1.A flow switch is used to guarantee flow through the boiler before allowing it to fire. The flow switch must be installed at the boiler outlet.
2.Remove the jumper wire from these terminals, and connect these terminals to the normally open contacts on the flow switch (FIG. 5-3).
System supply sensor
1.By installing the system supply sensor into the supply of the primary loop, the temperature of the primary supply can be controlled. The SMART SYSTEM control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply temperature to the set point (if the outlet sensor control is currently selected). If it is desired to control the system return temperature, then program the SMART SYSTEM control to use the inlet sensor as the controlling sensor. See the Outdoor Knight Boiler Service Manual for instructions on how to use the inlet sensor as the controlling sensor. When the inlet sensor is programmed as the controlling sensor, it is vital that the SYSTEM SUPPLY sensor be installed. DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO THE SYSTEM RETURN.
2.The TST2032 sensor provided with the boiler must be used for the system sensor.
3.Connect these terminals to the system supply sensor (FIG. 5-3).
Boiler management system
The United States Energy Policy and Conservation Act requires residential heating boilers with inputs less than 300,000 Btu/hr be equipped with a control that automatically adjusts boiler water temperature in relation to heat demand. An external control may be connected to control the firing rate or the set point of the boiler provided that either an external energy management system is installed that reduces the boiler water temperature as the heating load decreases, the boiler is not used for any space heating, or the boiler is part of a modular or multiple boiler system having a total input of 300,000 Btu/hr or greater.
1.An external control may be connected to control either the firing rate or the set point of the boiler. If the external control uses a set of contacts to enable the boiler, connect the contacts to the Heat/Loop Demand 1 terminals. Otherwise, the SMART SYSTEM control will be enabled by the 0-10V signal.
2.Make sure the (-) terminal is connected to the (-) or common output terminal of the external control, and
the 0 - 10 Vdc terminal is connected to the 0 - 10 Vdc terminal of the external control. Make sure the (-) voltage is not below ground.
The SMART SYSTEM control closes a set of dry contacts whenever the burner is running. This is typically used by Building Management Systems to verify that the boiler is
responding to a call for heat.
Alarm contacts
The SMART SYSTEM control closes another set of contacts whenever the boiler is locked out or the power is turned off. This can be used to turn on an alarm, or signal a Building Management System that the boiler is down.
Wiring of the cascade
When wiring the boilers for Cascade operation, select one boiler as the Leader boiler. The remaining boilers will be designated as Members. See page 38 “Configuration of the Cascade” for a detailed explanation of this procedure.
Connect the system supply sensor and outdoor air sensor (if used) to the Leader boiler. For the Cascade system to work properly the system supply sensor must be installed. The location of the system supply sensor should be downstream of the boiler connections in the main system loop (FIG.’s 3-5, 3-7, and 3-9). The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor (see FIG. 5-3). The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade.
The outdoor air sensor should be wired to the Low Voltage Connection Board at the terminals marked for the outdoor air sensor (FIG. 5-3). The Leader control will calculate the water temperature set point based on the programmed reset curve parameters.
If a Thermostat, Zone Control enable output, or Building Management System enable output is available, it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked for one of the heat/ loop demands 1-3 (FIG. 5-3). If the boilers are to run continuously, connect a jumper wire between the R and W terminals for the heat/loop demand input. This will initiate a call for heat on the Cascade.
Communication between the Leader boiler and the Member boilers is accomplished by using shielded, 2-wire twisted pair communication cable. Connect one of the twisted pair wires to Cascade terminal A on each of the Low Voltage Connection boards, and the other wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards. Connect the shield wires to one of the shield terminals on the Low Voltage Connection Boards (FIG. 5-3). If more than two boilers are on the Cascade, daisy chain the wiring from the Cascade terminals on the second boiler to the Cascade terminals on the third boiler, then from the third to the forth, and so on. The connections between boilers can be made in any order, regardless of the addresses of the boilers. Try to keep each cable as short as possible.
30 
