Watts AERCO Edge CFR 3000 Operator's And Service Manual
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Watts AERCO Edge CFR 3000 Operator's And Service Manual

Boiler with edge controller, natural gas modulating boilers
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• 9/20/2023
OMM-0164_A

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  • Page 1 • 9/20/2023 OMM-0164_A...

  • Page 2: Table Of Contents

    CONTENTS Table of Contents SECTION 1. SAFETY PRECAUTIONS ................5 1.1 WARNINGS & CAUTIONS ........................5 1.2 EMERGENCY SHUTDOWN ........................6 1.3 PROLONGED SHUTDOWN ........................6 1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ..............7 SECTION 2. EDGE CONTROLLER OPERATION ..............8 2.1 INTRODUCTION .............................
  • Page 3 CONTENTS 6.1 OUTDOOR AIR RESET MODE ......................31 6.1.1 Outdoor Air Temperature Sensor Installation ....................31 6.1.2 Outdoor Reset Mode Setup ..........................31 6.2 CONSTANT SETPOINT MODE ......................32 6.3 REMOTE SETPOINT MODE ........................ 33 6.4 DIRECT DRIVE MODES........................33 6.5 COMBINATION CONTROL SYSTEM (CCS) ..................
  • Page 4 FORWARD FOREWORD The AERCO CFR Boiler utilizes a breakthrough Condensing-Proof technology that maintains dry flue gas while exceeding efficiency standards. It delivers high performance of up to 86% thermal efficiency– helping engineers, contractors and owners comply with the latest energy conservation mandates. The CFR Boiler achieves this efficiency while safely reusing existing Category I/Type B venting, allowing for cost-friendly solution in retrofit projects.

  • Page 5: Safety Precautions

    SECTION 1 SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 Warnings & Cautions Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.

  • Page 6: Emergency Shutdown

    SECTION 1 SAFETY PRECAUTIONS 1.2 Emergency Shutdown If overheating occurs or the gas supply fails to shut off, close the manual shutoff valve (Figure 1-1) located external to the unit. NOTE: The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

  • Page 7: Important - For Massachusetts Installations

    SECTION 1 SAFETY PRECAUTIONS 1.4 IMPORTANT – For Massachusetts Installations • The boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts. • Prior to unit operation, the complete gas train and all connections must be leak tested using a non-corrosive soap.

  • Page 8: Edge Controller Operation

    SECTION 2 EDGE CONTROLLER OPERATION SECTION 2. EDGE CONTROLLER OPERATION 2.1 Introduction This section provides a brief outline of how to gain access to CFR Boiler’s Edge Controller functionality. The Edge Controller front panel is shown below. This panel’s touchscreen display contains the controls, indicators and displays necessary to operate, adjust and troubleshoot the boiler.

  • Page 9: Login And Password Entry

    SECTION 2 EDGE CONTROLLER OPERATION 2.2 Login and Password Entry The Edge Controller has multiple levels of password protection. Level Password Description No password The default. Many parameters are visible but “Read Only.” Allows routine maintenance by AERCO Trained Technicians (ATT). A higher-level password for AERCO Master Technicians (AMTs) is distributed on an individual basis.

  • Page 10: Start Sequence

    SECTION 3 START SEQUENCE SECTION 3. START SEQUENCE 3.1 Introduction The information in this section provides a guide to starting the CFR Boiler using the Edge Controller. It is imperative that the initial startup of this unit be performed by factory trained personnel. Operation prior to initial startup by factory trained personnel may void the equipment warranty.
  • Page 11 SECTION 3 START SEQUENCE High Pressure Gas Switch Low Pressure Gas Switch Figure 3-1: SSOV Location (P/N 22490 shown) 3. Auxiliary Delay occurs for a configurable length of time and the Delayed Interlocks close. 4. Once all required safety device switches are closed, a purge cycle initiates and: a.
  • Page 12 SECTION 3 START SEQUENCE Figure 3-3: Blower Proof Switch and Blocked Inlet Switch Figure 3-4: Ignition Sequence Screen – Purging 6. Upon completion of the purge cycle, the Controller initiates an ignition cycle, and the following events occur: he Air/Fuel Valve rotates to the low-fire (Ignition) position and closes the ignition switch. The Dial on the Air/Fuel Valve will read between 25 and 35 to indicate that the valve is in the low fire position.

