ECR 075 97gb, 100 97gb Installation, Operation & Maintenance Manual

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Page 1

CONDENSING

GAS BOILER

Models 075 & 100

WALL MOUNTED

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certied Company

ECR International, Inc.

2201 Dwyer Ave

Utica, NY 13501

P/N # 240008282, REV J [03/2014]

Page 2

VERIFY CONTENTS RECEIVED

Description

No. Illustration

Item

Fully Assembled Boiler 1

Metal Wall Bracket 2

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

*Safety Relief Valve 4

3/4" Elbow 90° 5

3/4" Close Nipple 6

3/4" F x 3/4" M NPT Tee 7

3/4" x 1/4" NPT 90° Elbow 8

Air Vent 9

**Temperature Pressure Gauge 10

Bushing 3/4" x 1/4" 11

3/4" Tee (Same as No. 11) 12

Nipple 1¼ x 5½ 13

Drain Valve, 3/4" 14

3/4" Tee 15

Nipple 1¼ x 5½ 16

Bushing 7/8" OD, Heyco (2 ea) 17

Used for electrical wire knockouts.

Outdoor Sensor 18 Used for measuring outside temperature.

Stopper, Rubber 5/16" (2 ea) 17

Plastic Plug (2 ea) 18

Outdoor Sensor 19

Used for packaging holes on back of boiler.

Used for measuring outside temperature.

Document Package 20 Includes essential documents.

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

than 25 psig.

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

pressure greater than 60 psig.

Page 3

FIGURE 1-1 Dimensions

DIMENSIONS

(D)

Wall Hanging

Bracket

(D)

(B)

Vent Connection

Supply Water

Gas

Connection

(G)

(F)

Floor

(E)

Combustion Air

Return Water

(E)

User Interface

(A)

(B)

Size

075

/100

Width

(A)

22-1/16"

(560mm)

(H)

(I)

Condensate

Drain

Height

(B)

35-5/8"

(905mm)

Alternate Gas

Connection

Alternate

Supply Water

Depth

(C)

16-3/16"

(411mm)

(F)

(E)

Bracket

(D)

27-1/2"

(969mm)

(C)

Table 1 : Physical Data

Water Connections

Size

(E)

1-1/4"

NPT

Height

(F)

31-1/16" (789mm)

Gas

Connection

(G)

1/2" NPT 7-1/2" 5"

Alternate

Return Water

(E)

Condensate Drain

(H) (I)

Weight

Shipping Unit

140 lb

(63.5 kg)

115 lb

(51.2 kg)

Page 4

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

6 - Combustion Air And Vent Piping ............................................................................................... 19

6.2 Removal Of Existing Boiler From Common Vent System.................................................................19

6.3 Venting Materials ................................................................................................................... 19

6.4 Pipe Installation ..................................................................................................................... 20

6.5 Termination ........................................................................................................................... 20

6.7 Venting Congurations ............................................................................................................ 21

6.8 Side Venting Terminal Requirements..............................................................................................26

6.9 Condensate Piping .................................................................................................................. 28

7 - Gas Supply Piping .................................................................................................................... 29

8 - Electrical Connections .............................................................................................................. 31

8.2 Line Voltage Connections ......................................................................................................... 31

8.3 External Connections .............................................................................................................. 31

9 - Start Up Procedure ................................................................................................................... 33

9.6 Perform Csd-1 Compliance Test..................................................................................................37

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

10 - Operating Instructions ........................................................................................................... 39

11 - General Maintenance And Cleaning ........................................................................................ 40

12 - Ratings And Capacities ........................................................................................................... 43

13 - Trouble Shooting .................................................................................................................... 44

14 - Wiring Diagram ...................................................................................................................... 61

15 - Glossary ................................................................................................................................. 63

Appendix A - Control Module �� 65

1.1 Introduction .......................................................................................................................... 65

1.2 Operation .............................................................................................................................. 65

1.3 Status Indication .................................................................................................................... 65

1.4 Sequence Of Operation ........................................................................................................... 66

1.5 User Menu ............................................................................................................................. 68

Page 5

1 - INTRODUCTION

1.1 Designated Use

• Hot water heating boiler.

• Indoor installation.

• Closet or alcove installation.

• Direct vent boiler.

• For use with natural gas or liqueed petroleum gases

(LP/propane).

1.2 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals

present (example, swimming pool water).

• Exceed 150 psig (1.03 MPa) system pressure.

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

1.3 Operational Features

• Modulating: 20-100%.

• Integral Dual Limit.

• Integral Low Water Cutoff (with test button).

• Outdoor Temperature Reset.

• Integral Multiple Boiler Control.

• Heat exchanger over heat protection.

Information and specications outlined in this manual in effect at the

time of printing of this manual. ECR International reserves the right to

discontinue, change specications or system design at any time without

notice and without incurring any obligation, whatsoever.

Check our website frequently for updates: www.ecrinternational.com

Page 6

2 - IMPORTANT SAFETY INFORMATION

2.1 General

Boiler installation shall be completed by qualied agency.

See glossary for additional information.

WARNING

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

2.2 Become familiar with symbols identifying potential hazards�

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

DANGER

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

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

•

United States

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

• National Electrical Code, NFPA 70.

• Canada

• Natural Gas and Propane Installation Code,

CAN/CSA B149.1.

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

2.4 Where required by authority having jurisdiction,

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

Additional manual reset low water cutoff may be required.

2.5 Requirements for Commonwealth of Massachusetts:

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

• Installation by licensed plumber or gas tter.

WARNING

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

CAUTION

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

NOTICE

Used to address practices not related to personal injury.

Page 7

3 - COMPONENT LISTING

3.1 Component Listing

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

Combustion Air Inlet (2" PVC) (see Section 6)

Return Water From Heating System (In) 1-1/4" NPT - Connections supplied to connection top and/or

bottom of boiler. See Section 5.

Low Voltage Terminal Strip Connection of all low voltage wiring, including thermostat. See section 8.

Igniter

Flame Sensor

Sight Glass Permits observation of burner ame.

Burner

Heat Exchanger

10.

Condensate Collector

21.

Supply Water Temperature Sensor and High Limit Switch

22.

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

23.

Safety Relief Valve Factory supplied, Field installed. See section 5.

24.

High Voltage Junction Box For connection of 120V components. See section 8.

25.

Vent Connector See section 6.

26.

Gas Connection (See section 7.

27.

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

28.

Auxiliary Power Outlet Convenience outlet for condensate pump or service. Controlled by Service Switch (29)

29.

Service Switch

30.

Air Vent

11.

Return Water Temperature Sensor

12.

Drain Valve

13.

Heat Exchanger Ball Valve

14.

Supply Water Outlet to Heating System (Out) 1-1/4"NPT Connections supplied for connecting from

either top or bottom of boiler. See section 5.

15.

Vent Temperature Sensor

16.

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

17.

Heat Exchanger Pump

18.

Gas Shutoff Valve - Fuel supply isolation during servicing. See section 7

19.

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

31.

Central Heating Pump Circuit Breaker 5 amp circuit breaker protects control module.

32.

Boiler Control Module

33.

Internal Access Panel (see page 9) - Gently pull upward then forward to access control module. Removable for access to internal components of boiler.

34.

Central Heating Pump Relay (see page 9)

35.

Transformer Supplies 24V power to low water cutoff.

36.

Air Pressure Switch (not shown)

37.

Test Port - (see page 8)

38.

Combustion Analysis Test Port - (see page 8)

20.

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

Page 8

FIGURE 3-1 Boiler Components

(4) LOW VOLTAGE

TERMINAL

STRIP

(2) COMBUSTION

AIR INLET- 2" PVC

3 - COMPONENT LISTING

(25) VENT

CONNECTOR - 2" PVC

(24) HIGH

VOLTAGE

JUNCTION BOX

(23)

SAFETY

RELIEF

VALVE

(30) AIR

VENT

(3) RETURN WATER

FROM HEATING

SYSTEM (IN)

(27) BRACKET FOR

OPTIONAL WALL MOUNT

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

NOTE:

See Section 5-3

For Safety Relief

Valve Piping Instructions

(26) GAS

CONNECTION

(29) SERVICE

SWITCH

(28) AUXILIARY

POWER OUTLET

(31) CENTRAL HEATING

PUMP CIRCUIT BREAKER

Page 9

FIGURE 3-2 Boiler Components

(24) HIGH VOLTAGE

JUNCTION BOX

(25) VENT CONNECTOR

(2" PVC)

(23) SAFETY

RELIEF VALVE

NOTE:

See Section 5

For Piping

Instructions

(22) LOW

WATER CUTOFF

(21) HIGH

TEMPERATURE

SUPPLY SWITCH

(20) GAS

(CONTROL)

VALVE

3 - COMPONENT LISTING

(1) USER INTERFACE

(3) RETURN

WATER FROM

HEATING SYSTEM

(IN) 1-1/4" NPT

(4) LOW

VOLTAGE

TERMINAL

STRIP

(5)

IGNITER

(6) FLAME

SENSOR

(7) SIGHT

GLASS

(19)

COMBUSTION

AIR

BLOWER

(18) GAS

SHUTOFF VALVE

(SHOWN IN OPEN

POSITION)

(38)

COMBUSTION

ANALYSIS TEST

PORT

(13) HEAT

EXCHANGER PUMP

(16)

CONDENSATE

DRAIN 1/2" PVC

(15) VENT

TEMPERATURE

SENSOR

(37)

PRESSURE

TEST PORT

(9) HEAT

EXCHANGER

(10)

CONDENSATE

COLLECTOR

(14) SUPPLY WATER

HEATING SYSTEM

(OUT) 1-1/4" NPT

(13) HEAT EXCHANGER BALL VALVE

(12) DRAIN

VALVE

(11) RETURN

TEMPERATURE

SENSOR

(3)

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

Page 10

Note: To open

Lift panel up

then pull forward

3 - COMPONENT LISTING

(33) INTERNAL ACCESS

PANEL - CLOSED

(32) CONTROL

MODULE

(33) INTERNAL ACCESS

PANEL - OPEN

(34) CENTRAL HEATING

PUMP RELAY

Control Module Fuse and holder

(35)TRANSFORMER

Page 11

4 - LOCATING BOILER

4.1 Boiler Location Considerations

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

• Approved for installation in closets and on combustible oors. Do not install boiler on carpeting.

• Protection of gas ignition system components from

water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).

• Floor or wall mounting.

• Wall must be plumb and capable of supporting boiler

weight plus 60 lbs (28 kg). See Table 1.

• Floor must be level. Leveling feet allow adjustment up to 1/4" (6 mm).

• Wall mounting. See section 4.3.

• Access to outdoors to meet minimum and maximum

pipe lengths for combustion air and vent piping. See section 6.

• Disposal of condensate. See section 6.

TABLE 2: BOILER CLEARANCES

Dimension

Top (A)

Left Side (B)

Right Side (C)

Front (D)

Back (E)

Bottom (F)

Combustion Air/Vent piping

Hot Water Piping

(1)

Required distances measured from boiler.

(2)

Service, proper operation clearance recommendation.

Combustible

Materials

0" (0 cm) 14" (36 cm)

6" (16 cm) 6" (16 cm)

0" (0 cm) 1½" (4 cm)

0" (0 cm) 6" (16 cm)

0" (0 cm) 0" (0 cm)

0" (0 cm)

0" (0 cm) 6" (16 cm)

See local code 6" (16 cm)

(1)

Service

0" (0 cm) Floor

12" (32 cm) for

Bottom Piped

(1)(2)

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

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

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

• Multiple Boilers can be placed side by side, back to back

or wall mounted.

FIGURE 4-1 Clearance to Combustible Materials

FLOOR FLOOR

Page 12

4 - LOCATING BOILER

FIGURE 4-2 Wall Mount Bracket Engaged with

Bracket on Boiler

Center brackets. Avoid

overhang on sides of wall

mount bracket.

4 Slots for attaching Wall

Mount Bracket to Studs

4.2 Pre-pipe supply and return water connections

with factory ttings before wall mounting.

4.3 Wall Mounting

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

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

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

See gure 4-2.

• Boiler includes (4) 3/8" x 3" lag screws and (4) washers

for attaching wall mount bracket to wood studs. Field source appropriate fasteners for other wall constructions (masonry, concrete).

• Attach wall mount bracket level on wall.

• Boiler must engage with wall mount bracket.

• Avoid overhang on sides of wall mount bracket. Verify boiler bracket is centered on wall bracket. See gure

4-2.

WARNING

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

FIGURE 4-3 Low Water Cutoff Orientation

5° ~ 15°

Factory Default 10°

• When mounting boiler onto wall insert two plastic stoppers and two plastic plugs to packaging holes on back of boiler.

• Mount boiler vertically or slightly tilted backward to insure the low water cutoff functions properly. See

gure 4-3 for low water cutoff orientation.

CAUTION

Boiler weight exceeds 115 pounds (51.2 kg). Do not lift boiler onto wall without assistance.

NOTICE

Lift boiler using chassis. Using front jacket, vent

piping, water or gas ttings to lift boiler may cause

damage to the boiler.

Page 13

5 - HYDRONIC PIPING

5.1 General

• Install piping in accordance with authority having jurisdiction.

NOTICE

Use two (2) wrenches when tightening and tting to pipe boiler's threaded ttings. Boiler's internal

piping can be damaged if subjected to excessive torque.

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

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

• Thoroughly clean and ush system before connecting to

boiler.

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

• Flush system to remove any solid objects such as metal chips, bers, or Teon tape, etc.

5.2 Special Conditions

• System piping exposed to freezing conditions: Use inhibited proplyene glycol solutions certied by uid

manufacturer for use with closed water heating system. Do not use automotive or ethylene glycol.

• Boiler installed above radiation level (or as required by authority having jurisdiction). Integral low water cutoff provided in boiler. See pages 7 & 9.

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

• System piping connected to heating coils located in air handling unit exposed to refrigerated air circulation. Install

ow control valves or other automatic means to prevent

gravity circulation of boiler water during cooling cycle.

WARNING

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

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

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

• Use only inhibited proplyene glycol solutions certied by uid manufacturer as acceptable for

use with closed water heating system.

• Thoroughly clean and ush any system that used

glycol before installing new Boiler.

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

NOTICE

Do not expose boiler and condensate piping to freezing temperatures.

FIGURE 5-1 Safety Relief Valve & Air Vent

Safety Relief

Valve

3/4" NPT

90° Elbow

Air Vent

3/4 NPT

5.3 Safety Relief Valve and Air Vent

NOTICE

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

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

• Install safety relief valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety

relief valve.

3/4" NPT

Close Nipple

3/4"F x 3/4"M

NPT Tee

3/4" x 1/4" NPT

90° Elbow

Page 14

5 - HYDRONIC PIPING

To use this format set your tiff output to

Print capture, 150dpi, C -Landscape, Scale to fit

for best results

WARNING

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

FIGURE 5-2 Safety Relief Valve Discharge Piping

Check Local Codes

For Maximum

Distance To Floor

• Systems with automatic ll valves require back ow

prevention device.

• Install discharge piping from safety relief valve. See gure 5-2.

• Use ¾" or larger pipe.

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

or greater.

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

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

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

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

• Install elbow(s), if used, close to safety relief valve

outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

5.4 Trim Piping

• Supply and Return Piping

• Supply - Select either top, bottom or both.

• Return - Select either top, bottom, or both.

• Use second temperature pressure gauge when piping

top and bottom.

• Install brass plug(s) provided with boiler in unused tapping(s). Use provided sealant.

• Temperature - Pressure Gauge. Install temperature pressure gauge using nipple, bushing and tee provided

with boiler. See gure 5-3.

5.5 System Piping

• See Table 3 for basic system piping congurations.

FIGURE 5-3 Temperature Pressure Gauge Installation

Temperature Pressure Gauge

shown at Optional Bottom

Supply Connection to Boiler

• Systems with automatic ll valves require back ow

• Single boiler system. See gures 5-4, 5-5, 5-6, 5-7

• Multiple boiler system.

• Heating system with existing primary loop, close internal

• Heating system without existing primary loop, leave internal

prevention device.

for

general guidance. Additional considerations:

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

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

See gure 5-8

guidance. Additional considerations:

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

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

primary loop ball valve.

primary loop ball valve open to use internal primary loop.

for general

Page 15

5 - HYDRONIC PIPING

NOTICE

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

FIGURE 5-4 System Piping

System

Supply

System

Return

Piping Legend

FLOOR

Pipe to

condensate

drain

Table 3 - System Piping Congurations

Two Pipe Zoned System

Single Boiler

Primary/Secondary Pumping

Typical Mulitple Boiler Piping

Multiple Boilers

Primary/Secondary Pumping

With Zone Valves gure 5-5

With Zone Pumps gure 5-6

Closed External Primary Loop or

Open External Primary Loop gure 5-7

With Zone Valves gure 5-8

With Zone Pumps Not Shown

Closed External Primary Loop Not Shown

Open External Primary Loop

gure 5-7

Not Shown

Page 16

5 - HYDRONIC PIPING

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

DHW Pump

CH/System

Pump

Heat exchanger

ball valve open

(as shipped)

3/8"/9.5 mm

Open End

Wrench

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

DHW Pump

Zone

Pump

Heat exchanger

ball valve open

Heat exchanger ball

(as shipped)

3/8"/9.5 mm

Open End

Wrench

Page 17

5 - HYDRONIC PIPING

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

12"/305mm Max. apart

valve open

3/8"/9.5 mm Open

End Wrench

12"/305mm Max. apart

CH/System

Pump

Existing closely

spaced tees

in primary

system loop

Limit length

5'/1.6 m

Heat exchanger

ball valves closed

3/8"/9.5 mm Open

End Wrench

Page 18

5 - HYDRONIC PIPING

5-8 Typical Multiple Boiler Piping - (See Multiple Boiler Guide)

DHW Pump

CH/

System

Pump

12"/305mm Max. apart

System

Temperature

Sensor

Size common piping

according to

maximum heat

capacity of

entire system

All heat exchanger

ball valves closed

Up to 16

boilers

(See Multiple Boiler Guide)

3/8"/9.5mm Open

End Wrench

Page 19

6 - COMBUSTION AIR AND VENT PIPING

6.1 General

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

and:

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

• Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1

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

Install vent system in accordance with these instructions.

6.2 Removal of Existing Boiler From Common Vent System

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

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

• Seal any unused openings in common venting system.

• Any improper operation of common venting system

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

6.3 Venting Materials

• See Table 4

Table 4 - Combustion air and vent pipe ttings

must conform with the following:

Item Material Standards

PVC schedule 40 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

ANSI/ASTM D1784/

F441

Vent Pipe

and Fittings

CPVC schedule 40

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

ABS-DWV ANSI/ASTM D2661

• Visually inspect venting system for proper size and horizontal pitch. Determine there is no blockage or

restrictions, leakage, corrosion and other deciencies

which could cause an unsafe condition.

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

replace dampers.

• Turn on appliance being inspected. Follow lighting

instructions. Adjust thermostat so appliances will operate continuously.

• Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use ame of match or

candle, smoke from cigarette, cigar or pipe.

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

Schedule 40ABS ANSI/ASTM F628

PP (Polypropylene)

Pipe and Components

Pipe

Cement/

Primer

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

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

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® , (Polyphenolsulfone) in venting systems shall be prohibited.

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Schedule 40 ABS ANSI/ASTM D2235

WARNING

UL 1738

ULC S636-08

Use of cellular core PVC for venting ue gas could

result in death, serious injury.

WARNING

Covering non-metallic vent pipe and ttings with

thermal insulation shall be prohibited.

Page 20

6 - COMBUSTION AIR AND VENT PIPING

6.4 Pipe Installation

• Minimum and maximum combustion air and vent pipe lengths listed in Table 5. Pipe length counted from combustion air connector to termination.

• Install eld-sourced 2" to 3" transition, if used, in

vertical section at combustion air inlet and vent connector.

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

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

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

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

• Certied vent system components must NOT be

interchanged with other vent systems or unlisted pipe/

ttings.

• Canadian installations only. All venting material, primer

and glue must be listed to ULC S636.

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

6.5 Termination

• Terminate combustion air and vent pipes with ttings or

concentric vent kit.

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

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

• Terminate combustion air and vent pipes in same

atmospheric pressure zone through exterior sidewall or roof.

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

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

WARNING

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

Table 5 - Combustion Air and Vent Piping Length

Minimum/Maximum Vent Lengths

2” Pipe 3” Pipe

Model 075/100 075/100

Min.

Max.

6 ft.

(1.8 m)

50 ft.

(15.2 m)

Table 6 -Equivalent Length of Venting Components

Equivalent Length of Venting Components

Component Feet Meters

90° Elbow 5 1.6

45° Elbow 3 1/2 1.1

2" x 4" Adapter 0 0

3" x 4" Adapter 0 0

Concentric Vent Kit 5 1.6

Polypropylene Flexible Pipe per Foot 2 5/8 0.8

6 ft.

(1.8 m)

100 ft.

(30.5 m)

Page 21

6.7 Venting Congurations

Various venting congurations can be applied to this boiler. For guidance see Venting Conguration Table 7 and

corresponding gures.

Table 7 - Venting Congurations

NOTICE

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

Flue Gas Location

Roof

Side Wall

Combustion Air

Location

Roof

Side Wall Single Pipe gure 6-8

Inside Air Single Pipe gure 6-9

Roof Single Pipe gure 6-10

Side Wall

Inside Air Single Pipe gure 6-11

Flue Gas Terminals

Two Pipe gure 6-1

Concentric gure 6-7

Two Pipe gures 6-2, 6-3

Concentric gures 6-4, 6-5, 6-6

Corresponding Figures

Page 22

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-1

12" (30 cm)

Minimum

8" (21 cm)

Minimum

Vent Combustion

12" (30 cm) US,

18" (46 cm) Canada

Minimum Above

Anticipated Snow Line

FIGURE 6-2

3" (80mm)

Minimum

Air

15" (38 cm)

Maximum

Roof Line

Roof

Terminations

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

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

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

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

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

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

12" (30 Cm)

Minimum From

Overhang

See Snow & Ice

Page 25

FIGURE 6-3

3" (8 Cm)

Minimum

Separation

12" (30 Cm) Separation

Between Bottom Of

Combustion Air Intake And

Vent

Combustion Air

12" (30Cm)

Minimum

Separation

Bottom Of Vent

Side Wall

Terminations

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

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

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

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

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

 Maintain a pitch of 1/2" per ft (0.15m/m) back to boiler to ensure proper condensate drainage for horizontal runs.

See Snow & Ice

Page 25

Combustion Air

Vent

Page 23

6 - COMBUSTION AIR AND VENT PIPING

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

Appliances

1"(2.54cm)

1" (25.4mm)

Maximum

Vent

Combustion

Air

FIGURE 6-6 Concentric Terminal Connection

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

PVC intake/combustion air

Roof

1" (25mm)

Maximum

* See Note

Below

Combustion

Air

Overhang

12" (305mm) Minimum

36"(0.9m(457mm)

Vent

Maintain 12"(30cm) US

(18"(46cm) Canada)

highest anticipated

Clearance Above

snow level or grade

Highest Anticipated

Snow Level Or Grade

(28m)) Minimum

Maintain 12"

clearance above

*Must be less than 4" (102mm) or greater than 24" (610mm) Horizontal distance between end bells of each air

intake to prevent ue gas recirculation.

Note: Securing strap must

be eld installed to prevent

movement of termination kit in side wall

Combustion Air

OD 3½" (

89mm)

- *2" (

51mm)

kit

OD 4½" (114mm) - 3" (77mm) kit

** Note Overall length may be modied by cutting or extending

both combustion air and vent pipes. 12" (305mm) is minimum allowable length and 60" (1.2m) is maximum allowable length for this dimension.

SDR-26 PVC (D2241) only may be used for extending pipes. Do not use Schedule 40 PVC or use couplings to extend pipes. Dimension will change if intake/vent pipes are lengthened or shortened.

**See

Note

*2" (

51mm)

Diameter = 41" Length (1.1m)

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

1"(25.4mm) Maximum

Vent

Combustion Air

* Note: 2" (51mm) For use with models 075/100 3" (77mm) For use with models 075/100

Page 24

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-7 Concentric Roof Terminal

Vent

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

Combustion Air

Roof boot/ashing (eld supplied)

Note: Support must

be eld installed to

secure termination kit to structure

Vent

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

Vent

anticipated snow level 24"

(610mm) above roof

Support

(eld supplied)

Combustion Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

anticipated snow level 24"

(610mm) above roof

Concentric

Vent Roof

Terminations

 Glue inner vent pipe to prevent

recirculation.

 Maintain 12" (305mm) US

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

 Support must be eld installed to

secure termination kit to structure.

 Elbow, roof boot/ashing eld supplied.  Allowed Wall/Roof thickness 1/2"-30"

(12.7mm - 762mm).

 Vertical concentric vent system can be

installed in unused masonry chimney.

 Contact Technical Support 800-

325-5479 for questions regarding installation or use.

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

Combustion Air

12" (305mm) Anticipated Snow Line

Ground Level

FIGURE 6-9 Flue on Roof, Combustion Air

Vent

Combustion

Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

anticipated snow level 24"

(610mm) above roof

24" (610mm) * Minimum Length

Grade, Snow

& Ice

Doors &

Windows

* See Tables

5 & 6

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

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

Combustion air and Vent Piping Length Page 19 .

Page 25

6 - COMBUSTION AIR AND VENT PIPING

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

Congurations of single pipe vent with ue on the

sidewall, requires a tee as the vent terminal. See

gures 6-10 and 6-11.

Combustion

Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

anticipated snow level 24"

(610mm) above roof

Vent

12" (305mm) Anticipated Snow Line

Ground Level

NOTICE

FIGURE 6-11 Flue on Sidewall, Inside Combustion Air

Vent

Combustion

Air

12" (305mm) Anticipated Snow Line

Ground Level

Page 26

6 - COMBUSTION AIR AND VENT PIPING

6.8 Side Venting Terminal Requirements of :

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

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

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

Venting terminal from snow level See gure 6-14

Venting terminal from vegetation See gure 6-15

Venting terminal from public walkway See gure 6-16

FIGURE 6-12

Doors &

Termination must be

12" (305mm) from

or below doors,

windows or gravity

inlet.

12"

(305mm)

Minimum

FIGURE 6-13

Forced Air

Inlet

FIGURE 6-14

Less than

10' (3m) Minimum

Termination

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

Windows

Condensate

Forced Air

Inlet

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

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

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

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

3' (0.9m) Minimum

Grade, Snow

& Ice

Corner

"L"

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

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

Page 27

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-15

Keep vent termination 3’ minimum

Vegetation,

Plants &

Shrubs

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

Termination

Meters,

Regulators,

deck, porch

3' (0.9m) Minimum

FIGURE 6-16

Walkways

People or

Pets

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

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

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

Multiple

Family

Dwellings

7' (2.1m)

Minimum

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

Stones,

Balls, Etc�

Vapors

Eddy, Flue

Gases

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

Position termination where vent vapors are not objectionable.

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

Page 28

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-17 Condensate Drain

6.9 Condensate Piping

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

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

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

• Insert 1/2" (1.3 cm) PVC pipe through grommet in chassis. See gure 3-2.

• Attach PVC tee provided with boiler and eld sourced

piping to condensate drain vertical tee on left side of

boiler. See gure 6-17.

• Slope condensate drain pipe minimum 1/4" per foot

(21mm/m) away from boiler.

• Use condensate pump if boiler located below disposal point. 120 VAC auxiliary power outlet can be used to power condensate pump.

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

PVC Tee (Field Installed)

On Condensate Drain Pipe

Page 29

7 - GAS SUPPLY PIPING

7-1 Gas Connection Knockout Plate at Bottom of Boiler

Bottom cover

for Optional Gas

Connection

7-2 Gas connection at Top of Boiler

Gas Connection Top

of Boiler

7-3 Bottom Gas Connection

Optional Bottom Gas

Connection

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switches; do not use

any phones in your building.

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

• If you cannot reach your gas supplier, call the re

department.

NOTICE

Use two (2) wrenches when tightening and tting to pipe boiler's threaded ttings. Boiler's internal

piping can be damaged if subjected to excessive torque.

7.1 General

• Use piping materials and joining methods acceptable to authority having jurisdiction. In absence of such requirements:

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

• Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1

• Size and install gas piping system to provide sufcient

gas supply to meet maximum input at not less than minimum supply pressure. See Table 8.

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

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

• Provide sediment trap up stream of gas valve.

SIZE

075/100 75,000

Maximum

Input (Btuh)

7.2 Conversion Kit Instructions

• See Gas Conversion Kit Instructions included with Boiler.

TABLE 8: GAS SUPPLY PRESSURE

Natural Gas Propane

Min. Max. Min. Max.

3.0" w.c.

(0.7 kPa)

Note: See Glossary - Piping Table 16

13.5" w.c. (3.3 kPa)

(1.2 kPa)

5.0" w.c.

13.5" w.c. (3.4 kPa)

Page 30

7 - GAS SUPPLY PIPING

DANGER

Fire Hazard. Do not use matches, candles, open

ames, or other methods providing ignition source.

Failure to comply will result in death or serious injury.

7.3 Near Boiler Gas Piping

•

Select top or bottom gas connection. To convert from top connection to bottom connection:

•

Remove bottom knockout by removing two (2)

screws. See gure 7-1.

•

Disconnect gas connection by removing two (2)

screws. See gure 7-2.

•

Relocate gas connection to bottom opening.

Secure with two (2) screws. See gure 7-3.

•

Relocate knockout cover to top opening. Secure

with two (2) screws. See gure 7-4.

•

Install eld sourced manual main shutoff valve and ground joint union. See gure 7-5.

7-4 Gas Connection Knockout Plate at Top of Boiler

Top of Boiler Cover for

Gas Connection

7-5 Manual Main Gas Shutoff Valve Outside Boiler Jacket

Manual Main Gas

Shutoff Valve

7.4 Leak Check Gas Piping

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

•

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

•

Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler from gas supply system by closing

manual gas shutoff valve. See gure 7-6.

•

Locate leakage using gas detector, noncorrosive

detection uid, or other leak detection method

acceptable to authority having jurisdiction. Do

not use matches, candles, open ames, or other

methods providing ignition source.

•

Correct leaks immediately and retest.

Option: Gas

Connection May be

Located

At Bottom of Boiler

7-6 Gas Shutoff Valve

Gas shutoff valve

(shown in closed

position)

Page 31

8 - ELECTRICAL CONNECTIONS

8.1 General

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

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

• Canada - Canadian Electrical Code, Part I, CSA C22.1:

Safety Standard for Electrical Installations.

8.2 Line Voltage Connections (Figure 8-1)

• Boiler

A. Provide individual 120V, 15 amp circuit

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

B. Open High Voltage Junction Box (see Figures 3-1,

3-2) to access line voltage terminal strip.

C. Connect 120 VAC circuit to line voltage terminal

strip 120 VAC L,N,G.

• Central Heating Pump, if used.

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

Load Amps) exceeds 5 amps.

B. Connect pump to line voltage terminal strip CH

PUMP L,N,G.

• Domestic Hot Water Pump, if used.

A. Isolate pump from control module if pump FLA

exceeds 1.0 amp.

B. Connect pump to line voltage terminal strip DHW

PUMP L,N,G.

8.3 External Connections (Figure 8-2)

• User Interface Terminals

A. Factory wired to low voltage terminal plug USER

INTERFACE terminals

B. Optional - Remote mount user interface for

improved access.

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

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

WARNING

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

NOTICE

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

8-1 LINE VOLTAGE CONNECTIONS

8-2 EXTERNAL CONNECTIONS (Do not apply external voltage to external

terminals.)

• Argus Link (Multiple boiler applications only)

Page 32

8 - ELECTRICAL CONNECTIONS

• Outdoor Sensor, if used.

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

direct sunlight. Mounting instructions provided with sensor.

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

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

D. Connect wires to low voltage terminal plug

OUTDOOR SENSOR terminals. Wires are interchangeable.

• System Sensor (Multiple boiler applications only)

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

A. Use temperature control with dry contacts rated

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

NOTICE

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

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

wire.

C. Connect wires (interchangeable) to low voltage

terminal plug DHW T-T terminals. Wires are interchangeable.

• Central Heating Thermostat

A. Use thermostat or boiler system control with dry

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

B. Locate and install thermostat per manufacturer's

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

C. Connect wires to low voltage terminal plug CH T-T

terminals. Wires are interchangeable.

NOTICE

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

Page 33

9 - START UP PROCEDURE

NOTICE

Condensate trap must be manually lled with water

at initial start up.

9�1 Fill Boiler With Water And Purge Air

NOTICE

To maintain boiler efciency and prevent boiling inside the heat exchanger, ush entire heating

system until clean.

• Flush heating system, including all heating zones.

• Fill boiler with potable water.

•

Fill boiler and system piping with water (or antifreezewater solution, if used). See antifreeze information page 12. Purge air from boiler using air vent. Purge air from system piping.

•

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

•

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

•

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

•

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

9-1 Condensate Drain Assembly

1. Disconnect collet clip

from hose barb and ll

Condensate trap with water.

9�2 Fill Condensate Trap with Water

•

Disconnect collet clip from elbow. See gure 9-1.

•

Disconnect tubing below elbow.

•

Pour about 1 cup (237ml) of water into condensate drain.

•

Reconnect tubing to elbow with collet clip. See Figure 9-1.

2. Reconnect collet clip to hose barb before starting boiler.

Page 34

9 - START UP PROCEDURE

9 -2 User Interface

9-3 Default Table

Control Parameter

9.3 Program Boiler Control

Key Description

- Manual Lockout Reset

- Enter/Exit user menu

- Go to previous screen

- Select a menu item

- Conrm new parameter value

- Scroll up to next menu item

- Increase value

- Scroll down to next menu item

- Decrease value

Boiler is factory programmed with following factory default settings, Figure 9-2. Parameters can be adjusted to suit particular application. Detailed explanation of each can be found in Appendix A

- Control Module. List parameters in event of Control Module Failure to

reprogram your settings.

Factory Default

Setting

Setting Range

*Actual

Parameter

Settings

Standard Metric Standard Metric

Central Heating Setpoint

User

Installer

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

Settings

Boiler

Conguration

CH Settings

DHW Setpoint 180°F 82°C 104 - 195°F 40 - 91°C

Temperature Units °F °F/°C

Language English English/French

Boiler Address 0 0-15

Low Water Cutoff Enabled Enable/Disabled

Pump Mode 0 0 & 4

Service Reminder Status On ON/OFF

Service Reminder Days 365 Days 1- 999 Days

CH Mode 1 0-3

Warm Weather Shutdown 70°F 21°C 35-100°F 2-38°C

Reset Curve Design Temperature - Boiler 180°F 82°C 60-195°F 40-91°C

Reset Curve Design Temperature - Outdoor 25°F -4°C -60-32°F -51-25°C

Reset Curve Mild Weather Temperature Boiler

Reset Curve Mild Weather Temperature Outdoor

Reset Curve Boiler Minimum Temperature 70°F 21°C 40-180°F 4-82°C

Reset Curve Boiler Maximum Temperature 180° 82°C 80-195°F 27-91°C

Boost Function Temperature 18°F 10°C 0-36°F 0-20°C

Boost Function Time 20 Minutes 1-120

Maximum Power CH 100% 1-100%

DHW Mode 0 0/2

DHW Maximum Priority Time 30 Minutes 1-60 minutes

140°F 60°C 104 - 195°F 40 - 91°C

70°F 21°C 35-120°F 2-49°C

70°F 21°C 35-85°F 2-29°C

Page 35

9 - START UP PROCEDURE

9.4 Boiler Start-up and Operational Test

1. Verify air is purged from hydronic piping

2. System test pumps - verify each pump is

operational

3. Verify gas piping

•

Conrm pressure test. See section 7.4.

•

Visually inspect piping to determine there are no

open ttings or ends, and all valves at unused

outlets are closed and plugged/capped.

•

Purge air from piping

•

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

4. Follow OPERATING INSTRUCTIONS to initiate boiler

operation. See section 10.

5. Inspect combustion air and vent piping. Verify pipe

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

6. Verify boiler functions.

7. Inspect condensate disposal system. Verify

condensate ows adequately and is disposed

properly.

8. Check control module operation.

9. Check eld sourced limits, low water cutoffs, etc.

per manufacturer's instructions.

9�5 Check Combustion

Natural Gas

1. Measure input. English units*

•

Turn off gas to all other appliances.

•

Activate some heating zones to dissipate heat.

•

Set boiler on high re.

•

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

•

Calculate input.

Input (MBH) =

Example: Gas ow from

Meter = 2 cu ft Measured time = 72 seconds

Rate (MBH) =

*Metric - See Glossary

3600 x cu ft

seconds

3600 x 2 cu ft

= 100 MBH

72 seconds

2. Compare measured input to table. Adjust input rate

if needed using Table 12 below.

Table 12 - Rate @ High Fire

Size Minimum Maximum

075 65 85

100 90 102

Natural Gas and Propane

3. Measure CO

Adjust CO2 if needed using gure 9-3 . See gure 9-5 combustion air analyzer port.

at high re and compare to table.

Natural Gas only**

4. Measure input. Compare to table above. Continue

to measure input and CO2 until both measured values are within range specied in tables.

Page 36

9 - START UP PROCEDURE

Gas

Natural Gas Propane

Min. Max.

9.0 9.5

10.0 11.0 <200ppm

<200ppm

NOTICE

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

Natural Gas only**

1. Measure input. Compare to table above. Continue

to measure input and CO2 until both measured

values are within range specied in tables.

Propane Gas

Most propane systems do not have ow meters.

1. Check CO

11.0%.

•

If CO2 is low increase gas ow following gure 9-3 & 9-4.

•

If CO2 is high decrease gas ow following gure 9-3 & 9-4.

FIGURE 9-3 Gas Valve - Models 075/100 MBH

. Propane should be between 10% and

Verify Burner, Proper Operation

1. Inspect burner ame through Sight Glass. See

gure 9-5.

2. Operate boiler through several heating cycles,

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

3. Reset control parameters to operating settings if

adjusted to allow startup and operation test.

4. Follow instructions TO TURN OFF GAS TO APPLIANCE

if boiler is not being placed into immediate operation.

5. Enter installer information on Warranty Registration

Card.

6. Gather all instructions, manuals, wiring diagrams,

warranty registration card and other supporting

information. Review with user and/or afx in

conspicuous location adjacent to boiler.

1/4" Flat Head

Screwdriver

•

To increase gas ow turn 'throttle' left or counter

clockwise .

•

To decrease gas ow turn 'throttle' right or

clockwise .

•

Limit adjustment to one turn and retest.

Page 37

9 - START UP PROCEDURE

NOTICE

Combustion analyzer port is provided. After use replace cover.

9-4 Combustion Analyzer Port

Combustion Analyzer Port

9-5 Burner Flame

9�6 Perform CSD-1 Compliance Test (see paragraph 2�5 page 6)

Verify operation of boiler safety control operation with

regard to no ow conditions as follows:

1. Turn off boiler using boiler service switch.

2. Disable primary boiler pump. Disconnect multi pin

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

3. Disable secondary system pumps attached to

system.

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

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

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

boiler, boiler will either: A.

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

Shut off burner E40 "Return Water Temp". This is a soft lockout. When water temperature drops

below limit boiler will automatically rere then

Lockout A-06 requiring manual reset of control module. Press Reset button on User Interface.

Shut off burner E39 "Flue Temperature Sensor".

This is a soft lockout. When ue sensor drops below limit, boiler will automatically rere then

Lockout A-06 requiring manual reset of control module. Press Reset button on User Interface.

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

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

system to verify operation.

Burner

Flame

Look for BLUE ame

with slight YELLOW tips

evenly spaced around

burner

Page 38

9 - START UP PROCEDURE

FIGURE

9-6Control Module J7 Connector

J7 CONNECTOR

9.7 Complete Start Up Procedure

1. Reset control parameters to operating settings if

adjusted to allow startup and operation test.

2. Follow instructions TO TURN OFF GAS TO APPLIANCE

(page 39) if boiler is not being placed into immediate operation.

3. Enter installer information on Warranty Registration

Card.

4. Gather all instructions, manuals, wiring diagrams,

warranty registration card and other supporting

information. Review with user and/or afx in

conspicuous location adjacent to boiler.

Page 39

10 - OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

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

causing property damage, personal injury or loss of life.

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

light this burner by hand.

• Before operating smell all around appliance area for gas. Be sure to smell next to oor because

some gas is heavier than air and will settle to the

oor.

• Use only your hand to turn the gas shutoff valve. Never use tools. If valve will not turn

by hand, do not try to repair it, call a qualied

service technician. Force or attempted repair may

result in re or explosion.

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

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

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switches; do not use

any phone in your building.

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

• If you cannot reach your gas supplier, call the re

department

10.2 TO TURN OFF GAS TO APPLIANCE

• Set thermostat to lowest setting.

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

to be performed.

• Remove front jacket panel.

• Turn gas shutoff valve handle clockwise to closed

position. Handle should be perpendicular to gas pipe.

• Replace front jacket panel.

10-1 Gas Shutoff Valve

10.1 OPERATING INSTRUCTIONS

Stop! Read Safety information above�

• Set thermostat to lowest setting.

• Turn "OFF" all electrical power to appliance.

• This appliance is equipped with an ignition device which

automatically lights the burner. Do not try to light burner by hand!

• Remove front jacket panel.

• Turn gas shutoff valve clockwise to closed position.

Handle should be perpendicular to gas pipe.

• Wait 5 minutes for any gas to clear. Smell for gas, including near oor. If you smell gas, STOP! Follow

instructions on this page: “What To Do If You Smell Gas.” If you do not smell gas, go to next step.

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

• Replace front jacket panel.

• Turn "ON" electrical power to appliance.

• Set thermostat to desired setting.

• If the appliance will not operate, follow instructions TO

TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier.

OPEN POSITION

CLOSED POSITION

Page 40

11 - GENERAL MAINTENANCE AND CLEANING

DANGER

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

CAUTION

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

NOTICE

Verify proper operation after servicing.

NOTICE

Perform regular service and maintenance by

qualied service agency at least once every 12

months to assure safe, trouble free operation and

maximum efciency.

11-1 Sight Glass

11.1 Beginning of Each Heating Season

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

• Visually inspect combustion air and vent piping for

proper operation. Check for and remove any obstruction

to ow of combustion air or vent gases. Immediately

repair or replace pipe showing deterioration or leakage. Reassemble per instructions in section 6. Ensure proper reassembly and resealing of system.

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

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

• Examine ue passages in heat exchanger, burner,

condensate lines, and cleaning (if necessary) by following instructions in “Annual Examination and Cleaning of Boiler

Components” in this section.

• Circulator pump and combustion air blower motor furnished with boiler are permanently lubricated from factory and require no further lubrication. Lubricate

eld sourced pumps and/or motors should be lubricated

according to pump and/or motor manufacturer’s instruction.

Sight Glass

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

• air vent;

• check venturi air inlet for blockage and clean as

required;

• check air hose is tight

• supply, return, and ue temperature sensor clips

must be securely seated on pipes; Check boiler for any sign of leaks.

• Check low water cutoff using user interface.

• Check operation by pressing test button on low water

cutoff.

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

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

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

• Every 10 years replace low water cutoff.

• Check ame signal with user interface. Should be 8 micro

amps at 100%.

• Visual inspection of ame through sight glass. Burner should be fully illuminated. See gure 11-1.

• Check expansion tank.

Page 41

11 - GENERAL MAINTENANCE AND CLEANING

11.2 Annual Shut Down Procedure

• Follow instructions “To Turn Off Gas To Appliance” unless boiler is also used to supply domestic hot water. See section 10 page 39.

• Drain system completely and add antifreeze when heating system is to remain out of service during freezing weather.

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

WARNING

Following service procedures must be performed

by qualied service agent. Boiler owner shall not

attempt these steps. Failure to do so could result in death or serious injury.

11.3 Annual Examination and Cleaning of Boiler

Components

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

• Burner and heat exchanger inspection and cleaning.

• Remove gasket and burner. Allow burner to clear top

lip of chassis.

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

11-2 Blower Inlet Assembly

Blower

Inlet

Housing

Refractory

Burner

Flame Sensor

Igniter

Sight Glass

• Clean burner using air hose directed into top of burner opening to dislodge any debris in burner

ports. Inspect burner for foreign matter in ame

ports or inside burner. Remove foreign matter by blowing with compressed air or vacuuming. Replace burner if it cannot be cleaned or is showing deterioration.

• Clean heat exchanger with low pressure water spray. Use exible handle nylon brush to loosen sediment

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

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

• Clean condensate collector if signicant debris found

in heat exchanger.

• Expand upper spring tension clip of condensate trap using hose clamp pliers. Disconnect condensate trap

from condensate collector. See gure 9-1 page 33.

• Disconnect wire harness from vent temperature s e n s o r . S e e ( 1 5 )  g u r e 3 - 2 p a g e 9 .

Page 42

11 - GENERAL MAINTENANCE AND CLEANING

11-3 Condensate Collector • Loosen upper hose clamp securing condensate

collector to ue pipe using 3/8" socket with 6"

extension.

• Remove ¼-20 hex ange nuts securing condensate

collector to heat exchanger using 7/16" deep well

socket. See gure 11-3.

Combustion

Condensate

Collector

Condensate

Drain

Chamber

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

• Flush collector and condensate trap with water.

• Follow Burner Inspection Kit instructions to reassemble

boiler and resume operation.

Page 43

12 - RATINGS AND CAPACITIES

SEA LEVEL RATINGS

NATURAL AND PROPANE GASES

Boiler Input Rate

Size

Maximum Minimum

075 100

(1)

1000 Btu/hr (British Thermal Units Per Hour)

(2)

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

procedures.

(3)

Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

(MBH)

75 15 69 60 97

100 20 91 79 97

(1)

12.1 Ratings and Capacities

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

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

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

Heating

Capacity

(MBH)

(1)(2)

Net AHRI

Rating, Water

(MBH)

(1)(3)

AFUE

(2)

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

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

• Canada - Boiler derates input 10% for every 2000 feet (610 m) above an elevation of 4500 feet (1.37 km).

Page 44

13 - TROUBLE SHOOTING

Page 45

13 - TROUBLE SHOOTING

Screen Display Explanation

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

Three unsuccessful ignition attempts in a row Go to Page 48

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

Safety Circuit is open. Go to Page 49

Blower speed does not reach speed calculated by Control Module.

Control Module internal error.

Go to Page For

Troubleshooting

Go to Page 47

Go to Page 50

Replace Control

Module

High Temperature opens during normal operation.

Control Module detects ame after gas valve

is closed more than 10 seconds.

Go to Page 51

Replace Gas Valve

Flame is detected before gas valve opens. Replace Gas Valve

Control module internal error.

Replace Control

Module

Lost ame signal 3 times during one heat call. Go to Page 52

Control Module internal error.

Replace Control

Module

Replace Control

Module

External voltage supplied to DHW T-T or CH

Blocking Error

REFLO too LO

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

Flame detected when gas valve is closed. Go to Page 52

Page 46

13 - TROUBLE SHOOTING

Screen Display Explanation

Low water cutoff sees no water. Go to Page 53

Go to Page For

Troubleshooting

Blocking Error

Flue Gas Error

Flue temperature sensor sees temperature higher than 200°F.

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

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

Boiler is powered by three wires, hot, neutral and ground. E44 displays when neutral wire is not neutral.

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

Boiler power supply ground wire is not grounded.

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

Go to Page 54

Go to Page 55

Replace Control

Module

Go to Page 55

Go to Page 56

Go to Page 57

Replace Control

Module

Supply temperature sensor is open. No continuity.

Return water temperature sensor is open. No continuity.

Flue temperature sensor is open. No continuity.

Supply water temperature sensor is shorted. '0' Ohm

Return water temperature sensor is shorted. '0' Ohm

Go to Page 56

Go to Page 57

Go to Page 59

Go to Page 60

Flue temperature sensor is shorted. '0' Ohm Go to Page 60

Reset button was pressed too many times.

Error Clears in 1-2

minutes

Fault detected in blower motor system. Go to page 56

Page 47

13 - TROUBLE SHOOTING

Replace Supply Sensor

hot?

YES

pipe at top of boiler)

Is supply pipe (copper

available?

YES

Unplug connector on supply

sensor. Measure continuity of high

two purple wires. Is continuity

between two pins connected to

limit sensor (close/open signal)

Is wire harness

connected to both

Gas Valve and J13

Boiler has been dry

red. System has too

Connect harness

Purge air from system,

much air. Close manual

gas valve (shut off gas).

Module?

YES

connector on Control

Disconnect J13 connector

on Control Module. Measure

resistance across third (blue

wire) and fourth (brown wire)

wait for system to cool.

Gas Valve. Does each

Disconnect harness from

Control Module

wire have continuity

between Gas Valve and

YES

terminals. Is resistance

between 1.0 and 1.2 kΩ?

Module

YES

Replace Gas Valve Replace Harness

Enter Installer Menu, Boiler

Status. Scroll to most recent

Lockout Alarm A 0 0

Blocking too long error

Lockout Alarm or Blocking Error.

_ _ _ _ _

Diagnose corrective action using

appropriate Troubleshooting Tree.

Replace Control

Page 48

13 - TROUBLE SHOOTING

Page 49

13 - TROUBLE SHOOTING

YES NO

heat exchanger) hot?

Is boiler supply pipe (above

hot?

YES

Is Heat Exchanger surface

drops.

temperature

Let all zones

run until water

Check high limit

Wait for boiler to

switches

and surface

temperature

cool down.

Replace Broken Switch

YES

Error shows when safety circuit is

open. Remove J13 connector from

pink wires, is continuity available?

between two pins connected to two

control module. Check for continuity

Is continuity available?

YES NO

between two pins on sensor (two

Unplug molex connector on supply

Replace Control Module

temperature sensor. Check continuity

pins connected to two pink wires) .

on two pink wires on J13

Check for loose connections

safety temperature switch.

connector, supply sensor, and

YES

Boiler red without enough water ow

through heat exchanger. Heat exchanger

Fix Loose Connections Replace Wire Harness

Check the following:

• Air in system?

• Verify water ow in system piping

exchanger temperature switch is open.

is over heated. Either high limit or heat

• Flush system if water is dirty.

Page 50

13 - TROUBLE SHOOTING

Page 51

Disconnect harness from High

Temperature Supply Switch and

Control Module J13.

Continuity from J13-5 to Switch

1? Continuity from J13-6 to

Switch 3 (continuity of the two

purple wires) ?

13 - TROUBLE SHOOTING

purple wires?

Control Module J13.

Disconnect harness from High

Check continuity of both purple

Temperature Supply Switch and

wires. Continuity available for both

Page 52

13 - TROUBLE SHOOTING

3.7µA

ring rate)?

Status, Flame Signal.

to initiate boiler operation.

Follow Operating Instructions

Is ame signal greater than

Enter Installer Menu, Boiler

YES

(Boiler may be running at any

Replace Flame

Sensor and Burner

Module

Replace Control

Module

NOYES

Replace Control

Blocking Error E 3 5

False flame detect

_ P _ _ _

glass. Is flame present?

Inspect burner through sight

shutoff valve.

Turn Gas Shutoff

Valve clockwise to

Turn off manual gas

closed position.

Follow instructions

Gas Valve.

TO APPLIANCE.

TO TURN OFF GAS

Replace Gas Valve.

APPLIANCE. Replace

TO TURN OFF GAS TO

Page 53

13 - TROUBLE SHOOTING

any remaining air in system.

Repair System Piping, remove

Water Cutoff.

YES NO

Is 24 vac at terminals 1 & 2

Disconnect harness from Low

Connect harness to Transformer.

(Between blue and yellow wires)?

Page 54

13 - TROUBLE SHOOTING

gas temperature through sampling

Use thermal couple to measure ue

Interface signicantly different?

port. Is the measured temperature

and ue temperature reading on User

Replace Control Module

YES

Interface.

Replace Flue Gas Sensor

YES

Blocking Error

Flue Gas Error

Read ue gas temperature on User

Is temperature higher than 200°F ?

system.

for boiler to cool. Fix

Boiler is over red. Wait

purging all air out of the

ow rate problem if any,

Page 55

13 - TROUBLE SHOOTING

YES

sensor (2 Brown Wires)?

Is correct harness connected to return

Correct wiring

properly oriented?

Is Heat Exchanger Pump

(Pump arrow pointing down?)

YES

wire. Is wiring/pins in right order? Does

sure volts on pins of black wire and white

Verify order of pins on J2. Pin order should

be: empty, black (or red), white, green. Mea-

Install Heat

proper orientation

Exchanger Pump in

pin have 0 VAC?

black/wire have 120 VAC? Does white wire/

Sensor

Replace Return Water

Module

Replace Control

antifreeze solution.

YES

Unplug molex connector on return

metal pins? Liquid might be water or

sensor. Is there moisture or liquid on

from connector.

Repair all leaks.

Check for leaks.

Remove all liquid

YES

Disconnect harness from

Return Water Sensor. Measure

950 to 33,000 ohms?

resistance using digital ohm

meter. Is resistance between

Replace Control Module

Page 56

13 - TROUBLE SHOOTING

+/- 2%

Blocking Error E 4 5

Net frequency error

_ P _ _ _

Is power supply between 59

and 61 Hz?

YES

stabilized power

Provide frequency

supply rated at 60 Hz

loose or faulty?

YES

Is power supply circuit breaker

YES

Is field wiring loose or faulty?

breaker

Replace circuit

Module

Replace Control

Correct wiring

blower motor system.

These error messages are displayed

Check wire connector to blower.

when the control board detects fault in

Check connector J9 on control board.

YES

Is any connection loose?

Replace Control Module

YES

this correct the problem?

Replace blower motor. Does

Fix the connection.

properly

Boiler is operating

Page 57

13 - TROUBLE SHOOTING

Module J5?

Water Sensor?

YES

Blocking Error E 5 1

Supply Sens Open

_ P _ _ _

Is harness plugged into Supply

Is harness plugged into Control

Insert Harness

YES

Disconnect J5 from Control

Module. Using digital meter

Using digital meter measure check

Disconnect J5 from Control Module.

and Sensor. Continuity?

measure check continuity of

continuity of white wires between

white wires between Control

Control Board and Sensor. Continuity?

Replace Wires

Unplug J5 connector on Control

resistance between Supply

Using digital meter measure

resistance between terminals J5-11

Water Sensor terminals J5-11

board. Using digital meter measure

and J5-3. Measure resistance

Resistance Chart?

range of the Resistance Chart?

of Sensor with digital meter.

and J5-3. Estimate

Estimate Sensor temperature.

Sensor temperature. Does it fall in the

YES

Does it fall in the range of the

Water Sensor

Replace Supply

Module

Replace Control

conductor

YES

connected to High Voltage

Is field grounding conductor

Blocking Error E 4 6

Faulty ground

Terminal Strip 120 VAC (G)?

_ P _ _ _

Connect ground

Disconnect field wiring. Is

continuity between field wiring

neutral and ground less than

10 ohms?

YES

conductor

Correct faulty ground

Module

Replace Control

Supply Water Sensor

Resistance

°F

Resistance Chart

°C

9K to 24K ohms

50 to 9010 to 32

3K to 9K ohms

90 to 130

32 to 54

2K to 3K ohms

130 to 150

54 to 66

2K to 1K ohms

150 to 200

66 to 94

Page 58

13 - TROUBLE SHOOTING

Return Temperature Sensor

2K to 1K ohms

2K to 3K ohms

3K to 9K ohms

°F°C Resistance

50 to 9010 to 32 9K to 24K ohms

Resistance Chart

90 to 130

32 to 54

130 to 150

54 to 66

150 to 200

66 to 94

Blocking Error E 5 2

Return Sens Open

_ P _ _ _

Temperature Sensor?

Is harness plugged into Return

Is harness plugged into Control

Module J5?

YES NO

Insert Harness

wires between Return

Check continuity of brown

Temperature Sensor and

Control Module J5-4 and J5-12

Continuity?

YES NO

Replace Wires

Replace Return

on chart?

YES NO

meter. Estimate Sensor

Measure Return Temperature

Sensor resistance with digital

Estimate Sensor temperature. Does

Sensor resistance with digital meter.

ranges shown in chart?

and resistance fall within

temperature. Do temperature

temperature fall within ranges shown

Temperature Sensor

Module

Replace Control

Page 59

13 - TROUBLE SHOOTING

shown in chart?

Disconnect wire harness from High

resistance across terminals 2 and 4.

Does temperature fall within ranges

Temperature Supply Switch. Measure

Resistance Chart

Supply Water Temperature Sensor

Page 60

Blocking Error E 6 5

Flue Sens Shorted

_ P _ _ _

Vent Temperature Sensor.

Disconnect wire harness from

Does resistance match

Measure Sensor resistance.

13 - TROUBLE SHOOTING

NOYES

estimated flue temperature?

Replace Vent

Temperature Sensor

in blue wires?

YES NO

Disconnect harness from

Control Module J5. Continuity

Replace wires

Module

Vent Temperature Sensor

2K to 1K ohms

2K to 3K ohms

3K to 9K ohms

°F°C Resistance

50 to 9010 to 32 9K to 24K ohms

Resistance Chart

90 to 130

32 to 54

130 to 150

54 to 66

150 to 200

66 to 94

Disconnect harness from

Blocking Error E 6 0

Return sens shorted

_ P _ _ _

less than 50 ohms?

Measure resistance across

Return Temperature Sensor.

sensor terminals. Is resistance

YES NO

Disconnect harness from

Control Module J5. Measure

Sensor

resistance between brown

12. Is resistance less than 50

wires at terminals J5-4 and J5-

Replace Control

NOYES

ohms?

Module

Replace Control

Replace wires

Replace Return Water

Page 61

14.1 Connection Diagram

14 - WIRING DIAGRAM

Page 62

14 - WIRING DIAGRAM

14.2 Schematic Diagram of Ladder Form

Page 63

15 - GLOSSARY

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

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

• AUTHORITY HAVING JURISDICTION - Individual or organization adopting and enforcing codes, rules, and by-laws governing various concerns of community.

Commonly referred to as "nal authority" for any matters

• HIGH-VOLTAGE - Circuit involving potential of not more

relating to LIFE SAFETY and BUILDING CONSTRUCTION within a community.

• Btu - Abbreviation for British Thermal Unit. Quantity of

• IGNITER - Device utilizing electrical energy to ignite gas

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

• LEAK CHECK - Operation performed on gas piping

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

of gas and air, to combustion zone.

• LOW WATER CUTOFF - Device constructed to

• COMBUSTION - Rapid oxidation of fuel gases

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

• COMBUSTIBLE MATERIAL - Materials made of or

surfaced with wood, compressed paper, plant bers,

• LOW-VOLTAGE - Circuit involving potential of not more

• METRIC GAS METERS

or other materials capable of being ignited and burned. Such material shall be considered combustible

even though ame-proofed, re-retardant treated, or

plastered.

For example: Gas Meter measures 0.1 cubic Meters in 100

• CONDENSATE - Liquid separated from ue gas due to

seconds

reduction in temperature.

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

• PRESSURE TEST - Operation performed to verify gas

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

through a chimney, vent, ue or appliance.

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

• FLA - Full load amps.

• GAS PIPE SIZES - Table 14

NATURAL GAS

Length of Pipe

- Ft.

20 92,000 190,000 350,000 625,000

40 63,000 130,000 245,000 445,000

60 50,000 105,000 195,000 365,000

Length of Pipe

- Ft.

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

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

60 72,000 121,000 103,000 217,000

Pipe Capacity - BTU Per Hour Input Includes Fittings

1/2” 3/4” 1” 1 1/4”

PROPANE GAS

Pipe Capacity - BTU Per Hour Input Includes Fittings

Copper Tubing

(Outside Diameter)

5/8” 3/4” 1/2” 3/4”

Iron Pipe

than 600 volts and having circuit characteristics in excess of those of low-voltage circuit.

at main burner.

system to verify system does not leak.

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

than 30 volts.

MBH =

127,116 x cu meters

Seconds

127,116 x 0.1

100

= 127 MBH

tight integrity of gas piping following its installation or

modication.

gas and air.

• FLUE GASES - Products of combustion plus excess air

in appliance ues or heat exchanger.

• PURGE TIME - Period of time intended to allow for dissipation of any unburned gas or residual products of combustion.

Page 64

15 - GLOSSARY

• QUALIFIED AGENCY - Any individual, rm, corporation,

or company engaged in and responsible for:

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

• Experienced in such work.

• Familiar with all precautions required.

• Complies with all requirements of authority having

jurisdiction.

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

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

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

• VENT - Passageway used to convey ue gases from

appliance vent connector to outdoors.

• VENTING SYSTEM - Continuous open passageway from of appliance vent connector to outdoors for purpose of

removing ue or vent gases.

Page 65

APPENDIX A - CONTROL MODULE

1.1 Introduction

The boiler is equipped with a programmable electronic control and user interface module.

1.2 Operation

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

• Function Keys

Key Description

- Manual Lockout Reset

- Enter/Exit user menu

- Go to previous screen

- Select a menu item

- Conrm new parameter value

- Scroll up to next menu item

- Increase value

- Scroll down to next menu item

- Decrease value

Operation with LCD character display module

1.3 Status Indication

The following status screens can be displayed:

Boiler Status Indicator

F = Flame Detected

SERVICE Reminder

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

Combustion Air Blower

Speed Indicator

Service Reminder Indicator Boiler in Standby Mode Boiler Supply Water

Temperature Indicator.

Boiler Running in Central Heat mode

Boiler Running in DHW mode

Lockout Alarm Indicator

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

Blocking Error in DHW

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

Page 66

1.4 Sequence of Operation

Operational State User Interface Display Explanation

APPENDIX A - CONTROL MODULE

Heat

Demand?

Yes

DHW CH

Pump on

Supply

Temperature

<Setpoint?

Yes

15 Second

Prepurge

Standby: No Demand

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

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

(CH call is illustrated)

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

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

Ignition

Sparking

After 2 seconds

Sparking initiated sequence.

Page 67

1.4 Sequence of Operation

Operational State User Interface Display Explanation

After 2 seconds

Flame

Detected?

Gas Valve Energized

Yes

Lockout

Error A21

APPENDIX A - CONTROL MODULE

Note:

5 Ignition

trials,

then

Lockout A01

If ame detected before Gas Valve opens

during ignition boiler will lockout.

Please refer to troubleshooting guide.

Gas Valve energized to deliver air/fuel to burner.

After 3 seconds

Flame

Detected?

Yes

Heat Demand

Met?

Simultaneous

DHW + CH

Demand?

Yes

DHW

Priority

Mode

See Max DHW

Priority Time

30 second

post purge

Yes

Setting

If ame undetected after 3 seconds boiler

will de-energize Gas Valve and enter post purge mode for 30 seconds.

Ignition attempted 5 times before lockout.

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

Refer to for more information.

Control module adjusts ring rate

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

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

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

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

Please refer to section Appendix A section

1.5 for more information.

Page 68

1.5 User Menu

APPENDIX A - CONTROL MODULE

User Interface Display

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

Explanation

STANDBY

User Menu (Press Menu button on user interface to access User Menu)

User Menu structure includes:

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

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

User Menu

• ‘Cascade Status’ submenu – Boiler set to function as part of multiple boiler installation; submenu used to view runtime parameters. See Multiple Boiler Manual. (This line is not shown if boiler is not in cascade system).

Boiler Status

Supply Temperature set point displayed.

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

Note:

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

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

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

Operational status of pump system also shown.

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

Page 69

APPENDIX A - CONTROL MODULE

User Interface Display

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

Settings

Explanation

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

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

Note:

For explanation of available CH heating modes, refer to ‘CH Mode’ section located in ‘CH Settings’ submenu in Installer Menu.

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

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

ser interface temperature unit of measure is selected using

‘Change Temperature Units’ screen.

Fahrenheit and Celsius available.

Page 70

APPENDIX A - CONTROL MODULE

User Interface Display

Installer Menu

Explanation

Installer Menu structure includes:

• User 'Menu' can be accessed by pressing 'Menu' key on user interface.

• Installer 'Menu' can be accessed by pressing and holding the 'Enter' key continue to hold and at the same time press and hold the 'Menu’ key for 5 seconds. (You must press and hold the 'Enter' key then press and hold the 'Menu' key).

• ‘Boiler Status’ submenu – Monitors detail boiler status parameters such as error codes.

• ‘Boiler

• ‘CH Settings’ submenu –

Heating settings including outdoor reset curve parameters and boost function.

submenu – general boiler settings.

signal, fan speeds and stored

advanced Central

Boiler Status

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

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

• ‘System Test’ – Tool aids setup of boiler installation or

diagnosis of common problems.

Combustion air Blower provides through Combustion and Vent systems.

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

Settings are for information only to aid in troubleshooting.

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

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

Page 71

APPENDIX A - CONTROL MODULE

User Interface Display

Installer Menu

Explanation

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

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

Figure A-1 Typical Ignition Cycle

Boiler Status

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

False Flame Detection

Re-ignition

Intermittent Operation

Flame out too late

Safety relay test

UL3563 High Limit Temperature Device

If ame is detected at end of pre-spark

period (Ignit_0) than lockout will occur.

If at end of safety period no ame

detected control will go to post-purge removing unburned gas. Re-ignition attempt started following same cycle. Number of re-ignition attempts limited to 3 after which lockout occurs.

Boiler can be ring continuously for 24

hours. Burner switched off and restart sequence follows.

If ame detected after post purge lockout

follows.

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

Boiler comes equipped with UL353 approved temperature high limit device.

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

Page 72

APPENDIX A - CONTROL MODULE

User Interface Display

Boiler Status

Explanation

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

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

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

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

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

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

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

Boiler Conguration

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

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

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

Page 73

APPENDIX A - CONTROL MODULE

User Interface Display

Explanation

Two pump modes are available:

Pump Mode = 0 ‘CH or CH&DHW’

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

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

• In the case of simultaneous call for both CH and DHW, the

energized pump depends on whether the boiler is currently supplying CH or DHW demand. Refer to DHW Priority settings below.

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

Pump Mode = 4 ‘System Pump’

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

Boiler Conguration

• Connect this pump to CH/System Pump electrical terminal block. See page 35 for diagram.

• DHW pump terminal does not function.

• This is typical of hydronic system design which utilizes zone

valves for all CH zones and DHW indirect tank.

Note:

• Pump Mode selection depends on electrical and

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

congurations.

• Internal heat exchanger pump is energized anytime

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

'Service Reminder’ feature allows the installer to enable or

disable a service reminder notication on the User Interface at a predened interval .

Service reminder does not affect operation of boiler in any way. It is only a reminder to End User that routine preventative

maintenance is required by qualied service technician.

Allowed Range: 1 to 999 days

Page 74

APPENDIX A - CONTROL MODULE

User Interface Display

CH Settings

Explanation

4. Central Heating (CH) modes available:

• CH Mode = 0 ‘CH with Thermostat’

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

• Boiler will modulate its ring rate to maintain CH set

point and match system heat load.

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

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

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

• Boiler will modulate its ring rate to maintain CH set

point and match system heat load.

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

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

• CH demand is determined by outdoor temperature and Warm Weather Shutdown temperature.

• Boiler will permanently attempt to satisfy CH demand, when CH demand is available.

• CH thermostat input is ignored.

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

• CH Mode = 3 ‘CH with Permanent Demand’

• CH demand is prermanently on.

• Boiler will permanently attempt to satisfy CH

demand.

• CH thermostat input is ignored.

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

‘User Menu’

Note:

• Once CH demand is satised (i.e. CH thermostat opens or boiler determines its minimum ring rate exceeds system

heating load):

• Burner shuts off, boiler enters post purge.

• CH pump continues to run for 30 seconds.

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

cycling.

• The internal heat exchanger pump is energized anytime demand

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

Page 75

User Interface Display

Reset Curve Design Points , A and B, d B s B f

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

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

Default Boiler Setting:180° F (82°C)

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

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

CH Settings

100

Explanation

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

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

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

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

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

Figure A-2 Outdoor Reset Curve

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

220

200

180

160

efine a s traignt line . oile r Min and Max, C and D, define a

ection on the stra ignt line.

oile r supply temperature Setpo int

ollows the bold line s ections

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

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

C D

140

120

100

Supply Temperature Setpoint F

Suppy Temperature Setpoint °F

0 20 40 60 80 100

Outdoor Temperature °F

Outdoor Temperature F

Note:

• Modes only function when outdoor temperature sensor connected.

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

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

Page 76

APPENDIX A - CONTROL MODULE

User Interface Display

CH Settings

Explanation

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

CH set point will continue to increase until set point reaches

195°F / 91°C

Allowable Temperature Increment: 0..36 °F (0..20 °C) Default Temperature increment: 0 °F (10 °C)

Allowable Time Delay: 1..120 minutes Default Time Delay: 20 minutes

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

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

Two DHW modes are available

• DHW Mode = 0 ‘No DHW

DHW Settings

• DHW Mode is disabled

• The DHW thermostat input is ignored and the DHW

pump is not used.

• DHW Mode = 2 ‘DHW Store with Thermostat’

• Boiler reacts to DHW demand when DHW thermostat

input closes.

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

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

Note:

• Outdoor reset function disabled while operating in DHW Mode.

• Typical when using a DHW indirect storage tank.

• After DHW demand satised, boiler enters post purge

mode and DHW pump continues to run for 15 seconds.

Page 77

APPENDIX A - CONTROL MODULE

User Interface Display

Allowed Range: 1 to 60 Minutes Default Setting: 30 Minutes

DHW Settings

Explanation

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

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

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

Process repeats until either CH or DHW demand satised.

System test can be activated via installer menu for testing

system at xed power rates.

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

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

The following modes are available:

System Test

• Disabled

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

• Ignition power - Burner starts. Stays at ignition power

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

Note:

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

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

• During System Test Mode, boiler will run at xed power

rates until supply water temperature is 93°C/195°F

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

Page 78

NOTES

Page 79

Company Address & Phone #Company Name & Tech InitialsService PerformedDate

Page 80

CONDENSING

GAS BOILER

Models 075 & 100

ECR International, Inc. 2201 Dwyer Ave. Utica, NY 13501

www.ecrinternational.com