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- Armstrong Fluid Technology

1. l Check water piping Check system piping for leaks If found shut down the boiler and repair immediately See WARNINGS on pages 38 and 39 startup regarding failure to repair leaks Vent any remaining air from the system using manual vents Air in the system will interfere with circulation and cause heat distribution problems and noise ECO PAK Installation amp Operation Manual BOILER Q Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Q Check gas piping 1 Check around the boiler for gas odor following the procedure on page 30 of this manual connecting gas supply piping If you discover evidence of any gas leak shut ale down the boiler at once Find the leak source with a bubble test and repair immediately Do not start the boiler again until corrected Failure to comply could result in severe personal injury death or substantial property damage Q Propane boilers verify conversion 1 Verify propane conversion has been completed per the Propane Conversion instructions DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring n
2. LOW VOLTAGE CONNECTION BOARD LINE VOLTAGE JUNCTION BOX LOW VOLTAGE WIRING KNOCKOUTS LINE VOLTAGE WIRING KNOCKOUTS Thermostat 1 Connect the room thermostat or end switch isolated contact only to terminals R and W as shown in FIG 8 3 2 Install the thermostat on the inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunlight or fireplaces 3 Thermostat anticipator if applicable a If connected directly to boiler set for 0 1 amps b If connected to relays or other devices set to match total electrical power requirements of connected devices See device manufacturers specifications and thermostat instructions for details Flow switch optional 1 A flow switch is used to guarantee flow through the boiler before allowing it to fire The flow switch must be installed in line with the boiler 2 Connect these terminals to the normally open contacts on the flow switch FIG 8 3 ECO PAK Installation amp Operation Manual BOILER Armstrong Integrated Control AIC 1 An external control may be connected to control either the firing rate or the set point of the boiler Connect the Room Thermostat Zone Control terminals to the enable output of the external control and connect the 0 10 vdc terminals to the 0 10 vdc output of the external control 2 Make sure the ground terminal is connected to the ground output terminal of the external
3. UP DOWN PREVIOUS NEXT e Press to change boiler water temperature set point during normal operation e Press to change displayed data values in Menu Mode e Press to navigate through menu listing in Menu Mode Press to toggle display during normal operation to show outlet and return temperatures fan speed and flame signal e Press to toggle between digits when entering access code or between hour minutes etc when entering date and time Page 66 of 118 ECO PAK BOILER 11 Operating information continued Access modes User The user can adjust space heating target temperature by using the UP and DOWN buttons FIG 11 1 at any time during normal operation By entering the USER code 0704 the user can also change temperature units time and date In User Mode the following parameters can be viewed but not changed Boiler model number Software version Total operating hours Total cycles Installer Most parameters are available only to the installer accessible only by entering the installer access code see the ECO PAK Boiler Service Manual Saving parameters reference the Parameter Table in the ECO PAK Boiler Service Manual To save parameters and exit programming Press the ENTER RESET button To keep parameter settings only for a current operating cycle Press the MENU EXIT button 3 times after making all desired parameter changes To enter a parameter and continue programming
4. 1 9 Heating Circulation System The ECO PAK MBS is designed to be the building s primary heat source lts intelligent control system is able to modulate its heat output and system supply temperature in relation to varying external conditions No other controls except thermostatic radiator valves or zone control valves if required are necessary for most applications The ECO PAK MBS can feed radiators fan convectors underfloor heating or a mixture of all three However zone pumps and low loss headers would be required when circuits with differing temperature requirements are installed Page 11 of 118 ARMSTRONG g Highest efficiencies can be gained when the system is designed to run in condensing mode To achieve this return temperatures should be below 130 F 55 C Ideal supply and return temperatures are therefore 150 F 65 C 115 F 46 C Radiators underfloor heating systems as well as air handling units and other constant temperature heat emitters can all be sized to operate efficiently at these temperatures The ECO PAK MBS should not be used to generate domestic hot water and should only be used in sealed LTHW heating systems 1 10 System Water Quality Warning Lowering water ph levels and changes in water temperature replacing conventional boilers with condensing boilers can cause scaling being freed from metal surfaces and clogging the system In existing systems where the non condensing boilers have been
5. Inspect ignition and flame sense electrodes 1 Remove the ignition and flame sense electrodes from the boiler heat exchanger access cover 2 Remove any deposits accumulated on the ignition flame sense electrode using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones 3 Replace ignition flame sense electrode making sure gasket is in good condition and correctly positioned Check ignition ground wiring 1 Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip 2 Verify all wiring is in good condition and securely attached 3 Check ground continuity of wiring using continuity meter 4 Replace ground wires if ground continuity is not satisfactory Check all boiler wiring 1 Inspect all boiler wiring making sure wires are in good condition and securely attached Page 72 of 118 1 2 Maintenance continued Check control settings 1 Set the control module display to Parameter Mode and check all settings See Section 1 of ECO PAK Boiler Service Manual Adjust settings if necessary See Section l of the ECO PAK Boiler Service Manual for adjustment procedures 2 Check settings of external limit controls if any and adjust if necessary Perform start up and checks l Start boiler and perform checks and tests specified in Section 10 Start up 2 Verify cold fill pressure is correct and that operating pressure does not go too high Ch
6. Press the MENU EXIT button 1 time to return to the parameter listings press again to return to the menu listings Remember to press the ENTER RESET button when finished programming in order to save the changes made See the ECO PAK Boiler Service Manual for a detailed description of parameters and access modes Page 67 of 118 Installation amp Operation Manual ECO PAK BATES Installation amp Operation Manual 11 Operating information Status Display Screens By using the Previous Next P arrow keys on the control module display panel you can navigate through the eight 8 display screens Each screen will contain two 2 viewable items The following is a description of the individual items and what they can display Screen Display shows The unit has been turned OFF by the Enter Reset button on the BLR OFF control module display panel The unit has not received a call for heat from a remote thermostat Standby nor has it received a call for heat from a DHW thermostat The unit has met the water temperature set point but is still receiving a call for heat from either a remote thermostat or a DHW thermostat Prepurge The unit has initiated a 10 second purge period on a call for heat an The unit has begun a 5 second spark period to ignite the main Ignition burner SH Rate The unit has fired and is running at the displayed percentage The call for heat has been satisfied and the unit ru
7. 3 SHART to start boiler FOR VIEVWING ONLY E wanna f systemowe mam sere Te 1 4 12 BYPASS PID SETUP B y PAS E ALYE PIO SETU E 1 Enter the PID Proportional Gain 2 Enter the PID Integral Time Pai 3 Enter the PID Derivative Time FOR VIEVWING ONLY E mamimeno f systemowe mam sere Te Page 96 of 118 ARMSTRONG g 1 4 13 BAS SETUP 1 4 14 CLOCK SETUP BAS SETUP SCREEN CLOCK SETUP FOR YIEMNGS ONLY FOR VIEVMING ONLY E mammen systemowe 4 manse T LEN wangu systemove mam sere EI 1 4 15 SCHEDULE SETUP MES ara lEM Sr oe E SETUR E Jo OU fis po DO AL FOR VIEVWING ONLY manen systemovr mamserue fl INSTALLER DISPLAYS Installer Displays include system displays alarm management displays trend displays and level 1 setup displays To access level 1 setup displays the user is required a level 1 password 2 1 System Displays See previously in the Operator Displays 2 22 Alarm Management Displays See previously in the Operator Displays 2 33 Trend Displays See previously in the Operator Displays 2 4 Level 1 Setup Displays Page 97 of 118 ARMSTRONG ly Most of the level 1 setup displays are almost the same as the level 1 setup displays except that the user can press Save button to save changed values to the system factory defaults on each setup display screen However some different displays are listed in the following table 2 4 0 LEVEL 1
8. Table 3A on page 14 of this manual Vertical termination installation d 1 Determine the best location for the termination kit see FIG 5 4 2 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 15 of this manual f Figure 5 4 Concentric Vertical Termination g h COMBUSTION AIR kit 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST 2 ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROOF b Figure 5 5 Do Not Install U Bent to Rain Cap Page 46 of 118 NOTICE 3 You must consider the surroundings when terminating the vent and air Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants Avoid possibility of accidental contact of flue products with people or pets Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas Do not terminate above any door or window Condensate can freeze causing ice formations Loc
9. temperature rise limiting temperature The outlet temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 185 F the unit will reduce the fan speed If the outlet water temperature exceeds 195 F the control will shut the unit down until it cools off The control module monitors the flue temperature by a sensor located in the flue exhaust If the flue temperature exceeds 215 F the control will reduce the maximum fan speed If the flue temperature exceeds 240 F the control will shut the unit down The unit will restart automatically once the flue temperature drops 25 F and the minimum off time has expired The control monitors the temperature difference between the inlet and the outlet sensor If this difference exceeds 55 F the control will reduce the fan speed If the temperature difference exceeds 60 F the control will shut the unit down The unit will restart automatically once the temperature difference has dropped below 55 F and the minimum off time has expired Freeze protection DO NOT install the boiler in a room likely to freeze The following integral feature of the control module provides some protection for the boiler only not for the system The control module provides freeze up protection as follows when the boiler water temperature drops below 45 F Below 45 F the boiler and system pumps operate constantly Below 37 F the boiler turns on Boi
10. 4000 2 Enter the PID Integral Time 3 Enter the PID Derivative Time FOR VIEWING ONLY EL mannen f sysTemovr MamSeTUP 2 4 13 BAS SETUP BAS SETUP SCREEN 1 Enter the BAS Protocol 21 Enter the BAS Address 3 Enter the Baud Rate 4 Confirm that the proper interface card is installed 5 Default Settings E mammeno 4 systemowe Y wmamserue AE Press BYPASS SETUP button from LEVEL 1 MAIN SETUP to bring up this screen Bypass valve can be enabled if it is installed in the system Enter the flow set point per boiler When the flow is lower than this value bypass valve opens and tries to maintain the flow above the set point Enter the default value of bypass valve When the flow sensor fails the bypass valve will open at this value Enter the time to keep lead boiler running when the bypass valve is 100 open Enter the time to keep duty pump running when the bypass valve is 100 open Press Restore button to retrieve bypass valve setup values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen This screen is for viewing only 1 2 Press bottom right navigation button from BYPASS VALVE SETUP to bring up this screen Touch the buttons on the menu at the bottom to bring up the desired screen From LEVEL 1 MAIN SETUP press on BAS Setup to set the protocol used to communicate between the ECO PA
11. Adjust lockup regulator for 14 inches w c maximum Propane Gas ECO PAK boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 12 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Pipe sizing for propane gas 1 Contact gas supplier to size pipes tanks and 100 lockup gas pressure regulator Propane Supply Pressure Requirements l Adjust propane supply regulator provided by the gas supplier for 14 inches w c maximum pressure 2 Pressure required at gas valve inlet pressure port e Maximum 14 inches w c with no flow lockup or with boiler on e Minimum 8 inches w c with gas flowing verify during boiler startup A WARNING Ensure that the high gas pressure regulator is at least 6 10 feet upstream of the appliance Page 51 of 118 ECO PAK n Ol EE Installation amp Operation Manual 7 Gas connections Table 7A Natural Gas Pipe Size Chart Norinal Single Unit SB pa Natural Gas Pipe Capacity Chart Size Inches Length of Pipe in Straight Feet for 1 2 PSI CE 20 30 40 50 60 70 80 80 100 125 150 175 200 923 050 700 vor 090 ese soa ore are aa 6 2 1 2 4460 3610 3100 2720 2460 2310 2100 19
12. The control module regulates blower speed to control the boiler firing rate The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow How the control module operates The control module receives input from boiler sensors and external inputs The control module activates and controls the blower and gas valve to regulate heat input and switches the boiler on and off as needed The user programs the module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Control inputs and outputs Room thermostat zone control This input tells the boiler to provide water for space heating 0 10V input set point or power The ECO PAK boiler will be controlled by the Armstrong Integrated Control using a 0 10 vdc signal Temperature control Modulation The ECO PAK boiler is capable of modulating its firing rate from a minimum of 20 to a maximum of 100 Gradient limiting If during operation of the boiler the outlet water temperature is rising too quickly the control will reduce the firing rate to its lowest setting Flame current support To prevent nuisance shutdowns when the boiler is firing at minimum rates the control will increase the firing rate when the flame signal drops too low ECO PAK entice Installation amp Operation Manual Protection features Outlet temperature flue and
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14. 14 Repeat the step 13 Set all the boilers in AUTO 100 15 The ECO PAK MBS will start up automatically Page 111 of 118 ARMSTRONG ul 6 0 Pump Operating Instructions OPERATION STARTING PUMP Ensure that the pump turns freely by hand or with some gentle mechanical help such as a strap or Allen key in coupling bolt Ensure that all protective guarding is securely fixed in position The pump must be fully primed on start up Fill the pump casing with liquid and rotate the shaft by hand to remove any air trapped in the impeller any air trapped in the casing as the system is filled must be removed by the manual air vent in the seal flush line ENSURE ENTRAINED AIR IS REMOVED PRIOR TO STARTING THROUGH THE AIR VENT ON THE SEAL FLUSH LINE OPEN VENT UNTIL CLEAR OF AIR Pumps are fitted with seal flush vent lines piped to the pump suction area When these units operate residual air is drawn out of the pump towards the suction piping Bump or energize the motor momentarily and check that the rotation corresponds with the directional arrow on the pump casing To reverse rotation of a three phase motor interchange any two power leads Start the pump with the discharge valve closed and the suction valve open then gradually open the discharge valve when the motor is at operating speed The discharge valve may be cracked or open slightly at start up to help eliminate trapped air When stopping the pump Close the discha
15. ARMSTRONG ul 4 0 Boiler I amp O Manual ENERGY STAR ARMSTRONG INSTALLATION AND OPERATING INSTRUCTIONS ECO PAK BOILER Installation amp Operation Manual Models 210 285 A WARNING This manual must only be used by qualified heating installer servic technician Read all instructions including this manual and th ECO PAK Boiler Service Manual before installing Perform steps i the order given Failure to compl could result in severe persona injury death or substantial propert damage Save this manual for future reference Page 21 of 118 HAZARD DEFINITIONS 2 PLEASE READ BEFORE PROCEEDING 3 THE BOILER HOW IT WORKS 4 6 RATINGS T 1 DETERMINE BOILER LOCATION Provide Clearances 8 Provide Air Openings to Room 10 Flooring and Foundation 10 Residential Garage Installation 10 Vent and Air Piping 10 Prevent Combustion Air Contamination 10 Corrosive Contaminants and Sources 11 Removing a Boiler from Existing Common Vent 11 2 PREPARE BOILER Gas Conversions 12 3 GENERAL VENTING Direct Venting Options 13 Install Vent and Combustion Air Piping
16. Code Page 31 of 118 ECO PAK BOILER 2 Prepare boiler Gas conversions For a boiler already installed you must turn off gas supply ie off aes and allow boiler to cool before proceeding You must also completely test the boiler after conversion to verify performance as described under Start up Section 10 of this manual Failure to comply could result in severe personal injury death or substantial property damage You must install a propane orifice to operate the ECO PAK boiler on propane gas Verify when installing that the orifice size marking matches boiler size Table 2A 1 Remove the top and front access covers from the unit no tools required for removal 2 Remove the three screws securing the gas valve to the venturi FIG 2 2 3 Locate the propane orifice disk from the conversion kit bag Verify that the stamping on the orifice disk matches the boiler size see Table 2A Place the orifice into the black rubber grommet in the side of the gas valve and secure in the valve FIG 2 2 4 Reposition the gas valve against the venturi and replace the screws FIG 2 2 securing the valve to the venturi 5 After installation is complete attach the propane conversion label in the conversion kit bag next to the boiler rating plate Attach the LP caution label in the conversion kit bag to the left side of the unit in the lower left corner 6 Replace the top and front access covers Table 2A LP Co
17. HIGH VOLTAGE INTEGRATED CONTROL JUNCTION BOX BOX DEPICTS PC Co B OPTIONAL ITEMS INTERFACE E an an AS CONNECTION BOARD Q are AUX LA Iw o w NSI en Q une O A DEVICE PILOT SUPPLY Y 3 m AUX DEVICE PY lt PROVING i s GAS o o PRESSURE a ON OFF SWITCH BK een E 5 FLOW o o 5 O SWITCH E lt g o BELL JUMPER EA CN2 9 x PR ALARM CONTACTS eee RUN TIME CONTACTS ee THERMOSTAT W aT A BL THERMOSTAT 95 O ZONE Pa CONTROL O gt O MANUAL RESET HI LIMIT AIR PRESSURE SWITCH O BLOCKED DRAIN SYSTEM gt OPO AUTO RESET SENSOR I CN1 11 HI LIMIT AUX DHW S4 9 S2 TANK CNS K CNH140 INLET SENSOR ag gt HH a SENSOR S5 a Hp OUTLET OUTDOOR CN1 8 a DI SA sensor ES NS h Pag AOR SHIELD Ir SENSOR To tp RS485 BK GAS SHIELD al y ZN VALVE EXTERNAL WIR FLAME CONTROL _ 10V ROD N SPARK G y ROD OUIAN HIGH VOLTAGE SPARK LEAD Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high volt
18. PAK Boiler Service Manual to familiarize yourself with control module operation Read this manual page 41 for proper steps to start boiler Verify the boiler and system are full of water and all system components are correctly set for operation Verify the preparation procedures of Section 10 pages 38 and 39 have been completed Fill the vent condensate trap with water removing the retaining screw in order to remove the 2 inch PVC cap with the switch located at the top of the trap Replace the cap Press the cap onto the trap until the cap makes contact with the drain Replace the retaining screw Verify electrical connections are correct and securely attached Inspect vent piping and air piping for signs of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Start the boiler I Read and follow the Operating instructions in FIG 10 2 page 41 If boiler does not start correctly l 4 oF Check for loose connections blown fuse or service switch off Is external limit control if used open Is boiler water temperature above 200 F Is thermostat set below room temperature Is gas turned on at meter or boiler Is incoming gas pressure less than 4 inches w c If none of the above corrects the problem refer to the Troubleshooting Section of the ECO PAK Boiler Service Manual Check system and boiler
19. SETUP MENU ARMSTRONG LEWWEL 1 MARN SETUP SCREEN CLOCK SETUP Defaut Settings i Local and Remote Control by pressing the toggle switch below af JF CLOCK SETUP SCHEDULE SETUP Default Settings Save RESTORE 2 4 1 SYSTEM HOT WATER TEMP SETUP LIMITS menmen systemove 4 mamserue E Pressing and inputting the proper password in LEVEL 0 SETUP screen will call up the Level 1 Setup screen Pressing the LOCAL REMOTE START button will pop up a box to switch ECO PAK MBS between LOCAL and REMOTE status next picture Under local status ECO PAK MBS will be started immediately Under remote status ECO PAK MBS will be stopped or started by BAS or the customer s hardwire contact The top left corner of the screen will flash A when there is a new alarm The A will be solid when the alarm is acknowledged or muted Pressing the A will call up the alarm screen Pressing any of the SETUP button will call up its corresponding Setup display These displays are for changing the system setup and restoring the system factory defaults PID setup displays are for viewing only After changing values in any setup screens should you want to regain the previous saved values press Restore button to retrieve all the setup values from the system factory defaults Below are the screens that the user sees when pressing on each of those buttons Touch the buttons on
20. SETUP SCREEN Touching the PRESSURE button from TREND HISTORY MENU will call up the History System Pressure Chart screen This will display 3 graphs consisting of e The strainer Inlet Pressure e The Suction Pressure e The Discharge Pressure Touching chart display area will display a vertical line Corresponding the time axis of the line the values of 3 charts are displayed on top of this screen The current time and the time point of the vertical line will be displayed on the left top of the chart area Touching the navigation buttons below the chart area will let you navigate the charts in different time periods Touching the button to the left of navigation buttons will bring up the History Trend Range pop up box to select the date to view history trend chart Touch the buttons on the menu at the bottom to bring up the desired screen Touching the SETUP SCREEN button from Main Menu will call up the Level O Setup screen Pressing the password area to the right of Log In will pop up a keypad to log on to installer display or factory display The top left corner of the screen will flash A when there is a new alarm The A will be solid when the alarm is acknowledged or muted Pressing the A will call up the alarm screen Pressing any of the SETUP button will call up its corresponding Setup display These displays are for viewing only No values can be modified on these displa
21. Section of AHRI Page 27 of 118 ECO PAK Installation amp Operation Manual BOILER 1 Determine boiler location Installation must comply with Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 latest edition Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 when required National Electrical Code For Canada only B149 1 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes NOTICE The ECO PAK boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21 13 latest edition Before locating the boiler check 1 Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power 2 Locate the appliance so that if water connections should leak water damage will not occur When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance or any of its components 3 Check area around the boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear
22. The D gain is rarely used in HVAC applications this parameter is used only when the changes in the controlled variable are rapid 1 Press bottom right navigation button from BOILER SETUP to bring up this screen in order to set the Proportional Integral and Derivative gains to be used for controlling bypass valve 2 Enter a proportional gain Increasing the value will slow down the speed reaction to a system step change Decreasing the value will increase the speed reaction to a system step change 3 Enter the Integral time gain Increasing the value will slow down the speed reaction to a system step change Decreasing the value will increase the speed reaction to a system step change 4 Enter the D derivative time Increasing the value will increase the speed reaction to a system step change Decreasing the value will decrease the speed reaction to a system step change NOTE The D gain is rarely used in HVAC applications this parameter is used only when the changes in the controlled variable are rapid Page 107 of 118 ARMSTRONG ul 3 4 44 CLOCK SETUP CLOCK SETUP SYSTEM START UP PROCEDURE 1 Ensure that the proper power supply is connected to the ECO PAK MBS as per specification 2 Turn on the main power disconnect on the door of ECO PAK MBS controller 3 Touch the SETUP SCREEN button in the main menu screen 4 The screen changes to LEVEL 0 MAIN SETUP SCREEN Press the button beside the t
