Carrier BWMAAN000050, BWMAAN000075, BWMAAN000100, BWMAAN000150, BWMAAN000200 Installation, Operation And Maintenance Manual

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WALL MOUNTED

STAINLESS STEEL COND ENSI NG

GAS BOILER

INST ALLATION, OPERATION

AND MAINTENANCE MANUAL

MODELS

BWMAAN000050 BWMAAN000075 BWMAAN000100 BWMAAN000150 BWMAAN000200

CAC/BDP

7310 West Morris St.

Indianapolis, IN. 48231

P/N# IM-BWMA-01

[240009473, Rev. A 06/2012]

FIGURE 1-1 Dimensions

DIMENSIONS

(D)

Wall Hanging

Bracket

(D)

Vent Connector

Safety Relief Valve Connection (¾ NPT)

(F)

Combustion Air

(A)

(B)

Models

Width (A)

Height (B)

Depth (C)

Bracket (D)

Water

Connections

Gas

Connection

Condensate Drain

Connection (H)

Weight

Vent Connector

Table 1 : Physical Data

050/075/100 150/200

20"

(508mm)

31"

(787mm)

14"

(356mm)

28"

(711mm)

Location

(I)

Size (E) 1-1/4" NPT

Location

(J)

Size (G)

Shipping

Unit

(51mm)

4-1/2"

(114mm)

1/2"

NPT

3/4" NPT

111 lb

(50 kg)

91 lb

(41 kg)

(51mm)

23"

(584mm)

42"

(1092mm)

16.0"

(406mm)

40"

(1016mm)

(51mm)

1-1/4" NPT

4-1/2"

(114mm)

3/4"

NPT

3/4" NPT

~182 lb (83 kg)

~157 lb (71 kg)

(76mm)

(C)

(I)

(J)

Supply Water (E)

Gas Connection (G)

Return Water (E)

Condensate Drain Connection (H)

TABLE OF CONTENTS

1 - Introduction ............................................................................................................................... 4

2 - Important Safety Information .................................................................................................... 5

3 - Component Listing .....................................................................................................................6

4 - Locating Boiler ...........................................................................................................................9

5 - Hydronic Piping ........................................................................................................................11

5.2 Special Conditions ................................................................................................................... 11

5.3 Safety Relief Valve and Air Vent .... ............................................................................................11

5.4 Trim Piping ............................................................................................................................. 12

5.5 System Piping ......................................................................................................................... 12

6 - Combustion Air And Vent Piping ............................................................................................... 17

6.2 Removal of Existing Boiler From Common Vent System..................................................................17

6.3 Materials ............................................................................................................................... 17

6.4 Pipe Installation ...................................................................................................................... 18

6.5 Termination ............................................................................................................................ 18

6.6 Condensate Piping ................................................................................................................... 24

7 - Gas Supply Piping ....................................................................................................................25

8 - Electrical Connections ..............................................................................................................27

8.3 Line Voltage Connections .......................................................................................................... 27

8.4 External Connections ............................................................................................................... 27

9 - Start Up Procedure ................................................................................................................... 29

9.6 CSD-1 Compliance Test.............................................................................................................32

10 - Operating Instructions ...........................................................................................................33

11 - General Maintenance And Cleaning ........................................................................................ 34

12 - Ratings And Capacities ........................................................................................................... 38

13 - Troubleshooting ..................................................................................................................... 39

14 - Wiring Diagram ...................................................................................................................... 53

15 - Glossary ................................................................................................................................. 55

Appendix A - Control Module ......................................................................................................... 57

1.1 Introduction ........................................................................................................................... 57

1.2 Operation ............................................................................................................................... 57

1.3 Status Indication ..................................................................................................................... 57

1.4 Sequence of Operation ............................................................................................................. 58

1.5 Theory of Operation................................................................................................................. 60

Information and speciﬁ cations outlined in this manual in effect at the

time of printing of this manual. Manufacturer reserves the right to

discontinue, change speciﬁ cations or system design at any time without

notice and without incurring any obligation, whatsoever.

1 - INTRODUCTION

1.1 Designated Use

• Hot water heating boiler.

• Indoor installation.

• Closet or alcove installation.

• Direct vent boiler.

• For use with natural gas or liqueﬁ ed petroleum gases (LP/propane).

1.2 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals present (example, swimming pool water).

• Exceed 50 psig (344 kPa) system pressure.

• Exceed 195°F (90.5°C) system design temperature.

1.3 Operational Features

• Modulating: 20-100%.

• Integral Dual Limit.

• Integral Low Water Cutoff (with test button).

• Outdoor Temperature Reset.

• Integral Multiple Boiler Control.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

2.2

Become familiar with symbols identifying

potential hazards.

2 - IMPORTANT SAFETY INFORMATION

2.1 General

Boiler installation shall be completed by qualiﬁ ed agency. See glossary for additional information.

WARNING

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

2.2

Become familiar with symbols identifying

potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury

2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, NFPA 70.

2.4 Where required by authority having

jurisdiction, installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cutoff may be required.

2.5 Requirements for Commonwealth of Massachusetts:

Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not

limited to:

• Installation by licensed plumber or gas ﬁ tter.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

3 - COMPONENT LISTING

Return Water From Heating System (In)

(see

page 8)

Connection supplied at bottom of boiler.

Low Voltage Terminal Strip

(see page 8) -

Connection of all low voltage wiring, including thermostat. See section

Heat Exchanger Pump

Gas Shutoff Valve

- Fuel supply isolation

during servicing. See section 7.3 page 26.

Combustion Air Blower

- Delivers proper quantity of combustion air, receives fuel from gas valve, mixes air and fuel sending mixture to burner for combustion.

Gas (Control) Valve

- Delivers proper quantity of fuel to Combustion Air Blower. See section 7.

High Temperature Supply Switch

Low Water Cutoff

Senses inadequate quantity of water. Turns off boiler before damage can occur.

Gas Connection

See section 7.

Control Module

3.1 Component Listing

User Interface (see Appendix A) - Displays information regarding boiler condition. Allows adjustment of boiler operating parameters. NOTE: Does not replace thermostat used to control central heating space.

Combustion Air Inlet (2"/3") (see page 7 & 8)

Return Water From Heating System (In)

page 8)

Low Voltage Terminal Strip

Connection of all low voltage wiring, including thermostat. See section

Igniter (see page 8)

Flame Sensor (see page 8)

Sight Glass (see page 8) - Permits observation of burner ﬂ ame.

Connection supplied at bottom of boiler.

(see page 8) -

(see

20.

Gas (Control) Valve (see page 8) proper quantity of fuel to Combustion Air Blower. See section 7.

21.

High Temperature Supply Switch (see page 8)

22.

Low Water Cutoff (see page 8) -- quantity of water. Turns off boiler before damage can occur.

23.

Safety Relief Valve (see pages 7 & 8) - Factory supplied, Field installed. See section 5.3 page 11.

24.

High Voltage Junction Box (see page 8) - For connection of 120V components. See section

25.

Vent Connector (see pages 7 & 8) - See section 6.

26.

Gas Connection (see page 8)

27.

Wall Hanging Support Bracket (see page 7) - Integral to boiler. Allows wall mounting when used with supplied wall mounting bracket. See section 4.

- Delivers

Senses inadequate

See section 7.

Burner (see page 32)

Heat Exchanger (see page 8)

10.

Condensate Collector (see page 8)

11.

Return Temperature Sensor (see page 8)

12.

Drain Valve (see page 12)

13.

Heat Exchanger Ball Valve (see page 8)

14.

Supply Water Outlet to Heating System (Out)

(see page 8) - Connections supplied for connecting from bottom of boiler. See section 5.

15.

Vent Temperature Sensor (see page 8)

16.

Condensate Drain (see Section 6.6 page 24) - Boiler produces a liquid (condensate) as a by-product of combustion. Condensate must be piped to appropriate drain.

17.

Heat Exchanger Pump (see page 8)

28.

Air Vent (see page 7 & 8)

29.

Control Module (see page 8)

30.

Transformer (see page 8) - Supplies 24V power to low water cutoff.

31.

Pressure Test Port - (see page 8)

32.

Combustion Analysis Test Port - (see page 8)

33.

Return Water Sensor - (see page 8)

34.

User Interface - (see page 8)

18.

Gas Shutoff Valve (see page 8) during servicing. See section 7.3 page 26.

19.

Combustion Air Blower (see page 8) proper quantity of combustion air, receives fuel from gas valve, mixes air and fuel sending mixture to burner for combustion.

- Fuel supply isolation

- Delivers

3 - COMPONENT LISTING

SAFETY RELIEF VALVE

AIR VENT

WALL HANGING

SUPPORT BRACKET

FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)

VENT CONNECTOR

COMBUSTION

AIR INLET

WALL HANGING

SUPPORT BRACKET

AIR VENT

SAFETY RELIEF VALVE

NOTE:

See Section 5-3

For Safety Relief

Valve Piping Instructions

FIGURE 3-2 Upper and Lower Jacket Latch

(Viewed from front of boiler)

Jacket Latch

Lift Jacket up,

engage jacket with chassis

push down.

3 - COMPONENT LISTING

GAS SHUTOFF

VALVE

COMBUSTION

AIR

BLOWER

GAS (CONTROL)

VALVE

LOW WATER

CUTOFF

SAFETY RELIEF VALVE

AIR VENT

HEAT EXCHANGER

PUMP

HEAT

EXCHANGER

RETURN WATER

FROM HEATING

SYSTEM (IN)

SUPPLY WATER TO

HEATING SYSTEM

(OUT)

LOW VOLTAGE

TERMINAL STRIP

IGNITER

SIGHT GLASS

GAS CONNECTION

CONDENSATE

DRAIN

COMBUSTION

ANALYSIS TEST

PORT

HIGH VOLTAGE JUNCTION BOX

HEAT EXCHANGER

BALL VALVE

USER INTERFACE

3 - COMPONENT LISTING

FIGURE 3-4 Boiler Components (View from Front of Boiler)

AIR VENT

HIGH TEMPERATURE

SUPPLY SWITCH

LOW WATER

CUTOFF

GAS (CONTROL)

VALVE

SAFETY RELIEF VALVE

VENT CONNECTOR

NOTE:

See Section 5

For Piping

Instructions

COMBUSTION

AIR INLET

IGNITER

FLAME

SENSOR

SIGHT GLASS

COMBUSTION

AIR

BLOWER

GAS SHUTOFF

VALVE

(SHOWN IN OPEN

POSITION)

HEAT EXCHANGER

PUMP

COMBUSTION

ANALYSIS TEST

PORT

VENT

TEMPERATURE

SENSOR

CONDENSATE

COLLECTOR

LOW VOLTAGE

TERMINAL STRIP

PRESSURE

TEST PORT

USER INTERFACE

CONTROL

MODULE

Fuse and

Holder

HEAT

EXCHANGER

TRANSFORMER

RETURN WATER

SENSOR (Located

behind piping)

CONDENSATE

DRAIN

HIGH VOLTAGE JUNCTION BOX

SUPPLY WATER TO

HEATING SYSTEM

(OUT)

HEAT EXCHANGER

BALL VALVE

RETURN WATER

FROM HEATING

SYSTEM (IN)

GAS CONNECTION

4 - LOCATING BOILER

4.1 Boiler Location Considerations

• Ambient room temperature always above 32°F (0°C) to prevent freezing of liquid condensate.

• Approved for installation in closets.

• Protect gas ignition system components from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).

• Wall mounting.

• Wall must be plumb and capable of supporting boiler weight plus 60 lbs (28 kg). See Table 1, page 2.

• Wall mounting. See section 4.2.

• Access to outdoors to meet minimum and maximum pipe lengths for combustion air and vent piping. See section 6.

• Disposal of condensate. See section 6.

• Drainage of water (or water - antifreeze solution) during boiler service or from safety relief valve discharge. See section 5.

• Access to system water piping, gas supply, and electrical service. See sections 5, 7 and 8.

FIGURE 4-1 Clearance to Combustible Materials

FLOOR

• Clearances to combustible materials and service clearances. See Table 2 and ﬁ gure 4-1.

• Multiple Boilers can be wall mounted, placed side by side, or back to back.

TABLE 2: BOILER CLEARANCES

Dimension

Model

Top (A)

Left Side (B)

Right Side (C)

Front (D)

Back (E)

Bottom (F)

Combustion Air/Vent

piping

Hot Water Piping

(1)

Required distances measured from boiler.

(2)

Service, proper operation clearance recommendation.

Combustible

Materials

050/075/100/

150/200

0" (0 cm) 14" (36 cm) 0" (0 cm) 0" (0 cm) 0" (0 cm) 0" (0 cm) 0" (0 cm) 6" (16 cm) 0" (0 cm) 0" (0 cm) 0" (0 cm) 12" (32 cm)

0" (0 cm)

½" (1.3 cm) 6" (16 cm)

FLOOR

(1)

Service

050/075/100/

150/200

6" (16 cm)

(1)(2)

4 - LOCATING BOILER

FIGURE 4-2 Wall Mount Bracket Engaged with Bracket on Boiler

Center brackets. Avoid

overhang on sides of wall

mount bracket.

4 Slots for attaching Wall

Mount Bracket to Studs

4.2 Pre-pipe supply and return water connections with factory ﬁ ttings before wall mounting.

4.3 Wall Mounting

Mount boiler on wall using wall mounting bracket included with unit.

• Structure must be capable of supporting boiler weight plus 60 lbs (28 kg). See Table 1, page 2.

• Wall mount bracket has 4 slots allowing mounting on two (2) wall studs spaced at 11½" to 16½" on center. See ﬁ gure 4-2.

• Boiler includes (4) 3/8" x 3" lag screws and (4) washers for attaching wall mount bracket to wood studs. Field source appropriate fasteners for other wall constructions (masonry, concrete).

• Attach wall mount bracket level on wall.

• Boiler must engage with wall mount bracket.

• Avoid overhang on sides of wall mount bracket. Verify boiler bracket is centered on wall bracket. See ﬁ gure 4-2.

CAUTION

Boiler weight exceeds 75 pounds (34 kg). Do not lift boiler onto wall without assistance.

5 - HYDRONIC PIPING

5.1 General

• Install piping in accordance with authority having jurisdiction.

NOTICE

Use two (2) wrenches when tightening and ﬁ tting to pipe boiler's threaded ﬁ ttings. Boiler's internal piping can be damaged if subjected to excessive torque.

• Support system piping and safety relief valve discharge piping. Boiler's internal piping and wall mount bracket can be damaged if subjected to excessive weight.

• Size central heating pump (and domestic hot water pump, if used) for system requirements only. Heat exchanger pump compensates for pressure drop through boiler internal piping and heat exchanger.

• Thoroughly clean and ﬂ ush system before connecting to boiler.

5.2 Special Conditions

• System piping exposed to freezing conditions: Use inhibited proplyene glycol solutions certiﬁ ed by ﬂ uid manufacturer for use with closed water heating system. Do not use automotive or ethylene glycol.

WARNING

• Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol.

• Never use automotive or standard glycol antifreeze, even ethylene glycol made for hydronic systems.

• Ethylene glycol can attack gaskets and seals used in hydronic systems.

• Use only inhibited proplyene glycol solutions certiﬁ ed by ﬂ uid manufacturer as acceptable for use with closed water heating system.

• Thoroughly clean and ﬂ ush any system that used glycol before installing new Boiler.

• Provide user with Material Safety Data Sheet (MSDS) on ﬂ uid used.

NOTICE

Do not expose boiler and condensate piping to freezing temperatures.

• Boiler installed above radiation level (or as required by authority having jurisdiction). Integral low water cutoff provided in boiler. See page 6.

• Boiler used in connection with refrigeration system. Install piping in parallel with boiler, with appropriate valves to prevent chilled medium from entering boiler.

• System piping connected to heating coils located in air handling unit exposed to refrigerated air circulation. Install ﬂ ow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

5.3 Safety Relief Valve and Air Vent

NOTICE

Boiler rated at 50 psig (345 kPa) maximum allowable working pressure. Boiler provided with 30 psig (206 kPa) safety relief valve. Field source safety relief valve for system pressures greater than 30 psig (206 kPa). Temperature Pressure Gauge and Air Vent satisfactory for 30-50 psig (206-345 kPa) operation.

FIGURE 5-1 Safety Relief Valve & Air Vent (View from front of boiler)

Safety Relief

Valve

Air Vent

3/4"F x 3/4"M

NPT Tee

3/4 NPT

3/4" x 1/4" NPT

90° Elbow

3/4" NPT

Close Nipple

• Install safety relief valve and air vent using pipe ﬁ ttings provided with boiler. See ﬁ gure 5-1

• Install safety relief valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety relief valve.

Position Air Vent and Safety Relief Valve

to provide space for discharge piping.

5 - HYDRONIC PIPING

WARNING

• Install discharge piping from safety relief valve. See

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

FIGURE 5-2 Safety Relief Valve Discharge Piping

Safety Relief Valve

5.4 Trim Piping

• Temperature - Pressure Gauge. Install temperature

ﬁ gure 5-2.

• Use ¾" or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C) or greater.

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

pressure gauge using nipple, tee and bushing provided with boiler. See ﬁ gure 5-3.

Check Local Codes

For Maximum

Distance To Floor

FIGURE 5-3 Temperature Pressure Gauge and Drain Valve Installations

Gas Supply

• Drain Valve. Install drain valve using nipple, tee and bushing provided with boiler. See ﬁ gure 5-3.

5.5 System Piping

• Systems with automatic ﬁ ll valves require back ﬂ ow prevention device.

• Single boiler system. See ﬁ gures 5-4, 5-5, 5-6, 5-7 for general guidance. Additional considerations:

• Control system designed for single central heating pump. Installer responsible for integration of multiple central heating pumps.

• Control system allows domestic hot water prioritization. Function could be lost if central heating pump not directly connected to control system.

• Multiple boiler system. See ﬁ gure 5-8 for general guidance. Additional considerations:

• Control system requires equivalent water temperatures entering each boiler to properly sequence and adjust system supply temperature.

• Install multi boiler sensor kit. See "Parts, Kits & Optional Accessories" manual for part number.

Temperature Pressure

Gauge shown at

System Supply

Connection

Drain Valve shown

at System Return

Connection to Boiler

5 - HYDRONIC PIPING

NOTICE

Illustrations are meant to show system piping concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction.

FIGURE 5-4 System Piping

Safety Relief Valve

Piping Legend

Check Local Codes

For Maximum

Distance To Floor

System

Supply

FLOOR

System

Return

5 - HYDRONIC PIPING

5-5 TWO-PIPE ZONED SYSTEM WITH VALVES

DHW Pump

CH/System

Pump

Heat exchanger

ball valve open

(as shipped)

5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS

DHW Pump

Zone

Pump

3/8"/10mm

Open End

Wrench

Heat exchanger

ball valve open

(as shipped)

3/8"/10mm

Open End

Wrench

5 - HYDRONIC PIPING

5-7A SINGLE BOILER USING PRIMARY/SECONDAY PUMPING

12"/305mm Max. apart

CH/System

Existing closely spaced tees

in primary system loop

Limit length

Pump

Heat exchanger

ball valves closed

5-7B SINGLE BOILER USING PRIMARY/SECONDAY PUMPING

5'/1.6 m

3/8"/10mm Open

End Wrench

12"/305mm Max. apart

CH/System

Pump

Heat exchanger

ball valve open

Existing closely spaced tees

in primary system loop

Limit length

5'/1.6 m

3/8"/10mm Open

End Wrench

5 - HYDRONIC PIPING

5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide)

DHW Pump

CH/

System

Pump

12"/305mm Max. apart

System

T emperature

Sensor

Size common piping

according to

maximum heat

capacity of

entire system

Up to 16

boilers

All heat exchanger

ball valves closed

3/8"/10mm Open

End Wrench

(See Multiple Boiler Guide)

6 - COMBUSTION AIR AND VENT PIPING

6.1 General

This boiler requires a dedicated direct vent system. Install combustion air and vent piping in accordance with these instructions, authority having jurisdiction, and

National Fuel Gas Code, ANSI 223.1/NFPA 54.

Vent connections serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

Install vent system in accordance with these instructions.

6.2 Removal of Existing Boiler From Common Vent System

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

After removal of existing boiler, following steps shall be followed with each appliance remaining connected to common venting system placed in operation, while other appliances remaining connected to common venting system are not in operation:

• Seal any unused openings in common venting system.

• Visually inspect venting system for proper size and horizontal pitch. Determine there is no blockage or restrictions, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

• When practical, close all building doors, windows, and all doors between space in which appliances remaining connected to common venting system are located and other spaces of building. Turn on clothes dryer and any appliance not connected to common venting system. Turn on exhaust fans, such as range hoods and bathroom exhaust so they will operate at maximum speed. Do not operate summer exhaust fan. Close ﬁ replace dampers.

• Turn on appliance being inspected. Follow lighting instructions. Adjust thermostat so appliances will operate continuously.

• Any improper operation of common venting system should be corrected so installation conforms with National Fuel Code, ANSI Z223.1/NFPA 54. When re-sizing any portion of common venting system, common venting system should be re-sized to approach minimum size as determined using appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

6.3 Materials

• See Table 3

Table 3 - Combustion air and vent pipe ﬁ ttings

must conform with the following:

Item Material Standards

PVC schedule 40 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

CPVC schedule 40

Vent Pipe

and Fittings

Pipe

Cement/

Primer

• IPEX is approved vent manufacturer in Canada listed to ULC-S636.

• IPEX System 636 Cements and Primers are approved in Canada listed to ULC-S636.

SDR-21 & SDR-26 PVC ANSI/ASTM D2241

ABS-DWV ANSI/ASTM D2661

Schedule 40 ANSI/ASTM F628

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Schedule 40 ABS ANSI/ASTM D2235

DO NOT USE CELLULAR (FOAM) CORE PIPE

ANSI/ASTM D1784/

F441

• Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use ﬂ ame of match or candle, smoke from cigarette, cigar or pipe.

