AFD Series Digital Heating Controller

Since 1944 364 Jackson Avenue ~ Bronx, New York 10454-1698 ~ Voice 718-665-6100 ~ Fax 718- Reg. U.S. Pat. Off. Manufacturers & Distributors of Electronic Heating & Smoke Limit Controls 364 Jackson Avenue Bronx, New York 10454-1698 718-665-6100 www.fuelwatchman.com AFD Series Digital Heating Controller Programming & Operation Manual For Steam or Hot Water Heating Systems Approved for use in New York City Under calendar # 44228 50C5 HEATING CONTROLLER Rev. 6 December 08, 2005

Thank you for selecting Fuel Watchman, a manufacturer of electronic heating and smoke limit controls since 1944! You have just purchased the most reliable and the best fuel conservation product on the market today. Once this control is properly installed, setup and used in conjunction with a 100 % operational and properly tuned boiler plant, we re sure it will bring you and your building years of service, comfort and fuel savings. Important notes about your Fuel Watchman Model AFD Series Controller: 1. The Controller is shipped from the factory with an insulating tab in the backup battery slot. Please REMOVE this insulating tab at the time of installation and before powering the unit to insure backup memory protection in the event of a power failure. 2. The AFD Series Controller is designed to also replace both Fuel Watchman Heating Controllers Model AFS for Steam (Use Mode #1) and AF1HR for Hot Water or Steam (Use Mode #2). The AFD Controller is 100% backwards compatible with both of these two (2) models. 3. Required Pressure Control, Aquastat Types & Clarification. a. In Mode #1 (Steam) controlling a STEAM HEATING SYSTEM ONLY, the AFD Series Controller uses a OPEN ON PRESSURE RISE Steam Pressure Control Type A. b. In Mode #2 controlling a STEAM SYSTEM the AFD Series Controller uses a CLOSE ON PRESSURE RISE Steam Pressure Control Type B. c. In Mode #2 controlling a HOT WATER HEATING SYSTEM, the AFD Series Controller uses a CLOSE ON TEMPERATURE RISE Aquastat. Why is Fuel Watchman Different? The Polarstat (outdoor sensor) is not just a thermostat or sensor. It s specifically designed to simulate your building and computes the heat loss determined by the outside weather conditions including wind chill factor. The Fuel Watchman Heating Control has an adjustment to fine-tune the Polarstat to your particular Building s heat loss. This can easily be done by increasing or decreasing the Heat Adjustment Knob located on the Fuel Watchman Control Panel. When the Fuel Watchman turns on your Heating System, your building is heated. At the same time, the Fuel Watchman Polarstat (Outside Sensor) is also heated internally. When your Heating System completes its heating cycle, the building and Fuel Watchman Polarstat starts to cool. The rate at which your building and Polarstat cools, (Heat Loss) is determined by several outside air factors. Temperature, Humidity, Wind Velocity (Wind Chill Factor) and Sun load all affect the rate that your Building and Polarstat cools down (Heat Loss). The Fuel Watchman uses this valuable information to determine the OFF period and to save fuel. Fuel savings are made possible by the completely automatic response to favorable weather changes that allow for smaller heat loads. 2

1. Signal Indicators a. Yellow - Power b. Red-Call for Heat c. Green - Heat Est. 2. Time and Program Schedule Display. 3. Control Status indicators. a. Day ON b. Night ON c. Morning Pick-Up d. Summer Mode e. A.M. f. P.M. g. Off Delay h. Run Limit 4. Keypad a. UP b. Down c. Copy d. DAY e. Day/Night f. CYCLE ADV g. PROGRAM h. CALIB. i. SET CLOCK j. TIMER k. BACK l. ENTER 5. One Button 6. Calibration Adjustment 7. Night Heat Temperature Selector 8. Day Heat Temperature Selector 9. Heat Adjustment Selector 10. Morning Pick-Up Switch 11. Manual/Automatic Switch 12. Summer/Winter Switch 1a, 1b & 1c 2 3a,b,c,d 4a - l 5 8 7 3e,f,g,h 6 9 10 11 12 AFD Controller Panel Front View 3

13 - Jumper JMP1 14 - Jumper JMP2 15 - Jumper W1 16 - Backup Battery (CR2032) 3 Volt 13 14 15 16 AFD Controller Panel Rear View 4

1. Signal Indicators - a. Yellow Indicates Summer/Winter Switch is in the Winter (ON) position and power is available to the control panel. b. Red Indicates Control has called for heat. Burner or pump should be on. c. Green Indicates heat has been established i. In STEAM Mode boiler Steam pressure has reached pressure control setting. ii. In Hot Water Mode Hot Water Circulating through heating loop or riser has reached return water Aquastat temperature setting (typically 20 F. below boiler supply water temperature). 2. Time and Program Schedule Display - a. Normal Mode - Displays current time in Summer or Winter mode indicated by flashing colon. b. Program Mode - i. Schedule Time. 1. s 1 to 8. 2. Day of Week (1=Mon, 2=Tue, 3=Wed, 4=Thu, 5=Fri, 6=Sat, 7=Sun). ii. Calibration offset range from 11 to +11 degrees F. iii. Time, Date & Year. (2000 2099) iv. Additional ON Time 0-60 minutes (Hot Water Mode ONLY) 3. Control Status indicators (Small Red LED s found on left side and right side of Program Display) a. Day ON Indicates control is in DAY ON Schedule and DAY HEAT SELECTOR temperature setting is being used. b. Night ON - Indicates control is in NIGHT ON Schedule and NIGHT HEAT SELECTOR temperature setting is being used. c. Morning Pick-Up Indicates morning pick-up is active. Morning pick-up is active when morning pick-up switch is in the ON position and the time of day is between 5:00 A.M. and 8:30 A.M. d. Summer mode Indicates the Summer/Winter Switch is in the Summer position and the control is OFF providing NO HEAT. e. A.M. Indicates the time of day is in the A.M. f. P.M. Indicates the time of day is in the P.M. g. Off Delay i. Steady ON - Indicates the control is in the OFF part of the Heat. Day and Night Heat Selectors are inoperative during this period. ii. Flashing Indicates a 15 second restart burner delay. Control will prevent burner from restarting until 15 seconds time has elapsed. h. On Limit Jumper selectable (JMP1 & JMP2) for NONE, 1, 1-1/2 and 2 hours. If selected, the controller will stop the burner or pump if the burner on-time exceeds the predetermined time limit. If the boiler or pump could not reach setpoint in the predetermine time limit, the burner or pump will be stopped until the next heat cycle and the indicator will flash until the Summer/Winter switch is toggled. 4. Keypad a. UP Increases current function in 1 second intervals. Hold UP key for 10 seconds and rate of change increases. b. Down - Decreases current function in 1 second intervals. Hold DOWN key for 10 seconds and rate of change increases. c. Copy Copies previous day schedule program cycles 1 through 8 to next day. COPY will be displayed during the operation. d. DAY In Program Schedule Mode, selects the day of week to program or view. (Mon=1, Tue=2, Wed=3, Thu=4, Fri=5 & Sat=6, Sun=7,). e. Day/Night In Program Schedule Mode selects DAY ON or NIGHT ON for time schedule displayed. f. CYCLE ADV In Program Mode selects one (1) of eight (8) programming cycles per day. g. PROGRAM Enters into the schedule programming mode. h. CALIB. Allows access to calibration adjustment and provides a temperature offset from 11 to +11 degrees F. i. SET CLOCK Function to set the clock, month/date and 4 digit year. j. TIMER Function to set the additional ON Time required after heat has been established in the building (Hot Water/Steam Mode #2 ONLY Disabled in STEAM Mode #1). 5

k. BACK When in a function (Program or Set Clock) it returns to the previous step. l. ENTER Saves new data. 5. One Button Provides one (1) cycle of heat regardless of outside air temperature. 1CYC will be displayed alternating with current time. Heat Established light must be OFF for One function to operate. Controller will return to normal operation after heat cycle is completed. 6. Calibration Adjustment When CALIB. Key (3h) is pushed, c and a number from 11 to 11 will be displayed. This number represents the current offset. Using a small screwdriver, rotate calibration adjustment to change the calibration offset. Hit ENTER Key to accept new value. Hit CALIB. again to return to NORMAL mode. 7. Night Heat Temperature Selector Set to provide heat during NIGHT ON program schedule. If no heat is required at night or during a NIGHT program schedule, turn knob to OFF position. This is provided for additional fuel savings at night. 8. Day Heat Temperature Selector Set to provide heat during DAY ON program schedule. Control will turn burner or pump on providing the outside temperature is below knob setting and the DAY ON indicator is lit. 9. Heat Adjustment Selector Adjusts amount of burner or pump off-time. On a #1 setting, the burner or pump will have a longer off-time generating LESS heat. On a #11 setting, the burner or pump will have a shorter off-time or generate MORE Heat. This provides a means to fine tune the control to the buildings heating requirements. 10. Manual/Automatic Switch a. Manual Position Burner or pump runs continuously with no control from panel or outside temperature. Yellow, Red & Green indicators have no meaning. Control panel is By-Passed. b. Automatic Position Burner or Pump will be controlled from controller for heat (this is the NORMAL Setting). 11. Morning Pick-Up Switch Provides additional boost of heat between 5:00 A.M. and 8:30 A.M. by reducing the offtime of the Burner or Pump. Morning pick-up is active when morning pick-up switch is in the ON position and the time of day is between 5:00 A.M. and 8:30 A.M. Indicator L.E.D. (3c) will display the current status of the Morning Pick Up function. 12. Summer/Winter Switch The ON and OFF switch for the AFD Controller. a. In the SUMMER Switch position, the AFD Controller will be OFF and will provide NO heat. The Correct time will be displayed and the SUMMER LED will be ON indicating the control is OFF. b. In the WINTER Switch position the AFD Controller will be ON and provide heat if necessary. SUMMER LED will be OFF. Initially, the display will indicate 4-S indicating Steam Mode #1 or 4-H indicating Hot Water/Steam Mode #2. Next, the display will indicate Software Version (F.W. use only). c. This switch can also be used for the following; i. To stop or end the heating cycle. 1. To end the heating cycle, move the Summer/Winter switch to the Summer position for 5 seconds, then back to the Winter position. ii. To stop or end the One operation. 1. To end the One, move the Summer/Winter switch to the Summer position for 5 seconds, then back to the Winter position. 13. Cabinet Door (Model AFD-C Complete only not shown here) Cabinet door is removable and is provided to protect the AFD Controller. It can be removed to make installation of the cabinet box easier. To remove, simply open cover door more than 90 from cabinet box and push cover in an upwards direction off the hinge pins. To replace, simply reverse the steps and slide the cover onto the hinge pins. 14. Cabinet Door Window (Model AFD-C Complete only not shown here) The window is provided to allow the operator to see the current time and status L.E.D. s without unlocking and opening the cover door. 15. Instructions & Wiring diagram in cover door (Model AFD-C Complete only not shown here). 16. Cabinet Hasp with customer provided lock, it will prevent unauthorized tampering of control and settings. 17. Terminal Wiring Board (Model AFD-C Complete only not shown here) A replaceable (Model # AF-PIB) terminal plug in board provided to plug the control panel in and to terminate control wires at the panel. 6

Setting The Clock: The Controller is shipped from the factory with the default time of 12:00, date 01/01 and year 2005. The Clock can be set in the Winter or Summer mode, but Summer Mode is recommended. To Change the controller clock; 1. Press black SET CLOCK function Button on Key Pad. 2. The current time will be displayed and the colon will stop flashing and remain on. 3. Using the gray UP or DOWN Buttons on the Keypad, advance the time forward or backward noting the A.M. and P.M. indicators on the top right. At first, the time will advance slowly. By holding the UP or DOWN button in for 10 seconds the rate of change will be faster. Advance the clock to the correct local time. 4. Press red ENTER Button to save the new time. 5. The display will automatically move to set the current MONTH and DAY. 6. Using the gray UP or DOWN buttons on the Keypad, advance the month and day to the correct date. By holding the UP or DOWN button in for 10 seconds the rate of change will be faster. 7. Press red ENTER Button on keypad to save the new Month and Day. 8. The display will automatically move to set the current YEAR. 9. Using the gray UP or DOWN buttons on the Keypad, advance the YEAR to the correct year. By holding the UP or DOWN button in for 10 seconds the rate of change will be faster. 10. Press red ENTER Button on keypad to save the new YEAR. 11. The display will automatically move back to the beginning and display current time entered in step #3. 12. Press black SET CLOCK function Button on Keypad to return to normal mode. Setting the timer (Mode #2 ONLY): The Controller timer is preprogrammed with a default setting of 15 minutes and will only function or can be changed in the Hot Water Mode (Mode #2). The timer can be changed as follows; 1. Press black TIMER Function Button on Keypad. 2. The current TIMER value is displayed. 3. Using the gray UP or DOWN Buttons on the Keypad, advance the value forward or backward. The timer value is in increments of 1 minute. At first the time will advance slowly. By holding the UP or DOWN button in for 10 seconds the rate of change will be faster. Advance the TIMER to the desired setting. 4. Press red ENTER Button to save new TIMER Value. Understanding the Program Schedule: The AFD Controller is shipped from the factory with the following default Program Schedule; To clarify this programming: Monday to Sunday 5:00 A.M. DAY ON Monday to Sunday 10:30 P.M. NIGHT ON The AFD Controller will be in a DAY ON Mode from 5:00 A.M. to 10:29 P.M. from Monday to Sunday. If the outside air temperature is at or below the DAY HEAT SELECTOR Setting (typically 55 F.), the AFD Controller will call for heat. At 10:30 P.M. the AFD Controller will be in a NIGHT ON Mode until 4:59 A.M. or until a DAY ON Program Schedule is 7

encountered. In NIGHT ON Mode, the AFD Controller will call for heat when the outside air temperature is at or below the NIGHT HEAT SELECTOR Temperature setting (typically 40 F.). If the NIGHT HEAT SELECTOR is set for OFF, the AFD Controller WILL NOT CALL FOR HEAT during this program schedule regardless of outside air temperature. You can program a DAY ON Schedule during the night and a NIGHT ON Schedule during the day if desired. DAY ON simply selects the DAY HEAT SELECTOR temperature setting for that time period programmed. NIGHT ON simply selects the NIGHT HEAT SELECTOR temperature setting for that time period programmed. Setting the Program Schedule: NOTE: Remember to set the NIGHT ON cycle time later than the DAY ON cycle time. Lets say you wish to change ONLY the weekend programming to the following; Saturday & Sunday 07:00 A.M. DAY ON 11:45 P.M. NIGHT ON 1. Press black PROGRAM Button on Keypad. 2. The program schedule for day 1 (Monday) will be displayed and the display colon for time will stop flashing and remain ON. The display will also alternate between Day / and program time for that day and cycle. 3. Using the white DAY Button on the Keypad, advance the day forward to DAY #6 (Saturday). 4. The current program time for DAY #6 (Saturday) #1 will be displayed. 5. Using the white CYCLE ADVance button on the keypad, advance to the desired cycle (1 8). For this example advance the cycle to CYCLE # 1. 6. Using the gray UP or DOWN Buttons on the Keypad, advance the program time forward or backward noting the A.M. and P.M. indicators on the top right. The time will advance in 15 minute intervals. At first, the time will advance slowly. By holding the gray UP or DOWN button in for 10 seconds, the rate of change will be faster. Advance the program time to the desired time. For this example advance the time to 07:00 A.M. 7. Using the white DAY/NIGHT Button on the keyboard, select DAY ON Mode or NIGHT ON Mode. For this example, select DAY ON Mode. 8. Press red ENTER Button to save new time. 9. Using the white CYCLE ADVance button on the keypad, advance to the next cycle (2 8). For this example, advance the cycle to CYCLE # 2. 10. Using the gray UP or DOWN Buttons on the Keypad, advance the program time forward or backward noting the A.M. and P.M. indicators on the top right. The time will advance in 15 minute intervals. At first the time will advance slowly. By holding the gray UP or DOWN button in for 10 seconds, the rate of change will be faster. Advance the program time to the desired time. For this example, advance the time to 11:45 P.M. 11. Using the white DAY/NIGHT Button on the keyboard, select DAY ON Mode or NIGHT ON Mode. For this example, select NIGHT ON Mode. 12. Press red ENTER Button to save new time. 13. Since the program for Sunday is the same as for Saturday, we will use the gray COPY Button. 14. Using the white DAY Button on the Keypad, advance the day forward to DAY #7 (Sunday). While still on DAY #7 (Sunday), press the gray COPY Button on the keypad once. The display will show COPY as the AFD Conroller will make an identical copy of Saturday s program into the current day (Day#7 Sunday). 15. Press black PROGRAM Button on the keypad to exit program function and return to normal mode. 8

FACTORY DEFAULT Settings: Should you need to return the FACTORY DEFAULT programming please follow these steps. One Operation 1. In Summer switch position, press and hold the black SET CLOCK, white DAY & white DAY/NIGHT Buttons simultaneously for three (3) seconds. The display will show U1xx indicating the Software Version. The Time, Date & Year will not be affected by the FACTORY DEFAULT RESET. 2. FACTORY DEFAULT SETTINGS are as follows; a. Sunday (Day #1) to Saturday (Day #7) i. #1 5:00 A.M. DAY ON ii. #2 10:00 P.M. NIGHT ON iii. #3, #4, #5, #6, #7 & #8 for Sunday to Saturday are erased and replaced with - - : - - indicating no time is programmed for this schedule/cycle. b. Additional ON Timer (Mode #2 ONLY) 15 Minutes c. Calibration Adjustment 0 F. 2. The One Function allows the operator to provide one (1) heat cycle. Once pushed, the control will call for heat. The display will alternate between the current time and 1cYc indicating the controller is in the One (1) Mode. a. Mode #1 (Steam System) i. The boiler will run until the operating steam pressure is reached determined by the Fuel Watchman Pressure control (OPEN on pressure rise TYPE A ). Once reached, the boiler will shut off. The control will return to normal mode and wait for the next heat cycle. To end the cycle, move the Summer/Winter switch to Summer for 5 seconds, then back to Winter. b. Mode #2 (Hot Water System) i. The boiler or pump will run until operating water temperature is reached determined by the Fuel Watchman AQUASTAT (CLOSE on temperature rise) located on the hot water return line from the building and additional on time programmed into the timer (0-60 minutes) has elapsed, it will shut off. The control will return to normal mode and wait for the next heat cycle. To end the cycle, move the Summer/Winter switch to Summer for 5 seconds, then back to Winter. c. Mode #2 (Steam System) i. The boiler will run until operating steam pressure is reached determined by the Fuel Watchman Pressure Control (CLOSE on pressure rise (TYPE B ) and additional on time programmed into the timer (0-60 minutes) has elapsed, it will shut off. The control will return to normal mode and wait for the next heat cycle. To end the cycle, move the Summer/Winter switch to Summer for 5 seconds, then back to Winter. OVER RUN Limit Protection In the event your boiler system develops an operating problem that would impair its ability to generate sufficient steam pressure (steam mode) or ample Supply Hot Water (H.W. mode) in a specified period of time, The Fuel Watchman AFD Controller will sense this condition and shut your boiler off by ending the heat cycle after a predetermined amount of time has elapsed. A RUN LIMIT EXCEEDED red status light on the AFD Controller will flash until the operator resets the AFD Controller and resolves the boiler system problem. The AFD 9

