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Gas Boiler Controls Wiring & Application Guide Featuring Burnham® Brand IQ Boiler Control and Intelligent Hydronic Control Systems boiler control ES2™ Intelligent Hydronic Control ESC™ Series 3™ Series 2™ ©2013 U.S. Boiler Company Gas Boiler Wiring & Application Guide U.S. Boiler Company 1 08/23/13 Table of Contents 1.0Introduction............................................................................................................................ 3 2.0 IQ Gas Boiler Control System........................................................................................................................................... 4 2.1 Single Zone Heating................................................................................................................................................ 5 2.2 Single Zone Heating, Power Stealing Thermostat.................................................................................................... 6 2.3 Single Zone Heating, IWH w/TPI Control................................................................................................................. 7 2.4 Single Zone Heating, IWH w/Aquastat Control........................................................................................................ 8 2.5 Two Zone Heating ................................................................................................................................................... 9 2.6 Zone Valves Heating.............................................................................................................................................. 10 2.7 Zone Valves Heating, IWH w/TPI Control, 2 Circulators........................................................................................ 11 2.8 Zone Valves Heating, IWH w/Aquastat Control, 2 Circulators................................................................................ 12 2.9 Zone Valves Heating, IWH w/TPI Control, 1 Circulators, No Priority..................................................................... 13 2.10 Zone Valves Heating, IWH w/Aquastat Control, 1 Circulators, No Priority............................................................. 14 2.11 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulator............................................................................... 15 2.12 Zone Valve Control Heating, IWH w/Aquastat Control, 2 Circulator....................................................................... 16 2.13 Zone Valve Control Heating, IWH w/TPI Control, 1 Circulator............................................................................... 17 2.14 Zone Valve Control Heating, IWH w/Aquastat Control, 1 Circulator....................................................................... 18 2.15 Zone Switching Relay Heating............................................................................................................................... 19 2.16 Zone Switching Relay Heating, IWH w/TPI Control............................................................................................... 20 2.17 Zone Switching Relay Heating, IWH w/Aquastat Control....................................................................................... 21 3.0 IQ Gas Boiler Control System, Outdoor Reset Card..................................................................................................22-24 3.1 Single Zone Heating.............................................................................................................................................. 25 3.2 Single Zone Heating, IWH w/TPI Control............................................................................................................... 26 3.3 Single Zone Heating, IWH w/Aquastat Control...................................................................................................... 27 3.4 Zone Valves Heating, IWH w/TPI Control, 2 Circulators........................................................................................ 28 3.5 Zone Valves Heating, IWH w/Aquastat Control, 2 Circulators................................................................................ 29 3.6 Zone Valves Heating, IWH w/TPI Control, 1 Circulators, No Priority..................................................................... 30 3.7 Zone Valves Heating, IWH w/Aquastat Control, 1 Circulators, No Priority............................................................. 31 3.8 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulator............................................................................... 32 3.9 Zone Valve Control Heating, IWH w/Aquastat Control, 2 Circulator....................................................................... 33 3.10 Zone Valve Control Heating, IWH w/TPI Control, 1 Circulator............................................................................... 34 3.11 Zone Valve Control Heating, IWH w/Aquastat Control, 1 Circulator ...................................................................... 35 3.12 Zone Switching Relay Heating, IWH w/TPI Control............................................................................................... 36 3.13 Zone Switching Relay Heating, IWH w/Aquastat Control....................................................................................... 37 4.0 Intelligent Hydronic Control (IHC) Series 2 & PVG Boilers Only 4.1 Single Zone Heating.............................................................................................................................................. 38 4.2 Single Zone Heating, Power Stealing Thermostat.................................................................................................. 38 4.3 Single Zone Heating, Indirect Water Heater (IWH) w/TPI Control.......................................................................... 39 4.4 Single Zone Heating, IWH w/Aquastat Control...................................................................................................... 40 4.5 Two Zones Heating................................................................................................................................................ 41 4.6 Zone Valves Heating.............................................................................................................................................. 42 4.7 Zone Valves Heating, IWH w/TPI Control, 2 Circulators........................................................................................ 43 4.8 Zone Valves Heating, IWH w/Aquastat Control, 2 Circulators................................................................................ 44 4.9 Zone Valves Heating, IWH w/TPI Control, 1 Circulators, No Priority..................................................................... 45 4.10 Zone Valves Heating, IWH w/Aquastat Control, 1 Circulators, No Priority............................................................. 46 4.11 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulator............................................................................... 47 4.12 Zone Valve Control Heating, IWH w/Aquastat Control, 2 Circulator....................................................................... 48 4.13 Zone Valve Control Heating, IWH w/TPI Control, 1 Circulator............................................................................... 49 4.14 Zone Valve Control Heating, IWH w/Aquastat Control, 1 Circulator....................................................................... 50 4.15 Zone Switching Relay Heating............................................................................................................................... 51 4.16 Zone Switching Relay Heating, IWH w/TPI Control............................................................................................... 52 4.17 Zone Switching Relay Heating, IWH w/Aquastat Control....................................................................................... 