPressLimitlOQ psi Move
cursor to
pressure
limit [+] to value
set
[ENTER]
when
done
Plus [+] increment
key
will
pressure100 psi for digit. single by a
example. this and the [FAST] [+]
keys pressure will increment
by 20 psi.

5a.
Enter
low oil [ENTER] BLC Program~oOilPressLimitl00 psi Oil pressure
low
limit
stored,
pressure
limit [>] to
value
set [VI
next
for

6a. Return to [MODE] Auto: 10 psi LoOilPressLimitl 00 psi Boiler Controller is returned to
Operate mode. Standby Oil Flame Signal 0V normal Operate mode.
~~ ~ ~~

b. From Operate Mode.

1b. Access oil [VI Auto: 10

psi LoOilPressLimit xx psi Assure cursor
Field
or
inis
3 4 to
pressure
Standby
low Oil Flame Signal 0 V pressure
access
oillimit.
low
limit parameter.

2b.
Set oil press 1. Auto: 10 psi LoOilPressLimit 1OQ psi Move
cursor to value, [>] key.
ure
low
limit [+] ... Standby Oil Flame Signal 0 V Plus [+I
key
increment
will
pressure parameter, single digit
100 psi and [FAST] the With [+I keys
inpressure
this example. psi. 20 by
will increment

3b.
Enter oil pressure
[ENTER]
Auto:lO psi oOilPressLimitlO0 psi Low
oil
pressure
limit
stored.
value.
Standby
limit
low Oil Flame Signal 0 V

Note: This example indicates no value was previously

entered. Values can be changed using steps
1b through
3b if value previouslyset.

12. Programming High Oil PressureLimit.

The oil pressure high limit setting provides ahigh pressure limit which if exceeded would result in unsafe burner opera-
tion. The high oil pressure limit setting will stopthe Boiler Controller sequence or locksout the Boiler Controller if a condi-
tion exists resulting in oil pressure above the high limit setting.
The oil pressure high limit can be adjusted in the Program or Operate mode.

a. From Program Mode.

ration Step

1a. Gain access to the Program mode, see 1 of this programming section.

Access
2a. high [VI BLC Program HiOilPressLimit xx psi Assure
Field
cursor
inis 3 to
oil pressure
limit [>]tovalue
set [VI
pressure
access
next
oil
for
high
limit
parameter. parameter.

Access
3a.high [>I BLC ProgramHiOilPressLimit xx psi Move
cursor to value, [>] key.
oil pressure
limit. [+I
tovalue
set [VInext
for

4a. Set
high oil [+] ... BLC ProgramHiOilPressLimitl4Q psi Move
cursor to value, [>] key.
pressure
limit [+Ito value
set
[ENTER]
when done Plus [+] increment
key
will
140 psi for digit. single a by pressure
example. this [+]
keys pressure will increment
by 20 psi.

5a.
Enter
high oil [ENTER]
BLC
Program
HiOilPressLimitl4Opsi Oil pressure
high
limit
stored,
pressure
limit [>] tovalue
set [VI
next
for

22
 6a. Return
[MODE]
to Auto:lO
HiOilPressLimit
psi 140 Boiler
psiController is returned
to
Signal
Flame
Operate
Standby
Oil 0V Operate
normal mode.
mode.

b. From Operate Mode.

1b. Access oil [VI Auto: 10 psi

HiOilPressLimit xx psi
Assure
cursor is in Field 3 or 4 to
pressureStandby
high Flame
Signal
Oil 0V access
high oil pressure limit.
limit parameter.

2b.
Set oil press [>I Auto: 10 psi
HiOilPressLimitl 00 psi
Movecursor
value,
to [>] key.
ure high limit [+] ... Standby 011 Flame Signal 0V Plus [+] key will increment
pressure 100 parameter, single by a digit
[FAST] the Withexample.
psi in this [+I and
keys pressurewill increment
by 20 psi.

3b. Enter
[ENTER]
oil Auto 10 HiOilPressLimit
psi 100 High
psi oil pressure limit stored.
pressure high Flame
Signal
Standby
Oil 0V
limit value.

Note: This example indicates no

value was previously entered. Values can be changed using steps l b through
3b if value previously set.

13 Programming Nominal Oil Temperature Setpoint.

The nominal oil temperature setpoint shouldbe programmed to theoil temperature required for properburner opera-
tion. With this setting the Boiler Controller calculates the maximum and minimum ranges for theandhigh
low oil tempera-
ture limits.
The oil temperaturesetpoint can be adjusted in the Program or Operate mode.

a. From Program Mode.

Press Step Operation Display Comments

la. Gain access to the Program mode, see 1 of this programming section.

2a. Access the [VI BLC

Program NomOilTemp xxAssure
'Fcursor is in Field 3 to
oil temperature [>I to
value
set [vlfor next access
nominal oil temperature
parameter. setpoint

3a.
Access
the oil [>] BLC
Program NomOilTemp xx 'F Move
cursor
value,
to [>] key.
temperature [+] to set value [VI
for next
value.

Set
4a. the oil [+I BLC
Program NomOilTem 1OQ 'F Plus [+I
keyMovecursor value,
to
temperature [+Ito set value [ENTER] when done [>] key.will increment
setting by
setpoint, 1OO'F [FAST] the 1 'F. With and
example. this for [+] keys oil temperature will
increment by 20 'F.

Enter
5a. oil [ENTER]
BLC
Program
NomOilTemp 1OO'F temperature
Oil setpoint
stored
temperature [>] to set value [VIfor next
setpoint.

Return
6a
[MODE]
to Auto: 10NomOilTemp
psi 1OO'F Boiler
Controller is returned to
Operate
mode.
Standby
Flame
Signal
Oil 0V normal
Operate
mode.

b. From Operate Mode.

1b. Access oil [VI Auto:

10 psi NomOilTemp xx 'F Assure
cursor is in Field 3 to
temperature Standby Oil game Signal 0 V access
the oil temperature
setpoint setpoint
parameter.

23 CB68-42
 Set
2b. temp-
oil[>I Auto:lO psi NomOilTemp 1OQ 'F Move cursor to value,key. [>]
erature setpoint [+I Standby Oil Flame
Signal 0V Plus [+I increment
key
will
parameter, temperature by 1 'F. With the
100 psi for this and [FAST] [+] keys temperature
example. 20 by will increment 'F.

Enter
3b. oil [ENTER] Auto:
10 UomOilTemp
psi temperature
Oil'F
100 setpoint
stored
temperature Standby
Signal
Flame
Oil 0V
setpint value.

Note: This example indicatesn o value was previouslyentered. Values can be changedusing steps 1b through
3b if value previouslyset.

14. Programming Low Oil Temperature LimitSetting.

The oil temperature low limit setting provides alow oil temperaturelimit point which if exceeded would result in unsafe
burner operation. The low oil temperature limit setting will stop the BoilerController sequence or locksout the Boiler
Controller if a conditionexists resulting in oil temperature below thelow limit setting.
The oil temperature low limit can be adjusted inthe Program or Operate mode.

a. From Program Mode.

ation Step

1a. Gain access to the Program mode, see 1 of this programming section.

2a. Access low [VI BLC Program

LoOilTempLimit x 'F Assure
Field
cursor
inis 3 to
oil temperature [>]to
value
set [VIfor next access
low oil temperature
mit limit parameter.

3a. Access low oil [>] BLC

Program
LoOilTempLimit 3F Move
cursor to value, [>] key.
temperature value [+I [+I to set
value [VIfor
next
~~

4a. Set low oil [+I. BLC Program

LoOilTempLimit 229F Move cursor
value,
to [>] key.
temperature limit,
[+I to set
value [ENTER] when done Plus [+] key will increment
this 225'F for by temperature
digit. a single
With example. [+]
keys temperaturewill increment
by 20'F.
~~

5a.
Enter low oil [ENTER] BLC Program4oOilTempLimit
225F Oil
temperature low
limit
stored.
temperature limit. [>]tovalue
set [VI
next
for

6a. Return
to [MODE] Auto:
10 psi LoOilTempLimit 225'F Boiler Controller is returned to
Operate mode. Standby OilFlame Signal 0 V normal Operate mode.

b. From Operate Mode.

1b. Access oil Auto:

[VI 10 psi LoOilTempLimit xF Assure
Field
cursor
in is 3 to
temperatureStandby
low Oil Flame Signal 0 V access
low oil temperature limit.
limit parameter.

