Tjernlund DCOP1 User Manual
Copyright © 2011, Tjernlund Products, Inc. All rights reserved P/N 8504174
OWNER INSTRUCTIONS, DO NOT DESTROY
Recognize this symbol as an indication of important Safety Information!
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED
SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND
OPERATION OF THIS PRODUCT. READ THESE INSTRUCTIONS THOROUGHLY
BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW
THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL
INJURY OR PROPERTY DAMAGE.
!
DO NOT DESTROY. PLEASE READ CAREFULLY AND
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
MODEL DCOP1
INSTALLATION INSTRUCTIONS
REV. 3/11
TJERNLUND PRODUCTS, INC.
1601 Ninth Street • White Bear Lake, MN 55110-6794
PHONE (800) 255-4208 • (651) 426-2993 • FAX (651) 426-9547
Visit our web site • www.tjernlund.com
UC1 VERSION
X.06
COP
CONTROL
SENSING
PORT
UC1
CONTROL
INTERIOR VIEW
1
TABLE OF CONTENTS
Page (s)
Description and General Information...............................................................................................................................1
Installation Restrictions and Cautions ........................................................................................................................1, 2
UC1 Universal Control Board Features ..........................................................................................................................2
UC1 LED Status / Fault Indicators and Fault Retrieval from Memory.............................................................................3
UC1 Pre / Post-Purge & Pre-Cycle Prover Status Check Settings..............................................................................3, 4
DCOP1 Installation .........................................................................................................................................................4
Sizing a Common Manifold Serving Multiple Heaters ....................................................................................................5
Electrical Wiring
Wiring Connections between DCOP1 and Rooftop Inducer ............................................................................6
UC1 Internal Schematic, Sequence of Operation & Specifications ..............................................................7, 8
UC1 Multiple and Millivolt Appliance interlocks ................................................................................................8
UC1 Wiring to Gas Fired Appliance ............................................................................................................9-11
UC1 Wiring to Oil Fired Equipment ...........................................................................................................11-13
How the Draft COP Works ............................................................................................................................................14
Vent Pipe Sensing Location & PSA-1 Fan Prover Installation.......................................................................................14
Adjusting Draft Set Point & Balancing Heater Draft ......................................................................................................14
Verifying System Operation ..........................................................................................................................................15
Adjustment of Draft Set Point, Balancing Baffles and Barometric Draft Controls .........................................................16
Final Operation and Draft Check...................................................................................................................................16
Troubleshooting, Service and Warranty...................................................................................................................16-19
DESCRIPTION
The DCOP1 combines Tjernlund's standard UC1 interlock control with the (COP) Constant Operating Pressure controller.
It can be interlocked with virtually any burner control circuit. Features include: adjustable pre & post purge, LED status/diagnostic
indicators, 10 second prover switch delay to avoid burner start up and wind induced short cycling. Interlocks with any 24-115 VAC
burner control circuit and also includes "dry" contact actuation option. After each burner cycle the UC1 will continue to operate in
post-purge mode to allow the Inducer to purge the heater and vent of residual flue gases. A pre-purge time is factory set at 5 seconds (adjustable up to 35 seconds) and a post-purge time is factory set at 2 minutes (adjustable up to 16 minutes), see "Pre / Post
Purge Settings" on page 3.
The COP controller measures draft/pressure and modulates the speed of an RT-Series Inducer to maintain a user adjustable
draft/pressure set point. Do not use with any other series of Tjernlund Inducers/Venters. The set point is adjusted through a pot
mounted on the COP circuit board.
GENERAL INFORMATION
Each DCOP1 is electrically factory line tested before shipment.
After opening carton, inspect thoroughly for hidden damage. If any damage is found notify freight carrier and your distributor
immediately and file a concealed damage claim.
INSTALLATION RESTRICTIONS
1. The Pre-Cycle Prover Status Check is deactivated from the factory. When activated, the UC1 Universal Control checks across
P1 & P2 safety circuit (Fan Prover) to verify that the Fan Prover switch is “Open” upon a call for heat and not stuck “Closed”.
Natural draft or winds may be sufficient to close the PSA-1 fan prover switch contacts prior to a call for heat. Keeping the Prover
Status Check activated may cause nuisance lockouts. Push up or “ON” to deactivate. See "P1 & P2 Pre-Cycle Fan Prover
Status Check", page 4 for details.
2. An Inducer post-purge on the UC1 has been factory set at 2 minutes. Confirm that dip switch #5 is in the up or "ON" position. Oil
fired equipment requires that the post-purge be long enough to eliminate post cycle nozzle drip odor. A longer post-purge may
be necessary for longer vent runs or high heat retention, refractory lined combustion chambers. A shorter post-purge may be
desired for gas installations. See "Pre / Post Purge and Prover Status Check Dip Switch Settings", page 3 for details.
3. The DCOP1 is intended for indoor installation only. Do not mount the DCOP1 on a heat source that exceeds 140
O
F (60OC).
Examples of improper mounting surfaces include vent pipe, top of heater casing or any place where radiant or convective heat
would cause the junction box temperature to exceed 140
O
F (60OC).
4. The maximum distance wire can be ran from the RT-Series Inducer junction box to the DCOP1 control is 250 feet.
CAUTIONS
The DCOP1 must be installed by a qualified installer (an individual properly licensed and/or trained) in accordance with all local
codes or, in their absence, in accordance with the appropriate National Fire Protection Association #31, #54, #211 and the
National Electrical Code.
2
Failure to install, maintain and/or operate the DCOP1 in accordance with manufacturer's instructions may result in conditions
which can produce bodily injury and property damage.
1. The installer must verify that the BTU/hr. input of the appliance(s) does not exceed the recommended input of the RT-Series
Inducer being controlled by the DCOP1. Refer to the RT-Series brochure or installation instructions for capacities.
2. Disconnect power supply from the DCOP1 and heating equipment when making wiring connections and servicing the DCOP1.
Failure to do so may result in personal injury and/or equipment damage. LED #6 (RED) on UC1 should be off with power removed.
3. All installation restrictions and instructions in the RT-Series Inducer installation instructions must be followed when using the
DCOP1.
4. Make certain power source is adequate for the DCOP1 and Inducer requirements. Do not add equipment to a circuit when the
total electrical load is unknown.
UC1 UNIVERSAL CONTROL BOARD FEATURES
# 1. Power supplied by board. Do not supply power to this area or control damage may result.
# 2. Do not supply power to the appliance interlock block with the call selector in the “DRY” position.
Control damage may result if power is supplied.
# 3. Circuit protection must be provided by the installer. 16 Amps is the maximum current allowed for this device at terminal L.
A 15 Amp circuit breaker is recommended.
VETI
APPLIANCE CALL
VOLTAGE SELECTION
Place RED voltage jumper in
proper location based on
appliance call interlock voltage. SEE WARNING # 2.
IMPORTANT
LED 1 (AMBER)
LED 2 (BLUE)
LED 3 (GREEN)
LED 4 (RED)
LED 5 (RED)
LED 6 (RED) POWER LED
DRY
24 V
115 V
APPLIANCE
INTERLOCK
RELAY
INDUCER
MOTOR
RELAY
A B 1 2 3 4 L N
J1 J2 XL XN
P1 P2 C GND F
(1 9)
N M MTR
J1- J2 CALL
JUMPER
Used when the call signal is
used as the “proven” return
signal to the appliance. See
wiring section for details.
L / N - 115 VAC POWER
SUPPLY BLOCK
115 VAC / 50-60 Hz
Circuit protection provided by installer.
SEE WARNING # 3.
MTR & M / N LOAD TERMINALS
FROM INDUCER MOTOR RELAY
Used to drive Inducer Motor.
1 HP MAX LOAD across terminals MTR & M / N.
Connected to DCOP1 T6 & T9 Power Terminals.
XL / XN AUXILIARY DEVICE
POWER TERMINALS
115 VAC - Maximum of 0.15 Amps.
Only connect to Tjernlund auxiliary devices.
SEE WARNING # 1.
APPLIANCE INTERLOCK
RELAY
1 HP MAX LOAD across
terminals 3 & 4.
P1 - P2 SAFETY CIRCUIT
TERMINALS
1 mA @ 5VDC.
SEE WARNING # 1.
C, GND, F AUXILIARY DEVICE
COMMUNICATION TERMINALS
2 mA @ 5VDC. For Tjernlund MAC1E or
MAC4E auxiliary devices. SEE WARNING # 1.
DIP SWITCH SETTINGS
Pre-Purge (1-2)
Post-Purge (3-8)
Prover status check (9)
See “Pre / Post Purge &
Prover Status Check Dip
Switch Settings”.
LED STATUS LIGHTS
See “LED Status & Fault
Indicator Section” for details.
APPLIANCE INTERLOCK
TERMINAL BLOCK (A-B, 1-4)
A - B - Dry Contact call. 3 mA @ 5VDC.
SEE WARNING # 1.
1 - 24 or 115 VAC intercepted call.
IMPORTANT: RED voltage jumper must
match intercepted call voltage.
2 - 24V common or 115V Neutral.
3 - Common terminal to appliance relay con-
tacts. IMPORTANT: J1-J2 jumper routes
call voltage at terminal 1 to 3. Remove
J1-J2 jumper if a different voltage source is
provided to terminal 3.
4 - Normally open terminal of appliance relay.
Will be energized from terminal 3 if safety
circuit is “proven”.
INDUCER MOTOR RELAY
1 HP MAX LOAD from
terminals L to MTR & M.
UC1 LED STATUS & FAULT INDICATORS
NDICATORS
LED INDICATOR LIGHTS
LED #1 (Amber) Appliance call for heat.
LED #2 (Blue) Safety circuit through P1 & P2 (PSA-1 Fan Prover and/or Limit). Indicates PSA-1 switch is closed during run
cycle. Burner circuit is energized with Interlock Relay contact closure from terminal 3 to 4.
LED #3 (Green) Power switched to COP controller from MTR & N.
LED #4 (Red) Status / Fault indicator.
LED #5 (Red) Used as a status indicator.
LED #6 (Red) 115 VAC power supplied to board.
LED STATUS INDICATORS
LED #4 & #5 (Red) Flashing Alternately = Inducer in Pre-purge. (Pre-Purge options 0, 5, 20, 35 seconds)
LED #4 & #5 (Red) Flashing in Unison = Inducer in Post-Purge. (Post-Purge options 0, 30 seconds or 1, 2, 4, 8, 16 minutes)
LED #4 (Red) Flashes Continuously* = PSA-1 Fan Prover opened for more than 10 seconds during burner cycle.
(Inducer will run for 10 minutes, attempting to close Fan Prover)
LED #5 (Red) Flashing Intermittently = With no call for heat, flashes 3 seconds on / 3 seconds off if microcontroller
is working properly.
LED FAULT INDICATORS
Fault conditions are indicated by counting the number of times LED #4 (Red) flashes.
LED #4 (Red) Flashes 2 Times PSA-1 Fan Prover was in electrically closed position prior to Inducer operation.
LED #4 (Red) Flashes 3 Times* PSA-1 Fan Prover does not close within 60 seconds after call for heat.
LED #4 (Red) Flashes 4 Times* PSA-1 Fan Prover opened during cycle and did not close within 10 minutes of Inducer operation.
LED #4 (Red) Flashes 5 Times* PSA-1 Fan Prover opened for more than 10 seconds during burner cycle but closed within 10 minutes.
* Investigate cause of PSA-1 Fan Prover short cycling such as; firing burner at capacities or temperatures exceeding Inducer
limits, excessive vent pipe runs, plugged / kinked Fan Prover sensing tube, PSA-1 Fan Prover setpoint too high or DCOP1 draft
setpoint too low. Adjustment may be required.
CHECKING MEMORY FOR LAST FAULT CODE
IMPORTANT: Prior to accessing the fault code memory, note the settings of the dip switches so that they can be returned to their
original Pre / Post-Purge positions. When power is supplied to the DCOP1 use caution when moving UC1 dip switches.The last
fault code can be retrieved at any time by setting all dip switches 1-8 to the up, or "on" position. The last fault code, or lack there
of, will be indicated by counting the number of times LED #4 (Red) flashes. By moving any of the dip switches back to their original
position, the fault code will be cleared. NOTE: The DCOP1 must have its 115 VAC power supply present when any of the UC1
(1-8) dip switches are moved back to their original position for the fault code to clear.
UC1 PRE / POST PURGE AND PROVER STATUS CHECK DIP SWITCH SETTINGS
Remove power to DCOP1 and heating equipment when installing, servicing or changing UC1 dip switch settings. Failure to do so
may result in personal injury and/or equipment damage. LED #6 (RED) should not be on if 115 VAC supply power is removed from
the control.
Pre-purge
An Inducer pre-purge has been factory set at 5 seconds (Adjustable from 0 to 35 seconds). Used
for longer vent runs to get draft fully established throughout the vent system prior to burner ignition.
Also beneficial for negative pressure prone environments. IMPORTANT: Nuisance equipment lockouts may occur if Inducer pre-purge is running in conjunction with and is longer than any equipment
timing circuit. Pre-purge settings must be shorter than burner control lockout time unless wired prior
to burner control timing circuit (i.e. aquastat / thermostat).
Post-purge
An Inducer post-purge has been factory set at 2 minutes (Adjustable from 0 to 16 minutes). Confirm
that dip switch #5 is in the up or "on" position. Oil fired equipment requires that the post-purge be
long enough to eliminate post cycle nozzle drip odor. A longer post-purge may be necessary for
longer vent runs or high heat retention, refractory lined combustion chambers. A shorter post-purge
may be desired for gas installations.
UC1 INSTALLATION
IMPORTANT: Fault codes will automatically be displayed after a fault condition occurs. If the call for heat interlock signal
or 115 VAC power is removed, the UC1 board will reset and the fault will be stored in memory instead of displayed. Any
new fault will replace any previous fault.
3
1 9
LED 1 AMBER
LED 2 BLUE
LED 3 GREEN
LED 4 RED
LED 5 RED
LED 6 RED
POWER LED
ON
4
DCOP1 INSTALLATION
Do not mount the DCOP1 junction box on a heat source that exceeds 140OF (60OC). Examples of improper mounting surfaces
include vent pipe, top of heater casing or any place where radiant or convective heat would cause the junction box temperature to
exceed 140
O
F (60OC). The DCOP1 is intended for indoor installation only.
Using the key hole slots on the back of the DCOP1 junction box as a template, mark 4 holes on the mounting surface, drill pilot
holes if necessary, and secure junction box using provided screws.
ELECTRICAL WIRING
P1 & P2 PRE-CYCLE FAN PROVER STATUS CHECK
Pre-Cycle
Prover Status
Check Deactivated
The Pre-Cycle Prover Status Check is deactivated from the factory. When activated, the UC1
Universal Control checks across P1 & P2 safety circuit (PSA-1 Fan Prover) to verify that the Fan
Prover switch is “Open” upon a call for heat and not stuck “Closed”. Natural draft or winds may be
sufficient to close the PSA-1 Fan Prover switch contacts prior to a call for heat. Keeping the Prover
Status Check activated may cause nuisance lockouts. Push dip switch 9 up or “ON” to deactivate.
9
ON
PRE-PURGE SETTINGS (SEE “PRE-PURGE” ON PAGE 3 PRIOR TO SETTING)
12 12 12 12
0 Seconds 5 Seconds 20 Seconds 35 Seconds
EXAMPLE OF DCOP1
& ROOFTOP INDUCER
INSTALLED WITH
MULTIPLE HEATERS
POST-PURGE SETTINGS (SEE “POST-PURGE” ON PAGE 3 PRIOR TO SETTING)
4348657 35678 345678 3 75468
4348657 35678 345678
4 Minutes 8 Minutes 16 Minutes
1 Minute0 Seconds 30 Seconds 2 Minutes
ON
ON
Pre-Purge
Post-Purge
Pre-Cycle
Prover Status
Check Deactivated
DIP SWITCH NUMBERING
1
ON
2
3
4
5
6
7
8 9
5
SIZING A COMMON MANIFOLD SERVING MULTIPLE HEATERS
The most important step towards assuring that individual heaters vented into a common manifold draft smoothly is to size the manifold large enough to negate the affects that velocity in the manifold has on the junctions of the heater vent connections.
Exhaust gases moving too quickly in a common vent manifold can amplify the draft at vent connectors by aspirating across the
connector opening and creating an amplified siphon affect. With a properly sized common vent manifold, velocities are maintained
below the point where they have a significant affect on the draft of the individual heater connections.
It is important to note that these sizing recommendations are for the common vent manifold only and that the typically smaller minimum vent diameter listed in the RT-Series Inducer selection table may be used for the remainder of the horizontal vent and chimney. The larger diameter vent common manifold should extend at least 2 diameters beyond the connection point of the last heater
farthest from the Inducer.
1. When in doubt, get help from Tjernlund Tech Service at 800-255-4208, push 0 and ask for technical assistance or
email fanmail@tjfans.com with details of your job.
2. If velocities are known, avoid exceeding 1200 FPM in the vent common manifold.
3. When possible use 45
O
Manifold Tee connections to the common vent manifold in the direction of the Inducer instead of 90
O
Tee connections.
4. Draft hoods/diverters create a disconnect from the heater’s flue outlet greatly buffering sudden changes in draft. Even though
the DCOP1 Constant Pressure Controller reacts quickly to maintain the draft/exhaust set-point, we still recommend installing
single acting barometric draft controls on fan assisted and power burner heaters. The barometric draft controls react instantly to
spikes in vent exhaust volume so that precise draft is always maintained.
5. If possible, locate the larger exhaust volume (i.e. higher BTU/hr. input) vent connections closer to the Inducer. This reduces the
affect of their exhaust on smaller volume connections.
6. The size of the common vent manifold should be at least 90% of the total area of all individual vent connections. See example
below.
Example: A vent layout is required for a job that consists of 4 heating appliances. 1 Appliance has an 8" diameter vent
connector, 2 appliances have 6" diameter vent connectors and 1 appliance has a 4" diameter vent connector.
Add these areas together:
1 x 0.3491 = 0.3491
2 x 0.1964 = 0.3928
1 x 0.0873 = 0.0873
______
0.8292
Total Area = 0.8292 Square Feet x 0.90 (90%) = 0.7463. In looking at the table above, this area is greater than a 10" diameter
pipe but smaller than a 12" diameter pipe. 12" diameter vent is the minimum size the common vent manifold diameter should be. It
is perfectly acceptable to be larger than this area if desired. It is also acceptable to have this area be reduced as the vent system
works backward towards the appliance furthest from the Inducer. In this example, the common vent manifold should extend at
least 24" past the connection point of the appliance farthest from the Inducer.
Breech Size Diameter Area (Square Feet)
3”
0.0491
4” 0.0873
5” 0.1364
6” 0.1964
8” 0.3491
10” 0.5454
12” 0.7854
14” 1.0690
16” 1.3960
18” 1.7670
20” 2.1820
BALANCING
BAROMETRIC
DRAFT CONTROL
(IF PRESENT)
BAFFLE
2D
MINIMUM
COMMON VENT MANIFOLD
MAINTAIN THE FLUE
OUTLET DIAMETER UNTIL
THE COMMON MANIFOLD
INSTALL THE BALANCING BAFFLE
AT LEAST 2 PIPE DIAMETERS ABOVE
THE BAROMETRIC OR FLUE OUTLET
D
2D
HEATER FURTHEST
FROM THE INDUCER
MINIMUM
FAN PROVER
SENSING TUBING TO
DCOP1 AND PSA-1
FIGURE 8054007 4/14/11
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