Dunkirk Q95M-200 User Manual

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Page 1

Model

Q95M-200

GAS-FIRED DIRECT VENT

MODULATING HOT WATER BOILER

Q95M-200

INSTALLATION, OPER ATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certied Company

Manufactured by:

ECR International, Inc.

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

P/N# 240006103D, Rev. E [02/2014]

Page 2

1 - DIMENSIONS

18”

(458mm)

30⅞”

(785mm)

OPENING FOR SAFETY

RELIEF VALVE DISCHARGE PIPE

39⅜”

(1.1m)

Page 3

2 - INTRODUCTION

1 - Dimensions .............................................................................................................. 2

2 - Introduction ............................................................................................................. 3

3 - Important Safety Information ..................................................................................... 4

4 - Boiler Ratings & Capacities ......................................................................................... 5

5 - Before Installing The Boiler ........................................................................................6

6 - Locating The Boiler ...................................................................................................7

7 - Near Boiler Piping ..................................................................................................... 9

8 - Combustion Air And Vent Pipe .................................................................................. 12

9 - Gas Supply Piping ................................................................................................... 17

10 - Electrical Wiring .................................................................................................... 19

11 - Controls And Accessories ....................................................................................... 21

12 - Boiler Startup ....................................................................................................... 23

13 - Operating Instructions ........................................................................................... 24

14 - Maintenance And Cleaning ..................................................................................... 25

Appendix A - Boiler Piping And Wiring ............................................................................ 27

Appendix B - Water Quality, Water Treatment and Freeze Protection ................................... 45

2.1 Introduction

• Boiler is certied in accordance with ANSI Z21.13 American National Standards Institute) and CSA (Canadian Standards Association) 4.9.

• This appliance is a gas-red direct vent modulating cast aluminum hot water boiler.

• Cast aluminum monoblock heat exchanger allows better heat transfer and thermal storage than similarly sized cast iron boilers resulting in higher efciency.

• The heating system water absorbs large amounts of heat from the cast aluminum heat exchanger, cooling ue gases and causing condensation.

• Sealed combustion, premix gas burner, and low ame temperature means reduced CO and NOx emissions, which contribute to cleaner and healthier environment.

• This appliance takes its combustion air directly from outdoors (sealed combustion) and does not compete with building occupants for fresh air.

• Sealed combustion (also known as “direct vent”) is safest and best way to obtain plenty of clean combustion air.

• Forced draft fan draws in outside combustion air, takes cooler ue gases from boiler unit and provides positive removal of ue gases from the building through readily available PVC and CPVC pipes. Canada use ULC S636 Material.

• These low pressure gas-red hot water boilers are design certied by CSA International for use with natural gas and propane gas.

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

Page 4

3 - IMPORTANT SAFETY INFORMATION

3.1 General

Boiler installation shall be completed by quali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.

Keep this manual near boiler

Retain for future reference

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

WARNING

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

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

•

United States

• 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. and .2

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

3.3 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 and/or manual reset high limit may be required.

3.4 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 tter.

Installers - Follow local regulations with respect to installation of CO (Carbon Monoxide) Detectors. Follow maintenance recommendations “Maintenance And Cleaning” Section 14 page 25.

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 5

4 - BOILER RATINGS & CAPACITIES

TABLE 1: SEA LEVEL RATINGS - NATURAL AND PROPANE GASES

Input (MBH)

(1)

Heating Capacity

(MBH)

(1)(2)

Net AHRI Rating

(MBH)

(1)

AFUE

(2)

Flue Diameter Shipping Wt.

High Fire 200 182 158

Low Fire 80 73 63

(1)

1 MBH = 1,000 BTUH (British Thermal Units Per Hour)

(2)

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

92.5% 2” CPVC & 3” PVC 284 lbs.

TABLE 2: 95M-200 HIGH ALTITUDE DERATE CHART

Input

(MBH)

3,000

(2)

4,000

(2)

5,000

Altitude (In Feet)

(3)

6,000 7,000 8,000 9,000 10,000

High Fire 196 192 177 174.5 172 169 168 167

Low Fire 78.4 76.8 115 113.5 112 110 109 108

Boiler Input Rate is determined at minimum vent length. The rate will decrease as vent length increases.

Parameter 17 is set to 2,250 at elevations of 2,000 feet and below.

Parameter 17 must be raised to 3,200 at altitudes or elevations of 2,000 feet and above.

• Heating Capacity indicates amount of heat available after subtracting losses up the stack. Most of this heat is available to heat water. Small portion is heat loss from jacket and boiler surfaces, and it is assumed this heat stays in the structure.

• Net AHRI Rating represents portion of remaining heat that can be applied to heat radiation or terminal units (i.e., nned tube baseboard, cast iron radiators, radiant oor, etc.) Difference between Heating Capacity and Net AHRI Rating, called piping and pickup allowance, establishes reserve for heating volume of water in the system and offsetting heat losses from piping.

• Net AHRI Ratings shown are based on piping and pickup factor of 1.15 in accordance with AHRI Standard. Net AHRI Rating of selected boiler should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.

Page 6

5 - BEFORE INSTALLING THE BOILER

5.1 Before Boiler Installation

Boiler is equipped for residential installations. If used for commercial applications, additional code requirements must be adhered to for installation. This may require additional controls including but not limited to a low water cut off, a manual reset high temperature limit, and wiring and/or piping modications.

Never vent products of combustion from this boiler to enclosed space. Always vent to outdoors. Never vent to another room or to inside building.

Keep boiler area clean of debris and free of combustible and ammable materials.

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

5.2 Boiler Sizing

• Verify you have selected boiler with proper capacity before continuing installation. AHRI Rating of selected boiler should be greater than or equal to calculated peak heating load (heat loss) for the building or area(s) served by boiler and associated hot water heating systems. See Sea Level Ratings - Natural and Propane Gases” Section 4.

• Heat loss calculations should be based on approved industry methods.

5.3 Considerations for Boiler Location

Before selecting boiler location consider following.

• Supplied with correct type of gas (natural gas or propane).

• Connected to suitable combustion air intake piping system to supply correct amounts of fresh (outdoor) air for combustion (15’ minimum equivalent length/100’ maximum equivalent length).

• Connected to suitable venting system. (15’ minimum equivalent length/100’ maximum equivalent length).

• Connected to suitable hot water heating system.

• Supplied with suitable electrical supply for all boiler motors and controls.

• Connected to properly located thermostat or operating control (not included with boiler).

WARNING

Fire hazard. Do not install on carpeting. Failure to follow these instructions could result in death or serious injury.

• Placed on level surface (must NOT be installed on carpeting).

• Pitch condensate drain line down to oor drain or external condensate pump with reservoir at ¼” per foot (wood frame or blocks may be used to raise boiler).

Page 7

6 - LOCATING THE BOILER

6.1 Locating the Boiler

Place crated boiler as close to selected location as possible and un-crate boiler. Boiler may be moved into position with appliance dolly or 2 wheel hand truck. Insert dolly or hand truck under right hand side of boiler. It is possible to slide boiler for short distance on smooth oor or surface.

Select level location central to piping systems served and as close to vent and air intake terminals as

possible.

Accessibility clearances, if more stringent (i.e. larger clearances) than required re protection clearances, must be used for boiler installation. Accessibility clearances may be achieved with use of removable walls or partitions.

WARNING

Fire hazard. Do not install on carpeting. Failure to follow these instructions could result in death or serious injury.

Boiler is approved for installation in closets and on combustible oors. Boiler shall NOT be installed on carpeting.

Clearances shown in Table 3 indicate required clearances per CSA listing. Minimum 1” (26mm) clearance must be maintained between combustible construction and each of the right, top and back surfaces of the boiler. Allow at least 24” (610mm) at front and left side and 8” (204mm) at top for servicing. No combustible clearances are required to venting or combustion air intake piping.

Install equipment in location which facilitates operation of venting and combustion air intake piping systems as described in this manual.

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

Install boiler so automatic gas ignition system components are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, control replacement, etc.).

Keep boiler area clean of debris and free of ammable and combustible materials, vapors and liquids.

10.

Locate boiler where ambient room temperatures (minimum possible temperatures where boiler is installed assuming boiler is not in operation and therefore contributes no heat to space) are always at or above 32°F (0°C) to prevent freezing of liquid condensate.

TABLE 3: BOILER CLEARANCES

Dimension

Top

Left Side

Right Side

Base

Front

Back

Intake/Vent Piping

Near Boiler Hot Water Piping

Figure 1 - Minimum Clearances To Combustible

Combustible

Construction

1” (26mm) 8” (204mm) 8” (204mm)

1” (26mm) 24” (610mm) 24” (610mm)

1” (26mm) - -

Combustible - -

0 24” (610mm) 24” (610mm)

6” (153mm) - -

0 - -

1” (26mm) - -

Construction

Accessibility/

Cleaning

Service

6”

(153mm)

8”

1”

(26mm)

Left Side

Rear

Boiler

Front

Right Side

1”

(26mm)

0”

(0mm)

Page 8

6 - LOCATING THE BOILER

6.2 Combustion Air and Vent Pipe Requirements

• This boiler requires dedicated direct vent system.