2b. Set oil temperature [>] Auto:

10 psi LoOilTempLimit
225FMove
cursor to value, [>] key.
low limit
[+I ... Standby Oil Flame
Signal 0V Plus [+]increment
will
key
parameter 225'F temperature
digit by a single
With
in this example. and the [FASTJ [+]
keys temperaturewill increment
by 20 'F.

Enter
3b. oil [ENTER] Auto:lO psi LoOilTempLimit
225F
Low oil temperature stored.
limit
temperature Standby Oil Flame Signal 0 V
low limit value.
~~

Note: This example indicates n o value was previouslyentered. Values can be changed using steps
l b through
3b if value previously set.

24
 15. Programming High Oil Temperature Limit
The oil temperature highlimit setting provides ahigh limit which if exceeded would resutt in unsafe burner operation.
or locksout the Boiler Controllerif a condition
The high oil temperature limit setting will stop the Boiler Controller sequence
exists resultingin oil temperature above thehigh limit setting.
The oil temperature high limit c a n be adjusted in the Program or Operate mode.

a. From Program Mode.

Press Step Operation Comments Display

la. Gain access to the Program mode, see 1 of this programming section.

Access
2a. high [VI BLC
ProgramYiOilTempLimit x 'F Assure cursor is in Field 3 to
oil temperature [>] to set value [VIforaccess
next
high temperature
oil
limit parameter. limit parameter.

3a. Access
high oil BLC
[>]
Program HiOilTempLimit xF Move cursor to value,
[>] key.
temperature
value. [+] to set value [VIfor next

Set
high
4a. oil [+] ... BLC
Program HiOilTempLimit 275F Plus [+) key will increment
temp limit, [+]to set [ENTER]
value when done temperature by a single digit.
275'F for With the [FAST] and [+I
this example. keys temperature will increment
by 20'F.

5a.
Enter high [ENTER]
oil BLC
Program
HiOilTempLimit
275F Oil temperature high limit stored.
temperature limit. [>]to set value [VIfor next

6a. Return to Operate [MODE] Auto: 10 psi YiOilTempLimit 275F Boiler Controller is returned to
mode. Standby
Flame
Signal 0V normal Operate mode.

b. From Operate Mode.

1b. Access oil [VI Auto: 10 psi HiOilTernpLimit

Assure
xF cursor
in is toField
3
temperature
Standby
Signal
Flame 0V access high oil temperature limit.
high limit
parameter.

2b.
Set oil
temperature [>] Auto: 10 psi HiOilTempLimit 2 7 r F Move cursor to value, [>] key.
high limit [+I Standby Oil Flame
Signal 0V Plus [+I key will increment
parameter,275'F singletemperature by a digit
example.in this [FAST]With the and [+I keys
temperature will increment by 20'F.

3b. [ENTER]
Enter
oil Auto:lO
HiOilTempLimit
psi 275OF High oil temperature limlt stored
temperature
Standby Oil Signal
Flame 0V
high limit value.

Note: This example indicates novalue was previously entered. Values can be changed using steps 1b
through 3b if value previously set.

16. Programming Boiler Response Factor.

A response factor is an input which matches the boiler typeto the control tightness. Five response values are provid-
ed, range 1-5. A response value of 1 provides loose control and minimizes damper motor repositions. A response value
of 5 minimizes deviations from setpoint, to accomplish this tighter controlmore damper motor repositions are required.
An initial setting of 3 is recommended, trial and error may be required to find the response factor which provides the
control band tightnessrequired. With 3 as the initial setting if tighter control is required adjust the response factor to4 or
5. With 3 as the initial setting if control tightnesscan be loosened adjust the response factor to 1 or 2.
The response factor canbe set in the Program or Operate mode.

25 CB68-42
 Program The Response Factor.

a. From the Programmode.

~~

peration Step

1a. Gain access to Program mode, see 1 of this programming section.

2a. Access the BLC

[VI Program Response x Assure
cursor
is in Field 3 to
response
factor. [>] tovalue
set access
[VI
next
for response factor
parameter.

Set3a. response
Program
BLC
[>]
Response x Move cursor to value, [>] key.
factor. [+]value
to set [VIfor next

Set
4a. response [+I ... Program
BLC Response 3 Plus [+]
increment
will
key
factor, 3 for [+] to set value [ENTER] when
done the response factorby a single
example. digit.

5a. Enter response [ENTER] BLC Program Response 3 Response factor stored.
factor. [>]
value
to set next
[VIfor

6a. Return to [MODE]

Auto: 10.0Besponse
psi 3 Boiler
Controller
returned to normal
Operate mode.
Standby Flame
Oil Signal 0V Operate mode.

b. From Operate Mode.

1b. Access resp- [VI Auto: 10 qesponse

psi x Assure cursor isField
in 3 or 4 to
onseStandby
factor Oil Flame Signal 0V access response factor.
parameter.

Set
2b. response [>] Auto: 10Response
psi 3 Move cursor to value, [>] key.
factor
para- [+] ... Standby Oil Flame Signal 0V Pluskey
will
[+I increment
this for meter, 3 factor
response digit.
by a single
example.

Enter
response
3b. [ENTER]
Auto: 10Response
psi 3 Response factor
stored.
Standby
value.
factor Oil Flame Signal 0 V
~~

Note: This example indicatesno value was previouslyentered. Values can be changed using steps 1b
through 3b if value previouslyset.

17. Programming Low Fire Rate.

Low fire rate is the minimum firing rateof the burner. The low fire rate is used at startup to fire the burner with the fir-
ing ratevalve in a low fire position to provide minimum fuel flow to provide asmooth start and safeoperating condition
during lightoff. Low fire rate is measured in termsof percent {YO}.The low fire rate can beset between 10% to 40% rate.
Low fire rate canbe set in the Program or Operate mode.

a. From Program Mode.

peration Step

1a. Gain access to Program mode, see 1 of this programming section.

~~ ~~

2a. Access the [VI BLC Program LoFire x O/O Rate Assure
cursor is in Field 3 to
low fire rate [>]to
value
set access
[VI
fire
next
low
for rate parameter.
parameter.
~

Access
low
3a. [>I Program
BLCLoFire Rate Move cursor to value, [>I key.
fire value.
rate [+I tovalue
set [VIfor next

Set
4a. fire
low [>I BLC
Program
LoFire lo"/. Rate
Move cursor to value, [>] key.
rate, 10% for [+] ... [+]to set
value [ENTER] when
done
Plus [+] key
will
increment
example. this percent by a single
the digit. With
[FAST] and [+] keys percent-
will increment by 20%.
26
 5a. Enter low fire
rate. [ENTER] BLC Program 4oFire 10% Rate Low fire
rate
stored
[>] to setvalue [VIfor next