Controller will continue to operate normally, that is, the Controller will call for heat at the next heat cycle. When the burner &/or boiler problem is resolved, the OVER RUN limit indication can be reset by switching the summer/winter switch to summer for 10 seconds then back to winter. This feature will prevent excessive fuel consumption and extend the life of your Fuel Watchman AFD Controller. This option comes standard with every Model AFD Heat Controller and is FACTORY set for a 2 hour time limit. The Model AFD has 4 settings of NONE, 2 hours, 1-1/2 hours and 1 hour user selectable from the back of the control panel (Jumpers JMP1 & JMP2). Selecting OVER RUN Limit Protection: Figure #1 - Jumper JMP1(removed) & JMP2(removed) Position NO OVER RUN Limit Protection. Figure #2 - Jumper JMP1 (removed) & JMP2 (installed) Position - 1 Hour OVER RUN Limit Protection. Figure #3 - Jumper JMP1 (installed) & JMP2 (removed) Position - 1-1/2 Hour OVER RUN Limit Protection. Figure #4 - Jumper JMP1 (installed) & JMP2 (installed) Position - 2 Hour OVER RUN Limit Protection. (Factory Default) Mode #1 & Mode #2 Selection Jumper W1 selects the operational mode of the AFD Controller. Figure #5 W1 jumper REMOVED Mode #1. The L.E.D. display will briefly show a 4- S when the Summer/Winter Switch is turned to winter indicating the control is in Mode #1 for STEAM ONLY applications or to replace an older Fuel Watchman Model AFS heating control panel (2 light Control). NOTE: Leave the jumper on 1 pin to save for later use if desired. o An OPEN on Pressure RISE Pressure control can only be used in Mode #1. o Addition 0-60 Minute ON Timer is disabled in Mode #1 Figure #6 W1 jumper INSTALLED Mode #2. The L.E.D. display will briefly show a 4-H when the Summer/Winter Switch is turned to Winter indicating the control is in Mode #2 for STEAM, HOT WATER applications or to replace an older Fuel Watchman Model AF1HR heating control panel (3 Light Control). o A CLOSE on Pressure RISE Pressure Control (Type B ) or a CLOSE on Temperature RISE Aquastat (TYPE B ) must be used in Mode #2 o Additional 0-60 Minute ON Timer is ENABLED. Figure - 1 Figure - 2 Figure - 3 Figure - 4 Figure - 5 Figure - 6 Daylight Savings Time Changes The Model AFD Controller has a built in daylight savings feature standard. The controller time will automatically advance ahead 1 hour in the spring and back 1 hour in the fall provided the correct month, day and year are entered correctly. Sequence of Operation Conditions: Control calibrated and operational. Typical control Settings are as follows; Program Schedule 5:00 AM to 10:30 PM Monday through Sunday. Night heat selector set at 40 degrees. Day Heat Selector set at 55 degrees. 10

Heat adjustment set at #1. MANUAL/AUTOMATIC switch set to AUTOMATIC. SUMMER/WINTER switch set to WINTER. Morning P/U Switch OFF. 1. Mode #1 for Steam applications: This AFD Series Model controller in Mode #1 can only be used on Steam heating systems. This mode is also used to replace the F.W. Model AFS heating control panel with 2 indicator lights. With the above settings, between 5:00 AM and 10:30 PM, the FUEL WATCHMAN will respond to the outside temperature when it is at or below 55 degrees. If the temperature is at or below 55 degrees, the FUEL WATCHMAN will call for heat and the burner will turn on. Heat is now being generated. When a boiler pressure of preset level is reached, the FUEL WATCHMAN pressure control (OPEN on rise type A ) will open and the Green Heat Established Light will turn on. At this time, the FUEL WATCHMAN will cut off (RED LIGHT OFF) and the burner will turn off. The OFF PERIOD Light will turn on and indicate that the system is in the OFF PERIOD. The Day heat Selector and Night Heat Selector are disabled during this period. Attempts to change the Night or Day Heat selector settings during the off period will have no affect on the controller. The Green Heat Established Light will remain on until the Boiler steam pressure drops below the threshold setting (differential) of the Fuel Watchman Pressure Control. The FUEL WATCHMAN pressure control (OPEN on rise type A ) should be set at the system design pressure and the boiler operating pressure control should be set at least 1-1/2 pounds above the FUEL WATCHMAN pressure control setting. The Boiler operating pressure control will act as a high limit cut off or control the burner when the FUEL WATCHMAN is placed in MANUAL. 2. MODE #2: This AFD Series Model controller in Mode #2 is primarily used on HOT WATER heating systems or it can be used for steam heating applications. Mode #2 is also used to replace the F.W. Model AF1HR heating control panel with 3 indicator lights. Mode #2 requires a make on pressure rise TYPE B pressure control or make on temperature Aquastat control. a. Hot Water Applications (MODE #2): If the outside air temperature is at or below 55 degrees, the FUEL WATCHMAN will call for heat and the hot water heating pump will turn on. Heat is now circulating through the building. A reverse acting Aquastat sensor (CLOSES on temperature rise TYPE B ) is placed on the hot water return water line so when a preset hot water return temperature is reached, the FUEL WATCHMAN can be signaled. When the FUEL WATCHMAN has been signaled (Green Heat Established Light ON), the Additional ON TIMING will then start. This Additional ON TIMING can be preset to provide an additional ON TIME from 0 minutes up to 1 hour in 1 minute intervals (software U129 only). Once the preset additional time has elapsed, the pump will shut off completing the heat cycle. The FUEL WATCHMAN hot water return aquastat should be set at a temperature lower than the boiler hot water supply temperature. If the boiler hot water supply temperature is 200 degrees, the FUEL WATCHMAN aquastat should not be any higher than 180 degrees, or a setting of 20 degrees below the boiler hot water supply temperature. If this differential is less, there is a good possibility that the temperature of the return water would not reach the FUEL WATCHMAN aquastat setting and therefore, continuous burner operation will result. b. Steam Applications (MODE #2): When the AFD Series Controller is used on a STEAM SYSTEM, a reverse acting pressure control (CLOSES on pressure rise TYPE B ) on the main steam line or a reverse acting aquastat (CLOSES on temperature rise TYPE B ) on the return line (DRY RETURN ABOVE WATER LINE) must be used. A setting of no higher than 130 degrees on the return aquastat or about 1 pound on the reverse pressure control, should be a starting point and should be varied to suit the specific building requirements. When the temperature is at or below 55 degrees, the FUEL WATCHMAN will call for heat and the burner will turn on. Heat is now being generated. When the FUEL WATCHMAN pressure control or return condensate aquastat setting is reached, the FUEL WATCHMAN sensing device will close, signaling the FUEL WATCHMAN heat has been established. When the FUEL WATCHMAN has been signaled (Green Heat Established Light ON), the preset timer will then start. This additional ON TIMING can be preset to 11

