PEERLESS PureFire PFC-2000 Installation instructions manual

PureFire
®
Boilers
PFC-2000, PFC-2500, PFC-3000, PFC-3500, PFC-4000
Gas
Boiler Control
Instruction &
Operation
Manual
®

Boiler Control Instruction & Operation Manual, Rev 1
Page 1 of 64
Contents
Introduction
Quick Reference 2
Overview 3
Product Features
Boiler Sequence 5
Protection Features 7
Single Boiler Control 10
Multiple Boiler Control Sequencer 11
Front Panel
General Navigation 14
Status Screens 15
Installation
Quick Setup 17
Terminal Layout 18
Boiler-To-Boiler Network 20
Energy Management Interface 22
Setup & Tuning
Manual Operation 29
Parameter Adjustment 31
Display Setup 44
Troubleshooting
General Issues 45
Sensor Status 48
Limit String Status 49
Holds 50
Lockouts 52
History 55
Specifications
General 58
Parameter Summary 60
Application
The Peerless Boiler Control (Control) has been
designed for commercial hot water boiler
applications.
Intent
This instruction manual includes detailed
functional, installation and setup information.
The intended users are application engineers, I&O
manual and brochure writers, development and
specifying engineers and installing contractors. For
further details please refer to the latest revision of
Honeywell manual 66-1171.
Figure 1: Control Front Panel
(Showing Home Screen)
Figure 2: Control

Introduction
Boiler Control Instruction & Operation Manual, Rev 1
Page 2 of 64
Quick Reference
Application
Single
Boiler
Multiple
Boilers
Energy Management System (EMS)
Boiler Control
Manual
Operation
Single Boiler
Setpoint Input
Multiple Boilers
Setpoint Input
Modulation
Rate Input
Setpoint
Temperature
Sensor
Supply
Header
Supply
Header
Ignored
Ignored
Setpoint
Operator
Operator
Input J8 (6-7)
or Modbus*
Input J8 (6-7)
or Modbus*
Ignored
Ignored
“On”and
“Off” Point
Operator
Operator
Operator
Operator
Ignored
Ignored
Outdoor Air
Reset
Option
Option
Ignored
Ignored
Ignored
Ignored
Domestic
Hot Water
Priority
(DHWP)
Option
Option
Ignored
Ignored
Ignored
Ignored
Warm
Weather
Shutdown
(WWSD)
Option
Option
Option
Option
Option
Ignored
Call For
Heat
Call For Heat
Based on
Setpoints
Based on
Setpoints
Based on
Setpoints
Based on
Setpoints
Input (RO) or
Modbus
Based on
Setpoints
Modulation
Rate
Firing Rate
Demand
Internal
From
Sequence
Master
Internal
From
Sequence
Master
Input 4-
20mAdc or
Modbus*
Ignored
Remote
Connection
External
Enable/
Disable
Enable/
Disable
Enable/
Disable
Enable/
Disable
Enable/
Disable
On/Off
Ignored
Remote
Control
Input J8 (6-7)
or Modbus*
No
No
Remote
Setpoint
Remote
Setpoint
Remote
Modulation
Ignored
Additional
Information
Page 9
Page 10
Page 20
Page 20
Page 20
Page 28
Table 1: Quick Reference
* Both Peer-To-Peer Network and Modbus Remote Control may be used at the same time.

