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PLAINTIFF'S EXHIBIT ASI-718
B. P. Er,g.
ELECTRONIC CONTROL
SYSTEMS
WITH OR LESS PANELS FOR
G-40 a G-60 GAS BOILERS
i '-'LsSsS'/ / /- (/ 2--
APPROVED BY AMERICAN GAS ASSOCIATION
NOTICE TO INSTALLER AND OPERATOR
THIS BOOKLET MUST BE AFFIXED ON OR ADJACENT TO THE HEATING*'EQUIPMENT
MA^iSAC A/s&7'/i/&PA/oP T<s> //3M-J3 <se/?/S
AMiRiCAN-c$taftdard
First in heating first in plumbing
21289
BP-15095
r.LCiiVtD
Jt"i ll 7 S5 SH '61
ELECTRONIC CONTROL SYSTEMS
1
SUPPLEMENTARY INSTRUCTIONS FOR OAS BOILERS '..TTH ELECTRONIC CONTROLS
CAUTION: All wiring should be installed in accordance with the National Electric Code. Reference should also be made to the electric company regulations and local codes covering the installation.
The installer should carefully study the printed forms provided with the equipment and become familiar with the terminology and purpose of the parts. Particular attention should be given to the diagram covering the location of the pilots and controls for the system adopted. The installation of the pilot gas supply line (s) is shown in the Installation, Operating and Maintenance Manual furnished with the boiler.
TYPES OF SYSTEMS:
EG-C P 73-
Electronic Control System is specifically designed for F.Ji. and F.I.A. installation. This system provides electric ignition on all pilots
(auxiliary and safety) also electronic control of all safety pilots and 100;i shutoff. A protectorelay is required for each individual combustion chamber.
EPG-0 -
27- 3o
Electronic Control System - Same as the EG-0 System, except furnished with a pre-wired Master Panel with Protectorelay for one combustion chamber and one sub-panel with a protectorelay for each additional combustion chamber.
EG-1
B~y
Electronic Control System - This system requires manual ignition of all pilots and provides electronic control of the last pilot on each pilot gas supply line. A protectorelay is required to serve each Manifold and its electronic safety pilot.
EPG-l P. 3 3 + JU
Electronic Control System - Same as the EG-1 System, except furnished with a pre-wired Master Control Panel also with a sub-control panel for boilers having two manifolds.
EG-2
P.3ri-3L
Electronic Control System - This system requires manual ignition of all pilots, provides electronic control of the last pilot on the pilot gas supply line and 100,C Shutoff on all pilots.
EPG-2 P.371 3*
Electronic Control System - Same as EG-2 except furnished with a pre-wired Master Control Panel also with a Sub-Control Panel for boilers having two
Manifolds.
EG-3 P. M
Electronic Control System - This system requires manual ignition of all pilots except the electronically controlled pilot which lights automatically. The system provides 100,') Shutoff on all pilots. A Protectorelay is required to serve each manifold and its electronic safety pilot.
EPG-3 -
Electronic Control System - Same as EG-3, except furnished with a pre-wired Master Control Panel also with a Sub-Control Panel for boilers having two
Manifolds.
21290
ELECTRONIC CONTROL SYSTEMS
2
TERMINOLOGY:
Non-100 Shutoff - Pilot gas supply is controlled manually,
100,11 Shutoff - Pilot gas is supplied through a valve which will automatically close upon pilot flame failure.
Continuous Pilot - (Standby or Auxiliary) - the pilot burns at all times and is manually ignited.
Safety Pilot
- Pilot with flame sensing device which prevents main burner operation in event of pilot flame failure. The flame sensing device is a thermocouple on the Baso type pilot and a flame rod on the L'-H (w-179) type pilots.
Q-179-A Pilot
- Has an igniter electrode for spark irnited gas pilot and a flame electrode. This Model is used for electric ignition, 100^ pilot gas shutoff on intermittent pilot applications.
Q-179-B Pilot
- Has only the flame electrode and is used for Manual Ignition, Non-100^ pilot gas shutoff.
Q-179-B Modified Pilot
Has special adapter for installing a thermocouple in place of an igniter electrode. Q-179-B modified pilot is used for manual ignition, 100fl pilot gas shutoff.
Protectorelay
This control provides electronic flame safeguard protection fcr the toiler by supervising the control of gas valve (s).
CAUTION - Remove the circuit jumper screw located on top side of the relay base if 0-179 Continuous Flame (not electrically ignited) safety pilot (s) is used. This screw MUST BE removed before installing the relay (s) in the Pre-wired Panel (s).
BASO PILOT VALVE - Located in the pilot line and actuated by a thermocouple. Used for 100'i pilot gas shutoff. To light pilot, depress the plunger on top of pilot valve and hold approximately 30 seconds until the thermocouple becomes hot.
GAS PILOT VALVE - M-H No. V-R95-A or No. V-)i5-3, 115 Volt., 60 Cycle. Used for Electric Ignition, 100',o Pilot Gas Shutoff. Model "A", less manual opener is furnished with manual openinr device packed in envelope (attached to the pilot
valve) as standard equipment.
IGNITION TRANSFORMER - Used with Q-179-A pilot for automatic electric ignition. Secondary (hot) connection provides 6000 Volts and is grounded internally to the case. TO COMPLETE IGNITION CIRCUIT, CASE LUST BE GROUNDED. Transformer operates on 115 Volt, 60 Cycle current.
GAS VALVE TRANSFORMER - Converts 110 Volt., 60 Cycle current to 2h Volts for use with low voltage gas valves. Must be mounted on junction box. NOTE: If line voltage gas valves are supplied, this transformer is omitted from the circuit and the valves are connected to the same terminal on the relay as shown for the transformer.
DISCONNECT SNITCH - Double pole single throw switch should be installed in the line to the installations without a pre-wired panel. All power to the boiler should be
supplied through the disconnect switch.
21291
elictaciiic c;::trcl systems
MASTER PANEL - Pre-wired, electronic control panel with protectorelay base has "Pilot" and "Automatic Gas Valve" li/hts and switches. Protectorelay with alarm contacts to be mounted within the panel.
SUB-PAliEL - Panel with protectorelay base, pilot light and switch. Sub-panel (s) are factory assembled and wired to master Panel as required. Frutectorelav with alarm contacts to be mounted within the panel.
SPECIAL CONTROLS - '.Then required, additional electrical safety controls that act to limit temperature or pressure should be wired in series with limit control shown on applicable wiring diagrams.
ALARM CIRCUIT: - The h-K RA-S0 relay (s) supplied with the boiler are provided with low voltage alarm contacts which close within approximately 1? seconds after pilot flame failure. These contacts energize the "Pilot Failure Alarm Light" on pre-wired panels. A remote alarm light or alarm bell may be connected in the system as shown in the two following diagrams.
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To 24 ^OLT PLAR.M l/GHT
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PL#e*t LiOnr Oa/ Pra/el
pEivtors Plrrm C/ecu/r W/e/M<s foe. Use With Prewired Control Prmels
BP-7814
21292
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ELECTRONIC CONTROL SYSTEMS
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ELECTRONIC CONTROL SYSTEMS
5
INSTALLATION RECOMMENDATIONS:
Relays - The M-H RA-890 Protectorelay should be mounted on a wall or permanent fixture as close to the boiler as possible. On installations less pre-wired panel, it is recommended that all electrical power to the boiler be controlled by a line disconnect switch located near the relay (s). A separate disconnect switch is not needed when the pre-wired panel is used.
All wiring should be completed to the relay sub-base or panel before installing the relay. When pre-wired panels are used, the internal circuit jumper screw located on the top side of the black relay base must be removed if the Q-179 safety pilot is to burn continuously (not electrically ignited). This screw must be removed before installing the relay (s) in the pre-wired panel (s).
Wiring - All wiring between boiler controls and relays should be protected. Wiring to Q-179 electronic pilot flame rod should be M-H spec. 1298-1 or equi valent high temperature (350 F) wire. This wire may be spliced outside of the heat zone to standard ih gauge wire. The splice should be a soldered connection. Wire from ignition transformer secondary (hot) connection to the Q-179-A Pilot igniter electrode should be M-H Spec. lOul-U.
Low Voltage wiring (flame rod circuit) should not be located in same conduit as line voltage wire.
START-UP PROCEDURE:
On initial start-up (or after long shutdown it is recommended that air be eliminated from pilot lines before attempting start-up on EG-0 or EPG-0 systems with automatic electric ignition. When pilot lines are full of air, the electronic relay safety switch may lock out on safety (15 seconds) before gas reaches the pilot burner. If "Lock out" occurs, wait approximately 3 or U minutes, actuate reset lever on relay (s) and proceed with lighting sequence.
MAINTENANCE:
1. All limit controls should be checked for proper operation once a year.
2. Replace tube (s) in relay (s) once a year. Replacement tubes should be obtained from Ninneapolia-Honeywell. In case of emergency replacement, regular tubes (with proper number) may be used, however, they should be replaced as soon as possible with M-H pre-tested tubes.
21294
ELECTRONIC CONTROL SYSTEMS
6
Q-I79B PILOT
THERMOCOUPLE
fc-f-tu-n * - -3 , P 3'-
Q-I79B MODIFIED PILOT
Q-I79A
II22
Q-I79B
MODIFIED
PILOT SYMBOLS
21295
ELECTRONIC CONTROL SYSTEMS
7
21296
ELECTRONIC CONTROL SYSTEMS
INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING ELECTRIC IGNITION --100% SHUTOFF
TO SHUT OFF:
1. OPEN LINE SWITCH 2. CLOSE MANUAL SHUTOFF VALVE(S) "A" AND
PILOT VALVE(S) "B".
TO LIGHT:
1. BE SURE MANUAL SHUTOFF VALVE(S) "A", PILOT VALVE(S) "B", AND LINE SWITCH HAVE BEEN SHUT OFF FOR AT LEAST FIVE MINUTES BEFORE PROCEEDING.
2. OPEN PILOT VALVE(S) "B". 3. ACTUATE RESET LEVER(S) (RED LEVER ON
PROTECTORELAY). 4. SET OPERATING CONTROL TO DESIRED TEMPERATURE
OR PRESSURF 5. CLOSE LINE SWITCH AND WAIT APPROX. 30 SECONDS. 6. MAKE SURE AUTOMATIC GAS VALVE IS NOT IN
MANUAL OPEN POSITION. 7. OPEN MANUAL SHUTOFF VALVE(S) "A".
MAIN CAS LINE
8
I-5T-I20I9
e:-c electro:;;c control system
INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING MANUAL IGNITION-------NON 100 % SHUTOFF
TO SHUT OFF:
1. OPEN LINE SWITCH. 2. CLOSE MANUAL SHUTOFF VALVE(S) "A" AND
PILOT VALVE(S) "B".
TO LIGHT:
1. BE SURE MANUAL SHUTOFF VALVE(S) "A", PILOT VALVE (S) "B", AND LINE SWITCH HAVE BEEN STILT OFF FOR AT LEAST FIVE MINUTES BEFORE PROCEEDING.
2. OPEN PILOT VALVE(S) "B". LIGHT ALL PILOT BURNERS.
3. RESET PILOT SWITCHES "C" (IF USED). 4. ACTUATE RESET LEVER(S) (RED LEVER ON
PROTECTORELAY-). 5. SET OPERATING CONTROL TO DESIRED TEMPERATURE
OR PRESSURE. 6. CLOSE LINE SWITCH AND WAIT APPROX. 30 SECONDS. 7. OPEN MANUAL SHUTOFF VALVE(S) "A".
MAIN CAS LINE
GUM FILTER (OPTIONAL)
TO PILOT
I- ST- 14278
EC-1 ELECTRONIC CONTROL SYSTEil
21297
ELECTRONIC CONTROL SYSTEMS
INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING MANUAL IGNITION -------- 100% SHUTOFF
TO SHUT OFF:
1. Close Manual Shutoff Valve(s) "A" And Pilot Valve MB'\
2. Open Line Switch.
MAIN CAS LINE
9
TO LIGHT:
1. Be Sure Manual Shutoff Valve(s) "A", Pilot Valve (s) "B" And Line Switch Have Been Shutoff For At Least 5 Minutes Before Proceeding.
2. Open Pilot Valve(s) "B". 3. Press Plunger "C" On 1st Pilot Line Valve And
Light Pilot. Hold Plunger "C" For One Minute. Repeat For Additional Pilots. 4. Actuate Reset Lever(s) (Red Lever On Protectorelay) 5. Set Operating Control To Desired Temperature Or Pressure. 6. Close Line Switch. 7. Open Manual Shutoff Valve(s) "A".
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I- ST- 14279
EC-2 ELECTRONIC CONTROL SYSTEM
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PILOT LINE VALVE
INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING ELECTRIC IGNITION ----- 100% SHUTOFF
TO SHUT OFF:
1. Close Manual Shutoff Valve(s) "A" And Pilot Valve "B".
2. Open Line Switch.
MAIN CAS LINE
TO LIGHT:
L. He Sure Manual Shutoff Valve(s) "A", Pilot Valve (s) "B" And Line Switch Have Been Shutoff For At Least 5 Minutes Before Proceeding. Open Pilot Valve "B". Press Plunger "C" On 1st Pilot Line Valve And Light Pilot. Hold Plunger "C" For One Minute. Repeat For Additional Pilots. Electronic Pilot(s) Will Light Automatically. Actuate Reset Lever(s). (Red Lever On Protectorelay) Set Operating Control To Desired Temperature Or Pressure.
6. Close Line Switch. 7. Open Manual Shutoff Valve(s) "A".
CUM FILTER (OPTIONAL)
B
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PILOT LINE VALVE
I -ST-14 2 80
EG-J ELECTRONIC CONTROL SYSTEM
21298
ELECTRONIC CONTROL SYSTEMS
10
POWER
PILOT AUTO GAS VALVE
LIGHTING INSTRUCTIONS
1. caution: be sure MAIN GAS SHUTOFF VALVE(S) AND PILOT VALVE(S) HAVE BEEN SHUT OFF AT LEAST 5 MINUTES BEFORE PROCEEDING.
2. TURN POWER SWITCH ON. (PUSrf^fcSET LEVER IF PILOT OUTAGE OCCURRED.)
3. OPEN MANUAL PILOT VALVE(S): A) MANUAL IGNITION - LIGHT PILOTS, RESET PILOT SWITCHES B) MANUAL IGNITION WITH PILOT VALVES - PUSH RED BUTTON ON PILOT VALVE, LIGHT PILOT AND HOLD BUTTON FOR APPROX. ONE MINUTE C) ELECTRIC IGNITION (LESS PILOT VALVES) - LIGHT PILOTS, RESET PILOT SWITCHES. (MAIN SAFETY PILOT WILL LIGHT AUTOMATICALLY) D) ELECTRIC IGNITION (WITH ELECTRIC PILOT VALVES) - PILOTS WILL LIGHT AUTOMATICALLY.
4. TURN PILOT SWITCH(ES) ON. (TURN ON PILOT SWITCHES ON SUB-PANELS FIRST WHEN PROVIDED.) PILOT LAMPS WILL LIGHT ONLY WHEN ALL THE FOLLOWING CONDITIONS EXIST. 1. ALL SAFETY PILOTS ARE LIT. 2. OPERATING CONTROL "CALLING FOR HEAT." 3. ALL LIMIT CONTROLS INDICATE SAFE CONDITIONS.
CZD<nrCrT BE SURE CONDITION CAUSING SAFETY KtLOL I LOCKOUT HAS BEEN CORRECTED.
5. SET OPERATING CONTROL TO DESIRED TEMPERATURE OR PRESSURE.
6. OPEN MANUAL MAIN GAS SHUTOFF VALVE(S). 7. TURN AUTO GAS VALVE SWITCH ON TO LIGHT MAIN BURNERS
SHUTDOWN INSTRUCTIONS
1. TURN ALL SWITCHES ON PANEL TO OFF POSITION. 2. CLOSE MAIN GAS SHUTOFF VALVE(S) AND PILOT VALVE(S).
'N__________________
NOTE:
"PILOT" AND "AUTO GAS VALVE" LAMPS WILL CYCLE "ON" AND "OFF" WITH OPERATING CONTROL.
PILOT FAILURE ALARM LIGHT
1-ST-1L261
EPG-O, EPG-1, EPG-2 and EPG-3 SYSTEMS LIGHTING INSTRUCTIONS FOR
PREWIRED ELECTRONIC CONTROL PANEL
21299
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ELECTRONIC CONTROL SYSTEMS
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G-40 GAS BOILER PILOT LOCATION FOR EG-O & EPG-O ELECTRONIC CONTROL SYSTEMS
ELECTRIC IGNITION - 100% SHUTOFF - 3 TO 10 SECTION BOILERS FOR ALL GASES
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ELECTRONIC CONTROL SYSTEMS
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PILOT LOCATION FOR EG-2 & EPG-2 ELECTRONIC CONTROL SYSTEMS
MANUAL IGNITION - 100 % SHUTOFF - 3 TO 10 SECTION BOILERS
FOR ALL GASES
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G - 40 GAS BOILER PILOT LOCATION FOR EG-3 & EPG-3 ELECTRONIC CONTROL SYSTEMS
ELECTRIC IGNITION - 100 % SHUTOFF - 3 TO 10 SECTION BOILERS FOR ALL GASES
21301
ELECTRONIC CONTROL SYSTEMS
EC--0 and EFC--0 Systems
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ELECTRONIC CONTROL SYSTEMS
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