• In direct vent system all air for combustion is taken directly from outside atmosphere, and all ue products are discharged to outside atmosphere.

• Combustion air and vent pipe connections must terminate together in same atmospheric pressure zone, either through roof or sidewall (roof termination preferred). See Figures 5 and 6 for required clearances. For proper set up of concentric vent termination see Figure 7 and Figure 8.

WARNING

Solvent cements are combustible. Keep away from heat, sparks, and open ame. Use only in well ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes. Failure these instructions could result in re, personal injury, or death.

• Locate combustion air inlet as far away as possible from swimming pool and swimming pool pump house.

• All combustion air and vent pipes must be airtight and watertight. Combustion air and vent piping must also terminate as shown in “Combustion Air and Vent Pipe” section.

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

• Covering non-metallic vent pipe and ttings with thermal insulation shall be prohibited.

6.3 Condensate Drain Requirements

• Condensate trap provided with boiler, an additional trap is not required and should not be used.

• Pitch condensate drain line down to oor drain at minimum of ¼” per foot. External condensate pump (not furnished) may be used if oor drain is not available.

• Condensate pump must be designed for ue gas condensate application.

• Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reservoir.

• If boiler is not level, condensate drain lines will not function properly. Adjustable feet are located on boiler to make up for minor surface irregularities or tilt.

• 115 volt AC receptacle provided on control panel to provide power for external condensate pump if used.

6.4 Removal of Existing Boiler From Common Vent System

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

Seal any unused openings in the common venting system.

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

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

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

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

After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, re place dampers, and any other gas-burning appliance to their previous condition of use.

Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Code, NFPA-54/ANSI -Z223.1 and/or the Natural Gas and Propane Installation Code, CAN/ CSA B149.1. When re-sizing any portion of common venting system, common venting system should be resized to approach minimum size as determined using appropriate tables in Chapter 13 of the National Fuel Gas Code, NFPA-54/ANSI- Z223.1 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

Page 9

7 - NEAR BOILER PIPING

7.1 Clean System First

Before system thoroughly. Verify system is free of sediment, ux and any residual boiler water additives.

Systems having antifreeze not recommended must be completely ushed to insure no old antifreeze remains. In older systems obviously discolored, murky or dirty water; or pH reading outside acceptable range (between 7.0 and

8.0) are indications system should be cleaned or treated. Thoroughly ush system with clean water to remove any sediment or contaminants. Sludge and iron oxide deposits can cause rapid breakdown of inhibitors.

Flushing with clean water. If chemical cleaners are used, use only those recommended for use with aluminum boilers. Follow chemical cleaner manufacturer’s instructions completely.

DO NOT

connecting boiler to heating system, clean and ush

mix different manufacturer’s products.

• When boiler installation is for new heating system, install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains.

• After all heating system piping and components have been installed, make nal connection of system piping to boiler.

• Hot water boiler installed above radiation level, or as required by the Authority having jurisdiction, must be equipped with low water cut off device. This boiler is factory equipped with manual reset probe type low water cutoff.

• Periodic inspection is necessary per low water cut off manufacturers specic instructions.

7.2 Supply & Return Lines

See Appendix A for piping examples.

• Packaged boiler set to receive 1¼” NPT return piping from rear of unit with option for left or right return connections.

• Use two furnished dielectric unions at boiler supply and return connections between copper system piping and boiler. Do not install copper supply and return piping directly into aluminum boiler casting due to galvanic corrosion between dissimilar metals.

• 1¼” NPT supply piping exits boiler jacket at top of unit.

• Some boilers supplied with circulator pump and isolation valves are furnished in a carton inside boiler cabinet and can be installed at installer preferred

location.

Page 10

7 - NEAR BOILER PIPING

GATE VALVE

REDUCED PRESSURE BACKFLOW PREVENTER

FEED WATER

PRESSURE REDUCING VALVE

AIR SCOOP

DIAPHRAGM TYPE EXPANSION TANK

SUPPLY PIPING

7.3

Safety Relief Valve / Temperature Pressure Gauge

WARNING

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

Installation of (supplied) safety relief valve shall conform to ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

• Install furnished safety relief valve using 3/4” pipe ttings provided with boiler. See Figure 2.

• Install safety relief valve with spindle in vertical position.

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

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

• 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).

Figure 2 - Safety Relief Valve Discharge Piping

Safety Relief Valve

Check local codes for maximum distance from oor.

FLOOR

Figure 3 -

Diaphragm Type Expansion Tank Piping

7.4 Expansion Tank & Make-up Water

• Determine required system ll pressure, system design temperature, and system water content.

• Boiler contains 2.6 gallons (US). Size expansion tank accordingly.

• Consult expansion tank manufacturer for proper sizing information. Connect properly sized expansion tank (not furnished) as shown in Figure 3 for diaphragm type expansion tank.

• Adjust tank air pressure on diaphragm type expansion tanks to match system ll pressure.

• Install air vent (furnished) as shown for diaphragm type expansion tank system only.

• Install make-up water connections as show.

• If pressure reducing valve is used, adjust to match system ll pressure.

• Verify clean water supply is available when connecting cold make-up water supply to boiler.

• Use sand strainer at pump if water supply is from well or pump.

Page 11

7 - NEAR BOILER PIPING

7.5 Condensate Drain Piping

Boiler is factory equipped with a condensate trap. Additional trap is not required and should NOT be used.

• Use supplied 1/2” PVC tee, transition to ½” pipe and ttings for PVC condensate drain line.

• The ½” diameter schedule 40 PVC or CPVC condensate drain and pipe ttings must conform to ANSI standards and ASTM D 1785 or D2846.

• Schedule 40 PVC or CPVC cement and primer must conform to ASTM D2564 or F493. In Canada, use CSA or ULC certied schedule 40 PVC drain pipe and cement.

• Condensate pump with reservoir (not furnished) to remove condensate to drain line (sanitary line) above boiler if oor drain is not available or is inaccessible.

7.6 Filling Condensate Trap with Water

On initial start up manually ll condensate trap with water. Following are steps required to initially ll condensate trap

for start up. Steps are only required at initial start up or if maintenance requires draining of condensate trap.

Remove vent drain line from CPVC vent pipe. Pour about 1 cup of cold tap water into vent drain line.

Excess water should go through overow and out through condensate drain line. Verify proper operation of drain line (or external condensate pump if used).

Reinstall vent drain line.

7.7 Chilled Water Piping

Install Boiler, when used in connection with refrigeration system, so chiller medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler.

Piping system of hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with ow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

Page 12

8 - COMBUSTION AIR AND VENT PIPE

8.1 Connections And Termination

Boilers for connection to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment” of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, or “Venting Systems and Air Supply for Appliances”, of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes.

Provisions for combustion and ventilation air must be in accordance with section, Air For Combustion and Ventilation, of the National Fuel Gas Code, ANSI 2223.1/ NFPA54, National Gas and Propane Installation Code, CAN/ CGA-B 149.1, in absence of such requirements to the Authority having jurisdiction.

Boilers require dedicated direct vent system. All air for combustion is taken directly from outdoors through combustion air intake pipe. All ue products are discharged to outdoors through vent pipe.

See Figures 5 and 6 for two pipe combustion air and vent pipe roof and sidewall termination. Roof termination is preferred. Combustion air and vent pipes must terminate together in same atmospheric pressure zone as shown.

Use of concentric vent termination see Figures 7-9for proper setup.

For Canadian installations all plastic venting material must be listed to ULC S636.

Construction through which vent and air intake pipes may be installed is maximum 24 inches, minimum ¼” thickness.

See Table 5 for combustion air and vent pipe ttings approved material and standards.

Canada construct all combustion air and vent pipes for this unit of ULC S636 listed schedule-40 CPVC, schedule-40 PVC, PVC-DWV or ABS-DWV pipe and pipe cement. SDR pipe is not approved in Canada.

• First 3 feet (900mm) of venting must be readily

available for visual inspection.

• Specied primers and glues of certied vent

system must be from single manufacturer, and not intermixed with other manufacturer’s vent system parts.

• Components of the certied system must not be

interchanged with other vent systems, or unlisted pipe and/or ttings.

Length of pipe is counted from end of supplied 2” CPVC pipe exiting boiler. Termination is not counted in “Total Equipment Length.”

TABLE 4

HDT

Material

PVC 158 70 – –

CPVC 210 100 – –

ABS 180 82 – –

°F °C °F °C

Maximum Allowable Temperatures

Of Typical Non-Metallic Vent Material

RTI

Standard

ASTM F 891 *

ASTM D2665 **

ASTM D1785 **

ASTM D2241 **

ASTM D2846 **

ASTM F441 **

ASTM F442 **

ASTM D2661 ***

ASTM F628 ***

* Allowable temperatures based on Classications covered in ASTM

D4396 [Deection Temperatures under Load (264psi) (1819 KPa)].

