Bryan Boilers 200 User Manual

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Bryan Steam LLC  
Installation and Operating Service Manual  
Triple-Flex  
High Efficiency Boilers  
 
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Table of Contents  
 
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Tables  
Figures  
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Section 1 Installation Instructions–  
Triple-Flex High Efficiency Boilers  
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Note:  
1.2.1 MINIMUM CLEARANCES TO  
COMBUSTIBLE SURFACES  
Please read and save for future reference the  
entire instruction manual before attempting  
installation of or starting the unit. Insurance and  
local or state regulatory codes may contain  
additional or more stringent requirements than  
those contained in this manual. Installation must  
conform to these codes and any other authority  
having jurisdiction. This instruction manual shall  
be posted and maintained in a legible condition.  
1.1 BOILER FOUNDATION  
Before uncrating, the boiler location should be  
prepared. The boiler should set upon a good  
level concrete floor. If the boiler is not level or  
the floor is not in good condition, a concrete  
foundation should be built, the dimensions being  
larger than the outside dimensions of the boiler  
base.  
A
4” high housekeeping pad is  
suggested.  
Figure 1 Minimum Clearances  
WARNING:  
Triple-Flex  
150 - 300  
Do not install boiler on combustible  
flooring.  
DIM. Description  
Clearance Above Top of  
A
B
18”  
Boiler  
Right Side  
18”  
From Chimney or Vent  
1.2 CLEARANCES  
C
D
Collector  
Measured 18”  
Horizontally  
Left Side – Tube Access  
See Table 1 for minimum clearances to walls,  
ceilings, or obstructions. The clearances in  
Side  
Construction  
From Chimney or Vent  
On  
Standard 27”  
are intended as  
a
general  
recommendation only. Local codes must be  
applied to specific installations and the minimum  
clearances established accordingly. Provisions  
must also be made for service, accessibility and  
clearance for piping and electrical connections.  
Do not obstruct combustion air and ventilation  
openings with piping or any other construction.  
All boilers must be installed in a space that is  
large compared to the boiler.  
E
F
Collector  
Measured 18”  
Vertically  
Front of Boiler – Gas Train  
& Control Panel End  
Rear of Boiler Opposite  
48”  
G
Gas Train & Control Panel 18”  
End  
Table 1 Minimum Clearance  
NOTE:  
These boilers should be installed in a room that  
is large compared to the size of the boiler. They  
are not intended for alcove installation and are  
suitable for installation on non-combustible  
flooring only. Adhere to all applicable local  
codes regarding boiler installation and  
clearances.  
1.3 RECEIVING THE BOILER  
The boiler is shipped from the factory with (4)  
shipping feet/legs bolted to the skids. These are  
provided to facilitate unloading/moving with a  
forklift. Lifting lugs are also provided to enable  
over-head lifting. The shipping feet/legs MUST  
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BE REMOVED after the boiler is set in-place on  
1.4.5 CONDENSATE DRAIN  
CONNECTION  
its  
concrete  
foundation  
before  
any  
piping/electrical connections are made.  
It is  
recommended that the plastic protective cover  
be left on as long as possible to reduce finish  
damage from the installation.  
A 1” MPT connection is provided to drain the  
condensed products of combustion from a trap  
located beneath the boiler. This must be run to  
a drain using stainless steel or PVC piping. The  
condensate temperature should never exceed  
212o F and the pH of the condensate should  
never be greater than 3.5. NO VALVE is to be  
installed in this line from the boiler to point of  
discharge.  
1.4 BOILER CONNECTIONS  
Do not run any pipes along the tube access  
panel side of the boiler. Maintain clearances as  
shown on the dimensional drawing for servicing  
of the boiler tubes. Provide at least 48" from the  
front of the boiler, unless a larger dimension is  
indicated on the dimensional. All piping should  
be designed and installed to avoid any loadings  
on the boiler connections or piping.  
1.4.6 GAS SUPPLY CONNECTION  
The installation must conform completely to the  
requirements of the authority having jurisdiction,  
or in the absence of such, requirements shall  
conform in the U.S. to the current National Fuel  
Gas Code, ANSI Z223.1-1984, or in Canada to  
the current Natural gas and propane installation  
code (CAN/CSA B149.1-05), and applicable  
regional regulations for the class; which should  
be followed carefully in all cases. Authorities  
having jurisdiction should be consulted before  
installations are made.  
1.4.1 FLOW CONNECTION  
The system supply and return flow connections  
are shown on Figure  
respectively. A gate valve should be installed on  
the boiler outlet and inlet lines. This allows the  
boiler to be isolated from the heating system for  
draining and servicing.  
1.4.2 SAFETY RELIEF VALVES  
1.4.7 DRIP LEG  
Safety relief valve(s) are shipped loose.  
Connections are provided in the top of the boiler  
for the safety relief valve(s). The safety relief  
valve discharge piping must be the same size as  
the safety relief valve discharge opening and run  
to a point of safe discharge. Avoid over-  
tightening as this can distort valve seats. All  
piping from the safety relief valve(s) must be  
independently supported with no weight carried  
by the valve.  
A drip leg, or sediment trap, must be installed in  
the gas supply line. See Fig. 1.5A. The gas line  
must be connected to a supply main at least as  
large as the gas train connection at the boiler.  
This connection should be made with a union so  
that the boiler gas train components and burner  
may be easily removed for service.  
1.4.8 GAS PIPING LEAK TEST  
1.4.3 EXPANSION TANK  
CONNECTIONS  
Leaks shall be checked using a soap and water  
solution.  
Connection(s) to an expansion tank are to be  
provided by others in the system piping separate  
from the boiler.  
After completion of the gas-piping hookup, the  
installation must be checked for leaks. All joints  
up to the main motorized gas valve shall be  
checked. A pressure gauge shall be installed  
down stream of the main motorized gas valve  
and up stream of the manual gas shutoff valve in  
the closed position to ensure the main motorized  
1.4.4 DRAIN CONNECTION  
valves are not leaking by.  
commissioning, the remainder of the gas train  
joints down stream of the main motorized gas  
During  
A drain valve must be installed on the boiler  
drain connection, the same pipe size as this  
connection, to allow draining of the boiler.  
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valve shall be tested for leaks.  
Model  
TF300/250  
TF200/150  
200 V – 240 V / 60 Hz / 3 Ph  
Blower Motor  
3 (4.02)  
N/A  
KW (HP)  
Full Load  
Amps1  
1.4.9 VENTING OF GAS TRAIN  
COMPONENTS  
15.6  
N/A  
N/A  
Service Fuse  
(3) 20 Amp  
400 V – 480V / 60 Hz / 3 Ph  
Blower Motor  
N/A  
N/A  
KW (HP)  
Full Load  
Amps1  
N/A  
N/A  
N/A  
N/A  
Service Fuse  
200 V – 240 V / 60 Hz / 1 Ph  
Blower Motor  
KW (HP)  
N/A  
1.05 (1.41)  
Full Load  
N/A  
N/A  
6
Amps1  
Service Fuse  
(2) 7 Amp  
Table 2 Electrical Requirements  
Figure 2 Main Gas Inlet Connection  
Equipment Grounding  
The boiler must be grounded in accordance with  
the current American National Standard  
Electrical Code, ANSI/NFPA #70.  
Normally open vent valves (when supplied) -  
These valves must be piped to outdoors using  
pipe no smaller than that of the valve.  
1.6 COMBUSTION AIR SUPPLY  
Gas pressure switches – All gas pressure  
switches provided are of the VENTLESS type  
and do not require venting to atmosphere.  
Combustion Air:  
For proper combustion it is necessary to provide  
the boiler room with appropriate openings for  
fresh air supply. Temporary air intakes such as  
windows and doors should be avoided since  
they may be closed. In addition to air needed  
for combustion, sufficient air must be supplied  
for ventilation as well as other air consuming  
equipment that may be present in the boiler  
room. Often when personnel are working in the  
boiler room, combustion air openings are closed  
due to the temperature of the outside air. THIS  
MUST BE AVOIDED AT ALL COSTS!  
Provisions should be made to heat the outside  
combustion air, if necessary, for personnel  
comfort.  
Gas pilot pressure regulator – A vent limiter for  
the pilot pressure regulator is provided  
eliminating the need to run a vent line to  
atmosphere.  
NOTE:  
Do not use Teflon tape for threaded joints in gas  
piping.  
1.5 ELECTRICAL REQUIREMENTS  
WARNING:  
All electrical connections must  
conform to the National Electrical  
Code and to all other applicable State  
and Local Codes. See boiler wiring  
diagram and equipment list for specific  
voltage requirements.  
Positive means for supplying an ample amount  
of outside air, allowing for the complete  
combustion of the gas, must be provided.  
Movable combustion air dampers, automatic or  
manually adjustable, must be electrically  
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Full load Amps include blower and control  
circuit.  
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interlocked with the boiler to prevent boiler  
operation if the dampers are closed.  
One Permanent Opening Method  
One opening commencing within 12” of the top  
of the room shall be provided. The opening  
shall be directly to the outside or shall be ducted  
to the outside with a horizontal or vertical duct.  
Combustion air openings must never be blocked  
or obstructed in any manner.  
The boiler room must be at a positive or neutral  
pressure relative to the outdoors. A negative in  
the boiler room will result in downdraft problems  
and incomplete combustion due to the lack of  
air.  
The opening or duct shall have a minimum free  
area of:  
1 in2 / 3000 BTU /hour of the total input ratting of  
all appliances (boilers) in the room.  
WARNING!  
Not less than the sum of the areas of all vent  
connectors in the room. A “vent connector” is  
defined as the pipe or duct that connects a fuel  
burning appliance to a vent or chimney.  
Failure to provide an adequate air  
supply will result in boiler damage and  
hazardous conditions in the building  
(fire and asphyxiation hazard as well  
as equipment damage).  
Additional area must be provided for other air  
consuming equipment in the room.  
Mechanical Air Supply Systems  
1.6.1 COMBUSTION AIR OPENINGS:  
The combustion air supply may be provided by a  
mechanical air supply system. If utilized, the  
combustion air must be provided from the  
outside at a minimum rate of 0.35 ft3/min. for  
every 1000 Btu/hr. input for all appliances  
located in the space.  
The design of combustion air openings MUST  
comply with local and/or State codes or the  
authority having jurisdiction. As a minimum,  
combustion air openings to the boiler room shall  
be provided as follows:  
Note:  
If exhaust fans are utilized, additional air shall be  
provided to replace the exhausted air.  
Combustion air provided solely from an indoor  
source is discouraged. No dimension for a  
round or rectangular opening shall be less than  
3”.  
Each boiler and other appliance must be  
interlocked to prevent operation when the  
mechanical air supply system is not in operation.  
Two Permanent Opening Method  
If the combustion air is provided by a buildings  
mechanical ventilation system, the system shall  
be sized to provide the specified combustion air  
in addition to the ventilation air requirements.  
One opening starting within 12” of the top of the  
boiler room and one starting within 12” of the  
bottom of the boiler room shall be provided. The  
openings shall be open directly to the outside or  
ducted directly to the outside.  
1.6.2 LOUVERS, GRILLES, AND  
SCREENS  
When directly open to the outside or ducted to  
the outside by vertical ducts, each opening or  
duct shall have a minimum fee open area of 1  
in2 per 4000 BTU total input rating of the  
boiler(s) in the room.  
Louvers and Grilles:  
The required size of openings for combustion,  
ventilation, and dilution air shall e based on the  
net free area of each opening. Where the free  
area through a design of louver, grille, or screen  
is know, it shall be used in calculating the size  
opening required to provide the free area  
If ducted to the outside through horizontal  
ducts, each opening or duct shall have a  
minimum free area of 1 in2 per 2000 BTU total  
input rating of the boiler(s) in the room.  
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specified. Where the louver and grille design  
and free area are not know, it shall be assumed  
that wood louvers have a 25 percent free area,  
and met louvers and grilles have 75 percent free  
area. Non-motorized louvers and grilles shall be  
fixed in the open position.  
BOCA, National Mechanical Code  
WARNING:  
Do not locate air intakes where  
petroleum distillates, CFC’s,  
detergents, volatile vapors or any  
other chemicals are present. Severe  
boiler corrosion and failure will result.  
Screens  
Minimum Screen Mesh Size:  
Screens shall not be smaller than 1/4 “ mesh.  
Motorized Louvers:  
Motorized louvers shall be interlocked with the  
appliance so they are proven in the full open  
position prior to main burner ignition and during  
main burner operation. Means shall be provided  
to prevent the main burner from igniting should  
the louver fail to opening during burner startup  
and to shut down the main burner if the louver  
close during burner operation.  
1.7 FLUE GAS VENTING SYSTEM  
Triple-Flex boilers are Category IV appliances  
that vent with a positive exhaust vent pressure  
and with a temperature that is likely to cause  
condensation. Any venting system used with  
the Triple-Flex boiler must comply with the  
requirements for Special Gas Vents per UL  
Category Code (CCN) DGSH, which are UL  
Listed per UL 1738 or UL Category Code  
DGSH7, which are cUL Listed (Canada) per UL  
1738.  
Combustion Air Ducts  
Combustion air ducts shall comply with the  
following:  
Ducts shall be constructed of galvanized steel or  
WARNING:  
a
material having equivalent corrosion  
resistance, strength and rigidity.  
The Triple-Flex boiler is NOT certified  
for use with other types of venting  
excepting Special Gas Vents. Use of  
any other types of venting may cause  
vent failure resulting in serious injury  
or death.  
Ducts shall terminate in an unobstructed space,  
allowing free movement of combustion air to the  
appliances.  
Ducts shall serve a single space.  
Ducts shall not serve both upper and lower  
combustion air openings where both such  
openings are used. The separation between  
ducts serving the upper and lower combustion  
air openings shall be maintained to the source of  
combustion air.  
1.7.1 DESIGN & INSTALLATION  
Ducts shall not be screened where terminating  
in an attic space.  
Horizontal upper combustion air ducts shall not  
slope downward toward the source of  
combustion air.  
A qualified venting professional experienced in  
venting system designs should design the boiler  
vent system. The vent size must be NO LESS  
THAN 8” IN DIAMETER and sized such that the  
pressure drop between the boiler and the point  
of discharge does not exceed 0.20” WC. While  
the vent must be UL Listed Special Gas Vent  
per Category Code DGSH or DGSH7 for  
Canada, Bryan Steam, LLC recommends the  
use of venting components fabricated from  
AL29-4C® material. The vent installation must  
be in strict compliance with the vent  
For informational purposes, there are several  
codes that address the amount of air and/or size  
of the opening(s) in walls for combustion air.  
NFPA 54, National Fuel Gas Code (ANSI  
Z223.1)  
ASME CSD-1, Controls and Safety Devices for  
Automatically Fired Boilers  
manufacturers requirements.  
combustible materials and  
Clearances to  
supporting  
ASME Section VI, Recommended Rules for  
Care and Operation of Heating Boilers  
requirements, per the vent manufacturers  
installation instructions, must be maintained.  
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Horizontal sections of the flue vent system must  
be pitched back towards the boiler at ¼ inch per  
foot to avoid condensate pooling and allow for  
proper drainage. Venting may be horizontal,  
through the wall installation or vertical, through  
the roof installation. The vent system, including  
terminus, must be sized in accordance with the  
flue gas flow(s) and pressure drop(s) per Table 3.  
Note:  
An existing masonry chimney may be utilized  
PROVIDING that the existing chimney is lined  
with Special Gas Vent material(s), primarily  
AL29-4C®. There are venting manufacturers  
that have these products available.  
1.7.2 COMBUSTION AIR AND VENTING  
REQUIREMENTS FOR CANADA  
Flue Gas  
Comb Air  
Flow,  
Req.  
SCFM  
Permissible  
P Thru  
Venting  
ACFM  
@40%X  
SA  
Boiler Model  
Canadian  
Standard  
CAN/CSA-B149.1-05,  
@40%XS  
Natural gas and propane installation code  
specifies venting systems and air supply for  
appliances in Section 8. Paragraph 8.1.4 states  
“Air supply shall be provided in accordance with  
Clause 8.4 when either an appliance or a  
combination of appliances has a total input  
exceeding 400,000 Btuh”. Air supply is defined  
as combustion air, excess air, flue gas dilution  
air, primary air, secondary air, and ventilation  
air. The air supply requirements below are a  
summation of Clause 8.4 specific to the Triple-  
Flex boiler.  
A60oF  
200oF  
0.2” WC  
(Max)  
0.2” WC  
(Max)  
0.2” WC  
(Max)  
0.2” WC  
(Max)  
TF-150  
TF-200  
TF-250  
TF-300  
452  
603  
753  
904  
330  
441  
550  
661  
Table 3 Boiler Draft  
Note:  
Air Supply Requirements per CAN/CSA-  
B149.1-05 for Appliances having an input  
exceeding 400 MBH.  
NFPA 54-2009 (ANSI Z223.1-2009) paragraph  
12.7.3.3 states, “The sizing of gas vents for  
Category II, Category III, and Category IV  
Appliances shall be in accordance with the  
appliance manufacturers instructions.”  
Ventilation Air: an opening for ventilation air at  
the highest point that opens to the outdoors shall  
provide Ventilation of the space. The cross  
sectional area of this opening shall be at least  
10% of the area required for combustion air, but  
in no case shall the cross-sectional area be less  
that 10 in2 (6500mm2).  
Combustion Air: For combustion air where the  
air supply is provided by natural airflow from  
outdoors, in addition to the opening for  
ventilation air, there shall be permanent opening  
having a total cross-sectional free area of not  
less than 1 in2 for each 30,000 BTU/hr. (70 mm2  
for each kW) of the total rated input of the  
boiler(s). The location of the opening(s) shall  
not interfere with the openings for ventilation air.  
Please refer to CAN/CSA-B149.1-05, Para.  
8.4.4, for combustion air openings if there are  
natural draft, fan assisted or power draft  
assisted equipment in the space.  
WARNING:  
Do not use a barometric damper with  
this boiler. This is a positive pressure  
system. The use of a barometric  
damper may cause flue gases to leak  
into the boiler room.  
The boiler vent must not be connected to any  
portion of another vent system without  
consulting the vent manufacturer. The boiler  
shall not be connected to any part of a vent  
system serving a Category I or Category II  
appliance, nor shall a Category I or Category II  
appliance be connected to the vent system  
serving this boiler. Improper connection of  
venting systems may result in leakage of flue  
gases into building spaces.  
When an air supply duct is used to supply  
combustion air, it’s discharge opening shall be  
located where there is no possibility of cold air  
affecting steam or water lines or other  
temperature sensitive equipment.  
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shaft used for return air, hot air,  
ventilating air, or combustion air.  
An appliance that operates at a positive  
vent pressure shall not be connected to  
a venting system serving any other  
Combustion Air Supply Dampers, Louvers,  
and Grilles  
The free area of the combustion air supply  
opening shall be calculated by subtracting the  
blockage area of all fixed louvers, grilles or  
screens from the gross area of the opening.  
Openings in a fixed louver, grille, or screen shall  
have no dimension smaller than ¼” (6 mm).  
No manually operated damper or manually  
operated adjustable louvers are permitted.  
appliance.  
The Triple-Flex boiler  
operates at a positive vent pressure.  
A factory-built chimney used for venting  
an appliance shall be certified.  
Vent Sizing  
A
motorized damper or louvers shall be  
A vent or chimney serving a single  
interlocked so the burner(s) cannot operate  
unless the damper or louver is in the fully open  
position.  
appliance shall provide effecting venting  
and shall be sized so that it’s effective  
area is not less than that of the flue  
outlet diameter of the boiler and in  
accordance with engineering venting  
tables acceptable to the authority having  
jurisdiction.  
A vent or chimney serving more than  
one appliance shall provide effective  
venting and shall be sized in  
accordance with good engineering  
practice, such as by the use of  
engineering venting tables acceptable to  
the authority having jurisdiction.  
Mechanical Combustion Air Supply  
When combustion air is supplied by mechanical  
means, an airflow sensing device shall be  
installed and wired into the safety limit circuit of  
the primary safety control to shut off the gas in  
the even a an air supply failure.  
Appliance Venting per CAN/CSA-B149.1-  
05  
Paragraph 8.9 of CAN/CSA-B149.1-05 addresses  
“Appliance Venting”. Paragraphs 8.9 through 8.31  
address many facets of flue gas vents, many of which  
do not apply to the Triple-Flex boiler, which is a  
Category IV listed appliance requiring the use of  
special venting systems as previously described.  
1.7.3 MARKING OF GAS VENTS  
Where solid and liquid fuels are used, gas vents,  
must be plainly and permanently identified by a  
label. The label should read, "This gas vent is  
for appliances that burn gas only. Do not  
connect to incinerators or solid or liquid fuel  
burning appliances."  
This label must be attached to the wall or ceiling  
at a point near where the gas vent connector  
enters the wall, ceiling or chimney.  
NOTE:  
Please note that the information provided in this  
manual relative to the Canadian Standard is not  
meant to be all-inclusive. Reading the entire  
Standard is strongly suggested.  
approval of all system designs must be  
acceptable to the authority having jurisdiction.  
The final  
The authority having jurisdiction must determine  
whether their area constitutes such a locality.  
Venting for Category IV appliances shall  
be as specified or furnished by the  
manufacturer of the listed appliance.  
The Triple-Flex boiler is a Category IV  
appliance requiring the use of special  
vent that is certified.  
Solid Fuel Appliance Vents  
Gas appliances shall not be vented to a vent or  
a chimney that serves a solid-fuel burning  
appliance.  
A special venting system shall be  
installed in accordance with the terms of  
it’s listing and the vent manufacturers  
certified installation manual.  
A flue gas vent or a vent connector shall  
not be installed in either a duct or a  
1.8 BEFORE PLACING BOILER IN  
OPERATION  
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1.8.1 HYDROSTATIC TEST OF  
BOILERS AND SYSTEM  
After completing the boiler and burner  
installation, the boiler connections, fittings,  
attachments and adjacent piping must be  
inspected for leaks by filling the unit with water.  
The pressure should be gradually increased to a  
pressure just below the setting of boiler safety  
relief valve(s).  
Remove the boiler tube access panels (see  
dimensional drawing in the boiler manual).  
Inspect the tube to header joints to be certain  
that all tube fittings are sealed.  
This is  
necessary because, although the boiler is  
hydrostatically tested at the factory, minor leaks  
in fittings and at attachments can develop from  
shipping  
vibration  
or  
from  
installation  
procedures. It is often necessary to retighten  
such fittings after installation and after the boiler  
has been operated for some time. Replace tube  
access panels before proceeding to start boiler.  
1.8.2 TEST OF GAS PIPING  
Reference the gas system test under paragraph  
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Section 2 Start-Up and Operation  
Triple-Flex High Efficiency Boilers  
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2.1.1 TRIPLE-FLEX FRONT VIEW  
WARNING:  
Improper servicing and start-up of this  
equipment may create a potential  
hazard to equipment, operators, or  
persons in the building.  
Only fully trained and qualified  
personnel should do servicing and  
start-up.  
WARNING:  
Before disconnecting or opening any  
fuel line, cleaning or replacing parts of  
any kind take the following  
precautions.  
Turn OFF the main fuel shutoff valves,  
including the pilot gas cock if  
applicable.  
Turn OFF all of the electrical  
disconnects to the burner, boiler and  
any other equipment or systems  
electrically interlocked with the burner  
or boiler.  
Figure 3 Triple-Flex Front View  
1. The boiler cabinet door provides easy  
access to boiler and burner components.  
This door should remain closed during  
normal operation to ensure proper flow of air  
around the boiler flue collector.  
All cover plates, enclosures, and  
guards must be in place at all times  
except during maintenance and  
servicing.  
2. The boiler supply water connection provides  
heated water to the system.  
connection is a standard ANSI 150# class 3”  
flange.  
This  
3. The boiler water pressure gauge is 2”  
diameter and will have a range not less than  
1-1/2 nor more than 3-1/2 times the  
pressure setting of the boiler safety relief  
valve.  
4. The boiler water temperature gauge is 2”  
diameter and is located so that it will indicate  
the boiler water temperature at the supply  
water connection of the boiler.  
5. The boiler touch panel display provides a  
human interface for controlling the boiler.  
Controlling the boiler with the touch panel  
display will be explained in section 2.2.  
6. The boiler on / off switch will turn on or off  
the 120 volt ac control voltage for every  
electrically connected device. This includes  
2.1 BOILER ASSEMBLY  
The Triple-Flex boiler is a fully integrated  
assembly consisting of a Metal Fiber Pre-Mix  
Burner Head and the necessary fittings, valves,  
and safety devices. The boiler equipment list  
provided in the boiler manual lists the  
components supplied for the boiler assembly.  
Refer to the boiler dimensional for location  
dimensions.  
A
description of the major  
components follows. For additional information  
refer to the manufactures literature provided in  
the boiler manual.  
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the touch panel display. There is a soft  
switch (paragraph 2.2.11) provided with the  
SOLA hydronic control that will put the boiler  
into standby for an indefinite period of time.  
2.1.2 TRIPLE-FLEX REAR VIEW  
WARNING:  
The boiler on / off switch will not turn  
off the 3 phase high voltage power to  
the motor.  
7. The boiler lockout reset button is a push  
button used to reset the hydronic control  
after a boiler failure.  
8. The power on light will be white in color and  
indicates that there is 120 volts ac being  
supplied to electrically connected devices.  
9. The enabled light will be green in color and  
indicates that the boiler is enabled. Enabled  
is a state in which the boiler is allowed to  
operate within the boiler’s predefined  
parameters.  
10. The fuel on light will be amber in color and  
indicates that the boiler is firing and  
producing heated water.  
11. The boiler lockout light will be red in color  
and indicates that the boiler has failed. The  
Figure 4 Triple-Flex Rear View  
SOLA  
control  
will  
have  
additional  
1. The flue gas vent is 8” diameter and  
exhausts products of combustion. Refer to  
section 1.7 for installation details.  
information displayed on the touch panel  
display. These failures will be explained in  
2. The rear jacket access panel provides  
access to the combustion air blower for  
servicing.  
3. The boiler return water connection receives  
cooled water from the system.  
This  
connection is a standard ANSI 150# class 3”  
flange.  
4. The drain connection is 1” NPT and provides  
a means for draining water from the boiler.  
For installation details refer to paragraph  
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1. Main gas inlet connection. This connection  
is a 2” male national pipe thread.  
2.1.3 TRIPLE-FLEX LEFT SIDE VIEW  
2. Condensate Drain Connection.  
This  
connection is a 1” male national pipe thread.  
For installation details refer to paragraph  
3. This jacket access panel will permit access  
to the majority of the boiler devices.  
4. These jacket access panels will permit  
access to the flue collector. There is no  
practical reason for the removal of these  
panels.  
5. This jacket access panel will permit access  
to the condensate trap. The condensate  
trap is provided with a ½” NPT plugged  
connection for cleanout purposes.  
6. This jacket access panel will permit access  
to the primary air-to-air exchanger.  
Figure 5 Triple-Flex Left Side View  
1. This jacket access panel will permit access  
to the primary air-to-air exchanger.  
2. This jacket access panel will permit access  
to the primary air-to-air exchanger and the  
boiler convection tube access panels.  
3. These jacket access panels will permit  
access to the convection and furnace tube  
access.  
2.1.5 TRIPLE-FLEX BEHIND THE  
CABINET DOOR  
4. Flame observation port. This port provides  
visual access to observe the pilot and main  
flame during operation and service.  
5. This jacket access panel will permit access  
to the majority of the boiler devices.  
WARNING:  
The flame observation port will  
become very hot during normal  
operation. Burn injuries can occur if  
come in contact with the skin.  
2.1.4 TRIPLE-FLEX RIGHT SIDE VIEW  
Figure 7 Triple-Flex Behind the Cabinet Door  
1. Auxiliary gas shutoff valve actuator.  
2. Low fire displacement adjustment that can  
be adjusted by removing the cap and  
rotating the slotted screw clockwise to  
increase gas flow and counter-clockwise to  
decrease gas flow.  
Fig. 2.1.2 Triple-Flex Rear View  
Figure 6 Triple-Flex Right Side View  
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port is also used to record the furnace  
pressure.  
NOTE:  
15. Boiler water flow switch. The boiler water  
flow switch is adjustable within the  
parameters listed in the table.  
The low fire displacement final adjustment  
should be made at low fire only.  
3. Main gas pressure regulating and shutoff  
valve actuator. The pressure regulating  
actuator provides slow opening fast closing  
safety shutoff and air/gas ratio control. The  
actuator controls the pressure difference  
across the gas limiting orifice valve (Figure 7  
item 26) as a function of the pressure  
difference across the furnace section so that  
the air to gas ratio remains constant  
irrespective of air volume changes. There is  
no need for an upstream constant pressure  
regulator when the supply gas pressure  
does not exceed 56 inches of water column.  
A minimum of 14 inches of water column  
must be supplied at the gas inlet connection  
be measured at the test port (Figure 7 item  
28).  
Mode Of Operation  
Settings  
Switch  
Closed  
30 gpm  
52.1  
Switch  
Open  
12 gpm  
46.1  
Minimum  
Maximum  
gpm  
gpm  
Table 4 Water Flow Switch Settings  
16. Low Water Cutoff (Manual Reset Probe  
Type).  
17. Combustion air-flow switch.  
An airflow  
switch is provided to prove that air is being  
provided to the burners before main flame  
can be established. The airflow switch can  
be adjusted by turning the screw (Figure 8  
item A) clockwise to increase the pressure  
setting and counter-clockwise to decrease  
the pressure setting. The switch will open  
on pressure drop. When the blower is  
running there should be continuity between  
the common and the normally open contacts  
(Figure 8 item B and C). When the blower is  
interrupted the switch should open and  
cause a safety shutdown.  
NOTE:  
The supply pressure is not static. The supply  
pressure is at the maximum full flow of gas  
through the burner.  
4. Manual main gas shutoff valve.  
5. Pilot ignition transformer.  
6. Manual pilot gas shutoff valve.  
7. Pilot gas pressure regulator. This regulator  
provides a constant gas pressure to the pilot  
when the solenoid valve is energized. The  
pressure can be adjusted by removing the  
cap and adjusting the slotted screw  
clockwise to increase the pressure and  
counter-clockwise to decrease the pressure.  
The pilot gas supply is taken upstream of  
the main gas cock so the pilot may be  
lighted and adjusted with the main gas cock  
closed.  
A
B
8. Low pilot gas pressure switch (Manual  
Reset)  
C
9. Pilot spark igniter assembly. For further  
10. Pilot gas solenoid valve.  
Figure 8 Air Flow Switch  
11. Flame scanner.  
12. Main gas manifold pressure test port (1/4”  
NPT).  
13. Main high gas pressure switch (Manual  
Reset). This switch should be set 1” of  
water column above the maximum gas  
manifold pressure.  
18. High burner air pressure switch manual  
reset. This switch will trip when the air  
pressure in the burner rises above the set-  
point, indicating that the burner has become  
plugged with dust or other foreign matter.  
19. Gas and air mixer assembly.  
20. Main 3-phase power connection and fuse  
14. Pilot gas pressure test port (1/4” NPT). This  
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block.  
2.1.6 PILOT SPARK IGNITER  
ASSEMBLY  
21. Control circuit transformer.  
22. 24 volt ac transformer.  
23. 12 volt dc power supply.  
24. SOLA hydronic and flame supervision  
control.  
25. Repeat cycle timer. This timer will ensure  
that a forced shut down and pre-start safety  
check is performed at least once in a 24  
hour period.  
This timer has been  
incorporated into the SOLA control for newer  
boilers.  
Figure 9 Pilot Spark Igniter Assembly  
26. Gas limiting orifice valve. This valve is used  
to increase or decrease the gas / air ratio for  
1. Spark grounding screw.  
2. Pilot igniter gas orifice (#49 Drill)  
3. Shell body ¾”.  
4. Gland nut.  
5. Igniter electrode.  
6. Brass bushing.  
combustion.  
Adjustments are made by  
removing the cap and using a flathead  
screwdriver. Clockwise rotation will increase  
the flue outlet % O2 levels and counter-  
clockwise will decrease the flue outlet % O2  
level. Starting point adjustments are listed  
in the table. This vale is factory set and the  
number of turns out is written in black  
adjacent to the adjustment cap.  
7. Gas inlet fitting.  
2.1.7 TRIPLE-FLEX LEFT FLUE  
COLLECTOR VIEW  
Turns Out From  
Boiler Model  
Bottom  
TF300  
TF250  
TF200  
TF150  
8-1/2 to 9  
8-1/2 to 9  
6-1/2 to 7  
6-1/2 to 7  
Table 5 Gas Limiting Orifice Rough Settings  
27. Main low gas pressure switch (Manual  
Reset). This switch should be set 2 – 3  
inches of water column below the minimum  
required supply gas pressure.  
28. Supply gas pressure test port (1/4” NPT).  
29. (-) Air pressure sensing line connection.  
30. (+) Air pressure sensing line connection.  
31. (-) Gas pressure sensing line connection.  
32. (+) Gas pressure sensing line connection.  
33. Burner internal temperature fuse. This fuse  
senses the internal burner temperature and  
will open at a temperature greater than  
425oF.  
Figure 10 Triple-Flex Left Flue Collector View  
1. 3” Lower drum cleanout and inspection  
opening.  
2. Furnace tube access panel.  
3. Convection tube access panel.  
4. Primary air-to-air exchanger access cover.  
5. ASME name-plate stamping.  
6. Combustion air blower.  
7. 3” Upper drum cleanout and inspection.  
8. ASME Safety relief valve.  
9. Air filter 20” x 25”. This filter is a polyester  
coated fiberglass. The frame is made of  
fiberboard and has two tin-plated steel grills  
(one bonded to each side) as well as sealed  
corners to prevent dust leakage. Filters are  
marked with size and airflow direction.  
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Actual length and width are 38” less than  
trade size shown. Filters meet UL Class 2  
flame retardance requirements. Maximum  
temperature is 180° F.  
2.2.2 HOME PAGE  
Make sure a screen similar to Figure 12 appears  
after the system is completely powered up. The  
directional map shown before each page  
description in this manual will start with this  
2.1.8 TRIPLE-FLEX RIGHT FLUE  
COLLECTOR VIEW  
symbol  
.
Pressing this symbol will return  
you to the home page.  
Figure 11 Triple-Flex Right Flue Collector View  
Figure 12 Home Page  
1. High primary air-to-air exchanger pressure.  
This switch will trip when the air pressure in  
the primary air-to-air exchanger rises above  
the set-point, indicating that the primary air-  
to-air exchanger has become plugged with  
dust or other foreign matter.  
2. Condensate trap cleanout. This connection  
is ½” NPT.  
3. Condensate trap. The condensate trap is  
welded and fixed into place.  
On multi-boiler applications, each boiler in the  
hydronic system is represented on the Home  
page by an icon and name. Pressing the boiler  
icon allows the user to zoom in on that boiler  
and see specific details about it. These details  
are provided on a new page, which can include  
additional buttons that display additional detail  
and operation information, which itself leads to  
other pages. The pages are traversed in a tree  
structure method. The boiler icon button will  
appear in one of four colors indicating the boiler  
status.  
4. Flue vent temperature sensor.  
2.2 SOLA HYDRONIC CONTROL  
SYSTEM  
Blue: Normal operation  
Red: Lockout condition  
Gray: Standby mode (burner switch off)  
Gray and crossed out: Hydronic control  
The Triple-Flex is equipped with a Honeywell  
SOLA control system (Figure 3 item 5). This  
section will explain navigation, configuration,  
history, and diagnostics.  
communication error (disconnected or powered  
off)  
Up to 8 boilers can be displayed on the System  
Home page.  
2.2.1 POWER-UP VALIDATION  
The name of each boiler is displayed next to the  
boiler icon. When Lead Lag is enabled, the  
system header temperature and firing rate are  
displayed for each boiler. When the burner is in  
standby or not firing the firing rate is not  
displayed.  
Flip the power button, (Figure 3 item 6), to the  
on position. After a few seconds the Home page  
will appear and the POWER LED will be blinking  
when the device is properly powered. Select the  
Setup button to adjust the contrast as desired.  
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NOTE:  
2.2.4 KEYBOARD  
The boiler name may be cut off on the Home  
page when all boilers are present for the  
hydronic system.  
The Home page also includes a System  
Analysis button that allows the user to view  
status information on a system-wide (that is,  
multiple boiler) basis. The user can choose  
which status information to compare from the  
boilers in the system. Pressing the Setup button  
on the Home page displays miscellaneous  
display setup and diagnostic functions.  
2.2.3 PAGE NAVIGATION  
Figure 13 Keyboard  
information and options in a paged manner.  
Pages are displayed in a tree structure in which  
the user navigates up and down to arrive at the  
desired function. The page descriptions are  
provided below so that you can understand the  
purpose of each and view the selections,  
parameters, and information that are available or  
required on each. Most pages have a Home  
Some pages request user entry of characters.  
When this type of input is required, a keyboard  
page appears, as shown in Figure 13.  
The text box at the top of the screen displays the  
current (or default) setting of the user input. The  
user can add to this text, clear it, or change it.  
The Shift key on the left side of the screen shifts  
between upper- and lowercase characters.  
Pressing the Shift key toggles the keyboard from  
one mode to the other (continuous pressing of  
the Shift button is not required). The OK button  
should be pressed when the user is done  
entering the text input. The Cancel button on the  
bottom of the screen allows the user to ignore  
any text changes that have been made and  
keep the original text value. Pressing the OK or  
Cancel buttons returns the user to the page  
displayed prior to the keyboard page.  
button  
in the top-left corner of the screen  
and a Back button in the top-right corner of the  
screen. The Home button returns the user to the  
Home page and terminates any operation in  
progress. The Back button  
returns the user  
to the previous page. Two other icons may be  
noticed near the boiler name. A bell will be  
displayed if the system is in lockout that reset  
will be required. A padlock will be shown on  
screens that a password is needed to change  
the parameter. An unlocked padlock  
indicates the password has been entered to  
change the parameter (either the installer or  
OEM), depending on the security level entered.  
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2.2.5 STATUS PAGE  
Details:  
Used to view boiler detail status information.  
History:  
Used to view R7910 history.  
Modulation:  
Used to toggle between two different status  
displays: modulation, and setpoints.  
2.2.6 CONFIGURATION PAGE  
CONFIGURE  
Figure 14 Status Page  
The status page (Figure 14) is displayed when a  
boiler is selected on the Home page. The status  
page displays the current condition of the boiler  
and displays some of the more important  
configuration settings.  
The boiler name is  
displayed in the title bar of the status page.  
NOTE:  
When the boiler has no name defined, the  
display will use the Modbus address to identify  
the boiler.  
Figure 15 Configuration Menu Page  
The standard status page displayed for the  
Triple-flex boiler contains summary status  
information as shown in Figure 14. Any status  
information not applicable for the installation is  
blanked out on the screen. Buttons on this  
screen include:  
The configuration page allows the user to view  
and set parameters that define how the boiler  
functions in the hydronic heating system.  
Configuration parameters for any boiler  
connected in the Global Modbus™ network can  
be accessed from the display. Press the boiler’s  
button on the Home page to acess the Status  
page. Pressing the Configure button on the  
status page starts a configuration session. The  
Configure:  
Used to configure the R7910 (see “Configuration  
configuration page contains  
a
menu of  
parameters grouped into functional areas that  
the user selects for configuration (see Figure  
Operation:  
Used to perform daily/frequent functions with the  
R7910, such as setpoint adjustment, etc. (See  
“Operation Page” 2.2.11 page 22 for more  
details.)  
No specific order for configuring the boiler is  
required. All parameters are enabled for editing,  
though some may not be applicable (e.g., a  
configuration parameter may disable a boiler  
feature). Selecting a parameter group from the  
Diagnostic:  
Used to view R7910 diagnostic information.  
menu  
displays  
parameters  
exclusively  
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applicable for the functional group on the page  
(Figure 16).  
for a parameter that has a lower access level  
than the access level achieved by an earlier  
password entry for any configuration group (as  
long as the user stays in the configuration  
pages). The user only needs to enter a  
password once until a parameter that has a  
higher access level is selected.  
The user enters the password from a keyboard  
as shown in Figure 13. After the password is  
entered, select the OK button. The Cancel  
button aborts the password login.  
WARNING:  
Explosion Hazard.  
Figure 16 Sample Configuration Page  
Improper configuration can cause fuel  
buildup and explosion. Improper user  
operation may result in PROPERTY  
LOSS, PHYSICAL INJURY or DEATH.  
Changing parameters, must be  
attempted by only experienced and/or  
licensed burner / boiler operators and  
mechanics.  
These parameters can be edited, and when the  
user is finished, control returns back to the  
configuration menu page. Each parameter is  
displayed in its group. If there are more  
parameters than will fit on the screen, a vertical  
scroll bar allows the user to scroll up and down  
to view all parameters. The parameter name is  
displayed on the left and the current setting is  
displayed in the text box on the right.  
Three levels of write access to boiler parameters  
are permitted. Each access level has defined  
rights when interfacing with configuration and  
status parameters in the Boiler.  
2.2.7 CONFIGURATION PASSWORD  
Any user can view the configuration parameters  
(default mode). No access-level password is  
End user:  
The lowest access rights (no  
required to view the parameters.  
A valid  
password login). The end user can, in most  
cases, only read or view boiler parameters. In  
some instances the end user can change boiler  
parameters, e.g., change the CH, central heat,  
setpoint.  
configuration password for the parameter’s level  
must be entered before the parameter can be  
changed. The password need only be entered  
once while the user remains on the configuration  
pages. Leaving the configuration pages ends  
the scope of the password entry. The user is  
notified that a new password is needed upon the  
first attempt to change a parameter (or until a  
password is entered successfully). The user can  
continue viewing the configuration parameters  
regardless of whether a password is entered  
successfully.  
Installer: The next highest level. The installer  
can read all boiler parameters and change most  
boiler parameters. This access level is used to  
customize the boiler for a particular installation.  
The default installer password is ‘bryan’.  
OEM: The highest access level. The OEM can  
read and change all R7910 parameters, as well  
as change sensor limits and burner control  
safety parameters.  
The boiler also maintains a password timeout  
that limits the scope of the password entry.  
Once a password is successfully entered the  
boiler starts an internal timer that expires after  
10 minutes of inactivity. After the timer expires,  
the user is required to re-enter a password  
before a parameter can be changed. The user  
is not required to enter a configuration password  
Different passwords exist in the boiler for each  
access level. The end user level requires no  
password, but the installer and OEM levels have  
unique passwords defined for them. The display  
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validates all password entry attempts with the  
boiler, but doesn’t conduct the validation itself.  
The boiler has sole responsibility to accept a  
password entry.  
There are two classes of parameters.  
Non-Safety: Non-safety parameters can be  
changed without placing the boiler in  
a
dangerous state. These parameters typically do  
not require a password to modify.  
The display gets information from each boiler  
about the access level settings for the status  
and configuration parameters.  
Safety: Safety parameters can be viewed the  
same way non-safety parameters can be  
viewed. If the user makes no attempt to change  
a safety parameter, the user isn’t required to  
enter safety verification mode.  
The installer and OEM passwords can be  
changed in the boiler after logging in with the  
current password. When the password is  
changed at the S7999B1026 it is saved in the  
R7910 and effective for all future logins.  
Safety parameters are grouped into blocks that  
include only safety parameters, not a mixture of  
safety data and non-safety data. All parameters  
within the safety group undergo a verification  
NOTE:  
Each boiler in a multi-boiler configuration has its  
own set of installer and OEM passwords. To  
avoid user confusion the passwords should be  
changed to the same setting in all the boilers,  
but there is no requirement to do so.  
(see  
paragraph  
2.2.9  
Safety  
Verification).  
A safety parameter group is  
identified on the display to indicate when the  
configuration parameters are safety-related.  
2.2.9 SAFETY VERIFICATION  
2.2.8 CHANGE PARAMETER SETTINGS  
CONFIGURE VERIFY  
Figure 17 Change Parameter Dialog  
Figure 18 Safety Parameter Verification  
Change parameter settings by selecting the  
parameter on the page. A dialog box displays  
for the parameter with controls allowing the user  
to change the value (Figure 17).  
For safety configuration parameters, safety  
verification is required to commit the changes.  
All safety configuration parameters in the group  
should have the same access level. If this  
condition isn’t so, the user is asked to enter  
another password when a higher access level is  
needed.  
After changing the setting to a new value, press  
the OK button. Pressing the Cancel button  
leaves the parameter unchanged.  
The changed setting is reflected on the screen  
and sent to the boiler when the OK button is  
pressed.  
Each safety parameter group is verified one at a  
time until all have been verified (Figure 18).  
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A verification step is required for each safety  
parameter block that is changed. The verification  
steps do not have to be completed immediately;  
the user can traverse between parameter  
groups before the verifications are done. If the  
user is logged in with the appropriate password  
After all safety parameter blocks have been  
confirmed, the user is asked to press and hold  
the reset button, (Figure 3 item 7), on the boiler  
to complete the safety configuration session  
(Figure 20).  
and has changed  
a
safety configuration  
parameter, a verify button is enabled that allows  
the user to conduct verification sessions.  
If the user terminates the safety configuration  
session after it has started, the boiler is left in an  
un-configured (boiler will not operate) state.  
The user can terminate the session by pressing  
the Menu button or by attempting to leave the  
Verification page with the Home or Back buttons  
(top-left and -right screen corners, respectively).  
The user is warned that leaving the session at  
this point leaves the boiler in an un-configured  
state and confirms whether the user still wants  
to do so.  
Figure 20 Safety Parameter Reset  
When the Reset button is pressed and held for 3  
seconds the confirmed safety parameters are  
committed in the boiler. The above reset dialog  
box automatically closes when this step is  
completed.  
The settings of all parameters in each safety  
block must be confirmed to commit them to the  
boiler.  
Selecting the begin button will start the  
verification process. The settings for all safety  
parameters in each changed block are  
presented and confirmed by the user (Figure  
19).  
NOTE:  
If the user doesn’t perform this step, the boiler  
remains in a locked state until the user resolves  
the unconfirmed safety parameters.  
Press the Yes button to confirm each safety  
parameter block. If the user selects the No  
button, the safety parameter block remains  
unconfirmed and the configuration menu page is  
2.2.10 FAULT/ALARM HANDLING  
Each boiler reports a fault code when a lockout  
condition occurs for one of the following  
annunciations:  
displayed.  
The boiler remains in an un-  
configured state in this case.  
• Burner control  
• Lockout  
• Lead/Lag control  
A less serious alarm condition may also occur  
that is treated as a warning instead of a fault.  
Each boiler can report active fault and warning  
codes for each annunciation.  
Any new fault code detected in a boiler is  
indicated as a lockout condition at the display.  
The notification method used depends on the  
page that is displayed. On the Home page the  
(Figure 21). On a boiler status page the History  
Figure 19 Safety Parameter User Confirmation  
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Figure 23 History Dialog  
button turns red (Figure 22). On all other pages  
and when the user is looking at a different boiler,  
a notification dialog box displays indicating  
which boiler just locked out.  
The lockout history can be displayed for each  
boiler. The state information about each lockout  
is displayed along with the date/time that the  
lockout occurred.  
Figure 21 Home Page Lockout  
Figure 24 Lockout History Page  
Use the following to clear a lockout and reset the  
boiler.  
INFO BAR LOCKOUTS ►  
CLEAR LOCKOUT  
2.2.11 OPERATION PAGE  
OPERATION  
Figure 22 Status Page Lockout  
Selecting the info bar will display the history  
dialog. If none of the buttons are selected the  
dialog box closes after 30 seconds.  
Figure 25 Operation Page  
The operation page displays the boiler running  
operation, including set point and firing rate  
values expressed in rpm. From this page the  
user can change set points, manually control the  
boiler’s firing rate, manually turn pumps on, view  
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annunciation information, and switch between  
heating loops (Central Heat and Domestic Hot  
Water), as shown in Figure 25. If a password is  
required to change any of the settings on this  
page, the user can press the Login button to  
enter the password.  
2.2.13 MODULATION CONFIGURATION  
CONFIGURE MODULATION  
CONFIGURATION  
2.2.12 ANNUNCIATION PAGE  
OPERATION►  
ANNUNCIATION  
Figure 27 Modulation Configuration  
The modulation configuration page is used to set  
the modulation range of the boiler.  
The  
recommended maximum and minimum rpm  
values can be found in  
Figure 26 Annunciation Page  
2.2.14 FIRING RATE CONTROL PAGE  
The annunciation page shows the status of the  
load control input (call for heat), pre-ignition  
interlock (proof of gas valve closure), and the  
running interlock strings. The components are  
listed in the order they are wired. This page can  
be called up at any time from the operation page  
(Figure 25). This page is very helpful for  
troubleshooting a lockout 67 (ILK off). All  
components for a given string are wired in  
series. The first component that indicates off will  
be the safety device to check.  
OPERATION FIRING RATE  
FIELD  
Figure 28 Firing Rate Control Page  
The firing rate control page enables the user to  
change how the firing rate is controlled. The first  
option is for automatic control based on the  
current set point. The second option enables  
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the user to manually control the firing rate while  
the boiler is firing. The third option can be  
selected to change the rpm of the blower while  
the boiler is off or in standby. The manual firing  
rate can be changed by pressing the clear  
button and entering the new value or by using  
the up and down arrows. To accept the new  
value press the ok button and the boiler will  
change the firing rate to the new value. An error  
message will display if the value entered  
exceeds the maximum firing rate or falls below  
the minimum firing rate.  
2.2.16 SYSTEM TIME  
1234 SETUP ADVANCED  
SETUP DATE & TIME  
Note:  
The firing rate control should come from the  
factory set to ‘Manual in Run’ with the manual  
firing rate value set to the light off rpm.  
2.2.15 ADVANCED SETUP  
Figure 30 System Time  
1234 SETUP ADVANCED SETUP  
Set the date and time by adjusting the  
appropriate boxes using the up and down arrow  
keys. Select the OK button when finished.  
Note:  
Currently the date and time will need to be reset  
when a loss of power to the display occurs.  
2.2.17 CALIBRATE TOUCH SCREEN  
1234 SETUP ADVANCED  
SETUP DIAGNOSTICS  
Figure 29 Advanced Setup  
The advanced setup page displays many more  
options that can be changed by the user.  
Figure 31 Display Diagnostics  
Occasionally the touch screen will need to be  
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calibrated. When the screen is touched in a  
spot and unexpected results occur this is a good  
indication that the display needs to be  
calibrated. To calibrate the touch screen select  
the ‘Calibrate’ button and follow the on screen  
directions. Try using a stylus of some kind if the  
problem persists. The eraser end of a pencil or  
the blunt end of a pen can be used as a good  
stylus.  
2.2.19 OUTDOOR RESET  
CONFIGURE  
OUTDOOR RESET  
(page) CENTRAL HEAT  
2.2.18 RESET / REBOOT DISPLAY  
1234 SETUP  
ADVANCED SETUP  
DISPLAY RESET  
Figure 33 Outdoor Reset  
When the outdoor  
temperature is equal  
or greater than this  
value the boiler  
setpoint will be set to  
the low water  
Max outdoor temp  
(x2)  
temperature.  
When the outdoor  
temperature is equal  
or less than this value  
the boiler setpoint will  
be set to the Central  
Heat Setpoint value  
(y2) see 2.2.21.  
This value represents  
the water temperature  
setpoint when the  
maximum outdoor  
temperature is  
Figure 32 Reset / Reboot Display  
Min outdoor temp  
(x1)  
The display can be reset or rebooted without  
powering down the boiler. Select the ‘OK’  
button and the display will reboot as shown in  
Low water temp  
(y2)  
reached.  
This value is used to  
override the low water  
temperature of the  
curve created with the  
above points without  
changing the slope.  
Undefined / Not Used  
Min water temp  
Max off point  
Select the ‘Show Line’ button to display a  
graphical representation for the inputted data  
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(Figure 34). The normal reset curve is shown in  
green and the time of day is red.  
CONFIGURE  
CH - CENTRAL HEAT  
CONFIGURATION  
(page) CENTRAL HEAT  
(Outdoor Reset) ENABLED  
Note:  
y1 is the maximum water setpoint value found in  
‘CH – Central heat Configuration’ on the  
‘Setpoint’ page.  
2.2.20 REMOTE SETPOINT (4 – 20  
MA)  
Figure 34 Outdoor Reset Curve  
CONFIGURE  
CONFIGURE  
SENSOR CONFIGURATION  
SENSOR CONFIGURATION  
(Sensor) S2 (J8-6) sensor  
(Connector type) 4-20mA  
(Sensor) S5 (J8-11) sensor  
(Connector type) 10K NTC single  
non-safety  
(Outdoor temperature source) S5  
(J8-11) sensor  
CONFIGURE  
CH - CENTRAL HEAT  
CONFIGURATION  
(page) SETPOINT  
(Setpoint Source) S2 (J8-6) 4-20mA  
(4 mA water temperature) MIN  
(20 mA water temperature) MAX  
Figure 35 Outdoor Reset Sensor Configuration  
Note:  
Update the sensor name to ‘Outdoor Sensor’ by  
selecting a different sensor then reselecting the  
S5 (J8-11) sensor.  
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Setpoint source  
Setpoint  
Local  
S2 (J8-6) 4-20mA  
Setpoint for normal  
Central Heat modulation:  
50 °F to 190 °F  
2.2.21 CENTRAL HEAT  
CONFIGURATION  
Time of day setpoint  
Off hysteresis  
Setpoint when Time Of  
Day switch is on. 50 °F to  
190 °F  
CONFIGURE  
CH - CENTRAL HEAT  
Differential above  
setpoint when boiler is  
turned off. 2 °F to 5 °F  
Differential from setpoint  
when boiler is turned on.  
2 °F to 30 °F  
CONFIGURATION  
On hysteresis  
4 mA water temperature  
50 °F to 190 °F  
20 mA water temperature 50 °F to 190 °F  
Figure 36 Central Heat Configuration (Central Heat Page)  
CH enable  
Disable or Enable Central  
Heating Loop  
Demand switch  
Sensor for Central Heat  
demand:  
Figure 38 Central Heat Configuration (Modulation Page)  
Sensor only  
Modulation sensor  
Outlet  
sensor, S5 (J8-11)  
Local  
applied for the P portion  
of the PID equation 0-400  
applied for the I portion of  
the PID equation 0-400  
Gain applied for the D  
portion of the PID  
equation 0-400  
sensor,  
Inlet  
Sensor & STAT terminal  
Sensor & Remote Stat  
LCI & Sensor  
Enabled  
Disabled  
Modulation Rate Source  
P-gain Gain  
Outdoor reset  
I-gain Gain  
D-gain  
CH has priority over Lead Yes, No, Cancel  
Lag  
Hysteresis step time Time between hysteresis  
(0=Disable  
stepping)  
hysteresis step changes: 0-600  
seconds  
2.2.22 SOUND PRESSURE LEVELS  
Sound pressure levels were measured at 4-1/2’  
above the floor and 3’ from the boiler at the  
front, rear and two sides. See Table 6 for  
decibel readings.  
Decibel Readings  
Figure 37 Central Heat Configuration (Setpoint Page)  
Tube  
Side  
Right  
Side  
Model  
Front  
Rear  
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Decibel Readings  
Tube  
Side  
59.5  
66.3  
82.7  
82.7  
Right  
Side  
58.5  
65.4  
82.8  
82.8  
Model  
Front  
Rear  
TF150  
TF200  
TF250  
TF300  
55.5  
62.1  
77.7  
77.7  
58.0  
65.1  
82.8  
82.8  
Table 6 Sound Pressure Readings  
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Annunciation  
restored from backup  
Safety group verification table was  
restored from factory defaults  
Safety group verification table was  
updated  
configuration  
was  
13  
14  
15  
2.2.23 MODBUS COMMUNICATION  
The hydronic control Global Modbus port is a 3-  
pin connector that interfaces to the following RS-  
485 signals:  
16  
17  
Invalid Parameter PCB was detected  
Invalid Range PCB was detected  
Table 7 Modbus Terminals  
Signal  
Terminal  
Alarm  
silence  
time  
exceeded  
18  
19  
Data +  
Data -  
Common  
a
b
c
maximum  
Invalid safety group verification table  
was detected  
20-26 RESERVED  
Modbus connections can be made at the display  
(Figure 3 item 5) or the hydronic control (Figure  
27  
28  
29  
30  
Safety processor was reset  
Application processor was reset  
Burner switch was turned OFF  
Burner switch was turned ON  
Program Module (PM) was inserted  
into socket  
For the modbus register map and other related  
information please download Honeywell’s  
R7910A product manual at:  
31  
32  
Program Module (PM) was removed  
from socket  
33  
34  
Alert PCB was configured  
Parameter PCB was configured  
35 Range PCB was configured  
Program Module (PM) incompatible  
with product was inserted into socket  
36  
37  
2.2.24 ALERT CODES  
Program  
Module  
application  
Table 8 Alert Codes  
parameter revision differs from  
application processor  
Code Description  
0
None (No alert)  
Program Module safety parameter  
revision differs from safety processor  
PCB incompatible with product  
contained in Program Module  
Parameter PCB in Program Module is  
too large for product  
Range PCB in Program Module was  
too large for product  
Alert PCB in Program Module was  
too large for product  
38  
39  
40  
41  
42  
43  
44  
Alert PCB was restored from factory  
defaults  
1
Safety configuration parameters were  
restored from factory defaults  
2
Configuration  
restored from factory defaults  
parameters  
were  
3
Invalid Factory Invisibility PCB was  
detected  
4
Invalid Factory Range PCB was  
detected  
5
IAS start check was forced on due to  
IAS enabled  
Low voltage was detected in safety  
processor  
Invalid range PCB record has been  
dropped  
6
EEPROM  
initialized  
lockout  
history  
was  
7
45  
46  
High line frequency occurred  
Low line frequency occurred  
Invalid subsystem reset request  
occurred  
Write large enumerated Modbus  
register value was not allowed  
Maximum cycle count was reached  
Maximum hours count was reached  
Illegal Modbus write was attempted  
Modbus write attempt was rejected  
(NOT ALLOWED)  
Switched application annunciation  
data blocks  
8
47  
48  
Switched application configuration  
data blocks  
9
Configuration was restored from  
factory defaults  
Backup configuration settings was  
restored from active configuration  
10  
11  
12  
49  
50  
51  
Annunciation  
configuration  
was  
52  
restored from factory defaults  
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53  
54  
Illegal Modbus read was attempted  
Safety processor brown-out reset  
occurred  
Application processor watchdog reset  
occurred  
Application processor brown-out reset  
occurred  
Safety processor watchdog reset  
occurred  
Alarm was reset by the user at the  
control  
Burner control firing rate was >  
absolute max rate  
Burner control firing rate was <  
absolute min rate  
Burner control firing rate was invalid,  
% vs. RPM  
Burner control was firing with no fan  
request  
Burner control rate (nonfiring) was >  
absolute max rate  
Burner control rate (nonfiring) was <  
absolute min rate  
Burner control rate (nonfiring) was  
absent  
Burner control rate (nonfiring) was  
invalid, % vs. RPM  
Fan off cycle rate was invalid, % vs.  
RPM  
Setpoint was overridden due to  
sensor fault  
Modulation was overridden due to  
sensor fault  
Slow start was end due to reference  
setpoint fault  
CH max modulation rate was invalid,  
% vs. RPM  
CH max modulation rate was >  
absolute max rate  
CH modulation range (max minus  
min) was too small (< 4% or 40 RPM)  
DHW max modulation rate was  
invalid, % vs. RPM  
DHW max modulation rate was >  
absolute max rate  
DHW modulation range (max minus  
min) was too small (< 4% or 40 RPM)  
Min modulation rate was < absolute  
min rate  
Min modulation rate was invalid, %  
vs. RPM  
Manual rate was invalid, % vs. RPM  
Slow start enabled, but forced rate  
was invalid  
97  
98  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
99  
100  
101  
102  
103  
104  
105  
106  
107  
108  
109  
Analog output hysteresis was invalid  
Analog modulation output type was  
invalid  
IAS open rate differential was invalid  
IAS open step rate was invalid  
110  
111  
112-  
114  
RESERVED  
Fan was limited to its minimum duty  
cycle  
115  
116  
117  
118  
119  
120  
121  
122  
123  
124  
125  
Manual rate was  
modulation rate  
>
CH max  
Manual rate was  
modulation rate  
>
DHW max  
70-74 RESERVED  
Absolute max fan speed was out of  
range  
Absolute min fan speed was out of  
range  
Fan gain down was invalid  
Fan gain up was invalid  
Fan minimum duty cycle was invalid  
Fan pulses per revolution was invalid  
Fan PWM frequency was invalid  
Manual rate was < min modulation  
rate  
75  
76  
Manual rate in Standby was  
absolute max rate  
>
77  
78  
79  
80  
81  
Modulation commanded rate was >  
CH max modulation rate  
Modulation commanded rate was >  
DHW max modulation rate  
Modulation commanded rate was <  
min modulation rate  
Modulation rate was limited due to  
outlet limit  
Modulation rate was limited due to  
Delta-T limit  
Modulation rate was limited due to  
stack limit  
Modulation rate was limited due to  
anti- condensation  
Fan Speed out of range in RUN  
Modulation rate was limited due to  
IAS was open  
82-89 RESERVED  
90  
Modulation output type was invalid  
Firing rate control parameter was  
invalid  
Forced rate was out of range vs.  
