Home

Burnham RTC (Return Temperature Control) Installation Operating Instructions

1. Supply from Boiler from Boiler CLOCKWISE CW OPEN TO SYSTEM COUNTER CLOCKWISE CCW CLOSED TO SYSTEM Supply RTC Terminals Actuator Terminals Full Flow No Flow to to System System lt Full Flow thru Bypass Flow thru Bypass Supply Sup from Boiler COUNTER CLOCKWISE CCW OPEN TO SYSTEM CLOCKWISE CW CLOSED TO SYSTEM RTC Terminals Actuator Terminals ply from Boiler The control s Test Sequence can be used to check the motor circuit Once the Test button is pressed the valve should move to the fully open position If the motor closes instead of opening the wiring of the actuating motor must be reversed Next the valve should move to the fully closed position If it does not chec any installation or troubleshooting information supplied with 15 k the wiring between the terminals and the actuating motor Refer to the motor of 60 Boiler Enable Contact The Boiler Enable terminals 7 and 8 are an isolated output in the control There is no power available on these terminals from the control These terminals are to be used as a switch to either make or break the boiler limit circuit When the control requires the boiler to fire it closes the contact between terminals 7 and 8 Sensor and Unpowered Input Connections Do not apply powe
2. Cw spe E n Cw spe E n Pee epe e Ee Pee s E om pr e E Pew Teele el ar DIVERTING VALVE amp ACTUATOR SEE NOTE 6 1 suppLy BOILER CIRCULATOR SEE NOTE 6 SEE NOTE 7 2 RETURN POINT OF MIXING SEE NOTE 8 DRAIN VALVE SEE NOTE 4 3 x 12 SPECIAL NIPPLE SEE NOTE 3 REAR OF KON RETURN BRANCH RETURN HEADER RETURN TEMPERATURE V912A W 20 F DROP SENSOR NOTES 1 ALL SUPPLY AND RETURN PIPING IS SCHEDULE 40 BLACK PIPE 2 PIPE SIZES LISTED IN TABLE ARE BASED ON EITHER A 20 F OR A 40 F TEMPERATURE DROP DIFFERENTIAL SELECT ONE DIFFERENTIAL THAT MATCHES THE APPLICATION 3 INSTALL SPECIAL 3 NPT X 12 LG X 1 NPT SIDE TAPPING PIPE NIPPLE INTO BOILER RETURN PORT WITH SIDE TAPPING NIPPLE END POSITIONED AWAY FROM BOILER USE BELL REDUCER FOR MODELS V903A THRU V911A WITH A 20 F TEMPERATURE DROP OR FOR MODELS V903A THRU V911A WITH A 40 F TEMPERATURE DROP TO ADAPT TO RECOMMENDED RETURN PIPING SIZE SEE TABLE 4 DRAIN VALVE ALTERNATE BALL VALVE IS PREFERABLE ALTERNATE GATE VALVE IS ACCEPTABLE MINIMUM VALVE SIZE IS 3 NPT PER ASME CODE 5 ALL PIPE REDUCTIONS SHALL BE MADE ONLY AT THE BOILER SUPPLY AND RETURN TAPINGS AND OR DIVERTING VALVE AND BOILER CIRCULATOR FLANGES UNLESS NOTED OTHERWISE 6 SEE APPENDIX B FOR BOILER CIRCULATOR AND DIVERTING VALVE SELECTION AND PART NUMBERS 7 MAXIMUM LINEAR DISTANCE FEET OF PIPE FROM 3 WAY DIVERTING VALV
3. 80160357 1 5 80149024 1 1725 V1104 Un o V1105 I 1 5 NPT 80160357 1 5 NPT 80149024 120 1725 1069 2 0 NPT 80160358 2 0 NPT 80149025 120 1725 1281 2 0 NPT 80160358 2 0 NPT 80149025 121 1725 2 V1106 V1107 V1108 N A 4 V1109 1729 1941 80160359 1635 1750 1517 30100358 E 1725 V1110 V1111 V1112 V1113 V1114 V1115 1750 V1116 1750 V1117 V1118 V1119 I ao 16036 Kva007 neo vno 207 20160361 amp va007 vna 20180361 7 V1122 4334 80160361 KV3007 4551 228 80160361 KV3007 Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 1160 1160 1160 V1123 1160 51 of 60 Appendix m V11 Boiler Circulator and Diverting Valve Selection Chart 20 F amp 40 F AT Grundfos V11 Boiler Circulator Selection Grundfos 20 F Differential IBR GROSS TOTAL a OUTPUT apm Pipe Size MBH Boiler Recirculation Boiler Recirculation Grundfos Circulating Pump e lt T lt Valve Size Valve Size Model No Imp HP RPM 2 0 NPT 80160358 2 0 NPT 80149025 UPS40 80 4 4 86 1 2 1587 2 5 Flange 80160359 2 5 Flange 80160366 UPS40 80 4 4 86 1 2 1688 2 5 Flange 80160359 2 5 Flange 80160366 UPS50 80 4 4 97 3 4 1694 2 5 Flange 80160360 2 5 Flange 80149026 UPS50 80 2 2 91 3 4 3426
4. Power Demand L N Pmp 10A 126046 Heat Power Demand L N Pmp 24 Volt Output 9 10 11 24 Volt Output REI 1 C1 CW Open to System CW Open to System br I Breaks on Temp Rise Al Breaks on Temp Rise Al Class II Transformer NOTES 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 5 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required if the Outdoor Reset feature is selected 6 System Pump P3 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 31 of 60 A4 3 way RTC in Primary Secondary Heating and DHW using Indirect Water Heater on Primary Loop without Outdoor Reset Mechanical A1 Indirect Hot Water Aquastat C1 Diverting Valve Actuating Motor M1 By Pass Mix Point P1 Boiler Circulator P2 Indirect Circulator P3 System Pump runs on call for heat
5. Repair Parts RTC PARTS Qty Boiler Number 80160916 80160355 80149013 80160356 80160357 80160358 80160359 80160360 80160361 80160362 80160363 80149016 80149017 80149024 80149025 80160366 80149026 80160348 80160364 80160365 80160915 806600426 7016034 6016085 6016086 80160173 80160172 80160196 80160165 60160870 60160871 60160872 60160873 60160874 60160875 Return Temperature Control RTC with boiler sensor and mounting screws Control Motor ESBE 92M 24V 50 Second motor Danfoss 065F 8953 3 Way Diverting Valve Danfoss 065B8968 1 NPT Model MG25 12 3 Way Diverting Valve Danfoss 065B8969 1 1 4 NPT Model MG32 8 3 Way Diverting Valve Danfoss 4065B8953 1 1 2 NPT Model G138 3 Way Diverting Valve Danfoss 065B8954 2 NPT Model G151 3 Way Diverting Valve Danfoss 065B8960 2 1 2 flanged Model F165 50 a mo 47 3 Way Diverting Valve Danfoss 065B8961 2 1 2 flanged Model F165 3 Way Diverting Valve Danfoss 065B8962 3 flanged Model F180 3 Way Diverting Valve Danfoss 065B8963 4 flanged Model F1100 3 Way Diverting Valve Danfoss 4065B8964 5 flanged Model F1125 4 Way Diverting Valve Danfoss 4065B8985 1 NPT Model 4 MG25 12 4 Way Diverting Valve Danfoss 4065B8986 1 1 4 NPT Model MG32 8 4 Way Diverting Valve Danfoss 4065B8979 1 1 2 NPT Model G438 4 Way Diverting Valve Danfoss 4065B8980 2 NPT Model G451 4 Way Diverting Valve Danfoss 406
6. Boiler Return Sensor S2 Mix Supply Sensor 071 S3 Outdoor Sensor 070 21 23 Zone Valves Zone Relays Thermostats or BMS Signal 24 Volt Output 12 N ENG Heat Power Boil Demand L N Pmp N BM Lif Li p M c1 CW Close CW Closed to System CW Open to System to System P1 OH 71 73 Z1 23 Za Ge XD I Om LOH PI Or R2 Onm 2O Ow O Qu 9 R1 Breaks on OPLO p Temp Rise gt Ri A1 P2 I Class II P2 Transformer gu DAV ac C l L I 20 V ac N 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 24 Volt Output CW Open to System Breaks on Temp Rise Al 5 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required if the Outdoor Reset feature is selected 6 System Pump P3 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 39 of 60 A8 4 way RTC in
7. How long has the problem existed for This information is critical in correctly diagnosing the problem Understand the sequence of operation of the system If a particular zone is not receiving enough heat _ Understanding which pumps or valves in the system must operate in order to deliver heat to the affected zone If the the Sequence of zone is receiving too much heat which pumps valves or check valves must operate in order to stop the Operation delivery of heat Press the Test button on the control and follow the control through the test sequence as described Use the Test in the Testing section Pause the control as necessary to ensure that the correct device is operating Routine as it should Sketch the piping of the system This is a relatively simple step that tends to be overlooked however it Sketch the can often save hours of time in troubleshooting a system Note flow directions in the system paying close Piping in the attention to the location of pumps check valves pressure bypass valves and diverting valves Ensure System correct flow direction on all pumps This is also a very useful step if additional assistance is required Document the control for future reference Before making any adjustments to the control write down Document the all of the items that the control is currently displaying This includes items such as error messages Control current temperatures and settings and which devices should be operating a
8. SEE NOTE 7 SUPPLY HEADER DRAIN VALVE SEE NOTE 5 SYSTEM SUPPLY DIVERTING VALVE amp ACTUATOR SEE NOTE 7 SWING JOINTS SEE NOTE 3 CLOSELY SPACED SYSTEM RETURN SEE NOTE 8 RETURN POINT OF MIXING SEE NOTE 9 3 X 12 SPECIAL NIPPLE SEE NOTE 4 RETURN TEMPERATURE SUPPLY BOILER CIRCULATOR SEE NOTE 7 SUPPLY HEADER DRAIN VALVE SEE NOTE 5 SENSOR sysrsu N Q SUPPLY SYSTEM DIVERTING PUMP VALVE amp ACTUATOR SEE NOTE 7 SWING JOINTS SEE NOTE 3 MAX 4D CLOSELY SPACED TEES SYSTEM RETURN SEE NOTE 8 RETURN POINT OF MIXING SEE NOTE 9 3 X 12 SPECIAL NIPPLE SEE NOTE 4 REAR OF BOILER RETURN HEADER RETURN BRANCH V1116 AND V1117 W 20 F DROP SUPPLY PIPING SIZE RETURN PIPING SIZE BOLLER SUPPLY RETURN RETURN SUPPLY RISER RETURN BRANCH HEADER QTY SIZE HEADER QTY SIZE DROP DROP DROP DROP DROP DROP DROP DROP DROP DROP DROP DROP Hue ERES ERE REESE d ER gt gt gt s r E EE 2257 IL L L2 9 j2o7 sj s gt lor 9 4 eee se L e lor EN viz s e ear 9 osos vies 8 e e gt lor gt 9 L 3 4 on RETURN TEMPERATURE SENSOR REAR OF BOILER RETURN HEADER RETURN BRANCH V1118 THRU V1123 W 20 F DROP NOTES 1 2 ALL SUPPLY AND RETURN PIPING IS SCHEDULE
9. 2 5 Flange 80160360 2 5 Flange 80149026 TP100 40 4 4 1 1 1750 2 5 Flange 80160360 2 5 Flange 80149026 TP100 40 4 4 1 1 1750 3 0 Flange 80160361 3 0 Flange 80160348 3 0 Flange 80160361 3 0 Flange 80160348 3 0 Flange 80160361 3 0 Flange 80160348 3 0 Flange 80160361 3 0 Flange 80160348 UPS80 160 2 3 56 4 0 Flange 80160362 4 0 Flange 80160364 4 0 Flange 80160362 4 0 Flange 80160364 4 0 Flange 80160362 4 0 Flange 80160364 4 0 Flange 80160362 4 0 Flange 80160364 4 0 Flange 80160362 4 0 Flange 80160364 80160365 vitte 3739 5 0 vi120 3957 5 0 Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 5 0 Flange 80160363 5 0 Flange Co 4 55 5 0 Flange 80160363 5 0 Flange 80160365 5 0 Flange 80160363 5 0 Flange 80160365 80160363 80160365 5 5 0 Flange 5 0 Flange 5 0 5 0 Flange 80160363 5 0 Flange 80160365 52 of 60 V11 Boiler Circulator Selection Grundfos 40 F Differential Boiler Recirculation Boiler Recirculation IBR Grundfos Circulating Pump GROSS TOTAL OUTPUT GPM MBH T Ey lt X Ey lt Pipe Size Valve Part Model No Number Valve Part Number Valve Size Valve Size RPM 1104 667 33 1667 V1105 43 i10
10. 5211 2003 by tekmar Control Systems Ltd All rights reserved 60 of 60 All specifications are subject to change without notice Used with permission of tekmar Control Systems Ltd Printed in Canada 06 03 ue
11. Do not use solvents or cleaning solutions 19 of 60 View Menu 1 of 1 BOIL Description icp BOIL 14 to 266 F Current boiler return temperature as measured by the boiler sensor 10 to 130 C MIX TARGET i3 d Target mixed supply is the temperature the control is currently trying to maintain 14 to 266 F at the mixing sensor Mix sensor is present or OUTDR DSGN OFF 10 to 130 C MIX iri n Mk uu Current mixed supply water temperature as measured by the mixing sensor eee C Mix sensor is present or OUTDR DSGN OFF 10g OUTDR cn 67 to 149 F LI Current outdoor air temperature as measured by the outdoor sensor 55 to 65 C Outdoor sensor is present and OUTDR DSGN z OFF BOIL Monitor BOIL run run Monitor The control records the number of hours the boiler enable contact has been closed run lt gt 0 to 99 999 BOIL ra E ucE r Monitor Monitor Monitor BOIL CYC The control records the number of boiler enable relay cycles Monitor BOIL MIN run Below return water minimum The control records the number of hours the boiler operates below the boiler minimum setting CYC lt gt 0 to 99 999 run lt gt 0 to 99 999 Monitor Monitor BOIL CS The number of times the boiler has experienced cold shock conditions CS lt gt 0 to 99 999 Moni
12. F However the MIX MAX setting must below the highest permissible temperature for any system component affected by the boiler supply water H OPEN DELAY This setting represents the number of seconds required for the actuator to move the valve from a fully closed to a fully open position Keep this setting at the default value of 50 seconds l BOIL MIN Boiler Minimum This setting represents the minimum allowable boiler return water temperature Keep this setting at 135 F unless a higher minimum return water temperature is required J BOIL MIN DELAY Boiler Minimum Delay This setting represents the number of seconds required for warm up during an initial cold start Use the appropriate value from Table or Il depending on the specific application These values include 90 seconds of pre purge time K PUMP DELAY This setting represents the time in seconds for boiler circulator pump purge after a heat demand cycle This minimizes the amount of boiler temperature overshoot at the end of a cycle During the pump purge the diverting valve will con tinue to operate and prevent low temperature return water from entering the boiler At the end of the pump purge period the diverting valve will close immediately Set the pump delay as desired The default setting is 30 seconds STEP EIGHT CLEANING THE CONTROL The control s exterior can be cleaned using a damp cloth Moisten the cloth with water and wring out prior to wiping control
13. Primary Secondary Heating and DHW using Indirect Water Heater on Primary Loop without Outdoor Reset Mechanical A1 Indirect Hot Water Aquastat C1 Diverting Valve Actuating Motor M1 By Pass Mix Point P1 Boiler Circulator P2 Indirect Circulator P3 System Pump runs on call for heat R1 Relay 1 Boiler Return Sensor V1 3 Way Diverting Valve V2 Ball Valve Balancing Valve V3 Ball Valve System Balancing 21 23 Zones Class II Transformer 120 V ac J 24 V ac Se ng Indirect DHW Tank eir REHEHHEREERN E ET RW ibiq mn v2 Boiler Return Sensor S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating DHW with an indirect water heater 2 This arrangement is NOT recommended for outdoor reset applications The reset temperature will constantly change DHW water performance 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 A domestic hot water priority could be used provided the diversion from the heating system loop does not impact the system heater s performance 5 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 6 The diverting valve V1 must be no greater
14. System Pump P3 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 29 of 60 A3 3 way RTC in Primary Secondary Heating and DHW using Indirect Water Heater with without Outdoor Reset Mechanical A1 Indirect Hot Water Aquastat C1 Diverting Valve Actuating Motor M1 By Pass Mix Point P1 Boiler Circulator P2 Indirect Circulator P3 System Pump runs on call for heat S1 Boiler Return Sensor S2 Mix Supply Sensor 071 Required for Reset or Set point Control S3 Outdoor Sensor 070 Required for Reset Control V1 3 Way Diverting Valve V2 Ball Valve Balancing Valve 21 23 Zones RTC E Outdoor Sensor Class II S3 070 Transformer 120 V ac QUEE ee i Indirect DHW Tank 1 v2 Boiler Return Sensor S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating DHW with an indirect water heater 2 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required when the Outdoor Reset feature is selected The mix sensor must be installed 10 pipe diameters downstream of the system pump in the primary loop The mix sensor must be secured to the surface of the pipe using a wire tie or similar device 3 The by pass pi
15. for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 5 System Pump P3 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 35 of 60 A6 4 way RTC in Primary Secondary Heating and DHW using Tankless Coil with without Outdoor Reset Mechanical A1 Tankless Coil or Storage Tank Aquastat C1 Mixing Valve Actuating Motor M1 By Pass Mix Point P1 Boiler Circulator P2 Tankless System Circulator P3 System Pump runs on call for heat R1 Relay Required with and without priority R2 Relay Required for Priority S1 Boiler Return Sensor S2 System Mix Sensor 071 S3 Outdoor Sensor 070 ST1 Storage Tank TK1 Tankless Coil V1 4 Way Diverting Valve V2 Ball Valve Balancing Valve 21 23 Zones RTC Outdoor Sensor Class 11 S3 070 Transformer 120 V ac D 24 V ac Z3 Z2 71 V V 7 V AO n z z i C1 i LA S2 I KR z 4D Max rm eb Vi Mi p bka a aannnnannnn Fununnanununti Sune one F L ann i v2 Boiler Return G Ai Sensor S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating DHW with tankless c
16. indicated Displays when the boiler relay is turned g by E Sequence of Operation Section A Section B Section C Section D General Control Control Temperature Operation Operation Settings Monitoring Page 3 4 Page 4 5 Page 5 6 Page 6 Section A General Operation POWERING UP THE CONTROL When the control is powered up with 120 V ac the control displays rtc for 2 seconds followed by the software version for 2 seconds The control then enters the normal operating mode OPERATION The control operates a floating action actuator motor connected to a 3 way or 4 way valve to control the boiler return water temperature to prevent flue gas condensation and thermal shock The control can also be used to provide outdoor reset or a fixed setpoint temperature to the supply water temperature 3 of 60 Outdoor Reset When the outdoor design OUTDR DSGN setting is set to a temperature the control calculates a mix supply temperature based on the outdoor air temperature and the programmed reset ratio An outdoor sensor and a mix supply sensor must be installed Seipoint Control When the outdoor design OUTDR DSGN setting is set to OFF and there is a mix supply sensor installed the control supplies a fixed mix supply temperature equal to the MIX TARGET setting An outdoor sensor is not required during this mode of operation No Diverting Valve If a diverting valve is not installed the outdoor des
17. is no longer able to read the mix supply sensor due to an open circuit In this case the control will operate the diverting valve at 30 output as long as there is a heat demand and until the sensor problem is repaired Locate and repair the problem as described in the Test the Sensors section To clear the error message from the control after the sensor has been repaired press the Item button Note If a diverting valve is not installed set the outdoor design OUTDR DSGN setting to OFF power off the control and then re power aE 3 MIX OUTDR E3 m The control is no longer able to read the outdoor sensor due to a short circuit In this case the control targets the design mix supply temperature and continues operation Locate and repair the problem as described in the Test the Sensors section To clear the error message from the control after the sensor has been repaired press the Item button wm The control is no longer able to read the outdoor sensor due to an open circuit In this case the control targets the design mix supply temperature and continues operation Locate and repair the problem as described in the Test the Sensors section To clear the error message from the control after the sensor has been repaired press the tem button Note If a diverting valve is operated as a setpoint control set the outdoor design OUTDR DSGN setting to OFF OUTDR B3 oF 3 23 of 60
18. larger header pipe diameter 5 The diverting valve V1 must be no greater than 11 linear feet of pipe from the Return Sensor S1 6 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 and the Return Sensor S1 7 The balancing valve in the boiler return line V2 may be necessary in low head by pass loop applications 8 Expansion tanks air scoops and other components left out for clarity 9 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 26 of 60 A1 3 way RTC in Primary Secondary Heating Only No DHW with without Outdoor Reset Electrical C1 Mixing Valve Actuating Motor P1 Boiler Circulator S1 Boiler Return Sensor S2 Mix Supply Sensor 071 S3 Outdoor Sensor 070 21 23 Zone Valves Zone Relays Thermostats or BMS Signal Class Il Transformer NOTES 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 10A Burnham RTC z 24 Volt Output PNIS 7129 24 Volt Output Enable C1 C1 CW Closed to System CW Open to System 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters fo
19. of the boiler using the appropriate conduit and connectors C Diverting Valve and Actuator A diverting 3 way or 4 way valve must be installed in the boiler loop piping in order for the RTC to provide boiler protection Only a Burnham approved valve and actuator may be used with the RTC The diverting valve sizing depends upon the designed boiler delta T See Appendix B for proper valve selection The valve actuator is mounted to the top of the diverting valve Position the valve so that the actuator is not on the underside of the valve Mount and connect the actuator as illustrated in Appendix C The electrical connections depend on the valve orientation D Boiler Circulator properly selected boiler circulator will maintain a constant and minimum flow through the boiler during each heat demand The appropriate circulator must be selected based upon the designed boiler delta T See Appendix B for appropriate boiler circulator selections for 20 F and 40 F delta T applications WARNING IF THE SELECTED BOILER CIRCULATOR IS GREATER THAN 1 3 HP AN ISOLATION RELAY MUST BE ADDED WHEN USING THE RTC IF A 3 PHASE BOILER CIRCULATOR OR A CIRCULATOR WITH AN AMP DRAW GREATER THAN 10 AMP IS SELECTED AN APPROPRIATE MOTOR STARTER MUST BE USED STEP THREE NEAR BOILER PIPING When using the RTC control the boiler loop piping must contain the boiler the boiler circulator a 3 way or 4 way diverting valve and the return sensor The boiler loop injects h
20. other wires or grounded surfaces Turn on the power and measure the voltage between the Power Land Power Nterminals 3 and 4 using an AC voltmeter the reading should be between 108 and 132 V ac Test the Powered Inputs 20 to 260 V Heat Demand Measure the voltage between the Heat Demand terminals 1 and 2 When the heat demand device calls for heat between 20 and 260 V ac should be measured at the terminals When the heat demand device is off less than 5 V ac should be measured 17 of 60 Test the Outputs Boiler Recirculating Pump Boil Pmp The boiler recirculating pump is connected to the Boil Pmp terminal 5 Make sure that power to the terminal block is off and install a jumper between the Power L and the Boil Pmp terminals 3 and 5 Install a second jumper between Power N and N terminals 4 and 6 When power is applied to the Power L and Power N terminals 3 and 4 the boiler recirculating pump should start If the pump does not turn on check the wiring between the terminal block and pump and refer to any installation or troubleshooting information supplied with the pump If the pump operates properly disconnect the power Boiler Recirculating and remove the jumpers Pump Boiler Enable Contact If the boiler limit circuit is connected to the Boiler Enable terminals 7 and 8 make sure power to the boiler circuit is off and install a jumper between the terminals When the boiler limit circui
21. removal or reinstallation The owner is responsible for the cost of removing and reinstalling any defective part and its replacements and all labor and material connected therewith 5 Exclusive Remedy Burnham Commercial s obligation for any breach of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties 6 Limitation of Damages Under no circumstances shall Burnham Commercial be liable for incidental indirect special or consequential damages of any kind whatsoever under these warranties including but not limited to injury or damage to persons or property and damages for loss of use inconvenience or loss of time Burnham Commercial s liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for RTC Return Temperature Control involved Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you 7 Limitation of Warranties These warranties set forth the entire obligation of Burnham with respect to any defect in RTC Return Temperature Control and Burnham Commercial shall have no express obligations responsibilities or liabilities of any kind whatsoever other than those set forth herein These warranties are given in lieu of all other express warranties ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY WARRANTY OF MERCHANTABILIT
22. test meter capable of measuring up to 2 000 000 O 1kO 1000 Q is required to measure the sensor resistance In addition to this the actual temperature should be measured with a good quality digital thermometer First measure the temperature using the thermometer Then measure the resistance of the sensor at the control The wires from the sensor must not be connected to the control while the test is performed Using the chart below estimate the temperature measured by the sensor The sensor and thermometer readings should be close If the test meter reads a very high resistance there may be a broken wire a poor wiring connection or a defective sensor If the resistance is very low the wiring may be shorted there may be moisture in the sensor or the sensor may be defective To test for a defective sensor measure the resistance directly at the sensor location Do not apply voltage to a sensor at any time as damage to the sensor may result Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance Q 490 813 46 218 405 710 39 913 336 606 34 558 280 279 29 996 234 196 26 099 196 358 22 763 165 180 19 900 139 402 17 436 118 018 15 311 100 221 13 474 85 362 11 883 72 918 10 501 62 465 9 299 53 658 8 250 Test the Power Supply Make sure exposed wires and bare terminals are not in contact with
23. the control from the boiler or burner circuit since there may be times where the boiler or burner circuit may be switched off in the summer This would prevent the exercising of the boiler recirculating pump and the diverting valve Boiler protection for dormant boilers in a multiple boiler application will not be possible if the control is not powered Heat Demand To generate a heat demand a voltage between 24 V ac and 240 V ac must be applied across the Heat Demand terminals 1 and 2 Output Connections Boiler Recirculating Pump Contact Boil Pmp The Boil Pmp output terminal 5 on the control is a powered output When the relay in the control closes 120 V ac is provided to the Boil Pmp terminal 5 from the Power L terminal 3 To operate the boiler recirculating pump connect one side of the boiler recirculating pump circuit to terminal 5 and the second side of the pump circuit to the neutral N terminal 6 14 of 60 Diverting Valve Actuator Terminals 9 10 and 11 are powered with 24 V ac from t There is no need to provide a separate 24 V ac power the diverting valve actuator H 9 is connected to the open terminal of the actuating motor and R 10 is connected to the close terminal of the actuating motor N 11 is then connected to the common terminal of the actuating motor Full Flow No Flow to System 24 Volt Output he control source for
24. to 6 3 Way and 4 Way rotary valves for mixing and diverting applications Use with 24Vac 3 point floating signal controller Mounting the Motor KLICK 1 Place drive sleeve onto shaft and secure with bolt Check that the valve is in mid position sleeve pointer set to position 5 on scaleplate 2 Mount threaded stud in one of the threaded holes For 172 and 2 valves replace one of the cover bolts with the threaded rod Tighten mounting piece onto threaded rod 3 Mount handle over drive sleeve set pointer to 5 on the scale plate Handie must be mounted opposite to the pointer of the drive sleeve 4 Mount motor onto sleeve so that the mounting piece m fits into the locking piece o Push locking piece to lock in place Labels are supplied to indicate the direction of rotation Determine the direction of rotation and mount the correct label under the plastic front cover of motor FULL FLOW TO SYSTEM NO FLOW SUPPLY SUPPLY FROM BOILER FROM BOILER CLOCKWISE CW CLOSED TO SYSTEM COUNTER CLOCKWISE CCW OPEN TO SYSTEM ACTUATOR RIC TERMINALS TERMINALS NOTE 1 VALVE POSITIONING LABEL ON BOTH SIDES Of PLATE SELECT DIAL FACE FOR CORRECT ORIENTATION Manual Operation Always disconnect power before operating by hand Note position of drive sleeve pointer to be returned to Depress the gray button A on the side to release the handle The valve can now be operated manually Never man
25. 0 2 5 Flange 80149026 2 5 Flange 80160360 2 5 Flange 80149026 1750 2 5 Flange 80160360 2 5 Flange 80149026 1150 3 0 Flange 80160361 3 0 Flange 80160348 1150 4 0 80160361 80160348 3 0 Flange 3 0 Flange 4 0 3 0 Flange 80160361 3 0 Flange 80160348 4 0 80160361 80160348 3 0 Flange 3 0 Flange KV4007 1160 KV4007 KV5007 KV5007 KV5007 1160 KV5007 1160 CI3009 1160 C13009 1160 C14007 do 1160 C14007 1160 C14007 est 2 1160 4 0 Flange 80160362 4 0 Flange 80160364 1160 4 0 Flange 80160362 4 0 Flange 80160364 1160 V1116 0 vi vie via V1120 5 0 Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 5 4 0 Flange 80160362 4 0 Flange 80160364 1150 5 0 4 0 Flange 80160362 4 0 Flange 80160364 5 0 4 0 Flange 80160362 4 0 Flange 80160364 5 0 5 0 Flange 80160363 5 0 Flange 80160365 5 0 Flange 80160363 5 0 Flange 80160365 5 0 Flange 80160363 5 0 Flange 80160365 5 0 Flange 80160363 5 0 Flange 80160365 80160363 80160365 o 5 0 Flange 5 0 Flange 50 of 60 V11 Boiler Circulator Selection TACO 40 F Differential Bn Boiler no Boiler aa TACO Circulating Pump GROSS TOTAL Pipe OUTPUT GPM Size Valve Valve Valve Valve MBH Size Part Size Part Imp RPM Number Number 667 1 5
26. 2 The Outdoor Sensor S4 and the Mix Supply Sensor S3 are required when the Outdoor Reset feature is selected An appropriate sequencer must also be selected The mix sensor must be installed 10 pipe diameters downstream of the system pump in the primary loop The mix sensor must be secured to the surface of the pipe using a wire tie or similar device 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 A domestic hot water priority could be used provided the diversion from the heating system loop does not impact the system heater s performance 5 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 6 The diverting valves V1 amp V2 must be no greater than 11 linear feet of pipe from the Return Sensor S1 amp S2 7 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 amp M2 and the Return Sensor S1 amp S2 8 The balancing valves in the boiler return lines V3 may be necessary in low head by pass loop applications 9 The indirect heater aquastat A1 is a normally closed switch Circuit breaks on temperature rise 10 Expansion tanks air scoops and other components left out for clarity 11 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the prop
27. 3 0 Flange 3 0 Flange 4 0 3 0 Flange 80160361 3 0 Flange 80160348 UPS100 40 4 3 4 0 80160361 80160348 UPS80 160 2 pes 3 0 Flange 3 0 Flange 4 0 3 0 Flange 80160361 3 0 Flange 80160348 UPS80 160 2 3 39 52 52 86 86 86 97 97 97 97 5 03 4 1 3 57 3 57 3 57 3 57 3 57 3 57 3 57 3 57 3 3 3 3 3 1712 3 3 3 4 0 80160361 80160348 UPS80 160 2 3 0 Flange 3 0 Flange 53 of 60 Appendix B7 V11 Boiler Circulator and Diverting Valve Selection Chart 20 F amp 40 F AT Bell and Gossett V11 Boiler Circulator Selection Bell and Gossett 20 F Differential Boiler Recirculati Boiler Recirculati IBR oller e ation oiler Recirculation Bell and Gossett Circulating Pump GROSS TOTAL pipe OUTPUT GPM Valve Valve MBH Size bou Part E Part Model No Imp HP RPM Number Number V1104 2 0 NPT 3200 V1105 857 25 2 5 Flange 80160366 PL 130 2 3200 V1106 2 5 Flange 80160366 Ser 60 Mod 610 2 E 5 g 8 ge 80160358 2 0 NPT 80149025 PL 130 2 80160359 2 5 Flange 80160359 2 5 Flange V1107 2 5 Flange 80160360 2 5 Flange 80149026 Ser 60 Mod 610 2 V1108 2 5 Flange 80149026 Ser 80 Mod 3x3x7B V1109 2 5 Flange 80149026 Ser 80 Mod 3x3x7B EBE V1110 3 0 Flange Ser 80 Mod 4x4x7 1150 V1111 3 0 Flange Ser 80
28. 3 of 60 A5 4 way RTC in Primary Secondary Heating Only No DHW with without Outdoor Reset Mechanical C1 Diverting Valve Actuating Motor M1 By Pass Mix Point P1 Boiler Circulator P2 System Pump runs on call for heat S1 Boiler Return Sensor S2 Mix Supply Sensor 071 Required for Reset Control S3 Outdoor Sensor 070 Required for Reset Control V1 4 Way Diverting Valve V2 Ball Valve Balancing Valve Z1 Z3 Zones E Outdoor Sensor Class II S3 070 Transformer 120 V ac v2 Boiler Return Sensor S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating application only 2 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required when the Outdoor Reset feature is selected The mix sensor must be installed 10 pipe diameters downstream of the system pump in the primary loop The mix sensor must be secured to the surface of the pipe using a wire tie or similar device 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 5 The diverting valve V1 must be no greater than 11 linear feet of pipe from the Return Sensor S1 6 There shall be a MINI
29. 40 BLACK PIPE PIPE SIZES LISTED IN TABLE ARE BASED ON EITHER A 20 F OR A 40 F TEMPERATURE DROP DIFFERENTIAL SELECT ONE DIFFERENTIAL THAT MATCHES THE APPLICATION SWING JOINTS ON TWO RISER SYSTEMS MAY BE PIPED OVER THE TOP OF THE BOILER IF SPACE IS LIMITED INSTALL SPECIAL 3 NPT X 12 LG X 1 NPT SIDE TAPPING PIPE NIPPLE INTO BOILER RETURN PORT WITH SIDE TAPPING NIPPLE END POSITIONED AWAY FROM BOILER USE BELL REDUCER FOR MODELS V1104 THRU V1108 WITH A 20 F TEMPERATURE DROP OR FOR MODELS V1104 THRU V1117 WITH A 40 F TEMPERATURE DROP TO ADAPT TO RECOMMENDED RETURN PIPING SIZE SEE TABLE DRAIN VALVE ALTERNATE BALL VALVE IS PREFERABLE ALTERNATE GATE VALVE IS ACCEPTABLE MINIMUM VALVE SIZE IS 3 NPT PER ASME CODE ALL PIPE REDUCTIONS SHALL BE MADE ONLY AT THE BOILER SUPPLY AND RETURN TAPINGS AND OR DIVERTING VALVE AND BOILER CIRCULATOR FLANGES UNLESS NOTED OTHERWISE SEE APPENDIX B FOR BOILER CIRCULATOR AND DIVERTING VALVE SELECTION AND PART MAXIMUM LINEAR DISTANCE FEET OF PIPE FROM 3 WAY DIVERTING VALVE BYPASS PORT TO RETURN TEMPERATURE SENSOR LOCATION IS EQUAL TO 11 ELEVEN FEET BYPASS LINE SHALL BE THE SAME DIAMETER AS RETURN PIPE MINIMUM LINEAR DISTANCE FEET OF PIPE FROM POINT OF MIXING WHERE BYPASS FLOW MEETS RETURN FLOW TO RETURN TEMPERATURE SENSOR LOCATION IS EQUAL TO 4 FOUR FEET 10 USE THESE PIPING ARRANGEMENTS FOR APPLICATIONS WHERE THE SYSTEM RETURN TEMPERATURE IS NOT LOWER THAN 135 F FOR PROLONGED
30. 5 5 vno V1108 76 vios vio vm V1112 117 V1113 125 V1114 137 V1115 148 V1116 156 vin V1118 179 V1119 187 V1120 198 via 208 V1122 217 V1123 228 Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 2 0 1 5 NPT 80160357 1 5 NPT 80149024 UPS32 40 4 2 0 1 5 NPT 80160357 1 5 NPT 80149024 UPS32 80 2 2 1 2 3281 2 0 2 0 NPT 80160358 2 0 NPT 80149025 UPS32 80 2 2 1 2 3400 157 1688 1688 ET ET 7007 ET T04 3395 3395 2 0 2 0 NPT 80160358 2 0 NPT 80149025 UPS40 80 4 4 2 0 2 0 NPT 80160358 2 0 NPT 80149025 UPS40 80 4 4 2 5 2 5 Flange 80160359 2 5 Flange 80160366 UPS40 80 4 4 2 5 2 5 Flange 80160359 2 5 Flange 80160366 UPS50 80 4 4 2 5 2 5 Flange 80160359 2 5 Flange 80160366 UPS50 80 4 4 3 0 2 5 Flange 80160360 2 5 Flange 80149026 UPS50 80 4 4 3 0 2 5 Flange 80160360 2 5 Flange 80149026 UPS50 80 4 4 3 0 2 5 Flange 80160360 2 5 Flange 80149026 UPS50 80 4 3 0 2 5 Flange 80160360 2 5 Flange 80149026 UPS50 160 2 3 0 2 5 Flange 80160360 2 5 Flange 80149026 UPS50 160 2 3 0 80160360 80149026 UPS50 160 2 3513 EHE 1712 2 5 Flange 2 5 Flange 4 0 3 0 Flange 80160361 3 0 Flange 80160348 UPS100 40 4 4 0 80160361 80160348 UPS100 40 4
31. 5B6150 2 1 2 flanged Model F450 mx ma ma 4 Way Diverting Valve Danfoss 4065B6165 2 1 2 flanged Model F465 4 Way Diverting Valve Danfoss 4065B6180 3 flanged Model F480 4 Way Diverting Valve Danfoss 4065B6200 4 flanged Model F4100 4 Way Diverting Valve Danfoss 4065B6225 5 flanged Model F4125 Boiler Sensor 1 4 NPT Brass with 32 Lead to be mounted in special nipple Nipple 3 X 12 Special 1 4 NPT 3 From End SCH40 Mounting Bracket for Return Temperature Control RTC V9 amp V11 Series RTC System Retrofit Kit Less Outdoor Reset and Mix Sensors V9 amp V11 Boiler RTC System Retrofit Kit With Outdoor Reset and Mix Sensors V9 amp V11 Boiler Mix Sensor tekmar 071 Universal Fluid Temperature Sensor 10 lead for surface pipe mounting Outdoor Air Sensor tekmar 070 Relay 24 Volt Coil tekmar 003P Relay 120 Volt Coil tekmar 004P 3 Way Flange Kit 20 flange x 20 NPT 3 Way Flange Kit 3 flange x 3 NPT k ao 3 Way Flange Kit 4 flange x 4 NP T 3 Way Flange Kit 5 flange x 5 NPT 3 Way Flange Kit 4 flange x 4 slip on weld flange 3 Way Flange Kit 5 flange x 5 slip on weld flange acter venter 4 90160369 1 Way Diverting Valve Danfoss 06586165 2 1 2 flanged Model F465 80148028 1 7016034 016085 1 80160196 4 eoreosz2 24 of 60 This p
32. A 4 V905A V906A 95 346 83 808 V907A 959 V908A 1110 V909A 1342 2 0 NPT 80160358 2 0 NPT 80149025 PL 130 2 3200 1528 2 5 Flange 80160359 2 5 Flange 80160366 PL 130 2 3200 1714 25 2 5 Flange 80160359 2 5 Flange 80160366 PL 130 2 3200 1900 95 2 5 2 5 Flange 80160359 2 5 Flange 80160366 PL 130 2 3200 Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power V910A V911A V912A 48 of 60 Appendix B4 V9 Boiler Circulator Selection Armstrong 20 F Differential Boiler Recirculation Boiler Recirculation Armstrong Circulating Eur IBR 3 Way 4 Way 9 FENG SIZE GROSS TOTAL Pipe Size Valve Valve Valve Valve Part i Part Model No Imp HP RPM Size Size Number Number V904A 1 5 NPT 80160357 1 5 NPT 80149024 3 875 1800 V9A Boiler Circulator and Diverting Valve Selection Chart 20 F amp 40 F AT Armstrong OUTPUT GPM MBH vera oso oe gt 25 Fane 2250526 soe vo Model F165 50 20 3 way valve or Model F450 20 4 way valve Jse Additional Relav for Sinale Phase Power Use Motor Starter for Phase Power V9 Boiler Circulator Selection Armstrong 40 F Differential IBR size GROSS TOTAL Pipe OUTPUT GPM Size V903A 346 1 5 V906A 808 1 5 Boiler Recirculation Boiler Recirculati
33. ASTAT MCDONNELL amp MILLER 750P MT 120 LOW WATER CUT OFF HONEYWELL HONEYWELL L4006E L4006A M amp M 750P MT LOW WATER CUT OFF BURNHAM RETURN TEMPERATURE CONTROL ON MOUNTING ET JUNCTION BOX J BOX 48 x 4 x 24 TO 750P MT FLEXIBLE CONDUIT TO BURNER Figure 1 Typical Boiler Wiring With RTC Front 8 of 60 STRAIGHT CONDUIT CONNECTOR WITH ANTI SHORT BUSHING 90 CONDUIT CONNECTOR WITH ANTI SHORT BUSHING WIRENUT ORANGE ALL WIRE 16 GA STRANDED BURNHAM RETURN TEMPERATURE CONTROL FRONT OF BOILER JUNCTION BOX O mesk GROMMET 1 WIRENUT ORANGE 2 WIRE CODE BL BLUE ALL WIRE 16 GA STRANDED TO TERM NO S J BOX 12 amp 13 ON RTC CONTROL Ald x 41d x 24 TO RETURN BRASS WELL SENSOR Figure 2 Typical Boiler Wiring With RTC Return Sensor Rear 9 of 60 SYSTEM SUPPLY DIVERTING VALVE amp ACTUATOR SEE NOTE 6 1 suppty BOILER CIRCULATOR SEE NOTE 6 DRAIN VALVE SEE NOTE 4 REAR OF BOILER SYSTEM RETURN SEE NOTE 7 2 RFTURN POINT OF MIXING SEE NOTE 8 3 X 12 NIPPLE AND BELL REDUCER SEE NOTE 3 SYSTEM YSTEM RETURN SUPPLY SYSTE RETURN TEMPERATURE SENSOR V903A THRU V911A W 20 F DROP V903A THRU V912A W 40 F DROP RETURN AND BYPASS PIPING SIZE SUPPLY PIPING me SIZE RETURN HEADER Cw sp
34. BURNHAM Installation amp Maintenance Manual COMMERCIAL RTC Return Temperature Control AMERICA S BOILER COMPANY The Burnham Return Temperature Control RTC is designed to operate a 3 way or a 4 way valve to protect the boiler against flue gas condensation and thermal shock The RTC can also optionally control the supply water temperature to the system based on a setpoint temperature or an outdoor reset strategy A boiler post purge is provided by keeping the boiler recirculating pump running after the call for heat is removed Additional functions include Counts boiler run time Warns of cold boiler return temperatures Counts the number of boiler cycles Test sequence to ensure proper operation Counts boiler cold shocks CSAC US certified VIEW BOIL 1 F i13 ce v y Monitor Delay Open Close Demand off not testing red testing A Y 3rede testing paused Item Test O BURNHAM GB 120 V 10 50 60 Hz 1300 VA Power Floating Output 24 V ac 0 34 A 8 AMER IONS BOLER COMPANY c Us Fog Out oy ey 10 A 1 3 hp pilot duty 240 VA RTC Return Temperature Control 158033 Demand 20 to 260 V ac 2 V xz 24 Volt Output Do not apply power Signal ib ignal wiring must be 12 13 14 15 16 rated at least 300 V Com Boil Mix Com Out Ret so Made in Canada 912 06 Inpu
35. E BYPASS PORT TO RETURN TEMPERATURE SENSOR LOCATION IS EQUAL TO 11 ELEVEN FEET BYPASS LINE SHALL BE THE SAME DIAMETER AS RETURN PIPE 8 MINIMUM LINEAR DISTANCE FEET OF PIPE FROM POINT OF MIXING WHERE BYPASS FLOW MEETS RETURN FLOW TO RETURN TEMPERATURE SENSOR LOCATION IS EQUAL TO 4 FOUR FEET 9 USE THESE PIPING ARRANGEMENTS FOR APPLICATIONS WHERE THE SYSTEM RETURN TEMPERATURE IS NOT LOWER THAN 135 F FOR PROLONGED PERIODS OF TIME Figure 3 V9A Series Boiler Recommended Minimum Piping RTC With 3 Way Diverting Valve 10 of 60 SYSTEM PUMP SYSTEM SUPPLY CLOSELY SPACED SUPPLY SYSTEM RETURN DIVERTING VALVE amp ACTUATOR SEE NOTE 7 RETURN SUPPLY SEE NOTE 8 SYSTEM SUPPLY DIVERTING VALVE amp ACTUATOR SEE NOTE 7 SUPPLY BOILER BOILER CIRCULATOR SEE NOTE 7 POINT OF MIXING SEE NOTE 9 CIRCULATOR SEE NOTE 7 SYSTEM CLOSELY SPACED TEES SYSTEM RETURN SEE NOTE 8 RETURN POINT OF MIXING SEE NOTE 9 3 X 12 NIPPLE 7 AND BELL REDUCER SEE NOTE 4 DRAIN VALVE SEE NOTE 5 REAR OF BOILER RETURN TEMPERATURE SENSOR V1104 THRU V1108 W 20 F DROP V1104 THRU V1117 W 40 F DROP 3 x12 SPECIAL NIPPLE SEE NOTE 4 DRAIN VALVE EE NOTE ISEENSTES RETURN REAR OF BOILER RETURN HEADER RETURN BRANCH V1109 THRU V1115 W 20 F DROP V1118 THRU V1123 W 40 F DROP RETURN TEMPERATURE SENSOR SUPPLY BOILER CIRCULATOR
36. Gossett Circulating Pump SIZE GROSS TOTAL pine OUTPUT GPM Size Valve Valve UU Valve Number Number boo 4720 so 20 25 Farge riso sa 7n sen Model F165 50 20 3 way valve or Model F450 2Q 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 55 of 60 Appendix B8 V11 Boiler Circulator Selection Armstrong 20 F Differential Boiler Recirculation Boiler Recirculation 4 Way Armstrong Circulating Pump GROSS TOTAL 4 Pipe Size OUTPUT GPM Valve Valve Valve Part Valve Part Model No Imp HP RPM Size Size Number Number V11 Boiler Circulator and Diverting Valve Selection Chart 20 F amp 40 F AT Armstrong sn via era aor ea range oer or rre oon sao axa x6 7o 1200 Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 56 of 60 V11 Boiler Circulator Selection Armstrong 40 Differential Boiler Recirculation Boiler Recirculation GROSS TOTAL pipe GPM a Size OUTPUT Valve Valve puis Part ae Part Model No Imp HP RPM Size Size Number Number MBH Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 57 of 60 Appendix C Valve and Actuator Mounting Instructions Application For use with ESBE
37. MUM of 4 linear feet of pipe between the By pass Mix Point M1 and the Return Sensor S1 7 The balancing valve in the boiler return line V2 may be necessary in low head by pass loop applications 8 Expansion tanks air scoops and other components left out for clarity 9 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 34 of 60 A5 4 way RTC in Primary Secondary Heating Only No DHW with without Outdoor Reset Electrical C1 Mixing Valve Actuating Motor P1 Boiler Circulator S1 Boiler Return Sensor S2 Mix Supply Sensor 071 S3 Outdoor Sensor 070 Z1 Z3 Zone Valves Zone Relays Thermostats or BMS Signal A 10 112 M 4 E Heat Power Boil Demand L N Pmp Burnham RTC 24 Volt Output 718 ROBE 12 13 14 15 16 Boiler Com Boil Mix Com Out Enable Ret 24 Volt Output 9 10 11 afafa du i de Ks x x sin C1 C1 CW Closed to System CW Open to System 21 23 Class 11 Transformer 20 V ac L NOTES 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays
38. Mod 4x4x7 1150 V1112 3 0 Flange Ser 80 Mod 5x5x7 1150 V1113 3 0 Flange Ser 80 Mod 5x5x7 1150 80160360 2 5 Flange 80160360 2 5 Flange 80160361 3 0 Flange 80160348 80160361 3 0 Flange 80160348 80160361 3 0 Flange 80160348 80160361 3 0 Flange 80160348 80160362 4 0 Flange 80160364 V1114 2730 4 0 Flange Ser 80 Mod 5x5x7 1150 V1115 2957 6 4 0 Flange 3 5 7 9 Ser 80 Mod 5x5x7 1 150 V1116 4 0 Flange 3 5 7 3 Ser 80 Mod 5x5x7 1 Ser 80 5x5x7 1 Ser 80 Mod 5x5x7 1 Ser 80 Mod 5x5x7 1 Ser 80 Mod 5x5x7 1 Ser 80 Mod 5x5x7 1 Ser 80 Mod 6x6x7 1 Ser 80 Mod 6x6x7 EN 1 80160362 4 0 Flange 80160364 80160362 4 0 Flange 80160364 150 80160364 150 80160362 4 0 Flange o 80160362 4 0 Flange 80160364 150 3 0 3 V1117 4 0 Flange V1118 4 0 Flange V1119 5 0 Flange V1120 5 0 Flange V1121 5 0 Flange V1122 5 0 Flange V1123 5 0 Flange Model F165 50 2Q 3 way valve or Model F450 2Q 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 80160363 80160365 o 5 0 Flange 150 o 80160363 5 0 Flange 80160365 150 o 80160363 5 0 Flange 80160365 150 150 80160363 5 0 Flange 80160365 o 80160363 5 0 Flange 80160365 150 54 of 60 V11 Boiler Circulator Selection Bell and Gossett 400 Differential IBR Boiler er Bell and
39. OUTPUT GPM Size Valve wave Valve Valve Model Size Part Size Part No Imp HP Number Number 07 MBH voosA 346 17 1 0 80149013 1 0 NPT 80199016 1 25 3250 V904A 483 24 1 25 80160356 1 25 NPT 80149017 0010 3250 V905A 646 32 80149024 1725 V906A 808 40 80149024 1 4 1725 vea 30149025 us 1725 95 2 5 Flange 80160366 1 2 Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power V909A 1342 V910A 1528 V911A 1714 V912A 1900 46 of 60 V9A Boiler Circulator and Diverting Valve Selection Chart 20 F amp 40 F AT Grundfos Appendix B2 V9 Boiler Circulator Selection Grundfos 20 F Differential iB Boiler do HN Boiler Grundfos Circulating Pump SIZE GROSS TOTAL Pipe OUTPUT GPM Size Valve Valve MBH Size Size Model No Imp HP RPM V903A 1 5 80160357 1 5 80149024 UPS32 40 4 1667 V904A 1 5 80160357 1 5 NPT 80149024 UPS32 80 2 3400 Lars ose oe 25 aer rae a Free essen Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power V9 Boiler Circulator Selection Grundfos 400 Differential BH Boiler va Boiler ia Grundfos Circulating Pump GROSS TOTAL Pipe OUTPUT GPM Size Valve alye Model N
40. PERIODS OF TIME Figure 4 V11 Series Boiler Recommended Minimum Piping RTC With 3 Way Diverting Valve 11 of 60 BOILER CIRCULATOR RETURN Figure 5 Typical Burnham Boiler Loop w 3 Way Diverting alve 12 of 60 SYSTEM 4 X D PUMP MAX r L RETURN Figure 6 Typical Burnham Boiler Loop w 4 Way Diverting Valve 13 of 60 On multiple boiler applications each boiler is installed in the same arrangement as a single boiler application Each boiler loop contains its own boiler circulator diverting valve and actuator RTC control and return sensor A number of different boiler sequencers can be used in conjunction with the RTC by energizing the control s heat demand circuit The RTC control s outdoor reset feature cannot be used on multiple boiler installations The sequencer s outdoor reset feature if available would have to be utilized instead STEP FOUR ROUGH IN WIRING All electrical wiring terminates in the control base wiring chamber The base has standard e 22 mm knockouts which accept common wiring hardware and conduit fittings Before removing the knockouts check the wiring diagram and select those sections of the chamber with common voltages Do not allow the wiring to cross between sections as the wires will interfere with safety dividers which should be installed at a later time Power must not be applied to any of the wires during the rough in wiring stage All wire
41. R1 Relay S1 Boiler Return Sensor V1 3 Way Diverting Valve V2 Ball Valve Balancing Valve V3 Ball Valve System Balancing 21 23 Zones Class II Transformer 120 V ac Indirect DHW Tank Sensor S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating DHW with an indirect water heater 2 This arrangement is NOT recommended for outdoor reset applications The reset temperature will constantly change DHW water performance 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 A domestic hot water priority could be used provided the diversion from the heating system loop does not impact the system heater s performance 5 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 6 The diverting valve V1 must be no greater than 11 linear feet of pipe from the Return Sensor S1 7 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 and the Return Sensor S1 8 The balancing valve in the boiler return line V2 may be necessary in low head by pass loop applications 9 The indirect heater aquastat A1 is a normally closed switch Circuit breaks on temperature rise 10 Expansion tanks air scoops
42. SD setting the control turns on the WWSD segment in the display When the control is in WWSD the Demand pointer is displayed if there is a demand However the control does not operate the heating system to satisfy this demand If the control is in setpoint mode the WWSD feature is not functional Mixing Minimum MIX MIN The MIX MIN is the lowest temperature that the control is allowed ilz co En to use as a mix target temperature During mild conditions if the Design 180 control calculates a mix target temperature that is below the MIX MIN setting the mix target temperature is adjusted to match the MIX MIN i setting During this condition the MIN segment will be displayed in Design the LCD when either the MIX TARGET or MIX temperature is being VIG 120 viewed Minimum Outdoor 140 100 p Mixing Maximum MIX MAX Fixed 80 The MIX MAX sets the highest water temperature that the control 60 is allowed to calculate as the mix target temperature If the control pee does target the MIX MAX setting and the MIX temperature is near 80 40 20 20 40 the MIX MAX the MAX segment will be displayed in the LCD while Outdoor Temperature either the MIX TARGET temperature or the MIX temperature is being viewed Supply Water Temperature 5 of 60 SETPOINT OPERATION Mix Target For setpoint control set the OUTDR DSGN to OFF The mix target becomes the setpoint suppl
43. Y OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF TWO YEARS Some states do not allow limitation on how long an implied warranty lasts so the above limitation may not apply to you PROCEDURE FOR OBTAINING WARRANTY SERVICE Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties the owner should notify the installer who will in turn notify the distributor If this action is not possible or does not produce a prompt response the owner should write to Burnham Commercial America s Boiler Company at P O Box 3939 Lancaster PA 17604 3939 giving full particulars in support of the claim The owner is required to make available for inspection by Burnham Commercial or its representative the parts claimed to be defective and if requested by Burnham to ship these parts prepaid to Burnham Commercial at the above address for inspection or repair In addition the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE TWO YEAR LIMITED WARRANTY ON RTC Return TEMPERATURE CONTROL 59 of 60 Burnham Commercial BURNHAM Box 3939 COMMERCIAL Lancaster PA 17604 3939 AMERICAS BOILER COMPANY 888 791 3790 Fax 877 501
44. again for 5 minutes while the test sequence is paused the control exits the entire test routine If the test sequence is paused the Test button can be pressed again to advance to the next step This can also be used to rapidly advance through the test sequence To reach the desired step repeatedly press and release the Test button until the appropriate device and segment in the display turn on Step 1 The diverting valve is run fully open Step 2 The diverting valve is run fully closed Step 3 The boiler recirculating pump Boil Pmp is turned on and waits 10 seconds Step 4 The Boiler Enable contact is turned on for 10 seconds After 10 seconds the Boiler Enable and Boil Pmp contacts are shut off Step 5 The test sequence is completed and the control resumes its normal operation Troubleshooting When troubleshooting any heating system it is always a good idea to establish a set routine to follow By following a consistent routine many hours of potential headaches can be avoided Below is an example of a sequence that can be used when diagnosing or troubleshooting problems in a hydronic heating system Establish the problem Get as much information from the customer as possible about the problem Is there Establish the too much heat not enough heat or no heat Is the problem only in one particular zone or area of the Problem building or does the problem affect the entire system Is this a consistent problem or only intermittent
45. age has intentionally been left blank m 25 of 60 Appendix A Application Drawings A1 3 way RTC in Primary Secondary Heating Only No DHW with without Outdoor Reset Mechanical C1 Diverting Valve Actuator M1 By Pass Mix Point P1 Boiler Circulator P2 System Pump runs on call for heat S1 Boiler Return Sensor S2 Mix Supply Sensor 071 Required for Reset or Set point Control S3 Outdoor Sensor 070 Required for Reset Control V1 3 Way Diverting Valve V2 Ball Valve Balancing Valve 21 23 Zones Outdoor Sensor Class II S3 070 Transformer i 120 V ac 24 V ac M A P s i apas 1 v2 Boiler Return ensor S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating application only 2 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required when the Outdoor Reset feature is selected The mix sensor must be installed 10 pipe diameters downstream of the system pump in the primary loop The mix sensor must be secured to the surface of the pipe using a wire tie or similar device 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the
46. an 135F and heating DHW with an indi rect water heater 2 The Outdoor Sensor S4 and the Mix Supply Sensor S3 are required when the Outdoor Reset feature is selected An appropriate sequencer must also be selected The mix sensor must be installed 10 pipe diameters downstream of the system pump in the primary loop The mix sensor must be secured to the surface of the pipe using a wire tie or similar device 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 A domestic hot water priority could be used provided the diversion from the heating system loop does not impact the system heater s performance 5 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 6 The diverting valves V1 amp V2 must be no greater than 11 linear feet of pipe from the Return Sensor S1 amp S2 7 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 amp M2 and the Return Sensor S1 amp S2 8 The balancing valves in the boiler return lines V3 may be necessary in low head by pass loop applications 9 The indirect heater aquastat A1 is a normally closed switch Circuit breaks on temperature rise 10 Expansion tanks air scoops and other components left out for clarity 11 Observe all applicable plumbing and electrical codes This diagram is for referenc
47. and other components left out for clarity 11 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 32 of 60 A4 3 way RTC in Primary Secondary Heating and DHW using Indirect Water Heater on Primary Loop without Outdoor Reset Electrical Ai Indirect Hot Water Aquastat C1 Mixing Valve Actuating Motor P1 Boiler Circulator P2 Indirect Circulator R1 Relay S1 Boiler Return Sensor 21 23 Zone Valves Zone Relays Thermostats or BMS Signal Burnham RTC 24 Volt Output ee Z Closed to System 4 e 21 23 C1 CW Open to System Temp Rise Al Class II Transformer NOTES 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 5 System Pump P3 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 3
48. ction B Control Operation Pg4 Appendix A Mechanical And Electrical Section C Control Settings Pg 5 Application Drawings asta Pg2a Appendix B Boiler Circulator And Diverting SECOND FHB Valve Selection Charts Pg 46 Installation eerie eene Pg 7 Appendix C Valve And Actuator Control Settings siisii Pg 20 Mounting Instructions Pg 58 View Menu esent Pg 20 Technical Data Pg 60 Adjust Menu Pg 21 Limited Warranty sese Pg 60 User Interface The control uses a Liquid Crystal Display LCD as the method of supplying information The LCD is used in order to setup and monitor the operation of the system The control has three push buttons tem A W for selecting and adjusting settings As the control is programmed record the settings in the Adjust menu table which is found in the second half of this manual Item The abbreviated name of the selected item will be displayed in the item field of the display To view the next available item press and release the Item button Once the last available item a menu has been reached pressing releasing the tem button will return the display to the first item in the selected menu Item A Y Adjust To make an adjustment to a setting in the co
49. culator R1 Relay Required with and without priority R2 Relay Required for priority 1 Boiler Return Sensor S2 Mix Supply Sensor 071 S3 Outdoor Sensor 070 21 23 Zone Valves Zone Relays Thermostats or BMS Signal 10A 10A 24 Volt Output 24 Volt Output 1 2 amp 4 1 2 amp 1 4 6 Heat Power Boil Demand L N Pmp Heat Power Boil Demand L N Pmp N 718 EE Boiler Enable Li al N C1 C1 C1 p CW Closed to System CW Open to System CW Open to System P1 71 73 Zi Qu 9 Om 2 Ow O R1 Breaks on Temp Rise Breaks on A1 Q D Temp Rise P2 Al Class II Transformer FE Eve EIIE veg 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 5 The Outdoor Sensor 53 and the Mix Supply Sensor S2 are required if the Outdoor Reset feature is selected 6 Connect the tankless aquastat A1 if you are not using a storage tank If you are using a storage tank with the tankless heater use the storage tank aquastat 7
50. e diameters downstream of the system pump in the primary loop The mix sensor must be secured to the surface of the pipe using a wire tie or similar device 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 5 The diverting valve V1 must be no greater than 11 linear feet of pipe from the Return Sensor S1 6 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 and the Return Sensor S1 7 The balancing valve in the boiler return line V2 may be necessary in low head by pass loop applications 8 The indirect heater aquastat A1 is a normally closed switch Circuit breaks on temperature rise 9 Expansion tanks air scoops and other components left out for clarity 10 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 38 of 60 A7 4 way RTC in Primary Secondary Heating and DHW using Indirect Water Heater with without Outdoor Reset Electrical Ai Indirect Hot Water Aquastat C1 Mixing Valve Actuating Motor P1 Boiler Circulator P2 Indirect Circulator R1 Relay Required with and without priority R2 Relay Required for priority S1
51. e only The installer or designer is responsible for the proper selection and design of the system 44 of 60 A10 4 way Multiple Boiler RTC in Primary Secondary Heating and DHW using Indirect Water Heater on Primary Loop Using Sequencer with amp without Outdoor Reset Electrical Ai Indirect Hot Water Aquastat C1 C2 Mixing Valve Actuating Motor P1 P2 Boiler Circulator P3 System Pump runs on call for heat P4 Indirect Circulator R1 Relay S1 S2 Boiler Return Sensor S3 Mix Supply Sensor 071 S4 Outdoor Sensor 070 21 23 Zone Valves Zone Relays Thermostats or BMS Signal 2 1 Heat Power Boi Demand L N 24 Volt Output Breaks on E At Temp Rise a X xx Lif Lif N C1 CW Open to System 24 Volt Output Low High Low High Boiler 2 Boiler 1 R R N Class II Transformer L FIA VET UN ulu s C1 CW Closed to System NOTES 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 5 System Pump P3 to b
52. e operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 45 of 60 Appendix B Boiler Circulator and Diverting Valve Selection Charts Appendix B1 V9A Boiler Circulator and Diverting Valve Selection Chart 20 F amp 40 F AT TACO V9 Boiler Circulator Selection TACO 40 F Differential IBR GROSS TOTAL Pipe OUTPUT GPM Size MBH 1 5 Boiler Recirculation Boiler Recirculation 4 Way TACO Circulating Pump lt Valve Valve Valve Part valve Part Mode imp HP RPM Size Number Number 1 0 NPT 80149013 1 0 NPT 80199016 007 1 5 1 25 NPT 80160356 1 25 NPT 80149017 0010 N V903A V904A V905A z NR gt zi 1 5 18 NPT 1 5 NPT mc 1 5 NPT 1 5 NPT 210 2 0 NPT 2 0 NPT 1200 2 0 NPT 2 0 NPT DI 2 0 NPT 2 0 NPT 1220 2 5 Flange 2 5 Flange 121C V911A 174 2 5 2 5 Flange 2 5 Flange 131 V912A 1900 95 2 5 2 5 Flange 2 5 Flange 1635 4 Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power V906A 1 5 V907A 2 0 95 V910A 1528 2 5 2 0 2 0 o V9 Boiler Circulator Selection TACO 400 Differential Boiler Recirculation Boiler Recirculation I IBR 4 Way TACO Circulating Pump GROSS TOTAL Pipe
53. ed 10 pipe diameters downstream of the system pump in the primary loop The mix sensor must be secured to the surface of the pipe using a wire tie or similar device 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 5 The diverting valve V1 must be no greater than 11 linear feet of pipe from the Return Sensor S1 6 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 and the Return Sensor S1 7 The balancing valve in the boiler return line V2 may be necessary in low head by pass loop applications 8 Domestic Hot Water must be tempered for safe usage The tankless aquastat and or storage tank aquastat A1 are normally closed switches Circuit breaks on temperature rise 9 Expansion tanks air scoops and other components left out for clarity 10 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 28 of 60 A2 3 way RTC in Primary Secondary Heating and DHW using Tankless Coil with without Outdoor Reset Electrical Ai Tankless Coil or Storage Tank Aquastat C1 Mixing Valve Actuating Motor P1 Boiler Circulator P2 Tankless Coil System Cir
54. er selection and design of the system 42 of 60 AQ 3 way Multiple Boiler RTC in Primary Secondary Heating and DHW using Indirect Water Heater on Primary Loop Using Sequencer with amp without Outdoor Reset Electrical Ai Indirect Hot Water Aquastat C1 C2 Mixing Valve Actuating Motor P1 P2 Boiler Circulator P3 System Pump runs on call for heat P4 Indirect Circulator R1 Relay S1 S2 Boiler Return Sensor S3 Mix Supply Sensor 071 S4 Outdoor Sensor 070 Z1 Z3 Zone Valves Zone Relays Thermostats or BMS Signal 10A v 112 IE 4 Heat Power Boil Demand L N Pmp See 9 10 8 11 at right igi at right 15 LM 24 Volt Output L RJ RIN Breaks on ea a Temp Rise I I R1 a i gt P2 P1 ee SS p I T x 9 wA H Lif Lt N o 0 ei P4 CW Open to System e 24 Volt Output Low High Low High Boiler 2 Boiler 1 tv ol 71 23 Class II Transformer d E 2 V ac Si ave T En S SJT PE CW Closed to System 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical si
55. ess One may find it easier to install some of the conduit connectors along with their corresponding conduit runs onto the RTC control base wiring chamber before mounting it to the bracket Before choosing which wiring knockouts to use read Step Four Mount the control base wiring chamber to the bracket using the four 4 48 32 x 77 Phillips pan head screws supplied with the RTC Then reattach the RTC controller to the control base B Return Sensor The return water temperature sensor must be mounted in a special 3 NPT x 12 long nipple with 1 4 NPT side tapping supplied by Burnham Apply pipe dope to special nipple both threaded ends and mount the nipple into the boiler s right rear return port as viewed from the rear of the boiler so that nipple side tapping end is positioned away from the boiler Apply pipe dope to the sensor threads and install the sensor into the nipple 1 2 NPT side tapping making sure the connection is watertight Use bell reducer refer to Figure 3 or Figure 4 to adapt to recommended return piping size See Figure 3 or 4 depending on the boiler being installed for the proper location of the return nipple See Figure 2 for return sensor wiring details Run the sensor wiring to a suitable junction box using a grommet to protect the leads as they enter the box Mount the junction box to the boiler s rear jacket panel as shown in Figure 2 Connect the sensor wiring from the junction box to the RTC control at the front
56. ge to the equipment and possibly even personal injury It is the installer s responsibility to ensure that this control is safely installed according to all applicable codes and standards This electronic control is not intended for uses as a primary limit control Other controls that are intended and certified as safety limits must be placed into the control circuit Do not open the control Refer to qualified personnel for servicing Opening voids warranty and could result in damage to the equipment and possibly even personal injury STEP ONE GETTING READY Check the contents of this package If any of the contents listed are missing or damaged please contact your wholesaler or Burnham representative for assistance Burnham RTC includes Burnham Return Temperature Control Return Temperature Control manual 1 boiler return sensor 4 48 32 x 7 Phillips screws STEP TWO m INSTALLING THE CONTROL AND RELATED COMPONENTS A Return Temperature Control RTC Mount the control to the boiler front jacket panel at the top right See Figures 1 and 2 for general component placement The RTC mounting bracket must be attached to the jacket first using four 4 8 x 34 drill point sheet metal screws Before attaching the RTC to the mounting bracket remove the controller from the control base wiring chamber by pressing the tab on the base and pulling the controller up and off This is to prevent accidental damage to the controller during the mounting proc
57. gnal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 5 System Pump P3 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 43 of 60 A10 4 way Multiple Boiler RTC in Primary Secondary Heating and DHW using Indirect Water Heater on Primary Loop Using Sequencer with amp without Outdoor Reset Mechanical A1 Indirect Hot Water Aquastat C1 C2 Diverting Valve Actuating Motor M1 M2 By Pass Mix Point P1 P2 Boiler Circulator P3 System Pump runs on call for heat P4 Indirect Circulator R1 Relay S1 S2 Boiler Return Sensor S3 Mix Supply Senor 071 S4 Outdoor Sensor 070 V1 V2 3 Way Diverting Valve V3 Ball Valve Balancing Valve Z1 Z3 Zones 264 Outdoor Sensor Class II ETT 54 070 Transformer 120 V ac ER RTC RTC qp 24 V ac i i Se vi v2 L lz H d 72 e O m VAN i Y i m vs X4 m A Boiler Return Boiler Return Sensor Sensor NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less th
58. h recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of two years from the date of original installation If any part of the control is found to be defective in material or workmanship during this two year period Burnham Commercial will at its option repair or replace the defective part ADDITIONAL TERMS AND CONDITIONS 1 Applicability The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada 2 Proper Installation The warranties extended by Burnham Commercial are conditioned upon the installation of the RTC Return Temperature Control in strict compliance with Burnham Commercial installation instructions Burnham Commercial specifically disclaims liability of any kind caused by or relating to improper installation 3 Proper Use and Maintenance The warranties extended by Burnham Commercial are conditioned upon the use of the RTC Return Temperature Control for its intended purposes and its maintenance in accordance with Burnham Commercial recommendations and hydronics industry standards These warranties will be inapplicable if the RTC Return Temperature Control is subjected to unauthorized modification or is damaged as a result of being otherwise improperly operated or serviced 4 Removal and Installation These warranties do not cover expenses of
59. ical Data RTC Return Temperature Control T Literature RTC Return Temperature Control manual Control Microprocessor PID control This is not a safety limit control um Packaged weight 3 1 Ib 1420 g Enclosure A black PVC plastic al Dimensions 6 5 8 H x 7 9 16 W x 2 13 16 D 170 x 193 x 72 mm cM Approvals CSA C US meets ICES amp FCC regulations for EMI RFI Monier Daley Coa Damai Ambient conditions Indoor use only 32 to 104 F 0 40 lt 90 RH non condensing Power supply 120 V 10 50 60 Hz 1300 VA Wem CAT N Motor Relay 24 V ac 0 34 8 VA Relays 240 V ac 10 A 1 3 hp pilot duty 240 VA RNHAM Demand 20 to 260 V ac 2 VA COMMERCIAL ie Sensors included 1 Well Sensor THEY came AEE i i i 1 7 8 12 13 4 15 16 Sew mest be Optional devices Outdoor Sensor 070 Universal Sensor 071 dl I 200250 22020 2200 Limited Warranty FOR RTC Return TEMPERATURE CONTROL Subject to the terms and conditions set forth below Burnham Commercial America s Boiler Co Lancaster Pennsylvania hereby extends the following limited warranties to the original owner of a RTC Return Temperature Control manufactured and shipped on or after May 1 2003 Burnham Commercial warrants to the original owner that its RTC Return Temperature Control complies at the time of manufacture wit
60. ign OUTDR DSGN is set to OFF The boiler return sensor must be installed to provide monitoring of the boiler conditions Floating Action A 24 V ac floating action actuator motor is connected directly to the control on the H R and N terminals 9 10 and 11 The H on terminal 9 is used to open the 3 way diverting valve to the system The valve can open either in the clockwise or the counterclockwise direction depending on the orientation of the valve The Ron terminal 10 is used to close the valve The control pulses the actuating motor to open or close to maintain the correct mixed supply water temperature at the mix sensor when there is a heat demand A visual indication as to whether the control is currently opening or closing the 3 way diverting valve is displayed in the LCD Boiler Protection The control is capable of providing boiler protection from cold return water temperatures If the boiler sensor temperature is cooler than the BOIL MIN setting while the boiler is firing the control reduces the output to the 3 way diverting valve This limits the amount of cool return water to the boiler and allows the boiler temperature to recover This feature can only be used if a 3 way diverting valve is installed Exercising The control has a built in exercising function If the boiler recirculating pump or valve has not been operated at least once every 3 days the control turns on the output for a minimum of 10 seconds This minimizes the p
61. iler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 5 System Pump P3 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 41 of 60 AQ 3 way Multiple Boiler RTC in Primary Secondary Heating and DHW using Indirect Water Heater on Primary Loop Using Sequencer with amp without Outdoor Reset Mechanical A1 Indirect Hot Water Aquastat C1 C2 Diverting Valve Actuating Motor M1 M2 By Pass Mix Point P1 P2 Boiler Circulator P3 System Pump runs on call for heat P4 Indirect Circulator R1 Relay S1 S2 Boiler Return Sensor S3 Mix Supply Senor 071 S4 Outdoor Sensor 070 V1 V2 3 Way Diverting Valve V3 Ball Valve Balancing Valve Z1 23 Zones E Outdoor Sensor Class II S4 070 Transformer i 120 V ac il ee i Indirect M1 DHW Qe wumumnununun ht DOLL Boiler Return Boiler Return Sensor Sensor S2 071 S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating DHW with an indi rect water heater
62. ntrol press all 3 buttons for 1 second the Item A and Y buttons The display will then show the word ADJUST in the top right corner Then select the desired item using the Item button Finally use the A and or Y button to make the adjustment Item A Y To exit the ADJUST menu leave the adjustment buttons alone for 20 seconds When the tem button is pressed and held in the VIEW menu the display scrolls through all the adjust items Additional information can be gained by observing the status field and pointers of the LCD The status field will indicate which of the control s outputs are currently active Most symbols in the status field are only visible when the VIEW menu is selected 2 of 60 Display Item Field Number Field Displays an abbreviated Displays the current value name of the selected item of the selected item BOIL TARGET ix i I MIX MINMAX C ROOM WWSD VL min ge Menu i OpenCl Demand ME cns ks Field Displays the current menu Y Status Field Buttons Displays the current status of the Selects Menus Items control s inputs outputs and operation and adjusts settings Symbol Description Pump F C Displays when the boiler recirculating pump is F C Displays the unit of measure that all of the in operation temperatures are to be displayed in the control pe Pointer gt Displays the control is operating as
63. o Imp HP RPM Size Size MBH 95 V903A V904A V905A V906A V907A V908A Model F165 50 20 3 way valve or Model F450 20 4 way valve Use Additional Relay for Single Phase Power Use Motor Starter for 3 Phase Power 47 of 60 Appendix B3 V9 Boiler Circulator Selection Bell and Gossett 20 F Differential Boiler Recirculation Boiler Recirculation IBR 3 Way Bell and Gossett Circulating Pump GROSS TOTAL Pipe OUTPUT GPM Size 2 0 1 5 NPT 80160357 1 5 80149024 PL 36 1 5 300 2 0 1 5 NPT 80160357 1 5 80149024 PL 75 2 1 6 400 V9A Boiler Circulator and Diverting Valve Selection Chart 20 F amp 40 F AT Bell and Gossett V903A 346 V904A 483 V905A 646 V906A 808 959 V907A 0 ISI V909A V910A V911A 1714 3 0 2 5 Flange 80160360 2 5 Flange 80149026 Ser 80 Mod 3x3x7B 1750 1900 4 0 3 0 Flange 80160361 3 0 Flange 80160348 Ser 80 Mod 3x3x7B 1750 Model F165 50 20 3 way valve or Model F450 20 4 way valve Additional Relav for Sinale Phase Power Use Motor Starter for Phase Power 4 4 1 V912A V9 Boiler Circulator Selection Bell and Gossett 40 Differential Boiler Recirculation Boiler Recirculation I 3 Way Bell and Gossett Circulating Pump GROSS TOTAL Pipe OUTPUT GPM Size Valve Valve Valve Part vane Part Model No HP RPM Size Size Number Number MBH V903A V904
64. oils 2 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required when the Outdoor Reset feature is selected The mix sensor must be installed 10 pipe diameters downstream of the system pump in the primary loop The mix sensor must be secured to the surface of the pipe using a wire tie or similar device 3 The by pass piping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 5 The diverting valve V1 must be no greater than 11 linear feet of pipe from the Return Sensor S1 6 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 and the Return Sensor S1 7 The balancing valve in the boiler return line V2 may be necessary in low head by pass loop applications 8 Domestic Hot Water must be tempered for safe usage The tankless aquastat and or storage tank aquastat A1 are normally closed switches Circuit breaks on temperature rise 9 Expansion tanks air scoops and other components left out for clarity 10 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 36 of 60 A6 4 way RTC in Primary Secondary Heating and DHW using Tankless Coil with without Outdoor Rese
65. on Armstrong Circulating Pump Ey lt pi D lt Valve Valve valve Part i Part Model No Imp HP RPM Number Number Valve 1 0 NPT 1 0 NPT 80199016 S 25 1800 1 25 NPT 1 25 NPT S 25 1800 1 5 NPT 1 5 NPT E 8 3600 2 0 NPT 2 0 NPT S 45 1800 2 0 NPT 2 0 NPT S 46 1800 1800 V907A 959 2 0 V908A 1110 56 2 0 V909A 1342 67 2 0 V910A 1528 76 2 5 1800 2 5 Flange 80160359 2 5 Flange 80160366 4380 3 x3 x 6 4 998 1200 V911A 1714 2 5 2 5 Flange 80160359 2 5 Flange 80160366 4380 3x 8x6 4 677 V912A 1900 95 2 5 2 5 Flange 80160359 2 5 Flange 80160366 4380 3 x3 x6 5 019 Model F165 50 2Q 3 way valve or Model F450 2Q 4 way valve 1200 N N 1200 49 of 60 Appendix B5 V11 Boiler Circulator and Diverting Valve Selection Chart 20 F amp 40 F AT TACO V11 Boiler Circulator Selection TACO 20 F Differential Boiler Recirculation Boiler Recirculation IBR TACO Circulating Pump GROSS TOTAL Pipe OUTPUT GPM Size MBH Ey lt Ey lt Valve Valve HENK Part Part Model Imp HP RPM Number Number 2 5 2 0 NPT 80160358 2 0 NPT 80149025 KV1506 1750 KV2006 1750 1635 1750 KV3006 1750 KV3006 KV3007 KV3007 KV3007 eo 1150 KV3007 1150 2 5 Flange 80160359 2 5 Flange 80160366 2 5 Flange 80160359 2 5 Flange 80160366 V1107 3 0 vios T 2 5 Flange 8016036
66. ossibility of a pump or valve seizing during a long period of inactivity The control ensures that the diverting valve operates over its entire range at least once each exercising period While the control is exercising the Test LED flashes Note The exercising function does not work if power to the control pump or valve is disconnected Section B Control Operation HEAT DEMAND A heat demand is required in order for the control to provide heat by firing the boiler and opening the 3 way diverting valve To generate a heat demand apply between 24 and 240 V ac across the Heat Demand terminals 1 and 2 Once voltage is applied the Demand pointer is displayed in the LCD When the heat demand is removed the 3 way diverting valve is fully closed before the control is allowed to register a new heat demand The Demand pointer will be displayed whenever voltage is present on the Heat Demand terminals even if the heat demand is not registered The 3 way diverting valve is closed to ensure the boiler is protected in the next boiler cycle Optionally the control can be set up to target a setpoint mix supply temperature or outdoor reset temperature through the diverting valve OUTDOOR RESET RATIO fe Mi Des n When the control is used as a mixing reset control the control uses and the Outdoor an outdoor sensor to measure the outdoor temperature The reset EE ratio increases the mix water temperature for every degree the o
67. ot selected this setting represents the fixed target supply water temperature On this type of application the MIX TARGET setting should be adjusted to match the boiler operating aquastat s setpoint temperature C MIX DSGN Mixing Design When the outdoor reset feature is selected this setting represents the design system supply water temperature If unsure about the original design temperature set the MIX DSGN to match the boiler operating aquastat s setpoint temperature D OUTDR DSGN Outdoor Design When the outdoor reset feature is selected this setting represents the typical coldest temperature of the year in the area where the installation is located If this value is unknown use the temperature value found in ASHRAE Fundamentals for the area closest to the installation 18 of 60 E WWSD Warm Weather Shut Down This feature is only used when the outdoor reset feature is selected Set the WWSD as desired keeping in mind that when the outdoor air temperature rises above the WWSD setting the control will not operate the boiler to satisfy any demands for heat F MIX MIN Mixing Minimum When the outdoor reset feature is selected this setting represents the minimum mix target supply water temperature Set as desired G MIX MAX Mixing Maximum When the outdoor reset feature is selected this setting represents the maximum allowable mix target supply water temperature Typically this is set between 200 F and 220
68. ot water into the primary loop provided that the boiler return water temperature measured by the return sensor is at least 135 F If the return temperature is below 135 F the diverting valve closes recirculating boiler supply water through the boiler loop until the return water has been heated to at least 135 F The RTC controls the diverting value actuator based upon the absolute return water temperature as well as the rate of temperature change Several typical RTC applications are shown in Appendix A Select the appropriate application before proceeding See Figures 5 and 6 for general component and piping arrangements when using 3 way and 4 way diverting valves See Figure 3 for V9A piping recommendations for 3 way valve applications See Figure 4 for V11 piping recommendations for 3 way valve applications As shown in these diagrams the boiler loop s supply and return are connected to the primary loop through two closely spaced tees at a maximum branch centerline distance of four times the primary loop diameter 4 x D Max 7 of 60 10A BURNHAM RTC DO NOT APPLY BB e POWER HERE T 2 4 vou ouput 215 aisle HEAT POWER DEMAND L 9 10 11 12 13 14 15 16 COM BOIL MIX COM OUT R RIN RET TO J BOX BL TO REAR PANEL BURNHAM RETURN JUNCTION BOX TEMPERATURE CONTROL HONEYWELL L4006E AQUASTAT HONEYWELL L4006A AQU
69. perature as measured by the mix supply sensor if a mix supply sensor is installed Outdoor The current outdoor temperature as measured by the outdoor sensor if the outdoor sensor is installed and Outdoor Design is set to a temperature Monitor Items Monitor Items are displayed using a five digit number The display cycles between the monitor name the first two digits and the last three digits BOIL run Boiler Run Time Monitor BOIL run The control records the number of hours the boiler enable contact has been closed Number of Boiler Cycles Monitor BOIL CYC The control records the number of cycles of the boiler enable contact Boiler Run Time Below Return Water Minimum Monitor BOIL MIN run 6 ci The control records the number of hours the boiler return temperature is below the boiler minimum temperature and the boiler enable contact is closed The control does not record any time while the control is within the boiler minimum delay period Monitor Number of Boiler Cold Shock Conditions Monitor BOIL CS The control records the number of large and quick temperature swings which could be an indication of erratic system behavior BOIL n 250 Boiler Sensor Error Time Monitor BOIL MIN Err The control records the number of hours the boiler return sensor is not functioning n 6 of 60 Installation Caution Improper installation and operation of this control could result in dama
70. ping diverting valve and boiler circulator must be sized using the sizing charts found in Appendix B 4 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 5 The diverting valve V1 must be no greater than 11 linear feet of pipe from the Return Sensor S1 6 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 and the Return Sensor S1 7 The balancing valve in the boiler return line V2 may be necessary in low head by pass loop applications 8 The indirect heater aquastat A1 is a normally closed switch Circuit breaks on temperature rise 9 Expansion tanks air scoops and other components left out for clarity 10 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 30 of 60 A3 3 way RTC in Primary Secondary Heating and DHW using Indirect Water Heater with without Outdoor Reset Mechanical Ai Indirect Hot Water Aquastat C1 Mixing Valve Actuating Motor P1 Boiler Circulator P2 Indirect Circulator R1 Relay Required with and without priority R2 Relay Required for priority S1 Boiler Return Sensor S2 Mix Supply Sensor 071 S3 Outdoor Sensor 070 21 23 Zone Valves Zone Relays Thermostats or BMS Signal 10A 12 FB 4 EJ Heat
71. r 3 phase circulators 5 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required if the Outdoor Reset feature is selected 6 System Pump P2 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 27 of 60 A2 3 way RTC in Primary Secondary Heating and DHW using Tankless Coil with without Outdoor Reset Mechanical A1 Tankless Coil or Storage Tank Aquastat C1 Mixing Valve Actuating Motor M1 By Pass Mix Point P1 Boiler Circulator P2 Tankless System Circulator P3 System Pump runs on call for heat R1 Relay Required with and without priority R2 Relay Required for Priority S1 Boiler Return Sensor S2 System Mix Sensor 071 S3 Outdoor Sensor 070 ST1 Storage Tank TK1 Tankless Coil V1 3 Way Diverting Valve V2 Ball Valve Balancing Valve 21 23 Zones Outdoor Sensor B S3 070 Class II Transformer Py diye E 120 V ac ELECO Cee eee M1 pt Boiler Return M 7 At Sensor S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating DHW with tankless coils 2 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required when the Outdoor Reset feature is selected The mix sensor must be install
72. r to these terminals as this will damage the control Boiler Return Sensor Connect the two wires from the Boiler Return Sensor to the Com and Boil Ret terminals 12 and 13 The boiler return sensor is used by the control to measure the boiler return temperature Mix Sensor Outdoor Reset and Setpoint Modes Connect the two wires from the Mix Sensor 071 to the Com and Mix terminals 12 and 14 The mix sensor is used by the control to mea sure the mixed supply water temperature in the primary loop Typi cally the sensor is attached to the pipe downstream of the system pump Mix Supply System Pump Outdoor Sensor Outdoor Reset Mode Connect the two wires from the Outdoor Sensor 070 to the Com and Out terminals 15 and 16 The outdoor sensor is used by the control to measure the outdoor air temperature STEP SIX m TESTING THE WIRING Each terminal block must be unplugged from its header on the control before power is applied for testing To remove the terminal block pull straight down from the control The following tests are to be performed using standard testing practices and procedures and should only be carried out by properly trained and experienced persons A good quality electrical test meter capable of reading from at least 0 300 V ac and at least 0 2 000 000 Ohms is essential to properly test the wiring and sensors 16 of 60 Test the Sensors H LT yT D 4 A good quality
73. s are to be stripped to a length of 3 8 in 9 mm to ensure proper connection to the control If a Mix Sensor 071 or an Outdoor Sensor 070 is used install the sensor according to the installation instructions in the Data Brochure D 070 and run the wiring back to the control Make sure the Boiler Return Sensor is installed and run the wiring back to the control Run wire from other system components pumps boilers etc to the control Run wires from the 120 V ac power to the control Ideally a separate dedicated circuit should power the control Use a clean power source with a 15 A circuit to ensure proper operation Multi strand 16 AWG wire is recommended for all 120 V ac wiring due to its superior flexibility and ease of installation into the terminals STEP FIVE ELECTRICAL CONNECTIONS TO THE CONTROL The installer should test to confirm that no voltage is present at any of the wires Push the control into the base and slide it down until it snaps firmly into place Powered Input Connections 120 V ac Power Connect the 120 V ac power supply to the Power L and Power N terminals 3 and 4 This connection provides power to the microprocessor and display of the control As well this connection provides power to the Boil Pmp terminal 5 The control should be powered from a dedicated circuit This avoids power disruption to the control in the event of failure on another electrical device on the same circuit DO NOT power
74. s indicated by the LCD This information is an essential step if additional assistance is required to diagnose the problem 22 of 60 Isolate the problem between the control and the system Now that the sequence of operation is known and Isolate the the system is sketched is the control operating the proper pumps and valves at the correct times Is the Problem control receiving the correct signals from the system as to when it should be operating Are the proper items selected in the menus of the control for the device that is to be operated Test the contacts voltages and sensors Using a multimeter ensure that the control is receiving adequate Test the Contacts voltage to the power terminals and the demand terminals as noted in the technical data Use the Voltages and multimeter to determine if the internal contacts on the control are opening and closing correctly Follow Sensors the instructions in the Testing the Wiring section to simulate closed contacts on the terminal blocks as required Test the sensors and their wiring as described in the Test the Sensors section Error Messages VIEW The control was unable to read a piece of information from its EEPROM This error can be caused by E noisy power source The control will load the factory defaults and continue operation if possible All settings in the Adjust menu must be reviewed before the error will clear The control is no longer able to read
75. t Electrical Ai Tankless Coil or Storage Tank Aquastat C1 Mixing Valve Actuating Motor P1 Boiler Circulator P2 Tankless Coil System Circulator R1 Relay Required with and without priority R2 Relay Required for priority S1 Boiler Return Sensor S2 Mix Supply Sensor 071 S3 Outdoor Sensor 070 21 23 Zone Valves Zone Relays Thermostats or BMS Signal 10A 1 6 Heat Power Bol Demand L N Pmp N 718 081 Boller Enable t Burnham RTC 12 13 14 15 16 Class II Transformer 24 Volt Output C1 CW Open to System Breaks on Temp Rise 10A Burnham RTC 24 Volt Output PET das 12 13 14 15 718 Eg Boller Enable 1 2 3 4 E Heat Power Boil Demand L N Pmp A1 NOTES 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 24 Volt Output CW Open to System Breaks on Temp Rise 5 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required if the Ou
76. t Heat Input Demand Outdoor Signal Sensor Optional Input 120 V ac Power Supply 4 Output Output Input Input Boiler Output Mixing Valve amp Well Sensor Universal Sensor Circulator Boiler Actuating Motor Included Optional P N 81460382 1 of 60 How To Use This Manual This manual is organized into four main sections They are 1 Sequence of Operation 2 Installation 3 Control Settings and 4 Testing and Troubleshooting The Sequence of Operation section has four sub sections We recommend reading Section A General Operation of the Sequence of Operation section as this contains important information on the overall operation of the control Then read the sub sections that apply to your installation The Control Settings section of this manual describes the various items that are adjusted and displayed by the control The control functions of each adjustable item are described in the Sequence of Operation Table of Contents User Interface Pg2 Testing the Control nen Pg 22 DIS PLAY u Pg 3 Troubleshooting Pg 22 Sequence of Operation Pg3 Error Messages Pg 23 Section A General Operation Pg 3 Repair P rts eere Pg 24 Se
77. t is powered up the boiler should fire If the boiler does not turn on refer to the installation or troubleshooting information supplied with the boiler Check for proper operation of each device in the boiler limit circuit If the boiler operates properly disconnect the power and remove the jumper Connecting the Control Make sure all power to the devices and terminal blocks is off and remove any remaining jumpers from the terminals Reconnect the terminal blocks to the control by carefully aligning them with their respective headers on the control and then pushing the terminal blocks into the headers The terminal blocks should snap firmly into place Install the supplied safety dividers between the unpowered sensor inputs and the powered or 120 V ac wiring chambers Apply power to the control The operation of the control on power up is described in the Sequence of Operation section of this manual STEP SEVEN ADJUSTING THE CONTROL SETPOINTS In order for the RTC to function properly several control settings must be adjusted Review the User Interface and Sequence of Operation sections of this manual for descriptions of each setting and instructions on how to adjust them Adjust the follow ing settings as specified A ROOM Room Temperature Set the desired room temperature B MIX TARGET This setting can only be used on applications where the mix sensor is installed When the outdoor reset feature is n
78. tdoor Reset feature is selected 6 Connect the tankless aquastat A1 if you are not using a storage tank If you are using a storage tank with the tankless heater use the storage tank aquastat 7 System Pump P3 to be operated by zone relay or other installer supplied device This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 37 of 60 AT 4 way RTC in Primary Secondary Heating and DHW using Indirect Water Heater with without Outdoor Reset Mechanical A1 Indirect Hot Water Aquastat C1 Diverting Valve Actuating Motor M1 By Pass Mix Point P1 Boiler Circulator P2 Indirect Circulator P3 System Pump runs on call for heat S1 Boiler Return Sensor S2 Mix Supply Sensor 071 Required for Reset or Set point Control S3 Outdoor Sensor 070 Required for Reset Control V1 4 Way Diverting Valve V2 Ball Valve Balancing Valve 21 73 Zones i Outdoor Sensor Class II S3 070 Transformer 120 V ac Indirect DHW Tank Boiler Return Sensor S1 071 NOTES 1 Install the boiler as indicated above for systems where return temperatures may be less than 135F and heating DHW with an indirect water heater 2 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required when the Outdoor Reset feature is selected The mix sensor must be installed 10 pip
79. than 11 linear feet of pipe from the Return Sensor S1 7 There shall be a MINIMUM of 4 linear feet of pipe between the By pass Mix Point M1 and the Return Sensor S1 8 The balancing valve in the boiler return line V2 may be necessary in low head by pass loop applications 9 The indirect heater aquastat A1 is a normally closed switch Circuit breaks on temperature rise 10 Expansion tanks air scoops and other components left out for clarity 11 Observe all applicable plumbing and electrical codes This diagram is for reference only The installer or designer is responsible for the proper selection and design of the system 40 of 60 A8 4 way RTC in Primary Secondary Heating and DHW using Indirect Water Heater on Primary Loop without Outdoor Reset Electrical Ai Indirect Hot Water Aquastat C1 Mixing Valve Actuating Motor P1 Boiler Circulator P2 Indirect Circulator R1 Relay S1 Boiler Return Sensor 21 23 Zone Valves Zone Relays Thermostats or BMS Signal 10 Burnham RTC 24 Volt Output 24 Volt Output 9 10 11 nr FIA C1 C1 e osed to System CW Open to System 1 Z o 21 23 D Breaks on Temp Rise A1 Class II Transformer WV NOTES 1 Refer to the I amp O to determine correct valve orientation and actuator wiring 2 120 VAC supplying the RTC should be separate from the burner bo
80. the boiler sensor due to a short circuit The control will continue to enable the boiler and will operate the diverting valve at 30 output while there is a heat demand POE 5 h r and until the sensor problem is repaired The control will also record the time without the boiler return sensor Locate and repair the problem as described in the Test the Sensors section To clear the error message from the control after the sensor has been repaired press the tem button The control is no longer able to read the boiler sensor due to an open circuit The control will continue BOIL n to enable the boiler and will operate the diverting valve at 3096 output while there is a heat demand LI P ri and until the sensor problem is repaired The control will also record the time without the boiler return sensor Locate and repair the problem as described in the Test the Sensors section To clear the error message from the control after the sensor has been repaired press the tem button The control is no longer able to read the mix supply sensor due to a short circuit In this case the control will operate the diverting valve at 3096 output as long as there is a heat demand and until the sensor problem is repaired Locate and repair the problem as described in the Test the Sensors section To clear the error message from the control after the sensor has been repaired press the Item button MIX Lh The control
81. tor Monitor BOIL MIN Err The number of hours the boiler return sensor is not functioning 20 of 60 Err lt gt 0 to 99 999 Adjust Menu 1 of 1 Description ROOM The desired room air temperature OUTDR DSGN z OFF 35 to 100 F 2 to 38 C Default 70 F 21 C Actual Setting TARGET MIX MIX TARGET Mixing setpoint temperature OUTDR DSGN OFF 60 to 200 F 16 to 93 C Default 180 F 82 C MIX DSGN The design supply water temperature used in the heat loss calculation for the heating system OUTDR DSGN z OFF 70 to 210 F 21 to 99 C Default 180 F 82 C OUTDR DSGN OUTDR DSGN The design outdoor air temperature used in the heat loss calculation for the heating system For setpoint operation set the OUTDR DSGN to OFF 60 to 32 F OFF 51 to 0 C OFF Default OFF WWSD The system s warm weather shut down during the occupied Day period 35 to 100 F OFF 2 to 38 C OFF Default 70 F 21 C MIX MIN MIX MIN The minimum supply temperature for the mixing system OUTDR DSGN z OFF OFF 35 to 150 F OFF 2 to 66 C Default OFF MIX MAX The maximum supply water temperature for the mixing system OUTDR DSGN z OFF 80 to 220 F 27 to 104 C Default 200 F 93 C cf LI Open Open Delay The time the actuating motor requires to operate from fully closed to f
82. ually operate when gears are engaged FULL FLOW TO SYSTEM FULL NO FLOW gt BYPASS SEE NOTE 1 SUPPLY SUPPLY FROM BOILER FROM BOILER CLOCKWISE CW OPEN TO SYSTEM COUNTER CLOCKWISE CCW CLOSED TO SYSTEM ACTUATOR RTC TERMINALS TERMINALS NOTE 1 VALVE POSITIONING LABEL ON BOTH SIDES OF PLATE SELECT DIAL FACE FOR CORRECT ORIENTATION Adjusting Cams Always disconnect power before making adjustments Typically cam adjustment is not necessary Before attempting cam adjustment check valve pointer travel Pointer travel should stay within 90 arc between 0 and 10 on positioning label It is advisable to remove manual valve handie before performing adjustments to avoid any gear damage Remove actuator cover and puli red indicator off of drive shaft to access cams Fit screwdriver into slot of cam and rotate to desired position Topmost cam operates auxiliary switch upper switch and is not used This cam can be moved out of the way to gain access to cams below Middle and bottom cams determine degree of rotation 30 to 180 Adjust middie cam so end switch is made when valve is fully closed to system pointer at 0 Adjust bottom cam so end switch is made when valve is fully open to system pointer at 10 Reinstall valve handle indicator and cover Depress Test switch on RTC control to test for proper valve travel and rotation before attempting to use valve Techn
83. ully open 30 to 230 seconds Default 50 seconds ADJUST 135 BOIL MIN The minimum boiler return water temperature 135 to 230 F 57 to 110 C Default 135 F 57 C BOIL MIN Delay The amount of time the boiler requires to heat up to the boiler minimum temperature from a cold start 210 to 540 seconds 10 second increments Default 540 seconds Pump Delay The amount of time the boiler recirculating pump purges the boiler 0 to 240 seconds Default 30 seconds Temperature Units The units of measure that all of the temperatures are to be displayed in the control 21 of 60 o F C Default F Testing the Control The control has a built in test routine which is used to test the main control functions The Im control continually monitors the sensors and displays an error message whenever a fault is off not testing found See the following pages for a list of the control s error messages and possible causes red testing When the Test button is pressed the test light is turned on The individual outputs and relays 3red testing paused are tested in the following test sequence Test TEST SEQUENCE Each step in the test sequence lasts at least 10 seconds During the test routine the test sequence may be paused by pressing the Test button Only if there is a heat demand can the control be paused in a step If the Test button is not pressed
84. utdoor changes temperature falls The slope of the reset ratio determines the rate at which the temperature increases with falling outdoor temperatures The reset ratio is adjustable using the mix design MIX DSGN and the outdoor design OUTDR DSGN settings s Fixed Point 70 F 4 of 60 MIX TARGET When used as a mixing reset control the MIX TARGET temperature is calculated from the reset ratio and outdoor air temperature When used as a Setpoint control the installer sets the MIX TARGET temperature The control displays the temperature that it is currently trying to maintain as the mix supply temperature If the control does not have a heat demand is displayed as the MIX TARGET BOILER RECIRCULATING PUMP The boiler recirculating pump contact Boil Pmp terminal 5 closes whenever there is a registered heat demand and the control is not in warm weather shut down WWSD The boiler recirculating pump segment is displayed in the LCD When the heat demand is satisfied the control continues to operate the boiler recirculating pump for the purge time The diverting valve remains open at the current setting during the purge time and will modulate to protect the boiler Once the purge time has expired the boiler recirculating pump shuts off and the valve closes If at any time the boiler return temperature falls below 135 F 57 C the purge is canceled During the WWSD the control e
85. xercises the pump for 10 seconds every 3 days of no activity Section C Control Settings OUTDOOR RESET SETTINGS Note For single boiler installations only When multiple boilers are installed use an appropriate staging control for outdoor reset functions Parallel Shift Using the e ROOM Setting E Room The ROOM setting is the desired room temperature in the heating zone The ROOM setting provides a method to parallel shift the reset ratio so that higher or lower mix water target temperatures are available over the entire reset range Adjusting the ROOM setting increases or decreases the heat delivery to the building Mixing Design MIX DSGN The MIX DSGN temperature is the supply water temperature required to heat the mixing zones when the outdoor air temperature is as cold as the OUTDR DSGN Setting Outdoor Design OUTDR DSGN The OUTDR DSGN is the outdoor air temperature that is the typical coldest temperature of the year where the building is located This temperature is used when doing the heat loss calculations for the building If a cold outdoor design temperature is selected the mix supply temperature rises gradually as the outdoor temperature drops If a warm outdoor design temperature is selected the mix supply temperature rises rapidly as the outdoor temperature drops Warm Weather Shut Down WWSD When the outdoor air temperature rises above the WW
86. y temperature that the control is to maintain The mix target temperature is set by the installer in the ADJUST menu An outdoor sensor is not required during this mode of operation COMMON SETTINGS The following settings are common to both the outdoor reset and setpoint operations Open Delay The open delay is the amount of time that the actuating motor requires to operate the valve from fully closed to fully open Boiler Minimum BOIL MIN Most boilers require a minimum water temperature in order to prevent flue gas condensation The BOIL MIN adjustment is set to the boiler s minimum recommended operating temperature The lowest boiler minimum temperature is 135 F 57 C Boiler Minimum Delay BOIL MIN Delay The boiler minimum delay allows a time for the boiler temperature to rise to the boiler minimum temperature while there is a heat demand After the time delay the control begins to count the boiler minimum run time Monitor BOIL MIN run Pump Delay The pump delay allows the boiler recirculating pump to purge heat from the boiler into the system after the heat demand is removed The amount of purge time is determined by the Pump Delay setting Section D Temperature Monitoring Boiler Temperature BOIL The actual boiler return temperature as measured by the boiler return sensor Mix Target The current mix target temperature if outdoor reset or setpoint operation is selected Mix The actual mix tem

Burnham RTC (Return Temperature Control) Installation Operating Instructions

Contents

Download Pdf Manuals

Related Search

Related Contents