23. aan maaan O E 97 E DP ua aun O ne ee ee aksi atunta a aha a anta ass 97 Page 77 of 118 ARMSTRONG g INSTALLER DISPLAY Oia i 97 240 EV Me Ve NVM VO tas 98 DAN SON VEO WATER TEMP SE HOP caia di 98 242 PUMP SETUP aiii 99 24 3 PUMPPIDSETUDS u uu amana a a aaa Ba a a a a kaa au upa 99 2AA NE uu uum amna aan O 100 249 BOLERSTAGING SETUR uuu u n u u up us u sa asus aan 101 A a E enn askubats ai 101 DAT GAS CONSUMPTION SETUP cada dada donada 102 ZHAO SENSORSETUP Md a 102 240 DENSON SETUP an 103 24 10 EROS PROTECTION SETUR u u td 103 DAN o O 104 ZAA DY SS AP O O EE 0 o A 104 ZA BAS is 104 DV A A A A 105 E A IS 105 FACTORY DISPLAY S ior on an u Ru usu A m a i 105 AO EEVEE 2 SETUP MEN osados 106 SAA PUMPE Ms SI NP idas 106 EZ IBOLER PUSE TU sarita 107 34 DURAS OPD SETUP ias 107 9AA SUELO rara ea 108 SOTEM STARTUP PROCEDUR E ui u lio e 108 Page 78 of 118 ARMSTRONG il The ECO PAK MBS Integrated Controller is powered through a step down transformer inside the cabinet Internal wiring between the main panel and the service junction box located on the back of the package has been completed tested and inspected in the factory prior to shipping Connect the 3 phase power supply to the appropriate terminals inside the service junction box as shown below NOTE All electrical wiring should be performed by a qualified electrician in accordance with the latest edition of the National Electrical Code local codes and regula
24. amp Operation Manual 11 Operating information continued Status Display Screens cont d By using the Previous Next lt gt gt arrow keys on the control module display panel you can navigate through the eight 8 display screens Each screen will contain two 2 viewable items The following is a description of the individual items and what they can display Display shows Description If the system supply sensor has not been selected as the control SYS OE l sensor only the system temperature will be displayed When the system supply sensor has been selected as the control aa i Sp sensor the control will display the system temperature as well as the set point in parenthesis 3 Opn The control does not detect the system supply sensor Shorted The system supply sensor wires or the sensor itself has become shorted OUTDOOR Open Not used Press the Next P gt arrow key on the control module display to access Screen 4 FLUE F The control will display the flue temperature 4 Om lt The control does not detect the flue sensor The flue sensor wires or the sensor itself has become shorted Press the Next P gt arrow key on the control module display to access Screen 5 Press the Next P gt arrow key on the control module display to access Screen 6 s Press the Next P gt arrow key on the control module display to access Screen 7 DHW PUMP OFF Not used 7 The control will display a
25. and comply with the instructions provided and with all requirements of applicable codes Failure to provide a properly installed vent and air system will cause severe personal injury or death Vent piping materials A WARNING Use only the materials listed in Table 3A below for vent pipe and fittings Failure to comply could result in severe personal injury death or substantial property damage Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations NOTICE For closet and alcove installations CPVC material MUST BE used in a closet alcove structure Failure to follow this warning could result in fire personal injury or death A WARNING All vent pipes must be glued properly supported and the exhaust must be pitched a minimum of a 1 4 inch per foot back to the boiler to allow drainage of condensate NOTICE Table 3A Vent Pipe and Fittings 4 The 3 This appliance requires a special venting system The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance The field provided vent fittings must be cemented to the CPVC pipe section using an All Purpose Cement suitable for PVC and CPVC pipe Use only the vent materials primer and cement specified in this manual to make the vent connections Failure to follow this warning could result in fire
26. and the burner Do not try to light the burner call your service technician or gas supplier by hand 5 Remove top cover ti piba 6 Turn gas shutoff valve clockwise to close valve Handle will be perpendicular to pipe Do not force oo 7 Wait five 5 minutes to clear out any gas to CLOSE If you then smell gas STOP Follow B in the safety information above this label If you don t smell gas go to next step TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Turn gas shut off valve clockwise to close valve Turn off all electric power to the Handle will be perpendicular to pipe Do not to OPEN appliance if service is to be performed force Remove top cover 5 Install top cover LBL2274 REVB Page 61 of 118 10 Start up Check flame and combustion continued 4 Place the boiler into the active position by pressing the SHUTDOWN button on the display board FIG 11 1 page 46 until BLR Standby appears in the display window 5 Locate the pinhole button below the ENTER RESET button on the display board FIG 11 1 Insert a thin wire such as a paper clip into the hole and press the button once and hold for 5 seconds to place the boiler into Service Mode In Service Mode the boiler will fire at ignition speed and will then modulate up to full fire 6 Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor 7 Once the boile
27. and 4 10 page 22 ANTICIPATED SNOW LEVEL MAXIMUM OF CAUTION DO NOT use field supplied couplings to extend pipes Airflow restriction will occur 8 Install the rain cap and the small diameter pipe assembly into the roof penetration assembly Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting for 3 Concentric Vent installations and fastened tightly into the rubber adapter for 4 Concentric Vent installations 9 Cement the appliance combustion air and vent pipes to the concentric vent termination assembly See FIG 5 6 for proper pipe attachment 10 Operate the appliance through one 1 heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections Multiventing vertical terminations When two 2 or more direct vent appliances are vented near each other each appliance must be individually vented see FIG 5 7 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented near each other two 2 vent terminations may be installed as shown in FIG 5 7 The next two 2 terminations must be at least 36 inches away from the first two 2 terminations It is important that vent terminations be made as shown to avoid recirculation of flue gases Dimension A in FIG 5 7 represents the distance between pipes or rain shields as touching or a 2 inch maximum separation Figure 5 7 Concentric Vent a
28. and free of A WARNING combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage 4 The ECO PAK boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service 5 If a new boiler will replace an existing boiler check for and correct system problems such as System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits Incorrectly sized expansion tank Lack of freeze protection in boiler water causing system and boiler to freeze and leak A WARNING This appliance is certified as an indoor appliance Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F Failure to install the appliance indoors could result in severe personal injury death or substantial property damage This appliance requires a special venting system The vent connection to the appliance must be made with the starter CPVC pipe section provided with the appliance The field provided vent fittings must be cemented to the CPVC pipe section Use only the vent materials primer and cement specified in this manual to make the vent connections Failure to follow this warning could result in fire personal injury or death Closet and alcove installations A close
29. been completed on the incoming supply this should however not be necessary Page 18 of 118 ARMSTRONG ul Commissioning 3 4 Factory Default Settings Default settings can be viewed using the HMI touch screen Follow the instructions in the Controller I amp O manual 3 5 Initial Firing The CO content in the flue must be checked during commissioning and during regular maintenance of the boiler as well as after reconstruction work on the boiler or on the flue system CO content during operation see section Technical Data Too high CO gt values can lead to unhygienic combustion high CO values and damage to the burner Too low CO values can lead to ignition problems The CO value has to be set by modifying the gas pressure at the gas valve Changing over from LPG to natural gas and vice versa The gas type of the boiler must only be modified by an approved gas installer e De energize gas boiler e Close gas shut off facility e Replace injector Use enclosed new seals The CO gt content has to be set by setting the injector pressure at the gas valve The CO content at full load as well as low load must be between the values according to Technical Data in section 1 2 Figure 2 2 Installing Propane Orifice GAS VALVES GROMMET BRASS ORIFICE a SCREWS OTY 3 For more details see Boiler I amp O manual Prepare Boiler section Page 19 of 118 ARMSTRONG ly Commissioning Adjusting
30. controlled by a PLC Programmable Logic Controller System data may be read from or input to the PLC by a 5 7 touch screen display panel HMI Output signals are to the variable frequency drives VFD condensing boilers and to the building automation system BAS The following summarizes the range of input output variables possible for the Integrated Controller Possible maximum Input Output I O Variables A SINS Oe NO 1 digital input DI for remote start stop signal from BAS 4 digital outputs DO for alarms pump motor VFD alarm temperature sensor alarm boiler alarm system general alarm for possibility to send to BAS 3 Al s for system hot water supply and return temperatures NTC type and for outdoor air temperature transmitter 4 20 mA configurable range 4 DO s for up to 4 boiler start stop run signal 4 DI s for up to 4 boiler run feedback signal 4 Dl s for up to 4 boiler alarm status fault signal 4 analog outputs AO for boiler capacity modulation signal 0 10Vdc 1 DI for gas emergency shut off for possibility of connection to external emergency switch 1 serial port for communication with the BAS standard protocol Modbus 1 serial port for communication with the VFD s using Modbus protocol communicate pump speed alarm feedback and kW Optional Integrated Controller I O Ole Da 1 Al for system HW supply flow measurement 1 AO for 2 way modulating bypass valve Pulse input for optional gas
31. hole openings and securely attach the vent cap to the vent plate 5 Seal all wall cavities Figure 4 4A Sidewall Termination Assembly VENT PIPING SS A AIR PIPING VENT PLATE WALL PLATE VENT CAP GALVANIZED THIMBLE Prepare wall penetrations Alternate Field Supplied Option l VENT Ka l Air pipe penetration a Cut a hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration a Cut a hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 414 inch hole for 3 inch vent pipe 5 inch hole for 4 inch vent pipe b Insert a galvanized metal thimble in the vent pipe hole as shown in FIG 4 4B Use a sidewall termination plate as a template for correct location of hole centers Follow all local codes for isolation of vent pipe when passing through floors or walls Seal exterior openings thoroughly with exterior caulk Figure 4 4B Alternate Sidewall Termination Assembly w Field Supplied Fittings ELBOW AIR PIPING BIRD SCREEN GALVANIZED THIMBLE ELBOW BIRD SCREEN SIDE WALL TERMINATION PLATE Termination and fittings The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in FIG 4 14 page 17 Maintain the required dimens
32. iio 82 OPERATOR DIS PEA Suns 82 ELO MAIN EIN aora dat io 83 js SOOTEMOVERVIE W u u y m uu uu A uuu eee a ss aas 83 EZ P UNMPIGOVERVIP i u u ratifica 84 o PUMP A CONTROLES ia aaa 84 S O ey OV YP Maa O pat ona 85 ES TAS CONSUMPTION POP UR Screen 85 AO BOILER CONTROL SC S S uN l u u u a dad itaii n 86 iz LON Sri 86 A A A EI A asia manyata 87 122 ALARMAS TORSO up hukaq abhi adne enc m dene anteanetedl 87 20 EVENT SOI atada 88 130 TREND MENO astuta tc Diada lt it 88 LS TREND TEMPERATURE a ri acia 89 132 TREND SYSTEW PO Wisin ida 89 35 9 REND BOILER FLAME ia tai a do 90 Ed TREND PUMP da 90 too TRENDS PRESSURE ainda 91 130 RENO HISTORY MENU anita ds 91 SA TFENDZPEMPERATUAE u u u uy l m y y um ee 92 15062 TREND SYSIEMTIDWIuuu uu uy u u yu u SS ot 92 1963 TREND BOILER PLAME i uu u uy uu uu uuu yu nun suu y aus 93 TO TREND PUMPR SPEED star iii 93 1506527 TREND PRESSURE ien a lo e ci e 94 12505 LEVELU SETUP MENU pt ios 94 14 1 SYSTEM HOT WATER TEMP SETUPu uu u ai 95 BEE O o AI E UI kasi qasa 95 PAS PUMPEPID SETUR u ooa io 95 A A St Dunstan atita 95 14 0 BOILER STAGING SETUP cortan 95 AO PI SETUP S an an uu Ee EE ee ee re ee usan 95 TAL GAS CONSUMPTION SETUP uu uu uuu uuu danna adn 96 TAO SENSOR SETUP T a o a id 96 AS SENSOR E UP Za AA 96 16 105 FROST RODE TOM SETUP aan 96 VARTA BRASS O TU 96 TZ ABRAS PD SETUR Sa ei 96 A at a aaa eS ee Se ee amaka aa aaa nu 97 Es OEIDD uu
33. least 5 seconds 2 The display changes to ready ENTER MENU CODE with four 4 zeros below it 3 Change the zeros to match the user code factory set at 0704 Use the UP and DOWN keys to increment or decrement the flashing digit and the NEXT and PREVIOUS keys to select which digit flashes 4 Press the ENTER key 5 The display changes to read USER CODE for a few seconds then displays a menu 6 Press the ENTER key 7 Press the UP key twice to display A3 DATE AND TIME 8 Press the ENTER key once 9 The date and time are displayed as YY MM DD W hh mm where mm minutes hh hour 24 hour time e g 2 00 PM 14 00 W day of the week 1 Sunday 2 Monday 3 Tuesday etc DD date MM month YY year The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment Use the UP and DOWN keys to increment or decrement the flashing number and the NEXT and PREVIOUS keys to select which number flashes 10 Press the ENTER key to save the setting 11 Press the MENU key twice to exit the Programming Mode Page 62 of 118 11 Operating information General How the boiler operates The ECO PAK boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping
34. makeup water Freeze protection fluids e NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems The Boiler How it works 10 11 12 13 14 15 16 17 18 Access cover front Provides access to the gas train and the heat exchanger Air intake adapter Allows for the connection of the PVC air intake pipe to the boiler Air pressure switch The air pressure switch detects blocked inlet conditions Automatic air vent Designed to remove trapped air from the heat exchanger coils Blower The blower pulls in air and gas through the venturi item 33 Air and gas mix inside the blower and are pushed into the burner where they burn inside the combustion chamber Boiler drain port Location from which the heat exchanger can be drained Boiler inlet temperature sensor This sensor monitors return water temperature system return If selected as the controlling sensor the control module adjusts the boiler firing rate so the inlet temperature is correct Boiler outlet temperature sensor This sensor monitors boiler outlet water temperature system supply If selected as the controlling sensor the control module adjusts boiler firing rate so the outlet temperature is correct Burner not shown Made with metal fiber an
35. meter 1 DI for gas meter open feedback signal Serial communication to BAS using BACnet IP BACnet Ethernet BACnet MSTP and Lonworks Processor Generic Logical Features 1 2 Standard MBS NA Integrated Controller is supplied with 5 7 Human Machine Interface HMI with color touch screen A schematic of the system is displayed on the HMI showing all variable speed primary pumps variables on the screen System hot water supply amp return temperatures shall be displayed These temperature sensors shall be located on inlet and outlet headers of the MBS NA package Outdoor air temperature shall be displayed Control boilers output temperature SHWST by sending modulating signal to maintain system hot water supply temperature set point control algorithm in Sequence of Operation section below Monitor boiler s minimum and maximum flows when flow sensor ordered separately and perform necessary control outside operating flow range Minimum and maximum pump speeds shall be pre defined and entered for each MBS Model Re set system hot water supply temperature based on outdoor air temperature Sequence boiler s based on their best efficiency performance curve as required by system demand Page 8 of 118 ARMSTRONG il Monitor System HWRT 10 Compare System hot water return temperature to its set point 11 SHWRT set point shall be reset based outdoor air temperature 12 PID control algorithms for pump speed control based on SHWRT and mod
36. need a film of liquid between the faces for proper operation Mechanical seals may weep slightly at start up Allow the pump to continue operating for several hours and the mechanical seal to seat properly prior to calling for service personnel SYSTEM CLEANLINESS Before starting the pump the system must be thoroughly cleaned flushed and drained and replenished with clean liquid Welding slag and other foreign materials Stop Leak and cleaning compounds and improper or excessive water treatment are all detrimental to the pump internals and sealing arrangement Proper operation cannot be guaranteed if the above conditions are not adhered to NOTE Particular care must be taken to check the following before the pump is put into operation A Pump primed B Rotation OK C Lubrication OK D Pipe work properly supported E Voltage supply OK F Overload protection OK G Is the system clean H Is the area around the pump clean Page 113 of 118 ARMSTRONG g Replacement Parts List 7 0 Replacement Parts ECO PAK Boiler 210 amp 285 Page 114 of 118 ARMSTRONG g HEAT EXCHANGER 210 CONTROL PANEL GAS TRAIN 210 amp 285 Page 115 of 118 ARMSTRONG uy ITEM NO DESCRIPTION MODEL NO HEAT EXCHANGER ASSEMBLY ASSEMBLY 1 HEATEXCHAGER CI ECO PAKT BOILER 210 4 HEATEXCHAGER sss ECO PAKTu BOILER 285 CONTROLS x 6 WATERTEMPSENSOR Iso x 8 AIRVENVAVE r
37. personal injury or death Requirements for installation in Canada 1 Installations must be made with a vent pipe system certified to ULC S636 IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC S636 2 The first three 3 feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection 3 The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe fittings For concentric vent installations the inner vent tube must be replaced with field supplied certified vent material to comply with this requirement Concentric Vent Kit available from the manufacturer see Section 4 Sidewall Termination Optional Concentric Vent and the 3 Concentric Vent Kit available from IPEX are both approved for use on the ECO PAK boiler Both kits are listed to the ULC S636 standard for use in Canada All vent pipe materials and fittings must comply with the following Standards for installation in United States PVC schedule 40 ANSI ASTM D1785 CPVC and PVC venting must be ULC S636 Certified IPEX is an Vent pipe and fittings PVC DWV ANSI ASTM D2665 approved manufacturer in Canada supplying vent material listed to ULC S636 CPVC schedule 40 ANSI ASTM F441 IPEX System 636 Pipe cement primer Cements amp Primers CPVC ANSI ASTM F493 NOTICE DO NOT USE CELLULAR FOAM CORE PIPE Page 34 of 118 3 Ge
38. pop up a box to switch MBS between LOCAL and REMOTE status next picture Under local status MBS will be started immediately Under remote status MBS will be closed or started by BAS or the customer s hardwire contact The top left corner of the screen will flash A when there is a new alarm The A will be solid when the alarm is acknowledged or muted Pressing the A will call up the alarm screen Pressing any of the SETUP button will call up its corresponding Setup display These displays are for changing the system setup saving and restoring the system factory defaults After changing values in any setup screens press Save button to save all the changes as system factory defaults After changing values in any setup screens should you want to regain the previous saved values press Restore button to retrieve all the setup values from the system factory defaults Below are the screens that the user sees when pressing on each of those buttons Touch the buttons on the menu at the bottom to bring up the desired screen Touching the Right and Left arrow will navigate between the Level 2 Setup Screens Press bottom right navigation button from PUMP SETUP to bring up this screen There are three groups of proportional gain integral gain and derivative gain for small medium and large size circuit The PID modulation is based on the parameters in the group selected beside the des
39. replaced with condensing boilers a use of filters to remove scaling and other deposits is recommended Filters such as Pentair C44 or C66 with replaceable media can offer good solution to potential boiler clogging problems These filters are typically installed as bypass with less than 40 of the total water flow They should be inspected 10 days after the initial installation and have cartridge replaced as necessary After the initial inspection they should be inspected frequently until the water has been cleaned from scaling and other deposits After the system has been clean an annual inspection is recommended Cleansing flushing and water treatment must be carried out in accordance with the requirements of the applicable local codes To ensure that the boiler heat exchangers remain in good condition it is essential to condition and monitor the system water to the following criteria e Water hardness If the system fill water has a hardness in excess of 7 grains the water should be softened prior to filling the system to ensure that excessive scaling does not occur within the heat exchanger e Water acidity The system fill water should have a pH value between 7 and 8 3 to ensure that corrosion of the heat exchanger does not occur If in special circumstances a need arises to use additives in a mixture e g hardness stabiliser frost protection agent sealing agent etc it is important that the additives are compatible with each other and t
40. result in severe personal injury death or substantial property damage A WARNING Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations NOTICE Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 15 of this manual 2 You must consider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas A WARNING Sidewall vent and air inlet terminations must terminate in the same pressure zone f Do not terminate above any door or window Condensate can freeze c
41. the gas supply piping 5 Before placing the boiler in operation check the boiler and its gas connection for leaks a The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5 kPa b The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5 kPa c The appliance and its gas connection must be leak tested before placing it in operation A WARNING Do not check for gas leaks with an open flame use the bubble test Failure to use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 6 Use pipe sealing compound compatible with propane gases Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow A WARNING Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury death or substantial property damage ECO PAK boilers are typically shipped ANS ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas 1t may be converted to LP by installing an orifice see page 12 In order to operate on LP gas an orifice MUST BE installed Failure to comply could resul
42. the layout of the system temperature setpoint and actual temperature value system flow inlet pressure discharge and suction pressure bypass valve opening if available pumps speed and boilers flame Press PUMP OVERVIEW to view pumps status speed run time and alarm Press BOILER OVERVIEW to view boilers status run time flame and total output capacity Press ALARM SCREEN to view any alarm condition that might have occurred Press SETUP SCREEN for boiler pump sensor bypass valve frost protection and system schedule setup password protected Press TREND MENU to view temperature trends system flow trends boiler flame trends pump speed trends system pressure trends Outdoor air temperature is displayed System Hot Water Return Temperature SHWRT set point and actual value are displayed System Hot Water Supply Temperature SHWST set point and actual value are displayed Pumps running status duty standby and speed are displayed Boilers running status duty lag and flame are displayed The strainer inlet pressure suction pressure and discharge pressure are displayed Flow is displayed if flow sensor is enabled in flow sensor setup screen Bypass valve opening value is displayed if bypass valve is enabled in bypass valve setup screen Pressing the boiler icons will change current screen to boiler control screen Pressing the pump icons will change current screen to pump