  • Page 13: Start/Stop Levels

    SECTION 3 START SEQUENCE d) If no spark is present 3 seconds into the ignition trial, the Controller aborts the Ignition Cycle and shuts down the boiler. Refer to SectionSECTION 9 in this guide for guidance if this occurs. Figure 3-4: Air/Fuel Valve in Ignition Position 7.

  • Page 14: Start/Stop Levels - Air/Fuel & Energy Input

    SECTION 3 START SEQUENCE 3.4 Start/Stop Levels – Air/Fuel & Energy Input The table below shows the relationship between the energy input and Air/Fuel Valve position document. TABLE 3-2: Air/Fuel Valve Position – NATURAL GAS AIR/FUEL VALVE POSITION ENERGY INPUT BOILER ENERGY INPUT (% OPEN) (BTU/HR)

  • Page 15: Initial Start-Up

    SECTION 4 INITIAL START-UP SECTION 4. INITIAL START-UP 4.1 Initial Start-Up Requirements The following are the prerequisites for the initial start-up of the CFR boiler: • Complete the installation, per the CFR Boiler Install-Startup Manual (OMM-0163) including gas supply piping, vent installation and condensate drain piping. Starting a unit without the proper piping, venting, or electrical systems can be dangerous and may void the product warranty.

  • Page 16: Installing A Gas Supply Manometer

    SECTION 4 INITIAL START-UP 4.2.2 Installing a Gas Supply Manometer A 16” W.C. (4.0 kPa) gas supply manometer (or gauge) is used in the following ways: • Mounted on the upstream side of the SSOV to verify that the gas supply pressure is within the required range of 4”...

  • Page 17: Accessing The Analyzer Probe Port

    SECTION 4 INITIAL START-UP 4.2.3 Accessing the Analyzer Probe Port CFR units contain a 1/4” NPT port on the side of the exhaust manifold, as shown in Figure 4-2. Prepare the port for the combustion analyzer probe as follows: 1. Refer to Figure 4-1 and remove the 1/4” NPT plug from the exhaust manifold. 2.
  • Page 18 SECTION 4 INITIAL START-UP Figure 4-3: First Manual Combustion Calibration Screen 7. Connect the gas pressure manometer to the upstream side of the gas train’s SSOV (see Section 4.2.2) and connect the Combustion Analyzer and Multimeter (per Section 4.2.3) and ensure that the heating loop is capable of dissipating sufficient heat at full fire.
  • Page 19 SECTION 4 INITIAL START-UP Figure 4-5: Manual Combustion Calibration Screens 12. Set the Controller’s Enable/Disable switch to Enable. 13. Change the valve position to 30%, press Go, then verify the unit has ignited. 14. Use the  (Right) arrow key to change the valve position to 100%, then press Go. 15.

  • Page 20: Reassembly

    SECTION 4 INITIAL START-UP NOTE: These instructions assume the inlet air temperature is between 50°F and 100°F (10°C – 37.8°C). If NOx readings exceed the target values in Table 4-1 or Table 4-3, increase the O level to 1% higher than the Target value, then record the increased O value on the Calibration sheet.

  • Page 21: Adjusting The Automatic Reset Limit Switch Temperature

    SECTION 4 INITIAL START-UP • Automatic Reset: If the unit’s operating temperature exceeds the limit set on the switch, the unit goes into an alarm mode and shuts the unit down. When the temperature falls 10 degrees below the limit, the unit automatically resumes operation without operator intervention. The limit range is manually adjustable from 32°F to 200°F (0°C to 93°C).

  • Page 22: Changing The Readout Between Fahrenheit And Celsius

    SECTION 4 INITIAL START-UP 1. Power the unit ON and remove the front panel to expose the Over-Temperature Limit switches. 2. Press the Manual Reset Limit Switch’s RST (Reset) button. 3. You can now restart the unit. Figure 4-8: Manual Reset Over-Temperature Limit Switch 4.5.3 Changing the Readout Between Fahrenheit and Celsius Perform the following steps to change the temperature reading between Fahrenheit or Celsius.

  • Page 23: Safety Device Testing

    SECTION 5 SAFETY DEVICE TESTING SECTION 5. SAFETY DEVICE TESTING 5.1 Testing of Safety Devices Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustion-related safety devices before, during and after the start sequence.

  • Page 24: High Gas Pressure Test

    SECTION 5 SAFETY DEVICE TESTING 5.3 High Gas Pressure Test To simulate a high gas pressure fault, refer to Figure 4-1 and perform the following steps: 1. Shut off the external gas supply by closing the external gas supply ball valve. 2.

  • Page 25: Water Temperature Fault Test

    SECTION 5 SAFETY DEVICE TESTING 9. Close the drain and pressure relief valve used in draining the unit. 10. Open the water shut-off valve in the return piping to the unit. 11. Open the water supply shut-off valve to the unit to refill. 12.

  • Page 26: Interlock Tests

    SECTION 5 SAFETY DEVICE TESTING 7. Repeat Step 2 to return the Automatic Reset switch but press the Up arrow to original setting. 8. The unit should start once the setting is above the actual outlet water temperature. 9. Repeat steps 1 – 4 on the Manual Reset switch. However, unlike the Automatic Reset switch, the unit will not restart automatically when the original temperature is restored.

  • Page 27: Air Flow Fault Tests - Blower Proof & Blocked Inlet Switches

    SECTION 5 SAFETY DEVICE TESTING Main Menu → Diagnostics → Manual 2. On the Controller, go Mode. 3. Enable the Manual Run control. 4. Set the valve position between 25% and 30% using the + (Plus) and – (Minus) controls. 5.

  • Page 28: Blocked Inlet Switch Test

    SECTION 5 SAFETY DEVICE TESTING Figure 5-5: Blower Proof & Blocked Inlet Switch Locations 5.8.2 Blocked Inlet Switch Test This test runs in simulated fire mode, the Blocked Inlet switch isolated from the rest of the circuitry. 1. Set the Controller’s Enable/Disable switch to Disable. 2.

  • Page 29: Ssov Proof Of Closure Switch Check

    SECTION 5 SAFETY DEVICE TESTING 7. The unit should shut down and display Airflow Fault During Run. This step confirms proper operation of the Blocked Inlet switch. 8. Remove cover from the air inlet opening and reinstall the Combustion Air Duct or air filter. 9.

  • Page 30: Ignition Switch Open During Ignition

    SECTION 5 SAFETY DEVICE TESTING 5. Remove one of the two wires (#171 or #172) from the Purge switch (Figure 5-11a – 5-11c). 6. Set the Controller’s Enable/Disable switch to Enable to start the unit. 7. The unit should begin its start sequence, then shut down and display Prg Switch Open During Purge. 8.

  • Page 31: Standalone Modes Of Operation

    SECTION 6 STANDALONE MODES OF OPERATION SECTION 6. STANDALONE MODES OF OPERATION The descriptions and instructions in this chapter apply to Standalone units only; the unit cannot be a BST Client or BST Manager. Main Menu → Advanced Setup → BST To verify that the unit is not a BST Client or Manager, go Cascade →...

  • Page 32: Constant Setpoint Mode

    SECTION 6 STANDALONE MODES OF OPERATION Unit Application = SH Unit Application = Outdoor Reset Figure 6-1: Application Configuration Screen 4. Set the following parameters to define the total outside air temperature span which will be used for Setpoint control. •...

  • Page 33: Remote Setpoint Mode

    SECTION 6 STANDALONE MODES OF OPERATION 6.3 Remote Setpoint Mode The setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage signal. NOTE: For field wiring instructions see Section 2.10 in the CFR Boiler Install-Startup Manual (OMM-0163). When using the Remote Setpoint mode default setting, 4 - 20 mA/1 - 5 VDC, a 4 to 20 mA/1 to 5 VDC signal, sent by an EMS or BAS, is used to change the unit's setpoint.

  • Page 34: Combination Control System (Ccs)

    SECTION 6 STANDALONE MODES OF OPERATION Main Menu → Advanced Setup → Unit →Application Go to: Configuration. 2. Press SH Operating Mode parameter and choose Direct Drive. 3. The Remote Signal parameter now appears. It can be set to one of six options: 4-20mA, 1-5V, BAS, 0-20mA, Network, or 0-5V.

  • Page 35: Combination Control System Field Wiring

    SECTION 6 STANDALONE MODES OF OPERATION operation. When the combo units switch over to space heating, their mode of operation changes to follow the ACS command. For more information concerning the operation of the ACS, consult the AERCO Control System Manual (OMM-0081, GF-131); for information on mounting and wiring the ACS Relay Box, see section 2.14 in that manual.

  • Page 36: Boiler Sequencing Technology

    SECTION 7 BOILER SEQUENCING TECHNOLOGY SECTION 7. BOILER SEQUENCING TECHNOLOGY 7.1 Introduction The Boiler Sequencing Technology system (BST) is an integrated 16 boiler control system. It is built into the Edge Controller. It has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up to 16 boilers while achieving maximum operational efficiency.

  • Page 37: Bst Implementation Instruction

    SECTION 7 BOILER SEQUENCING TECHNOLOGY b) Make sure that the Modbus load and bias resistors are properly configured for the system to operate without the ProtoNode installed. c) Temporarily set the BST system for Constant Setpoint mode of operation (see below). d) Turn on and completely test the installation to verify that it is operating properly.
  • Page 38 SECTION 7 BOILER SEQUENCING TECHNOLOGY – Figure 7-2: BST, BAS and Field Wiring SD-A-1174 • • •...

  • Page 39: Bst Setup: Constant Setpoint

    SECTION 7 BOILER SEQUENCING TECHNOLOGY 7.2.1 BST Setup: Constant Setpoint Complete the instructions below to configure the Controller for Constant Setpoint. On All Boilers: Main Menu → Advanced Setup → BST Cascade → Cascade Configuration 1. Go to: and set the Unit Mode parameter to BST Client.

  • Page 40: Bst Setup: Outdoor Air Temperature Reset

    SECTION 7 BOILER SEQUENCING TECHNOLOGY Menu/Screen Name Parameters Values Enabled (This is available on the Manager unit Auto Manager Transfer only) Backup Manager Address Enter the designated backup unit address Unit Mode BST Manager Cascade Configuration Hdr Temp Sensor Network Sensor Comm Address Hdr Temp Point Application...
  • Page 41 SECTION 7 BOILER SEQUENCING TECHNOLOGY Configuration SH Operating Mode Outdoor Reset The threshold outside temperature above which Warm Weather Shtdwn the unit shuts down The minimum outside temperature the system OAR Min Outside Temp can read; it is tied to the OAR Max Setpoint OAR Max Setpoint The maximum allowable setpoint Outdoor Air Reset Maximum Outside...

  • Page 42: Maintenance

    SECTION 8 MAINTENANCE SECTION 8. MAINTENANCE 8.1 Maintenance Schedule All CFR boilers require routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following procedures should be performed in the time periods. For a complete inspection check list see ASME CSD-1 chart.

  • Page 43: Flame Detector

    SECTION 8 MAINTENANCE inspect/replace the Igniter: Note that during installation, use the number of indexing (clocking) washers necessary so that, when tight, the gas injection tube is positioned as shown in Figure 8-1b. Figure 8-1a: Igniter-Injector & Flame Detector Figure 8-1b: Igniter-Injector Orientation 8.3 Flame Detector The Flame Detector (kit P/N 24356-1) is located on the burner plate at the top of the unit (see Figure 8-1a through This part and instructions are included in both 12 and 24 Month Maintenance Kits.

  • Page 44: Safety Device Testing

    SECTION 8 MAINTENANCE 8.4 Safety Device Testing Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed. Certain code requirements, such as ASME CSD-1, require that these tests be performed on a scheduled basis. Test schedules must conform to local jurisdictions. The results of the tests should be recorded in a logbook.

  • Page 45: Air Filter Cleaning And Replacement

    SECTION 8 MAINTENANCE – Figure 8-3: External Condensate Trap Cross-Section & Exploded View If your system includes a condensate neutralizer, the active ingredient must be replaced periodically. Figure 8-4: Condensate Trap and Neutralizer 8.7 Air Filter Cleaning and Replacement The boiler’s air filter should be cleaned every 12 months; it should be replaced after 24 months if it shows any signs of deterioration.