** Allowable temperatures based on Classications covered in ASTM

D1784 [Deection Temperatures under Load (264psi) (1819 KPa)].

*** Allowable temperatures based on Classications covered in ASTM

D3965 [Deection Temperatures under Load (264psi) (1819 KPa)].

Table 5 - Combustion air and vent pipe ttings

must conform with the following:

Item Material Standards

PVC schedule 40 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

ANSI/ASTM D1784/

F441

UL 1738

ULC S636-08

Vent Pipe

and Fittings

Pipe

Cement/

Primer

CPVC schedule 40

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

NOTICE

Transition from 2” pipe to 3” pipe must be made in vertical run.

Boiler combustion air and vent pipe connections are 2” but must increase to 3”. Due to potential for ue gas temperatures above 155°F, rst 30” of supplied vent pipe is CPVC while remaining vent pipe can be PVC. Any replacement of rst 30” of vent pipe must be made with

CPVC.

Covering non-metallic vent pipe and ttings with thermal insulation shall be prohibited.

• 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.

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 ue gas could result in death, or serious injury.

Page 13

8 - COMBUSTION AIR AND VENT PIPE

WARNING

Covering non-metallic vent pipe and ttings with thermal insulation shall be prohibited.

Allowable Vent and Air Intake Lengths

3” Pipe Min. Length 3” Pipe Max. Length

15 ft. equivalent length 100 ft. equivalent length

Length of pipe is counted from end of supplied 2” CPVC pipe exiting boiler. Termination is not counted in “Total Equivalent Length.”

Reduce maximum vent/air intake length by 5 feet per each 90° elbow.

Figure 4 - Combustion Air & Vent Piping

FIELD INSTALL 2” BY 3”

TRANSITION IN THE

VERTICAL POSITION

ONLY (2 REQ’D, NOT

FURNISHED)

2” (50.8MM)

COMBUSTION AIR

INTAKE PIPING

(FURNISHED)

Combustion air must be clean outdoor air. Do not take combustion air from inside structure because that air is frequently contaminated by halogens, which includes uorides, chlorides, phosphates, bromides and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, paints, adhesives, and other household products.

10.

Locate combustion air inlet as far away as possible from swimming pool and swimming pool pump house.

11.

All combustion air and vent pipes must be airtight and watertight.

12.

Pitch exhaust air piping back to boiler at minimum ¼” per foot from vent terminals so all moisture in vent piping drains to boiler. Pitch pipes with no sags or low spots where moisture can accumulate and block ow of ue gas.

13.

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

3” INTAKE AND

EXHAUST

TERMINATIONS

2” (50.8MM)

CPVC

VENT PIPING

(FURNISHED &

REQUIRED)

8.2 Vent/Air Intake Termination Location

Consider following when determining appropriate location for termination of combustion air and vent piping.

A. Position termination where vent vapors will not

damage plants/shrubs, air conditioning equipment, or siding on the house.

B. Position termination so it will not be effected by wind

eddy, air born leaves, snow, or recirculated ue gases.

C. Position termination where it will not be subjected to

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

D. Position termination where vent vapors are not

objectionable.

E. Put vent on wall away from prevailing winter wind.

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

F. Terminate vent above normal snow-line. Avoid locations

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

G. Under certain conditions, ue gas will condense,

forming moisture, and may be corrosive. In such cases, take steps to prevent building materials at vent from being damaged by exhaust of ue gas.

H. United States - Terminate vent system at least 4

feet (1.22 m) horizontally from, and in no case above or below, unless a 4 feet (1.22 m) horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.

I. Canada - Terminate vent system at least 6 feet

(1.83m) horizontally from, and in no case above or below, unless 6 feet (1.83m) horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.

J. Terminate venting system at least 3 feet (0.3m)

above any forced air inlet (except boiler’s combustion air inlet) within 10 feet (3m).

K. Terminate venting system at least 12 inches

(300mm) from any air opening into any building.

L. Locate bottom of vent at least 12 inches (300mm)

above grade.

M. Terminate vent not less than 7 feet (2.1m) above

adjacent public walkway.

N. Vent terminal shall not be installed closer than 3 feet

(0.9m) from inside corner of L shaped structure.

O. Termination of vent should be kept at least 3 feet

(0.9m) away from vegetation.

P. If multiple terminations are used, minimum of

12 inches (300 mm) between exhaust of one termination and air intake of next termination. See pages 14 & 15.

Q. All eld installed vent pipe must be 3”.

Page 14

8 - COMBUSTION AIR AND VENT PIPE

Figure 5 - Side Wall Vent / Intake terminations - Less Than 12” Clearance Above Grade

3” MIN

SEPARATION

Page 15

8 - COMBUSTION AIR AND VENT PIPE

Figure 6 -Roof Vent / Intake Terminations

3” MINIMUM

SEPARATION

Figure 7 - Concentric Vent Terminations

1" (26mm) Maximum

Combustion

Vent

Air

1" (26mm) Maximum

* See Note

Below

Combustion

Air

Roof Overhang

12" (300mm) Minimum

36"(915mm) Minimum

Maintain 12"(300mm)

Vent

clearance above highest

anticipated snow level or

grade

*Must be less than 4" (102mm) or greater than 24"(610mm) Horizontal distance between end bells of each air intake to prevent ue gas recirculation.

Page 16

8 - COMBUSTION AIR AND VENT PIPE

MAINTAIN 12 IN.

8.3 Installation

When transitioning from CPVC to PVC use Weld-On CPVC 724 or other cement approved for CPVC to PVC. In Canada

ULC S636 approved cement must be used.

Recommend all pipes be cut, prepared, and preassembled before permanently cementing any joint.

Rigid supports cause excess noise in vent piping.

Attach combustion air intake piping to supplied 2” piping on CVI gas valve. Attach vent piping to furnished 2” CPVC preformed exhaust pipe. Use 2” x 3” adapter in vertical position on both air intake and vent pipe.

All pipe joints are to be water tight.

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

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

Chamfer outside edge of pipe for better distribution of primer and cement.

Clean and dry all surfaces to be joined.

Check dry t of pipe and mark insertion depth on pipe.

10.

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

11.

While cement is still wet, insert pipe into socket with ¼ turn twist. Be sure pipe is fully inserted into tting socket.

12.

Wipe excess cement from joint. Continuous bead of cement will be visible around perimeter of properly made joint.

13.

Handle pipe joint carefully until cement sets.

14.

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

15.

Slope combustion air and vent pipes toward boiler minimum of ¼” per linear foot with no sags between hangers.

16.

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

Figure 8 - Concentric Vent w/ Dimensions

Dimension

D E F

4½” Dia.

³⁄16

46¾”

31⅞”

”

Dimension

3” Diameter PVC

Vent/Exhaust

Intake/Combustion Air

1½”

3” Diameter PVC

Figure 9 - Concentric Vent Roof Installation

Page 17

9 - GAS SUPPLY PIPING

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 re department.

9.1 Check Gas Supply

TABLE 6: GAS SUPPLY PRESSURE

Natural Gas 4” min. w.c. 10” max. w.c.

LP Gas 10” min. w.c. 14” max. w.c.

Check line pressure while unit is running in high re mode.

• Gas pipe to boiler must be correct size for length of run and total Btuh input of all gas utilization equipment connected to it.

• Verify your gas line complies with local codes and gas company requirements.

• Disconnect boiler and its individual shutoff valve from gas supply piping system during any pressure testing of system at test pressures in excess of ½ psig (3.5kPa).

• Isolate boiler from gas supply piping system by closing its manual shutoff valve during any pressure testing of gas supply piping system at test pressures equal to or less than ½ psig (3.5kPa).

• For proper boiler operation line pressure should be within minimum and maximum values in Table 6.

• Gas line enters boiler through left side panel. See page 2 Dimensions and Figure 10.

See Table 7

for proper size.

9.2 Connecting Gas Piping

Boiler is equipped with ½” NPT connection on gas valve for supply piping and ½” NPT ball valve for manual shut off. Following rules apply:

Use only those piping materials and joining methods listed as acceptable by the authority having jurisdiction, or in the absence of such requirements,

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

• Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1.

Use pipe joint compound suitable for liqueed petroleum gas on male threads only.

Refer to Figure 10 for general layout, which shows basic ttings needed. As shipped, gas line enters boiler through right side, as an option, it can be routed through either rear or left side panel.

Use ground joint unions.

Install sediment trap upstream of gas controls.

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

Install manual shutoff valve in vertical pipe about 5’ above oor outside boiler jacket in addition to shutoff valve supplied with boiler.

Tighten all joints securely.