6a. Return to [MOD E] Auto: 10 psi

LoFire 10% Rate Boiler Controller is returned to
Operate mode. Standby Oil Flame Signal 0 V normal Operate mode.
~~~~

b. From Operate Mode.

1b. Access low [VI Auto:lO psi

LoFire xx Yo Rate Assure cursorinis Field 3 or 4 to
fire rate Standby Oil Flame Signal 0 V access the low fireparameter.
rate
parameter.

2b. Set low

fire
rate
Auto:
[>] 10 psi LoFire loo/, Rate Move cursor to value, [>] key.
parameter, 10% [+I Standby Oil Flame Signal 0 V Plus [+I key will increment
is used in this percentdigit.
by a single With the
example. [FASTJ and [+I keys percent
will increment by 20%.

3b. Enter low fire [ENTER] Auto: 10 LoFire

psi 10% Rate Low rate
fire
stored.
rate value. Standby Oil Flame Signal 0 V

Note: This example indicates no value was previously entered. Values can be changed using steps 1b through
3b if value previously set.

18. Programming Rate Linearization Curve Characteristics.

Rate linearization is a user programmed parameter which is used to define the degree of rotation to which the damper
motor will drive during Drive to Purge Rate. Four rate linearization options are available. To determine which option to
select the turndown range of the burner must be known. Turndown range is the range of firing rates over which satisfac-
tory combustion may be obtained, eg the firing rate of a burner with a 4 to 1 turndown range can be varied from 25% to
100%.

Rate linearization can be programmed only in the Program mode.

Operation Step Comments

Press Display

1a. Gain access to Program mode, see 1 of this programming section.

Access
2a.rate
[VI BLC Program Rate Linearization 1 Assure cursorin is Field 3 to
linearization [>]to set value
for [VI next access rate linearization
parameter. parameter.

3a. Access
rate [>I BLC Program Rate Linearization 1 Move cursor to value, [>] key.
linearization value.
[+I to value
set [v] for next

4a. Set rate lin- [+I ... BLC Program Rate Linearization 3 Move cursor to value, [>] key.
earization, [+I
to set value [ENTER] when
done Plus [+] key will increment
3 for this example. digit. single
linearization by

Sa. Enter rate [ENTER] BLC Program Rate Linearization 3 Rate linearization curve value
linearization value. [>]to
valueset [VIfor next stored.

6a. Return to [MODE] Auto: 10 psi

Rate Linearization 3 Boiler Controller is returned to
Operate mode. Standby Oil Flame Signal 0V normal Operate mode.

19. Programming Maximum Firing Rate.

The maximum firing rate adjustment limits the firing rate of the burner. The maximum fire rate must be programmed
between the low fire rate value and 100%.
Maximum firing rate can be programmed in the Operate or Program mode.

a. From Program Mode.

Operation Step

1a. Gain access to Program mode, see 1 of this programming Section.

27 CB68-42
 ~ ~~~

Access
2a. the [VI BLC Program
MaxFire x% Rate
Assure
in
cursor
is Field 3 to
maximum
fire [>I
to
value
set [VI
access
next
maximum
for fire rate
rate

Access
3a. maximum [>] BLC
Program
MaxFire x% Rate
Move
cursor to value, [>] key.
value.
fire [+Ito
value
set next
[VIfor

maximum
Set
4a. [+j BLC ProgramMaxFire 8T/o Rate Plus [+]increment
will
key
fire rate, [+][ENTER]
value
todone
when
set percent by a single digit.
85% for this With the [FAST] and [+]
example. keys percent will increment
by 20%.

Enter
5a.
maxi-
[ENTER] BLC Program MaxFire 85% Rate
Maximum
rate
stored.
fire
mum fire rate. [>] tovalue
set [VI
next
for

6a. Return to [MODE] Auto: 10 psi MaxFire

85% Rate Boiler Controller is returned to
Operate mode. Standby Oil Flame Signal 0V normal Operate mode.

b. From Operate Mode.

1b. Access
maximum [VI Auto: 10 psi MaxFire x% Rate
Assure
cursor
inis Field 3 4or to
rate
parameter.
fire Standby Oil Flame
Signal 0V access the maximum
rate
fire
parameter.

maximum
Set
2b. [>] Auto: 10 psi MaxFire 8T/o Rate
Move
cursor to value, [>] key.
rate
parameter, [+] ... Standby
Flame
OilSignal 0V Plus [+] key
will
increment
percent used 85% is digit.
ple. this in [+I
keys percent will increment
by 20%.

3b.
Enter
maximum [ENTER]
Auto: 10 psi MaxFire 85% Rate
Maximum fire rate
stored.
Standby
rate. fire OilSignal
Flame 0V

Note: This example indicates no value was previously entered. Values can be changed using steps1 b through
3b if value previously set.

20. Programming Prepurge Extension Time

Prepurge is the period of time after burner startup during which the blower motor runs to change the airof the combus-
tion chamber and breaching prior to ignition trials. This removes any unburnedfuel so only the incoming fuel will be pre-
sent for ignition.
The Boiler Controller accomplishes prepurge by driving the damper motor from the low fire position to a specific purge
rate position {degree of rotation} and then back to low fire. The time it takes the motor to drive to the purge rate position,
as an example 68,and back to low fire enough air movement has occurred to purge the combustion chamber.
The purge extension period will add time to blower motor operation withthe damper motor at the purge rate position.
After the purge extension period has elapsed the damper mctor is driven to the low fire position for ignition trials. The
maximum prepurge extension time allowed is9000 seconds (2.5 hours or 150 minutes}.
Prepurge extension time can be set inthe Program or Operate mode.

a. From Program Mode.

Display
Press
Operation
Step Comments

1 a.Gainaccess to the Programmode,see 1 ofthisprogrammingsection.

Access
2a. the [VI BLC Program PrepurgeExtend x to Field
Assure
3 in
cursor
is
prepurge
extension [>] tovalue
set [VI
access
next
for
prepurge
extension time
time parameter.

Access
3a. prepurge [>] BLC
Program PrepurgeExtend x Move
cursor to value, [>] key
extension time [+] tovalue
set [VI
next
for
value.
 4a. Set
prepurge [+I
... BLC
Program
PrepurgeExtend 30 Move
cursor to value, [>I key.
extension
time, [+I
to set value
[ENTER]
when
done
Plus [+I key will increment
y times for seconds 30 thedigit. With
and [FAST] example. this time [+] keys will
increment by20 seconds.

5a. Enter
prepurge
[ENTER]
BLC
Program
PrepurgeExtend 30 Prepurge
extension
time
stored.
extension
time [>]to set value [VIfor next
value.

6a. Return
to [MODE] Auto: PrepurgeExtend
psi
10 30 Boiler Controller is returned to
Operate mode. StandbyOilFlameSignal 0V normal Operate mode.

b. From Operate Mode.

1b. Access
prepurge [VI PrepurgeExtend
psi10
Auto: x Assure
cursor is in Field
3 or 4 to
extension time Standby Oil Flame Signal 0V access
prepurge
extension
time.
parameter.

2b. prepurge
Set Auto:
[>I PrepurgeExtend
psi
10 3Q Move
cursor to value, [>I key.
extension [+] ... Standby
Flame
Oil
Signal 0V Plus [+I key will increment
time,seconds
30 seconds single by a the
digit. With
and [FAST]
is used in this seconds
[+I keys
example. seconds.
will increment by 20

3b. Enter
prepurge
[ENTER]
Auto:
PrepurgeExtend
psi
10 Prepurge
30 extension
time
stored.
extension
Flame
Signal
Standby
time
Oil 0V
value.

Note: This example indicates novalue was previouslyentered. Values can be changed using steps 1b through
3b if value previously set.

21. Programming Postpurge Extension Time.

Postpurge is the period of time after run during which the blower motor continues to run drivingall products of combus-
tion and any unburned fuel from the combustion chamber and supplying toairburn fuel being purged from the fuel line
downstream of the safetyshutoff valve{s}. The Boiler Controller provides a15 second postpurge. The maximum post-
purge extension time allowedis 9000 seconds (2.5 hours or 150 minutes}.
Postpurge extension can beset in the Program or Operate mode.

a. From Program Mode.

Operation Step Display Comments

la. Gain access to the Program mode, see section 1 of this programming section.

2a. Access
the [VI BLC Program PostpurgeExtend x Assure cursor is intoField
3
postpurge
ext- [>] to
value
set [VIfor next access
postpurge
extension
time
ension time
parameter.

3a. Access
postpurge [>] BLC Program PostpurgeExtend li Move
cursor to value, [>] key.
extension
time. [+I tovalue
set [VIfor next

4a. Set postpurge [+I... BLC

Program
PostpurgeExtend 15 Plus [+I key will increment
extension
time, [+I to set
value [ENTER] when done
seconds bysingle
a digit. With
the
T] for seconds 15 seconds
and [+I keys
example. this will increment by 20 seconds

5a. Enter
postpurge
[ENTER]
BLC Program PostpurgeExtend Postpurge
15 extension
time
stored.
extension