min/max modulation  
Forced rate was invalid, % vs. RPM  
Slow start ramp value was invalid  
Slow start degrees value was invalid  
Slow start was ended due to outlet  
sensor fault  
91  
92  
93  
94  
95  
126  
127  
128  
96  
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Slow start ramp setting of zero will  
result in no modulation rate change  
RESERVED  
CH demand source was invalid  
CH P-gain was invalid  
Lead Lag master was suspended due  
to fault  
Lead Lag slave was suspended due  
to fault  
Lead Lag header temperature was  
invalid  
Lead Lag was suspended due to no  
enabled Program Module installed  
Lead Lag slave session has timed out  
129  
204  
205  
206  
207  
130  
131  
132  
133  
134  
135  
136  
137  
138  
CH I-gain was invalid  
CH D-gain was invalid  
CH OFF hysteresis was invalid  
CH ON hysteresis was invalid  
CH sensor type was invalid  
CH hysteresis step time was invalid  
CH remote control parameter was  
invalid  
208  
209-  
221  
RESERVED  
CH frost protection temperature was  
invalid  
CH frost protection inlet temperature  
was invalid  
DHW frost protection temperature  
was invalid  
222  
223  
224  
139  
140  
CH ODR not allowed with remote  
control  
141-  
145  
RESERVED  
225-  
230  
231  
232  
233  
CH control was suspended due to  
fault  
CH header temperature was invalid  
CH outlet temperature was invalid  
CH steam pressure was invalid  
RESERVED  
146  
LL setpoint was invalid  
147  
148  
149  
150-  
156  
157  
158  
159  
160  
161  
162  
163  
164  
165  
LL time of day setpoint was invalid  
LL outdoor temperature was invalid  
LL ODR time of day setpoint was  
invalid  
LL ODR time of day setpoint  
exceeded normal setpoint  
LL max outdoor setpoint was invalid  
LL min outdoor setpoint was invalid  
LL min water setpoint was invalid  
LL outdoor temperature range was  
too small (minimum 12 C / 22 F)  
LL water temperature range was too  
small (minimum 12 C / 22 F)  
234  
235  
RESERVED  
DHW demand source was invalid  
DHW P-gain was invalid  
DHW I-gain was invalid  
236  
237  
238  
DHW D-gain was invalid  
DHW OFF hysteresis was invalid  
DHW ON hysteresis was invalid  
DHW hysteresis step time was invalid  
DHW sensor type was invalid  
Inlet sensor type was invalid for DHW  
Outlet sensor type was invalid for  
DHW  
239  
240  
241-  
245  
246  
247  
248  
RESERVED  
166  
CH setpoint was invalid  
167-  
170  
RESERVED  
CH time of day setpoint was invalid  
CH outdoor temperature was invalid  
CH ODR time of day setpoint was  
invalid  
CH ODR time of day setpoint  
exceeds normal setpoint  
CH max outdoor setpoint was invalid  
CH min outdoor setpoint was invalid  
CH min water setpoint was invalid  
CH outdoor temperature range was  
too small (minimum 12 C / 22 F)  
CH water temperature range was too  
small (minimum 12 C / 22 F)  
RESERVED  
DHW control was suspended due to  
fault  
DHW temperature was invalid  
DHW inlet temperature was invalid  
DHW outlet temperature was invalid  
171  
249  
250  
172  
173  
174  
175-  
182  
183  
184  
185  
186  
187  
188  
251  
252  
253  
RESERVED  
Lead Lag P-gain was invalid  
Lead Lag I-gain was invalid  
Lead Lag D-gain was invalid  
Lead Lag OFF hysteresis was invalid  
Lead Lag ON hysteresis was invalid  
Lead Lag slave enable was invalid  
Lead Lag hysteresis step time was  
invalid  
254  
255  
256-  
260  
261  
262  
189  
DHW setpoint was invalid  
DHW time of day setpoint was invalid  
190-  
203  
RESERVED  
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263-  
271  
Abnormal Recycle: Interrupted air  
flow switch was off during Measured  
Purge Time  
Abnormal Recycle: Interrupted air  
flow switch was off during Drive to  
Lightoff Rate  
Abnormal Recycle: Interrupted air  
flow switch was off during Pre-Ignition  
test  
Abnormal Recycle: Interrupted air  
flow switch was off during Pre-Ignition  
time  
Abnormal Recycle: Interrupted air  
flow switch was off during Main  
Flame Establishing Period  
Abnormal Recycle: Ignition failed due  
to interrupted air flow switch was off  
Abnormal Recycle: ILK off during  
Drive to Purge Rate  
Abnormal Recycle: ILK off during  
Measured Purge Time  
Abnormal Recycle: ILK off during  
Drive to Lightoff Rate  
Abnormal Recycle: ILK off during Pre-  
Ignition test  
Abnormal Recycle: ILK off during Pre-  
Ignition time  
Abnormal Recycle: ILK off during  
Main Flame Establishing Period  
Abnormal Recycle: ILK off during  
Ignition period  
Run was terminated due to ILK was  
off  
Run was terminated due to  
interrupted air flow switch was off  
Stuck reset switch  
Run was terminated due to fan failure  
Abnormal Recycle: Fan failed during  
Drive to Purge Rate  
Abnormal Recycle: Fan failed during  
Measured Purge Time  
Abnormal Recycle: Fan failed during  
Drive to Lightoff Rate  
RESERVED  
297  
298  
299  
300  
301  
Abnormal Recycle: Pressure sensor  
fault  
Abnormal Recycle: Safety relay drive  
test failed  
Abnormal Recycle: Demand off  
during Pilot Flame Establishing  
Period  
Abnormal Recycle: LCI off during  
Drive to Purge Rate  
Abnormal Recycle: LCI off during  
Measured Purge Time  
Abnormal Recycle: LCI off during  
Drive to Lightoff Rate  
Abnormal Recycle: LCI off during  
Pre-Ignition test  
Abnormal Recycle: LCI off during  
Pre-Ignition time  
Abnormal Recycle: LCI off during  
Main Flame Establishing Period  
Abnormal Recycle: LCI off during  
Ignition period  
Abnormal Recycle: Demand off  
during Drive to Purge Rate  
Abnormal Recycle: Demand off  
during Measured Purge Time  
Abnormal Recycle: Demand off  
during Drive to Lightoff Rate  
Abnormal Recycle: Demand off  
during Pre-Ignition test  
Abnormal Recycle: Demand off  
during Pre-Ignition time  
Abnormal Recycle: Flame was on  
during Safe Start check  
Abnormal Recycle: Flame was on  
during Drive to Purge Rate  
Abnormal Recycle: Flame was on  
during Measured Purge Time  
Abnormal Recycle: Flame was on  
during Drive to Lightoff Rate  
Abnormal Recycle: Flame was not on  
at end of Ignition period  
272  
273  
274  
275  
276  
277  
278  
279  
280  
281  
282  
283  
284  
285  
286  
287  
288  
289  
290  
291  
302  
303  
304  
305  
306  
307  
308  
309  
310  
311  
312  
313  
314  
315  
316  
317  
318  
319  
320  
321  
322  
Abnormal Recycle: Fan failed during  
Pre-Ignition test  
Abnormal Recycle: Fan failed during  
Pre-Ignition time  
Abnormal Recycle: Fan failed during  
Ignition period  
Abnormal Recycle: Fan failed during  
Main Flame Establishing Period  
Abnormal Recycle: Main Valve off  
after 10 seconds of RUN  
Abnormal Recycle: Flame was lost  
during Main Flame Establishing  
Period  
Abnormal Recycle: Flame was lost  
early in Run  
Abnormal Recycle: Flame was lost  
during Run  
Abnormal Recycle: Leakage test  
failed  
292  
293  
294  
295  
Abnormal Recycle: Interrupted air  
flow switch was off during Drive to  
Purge Rate  
296  
Abnormal Recycle: Pilot Valve off  
after 10 seconds of RUN  
32  
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Abnormal Recycle: Safety Relay off  
after 10 seconds of RUN  
Abnormal Recycle: Hardware flame  
bias  
Abnormal Recycle: Hardware static  
flame  
Abnormal Recycle: Hardware flame  
current invalid  
Abnormal Recycle: Hardware flame  
rod short  
Abnormal Recycle: Hardware invalid  
power  
Abnormal Recycle: Hardware invalid  
AC line  
Abnormal Recycle: Hardware SLO  
flame ripple  
Abnormal Recycle: Hardware SLO  
flame sample  
Abnormal Recycle: Hardware SLO  
flame bias range  
Abnormal Recycle: Hardware SLO  
flame bias heat  
Abnormal Recycle: Hardware SLO  
spark stuck  
Abnormal Recycle: Hardware SLO  
spark changed  
Abnormal Recycle: Hardware SLO  
static flame  
Abnormal Recycle: Hardware SLO  
rod shorted  
Abnormal Recycle: Hardware SLO  
AD linearity  
Abnormal Recycle: Hardware SLO  
bias not set  
Abnormal Recycle: Hardware HFS  
LFS shorted  
Abnormal Recycle: Invalid zero  
crossing  
Abnormal Recycle: fault stack sensor  
Abnormal Recycle: stack limit  
Abnormal Recycle: delta T limit  
Abnormal Recycle: fault outlet sensor  
Abnormal Recycle: outlet high limit  
Abnormal Recycle: fault DHW sensor  
Abnormal Recycle: DHW high limit  
Abnormal Recycle: fault inlet sensor  
323  
324  
325  
326  
327  
328  
329  
330  
331  
332  
333  
334  
335  
336  
337  
338  
339  
340  
341  
342  
343  
344  
345  
346  
347  
348  
349  
350  
351  
352  
353  
354  
355  
356  
357  
358  
359  
Abnormal  
Recycle:  
Check  
360  
361  
362  
363  
364  
365  
366  
367  
368  
369  
370  
371  
372  
373  
Parameters Failed  
Internal error: No factory parameters  
were detected in control  
Internal error: PID iteration frequency  
was invalid  
Internal error: Demand-Rate interval  
time was invalid  
Internal error: Factory calibration  
parameter for modulation was invalid  
Internal error: CH PID P-scaler was  
invalid  
Internal error: CH PID I-scaler was  
invalid  
Internal error: CH PID D-scaler was  
invalid  
Internal error: DHW PID P-scaler was  
invalid  
Internal error: DHW PID I-scaler was  
invalid  
Internal error: DHW PID D-scaler was  
invalid  
Abnormal Recycle: Hardware SLO  
bias shorted  
Abnormal Recycle: Hardware SLO  
electronics  
Internal error: Lead Lag master PID  
P-scaler was invalid  
Internal error: Lead Lag master PID I-  
scaler was invalid  
Internal error: Lead Lag master PID  
D-scaler was invalid  
Abnormal  
Recycle:  
Hardware  
processor clock  
Abnormal Recycle: Hardware AC  
phase  
Abnormal Recycle: Hardware A2D  
mismatch  
Abnormal Recycle: Hardware VSNSR  
A2D  
Abnormal Recycle: Hardware 28V  
A2D  
Abnormal Recycle: Hardware HFS  
IAS shorted  
Abnormal Recycle: Hardware PII  
INTLK shorted  
Abnormal Recycle: Hardware HFS  
LCI shorted  
374-  
459  
460  
461  
462  
463  
464-  
466  
RESERVED  
LCI demand lost in run  
Demand lost in run  
STAT demand lost in run  
Demand lost in run due to no flame  
RESERVED  
Internal error: EEPROM write was  
attempted before EEPROM was  
initialized  
Internal error: EEPROM cycle count  
address was invalid  
467  
468  
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Internal error: EEPROM days count  
address was invalid  
Internal error: EEPROM hours count  
address was invalid  
Internal error: Safety timer was  
corrupt  
Internal error: Safety timer was  
expired  
Internal error: Safety timings  
Internal error: Safety shutdown  
469  
470  
471  
472  
473  
474  
475  
476  
477  
478  
479  
480  
497  
498  
Internal  
error:  
Lockout  
record  
499  
500  
EEPROM index was invalid  
Internal error: Request to write PM  
status was invalid  
Internal error: PM parameter address  
was invalid  
Internal error: PM safety parameter  
address was invalid  
Internal error: Invalid record in lockout  
history was removed  
Internal error: EEPROM write buffer  
was full  
Internal error: Data too large was not  
written to EEPROM  
Internal error: Safety key bit 0 was  
incorrect  
Internal error: Safety key bit 1 was  
incorrect  
Internal error: Safety key bit 2 was  
incorrect  
481 Internal error: Safety key bit 3  
was incorrect  
482 Internal error: Safety key bit 4  
was incorrect  
Internal error: Safety key bit 5 was  
incorrect  
Internal error: Safety key bit 6 was  
incorrect  
Internal error: Safety key bit 7 was  
incorrect  
Internal error: Safety key bit 8 was  
incorrect  
Internal error: Safety key bit 9 was  
incorrect  
Internal error: Safety key bit 10 was  
incorrect  
Internal error: Safety key bit 11 was  
incorrect  
Internal error: Safety key bit 12 was  
incorrect  
483  
484  
485  
486  
487  
488  
489  
490  
491  
492  
Internal error: Safety key bit 13 was  
incorrect  
Internal error: Safety key bit 14 was  
incorrect  
Internal error: Safety key bit 15 was  
incorrect  
Internal error: Safety relay timeout  
493  
494  
495  
Internal  
error:  
Safety  
relay  
commanded off  
Internal error: Unknown safety error  
occurred  
496  
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The regulating gas valve is a 1:1 differential  
pressure air / gas ratio controller. This means  
that the control adjusts the same pressure  
difference on the gas side as it senses on the  
airside. The airside pressure is the difference  
between the pressure in the burner housing and  
the pressure downstream of the furnace section.  
The gas side pressure is the difference between  
the pressure upstream and downstream of the  
gas limiting orifice valve. For the locations of the  
+/- gas and air connections see (Figure 39). Air  
to gas ratios are adjusted with the gas limiting  
2.3 BOILER COMMISSIONING  
NOTE:  
All of the installation instructions found in section  
1 must be completed before commissioning the  
boiler.  
WARNING:  
The following procedures must be  
followed carefully before putting the  
boiler in operation. Failure to do so  
will present severe hazards to  
equipment, operating personnel and  
building occupants.  
During the burner pre-purge period, when the  
gas valve is closed, only the air pressure  
difference acts on the regulator causing the air  
diaphragm to move to the left and closes the  
regulating hydraulic bypass valve. When the  
actuator is powered, the gas valve begins to  
open. The downstream gas pressure difference  
immediately begins to increase until the gas  
pressure difference is in balance with the air  
pressure difference.  
2.3.1 MODULATION  
2.3.2 TEST SETUP  
Connect a u-tube manometer to the gas  
manifold pressure tapping (Figure 7 item 12).  
Connect a 0 – 5 psi gauge in the port provided in  
the low gas pressure switch connection (Figure  
Connect a u-tube manometer to the pilot gas  
pressure port provided (Figure 7 item 14).  
A suitable combustion analyzer shall be used for  
measuring O2, CO, and Nox levels.  
The  
analyzer probe should be inserted in the stack  
above the boiler outlet and before any draft  
controls. Calibration is required for the Nox and  
CO cells at the time of commissioning.  
Figure 39 Air / Gas Ratio Tappings  
2.3.3 PRE CHECKS AND SETUP  
Modulation on the Triple-flex boiler is  
accomplished with air / gas ratio control. The  
system consists of two major components, a  
blower (Figure 10 item 6) and a regulating gas  
valve (Figure 7 item 3). The blower is variable  
speed and provides combustion air to the  
burner. The blower rpm is controlled by a PWM  
(pulse width modulation) signal. The PWM  
signal increases or decreases as the load  
increases or decreases in the hydronic system.  
Close the manual gas cock (Figure 7 item 4).  
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seconds the purge timer will start and count to  
30. After 30 seconds the fan speed is reduced  
to the light off rate. When the fan speed is with  
in +/- 3% of the firing rate for 3 seconds the  
ignition transformer and the pilot valve are  
energized. The pilot will light and can be  
observed from the observation port (Figure 5  
item 4). After a duration of 5 seconds the  
ignition transformer will de-energize. The pilot  
valve will stay energized for another 5 seconds  
before the main gas valves are energized.  
During this 10 second period the pilot should be  
adjusted according to paragraph 2.3.5.  
WARNING:  
Do not open the manual main gas cock  
(Figure 7 item 4) before all pre checks,  
setups, and dry runs have been  
successfully completed.  
With a voltmeter check for the proper incoming  
main voltage and the proper control voltage from  
the control circuit transformer. Refer to the  
electrical wiring diagram and boiler-rating label  
for proper voltages.  
The main gas valves will energize for 10  
seconds. After this 10 second duration the pilot  
valve is de-energized. The control will lockout  
with a code of 106, Flame lost in Main Flame  
Establishing Period.  
Make sure the boiler is full of water and proper  
flow has been established.  
Power up the boiler see (paragraph 2.2.1).  
Navigate to the ‘Operation Screen’ (paragraph  
2.2.11). Select the burner switch to toggle the  
burner to the off state.  
WARNING:  
During the first 10 seconds of this  
process the automatic gas valves  
should not have opened or been  
energized. If any of the automatic gas  
valves are energized or open at this  
point correct the problem immediately.  
Navigate to the ‘Firing Rate Control Page’  
(paragraph 2.2.14). Select the ‘Manual in Run”  
option and enter the light off RPM from (Table 9  
Firing Rate box. This will prevent the burner  
from ramping up to high fire after the flame  
stabilization period.  
Navigate to the ‘Annunciation Page” (paragraph  
2.2.12). All load control inputs and interlocks  
should be in the on state with the exception of  
the air flow switch. The air flow switch will close  
when the burner is commanded to start. Correct  
any problem indicated. Refer to trouble shooting  
(paragraph 0) for further help.  
2.3.5 PILOT ADJUSTMENT  
Adjust the pilot gas pressure between 3.5 iwc  
and 4 iwc. The pilot flame signal can be  
observed from the status page (paragraph  
2.2.5). The minimum flame signal is .8 volts.  
The flame signal can vary between 4 volts and  
15 volts. A flame signal closer to 15 volts is  
preferred. Observe the pilot flame through the  
flame observation port (Figure 5 item 4). The  
pilot should appear stable. A stable pilot will not  
flicker on and off. Recycle the boiler as many  
times as needed to establish a good pilot. If the  
pilot fails to light refer to trouble shooting  
(paragraph 1.1.1) for further help.  
Navigate to the ‘Operation Screen’ (paragraph  
2.2.11). The boiler is now prepared to be placed  
in the on state by toggling the burner switch to  
on.  
2.3.4 DRY RUN  
Navigate to the ‘Operation Screen’ (paragraph  
2.2.11). Toggle the burner switch to on.  
Navigate to the ‘Status Page’ (paragraph 2.2.5).  
If there is demand for hot water the burner state  
will display driving to purge. When the fan  
speed is within +/- 3% of the firing rate for 3  
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for NOx, O2, and CO should be made at the  
maximum firing rate. No further adjustments are  
required of the gas limiting orifice valve. Return  
to the minimum low fire rate (paragraph 2.2.13)  
in increments of 500 rpm. For each increment  
verify combustion readings. Refer to trouble  
shooting (paragraph 0) for further help.  
WARNING:  
During pilot adjustment leave the  
manual main gas cock (Figure 7 item  
4) closed.  
NOTE:  
NOTE:  
Use rpm values that fall between the rpm values  
used going to high fire. This will give more  
points to verify on the modulation curve.  
Pilot gas pressures in excess of the  
recommended will lead to the formation of  
carbon hairs that will ground out the pilot igniter  
causing a safety shutdown.  
2.3.8 ADJUSTING BOILER MINIMUM  
INPUT  
2.3.6 INITIAL LIGHT OFF  
NOTE:  
The boiler maximum input must be adjusted  
before final adjustments can be made for  
minimum input.  
Open the manual main gas cock (Figure 7 item  
4). Clear the lockout fault (paragraph 2.2.10)  
and allow the burner to cycle and attempt to light  
off. If the main flame fails to light, the low fire  
displacement of the pressure regulating actuator  
(Figure 7 item 2) may need to be increased.  
Decrease the boiler firing rate to the minimum  
modulation rate (paragraph 2.2.13). Adjust the  
O2 level to obtain Nox levels desired by  
adjusting the low fire displacement on the gas  
WARNING:  
pressure  
regulating  
actuator  
to  
obtain  
appropriate NOx, O2, and CO levels. Allow  
sufficient time for combustion to stabilize after  
each ¼ to ½ turn of the low fire displacement  
Do not adjust the low fire displacement  
more than 1/4 to 1/2 turn for each main  
flame-establishing period.  
The boiler will light off at approximately 1.5 times  
the minimum firing rate rpm. The boiler will hold  
in this position for no less than 5 minutes to  
establish a stable flame before releasing the  
boiler to full modulation. Observe combustion  
readings and make small adjustments to the low  
fire displacement of the pressure regulating  
actuator (Figure 7 item 2) when the O2 is not  
within 6% to 10%. Allow sufficient time for  
combustion to stabilize after each ¼ to ½ turn of  
the low fire displacement (Figure 7 item 2).  
WARNING:  
O2 levels below 6% will overheat the  
metal fiber burner and cause the fuel /  
air mixture to ignite inside the burner.  
An internal temperature fuse is  
provided to open when the internal  
burner temperature reaches 425 oF.  
Boiler Model  
TF300 TF250 TF200 TF150  
2.3.7 ADJUSTING BOILER MAXIMUM  
INPUT  
Pilot Gas  
Pressure  
(IWC)  
Light Off  
RPM  
High Fire  
3.5 - 4 3.5 - 4 3.5 - 4 3.5 - 4  
1800 1800 1200 1200  
After the flame stabilization period increase the  
firing rate in 500 rpm increments until the  
maximum modulation rate (paragraph 2.2.13) is  
reached. For each 500 rpm increment observe  
combustion readings and make adjustments to  
the gas limiting orifice (Figure 7 item 26) if the  
O2 is not within 6% to 10%. Final adjustments  
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cubic feet per hour). Consult the National Fuel  
Gas Code (ANSI Z223.1, NFPA 54) or the local  
gas utility for further information. Refer to Table  
10 for correction factors for the gas pressure at  
the meter. Refer to Table 11 for the gas  
temperature correction factors.  
Gas  
Manifold  
Pressure  
(IWC)  
4.4  
3.6  
4.0  
2.0  
6000-  
7000  
5100-  
5500  
3550-  
4200  
2700-  
2850  
Max RPM  
Low Fire  
Gas  
Manifold  
Pressure  
(IWC)  
Gas Pressure at Meter Corr. Factor  
14" w.c.  
21" w.c.  
1 psig  
1.034  
1.051  
1.061  
1.136  
.3  
.3  
.2  
.2  
2 psig  
1200-  
1600  
1200-  
1600  
800-  
950  
800-  
950  
Min RPM  
5 psig  
1.340  
Table 10 Gas Pressure Correction  
Table 9 Approximate Boiler Settings  
Gas Temp. at Meter  
Corr. Factor  
1.04  
1.02  
1.0  
.981  
2.3.9 GAS METER READINGS  
40 °F  
50 °F  
60 °F  
70 °F  
80 °F  
90 °F  
Burner input rate can be checked by taking  
readings from the gas meter. Please note  
checking the rate with a meter is the only way to  
be sure of input. Manifold readings are only an  
approximate value and may vary from unit to  
unit.  
.963  
.945  
Table 11 Gas Temperature Correction  
In order to obtain accurate data, there must be  
no other appliances using gas from the same  
meter while the burner input rate is being  
checked.  
To correct for pressure and temperature use the  
following formula.  
Qc = Qtptt  
tp = pressure correction table 2.2A  
tt = temperature correction table 2.2B  
A stopwatch or a watch with a second hand is  
required to obtain a meter reading. Clock the  
amount of time it takes for the smallest dial to  
complete one revolution in seconds. Use the  
following formula to obtain the cubic feet per  
hour throughput of the unit.  
3600Vc  
CFH =  
gc  
CFH = ft3hr1 of gas  
Vc = ft clocked  
gc = time in seconds  
To obtain the Btu per hour throughput of the unit  
use the following formula.  
Q = CFH  
(
hv  
)
hv = heating value of fuelin Btu ft-3  
If the meter is not calibrated for gas temperature  
and pressure, correction factors must be applied  
to determine correct rate in SCFH (standard  
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2.4 TROUBLESHOOTING  
To support the recommended Troubleshooting, the R7910 has an Alert File. Review the Alert history for  
possible trends that may have been occurring prior to the actual lockout.  
Note Column:  
H = Hold message  
L = Lockout message  
H or L = either Hold or Lockout depending on Parameter Configuration  
Table 12 R7910A Lockout and Hold Codes  
Code Description  
Recommended Troubleshooting of Lockout Codes  
1.New Device, complete device configuration and safety  
verification.  
Code  
L
1
Unconfigured  
safety data  
2. If fault repeats, replace module.  
2
Waiting for safety 1. Device in Configuration mode and safety parameters need  
L
data verification  
verification and a device needs reset to complete verification.  
2. Configuration ended without verification, re enter  
configuration, verify safety  
parameters and reset device to complete verification.  
3. If fault repeats, replace module  
3
4
Internal  
Hardware fault  
Internal  
fault: Internal fault  
H
H
1. Reset module  
2. If fault repeats, replace module.  
fault:  
Safety Relay key  
feedback error  
5
Internal  
Unstable  
(DCDC) output  
Internal  
Invalid  
clock  
Internal  
Safety relay drive  
error  
Internal fault: Zero  
crossing  
detected  
Internal  
Flame bias out of  
range  
Internal  
Invalid  
control state  
Internal  
Invalid  
fault:  
power  
H
H
H
H
H
L
6
fault:  
processor  
7
fault:  
8
not  
9
fault:  
10  
11  
12  
fault:  
Burner  
fault:  
Burner  
L
control state flag  
Internal  
fault:  
H
Safety relay drive  
cap short  
13  
14  
Internal fault: PII  
shorted to ILK  
Internal fault: HFS  
shorted to LCI  
H OR L  
H OR L  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
Code  
15  
16  
17  
18  
Internal  
Safety relay test  
failed  
feedback ON  
fault:  
L
L
L
L
due  
to  
Internal  
fault:  
Safety relay test  
failed due to safety  
relay OFF  
Internal  
fault:  
Safety relay test  
failed due to safety  
relay not OFF  
Internal  
Safety relay test  
failed due to  
feedback not ON  
Internal fault:  
Safety RAM write  
fault:  
19  
20  
L
Internal  
fault:  
H
Flame ripple and  
overflow  
21  
22  
23  
24  
25  
Internal  
Flame number of  
sample mismatch  
Internal  
Flame bias out of  
range  
Internal fault: Bias  
changed  
heating cycle starts  
Internal fault: Spark  
voltage stuck low or  
high  
fault:  
H
H
H
H
H
fault:  
since  
Internal fault: Spark  
voltage  
changed  
too much during  
flame sensing time  
Internal fault: Static  
flame ripple  
26  
27  
H
H
Internal  
fault:  
Flame rod shorted  
to ground detected  
Internal fault: A/D  
linearity test fails  
28  
29  
H
H
Internal  
fault:  
Flame bias cannot  
be set in range  
30  
31  
Internal  
fault:  
H
H
Flame bias shorted  
to adjacent pin  
Internal fault: SLO  
electronics  
unknown error  
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Code Description  
32-46 Internal  
Recommended Troubleshooting of Lockout Codes  
Code  
L
fault:  
Key 0  
Safety  
through 14  
47  
48  
49  
Flame  
Rod  
to  
H
H
H
ground leakage  
Static flame (not  
flickering)  
24VAC voltage low/ 1. Check the Module and display connections.  
high  
2. Check the Module power supply and make sure that both  
frequency, voltage and VA meet the specifications.  
Internal sub-system fault.  
1. Review alert messages for possible trends.  
2. Correct possible problems.  
50  
51  
52  
Modulation fault  
Pump fault  
Motor tachometer  
fault  
H
H
H
53  
AC inputs phase 1. Check the Module and display connections.  
reversed 2. Check the Module power supply and make sure that both  
L
frequency and voltagemeet the specifications.  
3. On 24Vac applications, assure that J4 terminal 10 and J8  
terminal 2 are connected together.  
54-57 RESERVED  
58  
59  
60  
Internal fault: HFS Internal Fault.  
L
L
L
shorted to IAS  
Internal Fault: Mux  
pin shorted  
1. Reset Module.  
2. If fault repeats, replace module  
Internal Fault: HFS  
shorted to LFS  
Anti short cycle  
Fan speed not  
proved  
61  
62  
Will not be a lockout fault. Hold Only.  
H
H
63  
LCI OFF  
1. Check wiring and correct any faults.  
2. Check Interlocks connected to the LCI to assure proper  
function.  
H
3. Reset and sequence the module; monitor the LCI status.  
4. If code persists, replace the module  
1. Check wiring and correct any faults.  
2. Check Preignition Interlock switches to assure proper  
functioning.  
64  
PII OFF  
L
3. Check the valve operation.  
4. Reset and sequence the module; monitor the PII status.  
5. If code persists, replace the module.  
65  
66  
Interrupted Airflow 1. Check wiring and correct any possible shorts.  
H or L  
H or L  
Switch OFF  
Interrupted Airflow  
Switch ON  
2. Check airflow switches to assure proper functioning.  
3. Check the fan/blower operation.  
4. Reset and sequence the module; monitor the airflow status.  
5. If code persists, replace the module.  
67  
ILK OFF  
1. Check wiring and correct any possible shorts.  
2. Check Interlock (ILK) switches to assure proper function.  
3. Verify voltage through the interlock string to the interlock input  
with a voltmeter.  
L
4. If steps 1-3 are correct and the fault persists, replace the  
module.  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
Code  
68  
ILK ON  
This lockout occurs when the interlock string is closed before the  
blower starts. The airflow switch is the only device in the  
interlock string that will open when in standby. Probable causes  
are.  
L
1. Air pressure in the boiler room has become negative.  
2. Excessive downdraft in the stack.  
3. Blower is spinning before being commanded by the  
hydronic control. Make sure blower is not running in  
standby.  
4. Airflow switch is stuck closed.  
69  
70  
Pilot test hold  
1. Verify Run/Test is changed to Run.  
2. Reset Module.  
3. If fault repeats, replace module.  
H
Wait for leakage 1. Internal Fault. Reset Module.  
test completion 2. If fault repeats, replace module.  
71-77 RESERVED  
H
78  
Demand Lost in 1. Check wiring and correct any possible errors.  
H
Run  
2. If previous steps are correct and fault persists, replace the  
module.  
79  
Outlet high limit  
1. Check wiring and correct any possible errors.  
2. Replace the Outlet high limit.  
H or L  
3. If previous steps are correct and fault persists, replace the  
module.  
80  
81  
DHW high limit  
Delta T limit  
1. Check wiring and correct any possible errors.  
2. Replace the DHW high limit.  
3. If previous steps are correct and fault persists, replace the  
module.  
H or L  
1. Check Inlet and Outlet sensors and pump circuits for proper H or L  
operation.  
2. Recheck the Delta T Limit to confirm proper setting.  
3. If previous steps are correct and fault persists, replace the  
module.  
82  
Stack limit  
1. Check wiring and correct any possible errors.  
2. Replace the Stack high limit.  
H or L  
3. If previous steps are correct and fault persists, replace the  
module.  
83-90 RESERVED  
91  
92  
93  
94  
95  
Inlet sensor fault  
Outlet sensor fault  
DHW sensor fault  
1. Check wiring and correct any possible errors.  
2. Replace the Inlet sensor.  
3. If previous steps are correct and fault persists, replace the  
module.  
1. Check wiring and correct any possible errors.  
2. Replace the Outlet sensor.  
3. If previous steps are correct and fault persists, replace the  
module.  
1. Check wiring and correct any possible errors.  
2. Replace the DHW sensor.  
3. If previous steps are correct and fault persists, replace the  
module.  
H
H
H
H
H
Header sensor fault 1. Check wiring and correct any possible errors.  
2. Replace the header sensor.  
3. If previous steps are correct and fault persists, replace the  
module.  
1. Check wiring and correct any possible errors.  
Stack sensor fault  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
2. Replace the stack sensor.  
Code  
3. If previous steps are correct and fault persists, replace the  
module  
96  
Outdoor  
fault  
sensor 1. Check wiring and correct any possible errors.  
2. Replace the outdoor sensor.  
H
3. If previous steps are correct and fault persists, replace the  
module.  
97  
98  
Internal Fault: A2D Internal Fault.  
L
L
mismatch.  
1. Reset Module.  
2. If fault repeats, replace module.  
Internal  
Fault:  
Exceeded VSNSR  
voltage tolerance  
99  
Internal  
Exceeded  
Fault:  
28V  
L
voltage tolerance  
100  
Pressure  
Fault  
Sensor 1. Verify the Pressure Sensor is a 4-20ma source.  
2. Check wiring and correct any possible errors.  
3. Test Pressure Sensor for correct operation.  
4. Replace the Pressure sensor.  
H
5. If previous steps are correct and fault persists, replace the  
module.  
101-  
104  
105  
RESERVED  
Flame detected out 1. Check that flame is not present in the combustion chamber. H or L  
of sequence  
Correct any errors.  
2. Make sure that the flame detector is wired to the correct  
terminal.  
3. Make sure the F & G wires are protected from stray noise  
pickup.  
4. Reset and sequence the module, if code reappears, replace  
the flame detector.  
5. Reset and sequence the module, if code reappears, replace  
the module.  
106  
107  
Flame lost in MFEP 1. Check pilot valve (Main Valve for DSI) wiring and operation -  
L
L
correct any errors.  
Flame lost early in  
run  
2. Check the fuel supply.  
3. Check fuel pressure and repeat turndown tests.  
4. Check ignition transformer electrode, flame detector, flame  
detector setting or flame rod position.  
5. If steps 1 through 4 are correct and the fault persists, replace  
the module.  
108  
109  
Flame lost in run  
Ignition failed  
L
L
110  
111  
Ignition  
occurred  
Flame  
failure Hold time of recycle and hold option. Will not be a lockout fault.  
Hold Only. Internal hardware test. Not a lockout.  
current  
H
H
lower than WEAK  
threshold  
112  
113  
Pilot test flame Interrupted Pilot or DSI application and flame lost when system  
L
L
timeout  
in “test” mode.  
1. Reset the module to restart.  
Flame  
timeout  
circuit Flame sensed during Initiate or off cycle, hold 240 seconds, if  
present after 240 seconds, lockout.  
114-  
121  
RESERVED  
43  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
Code  
122  
Lightoff  
rate 1. Check wiring and correct any potential wiring errors.  
2. Check VFDs ability to change speeds.  
L
proving failed  
Purge rate proving  
failed  
3. Change the VFD  
4. If the fault persists, replace the module.  
123  
L
124  
125  
126  
127  
128  
129  
130  
131  
High fire switch 1. Check wiring and correct any potential wiring errors.  
H
OFF  
2. Check High Fire Switch to assure proper function (not welded  
or jumpered).  
High fire switch  
stuck ON  
Low fire switch  
OFF  
Low fire switch  
stuck ON  
H
3. Manually drive the motor to the High Fire position and adjust  
the HF switch while in this position and verify voltage through  
the switch to the HFS input with a voltmeter.  
4. If steps 1-3 are correct and the fault persists, replace the  
module.  
H
H or L  
H or L  
H or L  
H or L  
H
Fan speed failed 1. Check wiring and correct any potential wiring errors.  
during prepurge  
Fan speed failed  
during preignition  
Fan speed failed  
during ignition  
2. Check VFDs ability to change speeds.  
3. Change the VFD  
4. If the fault persists, replace the module.  
Fan  
detected  
standby  
movement  
during  
132  
Fan speed failed  
during run  
RESERVED  
H
H
133-  
135  
136  
Interrupted Airflow 1. Check wiring and correct any possible wiring errors.  
Switch failed to 2. Check Interrupted Airflow switch(es) to assure proper  
close  
function.  
3. Verify voltage through the airflow switch to the IAS input with  
a voltmeter.  
4. If steps 1-3 are correct and the fault persists, replace the  
module.  
137  
ILK failed to close  
1. Check wiring and correct any possible shorts.  
2. Check Interlock (ILK) switches to assure proper function.  
3. Verify voltage through the interlock string to the interlock input  
with a voltmeter.  
H
4. If steps 1-3 are correct and the fault persists, replace the  
module.  
138-  
148  
RESERVED  
FAULT  
149  
CODES  
THROUGH  
165 ARE OEM  
SPECIFIC FAULT  
CODES.  
149  
150  
Flame detected  
OEM Specific  
H or L  
H
1. Holds if flame detected during Safe Start check up to Flame  
Establishing period.  
Flame not detected OEM Specific  
1. Sequence returns to standby and restarts sequence at the  
beginning of Purge after the HF switch opens. if flame detected  
during Safe Start check up to Flame Establishing period.  
151  
High fire switch ON OEM Specific  
H or L  
44  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
1. Check wiring and correct any potential wiring errors.  
Code  
2. Check High Fire Switch to assure proper function (not welded  
or jumpered).  
3.Manually drive the motor to the High Fire position and adjust  
the HF switch while in this position and verify voltage through  
the switch to the HFS input with a voltmeter.  
4. If steps 1-3 are correct and the fault persists, replace the  
module.  
152  
153  
Combustion  
pressure ON  
Combustion  
Pressure Off  
OEM Specific  
1. Check wiring and correct any errors.  
2. Inspect the Combustion Pressure Switch to make sure it is  
working correctly.  
H or L  
H or L  
3. Reset and sequence the relay module.  
4. During STANDBY and PREPURGE, measure the voltage  
between J6 terminal 5 and L2 (N). Supply voltage should be  
present. If not, the lockout switch is defective and needs  
replacing.  
5. If the fault persists, replace the relay module.  
154  
155  
Purge Fan switch OEM Specific  
H or L  
H or L  
On  
1. Purge fan switch is on when it should be off.  
2. Check wiring and correct any errors.  
3. Inspect the Purge Fan switch J6 terminal 3 and its  
connections. Make sure the switch is working correctly and is  
not jumpered or welded.  
Purge fan switch  
OFF  
4. Reset and sequence the relay module.  
5. If the fault persists, replace the relay module.  
OEM Specific  
156  
157  
Combustion  
pressure  
Flame ON  
Combustion  
pressure  
H or L  
L
and 1. Check that flame is not present in the combustion chamber.  
Correct any errors.  
2. Make sure that the flame detector is wired to the correct  
terminal.  
and  
3. Make sure the F & G wires are protected from stray noise  
Flame OFF  
pickup.  
4. Reset and sequence the module, if code reappears, replace  
the flame detector.  
5. Reset and sequence the module, if code reappears, replace  
the module.  
158  
159  
Main valve ON  
Main valve OFF  
OEM Specific  
L
L
1. Check Main Valve terminal wiring and correct any errors.  
2. Reset and sequence the module. If fault persist, replace the  
module.  
160  
161  
Ignition ON  
Ignition OFF  
OEM Specific  
L
L
1. Check Ignition terminal wiring and correct any errors.  
2. Reset and sequence the module. If fault persist, replace the  
module.  
162  
163  
Pilot valve ON  
Pilot valve OFF  
OEM Specific  
L
L
1. Check Pilot Valve terminal wiring and correct any errors.  
2. Reset and sequence the module. If fault persist, replace the  
module.  
164  
Block intake ON  
OEM Specific  
L
45  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
1. Check wiring and correct any errors.  
Code  
L
165  
Block intake OFF  
2. Inspect the Block Intake Switch to make sure it is working  
correctly.  
3. Reset and sequence the module.  
4. During Standby and Purge, measure the voltage across the  
switch. Supply voltage should be present. If not, the Block Intake  
Switch is defective and needs replacing.  
5. If the fault persists, replace the relay module.  
166-  
171  
172  
RESERVED  
Main  
relay Internal Fault.  
L
L
L
feedback incorrect  
Pilot relay feedback  
incorrect  
1. Reset Module.  
2. If fault repeats, replace module.  
173  
174  
Safety  
relay  
feedback incorrect  
Safety relay open  
Main relay ON at  
safe start check  
Pilot relay ON at  
safe start check  
Safety relay ON at  
safe start check  
RESERVED  
175  
176  
L
L
177  
178  
L
L
179-  
183  
184  
Invalid BLOWER / 1. Return to Configuration mode and recheck selected  
L
L
L
L
L
HSI output setting  
Invalid Delta T limit  
enable setting  
Invalid Delta T limit  
response setting  
Invalid DHW high  
limit enable setting  
Invalid DHW high  
parameters, reverify and reset module.  
2. If fault repeats, verify electrical grounding.  
3. If fault repeats, replace module.  
185  
186  
187  
188  
limit  
response  
setting  
189  
190  
Invalid  
Flame  
L
L
sensor type setting  
Invalid interrupted  
air switch enable  
setting  
191  
Invalid interrupted  
air switch start  
L
check  
enable  
setting  
192  
193  
194  
195  
Invalid igniter on  
during setting  
Invalid ignite failure  
delay setting  
Invalid ignite failure  
response setting  
Invalid ignite failure  
retries setting  
L
L
L
L
46  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
Code  
196  
Invalid  
ignition  
L
source setting  
197  
Invalid  
open  
interlock  
response  
L
setting  
198  
199  
200  
201  
202  
Invalid  
interlock  
L
L
L
L
L
start check setting  
Invalid LCI enable  
setting  
Invalid lightoff rate  
setting  
Invalid lightoff rate  
proving setting  
Invalid Main Flame  
Establishing Period  
time setting  
203  
Invalid MFEP flame  
L
failure  
setting  
response  
204  
205  
Invalid NTC sensor  
type setting  
Invalid Outlet high  
L
L
limit  
response  
setting  
206  
Invalid Pilot Flame  
Establishing Period  
setting  
L
207  
208  
209  
210  
211  
212  
213  
214  
215  
216  
Invalid PII enable  
setting  
Invalid pilot test  
hold setting  
Invalid Pilot type  
setting  
Invalid Postpurge  
time setting  
Invalid Power up  
with lockout setting  
Invalid Preignition  
time setting  
L
L
L
L
L
L
L
L
L
L
Invalid  
Prepurge  
rate setting  
Invalid  
Prepurge  
time setting  
Invalid Purge rate  
proving setting  
Invalid Run flame  
failure  
setting  
Invalid  
stabilization  
setting  
response  
217  
218  
Run  
time  
L
L
Invalid Stack limit  
enable setting  
47  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
Code  
219  
Invalid Stack limit  
L
response setting  
220  
Unconfigured Delta  
L
T
limit setpoint  
setting  
221  
222  
Unconfigured DHW  
high limit setpoint  
setting  
L
L
Unconfigured  
Outlet high limit  
setpoint setting  
Unconfigured Stack  
limit setpoint setting  
223  
224  
Invalid  
demand  
setting  
Invalid  
DHW  
source  
L
225  
226  
227  
228  
229  
230  
231  
232  
233  
234  
235  
Flame  
L
L
L
L
L
L
L
L
L
L
L
threshold setting  
Invalid Outlet high  
limit setpoint setting  
Invalid DHW high  
limit setpoint setting  
Invalid Stack limit  
setpoint setting  
Invalid Modulation  
output setting  
Invalid CH demand  
source setting  
Invalid Delta T limit  
delay setting  
Invalid  
Pressure  
sensor type setting  
Invalid IAS closed  
response setting  
Invalid Outlet high  
limit enable setting  
Invalid  
connector  
setting  
Outlet  
type  
236  
237  
238  
239  
240  
Invalid  
connector  
setting  
Invalid  
connector  
setting  
Invalid  
connector  
setting  
Invalid  
connector  
setting  
Inlet  
type  
L
L
L
L
L
DHW  
type  
Stack  
type  
Header  
type  
Invalid  
connector  
setting  
Outdoor  
type  
48  
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Code Description  
Recommended Troubleshooting of Lockout Codes  
Code  
241-  
255  
RESERVED  
49  
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Section 3 Care and Maintenance  
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important to keep these fumes from air intakes  
that would distribute them throughout the  
building.  
WARNING:  
The boiler area should be kept free of  
combustible materials, gasoline and  
other flammable liquids.  
3.1.2 BOIL OUT PROCEDURE  
The boil out of the boiler and system is neither  
difficult nor expensive. The chemicals needed  
for cleaning are readily available. Tri-sodium  
phosphate, and sodium hydroxide (lye) are the  
most commonly used chemicals. Be certain the  
chemicals used contain NO CHLORIDES. Use  
only one type of solution in the system. The  
amount of chemical required will vary according  
to conditions, but one pound per fifty gallons of  
water is suggested.  
The boiler and venting system must be  
kept free of obstructions of the air  
louvers.  
The following procedures must be  
conducted as outlined to prevent  
damage to and assure safe operation  
of the boiler.  
Fill the system with this solution, venting all air.  
Then, with the circulating pump running, bring  
the system to design or operating temperature.  
After circulating water for two to three hours, the  
system should be drained completely, and  
All cover plates, enclosures, and  
guards must be in place at all times,  
except during maintenance and  
servicing.  
refilled with fresh, softened water.  
Usually  
enough of the cleaning solution will adhere to  
the piping to result in an alkaline solution  
3.1 CLEANING THE BOILER AND  
SYSTEM – NEW SYSTEMS  
satisfactory for operation.  
A pH reading  
between 7 and 8 is preferred. If necessary, to  
increase the pH, a small amount of cleaner may  
be added.  
3.1.1 PRE-BOIL OUT FLUSHING OF  
SYSTEM  
WARNING:  
The boil out procedure outlined must  
be performed by, or under the direct  
supervision of, a qualified technician.  
The chemicals used present a hazard  
of burns and physical injury if  
mishandled. Always use a suitable  
facemask, goggles, protective gloves,  
and garments when handling caustic  
chemicals. Do not permit the chemical  
to come into contact with skin or  
clothing. Always follow the safety  
precautions on the container's label.  
Add chemicals slowly and in small  
amounts to prevent excessive heat  
and agitation.  
Much of the dirt and contamination in a new hot  
water system can be flushed out before the boil  
out of the system. First, flush the system of  
waste with clear water.  
The boiler and  
circulating pumps must be isolated through the  
successive zones of the system to waste,  
carrying metal shavings, dirt, pipe joint  
compound, etc. with it. Follow with a chemical  
flush. NOTE! Be CERTAIN that the chemicals  
used to flush and boil-out the boiler and system  
contain NO CHLORIDES.  
The boiler is  
fabricated with austenitic stainless steels that  
can be severely damaged when exposed to  
chlorides. The removal of pipe chips and other  
debris from the system before opening the  
isolation valves to the boiler and pumps will help  
to protect this equipment from damage by such  
debris.  
In combination with system contamination,  
bacteria from ground water boiler water may  
produce objectionable odors, sometimes  
resembling the odorant used in natural gas. It is  
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the tank.  
3.1.3 DRAINING THE SYSTEM  
Install a strainer in the boiler return piping.  
A clean neutral hot water system should not be  
drained, except for an emergency or when  
unavoidable for servicing of equipment. See  
Section 3.3 for water treatment required when  
refilling.  
3.3 BOILER WATER TREATMENT  
Purpose of water treatment  
Water treatment is required for satisfactory  
operation of the boiler. It must be devised to  
prevent depositing of scale and corrosion from  
acids, oxygen and other such harmful elements  
that may be in the water supply. A qualified  
water treatment chemist should be consulted  
and the water systematically treated.  
3.2 REPLACEMENT BOILER  
INSTALLATIONS: PROTECTION  
AGAINST CORROSION AND SEDIMENT  
Clean or replace all system piping and  
heating units  
Arrange for chemical or mechanical cleaning of  
Objectives  
the entire system.  
A chemical treatment  
The basic objectives of water treatment are:  
Prevent the accumulation of scale and deposits  
in the boiler.  
company should be consulted for the proper  
means of any chemical cleaning.  
Replace any piping that is deteriorated beyond  
safe or cleanable condition.  
Flush the system clean, being certain to isolate  
the boiler.  
Remove dissolved gases from the water.  
Protect the boiler against corrosion.  
Maintain the highest possible boiler fuel  
efficiency.  
Decrease the amount of boiler down time from  
cleaning.  
WARNING:  
Water softener  
DO NOT FLUSH THE SYSTEM  
THROUGH THE BOILER.  
It is highly recommended that a zeolite water  
softener be used for all make-up to the boiler. It  
is intended that this be used in addition to the  
For some old systems, there is a reluctance to  
clean the piping because of possible leaks  
occurring in badly corroded lines. Should the  
customer refuse cleaning, it is necessary to  
chemical treatment of the boiler.  
softening removes calcium and magnesium, the  
primary causes of hard boiler scale.  
Water  
install filtration equipment.  
Install either a  
Continuous monitoring required  
fibrous filter or a centrifugal filter in the boiler  
return piping. This will collect and remove  
sediment from the system. A booster pump may  
be required to overcome the additional pressure  
drop introduced in the line by the filter. When  
filling the system, provide chemical treatment as  
outlined in Section 3.3.  
Water treatment should be checked and  
maintained whenever the boiler is operating.  
The boiler operator should be sure that the  
boiler is not operating for long periods without  
proper water treatment.  
Water treatment may vary from season to  
season or over a period of time. Therefore, the  
water treatment procedure should be checked  
not less than four times a year, and possibly  
more frequently as the local water conditions  
may indicate.  
Failure to properly clean the system or to install  
mechanical sediment removal equipment can  
result in tube blockage and severe corrosion  
plus damage to pumps, controls, and air  
removal devices.  
It should be noted that water boilers may well  
need chemical treatment for the first filling plus  
additional  
periodic  
chemical  
treatment,  
Inspect, repair as necessary, or replace system  
air control devices.  
depending on system water losses and the  
makeup requirements.  
Water treatment may vary from season to  
season or over a period of time. Therefore, the  
water treatment procedure should be checked  
Install gauge glasses on air expansion tanks and  
install a tank fitting in the system connection to  
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not less than four times a year, and possibly  
more frequently as the local water conditions  
may indicate. All water introduced into the boiler  
should be softened and should include an  
oxygen scavenger like sodium sulfite. This is  
required to remove dissolved oxygen from the  
water. Dissolved oxygen will cause severe  
boiler tube corrosion.  
WARNING:  
If soot or condensation is apparent, a  
boiler service technician should be  
consulted. The presence of soot  
indicates poor combustion and  
possibly hazardous boiler operation.  
Failure to do so may result in fire,  
explosion potential, or asphyxiation. A  
combustion test and burner  
Draining and refilling the boiler & system  
If the system is drained and then refilled,  
chemical treatment is essential to treat the raw  
water. Use only clean, softened water.  
adjustments should be undertaken at  
once.  
3.4 EXTERNAL “FIRE-SIDE”  
CLEANING  
Purpose  
3.5 SUGGESTED MAINTENANCE  
SCHEDULE  
Carbon (soot) is an insulator and corrosive. The  
heating surfaces of a boiler must be kept free  
from soot accumulation to keep the boiler  
operating at its highest efficiency and to avoid  
damage from corrosion.  
Daily  
1. Make visual inspection of gauges,  
monitors, and indicators and record  
readings in boiler log.  
2. Make visual check of instrument and  
equipment settings against factory  
recommended specifications.  
Soot removal  
If the yearly inspection of the boiler tube  
surfaces reveals a build-up of soot or rust  
(usually due to condensation), the tubes should  
be thoroughly brushed. (Tube cleaning brushes  
are available from Bryan Steam) To inspect  
and, if necessary, clean the tube surfaces and  
flue collector, first remove the tube access  
panels. Examine the exterior of the tubes for  
evidence of soot or rust. Using a flashlight,  
carefully look between the tubes. There should  
be an unobstructed opening between all tubes,  
and the top surfaces of the tube must be free  
from soot accumulation. Also inspect the interior  
of the flue collector. Brush or vacuum the soot  
from all surfaces. Be sure to cover Triple-Flex  
burner with a protective cover during cleaning to  
prevent soot from falling onto it.  
3. Check operation of probe type low water  
cutoff(s) to ensure control is functioning.  
Weekly  
1. Confirm boiler area is free of  
combustible materials and that there is  
nothing obstructing air openings, draft  
hood relief openings, etc.  
2. Check combustion safety controls for  
flame failure and flame signal strength  
as  
specified  
in  
manufacturer's  
instructions located at the back of this  
manual.  
3. Check all limit controls.  
4. Check low water cutoff as described  
above.  
If the buildup of soot is appreciable, the flue gas  
venting system must be thoroughly inspected  
internally as well, and cleaned as necessary.  
Monthly  
1. Check high and low gas pressure  
interlocks. Refer to manufacturer's  
instructions for correct procedure.  
Annually  
1. The flue gas passages and the exterior  
surfaces of the boiler tubes should be  
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inspected at least annually.  
Any  
accumulation of soot or debris should be  
thoroughly cleaned out.  
2. If the yearly inspection of the boiler tube  
surfaces reveals a build-up of soot  
(carbon), the tubes surfaces should be  
thoroughly brushed. Failure to do so  
may result in fire or asphyxiation  
hazards.  
3. The boiler pressure vessel and piping  
should be checked annually.  
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Section 4 Lead Lag  
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There are parameters that are available to set  
the features for Lead Lag.  
The LL master turns the first stage on and  
eventually turns the last stage off using the  
same criteria as for any modulation control loop.  
When the operating point reaches the Setpoint  
minus the On hysteresis, then the first Sola is  
turned on. When the operating point reaches  
the Setpoint plus the Off hysteresis then the last  
slave Sola (or all slave Solas) are turned off.  
Many of the descriptions used are internal  
functions or tables. The names help define the  
functions but are not controlled or selectable  
outside Sola, unless noted as a parameter.  
The LL master PID operates using a percent  
rate that is, 0% is a request for no heat at all,  
and 100% means firing at the maximum  
modulation rate.  
4.1 GENERAL DESCRIPTION OF THE  
LEAD LAG APPLICATION  
Sola devices contain the ability to be a stand  
alone control, operate as a Lead Lag Master  
control which also uses the Sola control function  
as one of the slaves or to operate solely as a  
slave to the lead lag system. Conceptually it is  
not a part of that specific control, but is an entity  
that is "above" all of the individual Sola controls  
(including the one that hosts it). The master  
sees each slave (including the one that hosts it)  
as a set of Modbus devices, each having certain  
registers, and in this regard it is entirely a  
communications bus device, talking to the slave  
Sola controls via Modbus.  
This firing rate sent to the slaves as a  
percentage, but this is apportioned to the slave  
Solas according to the rate allocation algorithm  
selected by the Rate allocation method  
parameter.  
For some algorithms this rate might be common  
to all slave Solas that are firing. For others it  
might represent the total system capacity and be  
allocated proportionally.  
For example, if there are 4 slaves and the LL  
master's percent rate is 30%, then it might  
satisfy this by firing all four slaves at 30%,  
Or  
by operating the first slave at 80% (20% of the  
system’s capacity) and a second slave at 40%  
(10% of the system’s capacity).  
Sola devices utilize two ‘ModBus™’ ports (MB1  
and MB2) for communications. One port will be  
designated to support a system S7999B display  
and the other port will support communications  
from the LL Master with its slaves. The diagram  
on page 4 shows a simplified wiring diagram  
connecting the system display with a 4 system  
Lead Lag arrangement.  
The LL master may be aware of slave Sola’s  
minimum firing rate and use this information for  
some of its algorithms, but when apportioning  
rate it may also assign rates that are less than  
this. In fact the add-stage and drop-stage  
algorithms may assume this and be defined in  
terms of theoretical rates that are possibly lower  
than the actual minimum rate of the Sola control.  
In any case a Sola that is firing and is being  
commanded to fire at less than its minimum  
modulation rate will operate at its minimum rate:  
this is a standard behavior for a Sola control in  
stand-alone (non-slave) mode.  
The Lead Lag master is a software service that  
is hosted by a Sola control.  
The LL master uses a few of the host Sola's  
sensors (header temperature and outdoor  
temperature) and also the STAT electrical inputs  
in a configurable way, to provide control  
information.  
4.2 LEAD LAG (LL) MASTER GENERAL  
OPERATION  
If any slave under LL Master control is in a Run-  
Limited condition, then for some algorithms the  
LL master can apportion to that stage the rate  
that it is actually firing at.  
The LL master coordinates the firing of its slave  
Solas. To do this it must add stages and drop  
them to meet changes in load, and it sends firing  
rate commands to those that are firing.  
Additionally when a slave imposes its own Run-  
limited rate this may trigger the LL  
Master to add a stage, if it needs more capacity,  
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or drop a stage if the run-limiting is providing too  
much heat (for example if a stage is running at a  
higher-than commanded rate due to anti-  
condensation).  
three groups: "Use First", "Equalize Runtime", or  
"Use Last". If one or more Solas are in the "Use  
First" category, then one of these (the one with  
the lowest sequence number) will always be the  
first boiler to fire. If there is no Sola in the "Use  
First" category and one or more are in the  
"Equalize Runtime" category, then the First  
boiler is also the Lead boiler.  
By adjusting the parameters in an extreme way  
it is possible to define add-stage and drop-stage  
conditions that overlap or even cross over each  
other. Certainly it is incorrect to do this, and it  
would take a very deliberate and non-accidental  
act to accomplish it. But there are two points in  
this:  
Add-stage method  
Add-stage detection timing  
LL master does not prevent it, and more  
important;  
it will not confuse the LL master because it is  
implemented as a state machine that is in only  
one state at a time; for example:  
• if its add-stage action has been triggered, it will  
remain in this condition until either a stage has  
been added, or  
• the criteria for its being in an add-stage  
condition is no longer met; only then will it take  
another look around to see what state it should  
go to next.  
Add-stage request An Add-stage method  
implements the criteria for adding another stage.  
Criteria that may apply are the firing rate of a  
stage or stages vs. a threshold, the amount of  
operating point versus setpoint error seen by the  
master, the rate at which setpoint error is  
developing, and the rate at which a stage or  
stages are approaching their maximum or  
baseload firing rate.  
Typically these use Add-stage detection  
timing to determine how long these things have  
persisted. When all criteria have been met for a  
sufficient time, then an Add-stage request is  
active.  
Assumptions:  
Modulating stage The modulating stage is the  
Sola that is receiving varying firing rate requests  
to track the load.  
Drop-stage method  
First stage This is the Sola that was turned on  
Drop-stage detection timing  
first, when no slave Solas were firing.  
Drop-stage request A Drop-stage method  
implements the criteria for dropping a stage.  
Criteria that may apply are the firing rate of a  
stage (or stages) vs. a threshold, the amount of  
operating point versus setpoint error seen by the  
master, the rate at which setpoint error is  
developing, and the rate at which a stage or  
stages are approaching their minimum firing  
rate.  
Previous stage The Sola that was added to  
those stages that are firing. Just prior to the  
adding of the Sola that is under discussion.  
Next stage The Sola that will or might be added  
as the next Sola to fire.  
Last stage The Sola that is firing and that was  
added the most recently to the group of slaves  
that are firing. Typically this is also the  
modulating stage, however as the load  
decreases then the last-added stage will be at  
its minimum rate and the previous stage will be  
modulating.  
Typically these use Drop-stage detection  
timing to determine how long these things have  
persisted. When all criteria have been met for a  
sufficient time, then an Drop-stage request is  
active.  
Lead boiler The Lead boiler is the Sola that is  
the first stage to fire among those stages which  
are in the equalize runtime (Lead/Lag) group. If  
a boiler is in the "Use first" group it may fire  
before the Lead boiler fires.  
First boiler A Sola may be assigned to any of  
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4.3 SYSTEM WIRING HOOKUP  
Figure 40 LL / Multi-Boiler Field Wiring  
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be used (a)Lead Outlet - Outlet temperature of  
the lead boiler will be used as the backup during  
firing (i) Slave Outlet Average - Average of the  
outlet temperatures of all slave boilers that are  
firing will be used as a backup (b) If the sensor  
chosen by the above parameter is faulty then  
the backup sensor provided may be used. When  
burner demand is off and no burners are firing  
then, for either "Lead Outlet" or "Slave Outlet  
Average", the lead boiler's outlet temperature is  
used to monitor for burner demand. 4. Local  
Display Configuration and Operation a. The  
configuration parameters available on the local  
display are edited in the Service Mode b. Access  
to the Service Mode is accomplished by  
pressing both up/down buttons for 3 seconds. c.  
Status and Operation (1) Slave status (a) “Rmt”  
and “Adr” icons are on to show slave (follower)  
has been enabled. (b)Current burner status is  
shown (c) To show slave CFH (i) Alternate “%”  
firing rate and actual (slave) Outlet temp to  
indicate slave CFH otherwise show the Home  
screen. (2) Master status (a)Rmt icon is on, Adr  
icon is off to show Master (Leader) has been  
enabled. (b)Current burner status is shown (c)  
Actual temperature LL (Header) temperature is  
shown as described in 4e below. (d)Pressing the  
up/down buttons allows setpoint adjustment for  
LL-CH only (not LL-DHW or LL-Mix or others). (i)  
All pump configurations must be done using the  
PC Configuration tool in the OEM factories.  
(e)To show Master CFH (i) Alternate “CH” or  
“LL” or “Hdr” in numbers field with the actual  
temperature to indicate LL CH CFH. d.  
Configuration (1) Continue scrolling through set-  
up screens until “Remote Firing Controlscreen  
is reached. (2) Rmt On/Off selection chooses to  
navigate the user through the Master/Slave  
configuration as existing today (3) Set  
master/slave remote address as is done on  
currently on the local display. (4) The following  
parameters are mapped to Modbus addresses.  
LEAD LAG 5 66—A1171 (a) “LL” = LL Operation (3  
user selections available) (i) “Ldr” (i-a)Master  
Enable (i-b)Slave Enable (ii)“SLA” (ii-a)Slave  
Only Enable (ii-b)Master Disable (i) “OFF” (iii-  
a)Master Disable (iii-b)Slave Disable (b)HS =  
On/Off Hysteresis (One value used for all LL  
boilers) (i) “HS” for on and off hysteresis values.  
(i-a)Only allow 1 setting for both on and off  
hysteresis values. (a-1)Must adhere to the  
strictest of either the HS On or Off limits. •  
Highest value of the “low” range limit in Sola  
control • Lowest value of the “high” range limit in  
Sola control (a-2)See Sola Modbus specification  
for details. • Typical values: 2-15 (c) BL =  
4.4 LEAD-LAG OPERATION  
This is a summary of the functional capability of  
the embedded lead-lag on the Sola control.  
OEM Configurable parameters may be adjusted  
as part of the OEM factory configuration and in  
the field using the System Display with  
appropriate password permissions. Specific  
parameters may also be configured in the field  
by the local display 1. Field Installation  
Configuration a. The master and slave  
controllers are enabled via the S7910 or S7999  
display. b. All Sola controllers are programmed  
with a default address of 1. Assuming the  
Master Sola controller remains address 1, the  
address of the slave controllers in the system  
must have a unique address (1..8) via the local  
display. 2. Basic Operation a. Firing rate  
determination – Parallel common-base limited  
(1) All boilers have a single assignable base  
load firing rate. (2) Allocation (a)As load  
increases: (i) Until all stages are Firing - No  
stage is requested to exceed the common base  
load rate. (ii)After all stages are Firing - There is  
no restriction on the slave's commanded firing  
rate. (b)As load decreases: (i) As long as all  
available stages are firing - There is no  
restriction on the slave's commanded firing rate.  
(ii)When at least one stage has been dropped -  
No stage is requested to exceed the common  
base load rate. b. Rotation (1) The lead boiler is  
rotated based sequence order. The lead boiler  
rotation time is a configurable OEM assigned  
parameter. Rotation is sequential by address (1-  
2-3-4; 2-3-4-1; etc.) (2) Rotation trigger occurs at  
the start of each new heat cycle. c. Source of  
heat for call – The call for heat originates at the  
master boiler. This source may be configured to  
be an external thermostat or via EnviraCOM  
Remote Stat. d. Slave boiler lockout – If any  
slave is in lockout the master boiler will cause it  
to be skipped and all system load setting  
calculation settings will be based only on  
available boilers. e. Master boiler lockout – If the  
master boiler is in lockout then its burner control  
function will be skipped in the rotation the same  
as the slave controllers. However, the master  
boiler function will continue to operate. 3.  
System Component Failure Responses a. If the  
system header sensor becomes disconnected  
from the master boiler then the master boiler will  
control off of one of the following OEM  
configurable actions (1) Disable - No backup will  
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Baseload common (i) “BL” for baseload (ii)User  
selection 0 – 100 % (d)Use existing timeout,  
Done button, and Next button functionality to  
enter these parameters. (e)User selections will  
be selected by MMI. (i) The local display does  
not adhere to the PCB (OEM parameter  
selections used by S7999). (5) In normal display  
operation the display allows a user to scroll  
through a list of temperatures with associated  
icons (CH, Inlet, Delta, DHW, Stack, Outdoor)  
using the Next button. With LL active the display  
will show the header temperature at the end of  
the list of temperatures as follows: (a)The  
characters “LL” are displayed in the number field  
(b)When the next button is pressed again the  
temperature is displayed. (c) If the Up or Down  
buttons are pressed then the LL set-point is  
changed. 5. System Display Configuration – The  
following parameters are available for OEM  
configuration and may be adjusted through a  
System Display or programmed at the OEM  
production facility. Master Sola Slave Sola LL  
frost protection enable Slave mode LL frost  
protection rate Base load rate Base load rate  
Slave sequence order LL CH demand switch LL  
Demand to firing delay LL CH set point source  
LL Modulation sensor LL Base load common LL  
Modulation backup sensor LL CH 4mA water  
temperature LL Lead selection method LL CH  
20mA water temperature LL Lag selection  
method LL Add stage method 1 LL Add stage  
detection time 1 LL Add stage error threshold LL  
Add stage rate offset LL Add stage inter-stage  
delay LL Drop stage method 1 LL Drop stage  
detection time 1 LL Drop stage error threshold  
LL Drop stage rate offset LL Lead rotation time  
LL Force lead rotation time LL Drop stage inter-  
stage delay  
diagram below:  
Frost protection requests  
The frost protection in this status register will be  
set or cleared to match the status generated by  
the frost protection detection functions.  
Firing for local frost protection This  
provides indication to the LL master that  
although the burner is firing independently, it is  
doing so for frost protection and thus is still  
available as a lead/lag slave. This is set when 1)  
frost protection is controlling the Sola per the  
priority scheme (which occurs only if frost  
protection is enabled), and 2) burner demand is  
true and the burner is currently firing or  
preparing to fire to serve that demand.  
Otherwise it will be clear.  
Aux Pump X, Y, and Z The pump control in  
the Slave can be used by previously existing  
command devices to create the same behavior.  
However before these bits controlled actions is  
specific pump blocks, they are now more  
general. The pump X, Y, and Z bits control  
actions in any pump block defined to handle  
them (see the pump control block definition).  
4.6 SLAVE PARAMETERS  
SLAVE ENABLE: DISABLE, ENABLE VIA  
MODBUS, ENABLE FOR SOLA MASTER  
It enables or disables the "LL Slave" Demand  
and Rate module. If the slave mode is set to  
Disable then: none of the slave functions are  
active, Slave Status register is zero, the LL –  
Master Service Status register is not writable  
and is held at zero (this is important for pump  
control which might otherwise use values in this  
location). The Slave Command register is  
writable but it is mostly ignored, however the  
Aux pump X, Y, and Z are effective for any  
setting of the Slave enable parameter. The  
Enable for Sola Master option Slave write and  
Slave read parameters; if "Enable for Sola  
Master" is not selected, then these parameters  
are disabled.  
4.5 SLAVE OPERATION AND SETUP  
Slave Data Supporting Lead Lag  
This data is provided by each slave Sola control  
to support operation when a LL master exists.  
The illustration below summarizes the slave's  
registers and data:  
SLAVE MODE: USE FIRST, EQUALIZE  
RUNTIME, USE LAST  
If set to Use First, then this Sola will be used  
prior to using other Solas with other values. If  
set to Equalize Runtime, then this Sola will be  
staged according to a run time equalization  
LL Slave  
Some slave changes relate to pump control,  
frost protection, and also are available to 3rd  
party (non Sola) LL master devices. The generic  
LL slave is updated to operate as shown by the  
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algorithm. (Any Solas set to Use First will  
precede any that are set to Equalize Run time.)  
If set to Use Last, then this burner will be used  
only after all Use First and Equalize Runtime  
Solas have been brought online.  
parameters that enable and disable its  
operation.  
Periodic data polling - The LL master uses  
polling to discover new slave Sola devices and  
to periodically refresh the information it has  
about a known slave Sola devices.  
SLAVE SEQUENCE ORDER: 0-255  
Slave control - the LL master sends each  
active slave a command and also performs a  
slave status read for each known slave device. It  
also sends a Master status broadcast that is  
heard by all slaves.  
Slave status manager - The LL master keeps  
track of slave status for each Sola that is  
enabled as a slave device.  
Demand and priority - different sources of  
demand can cause the LL master to operate in  
different ways. These sources have a priority  
relationship.  
Modulation - each demand source has one or  
more setpoints that may be active and an  
operation sensor. These are used to detect turn-  
on and turn-off conditions. The difference  
Slave sequence order is used to determine the  
order in which Solas will be used (staged on) for  
those Solas which the same Slave mode setting.  
Numbers may be skipped, that is 3 will be first if  
there is no 1 or 2. Note: For Equalize Runtime  
purposes, 1 does not mean the Sola will be used  
first every time; that will vary over time based on  
the master's run time equalization scheme. In  
this case the sequence number determines the  
relative order in which Sola controls will be used  
in a round-robin scheme. If the slave sequence  
number value is zero, then the slave Sola's  
ModBus address will be used instead. If two  
Solas which are set the same mode both have  
the same sequence number then an alert will  
occur and the order in which they are used will  
be arbitrary and is not guaranteed to be  
repeatable.  
between  
operating  
point  
and  
setpoint  
determines the LL master's firing rate.  
Stager - the stager determines when slave  
Solas should turn on as the need for heat  
increases, and when they should turn off as the  
need for heat decreases.  
DEMAND-TO-FIRING DELAY: MM:SS OR  
NONE  
This delay time is needed by the LL master to  
determine the length of time to wait between  
requesting a slave Sola to fire and detecting that  
it has failed to start. It should be set to the total  
time normally needed for the burner to transition  
from Standby to Run, including such things as  
transition to purge rate, prepurge time, transition  
to lightoff rate, all ignition timings, and some  
extra margin.  
Rate allocation - the PID block's output is used  
to determine the firing rate of each slave Sola  
using various rate allocation techniques.  
Add-stage methods - various methods can be  
used to determine when a new stage should be  
added.  
Drop-stage methods - various methods can  
be used to determine when a stage should be  
dropped  
Sequencer - the Sola sequencer determines  
which Sola will be the next one to turn on or turn  
off.  
BASE LOAD RATE: RPM OR %  
This specifies the preferred firing rate of a  
burner, which is used for some types of control  
algorithms.  
FAN DURING OFF-CYCLE RATE: RPM OR %  
(0=DISABLE)  
4.7.1 OVERALL CONTROL  
This determines if or where the fan is to be  
operating during the standby period.  
LL MASTER ENABLE: DISABLE, ENABLE, LL  
MASTER MODBUS PORT: MB1, MB2 If  
Disable is selected then all LL master functions  
are inactive. If Enable is selected then it acts as  
the active bus master on the ModBus port it is  
assigned. LL OPERATION SWITCH: OFF, ON  
This controls the LL master in the same way that  
the Burner switch controls a stand-alone Sola. If  
"On" then the LL master is enabled to operate. If  
this parameter is "Off" then the LL master turns  
4.7 LL MASTER OPERATION AND  
SETUP  
LL master operation is subdivided into the  
following functions:  
Overall control - The LL master has  
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off all slaves and enters an idle or standby  
condition.  
discover what happened in a subsequent status  
response). The LL master also sends this  
message to a slave that is OnLeave. (This  
ensures that if the slave is firing when it returns  
to LL master control, it will stay that way until the  
master has decided whether to use it; or  
conversely, if the slave stops firing for some  
reason that it will not start up again until the LL  
master has requested this. In either case, the  
command will be to turn on the off cycle fan if  
any other slave burners are firing, or to turn the  
fan off if the slave is the only slave that might (or  
might not) be firing.  
• The LL master sends message to turn the  
burner on and to assign the burner’s firing rate.  
If the commanded modulation rate is less than  
the burner’s minimum modulation rate, then the  
burner should always operate at its minimum  
rate.  
4.7.2 PERIODIC DATA POLLING  
MESSAGES  
The LL master uses polling to discover new  
slave Sola devices and to periodically refresh  
the information it has about a known slave Sola  
devices. Thereafter it polls the known devices to  
make sure they are still present and to obtain  
updated status information. It also periodically  
polls the entire slave address range to discover  
any new slave devices. A polled Sola is read to  
determine the values of the following data items:  
a. The slave's type (compatibility) as indicated  
by the Slave type b. The slave enable status  
Slave enable c. The slave mode as set in Slave  
mode d. The slave sequence order as set in  
Slave sequence order e. Demand-to-firing  
delay: mm:ss or None This delay time is  
needed by the LL master to determine the length  
of time to wait between requesting a slave Sola  
to fire and detecting that it has failed to start. It  
should be set to the total time normally needed  
for the burner to transition from Standby to Run,  
including such things as transition to purge rate,  
prepurge time, transition to lightoff rate, all  
ignition timings, and some extra margin. f. CT -  
Burner run time This parameter will be needed  
if measured run-time equalization is being used.  
4.7.3 SLAVE STATUS MANAGER  
The LL master keeps track of slave status for  
each Sola that is enabled as a slave device. The  
slave status manager operates internally for  
each slave Sola devices (up to 8). There is a  
table entry for each device containing the  
following data:  
• SlaveState:  
Unknown - indicates the table entry is unused  
and empty  
Available - indicates the slave is OK and ready  
to use, but is not  
currently firing as a slave  
Slave Control  
The LL master sends each active slave a  
command and also performs a slave status read  
for each known slave device. It also sends a  
Master status broadcast that is heard by all  
slaves. There are 5 commands that might be  
sent:  
• All slaves are commanded to turn off and  
remain off.  
• The LL master sends message to Solas that  
are off, to turn their fans on.  
• The LL master suspends operation which  
request a burner to recycle and remain in  
Standby if it has not yet opened its main valve  
(e.g. it is in Prepurge or PFEP) but to keep firing  
if it has reached MFEP or Run. This suspend  
may be for the fan to be on or off in standby.  
This message is used to abort the startup of a  
slave that is not yet firing (because demand  
went away just before it was firing), but to keep it  
on if it actually is firing (the LL master will  
AddStage - stage is getting ready to fire  
SuspendStage - stage was getting ready but is  
not needed  
Firing - indicates the slave is currently firing  
OnLeave - indicates the slave is operating for  
some other demand source within it that has  
higher priority than slave demand.  
Disabled - indicates the slave is locked out or  
disabled in some way  
Recovering - indicates the slave is in a time  
delay to ensure that it is OK before it is again  
considered to be available.  
RecoveryTime: Saves how long the slave  
must be OK to recover.  
RecoveryTimer: Used to measure the slaves  
recovery time  
RecoveryLimitTimer: Enforces a maximum  
slave recovery time  
DataPollFaultCounter: Used to tolerate  
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momentary communication problems and to act  
on these if they are excessive.  
INVALID RESPONSE OR NO RESPONSE  
StatusReadFaultCounter: Used to tolerate  
momentary communication problems and to act  
on these if they are excessive.  
AbnormalFaultCounter: Used to tolerate  
momentary abnormality  
StagingOrder: Used to record the stage-on  
order, for use by the sequencer when it needs to  
drop a stage.  
When a Sola responds to a data poll with an  
improperly formatted message or it does not  
respond then the slave status table is checked  
and: If the polled slave device is in the table then  
the Data Poll Fault is noted. If this causes a  
fault counter to exceed the fault value then the  
SetRecovering handling is invoked.  
• Storage for each item described in the Periodic  
data polling section • Storage for each item  
described in the Slave status read response  
section • Slave Command - the command word  
from the master to the slave.  
SlaveState states  
Recovering A slave that is recovering is  
checked once per second. If the slave has  
recovered the SlaveState table is changed to  
Available. If the slave has not yet recovered  
when its recovery timer reaches the  
RecoveryTimeLimit then: If the slave is not  
enabled for the Sola LL master its SlaveState  
table is Set to Unknown (which logically  
removes it from the slave table). Otherwise the  
Recovery- LimitTimer is cleared which starts a  
new recovery measurement and the slave  
remains in recovery (indefinitely).  
Features common to all states  
• Whenever a slave Sola device is not in an  
expected condition then a recovery function is  
used to set up timers to give a faulty slave: —  
minimum time that it must appear to be OK, and  
— limit how long a slave has to recover from any  
error.  
• If the slave status read was bad then the  
slave's FaultCounter is incremented and if it to  
reaches the fault value tries, then a recovery  
action is invoked. This action does nothing else  
if the status read was Bad. If the slave status  
read was OK then the status function puts the  
slave read response data in a slave status table.  
If a transition to another state is indicated then  
the SlaveState is simply set to the indicated  
state.  
Available A slave in the Available state remains  
that way until the Stager moves it into the  
AddStage state or the ProcessSlaveStatus  
action moves it to some other state.  
AddStage A slave in the AddStage state  
remains that way until the ProcessSlaveStatus  
moves it to Firing or some other state, or the  
Stager times out and moves it into the  
Recovering state if it fails to fire.  
Data poll response handling  
Valid Response Message  
SuspendStage A slave in the SuspendStage  
state  
remains  
that  
way  
until  
the  
ProcessSlaveStatus moves it to some other  
state, or the Stager times out and moves it into  
either the Firing or the Available state.  
Firing A slave in the Firing state remains that  
way until the ProcessSlaveStatus moves it to  
some other state, or the Stager drops the stage  
and moves it into the Available state.  
OnLeave A slave in the OnLeave state remains  
that way until the ProcessSlaveStatus moves it  
to some other state.  
Disabled A slave in the Disabled state remains  
that way until the ProcessSlaveStatus moves it  
to Recovering.  
When a slave Sola responds with a properly  
formatted message it is examined to see if  
Slave enable value is "Enable for Sola Master".  
• If the "Enable for Sola Master" value is not  
present then the slave status table is checked  
and if the slave is not in the table then the  
message is ignored (this is normal). However if  
the slave is in the table then the message is  
stored as usual and the slave will invoke the  
action as a disabled slave and cause recovery  
action to occur.  
• If the "Enable for Sola Master" value is present  
then the slave status table is checked and if the  
slave is not in the table then the slave data is  
stored in an empty position in the table.  
However if the slave is in the table then the  
message is stored as usual (this is the normal  
case).  
Demand and Priority  
Different sources of demand can cause the LL  
master to operate in different ways. These  
sources have a priority relationship.  
CH Demand  
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New occurrences of CH demand is inhibited.  
DHW demand is not affected.  
LL CH DEMAND SWITCH: DISABLE, STAT,  
ENVIRONCOM REMOTE STAT  
The inputs that can function as the CH demand  
switch are: STAT, EnvironCOM Remote Stat. If  
the CH demand switch value is Disable, the LL  
master does not respond to CH demand.  
Warm Weather Shutdown  
Frost protection  
LL master frost protection is enabled with Frost  
protection enable: Disable, Enable  
WARM WEATHER SHUTDOWN ENABLE:  
DISABLE, SHUTDOWN AFTER DEMANDS  
The need for frost protection is actually detected  
independently by each slave which notifies the  
master whether frost detection occurred in CH  
frost detection, and/or its DHW frost detection,  
and whether it is severe enough to require  
burner firing as well as pump operation. This is  
done via its Slave status parameter.  
HAVE ENDED, SHUTDOWN IMMEDIATELY  
WARM WEATHER SHUTDOWN SETPOINT:  
TEMPERATURE OR NONE  
When warm weather shutdown is Disabled then  
it has no effect (i.e. the Warm Weather  
Shutdown (WWSD) status shown on the priority  
diagram is false).  
If Frost protection enable is Enable then the  
master's Slave write message, will indicate CH  
or DHW frost protection or both as read from  
each slave's Slave Status. This will cause any  
slave pumps which are enabled to follow this  
status to turn on without any other action  
required from the master.  
These two parameters are shared by the stand-  
alone Sola control and the LL master and have  
the same effect for either control.  
This function requires the outdoor temperature.  
This temperature may be obtained from either a  
local sensor or a LL slave. If WWSD is enabled  
but the outdoor temperature is invalid and  
unknown, then the WWSD function acts as if it is  
disabled and has no effect and an alert is issued  
indicating an invalid outdoor temperature.  
If any slave is indicating CH or DHW frost  
protection, and additionally that slave's Slave  
status register indicates burner firing is  
requested then the LL master's frost protection  
burner demand will be true.  
If the priority scheme allows the master to honor  
this demand, then it will fire a single burner (the  
current lead burner as specified by the  
sequencer) at the rate indicated by Frost  
protection rate: 0-100%. (100% represents  
100% firing of this boiler, and where 0% or any  
value less than the boiler's minimum firing rate  
represents the minimum firing rate).  
If it is enabled then it uses a 4°F (2.2°C)  
hysteresis:  
If WWSD is false, then when the Outdoor  
temperature is above the value provided by  
Warm weather shutdown setpoint then:  
If "Shutdown after demands have ended" is  
selected then any current CH demand that is  
present prevents WWSD from becoming true;  
that is if CH demand is false then WWSD  
becomes true.  
Priority Control  
CH heat demand is a simple signal such as  
STAT, Enviro- COM remote stat, or Warm  
Weather Shutdown.  
Otherwise if "Shutdown immediately" is  
selected then WWSD becomes true, it  
immediatetly causes CH demand to end.  
Frost protection input to the priority logic is not a  
heat demand, it is a burner demand (because  
frost protection always turns on pumps without  
regard to the priority control - it is a priority item  
only if it also wants to fire).  
If WWSD is true, then when the Outdoor  
temperature is below the value provided by  
Warm weather shutdown setpoint minus 4°F  
(2.2°C) then WWSD becomes false.  
Master Status  
MASTER HEAT DEMAND  
When warm weather shutdown is true then:  
Is a data item which contains the status for the  
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following sources of demand. All sources that  
are currently calling for heat will be true (multiple  
items may be true at the same time) except  
when WWSD is active, then CH demand is  
inhibited.  
These are used to detect turn-on and turn-off  
conditions. The difference between operating  
point and setpoint determines the LL master's  
firing rate  
CH Demand  
4.7.5 MODULATION SENSOR  
CH Frost demand – true if any slave is calling for  
CH frost protection and Frost protection  
enable is true.  
LL MODULATION SENSOR: S5  
The LL master's modulation sensor uses the S5  
sensor (connector J8 terminal 11 and 12). If the  
LL master is enabled and its sensor is faulty  
then an alert will be issued.  
4.7.4 MASTER ACTIVE SERVICE  
Is a data item which contains the identity of a  
single source of demand that the LL Master is  
currently serving according to its priority:  
• None – no active service, LL master is idle  
• CH  
LL  
MODULATION  
BACKUP  
SENSOR:  
DISABLE, LEAD OUTLET, SLAVE OUTLET  
AVERAGE  
If the sensor chosen by the LL Modulation  
sensor is faulty then the backup sensor  
provided here may be used.  
• Frost – burner demand is true for frost  
protection  
• WWSD – no high priority demand is active, and  
WWSD is inhibiting CH demand (if any).  
If Disable is selected then no backup will be  
used.  
MASTER SERVICE STATUS  
If Lead Outlet is selected then the outlet  
temperature of the lead boiler will be used as the  
backup during firing.  
Is a data item used by pump control logic that  
combines the Master Heat Demand and Master  
Active Service data. It is implemented as  
described by the Pump Control Block diagram.  
If Slave Outlet Average is selected then  
average of the outlet temperatures of all slave  
boilers that are firing will be used as a backup.  
When the burner demand is off and no burners  
are firing then, for either Lead Outlet or Slave  
Outlet Average, the lead boiler's outlet  
temperature is used to monitor for burner  
demand.  
Outdoor Temperature  
For a Sola that hosts a LL master, the outdoor  
temperature may be known from either of two  
sources. If the host Sola has an outdoor sensor  
that is reporting a valid temperature then this  
sensor reading is used. Otherwise, if any slave  
Sola is reporting a valid temperature as part of  
its Data Poll message, then this temperature is  
used.  
Setpoints  
LL CH SETPOINT SOURCE: LOCAL, S2 4-  
20MA  
If the setpoint source is Local then the Sola  
control's local setpoint system is used. This  
setting enables the normal use of the CH  
setpoint, CH TOD setpoint, and the CH outdoor  
reset parameters and functions.  
The resulting outdoor temperature provides all  
outdoor temperature needs for both stand-alone  
and LL master purposes. If neither source has a  
valid temperature then the outdoor temperature  
is simply invalid and unknown, and the functions  
which need this information handle it accordingly  
per their individual definitions.  
If the setpoint source is S2 4-20mA then the  
setpoint is determined by the 4-20mA input on  
S2, and the two parameters described below. If  
the 4-20mA signal goes out of range or is  
invalid, and this persists for a specified time,  
then the setpoint source reverts to "Local". In  
this case once it has gone to "Local", it remains  
Modulation  
Each demand source has one or more setpoints  
that may be active and an operation sensor.  
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that way until the 4- 20mA signal is stable again.  
None  
• LL CH ODR boost step: degrees or None  
• LL CH ODR boost recovery step time:mm:ss or  
None  
LL CH 20MA WATER TEMPERATURE:  
TEMPERATURE OR NONE  
CH  
4MA  
WATER  
TEMPERATURE:  
The outdoor reset function requires the outdoor  
temperature. This temperature may be obtained  
from either a local sensor or a LL slave as  
described earlier. If the outdoor temperature is  
invalid and unknown, then no outdoor reset  
action occurs and an alert is issued indicating an  
invalid outdoor temperature.  
TEMPERATURE OR NONE  
These provide the 20mA and 4mA temperatures  
for the interpolation curve. If either of these have  
the None value, are invalid, are out of range, or  
are too close for interpolation, an alert is issued  
and the setpoint reverts to "Local" when it is  
selected as 4-20mA.  
LL  
CH  
ODR  
MINIMUM  
WATER  
LL CH SETPOINT: DEGREES OR NONE  
This setpoint is used when the time-of-day input  
is off. If the ODR function is inactive then the  
setpoint is used as-is. If the ODR function is  
active then this setpoint provides one coordinate  
for the outdoor reset curve.  
TEMPERATURE: DEGREES OR NONE  
This specifies the minimum outdoor reset  
setpoint for the LL master. If the outdoor reset  
function calculates a temperature that is below  
the temperature specified here, then this  
parameter's temperature will be used. If this  
parameter is invalid or None then the outdoor  
reset function will be inhibited and will not run: if  
it is enabled then an alert is issued.  
LL CH TOD SETPOINT: DEGREES OR NONE  
This setpoint is used when the time-of-day input  
is on. If the ODR function is inactive then the  
setpoint is used as-is.  
If the ODR function is active then this setpoint  
provides one coordinate for the shifted (because  
TOD is on) outdoor reset curve.  
4.7.6 DEMAND AND RATE  
On/Off Hysteresis Includes hysteresis shifting  
at turn-on, turn-off  
TIME OF DAY  
The Time of Day has one sources of control: a  
switch contact. Closed TOD is an on condition;  
open, then TOD is off.  
LL OFF HYSTERESIS: DEGREES OR NONE  
LL ON HYSTERESIS: DEGREES OR NONE  
OUTDOOR RESET AND BOOST (BOOST IS  
FUTURE)  
The outdoor reset and boost functions for the LL  
CH functions will be implemented as described  
for a stand-alone CH loop.  
The LL hysteresis values apply to all setpoint  
sources. The behavior of the hysteresis function  
is identical to the behavior of the stand-alone CH  
hysteresis function, except:  
Each of the loops which implements outdoor  
reset and boost has its own parameters. The  
parameters used by the LL master are:  
• LL setpoint  
• where stand-alone CH hysteresis uses the  
on/off status of a single burner, the LL hysteresis  
uses the on/off status of all slave burners: this  
status is true if any slave burner is on, and false  
only if all are off.  
• where stand-alone CH hysteresis uses time of  
turn-on and turn-off of a single burner, the LL  
hysteresis uses the turn-on of the first slave  
burners and the turn-off of the last slave burner.  
• LL CH TOD Setpoint  
• LL Outdoor reset enable: Disable, enable  
• LL CH ODR minimum outdoor degrees or  
None  
• temperature:  
• LL CH ODR maximum outdoor degrees or  
None temperature:  
• LL CH ODR low water temperature: degrees or  
None  
• LL CH ODR boost time: mm:ss or None  
• LL CH ODR boost max setpoint: degrees or  
LEAD LAG PID  
The behavior of the Lead Lag PID function is  
identical to the behavior of the stand-alone CH  
PID function. The same gain scalars and  
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algorithms are used. Additionally:  
of step 1 are no longer true (demand has  
decreased) then it clears the flag.  
Whenever the rate allocator completes an  
execution pass and detects both conditions of  
step 1 are true, and it also detects that the total  
rate potentially absorbed by the system (the  
commands have not yet been sent) has  
increased from the value that was saved when  
the flag was set, then it re-computes the  
integrator value based on the old commanded  
maximum, clears the flag, and actually allocates  
the old rate that was saved when the flag was  
set.  
4.7.7 RATE ADJUSTMENT  
When the Slave dropout/return compensation  
parameter specifies a rate adjustment and a rate  
compensation event occurs (a slave leaves  
while firing, or a slave returns) then rate  
adjustment will alter the integrator value so that  
the commanded rate compensates for the added  
or lost capacity.  
INTEGRATOR COMPENSATION  
Examples include:  
A stand-alone Sola includes a feature to smooth  
the response when a rate override has occurred  
(such as delta-T rate limit) causing the PID  
output to be ignored.  
• The rate allocator has encountered a limit such  
as base load (for a "limited" rate allocation  
scheme) and this limit is released.  
Whenever an override has occurred then, at the  
moment the override ends, the integrator is  
loaded with a value that causes the PID output  
to match the current rate, whenever this is  
possible within the integrator’s limits. The Lead  
Lag PID will implement similar behavior: The  
rate allocator will provide a trigger that causes  
the integrator's value to be recomputed and this  
trigger will activate whenever a rate allocation  
limit is released; that is, this event will occur any  
time the system transitions from the condition in  
which it is not free to increase the total  
modulation rate, to the condition where this rate  
may increase.  
• All stages are at their maximum (base load, or  
max modulation) and one or more stages are  
rate-limited (such as due to slow-start or  
stepped modulation limiting due to high stack  
temperature, etc.) and the rate limited stage  
recovers, changing from rate-limited to free to  
modulate.  
(This is indicated by the Slave Status "slave is  
modulating": the changing from false to true is  
not, itself, a trigger, but while it is true the rate  
allocator can assign to the slave only the firing  
rate that it is reporting; thus the release of this  
might allow more rate to be absorbed by the  
system. It also might not do this, if for example  
the slave was in anticondensation and thus the  
rate limit was maximum modulation rate.)  
4.7.8 IMPLEMENTATION  
• All firing stages are at their maximum (base  
load, or max modulation) and a stage which was  
OnLeave returns in the firing state and is  
available for modulation.  
The examples below are ways in which this may  
occur, but in implementation what is necessary,  
first of all, is to use a rate allocator that assigns  
rate to each slave and can detect when all of the  
assigned rate is absorbed, or if there is excess  
requested rate that the firing stages could not  
absorb.  
• An add-stage is in-progress and all firing  
burners are at their limits (max modulation rate  
or base load) and then the new stage becomes  
available.  
Then:  
Whenever the system is rate limited, that is,  
when A) all firing stages are commanded to their  
respective maximums and also B) the PID is  
asking for more heat than that, note that this has  
occurred by setting a flag and also record total  
rate that the system absorbed (the total of the  
commanded maximums, not the PID's requested  
rate which might include excess).  
This also applies when the system is first  
starting up, that is, all firing burners are at their  
limits (zero) because non are firing, and thus  
when the add-stage is finished the system  
transitions from no modulation at all, to  
modulating the first stage.  
Whenever the rate allocator completes an  
execution pass and detects that both conditions  
Lead Lag Burner Demand  
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Lead Lag burner demand will be present when  
Frost protection burner demand is true, as  
described in the section on Frost protection. For  
the CH, and DHW demand sources, Lead Lag  
burner demand will be true when one of these is  
true and also setpoint demand from the  
hysteresis block is true.  
each slave. Some rate allocation algorithms may  
specify the use of this parameter, and that the  
slave base load settings are ignored.  
RATE ALLOCATION METHOD: PARALLEL  
COMMONBASE LIMITED  
This selects the rate allocation method. This  
performs three purposes:  
it determines how the LL master allocates firing  
rate to each active stage,  
4.7.9 RATE ALLOCATION  
the modulating stage and last stage are  
determined for the Add-stage and Drop-stage  
methods,  
it determines the overflow rate and underflow  
rate and can provide this to staging algorithms.  
The PID block's output is used to determine the  
firing rate of each slave Sola using various rate  
allocation techniques.  
Common Features  
OVERFLOW RATE AND UNDERFLOW RATE  
The rate allocator knows the rate assigned to  
each stage, and the requested rate, and thus  
can determine the difference between these.  
All rate allocation methods share certain  
features. The rate allocator first generates the  
Slave Command. Except for the Firing state,  
the value ultimately depends only upon the  
SlaveState. The values are:  
This difference has two forms: overflow (used by  
Addstage methods), underflow (used by Drop-  
stage methods).  
Available  
AddStage  
When asked for rate overflow the threshold that  
is used is the upper limit of the modulating stage  
per the current rate allocation rules. Additionally  
this threshold may be shifted if the Add-stage  
method is using a dRate/dt behavior. Rate  
overflow is a positive or negative percentage  
offset from the threshold. For example:  
SuspendStage depending on whether any other  
slave stage is firing, no matter what SlaveState it  
is in.  
Firing  
OnLeave - same as SuspendStage  
This ensures that when a slave returns and is  
already firing, it will remain firing until the master  
decides what to do about that, or if it is not firing  
it will remain off.  
If the modulating stage is at the staging  
threshold position but the  
Disabled - same as Available  
Recovering - same as Available  
It next runs a rate allocator that depends upon  
the rate allocation method. This routine fills in  
the modulation rate for all Firing boilers.  
LL master is not asking for more heat than this,  
then the overflow rate is 0%. If it is at this  
location (limited) or above this location  
(unlimited) and the LL master is asking for 10%  
more than the threshold value, then the overflow  
rate is 10%. If it is below the staging threshold  
position by 5%, then the overflow rate is -5%.  
Each rate allocation method also provides  
functions to return identification of the  
modulating stage and the last stage, for use by  
the Add-stage and Drop-stage methods.  
When asked for rate underflow the threshold  
that is used is the minimum modulation rate of  
the last stage. Additionally this threshold may be  
shifted if the Dropstage method is using a  
dRate/dt behavior.  
Rate Allocation Parameters  
BASE LOAD COMMON: 0-100%  
If set to zero, this parameter is disabled. For any  
non-zero value, it uses the individual base load  
rates of each slave to be ignored by the LL  
master's routines and this common value to be  
used instead. It is an easy way to set all base  
loads to the same value, without having to set  
Rate underflow is a positive or negative  
percentage offset from the threshold. For  
example:  
If the last stage is at the threshold position but  
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the LL master is not asking for less heat than  
this, then the underflow rate is 0%. If it is at this  
location and the LL master is asking for 10%  
less than the threshold value, then the underflow  
rate is -10%. If the last stage is 5% above the  
threshold then the underflow rate is 5%.  
For the Parallel common-base limited the  
minimum modulation rate provides the underflow  
threshold.  
Stager  
The Stager is an internal program that  
determines when slave Solas should turn on as  
the need for heat increases, and when they  
should turn off as the need for heat decreases.  
Rate allocation methods  
PARALLEL  
Allocation  
COMMON  
BASE  
LIMITED  
In all cases:  
• The first burner turns on due to the  
combination of heat demand (call for heat) and  
setpoint demand (operating point falls below the  
setpoint minus the on hysteresis).  
All stages that are Firing receive the same firing  
rate.  
Only the Base load common parameter is used  
for base loading, the individual slave's base load  
values are ignored.  
• The last burner (or all burners) turn off due to  
the loss of burner demand which is caused by  
either the loss of heat demand (no call for heat)  
or the loss of setpoint demand (the operating  
point climbs above the setpoint plus the off  
hysteresis).  
• In between those two extremes the Add-stage  
and Dropstage methods determine when staging  
occurs. The stager handles burner on and  
burner off events. It operates according to this  
state transition diagram.  
As load increases:  
Until all stages are Firing:  
No stage is requested to exceed the common  
base load rate.  
After all stages are Firing:  
There is no restriction on the slave's  
commanded firing rate.  
The stager has the following variables:  
StagerState: encodes the current state of the  
stager.  
StagerTimer: multipurpose 1 second timer used  
by states which measure time.  
StagerTimeLimit: the timeout value for the  
StagerTimer  
As load decreases:  
As long as all available stages are Firing There  
is no restriction on the slave's commanded firing  
rate.  
When at least one stage has been dropped:  
No stage is requested to exceed the common  
base load rate.  
LeadStartup: flag indicating the lead boiler is  
starting  
AddStageA: the stage being added to those  
already firing  
MODULATING STAGE  
Since all Firing stages receive the same rate,  
any stage can be considered to be the  
modulating stage. The one with the highest  
StagingOrder number is considered to be the  
modulating stage.  
Stager Parameters  
ADD-STAGE INTERSTAGE DELAY: MM:SS  
This specifies the minimum time that the Stager  
waits after adding one stage before adding  
another stage or dropping a stage.  
Last stage  
DROP-STAGE INTERSTAGE DELAY: MM:SS  
This parameter specifies the minimum time that  
the Stager waits after dropping one stage before  
dropping another stage or adding a stage.  
The stage with the highest StagingOrder  
number is the last stage.  
OVERFLOW AND UNDERFLOW  
Functions common to all stager states  
These functions handle overall burner demand  
responsibility, and take care of cleaning up any  
anomalous conditions.  
For the Parallel common-base limited the  
Base load common parameter provides the  
overflow threshold.  
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4.7.10 BURNER DEMAND  
If so then the stager: Changes the SlaveState to  
Suspend- Stage, resets and starts its  
StagerTimer, sets the StagerTimeLimit to  
T_StagerSuspend. This allows additional time  
for the slave to reach its firing condition.  
The stager checks the Master’s LL burner  
demand. If this demand is off all slaves with  
SlaveStates of AddStage, SuspendStage, or  
Firing are set to Available by the Rate Allocator  
turning them all off and the StagerState is set to  
be Idle.  
STAGERSTATE = ADDSTAGESUSPEND  
During this state the stager is waiting to see if  
the slave has transitioned to Firing or Available.  
STAGERSTATE = IDLE WITH SLAVES ACTIVE  
If the stager runs and its state is Idle, it checks  
the status of all slaves. If any of these have  
SlaveState=AddStage, SuspendStage, or Firing  
then these are set to Available (this will cause  
the Rate Allocator to turn them all off).  
If the identified boiler has a SlaveState=Firing  
then the stager:  
Resets and starts its StagerTimer, sets the  
StagerTime- Limit to Add-stage interstage  
delay, it changes the StagerState to  
InterstageDelay.  
Stager States  
The stager's operation is defined for each of its  
states:  
STAGERSTATE = IDLE  
The stager checks to see if the StagerTimer  
has reached the StagerTimeLimit.  
Burner demand means that a demand source is  
calling for heat and there is also setpoint  
demand.  
If so then:  
If the boiler's SlaveState is set to Available.  
If any slave boiler is firing then StagerState =  
Active  
Otherwise StagerState = Idle  
When there is no burner demand the stager is  
forced to be Idle.  
When burner demand becomes true (Call for  
Heat) the stager checks the sequencer to  
identify the lead boiler. That boiler is given a  
command to start.  
STAGERSTATE = ACTIVE  
During this state the stager is ready to manage  
add-stage and drop-stage requests.  
If AddStageRequest is true  
The stager resets (to verify it is at 0) and starts  
its  
Stager-  
Timer,  
and  
sets  
the  
The Stager ask the Sequencer for an available  
slave.  
When an available slave is found the stager  
repeats the above steps to bring this stage to  
Active.  
StagerTimeLimit to the value of the slave's  
Demand-to-firing delay time.  
If the Stager fails to get even one boiler from the  
Sequencer, it issues an alert and suspends until  
it runs again.  
If DropStageRequest is true and more than 1  
slave burner is firing, the stager:  
STAGERSTATE = ADDSTAGERESPONSE  
During this state the stager is waiting for slave to  
transition to Firing. If the identified boiler has a  
SlaveState=Firing then the stager:  
Resets and starts it’s StagerTimer, sets the  
StagerTime- Limit to Add-stage interstage  
delay, and changes the StagerState to  
InterstageDelay.  
Invokes SetRecovering for the stage identified  
by DropStageRequest. This will turn the stage  
off and put it into the recovering state until it has  
finished its postpurge (if any).  
Resets and starts its StagerTimer, sets  
StagerTime- Limit to Drop-stage interstage  
delay,  
changes  
the  
StagerState  
to  
If the boiler's SlaveState is still AddStage then:  
InterstageDelay, invokes an action to reset the  
Add/Drop detection timers.  
The stager checks to see if the StagerTimer  
has reached the StagerTimeLimit.  
When the Interstage time has elapsed, the  
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Stager can execute an AddStage or DropStage  
request.  
amount greater than or equal to Add-stage  
error threshold  
Add Stage Methods  
When the Add-stage condition is false then  
AddStage- DetectTimerN is set to zero. (If the  
condition is true then AddStageDetectTimerN  
is not zeroed and thus allowed to run.) If this  
timer reaches or exceeds LLAdd- stage  
detection timeN then AddStageRequestN is  
true.  
Various methods can be used to determine  
when a new stage should be added. The internal  
algorithms that generate AddStageRequests  
are called Add-stage methods.  
All methods work by observing various criteria  
such as the Firing stages, the commanded rate,  
or setpoint error.  
RATE THRESHOLD For rate based staging, a  
stage is added based on the rate of the  
modulating stage.  
Adding Stages Parameters:  
ADD-STAGE CONDITION:  
ADD-STAGE DETECTION TIME1: MM:SS  
This provides time thresholds.  
The modulating burner is at a rate that is at or  
above the rate which is calculated by adding the  
Add-stage rate offset to the maximum position  
per the rate allocation rules.  
In the descriptions below, the relevant  
parameter is referred to as Add-Stage  
detection timeN.  
Examples: rate offset = 20% The add-stage  
condition will occur if the modulating stage is  
20% above base load for unlimited allocations,  
or, if limited, when there is 20% more rate to  
distribute than can be absorbed by firing the  
stages at base load.  
Add-Stage method1:  
Disable,  
Error threshold,  
Rate threshold,  
dError/dt and threshold,  
dRate/dt and threshold }  
rate offset = -20% The add-stage condition will  
be as described just above, but the threshold is  
now 20% below the modulating stage's base  
load rate.  
In the descriptions below, the relevant  
AddStageDetect- Timer is referred to as  
AddStageDetectTimerN.  
To support this, the current Rate Allocation  
method asks for the current "Overflow rate" -  
see the Rate Allocator section.  
ADD-STAGE  
DEGREES  
ERROR  
THRESHOLD:  
This provides the error threshold as defined by  
the methods below.  
Drop Stage Methods  
Various methods can be used to determine  
when a stage should be dropped. The internal  
algorithms that generate DropStageRequests  
are called Drop-stage methods.  
ADD-STAGE RATE OFFSET: -100% TO +100%  
This provides the rate offset threshold as  
defined by the methods below.  
One or two methods may be active at any time.  
If two are active then their requests are OR'd  
together.  
Add-stage methods  
ERROR THRESHOLD  
For error threshold staging, a stage is added  
when the error becomes excessive based on  
degrees away from setpoint, and time.  
All methods work by observing various criteria  
such as the Firing stages, the commanded rate,  
or Setpoint.  
ADD-STAGE CONDITION:  
Dropping Stages Parameters:  
- The modulating burner(s) is at its (their)  
maximum position per the rate allocation rules,  
- The operating point is below the setpoint by an  
DROP-STAGE DETECTION TIME: MM:SS  
This provides time thresholds. They differ only in  
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that:  
DropStageDetectTimerN is set to zero. (If the  
condition is true then DropStageDetectTimerN  
is not zeroed and thus allowed to run.) If this  
timer reaches or exceeds Dropstage detection  
timeN then DropStageRequestN is true.  
Drop-Stage detection time is used with  
DropStageDetectTimer  
In the descriptions below, the relevant  
parameter is referred to as LL – Drop Stage  
detection timeN}.  
Drop-Stage method:  
RATE THRESHOLD  
Disable,  
Error threshold,  
For rate based staging, a stage is dropped  
based on the rate of the last stage.  
Rate threshold,  
dError/dt and threshold,  
dRate/dt and threshold  
DROP-STAGE CONDITION:  
-The modulating burner(s) is at a rate that is at  
or below the minimum modulation rate plus a  
rate offset.  
DROP-STAGE  
DEGREES  
ERROR  
THRESHOLD:  
Examples:  
This provides the error threshold as defined by  
the methods below.  
rate offset = 20% The Drop-stage condition will  
occur when the last stage is less than a  
threshold that is the minimum modulation rate  
plus another 20%.  
DROP-STAGE RATE OFFSET: -100% TO  
+100%  
This provides the rate offset threshold as  
defined by the methods below.  
rate offset = 0% The Drop-stage condition will  
occur when the last stage is at the minimum  
modulation rate.  
LL boiler off options:  
Options disabled,  
rate offset = -20% The Drop-stage condition will  
occur if the last stage is at minimum modulation  
and there is 20% less rate to distribute than can  
be absorbed; that is, the rate allocator would like  
the minimum modulation rate to be lower than it  
is.  
Enable all boilers off (ABO)  
Enable lead drop-stage on error (LDSE)  
Enable both ABO and LDSE  
This provides options for customizing the way  
stages are dropped, as described below.  
To support this, the current Rate Alloction  
method asks for the current "Underflow rate" -  
see the Rate Allocator section.  
LL ALL BOILERS OFF THRESHOLD:  
TEMPERATURE OR NONE  
When the LL boiler off options specifies "Enable  
all boilers off (ABO)" or "Enable both ABO and  
LDSE" then this parameter provides the boiler  
off threshold temperature that is used. In this  
case, if the temperature is the None value then a  
parameter error lockout occurs.  
Boiler off options  
The LL boiler off option controls two optional  
behaviors. One option is to enable the use of the  
LL all boilers off threshold and is abbreviated  
"ABO", and the other controls whether a lead  
boiler is affected by a drop-stage method based  
upon error, and is abbreviated as "LDSE".  
Drop-stage methods Error threshold  
For error threshold staging, a stage is dropped  
when the error becomes excessive based on  
degrees away from setpoint and time.  
ALL BOILERS OFF - ABO:  
The ABO temperature provides a Burner Off  
threshold that essentially replaces the normal  
Burner Off threshold as given by the LL off  
hysteresis parameter; it is processed by the  
same logic block using some additional rules.  
DROP-STAGE CONDITION:  
- The modulating burner(s) is at its (their)  
minimum position per the rate allocation rules,  
- The operating point is above the setpoint by an  
amount greater than or equal to Drop-stage  
error threshold  
If ABO is enabled then:  
• When the LL master operating point reaches or  
exceeds the ABO threshold this turns off LL  
master burner demand.  
When the Drop-stage condition is false then  
• The Burner Off threshold provided by LL off  
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hysteresis is ignored if one or more lag boilers  
are firing.  
• If LDSE is enabled:  
The Burner Off threshold provided by LL off  
hysteresis is ignored also for the lead boiler  
when it is firing solo (i.e. when no lag boilers are  
firing).  
modulation rate. When LDSE is enabled and the  
lead is firing solo, then simply reaching the drop-  
stage threshold causes a dropstage event that  
causes the lead to turn off and [rf3259] which thus  
ends LL master demand until the operating point  
again falls to the Burner On threshold.  
• If LDSE is disabled:  
Sequencer  
When the lead is firing solo and the operating  
point reaches the Burner Off threshold specified  
by LL off hysteresis turns off LL master burner  
demand (and thus the lead boiler).  
The Sola sequencer determines which Sola will  
be the next one to turn on or turn off whenever  
an Add-stage event occurs. It maintains the  
following variables:  
As usual, whenever LL master burner demand is  
turned off by its hysteresis block, it does not  
recur until the operating point falls below the  
Burner On threshold.  
LeadBoilerSeqNum - sequence number of the  
current lead boiler in the Slave Status table.  
Lead BoilerRunTime - the cumulative time that  
the current lead boiler has been running.  
Summary of the burner-off thresholds that are  
used:  
In all cases, if a boiler sequence number is  
needed and Slave sequence order is 0, then  
the boiler's ModBus address is used as its  
sequence number.  
4.7.11 LEAD DROP-STAGE ON ERROR  
- LDSE:  
In all cases, if two boilers being compared have  
the same effective sequence number, then the  
one that is selected is undefined (either may  
prevail).  
If LDSE is enabled then either Drop-stage  
method1 must be enabled to provide staging  
based on "Error threshold"; otherwise  
parameter error lockout occurs.  
a
Sequencer Parameters  
LEAD SELECTION METHOD: ROTATE IN  
SEQUENCE ORDER, MEASURED RUN TIME  
This determines the selection method for lead  
selection and sequencing, as described below.  
Normally, for a lag boiler, dropping a stage  
based on error involves meeting three criteria: 1)  
the operating point temperature must exceed an  
offset from setpoint, 2) this condition must  
persist for a period of time, and 3) the measured  
time starts only when the modulating boilers are  
firing at the minimum modulation rate. And  
normally when LDSE is not enabled, the lead  
boiler is special case that is not affected by a  
drop-stage event: it shuts down only when the  
operating point reaches the burner-off threshold  
(or ABO threshold, if that is enabled).  
LAG SELECTON METHOD: SEQUENCE  
ORDER, MEASURED RUN TIME  
This determines the selection method for lag  
selection and sequencing, as described below.  
LEAD ROTATION TIME: HH:MM OR NONE  
This determines the lead rotation time as  
defined below.  
If LDSE is enabled:  
FORCE LEAD ROTATION TIME: HH:MM OR  
NONE  
If this parameter is a non-zero time, then it is  
used to force the rotation of the lead boiler if it  
stays on longer than the time specified.  
• Enabling (or disabling) LDSE has no effect on  
the dropstage behavior for a lag boiler; however  
• When only the lead boiler is firing then an error  
based drop-stage event does act to drop the  
lead boiler, and moreover, only one of the three  
criteria above are considered by the method in  
this case: the operating point temperature. Thus  
dropping the lead does not depend on  
exceeding this temperature for a period of time,  
nor does it require the lead to be at minimum  
Sequencer Add Boiler Selection  
The sequencer selects the next boiler to be  
added according to a sorted order. This  
description assumes this is implemented by  
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assigning an ordering number and that the  
lowest numbers are the first to be added.  
a sequence number greater than this number is  
used, or  
• Any Available slaves that have a mode of Use  
First will have the lowest ordering numbers. If  
two or more Use First boilers exist, they are  
numbered according to their assigned Slave  
sequence order or Modbus address if this value  
is zero, as descibed above.  
• Next are slaves that have the mode of Equalize  
Runtime. When the add boiler routine gets to  
this group it first invokes the Voluntary Lead  
Rotation routine (to make sure this is done, but  
only once) and then selects an Available boiler,  
if any, ordered according to:  
— If no boiler has a greater sequence number,  
then the one that has the smallest sequence  
number is used (wrap around).  
Otherwise when the Lead selection method is  
"Measured run time", then the lead boiler is the  
one having the lowest Measured run time value.  
If two have the same measured run time, then  
either may be selected.  
The LeadBoilerRunTime value is then set to  
zero to give the new lead boiler a fresh  
allotment. Note: if the old lead boiler is the only  
one, then this process may end up re-  
designating this as the "new" lead with a fresh  
time allotment.  
The first is the lead boiler per the  
LeadBoilerSeqNum parameter.  
— The rest are the other slaves ordered  
according to the LL –Lag selection method}  
parameter:  
• If this parameter is "Rotate in sequence order",  
then they are ordered according to their LL –  
Slave sequence order or Modbus address if  
this value is zero, as descibed above.  
• If this parameter is "Measured run time" then  
they are ordered according to their reported run  
time. If two have the same measured run time,  
then either may be selected.  
Sequencer ordering function  
Part of the sequencer is called by the stager just  
before the stager runs, to give the sequencer a  
chance to assign order numbers to stages that  
very recently turned on, and to maintain these in  
a sequence. It uses the StagingOrder item in  
the Slave Status table for this purpose.  
• Last are any Available slaves that have a mode  
of Use Last. These will have the highest  
numbers. If two or more Use Last boilers exist,  
they are numbered according to their assigned  
Slave sequence order or Modbus address if  
this value is zero, as described above.  
The sequencer ordering function examines all  
slaves and sets to zero the StagingOrder of any  
stage that is not Firing.  
This ensures that any stage that has left the  
Firing condition recently is no longer in the  
number sequence.  
Voluntary Lead Rotation  
Next, skipping all of those that have 0 values in  
StagingOrder it finds the lowest numbered  
StagingOrder and gives it the value 1, the next  
receive 2, etc.  
The current lead boiler is identified by the  
LeadBoilerSeqNum value. This value will  
change when the stager has asked the  
sequencer for a boiler to add and either:  
• the boiler identified by LeadBoilerSeqNum is  
neither Available nor Firing (i.e. it has a fault or  
is OnLeave), or  
Thus if gaps have developed due to a slave  
dropping out these are filled in.  
• the LeadBoilerRunTime value exceeds Lead  
rotation time.  
Finally, the ordering function continues on,  
giving the next numbers to and Firing stages  
which have a 0 StagingOrder values (i.e. they  
recently were added, or they recently returned  
from OnLeave).  
In either of these cases, the algorithm performed  
is: If the Lead selection method is "Rotate in  
sequence order", then LeadBoilerSeqNum is  
incremented, and then new lead boiler is the one  
that is a slave in Equalize Runtime mode that is  
responding to the LL master (i.e. not OnLeave or  
Recovering, but it might be Firing), and:  
Example: Before After Notfiring 3 0 Notfiring 0 0  
Firing 2 1 Firing 5 3 Firing 0 4 Firing 4 2  
Sequencer Drop Lag boiler selection  
has  
a
sequence number equal to  
LeadBoilerSeqNum, or.  
— If no boiler has this then the closest one with  
When the stager asks the sequencer for a lag  
boiler to drop the sequencer looks at the  
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StagingOrder numbers of all Firing boilers. If  
only one Firing boiler is found, or none are  
found, then this selection function returns a  
value that indicates no boiler may be dropped.  
Otherwise it returns an identifier for the boiler  
having the highest StagingOrder number.  
3 will be first if there is no 1 or 2.  
NOTE: For Equalize Runtime purposes, 1 does  
not mean the Sola will be used first every time;  
that will vary over time based on the master's  
run time equalization scheme. In this case the  
sequence number determines the relative order  
in which Sola controls will be used in a round-  
robin scheme.  
SEQUENCER 1 MINUTE EVENT  
Part of the sequencer is called by the timing  
service at a 1 minute rate to implement lead  
rotation.  
If the slave sequence number value is zero, then  
the slave Sola's ModBus address will be used  
instead.  
The 1 minute event checks the boiler identified  
by Lead- BoilerSeqNum. If it is Firing then the  
LeadBoilerRunTime is incremented.  
If two Solas are set the same mode and both  
have the same sequence number then an alert  
will occur and the order in which they are used  
will be arbitrary and is not guaranteed to be  
repeatable.  
FORCED LEAD ROTATION:  
When  
the  
boiler  
identified  
by  
LeadBoilerSeqNum is firing and also  
LeadBoilerRunTime reaches the Force lead  
rotation time parameter time then:  
1. The current lead boiler is noted.  
2. Lead rotation occurs as described above  
under Voluntary Lead Rotation (this changes the  
designation, but does not change the actual  
firing status).  
SLAVE WRITE: DATA  
This allows the slave to accept command  
messages from a Sola master  
SLAVE READ: DATA  
This provides the slave status message to be  
read by a Sola Master. It includes all of the data  
that is read from a slave.  
SLAVE MODE: USE FIRST, EQUALIZE  
RUNTIME, USE LAST  
• If set to Use First, then this slave Sola will be  
used prior to using other slave Solas with other  
values.  
• If this parameter is set to Equalize Runtime,  
then this slave Sola will be staged according to a  
run time equalization. (Any Solas set to Use  
First will precede any that are set to Equalize  
Runtime.)  
• If this parameter is set to Use Last, then this  
slave Sola will be used only after  
• all Use First and Equalize Runtime Solas have  
been brought online.  
SLAVE PRIORITY SEQUENCE ORDER: 0-255  
Slave sequence order is used to determine the  
order in which the slave Solas will be used  
(staged on) for those Solas with the same Slave  
mode setting. Numbers may be skipped, that is  
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