  • Page 46: Shutting Boiler Down For Extended Period

    SECTION 8 MAINTENANCE 8.8 Shutting Boiler Down for Extended Period If the boiler is to be taken out of service for one year or more, do the following. 1. Set Enable/Disable switch on the front panel to the Disable position to shut down the boiler’s operating controls.
  • Page 47 SECTION 8 MAINTENANCE TABLE 8-3: Recommended Periodic Testing ITEM FREQUENCY ACTION BY REMARKS Check with combustion calibration test equipment (see Section 4.2: Tools & Annually Service Tech Instruments for Combustion Calibration in this guide), and the O sensor (see Section 8.4: O Sensor in this guide).

  • Page 48: Recommended Spares

    SECTION 8 MAINTENANCE 8.11 Recommended Spares NOTE: Refer to the parts list illustrations in the for the locations of the parts listed below. For a list of 12- and 24-Month Maintenance Kits, see Section 8.1: Maintenance Schedule. TABLE 8-4: Recommended Emergency Spare Parts DESCRIPTION Part Number 58063-1 (460V)

  • Page 49: Troubleshooting

    SECTION 9 TROUBLESHOOTING SECTION 9. TROUBLESHOOTING 9.1 Introduction This section is intended to aid service/maintenance personnel in isolating the cause of a fault in your CFR boiler. The troubleshooting procedures below are presented in tabular form on the following pages. These tables are comprised of three columns labeled: Fault Indication, Probable Cause and Corrective Action.
  • Page 50 SECTION 9 TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective Blocked Inlet switch. Turn off unit and check the continuity of the Blocked Inlet switch. If there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace the switch.
  • Page 51 SECTION 9 TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Blockage in air filter or Blocked Inlet Remove the air filter and Blocked Inlet switch switch. and inspect for signs of blockage, clean or replace as necessary. Defective Blocked Inlet switch.
  • Page 52 SECTION 9 TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Worn Flame Detector or cracked Remove and inspect the Flame Detector for signs ceramic. of wear or cracked ceramic. Replace if necessary. Defective Regulator. Check gas pressure readings using a gauge or manometer into and out of the Air/Fuel Valve to ensure that the gas pressure into and out of the FLAME LOSS...
  • Page 53 SECTION 9 TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Unit setpoint is greater than Over Check setpoint of unit and setpoint of Temperature switch setpoint. Temperature switch; Ensure that the temperature switch is set higher than the unit’s setpoint.
  • Page 54 SECTION 9 TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective Ignition switch. If the Air/Fuel Valve does rotate to the ignition position, check the ignition position switch for continuity between the N.O. and COM terminals when in contact with the cam. Defective Power Supply Board or Check DS1 &...
  • Page 55 SECTION 9 TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action A/F Valve rotated open to purge Start the unit. The Air/Fuel Valve should rotate to and did not rotate to ignition the purge (open) position, then back to ignition position.
  • Page 56 SECTION 9 TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Remote setpoint signal not present: Check I/O Box to ensure signal is hooked up. • • Not yet installed. Hook up if not installed. • • Wrong polarity. If installed, check polarity.

  • Page 57: Additional Faults Without Specific Fault Messages

    SECTION 9 TROUBLESHOOTING TABLE 9-1: Boiler Troubleshooting Procedures Fault Probable Causes Corrective Action Defective switch or Actuator. Remove the electrical cover from the SSOV and check switch continuity. If the switch does not show continuity with the gas valve closed, either adjust or replace the switch or actuator.
  • Page 58 SECTION 9 TROUBLESHOOTING The Stack Guard Check the system return water temperature. The Low Stack Temp temperature is below the required minimum return water temperature is Shutdown Stack Guard Low Limit 120°F. Stack guard sensor is not Ensure the stack guard sensor is installed in the Stack Guard Sensor installed.

  • Page 59: Section 10. Appendix A: Wiring Schematics

    SECTION 10. APPENDIX A: WIRING SCHEMATICS CFR Drawing Number: 68109 rev A Sheet 1 of 4 • • •...
  • Page 60 CFR Drawing Number: 68109 rev A Sheet 2 of 4 • • •...
  • Page 61 CFR Drawing Number: 68109 rev A Sheet 3 of 4 • • •...
  • Page 62 CFR Drawing Number: 68109 rev A Sheet 4 of 4 • • •...

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