Dunkirk DKVLT-050, DKVLT-299, DKVLT-075, DKVLT-100, DKVLT-150 Installation, Operation & Maintenance Manual

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Page 1

Models

DKVL T-050 DKVL T-075

WALL MOUNTED

DKVL T-100 DKVL T-150 DKVLT-200 DKVL T- 299

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

050/075/100/150/200

SIZE SHOWN

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com

P/N# 240008888, Rev. J [06/2013]

Page 2

VERIFY CONTENTS RECEIVED

Description

Item

No. Illustration

Fully Assembled Boiler 1

Metal Wall Bracket 2

Lag Bolt, 3/8" x 3" Hex (4 ea) 3

*Safety Relief Valve 4

3/4" Tee 5

3/4" Nipple 6

299 SIZE

SHOWN

3/4" x 1/4" Elbow 7

Air Vent 8

**Temperature Pressure Gauge 9

Bushing 3/4" x 1/4" 10

3/4" Tee (Same as No. 11) 11

Nipple 1¼ x 5½ 12

Drain Valve, 3/4" 13

3/4" Tee 14

Nipple 1¼ x 5½ 15

Bushing 7/8" OD, Heyco (2 ea) 16

Used for electrical wire knockouts.

Stopper, Rubber 5/16" (2 ea) 17 Used for packaging holes on back of boiler.

Plastic Plug (2 ea) 18 Used for packaging holes on back of boiler.

Outdoor Sensor 19 Used for measuring outside temperature.

Critical Installation Instruction 20

11" x 17" Page for critical installation issues.

Document Package 21 Includes essential documents.

* Boiler provided with 30 psig (206 kpa) safety relief valve. Field source safety relief valve if system pressure

greater than 25 psig.

** Boiler provided with 75 psig temperature pressure gauge. Field source temperature pressure gauge if system

pressure greater than 60 psig.

Page 3

DIMENSIONS

FIGURE 1-1 Dimensions

(D)

Wall Hanging

Bracket

(D)

(E)

DIMENSIONS

Safety Relief Valve Connection (¾ NPT)

Vent Connector

Combustion Air

(A)

(B)

Models

Width (A) 20" (508mm)

Height (B) 30" (762mm)

Depth (C) 14" (356mm)

Bracket (D) 28" (711mm)

Height (E) 31" (787mm)

Water

Connections

Gas

Connection

Condensate Drain

Connection (L)

Weight

Location (G) 2" (51mm) 2" (51mm) Location (H)

Location (I) Location (J) 4-1/2" (114mm) 4-1/2" (114mm)

Table 1 : Physical Data

050/075/100 150/200 299

Size(F) 1-1/4" NPT

5" (127mm)

3" (76mm)

Size (K)

Shipping 111 lb (50 kg)

Unit 91 lb (41 kg)

1/2"

NPT

3/4" NPT

23" (584mm)

40" (1041mm)

16.0"

(406mm)

40" (1016mm)

42" (1092mm)

1-1/4" NPT

2" (51mm)

4-½"

(114mm)

3/4"

NPT

3/4" NPT

~182 lb (83 kg)

~157 lb (71 kg)

18.3"

(465mm)

~225 lb

(102 kg)

~195 lb (89 kg)

(G)

Supply Water (F)

Gas Connection (K)

Return Water (F)

(H)

(I)

(J)

(C)

Vent Connector 2" (51mm) 3" (76mm)

Condensate Drain Connection (L)

Page 4

TABLE OF CONTENTS

1 - Introduction ............................................................................................................................... 5

2 - Important Safety Information .................................................................................................... 6

3 - Component Listing .....................................................................................................................7

4 - Locating Boiler .........................................................................................................................11

5 - Hydronic Piping ........................................................................................................................13

5.2 Special Conditions ................................................................................................................. 13

5.3 Safety Relief Valve and Air Vent............................................................................................ 13

5.4 Trim Piping ........................................................................................................................... 14

5.5 System Piping....................................................................................................................... 14

6 - Combustion Air And Vent Piping ...............................................................................................21

6.2 Removal of Existing Boiler From Common Vent System........................................................... 21

6.3 Venting Materials ................................................................................................................. 21

6.4 Vent Pipe Installation ............................................................................................................. 22

6.5 Vent Termination .................................................................................................................. 22

6.6 Venting Conﬁ gurations ........................................................................................................... 23

6.7 Side Venting Terminal Requirements..........................................................................................28

6.8 Multiple Boiler Venting Installation............................................................................................30

6.9 Condensate Piping ................................................................................................................. 31

7 - Gas Supply Piping ....................................................................................................................32

8 - Electrical Connections .............................................................................................................. 34

8.3 Line Voltage Connections ....................................................................................................... 34

8.4 External Connections ............................................................................................................. 34

9 - Start Up Procedure ...................................................................................................................36

9.6 Perform CSD-1 Compliance Test ......................................................................................................40

9.7 Complete Start Up Procedure .................................................................................................. 41

10 - Operating Instructions ........................................................................................................... 42

11 - General Maintenance And Cleaning ........................................................................................ 43

12 - Ratings And Capacities ........................................................................................................... 46

13 - Trouble Shooting ....................................................................................................................47

14 - Wiring Diagram ......................................................................................................................65

15 - Glossary .................................................................................................................................68

Appendix A - Control Module ......................................................................................................... 70

1.1 Introduction ......................................................................................................................... 70

1.2 Operation ............................................................................................................................. 70

1.3 Status Indication ................................................................................................................... 70

1.4 Sequence of Operation ........................................................................................................... 71

1.5 Theory of Operation .............................................................................................................. 73

Page 5

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 150 psig (1.03 MPa) maximum allowable working 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.

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.

Page 6

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.

• Canada

• Natural Gas and Propane Installation Code, CAN/CSA B149.1.

• Canadian Electrical Code, Part I, Safety Standard for Electrical Installations, CSA C22.1

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.

Page 7

Low Voltage Terminal Strip

Heat Exchanger Pump

Gas Shutoff Valve

Fuel supply isolation during

servicing. See section 7

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.

Supply Water Temperature Sensor and High Limit Switch

Low Water Cutoff

Senses inadequate quantity of

water. Turns off boiler before damage can occur.

Gas Connection

See section 7.

Boiler Control Module

3 - COMPONENT LISTING

3.1 Component Listing - Refer to diagrams on

following pages.

User Interface 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 section 6.

Return Water From Heating System (In)

Connection supplied at bottom of boiler. See section 5.

Low Voltage Terminal Strip Connection of all low

voltage wiring, including thermostat.

Igniter

Flame Sensor

Sight Glass Permits observation of burner ﬂ ame.

Burner (see page 40)

20.

Gas (Control) Valve

to Combustion Air Blower. See section 7.

21.

Supply Water Temperature Sensor and High Limit Switch

22.

Low Water Cutoff

water. Turns off boiler before damage can occur.

23.

Safety Relief Valve Factory supplied, Field installed.

See section 5.

24.

High Voltage Junction Box For connection of 120V

components. See section 88.

25.

Vent Connector See section 6.

26.

Gas Connection

27.

Wall Hanging Support Bracket (see page 12)

Integral to boiler. Allows wall mounting when used with supplied wall mounting bracket. See section 4.

28.

Air Vent

Delivers proper quantity of fuel

Senses inadequate quantity of

See section 7.

Heat Exchanger

10.

Condensate Collector

11.

Return Water Temperature Sensor

12.

Drain Valve (see page 14)

13.

Internal Primary Loop Ball Valve

14.

Supply Water Outlet to Heating System (Out)

Connections supplied for connecting from bottom of boiler. See section 5.

15.

Vent Temperature Sensor

16.

Condensate Drain Boiler produces a liquid

(condensate) as a by-product of combustion. Condensate must be piped to appropriate drain. See section 6.

17.

Heat Exchanger Pump

18.

Gas Shutoff Valve

servicing. See section 7

Fuel supply isolation during

29.

Boiler Control Module

30.

Lower Jacket Panel Gently pull upward then forward

to access.

31.

Transformer Supplies 24V power to low water cutoff.

32.

Flue Air Mixture Pressure Test Port - Not available

on all models.

33.

Combustion Analysis Test Port

34.

Internal Pump Relay - Not available on all models.

35.

Heat Exchanger Surface Temperature Switch

36.

ASME Plate

19.

Combustion Air Blower

combustion air, receives fuel from gas valve, mixes air and fuel sending mixture to burner for combustion.

Delivers proper quantity of

Page 8

SAFETY RELIEF VALVE

AIR VENT

WALL MOUNT

SUPPORT

BRACKET

3 - COMPONENT LISTING

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

SAFETY RELIEF VALVE

VENT CONNECTOR

COMBUSTION

AIR INLET

AIR VENT

NOTE:

See Section 5-3 For

Safety Relief Valve Piping Instructions

WALL MOUNT

SUPPORT

BRACKET

FIGURE 3-2 Lower Jacket (Viewed from front of boiler)

Disconnect connector

Lower Jacket

Connector to User

Interface

(1) User Interface

before removing lower

jacket

FIGURE 3-3 Upper and Lower Jacket Latch (Viewed

from front of boiler)

Upper and Lower

Jacket Latch

Lift Jacket up,

engage jacket with

chassis,

push down.

Service Switch

Page 9

VALVE

AIR

BLOWER

(20) GAS (CONTROL)

VALVE

(22) LOW

WATER CUTOF

(23) SAFETY RELIEF VALVE

(28) AIR VENT

PUMP

(3) RETURN WATER

FROM HEATING

SYSTEM (IN)

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(26) GAS CONNECTION

PORT

JUNCTION BOX

(16) CONDENSATE

DRAIN

(

(13)

SURFACE TEMPERATURE

SWITCH

3 - COMPONENT LISTING

(36) ASME

PLATE

FIGURE 3-4 Boiler Components 50/75/100 MBH (View from Front of Boiler) As seen on front cover

NOTE:

(28) AIR VENT

(23) SAFETY RELIEF VALVE

See Section 5

For Piping

Instructions

(21) SUPPLY WATER

TEMPERATURE SENSOR

& HIGH LIMIT SWITCH

(22) LOW

WATER CUTOFF

(13)

INTERNAL PRIMARY

LOOP BALL VALVE

(20) GAS (CONTROL)

(10) CONDENSATE

VALVE

(19) COMBUSTION

(18) GAS SHUTOFF

(35) HEAT EXCHANGER

SURFACE TEMPERATURE

(17) HEAT EXCHANGER

(33) COMBUSTION

AIR

BLOWER

VALVE

(SHOWN IN OPEN

POSITION)

SWITCH

PUMP

(15) VENT

TEMPERATURE

SENSOR

ANALYSIS TEST

PORT

COLLECTOR

(25) VENT CONNECTOR

(2) COMBUSTION

AIR INLET

(5) IGNITER

(6) FLAME

SENSOR

(7) SIGHT GLASS

(32) FLUE

AIR MIXTURE

PRESSURE

TEST PORT

(29) BOILER

CONTROL

MODULE

Fuse and

Holder

(36) ASME

PLATE

(9) HEAT

EXCHANGER

(31) TRANSFORMER

(11) RETURN WATER

TEMPERATURE SENSOR

(4) LOW VOLTAGE

TERMINAL STRIP

(24) HIGH VOLTAGE

JUNCTION BOX

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(16) CONDENSATE

DRAIN

(3) RETURN WATER

FROM HEATING

(26) GAS CONNECTION

SYSTEM (IN)

Page 10

VALVE

CUTOFF

(23) SAFETY RELIEF VALVE

(28) AIR VENT

PUMP

(3) RETURN WATER

FROM HEATING

SYSTEM (IN)

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(4) LOW VOLTAGE

TERMINAL STRIP

(26) GAS CONNECTION

(24) HIGH VOLTAGE

JUNCTION BOX

(9) HEAT

(16) CONDENSATE

DRAIN

(13) INTERNAL PRIMARY

LOOP BALL VALVE

(35) HEAT

SENSOR

3 - COMPONENT LISTING

PLATE

FIGURE 3-5 Boiler Components 299 MBH (View from Front of Boiler)

(28) AIR VENT

(23) SAFETY RELIEF VALVE

(25) VENT CONNECTOR

NOTE:

See Section 5

For Piping

Instructions

(21) SUPPLY WATER

TEMPERATURE SENSOR &

HIGH LIMIT SWITCH

(22) LOW WATER

CUTOFF

(33) COMBUSTION

ANALYSIS TEST

PORT

(34) INTERNAL

PUMP RELAY

(29) BOILER CONTROL

(13) INTERNAL PRIMARY

MODULE

Fuse and Holder

LOOP BALL VALVE

(35) HEAT

EXCHANGER SURFACE

TEMPERATURE SWITCH

(17) HEAT EXCHANGER

PUMP

(2) COMBUSTION

AIR INLET

(7) SIGHT GLASS &

(31) TRANSFORMER

(15) VENT TEMPERATURE

(15) V

(19) BLOWER

VENTURI

(6) FLAME SENSOR

(5) IGNITER

(9) HEAT

EXCHANGER

(20) GAS (CONTROL)

VALVE

(36) ASME

PLATE

SENSOR

(10) CONDENSATE

COLLECTOR

(4) LOW VOLTAGE

TERMINAL STRIP

(24) HIGH VOLTAGE

JUNCTION BOX

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(26) GAS CONNECTION

(18) GAS SHUTOFF

VALVE

(SHOWN IN OPEN

POSITION)

(11) RETURN

TEMPERATURE

SENSOR

(16) CONDENSATE

DRAIN

(3) RETURN WATER

FROM HEATING

SYSTEM (IN)

Page 11

Model

Top (A)

Left Side (B)

Right Side (C)

Front (D)

Back (E)

Bottom (F)

Combustion Air/Vent

piping

Hot Water Piping

4 - LOCATING BOILER

4.1 Boiler Location Considerations

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

FIGURE 4-1 Clearance to Combustible Materials

• 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 mount only.

• 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.

• 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.

FLOOR

TABLE 2: BOILER CLEARANCES

Dimension

Model

Top (A)

Left Side (B)

Right Side (C)

Front (D)

Back (E)

Bottom (F)

Combustion Air/Vent

Hot Water Piping

(1)

Required distances measured from boiler jacket.

(2)

Service, proper operation clearance recommendation.

piping

Combustible

Materials

050/075/100/

150/200/299

0" (0 cm) 14" (36 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)

See local code 6" (16 cm)

(1)

FLOOR

Service

050/075/100/

150/200/299

6" (16 cm)

(1)(2)

Page 12

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.

WARNING

Fire, explosion hazard. Mount boiler vertically or slightly tilted backward to insure proper function of low water cutoff. Failure to follow these instructions could result in death or serious injury.

FIGURE 4-3 Low Water Cutoff Orientation

5° ~ 15°

Factory Default

10°

• When mounting boiler onto wall insert two plastic stoppers and two plastic plugs to packaging holes on back of boiler. See parts listed on page 2, number 17 and 18.

• Mount boiler vertically or slightly tilted backward to insure the low water cutoff functions properly. See ﬁ gure 4-3 for low water cutoff orientation.

CAUTION

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

NOTICE

Lift boiler using chassis. Using front jacket, vent piping, water or gas ﬁ ttings to lift boiler may cause damage to the boiler.

Page 13

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. Internal heat exchanger pump compensates for pressure drop through boiler internal piping and heat exchanger.

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

• If oil is present in system water, use approved detergent to wash system.

• Flush system to remove any solid objects such as metal chips, ﬁ bers, or Teﬂ on tape, etc.

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.

• Boiler installed above radiation level (or as required by authority having jurisdiction). Integral low water cutoff provided in boiler. See pages 9 & 10.

• 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

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.

FIGURE 5-1 Safety Relief Valve & Air Vent (Viewed

from front of boiler)

Safety Relief

Valve

Air Vent

3/4"F x 3/4"M

NPT Tee

3/4 NPT

NOTICE

Boiler rated at 150 psig (1.03 MPa) maximum allowable working pressure. Boiler provided with 30 psig (206 kPa) safety relief valve. Field source safety relief valve for system pressures greater than 25 psig. Temperature Pressure Gauge and Air Vent satisfactory for 75 psig operation. Field source temperature pressure gauge for system pressures greater than 60 psig.

• 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.

3/4" x 1/4" NPT

90° Elbow

3/4" NPT

Nipple

Position Air Vent and Safety Relief Valve

to provide space for discharge piping.

Page 14

5 - HYDRONIC PIPING

WARNING

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

• Install discharge piping from safety relief valve. See 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).

5.4 Trim Piping

• Temperature - Pressure Gauge. Install temperature 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

Temperature Pressure

Gauge shown at

System Supply

Connection

Drain Valve shown

at System Return

Connection to Boiler

5.5 System Piping

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

• See Table 3 for basic system piping conﬁ gurations.

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

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

• Boiler control is designed for single central heating pump. Installer responsible for integration of multiple central heating pumps.

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

• Multiple boiler system. 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.

• Heating system with existing primary loop, close internal primary loop ball valve.

• Heating system without existing primary loop, leave internal primary loop ball valve open to use internal primary loop.

See ﬁ gure 5-8A, B & C

for general

Page 15

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

MOUNTED

Piping Legend

WALL

ONLY

Pipe to

condensate

drain

Multiple Boilers

Single Boiler

System

Supply

System

Return

Table 3 - System Piping Conﬁ gurations

Two Pipe Zoned System

Primary/Secondary Pumping

Two Pipe Zoned System

Primary/Secondary Pumping

With Zone Valves ﬁ gure 5-5

With Zone Pumps ﬁ gure 5-6

Closed External Primary Loop

Open External Primary Loop ﬁ gure 5-7B

With Zone Valves ﬁ gure 5-8A

With Zone Pumps Not Shown

Closed External Primary Loop ﬁ gure 5-8B

Open External Primary Loop

ﬁ gure 5-7A

ﬁ gure 5-8C

Page 16

5 - HYDRONIC PIPING

FIGURE 5-5 Single Boiler Two-Pipe Zoned System With Zone Valves

DHW Pump

CH/System

Pump

Heat exchanger

ball valve open

(as shipped)

FIGURE 5-6 Single Boiler Two-Pipe Zoned System With Zone Pumps

DHW Pump

Zone

Pump

3/8"/10mm Open

End

Wrench

Heat exchanger

ball valve open

(as shipped)

3/8"/10mm Open

End Wrench

Page 17

5 - HYDRONIC PIPING

FIGURE 5-7A Single Boiler Using Primary/Secondary Pumping With Closed External Primary Loop

HeatingLoad HeatingLoad

12"(305mm) Maximum

separation

12"(305mm)

CH/System

Pump

Maximum

separation

Existing closely spaced tees

in primary system loop

Limit length

HeatingLoad

5' (1.6m)

Heating system

with existing

primary loop.

Internal primary

3/8"/10mm

Open End Wrench

loop ball valves

closed

FIGURE 5-7B Single Boiler Using Primary/Secondary Pumping With Open External Primary Loop

HeatingLoad HeatingLoad

12"(305mm) Maximum

12"(305mm)

CH/System

Pump

Maximum

separation

Existing closely spaced tees

in primary system loop

Limit length

HeatingLoad

5' (1.6m)

Internal primary loop

ball valves open.

Heating system without existing

3/8"/10mm

Open End Wrench

primary loop.

Page 18

5 - HYDRONIC PIPING

FIGURE 5-8A Multiple Boiler Two Pipe Zoned System With Zone Valves - (See Multiple Boiler Guide)

DHW Pump

CH/System

Pump

12"/305mm Maximum Separation

System

Temperature

Sensor

Size common piping

per maximum heat

capacity of entire

system

Limit

length to

5' (1.6m)

All internal

primary loop

ball valves

closed

Up to 16

boilers

(See Multiple Boiler Guide)

3/8"/10mm Open End

Wrench

Page 19

5 - HYDRONIC PIPING

FIGURE 5-8B Multiple Boilers Using Primary/Secondary Pumping with Closed External Primary Loop

HeatingLoad HeatingLoad

12"/305mm Maximum Separation

CH/System

Pump

System

Temperature

Sensor

Existing closely spaced tees

in primary system loop

HeatingLoad

Size common piping

per maximum heat

capacity of entire

system

Limit

length to

5' (1.6m)

Up to 16

boilers

All internal

primary loop

ball valves

closed

3/8"/10mm Open End

Wrench

Page 20

5 - HYDRONIC PIPING

5-8C Multiple Boilers Using Primary/Secondary Pumping with Open External Primary Loop

12"/305mm Maximum Separation

CH/System

Pump

System

Temperature

Sensor

Existing closely spaced tees

in primary system loop

Size common piping

per maximum heat

capacity of entire

system

Up to 16

boilers

Limit

length to

5' (1.6m)

Heat exchanger

ball valve open

(as shipped)

3/8"/10mm Open End

Wrench

Page 21

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:

• USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.

• Canada - Natural Gas and Propane Installation Code, CAN/CSA B149.1

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.

• Any improper operation of common venting system should be corrected so installation conforms with National Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1. 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 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

6.3 Venting Materials

• See Table 4

Table 4 - 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 40ABS ANSI/ASTM F628

PP (Polypropylene)

Pipe and Components

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Schedule 40 ABS ANSI/ASTM D2235

ANSI/ASTM D1784/

F441

UL 1738

ULC S636-08

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

• 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.

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® ,

(Polyphenolsulfone) in venting systems shall be prohibited.

WARNING

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

Page 22

6 - COMBUSTION AIR AND VENT PIPING

6.4 Vent Pipe Installation

• Minimum and maximum combustion air and vent pipe lengths listed in Table 5. 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. See Table 6.

• Use ﬂ exible Polyproplyene piping (PP) in a vertical position only. Check PP pipe manufacturer for details. Each foot of PP ﬂ exible pipe is equivalent to 2⅝ feet of smooth pipe of same diameter.

• 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.

• Canadian installations only. All venting material, primer and glue must be listed to ULC S636.

• Canadian installations only. First 3 ft (0.9 m) of plastic vent pipe from vent connector must be readily accessible for visual inspection.

6.5 Vent Termination

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

A. See "Parts, Kits and Optional Accessories" manual

for concentric vent kit part numbers.

B. 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.

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

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

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 5 - Combustion Air and Vent Piping Length

Minimum/Maximum Vent Lengths

2” Pipe 3” Pipe 4” Pipe

Model 050 075/100 075/100 150/200 299 299

Min.

Max.

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

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)

Table 6 -Equivalent Length of Venting Components

Equivalent Length of Venting Components

Component Feet Meters

90° Elbow 5 1.6

45° Elbow 3 1/2 1.1

2" x 4" Adapter 0 0

3" x 4" Adapter 0 0

Concentric Vent Kit 5 1.6

Polypropylene Flexible Pipe per Foot 2 5/8 0.8

6 ft.

(1.8 m)

100 ft.

(30.5 m)

WARNING

6 ft.

(1.8 m)

25 ft.

(7.7 m)

6 ft.

(1.8 m)

100 ft.

(30.5 m)

Page 23

6 - COMBUSTION AIR AND VENT PIPING

6.6 Venting Conﬁ gurations

Various venting conﬁ gurations can be applied to this boiler. For guidance see Venting Conﬁ guration Table 7 and

corresponding ﬁ gures.

Table 7 - Venting Conﬁ gurations

Flue Gas Location

Roof

Combustion Air

Location

Roof

Side Wall Single Pipe ﬁ gure 6-8

Inside Air Single Pipe ﬁ gure 6-9

Roof Single Pipe ﬁ gure 6-10

NOTICE

Use of vent covers may cause freezing. If using vent covers overall vent length must be considered. Failure to heed this information may compromise operation of this boiler.

Flue Gas Terminals

Two Pipe ﬁ gure 6-1

Concentric ﬁ gure 6-7

Corresponding Figures

Side Wall

Two Pipe ﬁ gures 6-2, 6-3

Side Wall

Concentric ﬁ gures 6-4, 6-5, 6-6

Inside Air Single Pipe ﬁ gure 6-11

Page 24

FIGURE 6-1 Two Pipe Roof Vent

3" (80mm)

Minimum

12" (305mm)

Minimum

8" (203mm)

Minimum

Vent Combustion

Air

12" (305mm) US,

18" (458mm) Canada

Minimum Above

Anticipated Snow Line

6 - COMBUSTION AIR AND VENT PIPING

 3" (80mm) Minimum horizontal

separation between combustion air

15" (381mm)

Maximum

Roof Line

Roof

Terminations

intake and vent of same appliance.

 8" (203mm) Minimum vertical

separation between combustion air intake and vent of different appliances.

 15" (381mm) Maximum horizontal

length of vent.

 Minimum vent/intake between

different appliances 12" (305mm).

 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.

FIGURE 6-2 Two Pipe Side Wall Vent

12" (305mm)

Minimum From

Overhang

See Snow & Ice

Page 22

FIGURE 6-3 Two Pipe Side Wall Vent (Multiple Appliances.

See snow & ice

page 23

3" (80mm)

Minimum

Separation

12" (305mm) Separation

Between Bottom Of

Combustion Air Intake And

Bottom Of Vent

Vent

Combustion Air

12" (305mm)

Minimum

Separation

Side Wall

Terminations

 3" (80mm) Minimum horizontal

separation between combustion air intake and vent terminations.

 8" (203mm) Minimum vertical

separation between combustion air intake and vent terminations.

 12" (305mm) 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” (305mm) 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.

Combustion Air

Vent

Page 25

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-4 Side Wall Concentric Terminal FIGURE 6-5 Side Wall Concentric Terminal Multiple

Appliances

1"(2.54cm)

1" (25.4mm)

Maximum

Vent

Combustion

Air

FIGURE 6-6 Concentric Terminal Connection

*2 or 3" (51 or 77 mm) Diameter

PVC intake/combustion air

Roof

1" (25mm)

Maximum

* See Note

Below

Combustion

Air

Overhang

12" (305mm) Minimum

36"(0.9m) Minimum

Vent

Maintain 12"(30cm) US

(18"(46cm) Canada)

highest anticipated

Clearance Above

snow level or grade

Highest Anticipated

Snow Level Or Grade

Maintain 12"

clearance above

*Must be less than 4" (102mm) or greater than 24" (610mm) 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

Combustion Air

OD 3½" (

89mm)

- *2" (

51mm)

kit

OD 4½" (114mm) - 3" (77mm) kit

** Note Overall length may be modiﬁ ed by cutting or extending both combustion air and vent pipes. 12" (305mm) is minimum allowable length and 60" (1.2m) 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.

**See

Note

*2" (

51mm)

Diameter = 41" Length (1.1m)

3" (77mm) Diameter = 47" Length (1.2m)

1"(25.4mm) Maximum

Vent

Combustion Air

* Note: 2" (51mm) For use with models 050/075/100. 3" (77mm) For use with models 075/100/150/200/299

4" (101mm) For use with model 299

Page 26

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-7 Concentric Roof Terminal

Vent

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

Combustion Air

Roof boot/ﬂ ashing (ﬁ eld supplied)

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

Vent

FIGURE 6-8 Flue on Roof, Air Intake on Side Wall

Vent

anticipated snow level 24"

(610mm) above roof

Support (ﬁ eld supplied)

Combustion Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

anticipated snow level 24"

(610mm) above roof

Concentric

Vent Roof

Terminations

 Glue inner vent pipe to prevent

recirculation.

 Maintain 12" (305mm) US

(18"(457mm) Canada) minimum clearance above highest anticipated snow level. Maximum of 24"(610mm) 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"

(12.7mm - 762mm).

 Vertical concentric vent system can be

installed in unused masonry chimney.

 Contact Technical Support 800-

325-5479 for questions regarding installation or use.

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

Combustion Air

12" (305mm) Anticipated Snow Line

Ground Level

FIGURE 6-9 Flue on Roof, Combustion Air

Vent

Combustion

Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

anticipated snow level 24"

(610mm) above roof

24" (610mm) * Minimum Length

Grade, Snow

& Ice

Doors &

Windows

* See Tables

4 & 5

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.

Combustion air and vent termination must be 12" (305mm) from or below doors, windows or gravity inlet.

Combustion air and Vent Piping Length Page 22 .

Page 27

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-10 Flue on Sidewall, Combustion Air on Roof

Maintain 12"(305mm) US

Combustion

Air

(18"(457mm) Canada)

clearance above highest

anticipated snow level 24"

(610mm) above roof

Vent

12" (305mm) Anticipated Snow Line

Ground Level

Conﬁ gurations of single pipe vent with ﬂ ue on the sidewall, requires a tee as the vent terminal. See ﬁ gures 6-10 and 6-11.

NOTICE

FIGURE 6-11 Flue on Sidewall, Inside Combustion Air

Vent

Combustion

Air

12" (305mm) Anticipated Snow Line

Ground Level

Page 28

6 - COMBUSTION AIR AND VENT PIPING

6.7 Side Venting Terminal Requirements of :

• USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.

• Canada - Natural Gas and Propane Installation Code, CAN/CSA B149.1

Venting terminal from doors and windows See ﬁ gure 6-12

Venting terminal from forced air inlet of other appliances See ﬁ gure 6-13

Venting terminal from snow level See ﬁ gure 6-14

Venting terminal from vegetation See ﬁ gure 6-15

Venting terminal from public walkway See ﬁ gure 6-16

FIGURE 6-12

Doors &

Termination must be

12" (305mm) from

or below doors,

windows or gravity

inlet.

12"

(305mm)

Minimum

FIGURE 6-13

Forced Air

Inlet

FIGURE 6-14

Less than

10' (3m)

Minimum

Termination

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

Windows

Condensate

Forced Air

Inlet

Combustion air and vent termination must be 12" (305mm) 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’ (0.9m) above and 10' (3.0m) from any forced air inlet (except boiler’s combustion air inlet).

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

3' (0.9m) Minimum

Grade, Snow

Corner

& Ice

"L"

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 NOT be installed closer than 3' (0.9m) from inside corner of “L” shaped structure.

Page 29

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-15

Keep vent termination 3’ minimum

Vegetation,

Plants &

Shrubs

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

Termination

Meters, Regulators, deck, porch

3' (0.9m)

Minimum

FIGURE 6-16

Walkways

People or

Pets

Vent termination US only - 4’ (1.2m), Canada - 6' (1.9m) horizontally from, no case above or below, electric meters, gas meters, regulators, and relief equipment, or under deck or porch.

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

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

Multiple

Family

Dwellings

7' (2.1m)

Minimum

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

Stones,

Balls, Etc.

Vapors

Eddy, Flue

Gases

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.

Position termination so it will not be effected by wind eddy, air born leaves, snow, or recirculated vent gases. Give consideration to excessive wind and locate away from windward side of building.

Page 30

6 - COMBUSTION AIR AND VENT PIPING

6.8 Multiple Boiler Venting Installation

• Multiple boiler application boiler can vent individually or use common vent pipes.

• If boilers vent individually follow guidelines as described in ﬁ gures 6-1 through 6-7.

• If boilers vent through common vent pipes, as shown in Figure 6-17, choose common vent pipe per Table 8. Choose size from Table 9 for pipes between boiler and common vent pipes.

• Longest individual vent lengths and common vent length together must be shorter than 100 ft. (30m).

H + L ≤ 100 ft (30m) (See ﬁ gure 6-17)

• Each boiler must have air ﬂ ow check valve to prevent ﬂ ue gas back ﬂ ow.

• External terminals follow same rule as single boiler venting as described in Section 6.6 and 6.7

Table 8 - Minimum Diameter for Individual Boiler in Common Venting System

Model

050 2" (51mm)

075 3" (73mm)

100 3" (73mm)

150 3" (73mm)

200 3" (73mm)

299 3" (73mm)

Minimum Diameter

Table 9 - Common Venting Pipe Diameters

Minimum

Total

Firing

Rate

Diameter of

Common vent

pipes if

L< 50 ft (16m)

400 4" (101mm)

600

5" (127mm)

800

1000

1200

6" (152mm)

1400

1600

1800

7" (177mm)

2000

Minimum

Diameter of

Common vent

pipes if

L>50 ft (16m)

5" (127mm)

6" (152mm)

7" (177mm)

8" (203mm)

FIGURE 6-17 Mulitple Boilers With Common Venting Pipe

Air Flow

Check Valve

Air Flow

Check Valve

Air Flow

Check Valve

Vent

Combustion

Air

12" (305mm) Anticipated Snow Line

Ground Level

Page 31

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-18 Condensate Drain

6.9 Condensate Piping

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

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

• Canada - CSA or ULC certiﬁ ed PVC/CPVC pipe, ﬁ ttings and cement.

• Attach PVC tee provided with boiler and ﬁ eld sourced piping to condensate drain at bottom of boiler. See ﬁ gure 6-18.

• 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.

Do not glue cap on if used

for dust protection. End

must be left open.

Condensate Tee

(ﬁ eld installed)

on condensate drain pipe

Do not place in environment with

temperatures below freezing.

Condensate outlet will block if

condensate freezes.

Page 32

7 - GAS SUPPLY PIPING

FIGURE 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 switch; do not use any phone 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:

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

• Canada - Natural Gas and Propane Installation Code, CAN/CSA B149.1

• 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 10.

• 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

050 075 100 150 200 299

7.2 Conversion Kit Instructions

• See Gas Conversion Kit Instructions included with Boiler.

Table 10 - Gas Supply Pressure

Gas Supply Pressure

Natural Gas Propane

Min. Max. Min. Max.

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)

13.5" w.c. (3.4 kPa)

Page 33

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 7-2.

•

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 that can provide ignition source.

FIGURE 7-2 Manual Main Gas Shutoff Valve Outside Boiler Jacket

Manual Main Gas

Shutoff Valve

FIGURE 7-3 Gas Shutoff Valve - 050/075/100/150/200

n Ga

•

Correct leaks immediately and retest.

Gas shutoff valve

(shown in closed

position)

FIGURE 7-4 Gas Shutoff Valve - 299

Gas shutoff valve

(shown in open

position)

Page 34

8 - ELECTRICAL CONNECTIONS

8.1 General

Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to:

• USA- National Electrical Code, ANSI/NFPA 70.

• Canada - Canadian Electrical Code, Part I, CSA C22.1: Safety Standard for Electrical Installations.

8.2 Electric Knockouts (ﬁ gure 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 (ﬁ gure 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 gures 3-4

and 3-5) 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 maximum allowable current draw. See Figure 8-3 and Table 11.

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 maximum allowable current draw. See Figure 8-3 and Table 11.

B. Connect pump to line voltage terminal strip DHW

PUMP L,N,G.

5" (127mm)

8.4 External Connections (ﬁ gure 8-4)

• 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.

• Argus Link (Multiple boiler applications only)

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.

FIGURE 8-1 Electric Knockouts Bottom Of Boiler

Front of Boiler

Low Voltage Knockouts

(Use supplied

High Voltage

Knockouts

4½" (114mm)

grommets when using

these knockouts)

Back of Boiler

FIGURE 8-2 Line Voltage Connections

Table 11 - Maximum Allowable Current Draw

MBH CH PUMP DHW PUMP NOTE

5 0

7 5 100 150 200

299 10 A 10 A

If CH or DHW pump current is more than the maximum allowable current draw install proper ﬁ eld sourced relays as shown in ﬁ gure 8-3.

1 A 1 A

Control Board

installed 10 Amp

relay

Page 35

8 - ELECTRICAL CONNECTIONS

• 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.

FIGURE 8-3 Isolation Relays for CH System Pump and DHW Pump

DHW Pump

Pump

DHW Pump Relay

120VAC

coil

Pump

Relay

120VAC

coil

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

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

interchangeable.

NOTICE

Use dry contact for wires to CH T-T terminal and DHW T-T terminal. E33 error code is displayed if voltage is sent back to the control board. If error is not corrected for extended period of time, this voltage can permanently damage control board.

FIGURE 8-4 External Connections

(Do not apply external voltage to external terminals.)

Page 36

9 - START UP PROCEDURE

NOTICE

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

FIGURE 9-1 Condensate Drain Assembly

1. Disconnect spring tension clip from hose barb and ﬁ ll Condensate trap with water.

9.1 Fill Boiler With Water And Purge Air

NOTICE

To maintain boiler efﬁ ciency and prevent boiling inside the heat exchanger, ﬂ ush entire heating system until clean.

• Flush heating system, including all heating zones.

• Fill boiler with potable water.

•

Fill boiler and system piping with water (or antifreeze-water solution, if used). See antifreeze information page 13. Purge air from boiler using air vent. Purge air from system piping.

•

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

•

Activate all heating zones and calls for heat, including CH calls and DHW calls (if available).

•

Close manual gas shut off valve. Let system run for 30 minutes. When boiler goes into lockout, reset boiler by pressing "Reset" button until boiler resets.

•

Do not open gas shutoff valve until all air is purged from system.

2. Reconnect hose to hose barb with spring tension clip before starting boiler.

9.2 Fill Condensate Trap with Water

•

Disconnect spring tension 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 spring tension clip. See ﬁ gure 9-1.

Page 37

9 - START UP PROCEDURE

9 -2 User Interface

-2 User Interfac

9-3 Default Table

User

Installer

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

Settings

Boiler

Conﬁ guration

CH Settings

Central Heating Setpoint 140°F 60°C 104-195°F 40-91°C

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

Control Parameter

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, Table 11.

Parameters can be adjusted to suit particular application using the user interface. See ﬁ gure 9-2.

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

List parameters in event of factory default parameters are changed.

Factory Default

Setting

Standard Metric Standard Metric

Setting Range

25°C

*Actual

Parameter

Settings

Page 38

9 - START UP PROCEDURE

9.4 Boiler Start-up and Operational Test

Verify air is purged from hydronic piping

2. System test pumps - verify each pump is

operational

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.

•

Activate some heating zones to dissipate heat.

•

Set boiler on high ﬁ re.

•

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.

Input (MBH) =

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

Rate (MBH) =

*Metric - See Glossary

3600 x cu ft

seconds

3600 x 2 cu ft

= 100 MBH

72 seconds

2. Compare measured input to table. Adjust input rate

if needed using Table 12 below.

Table 12 - Rate @ High Fire

Rate @ High Fire

Size From To

050 45 51

075 65 76

100 90 102

150 140 153

200 185 204

299 285 315

Natural Gas and Propane

3. Measure CO

Adjust CO2 if needed using ﬁ gure 9-3 & 9-4. See ﬁ gures 9-5 and 9-6 for combustion air analyzer

port.

at high ﬁ re and compare to table.

Page 39

9 - START UP PROCEDURE

Gas

Natural Gas 9.0 9.5 <100ppm Propane 10.0 11.0 <150ppm

Min. Max.

NOTICE

Contact Technical Support @ 800-325-5479 for additional information or assistance.

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 & 9-4.

•

If CO2 is high decrease gas ﬂ ow following ﬁ gure 9-3 & 9-4.

FIGURE 9-3 Gas Valve - Models 050/075/100/150/200 MBH

. Propane should be between 10% and

FIGURE 9-4 Gas Valve - Model 299 MBH

•

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.

•

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.

Verify Burner, Proper Operation

1. Inspect burner ﬂ ame through Sight Glass. See

ﬁ gure 11-1 & 11-2.

2. Operate boiler through several heating cycles,

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

Page 40

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.

FIGURE 050/075/100/150/200

FIGURE

Analyzer Port

9-5 Combustion Analyzer Port -

Combustion

Analyzer Port

9-6 Combustion Analyzer Port - 299

Combustion

9.6 Perform CSD-1 Compliance Test (see paragraph 2.4 page 6)

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 9-8.

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 .

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.

FIGURE

9-7 Burner Flame

Burner

Flame

Look for BLUE ﬂ ame with slight

YELLOW tips evenly spaced

around burner

Page 41

J7 Connector

9 - START UP PROCEDURE

9-8 Control Module J7 Connector

J7 Connector

9.7 Complete Start Up Procedure

1. Reset control parameters to operating settings if

adjusted to allow startup and operation test.

2. Follow instructions TO TURN OFF GAS TO APPLIANCE

(page 42) 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.

Page 42

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 Gas Shutoff Valve - 050/075/100/150/200 MBH

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 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.

• 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.

OPEN POSITION

10-2 Gas Shutoff Valve - 299 MBH

CLOSED POSITION

Gas Shutoff Valve

Page 43

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.

FIGURE 11-1 Sight Glass - 050/075/100/150/200

MBH

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. Ensure 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.

• Examine ﬂ ue passages in heat exchanger, burner, condensate lines, and cleaning (if necessary) by following instructions in “Annual Examination 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.

FIGURE

Sight Glass

11-2 Sight Glass - 299 MBH

• 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% ﬁ ring rate ( High ﬁ re).

micro

• Visual inspection of ﬂ ame through sight glass. Burner should be fully illuminated. See ﬁ gures 11-1 & 11-2.

• Check heating system expansion tank.

Page 44

11 - GENERAL MAINTENANCE AND CLEANING

Figure 11-3 Condensate Trap - 050,075,100,150,200

11.2 Annual Shut Down Procedure

• Follow instructions “To Turn Off Gas To Appliance” unless

• Drain system completely if system does not have

Flue Pipe

Coupling

• Drain condensate lines when boiler is to be exposed to

Temperature

Sensor

Condensate Collector

Condensate

Trap Connection

To Condensate

Collector

Flexible Gas Line

Figure 11-4 Condensate Trap - 299

Hose Barb w/Cap

11.3 Annual Inspection and Cleaning of Boiler

Components

• Obtain Burner Inspection Kit. Follow kit instructions to

• Burner and heat exchanger inspection and cleaning.

boiler is also used to supply domestic hot water. See section 10.

antifreeze when heating system is to remain out of service during freezing weather.

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.

prepare for examination and cleaning.

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

Condensate Collector

Flexible Gas Line

Condensate Trap Connection

To Condensate Collector

• 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 spring tension clip of condensate trap using hose clamp pliers. Disconnect condensate trap from condensate collector. See ﬁ gures 11-3 & 11-4.

• Disconnect wire harness from vent temperature sensor. See ﬁ gure 11-3 .

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

Page 45

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 gures 11-3 & 11-4.

• 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.

Page 46

12 - RATINGS AND CAPACITIES

TABLE 12-1: SEA LEVEL RATINGS

NATURAL AND PROPANE GASES

Size

050 075 100 150 200 299

(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. Contact Technical Support before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

Boiler Input Rate (MBH)

Maximum Minimum

50 10 46 40 95.0

75 15 69 60 95.0 100 20 91 79 95.0 150 30 139 121 95.0 200 40 185 161 94.0 299 60 273 239 94.0

(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 between 2000 ft (600m) and 4500 ft (1350m), install high altitude control kit

• For elevations above 4500 ft (1350m) install high altitude control kit and :

• USA - Reduce input rate 4% for each 1000 ft (300m) beyond 4500 ft.

• Canada - Contact Provincial authority having jurisdiction for installations above 4500 feet (1350 m) above sea level.

Page 47

13 - TROUBLE SHOOTING

Page 48

13 - TROUBLE SHOOTING

Screen Display Explanation

Control has blocking error for more than 20 hours in a row.

Three unsuccessful ignition attempts in a row Go to Page 51

Open gas valve power circuit. May involve high temperature switch, gas valve, or gas valve relay in control module.

Safety Circuit is open. Go to Page 52

Blower speed does not reach speed calculated by Control Module.

Control Module internal error.

Go to Page For

Troubleshooting

Go to Page 50

Go to Page 53

Replace Control

Module

High Temperature opens during normal operation.

Control Module detects ﬂ ame after gas valve is closed more than 10 seconds.

Go to Page 54

Replace Gas Valve

Flame is detected before gas valve opens. Replace Gas Valve

Control module internal error.

Replace Control

Module

Lost ﬂ ame signal 3 times during one heat call. Go to Page 55

Control Module internal error.

Replace Control

Module

Replace Control

Module

External voltage supplied to DHW T-T or CH

Blocking Error

REFLO too LO

T-T terminals. Eliminate voltage using dry contact relay.

Flame detected when gas valve is closed. Go to Page 55

Page 49

13 - TROUBLE SHOOTING

Screen Display Explanation

Low water cutoff sees no water. Go to Page 56

Go to Page For

Troubleshooting

Blocking Error

Flue Gas Error

Flue temperature sensor sees temperature

higher than 200°F.

Return water temperature sensor sees temperature higher than 200°F.

Control board internal error. Power down then power up boiler. If error repeatedly occurs replace control module.

Go to Page 57

Go to Page 58

Replace Control

Module

Boiler is powered by three wires, hot, neutral and ground. E44 displays when neutral wire is

Go to Page 58

not neutral.

Control board sees power supply frequency not in range of 59 to 61 Hz.

Boiler power supply ground wire is not grounded.

Control board internal error. Power down then power up boiler. If error repeatedly occurs replace control module.

Go to Page 59

Go to Page 60

Replace Control

Module

Supply temperature sensor is open. No continuity.

Return water temperature sensor is open. No continuity.

Flue temperature sensor is open. No continuity.

Supply water temperature sensor is shorted. '0' Ohm

Return water temperature sensor is shorted. '0' Ohm

Go to Page 60

Go to Page 61

Go to Page 62

Go to Page 63

Flue temperature sensor is shorted. '0' Ohm Go to Page 63

Reset button was pressed too many times.

Error Clears in 1-2

minutes

Fault detected in blower motor system. Go to page 59

Page 50

13 - TROUBLE SHOOTING

Replace Supply Sensor

hot?

YES

pipe at top of boiler)

Is supply pipe (copper

supply sensor.

YES

Measure continuity of high

two purple wires. Is continuity

between two pins connected to

limit sensor (close/open signal)

available? Unplug connector on

Is wire harness

connected to both

Gas Valve and J13

connector on Control

Boiler has been dry

Module?

YES

ﬁ red. System has too

Purge air from system,

much air. Close manual

wait for system to cool.

gas valve (shut off gas).

Connect harness

Disconnect harness from

resistance across third

Disconnect J13 connector

on Control Module. Measure

fourth (connected to brown

(connected to blue wire) and

YES

between 1.0 and 1.2 kΩ?

wire) terminals. Is resistance

Control Module

wire have continuity

Gas Valve. Does each

YES

between Gas Valve and

Module

Replace Gas Valve Replace Harness

Enter Installer Menu, Boiler

Status. Scroll to most recent

Lockout Alarm A 0 0

Blocking too long error

Lockout Alarm or Blocking Error.

_ _ _ _ _

Diagnose corrective action using

appropriate Troubleshooting Tree.

Replace Control

Page 51

13 - TROUBLE SHOOTING

Page 52

13 - TROUBLE SHOOTING

Is Heat Exchanger surface

YES NO

heat exchanger) hot?

Is boiler supply pipe (above

Let all zones

hot?

temperature

run until water

YES

drops.

switches

and surface

temperature

Check high limit

cool down.

Wait for boiler to

Replace Broken Switch

between two pins on sensor two

Unplug molex connector on supply

temperature sensor. Check continuity

YES

Error shows when safety circuit is

open. Remove J13 connector from

pink wires, is continuity available?

between two pins connected to two

control module. Check for continuity

Replace Control Module

Is continuity available?

before removing the connector.

pins connected to two pink wires

YES NO

YES

on two pink wires on J13

Check for loose connections

safety temperature switch.

connector, supply sensor, and

Fix Loose Connections Replace Wire Harness

Check the following:

Boiler ﬁ red without enough water ﬂ ow

is over heated. Either high limit or heat

through heat exchanger. Heat exchanger

• Air in system?

• Verify water ﬂ ow in system piping

exchanger temperature switch is open.

• Flush system if water is dirty.

Page 53

13 - TROUBLE SHOOTING

Page 54

13 - TROUBLE SHOOTING

Control Module J13.

Disconnect harness from High

Temperature Supply Switch and

(Continuity of two purple wires)?

Continuity from J13-6 to Switch 3

Continuity from J13-5 to Switch 1?

Page 55

13 - TROUBLE SHOOTING

Replace Flame

Sensor and Burner

3.7μA ﬁ ring rate)?

Status, Flame Signal.

to initiate boiler operation.

Follow Operating Instructions

Is ﬂ ame signal greater than

Enter Installer Menu, Boiler

YES

(Boiler may be running at any

Module

Replace Control

Module

NOYES

Replace Control

Blocking Error E 3 5

False flame detect

_ P _ _ _

glass. Is flame present?

Inspect burner through sight

TO TURN OFF GAS

APPLIANCE. Replace

TO TURN OFF GAS TO

Gas Valve.

TO APPLIANCE.

Replace Gas Valve.

shutoff valve.

Turn Gas Shutoff

Valve clockwise to

Turn off manual gas

closed position.

Follow instructions

Page 56

13 - TROUBLE SHOOTING

any remaining air in system.

Repair System Piping, remove

Water Cutoff.

YES NO

Is 24 vac at terminals 1 & 2

Disconnect harness from Low

Connect harness to Transformer.

(Between blue and yellow wires)?

Page 57

39 E

13 - TROUBLE SHOOTING

gas temperature through sampling

port. Is the measured temperature

Use thermal couple to measure ﬂ ue

and ﬂ ue temperature reading on User

YES

Interface signiﬁ cantly different?

Replace Control Module

Interface.

Blocking Error

Flue Gas Error

Read ﬂ ue gas temperature on User

YES

Is temperature higher than 200°F ?

system.

for boiler to cool. Fix

Boiler is over ﬁ red. Wait

purging all air out of the

ﬂ ow rate problem if any,

Replace Flue Gas Sensor

Page 58

13 - TROUBLE SHOOTING

YES

sensor (2 Brown Wires)?

Is correct harness connected to return

Correct wiring

antifreeze solution.

YES

properly oriented?

Is Heat Exchanger Pump

(Pump arrow pointing down?)

YES

Install Heat

proper orientation

Exchanger Pump in

Sensor

YES

Disconnect harness from

Return Water Sensor. Measure

950 to 33,000 ohms?

resistance using digital ohm

meter. Is resistance between

Replace Return Water

Module

Replace Control

Unplug molex connector on return

metal pins? Liquid might be water or

sensor. Is there moisture or liquid on

from connector.

Repair all leaks.

Check for leaks.

Remove all liquid

Replace Control Module

Page 59

13 - TROUBLE SHOOTING

+/- 2%

Blocking Error E 4 5

Net frequency error

_ P _ _ _

and 61 Hz?

YES

Is power supply between 59

stabilized power

Provide frequency

supply rated at 60 Hz

loose or faulty?

YES

Is power supply circuit breaker

Is field wiring loose or faulty?

Replace circuit

YES

breaker

Module

Replace Control

Correct wiring

blower motor system.

These error messages are displayed

when the control board detects fault in

any connection loose?

YES

Check wire connector to blower.

Check connector J9 on control board is

Replace Control Module

YES

this correct the problem?

Replace blower motor. Does

Fix the connection.

properly

Boiler is operating

Page 60

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

continuity between field wiring

Replace Control

conductor

NOYES

Correct faulty ground

10 ohms?

neutral and ground less than

Module

Replace Control

°F°C Resistance

Resistance Chart

Supply Water 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

Page 61

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

Control Module J5-4 and J5-12

YES NO

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

Page 62

13 - TROUBLE SHOOTING

Resistance Chart

Supply Water Temperature Sensor

Page 63

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

Page 64

14 - WIRING DIAGRAM

14.1 Connection Diagram - 050/075/100/150/200 MBH

Page 65

14 - WIRING DIAGRAM

14.2 Schematic Diagram of Ladder Form - 050/075/100/150/200 MBH

LADDER DIAGRAM

LIGHTED POWER

SWITCH

LWCO

THERMOSTAT

USER INTERFACE

SUPPLY SENSOR

RETURN SENSOR

DHW

THERMOSTAT

FLUE SENSOR

SYSTEM SENSOR (OPTIONA L)

OUTDOOR SENSOR

ARGUS LINK

POWER

ARGUS LINK / MULTI BOILER (OPTIONA L)

DISPLAY

OFF

J16-1 J16-4

J16-5

J16-8

J16-6

J16-7

J16-3 J16-2

J5-9

J5-1

J5-10

J5-2

J5-11

J5-3

J5-12

J5-4

J5-13

J5-5

J5-14

J5-6

J5-15

J5-7

J5-16

J5-8

J18-1 J18-2

ARGUS

CONTROL

J12

J13-2

J9-1 J9-2 J9-6 J9-7 J9-5 J9-4 J9-3

J13-1 J13-5

J13-6

J13-3 J13-4

J7-1

J7-4

J7-3

J7-2

J6-1

J6-3

J6-2

J4-1 J4-2 J4-3 J4-4

J2-1 J2-2 J2-3 J2-4

GROUND

FLAME SENSOR

BURNER

IGNITION

DC+/L

DATA/PWM

HALL

GND

DC-/N

FIELD SUPPLIED REFER TO ELECTRICAL CONNECTIONS SECTION

RELAYS

120VAC

G N L

FAN 120VAC

LIMIT

HEAT EXCHANGER TEMPERATURE SWITCH

GAS VALVE

HEAT EXCHANGER PUMP 120 VAC

DHW PUMP 120 VAC

CH PUMP

120 VAC

120V / 24V, 15VA TRANSFORMER

LWCO

24 VAC

Page 66

14.3 Connection Diagram - 299 MBH

14 - WIRING DIAGRAM

EXTERNAL PUMP RELAY - LIMIT OF 1 AMP PER PUMP SEE SECTION 8

Page 67

14 - WIRING DIAGRAM

14.4 Schematic Diagram of Ladder Form - 299 MBH

LADDER DIAGRAM

LIGHTED POWER SWITCH

LWCO

CH THERMOSTAT

USER INTERFACE

SUPPLY SENSOR

RETURN

SENSOR

DHW

THERMOSTAT

FLUE

SENSOR

SYSTEM SENSOR (OPTIONA L)

OUTDOOR SENSOR

ARGUS LINK

POWER

ARGUS LINK / MULTI BOILER (OPTIONAL)

DISPLAY

OFF

J16-1 J16-4

J16-5

J16-8

J16-6

J16-7

J16-3 J16-2

J5-9

J5-1

J5-10

J5-2

J5-11

J5-3

J5-12

J5-4

J5-13

J5-5

J5-14

J5-6

J5-15

J5-7

J5-16

J5-8

J18-1 J18-2

ARGUS

CONTROL

J12

J13-2

J9-1 J9-2 J9-6 J9-7

J9-5

J9-4

J9-3

J13-1 J13-5

J13-6

J13-3 J13-4

J6-1

J6-3

J6-2

J7-4

J7-2

J7-1

J7-3

J4-1

J4-2

J4-3

J4-4

J2-1

J2-2

J2-3

J2-4

BURNER

DC+/L

DATA/PWM

HALL

GND

DC-/N

RELAY 120VAC

G N L

DHW PUMP

CH PUMP

GROUND

FLAME SENSOR

IGNITION

FAN 120VAC

LIMIT

HEAT EXCHANGER

TEMPERATURE SWITCH

GAS VALVE

HEAT EXCHANGER PUMP RELAY 120 VAC

HEAT EXCHANGER

PUMP 120 VAC

DHW PUMP 120 VAC

CH PUMP 120 VAC

120V / 24V, 15VA TRANSFORMER

LWCO

24 VAC

Page 68

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.

• Btu - Abbreviation for British Thermal Unit. Quantity of

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

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

of gas and air, to combustion zone.

• 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.

• COMBUSTIBLE MATERIAL - Materials made of or

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

• 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

through a chimney, vent, ﬂ ue or appliance.

• FLA - Full load amps.

• GAS PIPE SIZES - Table 14

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.

• IGNITER - Device utilizing electrical energy to ignite gas

at main burner.

• LEAK CHECK - Operation performed on gas piping

system to verify system does not leak.

• LOW WATER CUTOFF - Device constructed to

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

• LOW-VOLTAGE - Circuit involving potential of not more

than 30 volts.

• METRIC GAS METERS

MBH =

127,116 x cu meters

Seconds

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

MBH =

127,116 x 0.1

100

= 127 MBH

• PRESSURE TEST - Operation performed to verify gas

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

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

gas and air.

• FLUE GASES - Products of combustion plus excess air

in appliance ﬂ ues or heat exchanger.

• PURGE TIME - Period of time intended to allow for

dissipation of any unburned gas or residual products of combustion.

Page 69

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.

Page 70

APPENDIX A - CONTROL MODULE

1.1 Introduction

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

1.2 Operation

• Display: 4 x 20 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

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.

Page 71

1.4 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

Standby: No Demand

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 pre-purge setting for 15 seconds.

Sparking initiated sequence.

After 2 seconds

Page 72

1.4 Sequence of Operation

Operational State User Interface Display Explanation

After 2 seconds

Flame

Detected?

Gas Valve

Energized

Yes

Lockout

Error A21

5 Ignition

Lockout A01

APPENDIX A - CONTROL MODULE

Note:

trials,

then

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.

After 3 seconds

Flame

Detected?

Yes

Heat Demand

Met?

Simultaneous

DHW + CH

Demand?

Yes

DHW

Priority

Mode

See Max DHW

Priority Time

30 second

post purge

Yes

Setting

If ﬂ ame undetected after 3 seconds 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.

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.

Page 73

1.5 Theory of Operation

APPENDIX A - CONTROL MODULE

STANDBY

User Menu

User Interface Display

Explanation

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

User Menu structure includes:

• ‘Boiler Status’ submenu– User can monitor general boiler status parameters such as sensor temperatures and pump operation.

• ‘Settings’ submenu – User can view CH , adjust DHW supply water set points and also select control language.

• ‘Cascade Status’ submenu – Boiler set to function as part of multiple boiler installation; submenu used to view runtime parameters. See Multiple Boiler Manual.

Boiler Status

Supply Temperature set point displayed.

If boiler running in CH mode, CH set point displayed.

Note:

• While running in Outdoor Reset mode, this value may change in proportion with the outdoor temperature.

• If the boiler is running in DHW mode, the DHW supply set point is displayed.

Several boiler runtime parameters can be viewed while in ‘Boiler Status’ submenu.

Operational status of pump system also shown.

Information available during all states of boiler operation. Sensor values with troubleshooting tree used to diagnose typical problems.

Page 74

APPENDIX A - CONTROL MODULE

User Interface Display

Setting Range: 104° F to 195° F (40° C to 91° C) Default Value: 140° F (60° C)

Settings

Explanation

Adjust CH set point to hydronic system design while in Operating in CH Mode = 0 (CH with Thermostat) or 3 (Permanent Demand).

In CH Mode = 1 (CH with Thermostat and Outdoor Reset) or 2 (CH with Full Outdoor Reset). Display will change to ‘OD Reset Setpoint’ and cannot be changed. Controller calculates set point based on outdoor temperature.

Note:

For explanation of available CH heating modes, refer to

‘CH Mode’ section located in ‘CH Settings’ submenu.

DHW set point determines supply water temperature set point while operating in DHW mode.

Setting Range: 104° F to 195° F (40° C to 91° C) Default Value: 180° F (82° C)

User interface temperature unit of measure is selected using ‘Change Temperature Units’ screen.

Fahrenheit and Celsius available.

Page 75

APPENDIX A - CONTROL MODULE

User Interface Display

Installer Menu

Explanation

The Installer Menu structure includes:

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.

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

Boiler Status

• ‘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.

Page 76

APPENDIX A - CONTROL MODULE

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.

Page 77

APPENDIX A - CONTROL MODULE

User Interface Display

Boiler Status

Explanation

Boiler stores information regarding total CH and DHW run time in hours.

Data stored in non-volatile memory and retained in event of power failure.

Boiler logs last 16 blocking errors and 16 lockout errors in non-volatile memory. Information retained in event of power failure.

Most recent blocking error code and its text description displayed with elapsed time in hours since logged.

Optional Computer interface Kit purchased separately to view extended error code history

‘Address Selection” screen used to set boiler position in multiple boiler cascade installation. Refer to Multiple Boiler Installation Manual.

Default setting of ‘0’ indicates boiler is operating in single boiler mode.

Boiler Conﬁ guration

Boiler incorporates integrated Low Water Cutoff device (LWCO) that disables boiler when low water condition exists. LWCO device located at high point of internal Heat Exchanger loop to detect low water condition.

Detection of low water condition will result in blocking error; boiler will automatically resume normal operation when proper water level returns. Refer to Troubleshooting Guide.

LWCO device can be disabled for diagnostic purposes or where applicable code permits.

Page 78

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

Page 79

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 Figure 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 Figure 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).

Page 80

APPENDIX A - CONTROL MODULE

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)

100

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

C D

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)

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

Calculated supply temperature follows thick black line in graph above based on outdoor temperature.

C°

F°

170°F

77°C

21°C 70°F

200

180

160

140

120

100

F° C°

-6

25°F

-4°C

Note:

• Modes only function when outdoor temperature sensor connected.

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

Points A and Bdeﬁ ne a straight line. Boiler min. and

max., C and Ddeﬁ ne a section on that straight line.

Reset Curve Boiler Maximum

Reset Curve

Boiler Minimum

60 16

70°F 21°C

100

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

Page 81

APPENDIX A - CONTROL MODULE

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.

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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.

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NOTES

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ECRInternational,Inc

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com