Page 1
™
VICTORY VSPH
This manual must be left
w
ith owner and should be
h
ung on or adjacent to
t
he boiler for reference.
DIRECT-VENT SEALED COMBUSTION BOILERS
HOT WATER MODELS VSPH-60 THROUGH VSPH-180
GAS-FIRED CAST-IRON BOILERS FOR NATURAL AND L.P. PROPANE GASES
INSTALLATION AND OPERATING INSTRUCTIONS
®
TABLE OF CONTENTS
Dimensions, Rating and Orifice Sizes ........................................2
Identification of Parts..................................................................3
Installation Requirements ...........................................................4
Venting Application .....................................................................5
Boiler Room Air Supply and Ventilation......................................5
Flue gas Venting Requirements..................................................5
Vent Material ..............................................................................5
Air Intake Material ......................................................................6
Flue and Air Intake Restrictions .................................................6
Non-Direct Vent Installation ........................................................8
Sidewall Venting, Non-Direct Vent ..............................................8
Vent Termination Location and Clearance ..................................8
Non-Direct Vent Vertical Venting.................................................8
Direct Vent Installation ................................................................8
Sidewall Venting, Direct Vent ......................................................8
Vent/Air Intake Termination Installation.......................................8
Direct Vent, Venting and Air Intake through a Roof ..................13
Venting and Air Intake Regular Inspection ...............................15
Gas Piping ................................................................................15
Electrical Wiring ........................................................................15
Multi Zoning ..............................................................................18
Water Piping .............................................................................18
Wiring Diagram.........................................................................16
Operating Instructions...............................................................19
Gas Input Rate Adjustment ......................................................20
Boiler Control............................................................................22
Sequence of Operation.............................................................21
Status of Indicator Lights (LED’s).............................................22
Safety Check ...........................................................................23
Care and Maintenance .............................................................24
General Troubleshooting Guide ...........................................25-27
WARNING
The venting system of this boiler is under positive pressure. Leakage from this system can be hazardous and if
not avoided can result in death or serious injury. In addition to the recommendations within this manual and the
User’
s Information Manual, the venting system, from the
blower to the outdoor discharge, must be carefully
checked annually by a qualified service agency.
IMPORTANT
READ ALL OF THE FOLLOWING
WARNINGS AND STATEMENTS
BEFORE READING THE
INSTALLATION INSTRUCTIONS
WARNING
LIQUEFIED PETROLEUM (L.P.)
PROPANE GAS-FIRED BOILERS
Installation location ONLY as permitted in paragraph
entitled "LIQUEFIED PETROLEUM (L.P.) PROPANE
GAS-FIRED BOILER LOCATION" on page 4 of this
instruction book.
The above warning does not apply to
fired boilers.
The installation must conform to the requirements of
the authority having jurisdiction or, in the absence of
such requirements, to the National Fuel Gas Code,
ANSI Z223.1-latest edition. The installation must also
conform to the additional requirements in this Slant/Fin
Instruction Book.
In addition where required by the authority having jurisdiction, the installation must conform to American
Society of Mechanical Engineers Safety Code for
Controls and Safety Devices for Automatically Fired
Boilers, No. CSD-1.
WARNING
This boiler, gas piping and accessories must be
installed, connected, serviced and repaired by a
trained, experienced service technician, familiar with all
precautions required for gas-fired equipment and
licensed or otherwise qualified, in compliance with the
authority having jurisdiction.
NATURAL gas-
Heating Contractor
Address
Phone Number
Printed in U.S.A. 207 Part No. 455035 Publication No. VSPH-40 Rev. A
Boiler Model Number
Boiler Serial Number
Installation Date
Page 2
2
VI
CTORY VSPH Models
RATINGS AND DIMENSIONS
NOTE: Height dimensions increase by
1
1
⁄2" and depth increases to 281⁄2" when
combustible floor kit is used.
Figure 1. Dimensions data
Boiler
Model
Input
Btuh
VSPH-60 60,000 3 11
VSPH-90 90,000 4 14
VSPH-120 120,000 5 17
VSPH-150 150,000 6 20
VSPH-180 180,000 7 23
No. of
Sections
A
1
⁄8"17
1
⁄8"20
1
⁄8" 233⁄8"
1
⁄8"26
1
⁄8"29
B
3
⁄8"
3
⁄8"
3
⁄8"
3
⁄8"
Gas Orifice Size
Orifice Sizes for High Altitudes
Includes 4% Reduction for Each 1000 Feet
Ele
vation — Feet
Gas
Type
Orifice
Size for
Sea Level
2000 3000 4000 5000 6000 7000 8000 9000 10000
Natural #49 50 50 50 51 51 51 52 52 52
Propane #57 58 59 59 60 60 61 62 63 63
Victory VSPH boiler
Orifice sizes indicated for sea level above are factory installed in boiler unless otherwise specified by the local authority. Orifice
table is based on a higher heating value between 1000 Btuh and 1010 Btuh for Natural Gas (See page 20, if local higher heating value exceeds these numbers). See page 20, for burner input adjustment.
Page 3
VI
CTORY VSPH Models
3
LOCATION AND IDENTIFICATION OF PARTS
Figure 2. Location and identification of parts
Base Assemb
ly
Page 4
4
VI
CTORY VSPH Models
INSTALLATION REQUIREMENTS
The installation must conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI Z223.1latest edition.
This installation must also conform to the additional requirements in this Slant/Fin Instruction Book.
N
ATURAL GAS-FIRED BOILER LOCATION
Provide a level, solid foundation for the boiler. Location
should be as near as possible to chimney or outside wall so
that the flue pipe from boiler is short and direct. (See Appendix A for vent terminal location restrictions.) The location
should also be such that all boiler components are protected
from water (dripping, spraying, rain, etc.) during appliance
operation and service (circulator replacement, control
replacement, etc.).
WARNING
LIQUEFIED PETROLEUM (L.P.) PROPANE GAS-FIRED
BOILER LOCATION
REQUIRES SPECIAL ATTENTION
Liquefied Petroleum (L.P.) propane gas is
heavier than air.
Therefore, propane boilers, piping, valves should NOT be
installed in locations where propane leaking from defective
equipment and piping will "pool" in a basement or other
space below the leak.
A spark or flame from the boiler or other source may ignite
the accumulated propane gas causing an explosion or fire.
Provide a level, solid foundation for the boiler. Location
should be as near the chimney as possible so that the flue
pipe from boiler to chimney is short and direct.
The UNIFORM MECHANICAL CODE may be in effect in
your geographic area.
The following precautions are cited by the 1994 UNIFORM
MECHANICAL CODE, section 304.6:
"LPG Appliances. Liquefied petroleum gas-burning
appliances shall not be installed in a pit, basement or
similar location where heavier-than-air-gas might collect.
Appliances so fueled shall not be installed in an abovegrade under-floor space or basement unless such location is provided with an approved means for removal of
unburned gas."
Consult Chapter 5 of the 1994 UNIFORM MECHANICAL
CODE for design criteria of the "approved" means for
removal of unburned gas.
MINIMUM CLEARANCES FROM COMBUSTIBLE
CONSTRUCTIONS
A. Minimum clearances to the exterior surfaces of the boiler
shall be as follows:
MINIMUM ALCOVE AND CLOSET CLEARANCE
For Combustible Recommended
Surf
ace Construction for Service
Front 6" 18"
Rear 6" 18"
Left Side 6" 18"
Right Side 12" 24"
Top 12" 12"
Flue Connector:
Enclosed — 6" 6"
Uninclosed — 2" 6"
B. Provide accessibility clearance of 24" on sides requiring
servicing and 18" on sides used for passage.
C. All minimum clearances shown above must be met. This
may result in increased values of some minimum clearances in order to maintain the minimum clearances of
others.
D. Clearance from hot water pipes shall be 1 inch**.
** At points where hot water pipes emerge from a floor, wall or ceiling,
the clearance at the opening through the finished floor boards or wall
or ceiling boards may be not less than 1/2 inch. Each such opening
shall be covered with a plate of uncombustible material.
BOILER FOUNDATION
A. Provide a solid, level foundation, capable of supporting
the weight of the boiler filled with water, and extending at
least 2" past the jacket on all sides. See dimensions of
boilers, page 2.
B. For installation on non-combustible floors only*.
C. If boiler is to be located over buried conduit containing
electric wires or telephone cables, consult local codes or
the National Board of Fire Underwriters for specific
requirements.
* Installation on combustible flooring allowed only with proper Com-
bustible Floor Kit. Kit part number is printed on boiler rating plate.
In no case may the boiler be installed on carpeting.
Figure 3. Victory “VSPH” boiler min. clearances for
combustible construction.
SAFETY
KEEP THE BOILER AREA CLEAR AND FREE FROM
COMBUSTIBLE MATERIALS, GASOLINE AND OTHER
FLAMMABLE VAPORS AND LIQUIDS.
Page 5
VI
CTORY VSPH Models
5
VENTING APPLICATION
V
SPH Series are sealed combustion type boilers, they maybe
installed and vented either as a direct vent boiler which all air
for combustion is obtained directly from outside or as a nondirect vent boiler which air for combustion is taken from inside
the boiler room.
V
SPH boilers must be vented by proper 3" diameter stainless
steel venting system (see “vent material” on this page) through
the roof or sidewall.
BOILER ROOM AIR SUPPLY AND VENTILATION
An ample supply of air is required for combustion and ventilation. When buildings are insulated, caulked and weatherstripped, now or later on, direct openings to outside may be
required and should be provided. If the boiler is not near an
outside wall, air may be ducted to it from outside wall openings.
Provisions for combustion and ventilation air must be made in
accordance with section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1-latest edition, or applicable provisions of the local building codes. The
following recommendation applies to buildings of energy-saving
construction, fully caulked and weatherstripped.
INSTALLATION IN ENCLOSED BOILER ROOM REQUIRES
TWO UNOBSTRUCTED OPENINGS FOR PASSAGE OF AIR
INTO THE BOILER ROOM:
NON-DIRECT VENT INSTALLATION
A.
1. Air drawn horizontally from outdoors DIRECTLY
through an outside wall;
one louvered opening near the
floor and one louvered opening near the ceiling, each opening with a minimum FREE air passage area of
1 square
inch per 4000 Btuh of total appliances’ input.
2. Air drawn horizontally through HORIZONTAL DUCTS;
one opening near the floor and one opening near the ceiling, each opening with a minimum FREE air passage area
1 square inc
of
3.
Air drawn VERTICALLY from outdoors; one opening at
h per 2000 Btuh
of total appliances’ input.
the floor and one opening at the ceiling, each opening with
a minimum FREE air passage area of
1 square inch per
4000 Btuh of total appliances’ input.
4.
Air drawn from inside the building; one opening near
the floor and one opening near the ceiling, each opening
with a minimum FREE air passage area of 1 square inch
per 1000 Btuh of total appliances’ input.
IF BOILERS ARE INSTALLED ADJACENT TO OTHER FUEL
BURNING EQUIPMENT, THE AREA OF FREE OPENINGS
MUST BE APPROPRIATELY INCREASED TO ACCOMMODATE THE ADDITIONAL LOAD.
DIRECT VENT INSTALLATION
B.
Adequate air supply should be provided to prevent overheating
of the boiler controls and boiler room. Openings for passage of
air into the boiler room for direct-vent installation must be at
1
⁄2 of the openings required for the non-direct vent as men-
least
tioned above.
If additional non-direct vent appliances are installed in the same
s
pace and adequate air openings are provided for them, there
are no additional air openings required for the VSPH boiler.
For both direct and non-direct installation, the following must be
considered:
-
Openings must never be reduced or closed. If doors or
windows are used for air supply, they must be locked
open.
-
Protect against closure of openings by snow and debris.
Inspect frequently.
- No mechanical draft exhaust or supply fans are to be
used in or near the boiler area.
- Boiler area must never be under negative pressure. The
flow of combustion and ventilating air to the boiler must
not be obstructed.
FLUE GAS VENTING REQUIREMENTS
The Victory VSPH series boiler is a high efficiency, mechanically induced draft boiler and, therefore, requires different venting
arrangements than natural draft, lower efficiency boilers.
THE FOLLOWING INSTRUCTIONS MUST BE CAREFULLY
READ AND FOLLOWED IN ORDER TO AVOID ANY HAZARDOUS CONDITIONS DUE TO IMPROPER INSTALLATION
OF THE AIR INTAKE AND FLUE GAS VENTING SYSTEM.
The vent piping installation MUST be in accordance with these
instructions and with ANSI Z223.1-latest edition NATIONAL
FUEL GAS CODE, Part 7, Venting of Equipment. Other local
codes may also apply and must be followed. Where there is a
conflict between these requirements, the more stringent case
shall apply.
The use of a vent damper is NOT permitted on this boiler
series.
VENT MATERIAL
The vent system for direct or non-direct vent installation must
be UL listed single wall 3” diameter AL29-4C* stainless steel
material. The following manufacturers’ systems are approved
for use within a specified minimum and maximum equivalent
vent length for each model. Proper adapter must be used as a
connector between Victory VSPH boilers flue collar and venting
system as shown below:
Man
ufacturer
Heat-Fab. Inc. Saf-T Vent Not required RTV 106 or Dow
Heat-Fab. Inc. Saf-T Vent Not required Not Required
ProTech System, FasNSeal FSA-HFA3 Not Required
Inc.
Fle
x-L StaR-34 SRASFA3 GE-IS806
International, Inc.
Z-Fle
x, Inc.
Heat-F
ab Part Numbers for various items of vent system are listed in
Slant/Fin Part List, Publication No.VSPH-10PL
Type/System
EZ Seal
Z-V
ent O2SVSSLA2 GE, RTV 106
Adapter Part
No.
Sealant
Corning 732
*AL29-4C is a registered Trademark of Allegheny Ludlum Corp
Page 6
6
VI
CTORY VSPH Models
When joining the various components of the above listed
v
ent systems, the manufacturers’ instructions should be
closely followed to insure proper sealing. Use sealant specified by vent system manufacturer for sealing of pipe and fittings. See Figure 4 for proper application of vent pipe sealing
for Saf-T vent system by Heat-Fab, Inc. All vent connections
must be liquid and pressure tight. Flue vent system CANNOT
b
e cut to length. Consult manufacturer’s instructions. For HeatFab system, use slip joint connector to adjust pipe lengths
d
imensions.
DO NOT use plastic or galvanized flue pipe.
EXAMPLE: Boiler model VSPH-180 is to be installed at sea
l
evel.The combustion air is provided by air intake piping
directly to the boiler (direct-vent installation). Flue piping
includes 2 elbows and using Heat-Fab system. Air intake is
PVC and includes 3 elbows.
Maximum straight flue length would be 30-2x3=24 feet.
M
aximum straight air intake pipe would be 40-3x5=25 feet.
If the air for combustion were taken from the boiler room
(
non-direct vent installation), still the maximum straight flue
length would be 24 feet.
6. All Victory VSPH boilers are equipped with a built-in
condensation drain and trap.The trap loop must be
filled with water. DO NOT operate the boiler without
filling the trap with water to prevent flue gas discharge
into space. The drain should extend to a floor drain or
to a container which may require emptying periodically.
7. The horizontal vent pipe must be sloped upward from
the boiler at a pitch of at least
1
⁄4" per 1 foot of run, so
that the condensate from the vent system runs to the
drain trap.
8. The horizontal vent pipes must be supported with pipe
straps at intervals no greater than indicated by vent
pipe manufacturer’s instructions. The vertical portion
vent pipe also must be supported per manufacturer’s
instructions. Support air intake piping in the same
manner as the vent pipes.
Figure: 4 Vent Sealing Instructions
(Consult vent manufacturer’s instructions.)
AIR INTAKE PIPE MATERIAL
3” PVC Schedule 40 or galvanized steel materials are recommended.
All joints must be sealed using appropriate sealants.
FLUE AND AIR INTAKE RESTRICTIONS
1. Maximum allowed equivalent flue and air intake length for
different flue systems at different altitudes are given in the
tables on page 7.
2. Equivalent of flue or air intake length is sum of the
straight pipe lengths and equivalent length of elbows as
shown in the table on this page.
3. The vent termination is in addition to the allowed equivalent lengths.
4. Minimum flue length is 2 feet.
5. Flue length restriction is for both direct and non-direct
vent installations.
9. Minimum clearances of vent pipes from combustible
constructions must be maintained (see Page 4). Maintain minimum 1" clearance between vent pipes and
PVC air intake pipes.
10. Common venting with other appliances or another
VSPH boiler is not allowed.
11. DO NOT install a vent damper or similar devices in
vent system or on the boiler.
12. Do not insulate venting system.
Equivalent Length of Various 90-Degree Elbows
Manufacturer
Heat-Fab, Inc. Saf-T Standard 3
Heat-Fab, Inc. Saf-T, tight radius elbow 6
ProTech System, Inc. FasNseal 6
Flex-L International, Inc. StaR-34 6
Z-Fle
x, Inc. Z-Vent 6
N/A
N/A
Type/System
elbo
w
PVC, Schedule 40 5
Galv
anized steel 6
Equivalent
Length (Feet)
Page 7
VI
CTORY VSPH Models
7
Maximum allowed flue and air intake equivalent length (Feet)
for
Heat-Fab Saf-T vent system (Including EZ Seal)
Boiler Model
Number
VSPH-60 Flue 40 40 40
VSPH-90 Flue 40 40 35
VSPH-120 Flue 40 35 30
VSPH-150 Flue 35 30 25
VSPH-180 Flue 33 28 23
Piping
Air Intake 40 40 40
Air Intake 40 40 40
Air Intake 40 40 40
Air Intake 40 40 35
Air Intake 40 35 30
0 - 5,000 Ft.
Elevation
5,000 - 7,500 Ft.
Elevation
7,500 - 10,000 Ft.
Elevation
Maximum allowed flue and air intake equivalent length (Feet)
for
Z-Flex Z-Vent and Flex-L StaR-34 vent systems
Boiler Model
Number
VSPH-60 Flue 35 35 35
VSPH-90 Flue 35 35 30
VSPH-120 Flue 35 30 25
VSPH-150 Flue 30 25 20
VSPH-180 Flue 28 23 18
Piping
Air Intake 40 40 40
Air Intake 40 40 40
Air Intake 40 40 40
Air Intake 40 40 35
Air Intake 40 35 30
0 - 5,000 Ft.
Elevation
5,000 - 7,500 Ft.
Elevation
7,500 - 10,000 Ft.
Elevation
Maximum allowed flue and air intake equivalent length (Feet)
for
ProTech FasNSeal vent systems
Boiler Model
Number
VSPH-60 Flue 30 30 30
VSPH-90 Flue 30 30 25
VSPH-120 Flue 30 25 20
VSPH-150 Flue 25 20 15
VSPH-180 Flue 23 18 15
Piping
Air Intake 40 40 40
Air Intake 40 40 40
Air Intake 40 40 40
Air Intake 40 40 35
Air Intake 40 35 30
0 - 5,000 Ft.
Elevation
5,000 - 7,500 Ft.
Elevation
7,500 - 10,000 Ft.
Elevation
Page 8
8
V
ENTING INSTALLATION
Follow the vent material manufacturer’s instructions in conjunction with these instructions for venting system installat
ion.
I. Non-Direct Vent Installation
The air for combustion is taken from the ambient air surrounding the boiler; therefore, ample supply of air is required
for combustion and ventilation (see page 5.)
D
O NOT use this installation method if the surrounding of the
boiler is contaminated. The harmful corrosive contamination
may be from the chlorine-type detergents, cleaners, bleaches, and fabric softeners used in laundry or chlorine-based
swimming pool chemicals.
VI
CTORY VSPH Models
s
age, an appropriate UL listed roof flashing must be used.
An existing chimney (see Figure 8) may be used as a chase
f
or vertical venting. Other appliances CANNOT be vented
into the same chimney or vent pipe with in the chimney.
T
he vertical vent piping must terminate with a screened tee,
combination of 45˚ elbow and a 90˚ screened elbow termination or a rain cap termination.
II. Direct Vent Installation
Air intake piping from outside to the boiler air intake collar
provides the air for combustion.The boiler surrounding may
be contaminated with chlorine-based products such as laundry detergents.
A. SIDEWALL VENTING - NON-DIRECT VENT
Figures 5 and 6 show typical horizontal sidewall venting. For
combustible wall passage of vent piping, a UL listed thimble
must be used, providing the wall thickness from 3" minimum
up to 12" maximum. The vent piping must terminate with a
screened tee or elbow termination facing down.
CAUTION: Flue gasses exiting from the vent terminal will
condense. Building materials in the area of the vent terminal
should be protected from discoloration and degradation.
VENT TERMINATION LOCATION AND CLEARANCES
1. The venting system shall terminate at least 3 feet above
any forced air inlet located within 10 feet.
2. The venting system shall terminate at least 4 feet below,
4 feet horizontally from, or 1 foot above any door, window
or gravity air inlet into any building.The bottom of the vent
terminal or air intake terminal shall be at least 12 inches
above grade or the normal snow level whichever is
greater.
3. Through the wall vents shall not terminate over public
walkways or over areas where condensate or vapor could
create a nuisance or hazard or could be detrimental to
the operation of regulators, relief valves or other equipment. Minimum clearance of 4 feet horizontal distance is
maintained, from electric meters, gas meters, regulators
and relief equipment.
A. SIDEWALL DIRECT VENTING
Figures 9 and 10 show typical sidewall direct venting.
Slant/Fin vent/air intake termination MUST be used for this
method of installation.
CAUTION: Flue gasses existing from the vent terminal will
condense. Building materials in the area of the terminal
should be protected from discoloration and degradation. See
page 8 for vent termination location and required clearances.
VENT/AIR INTAKE TERMINATION INSTALLATION
1. Termination must be installed horizontally.
2. Refer to Figure 11 for installation details.
3. Wall thickness should be 3" to 12" thick
4. Follow instruction for “vent termination location and
clearances” explained on this page
5. Cut a rectangular opening with following dimensions in
the wall.
Height: 5
Width: 123⁄4"
6. From outside of the wall, install outside termination
plate using 4 screws. Make sure the louvers are at
left side.
1
⁄4"
4. Vent termination must not be located in any confined
space (i.e. window wells, alcoves, narrow alleys) or under
any overhang or deck.Vent termination should not allow
flue gas discharge towards neighbor’s windows or where
personal injury or property damages can occur.
B. NON-DIRECT VENT - VERTICAL VENTING
Figure 7 shows typical venting through the roof.The vent
pipe must pass through the ceiling, floor and the roof vertically through a 7" minimum diameter cutout. A fire stop is
required for each ceiling and floor penetration. For roof pas-
7. For combustible wall a 4" galvanized pipe must be
used as a wall thimble.
The length of the 4" galvanized pipe should be
approximately 1" shorter than the wall thickness.
8. From inside the building, fit galvanized pipe over 4"
collar of the outside plate.
9. From inside, fit 3" diameter air intake pipe over 3"
collar located on the air box of the outside plate.
(text continued p.13)
Page 9
VI
CTORY VSPH Models
VICTORY VSPH MODELS NON - DIRECT VENT, SIDEWALL VENTING
9
All joints must be liquid and pressure tight. Use U/L listed single wall 3" dia.
AL29-4C S.S.*. venting materials (See page 5).
Figure 5. Non-direct vent, side wall venting.
Figure 6. Non-direct vent, side wall venting.
Definition of Snow Line: Knowledge of local conditions will reveal the maximum height that repeated snowfalls accumulate to.
The height should be used as the SNO
AL 29-4C IS A REGISTERED TRADEMARK OF ALLEGHENY LUDLUM CORP.
*
W LINE.
Page 10
10
VI
CTORY VSPH Models
VICTORY VSPH MODELS- NON- DIRECT VENT, VENTING THROUGH A ROOF
All joints must be liquid and pressure tight. Use U/L listed single wall 3" dia.
AL29-4C* S.S. venting materials (See page 5).
Figure 7. Victory VSPH models-non-direct vent, venting through the roof
AL 29-4C IS A REGISTERED TRADEMARK OF ALLEGHENY LUDLUM CORP
*
.
Page 11
VI
CTORY VSPH Models
VICTORY VSPH MODELS- NON - DIRECT VENT, UTILIZING AN EXISTING
CHIMNEY AS A CHASE
All joints must be liquid and pressure tight. Use U/L listed single wall 3" dia.
AL29-4C* S.S. venting materials (See page 5).
11
Figure 8. Victory VSPH models-non-direct vent, utilizing an existing chimney as a chase
AL 29-4C IS A REGISTERED TRADEMARK OF ALLEGHENY LUDLUM CORP
*
.
Page 12
12
VI
CTORY VSPH Models
VICTORY VSPH MODELS - DIRECT VENT, SIDEWALL VENTING
All joints must be liquid and pressure tight. Use U/L listed single wall 3" dia.
AL29-4C* S.S. venting materials (See page 5).
Figure 9. Direct vent, sidewall venting illustration; with straight horizontal vent.
Figure 10. Direct vent, sidewall venting illustration; horizontal vent using elbows.
** Definition of Snow Line: Knowledge of local conditions will reveal the maximum height that repeated snowfalls accumulate to.
The height should be used as the SNO
AL 29-4C IS A REGISTERED
*
TRADEMARK OF ALLEGHENY LUDLUM CORP
W
LINE.
.
Page 13
VI
CTORY VSPH Models
13
10. From inside, install inside termination plate using 4
screws. Make sure the 4" collar on the plate, penetrateed into the galvanized pipe.
1
1. Assemble and seal straight screened termination to
the slip joint connector.
1
2. From outside of the building, insert vent pipe (slip joint
connector and termination assembly) through the 3"
holes of the outside and inside termination plate.
13. From outside of the building seal outside termination
plate to building.
14. From inside, proceed with air intake and vent pipe
installation. Follow vent manufacturer’s instructions and
restrictions mentioned on page 6 of this manual. DO
NOT exceed the maximum allowed equivalent lengths
given in tables on page 7.
When joining various components of the vent system and air
intake piping, proper sealant must be used (see page 6).
Install horizontal vent pipe with seams on the top. Connect
and seal air intake piping to air intake collar of the boiler.
Adjust the air pipe support to hold air intake pipe securely
(see Figure 2).
B. DIRECT VENT - VENTING AND AIR INTAKE
THROUGH A ROOF
Figure 12 shows typical vertical venting. The vent pipe must
p
ass through the ceiling, floor and the roof vertically through a
7" minimum diameter cutout. A fire stop is required for each
ceiling and floor penetration. For roof passage an appropriate
U
L listed roof flashing must be used.
The vertical vent piping must terminate with a screened
s
traight termination.
The air intake terminal should be a screened 180˚ elbow facing down. The air intake opening must be at least 1 foot below
the vent opening.
Follow vent manufacturer’s instructions and restrictions mentioned on page 6 of this manual.
DO NOT exceed the maximum allowed equivalent length given
in tables on page 7. When joining various components of the
vent system and air intake piping, proper sealant must be
used (see page 6).
Install horizontal vent pipe with seams on the top. Connect
and seal air intake piping to air intake collar of the boiler.
Adjust the air pipe support to hold air intake pipe securely
(See Figure 2).
Figure 11.
V
ent/Air Intake
T
ermination
Page 14
14
VICTORY VSPH MODELS
DIRECT VENT,VENTING AND AIR INTAKE THROUGH A ROOF
All joints in vent system must be liquid and pressure tight. Use U/L listed
single wall 3” dia. AL29-4C S.S. venting materials (See page 5).
VI
CTORY VSPH Models
Figure 12. Direct vent, venting and air intake through a roof.
Page 15
VI
CTORY VSPH Models
15
VENTING AND AIR INTAKE SYSTEM REGULAR
INSPECTION
A
. Inspect the system regularly for condensation, corrosion
a
nd/or physical damage. A qualified professional should service the boiler annually and include such an inspection at that
time. The homeowner should look over the system monthly for
d
amage, water stains, any signs of rust, other corrosions or
separation of the vent and air intake piping (if direct-vent).
B. Should an inspection turn up signs of condensation, corrosion
or damage, the boiler should be shut down immediately and
t
he condition should be corrected by a qualified professional.
C. All Victory VSPH boilers are equipped with a built-in conden-
sation drain and trap.The trap loop must be filled with water.
DO NOT operate the boiler without filling the trap with water to
prevent flue gas discharge into space. Periodic inspection
should be made of this assembly for deterioration of the tubing and to insure that the trap is not plugged. If it is plugged or
appears to have excessive sediment in it, it should be
removed from the drain assembly, straightened out to clear
the obstruction, reformed, filled with water and reinstalled as
before.
GAS PIPING
A. Local installation codes apply.The pipe joint compound
used on threads must be resistant to the action of liquefied
petroleum gases.
B. The gas supply line to the boiler should run directly from the
meter for natural gas or from the fuel tank for L.P. propane
gas. See page 2 for location of union and manual main
shut-off valve that may be specified locally.
Selecting pipe size for natural gas:
1. Measure or estimate the length of piping from the meter
to the installation site.
2. Consult gas supplier for heating value of gas (Btu/cu. ft.).
3. Divide boiler rated input by heating value to find gas flow
in piping (cu. ft. per hour).
4. Use table below to select proper pipe size.
EXAMPLE: Boiler model VSPH-150 is to be installed. Distance
from gas meter to the boilers is 30ft. Heating value of natural
gas is 1020 Btu/cu. Ft. Select proper pipe size.
Gas flow = 150,000 Btu/hour
1020 Btu/cu. ft.
= 147 cu. ft. per hour
At 30 ft. length of pipe, match required capacity from table on
this page (choose higher capacity, in this case is 152 cu. ft. per
hour). Required pipe size is
3
⁄4".
Improper gas pipe sizing will result in pilot flame outages, insufficient heat and other installation difficulties. For more information and also if other appliances are to be attached to the piping system, see Appendix C of National Fuel Gas Code ANSI
Z223.1-latest edition.
C. The boiler and its gas connection must be leak tested
before placing the boiler in operation. Use liquid soap solution for all gas leak testing. DO NOT use open flame.This
boiler and its individual shutoff valve must be disconnected
f
rom the gas supply piping system during any pressure test-
ing of that system at test pressures in excess of
1
⁄2 PSIG.
This boiler must be isolated from the gas supply piping syst
em by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test
pressures equal to or less than
1
⁄2 PSIG.
D. All gas piping used should be inspected thoroughly for
cleanliness before makeup. A sediment trap must be provide
d, as illustrated on page 2.
E. The minimum and maximum gas supply pressure (at the
inlet of gas valve) are shown on the boiler rating plate for
the type of gas used. Gas supply pressure should never be
less than minimum or more than maximum pressure when
the boiler or any other appliance is turned on or off.
Length
of pipe
in Feet
Gas Flow In piping -- cu. ft. per hr.
Iron Pipe Size (IPS) — inches
1/2
3
/4 11
1
/4
11/2
10 132 278 520 1050 1600
20 92 190 350 730 1100
30 73 152 285 590 890
40 63 130 245 500 760
50 56 115 215 440 670
60 50 105 195 400 610
70 46 96 180 370 560
80 43 90 170 350 530
90 40 84 160 320 490
100 38 79 150 305 460
At pressure drop of 0.3 in.
w
ater, specific gravity = 0.6.
ELECTRICAL WIRING
DANGER:
Before wiring always turn off electric power supply
otherwise, shock or death can result.
1. Power Supply
A separately fused circuit is recommended. Use standard
15 Amp. fuse or breaker and 14 gage conductors in BX
cable or conduit.
Provide disconnect means and overload protection as
required. See boiler wiring diagram (Figure 13a) boiler control (Figure13b) and ladder diagram (Figure 13c).
Boiler must be electrically grounded in accordance with the
requirements of the authority having jurisdiction, or, in the
absence of such requirements, with the National Electrical
Code, ANSI/NFPA 70-latest edition.
Page 16
16
PILOT
BURNERBURNER
MODEL UT-1107MODEL UT-1107
P5P5
P4P4
P1P1
P6P6
P2P2
P3P3
INTEGRATED BOILER CONTROLINTEGRATED BOILER CONTR OL
P6P6
THERMOSTATTHERMOSTAT
K4K4
MVMV
MV/PVMV/PV
PVPV
NEUTRALNEUTRAL
H
OTHOT
MM
120 V/60Hz120 V/60Hz
120VAC120VAC
24VAC24VAC
K5K5
K1K1
MM
CIRCULATO RCIRCULATOR
BLOWER BLOWER
HIGHHIGH
LIMITLIMIT
PRESSUREPRESSURE
SWITCHSWITCH
ROLL-OUT
SWITCH SWITCH
L1L1
11
L2L2
GNDGND
P6P6
44
P5P5
P4P4
11
55
P4P4
11
P5P5
P4P4
22
33
DISCONNECTDISCONNECT
SWITCHSWITCH
P1P1
33
P1P1
11
P2P2
22
P2P2
11
P6P6
33
P6P6
22
P3P3
99
CHASSIS
GNDGND
P3P3
77
P3P3
44
P3P3
66
P3P3
33
P3P3
11
P3P3
55
P3P3
22
NOTE:NOTE:
PXPX
INDICATES CONNECTOR'S TERMINAL ON BOILER CONTROLINDICATES CONNECTOR'S TERMINAL ON BOILER CONTR OL
K3K3
P3P3
88
PRESSURE
SWITCH
R
OLL-OUT
SWITCH
CAUTION:
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE
APPLIIANCE MUST BE REPLACED, IT MUST BE REPLACED
WITH TYPE 105
∞C OR ITS EQUIVALENT.
WIRE LEGEND:
FACTORY WIRED
FIELD WIRED, FIELD SUPPLIED
BLOWER
(INDUCER)
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
PROPER OPERATION AFTER SERVICING".
1
C
IRCULATO R
MV
GND
VR8204A
1
J
UNCTION
BOX
DISCONNECT
SWITCH
120V/60Hz
AQUASTAT
RED
WHITE
BLACK
L
1-HOT
L2-NEUTRAL
1
2
M
BLACK
1
2
3
6
5
4
P
5
P4
BLACK
G/Y
1
2
3
4
1
2
3
P2
BLACK
WHITE
GREEN
PROVIDE DISCONNECT MEANS & OVERLOAD PROTECTION AS
R
EQUIRED.
120V/24V
TRANSFORMER
1
2
BLACK
WHITE
BROWN
PINK
1
2
3
4
5
6
7
8
9
PV
M
V/PV
L4080B
GAS VALVE
24V
T
HERMOSTAT
RED
BLUE
WHITE
RED
BLACK
YELLOW
YELLOW
P6
P3
P1
GREEN
WHITE
WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.
"VERIFY
RED
VI
CTORY VSPH Models
Figure 13b. Boiler control
Figure 13a. Schematic wiring diagram.
Figure 13c. Ladder wiring diagram
Page 17
VI
CTORY VSPH Models
17
MULTIZONING OF VSPH BOILER
ZONE VALVE SYSTEM USING V8043E/F ZONE VALVES
Figure 14.
MULTIZONING OF VSPH BOILER
PUMP ZONING SYSTEM USING R845A RELAY
Figure 15.
MULTIZONING OF VSPH BOILER
PUMP ZONING SYSTEM USING R882A/B RELAYS
Figure 16.
Page 18
18
GATE VALVEGATE VALVE
FACTORYFACTORY
CIRCULATORCIRCULATOR
LOC ATIONLOCATION
3/4" PRESSURE3/4" PRESSURE
RELIEF VALVERELIEF VALVE
AIR VENTAIR VENT
RETURNRETURN
SU PPLYSUPPLY
EXPA N SIONEXPAN SION
TANKTANK
ALTERNATE
CIRCULATORCIRCULATOR
LOLOCATCATIONION
FLO W CON TRO LFLOW CO NTROL
VALVEVALVE
W ATER FE EDW ATER FE ED
PRESSU REPRESSU RE
REDU CINGREDU C ING
(FILL)VALVE(FILL)VALVE
DRAIN COC KDRAIN COCK
VI
CTORY VSPH Models
2. Power Connection
A. Remove electrical junction box cover.
B. Hot connection lead is black. Neutral connection lead is white.
Proper polarity is important for VSPH boilers. Reversed
polarity will cause system lockout and the power LED will
flash continuously.
C. Connect ground wire to ground screw inside the junction box.
D.Replace junction box cover.
THERMOSTAT CONNECTIONS
Install thermostat on an inside wall and away from any heat
sources, sunshine and drafts.Thermostat wires must be connected to terminals block on boiler. See wiring diagram Figure 13a.
Thermostat heat anticipator: For a non-zoned system set thermostat heat anticipator to 0.4 Amps, for zoned system set to match
power requirements of zone valves or relays. Refer to manufacturer’s instructions and specifications. Also see instructions with thermostat.
MULTI ZONING
For multiple zoning, either zone valves or circulators maybe used.
.
22.
C
irculating Systems
Victory VSPH boilers are equipped with a water circulating
pump mounted to the return water connection on the boiler.This
p
ump location is appropriate for most installations. It may be
desired and proper to locate this pump to the alternate location
shown in Figure 17, especially when applied to larger systems
using high-head pumps.
1
When the pump is removed there is a 1
r
eturn pipe may be attached to.
⁄2” FPT tapping that the
At one month intervals after the last call for heat, the circulator
will be energized for 30 seconds. Short operation after long term
i
dle periods prevent damage of the pump from sedimentation.
For zone valve system see Figure 14.
For pump zoning system see Figure 15 and Figure 16.
DO NOT use boiler transformer to power external accessories like
zone valve and relays, overload and/or burned-out transformer
and boiler malfunction can result. Use separate transformer to
power such components. For pump zoning system, remove boiler
circulator wire connector from P5 of electronic boiler control (See
Figure 13b).
WATER PIPING
Always follow good piping practices. Observe minimum 1" clearance to combustibles around all uninsulated hot water pipes or
when openings around pipes are not protected by non-combustible materials.
On a hot water boiler installed above radiation level, the boiler
must be provided with a low water cutoff device at the the time of
installation by the installer (see Figure 17 for piping arrangement).
The low water cutoff must be wired in series with rollout safety
switch and Aquastat (limit control). See wiring diagram Figure
13a.
.
11.
Supply and Return
For tapping sizes see dimensions on page 2. Shut-off valves
are recommended.
Figure 17. Piping arrangement
.
33.
Radiant Floor, Low Water Temperature and large water
volume systems
A boiler by-pass loop, three way valve arrangement, or
primary secondary pumping (with a boiler loop) must be
used to provide a minumum 130˚ return water temperature
to the boiler.This will prevent condensation on the cast-iron
sections that can result in improper operation of the boiler.
.
44.
Air control system
Diaphragm type compression tank is used to control system
pressure. It must be installed at the boiler or between boiler
and supply main pump(s).
An automatic air vent is used to remove air from the system
in Figure 17. If system pressure needs further control, add
an additional tank in parallel with original tank or install a
larger capacity tank. Use appropriate size tank for volume of
water in system. See chart for boiler’s volume.
Boiler Water Content
Model Pounds Gallons
VSPH-60 24.75 3.0
VSPH-90 32.00 3.8
VSPH-120 39.25 4.7
VSPH-150 46.50 5.6
VSPH-180 53.75 6.4
Page 19
VI
CTORY VSPH Models
5. Cold Water Fill
P
ressure reducing (fill) valve and shut-off valve should be
installed.
6
. Relief Valve Discharge Piping
Use same size or larger piping than valve outlet. Must terminate 6" minimum from floor with a plain (no threads)
end. Place a bucket under pressure relief valve discharge.
Make sure discharge is always visible. DO NOT hard-pipe
t
o drain piping.
19
7. Providing Protection from Freezing
A
nti-freeze is sometimes used in hydronic heating systems
to protect against freeze-up in the event of power failure or
control shutdown when the building is unoccupied. It
should be recognized that unless the building is kept
above freezing temperature by some means, the plumbing
system is not protected. Two types of anti-freeze may be
used: ETHYLENE GLYCOL, used in automobiles, has
desirable properties, but is toxic. Its use maybe prohibited
when system water/glycol solution is in contact with a
potable water vessel (as an indirect hot water heater with
built-in heating coils). PROPYLENE GLYCOL is used in
the quick-freeze food industry; it is practically non-toxic. Its
use may be permitted when system solution is in contact
with a potable water vessel. When anti-freeze must be
used, inhibited propylene glycol is recommended. Useful
information on the characteristics, mixing proportions, etc.
of glycol in heating systems is given in Technical Topics
No. 2A, available from the Hydronics Institute, 34 Russo
Place, Berkeley Heights, NJ 07922. Consult glycol manufacturers for sources of propylene glycol.
8. Water Treatment
A good water treatment program will not only extend the
useful life of this boiler but it will also save much of the
time and expense of repairs made necessary by preventable occurrences. A reputable water treatment company should be consulted to evaluate and determine the best
overall treatment program for your boiler equipment.
Figure 18. Cooling system to a water boiler and chiller.
OPERATING INSTRUCTIONS
I. Filling and Venting Water Systems
A. Fill the system with water. Vent or purge of air.
B. Fire the boiler as soon as possible (see following warn-
ing and instructions) and bring water temperature in
the system.
C. Vent air and add water as needed to achieve operating
pressure on boiler gauge. Pressure must be between
approximately 12 psi (cold water) and 25 psi at water
temperature setting of high limit control, for boilers
equipped with 30 psi relief valves. Boilers rated for a
higher pressure and equipped with a matching relief
valve may operate at a higher pressure, but no higher
than 5 psi below the relief valve opening pressure.
D. Check for and repair any leaks before placing system
in service.
BEFORE FIRING BOILER, make these checks:
1. System is full of water. Air is vented or purged.
PIPING A HEATING - COOLING SYSTEM TO A WATER
BOILER AND CHILLER
Figure 18 illustrates a method of piping a heating-cooling system to a water boiler and a chiller. Hand valves (shown) or
automatic valves must be installed to prevent circulation of
chilled water in the boiler or hot water in the chiller.
The air control system and pressure control system must
operate with chiller only, or the boiler only, being valved to the
piping system. Separate control devices on the boiler and
chiller may be used, or a single set of air and pressure controls on the common piping may be preferred.
If the boiler is used to supply hot water to heating coils in air
handling units, flow control valves or other devices must be
installed to prevent g
ing the cooling cycle.
ravity circulation of water in the coils dur-
2. Relief valve is installed in accordance with ASME Boiler and Pressure Vessel Code, Section IV. Valve opening is not closed or reduced in size.
3. Venting is installed according to instructions under
“FLUE GAS VENTING REQUIREMENTS”.
4. All wiring is completed, following applicable wiring diagrams.
5. Using soap solution, check for gas leaks in all gas piping from meter to boiler pilot and manifold. DO NOT
use open flame.
Page 20
20
0FF0FF
ONON
HON EYWELLHON EYWELL
GAS GAS
INLETINLET
GAS CON TRO L KNO BGAS CON TRO L KNO B
SH O W N IN "OFF"SHOW N IN "OFF"
POSITIONPOSITION
OUTLETOUTLET
I
I. Initial Start
Safe lighting and other performance criteria were met when
testing various gas manifold and control assemblies used
on the Victory VSP Series Boilers under the ANSI Z21.13latest edition.
Instructions
Follow the lighting instructions in this manual.These
instructions are also attached to the boiler.
S
AFETY INFORMATION
For Your Safety Read Before Operating
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance is equipped with an ignition device which
automatically lights the pilot. D
hand.
B. BEFORE OPERATING smell all around the appliance area
for gas. Be sure to smell next to the floor because some gas
is heavier than air and will settle on the floor.
O NOT try to light the pilot by
VI
CTORY VSPH Models
1
1. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
“To Turn Off Gas to Appliance” and call your service
technician or gas supplier.
To Turn Off Gas to Appliance
1. Set thermostat to lowest setting.
2. Turn off all electric power to the appliance if service
is to be performed.
3
. Remove jacket front panel.
4
. Turn gas control knob clockwise till knob stops,
then continue to “OFF”. Do not force.
5. Replace jacket front panel.
Gas Valve VR8204 or VR8304
WHAT TO DO IF YOU SMELL GAS:
• DO NOT try to light any appliance.
• DO NOT touch any electric switch: DO NOT use any
phone in your building.
• Immediately call you gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to turn the gas control knob. Never
use tools. If the knob will not turn by hand, don’t try to
repair it, call a qualified service technician. Force or
attempted repair may result in a fire or explosion.
D. Do Not use this appliance if any part has been under
water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the
control system and any gas control which has been under
water.
OPERATING INSTRUCTIONS
1.
STOP! Read the safety information above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the pilot. D
hand.
5. Remove jacket front panel
6. Turn gas control knob clockwise to “OFF”.
NOT force.
DO
7. Wait five (5) minutes (longer for propane) to clear out any
gas, then smell for gas, including near the floor. If you then
smell gas, STOP! Follow “B” in the safety information
above on this page. If you don’t smell gas, go to next
step.
8. Turn as control knob counterclockwise to “ON”.
9. Replace jacket front panel.
10. Turn on all electric power to the appliance.
O NOT try to light the pilot by
Figure 19.
Removing Jacket Front Panel
1. Turn black screws 1⁄4 turn to open position.
2. Remove front panel.
To replace the panel, reverse procedure.
Gas Input Rate Adjustment
1. Consult gas supplier for higher heating value* of gas
(Btu/cu. ft.)
2. Set thermostat high enough so that boiler will remain on
3.
Measure manifold pressure.
Correct manifold pressure for gas used is printed on boiler
rating plate. NOTE: Gas pressure may be adjusted by
turning pressure regulator screw on combination gas valve
(turn clockwise to increase pressure, counterclockwise to
decrease pressure).
* ”Higher Heating” value of gas is commonly known as “heating value”.
Page 21
VI
CTORY VSPH Models
21
VSPH BOILER SEQUENCE OF OPERATION
THERMOSTAT CALLS FOR HEAT
CIRCULATOR ON
4 TIMES RE-TRIALS
FOR IGNITION
CONTROL RE-INSTATE
TRIAL FOR IGNITION
WITH 30 SECONDS
INTER-PURGE
PILOT LIGHTS AND
FLAME SENSED?
NO
YES
NO
NO
SPARK OFF. MAIN VALVE OPENS. BOILER HEATING PERIOD
CONTROL CONTINUOUSLY MONITORS THERMOSTAT, HIGH
LIMIT, PRESSURE SWITCH AND FLAME SENSOR.
BOILER WATER TEMPERATURE IS
B
ELOW HIGH LIMIT SETTING?
YES
PRESSURE SWITCH CONTACTS PROVED
OPEN WITHIN 45 SECONDS?
YES
INDUCER (BLOWER) ON
PRESSURE SWITCH CONTACTS CLOSED
WITHIN 5 MINUTES?
YES
30 SECONDS PRE-PURGE PERIOD
TRIAL FOR IGNITION-15 SECONDS
PILOT VALVE OPENS. IGNITION SPARK STARTS.
PILOT LIGHTS AND FLAME IS SENSED
DURING TRIAL FOR IGNITION?
YES
STARTS
NO
CONTROL LOCKOUT.
POWER AND
PRESSURE
SWITCH LED’S
FLASHING.
1 HOUR WAIT
PERIOD.
NO
CONTROL LOCKOUT
FLAME LED FLASHING.
1/2 HOUR WAIT PERIOD
THERMOSTAT CALLS FOR HEAT ENDS.
CIRCULATOR OFF, PILOT AND MAIN VALVE CLOSE.
15 SECONDS POST PURGE
BOILER WAITS FOR NEXT CALL FOR HEAT.
Page 22
22
VI
CTORY VSPH Models
a. Input for PROPANE is approximately at rating shown on
ating plate when manifold pressure is 9-
b. Input for NATURAL GAS is approximately at rating
when manifold pressure is 3-1/2" water column, but
should be checked on the gas meter:
B
tuh Input = Btu/cu. ft. metered in 3 minutes x 20
EXAMPLE #1:
F
or 1000 Btu/cu. ft. gas, this becomes:
Btuh Input = cu. ft. metered in 3 minutes x 1000 Btu/cu. ft. x 20
EXAMPLE #2:
For 1050 Btu/cu. ft. gas, this becomes:
Btuh Input = cu. ft. metered in 3 minutes x 1050 Btu/cu. ft. x 20
4. The higher heating value of gas varies substantially for
different localities. Consult with Slant/Fin’s Technical Service Department for reorificing procedures if any of the
following apply:
a. Boiler (burner) is over firing.
Gas Code (ANSI Z223. -latest edition) does NOT permit firing at a higher input rate than the input rate indicated on the boiler rating plate in order to avoid hazardous conditions such as explosion or carbon monoxide poisoning.
b. Poor higher heating value of gas is causing the actual
input to be substantially lower than the rating plate
indication.
CAUTION! National Fuel
1
⁄2" water column
Gas Rate Table
Boiler rated input in
cu. ft./hr. of 1000 Btu/cu. ft.
Natural Gas
6
0
9
0
120
1
50
180
The gas metered in 3 minutes to obtain rated input for
each boiler model, using 1000 Btu/cu. ft. gas, is tabulated in gas rate table.
INTEGRATED BOILER CONTROL
The integrated boiler control monitors the status of the room
thermostat, high limit control (Aquastat), pressure switch and
the flame sensor. It controls the operation of circulator, inducer motor, gas valve and spark for pilot ignition. The boiler control also determines the sequence of operation and timing for
pre and post purge periods, trail for ignition and lockout.
The control indicator lights (LED’s) provide information of boiler operation when lights are steady on or diagnostic information when they are flashing in order to help to determine the
cause of boiler failure.
Cubic Feet Gas Consumption
1
000 Btu/cu. ft. gas, in
3
minutes, at rated input
3
.00
4.50
6
.00
7
.50
9.00
A. NORMAL OPERATION - STATUS OF INDICATOR LIGHTS (LED’S)
O = LED off = LED steady on
DESCRIPTION OF OPERATION
Standby-Boiler waits for call for
heat
Thermostat calls for heat
Circulator on
Boiler water temperature below
high limit setting
Inducer on
Pressure switch contacts closed
30 seconds pre-purge period
Trial for ignition
Gas valve open
Pilot flame and main burners on
Boiler heating period
Thermostat call for heat ends
Circulator off
15 seconds post purge period.
Burners off.
POWER
LED
TSTAT/CIRC
LED
O
O
LIMIT
LED
O
O
PRESS
SWITCH
LED
O
O
O
FLAME
LED
O
O
O
O
O
Page 23
VI
CTORY VSPH Models
B. DIAGNOSTIC FLASH CODES
Flashing LED’s provide diagnostic information
WARNING: Only a trained, experienced service technician should perform troubleshooting. Turn off all electric power to
t
he boiler before service
23
L
ED’s FLASHING
POWER LED * 120 V power supply. Polarity is reversed Reverse Hot and NEUTRAL wires in the junction
POWER + TSTAT/CIRC LED’S * 48 VAC on thermostat circuit. Check and correct the thermostat or zone valves
POWER + PRES SWITCH LED’S * Pressure switch contacts are closed prior to Check air pressure switch.
POWER + FLAME LED’S * Flame sensed without call for heat. Remove air box front panel.
FLAME LED * Pilot flame was not established during trial for Check gas valve knob to be in “ON” position.
PRES SWITCH LED Pressure switch opened during boiler run Check pressure switch and its hoses.
* Control Lockout
energizing the blower motor or does not close Check hose connections to pressure switch.
within 5 minutes of the blower being turned on. Check for obstruction/restriction in venting, air
ignition. Check inlet gas pressure.
period. Wind gusts over 40 mph. Check for obstruction in venting, air intake
To reset the lockout condition: Turn down thermostat or turn
INDICATION
SAFETY CHECK
R
EMEDY
box.
wirings.
intake piping and termination.
Turn off power for at least 45 seconds.
Check if pilot flame exists during pre-purge
period (first 30 seconds). If pilot flame exists,
replace gas valve
Check pilot gas line.
Check ignition cable and the connections.
Check pilot flame to be 3/8” to 1/2" long
piping and ter
mination.
power off at disconnect switch for at least 45 seconds, then
restore power or set thermostat at desired setting.
1. Checking for gas leaks:
Using soap solution, check for gas leaks from meter to
gas v
Automatic reset: After one hour (1/2 hour for flame failure),
control will automatically retry.
alve including all pipes and fittings, gas valve connections, manifold and pilot burner gas line and its fittings.
Use liquid soap solution for all gas testing. DO NOT use
open flame.
Flame LED (Red)
Pressure Switch LED (Red)
Hi Limit LED (Red)
Thermostat/Circ. LED (Red)
Power LED (Green)
Figure 20. Integrated boiler control.
2. High limit control (Aquastat) test:
Set room ther
mostat high enough for boiler water temperature to reach high limit setting. When this temperature is
reached, the high limit switch should open. Pilot and main
gas valve should close. Inducer starts 15 seconds postpurge period. POWER and TSTAT/CIRC LED’s will stay
on.
3. Thermostat test:
Set ther
mostat setting to low enough to end call for heat.
Pilot and main gas valve should close circulator off and
inducer will star
t 15 seconds post-purge. POWER LIMIT
and PRESS SWITCH LED’s will stay on during postpurge
. After the post-purge period, POWER and LIMIT
LED’s stay on.
4. Control safety shutdown test:
With main burners firing (all LED’s on) disconnect ignition/sensor cable from boiler control. Gas valve should
shut off burners, FLAME LED starts flashing.
5.
Pressure switch test:
With burners firing, remove plastic hoses from pressure
s
witch or from aluminum tubing (see Figure 21), gas valve
must shut off, PRESS SWITCH LED starts flashing.
Page 24
24
VI
CTORY VSPH Models
Figure 21. Location and identification of pressure
switch and hoses.
CARE AND MAINTENANCE
This section must be brought to the attention of the owner by
the installer so that the owner can make the necessary
arrangements with a qualified service agency for the periodic
care and maintenance of the boiler.The installer must also
inform the owner that the lack of proper care and maintenance
of this boiler and any fuel burning equipment may result in a
hazardous condition. Installer should discuss contents of the
User’s Information Manual (Publication VSPH-UIM) with the
owner.
A trained and qualified service technician should perform the
inspection listed in these instructions before each heating season and at regular intervals.
I. General Maintenance
A. Safety check, see page 23.
B. Vent and air intake system inspection
1. Check for obstruction, condensation, corrosion and
physical damage.
2. Check outside termination. Screen and louvers should
be free of any debris and must be cleaned as required.
3. Perform “Venting and Air intake System Regular
Inspection”, see page 15.
C. Piping
Check the f
1. Water piping and accessories for leaks. Slightest leaks
should be corrected.
2. System to be full of water and pressure to remain stable at correct setting on gauge.
3. Air-control system. Noise and air binding in radiation
should not occur.
4. Low water cutoff for operation (see instructions furnished with unit).
D. Boiler Room Air Supply
Check air vents for continuous positive supply of air as
required. Air needs are greatest in cold weather if boiler
installation is non-direct vent method. Air vents must open
and free of obstruction.
ollowing:
Warning: The flow of combustion and ventilating air to the
I
I. Inspection During Heating Season
A. Check water pressure regularly and add water slowly to
system when needed. If much water is added, venting
may be necessary. Regular loss of water from boiler system may indicate either a system leak, or a faulty air control system, or a faulty automatic fill valve.
B. Check venting system. See “Venting and Air Intake Sys-
tem Regular Inspection” on page 15.
C. Check condensation drain trap to be full of water. Check
for deterioration of the tubing. Check that the trap is not
plugged.
D. With main burner firing all LED’s mst be steady “on”. See
“Normal operation-status of indicator lights” on page 22.
E. To prolong the life of the inducer motor, lubricate with
Anderol 465 or SAE 20 motor oil annually Turn off power
and place 4-6 drops of above mentioned lubricant in each
of two oil holes. Lubricate circulator per manufacturer’s
instruction. DO NOT over oil any motor.
The ceramic combustion chamber in the burner box contains
crystalline silica.
Wear proper dust mask and gloves when servicing combustion chamber or burners.
Crystalline Silica has been identified as a carcinogenic or
possibly carcinogenic to humans.
CLEANING
A. Flue passage cleaning See Figure 22
1. Turn off power to the boiler
2. Remove front jacket panel
3. Remove air box front panel
4. Remove jacket top
5. Remove inducer assembly
6. Remove flue collector
7. Remove combustion air screen
8. Use wire brush to clean flue passages. It is sug-
9. Replace flue collector and re-seal with high tem-
10. Remove and dispose of paper and accumulated
11. Replace all remo
12. Check boiler operation.
B. Cleaning of burners
1. Turn off power to the boiler.
2. Remove jacket front, air box front panel, air intake
3. Disconnect ignitor/sensor cable from the boiler con-
4. Remove pilot gas line from brass fitting located inside
5. Lift burners and remove from orifices.
6. Clean burners. To clean burners, run a clean flue
7. Replace all removed items.
8.
boiler should not be obstructed.
WARNING:
gested that paper be placed on burners to collect
any foreign material in cleaning flue passage.
perature sealer or with furnace cement.
material.
ved items.
screen and combustion air screen located inside the
air box.
trol.
the air box.
brush up the tube until all foreign matter is removed.
Check boiler operation.
Page 25
VI
TOP JACKETTOP JACKET
F
LUE COLLECTORFLUE COLLECTOR
I
NDUCERINDUCER
BRUSHBRUSH
CTORY VSPH Models
25
Figure 22. Flue passage cleaning illustration
General Troubleshooting Guide For Service Personnel
WARNING: Only a trained, experienced service technician should perform troubleshooting.
Turn off all electric power to the boiler before servicing.
A. BURNERS FAIL TO OPERATE- NO HEAT
CA
USE
1. No power, POWER LED off. Main electric switch open.
Blown or defective line fuse.
2. Gas supply valve shut off. Gas valve knob is on “off” position. FLAME LED flashing.
3. Flame sensor contaminated.
4. Pilot flame too low.
5. Roll-out switch open. POWER and TSTAT/CIRC LED’s are
on.
6. Harnesses plug-in connectors are not securely connected
REMED
1. Close switch. Check and replace
2. Open gas supply valve.Turn gas valve knob to “on “ posi-
3. Clean sensor.
4. Adjust pilot flame.
5. Check roll-out switch for continuity replace if blown out
6. Check connectors on boiler control.
Y
tion. Check gas pressure.
(inspect flue passages prior to replacement).
7. Defective transformer.
7. Remove P2 connector from boiler control. Check transformer terminals for 24V. Replace defective transformer.
Page 26
26
VI
CTORY VSPH Models
CAUSE
8. Defective pressure switch. POWER and PRES SWITCH
LED’s flashing
9. Defective high limit control
10. Defective inducer motor
11. Defective gas valve
12. Defective boiler control module
REMEDY
8. Check pressure switch. Replace defective pressure switch.
9. Set high limit setting above boiler water temperature, LIMIT
L
ED should turn on. If not, turn off power to the boiler,
r
emove wires to high limit and check continuity across high
limit contacts. If contacts are open, replace high limit.
10. With thermostat calling for heat and high limit setting above
boiler water temperature, remove blower motor plug from
boiler control (P4 connector). Check for 120 V between terminally 3 and 5 of P4 on control (See Figure 13a and 13b).
If voltmeter indicates 120V, replace inducer assembly.
11. a. Check all above causes.
b. check the gas supply pressure (at the inlet of gas valve)
as shown on the boiler rating plate for the type of gas
used.
c. With thermostat calling for heat and high limit setting
above water temperature, check the voltage across terminal
PV & PV/MV, if 24 VAC presents, replace the gas valve
12. Check all above causes. If all red indicator lights are off
while there is call for heat replace control module.
B. NOT ENOUGH HEAT
CAUSE
1. Thermostat setting is too low
2. Boiler water maintained at too low temperature.
3. Circulator not running.
4. Boiler water level too low.
5. Restriction or obstruction in air intake or venting system.
C. BURNER WILL NOT SHUT OFF
CAUSE
1. Defective Aquastat (high limit control)
REMEDY
1. Set thermostat at higher setting
2. Set Aquastat at higher setting.
3. With thermostat calling for heat, check for power to circulator. If power is O.K but circulator is not running, replace circulator.
4. Carefully snap open relief valve handle to determine if boiler is full of water, if not full of water, check for system leaks
and check water pressure regulator. Repair any system
leaks. Adjust or replace water pressure reducing valve.
5. Inspect flue and air intake piping. Inspect termination.
REMEDY
1. Turn off power to the boiler. Remove red and blue wire from
Aquastat ter
if burners stop firing, replace Aquastat.
minals. Restore power. Check boiler operation,
2. Aquastat sensor is not proper
ly inside Aquastat well.
2. Inser
t the sensor into the well.
Page 27
VI
CTORY VSPH Models
D. BURNER SHORT CYCLES
27
CAUSE
1. Thermostat heat anticipator set too low.
2. Excessive pressure drop due to excess venting or air intake
system.
3
. Blockage or restriction in venting or air intake system.
4. Defective air flow switch (out of adjustment).
E. FUMES AND GAS ODORS
CAUSE
1. Leaks in gas piping or accessories.
2. Gas leaks in service line or meter connections.
REMEDY
1. Reset anticipator.
2. System must be corrected.
3
. Check and Repair
4. Replace. DO NOT adjust.
REMEDY
1. Locate leaks and repair.
2. Close service supply valve - shut down boiler and notify
utility
3. Condensation trap is not full of water.
4. Venting system is physically damaged.
5. Over - firing
IF REPLACEMENT PARTS ARE NEEDED
When parts are needed, refer to boiler model and serial number
shown on the boiler name/rating plate. Refer to publication number VSPH-10PL replacement parts for part numbers. Whenever
possible refer to the original order by number and date.
Control identification and replacement should not be attempted
by unskilled personnel. Only, simple easily - identified controls
and parts may be obtained locally. All other controls and parts
should be identified by and ordered from Slant/Fin. Relief/Safety
valves must be ASME rated for the pressure and gross output of
the boiler.
3. Check and fill with water.
4. Check carefully and repair. Also, see “Venting System
Regular Inspection”.
5. Adjust gas input to that shown on boiler rating plate.
For replacement par
Slant/Fin boiler distributor.
ts, heating contractors should contact their
Page 28
©Slant/Fin Corp. 2007
SLANT/FIN CORPORATION, Greenvale, N.Y. 11548 • Phone: (516) 484-2600
FAX: (516) 484-5921 • Canada: Slant/Fin LTD/LTEE, Mississauga, Ontario
www.slantfin.com
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