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

10.

Two stage regulation should be used by propane installer.

11.

Propane gas piping should be checked by propane installer.

TABLE 7: GAS PIPING SIZES

Natural Gas

Pipe Length

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

Pipe Length

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

The length of pipe or tubing should be measured from the gas meter or propane second stage regulator.

Pipe Capacity - BTU/Hr. Input Includes Fittings

½” ¾” 1” 1¼”

LP Gas

Pipe Capacity - BTU/Hr. Input Includes Fittings

Copper Tubing (O.D.) Iron Pipe

⅝” ¾” ½” ¾”

Page 18

9 - GAS SUPPLY PIPING

1/2” GAS CONNECTION

*NOTE: 3/4” GAS SUPPLY TO BOILER JACKET REQUIRED TO FEED THE BOILER.

DANGER

Figure 10 - Gas Piping

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

9.3 Leak Check Gas Piping

After making gas connections, open manual shutoff valve(s) and check all gas connections for leaks before placing boiler in operation.

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

Correct leaks immediately and retest.

Page 19

10 - ELECTRICAL WIRING

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.

10.1 Codes

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

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

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

10.2 Line Voltage Connections

Connect 120 VAC power wiring to line voltage terminal strip on boiler control panel.

Provide and install fused disconnect or service switch (15 amp recommended) as required by code.

Boiler circulator is shipped loose. Wire boiler circulator as shown in wire diagram label on boiler side panel. (CH L1, CH L2) CH = Central Heat

When connecting DHW circulator, connect wiring to line voltage terminal strip on boiler control panel. (DHW L1, DHW L2) DHW = Domestic Hot Water

Route all wires and conduits to openings in right jacket panel.

10.3 Line Voltage Monitor

• Boiler is factory equipped with line voltage monitor that continuously monitors incoming voltage for errors.

• When incoming line voltage is greater than 12% or less than 8% of nominal voltage monitor will ash indicating fault.

• 6 Seconds after line voltage is back within acceptable range green light will illuminate on monitor and boiler will restart. Line voltage monitor is factory set at 115 VAC.

It is important that monitor be set to voltage present at installation site by following these directions:

Using multimeter, locate wall outlet nearest to boiler and determine line voltage present on site.

Disconnect power to boiler.

Remove boiler cover.

Locate line voltage monitor mounted to display panel.

Remove line monitor protective cover.

Using small screwdriver turn left dial until arrow points at input voltage measured during step 1.

Set right dial at 0.1 minute, this is factory setting.

Reinstall line monitor protective cover.

Replace boiler cover and re-connect power to unit.

Figure 11 - Line Voltage Monitor

L1 L2

10.4 Low Voltage Connections

Connect low voltage wiring to low voltage terminal strip as shown in boiler wiring diagram.

Route all low voltage wires through opening on right jacket panel. Use shielded cable.

NOTICE

Use only N.E.C. Class 1 wiring. If replacing original boiler wiring, use only type 105°C wire or equivalent.

See Piping and Wiring Appendix for wiring and piping diagrams.

Page 20

10 - ELECTRICAL WIRING

10.6 Thermostat

Connect room thermostat or end switch (isolated contact only) between terminals T1 and T2.

Install thermostat on inside wall away from inuences of drafts, hot or cold water pipes, lighting xtures, televisions, sun rays, or replaces.

Thermostat anticipator (if applicable)

A. Set for 0.1 amps if connected directly to boiler. B. Set to match total electrical power requirements of

connected devices if connected to relays or other devices. See device manufacturers’ specications and thermostat instructions for details.

10.7 Outdoor Temperature Sensor

Connect outdoor temperature sensor between terminals A1 and A2 to enable outdoor reset operation of the boiler. If xed temperature operation is required, do not install outdoor sensor.

Mount sensor on exterior wall, shielded from direct sunlight or ow of heat or cooling from other sources.

If desired, install a summer/winter switch across terminals A1 and A2. When the switch is closed, the boiler (space heating) circulator is disabled.

Route sensor wires through the holes provided on the right jacket panel of the boiler.

AVOID THE FOLLOWING

Dead Spots

Cold Spots

Hot Spots

Corners Alcoves Behind doors

Concealed pipes or ducts Stairwells - drafts Unheated rooms on the other side

of the wall

Concealed pipes Fireplaces TVs or radios Lamps Direct sunlight Kitchens

10.8 DHW Limit Control

Connect storage indirect water heater (DHW) limit control between terminals DHW T1 and DHW T2.

See Piping and Wiring Appendix for wiring and piping diagrams.

Page 21

11 - CONTROLS AND ACCESSORIES

Refer to Repair Parts Manual for illustrations, and Control Manual and Troubleshooting Guide for detailed sequence of operation and troubleshooting guide.

11.1 Aluminum Heat Exchanger

• Monoblock design cast aluminum heat exchanger eliminates need for mating sections eliminates leaks between sections.

• Cast aluminum has better heat transfer properties which leads to higher efciency and cooler exhaust temperatures.

• Cooler exhaust temperatures create condensation of ue gas, which would cause corrosion in traditional cast iron heat exchangers.

11.7 Gas/Air Mixer

Venturi design of gas/air ensures correct mixture of air and gas.

11.8 Modulating Burner

Burner is designed to operate over full range of input. Burner can operate under normal (blue ame) and infrared

conditions.

11.9 Direct Spark Igniter (DSI)

11.2 Main Power Switch

Main power switch is located on the display panel. Main power switch is illuminated when receiving power and in ON position.

11.3 Modulating Boiler Control

Integrated modulating control senses load necessary to heat structure and therefore uses less fuel than conventional xed ring rate boiler when there is lower than peak demand for heat.

Control senses supply water, return water, and outside air temperatures. If outside air sensor is connected and calculates load on system it adjusts ring rate to deliver amount of heat needed at that particular time.

Boiler uses DSI to ignite fuel/air mixture in combustion chamber and sense ame during operation. DSI is durable, reliable, and resists breakage.

11.10 Manual Reset Low Water Cut Off

11.4 NTC Sensors

NTC sensors measure supply water, return water, and outside air temperature. Congured to operate with modulating boiler control.

11.11 Normally Closed LWCO Switch

11.5 Modulating Blower

• Modulating blower provides introduction of gas/air mixture through burner and into combustion chamber then out exhaust vent where combustion products are discharged to outdoors.

• Blower is designed to communicate with modulating control to run at variable speeds dependent on heating system heat load.

• Variable speeds create pressures felt by gas valve and gas/air mixer that dictate how much fuel is introduced

to combustion process.

11.12 High Limit Control

11.6 Gas Control Valve

• Boiler gas controls have been developed for domestic heating appliances with premix burners and automatic direct burner ignition and are suitable for natural and LP gas.

• Gas controls perform all functions required to safely regulate gas ow to main burner of boiler.

• Gas valve is directly connected to gas/air mixer.

• Installed integral low water cut off (LWCO) must be manually reset if there is a low water condition.

• LWCO senses water through probe at boiler top that sends signal through water to ground. If the signal is not sensed LWCO enters lockout mode that disables boiler.

• LWCO in normal mode illuminates red indicator light on LWCO panel in boiler.

• During low water condition, red light goes out and LWCO and control reset buttons on display panel must be pressed to reset LWCO.

• Round button switch located next to digital display is normally closed and spring loaded, when depressed will open, when pressure is removed closes.

• Switch is used as manual reset for LWCO. LWCO will remain in lockout when tripped until water level reaches probe and switch is pressed to open state and then released to closed state, which sends signal to LWCO to resume normal operation.

• Boiler control reset button must then be pressed to reset from low water condition. LWCO switch and control reset button are located on boiler panel display.

• High limit control is safety limit control provides protection for boiler and heating system from unsafe operating conditions which could damage the boiler.

Page 22

11 - CONTROLS AND ACCESSORIES

• High limit control is mounted in ½” NPT control well and ¾” X ½” bushing on top of front boiler section at hot water outlet.

• High limit control is tied in with boiler control and is factory set at 180°F (82°C) water temperature.

• High limit setpoint is eld adjustable and may be set anywhere between 100°F (38°C) and 180°F (82°C), with maximum high limit setpoint not exceeding 180°F (82°C). Field high limit setpoint adjustment for each installation depends on heating system requirements.

• High limit control automatically resets when boiler water temperature decreases below high limit setpoint value by differential setpoint value. 5°F (3°C) to 30°F (17°C).

• Boiler operating temperature (temperature curve) is calculated and set in boiler control parameters.

Adjustable differential from

11.13 Casting Temperature Safety Switch

• Casting temperature safety switch, 230°F (110°C) setpoint, shuts off power to boiler control in event of boiler lack of or loss of water.

• Casting temperature safety switch is installed on top of aluminum boiler section behind supply piping.

• Failure code is displayed on digital readout. Fault requires manual reset of casting temperature safety switch to restart boiler. Press reset on user interface panel also.

