Document mBZay79VYryn6en67vpGaDopO

ELECTRONIC CONTROL SYSTEMS WITH OR LESS PANELS FOR G-40 GAS BOILERS APPROVED BY AMERICAN GAS ASSOCIATE ' NOTICE TO INSTALLER AND OPERATOR THIS BOOKLET MUST BE AFFIXEDON OR ADJACENT TO THE HEATING EQUIPMENT Americanj&l Flnl in heating first in piu r.~; BP-15095 REV. 9-67 13671 PLAINTIFF'S EXHIBIT PtSX' 323 ELECTRONIC CONTROL SYSTEMS SUPPLEMENTARY INSTRUCTIONS FOR GAS BOILERS WITH ELECTRONIC CONTROLS CAUTION: All wiring Bhould be installed in accordance with the National Electric Code. Reference should also be made to the electric company regulations and local codes covering tne Installation. The installer should carefully study the printed forms provided witn the equipment and become familiar with the terminology and purpose of the parts. Particular attention should be given to tne diagram covering the location of the pilots and controls for tne system adopted. The installation of the pilot gas supply line(s) is Bncwn in the Installation, Operating and Maintenance Manual furnished witn the boiler. TYPES OF SYSTEMS: EG-0 ThiB system provides electric ignition, 100# snutoff and electronic flame sensing of all pilots. EPG-0 Electronic Control System - Same as the EG-0 System, except furnished with a prewired Master Panel with Protectorelay for one pilot and one sub-panel with a Protectorelay for eacn additional pilot. EQ-OM Electronic Control System - This system provides electronic flame sensing, 100# shutoff and constant burning pilots. (Manual ignition). EPG-OM Electronic Control System - Same as EG-QM, except furnished with prewired Master Control Panel for one pilot and one sub-panel for each additional pilot. 13672 ELECTRONIC CONTROL SYSTEMS TERMINOLOGY: Nun-IOO% Snutoff - Pilot gas supply is controlled manually. 100% Shutoff - Pilot gas i6 supplied tnrough a valve which will automatically close upon pilot flame failure. Continuous Pilot - The pilot burns at all times and is manually ignited. Safety Pilot - Pilot with flame sensing device wnich prevents main burner operation in event of pliot flame failure. Vue flame sensing device is a thermocouple on tne Jiauo type pilot and a l'lame rod on the M-H (Q-17b) type pilots. Pliot - Has an Igniter electrode for spark lgnltea gao pilot and a flame electrode. This Model la used for electric ignition, 100% pilot gas snutoff on intermittent pilot applications. ti-17y-B Modified - Has special adapter for installing a thermocouple in Pliot place of an igniter electrode. Q-I7y-B modified pilot is used for manual ignition, 100% pilot gas shutoff. Protectorelay - This corftrol provides electronic flame cafeguard protection for tne boiler by supervising the control of gaB valve(s). CAUTION: Remove the circuit Jumper screw located on top slue of the re. ay oa so ii' Q-179 Continuous Flame (not electrically ignited) safety pilot (s) ia used. This screw MUST BE removed before installing tne relay(s) in the Prewired Panel(s). THERMOELECTRIC PILOT VALVE - Located in .the pilot line and actuated by a thermocouple. Used for 100% pilot gas shutoff. To lignt pilot, cepress the plunger on top of pilot valve and hold approximately 30 seconds until the thermocouple becomes hot. CAS PILOT VALVE - M-H No. V-496-A or No. V-495-B, lib volt, bO cycle. Used for Electric Ignition, 100% Pilot Gas Shutoff. Model 'A", less manual opener is furnished with manual opening 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 6,000 volts and is grounded internally to the case. TO COMPLETE IGNITION CIRCUIT, CASE MUST BE GROUNDED. Transformer operates on lib volt, 60 cycle current. GAS VALVE TRANSFORMER- Converts 110 volt, 60 cycle current to 24 volts for1 use wltn low voltage gaB valves. Must be mounted on Junction Pox. NOTE: If lino voltage gas valves are supplied, this transformer is omitted from the circuit and the valves are connected to tne same terminal on the relay as shown for the transformer. DISCONNECT SWITCH - Double pole, single tnrow switch should oe iruta-ied in tne line to tne installations wltnout a prewired panel. Ail power to tne boiler should be supplied tnrough the disconnect switen. 13673 ELECTRONIC CONTROL SYSTEMS 3 MASTER PANEL - Prewired, electronic control panel with protectorelay base has "Pilot" and "Automatic Gas Valve" lights and switches. Protectorelay wlcn alarm contacts to be mounted witnin the panel. SUB-PANEL - Panel with protectorelay base, pilot light and switch. Sub-panel(s) are factory assembled and wired to Master Panel as required. Protectorelay with als.rm contacts to be mounted within the panel. SPECIAL CONTROLS - When required, additional electrical safety controls thut act to limit temperature or presoure should be wired In series with limit control shown on applicable wiring diagrams. ALARM CIRCUIT: 'Jne M-H RaB^O relay(o) supplied with the boiler are provided with alarm contacts which close within approximately *5 seconds after pilot flame failure. These contacts energize the "Pilot Failure A*arm Light" on prewired panels. A remote alarm light or alarm boll may be connected in the system as Bhown in the two following diagrams. install or must make connections from tne panel alarm light to trie ulann contacts after the relay is Installed In tne master pane*. Alarm systems for Factory Mutual arid Factory Insurance Association controls are shown on wiring diagrams. MASTER PANEL RA890E RELAY | NC NO C \s V. TO AUXILIARY LINE VOLTAGE ALARM LIGHT (OR BELL) LINE VOLTAGE ALARM LIGHT ON PANEL REMOTE ALARM CIRCUIT WIRING FOR USE WITH PREWIRED CONTROL PANELS 13674 4 i i Cm f- O L> OUi o Sag 3 Cc(rfu,i aoh wH as fM3s /--v -^t: OH, o |i 00 *-i K -T, CO Ii- 4c*er: erfOFa-U-Jr <o^ 13675 OPERATING CONTROL LIM IT CONTROL w S-54 -4 09 O ALARM C IR CU IT WIRING DIAGRAM FOR USE WITH M .H . RA890E PROTFCTOREUAVS WITHOUT PREWIRED CONTROL PANELS 2 1 VOIT ALARM SYSTEM ELECTRONIC CONTROL SYSTEMS EG-0 AND EQ-OM SYSTEMS (WITHOUT PREWIRED PANELS) When the EG-0 ana EO-OM systems are used and line voltage (115 V) circuits are required to alarm terminals such as for PIA systems, the wiring and alarm terminals must be enclosed to meet the National Electric Code. If the relay Is not totally enclosed in an approved cabinet, tne following arrangement is necessary. A Junction box with open base is mounted as shown below to enclose the alarm terminals on the RA89OE relay. This does not interfere with servicing of the relay. All connections to alarm terminals must be made with Class 1 wiring to thiB Junction box. LEFT SIDE OF JUNCTION BOX MUST BE FLUSH WITH LEFT SIDE OF P.A890E RELAY ^SECURE JUNCTION BOXES TO MOUNTING BASE IN RELATIONSHIP SHOWN 13676 uU.. H O cafl ^j bow< cj oj s oz s ce o *-i <, j H hs oOi O o u z o o in r t? f' .si .>1,U)M C IK C P 1 T '" IK IN G P IU '.H W I TOIL USi; W ITH M H . p n o rrc ro n n .\Y S w ith o u t P i;r< 'irtrn co ntko i p m LIM IT CONTROL O P L IO T IN G CONTROL o- -- o-- Z --t i-> a: * cr u, z. f~ O cMr( c>*n* *r X^. W U* /- cc UHi W <oT> O UJ Q UJ "T* U ~ a*or cn >- cc -r cc H!_b -J Ou < o ^ cc 13677 ELECTRONIC CONTROL SYSTEMS 7 INSTALLATION RECOMMENDATIONS: Relays - The M-H RA-8yO Protectorelay snould ce mounted or. a wail or permanent fixture as close to tne boiler as possiole. On installations less prewired panel, it is recommended that all electrical power to tne boiler oe controlled oy a line disconnect switch located near tne relay (s). A separate disconnect switc.n is not needed when the prewired panel is used. All wiring should be completed to the relay sub-base or panel before installing the relay. When prewired panels are used, tne internal circuit jumper screw located on tne top side of tne blacx relay base must be removed if the Q-179 safety pilot is to burn continuously (not electrically ignitedj. Tms screw must oe removed before installing the relay(s) in tne prewired panel(s). Wiring - Ail wiring oetween boiler controls and relays snould oe protected. Wiring to Q-179 electronic pilot flame rod snould be M-H spec. 12yS-l or equivalent high temperature (35C P) wire. This wire may be spliced outside of tne neat zone to standard 14 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 De M-H spec. iOoi-4. Tms wire may also be spliced outside of tne heat zone to standard high voltage ignition cable. Wiring to pilots must be positioned and secured to prevent direct contact with burner and mixer tuces. CAUTION: Electronic relays and transformers snould not be located on inner jacket panels because higher ambient temperatures will decrease life of these components. Low voltage wiring (flame rod circuit) snould net be located m same conduit as line voltage wire. START-UP PROCEDURE: On initial start-up (or after long snutdown) it is recommended that air be eliminated from pilot lines before attempting start-up on EG-0 or EPG-0 systems witn 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 4 minutes, actuate reset level on relay (s) and proceed witn ligntmg sequence. MAINTENANCE: 1. All limit controls snould be checked for proper operation once a year. 2. Replace tube(s) in relay(s) once a year. Replacement tuoes should be obtained from Minneapolis-Honeyweil. In case of emergency replacement, regular tuces (witn proper number) may oe used; nowever, tney snould oe replaced as soon as possible with M-H pretested tubes. 13678 LLKCTRONIC COM'IMJ. sY.y;l\:. r Q-179A PILOT Q-179B MODIFIED PILOT Q-179A PILOT SYMBOLS Q-179B MODIFILD 13679 ELECTRONIC CONTROL "SYSTEMS rp. 3 VIGNITION ELECTRODE \(ELECTRIC IGNITION ONLY) 13680 ELlCVkG.n 1C COy/RUi, 10 INSTRUCT iO,NS FO:-? SHUTTING OFF AND LiG.-.T.nG manual ign.tion -------- 100% shutoff To SHUT OFF: I. Clime MnniKil .Shutoff Valve(s) "A" And Pilot v.i 1 vi' "B" . (. Open dine Switch Main GAS LINC TO LlC.nT: . .in 'mi.',' Manual J nuloff Vn 1 ve (b) "A", Pliot v.i I vihm) "11" Anc Line Switch Have Been Shutoi'f Air Ai i,i ms I d 1','iutl.oti Before Prner-nd Inn . - . |),V,, ,*| lot V.I I v. An) "B" . .1 . '.'ri'nn I-* 11111 k < >' On If t Pilot Line Va I ve And l.4;ni I'tlol . Ilf. Id Plunder "C" Fm One Minute. Hope.it For Add l ( 1 onal Pilots. I. A. In.ite Unset Ltvov(n) (Red Lover On Plot.'. I.i 1 re I a y ) a. Set Opera I 111K Control To Doaired Temperature Vi' Presell re . O, ('ill'll' litn 4 1 Nw 1 t f h . /. Opwn M.inuii I Shutoff Velve(n) "A". 1 st- INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING ELECTRIC IGNITION--100% SHUTOFF TO SHUT OFF: i . Oi'KN LINK SWITCH J. C.iOSK MANUAL SHL'fOFF VALVE(S) "A" AND i'iLOT VALVK(H) "d" . TO LIGHT: i. i'.,: od:,'K MANUAL f CUTOFF VAl.VKfS) "A", PILOT VAI V.CS) "ft", ANo LINK SWITCH HAVK flEKN SHUT o/K .'MK AT LEAST FIVK MINUTKS BEFORE PROCEED 1NO . <n'i .\ .*j ixvr vAi.vFts) "n" . d'ln.v.'i RESET U.VKH(S) (HKD LEVER ON i',i(iT.:t 'TOHKJiAY) . n.T (I.'f ItATiNG CONTROL TO DESIRED TEMPERATURE wK PR..SNURK . .'I. Oi-I.N MANUAL SHUTOFF VALVF.(S) "A". MAIN CAS siNE Jj II. Ci.O.M-. LINK swm.f AND WAIT APPROX, .'(0 SECONDS FOR FLAM.-: SAFETY HliUYii TO GO THRU SELF CHECK PRffCKDURf OILim< WILL NOT OPERATE AUTOMATICALLY. f.uM r LTi ST I/ii.'.i REV , l> 13681 ELECTRONIC CONTROL SYSTEMS U LIGHTING INSTRUCTIONS EO-OM SYSTEM FOR FIA 1. Make cure main manual shutoff valve and manual reset gaB valve have been shut off at least 5 minutes Defore proceeding. 2. Open alarm silencing BWltch and main power Bwitcn. 3. Open muln manual shutoff valve. 4. Push and hulu red button on pilot line valve and light pilot. When more than one pilot 1b provided, light pilots in sequence from left to right. 5. Reset all electronic relay flame failure switches. 6. Close main power switch. Delay timer 1b now energized requiring 5-minute waiting period before proceeding to Step 7. 7. Open manual reset safety shutoff valve. 8. Check, to see that mar/ual test valve(s) are open. 9. Close alarm Bllenclng awltch. 10. Adjust operating control to desired setting - boiler will automatically maintain this temperature (or pressure). SHUTDOWN INSTRUCTIONS TEMPORARY 1.- Open alarm silencing switch - this will prevent main burner operation. PERMANENT 1. Open main power switch. 2. Close main manual shutoff valve. 13682 ELECTRONIC CONTROL SYSTEMS 12 i POWER PILOT AUTO GAS VALVE LIGHTING INSTRUCTIONS 1. caution: be sure main GAS SHUTOFF VALVE(S) and manual pilot VALVE HAVE BEEN SHUT OFF AT LEAST 5 MINUTES BEFORE PROCEEDING. 2. TURN l*OWKH SWITCH ON. (PUSH RESET I.EVER IF PILOT OUTAGE OCCURRED.) It. OPEN MANUAL. PILOT VALVE. PI I AITS WILL LIGHT AUTOMATICALLY WHEN OPERATING CONTROL CALLS FOR HEAT. A. TURN PANEL PILOT SWITCH(ES) ON. (TURN ON PILOT SWITCHES ON SUB-PANELS FIRST WHEN PROVIDED.) PILOT LAMPS WILL LIGHT ONLY WHEN ALI. THE FOLLOWING CONDITIONS EXIST. 1. ALL SAFETY PILOTS ARE LIT. 2. OPERATING CONTROL "CALLING FOR HEAT." 3. ALL LIMIT CONTROLS INDICATE SAFE CONDITIONS. r VDrcrT BE SURE CONDITION CAUSING SAFETY y\r<c.ot. I lockout has been corrected, 5. SET OPERATING CONTROL TO DESIRED TEMPERATURE OR PRESSURE. <>. 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. NOTE: "PILOT" AND "AUTO GAS VALVE" LAMPS WILL CYCLE "ON" AND "OFr" WITH OPERATING CONTROL. PILOT FAILURE ALARM LIGHT * MK RICAN -Standard PLUMBING AND HEATING DIVISION 1 -ST-L.12G1 EV.A 13683 iLHCTRONIC CONTROL SYSTEMS Oas Pressure Switches (Where Req'd.) The Honeywell Ct^-A gas pressure swircr.es are normally supplim to meet ?IA requirements. Tne same model switm is used :'or corn "Hi'1 and "Lc1 pressure sensing; rowever. me metnoa c. connection is cifferent. Tne pressure svatcnes are located in tne mam; old piping as z.iovjh on page 17. Conneccions to me CD45A pressure svfircr. should ce maae as follows: `'Lc ' Pressure - use terminals narked R and W. Connecr gas line ro i/4 NPT tapping m dotcom of housing. Sec pointer cc scale division representing d inches water column uressure. This wil give safery sr.ucdcwn on low line pressure ci approximately 4 m oressure. "Hi'1 Pressure - use terminals marked R and A. Connect gas line to 1/4 NPT tapping m 'cotton of housing. S-:t pointer to scale division representing 5 inches water columr pressure. Tr.is wil give safety shutdown if gas manifold pressure to ourner exceeds d inches pressure. If venting of pressure switches is required, connect vent line to 1/3 NPT tapping in side of nousing. Operation - Tne above recommended pressure settings may nave tc oe adjusted sligntly tc prevent false shutdowns due to surges i line pressure. ELECTRONIC CONTROL SYSTEMS Law, POWER PILOT AUTO GAS VALVE LIGHTING INSTRUCTIONS 1. MAKE SURE MANUAL SHUTOFF VALVE(S) IS CLOSED AND MAIN POWER SWITCH IS OPEN FOR AT LEAST 5 MINUTES BEFORE PROCEEDING. 2. OPEN AUTO GAS VALVE SWITCH (AND ALARM INTERLOCK SWITCH IF USED). 3. OPEN MANUAL PILOT LINK VALVE. 4. PUSH AND HOLD RED BUTTON ON AUTOMATIC PILOT LINE VALVE AND LIGHT PILOT. WHEN MORE THAN ONE PILOT IS PROVIDED, LIGHT PILOTS IN SEQUENCE FROM LEFT TO RIGHT. 5. RESET PILOT FLAME FAILURE SWITCHES. 6. OPEN MANUAL SHUTOFF VALVE(S). 7. CLOSE MAIN POWER SWITCH, PANEL PILOT SWITCH(ES), AND ALARM INTERLOCK SWITCH. RESET BE SURE CONDITION CAUSING SAFET! LOCKOUT HAS BEEN CORRECTED. 8. CLOSE AUTO GAS VALVE SWITCH ON PANEL. BOILER WILL AUTOMATICALLY MAINTAIN TEMPERATURE OR PRESSURE SETTING OF OPERATING CONTROL. \ SHUTDOWN INSTRUCTION'S 1. OPEN MAIN POWER SWITCH. 2. CLOSE MANUAL SHUTOFF VALVE(3). NOTE: "PILOT" AND "AUTO GAS VALVE" LAMPS WILL CYCLE "ON" AND "OFF" WITH OPERATING CONTROL. PILOT FAILUR ALARM LIGH: AMKRir-ANvStandMrd PLUMBING AND HEATING DIVISION l-ST-15934 13685 ELECTRONIC CONTROL SYSTEMS v POWER _____^ PILOT AUTO GAS VALVE TM < J, 11IHTI NO ..I :> STRUCT IONS ]. MAKE SURE main manual shutoff valve and MANUAL RESET CAS VALVE HAVE BEEN SHUT OFF AT LEAST 5 MINUTES BEFORE PROCEEDING. 2. OPEN ALARM SILENCING SWITCH, POWER SWITCH Aim AUTO CAS VALVE SWITCI 3. OPEN MAIN MANUAL SHUTOFF-VALVE. 4. PUSH AND MOLD RED HUTTON ON PILOT LINE VALVE AND LIGHT PILOT, WHEN MOltE THAN ONE PILOT IS PROVIDED, LIGHT PILOTS IN SEQUENCE FROM LEFT TO RIGHT. 5. RESET PILOT FLAME FAILURE SWITCHES. G. CLOSE MAIN POWER SWITCH. DELAY TIMER IS NOW ENERGIZED REQUIRING 5 MINUTE WAITING PERIOD DEFORE PROCEEDING TO STEP 7. 7. OPEN MANUAL RESET SAFETY SHUTOFF VALVE. 8. CHECK TO SEE THAT TEST VALVE(S) ARE OPEN. OC-qc-t- XrctLOt- I BE SURE CONDITION CAUSING SAFETY LOCKOUT HAS BEEN CORRECTED. 9. CLOSE ALARM SILENCING SWITCH AND PANEL PILOT SWITCH(ES). 10. CLOSE AUTO GAS VALVE SWITCH ON PANEL. BOILER WILL . AUTOMATICALLY MAINTAIN TEMPERATURE OR PRESSURE / SETTING OF OPERATING CONTROL. j shutdown instructions 1. OPEN MAIN POWER SWITCH. ^ \ 2. CLOSE MAIN MANUAL SHUTOFF VALVE. NOTE: "PILOT" AND "AUTO GAS VALVE" LAMPS WILL CYCLE "ON" AND "OFF" WITH OPERATING CONTROL. PILOT FAILURE ALARM LIGHT AMKHitAN-.Standard PLUMBING AND HEATING DIVISION 1-ST-1G953 13686 ELECTRONIC CONTROL SYSTEMS 10-G-- I 5951 to cr u to o CO o cr K 02 V1 O O ou cr uo. 2 o cr 2 h" O U UJ 5 -1 ow 9i o* 0. 13687 ELECTRONIC CONTROL SYSTEMS P IP IN G AND CONTKOLS ARRANGEMENT FOR FM Co ID-G-15981 13688 ELECTRONIC CONTROL SYSTEMS P IP IN G AND CONTROLS ARRANGEMENT FOR 40-G-15982 13689 RA 890E RELAY Kon- 18 1. *Arrrr rti/r- rum non rnuxjskto im v itw.',Tic lam* anp hat r* ppi.rnti tv !A ikmimtxh tntr nirrffinjc or kxat /.uhk. s. At.'. fMpo hunt m m a<viipajic* rtm -nownirii nr rirr. natihiAL *i**tu n.r rtx rlA.1l l AXMlrr* itwtiiui. dir*At 1'INOItT- r-1--paiui, rim A-l- LIN* RttttR I --1 --l.tur LAMP -a--PIIiiT N1I11H Uj.-pil/rr inhivk* MRP IU1I VALW NttTV* L-S--KAIN TAr.Vr IJtP LL-run rAHA** tUM Ur MO/CO/I OVRRLY VOLTAOC MASTER PANEL WITH HONEYWELL RA09OE RELAY O (b 0) '"t) $>^ ' *) w r^} (;'i v ;) QOOOOO');Onno O i1 m *i i i ii Ilf U. r II ni PR SUB PANEL WITH HONEYWELL RAQ90E RELAY H-rHITT n-rru/j* COLOR CODF Or-'JRAXCT. pi-pikk PTr-PURPU: DBX[a--BdLlAuCkK W-BBOWX oPnB--CPRARKKQi BLUK GT-CPAY tRaP--RtaF^P G3A^OS'JrKiPDiNT30 * *UCt WMiTf SILASTIC CABLt .J sa*r ' u.ot RC` 13690 V 0 IT; *j ry >; S>! yi rv; Oi 2! *1 *0 <o 0 s * V\J s <i 01 <0 13691 2 PG -Q ELzcmou/c Cont/zol Srsrem-tcr<e/c Zo/v/r/nA/ - /00/o Snurofr 13692 13693 1 22 EPG-OM ELECTRONIC CONTROL SYSTEM - MANUAL IGNITION - 100% SHUTOFI FOR:- G-403 THRU G-4010 BOILERS 13694 U > 09 J J< oos oM > 23 13695 9 24 EPG--OM ELECTRONIC CONTROL SYSTEM - MANUAL IGNITION - 100% SHUTOFF FOR:- G--403 THRU G-4010 - BOILERS (FOR FIA) 13696 AMERICAN STANDARD PLUMBING & HEATING DIVISION 40 WEST 40TH STREET NEW YORK. N Y 10018