43. to the controller terminal strip it will display gas consumption reading in SCF on the HMI Safety valves are fitted to each boiler supply pipe and a plugged gas purge valve is fitted to the end of the gas header The ECO PAK MBS Integrated Heating Solution is manufactured by Armstrong to meet the requirements of its ISO 9001 2000 and 15014001 2004 Registrations Page 4 of 118 SLL Jo abed 296 LZLZ x 92 2l l eoe 68S 8621 OVS 061 1 jam 1UBI A ejo 1 826 9702 x eps og9or 8 9 v67 ersz sos Aup JuBI A e30 L 6281 ZZ 6281 ZZ 6281 ZZ 6281 ZZ 1961 ZV 9Z Jublay Ajquiesse 2J9AO 989 ZZ gga zz g 989 ZZ 198 OS u d p lquu sse lEJ AO r6 SZ SS x ogie ersz 08l 6L GzZL 91yZ L S6 91yZ L S6 y Bua Ajquiesse Je1anO AAA 232222222 222 O HEWIOJUl 1e19U39 01Z zop 01Z zop 012 zop 01Z zop 012 zop Jybiem ajnpou duind 1 SL 1 SL 1 SL 1 SL 1 SL ainsseaid Ajddns J9 eM pjoo uunuuluil i 61 v 61 b 61 p 61 v 1 BLE UOI O uUOO J3JEM SU eU Jajem pjoo pajsoog L Z L CL Z L CL Z L L Z L 1 EA UO JOBUUOD UleJP jesu puoO 0S z 09 z 09 z 09 z 09 z UOI JOBUUOD seo 09 z 0S Z 0S Z SUO O UUOD uin1 i pue Ajddns MH17 6 V OL LS SL 7 8 8 6 LZ SL 82 7 6 LO VL AS S A09t 90Z 18 juaJino peo ny ZHO9 AGZS 10 ZHO9 AO09p 0 Z2 80Z A ddns 91119913 0S Z 0S Z
44. will bring up the Gas consumption pop up box to view and reset the total gas consumption Total boiler output capacity is displayed when flow sensor is enabled Press the buttons on the menu at the bottom to bring up the desired screen The box to the left of Reset button displays the total gas consumption in cubic feet The middle box displays gas consumption rate in cubic feet per hour The right bottom box displays the thermal efficiency Pressing cross mark button will close this pop up Page 85 of 118 ARMSTRONG g 1 1 6 BOILER 1 CONTROL screen BOILER 1 CONTROL y Pera ES Ott 1 1 7 LOGIN screen This screen is to control the boiler Hand Off Auto and Duty mode Press the HAND OFF AUTO buttons to select the desired mode The boiler mode is displayed under these buttons no display means N A Press LEAD button to set current boiler as lead the other boilers will reorganize as lag 1 2 and 3 When in Hand the system will automatically start the duty pump The boiler will start when flow is detected and the flame will be modulated to maintain the SHWST set point The boiler s duty is displayed Lead Lag1 Lag2 Lag3 The Boiler s status is displayed Not Ready Ready Enabled Started Running and Alarm Run time indicates the boiler s total running time lt can be reset by pressing the displaying area Flame is displayed in value of full value The c
45. 0 represents 2 boilers with capacity of 285 BTU hr ea MBS 630 represents 3 boilers with capacity of 210 BTU hr ea MBS 855 represents 3 boilers with capacity of 285 BTU hr ea MBS1140 represents 4 boilers with capacity of 285 BTU hr ea Enter the minimum running capacity for boiler Boilers should not operate at less than the minimum Capacity Enter the high limit of Boiler Supply Temperature BST If BST is approaching its high limit the lag boiler shall be added on to maintain BST below its high limit Enter the period of time to operate boilers under minimum flow After this period of time lead boiler shall be shut down Enter SHWRT restart set point When the actual SHWRT is lower than this set point system will start the lead boiler Enter the lead boiler switch time After the lead boiler runs for the entered amount of hours the lead boiler will transfer lead to the lag boiler Lag 1 Enter the differential temperature set point between SHWST and SHWRT When the actual DT is approaching this set point all the boilers are going to reduce their capacity by an amount determined by the back off factor If DT remains high the boiler will shutdown Enter the back off factor Determines how fast the boiler capacity is reduced Press Restore button to retrieve boiler setup values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen Page 100 of 118 ARMSTRONG g 2
46. 0 10Vdc signal received from the _ A 0 10V IN Vdc Armstrong Integrated Control connected to the unit Press the Next P gt arrow key on the control module display to access Screen 8 8 Page 69 of 118 ECO PAK ipa i Installation amp Operation Manual 12 Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Service technician Owner maintenance see the following pages for instructions see the User s Information Manual for instructions General Address reported problems Inspect interior clean and vacuum if Check boiler area necessary Check pressure temperature Clean condensate trap and fill with gauge fresh water Check for leaks water gas flue condensate Verify flue and air lines in good condition and sealed tight Check vent piping Check system water pressure system piping expansion tank Check air piping Check control settings Check relief val Check ignition and flame sense Monthly i MAE electrodes sand off any deposits clean and reposition Check condensate drain system Check wiring and connections Check automatic air vents ou E lt E l lt lt lt lt Perform start up checkout and performance verification per Section 10 of this manual Test low water cutoff if used Flame inspection stable uniform Periodically Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue
47. 00 1700 1540 1400 1300 3 1200 7900 6400 5400 4870 4410 4000 3800 3540 3330 3000 2720 2500 2340 4 23500 16100 13100 11100 10000 9000 8300 7690 7380 6870 6150 5640 5130 4720 ECO PAK boilers are typically shipped ready to fire on natural gas Check boiler rating plate to A WARNING 2 i determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 12 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage 14 1 2 3 4 Check inlet gas supply 3 Loosen the set screw one 1 full turn from inside the CSA or UL listed flexible gas connections pressure tap on top of the gas valve Place the tubing of are acceptable but you must exercise the manometer over the tap once the set screw is caution to ensure that the line has adequate loosened as shown in FIG 7 4 capacity to allow your boiler to fire at full 4 Slowly turn on the gas supply at the field installed rate Consult with local codes for proper manual gas valve installation or service procedures 5 Turn the power switch to the ON position A WARNING PO NOT adjust or attempt to measure gas 6 Adjust the temperature set point on the control panel of valve outlet pressure The gas valve is the control module to call for heat factory set for the correct outlet pres
48. 1 2 CPVC PIPE FITTINGS or yva L D PLASTIC TUBING N FIELD SUPPLIED A a 1 2 PVC UNION FACTORY SUPPLIED FLOGR DRAIN or DRAIN PAN Incoming connections can then be made 2 50 mm NPT to the LTHW supply and return valve 2 50 mm NPT to the incoming gas isolation valve and 20 mm NPT to the incoming water make up line All connections should be tested to ensure that they are leak free 2 7 Electrical Connections Danger of electrical shock All electrical work in connection with the installation must be carried out by a qualified electrician and tested prior to energizing the supply All interconnecting wiring between the integrated controller pump boiler modules temperature and pressure sensors is completed and tested in the factory prior to shipping Plug and socket arrangements are provided to connect the boiler modules to the integrated controller on site The only site wiring required by others is to bring the incoming power supply into the 3 phase terminals inside the junction box as previously shown outdoor air sensor and BAS communication wiring if applicable should also be completed on site by a certified electrician All electrical work must be in accordance with the current NEC Wiring Regulations and any other local regulations that may apply A suitably sized and fused 4 wire 3 phase supply is to be terminated at the terminals provided within junction box in the back of the pump control modu
49. 14 Vent and Air Piping MaterialS 14 Requirements for Installation in Canada 14 Air Intake Vent Connections 15 Min Max Combustion Air amp Vent Piping Lengths 15 Removing from Existing Vent 16 Vent and Air Piping 16 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 17 20 Determine Location 17 18 Prepare Wall Penetrations 19 Termination and Fittings 19 Multiple Vent Air Terminations 0 20 Sidewall Termination Optional Concentric Vent 21 23 5 VERTICAL DIRECT VENTING Vent Air Termination Vertical 24 25 Determine Location 24 Prepare Roof Penetrations 25 Termination and Fittings 25 Multiple Vent Air Terminations _ 29 Vertical Termination Optional Concentric Vent 26 27 6 HYDRONIC PIPING System Water Piping Methods Low Water Cutoff Device 28 Chilled Water System 28 Freeze Protection 28 General Piping Information 28 Relief Valve T amp P Installation 28 29 Near Boiler Piping Components 31 7 GAS CONNECTIONS Conne
50. 3 3 100 5 4 4 100 5 Concentric System 3 4 100 5 4 6 100 5 The combustion air must be free from corrosive elements especially fluorine and chlorine vapours which are found for example in solvents and cleaning agents propellant gases etc When connecting boilers to under floor heating systems using plastic pipe work that is not impervious to oxygen heat exchangers must be used for separation purposes Installation 2 6 Piped Connections The ECO PAK MBS installation including commissioning servicing and maintenance must only be carried out by an approved gas installer The LTHW supply LTHW return and gas headers should be bolted together using the bolts and joint rings supplied Care should be taken to ensure that the joint rings are correctly positioned Under no circumstances should the bolting up of the headers be used to pull the units together as this could cause undue strain The gas purge valve should be fitted to the blank on the end of the gas header A reinforced hose and isolating valve are supplied to fit on to the end of the LTHW return header and connect to the expansion vessel supplied loose The Y plastic condensate drain piping should be headered on site and should then be connected and extended to discharge over the floor drain or into a condensate pump supplied by others if required Page 16 of 118 ARMSTRONG ul 1 2 PVC TEE ASSEMBLY FACTORY SUPPLIED 1 2 PVC PIPE amp FITTINGS a 7
51. 4 5 BOILER STAGING SETUP 1 Press bottom right navigation button from BOILER SETUP to bring up this screen 2 Enter the stage up capacity for Lag1 Lag2 and Lag3 boilers in the boxes beside the descriptions When the capacity of lead boiler reaches the corresponding capacity entered above for a specific time the corresponding lag boiler shall be staged up 3 Enter the stage down capacity for all the lag boilers When the capacity of lead boiler goes below this value for a specific time the last lag boiler shall be staged down 4 Enter the delay time for staging up or staging down 5 Enter minimum run time for boilers The minimum run time the boilers are going to run after they are started 6 Press Restore button to retrieve boiler sequencing setup values from the system factory defaults 7 Touch the buttons on the menu at the bottom to bring up the desired screen 2 4 6 BOILER PID SETUP This screen is for viewing only 1 Press bottom right navigation button from BOILER SETUP to bring up this screen 2 Touch the buttons on the menu at the bottom to bring up the desired screen Page 101 of 118 ARMSTRONG g 2 4 7 GAS CONSUMPTION SETUP 2 4 8 SENSOR SETUP 1 Press GAS CONSUMPTION SETUP button from LEVEL 1 MAIN SETUP to bring up this screen Gas Pulses can be enabled to measure the gas consumption when the gas meter is installed in the system Enter the magnitude
52. AS PRESSURE PRESSURE X6 4 SWITCH SWITCH INTEGRATED CONTROL INTEGRATED CONTROL INLET SENSOR OUTLET SENSOR FLUE SENSOR CONNECTION BOARD RUN TIME CONTACTS CONTACTS ALARM SYSTEM SENSOR gt AUX DHW CN1 5 EE a S S S S 9 S S O Q o SHIELD N RS485 SHIELD EXTERNAL CONTROL _ _ 0 10V a E CN1 2 one a e hu AUX DEVICE PILOT SUPPLY O O gt 24VAC ru AUX DEVICE gt PROVING CN4 2 O O g AIR PRESSURE SWITCH BLOCKED DRAIN SWITCH AUTO RESET HI LIMIT GAS VALVE BLOWER SPARK ROD T CAUTION NOTES X6 10 FLAME ROD HIGH VOLTAGE SPARK LEAD LOW VOLTAGE 120 VAC HIGH VOLTAGE INTEGRATED CONTROL 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present 2 See wiring diagram for additional notes Page 74 of 118 LADDER DIAGRAM LBL7083 REV G ES Installation amp Operation Manual BOILER 13 Diagrams continued Figure 13 2 Wiring Diagram ii ed AA WARNING DISCONNECT POWER BEFORE SERVICING
53. ATURE SHWWRT SP 105 0 10 55 05 19 09 230910 54 05 19 09 1 3 2 TREND SYSTEM FLOW 11 05 05 19 09 Flow Setpoint 0 0 Touching the TEMPERATURE button from TREND MENU will call up the Temperature Chart screen This will display 5 graphs consisting of Outside Air Temperature System Hot Water Return Temperature System Hot Water Return Temp Setpoint System Hot Water Supply Temperature System Hot Water Supply Temp Setpoint Touching chart display area will display a vertical line Corresponding the time axis of the line the values of 5 charts are displayed on top of this screen The current time and the time point of the vertical line will be displayed on the left top of the chart area Touching the navigation buttons below the chart area will let you navigate the charts in different time periods Touch the buttons on the menu at the bottom to bring up the desired screen Touching the SYSTEM FLOW button from TREND MENU will call up the System Flow Chart screen This will display 2 graphs consisting of e System Flow e System Flow Setpoint Touching chart display area will display a vertical line Corresponding the time axis of the line the values of 2 charts are displayed on top of this screen The current time and the time point of the vertical line will be displayed on the left top of the chart area Touching the navigation buttons below the chart area will let you navigate the charts
54. BACKUP TO USB button will save history event log alarm log and history trend data to USB within 31 days from today Touch the buttons on the menu at the bottom to bring up the desired screen Page 91 of 118 ARMSTRONG ul 1 3 6 1 TREND TEMPERATURE SHWMWRT_SP 95 0 06 03 09 15 31 06 03 09 show temperature history trends frorn o days aga Flow Setpoint 0 0 06 03 09 LEMA Mam mero setup meno TREND menu Touching the TEMPERATURE button from TREND HISTORY MENU will call up the History Temperature Chart screen This will display 5 graphs consisting of Outside Air Temperature System Hot Water Return Temperature System Hot Water Return Temp Setpoint System Hot Water Supply Temperature System Hot Water Supply Temp Setpoint Touching chart display area will display a vertical line Corresponding the time axis of the line the values of 5 charts are displayed on top of this screen The current time and the time point of the vertical line will be displayed on the left top of the chart area Touching the navigation buttons below the chart area will let you navigate the charts in different time periods Touching the button to the left of navigation buttons will bring up the History Trend Range pop up box to select the date to view history trend chart Touch the buttons on the menu at the bottom to bring up the desired screen Touching the SYSTEM FLOW button from TREND HISTORY M
55. BOILER INTAKE AIR CONNECTION r 4 12 MIN WS A 15 MAX FROM BOILER i Te J COUPLING VENT PIPE CONNECTION BIRD SCREEN BIRD SCREEN TYPICAL BIRD SCREEN ALTERNATE VENTING ARRANGEMENT IF SPACE PERMITS 5 Maintain clearances as shown in FIGs 4 1A thru 4 3B pages 17 and 18 Also maintain the following a Vent must terminate At least 6 feet from adjacent walls Figure 4 3A Clearance to Forced Air Inlets e No closer than 12 inches below roof overhang At least 7 feet above any public walkway At least 3 feet above any forced air intake within 10 feet VENT AIR TERMINATION e No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet b Air inlet must terminate at least 12 inches above grade or snow line at least 12 inches below the vent termination and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG 4 1B c Do not terminate closer than 4 feet horizontally EU from any electric meter gas meter regulator relief valve or other equipment Never terminate above or below any of these within 4 feet horizontally IF LESS THAN 10 36 MIN FORCED AIR INLET 6 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment Figure 4 3B Alternate Clearance to Forced Air Inlets
56. EE 3NV1 NOISNVdX3 AHI ANO IV 8L ZL l 4300W19 OY 9 92 NOLLDSNNOD 1dN WY Ud sed 1YO dns i NL so XOZ JO O1Z anog 331108 OZ 4 HOLVIW43S L uly t g TE INJA XY suimesq u uu BueuiV e19ua5 G ONOULSWUV SLL Jo Z aBed 38 01 35001 031 IddAS ANYL NOISNVAX3 Y 330333 10d I S3LON JLS 1Y I3dld 4 GITWISNI UTTOUNOI DUDA Ol ALT iv 100 HOLLINS cP 20 WINES WITOMUNOO A OL aq i e NVAO x C AS gt es PA na IYUN Q a e Ps es IES ANONO UITNOOI kesi E lili CAMDAN Q G31V8931M OL Kass no lt 191 8 8 Wi camoumo camoama DALVWOAM OL ORLVEDSIMI OL eit _ Poe 430334 10d WIIN3HD A zh uf a ka 33108 33108 33108 a SEN SEW San San L 2 A H eons M190 Ch c A L E 2 D j a D IFN SV9 IN JZ TWNOLLGO 35007 3 lddNS TWNOUGO sssi 931104 1N09 314390 31NI AMAS MH LAN Z Grd VL ONOULSWUV ARMSTRONG ly 1 General 1 5 ECO PAK MBS Integrated Controller Sequence of Operation General Information The MBS NA Integrated Controller is designed as a modular system controlling 2 to 4 condensing boilers and 2 variable speed pumps in duty standby configuration All system functions are monitored and
57. ENU will call up the History System Flow Chart screen This will display 2 graphs consisting of e System Flow e System Flow Setpoint Touching chart display area will display a vertical line Corresponding the time axis of the line the values of 2 charts are displayed on top of this screen The current time and the time point of the vertical line will be displayed on the left top of the chart area Touching the navigation buttons below the chart area will let you navigate the charts in different time periods Touching the button to the left of navigation buttons will bring up the History Trend Range pop up box to select the date to view history trend chart Touch the buttons on the menu at the bottom to bring up the desired screen Page 92 of 118 ARMSTRONG ly 1 3 6 3 TREND BOILER FLAME 06 03 09 LEMA Mam mero A setup menu TREND menu Be 1 3 6 4 TREND PUMP SPEED Pump 1 0 0 05 27 09 10 05 05 27 09 LEMA man mero setup meno TREND menu Touching the BOILERS FLAME button from TREND HISTORY MENU will call up the History Boiler Flame Chart screen This will display maximum 4 graphs consisting of Boiler 1 Flame Boiler 2 Flame Boiler 3 Flame Boiler 4 Flame The number of charts are depend on the number of boilers Set up by ECO PAK MBS Model Touching chart display area will display a vertical line Corresponding the time axis of the line the values of charts are displaye
58. ETWEEN EDGE OF AIR PIPE AND ADJACENT VENT PIPE Page 40 of 118 ECO PAK Installation amp Operation Manual BOILER 4 Sidewall direct venting continued Sidewall termination optional concentric Description and usage vent Armstrong offers optional concentric combustion air and vent e Do not terminate above any door or window pipe termination kits Factory Kit for 3 diameter Model 210 Condensate can freeze causing ice formations and for 4 diameter Model 285 Both combustion air and f Locate or guard vent to prevent condensate damage vent pipes must attach to the termination kit The termination to exterior finishes kits must terminate outside the structure and must be installed 4 Cut one 1 hole 5 inch diameter for 3 Concentric Vent as shown below in FIG 4 6 installations or 7 inch diameter for 4 Concentric Vent The required combustion air and vent pipe materials are listed in Table 3A on page 14 of this manual kit installations into the structure to install the termination 5 Partially assemble the concentric vent termination kit Figure 4 6 Concentric Sidewall Termination Clean and cement using the procedures found in these OVERHANG instructions OR ROOF a b GRADE SNOW LINE Sidewall termination installation 1 Determine the best location for the termination kit see FIG 4 6 2 The total length of piping for vent or air must not exceed the limits given in the General Vent
59. F Main 416 759 9101 F 716 693 8970 F 44 0 161 220 9660 S A Armstrong Limited 2009 For Armstrong locations worldwide please visit www armstrongintegrated com
60. FILE NO 81 79 ARMSTRONG DATES Bela SUPERSEDES 81 79 DATE Sep 16 2009 INSTALLATION AND OPERATING INSTRUCTIONS Armstrong ECO PAK MBS Ultra Efficient Integrated Heating Solution Armstrong Packaged ECO PAK MBS Systems are completely factory assembled tested adjusted and shipped to the job site as integral units ready to receive hot water supply and return piping and incoming power supply These instructions describe the procedures to be followed during installation commissioning and operation to ensure optimum performance and reliability When contacting the factory for assistance please provide the unit Serial Number and other pertinent data such as motor amperage voltage and suction and discharge pressures Page 1 of 118 ARMSTRONG ly CONTENTS 1 General Introduction Technical Data General Arrangement Drawings Hydraulic Schematic Control Philosophy Location Gas Supply Venting Systems Heating Circulation System System Water Quality Electric Supply Condensate RPZ Valve Drain Clearances A N U NU o U a e X ad 222200 O O Q N O N O 2 Installation 2 1 Offloading 2 2 Unpacking 2 3 Fixing in Position 2 4 Ventilation 2 5 Vent and Air Intake Installation 2 6 Piped Connections 2 7 Electrical Connections 3 Commissioning 3 1 Filling the System 3 2 Gas Purging 3 3 Controls 3 4 Factory Settings 3 5 Initial Firing 3 6 Starting the System 3 7 Handing Over Boiler I a
61. IPPLE Figure 6 2 Pressure Drop vs Flow Pressure Drop vs Flow HE NO al N o al Oo al Pressure Drop Feet of Head o 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Flow Rate GPM Page 49 of 118 Y Gas connections Connecting gas supply piping 1 Remove the top access panel and refer to FIG s 7 1 and 7 2 to pipe gas to the boiler a Install ground joint union for servicing when required b Install a manual shutoff valve in the gas supply piping outside boiler jacket when required by local codes or utility requirements c In Canada When using manual main shutoff valves it must be identified by the installer 2 Install sediment trap drip leg Figure 7 1 Gas Supply Piping Model 210 SEDIMENT TRAP DRIP LEG SHUTOFF VALVE FIELD SUPPLIED Figure 7 2 Gas Supply Piping Model 285 UNION SEDIMENT TRAP DRIP LEG MANUAL ECO PAK Installation amp Operation Manual BOILER 3 Support piping with hangers not by the boiler or its accessories The gas valve and blower will not support the weight of the piping Do not attempt to support the weight of the piping with the boiler or its accessories Failure to comply could result in severe personal injury death or substantial property damage A WARNING 4 Purge all air from
62. K MBS Controller and the BAS Check that the proper hardware is installed in the ECO PAK MBS controller panel Select the BAS communication protocol by pressing the protocol box to toggle between Modbus LonWorks and BacNet Enter the network address as specified by the Building Management Administrator Select the BAS communication baud rate as specified by the Building Management Administrator Press Restore button to retrieve bas setup values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen Page 104 of 118 ARMSTRONG il 2 4 14 CLOCK SETUP 1 From the LEVEL 1 MAIN SETUP press Clock Setup button to call up this screen to adjust the time in the HMI and display the time in the PLC 2 The HMI time and date can be adjusted by pressing the individual hour minute month day year and day of the week box and entering the corresponding value 3 Touch the buttons on the menu at the bottom to bring up the desired screen 2 4 15 SCHEDULE SETUP 1 Press SCHEDULE SETUP button from LEVEL 1 MAIN SETUP to bring up this screen 2 Schedule can be enabled or disabled by pressing the box beside the schedule text 3 Press the next box to enter minimum Outside Air Temperature When the OAT is lower than the value system schedule is enabled 4 Enter the on and off time respectively for weekday and weekend When the time is
63. NG material MUST BE used in a closet AROUND HOT WATER structure due to elevated PIPES AND VENT PIPE temperatures Failure to follow this S y warning could result in fire m personal injury or death VENTILATING AIR OPENING i CLOSED DOOR VENTILATING ne AIR OPENING LEFT NL Z A o lt A 0 14 we RIGHT REAR rs ee A AREA OF EACH OPENING 1 SQ INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ INCHES ES RECOMMENDED SERVICE CLEARANCES FRONT FRONT 24 TOP 24 LEFTSIDE 24 REAR 24 Figure 1 2 Alcove Installation Minimum Required Clearances ALCOVE INSTALLATION 1 MINIMUM CLEARANCE AROUND HOT WATER PIPES AND VENT PIPE For alcove installations CPVC A WARNING material MUST BE used in an alcove structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or death OPEN FRONT 12 LEFT 0 RIGHT RECOMMENDED SERVICE CLEARANCES FRONT 24 TOP 24 LEFTSIDE 24 REAR 24 Page 29 of 118 1 Determine boiler location Provide air openings to room ECO PAK boiler alone in boiler room 1 No air ventilation openings into the boiler room are needed when clearances around the ECO PAK boiler are at least equal to the SERVICE clearances shown in FIG s 1 1 and 1 2 For spaces that do NOT supply this clearance provide two openings as shown in FIG 1 1 Each opening must provide one squa
64. This notification will become active when either a set time frame has expired or a set amount of running hours or cycles has expired all adjustable by the installer The display will alternate the standard text on the display screen with Service Due every 5 seconds The service reminder notification can be reset by the installer Error logging The control will hold in memory the last 10 error codes as well as the last 10 turn off functions The date and time of the occurrence will be recorded as well Only the 10 most current occurrences will be held in memory Boiler temperature regulation Operating temperature target The control module senses water temperature and regulates boiler firing and firing rate to achieve a target temperature The target temperature can be set between 70 F and 190 Target temperature is fixed when the outdoor sensor 1s not installed ECO PAK Installation amp Operation Manual BOILER High limit operations When outlet temperature exceeds 200 F high limit action occurs The boiler shuts down until the outlet water cools down If local codes require manual reset an Adjustable Manual Reset High Limit Kit is available Low water cutoff protection optional 1 The control module uses temperature sensing of both supply and return areas of the heat exchanger If the flow rate is too low or the outlet temperature too high the control module modulates and shuts the boiler down This ensu
65. Y bypass valve Page 79 of 118 ARMSTRONG g ECO PAK MBS Pre Commissioning Check List Armstrong Sales Order Project Name Project Location Armstrong Service Dealer Name Requested Date of Site Visit To request a commissioning visit for your Armstrong IPP MBS unit installation please complete the following details and return to Armstrong giving a minimum of 7 days prior notice DETAILED TASK CHECK INITIALS COMMENTS Work to be completed in the boiler plant prior to Armstrong Service Technician arrival on site Piping system has been charged with water and pressure tested Electrical supply and external wiring Sensors and safety interlock have been completed and tested Serial communication between BMS and MBS Integrated Controller wiring is done if applicable Confirm that BAS ready to send receive commands to MBS Integrated Controller Turn on MBS Integrated Controller after power wiring installed record start up message from panel or program version Send pictures to Armstrong showing all wiring are terminated in the MBS Integrated Controller as specified standards materials The correct gas supply to system is tested and purged up to the MBS isolating valve NOTES Armstrong will confirm attendance of our commissioning engineer and every effort will be made to accommodate date s requested above Any postponement to the agreed date must be notified to Armstrong at least 48 hours prior All price
66. a boiler from an existing vent system Vent and air piping Vent and air system Installation must comply with local ONE requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations You must also install air piping from outside to the boiler alr intake adapter The resultant installation is direct vent sealed combustion You may use any of the vent air piping methods covered in this manual Do not attempt to install the ECO PAK boiler using any other means DO NOT mix components from different systems The vent system could fail causing leakage of flue products into the living space Use only PVC or CPVC pipe and fittings with primer and cement specifically designed for the material used ECO PAK Installation amp Operation Manual BOILER Vent air piping and termination The ECO PAK boiler vent and air piping can be installed through the roof or through a sidewall Follow the procedures in this manual for the method chosen Refer to the information in this manual to determine acceptable vent and air piping length Air contamination Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds When these chemicals pass through the boiler they can form strong acids The acid can eat through the boiler wall causing serious damage and presenting a possible threat of flue gas spillage or boil
67. age A WARNING Do not connect any other appliance to the 4 wanNiNc vent pipe or multiple boilers to a common vent pipe Failure to comply could result in severe personal injury death or substantial property damage NOTICE Installation must comply with local requirements and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations Determine location Locate the vent air terminations using the following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 15 of this manual 2 The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet 3 The air piping must terminate in a down turned 180 return pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 4 The vent piping must terminate in an up turned coupling as shown in FIG 5 1 The top of the coupling must be at least 1 foot above the air intake The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake ECO PAK Installation amp Operation Manual BOILER A WARNING Rooftop vent and air i
68. age spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit WIRING DIAGRAM LBL7082 REV E Page 75 of 118 ARMSTRONG ul 5 0 Integrated Controller I amp O Manual NSTALLATION AND OPERATING INSTRUCTIONS ECO PAK MBS INTEGRATED BOILER PLANT PACKAGE CONTROLLER Armstrong Ultra Efficient Integrated Boiler Plant Controllers ECO PAK MBS Controllers are completely factory assembled tested and shipped to the job site as integral units ready to receive incoming power supply These instructions describe the procedures to be followed during installation commissioning and operation to ensure optimum performance and reliability When contacting the factory for assistance please provide the unit Serial Number and other pertinent data such as ECO PAK MBS Model no Page 76 of 118 ARMSTRONG il Table of Contents ECO PAK MBS M Pre Commissioning CHECK stas aida 80 DISRLA TS OVERVIEN iaa 81 SO STIL Sly peat cece OE In O OE E ESO EOI Saa uhimuasa E 81 AMD a eee ee ee ee ee ee ee Pass 81 S pb a AA bu eave g a GN 81 Trend AUIS AVS at nkiku pah idas 82 SY ee IN PON Sn
69. alculated boiler supply temperature is displayed besides Boiler Supply Temp Press the buttons on the menu at the bottom to bring up the desired screen In order to be able to modify any of the Setup parameters you must Login with the proper password There are 3 level setup screens Level 1 and level 2 require operator to input password Level 0 will allow viewing the setup values only Level 1 will allow changes to setup values and to restore the system factory defaults except for the PID parameters Level 2 will allow changes to all the setup values and to save or restore all the system factory defaults All the three levels will allow controlling the pumps or boilers From MAIN MENU screen pressing the SETUP SCREEN button will call up this screen Pressing the password area to the right of Log In will pop up this keypad input the password through the keypad press Ent button in the keypad will return to this screen or go to the screen corresponding to the password Page 86 of 118 ARMSTRONG g 1 2 Alarm Management Displays 1 2 1 06 0309 06 0309 06 03 09 06 03 09 See the following table ALARMS screen 13 56 18 13 55 18 13 56 18 13 56 18 System Flow Transmitter SHART Transmitter Fautt SHWST Transmitter Faul Outside Air Temp Transit 14 10 56 14 10 56 14 10 56 14 10 56 13 56 10 13 56 10 13 56 10 13 56 10 m Flow Transmitter RT Transmitter Fault DIAGNOSTIC eT Transmi
70. and Checking the CO Values Turn on the local main disconnect switch and operate the ECO PAK MBS Boiler in the controller stop mode to adjust and check the CO value Each boiler should be operated individually to preserve the available load Only once the required checks have been carried out and the record sheet completed should all available boiler be left in the on position and allowed to be controlled by the plc For more details see Boiler I amp O manual Start up section 3 6 Starting the System Upon completion of the set up steps described in section 3 1 to 3 5 the plc will take over control of the MBS and operate the pump and boilers in accordance with the system requirements programmed in section 3 4 The plc control will automatically monitor the entire ECO PAK MBS system and display all relevant data on the touch screen All components are monitored for fault conditions and any fault condition will be displayed on the touch screen All details of starting the system is in Integrated Controller I amp O manual System Start up Procedure section 3 7 Handing Over Upon completion of the commissioning checks the system should be handed over to the end user Please provide copies of the completed record sheet in addition to this manual The end user should be instructed on how to alter basic settings within the first level control of the plc and instructed on what actions to take in the event of a fault occurring Page 20 of 118
71. as leaks Before starting the boiler and during Initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove the top access panel and smell the interior of the boiler enclosure Do not proceed with startup if there is any indication of a gas leak Use an approved leak detection solution Repair any leaks at once DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Figure 10 1 Condensate Trap 2 PVC CAP WITH BLOCKED DRAIN SWITCH RETAINING PVC TEE ASSEMBLY FACTORY SUPPLIED TO FLOOR DRAIN SCREW A FROM HEAT EXCHANGER ECO PAK Installation amp Operation Manual BOILER Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and the gas may no longer have an odor Before startup and _ periodically thereafter have the propane supplier verify the correct odorant level in the gas Check thermostat circuit s 1 Disconnect the two external wires connected to the room thermostat terminals on the connection board 2 Connec
72. ate or guard vent to prevent condensate damage to exterior finishes Do not attach a U Bent to the rain cap Doing so could cause recirculation see FIG 5 5 4 Cut one 1 hole 5 inch diameter for 3 Concentric Vent installations or 7 inch diameter for 4 Concentric Vent installations into the structure to install the termination 5 Partially assemble the concentric vent termination kit Clean and cement following the cleaning procedures in these instructions Cement the Y concentric fitting to the larger diameter kit pipe see FIG s 4 7 and 4 8 page 21 Cement rain cap to the smaller diameter kit pipe see FIG s 4 7 and 4 8 page 21 Instead of cementing the smaller pipe to the rain cap a field supplied stainless steel screw may be used to secure the two 2 components together when field disassembly is desired for cleaning see FIG 4 11 page 22 ARNING When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used Failure to drill adequate holes may cause cracking of PVC components allowing combustion products to be recirculated Failure to follow this warning could result in personal injury or death ECO PAK Installation amp Operation Manual BOILER 5 Vertical direct venting continue Vertical termination optional concentric vent Do not operate the appliance with the rain cap removed or recirculation of comb
73. ater duty pump at preset minimum speed and enable ALL boilers Once enable signal by BAS is received AND the building schedule is satisfied AND OAT drops below 60 F adjustable then enable MBS system Once started the Controller calculates the system hot water supply temperature SHWST set point by measuring outside air temperature Default values are as follows Min OAT 0 F Max OAT 60 F Min SHWST 100 F Max SHWST 140 F ALL boilers shall start once flow has been verified by their own control system boiler flow switch If hot water flow has not been verified by Controller within specified time delay then send start signal to HW standby pump at same preset minimum speed and issue HW duty pump alarm on HMI If lag pump does not start shut down and issue pump and general alarms Controller shall send an analog signal to modulate boilers capacity to maintain the SHWST set point Controller shall modulate HW duty pump speed to satisfy hot water system demand Controller shall calculate boiler heat output capacity in MBH if optional water flow sensor is selected and installed Display of actual boiler heat output capacity in MBH on HMI Page 9 of 118 ARMSTRONG ly BOILER SEQUENCING ALGORITHM 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Controller shall run the boilers at best efficiency by sequencing boilers on and off at predetermined optimum efficiency staging points When lead boiler
74. ation Basic steps are listed below to guide you through the installation of the relief valve and the temperature and pressure T amp P gauge provided with the unit Near boiler piping components 1 Boiler isolation valves Factory supplied Full port ball valves are required Failure to use full port ball valves could result in a restricted flow rate through the boiler 1 Install the tee with the 3 4 inch fitting positioned vertically and on the top as shown in FIG 6 1 2 Install the relief valve into the 3 4 inch fitting of the tee installed in Step 1 FIG 6 1 3 Install a nipple and tee field provided as depicted in 2 Unions Factory supplied serviceability Recommended for unit 3 Temperature and pressure gauge Factory supplied The temperature and pressure gauge FIG 6 1 Install a temperature and pressure gauge is shipped loose It is the responsibility of the FIG 6 1 contractor to install the temperature and pressure gauge on the boiler water outlet Figure 6 1 Relief Valve T amp P Installation 4 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 5 Auto Air Vent Factory supplied The boiler purge valve is used to remove entrapped air from the heat exchanger during start up RELIEF VALVE TEMPERATURE 8 W PRESSURE GAUGE gt E INSTALL INSTALL NIPPLE AND TEE FIELD PROVIDED TEE WITH 3 4 FITTING ON TOP CLOSE N
75. ausing ice formations g Locate or guard vent to prevent condensate damage to exterior finishes ECO PAK AE Installation amp Operation Manual Figure 4 1A Sidewall Termination of Air and Vent TO BOILER INTAKE AIR ES FROM o VENT PIPE CONNECTION VENT AIR TERMINATION SNOW LINE If using the alternate sidewall termination 3 The air piping must terminate in a down turned elbow as shown in FIG 4 1B This arrangement avoids recirculation of flue products into the combustion air stream 4 The vent piping must terminate in an elbow pointed outward or away from the air inlet as shown in FIG 4 1B A WARNING Do not exceed the maximum lengths of the outside vent piping shown in FIG 4 1B Excessive length exposed to the outside could cause freezing of condensate in the vent pipe resulting in potential boiler shutdown Figure 4 1B Alternate Sidewall Termination of Air and Vent w Field Supplied Fittings TO BOILER INTAKE AIR BIRD SCREEN CONNECTION FROM on VENT PIPE 12 MIN CONNECTION 15 MAX TERMINATION PLATE de E A SCREEN GRADE OR SNOW LINE Page 37 of 118 ECO PAK Installation amp Operation Manual BOILER 4 Sidewall direct venting Vent air termination sidewall Figure 4 2B Alternate Clearance to Gravity Air Inlets Figure 4 1C Alternate Venting Arrangement if Space w Field Supplied Fittings Allows w Field Supplied Fitting TO
76. bottom to bring up the desired screen Page 87 of 118 ARMSTRONG ly AL ABM HISTORY Transmitter Far Transmitter Fa 12 56 16 06 0303 H T Transmitter Fautt 13 55 18 E US a SHART Transmitter Faulk 13 56 16 06 0309 System Flow Transmitter Fault 1 2 3 EVENT screen 16 40 42 O51 4109 Outside Air Temp Transt 16 46 42 0541 409 SHAHART Transmitter Faul 16 46 42 0514 09 SHST Transmitter Faul 1 3 Trend Displays 1 3 0 TREND MENU ARMSTRONG MBS TREND REAL TIME TEMPERATURE oY STEM FLOW BOILERS FLAME PRESSURE The events saved in the internal memory of the HMI are displayed Press the top right button black arrow to select the event to display The selected number indicates the number of days before today The event will be displayed for that day Pressing the event displayed will bring up the event Information screen Press the up and down arrow buttons to view more alarms Press the left and right arrow buttons to view more content of alarms Press the buttons on the menu at the bottom to bring up the desired screen Touching the TREND MENU button from Main Menu will call up the Trend Menu screen Touching any button from this screen will call up its corresponding trend chart display Touching the HISTORY button will call up Trend History Menu screen Touch the buttons on the menu at the bottom to bring up the desired screen Page 88 of 118 ARMSTRONG ly 1 3 1 TREND TEMPER
77. bove could result in severe personal injury death or substantial property damage When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Page 23 of 118 When servicing boiler To avoid electric shock disconnect electrical supply before performing mai
78. ces remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA and or CAN CSA B149 1 Natural Gas and Propane Installation
79. charts can be accessed and backed up The list of Setup Displays for every level is as follow Trend Menu Temperature Trend System Flow Trend Boiler Flame Trend Pump Speed Trend System Pressure Trend History Trend Menu History Trend Temperature History Trend System Flow History Trend Boiler Flame History Trend Pump Speed History Trend System Pressure The Trend Data Displays can be accessed without any password SYSTEM FUNCTIONS The System functions of the HMI operator interface include the Operator Displays the Installer Displays and the Factory Displays To access the Installer Displays the user is required a level 1 password To access the Factory Displays the user is required a level 2 password There is no password requirement to access the Operator Displays OPERATOR DISPLAYS Operator Displays include system displays alarm management displays trend displays and level O setup displays These displays can be accessed without any password and level O setup displays are for viewing only 1 1 0 System Displays See the following table Page 82 of 118 ARMSTRONG g 1 1 0 MAIN MENU ARMSTRONG MBS OFF ECOPARK MBS INTEGRATED HEATING SOLUTION 1 1 1 SYSTEM OVERVIEW SYSTEM OVERVIEW 740 of 20 fe 2009 alll Y LS l 1 d ett Ott 3 RE ce OF 4 EE This is the screen the operator sees when powering up the unit 1 Press SYSTEM OVERVIEW to view
80. cold feed make up water line Install a pressure reducing valve on the cold feed make up water line 15 psi nominal Check temperature and pressure gauge shipped separately which should read a minimum pressure of 12 psi Make sure the circulator is properly sized for the system and friction loss Install an expansion tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank installation Size the expansion tank for the required system volume and capacity Install an air elimination device on the system supply Install a drain valve at the lowest point of the system NOTE The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the safety relief valve outlet Never block the outlet of the safety relief valve The relief valve tee and any necessary fittings are shipped in the install kit with the boiler and are to be field installed FIG 6 1 Page 48 of 118 ECO PAK Installation amp Operation Manual BOILER 6 Hydronic piping continued Relief valve and temperature and pressure gauge install
81. control and the 0 10 vdc terminal is connected to the 0 10 vdc terminal of the external control Runtime contacts The control module closes a set of dry contacts whenever the burner is running This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat Alarm contacts The control module closes another set of contacts whenever the boiler is locked out or the power is turned off This can be used to turn on an alarm or signal a Building Management System that the boiler is down Note that these contacts will close momentarily at the end of each call for heat Page 55 of 118 Installation amp Operation Manual ECO PAK BOILER Figure 8 3 Low Voltage Field Wiring Connections 8 Field wiring continued JVNOILdO 4SOLNO JOYLNOOD Y31VM MOT GSLVYDILNI ONOYLSINYV TOULNOD UND TWNYALXS DAGAOL 0 NONS Gd T3lHS dq V ANNOY9 d T3iHS YOSNAS YOOULINO YOSNIS ANVL MHA YOSNIS IWALSAS ONIDNANOAS O 4AOLND Y31VM MOT Sl ojoj TOULNOD INOZ M I IVLSONW IdHI1 WOON Y gt Se ON HOLIMS MOJA SLIVWLNOI I oo 3 NILNNY _ SLOVLNOD INV TV HOLIMS MO14 HOLIMS J3YNSSIYA SVD SNIAOYd 39130 XNV AIddNS LO ld 39130 XNV Page 56 of 118 9 Condensate disposal Condensate drain 1 This boiler is a high efficiency appliance that produces condensate 2 The side of the boiler has a 1 2 inch PVC union for connection of a 1 2 inch PVC
82. control screen Press the buttons on the menu at the bottom to bring up the desired screen Page 83 of 118 ARMSTRONG g 1 1 2 PUMP OVERVIEW PUMP OVERVIEW Nia Nia Nia Nia Stopped Stopped ETEC 1 1 3 PUMP 1 CONTROL screen PUMP 1 CONTROL Pra Stopped 1 Mode displays pump operation mode Hand Off or Auto 2 Duty shows which pump is duty and which one is standby 3 Run Fbk shows whether the pump is running or stopped 4 Speed is displayed in both value of full speed and absolute RPM 5 Run Hours are displayed and can be reset in pump control screen 6 Alarm will be displayed if there is a problem with the pump 7 Pressing Pump 1 button will bring up the pump 1 control screen to view and control pump parameters 8 Press the buttons on the menu at the bottom to bring up the desired screen This screen is to control the pump Hand Off Auto Duty mode and hand speed 1 Press the HAND OFF AUTO buttons to select the desired mode 2 The pump mode is displayed under these buttons no display means N A 3 Press DUTY button to set the Pump as duty pump the other pump will become Stand by 4 When in Hand mode enter the desired speed in the Hand Speed box 5 When in Auto mode the speed of the pump is automatically determined by the controller 6 Pump duty is displayed Duty or Standby 7 Pump status is displaye
83. cription of Select hot water circuit size Enter the P and D parameters for selected circuit Press Save button to save changed values to the system factory defaults press Restore button to retrieve pump PID setup value from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen Page 106 of 118 ARMSTRONG g 3 4 2 BOILER PID SETUP 3 4 3 BYPASS PID SETUP 1 Press bottom right navigation button from BOILER SETUP to bring up this screen in order to set the Proportional Integral and Derivative gains to be used for controlling boiler 2 Enter a proportional gain Increasing the value will slow down the speed reaction to a system step change Decreasing the value will increase the speed reaction to a system step change 3 Enter the Integral time gain Increasing the value will slow down the speed reaction to a system step change Decreasing the value will increase the speed reaction to a system step change 4 Enter the D derivative time Increasing the value will increase the speed reaction to a system step change Decreasing the value will decrease the speed reaction to a system step change 5 Press Save button to save changed values to the system factory defaults press Restore button to retrieve pump PID setup value from the system factory defaults 6 Touch the buttons on the menu at the bottom to bring up the desired screen NOTE
84. cting Gas Supply Piping 30 Natural Gas 31 Pipe Sizing for Natural Gas 31 Natural Gas Supply Pressure Requirements 31 Propane Gas 31 Pipe Sizing for Propane Gas 31 Propane Supply Pressure Requirements 31 Check Inlet Gas Supply 32 Gas Pressure 33 Gas Valve Replacement 33 8 FIELD WIRING Line Voltage Connections 34 Low Voltage Connections 35 TOCIMOSl Laurie eos rd eee epee sa oe 35 FION N cesos sciess seems ae bot eee as aaa 39 Armstrong Integrated Control 35 Fun ume COMICS cidade adas Ea 35 Alarm Contacts 30 9 CONDENSATE DISPOSAL Condensate Drain 37 10 STARTUP 38 42 11 OPERATING INFORMATION General A 43 44 Sequence of Operation 45 Control Module 46 47 Status Display Screens 48 49 12 MAINTENANCE Maintenance and Annual Startup 50 53 13 DIAGRAMS Ladder Diagram 54 Wiring Diagrami ya Bev ap ta le a e ec be a 55 Revision Notes Back Cover Hazard definitions The following de
85. d Running or Stopped 8 Run Hours indicates the pump total running time since the last reset and can be reset by pressing the displaying area 9 Alarm will be displayed if there is a problem with the pump 10 Controller output speed Referential speed sent to the VFD is displayed in value of pump full speed 11 Pump actual speed Feedback from the VFD is displayed in value of pump full speed 12 SHWRT error VFD amps voltage and power is displayed 13 Press the buttons on the menu at the bottom to bring up the desired screen Page 84 of 118 ARMSTRONG g 1 1 4 BOILER OVERVIEW BOILER OVER VIEVY MIA MA MA Ready Ready Ready 1 15 GAS CONSUMPTION POP UP screen Off 0000 CF Feset ae ue eady Ready ODO CFH Thermal Efficiency o000 0 him 24Days GAS CONSUMPTION Pressing BOILER N button will bring up the boiler n control screen to view and control boiler parameters Mode shows boilers operation mode Hand Off or Auto Duty shows boilers working sequence Lead Lag1 Lag2 Lag3 Status shows the boilers run status Not Ready Ready Enabled Started Running and Alarm Flame is displayed in value of full value Boiler run time is displayed System Hot Water Supply Temperature SHWST is displayed The remaining time to switch the lead boiler is displayed Gas consumption button is displayed when gas pulses are enabled Pressing Gas consumption button