provide an additional ON TIME from 0 to 60 minutes in 1 minute intervals (software U129 only). The burner will continue to run until the boiler pressure control setting is reached and will cycle to maintain a constant steam pressure. When the preset additional time has past, the burner will shut off completing the heat cycle. The boiler operating pressure control should be set at least 2 pounds above the FUEL WATCHMAN pressure control setting. This pressure control will act as a high limit cut off or control the burner when the FUEL WATCHMAN is placed in MANUAL. If the Fuel Watchman pressure control is set higher than boiler operating pressure control, continuous burner operation will result. The FUEL WATCHMAN will not call for heat again until the outside POLARSTAT senses that heat is required. The OFF period is affected by outside air temperature and wind chill factor. An OFF period of approximately two (2) hours can be expected when there is a mild day (about 55 degrees and no wind). The OFF period is significantly reduced when there is a cold windy day below 30 degrees. The Day & Night Heat Selectors are disabled during the OFF PERIOD. Turning the Day &/or Night Heat Selectors during this period will have no effect on the controller. Adjusting the HEAT ADJUSTMENT knob will vary the OFF period to FINE TUNE the control to the building s heat loss. A lower HEAT ADJUSTMENT number (#1) will increase the OFF period of the burner providing less heat. A higher HEAT ADJUSTMENT number (#11) will decrease the OFF period of the burner providing more heat. 1. Night Heat: The sequence of operation for the night cycle will be the same as for the DAY CYCLE except for the OFF period. The NIGHT CYCLE OFF period will be about 1-1/2 times longer than the day off cycle. With a setting of 40 degrees, the outside temperature must be at or below 40 degrees for the FUEL WATCHMAN to call for NIGHT heat. If the Night Heat Selector is set to OFF, there will be NO Night Heat regardless of outside air temperature. 2. Heat Adjustment Control: Adjusting the HEAT ADJUSTMENT knob will vary the OFF period to "FINE TUNE" the control to the building. A lower HEAT ADJUSTMENT number (#1 position) will increase the OFF period of the burner giving less heat. A higher HEAT ADJUSTMENT number (#11 position) will decrease the OFF period of the burner giving more heat. A suggested starting point would be a #3 position. Run the heating plant for several days. If the building is cold, increase the Heat Adjustment setting by 1. If the building is Hot, decrease the Heat Adjustment setting by 1. Allow the controller to run in automatic for another day or two. Repeat the operation until the desired comfort level is achieved. 3. Morning Pick-Up Switch: The morning pickup switch will provide an additional boost of heat between the hours of 5:00 AM and 8:30 AM (NOT ADJUSTABLE). This is equivalent to a #11 Heat Adjustment setting during the hours of 5:00 AM and 8:30 AM. 4. One Button: If an operating check of the boiler system is required, press the ONE CYCLE button and the burner will start even if the outside temperature is above the control settings. The L.E.D. Display will alternate the time and 1cYc to indicate the controller is in the 1 cycle mode. The FUEL WATCHMAN will then go through one (1) heating cycle then cut off and return to the last automatic setting. This procedure will help prevent the MANUAL SWITCH or AQUASTAT from being left ON. To stop or end the One operation, move the Summer/Winter switch to the Summer position for 5 seconds, then back to the Winter position. 5. Calibration Procedure: Periodic calibration is not required. Control calibration should be only performed by an experienced technician. Complete understanding of the AFD Series controller and its calibration procedure is required before calibration is attempted or unpredictable results could result. The warranty is void if the calibration procedure is performed incorrectly. Perform the following calibration procedure only if the AFD Series controller is calling for heat consistently at a temperature different from the Day or Night Heat Selector setting. Please note this difference in degrees Fahrenheit. To obtain accurate readings, the outside temperature MUST be measured at the Polarstat O.A. Sensor. Temperature readings taken from a local radio or TV station will be different from the actual temperature at your building. Press the black CALIB. Button once. The display will show a small c and the current offset value ranging from -11 to +11 degrees F. The (+) sign is not displayed. Using a small slotted screwdriver, insert the screwdriver into the black 12

calibration hole. Rotate the calibration adjustment counterclockwise to provide a negative offset and clockwise to provide a positive offset. Rotate the adjustment until the correct offset value appears on the L.E.D. display. Press the red ENTER key to save this value. Press black CALIB. button to exit calibration function. The Control is now calibrated to the new value. PROGRAMMING NOTES: 1. There MUST be a minimum of one (1) cycle programmed for each day and that cycle MUST be 1. You also can t leave blank cycles between two programmed cycles or start programming at cycle #6 for example. If there are 4 cycles to be programmed in a given day, #1, #2, #3 & #4 MUST be used in time order. 2. If cycle #1 is programmed for 6:00 A.M., the controller will not allow a programmed time before 6:15 A.M. for the remaining cycles. For example, if Day 1 #1 is programmed for 6:00 A.M., you must use a time later than 6:00 A.M. in cycle #2 - #8. 3. Care must be used when selecting the DAY ON or NIGHT ON modes. The controller does not automatically select DAY ON or NIGHT ON Mode. The operator MUST select the correct mode of operation. a. Example If the AFD controller is programmed for Day #1 #1 DAY ON @ 5:00 A.M. the operator must select NIGHT ON for the next #2. The operator must then select DAY ON for #3 if used. 13

Polarstat Sensor: The Polarstat consists of the following; Casing Cast Aluminum. Element Thermistor type. Composed of ceramic and carbon composition which is sensitive to slight temperature changes. Insulation Fiberglass to simulate the buildings insulation. Splice Box Simplified installation by just connecting two wires. Wiring Minimum 14 gauge wire should be used. Local electrical codes MUST be followed. The Polarstat is a device specifically designed to simulate your buildings heat loss. It consists of a highly sensitive material, insulation and an enclosure. Polarstat Sensor Location: The ideal location for the Polarstat would be a shady, northern part of the building subject to air movements. Shaft-ways are not recommended. NO false heating factors should be close to the Polarstat such as windows, doors, exhaust vents, lights, air conditioners, etc. The Polarstat must be at least 3 feet away from these heat sources. The Polarstat also must be more than 1 inch away from the building wall, because the wall retains heating and cooling factors over a long period of time. In case natural shade is not available, artificial shade can be made out of tin (or other similar material) to shield the Polarstat from the direct exposure to the sun. Figure 7 Wiring Diagram 120 VAC Neutral Hot Fuse 6-1/4 Amp Fuel Watchman Pressure Control Or Aquastat To Boiler or Pump Operating Control Common Normally Open Normally Closed Fuel Watchman A B C D E F F G H Com N.O. N.C. Polarstat O.A. Sensor Typically, Terminals E COM. & F N.O. are wired to thermostat terminals T&T, Burner Controls terminals T&T or in parallel (across) with the Hot Water Aquastat controller. 14

Deg F Ohms Deg F Ohms Deg F Ohms Deg F Ohms Deg F Ohms 5 6893Ω 13 5230Ω 21 4271Ω 29 3390Ω 37 2704Ω 45 2168Ω 53 1748.6Ω 61 1417Ω 69 1154Ω 6 6685Ω 14 5228Ω 22 4134Ω 30 3288Ω 38 2628Ω 46 2111Ω 54 1704.6Ω 62 1383Ω 70 1128Ω 7 6478Ω 15 5091Ω 23 4000Ω 31 3187Ω 39 2551Ω 47 2053Ω 55 1660.6Ω 63 1349Ω 71 1101Ω 8 6270Ω 16 4955Ω 24 3898Ω 32 3085Ω 40 2475Ω 48 1995Ω 56 1616.6Ω 64 1315Ω 72 1075Ω 9 6062Ω 17 4818Ω 25 3796Ω 33 3009Ω 41 2399Ω 49 1938Ω 57 1572.6Ω 65 1281Ω 73 1049Ω 10 5854Ω 18 4681Ω 26 3695Ω 34 2933Ω 42 2341Ω 50 1880Ω 58 1528.6Ω 66 1247Ω 74 1023Ω 11 5646Ω 19 4545Ω 27 3593Ω 35 2856Ω 43 2284Ω 51 1836Ω 59 1484.6Ω 67 1214Ω 75 997Ω 12 5438Ω 20 4408Ω 28 3492Ω 36 2780Ω 44 2226Ω 52 1792Ω 60 1450.8Ω 68 1180Ω 76 971Ω Table 1 - Fuel Watchman Standard Polarstat Resistance lookup Chart (Model AF-POL) Deg F Ohms Deg F Ohms Deg F Ohms Deg F Ohms Table 1 can be used to check Fuel Watchman Polarstat with a standard Volt-Ohm-Meter (analog or digital). The Fuel Watchman Polarstat requires no maintenance and trouble due to the Polarstat are rare. Generally, a loose connection or shorted wire to the polarstat presents the problem. With the power turned off and the heat control panel unplugged, measure the resistance between terminals G & H. When the measured resistance remains constant for a period of 5 minutes, the Polarstat temperature is stabilized and can be compared to Table 1 above. 15

Factory Default Programming MON(1) TUE(2) WED(3) THU(4) FRI(5) SAT(6) SUN(7) 1 2 3 4 5 6 7 8 5:00 A.M. 10:30 P.M. 5:00 A.M. 10:30 P.M. 5:00 A.M. 10:30 P.M. 5:00 A.M. 10:30 P.M. 5:00 A.M. 10:30 P.M. 5:00 A.M. 10:30 P.M. 5:00 A.M. 10:30 P.M. - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - - - : - - Blank chart for recording a custom program schedule MON(1) TUE(2) WED(3) THU(4) FRI(5) SAT(6) SUN(7) 1 2 3 4 5 6 7 8 16

Specifications: Operating Voltage 105 volts 135 volts AC 60 Hz @ 18 Watts max. DISPLAY: 0.54 RED L.E.D. Light Emitting Diode type. BOILER / PUMP CONTROL CONTACTS: SPDT rated for 6 amperes @ 125/250 A.C. - PILOT DUTY ONLY. SERVICE: Steam or Hot Water operation selectable by jumper W1. Over Run Protection selectable by jumpers JMP1 & JMP2. SERVICE ACKNOWLEDGEMENT: Input switch closure for Hot Water systems, input open for Steam Systems. Input should be isolated and not to exceed 120 VAC ONLY. PROGRAM SCHEDULE MEMORY: Eight (8) programmable cycles per day. Each day consisting of four (4) DAY ON times and NIGHT ON times. There is a maximum of 56 cycles. In addition to the 56 cycles, there is one (1) 0-60 minute timer adjustable in 1 minute intervals held in memory. The memory is EEPROM. Heat Settings: The DAY ON setting is user selectable from 50 F. to 65 F. in 1 F. increments, the NIGHT ON setting is user selectable from OFF, 15, 20, 25, 30 and 35 to 45 in 1 F. increments. TIME SETTINGS: The DAY ON and NIGHT ON are programmable over a 24 Hour Period. Timer: Programmable from 0 to 60 minutes in 1 minute steps. (Hot Water Mode only - Mode #2) RESIDENT PROGRAMMED SCHEDULE (Default Factory Programming) The controller is shipped with the following schedule: o DAY ON 5:00 A.M., NIGHT ON 10:30 P.M., This schedule is set for Monday through Sunday. o Timer set for 15 minutes Hot water Mode only. TIME CLOCK: The time clock utilizes a DS1307 Real Time Clock, with a 32.7 KHz Crystal. Time is displayed in 12 hour format with both A.M. and P.M. indicators. TIME CLOCK STABILITY ± 1 minute per month at 25 C. TIME CLOCK BATTERY BACKUP: a CR2032 lithium 3.0 Volt battery can maintain the clock with power off for up to 5 years in duration. INDICATORS: 3 large L.E.D. indicators display system status: yellow indicates that ac power is on and the internal DC supply and processor is functional. RED indicates that the boiler control relay is energized, and the system is calling for heat. Green indicates that the controller is receiving service acknowledgement, a contact closure for Hot Water across terminals C & D, a contact opening for Steam across terminals C & D. OUTDOOR TEMPERATURE SENSOR: Controller employs a standard Fuel Watchman Polarstat Model AF-POL. Controller is interchangeable with existing Polarstat sensors. Wiring to remote Polarstat must be in isolated conduit free from electrical power noise. Polarstat can be located up to 200 feet from controller. Wiring resistance drop must not exceed 5 ohms. OUTDOOR TEMPERATURE SENSOR ACCURACY: ± 1 F. or 2% whichever is greater CONTROL TEMPERATURE RANGE: 5 F. to 105 F. Below 5 F. will be interpreted as 5 F. and above 105 F. will be interpreted as 105 F. OPERATING TEMPERATURE OF CONTROLLER: 0 70 C. WIRING: All wiring 16 gauge (minimum) copper conductors only. 17

Fuel Watchman provides a One (1) Year Warranty on its products. Fuel Watchman Sales & Service, Inc. Fuel Watchman Sales & Service, Inc. Fuel Watchman Sales & Service, Inc. 1-Year Guarantee ALL F.W. products are guaranteed to be free from defects of workmanship, material and to function satisfactorily when properly installed, operated, programmed and maintained in accordance to F.W. instructions, for a period of ONE (1) year from date of purchase. F.W. will repair or, at its option, replace without charge, any F.W. product found defective upon examination at the factory if returned within the guarantee period, original purchase receipt is produced and transportation charges prepaid. Return shipment will be made transportation charges prepaid. This guarantee does not include any parts of the Fuel Watchman Control System which has been subject to misuse, neglect, accident, modification, tampering, programming changes and/or programming errors or damage caused by flood, fire or act of God. Furthermore, Fuel Watchman, or its authorizing representatives, are not liable for indirect or consequential damages or loss of any nature in connection with equipment sold by us. Fuel Watchman, N.Y. Fuel Watchman Sales & Service, Inc. Fuel Watchman Sales & Service, Inc. Fuel Watchman Sales & Service, Inc. Fuel Watchman Sales & Service, Inc. Fuel Watchman Sales & Service, Inc. Fuel Watchman Sales & Service, Inc. No data may be reproduced or duplicated without written permission from Fuel Watchman Sales & Service, Incorporated. 18