Contractor Presentation

1. Contractor Presentation

2. Receiving

3. Rigging When rigging the unit always lift from the lifting lugs provided. Also a spreader bar must ALWAYS be used.

4. Installation

5. Remember PV Xcelon Gas Electricity Ductwork Water PV Xcelon Yes Yes Yes Yes Yes Yes NoNo

6. Installation • Unit must be installed per IOM. • Unit must be installed level to ensure proper condensate draining. • Unit must be installed per local and federal code.

7. Service Clearances

8. Vent Clearance Requirements – Multiple Units

9. Venting • Venting must be a minimum of 1.5 ft above the snow line. • If snow or other foreign matter clog the exhaust, there is a serious danger of Carbon Monoxide Poisoning. Make sure that all exhaust vents are clear and will not become clogged during the course of the year. • Venting must be piped in accordance with the latest edition of Part 7, “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1 (NFPA No. 54)

10. Gas Piping • If the supply gas is above ½ psig (14”w.c.) a high pressure regulator must be installed upstream of the unit. • A drip pocket and shutoff valve must be installed upstream of the unit. • All piping should be in accordance with the National Fuel Gas Code ANSI Z21.13. and local codes. • Gas lines must be supported. NOTICE: All field installed gas piping must be installed per local codes.

11. Expansion Tank Installation • The expansion tank is sized so that pressure in the glycol loop will remain above 18 PSI regardless of the water temperature. The expansion tank ships loose for field installation to prevent damage to the glycol loop in transit.

12. Condensate • Integral condensate trap designed to drain in the event of a power failure. • Condensate neutralizer as a factory installed optional accessory. • Optional dedicated heat trace power supply for long condensate runs.

13. Electrical & Control Connections • All electrical connections must conform to the latest edition of ANSI/NFPA No. 70 National Electrical Code and applicable local codes. In Canada, to the Canadian Electrical Code, Part I CSA Standard C22.1 Main Supply Power Connection Thermostat Connection

14. Controls Sequence of Operation • When space temperature falls below set point, the space thermostat will call for heat. • The outside air damper will go to the full open position. • The first burner will begin its ignition sequence: • Boiler will enter pre-purge mode and combustion blower will engage. • After 10 seconds, the HRT Controller will reduce the combustion blower speed to the ignition rate and energize the ignition control. • The burner will then use a 4 second trial for ignition time. If the burner fails to light after 1 attempt, it will lock out requiring manual reset. • After the burner ignites, the HRT Controller will adjust the gas flow to meet the demand load. • If the lead burner reaches 50% fire rate and does not satisfy the demand load, the unit will begin the ignition sequence for the second burner once the “add burner” time delay has expired.

15. Controls Sequence of Operation • Once the water reaches the temperature called for by the HRT Control and the damper switch has proved, the VFD will begin to slowly ramp up until it reaches the static pressure set point or 100% CFM. • The HRT Control shall vary the water temperature set point in order to maintain a constant discharge air temperature set point. • Once the space thermostat is satisfied, the following will occur: • Boiler burners will disengage. • Supply air blower will run for 1 minute before shutting down. • Damper will close 1 minute after supply air blower has shutdown. • The combustion blower will continue to run for 10 seconds in post-purge mode. • Upon completion of post-purge mode, the unit will enter Standby mode.

16. Controls - Boiler • The PID loop looks at the Propylene Glycol mix temperature, the discharge air temperature and rate of change. • HRT Controls are configured to run the first burner to 50% fire then turn on the second burner. • True run time monitoring.

17. Controls - Safeties • Boiler – High Limit, Low Water Cutoff, Ignition Control Fault and Software Operator Limit • Air Side – VFD Temperature Status and Damper Prove

18. Start-Up

19. But I don’t know how to start a boiler… PV Xcelon Damper Blower VFD Gas Valve Burner Heat Exchanger Burner Pump Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes NoYes

20. Pre-start up - Unit inspection • Remove any debris or tools from inside the unit. • Verify disconnect switch on unit is in the “off” position. • Verify gas piping and ductwork are installed in accordance with manufacturer’s instructions.

21. Warning • If at any time you small gas, Stop! Do not try to light any appliance.

22. Start-up • Prior to starting the unit, measure supply voltage. • Open Expansion Tank Valve • Pressure – Check Glycol Loop Pressure • Pressure should be between 18-25 PSI

23. Start-up • Place disconnect switch in the “ON” position. • Verify Pump switch is in the “ON” position. • Verify both pumps are running. • Visually inspect Hydronic piping, checking joints and fittings throughout the system for leaks.

24. Start-up • Place jumper over heat demand. • Visually confirm that damper fully opens. • Visually check blower for proper rotation

25. Start-up – Calibration Mode • While on the SETUP SCREEN, hold the “BACK” key for 3 seconds. • This will allow you to access the hidden calibration menu. • Change CALIBRATE to “YES”.

26. Start-up • With both burners running, confirm supply gas pressure is between 3.5” W.C. and 13.5” W.C. • Jumper the high fire terminal. Leave jumper here to keep fan running

27. Start-up • Insert the probe of the Combustion Analyzer into the Combustion Test Port. • At high fire: • the CO2 should be between 8.5-9.5%. • The CO should be below 150 PPM.

28. High Fire Adjustment • Using an Allen key, turn the high fire adjustment screw clockwise to decrease the gas pressure and counter clockwise to increase pressure. High Fire Adjustment

29. Start-up • Jumper the low fire terminal. • Remove jumper from the high fire terminal. Leave jumper here to keep fan running • At low fire: • the CO2 should be between 8.0-8.5%. • The CO should be below 150 PPM.

30. Low Fire Adjustment • Using an Allen key, turn the low fire adjustment screw clockwise to increase the gas pressure and counter clockwise to decrease pressure. (Note: This is the opposite of High Fire) • Repeat the process for the second burner. Low Fire Adjustment

31. HRT - Controller

32. HRT – Setup Menu

33. Control Options • For Priority Mode, the user has two choices: • CFM -> When this is selected the unit will maintain the CFM set points regardless of the discharge air temperature. • TEMP -> When this is selected the unit will maintain a constant discharge air temperature. If required, it will reduce the CFM to achieve the set point.

34. Control Options • For VFD Mode, the user has two choices: • CFM -> The unit will maintain a constant CFM. • Pressure -> When this is selected, the unit will maintain a constant discharge air pressure by varying the CFM accordingly.

35. Maintenance

36. Maintenance • Filters should be checked monthly and should be changed when the pressure drop is 3 times the initial pressure drop. • Safety Shutoff Valves should be checked annually for leaks. • Condensate Neutralizer should be tested every 3 months for the first year to determine the required recharge schedule. It should be recharged when the pH falls below 6. Don’t forget about the filter located behind the air inlet for the boiler compartment

37. Maintenance – Before Heating Season • Inspect Air Intake and Exhaust Ventilation for any sign of blockage. • Check Glycol Loop for leaks. • Perform a combustion test on the unit to ensure high and low fire manifold pressures are correct. • Inspect burner for deterioration.

38. Maintenance – Before Heating Season • Ignition Test – With manual shutoff supply gas valve in the off position, place a jumper over the heat demand and high fire terminals. • Combustion blower should engage and begin 10 second pre-purge. • Burner should try to ignite for 4 seconds. • After ignition failure, blower should continue to run for 10 seconds in post-purge.

39. Maintenance – Before Heating Season Glycol Loop • Check the pH and Alkalinity of the Glycol Loop and if the pH is below 7 pH or the Alkalinity is below 9.0, then the Propylene Glycol needs to be replace.

40. Maintenance – Before Heating Season Glycol Loop To replace the Glycol, connect a hose to the bottom of drain valve. • Open the drain and purge valve to allow the system to fully drain. Purge Valve Drain Valve

41. Maintenance – Before Heating Season Glycol Loop • Close the drain valve and disconnect corresponding hose. • Close the expansion tank valve. • Open the fill valve. • Fill loop with 35% propylene glycol mixture using a transfer pump until the mixture comes out the purge valve. Fill Valve • Leaving the unit pumps on will assist with charging the system.

42. Maintenance – Before Heating Season Glycol Loop • Close the purge valve and continue charging until pressure gauge reads between 18-25 psi. • Close fill valve. • Disconnect Transfer Pump. • Open Expansion Tank Valve. • Check the pressure of the expansion tank using the bottom port. Expansion tank should be charged to 25 psi.

43. Maintenance – Annually Cleaning Boiler – Step 1 • Accessing the heat exchanger • Turn off main supply voltage disconnect and manual gas shutoff valve. • Disconnect condensate piping from drain connection so flow can be observed. • Disconnect flare nut on gas valve inlet and gas valve electrical connector. • Remove (6) nuts from burner plate assembly. • Disconnect wire leads to direct spark igniter and flame sensor. • Disconnect (2) Molex plugs from blower motor. • Remove air intake assembly. • Pull entire burner plate towards you.

44. Maintenance – Annually Cleaning Boiler – Step 2 • Using a spray bottle filled with Rydlyme or CLR, spray the coils liberally to make sure the solution penetrates and funnels down through the condensate hose. • Let chemical sit for at least 15 minutes or until it drains (whichever is longer).

45. Maintenance – Annually Cleaning Boiler – Step 3-4 • Using a nylon brush, scrub coils to remove any build-up. • Vacuum the debris from the coil after the brush loosens it. • Spray coils with clear water to remove any remaining chemicals.Flush the combustion chamber with fresh water. • Be careful to avoid wetting the back ceramic wall of the heat exchanger.

46. Maintenance – Annually Cleaning Boiler – Step 5 • Re-install the burner plate assembly. • Visually inspect heat exchanger prior to assembly for any remaining debris. • Install the burner plate assembly and replace (6) nuts. • Reconnect wire leads to direct spark igniter, flame sensor and gas valve. Reconnect (2) Molex plugs to blower motor. • Connect the flare nut on the gas valve inlet and reattach the gas valve electrical connectors. • Turn on main supply voltage disconnect switch and manual gas shutoff valve. • Initiate call for heat and observe the condensate flow. • Note when firing the first few times, you may experience some fluttering of the gas burner that may result in a flame lockout. This is normal and will require you to manually reset the unit until this clears up. This is caused by water still present in the combustion chamber. • Reconnect condensate piping to the drain connection. • Inspect air intake and exhaust vent for corrosion or obstruction.

47. TroubleShooting

48. HRT – Log Display Page 1 of Log Page 4 of Log Export HRT Log

49. Troubleshooting • Discharge Air Temperature too low • Incorrect Gas Input • Make sure the supply gas pressure is above 3.5” w.c. and below 13.5” w.c. • Ensure high and low fire rates are properly set (see start-up section). • Undersized Heater - If the heat load is greater than BTU output, the unit will not be able maintain the discharge temperature. • It is recommended that an additional heater be added to handle the additional load. • Another option would be to change the VFD priority to “TEMP”. This will reduce the CFM to maintain the discharge air temperature. NOTE: this will only increase the discharge air temperature. It will not increase the total BTUs delivered to the space, so the space may still feel cold. This should only be used when the unit is feeding air to a machine or process where the discharge air temperature is more important than the volume of air. • Discharge air temperature sensor malfunction. • Incorrect flow to the hot water coil/cycling on high limit. • Confirm system pressure is within proper operating range and pumps are running. • Incorrect glycol percentage • If the Propylene Glycol percentage is to high, the BTU output of the unit will be reduced.

50. Troubleshooting • Blower does not operate • Incorrect supply voltage • Control board failure • Unit not calling for blower to run or unit is locked out on alarm • Blower wheel is stuck • Motor failure • VFD malfunction/incorrect set up • CFM Low • Blower operating backwards • Damper not opening properly • VFD malfunction/incorrect set up • Clogged filters • External static pressure different than specified • Ductwork is undersized • Obstruction in the ductwork