Carrier BW9 Series, BW9-125, BW9-150, BW9-175, BW9-200 Installation Instructions Manual

Download

BW9

Gas---Fired, Direct Vent, Condensing

Hot Water Boiler

Sizes 125,000 Through 200,00

Series A

Installation Instructions

NOTE: Read the entire instruction manual before starting the installation.

PAGE

SAFETY CONSIDERATIONS 1........................

INTRODUCTION 2..................................

INSTALLATION 3...................................

Rules for Safe Installation and Operation 3.............

Before Installing the Boiler 3........................

Placing the Boiler 5...............................

Near Boiler Piping 5..............................

Combustion Air and Vent Pipe 6.....................

Gas Supply Piping 10.............................

Controls and Accessories 14........................

START--UP AND CHECK--OUT PROCEDURES 15........

Water Treatment and Freeze Protection 15..............

Filling Boiler With Water and Purging Air for

Systems With Diaphragm Type Expansion Tanks 17......

Filling Boiler With Water and Purging Air for Systems With Conventional Closed Type

Expansion Tanks 17...............................

Placing Boiler in Operation 18.......................

Check Out Procedures and Adjustments 18.............

CARE AND MAINTENANCE 20.......................

SERVICE HINTS AND TROUBLESHOOTING 23.........

REPAIR PART S 3 5...................................

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as maintaining water level. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply.

Recognize safety information. This is the safety--alert symbol

. When you see this symbol on the unit and in instruction manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING,

CAUTION, and NOTE. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death.

WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

ama

ASME

Read and obey the following rules to ensure safe installation and operation:

1. Read the entire installation manual before beginning the installation. Failure to follow these rules of 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 utility 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 practices.

3. Before servicing the boiler, allow boiler to cool. Always shut off any electricity and gas supply connected to the boiler prior to servicing.

4. Inspect gas line for leaks.

5. Be certain gas input rate is correct. Overfiring may result in early failure of boiler sections. This may cause dangerous operation. Underfiring may result in too much air for the pre--mix burner causing poor combustion 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 air supply to boiler for complete combustion.

8. Follow a regular service and maintenance schedule for efficient and safe operation.

9. Keep boiler area clean and free from combustible and flammable materials.

CERTIFIED

GAS SUPPLY OPENING (1/2 NPT)

OPENING FOR RELIEF VALVE DISCHARGE PIPE

JUNCTION BOX FOR 120V. POWER & 24 V THERMOSTAT LEADS

COMBUSTION AIR INTAKE FITTING (2 PVC)

6 1/4

25 1/4

4 7/16

TOP

OPENING FOR AIR VENT AND EXPANSION TANK CONNECTION

STANDARD SUPPLY & RETURN OPENINGS 1 1/4 NPT CONNECTIONS PROVIDED INSIDE BOILER CABINET.

32 5/16

VENT CONNECTION (2 CPVC)

20 1/8

40 1/4

LEFT SIDE FRONT

VENT TEE (2 CPVC)

CONDENSATE DRAIN FITTING (1/2 PVC)

Fig. 1 --- Boiler Jackets

10. Proper through the wall or through the roof combustion venting shall be in accordance with the materials and methods described in this manual. Installation must comply with local codes.

11. This boiler and related hot water heating systems are not do-- it--yourself items. They must be installed and serviced by qualified professionals.

WARNING

PERSONAL SAFETY AND INSTALLATION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

This boiler has been designed 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, manual reset high temperature limit, and wiring and/or piping modifications. The manufacturer is not responsible for any installation changes made to boiler installation which are not described or acknowledged in this manual.

INTRODUCTION

This appliance is a gas-- fired direct vent cast aluminum hot water boiler. 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

RIGHT SIDE

LEVELING FEET

BACK

clean combustion air. The forced draft fan draws in the outside combustion air to mix with gas, which flows into the pre--mix burner and combusts. The fan then forces the resulting 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.

BOILER RATINGS AND CAPACITIES

Ratings shown are for sea level applications. (See Table 1.) The boiler automatically derates input as altitude increases, at 4 percent for every 1000 feet above sea level. No alterations to boiler are required for altitudes above sea level.

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 gauge) in accordance with ASME (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.

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 loss 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 (i.e. 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.

A04049

Table 1—Sea Level Ratings--Natural and Propane Gases

{HEATING

MODEL INPUT* (MBH)

125 125 112.5 98 284 90

150 150 135 117 284 90

175 175 157.5 137 284 90

200 200 180 157 284 90

*1 MBH = 1,000 Btuh

Btuh = British Thermal Units per Hour

{ AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on the D.O.E. (Department of Energy) test procedure Ratings shown are for sea level applications. The boiler automatically derates input as altitude increases (See Table 6 and 7 for the approximate rate at given

altitudes). No alterations to boiler are required for altitudes above sea level.

CAPACITY*

(MBH)

INSTALLATION

STEP 1 —Rules for Safe Installation and Operation

1. Read the entire installation manual before beginning the installation. 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.

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.

4. 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. A combustion analyzer is required to properly determine the correct firing rate.

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 complete 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 venting shall be in accordance with the materials and methods described in this manual. Installation must comply with local codes.

11. This boiler and related hot water heating systems are not do it yourself items. They must be installed and serviced by qualified professionals.

STEP 2 —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 in accordance with all applicable federal, state and local building codes including, but not limited to the following:

NET I=B=R

RATING* (MBH)

Canada -- Installation shall be in accordance with CSA--B149.1 and .2 installation codes.

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.

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1 -latest revision.

Installers -- Follow local regulations with respect to installation of CO (Carbon Monoxide) Detectors. Follow maintenance recommendations in this manual.

BOILER

Check to be sure you have selected the boiler with the proper capacity before continuing the installation. The 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. (See Table 1.)

Heat loss calculations should be based on approved industry methods.

CONSIDERATIONS FOR BOILER LOCA

Before selecting a location for the boiler, the following should be considered. Each boiler considered for installation must be:

SHIPPING

WEIGHT (LBS)

}AFUE FLUE DIAM.

2” CPVC and 3”

PVC

2” CPVC and 3”

PVC

2” CPVC and 3”

PVC

2” CPVC and 3”

PVC

SIZING

TION

S Supplied with the correct type of gas (natural gas or

propane).

S Connected to a suitable combustion air intake piping

system to supply the correct amounts of fresh (outdoor) air for combustion (maximum length 60 ft).

S Connected to a suitable venting system to remove the

hazardous products of gas combustion (maximum length60ft).

S Connected to a suitable hot water heating system. S Supplied with a suitable electrical supply for all boiler

motors and controls.

S Connected to a properly located thermostat or operating

control (not included with boiler).

S Placed on level surface (must NOT be installed on

carpeting).

S Condensate drain line must be pitched down to floor

drain or external condensate pump with reservoir at 1/4 in. per foot (wood frame or blocks may be used to raise boiler).

United States -- Installation shall conform with National Fuel Gas Code (NFPA--54/ANSI Z223.1-- latest edition)

Table 2—Boiler Clearances (In.)

UNIT

Top 1 8 8

Left Side 8 24 24

Right Side 1 --- ---

Base 1 --- ---

Front 0 24 24

Back 1 --- ---

Intake/Vent Piping 0 --- ---

Near Boiler Hot Water Piping 1 --- ---

LOCATING THE BOILER

All distances measured from the cabinet of the boiler. (See Table

2.)

1. Select a location which is level, central to the piping systems served and as close to the vent and air intake terminals as possible.

2. 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.

3. The boiler is approved for installation in closets and on combustible floors. This boiler shall NOT be installed on carpeting.

4. The clearances shown in Table 2 indicate required clearances per CSA listing. A minimum 1 in. clearance must be maintained between combustible construction and each of the right, top and back surfaces of the boiler. A minimum 8” clearance is required on the left side, to allow room for the inlet air pipe. An 18” clearance must be maintained at the front where passage is required 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 combustible clearances are required to venting or combustion air intake piping.

5. Equipment shall be installed in a location which facilitates the operation of venting and combustion air intake piping systems as described in this manual.

6. Advise owner of boiler to keep venting and combustion air intake passages free of obstructions. Both the venting and combustion air intake piping systems connected to the outdoors must permit flow through the piping systems without restrictions for the boiler to operate.

7. The boiler shall be installed such that the automatic gas ignition system components are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, control replacement, etc.).

8. The boiler must be located where ambient temperatures (minimum possible room air temperatures where boiler is installed assuming boiler is not in operation and therefore contributes no heat to the space) are always at or above 32 degrees F to prevent freezing of liquid condensate.

COMBUSTION AND VENT PIPE

This boiler requires a dedicated direct vent system. In a direct vent system, all air for combustion is taken directly from outside atmosphere, 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 Fig. 8 through 12 for required clearances.

COMBUSTIBLE

CONSTRUCTION

REQUIREMENTS

ACCESSIBILITY/

CLEANING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in fire, explosion, personal injury or death.

Keep boiler area clear of debris and free of flammable and combustible materials, vapors, and liquids to prevent fires.

CARBON MONOXIDE POISONING AND FIRE HAZARD

Failure to follow this warning could result in property damage, personal injury, or death.

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 chaseway, vent pipe must be insulated with 1/2” Armaflex or equivalent. In extreme cold climate areas, use 3/4”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. 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 Fig. 8 or 9. If the concentric vent termination is being used, refer to Fig. 10 through 12 for proper setup.

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, open flame. Use only in well ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.

CONDENSATE DRAIN REQUIREMENTS

Condensate drain line to be pitched down to floor drain at a minimum of 1/4” 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.

WARNING

SERVICING

NOTE: Condensate trap is to be built in the field per Fig. 7. Wood frame or blocks may be used to raise the boiler to maintain drain pitch or to be above external condensate pump reservoir. There is a 115 volt AC receptacle provided on the service switch junction box 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.

NOTE: 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 VENT

SYSTEM

COMMON

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps oulined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

At the time of removal 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.

9. 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 and any other gas--burning appliances to their previous condition of use.

STEP 3 —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 right hand side of the boiler. It is possible to slide the boiler for a short distance on a smooth floor or surface.

SUPPLY TO SYSTEM

GATE VALVE

FEED WATER

REDUCED PRESSURE BACKFLOW PREVENTER

PRESSURE REDUCING VALVE

SHUT OFF VALVE

PURGE VALVE

SERVICE VALV E

CIRCULATOR

CAN VENT

SERVICE VALV E

RETURN FROM SYSTEM

EXPANSION TANK

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code, ANSI Z223.1--2002/NFPA 54--2002 or the CSA B149.1, Natural Gas and Propane Installation Code and these instructions. Determine there is no blockage or restrictions, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3. When it is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryer and any appliance 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.

6. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliances will operate continuously.

7. 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 a cigarette, cigar or pipe.

8. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Code, ANSI Z223.1--2002/NFPA 54--2002 and/or CSA--B149.1, Natural Gas and Propane Installation Code for Canadian standards.

A04050

Fig. 2 --- Single Zone Boiler Piping

NOTE: Refer to manual section “LOCATING THE BOILER”

for required clearances for servicing and maintenance.

STEP 4 —Near Boiler Piping

CAUTION

UNIT CORROSION HAZARD

Failure to follow this caution may result in property or unit damage.

Copper supply and return piping must NOT be installed directly into aluminum boiler section castings 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.

When the installation of the boiler is for a new heating system, first install all of the radiation units (panels, radiators, baseboard, or tubing) 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 radiation level must be equipped with a low water cut off device. A periodic inspection is necessary, as is flushing of float type devices, per low water cut off manufacturer’s specific instructions.

EXPANSION TANK AND MAKE --UP WA

TER

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 Fig. 6 for diaphragm type expansion tank. For diaphragm type expansion tanks, adjust the tank air pressure 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 and per local codes. If a pressure reducing valve is used, adjust to match the system fill pressure.

ZONE SERVICE VALVE

FEED WATER

RETURN FROM ZONES

ZONE SERVICE VALVE

SUPPLY TO ZONES

ZONE SERVICE VALVE

GATE VALVE

REDUCED PRESSURE BACKFLOW PREVENTER

A04051

EXPANSION TANK

SHUT OFF VALVE

PURGE VALVE

PRESSURE REDUCING VALVE

CAN VENT

CIRCULATOR

ZONE VALVE

ZONE SERVICE VALVE

Fig. 3 --- Multizone Boiler Piping with Zone Valves

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, a sand strainer should be installed at the pump.

PRESSURE RELIEF VALVE/TEMPERA PRESSURE

GAUGE

TURE

The boiler is furnished with a relief valve and temperature pressure gauge in the boiler parts bag. Provide 3/4” piping from the supplied relief valve to a local floor drain, but leave an air gap between piping and drain. Install the relief valve as shown in Fig.

5. 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 conform to ANSI/ASME Boiler and Pressure Vessel Code, Section IV. The manufacturer is not responsible for any water damage.

SUPPLY AND RETURN

LINES

The packaged boiler unit is set up to receive 1--1/4” NPT supply and return piping from top access.

NOTE: The circulator pump is furnished within a carton inside the boiler cabinet and can be installed at the installer preferred location.

CONDENSATE DRAIN

PIPING

The condensate trap is to be field installed as shown in Fig. 7.

The 1/2” PVC condensate drain fittings are provided in the loose parts bag. Condensate drain to be pitched down to floor drain at a minimum of 1/4” per foot.

The 1/2” diameter schedule 40 PVC or CPVC condensate drain piping and pipe fittings must conform to ANSI standards and ASTM D1785 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 and 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 is inaccessible.

FILLING CONDENSATE TRAP WITH WA

TER

NOTE: On the initial start up, the condensate trap must be

manually 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. Pour about 1 cup of cold tap water into the vent drain line.

2. 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).

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 heating 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.

STEP 5 —Combustion Air and Vent Pipe

CONNECTIONS AND TERMINA

TIONS

For boilers connected to gas vents or chimneys, vent installations shall be in accordance with part 7, V enting of Equipment, of the National Fuel Gas Code NFPA 54-- 2002/ANSI Z223.1-- 2002, CSA-- B149.1 and B149.2, and applicable provisions of the local building codes.

Provisions for combustion and ventilation air must be in accordance with section 5.3, Air For Combustion and Ventilation, of the National Fuel Gas Code NFPA 54-- 2002/ANSI Z223.1--2002, CSA--B149.1 and B149.2, or applicable provisions of the local building code.

These boilers require a dedicated direct vent system. All air for combustion is taken directly from outdoors through the combustion air intake pipe. All flue products are discharged to the outdoors through the vent pipe.

1. See Fig. 8 through 12 for combustion air and vent pipe roof and sidewall termination (Roof termination is preferred). Combustion air and vent pipes must terminate together in same atmospheric pressure zone as shown. Construction through which vent and air intake pipes may be installed is a maximum 24 inches, minimum 1/4” 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--DWV), 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--DWV pipe and pipe cement. SDR pipe is NOT approved in Canada.

ZONE SERVICE

ZONE SERVICE VALVE

VALVE

SUPPLY TO ZONES

ZONE SERVICE VALVE

FLOW CHECK VALVE

FEED WATER

RETURN FROM ZONES

GATE VALVE

REDUCED PRESSURE BACKFLOW PREVENTER

A04052

FLOW CHECK VALVE

PRESSURE REDUCING VALVE

EXPANSION TANK

NOTE: 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 wired nutted to prevent short circuits. Unplug the circulator pump wiring at the integrated boiler control.

CIRCULATORS

CAN VENT

Fig. 4 --- Multizone Boiler Piping with Circulators

3. Combustion air and vent piping connections on boiler are 2”, but must increase to ( 3”). Due to potential for flue gas temperatures over 155_F, the first 5 feet of vent pipe must be CPVC, the remaining vent pipe can be PVC. If any elbows are employed within the first 2--1/2 feet of vent, they must be CPVC. Two -- 30” pieces of 2” CPVC pipe and one -- 2” CPVC coupling are furnished with the boiler.

NOTE: The exhaust transition from 2” pipe to 3” pipe must be made in a vertical run. Transition pieces not included. (See Fig.

13.)

Combustion and Vent Pipe Lengths

The length of pipe is counted from the boiler jacket (air intake pipe) or from vent tee (vent pipe). The first five feet of “Total Equivalent Length” of vent pipe must be CPVC.

Boiler Size 3” Pipe Min.

Venting

125--- 200 6ftinlength+

4 --- 9 0 _ elbows

3” Pipe Max.

60 ft in length and u p t o 4 --- 9 0 _ elbows

Reduce the maximum vent length 5 feet per each additional elbow.

1. Combustion air and vent piping to be pitched back to boiler at minimum 1/4” per foot 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.

PRESSURE RELIEF DEVICE

A04053

Fig. 5 --- Relief Valve Discharge Piping

2. Consideration for the following should be used when determining an appropriate location for termination of combustion air and vent piping:

a. Comply with all clearances required as stated in

paragraph 3 below.

b. Termination should be positioned where vent vapors

will not damage plants/shrubs or air conditioning equipment.

c. Termination should be positioned so that it will not be

affected by wind eddy, airborne leaves, snow, or recirculated flue gases.

d. Termination should be positioned where it will not be

subjected to potential damage by foreign objects, such as stones, balls, etc.

e. Termination should be positioned where vent vapors

are not objectionable.

f. Put vent on a wall away from the prevailing winter

wind. Locate or guard the vent to prevent accidental contact with people or pets.

g. Terminate the vent above normal snowline. Avoid

locations where snow may drift and block the vent. Ice or snow may cause the boiler to shut down if the vent becomes obstructed.

h. Under certain conditions, flue gas will condense,

forming 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.

COMBINATION QUICK FILL VALVE, STRAINER, CHECK VALVE AND PRESSURE REDUCING VALVE

COLD WATER FILL

PRESSURE REDUCING VALVE

REDUCED PRESSURE BACKFLOW PREVENTER

GATE VALVE

Fig. 6 --- Diaphragm Type Expansion Tank Piping

FEED WATER

DIAPHRAGM TYPE EXPANSION TANK

EXPANSION TANK SERVICE VALVE (GATE VALVE OR FULL PORT BALL VALVE)

AUTOMATIC AIR VENT*

3/4" x 1/8" BUSHING*

- FURNISHED IN

PARTS BAG

A04054

TO CONDENSATE DRAIN (FIELD SUPPLIED)

1/2" UNTHREADED PVC TEE

1/2" UNTHREADED PVC PIPING 3-3/4" LONG

TO EXHAUST VENT

(2" CPVC)

1/2" ADAPTER MALE NPT X SOCKET WELD PVC PIPING

1/2" UNTHREADED PVC PIPING 1-3/8" LONG

1/2" UNTHREADED PVC PIPING 2" LONG

1/2" UNTHREADED PVC PIPING 3-3/4" LONG

1/2" UNTHREADED PVC ELBOW

1-3/8" LONG

2" UNTHREADED MALE X 2" NPT MALE PVC BUSHING

2" NPT MALE PVC BUSHING

Fig. 7 --- Condensate--Drain Piping

TO BOILER FLUE OUTLET

(2" CPVC)

A04055

Table 3—Gas Piping Sizes

NATURAL GAS

Length of Pipe (ft.)

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

Length of Pipe (ft.)

20 131,000 216,000 189,000 393,000

40 90,000 145,000 129,000 267,000

60 72,000 121,000 103,000 393,000

* Outside diameter The length of pipe or tubing should be measured form the gas meter or propane second stage regulator

1/2” 3/4” 1” 1--- 1/4”

Copper Tubing* Iron Pipe

5/8” 3/4” 1/2” 3/4”

Pipe Capacity --- BTU per hour Input Includes Fittings

PROPANE GAS

Pipe Capacity --- BTU per hour Input Includes Fittings

5. Clean and dry all surfaces to be joined.

3. The venting system shall terminate at least 3 feet above any forced air inlet (except the boiler’s combustion air inlet) within 10 feet. The venting system shall terminate at least 12 inches from any air opening into any building. The bottom of the vent shall be located at least 12 inches above grade. Termination of the vent shall be not less than 7 feet above an adjacent public walkway. The vent terminal shall not be installed closer than 3 feet from the inside corner of an L shaped structure. Termination of the vent should be kept at least 3 feet away from vegetation. The venting system shall terminate at least 4 feet horizontally from, and in no case above or below electric meters, gas meters, regulators, and relief equipment. If multiple terminations are used, there must be a minimum of 3 feet between the exhaust of one termination and the air intake of the next termination.

INSTALLA

TION

1. Attach combustion air intake piping to supplied Fernco 2” coupling on CVI gas valve. Attach vent piping to furnished 2” CPVC vent tee on draft inducer outlet.

NOTE: All pipe joints are to be watertight

2. Working from the boiler to the outside, cut pipe to required length(s).

3. Deburr inside and outside of pipe. Remove all chips and shavings.

4. Chamfer outside edge of pipe for better distribution of

6. Check dry fit of pipe and mark insertion depth on pipe.

NOTE: It is recommended that all pipes be cut, prepared, and pre--assembled before permanently cementing any joint.

7. After pipes have been cut and pre--assembled, apply cement primer to pipe fitting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in light, uniform coat on the inside of socket to prevent buildup of excess cement. Apply second coat.

8. While cement is still wet, insert pipe into socket with a 1/4 turn twist. Be sure pipe is fully inserted into fitting socket.

9. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint.

10. Handle pipe joint carefully until cement sets.

11. Support combustion air and vent piping a minimum of every 5 feet using pre--formed metal hanging straps. Do not rigidly support pipes. Allow movement due to expansion and contraction.

NOTE: Rigid supports will cause excess noise in vent piping

12. Slope combustion air and vent pipes toward boiler a minimum of 1/4” per linear foot with no sags between hangers.

13. Use appropriate methods to seal openings where vent and combustion air pipes pass through roof or side wall.

primer and cement.

12" MINIMUM VERTICAL SEPARATION BETWEEN COMBUSTION AIR INTAKE AND VENT

15" MAXIMUM

3" MAXIMUM SEPARATION

COMBUSTION AIR

MAINTAIN 12" MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL

A99164

Fig. 8 --- Roof Vent/Intake Terminations

STEP 6 —Gas Supply Piping

CHECK GAS SUPPL

The gas pipe to your boiler must be the correct size for the length of run and for the total BTU per hour input of all gas utilization equipment connected to it. See Table 3 for the proper size. Be sure your gas line complies with local codes and gas company requirements.

The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5kPa).

The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1/2 psig (3.5kPa).

Max. Gas Supply Pressure

Min. Gas Supply Pressure

NOTE: Check gas supply line pressure with all gas appliances running

CONNECTING THE GAS

Refer to Fig. 14 for the general layout at the boiler, which shows the basic fittings you will need. The gas line enters the boiler through the left side panel.

The boiler is equipped with a 1/2” NPT connection on the gas valve for supply piping and 1/2” NPT ball cock for manual shutoff. The following rules apply:

1. Use only those piping materials and joining methods listed as acceptable by the authority having jurisdiction, or in the absence of such requirements, by the National Fuel Gas Code NFPA 54-- 2002/ANSI Z223.1--2002. In Canada, follow the CAN/CGA B149.1 and .2 Installation Codes for Gas Burning Appliances and Equipment.

2. Use pipe joint compound suitable for liquefied petroleum gas on male threads only.

3. Use ground joint unions.

4. Install a sediment trap upstream of gas controls.

5. Use two pipe wrenches when making the connection to the gas valve to keep it from turning.

6. Install an additional external manual shutoff valve in the vertical pipe about 5 feet above floor outside the boiler jacket.

7. Tighten all joints securely.

8. Propane gas connections should only be made by a licensed propane installer.

9. Two stage regulation should be used by the propane installer.

10. Propane gas piping should be checked out by the propane installer.

11. It is recommended to use a 1/2” union suitable for natural and propane gas after the ball cock to facilitate service on the unit.

Natural Gas Propane Gas

10” w.c.

4” w.c.

PIPING

14” w.c.

10” w.c.

CHECKING THE GAS

After all connections have been made, check immediately for leaks. 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.

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Never use a match or open flame to test for leaks.

STEP 7 —Electrical Wiring

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Turn off electrical power at fuse box before making any line voltage connections. Follow electrical codes.

All electrical work must conform to local codes as well as the National Electrical Code, ANSI/NFPA--70, latest revision. In Canada, electrical wiring shall comply with the Canadian Electrical Codes, CSA--C22.1 and .2.

ELECTRICAL POWER SUPPL

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 120 volt circuit from a separate over current protection device in the electrical service entrance panel. (NOTE: Use copper conductors only.) This should be a 15 ampere circuit. A service switch has been pre--wired and located on the exterior boiler jacket. See Fig. 15 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 service 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 off, 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 accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA--70, latest revision. In Canada, electrical wiring shall comply with the Canadian Electrical Codes, CSA--C22.1 and .2.

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 grounded ground rod.

PIPING

WARNING

OVERHANG

12” MINIMUM

90°

VENT

3” MAXIMUM SEPARATION

15”

18”

MAXIMUM

LESS THAN 12” CLEARANCE

OVERHANG

12” MINIMUM

VENT

12” SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR INTAKE AND BOTTOM OF VENT

MAINTAIN 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE

RAINSHIELD

BRACKET

3” MAXIMUM SEPARATION

MAXIMUM

12″ MINIMUM

1″ MAXIMUM

COMBUSTION AIR

VENT

90°

18”

12” SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR INTAKE AND BOTTOM OF VENT

MAINTAIN 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE

12” OR MORE CLEARANCE

Fig. 9 --- Sidewall Vent/Intake Terminations

ROOF OVERHANG

VENT

COMBUSTION AIR

NOTE: SECURING STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT IN SIDE WALL.

(FIELD SUPPLIED)

ELBOW (FIELD SUPPLIED)

STRAP

Fig. 11 --- Concentric Vent

COMBUSTION AIR

VENT

MAXIMUM

A99165

A04057

MAINTAIN 12 IN.CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER

Fig. 10 --- Concentric Vent Terminations

A01382

COMBUSTION AIR

ROOF/BOOT FLASHING (FIELD SUPPLIED)

NOTE: SUPPORT MUST BE FIELD INSTALLED TO SECURE TERMINATION KIT TO STRUCTURE

VENT

Fig. 12 --- Concentric Vent Roof Installation

3 INCH INTAKE AND EXHAUST TERMINATIONS

INSTALL FIELD SUPPLIED 2˝ BY 3˝ TRANSITION IN THE VERTICAL POSITION ONLY

VENT

MAINTAIN 12 IN. (18 IN FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF

SUPPORT (FIELD SUPPLIED)

ELBOW (FIELD SUPPLIED)

COMBUSTION AIR

2˝ (50.8MM) CPVC COUPLING

(FURNISHED)

2˝ (50.8MM) CPVC VENT PIPING

(FURNISHED & REQUIRED)

A04058

INSTALL YOUR THERMOSTA

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 vertically mounted outlet box. It should be sensing average room temperature. Avoid the following:

DEAD SPOTS COLD SPOTS HOT SPOTS

Behind doors Concealed

pipes or ducts

Corners and alcoves

Stairwells --drafts

Unheated rooms on other side of wall

Concealed pipes

Lamps

Fireplace Direct

sunlight

TV sets

Radios

Kitchens

Set heat anticipator at 0.7 amps. Connect 24 volt thermostat leads to the # (2) yellow wires located in service switch junction box, located on outer jacket of boiler. See Fig. 15 for service switch junction box and thermostat field wiring connections.

CONNECT CIRCULATOR PUMP

WIRING

See Fig. 15 for service switch junction box and circulator pump field wiring connections. If the two 120 volt circulator wire terminals inside the junction box are not used, leave the two wire nuts to prevent the short circuit.

CAUTION

5˝

EXHAUST TEE (FURNISHED)

Fig. 13 --- Combustion Air and Vent Piping

2˝ (50.8MM) COMBUSTION AIR

INTAKE PIPING

NOT IN

HORIZONAL

SECTION

A04177

UNIT OPERATION HAZARD

Failure to follow this caution may result in improper unit operation.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

GAS CONNECTION

A04061

Fig. 14 --- Gas Piping

Fig. 15 --- Field Wiring Connections

A06088

If any of the original wire as supplied wiht this appliance must be replaced, it must be replaced with type 150_C Thermoplastic wire or its equivalent

A06089

Fig. 16 --- Schematic Wiring Connections

Fig. 17 --- Ladder Wiring Diagram

A06090

STEP 8 —Controls and Accessories

This section provides a brief description of the key controls and accessories found in this boiler.

See Troubleshooting in the Service Hints section of this installation manual for detailed sequences of operation and troubleshooting procedures. See the Repair Pa rts section of this manual for locations of all control components and accessories described.

INTEGRATED BOILER CONTROL

The Integrated Boiler Control (IBC) is a microprocessor based controller for a high efficiency gas boiler that monitors all safety controls and 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 diagnostic indicator lights. (See Fig. 18 and T able 4.)

GAS CONTROL VAL

The electronic 24 volt gas control valve contains a 1:1 gas/air pressure regulator to control the gas flow to the main burner of the appliance and is suited for natural and propane gases. The valve is rated in accordance with ANSI Z21.21-- latest revision and CGA--6.5--M95. (See Fig. 19.)

HOT SURFACE

The 120 volt Hot Surface Igniter heats up to 1800_F to initiate combustion of the gas in the burner. The igniter is mounted next to 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 ignition, the IBC will lockout. The “VALVE” and “FLAME” diagnostic indicator lamps (lamp “D” and “E” on the IBC, see Fig. 18) will blink indicating the failure mode as a lack of flame signal. The IBC is manually reset from lockout by either

IGNITER

(IBC)

removing and reestablishing the thermostat’s call for heat, or by turning the service switch off, then back on.

L4006A HIGH LIMIT AQUASTAT

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 1/2” NPT control well and 3/4” x 1/2” 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 20_ below the setpoint value. The reset value can be field adjusted within a range of 5 to 30_F.

NOTE: The maximum setpoint of the Aquastat must not exceed 200_F.

CASTING TEMPERATURE SAFETY

In the event of lack of or loss of water in the boiler, the Casting Temperature Safety Switch (230_F setpoint) installed on the top of the aluminum boiler section behind the supply piping 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.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

Never run cold water into a hot, empty boiler.

CONTROL

SWITCH

DIFFERENTIAL PRESSURE AIR PROVING SWITCH

(2)

The diaphragm type differential pressure switches are connected by vinyl tubing to the gas valve and the air inlet connection on the negative side and the sight glass adapter on the positive side. The pressure switches monitors airflow by sensing the diffential pressure measured in inches of water (“ w.c.). The factory settings on these switches are 0.5” w.c. on the normally open switch and

3.5” w.c. for the normally closed switch. See the Sequence of Operation section of this manual for details on the operation of the differential pressure switches.

BLOWER

The blower provides a means for pushing combustion air into and through the mixer, the burner, and the flue ways of the cast aluminum boiler section before being discharged through the vent piping to the outdoors.

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 (i.e. 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. The circulator(s) should always be located in the downstream (i.e., “pumping away”) side of the expansion tank.

DRAIN VAL

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 3/4” 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.

ASME RATED PRESSURE RELIEF VAL

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 the 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 ASME 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.

BLOCKED VENT SAFETY SHUT

OFF

The boiler is equipped with a blocked vent safety shutoff which shuts off the main burner gas in the event that the airflow of combustion products through the flue--way is reduced. In the event of a blocked flue--way, enough air will not be available to support combustion and the IBC will lock out due to loss of adequate air flow. Pressure switches monitor air flow by sensing differential pressure. The contacts are normally open and close when the draft inducer is running and causing the differential pressure at the switch to exceed its setting. 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, a

blocked boiler section, or a blocked air inducer. After 5 minutes of inadequate differential pressure, the IBC will lock out. The “Purge” indicator lamp will blink, indicating a failure to prove adequate combustion air flow or flue gas flow. (See Fig. 18.) The IBC will automatically reset after 15 minutes or can be manually reset as noted in the section titled “Hot Surface Igniter.” If the boiler cannot be restored to normal operating condition by resetting the control, contact a qualified service agency to check the heat exchanger flue--ways for blockage.

LOW WATER

CUT--OFF

This unit is equipped with a Low Water Cut--Off control that protects against dry firing. This control provides burner cut--off if there is an unsafe water loss, which can result from a broken or leaking radiator or pipe, or a cracked section in the boiler. A water/glycol mixture up to 50 percent concentration may be used with the Low Water Cut--Off.

(OPTIONAL) EXTERNAL CONDENSATE

PUMP

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. The condensate pump can be piped 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.

START--UP AND CHECK--OUT PROCEDURES

STEP 1 —Water Treatment and Freeze Protection

1. When filling the boiler and heating system, water treatment is generally not required or desired. Consult local water treatment specialist for water treatment recommendations if your water pH levels are below 7.0 or hardness is above 7 grains hardness.

a. This boiler is designed for use in a closed hydronic

heating system ONLY!

b. Excessive feeding of fresh make--up water to the boiler

may lead to premature failure of the boiler sections.

2. Use clean fresh tap water for initial fill and periodic make--up of boiler.

a. A sand filter must be used if fill and make--up water

from a well is to be used.

b. Consideration should be given to cleaning the heating

system, particularly in retrofit situations, where a new boiler is being installed in an older piping system.

c. In older systems, obviously discolored, murky, or dirty

water, or a pH reading below 7, are indications that the system should be cleaned.

d.ApHreadingbetween7and8ispreferred.

3. Antifreeze, if needed, must be of a type specifically designed for use in closed hydronic heating systems and must be compatible with aluminum and be compatible with type 356 T6 aluminum at operating temperatures between 20 and 250 degrees F.

a. Use of antifreeze must be in accordance with local

plumbing codes.

b. Pure glycol solutions are very corrosive, therefore

hydronic system antifreeze typically contains corrosion inhibitors. Different brands of hydronic system antifreeze contain different types of corrosion inhibitors. Some brands have corrosion inhibitors that break down more rapidly or become ineffective at higher temperatures when used with aluminum. This could lead to premature failure of the aluminum boiler. Consult the antifreeze manufacturer on the compatibility of their product with aluminum.

Table 4—Diagnostic Sequence

SEQUENCE OF OPERATION

Lamp A is illuminated, indicating that the integrated control

is receiving 24 volts and is in standby waiting for the thermostat to call for heat.

Thermostat calls for hea t, energizing the system circulator. X

Integrated boiler control performs self check of internal cir ---

cuitry, lasting approximately two seconds, and energizes the X

draft inducer.

The draft inducer comes up to speed and establishes combustion airflow, causing the normality open differential pressure air proving switch contacts to close.

When combustion air flow is proved, Lamp B is illuminated indicating that the 15 second pre---purge cycle has begun.

After the pre--- purge has completed, Lamp B is extinguished

and Lamp C is illuminated, indicating power is being deliv---

ered to the hot surface igniter for the 20 second igniter warm --up period. The bright yellow--- orange glow of the hot surfaceignitercanbeobservedthroughtheobservationport

on the boiler.

After the igniter warm - -- up period the integrated boiler con ---

trol ener gizes the gas valve, which is indicated by the illumi ---

nation of Lamp D. Two seconds later Lamp C will extinguish X X X

when the integrated boiler control stops sending power to the

hot surface igniter.

The integrated boiler control then enters a 6 second trial for

ignition mode. This is indicated by a low level illumination of

Lamp E. During the last 2 seconds of this trial for ignition

mode, main burner flame is proven by flame rectification X X X

through the hot surface igniter, providing a flame signal that

is relayed to the integrated boiler control, fully illuminating

Lamp E.

The thermostat ends its call for heat, causing the integrated

boiler control to de---energize the gas valve and system circulator. Lamp D is extinguished while the unit enters the 30 second

post purge mode, indicated by the illumination of Lamp B. Lamp E will remain illuminated as the remainder of the gas in the blower is burned off (approximately 2 seconds).

During post purge the blower remains powered and clears

out any residual products of combustion.

After the post purge mode the draft inducer is de--- energized,

lamp B is extinquished, and the unit goes into standby mode X

until the next call for heat from the thermostat.

NOTE: First attempts at cold starts may be rough due to gas line not being completely purged of air causing low firing r ate and h igh excess air level s.

A B C D E

X X

DIAGNOSTIC INDICATOR LAMPS

c. Follow the antifreeze manufacturer’s instructions on

determining proper ratio of antifreeze to water for the expected low temperature conditions, and for maintaining the quality of the antifreeze solution from year to year. Improperly maintained antifreeze solutions will gradually lose their ability to protect the aluminum boiler from corrosion.

d. The recommended premixed antifreeze solution is

INTERCOOL NFP-- 5 0 . This product is sold direct to installing contractors by the antifreeze manufacturer. Please contact Interstate Chemical Company, New York Customer Service at 1--800--422--2436 to purchase. Use of an alternate manufacturer’s premix antifreeze is acceptable if the product specifications are compatible with those of the recommended premix antifreeze and the antifreeze is compatible with type 356 T6 aluminum. Use of incompatible antifreeze could damage the heat exchanger and could void product warranty. The antifreeze must be maintained per the specifications of the manufacturer. Failure to do so could result in the warranty being voided. Follow the antifreeze manufacturer’s instructions on determining the proper ratio of antifreeze to water for the expected low temperature conditions and for maintaining the antifreeze solution from year to year.

e. DO NOT USE AUTOMOTIVE ANTIFREEZE,as

the type of corrosion inhibitors used will coat the boiler’s heat transfer surfaces and greatly reduce capacity and efficiency.

f. Use of antifreeze in any boiler will reduce heating

capacity by as much as 10 --20 percent, due to differing heat transfer and pumping characteristics. This must be taken into consideration when sizing the heating system, pump(s) and expansion tank. Consult antifreeze manufacturer’s literature for specific information on reduced capacity.

g. Water content of the boiler is 2.6 gallons (10 liters).

STEP 2 —Filling Boiler with Water and Purging Air for Systems with Diaphragm Type Expansion Tanks

Refer to appropriate “Near Boiler Piping” diagrams.

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.

STEP 3 —Filling Boiler with Water and Purging Air for Systems with Conventional Closed Type Expansion Tanks

Refer to appropriate “NEAR BOILING PIPING” diagrams.

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.

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 operation.

6. Inspect piping system. Repair any leaks immediately.

NOTE: DO NOT use stop leak compounds. Leaks in threaded connections in the aluminum boiler sections must be repa ired immediately. Aluminum threads will not seal themselves.

DIAGNOSTIC INDICATOR LAMPS

POWER

PURGE

IGNITER

VALVE

FLAME

UT-1013 INTEGRATED BOILER CONTROL

40 VA TRANSFORMER CONTROL

CONTROL PANEL

A04062

Fig. 18 --- Indicator Lights

STEP 4 —Placing Boiler in Operation

READ BEFORE OPERATING APPLIANCE

1. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do NOT try to light this burner by hand.

2. Before operating, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor.

WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance.

Do not touch any electric switch or use any phone in the building. Immediately call your gas supplier from a neighbor’s phone.

Follow the gas supplier’s instructions. If you cannot contact your gas supplier, call the fire department.

3. Use only your hand to turn the gas ball valve. Never use tools. If the valve will not turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may cause fire or explosion.

4. 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 before operating this appliance.

2. Set the thermostat to the lowest setting.

3. Turn off all electrical power to the appliance.

4. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do NOT try to light this burner by hand.

5. Remove the front jacket panel.

6. Turn off the gas ball valve. Valve handle should be perpendicular to the gas pipe.

7. Wait five minutes for any gas to clear. Then smell for gas, including near the floor. If you smell gas STOP! Follow instructions under “WHAT TO DO IF YOU SMELL GAS” above. If you do not smell gas, go to next step.

8. Turn the gas ball valve to the “on” position. The handle on the valve should be parallel to the gas pipe.

9. Replace the front jacket panel.

10. Turn on all electrical power to the appliance.

11. Set 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.

IF BURNER APPEARS TO PULSATE DURING

IGNITION

1. Turn off boiler power and shut off gas supply to the boiler.

2. Take the burner assembly apart by removing the combustion air blower and gas valve/venturi assembly from the boiler and visually inspect the inside of the burner. Look for any debris (PVC shavings, etc.) and if anything is present, remove it.

3. Reassemble burner assembly, turn gas supply and boiler power back on, and relight boiler.

IF BURNER STILL PULSATES OR FAILS TO

LIGHT

1. Check for proper vent and intake pipe sizing and for proper vent lengths and vent configuration by referring to Step 2, “Before Installing the Boiler,” and Step 5, “Combustion Air and Vent Pipe,” located in the INSTALLATION section in this manual.

2. Check for proper gas supply pressure and proper gas line sizing to the boiler by referring to Step 6, “Gas Supply

Piping,” located in the INSTALLATION section in this manual.

3. Check for orifice in negative pressure hose at gas valve and 2” air intake pipe upstream of gas valve.

4. Relight boiler.

5. If boiler still does not light, the air inlet pipe may need to be disconnected to allow the boiler to start in order to verify the boiler firing rate and combustion properties. The inlet air pipe can be disconnected by removing the PVC inlet air piping from the Femco fitting located on the air inlet of the gas valve/venturi assembly. Relight boiler.

6. When the boiler lights, the firing rate and combustion should be checked per the “Adjustments and Checkout” procedure in Step 5 of the START--UP AND CHECK--OUT PROCEDURES section of this manual. If the air inlet piping was disconnected in step 4 (above), leave it disconnected and make the first adjustment. Reconnect air inlet piping, recheck combustion CO

,and

adjust again if necessary.

7. If burner pulsation continues or boiler fails to light after performing the above procedures, please contact Technical Service at 1--800--325--5479 for further assistance.

TO TURN OFF GAS TO

APPLIANCE

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove the front jacket panel.

4. Turn gas ball valve off. The handle should be perpendicular to the gas pipe.

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.

STEP 5 —Check Out Procedure and Adjustments

VERIFY PROPER SEQUENCE OF OPERA

TION

The sequence can be followed via the diagnostic indicator lamps on the integrated boiler control in Fig. 18. This is the normal sequence of operation. (See Table 4.) A more detailed sequence of operation containing potential faults can be found in the service hints section.

INSPECT VENTING AND AIR INTAKE

SYSTEM

Operate the boiler and verify that all vent/air intake connections are gastight and watertight. Repair any leaks immediately.

INSPECT CONDENSATE

DRAIN

Verify that all connections are watertight, and that condensate flows freely. Repair any leaks immediately.

INSPECT SYSTEM

PIPING

Verify that all connections are watertight. Repair any leaks immediately.

TEST IGNITION SYSTEM SAFETY SHUTOFF

DEVICE

1. Turn off manual gas ball valve.

2. Set thermostat to call for heat.

3. Boiler begins normal sequence of operation.

4. After approximately 30 seconds (prepurge and igniter warm--up period), lamp D illuminates, indicating gas valve is powered.

5. After 4 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 “Step 4-- Placing Boiler in Operation.”

Table 5—Natural Gas

NOMINAL INPUT 200,000 175,000 150,000 125,000

Altitude

0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 197,000 196,500 172,400 172,200 147,800 147,400 123,500 123,000

2,000 194,000 193,000 169,800 169,400 145,600 144,800 122,000 121,000

3,000 191,000 189,500 167,200 166,600 143,400 142,200 120,500 119,000

4,000 188,000 186,000 164,600 163,800 141,200 139,600 119,000 117,000

5,000 185,000 182,500 162,000 161,000 139,000 137,000 117,500 115,000

6,000 182,000 179,000 159,400 158,200 136,800 134,400 116,000 113,000

7,000 179,000 175,500 156,800 155,400 134,600 131,800 114,500 111,000

8,000 176,000 172,000 154,200 152,600 132,400 129,200 113,000 109,000

9,000 173,000 168,500 151,600 149,800 130,200 126,600 111,500 107,000

10,000 170,000 165,000 149,000 147,000 128,000 124,000 110,000 105,000

Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Min Max Min Max Min Max Min Max

Table 6 — L P Ga s

NOMINAL INPUT 200,000 175,000 150,000 125,000

Altitude

0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 195,900 195,750 171,900 171,200 146,900 146,700 123,050 122,250

2,000 191,800 191,500 168,800 167,400 143,800 143,400 121,100 119,500

3,000 187,700 187,250 165,700 163,600 140,700 140,100 119,150 116,750

4,000 183,600 183,000 162,600 159,800 137,600 136,800 117,200 114,000

5,000 179,500 178,750 159,500 156,000 134,500 133,500 115,250 111,250

6,000 175,400 174,500 156,400 152,200 131,400 130,200 113,300 108,500

7,000 171,300 170,250 153,300 148,400 128,300 126,900 111,350 105,750

8,000 167,200 166,000 150,200 144,600 125,200 123,600 109,400 103,000

9,000 163,100 161,750 147,100 140,800 122,100 120,300 107,450 100,250

10,000 159,000 157,500 144,000 137,000 119,000 117,000 105,500 97,500

NOTE: The boiler automatically derates input as altitude increases. No alterations to boiler are required for altitudes above sea level. These low pressure gas --- fired h ot water boilers are design certified by CSA International, for use with natural and propane gases. T h e boilers are constructed

and hydrostatically tested for a maximum working pressure of 50 psig (pounds per square inch gauge) in accordance with A .S.M.E. (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards f or heating boilers.

Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Min Max Min Max Min Max Min Max

TEST HIGH LIMIT CONTROL AND ADJUST

While burner is operating, Adjust setting 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. Return high limit differential to original setting of 20_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.

SETTHERMOSTATHEATANTICIPATOR(IF AND VERIFY THERMOSTAT OPERA

TION

USED)

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 RA

Correct input rate is essential for proper and efficient operation of the burner and boiler.

1. Determine elevation at installation site.

2. See Table 5 and 6 to determine the correct approximate input rate for the local elevation.

3. 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.

4. Operate boiler for 5 minutes.

5. Turn off all other gas appliances, extinguishing standing pilots where applicable.

6. At gas meter, measure time in seconds required to use one cubic foot of gas.

7. Calculate “input rate” according to the following formula:

Btuh input rate = 3600 x heating value from step 3

time from step 6

8. The measured input rate should be within +/--2 percent of the input rating from step 2. If not, see the ADJUSTMENTS section.

ADJUSTMENTS AND

CHECKOUT

NOTE: It is important that this appliance operate between 8.5

and 10% CO

. To verify that the appliance is operating in this

range, follow the steps below:

1. Check incoming gas pressure to the appliance using a water column manometer with resolution of 0.1 inch w.c. or better and a range of 0 to 14 inches of w.c. Connect the positive side of the manometer to the inlet pressure tap on the gas valve by loosening the inlet pressure tap screw from the raised port on the gas valve and sliding the manometer hose over the port. (See Fig. 19.)

2. Drill a hole in the plastic CPVC vent pipe or exhaust tee, just large enough to allow access for the sample probe of your combustion analyzer.

3. Turn the thermostat to the closed position so the appliance is activated.

4. Allow the appliance to run for approximately 5 minutes.

5. Insert the sample probe of your combustion analyzer into the hole you drilled in step 2, about halfway into the exhaust gas stream. Take a flue gas reading and observe the CO

value. Adjust the throttle screw until the CO

value is between 8.5 and 10%. Turning the throttle screw clockwise decreases the rate and the CO

value. Turning

the throttle screw (See Fig. 19) counterclockwise increases therateandtheCO

value. Allow the appliance to

stabilize for approximately 1 minute after adjusting the throttle screw before you take a reading with your combustion analyzer.

6. After adjustments are made, turn the gas and electric supplies to the boiler off. Remove the manometer hose from the gas valve and tighten the screw on the inlet pressure tap. Remove the CO meter and plug the hole in the CPVC with 400_F high temperature silicone.

7. Return the thermostat switch to its original position.

THROTTLE ADJUSTMENT SCREW Turn clockwise to decrease rate and CO Counterclockwise to increase rate and CO

INLET PRESSURE TAP

INLET

MOLEX

HEADER

VENTURI VALVE

OUTLET

A06100

Fig. 19 --- Gas Valve

Final Checkout of the Installation

After any adjustment to the appliance, observe several complete cycles to ensure that all components function correctly.

SETTHERMOSTATTODESIRED TEMPERA

TURE

ROOM

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 AT THE END OF THIS MANUAL.

CARE AND MAINTENANCE

Maintenance as outlined below can be performed by the owner unless otherwise noted.

The acidic nature of flue gases condensing on the aluminum boiler 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 assure safe trouble free operation and maximum efficiency. It is recommended to service the appliance at least once every 12 months.

STEP 1 —Beginning of Each Heating Season

1. Schedule an 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 listed in Procedure 6.

b. Visually inspect venting and air intake system for

proper operation. 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.

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. Check for deteriorated or plugged condensate drain line.

g. Check all gasketed joints for leakage, and tighten bolts

or replace gaskets, if necessary.

h. 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.

2. Check that boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids.

3. Circulator pump and blower motor furnished with boiler are permanently lubricated from the 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.

STEP 2 —Daily During Heating Season

1. Check for and remove any obstruction to the flow of combustion air or venting of flue gases.

2. Check that boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids.

STEP 3 —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 manufacturer’s instructions packaged with relief valve.

3. Visually inspect venting and air intake system for proper function. 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 PVC condensate drain pipe for proper operation. If the drain pipe shows any signs of blockage, leakage, or deterioration contact a qualified service agency to clean, repair, or replace it immediately.

5. Check air vent(s) for leakage.

STEP 4 —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.

STEP 5 —End of Heating Season--Annual Shutdown Procedure

1. Follow instructions “TO TURN OFF GAS TO APPLIANCE.”

2. 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.

STEP 6 —Annual Examination and Cleaning of Boiler Components

The following service procedures must be performed only by a qualified service agency. Boiler owner should not attempt these procedures.

1. Before Servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn off gas supply to boiler.

2. Flue passages are examined by removing the blower assembly from the casting. Refer to the repair parts diagram for the boiler block and piping assembly at the end of this manual. The procedure for examining and cleaning the burner is described below. Any buildup of sediment or aluminum oxide (white powdery or flaky substance) in the flue passages must be cleaned as follows:

a. Remove jacket front and top panels.

b. Confirm that manual gas valve is closed and

disconnect gas line to gas valve at union.

c. Disconnect wires to gas valve and igniter.

d. Remove air inlet assembly from gas valve.

e. Loosen but do not remove five (5) nuts attaching

blower adapter assembly to boiler.

f. Remove two (2) igniter screws and very carefully

remove the igniter. Use care when removing the igniter, it is very brittle! Do not touch the igniter element with your fingers or hands as oil or debris will cause premature failure to the igniter.

g. Remove five (5) nuts and remove blower adapter

assembly. Remove burner and gaskets.

h. Aluminum oxide deposits are water soluble and may

be rinsed away with spraying or running water.

i. Use a flexible handle nylon brush to loosen sediment

and aluminum oxide on all heating surfaces of boiler. Refer to the repair parts diagrams. Be sure that you

do not get brush stuck in heat exhanger!

j. After brushing and rinsing, remove any remaining

loosened sediment using a shop vacuum with a snorkel attachment.

k. 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.

l. Reinstall burner and gaskets and position blower

adapter 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! Do not touch the igniter element with your fingers or hands as oil or debris will cause premature failure to the igniter. Tighten five (5) nuts holding blower adapter assembly.

m. Connect:

(1.) gas line to gas valve (2.) air inlet assembly to gas valve using 2” x 1--1/2”

flexible coupling

(3.) pressure switch hose to gas valve and air inlet

assembly

(4.) 2 inch flexible coupling to boiler exhaust port (5.) igniter wires

(6.) gas valve wires

3. Visually inspect 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 described below.

a. Remove 1/2” PVC cap from 1/2” PVC tee.

b. Inspect for sediment or blockage.

c. Flush out with water or vacuum.

d. Follow the instructions under “NEAR BOILER

PIPING” for filling condensate trap with water.

e. Replace 1/2” PVC cap.

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

inch flexible coupling that connects the vent tee to the exhaust port.

b. Inspect interior of vent tee. Any buildup of sediment

on the inside surface must be cleaned.

c. Reconnect the 2 inch flexible coupling to the draft

inducer outlet.

STEP 7 —Differential Air Pressure Switch Check

The following steps and diagram indicate the locations of the connection 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. Install testing lines as shown to inclined manometer or differential pressure gauge with the ability to read 0.01” to 5.0” w.c.

Turn on service switch and set thermostat to call for heat. (See Fig. 20.)

If manometer readings do not correspond to the chart above, check for possible causes:

S Blockage or moisture in suction lines to switch. S Blockage in air intake or vent pipes. S Undersized air intake or vent pipes. S Loose blower wheel on motor shaft. S Incorrect pressure switch or pressure switch setpoint

When pressure reading is proper and the pressure switch is operating properly, remove testing lines and reinstall vinyl caps to Tee and 3--way connector.

SERVICE HINTS AND TROUBLESHOOTING

See Fig. 21--32.

BOILER STATUS DIFFERENTIAL PRESSURE SWITCH CONTACTS

Not Running 0”

Running without Blockage (Approximate)

Running with Blockage Less Than or Equal to Setpoints

Closed at 3.5” Closed at 0.5”

1.00” For Model --125 Closed at 3.5”

1.50” For Model --150 Closed at 0.5”

1.50” For Model --175

2.00” For Model --200

Open at 3.5”

Closed at 0.5”

SIGHT GLASS & ADAPTER

AIR INLET CONNECTION

13 1/4"

5 1/2"

Fig. 20 --- Differential Air Pressure

2 @ 2" EA.

GAS VALVE

16 1/2"

A06107

PO WER ON

STANDBY

NORMAL SEQUENCE OF OPERATION

THERMOSTAT

CALLS FOR HEAT

CIRCULATOR

ENERGIZES THRU

2K1 CONTACTS

IBC SELF CHECK OF

INTERNAL CIRCUITRY

1-2 SEC

IBC

CHECKS

N.O. AIR

PRESSURE

SWITCH

CONTACTS

OPEN

DRAFT INDUCER ENERGIZES THRU 1K1 CONTACTS

CLOSED

FALSE POSITIVE PROOF OF AIRFLOW. IBC WAITS FOR 45 SEC FOR AIR PRESSURE SWITCH CONTACTS TO OPEN

OPEN

IF MAIN BURNER DOES NOT PROVE FLAME IN 3 TRIALS, CONTROL LOCKOUT. VALVE/FLAME LIGHT BLINKS. RESET IS REQUIRED. THIS PROBLEM IS A RESULT OF NOT ESTABLISHING FLAME SIGNAL.

CONTROL WILL ATTEMPT 2 ADDITIONAL IGNITION SEQUENCES STARTING WITH PREPURGE

DOES MAIN

CLOSED

BURNER PROVE FLAME WITHIN INITIAL FOR IGNITION PERIOD

YES

NORMAL OPERATION

IBC

WAITS FOR

UP TO 5 MINUTES

CLOSED

CONTROL LOCKOUT. PURGE LIGHT BLINKS. MANUAL RESET REQUIRED OR CONTROL WILL AUTOMATICALLY RESET AFTER 15 MINUTES. CIRCULATOR REMAINS ENERGIZED AS LONG AS THERE IS A CALL FOR HEAT

PURGE LIGHT ON. AIRFLOW APPROVED. DRAFT INDUCER RUNS FOR 15 SEC PREPURGE

FOR AIR PRESSURE

SWITCH CONTACTS

TO CLOSE

INDICATING FAN

SUCTION PRESENT

OPEN

DURING THE LAST 2 SEC OF THE 5 SEC IGNITION TRIAL, MAIN BURNER FLAME IS PROVED BY FLAME RECTIFICATION THRU HOT SURFACE IGNITER, PROVIDING A FLAME SIGNAL TO IBC. GAS VALVE REMAINS ENERGIZED. BOILER RUNS.

2 SEC INTO THE 5 SEC IGNITION TRIAL, POWER IS TURNED OFF TO THE HOT SURFACE IGNITER. IGNITER LIGHT OFF.

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 3K1 AND 4K1.

CONTACTS. VALVE LIGHT ON.

PURGE LIGHT GOES OUT. HOT SURFACE IGNITER POWERED THRU 5K1 AND 5K2 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 IGNITER. IGNITER LIGHT ON.

DETAILED SEQUENCE OF OPERATION

Fig. 21 --- Normal Sequence of Operation

A06101

LOSS OF FLAME SIGNAL

IF AN ESTABLISHED FLAME SIGNAL IS LOST

WHILE CONTROL EXPECTS THAT THE BURNER

IS OPERATING, CONTROL WILL IMMEDIATELY

DE-ENERGIZE GAS VALVE. (VALVE LIGHT GOES OUT)

CASTING TEMPERATURE SAFETY SWITCH

IF BURNER OPERATES WHEN BOILER HAS NO

WATER, ALUMINUM BOILER SECTIONS

HEAT UP RAPIDLY.

DRAFT INDUCER RUNS THRU 30 SECOND POST

CONTROL WILL ATTEMPT TO RE-LIGHT BOILER

3 TIMES. IF FLAME IS NOT PROVEN. CONTROL LOCKOUT - PROBLEM ESTABLISHING A FLAME

SIGNAL. VALVE LIGHT IS BLINKING.

PURGE

LOSS OF COMBUSTION AIRFLOW

IF COMBUSTION AIRFLOW IS LOST WHILE BURNER

IS FIRING ( DIFFERENTIAL AIR PRESSURE

SWITCH CONTACTS OPEN) GAS VALVE WILL

BE DE-ENERGIZED. (VALVE LIGHT GOES OUT)

DRAFT INDUCER RUNS THRU 30 SECOND POST

IF CALL FOR HEAT REMAINS, IBC WAITS

5 MINUTES FOR AIRFLOW TO BE RE-ESTABLISHED

IF AIRFLOW DOES NOT RE-ESTABLISH, CONTROL WILL

LOCKOUT - PROBLEM WITH COMBUSTION AIRFLOW.

PURGE LIGHT BLINKS. CONTROL WILL AUTOMATICALLY RESET AFTER 15 MINUTES

PURGE

CASTING TEMPERATURE SAFETY SWITCH

CONTACTS WILL OPEN BREAKING 24 VOLT POWER

TO IBC. POWER INDICATOR LIGHT GOES OUT.

REQUIRES MANUAL RESET TO RE-CLOSE

CONTACTS

POWER LIGHT GOES OUT.

HI LIMIT CONTROL

IF BOILER WATER TEMPERATURE REACHES

HI LIMIT (AQUASTAT) SETPOINT, HI LIMIT

N.C. CONTACTS OPEN IMMEDIATELY,

CLOSING GAS VALVE. (VALVE LIGHT GOES OUT)

DRAFT INDUCER CONTINUES TO RUN FOR 30

SECOND POST PURGE AND SWITCH OFF.

CIRCULATOR RUNS AS LONG AS THERMOSTAT

WHEN HI LIMIT CONTACTS REMAKE BEFORE END

OF CALL FOR HEAT - CONTROL GOES INTO

CALLS FOR HEAT.

A NORMAL LIGHT OFF SEQUENCE

CIRCULATOR PUMP

CIRCULATOR WILL BE ENERGIZED AS LONG AS

THERMOSTAT CALLS FOR HEAT DURING LOCKOUT

RECOVERY FROM ANY LOCKOUT REQUIRES RESET

WHICH IS ACCOMPLISHED BY REMOVING AND

REAPPLYING THE THERMOSTAT CALL FOR HEAT

Fig. 22 --- Safety Sequences During Operation

OR POWER TO CONTROL

A06102

GAS VALVE AND CIRCULATOR PUMP

ARE DE-ENERGIZED. VALVE LIGHT GOES OUT.

BLOWER RUNS FOR 30 SECOND POST

PURGE. PURGE LIGHT ON.

AFTER 30 SECONDS. PURGE LIGHT SHUTS OFF.

BLOWER IS DE-ENERGIZED

A04066

Fig. 23 --- End of Normal Sequence of Operation

FIRE, EXPLOSION OR SHOCK HAZARD

Failure to follow this warning could result in personal injury, death or property damage.

Do not attempt to modify the physical or electrical characteristics of this boiler in any way.

WARNING

IMPORTANT

1. IN A RESET FROM LOCKOUT CONDITION, ALL ELECTRICAL METER READINGS AT THE GAS CONTROL VALVE (24 VAC) MUST BE TAKEN WITHIN THE TRIAL FOR IGNITION PERIOD.

2. IF ANY COMPONENT DOES NOT FUNCTION PROPERLY, MAKE SURE IT IS CORRECTLY INSTALLED AND WIRED BEFORE REPLACING IT.

3. STATIC ELECTRICITY DISCHARGE CAN DAMAGE THE INTEGRATED BOILER CONTROL (IBC). TOUCH METAL SURFACE TO DISCHARGE STATIC ELECTRICITY BEFORE TOUCHING IBC.

4. THE IBC CANNOT BE REPAIRED. IF IT MALFUNCTIONS IT MUST BE REPLACED.

5. 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.

6. 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.

7. 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 CONTROL 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.

2. TROUBLESHOOTING TOOLS: A. VOLTMETER TO CHECK 120 VAC AND 24 VAC B. CONTINUITY TESTER. C. INCLINED MANOMETER OR PRESSURE GAUGE WITH 0-5.0 RANGE (0.01 SCALE) FOR

MEASURING SUCTION PRESSURES AT PRESSURE SWITCH. D. U-TUBE MANOMETER OR DIFFERENTIAL PRESSURE GAUGE WITH 0-14 RANGE (0.1

SCALE) FOR MEASURING INLET AND MANIFOLD GAS PRESSURES.

3. WHAT IS SYSTEM STATUS? A. CONSULT THE CHART ON THE FOLLOWING PAGE. B. FIGURE 18

INDICATOR LAMPS.

SHOWS

DETAILED SEQUENCE OF OPERATION

THE LOCATION ON THE BOILER OF THE DIAGNOSTIC

A06156

Fig. 24 --- Initial Service Checks

SYSTEM STATUS

OPERATING SEQUENCE. IF THE SYSTEM LOCKS OUT, THE LIGHTS

THE INDICATOR LIGHTS TRACK THE

INDICATE THE POINT IN THE SEQUENCE OF OPERATION WHERE LOCKOUT

OCCURS. IF THIS TABLE DOES NOT READILY PROVIDE THE REASON FOR

BOILER MALFUNCTION OR NON-OPERATION, REFER TO THE FOLLOWING

PAGES FOR MORE DETAILED TROUBLESHOOTING PROCEDURES.

LIGHT STATUS INDICATES

POWER

PURGE

IGNITER

VALV E

OFF

BLINKING

OFF

BLINKING

OFF

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

IGNITER IS NOT ENERGIZED

IBC IS ENERGIZING GAS CONTROL VALVE TO OPEN.

GAS CONTROL VALVE IS CLOSED.

FLAME

BLINKING

ON BRIGHT

OFF

ON DIM

IBC IS LOCKED OUT. FLAME HAS NOT BEEN PROVEN IN 3 IGNITION ATTEMPTS. MAY BE DUE TO BROKEN IGNITER LACK OF OR LOW FLAME SIGNAL OR NO GAS.

FLAME PROVEN

FLAME UNPROVEN

CHECKING FOR FLAME SIGNAL (DURING TRIAL FOR IGNITION)

TROUBLESHOOTING

Fig. 25 --- System Status Symbols

A06103

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

The following procedures may expose you to dangerous line voltage. Use caution to avoid touching live electrical contacts. Service must be performed by a trained, experienced service technician.

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

--If you cannot reach your gas supplier, call the 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, do not try to repair it. Force or attempted repair may result in a fire or explosion.

WARNING

Fig. 26 --- Electrical Shock Hazard Warning

A04070

Fig. 27 --- Troubleshooting Chart No. 1

CHART 1

TROUBLESHOOTING CHART 2

CHECK THAT CIRCUIT BREAKERS IS ON OR

FUSES ARE OK AT THE ELECTRICAL PANEL

CHECK THAT SERVICE SWITCH IS ON

CHECK CASTING TEMPERATURE SAFETY SWITCH. PUSH RESET BUTTON ON SWITCH. CONTACTS OPEN (BUTTON UP) OR CLOSED

CHECK WIRING TO IBC. I20 VAC BETWEEN

TERMINALS 1 AND 3 AT WIRING HARNESS

120 VAC BETWEEN TERMINALS 1 AND 3 AT

120 VAC AT TRANSFORMER PRIMARY

24 VAC AT TRANSFORMER SECONDARY

24 VAC AT WIRING HARNESS PLUG CN2?

(BUTTON DOWN)?

CLOSED

PLUG CN7?

YES

CONNECTOR CN3 OR IBC?

YES

TERMINALS?

YES

TERMINALS?

YES

REPLACE IBC

OPEN

CHECK WATER LEVEL IN BOILER. CHECK

FOR AIR TRAPPED IN TOP OF BOILER.

CONTACTS WILL NOT STAY CLOSED UNTIL

REPLACE/REPAIR WIRING FROM SERVICE

PUSH RESET BUTTON ON CASTING TEMP SAFETY SWITCH. CHECK CONTINUITY OF

CASTING TEMP. SAFETY SWITCH CONTACTS.

BOILER COOLS OFF.

SWITCH TO IBC

REPLACE IBC

REPAIR WIRING TO TRANSFORMER

REPLACE TRANSFORMER

CONACTS OPEN OR CLOSED?

CLOSED

REPLACE CAST. TEMP.

SAFETY SWITCH.

OPEN

CHART 1

CHECK FOR 120 VAC BETWEEN TERMINALS 1

AND 3 AT CONNECTOR CN5 ON IBC?

YES

CHECK FOR 120 VAC AT CIRCULATOR

YES

REPAIR/REPLACE CIRCULATOR

TROUBLESHOOTING

Fig. 28 --- Troubleshooting Chart No. 2

REPLACE/REPAIR WIRING FROM

TRANSFORMER TO IBC

REPLACE IBC

REPLACE/REPAIR WIRING FROM IBC TO

CIRCULATOR

A99352

CHART 1

OPEN

TROUBLE SHOOTING CHART 3

BLOWER STARTS

YES

PURGE LIGHT ON?

YES

CHECK FOR 120 VAC

BETWEEN TERMINALS 1

AND 3 AT CONNECTOR

CN4 ON IBC

CHECK FOR 120 VAC AT

BLOWER LEADS

ON WIRING HARNESS

REPAIR/REPLACE

BLOWER

IBC WAITS UP TO 5

MINUTES FOR NORMALLY

OPEN AIR PRESSURE

SWITCH CONTACTS TO

CLOSE, INDICATING

BLOWER SUCTION

IS PRESENT

YES

REPLACE IBC

REPAIR/REPLACE

WIRING FROM IBC

TO DRAFT INDUCER

CONTACTS OPEN

ARE ORIFICES IN

NEGATIVE PRESSURE

HOSE CLEAR?

ARE VENT PIPE AND

AIR INTAKE PIPE CLEAR

(NO BLOCKAGE)

CHECK AIR PRESSURE

SWITCH PER

INSTRUCTIONS ON

FOLLOWING PAGES. ARE

SAMPLING LINES CLEAR

AND CONNECTED

PROPERLY?

YES

CLEAN OUT BLOCKAGE

AT ORIFICES

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

15 SECOND PRE PURGE COMPLETE.

PURGE LIGHT OFF. SIMULTANEOUSLY

IGNITER LIGHT IS ON AS IGNITOR

CIRCUIT IS ENERGIZED

YES

CHART 4

CHECK FLUE PASSAGES

IN BOILER PER

MAINTENANCE AND CLEANING. ARE FLUE PASSAGES IN BOILER

CLEAN?

YES

CHECK DRAFT INDUCER

MOTOR RPM. IS IT

3400-3600?

YES

CHECK FOR BROKEN OR

LOOSE IMPELLER ON

DRAFT INDUCER AND

REPLACE BLOWER

IF FOUND TO BE

BROKEN OR LOOSE

REPLACE IBC

TROUBLESHOOTING

Fig. 29 --- Troubleshooting Chart No. 3

CLEAN BOILER FLUE

PASSAGES PER

MAINTENANCE AND

CLEANING INSTRUCTIONS

REPLACE BLOWER

A06155

CHART 3

YES

IGNITER/SENSOR WARMS

UP AND GLOWS YELLOW/

ORANGE DURING 20

SECOND WARM UP

YES

TROUBLESHOOTING CHART 4

CHECK FOR 120 VAC

BETWEEN TERMINALS 1

AND 2 AT CONNECTOR

CN1 ON IBC (DURING

IGNITER WARM UP)

YES

REPLACE IBC

AFTER 20 SECOND IGNITER WARM UP, GAS VALVE IS ENERGIZED VALVE LIGHT ON.

1 SECOND LATER POWER IS REMOVED FROM IGNITER/SENSOR

POWER LIGHT IS OFF. DOES MAIN BURNER LIGHT?

YES

CHECK FOR 120 VAC AT

IGNITER/SENSOR LEADS

ON WIRING HARNESS

(DURING IGNITER

WARM UP)

YES

CHECK FOR 24 VAC

ACROSS TERMINALS MV

ON THE GAS CONTROL. WHILE VALVE/ FLAME INDICATOR LIGHT

SENSOR POSITION IS OK?

TIP SHOULD BE SLANTED

IS ON

YES

CHECK IF IGNITER/

TOWARDS BURNER

YES

REPAIR/REPLACE WIRING

FROM IBC TO IGNITER/

SENSOR

REPLACE IGNITER/SENSOR

CHECK FOR 24 VAC

ACROSS TERMINALS

NO NONO

CN6-Z AND CN6-5 ON

IBC, WHILE THE VALVE/

FLAME LED IS LIT

REPAIR/REPLACE WIRING

BETWEEN IBC AND

GAS CONTROL

RESTORE IGNITER/SENSOR

TO CORRECT POSITION

DO NOT RELOCATE

REPLACE IBC

YES

CHECK GAS SUPPLY PRESSURE AT INLET

PRESSURE TAPPING ON

GAS CONTROL. IS GAS

PRESSURE GREATER

THAN 4.0" W.C.?

YES

CHART 5 CHART 5

TROUBLESHOOTING

Fig. 30 --- Troubleshooting Chart No. 4

ARE ALL MANUAL SHUT-

OFFS IN THE GAS

SUPPLY LINE AND ON

THE GAS CONTROL IN

THE OPEN OR ON

CONTACT THE GAS

UTILITY TO TURN THE

POSITION?

YES

GAS ON

OPEN OR TURN ON ALL

MANUAL SHUTOFFS

A04072

A04073

Fig. 31 --- Troubleshooting Chart No. 5

REPLACE GAS CONTROL

CHECK GAS ORIFACE SIZE

IS GAS ORIFICE SIZE CORRECT.

CHECK REPAIR PARTS LIST

FOR CORRECT SIZE. IS GAS

ORIFICE CLEAR OF BLOCKAGE.

THEN TURNS OFF.

CHECK FIRING RATE OF UNIT.

IS UNIT FIRING AT THE CORRECT RATE?

DOES THIS UNIT USE LP GAS.

ADJUST RATE AS DESCRIBED IN

THE CHECK OUT PROCEDURE

AND ADJUSTMENT SECTION OF

THE MANUAL.

VALVE LIGHT OFF.

DOES DRAFT BLOWER

STOP AFTER 30

SECOND POST PURGE?

A04074

Fig. 32 --- Troubleshooting Chart No. 6

REPAIR PART S

11a

11b

A04076

Fig. 33 --- Jacket and Base Assembly

*Not Shown

JACKET AND BASE AS SEMBLY

Item Part No. Description Quantity

1 2272144 Base Replacement Kit 1

2 650001028 Control Panel 1

3 146622803 Integrated Boiler Control 1

4 550001339 40 VA Transformer Kit 1

5 14631316 4” x 4” x 2 - -- 1/8” J--- Box 1

6 14631319 Switch P & S 1

7 14631318 J --- B o x P l a t e C o v e r 1

8 2272152AB

9 2272151AB

10 750701031AB Jacket Panel, Back 1

11a 2370007AB Jacket Panel, Top Left 1

11b 2370008AB Jacket Panel, Top Right 1

12 12695074 Screw 10 x 1/2” ZP 12

13 750001034 Jacket Tie Bar 1

14 14695060 Screw 10 x 1/2” Tech 14

15 1225013 Tap B u m p e r 1

16 1225012 Latch and Clip Kit 1

17 14631095 Door Pull

19 2485001 Pressure Switch Mounting Plate 1

* 1263010 Harness Low Water Cutoff 1

* 1263020 Wiring Harness 1

* 14631174 2--- 1/2” Plug 1

2272150AB

2272164AB

Jacket Panel Left Side Kit

(Includes Items 15 and 16)

Jacket Panel Right Side Kit (Includes Items 15 and 16)

Jacket Service Door Replacement Kit

(Includes Items 16 and 17)

Jacket, Complete Replacement Kit

(Includes Items 8, 9, 11a, and 18)

1 29 1/2" LONG

*Not Shown

3 7" LONG

3 3/4" LONG

11 12" LONG

1 3/8" LONG

9 2" LONG

8 3 3/4" LONG

Fig. 34 --- Exhaust Tee and Condensate Assembly

EXHAUST TEE AND CONDENSATE ASSEMBLY

Item Part Number Description Quantity

1 1400008

Vent Pipe 2” C PVC

S C H --- 4 0 x 2 9 --- 1 / 2 ” L o n g

2 14631305 Te e 2 ” C P V C S C H --- 80 1

3 1400008 Vent Pipe 2” CPVC SCH---40 x 7” Long 1

4 240005852 Cleanout PVC 2” 1

5 1001002

PVC Fitting 1/2” NPT Male x 1/2”

Slip Female 6 140014 Pipe 1/2” PVC SCH---40 x 1--- 3/8” 1 7 1190005 Elbow 1/2” x 90 deg. PVC SCH ---40 3

8 1400014 Pipe 1/2” PVC SCH--- 40 x 3- -- 3/4” 2 9 1400014 Pipe 1/2” PVC SCH---40 x 2” 1

10 1510012 Tee 1/2” x 1/2” x 1/2” PVC SCH---40 1

11 1400014 Pipe 1/2” PVC SCH --- 40 x 12” 1

* KGAVT0601CVT 3” Concentric Vent 1

A06154

23 22

Fig. 35 --- Boiler Block and Piping Assembly

A06153

* Not Shown

BOILER BLOCK AND PIPING ASSEMBLY

Item Part Number Description Quantity

1 2272160 Replacement Block Kit

(Includes Items 2 and 30)

2 1395002 1--- 1/4” Plug Cast Iron Square Head Plug 12

3 14631301 Hose 3” Long x 2--- 3/8 I.D. x 2 ---3/4” O.D. 1

4 1400008 Vent Pipe 2” CPVC SCH ---40 x 7” Long 1

5 1310015 Nipple, Black 1 --- 1/2” Close 1

6 14622000 Valve BLR DR 3/4” 1

7 1510010 Reducing Tee 1-- -1/2” x 1---1/4” x 3/4” 1

8 1190004 1--- 1/4” Street Elbow BLK 90_ 1

9 1310002 Nipple Std Black 1--- 1/4” x 3/4” 1

10 1190002 Elbow 1--- 1/4” x 90_ 1

11 14631004 Sight Glass Adapter 1

12 14619002 Observation Port 3/4” 1

13 1230010 Fitting, Brass 1/8” NPT x 3/16” Straight Barb 1

14 14631324 Aquastat 1

15 14662804 Well Control ½” 1

16 14693004 ¾” x ½” Std. Black Bushing 1

17 14693204 1½” x 1¼” Std. Black Bushing 1

18 PF06501 1¼” x 7” NPT Std. Black Pipe Nipple 1

19 1260006SP Temp/Pressure Gauge 2” Shank 1

20 1060002 ¾” x ¼” Std. Black Iron Bushing 1

21 PF05901 1¼” x 1¼” x ¾” Std. Black Tee 1

22 14693001 3/4” x 1/8” Black Bushing 1

23 1580006 AirPurgerw/CheckValve 1

24 14622011 ¾” Relief Valve 1

25 14607002 ¾” x 6½” Std. Black Nipple 1

26 14695802 Screw Soc HD Cap 8---32 x 3/16” 2

27 1500005 Casting Temperature Switch 1

28 2272137 Replacement LWCO Kit 1

29 14693005 1” x ¾” Black Bushing 1

30 1395004 1” Cast Iron Square Head Solid Plug 2

31 14631302 Clamp, Stainless Steel #44 2

* CI---001.03 Circulator Pump w/Flange, Taco 1

* Not Shown

Fig. 36 --- Burner Assembly

BURNER ASSEMBLY

Item Part Number Description Quantity

1 2272149

2 1250009 Burner/Casting Gasket 1

3 1250008 Burner/Flue Adapter Gasket 1

4 1210122 Flue Adapter 1

5 14695810 Hex Nut w/Serrated Washer ¼” x 20 5

6 1450011 Threaded Stud ¼” x 20 x 1½” 5

7 1250010 Igniter/Mixer Gasket 1

8 1264005 Hot Surface Igniter 1

9 14695809 Sc r e w 1 0 --- 3 2 x 3 / 8 ” 2

* 2272133

Burner Replacement Kit

(Includes Items 2 and 3)

Hot Surface Igniter Kit

(Includes Items 7, 8 and 9)

A04079

AIR INLET CONNECTION

SIGHT GLASS & ADAPTER

13 1/4"

5 1/2"

Fig. 37 --- Mixer and Air Pressure Switch Assembly

2 @ 2" EA.

GAS VALVE

16 1/2"

A06107

MIXERANDAIRPRESSURESWITCHASSEMBLY Item Item

1 14629003 Silicone Tubing, 3/16” I.D. Varies

Part Number Description Quantity

Item

2 1401004 Air Pressure Switch 3.5 IWC 1 3 1401002 Air Pressure Switch Clip 2 4 1552004 Orange Silicone Tubing, 3/16” I.D. Varies 5 1401003 Air Pressure Switch 1/2 IWC 1 6 1230006

3/16” Black Vinyl 7 1510009 Plastic Barbed Hose Tee, 3/16” I.D. 5 8 1110001 Rotor C lamp 22 9 PB --- 002.02 Pilot Orifice, BBR10 2

BLOWER GASKET

Fig. 38 --- Flue Adapter and Exhauster Assembly

FLUE ADAPTER AND EXHAUSTER ASSEMBLY

Item Part Number Description Quantity

1 2272145

2272140 Gas Valve Replacement Kit (125 Only) 1

2272141 Gas Valve Replacement Kit (150 Only) 1

2272142 Gas Valve Replacement Kit (175 Only) 1

2272143 Gas Valve Replacement Kit (200 Only) 1

3 14631311 2” x 1½” Flex Coupling 1

4 1570038 Ball Valve ½” (Blue) 1

5 1400007 Vent Pipe 2” PVC SCH --- 40 8” Long 1

6 1230011 Fitting PE 1/8” NPT x 3/16” Barb 90_ 1

7 1450012 Screw T25 Torx 2

8 14693801 Elbow Street Mall Iron ½”--- 90 PWX 2

9 14607301 NippleBlk.Std.½”NPTx3” 2

10 1225015 Cap ½” Cast Iron 1

11 14657015 Tee Bl a c k ½” 1

12 14607803 NippleBlk.Std.½”x4½” 1

13 1250021 Gasket, Cork, Venturi 1

14 1250007 Gasket, Fan Flue Adapter 1

Blower Replacement Kit

(Includes Item 13)

A04081

Table 7—Conversion Kits -- Nat to LP for 125--200MBH

MODEL # KIT # INCLUDES:

Plastic Bag 3 x 6 x 18

Orifice LP Model 125, 3.9MM

BW9AAN000125 KBANP1401DNK

BW9AAN000150 KBANP1501DNK

BW9AAN000175 KBANP1601DNK

BW9AAN000200 KBANP1701DNK

Label Propane

Literature, Conversion 125/200

K e y , To r x T --- 2 0

Label Propane Only Data Plate

Plastic Bag 3 x 6 x 18

Orifice LP Model 150, 4.2MM

Label Propane

Literature, Conversion 125/200

K e y , To r x T --- 2 0

Label Propane Only Data Plate

Plastic Bag 3 x 6 x 18

Orifice LP Model 175, 5.2MM

Label Propane

Literature, Conversion 125/200

K e y , To r x T --- 2 0

Label Propane Only Data Plate

Plastic Bag 3 x 6 x 18

Orifice LP Model 200, 6.0MM

Label Propane

Literature, Conversion 125/200

K e y , To r x T --- 2 0

Label Propane Only Data Plate

INSTALLATION AND CHECK-OUT CERTIFICATE

Boiler Model Serial # Date Installed___________

Measured BTU/HR input____________

Installation instructions have been followed

Checkout procedure and adjustment

s performed

Maintenance and Service issues reviewed with owner/ maintenance person

Installation booklet affixed on or adjacent to boiler

aller (Company)

Inst

Address

Phone

Installer'sí Name

Signature

Manufacturer reserv es the right to change, at any time, specifications and designs without notice an d without obligations.

Printed in U.S.A. Edition Date: 3/06

A04082

C a t a l o g N o : I M -- B W 9 A -- 0 5

Replaces:IM--BW9A--04

Carrier BW9 Series, BW9-125, BW9-150, BW9-175, BW9-200 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual