MPO-IQ Controls Wiring & Application Guideand+application+guide+-+MPO-IQ.pdf · MPO-IQ Controls....

Oil Boiler Wiring & Application GuideU.S. Boiler Company

10/14/131

MPO-IQ ControlsWiring & Application Guide

Featuring the IQ Boiler Control System

boilercontrol

©2013 U.S. Boiler Company


10/14/132

Table of Contents1.0 Introduction ........................................................................................................................... 3

2.0 IQ Oil Boiler Control System .........................................................................................................................................4-6 2.1 Single Zone Heating ............................................................................................................................................... 7 2.2 Single Zone Heating, Power Stealing Thermostat ................................................................................................... 8 2.3 Single Zone Heating, Indirect Water Heater (IWH) w/TPI Control ........................................................................... 9 2.4 Single Zone Heating, IWH w/Aquastat Control ..................................................................................................... 10 2.5 Two Zone Heating w/Additional 24V-AC Relay ..................................................................................................... 11 2.6 Two Zone Heating, One Low Voltage & One Line Voltage Thermostat .................................................................. 12 2.7 Zone Valves Heating ............................................................................................................................................. 13 2.8 Zone Valves Heating, IWH w/TPI Control, 2 Circulators ....................................................................................... 14 2.9 Zone Valves Heating, IWH w/Aquastat Control, 2 Circulators ............................................................................... 15 2.10 Zone Valves Heating, IWH w/TPI Control, 1 Circulator ......................................................................................... 16 2.11 Zone Valves Heating, IWH w/Aquastat Control, 1 Circulator ................................................................................. 17 2.12 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulators ............................................................................. 18 2.13 Zone Valve Control Heating, IWH w/Aquastat Control, 2 Circulators .................................................................... 19 2.14 Zone Valve Control Heating, IWH w/TPI Control, 1 Circulator .............................................................................. 20 2.15 Zone Valve Control Heating, IWH w/Aquastat Control, 1 Circulator ...................................................................... 21 2.16 Zone Switching Relay Heating .............................................................................................................................. 22 2.17 Zone Switching Relay Heating, IWH w/TPI Control .............................................................................................. 23 2.18 Zone Switching Relay Heating, IWH w/Aquastat Control ...................................................................................... 24 2.19 Zone Switching Relay Heating, IWH w/Aquastat Control ...................................................................................... 25

3.0 IQ Oil Boiler Control System, Outdoor Reset Card ..................................................................................................26-27 3.1 Single Zone Heating ............................................................................................................................................. 28 3.2 Single Zone Heating, Power Stealing Thermostat ................................................................................................. 29 3.3 Single Zone Heating, IWH w/TPI Control .............................................................................................................. 30 3.4 Single Zone Heating, IWH w/Aquastat Control ..................................................................................................... 31 3.5 Zone Valves Heating, IWH w/TPI Control, 2 Circulators ....................................................................................... 32 3.6 Zone Valves Heating, IWH w/Aquastat Control, 2 Circulators ............................................................................... 33 3.7 Zone Valves Heating, IWH w/TPI Control, 1 Circulator, No Priority....................................................................... 34 3.8 Zone Valve Heating, IWH w/Aquastat Control, 1 Circulator, No Priority ................................................................ 35 3.9 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulators ............................................................................. 36 3.10 Zone Valve Control Heating, IWH w/Aquastat Control, 2 Circulators .................................................................... 37 3.11 Zone Valve Control Heating and IWH w/TPI Control, 1 Circulator ........................................................................ 38 3.12 Zone Valve Control Heating and IWH w/Aquastat Control, 1 Circulator ................................................................ 39 3.13 Zone Switching Relay, IWH w/TPI Control ............................................................................................................ 40 3.14 Zone Switching Relay, IWH w/Aquastat Control ................................................................................................... 41


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1.0 Introduction The IQ Control System included on the MPO-IQ boiler contains 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 system. 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 Voltage AbbreviationsL1 – 120Vac Hot – Black L2 – 120Vac Neutral - White OCP IQ Option PanelGround - Green 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 HotWhite (Grey) 24Vac Ground

Polarity Not ImportantBlue wires


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2.0 IQ Oil Boiler Control SystemThe MPO-IQ features the IQ Oil Boiler Control system, which greatly simplifies installation and set-up in both existing and new heating systems. This 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 Oil Boiler Control System consists of the following components:

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.

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.

IQ Oil Boiler Control This control may look like a normal Aquastat, but it does things no other Aquastat can do. Features like Circulator Pre Purge, Circulator Post Purge, and built-in control for a second (heating or DHW) zone can be selected and adjusted to improve comfort and efficiency in many heating systems – while simplifying installation. The IQ Oil Boiler Control is factory mounted and wired, saving the installer time, and reducing the potential for errors in the field.


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Parameter Range Parameter Description Default

HL 140°F – 240°F High Limit Setting 180°F

HdF 10°F – 30°F High Limit Differential 15°F

Or 0 – 10 Minutes Circulator Overrun Time 0 Minutes

PP 0 –20 Minutes Circulator Pre-purge Time 2 Minutes

St 140°F –180°F Start Temperature 140°F

2C ZR, DHW 2nd Zone Input ZC

Pt On - Off Priority Time On

F-C F or C Degrees F or C F

2.0 IQ Oil Boiler Control System – Settings / Factory DefaultsThe IQ Oil 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. During normal operation the LED displays a status code described below. The IQ Oil Boiler Control settings can be adjusted to fine tune the boiler to the heating system.Settings can be adjusted while the IQ Oil Boiler Control is in the Adjustment mode. IQ Oil Boiler Settings, Ranges and Defaults are listed in the tables below:

The IQ Oil Boiler Control’s “ZR” parameter provides the ability to control two separate input demands and two zone circulators. The control can be respond to a demand when 120V is input to the Brown “DHW” wire in the boiler junction box. This feature can be used to respond to a second zone demand using a 120V signal – such as an indirect water heater aquastat – without the use of any additionalcontrols. The boiler can also respond to a second heat demand of either a120Vac line voltage thermostat or a 24V heating zone with a field-installed SPST relay is used to energize the Brown “ DHW” wire with the 24V demand to 120V. Additionally, the IQ Oil Boiler Control can be configured to respond to both demands simultaneously, or to provide a priority response for the 120V demand, which may be desirable in DHW applications.

ERROR CODESError Value Description

1 Temperature Sensor Fault2 Communication Fault3 Internal Hardware Fault4 Burner Output (B1) Fault5 Low Voltage Fault (<80V-ac)6 Fuse Missing7 User Setting Lost (Reset to Factory Defaults)8 Manual Reset Lockout (Resettable)


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IQ Oil Boiler Status CodesDisplay Description Detail

StA 1 Standby No call for heat is sensed, burner and pump are off.

StA 4 Prepurge* Burner fan is started for 15 seconds. Fan begins pre-purge cycle.

StA 6 Trial for Ignition* Solenoid valve opens, burner attemps to light for 15 seconds.

StA 7 Carryover* Once the burner lights, the ignition remails on for 10 seconds.

StA 8 Running Burner runs until high limit temp is reached, or call for heat is satisfied.

StA 9 Postpurge* Fuel valve is closed, fan runs for 15 seconds.

StA 10 Retry/Recycle*

If flame is lost while burner is firing, the Primary Control shuts the burner for 60 seconds, then attempts to re-light. If the flame is lost three times in a row, the control locks out, and must be

reset by pressing the red button on the Primary Control.

Sta 14 Hard Lockout*

If flame is not sensed by the end of the trial for ignition, the control enters a safety lock-out, and must be manually reset by pressing the red button on the primary control. If the primary locks out three times in a row, it enters a restricted lock-out.

Press and hold the red reset button on the Primary for 30 sec-onds to reset the control.

StA 15 Limit Open*Call for heat is sensed, and start sequence is haldted due to an open limit. Open limits include high water temp or low water

detected by IQ Option Cards.

StA 16 Flame out of Sequence* Flame signal sensed when expected to be 0 (no flame).

StA 17 Self Test Control is performing an internal self test.

* When burner is equipped with Honeywell R7184P Primary Control


10/14/137

2.0 IQ Oil Boiler Control System

120 VACPowerSupply

SystemCirculator

Boiler Junction BoxLine Voltage Wiring Connections

Green

White

Black

Yellow

SystemCirculator

Service Switch(Optional)

OvercurrentProtection/DisconnectGND

L2

L1

PowerSupply

120/60/1

Thermostat 1

1 2 3 T T

Brown

To IQ Oil Boiler

Control

DHWCirculator

White

DHWDemand

Violet

Explanation:This arrangement can be used when an MPO-IQ is connected to a single zone heating system.

• AthermostatwiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellowsystemwire.

2.1 Single Zone Heating


10/14/138


Explanation:

This arrangement can be used with a single zone heating system with a power stealing thermostat

• AthermostatwiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellowsystemcirculatorwire.

2.2 Single Heat Zone, Power Stealing Thermostat

120 VACPowerSupply


Green

White

Black

SystemCirculator



L2

L1

PowerSupply

120/60/1

Thermostat 1

1 2 3 T T

Terminal 2 is 24V AC positiveTerminal 3 is 24V AC groundLeft T is 24V AC positive

To IQ Oil Boiler

Control

SystemCirculatorYellow

Brown

DHWCirculator

White

DHWDemand

Violet


10/14/139


Explanation:

This arrangement allows the boiler to respond to a space heating demand, as well as a 120V DHW demand via the Alliance TPI Control.


• TheDHWTPIcontrolclosesL1(120V-ACtothebrownwire(ZR)andenergizesthevioletwire

• Whenthe“2C” parameter is set to “dh” the boiler will prioritize the DHW demand.

• CAUTION: Proper polarity must be maintained on the low voltage red and white wires to avoid possible damage to the OCP and TPI controls.

