Quantum Boiler GAS FIRED BOILERS User Guide

GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER

BOILERS

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

WARNING

Improper installation, adjustment, alteration, service, or maintenance can cause injury or

property damageꢀ Refer to this manualꢀ For assistance or additional information consult a

qualified installer, service agency, or gas supplierꢀ

DUNKIRK BOILERS

DUNKIRK, NEW YORK 14048 - 716 366-5500

Member: The Hydronics Institute

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE OF CONTENTS INTRODUCTION ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 3

BOILER RATINGS AND CAPACITIES ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 4

RULES FOR SAFE INSTALLATION AND OPERATIONꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7

BEFORE INSTALLING THE BOILER ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7

Aꢀ codes ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 7

Bꢀ boiler sizing ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 8

Cꢀ considerations for boiler location ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 8

Dꢀ locating the boiler ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 8

Eꢀ combustion air and vent pipe requirements ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 9

Fꢀ condensate drain requirementsꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 10

Gꢀ foundation requirementsꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 11

Hꢀ removing existing boiler from common venting system ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 11

PLACING THE BOILER ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 11

NEAR BOILER PIPING ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 12

Aꢀ supply and return linesꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 12

Bꢀ pressure relief valveꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 16

Cꢀ expansion tank and make-up waterꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 16

Dꢀ condensate drain piping ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 19

Eꢀ filling condensate trap ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 19

Fꢀ chilled water piping ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 20

COMBUSTION AIR AND VENT PIPE ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 21

Aꢀ connections and terminations ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 21

Bꢀ installation ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 22

GAS SUPPLY PIPING ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 25

Aꢀ check gas supply ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 25

Bꢀ connecting the gas piping ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 25

Cꢀ checking the gas piping ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 26

ELECTRICAL WIRING ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 27

Aꢀ electric power supply ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 27

Bꢀ install your thermostatꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 28

Cꢀ field wiring connections ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 29

Dꢀ schematic wiring diagram ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 30

Eꢀ ladder wiring diagramꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 31

CONTROLS AND ACCESSORIES ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 32

Aꢀ UT 1013-10 integrated boiler control ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 32

Bꢀ gas control valve ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 32

Cꢀ hot surface igniter ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 32

Dꢀ L4006A high limit aquastat control ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 32

Eꢀ draft inducer temperature safety switch ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 32

Fꢀ casting temperature safety switchꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 33

Gꢀ differential pressure air proving switch ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 33

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Hꢀ draft inducerꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 33

Iꢀ circulator pumpꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ33

Jꢀ drain valveꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 33

Kꢀ relief valveꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 34

Lꢀ flame rollout safety shutoffꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 34

Mꢀ external condensate pumpꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 34

START-UPꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 34

Aꢀ water treatment and freeze protectionꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 34

Bꢀ filling boiler with water and purging air with diaphragm type expansion tanksꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 35

Cꢀ filling boiler with water and purging air with conventional closed type expansion tanksꢀꢀꢀꢀ 35

Dꢀ boiler in placingꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ36

Iꢀ for your safety read before operating

IIꢀ operating instructions

IIIꢀ to turn off gas to appliance

CHECK-OUT PROCEDURES AND ADJUSTMENTSꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 37

Aꢀ verify proper sequence of operationꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 37

Bꢀ inspect venting and air intake systemꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 38

Cꢀ inspect condensate drainꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ38

Dꢀ inspect system pipingꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ38

Eꢀ test ignition system safety shutoffꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 38

Fꢀ test high limit control and adjustꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ38

Gꢀ test other safety controlsꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ39

Hꢀ set thermostat heatꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 39

1ꢀ measure the gas input rateꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ39

Jꢀ set thermostat to desired room temperatureꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ41

Kꢀ review all instructionsꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 41

Lꢀ installation and check-out certificateꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 41

MAINTENANCE AND CLEANINGꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 43

Aꢀ beginning of each seasonꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 43

Bꢀ daily during heating seasonꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 43

Cꢀ monthly during heatingꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 44

Dꢀ periodically during heatingꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 44

Eꢀ end of each heating season -annual shut down procedureꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 44

Fꢀ annual examination and cleaning of boiler componentsꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 44

SERVICE HINTSꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 47

A flow chart/detailed sequence of operationꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 47

Bꢀ trouble shootingꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 50

Cꢀ differential air pressure switch checkꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 58

REPAIR PARTSꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ59

Aꢀ jacket and baseꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ59

Bꢀ condensate drain trap assembly ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 61

Cꢀ block and piping assemblyꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ62

Dꢀ mixer and air pressure switch assemblyꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 64

Eꢀ flue adapter and exhauster assemblyꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ 66

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INTRODUCTION

This appliance is a gas-fired direct vent hot water boiler with cast aluminum boiler sectionsꢀ A

revolutionary cast aluminum heat exchanger means better heat transfer and thermal storage than

similarly sized cast iron boilers, which results in higher efficiencyꢀ The heating system water absorbs large

amounts of heat from the cast aluminum heat exchanger, cooling the flue gases and causing

condensationꢀ Sealed combustion, premix gas burner, and low flame temperature means drastically

reduced CO and NOx emissions, which contribute to a cleaner and healthier environmentꢀ

This appliance, unlike normal residential atmospheric and induced draft units, takes its combustion air

directly from the outdoors (sealed combustion) and does not compete with building occupants for fresh

airꢀ Sealed combustion (also known as “direct vent”) is the safest and best way to obtain plenty of clean

combustion airꢀ The induced draft fan draws in the outside combustion air, then takes the cooler flue

gases from the boiler unit and provides a positive removal of the flue gases from the building through

inexpensive and readily available PVC and CPVC pipesꢀ

FIGURE 1

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BOILER RATINGS AND CAPACITIES

7$%/(ꢀꢁꢀꢀꢀ6($ꢀ/(9(/ꢀ5$7,1*6ꢀꢂꢀ1$785$/ꢀ$1'ꢀ3523$1(ꢀ*$6(6

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These low pressure gas-fired hot water boilers are design certified by CSA International for use

with natural and propane gasesꢀ The boilers are constructed and hydrostatically tested for a

maximum working pressure of 50 psig (pounds per square inch gage) in accordance with

AꢀSꢀMꢀEꢀ (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section

IV Standards for heating boilersꢀ

++ AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on the DꢀOꢀEꢀ

(Department of Energy) test procedureꢀ

The Boilers are certified in accordance with ANSI (American National Standards Institute)

Z21ꢀ13 standards as gas-fired, direct vent, condensing, hot water boilersꢀ

The Heating Capacity indicates the amount of heat available after subtracting the losses up the

stackꢀ Most of this heat is available to heat waterꢀ A small portion is heat from the jacket and

surfaces of the boiler, and it is assumed that this heat stays in the structureꢀ The Net I=B=R

Rating represents the portion of the remaining heat that can be applied to heat the radiation or

terminal units (iꢀeꢀ finned tube baseboard, cast iron radiators, radiant floor, etcꢀ)ꢀ The difference

between the Heating Capacity and the Net I=B=R Rating, called the piping and pickup

allowance, establishes a reserve for heating the volume of water in the system and offsetting

heat losses from the pipingꢀ The Net I=B R Ratings shown are based on a piping and pickup

factor of 1ꢀ15 in accordance with the I=B=R Standard as published by the Hydronics Instituteꢀ

The Net I=B=R Rating of the boiler selected should be greater than or equal to the calculated

peak heating load (heat loss) for the building or area(s) served by the boiler and associated hot

water heating systemsꢀ The manufacturer should be consulted before selecting a boiler for

installations having unusual piping and pickup requirementsꢀ

BOILERS FOR USE AT HIGH ALTITUDE

The boilers are factory equipped for operation at altitudes ranging from 0-2,000 feet above sea

levelꢀ For use of these boilers at altitudes above 2,000 feet above sea level, the gas input

ratings (MBH) must be reducedꢀ

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UꢀSꢀAꢀ ONLY: For altitudes above 2,000 feet above sea level, input ratings should be reduced

as shown in tables IA, C, & E for natural gas boilers or in tables 1B, D & F for propane fired

boilersꢀ Reduced input ratings are achieved by the natural deration of the gas at higher

elevations and fine tuned by adjusting the manifold pressureꢀ

CANADA ONLY: For altitudes in the range of 2,000-4,500 feet above sea level, boilers may be

field equipped for use at high altitude by using a certified high altitude conversion kitꢀ The change

in main burner orifice size results in a 10% reduction of the boiler gas input rating (MBH)ꢀ

The conversion shall be carried out by a manufacturer’s authorized representative, in

accordance with the requirements of the manufacturer, provincial or territorial authorities having

jurisdiction, and in accordance with the requirements of the CSA-B 149ꢀ1 and CSA-B 149ꢀ2

Installation Codesꢀ The certified field conversion kit includes a conversion data plate, indicating

that the boiler has been converted for high altitude useꢀ The correct conversion information must

be entered on the conversion data plateꢀ

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120,1$/ ,1387 ꢀ0%+ꢁ

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RULES FOR SAFE INSTALLATION AND OPERATION

lꢀ Read the entire installation manual before beginning the installationꢀ Failure to follow these

rules for safe installation and operation and these instructions could cause a malfunction of

the boiler and result in death, serious bodily injury, and/or property damageꢀ

2ꢀ Check all applicable state and local building codes and utility company requirements

before installationꢀ The installation must conform with these requirements in their

entiretyꢀ In the absence of these codes, use NFPA Installation Codes and good

industry practiceꢀ

3ꢀ Before servicing the boiler - allow the boiler to coolꢀ Always shut off any electricity and

gas supply connected to the boiler prior to servicingꢀ

4ꢀ Inspect gas line for leaksꢀ

5ꢀ Be certain gas input rate is correctꢀ Over firing may result in early failure of the boiler

sectionsꢀ This may cause dangerous operationꢀ Under firing may result in too much air

for the pre-mix burner causing poor or loss of combustionꢀ

6ꢀ Never vent the products of combustion from this boiler to an enclosed spaceꢀ Always

vent to the outdoorsꢀ Never vent to another room or to inside a buildingꢀ

7ꢀ Be sure there is adequate outdoor air supply to boilerꢀfor complete combustionꢀ

8ꢀ Follow a regular service and maintenance schedule for efficient and safe operationꢀ 9ꢀ

Keep boiler area clean of debris and free of combustible and flammable materialsꢀ

10ꢀ Proper through the wall or through the roof combustion venting shall be in accordance with the

materials and methods described in this manualꢀ Installation must comply with local codesꢀ