53 Gas Boiler Wiring & Application Guide U.S. Boiler Company 2 08/23/13 1.0 Introduction Intelligent Hydronic Control and IQ Control Systems included on various Burnham Brand boilers contain features and capabilities, which can improve heating system operation, reduce fuel costs, improve comfort, and efficiency. By including unique capabilities, Burnham brand boilers can do more, with less field wiring, and fewer aftermarket controls and components – improving the operation of both new and replacement boiler installations. These application drawings include detailed wiring diagrams, and set-up details, allowing installers to fully utilize the capability and versatility of the control systems. These applications can save installers time and money on just about any heating system – whether it’s a new installation, or replacing an older, less efficient boiler. Notice: While this manual contains wiring diagrams and set-up details, the Installation Operating and Service Instruction’s provided with each Burnham brand boiler must be followed. Notice: Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1 Electric Code. Using this Guide Line VoltageAbbreviations L1 – 120Vac Hot – Black L2 – 120Vac Neutral - White Ground - Green IHC Intelligent Hydronic Control OCP IQ Option Panel TPI Alliance IWH control IQ (Gas Boiler System) Combination of IHC and OCP on the boiler “T-T” Thermostat connection terminals Low Voltage Polarity Important Red 24 Vac Hot White (Grey) 24Vac Ground Polarity Not Important Blue wires Gas Boiler Wiring & Application Guide U.S. Boiler Company 3 08/23/13 2.0 IQ Gas Boiler Control System The Burnham ES2, ESC & Series 3 boilers feature Burnham’s IQ gas Boiler Control system, which greatly simplifies installation and set-up in both existing and new heating systems. The IQ Control system contains many unique features and capabilities that save the installer time and take the mystery out of controls by providing simple, clear information about settings, status, and diagnostics on an LED display on the boiler. The IQ gas Boiler Control System consists of the following components: Intelligent Hydronic Gas Boiler Control features an integrated boiler temperature sensor, and ignition control into one for seamless operation. The Intelligent Hydronic Control features an LED read-out, which displays operating information such as boiler status and boiler water temperature. The Intelligent Hydronic Control also displays diagnostic info such as run time hours, the number of heating cycles, flame signal strength, and error codes for improved diagnostics The IQ Option Panel is a separate control panel that accepts IQ Option Cards for added efficiency and safety. IQ Option Cards snap into any one of the three Slots in the Option Panel, and are instantly recognized when the IQ System is powered up. A separate LED display provides setting, status, & diagnostic info for each of the IQ Option Cards, greatly simplifying the set-up and operation of the control. IQ Option Cards are cost effective, they save time, and they are functionally superior to stand alone Limits, LWCO’s and Outdoor Reset controls. Not available with the Series 2 Boiler. IQ Option Cards are snap-in control modules which attach to the Option Panel, and contain various control upgrades, such as Auxiliary High Temperature Limit, Low Water Cut-Off protection, and Outdoor Air Reset. There’s an IQ Option Card for each feature. Option Cards simply plug into the Option Panel, and feature a one or two wire connection to a sensor. Not available with the Series 2 boiler. Intelligent Hydronic Control Adjustment Mode Options The Intelligent Hydronic Control’s (IHC) “Dh” parameter provides the ability to control the two separate heating demands or a heating demand and an Indirect Water Heater (IWH) demand without the use of additional controls. Gas Boiler Wiring & Application Guide U.S. Boiler Company Parameter Range Parameter Description Default HL dF Or PP St Pt dh F-C 140°F – 220°F High Limit Setting 180°F 10°F – 30°F High Limit Differential 15°F 0 – 20 Minutes Circulator Overrun Time 0 Minutes 2 –20 Minutes Circulator Pre-purge Time 2 Minutes 140°F –180°F Start Temperature 140°F On – Off Priority Time (DHW) On Dh or TT2 DH Terminal Function dh F or C Degrees F or C F 4 08/23/13 2.0 IQ Gas Boiler Control System 2.1 Single Zone Heating Boiler Junction Box Line Voltage Wiring Connections GND L2 Overcurrent Protection/ Disconnect Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator System Circulator 12 123 123TT Thermostat 1 Explanation: This arrangement can be used when an IQ gas boiler is connected to a single zone heating system. • A thermostat wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system wire. Gas Boiler Wiring & Application Guide U.S. Boiler Company 5 08/23/13 2.0 IQ Gas Boiler Control System 2.2 Single Heat Zone, Power Stealing Thermostat Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator System Circulator 12 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left T is 24V AC positive 123 123TT Thermostat 1 Explanation: This arrangement can be used with a single zone heating system with a power stealing thermostat • A thermostat wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. Gas Boiler Wiring & Application Guide U.S. Boiler Company 6 08/23/13 2.0 IQ Gas Boiler Control System 2.3 Single Heat Zone Heating, IWH w/TPI Control Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect 120V AC Power Supply Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator System Circulator DHW/Zone Circulator 12 Alliance SL Indirect Water Heater TPI Control 123 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground pump/TT 24V 123TT Thermostat 1 Explanation: This arrangement can be used with a single heat zone and DHW demand from the TPI control. • A thermostat wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The TPI control wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parmater “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without at time out period. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI controls. Gas Boiler Wiring & Application Guide U.S. Boiler Company 7 08/23/13 2.0 IQ Gas Boiler Control System 2.4 Single Heat Zone Heating, IWH w/Aquastat Control Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW Circulator System Circulator DHW/Zone Circulator 12 123 IWH Aquastat Controls 123TT Thermostat 1 Explanation: This arrangement can be used with a single heat zone and DHW demand from an Aquastat. • A thermostat wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The TPI control wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parmater “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without at time out period. Gas Boiler Wiring & Application Guide U.S. Boiler Company 8 08/23/13 2.0 IQ Gas Boiler Control System 2.5 Two Zone Heating Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow Zone 1 Circulator Red Zone 2 Circulator System Circulator DHW/Zone Circulator 12 123 Thermostat 2 123TT Thermostat 1 Explanation: This arrangement allows the boiler to respond to two heating demands through the IHC control and operate both circulators without priority. • A Zone-1 thermostat wired to the OCP “TT” Terminals provides a Zone-1 heating demand and energizes the yellow system circulator wire. A Zone-2 thermostat wired to the IHC “1” and “2” terminals provides a Zone-2 demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “tt2” and the “Pt” Priority Time parameter is ignored so both circulators can run simultaneously. Gas Boiler Wiring & Application Guide U.S. Boiler Company 9 08/23/13 2.0 IQ Gas Boiler Control System 2.6 Zone Valve Heating Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator 40VA Transformer Field Installed L1 Thermostat 1 120V AC Power Supply Thermostat 2 System Circulator DHW/Zone Circulator 12 123 Thermostat 3 24V AC Positive Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive L2 Power Supply 120/60/1 123TT NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves. • The zone valve end switches wired to the OCP “TT” Terminals, provide a heating demand, and energize the yellow system circulator wire. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP. Gas Boiler Wiring & Application Guide U.S. Boiler Company 10 08/23/13 2.0 IQ Gas Boiler Control System 2.7 Zone Valve Heating, IWH w/TPI Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator L1 Thermostat 1 Thermostat 2 System Circulator DHW/Zone Circulator 12 pump/TT 40VA Transformer Field Installed 120V AC Power Supply 24V Alliance SL Indirect Water Heater TPI Control 123 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Thermostat 3 24V AC Positive Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive L2 Power Supply 120/60/1 123TT NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from a TPI control. • The zone valve end switches wired to the OCP “TT” Terminals, provide a heating demand, and energize the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provide a DHW demand and energize the red DHW/ Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on” it will prioritize the IWH without a time out period • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 11 08/23/13 2.0 IQ Gas Boiler Control System 2.8 Zone Valve Heating, IWH w/Aquastat Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW Circulator System Circulator DHW/Zone Circulator 12 123 IWH Aquastat Control 40VA Transformer Field Installed L1 Thermostat 1 Thermostat 2 Thermostat 3 24V AC Positive Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive L2 Power Supply 120/60/1 123TT NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from an Aquastat control. • The zone valve end switches wired to the OCP “TT” Terminals, provide a heating demand, and energize the yellow system circulator wire. The IWH Aquastat Control wired to the IHC “1” & “2” terminals provide a DHW demand and energize the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on” it will prioritize the IWH without a time out period • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP. Gas Boiler Wiring & Application Guide U.S. Boiler Company 12 08/23/13 2.0 IQ Gas Boiler Control System 2.9 Zone Valve Heating, IWH w/TPI Control, 1 Circulator, No Priority Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 System Circulator 120V AC Power Supply Yellow System Circulator Red With this application, there will not be DHW priority System Circulator DHW/Zone Circulator 12 Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the domestic water side of the indirect water heater Alliance SL Indirect Water Heater TPI Control Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground pump/TT 40VA Transformer Field Installed L1 Thermostat 1 Thermostat 2 123 24V 24V AC Positive L2 Power Supply 120/60/1 123TT NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive Explanation: This arrangement allows the use of zone valves for heat and hot water using a single circulator without DHW priority. • The heating zone valve end switches wired to the OCP “TT” Terminals, provide a heating demand, and energize the yellow system circulator wire. The TPI Control connected zone valve end switch wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. There is no priority in this application due to using only one circulator • Wiring the DHW zone valve end switch to the IHC will avoid the boiler temperature delayed start used on heat demand • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 13 08/23/13 2.0 IQ Gas Boiler Control System 2.10 Zone Valve Heating, IWH w/TPI Control, 1 Circulator, No Priority Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) 120V AC Power Supply Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW/Zone Circulator System Circulator With this application, there will not be DHW priority 12 Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the domestic water side of the indirect water heater 40VA Transformer Field Installed L1 Thermostat 1 123 IWH Aquastat Control Thermostat 2 24V AC Positive L2 Power Supply 120/60/1 123TT NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive Explanation: This arrangement allows the use of zone valves for heat and hot water using a single circulator without DHW priority. • The heating zone valve end switches wired to the OCP “TT” Terminals, provide a heating demand, and energizes the yellow system circulator wire. The IWH Aquastat Control connected zone valve end switch wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. There is no priority in this application due to using only one circulator. • Wiring the DHW zone valve end switch to the IHC will avoid the boiler temperature delayed start used on heat demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and IHC. Gas Boiler Wiring & Application Guide U.S. Boiler Company 14 08/23/13 2.0 IQ Gas Boiler Control System 2.11 Zone Valve Heating, IWH w/TPI Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator POWER IN X X ISOLATED END SWITCH R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) R W C ZONE 3 PRIORITY ZVC 403-4 Alliance SL Indirect Water Heater TPI Control PUMP END SWITCH X X ZONE 3 PUMP END SWITCH N/O COM N/C 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 ZONE 3 PRIORITY ON OFF DHW/Zone Circulator 123 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground pump/TT 24V LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL System Circulator 12 Thermostat 1 Thermostat 2 Thermostat 3 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 123TT PRIORITY ZONE 3 1 2 3 4 Explanation: This application uses a zone valve control for heating demands and the DHW demand using at TPI control • The zone control end switch wired to the OCP “TT” Terminals, provide a heating demand, and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/ Zone circulator wire. • The IHC parameter “dh” must be set to “dh”, and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI Control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 15 08/23/13 2.0 IQ Gas Boiler Control System 2.12 Zone Valve Control Heating, IWH w/Aquastat Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator POWER IN X X ISOLATED END SWITCH R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) R W C ZONE 3 PRIORITY ZVC 403-4 PUMP END SWITCH X X ZONE 3 PUMP END SWITCH N/O COM N/C 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 DHW/Zone Circulator 123 IWH Aquastat Control ZONE 3 PRIORITY ON OFF LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL System Circulator 12 Thermostat 1 Thermostat 2 Thermostat 3 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 123TT PRIORITY ZONE 3 1 2 3 4 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive Explanation: This application uses a zone valve control for heating demands and the DHW demand using an Aquastat control • The zone control end switch wired to the OCP “TT” Terminals, provide a heating demand, and energizes the yellow system circulator wire. The IWH Aquastat Control wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”, and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP. Gas Boiler Wiring & Application Guide U.S. Boiler Company 16 08/23/13 2.0 IQ Gas Boiler Control System 2.13 Zone Valve Control Heating, IWH w/TPI Control, 1 Circulator Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the Domestic water side of the Indirect Water Heater 12 POWER IN R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) R W C ZONE 3 PRIORITY ZVC 403-4 ZONE 3 PUMP END SWITCH N/O COM N/C 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 24V ZONE 3 PRIORITY ON OFF LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL PUMP END SWITCH X X 123 Alliance SL Indirect Water Heater TPI Control pump/TT X X ISOLATED END SWITCH System Circulator DHW/Zone Circulator Thermostat 1 Thermostat 2 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 123TT PRIORITY ZONE 3 1 2 3 4 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive Explanation: This application uses a zone valve control for heating demands and the DHW demand wired directly to the IHC control utilizing one circulator. Priority is controlled by the zone valve relay control. • The zone control end switch wired to the OCP “TT” Terminals, provide a heating demand, and energizes the yellow system circulator wire. The Zone 3 Pump end switch wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. There is no circulator priority in this application due to using only one circulator. • Wiring the zone valve control “zone pump 3 end switch” to DHW terminals will avoid the boiler temperature delayed start used on heat demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the TPI Control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 17 08/23/13 2.0 IQ Gas Boiler Control System 2.14 Zone Valve Control Heating, IWH w/Aquastat Control, 1 Circulator Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 System Circulator Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the Domestic water side of the Indirect Water Heater POWER IN X X ISOLATED END SWITCH R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) Yellow 12 R W C ZONE 3 PRIORITY 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 ZONE 3 PRIORITY ON OFF LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL ZONE 3 PUMP END SWITCH N/O COM N/C 123 IWH Aquastat Control ZVC 403-4 PUMP END SWITCH X X System Circulator DHW/Zone Circulator Thermostat 1 Thermostat 2 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 123TT PRIORITY ZONE 3 1 2 3 4 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive Explanation: This application uses a zone valve control for heating demands and the DHW demand wired directly to the IHC control utilizing one circulator. Priority is controlled by the zone valve relay control. • The zone control end switch wired to the OCP “TT” Terminals, provide a heating demand, and energizes the yellow system circulator wire. The Zone 3 Pump end switch wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. There is no circulator priority in this application due to using only one circulator. • Wiring the zone valve control “zone pump 3 end switch” to DHW terminals will avoid the boiler temperature delayed start used on heat demand. Gas Boiler Wiring & Application Guide U.S. Boiler Company 18 08/23/13 2.0 IQ Gas Boiler Control System 2.15 Zone Switching Relay Heating NOTE Supply power to Zone Switching Relay from same discount as boiler Overcurrent Protection/ Disconnect GND Boiler Junction Box Line Voltage Wiring Connections Green White L2 Service Switch (Optional) 120V AC Power Supply Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW/Zone Circulator Thermostat 1 Thermostat 2 Thermostat 3 12 24V AC X X R W R W R W ISOLATED ZONE 1 ZONE 2 ZONE 3 PRIORITY END SWITCH THERMOSTATS (24V AC) COM THREE ZONE SWITCHING RELAY FUSE 5 AMP 120 VAC ZC ZR H H FUSE 5 AMP FUSE 5 AMP FUSE 5 AMP 120 VAC CIRCULATORS ZONE 3 ZONE 1 ZONE 2 PRIORITY N H N H N H 123 ZONE 3 PRIORITY ON OFF LED INDICATORS POWER ZONE 1 ZONE 2 ZONE 3 INPUT 120V AC N H SR 503-4 123TT Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive Explanation: This arrangement allows the boiler to respond to heating demands and control all the circulators from a zone switching relay. • The zone control end switch wired to the OCP “TT” Terminals, provide a heating demand, and energizes the yellow system circulator wire. Gas Boiler Wiring & Application Guide U.S. Boiler Company 19 08/23/13 2.0 IQ Gas Boiler Control System 2.16 Zone Switching Relay Heating, IWH w/TPI Control NOTE Supply power to Zone Switching Relay from same discount as boiler Overcurrent Protection/ Disconnect GND L2 Boiler Junction Box Line Voltage Wiring Connections Green White Service Switch (Optional) 120V AC Power Supply Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW/Zone Circulator DHW Circulator Thermostat 1 Thermostat 2 Thermostat 3 12 24V AC X X R W R W R W ISOLATED ZONE 1 ZONE 2 ZONE 3 PRIORITY END SWITCH THERMOSTATS (24V AC) COM THREE ZONE SWITCHING RELAY Remove jumper between ZC & ZR FUSE 5 AMP 120V AC ZC ZR H H FUSE 5 AMP FUSE 5 AMP FUSE 5 AMP 120 VAC CIRCULATORS ZONE 3 ZONE 1 ZONE 2 PRIORITY N H N H N H Alliance SL Indirect Water Heater TPI Control ZONE 3 PRIORITY ON OFF pump/TT Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground 24V LED INDICATORS POWER ZONE 1 ZONE 2 ZONE 3 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive INPUT 120V AC N 123 H SR 503-4 123TT Explanation: This arrangement allows the boiler to respond to heating demands and control all the circulators from a Zone Switching Relay. IHW takes priority through the IHC control via the yellow system pump wire. • The zone control end switch wired to the OCP “TT” Terminals, provide a heating demand, and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/ Zone circulator wire. • A heat demand will energize the yellow wire which will supply voltage to the zone pumps via the “ZC” terminals on the zone relay. When the DHW demand activates, the IHC will de-energize the yellow system circulator wire and energize the red DHW circulator. When the DHW demand expires, the IHC will de-energzie the red wire and re-energize the yellow wire, providing there is still a call for heat • The IHC parameter “dh” must be set to “dh”, and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI Control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 20 08/23/13 2.0 IQ Gas Boiler Control System 2.17 Zone Switching Relay Heating, IWH w/Aquastat Control GND L2 Boiler Junction Box Line Voltage Wiring Connections NOTE Supply power to Zone Switching Relay from same discount as boiler Overcurrent Protection/ Disconnect Green White Service Switch (Optional) 120V AC Power Supply Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW/Zone Circulator DHW Circulator Thermostat 1 Thermostat 2 Thermostat 3 1 2 24V AC X X R W R W R W ZONE 3 ZONE 2 PRIORITY ISOLATED ZONE 1 END SWITCH THERMOSTATS (24V AC) COM THREE ZONE SWITCHING RELAY Remove jumper between ZC & ZR FUSE 5 AMP 120V AC ZC ZR H H FUSE 5 AMP FUSE 5 AMP FUSE 5 AMP 120V AC CIRCULATORS ZONE 3 ZONE 1 ZONE 2 PRIORITY N H N H N H ZONE 3 PRIORITY ON OFF IWH Aquastat Control LED INDICATORS POWER ZONE 1 ZONE 2 ZONE 3 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Left “T” is 24V AC positive INPUT 120 VAC N 1 2 3 H SR 503-4 123TT Explanation: This arrangement allows the boiler to respond to heating demands and control all the circulators from a Zone Switching Relay. • The zone control end switch wired to the OCP “TT” Terminals, provide a heating demand, and energizes the yellow system circulator wire. The IWH Aquastat Control wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/Zone circulator wire. • A heat demand will energize the yellow wire which will supply voltage to the zone pumps via the “ZC” terminals on the zone relay. When the DHW demand activates, the IHC will de-energize the yellow system circulator wire and energize the red DHW circulator. When the DHW demand expires, the IHC will de-energzie the red wire and re-energize the yellow wire, providing there is still a call for heat • The IHC parameter “dh” must be set to “dh”, and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. Gas Boiler Wiring & Application Guide U.S. Boiler Company 21 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card The IQ Outdoor Reset Option Card is an auxiliary control designed specifically for all Burnham products that feature the IQ Control System. The device than plugs into the IQ Option Panel making it the quickest, simplest way to install the energy savings and improved comfort of a full-featured outdoor reset system in any nearly heating system. The included weatherproof outdoor temperature sensor is mounted outside the building, and a 2-wire connection is all that’s required to connect the Option Card. An additional 2-wire connection to the DHW Aquastat provides a DHW demand. IQ option card The IQ Outdoor Reset Option Card contains an impressive list of features normally found only on expensive, standalone control systems. A simple click is all it takes to add the these great features: • Adjustable reset ratio • Selectable & Adjustable Temperature Boost • Domestic Hot Water Set Point • Selectable, Adjustable Domestic Priority • Selectable, Adjustable Domestic Priority Protection • Built-In Diagnostics display error codes on LED display • Can be easily by-passed for service or diagnostics • Settings and status is displayed on IQ Option Panel • Adjustments made right on the boiler Gas Boiler Wiring & Application Guide U.S. Boiler Company 22 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card IQ Outdoor Reset Option Card Settings / Defaults Display Description Range Factory Defaults View Mode SP ot Set Point Set Point of Boiler 180°F Outdoor Temperature Actual Temp from Sensor Adjustment Mode dS Pt tb Lo Ho Lb Hb Lt F-C Domestic Set Point Range: 150°F – 180°F 180°F Priority Time Range: 0-101 Minutes 0 Minutes Boost Time Range: 0-30 Minutes 20 Minutes Low Outdoor Temp Range: 50°F – 32°F 0°F High Outdoor Temp Range: 35°F – 100°F 70°F Low Boiler Temp Range: 70°F – 180°F 110°F High Boiler Temp Range: 70°F – 220°F 180°F Minimum Boiler Temp Range: 70°F – 180°F 130°F Display in °F or °C Degrees: °F/°C Degrees °F Error Codes Err 18 Err 53 Err 89 Electronics Failure Replace Card Temp Sensor Failure Replace Sensor Communication Error Loose wire between boiler control and option panel or card failure The IQ Option Panel features a 3-digit LED, which displays status, settings, and error codes for any IQ Option Cards Installed on the boiler. • The “I” button is used to toggle between each option card. • The “UP” and “Down” arrows are used to adjust settings when the IQ Option Panel is in the Adjust Mode. • When all 3 buttons are held down for 3 seconds, the Option Panel will enter the Adjust Mode and an underscore will be displayed. • If no keys are pressed, after 5 minutes the Option Panel will automatically return to the View Mode. Gas Boiler Wiring & Application Guide U.S. Boiler Company 23 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card Optional Control Panel – ODR Card Adjustable Mode The optional Control Panel (OCP) has three usable slots for plug in cards. Cards can be plugged in in any order. If less than three cards are used they can be in any slot, they do not have to be in any specific order. Once the card is placed in a slot it cannot be moved to another slot without using the “Lrn” function on the OCP. If the card is moved you will receive an error code but no damage will occur to the card. The control has three buttons used to view error codes and access the cards to view or change the parameters. If using the Outdoor Reset (ODR) card you may want to change some of the outdoor reset parameters for a more efficient operation. If there is an IWH on the jobsite it will need to be wired to the ODR card to override the ODR feature on a call for DHW. The card will prioritize the DHW demand and you may be required or choose to change the Priority Time (Pt) the IWH will run before the heating circulators will be re-energized. A required priority time change would be if you have two circulators, one for heating and the other for DHW. The “Pt” factory default is “0” minutes, left at “0” will start both pumps wired to the boiler on a DHW demand. Starting just the DHW circulator on a DHW demand you would change the “Pt” setting from “0” to any value more than “0”. A normal range would be 20 minutes or more depending on tank size and demand. The ODR card is located in the #2 slot on the OCP pictured above. To access the card follow the directions below; 1. Press and release the “I” button until “C2” appears on the display. 2. Press one of the Arrow buttons 3. Press and hold all three buttons at the same time until an underscore appears on the display where the bottom of the third digit would appear. 4. Press the “I” button until you see the Priority Time (Pt) parameter. 5. Press the “up arrow” button to set to desired number of minutes. 6. Press the “I” button to advance to the next parameter, this also saves the setting 7. Continue to press the “I” button until “bAc” is displayed 8. Press an arrow key to leave the parameter adjust mode. You can stop at any parameter and make changes if needed. Gas Boiler Wiring & Application Guide U.S. Boiler Company 24 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.1 Single Zone Heating Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator System Circulator Terminal 2 is 24V AC Positive Terminal 3 is 24V Gnd Left “T” is 24V AC Positive 123TT 1234 Thermostat 1 Explanation: This arrangement can be used when an IQ Gas Boiler is connected to a singe zone heating system • A thermostat wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature. Gas Boiler Wiring & Application Guide U.S. Boiler Company 25 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.2 Single Zone Heating, IWH w/TPI Control Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator Zone 1 Circulator Zone 2 Circulator Alliance SL Indirect Water Heater TPI Control Terminal 2 is 24V AC Positive Terminal 3 is 24V Gnd Left “T” is 24V AC Positive pump/TT 123TT 1234 24V Thermostat 1 Explanation: This arrangement can be used when there is a single heat zone and a DHW demand. • A thermostat wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” • Priority time (Pt) and DHW Setpoint can be set on the IQ Outdoor Reset Option Card. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI Control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 26 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.3 Single Zone Heating, IWH w/Aquastat Control Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator Zone 1 Circulator Zone 2 Circulator IWH Aquastat Control Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive 123TT 1234 Thermostat 1 Explanation: This arrangement can be used when there is a single heat zone and a DHW demand. • A thermostat wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The IWH Aquastat Control wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” • Priority time (Pt) on the ODR card must be set > “0”. See instructions on page 24. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. Gas Boiler Wiring & Application Guide U.S. Boiler Company 27 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.4 Zone Valves Heating, IWH w/TPI Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator System Circulator DHW Circulator Alliance SL Indirect Water Heater TPI Control pump/TT Thermostat 1 40VA Transformer Field Installed L1 Thermostat 2 24V Thermostat 3 24V AC Positive Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive L2 Power Supply 120/60/1 123TT 1234 NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from a TPI control. • The zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” • Priority time (Pt) on the ODR card must be set > “0”. See instructions on page 24. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI Control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 28 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.5 Zone Valves Heating, IWH w/Aquastat Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator System Circulator DHW Circulator IWH Aquastat Control Thermostat 1 40VA Transformer Field Installed L1 Thermostat 2 Thermostat 3 24V AC Positive Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive L2 Power Supply 120/60/1 123TT 1234 NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from an Aquastat control. • The zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The IWH Aquastat Control connected zone valve end switch wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” • Priority time (Pt) on the ODR card must be set > “0”. See instructions on page 24. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP. Gas Boiler Wiring & Application Guide U.S. Boiler Company 29 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.6 Zone Valves Heating, IWH w/TPI Control, 1 Circulator, No Priority Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 L1 System Circulator Red DHW/Zone Circulator Alliance SL Indirect Water Heater TPI Control With this application, there will NOT be DHW priority pump/TT Thermostat 1 40VA Transformer Field Installed Yellow System Circulator Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the domestic water side of the indirect water heater 120V AC Power Supply Terminal 4 is 24V AC Positive 24V Thermostat 2 24V AC Positive L2 Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive Power Supply 120/60/1 123TT 1234 NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from a TPI control. • The zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The TPI Control connected zone valve end switch wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. There is no priority in this application due to using only one circulator. • Wiring the zone valve end switches to DHW terminals will avoid the boiler temperature delayed start used on heat demand and provides a DHW setpoint. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and the TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 30 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.7 Zone Valves Heating, IWH w/Aquastat Control, 1 Circulator, No Priority Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Thermostat 1 40VA Transformer Field Installed L1 Yellow System Circulator Red DHW/Zone Circulator System Circulator Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the domestic water side of the indirect water heater 120V AC Power Supply IWH Aquastat Control With this application, there will NOT be DHW priority Terminal 4 is 24V AC Positive Thermostat 2 24V AC Positive L2 Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive Power Supply 120/60/1 123TT 1234 NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from an Aquastat control. • The heating zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The IWH Aquastat Control connected zone valve end switch wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. There is no priority in this application due to using only one circulator. • Wiring the zone valve end switches to DHW terminals will avoid the boiler temperature delayed start used on heat demand and provides a DHW setpoint. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP. Gas Boiler Wiring & Application Guide U.S. Boiler Company 31 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.8 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator POWER IN FUSE 5 AMP R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 Alliance SL Indirect Water Heater TPI Control ZONE 3 PRIORITY ZONE 3 ON PRIORITY OFF pump/TT 123 24V Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL ZONE 3 PUMP END SWITCH N/O COM N/C DHW/Zone Circulator R W C R W C ZVC 403-4 PUMP END SWITCH X X System Circulator 12 Thermostat 1 Thermostat 2 Thermostat 3 X X ISOLATED END SWITCH 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 PRIORITY ZONE 3 1 2 3 4 123TT 1234 Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing a zone valve control and a DHW demand from a TPI control. • The heating zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. • Priority time (Pt) on the ODR card must be set > “0”. See instructions on page 24. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP. Gas Boiler Wiring & Application Guide U.S. Boiler Company 32 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.9 Zone Valve Control Heating, IWH Aquastat Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) 120V AC Power Supply Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator System Circulator DHW/Zone Circulator 12 Thermostat 1 Thermostat 2 Thermostat 3 123 IWH Aquastat Control POWER IN Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive X X ISOLATED END SWITCH FUSE 5 AMP R W C R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) ZONE 3 PRIORITY ZVC 403-4 ZONE 3 PUMP END SWITCH N/O COM N/C 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL PUMP END SWITCH X X ZONE 3 PRIORITY ON OFF VALVE 1 VALVE 2 VALVE 3 PRIORITY ZONE 3 1 2 3 4 123TT 1234 Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing a zone valve control and a DHW demand from an Aquastat control. • The heating zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The IWH Aquastat Control wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. • Priority time (Pt) on the ODR card must be set > “0”. See instructions on page 24. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. Gas Boiler Wiring & Application Guide U.S. Boiler Company 33 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.10 Zone Valve Control Heating, IWH w/TPI Control, 1 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 System Circulator Yellow Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the Domestic water side of the Indirect Water Heater 12 POWER IN pump/TT X X ISOLATED END SWITCH R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) ZONE 3 PRIORITY ZONE 3 ON PRIORITY OFF 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL ZONE 3 PUMP END SWITCH N/O COM N/C 24V 123 Alliance SL Indirect Water Heater TPI Control R W C ZVC 403-4 PUMP END SWITCH X X System Circulator DHW/Zone Circulator Thermostat 1 Thermostat 2 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 PRIORITY ZONE 3 1 2 3 4 123TT 1234 Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing a zone valve control and a DHW demand from a TPI control. • The zone control end switch wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The zone 3 pump end switch wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. Priority time and DHW setpoint can be set on the IQ Outdoor Reset Option Card. • Wiring the zone valve control “zone pump end switch” to DHW terminals will avoid the boiler temperature delayed start used on heat demand and provides a DHW setpoint. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and the TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 34 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.11 Zone Valve Control Heating, IWH w/Aquastat Control, 1 Circulator Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 System Circulator Yellow Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the Domestic water side of the Indirect Water Heater POWER IN X X ISOLATED END SWITCH R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) 12 R W C ZONE 3 PRIORITY 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 ZONE 3 PRIORITY ON OFF Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL ZONE 3 PUMP END SWITCH N/O COM N/C 123 IWH Aquastat Control ZVC 403-4 PUMP END SWITCH X X System Circulator DHW/Zone Circulator Thermostat 1 Thermostat 2 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 PRIORITY ZONE 3 1 2 3 4 123TT 1234 Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing a zone valve control and a DHW demand from an Aquastat control. • The heating zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The zone 3 pump end switch wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. Priority time and DHW setpoint can be st on the IQ Outdoor Reset Option Card. • Wiring the zone valve control “zone pump end switch” to DHW terminals will avoid the boiler temperature delayed start used on heat demand and provides a DHW setpoint. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. Gas Boiler Wiring & Application Guide U.S. Boiler Company 35 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.12 Zone Switching Relay Heating, IWH w/TPI Control GND L2 Boiler Junction Box Line Voltage Wiring Connections NOTE Supply power to Zone Switching Relay from same discount as boiler Overcurrent Protection/ Disconnect Green White Service Switch (Optional) 120V AC Power Supply Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW/Zone Circulator DHW Circulator Thermostat 1 Thermostat 2 Thermostat 3 12 24V AC X X R W R W R W ISOLATED ZONE 1 ZONE 2 ZONE 3 PRIORITY END SWITCH THERMOSTATS (24V AC) COM THREE ZONE SWITCHING RELAY Remove jumper between ZC & ZR FUSE 5 AMP 120V AC ZC ZR H H FUSE 5 AMP FUSE 5 AMP FUSE 5 AMP 120V AC CIRCULATORS ZONE 3 ZONE 1 ZONE 2 PRIORITY N H N H N H 123 Alliance SL Indirect Water Heater TPI Control ZONE 3 PRIORITY ON OFF LED INDICATORS pump/TT 24V POWER ZONE 1 ZONE 2 ZONE 3 Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive INPUT 120V AC N H SR 503-4 123TT 1234 Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing a zone switching relay and a DHW demand from a TPI control. • The heating zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. • Priority time (Pt) on the ODR card must be set > “0”. See instructions on page 24. • The IQ Outdoor Reset Option Card will raise or lower the heating system water temperature setpoint based on measured outside air temperature and will be overridden on a DHW demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 36 08/23/13 3.0 IQ Gas Boiler Control System, IQ Reset Option Card 3.13 Zone Switching Relay Heating, IWH w/Aquastat Control Overcurrent Protection/ Disconnect GND L2 Boiler Junction Box Line Voltage Wiring Connections NOTE Supply power to Zone Switching Relay from same discount as boiler 120V AC Power Supply Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW/Zone Circulator DHW Circulator Thermostat 1 Thermostat 2 Thermostat 3 12 24V AC X X R W R W R W ZONE 3 ZONE 2 PRIORITY ISOLATED ZONE 1 END SWITCH THERMOSTATS (24V AC) COM THREE ZONE SWITCHING RELAY Remove jumper between ZC & ZR FUSE 5 AMP 120V AC ZC ZR H H FUSE 5 AMP FUSE 5 AMP FUSE 5 AMP 120V AC CIRCULATORS ZONE 3 ZONE 1 ZONE 2 PRIORITY N H N H N H ZONE 3 PRIORITY ON OFF 123 IWH Aquastat Control LED INDICATORS POWER ZONE 1 ZONE 2 Terminal 2 is 24V AC Positive Terminal 3 is 24V Ground Left “T” is 24V AC Positive ZONE 3 INPUT 120V AC N H SR 503-4 123TT 1234 Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing a zone valve control and a DHW demand from an Aquastat control. • The heating zone valve end switches wired to the OCP “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The zone 3 pump end switch wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. • The Priority time (Pt) on the ODR card must be set to > “0”. See instruction on page 24. • When the zone valve control “zone pump end switch” to DHW terminals will avoid the boiler temperature-delayed start used on heat demand and provides a DHW setpoint. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP. Gas Boiler Wiring & Application Guide U.S. Boiler Company 37 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.1 Single Zone Heating Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator System Circulator Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive 1 2 1 2 3 Thermostat 1 Explanation: This arrangement can be used when an IQ gas boiler is connected to a single zone heating system • A thermostat wired to the IHC “TT” terminals provide a heating demand and energizes the yellow system circulator wire. 4.2 Single Zone Heating, Power Stealing Thermostat Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red DHW/Zone Circulator System Circulator 1 2 1 2 3 Thermostat 1 Explanation: This arrangement can be used when an IQ gas boiler is connected to a single zone heating system with a power stealing thermostat • A thermostat wired to the IHC “TT” terminals provide a heating demand and energizes the yellow system circulator wire. Gas Boiler Wiring & Application Guide U.S. Boiler Company 38 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.3 Single Zone Heating, IWH w/TPI Control Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 120V AC Power Supply Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW/Zone Circulator Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive System Circulator Alliance SL Indirect Water Heater TPI Control DHW Circulator pump/TT 1 2 1 2 3 24V Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground Thermostat 1 Explanation: This arrangement can be used when there is a single heat zone and a DHW demand from a TPI control. • The heating zone valve end switches wired to the IHC “TT” terminals provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the IHC and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 39 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.4 Single Zone Heating, IWH w/TPI Control Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator IWH Aquastat Controls 120V AC Power Supply Red DHW Circulator Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive System Circulator DHW/Zone Circulator 1 2 1 2 3 Thermostat 1 Explanation: This arrangement can be used when there is a single heat zone and a DHW demand from an Aquastat control. • A thermostat wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The IWH Aquastat Control wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. Gas Boiler Wiring & Application Guide U.S. Boiler Company 40 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.5 Two Zone Heating Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect L2 Green White Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow Zone 1 Circulator Red Zone 2 Circulator Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive System Circulator DHW/Zone Circulator 1 2 1 2 3 Thermostat 2 Thermostat 1 Explanation: This arrangement allows the boiler to respond to two heating demands through the IHC control and operate both circulators without priority • A Zone 1 thermostat wired to the IHC “TT” wires provide a Zone 1 heating demand and energizes the yellow system circulator wire. A Zone 2 thermostat wired to the IHC “1” & “2” terminals provides a Zone 2 demand and energizes the res DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “tt2” and when the “Pt” Priority Time parameter is ignored so both circulators can run simultaneously. Gas Boiler Wiring & Application Guide U.S. Boiler Company 41 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.6 Zone Valve Heating Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive System Circulator DHW/Zone Circulator 1 2 40VA Transformer Field Installed L1 Thermostat 1 Thermostat 2 1 2 3 Thermostat 3 24V AC Positive L2 Power Supply 120/60/1 NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves • The zone valve end wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the IHC Gas Boiler Wiring & Application Guide U.S. Boiler Company 42 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.7 Zone Valve Heating, IWH w/TPI Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Yellow System Circulator Red DHW Circulator 40VA Transformer Field Installed L1 Thermostat 1 Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive Black L1 Power Supply 120/60/1 120V AC Power Supply Thermostat 2 System Circulator DHW/Zone Circulator 1 2 Thermostat 3 1 2 3 Alliance SL Indirect Water Heater TPI Control 24V AC Positive pump/TT 24V L2 Power Supply 120/60/1 NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from a TPI control. • The zone valve end wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provides a Zone 2 demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the IHC and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 43 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.8 Zone Valve Heating, IWH w/Aquastat Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Yellow System Circulator Red DHW Circulator 40VA Transformer Field Installed L1 Thermostat 1 Thermostat WIres (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive Black L1 Power Supply 120/60/1 120V AC Power Supply Thermostat 2 System Circulator DHW/Zone Circulator 1 2 1 2 3 Thermostat 3 IWH Aquastat Control 24V AC Positive L2 Power Supply 120/60/1 NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from an Aquastat control. • The zone valve end wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provides a Zone 2 demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the IHC. Gas Boiler Wiring & Application Guide U.S. Boiler Company 44 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.9 Zone Valve Heating, IWH w/TPI Control, 1 Circulator, No Priority Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND 120V AC Power Supply Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 System Circulator Yellow System Circulator Red Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the domestic water side of the indirect water heater 40VA Transformer Field Installed L1 Thermostat 1 Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive DHW/Zone Circulator 1 2 Thermostat 2 24V AC Positive Alliance SL Indirect Water Heater TPI Control Terminal 2 is 24V AC Positive Terminal 1 is 24V AC Ground pump/TT 24V 1 2 3 Terminal 2 is 24V AC Positive Terminal 3 is 24V AC Ground L2 Power Supply 120/60/1 With this application, there will not be DHW priority NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from a TPI control. • The zone valve end wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The TPI Control connected zone valve end switch wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt”. There is no priority in this application due to using only one circulator. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the IHC and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 45 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.10 Zone Valve Heating, IWH w/Aquastat Control, 1 Circulator, No Priority Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 120V AC Power Supply Yellow System Circulator Red Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive System Circulator DHW/Zone Circulator 1 2 40VA Transformer Field Installed L1 Thermostat 1 Thermostat 2 1 2 3 IWH Aquastat Control 24V AC Positive L2 Power Supply 120/60/1 With this application, there will not be DHW priority NOTE Zone Valve Terminal 2 must be connected to 24V AC Common failure to do so will result in damaged equipment Explanation: This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves and a DHW demand from an Aquastat control. • The heating zone valve end wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The IWH Aquastat Control connected zone valve end switch wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt”. There is no priority in this application due to using only one circulator. • Wiring the DHW zone valve end switch to the IHC will avoid the boiler temperature delayed start used on heat demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the IHC and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 46 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.11 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) 120V AC Power Supply L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator System Circulator DHW/Zone Circulator 12 Alliance SL Indirect Water Heater TPI Control Thermostat 1 Thermostat 2 Thermostat 3 POWER IN X X ISOLATED END SWITCH R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) R W C ZONE 3 PRIORITY ZVC 403-4 ZONE 3 PUMP END SWITCH N/O COM N/C 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 24V LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL PUMP END SWITCH X X ZONE 3 PRIORITY ON OFF 123 Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground pump/TT FUSE 5 AMP Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive Black VALVE 1 VALVE 2 VALVE 3 PRIORITY ZONE 3 1 2 3 4 Explanation: This application uses a zone valve control for heating demands and the DHW demand wired directly to the IHC control utilizing two circulators, and offers priority. • The zone valve end wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the IHC and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 47 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.12 Zone Valve Control Heating, IWH w/Aquastat Control, 2 Circulators Boiler Junction Box Line Voltage Wiring Connections GND Overcurrent Protection/ Disconnect Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW Circulator POWER IN X X ISOLATED END SWITCH R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) R W C ZONE 3 PRIORITY ZVC 403-4 PUMP END SWITCH X X ZONE 3 PUMP END SWITCH N/O COM N/C 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 System Circulator DHW/Zone Circulator 123 IWH Aquastat Control ZONE 3 PRIORITY ON OFF LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive 12 Thermostat 1 Thermostat 2 Thermostat 3 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 PRIORITY ZONE 3 1 2 3 4 Explanation: This application uses a zone valve control for heating demands and the DHW demand wired directly to the IHC control utilizing an Aquastat. • • The zone control end switch wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/ Zone circulator wire. The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the IHC control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 48 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.13 Zone Valve Control Heating, IWH w/TPI Control, 1 Circulator Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the Domestic water side of the Indirect Water Heater Red POWER IN R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) R W C ZONE 3 PRIORITY ZVC 403-4 ZONE 3 PUMP END SWITCH N/O COM N/C DHW/Zone Circulator 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 123 24V ZONE 3 PRIORITY ON OFF LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL PUMP END SWITCH X X System Circulator 12 pump/TT X X ISOLATED END SWITCH Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive Alliance SL Indirect Water Heater TPI Control Thermostat 1 Thermostat 2 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 PRIORITY ZONE 3 1 2 3 4 Explanation: This application uses a zone valve control for heating demands and the DHW demand wired directly to the IHC control utilizing one circulator. Priority is controlled by the zone valve relay control. • The zone control end switch wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/ Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. There is no circulator priority in this application due to using only one circulator. • Wiring the zone valve control “zone pump 3 end switch” to DHW terminals will avoid the boiler temperature delayed start used on heat demand. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 49 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.14 Zone Valve Control Heating, IWH w/Aquastat Control, 1 Circulator Boiler Junction Box Line Voltage Wiring Connections Overcurrent Protection/ Disconnect GND Green White L2 Service Switch (Optional) Black L1 Power Supply 120/60/1 Yellow System Circulator Caution: When using a zone valve on an IWH, we strongly suggest the use of a mixing valve installed on the Domestic water side of the Indirect Water Heater Red POWER IN X X ISOLATED END SWITCH R W C R W C ZONE 1 ZONE 2 THERMOSTATS (24V AC) R W C ZONE 3 PRIORITY 24V AC ZONE VALVES ZONE 1 ZONE 2 1 2 3 4 1 2 3 4 ZONE 3 PRIORITY ON OFF DHW/Zone Circulator 123 LED INDICATORS POWER T STAT 1 T STAT 2 T STAT 3 THREE ZONE ZONE VALVE CONTROL ZONE 3 PUMP END SWITCH N/O COM N/C System Circulator IWH Aquastat Control ZVC 403-4 PUMP END SWITCH X X Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive 12 Thermostat 1 Thermostat 2 FUSE 5 AMP 120V AC Power Supply VALVE 1 VALVE 2 VALVE 3 PRIORITY ZONE 3 1 2 3 4 Explanation: This application uses a zone valve control for heating demands and the DHW demand wired directly to the IHC control utilizing one circulator. Priority is controlled by the zone valve relay control. • The zone control end switch wired to the IHC “TT” wires provide a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provides a DHW demand and energizes the red DHW/ Zone circulator wire. • The IHC parameter “dh” must be set to “dh”. There is no circulator priority in this application due to using only one circulator. • Wiring the zone valve control “zone pump 3 end switch” to DHW terminals will avoid the boiler temperature delayed start used on heat demand. Gas Boiler Wiring & Application Guide U.S. Boiler Company 50 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.15 Zone Switching Relay Heating NOTE Supply power to Zone Switching Relay from same discount as boiler Overcurrent Protection/ Disconnect GND Boiler Junction Box Line Voltage Wiring Connections Green White L2 Service Switch (Optional) 120V AC Power Supply Black L1 Power Supply 120/60/1 Yellow System Circulator Red DHW/Zone Circulator Thermostat 1 Thermostat 2 Thermostat 3 Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive 12 24V AC X X R W R W R W ISOLATED ZONE 1 ZONE 2 ZONE 3 PRIORITY END SWITCH THERMOSTATS (24V AC) COM THREE ZONE SWITCHING RELAY FUSE 5 AMP 120V AC ZC ZR H H FUSE 5 AMP FUSE 5 AMP FUSE 5 AMP 120V AC CIRCULATORS ZONE 3 ZONE 1 ZONE 2 PRIORITY N H N H N H 123 ZONE 3 PRIORITY ON OFF LED INDICATORS POWER ZONE 1 ZONE 2 ZONE 3 INPUT 120V AC N H SR 503-4 Explanation: This arrangement allows the boiler to respond to heating demands and control all the circulators from a zone switching relay. • The zone switching relay end switch wired to the IHC “TT” wires provides a heating demand and energizes the yellow system circulator wire. Gas Boiler Wiring & Application Guide U.S. Boiler Company 51 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.16 Zone Switching Relay Heating, IWH w/TPI Control NOTE Supply power to Zone Switching Relay from same discount as boiler Overcurrent Protection/ Disconnect GND Boiler Junction Box Line Voltage Wiring Connections Green White L2 Service Switch (Optional) 120V AC Power Supply Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive Black L1 Power Supply 120/60/1 DHW Circulator Yellow Red Thermostat 1 Thermostat 2 Thermostat 3 System Circulator DHW/Zone Circulator 12 24V AC X X R W R W R W ZONE 3 ZONE 2 PRIORITY ISOLATED ZONE 1 END SWITCH THERMOSTATS (24V AC) COM THREE ZONE SWITCHING RELAY Remove Jumper Between ZC & 2R FUSE 5 AMP 120V AC ZC ZR H H FUSE 5 AMP FUSE 5 AMP FUSE 5 AMP 120V AC CIRCULATORS ZONE 3 ZONE 1 ZONE 2 PRIORITY N H N H N H Alliance SL Indirect Water Heater TPI Control ZONE 3 PRIORITY ON OFF Terminal 2 is 24V AC positive Terminal 3 is 24V AC ground pump/TT LED INDICATORS 123 24V POWER ZONE 1 ZONE 2 ZONE 3 INPUT 120V AC N H SR 503-4 Explanation: This arrangement allows the boiler to respond to heating demands and control all the circulators from a zone switching relay. DHW is controllled by the TPI control. • The zone switching relay end switch wired to the IHC “TT” wires provides a heating demand and energizes the yellow system circulator wire. The TPI Control wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/Zone circulator wire. • A heat demand will energize the yellow wire which will supply voltage to the zone pumps via the “ZC” terminals on the zone relay. When the DHW demand activates, the IHC will de-energize the yellow system circulator wire and energize the red DHW circulator. When the DHW demand expires, the IHC will de-energize the red wire and re-energize the yellow wire providing there is still a call for heat. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. • CAUTION: Proper polarity must be maintained on the red and white wires to avoid damge to the IHC and TPI control. Gas Boiler Wiring & Application Guide U.S. Boiler Company 52 08/23/13 4.0 Intelligent Hydronic Control (IHC) 4.17 Zone Switching Relay Heating, IWH w/Aquastat Control NOTE Supply power to Zone Switching Relay from same discount as boiler Overcurrent Protection/ Disconnect GND Boiler Junction Box Line Voltage Wiring Connections Green White L2 Service Switch (Optional) 120V AC Power Supply Black L1 Power Supply 120/60/1 DHW Circulator Yellow Red Thermostat 1 Thermostat 2 Thermostat 3 Thermostat Wires (Connect into corresponding wires in wiring harness) Bottom: Yellow wire is 24V AC Positive System Circulator DHW/Zone Circulator 12 24V AC X X R W R W R W ISOLATED ZONE 1 ZONE 2 ZONE 3 PRIORITY END SWITCH THERMOSTATS (24V AC) COM THREE ZONE SWITCHING RELAY Remove Jumper Between ZC & 2R FUSE 5 AMP 120V AC ZC ZR H H FUSE 5 AMP FUSE 5 AMP FUSE 5 AMP 120V AC CIRCULATORS ZONE 3 ZONE 1 ZONE 2 PRIORITY N H N H N H 123 IWH Aquastat Control ZONE 3 PRIORITY ON OFF LED INDICATORS POWER ZONE 1 ZONE 2 ZONE 3 INPUT 120 VAC N H SR 503-4 Explanation: This arrangement allows the boiler to respond to heating demands and control all the circulators from a zone switching relay. DHW is controllled by an Aquastat control. • The zone switching relay end switch wired to the IHC “TT” wires provides a heating demand and energizes the yellow system circulator wire. The IWH Aquastat Control wired to the IHC “1” & “2” terminals provide a DHW demand and energizes the red DHW/Zone circulator wire. • A heat demand will energize the yellow wire which will supply voltage to the zone pumps via the “ZC” terminals on the zone relay. When the DHW demand activates, the IHC will de-energize the yellow system circulator wire and energize the red DHW circulator. When the DHW demand expires, the IHC will de-energize the red wire and re-energize the yellow wire providing there is still a call for heat. • The IHC parameter “dh” must be set to “dh” and when the “Pt” Priority Time parameter is set to “on”, it will prioritize the IWH without a time out period. Gas Boiler Wiring & Application Guide U.S. Boiler Company 53 08/23/13 NOTES Gas Boiler Wiring & Application Guide U.S. Boiler Company 54 08/23/13 NOTES Gas Boiler Wiring & Application Guide U.S. Boiler Company 55 08/23/13 UNMATCHED ANYWHERE www.usboiler.net Gas Boiler Wiring & Application Guide U.S. Boiler Company 56 08/23/13