• Determine each appliance remaining connected to common venting system properly vents when tested as outlined above. Then return doors, windows, exhaust fans and any other gas-burning appliance to their previous condition of use.

WARNING

Use of cellular core PVC for venting ﬂ ue gas could result in death, serious injury.

6 - COMBUSTION AIR AND VENT PIPING

6.4 Pipe Installation

• Minimum and maximum combustion air and vent pipe lengths listed in Table (3). Pipe length counted from combustion air connector to termination.

• Install ﬁ eld-sourced 2" to 3" transition, if used, in vertical section at combustion air inlet and vent connector.

• 90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no equivalent length.

• Slope vent pipes minimum 1/4" per foot (21 mm/m) back toward boiler. Support horizontal sections to prevent sags capable of accumulating condensate.

• Support piping in accordance with pipe manufacturer's instruction and authority having jurisdiction. In absence of manufacturer's instruction use pipe hooks, pipe straps, brackets, or hangers of adequate and strength located at intervals of 4 ft (1.2m) or less. Allow for expansion/contraction of pipe.

• Combustion air and vent piping must be air tight and water tight.

• Certiﬁ ed vent system components must NOT be inter- changed with other vent systems or unlisted pipe/ﬁ ttings.

6.5 Termination

• Terminate combustion air and vent pipes with ﬁ ttings or concentric vent kit.

• See "Parts, Kits and Optional Accessories" manual for concentric vent kit part numbers.

• Use horizontal pipe for vent and 90° elbow for combustion air termination when using ﬁ ttings.

• Terminate combustion air and vent pipes in same atmospheric pressure zone through exterior sidewall or roof.

• Locate combustion air termination as far as possible from swimming pool, swimming pool pump house, and other sources of airborne chlorine.

• Locate combustion air and vent terminals as required by authority having jurisdiction.

WARNING

Vent extending through exterior wall shall not terminate adjacent to wall or below building extensions such as eaves, balconies, parapets or decks. Failure to comply could result in death or serious injury.

Table 4 - Combustion Air and Vent Piping Length

Combustion Air and Vent Pipe Equivalent Length

2” Pipe 3” Pipe

Model 050 075/100 075/100 150/200

Min.

Max.

6 ft.

(1.8 m)

100 ft.

(30.5 m)

6 ft.

(1.8 m)

50ft.

(15.2 m)

6 ft.

(1.8 m)

100 ft.

(30.5 m)

6 ft.

(1.8 m)

100 ft.

(30.5 m)

1 - 90° elbow = 5 ft (1.6 m) 1 - 45° elbow = 3.5 ft (1.1 m) 1- 2" x 3" adapter = 0 ft (0 m)

Note: Concentric Vent Kit=5 ft (1.6m) equivalent length

For Example: Boiler can be installed on outside wall and vented with 1-90° elbow and 1 ft (0.30 m) of vent pipe.

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-1

12" (30 cm)

Minimum

8" (21 cm)

Minimum

Vent Combustion

12" (30 cm) Minimum above

anticipated snow line

FIGURE 6-2

3" (8 cm) Maximum

Air

15" (38 cm)

Maximum

Roof Line

Roof

Terminations

 3" (8 cm) Maximum horizontal separation between combustion air intake and vent of same appliance.

 8" (21 cm) Minimum vertical separation between combustion air intake and vent of different appliances.

 15" (38 cm) Maximum horizontal length of vent.

 Maximum vent/intake between different appliances 12" (30cm).

 Maximum allowable total vertical vent length with outside exposure is 10 ft.(3.05m).

 Abandoned unused masonry chimney may be used as chaseway for combustion air and vent. Both combustion air and vent pipe must exit above top of chimney with clearances as shown in ﬁ gure 6-1.

12" (30 cm)

Minimum from

overhang

See snow & ice

page 23

FIGURE 6-3

3" (8 cm)

Minimum

separation

12" (30 cm) Separation

between bottom of

combustion air intake

and bottom of vent

Vent

Combustion Air

12" (30cm)

Minimum

separation

Side Wall

Terminations

 3" (8 cm) Minimum horizontal separation between combustion air intake and vent terminations.

 8" (21 cm) Minimum vertical separation between combustion air intake and vent terminations.

 12" (30 cm) Separation between bottom of combustion air intake and bottom of vent.

 Multiple terminations as shown in 6-1, 6-2, and 6-3 must be a minimum of 12” (30 cm) horizontally between vent of one termination and air intake of next appliance.

 Maximum allowable total outside exposure vent length equals 10 ft. (3.05m).

 Maintain a pitch of 1/2" per ft. (42mm/m) outside exposure back to boiler to ensure proper condensate drainage for horizontal runs.

See snow & ice

page 23

Combustion Air

Vent

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-4

Combustion

Air

1" (2.54cm) Maximum

1"(2.54cm) Maximum

Vent

FIGURE 6-7

FIGURE 6-5

1" (2.54cm) Maximum

* See Note Below

Combustion

Air

*Must be less than 4" or greater than 24" Horizontal distance between end bells of each air intake to prevent ﬂ ue gas recirculation.

Note: Securing strap must be ﬁ eld installed to prevent movement of termination kit in side wall

Roof overhang

12" (30cm) Minimum

36"(0.9m) Minimum

Maintain 12"(30cm)

Vent

clearance above

clearance above highest

highest anticipated

anticipated snow level or

snow level or grade

Maintain 12"

grade

OD 3½" ( OD 4½" (11.4cm) - 3" (7.6cm) kit

Combustion Air

Elbow ﬁ eld supplied

** Note Overall length may be modiﬁ ed by cutting or extending both combustion air and vent pipes. 12" is minimum allowable length and 60" is maximum allowable length for this dimension. SDR-26 PVC (D2241) only may be used for extending pipes. Do not use Schedule 40 PVC or use couplings to extend pipes. Dimension will change if intake/vent pipes are lengthened or shortened.

8.9cm)

- *2" (

5.0cm)

kit

**See

Note

*2 or 3" (5.0 or 7.6cm) Diameter

PVC intake/combustion air

*2" (

5.0cm)

Diameter = 41" Length (1.0m))

46-3/4" (1.2 m)

3" (7.6cm) Diameter = 47" Length (1.2m)

Combustion Air

Vent

1"(2.54cm) Maximum

* Note: 2" For use with models 050/075/100. 3" For use with models 075/100/150/200

6 - COMBUSTION AIR AND VENT PIPING

Concentric

Vent Roof

Terminations

 Glue inner vent pipe to prevent recirculation.

 Maintain 12" (30 cm) minimum clearance above highest anticipated snow level. Maximum of 24"(0.61m) above roof.

 Support must be ﬁ eld installed to secure termination kit to structure.

 Elbow, roof boot/ﬂ ashing ﬁ eld supplied.

 Allowed Wall/Roof thickness 1/2"-30" (1.2 - 76cm).

 Vertical concentric vent system can be installed in unused masonry chimney.

 Contact Technical Support for questions regarding installation or use.

FIGURE 6-6

Combustion Air

Roof boot/ﬂ ashing (ﬁ eld supplied)

Note: Support must be ﬁ eld installed to secure termination kit to structure

Vent

Maintain 12"(30cm)

clearance above highest

anticipated snow level

24" above roof

Support (ﬁ eld supplied)

Combustion Air

6 - COMBUSTION AIR AND VENT PIPING

Forced Air

Inlet

12"

(30.5cm m)

Minimum

Less than 10' (3 m)

Minimum

Termination must be 12" (30.5 cm)

from or below doors,

windows or gravity

inlet.

Termination

3' (0.9 m) [If located within 10' (3 m) of forced air inlet]

Doors &

Windows

Condensate

Forced Air

Inlet

Combustion air and vent termination must be 12" (300mm) from or below doors, windows or gravity inlet.

Vent gas may condense, forming moisture, may be corrosive. Protect building materials at vent from exhaust of vent gas.

Terminate venting system 3’ (0.9 m) above and 10' (3.0 m) from any forced air inlet (except boiler’s combustion air inlet).

3' (0.9 m)

Minimum

Grade, Snow

& Ice

"L"

Corner

Terminate vent system bottom, minimum 12" (300 mm) above highest anticipated snow level.

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

Vent termination shall NO T be installed closer than 3' (0.9 m) from inside corner of “L” shaped structure.

Vegetation,

Plants &

Shrubs

Meters, Regulators, deck, porch

Walkways

6 - COMBUSTION AIR AND VENT PIPING

Keep vent termination 3’ minimum (0.9m) away from vegetation. Position termination where vent vapors will not damage plants/shrubs or air conditioning equipment.

Termination

Vent termination 4’ (1.2m), horizontally from, no case above or below, electric meters, gas meters, regulators, and relief equipment, or under deck or porch.

3' (0.9 cm)

Minimum

Locate vent termination minimum 7' (2.1 m) above any public walkway, with consideration to condensate.

People or

Pets

Stones,

Balls,

Etc.

Vapors

Locate combustion air and vent termination to prevent accidental contact with people or pets.

Position combustion air and vent termination where it will NOT be damaged by foreign objects, such as stones, balls, etc.

Position termination where vent vapors are not objectionable.

7' (2.1 m)

Minimum

Position termination so it will not be effect-

Eddy,

Flue

Gases

ed by wind eddy, air born leaves, snow, or recirculated vent gases. Give consideration to excessive wind and locate away from windward side of building.

Multiple

Family

Dwellings

Vent shall not terminate directly above paved sidewalk or paved driveway located between two single-family dwellings serving both dwellings.

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-1 Condensate Drain

6.6 Condensate Piping

• Use materials acceptable to authority having jurisdiction. In absence of such authority:

• PVC or CPVC per ASTM D1785/D2845 Cement or primer per ASME D2564 or F493.

• Attach PVC tee provided with boiler and ﬁ eld sourced piping to condensate drain at bottom of boiler. See ﬁ gure 6-1.

• Slope condensate drain pipe minimum 1/4" per foot (21mm/m) away from boiler.

• Use ﬁ eld source condensate pump if boiler located below disposal point.

• Field source condensate neutralizing kit as required by authority having jurisdiction or for environmentally friendly condensate disposal.

Condensate Tee

(ﬁ eld installed)

on condensate drain

pipe

7 - GAS SUPPLY PIPING

7-1 Gas Connection

Gas Connection

NOTICE

Use two (2) wrenches when tightening and ﬁ tting to pipe boiler's threaded ﬁ ttings. Boiler's internal piping can be damaged if subjected to excessive torque.

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switches; do not use any phones in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department.

7.1 General

• Use piping materials and joining methods acceptable to authority having jurisdiction. In absence of such requirements National Fuel Gas Code, ANSI Z223.1/ NFPA 54.

• Size and install gas piping system to provide sufﬁ cient gas supply to meet maximum input at not less than minimum supply pressure. See Table 5.

• Support piping with hooks straps, bands, brackets, hangers, or building structure components to prevent or dampen excessive vibrations and prevent strain on gas connection. Boiler will not support piping weight.

• Use thread (joint) compound (pipe dope) suitable for liqueﬁ ed petroleum gas.

• Provide sediment trap up stream of gas valve.