Introduction
Boiler Control Instruction & Operation Manual, Rev 1
Page 3 of 64
Overview
Boiler Control
The Peerless Boiler Control (Control) contains
features and capabilities which help improve
heating system operation, and efficiency. By
including unique capabilities, the Control can do
more, with less field wiring, and fewer aftermarket
controls and components –improving the
operation of both new and replacement boiler
installations.
Advanced Touch Screen Display
Boiler status and setup selections are available
from an easy to use, full color, Touch Screen
Display. In the event of a fault condition the user is
guided by blinking touch buttons to help screens that
explain the problem, cause, and corrective
action. Operation evaluation and problem-solving
is enhanced by historical capability including
graphic trends, lockout history records, as well as
boiler and circulator cycle counts and run time hours.
Archives
Evaluation, optimization, and troubleshooting are
enhanced by the collection of an operational
record. Operation history is provided by major,
time and day stamped alarms, lockout history,
cycles, and run hours.
Advanced Modulating Control
The Controlmodulates the boiler input by varyingthe
fan speed. As the fan speed increases, so
does the amount of fuel gas drawn into the blower.
As a result, a fairly constant air-fuel ratio is
maintained across all inputs. The Control
determines the input needed by looking at both
current and recent differences between the
measured temperature and the setpoint
temperature. As the measured temperature
approaches the setpoint temperature, the fan will
slow down and the input will drop. The Control also
utilizes boiler return water and flue gas temperatures
to adjust fan speed.
Built-in Safety Control
The Control includes safety controls designed to
ensure safe and reliable operation. In addition to
flame safety controls the Control includes supply
water temperature, differential water temperature,and
stack temperature safety limits, as well as stepped
modulation responses. Boiler modulation is adjusted
when required to help avoid loss of boiler operation
due to exceeding limits. Additionally, the Control
monitors the safety limits and displays cause of
boiler alarm trip and start delay.
Outdoor Air Reset
When selected the active setpoint is automatically
adjusted based on outside air temperature, time of
day, and length of demand (boost) settings.
Outdoor air “reset”setpoint saves fuel by adjusting the
water temperature of a heating boiler lower as the
outside air temperature increases.
Auxiliary Equipment Control
The Control may be used to sequence the domestic
hot water, boiler and system circulators, or fresh air
damper. Circulators are automatically run for a 20
second exercise period after not being used for longer
than 7 days. Circulator exercise helps prevent
pump motor shaft seizing.
Energy Management System (EMS) Interface
The control accepts a 4-20mAdc input from the EMS
system for either direct modulation rate or setpoint.
A factory configured RS485 Modbus interface is
available for Energy Management System (EMS)
monitoring or control. Additionally the boiler Multiple
Boiler Sequencer Peer-To- Peer Network may be
used at the same time the EMS is monitoring and
providing setpoint over the Modbus network.
Multiple Boiler Peer-To-Peer Network
The Control includes state-of-the-art modulating
lead- lag sequencer for up to eight (8) boilers,
capable of auto rotation, outdoor reset, and peer-to-
peer communication. The peer-to-peer network is
truly “plug and play”. Communication is activated by
simply connecting a RJ45 Ethernet cable between
boilers. The Control provides precise boiler
coordination by sequencing boilers based on both
header water temperature and boiler modulation
rate. For example, the lead boiler can be configured
to start a lag boiler after operating at 50%
modulation rate for longer than an adjustable time.
The boilers are modulated in “unison” (parallel)
modulation rate to ensure even heat distribution.

Introduction Overview
Boiler Control Instruction & Operation Manual, Rev 1
Page 4 of 64
Return Water
Stack
System Pump
Domestic Hot
Water Pump
Header
Temperature Sensor
Domestic Hot Water
Temperature Sensor
or Switch
System
Supply Water
Domestic
Hot Water
Supply
Water Flow
Switch
Stack
Temperature
Sensor
Boiler Pump
Outside Air
Temperature
Sensor
Return
Temperature
Sensor
Building Automation
System
Hardwired Connections
Boiler On/Off
Switch
Low Water Cutoff Switch
High Limit Auto Reset Supply
Supply Temperature Sensor
Vestibule and Burner
Thermal Fuses
Min. & Max Air Press Switches
Variable
Fresh Air
Supply
Modbus RS-485 Monitoring & Control:
- Enable/Disable
- Remote Firing Rate
- Remote Setpoint
Fuel
Supply
Figure 3: Boiler Control
- Lockout Indicator
- Enable/Disable Input
- Boiler Running Contact (Optional)
- Remote Firing Rate 4-20mAdc
- Remote Setpoint 4-20mAdc
Flame
Ignition
Transformer
FAN
Speed Fan
Boiler
Jacket
M
Combustion Air
Damper
Blocked Condensate Drain
Gas
Valve
Low & High
Gas Pressure
Switches

Product Features
Boiler Sequence
Boiler Control Instruction & Operation Manual, Rev 1
Page 5 of 64
Boiler “Priority”Figure 4: Home Screen Details
The Control accepts a call for heat (demand) from multiple places and responds according to the “Priority.”
When more than 1 demand is present the higher priority demand is used to determine active boiler
settings. For example, when Domestic Hot Water (DHW) has priority the setpoint, “Diff Above”, “Diff
Below”and pump settings are taken from DHW selections. Active “Priority”(Demand) is displayed on the
“Home” screen above. Priority Order is shown in Table 2.
Table 2: Order of Priority
Priority
Display
Boiler Responding to:
1st
Sequencer Control
The boiler is connected to the peer- to-peer network. The boiler accepts
demand from the Sequencer Master.
2nd
Domestic Hot Water
DHW call for heat is on and selected as the priority demand. DHW is
always higher priority than Central Heat. It also has higher priority than the
Sequencer Control when DHW priority is “enabled”and “Boiler Piped” IWH
is selected.
3rd
Central Heat
Central Heat call for heat is on and there is no DHW demand or DHW
priority time has expired.
4th
Frost Protection
Frost Protection is active and there is no other call for heat. Frost protection
will be a higher priority than Sequencer Control if the Sequence Master has
no active call for heat.
5th
Warm Weather
Shutdown (WWSD)
WWSD is active and the boiler will not respond to central heat demands.
DHW demand is not blocked by WWSD.
Screenshot button
Boiler’s Measured
Temperatures
Combustion Air
Setpoint with
actual RPM
Boiler “Status”
Initiate
Standby
Standby Delay
Safe Startup
Drive Purge
Prepurge
Drive to Lightoff
Preignition Test
Preignition
Direct Ignition
Running
Postpurge
Lockout
Navigation Menus
Lockout, Hold, and
Alert Codes

Product Features
Boiler Sequence
Boiler Control Instruction & Operation Manual, Rev 1
Page 6 of 64
Standby
Drive Purge
Prepurge
Drive Lightoff
Direct Ignition
Boiler Running
Fan Post Purge
Pump Overrun Time
Boiler Sequence Status is shown on both the Home screen and the Status Screen. Once limits have been
established the boiler start/stop sequence progresses as show in the graph below;
Boiler
“Status”
Shown on Display:
Run
Stabilization
Time
Low Fire
Hold
Time
Slow
Start
Ramp
Released
to
Modulate
CH Maximum Modulation
Purge Rate
Postpurge
Rate
Minimum Modulation
Lightoff Rate
CH Low Fire Hold Rate
Slow Start Ramp Rate
Symbol Legend
Adjustable parameters are
shown in shaded box:
Adjustable Parameter
30s 4s 1 minute
CH Low Fire
Hold Time
Slow Start Enable
Slow Start Degrees
5 minute
Pump
Overrun
Time
(Note; refer to Parameter Adjustment for additional information.)
Figure 5: Central Heat Start sequence (Typical for Domestic Hot Water)
Table 3: Boiler Sequence
Status:
Description
Standby
Boiler is not firing. Appropriate circulators are “On” if “Priority” is not standby. There is a
Central Heat call for heat and the Supply temperature is greater than setpoint minus the
“Diff Below”.
Prepurge
When supply temperature drops below setpoint minus the “Diff Below,”burner demand
continues with following Status shown:
Safe Startup: Flame circuit is tested.
Drive purge: The blower is driven to the fan purge speed.
Prepurge: After the blower reaches the fan purge speed setting the 30 second
combustion chamber purge is conducted.
Direct
Ignition
After purge time is complete the following Status is shown:
Drive light-off: The blower is driven to light-off rate.
Pre-Ignition Test: After the blower reaches light-off rate a safety relay test is conducted.
Pre-ignition: Spark is energized and it is confirmed that no flame is present.
Direct Ignition: Spark and Main fuel valve are energized.
Running
After the flame is proven the sequence continues with run stabilization and, when
selected, low fire hold time and slow start ramp. Once the field adjustable low fire hold
time and ramp rate is completed normal boiler operation begins, modulation rate
depending on temperature and setpoint selections.
Post-
purge
When the call for heat ends the main fuel valve is closed and the blower is driven to the
fan post-purge speed. After the blower reaches the fan post-purge speed setting the 5
minute second combustion chamber purge is conducted.

Boiler Control Instruction & Operation Manual, Rev 1
Page 7 of 64
Product Features
Boiler Protection Features
Supply Water Temperature High Limit
The Control is equipped with internal operating
control and high limit features. The Control
monitors a dual element temperature sensor that
is mounted in the supply water manifold and
provides UL353 and UL1998 internal safety
algorithms. If supply water temperature increases
above the active setpoint plus diff above, default
180°F (82°C) (maximum setting 190°F (88°C)) the
boiler is cycled off. If the temperature exceeds
200°F (99°C), a manual reset hard lockout results.
Additionally, the supply temperature is monitored
by a L4008A High Limit Aquastat set to recycle the
boiler at 195°F with a 5°F differential.
Stepped Modulation
While the boiler is a slave responding to the
internal Multiple Boiler Control Peer-Peer Network,
an Energy Management System (EMS) demand,
or has Header sensor selected as Central Heat
Modulation Sensor the Control still monitors
supply water temperature to prevent boiler over
firing. The boilers maximum modulation is
reduced from 100 to 0% if the supply water
temperature increases from 190°F (88°C) to 200°F
(93°C). If supply water temperature exceeds
200°F (93°C) a forced recycle results.
Sequence Master Stop All Boilers
All boilers are stopped without delay if the Call for
Heat input is removed or if the header temperature
is higher than 195°F (90.6°C) (field adjustable).
High Differential Temperature Limit
The Control monitors the temperature difference
between the return and supply sensors. If this
difference exceeds 80°F (45°C) the control begins
to reduce the maximum blower modulation. If
temperature difference exceeds 90°F (50°C) a
forced boiler recycle results. If the temperature
difference exceeds 100°F (56°C) the control will
shut the unit down. The unit will restart automatically
once the temperature difference has
decreased and the minimum off time has expired.
If the differential temperature exceeds the 100°F
limit ten times the boiler manual reset Hard
Lockout is set. Additionally, if the supply
temperature rises faster than the 4°F (2°C) per
second limit, a soft lockout is activated.
Return Higher Than Supply Temperature
The Control monitors the supply and return
temperature sensors. If the return water
temperature exceeds the supply water
temperature for longer than a limit time delay, the
Control shuts down the boiler and delays restart.
If the inverted temperature is detected more than
five times the boiler manual reset Hard Lockout is
set. This condition is the result of incorrectly
attaching the supply and return piping.
Stack High Limit
The Control monitors a dual element temperature
sensor that is mounted in the boiler vent connector
and provides UL353 and UL1998 internal safety
algorithms. If the flue temperature exceeds 210°F
(99°C), the control begins to reduce the maximum
blower modulation. If the flue temperature exceeds
220°F (104°C), a forced boiler recycle results. If
the flue temperature exceeds 230°F (110°C), the
boiler manual reset Hard Lockout is set.
Ignition Failure
The Control uses an external igniter. The Control
monitors ignition using a burner mounted flame
sensor. In the event of an ignitionfailure, the control
will recycle. If ignition fails after a single retry, a
manual reset Hard Lockout is set.
Central Heating System Frost Protection
When enabled, Frost Protection starts the boiler and
system pump and fires the boiler when low
outside air and low supply water temperatures are
sensed. Outdoor Air setpoint is field adjustable.
The Control provides the following control action
when frost protection is enabled:
Device
Start
Temperatures
Stop
Temperatures
Boiler &
System
Pump
Outside Air < 32°F
Supply Water < 45°F
Outside Air > 36°F
Supply Water > 50°F
Boiler
Supply Water < 38°F
Supply Water > 50°F
Table 4: Frost Protection
FROST PROTECTION NOTE
The Control helps provide freeze protection for
the boiler water. Boiler flue gas condensate
drain is not protected from freezing. Since the
Control may only cycle the system and boiler
circulators individual zones are not protected.
It is recommended that the boiler be installed in
a location that is not exposed to freezing
temperatures.

Product Features
Boiler Control Instruction & Operation Manual, Rev 1
Page 8 of 64
Relay Outputs
Inputs
Standby CH Disabled
Standby DHW Disabled
Standby DHW Enabled
Standby
CH Enabled
Frost Protection On
Lockout
LCI Open
Warm Weather Shutdown
Standby
Limit Hold
Drive Purge
Prepurge
Drive Lightoff
Direct Ignition
Boiler Running
Pump Overrun Time
Fan Post Purge
Boiler Sequence
Boiler
“Status”
Shown on Display:
Temp >Setpoint CH Enabled & Termp < Setpoint (lead boiler demand active)
ILK OFF
LCI OFF
Warm Weather
Shutdown
Frost Protection
On
CH Enabled
DHW Enabled
Blower Output
Alarm Relay
System Pump
DHW Pump
Isolation Valve Lea d
B oiler
Onl y
Boiler Pump
Notes
System Pump: Runs when boiler room has heat demand enabled. Is shut off when boiler is in Warm Weather Shutdown (WWSD).
DHW Pump: Runs when there is a domestic demand.
Isolation Valve: Opens boiler is a lead boiler and when the boiler has burner demand. Closes when the boiler is locked out or in WWWSD.
Boiler Pump: Runs when boiler has burner demand. Stops when the boiler is locked out or in WWSD.

Product Features
Boiler Control Instruction & Operation Manual, Rev 1
Page 9 of 64
Boiler Protection Features
Limit Devices
The control monitors individual limit devices as shown in Figure 6 below. If any of these limits open the
boiler will shut down and an open limit indication is provided. Additionally, the control monitors an air proving
switch.
Note
During the boiler start sequence the
control requires the Air Proving Switch,
“API” to be “OFF” before the blower
starts and in the “ON” position after the
blower starts. If the API is not in the
required position the start sequence is
halted or the boiler is shut down and
the “Low Air Pressure” OFF limit
indication is provided.
Figure 6: Limit Monitoring Screen Showing Central Heat Demand
Table 5: Limit String
Limit
String
Type
Description
Action
STAT
Heat Demand
After a Heat demand is received, “ON” the control is enabled to fire to
maintain water temperature at setpoint.
•Heat demand may be received from “STAT” terminal for Central Heat
demand, “S6” terminal for Domestic Hot Water demand, the Sequence
Master, or EMS Modbus Inputs.
•A Heat Demand input ON initiates pumps and Fresh Air Damper outputs.
LCI
Load Control
Input
The boiler will not start if the LCI is OFF, when it is turned OFF during run the
boiler shuts down.
•Hold message is shown when LCI limit is OFF and Heat Demand ON.
•LCI Hold will never cause a manual reset lockout.
•Boiler may be disabled remotely by wiring an enable contact to the LCI
“External Limit”terminals.
•When the Low Air Pressure Switch (APS) is proven OFF the LCI input
turns ON and initiates blower start. When Low APS fails to turn ON, the
control enters a manual reset Lockout state.
ILK
Interlock
The boiler will not start if the ILK is OFF. When it is turned OFF during run the
boiler enters a manual reset Lockout state.
•The ILK must be ON within 1 minute after the LCI is ON. This time allows
the blower to start and the air flow proving switch to turn ON. Failure to
close will cause a manual reset lockout
•ILK OFF Lockout cause the Lockout Alarm contact to turn ON.

Product Features
Boiler Control Instruction & Operation Manual, Rev 1
Page 10 of 64
Single Boiler Control
Control Options
•Modulating Sensors
1. Supply
2. Header
3. Domestic Hot Water
•Modulation Setpoint
- Outdoor Air Reset
- Warm Weather Shutdown
- Frost Protection
- EMS interface
•Device Control
Return
Water
System
Circulator
DHW
Circulator
Header
Temperature
DHW
Temperature
Sensor
or
Switch
Options
- Boiler, System & Domestic pumps
- Fresh Air Damper Figure 7: Single Boiler Hydronic Options
Modulation Setpoint
The Control starts and stops the boiler and
modulates the boiler input from minimum
(MBH) to maximum (MBH) in order to heat
water to the active setpoint. The setpoint is
determined by the priority (Domestic Hot
Water, Central Heat, Frost Protection and
Warm Weather Shutdown) and as described
in the following paragraphs
Central Heat
User may select the Supply sensor or Header
Sensor as the Modulation Sensor. Upon a
Central Heat call for heat the setpoint is either
the user entered Central Heat Setpoint, or
automatically adjusted by Outdoor Air Reset,
Energy Management System (EMS), supplied
4-20mAdc, or Modbus setpoint input.
Outdoor Air Reset
When selected the modulation rate setpoint is
automatically adjusted based on outside air
temperature, time of day input and demand
duration (boost) settings. Outdoor air “reset”
setpoint saves fuel by adjusting the active
setpoint of a heating boiler lower as the
outside air temperature increases.
Domestic Hot Water (DHW) Setpoint
User May select the Supply sensor or DHW
Sensor as Modulation Sensor. Upon a DHW
call for heat the setpoint is either the user
entered DHW setpoint or the time of day input DHW
setpoint. The optimal value of this setpoint is established
based on the requirements of the indirect water heater.
Domestic Hot Water Priority (DHWP)
Some boilers are used primarily for building space
heating, but also provide heat for the domestic hot water
users. When the outdoor temperature is warm, the
outdoor reset setpoint may drop lower than a desirable
domestic hot water temperature. Also, often it is required
to quickly recover the indirect water heater. When
DHWP is enabled, heating circulators are stopped, the
domestic circulator is started and the domestic hot water
setpoint is established in response to a domestic hot water
demand. Priority protection is provided to allow the heating
loop to be serviced again in the event of an excessively
long domestic hot water call for heat.
Device Control
The Control may be used to sequence the domestic hot
water, boiler and system circulators or fresh air damper.
Selecting This Control Mode
To select single boiler control set the following:
Press Configure > Lead Lag Master Configuration;
Select Master enable = Disabled
Press Configure > Central Heat Configuration >
Modulation;
Select Modulation rate source = Local

