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Centauri Plus - 1500 to 2000 MBH

1. Burner Assembly Components Item Aty Part No Description 1 2 1 116444 Assy Burner IF IFC 2000M 3 1 109863 Assy Burner Top Plate Return Tube 17 4 1 109877 Assy Filter Box 12 X 24 IF IFC 5 1 114310 Gas Air Inlet Tube 6 1 109873 Assy Blower Housing FB14 2000M IF IFC 7 1 109874 Housing Blower Housing FB14 8 1 109871 Plate Mtg Blower Motor FB14 9 1 100467 Wheel Fan Punker HL45 Plated 10 1 See Bom Motor 1 1 2 HP 11 4 30 110483 Strip Adhesive 1 8 X 3 4 Silicone Foam 12 2 111037 Gasket Blower Inlet 8 Round 13 1 111038 Gasket Blower Outlet 6 1 2 Sguare 14 4 00 104911 Strip Adhesive 3 4 X 3 16 Vinyl Foam 15 1 109959 Connector 3 8 X 3 8 Comp 16 1 114076 Support Gas Train IF IFC 17 1 110265 Filter Air 12 X 24 18 19 20 2 6480 Connector 1 8 X 1 4 Comp 21 2 6493 Ell 1 8 1 4 Comp 22 2 79972 Nut Wing 1 4 X 20 Steel 23 1 107775 Igniter Hot Surface 271Y 1 Insertion 24 1 111791 Gasket Igniter 232 Craneglas Y271 25 1 111810 Insulation Composite 12 625 OD W HSI 26 1 5616 Box Handy 2 X 2 X 4 27 1 5617 Cover Handy Box 2 X 2 X 4 28 1 100476 U Bolt 1 4 X 2 X 3 1 4 W Plate 29 4 3476 Nut Flange Lock 5 16 X 18NC 30 5 3506 Washer Flat 5 16 31 2 59189 Switch Air Proving Antunes SMD 32 3420 Bolt 1 4 X 20NC X 3 4 PLT 33 33 15607 Washer Flat 1 4 PLT 34 35 3494 Washer Lock 1 4 PLT 35 1 76797 Screw Sealing 8 X 3 4 410 SS 36 35 3475 Nut Hex 1 4 X 20NC Zinc PLT 37 7 3422 Bolt 5 16 X 18NC X 3 4 PLT
2. 9 O Xs 45 s GAS CONNECTION 1 1 2 FLUE OUTLET PRESSURE GAUGE T COMBUSTION AIR INLET CONNECTION N HANDHOLE CLEANOUT RETURN INLET j s 9 10 9 1 3 64 I BEAM SKIDS E 27 Model 2000 WBX 250A IFC 34 54 07 13 4 1 4 2 4 3 4 4 4 5 BOILER INSTALLATION Checking Eguipment Before You Install Inspect the unit completely upon receipt from the freight carrier before signing the bill of lading Inspect the appliance and all accompanying parts for signs of impact or mishandling Verify the total number of pieces shown on packing slips with those actually received Contact the freight carrier immediately if any damage or shortage is detected Codes The eguipment must be installed in accordance with those installation regulations in force in the local area where the installation is to be made Authorities having jurisdiction must be consulted before installation is made In the absence of such requirements the installation must conform to the latest edition of the National Fuel Gas Code ANSI Z223 1 Where reguired by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code f
3. Vent Fitting Eguivalent Length Vent Pipe 6 Vent 7 Vent 8 Vent 9 Vent 90 Elbow 8 feet 9 feet 10 feet 11 feet 90 Long Radius Elbow 5 feet 5 feet 5 feet 6 feet 45 Elbow 5 feet 5 feet 5 feet 5 feet The following vent information is provided for use in design calculations if needed Venting Specifications Boiler Required Max Vent Input Mbtu Air cfm Press W C 1500 350 1 7 1800 420 2 0 2000 467 2 0 8 4 Vertical or Horizontal Vent Termination 8 5 The vent terminal must extend at least 3 ft 09 m above the highest point where it passes through the roof of a building and at least 2 ft 06 m higher than any portion of a building within a horizontal distance of 10 ft 3 0 m The vent cap must terminate at least 3 feet 0 91 m above any forced air inlet within 10 feet 3 05 m 4 feet 1 22 m below 4 feet 1 22 m horizontally from or 1 foot 0 3 m above any door window or gravity air inlet to the building 1 foot 0 3 m above grade 1 foot 0 3m above normal snow levels and shall terminate at least 7 feet 2 13 m above grade when located adjacent to public walkways or gathering areas The vent terminal should not be installed closer than 3 feet 0 91 m from an inside corner of an L shaped structure Combining Category IV Vents Combined Centauri or Centauri Plus Category IV gas vent systems must incorporate an Exhausto or Tjernlund variable speed modulating mechani
4. Burner Gas Train Components 50 1 109991 Pkg Gas Train 1 1 2 3 8 P X 1 1 2 C 51 1 102830 Regulator 1 1 2 Dungs FRG715 6 52 1 102836 Valve Gas Dungs DMV D 703 6 24vac 53 54 1 102838 Flange Valve 1 1 2 Dungs 55 2 45327 Valve Shutoff 1 1 2 Gas Combu 56 57 58 1 101216 Switch Pressure HKGP G Antunes Manual 59 1 101201 Switch Pressure RLGP G Antunes Manual 60 2 110483 Nipple Black 1 1 2 X 3 61 1 69559 Nipple Black 1 1 2 X 4 1 2 62 1 57612 Nipple Black 1 1 2 X 7 63 1 6059 Nipple Black 1 1 2 X 6 64 1 6053 Nipple Black 1 1 2 X 2 65 1 6107 Bushing Black 3 8 X 1 4 67 1 5972 Nipple Black 1 4 X 1 68 1 5973 Nipple Black 1 4 X 2 69 2 6168 Ell Black 90 DEG 1 1 2 34 34 54 07 13 16 PERIODIC MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations Maintenance must be performed by a gualified service or maintenance provider To ensure proper maintenance the following instructions should be posted near the appliance and maintained in legible condition Verify proper operation after servicing Warning When servicing the controls use exact Factory authorized replacement parts and label all wires prior to disconnection Verify proper operation after servicing Incorrect parts substitution and wiring errors can cause damage improper operation fire carbon monoxide and other unexpected and unsafe conditions that could result in fire injury or death 1 Examine the ap
5. To Change Other Parameters 10 9 LED Display Alarm Messages Boiler Control Interface 11 1 If BMS is to provide remote on off control only 11 2 If BMS provides Modulation control through a 4 to 20 milliamp 11 3 Modbus Application for TempTrac 11 4 Boiler Management System BMS Remote Connections 11 5 Outdoor Reset 11 6 Boiler Management System BMS 11 7 BAS Protocol Gateway Sequence of Operation Initial Startup 13 1 Initial Startup Requirements 13 2 Tools and Instrumentation Required 13 3 Resources 13 4 On Site Considerations 13 5 Startup Procedure Troubleshooting Guide Replacement Parts 15 1 Control Panel 15 2 Control Panel Components Parts List 15 3 Burner Assembly and Gas Train Exploded View 15 4 Burner Assembly and Gas Train Parts List Periodic Maintenance Recommended Maintenance Schedule Warranty Forms amp Wiring Diagrams Ship Separately With Each Product 34 54 07 13 SAFETY CONSIDERATIONS WARNING Ifthe information in the supplied manual s is not followed exactly a fire explosion or exposure to hazardous materials may result causing property damage personal injury or loss of life FOR YOUR SAFETY Donotstore or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately cal
6. drainage 2 Use 3 4 CPVC pipe to plumb each condensate drain separately to a suitable floor drain or collection system 3 Each condensate drain must contain a trap or siphon pigtail to provide at least 3 inches of standing water to prevent flue gas flow through the condensate piping To construct the trap connect to the 3 4 condensate drain route the piping downward until the standing water in the trap is not higher than the bottom of the boiler 4 Install the condensate plumbing as shown the following diagram 5 condensate plumbing must be protected from freezing Do no locate the condensate piping such that an ice dam of frozen condensate can block the outlet OPTIONAL CONDENSATE BOTTOM OF HEATER j NEUTRALIZATION SYSTEM 3 PIPING MAY BE LOWER SUITABLE FROM THIS POINT DRAIN IF HEATER IS ON HOUSKEEPING PAD ROTATE FITTINGS AS REQUIRED TO REST ON FLOOR Condensate Neutralization System optional Although only slightly acidic 3 5 PH boiler condensate can be routed through an optional Condensate Neutralization System see image below to become pH neutral allowing for disposal into any drain or sewer system without concern for corrosion Condensate slowly flows through a neutralization bath filled with renewable crushed limestone becoming neutraliz
7. Automation Systems through either a 4 20mA analog signal for remote set point or over the non proprietary Modbus TCP IP network protocol Gateways are available for other protocols Includes two equipment activation and proving terminals for system pumps and combustion air BAS Protocol Gateways When communicating over a network connection the standard protocol of the TempTrac control is Modbus RTU The standard protocol between the OnTrac and the BAS is Modbus TCP IP A gateway will be required to communicate with the BAS if it uses a different protocol Riverside Hydronics offers pre mapped gateways that support BACnet MSTP BACnet IP Lonworks or Johnson Controls N2 Consult factory for other protocols For a general overview of the application of this gateway refer to Setup Manual 434 525 These third party supplied gateways are custom programmed components that must be sourced through Riverside Hydronics 23 34 54 07 13 12 SEGUENCE OF 1 Incoming 120VAC a Full time power to the Main Control Switch b Full time power to the Variable Freguency Drive Power On When the main control switch is turned on a 120v is applied to the step down transformer 24v b 120v is applied to the L W C O terminal L1 120v is applied to the Fenwal Flame Safeguard Control d 24v is applied to the TempTrac operating temperature control terminal L1 Call For Heat Ifthe TempTrac operating control senses a call for heat con
8. These chemicals when in contact with the equipment or when burned form acids which quickly attack the tubes flue collector stack and other appliance and auxiliary equipment The result of inadequate clean combustion air or negative pressure can be premature unwarranted product failure or unsafe operation producing carbon monoxide that could escape into the building Exposure to carbon monoxide can lead to injury or death 13 34 54 07 13 7 2 Maximum Allowed Remote Combustion Air Inlet Length Eguivalent Length A vertical or horizontal remote air inlet system can be connected to this appliance without modification The maximum length of field supplied single wall pipe such as galvanized ventilation pipe is shown in the chart below titled Maximum Air Inlet Duct Eguivalent Length Use metal tape or RTV sealant to seal each pipe joint Maximum Air Inlet Duct Equivalent Length 6 Duct 7 Duct 8 Duct 100 feet 130 feet 250 feet Duct Size 9 Duct 450 feet Max Equivalent Length To determine the maximum straight length of duct allowed use the Duct Fitting Equivalent Length chart below to find the total equivalent length for all duct fittings in your combustion air system Then subtract this number of feet from the total equivalent length allowed in Maximum Air Inlet Duct Equivalent Length chart above The sum of this calculation is the maximum length of straight duct allowed If a longer length is required repe
