Pool Boiler - Revision history

Matt Parnell: /* Stage E: High Air Pressure and High Operator */

2022-01-04T20:45:26Z

Stage E: High Air Pressure and High Operator

← Older revision		Revision as of 20:45, 4 January 2022
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	# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.		# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.

	=== Stage E: ~~High Air Pressure and High Operator~~ ===		=== Stage E: Stage 2 Active ===

	Description pending.		Description pending.

Matt Parnell: /* Stage E */

2022-01-04T20:45:00Z

Stage E

← Older revision		Revision as of 20:45, 4 January 2022
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	# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.		# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.

	=== Stage E ===		=== Stage E: High Air Pressure and High Operator ===

	Description pending.		Description pending.

Matt Parnell at 20:40, 4 January 2022

2022-01-04T20:40:34Z

← Older revision		Revision as of 20:40, 4 January 2022
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	== Theory of Operation ==		== Theory of Operation ==

	~~=== Operation Sequence ===~~

	The operation sequence below is based upon the procedure described in the LCD Series manual, with adaptations per the installation wiring.		The operation sequence below is based upon the procedure described in the LCD Series manual, with adaptations per the installation wiring.

	==== Stage 0: Water Level OK ====		=== Stage 0: Water Level OK ===

	The low-water cut-out disconnects power from the 75 VA control transformer in the boiler. This prevents boiler operation when a low water situation is encountered.		The low-water cut-out disconnects power from the 75 VA control transformer in the boiler. This prevents boiler operation when a low water situation is encountered.

	==== Stage A: Demand for Heat ====		=== Stage A: Demand for Heat ===

	A demand for heat occurs when all of the following conditions are met:		A demand for heat occurs when all of the following conditions are met:
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	# The automation system relay CR2110 is energized, which activates [[Pool Systems Automation#Digital Inputs\|PLC input X10]].		# The automation system relay CR2110 is energized, which activates [[Pool Systems Automation#Digital Inputs\|PLC input X10]].

	==== Stage B: Temperature and Water Flow OK ====		=== Stage B: Temperature and Water Flow OK ===

	The temperature and water flow are deemed OK when:		The temperature and water flow are deemed OK when:
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	# The automation system relay CR2111 is energized, which activates [[Pool Systems Automation#Digital Inputs\|PLC input X11]].		# The automation system relay CR2111 is energized, which activates [[Pool Systems Automation#Digital Inputs\|PLC input X11]].

	==== Stage C: Low Air Pressure OK ====		=== Stage C: Low Air Pressure OK ===

	The low air pressure switch closes in response to sufficient positive pressure in the combustion chamber.		The low air pressure switch closes in response to sufficient positive pressure in the combustion chamber.
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	NOTE: Flame fail/lockout is not considered here. The present flame sense module (FSM), or "intermittent pilot ignition" module, does not include alarm contacts (UTEC 1003-638A). The specified module, a UTEC 1003-61A is unavailable on the market at this time. The alarm contacts are required to engage R1, the flame fail/lockout relay. This is problematic, as it would allow the ignition transformer to spark indefinitely, eventually resulting in component failure. As a work-around, the automation system provides a monitored lockout function via the <b>Boiler Disable</b> relay.		NOTE: Flame fail/lockout is not considered here. The present flame sense module (FSM), or "intermittent pilot ignition" module, does not include alarm contacts (UTEC 1003-638A). The specified module, a UTEC 1003-61A is unavailable on the market at this time. The alarm contacts are required to engage R1, the flame fail/lockout relay. This is problematic, as it would allow the ignition transformer to spark indefinitely, eventually resulting in component failure. As a work-around, the automation system provides a monitored lockout function via the <b>Boiler Disable</b> relay.

	==== Stage D: Main Gas Valve On ====		=== Stage D: Main Gas Valve On ===

	The main gas valve (also referred to as the "main valve" or MV) turns on (becomes active) when the flame sense module (FSM) confirms the presence of the pilot flame.		The main gas valve (also referred to as the "main valve" or MV) turns on (becomes active) when the flame sense module (FSM) confirms the presence of the pilot flame.
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	# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.		# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.

	==== Stage E ====		=== Stage E ===

	Description pending.		Description pending.

	=== Control Interlocks ===		== Summary of Control Interlocks ==

	The list below includes interlocks with electrical interfaces only and is intended to align with the CSD-1. This table is for reference only; the CSD-1 should always be considered the master.		The list below includes interlocks with electrical interfaces only and is intended to align with the CSD-1. This table is for reference only; the CSD-1 should always be considered the master.

Matt Parnell: /* Adjustments */

2022-01-04T20:38:51Z

Adjustments

← Older revision		Revision as of 20:38, 4 January 2022
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	== Adjustments ==		== Adjustments ==

			Details to follow.

	== Maintenance ==		== Maintenance ==

Matt Parnell: /* Operation */

2022-01-04T20:38:42Z

Operation

← Older revision		Revision as of 20:38, 4 January 2022
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	== Operation ==		== Operation ==

			Details to follow.

	== Adjustments ==		== Adjustments ==

Matt Parnell: /* Stage D: Main Gas Valve On */

2022-01-04T20:33:27Z

Stage D: Main Gas Valve On

← Older revision		Revision as of 20:33, 4 January 2022
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	# The MAIN GAS indicator on the boiler is illuminated.		# The MAIN GAS indicator on the boiler is illuminated.
	# The automation system relay CR2113 is energized, which activates [[Pool Systems Automation#Digital Inputs\|PLC input X13]].		# The automation system relay CR2113 is energized, which activates [[Pool Systems Automation#Digital Inputs\|PLC input X13]].
	# The relay in the [[Pool Temperature Controller\|pool temperature controller] is energized, which provides confirmation that a request for heat has been satisfied.		# The relay in the [[Pool Temperature Controller\|pool temperature controller]] is energized, which provides confirmation that a request for heat has been satisfied.
	# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.		# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.

Matt Parnell: /* Theory of Operation */

2022-01-04T20:33:14Z

Theory of Operation

← Older revision		Revision as of 20:33, 4 January 2022
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	NOTE: Flame fail/lockout is not considered here. The present flame sense module (FSM), or "intermittent pilot ignition" module, does not include alarm contacts (UTEC 1003-638A). The specified module, a UTEC 1003-61A is unavailable on the market at this time. The alarm contacts are required to engage R1, the flame fail/lockout relay. This is problematic, as it would allow the ignition transformer to spark indefinitely, eventually resulting in component failure. As a work-around, the automation system provides a monitored lockout function via the <b>Boiler Disable</b> relay.		NOTE: Flame fail/lockout is not considered here. The present flame sense module (FSM), or "intermittent pilot ignition" module, does not include alarm contacts (UTEC 1003-638A). The specified module, a UTEC 1003-61A is unavailable on the market at this time. The alarm contacts are required to engage R1, the flame fail/lockout relay. This is problematic, as it would allow the ignition transformer to spark indefinitely, eventually resulting in component failure. As a work-around, the automation system provides a monitored lockout function via the <b>Boiler Disable</b> relay.

	==== Stage D ====		==== Stage D: Main Gas Valve On ====

	~~Description pending~~.		The main gas valve (also referred to as the "main valve" or MV) turns on (becomes active) when the flame sense module (FSM) confirms the presence of the pilot flame.

			Once this has occurred:

			# Relay R8 is energized to disable the spark generator transformer.
			# The MAIN GAS indicator on the boiler is illuminated.
			# The automation system relay CR2113 is energized, which activates [[Pool Systems Automation#Digital Inputs\|PLC input X13]].
			# The relay in the [[Pool Temperature Controller\|pool temperature controller] is energized, which provides confirmation that a request for heat has been satisfied.
			# The boiler temperature controller [[Pool Boiler Temperature Controller#Main Valve Active\|main valve active]] input (relay) is energized.

	==== Stage E ====		==== Stage E ====

Matt Parnell at 18:43, 4 January 2022

2022-01-04T18:43:28Z

@@ Line 57: / Line 57: @@
 === High Temperature Fault ===
 == Theory of Operation ==
@@ Line 226: / Line 206: @@
 * Relay coil taps were added to add monitoring of operating conditions by an external PLC.  These connections are documented in the pool systems automation [[:File:FFSC-001_Pg_40_-_Boiler_Auxiliary.png|Boiler Auxiliary]] drawing.
 * Re-routing of some electrical in new liquid-tight conduit.

Matt Parnell: /* Low Temperature Fault */

2022-01-04T18:41:16Z

Low Temperature Fault

← Older revision		Revision as of 18:41, 4 January 2022
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	=== Low Temperature Fault ===		=== Low Temperature Fault ===

	A boiler controller [[~~Pool_Boiler_Temperature_Controller~~#~~Low_Temperature_Fault~~\|Low Temperature Fault]] is often caused by one of the following:		A boiler controller [[Pool Boiler Temperature Controller#Low Temperature Fault\|Low Temperature Fault]] is often caused by one of the following:

	* The recirculation valve is not in the optimal position and should be [[#Recirculation Valve\|adjusted]]. Reasons the valve may need adjustment include:		* The recirculation valve is not in the optimal position and should be [[#Recirculation Valve\|adjusted]]. Reasons the valve may need adjustment include:

Matt Parnell: /* Troubleshooting */

2022-01-04T18:40:29Z

Troubleshooting

← Older revision		Revision as of 18:40, 4 January 2022
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	First, always ensure that the breaker and GFCI are not tripped, and that the power switch on the side of the unit is turned on.		First, always ensure that the breaker and GFCI are not tripped, and that the power switch on the side of the unit is turned on.

	If the boiler does not fire in response to a call for heat, the issue is likely related to an interlock or the ignition system. Verify that the low water sensor is reset; it can be tripped by air infiltration ~~during filter back-washing~~. Ensure that the pump is operating. Verify that the covers are securely fastened; a loose cover leaks air and may not close the air pressure switches. Finally, check for the presence of spark and/or pilot light. This is visible via a small window on the lower-left of the unit.		If the boiler does not fire in response to a call for heat, the issue is likely related to an interlock or the ignition system. Verify that the low water sensor is reset; it can be tripped by air infiltration when the pump is stopped. Ensure that the pump is operating. Verify that the covers are securely fastened; a loose cover leaks air and may not close the air pressure switches. Finally, check for the presence of spark and/or pilot light. This is visible via a small window on the lower-left of the unit.

			The automation system may provide some additional insight regarding a boiler fault state via the [[Pool_Systems_Automation#Display_and_Keypad\|PLC Display]]. In the topics below, additional faults and possible remedies are explored.

	The flame sensor unit is a consumable item and may need to be replaced at a regular interval (every two years?). If the pilot valve (PV) is open, but the main valve (MV) never opens, it is likely that adequate flame is not being detected. This can be verified by measuring the microamp current output of the flame sensor and should be done by a qualified technician.

	=== Low Air Pressure ===		=== Low Air Pressure ===