86. d on top of this screen The current time and the time point of the vertical line will be displayed on the left top of the chart area Touching the navigation buttons below the chart area will let you navigate the charts in different time periods Touching the button to the left of navigation buttons will bring up the History Trend Range pop up box to select the date to view history trend chart Touch the buttons on the menu at the bottom to bring up the desired screen Touching the PUMPS SPEED button from TREND HISTORY MENU will call up the History Pump Speed Chart screen This will display 2 graphs consisting of e Pump 1 Speed e Pump 2 Speed Touching chart display area will display a vertical line Corresponding the time axis of the line the values of 2 charts are displayed on top of this screen The current time and the time point of the vertical line will be displayed on the left top of the chart area Touching the navigation buttons below the chart area will let you navigate the charts in different time periods Touching the button to the left of navigation buttons will bring up the History Trend Range pop up box to select the date to view history trend chart Touch the buttons on the menu at the bottom to bring up the desired screen Page 93 of 118 ARMSTRONG g 1 3 6 5 TREND PRESSURE 06 03 09 1 4 Level 0 Setup Displays See the following table 1 4 0 LEVEL 0 SETUP MENU IRMSTRONG j MEE uN MAIN
87. d stainless steel construction the burner uses pre mixed air and gas and provides a wide range of firing rates Condensate drain connection Connects the condensate drain line to a 1 2 PVC union Control Module The Control Module responds to internal and external signals and controls the blower gas valve and pumps to meet the heating demand Electronic display The electronic display consists of 7 buttons and a dual line 32 character liquid crystal display Flame inspection window The quartz glass window provides a view of the burner surface and flame Flame sensor Used by the control module to detect the presence of burner flame Flue gas sensor This sensor monitors the flue gas exit temperature The control module will modulate and shut down the boiler if flue gas temperature gets too hot This protects the flue pipe from overheating Flue pipe adapter Allows for the connection of the PVC vent pipe system to the boiler Gas connection pipe Threaded pipe connection either 1 2 or 3 4 depending on the model This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler Gas shutoff valve Manual valve used to isolate the gas valve from the gas supply ECO PAK BOILER 19 20 21 22 23 24 25 26 27 28 29 30 32 33 34 35 Installation amp Operation Manual Gas valve The gas valve senses the negative pressu
88. del 285 INTAKE COMBUSTION AIR NOTE Not available for Canadian installation A B DIA PVC A Ae B B DIA PVC VENT EXHAUST B DIA PVC VENT EXHAUST CUORE ae ae NOTICE Instead of cementing the smaller pipe to the rain cap a field supplied stainless steel screw may be used to secure the two 2 components together when field 6 Install the Y concentric fitting and pipe assembly through the structure s hole from an inside wall disassembly is desired for cleaning see FIG 4 11 When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used Failure to drill adequate holes may cause cracking of PVC components allowing combustion products to be recirculated Failure to follow this warning could result in personal Injury or death NOTICE Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 7 Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly from an outside wall Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting for 3 Concentric Vent installations and fastened tightly into the rubber adapter for 4 Concentric Vent installations 8 Secure the assembly to the structure as shown in FIG 4 12 using field supplied me
89. e resulting in potential water damage to property 8 A condensate removal pump is required if boiler is below drain When installing a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage The switch should be wired to the auxiliary device proving switch terminals on the low voltage connection board 1 2 PVC UNION FACTORY SUPPLIED NEUTRALIZER KIT Page 57 of 118 10 Start up Check control water chemistry A CAUTION Do not use petroleum based cleaning or sealing compounds in the boiler system Damage to elastomer seals and gaskets in the system could occur resulting in substantial property damage Hardness less than 7 grains 1 Consult local water treatment companies for hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 Do not fill boiler or operate with water containing chlorine in excess of 200 ppm 2 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower 3 Do not use the boiler to directly heat swimming pool or spa water Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructi
90. e PVC cap A WARNING Contato alo ts milsd FIG 12 1 boiler life Minerals can build up in 3 Remove the 2 inch PVC cap with the switch located at the sections reducing heat transfer top of the trap FIG 12 1 overheating heat exchanger and causing heat exchanger failure Leaking water may 4 Remove any sediment in the trap i j also cause severe property damage 5 Fill with fresh water until the water begins to pour out of o f bedan 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems 6 Replace the cap Press the cap onto the trap until the cap found makes contact with the drain 3 Check gas line using the procedure found in Section 7 7 Replace the retaining screw Gas Connections Page 71 of 118 12 Maintenance Flue vent system and air piping 1 Visually inspect the entire flue gas venting system and air ECO PAK BOILER piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that air inlet pipe is connected and properly sealed Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system l Verify all system components are correctly installed and operational Check the cold fill pressure for the system V
91. e installed to prevent gravity circulation of heater water in the coils during the cooling cycle A chilled water medium must be piped in parallel with the heater Freeze protection Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose This includes inhibitors which prevent the glycol from attacking the metallic system components Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level The system should be tested at least once a year and as recommended by the producer of the glycol solution Allowance should be made for the expansion of the glycol solution in the system piping A WARNING Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems ECO PAK Installation amp Operation Manual BOILER General piping information Basic steps are listed in this section which will guide you through the installation of the ECO PAK boiler l 10 A WARNING Connect the system return marked Inlet make sure to install with pipe sealant compound Connect the system supply marked Outlet make sure to install with pipe sealant compound Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone Install a backflow preventer on the
92. e second two boxes in column 1 to enter the range and zero for system discharge pressure sensor Press the third two boxes in column 1 to enter the range and zero for system strainer inlet pressure sensor Press any box in column 2 to toggle the pressure unit among psi ft KPa m and bar Press Restore button to retrieve sensor setup 2 values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen Press FROST PROT SETUP button from LEVEL 1 MAIN SETUP to bring up this screen Frost protection can be enabled or disabled Enter SHWRT set point 1 When SHWRT drops below this value duty pump will be started at the minimum speed Enter SHWRT set point 2 When SHWRT drops below this value lead boiler will be started at the minimum capacity Press Restore button to retrieve frost protection setup values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen Page 103 of 118 ARMSTRONG ul 2 4 11 BYPASS SETUP BYPASS YALWE SETUP 3 Defaut valve opening when sensor fails BE WHEN BYPASS VALVE IS OPENED AT 100 1 1 By pra Y alye 2 Flow setpoint 4 Shut down lead boiler after SH Shut down duty pump after RESTORE E wanu systemowe mam sere E Default Settings 2 4 12 BYPASS PID SETUP BYPASS VALVE PID SETUP 1 Enter the PIC Proportional Gain
93. e the motor with correctly sized overload protection 3 Keep moisture refuse dust or other loose particles away from the pump and ventilating openings of the motor 4 Avoid operating the unit in overheated surroundings Above 100 F 40 C Page 112 of 118 ARMSTRONG g WARNING Whenever any service work is to be performed on a pumping unit disconnect the power source to the driver LOCK it OFF and tag with the reason Any possibility of the unit starting while being serviced must be eliminated If mechanical seal environmental accessories are installed ensure water is flowing through the sight flow indicator and that filter cartridges are replaced as recommended LUBRICATION Pump Lubrication is not required There are no bearings in the pump that need external lubrication service Motor Follow the lubrication procedures recommended by the motor manufacturer Many small and medium sized motors are permanently lubricated and need no added lubrication Generally if there are grease fittings evident the motor needs periodic lubrication None if not Check the lubrication instructions supplied with the motor for the particular frame size indicated on the motor nameplate Mechanical Seal Mechanical seals require no special attention The mechanical seal is fitted with a flush line The seal is flushed vented to the suction on close coupled pumps Do not run the pump unless properly filled with water as the mechanical seals
94. e to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems Figure 12 1 Condensate Trap 1 Inspect any problems reported by the owner and correct before proceeding Eee BLOCKED DRAIN SWITCH RETAINING SCREW q aa FROM HEAT EXCHANGER Inspect boiler area PVC TEE ASSEMBLY l Verify that boiler area is free of any combustible FACTORY SUPPLIED materials gasoline and other flammable vapors and liquids 2 Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual and the ECO PAK Boiler Service Manual TO FLOOR DRAIN Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler A WARNING The condensate trap must be filled with water during all times of boiler operation 2 Vacuum any sediment from inside the boiler and to avoid flue gas emission from the components Remove any obstructions condensate drain line Failure to fill the trap could result in severe personal injury Clean condensate trap or death 1 Inspect the condensate drain line condensate PVC Check all piping for leaks fittings and condensate trap Eliminate all system or boiler leaks 2 Remove the PVC cap retaining screw from th
95. eck burner flame 1 Inspect flame through observation window 2 If the flame is unsatisfactory at either high fire or low fire turn off boiler and allow boiler to cool down Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air Do not use compressed air to clean burner if performed inside a building 3 Remove the burner reference FIG 12 2 below 4 When replacing the burner ensure gasket is in good condition and positioned correctly FIG 12 2 Figure 12 2 Burner Assembly ll J SCREWS Fi QTY 5 Check flame signal 1 At high fire the flame signal shown on the display should be at least 10 microamps 2 A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrode does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode 3 See Section 3 Troubleshooting of the ECO PAK Boiler Service Manual for other procedures to deal with low flame signal Review with owner 1 Review the User s Information Manual with the owner 2 Emphasize the need to perform the maintenance schedule specified in the User s Information Manual and in this manual as well 3 Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behay or ECO PAK SER Installation amp Operation Manual 4 Remind the owner to follow the pro
96. ent on the air separator of the ECO PAK MBS If large amounts of air are expelled the water make up will be opened and refill the system Once venting is complete the entire system should be flushed and the appropriate water treatment applied see section 1 10 3 2 Gas Purging The gas type and supply pressure must be checked before commissioning The gas type should be natural gas and the supply pressure between 4 and 14 of w c For LPG the nominal pressure should be 10 inches of w c not exceeding 14 inches of w c To prevent damage to the gas meter the incoming gas valve must be opened slowly The entire gas inlet pipe system particularly the joints should be checked for leaks before commissioning The gas burner valve must only be tested up to a maximum of 60 of w c The ECO PAK MBS must not be operated at gas pressures outside the quoted figures For detailed information refer to Boiler I amp O manual Gas Connections section 3 3 Controls With all boilers switched OFF at their local isolators the control system can now be commissioned The plc has been factory tested and pre programmed with default settings The plc menu structure should now be accessed and the default settings confirmed Any alterations required for the specific application min speed temperatures etc should be recorded The pump rotation should also be checked If found to be incorrect swap two of the incoming phases If phase rotation checks have
97. er water leakage into the building Please read the information given in Table 1A page 11 listing contaminants and areas likely to contain them If contaminating chemicals will be present near the location of the boiler combustion air inlet have your installer pipe the boiler combustion air and vent to another location per this manual A WARNING If the boiler combustion air inlet IS located in a laundry room or pool facility for example these areas will always contain hazardous contaminants A WARNING To prevent the potential of severe personal injury or death check for areas and products listed in Table 1A page 11 before installing the boiler or air inlet piping If contaminants are found you MUST e Remove contaminants permanently _OR Relocate air inlet and vent terminations to other areas Page 36 of 118 4 Sidewall direct venting Vent air termination sidewall Follow instructions below when determining A WARNING U ae vent location to avoid possibility of severe personal injury death or substantial property damage A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves parapets balconies or decks Failure to comply could result in severe personal injury death or substantial property damage A WARNING Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe Failure to comply could
98. eral 1 6 Location The ECO PAK MBS modules should be installed on a clean flat surface Modules installed in a straight line or L configuration should be located against a solid preferably external wall It is recommended that the modules are fixed back to the wall to prevent accidental toppling of the units Where units are located in the centre of a plant room they should be fixed down to floor Space should be allowed at the front of the modules minimum 3 ft to allow for maintenance and at the sides for access to the pipe connections see section 1 13 The boiler room must be dry and the room temperature should be between 40 F and 104 F 1 7 Gas Supply At the early planning stage please contact the local gas supplier to determine the availability of an adequate supply An existing supply must only be used with the permission of the gas supplier and a new primary gas meter can only be connected by the gas supplier or a gas registered installer The primary meter and its associated supply pipe must be capable of passing the gas quantity and nominal pressure detailed in section 1 2 The supply pipe must not be smaller than the gas header 2 inches and may in some cases need to be larger to offset the pressure loss through the pipe A secondary in line turbine type gas meter is provided on the ECO PAK MBS gas header as an option The complete gas installation site supply pipe and ECO PAK MBS gas header must be tested for
99. erature and pressure gauge field installed not shown Monitors the outlet temperature of the boiler as well as the system water pressure Top panel Removable panel to gain access to the internal components Venturi The venturi controls air and gas flow into the burner Water inlet system return NPT water connection that returns water from the system to the heat exchanger either 1 or 1 1 4 depending on the model Water outlet system supply NPT water connection that supplies hot water to the system either 1 or 1 1 4 depending on the model Page 24 of 118 Installation amp Operation Manual ECO PAK BOILER The Boiler How it works continued Model 210 Model 210 Rear View Front View Model 210 Z y gt Y f Y D gt UR N NE LOOTI NIT CI I O NI j Right Side inside unit Model 210 Left Side inside unit Model 210 Page 25 of 118 ECO PAK Installation amp Operation Manual BOILER The Boiler How it works Model 285 Front View Model 285 Rear View Model 285 Left Side inside unit Model 285 Right Side inside unit Model 285 Page 26 of 118 ECO PAK Baie Installation amp Operation Manual ECO PAK Boiler I B R Rating Net Input Gross IFB R Boiler MBH Output Ratings Water Model Number MBH Water Content Note 5 MBH Gallons Note 2 7 Note 3 7 ECO PAK 285 285 NOTICE Maximum allo
100. erify it is correct must be a minimum of 12 psi Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expansion tank l Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 6 Hydronic Piping for suggested best location of expansion tanks and air eliminators Check boiler relief valve l Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 6 Hydronic Piping before proceeding further Following installation the valve lever must be A WARNING operated AT LEAST ONCE A YEAR to ensure Certain naturally that waterways are clear occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check t
101. eter from the pressure tap on top of the gas valve Re tighten the set screw inside the pressure 2 Shut off gas supply at the manual gas valve in the gas tap piping to the appliance Page 52 of 118 Y Gas connections continued A WARNING When re tightening the set screw be sure to tighten securely to prevent gas leaks Do not check for gas leaks with an open flame use the bubble test Failure to use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 14 Turn on the gas supply at the manual gas valve 15 Turn the power switch to the ON position 16 Adjust the temperature set point on the control panel of the control module to the desired water temperature so the appliance will call for heat 17 Check burner performance by cycling the system while you observe burner response The burner should ignite promptly Flame pattern should be stable Turn system off and allow burner to cool then cycle burner again to ensure proper ignition and flame characteristics Figure 7 4 Inlet Gas Supply Check LOOSEN THE SET SCREW ONE 1 FULL TURN AND PLACE THE MANOMETER TUBING OVER THE PRESSURE TAP DETAIL ECO PAK Installation amp Operation Manual BOILER Gas Pressure The gas pressure must remain between 4 inches w c natural 8 inches w c LP minimum and 14 inches w c natural and LP maximum during stand by static mode and
102. ext of Log In 1 From the LEVEL 2 MAIN SETUP press Clock Setup button to call up this screen to adjust the time in the HMI and the time in the PLC 2 The HMI time and date can be adjusted by pressing the individual hour minute second month day year box and entering the corresponding value The day of the week will be changed automatically 3 The system PLC time and date can be adjusted by pressing the individual hour minute month day year and day of the week box and entering the corresponding value 4 Press Set PLC button to write the displayed time and date to system 5 Touch the buttons on the menu at the bottom to bring up the desired screen ARMSTRONG a OFF ECOPARK MB INTEGRATED HEATING S OLL ITION SYSTEM OVERVIEW BOILER OVER VIEVY PUMP OVERVIEVY ALARM SCREEN SETUP SCREEN TREND MENU IRMSTRONG LEWEL O gt MAIN SETUP SCREEN WATER TEMP SETUP PUMP SETUP BOILER SETUP SENSOR SETUP FROST PROT SETUP BYPASS SETUP BAS SETUP CLOCK SETUP SCHEDULE SETUP Log In i menor sysovre Bower ovr Pump ovr Page 108 of 118 ARMSTRONG g 5 A keypad pops up Touch the level 1 or level 2 password then press Ent 6 The screen changes to LEVEL 1 MAIN SETUP SCREEN or LEVEL 2 MAIN SETUP SCREEN Press the button on the top right corner indicated x EVEL 2 as REMOTE START MAN SETUP SCREEN ARMSTRONG ES Default Settings save RESTORE CEL EE PR
103. fined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product A DANGER Injury A WARNING Injury DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate A CAUTION oy CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Page 22 of 118 ECO PAK SOLER Installation amp Operation Manual Please read before proceeding A WARNING NOTICE A WARNING A WARNING Installer Read all instructions including this manual and the ECO PAK Boiler Service Manual before installing Perform steps in the order given User This manual is for use only by a qualified heating installer service technician Refer to the User s Information Manual for your reference Have this boiler serviced inspected by a qualified service technician at least annually Failure to comply with the a
104. following list PVC CPVC or ABS Dryer Vent or Sealed Flexible Duct not recommended for rooftop air inlet Galvanized steel vent pipe with Joints and seams sealed as specified in this section Type B double wall vent with joints and seams sealed as specified in this section Plastic pipe may require an adapter not provided to transition between the air inlet connection on the appliance and the plastic air inlet pipe The ECO PAK boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3B below Table 3B Air Intake Vent Piping Sizes Air Intake Vent 3 inches 285 4 inches NOTICE Increasing or decreasing combustion air or vent piping is not authorized Minimum Maximum allowable combustion air and vent piping lengths are as follows 4 inches Combustion Air 12 equivalent feet minimum 100 equivalent feet maximum Vent 12 equivalent feet minimum 100 equivalent feet maximum When determining equivalent combustion air and vent length add 5 feet for each 90 elbow and 3 feet for each 45 elbow EXAMPLE 20 feet of PVC pipe 4 90 elbows 2 45 elbows 1 3 concentric vent kit 49 equivalent feet of piping NOTICE The appliance output rating will reduce by up to 1 5 for each 25 feet of vent length Page 35 of 118 3 General venting Removing from existing vent Follow the instructions in Section 1 page 11 of this manual when removing
105. gas soundness and purged in accordance with the applicable local standards The ECO PAK MBS is designed for use with natural gas with a nominal supply pressure of 8 in water column LPG option available For more detailed information see Boiler I amp O manual Gas Supply section 1 8 Venting Systems ECO PAK MBS boiler modules are designed as room sealed appliances and must use Direct Venting Cat IV Individual vent terminations can be made either vertically through the roof or horizontally through the sidewall Horizontal vent runs must be inclined for every ft of pipe run to allow condensate to drain back to the boiler The vent ducts and terminals MUST NOT be closer than 1 inch to combustible material 3 75 mm and 4 100 mm Concentric Vent kits are available through Armstrong upon request Due to the high efficiency of the boilers pluming will occur For this reason it is generally recommended that vents terminate through the roof However regardless of whether vents are installed vertically or horizontally they should never terminate in a position that could cause problems It is the responsibility of the installer to ensure that products of combustion cannot re enter the building or any adjacent building through louvres windows doors mechanical ventilation air conditioning systems or natural infiltration For minimum distances between vents and air intakes refer to Boiler I amp O manual General Venting section
106. ght setback holiday settings virtual hand off auto HOA and time extension buttons Subsequent screens are also password protected and provide access to mode system set up PID set up frost protection clock set up and reset and restore default screen Page 3 of 118 ARMSTRONG ly The logic controller is based on Flash style memory The integrated controller performs self diagnostic testing of the CPU s RAM and flash memory Existing data is stored and protected during momentary power supply interruptions The ECO PAK MBS integrated controller is capable of both hard wired and serial communication with the BAS The standard communication protocol is Modbus Optional communication protocols include BACnet IP BACnet Ethernet BACnet MS TP and LonWorks Clearly marked terminals are provided for BAS interface and for various field mounted devices such as OA sensor A hot water flow sensor can also be supplied as an option connected to the terminal strip and will display water flow reading in GPM on the HMI A make up cold water fill assembly is provided to automatically fill the entire system to the pre set cold fill pressure An expansion tank with heavy duty butyl replaceable bladder is provided loose for field connection to the return header with isolating valve An optional in line turbine type gas flow meter shall be fitted in the gas header in order to read gas consumption and monitor thermal efficiency When the gas meter is connected