9. be eguipped with an optional air vent If venting through the safety valve when filling the appliance insure gags or fixtures are removed from the safety valve prior to start up Open the safety valve to allow air in the tank to escape Be sure all connections into the tank are tight as leaks at tank fittings will damage the insulation CAUTION Conduct the following gas train leakage test before start up at annual intervals and prior to investigating the cause of any reported occurrences of delayed ignition a Using an appropriate bubble detection solution thoroughly coat all gas train pipe connections If any bubbles are detected the leaking connection must be tightened recoated and rechecked to assure stoppage of the leak b Attach a manometer to measure the gas pressure at the manual gas shutoff valve located just upstream of the gas train Adjust gas train inlet pressure to the specified value e g 14 W C and tightly close the gas train manual shutoff valve closest to the burner c Reattach the manometer to the gas train manual shutoff valve at the burner and record the measured gas pressure in inches of water column W C Measure gas pressure again after 15 minutes If gas pressure has increased 0 5 W C or more the gas leak must be isolated to one or more of the operating gas valves For example a solenoid actuated gas shutoff valve After any leaking valve is replaced the reassembled gas train must be leak tested again
10. before start up is attempted Remove enclosure panel cover on the appliance to expose control circuit A wiring diagram included in this packet will show the controls used in our circuitry Visually check that all components are intact and no damage has occurred during transit Check all connections within the control cabinet A loose connection could cause intermittent shutdowns All burners will use a hot surface igniter HSI as the ignition source They may use a single gas pressure regulator and valves valve regulator combinations or multiple gas trains Connect a test meter to the control for reading the flame response signal NOTE Some flame controls read the flame signal in micro amps and some in volts DC CAUTION Be sure the tank is filled with water Dry firing can destroy the appliance Check the inlet gas pressure before start up using a manometer or a 0 to 28 W C pressure gauge for inlet gas pressure This is the pressure measured before all components in the gas train This manometer must stay connected throughout the testing as the inlet pressure must be monitored during the firing of the burner Record static pressure it must not exceed 14 W C Pressures above this could cause damage to the diaphragm in the gas valve or pressure regulator Connect a second manometer to the manifold test port at the shutoff valve closest to the burner Turn off main gas shutoff valve Disable or jumper out any BMS BAS or
11. for assistance Enable or reconnect any BMS BAS or OnTrac boiler control interface removed prior to the setup and adjustment of each boiler 27 34 54 07 13 VALVE ORIFICE MANIFOLD ADJUSTMENT PRESSURE REGULATOR ADJUSTMENT m 1 m INLET PRESSURE Gas Train Illustration REGULATOR VALVE ORIFICE ADJUSTMENT ADJUSTMENT MSN LI LS e E LOW PRESSURE GAS SWITCH DUAL SAFETY SHUTOFF VALVE or HIGH GAS PRESSURE SWITCH MANIFOLD PRESSURE Alternate Gas Train Illustration 28 34 54 07 13 14 TROUBLESHOOTING GUIDE Problem Probable Cause Corrective Action Starting or Pre purge Failure Power Supply Check fuse and or circuit breaker Check voltage at 120 24V step down transformer On Off Switch Check if On Off switch is lighted Temperature Control Check that the operating temperature control is set higher than the temperature of the boiler Flame Safeguard Control Check for bad
12. ground or bad control Replace if necessary Remote enable disable open Enable boiler or place jumper between terminals R1 R2 Combustion Air blower Air proving Switch Check if fan connection terminals on flame control is closed Check for 24V at field access terminal C2 Remote interlock may be open Fan VFD may be defective Verify proper voltage Check switch contacts are closed Check for 24V at the NOW side of air switch Check for 24V at the common side of air switch Check for proper blower pressure setting adjust if required Air switch may be defective Blocked Filter Switch Check for 24V at the N C side of the blocked filter switch Replace filter or switch as required Flame Control Pressure Switch Check for 24V at the pressure switch terminal Loose Wire Connections Check connections to all components Flame Failure Power Supply Check fuse and or circuit breaker Check voltage at 120 24V step down transformer Flame Safeguard Control Check for bad ground or bad control Replace if necessary Hot Surface Igniter Check amp draw during heat up Replace if amps greater than 3 1A Check for overheating condition due to damaged refractory around igniter Air proving Switch Check if switch is bouncing Adjust or replace Gas Pressure Check for proper inlet static and dynamic gas pressure Combustion Inadeguate flame signal may resu
13. hazardous materials or loss of life PRODUCT SAFETY INFORMATION REFRACTORY CERAMIC FIBER PRODUCT WITH CRYSTALLINE SILICA WARNING This product contains or may come to contain crystalline silica which has been identified by the International Agency for Research on Cancer IARC as carcinogenic to humans This product also contains refractory ceramic fibers which have been identified by the IARC as possibly carcinogenic to humans Avoid breathing fiber particulates and dust RISKS Airborne fibrous insulation is a possible cancer hazard by inhalation Airborne crystalline silica may cause silicosis lung disease by inhalation May cause temporary irritation to eyes skin and respiratory tract PRECAUTIONARY MEASURES Minimize airborne fibers with engineering controls Use NIOSH MSHA approved respirators as required see MSDS Wear long sleeved loose fitting clothing eye protection and gloves FIRST AID MEASURES If any of the irritations listed persists seek medical attention Eyes Flush with water Skin Wash with soap and warm water Ingestion Do not induce vomiting Get medical attention if gastrointestinal symptoms develop Inhalation Remove to fresh clean air WARNING If you are unfamiliar with the safe handling of refractory ceramic fiber products or if you wish additional information prior to beginning any disassembly of the water heater or boiler that might expose refract
14. least 24 above the boiler is required for filter replacement and burner gas control service 34 54 07 13 4 6 Clearances To Combustible Surfaces 5 1 Minimum 1 clearance must be provided from any vent surface to adjacent combustible material The minimum clearances to unprotected combustible material are 24 be provided at the front 8 be provided at the rear and 8 at top left and right sides of the appliance GENERAL PIPING GUIDELINES Inlet and Outlet Connections The connection to the unit marked Inlet on the header connects to the return from the system water to be heated The connection on the header marked Outlet connects to the supply side of the system hot water out of the unit 5 2 Supply and Return Piping For Non hybrid Boiler System Building Circulator Makeup Water OnTrac temperature probe is placed in the return piping Provide a 1 2 inch fitting and thermowell 102560 Air Separator Supply Piping maintain minimum static pressure of 15 psi in the boiler room piping 77777 Control Normally closed bypass Return Piping Continue piping pattern with additional boilers Locate TempTrac operating probe in return pipe to boiler A 1 2 inch fitting and thermowell are required thermowell part number 102560 Note For motorized isolation valves on each boiler s inlet piping n constant flow building loops motorized isolation valves must NOT be used I
15. not occur When such locations are unavoidable install a suitable drain pan and plumb pan to ensure adequate drainage in the event of a leak Under no circumstances is the manufacturer responsible for water damage in connection with this unit or any of its components The manufacturer s warranty does not cover water damage e Protect associated electrical components and electrical connections from water dripping spraying rain etc during appliance operation and service Place the appliance on a level non combustible floor Concrete over wood is not considered non combustible Do not install on carpet or other combustible floor coverings If installation over a combustible floor is required follow these guidelines Use a base of hollow clay or concrete blocks from 8 to 12 thick and extending 24 beyond the sides the blocks in line so that the holes line up horizontally to provide a clear passage through the blocks Install 1 2 fireproof millboard with a 20 gage sheet metal cover over the block base Center the unit on the base Also follow this procedure if electrical conduit runs through the floor and beneath the appliance A field installed base must meet all local fire and safety code requirements Service Clearances Provide adequate clearances on all sides for installing and servicing connections such as water gas vent combustion air duct electrical pump and other auxiliary equipment At
