Utica Boilers SSV Operation and Installation Manual

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Page 1

WALL MOUNTED

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Models

SSV-050

SSV-075 SSV-100

SSV-150

SSV-200

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N# 240010615, Rev. D [03/2015]

Page 2

VERIFY CONTENTS RECEIVED

Description

No. Illustration

Item

Fully Assembled Boiler 1

Metal Wall Bracket 2

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

*Safety Relief Valve 4

SIZE

SHOWN

050/075/100

Condensate Trap Height 12.45" [316mm]

**Temperature Pressure Gauge 6

Bushing 3/4" x 1/4" 7

3/4" FNPT Adapter 8

3/4" Tee

50/75/100

3/4" Tee

50/75/100

1"x 1" x 3/4" Reducing

Tee 150/200

1"x 1" x 3/4" Reducing

Tee 150/200

3/4" FNPT Adapter 11

Drain Valve, 3/4" 12

1/2" Gas Shutoff Valve 50/75/100 3/4" Gas Shutoff Valve with Increaser

and Nipple 150/200

Bushing 7/8" OD, Heyco (2 ea) 14

050/75/100 150/200

(shown in open position)

Used for electrical wire knockouts.

Stopper, Rubber 5/16" (2 ea) 15 Used for packaging holes on back of boiler.

Plastic Plug (2 ea) 16 Used for packaging holes on back of boiler.

Outdoor Sensor 17 Used for measuring outside temperature.

Critical Installation Instruction 18

11" x 17" Page for critical installation issues.

Document Package 19 Includes essential documents.

* Boiler provided with 30 psig (206 kpa) safety relief valve. Field source safety relief valve if system pressure greater than 25 psig.

Boiler provided with 75 psig temperature pressure gauge. Field source temperature pressure gauge if system pressure greater than 60 psig.

Page 3

OVERALL DIMENSIONS

(D)

Wall Hanging

Bracket

(D)

BACK OF BOILER

LEFT SIDE

OF BOILER

(B)

Vent Connector

Gas Connection(K)

Safety Relief Valve

(L)

Connection (¾ NPT)

Combustion Air

TOP OF BOILER

(A)

FRONT OF BOILER

(M)

(E)

RIGHT SIDE

OF BOILER

Table 1 : Physical Data

Models

Width (A) 20" (508mm)

Height - Unit only (B) 27.75" (705mm)

Depth (C) 14.75" (375mm)

Bracket (D)

Height unit w/ Piping (E) 30.75" (781mm)

Height unit w/vent (L) 31" (787mm)

Height unit from vent w/piping

supply & return (M)

Water

Connections

Bottom of Boiler

Condensate

Drain

Connection

Gas Connection

Top of Boiler - Size (K)

Weight

Vent Connector/Combustion Air 2" (51mm) 3" (76mm)

Size (F) 3/4" Type L Copper 1" Type L Copper

Location (G) 2.22" (56.4mm)

Location (H) 2.33" (59mm)

Location (I) 9.32" (237mm)

Location (J) 1.4" (35.6mm)

Size 3/4" NPT

Shipping 135 lb (61 kg) ~200 lb (91kg)

Unit 75 lb (34kg) ~127 lb (58kg)

050/075/100 150/200

23" (584mm)

37.75" (959mm)

16.3" (414mm)

24.41" (620mm)

33.94" (862mm}

1/2" NPT

35.6" (904mm)

40.75" (104cm)

41.8" (106cm)

44.75" (114cm)

2" (51mm)

3" (76mm)

11" (282mm)

4.6" (116.8)

3/4" NPT

Wire

Knockouts

Supply Water

to Heating

System (F)

(G)

BOTTOM OF BOILER

(I)

(H)

BOTTOM OF BOILER

Condensate

Drain (K)

(C)

(J)

Return Water from Heating

System (F)

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 ...............................................................................................22

6.2 Removal of Existing Boiler From Common Vent System................................................................22

6.3 Venting Materials ................................................................................................................. 22

6.4 Vent Pipe Installation ............................................................................................................. 23

6.5 Vent Termination .................................................................................................................. 23

6.7 Venting Congurations ........................................................................................................... 24

6.8 Side Venting Terminal Requirements of : .................................................................................. 29

6.9 Multiple Boiler Venting Installation ........................................................................................... 31

6.10 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 ........................................................................................................... 45

13 - Trouble Shooting .................................................................................................................... 46

13 - Trouble Shooting (Temperature Resistance Chart).................................................................63

14 - Wiring Diagram ...................................................................................................................... 64

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

OPTIONAL USER INTERFACE RELOCATION......................................................................................83

PRIMARY LOOP EQUIVALENT LENGTH CALCULATIONS & PUMP SELECTION...............................84-87

Page 5

1 - INTRODUCTION

1.1 Designated Use

• Hot water heating boiler.

• Indoor installation.

• Closet or alcove installation.

• Direct vent or single vent pipe boiler.

• For use with natural gas or liqueed petroleum gases (LP/propane).

1.2 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals present (example, swimming pool water).

• Exceed 150 psig (1.03 MPa) maximum allowable working pressure.

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

1.3 Operational Features

• Modulating: 20-100%.

• Integral Dual Limit.

• Connection provided for required eld sourced low water cutoff (LWCO).

• Outdoor Temperature Reset.

• Integral Multiple Boiler Control.

• Heat exchanger over heat protection.

• Alternate mounting of User Interface

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

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

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

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

notice and without incurring any obligation, whatsoever.

Page 6

2 - IMPORTANT SAFETY INFORMATION

2.1 General

Boiler installation shall be completed by qualied agency.

See glossary for additional information.

WARNING

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

2.2 Become familiar with symbols identifying potential hazards.

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

DANGER

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

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

•

United States

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

• National Electrical Code, NFPA 70.

• Canada

• Natural Gas and Propane Installation Code, CAN/CSA B149.1.

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

2.4 Where required by authority having jurisdiction,

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

Additional manual reset low water cutoff may be required.

2.5 Requirements for Commonwealth of Massachusetts:

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

• Installation by licensed plumber or gas tter.

WARNING

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

CAUTION

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

NOTICE

Used to address practices not related to personal injury.

Page 7

3 - COMPONENT LISTING

3.1 Component Listing - Refer to diagrams on

following pages.

Gas Shutoff Valve (Field Installed) Fuel supply isolation during servicing. Factory supplied, Field installed. See section 7.

Vent Connector See section 6.

Combustion Air Inlet (2"/3") See section 6.

Igniter

Flame Sensor

Sight Glass Permits observation of burner ame.

Flue Air Mixture Pressure Test Port - Not available on all models.

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

18.

Supply Water Outlet to Heating System (Out)

Connections supplied for connecting from bottom of boiler. See section 5.

19.

Temperature Pressure Gauge (Field Installed)

20.

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

21.

Flue Collector

22.

Vent Temperature Sensor

23.

Combustion Analysis Test Port

24.

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

25.

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

26.

Heat Exchanger Surface Temperature Switch

Boiler Control Module

10.

Heat Exchanger

11.

ASME Plate

12.

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

13.

Return Water Temperature Sensor

14.

Return Water From Heating System (In) and Drain Valve Connection supplied at bottom of boiler.

See section 5.

15.

Condensate Drain Boiler produces a liquid (condensate) as a by-product of combustion. (See page

14)

16.

Condensate Trap (Field Installed) Condensate must be piped to appropriate drain. See section 6.

27.

Supply Water Temperature Sensor and High Limit Switch

28.

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

29.

Pump Relay

30.

Burner not shown (see page 39)

31.

Wall Hanging Support Bracket not shown (see page

12) Integral to boiler. Allows wall mounting when used with supplied wall mounting bracket. See section 4.

32.

Gas Connection (See section 7)

17.

Jacket Panel Latch

Page 8

3 - COMPONENT LISTING

FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)

050/075/100/150/200

SIZE SHOWN

(2) VENT CONNECTOR

(3) COMBUSTION

AIR INLET

(31) WALL MOUNT SUPPORT BRACKET

See Section 5-3

For Safety Relief

(32) GAS CONNECTION

(28) SAFETY RELIEF VALVE

NOTE:

Valve Piping Instructions

FIGURE 3-2 Jacket Removal (Viewed from Bottom of Boiler

FIGURE 3-3 Jacket Removal (Viewed from Left Side of Boiler

Bottom of Boiler

Jacket Latch - Lift

latch to dis-engage

Jacket Support (Lip)

Jacket Latch

Disengage latch and lift jacket up and off

jacket support

Page 9

3 - COMPONENT LISTING

FIGURE 3-4 Boiler Components 50/75/100 MBH (View from Front of Boiler) As seen on front cover

(28) SAFETY RELIEF

VALVE

(27) SUPPLY WATER

TEMPERATURE SENSOR

& HIGH LIMIT SWITCH

(26) HEAT

EXCHANGER SURFACE

TEMPERATURE SWITCH

BRACKET

(25) COMBUSTION

AIR

BLOWER

(24) GAS (CONTROL)

VALVE

(23) COMBUSTION

ANALYSIS TEST

PORT

(22) VENT

TEMPERATURE

SENSOR

(1) GAS (CONNECTION)

SHUT OFF VALVE

(2) VENT CONNECTOR

(3) COMBUSTION

AIR INLET

NOTE:

See Section 5

For Piping

Instructions

(4) IGNITER

(5) FLAME

SENSOR

(6) SIGHT GLASS

(7)AIR FLUE

MIXTURE

PRESSURE

TEST PORT

(8) USER

INTERFACE

(9) BOILER

CONTROL

MODULE

Fuse and

Holder

(10) HEAT

EXCHANGER

(21) FLUE

COLLECTOR

(20) HIGH VOLTAGE

JUNCTION BOX

(19) TEMPERATURE/PRESSURE

GAUGE

(18) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(17) Jacket Latch

(16) CONDENSATE

TRAP

(11) ASME

PLATE

(29) Pump Relay

(12) LOW VOLTAGE

TERMINAL STRIP

(13) RETURN WATER

TEMPERATURE

SENSOR

(14) RETURN WATER

FROM HEATING

SYSTEM (IN)

(15) CONDENSATE

DRAIN

Page 10

3 - COMPONENT LISTING

FIGURE 3-5 Boiler Components 150-200 MBH (View from Front of Boiler)

(1) ) GAS (CONNECTION)

(28) SAFETY RELIEF VALVE

SHUT OFF VALVE

(2) VENT CONNECTOR

NOTE:

See Section 5

For Piping

Instructions

(27) SUPPLY

WATER

TEMPERATURE

SENSOR & HIGH

LIMIT SWITCH

(25)

COMBUSTION

AIR

BLOWER

(24) GAS (CONTROL)

VALVE

(26) HEAT

EXCHANGER SURFACE

TEMPERATURE

SWITCH

(29) PUMP RELAY

(9) BOILER CONTROL

MODULE

Fuse and Holder

(3) COMBUSTION

AIR INLET

(4) IGNITER

(5) FLAME SENSOR

(6) SIGHT GLASS

(8) USER INTERFACE

(10) HEAT

EXCHANGER

(23) COMBUSTION

ANALYSIS TEST

PORT

(22) VENT TEMPERATURE

SENSOR

(21) FLUE

COLLECTOR

(20) HIGH VOLTAGE

JUNCTION BOX

(19) TEMPERATURE/

PRESSURE GAUGE

(18) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(17) Jacket

Latch

(16) CONDENSATE

TRAP

(11) ASME

PLATE

(12) LOW VOLTAGE

TERMINAL STRIP

(13) RETURN

TEMPERATURE

SENSOR

(14) RETURN WATER

FROM HEATING

SYSTEM (IN)

(15) CONDENSATE

DRAIN

Page 11

4 - LOCATING BOILER

4.1 Boiler Location Considerations

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

• Approved for installation in closets.

• Protect gas ignition system components from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).

• Wall mount, optional oor stand available.

• Determine alternate User Interface mounting location if desired. See page 83 - Optional User Interface Relocation.

• 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.

FIGURE 4-1 Clearance to Combustible Materials

FRONT OF BOILER

FLOOR

• 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.

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/

See local code 6" (16 cm)

LEFT SIDE OF BOILER

FLOOR

(1)

150/200

0" (0 cm) 14" (36 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) 6" (16 cm)

Service

050/075/100/

150/200

(1)(2)

Page 12

4 - LOCATING BOILER

FIGURE 4-2 Wall Mount Bracket Engaged with Bracket on Boiler (50-100 size shown)

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.

• 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 15 and 16.

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.

Page 13

5 - HYDRONIC PIPING

5.1 General

• Install piping in accordance with authority having jurisdiction.

NOTICE

Use two (2) wrenches when tightening boiler's

tting and pipes. 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.

• Thoroughly clean and ush system before connecting to boiler.

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

• Flush system to remove any solid objects such as metal

chips, bers, or Teon tape, etc.

5.2 Special Conditions

• System piping exposed to freezing conditions: Use

inhibited propylene glycol solutions certied by uid

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

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

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

ow control valves or other automatic means to prevent

gravity circulation of boiler water during cooling cycle.

WARNING

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

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

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

• Use only inhibited propylene glycol solutions

certied by uid manufacturer as acceptable for

use with closed water heating system.

• Thoroughly clean and ush any system that used glycol before installing new Boiler.

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

NOTICE

Do not expose boiler and condensate piping to freezing temperatures.

FIGURE 5-1 Safety Relief Valve (Viewed from rear of boiler)

Shown 50/75/100 Model

Safety Relief

Valve

5.3 Safety Relief Valve

NOTICE

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

• Install safety relief valve. See gure 5-1

• Install safety relief valve with spindle in vertical position.

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

• Install discharge piping from safety relief valve. See

gure 5-2.

• Use ¾" or larger pipe.

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

Position Safety Relief Valve to provide

space for discharge piping.

Page 14

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

• 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).

• Arrange piping to prevent water dripping onto boiler.

5.4 Trim Piping

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

with boiler. See gure 5-3.

• Protect chassis grommets from heat damage while soldering.

• Drain Valve. Install drain valve using, tee and adapter

provided with boiler. See gure 5-3.

5.5 System Piping

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

Check Local Codes

For Maximum

Distance To Floor

FIGURE 5-3 Temperature Pressure Gauge and Drain Valve Installations

Temperature Pressure

Gauge shown at

System Supply

Connection

Drain Valve shown

at System Return

Connection to Boiler

• Systems with automatic ll valves require back ow prevention device.

• Single boiler system. See gures for general guidance. Additional considerations:

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

• Boiler control allows domestic hot water pri o riti zation. Function could be lost if central heating pump not directly connected to control system.

• Multiple boiler system. general 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.

• Low Water Cutoff (LWCO) probe location. See gures 5-4A for minimum probe height. Do not install shutoff valve between boiler and LWCO probe.

• If boiler is below radiation level, use gure 5-4A.

Boilers above radiation level use gures 5.4B thru

5.4D.

• If using separate stand pipe, install air vent using tee to avoid nuissance shutdowns.

• See gures 5-4B, 5-4C and 5-4D for suggested probe location alternatives.

• Arrange piping to prevent water dripping onto boiler.

See gures 5-8A, B & C

5-4A,

5-5, 5-6, 5-7A & B

for

Page 15

5 - HYDRONIC PIPING

FIGURE 5-4A System Piping - LWCO Probe Location

Safety Relief Valve

MINIMUM ACCEPTABLE HEIGHT FOR

LWCO PROBE

WALL

MOUNTED

ONLY

FIGURE 5-4C LWCO Suggested Probe Location

Shown 50/75/100 Model

Air Vent

Safety Relief Valve

LWCO

MINIMUM

ACCEPTABLE

HEIGHT FOR

LWCO PROBE

Pipe to

condensate

drain

System

Supply

Pipe to

condensate

drain

FIGURE 5-4B LWCO Suggested Probe Location

Shown 50/75/100 Model

LWCO

Safety Relief Valve

Air Vent

System

Return

MINIMUM ACCEPTABLE HEIGHT FOR

LWCO PROBE

Stand

Pipe

Valves

System

Supply

FIGURE 5-4D LWCO Suggested Probe Location

Shown 50/75/100 Model

LWCO

MINIMUM ACCEPTABLE HEIGHT FOR

LWCO PROBE

Air Vent

Safety Relief Valve

System Return

Valves

System

Supply

12"

Max.

System Return

System

Supply

12"

Max.

System Return

Page 16

5 - HYDRONIC PIPING

NOTICE

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

NOTICE

Arrange piping to prevent water dripping onto boiler.

Primary Loop Equivalent Length Calculation & Pump Selections may be found on pages 84 thru 87 of this

manual.

Piping Legend

Single Boiler

Multiple Boilers

Table 3 - System Piping Congurations

Primary/Secondary

Two Pipe Zoned System

Primary/Secondary Pumping

Primary/Secondary

Two Pipe Zoned System

Primary/Secondary Pumping

With Zone Valves gure 5-5

With Zone Pumps gure 5-6

Without DHW Tank

With DHW Tank gure 5-7B

With Zone Valves gure 5-8A

With Zone Pumps Not Shown

Without DHW Tank

With DHW Tank

gure 5-7A

gure 5-8B

gure 5-8C

Page 17

5 - HYDRONIC PIPING

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

DHW Pump

CH/System

Pump

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

DHW Pump

Zone

Pump

Primary Loop Equivalent Length

Calculation & Pump Selections may

be found on pages 84 thru 87 of this

manual.

Page 18

5 - HYDRONIC PIPING

FIGURE 5-7A Single Boiler Using Primary/Secondary Pumping

12"(305mm)

Maximum

separation

closely spaced tees

in primary system loop

CH/System

Pump

Limit length

5' (1.6m)

FIGURE 5-7B Single Boiler Using Primary/Secondary Pumping With DHW Tank

Heating Load Heating Load

12"(305mm) Maximum separation

Closely spaced

tees

in primary

system loop

Heating Load

CH/System

Pump

Limit length

5' (1.6m)

Primary Loop Equivalent Length

Calculation & Pump Selections may

be found on pages 84 thru 87 of this

manual.

Page 19

5 - HYDRONIC PIPING

FIGURE 5-8A Multiple Boiler Primary/Secondary 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)

Up to 16

boilers

(See Multiple Boiler Guide)

Page 20

5 - HYDRONIC PIPING

FIGURE 5-8B Multiple Boilers Using Primary/Secondary Pumping

12"/305mm Maximum Separation

Closely spaced tees

in primary system loop

CH/System

Pump

System

Temperature

Sensor

Size common piping

per maximum heat

capacity of entire

system

Limit

length to

5' (1.6m)

Up to 16

boilers

Page 21

5 - HYDRONIC PIPING

5-8C Multiple Boilers Using Primary/Secondary Pumping with DHW Tank

12"/305mm Maximum Separation

Closely

spaced tees

in primary

system loop

CH/System

Pump

System

Temperature

Sensor

Size common piping

per maximum heat

capacity of entire

system

Limit

length to

5' (1.6m)

Up to 16

boilers

Page 22

6 - COMBUSTION AIR AND VENT PIPING

6.1 General

This boiler requires a dedicated 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 deciencies

which could cause an unsafe condition.

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

replace dampers.

• Turn on appliance being inspected. Follow lighting instructions. Adjust thermostat so appliances will operate continuously.

• Test for spillage at draft hood relief opening after 5

minutes of main burner operation. Use ame of match or

candle, smoke from cigarette, cigar or pipe.

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

• 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.

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® ,

(Polyphenolsulfone) in venting systems shall be prohibited.

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

WARNING

ANSI/ASTM D1784/

F441

UL 1738

ULC S636-08

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.

Page 23

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 Polypropylene 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.

• Certied vent system components must NOT be interchanged with other vent systems or unlisted pipe/

ttings.

• Canadian installations only. All venting material, primer and glue must be listed to ULC S636.

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

6.5 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.

• Follow gures 6-1 thru 6-11 for termination of combustion air and vent pipes.

• 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.

WARNING

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

Table 5 - Combustion Air and Vent Piping Length

Minimum/Maximum Vent Lengths

2” Pipe 3” Pipe

Model 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)

50 ft.

(15.2 m)

Table 6 -Equivalent Length of Venting Components

Equivalent Length of Venting Components

Component Feet Meters

90° Elbow 5 1.6

45° Elbow 3½ 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 2⅝ 0.8

6 ft.

(1.8 m)

100 ft.

(30.5 m)

6 ft.

(1.8 m)

100 ft.

(30.5 m)

Page 24

6 - COMBUSTION AIR AND VENT PIPING

6.6 Venting Congurations

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

corresponding gures.

Table 7 - Venting Congurations

Flue Gas Location

Roof

Combustion Air

Location

Roof

Side Wall Single Pipe gure 6-8

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

Inside Air Single Pipe gure 6-9

Roof Single Pipe gure 6-10

Two Pipe gures 6-2, 6-3

Side Wall

Concentric gures 6-4, 6-5, 6-6

Inside Air Single Pipe gure 6-11

Page 25

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-1 Two Pipe Roof Vent

3" (76mm)

Minimum

12" (305mm)

Minimum

8" (203mm)

Minimum

Vent Combustion

Air

12" (305mm) US,

18" (457mm) Canada

Minimum Above

Anticipated Snow Line

15" (381mm)

Maximum

Roof Line

Roof

Terminations

 3" (76mm) Minimum horizontal

separation between combustion air 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

3" (76mm)

Minimum

Separation

See Snow & Ice

Page 29

FIGURE 6-3 Two Pipe Side Wall Vent (Multiple Appliances.

12" (305mm)

Overhang

12" (305mm) Minimum

Separation Between

Bottom Of Combustion Air

Intake And Bottom Of Vent

Vent

Combustion Air

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) Minimum separation

between bottom of combustion air intake and bottom of vent.

 Multiple terminations as shown in

6-1, 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.

(13mm/m) outside exposure back to boiler to ensure proper condensate drainage for horizontal runs.

See Snow & Ice

Page 29

Combustion Air

Vent

Page 26

6 - COMBUSTION AIR AND VENT PIPING

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

Appliances

1"(2.54cm)

1" (25.4mm)

Maximum

Vent

Combustion

Air

FIGURE 6-6 Concentric Terminal Connection

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

PVC intake/combustion air

Roof

1" (25mm)

Maximum

* See Note

Below

Combustion

Air

Overhang

12" (305mm) Minimum

36"(0.9m(914mm)

Vent

Maintain 12"(30cm) US

(18"(46cm) Canada)

highest anticipated

Minimum Clearance Above

snow level or grade

Highest Anticipated Snow

(28m)) Minimum

Maintain 12"

clearance above

Level Or Grade

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

intake to prevent ue gas recirculation.

Note: Securing strap must

be eld installed to prevent

movement of termination kit in side wall

Combustion Air

OD 3½" (

89mm)

- *2" (

51mm)

kit

OD 4½" (114mm) - 3" (77mm) kit

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

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

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

**See

Note

*2" (

51mm)

Diameter = 41" Length (1.1m)

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

1"(25.4mm) Maximum

Vent

Combustion Air

* Note: 2" (51mm) For use with models 050/075/100. 3" (77mm) For use with models 075/100/150/200

Page 27

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-7 Concentric Roof Terminal

Vent

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

Maintain 12"(305mm) US

(18"(457mm) Canada)

minimum clearance above

highest anticipated snow

level 24" (610mm) above

roof

Support

(eld supplied)

Combustion Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

minimum clearance above

highest anticipated snow

level 24" (610mm) above

roof

Combustion Air

Concentric

Vent Roof

Terminations

Grade, Snow

& Ice

 Glue inner vent pipe to prevent

recirculation.

 Maintain 12" (305mm) US

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

 Support must be eld installed to

secure termination kit to structure.

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

(12.7mm - 762mm).

 Vertical concentric vent system can be

installed in unused masonry chimney.

 Contact Technical Support 800-

325-5479 for questions regarding installation or use.

Terminate vent system bottom, minimum 12" (305mm) 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.

12" (305mm) Minimum anticipated snow line

Ground Level

FIGURE 6-9 Flue on Roof, Combustion Air

Vent

Combustion

Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

minimum clearance above

highest anticipated snow level

maximum 24" (610mm) above

roof

24" (610mm) * Minimum Length

Doors &

Windows

* See Tables

4 & 5

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

Combustion air and Vent Piping Length Page 23 .

Page 28

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)

minimum clearance

above highest anticipated

snow level 24" (610mm)

maximum above roof

Vent

12" (305mm) Minimum anticipated snow line

Ground Level

Congurations of single pipe vent with ue on sidewall, requires tee as vent terminal. See gures

6-10 and 6-11.

NOTICE

FIGURE 6-11 Flue on Sidewall, Inside Combustion Air

Vent

Combustion

Air

12" (305mm) Minimum anticipated snow line

Ground Level

Page 29

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

Combustion air and vent termination

Doors &

Termination must be

12" (305mm) from

or below doors,

windows or gravity

inlet.

12"

(305mm)

Minimum

FIGURE 6-13

Termination

Windows

Condensate

must be 12" (305mm) minimum 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)

Termination

3' (0.9m) [If located

Forced Air

Inlet

FIGURE 6-14

3' (0.9m) Minimum

10' (3m) Minimum

minimum within 10' (3m) of forced air inlet]

Forced Air

Inlet

Grade, Snow

& Ice

"L"

Corner

minimum above and 10' (3.0m) minimum from any forced air inlet (except boiler’s combustion air inlet).

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

Page 30

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' (1.8m) horizontally from, no case above or below, electric meters, gas meters, regulators, and relief equipment, or under deck or porch.

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

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

Multiple

Family

Dwellings

7' (2.1m)

Minimum

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

Stones,

Balls, Etc.

Vapors

Eddy, Flue

Gases

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

Position termination where vent vapors are not objectionable.

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

Page 31

6 - COMBUSTION AIR AND VENT PIPING

6.8 Multiple Boiler Venting Installation

• Multiple boiler application boiler shall be vented individually.

• Follow guidelines as described in gures 6-1 through 6-7.

6.9 Condensate Piping

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

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

• Canada - CSA or ULC certied PVC/CPVC pipe,

ttings and cement.

• Attach condensate trap provided with boiler and eld sourced piping to condensate drain at bottom of boiler.

See gure 6-17.

• 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.

FIGURE 6-17 Condensate Drain

Condensate Trap

(eld installed)

on condensate drain

pipe

Do not place in environment

with temperatures below

freezing. Condensate outlet

will block if condensate

End must be

left open.

freezes.

Page 32

7 - GAS SUPPLY PIPING

FIGURE 7-1A Gas Connection (at top of Boiler)

50/75/100 Shown

Attach Supplied Gas

Shutoff Valve (shown

in open position)

FIGURE 7-1B Gas Connection (at top of Boiler) 150/200 Shown

Attach Supplied Gas

Shutoff Valve (shown

in open position)

3/4"

Nipple

1/2"x 3/4"

Increaser

Gas

Connection

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

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

• Use thread (joint) compound (pipe dope) suitable for

liqueed petroleum gas.

• Install manual main shutoff valve outside of jacket. See

gures 7-1A and 7-1B.

Gas

Connection

NOTICE

Use two (2) wrenches when tightening boiler

ttings and pipes. Boiler's internal piping can be

damaged if subjected to excessive torque.

7.2 Conversion Kit Instructions

• See Gas Conversion Kit Instructions included with Boiler.

Table 8 - Gas Supply Pressure

Gas Supply Pressure

MODEL

050

075

100

150

200

Note: See Glossary - Piping Table 14

Natural Gas Propane

Min. Max. Min. Max.

3.0" w.c.

(0.7 kPa)

13.5" w.c. (3.3 kPa)

5.0" w.c.

(1.2 kPa)

13.5" w.c. (3.4 kPa)

Page 33

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, thru

7-4.

•

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.

•

Correct leaks immediately and retest.

FIGURE 7-2 Manual Gas Shutoff Valve - Outside Boiler Jacket (view from top rear of boiler)

Shown 50/75/100 Model

Supplied Manual

Main Gas

Shutoff Valve

(shown in open

position)

FIGURE 7-3 Gas Shutoff Valve - OPEN PARALLEL TO PIPE

OPEN

FIGURE 7-4 Gas Shutoff Valve - OFF PERPENDICULAR TO PIPE

PIPE

GAS SHUTOFF VALVE

PIPE

GAS SHUTOFF VALVE

Page 34

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)

• Six knockouts located on bottom of chassis.

A. Four 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

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

Load Amps) exceeds maximum allowable current draw. See Figure 8-3 and Table 9.

B. Connect pump to line voltage terminal strip CH

PUMP L,N,G.

• Domestic Hot Water Pump

A. Isolate pump from control module if pump FLA

exceeds maximum allowable current draw. See Figure 8-3 and Table 9.

B. Connect pump to line voltage terminal strip DHW

PUMP L,N,G.

• Primary Pump

A. Isolate pump from control module if pump FLA

exceeds maximum allowable current draw. See Figure 8-3 Table 9.

B. Connect pump to line voltage terminal strip primary

pump, L, N, G.

5.26"(134mm) 50-100mbh

8.17"(208mm) 150/200mbh

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.

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

High Voltage

Knockouts

Back of Boiler

FIGURE 8-2 Line Voltage Connections

Table 9 - Maximum Allowable Current Draw

MBH CH

PUMP

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.

Maximum allowable total amperage of all 3 pumps must not exceed 20 amps.

1 A* 1 A* 10 A**

10 A** 10 A** 10 A**

DHW

PUMP

PRIMARY

PUMP

grommets when using

these knockouts)

NOTE

*Powered by

Control Board

**Powered by

installed 10 Amp

relay

Page 35

8 - ELECTRICAL CONNECTIONS

• Argus Link (Multiple boiler applications only)

• 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.

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.

• Low Water Cutoff (LWCO)

Connect LWCO switch leads to terminals provided. See Figures 14.1 thru 14.4 for wiring diagrams. Provide power to LWCO per manufacturer's instructions.

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 8-3 Isolation Relays for CH System Pump and DHW Pump

DHW

Pump

DHW Pump Relay

120VAC

coil

CH Pump Relay

120VAC

coil

NOTICE

Boiler transformer does not have adequate VA to power accessories, including LWCO.

FIGURE 8-4 External Connections (Do not apply external voltage to external terminals.)

Page 36

9 - START UP PROCEDURE

NOTICE

IMPORTANT: Condensate trap must be manually

lled with water at initial start up.

FIGURE 9-1 Condensate Drain Assembly

Condensate

Collector

Remove Spring

Tension Clip

Remove Hose

Barb

Attach Supplied

Condensate Trap

to Hose Barb

9.1 Fill Boiler With Water And Purge Air

NOTICE

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

system until clean.

• Flush heating system, including all heating zones.

• Fill boiler with potable water.

•

Fill boiler and system piping with water (or antifreeze-water solution, if used). See antifreeze information page 13. Purge air from boiler using safety relief valve. 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.

Secure Hose onto

Hose Barb with

Spring Tension

Clip

9.2 Fill Condensate Trap with Water

• Remove spring tension clip from clear hose attached to

barbed tting at bottom of boiler chassis.

9-1.

• Disconnect hose from barbed tting.

• Remove barbed tting from boiler.

• Attach supplied condensate trap to barbed tting using pipe tape.

• Fill trap through tting with approximately 2 cup ml)

water.

• Place barbed tting back through bottom of chassis.

• Reassemble clear tube to barbed tting.

• Secure tube to barbed tting with spring tension clip.

See gure 9-1.

See gure

(473

Page 37

9 - START UP PROCEDURE

FIGURE 9 -2 User Interface

Table 10 - Default Parameters

Control Parameter

User

Installer

* List parameters when factory default settings are changed.

Settings

Boiler

Conguration

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

Required Low Water Cutoff (Field Supplied) - -

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

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 2 0/2

DHW Maximum Priority Time 30 Minutes 1-60 minutes

9.3 Program Boiler Control

Key Description

- Manual Lockout Reset

- Enter/Exit user menu

- Go to previous screen

- Select a menu item

- Conrm new parameter value

- Scroll up to next menu item

- Increase value

- Scroll down to next menu item

- Decrease value

Boiler is factory programmed with following factory default settings, Table 10.

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 factory default parameters are

changed.

Factory Default

Setting

Standard Metric Standard Metric

Setting Range

-51-

25°C

*Actual

Parameter

Settings

Page 38

9 - START UP PROCEDURE

9.4 Boiler Start-up and Operational Test

1. Verify air is purged from hydronic piping

2. System test pumps - verify each pump is

operational

3. Verify gas piping

•

Conrm pressure test. See section 7.3 page 33.

•

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.

•

Operate boiler for 10 minutes, prior to sampling with analyzer.

•

Set boiler on high re. See Appendix A, Installer

Menu, system test page 75.

•

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 table. Adjust input rate if

needed using Table 11 below.

Table 11 - Rate @ High Fire

Rate @ High Fire

Size From To

050 45 51

075 65 76

100 90 102

150 140 153

200 185 204

Page 39

9 - START UP PROCEDURE

Natural Gas and Propane

3. Measure CO

at high re and compare to table.

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

High Fire Combustion - 50/75/100/15/200 MBH

Gas

Natural Gas 9.0 9.5% 9.5%

Propane 10.0 11.0 11.0%

Low Fire Combustion - 50/75/100/15/200 MBH

Gas

Natural Gas 8.8 9.3% 9.0%

Propane 9.8 10.5 10.0%

Min. Max. μA

Design

Target

Design

Target

<200ppm 6.5-7.5

<100ppm >3.3

NOTICE

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

Flame Signal

FIGURE 9-3 Gas Valve - Models

1/4" Flat Head

Screwdriver

Natural Gas only

4. Measure input. Compare to table 11. Continue to

measure input and CO2 until both measured values

are within range specied in tables.

Propane Gas

Most propane systems do not have ow meters.

1. Check CO

11.0%.

•

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

•

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

. Propane should be between 10% and

•

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.

Verify Burner, Proper Operation

1. Inspect burner ame through Sight Glass. See

gure 11-1.

2. Operate boiler through several heating cycles,

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

Page 40

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

Shown 50/75/100 Model

FIGURE

9-4 Combustion Analyzer Port

Combustion

Analyzer Port

9-5 Burner Flame

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 9-6.

3. Disable secondary system pumps attached to

system.

4. Establish call for heat. Jump CH 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

Control

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

below limit, boiler will automatically rere then

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

Shut off burner E39 "Flue Temperature Sensor".

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

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

Program Boiler

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

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

system to verify operation. See gure 9-6 page 41.

7. Verify eld sourced external low water cutoff

(LWCO) is functional.

Flame

Burner

Flame

Look for BLUE ame with slight

YELLOW tips evenly spaced

around burner

Page 41

9 - START UP PROCEDURE

FIGURE

9-6 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 afx in

conspicuous location adjacent to boiler.

Page 42

10 - OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

If you do not follow these instructions

exactly, a re or explosion may result

causing property damage, personal injury or loss of life.

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

light this burner by hand.

• Before operating smell all around appliance area

for gas. Be sure to smell next to oor because

some gas is heavier than air and will settle to the

oor.

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

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

service technician. Force or attempted repair may

result in re or explosion.

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

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

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical 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 to closed position. Handle should be perpendicular to gas pipe.

• Replace front jacket panel.

FIGURE

10-1 Gas Shutoff Valve -

Shown 50/75/100 Model

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 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 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.

O PE N

POSITION

C LO S E D

POSITION

Page 43

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

qualied service agency at least once every 12

months to assure safe, trouble free operation and

maximum efciency.

FIGURE 11-1 Sight Glass -

Shown 50/75/100 Model

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 clean (if necessary) by following instructions in “Annual Examination and Cleaning of Boiler Components” in this section.

• 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:

• system 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 eld sourced low water cutoff according to relief valve manufacturer instructions.

• Check ame signal with user interface. Flame signal should be 6.5 micro amps or higher at 100% ring rate

( High re). Flame signal should be 3.3 micro amps or higher at 1% (low re).

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

• Check heating system expansion tank.

Page 44

11 - GENERAL MAINTENANCE AND CLEANING

Figure 11-2 Condensate Trap

Coupling to

Connection to

Flue Pipe

Condensate Tubing

Connection at

Bottom of Condnsate

Collector

1/4-20 Hex

Flange Nuts at

Bottom of Heat

Echanger

Vent Temperature

Sensor

Field Installed

Supplied

Condensate Trap

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 qualied service agent. Boiler owner shall not

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

11.3 Annual Inspection and Cleaning of Boiler

Components

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

• Burner and heat exchanger inspection and cleaning.

• Remove gasket and burner. Allow burner to clear top lip of chassis.

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

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

Inspect burner for foreign matter in ame ports or

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

• Clean heat exchanger with low pressure water spray.

Use exible handle nylon brush to loosen sediment

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

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

• Clean condensate collector if signicant debris found in heat exchanger. A. Expand upper spring tension clip of condensate trap

using hose clamp pliers. Disconnect condensate

trap from condensate collector. See gures 11-2.

B. Disconnect wire harness from vent temperature

s e n so r . S ee  g u re 1 1- 2.

C. Loosen upper hose clamp securing condensate

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

extension.

D. Remove ¼-20 hex ange nuts securing condensate

collector to heat exchanger using 7/16" deep well

socket. See gures 11-2.

E. Remove condensate collector assembly from heat

exchanger and ue pipe.

F. Flush collector and condensate trap with water.

• Follow Burner Inspection Kit instructions to reassemble boiler and resume operation.

Page 45

Table 13 - Sea Level Ratings

12 - RATINGS AND CAPACITIES

SEA LEVEL RATINGS

NATURAL AND PROPANE GASES

Boiler Input Rate

Size

Maximum Minimum

050 075 100 150 200

(1)

1000 Btu/hr (British Thermal Units Per Hour)

(2)

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

procedures.

(3)

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

(MBH)

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 95.0

(1)

12.1 Ratings and Capacities

• Constructed and hydrostatically tested for maximum allowable working pressure of 150 psig (pounds per square inch gauge) (1035 kPa) in accordance with ASME Boiler and Pressure Vessel Code, Section IV, Rules for Construction of Heating Boilers.

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.

Page 46

13 - TROUBLE SHOOTING

If boiler does not function.

Remove Jacket.

Is User Interface lit?

Check for 120 vac in boiler high

voltage terminal box.

Is 120 vac present?

Check power supply to boiler. Check breakers,

disconnect and

emergency switch for

voltage. Fix or repair

external wiring.

Remove User Interface from

base. Using Digital Voltmeter

check for 25 to 30 Vdc. Is voltage

YES

Locate fuse holder on front of

control and pull to check fuse.

Spare fuse located on controller.

Make sure all wire harness plugs

are properly pushed in. Release

plug lock with nger, remove

and reconnect all 7 plugs. Check

wiring from User Interface to Low

Voltage Terminal Strip including

checking continuity of wires. Does

User Interface Display work?

present?

YES

Does display show "Standby - No

Demand?

YES

There is no call for

heat or hot water.

Check thermostat.

Outdoor air sensor

may be faulty - boiler

in warm weather

shutdown.

GO TO NEXT PAGE

Replace Control Module Replace User Interface

YES

Page 47

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 50

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 51

Blower speed does not reach speed calculated by Control Module.

Control Module internal error.

Go to Page For

Troubleshooting

Go to Page 49

Go to Page 52

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 53

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 54

Control Module internal error.

Replace Control

Module

Replace Control

Module

Blocking Error

REFLO too LO

External voltage supplied to DHW T-T or CH T-T terminals. Eliminate voltage using dry

contact relay.

Flame detected when gas valve is closed. Go to Page 54

Page 48

13 - TROUBLE SHOOTING

Screen Display Explanation

Low water cutoff sees no water. Go to Page 55

Go to Page For

Troubleshooting

Blocking Error

Flue Gas Error

Flue temperature sensor sees temperature higher than 200°F.

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

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

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

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

Boiler power supply ground wire is not grounded.

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

Go to Page 56

Go to Page 57

Replace Control

Module

Go to Page 57

Go to Page 58

Go to Page 59

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 59

Go to Page 60

Go to Page 61

Go to Page 62

Flue temperature sensor is shorted. '0' Ohm Go to Page 62

Reset button was pressed too many times.

Error Clears in 1-2

minutes

Fault detected in blower motor system. Go to page 58

Page 49

_ _ _ _ _

Lockout Alarm A 0 0

Blocking too long error

Enter Installer Menu, Boiler

Status. Scroll to

Lockout Alarm or Blocking Error.

Diagnose corrective action using

appropriate Troubleshooting Tree.

13 - TROUBLE SHOOTING

Replace Supply Sensor

hot?

YES

pipe at top of boiler)

Is supply pipe (copper

available?

YES

Unplug connector on supply

sensor. Measure continuity of high

two purple wires. Is continuity

between two pins connected to

limit sensor (close/open signal)

Is wire harness

connected to both

Gas Valve and J13

Boiler has been dry

red. System has too

Connect harness

Purge air from system,

much air. Close manual

gas valve (shut off gas).

Module?

YES

connector on Control

Disconnect J13 connector on

gas valve. Measure resistance

across top and bottom pins (1

wait for system to cool.

Control Module

wire have continuity

Gas Valve. Does each

Disconnect harness from

YES

between Gas Valve and

1.0 and 1.2 kΩ?

YES

& 5). Is resistance between

Module

Replace Gas Valve Replace Harness

Replace Control

most recent

Page 50

13 - TROUBLE SHOOTING

Page 51

13 - TROUBLE SHOOTING

Is Heat Exchanger surface

YES NO

heat exchanger) hot?

Is boiler supply pipe (above

Let all zones

hot?

temperature

run until water

YES

drops.

switches

and surface

temperature

Check high limit

cool down.

Wait for boiler to

Replace Broken Switch

YES

Error shows when safety circuit is

open. Remove J13 connector from

pink wires, is continuity available?

between two pins connected to two

control module. Check for continuity

Is continuity available?

YES NO

between two pins on sensor (two

Unplug molex connector on supply

Replace Control Module

temperature sensor. Check continuity

pins connected to two pink wires) .

on two pink wires on J13

Check for loose connections

safety temperature switch.

connector, supply sensor, and

YES

Boiler red without enough water ow

through heat exchanger. Heat exchanger

Fix Loose Connections Replace Wire Harness

Check the following:

• Air in system?

• Verify water ow in system piping

exchanger temperature switch is open.

is over heated. Either high limit or heat

• Flush system if water is dirty.

Page 52

13 - TROUBLE SHOOTING

Page 53

Disconnect harness from High

Temperature Supply Switch and

Control Module J13.

Continuity from J13-5 to Switch

1? Continuity from J13-6 to

Switch 3 (continuity of the two

purple wires) ?

13 - TROUBLE SHOOTING

Page 63 of this manual

See Thermistor Resistance Chart -

purple wires?

Control Module J13.

Disconnect harness from High

Check continuity of both purple

Temperature Supply Switch and

wires. Continuity available for both

Page 54

Inspect burner through sight

glass. Is flame present?

Blocking Error E 3 5

False flame detect

Turn Gas Shutoff

Valve clockwise to

closed position.

Follow instructions

TO TURN OFF GAS

TO APPLIANCE.

Replace Gas Valve.

13 - TROUBLE SHOOTING

3.7µA

ring rate)?

Status, Flame Signal.

to initiate boiler operation.

Follow Operating Instructions

Is ame signal greater than

Enter Installer Menu, Boiler

YES

(Boiler may be running at any

Replace Flame

Sensor and Burner

Module

Replace Control

Module

NOYES

Replace Control

_ P _ _ _

shutoff valve.

Follow instructions

Turn off manual gas

Gas Valve.

APPLIANCE. Replace

TO TURN OFF GAS TO

Page 55

13 - TROUBLE SHOOTING

manufacturer's

Check LWCO per

instructions repair

Disconnect LWCO from low

voltage terminal strip. Check for

continuity through LWCO safety

circuit. Continuity?

YES

or replace.

YES

Replace Control Module

YES

I s  l e d S o u r c e d

LWCO installed?

Check low voltage terminal

strip connections. Verify J16

connector is connected. Verify

connections.

Install LWCO wire to low

Voltage terminal strip LWCO

Continuity?

and J16-1 and J16-4.

continuity between low voltage

terminal strip LWCO connections

Replace Wire Harness

Page 56

13 - TROUBLE SHOOTING

gas temperature through sampling

port. Is the measured temperature

Use thermal couple to measure ue

and ue temperature reading on User

YES

Interface signicantly 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,

Page 57

13 - TROUBLE SHOOTING

YES

sensor (2 Brown Wires)?

Is correct harness connected to return

Correct wiring

antifreeze solution.

YES

Is Primary Pump

properly oriented?

YES

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,

orientation

Install Primary

Pump in proper

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

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.

Repair all leaks.

Check for leaks.

Remove all liquid

Replace Control Module

Page 58

Is power supply circuit breaker

Replace circuit

13 - TROUBLE SHOOTING

+/- 2%

Blocking Error E 4 5

Net frequency error

_ P _ _ _

Is power supply between 59

and 61 Hz?

YES

stabilized power

Provide frequency

supply rated at 60 Hz

loose or faulty?

YES

Is field wiring loose or faulty?

breaker

Module

Replace Control

Correct wiring

YES

blower motor system.

These error messages are displayed

Check wire connector to blower.

when the control board detects fault in

Check connector J9 on control board.

YES

Is any connection loose?

this correct the problem?

Replace blower motor. Does

Boiler is operating

Fix the connection.

Replace Control Module

properly

Page 59

13 - TROUBLE SHOOTING

Replac

Module J5?

Water Sensor?

YES

Blocking Error E 5 1

Supply Sens Open

_ P _ _ _

Is harness plugged into Supply

Is harness plugged into Control

Insert Harness

YES

Disconnect J5 from Control

Module. Using digital meter

and Sensor. Continuity?

measure check continuity of

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

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

YES

connected to High Voltage

Is field grounding conductor

Blocking Error E 4 6

Faulty ground

Terminal Strip 120 VAC (G)?

_ P _ _ _

Connect ground

Disconnect field wiring. Is

continuity between field wiring

neutral and ground less than

10 ohms?

YES

conductor

Correct faulty ground

e Control

Module

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 1K ohms

2K to 3K ohms

150 to 200

130 to 150

Page 63 of this manual

54 to 66

66 to 94

See Thermistor Resistance Chart -

Page 60

13 - TROUBLE SHOOTING

Replace Control

Control Module J5-4 and J5-12

Measure Return Temperature

Sensor resistance with digital

meter. Estimate Sensor

temperature. Do temperature

and resistance fall within

ranges shown in chart?

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

Page 63 of this manual

150 to 200

130 to 150

Blocking Error E 5 2

Return Sens Open

_ P _ _ _

Temperature Sensor?

Is harness plugged into Return

Is harness plugged into Control

Module J5?

YES NO

Insert Harness

wires between Return

Check continuity of brown

Temperature Sensor and

Continuity?

YES NO

Return Temperature Sensor

Replace Wires

Sensor resistance with

digital meter. Estimate

Measure Return Temperature

Sensor temperature. Does

See Thermistor Resistance Chart -

54 to 66

32 to 54

shown on chart?

YES NO

temperature fall within ranges

66 to 94

Replace Return

Temperature Sensor

Module

Page 61

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

Page 63 of this manual

See Thermistor Resistance Chart -

Supply Water Temperature Sensor

Page 62

13 - TROUBLE SHOOTING

Blocking Error E 6 0

Return sens shorted

Disconnect harness from

Return Temperat

Measure resistance across

sensor terminals. Is resistance

Replace Return Water

NOYES

Replace 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

150 to 200

130 to 150

Blocking Error E 6 5

Flue Sens Shorted

_ P _ _ _

Vent Temperature Sensor.

Disconnect wire harness from

Does resistance match

Measure Sensor resistance.

estimated flue temperature?

in blue wires?

Disconnect harness from

Control Module J5. Continuity

YES NO

Replace wires

Replace Control

NOYES

ohms?

Module

Replace Control

Vent Temperature Sensor

Module

Page 63 of this manual

54 to 66

32 to 54

66 to 94

See Thermistor Resistance Chart -

_ P _ _ _

ure Sensor.

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 wires

Page 63

Thermistor Resistance Chart

13 - TROUBLE SHOOTING

Temperature °CTemperature

°F

0 32 36100

5 41 28590

10 50 22790

15 59 18290

20 68 14770

25 77 12000

30 86 9805

35 95 8055

40 104 6653

45 113 5524

50 122 4809

55 131 3863

60 140 3253

65 149 2752

70 158 2337

75 167 1994

80 176 1707

85 185 1467

90 194 1265

95 203 1095

100 212 952

Resistance

Page 64

14 - WIRING DIAGRAM

14.1 Connection Diagram - 050/075/100 MBH

Page 65

14 - WIRING DIAGRAM

14.2 Schematic Diagram of Ladder Form - 050/075/100 MBH

Page 66

14 - WIRING DIAGRAM

14.3 Connection Diagram - 150/200 MBH

Page 67

14 - WIRING DIAGRAM

14.4 Schematic Diagram of Ladder Form - 150/200 MBH

Page 68

15 - GLOSSARY

• ANSI - American National Standards Institute, Inc.

• GAS PIPE SIZES - Table 14

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

relating to LIFE SAFETY and BUILDING CONSTRUCTION within a community.

• Btu - Abbreviation for British Thermal Unit. Quantity of heat required to raise temperature of 1 pound of water 1°F.

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

of gas and air, to combustion zone.

• 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,

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

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

plastered.

• CONDENSATE - Liquid separated from ue gas due to

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.

• DRAFT - Pressure difference causes gases or air to ow through a chimney, vent, ue or appliance.

• 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

• HIGH-VOLTAGE - Circuit involving potential of not more than 600 volts and having circuit characteristics in excess of those of low-voltage circuit.

• IGNITER - Device utilizing electrical energy to ignite gas at main burner.

• LEAK CHECK - Operation performed on gas piping system to verify system does not leak.

• LOW WATER CUTOFF - Device constructed to automatically cut off fuel supply when surface of water in boiler falls to lowest safe water level.

• LOW-VOLTAGE - Circuit involving potential of not more than 30 volts.

• METRIC GAS METERS

MBH =

127,116 x cu meters

Seconds

For example: Gas Meter measures 0.1 cubic Meters in 100 seconds

MBH =

127,116 x 0.1

100

= 127 MBH

• PRESSURE TEST - Operation performed to verify gas tight integrity of gas piping following its installation or

modication.

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

• FLUE GASES - Products of combustion plus excess air

in appliance ues or heat exchanger.

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

Page 69

15 - GLOSSARY

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

or company engaged in and responsible for:

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

• Experienced in such work.

• Familiar with all precautions required.

• Complies with all requirements of authority having jurisdiction.

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

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

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

• VENT - Passageway used to convey ue gases from

appliance vent connector to outdoors.

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

removing ue or vent gases.

Page 70

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

- Conrm new parameter value

- Scroll up to next menu item

- Increase value

- Scroll down to next menu item

- Decrease value

Operation with LCD character display module

1.3 Status Indication

The following status screens can be displayed:

Boiler Status Indicator

F = Flame Detected

SERVICE Reminder

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

Combustion Air Blower Speed Indicator

Service Reminder Indicator Boiler in Standby Mode Boiler Supply Water

Temperature Indicator.

Boiler Running in Central Heat mode

Boiler Running in DHW mode

Lockout Alarm Indicator

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

Blocking Error

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

Page 71

1.4 Sequence of Operation

Operational State User Interface Display Explanation

Heat

Demand?

Yes

APPENDIX A - CONTROL MODULE

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

DHW CH

Pump on

Supply

Temperature

<Setpoint?

Yes

15 Second

Prepurge

Ignition

Sparking

After 2 seconds

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.

Page 72

1.4 Sequence of Operation

Operational State User Interface Display Explanation

APPENDIX A - CONTROL MODULE

After 2 seconds

Flame

Detected?

Gas Valve

Energized

After 3 seconds

Flame

Detected?

Yes

Heat Demand

Met?

Yes

Lockout

Error A21

Note:

5 Ignition

trials,

then

Lockout A01

30 second

post purge

Yes

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.

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.

Simultaneous

DHW + CH

Demand?

Priority

Yes

DHW

Mode

See Max DHW

Priority Time

Setting

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

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

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

Please refer to section Appendix A section 1.5 for more information.

Page 73

1.5 User Menu

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.

STANDBY

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

User Menu structure includes:

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

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

• ‘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).

Explanation

Boiler Status

Supply Temperature set point displayed.

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

Note:

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

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

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

Operational status of pump system also shown.

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

Page 74

APPENDIX A - CONTROL MODULE

User Interface Display

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

Settings

Explanation

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

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

Note:

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

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

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

ser interface temperature unit of measure is selected using

‘Change Temperature Units’ screen.

Fahrenheit and Celsius available.

Page 75

APPENDIX A - CONTROL MODULE

User Interface Display

Installer Menu

Explanation

Installer Menu structure includes:

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

• Installer 'Menu' can be accessed by 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 – Monitors detail boiler status

parameters such as ame signal, fan speeds and stored

error codes.

• ‘Boiler Cong’ submenu – Modies general boiler settings.

• ‘CH Settings’ submenu – Modies advanced Central Heating settings including outdoor reset curve parameters and boost function.

Boiler Status

• ‘DHW Settings’ – Modies 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 airow 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 rectication 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.

Page 76

APPENDIX A - CONTROL MODULE

User Interface Display

Installer Menu

Explanation

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

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

Figure A-1 Typical Ignition Cycle

Boiler Status

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

False Flame Detection

Re-ignition

Intermittent Operation

Flame out too late

Safety relay test

UL3563 High Limit Temperature Device

If ame is detected at end of pre-spark

period (Ignit_0) than lockout will occur.

If at end of safety period no ame

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

Boiler can be ring continuously for 24

hours. Burner switched off and restart sequence follows.

If ame detected after post purge lockout

follows.

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

Boiler comes equipped with UL353 approved temperature high limit device.

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

Page 77

Boiler Status

Boiler Conguration

APPENDIX A - CONTROL MODULE

User Interface Display

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

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

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

Page 78

APPENDIX A - CONTROL MODULE

User Interface Display

Explanation

Two pump modes are available:

Pump Mode = 0 ‘CH or CH&DHW’

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

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

• In the case of simultaneous call for both CH and DHW, the energized pump depends on whether the boiler is currently supplying CH or DHW demand. Refer to DHW Priority settings below.

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

Pump Mode = 4 ‘System Pump’

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

Boiler Conguration

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

• DHW pump terminal does not function.

• This is typical of hydronic system design which utilizes zone valves for all CH zones and DHW indirect tank.

Note:

• Pump Mode selection depends on electrical and

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

congurations.

• Internal heat exchanger pump is energized anytime

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

'Service Reminder’ feature allows the installer to enable or

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

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

maintenance is required by qualied service technician.

Allowed Range: 1 to 999 days

Page 79

APPENDIX A - CONTROL MODULE

User Interface Display

CH Settings

Explanation

4. Central Heating (CH) modes available:

• CH Mode = 0 ‘CH with Thermostat’

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

• Boiler will modulate its ring rate to maintain CH set point and match system heat load.

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

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

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

• Boiler will modulate its ring rate to maintain CH set point and match system heat load.

• CH set point calculated as function of outdoor

temperature using outdoor reset curve. See gure A-2

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

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

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

• CH thermostat input is ignored.

• CH set point calculated as function of outdoor

temperature using outdoor reset curve. See gure A-2

• CH Mode = 3 ‘CH with Permanent Demand’

• CH demand is permanently on.

• Boiler will permanently attempt to satisfy CH demand.

• CH thermostat input is ignored.

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

Note:

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

heating load):

• Burner shuts off, boiler enters post purge.

• CH pump continues to run for 30 seconds.

• Control will wait until Anti-cycle time of 180 seconds

elapses before boiler res again. Prevents short-

cycling.

• The internal heat exchanger pump is energized anytime demand exists regardless of Pump Mode setting or type of demand (CH or DHW).

Page 80

APPENDIX A - CONTROL MODULE

100

120

140

160

180

200

220

0 20 40 60 80 100

Outdoor Temperature F

Supply Temperature Setpoint



Reset Curve Design Points , A and B, de fin e a st ra ignt line . Boile r Min a nd Max,

C and D, define a section on the straignt line. Boiler supply temperature Setpoint follo w s t he b o ld line s e ctio n s

User Interface Display

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

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

Default Boiler Setting:180° F (82°C)

100

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

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

CH Settings

C D

Suppy Temperature Setpoint °F

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)

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.

Outdoor Temperature °F

Page 81

APPENDIX A - CONTROL MODULE

User Interface Display

CH Settings

Explanation

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

CH set point will continue to increase until set point reaches 195°F / 91°C

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

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

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

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

Two DHW modes are available

• DHW Mode = 0 ‘No DHW

DHW Settings

• DHW Mode is disabled

• The DHW thermostat input is ignored and the DHW pump is not used.

• DHW Mode = 2 ‘DHW Store with Thermostat’

• Boiler reacts to DHW demand when DHW thermostat input closes.

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

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

Note:

• Outdoor reset function disabled while operating in DHW Mode.

• Typical when using a DHW indirect storage tank.

• After DHW demand satised, boiler enters post purge mode and DHW pump continues to run for 15 seconds.

Page 82

DHW Settings

APPENDIX A - CONTROL MODULE

User Interface Display

Allowed Range: 1 to 60 Minutes 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 satised.

System test can be activated via installer menu for testing

system at xed power rates.

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

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

The following modes are available:

System Test

• Disabled

• Low power - Burner starts. After ignition period has

nished the burner stays at low power

• Ignition power - Burner starts. Stays at ignition power

• High power - Burner starts. After ignition period has

nished burner stays at high power.

Note:

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

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

• During System Test Mode, boiler will run at xed power rates until supply water temperature is 93°C/195°F

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

Page 83

OPTIONAL USER INTERFACE RELOCATION

User interface can be easily relocated outside of the boiler.

Follow instructions TO TURN OFF GAS TO APPLIANCE found on page 42. Verify all electrical power to boiler is turned off.

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel.

Remove front jacket panel.

WARNING

Burn hazard. Verify heat exchanger, igniter, and ame

sensor have cooled or use appropriate personal protection equipment before removing.

Inspect combustion chamber through sight glass.

Verify ame is not present. See gure 11.1 page 43.

Disconnect the two position Molex connector between

main boiler harness and user interface. See gure A.

Use small screwdriver to push in the plastic clip on bottom of user interface. Pull outward on bottom of user interface to release it from it base.

Use small at blade screwdriver to disconnect the two

wire harness from the terminal block located in user interface base. Disconnect other end of harness at 2 pin connector. Secure unused connector to harness bundle with wire tie. This harness will not be required when mounting user interface outside of boiler.

Before installing user interface in new location, route new two conductor wire through hole in back of user interface base. Connect the wires to terminal block. This connection is not polarity sensitive.

Install user interface base in new location using

appropriate eld sourced screws.

Install user interface on the base by engaging upper tabs on rear into user interface base slots. With downward hinging motion lower the display until user interface snaps onto the base. Verify two pins on back of user interface are properly aligned with the holes in user interface base terminal block as user interface is installed.

10.

Route other end of new two conductor wire through low voltage knockout on boiler.

11.

Connect two conductor wire to low voltage terminal block terminals labeled user interface. This connection is not polarity sensitive.

12.

Replace front jacket panel.

13.

Apply power and verify proper operation of the display following instructions in Appendix A - Control Module.

14.

Verify proper boiler operation by following START UP PROCEDURE located in this manual.

Figure - A User Interface Terminal Block

Base

Screw

Location

Terminal

Block

Page 84

50/75/100 MBH - PRIMARY LOOP EQUIVALENT LENGTH CALCULATION & PUMP SELECTION

For 50/75/100 MBH Boilers

(This boiler must be piped with a primary loop)

These charts are valid for piping diagrams on pages 17 & 18

Instructions:

Pipe diameter determines pump size. Smaller the diameter of pipe, larger the pump. 50/75/100 Mbh boilers can be piped in 3/4" , 1" or 1¼" pipe. Use charts 1-4 to determine pipe size and respective pump size.

Fill in chart using the 3/4" section rst. Then consult chart 4 for pump selection.

Pump size may be decreased by decreasing equivalent length of pipe. Use larger diameter pipe as primary loop to decrease equivalent length. Use chart 2 or 3.

Note: The gures below are based on industry average. Consult valve/tting manufaturer for exact equivalent length or for ttings not shown below.

Chart 1

Pipe Diameter Fitting

90° Elbow 1.875

45° Elbow 1

3/4"

Tee-branch 3.75

Tee-through 1.25

Swing check valve 6.25

Lift check valve 37.5

Chart 2

Pipe Diameter Fitting

90° Elbow 1.875

45° Elbow 1

Tee-branch 3.75

Tee-through 1.25

Swing check valve 6.25

Lift check valve 37.5

A B C

Enter Number Of

Fittings

Enter Total 3/4" straight pipe length in feet

Add up numbers in column C

Total equivalent length of Primary

A B C

Enter Number of

Fittings

Enter Total 1" straight pipe length in feet

Add up numbers in column C

Total equivalent length of Primary

Multiply Total of Column C in Chart 2 by 0.26

Multiply By

Equivalent Length

A x B

Pump Factor

Equivalent Length

A x B

Pump Factor

Page 85

50/75/100 MBH - PRIMARY LOOP EQUIVALENT LENGTH CALCULATION & PUMP SELECTION

Chart 3

Pipe Diameter Fitting

90° Elbow 1.875

1¼"

(Any pipe/tting

larger than 1¼",

count as 1¼")

45° Elbow 1

Tee-branch 3.75

Tee-through 1.25

Swing check valve 6.25

Lift check valve 37.5

A B C

Enter Number of

Fittings

Enter Total 1¼" straight pipe length in feet

Add up numbers in column C

Total equivalent length of Primary

Multiply Total of Column C in Chart 3 by 0.088

Multiply By

Equivalent Length

A x B

Pump Factor

Chart 4

Total Equivalent Length of 3/4"

Pipe Loop, L, ft.

From To Grundfos Taco B&G

0 15 UP 15-42 Taco-008 NRF-22

16 40 UP 26-64 Taco-0014 NRF-45 speed-3

41 80 UP 26-99 Taco-0013 NRF-36 speed-3

Note: If the heating system uses antifreeze solution 30% or higher, choose the next larger size pump listed in this table.

Pump options (Minimum)

Page 86

150/200 MBH - PRIMARY LOOP EQUIVALENT LENGTH CALCULATION & PUMP SELECTION

For 150/200 MBH Boilers

(This boiler must be piped with a primary loop)

These charts are valid for piping diagrams on pages 17 & 18

Instructions:

Pipe diameter determines pump size. Smaller the diameter of pipe, larger the pump. 150/200 Mbh boilers can be piped in 3/4" , 1" or 1¼" pipe. Use charts 1-4 to determine pipe size and respective pump size.

Fill in chart using the 1" section rst. Then consult chart 4 for pump selection.

Pump size may be decreased by decreasing equivalent length of pipe. Use larger diameter pipe as primary loop to decrease equivalent length. Use charts 2 or 3.

Note: The gures below are based on industry average. Consult valve/tting manufaturer for exact equivalent length or for ttings not shown below.

Chart 1

Pipe Diameter Fitting

90° Elbow 2.5

45° Elbow 1.3

Tee-branch 5.0

Tee-through 1.7

Swing check valve 8.3

Lift check valve 50.0

Chart 2

Pipe Diameter Fitting

90° Elbow 3.1

1¼"

(Any pipe/tting

larger than 1¼",

count as 1¼")

45° Elbow 1.7

Tee-branch 6.3

Tee-through 2.1

Swing check valve 10.4

Lift check valve 62.5

A B C

Enter Number of

Fittings

Enter Total 1" straight pipe length in feet

Add up numbers in column C

Total equivalent length of Primary

A B C

Enter Number of

Fittings

Enter Total 1¼" straight pipe length in feet

Add up numbers in column C

Total equivalent length of Primary

Multiply Total of Column C in Chart 2 by 0.35

Multiply By

Equivalent Length

A x B

Pump Factor

Equivalent Length

A x B

Pump Factor

Page 87

150/200 MBH - PRIMARY LOOP EQUIVALENT LENGTH CALCULATION & PUMP SELECTION

Chart 3

Pipe Diameter Fitting

90° Elbow 3.8

1½"

(Any pipe/tting

larger than 1½",

count as 1½")

45° Elbow 2.0

Tee-branch 7.5

Tee-through 2.5

Swing check valve 12.5

Lift check valve 75.0

A B C

Enter Number of

Fittings

Enter Total 1½" straight pipe length in feet

Add up numbers in column C

Total equivalent length of Primary

Multiply Total of Column C in Chart 3 by 0.15

Multiply By

Equivalent Length

A x B

Pump Factor

Chart 4

Total Equivalent Length of Primary

From To Grundfos Taco B&G

0 20 UP 26-99 Taco-0013 NRF-36 speed-3

21 35 UP 26-116 Taco 2400-20 PL-36

Note: If the heating system uses antifreeze solution 30% or higher, choose the next larger size pump listed in this table.

Pump options (Minimum)

Page 88

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.

UTICA BOILERS

2201 Dwyer Avenue

Utica NY 13501

web site: www.ecrinternational.com

Utica Boilers SSV Operation and Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual