c0094 form 2. Project Identification Year: 2001 Project nº: 910

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1 1. History of processing of this form v1 Jul 19, 2001 by JN RBI 4 Stage Boiler Control. v2 Aug 7, 2001 by JN Packaging of BTC and 071 Sensors, and finalized mounting option, etc. v3 Aug 29, 2001 by JN Packaging of 080 Enclosure. 2. Project Identification Year: 2001 Project nº: Sources Project Concepts (c0093) of Authorization to make on July 19, 2001 Authorization to begin development on 4. A brief technical description of the project This Boiler Control is designed to operate four stages of heat to provide either outdoor reset with setpoint override, DHW or a setpoint temperature. 5. Project Name RBI BTC 4PA File and Revision v3 Spec RBI BTC 4PA 1 of 9 Initial Printed Feb 05, 2002

2 6. Inputs, Outputs, Decals and Indicators SENSORS and DEMANDS Boiler Out 071 Boiler In 071 Boiler Supply 071 / Tank sensor 071 Outdoor sensor 070 Heat Demand SWITCHES Installer / Advanced FACTORY Installer OUTPUTS, DECALS See drawing 910f v2 RBI BTC 4PA dated Aug 7, INDICATORS LCD COLOUR 7. Technical Data Literature Control Microprocessor control; This is not a safety (limit) control. Enclosure Enclosure D, black Noryl plastic Packaged weight Dimensions 4-3/4 H x 2-7/8 W x 1-7/8 D (120 x 74 x 48 mm) Approvals CSA C US, meets ICES & FCC regulations for EMI/RFI. Ambient conditions Indoor use only, -40 to 140 F (-40 to 60 C), < 90% RH non-condensing. Power supply 24 V ±10% 50/60 Hz 75 VA Pump / Stage Relay 120 V (ac) 5 A 1/6 hp, pilot duty 240 VA Other Relays 120 V (ac) 3 A 1/6 hp, pilot duty 240 VA Demands 20 to 260 V (ac) 2VA Sensors NTC thermistor, F (25 C ±0.2 C) ß=3892 included: 2 of Universal Sensor 071. Adjustments (See User Interface at Item 14 below) This electronic control is not intended for use as a primary limit control. Other controls that are intended and certified as limit controls must be placed into the control circuit where required. The installer must ensure that this control and its wiring are isolated and/or shielded from strong sources of electromagnetic noise. Conversely, this Class B digital apparatus complies with Part 15 of the FCC Rules and meets all requirements of the Canadian Interference-Causing Equipment Regulations. However, if this control does cause harmful interference to radio or television reception, which can be determined by turning the control off and on, the user is encouraged to try to correct the interference by reorienting or relocating the receiving antenna, relocating the receiver with respect to this control, and/or connecting the control to a different circuit from that to which the receiver is connected. File and Revision v3 Spec RBI BTC 4PA 2 of 9 Initial Printed Feb 05, 2002

3 8. Standards Regarding the Technical Data section above. The control must meet or exceed all load capacities with the stated control accuracy with max. sensor cable and at the stated temperature and voltage extremes. CSA C22.2 Nº 142-M Process Control Equipment CSA C22.2 Nº 15-M90 - Adhesive Labels UL Nº th edition - Industrial Control Equipment ICES and FCC regulations for EMI/RFI 9. Packaging contents Bulk pakaging of RBI BTC 4PA Bulk packaging of Universal Sensor 071 Bulk packaging of Universal Sensor Enclosure 080 (Separate P.O. from BTC units per box) 10. Options (purchased separately) Outdoor Sensor 070 System Sensor 071 / DHW Sensor 071 Note: 070 and 071 sensors may be purchased in packages of 10. File and Revision v3 Spec RBI BTC 4PA 3 of 9 Initial Printed Feb 05, 2002

4 12. Applications (See application drawings) A 4St-a MODE 1- Four stage boiler, piped in parallel with the system. Boiler demand comes from the zone valve end switches. The control operates the stages to provide a setpoint temperature at the Boil Out sensor. A 4St-b MODE 2- Four stage boiler, piped in primary / secondary. Additional system sensor is required for proper operation. Boiler demand is permanent. The control operates the stages to provide a setpoint temperature at the system supply sensor. A 4St-c MODE 3- Four stage boiler, for DHW generation. Boiler piped in parallel with the tank. DHW demand comes from a universal sensor 071. The control operates the stages to provide a setpoint temperature and maintain DHW tank temperature. A 4St-d MODE 4- Four stage boiler, piped in parallel with the system. Boiler demand comes from the zone valve end switches. The control operates the stages to provide outdoor reset. A 4St-e MODE 5- Four stage boiler, piped in primary / secondary. Additional system sensor is required for proper operation. Boiler demand comes from the zone valve end switches. The control operates the stages to provide outdoor reset. A 4St-f MODE 6- Two four stage boilers, piped in primary/secondary. Eight Stage boiler Control 258 stages the boilers to provide outdoor reset. The BTC provides boiler pump control and boiler purging. Stage outputs 2, 3 & 4 on the BTC are not used. Rotation must be turned off in the 258 control. A 4St-g MODE 5- Four stage boiler, piped in primary / secondary. Additional system sensor is required for proper operation. Boiler demand comes from the zone pump relays. The control operates the stages to provide the outdoor reset temperature at the system sensor. A DHW tank controlled by a pump provides a reset override (setpoint) demand whenever DHW generation is required. The control overrides the outdoor reset operation and provides the set target temperature setting. A 4St-h MODE 4- Four stage boiler, piped in parallel with the system. Boiler demand comes from the zone pump relays. The control operates the stages to provide the outdoor reset temperature at the Boil Out sensor. A DHW tank controlled by a pump provides a reset override (setpoint) demand whenever DHW generation is required. The control overrides the outdoor reset operation and provides the set target temperature setting. Other application comments: 13. Other function requirements (See notes regarding the application drawings) Q01 DIP switch is continuously read once per second. Q02 User (field) test override: Press and hold the up button in the View menu. After 1 sec the pump turns on. After 4 seconds Stage1 turns on. After 7 seconds Stage2 turns on. After 10 seconds Stage3 turns on. After 13 seconds Stage4 turns on. After 16 seconds Alarm turns on. Releasing the up button returns the control to normal operation. Q03 Calibration and factory test to test sensor and switch inputs and relay outputs. Q04 Sensor ranges for the 8 bit A/D converter are as follows. Outdoor: -50 to 200 F; Sup/Tank, Boil in, Boil Out: 14 to 266 F. Resolution is limited by the display to 1 F (1 C). General Q10 The alarm contact operates whenever selected control error messages are present. Q11 Pump contact operates based on demands, WWSD (reset), exercising, and purging. File and Revision v3 Spec RBI BTC 4PA 4 of 9 Initial Printed Feb 05, 2002

5 Q12 Q13 Q14 Q16 Q17 Q18 Q19 Q20 Q21 Purging by the pump is adjustable based on the T MIN setting after the demand is removed. The purge should last for a minimum of 20 secs unless T MIN = OFF. A STG MODE setting of "PId" allows the control to use the built-in staging routine which automatically calculates on and off time delays, inter-stage delays, and the interstage differential. A "P" setting allows the installer to manually adjust these settings. The maximum boiler target temperature does not exceed 230 F-1/2*differential. The fire delay for each stage is automatically detected as a change in T output of the boiler and is used to improve staging operation and to determine proper run times in the automatic staging mode. The Boil Out and Boil In provide the actual boiler T. The control changes operational coefficients based on boiler mass selected when automatic staging is used (i.e. on and off times, and interstage delays and interstage differential are be based on the boiler mass setting). The automatic staging operation when BOIL MASS = 2 should be like that of the 254 boiler control. A BOIL MASS = 1 setting should speed up the staging, and a BOIL MASS setting = 3 should slow down the staging. When using primary / secondary piping an additional sensor should be installed. This sensor measures the actual primary loop temperature. If the sensor is not installed, operation based on the Boiler Out sensor may occur. Control may be used to provide outdoor reset with setpoint temperature override, DHW or a setpoint temperature. Selectable via a Mode setting. Setpoint Operation (Mode = 1 or 2): Q30 The control operates the boiler stages to maintain the programmed BOIL TARGET temperature at the Boil Out or Sup sensor whenever a heat demand is present. The reset override (setpoint) demand is not functional. DHW Operation (Mode = 3): Q31 The control operates the boiler to maintain the programmed BOIL TARGET temperature at the Boil Out sensor whenever an internal DHW demand is present. Q32 A DHW demand is generated whenever the DHW sensor temperature drops TANK DIFF/2 below the programmed TANK TARGET and remains until the DHW sensor temperature rises TANK DIFF/2 above the programmed TANK TARGET temperature. Outdoor Reset (Mode = 4 or 5): Q33 The minimum and maximum settings are operating, not safety, limits. Therefore, the actual water temperature will cycle around these settings ± 1/2 differential. Q34 The Reset Ratio = (Boiler Design - Boiler Start) / (Outdoor Start - Outdoor Design) 4.0 and 0.0. Target Occupied Supply = Boiler Start + HC*(Outdoor Start - Actual Outdoor). Q35 WWSD occurs when the outdoor air temperature is warmer than the WWSD setting. (with ±1 F hysteresis) The demand pointers in the display turn on even during WWSD. Q36 The control operates the boiler stages to maintain the Target Occupied Supply (or BOIL MIN or BOIL MAX) at the Boil Out or Sup sensor whenever a heat demand is present and the control is not in WWSD. Q37 Whenever a reset override (setpoint) demand is present, the target water temperature is increased up to the selected boiler target temperature (unless reset operation already requires a higher target water temperature). Pump Only Operation: Q38 When Mode = 6 is selected, the control only operates the pump and boiler stage1. When the heat demand appears, the pump and stage1 are turned on. When the heat demand is removed, stage 1 turns off immediately, and the pump is turned off after purging. This mode of operation is used to connect a boiler staging control (such as type 258) to a BTC. The BTC provides pump control and purging of the boiler. The reset override (setpoint) demand is not functional. File and Revision v3 Spec RBI BTC 4PA 5 of 9 Initial Printed Feb 05, 2002

6 14. User Interface and Settings Items underlined are flashing. Items in italic are displayed as pointers. Access level 1 is installer and access level 0 is advanced. The advanced access level includes all items. Item Up/Down Access When Active Mode Range VIEW MENU ERROR 1 Always See section 15 Error and warning messages OUTDR 1 MODE = 4,5-60 to 190 F Outdoor air temperature BOIL TARGET 1 MODE 6 ---, 35 F to 226 F Target boiler supply BOIL SUP 1 MODE = 2,5 14 to 266 F Actual system supply temperature. BOIL OUT 0 MODE = 2,5 14 to 266 F 1 MODE = 1,3,4,6 Actual boiler supply water temperature BOIL IN 0 Always 14 to 266 F Actual boiler return water temperature BOIL T 0 Always -99 to 252 F Temperature differece between supply and return TANK 1 MODE = 3 14 to 266 F Actual temperature at the tank sensor BOIL ON 0 Always 0 to 999 Accumulated runtime of boiler. ADJUST MENU MODE Adjust from 1 1 Always 1 <> 2 <>...<> 5 <> 6 Application which the control is being used in. Refer to applications in section 12. STGMODE Adjust from PId 0 MODE 6 PId <> P Selection for automatic or user settings control of staging operation. BOIL TARGET Adjust from 180 F 1 MODE 6 OFF, 70 to 220 F Boiler Setpoint target temperature. TANK TARGET Adjust from 130 F 1 MODE = 3 OFF, 70 to 190 F Storage tank / Pool temperature. TANK DIFF Adjust from 3 F 0 MODE = 3 2 to 10 F Tank differential. OUTDR START Adjust from 70 F 1 MODE = 4,5 35 to 85 F Outdoor starting temperature. OUTDR DSGN Adjust from 25 F 1 MODE = 4,5-60 to 32 F Design outdoor air temperature used in the heat loss calculations. BOIL START Adjust from 70 F 1 MODE = 4,5 35 to 150 F Starting temperature of the boiler heating curve at outdoor starting temperature. BOIL DSGN Adjust from 180 F 1 MODE = 4,5 70 to 220 F Design heating supply water temperature. BOIL MAX Adjust from 210 F 0 MODE to 225 F, OFF Maximum boiler target supply at any time. BOIL MIN Adjust from 140 F 0 MODE 6 OFF, 80 to 180 F Minimum boiler target supply water temperature. BOIL MASS Adjust from 1 1 MODE 6 AND STGMODE = PId 1 <> 2 <> 3 Boiler s thermal mass.(1=lite, 2= Med, 3 = Hevy) DIFF Adjust from 20 F 0 MODE 6 2 to 42 F Boiler differential. STG DIFF Adjust from 4 F 0 MODE 6 AND STGMODE = P 0 to 10 F Boiler interstage differential. ON DLY Adjust from 1:00 0 MODE 6 AND STGMODE = P 0:30 to 8:00 minutes Interstage delay to turn on between stages OFF DLY Adjust from 0:30 0 MODE 6 AND STGMODE = P 0:10 to 4:00 minutes Interstage delay to turn off between stages File and Revision v3 Spec RBI BTC 4PA 6 of 9 Initial Printed Feb 05, 2002

7 MIN ON Adjust from 0:30 0 MODE 6 AND STGMODE = P 0:10 to 5:00 minutes Minimum on time of each stage. MIN OFF Adjust from 0:50 0 MODE 6 AND STGMODE = P 0:30 to 5:00 minutes Minimum off time of each stage. T MIN Adjust from 5 F 0 Always 2 to 20 F, OFF Determines when to stop the purging. WWSD Adjust from 70 F 1 MODE = 4,5 35 to 100 F, OFF System warm weather shut down during Occupied. Units Adjust from F 1 Always F <> C File and Revision v3 Spec RBI BTC 4PA 7 of 9 Initial Printed Feb 05, 2002

8 15. Error handling IF Out sensor error THEN Assume an outdoor temperature of 32 F. IF Boil Out sensor error THEN IF Sup sensor present AND no Sup sensor error THEN Run Boiler using Sup sensor ELSE IF Boil In sensor is present AND no Boil In sensor error THEN Run Boiler using Boil In sensor ELSE Hold boiler off IF Sup/Tank sensor error THEN IF MODE 3 THEN IF Boil Out sensor present AND no Boil Out sensor error THEN Run Boiler using Boil Out sensor ELSE IF Boil In sensor is present AND no Boil In sensor error THEN Run Boiler using Boil In sensor + T ELSE Hold boiler off IF MODE = 3 THEN Hold boiler off IF boiler In sensor error THEN Continue operation, use a 20 second boil pump purge time IF EEprom read error (at power up) THEN Hold boiler off until settings are verified Error and Warning messages These messages are a hidden item of the VIEW menu that only comes up when the control detects incorrect installation, control malfunction, or sensor errors. The messages are displayed by flashing the appropriate item (if applicable) and 'Shr' or 'OPn'. (e.g. OUTDR Shr). Non sensor errors are displayed based on an error number. (e.g. E01) When an error or warning message is detected, the temperature displayed in the VIEW Menu will show 'Err'. The error / warning display is latched only once the control has detected the error or warning three consecutive passes. In order to clear a latched warning or error, the problem must be solved and any button pressed or a new, higher ranking error must occur; In this way the most recent message is latched until read by the installer. If an error is present, the user can still view items, however, after 10 seconds the display will timeout to the error message again. Adjustments are still accessible with no special timeout. Rank Description Number Type Notes 0 E01 Err EEprom read error at power up 1 BOIL OUT SHr Boiler Out Sensor short 2 BOIL OUT OPn Boiler Out Sensor open 3 BOIL IN SHr Boiler In Sensor short 4 BOIL IN OPn Boiler In Sensor open 5 SUP SHr Supply Sensor short 6 SUP OPn Supply Sensor open (Mode = 2, 5) 7 OUTDR Shr Outdoor Sensor short 8 OUTDR OPn Outdoor Sensor open (Mode = 4, 5) 9 TANK SHr Tank Sensor short 10 TANK OPn Tank Sensor open (Mode = 3) File and Revision v3 Spec RBI BTC 4PA 8 of 9 Initial Printed Feb 05, 2002

9 16. Other All wiring is provided through 24 pin Molex connector (type 5566 ( )) on back of control Male connector (type 5557R ( )) supplied by boiler manufacturer Mounting bracket (if required) provided by boiler manufacturer Two labels used for back of control. standard tektra BTC label used for front of control. (RBI using clear Overlay) Wiring cover not required. DIP switch to be at back of control. Buttons to be 1/8" long. File and Revision v3 Spec RBI BTC 4PA 9 of 9 Initial Printed Feb 05, 2002