Lennox GWM-050IE, GWM-075IE, GWM-100IE, GWM-150IE, GWM-200IE Installation Instructions Manual
Page 1
INSTALLATION
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
INSTRUCTIONS
GWM-050IE, GWM-075IE,
GWM-100IE, GWM-150IE,
GWM-200IE,
WALL MOUNTED GAS
BOILER
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE
These instructions must be afxed
on or adjacent to the boiler.
WARNING
Improper installation, adjustment, alteration, service,
or maintenance could result in death or serious injury.
Refer to this manual for assistance. For additional
information consult a qualied installer, service
agency, or the gas supplier.
WALL MOUNTED GAS-FIRED HOT WATER
BOILERS
These Gas-Fired Water boilers are low pressure,
stainless steel boilers Design Certied by CSA
(Canadian Standards Association) for use with
Natural and Propane Gases. They are constructed
and hydrostatically tested for a maximum working
pressure of 50 psi (pounds per square inch) in
accordance with A.S.M.E. (American Society
of Mechanical Engineers) Boiler and Pressure
Vessel Code Section IV Standards for Heating
Boilers.
PN# 240009475, Rev. C [03/2014]
Page 2
VERIFY CONTENTS RECEIVED
Description
Item
No. Illustration
Fully Assembled Boiler 1
Metal Wall Bracket 2
Lag Bolt, 3/8" x 3" Hex (4 ea) 3
*Safety Relief Valve 4
3/4" Tee 5
3/4" Nipple 6
2
3
4
8
3/4" x 1/4" Elbow 7
Air Vent 8
7
6
5
**Temperature Pressure Gauge 9
Bushing 3/4" x 1/4" 10
3/4" Tee (Same as No. 11) 11
12
11
9
10
Nipple 1¼ x 5½ 12
Drain Valve, 3/4" 13
3/4" Tee 14
15
14
13
Nipple 1¼ x 5½ 15
Bushing 7/8" OD, Heyco (2 ea) 16
Used for electrical wire knockouts.
Stopper, Rubber 5/16" (2 ea) 17 Used for packaging holes on back of boiler.
Plastic Plug (2 ea) 18 Used for packaging holes on back of boiler.
Outdoor Sensor 19 Used for measuring outside temperature.
Critical Installation Instruction 20 11" x 17" Page for critical installation issues.
Document Package 21 Includes essential documents.
* Boiler provided with 30 psig (206 kpa) safety relief valve. Field source safety relief valve if system pressure
greater than 25 psig.
** Boiler provided with 75 psig temperature pressure gauge. Field source temperature pressure gauge if system
pressure greater than 60 psig.
2
Page 3
DIMENSIONS
FIGURE 1-1 Dimensions
(D)
Wall Hanging
Bracket
(D)
(E)
DIMENSIONS
Safety Relief
Valve
Connection
(¾ NPT)
Vent Connector
Combustion Air
(A)
(B)
Models
Width (A) 20" (508mm)
Height (B) 30" (762mm)
Depth (C) 14" (356mm)
Bracket (D) 28" (711mm)
Height (E) 31" (787mm)
Water
Connections
Gas
Connection
Condensate Drain
Connection (L)
Weight
Table 1 : Physical Data
050/075/100 150/200
23" (584mm)
40" (1041mm)
16.0"
(406mm)
40" (1016mm)
42" (1092mm)
Size(F) 1-1/4" NPT
Location (G) 2" (51mm) 2" (51mm)
Location (H)
Location (I)
Location (J) 4-1/2" (114mm) 4-1/2" (114mm)
Size (K)
Shipping 111 lb (50 kg)
Unit 91 lb (41 kg)
5" (127mm)
3" (76mm)
1/2"
NPT
3/4" NPT
1-1/4" NPT
2" (51mm)
4-½"
(114mm)
3/4"
NPT
3/4" NPT
~182 lb
(83 kg)
~157 lb
(71 kg)
(G)
Supply Water (F)
Gas Connection (K)
Return Water (F)
(H)
(I)
(J)
(C)
Vent Connector 2" (51mm) 3" (76mm)
Condensate Drain Connection (L)
3
Page 4
TABLE OF CONTENTS
1 - Introduction ............................................................................................................................... 5
2 - Important Safety Information ....................................................................................................6
3 - Component Listing ..................................................................................................................... 7
4 - Locating Boiler ......................................................................................................................... 11
5 - Hydronic Piping ........................................................................................................................ 13
5.2 Special Conditions ................................................................................................................. 13
5.3 Safety Relief Valve and Air Vent............................................................................................ 13
5.4 Trim Piping ........................................................................................................................... 14
5.5 System Piping....................................................................................................................... 14
6 - Combustion Air And Vent Piping ............................................................................................... 21
6.2 Removal of Existing Boiler From Common Vent System........................................................... 21
6.3 Venting Materials ................................................................................................................. 21
6.4 Vent Pipe Installation ............................................................................................................. 22
6.5 Vent Termination .................................................................................................................. 22
6.6 Venting Congurations ........................................................................................................... 23
6.7 Side Venting Terminal Requirements..........................................................................................28
6.8 Multiple Boiler Venting Installation............................................................................................30
6.9 Condensate Piping ................................................................................................................. 31
7 - Gas Supply Piping .................................................................................................................... 32
8 - Electrical Connections .............................................................................................................. 34
8.3 Line Voltage Connections ....................................................................................................... 34
8.4 External Connections ............................................................................................................. 34
9 - Start Up Procedure ................................................................................................................... 36
9.6 Perform CSD-1 Compliance Test ......................................................................................................40
9.7 Complete Start Up Procedure .................................................................................................. 41
10 - Operating Instructions ........................................................................................................... 42
11 - General Maintenance And Cleaning ........................................................................................ 43
12 - Ratings And Capacities ........................................................................................................... 46
13 - Trouble Shooting .................................................................................................................... 47
14 - Wiring Diagram ...................................................................................................................... 65
15 - Glossary ................................................................................................................................. 68
Appendix A - Control Module ......................................................................................................... 70
1.1 Introduction ......................................................................................................................... 70
1.2 Operation ............................................................................................................................. 70
1.3 Status Indication ................................................................................................................... 70
1.4 Sequence of Operation ........................................................................................................... 71
1.5 User Menu ........................................................................................................................... 73
4
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 liqueed petroleum gases
(LP/propane).
1.2 The unit MUST NOT:
• Directly heat potable water. Indirect heating is acceptable.
• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
• Exceed 150 psig (1.03 MPa) maximum allowable
working pressure.
• Exceed 195°F (90.5°C) system design temperature.
1.3 Operational Features
• Modulating: 20-100%.
• Integral Dual Limit.
• Integral Low Water Cutoff (with test button).
• Outdoor Temperature Reset.
• Integral Multiple Boiler Control.
Information and specications outlined in this manual in effect at the
time of printing of this manual. ManufacturerManufacture reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
5
Page 6
2 - IMPORTANT SAFETY INFORMATION
2.1 General
Boiler installation shall be completed by qualied 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.
6
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3 - COMPONENT LISTING
3.1 Component Listing - Refer to diagrams on
following pages.
1.
User Interface Displays information regarding boiler
condition. Allows adjustment of boiler operating
parameters. NOTE: Does not replace thermostat used
to control central heating space.
2.
Combustion Air Inlet (2"/3") See section 6.
3.
Return Water From Heating System (In)
Connection supplied at bottom of boiler. See section 5.
4.
Low Voltage Terminal Strip Connection of all low
voltage wiring, including thermostat.
5.
Igniter
6.
Flame Sensor
7.
Sight Glass Permits observation of burner ame.
8.
Burner (see page 40)
20.
Gas (Control) Valve Delivers proper quantity of fuel
to Combustion Air Blower. See section 7.
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 12)
Integral to boiler. Allows wall mounting when used
with supplied wall mounting bracket. See section 4.
28.
Air Vent
9.
Heat Exchanger
10.
Condensate Collector
11.
Return Water Temperature Sensor
12.
Drain Valve (see page 14)
13.
Internal Primary Loop Ball Valve
14.
Supply Water Outlet to Heating System (Out)
Connections supplied for connecting from bottom of
boiler. See section 5.
15.
Vent Temperature Sensor
16.
Condensate Drain Boiler produces a liquid
(condensate) as a by-product of combustion. Condensate
must be piped to appropriate drain. See section 6.
17.
Heat Exchanger Pump
18.
Gas Shutoff Valve Fuel supply isolation during
servicing. See section 7
29.
Boiler Control Module
30.
Lower Jacket Panel Gently pull upward then forward
to access.
31.
Transformer Supplies 24V power to low water cutoff.
32.
Flue Air Mixture Pressure Test Port - Not available
on all models.
33.
Combustion Analysis Test Port
34.
Internal Pump Relay - Not available on all models.
35.
Heat Exchanger Surface Temperature Switch
36.
ASME Plate
19.
Combustion Air Blower Delivers proper quantity of
combustion air, receives fuel from gas valve, mixes air
and fuel sending mixture to burner for combustion.
7
Page 8
3 - COMPONENT LISTING
FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)
SAFETY RELIEF VALVE
VENT CONNECTOR
COMBUSTION
AIR INLET
AIR VENT
NOTE:
See Section 5-3 For
Safety Relief Valve
Piping Instructions
WALL MOUNT
SUPPORT
BRACKET
FIGURE 3-2 Upper and Lower Jacket Latch (Viewed
from front of boiler)
Upper and Lower
Jacket Latch
Lift Jacket up,
engage jacket with
chassis,
push down.
8
Page 9
(7) SIGHT GLASS
(6) FLAME
3 - COMPONENT LISTING
FIGURE 3- Boiler Components 50/75/100 MBH (View from Front of Boiler) As seen on front cover
NOTE:
(28) AIR VENT
(23) SAFETY RELIEF VALVE
See Section 5
For Piping
Instructions
(21) SUPPLY WATER
TEMPERATURE SENSOR
& HIGH LIMIT SWITCH
(22) LOW
WATER CUTOFF
(13) INTERNAL PRIMARY
LOOP BALL VALVE
(20) GAS (CONTROL)
VALVE
(19) COMBUSTION
AIR
BLOWER
(18) GAS SHUTOFF
VALVE
(SHOWN IN OPEN
POSITION)
(35) HEAT EXCHANGER
SURFACE TEMPERATURE
SWITCH
(17) HEAT EXCHANGER
PUMP
(15) VENT
TEMPERATURE
SENSOR
(33) COMBUSTION
ANALYSIS TEST
PORT
(10) CONDENSATE
COLLECTOR
(25) VENT CONNECTOR
(2) COMBUSTION
AIR INLET
(5) IGNITER
(6) FLAME
SENSOR
(7) SIGHT GLASS
(32) FLUE
AIR MIXTURE
PRESSURE
TEST PORT
(1) USER INTERFACE
(29) BOILER
CONTROL
MODULE
Fuse and
Holder
(36) ASME
PLATE
(9) HEAT
EXCHANGER
(31) TRANSFORMER
(11) RETURN WATER
TEMPERATURE SENSOR
(4) LOW VOLTAGE
TERMINAL STRIP
(24) HIGH VOLTAGE
JUNCTION BOX
(14) SUPPLY WATER TO
HEATING SYSTEM (OUT)
(16) CONDENSATE
DRAIN
(3) RETURN WATER
FROM HEATING
SYSTEM (IN)
(26) GAS CONNECTION
9
Page 10
A
4 - LOCATING BOILER
4.1 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
prevent freezing of liquid condensate.
• Approved for installation in closets.
• Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, condensate trap, control
replacement, etc.).
• Wall mount only.
• Access to outdoors to meet minimum and maximum
pipe lengths for combustion air and vent piping. See
section 6.
• Disposal of condensate. See section 6.
• Drainage of water (or water - antifreeze solution) during
boiler service or from safety relief valve discharge. See
section 5.
• Access to system water piping, gas supply, and electrical
service. See sections 5, 7 and 8.
• Clearances to combustible materials and service
clearances. See Table 2 and gure 4-1.
• Multiple Boilers can be wall mounted, placed side by
side, or back to back.
FIGURE 4-1 Clearance to Combustible Materials
A
B
F
A
C
F
FLOOR
A
E
TABLE 2: BOILER CLEARANCES
Dimension
Model
Top (A)
Left Side (B)
Right Side (C)
Front (D)
Back (E)
Bottom (F)
Combustion Air/Vent
piping
Hot Water Piping
(1)
Required distances measured from boiler jacket.
(2)
Service, proper operation clearance recommendation.
Combustible
Materials
050/075/100/
150/200
0" (0 cm) 14" (36 cm)
0" (0 cm) 0" (0 cm)
0" (0 cm) 0" (0 cm)
0" (0 cm) 6" (16 cm)
0" (0 cm) 0" (0 cm)
0" (0 cm) 12" (32 cm)
0" (0 cm)
See local code 6" (16 cm)
(1)
E
F
FLOOR
Service
050/075/100/
150/200
6" (16 cm)
(1)(2)
D
F
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Page 11
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. See parts listed on page 2, number 17
and 18.
• Mount boiler vertically or slightly tilted backward to
insure the low water cutoff functions properly. See
gure 4-3 for low water cutoff orientation.
!
CAUTION
Boiler weight exceeds 75 pounds (34 kg). Do not
lift boiler onto wall without assistance.
NOTICE
Lift boiler using chassis. Using front jacket, vent
piping, water or gas ttings to lift boiler may cause
damage to the boiler.
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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. Internal
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 Teon tape, etc.
5.2 Special Conditions
• System piping exposed to freezing conditions: Use
inhibited propylene glycol solutions certied 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 9 & 10.
• Boiler used in connection with refrigeration system.
Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
• System piping connected to heating coils located in air
handling unit exposed to refrigerated air circulation. Install
ow control valves or other automatic means to prevent
gravity circulation of boiler water during cooling cycle.
5.3 Safety Relief Valve and Air Vent
!
WARNING
• Poison hazard. Ethylene glycol is toxic. Do not
use ethylene glycol.
• Never use automotive or standard glycol antifreeze,
even ethylene glycol made for hydronic systems.
• Ethylene glycol can attack gaskets and seals used
in hydronic systems.
• Use only inhibited proplyene glycol solutions
certied 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 (Viewed
from front of boiler)
Safety Relief
Valve
Air Vent
3/4"F x 3/4"M
NPT Tee
3/4 NPT
NOTICE
Boiler rated at 150 psig (1.03 MPa) maximum
allowable working pressure. Boiler provided with
30 psig (206 kPa) safety relief valve. Field source
safety relief valve for system pressures greater
than 25 psig. Temperature Pressure Gauge and Air
Vent satisfactory for 75 psig operation. Field source
temperature pressure gauge for system pressures
greater than 60 psig.
• Install safety relief valve and air vent using pipe 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" x 1/4" NPT
90° Elbow
3/4" NPT
Nipple
Position Air Vent and Safety Relief Valve
to provide space for discharge piping.
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Page 13
5 - HYDRONIC PIPING
!
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
FIGURE 5-2 Safety Relief Valve Discharge Piping
Safety Relief Valve
• Install discharge piping from safety relief valve. See
gure 5-2.
• Use ¾" or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C)
or greater.
• Individual boiler discharge piping shall be independent
of other discharge piping.
• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
5.4 Trim Piping
• Temperature - Pressure Gauge. Install temperature
pressure gauge using nipple, tee and bushing provided
with boiler. See gure 5-3.
Check Local Codes
For Maximum
Distance To Floor
FIGURE 5-3 Temperature Pressure Gauge and Drain
Valve Installations
Gas Supply
Temperature Pressure
Gauge shown at
System Supply
Connection
Drain Valve shown
at System Return
Connection to Boiler
5.5 System Piping
• Drain Valve. Install drain valve using nipple, tee and
bushing provided with boiler. See gure 5-3.
• See Table 3 for basic system piping congurations.
• Systems with automatic ll valves require back ow
prevention device.
• Single boiler system. See gures 5-4, 5-5, 5-6, 5-7A, & B
for general guidance. Additional considerations:
• Boiler control is designed for single central heating
pump. Installer responsible for integration of
multiple central heating pumps.
• Boiler control allows domestic hot water
prioritization. Function could be lost if central
heating pump not directly connected to control
system.
• Multiple boiler system.
guidance. Additional considerations:
• Control system requires equivalent water
temperatures entering each boiler to properly
sequence and adjust system supply temperature.
• Install multi boiler sensor kit. See "Parts, Kits &
Optional Accessories" manual for part number.
• Heating system with existing primary loop, close internal
primary loop ball valve.
• Heating system without existing primary loop, leave internal
primary loop ball valve open to use internal primary loop.
See gure 5-8A, B & C
for general
13
Page 14
5 - HYDRONIC PIPING
NOTICE
Illustrations are meant to show system piping
concept only. Installer responsible for all
equipment and detailing required by authority
having jurisdiction.
FIGURE 5-4 System Piping
Safety Relief Valve
MOUNTED
Piping Legend
WALL
ONLY
Pipe to
condensate
drain
Multiple Boilers
Single Boiler
System
Supply
System
Return
Table 3 - System Piping Congurations
Two Pipe Zoned System
Primary/Secondary Pumping
Two Pipe Zoned System
Primary/Secondary Pumping
With Zone Valves gure 5-5
With Zone Pumps gure 5-6
Closed External Primary Loop
Open External Primary Loop gure 5-7B
With Zone Valves gure 5-8A
With Zone Pumps Not Shown
Closed External Primary Loop gure 5-8B
Open External Primary Loop
gure 5-7A
gure 5-8C
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5 - HYDRONIC PIPING
FIGURE 5-5 Single Boiler Two-Pipe Zoned System With Zone Valves
DHW
Pump
CH/System
Pump
Heat exchanger
ball valve open
(as shipped)
FIGURE 5-6 Single Boiler Two-Pipe Zoned System With Zone Pumps
DHW
Pump
Zone
Pump
3/8"/10mm Open
End Wrench may
be required to
turn valve
Heat exchanger
ball valve open
(as shipped)
3/8"/10mm Open
End Wrench may
be required to
turn valve
15
Page 16
5 - HYDRONIC PIPING
FIGURE 5-7A Single Boiler Using Primary/Secondary Pumping With Closed External Primary Loop
Heating Load Heating Load
12"(305mm) Maximum
separation
12"(305mm)
CH/System
Pump
Maximum
separation
Existing closely spaced tees
in primary system loop
Limit length
Heating Load
to
5' (1.6m)
Heating system
with existing
primary loop.
Internal primary
loop ball valves
closed
3/8"/10mm Open
End Wrench may
be required to
turn valve
FIGURE 5-7B Single Boiler Using Primary/Secondary Pumping With Open External Primary Loop
Heating Load Heating Load
12"(305mm) Maximum
12"(305mm)
CH/System
Pump
Maximum
separation
separation
Existing closely spaced tees
in primary system loop
Limit length
Heating Load
to
5' (1.6m)
Internal primary loop
ball valves open.
Heating system
without existing
primary loop.
3/8"/10mm Open
End Wrench may
be required to
turn valve
16
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5 - HYDRONIC PIPING
FIGURE 5-8A Multiple Boiler Two Pipe Zoned System With Zone Valves - (See Multiple Boiler Guide)
DHW
Pump
CH/System
Pump
12"/305mm Maximum Separation
System
Temperature
Sensor
Size common piping
per maximum heat
capacity of entire
system
Limit
length to
5' (1.6m)
All internal
primary loop
ball valves
closed
Up to 16
boilers
3/8"/10mm Open
End Wrench may
be required to
turn valve
(See Multiple Boiler Guide)
17
Page 18
5 - HYDRONIC PIPING
FIGURE 5-8B Multiple Boilers Using Primary/Secondary Pumping with Closed External Primary Loop
Heating Load Heating Load
12"/305mm Maximum Separation
12"/305mm
Maximum
Separation
CH/System
Pump
System
Temperature
Sensor
Existing closely spaced tees
in primary system loop
Heating Load
Size common piping
per maximum heat
capacity of entire
system
Limit
length to
5' (1.6m)
Up to 16
boilers
All internal
primary loop
ball valves
closed
3/8"/10mm Open
End Wrench may
be required to
turn valve
18
Page 19
5 - HYDRONIC PIPING
5-8C Multiple Boilers Using Primary/Secondary Pumping with Open External Primary Loop
12"/305mm Maximum Separation
12"/305mm
Maximum
Separation
CH/System
Pump
System
Temperature
Sensor
Existing closely spaced tees
in primary system loop
Size common piping
per maximum heat
capacity of entire
system
Up to 16
boilers
Limit
length to
5' (1.6m)
Heat exchanger
ball valve open
(as shipped)
3/8"/10mm Open
End Wrench may
be required to turn
valve
19
Page 20
6 - COMBUSTION AIR AND VENT PIPING
6.1 General
This boiler requires a dedicated direct vent system.
Install combustion air and vent piping in accordance
with these instructions, authority having jurisdiction,
and:
• USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
Vent connections serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
Install vent system in accordance with these instructions.
6.2 Removal of Existing Boiler From Common
Vent System
When existing boiler is removed from common venting
system, common venting system is likely to be too large for
proper venting of appliances remaining connected to it.
After removal of existing boiler, following steps shall
be followed with each appliance remaining connected to
common venting system placed in operation, while other
appliances remaining connected to common venting system
are not in operation:
• Seal any unused openings in common venting system.
• Visually inspect venting system for proper size and
horizontal pitch. Determine there is no blockage or
restrictions, leakage, corrosion and other deciencies
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.
• 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
CPVC schedule 40
Vent Pipe
and Fittings
Pipe
Cement/
Primer
• IPEX is approved vent manufacturer in Canada listed
to ULC-S636.
• IPEX System 636 Cements and Primers are approved
in Canada listed to ULC-S636.
SDR-21 & SDR-26 PVC ANSI/ASTM D2241
ABS-DWV ANSI/ASTM D2661
Schedule 40ABS ANSI/ASTM F628
PP (Polypropylene)
Pipe and Components
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
Schedule 40 ABS ANSI/ASTM D2235
ANSI/ASTM D1784/
F441
UL 1738
ULC S636-08
• Turn on appliance being inspected. Follow lighting
instructions. Adjust thermostat so appliances will operate
continuously.
• Test for spillage at draft hood relief opening after 5
minutes of main burner operation. Use ame of match or
candle, smoke from cigarette, cigar or pipe.
• Determine each appliance remaining connected to
common venting system properly vents when tested
as outlined above. Then return doors, windows,
exhaust fans and any other gas-burning appliance to
their previous condition of use.
Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® ,
(Polyphenolsulfone) in venting systems shall be prohibited.
!
WARNING
Use of cellular core PVC for venting ue gas could
result in death, or serious injury.
WARNING
Covering non-metallic vent pipe and ttings with
thermal insulation shall be prohibited.
20
Page 21
6 - COMBUSTION AIR AND VENT PIPING
6.4 Vent Pipe Installation
• Minimum and maximum combustion air and vent pipe
lengths listed in Table 5. Pipe length counted from
combustion air connector to termination.
• Install eld-sourced 2" to 3" transition, if used, in vertical
section at combustion air inlet and vent connector.
• 90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows
equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no
equivalent length. See Table 6.
• Use exible Polyproplyene piping (PP) in a vertical
position only. Check PP pipe manufacturer for details.
Each foot of PP exible pipe is equivalent to 2⅝ feet of
smooth pipe of same diameter.
• Slope vent pipes minimum 1/4" per foot (21 mm/m)
back toward boiler. Support horizontal sections to
prevent sags capable of accumulating condensate.
• Support piping in accordance with pipe manufacturer's
instruction and authority having jurisdiction. In absence
of manufacturer's instruction use pipe hooks, pipe
straps, brackets, or hangers of adequate and strength
located at intervals of 4 ft (1.2m) or less. Allow for
expansion/contraction of pipe.
• Combustion air and vent piping must be air tight and
water tight.
• Certied 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 Vent Termination
• Terminate combustion air and vent pipes with ttings or
concentric vent kit.
A. See "Parts, Kits and Optional Accessories" manual
for concentric vent kit part numbers.
B. Use horizontal pipe for vent and 90° elbow for
combustion air termination when using ttings.
• Terminate combustion air and vent pipes in same
atmospheric pressure zone through exterior sidewall or
roof.
• Locate combustion air termination as far as possible
from swimming pool, swimming pool pump house, and
other sources of airborne chlorine.
• Locate combustion air and vent terminals as required by
authority having jurisdiction.
Vent extending through exterior wall shall not
!
WARNING
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 050 075/100 075/100 150/200
Min.
Max.
For Example: Boiler can be installed on outside wall and vented with one 90° elbow and 1 ft (0.30 m) of vent pipe.
6 ft.
(1.8 m)
100 ft.
(30.5 m)
6 ft.
(1.8 m)
50ft.
(15.2 m)
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)
6 ft.
(1.8 m)
100 ft.
(30.5 m)
21
Page 22
6 - COMBUSTION AIR AND VENT PIPING
6.6 Venting Congurations
Various venting congurations can be applied to this boiler.
For guidance see Venting Conguration Table 7 and
corresponding gures.
Table 7 - Venting Congurations
Flue Gas Location
Roof
Combustion Air
Location
Roof
Side Wall Single Pipe gure 6-8
Inside Air Single Pipe gure 6-9
Roof Single Pipe gure 6-10
NOTICE
Use of vent covers may cause freezing. If using
vent covers overall vent length must be considered.
Failure to heed this information may compromise
operation of this boiler.
Flue Gas
Terminals
Two Pipe gure 6-1
Concentric gure 6-7
Corresponding Figures
Side Wall
Two Pipe gures 6-2, 6-3
Side Wall
Concentric gures 6-4, 6-5, 6-6
Inside Air Single Pipe gure 6-11
22
Page 23
FIGURE 6-1 Two Pipe Roof Vent
3" (80mm)
Minimum
12" (305mm)
Minimum
8" (203mm)
Minimum
Vent Combustion
Air
12" (305mm) US,
18" (458mm) Canada
Minimum Above
Anticipated Snow Line
6 - COMBUSTION AIR AND VENT PIPING
3" (80mm) Minimum horizontal
separation between combustion air
15" (381mm)
Maximum
Roof Line
Roof
Terminations
intake and vent of same appliance.
8" (203mm) Minimum vertical
separation between combustion
air intake and vent of different
appliances.
15" (381mm) Maximum horizontal
length of vent.
Minimum vent/intake between
different appliances 12" (305mm).
Maximum allowable total vertical
vent length with outside exposure is
10 ft.(3.05m).
Abandoned unused masonry
chimney may be used as chaseway
for combustion air and vent. Both
combustion air and vent pipe must
exit above top of chimney with
clearances as shown in gure 6-1.
FIGURE 6-2 Two Pipe Side Wall Vent
12" (305mm)
Minimum From
Overhang
See Snow & Ice
Page 22
FIGURE 6-3 Two Pipe Side Wall Vent (Multiple Appliances.
See snow & ice
page 23
3" (80mm)
Minimum
Separation
12" (305mm) Separation
Between Bottom Of
Combustion Air Intake And
Bottom Of Vent
Vent
Combustion Air
12" (305mm)
Minimum
Separation
Side Wall
Terminations
3" (80mm) Minimum horizontal
separation between combustion air
intake and vent terminations.
8" (203mm) Minimum vertical
separation between combustion air
intake and vent terminations.
12" (305mm) Separation between
bottom of combustion air intake and
bottom of vent.
Multiple terminations as shown
in 6-1, 6-2, and 6-3 must be
a minimum of 12” (305mm)
horizontally between vent of one
termination and air intake of next
appliance.
Maximum allowable total outside
exposure vent length equals 10 ft.
(3.05m).
Maintain a pitch of 1/2" per ft.
(42mm/m) outside exposure back to
boiler to ensure proper condensate
drainage for horizontal runs.
Combustion Air
Vent
23
Page 24
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
Maximum
Vent
Combustion
Air
FIGURE 6-6 Concentric Terminal Connection
*2 or 3" (51 or 77 mm) Diameter
PVC intake/combustion air
Roof
1" (25mm)
Maximum
* See Note
Below
Combustion
Air
Overhang
12" (305mm) Minimum
36"(0.9m) Minimum
Vent
Maintain 12"(30cm) US
(18"(46cm) Canada)
highest anticipated
Clearance Above
snow level or grade
Highest Anticipated
Snow Level Or Grade
Maintain 12"
clearance above
*Must be less than 4" (102mm) or greater than 24"
(610mm) Horizontal distance between end bells of each air
intake to prevent 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 modied by cutting or extending
both combustion air and vent pipes. 12" (305mm) is minimum
allowable length and 60" (1.2m) is maximum allowable length for
this dimension.
SDR-26 PVC (D2241) only may be used for extending pipes.
Do not use Schedule 40 PVC or use couplings to extend pipes.
Dimension will change if intake/vent pipes are lengthened or
shortened.
**See
Note
*2" (
51mm)
Diameter = 41" Length (1.1m)
3" (77mm) Diameter = 47" Length (1.2m)
1"(25.4mm)
Maximum
Vent
Combustion Air
* Note: 2" (51mm) For use with models 050/075/100.
3" (77mm) For use with models 075/100/150/200/299
4" (101mm) For use with model 299
24
Page 25
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.
Terminate vent system bottom, minimum
12" (300 mm) above highest anticipated
snow level.
Combustion Air
12" (305mm)
Anticipated
Snow Line
Ground Level
FIGURE 6-9 Flue on Roof, Combustion Air
Vent
Combustion
Air
Maintain 12"(305mm) US
(18"(457mm) Canada)
clearance above highest
anticipated snow level 24"
(610mm) above roof
24" (610mm)
* Minimum Length
Grade, Snow
& Ice
Doors &
Windows
* See Tables
4 & 5
Avoid locations where snow may drift
and block vent and combustion air.
Ice or snow may cause boiler to shut
down if vent or combustion air becomes
obstructed.
Combustion air and vent termination
must be 12" (305mm) from or below
doors, windows or gravity inlet.
Combustion air and Vent Piping Length
Page 22 .
25
Page 26
6 - COMBUSTION AIR AND VENT PIPING
FIGURE 6-10 Flue on Sidewall, Combustion Air on Roof
Maintain 12"(305mm) US
Combustion
Air
(18"(457mm) Canada)
clearance above highest
anticipated snow level 24"
(610mm) above roof
Vent
12" (305mm)
Anticipated
Snow Line
Ground Level
Congurations of single pipe vent with ue on the
sidewall, requires a tee as the vent terminal. See
gures 6-10 and 6-11.
NOTICE
FIGURE 6-11 Flue on Sidewall, Inside Combustion Air
Vent
Combustion
Air
12" (305mm)
Anticipated
Snow Line
Ground Level
26
Page 27
6 - COMBUSTION AIR AND VENT PIPING
6.7 Side Venting Terminal Requirements of :
• USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.
• Canada - Natural Gas and Propane Installation Code, CAN/CSA B149.1
Venting terminal from doors and windows See 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
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).
3' (0.9m)
Minimum
Grade, Snow
Corner
27
& Ice
"L"
Terminate vent system bottom,
minimum 12" (300 mm) above highest
anticipated snow level.
Avoid locations where snow may drift
and block vent and combustion air. Ice
or snow may cause boiler to shut down
if vent or combustion air becomes
obstructed.
Vent termination shall NO T be installed
closer than 3' (0.9m) from inside
corner of “L” shaped structure.
Page 28
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.
28
Page 29
6 - COMBUSTION AIR AND VENT PIPING
6.8 Multiple Boiler Venting Installation
• Multiple boiler application boiler can vent individually
or use common vent pipes.
• If boilers vent individually follow guidelines as
described in gures 6-1 through 6-7.
• If boilers vent through common vent pipes, as shown
in Figure 6-17, choose common vent pipe per Table 8.
Choose size from Table 9 for pipes between boiler and
common vent pipes.
• Longest individual vent lengths and common vent
length together must be shorter than 100 ft. (30m).
H + L ≤ 100 ft (30m) (See gure 6-17)
• Each boiler must have ow check valve to prevent ue
gas back ow.
• External terminals follow same rule as single boiler
venting as described in Section 6.6 and 6.7
Table 8 - Minimum Diameter for Individual
Boiler in Common Venting System
Model
050 2" (51mm)
075 3" (73mm)
100 3" (73mm)
150 3" (73mm)
200 3" (73mm)
Minimum
Diameter
Table 9 - Common Venting Pipe Diameters
Minimum
Total
Firing
Rate
Diameter of
Common vent
pipes if
L< 50 ft (16m)
400 4" (101mm)
600
5" (127mm)
800
1000
1200
6" (152mm)
1400
1600
1800
7" (177mm)
2000
Minimum
Diameter of
Common vent
pipes if
L>50 ft (16m)
5" (127mm)
6" (152mm)
7" (177mm)
8" (203mm)
FIGURE 6-17 Mulitple Boilers With Common Venting Pipe
L
H
Flow Check
Valve
Flow Check
Valve
Flow Check
Valve
29
Vent
Combustion
Air
12" (305mm)
Anticipated
Snow Line
Ground Level
Page 30
6 - COMBUSTION AIR AND VENT PIPING
FIGURE 6-18 Condensate Drain
6.9 Condensate Piping
• Use materials acceptable to authority having jurisdiction.
In absence of such authority:
• USA - PVC or CPVC per ASTM D1785/D2845 Cement
or primer per ASME D2564 or F493.
• Canada - CSA or ULC certied PVC/CPVC pipe,
ttings and cement.
• Attach PVC tee provided with boiler and eld sourced
piping to condensate drain at bottom of boiler. See
gure 6-18.
• Slope condensate drain pipe minimum 1/4" per foot
(21mm/m) away from boiler.
• Use eld source condensate pump if boiler located
below disposal point.
• Field source condensate neutralizing kit as required
by authority having jurisdiction or for environmentally
friendly condensate disposal.
Do not glue cap on if used
for dust protection. End
must be left open.
Condensate Tee
(eld installed)
on condensate drain pipe
Do not place in environment with
temperatures below freezing.
Condensate outlet will block if
condensate freezes.
30
Page 31
7 - GAS SUPPLY PIPING
FIGURE 7-1 Gas Connection
Gas Connection
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.
!
CAUTION
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the re
department.
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 sufcient
gas supply to meet maximum input at not less than
minimum supply pressure. See Table 10.
• Support piping with hooks straps, bands, brackets,
hangers, or building structure components to prevent or
dampen excessive vibrations and prevent strain on gas
connection. Boiler will not support piping weight.
• Use thread (joint) compound (pipe dope) suitable for
liqueed petroleum gas.
• Provide sediment trap up stream of gas valve.
• Install manual main shutoff valve outside of jacket. See
gure 7-2.
MODEL
050
075
100
150
200
31
7.2 Conversion Kit Instructions
• See Gas Conversion Kit Instructions included with Boiler.
Table 10 - Gas Supply Pressure
Gas Supply Pressure
Natural Gas Propane
Min. Max. Min. Max.
3.0" w.c.
(0.7 kPa)
Note: See Glossary - Piping Table 16
13.5" w.c.
(3.3 kPa)
5.0" w.c.
(1.2 kPa)
13.5" w.c.
(3.4 kPa)
Page 32
Gas shutoff valve
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 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 7-2.
•
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 that can provide ignition source.
FIGURE 7-2 Manual Main Gas Shutoff Valve Outside
Boiler Jacket
Manual Main Gas
Shutoff Valve
FIGURE 7-3 Gas Shutoff Valve - 050/075/100/150/200
•
Correct leaks immediately and retest.
Gas shutoff valve
(shown in closed
position)
FIGURE 7-4 Gas Shutoff Valve - 299
Gas shutoff valve
(shown in open
position)
32
Page 33
8 - ELECTRICAL CONNECTIONS
8.1 General
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to:
• USA- National Electrical Code, ANSI/NFPA 70.
• Canada - Canadian Electrical Code, Part I, CSA C22.1:
Safety Standard for Electrical Installations.
8.2 Electric Knockouts (gure 8-1)
• Five knockouts located on bottom of chassis.
A. Three knockouts located under junction box are
reserved for high voltage wires. Choose connectors
using total diameter of wire bundles.
B. Two knockouts located to right of high voltage
knockouts (outside of junction box) are reserved
for low voltage wiring. Use supplied grommets
when using these knockouts.
8.3 Line Voltage Connections (gure 8-2)
• Boiler
A. Provide individual 120V, 15 amp circuit
(recommended) with fused disconnect or service
switch as required by authority having jurisdiction.
B. Open High Voltage Junction Box (see gures 3-4
and 3-5) to access line voltage terminal strip.
C. Connect 120 VAC circuit to line voltage terminal
strip 120 VAC L,N,G.
• Central Heating Pump, if used.
A. Isolate pump from control module if pump FLA (Full
Load Amps) exceeds maximum allowable current
draw. See Figure 8-3 and Table 11.
B. Connect pump to line voltage terminal strip CH
PUMP L,N,G.
• Domestic Hot Water Pump, if used.
A. Isolate pump from control module if pump FLA
exceeds maximum allowable current draw. See
Figure 8-3 and Table 11.
B. Connect pump to line voltage terminal strip DHW
PUMP L,N,G.
8.4 External Connections (gure 8-4)
• User Interface Terminals
A. Factory wired to USER INTERFACE terminals
B. Optional - Remote mount user interface for
improved access. Use low voltage knockout.
C. Maximum wire length is 100 ft (30m) for 22 ga.
wire, or 150 ft (45m) for 18 ga. wire.
• Argus Link (Multiple boiler applications only)
!
WARNING
Electrical shock hazard. Turn OFF electrical power
supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.
NOTICE
Wiring diagrams can be found in Section 14 of this
Manual.
FIGURE 8-1 Electric Knockouts Bottom Of Boiler
Front of Boiler
Low Voltage Knockouts
(Use supplied
grommets when using
these knockouts)
5"
(127mm)
High Voltage
Knockouts
4½"
(114mm)
Back of Boiler
FIGURE 8-2 Line Voltage Connections
Table 11 - Maximum Allowable Current Draw
MBH CH PUMP DHW PUMP NOTE
50
75
100
150
200
If CH or DHW pump current is more than the maximum
allowable current draw install proper eld sourced relays
as shown in gure 8-3.
1 A 1 A
10 A 10 A
Powered by
Control Board
Powered by
installed 10 Amp
relay
33
Page 34
8 - ELECTRICAL CONNECTIONS
• Outdoor Sensor, if used.
A. Provided with boiler.
B. Locate outdoor sensor to protect against wind and
direct sunlight. Mounting instructions provided with
sensor.
C. Maximum wire length is 100 ft (30m) for 22 ga.
wire, or 150 ft (45m) for 18 ga. wire.
D. Connect wires to OUTDOOR SENSOR terminals.
Wires are interchangeable.
• System Sensor (Multiple boiler applications only)
• Domestic Hot Water (DHW) Thermostat, if used.
A. Use temperature control with dry contacts rated
at 0.5 amps @ 120 VAC. Boiler control does not
provide power to DHW temperature control.
NOTICE
IMPORTANT: Do not apply power to DHW T-T
terminals. Dry contact only, use of isolation relay
may be necessary.
FIGURE 8-3 Isolation Relays for CH System Pump
and DHW Pump
DHW
Pump
CH
Pump
DHW
Pump
Relay
120VAC
coil
CH
Pump
Relay
120VAC
coil
B. Maximum wire length is 330 ft (100m) 22 gauge
wire.
C. Connect wires (interchangeable) to DHW T-T
terminals. Wires are interchangeable.
• Central Heating Thermostat
A. Use thermostat or boiler system control with dry
contacts related 0.5 amps @ 120 VAC. Boiler
control does not provide 24 VAC power to central
heating thermostat.
B. Locate and install thermostat per manufacturer's
instructions. Maximum wire length is 330 ft (100m)
for 22 ga. wire.
C. Connect wires to CH T-T terminals. Wires are
interchangeable.
NOTICE
Use dry contact for wires to CH T-T terminal and
DHW T-T terminal. E33 error code is displayed if
voltage is sent back to the control board. If error
is not corrected for extended period of time, this
voltage can permanently damage control board.
FIGURE 8-4 External Connections
(Do not apply external voltage to external terminals.)
34
Page 35
condensate drain.
clip. See gure 9-1.
9 - START UP PROCEDURE
NOTICE
IMPORTANT: Condensate trap must be manually
lled with water at initial start up.
FIGURE 9-1 Condensate Drain Assembly
1. Disconnect spring tension
clip from hose barb and ll
Condensate trap with water.
9.1 Fill Boiler With Water And Purge Air
NOTICE
To maintain boiler efciency 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
antifreeze-water solution, if used). See antifreeze
information page 13. Purge air from boiler using air
vent. Purge air from system piping.
•
Inspect system piping and boiler connections. Repair
any leaks immediately.
•
Activate all heating zones and calls for heat,
including CH calls and DHW calls (if available).
•
Close manual gas shut off valve. Let system run for
30 minutes. When boiler goes into lockout, reset
boiler by pressing "Reset" button until boiler resets.
•
Do not open gas shutoff valve until all air is purged
from system.
2. Reconnect hose to hose
barb with spring tension clip
before starting boiler.
9.2 Fill Condensate Trap with Water
•
Disconnect spring tension clip from condensate hose
barb. See gure 9-1.
•
Disconnect tubing below from hose barb.
•
Pour approximately 2 cups (473 ml) of water into
condensate drain.
•
Reconnect tubing to hose barb with spring tension
clip. See gure 9-1.
35
Page 36
9 - START UP PROCEDURE
9 -2 User Interface
9.3 Program Boiler Control
Key Description
Boiler is factory programmed with following factory
default settings, Table 11.
Parameters can be adjusted to suit particular application
using the user interface. See gure 9-2.
Detailed explanation of each can be found in Appendix
A - Control Module.
List parameters in event of factory default parameters are
changed.
9-3 Default Table
User
Menu
Installer
Menu
* List parameters in event of Control Module Failure to reprogram your settings.
Settings
Boiler
Conguration
CH Settings
Central Heating Setpoint 140°F 60°C 104-195°F 40-91°C
DHW Setpoint 180°F 82°C 104-195°F 40-91°C
Temperature Units °F °F/°C
Boiler Address 0 0-15
Low Water Cutoff Enabled Enable/Disabled
Pump Mode 0 0 & 4
Service Reminder Status On ON/OFF
Service Reminder Days 365 Days 1- 999 Days
CH Mode 1 0, 1, 2, 3
Warm Weather Shutdown 70°F 21°C 35-100°F 2-38°C
Reset Curve Design Temperature - Boiler 180°F 82°C 60-195°F 40-91°C
Reset Curve Design Temperature - Outdoor 25°F -4°C -60-32°F -51-
Reset Curve Mild Weather Temperature - Boiler 100°F 37°C 35-120°F 2-49°C
Reset Curve Mild Weather Temperature - Outdoor 70°F 21°C 35-85°F 2-29°C
Reset Curve Boiler Minimum Temperature 70°F 21°C 40-180°F 4-82°C
Reset Curve Boiler Maximum Temperature 180° 82°C 80-195°F 27-91°C
Boost Function Temperature 0°F 0°C 0-36°F 0-20°C
Boost Function Time 20 Minutes 1-120
Maximum Power CH 100% 1-100%
DHW Mode 0 0/2
DHW Maximum Priority Time 30 Minutes 1-60 minutes
Control Parameter
- Manual Lockout Reset
- Enter/Exit user menu
- Go to previous screen
- Select a menu item
- Conrm new parameter value
- Scroll up to next menu item
- Increase value
- Scroll down to next menu item
- Decrease value
Factory Default
Setting
Standard Metric Standard Metric
Setting Range
25°C
*Actual
Parameter
Settings
36
Page 37
9 - START UP PROCEDURE
9.4 Boiler Start-up and Operational Test
Verify air is purged from hydronic piping
1.
2. System test pumps - verify each pump is
operational
3. Verify gas piping
•
Conrm pressure test. See section 7.3.
•
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
Rate @ High Fire
Size From To
050 45 51
075 65 76
100 90 102
150 140 153
200 185 204
Natural Gas and Propane
3. Measure CO
Adjust CO
gures 9-5 and 9-6 for combustion air analyzer
port.
at high re and compare to table.
2
if needed using gure 9-3 & 9-4. See
2
37
Page 38
9 - START UP PROCEDURE
CO
Gas
Natural Gas 9.0 9.5 <200ppm
Propane 10.0 11.0 <200ppm
Min. Max.
2
CO
Natural Gas only**
1. Measure input. Compare to table above. Continue
to measure input and CO2 until both measured
values are within range specied in tables.
Propane Gas
Most propane systems do not have ow meters.
1. Check CO
11.0%.
•
If CO
9-3 .
•
If CO
FIGURE 9-3 Gas Valve - Models
050/075/100/150/200 MBH
. Propane should be between 10% and
2
is low increase gas ow following gure
2
is high decrease gas ow following gure 9-3.
2
Verify Burner, Proper Operation
1. Inspect burner ame through Sight Glass. See
gure 11-1 & 11-2.
2. Operate boiler through several heating cycles,
including domestic hot water, if used. Verify proper
operation.
•
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.
38
Page 39
9 - START UP PROCEDURE
WARNING
!
Asphyxiation hazard. Carbon monoxide is odorless,
tasteless, clear colorless gas, which is highly toxic.
Verify cap is rmly placed on combustion analyzer
port to prevent CO emission. Failure to do so could
result in death or serious injury.
FIGURE
050/075/100/150/200
FIGURE
Analyzer Port
9-5 Combustion Analyzer Port -
Combustion
Analyzer Port
9-6 Combustion Analyzer Port - 299
Combustion
9.6 Perform CSD-1 Compliance Test (see
paragraph 2.4 page 6)
Verify operation of boiler safety control operation with
regard to no 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 9-8.
3. Disable secondary system pumps attached to
system.
4. Establish call for heat. Jump CHW T-T terminals
on low voltage terminal block. Turn on boiler using
boiler service switch.
5. Boiler will 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 .
OR
B.
Shut off burner E40 "Return Water Temp". This
is a soft lockout. When water temperature drops
below limit boiler will automatically rere then
Lockout A-06 requiring manual reset of control
module. Press Reset button on User Interface.
OR
C.
Shut off burner E39 "Flue Temperature Sensor".
This is a soft lockout. When ue sensor drops
below limit, boiler will automatically rere then
Lockout A-06 requiring manual reset of control
module. Press Reset button on User Interface.
6. After safety operation is veried, turn off boiler via
service switch. Remove jumper in T-T. Replace J7
connector into control module, enable secondary
pump operation, turn service switch on and restart
system to verify operation.
FIGURE
9-7 Burner Flame
Burner
Flame
Flame
Look for BLUE ame with slight
YELLOW tips evenly spaced
around burner
39
Page 40
9 - START UP PROCEDURE
9-8 Control Module J7 Connector
J7 Connector
9.7 Complete Start Up Procedure
1. Reset control parameters to operating settings if
adjusted to allow startup and operation test.
2. Follow instructions TO TURN OFF GAS TO APPLIANCE
(page 42) if boiler is not being placed into
immediate operation.
3. Enter installer information on Warranty Registration
Card.
4. Gather all instructions, manuals, wiring diagrams,
warranty registration card and other supporting
information. Review with user and/or afx in
conspicuous location adjacent to boiler.
40
Page 41
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 qualied
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 qualied
service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.
!
CAUTION
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the 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
position. Handle should be perpendicular to gas pipe.
• Replace front jacket panel.
10-1 Gas Shutoff Valve - 050/075/100/150/200 MBH
to closed
10.1 OPERATING INSTRUCTIONS
Stop! Read Safety information above.
• Set thermostat to lowest setting.
• Turn "OFF" all electrical power to appliance.
• This appliance is equipped with an ignition device which
automatically lights the burner. Do not try to light
burner by hand!
• Remove upper jacket panel.
• Turn gas shutoff valve clockwise to closed position.
Handle should be perpendicular to gas pipe.
• Wait 5 minutes for any gas to clear. Smell for gas,
including near oor. If you smell gas, STOP! Follow
instructions on this page: “What To Do If You Smell
Gas.” If you do not smell gas, go to next step.
• Turn gas shutoff valve counter clockwise to the
open position. Handle should be parallel to gas pipe.
• Replace upper jacket panel.
• Turn "ON" electrical power to appliance.
• Set thermostat to desired setting.
• If the appliance will not operate, follow instructions TO
TURN OFF GAS TO APPLIANCE and call your service
technician or gas supplier.
OPEN POSITION
41
Page 42
11 - GENERAL MAINTENANCE AND CLEANING
!
DANGER
Before servicing, turn off electrical power to boiler
at service switch. Close manual gas valve to turn
gas supply OFF to boiler. Failure to comply will
result in death or serious injury.
!
CAUTION
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation.
NOTICE
Verify proper operation after servicing.
NOTICE
Perform regular service and maintenance by
qualied service agency at least once every 12
months to assure safe, trouble free operation and
maximum efciency.
FIGURE 11-1 Sight Glass - 050/075/100/150/200
MBH
11.1 Beginning of Each Heating Season
• Check boiler area is free from combustible materials,
gasoline, and other 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 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;
• verify pressure test port cap and combustion test port
are in place;
• return temperature sensor clip must be securely
seated on pipe; Check boiler for any sign of leaks.
• Check low water cutoff using user interface.
• Check operation by pressing test button on low water
cutoff.
• "Low Water" LED should illuminate and burner
should shut down.
• Should get error message on User Interface
(E36).
• Every 5 years remove low water cutoff. Reinstall
after cleaning.
• Every 10 years replace low water cutoff.
• Check ame signal with user interface. Should be 8 micro
amps at 100% ring rate ( High re).
• Visual inspection of ame through sight glass. Burner
should be fully illuminated. See gures 11-1.
• Check heating system expansion tank.
42
Page 43
11 - GENERAL MAINTENANCE AND CLEANING
Figure 11-3 Condensate Trap - 050,075,100,150,200
11.3 Annual Inspection and Cleaning of Boiler
Components
• Obtain Burner Inspection Kit. Follow kit instructions to
• Burner and heat exchanger inspection and cleaning.
Flue Pipe
Temperature
Sensor
Condensate Collector
Condensate
Trap Connection
To Condensate
Collector
Flexible Gas Line
Hose Barb w/Cap
Coupling
11.2 Annual Shut Down Procedure
• Follow instructions “To Turn Off Gas To Appliance” unless
boiler is also used to supply domestic hot water. See
section 10.
• Drain system completely if system does not have
antifreeze when heating system is to remain out of
service during freezing weather.
• Drain condensate lines when boiler is to be exposed to
freezing temperatures.
!
WARNING
Following service procedures must be performed
by qualied service agent. Boiler owner shall not
attempt these steps. Failure to do so could result in
death or serious injury.
• Follow Burner Inspection Kit instructions to reassemble
prepare for examination and cleaning.
• Remove gasket and burner. Allow burner to clear top
lip of chassis.
• Remove any residual sleeve and/or gasket material
from removed burner.
• Clean burner using air hose directed into top of
burner opening to dislodge any debris in burner ports.
Inspect burner for foreign matter in 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 signicant 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 11-3.
• Disconnect wire harness from vent temperature
sensor. See g u r e 1 1 - 3 .
• 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.
• Remove condensate collector assembly from heat
exchanger and ue pipe.
• Flush collector and condensate trap with water.
boiler and resume operation.
43
Page 44
12 - RATINGS AND CAPACITIES
TABLE 12-1: SEA LEVEL RATINGS
NATURAL AND PROPANE GASES
Size
050
075
100
150
200
(1)
1000 Btu/hr (British Thermal Units Per Hour)
(2)
Heating Capacity and AFUE (Annual Fuel Utilization Efciency) are based on DOE (Department of Energy) test
procedures.
(3)
Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for
installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems,
etc.
Boiler Input Rate (MBH)
Maximum Minimum
50 10 46 40 95.0
75 15 69 60 95.0
100 20 91 79 95.0
150 30 139 121 95.0
200 40 185 161 94.0
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.
(1)
Heating Capacity
(MBH)
(1)(2)
Net AHRI Rating,
Water (MBH)
(1)(3)
AFUE
(2)
• Ratings used for elevations up to 2000 ft (600m) above
sea level.
• For elevations between 2000 ft (600m) and 4500 ft
(1350m), install high altitude control kit
• For elevations above 4500 ft (1350m) install high
altitude control kit and :
• USA - Reduce input rate 4% for each 1000 ft
(300m) beyond 4500 ft.
• Canada - Contact Provincial authority having
jurisdiction for installations above 4500 feet (1350
m) above sea level.
44
Page 45
13 - TROUBLE SHOOTING
45
Page 46
3
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 49
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 50
Blower speed does not reach speed calculated
by Control Module.
Control Module internal error.
Go to Page For
Troubleshooting
Go to Page 48
Go to Page 48
Go to Page 51
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 52
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 55
Control Module internal error.
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 53
-
46
Page 47
3
13 - TROUBLE SHOOTING
Screen Display Explanation
Low water cutoff sees no water. Go to Page 54
Go to Page For
Troubleshooting
Blocking Error
Flue Gas Error
Flue temperature sensor sees temperature
E
39
higher than 200°F.
Return water temperature sensor sees
temperature higher than 200°F.
Control board internal error. Power down then
power up boiler. If error repeatedly occurs
replace control module.
Go to Page 55
Go to Page 56
Replace Control
Module
Boiler is powered by three wires, hot, neutral
and ground. E44 displays when neutral wire is
Go to Page 56
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 57
Go to Page 58
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 58
Go to Page 59
Go to Page 60
Go to Page 60
Go to Page 61
Flue temperature sensor is shorted. '0' Ohm Go to Page 61
Reset button was pressed too many times.
Error Clears in 1-2
minutes
Fault detected in blower motor system. Go to page 57
47
Page 48
13 - TROUBLE SHOOTING
Replace Supply Sensor
NO
hot?
YES
pipe at top of boiler)
Is supply pipe (copper
NO
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
NO
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.
NO
wire have continuity
Gas Valve. Does each
Disconnect harness from
between Gas Valve and
YES
terminals. Is resistance
between 1.0 and 1.2 kΩ?
Module
NO
Control Module
YES
Replace Gas Valve Replace Harness
Enter Installer Menu, Boiler
Status. Scroll to most recent
Diagnose corrective action using
Lockout Alarm A 0 0
Blocking too long error
Lockout Alarm or Blocking Error.
_ _ _ _ _
Replace Control
appropriate Troubleshooting Tree.
48
Page 49
13 - TROUBLE SHOOTING
49
Page 50
13 - TROUBLE SHOOTING
hot?
NO
switches
and surface
temperature
Check high limit
Replace Broken Switch
Error shows when safety circuit is
between two pins on sensor (two
pins connected to two pink wires) .
Is continuity available?
NO
Unplug molex connector on supply
temperature sensor. Check continuity
YES
open. Remove J13 connector from
pink wires, is continuity available?
between two pins connected to two
control module. Check for continuity
YES NO
NO
YES
heat exchanger) hot?
Is boiler supply pipe (above
YES
Is Heat Exchanger surface
drops.
temperature
Let all zones
run until water
NO
cool down.
Wait for boiler to
Boiler red without enough water ow
is over heated. Either high limit or heat
through heat exchanger. Heat exchanger
Check the following:
• Air in system?
• Verify water ow in system piping
exchanger temperature switch is open.
• Flush system if water is dirty.
Replace Control Module
on two pink wires on J13
Check for loose connections
50
safety temperature switch.
connector, supply sensor, and
YES
Fix Loose Connections Replace Wire Harness
Page 51
13 - TROUBLE SHOOTING
51
Page 52
13 - TROUBLE SHOOTING
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) ?
purple wires?
Control Module J13.
Disconnect harness from High
Check continuity of both purple
T empera ture Supply Switch and
wires. Continuity available for both
52
Page 53
13 - TROUBLE SHOOTING
NO
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
53
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
Follow instructions
Gas Valve.
TO APPLIANCE.
TO TURN OFF GAS
Replace Gas Valve.
APPLIANCE. Replace
TO TURN OFF GAS TO
Page 54
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)?
54
Page 55
3
39
E
13 - TROUBLE SHOOTING
NO
NO
gas temperature through sampling
port. Is the measured temperature
Use thermal couple to measure ue
and ue temperature reading on User
YES
Interface signicantly different?
Replace Control Module
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,
55
Page 56
13 - TROUBLE SHOOTING
sensor (2 Brown Wires)?
Is correct harness connected to return
NO
YES
Correct wiring
NO
antifreeze solution.
YES
properly oriented?
Is Heat Exchanger Pump
NO
YES
(Pump arrow pointing down?)
Verify order of pins on J2. Pin order
green. Measure volts on pins of black
wire and white wire. Is wiring/pins in
right order? Does black/wire have 120
should be: empty, black (or red), white,
Install Heat
proper orientation
Exchanger Pump in
Disconnect harness from
Return Water Sensor. Measure
950 to 33,000 ohms?
resistance using digital ohm
meter. Is resistance between
VAC? Does white wire/pin have 0 VAC?
Sensor
NO
Replace Return Water
YES
Module
Replace Control
Unplug molex connector on return
metal pins? Liquid might be water or
sensor. Is there moisture or liquid on
from connector.
Remove all liquid
56
Repair all leaks.
Check for leaks.
Replace Control Module
Page 57
13 - TROUBLE SHOOTING
+/- 2%
Blocking Error E 4 5
Net frequency error
_ P _ _ _
Is power supply between 59
and 61 Hz?
NO
YES
stabilized power
Provide frequency
supply rated at 60 Hz
NO
loose or faulty?
YES
Is power supply circuit breaker
NO
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
Is any connection loose?
Check connector J9 on control board.
NO
YES
NO
Replace Control Module
YES
this correct the problem?
Replace blower motor. Does
Fix the connection.
properly
Boiler is operating
57
Page 58
13 - TROUBLE SHOOTING
NO
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
NO
YES
Disconnect J5 from Control
Disconnect J5 from Control
Module. Using digital meter
Module. Using digital meter
and Sensor. Continuity?
measure check continuity of
measure check continuity of
white wires between Control
white wires between Control
Board and Sensor. Continuity?
Replace Wires
resistance between Supply
board. Using digital meter
Using digital meter measure
Water Sensor terminals J5-11
Unplug J5 connector on Control
NO
Resistance Chart?
Resistance Chart?
YES
terminals J5-11 and J5-3.
of Sensor with digital meter.
measure resistance between
and J5-3. Measure resistance
Does it fall in the range of the
Estimate Sensor temperature.
Does it fall in the range of the
Estimate Sensor temperature.
Water Sensor
Replace Supply
Module
Replace Control
conductor
NO
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
NO
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
58
Page 59
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
Check continuity of brown
wires between Return
Temperature Sensor and
Control Module J5-4 and J5-12
Continuity?
YES NO
Replace Wires
shown on chart?
Sensor resistance with
digital meter. Estimate
meter. Estimate Sensor
Measure Return Temperature
Measure Return Temperature
Sensor temperature. Does
Sensor resistance with digital
temperature. Do temperature
ranges shown in chart?
and resistance fall within
temperature fall within ranges
YES NO
Replace Return
Temperature Sensor
Module
Replace Control
59
Page 60
13 - TROUBLE SHOOTING
shown in chart?
High Temperature Supply
Switch. Measure resistance
Disconnect wire harness from
temperature fall within ranges
across terminals 2 and 4. Does
Resistance Chart
Supply Water Temperature Sensor
60
Page 61
Blocking Error E 6 5
Flue Sens Shorted
_ P _ _ _
Vent Temperature Sensor.
Disconnect wire harness from
13 - TROUBLE SHOOTING
Replace Vent
Temperature Sensor
in blue wires?
YES NO
Disconnect harness from
Control Module J5. Continuity
Does resistance match
Measure Sensor resistance.
NOYES
estimated flue temperature?
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 _ _ _
Measure resistance across
Return Temperature Sensor.
sensor terminals. Is resistance
less than 50 ohms?
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
61
Page 62
14 - WIRING DIAGRAM
14.1 Connection Diagram - 050/075/100 MBH
62
Page 63
14 - WIRING DIAGRAM
LADDER DIAGRAM
NG
14.2 Schematic Diagram of Ladder Form - 050/075/100 MBH
L
J12
J13-2
J9-1
J9-2
J9-6
J9-7
J9-5
J9-4
J9-3
J13-1
J13-5
J13-6
J13-3
J13-4
J6-1
J6-3
J6-2
J7-4
J7-2
J7-1
J7-3
J4-1
J4-2
J4-3
J4-4
J2-1
J2-2
J2-3
J2-4
T2
LWCO
CH
THERMOSTAT
USER
INTERFACE
SUPPLY
SENSOR
RETURN
SENSOR
DHW
THERMOSTAT
FLUE
SENSOR
SYSTEM
SENSOR
(OPTIONAL)
OUTDOOR
SENSOR
ARGUS LINK
POWER
ARGUS LINK /
MULTI BOILER
(OPTIONAL)
43
DISPLAY
4
2
ON
OFF
J16-1
J16-4
J16-5
J16-8
J16-6
J16-7
J16-3
J16-2
J5-9
J5-1
J5-10
J5-2
J5-11
J5-3
J5-12
J5-4
J5-13
J5-5
J5-14
J5-6
J5-15
J5-7
J5-16
J5-8
S4
J18-1
J18-2
ARGUS
CONTROL
G
BURNER
PE
DC+/L
+
DATA/PWM
HALL
GND
DC-/N
13
DHW PUMP
RELAY 120VAC
L
N
L
CH PUMP
RELAY 120VAC
L
N
5
L
L
G
N
L
GROUND
FLAME SENSOR
IGNITION
FAN
120VAC
LIMIT
HEAT EXCHANGER
TEMPERATURE SWITCH
GAS VALVE
G
L
N
G
L
L
1
HEAT EXCHANGER PUMP
RELAY 120 VAC
HEAT EXCHANGER
43
PUMP 120 VAC
G
N
GAS VALVE WIRING FOR
150 / 200 MBH BOILERS
J13-3
J13-4
GAS VALVE
120V / 24V, 15VA
TRANSFORMER
LWCO
24 VAC
1
2
63
Page 64
14 - WIRING DIAGRAM
14.3 Connection Diagram - 150/200 MBH
EXTERNAL PUMP
RELAY - LIMIT OF
1 AMP PER PUMP
SEE SECTION 8
64
Page 65
14 - WIRING DIAGRAM
NG
14.4 Schematic Diagram of Ladder Form - 150/200 MBH
LADDER DIAGRAM
L
J12
J13-2
J9-1
J9-2
J9-6
J9-7
J9-5
J9-4
J9-3
J13-1
J13-5
J13-6
J13-3
J13-4
J6-1
J6-3
J6-2
J7-4
J7-2
J7-1
J7-3
J4-1
J4-2
J4-3
J4-4
J2-1
J2-2
J2-3
J2-4
T2
PE
DC+/L
+
DATA/PWM
HALL
GND
DC-/N
L
N
L
LWCO
CH
THERMOSTAT
USER
INTERFACE
SUPPLY
SENSOR
RETURN
SENSOR
DHW
THERMOSTAT
FLUE
SENSOR
SYSTEM
SENSOR
(OPTIONAL)
OUTDOOR
SENSOR
ARGUS LINK
POWER
ARGUS LINK /
MULTI BOILER
(OPTIONAL)
43
DISPLAY
4
2
ON
OFF
J16-1
J16-4
J16-5
J16-8
J16-6
J16-7
J16-3
J16-2
J5-9
J5-1
J5-10
J5-2
J5-11
J5-3
J5-12
J5-4
J5-13
J5-5
J5-14
J5-6
J5-15
J5-7
J5-16
J5-8
S4
J18-1
J18-2
ARGUS
CONTROL
G
BURNER
13
DHW PUMP
RELAY 120VAC
CH PUMP
RELAY 120VAC
L
N
5
L
L
G
N
L
GROUND
FLAME SENSOR
IGNITION
FAN
120VAC
LIMIT
HEAT EXCHANGER
TEMPERATURE SWITCH
GAS VALVE
G
L
N
G
L
L
1
HEAT EXCHANGER PUMP
RELAY 120 VAC
HEAT EXCHANGER
43
PUMP 120 VAC
G
N
GAS VALVE WIRING FOR
150 / 200 MBH BOILERS
J13-3
J13-4
GAS VALVE
120V / 24V, 15VA
TRANSFORMER
LWCO
24 VAC
1
2
65
Page 66
15 - GLOSSARY
• ANSI - American National Standards Institute,
• GAS PIPE SIZES - Table 14
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 othe r 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.
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 =
MBH =
127,116 x cu meters
Seconds
127,116 x 0.1
100
= 127 MBH
tight integrity of gas piping following its installation or
modication.
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.
66
Page 67
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.
67
Page 68
APPENDIX A - CONTROL MODULE
1.1 Introduction
Boiler is equipped with programmable electronic control
and user interface module.
1.2 Operation
• Display: 4 x 20 character LCD screen to show boiler
status.
• Function Keys
Key Description
- Manual Lockout Reset
- Enter/Exit user menu
- Go to previous screen
- Select a menu item
- Conrm new parameter value
- Scroll up to next menu item
- Increase value
- Scroll down to next menu item
- Decrease value
Operation with LCD character display module
1.3 Status Indication
The following status screens can be displayed:
Boiler Status Indicator
F = Flame Detected
SERVICE Reminder
P = Central Heating System pump On
B = Combustion Air Blower On
S = Safety Relay Check
G = Gas Valve Open
D = DHW Pump On
Combustion Air Blower
Speed Indicator
Service Reminder Indica
Boiler in Standby Mode
Boiler Supply Water
Temperature Indicator.
tor
Boiler Running in Central
Heat mode
Boiler Running in DHW
mode
Lockout Alarm Indicator
Error code and short text
description is displayed
Press 'Reset" key for manual
reset.
Blocking Error
Error code and short text
description is displayed Boiler
automatically returns to
Standby Mode when condition is
eliminated.
68
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1.4 Sequence of Operation
Operational State User Interface Display Explanation
APPENDIX A - CONTROL MODULE
No
Heat
Demand?
Yes
DHW CH
Pump on
Supply
Temperature
<Setpoint?
Yes
15 Second
Prepurge
Ignition
Sparking
No
Standby: No Demand
Boiler operates in standby mode until
demand for Central Heat (CH) or
Domestic Hot Water (DHW) is detected.
CH or DHW pump is turned on based on
type of heating demand.
(CH call is illustrated)
Control Module compares supply
temperature to set point. Boiler proceeds
to ignition if supply temperature is less
than set point.
Combustion Air Blower speed
modulates to pre-purge setting for 15
seconds.
Sparking initiated sequence.
After 2 seconds
69
Page 70
1.4 Sequence of Operation
Operational State User Interface Display Explanation
After 2 seconds
Flame
Detected?
No
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?
No
No
Simultaneous
DHW + CH
Demand?
Yes
DHW
Priority
Mode
No
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.
70
Page 71
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 botton 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.
71
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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)
User interface temperature unit of measure is selected using
‘Change Temperature Units’ screen.
Fahrenheit and Celsius available.
72
Page 73
APPENDIX A - CONTROL MODULE
User Interface Display
Installer Menu
Installer Menu
Explanation
The Installer Menu structure includes:
Installer Menu can be accessed by simultaneously holding
‘Menu’ and ‘Enter’ keys for 5 seconds.
Installer 'Menu' can be accessed by rst 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 rst then press and hold the
'Menu' key).
• ‘Boiler Status’ submenu – User monitors detailed boiler
status parameters such as ame signal, fan speeds and
stored error codes.
• ‘Boiler Cong’ submenu – Modies general boiler
settings.
• ‘CH Settings’ submenu – Modies advanced Central
Heating settings including outdoor reset curve
parameters and boost function.
Boiler Status
• ‘DHW Settings’ – Modies 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 airow 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 ame rectication method. When ame is
present, ame ionization rod measures small DC offset current
across ame to ground (i.e. burner surface).
‘Flame’ screen in ‘Boiler Status’ submenu displays information
regarding ame ionization system; for information only and
used in diagnosing combustion problems. See troubleshooting
guide.
73
Page 74
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.
74
Page 75
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 Conguration
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.
75
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APPENDIX A - CONTROL MODULE
User Interface Display
Explanation
Two pump modes are available:
1.
Pump Mode = 0 ‘CH or CH&DHW’
• In this mode either the CH or DHW pump terminal is
energized depending on the type of demand (CH or DHW).
• CH and DHW pumps are never energized at the same time.
• In the case of a simultaneous call for both CH and DHW,
the energized pump depends on whether the boiler is
currently supplying the CH or DHW demand. Refer to DHW
Priority settings below.
• This is typical of a hydronic system design with separate CH
and DHW Pumps.
2.
Pump Mode = 4 ‘System Pump’
• In this mode only one external system pump is installed in
the hydronic system. This pump will energize independent
of the type of demand (CH or DHW).
Boiler Conguration
• Connect this pump to the CH/System Pump electrical
terminal block. See page 56 for diagram.
• The DHW pump terminal does not function.
• This is typical of a hydronic system design which utilizes
zone valves for all CH zones and an DHW indirect tank.
Note:
• Pump Mode selection depends on electrical and
hydronic system design. Please refer to sections 5
and 8 for recommended hydronic piping and electrical
congurations.
• 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 notication on the User Interface at a
predened 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 qualied service technician.
Allowed Range: 1 to 999 days
76
Page 77
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 Figure 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 Figure 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 satised (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).
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APPENDIX A - CONTROL MODULE
R eset Curve Design Point s , A and B,
define a straignt line.
Boiler Min and Max,
, d efine a
section on the straignt line.
Bo iler supply t emperature Setpoint
follows the bold line sections
User Interface Display
Allowed Range: 35°F to 100°F (2°C to 38°C)
Default Setting: 70°F (21°C)
A
Allowed Boiler Range: 60°F to 195°F (40°C
to 91°C)
Default Boiler Setting:180° F (82°C)
100
B
Allowed Boiler Range: 35°F to 120 F (2°C to
49°C)
Default Boiler Setting: 100°F (37°C)
Allowed Outdoor Range: 35°F to 85°F (2°C to
29°C)
Default Outdoor Setting: 70°F (21°C)
CH Settings
C
D
Allowed Min. Range: 40°F to 180°F (4°C to 82°C)
Default Min. Setting: 70°F (21°C)
Allowed Max. Range: 80°F to 195°F (27°C to 91°
C)
Default Max. Setting: 180°F (82°C)
Explanation
If outdoor temperature is greater than Warm Weather
Shutdown Temperature, demand for CH blocked and pumps
stopped.
Boiler capable of operating in Outdoor Reset Mode when
included Outdoor Sensor is connected and proper CH Mode
selected.
If CH Mode = 1, ‘Outdoor Temperature Reset with
Thermostat’ or 2, ‘Full Outdoor Reset’ boiler will adjust
CH set point proportional to outdoor temperature as
dened by Outdoor Reset Curve below.
Outdoor reset curve adjusted by modifying Design and Mild
Weather reference temperatures. See points A & B of Reset
Curve below.
Calculated CH set point always limited between ‘Reset Curve
Boiler Minimum/Maximum’ temperatures. See points C & D
of Reset Curve below.
Figure A-2 Outdoor Reset Curve
Calculated supply temperature follows thick black line in
graph below based on outdoor temperature.
220
200
180
160
140
120
100
Supply Temperature Se tpoint F
Suppy Temperature Setpoint °F
80
0 20 40 60 80 100
A
D
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.
C and D
C
B
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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 satised, boiler enters post purge
mode and DHW pump continues to run for 15 seconds.
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APPENDIX A - CONTROL MODULE
User Interface Display
Allowed Range: 1 to 60 Minutes
DHW Settings
Default Setting: 30 Minutes
Explanation
Maximum time boiler operates in DHW mode limited by DHW
Maximum Priority Time Setting.
Priority timer starts when both CH and DHW demand is
present. Boiler will switch from DHW back to CH operation after
Maximum Priority Time has elapsed.
CH demand then has priority until Maximum Priority Time has
elapsed.
Process repeats until either CH or DHW demand satised.
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.
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NOTES
81
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NOTES
NOTES
82
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NOTES
83
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IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and
Conservation Act, this boiler is equipped with a feature that saves energy
by reducing the boiler water temperature as the heating load decreases.
This feature is equipped with an override which is provided primarily to
permit the use of an external energy management system that serves the
same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE
FOLLOWING CONDITIONS IS TRUE:
• An external energy management system is installed that reduces the boiler water
temperature as the heating load decreases.
• This boiler is not used for any space heating
• This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/hr or greater.
• This boiler is equipped with a tankless coil.
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
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