11ꢀ This boiler and related hot water heating systems are not do it yourself itemsꢀ They

must be installed and serviced by qualified professionalsꢀ

WARNING

This boiler has been equipped for residential installationsꢀ If used for commercial applications, any

additional code requirements must be adhered to for installationꢀ This may require additional

controls including but not limited to a low water cut off, a manual reset high temperature limit, and

wiring and/or piping modificationsꢀ The manufacturer is not responsible for any field installation

changes made to a boiler installation which are not described or acknowledged in this manualꢀ

BEFORE INSTALLING THE BOILER

Complete all of the following prior to installing the boilerꢀ

Aꢀ CODES

This boiler product is a gas-fired, direct vent, condensing boiler and must be installed in

accordance with all applicable federal, state and local building codes including, but not

limited to the following:

United States -Installation shall conform with National Fuel Gas Code (NFPA-54/ANSI

Z223ꢀ1-latest edition)

Canada -

Installation shall be in accordance with CSA B 149ꢀ1 and ꢀ2ꢀ installation

codesꢀ

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Where required by the authority having jurisdiction, the installation must conform to the

American Society of Mechanical Engineers Safety Code for Controls and Safety Devices

for Automatically Fired Boilers, NoꢀCSD-1ꢀ

The installation must conform to the requirements of the authority having jurisdiction or, in the

absence of such requirements, to the National Fuel Gas Code, ANSI Z223ꢀ1 - latest revisionꢀ

Installers - Follow local regulations with respect to installation of CO (Carbon

Monoxide) Detectorsꢀ Follow maintenance recommendations in this manualꢀ

Techniciens -Veuillez vous conformer à la réglementation en vigueur concernant 1'

installations des détecteurs d'oxyde de carboneꢀ Suivre les consignes

d'entretien figurant dans le manuel d'instruction ci-jointꢀ

Bꢀ BOILER SIZING

• Check to be sure you have selected the boiler with the proper capacity before starting

the installationꢀ The I=B R Rating of the boiler selected should be greater than or equal

to the calculated peak heating load (heat loss) for the building or area(s) served by the

boiler and associated hot water heating systemsꢀ See the table "BOILER RATINGS

AND CAPACITIES"ꢀ

• Heat loss calculations should be based on approved industry methodsꢀ

Cꢀ CONSIDERATIONS FOR BOILER LOCATION

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

consideredꢀ

• Supplied with the correct type of gas (natural gas or propane)ꢀ

• Connected to a suitable combustion air intake piping system to supply the correct

amounts of fresh (outdoor) air for combustionꢀ (maximum length 80' for the Model-100

boiler, and maximum length 100' for the Model-75 and Model-50 boilers)ꢀ

• Connected to a suitable venting system to remove the hazardous products of gas

combustion (maximum length 80' for the Model-100 boiler, and maximum length 100' for

the Model-75 and Model-50 boilers)ꢀ

• Connected to a suitable hot water heating system

• Supplied with a suitable electrical supply for all boiler motors and controlsꢀ

• Connected to a properly located thermostat or operating controlꢀ (not included with

boiler)

• Placed on level surface (must NOT be installed on carpeting)

• Condensate drain line must be pitched down to floor drain or external condensate

pump with reservoir at ¼" per foot (wood frame or blocks may be used to raise boiler)ꢀ

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Dꢀ LOCATING THE BOILER

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1ꢀ Select a location which is level, central to the piping systems served and as close to the

vent and air intake terminals as possibleꢀ

2ꢀ Accessibility clearances, if more stringent (iꢀeꢀ larger clearances) than required fire protection

clearances, must be used for the boiler installationꢀ Accessibility clearances may be achieved

with the use of removable walls or partitionsꢀ

3ꢀ The boiler is approved for installation in closets and on combustible floorsꢀ This boiler

shall NOT be installed on carpetingꢀ

4ꢀ The clearances shown in Table 2 indicate required clearances per IAS listingꢀ A minimum

1" clearance must be maintained between combustible construction and each of the left,

top and back surfaces of the boilerꢀ A minimum 8" clearance is required on the right side,

to allow room for the inlet air pipeꢀ An 18" clearance must be maintained at a side where

passage is required to access another side for cleaning or servicing, inspection or

replacement of any parts that normally may require such attentionꢀ Allow at least 24" at

the front and left side and 8" at the top for servicingꢀ No clearances are required to

venting or combustion air intake pipingꢀ

5ꢀ Equipment shall be installed in a location which facilitates the operation of venting and

combustion air intake piping systems as described in this manualꢀ

6ꢀ Advise owner of boiler to keep venting and combustion air intake passages free of obstructionsꢀ

both the venting and combustion air intake piping systems connected to the outdoors must

permit flow through the piping systems without restrictions for the boiler to operateꢀ

7ꢀ The boiler shall be installed such that the automatic gas ignition system components are

protected from water (dripping, spraying, rain, etcꢀ) during operation and service

(circulator replacement, control replacement, etcꢀ)ꢀ

Eꢀ COMBUSTION AIR AND VENT PIPE REQUIREMENTS

This boiler requires a dedicated direct vent systemꢀ In a direct vent system, all air for

combustionis taken directly from outside atmosphere, and all flue products are discharged to

outside atmosphereꢀ

Combustion air and vent pipe connections must terminate together in the same atmospheric

pressure zone, either through the roof or sidewall (roof termination preferred)ꢀ See Figꢀ9 & 10

for required clearancesꢀ

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CAUTION

KEEP BOILER AREA CLEAN OF DEBRIS AND FREE OF FLAMABLE AND COMBUSTIBLE

MATERIALS, VAPORS AND LIQUIDS

WARNING

When vent pipe is exposed to temperatures below freezing, such as when it passes through an

unheated space or when a chimney is used as a raceway, vent pipe must be insulated with 1/2”

Armaflex or equivalentꢀ In extreme cold climate areas, use ³/4" Armaflex or equivalentꢀ

Combustion air must be clean outdoor airꢀ Combustion air must not be taken from inside struc-

ture because that air frequently is contaminated by halogens, which include fluorides, chlorides,

phosphates, bromides and iodidesꢀ These elements are found in aerosols, detergents, bleaches,

cleaning solvents, salts, air fresheners, paints, adhesives and other household productsꢀ

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

pump houseꢀ

All combustion air and vent pipes must be airtight and watertightꢀ Combustion air and vent

piping must also terminate exactly as shown in Figꢀ9 or 10ꢀ

Vent connections serving appliances vented by natural draft shall not be connected into any

portion of mechanical draft systems operating under positive pressureꢀ

Solvent cements are combustibleꢀ Keep away from heat, sparks, and open flameꢀ Use only in

well ventilated areasꢀ Avoid breathing in vapor or allowing contact with skin or eyesꢀ

FAILURE TO FOLLOW THE AFOREMENTIONED WARNINGS COULD RESULT IN FIRE,

PROPERTY DAMAGE, PERSONAL INJURY, OR DEATHꢀ

Fꢀ CONDENSATE DRAIN REQUIREMENTS

Condensate drain line to be pitched down to floor drain at a minimum of ¹/4" per footꢀ An external

condensate pump (not furnished) may be used if floor drain is not availableꢀ The condensate

pump must be designed for flue gas condensate application

NOTE:1ꢀ Condensate trap is built into the boiler, an external trap is not required and should not

be usedꢀ

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

above external condensate pump reservoirꢀ

3ꢀ There is a 115 volt AC receptacle provided on the service switch junction box which

is located at the boiler right side, to provide power for an external condensate

pump (if needed)ꢀ

Gꢀ FOUNDATION REQUIREMENTS

Boiler must be placed on level surfaceꢀ Boiler is NOT to be installed on carpetingꢀ

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NOTE:

1ꢀ If boiler is not level condensate drain lines will not function properlyꢀ Adjustable

feet are located on the boiler to make up for minor surface irregularities or tiltꢀ

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

above external condensate pump reservoirꢀ

Hꢀ REMOVAL OF EXISTING BOILER FROM COMMON VENT SYSTEM

When an existing boiler is removed from a common venting system, the common venting

system is likely to be too large for proper venting of the appliances remaining connected to itꢀ

At the time of removal of an existing boiler, the following steps shall be followed with each

appliance remaining connected to the common venting system placed in operation, while the

other appliances remaining connected to the common venting system are not in operationꢀ

1ꢀ Seal any unused openings in the common venting systemꢀ

2ꢀ Visually inspect the venting system for proper size and horizontal pitch and determine

there is no blockageꢀ or restrictions, leakage, corrosion and other deficiencies which could

cause an unsafe conditionꢀ

3ꢀ Insofar as is practical, close allꢀ building doors and windows and all doors between the

space in which the appliances remaining connected to the common venting system are

located and other spaces of the buildingꢀ Turn on clothes dryer and any appliance not

connected to the common venting systemꢀ Turn on any exhaust fans, such as range

hoods and bathroom exhaust, so they will operate at maximum speedꢀ Do not operate a

summer exhaust fanꢀ Close fire dampersꢀ

4ꢀ Place in operation the appliance being inspectedꢀ Follow the lighting instructionsꢀ Adjust

thermostat so appliances will operate continuouslyꢀ

5ꢀ Test for spillage at the draft hood relief opening after 5 minutes of main burner operationꢀ

Use the flame of a match or candle, or the smoke from a cigarette, cigar or pipeꢀ

6ꢀ After it has been determined that each appliance remaining connected to the common venting

system properly vents when tested as outlined above, return doors, windows, exhaust fans

and any other gas-burning appliance to their previous condition of useꢀ

7ꢀ Any improper operation of the common venting system should be corrected so the

installation conforms with the National Fuel Code, NFPA-54/ANSI -Z223ꢀ1-latest revision,

or section 5 of CSA-B 149 for Canadian standardsꢀ When resizing any portion of the

common venting system, the common venting system should be resized to approach the

minimum size as determined using the appropriate tables in part 11 in the National Fuel

Gas Code, NFPA-54/ANSI- Z223ꢀ1-latest revision, or section 5 of CSA-B 149 for

Canadian standardsꢀ

PLACING THE BOILER

The boiler should be placed to provide the most direct connections to the combustion air, vent

and system piping as possibleꢀ

Place crated boiler as close to selected location as possible and uncrate boilerꢀ The uncrated

boiler may be moved into position with an appliance dolly or 2-wheel hand truckꢀ The dolly or hand

truck should be inserted under the left hand side of the boilerꢀ It is possible to slide the boiler for a

short distance on a smooth floor or surfaceꢀ

NOTE: Refer to manual section “LOCATING THE BOILER” for required clearances for servic

ing and maintenanceꢀ

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NEAR BOILER PIPING

CAUTION

Copper supply and return pipingꢀ must NOT be installed directly into aluminum boiler section

casings due to galvanic corrosion between dissimilar metalsꢀ Iron or steel bushings or pipe

nipples should be used between copper system piping and boiler to make final connection to

boilerꢀ Also, the use of dielectric unions is acceptableꢀ The packaged boiler is furnished with iron

piping in the front boiler section for the supply and return connectionsꢀ

When the installation of the boiler is for a new heating system, first install all of the radiation

units (panels, radiators, baseboard, or tubing) and the supply and return mainsꢀ After all heating

system piping and components have been installed, make final connection of the system piping

to the boilerꢀ A hot water boiler installed above radiation level must be equipped with a low water

cut off deviceꢀ A periodic inspection is necessary us is flushing of float type devices, per low

water cut off manufacturers specific instructionsꢀ

A$ SUPPLY AND RETURN LINES

The packaged boiler unit is set up to receive 1 1/4" NPT supply and return piping from top

accessꢀ The boiler unit can also be piped from the left side by turning the supply elbow, and

from the rear of the unit by removing plugs in the rear boiler sectionꢀ

NOTE: The circulator pump and isolation valves are furnished within a carton inside the boiler

cabinet and can be installed at the installer preferred locationꢀ

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FIGURE 2 SINGLE ZONE BOILER PIPING

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FIGURE 3 MULTI ZONE BOILER PIPING WITH ZONE VALVES

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NOTE: When zoning with circulators, the furnished circulator pump should be used as one of the

zone pumpsꢀ Each stripped end of the electrical wires for the circulator pump inside the junction

box should be taped or wire nutted to prevent short circuitsꢀ Unplug the circulator pump wiring at

the integrated boiler controlꢀ

FIGURE 4 MULTI ZONE BOILER PIPING WITH CIRCULATORS

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FIGURE 5 SINGLE ZONE BOILER PIPING

Bꢀ PRESSURE RELIEF VALVE

The boiler is furnished with a factory installed relief valve in the top of the boilerꢀ Provide ¾”

piping from the supplied relief valve to a local floor drain, but leave an air gap between piping

and drainꢀ No shutoff of any description shall be placed between safety relief valve and the

boiler, or on the discharge pipes between such safety valve and the atmosphereꢀ Installation

of the safety relief valve shall conform to ANSI/ASME Boiler and Pressure Vessel Code,

Section IVꢀ The manufacturer is not responsible for any water damageꢀ

Cꢀ EXPANSION TANK AND MAKE-UP WATER

Determine required system fill pressure, system design temperature, and system water

contentꢀ Boiler contains 2ꢀ6 gallons (UꢀSꢀ)ꢀ Size expansion tank accordinglyꢀ Consult

expansion tank manufacturer for proper sizing informationꢀ Connect properly sized

expansion tank (not furnished) as shown in Figꢀ 6 for diaphragm type expansion tank and

Figꢀ 7 for conventional closed type expansion tanksꢀ For diaphragm type expansion tanks,

adjust the tank air pressure to match the system fill pressureꢀ Install air vent (furnished) as

shown for diaphragm type expansion tank system onlyꢀ Install make-up water connections

as shown per local codesꢀ If a pressure reducing valve is used, adjust to match the system

fill pressureꢀ In connecting the cold make-up water supply to the boiler, make sure that clean

water supply is availableꢀ When the water supply is from a well or pump, sand strainer

should be installed at the pumpꢀ

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FIGURE 6 DIAPHRAGM TYPE EXPANSION TANK PIPING

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FIGURE 7 CONVENTIONAL (closed type) EXPANSION TANK PIPING

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FIGURE 8 CONDENSATE - DRAIN PIPING

Dꢀ CONDENSATE DRAIN PIPING

The condensate trap is built into the boiler, an external trap is not required and should NOT be usedꢀ

Provide ½” PVC condensate drain and fittingsꢀ Condensate drain to be pitched down to floor drain at

a minimum of ¼” per footꢀ

Install furnished ½” PVC tee to overflow fitting as shown in Figꢀ 8ꢀ

The ½” diameter schedule 40 PVC or CPVC condensate drain and pipe fittings must conform to ANSI

standards and ASTM D 1785 or D2846ꢀ Schedule 40 PVC or CPVC cement and primer must conform

to ASTM D2564 or F493ꢀ In Canada, use CSA or ULC certified schedule 40 PVC or CPVC drain pipe

cementꢀ

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

(sanitary line) above boiler if a floor drain is not available or its in accessibleꢀ

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Eꢀ FILLING CONDENSATE TRAP WITH WATER ON THE INITIAL START UP THE CONDEN

SATE TRAP MUST BE MANUALLY FILLED WITH WATER

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

are only required at the initial start up or if maintenance requires draining of the condensate trap:

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

2ꢀ Pour about 1 cup of cold tap water into the vent drain line with a proper funnelꢀ

3ꢀ Excess water should go through the overflow and out through the condensate drain lineꢀ

Verify proper operation of the drain line (or external condensate pump if used)ꢀ

4ꢀ Reinstall the vent drain lineꢀ

Fꢀ CHILLED WATER PIPING

The boiler, when used in connection with a refrigeration system, must be installed so the

chiller medium is piped in parallel with the boiler with appropriate valves to prevent the chilled

medium from entering the boilerꢀ

The boiler piping system of a hot water boiler connected to heating coils is located in air

handling units where they may be exposed to refrigerated air circulation must be equipped

with flow control valves or other automatic means to prevent gravity circulation of the boiler

water during cooling cycleꢀ

COMBUSTION AIR AND VENT PIPE

Aꢀ CONNECTIONS AND TERMINATION

For boilers connected to gas vents or chimneys, vent installations shall be in accordance with

part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI 2223ꢀ1-latest revision,

CAN/CGA-B 149ꢀ1 and B 149ꢀ2, and applicable provisions of the local building codesꢀ

Provisions for combustion and ventilation air must be in accordance with section 5ꢀ3, Air For

Combustion and Ventilation, of the National Fuel Gas Code,ANSI 2223ꢀ1-latest revision,

CAN/CGA-B 149ꢀ1 and B 149ꢀ2, or applicable provisions of the local building codeꢀ

These boilers require a dedicated direct vent systemꢀ All air for combustion is taken directly

from outdoors through the combustion air intake pipeꢀ All flue products are discharged to the

outdoors through the vent pipeꢀ

1ꢀ See Figꢀ9 & 10 for combustion air and vent pipe roof and sidewall terminationꢀ (Roof termi

nation is preferred) Combustion air and vent pipes must terminate together in same atmo

spheric pressure zone as shownꢀ Construction through which vent and air intake pipes

may be installed is a maximum 24 inches, minimum ¹/4" thicknessꢀ

2ꢀ Combustion air and vent pipe fittings must conform to American National Standards Insti

tute (ANSI) standards and American Society for Testing and Materials (ASTM) standards

D1784 (schedule-40 CPVC), D1785 (schedule-40 PVC), D2665 (PVC-DWV), D2241

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

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

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In Canada construct all combustion air and vent pipes for this unit of CSA or ULC certified

schedule-40 CPVC, schedule-40 PVC, PVC-DWV or ABS-DWV pipe and pipe cementꢀ

SDR pipe is NOT approved in Canadaꢀ

3ꢀ Combustion air and vent piping connections on boiler are sized for 2" pipeꢀ Any pipe size

change (to 3") must be made outside of the boiler casing in a vertical run of pipe to allow

for proper drainage of vent condensateꢀ Due to potential for flue gas temperatures over

155°F, the first five (5) feet of vent pipe must be CPVC, the remaining vent pipe can be

PVCꢀ If any elbows are employed within the first 5 feet of vent, they must be CPVC tooꢀ

Two (2) - 30" pieces of 2" CPVC pipe are furnished with the boilerꢀ

NOTE: The transition from 2" pipe to 3" pipe must be made in a vertical runꢀ

4ꢀ Combustion air and vent piping lengths,

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The first 5 feet of “TOTAL EQUIVALENT LENGTH” of vent piping run must be CPVC:

The length of pipe is counted from the boiler jacket (air intake pipe) or from vent tee (vent

pipe)ꢀFor additional elbows, reduce the maximum vent length as shown:

2" 90 degree elbow -1 ½ feet per additional elbowꢀ

3" 90 degree elbow - 3 feet per additional elbowꢀ

Example: To add 2 additional 90 degree elbows to a 3" pipe for a 75 boilerꢀ

Each elbow is 3 additional feet per 90 degree elbow for a total of 6 feetꢀ (1 elbow @ 3

feet + 1 elbow @ 3 feet = 6 additional feet of pipe) The total additional pipe is then

subtracted from the maximum allowable pipe length to give the new maximum length

of 94 feet with 6, 90 degree elbowsꢀ (“TOTAL EQUIVALENT LENGTH”: Original 100

feet maxꢀ - 6 feet for 2 additional elbows = new 94 feet maximum length)ꢀ

5ꢀ Combustion air and vent piping to be pitched back to boiler at minimum ¼” per foot from

intake and vent terminals so that all moisture in combustion air and vent piping drains to

boilerꢀ Pipes must be pitched continuously with no sags or low spots where moisture can

accumulate and block the flow of air or flue gasꢀ Combustion air and vent pipes must be

airtight and watertightꢀ

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6ꢀ Consideration for the following should be used when determining an appropriate location

for termination of combustion air and vent pipingꢀ

• Comply with all clearances required as stated in paragraph 7ꢀ

• Termination should be positioned where vent vapors will not damage plants/shrubs or air

conditioning equipmentꢀ

• Termination should be positioned so that it will not be effected by wind eddy, air born

leaves, snow, or recirculated flue gasesꢀ

• Termination should be positioned where it will not be subjected to potential damage by

foreign objects, such as stones, balls, etcꢀꢀ

• Termination should be positioned where vent vapors are not objectionableꢀ

• Put vent on a wall away from the prevailing winter windꢀ Locate or guard the vent to

prevent accidental contact with people or petsꢀ

• Terminate the vent above normal snowlineꢀ Avoid locations where snow may drift and

block the ventꢀ Ice or snow may cause the boiler to shut down if the vent becomes

obstructedꢀ

• Under certain conditions, flue gas will condense, forming moisture, and may be corrosiveꢀ