2.3 Single Heat Zone Heating, IWH w/TPI Control

120 VACPowerSupply


Green

White

Black

SystemCirculator



L2

L1

PowerSupply

120/60/1

Alliance SLIndirect

Water HeaterTPI Control

1 2 3 T T

DHWCirculator

Thermostat 1

24Vpump/TT


Brown

DHWCirculator

White

DHWDemand

Violet

White

To IQ Oil Boiler

Control



10/14/1310


Explanation:

This arrangement allows the boiler to respond to space heating demand, as well as a 120V DHW demand via the Aquastat control.


• TheDHWAquastatclosesL1(120V-ACtothebrownwire(ZR)andenergizesthevioletwire.


2.4 Single Heat Zone Heating, IWH w/Aquastat Control

120 VACPowerSupply


Green

White

Black

SystemCirculator



L2

L1

PowerSupply

120/60/1

1 2 3 T T

DHWCirculator

Thermostat 1


Brown

DHWCirculator

White

DHWDemand

Violet

White

To IQ Oil Boiler

Control


IWH Aquastat Controls


10/14/1311


Explanation:

This arrangement allows the boiler to respond to twoseparate space heating demands, and control a circulator for each zone. The 24V-AC relay controls the 120V-AC heat demand on the IQ Boiler Control.

• AZone-1thermostatwiredtotheOCP“TT”TerminalsprovideaZone-1heatingdemandandenergizestheyellowsystem circulator wire. A Zone-2 thermostat wired between L1 (120V-AC and the brown wire (ZR) provides a Zone 2 demand and energizes the violet DHW/Zone circulator wire.

• Adjust“2C” parameter to “2r” on the IQ Oil Boiler Control. This will allow the boiler to fire in response to either thermostat demand with no priority.

2.5 Two Zone Heating w/ Additional 24V-AC Relay

120 VACPowerSupply


Green

White

Black

SystemCirculator



L2

L1

PowerSupply

120/60/1

1 2 3 T T

DHWCirculator

Thermostat 1


Brown

DHWCirculator

White

DHWDemand

Violet

White

To IQ Oil Boiler

Control


Switching Relay 24V-AC coil, SPST or SPDT

(example relays: Taco SR501, Tekmar 004, RIB

RIB2401D, White Rodgers 90-124 or 90-314)

Thermostat 2


10/14/1312


Explanation:

This arrangement allows the boiler to respond to two separate space heating demands. One 24V-AC and the second 120V-AC, and control two circulators, one for each zone.

• Thermostatoneisastandard24V-ACthermostatconnectedtotheIQOptionPanel.

• Thermostattwoisa120V-AC(L1)linevoltagethermostatconnectedbetweenL1(120V-AC)andthebrownwire(ZR)intheboiler junction box.

• Zone1thermostatwiredtotheOCP“TT”TerminalsprovideaZone1heatingdemandandenergizestheyellowsystemcirculator wire. Zone 2 thermostat wired between L1 (120V-AC) and the brown wire (ZC) wich provides a Zone 2 demand and energizes the violet DHW/Zone circulator wire.

• Adjust“2C” parameter to “2r” on the IQ Oil Boiler Control. This will allow the boiler to run in response to either thermostat without priority.

2.6 Two Zone Heating, One Low Voltage & One Line Voltage Thermostat

120 VACPowerSupply


Green

White

Black

SystemCirculator



L2

L1

PowerSupply

120/60/1

Optional 120V-AC Line

Voltage Thermostat

1 2 3 T T

DHWCirculator

Thermostat 1


Brown

DHWCirculator

White

DHWDemand

Violet

White

To IQ Oil Boiler

Control



10/14/1313


Explanation:

This arrangement allows the boiler to respond to a space heating demand utilizing Taco 3-wire zone valves.

• ThezonevalveendswitcheswiredtotheOCP“TT”Terminals,provideaheatingdemand,andenergizetheyellowsystem circulator wire.

• CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP control.

2.7 Zone Valve Heating

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

Thermostat 3

1 2 3 T T

Terminal 2 is 24V AC positiveTerminal 3 is 24V AC groundLeft “T” is 24V AC positive

Thermostat 2Thermostat 1

24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2

NOTEZone Valve Terminal 2 must be

connected to 24 V ACCommon failure to do so will result in

damaged equipment

SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown


10/14/1314


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.

• ThezonevalveendswitcheswiredtotheOCP“TT”Terminals,provideaheatingdemand,andenergizetheyellowsystemcirculator wire. The TPI Control wired to L1 (120V-AC) and the brown wire provide a DHW demand and energizes the violet DHW/Zone circulator wire.


• CAUTION: Proper polarity must be maintained on the low voltage red and white wires to avoid possible damage to the OCP and TPI control.

2.8 Zone Valve Heating, IWH w/TPI Control, 2 Circulators

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

Thermostat 3

1 2 3 T T



24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2



damaged equipment

SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

BrownAlliance SL

IndirectWater HeaterTPI Control

24Vpump/TT

White

DHWCirculator


10/14/1315


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.

• ThezonevalveendswitcheswiredtotheOCP“TT”Terminalsprovideaheatingdemandandenergizestheyellowsystemcirculator wire. The Aquastat control wired to L1 (120V-AC) and the brown wire provide a DHW demand and energizes the violet DHW/Zone circulator wire.


• WiringtheDHWzonevalveendswitchtotheIHCwillavoidtheboilertemperaturedelayedstartusedonheatdemand

• CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP.

2.9 Zone Valve Heating, IWH w/Aquastat Control, 2 Circulators

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

Thermostat 3

1 2 3 T T



24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2



damaged equipment

SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown

White

DHWCirculator

Aquastat Control


10/14/1316


Explanation:

This arrangement allows the use of zone valves for heat and hot water, a TPI control, and a single circulator without DHW priority.

• Aheatingorhotwaterdemandisprovidedtothe“T-T”terminalsontheIQBoilerControlbythezonevalveendswitchwhich energizes the yellow system circulator wire.

• CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI control.

2.10 Zone Valve Heating and IWH w/TPI Control, 1 Circulator, No Priority

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T



24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2



damaged equipment

SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown

Alliance SLIndirect


24Vpump/TT

This application offers no DHW priority

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


10/14/1317


Explanation:

This arrangement allows the use of zone valves for heat and hot water, an Aquastat control, and a single circulator without DHW priority.

• Aheatingorhotwaterdemandisprovidedtothe“T-T”terminalsontheIQBoilerControlbythezonevalveendswitchwhich energizes the yellow system circulator wire


2.11 Zone Valve Heating and IWH w/Aquastat Control, 1 Circulator, No Priority

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T



24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2



damaged equipment

SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown

Aquastat Control




10/14/1318


Explanation:

This arrangement allows the boiler to respond to a space heating demand utilizing Zone Valve Control and a DHW demand from a TPI control.

• TheZoneValvecontrolendswitcheswiredtotheOCP“TT”Terminalsprovideaheatingdemandandenergizestheyellowsystem circulator wire. The TPI Control wired to L1 (120V-AC) and the brown wire (ZR) provide a DHW demand and energizes the violet DHW/Zone circulator wire.

• Whenthe“2C” parameter is set to “dh”, the boiler will prioritize the DHW demand

• CAUTION: Proper polarity must be maintained on the low voltage red and white wires to avoid possible damage to the OCP and TPI control.

2.12 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulators

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T


SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown

Alliance SLIndirect


24Vpump/TT

WhiteDHW

Circulator

Thermostat 1 Thermostat 2

X X R W C R W C R W CZONE 1 ZONE 2 ZONE 3

THERMOSTATS (24 VAC) PRIORITYISOLATED

END SWITCH

ZVC 403-4

THREE ZONEZONE VALVE CONTROL

ZONE 1 ZONE 2 ZONE 3PRIORITY24 VAC ZONE VALVES

1 2 3 4 1 2 3 41 2 3 4

ZONE 3PRIORITY

ONOFF

LEDINDICATORS

POWERT STAT 1T STAT 2T STAT 3

VALVE 1VALVE 2VALVE 3

FUSE5 AMP

PO

WE

R IN

ZONE 3 PUMPEND SWITCH

PUMP END SWITCH

N/O COM N/CX X

Thermostat 3


10/14/1319


Explanation:

This arrangement allows the boiler to respond to a space heating demand utilizing Zone Valve Control and a DHW demand from an Aquastat control.

• ThezonevalvecontrolendswitcheswiredtotheOCP“TT”Terminals,provideaheatingdemand,andenergizestheyellowsystem circulator wire. The Aquastat control wired to L1 (120V-AC) and the brown wire (ZR) provide a DHW demand and energizes the violet DHW/Zone circulator wire.

• Whenthe“2C” parameter is set to “dh”, the boiler will prioritize the DHW demand.


2.13 Zone Valve Control Heating, IWH w/Aquastat Control, 2 Circulators

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T


SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown

IWH Aquastat Control

WhiteDHW

Circulator




END SWITCH

ZVC 403-4



1 2 3 4 1 2 3 41 2 3 4

ZONE 3PRIORITY

ONOFF

LEDINDICATORS



FUSE5 AMP

PO

WE

R IN


PUMP END SWITCH

N/O COM N/CX X

Thermostat 3


10/14/1320


Explanation:

This arrangement allows the use of a zone valve control for heat and hot water, a TPI control and a single circulator with DHW priority.

• Aheatingorhotwaterdemandisprovidedtothe“T-T”terminalsontheIQBoilerControlbythezonevalveendswitchwhich energizes the yellow system circulator wire.

• CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the TPI control.

2.14 Zone Valve Control Heating, IWH w/Aquastat Control, 1 Circulator

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T


SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown




END SWITCH

ZVC 403-4



1 2 3 4 1 2 3 41 2 3 4

ZONE 3PRIORITY

ONOFF

LEDINDICATORS



FUSE5 AMP

PO

WE

R IN


PUMP END SWITCH

N/O COM N/CX X


Alliance SLIndirect


24Vpump/TT


10/14/1321


Explanation:

This arrangement allows the boiler to respond to heating demands and control all the circulators from a zone switching relay.

• ThezonecontrolendswitchwiredtotheOCP“TT”Terminals,provideaheatingdemand,andenergizestheyellowsystemcirculator wire.

2.15 Zone Valve Control Heating and IWH w/Aquastat Control, 1 Circulator

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T


SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown




END SWITCH

ZVC 403-4



1 2 3 4 1 2 3 41 2 3 4

ZONE 3PRIORITY

ONOFF

LEDINDICATORS



FUSE5 AMP

PO

WE

R IN


PUMP END SWITCH

N/O COM N/CX X




10/14/1322


Explanation:

This arrangement allows the boiler to respond to multiple heating demands through a Zone Circulator Panel

• Aheatingdemandisprovidedtothe“TT”terminalsontheIQOptionPanelbythezonerelaypanelendswitch.

2.16 Zone Switching Relay Heating

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T



DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown

WhiteThermostat 1 Thermostat 2

ISOLATEDEND

SWITCH

SR 503-4

THREE ZONE SWITCHING RELAYLED

INDICATORS

POWER

ZONE 1

ZONE 2

ZONE 3

FUSE5

AMP

Thermostat 3

X X R W R W R W

ZONE 1 ZONE 2 ZONE 3PRIORITY

THERMOSTATS (24VAC)

FUSE5

AMP

FUSE5

AMP

FUSE5

AMP

ZONE 3PRIORITY

ONOFF

24 VAC

COM

INPUT120 VAC

120 VAC CIRCULATORS120 VAC

ZC ZR ZONE 1 ZONE 2ZONE 3

PRIORITYH H N H N H N H N H


10/14/1323


Explanation:

This arrangement allows the use of a zone switching relay for heat and hot water, a TPI control and a single circulator with DHW priority.


2.17 Zone Switching Relay Heating and IWH w/TPI Control

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T



DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown


ISOLATEDEND

SWITCH

SR 503-4


INDICATORS

POWER

ZONE 1

ZONE 2

ZONE 3

FUSE5

AMP

X X R W R W R W


THERMOSTATS (24VAC)

FUSE5

AMP

FUSE5

AMP

FUSE5

AMP

ZONE 3PRIORITY

ONOFF

24 VAC

COM

INPUT120 VAC




Alliance SLIndirect


24Vpump/TT


10/14/1324


2.18 Zone Switching Relay Heating, IWH w/TPI Control

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 IQ Boiler Control via the yellow system pump wire.

• ThezoneswitchingrelayendswitchwiredtotheOCP“TT”terminals,provideaheatingdemand,andenergizetheyellow system circulator wire. The TPI Control wired to L1 (120V-AC) and the brown wire (ZR) provide a DHW demand and energize the violet DHW/Zone circulator wire.

• Aheatdemandwillenergizetheyellowwirewhichwillsupplyvoltagetothezonepumpsviathe“ZC”terminalsonthezone relay. When the DHW demand activates, the IQ Boiler Control will de-energize the red wire and re-energize the yellow wire, providing there is still a call for heat.



120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T



DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown


ISOLATEDEND

SWITCH

SR 503-4


INDICATORS

POWER

ZONE 1

ZONE 2

ZONE 3

FUSE5

AMP

X X R W R W R W


THERMOSTATS (24VAC)

FUSE5

AMP

FUSE5

AMP

FUSE5

AMP

ZONE 3PRIORITY

ONOFF

24 VAC

COM

INPUT120 VAC




Alliance SLIndirectWater Heater

TPI Control

24Vpump/TT

Thermostat 3 DHWCirculator

Remove jumper

between ZC & ZR


10/14/1325


2.19 Zone Switching Relay Heating, IWH w/Aquastat Control

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 IQ Boiler Control via the yellow system pump wire.

• ThezoneswitchingrelayendswitchwiredtotheOCP“TT”terminals,provideaheatingdemand,andenergizetheyellow system circulator wire. The Aquastat Control wired to L1 (120V-AC) and the brown wire (ZR) provide a DHW demand and energize the violet DHW/Zone circulator wire.

• Aheatdemandwillenergizetheyellowwirewhichwillsupplyvoltagetothezonepumpsviathe“ZC”terminalsonthezone relay. When the DHW demand activates, the IQ Boiler Control will de-energize the red wire and re-energize the yellow wire, providing there is still a call for heat.


120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1

1 2 3 T T



DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown


ISOLATEDEND

SWITCH

SR 503-4


INDICATORS

POWER

ZONE 1

ZONE 2

ZONE 3

FUSE5

AMP

X X R W R W R W


THERMOSTATS (24VAC)

FUSE5

AMP

FUSE5

AMP

FUSE5

AMP

ZONE 3PRIORITY

ONOFF

24 VAC

COM

INPUT120 VAC






Remove jumper

between ZC & ZR


10/14/1326

3.0 IQ Oil 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.

The IQ Outdoor Reset Option Card contains an impressive list of features normally found only on expensive, stand-alone control systems. A simple click is all it takes to add the these great features:

• Adjustableresetratio

• Selectable&AdjustableTemperatureBoost

• DomesticHotWaterSetPoint

• Selectable,AdjustableDomesticPriority

• Selectable,AdjustableDomesticPriorityProtection

• Built-InDiagnosticsdisplayerrorcodesonLEDdisplay

• Canbeeasilyby-passedforserviceordiagnostics

• SettingsandstatusisdisplayedonIQOptionPanel

• Adjustmentsmaderightontheboiler

IQoptioncard


10/14/1327


IQ Outdoor Reset Option Card Settings / DefaultsDisplay Description Range Factory Defaults

View Mode

SP Set Point Set Point of Boiler 180°F

ot Outdoor Temperature Actual Temp from Sensor

Adjustment Mode

dS Domestic Set Point Range: 150°F – 180°F 180°F

Pt Priority Time Range: 0-101 Minutes 0 Minutes

tb Boost Time Range: 0-30 Minutes 20 Minutes

Lo Low Outdoor Temp Range: 50°F – 32°F 0°F

Ho High Outdoor Temp Range: 35°F – 100°F 70°F

Lb Low Boiler Temp Range: 70°F – 180°F 110°F

Hb High Boiler Temp Range: 70°F – 220°F 180°F

Lt Minimum Boiler Temp Range: 70°F – 180°F 130°F

F-C Display in °F or °C Degrees: °F/°C Degrees °F

Error Codes

Err 18 Electronics Failure Replace Card

Err 53 Temp Sensor Failure Replace Sensor

Err 89 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 codesfor any IQ Option Cards Installed on the boiler.

• The“I”buttonisusedtotogglebetweeneachoption card.

• The“UP”and“Down”arrowsareusedtoadjust settings when the IQ Option Panel is in the Adjust Mode.

• Whenall3buttonsarehelddownfor3seconds, the Option Panel will enter the Adjust Mode and an underscore will be displayed.

• Ifnokeysarepressed,after5minutestheOption Panel will automatically return to the View Mode.


10/14/1328


Explanation:

This arrangement can be used when an MPO-IQ Boiler is connected to a singe zone heating system.

• Aheatingdemandisprovidedtothe“TT”terminalsontheOCPbythethermostatandtheyellowsystemcirculatorwireisenergized.

• TheheatingsystemwaterwillberesetaccordingtoODairtemperature.

3.1 Single Zone Heating

120 VACPowerSupply

SystemCirculator


Green

White

Black

Yellow

SystemCirculator



L2

L1

PowerSupply

120/60/1

Brown

To IQ Oil Boiler

Control

DHWCirculator

White

DHWDemand

Violet

Thermostat 1

1 2 3 T T 1 2 3 4Terminal 2 is 24V-AC Positive

Terminal 3 is 24V-GndLeft “T” is 24V-AC Positive


10/14/1329


3.2 Single Zone Heating, Power Stealing Thermostat

120 VACPowerSupply

SystemCirculator


Green

White

Black

Yellow

SystemCirculator



L2

L1

PowerSupply

120/60/1

Brown

To IQ Oil Boiler

Control

DHWCirculator

White

DHWDemand

Violet

Thermostat 1

1 2 3 T T 1 2 3 4Terminal 2 is 24V-AC Positive

Terminal 3 is 24V-GndLeft “T” is 24V-AC Positive

Explanation:

This arrangement can be used when an MPO-IQ Boiler is connected to a singe zone heating system with a power stealing thermostat.

• AthermostatwiredtotheOCP“TT”terminalsprovdeaheatingdemandandenergizestheyellowsystemcirculatorwire.

• TheIQOutdoorResetOptionCardwillraiseorlowertheheatingsystemwatertemperaturesetpointbasedonmeasuredoutside air temperature.


10/14/1330


Explanation:

This arrangement allows the boiler to respond to space heating demand, as well as 120V DHW demand via the Alliance TPI Control.


• Whenthe“2C” parameter is set to “dh”, the boiler will prioritize the DHW demand.

• TheIQOutdoorResetOptionCardwillraiseorlowertheheatingsystemwatertemperaturesetpointbasedonmeasuredoutside air temperature and will be overridden on a DHW demand.

• CAUTION: Proper polarity must be maintained on the low voltage red and white wires to avoid possible damage to the OCP and TPI Control.

3.3 Single Zone Heating, Indirect Water Heater w/TPI Control

120 VACPowerSupply

SystemCirculator


Green

White

Black

Yellow

SystemCirculator



L2

L1

PowerSupply

120/60/1

Brown

To IQ Oil Boiler

Control

DHWCirculator

White

DHWDemand

Violet

Thermostat 1

1 2 3 T T 1 2 3 4

Terminal 2 is 24V-AC PositiveTerminal 3 is 24V-Gnd

Left “T” is 24V-AC Positive

Alliance SLIndirect


24Vpump/TT

DHWCirculator White


10/14/1331


Explanation:

This arrangement allows the boiler to respond to a space heating demand as well as a 120V DHW demand via the Alliance TPI Control.


• Whenthe“2C”parameter is set to “dh”, the boiler will prioritize the DHW demand.


• CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and TPI Control.

3.4 Single Zone Heating, IWH w/Aquastat Control

120 VACPowerSupply

SystemCirculator


Green

White

Black

Yellow

SystemCirculator



L2

L1

PowerSupply

120/60/1

Brown

To IQ Oil Boiler

Control

DHWCirculator

White

DHWDemand

Violet

Thermostat 1

1 2 3 T T 1 2 3 4


Left “T” is 24V-AC Positive

DHWCirculator White



10/14/1332


Explanation:


• ThezonevalveendswitcheswiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellowsystemcirculator 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.

• TheIQBoilerControlparameter“dh” must be set to “dh”. Priority time and DHW Setpoint can be set on the IQ Outdoor Reset Option Card.



3.5 Zone Valves Heating, IWH w/TPI Control, 2 Circulators

120 VACPowerSupply

SystemCirculator


Green

White

Black

Yellow

SystemCirculator



L2

L1

PowerSupply

120/60/1

Brown

To IQ Oil Boiler

Control

DHWCirculator

White

DHWDemand

VioletDHW

Circulator White

1 2 3 T T 1 2 3 4

Terminal 2 is 24V-AC PositiveTerminal 3 is 24V-GndLeft “T” is 24V-AC Positive

Alliance SLIndirect


Thermostat 3Thermostat 2Thermostat 1

24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2



damaged equipment

24Vpump/TT


10/14/1333

3.0 IQ Gas Boiler Control System, IQ Reset Option Card

3.6 Zone Valves Heating, IWH w/TPI Control, 1 Circulator, No Priority

120 VACPowerSupply

SystemCirculator


Green

White

Black

Yellow

SystemCirculator



L2

L1

PowerSupply

120/60/1

Brown

To IQ Oil Boiler

Control

DHWCirculator

White

DHWDemand

VioletDHW

Circulator White

1 2 3 T T 1 2 3 4


Thermostat 3Thermostat 2Thermostat 1

24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2



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.

• ThezonevalveendswitcheswiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellowsystemcirculator wire. The Aquastat control connected wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the red DHW/Zone circulator wire.

• TheIQBoilerControlparameter“dh” must be set to “dh”. Priority time and DHW Setpoint can be set on the IQ Outdoor Reset Option Card




10/14/1334


3.7 Zone Valve Heating, IWH w/TPI Control, 1 Circulator, No Priority

1 2 3 T T 1 2 3 4

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1


24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2



damaged equipment

SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown

Alliance SLIndirect


24Vpump/TT




Terminal 3 is Grounded 24V-AC ComTerminal 4 is 24V-AC Positive

Explanation:


• ThezonevalveendswitcheswiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellowsystemcirculator wire. The DHW zone valve end switch switch wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the violet DHW/Zone circulator wire.

• TheIQBoilerControlparameter“2C” must be set to “dh”. Priority time and DHW setpoint can be set on the IQ Outdoor Reset Option Card




10/14/1335


3.8 Zone Valve Heating, IWH w/Aquastat, 1 Circulator, No Priority

1 2 3 T T 1 2 3 4

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1


24V ac Positive

40VA Transformer

Field Installed

Power Supply

120/60/1

L1L2



damaged equipment

SystemCirculator


DHWCirculator

White

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown



Terminal 3 is Grounded 24V-AC ComTerminal 4 is 24V-AC Positive


Explanation:


• ThezonevalveendswitcheswiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellowsystemcirculator wire. The DHW zone valve end switch wired to the IQ Outdoor Reset Option Card “3” & “4” terminals provides a DHW demand and energizes the violet DHW/Zone circulator wire.

• TheIQBoilerControlparameter“2C” must be set to “dh”. Priority time and DHW setpoint can be set on the IQ Outdoor Reset Option Card




10/14/1336


3.9 Zone Valve Control Heating, IWH w/TPI Control, 2 Circulators

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1System

Circulator


DHWCirculator

White

DHWDemand

To IQ Oil Boiler

Control

Brown

1 2 3 T T 1 2 3 4




END SWITCH

ZVC 403-4



1 2 3 4 1 2 3 41 2 3 4

ZONE 3PRIORITY

ONOFF

LEDINDICATORS



FUSE5 AMP

PO

WE

R IN


PUMP END SWITCH

N/O COM N/CX X

Alliance SLIndirect


Thermostat 3

Terminal 2 is 24V-ac PositiveTerminal 3 is 24V-Gnd

Left “T” is 24V-ac Positive

24Vpump/TT

DHWCirculator

Violet

White

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.

• TheheatingzonevalvecontrolendswitchwiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellow 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.

• TheIQBoilerControlparameter“2C” must be set to “dh”. Priority time and DHW setpoint can be set on the IQ Outdoor Reset Option Card.


• CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and the TPI control.


10/14/1337


3.10 Zone Valve Control Heating, IWH w/Aquastat, 2 Circulators

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1System

Circulator


DHWCirculator

White

DHWDemand

To IQ Oil Boiler

Control

Brown

1 2 3 T T 1 2 3 4




END SWITCH

ZVC 403-4



1 2 3 4 1 2 3 41 2 3 4

ZONE 3PRIORITY

ONOFF

LEDINDICATORS



FUSE5 AMP

PO

WE

R IN


PUMP END SWITCH

N/O COM N/CX X

Thermostat 3


Left “T” is 24V-AC PositiveRight “T” is 24V-AC Gnd

DHWCirculator

Violet

White


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.

• TheheatingzonevalvecontrolendswitchwiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellow system circulator wire. The 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.

• TheIQBoilerControlparameter“2C” must be set to “dh”. Priority time and DHW setpoint can be set on the IQ Outdoor Reset Option Card.




10/14/1338


3.11 Zone Valve Control Heating, IWH w/TPI Control, 1 Circulator

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1System

Circulator


DHWCirculator

White

DHWDemand

To IQ Oil Boiler

Control

Brown

1 2 3 T T 1 2 3 4




END SWITCH

ZVC 403-4



1 2 3 4 1 2 3 41 2 3 4

ZONE 3PRIORITY

ONOFF

LEDINDICATORS



FUSE5 AMP

PO

WE

R IN


PUMP END SWITCH

N/O COM N/CX X



Violet

White

Alliance SLIndirect


24Vpump/TT


Explanation:

This arrangement allows the use of a zone valve control for heat and hot water, a TPI control and a single circulator with DHW priority.

• Aheatingorhotwaterdemandisprovidedtothe“T-T”terminalsontheIQBoilerControlbythezonevalveendswitchwhich engages the yellow system circulator wire.




10/14/1339


3.12 Zone Valve Control Heating and IWH w/Aquastat Control, 1 Circulator

120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1System

Circulator


DHWCirculator

White

DHWDemand

To IQ Oil Boiler

Control

Brown

1 2 3 T T 1 2 3 4




END SWITCH

ZVC 403-4



1 2 3 4 1 2 3 41 2 3 4

ZONE 3PRIORITY

ONOFF

LEDINDICATORS



FUSE5 AMP

PO

WE

R IN


PUMP END SWITCH

N/O COM N/CX X



Violet

WhiteCaution: 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 IWH Aquastat

Control

Explanation:

This arrangement allows the use of a zone valve control for heat and hot water, an Aquastat control and a single circulator with DHW priority.

• Aheatingorhotwaterdemandisprovidedtothe“T-T”terminalsontheIQboilerbythezonevalveendswitchwhichenergizes the yellow system circulator wire.



10/14/1340


3.13 Zone Switching Relay, IWH w/TPI Control

1 2 3 T T 1 2 3 4



120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1


DHWCirculator

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown


ISOLATEDEND

SWITCH

SR 503-4


INDICATORS

POWER

ZONE 1

ZONE 2

ZONE 3

FUSE5

AMP

X X R W R W R W


THERMOSTATS (24VAC)

FUSE5

AMP

FUSE5

AMP

FUSE5

AMP

ZONE 3PRIORITY

ONOFF

24 VAC

COM

INPUT120 VAC




Alliance SLIndirectWater Heater

TPI Control

24Vpump/TT


Remove jumper

between ZC & ZR

NOTESupply power to Zone Switching Relay

from same discount as boiler

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.

• TheheatingzonevalveendswitcheswiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellow 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.

• TheIQBoilerControlparameter“2C” must be set to “dh”. Priority time and DHW setpoint can be set on the IQ Outdoor reset option card.


• CAUTION: Proper polarity must be maintained on the red and white wires to avoid possible damage to the OCP and the TPI Control.


10/14/1341


3.14 Zone Switching Relay, IWH w/Aquastat Control

1 2 3 T T 1 2 3 4



120 VACPowerSupply


Green

White

Black



L2

L1

PowerSupply

120/60/1


DHWCirculator

DHWDemand

Violet

To IQ Oil Boiler

Control

Brown


ISOLATEDEND

SWITCH

SR 503-4


INDICATORS

POWER

ZONE 1

ZONE 2

ZONE 3

FUSE5

AMP

X X R W R W R W


THERMOSTATS (24VAC)

FUSE5

AMP

FUSE5

AMP

FUSE5

AMP

ZONE 3PRIORITY

ONOFF

24 VAC

COM

INPUT120 VAC





Remove jumper

between ZC & ZR


NOTESupply power to Zone Switching Relay

from same discount as boiler

Explanation:

This arrangement allows the boiler to respond to a space heating demand utilizing a zone switching relay and a DHW demand from an Aquastat control.

• TheheatingzonevalveendswitcheswiredtotheOCP“TT”terminalsprovideaheatingdemandandenergizestheyellow 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.

• TheIQBoilerControlparameter“2C” must be set to “dh”. Priority time and DHW setpoint can be set on the IQ Outdoor reset option card.




10/14/1342

Notes


10/14/1343

Notes


10/14/1344

www.usboiler.net

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