107. ground level the modules can be moved into position with a forklift or trolley Do not attempt to join modules together until they are in their final position 2 2 Unpacking Each module is individually wrapped with plastic and system components are enclosed inside an enclosure made of galvanized steel framework and metal panels protecting the equipment It is recommended that wrapping is kept in position initially particularly whilst holes are cut for flues to provide protection during installation The wrapping can then be cutback around the pipe and flue connections to facilitate the installation Prior to the commencement of pre commissioning activities remove all wrapping and protection making sure that none remains to block pipes vents or air intake piping 2 3 Fixing in Position To allow perfect alignment it is not recommended to fix the frames to the wall or floor until the flanged connections on each module have been bolted together Although each module is stable care must be taken at this stage not to put excessive force on to the top of any module to prevent accidental toppling Once the flanged connections are made good fine adjustments can be achieved using the levellers on each module so the modules sit straight on the concrete pad Page 14 of 118 ARMSTRONG g Then modules can be anchored and fixed to the ground using the angle brackets supplied with each module 2 4 Ventilation Although these are roo
108. he pH value is not altered Preferably additives from the same manufacturer should be used The instructions of the manufacturer should always be observed The hardness of the system water has to be checked every year and an appropriate amount of additive introduced via the dosing pot as necessary Failure to observe the requirements in this section will render the warranty void For more detailed information on water quality see Boiler I amp O manual Start up section 1 11 Electric Supply All interconnecting wiring between the control panel twin head pump boiler modules and sensors is completed and tested in the factory prior to shipping Plug and socket arrangements are provided to connect the boiler modules to the control module The only site wiring required by others is to bring the incoming 3 phase power supply outdoor air temperature sensor and BAS serial communication wiring into the junction box located on the back of the pump module All electrical work must be in accordance with the current NEC Wiring Regulations and any other local regulations that may apply Page 12 of 118 ARMSTRONG ll Junction Box Terminals Junction Box TB x 37 PH1 38 PH2 Incoming Power 208 230 460 or 575 39 PH3 VAC 60 Hz 40 GND 2 y Outside Air Temperature Sensor GND LE a Flow Sensor Optional For more detailed information on electrical wiring 14 E connections on site refer to Controller I amp O manual Remote Star
109. ical line will be displayed on the left top of the chart area 4 wo i P lo 4 Touching the navigation buttons below the chart area E will let you navigate the charts in different time CMA Mammen serve meras treo menu RL periods 5 Touch the buttons on the menu at the bottom to bring up the desired screen Page 90 of 118 ARMSTRONG g 1 3 5 TREND PRESSURE 1 3 6 TREND HISTORY MENU ARMSTRONG _ i HISTORY DATA BACKUP MBS TREND HISTORY Touching the PRESSURE button from TREND MENU will call up the System Pressure Chart screen This will display 3 graphs consisting of e The strainer Inlet Pressure e The Suction Pressure e The Discharge Pressure Touching chart display area will display a vertical line Corresponding the time axis of the line the values of 3 charts are displayed on top of this screen The current time and the time point of the vertical line will be displayed on the left top of the chart area Touching the navigation buttons below the chart area will let you navigate the charts in different time periods Touch the buttons on the menu at the bottom to bring up the desired screen Touching the HISTORY button from TREND MENU will call up the Trend History Menu screen Touching any button from this screen will call up its corresponding trend history chart display Touching the TREND MENU button will go back to Trend Menu screen Touching the
110. in different time periods Touch the buttons on the menu at the bottom to bring up the desired screen Page 89 of 118 ARMSTRONG ly 1 3 3 TREND BOILER FLAME 1 Touching the BOILERS FLAME button from TREND MENU will call up the Boiler Flame Chart 06 03 09 screen This will display maximum 4 graphs consisting of Boiler 1 Flame Boiler 2 Flame Boiler 3 Flame Boiler 4 Flame 2 The number of charts are depend on the number of boilers Set up by ECO PAK MBS Model 3 Touching chart display area will display a vertical line Corresponding the time axis of the line the values of OMAIN MENU SETUP MENU TREND MENU Ci charts are displayed on top of this screen 4 The current time and the time point of the vertical line will be displayed on the left top of the chart area 5 Touching the navigation buttons below the chart area will let you navigate the charts in different time periods 6 Touch the buttons on the menu at the bottom to bring up the desired screen 1 3 4 TREND PUMP SPEED Pump 1 0 0 1 Touching the PUMPS SPEED button from TREND MENU will call up the Pump Speed Chart screen 11 10 05 19 09 This will display 2 graphs consisting of e Pump 1 Speed e Pump 2 Speed 2 Touching chart display area will display a vertical line Corresponding the time axis of the line the values of 2 charts are displayed on top of this screen 3 The current time and the time point of the vert
111. ing section on page 15 of this manual 3 You must consider the surroundings when terminating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets Page 41 of 118 Cement the Y concentric fitting to the larger kit pipe FIG s 4 7 and 4 8 Cement the rain cap to the smaller diameter kit pipe FIG s 4 7 and 4 8 Figure 4 7 Kit Contents_3 Concentric Vent RAIN CAP 4 DIA SDR 26 PIPE 3 DIA SDR 26 PIPE Y CONCENTRIC FITTING Figure 4 8 Kit Contents_4 Concentric Vent NOTE Not available for Canadian installation RAIN CAP 6 152 MM TO 4 102 MM REDUCER 6 152 MM DIA 6 152 MM DIA 4 102 MM DIA Y CONCENTRIC FITTING 6 152 MM DIA FLEXIBLE PIPE COUPLING ECO PAK Installation amp Operation Manual BOILER 4 Sidewall direct venting Sidewall termination optional concentric vent Figure 4 9 Concentric Vent Dimensional Drawing Figure 4 10 Concentric Vent Dimensional Drawing Model 210 Mo
112. inside the range the MBS is enabled 5 Press Restore button to retrieve schedule setup values from the system factory defaults 6 Touch the buttons on the menu at the bottom to bring up the desired screen FACTORY DISPLAYS Factory Displays include system displays alarm management displays trend displays and level 2 setup displays To access level 2 setup displays the user is required a level 2 password 3 1 System Displays See previously in the Operator Displays 3 2 Alarm Management Displays See previously in the Operator Displays 3 3 Trend Displays See previously in the Operator Displays 3 4 Level 1 Setup Displays Most of the level 2 setup displays are almost the same as the level 1 setup displays except that the user can press Save button to save changed values to the system factory defaults on each setup display screen However some different displays are listed in the following table Page 105 of 118 ARMSTRONG ly 3 4 0 LEVEL 2 SETUP MENU ARMSTRONG LEVEL 2 MAN SETIP SCREEN PUMP SETUP SENSOR SETUP _ CLOCK SETUP SCHEDULE SETUP Default Settings Save RESTORE gt F Local and Remote Control by pressing the toggle switch below 3 4 1 PUMP PID SETUP PUMP PICO SETHE menmen evetemowe 4 mamserue Yo Pressing and inputting the proper password in LEVEL 0 SETUP screen will call up the Level 2 Setup screen Pressing the LOCAL REMOTE START button will
113. ions of the finished termination piping as shown in FIG 4 14 page 17 If using the alternate sidewall termination do not extend exposed vent pipe outside of the building more than what is shown in this document Condensate could freeze and block vent pipe Page 39 of 118 4 Sidewall direct venting Multiple vent air terminations 1 When terminating multiple ECO PAK boilers terminate each vent air connection as described in this manual FIG 4 5A 4 WARNING All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury death or substantial property damage 2 Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet as shown in FIG 4 5A for U S installations For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of an ECO PAK boiler is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 4 5A Multiple Vent Terminations must also comply with Figure 4 1A 12 MIN BETWEEN EDGE OF AIR INLET AND ADJACENT VENT OUTLET VENT AIR VENT AIR TERMINATION ECO PAK ae Installation amp Operation Manual Figure 4 5B Alternate Multiple Vent Terminations w Field Supplied Fittings must also comply with Figure 4 1B VENT 12 MIN 15 MAX 12 MIN B
114. is running at less than its minimum capacity for more than 2 minutes adjustable shut down boiler Duty pump still running at pre determined minimum speed Ifno heat demand is required while lead boiler is OFF for more than 20 minutes adjustable shut OFF HW duty pump Should more heat capacity to building load be required start LEAD boiler provided a time delay has elapsed since LEAD boiler has been OFF HW duty pump will start once LEAD boiler is enabled Any boiler alarm shall be displayed on HMI touch screen Controller shall perform manual and automatic alternation of HW pumps based on hours of operation 1 week alternation adjustable IF gas emergency shut off signal is connected to Controller when activated Controller will shut off operation of MBS system and issue an alarm general system alarm First shut down boiler and after 1 minute delay adjustable shut down pump 1 and 2 stage frost protection shall be provided as standard This feature is only active when MBS system is disabled by BAS Controller shall monitor SHWST and maintain it above 41 F adjustable When SHWST drops below 41 F but above 37 F adjustable then start duty pump and run at preset minimum speed If SHWST drops below 37 F then LEAD boiler is signaled to run at minimum capacity with pump running at minimum speed The frost protection shall be enabled even though the MBS is in REMOTE and BAS is commanding OFF Page 10 of 118 ARMSTRONG la 1 Gen
115. le Refer to the project specification for the main power supply requirement The outdoor air temperature sensor should be sited on a nearby north facing wall and wired to terminals 1 4 2 within the junction box using a two wire shielded twisted cable The shield should be earthed within the junction box Cables for sensors do not carry mains voltage but are low voltage The maximum lengths of wires for all sensors are Copper wires up to 394 ft 120 m 16 gauge 1 5 mm Page 17 of 118 ARMSTRONG ly Commissioning The commissioning of the system should be undertaken by suitably qualified personnel The following steps should be undertaken in the sequence described below The commissioning process is to be documented and the results recorded on the commissioning record sheet provided Please return the completed record sheet to Armstrong to confirm your warranty period 3 1 Filling the System Before attempting to fill the system ensure that there are no loose or open connections on the ECO PAK MBS or within the system Once satisfied then Check the expansion vessel charge pressure and adjust if necessary Factory set at 15 psig 1 0 bar Open L THW isolating valves and incoming water isolating valve Turn the main disconnect switch on to integrated controller System overview screen is on Fill the system using make up water line On completion of filling the entire system should be thoroughly vented while cold using the air v
116. ler and pumps turn off temperature rises above 45 F A CAUTION This feature of the control module does not eliminate the possibility of freezing The installation must still use recognized design installation and maintenance practice to prevent freeze potential for the boiler and system if boiler water Page 63 of 118 11 Operating information Monitor external limits Connections are provided on the connection board for external limits such as flow switch low water cutoff gas pressure switches and an auxiliary device proving switch The control module will shut off the burner and inhibit relighting whenever any of these external limits open Run time and alarm outputs The boiler provides dry contacts for indicating when the boiler is running and when it is unable to operate Run time and cycle counting The control uses two timers to monitor the total hours of burner operation One timer monitors the time the boiler is firing under 50 of rate The other timer monitors the time the boiler is firing over 50 rate The control uses four 4 ignition counters to monitor the amount of boiler cycles The first counter counts all ignitions of the control The second counter counts only ignition attempts that have failed The third and fourth counters are the same as the first and second respectively but can be reset by the installer Service reminder The control can be programmed for service reminder notification
117. lied couplings to extend pipes Airflow restriction will occur and may cause intermittent operation 9 Cement appliance combustion air and vent pipes to the concentric vent termination assembly See FIG 4 12 for proper pipe attachment 10 Operate the appliance one 1 heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections VENT AIR COMBUSTION Multiventing sidewall terminations When two 2 or more direct vent appliances are vented near each other each appliance must be individually vented see FIG 4 13 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented near each other two 2 vent terminations may be installed as shown in FIG 4 13 The next two 2 vent terminations must be at least 36 inches away from the first two 2 terminations It is important that vent terminations be made as shown to avoid recirculation of flue gases Dimension A in FIG 4 13 represents the distance between pipes or rain shields as touching or a 2 inch maximum separation A Figure 4 13 Concentric Vent and Combustion Air Termination Dimension A as Touching or 2 inches Maximum Separation Page 43 of 118 5 Vertical direct venting Vent air termination vertical A WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property dam
118. ll air inlet piping for the ECO PAK boiler as described in this manual Do not terminate vent air in locations that can allow contamination of combustion air Refer to Table 1A page 11 for products and areas which may cause contaminated combustion air A WARNING must pipe combustion air to the boiler air intake Ensure that the combustion air will not contain any of the contaminants in Table 1A page 11 Contaminated combustion air will damage the boiler resulting in possible severe personal injury death or substantial property damage Do not pipe combustion air near a swimming pool for example Also avoid areas subject to exhaust fumes from laundry facilities These areas will always contain contaminants Page 30 of 118 ECO PAK Installation amp Operation Manual BOILER 1 Determine boiler location continued Table 1A Corrosive Contaminants and Sources Products to avoid Spray cans containing chloro fluorocarbons Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products likely to have c
119. lowed to run in Auto or Hand mode Enter the pump default speed If SHWRT sensor fails the running pump in Auto mode will have its speed set to the default speed Enter the pump rated RPM as indicated on the motor Enter the speed ramp time The minimum amount of time it will take the pumps to increase the speed from 0 to 100 or to decrease the speed from 100 to 0 Enter the pump run time After an emergent stop the pump will continue to run for this period of time Enter the pump run time When all boilers are off the pump will continue to run for this period of time Enter the lead pump switch time After the duty pump runs for the entered amount of hours the standby pump will switch to lead Press Restore button to retrieve pump setup values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen This screen is for viewing only A 2 Press bottom right navigation button from PUMP SETUP to bring up this screen Touch the buttons on the menu at the bottom to bring up the desired screen Page 99 of 118 ARMSTRONG g 2 4 4 BOILER SETUP 10 11 Press BOILER SETUP button from LEVEL 1 MAIN SETUP to bring up this screen Touching the MBS model beside the description will toggle between MBS 420 MBS 570 MBS 630 MBS 855 and MBS 1140 MBS 420 represents 2 boilers with capacity of 210 BTU hr ea MBS 57
120. m sealed appliances general ventilation is still required The air supplied for the boiler space ventilation shall be such that the maximum temperatures shall not exceed 77 F 25 C at floor level or 4 100 mm above 90 F 32 C at mid level 5 ft or 1 5 m above floor level and 104 F 40 C at ceiling level or 4 100 mm below ceiling level Failure to provide and maintain adequate ventilation will mean that the units will have to be shutdown Page 15 of 118 ARMSTRONG ly 2 5 Vent and Air Intake Installation The ECO PAK MBS utilizes two sizes of vent and air intake piping 3 on the ECO PAK MBS 420 and 630 and 4 on the ECO PAK MBS 570 855 and 1140 Use a core drill of 4 1 2 for 3 vent and 5 1 2 for 4 vent size to form holes through the wall For concentric venting option use 5 core drill size for a 3 venting system and 7 for a 4 venting system It is important to make sure that masonry falling outside the building does not cause damage or injury Cavity walls must be sleeved if there is a joint within the cavity Keep the vent piping length below 100 ft long the ECO PAK MBS output rating will reduce by up to 1 5 for each 25 ft of vent length For more detailed information see Boiler I amp O manual Venting section Installation m Vent Type Vent Air size max vent max no 90 Vent Air size max flue max no 90 inches length ft bends inches length ft bends Two Pipe System
121. me T Maximum DT across boilers 0 Maximum DT backott factor FOR VIEWING ONLY E wanuna f systemowe mam sere De 1 4 6 BOILER PID SETUP BOLLER PID SETE 1 Enter the PID Proportional ain 2 Enter the PID Integral Time 3 Enter the PID Derivative Time FOR VIEVWING ONLY E mammeno f systemowe mam sere Te Page 95 of 118 ARMSTRONG ul 1 4 7 GAS CONSUMPTION SETUP GAS CONSUMPTION SETUP 1 Gas pulses 211 pulse equals EE FOR VIEMNG ONLY E mammeno 4 systemowe Y wmamserue E 1 4 9 SENSOR SETUP 2 Sa 1 Suction pressure range tooo Pasi 2 SUCTION pressure zero 3 Discharge pressure range 4 Discharge pressure zero 5 strainer inlet pressure range 6 Strainer inlet pressure zero Default Settings menmen systemove 4 mamserue Yo 1 4 11 BYPASS SETUP BYPASS YALE SETUP 1 Bypass valve Disabled 2 Flow setpoint Tso 3 Default valve opening when sensor fails soo WHEN BYPASS w AL E IS OPENED AT 100 4 Shut dowen lead boiler after Tis 5 Shut dowen duty pump after Po FOR VIEWING ONLY E mammeno 4 systemowe Y wmamserue E 1 4 8 SENSOR SETUP 1 bh j I 1 Outside Air Temp range 2 Outside Air Temp zero Par 3 Flow Sensor 41 Hut water L B ply flow ra nge Hot water supply flow zero Too FOR VIEWING ONLY E manens systemowe Y mamn sere o 1 4 10 FROST PROTECTION SETUP PEA SETUP 1 Frost protection 2 SHART to start pump Pao
122. mp O Manual Integrated Controller I amp O Manual Pump Operating Instructions Replacement Parts NOOA Page 2 of 118 ARMSTRONG il 1 General 1 1 Introduction The Armstrong ECO PAK MBS is a fully integrated high efficiency modular heating system with a compact design that makes it an ideal solution for new constructions retrofit commercial installations and larger residential applications Available in standard model sizes ranging from 420 to 1 140 MBH this packaged boiler system is pre engineered for optimal performance under varying load conditions and therefore it is significantly more efficient than conventional field assembled boiler systems The innovative modular configuration results in a small package that can be easily moved through the doors positioned in place and installed in a matter of hours The ECO PAK MBS includes as standard the following components intelligent variable speed hot water pumps condensing boilers integrated controller with temperature sensors amp serial communication to BAS expansion tank air separator isolating valves strainer chemical pot feeder water make up system interconnecting piping with air vents drain cocks and test points electrical wiring and thermal insulation As an option the ECO PAK MBS can be supplied with a gas meter and hot water flow sensor Armstrong intelligent twin head pump for duty standby operation incorporates Armstrong s motor mounted variable frequency drive
123. nce is located in a residential garage it should be installed in compliance with the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches 46 cm above the floor The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle Vent and air piping The ECO PAK boiler requires a special vent system designed for pressurized venting You must also install air piping from outside to the boiler air intake adapter The resultant installation is direct vent sealed combustion Note prevention of combustion air contamination below when considering vent air termination Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall You may use any of the vent air piping methods covered in this manual Do not attempt to install the ECO PAK boiler using any other means Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated The vent air piping lengths routing and termination method must all comply with the methods and limits given in this manual Prevent combustion air contamination Insta
124. nd Combustion Air Vertical Termination Dimension A as Touching or 2 inches Maximum Separation COMBUSTION AIR TYPICAL 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST DIMENSION A IS TOUCHING OR 2 MAXIMUM SEPARATION 24 ABOVE ROOF Page 47 of 118 6 Hydronic piping System water piping methods The ECO PAK boiler is designed to function in a closed loop pressurized system not less than 12 psi A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet It is important to note that the boiler has a minimal amount of pressure drop and must be figured in when sizing the circulators Each boiler installation must have an air elimination device which will remove air from the system Install the boiler so the gas ignition system components are protected from water dripping spraying etc during appliance operation for basic service of circulator replacement valves and others Observe a minimum of 1 inch clearance around all un insulated hot water pipes when openings around the pipes are not protected by non combustible materials Low water cutoff device On a boiler installed above radiation level some states and local codes require a low water cutoff device at the time of installation Chilled water system If the boiler supplies hot water to heating coils in air handler units flow control valves or other devices must b
125. neral venting continued Combustion air piping to the outside NOTICE MUST BE used Use of combustion air from the room via louvers plenums or any other device is not authorized Air intake vent connections 1 Combustion Air Intake Connector FIG s 3 5 and 3 6 Used to provide combustion air directly to the unit from outdoors A fitting is provided on the unit for final connection Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG s 3 5 and 3 6 Used to provide a passageway for conveying combustion gases to the outside A transition fitting is provided on the unit for final connection Vent piping must be supported per the National Building Code Section 305 Table 305 4 or as local codes dictate Figure 3 5 Near Boiler Venting Model 210 AIR 3 CPVC PIPE SUPPLIED WITH BOILER MUST BE USED FOR VENT CONNECTION NOTE CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS Figure 3 6 Near Boiler Venting Model 285 lt m z 4 CPVC PIPE SUPPLIED WITH BOILER MUST BE USED FOR VENT CONNECTION NOTE CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS ECO PAK Installation amp Operation Manual BOILER Air inlet pipe materials The air inlet pipe s must be sealed Choose acceptable combustion air inlet pipe materials from the
126. nlet terminations must terminate in the same pressure zone Figure 5 1 Vertical Termination of Air and Vent ALTERNATE INTAKE LOCATIONS INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24 OF VENT PIPE BIRD SCREEN O NZ TYPICAL ANA RE s D lt lt E i D gt 2 P De r COUPLING gt i 2 Sl A FIELD SUPPLIED VIA ADA AAA A 6 MINIMUM Se OA ABOVE ROOF Ne A A SNOW LINE PE gt VENT OUTLET AAN 12 MINIMUM 2 COMBUSTION lt ABOVE AIR INLET Q gt ae e Le 5 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment Page 44 of 118 ECO PAK Installation amp Operation Manual BOILER 5 Vertical direct venting continues Vent air termination vertical Prepare roof penetrations 1 Air pipe penetration a Cut a hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration a Cut a hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 414 inch hole for 3 inch vent pipe 5 inch hole for 4 inch vent pipe b Insert a galvanized metal thimble in the vent pipe hole 3 Space the air and vent holes to provide the minimum spacing shown in FIG 5 1 page 24 4 Follow all local codes for isolation of vent pipe when passing
127. ns the fan for an additional 10 seconds to clear the combustion chamber and vent system of residual flue products Set Point Met Postpurge The unit has been placed in a temporary mode that will allow the Service i unit to fire at 100 of rate for the purpose of combustion analysis OUT F When the outlet sensor has been selected as the control sensor default the control will display the outlet temperature as well as the set point in parenthesis HOt EB If the outlet sensor has not been selected as the control sensor only the outlet temperature will be displayed Open The control does not detect the outlet sensor Shorted The outlet sensor wires or the sensor itself has become shorted Press the Next P gt arrow key on the control module display to access Screen 2 AS If the inlet sensor has not been selected as the control sensor only the inlet temperature will be displayed When the inlet sensor has been selected as the control sensor the PRETE a control will display the inlet temperature as well as the set point in parenthesis Open The control does not detect the inlet sensor Shorted The inlet sensor wires or the sensor itself has become shorted RISE E The difference between the inlet temperature and the outlet temperature Press the Next P gt arrow key on the control module display to access Screen 3 INE P o N Page 68 of 118 ECO PAK AS Installation
128. ntenance e To avoid severe burns allow boiler to cool before performing maintenance Boiler operation e Do not block flow of combustion or ventilation air to the boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced Boiler water e Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment e Do not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage e Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent
129. nversion Table LP Conversion Table LP Orifice Stamping 2107 W150 285 Page 32 of 118 BRASS ORIFICE Installation amp Operation Manual After converting to LP check combustion per the Start up procedure in Section 10 of this manual Failure to check and verify combustion could result in severe personal injury death or substantial property damage Figure 2 2 Installing Propane Orifice GAS VALVE GROMMET ECO PAK Installation amp Operation Manual BOILER 3 General venting Direct venting options ae SLT J a NL a Z ae Figure 3 1 Two Pipe Vertical Termination See page Figure 3 2 Two Pipe Sidewall Termination See 24 for more details page 17 for more details Y Y S lt Y a q a No m Ne ie Figure 3 3 Concentric Vertical Termination See Figure 3 4 Concentric Sidewall Termination See page 26 for more details page 21 for more details Page 33 of 118 3 General venting ECO PAK Installation amp Operation Manual BOILER Install vent and combustion air piping The ECO PAK boiler must be vented and supplied with combustion and ventilation air as described in this section Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system air system and combustion air quality See also Section 1 of this manual A DANGER Inspect finished vent and air piping thoroughly to ensure all are airtight
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131. o field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage ECO PAK boilers are typically shipped ready to fire on natural gas Check boiler rating plate to determine which fuel the boiler is set for If set to natural gas it may be converted to LP by installing an orifice see page 12 In order to operate on LP gas an orifice MUST BE installed Failure to comply could result in severe personal injury death or substantial property damage Check flame and combustion 1 Turn the main power off to the boiler by placing the On Off switch in the OFF position 2 Remove the flue temperature sensor from the flue pipe connection NOTE Combustion measurements will be made at this point 3 Turn the main power on to the boiler by placing the On Off switch in the ON position Page 60 of 118 ECO PAK Installation amp Operation Manual BOILER 1 0 Start up continued Figure 10 2 Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot It is Immediately call your gas supplier from a equipped with an ignition device which neighbor s phone Follow the gas supplier s automatically lights
132. o see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed Installation amp Operation Manual Safety relief valves should be re inspected SAS AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage 2 After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing
133. of each pulse in Cubic Feet Press Restore button to retrieve gas consumption setup values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen Press SENSOR SETUP button from LEVEL 1 MAIN SETUP to bring up this screen Press the first two boxes to enter the range for outside air temperature sensor and toggle the temperature unit between F and C Press the second two boxes to enter the zero the lowest measure value for outside air temperature sensor and toggle the temperature unit between F and C Flow sensor can be enabled when the flow sensor is installed in the system Press the boxes beside the flow range to enter flow sensor s range and toggle the flow unit among usgpm lps and m hr Press the boxes beside the flow zero to enter flow sensor s zero the lowest measure value and toggle the flow unit among usgpm Ips and m hr Press Restore button to retrieve sensor setup 1 values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen Page 102 of 118 ARMSTRONG g 2 4 9 SENSOR SETUP 2 2 4 10 FROST PROTECTION SETUP Press bottom right navigation button from SENSOR SETUP 1 to bring up this screen Press the first two boxes in column 1 to enter the range and zero for system suction pressure sensor Press th
134. ons Freeze protection when used 1 Determine freeze protection fluid quantity using system water content following fluid manufacturer s instructions Boiler water content is listed on page 7 Remember to include expansion tank water content 2 Local codes may require a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level Fill and test water system 1 Fill system only after ensuring the water meets the requirements of this manual 2 Close manual and automatic air vents and boiler drain valve 3 Fill to correct system pressure Correct pressure will vary with each application a The minimum cold water fill pressure for a residential system is 12 psi b Pressure will rise when boiler is turned on and system water temperature increases ECO PAK BOILER Installation amp Operation Manual 4 At initial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating the heat exchanger and causing heat exchanger failure Purge air from
135. ontaminants Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body shops Plastic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops When removing a boiler from existing common vent system Do not install the ECO PAK boiler into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible severe personal injury death or substantial property damage A WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition c Test vent system Insofar as is practical close all building doors and windows and all doors between the space in which the applian
136. ord Setup Displays The Setup Displays are divided in three levels All the three levels have the same number of displays with different level of access Level 0 setup displays are for viewing only and no adjustment can be made Level 1 setup displays can be used for changing the system setup restoring the system factory defaults except for the PID parameters in the PID Setup Displays Level 2 setup displays can be used for changing the system setup and saving and restoring the system factory defaults To access Level 1 and level 2 Setup Displays an operator need to enter the proper password The list of Setup Displays for every level is as follow SHWT System Hot Water Temperature Set point Setup Pump Setup Pump PID Setup Boiler Setup Boiler Staging Setup Boiler PID Setup Gas Consumption Setup Sensor Setup 1 Sensor Setup 2 Page 81 of 118 ARMSTRONG g Frost Protection Setup Bypass Valve Setup Bypass Valve PID Setup BAS Setup Clock Setup ECO PAK MBS System Schedule Setup The Level 1 Setup Screens also have a set of Restore Default Settings to restore the default setup values on each screen The Level 2 Setup Screens have a set of Restore Default Settings and Save Default Settings to restore or save the default values on each screen Trend Data Displays The Trend Data Displays include 5 real time data trend charts and a history data menu Through the history data menu the history data trend
137. per shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning boiler heat exchanger 1 Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 10 Startup e Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain 2 Allow time for the boiler to cool to room temperature if 1t has been firing 3 Remove the blower assembly gas air arm from the heat exchanger access cover Set bolts aside 4 Remove the nuts securing the heat exchanger access cover to the heat exchanger and set aside 5 Remove the heat exchanger access cover cover gasket s and chamber insulation assembly The boiler contains ceramic fiber materials Use care when handling these materials per instructions in the ECO PAK Boiler Service Manual Failure to comply could result in severe personal injury 6 Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces Do not use any solvent 7 Finish cleaning using a clean cloth dampened with warm water 8 Install access cover gasket chamber insulation assembly and cover 9 Secure nuts on the studs DO NOT overtighten 10 Re install the blower assembly gas air arm using the bolts set aside in Step 3 11 Close isolation valves on piping to isolate boiler from system Attach a hose to the boiler d
138. pipe FIG 9 1 3 Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter Condensate from the ECO PAK boiler will be slightly acidic typically with a pH from 3 to 5 Install a neutralizing filter if required by local codes A Neutralizer Kit FIG 9 1 is available from the factory 4 Install the 1 2 inch PVC tee assembly shipped with the unit as shown in FIG 9 1 5 Leave the top of the 1 2 inch tee OPEN This is needed as a vacuum break 6 Do not expose condensate line to freezing temperatures 7 Use only plastic tubing or piping as a condensate drain line FIG 9 1 Figure 9 1 Condensate Disposal 1 2 PVC TEE ASSEMBLY FACTORY SUPPLIED DRAIN PAN ECO PAK FLOOR DRAIN OR O IEE Installation amp Operation Manual Use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement NOTICE To allow for proper drainage on large horizontal runs a second line vent may be required and tubing size may need to increase to 1 inch The condensate line must remain unobstructed allowing free flow of condensate If condensate is allowed to freeze in the line or if the line is obstructed in any other manner condensate can exit from the boiler te
139. r has modulated up to full fire measure the combustion The values should be in the range listed in Table 10A below The CO levels should be less than 150 ppm for a properly installed unit If the combustion is not within the specified range reference the Troubleshooting Section of the ECO PAK Boiler Service Manual for possible causes and corrective actions Table 10A Flue Products Chart DCI mee _ co 8 0 10 CO 8 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the boiler shuts down Open the manual shutoff valve and return to Service Mode 9 Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection 10 Place the boiler back into normal operation A WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage 3 0 6 5 9 0 11 4 1 6 9 ECO PAK oek Installation amp Operation Manual Set clock The control module has a built in clock that it uses for its night setback feature and for logging events This clock must be set when the boiler is installed and anytime the boiler has been powered off for more than one month Use the following procedure to set the clock 1 Press and hold the MENU key for at
140. r r r Porr_ O O 9 FANASSEMBY SS ECO PAKT BOILER 210 _ 9 FANASEMRIYV ECOPAKT BOILER 285 ECO PAK BOILER 210 ECO PAK BOILER 285 GAS VALVES ECO PAK BOILER 210 ECO PAK BOILER 285 ECO PAK BOILER 210 ECO PAK BOILER 285 PILOT amp BURNER ASSEMBLIES ECO PAK BOILER 210 ECO PAK BOILER 285 Page 116 of 118 ARMSTRONG uy ITEM NO DESCRIPTION MODEL NO MISCELLANEOUS Y Y Y C 24 SiGHGLSS lea 25 GASKET SIGHT GLASS SIS lero ECO PAK BOILER 210 ECO PAK BOILER 285 LEVELING LEG x FOWSWICH o BT RELEF VAWE BOP IIS BOTH ee TA BOTH RARA sss BOTH SAME BOTH O CONDENSATE TRAP II ECO PAKT BOILER 210 CONDENSATETRAP ECO PAK BOILER 285 __ GAUGETRIOMETER 75 PS IIS BOTH _ __ FLUE TEMP SENSOR KIO lero a ae A A BTH C LP CONVERSION KI ECO PAKT BOILER 210 CONVERSION ECO PAKMBOILER 285 Page 117 of 118 ARMSTRONG g 7 2 Pump ITEM NO DESCRIPTION PART NO Mechanical Seal 1 1 4 Ttype 21 9975000 991 Motor 2HP 575V NEMA Premium TEFC 4001516 068 Motor 2HP 208 230 460V NEMA Premium TEFC FONTO LOUSA Integrated VFD 2HP 208 230V 751122 364 S A Armstrong Limited Armstrong Pumps Inc Armstrong Holden Brooke Pullen 23 Bertrand Avenue 93 East Avenue Wenlock Way Toronto Ontario North Tonawanda New York Manchester Canada M1L 2P3 U S A 14120 6594 United Kingdom M12 5JL Ce T 416 755 2291 T 716 693 8813 T 44 0 161 223 2993 4
141. rain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler When the boiler has been flushed restore boiler to operation 12 13 Perform start up and check out procedures in Section 10 Startup Oiled bearing circulators 1 Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer s Instructions Over oiling will damage the circulator 9873 of 118 ECO PAK BOILER 13 Diagrams Figure 13 1 Ladder Diagram 120VAC 120V SU JUNCTION BOX NEUTRAL GROUND TERMINAL STRIP PPLY L KB I ON OFF 1 f MS SWITCH JUNCTI BOX ON INTEGRATED CONTROL SYSTEM PUMP L TERMINAL STRIP Se 120V SUPPLY N Q BOILER RS TERMINAL STRIP Installation amp Operation Manual A WARNING DISCONNECT POWER BEFORE SERVICING NS S TERMINAL STRIP X6 3 RESISTOR BOX DEPICTS OPTIONAL ITEMS JUNCTION BOX CONNECTION BOARD CN4 1 CN5 2 CN5 4 CONNECTION BOARD CN5 1 CONNECTION ES BOARD CN5 3 pe A Ora orao ROOM THERMOSTAT ZONE CONTROL HIGH L MANUAL RESET IMIT X5 14 SILENCING SWITCH ALARM BELL O v DHW E THERMOSTAT NN no an CN2 3 LOWGAS HIGH G
142. re created by the blower allowing gas to flow only if the gas valve is powered and combustion air is flowing Heat exchanger access cover Allows access to the combustion exchanger coils side of the heat High limit sensor Device that monitors the outlet water temperature If the temperature exceeds its setting 1t will break the control circuit shutting the boiler down High voltage junction box The junction box contains the connection points for the line voltage power and all pumps Ignition electrode Provides direct spark for igniting the burner Leveling legs Used to allow the heat exchanger to be leveled This is needed for the proper draining of the condensate from the combustion chamber Line voltage wiring connections knockouts Conduit connection points for the high voltage junction box Low voltage connection board The connection board is used to connect external low voltage devices Low voltage wiring connections knockouts Conduit connection points for the low connection board voltage Power switch Turns 120 VAC ON OFF to the boiler Relief valve Protects the heat exchanger from an over pressure condition The relief valve may be set at 30 psi Stainless steel heat exchanger Allows system water to flow through specially designed coils for maximum heat transfer while providing protection against flue gas corrosion The coils are encased in a jacket that contains the combustion process Temp
143. re inch free area per 1 000 Btu hr of boiler input ECO PAK boiler in same space with other gas or oil fired appliances 1 Follow the National Fuel Gas Code U S or CSA B149 1 Canada to size verify size of the combustion ventilation alr openings into the space A WARNING Lhe space must be provided with combustion ventilation air openings correctly sized for all other appliances located in the same space as the ECO PAK boiler Do not install the boiler in an attic Failure to comply with the above warnings could result in severe personal injury death or substantial property damage 2 Size openings only on the basis of the other appliances in the space No additional air opening free area is needed for the ECO PAK boiler because it takes its combustion air from outside direct vent installation Flooring and foundation Flooring The ECO PAK boiler is approved for installation on combustible flooring but must never be installed on carpeting A WARNING Do not install the boiler on carpeting even if foundation is used Fire can result causing severe personal injury death or substantial property damage If flooding is possible elevate the boiler sufficiently to prevent water from reaching the boiler ECO PAK ER Installation amp Operation Manual Residential garage installation Precautions Take the following precautions when installing the appliance in a residential garage If the applia
144. res boiler shutdown in the event of low water or low flow conditions 2 Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff Consult local jurisdiction to determine A low water cutoff kit s is available Page 64 of 118 ECO PAK OR Installation amp Operation Manual 11 Operating information continued Sequence of operation OPERATION DISPLAY Upon a call for heat the control checks certain limit switches If the unit is equipped with a flow switch or low water cutoff it must close before the control powers up the blower If the unit is equipped with a solenoid valve and or a vent valve they will be energized along with the blower If the unit is equipped with a gas pressure switch it must close at this time If there is an auxiliary device connected to the unit and it has a proving switch it must close before the sequence continues The control then starts a 10 second prepurge cycle Once the prepurge cycle is complete and the blocked drain and auto reset high limit are closed the control starts the 5 second trial for ignition by sending spark voltage to the spark electrode and opening the gas valve If the control does not detect flame by the end of the trial for ignition the control performs a 10 second postpurge another prepurge and tries to light the burner again If the burner does not light after 4 t
145. rge valve and de energize the motor DO NOT run the pump against a closed discharge valve for an extended period of time A few minutes maximum Should the pump be noisy or vibrate on start up a common reason is overstated system head Check this by calculating the pump operating head by deducting the suction pressure gauge value from the discharge gauge reading Convert the result into the units of the pump head as stated on the pump nameplate and compare the values Should the actual pump operating head be significantly less than the nameplate head value it is typically permissible to throttle the discharge isolation valve until the actual operating head is equal to the nameplate value Any noise or vibration usually disappears The system designer or operator should be made aware of this soon as some adjustment may be required to the pump impeller diameter or drive settings if applicable to make the pump suitable for the system as installed CAUTION Check rotation arrow prior to operating the unit The rotation of all Armstrong Vertical In Line units is clockwise when viewed from the drive end Looking from on top of behind the motor GENERAL CARE Vertical In Line pumps are built to operate without periodic maintenance other than motor lubrication on larger units A systematic inspection made at regular intervals will ensure years of trouble free operation giving special attention to the following 1 Keep unit clean 2 Provid
146. rials the control locks out for 1 hour and then tries another set of 4 trials If the control detects a flame before the trial for ignition ends it begins to modulate the burner in order to maintain the set point Once the call for heat is satisfied the control will turn off the burner The blower will remain on for the 10 second postpurge cycle Any pumps that are running will continue to run for their respective pump delay times then turn off Boiler pump off system pump continues its delay if longer Boiler off Page 65 of 118 Standby 123 8F 129 PREPURGE 123 9F 129 IGNITION 123 9F 129 POSTPURGE PREPURGE 123 9F 129 SH 20 RATE 124 8F 129 POSTPURGE 127 4F 129 Standby 124 7F 129 Standby 122 9F 129 ECO PAK Installation amp Operation Manual BOILER 11 Operating information Control module Use the control panel FIG 11 1 to set temperatures operating conditions and monitor boiler operation Figure 11 1 Control Panel e Press to turn boiler off or Hold 5 seconds to enter code Input Mode Menu Mode back on SHUTDOWN Press to move up one level e Press to select a menu item in Menu Mode or to exit e Press after parameter programming Menu Mode to store parameter data ENTER RESET Press to exit Service Mode DISPLAY SCREEN SHUTDOWN SERVICE O T O BUTTON ENTER RESET MENU EXIT ARMSTRONG 8 aa J ae DOWN PREVIOUS NEXT 2 amp lt
147. s VFD s which will constantly adapt to changes in the distribution system characteristics The pump features economical inside type single spring mechanical seal serviced by removing the rotating assembly while the pump casing remains in the line Dynamically balanced impeller assures smooth vibration free operation Radially split volute has equal suction and discharge flange sizes Separate tapped openings are provided for gauge flush and drain connections The pump controls and boiler combustion controls are integrated to ensure that the minimum flow rates are maintained and that the boilers are running in the condensing mode as long as possible Low NOx gas fired condensing boilers with stainless steel heat exchangers and modulating premix gas burners are at the heart of the ECO PAK MBS System Through the sophisticated ECO PAK MBS integrated controller the boilers are capable of operating at overall seasonal efficiencies of over 94 with low carbon emissions The boilers bear ASME and National Board stamps and are certified for use on Natural Gas and LPG The boilers comply also with the energy efficiency requirements of the latest edition of the ASHRAE 90 1 Standard and the minimum efficiency requirements of the latest edition of the ASHRAE 103 Standard The boilers meet as a minimum U S Environmental Protection Agency and Department of Energy guidelines for Energy Star efficiency On site a concentric balanced flue system discharges prod
148. s PRU 7 A pop up window displays Press the button indicated as Remote and the button will show as Local Close the window by touching the crossing mark button eT TOL ee ARS Local and Remote Control by pressing the toggle switch below Default Settings save RESTORE woo Page 109 of 118 ARMSTRONG g 8 The screen changes back to LEVEL 2 SETUP SCREEN The top right corner displays MBS ON RMSTRON M P the PUMP OVR l ress the button ETE MAIN SETUP SCREEN A Gl ALA I ose SCHEDULE SETUP Default Settings O SAVE RESTORE 9 The screen changes to PUMP OVERVIEW Press PUMP OVER VIEVY PUMP 1 button _ PUMP 1 MITA MA MA MA MA Stopped Stopped 10 The screen changes to PUMP 1 CONTROL Press AUTO button Press the green right arrow button on the bottom right corner The screen changes to PUMP OVERVIEW again PUMP 1 CONTROL HAND OFF AUTO MA stopped Page 110 of 118 ARMSTRONG il 11 The screen changes to PUMP 2 CONTROL PUMP 2 CONTROL Press AUTO button Press BOILER OVR button MA Stopped 12 The screen changes to BOILER OVERVIEW Press BOILER 1 button 13 The screen changes to BOILER 1 CONTROL Press AUTO button Press the green right arrow button on the bottom right corner The screen changes to BOILER 2 CONTROL again BOILER 1 CONTROL Ott
149. s quoted by Armstrong assume a single visit to site and do not include for abortive visits waiting time site induction courses revisiting site for hand over training sessions or servicing during guarantee period Signatures Pre Commissioning Prepared by Pre Commissioning Reviewed by Project Manager Release Page 80 of 118 ARMSTRONG ly DISPLAYS OVERVIEW The ECO PAK MBS integrated controller HMI is divided in four set of displays System Setup Alarm and Trend Data management The System Displays are used by the users to view and control the Boilers and Pumps The Setup Screens are used to set view save and restore the system specific settings i e ECO PAK MBS model boilers parameters pumps parameters etc The Alarm screens are used to display the current alarms store and display history alarms give helpful information on each alarm and display events The Trend Data screens are used to view real time trend charts and history trend charts backup history data to USB The list of displays in each set is as follow System Displays Main Menu System Overview Pump Overview Boiler Overview Pump 1 Control Pump 2 Control Boiler 1 Control Boiler 2 Control Boiler 3 Control Boiler 4 Control Login The System Displays can be accessed without any password Alarm Displays e Alarm e Alarm History e Event The Alarm Displays can be accessed and operated such as pressing a reset button without any passw
150. sure 7 This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Observe the gas supply pressure as the burner fires at 100 of rated input Percent of burner input will be displayed on the control panel 8 Ensure inlet pressure is within specified range Minimum and maximum gas supply pressures are specified in this section of the manual 9 If gas supply pressure is within normal range and no djustment ded don to Step 11 The gas piping must be sized for the proper flow and length 5 1 U 55 1 of pipe to avoid excessive pressure drop Both the gas meter 10 If the gas pressure is out of range contact the gas utility and the gas regulator must be properly sized for the total gas aad supplier qualified installer or service agency to load determine the necessary steps to provide proper gas f pressure to the control If you experience a pressure drop greater than 1 inch w c the meter regulator or gas line is undersized or in need of service Perform the steps below when checking inlet gas supply 1 Turn the main power switch to the OFF position 11 Turn the power switch to the OFF position 12 Shut off the gas supply at the manual gas valve in the gas piping to the appliance 13 Remove the manom
151. t Stop BAS Installation Instructions 47 m 18 Gas Emergency Shutoff Optional 1 12 Condensate Drain a y General System Alarm I 23 l The condensate drains from each boiler to be 4 s Boiler Alarm connected on site by others into a 2 50 mm 25 mln plastic drainpipe header The drainpipe header must 26 i be extended to discharge over a suitable drain A Sensor Alarm Plastic PVC drainpipe must be used 34 GND ve 35 eer ee sm t The condensate is slightly acidic and its discharge 36 ae nee into the sewage system is permitted neutralizing filters are available upon request if required by local codes If the ECO PAK MBS is installed below ground level and surface drains are not available a condensate removal pump set should be installed See Boiler I amp O manual Condensate Disposal section for information on condensate lines 1 13 Clearances The boiler modules are fully serviceable from the front but the following minimum clearances must be maintained for efficient operation and servicing Front 36 915 mm Sides Pump module 24 610 mm Opposite end 24 610 mm Top 24 610 mm Page 13 of 118 ARMSTRONG il Installation 2 1 Offloading ECO PAK MBS modules are normally delivered to site on wooden skids with transparent plastic wrapped around wooden frame The modules should preferably be offloaded by forklift or crane using slings attached to the steel module framework Once safely at
152. t a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the connection board Allow the boiler to cycle Inspect fill condensate system Inspect check condensate lines and fittings 1 Inspect the condensate drain line condensate PVC fittings and condensate trap Fill condensate trap with water 1 Remove the PVC cap retaining screw from the PVC cap FIG 10 1 2 Remove the 2 inch PVC cap with the switch located at the top of the trap FIG 10 1 3 Fill with fresh water until the water begins to pour out of the drain 4 Replace the cap Press the cap onto the trap until the cap makes contact with the drain 5 Replace the retaining screw The condensate trap FIG 10 1 must be A WARNING filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death Page 59 of 118 10 Start up Final checks before starting the boiler a Read the ECO
153. t in severe personal injury death or substantial property damage Page 50 of 118 Y Gas connections continued A WARNING Use two wrenches when tightening gas piping at boiler FIG 7 3 using one wrench to prevent the boiler gas line connection from turning Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components Figure 7 3 Inlet Pipe with Backup Wrench USE BACK NOTICE UP WRENCH TO PREVENT PIPE FROM ROTATING Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment ECO PAK BO IEE Installation amp Operation Manual Natural gas Pipe sizing for natural gas 1 Refer to Table 7A for pipe length and diameter Based on rated boiler input divide by 1 000 to obtain cubic feet per hour a Table 7A is only for natural gas with specific gravity 0 60 inches with a pressure drop through the gas piping of 0 5 inches w c b For additional gas pipe sizing information refer to ANSI 2Z223 1 or Bl149 1 for Canadian installations Natural gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on e Minimum 4 inches w c with gas flowing verify during boiler startup 2 Install 100 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c at any time
154. t is any room the boiler is installed in which is less than 107 cubic feet for ECO PAK 210 models and 120 cubic feet for ECO PAK 285 models An alcove is any room which meets the criteria for a closet with the exception that it does not have a door Example Room dimensions 3 feet long 3 feet wide and 9 foot ceiling 3 x 3 x 9 81 cubic feet This would be considered a closet for an ECO PAK Boiler For closet and alcove installations as shown in FIG s 1 1 and 1 2 CPVC vent material must be used inside the structure The ventilating air openings shown in FIG s 1 1 and 1 2 are required for this arrangement Failure to follow this warning could result in fire personal injury or death Provide clearances Clearances from combustible materials 1 Hot water pipes at least 1 from combustible materials 2 Vent pipe at least 1 from combustible materials 3 See FIG s 1 1 and 1 2 on page 9 for other clearance minimums Clearances for service access l See FIG s 1 1 and 1 2 on page 9 for recommended service clearances If you do not provide the minimum clearances shown it may not be possible to service the boiler without removing it from the space Page 28 of 118 ECO PAK Installation amp Operation Manual BOILER 1 Determine boiler location continued Figure 1 1 Closet Installation Minimum Required Clearances 4 MINIMUM CLEARANCE CLOSET INSTALLATION E For closet installations CPVC A WARNI
155. tal strapping or equivalent support material NOTICE Ensure termination location clearance dimensions are as shown in FIG 4 6 NOTICE If assembly needs to be extended to allow sidewall thickness requirement the two 2 pipes supplied in the kit may be replaced by using the same diameter field supplied SDR 26 PVC D2241 pipe for 3 Concentric Vent and standard schedule 40 PVC for 4 Concentric Vent Do not extend dimension D more than 60 inches see FIG s 4 9 and 4 10 NOTICE If assembly depth needs to be reduced dimension D can be as short as possible Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur Water may also collect inside the larger combustion air pipe and flow to the burner enclosure Failure to follow this warning could result in product damage or improper operation personal injury or death Figure 4 11 Rain Cap to Vent Pipe Alternate Assembly STAINLESS STEEL SCREW FIELD SUPPLIED DRILL CLEARANCE HOLE IN RAIN CAP amp PILOT HOLE IN VENT PIPE Page 42 of 118 ECO PAK Installation amp Operation Manual BOILER 4 Sidewall direct venting continued Sidewall termination optional concentric vent Figure 4 12 Concentric Vent Sidewall Attachment ELBOW FIELD SUPPLIED COMBUSTION AIR STRAP FIELD SUPPLIED COMBUSTION AIR NOTE 3 Concentric Vent shown for illustration purposes CAUTION DO NOT use field supp
156. temperature is more than 54 F above return water temperature Reset button low water cutoff e Check boiler piping gas and Every water for leaks 6 months If combustion or performance e Operate relief valve indicate need e Clean heat exchanger e Remove and clean burner using compressed air only End of season Shut boiler down unless boiler months used for domestic hot water e Clean the blower wheel Page 70 of 118 ECO PAK Installation amp Operation Manual BOILER 1 2 Maintenance continued Follow the service and maintenance procedures given throughout this manual and in component literature A WARNING l U l U i shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage The boiler should be inspected annually only by a qualified service technician In addition the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as WARNING la noted otherwise in this instruction manual Failur
157. the burner Do not try instructions to light the burner by hand If you cannot reach your gas supplier call BEFORE OPERATING smell all around the fire department the appliance area for gas Be sure to C Use only your hand to turn the gas control knob smell next to the floor because some gas ler th ii f h Never use tools If the handle will not turn by is heavier than air and will settle on the hand don t try to repair it call a qualified service floor technician Force or attempted repair may result WHAT TO DO IF YOU SMELL GAS in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under water Immediately call a qualified service Do not touch any electric switch do technician to inspect the appliance and to not use any phone in your building replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Turn gas shutoff valve counterclockwise to open above on this label valve Handle will be parallel to pipe 2 Set the thermostat to lowest setting 9 Install top cover 3 Turn off all electric power to the 10 Turn on all electric power to appliance appliance 11 Set thermostat to desired setting 4 This appliance is equipped with an 12 If the appliance will not operate follow the ignition device which automatically lights instructions To Turn Off Gas To Appliance
158. the menu at the bottom to bring up the desired screen Touching the Right and Left arrow will navigate between the Level 1 Setup Screens Touching the WATER TEMP SETUP button from LEVEL 1 MAIN SETUP screen will call up the System Hot Water Temperature Setpoint Setup screen Indoor Temperature setpoint Minimum OAT Maximum OAT Minimum OAT SHWRT Minimum OAT SHWRT Maximum OAT SHWST Maximum OAT SHWST Contact S A Armstrong for information on these parameters Enter the default SHWST and SHWRT set point When the OAT sensor returns an error value SHWST and SHWRT set point will be set at the value entered After input the Setpoint at Min OAT Setpoint at Max OAT Default setpoint when sensor fails and Page 98 of 118 ARMSTRONG g 2 4 2 PUMP SETUP 2 4 3 PUMP PID SETUP Schedule minimum OAT in SCHEDULE SETUP screen press UPDATE LIMITS button to make sure the values are within the limits Enter calculation period for the SHWST and SHWRT set point Press Restore button to retrieve SHWT set point setup values from the system factory defaults Touch the buttons on the menu at the bottom to bring up the desired screen From LEVEL 1 MAIN SETUP press on PUMP SETUP to call up this screen Enter the pump minimum speed The minimum speed the pump will be allowed to run in Auto or Hand mode Enter the pump maximum speed The maximum speed the pump will be al
159. through floors ceilings and roofs 5 Provide flashing and sealing boots sized for the vent pipe and air pipe Termination and fittings l Prepare the vent termination coupling and the air termination elbow FIG 5 1 by inserting the bird screens provided with the boiler Bird screens are provided for either 3 ECO PAK 210 or 4 ECO PAK 285 fittings 2 The air piping must terminate in a down turned 180 return bend as shown in FIG 5 1 Locate the air inlet pipe no further than 2 feet from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 3 The vent piping must terminate in an up turned coupling as shown in FIG 5 1 The top of the coupling must be at least 1 foot above the air intake The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake 4 Maintain the required dimensions of the finished termination piping as shown in FIG 5 1 5 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe Multiple vent air terminations 1 When terminating multiple ECO PAK boilers terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent pipes at the same height 4 WARNING and all air pipes at the same height
160. tions Junction Box TB 37 PH1 38 PH2 I Incoming Power 208 230 460 or 575 39 PH3 VAC 60 Hz 40 GND FIELD DEVICES INSTALLATION INSTRUCTIONS Before attempting to start configuring the ECO PAK MBS Controller using the Operator Interface HMI touch screen make sure all the field installed devices such as temperature sensors flow sensors are properly installed and wired to the ECO PAK MBS Controller as per terminal block configuration All field devices connections shall be wired inside the service junction box BUILDING AUTOMATION SYSTEM BAS CONNECTION The ECO PAK MBS Controller is provided with an RS 485 serial port to communicate serially to the BAS The standard communication protocol is Modbus BACnet and Lonoworks are options Refer to wiring diagram for wiring instructions Please refer to the ECO PAK MBS Controller generic terminal block drawing for the different parameters and data points communicated to the BAS 2 y Outside Air Temperature Sensor GND 13 l 14 7 Flow Sensor Optional E Remote Start Stop BAS x Gas Emergency Shutoff Optional 21 22 E General System Alarm 23 l 24 7 Boiler Alarm 25 Pump Alarm 26 Te 27 NOTE Please fill in the ECO PAK MBS V Pre a 90 Alarm Commissioning Check List below which will help 34 GND pas you through the set up procedure of the ECO PAK z Communication MBS Controller The main information required would be the ECO PAK MBS
161. to avoid possibility of severe personal injury death or substantial property damage 2 Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U S installations see FIG 5 2 For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of an ECO PAK boiler is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 5 2 Vertical Terminations with Multiple Boilers 12 MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET 12 MINIMUM FROM EDGE OF AIR INTAKE PIPE TO ADJACENT VENT PIPE FROM ANOTHER BOILER Figure 5 3 Alternate Vertical Terminations with Multiple Boilers 12 MINIMUM VERTICALLY FROM VENT OUTLET TO ANY AIR INLET Page 45 of 118 ECO PAK BOILER 5 Vertical direct venting Installation amp Operation Manual Vertical termination optional concentric vent Description and usage An optional concentric combustion air and vent pipe termination kit is offered Both combustion air and vent pipes must attach to the termination kit The termination kit a must terminate outside the structure and must be installed as shown in FIG 5 4 Field supplied pipe and fittings are required to complete the i installation The required combustion vent pipe and fittings are listed in c
162. trical 1 National Electrical Code and any other national state connections to avoid possible electric provincial or local codes or regulations shock hazard Failure to do so can cause 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 severe personal injury or death and any local codes Wiring must be N E C Class 1 I li Line voltage connections If original wiring as supplied with boiler must be replaced use only type 105 C 1 Connect 120 vac power wiring to the line voltage terminal wire or equivalent strip in the junction box as shown in FIG 8 1 Boiler must be electrically grounded as 2 Provide and install a fused disconnect or service switch required by National Electrical Code 15 amp recommended as required by the code see ANSI NFPA 70 latest edition FIG 8 1 Label all wires prior to disconnection A CAUTION O e when servicing controls Wiring errors can cause improper and dangerous operation Figure 8 1 Line Voltage Field Wiring Connections SERVICE SWITCH 120V SUPPLY LINE GROUND NEUTRAL BK G W En a SUPPLY PUMP OUTPUTS 1 8A MAX Page 54 of 118 8 Field wiring continued Low voltage connections 1 Route all low voltage wires through the knockouts in the rear of the boiler as shown in FIG 8 2 2 Connect low voltage wiring to low voltage connection board as shown in FIG 8 3 on page 36 of this manual and the boiler wiring diagram Figure 8 2 Routing Field Wiring
163. tter Fault de Air Temp Transit 1 2 2 ALARM HISTORY screen ALARM HISTORY 06 03 09 06 0309 06 0309 06 03 09 06 0309 06 0309 06 03 09 06 0309 Outside Air Temp Transmitter Far SHST Transmitter Fault SHART Transmitter Fault System Flow Transmitter Faul Outside Air Temp Transmitter Far SHAST Transmitter Fault SHART Transmitter Fault System Flow Transmitter Faul G ew a O All alarms will be displayed in chronological order The last alarm will be at the top of the screen Press DIAG to pop up the PLC DIAGNOSTIC box Press RESET to reset all active alarms Pressing the MUTE button will silence the alarm Horn and stop the flashing of alarm light Press the up and down arrow buttons to view more alarms Press the left and right arrow buttons to view more content of alarms Press the HISTORY button to bring up the Alarm History screen Press the EVENT button to bring up the Event screen Press the buttons on the menu at the bottom to bring up the desired screen The history alarms saved in the internal memory of the HMI are displayed Press the top right button black arrow to select the history alarm to display The selected number indicates the number of days before today The history alarms will be displayed for that day Press the up and down arrow buttons to view more alarms Press the left and right arrow buttons to view more content of alarms Press the buttons on the menu at the
164. ucts of combustion through the inner annulus and draws combustion air through the outer annulus allowing room sealed applications The integrated controller provides the following functions 1 Ensure minimum hot water flow rates are maintained to operate in the high efficient condensing mode at all times within a variable primary flow configuration 2 Optimize boiler firing rate to match exact heating loads 3 Optimize boiler sequencing to achieve the highest efficiency possible from the system The integrated controller has a NEMA 12 enclosure and houses PLC s circuit breaker terminal strip and main disconnect switch The controller incorporates a door mounted 5 7 touch screen Human Machine Interface HMI for all necessary user set up and troubleshooting operations The integrated controller is pre programmed with project specific data for easy start up and commissioning On start up a read only screen displays Outdoor Air OA temperature HWS temperature HWR temperature system hot water AT system heat output in MBH optional and pump kW usage The initial screen displays also boilers status pump status system status system run time and individual pump hours run time Alarms data trending of system parameters are also displayed on the touch screen HMI and logged in the memory of the HIM available for upload when required A second screen password protected for access to field adjustable parameters provides access to input time ni
165. ulating boiler capacity control in PLC based on 13 Ability to select one of three default hot water system sizes small medium amp large for pump control loop 14 Manual and automatic alternation of primary pumps based on hours of operation 1 week alternation adjustable 15 Alarms shall include temperature sensor failure pump motor drive failure boiler failure and general system alarm 16 3 levels of password protection on operator interface a level 1 is operator level H O A function display of all parameters b level 2 is installer level all parameter setup except for PID variables c level 3 is factory level all parameter settings including defaults 17 As options display system hot water flow and gas consumption on the HMI Pump Speed Control Algorithm Upon start up the Integrated Controller shall calculate the SHWRT set point based on outdoor air temperature sensor The Controller shall compare actual SHWRT with its set point and display an error value which shall control pump speed Controller shall vary pump speed in order to maintain SHWRT set point Sequence of Operation 1 2 3 or A When MBS NA Integrated Controller Controller is set to Local the HW duty pump shall automatically be started at preset minimum speed and ALL boilers enabled When Controller is set to REMOTE BAS shall sense heat demand called by system BAS shall send signal to controller to start hot w
166. ustion products may occur Water may also collect inside the larger combustion air pipe and flow to the burner enclosure Failure to follow this warning could result in product damage or improper operation personal injury or death 6 Install the Y concentric fitting pipe assembly up through the structure s hole and field supplied roof boot flashing NOTICE Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole 7 Secure the assembly to the roof structure as shown below in FIG 5 6 using field supplied metal strapping or equivalent support material Figure 5 6 Concentric Vent Roof Installation NOTE 3 Concentric Vent shown for illustration purposes VENT 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 ABOVE ROOF COMBUSTION AIR ROOF BOOT FLASHING FIELD SUPPLIED SUPPORT FIELD SUPPLIED ELBOW FIELD SUPPLIED COMBUSTION AIR Ensure termination height is above the roof surface or anticipated snow level 12 inches in U S A or 18 inches in Canada as shown in FIG 5 4 page 26 If assembly is too short to meet height requirement the two 2 pipes supplied in the kit may be replaced by using the same diameter field supplied SDR 26 PVC D2241 pipe for 3 Concentric Vent and standard schedule 40 PVC for 4 Concentric Vent Do not extend dimension D more than 60 inches see FIG s 4 9
167. w Field Supplied Fittings IF LESS THAN 10 Figure 4 2A Clearance to Gravity Air Inlets FORCED AIR INLET BIRD SCREEN TYPICAL 7 MIN ABOVE ANY PUBLIC WALKWAY VENT AIR TERMINATION Page 38 of 118 ECO PAK BOILER Installation amp Operation Manual 4 Sidewall direct venting continued Prepare wall penetrations l Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes Air pipe penetration a Cut a hole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration a Cuta hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole with at least a 1 2 inch clearance around the vent pipe outer diameter 414 inch hole for 3 inch vent pipe 5 inch hole for 4 inch vent pipe Drill 3 16 diameter holes for inserting the plastic anchors into the wall Install the vent and air intake piping through the wall into the vent plate openings Seal all gaps between the pipes and wall Use RTV silicone sealant to seal the air pipe Use the cement primer listed in Table 3A on page 14 to seal the vent pipe Mount and secure the vent plate to the wall using stainless steel screws Seal around the plate to the wall assuring no alr gaps Assemble the vent cap to the vent plate see FIG 4 4A Insert the stainless steel screws into the vent cap screw
168. water system 1 Purge air from system a Connect a hose to the purge valve Route the hose to an area where water can drain and be seen b Close the boiler or system isolation valve between the purge valve and fill connection to the system Close zone isolation valves Open quick fill valve on cold water makeup line Open purge valve One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure h After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system i If purge valves are not installed in the system open the manual air vents in the system one at a time beginning with the lowest floor Close the vent when water squirts out Repeat with remaining vents moan 2 Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn 3 Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents A Refill to correct pressure Page 58 of 118 1 0 Start up continued Check for g
169. wed working pressure is located on the rating plate Notes 1 As an Energy Star Partner Armstrong has determined that ECO PAK boilers meet the Energy Star guidelines for energy efficiency 2 The ratings are based on standard test procedures prescribed by the United States Department of Energy 3 Net I B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 4 ECO PAK boilers require special gas venting Use only the vent materials and methods specified in the ECO PAK Boiler Installation and Operation Manual 5 Standard ECO PAK boilers are equipped for operation up to 4 500 feet with no field adjustments Output ratings will be reduced by 4 for each 1 000 feet above sea level up to 4 500 feet only 6 High altitude ECO PAK boilers will have a high altitude label affixed to the unit as shown in FIG A and are equipped for operation of 4 501 feet to 12 000 feet only with no field adjustments For high altitude models output ratings will be reduced by 2 for each 1 000 feet above sea level Figure A High Altitude Label Location High altitude models have a different control module for altitude operation but the operation given in this manual for standard models remains the same 7 Ratings have been confirmed by the Hydronics Institute
170. while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet from the ECO PAK boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure The problem is especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines Gas valve replacement The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances As an additional safety feature this gas valve has a flanged connection to the venturi and blower A WARNING Failure to follow all precautions could result in fire explosion or death A WARNING DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Page 53 of 118 ECO PAK Installation amp Operation Manual BOILER 8 Field wiring A WARNING ELECTRICAL SHOCK HAZARD For Installation must comply with your safety turn off electrical power supply before making any elec
171. ys Below are the screens that the user sees when pressing on each of those buttons Touch the buttons on the menu at the bottom to bring up the desired screen Touching the Right and Left arrow will navigate between the viewing only Setup Screens Page 94 of 118 ARMSTRONG il 1 4 1 SYSTEM HOT WATER TEMP SETUP SYSTEM HOT WATER TEMPERATURE SETPOINT SETUP 11 Indoor temp setpoint 2 Outside Air Temp Min e p A im sensor Tail FOR VIEVWING ONLY E mammeno 4 systemowe Y mamserue E 1 4 3 PUMP PID SETUP EA STE 11 Enter the PID parameter for corresponding circuit Small O Smal Medium arge po FOR VIEWING ONLY E mammeno 4 systemowe Y wmamserue Te 1 4 5 BOILER STAGING SETUP BOILER STAGING SETUP 11 Enter the Ci aul ity Setpoints ta Start and Stop Lag Boilers 1 2 and 3 2 Lag Boilers Minimun Run Time FOR VIEVWING ONLY E mammeno 4 systemowe Y mamserue De 1 4 2 PUMP SETUP Elle Ei 3 Default speed when SAART sensor falls 4 Pump rated RPM 5 Ramp time for pump speed B Run time after emergency stop A Run time when all boilers ott 0 Lead pump switch time RESTORE E damu systemowe A man sere o 9 Default Settings 1 4 4 BOILER SETUP BOILER SE THIR 11 MBS model 2 Minimum capacity setpoint 3 Boiler supply temp high limit 4 Maximum time under minimum flor 5 SHART restart setpoint B Lead boiler switch ti

- Armstrong Fluid Technology

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