In such cases, steps should be taken to prevent building materials at the vent from being

damaged by exhaust of flue gasꢀ

7ꢀ The venting system shall terminate at least 3 feet above any forced air inlet (except the

boiler’s combustion air inlet) within 10 feetꢀ The venting system shall terminate at least 12

inches from any air opening into any buildingꢀ The bottom of the vent shall be located at

least 12 inches above gradeꢀ Termination of the vent shall be not less than 7 feet above an

adjacent public walkwayꢀ The vent terminal shall not be installed closer than 3 feet from the

inside corner of an L shaped structureꢀ Termination of the vent should be kept at least 3

feet away from vegetationꢀ The venting system shall terminate at least 4 feet horizontally

from, and in no case above or below, unless a 4 foot horizontal distance is maintained, from

electric meters, gas meters, regulators, and relief equipmentꢀ

FIGURE 9 ROOF VENT/INTAKE TERMINATIONS

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FIGURE 10 SIDEWALL VENT/INTAKE TERMINATIONS

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FIGURE 11 COMBUSTION AIR AND VENT PIPING

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Bꢀ INSTALLATION

1ꢀ Attach combustion air intake piping to supplied Fernco 2" coupling on mixerꢀ Attach

vent piping to furnished 2" CPVC vent tee on draft inducer outletꢀ

NOTE: All pipe joints are to be water tightꢀ

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

3ꢀ Deburr inside and outside of pipeꢀ

4ꢀ Chamfer outside edge of pipe for better distribution of primer and cementꢀ

5ꢀ Clean and dry all surfaces to be joinedꢀ

6ꢀ Check dry fit of pipe and mark insertion depth on pipeꢀ

NOTE: It is recommended that all pipes be cut, prepared, and pre-assembled before

permanently cementing any jointꢀ

7ꢀ After pipes have been cut and pre-assembled, apply cement primer to pipe fitting

socket and end of pipe to insertion markꢀ Quickly apply approved cement to end of pipe

and fitting socket (over primer)ꢀ Apply cement in light, uniform coat on the inside of

socket to prevent buildup of excess cementꢀ Apply second coatꢀ

8ꢀ While cement is still wet, insert pipe into socket with a’/a turn twistꢀ Be sure pipe is fully

inserted into fitting socketꢀ

9ꢀ Wipe excess cement from jointꢀ A continuous bead of cement will be visible around

perimeter of a properly made jointꢀ

10ꢀ Handle pipe joint carefully until cement setsꢀ

11ꢀ Support combustion air and vent piping a minimum of every 5 feet using pre-formed

metal hanging strapsꢀ Do not rigidly support pipesꢀ Allow movement due to expansion

and contractionꢀ

12ꢀ Slope combustion air and vent pipes toward boiler a minimum of ¹/4" per linear foot with

no sags between hangersꢀ

13ꢀ Use appropriate methods to seal openings where vent and combustion air pipes pass

through roof or side wallꢀ

GAS SUPPLY PIPING

Aꢀ CHECK GAS SUPPLY

The gas pipe to your boiler must be the correct size for the length of run and for the total

BTU per hour input of all gas utilization equipment connected to itꢀ See Table 3 for the

proper sizeꢀ Be sure your gas line complies with local codes and gas company

requirementsꢀ

The boiler and its individual shutoff valve must be disconnected from the gas supply piping

system during any pressure testing of that system at test pressures in excess of ‘/z psig (3ꢀ5kpa)ꢀ

The boiler must be isolated from the gas supply piping system by closing its individual

manual shutoff valve during any pressure testing of the gas supply piping system at test

pressures equal to or less than ‘/z psig (3ꢀ50ka)ꢀ

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Bꢀ CONNECTING THE GAS PIPING

Refer to Figꢀ12 for the general layout at the boilerꢀ It shows the basic fittings you will needꢀ

The gas line enters the boiler from the right side jacket panelꢀ The boiler may receive the gas

supply pipe through the left side, or rear jacket panel by relocating the gas valve connector

and pipe assemblyꢀ The boiler is equipped with a ‘/z” NPT connection on the gas valve for

supply pipingꢀ The following rules apply:

1ꢀ Use only those piping materials and joining methods listed as acceptable by the authority

having jurisdiction, or in the absence of such requirements, by the National Fuel Gas

Code, ANSI Z223ꢀ1- latest revisionꢀ In Canada, follow the CSA- B 149ꢀ1 and ꢀ2

Installation Codes for Gas Burning Appliances and Equipmentꢀ

2ꢀ Use pipe joint compound suitable for liquefied petroleum gas on male threads onlyꢀ

3ꢀ Use ground joint unionsꢀ

4ꢀ Install a sediment trap upstream of gas controlsꢀ

5ꢀ Use two pipe wrenches when making the connection to the gas valve to keep it from

turningꢀ

6ꢀ Install a manual shutoff valve in the vertical pipe about 5 feet above floorꢀ

7ꢀ Tighten all joints securelyꢀ

8ꢀ Propane gas connections should only be made by a licensed propane installerꢀ

9ꢀ Two stage regulation should be used by the propane installerꢀ

10ꢀ Propane gas piping should be checked out by the propane installerꢀ

Cꢀ CHECKING THE GAS PIPING

After all connection have been made, check immediately for leaksꢀ Open the manual shutoff

valveꢀ Test for leaks by applying soap suds (or a liquid detergent) to each jointꢀ Bubbles forming

indicate leakꢀ CORRECT EVEN THE SMALLEST LEAK AT ONCEꢀ

WARNING

NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKSꢀ

TABLE 3 GAS PIPE SIZES

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The length of pipe or tubing should be measured from the gas meter or propane second stage regulatorꢀ

FIGURE 12 GAS PIPING

ELECTRICAL WIRING

WARNING

TURN OFF ELECTRICAL POWER AT FUSE BOX BEFORE MAKING ANY LINE

VOLTAGE CONNECTIONSꢀ FOLLOW LOCAL ELECTRICAL CODESꢀ

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

NFPA70, latest revisionꢀ In Canada, electrical wiring shall comply with the Canadian Electrical

Codes, CSAC22ꢀ1 and ꢀ2

Aꢀ ELECTRIC POWER SUPPLY

Prior to making any line voltage connections, service switch at boiler should be in the off

position and the power turned off at the fuse box

Run a separate 120 volt circuit from a sperate over current protection device in the

electrical service entrance panelꢀ This should be a 15 ampere circuitꢀ A service switch has

been pre-wired and located on the exterior boiler jacketꢀ See Figꢀ 13 for diagram showing

location of service switch junction box and power supply connection pointsꢀ Connect black

(hot) lead from the power supply

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to either of the unused brass screws on the service switchꢀ Connect the white (neutral) lead from

the power supply to the white screw on the service switchꢀ Connect the green (ground) lead

from the power supply to the ground (green) screw on the service switchꢀ The receptacle on the

service switch is always powered regardless of whether the switch is on or off, and could be

used as a power supply for an external condensate pump if one is usedꢀ

The boiler, when installed, must be electrically grounded in accordance with the requirements of

the authority having jurisdiction or, in the absence of such requirements, with the National Elec-

trical Code, ANSI/NFPA-70, latest revisionꢀ In Canada, electrical wiring shall comply with the

Canadian Electrical Codes, CSA-C22ꢀ1 and ꢀ2ꢀ

Run a 14 gauge or heavier copper wire from the boiler to a grounded connection in the service

panel or a properly driven and electrically grounded ground rodꢀ

Bꢀ INSTALL YOUR THERMOSTAT

The thermostat location has an important effect on the operation of your boiler systemꢀ BE

SURE TO FOLLOW THE INSTRUCTIONS INCLUDED WITH YOUR THERMOSTATꢀ

Locate the thermostat about five feet above the floor on an inside wallꢀ It may be mounted di-

rectly on the wall or on a vertical mounted outlet boxꢀ It should be sensing average room tem-

peratureꢀ Avoid the Following:

DEAD SPOTS:

COLD SPOTS:

HOT SPOTS:

Behind doors

Concealed pipes or ducts Concealed pipes

Lamps

Comers and alcoves Stairwells - drafts

Unheated rooms on

Fireplace

TV sets

Radios

Direct sunlight

Kitchens

other side of wall

Set heat anticipator at 0ꢀ7 ampsꢀ Connect 24 volt thermostat leads to the two(2) yellow wires

located in service switch junction box, located on outer jacket of boilerꢀ See Figꢀ13 for service

switch junction box and thermostat field wiring connectionsꢀ

Cꢀ Connect Circulator Pump Wiring

See Figꢀ13 for service switch junction box and circulator pump field wiring connectionsꢀ A 5 feet

wiring harness with flexible metal conduit is supplied to connect the circulator pump to the ser-

vice switch junction boxꢀ If the two 120 volt circulator wire terminals inside the junction box are

not used, please leave the two wire nuts to prevent the short circuitꢀ

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLSꢀ WIRING

ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATIONꢀ VERIFY PROPER

OPERATION AFTER SERVICINGꢀ

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Cꢀ

FIGURE 13 FIELD WIRING CONNECTIONS

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If any of the original wire as supplied with this appliance must be replaced, it must be replaced

with type 150°C Thermoplastic wire or its equivalent

Dꢀ

FIGURE 14 SCHEMATIC WIRING DIAGRAM

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Eꢀ

FIGURE 15 LADDER WIRING DIAGRAM

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CONTROLS AND ACCESSORIES

This section provides a brief description of the key controls and accessories found in this boilerꢀ

See the Troubleshooting section of the Service Hints chapter of this installation manual for detailed

sequences of operation and troubleshooting proceduresꢀ See the Repair Parts chapter of this manual for

locations of all control components and accessories describedꢀ

Aꢀ INTEGRATED BOILER CONTROL (IBC)

The Integrated Boiler Control (IBC) is a microprocessor based controller for a high efficiency gas

boiler that monitors all safety controls and which controls the operation of the combustion air blower,

circulator pump, burner, and a combination hot surface igniter/flame sensorꢀ This controller is not

intended for use with a vent damperꢀ This controller is mounted on the control panel inside of the

boiler and contains four (5) diagnostic indicator lightsꢀ

Bꢀ GAS CONTROL VALVE

The electrically controlled 24 Volt Honeywell Model VR8205 Combination Gas Control Valve is

designed to meet the requirements for use with hot surface ignition systems found in this boilerꢀ

The valve is piped to the gas/air mixerꢀ

Cꢀ HOT SURFACE IGNITER

The 120 volt Hot Surface Igniter heats up to 1800 °F to initiate combustion of the gas in the burnerꢀ

The igniter is mounted next to the burner through the gas/air mixerꢀ The igniter also serves as a

means for proving the main burner flame by flame rectificationꢀ In the event of a lack of flame signal

on three (3) consecutive trials for ignition, the IBC will lockoutꢀ The “VALVE” and “FLAME” diagnostic

indicator lamps (lamp “D” and “E” on the IBC, See Figꢀ 16) will blink indicating the failure mode as a

lack of flame signalꢀ The IBC is manually reset from lockout by either removing and reestablishing the

thermostat’s call for heat, or by turning the service switch off, then back onꢀ

Dꢀ HIGH LIMIT AQUASTAT CONTROL

The High Limit Aquastat Control determines the maximum boiler water temperature and also

provides a means for protecting the boiler and heating system from unsafe operating conditions

which could damage the boilerꢀ The aquastat is mounted in the ½" NPT control well and ¾”x½”

bushing on the top of the front boiler section at the hot water outletꢀ The aquastat is tied in with the

IBC and is factory set at 180 °F water temperatureꢀ The high limit setpoint is field adjustable and may

be set anywhere between 100 °F and 200 °Fꢀ The field setpoint adjustment for each installation

depends on heating system requirementsꢀ The aquastat automatically resets when the boiler water

temperature decreases (5-30 °F adjustable differential)ꢀ The differential can be adjusted with the

(white) Differential Adjustment Wheel on the aquastat and gives the flexibility for boiler operationꢀ The

larger the differential, the longer the run cycle of the boilerꢀ

NOTE: The maximum setpoint of the Aquastat must not exceed 200 °Fꢀ

Eꢀ DRAFT INDUCER TEMPERATURE SAFETY SWITCH

The Draft Inducer Temperature Safety Switch is a disc thermostat (180 °F setpoint) located on the

induced draft fan outlet portꢀ The switch protects the inducer and vent pipe from a potential high

temperature condition for the discharging flue gasesꢀ This condition would typically be a result of

higher aquastat setting or over firingꢀ The temperature safety switch automatically resets when the

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higher aquastat setting or over firingꢀ The temperature safety switch automatically resets

when the vent temperature decreasesꢀ (15 °F switch differential)ꢀ

Fꢀ CASTING TEMPERATURE SAFETY SWITCH

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

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

shutting off power to the Integrated Boiler Control (IBC) and causes the Power Indicator Light

to go outꢀ This fault requires manual reset of the casting temperature safety switch to restart

the boilerꢀ Verify that the boiler is properly filled with water before resetting this switchꢀ

WARNING-Never run cold water into a hot empty boilerꢀ

Gꢀ DIFFERENTIAL PRESSURE AIR PROVING SWITCH

The diaphragm type differential pressure switch is connected by vinyl tubing to the pressure

signal hose adaptersꢀ The pressure switch monitors air flow by sensing the diffential

pressure measured in inches of water(“ wꢀcꢀ)ꢀ The factory settings on these switches are

1ꢀ00 “wꢀcꢀ for Model-100, 1ꢀ35 “wꢀcꢀ for Model-75 and 1ꢀ55 “wꢀcꢀ for Model-50ꢀ The contacts

are normally open, and close when the draft inducer is running and causing the diffential

pressure at the switch to exceed the settingꢀ The closed switch proves there is adequate air

flow for combustionꢀ The pressure switch shuts off the main burner if the differential pressure

is inadequate due to a blocked vent pipe or a blocked air intake or blocked boiler sections or

blocked draft inducerꢀ After five (5) minutes of lack of the adequate differential pressure, the

IBC will lockoutꢀ The “PURGE” indicator light will blink, indicating a failure to prove adequate

combustion air flow or flue gas flowꢀ The IBC is manually reset from lockout as described in

the Sequence of Operation section of this chapterꢀ

Hꢀ DRAFT INDUCER

The draft inducer (blower) provides a means for pulling combustion air into and through the

mixer, the burner, the flue ways of the cast aluminum boiler sections and the flue adapter

before being discharged through the vent piping to the outdoorsꢀ See applicable sections for

proper sizing and installation of combustion air and vent piping in this manualꢀ

Iꢀ CIRCULATOR PUMP

Every forced hot water system requires at least one circulating pumpꢀ The circulating pump

imparts the necessary energy to move the water through the closed loop supply and return

piping systems, terminal heating equipment (iꢀeꢀ finned tube radiators, etcꢀ) and back

through the boiler for reheatingꢀ To provide the required hot water flow rates, the circulator

pump must be properly sized to overcome frictional losses (usually measured in feet of

water, also referred to as “pump head loss”) of the supply and return piping systems and

boilerꢀ The circulator pump is furnished in a carton within the boiler cabinet for a single zone

or zone valve controlled heating system and should be correctly located on the downstream

(iꢀeꢀ, pumping away) side of the expansion tankꢀ For a pump controlled system (where there

is a circulator for each zone) the circulator provided with the boiler can work for one zoneꢀ

For more details on piping and circulators, see Near Boiler Piping section of this manualꢀ

Jꢀ DRAIN VALVE

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

the boiler and hot water supply and return piping systems installed above the drain valveꢀ This

drain valve is installed in the 3/4" tapping at the bottom of the front boiler sectionꢀ Any piping

installedbelow the elevation of this drain valve will require additional drain valves to be installed

at low points in the piping systems in order to drain the entire systemꢀ

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Kꢀ AꢀSꢀMꢀEꢀ RATED PRESSURE RELIEF VALVE

Each boiler must have a properly sized and installed American Society of Mechanical Engi-

neers rated pressure relief valveꢀ Water expands as it is heated by the burner/boiler sectionsꢀ

If there is no place for the water to expand its volume, (iꢀeꢀ a properly sized and properly

functioning expansion tank) pressure on the inside of the boiler and heating system will

increaseꢀ The furnished relief valve will automatically open at 30 psig pressure to relieve the

strain on the boiler and heating system from the increasing pressureꢀ The pressure relief

valve discharge must be piped with piping same size as the valve discharge opening to an

open drain, tub or sink, or other suitable drainage point not subject to freezing, in accordance

with AꢀSꢀMꢀEꢀ specificationsꢀ Failure to provide the pressure relief valve with piping as herein

described may cause water damage and/or serious bodily injuryꢀ The boiler manufacturer is

not responsible for any water damage or personal injuryꢀ

Lꢀ FLAME ROLLOUT SAFETY SHUTOFF

As required, this boiler is equipped with a manual reset flame rollout safety shutoff means,

which shuts off main burner gas in the event that the flow of combustion products through

the flueways is reducedꢀ In the event of blocked flueways, enough air will not be available to

support combustion, and the S9301 Integrated Boiler Control (IBC) will lockout due to loss of

adequate air flow (after 3 trials for ignition)ꢀ The “PURGE” diagnostic indicator lamp (lamp “B”

on the IBC, see Figꢀ16) will blink indicating the failure mode as a lack of adequate air flowꢀ

The IBC is manually reset from lockout by either removing and reestablishing the

thermostat’s call for heat, or by turning the service switch off, then back onꢀ If the boiler

cannot be restored to normal operating condition by resetting the control, contact a qualified

service agency to check heat exchanger flueways for blockageꢀ

Mꢀ (OPTIONAL) EXTERNAL CONDENSATE PUMP

For installations where there is no floor drain or other appropriate drainage receptacle avail-

able to receive condensate from the boiler, an external float activated condensate pump with

integral sump is requiredꢀ This unit can be installed to pump the condensate to a remote tie

in point to a sanitary sewer systemꢀ For this application, the boiler must be installed so that

proper pitch of piping to the external condensate reservoir (sump) can be accomplishedꢀ Use

wood frame or blocks to raise boiler as required for proper installationꢀ

START - UP

Aꢀ WATER TREATMENT AND FREEZE PROTECTION

1ꢀ When filling the boiler and heating system, water treatment is generally not required or

desiredꢀ For localities where the water is unusually hard (above 7 grains hardness) or for

low pH water conditions (below 7ꢀ0), consult a local water treatment specialistꢀ

aꢀ This boiler is designed for use in a closed hydronic heating system ONLY!

bꢀ Excessive feeding of fresh make-up water to the boiler may lead to premature failure

of the boiler sectionsꢀ

2ꢀ Use clean fresh tap water for initial fill and make-up of boilerꢀ

aꢀ A sand filter must be used if fill and make-up water from a well is to be usedꢀ

bꢀ Consideration should be given to cleaning the heating system, particularly in

retrofit situations, where a new boiler is being installed in an older piping systemꢀ

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cꢀ In older system, obviously discolored, murky, or dirty water, or a pH reading below 7, are

indications that the system should be cleanedꢀ

dꢀ A pH reading between 7 and 8 is preferredꢀ

3ꢀ Antifreeze if needed, must be of a type specifically designed for use in closed hydronic heating

systems and with aluminumꢀ

aꢀ Choice and use of antifreeze must be in accordance with local plumbing codesꢀ

b Only INTERCOOL NFP-50 is approved for useꢀ

Ÿ Use of any antifreeze other than INTERCOOL NFP-50 will void warrantyꢀ

Ÿ Antifreeze must be maintained per manufacturers specifications, failure to do so will

result in the warranty being voidedꢀ

cꢀ Do not use automotive antifreeze as the type of corrosion inhibitors used will coat the boiler’s

heat transfer surfaces and greatly reduce capacity and efficiencyꢀ

dꢀ Consult antifreeze manufacturer’s literature for compatibility of antifreeze with

aluminum boilerꢀ For approved manufactured antifreeze (INTERCOOL NFP-50 Coolant)

please contact Interstate Chemical Coꢀ New York Customer Service at 1-800-422-2436ꢀ

Some brands have corrosion inhibitors that break down more rapidly or become ineffective at

higher operating temperatures when used with aluminumꢀ Follow the antifreeze manufacturers

instructions on determining the proper ratio of antifreeze to water for the expected low

temperature conditions, and for maintaining the quality of the antifreeze solutions from year to

yearꢀ

eꢀ Use of antifreeze in any boiler will reduce capacity by as much as 10 to 20%, due to differing

heat transfer and pumping characteristicsꢀ This must be taken into consideration when sizing

the heating system, pump(s), and expansion tankꢀ Consult antifreeze manufacturer’s literature

for specific information on reduced capacityꢀ

fꢀ Water content of the boiler is 2ꢀ6 gallonsꢀ (10 liters)

Bꢀ FILLING BOILER WITH WATER AND PURGING ARE FOR SYSTEMS WITH DIAPHRAGM

TYPE EXPANSION TANKSꢀ

Refer to appropriate “Near Boiler Piping” diagramsꢀ

1ꢀ Close all zone service valves on the supply and return pipingꢀ Open the feed valve and fill boiler

with waterꢀ Make sure air vent is openꢀ Hold relief valve open until water runs air free for five

seconds to rapidly bleed air from boiler, then let the relief valve snap shutꢀ

2ꢀ Open the zone service valve on the supply pipe for the first zoneꢀ Open the purge valve on the

first zoneꢀ Feed water will fill the zone, pushing air out the purge valveꢀ Close the purge valve

when the water runs air freeꢀ Close the zone service valveꢀ

3ꢀ Repeat step 2 for all remaining zonesꢀ

4ꢀ Open all service valvesꢀ Any air remaining trapped in the return lines between the service valves

and the boiler will be pushed towards the air vent when the boiler is placed in operationꢀ

5ꢀ Inspect piping systemꢀ Repair any leaks immediatelyꢀ

Cꢀ FILLING BOILER WITH WATER AND PURGING AIR FOR SYSTEMS WITH

CONVENTIONAL CLOSED TYPE EXPANSION TANKS

Refer to appropriate “Near Boiler Piping” diagramsꢀ

1ꢀ Close all zone service valves on the supply and return piping and close the expansion tank service

valveꢀ Drain expansion tankꢀ Open the feed valve and fill boiler with waterꢀ Hold relief valve open

until water runs air free for five seconds to rapidly bleed air from boiler, then let the relief valve

snap shutꢀ

2ꢀ Open the zone service valve on the supply pipe for the first zoneꢀ Open the purge valve on the

first zoneꢀ Feed water will fill the zone, pushing air out the purge valveꢀ Close the purge valve

when the water runs air freeꢀ Close the zone service valveꢀ

3ꢀ Repeat step 2 for all remaining zonesꢀ

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4ꢀ Open the expansion tank service valve and the tank ventꢀ Fill the tank to the proper level

and close the tank ventꢀ Remove the handle from the expansion tank service valve so

the homeowner doesn’t accidentally close itꢀ

5ꢀ Open all service valvesꢀ Any air remaining trapped in the return lines between the

service valves and the boiler will be pushed towards the expansion tank when the boiler

is placed in operationꢀ

6ꢀ Inspect piping systemꢀ Repair any leaks immediatelyꢀ

NOTE: DO NOT use stop leak compoundsꢀ Leaks in threaded connections in the

aluminumboiler sections must be repaired immediatelyꢀ Aluminum threads will not

seal themselvesꢀ

Dꢀ PLACING BOILER IN OPERATION

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life

Aꢀ

Bꢀ

This appliance is equipped with an ignition device which

automatically lights the pilotꢀ Do not try to light the pilot

by handꢀ

· If you cannot reach your gas supplier, call the fire

departmentꢀ

Cꢀ

Dꢀ

Use only your hand to move the system control switchꢀ

Never use toolsꢀ If the switch will not move by hand,

don't try to repair it, call a qualified service technicianꢀ

Force or attempted repair may result in a fire or

explosionꢀ

BEFORE OPERATING smell all around the appliance

area for gasꢀ Be sure to smell next to the floor because

some gas is heavier than air and will settle on the floorꢀ

WHAT TO DO IF YOU SMELL GAS

· Do not try to light any applianceꢀ

Do not use this appliance if any part has been under

waterꢀ Immediately call a qualified service technician

to inspect the appliance and to replace any part of the

control system and any gas control which has been

· Do not touch any electrical switch; do not use any phone

in your buildingꢀ

· Immediately call your gas supplier from a neighbor's

phoneꢀ Follow the gas supplier's instructionsꢀ

under waterꢀ

OPERATING INSTRUCTIONS

5ꢀ Remove the front jacket panelꢀꢀ

1ꢀ STOP! Read the safety information above on this labelꢀ

2ꢀ Set thermostat to lowest settingꢀ

6ꢀ Turn the gas control knob clockwise

to “OFF”ꢀ

7ꢀ Wait five (5) minutes to clear out any gasꢀ Then smell for

gas, including near the floorꢀ If you smell gas, STOP!

Follow “B” in the safety information above on this labelꢀ If

you don’t smell gas go on to next stepꢀ

3ꢀ Turn off all electric power to the applianceꢀ

4ꢀ This appliance is equipped with an ignition device which

automatically lights the burnerꢀ DO NOT try to light the

burner by handꢀ

8ꢀ Turn the gas control knob counter clockwise

“ON”ꢀ

9ꢀ Replace front jacket panelꢀ

10ꢀ Turn on all electrical power to the applianceꢀ

11ꢀ Set the thermostat to desired settingꢀ

12ꢀ Iftheappliancewillnotoperate, followtheinstructions“To

TurnOffGasToAppliance”andcallyourservicetechnician

or gas supplierꢀ

TO TURN OFF GAS TO APPLIANCE

1ꢀ Set the thermostat to lowest settingꢀ

2ꢀ Turn off all electric power to the appliance if service is to

be preformedꢀ

4ꢀ Turn gas control knob clockwise

5ꢀ Replace the front jacket panelꢀ

to “OFF”ꢀ

3ꢀ Remove the front jacket panelꢀ

Safe lighting and other performance criteria were met with the gas manifold and control assembly

provided on the boiler when the boiler underwent tests specified in ANSI Z21ꢀ13-latest revisionꢀ

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CHECK OUT PROCEDURE AND ADJUSTMENT

FIGURE 16 INDICATOR LAMPS

Aꢀ VERIFY PROPER SEQUENCE OF OPERATION

The sequence can be followed via the diagnostic indicator lamps on the Honeywell S9301A

integrated boiler control in Figꢀ 16ꢀ This is the normal sequence of operationꢀ A more detailed

sequence of operation containing potential faults can be found in the service hints sectionꢀ

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NOTE: First couple of cold starts may be rough due to gas line not being completely purged

of air, causing low firing rate and high excess air levelsꢀꢀ

Bꢀ INSPECT VENTING AND AIR INTAKE SYSTEM

Operate the boiler and verify that all vent/air intake connections are gastight and watertightꢀ

Repair any leaks immediatelyꢀ

Cꢀ INSPECT CONDENSATE DRAIN

Verify that all connections are watertight, and that condensate flows freelyꢀ Repair any leaks

immediatelyꢀ

Dꢀ INSPECT SYSTEM PIPING

Verify that all connections are watertightꢀ Repair any leaks immediatelyꢀ

Eꢀ TEST IGNITION SYSTEM SAFETY SHUTOFF DEVICE

1ꢀ Turn off manual gas valve

2ꢀ Set thermostat to call for heat

3ꢀ Boiler begins normal sequence of operation

4ꢀ After approximately 40 seconds (pre purge and igniter warm-up period), lamp D illumi

nates, indicating gas valve is powered

5ꢀ After 6 seconds, gas valve closes, lamp D goes out as integrated boiler control senses

that flame is not present

6ꢀ To restart system, follow operating instructions under “START-UP PLACE IN OPERATION”

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Fꢀ TEST HIGH LIMIT CONTROL AND ADJUST

While burner is operating, move indicator on high limit control below actual boiler water

temperatureꢀ Burner should go off while circulator continues to operateꢀ Raise limit setting

above boiler water temperature and burner should reignite after pre purge and igniter warm-

up periodꢀ Set the high limit control to the design temperature requirements of the systemꢀ

Maximum high limit setting is 200^°Fꢀ Minimum high limit setting is 100°Fꢀ

Gꢀ TEST OTHER SAFETY CONTROLS

If the boiler is equipped with a low water cut off, a manual reset high limit, or additional safety

controls, test for operation as outlined by the control manufacturerꢀ Burner should be operat-

ing and should go off when controls are testedꢀ When safety controls are restored, burner

should reigniteꢀ

Hꢀ SET THERMOSTAT HEAT ANTICIPATOR (IF USED) AND VERIFY THERMOSTAT OPERATION

For a single thermostat connected to the yellow thermostat lead wires in the furnished field

wiring junction box, the heat anticipator should be set at 0ꢀ7 ampsꢀ For other wiring configura-

tions, refer to the instructions provided by the thermostat manufacturer regarding adjustment

of heat anticipatorꢀ Cycle boiler with thermostatꢀ Raise the thermostat to the highest setting

and verify boiler goes through normal start up cycleꢀ Lower thermostat to lowest setting and

verify boiler goes offꢀ

Iꢀ MEASURE THE NATURAL GAS INPUT RATE

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

1ꢀ Determine elevation at installation siteꢀ

2ꢀ See page 4 and 5 of this manual to determine the correct input rate for the local elevationꢀ

3ꢀ Obtain the yearly average heating value of the local gas supply from the gas utilityꢀ At sea

level elevation, it should be approximately 1000 Btu’s per standard cubic footꢀ

4ꢀ Operate boiler for 5 minutesꢀ

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

6ꢀ At gas meter, measure time in seconds required to use one cubic foot of gasꢀ

7ꢀ Calculate input rate according to the following formula:

3600xheating value from step 3

Btuh input rate = time from step 6

8ꢀ Measured input rate should be within +/-2% of the input rating from step 2ꢀ If within 2%, go

to step 9ꢀ If not, adjustment is required, proceed as follows:

aꢀ Turn boiler off

bꢀ Set up U-tube manometer or differential pressure gauge for measuring manifold pres

sure, see FIGꢀ 17ꢀ

cꢀ Manometer or gauge must be able to read at least 0ꢀ0 to 3ꢀ0 inches water column of

pressure, and resolve to at least 0ꢀ1 inches water columnꢀ

dꢀ Turn boiler onꢀ

eꢀ Manifold pressure has been nominally set at 2ꢀ5 inches wꢀcꢀ Manifold pressure and input

rate must always be measured with pressure regulator cover screw installedꢀ Cover screw

must be removed for adjustmentꢀ Manifold pressure reading will change (increase) when

cover screw is removedꢀ

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THE FOLLOWING STEPS AND DIAGRAM INDICATE THE LOCATION OF THE CONNECTION

POINTS REQUIRED TO MEASURE THE MANIFOLD PRESSUREꢀ

THE MANIFOLD PRESSURE MAY BE MEASURED USING A U-TUBE MANOMTERE OR A

DIFFERENTILA PRESSURE GAUGEꢀ THE DIAGRAM SHOWS THE CONNECTION OF BOTH

MEASURING DEVICES BUT ONLY ONE DEVICE IS REQUIRED TO MEASURE THE MANIFOLD

PRESSUREꢀ

SIDE LINE FROM THE U-TUBE MANOMETER OR THE DIFFERENTIAL PRESSURE GAUGEꢀ

REFER TO “CHECK OUT PROCEDURE AND ADJUSTMENTS” IN THIS MANUAL WHEN READING

MANIFOLD PRESSUREꢀ

WHEN MEASUREMENT IS COMPLETE, DISCONNECT U-TUBE MANOMETER OR DIFFERENTIAL

PRESSURE GAUGEꢀ BE SURE TO REINSTALL 1/8" PLUG, USING APPROPRIATE PIPE THREAD

SEALANT APPROVED FOR USE WITH NATURAL AND LIQUIFIED PETROLEUM GASESꢀ

FIGURE 17 MANIFOLD PRESSURE MEASUREMENT DETAIL

Top view of gas control

NOTE: Regulator cover screw must be installed

at all times unless adjusting manifold

pressureꢀ Firing rate and manifold

pressure must only be measured with

cover screw firmly installedꢀ

FIGURE 18 GAS VALVE

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Iꢀ Remove regulator cover screw on top of gas valve, and insert an appropriate screw-

driver into adjustment screwꢀ

IIꢀ Turn adjustment screw clockwise to increase input rate, or counter clockwise to de-

crease input rateꢀ

IIIꢀ Replace cover screw, or cover hole temporarily with your finger to check new mani-

fold pressure settingꢀ Do not set manifold pressure lower than 2ꢀ0 inches wꢀcꢀ or

higher than 3ꢀ0 inches wꢀcꢀ when adjusting input rateꢀ

IVꢀ Measure new input rate (cover screw must be installed)ꢀ Repeat steps Iꢀ-IV until the

input rate is within +/-2% of the nameplate input ratingꢀ

Vꢀ If the actual input rate can not be set to within 2% of the correct input rating by adjust-

ing manifold pressure, a change in gas orifice size is requiredꢀ Consult the boiler

manufacturer for information on correct orifice sizingꢀ The specific gravity (G) and the

higher heating value (HHV) of the local natural gas must be obtained from the local

gas utility in order to determine the proper orifice sizeꢀ

fꢀ After adjusting input rate, turn boiler off, remove manometer or pressure gauge, reinstall

1/8" plug on gas valveꢀ Turn boiler onꢀ

9ꢀRestore all gas appliances that may have been shut off (while measuring boiler input

rate) to normal operating conditionsꢀ

Jꢀ SET THERMOSTAT TO DESIRED ROOM TEMPERATURE

Observe several operating cycles to verify proper operationꢀ

K REVIEW ALL INSTRUCTIONS

Review all instructions shipped with this boiler with owner or maintenance personꢀ Instructions

must be affixed on or adjacent to the boilerꢀ

Lꢀ COMPLETE AND SIGN THE INSTALLATION AND CHECK-OUT CERTIFICATE ON THE

FOLLOWING PAGEꢀ

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INSTALLATION AND CHECK-OUT CERTIFICATE

Boiler Model

Serial #

Date Installed___________

Measured BTU/HR input____________

¡ Installation instructions have been followed

¡ Checkout procedure and adjustments performed

¡ Maintenance and Service issues reviewed with owner/ maintenance person

¡ Installation booklet affixed on or adjacent to boiler

Installer (Company)

Address

Phone

Installer’s Name

Signature

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MAINTENANCE AND CLEANING

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

The acidic nature of flue gasses condensing on the aluminum boiler sections will cause the

formation of aluminum oxideꢀ This oxide formation is normal, is generally uniform throughout the

boiler sections, and represents a negligible mass of aluminum that is consumed by oxidation

during the life of the boilerꢀ If left unchecked, this buildup may eventually cause blockage of the

flue gas passages in the boiler sections, reducing efficiency, and ultimately shutting down the

boiler due to lack of combustion air flowꢀ Regular service and maintenance by a qualified service

agency must be performed to assure safe trouble free operation and maximum efficiencyꢀ

Aꢀ BEGINNING OF EACH HEATING SEASON

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

aꢀ Examine flue passages between boiler sections, burner, and condensate lines, and

clean if necessary following the annual examination and cleaning instructions in para

graph “F” on the next pageꢀ

bꢀ Visually inspect venting and air intake system for proper function, deterioration or

leakageꢀ If the vent or air intake show any signs of deterioration or leakage, repair or

replace them, immediatelyꢀ Insure proper reassembly and resealing of the vent and air

intake systemꢀ cꢀCheck for and remove any obstruction to the flow of combustion air

or venting of flue gasesꢀ Check the air baffle located inside 1 1/2"x2" flexible coupling

on the mixer, clean it if necessary and make sure to put it backꢀ Refer to repair parts

diagram of mixer and pressure switch assembly for exact locationꢀ

dꢀ Follow instructions for “PLACING BOILER IN OPERATION”ꢀ

eꢀ Follow instructions for” CHECK OUT PROCEDURE AND ADJUSTMENTS”ꢀ

fꢀ Visually inspect condensate drain line for proper operation and deteriorationꢀ Check

for plugged condensate drain lineꢀ

gꢀ Check the silicone rubber seals between boiler sectionsꢀ Insure that there are no

leaksꢀ Use RTV silicone rubber adhesive sealant (available in caulking gun tubes)

rated for at least 400° F to replace or repair seals in locations where original seals

have deterioratedꢀ

hꢀ Check all gasketed joints for leakage, and tighten bolts or replace gaskets if necessaryꢀ

iꢀ Remove jacket front and top panels and check for piping leaks around relief valve and

other fittingsꢀ Repair, if foundꢀ DO NOT use stop leak compoundsꢀ

2ꢀ Check that boiler area is free from combustible materials, gasoline, and other flammable

vapors and liquidsꢀ

3ꢀ Circulator pump and blower motor furnished with boiler are permanently lubricated from

factory and require no further lubricationꢀ Additional or non-factory supplied pumps and/or

motors should be lubricated according to the pump and/or motor manufacturer’s instructionꢀ

Bꢀ DAILY DURING HEATING SEASON

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

2ꢀ Check that boiler area is free from combustible materials, gasoline, and other flammable

vapors and liquidsꢀ

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Cꢀ MONTHLY DURING HEATING SEASON

1ꢀ Remove jacket front and top panels and check for piping leaks around relief valve and

other fittingsꢀ If found, contact a qualified service agency to repairꢀ DO NOT use stop leak

compoundsꢀ

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

3ꢀ Visually inspect venting and air intake system for proper function, deterioration, or

leakageꢀ If the vent or air intake show any signs of deterioration or leakage, contact a

qualified service agency to repair or replace them immediately and to insure proper

reassembly and resealing of the vent and air intake systemꢀ

4ꢀ Visually inspect the clear vinyl condensate lines and the PVC condensate drain pipe for

proper operation, leakage, and deteriorationꢀ If the condensate lines or drain pipe show

any signs of blockage, leakage, or deterioration contact a qualified service agency to

clean, repair, or replace them immediatelyꢀ

5ꢀ Check the air baffle located inside 1 1/2"x 2" flexible coupling, clean it if necessary and

make sure to put it backꢀ Refer to repair parts diagram, mixer and pressure switch

assemblyꢀ

Dꢀ PERIODICALLY DURING HEATING SEASON

1ꢀ Where low water cut offs are used, a periodic inspection of the low water cut off is

necessary, including flushing of float type devicesꢀ Refer to low water cut off

manufacturer’s specific instructionsꢀ

Eꢀ END OF EACH HEATING SEASON - ANNUAL SHUTDOWN PROCEDUR

1ꢀ Follow instructions “TO TURN OFF GAS TO APPLIANCE”ꢀ

2ꢀ If heating system is to remain out of service during freezing weather, and does not contain

antifreeze, drain system completelyꢀ If boiler will be exposed to freezing temperatures,

drain condensate linesꢀ Otherwise, do not drain system or boilerꢀ

Fꢀ ANNUAL EXAMINATION AND CLEANING OF BOILER COMPONENTS

The following service procedures must be performed only by a qualified service

agencyꢀ Boiler owner should not attempt these proceduresꢀ

1ꢀ Before Servicing, turn off electrical power to boiler at service switchꢀ Close manual gas

valve to turn off gas supply to boilerꢀ

2ꢀ Cleaning Flue passages between boiler sectionsꢀ

aꢀAny buildup of sediment or aluminum oxide (white powdery or flaky substance) in the

flue passages must be cleaned as follows:

bꢀRemove jacket front and top panelsꢀ Disconnect condensate drain line from the barbed

fitting on the bottom of the boilerꢀ Keep the open end of the drain line above the water

level in the condensate trap to prevent the trap from drainingꢀ Disconnect pressure switch

hose from barbed fitting on gas valveꢀ Disconnect 1½ x 2” flexible coupling from air inletꢀ

Disconnect air by-pass (½” transparent vinyl tube) from the bottom of the mixerꢀ

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cꢀ Remove air baffle from 1%z” x2" flexible coupling and clean air baffle if necessaryꢀ

Refer to repair parts diagram, mixer and pressure switch assemblyꢀ

dꢀ Confirm that manual gas valve is closed and disconnect gas line to gas valve at unionꢀ

Disconnect wires to gas valveꢀ and igniterꢀ

eꢀ Loosen but do not remove five (5) nuts attaching mixer assembly to boilerꢀ Remove

two (2) igniter screws and very carefully remove the igniterꢀ Use care when removing

the igniter, it is very brittle!!

fꢀ Remove five (5) nuts and remove mixer assemblyꢀ Remove burner and mixer gasketꢀ

gꢀ Aluminum oxide deposits are water soluble and may be rinsed away with spraying or

running waterꢀ Before rinsing, connect a ‘/z” IꢀDꢀ hose to the barbed fitting on the

bottom of the boiler and run the hose to a bucket or drainꢀ

hꢀ After rinsing, remove any remaining loosened sediment using a shop vacuum with a

snorkel attachmentꢀ

i Inspect burner for any foreign matter in the flame ports or inside the burnerꢀ Any for-

eign matter should be removed by blowing with compressed air or vacuumingꢀ

jꢀ Inspect interior of mixer for any signs of sediment or aluminum oxide and clean if necessaryꢀ

kꢀ Reinstall burner and mixer gasket and position mixer assembly over studsꢀ Install five

(5) nuts but do not tightenꢀ Reinstall igniter and igniter gasket and fasten with two (2)

screwsꢀ Use care when installing the igniterꢀ It is very brittle!! Tighten five (5) nuts

holding mixer assemblyꢀ

lꢀ Connect:

• gas line to gas valve

• condensate drain line to boiler

• pressure switch hose to gas valve

• air by-pass to mixer

• 1 1/2" x2" flexible coupling to air inlet and make sure to put air baffle back to

correct position

• igniter wires

• gas valve wires

3ꢀ Visually inspect condensate lines leading from the boiler sections and the vent tee to the

condensate trapꢀ Refer to repair parts diagramsꢀ Any foreign material or debris that is

visible in the condensate lines needs to be cleaned out as follows: ꢀ

aꢀ Raise condensate trap and drain condensate lines completelyꢀ

bꢀ Once the condensate trap is emptied of water, disconnect condensate lines from the

fittings on the boiler, the vent tee, and the condensate outletꢀ

cꢀ Remove the condensate trap and run cold water through the condensate lines to

thoroughly flush out any sediment or debris in the linesꢀ

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dꢀ Reinstall and connect the condensate trap, using the hose clamps to secure the various

condensate lines to their fittingsꢀ

eꢀ Follow the instructions under “NEAR BOILER PIPING” for”filling condensate trap with

water”

4ꢀ Inspection of the flue connector requires the following steps (Refer to the repair parts diagramꢀ)

aꢀ Loosen the clamp on the draft inducer end of the 2" flexible coupling that connects the

vent tee to the draft inducerꢀ Disconnect (unplug) wiring harness from draft inducer motor

and draft inducer temperature safety switchꢀ Remove four (4) bolts that attach draft in

ducer to flue connectorꢀ

bꢀ Remove draft inducer and gasket from top of flue connectorꢀ

cꢀ Inspect interior of flue connectorꢀ Any buildup of sediment or aluminum oxide on the

inside surface must be cleanedꢀ Position the draft inducer gasket and the draft inducer

and fasten with four (4) screwsꢀ Be sure to connect ground wire from draft inducer motor

to one of the four mounting screwsꢀ

dꢀ Connect wiring harness leads to the draft inducer motor and the draft inducer tempera

ture safety switchꢀ

eꢀ Connect the 2" flexible coupling to the draft inducer outletꢀ

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SERVICE HINTS

DETAILED SEQUENCE OF OPERATION

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DETAILED SEQUENCE OF OPERATION

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END OF NORMAL SEQUENCE OF OPERATION

DETAILED SEQUENCE OF OPERATION

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!!WARNING!!

FIRE, EXPLOSION OR SHOCK HAZARD MAY CAUSE

PROPERTY DAMAGE, SEVERE INJURY OR DEATHꢀ

DO NOT ATTEMPT TO MODIFY THE PHYSICAL OR ELECTRICAL

CHARACTERISTICS OF THIS BOILER IN ANY WAYꢀ

IMPORTANT

1ꢀ IN A RESET FROM LOCKOUT CONDITION, ALL ELECTRICAL METER READINGS AT THE GAS

CONTROL VALVE (24 VAC) MUST BE TAKEN WITHIN THE TRIAL FOR IGNITION PERIODꢀ

2ꢀ IF ANY COMPONENT DOES NOT FUNCTION PROPERLY, MAKE SURE IT IS CORRECTLY INSTALLED

AND WIRED BEFORE REPLACING ITꢀ

3ꢀ STATIC ELECTRICITY DISCHARGE CAN DAMAGE THE INTEGRATED BOILER CONTROL (IBC)ꢀ

TOUCH METAL SURFACE TO DISCHARGE STATIC ELECTRICITY BEFORE TOUCHING IBCꢀ

4ꢀ THE IBC CANNOT BE REPAIREDꢀ IF IT MALFUNCTIONS IT MUST BE REPLACEDꢀ

5ꢀ ONLY TRAINED, EXPERIENCED SERVICE TECHNICIANS SHOULD SERVICE THE IBC SYSTEMSꢀ

FOLLOWING TROUBLESHOOTING, CHECK OUT THE SYSTEM FOLLOWING THE SEQUENCE OF

OPERATION SECTION OF THIS CHAPTER FOR A NORMAL LIGHT OFF SEQUENCEꢀ

6ꢀ ALL CONTROLS ARE FACTORY TESTED IN THE ASSEMBLY PROCESS AND A DEFECTIVE

CONTROL IS GENERALLY THE LEAST LIKELY CAUSEꢀ IF YOU SUSPECT YOU HAVE A DEFECTIVE

CONTROL, READ THROUGH THE TROUBLESHOOTING CHART BEFORE YOU REPLACE ITꢀ

7ꢀ IT IS EXTREMELY UNLIKELY THAT THE TWO CONSECUTIVE CONTROLS ARE DEFECTIVEꢀ IF IT

SEEMS TO BE HAPPENING, CHANCES ARE THAT EITHER THERE IS NOTHING WRONG WITH THE

CONTORL OR IT IS BEING DAMAGED BY SOME OTHER PROBLEM (AN ELECTRICAL SHORT

BURNING OUT A TRANSFORMER, FOR EXAMPLE)ꢀ

INITIAL SERVICE CHECKS

1ꢀ BEFORE TROUBLESHOOTING:

Aꢀ MAKE SURE THAT CIRCUIT BREAKER IS ON OR FUSE IS OK AT ELECTRICAL PANELꢀ

Bꢀ MAKE SURE THAT SERVICE SWITCH IS ONꢀ

Cꢀ MAKE SURE THAT GAS IS ON AT THE GAS METER, AT ALL APPROPRIATE MANUAL

SHUTOFF VALVES AND AT THE GAS CONTROL VALVEꢀ

Dꢀ MAKE SURE THAT THE THERMOSTAT IS CALLING FOR HEATꢀ

Eꢀ CHECK THAT WIRE CONNECTORS AT THE INTEGRATED BOILER CONTROL AND AT THE

ORIGINATING CONTROL ARE SECURELY PLUGGED IN OR CONNECTEDꢀ

Fꢀ CHECK THAT HOSES ARE SECURELY CONNECTED AND ARE NOT PLUGGED IN OR

DAMAGEDꢀ

2ꢀ TROUBLESHOOTING TOOLS:

Aꢀ VOLTMETER TO CHECK 120 VAC AND 24 VAC

Bꢀ CONTINUITY TESTERꢀ

Cꢀ INCLINED MANOMETER OR PRESSURE GAUGE WITH 0-2ꢀ0” RANGE (0ꢀ01” SCALE) FOR

MEASURING SUCTION PRESSURES AT PRESSURE SWITCHꢀ

Dꢀ U-TUBE MANOMETER OR DIFFERENTIAL PRESSURE GAUGE WITH 0-14” RANGE (0ꢀ1”

SCALE) FOR MEASURING INLET AND MANIFOLD GAS PRESSURESꢀ

3ꢀ WHAT IS SYSTEM STATUS?

Aꢀ CONSULT THE CHART ON THE FOLLOWING PAGEꢀ

Bꢀ FIGURE 15 ON PAGE 29 SHOWS THE LOCATION ON THE BOILER OF THE DIAGNOSTIC

INDICATOR LAMPSꢀ

TROUBLE SHOOTING

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TROUBLE SHOOTING

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TROUBLESHOOTING CHART 1

!!WARNING!!

ELECTRICAL SHOCK HAZARD MAY CAUSE

SERIOUS INJURY OR DEATH#

THE FOLLOWING PROCEDURES MAY EXPOSE YOU TO

DANGEROUS LINE VOLTAGEꢀ USE CAUTION TO AVOID

TOUCHING LIVE ELECTRICAL CONTACTSꢀ SERVICE

MUST BE PERFORMED BY A TRAINED, EXPERIENCED

SERVICE TECHNICIANꢀ

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 BUILIDNGꢀ

IMMEDIATLEY CALL YOUR GAS SUPPLIER

FROM A NEIGHBOR’S PHONEꢀ FOLLOW THE GAS

SUPPLIER’S INSTRUCTIONꢀ

—

IF YOU CAN NOT REACH YOUR GAS SUPPLIER,

CALL THE FIRE DEPARTMENTꢀ

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY

FAIL TO SHUT OFF, DO NOT TURN OFF OR DISCONNECT

THE ELECTRICAL SUPPLY TO THE PUMPꢀ INSTEAD,

SHUT OFF THE GAS AT A LOCATION EXTERNAL TO THE

APPLIANCEꢀ

DO NOT USE THE BOILER IF ANY PART OF THE GAS

CONTROL SYSTEM HAS BEEN UNDER WATER A

QUALIFIED SERVICE TECHNICIAN SHOULD INSPECT THE

BOILER AND REPLACE ANY PART OF THE CONTROL

SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN

UNDER WATERꢀ

USE ONLY YOUR HAND TO TURN THE GAS CONTROL

KNOBꢀ NEVER USE TOOLSꢀ IF THE_ꢀKNOB WILL NOT TURN

BY HANDꢀ DON’T TRY TO REPAIR ITꢀ FORCE OR

ATTEMPTED REPAIR MAY RESULT IN A FIRE OR

EXPLOSIONꢀ

TROUBLE SHOOTING

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TROUBLESHOOTING CHART 2

TROUBLE SHOOTING

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TROUBLESHOOTING CHART 3

TROUBLE SHOOTING

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TROUBLESHOOTING CHART 4

TROUBLE SHOOTING

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TROUBLESHOOTING CHART 5

TROUBLE SHOOTING

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TROUBLESHOOTING CHART 6

TROUBLE SHOOTING

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The following steps and diagram

indicate the locations of the

connection points required to check

the differential air pressureꢀ

The differential air pressure switch is

a safety device which will prevent the

boiler from firing if there is an air

intake, boiler heat exchanger or vent

blockageꢀ

Turn off service switch, or lower

thermostat settingꢀ

Remove vinyl caps from Tee and 4-

way connectorꢀ

Install testing lines as shown to

inclined manometer or differential

pressure gauge with the ability to

read 0ꢀ01” to 2ꢀ0” wꢀcꢀ

Turn on service switch and set

thermostat to call for heatꢀ

Boiler Status

Not Running

Setpoint

Differential Pressure (wꢀcꢀ)

Pressure Switch Connects

Normally Open

0”

1ꢀ00” for Model-100

1ꢀ35” for Model-75

1ꢀ55” for Model-50

Running Without

Blockage

Greater Than Setpoints

Closed

Open

Running With

Blockage

Less Than or Equal to

Setpoints

If manometer readings do not correspond to the chart above, check for possible causes:

- Blockage or moisture in suction lines

- Blockage in air intake or vent pipes

- Undersized air intake or vent pipes

- Loose blower wheel or motor shaft

- Inncorect pressure switch or pressure switch setpoint

When pressure reading is proper and the pressure switch is operating properly, remove testing

lines and reinstall vinyl caps to Tee and 4-way connectorꢀ

Cꢀ

DIFFERENTIAL AIR PRESSURE SWITCH CHECK

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Aꢀ

JACKET AND BASE ASSEMBLY

REPAIR PARTS

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REPAIR PARTS

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Bꢀ

CONDENSATE DRAIN TRAP ASSEMBLY

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REPAIR PARTS

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Cꢀ

BOILER BLOCK AND PIPING ASSEMBLY

REPAIR PARTS

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