SECTION 1Introduction ............................................................. 2

SECTION 2Components and Accessories ................................ 3

SECTION 3Operation ................................................................ 5

SECTION 4Installation ............................................................... 9

SECTION 5Wiring Connections ................................................. 9

SECTION 6Programming......................................................... 10

SECTION 7Programmable Variables....................................... 12

SECTION 8Troubleshooting .................................................... 20

MAIN BOARD JUMPER CONFIGURATION ....... 23

MAIN BOARD CALIBRATION...............................25

DIAGRAMS ........................................................... 27

SAMPLE RESET SCHEDULE ............................. 28

OWNER RESET SCHEDULE ............................... 29

S1000B WORKSHEET ......................................... 30

S1000B PROGRAM SETTINGS .......................... 31

RS1000B-120582-0285

MODEL S1000BPROGRAMMABLE

CONTROLLERINSTALLATION &

OPERATIONMANUAL

260 North Elm Street 7555 Tranmere DriveWestfield, MA 01085

�Mississauga, Ontario L5S 1L4 Canada

Phone: (413) 568-9571 Phone: (905) 670-5888Fax: (413) 568-9613 Fax: (905) 670-5782

2

The new S1000B programmable controller for RBI’smodular boiler systems brings a new level of automationand sophistication to today’s requirements for efficientand comfortable hydronic heating systems. Along withthe popular demands for lower fuel consumption, limitedmaintenance, and longer equipment life, have come theincreasing demands for controllers that can monitor andcontrol boilers from remote locations, as well aselectronically communicate with other components of abuilding’s mechanical system. The development ofmicro-processor technology in recent years has allowedRBI to create the intelligent S1000B Controller to fulfillthese requests. RBI is now able to offer a sophisticatedboiler room controller to satisfy building owners, utilitycompanies, and system designers.

NOTE:1) The S1000B IS NOT A SAFETY CONTROL. It is up

to the system designer to determine componentsrequired of the system to be designed. Allapplicable safety devices required need to beinstalled. Follow all building and safety coderequirements during installation.

2) The S1000B does not provide motor overloadprotection for the circulator pump motors.

3) All connections to Inputs AI-1–AI-16 and OutputRelays K1–K16 must be Class 2.

4) The leads to the circulator pump relays and thecontrollers power must be the ONLY leads to goinside the controller that carry more than 24 volts.

5) All conductor to panel must be copper, all wiresto relays must be 18AWG, MTW, rated for 105°C,600V.

The controller has 16 output relays which can be usedto control multi-stage heating boilers, domestic hot waterboilers, motorized valves, combustion air dampers anddraft inducers. It has event programming for alarms, adata logging feature to allow you to review what boilershave been on, when and what the temperatures andsetpoints were, etc. It can be monitored from a remotelocation using the optional modem and software tocheck on the current operation, download the data log,or even change the settings, all protected by passwordagainst unauthorized access.

The S1000B has a user friendly menu. Features include:

1. Support for up to eight 2-stage, four 4-stage, orsixteen single stage heating boilers.

2. Automatic lead boiler rotation.

3. Viewable accumulated boiler runtimes.

SECTION 1: INTRODUCTION

4. A new 12 bit analog to digital converter for greatertemperature/sensor accuracy.

5. Ability to use a standard 10K thermistor B,Z, andthe ability to calibrate the sensor inputs to aprecision resistor.

6. Support for motorized valves without spring returns(NO & NC) contacts.

7. The ability to disable the password and silencethe keyclick.

8. Allow the disabling of the S1000B remotely with aset of open or closed contacts (selectable).

9. Permanent storage of setup values. No lost setupvalues if panel is OFF for an extended time.

10. Induced draft fan setup now allows the proof timeto be changed from 0 to 4 minutes like thecombustion air damper.

11. Two circulator pumps are now supported. Thesecond may be used as a backup or rotated usingup to a 240 hour schedule. Both pumps havededicated relays.

12. Optional on-board modem for security.

13. Maintenance friendly, removable panels, plug interminal blocks, polarized plugs and jacks, andreplacable/swappable relays.

14. Integrated 24VAC, (2) wire transformer withresettable fuses. If an acidental short occurs, wait3-5 minutes and the fuse is restored.

15. Relay status indicator LEDs for all relays includingcirculator pumps.

16. Backlit LCD or a vacuum display.

17. Termination jumpers for a RS485 bus connection.

18. Boilers are staged one at a time using the DELAYTIME at startup regardless of how many are needed(prevents low line gas pressure problems if all boilerswere called at once).

19. Allow an override of the outdoor reset function andthe high/low mode proportional band when acontact is closed on Analog Input 9. The overrideuses the FIXED mode setpoint.

3

20. Allow field programming of the S1000B. Using aserial port and setting a jumper on the main board,an updated program may be downloaded into theS1000B in the field. Updated programs can beposted on Web sites for downloading or emailed.

21. A diagnostic screen has been added to allow all (16)analog inputs to be viewed as their respective countvalues. For a 12 bit analog to digital converter(A/D), this means count values ranging from 0 to4095. Entering the diagnostic screen may be doneby holding the DOWN key, down during a power up.To exit the screen, press the ENTER key. See thetroubleshooting section: Situation: One or morecomponents being controlled by the S1000B(boilers, dampers, fans, alarms, etc.) are notoperating as they should, or the controller haslocked up.

22. New menu item in the RUN screen. By holding downthe UP or DOWN keys while in the RUN screen,additional information on the status of the systemcan be viewed. The bottom line is a scrolling menuwhere the first item is the boiler firing status, thenext is the system status, the next lines are primarilyruntime hours for devices.

23. Detection added for open and shorted temperaturesensors or their connections on status screen,Line 4.

SECTION 2: COMPONENTS AND ACCESSORIES

The basic controller package includes the S1000Bcontroller, the supply water and outside air temperaturesensors with hardware, a 24VAC transformer to powerthe S1000B, a thermal well and programming CD.

Optional accessories include a domestic hot watersensor, with hardware, the communications package,consisting of a modem and cables to connect a phoneline to the S1000B, PC software and instructions. Ageneral purpose DPDT relay for operating 115VAC or230VAC loads from the low voltage output relays on theS1000B, and a transformer which will power up to 3 ofthe general purpose relays are also available.

The embedded modem complies with Part 68 of FCCrules.

Registration # LVRPHL-25931-MD-E.Ringer Equivalence: 0.6B.Required Connection: RJ-11.

The parts are identified as follows:

The S1000B CONTROL PANEL includes:part number component

70-9017 S1000B Controller

40-1008 Supply water sensor with mountinghardware

40-1009 Thermal well for immersion sensors

40-1007 Outside air temperature sensor withmounting hardware

82-0285 Installation and Operation Manual

82-0287 Programming Examples Manual

Optional Accessories:

part number component

40-1008 Domestic hot water sensor withmounting hardware

15-0125 General purpose DPDT relay

15-0009 Transformer - will handle up to 3 ofthe above relays

4

OPTIONAL COMPONENTS AND ACCESSORIESSTANDARD COMPONENTS AND ACCESSORIES

S1000BController70-9017

Outside AirTemperatureSensor withMountingHardware40-1007

DHW Sensorwith MountingHardware40-1008

GeneralPurposeRelay15-0125

Transformer(will power upto 3 of theabove Relays)15-0009

ProgrammingExamplesManual82-0287

I/O Manual(presentlyutilizing)82-0285

Supply WaterSensorwith MountingHardware40-1008

Thermal Wellfor ImmersionSensors40-1009

5

SECTION 3: OPERATION

After the circulator pump relay is energized the controllerwaits 10 seconds to see if the FPS (Flow Prove Switch)closes. The FPS is connected to Input #4 (AI-4). If theFPS does close within that 10 second period, theheating boilers will be enabled and will fire as needed.

If the FPS remains open at the end of the 10 secondperiod, the circulator pump relay will be de-energized(if no 2nd Circulator pump is installed), an alarm (a high-pitched beeping) will sound, and the following errormessage will be displayed:

SYSTEM ERRORNO FLOW SENSED

If a second circulator pump is installed, the 2nd pumpwill be energized and the trial for flow will be attemptedagain. If the 2nd pump fails the alarm will sound.

Every ten minutes thereafter the controller will energizethe circulator pump relay again and wait 10 seconds tosee if the FPS will close. If it does close, the errormessage will be removed, the alarm will stop, andnormal operation will resume.

When the controller is switched back to DISABLEDmode all boilers are turned off and the circulator pumprelay is de-energized.

If the FPS opens during ENABLED mode the controllerwill keep the circulator pump relay energized, along withany boilers that may be on, and it will wait 10 secondsto see if the FPS closes again. If a 2nd circulator pumpis installed, the 2nd pump will energize, and if the FPScloses, the 1st pump will de-energize. A “PUMP RETRY”will be entered in the LOG.

If the FPS remains open at the end of the 10 secondperiod all heating boilers will be turned off, the errormessage will be displayed, and the alarm will start. TheDHW boilers will remain energized.

Every ten minutes thereafter the controller will energizethe circulator pump relay again and wait 10 seconds tosee if the FPS will close. If it does close, the errormessage will be removed, the alarm will be turned off,and normal operation will resume.

Also, if circulator pump rotation is enabled with 2 pumps,the pumps will rotate every interval set by the rotationinterval. The default interval is 5 days.

The first time you turn on the S1000B controller, youmay want to hold down the ESC key on thetouchpad while you switch the controller on. This willautomatically load the default values into the controller.By reloading the default values you make sure there areno random values in memory to interfere with theoperation of the controller. It is not as important to dothis on the S1000B, since the setup values arepermanently stored in memory. The S1000B is shippedwith the default factory settings. For reference there isa list of the default values at the end of Section 7.

The S1000B controller is password protected againstunauthorized tampering. The controller will normally bein PROTECTED MODE, which means the passwordmust be entered before any changes can be made tothe settings. The default password is “AAAAAA”. Thepassword must be entered into the controller on initialstart-up, and any time after that when there has beenno activity on the touchpad for 60 minutes. Thepassword may be left as is, or changed to any desired6-character combination of letters and numbers. It mayalso be disabled using the SCREEN OPTIONS menu.

The only thing that is not protected from being changedis the OVERRIDE SETBACK feature. If one of theNIGHT SETBACK features is active, and has loweredthe setpoint to conserve energy, an occupant may usethis to bring the setpoint back up to its normal level fora period of 2 hours. If a setback is active, a ‘b’ isdisplayed after the SET(b) on the status screen.

Be aware, many of the S1000B’s settings can only bechanged when in the DISABLED run state. Themsessage “DISABLE TO CHANGE” will appear if anitem can not be changed while the S1000B is in the“ENABLED” run state.

When the S1000B controller has been installed and allthe boilers, sensors and other components have beenproperly wired, it will operate as follows:

Definitions of variables in capital letters are included inSection 7 Programmable Variables.

CIRCULATOR PUMP AND FLOW PROOF SWITCH:The circulator pump relay will not be energized whenin DISABLED ( inactive ) mode.

When the controller is switched to ENABLED (run)mode, the circulator pump relay is controlled by twothings: the OA RESET setting and the OA (outside air)temperature. If OA RESET is OFF, the relay will beenergized regardless of the OA temperature. If the OARESET is ON the circulator pump relay will not beenergized if the OA temperature is above the OASETPOINT. If the OA temperature is equal to or belowthe OA SETPOINT the relay will be energized.

6

FIRING MODE:The firing mode can be set for automatic rotation usingFIRST ON, FIRST OFF (FOFO), or for manual rotationusing LAST ON, FIRST OFF (LOFO). When usingLOFO the LEAD boiler can be changed manually orautomatically after a specified amount of boiler runtime.

The FIRING MODE specified applies to all boilers,heating and DHW, EXCEPT when multi-stage heatingboilers are being used and FIRING MODE is set toFOFO. In this case the DHW boilers will run in LOFOmode.

The heating boilers and DHW boilers are treated asseparate groups and, for each group, the controllerkeeps track of the next boiler to turn on and to turn off.

OPERATING MODE AND HEATING SETPOINT:The operating mode can be specified as either FIXEDor HIGH/LOW.

When in FIXED mode the heating water setpoint isequal to the value specified for the variable FIXEDMODE WATER TEMP.

When in HIGH/LOW mode the heating water setpointis a linear function of OA. The line is determined by thetwo points (WATER TEMP @ high OA, High OA TEMP)and (WATER TEMP @ low OA, Low OA TEMP). Asample of this is shown in Section 9.

The setpoint can be temporarily raised due to the ShortCycle Prevention Subroutine, which is explained at theend of this section.

FIXED MODE HEATING:Once in ENABLED mode, with the circulator pumprunning and the FPS closed, the heating boilers will becycled on and off in response to the heating watersupply temperature.

The setpoint will be kept at the constant value of theFIXED MODE WATER TEMP, unless it is temporarilyraised as part of the Short Cycle Prevention Subroutine,which is explained at the end of this section.

The OA temperature will have no effect on the heatingsetpoint.

If the OA RESET is ON, all heating boilers and thecirculator pump will be turned off if the OA temperaturerises above the OA SETPOINT, whether or not the watertemperature is at setpoint. If the OA RESET is OFF, thecirculator pump will remain on, and the heating boilerswill continue to operate as needed, even when the OAtemperature is above the OA SETPOINT.

The boilers will be turned on and off in the sequencedetermined by the FIRING MODE.

Each boiler will fire when called, after a delay equal tothe setting of the DELAY TIME variable.

Boilers will fire as the heating water supply temperaturedrops below the setpoint, in increments of one boiler perTEMP DIFF (temperature differential).

As the heating water supply temperature rises eachboiler will be turned off at a temperature equal to theheating water supply temperature they turned on at, plusthe temperature differential.

HI/LOW MODE HEATING:Once in ENABLED mode, with the circulator pumprunning and the FPS closed, the heating boilers will becycled on and off in response to the heating watersupply temperature.

The setpoint will be determined by the high and lowconditions specified, and the OA temperature, unless itis temporarily raised as part of the Short Cycle PreventionSubroutine, which is explained at the end of this section.

Once the OA temperature rises above the OASETPOINT, there is a minimum off time of 5 minutesbefore the S1000B will try to call for heat, even if theOA temperature falls below the OA SETPOINT.

If DHW OVERRIDE is ON, then the boilers will fire to theFIXED mode setpoint regardless if the OA RESET isON and the OA temp is above the OA setpoint, or if theHI/LOW proportional band is in effect. With DHWOVERRIDE ON, a closed contact on Analog Input 9will force the heating boilers to the FIXED mode setpoint.

If the OA RESET is OFF, the circulator pump andheating boilers will continue to operate when the OAtemperature is above the OA SETPOINT.

The boilers will be turned on and off in the sequencedetermined by the FIRING MODE. Each boiler will firewhen called, after a delay equal to the setting of theDELAY TIME variable. Boilers will fire as the heatingwater supply temperature drops below the setpoint, inincrements of one boiler per TEMP DIFF (temperaturedifferential). As the heating water supply temperaturerises each boiler will be turned off at a temperatureequal to the heating water supply temperature theyturned on at, plus the TEMP DIFF.

DOMESTIC HOT WATER BOILERS:Once in ENABLED mode the DHW boilers will be cycledon and off in response to the DHW water supplytemperature. The setpoint will be kept at the constantvalue of the DHW SETPOINT. The Shor t CyclePrevention Subroutine does not apply to the setpoint ofthe DHW boilers.

The OA temperature has no effect on the DHW setpoint.

The status of the circulator pump relay and the FPS hasno effect on the operation of the DHW boilers.

The DHW boilers will be turned on and off in thesequence determined by the FIRING MODE, EXCEPTwhen multi-stage heating boilers are being used andFIRING MODE is set to FOFO. In this case the DHWboilers will run in LOFO mode.

7

Each boiler will fire when called, after a delay equal tothe setting of the DELAY TIME variable.

Boilers will fire as the DHW water supply temperaturedrops below the setpoint, in increments of one boiler perHW TEMP DIFF.

As the DHW water supply temperature rises each boilerwill be turned off at a temperature equal to the DHWwater supply temperature they turned on at, plus the HWTEMP DIFF.

HEAT AND DHW:In those applications where there are both heating anddomestic hot water boilers, each group of boilers willoperate independently of the others, except in thefollowing cases:

If all the heating boilers are on, and the temperaturecontinues to drop, and if the DHW water temperatureis above the LOW SHARE LIMIT, then the first motorizedvalve will open up to let the first group of DHW boilersact as additional heating boilers. The first motorizedvalve will close when either of two things happen. It willclose if the DHW water temperature drops below theLOW SHARE LIMIT. It will also close when the heatingsupply water temperature rises to the point whereadditional boilers are no longer needed to help theheating boilers (based on the the TEMP DIFF value).

In some installations, there may be a second group ofDHW boilers and a second motorized valve. TheS1000B will not control this second group; they needto be controlled independently. However, if the firstmotorized valve is open and if the temperature of theheating supply water continues to drop, then the secondmotorized valve will be opened to let the second groupof DHW boilers help the heating boilers.

The second motorized valve can also operateindependantly of the first motorized valve. The secondmotorized valve will open if all the heating boilers areon, the heating supply water temperature continues todrop and the DHW temperature is below the LOWSHARE LIMIT. It will close when the heating supplywater temperature rises to the point where additionalboilers are no longer needed to help the heating boilers(based on the the TEMP DIFF value).

NIGHT SETBACK:There are 4 different sections of NIGHT SETBACK,each completely independent of the others.

If at any time there is more than one section active,whichever is calling for the greater amount of setbackwill control.

If a section of NIGHT SETBACK is active, when the clocktime reaches 30 minutes before the programmed STARTTIME the controller will begin to ramp the setpoint downso that when the START TIME is reached the setpointwill have been reduced by SETBACK DEGREES.

When the clock time reaches 60 minutes before theprogrammed END TIME the controller will begin to rampthe setpoint back up, so that when the END TIME isreached the setpoint will be back to its normal value.

The NIGHT SETBACK can be over-ridden for a periodof 2 hours by using the OVERRIDE SETBACK feature.

HOLIDAY SETBACK:There is only one section of HOLIDAY SETBACK, and itis always active in the sense that it cannot be turned off.However, once the END time is past it is, in effect, inactive.

It can be programmed for the start time and end time.Each time includes the month, day of the month, yearand time of day.

The HOLIDAY SETBACK has the same 30 minuteramp-down to the start, and 60 minute ramp-up to theend as the NIGHT SETBACK sections do.

If the HOLIDAY SETBACK and one or more of theNIGHT SETBACK sections are both active, whicheveris calling for the greatest amount of setback will control.

SHORT CYCLE PREVENTION SUBROUTINE:Short Cycle Prevention Subroutine applies to theheating boilers only.

Its purpose is to compensate for increased demandby temporarily increasing the setpoint so that moreboilers will remain on to bring the water temperature upmore quickly.

The controller records the time when a heating boiler isturned off. When a heating boiler is disengaged, and thenanother boiler is called to fire within 120 seconds, thecontrol enters the Short Cycle Prevention Subroutine.

The controller will check to see if the call for anotherboiler is due to a drop in outside temperature whichraised the setpoint (if in HI/LOW mode), or whether itwas a drop in heating supply water temperature.

If due to a drop in outside temperature the controller willcheck to see whether or not it was a temporary changeby internally recording the temperature, waiting 30seconds, and checking the temperature again to see if ithas gone back up or not. If the temperature has not goneback up, the controller will raise the setpoint by one-halfthe TEMP DIFF (temperature differential). This will stayin effect until this elevated setpoint has been satisfiedand all the boilers have been turned off, at which pointthe setpoint will be reset to its regular value.

If due to a drop in the heating supply water temperaturethe controller will check to see if it was only a transientchange by internally recording the supply watertemperature, waiting 15 seconds and checking it againto see if it has gone back up or not. If the temperaturehas not gone back up, the controller will temporarilyraise the setpoint by one-half the TEMP DIFF until allthe heating boilers have been turned off.

8

At any given time the setpoint can only be incrementedtwice, for a total increase of one TEMP DIFF.

EVENT PROGRAMMING:Events increase the flexibility of the S1000B controller,allowing it to be customized for individual boiler roomconfigurations. Events can be used to control additionalcombustion air dampers, trigger alarms, etc. based onsensed occurrences (temperature or switches), time, orthe number of boilers on.

The controller can be programmed for a maximum of16 sets of events (1 set for each output). Prior toprogramming an event, the input that will be used mustbe configured on the SENSOR TYPE screen. This isnecessary so that during the event programming thecorrect input choices will be present as options.

Events are programmed in pairs, sharing the same input.The first event of the pair causes a change in the outputstate when the event conditions are met (for example,closes output relay 13 when the water temperature getsdown to 170° F, 77° C). The second event of the pairshould be set up to set the output back to the originalstate when those conditions no longer apply (in thisexample it would open output relay 13 when the watertemperature rises above 170° F, 77° C).

Events must be planned carefully to avoid overlapping,or contradictory output conditions.

When using multi-stage heating boilers, the RELAYOUTPUTS available for EVENT programming are limitedto non-boiler designated outputs.

Detailed examples of how to program events arecovered in the separate manual on S1000BProgramming Examples.

NOTE: When Event entries are ON, they are activeeven when the S1000B is in DISABLED Mode.

AUX FUNCTIONS:The auxiliary functions include: remote enable/disable,combustion air dampers, induced draft fans, spillswitches, and multiple circulator pumps.

When you program the controller for a combustion airdamper you tell it which of the output relays is used toenergize the damper. When the controller is ENABLEDthe output relay for the combustion air damper isimmediately energized, and the controller waits thespecified proof time to see if the prove switch for thedamper has closed. The prove switch must be wired toinput connection #5 (JP2) or, if there is no prove switch,a jumper wire must be placed across these terminals.

After the specified proof time, if the prove switch hasclosed the controller will permit boilers to be energizedas needed. If the controller sees an open circuit acrossinput connection # 5 (AI-5) after the specified proof timeit will lock out all heating and DHW boilers, beginsounding an alarm, and display the following errormessage:

SYSTEM ERROR COMBUST AIR DAMPER

The controller must then be switched back to DISABLEDmode and the problem corrected before the boilers willbe allowed to operate.

If boilers are in operation when the combustion airdamper prove switch opens, the controller will wait thespecified proof time to see if it is a transient condition.If the switch is still open after the specified proof timethe controller shuts down all heating and DHW boilers,sounds an alarm and displays the above error message.

The induced draft fan is programmed the same as thecombustion air damper, except the prove switch, or ajumper wire, is connected to input connection # 6. Theoperation is also the same as for the combustion airdamper, but the error message will be:

SYSTEM ERROR INDUCED DRAFT FAN

When programming the controller for spill switches anoutput relay is not specified, but the rest of it is similarto the programming for the combustion air damper andthe induced draft fan. The spill switches are wired up inseries and hooked up to input connection #7.

The difference in operation from the other two auxfunctions is that there is no proof time delay. If a spillswitch has been specified, and the controller sees anopen circuit to input connection #7, either on start upor during operation, the controller will immediately lockout all heating and DHW boilers, sound an alarm anddisplay the following error message:

SYSTEM ERROR SPILL SWITCH

If 2 circulator pumps are available, the S1000B can beused to allow the 2nd pump to perform a backup role. Itmay also be used to rotate the pumps to keep the 2nd(or standby pump) from ceasing up or just to provide aneven wear of the pumps.

The last pump change can be viewed in the VIEW LOGmenu. The next rotation can be calculated from this timebased on ROTATE HOURS.

If a pump fails due to flow, and the 2nd pump producesflow, no SYSTEM ERROR will be displayed. Instead, aPUMP RETRY entry will be set in the LOG. Use VIEWLOG to look for a PUMP RETRY log entry.

9

SECTION 4: INSTALLATION

Step 1: Install the water temperature sensor in thesupply line to the heating system. Follow the installationinstructions packaged with the sensor. Install the sensordownstream of all boiler modules, a minimum of 5 ft,1.5 m from the connection of the last module.

If your system has domestic hot water boilers, install theDHW temperature sensor in the tank, again followingthe instructions with the sensor.

Step 2: Install the air temperature sensor outside wherethe sun's effects will be minimized, preferably on thenorth wall of the building. The sensor must not bemounted anywhere where electrical interference ispresent, such as: radio antennas, building powertransformer, outside air conditioner, vents, etc. Followthe installation instructions packaged with the sensor.

Step 3: Mount the S1000B control panel.

NOTE: All wiring must be installed in accordancewith the latest release of the National Electric Code,and any additional state and local codes.

Step 4: Connect 120VAC line voltage to the controllerusing the wire nuts provided.

Step 5: Install wiring to all sensors. Shielded wiring isstrongly recommended for all installations, and is requiredwhen the run is over 25 ft, 7.6 m long. In addition, sensorwiring must not be run in the same conduit as any otherwiring. Remember, when using shielded wire, ground theshield only at the controller, since the shield becomesan extension of the controllers enclosure. Grounding theshield at the sensor will cause a ground loop. See Section5 for details on connections to the controller.

NOTE: Sensor circuitry is susceptible to electricalinterference. Sensor wiring must not be run in thesame conduit as any other wiring. Erratic operationmay result.

NOTE: Do not allow 24VAC or 120VAC power leadsto touch any of the sensor input terminals. Applyinga power source at these connections will damagethe controller.

Step 6: Install wiring from the circulator pump to thecirculator pump relay on the bottom of the relay card.This relay is rated for 3 amps, at a maximum of 120VAC.If the circulator pump operates on higher voltage ordraws a higher current (including inrush) you must usea separate contactor to energize the pump, and use thecirculator pump relay to power the contactor.

NOTE: The S1000B does not provide motor overloadprotection for the circulator pump motors.

NOTE: The leads to the circulator pump relay andthe controllers power must be the ONLY leads to goinside the controller that carry more than 24 volts.

Step 7: Install wiring from the boiler modules to theoutput relays. Refer to Section 5 for details of how theboiler modules should be connected.

SECTION 5: WIRING CONNECTIONS

Refer to the diagrams in Section 8 for the location ofthe input connections and output relays.

INPUT CONNECTIONS (Class 2 Connections Only): AI-1 Outdoor air temp sensor

(Input 1)

AI-2 Heating supply water (Input 2) temp sensor

AI-3 DHW supply water temp (Input 3) sensor

AI-4 Circulator pump flow prove switch - (Input 4) if there is no flow prove switch

you must put a jumper wire acrossthese terminals

AI-5 Combustion air damper prove(Input 5) switch - you should only put a

jumper wire across these terminalsif you have specified a combustionair damper, and there is nocombustion air damper prove switch

AI-6 Induced draft fan prove switch - (Input 6) you should only put a jumper

wire across these terminals if youhave specified an induced draft fan,and there is no induced draft fanprove switch

AI-7 (Input 7) Spill switch

AI-8 (Input 8) Remote disable

AI-9 thru The remaining input AI-16 connections may be used

for event programming

10

SECTION 6: PROGRAMMING

The S1000B has a 4-line by twenty-character displaypanel, and a 4-key touch pad. The keys are UP (an UParrow), DOWN (a DOWN arrow), ESC (Escape), andENTER. The UP and DOWN keys let you move thecursor (a blinking rectangle) up and down the screen,and also change the displayed values of settings. TheENTER key lets you go into the next level of the menu.It also lets you accept the displayed setting for aparameter. The ESC key lets you go back up throughthe higher levels of the menu.

The first screen you’ll see, the TITLE SCREEN, has thecursor beside the line “ACCESS CTRL PARAMS”, andlooks like...

When you touch the ENTER key the display changesto the PASSWORD SCREEN... This screen may not bedisplayed if the SKIP PASSWORD is ON in theSCREEN OPTIONS menu.

At this point you may use the arrow keys to display thedesired value for the first character of the password,then hit ENTER to select that value for that character.Remember that the default password is “AAAAAA”.When the complete password has been entered andaccepted the panel will change to the MAIN SCREEN...

The MAIN SCREEN lets you select between RUN,SETUP, VIEW LOG and MANUAL OVERRIDE. Youmake a selection by using the arrow keys to place theblinking cursor next to your choice and hitting ENTER.

When you select RUN the display will show you the RUNMODE SCREEN...

where you can use the arrow keys to toggle betweenDISABLED and ENABLED modes.

The DISABLED mode is a standby or inactive mode,and the ENABLED mode is the run mode, so you shouldnot select ENABLED until you are ready to have theS1000B start operating boilers.

OUTPUT CONNECTIONS (Class 2 Connections Only)(K1 through K16)These are all normally open contacts, rated for 5 amps.Each of them will close when the controller wants toactivate the device connected to it. These devices canbe heating boilers, DHW boilers, motorized valves,combustion air dampers, induced draft fans, or alarms.

NOTE: The output relays are rated for 24VAC. Do nothook up any circuits which will carry line voltage tothese relays. All conductors running to K1 - K16should be run outside of standoffs to providesegregation from control board.

The order in which these devices are connected on thecontroller is important. Boilers are always connected first,starting with output K1 (Relay1). If multi-stage heatingboilers are in use the stages must be connected to theS1000B in the correct sequential order. For example, ifusing two stage boilers, the first stage of the first boilershould be connected to RELAY K1, and the second stageof the first boiler should be connected to RELAY K2. Next,the first stage of the second boiler should be connectedto RELAY K3 and the second stage of the second boilershould be connected to RELAY K4. If the installation hasboth heating and Domestic Hot Water boilers, the heatingboilers are always hooked up first, followed immediatelyby the DHW boilers. If there is a motorized valve, it alwaysgoes on the last output relay K16 (Relay16). If there aretwo motorized valves the first always goes on output relayK16, and the second goes on output relay K15.

11

When you select either ENABLED or DISABLED bypressing the ENTER key, the display will drop down tothe OPERATION SCREEN...

This is the screen which will be displayed during normaloperations.

From the OPERATION SCREEN, when you press theESC key, the display will switch back to the MAINSCREEN. There you can select SETUP, and begin toprogram the controller for your specific system.

As you program the controller, you should refer toSection 7 on PROGRAMMABLE VARIABLES whichdefines all of the terms you will see on the display panel.

The basic process of how to program the S1000B isstraightforward. The arrow keys are used to move thecursor to different lines on the display, and to vary thedisplayed values. The ENTER key is used to assigndisplayed values to the variables and to move intoother screens. The ESC key is used to “back out”through the screens.

If additional details are desired for the programmingprocess there are detailed instructions on how to programthe controller in the manual, “S1000B PROGRAMMABLECONTROLLER - PROGRAMMING EXAMPLES” whichwas also shipped with the S1000B Controller.

In addition, the following is a guide for how theSENSORS should be programmed:

Sensor #1: Should always be set to “TYPEZ”

Sensor #2: Should always be set to “TYPEZ”

Sensor #3: Should be set as “TYPEZ” if your installationhas domestic hot water boilers; otherwise it should beset to “NONE”

Sensor #4: Should always be set to “ON/OFF”. If yourinstallation does not have a flow prove switch ajumper wire must be put across the connections forthis sensor (Input 4)

Sensor #5: If your installation does not have anycombustion air dampers to be controlled by the S1000Bthis should be set to “NONE”. If there are anycombustion air dampers this should be set to “ON/OFF”.If you have combustion air dampers but do not have aprove switch to verify that the dampers have opened,you must put a jumper wire across terminals (Input 5).

Sensor #6: If your installation does not have any draftinducers to be controlled by the S1000B this should be setto “NONE”. If there are draft inducers this should be setto “ON/OFF”. If you have draft inducers but do not have aprove switch to verify that the inducer fans are operating,you must put a jumper wire across terminals (Input 6).

Sensor #7: If your installation does not have any spillswitches connected into the S1000B this should be setto “NONE”. If there will be spill switches hooked into theS1000B this must be set to “ON/OFF”.

Sensors #8 - #16: Unless any of these inputs are usedfor event programming they should be set to “NONE”.If they are used for event programming the specificsensor must be set to “ON/OFF” or the programmedevent will not operate.

NOTE: The S1000B has added the ability to usea 10K type Z sensor. These are shipped withthe S1000B. If TE6000 (1K) sensors are to be used,SIP1/SIP2 on the main controller board must be 1KSIPs.

12

SECTION 7: PROGRAMMABLE VARIABLES

Following is a list of the variables which are currently included in the program.

DESCRIPTION ASIT APPEARS ON ALLOWABLEDISPLAY SCREEN RANGE DEFINITION & COMMENTS

UNDER SETUP, BOILERS:# OF BOILERS 1 - 16 The number of heating boilers.

STGS PER BOILERS 1, 2, 4 This is the number of stages that each HEATING BOILER has.

LEAD BOILER # 1 - 16 If in LOFO (last on, first off) mode this specifies which boiler comes(Heating Boilers Only) on first every time. If in FOFO (first on,first off) mode it specifies

which boiler comes on for initial start-up only.

TEMP DIFF 1° F - 10° F This is the temperature difference between heating boilers. When the-17° C - -12°C heating supply water temperature drops to one TEMP DIFF below

setpoint the first heating boiler will fire, when it drops to twice theTEMP DIFF below setpoint the second heating boiler will fire, etc.

SYSTEM HIGH LIMIT 180° F - 250° F If the water temperature gets to within 2% of the selected value, the82° C - 121° C controller will begin turning off boilers. If the water temperature

exceeds the selected value, the controller will display a warningmessage and will begin to shut down any boilers that may still be on.

UNDER SETUP, DOMESTIC HOT WATER:DHW BOILERS 0 - 15 The number of Domestic Hot Water boilers. These are the boilers

associated with the first motorized valve.

DHW SETPOINT 140° F - 220° F This is the control temperature for the DHW boilers. It does not vary60° C - 104° C with the outdoor air temperature.

HW TEMP DIFF 1° F - 10° F This is the temperature difference between DHW boilers. When the- 17° C - -12° C DHW supply water temperature drops to one HW TEMP DIFF below

setpoint the first DHW boiler will fire, when it drops to twice the HWTEMP DIFF the second DHW boiler will fire, etc.

APPLY TO HEAT 0 - 60 min If all the heating boilers are on, and the heating water temperaturecontinues to fall, and if the DHW temp is above the LOW SHARELIMIT, this is the time delay, in minutes, before the motorized valveopens to let the DHW boilers help with the heating load.

LOW SHARE LIMIT 160° F - 200° F This is the DHW temperature below which the first motorized valve is71° C - 93° C not allowed to open.

BYPASS VALVES 0 - 2 These are the motorized valves in the system which allow the DHWboilers to temporarily help meet the heating load. If “1” is selected itwill be controlled through output relay K16, and will be the valveassociated with the parameters defined above. If “2” is selected thesecond motorized valve will be controlled through output relay K15.This second group of DHW boilers can be used as a supplementalheat source but will not be controlled by the S1000B.

13

DESCRIPTION ASIT APPEARS ON ALLOWABLEDISPLAY SCREEN RANGE DEFINITION & COMMENTS

UNDER SETUP, SENSORS:TYPE TE6000 The “SENSOR #” at the top of the screen refers to the input

ON/OFF connection number; sensor # 1 is the input connectionTYPEZ #1 (AI-1) and so on. Sensors #1, #2 and #3 should be set toNONE “TE6000” whenever there are, respectively, an outdoor air sensor, a

heating supply water temp sensor, and a DHW supply water tempsensor. Sensor # 4 should always be set to “ON/OFF”.

The S1000B has added the ability to use a 10K type Z sensor. Ifthese sensors are to be used, SIP1 and SIP2 on the main controllerboard must be replaced with 10K SIPS. The sensor would then beset to TYPEZ.

If there is a combustion air damper prove switch sensor #5 should beset to “ON/OFF”, otherwise it should be set to “NONE”. If there is aninduced draft fan prove switch sensor #6 should be set to “ON/OFF”,otherwise it should be set to “NONE”. If a spill switch is being usedwith the controller sensor #7 should be set to “ON/OFF”, otherwise itshould be set to “NONE”.

All other sensors should be set to “NONE” unless they are beingused as inputs for the event programming.

CALIBRATE OHMS Setting this value to YES calculates an offset for drift of the on-boardmeasuring circuits. Prior to setting this value to YES, a precision 1K(TE6000) resistor needs to be substituted for the sensor. The trim inohms, the controller calculated, will then be displayed. If this isacceptable, press the ENTER key, if not, press the ESCAPE key. Fora TYPEZ sensor, the precision resistor will be 10K. If the ENTER keyis pressed, the channel is now calibrated for operation with this sensor.

UNDER SETUP, OPERATING MODE:OPERATING MODE FIXED In Fixed mode the heating water setpoint does not vary with outside

HIGH/LOW air temperature. In High/Low (otherwise known as the Outdoor ResetCurve) mode it does. Boiler water temp is set to a proportional bandof outdoor air temperatures.

DHW OVERRIDE HI/LO YES A ‘YES’ here will override HI/LO mode with a closed contact onNO Analog Input 9. The OUTDOOR reset temperature will also be

overridden and fire the boilers to the FIXED mode setpoint. Thepurpose of this, is to allow DHW to place a call for heat when theheating water is used to heat DHW, even though the system is off(outdoor reset) or water temp is between the HIGH OUTSIDE AIRTEMP and the LOW OUTSIDE AIR TEMP.A ‘NO’ disables the DHW override feature.

UNDER SETUP, SETPOINTS:OA SETPOINT 40° F - 100° F This is the outdoor temperature above which the heating boilers will(“System On” setting) 4° C - 38° C not operate, unless the OA RESET is OFF.

OA RESET ON When this is ON, the circulator pump relay will be de-energized and(Enables / Disables OFF none of the heating boilers will operate when the outdoor

“System On” setting) temperature is above the OA set-point. If it is OFF then the heatingboilers are still allowed to operate when the outdoor air temperatureis above the OA SETPOINT. The DHW boilers are independent ofOA temperature and the OA RESET. See: DHW OVERRIDE HI/LO.

14

DESCRIPTION ASIT APPEARS ON ALLOWABLEDISPLAY SCREEN RANGE DEFINITION & COMMENTS

FIXED MODE 60° F - 245° F Fixed mode is the constant heating water setpoint, regardless WATER TEMP 16° C - 118° C of the outdoor air temperature. See: DHW OVERRIDE HI/LO.

WATER TEMP 60° F - 150° F This is the heating water setpoint at the HIGH OA TEMP. (at high OA) 16° C - 66° C

HIGH OA TEMP 50° F - 90° F This is the outdoor air temperature at which the above water temp10° C - 32° C setting is valid.

WATER TEMP 70° F - 245° F This is the heating water setpoint at the low OA setpoint.(at low OA) 21° C - 118° C

LOW OA TEMP -35° F - 40° F This is the low OA setpoint.-37° C - 4° C

UNDER SETUP, FIRING MODE:FIRING MODE FOFO First on, first off - also called Auto-rotation. And LOFO, last ON,

LOFO first off. This applies to DHW as well as heating boilers.

LOFO OPTIONSROTATION TIME OFF, 24, This is the time interval that LEAD BOILER will automatically change

48, 72, 96 to the BOILER with the least runtime.

UNDER SETUP, DELAY TIME:DELAY TIME 0 - 5 min This is the amount of time delay between the call for a boiler and the

actual firing of that boiler. If the conditions calling for the boiler nolonger exist at the end of the delay time the boiler does not fire. Thetime can be set in 10 second increments.

UNDER SETUP, MIN ON/OFF TIMES:MIN ON TIME 0 - 5 min This is the minimum length of time that a boiler will remain on after it

is started. It can be set anywhere between 0 and 5 minutes inincrements of one second.

MIN OFF TIME 0 - 5 min This is the minimum length of time that a boiler will remain off after itis shut down. It can be set anywhere between 0 and 5 minutes inincrements of one second.

UNDER SETUP, SETBACK SETTINGS, NIGHT SETBACK:SETBACK ENTRY 1 - 4 This specifies which of the 4 different night setbacks is being defined

by the following six variables.

ENTRY IS ON Turns the specified night setback on or off.OFF

SETBACK 0° F - 50° F The amount that the heating setpoint is lowered during the specified-18° C - 10° C night setback.

START DAY The day(s) of the week when the specified night setback is active.

(start) TIME The time of day when the setpoint has been reduced the specifiedamount. Thirty (30) minutes prior to this time the controller beginsramping the setpoint down.

END DAY The day(s) of the week the specified night setback ends.

(end) TIME The time of day when the setpoint is back to its normal value. Sixty (60)minutes prior to this time the controller begins to ramp the setpoint back up.

15

DESCRIPTION ASIT APPEARS ON ALLOWABLEDISPLAY SCREEN RANGE DEFINITION & COMMENTS

UNDER SETUP, SETBACK SETTINGS, HOLIDAY SETBACK:START MONTH JAN - DEC The month when the holiday setback begins.

START DAY 1 - 31 The day of the month when the holiday setback begins.

START YEAR 2000 - 2100 The year when the holiday setback begins.

ST TIME The time of day when the holiday setback begins.

END MONTH JAN - DEC The month when the holiday setback ends.

END DAY 1 - 31 The day of the month when the holiday setback ends.

END YEAR 2000 - 2100 The year when the holiday setback ends.

END TIME The time of day when the holiday setback ends.

SETBACK 0° F - 50° F The amount the setpoint is lowered during the holiday setbackDEGREES -18° C - 10° C period.

UNDER SETUP, EVENTS:EVENT ENTRY 1 - 32 This is the number of the event to be programmed.

EVENT IS ON When this is ON the specified EVENT is active, when it is OFFOFF it is inactive. This can be used to program EVENTS ahead of time,

then activate them when needed.

EVENT TYPE SENSED Select SENSED if the event trigger is either a temperature or aTIMED switch opening or closing. Select TIMED if the event trigger is to beCOUNT a date and time. Select COUNT if the event trigger will be the

number of heating boilers + DHW boilers on.

EVENT INPUT 1 - 16 This is the number of the input connection which will be used for theevent being programmed.

EV CONDITION <, <=, = The event will be triggered when this condition, applied to the Input>=, >, <> Value, is TRUE.

BOILER COUNT 1 - 16 Number of boilers.

INPUT VALUE - 50° F to +250° F This is the level, or state, at which a sensed event is triggered.-46° C to +121° C

ONOFF

EVENT MONTH JAN - DEC The month in which a timed event is triggered.

EVENT DAY 1 - 31 The day of the month in which a timed event is triggered.

EV TIME The time of day, in hours and minutes when a timed event is triggered.

EVENT OUTPUT 1 - 16 The output relay which will be controlled as a result of an event occurring.

OUTPUT STATE AUTO The output relay specified in the event output will be switched to thisON state when the event is triggered.OFF

16

DESCRIPTION ASIT APPEARS ON ALLOWABLEDISPLAY SCREEN RANGE DEFINITION & COMMENTS

UNDER SETUP, FAHRENHEIT/CELSIUS: TEMPERATURE This allows the temperature values to be displayed as either MODE Fahrenheit or Celsius. Toggling from one to the other will automatically

convert all temperature settings, and temperature differentials.

UNDER SETUP, SCREEN OPTIONS:BLANKING ON When “BLANKING ON” is selected the display will go blank after a

period of 5 minutes when none of the keys are being pressed. Assoon as a key is struck the display will become active again. If“BLANKING OFF” is selected the display will always remain active.

KEY CLICK OFF When “KEY CLICK” is ON, an audible chirp will be heard every timea key is pressed. When OFF, no sound is heard.

SKIP PASSWORD ON When “SKIP PASSWORD” is ON, no password will be displayedprior to the opening menu, security for changing the controller’ssettings is disabled. When OFF, normal security is enabled.

BRIGHTNESS 25, 50, 75, 100% Brightness controls the brightness when using the flourescentdisplay. Four levels of brightness from 25% to 100%.

UNDER SETUP, CLEAR DATA LOG:CLEAR DATA LOG NO The data log automatically records each event that occurs, such as

YES when a boiler turns on or off. When the data log is full it beginsautomatically to write over the earliest entry, so there is normally noreason to select “YES”.

UNDER SETUP, DEMAND LIMIT:DEMAND LIMIT 0 - 100% This is the percent of the total number of heating boilers that can be

on at any given time. The controller rounds the percentage to thenearest whole boiler.

UNDER SETUP, AUX FUNCTIONS REMOTE DISABLE:REMOTE DISABLE YES Setting this value to YES allows a building management system to

shut down the controllers operation, by placing the unit in DISABLEmode with either an open or a closed condition on INPUT #8 (AI-8).

DISABLE ON CLOSED DISABLE ON if set to CLOSED, will disable the S1000B when AI-8’sOPEN inputs are shorted (closed relay contact). When set to OPEN, no

connection on AI-8 will cause the S1000B to be disabled.

NOTE: This should be set to YES only after all programming iscomplete, since this relinquishes control to the remote system.

17

DESCRIPTION ASIT APPEARS ON ALLOWABLEDISPLAY SCREEN RANGE DEFINITION & COMMENTS

UNDER SETUP, AUX FUNCTIONS COMBUSTION AIR DAMPER:IN USE? YES This tells the controller whether or not there is a combustion air

NO damper. If there is, then before any boiler can be activated, thecontroller will close the output relay which has been assigned as therelay controlling the damper, then wait for for the PROOF TIMEsetting to see if the prove switch (input connection #5) is closed. Ifthe switch has not closed after that time an error message isdisplayed, and no boilers are allowed to be turned on.

PROOF TIME 0 - 4 min This is the length of time that the combustion air damper has toprove to allow boilers to be turned on. It can be set anywherebetween 0 and 4 minutes in increments of one second.

OUTPUT RELAY # 1 - 16 This specifies which output relay will be used to turn on thecombustion air damper.

UNDER SETUP, AUX FUNCTIONS, INDUCED DRAFT FAN:IN USE? YES This tells the controller whether or not there is an induced draft fan.

NO If there is, then before any boiler can be activated the controller willclose the output relay which has been assigned as the relaycontrolling the fan, then wait for 10 seconds to see if the prove switch(input connection #6) is closed. If the switch has not closed after thattime an error message is displayed, and no boilers are allowed to beturned on.

OUTPUT RELAY # 1 - 16 This specifies which output relay will be used to turn on the induceddraft fan.

PROOF TIME 0 - 4 min This is the length of time that the induced draft fan has toprove before boilers are allowed to be turned on. It can be setanywhere between 0 and 4 minutes in increments of one second.

UNDER SETUP, AUX FUNCTIONS, SPILL SWITCH:IN USE? YES This tells the controller whether or not there is a spill switch being

NO used. If there is, at any time when boilers are being operated, if thespill switch circuit connected to input connection #7 opens, thecontroller will immediately shut down ALL boilers and display asystem error message. When that happens the problem must becorrected and the controller reset before any boilers can beoperated again.

The controller is reset by switching to DISABLED mode, fixing theproblem, then switching back to ENABLED mode.

18

DESCRIPTION ASIT APPEARS ON ALLOWABLEDISPLAY SCREEN RANGE DEFINITION & COMMENTS

UNDER SETUP, AUX FUNCTIONS, PUMP OPTIONS: NUMBER OF PUMPS 1 If only one pump, no rotation is allowed, nor is backup function.

2 Allows the 2nd pump to kick in if no flow is sensed. Also allows the(2) pumps to rotate if the following: “ROTATE PUMPS” is set to YES.

ROTATE PUMPS YES Pumps are rotated every ROTATE HOURS, and also performbackup.NO Second pump is just used as a backup if there is a second pump.

ROTATE HOURS 1 - 240 If ROTATE PUMPS = YES, then pumps are rotated after this timeinterval.

RESET COUNTER NO Selecting YES, allows the resetting of both pump runtime counters.

UNDER SETUP, PASSWORD: OLD This is the password currently active. It has 6-characters, each of

which can be any letter or number. The default password is“AAAAAA”. The arrow keys are used to scroll through the choices foreach character, and the ENTER key is used to select a value.

NEW This is what you want the new password to be.

ACCEPT PASSWORD To accept the new password hit ENTER, otherwise hit ESC.

UNITID This the identification for this unit when on a network (RS485).

UNDER SETUP, VIEW RUNTIME:Selecting this option will display the accumulated RUNTIME of eachstage that can be scrolled through.

RESET? NO Selecting YES will reset the runtime of the current stage to 0.YES

UNDER SETUP, SYSTEM CLOCK:TIME These are used to set the internal clock for use with night andDAY OF WEEK holiday setbacks, and for EVENTS that are time-activated.MONTHDAYYEAR

COMMUNICATIONS: MODEM INSTALLED NO If the 2400 BAUD modem is installed this will be YES.

RS232 INSTALLED NO RS232 is always installed, so this value is always YES, unless the RS485 INSTALLED NO RS485 is selected as YES. The port can be used as an RS232 or

RS485 port.

UNDER MANUAL OVERRIDE:

( mode ) AUTO The relay # at the top of the screen refers to the output relay forON which the setting is being chosen. The “AUTO” mode allow theOFF specified relay to be controlled by the S1000B, to be turned on or off

as needed. The “ON” and “OFF” selections are overrides to thecontroller. This allows each of the 16 output relays to be locked out.

19

PASSWORD ------------------------ AAAAAA

id: UNITID

# OF BOILERS --------------------- 1

STGS PER BOILER -------------- 1

LEAD BOILER # ------------------- 1

TEMP DIFF ------------------------- 4

SYS HI LIMIT ----------------------- 240

DHW BOILERS -------------------- 0

DHW SETPOINT ------------------ 200

HW TEMP DIFF -------------------- 4

APPLY TO HEAT ------------------- 10

LO SHARE LIM -------------------- 160

BYPASS VALVES ------------------ 0

SENSOR #1 thruthru SENSOR #3---------------- TYPE Z

SENSOR #4 ------------------------ ON/OFF

SENSOR #5thru SENSOR #16 -------------- NONE

OPERATING MODE -------------- FIXED

DHW OVERRIDE --------------- NO

OA SETPOINT --------------------- 68

OA RESET -------------------------- OFF

FIXED MODEWATER TEMP ------------------- 160

WATER TEMP ---------------------- 140AT HIGH OA TEMP------------- 70

WATER TEMP ---------------------- 180AT LO OA TEMP ---------------- 10

FIRING MODE --------------------- FOFO

ROTATION TIME ------------------- OFF

DELAY TIME ------------------------ 30 SEC

MIN ON TIME ---------------------- 2 MIN

MIN OFF TIME --------------------- 1 MIN

Default Values

Following is a complete list of the default values which will be assigned when the controller is turned on while theESC key is held down.

NOTE: Manual Override settings remainenabled even in Disabled Mode

NIGHT SETBACK#1 thru #4:ENTRY IS ------------------------- OFFSETBACK IS --------------------- 20

HOLIDAY SETBACKSTART ----------------------------- JAN 1, 2005END -------------------------------- JAN 1, 2005

EVENTS (all 32) ------------------- OFF

TEMP MODE ----------------------- Fahrenheit

SCREEN BLANKING ------------- OFF

PASSWORD ENABLED -- OFF

KEYCLICK ENABLED ----------- OFF

BRIGHTNESS ---------------------- 25%

DEMAND LIMIT -------------------- 100

REMOTE ENABLE ---------------- DISABLED

COMBUSTION AIRDAMPER:IN USE? --------------------------- NOOUTPUT RELAY # ------------- 13

TIME -------------------------------- 2 MINUTES

INDUCED DRAFT FAN:IN USE? --------------------------- NOOUTPUT RELAY # ------------- 14

TIME -------------------------------- 2 MINUTES

SPILL SWITCH:IN USE? --------------------------- NO

PUMP OPTIONS NUMBER OF PUMPS --------- 1 ROTATE PUMPS ---------------- NO ROTATE HOURS ---------------- 120 (5 day) RESET COUNTER ------------- NO

MANUAL OVERRIDE:RELAYS #1 thru 16------------- AUTO

LOG ENTRIES- -------------------- 0

COMMUNICATIONS: MODEM INSTALLED --------- YES RS232 INSTALLED ------------- YES RS485 INSTALLED ------------- NO

20

SECTION 8: TROUBLESHOOTING

Situation: Nothing happens when the power switchis turned on.1. Check to make sure the primary side of the S1000B

transformer has line voltage to it, and that thesecondary side of the 2-wire transformer is correctlyconnected to the controller

2. If the secondary wires are correctly connected tothe controller, and have voltage (24VAC betweenterminals 1 and 2 on J9), return the controller forreplacement.

3. If an audible beep is heard on powerup, but there isno display, check the cable connection from thedisplay to the controller board. The audible beepimplies that the control board is somewhat functional.

NOTE: The S1000B is equiped with resetable fuseson the power circuit. Wiring power incorrectly to theunit will cause these fuses to open. Once theincorrect wiring is removed, the fuses should resetthemselves in less than 5 minutes.

NOTE: Incorrect wiring of the controller is in directviolation of the warning label on the controller door,and the warning instructions in this manual, and willvoid the warranty.

Situation: Unable to change the # of Boilers in theBOILERS menu.Ensure that the controller is in the DISABLED mode. Thenumber of boilers can not be changed when operatingthe S1000B in the RUN mode. Also, the sensors or theirvalues may not be changed when in the RUN mode. A“DISABLE TO CHANGE” message will be displayed ifthe S1000B is running.

Situation: Unable to change the SENSORS in theSENSORS menu.Ensure that the controller is in the DISABLED mode.Thesensors or their values may not be changed when inthe RUN mode. Also, the number of boilers can not bechanged when operating the S1000B in the RUN mode.

Situation: The OPERATION SCREEN displays 251degrees for a temperature and when in the STATUSSCREEN, an OPEN or SHORTED SENSOR messageis displayed on line 4 .If using the TE6000, then there is an open circuit to theinput connection for that sensor. If using the TYPEZ,thenthere is a short circuit to the input connection for thatsensor. A jumper wire may have been inadvertentlyconnected across the input connections, check to makesure the sensor is properly connected to the correctinput connection. If it is, the sensor is defective andshould be replaced.

Situation: The OPERATION SCREEN displays -51degrees for a temperature and when in the STATUSSCREEN, an OPEN or SHORTED SENSOR isdisplayed on line 4.If using the TE6000, then there is a short circuit to theinput connection for that sensor. If using the TYPEZ,thenthere is a open circuit to the input connection for thatsensor. Either a jumper wire was inadvertently placedacross the input connections, or the sensor is defectiveand should be replaced.

Situation: The display is displaying randomcharacters or the control keeps resetting.There may exist a grounding problem with the controlleror one of the boilers, pumps, contactors or other devicesconnected to it. If all grounding is correct, there may bean issue with radiated or induced electrical noise(interference). This may be caused by arcs across acontactor's contacts when starting a pump motor or alarge electrical load.

Attempt to identify the noise source:1.) What is the controller trying to do at the

time of the failure?2.) Is the controller on the same circuit as the

noise source? (Controller should haveisolated power.)

3.) Is the controller located near an electricallynoisey source? (It may need to be moved)

4.) Are shielded sensor wires used? (Ensurethe shields are grounded only at the controller.)

5.) Are any sensors located near a radiotransmitting antenna, CB, Ham, Cell tower,etc?(Move sensor)

Situation: There are no heating boilers on.1. Check the settings for OA SETPOINT and OA

RESET; if the outdoor air temperature is above theOA SETPOINT and OA RESET is on, the circulatorpump relay will be locked out and the heating boilerswill not fire.

2. Check the manual override settings. Relays must beset to AUTO for the controller to be able to bringthem on in response to a call for heat.

3. Ensure that a remote building management systemis not contolling the S1000B using the REMOTEDISABLE feature.

Situation: There are no boilers on at all, heating orDHW.1. Check to make sure the controller is in “ENABLED”

mode.2. Check to make sure the demand limit is set to 100%.3. Check the manual override settings. Relays must be

set to AUTO for the controller to be able to bringthem on in response to a need for heat.

21

Situation: You get the error message for theCombustion Air Damper.1. The prove switch for the combustion air damper is

not closing. Check to make sure the dampers arebeing controlled by the output relay you specifiedwhen programming for the damper. Also check tomake sure the prove switch is working properly.

2. There is no prove switch. If there is no prove switchyou must put a jumper wire across input connection#5 (AI-5).

3. There is no prove switch, and you did put a jumperwire across input connection #5. If this has been doneand you continue to get the error message, check theTYPE specified for sensor #5. If it is set to NONE thecontroller will not recognize the closed circuit.

4. Check that the prove time is set long enough forthe prove switch to be made.

Situation: You get the error message for the InducedDraft Fan.1. The prove switch for the induced draft fan is not

closing. Check to make sure the fan is beingcontrolled by the output relay you specified whenprogramming for the damper. Also check to makesure the prove switch is working properly.

2. There is no prove switch. If there is no prove switchyou must put a jumper wire across input connection#6 (AI-6).

3. There is no prove switch, and you did put a jumperwire across input connection #6. If this has been doneand you continue to get the error message, checkthe TYPE specified for sensor #6. If it is set to NONEthe controller will not recognize the closed circuit.

4. Check that the induced draft fan prove time is setlong enough for the prove switch to be made.

Situation: You get the error message for the SpillSwitch.1. There is an open circuit to input connection # 7.

Check through the circuit to locate the breakand correct it.

2. Check to make sure the TYPE specified for inputconnection #7 is ON/OFF.

3. If you have confirmed that the circuit to inputconnection #7 is CLOSED and the TYPE is correct,but the error message continues, return thecontroller for replacement.

Situation: You get the error message - NO FLOWSENSED.1. The controller does not sense a closed circuit at

input connection # 4. Check to make sure the circuitfor the circulator pump is correct, that the pump isbeing energized, and that the flow prove switch isworking properly.

2. If there is no flow prove switch, check to make surethat a jumper wire has been connected to inputconnection # 4.

3. Check to make sure the TYPE specified for inputconnection # 4 is ON/OFF.

4. Ensure that the proper number of circulator pumpsis set under AUX FUNCTIONS.

Situation: An event which was programmedactivated as intended, but did not de-activate.Events need to be programmed in pairs. Refer toSection 3 in this manual, at the part which covers eventprogramming, for details.

Situation: One or more components beingcontrolled by the S1000B (boilers, dampers, fans,alarms, etc.) are not operating as they should, or thecontroller has locked up.If you have checked through all of the previous situationsand found that everything is correctly wired, and thesensor TYPE has been properly set, then you need toreview the programming.

Use the S1000B worksheet to review all the programmedvalues in the controller. Then check to make sure theconnections to the controller match what has beenprogrammed. If there has been a conflict in the valuesprogrammed (for example, output relay #1 is controllingthe first heating boiler, but the combustion air damperoutput relay was inadvertently set to #1 instead of #13)the controller can act erratically or lock up completely.

If the controller has locked up and does not respond tothe keypad, turn it off. Then turn it back on, quickly enterthe password, and switch the controller to DISABLEDmode. Then review the programming and eliminate anyprogramming conflicts.

First, before continuing, enter the DISABLED mode.Ifone of the Analog Inputs is suspected of a problem, theinput may be checked by using the Analog Inputdiagnostic screen. If the DOWN key is held down duringa power up, the 16 Analog Input channels are displayed.Counts of greater than 4090 are associated with anOPEN input. Counts of 10 or less are considered ashorted input. Counts of approximately 2048 areconsidered 77° F, 25° C (10K ohms if using TypeZsensors). By unplugging each channel, the input canbe checked for counts greater than 4090. Then, eachinput can be shorted and checked for less than 10. If a10K (10K SIP pack) or 1K (1K SIP pack) resistor isavailable, it may be substituted for the sensor andchecked for a count of approx 2048. Calibration valuesare not applied to the count values so counts areapproximate. Count values are raw. Starting in the upperleft corner of the display is channel 1, and each channelfollows as if reading a book. Channel 16 is in the lowerright corner. This screen may be cleared by pressingthe ENTER key.

If this still does not work, turn the control off. Whileholding the ESC key down, power the S1000B on. Thiswill load the default settings. Do this as a last resort. TheS1000B will then need to be reprogrammed.

22

Situation: You have forgotten the password, or thecontroller has locked up, and after turning it off andthen back on, you cannot enter the correctpassword fast enough to prevent it from lockingback up again.As a last resort, you can turn the controller off, thendepress and hold the ESC key while turning it back on.This will load all the default values, including the defaultpassword “AAAAAA”. The controller will then need to bereprogrammed with the settings that apply to yourinstallation. This will be easier if you have a filled-outworksheet with all the correct settings.

Situation: Irratic behavior when sensing inputs.The S1000B’s analog inputs do not sense poweredcircuits. A dry set of contacts (not powered contactssuch as: 24VAC or 120VAC) is required to act as ashort or open circuit on the analog inputs. Placing avoltage such as 24VAC or 120VAC could damage theinputs and void the warranty. The controller supplies it’sown voltage/current, and during normal operation,voltages can be measured:

An OPEN Analog Input = approximately 5 VDC.A SHORTED Analog Input = approximately 0 VDC.

Situation: Display contains 16 values where noneare greater than 4096 and less than 0.If the DOWN key is held down on a power up, the 16Analog Input channels are displayed. Counts of greaterthan 4090 are associated with an OPEN input. Counts of10 or less are considered a shorted input. Counts ofapproximately 2045 are considered 77° F, 25° C. Thisscreen may be cleared by pressing the ENTER key.This screen is a diagnostic screen for checking thefunctionality/performance of the Analog Inputs. You mayenter it for troubleshooting, and to see if an event input ora dedicated input is functioning. The count values do notcontain the calibration offsets, but are raw A/D counts.

Situation: You can’t ENABLE or DISABLE theS1000B or the ENABLE/DISABLE function does notappear to work properly.When using the REMOTE ENABLE/DISABLE option, theENABLE/DISABLE feature relinquishes control to theremote building management system. In order to getcontrol back, you will need to temporarily disable theREMOTE DISABLE feature under the AUX FUNCTIONSmenu in SETUP. Remember to re-enable this option afteryou make your changes.

Also, the panel may be in the OA reset state. If this isthe case, the boilers will not fire unless the DHWoverride is in effect and a AI9 is shorted by a closedcontact, or OA RESET is turned OFF.

Situation: The S1000B is beeping, but still running.When the panel is beeping you need to go to theSTATUS screen to view the condition. You may alsoview the log. Since the panel is still running, it is mostlikely that a sensor has failed. This will be indicated inthe status screen as a SENSOR SHORTED orSENSOR OPEN. Temperature sensor inputs are theonly inputs that are checked for an open or a short.View your temperatures in the status screen window,and if one or more indicate -51° F, -46° C or 251° F,122° C the sensor(s) are suspect. These temperaturesindicate an out of range sensor. Also, the alarm beepingwill sound if your temperatures are above or below the250° F, 121° C and -50° F, -46° C temperature range.And finally, make sure the sensors and their respectiveterminal block are connected and seated properly inthe main board.

Situation: My stainless steel panel is messy looking.We have found that WHITE BOARD CLEANER workswonders and is readily available around the office.Sanford EXPO, for dry erase boards work exceptionallywell. Be carfull not to get it in the display or the keypad,since in it's liquid form, it is conductive. If someinadvertantly gets into the panel it will cause atemporary lack of display or keypad functionality until itevaporates, but should not harm the S1000B.

23

S1000B MAIN BOARD JUMPER CONFIGURATION

Jumper blocks are assigned to Channels: 5, 6, 7, 8.These are fixed for use as voltage dividers ( used forthermistors, RTDs, and with switches). These arefactory set.

J7 & J8 are used to enablethe RS485 termination.

Shown withouttermination (RS232).

Enable termination RS485:

J2 used to select eitherRS232 port or RS485 port.Shown in RS232 normalrun position.

Communication in RS485mode, normal run:

Reset Switch

J4 shunt used to downloadnew firmware. Shown in

RS232 normal run position.

To program flash memoryset jumper to (RS232):

24

S1000B MAIN BOARD SIP PACKS

The main control board is pictured here as an aide in identifying the SIP packs. These packs are used to allow(2) different types of sensors. The S1000B is shipped with a 10K thermistor and requires the use of a 10K SIPpack. This is the normal ship condition from the factory and changing the SIP pack is not neccessary.

NOTE: If the 1K SIP pack is used along with a 1K, TE6000 sensor, the type of sensor under the SENSORS menuwill need to be changed to TE6000. The default values are for the 10K thermistor (TYPEZ) and will be loadedif the ESC key is held down during a power-up. Also, calibration is required for all sensor inputs using the 1KSIP pack. See: S1000B Main Board Calibration.

Sip 1 is used to form a voltage divider for the first 8 sensors(Analog Inputs 1-8). Two values are supported, a 10K and a 1KSIP pack. Care should be taken when removing and inserting theSIP pack. A round dot on the SIP designates pin 1 and should bealigned with the pin 1 designator on the circuit board. Removal isaccomplished by gently lifting one side, and then the other side sothat a rocking type motion is achieved. Look for the markings onthe SIP pack: 103 or 102. The 103 = 10K and the 102 = 1K.

OBSERVE POLARITY WHEN RE-INSERTING.

SIP pack 2, PIN 1designator

Sip 2 is used to form avoltage divider for thesensors, This SIP pack isused for Analog Inputs 9through 16. The SIPpack may be differentfrom SIP pack 1 ( 1K &10K mix). Be sure to setthe sensor to the correcttype in the SENSORSmenu.

SIP pack 1, PIN 1 designator

25

S1000B MAIN BOARD CALIBRATION

The Analog Inputs must be calibrated if the 1K sensor option is to be used, or if accuracy is in question. TheS1000B is calibrated for 10K thermistor sensors at the factory, prior to shipment and calibration is not required.Calibration values are stored in an EEPROM memory device and become permanent.

To calibrate the S1000B a precise 1K (TE6000) or a precision 10K (TYPEZ thermistor) resistor needs tobe substituted for the sensor. Next, the sensor menu needs to be entered and the sensor which is to be calibrated,selected. Remember the S1000B must be in the DISABLED RUN state before changing any sensor parameters.Select the calibrate option and enter YES. The trim in ohms, the controller calculated, will then be displayed.Pressing ENTER key will permanently save the offset value in memory. This process will need to be repeated foreach channel in need of calibration.

By moving the Calibration connector block from one connector to the next, groups of (4) sensor inputs maybe calibrated.

CalibrationConnector of:

Precision1K or 10K

OhmResistors

26

COMMUNICATIONS CONNECTIONS

The S1000B has to ability to connect to the outside world through an RS232 port or internal modem using aproprietary protocol. The S1000B can use a standard 9 pin D connector cable assembly to connect between aPC and the S1000B (a null modem cable is not used and will not work).

If the internal modem is installed the S1000B may communicate through the telephone system using aproprietary protocol. The S1000B will still function with an external modem with the switch set to the RS232position as described below.

Presently, only the DB9 RS232 port is available. If a USB connection is required, an RS232 to USBconverter would be needed. Catalog #26-183 from Radio Shack.

Selection between the Modem and the RS232 ports is accomplished by a switch. A small opening abovethe ports is provided to allow insertion of a small screwdriver so that the internal switch may be moved. The switchin the UP position selects the MODEM and the switch in the DOWN position selects the RS232 port.

If new S1000B firmware needs to be downloaded, the switch will need to be placed in the RS232position, J4 to update flash memory position (see: S1000B Main Board Jumper Configuration), the power cycled,and the firmware download program run on a PC connected to the 9 pin D connector using one of the PC’s ports.If J4 is moved, remember to move it back to the RUN position, otherwise solid block characters will appear onthe display and the S1000B will not function.

MODEM/RS 232 Switch. TheUP position is for the internalMODEM (if installed). TheDOWN position is for the RS232port.

Telephone jack forconnecting to a telephonenetwork if internal modemoption installed.

RS 232 DB9 Connection used forprogramming or if external modemis used. This port may also be usedfor a direct connection for ease ofprogramming and setup.

27

DIAGRAMS

The drawing below illustrates a very simplified connection diagram. The upper board is the control board whichis used for acquistion and control. The left side of the board contains the primary analog inputs. These inputs arereserved for ease of setup and programming. The top of the board contains (8) more inputs, which are primarilysetup for special installations requiring event programming. The lower right portion of the control board has a (2)position plug used to bring 24VAC in from the transformer and power switch. Above the (2) position plug exists a(5) position plug which is used for communication. The communications plug also provides a source for 24VACthat may be required by the communications board.

The lower board is the relay input/output board. The left side top, is relay 1 and will always be connectedto the first boiler to be controlled. Proceeding down, relays 2-8 follow, then relay 9 is located in the top right corner.Continuing down the right side, relays 10-15 follow. If mixed heating and domestic hot water boilers are to be used,start by connecting the heating boilers contiguously by relay #, and then immediately following, connect thedomestic hot water boilers also contiguously. The last (4) boilers (K13-K15) are reserved, but may be used for otherfunctions if the reserved functions are not used, such as for event programming, or additional boilers. The bottomof the board contains the circulating pump control. The ability to control (2) pumps is provided. As marked on theboard, circulating pump 1 is to the lower right.

NOTE: Only Class 2 Connections should be made to Inputs 1-16 and Relays 1-16.

28

SAMPLE HIGH/LOW OPERATING MODE (also known as OUTDOOR RESET SCHEDULE)

EXAMPLE: You decide to have the supply water setpoint at 200°F when the outdoor air temperature is 0°F, andat 130°F when the outdoor air temperature is 70°F. The solid black curve now represents the supplywater temperature relative to the outdoor air temperature.

THEREFORE:

Water temperature @ high OA = 130°F

High OA temperature = 70°F

Water temperature @ low OA = 200°F

Low OA temperature = 0°F

Outdoor Reset Proportional Band

100

110

120

130

140

150

160

170

180

190

200

210

220

-20 -10 0 10 20 30 40 50 60 70 80 90

Outdoor Air Temp

Water Temp.@Low OA

Water Temp.@ High OA

Low OA Temp

High OA Temp

Su

pp

ly W

ate

r T

em

p

29

OWNER RESET WORKSHEET

Water temperature @ high OA = ____________

High OA temperature = ___________________

Water temperature @ low OA = _____________

Low OA temperature = ____________________

Outdoor Reset Proportional Band

100

110

120

130

140

150

160

170

180

190

200

210

220

-20 -10 0 10 20 30 40 50 60 70 80 90

Outdoor Air Temp

Su

pp

ly W

ate

r T

em

p

30

S1000B WORKSHEET

LOCATION DATE APPROVAL

UNIT ID #

MODEM PHONE #

OUTPUT RELAYS

RELAY # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Heating Boilers

DHW Boilers

Motorized Valve(s)

Combustion Air Damper(s)

Draft Inducer Fan

INPUT CONNECTIONS

(only one “ X “ per column ) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Outdoor Ambient Sensor X

Heating Supply Water Temp Sensor X

DHW Supply Water Sensor X

Circ. Pump Flow Prove Switch X

Combustion Air Damper Prove Switch

Induced Draft Fan Prove Switch

Spill Switch

NOTES:

31

S1000B PROGRAM SETTINGS

HEATING BOILERS DHW BOILERS OP MODE# OF BOILERS DHW BOILERS FIXEDSTGS PER BOILER DHW SETPOINT HI / LOWLEAD BOILER # HW TEMP DIFFTEMP DIFF APPLY TO HEAT FIRING MODESYS HI LIMIT LO SHARE LIM FOFO

BYPASS VALVES LOFODELAY TIME ROTATION TIMEMINSEC

ASSIGNMENTS FOR SENSOR TYPESSENSOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16TYPE Z (10K)TE6000ON / OFFNONE

SETPOINTS AUX FUNCTIONS MIN ON TIMEOA SETPOINT COMB. AIR IN USE ? MINUTESOA RESET DAMPER RELAY # SECONDSFIXED MODE WATER TEMP INDUCED IN USE ?WATER TEMP DRAFT FAN RELAY # MIN OFF TIMEAT HI OA TEMP SPILL SWITCH IN USE ? MINUTESWATER TEMP REMOTE DIS IN USE ? SECONDSAT LO OA TEMP # OF PUMPS ROTATION Y NDHW OVERRIDE HI/LO AI9 ROTATE TIME IN HOURS DEMAND LIMIT

NIGHT SETBACK HOLIDAY SETBACKNIGHT SETBACK # 1 2 3 4 START ENDENTRY IS (ON? OFF?) MONTHAMOUNT OF SETBACK DAYSTART DAY YEARSTART TIME TIMEEND DAY AMOUNT OF SETBACKEND TIME

PROGRAMMED EVENTSEVENT ENTRY #EVENT IS ( ON? OFF? )EVENT TYPE (SENSED, TIMED, COUNT)EVENT INPUTEVENT CONDITON ( <, <=, =, >=, >, <> )INPUT VALUE ( -50 to 250, ON, OFF )EVENT MONTHEVENT DAYEVENT TIMEEVENT OUTPUTOUTPUT STATE (AUTO,ON, OFF )CONTROLLER PROGRAMMED BY: Name:

Company:

Phone:

260 North Elm Street 7555 Tranmere DriveWestfield, MA 01085

�Mississauga, Ontario L5S 1L4 Canada

Phone: (413) 568-9571 Phone: (905) 670-5888Fax: (413) 568-9613 Fax: (905) 670-5782