Dunkirk 90-50, 90-75, 90-100, Quantum 90 Installation, Operation & Maintenance Manual

GAS-FIRED,DIRECTVENT,

CONDENSING, HOT WATER BOILER

INSTALLATION, OPERATION&

MAINTENANCE MANUAL

DUNKIRK BOILERS
85 Middle Rd.

Dunkirk, NY 14048

www. dunkirk, com

P/N# 14683301,Rev.C [12/2010]

90-75

90= 1 O0

These instructions

must be affixed on or

adjacent to the boiler.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiitheinstallation.
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiSave this manual for reference.

Improper installation, adjustment, alteration,
service, or maintenance can cause injury or
property damage. Refer to this manual. For

assistance or additional information consult a
qualified installer, service agency, or the gas

supplier.

Read all instructions carefully before starting

Warnings and Safety Symbols ....................................................................................................... 3

Introduction ................................................................................................................................ 4

Boiler Ratings & Capacities ........................................................................................................... 5

Boilers For Use At High Altitude ..................................................................................................... 6

Rules For Safe Installation And Operation ....................................................................................... 8

Before Installing The Boiler ........................................................................................................... 8

Pladn( The Boiler ....................................................................................................................... 11

Near Boiler Piping ....................................................................................................................... 12

Combustion Air and Vent Pipe ...................................................................................................... 19

Gas Supply Piping ....................................................................................................................... 24

Electrical Wiring ......................................................................................................................... 26

Controls and Accessories ............................................................................................................. 30

Water Treatment & Freeze Protection ............................................................................................ 32

Start Up .................................................................................................................................... 34

Operating Instructions ................................................................................................................. 35

To Turn Off Gas To Appliance ........................................................................................................ 35

Check Out Procedure and Adjustment ........................................................................................... 36

Installation and Check-Out Certificate ............................................................................................ 40

Maintenance And Cleaning ........................................................................................................... 41

Detailed Sequence Of Operation ................................................................................................... 44

Troubleshooting .......................................................................................................................... 47

Differential Air Pressure Switch Check ........................................................................................... 55

IMPORTANT: THIS MANUAL MUST BE KEPT NEAR THE BOILER FOR FUTURE REFERENCE!!

Indicates an imminently hazardous situation
which, if not avoided, WILL result in death,

serious injury or substantial property damage,

which, ifn ot avoid ed, mayresu It in death,
serious injury or substantial property damage.

Indicates an imminently hazardous situation
which, if not avoided, may result in injury or

property damage.

Indicates information which should be
followed to ensure proper installation and

operation.

This appliance is a gas-fired direct vent hot water boiler with cast
aluminum boiler sections. A revolutionary cast aluminum heat

exchanger means better heat transfer and thermal storage than
sirnilarly sized cast iron boilers, which results in higher efiqciency.
The heating system water absorbs large amounts of heat from the
cast aluminum heat exchanger, cooling the flue gases and causing

condensation. Sealed combustion, premix gas burner, and low flame
temperature means drastically reduced CO and NOx emissions,

which contribute to a cleaner and healthier environment.

(sealedcombustion)and does not competewith building occupants

for fresh air. Sealedcombustion (also known as"directvent") is the

safestand best wayto obtainplentyofcleancombustion air. The
induced draft fan drawsin the outside combustion air,then takesthe

coolerfluegasesfrom the boilerunit and providesa positiveremoval

of thefluegasesfrom the building through inexpensiveand readily

availablePVCand CPVC pipes.

Thisappliance,unlikenormal residential atmospheric and induced
draft units, takes itscombustion airdirectly from the outdoors

Figure 1 - Boiler Dimensions

19 3/4"

(502ram}

ALTERNATE SUPP|.Y _,

& RETURN OPENINGS

CONN{::<7_ONS
_ROVID_DINEID_

gOILER(A@_[ [

RETURN
(1_/4' _4_P_ (3175_'nm) CONNECTIOP#S

PROVID£FJ INSIDE

4 V8"......(iu4.Smm)

22

(572mm)

JUNCTION BOX FOR _20 V POWER,

120 V CIRCULATOR LEADS, AND

24 V THERMOSTAT LEADS

VENT CONNECTION

CPvC) (50,Smm}

ALTERNATE GAS

39 112"

( _O05mm)

SUPPLY OPENING

ALTERNATE OPENING FOR
VENT TEE

IMPORTANT: Read the following instructions
COMPLETELY before installing!

( t 27r,nm)

VENT CONNECTION
(2" CPvC) (SO gin.' 0

DRA_N

CONDENSATE
DRAN FITIINO

(1/2" pro) O2.Tmm)

FRONT

(609.6mr,n}

2t"

24 _

(833 4ram)

VENT AND EXPANSION
TANK CONNECT{ON

FOR AIR

L

PROV_O_D iNS_g£ 80{LER C_81NE[)

13 ¸,1

(350.2mm)

BACK

TO_

90-50 50 45 39 220 2" CPVC & PVC
90-75 75 68 59 220 2" CPVC & PVC

90-100 100 90 78 220 2" CPVC & PVC

*1MBH = 1,000 Btuh Btuh =British Thermal Units Per Hour

These low pressure gas-fired hot water boilers are design certified
by CSA International for use with natural and propane gases. The
boilers are constructed and hydrostatically tested for a rnaximurn
working pressure of 50 psig (pounds per square inch gage) in
accordance with A.S.M.E. (Arnerican Society of Mechanical

Engineers) Boiler and Pressure Vessel Code Section IV Standards for
heating boilers.

++ AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity
is based on the D.O.E. (Departrnent of Energy) test procedure.

The Boilers are certified in accordance with ANSI (American
National Standards Institute) Z21.13 standards as gas-fired, direct
vent, condensing, hot water boilers.

The Heating Capacity indicates the arnount of heat available after
subtracting the losses up the stack. Most of this heat is available to
heat water. A srnall portion is heat frorn the jacket and surfaces of
the boiler, and it is assumed that this heat stays in the structure. The
Net I=B=R Rating represents the portion of the rernaining heat that
can be applied to heat the radiation or terminal units (i.e. finned
tube baseboard, cast iron radiators, radiant floor, etc.). Thedifference

between the Heating Capacity and the Net I=B=R Rating, called the
piping and pickup allowance, establishes a reserve for heating the
volurne of water in the systern and offsetting heat losses frorn the

piping.

The Net I=B R Ratings shown arebased on a piping and pickup
factor of 1.15 in accordance with the I=B=R Standard as published
by the Hydronics Institute. The Net I=B=R Rating of the boiler
selected should be greater than or equal to the calculated peak

heating load (heat loss) for the building or area(s) served by the
boiler and associated hot water heating systems. The rnanufacturer
should be consulted before selecting a boiler for installations having
unusual piping and pickup requirernents.

The boilers are factory equipped for operation at altitudes ranging
frorn 0-2,000 feet above sea level. For use of these boilers at altitudes

above 2,000 feet above sea level, the gas input ratings (MBH)
autornatically reduced.

Theboilers(with the exceptionof the 90-75LPproduct) arefactory
equipped foroperation at altitudesranging from 0-10,000feetabove

sealevel.Nochanges to the factory settings arerequired for instal-
lationsfrom 0-5,000feet abovesealevel.Foraltitudes from 5,000-

10,000feetabovesealevel thegasmanifoldpressurewill need to be
adjustedbased upon calorific (Btu)valueof supplygas (contact local

gasutilityor distributor for thisvalue). For specificsettings refer to
Table#1 for natural gasapplicationsand Table #2 for LPgasap-
plications.Instructions on how to adjust the gasmanifold pressure
settings are shown in Figures 17 & 18.

TABLE#1: SERIES90 NATURAL GAS

Note that 90-75 LP applications for 5,000- 10,000 feet above sea
level will require an orifice change aswell as a gas manifold pres-

sure adjustment based upon calorific (Btu) value of supply gas. Refer
to Table #2 for altitude orifice kit part number. For replacing the
orifice refer to specific instructions included with the kit.

Altitude in Ft.

Normal Input (MBH)

Manifold Pressure In W.C.

Orifice

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 75 - _ - - / - / -

Manifold Pressure In W.C. 2.5 3.5 / 3.5 2.5 / 2.5 / 2.5

Orifice 43331092 43331092

Altitude in Ft.

Normal Input (MBH)

Manifold Pressure In W.C.

Orifice

++Contact local gas utility or distributor for Btu value of gas.

0-5,000

50

2.5

43331094

0-5,000

100

2.5

43331090

5,000-10,000

- i - - i -

4 1 4 2.5 1 2.5

t t

3.5 3.5 2.5 2.5

- ]

3.5 _

43331094

5,000-10,000

-t

2.5

43331090

i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i

For model 90-75 LP units only at altitudes

above 5,000 ft., install 90-75 High Altitude

Orifice Kit #550001810*. For all other

altitudes use factory installed orifice.

TABLE#2: SERIES90 PROPANEGAS

Altitude in Ft.

Normal Input (MBH)

Manifold Pressure In W.C.

Orifice

Altitude in Ft.

Normal Input (MBH) - - [ - -

Manifold Pressure In W.C. 2.5 3.5 3.5 l 3 3

Orifice 43331093

* For model 90-75 LP units only at altitudes above 5,000 ft., install 90-75 High Altitude Orifice Kit #550001810. For all other alti-

tudes use factory installed orifice.

Altitude in Ft.

Normal Input (MBH)

Manifold Pressure In W.C.

Orifice

++Contact local gas utility or distributor for Btu value of gas.

0-5,000

50

2.5

43331095

0-5,000

75

0-5,000

100

2.5

43331091

5,000-10,000

[ - ]

3 3 2.5 2.5

43331095

5,000-10,000

- ]

3.5 l

43331096*

5,000-10,000

3 3 2.5 2.5

43331091

1. Readtheentireinstallationmanualbeforebeginningtheinstal-
lation.Failuretofollowtheserulesforsafeinstallationand

operationandtheseinstructionscouldcauseamalfunction
oftheboilerandresultindeath,seriousbodilyinjury,and/or
propertydamage.

2. Checkallapplicablestateandlocalbuildingcodesandutil-
itycompanyrequirementsbeforeinstallation.Theinstallation

mustconforrnwiththeserequirementsintheirentirety.Inthe
absenceofthesecodes,useNFPAInstallationCodesandgood
industrypractice.

3. Beforeservicingtheboiler-allowtheboilertocool.Always
shutoffanyelectricityandgassupplyconnectedtotheboiler

priortoservicing.

4. Inspectgaslineforleaks.

5. Becertaingasinputrateiscorrect.Overfiringmayresultin
earlyfailureoftheboilersections.Thismaycausedangerous
operation.Underfiringmayresultintoomuchairforthepre-
mixburnercausingpoororlossofcombustion.

6. Never vent the products of combustion from this boiler to an
enclosed space. Always vent to the outdoors. Never vent to

another room or to inside a building.

7. Be sure there is adequate outdoor air supply to boiler for com-
plete combustion.

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

9. Keep boiler area clean of debris and flee of combustible and
flammable rnaterials.

10.

Proper through the wall or through the roof cornbustion vent-
ing shallbe in accordance with the materials and methods

described in this manual. Installation must complywith local

codes.

11.

This boiler and related hot water heating systems are not do it

yourself items. They must be installed and serviced by qualified
professionals.

This boiler has been equipped for residential

installations. If used for commercial
applications, any additional code requirements
must be adhered to for installation. This may

require additional controls including but not
limited to a low water cut off, a manual reset
high temperature limit, and wiring and/or
piping modifications. The manufacturer is not

responsible for any field installation changes
made to a boiler installation which are not

described or acknowledged in this manual.

Complete all of the following prior to installing the boiler.
Codes

This boiler product is a gas-fired, direct vent, condensing boiler and
must be installed to conforrn to the requirernents of the authority

having jursidiction or, in the absence of such requirements:
United States- National Fuel Gas Code (NFPA-54/ANSI Z223.1).

Canada- National Gas and Propane Installation Code, Can/CSA
B149.1.

Where required bythe authority havingjurisdiction, the installation
must conform to the Arnerican Societyof MechanicalEngineers

SafetyCode for Controls and SafetyDevicesfor AutomaticallyFired
Boilers,No.CSD-1.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_

Important - In the state of Massachusetts

this product must be installedby a licensed

plumber or gas fitter and the installation must
be in accordance with 248 CHR.

Installers- Followlocal regulationswith respect to installation of
CO (Carbon Monoxide) Detectors. Followmaintenance recommen-

dations in this manual.

Installation Requirements Specific To The State Of
Massachusetts For Direct Vent, Mechanical Vent_ And

Domestic Hot Water Appliances

For all side wall horizontally vented gas fueled equiprnent installed
in every dwelling, building or structure used in whole or in part

for residential purposes, including those owned or operated by the

comrnonwealth and where the side wall exhaust vent terrnination is

less than seven (7) feet above finished grade in the area of the vent-

ing, including but not limited to decks and porches, the following
requirernents shall be satisfied:

. Installationof carbon rnonoxide detectors: atthe time ofinstal-

lation of the sidewall horizontal vented gasfueledequipment,
the installingplurnber or gasfittershallobserve that a hard
wired carbon rnonoxide detectorwith an alarrn and battery
back-up is installedon the floor levelwhere the gas equipment

isto be installed. In addition, the installing plurnber or gasfitter
shallobserve that a battery operated or hard wired carbon rnon-

oxidedetector with an alarrnisinstalled on each additional level
of thedwelling,building or structure servedby the side wall

horizontal vented gasfueledequipment. It shallbe the respon-

sibilityof the property owner to securethe servicesof qualified

licensed professionalsfor the installationof hard wired carbon
rnonoxide detectors.

a.

In the event that the side wall horizontally vented gas
fueled equiprnent is installed in a crawl space or an attic,

the hard wired carbon rnonoxide detector with alarm and
battery back-up may be installed on the next adjacent floor

level.

g.

In the event that the requirernents of this subdivision can
not be rnet at the time of cornpletion of installation, the

owner shall have a period of thirty (30) days to comply
with the above requirernents; provided, however, that dur-
ing said thirty (30) day period, a battery operated carbon

monoxide detector with an alarm shall be installed.

o

Approved carbon monoxide detectors: each carbon monoxide
detector as required in accordance with the above provisions

shall comply with NFPA720 and be ANSI/UL 2034 listed and
IAS certified.

3. Signage: a metal or plastic identification plate shall be perrna-
nently mounted to the exterior of the building at a rninimum
height of eight (8) feet above grade directly in line with the
exhaust vent terminal for the horizontally vented gas fueled

heating appliance or equipment. The sign shall read, in print
size no less than one-half (112)inch in size, "gas vent directly
below. Keep clear of all obstructions".

4. Inspection: the state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve
the installation unless, upon inspection, the inspector observes

carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(A)1 through 4.

5. Product-approved vent/air-intake: a product-approved vent ter-
minal must be used and, if applicable, a product-approved air
intake must be used. Installation shall be in strict compliance

with the rnanufacturer's instructions.

o

Installation instructions: a copy of allinstallation instructions
for all product approved side wall horizontally vented gas fueled
equipment, all venting instructions, all parts lists for venting
instructions, and/or all venting design instructions shall remain
with the appliance or equipment at the completion of the instal-

lation.

Boiler Sizing
Checktobe sure you haveselected the boiler with the proper capac-

itybeforestarting the installation. TheI=B=RRatingofthe boiler
selectedshould be greater than or equal to the calculatedpeak heat-

ing load (heat loss)for the building or area(s) served by the boiler
and associatedhot waterheating systems.Seethe table"BOILER
RATINGSAND CAPACITIES"(page5 of this docurnent).

Heat losscalculationsshould be based on approved industry meth-
ods.

Considerations For Boiler Location

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

•Suppliedwith the correct type of gas(natural gasor pro-
pane).

• Connected to a suitable cornbustion air intake piping sys-
tern to supply the correct amounts of fresh (outdoor) air
for cornbustion, refer to Combustion Air And Vent Pipe

section (near center of this manual) for details.

• Connected to a suitable venting systern to remove the
hazardous products of gas combustion, refer to Cornbus-
tion Air And Vent Pipe section (page 19 of this rnanual) for

details.

•Connectedto asuitablehot water heating systern.

•Suppliedwith a suitableelectricalsupplyfor allboilerrno-
tors and controls.

• Connected to a properly located therrnostat or operating

control. (not included with boiler)

•Placedon levelsurface (rnust NOT be installedon carpet-

ing)

•Condensate drain line must bepitched down to floor drain
or externalcondensate purnp with reservoir at1A"per foot

(woodfrarneor blocksrnay beused to raise boiler).

Locating The Boiler

1. Selecta locationwhich is level,central to the piping systerns
served and as closeto the vent and air intaketerrninals aspos-
sible.

2. Accessibility clearances, if more stringent (i.e. larger clearances)

than required fire protection clearances, rnust be used for the
boiler installation. Accessibility clearances rnay be achieved
with the use of removable walls or partitions.

3. The boiler is approved for installation in closets and on com-

bustible floors. This boiler shall NOT be installed on carpeting.

4. The clearances shown in Table #2 indicate required clearances.
A rninimurn 1" clearance rnust be rnaintained between corn-

bustible construction and each of the left, top and back surfaces
of the boiler. A rninimum 8" clearance is required on the right

side, to allow roorn for the inlet air pipe. An 18" clearance rnust
be rnaintained at a side where passage is required to access an-
other side for cleaning or servicing, inspection or replacernent
of any parts that norrnally rnay require such attention. Allow at

least 24" at the front and left side and 8" at the top for servicing.
No clearances are required to venting or cornbustion air intake
piping.

5. Equipment shall be installed in a location which facilitates the
operation of venting and cornbustion air intake piping systems

as described in this rnanual.

6. Adviseownerofboilertokeepventingandcombustionair
intakepassagesfreeofobstructions,boththeventingandcorn-

bustionairintakepipingsystemsconnectedtotheoutdoors
rnustpermitflowthroughthepipingsysternswithoutrestric-
tionsfortheboilertooperate.

7. Theboilershallbeinstalledsuchthattheautomaticgasignition
systerncornponentsareprotectedfromwater(dripping,spray-

ing,rain,etc.)duringoperationandservice(circulatorreplace-
rnent,condensatetrap,controlreplacernent,etc.).

Combustion Air And Vent Pipe Requirements

This boiler requires adedicated direct vent systern. In a direct vent
systern, all air for cornbustion is taken directly frorn outside atrno-

Top 1 (25.4) 8 (203.2)

Left Side 1 (25.4) 24 (609.6)

Right Side 8 (203.2)

sphere,and all flue products are discharged to outside atmosphere.
Cornbustion air and ventpipe connections rnust terrninate together

in the sameatmosphericpressure zone, either through the roof

or sidewall(roof termination preferred). SeeFigures 9 & 10 (in

Combustion Air AndVentPipe sectionofthis manual) for required
clearances.

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

Base 1 (25.4)
Front 1 (25.4) 24 (609.6)

Back 1 (25.4)

Intake/Vent Piping 0 (0)

Near Boiler Hot Water Piping 1 (25.4)
All distances measured from the cabinet of the boiler.

When vent pipe is exposed to temperatures below freezing, such as when it passes through an
unheated space or when a chimney is used as a raceway, vent pipe must be insulated with :!./2"
Armaflex or equivalent. In extreme cold climate areas, use 3/4" Armaflex or equivalent.

Combustion air must be clean outdoor air. Combustion air must not be taken from inside structure

because that air frequently is contaminated by halogens, which include fluorides, chlorides, phosphates,
bromides and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents,

salts, air fresheners, paints, adhesives and other household products.

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

All combustion air and vent pipes must be airtight and watertight. Combustion air and vent piping must
also terminate exactly as shown in Figure 9 or 10 (in Combustion Air And Vent Pipe section, page 19

of this manual).
Vent connections serving appliances vented by natural draft shall not be connected into any portion of

mechanical draft systems operating under positive pressure.

Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well
ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.

FAILURE TO FOLLOW THE AFOREMENTIONED WARNINGS COULD RESULT IN FIRE, PROPERTY DAMAGE,
PERSONAL INJURY, OR DEATH.

Condensate Drain Requirements
Condensate drain line to be pitched down to floordrain atamini-

rnurnof 1A"per foot.An external condensatepump (not furnished)
maybe used if floordrain isnot available.Thecondensate pump
must be designed for fluegas condensate application.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_

:[.Condensatetrap bu,t ntothebo ler,an

external trap is not required and should not

2. Wood frame or blocks may be used to raise
the boiler to maintain drain pitch or to be

above external condensate pump reservoir.

3. There is a :[::[5 Volt AC receptacle provided
on the service switch junction box which is

located at the boiler right side, to provide
power for an external condensate pump (if

needed).

Foundation Requirements

Boilermust be placedon levelsurface.Boileris NOT to be installed
on carpeting.

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If boiler is not level condensate drain lines
will not function properly. Adjustable feet are

located on the boiler to makeup for minor

surface irregularities or tilt.
Wood frame or blocks may be used to raise

boiler to maintain drain pitch or to be above

external co ndensate pum p rese rv oir.

Removal of Existing Boiler From Common Vent System

When an existing boiler is rernoved from a common venting system,
the comrnon venting systern is likely to be too large for proper vent-

ing of the appliances remaining connected to it. At the time of re-

moval of an existing boiler, the following steps shall be followed with

each appliance rernaining connected to the common venting systern
placed in operation, while the other appliances rernaining connected
to the cornmon venting systern are not in operation.

1. Seal any unused openings in the comrnon venting systern.

2. Visually inspect the venting system for proper size and hori-
zontal pitch and deterrnine there isno blockage, or restrictions,

leakage, corrosion and other deficiencies which could cause an

unsafe condition.

3. In-so-far as is practical, close all building doors and windows
and all doors between the space in which the appliances remain-
ing connected to the common venting system are located and

other spaces of the building. Turn on clothes dryer and any ap-
pliance not connected to the common venting systern. Turn on

any exhaust fans, such as range hoods and bathroom exhaust, so

they will operate at maximum speed. Do not operate a summer

exhaust fan. Close fire darnpers.

4. Place in operation the appliance being inspected. Follow the
lighting instructions. Adjust therrnostat so appliances will oper-

ate continuously.

5. Test for spillage at the draft hood relief opening after 5minutes
of main burner operation. Use the flame of a match or candle,
or the smoke frorn acigarette, cigar or pipe.

6. After it has been deterrnined that each appliance remaining

connected to the common venting systern properly vents when

tested as outlined above, return doors, windows, exhaust fans,
fire place dampers, and any other gas-burning appliance to their

previous condition of use.

7. Any improper operation of the comrnon venting systern should
be corrected so the installation conforms with the National Fuel

Code, NFPA-54/ANSI -Z223.1 and/or the Natural Gas and
Propane Installation Code, CAN/CSA B149.1.. When resizing

any portion of the common venting systern, the comrnon vent-
ing system should be resized to approach the minimum size as
deterrnined using the appropriate tables in Chapter 13 of the

National Fuel Gas Code, NFPA-54/ANSI- Z223.1 and/or the
Natural Gas and Propane Installation Code, CAN/CSA B149.1.

The boiler should be placed to provide the most direct connections
to the combustion air, vent and systern piping as possible.

Place crated boiler as close to selected location as possible and
uncrate boiler. The uncrated boiler may be moved into position with

an appliance dolly or 2-wheel hand truck. The dolly or hand truck
should be inserted under the left hand side of the boiler. It is possible
to slide the boiler for a short distance on a smooth floor or surface.

Refer to manual section "locating the
boiler" (page 9 of this manual), for required

clearances for servicing and maintenance.

When the installation of the boiler is for a new heating system, first
install all of the radiation units (panels, radiators, baseboard, or tub-

ing) and the supply and return mains. After all heating system piping
and components have been installed, make final connection of the
system piping to the boiler. A hot water boiler installed above radia-
tion level, or as required by the Authority having jurisdiction, must
be equipped with a low water cut off&vice. A periodic inspection

is necessary for flushing of float type devices, per low water cut off
manufacturers specific instructions.

Supply And Return Lines
The packaged boiler unit is set up to receive 11_,,NPT supply and

return piping from top access. The boiler unit can also be piped from
the left side by turning the supply elbow, and from the rear of the
unit by removing plugs in the rear boiler section.

Figure 2 - Single Zone Boiler Piping

SERVICE -

The circulator pump and isolation valves are

furnished within a carton inside the boiler
cabinet and can be installed at the installer

preferred location.

Copper supply and return piping must NOT be
installed directly into aluminum boiler section
casings due to galvanic corrosion between

dissimilar metals. Iron or steel bushings or
pipe nipples should be used between copper
system piping and boiler to make final
connection to boiler. Also, the use of dielectric
unions is acceptable. The packaged boiler is

furnished with iron piping in the front boiler
section for the supply and return connections.

SUPPLYTO

CIRCULATOR

SERVICE
VALVE

VALVE

-SYSTEM

_.jj-- RETURN FROM

SYSTEM

PURGE(DRAIN)

VALVE

Figure 3 - Multi-zone Boiler Piping With Zone Valves

ZONE
\JAWE

CIRCU LATOR

ZONE SERVICE
VALVE

SUPPLYTO

ZONES

ZONESERVICE
VAWE

FROM

ZONES

PURGE (DRAIN)

VALVES

VALVE

Figure4-Multi-ZoneBoilerPipingWithCirculators

FLOW CHECK

VALVE "\

CIRCULATORS

ZONE SERVICE
VALVE

SUPPLYTO
ZONES

_WE

FLOW CHECK
VALVE

RETURNFROM

ZONES

PURGE(DRAIN)
VALVES

SERVICE

VALVE

When zoning with circulators, the furnished circulator pump should be used as one of the zone pumps.

Each stripped end of the electrical wires for the circulator pump inside the junction box should be taped

or wire nutted to prevent short circuits. Unplug the circulator pump wiring at the integrated boiler
control.

Figure5-SingleZoneBoilerPiping

DISCHARGE
PIPING

PressureReliefValve

Theboileris furnished with a factoryinstalled reliefvalvein the top
ofthe boiler. Provide3_,,piping frorn the supplied reliefvalveto a
localfloordrain, but leavean air gapbetweenpiping and drain. No
shutoffof any description shallbe placed betweensafetyreliefvane

and the boiler,oron the discharge pipes between such safetyvalve
and the atmosphere. Installationofthe safetyreliefvalveshall con-

forrn to ANSI/ASMEBoilerand Pressure VesselCode, Section IV.
Themanufacturer isnot responsiblefor aW water damage.

Expansion Tank And Make-Up Water

Deterrnine required systern fill pressure, systern design ternperature,
and systern water content. Boiler contains 2.6 gallons (U.S.). Size
expansion tank accordingly. Consult expansion tank manufacturer

for proper sizing information. Connect properly sized expansion
tank (not furnished) as shown in Figure 6 for diaphragm type ex-

pansion tank and Figure 7 for conventional closed type expansion
tanks. For diaphragm type expansion tanks, adjust the tank air pres-

sure to match the systern fill pressure. Install air vent (furnished)
as shown for diaphragm type expansion tank systern only. Install

make-up water connections as shown per local codes. If a pressure

reducing valve is used, adjust to match the systern fill pressure. In

connecting the cold make-up water supply to the boiler, make sure
that clean water supply is available. When the water supply is from a
well or pump, sand strainer should be installed at the pump.

Figure 6 - Diaphragm Type Expansion Tank Piping

MANUAL FILL

VALVE

AUTOMATIC AIR
VENT _

3/4"xI/8" BUSHING _

3/4" TEE_

3/4" NIPPLE (FURNISHED
AND INSTALLED ON

PACKAGED BOILER)

3/4" STREET ELL*

COLD
WATER

FILL

FURNISHED IN

PARTS BAG.

DIAPHRAGM TYPE
EXPANSION TANK

COMBINATION QUICK FILL
VALVE, STRAINER, CHECK

VALVE AND PRESSURE

REDUCING VALVE

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Figure 7 - Conventional (closed type) Expansion Tank Piping

MANUAL FILL

VALVE

CLOSEDTYPE

EXPANSION TANK

EXPANSION TANK SERVICE

VALVE (GATE VALVE OR

FULL PORT BALL VALVE)

COLD WATER
FILL

CHECK AND PRESSURE

REDUCING VALVE

Figure8-CondensateDrainPiping

OPEN

DRAIN PIPETO
BE PITCHED DOWN

TO FLOOR DRAIN

ATA MINIMUM

THREADED NIPPLE (PVC)

(INSTALLED)

Condensate Drain Piping

The condensate trap isbuilt into the boiler, an external trap is not
required and should NOT be used.

Provide 1/2"PVC condensate drain and fittings. Condensate drain to
be pitched down to floor drain at a minimum of 1A"per foot.

Install furnished 1/2"PVC tee to overflow fitting as shown in Figure

8.
The 1/2"diacneter schedule 40 PVC or CPVC condensate drain and

pipe fittings must conform to ANSI standards and ASTM D 1785
or D2846. Schedule 40 PVC or CPVC cement and primer must

conform to ASTM D2564 or F493. In Canada, use CSA or ULC
certified schedule 40 PVC or CPVC drain pipe cement.

A condensate pump with a reservoir (not furnished) may be used
to remove condensate to a drain line (sanitary line) above boiler ifa

floor drain is not available or its in accessible.

_"-'-'\'\\'_""" "\\-- T01/4"PER FOOT

DRAIN

_"\_v_CONDENSATE

DRAIN

PVCTEE
1/2 SLIPxl/2 SLIPx1/2 NPT
FURNISHED IN PARTSBAG

Filling Condensate Trap With Water

On The Initial Start Up The Condensate Trap Must Be Manuall,_

Filled With Water.

The following are the steps required to initially fill the condensate
trap for start up, these steps are only required at the initial start up or

ifmaintenance requires draining of the condensate trap:

1. Disconnect the vent condensate drain line from the bottom of
the vent tee on the boiler.

2. Pour about 1cup of coldtapwater into the ventdrain line with

aproper funnel.

3. Excesswatershould go through the overflowand out through
the condensatedrain line.Verifyproper operation of the drain
line (or external condensate pump if used).

4. Reinstall the vent drain line.

Chilled Water Piping

The boiler, when used in connection with a refrigeration system,
must be installed so the chiller medium is piped in parallel with the

boiler with appropriate valves to prevent the chilled medium frorn
entering the boiler.

Connections And Termination

Provisions for combustion and ventilation air must be in accordance
with section, Air For Combustion and Ventilation, of the National

Fuel Gas Code,ANSI 2223.1/NFPA54, or Sections 8.2, 8.3 or 8.4 of
National Gas and Propane Installation Code, CAN/CGA-B 149.1, or
applicable provisions of the local building code.

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

1. Refer to Combustion Air And Vent Pipe section that follows,
also see Figures 9 & 10 for combustion air and vent pipe
roof and sidewall termination. (Roof termination is preferred)

Combustion air and vent pipes must terminate together in same
atrno spheric pressure zone as shown. Construction through

which vent and air intake pipes may be installed is a maximum

24 inches, minimum 1A"thiclca_ess.

2. Combustion air and vent pipe fittings must conform to
American National Standards Institute (ANSI) standards and

American Society for Testing and Materials (ASTM) standards
D1784 (schedule-40 CPVC), D1785 (schedule-40 PVC), D2665

(PVC-DWV), D2241 (SDR-21 and SDR-26 PVC), D2661 (ABS-
DWV), or F628 (schedule-40 ABS). Pipe cement and primer

must conform to ASTM standards D2564 (PVC) or D2235
(ABS).

In Canada construct all combustion air and vent pipes for this unit
of CSA or ULC certified schedule-40 CPVC, schedule-40 PVC,

PVC-DWV or ABS-DWV pipe and pipe cement. SDR pipe is NOT
approved in Canada.

3. Combustion air and vent piping connections on boiler are sized
for 2" pipe. Any pipe size change (to 3") must be made outside
of the boiler casing in a vertical run of pipe to allow for proper
drainage ofvent condensate. Due to potential for flue gas tem-
peratures over 155°F, the first five (5) feet of vent pipe must be

CPVC, the remaining vent pipe can be PVC. If any elbows are
employed within the first 5 feet of vent, they must be CPVC too.
Two (2)- 30" pieces of 2" CPVC pipe are furnished with the

boiler.

The boiler piping system of a hot water boiler connected to heat-

ing coils islocated in air handling units where they may be exposed
to refrigerated air circulation must be equipped with flow control
valves or other automatic means to prevent gravity circulation of the

boiler water during cooling cycle.

The transition from 2" pipe to 3" pipe must be

made in a vertical run.

ASTM F891 *

ASTM D2665 **
ASTM D1785 **
ASTM D2241 **

ASTM D2846 **

ASTM F441 **
ASTM F442 **

ASTM D2661 ***

ASTM F628 ***

UL-1738

ULC $636

* Allowable temperatures based on Classifications covered inASTM

D4396 [Deflection Temperatures under Load (264 psi) (1819KPa)].

** Allowable temperatures based on Classifications covered in ASTM D1784

[Deflection Temperatures under Load (264 psi) (1819KPa)].

*** Allowable temperatures based on Classifications covered inASTM D3965

[Deflection Temperatures under Load (264 psi) (1819KPa)].

4. Combustion air and vent piping lengths:

2 FEET 21 FEET 15 FEET 92 FEET

1 l l 112FEET

The first 5 ft. of"TOTAL EQUIVALENT LENGTH" of vent piping
run must be 2" CPVC:

Thelengthofpipe iscounted frorn the boilerjacket (air intake pipe)
or fromvent tee (ventpipe) the termination isnot counted toward

the "TotalEquivalent Length".
For additional elbows,reduce the maximum vent length as shown:

• 2" 90°elbow-1 1/2ft.per additional elbow.

• 3" 90°elbow- 3ft. per additional elbow.

N. Cornbustion air and vent piping to be pitched back to boiler at

minimum 1A"per ft. (21 rnrn/rn) from intake and vent terminals
so that all moisture in combustion air and vent piping drains to
boiler. Pipes must be pitched continuously with no sags or low
spots where moisture can accumulate and block the flow of air

or flue gas. Combustion air and vent pipes must be airtight and
watertight.

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

• Comply with all clearances required as stated in paragraph 7.

Termination should be positioned where itwill not be
subjected to potential damage by foreign objects, such as

stones, balls, etc..
Termination should be positioned where vent vapors are not

objectionable.
Put vent on a wall away from the prevailing winter wind.

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

Terminate the vent above normal snowline. Avoid locations
where snow may drift and block the vent. Ice or snow may

cause the boiler to shut down ifthe vent becomes obstructed.

Under certain conditions, fluegaswill condense, forming
moisture, and may becorrosive. In suchcases,steps should
be taken to prevent building materials at the vent from being

damaged by exhaust of fluegas.

• Vent shallnot terminate whereit may causehazardous frost or
iceaccumulations on adjacent property surfaces.

o

The venting system shall terminate at least 3 ft. (0.9m) above
any forced air inlet (except the boiler's combustion air inlet)

within 10 ft.(3m). The venting system shall terminate at least 12

in. from any air opening into any building. The bottom of the
vent shall be located at least 12in. above grade. Termination
of the vent shall be not less than 7ft. (2.1m) above an adjacent
public wall<way or paved driveway. The vent terminal shall

not be installed closer than 3 ft. from the inside corner of an

Lshaped structure. Termination of the vent should be kept at
least 3 ft. away from vegetation.

USA onl.>.The venting system shall terminate at least 4 ft.
horizontally from, and in no case above or below, unless a
4 ft. (1.22m) horizontal distance is maintained, from elec-

tric meters, gas meters, regulators, and relief equipment.

Canada only_. The venting system shall terminate at least 6 ft.

(1.83m) horizontally from, an in no case above or below, unless

a 6 ft. (1.83m) horizontal distance is maintained, from electric
meters, gas meters, regulators, and relief equipment.

• Termination should be positioned where vent vapors willnot
damage plants/shrubs or air conditioning equipment.

• Termination should be positioned so that it willnot be effected
by wind eddy,air born leaves,snow, or recirculatedfluegases.

Figure 9 - Roof Vent / intake terminations

8" MINIMUM

VERTICAL SEPAPJ_.T[ON

BETWEEN COMBUSTION

AIR INTAKE AND VENT

MAiNTAiN 12" MiNiMUM _//

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL

USA- 12" (300ram)
Canada - 18" (450ram)

Vent shall not terminate with 6 ft. (1.8m) of a mechanical
air-supply inlet to any building.

Vent shall not terminate above a regulator within 3 ft. (900
mm) horizontally of the vertical centerline of the regulator

vent outlet to a maximum vertical distance of 15ft (9.5m).
Vent shall not terminate within 3 ft. (900mm) ofa window

or door that can be opened in any building, or any non-
mechanical air-supply inlet to any building, or ofthe
combustion air inlet of any other appliance.

Vent shall not terminate underneath a veranda, porch or
deck unless, (a) the veranda, porch or deck is fully open
on a minimum of two sides beneath the floor, and (b) the

distance between the top of the vent termination and the
underside of the veranda, porch or deck is greater than 1 ft.

(300ram).

Figure 10A - Side Wail Vent / Intake terminations - Less Than 12" Clearance Above Grade

LessThan 12" Clearance

Figure 10B - Side Wail Vent / Intake Terminations - 12" Or More Clearance Above Grade

Figure11-CombustionAirandVentPiping

2° (S&Smm) COMBUSTION A_R

INTAKE P{PiNG ....._.

2" 1508ram) CPVC VENT PIPING ',

(FURNiSHED) _°-,_,,__

2" (50,8mm} CPVC COUPLING

(FURNISHED

5'

1,52m

VENT/_NTAKE
TERMiNATiONS

2* (50,Bmm) DIAMETER VENT AND

COMBUSTION AiR iNTAKE
P_PING -
15' (4,57m)MAXIMUM LENGTH TOTAL

W_TH 4 ° 90 ° ELBOWS FOR K£0 - 100

20' (&lOre) MAXIMUM LENGTH TOTAL WITH

4 - 90 ° ELBOWS FOR K90 - 75 AND Kg0 - 50

2' (61 m) MINIMUM LENGTH TOTAL

WiTH 4 - 90° ELBOWS FOR ALL

EXHAUST TEE
(FURNISHED_

3" (7&2ram) COMBUSTION

INTAKE PiPiNG

2" (50 8mm) CPVC VENT PIPmNG

(FURNISHED)

2" (50 8mm) CPVC COUPLING

(FURNISHED)

TERM{NATIONS

3" (76.2mm) VENT PiPiNG

TRANSiTiON FITTING

//-- 2" (50,8ram) O TO 3" (76,2mm) _ iN

.,,./// 3" (76,2mm), D AMETER VENT' AND

5' 100' (3&48m) MAXIMUM LENGTH TOTAL

1,52m WiTH 4 - 90_ ELBOWS

. VERTICAL RUN

COMBUSTION AiR iNTAKE PtPING
FOR K90 - 100
80' (24,38m) MAXIMUM LENGTH TOTAL

W_TH 4 _ 90° ELBOWS
15' (6,10m) MINIMUM LENGTH TOTAL

WITH 4 - 90_ ELBOWS

FOR t<90- 75 AND K90 - 50

20' (6o10m) MINIMUM LENGTH TOTAL

WITH 4 - 90 ° ELBOWS

TRANSITION FITTING
2" (50,Bmm) O TO 3" (76,2mm) O iN

VERTICAL RUN

EXHAUST TEE
(FURNISHED)

Installation

1. Attach cornbustion air intake piping to supplied Fernco 2" cou-
pling on mixer. Attach vent piping to furnished 2" CPVC vent

tee on draft inducer outlet.

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

3. Deburr inside and outside of pipe.

4. Charnfer outside edgeof pipe for better distribution of primer
and cement.

5. Clean and dry all surfacesto be joined.

6. Check dry fitof pipeand mark insertion depth on pipe.

It is recommended that all pipes be cut,

prepared, and pre-assembled before
permanently cementing any joint.

7.

After pipes have been cut and pre-assernbled,apply cement
primer to pipefitting socketand end ofpipe to insertion rnark.

Quicklyapply approvedcernentto end of pipe and fitting
socket(overprimer). Apply cernent in light,uniform coaton

the inside of socketto prevent buildup of excesscement. Apply

second coat.

8. While cement isstill wet, insert pipe into socket with 1Aturn

twist. Be sure pipe is fully inserted into fitting socket.

9. Wipe excess cement from joint. A continuous bead of cernent
will be visible around perirneter of a properly rnade joint.

10. Handle pipe joint carefully until cement sets.

11. Support combustion air and vent piping a minimum of

every 5 feet using pre-forrned rnetal hanging straps. Do not
rigidly support pipes. Allow rnovernent due to expansion and

contraction.

12. Slope horizontal portion of cornbustion air and vent pipes
toward boiler a minimum of 1A"per linear ft. (2h-nrn/rn) with
no sags between hangers.

13° Use appropriate rnethods to seal openings where vent and

combustion air pipes pass through roof or side wall.

Check Gas Supply

The gas pipe to your boiler rnust be the correct size for the length
of run and for the total Btuper hour input of all gas utilization
equipment connected to it. See Table #:3 for the proper size (next
page). Be sure your gas line cornplies with local codes and gas

cornpany requirernents.
The boiler and its indMdual shutoff valve rnust be disconnected

from the gas supply piping systern during aW pressure testing of
that systern at test pressures in excess of 1/2psig (3.5kpa).

The boiler rnust be isolated frorn the gas supply piping systern by
closing its indMdual rnanual shutoff valve during any pressure
testing of the gas supply piping systern at test pressures equal to or

less than 1/2psig (3.50ka).

MAXIMUM GAS SUPPLY

PRESSURE

MINIMUM GAS SUPPLY

PRESSURE

Connecting The Gas Piping
Refer to Figure 12 (on following page) for the general layout at the

boiler. It shows the basic fittings you will need. The gas line enters
the boiler frorn the right side jacket panel. The boiler rnay receive

the gas supply pipe through the left side, or rear jacket panel by
relocating the gas valve connector and pipe assernbly. The boiler
is equipped with a1/2"NPT connection on the gas valve for supply
piping. The following rules apply:

10" w.c. 14" w.c.

4" w.c. 10" w.c.

1. Use only those piping rnaterials and joining rnethods listed

as acceptable by the authority having jurisdiction, or in the
absence of such requirements, by the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 and or the Natural Gas and Propane

Installation Code, CAN/CSA B149.1.

2. Use pipe joint cornpound suitable for liquefied petroleurn gas
on rnale threads only.

3. Use ground joint unions.

4. Install a sediment trap upstrearn of gas controls.

5. Use two pipe wrenches when rnaldng the connection to the gas
valve to keep it frorn turning.

6. Install arnanual shutoff valve in the vertical pipe about 5 feet

above floor.

7. Tighten alljoints securely.

8. Propane gasconnections should onlybe rnade by alicensed

propane installer.

9. Two stageregulation should be used by the propane installer.

10. Propane gas piping should be checkedout by thepropane

installer.

Checking The Gas Piping

The boiler and its gas connection must be leak tested before placing
the boiler in operation. Open the manual shutoff valve. Test for leaks

by applying soap suds (or a liquid detergent) to each joint. Bubbles
forming indicate leak. CORRECT EVEN THE SMALLEST LEAK

AT ONCE.

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

20
40
60

20 131,000 216,000 189,000 393,000
40 90,000 145,000 129,000 267,000
60 72,000 121,000 103,000 217,000

* Outside diameter

Figure 12 - Gas Piping

92,000 190,000 350,000 625,000
63,000 130,000 245,000 445,000
50,000 105,000 195,000 365,000

818" 3/4" 1/2" 3/4"

_///S GAS SUPPLY

PIPING

MANUAL
SHUT=OFF

VALVE

SEDIMENT

TRAP

GROUND JOINT
UNION

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All electrical work must conform to local codes as well as the
National Electrical Code, ANSI/NFPA70, and/or the Canadian

Electrical Code, Part 1,CSA C22.1, Electrical Code.

Electric Power Supply

Prior to making any line Voltage connections, service switch at
boiler should be in the OFF position and the power turned OFF at

the fuse box.

Turn off electrical power at fuse box before

making any line voltage connections. Follow
local electrical codes.

Run a separate 120Voltcircuit from aseparate over current protec-
tion devicein the electricalservice entrance panel. Thisshould be a

15amperecircuit. A service switchhas been pre-wired and located
on the exterior boilerjacket. See Figure 13 for diagracnshowing
locationof serviceswitchjunction box and power supply connection
points. Connect black(hot) leadfrom the power supplyto either

ofthe unused brassscrewsonthe service switch.Connect the white
(neutral) lead from the power supplyto the white screwon the ser-

viceswitch. Connect the green (ground) lead fromthe power supply
to the ground (green)screw on the serviceswitch.Thereceptacleon
the serviceswitchis alwayspoweredregardlessofwhether the switch

is ON or OFF,and could be used asa power supplyfor an external
condensatepump if one is used.

Theboiler,when installed, must be electricallygrounded in accor-
dancewith the requirements ofthe authority having jurisdiction or,
in the absenceof such requirements, with the National Electrical

Code, ANSI/NFPA-70and/or the Canadian Electrical Code Part 1,
CSA-C22.1,ElectricalCode.

Run a 14gaugeor heavier copper wire from the boilertoa grounded
connection in the servicepanel or a properlydriven and electrically

_._nr_ai f.t_au_d'. Pump Wiring

SeeFigure 13 (followingpage)for service switchjunction box and

circulatorpump fieldwiring connections. A5feetwiring harness
with flexiblemetal conduit is supplied to connect the circulator
pump to the service switchjunction box. Ifthe two 120Voltcircula-
tor wire terminals inside the junction box are not used, pleaseleave
the two wire nuts to prevent the short circuit.

LABEL ALL WIRES PRIOR TO DISCONNECTION
WHEN SERVICING CONTROLS. WIRING ERRORS

OPERATION. VERIFY PROPER OPERATION AFTER
CAN CAUSE IMPROPER AND DANGEROUS

SERVICING.

Corners and alcoves Behind doors

Concealed pipes

Concealed pipes or ducts

Fireplace

TV sets

Stairwells- drafts

Unheated rooms on

other side of wall

Radios
Lamps

Direct sunlight

Kitchens

Install Your Thermostat

The thermostat location has an important effect on the operation of
your boiler system. BE SURE TO FOLLOW THE INSTRUCTIONS

INCLUDED WITH YOUR THERMOSTAT.
Locate the thermostat about five feet above the floor on an inside
wall. It may be mounted directly on the wall or on a vertical mount-

ed outlet box. It should be sensing average room temperature.
Avoid the Following:
Set heat anticipator at 0.7 amps. Connect 24 Volt thermostat leads

to the two(2) yellow wires located in service switch junction box,
located on outer jacket of boiler. See Figure 13 for service switch

junction box and thermostat field wiring connections.

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Figure 13 - Field Wiring Connections

f

BOILER
WIRING

tN J-BOX

120 VOLT

CIRCULATOR BK= BLACK

W = WHITE

y G = GREEN

24 VOLT

THERMOSTATW NEUTRALq

Y= YELLOW

// SERVICESWITCH

EIELD WIRING CONNECTIONS

BK HOT _-120 VOLTS

!

J

SERVICE SWITCH

JUNCTION BOX

Figure 14 - D - Schematic Wiring Diagram

E

,, >- (-9 r_ _ "

m

n u n n

cD _ cD _

m LU

UJ _ LT_

0 0

0 0 _

_8

(-9

s9

_<

Ssd

_S£S

£S8S

85E

o

8SSS

_$ss

s_g
_Ss<

<

S

o

!

! I 0

! I-!

_] I ii

.r ! I !

i

_- | i i

! i !

if any of the 0riginal wire as supplied with this appliance must be replaced, it must be replaced with type
150° CTherm0piastic wire or its equivalent

Figure 15 - E- Ladder Wiring Diagram

120 VOLT

POWER SUPPLY,/_X

L1 ,,

HOT' L2

I

ON/OFF SWITCH__f _BLK. WHT

P7-1

2K1 P4-1 / ",

_I )) ------m _ .......

1K1 P10-I CIRCULATOR MOTOR

P5-1 ' " ' ">

DRAFT INDUCER P10-2

HOT SURFACE IGNITER

5K1 P6-1 P12-1 P12-2 P6-2 5K2

l_-->>--4_) (( II ]

120 P1-3

P1-1 _'t_ TRANSFORMER

_L

P4-3

P7-3

<(

P5-3

P2-1

"_' "_>>_-_ __-2

CASTING TEMPERATURE

SAFETY SWITCH GAS VALVE I

(MANUAL RESET) VR8205A /

1 P3-5 P9-3 _ P9-2 P3-2

¥' " ' I I

II ELECTRONIC

G) I_ _ I -_ LOGIC&TIMERS --

Q 1__¢1DIFFERENTIALAIR INDICATOR LIGHTS
O J _ PRESSURE SWITCH _ -- _-_I

£'P3 3 U POWER .'_KI

"ro-o __ O PURGE

;P3-6 O IGNITER

P3-9 AQUASTAT O FLAME " I

HIGH LIMIT O VALVE _t__ 1

P7-2

_- TEMPERATURE

i _- CONTROL lO13-1oCONTROL

I

P3-7

: P3-4

THERMOSTAT

BLOWER
SAFETY SWITCH

POWER SUPPLY. PROVIDE
DISCONNECT MEANS AND

OVERLOAD PROTECTION AS

REQUIRED USE ONLY COPPER

WIRE BETWEEN DISCONNECT
AND THE UNIT

NOTE: "P" LABEL REFERENCE

LOCATION OF CONNECTOR PLUG

BETWEEN SCHEMATIC AND

LADDER DIAGRAM

* CAUTION: RECEPTACLE IS LIVE WHEN

BOILER SWITCH IS OFF

--_>--- REFERENCES PLUG CONNECTION

Thissection provides abrief description of the keycontrolsand
accessoriesfound in this boiler.

Seethe Troubleshooting section (page47 of the ofthis installation
manual) for detailed sequencesofoperation andtroubleshooting

procedures.Seethe RepairPartsManual for locationsof allcontrol
components and accessoriesdescribed.

Integrated Boiler Control (IBC)
The Integrated Boiler Control (IBC) is a microprocessor based

controller for a high efficiency gas boiler that monitors all safety
controls and which controls the operation of the combustion air
blower, circulator pump, burner, and a combination hot surface

igniter/flame sensor. This controller is not intended for use with a
vent damper. This controller is mounted on the control panel inside
of the boiler and contains five (5) diagnostic indicator lights.

Gas Control Valve
The electrically controlled 24 Volt Honeywell Model VR8205

Combination Gas Control Valve is designed to meet the
requirements for use with hot surface ignition systems found in this

boiler. The valve is piped to the gas/air mixer.

Hot Surface Igniter

The 120Volt Hot Surface Igniter heats up to 1800 °F to initiate com-
bustion of the gas in the burner. The igniter is mounted next to the

burner through the gas/air mixer. The igniter also serves as a means
for proving the main burner flame by flame rectification. In the event
of a lack of flame signal on three (3) consecutive trials for igni-
tion, the IBC will loci<out. The "VALVE"and "FLAME" diagnostic
indicator lamps (lamp "D" and "E" on the IBC, See Figure 16) will

blink indicating the failure mode as a lack of flame signal. The IBC is
manually reset from lockout by either removing and reestablishing
the thermostat's call for heat, or by turning the service switch OFF,

then back ON.

High Limit Aquastat Control
TheHighLimitAquastat Control determines the maximum boiler

watertemperature and alsoprovides a means for protecting the
boilerand heating systemfrom unsafe operating conditions which

coulddamagethe boiler. Theaquastat ismounted in the 1/2"NPT
controlwelland 3_,,xl/2,,bushing on the top of the front boiler
section atthe hot wateroutlet. The aquastatis tied in with the
IBCand is factory set at 180°Fwater temperature. Thehigh limit

setpoint isfieldadjustableand maybe set anywherebetween 100
°Fand 200 °E Thefield setpoint adjustment for each installation
depends on heating systemrequirements. Theaquastat automatically
resetswhen the boilerwatertemperature decreases(5-30°F
adjustabledifferential).Thedifferentialcanbe adjusted with the

(white) DifferentialAdjustment Wheel on the aquastat andgivesthe
fexibility for boileroperation. The largerthe differential,the longer
the run cycleofthe boiler.

The maximum setpoint of the Aquastat must

not exceed 200 °F.

Draft Inducer Temperature Safety Switch

The Draft Inducer Temperature Safety Switch is a disc thermostat

(180 °F setpoint) located on the induced draft fan outlet port. The

switch protects the inducer and vent pipe from a potential high
temperature condition for the discharging flue gases. This condition
would typically be a result of higher aquastat setting or over firing.

The temperature safety switch automatically resets when the higher

aquastat setting or over firing. The temperature safety switch

automatically resets when the vent temperature decreases. (15 °F

switch differential).

Casting Temperature Safety Switch

In the event of lack of or loss of water in the boiler, the Casting

Temperature Safety Switch (300 °F setpoint) installed on the top
of the aluminum boiler section shuts off the boiler by shutting off

power to the Integrated Boiler Control (IBC) and causes the Power

Indicator Light to go out. This fault requires manual reset of the

casting temperature safety switch to restart the boiler. Verify that
the boiler is properly filled with water before resetting this switch.

WARNING=Never run cold water into a hot empty boiler.

Differential PressureAir Proving SwRch/BIocked Vent

Safety Shutoff

All 90 SeriesHot Water Boilerscomeequipped with either one (100

Series)or two (200 Series)diaphragm-type differentialpressure

switches.Thedifferentialpressure switchmonitors air flowby

sensingthe differentialpressure measured in inchesof water ("w.c.).

Thepressureswitch contactsclosewhen the draft inducer is running.

Theclosedswitchprovesthere is adequateair flowfor combustion.

Thepressureswitch shutsoffthe main burner if the differential
pressure isinadequate due to a blockedvent pipe, a blocked air

intake,blocked boilersections, or a blockeddraft inducer. After
five(5)minutes of lackofadequate differentialpressure, the IBC

willlockout and the "Purge"indicator light willblink,indicating a
failure to prove adequate combustion air floworflue gas flow.The

IBCwill beautomaticallyreset after fifteen(15)minutes or can be
manually resetfrom loci<outby (a) removing and reestablishingthe
thermostat callfor heat or (b) byturning the serviceswitchOFFand
back ON again.Ifthe boiler cannot be restored to normal operating

conditions byresetting the control, contact a quallified service

agencyto checkthe heat exchangerflue-waysforblockage.

Draft Inducer

The draft inducer (blower) provides a means for pulling combustion
air into and through the mixer, the burner, the flue ways of the
cast aluminum boiler sections and the flue adapter before being
discharged through the vent piping to the outdoors. See applicable
sections for proper sizing and installation of combustion air and vent

piping in this manual.

Circulator Pump

Everyforcedhot water systernrequiresatleastone circulating purnp.
Thecirculatingpump imparts the necessaryenergyto movethe
waterthrough the closedloop supplyand return pipingsystems,

terminal heating equipment (i.e.finned tube radiators, etc.)and back
through the boilerfor reheating. Toprovide the required hot water
flowrates,the circulator pump must be properly sizedtoovercome
frictional losses(usuallymeasured in feet of water,alsoreferredto
as"pump head loss")of the supplyand return piping systemsand
boiler.The circulatorpump isfurnished in acartonwithin the boiler

cabinet for a singlezone or zone valvecontrolledheating systernand
should be correctlylocatedon the downstream (i.e.,pumping away)
side ofthe expansion tank. Fora pump controlled system(where
there is a circulator for each zone) the circulatorprovided with

the boilercanwork forone zone. For more detailsonpiping and
circulators,seeNear Boiler Pipingsection (page 12of this manual).

Drain Valve

Blocked Vent Safety Shutoff

This boiler is equipped with ablocked vent safety shutoff rneans,
which shuts offrnain burner gas in the event that the flow of

combustion products through the flueways is reduced. In the event
of blocked flueways, enough air will not be available to support

combustion, and the $9301 Integrated Boiler Control (IBC) will
loci<out due to loss of adequate air flow (after 3 trials for ignition).

The "PURGE" diagnostic indicator larnp (larnp "B" on the IBC,

see Figure 16) will blink indicating the failure rnode as a lack of

adequate air flow. The IBC is rnanually reset frorn loci<out by either

removing and re-establishing the thermostat's call for heat, or by
turning the service switch OFF, then back ON. If the boiler cannot

be restored to normal operating condition by resetting the control,

contact a qualified service agency to check heat exchanger flueways
for blockage.

External Condensate Pump (Optional)

For installations where there is no floor drain or other appropriate
drainage receptacle available to receive condensate frorn the boiler,

an external float activated condensate purnp with integral sump is

required. This unit can be installed to purnp the condensate to a

remote tie in point to a sanitary sewer system. For this application,
the boiler rnust be installed so that proper pitch of piping to
the external condensate reservoir (surnp) can be accornplished.

Use wood frarne or blocks to raise boiler as required for proper

installation.

The manual drain valve provides a means of draining the water in
the heating system, including the boiler and hot water supply and

return piping systems installed above the drain valve. This drain
valve is installed in the 3_,,tapping at the bottom of the front boiler
section. Any piping installed below the elevation of this drain valve
will require additional drain valves to be installed at low points in
the piping systerns in order to drain the entire systern.

A.S.M.E. Rated Pressure Relief Valve

Each boiler rnust have a properly sized and installed American
Society of Mechanical Engineers rated pressure relief valve. Water
expands as it is heated by the burner/boiler sections. If there is no

place for the water to expand its volurne, (i.e. a properly sized and
properly functioning expansion tank) pressure on the inside of the
boiler and heating systern will increase. The furnished relief valve
will automatically open at 30 psig pressure to relieve the strain on
the boiler and heating system frorn the increasing pressure. The

pressure relief valve discharge rnust be piped with piping sarne size
as the valve discharge opening to an open drain, tub or sink, or other
suitable drainage point not subject to freezing, in accordance with
A.S.M.E. specifications. Failure to provide the pressure relief valve
with piping as herein described may cause water darnage and/or

serious bodily injury. The boiler rnanufacturer is not responsible for
any water damage or personal injury.

Whenfillingtheboilerwateristhepreferredheatingsolution.Most
potablewatersuppliesmaybeusedtochargeandre-fillprovidedthe

chlorineandchlorideionslevelsarelessthan100ppm.
Antifreezemaybeusedinmostapplicationsprovidedallofthefol-

lowingconditionsaremet:

1. Unlessastrictscheduleofsampling,analysisandmaintenance
oftheantifreezesolutionisfollowed,theboilermustbepiped

asaprimaryloopconnectedtosecondaryloopasshowninthe
Piping&WiringDiagramAppendix.Failuretoperformregular

rnaintenancetotheantifreezernanufacturer'sinstructionswill
resultindamagetotheheatexchangerandthevoidingofboiler

warranty.

2. Onlytheantifreezemanufacturerslistedbelowareselected.

3. Atinstallationofaneworreplacementboilerandatleaston
anannualbasisthesystemantifreezemustbeanalyzedbythe

antifreezesupplierortheirrecommendedlaboratory.

4. Adjustmentstothesystemantifreezemustbemadeaccording
totheantifreezemanufacturersrecornrnendationsusingonly
theirrecornrnendedproducts.

S. All existing systems MUST be flushed of ALL old system fluid.

Failure to do so may void the boiler warranty if evidence of im-
proper flushing is revealed. Consult with your heating profes-

sional for recommendations.

Piping Recommendations

Systemleaks may not alwaysbe visible.An unseen systemleakwill
become obviousif boiler pressure decreaseswhen make upvalveis

closed.
Allsysternleaksmust be repaired immediately.Constant introduc-

tion of make up waterwillintroduce dissolved oxygen,resulting in
acceleratedboiler corrosion.

It is recommended that Primary/Secondary piping be used with any
of the recornmended antifreeze solutions found in this rnanual. See

the Piping & Wiring Diagram Appendix.

Water Chemistry
Thisboiler is designed for a closedloop hydronicheat systernONLY!

Thisboiler is not suitablefor natural gravity type installations,or any
other open type systern.

Systernfluid pH rnust be rnaintainedbetween 7.0 and 8.0.
Maintain waterhardnessbelow7grains hardness.
Fillingwith chlorinated freshwatershould be acceptablesince

drinldng water chlorine levelsare typicallylessthan 5 ppm. Do not
fillboiler withwater containing chlorine and chloride ions levels

greaterthan 100pprn.
Donot use inhibitorsor other additivesthat are not specificallyap-

provedby the antifreeze rnanufacturer for this product.
Consult the antifreezemanufacturer if any ofthe aboveare outside

the statedranges.

Cleaning the Hydronic System

IMPORTANT: Do not mix different manufacturers'
products, Doing so will void the warranty of the boiler,

Consideration MUST be given to cleaning the heating systern,

particularly in retrofit situations where a new boiler with an

alurninurn heat exchanger is being installed in an existing piping
systern.

All existing systems rnust be cleaned and flushed according to the

antifreeze rnanufacturer's recornrnendations.
Systerns that have antifreeze that is not recornmended by the boiler

rnanufacturer rnust be completely flushed to ensure no unapproved

antifreeze remains according to the recomrnended antifreeze

rnanufactures recornrnendations. Evidence of an alternate antifreeze

in the systern may void the boiler warranty.
In older systems obviously discolored, murky or dirty water; or a pH
reading outside the boiler rnanufacturer's stated acceptable range

(pH 7.0 to 8.0) are indications that the systern should be cleaned or

treated.

1. Measure total capacity of the systern including the piping,
tanks, boiler, collector plates, etc. The most accurate rnethod
of rneasuring fluid capacity is to fill the system and then

cornpletely drain it, volurnetrically rneasuring the fluid drained.

2. Thoroughly flush the systern with clean water to remove any

sediment or contarninants. Sludge and iron oxide deposits can
cause rapid breakdown of inhibitors.

3. Cleaning fluid - Flushing with clean water is preferred. If

cleaning fluid is used, only use cleaner specifically approved for
use with aluminurn boilers. Use only cleaning fluids and the

procedure recornrnended by the antifreeze rnanufacturer.

Freeze Protection

Aluminum Safe Antifreeze, Treatments and Additive

Guidelines:

Antifreeze, if required, must be one of the antifreeze manufacturers
listed in this rnanual. See the "Recommended Alurninurn Antifreeze

& Inhibitor Suppliers" section of this rnanual for a list of boiler

rnanufacturer approved products.
Always clean system prior to using antifreeze, refer to the Cleaning

the Hydronic Systern section of this rnanual for details.

Only use the antifreeze rnanufacturers' products outlined in this

docurnent.

Use of antifreeze rnust be in accordance with local plurnbing codes.
Dispose of old antifreeze and boiler systern water in accordance with

local authorities.

Antifreeze will raise the pH of the hydronic solution in

a heating system above the recommended level due to

the corrosion inhibitors in the antifreeze. The solution

must be treated to rnaintain a pH within the boiler rnanufacturer's
recornmended level to avoid darnage to the heat exchanger. Follow

antifreeze manufacturer's instructions for details on how to adjust
the pH.

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If the systern has leaked for some reason, the water and antifreeze
chemistry will need to be adjusted. To avoid damage to the boiler,

check the pH and chemistry of the boiler solution and consult the
antifreeze manufacturer for recommendations.

It is recommended that apH reading is taken annually, and adjusted
as necessary. Follow antifreeze / inhibitor manufacturer's instruc-

tions for details on how to adjust the pH.

• Use of antifreeze in any boiler will reduce heating capacity as
much as 10-20%. This must be taken into consideration when

sizing the heating system, pumps and expansion tank. Consult
antifreeze manufacturer's literature for specific information on
reduced capacity.

• Using the antifreezemanufacturer'sinstructions to determinethe

Interstate Chemical
2797 Freedland Road

P.O. Box 1600 Hermitage, PA 16148-0600

www.interstatechemical.com

Tel:[phone] Fax: [phone]

freezing temperature needed and use the correct amotmt of anti-
freeze.Never exceed 50%antifreeze by volume.

The boiler operating pressure must remain below 15 psi for anti-
freeze solutions that specify a maximum of 250°F (12I°C).

nt_freezesolutionscanbreakdownovert_me.

Failure to check antifreeze chemistry, includ-

...........................ing inhibitors, annually may result in accel-

erated corrosion of boiler and other system
components. Consult with the antifreeze

manufacturer for recommendations.

Intercool NFP-30,40,50 AA
Intercool RPH- 15*

Noble Company

PO Box 350 Grand Haven, MI 49417

www.noblecompany.com

Tel:[phone] Fax: [phone]

Rhomar Water Management, Inc.
PO Box 229 Springfield, MO 65801

www.rhomarwater.com

Tel:[phone] Fax: [phone]

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

cases it is recommended to flush the system and refill with untreated water and new boiler manufacturer approved antifreeze suitable
for Aluminum heat exchangers.

Noburst AL Antifreeze

RhogardAntifreeeze
Pro-Tek922 Inhibitor*

I_PORTANT: Regardlessofantifreezeor inhibitors used, besure to followthe antifreeze manufacturer's instructions for use,safe
handling and storageoftheir products. Refer to the MSDS(Material SafetyDataSheets)provided bythe antifreezemanufacturer for
potential hazards and first aid procedures for exposureor ingestion.

_ntffreeze Te_ting Services: Each ofthe recommended antifreezemanufacturers havedevelopeda samplingprogram availableto
the homeowner and contractor. Contact the antifreeze manufacturer regardingtheir samplingplanprocedure. Consult the antifreeze

manufacturer for details on sample requirements and recommendations.

Theboiler manufacturer reservesthe right to make changeswithout notice.

Filling Boiler With Water And Purging Air For Systems
With Diaphragm Type Expansion Tanks

Referto the appropriate diagrams in Section VII, "NearBoilerPip-
ing_'formore information.

1. Closeallzoneservicevalveson the supplyand return piping.
Open the feedvalve and fillboilerwith water. Make sure air
vent isopen. Hold reliefvalveopen until water runs air free for
fiveseconds to rapidly bleed air from boiler,then let the relief
valvesnap shut.

2. Open the zone servicevalveon the supply pipefor the first
zone.Open the purge valveon thefirst zone. Feed waterwillfill

the zone,pushing air out thepurgevalve.Closethe purge valve
when the water runs air free. Closethe zone servicevalve.

3. Repeatstep2for allremaining zones.

4. Open all servicevalves.Any air remaining trapped in the return
lines between theservicevalves and the boiler willbepushed
towards the airvent when the boilerisplaced in operation.

5. Inspect piping system. Repairany leaksimmediately.

Purging Air ForSystemsWith Conventional Closed Type
Expansion Tanks:

Referto the appropriate diagrams in Section VII,"NearBoiler
Piping;' formore information.

1. Closeallzoneservicevalveson the supplyand return piping
and close the expansiontank servicevalve.Drain expansion
tank. Open the feed valve and fillboilerwith water. Hold relief
valveopen untilwater runs air freefor fivesecondsto rapidly
bleedair from boiler, then let the reliefvalvesnap shut.

2. Open the zone servicevalveon the supply pipefor the first
zone.Open the purge valveon thefirst zone. Feed waterwillfill

the zone,pushing air out thepurgevalve.Closethe purge valve
when the water runs air free. Closethe zone servicevalve.

3. Repeatstep 2for allremaining zones.

4. Open the expansion tank servicevalveand the tank vent. Fill
the tankto the proper leveland closethe tank vent. Removethe
handle from the expansion tank servicevalvesothe homeowner

doesn't accidentallycloseit.

5. Open all servicevalves.Any air remaining trapped in the return
lines between theservicevalves and the boiler willbepushed

towards the expansiontank when the boiler isplaced in opera-
tion.

6. Inspect piping system. Repairany leaksimmediately.

Placing Boiler In Operation

If you do not follow these instructions
exactly, a fire or explosion may result

causing property damage, personal injury or

loss of life.

A. This appliance is equipped with an ignition device which

automatically lights the pilot. Do not try to light the pilot

by hand.

B. BEFORE OPERATING smell all around the appliance area

for gas. Be sure to smell next to the floor because some gas

is heavier than air and will settle on the floor.

What To Do If You Smell Gas

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in
your building.

•Immediatelycallyour gas supplier from a neighbor's
phone. Follow thegassupplier's instructions.

• If you cannot reach your gas supplier, call the fire depart-
rnent.

C. Use only your hand to move the system control switch.

Never use tools. If the switch will not move by hand, don't
try to repair it, call a qualified service technician. Force or

attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water.

Immediately call a qualified service technician to inspect

the appliance and to replace any part of the control system

and any gas control which has been under water.

DO NOT use stop leak compounds. Leaks

in threaded connections in the aluminum

boiler sections must be repaired immediately.

Aluminum threads will not seal themselves.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

1, STOP! Read the safety information above on this label.

2, Set thermostat to lowest setting.
3, Turn off all electric power to the appliance.

4, This appliance is equipped with an ignition device which

automatically lights the burner. DO NOT try to light the burner
by hand.

5, Remove the front jacket panel.
6, Turn the gas control knob clockwise _'_ to "OFF".

GAS CONTROL KNOB /

SHOWN IN "ON" POSITION

1. Set the thermostat to lowest setting.

2, Turn off all electric power to the appliance ifservice is to be

preformed.

/

7. Wait five(5) minutes to clearout anygas.Then smellfor gas,
including near the floor. Ifyousmellgas, STOP! Follow"B"

in the safetyinformation aboveon this label. Ifyou don't smell
gasgoonto next step.

13. Turn thegascontrol lmob counterclockwise_'_ to "ON".

9. Replacefront jacket panel.

10. Turn on allelectricalpower to the appliance.

11. Setthe thermostat to desiredsetting.

12. Ifthe appliance willnot operate, followthe instructions "To
Turn OffGasTo Appliance" and callyour servicetechnician or

gassupplier.

3. Removethe Dont jacket panel.

4. Turn gascontrolknob clockwise_ to "OFF".

5. Replacethe front jacket panel.

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler
underwent tests specified in ANSI Z21.13-latest revision.

Verify Proper Sequence Of Operation

The sequence can be followed via the diagnostic indicator lamps on
the Honeywell $9301A integrated boiler control in Figure #16.
This is the normal sequence of operation. A more detailed sequence
of operation containing potential faults can be found in the service

hints section.

Figure 16 - Indicator Lamps

""- T_NSFORMER

"Power ON, boiler standing by. Lamp A is illuminated

indicating 2 Volt power is being supplied to the inte-

grated control."

Thermostat calls for heat, energizing system circulator

"Integrated boiler control goes through self check of

internal circuitry (1-2 seconds) and energizes draft
inducer"

"Draft inducer comes up to speed and establishes com-

bustion airflow, causing the normally open differential
pressure air proving switch contacts to close. Lamp B is
illuminated indicating that combustion airflow is proved

and the 15 second pre purge cycle"

CONTROLPANEL

AIRPRESSURESWITCH

A.O

B.O
C.O
D.O

E.O

A.O

B.O
C.O
D.O

E.O

A.O

B.O
C.O
D.O

E.O

A.®

B.O

C.O
D.O

E.O

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After pre purge, Lamp B goes out and Lamp C illuminates, in-
dicating the hot surface igniter is powered for the 20 second

igniter warm-up period. The bright yellow orange glow of the
hot surface igniter can be observed through the observation
port in the front boiler section just above the igniter.

After igniter warm-up, the gas valve is energized, and opens
on the normal firing rate regulator (2.5" w.c.) for a 6 second trial
for ignition. Lamp D illuminates. The blue orange glow of the

burner can be seen through the observation port.

A.O

B.O
C.o

D.O

E.O

A.O

B.O
C.®
D._
E.®

Two seconds later, Lamp C goes out as power is turned off to the

hot surface igniter. During the last two seconds of the 6 seconds
trial for ignition, main burner flames is proven by flame rectifica-
tion through the hot surface igniter, providing flame rectification
to the integrated boiler control and fully illuminating Lamp E. The
gas valve remains energized, and the boiler runs.

Thermostat ends call for heat, de-energizing gas valve and
system circulator. Burner stops firing, and Lamp D goes out.

Draft inducers remains powered. Lamp B illuminates, indicating
draft inducer is running for 30 second post-purge.

After 30 seconds, draft inducer is de-energized. Lamp B goes
out. Boiler stands by for next call for heat.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

First couple of cold starts may be rough due

to gas line not being completely purged of

air, causing low firing rate and high excess air

levels.

Inspect Venting And Air Intake System

Operate the boiler and verify that allvent/air intake connections
are gas-tight and watertight. Repair any leaks immediately.

Inspect Condensate Drain

Verify that all connections are watertight, and that condensate flows

freely. Repair any leaks immediately.

A.®

B.O

C.O

D._

E.®

A.®

B._
C.O
D.O

E.O
A._

B.O
C.O
D.O

E.O

Inspect System Piping

Verify that all connections are watertight. Repair any leaks

immediately.

Test Ignition System Safety Shutoff Device

1. Turn offmanual gas valve

2. Set thermostat to call for heat

3. Boiler begins normal sequence of operation

4. After approximately 40 seconds (pre purge and igniter warm-
up period), lamp D illuminates, indicating gas valve is powered

5. After 6 seconds, gas valve closes, lamp D goes out as integrated
boiler control senses that flame is not present

6. To restart system, follow operating instructions under "START-

UP PLACE IN OPERATION"

Test High Limit Control And Adjust

While burner is operating, move indicator on high limit control
below actual boiler water temperature. Burner should go offwhile
circulator continues to operate. Raise limit setting above boiler water
ternperature and burner should reignite after pre purge and igniter
warm-up period. Set the high limit control to the design ternperature

requirernents of the systern. Maximum high limit setting is 200°E
Minirnurn high limit setting is 100°F.

Test Other Safety Controls
Ifthe boiler is equipped with a lowwater cut off,amanual reset high

limit,or additional safetycontrols,test for operation asoutlined by
the controlmanufacturer. Burner shouldbe operating and should

go offwhen controlsaretested.When safetycontrols are restored,
burner should reignite.

Set Thermostat Heat Anticipator (If Used) And Verify
Thermostat Operation

For a single therrnostat connected to the yellow thermostat lead
wires in the furnished field wiring junction box, the heat anticipator
should be set at 0.7 amps. For other wiring configurations, refer to
the instructions provided by the thermostat manufacturer regarding

adjustment of heat anticipator. Cycle boiler with thermostat. Raise
the therrnostat to the highest setting and verify boiler goes through
normal start up cycle. Lower thermostat to lowest setting and verify
boiler goes off.

Measure The Natural Gas Input Rate

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

1. Deterrnine elevation at installation site.

2. See page 6 and 7 of this manual to deterrnine the correct input
rate for the local elevation.

3. Obtain the yearly average heating value of the local gas
supply from the gas utility. At sea level elevation, it should be

approximately 1000 Btu's per standard cubic foot.

4. Operate boiler for 5minutes.

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

6. At gas rneter, rneasure time in seconds required to use one
cubic foot of gas.

7. Calculate input rate according to the following forrnula:

3600xheating value from step 3

Btuh inputrate = time frorn step 6

8. Measured input rate should be within +/-2% of the input rating
from step 2. If within 2%, go to step 9. If not, adjustment is
required, proceed as follows:
A. Turn boiler off

B. Set up U-tube manometer or differential pressure gauge for

measuring manifold pressure, see Figure #17.

C. Manometer or gauge rnust be able to read at least 0.0 to 3.0

inches water colurnn of pressure, and resolve to at least 0.1
inches water colurnn.

D. Turn boileron.
E.

Manifoldpressurehas been norninally set at 2.5inches

w.c.Manifold pressure and input rate rnust alwaysbe
rneasured with pressure regulator cover screw installed.

Coverscrewmust be removed for adjustrnent. Manifold

pressure readingwill change (increase)when cover screwis

rernoved.

P.

After adjustinginput rate, turn boiler off,rernove
rnanometer or pressure gauge,reinstall V8"plug on gas

valve.Turn boileron.

9o

Restoreallgas appliancesthat rnayhave been shut off (while

rneasuring boilerinput rate) to norrnal operating conditions.

I.

Rernoveregulator cover screw on top of gasvalve,and insert
an appropriate screwdriver into adjustrnent screw.

II. Turn adjustrnent screw clockwiseto increase input rate,or

counter clockwiseto decrease input rate.

III.Replacecover screw,or cover hole temporarily with your

fingerto checknewrnanifold pressure setting. Donot set
rnanifoldpressure lower than 2.0 inchesw.c.or higher than 3.0
inchesw.c.when adjusting input rate.

IV.Measure new input rate (cover screw rnust be installed).

Repeat steps I.-IV until the input rate iswithin +/-2% of the
narneplate input rating.

V.

If the actual input rate can not be set to within 2% of the
correct input rating by adjusting rnanifold pressure, a change
in gas orifice size is required. Consult the boiler manufacturer
for inforrnation on correct orifice sizing. The specific gravity

(G) and the higher heating value (HHV) of the local natural

gas must be obtained from the local gas utility in order to
deterrnine the proper orifice size.

Set Thermostat To Desired Room Temperature
Observe several operating cycles to verify proper operation.

Review All Instructions

Review all instructions shipped with this boiler with owner or

rnaintenance person. Instructions rnust be affixed on or adjacent to
the boiler.

Complete and sign the installation and check-out

certificate found in this rnanual.

The following steps and diagram indicate the location of the
connection points required to measure the manifold pressure.

The manifold pressure may be measured using aU-Tube Manometer
or a Differential Pressure Gauge. The diagram shows the connection
of both measuring devices. Only ONE DEVICE IS REQUIRED to
measure the manifold pressure.

Remove the plug. Install the appropriate barbed fitting and connect
the pressure side line from the U-Tube Manometer or Differential

Pressure Gauge.

Figure 17 - Manifold Pressure Measurement Detail

Refer to "CHECK OUT PROCEDUREAND ADJUSTMENTS" in

this manual when reading themanifold pressure.
When measurement is completed,disconnect the U-Tube

Manometer or DifferentialPressureGauge.Be suretoreinstallthe
V8"plug, using appropriate pipe thread sealant approved for usewith

natural and liquefiedPetroleumgases.

PRESSUREREGULATOR

ADJUSTMENT

(UNDER COVER SCREW)

OUTLET PRESSURE TAP

(1/8,_

//G IAL _,,.......

VALVE VENT

CONNECTOR W/CAP

.........................................TO PRESSURE SWITCH

WH[TETRANSPARENT
VINYLTUBING

MANOMETER

Figure 18 - Gas Valve

PRESSURE REGULATOR

ADJUSTMENT (UNDER CAP SCREW)

VR8205

INLET

PRESSURE

TAP _

INLET I_

GASCONTROLKNOB

WIRING TERMINALS(2)

OUTLET
PRESSURE

I_ OUTLET

Regulator cover screw must be installed at
all times unless adjusting manifold pressure.
Firing rate and manifold pressure must only
be measured with cover screw firmly installed.

INSTALLATION AND CHECK-OUT CERTIFICATE

Boiler Model Serial # Date Installed

Measured BTU/HR input

© Installation instructions have been followed

© Checkout procedure and adjustments performed

© Maintenance and Service issues reviewed with owner/maintenance person

© Installation booklet affixed on or adjacent to boiler

Installer (Company)

Address

Phone

lnstaller's Name

Signature

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

Theacidicnature offlue gassescondensing on the aluminum boiler
sectionswillcause the formation of aluminum oxide.Thisoxide

formation is normal, isgenerallyuniform throughout the boiler
sections,and represents anegligiblemassofaluminum that is

consumed byoxidationduring the lifeof the boiler.If leftunchecked,
this buildup may eventuallycause blockageof the fluegas passages
in the boiler sections,reducing efficiency,and ultimatelyshutting
downthe boilerdue to lack ofcombustion air flow.Regularservice

and maintenance by a qualifiedservice agencymust be performed to
assure safetrouble freeoperation andmaximum efficiency.

Beginning Of Each Heating Season

1. Annual service call by a qualified service agency, which
includes:

A. Examine flue passages between boiler sections, burner,

and condensate lines, and clean if necessary following
the annual examination and cleaning instructions in para
graph "F" on the next page.

B. Visually inspect venting and air intake system for proper

function, deterioration or leakage. If the vent or air intake
show any signs of deterioration or leakage, repair or replace

them, immediately. Insure proper reassembly and resealing
of the vent and air intake system

C. Check for and remove any obstruction to the flow of

combustion air or venting of flue gases. Check the air baffle
located inside 11/2"x 2" fexible coupling on the mixer,

clean it if necessary and make sure to put it back. Refer to
repair parts diagram of mixer and pressure switch assembly

for exact location.

D. Follow instructions for "PLACING BOILER IN

OPERATION".

E. Follow instructions for" CHECK OUT PROCEDURE

AND ADJUSTMENTS".

F. Visually inspect condensate drain line for proper operation

and deterioration. Check for plugged condensate drain
line.

G. Checkthe silicone rubber sealsbetween boiler sections.

Insure that there are no leaks. UseRTVsiliconerubber
adhesivesealant (availablein caulkinggun tubes) rated for

atleast400°Fto replace or repair sealsin locations where
original sealshave deteriorated.

H. Checkallgasketedjoints for leakage,and tighten bolts or

replacegaskets if necessary.

I. Removejacket front and top panels and check for piping

leaksaround reliefvalveand other fittings. Repair,if found.
DO NOT use stop leak compounds.

.

Checkthat boiler areais freefrom combustible materials,

gasoline, and other flammablevapors and liquids.

.

Circulator pump and blowermotor furnished with boiler are
permanently lubricated from factoryand require no further
lubrication. Additional or non-factory suppliedpumps and/
or motors should be lubricated accordingto the pump and/or

motor manufacturer's instruction.

Daily During Heating Season

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

2. Check that boiler area is free from combustible materials,

gasoline, and other flammable vapors and liquids.

Monthly During Heating Season

I. 1. Remove jacket front and top panels and check for piping

leaks around relief valve and other fittings. If found, contact
a qualified service agency to repair. DO NOT use stop leak
compounds.

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

3. 3. Visually inspect venting and air intake system for proper
function, deterioration, or leakage. Ifthe vent or air intake show
any signs of deterioration or leakage, contact a qualified service
agency to repair or replace them immediately and to insure

proper reassembly and resealing of the vent and air intake
system.

4. 4. Visually inspect the clear vinyl condensate lines and the
PVC condensate drain pipe for proper operation, leakage, and
deterioration. If the condensate lines or drain pipe show any

signs of blockage, leakage, or deterioration contact a qualified
service agency to clean, repair, or replace them immediately.

5. 5. Check the air baffle located inside 11/2"x 2" flexible coupling,
clean it if necessary and make sure to put it back. Refer to repair
parts diagram, mixer and pressure switch assembly.

Periodically During Heating Season

Where low water cut offs are used, a periodic inspection of the low
water cut offis necessary, including flushing of float type devices.
Refer to low water cut offmanufacturer's specific instructions.

End of Each Heating Season - Annual Shutdown Procedure

Follow instructions "TO TURN OFF GAS TO APPLIANCE".
If heating system is to remain out of service during freezing weather,

and does not contain antifreeze, drain system completely. Ifboiler
will be exposed to freezing temperatures, drain condensate lines.
Otherwise, do not drain system or boiler.

Annual Examination And Cleaning Of Boiler Components

1. BeforeServicing,turn offelectricalpower to boiler at service
switch.Close manual gas valveto turn offgas supplyto boiler.

The following service procedures must be

performed only by a qualified service agency.
Boiler owner should not attempt these
procedures.

o

Cleaning Fluepassagesbetween boiler sections.

A. Any buildup of sediment or aluminum oxide (white

powdery or flakysubstance) in the flue passagesmust be

cleanedasfollows:

B. Removejacketfront and top panels. Disconnect

condensate drain line from the barbed fittingon the

bottom ofthe boiler. Keepthe open end ofthe drain line

abovethe water levelin the condensatetrap to prevent

the trap from draining. Disconnect pressure switchhose
from barbedfitting on gas valve.Disconnect 11/2x 2"

flexiblecouplingfrom airinlet. Disconnect air by-pass(1/2"

transparent vinyl tube) from the bottom ofthe mixer.

C. Removeair bafflefrom 1/2"x 2"flexiblecoupling and clean

airbaffleif necessary.Referto repair parts diagram, mixer
and pressure switch assembly.

D. Confirm that manual gasvalveis closed and disconnect gas

line to gasvalve atunion. Disconnect wires to gasvalve.

and igniter.

E. Loosenbut do not removefive(5) nuts attaching mixer

assemblyto boiler. Removetwo (2) igniter screwsand very
carefullyremove the igniter. Usecare when removing the
igniter,it is verybrittle!

F. Removefive (5)nuts and remove mixer assembly.Remove

burner and mixer gasket.

G. Aluminum oxidedeposits arewater solubleand may be

rinsed awaywithsprayingor running water. Beforerinsing,
connect a1/2"I.D.hoseto the barbedfitting on the bottom

of theboiler and run thehose to a bucket or drain.

H. After rinsing, remove any remaining loosened sediment

using a shop vacuum with asnorkel attachment.

I. Inspect burner for any foreign matter in the flame ports or

inside the burner. Any foreign matter should be removed

by blowing with compressed air or vacuuming.

]. Inspect interior of mixer for any signs of sediment or

aluminum oxide and clean ifnecessary.

K. Reinstall burner and mixer gasket and position mixer

assembly over studs. Install five (5) nuts but do not tighten.
Reinstall igniter and igniter gasket and fasten with two
(2) screws. Use care when installing the igniter. It is very
brittle! Tighten five (5) nuts holding mixer assembly.

L. Connect:

•Gas line to gasvalve

•Condensate drain line to boiler

•Pressure switch hose to gas valve

•Air by-pass to mixer

• 1 1/2"x 2" flexible coupling to air inlet and make sure to put
air baffle back to correct position

•Igniter wires

•Gas valve wires

o

Visuallyinspect condensate lines leadingfrom the boiler
sectionsand the vent tee to the condensate trap. Referto repair
parts diagrams. Any foreign material or debris that is visiblein

the condensate linesneeds to be cleanedout asfollows:
A. Raisecondensate trap and drain condensate lines

completely.

B. Oncethe condensate trap isemptied ofwater,disconnect

condensate linesfrom the fittings on the boiler,the vent
tee, and the condensate outlet.

C. Removethe condensate trap and run coldwater through

the condensate linesto thoroughly flush out any sediment
or debris in the lines.

o

Inspectionoftheflueconnectorrequiresthefollowingsteps(Referto

therepairpartsdiagram.)
A. Loosenthe clamp on the draft inducer end of the 2"

flexiblecouplingthat connects thevent tee to the draft
inducer. Disconnect (unplug)wiring harness from draft
inducer motor and draft inducer temperature safetyswitch.

Removefour (4)bolts that attach draft inducer to flue
connector.

B. Removedraft inducer and gasketfrom top of flue

connector.

C.

Inspect interior of flue connector. Any buildup of sediment

or aluminum oxide on the inside surface must be cleaned.

Position the draft inducer gasket and the draft inducer
and fasten with four (4) screws. Be sure to connect ground

wire from draft inducer motor to one of the four mounting

screws.

D. Connect wiring harness leads to the draft inducer motor

and the draft inducer temperature safety switch.

E. Connect the 2" flexible coupling to the draft inducer outlet.

D. Reinstall and connect the condensate trap, using the hose

clamps to secure the various condensate lines to their
fittings.

E. Follow the instructions under "NEAR BOILER PIPING"

for" filling condensate trap with water"

Service Hints

THERMOSTAT

CALLS FOR HEAT

CIRCULATOR

ENERGIZES THRU

2KI CONTACTS

iNTERNAL CiRCUiTRY

°2 SEC

CONTROL W_LL ATTEMPT 2

ADDITTI:ONAL IGNITION SEQUENCES_

[

STARTING WITH PREPURGE

L

DRAFT INDUCER

ENERGIZES THRU

1K1 CONTACTS

CLOiSED

DURING THE _ST 2 SEC OF THE 5 SEC IGNmON

TRIAL MAIN BURNER FLAME JS PR:OVED BY FLAME

RECTiF|CATION A F_ME S{GNAL TO 18C GAS \JALVE

REMAINS ENERGIZED 80_LER RUNS

2 SEC _NTO THE 5 SEC IGNmON TRIAL, POWER

_S TURNED OFF TO THE HOT SURFACE _GNITER

|GNiTER LIGHT iS OFF.

DOES

MA_N

BURNER PROVE

FUME W_TNiN [NmAL

"TRIAL FOR

IGNmON

PERIOD?

NORMAL

OPERATION

_OPEN _ F

- _

PURGE LIGHT |S ONAiRFLOW PROVED

DRAFT INDUCER RUNS FOR i5 SEC PREPURGE

GAS VALVE OPENS FOR 5 SEC TRIAL FOR

iGNITiON, BLUE ORANGE GLOW OF THE BURNER

q

!

!

CAN BE SEEN THRU OBSERVATI[ON PORT

GAS VALVE ENERGIZED THRU 3K1 AND 4Ki,

CONTACTS VALVE LIGHT IS ON.

[

PURGE LIGHT GOES OUT HOT SURFACE IGNITER

POWERED THRU 5Kt 5K2 CONTACTS FOR 20

SEC iGNITER WARMUP. ERIGHT YELLOW

ORANGE GLOW OF THE HOT SURFACE iGNiTER

CAN BE DESERVED THRU THE OBSERVATION

PORT IN FRONT OF BOILER SECTION JUST

ABOVE tGN_TER_GNITOR LIGHT IS ON

DRAFT INDUCER TEMPERATURE SAFETY SWITCH

CASTING TEMPERATURE SAFETY SWITCH

IF DRAFT INDUCER TEMPERATURE REACHES

TEMPERATURE SAFETY SWITCH SETPOINT,

SAFETY SWITCH CONTACTS OPEN IMMEDIATELY

CLOSING GAS VALVE (LIGHT GOES OUT)

I Draft Inducer Runs Thru 30 Second Post Purge And I

I CIRCULATOR RUNS WITH THERMOSTAT ON !

WHEN TERMPERATURE SAFETY SWITCH

CONTACTS REMAKE BEFORE END OF CALL

FOR HEAT, CONTROL GOES INTO NORMAL

IFAN ESTABLISHED FLAME SIGNAL IS LOST WHILE

CONTROL EXPECTS THAT THE BURNER IS OPERAT-

ING, CONTROL WILL IMMEDIATELY DE-ENERGIZE
GAS VALVE. VALVE AND FLAME LIGHTS GO OUT.

Switches Off.

CALL FOR HEAT.

SEQUENCE.

LOSS OF FLAME SIGNAL

IF BURNER OPERATES WHEN BOILER HAS NO

WATER, ALUMINUM BOILER SECTIONS HEAT UP

RAPIDLY.

i

!

CASTING TEMERATURE SAFETY SWITCH CON-

TACS WILL OPEN BREAKING 24 VOLT POWER
TO IBC. POWER INDICATOR LIGHT GOES OUT.
REQUIRES MANUAL RESET TO RE-CLOSE CA-

ONTACTS. POWER LIGHT GOES OUT.

HIGH LIMIT CONTROL

IF BOILER WATER TEMPERATURE REACHES HI

LIMIT (AQUASTAT) SETPOINT, HI LIMIT N.C. CON-

TACTS OPEN IMMEDIATLEY, CLOSING GAS VALVE.

VALVE AND FLAME LIGHTS GO OUT.

DRAFT INDUCER CONTINUES TO RUN FOR 30

SECONDS POST PURGE AND SWITCH OFF.

DRAFT INDUCER RUNS THROUGH 30 SECOND }

CONTROL WILLATTEMPT TO RELIGHT BOILER
3 TIMES. IF FLAME IS NOT PROVEN, CONTROL

LOCKOUT - PROBLEM ESTABLISHING A FLAME

SIGNAL. VALVE LIGHT IS BLINKING. CONTROL

WILL AUTOMATICALLY RESET AFTER 1 HOUR.

LOSS OF COMBUSTION AIRFLOW

lF COMBUSTION AIRFLOW IS LOST WHILE BURNER

IS FIRING (DIFFERENTIALAIR PRESSURE SWITCH

CONTACTS OPEN) GAS VALVE WILL BE DE-ENER-

G ZED. VALVE AND FLAME L GHTS GO OUT.

DRAFT INDUCER RUNS THROUGH 30 SECOND }

IF CALL FOR HEAT REMAINS, IBC WAITS 5 MIN- i

UTES FOR AIRFLOW TO BE RE-ESTABLISHED.

IFAIRFLOW DOES NOT RE-ESTABLISH CON- i

TROL LOCKOUT - PROBLEM WITH COMBUSTION I

AIRFLOW. PURGE LIGHT BLINKS. CONTROL WILL

AUTOMAT CALLY RESETAFTER 15 M NUTES. j

POST PURGE.

POST PURGE.

CIRCULATOR RUNS AS LONG AS THERMOSTAT

CALLS FOR HEAT.

WHEN HI LIMIT CONTACTS REMAKE BEFORE

END OF CALL FOR HEAT, CONTROL GOES INTO

A NORMAL LIGHT OFF SEQUENCE.

CIRCULATOR PUMP

CIRCULATOR WILL BE ENERGIZED AS LONG AS

THERMOSTAT CALLS FOR_HEAT DURING LOCKOUT. I

RECOVERY FROM ANY LOCKOUT REQUIRES

RESET, WHICH CAN BE ACCOMPLISHED BY:

(A) REMOVING AND REESTABLISHING THE

THERMOSTAT'S CALL FOR HEAT OR TURNING

THE SERVICE SWITCH OFF AND BACK ON;

J

OR (B) WAITING FOR THE CONTROL TO

AUTOMATICALLY RESET AFTER 15 MINUTES

FOR LOSS OF COMBUSTION AIRFLOW OR

ONE HOUR FOR LOSS OF FLAME.

I

THERMOSTAT ENDS CALLFOR HEAT

GAS VALVE AND CIRCULATOR PUMP

ARE DE=ENERGIZED

AND FLAME LIGHTS GO OUT

BLOWER RUNSFOR30 SECONDS

POSTPURGE

PURGELIGHTiS "ON"

BLOWER iSDE-ENERGIZED FOR30 SECONDS

PURGELIGHT SHUTS "OFF"

BOILER STANDS BY FOR NEXTCALL FORHEAT

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiili_ii_ii_!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!!!i!!i!I....

Fire, explosion or shock hazard may cause
property damage, severe injury or death.
Do not attempt to modify the physical or

electrical characteristics of this boiler in any
way.

Important

1. In a reset from lockout condition, all electrical meter readings
at the gas control valve (24 vac) must be taken within the trial
for ignition period.

2. If any component does not function properly, make sure it is
correctly installed and wired before replacing it.

3. Static electricity discharge can damage the integrated boiler
control (IBC). Touch metal surface to discharge static
electricity before touching IBC.

4. The IBC cannot be repaired. If itmalfunctions it must be
replaced.

5. Only trained, experienced service technicians should service the
IBC systems. Following troubleshooting, check out the system

following the sequence of operation section of this chapter for a
normal light off sequence.

6. All controls are factory tested in the assembly process and
a defective control is generally the least likely cause. If
you suspect you have a defective control, read through the

troubleshooting chart before you replace it.

7. It is extremely unlikely that the two consecutive controls are
defective. If it seems to be happening, chances are that either
there is nothing wrong with the contorl or it is being damaged
by some other problem (an electrical short burning out a
transformer, for example).

2. Troubleshooting tools:
A. Voltmeter to check 120vac and 24 vac

B. Continuity tester.
C. Inclined manometer or pressure gauge with 0-2.0" Range

(0.01" Scale) for measuring suction pressures at pressure
switch.

D. U-tube manometer or differential pressure gauge with

0-14" range (0.1" Scale) for measuring inlet and manifold
gas pressures.

3. What is system status?
A. Consult the chart on the following page.

B. Figure #16 shows the location on the boiler of the

diagnostic indicator lamps.

Initial ServiceChecks

1. Beforetroubleshooting:

A. Make surethat circuitbreaker is on or fuseis ok at

electricalpanel.

B. Make surethat serviceswitch ison.
C. Make surethat gas is on atthe gas meter, at all appropriate

manual shutoffvalves and at the gas control valve.
D. Make surethat the thermostat iscalling forheat.
E. Checkthat wire connectors atthe integrated boilercontrol

and at the originating control are securelyplugged in or

connected.
F. Checkthat hosesare securely connected and are not

pluggedin or damaged.

TROUBLESHOOTING CHART I

Electrical shock hazard may cause Serious

inj ury or deat h.
The following procedures may expose you to

dangerous line volta ge. Use caut ion to avoid
touching live electrical contacts. Service

must be performed by a trained, experienced

service technician.
What to do if yousmell gas:

Do not try to lightanyappliance
Do not touch any electrical switch; do not use

any phone in your builidng.

Immediatley call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instruction.

,_ If you can not reach your gas supplier, call the

fire department.
Should overheating occur or the gas supply

fail to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead,
shut off the gas at a location external to the

appliance.

Do not use the boiler if any part of the gas
control system has been under water a
qualified service technician should inspect

the boiler and replace any part of the control
system and any gas control which has been

under water.
Use only your hand to turn the gas control

knob. Never use tools. If the. Knob will not
turn by hand. Don't try to repair it. Force
or attempted repair may result in a fire or

GREEN POWER INDICATOR LIGHT IS

ILLUMINATED ON THE IBC,

_l YES

CHECK SYSTEM STATUS. IF LOCKED

OUT NOTE FAILURE MODE. WHICH

INDICATOR LIGHT IS BLINKING?

RESET SYSTEM BY TURNING SERVICE

SWITCH OFF THEN ON. IF NOT

LOCKED OUT, SET THERMOSTAT TO

CALL FOR HEAT.

L

CIRCULATOR STARTS?

YES

INO _
ICHART 2

NO

iiiiiiiiiiiiiiiiiiiiiii ,o ,on

FALSE POSITIVE PROOF OF AIRFLOW. CHECK

AIR PRESSURE SWITCH CONTACTS,

IF CONTACTS ARE CLOSED WITH NO

AIRFLOW, REPLACE PRESSURE SWITCH.

F

CLOSED

r

IBC CHECKS NORMALLY OPEN AIR

PRESSURE SWITCH CONTACTS

OPEN

CHART 3

CHART 2

TROUBLESHOOTING CHART 2

NO

CHART 1

CHECK THAT CIRCUIT BREAKER IS ON OR

Y

FUSES ARE OK AT THE ELECTRICAL PANEL

,OK

CHECK THAT SERVICE SWITCH IS ON

,OK

CHECK CASTING TEMPERATURE SAFETY

SWITCH. PUSH RESET BUTTON ON SWITCH.

CONTACTS OPEN (BUTTON UP) OR CLOSED

CHECK WIRING TO IBC. !20 VAC BETWEEN

TERMINAL 1 AND 3 AT WIRING HARNESS

120 VAC BETWEEN TERMINALS 1 AND 3 AT

120 VAC AT TRANSFORMER PRIMARY

(BUTTON DOWN)?

CLOSED

PLUG CN7?

YES

CONNECTOR CN3 ON IBC?

YES

TERMINALS?

I

I

I

OPEN

NO

NO

NO

CHECK WATER LEVEL IN BOILER. CHECK

FOR AIR TRAPPED IN TOP OF BOILER.

CONTACTS WILL NOT STAY CLOSED UNTIL

BOILER COOLS OFF.

REPLACE/REPAIR WIRING FROM SERVICE

SWITCH TO IBC

REPLACE IBC

REPAIR WIRING TO TRANSFORMER

( NO

)

CHART 1

24 VAC AT TRANSFORMER SECONDARY

24 VAC AT WIRING HARNESS PLUG CN2?

CHECK FOR 120 VAC BETWEEN TERMINALS

.I

1 AND 3 AT CONNECTOR CN5 ON IBC?

CHECK FOR 120 VAC AT CIRCULATOR

TERMINALS?

REPLACE IBC

YES

YES

YES

YES

I

J

I
I

NO

NO

NO

NO

REPLACE TRANSFORMER

PUSH RESET BUTTON ON CASTING TEMP.

SAFETY SWITCH.

CHECK CONTINUITY OF CASTING TEMP.

SAFETY SWITCH CONTACTS. CONTACTS

OPEN OR CLOSED?

OPEN

REPLACE CAST. TEMP.

SAFETY SWITCH.

l CLOSED

REPLACE/REPAIR WIRING FROM

TRANSFORMER TO IBC

REPLACE IBC

REPLACE/REPAIR WIRING FROM

IBC TO CIRCULATOR

YES

REPAIR/REPLACE CIRCULATOR

1

TROUBLESHOOTING CHART 3

CHART 1
OPEN

.I

BLOWER STARTS

I

YES

_r

I PURGE LIGHT ON?

YES

CHECK FORVAC I NO . [

BETWEEN TERMINALS 1 AND

AT CONNECTOR CN4 ON IBCI l

YES

CHECK FOR 120 VAC AT I NO

BLOWER LEADS ON WIRING

HARNESS I

YES

REPAIR/REPLACEBLOWER J

IBC WAITS UP TO 5

MINUTES FOR NORMALLY

OPEN AIR

PRESSURE SWITCH

CONTACTS TO CLOSE,

INDICATING BLOWER

SUCTION IS

PRESENT

REPLACE IBC

REPAIR/REPLCE

WIRING FROM IBC

TO BLOWER

PRESSURE SWITCH

OPEN

ARE VENT PIPE AND AIR

INTAKE PIPE CLEAR

(NO BLOCKAGE)

,_LrYES

CHECKAIR

PRESSURE SWITCH PER

INSTRUCTIONS ON

FOLLOWING PAGES, ARE

SAMPLING LINES CLEAR

AND CONNECTED

PROPERLY?

.z:l,

CLEAN OUT VENT PIPE

AND/OR AIR INTAKE PIPE.

CHECK FOR SAGS OR

LOW SPOTS WHERE

CONDENSATE MAY

PUDDLE AND BLOCK

THE VENT

CLEAN OUT SAMPLING

LINES OR REPLACE
DEFECTIVE SWITCH

_r

15 SECOND PRE PURGE COMPLETE.

PURGE LIGHT IS OFF. SIMULTANEOUSLY

IGNITOR LIGHT IS ON AS IGNITOR CIRCUIT

IS ENERGIZED.

REPLACE IBC

YES

CHECK FLUE PASSAGES

IN BOILER PER

"MAINTENACE AND

CLEANING", ARE FLUE

PASSAGES IN BOILER CLEAN?

CHECK DRAFT INDUCER

MOTOR RPM, IS IT

3400-3600?

CHECK FOR BROKEN OR

LOOSE IMPELLER ON DRAFT

INDUCER AND REPLACE

BLOWER IF FOUND TO
BE BROKEN OR LOOSE

CLEAN BOILER FLUE

PASSAGES PER

MAINTENANCE AND

CLEANING INSTRUCTIONS

REPLACE

BLOWER

TROUBLESHOOTING CHART 4

CHART 3

_ YES

IGNITER/SENSOR WARMS

UP AND GLOWS

YELLOW/ORANGE

DURING 20 SECOND

WARM UP

YES

_r

AFTER 20 SECOND
IGNITER WARM UP, GAS

VALVE IS ENERGIZED
VALVE LIGHT IS ON

2 SECONDS LATER POWER
IS REMOVED FROM
IGNITER/SENSOR

IGNITER LIGHT IS OFF
DOES MAIN BURNER
LIGHT?

CHECK FOR 120 VAC

BETWEEN TERMINALS 1

AND 2 AT CONNECTOR

CN1 ON IBC (DURING

IGNITER WARM UP)

YES

CHECK FOR 120 VAC AT

IGNITER/SENSOR LEADS

ON WIRING HARNESS

(DURING IGNITER

WARM UP)

YESI ,J

CHECK FOR 24 VAC

ACROSS TERMINALS MV

ON THE GAS CONTROL,

WHILE VALVE/FLAME

INDICATOR LIGHT IS ON

YES

REPLACE IBC

REPAIR/REPLACE WIRING

FROM IBC

TO IGNITER/SENSOR

REPLACE IGNITER/SENSOR I

'1

CHECK FOR 24 VAC
ACROSS TERMINALS
CN6-2 AND CN6-5 ON

IBC, WHILE THE VALVE!

FLAME LED IS LIT

YES

I

REPLACE IBC

I

YES

CHECK IF IGNITER/

SENSOR POSITION IS OK?

TIP SHOULD BE SLANTED

TOWARDS BURNER

YES

CHECK GAS SUPPLY
PRESSURE AT INLET

PRESSURE TAPPING ON

GAS CONTROL IS GAS

PRESSURE GREATER

THAN 4,0" W,C,?

YES

BETWEEN IBC AND

I REPAIR/REPLACE WIRING

GAS CONTROL

RESTORE IGNITER/SENSOR

TO CORRECT POSITION.

DO NOT RELOCATE

ARE ALL MANUAL

SHUT-OFFS IN THE GAS

SUPPLY LINE AND ON

THE GAS CONTROL IN

THE OPEN OR ON

POSITION?

YES

CONTACT THE GAS UTILITY

TO TURN THE GAS ONI I

OPEN OR TURN ON ALL

MANUAL SHUTOFFS

I

_ CHART 5

_E. CHART 5

TROUBLESHOOTING CHART S

CHART 4 CHART 4

YES I YES

POSSIBLY MIXTURE TOO LEAN!

CHECK GAS LINES DOWNSTREAM OF GAS

ARE GAS LINES CLEAR?

IS GAS/VENTURI VALVE CORRECT SIZE?

SEE REPAIR PARTS DIAGRAM.

POSSIBLY MITURE TOO RICH!

CHECK FLUE PASSAGES IN BOILER PER

"MAINTENANCE AND CLEANING". ARE

FLUE PASSAGES IN BOILER CLEAN?

VALVE FOR BLOCKAGE.

,_YES

CLEAN/REPLACE GAS LINES.

BE SURE TO USE CORRECT GASNENTURI VALVE SIZE.

CLEAN BOILER FLUE PASSAGES PER MAINTENANCE

AND CLEANING INSTRUCTIONS

_r

DOES MAIN BURNER

RUN UNTILCALLFOR

HEAT ENDS OR HI

LIMIT AQUASTAT

CONTACTS OPEN?

CHECK MIXER AND BURNER FOR

BLOCKAGE PER MAINTENANCE AND

CLEANING INSTRUCTIONS. ARE AIR

PASSAGES IN MIXER AND BURNER

CLEAN?

4,

CHECK AIR ORIFICE AT BURNER INLET

FOR CORRECT SIZE. SEE REPAIR PARTS

DIAGRAM. IS ORIFICE CORRECT SIZE?

NO#1

NO #2

i

NO #3

q

* IF THE ANSWER IS NO.
CHOOSE THE APPROPRIATE

PATH (#1, #2, OR #3) BASED ON
SYMPTOMS SHOWN.

CLEAN MIXER AND BURNER PER MAINTENANCE AND

RUNS SMOOTHLY FOR ABOUT 6

SECONDS THEN SHUTS OFF.

INDICATES POOR FLAME SIGNAL.

CHECK IGNITER/SENSOR

POSITION. TIP SHOULD BE

SLANTED TOWARDS BURNER

YES

CHECK FLAME SIGNAL >0.6uA?

CONSULT BOILER MFGR. FOR

SPECIFIC INSTRUCTIONS.

REQUIRES SPECIAL TOOLS.

CLEANING INSTRUCTIONS

REPLACE BURNER

RESTORE

IGNITER/SENSOR

TO CORRECT POSITION.

DO NOT RELOCATE.

OXIDE COATING ON

IGNITER PREVENTING

FLAME SIGNAL.

REPLACE

IGNITER/SENOR.

_r

CHART 6

CHART 6 CHART 6

YES

REPLACE IBC

TROUBLESHOOTING CHART 6

CHART 5

YES

[

I

CHART 5

NO #3

CHART 5

I NO #2

RUNS FOR 25-50 SECONDS,

THEN TURNS OFF.

CHECK FIRING RATE OF UNIT.

IS UNIT FIRING AT THE CORRECT RATE'?

_IV YES I

/

CHECK BURNER FOR ANY DETERIORATION I NO I
IN THE FLAME PORTS. ARE BURNER PORTS

[

IN GOOD CONDITION.

YES

CHECK FLAME SIGNAL > 0.6uA? ' I'qO_INI'_I _

CONSULT BOILER MFGR. FOR

SPECIFIC INSTRUCTIONS, REQUIRES

SPECIFIC TOOLS,

¼

REPLACE GASCONTROL

I

rYES

CHECK GAS ORFICICE SIZE.

IS GAS ORIFICE SIZE CORRECT.

CHECK REPAIR PARTS LIST

FOR CORRECT SIZE, IS GAS ORIFICE

CLEAR OF BLOCKAGE,

rYES

DOES THE UNIT USE LP GAS.

NO

ADJUST RATEAS DESCRIBEDIN THE

CHECK OUTPROCEDUREAND

ADJUSTMENT SECTION

OF THE MANUAL.

REPLACE WITH CORRECT

AIR BAFFLE.

REPLACE BURNER

REPLACEIBC

I

I

I

I
I

I

I

_q

_r

SET THERMOSTAT BELOW ROOM

TEMPERATURE TO END CALL FOR

HEAT

_1!,YES

DOES CIRCULATOR PUMP STOP?

YES

VALE LIGHT IS OFF

!,YES

DOES DRAFT BLOWER

STOP AFTER 30

SECOND POST PURGE?

r

BOILER SHUTS OFF BEFORE END OF

CALL FOR HEAT. ARE HI LIMIT

AQUASTAT CONTACTS CLOSED?

YES

SEE TROUBLESHOOTING PATH

#2 ABOVE I

F_

ARE THERMOSTAT CONTACTS OPEN?

I

REMOVE WIRING HARNESS

CONNECTION CN9FROM GAS

CONTROLDOES GAS CONTROL

REPLACEIBC

REPLACEIBC

_YES

CLOSE?

_YES

BOILER OFF ON HIGH LIMIT. IS

ACTUAL BOILER WATER TEMP.

GREATER THAN HI LIMIT SET POINT

MINUS 30°F CONTROL DIFFERENTIAL?

REPLACE THERMOSTAT

REPLACE GAS CONTROL

AQUASTAT

NNNo_ REPLACE

OK

I
I

YES

SYSTEM OK

What Is System Status?
The following steps and diagram indicate the locations of the con-

nection points required to check the differential air pressure.

!

Thedifferentialairpressure switchis asafetydevicewhichwill
prevent the boilerfrom firing if there is an air intake,boiler heat
exchangeror ventblockage.

Turn off service switch, or lower thermostat setting.

Remove vinyl caps from Tee and 4-way connector.

Install testing lines as shown to inclined manometer or differential
pressure gauge with the ability to read 0.01" to 2.0" w.c.

Turn on service switch and set thermostat to call for heat.

Not Running

1.00" for Modem 00

Setpoint

Running

Without

Blockage

Running

With

Blockage

Ifmanometer readingsdonot correspond to the chart above,check

for possiblecauses:

•-Blockageor moisture in suction lines

•-Blockagein airintake or vent pipes

•-Undersized air intake or ventpipes

•-Loose blowerwheelor motor shaft

•-Inncorect pressure switch or pressure switch setpoint

1.35" for Model-75

1.55" for Model-50

Greater Than Set-

Less Than or Equal to

_

points

Setpoints

Normally Open

Closed

Open

When pressure reading isproper and the pressureswitchisoperat-
ing properly, removetesting lines and reinstall vinylcapsto Teeand

4-way connector.

85 Middle Rd.

Dunkirk, NY 14048