• Verify boiler is properly lled with water and no air is trapped in top of casting (check cap on Cam Vent at heat exchanger) before resetting.

WARNING

Burn and scald hazard. Never run cold water into a hot, empty boiler. Failure to follow these instructions could result in death or serious injury

11.15 Blocked Vent Safety Assembly

Blocked vent safety assembly incorporates two pressure switches designed to discontinue operation of boiler if there is a problem with blower or venting system.

The normally open switch closes upon initiation of blower and functions as air proving switch.

The normally closed switch opens if there is a blockage in combustion air intake or exhaust vent pipes.

11.16 Drain Valve

Manual drain valve drains water in heating system, including boiler, hot water supply and return piping systems installed above drain valve.

Drain valve is installed in return piping at bottom front of boiler section. Any piping installed below elevation of drain valve requires additional drain valves to be installed at low points in piping system in order to drain entire system.

WARNING

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

11.17 Safety Relief Valve

• Each boiler must have a properly sized and installed American Society of Mechanical Engineers (ASME) rated safety relief valve.

• Furnished safety relief valve automatically opens at 30 psig

pressure to relieve strain on boiler and heating

system from increasing pressure.

• Pipe Safety relief valve discharge with same size pipe as valve discharge opening to open drain, tub or sink, or other suitable drainage point not subject to freezing.

11.14 Circulator Pump

• Circulating pump moves water through closed loop supply and return piping systems, terminal heating equipment (nned tube radiators, etc.) and back through boiler for reheating.

• Properly size circulator pump to overcome frictional losses (usually measured in feet of water, also referred to as “pump head loss”) of supply and return piping systems and boiler to provide required hot water ow rates.

• Circulator pump is furnished in carton within boiler cabinet.

• Locate circulator(s) on downstream (“pumping away”) side of expansion tank.

11.18 External Condensate Pump (optional)

For installations where there is no oor drain or other appropriate drainage receptacle available to receive condensate from boiler, external oat activated condensate pump with integral sump is required. Condensate pump can be piped to remote tie in point to sanitary sewer system. For this application, boiler must be installed so that proper pitch of piping to external condensate reservoir (sump) can be accomplished. Use wood frame or concrete blocks to raise boiler as required for proper installation.

11.19 Concentric Vent/Air Intake Termination (Optional)

Optional concentric vent/air intake termination utilizes single opening per each appliance through wall or roof of structure.

Page 23

12 - BOILER STARTUP

Water Treatment And Freeze Protection - See Appendix B

12.1 Filling Boiler With Water And Purging Air

Systems With Diaphragm Type Expansion Tanks

A. Close all zone service valves on supply and return

piping. Open feed valve and ll boiler with water. Verify air vent is open. Hold relief valve open until water runs air free for ve seconds to rapidly bleed air from boiler, then let relief valve snap shut.

B. Open zone service valve on supply pipe for rst

zone. Open purge valve on rst zone. Feed water will ll zone, pushing air out purge valve. Close purge valve when water runs air free. Close zone service valve.

C. Repeat step 2 for all remaining zones. D. Open all service valves. Any air remaining trapped

in return lines between service valves and boiler will be pushed towards air vent when boiler is placed in operation.

E. Inspect piping system and repair any leaks

immediately.

Systems With Conventional Closed Type Expansion Tanks

A. Close all zone service valves on supply and return

piping and close expansion tank service valve. Drain expansion tank. Open feed valve and ll boiler with water. Hold relief valve open until water runs air free for ve seconds to rapidly bleed air from boiler, then let relief valve snap shut.

B. Open zone service valve on supply pipe for rst

zone. Open purge valve on rst zone. Feed water will ll zone, pushing air out purge valve. Close purge valve when water runs air free. Close zone service valve.

C. Repeat step 2 for all remaining zones. D. Open expansion tank service valve and tank

vent. Fill tank to proper level and close tank vent. Remove handle from expansion tank service valve so it is not accidentally closed.

E. Open all service valves. Any air remaining trapped

in return lines between service valves and boiler will be pushed towards expansion tank when boiler is placed in operation.

F. Inspect piping system. Repair any leaks immediately.

NOTICE

Do not use stop leak compounds. Repair leaks in threaded connections of aluminum boiler sections. Aluminum threads do not seal themselves.

Page 24

13 - OPERATING INSTRUCTIONS

13.1 Lighting Instructions

For Your Safety Read Before Operating!!

WARNING

If you do not follow these instructions

exactly, a 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 oor because some gas is heavier than air and will settle to the 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 qualied service technician. Force or attempted repair may result in re or explosion.

• Do not use this appliance if any part has

been under water. Immediately call a qualied

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

Stop! Read Safety information above.

13.2 Operating Instructions

Set thermostat to lowest setting.

Turn off all electrical power to appliance.

Boiler does not have a pilot. It is equipped with ignition device which automatically lights burner. Do not try to light this burner by hand!

Remove front jacket panel.

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

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

Turn gas ball valve to “on” position. Handle on valve should be parallel to gas pipe. See Figure 12.

Replace front jacket panel.

Turn on all electrical power to appliance.

10.

Set thermostat to desired setting.

11.

If boiler will not operate, follow instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switches; do not use any 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 re department.

13.3 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 ball valve off, handle should be perpendicular to gas pipe.

Replace front jacket panel.

Figure 12 - Gas Valve

Control Valve “ON”

Control Valve “OFF”

Page 25

14 - MAINTENANCE AND CLEANING

Acidic nature of ue gases condensing on aluminum boiler sections cause formation of aluminum oxide. This oxide formation is normal, and represents negligible mass of aluminum consumed by oxidation during life of boiler. If left unchecked, this buildup may eventually cause blockage of ue gas passages in boiler sections, reducing efciency, and ultimately shutting boiler down due to lack of combustion air ow, or drainage of condensate.

14.2 Daily During Heating Season

14.3 Monthly During Heating Season

Regular service and maintenance by qualied service

agency must be performed at least once every 12 months to assure safe, trouble free operation and

maximum efciency.

14.1 Beginning of each heating season

Schedule annual service call by qualied service agency which includes:

• Examine ue passages in heat exchanger, burner, and condensate lines, and clean (if necessary) follow instructions in “Annual Examination and Cleaning of Boiler Components” page 26.

• Inspect venting and air intake system for proper operation, immediately repair or replace any sign of deterioration or leakage, and verify proper reassembly and resealing of system.

• Check for and remove any obstruction to ow of combustion air or venting of ue gases.

• Follow “Operating Instructions” Section 13. Follow “Boiler Startup” Section 5 and “Checkout Procedures And Adjustments”, section 6 of Control Manual and Troubleshooting Guide.”

• Inspect condensate drain line for proper operation. Check for deteriorated or plugged condensate drain line.

• Check all gasketed joints for leakage. Tighten bolts or replace gaskets as needed.

• Remove jacket front and top panels, check for piping leaks around safety relief valve and other ttings, and repair if found. Do not use stop leak compounds.

Verify boiler area is free from combustible materials, gasoline, and other ammable vapors and liquids.

Circulator pump and blower fan motor furnished with boiler are permanently lubricated from factory and require no further lubrication. Additional or non-factory supplied pumps and/or motors should be lubricated according to pump and/or motor manufacturer’s

instruction.

Check for and remove any obstruction to ow of combustion air or venting of ue gases.

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

Remove jacket front and top panels and check for piping leaks around safety relief valve and other ttings. If found, contact qualied service agency. DO NOT use stop leak compounds.

Test safety relief valve. Refer to valve manufacturers instructions packaged with safety relief valve.

Visually inspect venting and air intake system for proper operation. If vent or air intake show any signs of deterioration or leakage, contact qualied service agency to repair or replace them immediately and to insure proper reassembly and resealing of system.

Visually inspect condensate drain pipe for proper operation. If drain pipe shows any signs of blockage, leakage, or deterioration contact qualied service agency to clean, repair, or replace it immediately.

Check air vent(s) for leakage. Periodic inspection of low water cut off is necessary,

including ushing of oat type devices. Refer to low water cut off manufacturer’s specic instructions.

Page 26

14 - MAINTENANCE AND CLEANING

WARNING

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

NOTICE

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

NOTICE

Verify proper operation after servicing.

14.4 Annual Shut Down Procedure

Turn off gas to boiler as described in “To Turn Off Gas To Appliance” Section 13.3 page 24.

If heating system is to remain out of service during freezing weather and does not contain antifreeze, drain system completely. If boiler will be exposed to freezing

temperatures, drain condensate lines.

14.5 Annual Examination And Cleaning Of Boiler Components

Following service procedures must be performed by qualied service agency. Boiler owner should not attempt these steps.

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

Examine ue passages by removing blower/burner assembly from casting. Procedure for examining and cleaning the burner is described below.

Clean any buildup of sediment or aluminum oxide (white powdery or aky substance) in ue passages as follows

A. Remove jacket front and top panels. B. Conrm manual gas valve is closed and disconnect

gas line to gas valve at union. Disconnect pressure switch hoses to gas valve and air inlet.

C. Disconnect wires to gas valve and igniter. D. Loosen but do not remove ve nuts attaching

blower adapter assembly to boiler.

E. Remove two igniter screws and carefully remove

igniter.

F. Remove ve nuts and remove blower adapter

assembly, burner, and gaskets.

G. Aluminum oxide deposits are water soluble and

may be rinsed away by inserting hose into burner opening of casting and slowly run water through ue side of boiler and out condensate drain. Debris rinsed away by this method will exit through condensate drain. Be wary of drain lines getting clogged and causing water to back up in the bottom of casting.

H. Use exible handle nylon brush to loosen sediment

and aluminum oxide on all accessible heating surfaces of boiler. Take care not to get brush stuck in heat exchanger.

I. After brushing and rinsing, remove any remaining

loosened sediment using shop vacuum with snorkel attachment.

J. Inspect burner for any foreign matter in ame

ports or inside burner. Remove any foreign matter by blowing with compressed air or vacuuming. If burner cannot be cleaned, it must be replaced.

K. Reinstall burner and gaskets and position blower

adapter assembly over studs. Install ve nuts do not tighten. Reinstall igniter and igniter gasket and fasten with two screws. Tighten ve nuts

holding blower adapter assembly.

L. Connect gas line to gas valve, pressure switch hose

to gas valve and air inlet assembly, igniter wires, and gas valve wires.

Inspect condensate trap. Clean out any foreign material visible in condensate lines.

A. Inspect for sediment or blockage. B. Flush out with water or vacuum. C. Follow instructions in, “Filling Condensate Trap With

Water.”

Inspect ue connector. A. Loosen clamp on vent tee side of 2” exible

coupling that connects vent tee to exhaust port.

B. Inspect interior of vent tee. Clean any buildup of

sediment on inside surface.

C. Reconnect 2” exible coupling to vent tee.

Page 27

APPENDIX A - BOILER PIPING AND WIRING

Electrical Wiring Diagram

Page 28

APPENDIX A - BOILER PIPING AND WIRING

Boiler Control Wiring Diagram: Single Zone System With Domestic Hot Water Priority

BOILER CONTROL PANEL

T-STAT

CH T1

CH T2

DHW T1

DHW T2

OUTDOOR

AIR SENSOR

CH C1

CH C2

DHW C1

DHW C2

Note: CH & DHW Circulator connections on boiler only

support pump with 1 amp rating or less.

120 VAC

CIRC

DHW CIRC

Page 29

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 1: Single Zone System With Domestic Hot Water Priority

NOTE: NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS

Wiring Diagram 1 : Single Zone System With Domestic Hot Water Priority

Hotline indirect water heater

aquastat or thermostat

Boiler Control Panel

CH T1

CH T2

DHW T1

DHW T2

CH C1

CH C2

DHW C1

DHW C2

AR822-II

AR822-TT

T-STAT

ELECTRONIC FUSE

TORQUE TERMINAL

6 TO 7 INCH LBS

W CT5

CIRCUIT ON

SCREWS

24V

6 6

120

VAC

OUTDOOR

AIR SENSOR

DHW CIRC

L2 N

L1 (HOT)

CH CIRC

120V AC

Page 30

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 2 :

Multizone Piping With Zone Valves And Domestic Hot Water Priority (With Zone Valve)

NOTE: NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS

Page 31

APPENDIX A - BOILER PIPING AND WIRING

Wiring Diagram 2:

Multizone Wiring With Zone Valves And Domestic Hot Water Priority (With Zone Valve)

24VAC 40 VA

TRANSFORMER

SWITCH LEGEND

ON OFF

Yellow

Black

White

24VAC

X X

LINE IN

120 VAC

N L N L N L ZR ZC

PRIMARY

PUMP

PRIORITY

PUMP

ARGO AZ-4CUP

CONTROL

STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON

FROM BOILER

TANK

CONTROL

INDIRECT WATER

HEATER AQUASTAT

OR THERMOSTAT

T-STAT

T T T T T T T T

ZC ON

OPTION SWITCH

T-STAT

ZONE VALVE/PUMP

PRIORITY

ZR-ZC

DPM-2

Boiler Control Panel

CH T1

CH T2

DHW T1

DHW T2

CH C1

CH C2

DHW C1

DHW C2

120 VAC

AZ-4CP

CH & DHW SYSTEM CIRCULATOR

PRI ZONE

1 2 3 4

BLACK

SWITCH

MOTOR

21 3 4

JUMPER

END

4 WIRE ZONE

VALVE ONLY

ZONE 2

1 2 3 4

ZONE 3

1 2 3 4

1 2 3

DO NOT USE

SPARCO TACO TYPE

B&G COMFORT-TROL,

ZONE 4

1 2 3 4

Note: Install wire jumper between

BLACK

MOTOR

RED

BLACK

RED

END

SWITCH

terminals 3 and 4 when using zone valves without an end switch.

ZONE VALVE

SUPERIOR TYPE

HONEYWELL, ERIE

Page 32

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 3 : Multizone System With Zone Valves And Domestic Hot Water Priority (With Circulator)

NOTE: NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS

Page 33

APPENDIX A - BOILER PIPING AND WIRING

Wiring Diagram 3: Multizone System With Zone Valves And Domestic Hot Water Priority (With Circulator)

TRANSFORMER

Boiler Control Panel

CH T1

CH T2

DHW T1

DHW T2

CH C1

CH C2

DHW C1

DHW C2

24VAC 40 VA

120 VAC

SWITCH LEGEND

ON OFF

Yellow

Black

White

24VAC

X X

LINE IN

120 VAC

N L N L N L ZR ZC

PRIMARY

PUMP

AZ-4CP

CIRCULATOR

ARGO AZ-4CP

CONTROL

PRIORITY

PUMP

DWH

CIRCULATOR

STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON

FROM BOILER

CONTROL

OR THERMOSTAT

INDIRECT WATER

TANK

HEATER AQUASTAT

T-STAT

T T T T T T T T

ZC ON

JUMPER

END

ZONE 2

1 2 3 4

4 WIRE ZONE

VALVE ONLY

ZONE 3

1 2 3 4

1 2 3

DO NOT USE

B&G COMFORTROL,

SPARCO TACO TYPE

PRI ZONE

1 2 3 4

BLACK

SWITCH

MOTOR

21 3 4

T-STAT

ZONE VALVE/PUMP

PRIORITY

ZR-ZC

DPM-2

OPTION SWITCH

1 2 3 4

BLACK

MOTOR

ZONE VALVE

ZONE 4

BLACK

RED

SWITCH

SUPERIOR TYPE

HONEYWELL, ERIE

END

Note: Install wire jumper between terminals 3

RED

and 4 when using zone valves without an end switch.

ZONE VALVE

Page 34

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 4: Multizone System With Circulators And Domestic Hot Water Priority

NOTE: NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS

Page 35

L1 (HOT)

APPENDIX A - BOILER PIPING AND WIRING

Wiring Diagram 4: Multizone System With Circulators And Domestic Hot Water Priority

Hotline indirect water heater

aquastat or thermostat

NOTE: IN PLACE OF 115

VOLT ISOLATION RELAY,

OPTIONAL CONTROL

ARGO AR822II

TERMINAL 5 & 6 N.O. TO DHW T1 & DHW T2

TORQUE TERMINAL

ELECTRONIC FUSE

R W

CIRCUIT ON

SCREWS

6 TO 7 INCH LBS

24V

C 5 6NO6

AR822-TT

T-STAT

THERMOSTATS

ZONE 2

TRT

DATA PORT

X-X

ZR-ZC

PRIORITY

ZONE

ZONE 3

T-STAT

ZONE 4

TO EXTRA

ZONE MODULE

COMMON

24 VAC

@ 1VA

120

VAC

L1 & L2 TO ARM L & N ON PRIORITY ZONE

OUTDOOR

AIR SENSOR

NO4NC

ARM-4P

CONTROL WITH

PRIORITY

X X

ISOLATED

SWITCH

ZONE 1

ZONE 2

L1N

L2N L N

ZONE 2

ZONE 3

ZONE 4

PRIORITY ON

ZONE 4

L N

120 VAC

CIRC 2

CIRC 3

CIRC 4

115 V COIL / ISOLATION RELAY

NORMALY OPEN

Boiler Control Panel

CH T1

CH T2

DHW T1

DHW T2

CH C1

CH C2

DHW C1

DHW C2

DHW CIRC

L2 N

120V AC

Page 36

MAX = 4 X DIAMETER

CLOSELY - SPACED TEES

BOILER PUMP

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 5 : Primary/Secondary Piping With Circulators And Domestic Hot Water

*SEE NOTE

NOTE: RECOMMENDED FOR ANTIFREEZE APPLICATIONS

Page 37

APPENDIX A - BOILER PIPING AND WIRING

Wiring Diagram 5 : Primary/Secondary Wiring With Circulators And Domestic Hot Water

INDIRECT HOT WATER HEATER

NOTE: IN PLACE OF 115 VOLT ISOLATION RELAY, OPTIONAL CONTROL ARGO AR822II

TERMINAL 5 & 6 N.O. TO DHW T1 & DHW T2

TORQUE TERMINAL

R W

ELECTRONIC FUSE

CIRCUIT ON

SILKSCREEN

SCREWS

6 TO 7 INCH LBS

24V

C 5 6NO6

2.7K

L2NO4NC4

120

VAC

AR822-TT

15 VA

L1 & L2 TO ARM L & N ON PRIORITY ZONE

1.2K

AQUASTAT OR THERMOSTAT

DATA PORT

X-X

ZR-ZC

PRIORITY

ZONE

ZONE 1

T-STAT

THERMOSTATS

ZONE 2

T-STAT

ZONE 3

WTR

ZONE 3ZONE 2

T T

T-STAT

ZONE 4

PRIORITY ON

COMMON

24 VAC

@ 1VA

TO EXTRA

ZONE MODULE

AR822-II

AR822-TT

L2 N

120V AC

L1 (HOT)

ARM-4P

CONTROL WITH

PRIORITY

X X

ISOLATED

SWITCH

L1N

ZRZC

N2L N3L

L N

ZONE 4ZONE 3ZONE 2

120 VAC

CIRC 2

CIRC 3

TORQUE TERMINAL

T T

R W

ELECTRONIC FUSE

6 TO 7 INCH LBS

CIRCUIT ON

120

VAC

SCREWS

24V

5 6NO6

NO4NC

Boiler Control Panel

115 V COIL / ISOLATION RELAY

CH T1

CH T2

DHW T1

DHW T2

OUTDOOR

AIR SENSOR

CH C1

CH C2

DHW C1

DHW C2

NORMALY OPEN

DHW CIRC

CIRC 4

BOILER CIRC (WILL RUN FOR ALL CH AND DHW CALLS FOR HEAT)

Page 38

ZONE 1 (PRIORITY ZONE)*

* USE FULL PORT ZONE

VALVE.

FOR OPTIMUM TANK

PERFORMANCE,

CONSIDER USING ZONE

CIRCULATOR.

BOILER

PUMP

MAX = 4 X DIAMETER

CLOSLEY - SPACED

TEES

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 6 : Primary/Secondary Multizone System Piping With Zone Valves And Domestic Hot Water (With Zone Valve)

NOTE: RECOMMENDED FOR ANTIFREEZE APPLICATIONS

*SEE NOTE

Page 39

APPENDIX A - BOILER PIPING AND WIRING

Wiring Diagram 6 : Primary/Secondary Multizone System Wiring With Zone Valves And Domestic Hot Water (With Zone Valve)

AR822-TT

L1/3 FACTORY

INSTALLED

JUMPER

TRANSFORMER

24VAC 15 VA

R W

CIRCUIT ON

24V

C 5 6 6

24VAC

120 VAC

RELAY

N.O. N.C.

N.O.

N.C.

SWITCH LEGEND

ON OFF

24VAC 40 VA

TRANSFORMER

*SYSTEM

CIRC

Yellow

Black

White

120 VAC

N L N L N L ZR ZC

PRIMARY

PUMP

X X

AZ-4CP

INDIRECT WATER

HEATER AQUASTAT

OR THERMOSTAT

ARGO AZ-4CP

CONTROL

PRIORITY

PUMP

STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON

FROM BOILER

TANK

CONTROL

T-STAT

T T T T T T T T

ZC ON

JUMPER

END SWITCH

ZONE 2

1 2 3 4

4 WIRE ZONE

VALVE ONLY

DO NOT USE

OUTDOOR

AIR SENSOR

ZONE 3

1 2 3 4

1 2 3

SPARCO TACO TYPE

B&G COMFORT-TROL,

PRI ZONE

1 2 3 4

BLACK

MOTOR

21 3 4

OPTION SWITCH

ZONE VALVE

Boiler Control Panel

CH T1

CH T2L1L2

DWH T1

DHW T2

T-STAT

ZONE VALVE/PUMP

PRIORITY

ZR-ZC

DPM-2

ZONE 4

1 2 3 4

RED

BLACK

RED

END

MOTOR

SWITCH

ZONE VALVE

SUPERIOR TYPE

HONEYWELL, ERIE

CH C1

CH C2

DHW C1

DHW C2

Note: Install wire jumper between terminals 3 and 4 when using zone valves without an end switch.

*BOILER

CIRC

*BOTH CIRCULATORS WILL RUN

WITH ANY CALL FOR HEAT.

120 VAC

Note: a priority loop zone valve is used with this conguration

Page 40

ZONE VALVE

MAX = 4 X DIAMETER

CLOSELY - SPACED

TEES

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 7 :

Primary/Secondary Piping With Zone Valves And Domestic Hot Water (With Circulator)

*SEE NOTE

NOTE: RECOMMENDED FOR ANTIFREEZE APPLICATIONS

Page 41

APPENDIX A - BOILER PIPING AND WIRING

Wiring Diagram 7 : Primary/Secondary Piping With Zone Valves And Domestic Hot Water (With Circulator)

INDIRECT WATER

SWITCH LEGEND

ON OFF

HEATER AQUASTAT

OR THERMOSTAT

TANK

CONTROL

AR822-II

L1/3 FACTORY

INSTALLED

JUMPER

TRANSFORMER

24VAC 15 VA

R W

CIRCUIT ON

24V

C 5 6 6

24VAC

120 VAC

RELAY

N.O. N.C.

N.O.

N.C.

24VAC 40 VA

TRANSFORMER

Yellow

Black

White

120 VAC

N L N L N L ZR ZC

PRIMARY

PUMP

X X

AZ-4CP

ARGO AZ-4CP

CONTROL

PRIORITY

PUMP

STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON

FROM BOILER

T-STAT

T T T T T T T T

ZC ON

JUMPER

ZONE 2

1 2 3 4

4 WIRE ZONE

VALVE ONLY

1 2 3 4

1 2 3

DO NOT USE

B&G COMFORT-TROL,

Boiler Control Panel

CH T1

CH T2L1L2

DWH T1

CH C1

DHW T2

CH C2

DHW C1

DHW C2

ZONE 3

SPARCO TACO TYPE

PRI ZONE

1 2 3 4

BLACK

END

MOTOR

SWITCH

21 3 4

OUTDOOR

AIR SENSOR

OPTION SWITCH

ZONE VALVE

T-STAT

ZONE VALVE/PUMP

PRIORITY

ZR-ZC

DPM-2

ZONE 4

1 2 3 4

RED

BLACK

RED

END

MOTOR

SWITCH

ZONE VALVE

SUPERIOR TYPE

HONEYWELL, ERIE

Note: Install wire jumper between terminals 3 and 4 when using zone valves without an end switch.

CIRC

DHW CIRC

*BOILER

CIRC

*BOILER CIRCULATOR WILL RUN WITH ALL CALLS FOR HEAT.

120 VAC

Note: a priority loop zone valve is used with this conguration

Page 42

BOILER

WATER INLET

ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM

FROM SYSTEM

EXPANSION

TANK

BOILER

ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM

FROM SYSTEM

V2V1

EXPANSION

TANK

WATER INLET

SYSTEM

CIRCULATOR

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 8 : Bypass Piping (Automatic Mixing Valve)

Piping Diagram 9 : Bypass Piping (Fixed Low Temp Only)

Page 43

BOILER

ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM

FROM SYSTEM

WATER INLET

EXPANSION

TANK

12” MAX12” MAX

TO SYSTEM FROM SYSTEM

ALTERNATE

CIRCULATOR

LOCATION

ALTERNATE

CIRCULATOR

LOCATION

BOILER

EXPANSION TANK

WATER INLET

APPENDIX A - BOILER PIPING AND WIRING

Piping Diagram 10 : Bypass Piping (4-Way Valve Option With Circulator On Supply)

Piping Diagram 11 : Multiple Boiler Piping

Page 44

APPENDIX A - BOILER PIPING AND WIRING

Wiring Diagram 9: Multiple Boiler Wiring (AMB-4)

WATER SENSOR

OUTSIDE SENSOR

IF USING EXTERNAL DAY/NIGHT FEATURE

CONNECT HERE (DRY CONTACT)

IF USING REQ/ACK CONNECT HERE

(TT/THERMOSTAT DRY CONTACT)

TO PRIORITY IF USING

(DRY CONTACT)

Yellow

AMB-4

CH T1 CH T2 DWH T1

DHW T2 A1 A2

BOILER CONTROL PANEL

CH C1

CH C2 DHW C1

DHW C2

L1 L2

BOILER 1 CIRC

24VAC 40 VA

TRANSFORMER

Black

White

AUXILIARY

DEVICE

WHITE

120 V

BLACK

Wiring Diagram 10: Multiple Boiler Wiring (AMB-8)

WATER SENSOR

OUTSIDE SENSOR

IF USING EXTERNAL DAY/NIGHT FEATURE

CONNECT HERE (DRY CONTACT)

IF USING REQ/ACK CONNECT HERE

(TT/THERMOSTAT DRY CONTACT)

TO PRIORITY IF USING

(DRY CONTACT)

Yellow

BOILER T-T

(TERMINALS

1&2)

BOILER

T-T

BOILER

CH T1

BOILER

CH T2 DWH T1

DHW T2

A1 A2

BOILER CONTROL PANEL

CH C1

CH C2

DHW C1

DHW C2

BOILER 2 CIRC

AMB-8

CH T1 CH T2 DWH T1

DHW T2 A1 A2

BOILER CONTROL PANEL

CH C1

CH C2 DHW C1

DHW C2

BOILER 1 CIRC

24VAC 40 VA

TRANSFORMER

Black

White

120 V

WHITE

BLACK

BOILER

T-T

BOILER

T-T

BOILER

T-T

BOILER T-T

(TERMINALS

1&2)

BOILER T-T

(TERMINALS

1&2)

BOILER

T-T

BOILER

CH T1

BOILER

CH T2 DWH T1

DHW T2 A1 A2

BOILER CONTROL PANEL

CH C1

CH C2 DHW C1

DHW C2

L1 L2

BOILER

2 CIRC

Page 45

APPENDIX B - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION

WARNING

Install boiler so gas ignition system components are protected from water (dripping, spraying, rain, etc) during appliance operation and service (circulator replacement, etc).

• DIELECTRIC ISOLATION Two (2) 1-1/4” X 1-1/4” Female to female dielectric

isolation unions are shipped loose in boiler parts bag. Install Dielectric Isolation unions at boiler supply line and return line. Install isolation ttings nearest boiler prior to system piping connections.

• WATER TREATMENT and ANTIFREEZE

PROTECTION

MUST be applied for ALL aluminum series high efciency gas-red boilers using antifreeze protection.

Page 46

APPENDIX B - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION

System and Operating Precautions

Applies to ALL Aluminum High Efciency Gas-Fired Water Boilers

Clean System First

BEFORE connecting boiler to heating system, clean and ush system thoroughly. Verify system is free of sediment, ux and any residual boiler water additives.

Systems having not recommended antifreeze must be completely ushed to ensure no old antifreeze remains. In older systems obviously discolored, murky or dirty water; or pH reading outside acceptable range (between 7.0 and

Flushing with clean water. If chemical cleaners are used, use only those recommended for use with aluminum boilers. Follow chemical cleaner manufacturer’s instructions completely.

DO NOT mix different manufacturer’s products.

Fill Water and Chemistry

Verify water used to ll system meets these requirements: System uid pH maintained between 7.0 and 8.0. Maintain water hardness below 7 grains hardness. Filling with chlorinated potable water is acceptable. DO

NOT ll boiler with water containing chlorine in excess of 100 ppm.

DO NOT use inhibitors or other additives that are not listed at end in this addendum.

Consult local water treatment specialist for recommendations if any of above requirements is outside stated ranges.

Eliminate System Leaks

Continuous addition of make-up water will constantly add oxygen to system. Eliminate all system leaks. All system leaks must be repaired immediately.

Verify expansion tank is operational and properly sized. Undersized expansion tanks cause relief valve weeping and substantial make-up water addition.

Operation of this boiler in system containing signicant amounts of dissolved oxygen can cause severe heat exchanger corrosion damage.

This boiler is not designed for use in systems containing regular additions of make-up water. Regular additions of make-up water may cause severe heat exchanger damage. System leaks may not always be visible. Unseen system leak will become obvious if boiler pressure decreases when make-up valve is closed.

This boiler is designed for closed loop hydronic heat system

ONLY!

installations, or any other open type system.

This boiler is not suitable for natural gravity type

Page 47

APPENDIX B - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION

System and Operating Precautions

Applies to ALL Aluminum High Efciency Gas-Fired Water Boilers

General Guidelines When Using Antifreeze

• Use only antifreeze products recommended for use with aluminum boilers, as listed in this addendum. See Table 1, page 48.

• Continuous addition of make-up water will dilute power of antifreeze and change buffers ability to maintain pH.

• Flush old antifreeze from system. Flush boiler and system separately.

• Do not use antifreeze unless required.

• Antifreeze, if needed, must be of type listed on next page due to their operational characteristics of : type 356 T6 aluminum at operating temperatures between 20°F (-6.7°C) and 250°F (121°C). (See Table 1 for allowable products.)

• Always clean system prior to using antifreeze as stated in this supplement.

• Be sure to follow antifreeze manufacturer’s instructions for use, safe handling and storage of their products. Refer to MSDS (Material Safety Data Sheets) provided by antifreeze manufacturer for potential hazards and rst aid procedures for exposure or ingestion.

• Antifreeze will raise pH of hydronic solution in heating system above recommended level due to corrosion inhibitors. Solution must be treated to maintain a pH within recommended level. Follow antifreeze manufacturer’s instructions to adjust pH.

• It is recommended that pH reading be taken annually, and adjusted as necessary. Follow antifreeze/inhibitor manufacturer’s instructions for details on how to adjust pH.

• Antifreeze solutions can break down over time. Failure to check antifreeze chemistry on annual basis may result in accelerated corrosion of boiler and other system components. Consult with antifreeze manufacturer for recommendations.

• Use of antifreeze in any boiler will reduce heating capacity as much as 10-20%. Take into consideration when sizing heating system, pumps and expansion tank. Consult antifreeze manufacturer’s literature for specic information on reduced capacity.

• Using antifreeze manufacturer’s instructions, determine freezing temperature needed and use correct amount of antifreeze. Never exceed 50% antifreeze by volume.

• Boiler operating pressure must remain below 15 psi for antifreeze solutions that specify a maximum of 250°F (121°C). Otherwise, increase system operating/tank pressure to 20 psig.

to expansion tank manufacturer instructions for adjusting tank pressure.

Note: Refer

• If system has leaked, water and antifreeze chemistry will need to be adjusted. To avoid damage to boiler, check pH and chemistry of boiler

solution and consult the antifreeze manufacturer for recommendations.

Page 48

APPENDIX B - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION

System and Operating Precautions

Applies to ALL Aluminum High Efciency Gas-Fired Water Boilers

Table 1

Antifreeze Products

Compatible Aluminum Antifreeze & Inhibitor Suppliers

Noble Company P. O. Box 350

Noburst AL Antifreeze

Rhogard Antifreeze &

Pro-Tek 922 Inhibitor*

* Pro-Tek 922 Inhibitor may be used to adjust the pH level of the hydronic system, but on occasion may not resolve the

pH issue. In these cases, ush the system and rell with untreated water and antifreeze suitable for aluminum heat exchangers, as listed in this supplement.

Alphi-11

Intercool NFP-30,40,50 AA

Intercool RPH-15*

Grand Haven, MI 49417 www.noblecompany.com Tel: 800-878-5788 Fax: 231-799-8850

Rhomar Water Management, Inc. P. O. Box 229 Springeld, MO 65801 www.rhomarwater.com Tel: 800-543-5975 Fax: 417-862-6410

Hydronic Agencies, Ltd. (Fernox North Distributor) 15363 117 Avenue Edmonton, AB T5M 3X4 Canada www.hydronicagencies.com Tel: 780-452-8661 Fax: 780-488-2304 Fernox www.fernox.com

Interstate Chemical 2797 Freedland Road P.O. Box 1600 Hermitage, PA 16148-0600 www.interstatechemical.com Tel: 800-422-2436 Fax: 724-981-8383

Hercules Chemical Company, Inc. 111 South Street

Hercules cryo-tek™-100/Al

* This product may be used to adjust pH level of hydronic system, but on occasion may not resolve pH issue. In these

cases it is recommended to ush system and rell with untreated water and new boiler manufacturer approved antifreeze suitable for Aluminum heat exchangers.

Passaic, NJ 07055 www.herchem.com Tel: 800-221-9330 Fax: 800-333-3456

Page 49

NOTES

Page 50

NOTES

Page 51

SERVICE RECORD

Company Address & Phone #Company Name & Tech InitialsService PerformedDate

Page 52

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and

Conservation Act, this boiler is equipped with a feature that saves energy

by reducing the boiler water temperature as the heating load decreases.

This feature is equipped with an override which is provided primarily to

permit the use of an external energy management system that serves the

same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE

FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

DUNKIRK BOILERS

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Dunkirk Q95M-200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual