Q90-75 Dunkirk boiler & storage tank User Manual

Quanrum

=aeQO

GAS-FIRED,

DIRECT

VENT,

CONDENSING,

HOT

WATER

BOILER

INSTALLATION,

OPERATION

&

MAINTENANCE

MANUAL

SE

DUNKIRK

BOILERS

85

Middle

Rd.

Dunkirk,

NY 14048

www.dunkirk.com

P/N#

14683301,

Rev.

C

[12/2010]

50-100

GAS-FIRED

B

Model

No.

90-50

90-75

90-100

US

ENERGY

STAR

|

These

instructions

must

be

affixed

on

or

adjacent

to

the

boiler.

WARNING

Improper

installation,

adjustment,

alteration,

A

service,

or

maintenance

can

cause

injury

or

property

damage.

Refer

to

this

manual.

For

assistance

or

additional

information

consult

a

qualified

installer,

service

agency,

or

the

gas

supplier.

CAUTION

Ay

Read

all

instructions

carefully

before

starting

the

installation.

Save

this

manual

for

reference.

TABLE

OF

CONTENTS

Warnings

and

Safety

SYMDOIS

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5

Boilers

For

Use

At

High

AILiICUCS

2...

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6

Rules

For

Safe

Installation

ANd

Operation

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Before

Installing

The

Boller

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PIACING

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Ne@ar

Boller

PIDING

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DEEDES

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12

Combustion

Air

and

V@nt

PIPE

20...

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19

GAS

SUPPLY

PIDING.....ccccccce

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26

Controls

and

ACCESSOFICS

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Water

Treatment

&

Freeze

Protection

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De)

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34

Operating

INSEUCTIONS.

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35

To

Turn

OFF

GAS

TO

ADDHANCE

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Check

Out

Procedure

and

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36

Installation

and

Check-Out

Certificate.

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Maintenance

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41

Detailed

Sequence

Of

ODEration

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Differential

Air

Pressure

Switch

Check

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55

IMPORTANT:

THIS

MANUAL

MUST

BE

KEPT

NEAR

THE

BOILER

FOR

FUTURE

REFERENCE!!

WARNINGS

AND

SAFETY

SYMBOLS

Indicates

an

imminently

hazardous

situation

A

Indicates

an

imminently

hazardous

situation

which,

if

not

avoided,

WILL

result

in

death,

which,

if

not

avoided,

may

result

in

injury

or

serious

injury

or

substantial

property

damage.

property

damage.

WARNING

NOTICE

A

Indicates

an

imminently

hazardous

situation

Indicates

information

which

should

be

which,

if

not

avoided,

may

result

in

death,

followed

to

ensure

proper

installation

and

serious

injury

or

substantial

property

damage.

operation.

3

oe

et

eanee

HS

®

INTRODUCTION

This

appliance

is

a

gas-fired

direct

vent

hot

water

boiler

with

cast

aluminum

boiler

sections.

A

revolutionary

cast

aluminum

heat

exchanger

means

better

heat

transfer

and

thermal

storage

than

similarly

sized

cast

iron

boilers,

which

results

in

higher

efficiency.

The

heating

system

water

absorbs

large

amounts

of

heat

from

the

cast

aluminum

heat

exchanger,

cooling

the

flue

gases

and

causing

condensation.

Sealed

combustion,

premix

gas

burner,

and

low flame

temperature

means

drastically

reduced

CO

and

NOx

emissions,

which

contribute

to

a

cleaner

and

healthier

environment.

This

appliance,

unlike

normal

residential

atmospheric

and

induced

draft

units,

takes

its

combustion

air

directly

from

the

outdoors

(sealed

combustion)

and

does

not

compete

with

building

occupants

for

fresh

air.

Sealed

combustion

(also

known

as

“direct

vent”)

is

the

safest

and

best

way

to

obtain plenty

of

clean

combustion

air.

The

induced

draft

fan

draws

in

the

outside

combustion

air,

then

takes

the

cooler

flue

gases

from

the

boiler

unit

and

provides

a

positive

removal

of

the

flue

gases

from

the

building

through

inexpensive

and

readily

available

PVC

and

CPVC

pipes.

NOTICE

IMPORTANT:

Read

the

following

instructions

COMPLETELY

before

installing!

Figure

1 -

Boiler

Dimensions

19374"

(S02nim)

gs

(101

.6mm)

ALTERNATE

OPENING

FOR

GAS

SUPPLY

ALTERNATE

SUPPLY

__

&

PRESSURE

GAUGE

&

RETURN

OPENINGS

:

LEA”

NPT

GL?

Seca

ns

FRONT

PANEL

DOOR

FULL

COMMER

TIONS

.

PROVIDED

INSIDE

|

(782mm)

ye

BOILER

CABINET)

|

(787-4mm)

gure

(241.Smrm)

(12mm)

RIGHT

SIDE

ALTERNASTE

BOILER

WATER

RETURN

BOILER

WATER

TEMPERATURE

LEVELING

FEET

To

29°.

(71

ime)

—~

|

fy

fenen)

VENT

CONNECTION

(2°

CPYC)

{50

Benet}

DRAIN

a

CONDENSATE

GRAIN

FITTING

(1/2

PVE}

(12.

Fenen)

(ot

/d"

NPT

(31.

78men)

CONNECTIONS

PROVIDED

INSIDE

GAS

SUPPLY

OPENING

Cif)e"

MPT)

(12.

7reen)}

‘

__VENT

CONNECTION

‘i

Ser

(2*

CPVC)

(50.

8ramn}

(69.9)

44/2"

(114.3mm)

COMBUSTION

AIR

INTAKE

PITTING

(2°

PVC}

(40.

Beer)

AL

FERNATE

GAS

.

SUPPLY

OPENING

Oy

39

1/2"

(100Seirr)

VENT

TEE

11

3/4"

(298.

45rnm)

|.

18

1/2"

(393.

7mm)

RIGHT

SIDE

STANDARD

BOILER

WATER

SUPPLY

&

RETURN

OPENINGS

(1-1

/4"

NPT

(31,78men)

CONNECTIONS

PROVIDED

INSIDE

GOMER

Caginet)

JUNCTION

BOX

FOR

120

V

POWER,

120

V

CIRCULATOR

LEADS,

AND

24

¥

THERMOSTAT

LEADS

ALTERNATE

OPENING

FOR

24"

[~

(609.6rern)

OPENING

FOR

RELIEF,

VALVE

DISCHARGE

PIPE

OPENING

FOR

AIR

VENT

AND

EXPANSION

TANK

CONNECTION

at

(S33

4enen)

“5

1/4"

(133.35em)

ALTERNATE

BOILER

WATER

SUPPLY

(31.78rm)

CONNECTIONS

(i-t/@"

NPT

BOILER

CABINET)

PROVIDED

IMSIIE

Visa

91/2"

(241.

3mm)

(4.38,

15mm)

ALTERMATE

GCILER

WATER

13"

RETURN

(S50.2nrn)

(i1

fa"

NET

(317mm)

BACK

CONNECTIONS

PROMDEG

IMS

c

BOILER

RATINGS

&

CAPACITIES

TABLE

#1

-

SEA

LEVEL

RATINGS

-

NATURAL

AND

PROPANE

GASES

90-50

50

45

39°

|

220

2?

CPVCKPVC

90-75

75

68 59

220

2°

CPVC

&

PVC

90-100

100

90 78

220

2°

CPVC

&

PVC

*

1

MBH

=

1,000

Btuh Btuh

=

British

Thermal

Units

Per

Hour

These

low

pressure

gas-fired

hot

water

boilers

are

design

certified

by

CSA

International

for

use

with

natural

and

propane

gases.

The

boilers

are

constructed

and

hydrostatically

tested

for

a

maximum

working

pressure

of 50

psig

(pounds

per

square

inch

gage)

in

accordance

with

A.S.M.E.

(American

Society

of

Mechanical

Engineers)

Boiler

and

Pressure

Vessel

Code

Section

IV

Standards

for

heating

boilers.

++

AFUE

(Annual

Fuel

Utilization

Efficiency)

and

Heating

Capacity

is

based

on

the

D.O.E.

(Department

of

Energy)

test

procedure.

The

Boilers

are

certified

in

accordance

with

ANSI

(American

National

Standards

Institute)

Z21.13

standards

as

gas-fired,

direct

vent,

condensing,

hot

water

boilers.

The

Heating

Capacity

indicates

the

amount

of

heat

available

after

subtracting

the

losses

up

the

stack.

Most

of

this

heat

is

available

to

heat

water.

A

small

portion

is

heat

from

the

jacket

and

surfaces

of

the

boiler,

and

it

is

assumed

that

this

heat

stays

in

the

structure.

The

Net

I=B=R

Rating

represents

the

portion

of

the

remaining

heat

that

can

be

applied

to

heat

the

radiation

or

terminal

units

(Le.

finned

tube

baseboard,

cast

iron

radiators,

radiant

floor,

etc.).

The

difference

between

the

Heating

Capacity

and

the

Net

I=B=R

Rating,

called

the

piping

and

pickup

allowance,

establishes

a

reserve

for

heating

the

volume

of

water

in

the

system

and

offsetting

heat

losses

from

the

piping.

The Net

I=B

R

Ratings

shown

are

based

on

a

piping

and

pickup

factor

of

1.15

in

accordance

with

the

I=B=R

Standard

as

published

by

the

Hydronics

Institute.

The

Net

I=B=R

Rating

of

the

boiler

selected

should

be

greater

than

or

equal

to

the

calculated

peak

heating

load

(heat

loss)

for

the

building

or

area(s)

served

by

the

boiler

and

associated

hot

water

heating

systems.

The

manufacturer

should

be

consulted

before

selecting

a

boiler

for

installations

having

unusual

piping

and

pickup

requirements.

The

boilers

are

factory

equipped

for

operation

at

altitudes

ranging

from

0-2,000

feet

above

sea

level.

For

use

of

these

boilers

at

altitudes

above

2,000

feet

above

sea

level,

the gas

input

ratings

(MBH)

automatically

reduced.

BOILERS

FOR

USE

AT

HIGH

ALTITUDE

The

boilers

(with

the

exception

of

the

90-75

LP

product)

are

factory

equipped

for

operation

at

altitudes

ranging

from

0-10,000

feet

above

sea

level.

No

changes

to

the

factory

settings

are

required

for

instal-

lations

from

0-5,000

feet

above

sea

level.

For

altitudes

from

5,000-

10,000

feet

above

sea

level

the gas

manifold

pressure

will

need

to

be

adjusted

based

upon

calorific

(Btu)

value

of

supply

gas

(contact

local

gas

utility

or

distributor

for

this

value). For

specific

settings

refer

to

Table

#1

for

natural

gas

applications

and

Table

#2

for

LP

gas

ap-

plications.

Instructions

on

how

to

adjust

the

gas

manifold

pressure

settings

are

shown

in

Figures

17

&

18.

Note

that

90-75

LP

applications

for

5,000

-

10,000

feet

above

sea

level

will

require

an

orifice

change

as

well

as

a

gas

manifold

pres-

sure

adjustment

based

upon

calorific

(Btu)

value

of

supply

gas.

Refer

to

Table

#2

for

altitude

orifice

kit

part

number.

For

replacing

the

orifice

refer

to

specific

instructions

included

with

the

kit.

TABLE

#1:

SERIES

90

NATURAL

GAS

SERIES

90-50

950

Altitude

in

Ft.

0-5,000

5,000-10,000

Normal

Input

(MBH)

50

- - - - -

Manifold

Pressure

In

W.C.

2.5

4 4

3.5 2.5

2.5

Orifice

43331094

Settings

SERIES

90-100

Ee!)

Settings

Rhye

Altitude

in

Ft.

0-5,000

5,000-10,000

Normal

Input

(MBH)

75

- - - - -

Manifold

Pressure

In

W.C.

2.5 3.5

3.5

2.5 2.5

2.5

Orifice

43331092 43331092

Altitude

in

Ft.

0-5,000

5,000-10,000

Normal

Input

(MBH)

100

- - - - -

Manifold

Pressure

In

W.C.

2.5 3.5 3.5 2.5 2.5 2.5

Orifice

43331090

++Contact

local

gas

utility

or

distributor

for

Btu

value

of

gas.

BOILERS

FOR

USE

AT

HIGH

ALTITUDE

NOTICE

For

model

90-75

LP

units

only

at

altitudes

above

5,000

ft.,

install

90-75

High

Altitude

Orifice

Kit

#550001810*.

For

all

other

altitudes

use

factory

installed

orifice.

TABLE

#2:

SERIES

90

PROPANE

GAS

SERIES

90-50

eure

2300

|

2350

|

2400

Pye

Altitude

in

Ft.

0-5,000

5,000-10,000

Normal

Input

(MBH)

50

- - - - -

Manifold

Pressure

In

W.C.

2.9

3 3

2.9

2.5

2.9

Orifice

43331095 43331095

Ut)

ares

Settings

2300 2350 2400

2450

2500

Altitude

in

Ft.

0-5,000

5,000-10,000

Normal

Input

(MBH)

75

_ _ _ _ _

Manifold

Pressure

In

W.C.

2.9

3.9 3.9 3.9

3 3

Orifice

43331093

4333

1096*

*

For

model

90-75

LP

units

only

at

altitudes

above

5,000

ft,

install

90-75

High

Altitude

Orifice

Kit

#550001810.

For

all

other

aiti-

tudes

use

factory

installed

orifice.

SERIES

90-100

Settings

peje!)

2350 2400

2450 2500

Altitude

in

Ft.

0-5,000

5,000-10,000

Normal

Input

(MBH)

100

- - - - -

Manifold

Pressure

In

W.C.

2.9

3 3 3

2.5

2.9

Orifice

43331091 43331091

++Contact

local

gas

utility

or

distributor

for

Btu

value

of

gas.

RULES

FOR

SAFE

INSTALLATION

AND

OPERATION

1.

Read

the

entire

installation

manual

before

beginning

the

instal-

lation.

Failure

to

follow

these

rules

for

safe

installation

and

operation

and

these

instructions

could

cause

a

malfunction

of

the

boiler

and

result

in

death,

serious

bodily

injury,

and/or

property

damage.

2.

Check

all

applicable

state

and

local

building

codes and

util-

ity

company

requirements

before

installation.

The

installation

must

conform

with

these

requirements

in

their

entirety.

In

the

absence

of

these

codes,

use

NFPA

Installation

Codes

and

good

industry

practice.

3.

Before

servicing

the

boiler

-

allow

the

boiler

to

cool.

Always

shut

off

any

electricity

and

gas

supply

connected

to

the

boiler

prior

to

servicing.

Inspect

gas

line

for

leaks.

5.

Be

certain

gas

input

rate

is

correct.

Over

firing

may

result

in

early

failure

of

the

boiler

sections.

This

may

cause

dangerous

operation.

Under

firing

may

result

in

too

much

air

for

the

pre-

mix

burner

causing

poor

or

loss

of

combustion.

6.

Never

vent

the

products

of

combustion

from

this

boiler

to

an

enclosed

space.

Always

vent

to

the

outdoors.

Never

vent

to

another

room

or

to

inside

a

building.

7.

Be

sure

there

is

adequate

outdoor

air

supply

to

boiler

for

com-

plete

combustion.

8.

Follow

a

regular

service

and

maintenance

schedule

for

efficient

and

safe

operation.

9.

Keep

boiler

area

clean

of

debris

and

free

of

combustible

and

flammable

materials.

10.

Proper

through

the

wall

or

through

the

roof

combustion

vent-

ing

shall

be

in

accordance

with

the

materials and

methods

described

in

this

manual.

Installation

must

comply

with

local

codes.

11.

This

boiler

and

water

heating

systems

are

not

do

it

yourself

items.

They

must

be

installed

and

serviced

by

qualified

professionals.

WARNING

This

boiler

has

been

equipped

for

residential

installations.

If

used

for

commercial

applications,

any

additional

code

requirements

must

be

adhered

to

for

installation.

This

may

require

additional

controls

including

but

not

limited

to

a

low

water

cut

off,

a

manual

reset

high

temperature

limit,

and

wiring

and/or

piping

modifications.

The

manufacturer

is

not

responsible

for

any

field

installation

changes

made

to

a

boiler

installation

which

are

not

described

or

acknowledged

in

this

manual.

BEFORE

INSTALLING

THE

BOILER

Complete

all

of

the

following

prior

to

installing

the

boiler.

Codes

This

boiler

product

is

a

gas-fired,

direct

vent,

condensing

boiler

and

must

be

installed

to

conform

to

the

requirements

of

the

authority

having

jursidiction

or,

in

the

absence

of

such

requirements:

United

States

-

National

Fuel

Gas

Code

(NFPA-54/ANSI

Z223.1).

Canada

-

National

Gas

and

Propane

Installation

Code,

Can/CSA

B149.1.

Where

required

by

the

authority

having

jurisdiction,

the

installation

must

conform

to

the

American

Society

of

Mechanical

Engineers

Safety

Code

for

Controls

and

Safety

Devices

for

Automatically

Fired

Boilers,

No.CSD-1.

NOTICE

Important

-

In

the

state

of

Massachusetts

this

product

must

be

installed

by

a

licensed

plumber

or

gas

fitter

and

the

installation

must

be

in

accordance

with

248

CMR.

Installers

-

Follow

local

regulations

with

respect

to

installation

of

CO

(Carbon

Monoxide)

Detectors.

Follow

maintenance

recommen-

dations

in

this

manual.

Installation

Requirements

Specific

To

The

State

Of

Massachusetts

For

Direct

Vent,

Mechanical

Vent,

And

Domestic

Hot

Water

Appliances

For

all

side

wall

horizontally

vented

gas

fueled

equipment

installed

in

every

dwelling,

building

or

structure

used

in

whole

or

in

part

for

residential

purposes,

including

those

owned

or

operated

by

the

commonwealth

and

where

the

side

wall

exhaust

vent

termination

is

less

than

seven

(7)

feet

above

finished

grade

in

the

area

of

the

vent-

ing,

including

but

not

limited

to

decks

and

porches,

the

following

requirements

shall

be

satisfied:

1.

Installation

of

carbon

monoxide

detectors:

at

the

time

of

instal-

lation

of

the

side

wall

horizontal

vented

gas

fueled

equipment,

the

installing

plumber

or

gasfitter

shall

observe

that

a

hard

wired

carbon

monoxide

detector

with

an

alarm

and

battery

back-up

is

installed

on

the

floor

level

where

the

gas

equipment

is

to

be

installed.

In

addition,

the

installing

plumber

or

gasfitter

shall

observe

that

a

battery

operated

or

hard

wired

carbon

mon-

oxide

detector

with

an

alarm

is

installed

on

each

additional

level

of

the

dwelling,

building

or

structure

served

by

the

side

wall

horizontal

vented

gas

fueled

equipment.

It

shall

be

the

respon-

sibility

of

the

property

owner

to

secure

the

services

of

qualified

licensed

professionals

for

the

installation

of

hard

wired

carbon

monoxide

detectors.

BEFORE

INSTALLING

THE

BOILER

A.

Inthe

event

that

the

side

wall

horizontally

vented

gas

Considerations

For

Boiler

Location

fueled

equipment

is

installed

in

a

crawl space

or

an

attic,

the

hard

wired

carbon

monoxide

detector

with

alarm

and

battery

back-up

may

be

installed

on

the

floor

level.

B.

Inthe

event

that

the

requirements

of

this

subdivision

can

not

be

met

at

the

time

of

completion

of

installation,

the

owner

shall

have

a

period

of

thirty

(30)

days

to

comply

with

the

above

requirements;

provided,

however,

that

dur-

ing

said

thirty

(30)

day

period,

a

battery

operated

carbon

monoxide

detector

with

an

alarm

shall

be

installed.

2.

Approved

carbon

monoxide

detectors:

each

carbon

monoxide

detector

as

required

in

accordance

with

the

above

provisions

shall

comply

with

NFPA720

and

be

ANSI/UL

2034

listed

and

IAS

certified.

3.

Signage:

a

metal

or

plastic

identification

plate

shall

be

perma-

nently

mounted

to

the

exterior

of

the

building

at

a

minimum

height

of

eight

(8)

feet

above

grade

directly

in

line

with

the

exhaust

vent

terminal

for

the

horizontally

vented

gas

fueled

heating

appliance

or

equipment.

The

sign

shall

read,

in

print

size

no

less

than

one-half

(1/2)

inch

in

size,

“gas

vent

directly

below.

Keep

clear

of

all

obstructions”.

4.

Inspection:

the

state

or

local

gas

inspector

of

the

side

wall

horizontally

vented

gas

fueled

equipment

shall

not

approve

the

installation

unless,

upon

inspection,

the

inspector

observes

carbon

monoxide

detectors

and

signage

installed

in

accordance

with

the

provisions

of

248

CMR

5.08(2)(A)1

through

4.

5.

Product-approved

vent/air-intake:

a

product-approved

vent

ter-

minal

must

be

used

and,

if

applicable,

a

product-approved

air

1.

intake

must

be

used.

Installation

shall

be

in

strict

compliance

with

the

manufacturer’s

instructions.

6.

Installation

instructions:

a

copy

of

all

installation

instructions

2.

for

all

product

approved

side

wall

horizontally

vented

gas

fueled

equipment,

all

venting

instructions,

all

parts

lists

for

venting

instructions,

and/or

all

venting

design

instructions

shall

remain

with

the

appliance

or

equipment

at

the

completion

of

the

instal-

3,

lation.

Boiler

Sizing

Check

to

be

sure

you

have

selected

the

boiler

with

the

proper

capac-

ity

before

starting

the

installation.

The

I=B=R

Rating

of

the

boiler

selected

should

be

greater

than

or

equal

to

the

calculated

peak

heat-

ing

load

(heat

loss)

for

the

building

or

area(s)

served

by

the

boiler

and

associated

hot

water

heating

systems.

See

the

table

“BOTLER

RATINGS

AND

CAPACITIES”

(page

5

of

this

document).

Heat

loss

calculations

should

be

based

on

approved

industry

meth-

ods.

Before

selecting

a

location

for

the

boiler,

the

following

should

be

considered.

Each

boiler

considered.

¢Supplied

with

the

correct

type

of

gas

(natural

gas

or

pro-

pane).

«Connected

to

a

suitable

combustion

air

intake

piping

sys-

tem

to

supply

the

correct

amounts

of

fresh

(outdoor)

air

for

combustion,

refer

to

Combustion

Air

And

Vent

Pipe

section

(near

center

of

this

manual)

for

details.

«Connected

to

a

suitable

venting

system

to

remove

the

hazardous

products

of

gas

combustion,

refer

to

Combus-

tion

Air

And

Vent

Pipe

section

(page

19

of

this

manual)

for

details,

*Connected

to

a

suitable

hot

water

heating

system.

¢Supplied

with

a

suitable

electrical

supply

for

all

boiler

mo-

tors

and

controls.

«Connected

to

a

properly

located

thermostat

or

operating

control,

(not

included

with

boiler)

«Placed

on

level

surface

(must

NOT

be

installed

on

carpet-

ing)

«Condensate

drain

line

must

be

pitched

down

to

floor

drain

or

external

condensate

pump

with

reservoir

at

4”

per foot

(wood

frame

or

blocks

may

be

used

to

raise

boiler).

Locating

The

Boiler

Select

a

location

which

is

level,

central

to

the

piping

systems

served

and

as

close

to

the

vent

and

air

intake

terminals

as

pos-

sible.

Accessibility

clearances,

if

more

stringent

(i.e.

larger

clearances)

than

required

fire

protection

clearances,

must

be

used

for

the

boiler

installation.

Accessibility

clearances

may

be

achieved

with

the

use

of

removable

walls

or

partitions.

The

boiler

is

approved

for

installation

in

closets

and

on

com-

bustible

floors.

This

boiler

shall

NOT

be

installed

on

carpeting.

The

clearances

shown

in

Table

#2

indicate

required

clearances.

A

minimum

1”

clearance

must

be

maintained

between

com-

bustible

construction

and

each

of

the

left,

top

and

back

surfaces

of

the

boiler.

A

minimum

8”

clearance

is

required

on

the

right

side,

to

allow

room

for

the

inlet

air

pipe.

An

18”

clearance

must

be

maintained

at

a

side

where

passage

is

required

to

access

an-

other

side

for

cleaning

or

servicing,

inspection

or

replacement

of

any

parts

that

normally

may

require

such

attention.

Allow

at

least

24”

at

the

front

and

left

side

and

8”

at

the

top

for

servicing.

No

clearances

are

required

to

venting

or

combustion

air

intake

piping.

Equipment

shall

be

installed

in

a

location

which

facilitates

the

operation

of

venting

and

combustion

air

intake

piping

systems

as

described

in

this

manual.

BEFORE

INSTALLING

THE

BOILER

6.

Advise

owner

of

boiler

to

keep

venting

and

combustion

air

intake

passages

free of

obstructions.

both

the

venting

and

com-

bustion

air

intake

piping

systems

connected

to

the

outdoors

must

permit

flow

through

the

piping

systems

without

restric-

tions

for

the

boiler

to

operate.

7.

The

boiler

shall

be

installed

such

that

the

automatic

gas

ignition

system

components

are

protected

from

water

(dripping,

spray-

ing,

rain,

etc.)

during

operation

and

service

(circulator

replace-

ment,

condensate

trap,

control

replacement,

etc.).

Combustion

Air

And

Vent

Pipe

Requirements

This

boiler

requires

a

dedicated

direct

vent

system.

In

a

direct

vent

system,

all

air

for

combustion

is

taken

directly

from

outside

atmo-

Top

sphere,

and

all

flue

products

are

discharged

to

outside

atmosphere.

Combustion

air

and

vent

pipe

connections

must

terminate

together

in

the

same

atmospheric

pressure

zone,

either

through

the

roof

or

sidewall

(roof

termination

preferred).

See

Figures

9

& 10

(in

Combustion

Air

And

Vent

Pipe

section

of

this

manual)

for

required

clearances.

CAUTION

A

Keep

boiler

area

clean

of

debris

and

free

of

flamable

and

combustible

materials,

vapors

and

liquids.

TABLE

#2

-

Required

Clearances

8

(203.2)

1

(25.4)

Left

Side

1

(25.4)

24

(609.6)

Right

Side

8

(203.2)

-

Base

1

(25.4)

-

Front

1

(25.4)

24

(609.6)

Back

1

(25.4)

-

Intake/Vent

Piping

0

(0)

-

Near

Boiler

Hot

Water

Piping

1

(25.4)

-

All

distances

measured

from

the

cabinet

of

the

boiler.

WARNING

When

vent

pipe

is

exposed

to

temperatures

below

freezing,

such

as

when

it

passes

through

an

unheated

space

or

when

a

chimney

is

used

as

a

raceway,

vent

pipe

must

be

insulated

with

1/2”

Armaflex

or

equivalent.

In

extreme

cold

climate

areas,

use

34”

Armaflex

or

equivalent.

Combustion

air

must

be

clean

outdoor

air.

Combustion

air

must

not

be

taken

from

inside

structure

because

that

air

frequently

is

contaminated

by

halogens,

which

include

fluorides,

chlorides,

phosphates,

bromides

and

iodides.

These

elements

are

found

in

aerosols,

detergents,

bleaches,

cleaning

solvents,

salts,

air

fresheners,

paints,

adhesives

and

other

household

products.

A

Locate

combustion

air

inlet

as

far

away

as

possible

from

swimming

pool

and

swimming

pool

pump

house.

All

combustion

air

and

vent

pipes

must

be

airtight

and

watertight.

Combustion

air

and

vent

piping

must

also

terminate

exactly

as

shown

in

Figure

9

or

10

(in

Combustion

Air

And

Vent

Pipe

section,

page

19

of

this

manual).

Vent

connections

serving

appliances

vented

by

natural

draft

shall

not

be

connected

into

any

portion

of

mechanical

draft

systems

operating

under

positive

pressure.

Solvent

cements

are

combustible.

Keep

away

from

heat,

sparks,

and

open

flame.

Use

only

in

well

ventilated

areas.

Avoid

breathing

in

vapor

or

allowing

contact

with

skin

or

eyes.

FAILURE

TO

FOLLOW

THE

AFOREMENTIONED

WARNINGS

COULD

RESULT

IN

FIRE,

PROPERTY

DAMAGE,

PERSONAL

INJURY,

OR

DEATH.

10

BEFORE

INSTALLING

THE

BOILER

Condensate

Drain

Requirements

Condensate

drain

line

to

be

pitched

down

to

floor

drain

at

a

mini-

mum

of

4”

per

foot.

An

external

condensate

pump

(not

furnished)

may

be

used

if

floor

drain

is

not

available.

The

condensate

pump

must

be

designed

for

flue

gas

condensate

application.

NOTICE

1.

Condensate

trap

is

built

into

the

boiler,

an

external

trap

is

not

required

and

should

not

be

used.

2.

Wood

frame

or

blocks

may

be

used

to

raise

the

boiler

to

maintain

drain

pitch

or

to

be

above

external

condensate

pump

reservoir.

3.

There

is

a

115

Volt

AC

receptacle

provided

on

the

service

switch

junction

box

which

is

located

at

the

boiler

right

side,

to

provide

power

for

an

external

condensate

pump

(if

needed).

Foundation

Requirements

Boiler

must

be

placed

on

level

surface.

Boiler

is

NOT

to

be

installed

on

carpeting.

NOTICE

If

boiler

is

not

level

condensate

drain

lines

will

not

function

properly.

Adjustable

feet

are

located

on

the

boiler

to

make

up

for

minor

surface

irregularities

or

tilt.

Wood

frame

or

blocks

may

be

used

to

raise

boiler

to

maintain

drain

pitch

or

to

be

above

external

condensate

pump

reservoir.

Removal

of

Existing

Boiler

From

Common

Vent

System

When

an

existing

boiler

is

removed

from

a

common

venting

system,

the

common

venting

system

is

likely

to

be

too

large

for

proper

vent-

ing

of

the

appliances

remaining

connected

to

it.

At

the

time

of

re-

moval

of

an

existing

boiler,

the

following

steps

shall

be

followed

with

each

appliance

remaining

connected

to

the

common

venting

system

placed

in

operation,

while

the

other

appliances

remaining

connected

to

the

common

venting

system

are

not

in

operation.

1.

Seal

any

unused

openings

in

the

common

venting

system.

2.

Visually

inspect

the

venting

system

for

proper

size

and

hori-

zontal

pitch

and

determine

there

is

no

blockage,

or

restrictions,

leakage,

corrosion

and

other

deficiencies

which

could

cause

an

unsafe

condition.

3.

In-so-far

as

is

practical,

close

all

building

doors

and

windows

and

all

doors

between

the

space

in

which

the

appliances

remain-

ing

connected

to

the

common

venting

system

are

located

and

other

spaces

of

the

building.

Turn

on

clothes

dryer

and any

ap-

pliance

not

connected

to

the

common

venting

system.

Turn

on

any

exhaust

fans,

such

as

range

hoods

and

bathroom

exhaust,

so

they

will

operate

at

maximum

speed.

Do

not

operate

a

summer

exhaust

fan.

Close

fire

dampers.

4.

Place

in

operation

the

appliance

being

inspected.

Follow

the

lighting

instructions.

Adjust

thermostat

so

appliances

will

oper-

ate

continuously.

5.

Test

for

spillage

at

the

draft

hood

relief

opening

after

5

minutes

of

main

burner

operation.

Use

the

flame

of

a

match

or

candle,

or

the

smoke

from

a

cigarette,

cigar

or

pipe.

6.

After

it

has

been

determined

that

each

appliance

remaining

connected

to

the

common

venting

system

properly

vents

when

tested

as

outlined

above, return

doors,

windows,

exhaust

fans,

fire

place

dampers,

and

any

other

gas-burning

appliance

to

their

of use.

7.

Any

improper

operation

of

the

common

venting

system

should

be

corrected

so

the

installation

conforms

with

the

National

Fuel

Code,

NFPA-54/ANSI

-Z223.1

and/or

the

Natural

Gas and

Propane

Installation

Code,

CAN/CSA

B149.1..

When

resizing

any

portion

of

the

common

venting

system,

the

common

vent-

ing

system

should

be

resized

to

approach

the

minimum

size

as

determined

using

the

appropriate

tables

in

Chapter

13

of

the

National

Fuel

Gas

Code,

NFPA-54/ANSI-

Z223.1

and/or

the

Natural

Gas and

Propane

Installation

Code,

CAN/CSA

B149.1.

PLACING

THE

BOILER

The

boiler

should

be

placed

to

provide

the

most

direct

connections

to

the

combustion

air,

vent

and

system

piping

as

possible.

Place

crated

boiler

as

close

to

selected

location

as

possible

and

uncrate

boiler.

The

uncrated

boiler

may

be

moved

into

position

with

an

appliance

dolly

or

2-wheel

hand

truck.

The

dolly

or

hand

truck

should

be

inserted

under

the

left

hand

side

of

the boiler.

It

is

possible

to

slide

the

boiler

for

a

short

distance

on

a

smooth

floor

or

surface.

1

NOTICE

Refer

to

manual

section

“locating

the

boiler”

(page

9

of

this

manual),

for

required

clearances

for

servicing

and

maintenance.

NEAR

BOILER

PIPING

When

the

installation

of

the

boiler

is

for

a

new

heating

system,

first

install

all

of

the

radiation

units

(panels,

radiators,

baseboard,

or

tub-

ing)

and

the

supply

and

return

mains.

After

all

heating

system

piping

and

components

have

been

installed,

make

final

connection

of

the

system

piping

to

the

boiler.

A

hot

water

boiler

installed

above

radia-

tion

level,

or

as

required

by

the

Authority

having

jurisdiction,

must

be

equipped

with

a

low

water

cut

off

device.

A

periodic

inspection

is

necessary

for

flushing

of float

type

devices,

per

low

water

cut

off

manufacturers

specific

instructions.

Supply

And

Return

Lines

The

packaged

boiler

unit

is

set

up

to

receive

1

4”

NPT

supply

and

return

piping

from

top

access.

The

boiler

unit

can

also

be

piped

from

the

left

side

by

turning

the

supply

elbow,

and

from

the

rear

of

the

unit

by

removing

plugs

in

the

rear

boiler

section.

NOTICE

The

circulator

pump

and

isolation

valves

are

furnished

within

a

carton

inside

the

boiler

cabinet

and

can

be

installed

at

the

installer

preferred

location.

CAUTION

Copper

supply

and

return

piping

must

NOT

be

installed

directly

into

aluminum

boiler

section

casings

due

to

galvanic

corrosion

between

dissimilar

metals.

Iron

or

steel

bushings

or

pipe

nipples

should

be

used

between

copper

system

piping

and

boiler

to

make

final

connection

to

boiler.

Also, the

use

of

dielectric

unions

is

acceptable.

The

packaged

boiler

is

furnished

with

iron

piping

in

the

front

boiler

section

for

the

supply

and

return

connections.

Figure

2

-

Single

Zone

Boiler

Piping

SERVICE

VALVE

\

CIRCULATOR

————a-

SUPPLY

TO

J

SYSTEM

RETURN

FROM

SYSTEM

By

tee

PURGE

(DRAIN)

SERVICE

VALVE

12

NEAR

BOILER

PIPING

Figure

3

-

Multi-zone

Boiler

Piping

With

Zone

Valves

ZONE

SERVICE

ZONE

VALVE

SUPPLY

TO

ZONES

ZONE

SERVICE

VALVE

CIRCULATOR

RETURN

FROM

ZONES

PURGE

(DRAIN)

VALVES

ZONE

SERVICE

VALVE

13:

NEAR

BOILER

PIPING

Figure

4

-

Multi-Zone

Boiler

Piping

With

Circulators

ZONE

SERVICE

VALVE

SUPPLY

TO

ZONES

FLOW

CHECK

VALVE

ZONE

SERVICE

Oval

VALVE

tremens

EL

OW

CHECK

VALVE

——

RETURN

FROM

~

ZONES

PURGE

(DRAIN)

VALVES

None

SERVICE

VALVE

CIRCULATORS

<

J

NOTICE

When

zoning

with

circulators,

the

furnished

circulator

pump

should

be

used

as

one

of

the

zone

pumps.

Each stripped

end

of

the

electrical

wires

for

the

circulator

pump

inside

the

junction

box

should

be

taped

or

wire

nutted

to

prevent

short

circuits.

Unplug

the

circulator

pump

wiring

at

the

integrated

boiler

control.

14

NEAR

BOILER

PIPING

Figure

5

-

Single

Zone

Boiler

Piping

RELIEF

VALVE

DISCHARGE

PIPING

Pressure

Relief

Valve

The

boiler

is

furnished

with

a

factory

installed

relief

valve

in

the

top

of

the

boiler.

Provide

%4”

piping

from

the

supplied

relief

valve

to

a

local

floor

drain,

but

leave

an

air

gap

between

piping

and

drain.

No

shutoff

of

any

description

shall

be

placed

between

safety

relief

valve

and

the

boiler,

or

on

the

discharge

pipes

between

such

safety

valve

and

the

atmosphere.

Installation

of

the

safety

relief

valve

shall

con-

form

to

ANSI/ASME

Boiler

and

Pressure

Vessel

Code,

Section

IV.

The

manufacturer

is

not

responsible

for

any

water

damage.

15

Expansion

Tank

And

Make-Up

Water

Determine

required

system

fill

pressure,

system

design

temperature,

and

system

water

content.

Boiler

contains

2.6

gallons

(U.S.).

Size

expansion

tank

accordingly.

Consult

expansion

tank

manufacturer

for

proper

sizing

information.

Connect

properly

sized

expansion

tank

(not

furnished)

as

shown

in

Figure

6

for

diaphragm

type

ex-

pansion

tank

and

Figure

7

for

conventional

closed

type

expansion

tanks.

For

diaphragm

type

expansion

tanks, adjust

the

tank

air

pres-

sure

to

match

the

system

fill

pressure.

Install

air

vent

(furnished)

as

shown

for

diaphragm

type

expansion

tank

system

only.

Install

make-up

water

connections

as

shown

per

local

codes.

Ifa

pressure

reducing

valve

is

used,

adjust

to

match

the

system

fill

pressure.

In

connecting

the

cold

make-up

water

supply

to

the

boiler,

make

sure

that

clean

water

supply

is

available.

When

the

water

supply

is

from

a

well

or

pump,

sand

strainer

should

be

installed

at

the

pump.

NEAR

BOILER

PIPING

Figure

6

-

Diaphragm

Type

Expansion

Tank

Piping

MANUAL

FILL

VALVE

AUTOMATIC

AIR

VENT*

3/4"x1/8"

BUSHING*

3/4"

TEE*

3/4"

NIPPLE

(FURNISHED

AND

INSTALLED

ON

PACKAGED

BOILER)

3/4"

STREET

ELL*

COLD

WATER

FILL

»

FURNISHED

IN

PARTS

BAG.

DIAPHRAGM

TYPE

EXPANSION

TANK

COMBINATION

QUICK

FILL

VALVE,

STRAINER,

CHECK

VALVE

AND

PRESSURE

REDUCING

VALVE

16

NEAR

BOILER

PIPING

Figure

7

-

Conventional

(closed

type)

Expansion

Tank

Piping

CLOSED

TYPE

EXPANSION

TANK

EXPANSION

TANK

SERVICE

VALVE

(GATE

VALVE

OR

FULL

PORT

BALL

VALVE)

MANUAL

FILL

VALVE

COLD

WATER

FILL

CHECK AND

PRESSURE

REDUCING

VALVE

7

NEAR

BOILER

PIPING

Figure

8

-

Condensate

Drain

Piping

THREADED

NIPPLE

(PVC)

(INSTALLED)

Condensate

Drain

Piping

The

condensate

trap

is

built

into

the

boiler,

an

external

trap

is

not

required

and

should

NOT

be

used.

Provide

4%”

PVC

condensate

drain

and

fittings.

Condensate

drain

to

be

pitched

down

to

floor

drain

at

a

minimum

of

4”

per

foot.

Install

furnished

%”

PVC

tee

to

overflow

fitting

as

shown

in

Figure

8.

The

2”

diameter

schedule

40

PVC

or

CPVC

condensate

drain

and

pipe

fittings

must

conform

to

ANSI

standards

and

ASTM

D

1785

or

D2846.

Schedule

40

PVC

or

CPVC

cement

and

primer

must

conform

to

ASTM

D2564

or

F493.

In

Canada,

use

CSA

or

ULC

certified

schedule

40

PVC

or

CPVC

drain

pipe

cement.

A

condensate

pump

with

a

reservoir

(not

furnished)

may

be

used

to

remove

condensate

to

a

drain

line

(sanitary

line)

above

boiler

if

a

floor

drain

is

not

available

or

its

in

accessible.

OPEN

DRAIN

PIPE

TO

BE

PITCHED

DOWN

TO

FLOOR

DRAIN

AT

A

MINIMUM

1/4"

PER

FOOT

TO

DRAIN

CONDENSATE

DRAIN

PVC

TEE

1/2"SLIPX1/2"SLIPX1/2"NPT

FURNISHED

IN

PARTS

BAG

Filling

Condensate

Trap

With

Water

Qn

The

Initial

Start

Up

The

Condensate

Trap

Must

Be

Manuall

Filled

With

Water,

The

following

are

the

steps

required

to

initially

fill

the

condensate

trap

for

start

up,

these

steps

are

only

required

at

the

initial

start

up

or

if

maintenance

requires

draining

of

the

condensate

trap:

1.

Disconnect

the

vent

condensate

drain

line

from

the

bottom

of

the

vent

tee

on

the

boiler.

2.

Pour

about

1

cup

of

cold

tap

water

into

the

vent

drain

line

with

a

proper

funnel.

3.

Excess

water

should

go

through

the

overflow

and

out

through

the

condensate

drain

line.

Verify

proper

operation

of

the

drain

line

(or

external

condensate

pump

if

used).

4.

Reinstall

the

vent

drain

line.

NEAR

BOILER

PIPING

Chilled

Water

Piping

The

boiler,

when

used

in

connection

with

a

refrigeration

system,

must

be

installed

so

the

chiller

medium

is

piped

in

parallel

with

the

boiler

with

appropriate

valves

to

prevent

the

chilled

medium

from

entering

the boiler.

The

boiler

piping

system

of

a

hot

water

boiler

connected

to

heat-

ing

coils

is

located

in

air

handling

units

where

they

may

be

exposed

to

refrigerated

air

circulation

must

be

equipped

with

flow

control

valves

or

other

automatic

means

to

prevent

gravity

circulation

of

the

boiler

water

during

cooling

cycle.

COMBUSTION

AIR

AND

VENT

PIPE

Connections

And

Termination

Provisions

for

combustion

and

ventilation

air

must

be

in

accordance

with

section,

Air

For

Combustion

and

Ventilation,

of

the

National

Fuel

Gas

Code,

ANSI

2223.1/NFPA54,

or

Sections

8.2, 8.3

or

8.4

of

National

Gas

and

Propane

Installation

Code,

CAN/CGA-B

149.1,

or

applicable

provisions

of

the

local

building

code.

These

boilers

require

a

dedicated

direct

vent

system.

All

air

for

com-

bustion

is

taken

directly

from

outdoors

through

the

combustion

air

intake

pipe.

All

flue

products

are

discharged

to

the

outdoors

through

the

vent

pipe.

1.

Refer

to

Combustion

Air

And

Vent

Pipe

section

that

follows,

also

see

Figures

9

&

10

for

combustion

air

and

vent

pipe

roof

and

sidewall

termination.

(Roof

termination

is

preferred)

Combustion

air

and

vent

pipes

must

terminate

together

in

same

atmo

spheric

pressure

zone

as

shown.

Construction

through

which

vent

and

air

intake

pipes

may

be

installed

is

a

maximum

24

inches,

minimum

'4”

thickness.

2.

Combustion

air

and

vent

pipe

fittings

must

conform

to

American

National

Standards

Institute

(ANSI)

standards

and

American

Society

for

Testing

and

Materials

(ASTM)

standards

D1784

(schedule-40

CPVC),

D1785

(schedule-40

PVC),

D2665

(PVC-DWYV),

D2241

(SDR-21

and

SDR-26

PVC),

D2661

(ABS-

DWV),

or

F628

(schedule-40

ABS),

Pipe

cement

and

primer

must

conform

to

ASTM

standards

D2564

(PVC)

or

D2235

(ABS).

In

Canada

construct

all

combustion

air

and

vent pipes

for

this

unit

of

CSA

or

ULC

certified

schedule-40

CPVC,

schedule-40

PVC,

PVC-DWV

or

ABS-DWYV

pipe

and

pipe

cement.

SDR

pipe

is

NOT

approved

in

Canada.

3.

Combustion

air

and

vent

piping

connections

on

boiler

are

sized

for

2”

pipe.

Any

pipe

size

change

(to

3”)

must

be

made

outside

of

the

boiler

casing

in

a

vertical

run

of

pipe

to

allow

for

proper

drainage

of

vent

condensate.

Due

to

potential

for

flue

gas

tem-

peratures

over

155°F,

the

first

five

(5)

feet

of

vent

pipe

must

be

CPVC,

the

remaining

vent

pipe

can

be

PVC.

If

any

elbows

are

employed

within

the

first

5

feet

of

vent,

they

must

be

CPVC

too.

Two

(2)

-

30”

pieces

of

2”

CPVC

pipe

are

furnished

with

the

boiler.

NOTICE

The

transition

from

2”

pipe

to

3”

pipe

must

be

made

in

a

vertical

run.

HoT

|

arti

|

Standard

ASTM

F891

*

ASTM

D2665

**

ASTM

D1785

**

ASTM

D2241

**

158

|

70

- -

ASTM

D2846

**

ASTM

F441

*

ASTM

F442

*

210

|

100

|

— -

ASTM

D2661

***

180

|

82

7 7

ASTM

F628

***

UL-1738

414

ULC

S636

212

|

— -

*

Allowable

temperatures

based

on

Classifications

covered

in

ASTM

D4396

[Deflection

Temperatures

under

Load

(264

psi)

(1819KPa)].

*™

Allowable

temperatures

based

on

Classifications

covered

in

ASTM

D1784

[Deflection

Temperatures

under

Load

(264

psi)

(1819KPa)].

***

Allowable

temperatures

based

on

Classifications

covered

in

ASTM

D3965

[Deflection

Temperatures

under

Load

(264

psi)

(1819KPa)].

12

COMBUSTION

AIR

AND

VENT

PIPE

4.

Combustion

air

and

vent

piping

lengths:

BOILER

2

PIPE

MINIMUM

2

PIPE

MAXIMUM

|

3°

PIPE

MINIMUM

3

PIPE

MAXIMUM

SIZE

VENTING VENTING

VENTING

cee

2

FEET

21

FEET

15

FEET

92

FEET

75

&

50

2

FEET

26

FEET

20

FEET

112

FEET

The

first

5

ft.

of

“TOTAL

EQUIVALENT

LENGTH”

of

vent

piping

¢

Termination

should

be

positioned

where

it

will

not

be

run

must

be

2”

CPVC:

subjected

to

potential

damage

by

foreign

objects,

such

as

The

length

of

pipe

is

counted

from

the

boiler

jacket

(air

intake

pipe)

stones,

balls,

etc..

or

from

vent

tee

(vent pipe)

the

termination

is

not

counted

toward

+

Termination

should

be

positioned

where

vent

vapors

are

not

the

“Total

Equivalent

Length”.

objectionable.

For

additional

elbows,

reduce

the

maximum

vent

length

as

shown:

»

Put

vent

on

a

wall

away

from

the

prevailing

winter

wind.

*

2°

90°

elbow

-1

'

ft.

per

additional

elbow.

Locate

or

guard

the

vent

to

prevent

accidental

contact

with

+

3”

90°

elbow

-

3 ft.

per

additional

elbow.

people

or

pets.

Terminate

the

vent

above

normal

snowline.

Avoid

locations

Example:

where

snow

may

drift

and block

the

vent.

Ice

or

snow

may

cause

the

boiler

to

shut

down

if

the

vent

becomes

obstructed.

To

add

2

additional

90

*

elbows

to

a

3°

pipe

for

a

75

boiler,

Under

certain

conditions,

flue

gas

will

condense,

forming

Fach

elbow

is

3

additional

ft.

per

90

°

elbow

for

a

total

of

6

ft..

moisture,

and

may

be

corrosive.

In

such

cases,

steps

should

be

taken

to

prevent

building

materials

at

the

vent

from

being

damaged

by

exhaust

of

flue gas.

(1

elbow

@

3

ft.

+

|

elbow

@ 3

ft.

=

6

additional

ft.

of

pipe)

Vent

shall

not

terminate

where

it

may

cause

hazardous

frost

or

ice

accumulations

on

adjacent

property

surfaces.

‘The

total

additional

pipe

is

then

subtracted

from

the

maximum

props’

allowable

pipe

length

to

give

the

new

maximum

length

of

94

ft.

7.

The

venting

system

shall

terminate

at

least

3 ft.

(0.9m)

above

with

6,

90°

elbows.

any

forced

air

inlet

(except

the

boiler’s

combustion

air

inlet)

(“TOTAL

EQUIVALENT

LENGTH’).

within

10

ft.(3m).

The

venting

system

shall

terminate

at

least

12

_

in.

from

any

air

opening

into

any

building.

The

bottom

of

the

Original

100

ft.

max,

-

6

ft,

for

2

additional

elbows

=

new

9

ft.

vent

shall

be

located

at

least

12

in.

above

grade.

Termination

maximum

length.

of

the

vent

shall

be

not

less

than

7

ft.

(2.1m)

above

an

adjacent

public

walkway

or

paved

driveway.

The

vent

terminal

shall

not

be

installed

closer

than

3 ft.

from

the

inside

corner

of

an

L

shaped

structure.

Termination

of

the

vent

should

be

kept

at

least

3 ft.

away

from

vegetation.

USA

only,

The

venting

system

shall

terminate

at

least

4

ft.

horizontally

from,

and

in

no

case

above

or

below,

unless

a

4

ft.

(1.22m)

horizontal

distance

is

maintained,

from

elec-

tric

meters,

gas

meters,

regulators,

and

relief

equipment.

Canada

only,

The

venting

system

shall

terminate

at

least

6

ft.

(1.83m)

horizontally

from,

an

in

no

case

above

or

below,

unless

a

6

ft.

(1.83m)

horizontal

distance

is

maintained,

from

electric

meters,

gas

meters,

regulators,

and

relief

equipment.

5.

Combustion

air

and

vent

piping

to

be

pitched

back

to

boiler

at

minimum

'4”

per

ft.

(21

mm/m)

from

intake

and

vent

terminals

so

that

all

moisture

in

combustion

air

and

vent

piping

drains

to

boiler.

Pipes

must

be

pitched

continuously

with

no

sags

or

low

spots

where

moisture

can

accumulate

and block

the

flow

of

air

or

flue gas.

Combustion

air

and

vent

pipes

must

be

airtight

and

watertight.

6.

Consideration

for

the

following

should

be

used

when

determining

an

appropriate

location

for

termination

of

combustion

air

and

vent

piping.

¢

Comply

with

all

clearances

required

as

stated

in

paragraph

7.

e

Termination

should

be

positioned

where

vent

vapors

will

not

damage

plants/shrubs

or

air

conditioning

equipment.

¢

Termination

should

be

positioned

so

that

it

will

not

be

effected

by

wind

eddy,

air

born

leaves,

snow,

or

recirculated

flue

gases.

20

COMBUSTION

AIR

AND

VENT

PIPE

Figure

9

-

Roof

Vent

/

Intake

terminations

8"

MINIMUM

VERTICAL

SEPARATION

BETWEEN

COMBUSTION

AIR

INTAKE

AND

VENT

MAINTAIN

12"

MINIMUM

CLEARANCE

ABOVE

HIGHEST

ANTICIPATED

SNOW

LEVEL

USA

-

12”

(300mm)

Canada

-

18”

(450mm)

COMBUSTION

AIR

e

Vent

shall

not

terminate

with

6

ft.

(1.8m)

of

a

mechanical

air-supply

inlet

to

any

building.

¢

Vent

shall

not

terminate

above

a

regulator

within

3

ft.

(900

mm)

horizontally

of

the

vertical

centerline

of

the

regulator

vent

outlet

to

a

maximum

vertical

distance

of

15ft

(9.5m).

e

Vent

shall

not

terminate

within

3

ft.

(900mm)

of

a

window

or

door

that

can

be

opened

in

any

building,

or

any

non-

mechanical

air-supply

inlet

to

any

building,

or

of

the

combustion

air

inlet

of

any

other

appliance.

¢

Vent

shall

not

terminate

underneath

a

veranda,

porch

or

deck

unless,

(a)

the

veranda,

porch

or

deck

is

fully

open

on

a

minimum

of

two

sides

beneath

the

floor,

and

(b)

the

distance

between

the

top

of

the

vent

termination

and

the

underside

of

the

veranda,

porch

or

deck

is

greater

than

|

ft.

(300mm).

Zi

COMBUSTION

AIR

AND

VENT

PIPE

Figure

10A

-

Side

Wall

Vent

/

Intake

terminations

-

Less

Than

12”

Clearance

Above

Grade

Less

Than

12”

Clearance

oon

MINIMUM...

MAXIMUM

SEPARATION

36"MIN

ye

a é

MAX

IMUM

La

ogg

EE

Figure

10B

-

Side

Wall

Vent

/

Intake

Terminations

-

12”

Or

More

Clearance

Above

Grade

12”

Or

More

Clearance

18"

MAXIMUM

22

COMBUSTION

AIR

AND

VENT

PIPE

Figure

11

-

Combustion

Air

and

Vent

Piping

2"

(0.4mm)

COMBUSTION

AIR

INTAKE

PIPING

-—~,

VENTIUNTAKE

TERMINATIONS

2"

(50.8mm)

CPVG

VENT

PIPING

*

(FURNISHED)

2"

(60,.8mm)

CPVC

COUPLING

(FURNISHED)

aN

2"

(60.8mm)

DIAMETER

VENT

AND

COMBUSTION

AIR

INTAKE

PIPING

-

15°

(4.57m)

MAXIMUM

LENGTH

TOTAL

WITH

4

-

90°

ELBOWS

FOR

K90

-

100

20

(6.10m)

MAAIMUM

LENGTH

TOTAL

WITH

4-90"

ELBOWS

FOR

K90

-

75

AND

KQ0

-

50

2'

(.61m)

MINIMUM

LENGTH

TOTAL

WITH

4

-

90°

ELBOWS

FOR

ALL

“Se

EXHAUST

TEE

(FURNISHED)

VENTANTAKE

TERMINATIONS

3"

(76.2mm)

COMBUSTION

AIR

INTAKE

PIPING

3"

(76.2mm)

VENT

PIPING

2"

(60.8mm)

CPVC

VENT

PIPING

(FURNISHED)

TRANSITION

FITTING

2"

(508mm)

@

TO

3"

(76.2mm)

@

IN

2”

(0.8mm)

CPVC

COUPLING

VERTICAL

RUN

(FURNISHED)

3"

(76.2mm)

DIAMETER

VENT AND

COMBUSTION

AIR

INTAKE

PIPING

FOR

K90

-

100

80"

(24.38m)

MAXIMUM

LENGTH

TOTAL

WITH

4

-

90°

ELBOWS

15°

(6.10m)

MINIMUM

LENGTH

TOTAL

WITH

4

-

90°

ELBOWS

FOR

K90

-

75

AND

K90

-

50

100°

(30.48m)

MAXIMUM

LENGTH

TOTAL

WITH

4

-

90°

ELBOWS

20'

(6.10m)

MINIMUM

LENGTH

TOTAL

WITH

4

-

90°

ELBOWS

TRANSITION

FITTING

2"

(50.8mm)

@

TO

3°

(76.2mm)

@

IN

VERTICAL

RUN

EXHAUST

TEE

(FURNISHED)

23

COMBUSTION

AIR

AND

VENT

PIPE

Installation

7.

After

pipes

have

been

cut

and

pre-assembled,

apply

cement

1.

Attach

combustion

air

intake

piping

to

supplied

Fernco

2”

cou-

primer

to

pipe

fitting

socket

and

end

of

pipe

to

insertion

mar

k

pling

on

mixer.

Attach

vent

piping

to

furnished

2”

CPVC

vent

Quickly

apply

approved cement

to

end

of

pipe

and

fitting

tee

on

draft

inducer

outlet,

socket

(over

primer).

Apply

cement

in

light,

uniform

coat

on

the

inside

of

socket

to

prevent

buildup

of

excess

cement.

Apply

NOTICE

second

coat.

All

pipe

joints

are

to

be

water

tight

8.

While

cement

is

still

wet,

insert

pipe

into

socket

with

4%

turn

twist.

Be

sure

pipe

is

fully

inserted

into

fitting

socket.

2.

Working

from

the

boiler

to

the

outside,

cut

pipe

to

required

; . ;

9.

Wipe

excess

cement

from

joint.

A

continuous

bead

of

cement

length(s).

. . .

..

will be

visible

around

perimeter

of

a

properly

made

joint.

3.

Deburr

inside

and

outside

of

pipe.

-

10.

Handle

pipe

joint

carefully

until

cement

sets.

4.

Chamfer

outside

edge

of

pipe

for

better

distribution

of

primer

Lo,

a

we

11.

Support

combustion

air

and

vent

piping

a

minimum

of

and

cement.

.

-

every

5

feet

using

pre-formed

metal

hanging

straps.

Do

not

5.

Clean

and

dry

all

surfaces

to

be

joined.

rigidly

support

pipes.

Allow

movement

due

to

expansion

and

Check

dry

fit

of

pipe

and

mark

insertion

depth

on

pipe.

contraction.

NOTICE

12.

Slope

horizontal

portion

of

combustion

air

and

vent

pipes

toward

boiler

a

minimum

of

4”

per

linear

ft.

(21mm/m)

with

It

is

recommended

that

all

pipes

be

cut,

no

sags

between

hangers.

prepared,

ane

menting

2

bled

mere

re

13.

Use

appropriate

methods

to

seal

openings

where

vent

and

permanentiy

cementing

any

joint.

combustion

air

pipes

pass

through

roof

or

side

wall.

GAS

SUPPLY

PIPING

Check

Gas

Supply

.

th

boil

be

th

size

for

the

lenoth

Use

only

those

piping materials

and

joining

methods

listed

f f

Bas

oe

to

bo

Bin

ee

ene

tof,

he.

il

€

tens

as

acceptable

by

the

authority

having

jurisdiction,

or

in

the

orrun

an

or

the

ad

tu

ene

tbl

a

f,

h

gas

ull

ization

absence

of

such

requirements,

by

the

National

Fuel

Gas

Code,

equipment

connecte

tout

ce

Fable

#2

tor

the

proper

size

(next

ANSI

Z223.1/NFPA

54

and

or

the

Natural

Gas

and

Propane

page).

Be sure

your

gas

line

complies

with

local

codes

and

gas

Installation

Code,

CAN/CSA

B149.1

company

requirements.

,

oo

Use

pipe

joint

compound

suitable

for

liquefied

petroleum

gas

The

boiler

and

its

individual

shutoff

valve

must

be

disconnected

on

male

threads

only

from

the

gas

supply

piping

system during

any

pressure

testing

of

dio;

-

that

system

at

test

pressures

in

excess

of

%

psig

(3.5kpa).

Use

ground

joint

unions.

The

boiler

must

be

isolated

from

the gas

supply

piping

system

by

Install

a

sediment

trap

upstream

of

gas

controls.

closing

its

individual

manual

shutoff

valve

during

any

pressure

Use

two

pipe

wrenches

when

making

the

connection

to

the gas

testing

of

the gas

supply

piping

system

at

test

pressures

equal

to

or

valve

to

keep

it

from

turning.

less

than

%

psig

(3.50ka).

6.

Install

a

manual

shutoff

valve

in

the

vertical

pipe

about

5

feet

NATURAL

|

PROPANE

above

floor.

GAS GAS

7.

Tighten

all

joints

securely.

MAXIMUM

GAS

SUPPLY

40’

we.

14”

we.

8.

Propane

gas

connections

should

only

be

made

by

a

licensed

PRESSURE

propane

installer.

aa

enEScy

wt

4’

we.

40”

we.

9.

Two

stage

regulation

should

be

used

by

the

propane

installer.

10.

Propane

gas

piping

should

be

checked

out

by

the

propane

Connecting

The

Gas

Piping

Refer

to

Figure

12

(on

following

page)

for

the

general

layout

at

the

boiler.

It

shows

the

basic

fittings

you

will

need.

The

gas

line

enters

the

boiler

from

the

right

side

jacket panel.

The

boiler

may

receive

the gas

supply

pipe

through

the

left

side,

or

rear

jacket

panel

by

relocating

the gas

valve

connector

and

pipe

assembly.

The

boiler

is

equipped

with

a

%”

NPT

connection

on

the

gas

valve

for

supply

piping.

The

following

rules

apply:

24

installer.

GAS

SUPPLY

PIPING

Checking

The

Gas

Piping

The

boiler

and

its

gas

connection

must

be

leak

tested

before

placing

the

boiler

in

operation.

Open

the

manual

shutoff

valve.

Test

for

leaks

by

applying

soap

suds

(or

a

liquid

detergent)

to

each

joint.

Bubbles

forming

indicate

leak.

CORRECT

EVEN

THE

SMALLEST

LEAK

AT

ONCE.

WARNING

Never

use

a

match

or

open

flame

to

test

for

leaks.

NATURAL

GAS

ey

20

92,000

190,000

350,000 625,000

40

63,000

130,000

245,000 445,000

60

50,000

105,000 195,000

365,000

PROPANE

GAS

Copper

Tubing”

Iron

Pipe

5/8” 3/4”

4/2”

3/4”

20

131,000

216,000

189,000

393,000

40

90,000

145,000

129,000

267,000

60

72,000

121,000

103,000

217,000

*

Outside

diameter

Figure

12

-

Gas

Piping

GAS

SUPPLY

PIPING

MANUAL

SHUT-OFF

VALVE

__--——

SEDIMENT

-

TRAP

UNION

29

GROUND

JOINT

ELECTRICAL

WIRING

WARNING

A

Turn

off

electrical

power

at

fuse

box

before

making

any

line

voltage

connections.

Follow

local

electrical

codes.

All

electrical

work

must

conform

to

local

codes

as

well

as

the

National

Electrical

Code,

ANSI/NFPA70,

and/or

the

Canadian

Electrical

Code,

Part

1,

CSA

C22.1,

Electrical

Code.

Electric

Power

Supply

Prior

to

making

any

line

Voltage

connections,

service

switch

at

boiler

should

be

in

the

OFF

position

and

the

power

turned

OFF

at

the

fuse

box.

Run

a

separate

120

Volt

circuit

from

a

separate

over

current

protec-

tion

device

in

the

electrical

service

entrance

panel.

This

should

be

a

15

ampere

circuit.

A

service

switch

has

been

pre-wired

and

located

on

the

exterior

boiler

jacket.

See

Figure

13

for

diagram showing

location

of

service

switch

junction

box

and

power

supply

connection

points.

Connect

black

(hot)

lead

from

the

power

supply

to

either

of

the

unused

brass

screws

on

the

service

switch.

Connect

the

white

(neutral)

lead

from

the

power

supply

to

the

white

screw

on

the

ser-

vice

switch.

Connect

the

green

(ground)

lead

from

the

power

supply

to

the

ground

(green)

screw

on

the

service

switch.

The

receptacle

on

the

service

switch

is

always

powered

regardless

of

whether

the

switch

is

ON

or

OFE

and

could

be

used

as

a

power

supply

for

an

external

condensate

pump

if

one

is

used.

The

boiler,

when

installed,

must

be

electrically

grounded

in

accor-

dance

with

the

requirements

of

the

authority

having

jurisdiction

or,

in

the

absence

of

such

requirements,

with

the

National

Electrical

Code,

ANSI/NFPA-70

and/or

the

Canadian

Electrical

Code

Part

1,

CSA-C22.1,

Electrical

Code.

Run

a

14

gauge

or

heavier

copper

wire

from

the

boiler

to

a

grounded

connection

in

the

service

panel

or

a

properly

driven

and

electrically

install

Your

Thermostat

The

thermostat

location

has

an

important

effect

on

the

operation

of

your

boiler

system.

BE

SURE

TO

FOLLOW

THE

INSTRUCTIONS

INCLUDED

WITH YOUR

THERMOSTAT.

Locate

the

thermostat

about

five

feet

above

the

floor

on

an

inside

wall.

It

may

be

mounted

directly

on

the

wall

or

on

a

vertical

mount-

ed

outlet

box.

It

should

be

sensing average

room

temperature.

Avoid

the

Following:

Set

heat

anticipator

at

0.7

amps.

Connect

24

Volt

thermostat

leads

to

the

two(2) yellow

wires

located

in

service

switch

junction

box,

located

on

outer

jacket

of

boiler.

See

Figure

13

for

service

switch

junction

box

and

thermostat

field

wiring

connections.

26

Gonnéat

Givculatel

Pump

Wiring

See

Figure

13

(following

page)

for

service

switch

junction

box

and

circulator

pump

field

wiring

connections.

A

5

feet

wiring

harness

with

flexible

metal

conduit

is

supplied

to

connect

the

circulator

pump

to

the

service

switch

junction

box.

If

the

two

120

Volt

circula-

tor

wire

terminals

inside

the

junction

box

are

not

used,

please

leave

the

two

wire

nuts

to

prevent

the

short

circuit.

CAUTION

LABEL

ALL

WIRES

PRIOR

TO

DISCONNECTION

A

WHEN

SERVICING

CONTROLS.

WIRING

ERRORS

CAN

CAUSE

IMPROPER

AND

DANGEROUS

OPERATION.

VERIFY

PROPER

OPERATION

AFTER

SERVICING.

DEAD

SPOIS:

Behind

doors

COLD

SPOTS:

HOT

SPOTS:

C led

pi

Concealed

pipes

or

ducts

—

pe

Fireplace

TV

set

Stairwells

-

drafts

~<

:

Radios

L

Unheated

rooms

on

—

Direct

sunlight

other

side

of

wall

-

Kitchens

ELECTRICAL

WIRING

Figure

13

-

Field

Wiring

Connections

120

VOLT

WIRE

COLOR

CODE

CIRCULATOR

BK

=

BLACK

oe

on

24

VOLT

THERMOSTAT

NEUTRAL

BOILER

p

BK

WIRING

—

:

INJ-BOX

=

—y

G

HOT

120

VOLTS

60HZ1@

GROUND

POWER

SUPPLY

SERVICE

SWITCH

FIELD

WIRING

CONNECTIONS

SERVICE

SWITCH

JUNCTION

BOX

2/

ELECTRICAL

WIRING

Figure

14

-

D

-

Schematic

Wiring

Diagram

Wvddvid

UadGV7

GNV

OLWWAHOS

NASM

138

OMId

YOLOANNOOD

JO

NOLLV9OT

SONSUSITY

T38V7

NO.

SLON

“LIND

FHL

GNY

LOINNOOSIG

N3IMLI9

JUIM

dddOO

AINO

Jsn

CAMINDAY

SV

NOILOSLONd

SCOTYIAO

CNY

SNVAW

LOSNNOOSIG

FGIAOUd

‘AlddNS

YAMOd

VV

ONTIM

(141d

DOA

O¢L

sss

ONIMIM

TOA

cL

ONIMIM

(T4ld

LIOA

Pe

-- >a nn

roo

ONTMIM

LIOA

be

Alddfd=

ud

NMOUd

=

ud

LFIOIA=

A

ddd

=

4

Nadu

=

9

MOTISA=A

WOWTd

=

Hg

ALIHM

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if

any

of

the

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wire

as

supplied

with

this

appliance

must

be

replaced,

it

must

be

replaced

with

type

150°

C

Thermoplast

its

equivalent

ic

wire

Ori

28

ELECTRICAL

WIRING

Figure

15

-

E-

Ladder

Wiring

Diagram

120

VOLT

POWER

SUPPLY

L1

;

HOT

!

1

Le

nn

WHT

ON/OFF

SWITCH

(sr

—

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P12-2

P6-2

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120

.

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TRANSFORMER

|

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34

q

yvac

Ops

CASTING

TEMPERATURE

SAFETY

SWITCH

GAS

VALVE

(MANUAL

RESET)

VR8205A

tt

1t

—

@

i

ak

aka

P35

psa

[OT

pss Poe

t

P3-1

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@

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LOGIC

&

TIMERS

@‘_,DIFFERENTIALAIR

INDICATOR

LIGHTS

*

@]

“PRESSURE

SWITCH

©

POWER

pe3-3

Q

PURGE

P3-6

©

IGNITER

HIGH

LIMIT

©

VALVE

uK

P3-9

AQUASTAT

O

FLAME

CONTROL

1013-10

CONTROL

BLOWER

TEMPERATURE

SAFETY SWITCH

P3-7

fF

P3-4

® @

Z\,

POWER

SUPPLY.

PROVIDE

THERMOSTAT

DISCONNECT

MEANS

AND

OVERLOAD

PROTECTION

AS

REQUIRED

USE

ONLY

COPPER

WIRE

BETWEEN

DISCONNECT

AND

THE

UNIT

"P"

LABEL

REFERENCE

LOCATION

OF

CONNECTOR

PLUG

BETWEEN

SCHEMATIC

AND

LADDER

DIAGRAM

NOTE:

RECEPTACLE

IS

LIVE

WHEN

BOILER

SWITCH

IS

OFF

*

CAUTION:

REFERENCES

PLUG

CONNECTION

29

P7-2

CONTROLS

AND

ACCESSORIES

This

section

provides

a

brief

description

of

the

key

controls

and

accessories

found

in

this

boiler.

See

the

Troubleshooting

section

(page

47

of

the

of

this

installation

manual)

for

detailed

sequences

of

operation

and

troubleshooting

procedures.

See

the

Repair

Parts

Manual

for

locations

of

all

control

components

and

accessories

described,

Integrated

Boiler

Control

(IBC)

The

Integrated

Boiler

Control

(IBC)

is

a

microprocessor

based

controller

for

a

high

efficiency

gas

boiler

that

monitors

all

safety

controls

and

which

controls

the

operation

of

the

combustion

air

blower,

circulator

pump,

burner,

and

a

combination

hot

surface

igniter/flame

sensor.

This

controller

is

not

intended

for

use

with

a

vent

damper.

This

controller

is

mounted

on

the

control

panel

inside

of

the

boiler

and

contains

five

(5)

diagnostic

indicator

lights.

Gas

Control

Valve

The

electrically

controlled

24

Volt

Honeywell

Model

VR8205

Combination

Gas

Control

Valve

is

designed

to

meet

the

requirements

for

use

with

hot

surface

ignition

systems

found

in

this

boiler.

The

valve

is

piped

to

the

gas/air

mixer.

Hot

Surface

Igniter

The

120

Volt

Hot

Surface

Igniter

heats

up

to

1800

°F to

initiate

com-

bustion

of

the gas

in

the

burner.

The

igniter

is

mounted

the

burner

through

the

gas/air

mixer.

The

igniter

also

serves

as

a

means

for

proving

the

main

burner

flame

by

flame

rectification.

In

the

event

of

a

lack

of

flame

signal

on

three

(3)

consecutive

trials

for

igni-

tion,

the

IBC

will

lockout.

The

“VALVE”

and

“FLAME”

diagnostic

indicator

lamps

(lamp

“D”

and

“E”

on

the

IBC,

See

Figure

16)

will

blink

indicating

the

failure

mode

as

a

lack

of

flame

signal.

The

IBC

is

manually

reset

from

lockout

by

either

removing

and

reestablishing

the

thermostat’s

call

for

heat,

or

by

turning

the

service

switch

OFF,

then

back

ON.

High

Limit

Aquastat

Control

The

High

Limit

Aquastat

Control

determines

the

maximum

boiler

water

temperature

and

also

provides

a

means

for

protecting

the

boiler

and

heating

system

from

unsafe

operating

conditions

which

could

damage

the boiler.

The

aquastat

is

mounted

in

the

2”

NPT

control

well

and

%4°x'2”

bushing

on

the

top

of

the

front

boiler

section

at

the

hot

water

outlet.

The

aquastat

is

tied

in

with

the

IBC

and

is

factory

set

at

180

°F

water

temperature.

The

high

limit

setpoint

is

field

adjustable

and

may

be

set

anywhere

between

100

°F

and

200

°F,

The

field

setpoint

adjustment

for

each

installation

depends

on

heating

system

requirements.

The

aquastat

automatically

resets

when

the

boiler

water

temperature

decreases

(5-30

°F

adjustable

differential).

The

differential

can

be

adjusted

with

the

(white)

Differential

Adjustment

Wheel

on

the

aquastat

and

gives

the

flexibility

for

boiler

operation.

The

larger

the

differential,

the

longer

the

run

cycle

of

the

boiler.

30

NOTICE

The

maximum

setpoint

of

the

Aquastat

must

not

exceed

200

°F.

Draft

Inducer

Temperature

Safety

Switch

The

Draft

Inducer

Temperature

Safety

Switch

is

a

disc

thermostat

(180

°F

setpoint)

located

on

the

induced

draft

fan

outlet

port.

The

switch

protects

the

inducer

and

vent

pipe

from

a

potential

high

temperature

condition

for

the

discharging

flue

gases.

This

condition

would

typically

be

a

result

of

higher

aquastat

setting

or

over

firing.

The

temperature

safety

switch

automatically

resets

when

the

higher

aquastat

setting

or

over

firing.

The

temperature

safety

switch

automatically

resets

when

the

vent

temperature

decreases.

(15

°F

switch

differential).

Casting

Temperature

Safety

Switch

In

the

event

of

lack

of or

loss

of

water

in

the

boiler,

the

Casting

Temperature

Safety

Switch

(300

°F

setpoint)

installed

on

the

top

of

the

aluminum

boiler

section

shuts

off

the

boiler

by

shutting

off

power

to

the

Integrated

Boiler

Control

(IBC)

and

causes

the

Power

Indicator

Light

to

go

out.

This

fault

requires

manual

reset

of

the

casting

temperature

safety

switch

to

restart

the

boiler.

Verify

that

the

boiler

is

properly

filled

with

water

before

resetting

this

switch.

WARNING-Never

run

cold

water

into

a

hot

empty

boiler.

Differential

Pressure

Air

Proving

Switch/Blocked

Vent

Safety

Shutoff

All 90

Series

Hot

Water

Boilers

come

equipped

with

either

one

(100

Series)

or

two

(200

Series)

diaphragm-type

differential

pressure

switches.

The

differential

pressure

switch

monitors

air

flow

by

sensing

the

differential

pressure

measured

in

inches

of

water

(”

w.c.).

The

pressure

switch

contacts

close

when

the

draft

inducer

is

running.

The

closed

switch

proves

there

is

adequate

air

flow

for

combustion.

The

pressure

switch

shuts

off

the

main

burner

if

the

differential

pressure

is

inadequate

due

to

a

blocked

vent

pipe,

a

blocked

air

intake,

blocked

boiler

sections,

or

a

blocked

draft

inducer.

After

five

(5)

minutes

of

lack

of

adequate

differential

pressure,

the

IBC

will

lock

out

and

the

“Purge”

indicator

light

will

blink,

indicating

a

failure

to

prove

adequate

combustion

air

flow

or

flue

gas

flow.

The

IBC

will be

automatically

reset

after

fifteen

(15)

minutes

or

can

be

manually

reset

from

lockout

by

(a)

removing

and

reestablishing

the

thermostat

call

for

heat

or

(b)

by

turning

the

service

switch

OFF

and

back

ON

again.

If

the

boiler

cannot

be

restored

to

normal

operating

conditions

by

resetting

the

control,

contact

a

quallified

service

agency

to

check

the

heat

exchanger

flue-ways

for

blockage.

CONTROLS

AND

Draft

Inducer

The

draft

inducer

(blower)

provides

a

means

for

pulling

combustion

air

into

and

through

the

mixer,

the

burner,

the

flue

ways

of

the

cast

aluminum

boiler

sections

and

the

flue

adapter

before

being

discharged

through

the

vent

piping

to

the

outdoors.

See

applicable

sections

for

proper

sizing

and

installation

of

combustion

air

and

vent

piping

in

this

manual.

Circulator

Pump

Every

forced

hot

water

system

requires

at

least

one circulating

pump.

The

circulating

pump

imparts

the

necessary

energy

to

move

the

water

through

the

closed

loop

supply

and

return

piping

systems,

terminal

heating

equipment

(ie.

finned

tube

radiators,

etc.)

and

back

through

the

boiler

for

reheating.

To

provide

the

required

hot

water

flow

rates,

the

circulator

pump

must

be

properly

sized

to

overcome

frictional

losses

(usually

measured

in

feet

of

water,

also

referred

to

as

“pump

head

loss”)

of

the

supply

and

return

piping

systems

and

boiler.

The

circulator

pump

is

furnished

in

a

carton

within

the

boiler

cabinet

for

a

single

zone

or

zone

valve

controlled

heating

system

and

should

be

correctly

located

on

the

downstream

(i.e.,

pumping

away)

side

of

the

expansion

tank.

For

a

pump

controlled

system (where

there

is

a

circulator

for

each

zone)

the

circulator

provided

with

the

boiler

can

work

for

one

zone.

For

more

details

on

piping

and

circulators,

see

Near

Boiler

Piping

section

(page

12

of

this

manual).

Drain

Valve

The

manual

drain

valve

provides

a

means

of

draining

the

water

in

the

heating

system,

including

the

boiler

and

hot

water

supply

and

return

piping

systems

installed

above

the

drain

valve.

This

drain

valve

is

installed

in

the

%4”

tapping

at

the

bottom

of

the

front

boiler

section.

Any

piping

installed

below

the

elevation

of

this

drain

valve

will

require

additional

drain

valves

to

be

installed

at

low

points

in

the

piping

systems

in

order

to

drain

the

entire

system.

A.S.M.E.

Rated

Pressure

Relief

Valve

Each

boiler

must

have

a

properly

sized

and

installed

American

Society

of

Mechanical

Engineers

rated

pressure

relief

valve.

Water

expands

as

it

is

heated

by

the

burner/boiler

sections.

If

there

is

no

place

for

the

water

to

expand

its

volume,

(i.e.

a

properly

sized

and

properly

functioning

expansion

tank)

pressure

on

the

inside

of

the

boiler

and

heating

system

will

increase.

The

furnished

relief

valve

will

automatically

open

at

30

psig

pressure

to

relieve

the

strain

on

the

boiler

and

heating

system

from

the

increasing

pressure.

The

pressure

relief

valve

discharge

must

be

piped

with

piping

same

size

as

the

valve

discharge

opening

to

an

open

drain,

tub

or

sink,

or

other

suitable

drainage

point

not

subject

to

freezing,

in

accordance

with

A.S.MLE.

specifications.

Failure

to

provide

the

pressure

relief

valve

with

piping

as

herein

described

may

cause

water

damage

and/or

serious

bodily

injury.

The

boiler

manufacturer

is

not

responsible

for

any

water

damage

or

personal

injury.

3

ACCESSORIES

Blocked

Vent

Safety

Shutoff

This

boiler

is

equipped

with

a

blocked

vent

safety

shutoff

means,

which

shuts

off

main

burner

gas

in

the

event

that

the

flow

of

combustion

products

through

the

flueways

is

reduced.

In

the

event

of

blocked

flueways,

enough

air

will

not

be

available

to

support

combustion,

and

the

$9301

Integrated

Boiler

Control

(IBC)

will

lockout

due

to

loss

of

adequate

air

flow

(after

3

trials

for

ignition).

The

“PURGE”

diagnostic

indicator

lamp

(lamp

“B”

on

the

IBC,

see

Figure

16)

will

blink

indicating

the

failure

mode

as

a

lack

of

adequate

air

flow.

The

IBC

is

manually

reset

from

lockout

by

either

removing

and

re-establishing

the

thermostat’s

call

for

heat,

or

by

turning

the

service

switch

OFF,

then

back

ON.

If

the

boiler

cannot

be

restored

to

normal

operating

condition

by

resetting

the

control,

contact

a

qualified

service

agency

to

check

heat

exchanger

flueways

for

blockage.

External

Condensate

Pump

(Optional)

For

installations

where

there

is

no

floor

drain

or

other

appropriate

drainage

receptacle

available

to

receive

condensate

from

the

boiler,

an

external

float

activated

condensate

pump

with

integral

sump

is

required.

This

unit

can

be

installed

to

pump

the

condensate

to

a

remote

tie

in

point

to

a

sanitary

sewer

system.

For

this

application,

the

boiler

must

be

installed

so

that

proper

pitch

of

piping

to

the

external

condensate

reservoir

(sump)

can

be

accomplished.

Use

wood

frame

or

blocks

to

raise

boiler

as

required

for

proper

installation.

WATER

TREATMENT

&

FREEZE

PROTECTION

When

filling

the

boiler

water

is

the

preferred

heating

solution.

Most

potable

water

supplies

may

be

used

to

charge

and

re-fill

provided

the

chlorine

and

chloride

ions

levels

are

less

than

100

ppm.

Antifreeze

may

be

used

in

most

applications

provided

all

of

the

fol-

lowing

conditions

are

met:

1.

Unless

a

strict

schedule

of

sampling,

analysis

and

maintenance

of

the

antifreeze

solution

is

followed,

the

boiler

must

be

piped

as

a

primary

loop

connected

to

secondary

loop

as

shown

in

the

Piping

&

Wiring

Diagram

Appendix.

Failure

to

perform

regular

maintenance

to

the

antifreeze

manufacturer’s

instructions

will

result

in

damage

to

the

heat

exchanger

and

the

voiding

of

boiler

warranty.

Only

the

antifreeze

manufacturers

listed

below

are

selected.

At

installation

of

a

new

or

replacement

boiler

and

at

least

on

an

annual

basis

the

system

antifreeze

must

be

analyzed

by

the

antifreeze

supplier

or

their

recommended

laboratory.

Adjustments

to

the

system

antifreeze

must

be

made

according

to

the

antifreeze

manufacturers

recommendations

using

only

their

recommended

products.

All

existing

systems

MUST

be

flushed

of

ALL

old

system

fluid.

Failure

to

do

so

may

void

the

boiler

warranty

if

evidence

of

im-

proper

flushing

is

revealed.

Consult

with

your

heating

profes-

sional

for

recommendations.

Piping

Recommendations

System

leaks

may

not

always

be

visible.

An

unseen

system

leak

will

become

obvious

if

boiler

pressure

decreases

when

make

up

valve

is

closed.

All

system

leaks

must

be

repaired

immediately.

Constant

introduc-

tion

of

make

up

water

will

introduce

dissolved

oxygen,

resulting

in

accelerated

boiler

corrosion.

It

is

recommended

that

Primary/Secondary

piping

be

used

with

any

of

the

recommended

antifreeze

solutions

found

in

this

manual.

See

the

Piping

&

Wiring

Diagram

Appendix.

Water

Chemistry

This

boiler

is

designed

for

a

closed

loop

hydronic

heat

system

ONLY!

This

boiler

is

not

suitable

for

natural

gravity

type

installations,

or

any

other

open

type

system.

System

fluid

pH

must

be

maintained

between

7.0

and

8.0.

Maintain

water

hardness

below

7

grains

hardness.

Filling

with

chlorinated

fresh

water

should

be

acceptable

since

drinking

water

chlorine

levels

are

typically

less

than

5

ppm.

Do

not

fill

boiler

with

water

containing

chlorine

and

chloride

ions

levels

greater

than

100

ppm.

Do

not

use

inhibitors

or

other

additives

that

are

not

specifically

ap-

proved

by

the

antifreeze

manufacturer

for

this

product.

Consult

the

antifreeze

manufacturer

if

any

of

the

above

are

outside

the

stated

ranges.

32

Cleaning

the

Hydronic

System

IMPORTANT:

Do

not

mix

different

manufacturers’

products.

Doing

so

will

void

the

warranty

of

the

boiler.

Consideration

MUST

be

given

to

cleaning

the

heating

system,

particularly

in

retrofit

situations

where

a

new

boiler

with

an

aluminum

heat

exchanger

is

being

installed

in

an

existing

piping

system.

All

existing

systems

must

be

cleaned

and flushed

according

to

the

antifreeze

manufacturer's

recommendations.

Systems

that

have

antifreeze

that

is

not

recommended

by

the

boiler

manufacturer

must

be

completely

flushed

to

ensure

no

unapproved

antifreeze

remains

according

to

the

recommended

antifreeze

manufactures

recommendations.

Evidence

of

an

alternate

antifreeze

in

the

system

may

void

the

boiler

warranty.

In

older

systems

obviously

discolored,

murky

or

dirty

water;

or

a

pH

reading

outside

the

boiler

manufacturer’s

stated

acceptable

range

(pH

7.0

to

8.0)

are

indications

that

the

system

should

be

cleaned

or

treated,

1.

Measure

total

capacity

of

the

system

including

the

piping,

tanks,

boiler,

collector

plates,

etc.

The

most

accurate

method

of

measuring

fluid

capacity

is

to

fill

the

system

and

then

completely

drain

it,

volumetrically

measuring

the fluid

drained.

Thoroughly

flush

the

system

with

clean

water

to

remove

any

sediment

or

contaminants.

Sludge

and

iron

oxide

deposits

can

cause

rapid

breakdown

of

inhibitors.

Cleaning

fluid

-

Flushing

with

clean

water

is

preferred.

If

cleaning

fluid

is

used,

only

use

cleaner

specifically

approved

for

use

with

aluminum

boilers.

Use

only

cleaning

fluids

and

the

procedure

recommended

by

the

antifreeze

manufacturer.

Freeze

Protection

Aluminum

Safe

Antifreeze,

Treatments

and

Additive

Guidelines:

Antifreeze,

if

required,

must

be

one

of

the

antifreeze

manufacturers

listed

in

this

manual.

See

the

“Recommended

Aluminum

Antifreeze

&

Inhibitor

Suppliers”

section

of

this

manual

for

a

list

of

boiler

manufacturer

approved

products.

Always

clean

system

prior

to

using

antifreeze,

refer

to

the

Cleaning

the

Hydronic

System

section

of

this

manual

for

details.

Only

use

the

antifreeze

manufacturers’

products

outlined

in

this

document.

Use

of

antifreeze

must

be

in

accordance

with

local

plumbing

codes.

Dispose

of

old

antifreeze

and

boiler

system

water

in

accordance

with

local

authorities.

Antifreeze

will

raise

the

pH

of

the

hydronic

solution

in

a

heating

system

above

the

recommended

level

due

to

the

corrosion

inhibitors

in

the

antifreeze.

The

solution

must

be

treated

to

maintain

a

pH

within

the

boiler

manufacturer's

recommended

level

to

avoid

damage

to

the

heat

exchanger.

Follow

antifreeze

manufacturer's

instructions

for

details

on

how

to

adjust

the

pH.

WATER

TREATMENT

&

FREEZE

PROTECTION

If

the

system

has

leaked

for

some

reason,

the

water

and

antifreeze

chemistry

will

need

to

be

adjusted.

To

avoid

damage

to

the

boiler,

check

the

pH

and

chemistry

of

the

boiler

solution

and

consult

the

antifreeze

manufacturer

for

recommendations.

It

is

recommended

that

a

pH

reading

is

taken

annually,

and

adjusted

as

necessary.

Follow

antifreeze

/

inhibitor

manufacturer's

instruc-

tions

for

details

on

how

to

adjust

the

pH.

«

Use

of

antifreeze

in

any

boiler

will

reduce

heating

capacity

as

much

as

10-20%.

This

must

be

taken

into

consideration

when

sizing

the

heating

system,

pumps

and

expansion

tank.

Consult

antifreeze

manufacturer's

literature

for

specific

information

on

reduced

capacity.

¢

Using

the

antifreeze

manufacturer’s

instructions

to

determine

the

freezing

temperature

needed

and

use

the

correct

amount

of

anti-

freeze.

Never

exceed

50%

antifreeze

by

volume.

¢

The

boiler

operating

pressure

must

remain

below

15

psi

for

anti-

freeze

solutions

that

specify

a

maximum

of

250°F

(121°C).

NOTICE

Antifreeze

solutions

can

breakdown

over

time.

Failure

to

check

antifreeze

chemistry,

includ-

ing

inhibitors,

annually

may

result

in

accel-

erated

corrosion

of

boiler

and

other

system

components.

Consult

with

the

antifreeze

manufacturer

for

recommendations.

Interstate

Chemical

2797

Freedland

Road

P.O.

Box

1600

Hermitage,

PA

16148-0600

www.interstatechemical.com

Tel:

800-422-2436

Fax:

724-981-8383

Intercool

NFP-30,40,50

AA

Intercool

RPH-15*

Noble

Company

PO

Box

350

Grand

Haven,

MI

49417

www.noblecompany.com

Tel:

800-878-5788

Fax:

800-272-1519

Noburst

AL

Antifreeze

Rhomar

Water

Management,

Inc.

PO

Box

229

Springfield,

MO

65801

www.thomarwater.com

Tel:

800-543-5975

Fax:

417-862-6410

Rhogard

Antifreeeze

Pro-Tek

922

Inhibitor*

for

Aluminum

heat

exchangers.

*

These

products

may

be

used

to

adjust

the

pH

level

of

the

hydronic

system,

but

on

occasion

may

not

resolve

the

pH

issue.

In

these

cases

it

is

recommended

to

flush

the

system

and

refill

with

untreated

water

and

new

boiler

manufacturer

approved

antifreeze

suitable

IMPORTANT:

Regardless

of

antifreeze

or

inhibitors

used,

be

sure

to

follow

the

antifreeze

manufacturer's

instructions

for

use,

safe

handling

and

storage

of

their

products.

Refer

to

the

MSDS

(Material

Safety

Data

Sheets)

provided

by

the

antifreeze

manufacturer

for

potential

hazards

and

first

aid

procedures

for

exposure

or

ingestion.

Antifreeze

Testing

Services:

Each

of

the

recommended

antifreeze

manufacturers

have

developed

a

sampling

program

available

to

the

homeowner

and

contractor.

Contact

the

antifreeze

manufacturer

regarding

their

sampling

plan

procedure.

Consult

the

antifreeze

manufacturer

for

details

on

sample

requirements

and

recommendations.

The

boiler

manufacturer

reserves

the

right

to

make

changes

without

notice.

33

START

UP

Filling

Boiler

With

Water

And

Purging

Air

For

Systems

With

Diaphragm

Type

Expansion

Tanks

Refer

to

the

appropriate

diagrams

in

Section

VII,

“Near

Boiler

Pip-

ing,’ for

more

information.

1.

Close

all

zone

service

valves

on

the

supply

and

return

piping.

Open

the

feed

valve

and

fill

boiler

with

water.

Make

sure

air

vent

is

open.

Hold

relief

valve

open

until

water

runs

air

free

for

five

seconds

to

rapidly

bleed

air

from

boiler,

then

let

the

relief

valve

snap

shut.

2.

Open

the

zone

service

valve

on

the

supply

pipe

for

the

first

zone.

Open

the

purge

valve

on

the

first

zone.

Feed

water

will

fill

the

zone,

pushing

air

out

the

purge

valve.

Close

the

purge

valve

when

the

water

runs

air

free.

Close

the

zone

service

valve.

3.

Repeat

step

2

for

all

remaining

zones.

4.

Open

all

service

valves.

Any

air

remaining

trapped

in

the

return

lines

between

the

service

valves

and

the

boiler

will

be

pushed

towards

the

air

vent

when

the

boiler

is

placed

in

operation.

5.

Inspect

piping

system.

Repair

any

leaks

immediately.

Purging

Air

For

Systems

With

Conventional

Closed

Type

Expansion

Tanks:

Refer

to

the

appropriate

diagrams

in

Section

VII,

“Near

Boiler

Piping,

for

more

information.

1.

Close

all

zone

service

valves

on

the

supply

and

return

piping

and

close

the

expansion

tank

service

valve.

Drain

expansion

tank.

Open

the

feed

valve

and

fill

boiler

with

water.

Hold

relief

valve

open

until

water

runs

air

free

for

five

seconds

to

rapidly

bleed

air

from

boiler,

then

let

the

relief

valve

snap

shut.

2.

Open

the

zone

service

valve

on

the

supply

pipe

for

the

first

zone.

Open

the

purge

valve

on

the

first

zone.

Feed

water

will

fill

the

zone,

pushing

air

out

the

purge

valve.

Close

the

purge

valve

when

the

water

runs

air

free.

Close

the

zone

service

valve.

3.

Repeat

step

2

for

all

remaining

zones.

4.

Open

the

expansion

tank

service

valve

and

the

tank

vent.

Fill

the

tank

to

the

proper

level

and

close

the

tank

vent.

Remove

the

handle

from

the

expansion

tank

service

valve

so

the

homeowner

doesn’t

accidentally

close

it.

5.

Open

all

service

valves.

Any

air

remaining

trapped

in

the

return

lines

between

the

service

valves

and

the

boiler

will

be

pushed

towards

the

expansion

tank

when

the

boiler

is

placed

in

opera-

tion.

6.

Inspect

piping

system.

Repair

any

leaks

immediately.

NOTICE

DO

NOT

use

stop

leak

compounds.

Leaks

in

threaded

connections

in

the

aluminum

boiler

sections

must

be

repaired

immediately.

Aluminum

threads

will

not

seal

themselves.

Placing

Boiler

In

Operation

WARNING

If

you

do

not

follow

these

instructions

exactly,

a

fire

or

explosion

may

result

causing property

damage,

personal

injury

or

loss

of

life.

This

appliance

is

equipped

with

an

ignition

device

which

automatically

lights

the

pilot.

Do

not

try

to

light

the

pilot

by

hand.

BEFORE

OPERATING

smell

all

around

the

appliance

area

for

gas.

Be

sure

to

smell

the

floor

because

some

gas

is

heavier

than

air

and

will

settle

on

the

floor.

What

To

Do

If

You

Smell

Gas

«Do

not

try

to

light

any

appliance.

«Do

not

touch

any

electrical

switch;

do

not

use

any

phone

in

your

building.

«Immediately

call

your

gas

supplier

from

a

neighbor's

phone.

Follow

the gas

supplier's

instructions.

eIf

you

cannot

reach

your

gas

supplier,

call

the

fire

depart-

ment.

Use

only

your

hand

to

move

the

system

control

switch.

Never

use

tools.

If

the

switch

will

not

move

by

hand,

don’t

try

to

repair

it,

call

a

qualified

service

technician.

Force

or

attempted

repair

may

result

in

a

fire

or

explosion.

Do

not

use

this

appliance

if

any

part

has

been

under

water.

Immediately

call

a

qualified

service

technician

to

inspect

the

appliance

and

to

replace

any

part

of

the

control

system

and

any

gas

control

which

has

been

under

water.

OPERATING

INSTRUCTIONS

1.

STOP!

Read

the

safety

information

above

on

this

label.

7.

Wait

five

(5)

minutes

to

clear

out

any

gas.

Then

smell

for

gas,

2.

Set

thermostat

to

lowest

setting.

including

near

the

floor.

If

you

smell

gas,

STOP!

Follow

“B”

3.

Turn

offall electric

power

to

the

appliance

in

the

safety

information

above

on

this

label.

If

you

don’t smell

1.

Str

p

dwith

PP

i

device

which

gas

go

on

to

.

This

appliance

is

equipped

with

an

ignition

device

whic

ean

automatically

lights

the

burner.

DO

NOT

try

to

light

the

burner

Turn

the

gas

control

knob

counterclockwise

y™~

to

“ON”.

by

hand.

9.

Replace

front

jacket

panel.

5.

Remove

the

front

jacket

panel.

10.

Turn

on

all

electrical

power

to

the

appliance.

6.

Turn

the gas

control

knob

clockwise

ry

fo

“OFF”.

11.

Set

the

thermostat

to

desired

setting.

12.

If

the

appliance

will

not

operate,

follow

the

instructions

“To

Turn

Off

Gas

To

Appliance”

and

call

your

service

technician

or

gas

supplier.

TOTURN

OFF

GAS

TO

APPLIANCE

1.

Set

the

thermostat

to

lowest

setting.

3.

Remove

the

front

jacket

panel.

2.

Turn

off

all

electric

power

to

the

appliance

if

service

is

to

be

4.

Turn

gas

control

knob

clockwise

to

“OFP”.

preformed.

5.

Replace

the

front

jacket panel.

Safe

lighting

and

other

performance

criteria

were

met

with

the gas

manifold

and

control

assembly

provided

on

the

boiler

when

the

boiler

underwent

tests

specified

in

ANSI

Z21.13-latest

revision.

35

CHECK

OUT

PROCEDURE

AND

ADJUSTMENT

Verify

Proper

Sequence

Of

Operation

The

sequence

can

be

followed

via

the

diagnostic

indicator

lamps

on

the

Honeywell

$9301A

integrated

boiler

control

in

Figure

#16.

This

is

the

normal

sequence

of

operation.

A

more

detailed

sequence

of

operation

containing

potential

faults

can

be

found

in

the

service

hints

section.

Figure

16

-

Indicator

Lamps

( \

DIAGNOSTIC

INDICATOR

LAMPS

CONTROL

PANEL

AIR

PRESSURE

SWITCH

TRANSFORMER

“DIAGNOSTIC

SEQUENCE

OF

OPERATION

INDICATOR

LANIPS”

A.

@

“Power

ON,

boiler

standing

by.

Lamp

Ais

illuminated

B.O

indicating

2

Volt

power

is

being

supplied

to

the

inte-

Cc.O

grated

control.”

D.O

E.O

A.

@

B.O

Thermostat

calls

for

heat,

energizing

system

circulator

Cc.O

D.O

E.O

A.

@

“Integrated

boiler

control

goes

through

self

check

of

B.O

internal

circuitry

(1-2

seconds)

and

energizes

draft

Cc.O

inducer”

D.O

E.O

“Draft

inducer

comes

up

to

speed

and

establishes

com-

A.

@

bustion

airflow,

causing

the

normally

open

differential

B.

@

pressure

air

proving

switch

contacts

to

close.

Lamp

Bis

Cc.O

illuminated

indicating

that

combustion

airflow

is

proved

D.O

and

the

15

second

pre

purge

cycle”

E.O

36

CHECK

OUT

PROCEDURE

AND

ADJUSTMENT

SEQUENCE

OF

OPERATION

“DIAGNOSTIC

INDICATOR

LAMPS”

After

pre

purge,

Lamp

B

goes

out

and

Lamp

C

illuminates,

in-

dicating

the

hot

surface

igniter

is

powered

for

the

20

second

igniter

warm-up

period.

The

bright

yellow

orange

glow

of

the

hot

surface

igniter

can

be

observed

through

the

observation

port

in

the

front

boiler

section

just

above

the

igniter.

After

igniter

warm-up,

the

gas

valve

is

energized,

and

opens

on

the

normal

firing

rate

regulator

(2.5”

w.c.)

for

a 6

second

trial

for

ignition.

Lamp

D

illuminates.

The

blue

orange

glow

of

the

burner

can

be

seen

through

the

observation

port.

Two

seconds

later,

Lamp

C

goes

out

as

power

is

turned

off

to

the

hot

surface

igniter.

During

the

last

two

seconds

of

the

6

seconds

trial

for

ignition,

main

burner

flames

is

proven

by

flame

rectifica-

tion

through

the hot

surface

igniter,

providing

flame

rectification

to

the

integrated

boiler

control

and

fully

illuminating

Lamp

E.

The

gas

valve

remains

energized,

and

the

boiler

runs.

Thermostat

ends

call

for

heat,

de-energizing

gas

valve

and

system

circulator.

Burner

stops

firing,

and

Lamp

D

goes

out.

Draft

inducers

remains

powered.

Lamp

B

illuminates,

indicating

draft

inducer

is

running

for

30

second

post-purge.

After

30

seconds,

draft

inducer

is

de-energized.

Lamp

B

goes

out.

Boiler

stands

by

for

heat.

MOODr

MIOOmMr

MmoOOWDr

MmOODp

MOODY

COCOCe/OOCCee@|

@eOCOOelOe@e@eOe@e

OCe0O

NOTICE

First

couple

of

cold

starts

may

be

rough

due

to

gas

line

not

being

completely

purged

of

air,

causing

low

firing

rate

and

high

excess

air

levels.

Inspect

Venting

And

Air

Intake

System

Operate

the

boiler

and

verify

that

all

vent/air

intake

connections

are

gas-tight

and

watertight.

Repair

any

leaks

immediately.

Inspect

Condensate

Drain

Verify

that

all

connections

are

watertight, and

that

condensate

flows

freely.

Repair

any

leaks

immediately.

3/

Inspect

System

Piping

Verify

that

all

connections

are

watertight.

Repair

any

leaks

immediately.

Test

Ignition

System

Safety

Shutoff

Device

1.

Turn

off

manual

gas

valve

Set

thermostat

to

call

for

heat

Boiler

begins

normal

sequence

of

operation

PWN

After

approximately

40

seconds

(pre

purge

and

igniter

warm-

up

period),

lamp

D

illuminates,

indicating

gas

valve

is

powered

5.

After

6

seconds,

gas

valve

closes,

lamp

D

goes

out

as

integrated

boiler

control

senses

that

flame

is

not

present

6.

To

restart

system,

follow

operating

instructions

under

“START-

UP

PLACE

IN

OPERATION”

CHECK

OUT

PROCEDURE

AND

ADJUSTMENT

Test

High

Limit

Control

And

Adjust

While

burner

is

operating,

move

indicator

on

high

limit

control

below

actual

boiler

water

temperature.

Burner

should

go

off

while

circulator

continues

to

operate.

Raise

limit

setting

above

boiler

water

temperature

and

burner

should

reignite

after

pre

purge

and

igniter

warm-up

period.

Set

the

high

limit

control

to

the

design

temperature

requirements

of

the

system.

Maximum

high

limit

setting

is

200°F.

Minimum

high

limit

setting

is

100°F.

Test

Other

Safety

Controls

If

the

boiler

is

equipped

with

a

low

water

cut

off,

a

manual

reset

high

limit,

or

additional

safety

controls,

test

for

operation

as

outlined

by

the

control

manufacturer.

Burner

should

be

operating

and

should

go

off

when

controls

are

tested.

When

safety

controls

are

restored,

burner

should

reignite.

Set

Thermostat

Heat

Anticipator

(If

Used)

And

Verify

Thermostat

Operation

For

a

single

thermostat

connected

to

the

yellow

thermostat

lead

wires

in

the

furnished

field

wiring

junction

box,

the

heat

anticipator

should

be

set

at

0.7

amps.

For

other

wiring

configurations,

refer

to

the

instructions

provided

by

the

thermostat

manufacturer

regarding

adjustment

of

heat

anticipator.

Cycle

boiler

with

thermostat.

Raise

the

thermostat

to

the

highest

setting

and

verify

boiler

goes

through

normal

start

up

cycle.

Lower

thermostat

to

lowest

setting

and

verify

boiler

goes

off.

Measure

The

Natural

Gas Input

Rate

Correct

input

rate

is

essential

for

proper

and

efficient

operation

of

the

burner

and

boiler.

1.

2.

Determine

elevation

at

installation

site.

See

page

6

and

7

of

this

manual

to

determine

the

correct

input

rate

for

the

local

elevation.

Obtain

the

yearly

average heating

value

of

the

local

gas

supply

from

the gas

utility.

At

sea

level

elevation,

it

should

be

approximately

1000

Btu’s

per

standard

cubic

foot.

Operate

boiler

for

5

minutes.

Turn

off

all

other

gas

appliances,

extinguishing

standing

pilots

where

applicable.

At

gas

meter,

measure

time

in

seconds

required

to

use

one

cubic

foot

of

gas.

Calculate

input

rate

according

to

the

following

formula:

3600xheating

value

from

step

3

Btuh

inputrate

=

time

from

step

6

8.

Measured

input

rate

should

be

within

+/-2%

of

the

input

rating

from

step

2.

If

within

2%,

go

to

step

9.

If

not,

adjustment

is

required,

proceed

as

follows:

A.

Turn

boiler

off

38

B.

Set

up

U-tube

manometer

or

differential

pressure

gauge

for

measuring

manifold

pressure,

see

Figure

#17.

C.

Manometer

or

gauge

must

be

able

to

read

at

least

0.0

to

3.0

inches

water

column

of

pressure,

and

resolve

to

at

least

0.1

inches

water

column.

Turn

boiler

on.

Manifold

pressure

has

been

nominally

set

at

2.5

inches

w.c.

Manifold

pressure

and

input

rate

must

always

be

measured

with

pressure

regulator

cover

screw

installed.

Cover

screw

must

be

removed

for

adjustment.

Manifold

pressure

reading

will

change

(increase)

when

cover

screw

is

removed.

After

adjusting

input

rate,

turn

boiler

off,

remove

manometer

or

pressure

gauge,

reinstall

%”

plug

on

gas

valve,

Turn

boiler

on.

Restore

all

gas

appliances

that

may

have

been

shut

off

(while

measuring

boiler

input

rate)

to

normal

operating

conditions.

I.

Remove

regulator

cover

screw

on

top

of

gas

valve,

and

insert

an

appropriate

screwdriver

into

adjustment

screw.

II,

Turn

adjustment

screw

clockwise

to

increase

input

rate,

or

counter

clockwise

to

decrease

input

rate.

Il].

Replace

cover

screw,

or

cover

hole

temporarily

with

your

finger

to

check

new

manifold

pressure

setting.

Do

not

set

manifold

pressure

lower

than

2.0

inches

w.c.

or

higher

than

3.0

inches

w.c.

when

adjusting

input

rate.

IV.

Measure

new

input

rate

(cover

screw

must

be

installed).

Repeat

steps

I-IV

until

the

input

rate

is

within

+/-2%

of

the

nameplate

input

rating.

V.

If

the

actual

input

rate

can not

be

set

to

within

2%

of

the

correct

input

rating

by

adjusting

manifold

pressure,

a

change

in

gas

orifice

size

is

required.

Consult

the

boiler

manufacturer

for

information

on

correct

orifice

sizing.

The

specific

gravity

(G)

and

the

higher

heating

value

(HHV)

of

the

local

natural

gas

must

be

obtained

from

the

local

gas

utility

in

order

to

determine

the

proper

orifice

size.

Set

Thermostat

To

Desired

Room

Temperature

Observe

several

operating

cycles

to

verify

proper

operation.

Review

All

Instructions

Review

all

instructions

shipped

with

this

boiler

with

owner

or

maintenance

person.

Instructions

must

be

affixed

on

or

adjacent

to

the

boiler.

Complete

and

sign

the

installation

and

check-out

certificate

found

in

this

manual.

CHECK

OUT

PROCEDURE

AND

ADJUSTMENT

The

following

steps

and

diagram

indicate

the

location

of

the

connection

points

required

to

measure

the

manifold

pressure.

The

manifold

pressure

may

be

measured

using

a

U-Tube

Manometer

or

a

Differential

Pressure

Gauge.

The

diagram

shows

the

connection

of

both

measuring

devices.

Only

ONE

DEVICE

IS

REQUIRED

to

measure

the

manifold

pressure.

Remove

the

plug.

Install

the

appropriate

barbed

fitting

and

connect

the

pressure

side

line

from

the

U-Tube

Manometer

or

Differential

Pressure

Gauge.

Refer

to

“CHECK

OUT

PROCEDURE

AND

ADJUSTMENTS?

in

this

manual

when

reading

the

manifold

pressure.

When

measurement

is

completed, disconnect

the

U-Tube

Manometer

or

Differential

Pressure

Gauge.

Be sure

to

reinstall

the

¥4”

plug,

using

appropriate

pipe

thread

sealant

approved

for

use

with

natural

and

liquefied

Petroleum

gases.

Figure

17

-

Manifold

Pressure

Measurement

Detail

PRESSURE

REGULATOR

ADJUSTMENT

(UNDER

COVER

SCREW)

vw

OUTLET

PRESSURE

TAP

(1/8"

PLUG)

_-—

GAS VALVE

VENT

_-

GROSS

CONNECTOR

W/CAP

AB

Bo

J —..»

TO

PRESSURE

SWITCH

v

PRESSURE,

Sine...

WHITE

TRANSPARENT

/

VINYL

TUBING

/

Cy

ee

REFERENCE

PRESSURE

el

oo

<.

DIFFERENTIAL

PRESSURE

U-TUBE

GAUGE

MANOMETER

Figure

18

-

Gas

Valve

PRESSURE

REGULATOR

ADJUSTMENT

(UNDER

CAP

SCREW)

WIRING

TERMINALS

(2)

VR8205

INLET

OUTLET

NOTICE

PRESSURE

TAP

INLET

»

OUTLET

GAS

CONTROL

KNOB

39

Regulator

cover

screw

must

be

installed

at

all

times

unless

adjusting

manifold

pressure.

Firing

rate

and

manifold

pressure

must

only

be

measured

with

cover

screw

firmly

installed.

INSTALLATION

AND

CHECK-OUT

CERTIFICATE

40

au

nl

|

aa

INSTALLATION

AND

CHECK-OUT

CERTIFICATE

Boiler

Model

Serial

#

Date

Installed

Measured

BTU/HR

input

©

Installation

instructions

have

been

followed

©

Checkout

procedure

and

adjustments

performed

O

Maintenance

and

Service

issues

reviewed

with

owner/

maintenance

person

©

Installation

booklet

affixed

on

or

adjacent

to

boiler

installer

(Company)

Address

Phone

installer’s

Name

Signature

—

poe.

EN

io

MAINTENANCE

AND

CLEANING

Maintenance

as

outlined

below

can

be

performed

by

the

2.

owner

unless

otherwise

noted.

The

acidic

nature

of

flue

gasses

condensing

on

the

aluminum

boiler

—3.

sections

will

cause

the

formation

of

aluminum

oxide.

This

oxide

formation

is

normal,

is

generally

uniform

throughout

the

boiler

sections,

and

represents

a

negligible

mass

of

aluminum

that

is

consumed

by

oxidation

during

the

life

of

the

boiler.

If

left

unchecked,

this

buildup

may

eventually

cause

blockage

of

the

flue

gas

passages

in

the

boiler

sections,

reducing

efficiency,

and

ultimately

shutting

down

the

boiler

due

to

lack

of

combustion

air

flow.

Regular

service

and

maintenance

by

a

qualified

service

agency

must

be

performed

to

2.

Beginning

Of

Each

Heating

Season

1.

Annual

service

call

by

a

qualified

service

agency,

which

includes:

A.

Examine

flue

passages

between

boiler

sections,

burner,

and

condensate

lines,

and

clean

if

necessary

following

the

annual

examination

and

cleaning

instructions

in

para

graph

“F”

on

the

B.

Visually

inspect

venting

and

air

intake

system

for

proper

function,

deterioration

or

leakage.

If

the

vent

or

air

intake

show

any

signs

of

deterioration

or

leakage,

repair

or

replace

them,

immediately.

Insure

proper

reassembly

and

resealing

of

the

vent

and

air

intake

system

C.

Check

for

and

remove

any

obstruction

to

the

flow

of

combustion

air

or

venting

of

flue

gases.

Check

the

air

baffle

located

inside

112”

x

2”

flexible

coupling

on

the

mixer,

clean

it

if

necessary

and

make

sure

to

put

it

back.

Refer

to

repair

parts

diagram

of

mixer

and

pressure

switch

assembly

for

exact

location.

D.

Follow

instructions

for

“PLACING

BOILER

IN

OPERATION”.

E.

Follow

instructions

for?

CHECK

OUT

PROCEDURE

AND

ADJUSTMENTS”,

F.

Visually

inspect

condensate

drain

line

for

proper

operation

and

deterioration.

Check

for

plugged

condensate

drain

line.

G.

Check

the

silicone

rubber

seals

between

boiler

sections.

Insure

that

there

are

no

leaks.

Use

RTV

silicone

rubber

adhesive

sealant (available

in

caulking

gun

tubes)

rated

for

at

least

400°

F

to

replace

or

repair

seals

in

locations

where

original

seals

have

deteriorated,

H.

Check

all

gasketed

joints

for

leakage,

and

tighten

bolts

or

replace

gaskets

if

necessary.

I.

Remove

jacket

front

and

top

panels

and

check

for

piping

leaks

around

relief

valve

and

other

fittings.

Repair,

if

found.

DO

NOT

use

stop

leak

compounds.

4)

Check

that

boiler

area

is

free

from

combustible

materials,

gasoline,

and

other

flammable

vapors

and

liquids.

Circulator

pump

and

blower

motor

furnished

with

boiler

are

permanently

lubricated

from

factory

and require

no

further

lubrication.

Additional

or

non-factory

supplied

pumps

and/

or

motors

should

be

lubricated

according

to

the

pump

and/or

motor

manufacturer’s

instruction.

Daily

During

Heating

Season

assure

safe

trouble

free

operation

and

maximum

efficiency.

1.

Check

for

and

remove

any

obstruction

to

the

flow

of

combustion

air

or

venting

of

flue

gases.

Check

that

boiler

area

is

free

from

combustible

materials,

gasoline,

and

other

flammable

vapors

and

liquids.

MAINTENANCE

AND

CLEANING

Monthly

During

Heating

Season

1.

Remove

jacket

front

and

top

panels

and

check

for

piping

leaks

around

relief

valve

and

other

fittings.

If

found,

contact

a

qualified

service

agency

to

repair.

DO

NOT

use

stop

leak

compounds.

2.

Test

relief

valve.

Refer

to

valve

manufacturers

instructions

packaged

with

relief

valve.

3.

Visually

inspect

venting

and

air

intake

system

for

proper

function,

deterioration,

or

leakage.

If

the

vent

or

air

intake

show

any

signs

of

deterioration

or

leakage,

contact

a

qualified

service

agency

to

repair

or

replace

them

immediately

and

to

insure

proper

reassembly

and

resealing

of

the

vent

and

air

intake

system.

4,

Visually

inspect

the

clear

vinyl

condensate

lines

and

the

PVC

condensate

drain

pipe

for

proper

operation,

leakage,

and

deterioration.

If

the

condensate

lines

or

drain

pipe

show

any

signs

of

blockage,

leakage,

or

deterioration

contact

a

qualified

service

agency

to

clean,

repair,

or

replace

them

immediately.

5,

Check

the

air

baffle

located

inside

1

4”

x

2”

flexible

coupling,

clean

it

if

necessary

and

make

sure

to

put

it

back.

Refer

to

repair

parts

diagram,

mixer

and

pressure

switch

assembly.

Periodically

During

Heating

Season

Where

low

water

cut

offs

are

used,

a

periodic

inspection

of

the

low

water

cut

off

is

necessary,

including

flushing

of float

type

devices.

Refer

to

low

water

cut

off

manufacturer's

specific

instructions.

End

of

Each

Heating

Season

-

Annual

Shutdown

Procedure

Follow

instructions

“TO

TURN

OFF

GAS

TO

APPLIANCE”

If

heating

system

is

to

remain

out

of

service

during

freezing

weather,

and

does

not

contain

antifreeze,

drain

system

completely.

If

boiler

will be

exposed

to

freezing

temperatures,

drain

condensate

lines.

Otherwise,

do

not

drain

system

or

boiler.

Annual

Examination

And

Cleaning

Of

Boiler

Components

1.

Before

Servicing,

turn

off

electrical

power

to

boiler

at

service

switch.

Close

manual

gas

valve

to

turn

off

gas

supply

to

boiler.

42

NOTICE

The

following

service

procedures

must

be

performed

only

by

a

qualified

service

agency.

Boiler

owner

should

not

attempt

these

procedures.

Cleaning

Flue

passages

between

boiler

sections.

A.

O

Any

buildup

of

sediment

or

aluminum

oxide

(white

powdery

or

flaky

substance)

in

the

flue

passages

must

be

cleaned

as

follows:

Remove

jacket

front

and

top

panels.

Disconnect

condensate

drain

line

from

the

barbed

fitting

on

the

bottom

of

the

boiler.

Keep

the

open

end

of

the

drain

line

above

the

water

level

in

the

condensate

trap

to

prevent

the

trap

from

draining.

Disconnect

pressure

switch

hose

from

barbed

fitting

on

gas

valve.

Disconnect

1%

x

2”

flexible

coupling

from

air

inlet.

Disconnect

air

by-pass

(4”

transparent

vinyl

tube)

from

the

bottom

of

the

mixer.

Remove

air

baffle

from

%”

x

2”

flexible

coupling

and

clean

air

baffle

if

necessary.

Refer

to

repair

parts

diagram,

mixer

and

pressure

switch

assembly.

Confirm

that

manual

gas

valve

is

closed

and

disconnect

gas

line

to

gas

valve

at

union,

Disconnect

wires

to

gas

valve.

and

igniter,

Loosen

but

do

not

remove

five

(5)

nuts

attaching

mixer

assembly

to

boiler.

Remove

two

(2)

igniter

screws

and

very

carefully

remove

the

igniter.

Use

care

when

removing

the

igniter,

it

is

very

brittle!

Remove

five

(5)

nuts

and

remove

mixer

assembly.

Remove

burner

and

mixer

gasket.

Aluminum

oxide

deposits

are

water

soluble

and

may

be

rinsed

away

with

spraying

or

running

water.

Before

rinsing,

connect

a

%”

ID,

hose

to

the

barbed

fitting

on

the

bottom

of

the

boiler

and

run

the

hose

to

a

bucket

or

drain.

After

rinsing,

remove

any

remaining

loosened

sediment

using

a

shop

vacuum

with

a

snorkel

attachment.

Inspect

burner

for

any

foreign

matter

in

the

flame

ports

or

inside

the

burner.

Any

foreign

matter

should

be

removed

by

blowing

with

compressed

air

or

vacuuming.

Inspect

interior

of

mixer

for

any

signs

of

sediment

or

aluminum

oxide

and

clean

if

necessary.

MAINTENANCE

AND

CLEANING

K.

Reinstall

burner

and

mixer

gasket

and

position

mixer

L.

assembly

over

studs.

Install

five

(5)

nuts

but

do

not

tighten.

Reinstall

igniter

and

igniter

gasket

and

fasten

with

two

(2)

screws.

Use

care

when

installing

the

igniter.

It is

very

brittle!

Tighten

five

(5)

nuts

holding

mixer

assembly.

Connect:

¢Gas

line

to

gas

valve

«Condensate

drain

line

to

boiler

«Pressure

switch

hose

to

gas

valve

«Air

by-pass

to

mixer

1

%”

x2”

flexible

coupling

to

air

inlet

and

make

sure

to

put

air

baffle

back

to

correct

position

«Igniter

wires

Gas

valve

wires

3.

Visually

inspect

condensate

lines

leading

from

the

boiler

sections

and

the

vent

tee

to

the

condensate

trap.

Refer

to

repair

parts

diagrams.

Any

foreign

material

or

debris

that

is

visible

in

the

condensate

lines

needs

to

be

cleaned

out

as

follows:

A.

Raise

condensate

trap

and

drain

condensate

lines

B,

completely.

Once

the

condensate

trap

is

emptied

of

water,

disconnect

condensate

lines

from

the

fittings

on

the

boiler,

the

vent

tee,

and

the

condensate

outlet.

Remove

the

condensate

trap

and

run

cold

water

through

the

condensate

lines

to

thoroughly

flush

out

any

sediment

or

debris

in

the

lines.

Reinstall

and

connect

the

condensate

trap,

using

the

hose

clamps

to

secure

the

various

condensate

lines

to

their

fittings.

Follow

the

instructions

under

“NEAR

BOILER

PIPING”

for”

filling

condensate

trap

with

water”

43

4,

Inspection

of

the

flue

connector

requires

the

following

steps

(Refer

to

the

repair

parts

diagram.)

A.

Loosen

the

clamp

on

the

draft

inducer

end

of

the

2”

flexible

coupling

that

connects

the

vent

tee

to

the

draft

inducer.

Disconnect

(unplug)

wiring

harness

from

draft

inducer

motor

and

draft

inducer

temperature

safety

switch.

Remove

four

(4)

bolts

that

attach

draft

inducer

to

flue

connector.

Remove

draft

inducer

and

gasket

from

top

of

flue

connector.

Inspect

interior

of

flue

connector.

Any

buildup

of

sediment

or

aluminum

oxide

on

the

inside

surface

must

be

cleaned.

Position

the

draft

inducer

gasket

and

the

draft

inducer

and

fasten

with

four

(4)

screws.

Be

sure

to

connect

ground

wire

from

draft

inducer

motor

to

one

of

the

four

mounting

screws.

Connect

wiring

harness

leads

to

the

draft

inducer

motor

and

the

draft

inducer

temperature

safety

switch.

Connect

the

2”

flexible

coupling

to

the

draft

inducer

outlet.

DETAILED

SEQUENCE

OF

OPERATION

Service

Hints

POWER

ON

STAND

BY

y

THERMOSTAT

CALLS

FOR

HEAT

v

CIRCULATOR

ENERGIZES

THRU

2K1

CONTACTS

y

IBC

SELPCHECK

OF

INTERNAL CIRCUITRY

4-2

SEC

IBC

CHECKS

NO.

AIR

PRESSURE

SWITCH

CONTACTS

IF

MAIN

BURNER

DOES

NOT

PROVE

FLAME

IN

3

TRIALS,

CONTROL

LOCKOUT.

VALVE/FLAME

LIGHT

BLINKS.

MANUAL

RESET

IS

REQUIRED

OR

CONTROL

WILL

AUTOMATICALLY

RESET

AFTER

1

HOUR.

THIS

PROBLEM

IS

A

RESULT

OF

NOT

ESTABLISHING

A

FLAME

SIGNAL.

4

CONTROL

WILL

ATTEMPT

2

ADDITTIONAL

IGNITION

SEQUENCES.

STARTING

WITH

PREPURGE.

FALSE

POSITIVE

PROOF

OF

AIRFLOW.

IBC

WAITS

CLOSED

FOR

45

SEC

oN

FOR

AIR

PRESSURE

SWITCH

CONTACTS

_

BURNER

PROVE

NORMAL

TO

OPEN

AA

ato

OPERATION

IGNITION

PERIOD?

DRAFT

INDUCER

ENERGIZES

THRU

1K1

CONTACTS

IBC

WAITS

FOR

UPTO

&

MINUTES

FOR

AIR

PRESSURE

SWITCH

CONTACTS

TO

CLOSE

INDICATING

FAN

SUCTION

PRESENT

¥

CONTROL

LOCKOUT.

PURGE

LIGHT

BLINKS.

MANUAL

RESET

1S

REQUIRED

OR

CONTROL

WILL

AUTOMATICALLY

RESET

AFTER

15

MINUTES.

CIRCULATOR

REMAINS

ENERGIZED

AS

LONG

AS

THERMOSTAT

CONTINUES

TO

CALL

FOR

HEAT.

>

PURGE

LIGHT

IS

ONAIRFLOW

PROVED.

DRAFT

INDUCER

RUNS

FOR

15

SEC

PREPURGE

DURING

THE

LAST

2

SEC

OF

THE

5

SEC

IGNITION

TRIAL

MAIN

BURNER

FLAME

IS

PROVED

BY

FLAME

RECTIFICATION

A

FLAME

SIGNAL

TO

IBC.

GAS

VALVE

REMAINS

ENERGIZED.

BOILER

RUNS.

t

2

SEC

INTO

THE

5

SEC

IGNITION

TRIAL.

POWER

IS

TURNED

OFF

TO

THE

HOT

SURFACE

IGNITER.

IGNITER

LIGHT

IS

OFF.

t

GAS VALVE

OPENS

FOR

5

SEC

TRIAL

FOR

IGNITION,

BLUE

ORANGE

GLOW

OF

THE

BURNER

CAN

BE

SEEN

THRU

OBSERVATION

PORT.

GAS VALVE

ENERGIZED

THRU

341

AND

4K1.

CONTACTS,

VALVE

LIGHT

IS

ON.

t

PURGE

LIGHT

GOES

OUT.

HOT

SURFACE

IGNITER

POWERED

THRU

SK1

SK2

CONTACTS

FOR

20

SEC

IGNITER

WARMUP

BRIGHT

YELLOW

>

ORANGE GLOW

OF

THE

HOT

SURFACE

IGNITER

CAN

BE

OBSERVED

THRU

THE

OBSERVATION

PORT

IN

FRONT

OF

BOILER

SECTION

JUST

ABOVE

IGNITERIGNITOR

LIGHT

IS

ON

44

DETAILED

SEQUENCE

OF

OPERATION

DRAFT

INDUCER

TEMPERATURE

SAFETY

SWITCH

IF

DRAFT

INDUCER

TEMPERATURE

REACHES

TEMPERATURE

SAFETY

SWITCH

SETPOINT,

SAFETY

SWITCH

CONTACTS

OPEN

IMMEDIATELY

CLOSING

GAS

VALVE

(LIGHT

GOES

OUT)

v

Draft

Inducer

Runs

Thru

30

Second

Post

Purge

And

Switches

Off.

v

CIRCULATOR

RUNS

WITH

THERMOSTAT

ON

CALL

FOR

HEAT.

v

WHEN

TERMPERATURE

SAFETY

SWITCH

CONTACTS

REMAKE

BEFORE

END

OF

CALL

FOR

HEAT,

CONTROL

GOES

INTO

NORMAL

SEQUENCE.

LOSS

OF

FLAME

SIGNAL

IF

AN

ESTABLISHED

FLAME

SIGNAL

IS

LOST

WHILE

CONTROL

EXPECTS

THAT

THE

BURNER

IS

OPERAT-

ING,

CONTROL

WILL

IMMEDIATELY

DE-ENERGIZE

GAS

VALVE.

VALVE

AND

FLAME

LIGHTS

GO

OUT.

DRAFT

INDUCER

RUNS

THROUGH

30

SECOND

POST

PURGE.

CONTROL

WILL

ATTEMPT

TO

RELIGHT

BOILER

3

TIMES.

IF

FLAME

IS

NOT

PROVEN,

CONTROL

LOCKOUT

-

PROBLEM

ESTABLISHING

A

FLAME

SIGNAL.

VALVE

LIGHT

IS

BLINKING.

CONTROL

WILL

AUTOMATICALLY

RESET

AFTER

1

HOUR.

LOSS

OF

COMBUSTION

AIRFLOW

IF

COMBUSTION

AIRFLOW

IS

LOST

WHILE

BURNER

IS

FIRING

(DIFFERENTIAL

AIR

PRESSURE

SWITCH

CONTACTS

OPEN)

GAS

VALVE

WILL

BE

DE-ENER-

GIZED.

VALVE

AND

FLAME

LIGHTS

GO

OUT.

DRAFT

INDUCER

RUNS

THROUGH

30

SECOND

POST

PURGE.

IF

CALL

FOR

HEAT

REMAINS,

IBC

WAITS

5

MIN-

UTES

FOR

AIRFLOW

TO

BE

RE-ESTABLISHED.

IF

AIRFLOW

DOES

NOT

RE-ESTABLISH

CON-

TROL

LOCKOUT

-

PROBLEM

WITH

COMBUSTION

AIRFLOW.

PURGE

LIGHT BLINKS.

CONTROL

WILL

AUTOMATICALLY

RESET AFTER

15

MINUTES.

45

CASTING

TEMPERATURE

SAFETY

SWITCH

IF

BURNER

OPERATES

WHEN

BOILER

HAS

NO

WATER,

ALUMINUM

BOILER

SECTIONS

HEAT

UP

RAPIDLY.

v

CASTING

TEMERATURE

SAFETY SWITCH

CON-

TACS

WILL

OPEN

BREAKING

24

VOLT

POWER

TO

IBC.

POWER

INDICATOR

LIGHT

GOES

OUT.

REQUIRES

MANUAL

RESET

TO

RE-CLOSE

CA-

ONTACTS.

POWER

LIGHT

GOES

OUT.

HIGH

LIMIT

CONTROL

IF

BOILER

WATER

TEMPERATURE

REACHES

HI

LIMIT

(AQUASTAT)

SETPOINT,

HI

LIMIT

N.C.

CON-

TACTS

OPEN

IMMEDIATLEY,

CLOSING

GAS

VALVE.

VALVE

AND

FLAME

LIGHTS

GO

OUT.

v

DRAFT

INDUCER

CONTINUES

TO

RUN FOR

30

SECONDS

POST

PURGE

AND

SWITCH

OFF.

v

CIRCULATOR

RUNS

AS

LONG

AS

THERMOSTAT

CALLS

FOR

HEAT.

v

WHEN

HI

LIMIT

CONTACTS

REMAKE

BEFORE

END

OF

CALL

FOR

HEAT,

CONTROL

GOES

INTO

A

NORMAL

LIGHT

OFF

SEQUENCE.

CIRCULATOR

PUMP

CIRCULATOR

WILL

BE

ENERGIZED

AS

LONG

AS

THERMOSTAT

CALLS

FOR

HEAT

DURING

LOCKOUT.

v

RECOVERY

FROM

ANY

LOCKOUT

REQUIRES

RESET,

WHICH

CAN

BE

ACCOMPLISHED

BY:

(A)

REMOVING

AND

REESTABLISHING

THE

THERMOSTAT’S

CALL

FOR

HEAT

OR

TURNING

THE

SERVICE

SWITCH

OFF

AND

BACK

ON;

OR

(B)

WAITING

FOR

THE

CONTROL

TO

AUTOMATICALLY

RESET

AFTER

15

MINUTES

FOR

LOSS

OF

COMBUSTION

AIRFLOW

OR

ONE

HOUR

FOR

LOSS

OF

FLAME.

DETAILED

SEQUENCE

OF

OPERATION

THERMOSTAT

ENDS

CALL

FOR

HEAT

Vv

GAS

VALVE

AND

CIRCULATOR

PUMP

ARE

DE-

ENERGIZED

AND

FLAME

LIGHTS

GO

OUT

BLOWER

RUNS

FOR

30

SECONDS

POST

PURGE

LIGHT

IS

“ON”

BLOWER

IS

DE-ENERGIZED

FOR

30

SECONDS

PURGE

LIGHT

SHUTS

“OFF”

BOILER

STANDS

BY

FOR

HEAT

46

A

property

damage,

severe

injury

or

death.

TROUBLESHOOTING

2.

Troubleshooting

tools:

A.

Voltmeter

to

check

120

vac

and

24

vac

Fire,

explosion

or

shock

hazard

may

cause

B.

Continuity

tester.

WARNING

C.

Inclined

manometer

or

pressure

gauge

with

0-2.0”

Range

(0.01”

Scale)

for

measuring

suction

pressures

at

pressure

switch.

Do

not

attempt

to

modify

the

physical

or

electrical

characteristics

of

this

boiler

in

any

way.

D.

U-tube

manometer

or

differential

pressure

gauge

with

important

0-14”

range

(0.1”

Scale)

for

measuring

inlet

and

manifold

1.

In

a

reset

from

lockout

condition,

all

electrical

meter

readings

gas

pressures.

at

the

gas

control

valve

(24

vac)

must

be

taken

within

the

trial

3.

What

is

system

status?

for

ignition

period.

A.

Consult

the

chart

on

the

following

page.

If

any

component

does

not

function

properly,

make

sure

it

is

B.

Figure

#16

shows

the

location

on

the

boiler

of

the

correctly

installed

and

wired

before

replacing

it.

diagnostic

indicator

lamps.

Static

electricity

discharge

can

damage

the

integrated

boiler

control

(IBC).

Touch

metal

surface

to

discharge

static

electricity

before

touching

IBC.

The

IBC

cannot

be

repaired.

If

it

malfunctions

it

must

be

replaced.

Only

trained,

experienced

service

technicians

should

service

the

IBC

systems.

Following

troubleshooting,

check

out

the

system

following

the

sequence

of

operation

section

of

this

chapter

for

a

normal

light

off

sequence.

All

controls

are

factory

tested

in

the

assembly

process

and

a

defective

control

is

generally

the

least

likely

cause.

If

you

suspect

you

have

a

defective

control,

read

through

the

troubleshooting

chart

before

you

replace

it.

It is

extremely

unlikely

that

the

two

consecutive

controls

are

defective.

If

it

seems

to

be

happening,

chances

are

that

either

there

is

nothing

wrong

with

the

contorl

or

it

is

being

damaged

by

some

other

problem

(an

electrical

short

burning

out

a

transformer,

for

example).

Initial

Service

Checks

1.

Before

troubleshooting:

A.

Make

sure

that

circuit

breaker

is

on

or

fuse

is

ok

at

electrical

panel.

B.

Make

sure

that

service

switch

is

on.

C.

Make

sure

that

gas

is

on

at

the gas

meter,

at

all

appropriate

manual

shutoff

valves

and

at

the

gas

control

valve.

D.

Make

sure

that

the

thermostat

is

calling

for

heat.

E.

Check

that

wire

connectors

at

the

integrated

boiler

control

and

at

the

originating

control

are

securely

plugged

in

or

connected.

F.

Check

that

hoses

are

securely

connected

and

are

not

plugged

in

or

damaged.

47

TROUBLESHOOTING

System

Status

The

indicator

lights

track

the

operating

sequence.

If

the

system

locks

out,

the

lights

indicate

the

point

in

the

sequence

of

operation

where

lockout

occurs.

IBC

IS

ENERGIZED

THROUGH

24

VOLT

TRANSFORMER.

IBC

IS

NOT

ENERGIZED.

IBC

RECEIVES

MORE

THAN

40

VAC

IBC

IS

ENERGIZING

THE

DRAFT

INDUCER

AND

AIR

FLOW

IS

PROVEN.

OFF

DURING

PURGE

CYCLE-DRAFT

INDUCER

IS

NOT

POWERED

OR

AIR

FLOW

IS

NOT

PROVEN.

OFF

DURING

IGNITER

AND

RUN

CYCLE-NORMAL

OPERATION,

PURGE

CYCLE

COMPLETE.

IBC

IS

LOCKED

OUT.

PROBLEM

COULD

INDICATE

FALSE

POSITIVE

PROOF

OF

AIR

FLOW.

BLOCKED

VENT

OR

INTAKE

AIR

PIPE

OR

FLUE

WAY.

IBC

IS

ENERGIZING

IGNITER

IS

NOT

ENERGIZED

IBC

IS

ENERGIZING

GAS

CONTROL

VALVE

TO

OPEN.

GAS

CONTROL

VALVE

IS

CLOSED.

IBC

IS

LOCKED

OUT.

PROBLEM

IS

FLAME

HAS

NOT

BEEN

PROVEN

IN

THREE

(3)

IGNITION

ATTEMPTS.

MAY

BE

DUE

TO

BROKEN

IGNITER

OR

LACK

OF

OR

LOW

FLAME

SIGNAL,

OR

NO

GAS.

FLAME

PROVEN

FLAME

UNPROVEN

48

TROUBLESHOOTING

CHART

1

WARNING

GREEN

POWER

INDICATOR

LIGHT

IS

NO

>

ILLUMINATED

ON

THE

IBC.

CHART

2

Electrical

shock

hazard

may

cause

Serious

YES

injury

or

death.

The

following

procedures

may

expose

you

to

dangerous

line

voltage.

Use

caution

to

avoid

touching

live

electrical

contacts.

Service

i i

CHECK SYSTEM

STATUS.

IF

LOCKED

must

be

performed

by

a

trained,

experienced

OUT

NOTE

FAILURE

MODE.

WHICH

service

technician.

INDICATOR

LIGHT

IS

BLINKING?

.

RESET

SYSTEM

BY

TURNING

SERVICE

What

to

do

if

you

smell

gas:

SWITCH

OFF

THEN

ON.

IF

NOT

. .

LOCKED

OUT,

SET

THERMOSTAT

TO

Do

not

try

to

light

any

appliance

CALL

FOR

HEAT.

Do

not

touch

any

electrical

switch;

do

not

use

any

phone

in

your

builidng.

Immediatley

call

your

gas

supplier

from

a

v

neighbor’s

phone.

Follow

the

gas

supplier’s

NO

instru

ction

CIRCULATOR

STARTS?

If

you

can

not

reach

your

gas

supplier,

call

the

YES

A

fire

department.

Should

overheating

occur

or

the

gas

supply

fail

to

shut

off,

do

not

turn

off

or

disconnect

the

electrical

supply

to

the

pump.

Instead,

shut

off

the

gas

at

a

location

external

to

the

appliance.

Do

not

use

the

boiler

if

any

part

of

the

gas

control

system

has

been

under

water

a

qualified

service

technician

should

inspect

the

boiler

and

replace

any

part

of

the

control

system

and

any

gas

control

which

has

been

under

water.

Use

only

your

hand

to

turn

the

gas control

knob.

Never

use

tools.

If

the.

Knob

will

not

turn

by

hand.

Don’t

try

to

repair

it.

Force

or

attempted

repair

may

result

in

a

fire

or

explosion.

CHART

2

FALSE

POSITIVE

PROOF

OF

AIRFLOW.

CHECK ¥

AIR

PRESSURE

SWITCH

CONTACTS,

‘

CLOSED

IBC

CHECKS

NORMALLY

OPEN

AIR

IF

CONTACTS

ARE

CLOSED

WITH

NO

PRESSURE

SWITCH

CONTACTS

AIRFLOW,

REPLACE

PRESSURE

SWITCH.

OPEN

CHART

3

49

TROUBLESHOOTING

CHART

2

NO

CHECK

THAT

CIRCUIT

BREAKER

IS

ON

OR

FUSES

ARE

OK

AT

THE

ELECTRICAL

PANEL

CHART

1

J

OK

CHECK

THAT

SERVICE

SWITCH

IS

ON

J

OK

CHECK

CASTING

TEMPERATURE

SAFETY

CHECK

WATER

LEVEL

IN

BOILER.

CHECK

SWITCH.

PUSH

RESET

BUTTON

ON

SWITCH.

OPEN

>

FOR

AIR

TRAPPED

IN

TOP

OF

BOILER.

CONTACTS

OPEN

(BUTTON

UP)

OR

CLOSED

CONTACTS

WILL

NOT

STAY

CLOSED

UNTIL

(BUTTON

DOWN)?

BOILER

COOLS

OFF.

J

CLOSED

CHECK

WIRING

TO

IBC.

120

VAC

BETWEEN

NO

TERMINAL

1

AND

3

AT

WIRING

HARNESS

———

REPLACE!

Tee

ren

Toe

SERVICE

PLUG

CN7?

J

YES

420

VAC

BETWEEN

TERMINALS

1

AND

3

AT

NO

CONNECTOR

CN3

ON

IBC?

>

REPLACE

IBC

J

YES

420

VAC

AT

TRANSFORMER

PRIMARY

NO

+}

TERMINALS?

REPAIR

WIRING

TO

TRANSFORMER

J

YES

24

VAC

AT

TRANSFORMER

SECONDARY

NO

|}-—_______—__—__—_>

TERMINALS?

REPLACE

TRANSFORMER

J

YES

NO

24

VAC

AT

WIRING

HARNESS

PLUG

CN2?

(——

PUSH

RESET

BUTTON

ON

CASTING

TEMP.

SAFETY

SWITCH.

J

YES

CHECK

CONTINUITY

OF

CASTING

TEMP.

SAFETY SWITCH

CONTACTS.

CONTACTS

REPLACE

IBC

OPEN

OR

CLOSED?

CLOSED

J

OPEN

REPLACE

CAST.

TEMP.

SAFETY

SWITCH.

REPLACE/REPAIR

WIRING

FROM

TRANSFORMER

TO

IBC

NO

CHECK

FOR

120

VAC

BETWEEN

TERMINALS

NO

+

AND

3

AT

CONNECTOR

CN5

ON

IBC?

>

REPLACE

IBC

CHART

1

J

YES

NO

CHECK

FOR

120

VAC

AT

CIRCULATOR

>

REPLACE/REPAIR

WIRING

FROM

J

YES

REPAIR/REPLACE

CIRCULATOR

IBC

TO

CIRCULATOR

50

TROUBLESHOOTING

IS

ENERGIZED.

y

51

TROUBLESHOOTING

CHART

3

CHART

1

OPEN

Vv

NO

CHECK

FOR

VAC

NO

BLOWER

STARTS

+>

BETWEEN

TERMINALS

1

AND

+——>

REPLACE

IBC

AT

CONNECTOR

CN4

ON

IBC

YES

y

5

CHECK

FOR

120

VAC

AT

NO

REPAIR/REPLCE

BLOWER

LEADS

ON

WIRING

-/}——>

WIRING

FROM

IBC

HARNESS

TO

BLOWER

ye

REPAIR/REPLACE

BLOWER

PRESSURE

SWITCH

CONTACTS

OPEN

IBC

WAITS

UP

TO

5

MINUTES

FOR

NORMALLY

¥

NO

PRESSURE

SWITCH

ARE

VENT

PIPEANDAIR

|

No

PURGE

LIGHT

ON?

+———>

INTAKE

PIPE

CLEAR

|}

CONTACTS

TO

CLOSE,

(NO

BLOCKAGE)

YES

INDICATING

BLOWER

SUCTION

IS

PRESENT

ve

CHECK

AIR

PRESSURE

SWITCH

PER

INSTRUCTIONS

ON NO

FOLLOWING

PAGES.

ARE

SAMPLING

LINES

CLEAR

AND

CONNECTED

PROPERLY?

ye

CHECK

FLUE

PASSAGES

IN

BOILER

PER

NO

"MAINTENACE

AND

+>}

CLEANING".

ARE

FLUE

PASSAGES

IN

BOILER

CLEAN?

ys

CHECK

DRAFT

INDUCER

|

NO

MOTOR

RPM.

IS

IT

|—_——_}>}

3400-3600?

ue

CHECK

FOR

BROKEN

OR

LOOSE

IMPELLER

ON

DRAFT

INDUCER

AND

REPLACE

BLOWER

IF

FOUND

TO

BE

BROKEN

OR

LOOSE

Vv.

15

SECOND

PRE

PURGE

COMPLETE.

NO

PURGE

LIGHT

IS

OFF.

SIMULTANEOUSLY

IGNITOR

LIGHT

IS

ON

AS

IGNITOR

CIRCUIT

>

REPLACE

IBC

CLEAN

OUT

VENT

PIPE

AND/OR

AIR

INTAKE

PIPE.

CHECK

FOR

SAGS

OR

LOW

SPOTS

WHERE

CONDENSATE

MAY

PUDDLE

AND

BLOCK

THE

VENT

CLEAN

OUT

SAMPLING

LINES

OR

REPLACE

DEFECTIVE

SWITCH

CLEAN

BOILER

FLUE

PASSAGES

PER

MAINTENANCE

AND

CLEANING

INSTRUCTIONS

REPLACE

BLOWER

TROUBLESHOOTING

CHART

3

YES

TROUBLESHOOTING

CHART

4

IGNITER/SENSOR

WARMS,

CHECK

FOR

120

VAC

REPLACE

IBC

REPAIR/REPLACE

WIRING

FROM

IBC

TO

IGNITER/SENSOR

REPLACE

IGNITER/SENSOR

CHECK

FOR

24

VAC

ACROSS

TERMINALS

CN6-2

AND

CN6-5

ON

IBC,

WHILE

THE

VALVE/

FLAME

LED

IS

LIT

NO

REPLACE

IBC

i

REPAIR/REPLACE

WIRING

BETWEEN

IBC

AND

GAS

CONTROL

RESTORE

IGNITER/SENSOR

TO

CORRECT

POSITION.

DO

NOT

RELOCATE

ARE

ALL

MANUAL

SHUT-OFFS

IN

THE

GAS

SUPPLY

LINE

AND

ON

THE

GAS

CONTROL

IN

THE

OPEN

OR

ON

POSITION?

NO

OPEN

OR

TURN

ON

ALL

MANUAL

SHUTOFFS

ye

CONTACT

THE

GAS

UTILITY

TO

TURN

THE

GAS

ON

UP

AND

GLOWS

NO

BETWEEN

TERMINALS

1

NO

YELLOW/ORANGE

iH

AND

2

AT

CONNECTOR

+}

DURING

20

SECOND

CN1

ON

IBC

(DURING

WARM

UP

IGNITER

WARM

UP)

YES

ye

CHECK

FOR

120

VAC

AT

IGNITER/SENSOR

LEADS

NO

ON

WIRING

HARNESS

|}

___BpI

(DURING

IGNITER

WARM

UP)

YeEs|

>

AFTER

20

SECOND

IGNITER

WARM

UP,

GAS

VALVE

IS

ENERGIZED

VALVE

LIGHT

IS

ON

CHECK

FOR

24

VAC

NO

ACROSS

TERMINALS

MV

NO

2

SECONDS

LATER

POWER

IS

REMOVED

FROM

i

ON

THE

GAS

CONTROL.

+>

IGNITERISENSOR

WHILE

VALVE/FLAME

~

INDICATOR

LIGHT

IS

ON

IGNITER

LIGHT

IS

OFF

DOES

MAIN

BURNER

YES

LIGHT?

YES

Vv

CHECK

IF

IGNITER/

NO

SENSOR

POSITION

IS

OK?

TIP

SHOULD

BE

SLANTED

>

TOWARDS

BURNER

YES

CHECK

GAS

SUPPLY

PRESSURE

AT

INLET NO

PRESSURE

TAPPING

ON

GAS

CONTROL

IS

GAS

>

PRESSURE

GREATER

THAN

4.0"

W.C.?

YES

¥

cuarrs

CHART

5

52

TROUBLESHOOTING

CHART

5

_.

CHART

4

CHART

4

YES

POSSIBLY

MIXTURE

TOO

LEAN!

CHECK

GAS

LINES

DOWNSTREAM

OF

GAS

VALVE

FOR

BLOCKAGE.

ARE GAS

LINES

CLEAR?

IS

GAS/VENTURI

VALVE

CORRECT

SIZE?

SEE

REPAIR

PARTS

DIAGRAM.

NO

CLEAN/REPLACE

GAS

LINES

.

BE

SURE

TO

USE

CORRECT

GAS/VENTURI

VALVE

SIZE.

yi

POSSIBLY

MITURE

TOO

RICH!

CHECK

FLUE

PASSAGES

IN

BOILER

PER

"MAINTENANCE

AND

CLEANING".

ARE

FLUE

PASSAGES

IN

BOILER

CLEAN?

NO

CLEAN

BOILER

FLUE

PASSAGES

PER

MAINTENANCE

AND

CLEANING

INSTRUCTIONS

i

CHECK

MIXER

AND

BURNER

FOR

BLOCKAGE

PER

MAINTENANCE

AND

CLEANING

INSTRUCTIONS.

ARE

AIR

PASSAGES

IN

MIXER

AND

BURNER

CLEAN?

NO

CLEAN

MIXER

AND

BURNER

PER

MAINTENANCE

AND

CLEANING

INSTRUCTIONS

‘

CHECK

AIR

ORIFICE

AT

BURNER

INLET

FOR

CORRECT

SIZE.

SEE

REPAIR

PARTS

DIAGRAM.

IS

ORIFICE

CORRECT

SIZE?

NO

REPLACE

BURNER

Vv

DOES

MAIN

BURNER

RUN

UNTIL

CALL

FOR

HEAT

ENDS

OR

HI

LIMIT

AQUASTAT

CONTACTS

OPEN?

pNom

RUNS

SMOOTHLY

FOR

ABOUT

6

SECONDS

THEN

SHUTS

OFF.

RESTORE

INDICATES

POOR

FLAME

SIGNAL.

NO

>

IGNITER/SENSOR

NO

#2

CHECK

IGNITER/SENSOR

TO

CORRECT

POSITION.

TIP

SHOULD

BE

DO

NOT

RELOCATE.

SLANTED

TOWARDS

BURNER

NO

#3

y=

|

OXIDE

COATING

ON

CHOOSE

THE

APPROPRIATE

:

+>

FLAME

SIGNAL.

PATH

(#1,

#2,

OR

#3)

BASED

ON

SPECIFIC

INSTRUCTIONS.

REPLACE

SYMPTOMS

SHOWN. REQUIRES

SPECIAL

TOOLS.

IGNITER/SENOR.

CHART

6

CHART

6

.

CHART

6

y=

REPLACE

IBC

53

TROUBLESHOOTING

CHART

6

CHART

5

CHART

5

CHART

5

YES

NO

#3

NO

#2

REPLACE

GAS

CONTROL.

Fives

————

+

RUNS

FOR

25-50

SECONDS,

|

____THENTURNS

OFF.

CHECK

FIRING

RATE

OF

UNIT.

IS

UNIT

FIRING

AT

THE

CORRECT

RATE?

CHECK

GAS

ORFICICE

SIZE.

IS

GAS ORIFICE

SIZE

CORRECT.

CHECK

REPAIR

PARTS

LIST

FOR

CORRECT

SIZE.

IS

GAS

ORIFICE

CLEAR

OF

BLOCKAGE.

Ties

NO

DOES

THE

UNIT

USE

LP

GAS.

{°

ADJUST

RATE

AS

DESCRIBED

IN

THE

CHECK

OUT

PROCEDURE

AND

ADJUSTMENT

SECTION

YES

OF

THE

MANUAL.

CHECK

BURNER

FOR

ANY

DETERIORATION

|

NO

IN

THE

FLAME

PORTS.

ARE

BURNER

PORTS

->-——

ee

GAIL

IN

GOOD

CONDITION.

ye

No

CHECK

FLAME

SIGNAL

>

0.6uA?

-——>

REPLACE

BURNER

CONSULT

BOILER

MFGR.

FOR

SPECIFIC

INSTRUCTIONS.

REQUIRES

ves

SPECIFIC

TOOLS.

REPLACE

IBC

¥v

NO

>

REPLACE

BOILER

SHUTS

OFE

BEFORE

ENDOE

|

NO

BOILER

OFF

ON

HIGH

LIMIT,

IS

AQUASTAT

ACTUAL

BOILER

WATER

TEMP.

CALL

FOR

HEAT.

ARE

HI

LIMIT

|_$_

AOQUASTAT

CONTACTS

CLOSED?

GREATER

THAN

HI

LIMIT

SET

POINT

NO

MINUS

30°F

CONTROL

DIFFERENTIAL?

=

LNO_

OK

YES

TTT

TT

TT TT TT

TTT

SEE

TROUBLESHOOTING

PATH

#2

ABOVE

Vv

SET

THERMOSTAT

BELOW

ROOM

TEMPERATURE

TO

END

CALL

FOR

HEAT

ye

NO NO

DOES

CIRCULATOR

PUMP

STOP?

i

ARE

THERMOSTAT

CONTACTS

OPEN?

=[-——

REPLACE

THERMOSTAT

YES

i

REPLACE

IBC

NO

REMOVE

WIRING

HARNESS

NO

CONNECTION

CN9

FROM

GAS

VALE

LIGHT

IS

OFF

CONTROL

DOES

GAS

CONTROL

1+

REPLACE

GAS

CONTROL

?

VES

CLOSE?

vw

DOES

DRAFT

BLOWER

NO

STOP

AFTER

30

REPLACE

IBC

SECOND

POST

PURGE?

y

SYSTEM

OK

54

DIFFERENTIAL

AIR

PRESSURE

SWITCH

CHECK:

What

Is

System

Status?

The

following

steps

and

diagram

indicate

the

locations

of

the

con-

nection

points

required

to

check

the

differential

air

pressure.

The

differential

air

pressure

switch

is

a

safety

device

which

will

prevent

the

boiler

from

firing

if

there

is

an

air

intake,

boiler

heat

exchanger

or

vent

blockage.

Turn

off

service

switch,

or

lower

thermostat

setting.

Remove

vinyl

caps

from

Tee

and

4-way

connector.

Install

testing

lines

as

shown

to

inclined

manometer

or

differential

pressure

gauge

with

the

ability

to

read

0.01”

to

2.0”

wc.

Turn

on

service

switch

and

set

thermostat

to

call

for

heat.

Oiterential

Air

.

Preseue

Swi

|

White

Transparent

Vinyl

Tubing

‘

To

Sight

Glass

Silicone

Suction

Port

o>

Fubing

White

Transparent

Vinyl

Tubing

ey

Gas

Valve

Vent

-—-

\

Red

Transparent

eM ip

4.

Way

Cannecture—

{

My

»

Vinyl

Tobing

NS

“Tee

\

vin

Cap

(VP

2)

White

Transparent

Vinyl

Tubing

Test

rome

Lan

—/

incined

Manometer

_AOr

Difarential

Pressure

Gauge)

55

BOILER

Sige

sa

ee

re

ed

ni

meo

ye

aden

(1)

Not

Running

0”

PRESSURE

yes

CONNECTS

Normally

Open

1.00”

for

Model-100

Setpoint

1.35”

for

Model-75

1.55”

for

Model-50

Running

Without

Greater

Than Set

Closed

Blockage

P

Running

With

Less

Than

or

Equal

to

Open

Setpoints

Blockage

If

manometer

readings

do

not

correspond

to

the

chart

above,

check

for

possible

causes:

e-

Blockage

or

moisture

in

suction

lines

e-

Blockage

in

air

intake

or

vent

pipes

¢-

Undersized

air

intake

or

vent

pipes

e-

Loose

blower wheel

or

motor

shaft

¢-

Inncorect

pressure

switch

or

pressure

switch

setpoint

When

pressure

reading

is

proper

and

the

pressure

switch

is

operat-

ing

properly,

remove

testing

lines

and

reinstall

vinyl

caps

to

Tee

and

4-way

connector,

“

85

Middle

Rd.

Dunkirk’

Dunkirk,

NY

14048

Q90-75 Dunkirk boiler & storage tank

Product's Documents

User Manual

Specifications

Dunkirk Q90-75 Questions and Answers