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INSTALLATION AND OPERATING
INSTRUCTIONS
COLD WATER START & COLD WATER RUN
For Hi Delta & MVB
Heaters & Boilers
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place
for future reference.
Catalog No: 1000.57A Effective: 02-28-07 Replaces: 02-24-06 P/N 241275 Rev. 2
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2
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GENERAL SAFETY To meet commercial hot water use needs, the high limit safety control on this water heater is adjustable up to 210°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. When supplying general purpose hot water, the rec- ommended initial setting for the temperature control is 125°F. Safety and energy conservation are factors to be con- sidered when setting the water temperature on the Water temperature over 125°F can thermostat. The most ene
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COLD WATER START Before arriving at the job site to begin the installation, it's important to first inspect the system and determine what materials you will need. Some parts are includ- ed with the controller while others you will need to provide. 1 Control Box 1 Temperature Sensor 1 Valve assembly with actuator (Shipped separately) Wiring and mounting hardware (Provided by installer) INSTALLATION Check the Power Source Fig. 2: Multi-meter CAUTION: Do not use for swimming pool applica- tions
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NOTE: If a “DIP” switch is provided on the control PCB, verify that the switch settings are correct: 1 = OFF, 2 = ON, 3 = OFF. OPERATION Verify the following upon a CALL FOR HEAT signal from the heater: 1. CALL FOR HEAT LED on PCB illuminates GREEN. 2. START UP MODE LED on PCB illuminates YEL- LOW. Before 7 minutes it should go out if boiler inlet temperature is approaching the set point tem- perature. Models X CALL FOR HEAT START UP MODE 302B-902B 7.0″ INLET TEMP ERROR 992B-2342B 13.20″ SEN
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16) Once the NO contacts of the DPST close, the NOTE: The minimum return water temperature to heater 24 VAC is sent back to the heater to com- the heater to prevent condensate is 105°F on stan- plete the Economaster circuit (pin 3 of terminal dard heaters and 120°F on 87% Efficiency heaters. block 3) and the interlock circuit (pin 1 of terminal Ensure that during operation the Set Point Pot is block 3) allowing the heater to fire. adjusted properly. 17) Pin FR on the TVC board outputs 10VDC to t
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TROUBLESHOOTING Check your power source using a Volt-Ohm meter; check the following voltages at TB1 terminal block: TB1-1 to TB1-2 = 108 VAC Minimum, 132 VAC Maximum TB1-1 to TB1-3 = 108 VAC Minimum, 132 VAC Maximum TB1-2 to TB1-3 = Must be less than .6 VAC IF CALL FOR HEAT LED does not illuminate when the heater has a CFH signal, check for 24VAC at the heater CPW Board (J17-TRIG) output. If voltage is present, check wiring using the wiring diagram. If volt- age is not present, the problem exist
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Cold Water Start Troubleshooting Guide 8
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Wiring Diagram 9
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Installation Codes COLD WATER RUN Installations must be in accordance with local, state, Purpose provincial, and national codes, laws, regulations and ordinances. In the absence of local codes, installa- tions must be in accordance with the latest editions of The Cold Water Run system utilizes a variable-speed the: pump to inject the proper amount of water from the • National Fuel Gas Code, ANSI Z223.1/NFPA 54 main system loop into the boiler to maintain the opti- • National Electrical Code, AN
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Injection & Heater Pump Comparison — Hi Delta Heater Pump Injection Pump Heater Injection Flow Temp. Rise Press. Drop Flow Temp. Rise Heater Pump Model Pump 1 302 32 16 2 13 40 1911- ⁄4 hp 112 1 402 34 20 2 17 40 1911- ⁄4 hp 112 1 502 42 20 2.3 22 40 1911- ⁄4 hp 1630 4.0 1 652 55 20 4.1 28 40 1911- ⁄4 hp 1630 4.0 1 752 63 20 5.7 32 40 1911- ⁄4 hp 1630 4.2 1 902 76 20 8.4 38 40 1911- ⁄4 hp 1630 4.2 1 992 83 20 5.2 42 40 1911- ⁄4 hp 1630 4.7 1 1262 107 20 9.6 54 40 1911- ⁄3hp 1630 4.7 1 1532 120 2
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Injection Pump Cover Installation Before Starting 1) Turn off power to the unit at the circuit breaker. 2) Turn off gas supply. 3) Shut off the water supply to the heater and, if nec- essary, drain water from the system. 4) Allow heater to cool down before attempting work. In order to install the pump cover, you will need to rotate the pump body so that the electrical box is point- ing downward, as outlined in the following steps: 1. Loosen and remove the eight (8) 9/16” wrench bolts holding the
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Fig 17: Pump cover - angle view Fig 15: Reposition the pump body so that the electrical box points downward 3. Insert and tighten all eight (8) wrench bolts, secur- ing the pump body in place. 4. You will now be able to install the pump cover. See Fig. 18 and 19. Fig. 16: Place the cover on the pump 13
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Typical Boiler Piping (Hi Delta shown) 14
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the cold run control panel. START-UP PROCEDURE 8) After the two second delay on the cold run circuit board, pin MC outputs a 24 VAC signal to terminal AL0 of the Hitachi inverter. • Run full system flow for two minutes. 9) The AL0 relay closes and outputs a 24 VAC signal • Initiate PID pump control to achieve target inlet to the coil of the DPST relay located in the cold run temperature by slowing injector pump. control panel. • Boiler ΔT will not increase during bypass operation. 10) The DPST r
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Wiring Diagram 16
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Cold Water Run Troubleshooting Guide Does TB1 of cold run Verify 120VAC from controller have 120 NO TB1 on the heater VAC? Step 1 and correct Is there a Call For YES Heat at the heater? YES NO Heater is in standby mode Is the 220VAC inverter in the Correct Wiring Step 2 NO cold run controller powered? YES Does the cold run inverter output Replace inverter or install jumper Step 3 NO 12VDC from PCS to pin FS? and correct switch settings YES Is 24VAC present at Poolstat Check 24VA
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ILLUSTRATED PARTS LISTS Cold Water Start 18
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2-M 1-M 3-M 4-M CALL OUT DESCRIPTION HI DELTA MVB 1-C PC BOARD ASSY-CONTROL 011717F 011717F 2-C TRANSFORMER 011718F 011718F 3-C POWER SUPPLY 120VAC/12VDC 011719F 011719F 4-C RELAY-DPDT 24V 011720F 011720F 5-C RELAY-SPDT 24V 009039F 009039F 6-C GROUND LUG 007155F 007155F 7-C TEMP SENSOR 10K (NOT SHOWN) 010787F 010787F 8-C RESET SWITCH 005641F 005641F 1-M PUMP-WATER BR 2" FLANGE, 1/4 HP 007226F 007226F PUMP-WATER CI 2" FLANGE, 1/4 HP 007232F 007232F PUMP-WATER BR 2" FLANGE, 1/2 HP N/A 007347F PUMP
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Cold Water Run 20