16. trouble free service life WARNING Start up must be performed by a qualified technician The Start up Forms is included with each product and must be furnished to the manufacture to register the warranty Copies are available at www riversidehydronics com Failure to comply can cause property damage personal injury and exposure to hazardous materials or loss of life WARNING Turn off all power to the boiler when servicing or accessing the blower drive The blower drive still has power when appliance switch is off Failure to turn off all power to the boiler can cause personal injury property damage or loss of life Tools and Instrumentation Required Stack Temperature Gauge Stack Draft Gauge Electronic Combustion Analyzer Manometer for checking gas pressure 2 minimum AC DC Multi meter with 20 000 OHM Volt rating Amp Meter Normal Hand Tools Resources e Product Installation amp Maintenance Manuals Start up Report with instructions e Local State 8 Federal Codes e Toll Free 24 Hour Technical Support 1 800 433 5654 25 34 54 07 13 13 4 Site Considerations Electrical Supply accordance with Nameplate Rating Uncontaminated Combustion Air Adeguate Fuel Supply Treated Water Supply Boilers Consistent Draft 13 5 Startup Procedure 1 2 10 11 12 13 14 15 Carefully study the burner start up information included in this manual Fill system tank with water Some water appliances may
17. valve during any pressure testing of the gas supply piping system at test pressures equal to or less than gt PSI 3 5 kPa The appliance and its gas connection must be leak tested before placing it in operation 6 5 Gas Connection 6 6 1 Safe operation of unit requires adequate gas supply with the required static and dynamic flow pressures Actual piping selection depends on many variables that must be carefully considered by the gas piping system designer Do not select gas pipe sizes based only on the supplied tables These tables are for use by the gas piping System designer as a reference in checking pipe size selections Gas pipe size may be larger than heater connection Installation of a union is suggested for ease of service Install a manual main gas shutoff valve outside of the appliance gas connection and before the provided appliance manual shutoff gas valve as required by the National Fuel Gas Code The gas system installer should clearly identify the emergency shut off device A sediment trap drip leg MUST be provided in the inlet of the gas connection to the unit The code compliant vent limiters are designed and must respond to pressure changes in the installation environment as opposed to outdoor pressure For proper operation do not connect to outdoor atmosphere Gas Train and Controls Certification NOTE The gas train and controls assembly provided on this unit have been tested under the applicable Natio
18. 0 W C 1 41 2 0 W C 2 00 and 4 0 W C 2 82 34 54 07 13 MULTIPLE UNIT INSTALLATIONS GAS PIPING SIZE CHART Maximum Capacity of Pipe in Thousands of BTU s per hour for gas pressures of 14 Inches Water Column 0 5 PSIG or less and a pressure drop of 0 05 Inch Water Column Based on NAT GAS 1025BTU s per Cubic Foot of Gas and 0 60 Specific Gravity Nominal Iron Length of Pipe in Straight Feet Pipe Size Inches 80 ES 100 ms 150 175 em 328 292 246 256 210 200 179 164 138 174 ses 502 472 441 410 369 333 308 287 1500 120 1020 923 exo 769 707 EI 636 564 513 472 441 2 1 2 6460 4460 3610 3100 2720 2460 2310 2100 2000 1900 1700 1540 1400 1300 2260 1950 1720 1560 1440 1330 1250 1180 1100 974 71 820 6400 5400 4870 4410 4000 3800 3540 3300 3000 2720 2500 2340 23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720 6 4 Appliance Isolation during Gas Supply Piping Pressure Test 1 3 The appliance and its provided manual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of PSI 3 5 kPa The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff
19. 4 13 Minimum Flow Pressure Inches Water Column 4 5 11 Manifold Pressure Measure at the pressure tap on the downstream side of the manual shutoff valve closest to the burner The rated manifold pressure appears on the product data label located on the front of the appliance Gas Piping Size Use the values in Convert Fittings To Eguivalent Straight Pipe to add the eguivalent straight pipe for each elbow or tee to obtain the total distance from the meter Use this corrected total distance from the meter for determining the suggested pipe size in the Single Unit Installation Suggested Gas Pipe Size table CONVERT FITTINGS TO EGUIVALENT STRAIGHT PIPE Diameter Fitting inches 34 1 1 1 2 3 4 5 Eguivalent Length of i i 1 i Straight Pipe 2 Z gt 10 1420 SINGLE UNIT INSTALLATION SUGGESTED PIPE SIZE Equivalent Feet Fro Maximum Capacity for Natural Gas Mater MBTU HR Based on 0 5 W C Pressure Drop 1 1 4 1 1 2 2 2 3 4 25 860 1320 2475 3900 7000 40 660 990 1900 3000 5300 60 810 1520 2400 4300 80 690 1300 2050 3700 100 620 1150 1850 3250 6700 125 1020 1650 2950 6000 150 950 1500 2650 5500 175 850 1370 2450 5000 200 800 1280 2280 4600 Multiplier for Propane 1 57 Multiplier for alternate pressure drops 0 3 W C 0 77 1
20. ER PANEL 10 1 Principle Of Operation The boiler operates to satisfy the setpoint of the TempTrac digital control whose sensor is located in the return line of a Hydronic system Demand flow will typically create a drop in temperature thus activating the Centauri to add heat to the system This setpoint is the highest temperature the appliance permits any firing to occur OPERATING CONTROL HYDRONICS c LOW WATER RESET 5 CALL FOR HEAT LOW WATER TEST IGNITION TRIAL 10 22 Upper Led Readout The default display of this readout is the supply temperature sensed in the thermal well at the top of the boiler tank Probe 2 10 3 Lower Led Readout The default display of this readout is the return water temperature sensed in the thermo well installed in the return water piping Probe 1 This is used to regulate the temperature of the boiler 10 4 Control Buttons SET Displays and modifies the temperature set points In programming mode it selects a parameter or confirms an operation UP Displays and modifies the energy saving Night Time setback settings In programming mode it browses the parameter codes or increases a displayed value Displays the working hours of the load relays DOWN 8 2 In programming mode it browses the parameter codes decreases displayed value CLOCK Changes lower display from inlet temperature to current time and day Changes upper display from supply temperat
21. Each opening reguires a minimum free area of 1 sguare inch per 4000 Btu hr input if directly communicating with the outdoors or communicating to the outdoors through vertical ducts Each opening requires a minimum free area of 1 square inch per 2000 Btu hr input if communicating with the outdoors through horizontal ducts All Air From Inside The Building Each opening reguires a minimum free area of 1 sguare inch per 1000 Btu hr input but not less than 100 sguare inches 0 06 m e Combination Of Air From The Indoors And From The Outdoors Refer to National Fuel Gas Code ANSI 2223 1 and or CAN CSA B149 Installation Codes or applicable provisions of the local building codes NOTE This unit may be installed with a remote air intake system which uses a make up air duct to draw combustion air directly from outdoors See Vertical and Horizontal Remote Air WARNING Adequate clean combustion air must be provided to the appliance Under no circumstances should the appliance ever be under a negative pressure Particular care should be taken when exhaust fans compressors air handling units etc may rob air from the appliance The combustion air supply must be completely free of any chemical or fumes which may be corrosive to the appliance Some common chemical fumes to avoid are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as Freon trichloroethylene perchlorethylene chlorine etc
22. Riverside P Centauri Plus CONDENSING WATER BOILER INSTALLATION amp MAINTENANCE MANUAL Models 1500 1800 2000 WBX 250 W Intertek Installation and service must be performed by a gualified service installer service agency or the gas supplier IMPORTANT THIS MANUAL CONTAINS INFORMATION REQUIRED FOR INSTALLATION OPERATION AND MAINTENANCE OF THIS EQUIPMENT READ AND FOLLOW THE INFORMATION IN THIS MANUAL AND ALL OTHER PROVIDED INSTRUCTIONS LABELS AND MARKINGS BEFORE INSTALLING OPERATING OR SERVICING THIS UNIT TO THE INSTALLER After installation these instructions must be given to the equipment user or left near the appliance SPECIAL INSTRUCTIONS TO THE OWNER Retain this manual for future reference These instructions contain important information that will help you in maintaining and operating this appliance Riverside Hydronics LLC 990 Haltom Road Fort Worth Texas 76117 1 800 990 5918 www riversidehydronics com 34 54 07 13 TABLE OF CONTENTS Safety Considerations Standard Features and Eguipment 2 1 Performance 2 2 Burner Combustion Controls amp Operating Controls 2 3 Remote Network BAS Interface 2 4 Warranty and Service Policy Product Description Boiler Installation 4 1 Checking Equipment Before You Install 4 2 Codes 4 3 Electrical Requirements 4 4 Location 4 5 Service Clearances 4 6 Clearances to Combustible Surfaces General Piping Guidelines 5 1 Inlet
23. TL or CSA certified for use with an appliance requiring a Category IV pressurized vent system Seal all joints and support horizontal lengths of vent and follow all installation instructions required by the vent manufacturer Maximum Category IV Vent Length Equivalent Length A vertical or horizontal remote Category IV vent system must be used with this appliance The maximum length of field supplied Category IV vent is shown in the chart below titled Category IV Vent Equivalent Length Maximum Category IV Vent Equivalent Length Vent Size 6 Vent 7 Vent 8 Vent 9 Vent Max Equivalent Length 100 feet 130 feet 250 feet 450 feet Pipe fittings reduce the maximum allowable vent length Use the Category IV vent manufacturer s equivalent length deduction for all elbows terminations etc If the information is not readily available from the vent manufacturer use the Vent Fitting Equivalent Length chart below to find the total equivalent length for all vent fittings in your combustion air system Then subtract this number of feet from the total equivalent length allowed in Maximum Category IV Vent Equivalent Length chart above The sum of this calculation is the maximum length of straight vent allowed If a longer length is required repeat the calculation using a larger vent size When using this chart no additional deduction is required for the addition of the vent system terminal 34 54 07 13
