AJAX A050-A300 Operating Instructions Manual

Text of AJAX A050-A300 User Guide:

• AJAX A050-A300, 100 Rev 2.1 If combustion readings are not between recommended values, then adjustments should be made to the gas valve until all readings are within these recommended values. Carbon Monoxide __________ ppm (must be kept below 100 ppm) Carbon Dioxide __________ % (should be kept between 7-9%) Excess Air __________ % (should be kept between 30-45%) NOx __________ ppm (should be kept under 15 ppm) Combustion Chamber Pressure __________ in w.c. (must be kept under 0.5 in w.c.) After maintenance is complete refer to pre start checklist. Check gas pressure and perform

• AJAX A050-A300, 19 Rev 2.1 US Installations Refer to the latest edition of the National Fuel Gas Code. 1. Vent must terminate at least 4ft below, 4 ft horizontally from or 1 ft above any door, window or gravity air inlet to the building. 2. The vent must not be less than 7ft above grade when located adjacent to public walkways. 3. Terminate vent at least 3ft above forced air inlet located within 10ft. 4. Vent must terminate at least 4ft horizontally, and in no case above or below unless 4ft horizontal distance is maintained, from electric meters, gas meters, regulators, and relief e

• AJAX A050-A300, 94 Rev 2.1 The gas train has been checked before shipping, but could come loose during shipping. Turn “OFF” all electric power and open the main gas valve. Turn the unit’s switch to the “ON” position and open the main gas valve and the ball valve to the burner mixer tube (the one between the fuel-air ratio valve and the venturi). If you smell gas, shut the main gas valve to the boiler immediately and check for and eliminate all gas piping leaks! In addition to smelling for the natural gas, it is necessary to spray a soapy water mixture

• AJAX A050-A300, 49 Rev 2.1 Figure 4.8 – Login Request The Honeywell Sola Controller on each boiler also maintains a password time out that limits the scope of the password entry. Once a password is successfully entered the unit starts an internal timer that expires after 10 minutes of inactivity. After the timer expires, the user is required to re-enter a password before a parameter can be changed. The user is not required to enter a configuration password for a parameter that has a lower access level than the access level achieved

• AJAX A050-A300, 89 Rev 2.1 6 Start Up Instructions Your unit has been pressure tested in accordance with ASME CODE SECTION IV and fire tested in accordance with UL 795. A copy of the factory test report is included inside the unit behind the display panel, and a test report label is located on the inside of the top lid. It is required that the boiler and the system into which it is installed be tested before operating the system. The exact natures of the tests are listed on the start-up fire test report located in the back of this

• AJAX A050-A300, 92 Rev 2.1 5) If the flame signal is higher than 0.5 Vdc and the flame LED does come on, contact your local Ajax Boiler Inc. representative for more help. Figure 6.4. Voltmeter Connected to Control Panel 6-4.4 Gas Valve Leak Test This test is to check the closure tightness of the gas shutoff valve. It should only be performed by trained, experienced, flame safeguard technicians during the initial start up of the burner system of whenever the valve is to be replaced. This test should also be included in the scheduled maintenance and inspection procedures. For the test below, refer to figures 6.6 and 6.7 belo

• 17 Rev 2.1 3. The opening must have a minimum free area of 1 sq. in. per 3,000 BTUH of the total input rating of all equipment in the room, or no less than the sum of the areas of all vent connectors in the confined space. (For additional information, referred to the latest NFGC) Warning: Do not use the “one permanent opening” method if the equipment room is under negat

• AJAX A050-A300, 62 Rev 2.1 Table 4.18 – Lead Lag Slave Configuration Parameters 4-32 Lead Lag Master Configuration Parameters Table 4.19 displays Lead Lag Master configuration parameters. Refer to 5-14 LEAD LAG MASTER CONFIGURATION for Lead Lag Master parameter programming. Parameter Comment Password Master enabled Disabled: The master function is disabled. Enabled: Enable the lead lag master. Installer LL CH setpoint This parameter provides the setpoint used during LL CH demand. Installer LL CH TOD setpoint This setpoint is used when the time-of-day switch is on

• AJAX A050-A300, 106 Rev 2.1 209 Invalid Pilot type setting L 210 Invalid Postpurge time setting L 211 Invalid Power up with lockout setting L 212 Invalid Pre-ignition time setting L 213 Invalid Prepurge rate setting L 214 Invalid Prepurge time setting L 215 Invalid Purge rate proving setting L 216 Invalid Run flame failure response Setting L 217 Invalid Run stabilization time setting L 218 Invalid Stack limit enable setting L 219 Invalid Stack limit response setting L 220 Unconfigured Delta T limit setpoint setting L 221 Unconfigured DHW high limit setpoint setting

• AJAX A050-A300, 103 Rev 2.1 2. Check the Module power supply and make sure that frequency, voltage and VA meet the specifications. 50 Modulation fault Internal sub-system fault. 1. Review alert messages for possible trends. 2. Correct possible problems. H 51 Pump fault H 52 Motor tachometer fault H 53 AC inputs phase reversed 1. Check the Module and display connections. 2. Check the Module power supply and make sure that both frequency and voltage meet the specifications. L 58 Internal fault: HFS shorted to IAS Internal Fault. 1. Reset Module. 2. If fault repeats, consult

• AJAX A050-A300, 51 Rev 2.1 The settings of all parameters in each safety block must be confirmed to commit them in the Honeywell Sola Controller. When the user is done changing safety parameters, pressing the Confirm button begins the confirmation stage. The settings for all safety parameters in each changed block are presented and confirmed by the user as in Figure 4.13. Figure 4.13 – Safety Parameter Confirmation Page Press the Yes button to confirm each safety parameter block. If the user selects the No button, the safety parameter block remains unconfirmed and the Configuration Page is displayed. The boiler remains in an un-configured state in this

• 109 Rev 2.1 164 DHW sensor type was invalid 165 Inlet sensor type was invalid for DHW 166 Outlet sensor type was invalid for DHW 171 DHW control was suspended due to fault 172 DHW temperature was invalid 173 DHW inlet temperature was invalid 174 DHW outlet temperature was invalid 183 Lead Lag P-gain was invalid 184 Lead Lag I-gain was

• AJAX A050-A300, 105 Rev 2.1 2. If fault repeats, consult factory 152 Combustion pressure ON 1. Check wiring and correct any errors. 2. Inspect the Combustion Pressure Switch to make sure it is working correctly. 3. Reset and sequence the relay module. 4. During STANDBY and PREPURGE, measure the voltage between J6 terminal 5 and L2 (N). Supply voltage should be present. If not, the lockout switch is defective and needs replacing. 5. If the fault persists, replace the relay module. 153 Combustion Pressure Off 154 Purge Fan switch On 1. Purge fan switch is on when it should be off. 2. 3. Inspect the Purge

• AJAX A050-A300, 46 Rev 2.1 4-4 System Operator Interface Panel Home Page For System Operator Interface multiple unit applications, each boilers is represented on the Home page by an icon and name. Pressing the icon allows the user to zoom in on that boiler and see specific details about it. These details are provided on a new page, which can include additional buttons that display additional detail and operation information, which itself leads to other pages. The System Operator Interface Boiler Icon button will appear in one of four colors indicating the boiler status. • Blue: Normal operation • Red: Lockout condition • Gray: Standby mode (burner switch off)

• AJAX A050-A300, 77 Rev 2.1 • Select Disable to disable DHW loop high limit This parameter enables or disables the DHW high limit function. It must be disabled when the DHW input is used as a switch to indicate DHW demand. 5-6.2 To Change DHW High Limit Setpoint Configure → High Limits → DHW High Limit Setpoint Textbox (Default: 200⁰F) • Type in desired temperature between 32⁰F and 240⁰F (0⁰C and 115⁰C) If the DHW temperature reaches the value given by this parameter then a response will occur. 5-6.3 To Ch

• AJAX A050-A300, 39 Rev 2.1 Symbol Value Description Outlet Outlet Temperature or Outlet Setpoint Display current outlet temperature and display and modify current Outlet (CH) setpoint temperature Inlet Inlet Temperature Display current inlet temperature ∆ T Delta Temperature Display delta T temperature [outlet] - [inlet] DHW DHW Temperature or DHW Setpoint Display current DHW temperature and Display and modify current DHW setpoint temperature (if equipped) Stack Stack Temperature Display current stack temperature (if equipped) Outdoor Outdoor Temperature Display current outdoor temper

• 42 Rev 2.1 Symbol Value Description ųA Flame Signal Display current flame signal strength value in VDC. Alert Alert Display last Alert code number (See Appendix A for description). Lockout Lockout Display last Lockout code number (See Appendix B for description). Outlet Outlet Temp High Limit Display current outlet temperature high limit setting. Stack Sta

• 65 Rev 2.1 Figure 4.40 – Honeywell Sola Controller Detail Status Page Status information on the Detail Status Page is organized into groups and displayed on the page one group at a time. The user moves from one group to another using the Left and Right arrow buttons. Status data on the Detail Status Page is displayed in a menu for the group that is

• AJAX A050-A300, 83 Rev 2.1 Differential above setpoint when last LL stage boiler is turned off. 5-15.3 To Change Lead Lag On Hysteresis Configure → Lead Lag Master Configuration → Advanced Setting → Modulation → On Hysteresis Textbox (Default: 10⁰F) • Type in desired LL on hysteresis Differential below setpoint when first LL stage boiler is turned on. 5-15.4 To Change Lead Lag Hysteresis Step Time Configure → Lead Lag Master Configuration → Advanced Setting → Modulation → Hysteresis Step Time Textbox (Default: 0m0s) • Type in desired LL hysteresis step time 5-15.5 To Change Lead Lag P-I-D Parameters Configure → Lead Lag Master Configuration

• AJAX A050-A300, 91 Rev 2.1 6-4.2 Pilot Turndown Test - (Optional at Installation, Required Annually After) To test that the main burner can be lit by the smallest pilot flame the can be seen by the flame amplifier and energize the FLAME LED. Clean the flame detector to make sure that it detects the smallest acceptable pilot flame. This test should be performed annually. 1) Open the Master switch 2) Close the manual main fuel shut off valves. 3) Connect a manometer, or pressure gauge, to measure pilot gas pressure during the turndown test. 4) Open the manual pilot shutoff valves. 5) Close the master switch a. Go to Pilot Test Mode, i. If using the standard panel, refer to section

• 45 Rev 2.1 4 Enhanced/System Operator Interface Panel Operating Procedures 4-1 Introduction The information in this Chapter provides a guide to the operation of the boiler using the Enhanced Panel or System Operator Interface Panel. It is imperative that the initial startup of this unit be performed by factory trained personnel. Operation prior to initi

• AJAX A050-A300, 9 Rev 2.1 Caution: This boiler requires forced water circulation when burner is operating. See minimum and maximum flow rates. Severe damage will occur if the boiler is operated without proper water flow circulation. A flow switch is used to ensure that water flows through the boiler, but does not check for the minimum flow rate into the boiler. Numbers are approximate and may vary depending on installation. See Chart below. Model Inlet Temp Outlet Temp Recommended Flow rate Pressure Drop (ft) for Rec Flow Min Flow rate (gpm) Max Flow

• Atlas Copper-Fin Coil High Efficiency Condensing Boiler Models A050-A300 Operating and Maintenance Manual Designed and Manufactured in Accordance with ASME Code Section IV U.L. 795 CSA 3.1 c E.T.L. Canadian Listed E.T.L. Listed ASME ASME AJAX BOILER INC. Photo shown may vary from actu

• AJAX A050-A300, 111 Rev 2.1 360 Abnormal Recycle: Check Parameters Failed 361 Internal error: No factory parameters were detected in control 362 Internal error: PID iteration frequency was invalid 363 Internal error: Demand-Rate interval time was invalid 364 Internal error: Factory calibration parameter for modulation was invalid 365 Internal error: CH PID P-scaler was invalid 366 Internal error: CH PID I-scaler was invalid 367 Internal error: CH PID D-scaler was invalid 368 Internal error: DHW PID P-scaler was invalid 369 Internal error: DHW PID I-scaler was invalid 370 Internal err

• AJAX A050-A300, 18 Rev 2.1 Note: Your Atlas Series Condensing Boiler requires Category IV venting. (See NFGC, NFPA 54, Section 7 “Venting Equipment” for more detailed information). The Atlas is designed to operate with a chamber pressure of 0 to +0.5" w.c. The Atlas Condensing boiler is capable of 100 feet of vertical equivalent exhaust when equipped with the standard exhaust vent. When more than 100 feet of exhaust venting is used, the chamber pressure could increase beyond the maximum designed +0.5”w.c. An optional enlarged vent maybe be used to increase vent runs in case more than the 100ft maximum is needed, however venting must be designed by a profession

• AJAX A050-A300, 101 Rev 2.1 7-2 Maintenance Schedule Atlas Model A Condensing Boiler Yearly Maintenance Schedule Daily Notes Observe Op Temp Observe Noise Check for Water Leak Check Lockout Codes Monthly Check 1 2 3 4 5 6 7 8 9 10 11 12 Test Operating Control Pilot/Main Flame Sig Air Filter

• AJAX A050-A300, 53 Rev 2.1 Figure 4.17 – Honeywell Sola Controller Alert Log 4-13 Operation Page The Operation Page displays the boiler running operation, including setpoint and firing rate. From this page the user can change setpoints, view annunciation information, and switch between Central Heating or Domestic Hot Water loops, as shown in Figure 4.20. If a password is required to change any of the settings on this page, the user can press the Login button to enter the password. Figure 4.20 – Honey

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