• Install manual main shutoff valve outside of jacket. See ﬁ gure 7-2.

MODEL

050

075

100

150

200

7.2 Conversion Kit Instructions

• See Gas Conversion Kit Instructions included with Boiler.

TABLE 5: GAS SUPPLY PRESSURE

Natural Gas Propane

Min. Max. Min. Max.

3.0" w.c.

(0.7 kPa)

3.0" w.c.

(0.7 kPa)

3.0" w.c.

(0.7 kPa)

3.0" w.c.

(0.7 kPa)

3.0" w.c.

(0.7 kPa)

Note: See Glossary - Piping Table 16

13.5" w.c. (3.3 kPa)

5.0" w.c.

(1.2 kPa)

5.0" w.c.

(1.2 kPa)

5.0" w.c.

(1.2 kPa)

5.0" w.c.

(1.2 kPa)

5.0" w.c.

(1.2 kPa)

13.5" w.c. (3.4 kPa)

7 - GAS SUPPLY PIPING

DANGER

Fire Hazard. Do not use matches, candles, open ﬂ ames, or other methods providing ignition source. Failure to comply will result in death or serious injury.

7.3 Leak Check Gas Piping

Pressure test boiler and gas connection before placing boiler in operation.

•

Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler and its individual gas shutoff valve from gas supply system.

•

Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler from gas supply system by closing manual gas shutoff valve. See ﬁ gure 7-3.

•

Locate leakage using gas detector, noncorrosive detection ﬂ uid, or other leak detection method acceptable to authority having jurisdiction. Do not use matches, candles, open ﬂ ames, or other methods providing ignition source.

7-2 Manual Main Gas Shutoff Valve Outside Boiler Jacket

Manual Main Gas

Shutoff Valve

•

Correct leaks immediately and retest.

7-3 Gas Shutoff Valve

Gas shutoff valve

(shown in closed

position)

8 - ELECTRICAL CONNECTIONS

8.1 General

Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to National Electrical Code, ANSI/NFPA 70.

8.2 Electric Knockouts (Figure 8-1)

• Five knockouts located on bottom of chassis.

A. Three knockouts located under junction box are

reserved for high voltage wires. Choose connectors using total diameter of wire bundles.

B. Two knockouts located to right of high voltage

knockouts (outside of junction box) are reserved for low voltage wiring. Use supplied grommets

when using these knockouts.

8.3 Line Voltage Connections (Figure 8-2)

• Boiler

A. Provide individual 120V, 15 amp circuit

(recommended) with fused disconnect or service switch as required by authority having jurisdiction.

B. Open High Voltage Junction Box (see ﬁ gure 3-4) to

access line voltage terminal strip.

C. Connect 120 VAC circuit to line voltage terminal

strip 120 VAC L,N,G.

• Central Heating Pump, if used.

A. Isolate pump from control module if pump FLA (Full

Load Amps) exceeds 2 amps (or 1 amp if external DHW pump is used).

B. Connect pump to line voltage terminal strip CH

PUMP L,N,G.

• Domestic Hot Water Pump, if used.

A. Isolate pump from control module if pump FLA

exceeds 1.0 amp.

B. Connect pump to line voltage terminal strip DHW

PUMP L,N,G.

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

NOTICE

Wiring diagrams can be found in Section 14 of this Manual.

8-1 ELECTRIC KNOCKOUTS BOTTOM OF BOILER

Front of Boiler

Low Voltage

High Voltage

Knockouts

4½"

(1.6m)

(1.4m)

Back of Boiler

8-2 LINE VOLTAGE CONNECTIONS

Knockouts

(Use supplied

grommets when using

these knockouts)

8.4 External Connections (Figure 8-3)

• User Interface Terminals

A. Factory wired to USER INTERFACE terminals B. Optional - Remote mount user interface for

improved access. Use low voltage knockout.

C. Maximum wire length is 100 ft (30m) for 22 ga.

wire, or 150 ft (45m) for 18 ga. wire.

8 - ELECTRICAL CONNECTIONS

• Argus Link (Multiple boiler applications only)

• Outdoor Sensor, if used.

A. Provided with boiler. B. Locate outdoor sensor to protect against wind and

direct sunlight. Mounting instructions provided with sensor.

C. Maximum wire length is 100 ft (30m) for 22 ga.

wire, or 150 ft (45m) for 18 ga. wire.

D. Connect wires to OUTDOOR SENSOR terminals.

Wires are interchangeable.

• System Sensor (Multiple boiler applications only)

• Domestic Hot Water (DHW) Thermostat, if used.

A. Use temperature control with dry contacts rated

at 0.5 amps @ 120 VAC. Boiler control does not provide power to DHW temperature control.

NOTICE

IMPORTANT: Do not apply power to DHW T-T terminals. Dry contact only, use of isolation relay may be necessary.

8-3 EXTERNAL CONNECTIONS

(Do not apply voltage to external terminals.)

B. Maximum wire length is 330 ft (100 m) 22 gauge

wire.

C. Connect wires (interchangeable) to DHW T-T

terminals. Wires are interchangeable.

• Central Heating Thermostat

A. Use thermostat or boiler system control with dry

contacts related 0.5 amps @ 120 VAC. Boiler control does not provide 24 VAC power to central heating thermostat.

B. Locate and install thermostat per manufacturer's

instructions. Maximum wire length is 330 ft (100 m) for 22 ga. wire.

C. Connect wires to CH T-T terminals. Wires are

interchangeable.

9 - START UP PROCEDURE

NOTICE

IMPORTANT: Condensate trap must be manually ﬁ lled with water at initial start up.

9-1 Condensate Drain Assembly

9.1 Fill boiler with water and purge air

• Fill boiler with potable water.

•

Fill boiler and system piping with water (or antifreezewater solution, if used). See antifreeze information page 11. Purge air from boiler using air vent. Purge air from system piping.

•

Inspect system piping and boiler connections. Repair any leaks immediately.

9.2 Fill Condensate Trap with Water

•

Disconnect collet clip from condensate hose barb. See ﬁ gure 9-1.

•

Disconnect tubing below from hose barb.

•

Pour approximately 2 cups (473 ml) of water into condensate drain.

•

Reconnect tubing to hose barb with collet clip. See ﬁ gure 9-1.

1. Disconnect collet clip from hose barb and ﬁ ll Condensate

trap with water.

2. Reconnect hose to hose barb with collet clip before

starting boiler.

9 - START UP PROCEDURE

9 -2 User Interface

-2 User Interfac

9.3 Program Boiler Control

Key Description

- Manual Lockout Reset

- Enter/Exit user menu

- Go to previous screen

- Select a menu item

- Conﬁ rm new parameter value

- Scroll up to next menu item

- Increase value

- Scroll down to next menu item

- Decrease value

Boiler is factory programmed with following factory default settings, ﬁ gure 9-3.

Parameters can be adjusted to suit particular application.

Detailed explanation of each can be found in Appendix A - Control Module.

List parameters in event of Control Module Failure to reprogram your settings.

Factory Default

9-3 Default Table

Control Parameter

Central Heating Setpoint

User

Installer

* List parameters in event of Control Module Failure to reprogram your settings.

Settings

Boiler

Conﬁ guration

CH Settings

DHW Setpoint 180°F 82°C 104-195°F 40-91°C Temperature Units °F °F/°C Boiler Address 0 0-15 Low Water Cutoff Enabled Enable/Disabled Pump Mode 0 0 & 4 Service Reminder Status On ON/OFF Service Reminder Days 365 Days 1- 999 Days

CH Mode 1 0, 1, 2, 3 Warm Weather Shutdown 70°F 21°C 35-100°F 2-38°C Reset Curve Design Temperature - Boiler 180°F 82°C 60-195°F 40-91°C Reset Curve Design Temperature - Outdoor 25°F -4°C -60-32°F -51-

Reset Curve Mild Weather Temperature - Boiler 100°F 37°C 35-120°F 2-49°C Reset Curve Mild Weather Temperature - Outdoor 70°F 21°C 35-85°F 2-29°C

Reset Curve Boiler Minimum Temperature 70°F 21°C 40-180°F 4-82°C Reset Curve Boiler Maximum Temperature 180° 82°C 80-195°F 27-91°C Boost Function Temperature 0°F 0°C 0-36°F 0-20°C Boost Function Time 20 Minutes 1-120 Maximum Power CH 100% 1-100% DHW Mode 0 0/2 DHW Maximum Priority Time 30 Minutes 1-60 minutes

Setting

Standard Metric Standard Metric

140°F 60°C 104-195°F 40-91°C

Setting Range

25°C

*Actual

Parameter

Settings

9 - START UP PROCEDURE

9.4 Boiler Start-up and Operational Test

1. Verify air is purged from hydronic piping

2. System test pumps - verify each pump is opera-

tional

3. Verify gas piping

•

Conﬁ rm pressure test. See section 7.3.

•

Visually inspect piping to determine there are no open ﬁ ttings or ends, and all valves at unused outlets are closed and plugged/capped.

•

Purge air from piping

•

Check piping and connections for leaks immediately after gas is turned on. Shut off gas supply and make necessary repairs if leaks found.

4. Follow OPERATING INSTRUCTIONS to initiate boiler

operation. See section 10.

5. Inspect combustion air and vent piping. Verify pipe

is not leaking and terminations are unobstructed and vent gas discharge is not a nuisance or hazard.

6. Verify boiler functions.

7. Inspect condensate disposal system. Verify

condensate ﬂ ows adequately and is disposed properly.

8. Check control module operation.

9. Check ﬁ eld-sourced limits, low water cutoffs, etc.

per manufacturer's instructions.

9.5 Check Combustion

Natural Gas

1. Measure input. English units*

•

Turn off gas to all other appliances.

if needed using ﬁ gure 9-3 below.

Size Minimum Maximum

050 45 51 075 65 76

100 90 102 150 140 153

200 185 204

Natural Gas and Propane

3. Measure CO

and compare to table. Adjust CO2 if

needed using ﬁ gure 9-3 below. See ﬁ gure 9-4 for combustion air analyzer port.

Gas

Natural Gas 8.5 9.5 <100ppm Propane 10.0 11.0 <150ppm

Min.

Max.

Natural Gas only**

Measure input. Compare to table above. Continue to measure input and CO2 until both measured

values are within range speciﬁ ed in tables.

Propane Gas

Most propane systems do not have ﬂ ow meters.

1. Check CO

11.0%.

•

If CO2 is low increase gas ﬂ ow following ﬁ gure 9-3.

•

If CO2 is high decrease gas ﬂ ow following ﬁ gure 9-3.

. Propane should be between 10% and

•

Use ½, 1 or 2 cu ft dial on gas meter. Measure time required for one or more complete revolutions. Measure time for 1-2 minutes.

•

Calculate input.

3600 x cu ft

Input (MBH) =

seconds

Example: Gas ﬂ ow from Meter = 2 cu ft Measured time = 72 seconds

3600 x 2 cu ft

Rate (MBH) =

= 100 MBH

72 seconds

*Metric - See Glossary ** Most propane systems do not have gas ﬂ ow meters.

2. Compare measured input to table. Adjust input rate

9-3 Gas Valve

•

To increase gas ﬂ ow turn 'throttle' left or counter clockwise .

•

To decrease gas ﬂ ow turn 'throttle' right or clockwise .

•

Limit adjustment to one turn and retest.

9 - START UP PROCEDURE

WARNING

Asphyxiation hazard. Carbon monoxide is odorless, tasteless, clear colorless gas, which is highly toxic. Verify cap is ﬁ rmly placed on combustion analyzer port to prevent CO emission. Failure to do so could result in death or serious injury.

9-4 Combustion Analyzer Port

Combustion Analyzer Port

9-5 Burner Flame

Burner

Flame

Look for BLUE ﬂ ame

with slight YELLOW tips

evenly spaced around

burner

Verify Burner, Proper Operation

1. Inspect burner ﬂ ame through Sight Glass. See

ﬁ gure 9-5.

2. Operate boiler through several heating cycles,

including domestic hot water, if used. Verify proper operation.

3. Reset control parameters to operating settings if

adjusted to allow startup and operation test.

4. Follow instructions TO TURN OFF GAS TO APPLIANCE

if boiler is not being placed into immediate operation.

5. Enter installer information on Warranty Registration

Card.

6. Gather all instructions, manuals, wiring diagrams,

warranty registration card and other supporting information. Review with user and/or afﬁ x in conspicuous location adjacent to boiler.

9.6 Perform CSD-1 Compliance Test (see paragraph 2.4 page 5)

Verify operation of boiler safety control operation with regard to no ﬂ ow conditions as follows:

1. Turn off boiler using boiler service switch.

2. Disable primary boiler pump. Disconnect multi pin

connector J7 from control module. See ﬁ gure 9-6.

3. Disable secondary system pumps attached to

system.

4. Establish call for heat. Jump CHW T-T terminals

on low voltage terminal block. Turn on boiler using boiler service switch.

5. Boiler will ﬁ re. Based on natural convection within

boiler, boiler will either: A.

Lockout A-06 "Safety Relay Error". Requires manual reset of control module. Press reset button on User interface. See 9.3 Program Boiler Control page 30 .

Shut off burner E40 "Return Water Temp". This is a soft lockout. When water temperature drops below limit boiler will automatically reﬁ re then Lockout A-06 requiring manual reset of control module. Press Reset button on User Interface.

Shut off burner E39 "Flue Temperature Sensor". This is a soft lockout. When ﬂ ue sensor drops below limit, boiler will automatically reﬁ re then Lockout A-06 requiring manual reset of control module. Press Reset button on User Interface.

6. After safety operation is veriﬁ ed, turn off boiler via

service switch. Remove jumper in T-T. Replace J7 connector into control module, enable secondary pump operation, turn service switch on and restart

system to verify operation.

9 - START UP PROCEDURE

9-6 Control Module J7 Connector

9.7 Complete Start Up Procedure

Reset control parameters to operating settings if adjusted to allow startup and operation test.

2. Follow instructions TO TURN OFF GAS TO APPLIANCE

if boiler is not being placed into immediate operation.

3. Enter installer information on Warranty Registration

Card.

4. Gather all instructions, manuals, wiring diagrams,

warranty registration card and other supporting information. Review with user and/or afﬁ x in

conspicuous location adjacent to boiler.

10 - OPERATING INSTRUCTIONS

Gas Shutoff Valve

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

If you do not follow these instructions exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life.

• This appliance is equipped with an ignition device which automatically lights burner. Do NOT try to

light this burner by hand.

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

• Use only your hand to turn the gas shutoff valve. Never use tools. If valve will not turn by hand, do not try to repair it, call a qualiﬁ ed service technician. Force or attempted repair may result in ﬁ re or explosion.

• Do not use this appliance if any part has been under water. Immediately call a qualiﬁ ed service

technician to inspect appliance and to replace any part of control system and any gas control which has been under water.

CAUTION

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 ﬁ re department.

10.2 TO TURN OFF GAS TO APPLIANCE

• Set thermostat to lowest setting.

• Turn "OFF" all electric power to appliance if service is to be performed.

• Remove front jacket panel.

• Turn gas shutoff valve handle clockwise to closed position. Handle should be perpendicular to gas pipe.

• Replace front jacket panel.

10.1 OPERATING INSTRUCTIONS

Stop! Read Safety information above.

• Set thermostat to lowest setting.

• Turn "OFF" all electrical power to appliance.

• This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light

burner by hand!

• Remove upper front jacket panel.

• Turn gas shutoff valve clockwise to closed position. Handle should be perpendicular to gas pipe.

• Wait 5 minutes for any gas to clear. Smell for gas, including near ﬂ oor. If you smell gas, STOP! Follow instructions on this page: “What To Do If You Smell Gas.” If you do not smell gas, go to next step.

• Turn gas shutoff valve counter clockwise to the open position. Handle should be parallel to gas pipe.

• Replace upper jacket panel.

• Turn "ON" electrical power to appliance.

10-1 Gas Shutoff Valve

OPEN POSITION

CLOSED POSITION

• Set thermostat to desired setting.

• If the appliance will not operate, follow instructions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier.

Gas Shutoff Valve

11 - GENERAL MAINTENANCE AND CLEANING

DANGER

Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn gas supply OFF to boiler. Failure to comply will result in death or serious injury.

CAUTION

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

NOTICE

Verify proper operation after servicing.

NOTICE

Perform regular service and maintenance by qualiﬁ ed service agency at least once every 12 months to assure safe, trouble free operation and maximum efﬁ ciency .

11-1 Sight Glass

11.1 Beginning of Each Heating Season

• Check boiler area is free from combustible materials, gasoline, and other ﬂ ammable vapors and liquids.

• Visually inspect combustion air and vent piping for proper operation. Check for and remove any obstruction to ﬂ ow of combustion air or vent gases. Immediately repair or replace pipe showing deterioration or leakage. Reassemble per instructions in section 6. Verify proper reassembly and resealing of system.

• Visually inspect condensate drain line for proper operation. Checking for deteriorated or plugged condensate drain line. Verify condensate trap drains freely.

• Test safety relief valve for proper operation. Refer to valve manufacturer's instructions packaged with relief valve.

• Inspect burner and heat exchanger and clean (if necessary) by following instructions in “Annual Inspection

and Cleaning of Boiler Components” in this section.

• Circulator pump and combustion air blower motor furnished with boiler are permanently lubricated from factory and require no further lubrication. Lubricate ﬁ eld sourced pumps and/or motors according to pump and/or motor manufacturer’s instruction.

Sight Glass

Pressure Test Port

• Check following components are operating properly and are free of blockages or obstructions:

• air vent;

• check venturi air inlet for blockage and clean as required;

• verify pressure test port cap and combustion test port are in place;

• return temperature sensor clip must be securely seated on pipe; Check boiler for any sign of leaks.

• Check low water cutoff using user interface.

• Check operation by pressing test button on low water cutoff.

• "Low Water" LED should illuminate and burner should shut down.

• Should get error message on User Interface (E36).

• Every 5 years remove low water cutoff. Reinstall after cleaning.

• Every 10 years replace low water cutoff.

• Check ﬂ ame signal with user interface. Should be 8 amps at 100%.

micro

• Visual inspection of ﬂ ame through sight glass. Burner should be fully illuminated. See ﬁ gure 9-5.

• Check expansion tank.

11 - GENERAL MAINTENANCE AND CLEANING

Figure 11-2 Condensate Trap

Flue Pipe

Coupling

Condensate Collector

Condensate Trap connection

to Condensate Collector

Flexible Gas Line

Temperature Sensor

Hose Barb w/Cap

11.2 Annual Shut Down Procedure

• Follow instructions “To Turn Off Gas To Appliance” unless boiler is also used to supply domestic hot water. See section 10.

• Drain system completely if system does not have antifreeze when heating system is to remain out of service during freezing weather.

• Drain condensate lines when boiler is to be exposed to freezing temperatures.

WARNING

Following service procedures must be performed by qualiﬁ ed service agent. Boiler owner shall not attempt these steps. Failure to do so could result in death or serious injury.

11.3 Annual Inspection and Cleaning of Boiler

Components

• Obtain Burner Inspection Kit. Follow kit instructions to prepare for examination and cleaning.

• Burner and heat exchanger inspection and cleaning.

• Remove gasket and burner. Allow burner to clear top lip of chassis.

• Remove any residual sleeve and/or gasket material from removed burner.

• Clean burner using air hose directed into top of burner opening to dislodge any debris in burner ports. Inspect burner for foreign matter in ﬂ ame ports or inside burner. Remove foreign matter by blowing with compressed air or vacuuming. Replace burner if it cannot be cleaned or is showing deterioration.

• Clean heat exchanger with low pressure water spray. Use ﬂ exible handle nylon brush to loosen sediment and oxide on all accessible heating surfaces of heat exchanger. Take care not to get brush stuck in heat exchanger.

• Remove any remaining loosened sediment using shop vacuum with snorkel attachment.

• Clean condensate collector if signiﬁ cant debris found in heat exchanger.

• Expand upper collet clip of condensate trap using hose clamp pliers. Disconnect condensate trap from condensate collector. See ﬁ gure 11-2.

• Disconnect wire harness from vent temperature sensor. See ﬁ gure 11-2.

• Loosen upper hose clamp securing condensate collector to ﬂ ue pipe using 3/8" socket with 6" extension.

11 - GENERAL MAINTENANCE AND CLEANING

• Remove ¼-20 hex ﬂ ange nuts securing condensate collector to heat exchanger using 7/16" deep well socket. See ﬁ gure 11-2.

• Remove condensate collector assembly from heat exchanger and ﬂ ue pipe.

• Flush collector and condensate trap with water.

• Follow Burner Inspection Kit instructions to reassemble boiler and resume operation.

12 - RATINGS AND CAPACITIES

TABLE 12-1: SEA LEVEL RATINGS

NATURAL AND PROPANE GASES

Size

050 075 100 150 200

(1)

1000 Btu/hr (British Thermal Units Per Hour)

(2)

Heating Capacity and AFUE (Annual Fuel Utilization Efﬁ ciency) are based on DOE (Department of Energy) test procedures.

(3)

Net AHRI Ratings based on piping and pickup allowance of 1.15.

Boiler Input Rate (MBH)

Maximum Minimum

50 10 46 40 96.0

75 15 69 60 96.0 100 20 91 79 96.0 150 30 139 121 96.0 200 40 185 161 96.0

(1)

12.1 Ratings and Capacities

• Constructed and hydrostatically tested for maximum allowable working pressure of 50 psig (pounds per square inch gauge) (345 kPa) in accordance with ASME Boiler and Pressure Vessel Code, Section IV, Rules for Construction of Heating Boilers.

Heating Capacity

(MBH)

(1)(2)

Net AHRI Rating,

Water (MBH)

(1)(3)

AFUE

(2)

• Ratings used for elevations up to 2000 ft (600m) above sea level.

• For elevations above 2000 ft. (600m) reduce input rate 4% for each 1000 ft (300m) above sea level.

YESNO

Does User Interface Display work?

13 - TROUBLE SHOOTING

YESNO

NO YES

Locate fuse holder on front of

control and pull to check fuse.

Spare fuse located on controller.

Make sure all wire harness plugs

are properly pushed in. Release

plug lock with finger, remove and

reconnect all 7 plugs . Check

Voltage Terminal Strip including

wiring from User Interface to Low

checking continuity of the wires.

Does User Interface Display work?

Remove User Interface from

base. Using Digital Voltmeter

voltage present?

check for 25 to 30 Vdc. Is

GO TO NEXT PAGE

YES

Remove Top Jacket.

Is User Interface Lit?

NO YES

External Power Switch ON?

Turn ON power to Boiler.

Is Power Light Lit?

YES

Check for 120 Vac Inside High

Check 120 Vac on Molex

available?

Voltage Terminal Box. Is 120 Vac

is 120 Vac available?

Connector on top of Lower Jacket

YES NO

NOYES

Check Circuit Breaker or

Emergency Disconnect Switch

and 120 Vac Wiring to Boiler. Fix

Replace Wire

Replace Control Module Replace User Interface

or Repair External Wiring.

Harness.

Replace Power Light

13 - TROUBLE SHOOTING

Go to Page 41

Go to Page 42

Go to Page 41

Replace Control Module

Go to Page 43

Replace Control Module

Go to Page 44

Go to Page 45

Go to Page 46

Go to Page 47

Replace Control Module

Go to Page 47

Go to Page 48

Go to Page 49

Replace Gas Valve

Replace Control Module

Go to Page 45

Replace Control Module

Go to Page 49

Go to Page 50

Go to Page 51

Go to Page 52

Error Clears in 1-2 minutes

Replace Control Module

13 - TROUBLE SHOOTING

to Control Module J13?

Is harness connected to Gas

Lockout Alarm A 0 5

GV relay error

Valve? Is harness connected

_ P _ _ _

NOYES

Connect harness

YES NO

and Control Module?

Valve. Does each wire have

Disconnect harness from Gas

continuity between Gas Valve

Replace harness

Replace Gas Valve

1.0 and 1.2 kohms?

Disconnect harness from

resistance across J13-3 and

Control Module J13. Measure

J13-4. Is resistance between

YES NO

Module

Replace Control

Lockout Alarm A 0 0

Blocking too long error

_ _ _ _ _

Enter Installer Menu, Boiler

Status. Scroll to most recent

Diagnose corrective action using

Lockout Alarm or Blocking Error.

appropriate Troubleshooting Tree.

13 - TROUBLE SHOOTING

Tree

Valve

Refer to the Gas

Is there any

apparent debris or

flue way?

obstruction of the

YES NO

blockages.

way along the

Inspect the flue

near the coil for

sides of the baffle

Clear vent blockage

check for secure fit

Connect all wires and

Troubleshooting

section

Refer to the Heat

Exchanger cleaning

inspect.

burner and

Remove the

flue transition.

Remove the gas

all wires

including the

Check all wires

startup?

Is this a new boiler on first

YES NO

and tight

sensor leads.

Check for proper

igniter and flame

Valve closed?

Is the Gas Shutoff

connected?

connections to

control board. Are

YES NO

Open gas shutoff

valves

System for

Inspect Vent

clear?

blockages.

Is the vent system

Reset the boiler by

pressing the

YES NO

‘Reset’ button.

When the boiler

tries to ignite, is

there a strong,

consistent spark

Disconnect the gas

evident throught

train including the

valve.

valve electrical

the gas shutoff

harness and close

YES NO

the sight glass?

With the ignition

lead connected to

the igniter, hold the

Any sign of

damage to burner

ignition.

tip near the chassis

ground and attempt

sensor and igniter

Remove the flame

surface?

YES NO

and ground?

between the igniter

Is a spark observed

there any

indication of

and inspect. Is

damage or debris

YES NO

baked on?

YES NO

Replace Burner

Module

Replace Control

to run with

Is this boiler

Lockout Alarm A 0 1

Ignit error

YES NO

propane gas?

gas orifice

Is the propane

_ P _ _ _

YESNO

properly

installed?

sensor or igniter

Check vent

Replace/clean flame

consideration of wind

termination for proper

effects

running?

YES NO

ignite and stay

Does the boiler

Install

Orifice

propane

Once the boiler

Menu and place

Enter the Installer

starts, go to the

mode in high fire.

the boiler into test

signal.

screen and

boiler status

monitor the flame

8.0uA?

greater than

YES NO

Is the flame signal

13 - TROUBLE SHOOTING

operating?

YES

Is Combustion Air Blower

Lockout Alarm A 0 8

Fan error

_ _ _ _ _

Are 3-wire and 4-wire

YES

harnesses connected to

Combustion Air Blower?

Connect harness

Disconnect harness from

Is voltage 120 Vac ± 10%

Control Module J9. Measure

voltage between J9-2 and J9-3.

Air Blower

Replace Combustion

YES

Module

Replace Control

YES

Disconnect 3-wire harness

Measure continuity in each

from Combustion Air Blower.

wire. Continuity in each wire?

Replace harness

Air Blower

Replace Combustion

speed increase?

YES

Disconnect 4-wire harness

from Combustion Air Blower.

Does Combustion Air Blower

Replace harness

Disconnect harness from

Control Module J9. Continuity

(yellow, red, white, black)?

in each wire of 4-wire harness

YES NO

Module

Replace Control

13 - TROUBLE SHOOTING

Replace Control

Module

2K to 1K ohms

2K to 3K ohms

3K to 9K ohms

°F°C Resistance

50 to 9010 to 32 9K to 24K ohms

Resistance Chart

90 to 130

150 to 200

130 to 150

and Control Module J13.

Temperature Supply Switch

Lockout Alarm A 1 8

Max Temp Error

Disconnect harness from High

_ _ _ _ _

Switch 3?

YES

1? Continuity from J13-6 to

Continuity from J13-5 to Switch

Replace wire(s)

YES

less than 185°F (91°C)?

Is supply water temperature

High Temperature Supply Switch

YES NO

Switch open (no continuity

Is High Temperature Supply

between terminals 1 and 3)?

Switch

Replace High

Temperature Supply

Replace High

Temperature Supply

YES NO

High Temperature Supply

Switch terminals 2 and 4?

Measure resistance across

Does resistance match supply

water temperature (see table)?

Module

32 to 54

Switch

54 to 66

66 to 94

Is High Temperature Supply

Switch open (no continuity

between terminals 1 and 3)?

Replace Control

YES NO

Switch

Replace High

Temperature Supply

13 - TROUBLE SHOOTING

clean and secure?

Inspect harness connection

Lockout Alarm A 2 4

3 flame failures

Flame Sensor. Is connection

_ P _ _ _

YES

Replace Flame

Sensor or harness

YES

free of contamination?

Remove Flame Sensor. Is rod

Clean or replace

Follow OPERATING

Flame Sensor

INSTRUCTIONS to initiate

boiler operation. Enter Installer

Menu, Boiler Status, Flame

Signal. Is flame signal greater

than 3.7 uA?

YES

Replace Flame

Sensor and Burner

Module

Blocking Error E 3 5

False flame detect

_ P _ _ _

Replace Control

Module

NOYES

glass. Is flame present?

Inspect burner through sight

Replace Control

Turn Gas Shutoff

Valve clockwise to

closed position.

Follow instructions

TO APPLIANCE.

TO TURN OFF GAS

Replace Gas Valve.

13 - TROUBLE SHOOTING

Blocking Error E 4 0

Return Temp

_ _ _ _ _

Is correct harness connected to

return sensor (2 Brown Wires)?

NOYES

Correct wiring

oriented properly?

Is Heat Exchanger Pump

YES NO

(Pump Arrow pointing down?)

Install Heat

proper orientation

Exchanger Pump in

Return Water Sensor.

Disconnect harness from

Measure resistance using

digital ohm meter. Is

resistance between 950 to

Sensor

Replace Return Water

33,000 ohms?

YES NO

Module

Replace Control

13 - TROUBLE SHOOTING

Blocking Error E 5 1

Supply Sens Open

_ P _ _ _

NOYES

Module J5?

Water Sensor?

Is harness plugged into Supply

Is harness plugged into Control

Insert Harness

Disconnect J5 from Control

Module. Using digital meter

measure check continuity of

and Sensor. Continuity?

brown wires between Control

YES NO

Replace Wires

Using digital meter measure

resistance between Supply

of Sensor with digital meter.

Water Sensor terminals J5-11

and J5-3. Measure resistance

Estimate Sensor temperature.

Does it fall in the range of the

Resistance Chart?

YES NO

Water Sensor

Replace Supply

Module

Blocking Error E 4 6

Faulty ground

_ P _ _ _

conductor

Connect ground

YES NO

connected to High Voltage

Is field grounding conductor

Terminal Strip 120 VAC (G)?

Disconnect field wiring. Is

neutral and ground less than

continuity between field wiring

10 ohms?

Replace Control

conductor

NOYES

Correct faulty ground

°F°C Resistance

Resistance Chart

Supply Water Sensor

Module

Replace Control

3K to 9K ohms

50 to 9010 to 32 9K to 24K ohms

90 to 130

32 to 54

2K to 1K ohms

2K to 3K ohms

150 to 200

130 to 150

54 to 66

66 to 94

13 - TROUBLE SHOOTING

2K to 1K ohms

2K to 3K ohms

3K to 9K ohms

°F°C Resistance

50 to 9010 to 32 9K to 24K ohms

Resistance Chart

Return Temperature Sensor

90 to 130

32 to 54

150 to 200

130 to 150

54 to 66

66 to 94

Blocking Error E 5 2

Return Sens Open

_ P _ _ _

Module J5?

Temperature Sensor?

Is harness plugged into Return

Is harness plugged into Control

YES NO

Insert Harness

Continuity?

wires between Return

Temperature Sensor and

Check continuity of brown

YES NO

Control Module J5-4 and J5-12

Replace Wires

meter. Estimate Sensor

Measure Return Temperature

Sensor resistance with digital

temperature. Do temperature

ranges shown in chart?

and resistance fall within

Replace Return

Temperature Sensor

YES NO

Module

Replace Control

13 - TROUBLE SHOOTING

Replace wires

Switch 4?

High Temperature Supply

Blocking Error E 5 9

Supply Sensor Shorted

Disconnect wire harness from

_ P _ _ _

Switch. Measure resistance

across terminals 2 and 4. Do

temperature and resistance fall

within ranges shown in chart?

NOYES

Insert harness

J5-11 and Switch 2?

Disconnect J5 from Control

Module. Continuity between

Switch

Replace High

Temperature Supply

YES NO

Continuity between J5-3 and

Module

Replace Control

Resistance Chart

High Temperature Supply Switch

°F°C Resistance

3K to 9K ohms

50 to 9010 to 32 9K to 24K ohms

90 to 130

32 to 54

2K to 1K ohms

2K to 3K ohms

150 to 200

130 to 150

54 to 66

66 to 94

Module J5?

Temperature Sensor? Is

Is harness plugged into Vent

Blocking Error E 5 7

Flue sens open

harness plugged into Control

_ P _ _ _

Replace wires

NOYES

Replace Vent

Temperature Sensor

for each blue wire?

Temperature Sensor and

Disconnect harness from Vent

YES NO

Control Module J5. Continuity

YES NO

match estimated flue

terminals. Does resistance

temperature (see table)?

Vent Temperature Sensor

Measure resistance across

Module

Replace Control

Blocking Error E 6 5

Flue Sens Shorted

_ P _ _ _

13 - TROUBLE SHOOTING

NOYES

Does resistance match

Vent Temperature Sensor.

Measure Sensor resistance.

Disconnect wire harness from

estimated flue temperature?

Replace Vent

Temperature Sensor

in blue wires?

Disconnect harness from

Control Module J5. Continuity

YES NO

Replace wires

Module

°F°C Resistance

Resistance Chart

Vent Temperature Sensor

3K to 9K ohms

50 to 9010 to 32 9K to 24K ohms

90 to 130

32 to 54

2K to 1K ohms

2K to 3K ohms

150 to 200

130 to 150

54 to 66

66 to 94

Disconnect harness from

Blocking Error E 6 0

Return sens shorted

_ P _ _ _

Disconnect harness from

Control Module J5. Measure

less than 50 ohms?

YES NO

Measure resistance across

Return Temperature Sensor.

sensor terminals. Is resistance

Sensor

resistance between brown

wires at terminals J5-4 and J5-

Replace Control

NOYES

ohms?

12. Is resistance less than 50

Module

Replace Control

Replace wires

Replace Return Water

14.1 Connection Diagram

14 - WIRING DIAGRAM

14.2 Schematic Diagram of Ladder Form

15 - GLOSSARY

• ANSI - American National Standards Institute, Inc. oversees creation and maintenance of voluntary consensus standards, including ANSI Z21.13/CSA 4.9: Gas-Fired Low Pressure Steam and Hot Water Boilers.

• ASTM - American Society for Testing and Materials. ASTM International is one of largest voluntary standards development organizations in world trusted source for technical standards for materials, products, systems, and services. Known for their high technical quality and market relevancy, ASTM International standards have important role in information infrastructure that guides design, manufacturing and trade in the global economy.

• AUTHORITY HAVING JURISDICTION - Individual or organization adopting and enforcing codes, rules, and by-laws governing various concerns of community. Commonly referred to as "ﬁ nal authority" for any matters relating to LIFE SAFETY and BUILDING CONSTRUCTION within a community.

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 72,000 121,000 103,000 217,000

Pipe Capacity - BTU Per Hour Input Includes Fittings

1/2” 3/4” 1” 1 1/4”

PROPANE GAS

Pipe Capacity - BTU Per Hour Input Includes Fittings

Copper Tubing

(Outside Diameter)

5/8” 3/4” 1/2” 3/4”

Iron Pipe

• HIGH-VOLTAGE - Circuit involving potential of not more than 600 volts and having circuit characteristics in excess of those of low-voltage circuit.

• Btu - Abbreviation for British Thermal Unit. Quantity of

• IGNITER - Device utilizing electrical energy to ignite gas

heat required to raise temperature of 1 pound of water 1°F.

• LEAK CHECK - Operation performed on gas piping system

• BURNER - Device for ﬁ nal conveyance of gas or mixture

of gas and air, to combustion zone.

• LOW WATER CUTOFF - Device constructed to automati-

• COMBUSTION - Rapid oxidation of fuel gases accompanied

by production of heat or heat and light. Complete combustion of fuel is possible only in presence of adequate supply of Oxygen.

• LOW-VOLTAGE - Circuit involving potential of not more

• COMBUSTIBLE MATERIAL - Materials made of or surfaced

with wood, compressed paper, plant ﬁ bers, or other

• METRIC GAS METERS

materials capable of being ignited and burned. Such material shall be considered combustible even though ﬂ ame-proofed, ﬁ re-retardant treated, or plastered.

• CONDENSATE - Liquid separated from ﬂ ue gas due to reduction in temperature.

For example: Gas Meter measures 0.1 cubic Meters in 100 seconds

• DIRECT VENT BOILER - Boiler constructed and installed so all combustion air is derived directly from outdoors and all vent gases are discharged to outdoors.

• DRAFT - Pressure difference causes gases or air to ﬂ ow

• PRESSURE TEST - Operation performed to verify gas

through a chimney, vent, ﬂ ue or appliance.

• FLA - Full load amps.

• PURGE - To free gas conduit of air or gas, or mixture of

• FLUE GASES - Products of combustion plus excess air in

appliance ﬂ ues or heat exchanger.

• PURGE TIME - Period of time intended to allow for

• GAS PIPE SIZES - Table 16

at main burner.

to verify system does not leak.

cally cut off fuel supply when surface of water in boiler falls to lowest safe water level.

than 30 volts.

MBH =

127,116 x cu meters Seconds

127,116 x 0.1

100

= 127 MBH

tight integrity of gas piping following its installation or modiﬁ cation.

gas and air.

dissipation of any unburned gas or residual products of combustion.

15 - GLOSSARY

• QUALIFIED AGENCY - Any individual, ﬁ rm, corporation, or company engaged in and responsible for:

• Installation, testing, or replacement of gas piping, or connection, installation, testing, repair or servicing of appliances and equipment.

• Experienced in such work.

• Familiar with all precautions required.

• Complies with all requirements of authority having jurisdiction.

• SAFETY RELIEF VALVE - Valve designed to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment.

• SAFETY SHUTOFF DEVICE - Device that will shut off gas supply to controlled burner in event source of ignition fails.

• SEDIMENT TRAP - Gas piping arrangement designed to collect any liquid or solid contaminant before reaching gas valve.

• VENT - Passageway used to convey ﬂ ue gases from appliance vent connector to outdoors.

• VENTING SYSTEM - Continuous open passageway from of appliance vent connector to outdoors for purpose of removing ﬂ ue or vent gases.

APPENDIX A - CONTROL MODULE

1.1 Introduction

Boiler is equipped with programmable electronic control and user interface module.

1.2 Operation

• Display: 4x20 character LCD screen to show boiler status.

• Function Keys

Key Description

- Manual Lockout Reset

- Enter/Exit user menu

- Go to previous screen

- Select a menu item

- Conﬁ rm new parameter value

- Scroll up to next menu item

- Increase value

- Scroll down to next menu item

- Decrease value

Operation with LCD character display module

eration with LCD character display module

1.3 Status Indication

The following status screens can be displayed:

Boiler Status Indicator

F = Flame Detected

SERVICE Reminder

P = Central Heating System pump On B = Combustion Air Blower On S = Safety Relay Check G = Gas Valve Open D = DHW Pump On

Combustion Air Blower Speed Indicator

Service Reminder Indica Boiler in Standby Mode

Boiler Supply Water Temperature Indicator.

tor

Boiler Running in Central Heat mode

Boiler Running in DHW mode

Lockout Alarm Indicator

Error code and short text description is displayed Press 'Reset" key for manual reset.

Blocking Error

Error code and short text description is displayed Boiler automatically returns to Standby Mode when condition is eliminated.

2.4 Sequence of Operation

Operational State User Interface Display Explanation

APPENDIX A - CONTROL MODULE

Heat

Demand?

Yes

DHW CH

Pump on

Supply

Temperature

<Setpoint?

Yes

15 Second

Prepurge

Ignition

Sparking

Boiler operates in standby mode until demand for Central Heat (CH) or Domestic Hot Water (DHW) is detected.

CH or DHW pump is turned on based on type of heating demand.

(CH call is illustrated)

Control Module compares supply temperature to set point. Boiler proceeds to ignition if supply temperature is less than set point.

Combustion Air Blower speed modulates to prepurge setting for 15 seconds.

Sparking initiated sequence.

After 2 seconds

2.4 Sequence of Operation

Operational State User Interface Display Explanation

APPENDIX A - CONTROL MODULE

After 2 seconds

Flame

Detected?

Gas Valve Energized

After 3 seconds

Flame

Detected?

Yes

Heat Demand

Met?

Yes

Lockout

Error A21

Note:

5 Ignition

trials,

then

Lockout A01

30 second

post purge

Yes

If ﬂ ame detected before Gas Valve opens during ignition boiler will lockout.

Please refer to troubleshooting guide.

Gas Valve energized to deliver air/ fuel to burner.

If ﬂ ame undetected after 3 sec- onds boiler will de-energize Gas Valve and enter post purge mode for 30 seconds.

Ignition attempted 5 times before lockout.

Boiler will run provided all operational and safety devices are within limits

Refer to for more information. Control module adjusts ﬁ ring rate

according to heating demand. When Boiler detects demand met, will enter post purge mode then standby mode.

Simultaneous

DHW + CH

Demand?

Yes

DHW

Priority

Mode

See Max DHW

Priority Time

Setting

If simultaneous demand for Central Heat and DHW, boiler will enter DHW Priority Mode.

Priority mode limits amount of time boiler can run in DHW mode to meet CH demand.

Max DHW Priority Time setting determines maximum time allowed for DHW heating mode.

Please refer to section Appendix A section 1.5 for more information.

APPENDIX A - CONTROL MODULE

INS

TALLER MENU



Bo i l e r S t a

tus

Bo i l e r Con f i g

CH Se t t i n g s

DHW S e t t i n g s

Casc a

de Se t t i ngs

Sys t em Tes t

STATUS

Fa n S p e ed

Ac t u a l 4000RPM

L ow P o we r 1560RPM

▼

STATUS ▲

Fa n S p e ed

I g n i t i on 3500RPM

Hi Power 5725RPM

▼

STATUS ▲

Fl ame

Signal 07.2uA

Fa i l ures 2

▼

APPENDIX A - CONTROL MODULE

User Interface Display

Installer Menu

Explanation

The Installer Menu structure includes:

• User Menu can be accessed by pressing ‘Menu’ key on user interface. Installer Menu can be accessed by simultaneously holding ‘Menu’ and ‘Enter’ keys for 5 seconds.

• ‘Boiler Status’ submenu – User monitors detailed boiler status parameters such as ﬂ ame signal, fan speeds and stored error codes.

• ‘Boiler Conﬁ g’ submenu – Modiﬁ es general boiler settings.

• ‘CH Settings’ submenu – Modiﬁ es advanced Central Heating settings including outdoor reset curve parameters and boost function.

• ‘DHW Settings’ – Modiﬁ es Domestic hot Water control settings such as DHW priority time.

Boiler Status

• ‘Cascade Settings’ - Refer to Multiple Boiler Manual.

• ‘System Test’ – Tool aids setup of boiler installation or diagnosis of common problems.

Combustion air Blower provides airﬂ ow through Combustion and Vent systems.

Fan speed status screen indicates actual and operational fan speeds in RPM, high, low and ignition power speed settings.

Settings are for information only to aid in troubleshooting.

Boiler equipped with ionization rod to detect presence of combustion using ﬂ ame rectiﬁ cation method. When ﬂ ame is present, ﬂ ame ionization rod measures small DC offset current across ﬂ ame to ground (i.e. burner surface).

‘Flame’ screen in ‘Boiler Status’ submenu displays information regarding ﬂ ame ionization system; for information only and used in diagnosing combustion problems. See troubleshooting guide.

APPENDIX A - CONTROL MODULE

STATUS ▲

Ign i t i on Attempts

Su c c e s f u l 4267

Fa i led 21

▼

User Interface Display

Installer Menu

Explanation

Control module logs successful and failed ignition attempts. Information accessed in ‘Ignition Attempts’ Screen as shown.

Ignition attempts are stored in non-volatile memory and are retained in event of power failure.

Figure A-1 Typical Ignition Cycle

Boiler Status

Following control features are implemented to ensure safe and reliable operation of Combustion System:

False Flame Detection

Re-ignition

Intermittent Operation

Flame out too late

Safety relay test

UL3563 High Limit Temperature Device

If ﬂ ame is detected at end of pre-spark period (Ignit_0) than lockout will occur.

If at end of safety period no ﬂ ame detected control will go to post-purge removing unburned gas. Re-ignition attempt started following same cycle. Number of re-ignition attempts limited to 4 after which lockout occurs.

Boiler can be ﬁ ring continuously for 24 hours. Burner switched off and restart sequence follows.

If ﬂ ame detected after post purge lockout follows.

In Safety ON/OFF state correct operation of safety relay is proved before ignition.

Boiler comes equipped with UL353 approved temperature high limit device.

Gas Valve de-energized when supply temperature exceeds 203°F lockout follows.

APPENDIX A - CONTROL MODULE

BO I L E R C ON F I G

▲

Pump Mo de MODE : 0

CH o r C H&DHW

▼

BO I L E R C ON F I G ▲

SE R V I C E REM I NDER

Sta tus On

R em i n d e r 365 days

APPENDIX A - CONTROL MODULE

User Interface Display

Explanation

Two pump modes are available:

Pump Mode = 0 ‘CH or CH&DHW’

• In this mode either the CH or DHW pump terminal is energized depending on the type of demand (CH or DHW).

• CH and DHW pumps are never energized at the same time.

• In the case of a simultaneous call for both CH and DHW, the energized pump depends on whether the boiler is currently supplying the CH or DHW demand. Refer to DHW Priority settings below.

• This is typical of a hydronic system design with separate CH and DHW Pumps.

Pump Mode = 4 ‘System Pump’

• In this mode only one external system pump is installed in the hydronic system. This pump will energize independent of the type of demand (CH or DHW).

Boiler Conﬁ guration

• Connect this pump to the CH/System Pump electrical terminal block. See page 56 for diagram.

• The DHW pump terminal does not function.

• This is typical of a hydronic system design which utilizes zone valves for all CH zones and an DHW indirect tank.

Note:

• Pump Mode selection depends on electrical and

hydronic system design. Please refer to sections 5 and 8 for recommended hydronic piping and electrical conﬁ gurations.

• Internal heat exchanger pump is energized anytime

demand exists regardless of Pump Mode setting or type of demand (CH or DHW).

'Service Reminder’ feature allows the installer to enable or disable a service reminder notiﬁ cation on the User Interface at a predeﬁ ned interval .

Service reminder does not affect operation of boiler in any way. It is only a reminder to End User that routine preventative maintenance is required by qualiﬁ ed service technician.

Allowed Range: 1 to 999 days

CH SETT I NGS

CH mo d e MODE: 1

CH w i t h the rmost at

▼

APPENDIX A - CONTROL MODULE

User Interface Display

Explanation

4. Central Heating (CH) modes available:

• CH Mode = 0 ‘CH with Thermostat’

• Boiler will attempt to satisfy CH demand while CH thermostat input is closed.

• Boiler will modulate its ﬁ ring rate to maintain CH set point and match system heat load.

• CH set point adjusted in ‘Settings’ submenu under ‘User Menu’

• CH Mode = 1 ‘CH with Thermostat and Outdoor Reset’

• Boiler will attempt to satisfy CH demand when CH thermostat input is closed.

• Boiler will modulate its ﬁ ring rate to maintain CH set point and match system heat load.

• CH set point calculated as function of outdoor temperature using outdoor reset curve. See ﬁ gure A-2

• CH Mode = 2 ‘CH with Full Outdoor Reset’

• Boiler will permanently attempt to satisfy CH demand.

• CH thermostat input is ignored.

• CH set point calculated as function of outdoor temperature using outdoor reset curve. See ﬁ gure A-2

CH Settings

• CH Mode = 3 ‘CH with Permanent Demand’

• Boiler will permanently attempt to satisfy CH demand.

• CH thermostat input is ignored.

• CH set point is adjusted in ‘Settings’ submenu under ‘User Menu’

Note:

• Once CH demand is satisﬁ ed (i.e. CH thermostat opens or boiler determines its minimum ﬁ ring rate exceeds system heating load):

• Burner shuts off, boiler enters post purge.

• CH pump continues to run for 30 seconds.

• Control will wait until Anti-cycle time of 180 seconds elapses before boiler ﬁ res again. Prevents short- cycling.

• The internal heat exchanger pump is energized anytime demand exists regardless of Pump Mode setting or type of demand (CH or DHW).

APPENDIX A - CONTROL MODULE

CH SETT I NGS ▲

rm We ather

Shut down Temp

70°F

▼

CH SETT I NGS ▲

Rese t Curve

Bo i l e r Min 070 °F

Bo i l e r Max 180 °F

▼

CH SETT I NGS ▲

R.Curve Mild Weath.

Bo i l e r 70°F

Ou t d o o r 70°F

▼

CH SETT I NGS ▲

Rese t Curve

Bo i l e r Mi n 070 °F

Bo i l e r Max 180 °F

▼

User Interface Display

Allowed Range: 35°F to 100°F (2°C to 38°C) Default Setting: 70°F (21°C)

Allowed Boiler Range: 60°F to 195°F (40°C to 91°C)

Default Boiler Setting:180° F (82°C)

Allowed Boiler Range: 35°F to 120 F (2°C to 49°C) Default Boiler Setting: 100°F (37°C)

Allowed Outdoor Range: 35°F to 85°F (2°C to 29°C) Default Outdoor Setting: 70°F (21°C)

CH Settings

100

Explanation

If outdoor temperature is greater than Warm Weather Shutdown Temperature, demand for CH blocked and pumps stopped.

Boiler capable of operating in Outdoor Reset Mode when included Outdoor Sensor is connected and proper CH Mode selected.

If CH Mode = 1, ‘Outdoor Temperature Reset with Thermostat’ or 2, ‘Full Outdoor Reset’ boiler will adjust CH set point proportional to outdoor temperature as deﬁ ned by Outdoor Reset Curve below.

Outdoor reset curve adjusted by modifying Design and Mild Weather reference temperatures. See points A & B of Reset Curve below.

Calculated CH set point always limited between ‘Reset Curve Boiler Minimum/Maximum’ temperatures. See points C & D of Reset Curve below.

Figure A-2 Outdoor Reset Curve

Allowed Min. Range: 40°F to 180°F (4°C to 82°C) Default Min. Setting: 70°F (21°C)

Allowed Max. Range: 80°F to 195°F (27°C to 91° C) Default Max. Setting: 180°F (82°C)

C D

Note:

• Modes only function when outdoor temperature sensor connected.

• If ‘Open’ outdoor sensor detected CH set point equal to ‘Boiler Reset Curve Design’ temperature.

• Outdoor temperature used for CH set point calculation measured once a minute and averaged with previous measurement to compensate for rapid outdoor temperature variations.

APPENDIX A - CONTROL MODULE

CH SETT I NGS ▲

Boos t F unct ion

Temp 10°F

Time 20min

▼

CH SETT I NGS ▲

Max i mum Power CH

Max 100%

▼

HW S E T T I NGS

DHW m o d e MODE : 1

DHW s t o r e w i t h

se n s o r

▼

User Interface Display

CH Settings

Explanation

Outdoor reset boost function increases CH set point by increment (‘Temp’) if CH demand continues beyond pre-set time limit (‘Time’).

CH set point will continue to increase until set point reaches

195°F / 91°C Allowable Temperature Increment: 0..36 °F (0..20 °C)

Default Temperature increment: 0 °F (10 °C) Allowable Time Delay: 1..120 minutes

Default Time Delay: 20 minutes

Maximum boiler power in CH mode limited by adjusting ‘Maximum Power CH’ setting. Boiler will not exceed this value while operating in CH Mode.

Allowable Range: 1..100% Default Setting: 100%

Two DHW modes are available

• DHW Mode = 0 ‘No DHW

DHW Settings

• DHW Mode is disabled

• The DHW thermostat input is ignored and the DHW pump is not used.

• DHW Mode = 2 ‘DHW Store with Thermostat’

• Boiler reacts to DHW demand when DHW thermostat input closes.

• Boiler modulates to meet DHW demand similar to CH Mode except DHW set point is used. DHW set point set in Settings’ submenu found in 'User Menu’.

• Simultaneous CH & DHW demands handled using DHW Priority Timing. See ‘DHW Maximum Priority Time’ setting below.

Note:

• Outdoor reset function disabled while operating in DHW Mode.

• Typical when using a DHW indirect storage tank.

• After DHW demand satisﬁ ed, boiler enters post purge mode and DHW pump continues to run for 15 seconds.

DHW S E T T I NGS ▲

DH W m a x . p r i o r i t y

time

30mi n

SYSTEM TEST

Set t e s t power

Of f

YSTEM TEST

Bo i l e r Pump Off

CH \ S y s t em Pump Off

DHW Pump Of f

APPENDIX A - CONTROL MODULE

User Interface Display

Allowed Range: 1 to 60 Minutes

DHW Settings

Default Setting: 30 Minutes

Explanation

Maximum time boiler operates in DHW mode limited by DHW Maximum Priority Time Setting.

Priority timer starts when both CH and DHW demand is present. Boiler will switch from DHW back to CH operation after Maximum Priority Time has elapsed.

CH demand then has priority until Maximum Priority Time has elapsed.

Process repeats until either CH or DHW demand satisﬁ ed.

System test can be activated via installer menu for testing system at ﬁ xed power rates.

Boiler can be started without CH or DHW demand being present. System Test has priority over any system demand while test mode activated.

System test mode automatically ends after 30 minutes boiler resumes normal operation.

The following modes are available:

System Test

• Disabled

• Low power - Burner starts. After ignition period has ﬁ nished the burner stays at low power

• Ignition power - Burner starts. Stays at ignition power

• High power - Burner starts. After ignition period has ﬁ nished burner stays at high power.

Note:

• Before running system test modes, check if hydronic system capable of dissipating heat.

• Both heat exchanger and CH pumps are activated during system test only.

• During System Test Mode, boiler will run at ﬁ xed power rates until supply water temperature is 93°C/195°F

• All other safety functions remain active while in System Test Mode.

NOTES

Date Service Performed Company Name & Tech Initials Company Address & Phone #

CAC/BDP

7310 West Morris St.

Indianapolis, IN. 48231

Carrier BWMAAN000050, BWMAAN000075, BWMAAN000100, BWMAAN000150, BWMAAN000200 Installation, Operation And Maintenance Manual

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