24. When the setpoint temperature is reached the call for heat signal to the flame safeguard control is discontinued c The flame safeguard control deenergizes the VFD blower system and the gas valve thereby suspending burner operation d As heat is transferred to the building the boiler loop temperature will fall below the set point The TempTrac will sense this condition and begin the call for heat sequence again Flame Safeguard LED Diagnostic Indicator If the Fenwal Flame Safeguard Control at any time during the operating sequence senses an improper operating state and locks out the diagnostic red LED located on the control board will flash to indicate one of the following conditions exist LED INDICATION FAULT MODE On Normal Operation OFF Internal Control Failure check power 1 Flash Airflow Fault 2 Flashes Erroneous Flame Signal 3 Flashes Ignition Lockout 4 Flashes Hot Surface Igniter Fault 5 Flashes Low Voltage 24 VAC 6 Flashes Valve Relay Problem INITIAL STARTUP Initial Startup Requirements Installation should be complete prior to performing initial startup and the startup must be complete prior to placing the boiler into service Starting the boiler without proper piping combustion air venting or electrical systems can be dangerous and may void the product warranty The following startup instructions should be followed precisely in order to achieve safe and efficient operation to assure
25. a vacuum to remove from the burner cavities Do not brush or scrub the metal fiber burner surface as this can cause permanent damage to the burner material h Replace any damaged components and reassemble in reverse order 4 5 ft lbs i Cycle unit and test to verify all safety and operating controls are properly functioning and the burner top plate flange is free of leaks 35 34 54 07 13 11 12 The combustion air filter should be replaced every six months If filter blockage becomes excessive the filter safety switch will not allow the burner to fire To avoid nuisance shutdown in dirty environments check and replace filter more frequently See Filter Replacement Illustration below for removal detail Inspect low water cutoffs and relief valves for proper operation at every six months or more often if indicated by inspection Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids Check frequently to be sure the flow of combustion and ventilation air is unobstructed to the appliance When electrical controls are serviced or replaced refer to ELECTRICAL COMPONENT LOCATIONS for identification and location of components All replacement parts are available through your Riverside Hydronics Dealer If you need assistance identifying or contacting your local dealer you may contact Riverside Hydronics directly at the address and telephone number located on the first and last pa
26. all the air inlet must terminate at least 12 inches 0 3 m above grade and or at least 12 inches 0 3 m above normal snow levels 34 54 07 13 7 5 8 1 8 2 8 3 Vertical Remote Air Horizontal Remote Air SS SCT E 1 HORIZONTAL OTE AIR Remote Air Consideration for Combined Remote Air Ducting Each boiler MUST have separate intake piping Consult factory for common air intake assistance VENTING The Category IV gas vent connected to this appliance may terminate either above the roof surface or through the side wall It must comply with the latest edition of the National Fuel Gas Code ANSI Z223 1 or in Canada CAN CSA B149 Installation Codes and the applicable provisions of the local building codes gt Follow the category IV vent manufacturers instruction for installation sealing and support of their vent system For proper vent operation and to protect the gas vent from wind and weather use ONLY the listed vent terminal specified by the Category IV vent system manufacturer Important Do not use a barometric damper when applying Category IV venting Category IV The Centauri product operates with a positive vent static pressure and with a vent gas temperature that forms condensate in the vent This product uses the positive pressure generated by the burner system blower to push combustion products out of the vent The vent system must be a stainless steel and UL ULC E
27. and Outlet Connections 5 2 Supply and Return Piping 5 3 Condensate Drain amp Disposal 5 4 Condensate Neutralization System optional 5 5 Temperature Control Sensor Install in system return piping 5 6 Suggested Economizer Plumbing 5 7 Filling the Boiler Gas Supply Piping 6 1 Inlet Gas Pressure 6 2 Manifold Gas Pressure 6 3 Gas piping Size 6 4 Appliance Isolation during Gas Supply Piping Pressure Test 6 5 Gas Connection 6 6 Gas Train and Controls Certification 6 7 Gas Control Trains Combustion and Ventilation Air TA Eguipment Located In Confined Spaces 7 2 Maximum Allowed Remote Combustion Air Inlet Length Eguivalent Length 7 3 Remote Combustion Air Cap 7 4 Vertical or Horizontal Remote Air Duct Termination 7 5 Remote Air Consideration for Combined Remote Air Ducting Venting 8 1 Venting Options 8 2 Category IV 8 3 Maximum Category IV Vent Length Eguivalent length 8 4 Vertical or Horizontal Vent Termination 8 5 Combining Category IV Vents 34 54 07 13 10 11 12 13 14 15 16 17 Operating and Safety Controls 9 1 Operating Temperature Control 9 2 High Water Temperature Limit Control 9 3 Relief Valve 9 4 Electronic Low Water Cut Off TempTrac Controller Panel 10 1 Principle of Operation 10 2 Upper LED Readout 10 3 Lower LED Readout 10 4 Control Buttons 10 5 Modulation Firing Sequence 10 6 To View the Setpoint 10 7 To Change The Setpoint 10 8
28. at the calculation using a larger duct size No additional deduction is required for the addition of the duct system terminal Duct Fitting Equivalent Length Duct Pipe 6 Duct 7 Duct 8 Duct 9 Duct 90 Elbow 8 feet 9 feet 10 feet 11 feet 90 Long Radius Elbow 5 feet 5 feet 5 feet 6 feet 45 Elbow 5 feet 5 feet 5 feet 5 feet The following remote air duct information is provided for use in design calculations if needed Remote Air Duct Specifications Boiler Required Max Duct Loss Input Mbtu Air SCFM inches Water 1500 325 0 784 1800 390 1 11 2000 433 1 356 7 3 Remote Combustion Air Cap 7 4 A UL Listed air intake vent termination cap MUST be attached to the remote combustion air vent termination to adequately protect the combustion air inlet from wind and weather A UL Listed air intake termination cap is available from Riverside Hydronics and may have shipped with the boiler as a purchased option Vertical or Horizontal Remote Air Duct Termination Air inlet and exhaust vents should terminate in the same wind pressure area whenever possible Air inlet must be located no less than feet 0 91m below the exhaust terminal if they are within 10 feet 3 05 m of each other e f terminating through the roof the air inlet must terminate at least 12 inches 0 3 m above roof level and at least 12 inches 0 3 m above snow levels e f terminating through a sidew
29. ater is observed Close valve and complete filling the system 2 In hard water areas water treatment should be used to reduce introduction of minerals into the system Excessive buildup of minerals in the heat exchanger can cause a non warrantable failure 3 sure there are no system leaks DO NOT use petroleum based stop leak products All system leaks must be repaired The constant addition of make up water to a closed loop boiler system can cause minerals to collect in the heat exchanger Excessive buildup of minerals in the heat exchanger can cause a non warrantable failure 4 For systems requiring freeze protection use only hydronic system antifreeze with a maximum concentration of 5096 Follow the glycol manufacturer s instructions DO NOT use undiluted or automotive type antifreeze 10 34 54 07 13 6 1 6 2 6 3 GAS SUPPLY AND PIPING Verify that the type of gas specified on rating plate is supplied to the unit This unit is orificed for operation up to 2000 feet altitude Appliance Btuh output derates 4 per 1000 feet elevation above sea level Consult Factory for installations above 2000 feet elevation Inlet Pressure Measured at the inlet pressure tap located at the main gas cock The inlet pressure must remain within the minimum and maximum values while the unit is at rest and while the unit is operating at maximum firing rate INLET PRESSURE NAT GAS LP Maximum Static Pressure Inches Water Column 1
30. boiler control interface to allow independent setup and adjustment of each boiler Turn unit on using the rocker switch on the front of the control enclosure assembly When the burner fails to light the flame control will lockout Start the burner in Low Fire Burner combustion must be optimized at both Low and High Fire To set the TempTrac control for manual modulation output Push and hold the EXT key for more than seconds The ED switches and the 4 parameter is displayed in the upper display while the PAS label is shown in the lower display 26 34 54 07 13 16 17 18 20 21 22 23 Release the key and insert the password 3 2 1 The value of the modulation parameter PS4 will be displayed in the lower display nu stands for not used Return to this condition for automatic operation adjust modulation manually push the SET key the value starts flashing Then use UP or DOWN keys to modify it 100 High Fire 0 Low Fire To exit press SET UP or wait 30s without pressing any key NOTE After a modification it will be possible to enter the Modulation output setting without entering the password for 10min After this time you will be asked for the password again Turn on main gas shutoff valve If the operating control switches are closed the burner blower should come on and pre purge begins If nothing happens check for a lockout condition and reset it by pushing the fla