Boiler Control Instruction & Operation Manual, Rev 1
Page 11 of 64
Product Features
Multiple Boiler Control Sequencer
Control Options
•Modulating Sensors
1. Header
•Modulation Setpoint
- Outdoor Air Reset
- Warm Weather Shutdown
- Frost Protection
- EMS interface
•Device Control
- Boiler, System & Domestic
pumps
- Fresh Air Damper
Return
Water
System
Circulator
DHW
Circulator
Connects to
Up to Eight
Boilers
Header
Temperature
DHW
Temperature
Switch
ONLY
Sequencer Master
A single Control is parameter selected to be the
Sequencer Master. The Sequence Master does
not rotate. The call for heat, outdoor and header
sensors, and common pumps are wired to the
Sequencer Master “enabled”Control.
Lead/Slave Sequencing
The Sequence Master is independent of the
“Lead”boiler. One boiler is a “Lead”boiler and the
remaining networked boilers are “Slaves”. When
demand is increasing, the Lead boiler is the first to
start and the Slave boilers are started in
sequential order (1, 2, 3,…) until the demand is
satisfied. When demand is decreasing, the boilers
are stopped in reverse order with the Lead boiler
stopped last (…, 3, 2, 1). To equalize the run time
the sequencer automatically rotates the Lead
boiler after 24 hours of run time.
Customized Sequences
Normally, boilers are started and stopped in
numerical order. However, custom sequences
may be established to optimize the heat delivery.
For example, in order to minimize boiler cycling, a
large boiler may be selected to run first during
winter months and then selected to run last for the
remainder of the year.
DHW Two boiler Start
When the Indirect Water Heater (IWH) parameter
is set to “Primary Piped” and the DHW Two Boiler
Start parameter is set to “Enabled”two boilers are
started without delay in response to a DHW call for
heat. This feature allows rapid recovery of large
IWH’s and multiple IWH’s.
Figure 8: Multiple Boiler Hydronic Options
Shared or Isolated DHW Demand
When the Indirect Water Heater (IWH) parameter
is set to “Primary Piped” the Sequence Master
sequences all required boilers to satisfy the DHW
setpoint (default 180°F (82.2°C). When “Boiler
Piped” is selected only the individual slave boiler,
with the wired DHW demand and pump, fires to
satisfy the DHW setpoint.
Multiple Demands
The Sequence Master responds to Central Heat,
DHW and frost protection demands similar to the
stand alone boiler. For example, when selected
and DHW priority is active, the sequence master
uses DHW setpoint, “Diff Above”, “Diff Below”and
pump settings. However, the Sequence Master
always uses the Header sensor and does not use
the DHW Sensor.
Optimized Boiler Modulation
Boiler firing rate is managed to increase smoothly as
boilers are started. For example, when a
second boiler is started the initial firing rate is
100%/2 or 50%, when the third boiler is started the
firing rate starts at 200%/3 or 66%. After the initial
start, the Sequence Master develops a unison
firing rate demand based on its setpoint and
header temperature.
Selecting This Control Mode
Press Configure > Lead Lag Master Configuration;
Select Master enable = Enabled

Boiler Control Instruction & Operation Manual, Rev 1
Page 12 of 64
Product Features
Multiple Boiler Control Sequencer (continued)
PLANT LOAD
(# BOILERS REQURED)
BOILER
FIRING RATE
SYSTEM
TEMPERATURE
During low loads, the Sequence Master limits firing rates to a “Base Load Rate”to ensure modulating
condensing boiler peak operating efficiency. Lower firing rates boost efficiency by helping increase the
amount of flue gas water vapor condensation. The Control maintains a “Base Load Rate” until the last lag
boiler is started. At this point, the “Base Load Common Rate”is released to allow boilers to
modulate as required to meet heat load.
185
Setpoint
180
5
175 1 2
Base Load
Rate Default
40% Range
(25 –100%)
100
40
0
2
3 4 4
5
3
2 Fast
1 Load
0 Change
Slow
Load
Change
Start
Lead Boiler Start
1st Lag Start 2nd Lag Stop 2nd Lag Stop 1st Lag Stop
Lead Boiler
Figure 9: Boiler Start and Stop Peer-To-Peer Network Sequence Diagram
(3 boiler system shown, typical for up to 8 boilers)
Advanced Boiler Sequencing
After there is a Call for Heat input,
both header water temperature and
boiler firing rate percent are used to
start and stop the networked
boilers. The control starts and stops
boilers when the water temperature
is outside the user selected
“Difference Above” and “Difference
Below”settings. Also, in order to
minimize temperature deviations,
the control adjusts the number of
boilers running based on the firing
rate. This combination allows the
boilers to anticipate slow load
changes before they disrupt water
temperature, yet still respond
quickly to sudden load changes.
These special sequencer features
help reduce energy wasting system
temperature swings and the
resulting unnecessary boiler cycling.
1 - Lead Boiler Start
Water temperature is below the setpoint by more than
the “On Point” differential.
2 - Temperature Based Lag Boiler Start
Water temperature is below the setpoint by more than
the “Difference Below”parameter for longer than the
adjustable time delay (“Boiler Start Delay”parameter).
3 - Modulation % Based Lag Boiler Start
The boiler modulation rate has been at the maximum
firing rate for longer than twenty minutes.
4 - Lag Boiler Stop
The boiler modulation rate has been at minimum fire for
longer than twenty minutes. Additionally, lag boilers are
stopped when water temperature is above the setpoint
by more than the “Difference Above” parameter for
longer than the “Boiler Stop Delay”parameter.
5 - Lead Boiler Stop
The last boiler remains on line until the water
temperature is above the setpoint more than the
“Difference Above”for longer than the time delay.

Boiler Control Instruction & Operation Manual, Rev 1
Page 13 of 64
Product Features
Multiple Boiler Control Sequencer (continued)
Improved Availability - The following features help improve the heat availability:
Backup Header Sensor
In the event of a header sensor failure the lead boiler’s supply sensor is used by the Sequence Master
to control firing rate. This feature allows continued coordinated sequencer control even after a header
sensor failure.
Slave Boiler Rate Adjustment
Each slave boiler continues to monitor supply, return and flue gas temperatures and modifies the
Sequence Master’s firing rate demand to help avoid individual boiler faults, minimize boiler cycling and
provide heat to the building efficiently.
Slave Boiler Status Monitoring
The Sequence Master monitors slave boiler lockout status and automatically skips over disabled boilers
when starting a new slave boiler.
“Stand Alone” Operation Upon Master Failure
Individual boilers are configured to continue to operate in the event the Sequence Master Control is
powered down, disabled or Boiler-to-boiler communication is lost. The following are design
considerations for backup “Stand Alone” operation;
•Enable/Disable
Upon loss of the Sequence Master each boiler will automatically begin local control. This
means it will operate only if it has a call for heat. For this reason slave boilers should have their
“External Enable/Disable” J8 terminal 1 to 3 jumpered. In the event of loss of Sequence Master
the slave boiler will have demand to run.
•Modulation
Once running the Slave boiler will use the selected central heat modulation sensor and setpoint
to produce heat for the building. Optionally, slave boilers may have a separate header sensor
wired and select the “Central Heat Modulation Sensor”parameter as Header Sensor”. This will
allow continued header water temperature control.
•Pumping
Consideration must be given to how the system pump is powered. If the Sequence Master
enabled boiler is powered down, how will the system pump be operated? It may be required to
wire the system pump to multiple boilers.
Once the Sequence Master is restored to operation the individual boilers automatically resume their
position as sequencer slaves.

Boiler Control Instruction & Operation Manual, Rev 1
Page 14 of 64
Front Panel
General Navigation
Figure 10: Configure Menu
Main Screen
The Main Screen provides access to all display
functions. It is the first screen that appears after
boot up. Touching the control icon leads to the
home screen, where the following menus can
be accessed:
CONFIGURE
Each adjustable parameter is presented for
adjustment. Proper login is required.
OPERATION
The operation screens allow the user to take
manual or automatic control of the unit. These
screens are intended to allow a technician to set
firing rate to support combustion testing and
support fine tuning the boilers response to load
changes.
DIAGNOSTICS
Provide a “walk” through boiler operation. These
screens provide an overview of boiler operation.
The diagnostics screens include Modulation and
Pump Tests, Burner Control I/O status, Digital I/O
status, and Analog I/O status.
DETAILS
Status and details are provided on all sensors
connected to the Control as well as cycles and run
times for the burner and pumps.
HISTORY
Shows log of recorded issues during operation and
provides details to review the state of the boiler at
the time of the issues;
•Lockout History –provides data on up to 15
manual reset Lockouts. Data collected
includes cause of boiler trip, run hour and
status when lockout occurred.
•Alert History –All other non-lockout alarms
are recorded with time and date stamp.
Setup Menus
Touching the “Setup” button on the main screen
will lead to menus for adjusting the operation of
the display. This includes communication,
video, and audio settings.

Boiler Control Instruction & Operation Manual, Rev 1
Page 15 of 64
Front Panel
Status Screens
Boiler Status screens are the primary boiler monitoring screens. The user may simply “tab”through
boiler operation by selecting the desired screen along the bottom of the page. These screens are
accessed by selecting the “Diagnostics”button from the “Home” screen.
Figure 11: Status Screen Navigation
Diagnostic Tests
This screen provides a test for the fan speed
modulation and the pump contact. The tests can be
used to check for proper operation of controls.
Burner Control I/O
This screen gives an overview of the current status
of the control’s primary inputs (Demand STAT, LCI,
ILK, Interrupted Air Switch) and outputs (Pilot Gas
Valve, Main Gas Valve, External Ignition).
A green circle next to the I/O name indicates that I/O
is currently receiving/producing voltage.
Digital I/O
This page gives the current status of all of the digital
(on/off) inputs and outputs on the control. Inputs
include Central Heat demand, Domestic Hot Water
demand, and all safety limit annunciators. Outputs
include gas valves, external ignition, pump contacts,
and the alarm contact.
A green circle next to the I/O name indicates that I/O
is currently receiving/producing voltage.
Analog I/O
This is an overview of all sensors installed on the
boiler represented as bar graphs. Numeric values
are also provided for accurate readings.

Boiler Control Instruction & Operation Manual, Rev 1
Page 16 of 64
Front Panel
Detail Screens
The detail screens shows data relevant to current boiler operation. A relevant sensor to the detail category
is shown on each page as well as current setpoint, active sensor, and much more. A screen map is shown
below.
Manual
Figure 12: Detail Screen Map
Detail Pages:
Central Heat
Domestic Hot Water
Burner Control
Demand & Modulation
Fan
Central Heat pump
DHW pump
Boiler pump
Flame Detection
Statistics
Delta T inlet/outlet
Outlet T-rise
CH Frost Protection
Lead Lag Slave
Relevant Sensor
Page Navigation

Boiler Control Instruction & Operation Manual, Rev 1
Page 17 of 64
Installation
Quick Setup
The following tables are provided to allow the user to review and adjust the most commonly adjusted
parameters, such as Setpoints and pump output settings. Refer to Parameter Adjustment section for
additional information.
Setpoints
Factory
Setting
Range /
Choices
Parameter and Description
180
50 to 190 (ºF)
Central Heat Setpoint
10
3 to 29 (ºF)
Central Difference Above
5
3 to 29 (ºF)
Central Difference Below
180
50 to 190 (ºF)
Domestic Hot Water Setpoint
10
3 to 29 (ºF)
Domestic Difference Above
5
3 to 29 (ºF)
Domestic Difference Below
32
-50 to 50 (ºF)
CH Frost Protection Setpoint
70
20 to 100 (ºF)
Warm Weather Shutdown Setpoint
195
50 to 195 (ºF)
Stop All Boilers
Comfort
Factory
Setting
Range /
Choices
Parameter and Description
30 (ºF)
-50 to 32 (ºF)
Minimum Outdoor Temperature
70 (ºF)
35 to 100 (ºF)
Maximum Outdoor Temperature
110 (ºF)
70 to 180 (ºF)
Low Water Temperature
130 (ºF)
50 to 185 (ºF)
Minimum Boiler Water Temperature
Response
Factory
Setting
Range /
Choices
Parameter and Description
3
1 to 5
Central Heat Response Speed
0
0 to 30 Minutes
Central Heat Low Fire Hold Time
3
1 to 5
Domestic Heat Response Speed
0
0 to 30 Minutes
Domestic Heat Low Fire Hold Time
Hydronic System
Factory
Setting
Range /
Choices
Parameter and Description
Boiler Pump
Any Demand
Never
Any Demand
CH, OFF DHW Demand
Boiler Pump
System Pump
Any Demand
System Pump: Never
System Pump: Any Demand System Pump:
Central Heat, No Priority System Pump:
Central Heat, Optional Priority Fresh Air
Damper
Spare Output J4, 6-7
DHW
Pump Primary
Loop Piped IWH
DHW Pump: Never
DHW Pump: Primary Loop Piped IWH
DHW Pump: Boiler Piped IWH
Fresh Air Damper
Spare Output J4, 6-7

Boiler Control Instruction & Operation Manual, Rev 1
Page 18 of 64
Installation
Terminal Layout
Figure 13: Control Terminal Layout and wiring note

Boiler Control Instruction & Operation Manual, Rev 1
Page 19 of 64
Installation
Terminal Layout
A B C A B C
Boiler to Boiler
Sequence Master
Communication
MB1
MB2
From Control
J3 Terminal
2
3
4
10
9
8
60
59
58
57
56
55
2
31
4
5
RJ45 Port
Connects to
Up to 8 boilers
Connection to
Protonode
Factory Supplied
P26
P21 P27
N
To Energy Management
System (EMS)
RS485 Modbus
Communication
To Energy Management
System (EMS)
BACnet MSTP, Metasys N2,
Or LonWorks
Communication
Note
The Sequence Master communicates to all
networked boilers using the MB2 Connection on
each boiler. Separately the Display COM 3 port
(Internal System Menu) on each boiler is used to
communicate RS485 Modbus to the Energy
Management System (EMS).
These communications are electrically separate from
each other and make the connection between boilers
using a common RJ45 Module and Ethernet Cable.
Note - Display to EMS wiring;
Function COM 2 Terminal RJ45 Terminal
RS485 (+) Pin 4 - Pin 1
RS485 (-) Pin 5 - Pin 3
Ground Pin 6 - Pin 2
Note - Control to Peer-to-peer wiring;
Function J3 Terminal RJ45 Terminal
RS485 (+) MB2 A - Pin 8
RS485 (-) MB2 B - Pin 7
Ground MB2 C - Pin 2
PCB-06
COM1 COM2 24 VAC
A B C A B C COM PWR
24VAC
Transformer
N+24V
USB Connection for
Historical Data
Collection
Battery located
behind door
Display Rear View
Figure 14: Display Terminal Layout and wiring notes