time [>]to set value [v] for next
value.

6a. Return
to [MODE]
Auto:
1 Opsi EostpurgeExtend 15 Boiler Controller is returned to
Operate mode. StandbyOilFlameSignal 0V normal Operate mode.

29 CB68-42
 b. From OperateMode.

1Access
b. postpurge [VI Auto: 10 psi PostpurgeExtend xx Assure
cursor
Field
inis 3 4or to
extension time Standby Oil Flame Signal 0 V access
postpurge
extension
time.
parameter.
~~

postpurge
Set
Auto:
2b.
[>] 10 psi PostpurgeExtend 15 Move cursor to value, [>] key.
extension
time, [+I Standby Oil Flame
Signal 0V Plus [+Iincrement
will
key
by seconds is 15 seconds the
in used this and seconds
[FAST] [+Ikeys
will example. seconds by 20

3b.
Enter
postpurge
[ENTER] Auto: 1Opsi PostpurgeExtend 15 Postpurge
extension
time
stored.
extension
Standby
time Oil Flame Signal 0 V
value.

Note: This example indicatesno value was previouslyentered. Values can be changed using steps
1b through
3b if value previouslyset.

22. Accessing Historical Data.

The Boiler Controller retains historical files of the total hours of operation, total number of cycles, and history of the
last 6 lockouts. Each fault lockout provides the cycle when the fault occurred, hour of operation when fault occurred, spe-
cial fault code to be used by service mechanic to aid in troubleshooting, actual fault description ie Steam Sensor, and the
activity of burner when fault occurred when the fault occurred ie Run Low Fire Cutoff.
Historical data can beaccessed only in the Operate mode.

ration Step

1. Access historical [VI Auto: 8.0 psi OperSetpoint 7.7 psi Assure
cursor
inis Fieldor3
data parameter.
Run Fire 80% History Data No 4 to access
historical
data.

Select
history
2. [>] Auto: 8.0 psi OperSetpoint 7.7 psi Move cursor to No. Plus [+I
data parameter. [+] Run Fire 80% History
Yes
Data key will select Yes option to
open History Data file.

3. Select yes.
[ENTER]
Auto: 8.0 psi OperSetpoint 7.7 psi The [ENTER] key will
open
RunFire 80% H: Iota1 Hours12345history data files.Firstexample
indicates total hours of
operation, 12,345.

4. Select
next [VI Auto: 8.0 psi OperSetpoint 7.7 psi The [VI
key will scroll
through
parameter.
FireRun 80% H:IotalCycles
parameters.
Data
History
23456

5. Return to first
[CLEAR]
Auto: 8.0psi OperSetpoint 7.7 psi Select
another
parameter
or
level history
Fire
Run
data 80% HistoryData?
No discontinue search.
prompt to exit
history file.

23. Accessing Diagnostic Information.

The Boiler Controller provides diagnostic information as an aide in troubleshooting the system, The Diagnostic
Information parameter can accessed only in the Operate mode.

ration Step

1. Place
cursor 1.1 Auto: 8.0 psi OperSetpoint 7.7 psi Assure
cursor Field
in is or3
to Fire
access
Run 80% CoFireRate 25 o/o 4 to access
Diagnostic
Diagnostic example this Information. For
Information will 4 field be used to display
parameter. Diagnostic

2. Access Diag- [VI Auto: 8.0 OperSetpoint

psi 7.7 psi Use [VIkey to access the
nostic
parameter
Fire
Run 80% Diagnostic
Info? No Diagnostic
parameter.

30
 3. Select diagnos [>] Auto: 8.0 psi
OperSetpoint 7.7 psi Move cursor to No. Plus [+] key
tic parameter. [+I Run
Fire 80% Diagnostic Info? Yes will select Yes option to open
Information Diagnostic [ENTER]
[ENTER] key opens Diagnostic
Info file.
~~

4. Continue display [VI Auto: 8.0 psi OperSetpoint 7.7 psi scroll to the next
The [VIkey will
play of Diagnostic
Run
Fire 80% I:GasPressSensor .5V diagnostic parameter. In this
file. the pressure case gas sensor
is signaling .5Vdc. Field 3 could
be accessedto display the actual
gas pressure along with the vottage
signal as a checkto assure
proper gas pressure sensor
operation.

5. Continuethrough remaining diagnostic information displays following step 4 as required.

6. Return to the
[CLEAR] Auto: 8.0 psi OperSetpoint 7.7 psi Another display parameter or
level
first of Fire
Run 80% Piagnosticlnfo? No discontinue
accessing Diagnostic
Diagnostic review by using the [>] key
[Enter] and Information select No.
data prompt.

24. Different Module?

The Boiler Controller will have future addon modules which will beable to control firingrate, eg Lead-Lag and
Indoor/Outdoor Reset. In structuring the system an option was created for identification of what system module was con-
trolling the sequence. The Different Module selection indicates what is located on the three wire RS485 ControlBus and
what options are available to be choosen for sequence control.

Operation Step Comments

1. Gain access to Program mode,see 1 of the Programming section.

2. Access
the [VI Program:
BLCDifferent Module? No Assure the cursor is in Field 3
Different Module [>I to set value [VIfor next to access theDifferent
Module parameter.

2. Select Different [>] BLC

Program: Different Module? Yes Move cursor to No. Plus [+I
Module
[+I [+I to set valve [VIforkey
next will select Yes option to
"open"
parameter. [ENTER] Different Module
parameter. ENTER opens
parameter.

3. Review
options [VI OPTIONS: Boiler Controller Option to select control Boiler
for Different [VIto view [ENTER] to select Boiler Controler option.
Module.

4. Review
options [VI OPTIONS:
KeyboardDisplay Module Keyboard
Theand Display
for Different [VIto view have
does not the ability to
control Module. sequence. It
therefore cannot beselected.
It does however sit on the
ControlBus and is therefore
listed.

25. Programming The Boiler Model Number

The boiler modelnumber identifies operating parametersof the applied equipment for the Boiler Controller.
The boiler model numberconsists of the following
A B C D E
Model xx - xxx - xxx - xxx - xx
A) Boiler type
B) Fuel series
C) Boilerhurner size
D) Design pressure
E) Medium
31 CB68-42
 The boiler modelnumber can only be enteredwhile in the Program mode, seeinstructions under Gaining Access to the
Program mode.

on Step Press
Comments Dlsplay

1. Gainaccess to Program mode,see 1 of the Programmingsection.

2. Access the [VI BLC PROGRAM Model xxxxxxxxxxxxx Model number is not defined.
number
Model [>]value
to set
parameter.

3. Cursor to [>I BLC PROGRAM Model

x~xxxxxxxxxxx
boiler type. [+I value
to set next
[>] for

~ 4. Set boiler
type [+I ... BLC PROGRAM Model ~ x x x x x x x x x x x WT for
watertube
or
CBfor
Firetube
type, watertube [+] to
value
set [>I for next
for thisexample.

5. Cursor to fuel BLC

[>] PROGRAM Model WTxxxxxxxxxxx
series. [+] to set
value [>] for next

6. Set fuel
series
[+I ... BLC PROGRAM Model WT4OQxxxxxxxx Plus {+) key
will
increment
series
example
this
for [+I
to
value
set [>]
by
next
for 100.
#6 oil and gas.

7. Cursor to [>I BLC PROGRAM Model

WT4OOxx~xxxxx
boiler size. [+I to set
value [>] for next
~~ ~~

8. Set
boiler
size ...
[+I BLC PROGRAM Model WT400BR~xxxxx Plus {+) key will scroll size options
example
this
for [+I
tovalue
set [>] for next 1/2
per
one second.
BR3, must have
some value.

9. Cursor to Design [>I BLC PROGRAM Model

WT400BR3xx~xx
Pressure. [+] to set value[>] for next

10. Set
design ...
[+I BLC PROGRAM Model Wr400BR34OQxx Plus {+) key will increment
pressure,this
for [+I
to set value [>]next
for pressure by a single
digit. If
example 400, FAST key is used with the [+I
essuresome have must will increment by 20 psi.
value.

11. Cursor to output [>] BLC PROGRAM Model WT400BR3400x~

medium. [+]
[ENTER]
value
when
to set done

12. Set
output [+I ... BLC PROGRAM Model
WT400BR3400SI
ST for
steam, HW for
hot
water.
medium,this
for [+I
to value
set [ENTER] when
done
example steam.

13. Enter
model
[ENTER]
BLC PROGRAM New Model# selected
number [VIto enter model # again to verify

Verify
14. model [VI BLC PROGRAM Modelxxxxxxxxxxxxx Verify model number, complete
number. to set
[+Ivalue [>I for
steps
next through4 12.
~~

15. Enter
verii- [ENTER] BLCPROGRAM New model# veriiied
Second entry the
same as the first.
ied number. [VIto continue
~~ ~ ~~~ ~ ~ ~~

16. Return to [MODE] Auto: 10.0 psi QperSetPoint 8.0 psi The BoilerController is returned to
operate Standby Oil Flame signal 0V to normal
Operate mode.
 26. Programming the Steam Pressure Sensor
The steam pressure sensor provides input to the rate control to determine on/off cycling of the burner and firing rate
adjustments needed to match the burner firing rate to the load on the boiler. Four settings are required for proper steam
pressure sensor operation. These are, steam sensor range, boiler on, boiler off, and operating setpoint.
The steam sensor range must be entered while in the Program mode. See instructions under gaining access to the
Program mode, #1 of this programming section.

26A Program Steam Sensor Range

Operation Step

1.Gain access to the Program mode, see section 1 of this Programming section.

2. Access steam [VI BLC Program SteamSensRange 15 psi Assure cursor is in Field 3 to
sensor range value
set to [>] [VI
next
for access steam sensor range
parameter. parameter.

3. Set steam sensor [>] BLC Program SteamSensRange 15 psi Move cursor to value, [>] key.
range 15psi for [+I
... [+] to
set
value [ENTER] when done Plus [+I key will scroll through
this example. the the pressures by the
available pressure ranges, 15 or
150 or 300 or 750 psi.

4. Enter steam [ENTER] BLC Program SteamSensRange 15 psi Steam sensor range stored.
sensor range. to[>] set value [VI
next
for

5. Return to [MODE] Aut0:lO.O psiSteamSensRange 15 psi Boiler returned to normal

Operate mode. Standby Oil Flame Signal ov Operate mode.

268 Program Steam Sensor Operating Setpoint.

a. From ProgramMode.

Operation Step

1a. Gain access to Program mode, see 1 of this programming section.

2a. Access steam [VI

BLC Program QperSetpoint x psi Assure the cursor is in Field 3 to the
sensor opera- [>] value
to set [VIfor next operating setpoint
parameter.
ting setpoint
parameter.

3a. Access steam [>] BLC Program OperSetpoint psi x Move cursor to value, [>I key,
sensor opera value
[+]to set [ENTER] when done
ting set point
value.

4a. Set steam sensor [+] ... BLC Program OperSetpoint 10 psi Move cursor to value, [>] key.
operating set [+I
to set
value [ENTER] when done Plus [+I key will increment psi by a
digit. point,
single
10 psi for With the [FASTJ and
this example. psi [+I
increment
keys will by 20 psi.

5a. Enter steam [ENTER] BLC Program DerSetpoint 10 psi Operating setpoint
stored.
sensor oper- [>I
to set value [VI
for next
ating setpoint
value.

6a. Return
[MODE]
to Auto: 10 psi OperSetpoint 10 psi Boiler is returned to normal
Operate mode. Standby Oil Fame Signal 0V Operate mode.

33 CB68-42
 b. From OperateMode.
~~ ~

1 b. Access steam [VI Auto: 12 psi QperSetpoint x psi Assure

cursor inis Field 3 or 4 to
sensor
operating
Standby
Oil Flame Signal 0V accessoperating
thesetpoint.
setpoint
parameter.
~~

2b.
Set
steam
sensor [>] Auto: 12 psi OperSetpoint 1Q psi Move cursor to value, [>] key.
sensor
operating
[+I ... Standby Oil Flame Signal 0V Plus [+I key
will
increment
setpoint With digit.psi by a single the
nd [FAST] parameter, [+I keys psi will
10 psi for this increment by 20 psi.
example.
~~

Enter
3b. steam [ENTER] Auto: 12 psi QperSetpoint 10 psi Operating
setpoint
stored.
operating
Standby
sensor Flame Signal 0V
setpoint value.

Note: This example indicatesno value was previouslyentered. Values can be changed using steps
1b through
3b if value previouslyset.

26C Program Boiler OnLimit Parameter.

a. From ProgramMode.

ation Step
~

1a Gain access to Program mode,see 1 of thisProgrammingsection.

2a Access
boiler [VI Program
BLC Boileron x psi Assure the cursor is in Field 3 to
on parameter. [>] to set value [ENTER] when done access low operating limit
parameter.

Access
3a. boiler on [>] BLC ProgramBoilerOn -x psi Move cursor to value, [>] key.
parameter value. [+]tovalue
set [VI
next
for
~~ ~ ~ ~ ~~~

4a Set boiler on [+I ... BLC Program BoilerOn lQ psi Plus [+I key will increment pressure
limit
value. [+] to value
set [ENTER] when
done by a single
digit.
With the [FAST]
and [+I keys pressure will increment
by 20 psi.
~~

Enter
sa.
boiler on [ENTER] BLC
Program BoilerOn 10 psi Low
operating
limit
stored.
parameter.
[>] value
to set [VI
nextfor

Return
6a. to [MODE] Auto: 10 psi Boileron 10 psi Boiler Controller is returned to
Operate mode. Standby Oil Flame Signal 0V normal Operate mode.

b. From OperateMode.

1Access
b. boiler on [VI Auto: 10 psi BoilerOn x psi Assure
cursor
Field
inis 3 or 4 to
parameter.
Standby Oil Flame Signal 0V access the boiler on parameter.

2b. boiler
Set on [>I Auto: 10 psi BoilerOn lQ psi Move
cursor to value, [>] key.
parameter, [+I Standby
Flame
Signal
Oil 0V Plus [+]
increment
will
key
for 10 psi the With psi
digit.
by a single
[FAST] example. this [+Ikeys psi will
increment by 20 psi.

Enter
3b.
boiler
[ENTER]
Auto: 10 psi Boileron 10 psi Boiler on value
stored.
Signal
Flame Oil
Standby
on value. 0V

34
 Note: This example indicates no value was previously entered. Values can be changed using steps1b through
3b if value previously set.

26D Program Boiler Off Parameter.

a. From Program Mode.

Operation Step Comment

Press Display

1a. Gain access to Program mode, see 1 of this Programming section

2a. Access
boiler [VI BLC Program BoilerOff x psi Assure cursor
the is in Field 3 to
off parameter. to[>] value
set [VIfor next access
boiler
the of parameter.
~~ ~

Access
boiler
3a. [>] BLC Program
BoilerOff x psi
Move
cursor
to
value, [>] key.
off value. [+I to set[ENTER]
value whendone

Set
4a. boiler off [>I BLC Program Boilem 12Plus
psi key
[+] will increment
psi by
parameter, [+I to set value
[ENTER] when done
single digit. With
[FAST]
the and [+]
s this for psi 12 will increment by 20 psi.
example.
~~

Enter
5a.
boiler
[ENTER]
BLC Program BoilerOff 12 psi Boiler off value stored.
off value. [ >value
] t o set [VIfor next

Return
6a to [MODE]
Auto: 10.0BoilerOff
psiBoiler
psi
12 is returned
normal
to
Operate
mode. Standby Oil Flame Signal 0V Operate
mode.

b. From Operate Mode.

1b. Access
boiler [VI Auto:BoilerOff
psi
10 x psi Assure cursor
in is Field 3 or
off parameter.
Standby
Flame
Oil
Signal 0V access
4 to boiler
the off parameter.

2b Set boiler off 1.1 Auto: 10 psi BoilerOff 12Move

psi
cursor to value, [>] key.
parameter. [+] ... Standby
Flame
Oil
Signal 0V Plus [+I will
key increment
pressure by a single digit. With the
[FAST] and [+] keys psi will
increment by 20 psi.

3b. Enter
boiler
[ENTER] Auto: 10BoilerOff
psi 12Boiler
psi off value stored.
Signal
Flameoff
Standby
Oilvalue. 0V

Note: This example indicates no valuewas previously entered. Values canbe changed using steps 1b through
3b if value previously set.
~~

27. Programming The Hot Water Temperature Sensor.

The hot water temperature sensor provides input to the Boiler Controller rate control to control on/off cycling of the
burner and firing rate adjustments to match the burnerfiring rate to the load on the boiler. Four settings are required for
proper temperaturesensor operation. These are; water sensor range, operating setpoint, boiler on and boiler off.
The hot water sensor range mustbe entered while in the Program mode. See instructions under gainingaccess to the
Program mode. The operating setpoint, boileron and boiler off can be changed in the Operate or Program mode.

27A Program Water Sensor Range

Operation Step

1. Gainaccesstothe Program mode,see 1 of thisProgrammingsection.

Access
2. water [VI BLC Program WaterSensRange x 'F Assure
cursor is in Field 3 to
sensor range sensorwater
[>]to
access
set value range
parameter. parameter.

35 CB68-42
 3. Set
water
sensor
[>] BLC Program
WaterSensRange 30pF Move cursor to value, [>I key.
range300'F
for [+] ... [+I
to set
value [ENTER] when
done Plus [+I key
will
scroll through the
example. this temperatures by the available
ranges, 300'F or 500'F
~~

4. Enter
water [ENTER] BLC
Program WaterSensRange 300'F Water
sensor range stored.
sensor
range.
[>] tovalue
set [VI
next
for

5. Return to [MODE] Auto:

175'F WaterSensRange 300'F Boiler
returned to normal Operate
Operate
Standby
mode. Oil Flame Signal ov mode.

278 Program Hot Water Sensor Operating Setpoint.

a. From ProgramMode.

Press Step Operation

1a. Gain access to Program mode,see 1 of this programming section.

Access
2a. water [VI BLC Program mersetpoint x 'F Assure
cursor
the is in Field 3 to
sensor opera- to [>] set value [VIforoperating
access
next
the
setpoint
ting setpoint parameter.
parameter.

Access
3a.
water [>] BLC Program
OperSetpoint 'F Move cursor to value, [>] key.
sensor operating [+I
tovalue
set [VIfor next
set point, value.

4a.
Set
water
sensor[+I ... BLC ProgramOperSetpoint 20pF Move cursor to value, [>] key.
operarating set [+]tovalue
set [ENTER] when
done
Plus [+I key
will increment
by temperature
point, 200F for digit, a single
with this example. the [FAST] and [+] keys
temperature will increment by
20 degrees.

Enter
water
5a. [ENTER] BLC ProgramQperSetpoint 200'F Operating setpoint
stored.
sensor
operating [>] tovalue
set [VInext
for
setpoint value.
~~~ ~

6a. Return to [MODE] Auto:

175'F
QperSetpoint 200'F returned
Boiler
is to normal
Operate Standby
mode. Oil Flame Signal 0V Operate mode.

b. From OperateMode.

Access
1b. water [VI Auto:
175'F
QperSetpoint x 'F Assure
cursor is in Field 3 or 4 to
sensor
operating
Standby Oil Flame Signal 0V access
operating
thesetpoint.
setpoint
parameter.

Set
2b.
water
sensor [>] Auto: 175'F OperSetpoint
200F Move cursor to value, key.
[>]
operating set- [+I ... Standby Oil Flame Signal 0V Plus [+] key
will increment
parameter,
point the with degrees
digit,by a single
200'F for this and [FAST] [+Iwill
keys degrees
increment example.

Enter
water
3b. [ENTER] Auto:
175'F
QperSetpoint 200'F Operating
setpoint
stored.
sensor
operating
Standby Oil Flame Signal 0V
value.

Note: This example indicates no value was previously

entered. Values can be changed using steps
1b through
3 b if value previouslyset.

36
 27C Program Hot Water Boiler On Parameter.

a. From Program Mode.

Display
Press
Operation
Step Comments

la Gainaccess to Programmode, see 1 of thisProgrammingsection.

2a Access
boiler [VI BLC
Program Boileron Assure
xaF
cursor
the is in Field
3 to
on parameter. [>I to set value [VI
next
for access
boiler on parameter.

3a. Access
boiler [>] BLC ProgramBoilerOn
Move
cursor
xF to value, [>] key.
parameter.
on [+I to set value [v] for next
~~

4a Set boiler [+] ... Program

BLCBoilerOn 17FF Plus [+] key will increment
value.
on [+Ito set value
[ENTER] when done
temperature by
single
a digit.
With the [FAST] and[+] keys
temperature will increment by
20 degrees.
~~~~ ~

Enter
boiler
5a.
[ENTER]
Program
BLC Boileron 175F Boiler on value
stored.
on parameter. [>] to set value [VIfor next

6a. Return to [MODE] Auto: 175'F Boileron Boiler

175'F Controller
returned to
Operate
mode. Standby
Flame
Signal
Oil 0V normal
Operate
mode.

b. From Operate Mode.

lb. Access
boiler [VI Auto: 175'F Boileron Assure
x"Fcursor is in Field 3 or 4 to
on parameter.
Standby
Flame
Oil
Signal 0V access
boiler
the on parameter.

2b. boiler
Set
on b-I Auto:
175'F BoilerOn 17FF Move
cursor to value, [>] key.
parameter, [+I StandbyFlame
Oil
Signal 0V Plus [+] key will increment
degrees
for 175'F single
[FAST] by a the digit. With
and example. this keys [+I degrees will increment
by 20.

3b. Enter
boiler
[ENTER] Auto: 175'F
BoilerOn
175F
value
Boiler
on stored.
on value. Signal
Flame
Standby 0V

Note: This example indicates no

value was previously entered. Values can be changedusing steps 1b through
3b if value previously set.

27D Program HotWater Boiler Off Parameter.

a. From Program Mode.

Operation Step

1a. Gain access to Program mode, see 1 of this Programming section

2a. Access
boiler [VI BLC
ProgramBoilerotr xAssure
"Fcursor
the is in Field
3 to
off parameter. [>] tovalue
set [VIfor next access
boiler
the off parameter.

3a. Access
boiler off [>] BLC
Program
Boileroff g'F Move
cursor to value, [>] key.
value. [+I
to set value [VIfor next

37 CB68-42
 Set 4a. [>I BLC Program Boileroff Plus
225F [+] key
increment
will
boiler off [+I tovalue
set
[ENTER]
when
done
degrees
by 1 digit.
With the
[FAST] parameter, degrees [+I
keys
ent will 225 'F for by 20
this example.

[ENTER]
Program
Enter
BLC
5a. Boileroff Boiler
225F offstored.
value
boiler off. [>I value
to set [VI
next
for

[MODE]
Return
Auto:
175'F
to6a Boileroff 225F
Boiler is normal
returned
to
Operate
Standby
mode. Oil Signal
Flame 0V Operate
mode.

b. From Operate Mode.

ration Step

Access
1b. [VI 175'F
Auto: Boileroff inxxx"F
Assure
cursor
is Field
or 3
boiler off Standby Oil Flame
Signal 0V 4 to access the boiler off
parameter parameter.

2b Set [>I 175'F

Auto: Boileroff cursor
Move
225F to value, [>I key.
boiler off [+I ... Standby Oil Flame
Signal 0V Plus [+]increment
will
key
temperature parameter.
With the [FAST] and [+I keys
degrees will increment by 20

Enter
3b. boiler off [ENTER]
Auto: 175'F
Boileroff 225F
Boiler off value
stored.
Signal FlameStandby
value. 0V

Note: This example indicatesno value was previously entered. Values can be changed using steps1b through
3b if value previously set.

28. Programming Gas Pressure Sensor Range

The gas pressure sensor range is the maximum gas pressure the sensor is designed to sense, As an example the
817-2092 has a range of 0.5 to 5.0 psi. The Boiler Controller requires the gas pressure sensor range be programmedto
5.0 psi to identify this gas sensor as being applied.
The gas pressure sensor range can be set only when in the Program mode.

ration Step

1. Gainaccess to the Programmode,see 1 of this programmingsection.

Access
2. gas [VI BLC
Program
GasSensRange x psi Assure
cursor
in is Field
to 3
pressure
sensor [>]to
value
set [VI
sensor
access
range
next
gasfor
range

3. Access
gas [>I Program
BLCGasSensRange psi Move
cursor to value, [>] key.
pressure
sensor [+I tovalue
set
[ENTER]
when
done
range value.

4. Set
gas
pressure [+] ... BLC
Program
GasSensRange 5 psi Movecursor to value, [SI key.
sensor
range, [+I
to value
set
[ENTER]
when
done Plus [+I scroll
key
will
through this 5 psi for ranges,
the available
example. ~ ~1 .O psi or 2.0 psi
1 5 . 0 " or
or 5.0 psi or 15.0 psi.

[ENTER]
Enter
gas
4.
Program
BLCGasSensRange 5 psi pressure
Gas
pressure sen- [>]value
to set [VI
range
sensor
nextfor
sor range.

5. Return to [MODE] Auto: 10 psi GasSensRange 5 psi Boiler returned to normal

Operate
Standby
mode. Oil Signal
Flame 0V Operate
mode.

38
 29. Setback Control
The Boiler Controller allows for programming a normaloperating setting and setback settings. The Keyboard and
Display Module accesses a setback parameter which shifts control to these setback points. Five settingsare required for
setback operation. These are setbacksetpoint, setback boiler off, setback capable, setbackmode, and setback boileron.
These settings are shown separately noted below.

29A Setback Capable

Setback capableis a selectionto indicate if this boiler controller will or will not utilize the setback modeoption.
Selecting setback capableallows entry of setback data. If setback capable is not chosen the setback datawill not be
entered.
~~~~

lay PressOperation Step Comments

1a Gain access to Program mode, see 1 of this programming section.

~~~~ ~~~~ ~

2a Access
set- [VI BLC Program
Setback
Capable?
Assure
No the cursor
in is
back cap- to [>] set value [VIfor next Field 3 to access the setback
able. capable mode parameter.

3a. Select setback

[>]
BLC
Program:
Setback
Capable? NQ Move
cursor
to No, [>I key
capable
[+I to set value [VIfor next

4a. Set setback [+I BLC

Program
Setback
Capable? Yes Move
cursor to value,
key.
[>]
capable. [>] to set value
[ENTER] when done
key
Plus
[+I will select Yes.

Sa Enter
setback
[ENTER] BLC Program Setback
Capable? Yes Setback
capable entered.
capable.. [>] to set value [VIfor next

6a Return to [MODE] Auto: 10 Setback

psi Mode? Yes Boiler is returnednormal
to
Operate
Flame
mode.
Signal
Standby
Oil 0V Operate mode.

298 Selecting Setback Mode

The Boiler Controlleris placed in the setback mode at the Keyboard andDisplay Module. The following format is
used. This format is shown in both the operate and programmode. This mode would normally be entered in the operate
mode.

a. From ProgramMode.

1a. Gain access to Program mode, see 1 of this programming section.

2a. Access
setback [VI BLC
Program
Setback
Mode?
No
Assure the cursor isField
in 3 to
mode
parameter [VIfor next
[>] to set value access
setback
the
mode
parameter.

3a Select set- [>I BLC

Program
Setback
Mode? NQ Move
cursor to No, [>] key.
back mode. [+I to set value [VIfor next

~~~~~~ ~ ~

4a. Set setback

BLC
[+I
Program
Setback
Mode? Yes Move cursor to value, [>] key.
mode. [+I tovalue
set [ENTER] when done key
Plus
[+I will select Yes.
~~ ~

Sa. Enter
setback
[ENTER]
BLC
Program
Setback
Mode? Yes Setback
mode entered.
mode. 1.1 to set value [VIfor next

6a Return to [MODE] Auto: Setback

psi
10 Mode? Yes Boiler is returned to normal
Operate mode. Flame
Standby
Oil Signal 0V Operate
mode.

b. From Operate Mode.

Step
Operation Display Press Comment

lb. Access setback [VI Auto: 10Setback

psi Mode? No Assure cursor is in Field 3 or 4
mode
parameter.
Standby
Flame
Oil Signal 0V to access the setback mode
parameter.

39 CB68-42
 2b. Select setback [>I Auto: 10 psi Setback
Mode? Yes. Move
cursor to value, [>] key.
mode [+I ~~~~ ~~ ~~
Standby Oil Flame Signal 0V Plus [+] key will select Yes.

3b. Enter setback

[ENTER] Auto: 10 Setback
psi Mode? Yes Setback
mode
selected.
Standby
mode. Oil
Signal
Flame 0V

29C Program Setback SetpointParameter.

a. From ProgramMode.

ation Step
~~ ~~~~ ~

la Gain access to Programmode,see section 1 of thisProgrammingsection.

2a Access
setback [VI BLC Program SetbackSetPt x Assure the cursor
is in Field
3 to
setpoint parameter [>I
tovalue
set [VI
access
next
for
setback
setpoint
parameter.

3a. Access set- [>I Program

BLCSetbackSetPt 5 Move cursor to value, [>] key.
back setpoint [+]to
value
set [VI
next
for
value.

Set
4a setback [+I ... BLC
Program
SetbackSetPt 19 psi
Plus [+I key
will
increment pressure
setpoint
value, [+] to set
value [ENTER] when
done by a single digit. With
the [FAST]
for 10 psi and [+] keys pressure will
increment this example. by 20 psi.

5a. Enter
setback [ENTER]
BLC Program SetbackSetPt 10 psi Setback
setpoint
stored.
setpoint parameter. [>] to set value [VIfor next

6a. Return to [MODE] Auto: 10 psi SetbackSetFt 10 psi Boiler

Controller
is returned to
Operate mode.
Standby Oil Flame
Signal 0V normal
Operate mode.

b. From Operate Mode.

ation Step

1b. Access setback [VI Auto: 10 psi SetbackSetPt x Assure

cursor is in Field3 or 4 to
setpoint parameter. Standby Oil Flame Signal 0 V access the setback
setpoint
parameter.

setback
Set
2b. [>I Auto: 10 psi SetbackSetPt 1Q psi Move
cursor to value, [>] key.
setpoint [+I Standby Oil Flame Signal 0 V Plus [+]
increment
will
key psi by
parameter, a single digit.
and
With the [FAST1
for 10 psi psi [+I keys will increment by
this example. 20 psi.

Enter
3b. setback
[ENTER] Auto: 10 SetbackSetPt
psi 10 psi Setback
setpoint
stored.
setpoint Standby
value. Oil Flame Signal 0 V
~~ ~

Note: This example indicatesno value was previouslyentered. Values can be changed using steps1b through
3b if value previouslyset.

29D Program Setback BoilerOn Setpoint.

a. From ProgramMode.

ation Step

1a. Gain access to Program mode, see 1 of this programming section.

~~~ ~~

2a. Access
setback [VI BLCProgram SetbkBoiferOn x Assure the cursor
is in Field3 to
boiler
setpoint
on [>]to set value [v]
access
next
for the setback boiler on
parameter. parameter.

40
 Access
Program
BLC
3a.
[>I
set-
SetbkBoilerOn x Move
cursor to value,
[>I key.
back
boiler on [+I
value
set
to [VIfor next
value.

4a.
Set setback [+I ... BLC
Program
SetbkBoilerOn 1 1 psi
Movecursor
value,
to [>] key.
boiler on setpoint, [+]to set value
[ENTER] when done
Plus [+I key will increment
psi by
le a this for 11 psi [FAST] the digit. With and
example. psi [+I keys will increment by
20 psi.
~~ ~~ ~~~ ~~ ~~~

5a. Enter
setback
[ENTER]
BLC
Program
SetbkBoilerOn 11 psi
Setback
boiler
stored.
on
boiler on setpoint [ > ] t o set value [VI
for next
value.

6a. Return
[MODE]
to Auto: 11 SetbkBoilerOn
psi 11 psi Boiler is returned
normal
to
Operate
Standby
mode. Signal
Flame
' 0V Operate
mode.

b. From Operate Mode.

Operation Step Display Comment

1b. Access
setback [VI Auto: 11 SetbkBoilerOn
psi x Assure
cursor in is Field
3 or
boiler on setpoint
Standby
Flame
OilSignal 0V access
to 4 the setback
boiler
parameter. on

Set
2b. setback
[>I Auto: 11 SetbkBoilerOn
psi 1 1Move
psi
cursor to value, [>] key.
boiler on setpoint [+I ... Standby
Oil
FlameSignal 0V Plus [+I key will increment
psi by
single parameter,
a 11 psi [FAST] thedigit. With and
example. this for psi [+I keys will increment by
20 psi.

3b. Enter
setback
[ENTER]Auto: 11 psi
SetbkBoilerOn 11 psi
Setback
boiler
stored.
on
boiler on setpoint
Standby
Flame
Signal
Oil 0V
value.

Note: Thisexample indicates novalue was previouslyentered. Values can be changed using steps 1b through
3b if value previouslyset.

29E Program Setback Boiler Off Parameter.

a. From Program Mode.

Step Operation Press Display Comment

la. GainaccesstoProgrammode, see 1 of thisProgrammingsection

2a. Access
setback [VI BLC Program SetbkBoilerOff x Assure the cursor is in Field 3
boiler off parameter [>] to set value [v] for next to access the setback boilerof
parameter.

Access
3a.
setback [>] Program
BLC SetbkBoilerOff Move
value,
cursor
[>]
to key.
boiler off value
to[+I set value [VIfor next

Set
4a. setback [+I BLC
Program SetbkBoilerOff 12Plus
psi [+I key will increment
psi by
boiler off [+I
tovalue
set [ENTER] when donesingle digit. With
the [FASTJand
parameter, psi [+I keys will increment by
psi 12 psi.
this example.

5a.
Enter
setback
[ENTER]BLC
Program
SetbkBoilerOff 12 psi
Setback
boiler off stored
boiler off value. [>]to set value [VI
next
for

6a Return
[MODE]
to Auto:
10.0
SetbkBoilerOff
psi 12 psi Boiler
is returned to normal
Operate
mode. Standby Flame
Signal
Oil 0V Operate
mode.

41 CB68-42
 b. From Operate Mode.

tion Step

1b. Access setback [VI Auto: 10 psi SetbkBoilerOff x Assure cursor is in Field 3 or 4
boiler off Standby Oil Flame Signal 0 V to access the setback boiler off
parameter parameter.

2b Set setback [>I Auto:

10 psi SetbkBoilerOff 12 psi Move cursor to value, [>] key.
boiler offparameter, [+I ... Standby Oil Flame Signal 0V Plus
[+I key will increment
12pressure
psi for this by aWith
single digit. the
example. will psi keys [FAST] and [+I
increment by 20 psi.

3b. Enter setback [ENTER] Auto: 10

psi SetbkBoilerOff 12 psi Setback boiler off stored.
boiler off. Standby Oil Flame Signal 0V

Note: This example indicatesno value was previouslyentered. Values can be changed using steps
1b through
3b if value previously
set.

30. Erasing Historical Data

At times it may be requireddesired to erase the historical fields, total hours, total cycles, and fault history. History data
can be erased only in the Program mode.

ation Step

1 Gain access tothe Program mode, see 1 of this programming section.

2 Access the [VI BLC Program Erase History Data? No

Assure cursor
Field
inis 3 to
erase history [VI
[>] to set value for access
next the Erase history parameter.
parameter.

3 Select [>I BLC Program Erase History Data? Move

NQ cursor to value,[>]
key.
Erase History [+I to set value [VIfor next
parameter

4 Choose [+I BLC ProgramErase History Data? Yes Select Yes,[+] key
Erase
history
[>I to select digits [Enter] when done

5 Erase history
[Enter] BLC Program History Data Erased
[VIto continue

6 Return to [MODE] Auto: 10 psi NomOilTemp 1OO'F Boiler Controller is returned to

Operate mode. Standby Oil Flame Signal 0V normal Operate mode.

DIVISION OF AQUA-CHEM. INC. Form No. 63-2171/1-89

InstallationInstructions
 U U
SEE SHEET #3
GAS PRESS,
FOR INSTALLATIDN
VENT NUTES
SENSOR

3-WAY

j~ p GAS T R A I N

I
LEI
Cleaver
DN. M" D(t
Brooks
HRY-VIfCOKSIN

CB-HAWK INSTALLATIDNDRAWINt
TYPICAL 48-60' FIRETUBE
IDWG, NU, SHEET 1 OF 3
 r
I
-- I

0
7
L

I 0

0
I

I 0
m-

I CB-HAWK INSTALLATIDN DRAWING

TYPICAL 48-60' FIRETUBE
IDWG, ND, SHEET 2 UF 3 I
 1NSTALLATI.P.N.
,,NOTES
1. High Voltage refers to any voltage greater than the
115 V A C control circuit.

2. The high voltage wires should neverbe run in the

same conduit or parallel to the sensor cables.

3. The motor leads may be routed through the control

cabinet, but kept away from the sensor cables.

6. A l l sensor5 are tobe wired using shielded cable.

Pressure sensors - Belden #9365 and Temperature
sensors - Belden #9318.

5. A l l sensor cable shields must be grounded in the

"CB-HAWK" control \cabinet ONLY! The ground/shield
wire should be snipped off inside the sensor. NEVER
GROUND SENSOR SHIELDSA T BOTH ENDS.

6 . The sensor cable canbe routed through the entrance

cabinet, but away from high voltage wiring.

7 . Run a seperate conduit (EMT,rigid,or flexible

conduit - follow local codes) between the junction
boxes located on the left and right side of the
base rails, beneath the front head of the boiler.

8. Gas Pressure sensor vent port must be attached to

the vent line. This vent must be installed if not
already present.

9. Mount the blower motor starter enclosure [where

applicable) in a convenient location.

10. On 68 and 6 0 " boilers mount a seperate 6 X 6 X 1 - 1 / 2 "

junction box in a convienent location above andto
the left of the fuel oil controller.

11. Remove the operating and modulating controls from

the boiler, do not remove the high l i m i t .

12. Use Belden t9365 cable for the modulating motor

feedback wiring. This cable can be run in the
conduit with the mod. motor wiring.

13. The CB-HAWK display is wired with Belden #8723, N.T.S.

attach the supplied 120 ohm resistor to the display
end o f the cable between terminals A & b.
CHECKED
I
APPROVED
I USED ON:
LEBANON. PA.
GREENVILLL MISS.
Dm0 .c
-4.1
STRATFORD. ONT.
U U SEE SHEET #3
FOR INSTALLATION
NOTES

G A S TRAIN N.T.S.
4-4-89
TorVN

m
vE
D

IIDWG,
CB-HAWK INSTALLATION DRAWING
TYPICAL 78-96' FIRETUBE
NO, SHEET 1 OF 3 I
 0
(-2
-- 1
I

I
..
Ln
K
W
d
0
I1
II
I

C B - H A W KI N S T A L L A T I O ND R A W I N G
T Y P I C A L 78-96' FIRETUBE
DWG,
NO, SHEET 2 OF 3 I
 N.0,TES
I.N.%T.a.L.L,a.T.I.,o.N
1. H i g h v o l t a g e r e f e r s t o any v o l t a g e g r e a t e r t h a n the
115 V A C c o n t r o l c i r c u i t .

2. The h i g h v o l t a g ew i r e ss h o u l dn e v e r be r u n i n t h e
same c o n d u i t o r p a r a l l e l t o t h e s e n s o r c a b l e s .

3 . T h e m o t o rl e a d s may be r o u t e dt h r o u g h the control

c a b i n e t ,b u tk e p t away f r o m t h e s e n s o rc a b l e s .

6. A l l s e n s o r sa r et o be w i r e du s i n gs h i e l d e dc a b l e .
P r e s s u r es e n s o r s -
Bclden #9365 andTemperature
sensors - Belden 19318.

5 . A l l s e n s o rc a b l es h i e l d s mustbe grounded i n t h e
"CB-HAWK" c o n t r o lc a b i n e t ONLY! T h e g r o u n d / s h i e l d
w i r e s h o u l d b es n i p p e d o f fi n s i d e t h e s e n s o r . NEVER
GROUND SENSORSHIELDS A T BOTH ENDS.

6. The s e n s o rc a b l ec a nb er o u t e dt h r o u g ht h ee n t r a n c e
c a b i n e t ,b u t away f r o m h i g h v o l t a g e w i r i n g .

7. Run a s e p e r a t ec o n d u i t( E M T , r i g i d , or f l e x i b l e
conduit - f o l l o wl o c a lc o d e s ) between t h e j u n c t i o n
b o x e sl o c a t e d on t h e l e f t and r i g h t s i d e o f t h e
base r a i l s , b e n e a t h t h e f r o n t head o f t h e b o i l e r .

8. Gas p r e s s u r es e n s o rv e n tp o r t mustbe a t t a c h e dt o
t h e v e n tl i n e .T h i sv e n t mustbe installed i f not
a l r e a d yp r e s e n t .

9. Mount t h eb l o w e r m o t o rs t a r t e re n c l o s u r e( w h e r e
a p p l i c a b l e ) i n a c o n v e n i e n tl o c a t i o n .

1 0 . O n 96" b o i l e r s t h e s t e a mp r e s s u r es e n s o rc a b l ec a n
be run i n t o t h e j u n c t i o n box l o c a t e dn e a r t h e steam
m a n i f old.

11. Remove t h e o p e r a t i n g a n dm o d u l a t i n gc o n t r o l sf r o m
t h eb o i l e r , d o n o t remove t h e h i g h l i
m i
t .

12. Use Bcldcn #9365 c a b l e f o r t h e m o d u l a t i n s m o t o r

f e e d b a c kw i r i n g . T h i sc a b l ec a nb er u n i n the
c o n d u i t w i t h t h e mod. m o t o r w i r i n g .

13. The CB-HAWK displayiswired w i t h Bcldcn #8723,

a t t a c ht h es u p p l i e d 120 ohm r e s i s t o r t o t h e d i s p l a y
end of t h ec a b l eb e t w e e nt e r m i n a l s A & b.

APPROVED
1USED ON:
LEBANON. PA.
GREENVILLE. MISS.
STRATFORD. ONT.
L
CB -HAWK INSTALLATION DRAWING
TYPICAL 78-96"FIETUBE