31. cal draft inducer capable of maintaining the appropriate negative draft at the end of the common flue to assure that all boilers in the combined vent system operate with a negative draft Do not exceed negative 0 25 W C See Combining Vents with a Draft Inducer illustration below WARNING Do not connect multiple boiler vents into a single unpowered or fixed speed powered vent This could cause unsafe operation and the potential for poisonous carbon monoxide to enter occupied areas Such improper installation can cause property damage personal injury exposure to hazardous materials or loss of life Conventional Venting Through the Wall Venting Combining Vents with a Draft Inducer 16 34 54 07 13 9 1 9 2 9 3 9 4 OPERATING AND SAFETY CONTROLS Operating Temperature Control An adjustable digital operating control is located in the front control panel See TempTrac Electronic Controller Panel in this manual for more information High Water Temperature Limit Control The boiler is eguipped with adjustable limit and high limit controls to control the maximum discharge water te
32. dition a The High Gas Pressure and low Gas Pressure Switch both optional are energized and their safe condition is proved b The thermostat contact on the Fenwal Flame Safeguard Control is energized c The flame control will then verify the Airflow Proving Switch is in the open position which must exist before the blower is powered d Energizing the blower should close the airflow proving switch If the airflow proving switch is not in the closed position the flame control s fan terminals F1 F2 will power the Variable Frequency Drive VFD blower system at low speed for pre purge e f the airflow proving switch does not close following the blower being energized the flame control will lockout Proof of Air Pressure Switch The control will look for a signal from the airflow proving switch indicating that the blower is operating a When the airflow generated by the blower is sufficient to cause the differential air switch to close the 15 second pre purge delay will start b During this period any flue products or combustible gases which may have settled in the boiler are evacuated Heat Up Following the pre purge delay the hot surface igniter will be energized a The flame control will monitor the current applied to the hot surface igniter b If the flame control determines the proving current meets the threshold a dwell time delay starts to assure the hot surface igniter has sufficient time to reach ignition temp
33. ed thus avoiding chemical treatment or dilution using substantial quantities of tap water To obtain a Condensate Neutralization System please contact your local Riverside Hydronics representative 1 Follow the steps 1 through 4 in the Condensate Drain Trap amp Disposal section above Locate the Condensate Neutralization System in the condensate piping as shown in the FIELD INSTALLED CONDENSATE DIAGRAM above 3 Position with removable crushed limestone fill cap in vertical position only The bottom of the condensate neutralization system outlet pipe must not be higher than the bottom of the boiler 4 For proper operation the boiler condensate outlet must be plumbed with CPVC plastic pipe to the lowest fitting of the Condensate Neutralization System connecting to the as shown in the graphic below 5 Keep the Condensate Neutralization System closed at all times except for maintenance 15 a 16 4 50440 PLUG 4 H 4 CA 2222222 Zzzzzzz2 2 SS 4202 N n OUTLET INLET EHH CRUSHED LIMESTONE Condensate Neutralization System WARNING Keep the Condensate Neutralization System closed at all times the appliance is operating The system must remain closed to prevent hazardous products combustion from continually enter the room Failure to keep the Condensate Neutralization System closed can cause pro
34. er cutoff with test switch no lockout power loss _ Pressure gauge on tank _ High and low gas pressure switches _ CSD 1 compliant FM compliant _ Intertek ETL listed to U S and Canadian standards _ Maximum 240 F operating limit _ Combustion air filter Analog or Network BAS Interface to Individual Boilers connection options to multiple boiler controls differ from connection options to individual boilers _ Modbus protocol on operating control through a 485 serial connection optional cable required _ Remote on off terminals _ Remote 4 20mA or 0 10V modulation control terminals this is for motor drive and not for loop reset Warranty and Service Policy see warranty or service policy for details _ Ten year pressure vessel workmanship materials and thermal shock warranty _ Service Advantage Plan covering parts materials freight and labor on any repair or replacement for the first year of operation 34 54 07 13 3 PRODUCT DESCRIPTION Locations May Vary Component Controls and Connection Locations CONDENSATE OUTLET NPT N 8 O RELIEF VALVE DRAIN VALVE 1 SUPPLY OUTLET CONNECTION 3 CONTROL BOX ELECTRICAL CONNECTION SUPPLY OUTLET CONNECTION NI Y BACK OF BOILER BAS CONNECTION 62 FLUE OUTLET CONNECTION RETURN INLET CONNECTION 1 25 NPT COMBUSTION AIR INLET 55
35. erature Ignition When dwell time is completed a 4 second Trial for Ignition TFI period is initiated a The Delay On Low Fire Hold Relay and the Gas Safety Valves are energized b During TFI the flame safeguard control will monitor the flame using flame rectification through the hot surface igniter C If the flame control senses the presence of flame before the end of the TFI period the igniter will be de energized and the flame control will continue to monitor the flame through the igniter until the operating thermostat ends the call for heat condition Loss of Flame Signal a If the igniter fails to sense flame at any time the igniter and gas valve will be de energized and the flame control will reset and begin the call for heat sequence again This will occur 3 times one time if CSD 1 before the flame control will lockout b When the call for heat condition ends or flame failure occurs following the third TFI period one time if CSD 1 a 30 second post purge period will begin This period of blower operation will exhaust any remaining combustion products from the system 24 34 54 07 13 13 13 1 13 2 13 3 8 Delay On Relay Once the Delay On Low Fire Hold Relay has timed out it energizes the Modulation Release Relay SPDT to enable the analog signal from the TempTrac to the VFD to regulate the speed of the blower a The TempTrac will continue to monitor the stored water temperature in the tank b
36. es on heat load is satisfied unit goes off Boiler will hold at low fire until parameter St4 is reached causing burner to modulate higher or parameter is reached causing the burner to shutoff St4 The Modulation Threshold This additional differential from the St1 setting is the value when the change from low fire to modulation occurs The factory default setting is 10 F and is field adjustable SR The Modulation Band This parameter is added to the St4 setting and establishes the lower end temperature of the modulation range where the burner will be operating at 10096 of rate The firing rate will increase or decrease proportionately between 100 and low fire depending upon the differential between this setpoint and St4 If loop temperature drops below the modulation range boiler will hold at high fire The factory default setting is 10 F and is field adjustable The Following Example Is Based On The Factory Setting Of The TempTrac Control 170 165 160 150 145 4 140 low fire 100 of rate A BC D E F Time l gt A to A system with a setpoint of 165 F St1 has a heating demand placed upon it and the system temperature begins to fall No action B If the sensed temperature at Probe 1 falls to 157 F Hy1 the BURNER ON THRESHOLD is activated This initiates the burner Call for Heat with a firing rate established at low fire B to C If further te
37. es option for outdoor reset through the TempTrac control code OUTRC The TempTrac control is capable of an outdoor reset function independent of an external control The option includes a third sensing probe and activates the probe in the TempTrac The outdoor reset function overrides the St1 setting when the outdoor air temperature falls to the tt setting St1 is increased in increments through the range established by rr2 When the outdoor air temperature falls to the bottom of the rr2 range the St1 setting will have been adjusted upward by the amount of the rr1 value See Outdoor Reset Manual 34 400 6 for full description Factory Default Settings The values of the Outdoor Reset and Warm Weather Shutdown functions in the TempTrac control s parameter Pr2 menu can be changed from the factory default values listed below 22 34 54 07 13 Display Parameter Description Value St1 Temperature at the return boiler loop that activates deactivates boiler firing 165 tt Outdoor air temperature where outdoor reset is activated and deactivated 30 F rr2 Outdoor air temperature range through which St1 setting will be adjusted 20 F rr1 Maximum increase of St1 setting when outdoor reset is activated 10 F tt2 Outdoor air temperature where boiler is de energized 100 F Ht2 Differential from tt2 required to reenergize the boiler 10 Outside Air Temperature Sensor Installation The wire leads for the outdoo
38. f the hinged cover If BMS BAS provides remote on off control directly to each boiler but allows boiler to control modulation on its own e Remove the jumper connecting terminals R1 and R2 e Connect the BMS output leads for the enable disable function to terminals R1 and R2 Leave all other wires in their initial positions If BMS BAS provides MODULATION control through a 4 to 20 milliamp directly to each boiler e Remove the jumper connecting terminals R1 and R2 e Connect the BMS output leads for the enable disable function to terminals R1 and R2 no polarity Remove blue wire from terminal T1 and cap the end with a wire nut Secure the loose wire Connect the BMS variable signal output leads to terminals T1 and T2 T1 is positive T2 is negative On the TempTrac Control move parameter up to its maximum setting of 230 F This setting effectively takes the TempTrac out of the way and allows complete control by the BMS system BAS connection over network with MODBUS protocol requires option ALMMB An optional serial connection cable part no 106624 enables the TempTrac to communicate via Modbus RTU to a Building Automation System or to the OnTrac multiple boiler control Connections are made using shielded twisted pair wiring in a daisy chain arrangement 21 34 54 07 13 11 4 Making BMS BAS remote connections for analog and binary on off signals A terminal strip for the remote con
39. ge of this manual If the appliance is to be shut down for an extended period of time the primary gas valve and the water supply should be shut off When the appliance is returned to service a thorough inspection of all utilities and general appliance condition should be conducted FILTER REPLACEMENT ILLUSTRATION REMOVE FILTER BOX ACCESS COVER TO REPLACE FILTER NOMINAL FILTER SIZE 12 X 24 PLEATED 36 34 54 07 13 17 RECOMMENDED MAINTENANCE SCHEDULE 1 Annual Maintenance e o oo o Check all joints and pipe connections for tightness corrosion or deterioration Check the electronic ignition system for quick ignition and a proper flame signal Check all safety controls including thermostats for proper operation Check safety shut off valves for operation and tightness Test flame failure detection system Test high limit and operating temperature controls Conduct a combustion test Perform leakage test on pilot and main gas valves Test air switch in functionality Semi Annually gt e 55 o 0 o Recalibrate all indicating and recording gauges Check flame failure detection system components Check firing rate control Check piping and wiring of all interlocks and shutoff valves Inspect burner component
40. ischarge and water damage pipe the discharge from the relief valve to a suitable floor drain for disposal when relief occurs Avoid contact with hot discharge water Thermal Expansion A relief valve that discharges periodically may be due to thermal expansion in a closed system by components such as a backflow preventer or check valve in the cold water supply or a closed boiler heating loop These systems must be provided with means to control expansion Contact a boiler or plumbing professional to resolve this situation Do not plug the relief valve Electronic Low Water Cut Off Low Water Cut Off Operation When the water level is above the electrode position in the tank the reset pushbutton will energize the control LED will be lit The control remains energized until the water level recedes below the electrode position LED will not be lit Unless otherwise specified there is a three second time delay on decreasing level Water level must be below tank probe location for full three seconds before control de energizes Manual Reset Operation for CSD 1 Code Compliance If the manual reset low water cut off control is in a low water condition water off probe and there is an interruption of power the control will remain in the low water condition when power is restored To reset the low water cut off press he reset button when the water level is restored to a point above the probe 17 34 54 07 13 10 TEMPTRAC ELECTRONIC CONTROLL
41. l your gas supplier from a location away from your building and the smell of gas Follow the gas supplier s instructions e Ifyou cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier This product contains or may come to contain materials that have been identified as carcinogenic or possibly carcinogenic to humans Before installing servicing or removing this product read and follow the supplied instructions WARNING Installation and service must be performed by a qualified installer service agency or the gas supplier who must read and follow the supplied instructions before installing servicing or removing this appliance Refer to the information contained in this manual Improper installation adjustment alteration service or maintenance can cause property damage personal injury exposure to hazardous materials or loss of life WARNING Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the unit and to replace any part of the control system all gas controls and all other items affecting safe appliance operation and which has been under water WARNING In an emergency shut the main gas supply valve to the appliance from a location safely away from the emergency Failure to follow these instructions can cause property damage personal injury and exposure to
42. lt from improper combustion Adjust to proper CO2 levels at low fire Grounding Safety Limits Check for proper ground from flame control to burner housing Check all safety limits for fault condition and correct as reguired 29 34 54 07 13 15 REPLACEMENT PARTS REPLACEMENT PARTS 15 1 Control Panel ALARM BUZZER ENUNCIATOR WHEN USED 5 6 TERMINAL STRIP L1 120VAC L2 NEUT 120VAC L2 NEUT 120VAC L1 FUSED L3 24VAC L3 24VAC L4 NEUT GROUND L4 NEUT GROUND TERMINAL STRIP VALVE HIGH TEMP LIMIT LOW PRESS GAS HIGH PRESS GAS ELWCO FLAME FAIL FILTER SWITCH AIR SWITCH B GROUND LUG FOR TH FIELD CONNECTION 31 ELECTRICAL KNOCKOUTS 13 2 8 INDICATING LIGHTS ALARM SILENCING SWITCH WHEN USED 34 54 07 13 15 2 Control Panel Components Optional components may not be included MM M REM 0 0068 WE 5 32 34 54 07 13 Burner Assembly 15 3 XIHRGSSV Svo mon AQOB JATVA ONY N33 138 5 TWLSNI 2M Z 135 HOLMS 35410553544 SYI HSIH 1 eol HLM HsmH 1404135 15060 SOL mONJ SNYML L 1NIOdL3S Lsnrdy 33 34 54 07 13 15 4 Burner Assembly and Gas Train Components Optional components may not be included
43. me safeguard reset button Some safety devises are wiring in the operating circuit and may not indicate alarm If no indication of alarm exists check gas pressure switches electronic and float low water cutoffs and temperature limits When the blower motor starts the flame control will check for a positive air flow If the air switch or blocked filter switch is not made the blower will stay on for a period of time then lockout To adjust the air proving switch turn the adjustment screw counter clockwise until the air proving light comes on then turn the screw one turn counter clockwise The blocked filter switch should only be adjusted when the filter is new This switch should be turned clockwise until switch makes and then two additional turns If the gas valves open and close intermittently during normal operation adjust pressure switches to increase the operational threshold until this condition ceases This procedure should be followed with every burner After the pre purge the flame control energizes the HSI for the heat up period approximately 30 seconds At the end of that period the gas valve is opened for approximately 4 seconds After the burner has lit and the primary safety control senses a flame the burner will remain on until the call for heat is satisfied or operation is interrupted by a safety devise If the burner fails to light the flame control will lockout When this happens press the reset button on the front of the control
44. mperature These controls are located inside the control cabinet and are accessed by removing the bottom cover The High Limit Control is of the manual reset type and may be reset by pressing the limit reset button accessible through the control panel cover The Lower Limit is of the auto reset type and can be dial adjusted to operate just above the set point of the main Operating Temperature Control Pressing the reset on the High Limit Control will not cause the control to reset until the water temperature has dropped below the set point of the manual reset High Limit Control Warning Turn off all electrical service to the appliance when accessing the limit or high limit controls located inside the control cabinet This cabinet contains High Voltage wiring and terminals Ifthe electrical service is not turned off and these terminals are touched a dangerous shock causing personal injury or loss of life could occur Close and fasten the control cabinet cover before restoring electrical service to the appliance Relief Valve A pressure only relief valve s sized in accordance with the ASME Boiler and Pressure Vessel Code Section IV is installed in the tank Caution Do not install a reducing coupling valve or other restriction in the relief valve s discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year Warning To prevent burns caused by hot water d
45. mperature fall occurs approaching 155 F the firing rate remains at low fire C Temperature drop at 155 F St4 enters the MODULATION THRESHOLD C to D Once modulation is established the sensed loop temperature can fluctuate between 155 F and 145 F between St4 and SR The firing rate increases or decreases proportionately between 10096 and low fire depending upon the temperature sensed in the return loop Temperature rise in the heat exchanger varies accordingly 45 to 15 depending upon the firing rate 19 34 54 07 13 10 6 10 7 10 8 10 9 D The unit will remain in modulation until the sensed temperature rises above 155 F 514 The firing rate returns to low fire Modulation will only reactivate when return loop temperature drops to 155 F e Eto F Low fire is maintained if the return loop temperature ranges between 155 and 165 F e F This firing pattern will continue until the temperature reaches the Burner OFF threshold of 165 F St1 and shuts off To View The Setpoint e Push and release the SET key to see the set point value e Toreturn to normal display press SET UP or wait 15 seconds without pressing any key To Change The Setpoint e Push the SET key The upper display will show the parameter name while the lower display will show its value e Use the UP or DOWN key to cycle through the parameter names Push the SET key to modify a parameter value The value starts flashi
46. n buildings with variable flow pumping systems on the boiler loop motorized isolation valves be recommended Building flow may have to be limited to only the firing boilers during periods of low building heat demand to prevent temperature from reaching the boiler s operating limit t is recommended that the OnTrac multiple boiler control be used to control these valves Consult your Riverside Hydronics representative for design assistance 5 3 Condensate Drain Trap amp Disposal The Centauri boiler is designed to produce significant amounts of condensate because of its high efficiency Condensate occurs naturally when water vapor in combustion gases is cooled below the dew point A 3 4 NPT drain connection is provided A trap with three inches of standing water below the bottom of the heater 3 above the base of the skids and no higher than the bottom of the heater must be field installed as part of the condensate piping WARNING A trap with three inches of standing water as described in these instructions must be included as part of the condensate piping system This trap is required to keep hazardous products of combustion from continually entering the room through the condensate piping Failure to provide this trap can cause personal injury exposure to hazardous materials or loss of life 34 54 07 13 5 4 1 Installing the boiler on a 4 inch to 6 inch housekeeping pad is recommended to ensure proper condensate
47. nally Recognized Standard to comply with safety and performance criteria such as proper ignition combustion and safety shutdown operation 34 54 07 13 6 7 Gas Control Trains 7 1 All models include gas control trains with the following components main gas cock two safety shutoff valves proportionator regulator and a final manual shutoff valve with the manifold pressure tap on the side of the valve These components may be separate or two or more may be combined in a common housing Caution Do not adjust or remove any screws or bolts on gas train control components which are sealed with a red or blue colored compound Doing so will void all approvals and warranties COMBUSTION AND VENTILATION AIR Provisions for adequate combustion and ventilation air to the mechanical room must be in accordance with Section 5 3 Air for Combustion and Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 Installation Codes or applicable provisions of the local building codes Equipment Located In Confined Spaces Equipment located in confined spaces requires two openings installed within 12 300 m from the top and bottom of the room to assure adequate combustion air and proper ventilation The total input of all gas utilization equipment installed in the room must be used to determine the required minimum air volume needed for combustion ventilation and dilution of flue gasses All Air From Outdoors
48. nection is located behind the hinged control panel at the top of the cabinet and is accessed by removing the bottom cover and then removing the screws at the top of the hinged cover Important Do not use single strand bell wire for remote field connections to terminals R1 R2 and C1 C2 Use only multi strand copper wire See table below for wire length and gauge Wire Gauge 18 16GA 14GA 12 GA Maximum Length 30FT 50FT 75 100 FT Warning Turn off all electrical service to the appliance when accessing the remote connections located inside the control cabinet These terminals are High Voltage If the electrical service is not turned off and these terminals are touched a dangerous shock causing personal injury or loss of life could occur Close and fasten the control cabinet cover before restoring electrical service to the appliance The Following Describes The Functions Of Each Of These Terminals And The Factory Installed Options Reguired To Activate The Terminals Note Terminals A1 A2 and P1 P2 are functional only when the boiler is eguipped with the factory installed options reguired to activate the terminals Terminals R1 R2 C1 C2 and T1 T2 are standard pre wired functions on all models R1 R2 Used to activate de activate boiler from remote master control Terminals are wired to a relay in a remote Boiler Management or Energy Management System When relay closes circuit from R1 to R2 is com
49. ng in the lower display To change it push the UP or DOWN keys Push the SET key again to confirm the value and pass to the setting of next set point e Repeat the operations described at points 3 4 5 Exit press SET UP or wait 15 seconds without pressing any key NOTE Each point has a time out of 15 seconds If any key is pushed within 15 seconds the controller exits the Set points programming procedure NOTE The set value is stored even when the procedure is exited by waiting the time out to expire To Change Other Parameters Push the SET and DOWN arrow simultaneously for seconds e Select the required parameter The name of the parameter is on the upper display its value is on the lower display e Press the SET key the value of the parameter will start blinking e Use UP or DOWN to change the value Press SET to store the new value and move to the following parameter Exit Press SET UP or wait 15s without pressing a key LED Display Alarm Messages Alarm messages are displayed in the upper LED readout and alternate with the default display An alarm LED ICON is also illuminated See TempTrac User Manual 34 80 for full description 20 34 54 07 13 ALARM RECOMMENDED MESSAGE CAUSE RESULTS OF ALARM CONDITION ACTION Inlet temperature sensor is not connected or Check winria and Sensor P1 TP1 probe failure is reading incorrectly Call for heat and bu
50. or Controls and Safety Devices for Automatically Fired Boilers No CSD 1 Where reguired by the Canadian authority having jurisdiction the eguipment must be installed in accordance with the latest edition of the Installation Code for Gas Burner Appliances and Eguipment CAN CSA B149 and or B149 2 and applicable Provincial Regulations All appliances conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Electrical Reguirements See appliance rating decal for electrical service reguirements The appliance must be electrically supplied and grounded in accordance with the reguirements of the authority having jurisdiction or in the absence of such reguirements with the latest edition of the National Electrical Code ANSI NFPA No 70 In Canada the electrical service must conform to local electrical codes and or CSA C22 1 Canadian Electrical Code Part 1 e All wiring between the unit and field installed devices must be made with type T copper wire e Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable To avoid serious damage DO NOT energize the unit until the system and appliance is full of water Location These units are suitable for indoor installation only Installing the boiler on a 4 inch to 6 inch housekeeping pad is recommended to ensure proper condensate drainage Locate the unit so that if water connections should leak water damage will
51. ory ceramic fiber materials contact Unifrax Corporation 2351 Whirlpool Street Niagara Falls NY 14305 2413 1 800 322 2293 IDENTIFICATION OF REFRACTORY CERAMIC FIBER MATERIALS RCF The burner lower tank and upper and lower flue collector assemblies utilize RCF material The RFC materials are located within the product and not generally exposed except during service disassembly or assembly 34 54 07 13 2 STANDARD FEATURES AND EQUIPMENT 2 1 2 2 2 3 2 4 Performance _ Up to 99 efficiency at low fire with low return temp _ Inward fired burner technology with seamless modulation capable of 20 to 1 turndown Low NOx emissions SCAQMD compliant lt 15 ppm no derate or efficiency reduction to obtain 515 ppm _ Ducts direct combustion air up to 100 equivalent feet through 6 diameter material requires UL approved vent cap see optional equipment list _ Vents up to 100 equivalent feet through 6 diameter material UL approved vent cap supplied Burner Combustion Controls amp Operating Controls _ Pre mix surface burner with proportional gas air control and variable speed blower motor _ Electronic ignition control with pre and post purge _ Electronic operating control with digital readout _ Firing cycle status panel lights _ Indicating light for flame failure with remote indication contacts _ Dual temperature limits with manual reset on high limit temperature control Manual reset electronic low wat
52. perty damage personal injury exposure to hazardous materials or loss of life 34 54 07 13 5 5 Temperature Control Sensor The Temperature Control Sensor is coiled and secured to the control enclosure along with the Sensor Thermal Well Important The thermal well must be installed in the return plumbing 1 to 4 feet from the return connection on the boiler The sensor should then be inserted into the thermal well along with thermal conductive paste Use the plastic threaded plug to secure the sensor in place See Illustration below 5 6 Suggested Plumbing It is recommended that the following plumbing arrangement be used During normal operation the system return water will be circulated first to the inlet connection on the economizer and then to the boiler When the arrangement below is applied the economizer can be isolated for service and the boiler can then be operated by opening the bypass valve ISOLATION VALVES SHOULD BE COSED WHEN SERVISING THE ECONOMIZER HB TEMPERATURE CONTROL SENSOR AND THERMAL WELL BYPASS VALVE SHOULD BE OPENED FOR SERVISING ECONOMIZER ONLY Suggested Plumbing and Temperature Control Sensor Installation 5 7 Filling The Boiler 1 Fill the system with water To be sure that the unit is not air bound open the relief valve Leave the valve open until a steady flow of w
53. pleted and appliance controls are enabled Appliance ships from factory with jumper between terminals Remove jumper when connecting to a remote controller A1 A2 Used To Activate A Remote Alarm Signaling Shutdown Of Combustion Control Provides a maximum 10 amp relay contact closure when the flame safeguard terminates combustion due to a tripped safety interlock i e air proving switch high limit switch low water flow switch or flame sensor etc Options Required Consult Factory P1 P2 Activates remote equipment and requires confirmation signal back to the appliance Provides a maximum 10 amp relay contact closure to activate a remote device i e mechanical room air louvers draft inducer or power vent etc The remote device must send return signal via proving switch to confirming proper operation to terminals C1 C2 prior to the appliance being able to energize Options Required Consult Factory C1 C2 Used for proving operation of remote device Terminals are wired to a proving switch on a remote device such as a power venter When relay closes circuit from C1 to C2 is completed and appliance controls are enabled This appliance ships form the factory with jumper between terminals T1 T2 Used for external modulation control To connect external modulation control disconnect and cap the blue wire connected to terminal T2 and connect the external modulating signal to terminals T1 positive and T2 negative Outdoor Reset requir
54. pliance and venting system at least once a year Check more often in first year to determine inspection interval a Check joints and pipe connections for tightness corrosion or deterioration b Checkthe electronic ignition system for quick ignition and a proper flame signal Check all safety controls including thermostats for proper operation d Check safety shut off valves for operation and tightness e Have the entire system including but not limited to the burner heat exchanger and venting system periodically inspected by a qualified service agency Exposure to Dusty or Dirty Combustion Air An appliance installed in a dust or dirt contaminated atmosphere will require replacement of the filter on a 3 to 6 month schedule or more often based on severity of contamination Contaminants can be drawn in with the combustion air Inadequate combustion air or non combustible particulate matter such as dust dirt dryer lint concrete dust dry wall dust or the like can block burner ports and cause unsafe operation and a non warrantable failure Do not remove filter without a suitable replacement To inspect and clean the burner a qualified serviceman or installer should use the procedures described in item 5 amp 6 below Any sign of soot on the heat exchanger or in the flue indicates the need for a combustion inspection Properly installed and adjusted units seldom need heat exchanger cleaning If soot has formed the most common ca
55. r sensor should be connected to the TempTrac control located on the control panel of the boiler Use sensor P N 102163 Pass the temperature sensing probe through the wall to the building s exterior Use sound construction techniques to create and insulate the wall penetration To operate properly the sensor must be located away from direct sunlight and protected from the weather The length of the wire leads on the thermistor is 25 feet If more wire is needed it is admissible to splice 22 gage multi strand copper wire into the thermistor coil Thermistor probe should be protected with suitable outdoor cover 11 6 Riverside Hydronics ONTRAC Boiler Management System BMS The is a separate multiple boiler control designed to coordinate the operation of multiple boilers using TempTrac controls This section will briefly summarize the controller s capabilities and features See ONTRAC Programming Manual 434 152 and Wiring Guide 34 151 for full description Controls up to 20 boilers more with expansion card PID control with full color touch screen interface Basic functions include lead lag outdoor reset nighttime setback and isolation valve control In hybrid systems prioritizes and rotates through up to 12 condensing boilers before energizing and rotating through up to 8 non condensing boilers Communicates with boilers by Modbus RTU protocol over 485 serial connection 2 wire shielded daisy chain Connects to Building
56. rner ng 4 Terminals 14 amp 17 modulation output signal will revert to low fire Temperature sensor is not connected or is Sensor P2 TP2 probe failure reading correctly Freeze protection is 109 Terminals 15 amp 17 disabled Temperature sensor is not connected or is Chock winndand Sensor P3 TP3 probe failure reading correctly Outdoor reset disabled Terminals 16 amp 17 Warm weather shutdown disabled HA High temperature nt Buzzer sounds operation continues Manual reset reguired setpoint exceeded LA Buzzer sounds operation continues HP Milos pressure Unit deenergized after timer delay Manually reset required LP 2 Unit deenergized after timer delay Manually reset reguired 1 Maintenance alarm Buzzer sounds operation continues Check wiring and sensor for output 1 Mn2 Maintenanee alarm Buzzer sounds operation continues Check wiring and sensor for output 2 Mn3 Maintenance alarm Buzzer sounds operation continues Check wiring and sensor for output 3 P The real time clock has lost its setting Energy saving function disabled Reprogram clock Real time clock failure Energy saving function disabled Replace control 11 11 1 BOILER CONTROL INTERFACE A terminal strip for the remote connection is located behind the hinged control panel at the top of the cabinet and is accessed by removing the bottom cover and then removing the screws at the top o
57. s Check igniter Test high and low gas pressure interlocks Check air filter and replace if required Monthly Maintenance 7 Qo Test low water cutoff device and alarm Check flue vent stack or outlet dampers Check flame signal strength Check flame failure detection system Check firing rate control Listen to and visually check the pilot and main fuel valves Daily Maintenance a Check gauges monitors and indicators b Check instrument and equipment settings As Required a Recondition or replace float low water cutoff device b Check drip leg and gas strainers c Test flame failure detection system d Test safety relief valves in accordance with ASME Boiler and Pressure Vessel Code Sections VI 8 VII 37 34 54 07 13 Riverside Hydronics LLC 990 Haltom Road e Ft Worth TX 76117 1 800 990 5918 www riversidehydronics com 38 34 54 07 13
58. to recycle burner and check for improper combustion or week flame signal as a possible cause Once the main burner flame is established the firing rate will be controlled by the TempTrac control Refer to TempTrac manual 34 81 Burner Combustion Adjustment Burner combustion should only be adjusted using a combustion analyzer Do not attempt to adjust burner by sound or sight With the burner firing insert the combustion analyzer probe in the flue vent approximately two feet from the appliance See Gas Train Illustration below for details With the burner firing and adjusted to low fire adjust the regulator screw clockwise to increase gas flow or counter clockwise to decrease flow The desired in the combustion products should be between 7 5 and 8 5 Do not attempt to adjust combustion based on manifold pressure alone Manifold pressure should only be used as a reference point a Once the desired combustion is achieved at low fire raise the burner firing rate to high fire Adjust the valve orifice clockwise to reduce the flow of gas and counter clockwise to increase the flow of gas in order to maintain the desired CO the combustion products between 7 5 and 8 5 b When high fire combustion has been reached and combustion is within the proper range return to low fire to confirm settings again c CAUTION If at any point of the modulation range carbon monoxide is in excess of 300ppm contact Riverside Hydronics customer service
59. ure to outdoor reset temperature probe when EXT installed Also displays the temperature difference of the return temperature minus supply temperature In programming mode it sets the 4 20mA output password is required ON OFF Switches the control ON or OFF See TempTrac User Manual 34 80 for full description 10 5 Modulating Firing Seguence The boiler is fully modulating and initiates combustion at the lowest firing rate It will modulate between this lowest possible rate and full rate as the boiler loop temperature rises and falls in relation to the operating set point The Parameters involved with the modulation control seguence are St1 Hy1 St4 and SR 18 34 54 07 13 LABEL DEFAULT VALUE TEMPERATURE TEMP DETERMINED 51 165 165 LED display value Hy1 8 157 F St1 Hy1 St4 10 155 F St1 St4 SR 10 145 F St4 SR St1 The system s desired maximum setpoint when all firing ceases This is the temperature setpoint of the appliance The factory setpoint is 165 F Hy1 The differential from St1 This is the Burner On threshold The burner Call For Heat is initiated and establishes the firing rate at low fire The factory default is 8 F and is adjustable to 1 F This is the drop in temperature F below the setpoint that the boiler must drop for the heat load to re establish following a heat cycle heat cycle heat load is established unit com
60. uses are restricted combustion air or excessive gas A blocked heat exchanger can cause unsafe operation and will reduce efficiency To inspect and clean the heat exchanger a qualified serviceman or installer should use the procedures described in item 5 amp 6 below All gaskets on disassembled components must be replaced on reassembly with exact Factory Authorized replacement parts only Gasket kits are available from your Riverside Hydronics Representative or by contacting Riverside Hydronics LLC Burner and or Heat Exchanger Inspection and Cleaning Procedure a Turn off main power to unit b Turn off gas supply c Write notes and or take pictures during this process to aid in correct reassembly d Remove the hot surface igniter HSI from the burner Be very careful not to bump the igniter element due to the fragility of the igniter e Remove the nuts that secure the burner top plate to the burner flange and lift the burner top plate up until it is completely extracted from the burner f Inspect top plate refractory for damage The refractory should provide a tight seal against the top edge of the burner deck The silicone foam gasket located on the top plate flange should also be checked for damage or excessive compression set g With the burner top plate removed inspect the deck surface of the burner for lent or other blockage carried in the fuel air stream If blockage has accumulated use brush to loosen debris and use

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