DUNKIRK Boiler Manual L0611511
User Manual: DUNKIRK DUNKIRK Boiler Manual DUNKIRK Boiler Owner's Manual, DUNKIRK Boiler installation guides
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GAS-FIRED,
DIRECT VENT,
CONDENSING,
HOT WATER
BOILERS
INSTALLATION
These instructions
INSTRUCTIONS
must be affixed on or adjacent to the boiler
WARNING
Improper installation, adjustment, alteration, service,
property
damage. Refer to this manual. For assistance
qualified installer, service agency, or gas supplier.
or maintenance
can cause injury or
or additional information consult a
@@
DUNKIRK BOILERS
DUNKIRK,
NEW YORK
14048 - 716 366-5500
Member: The Hydronics Institute
TABLE
OF CONTENTS
BOILER
RULES
BEFORE
RATINGS
INTRODUCTION
AND CAPACITIES
FOR SAFE INSTALLATION
INSTALLING
.............................................................................
..................................................................................
AND OPERATION
THE BOILER
.......................................................
....................................................................................
3
4
7
7
A. codes ...............................................................................................................................
7
B. boiler sizing ......................................................................................................................
C. considerations
for boiler location .....................................................................................
8
8
D. locating the boiler ............................................................................................................
E. combustion air and vent pipe requirements .....................................................................
8
9
F. condensate
drain requirements
G. foundation
requirements
H. removing
PLACING
existing
................................................................................................
boiler from common
THE BOILER
NEAR BOILER
......................................................................................
PIPING
venting system .................................................
10
11
11
.......................................................................................................
11
........................................................................................................
12
A. supply and return lines ...................................................................................................
12
B. pressure
16
relief valve .......................................................................................................
C. expansion
tank and make-up
D. condensate
water ...............................................................................
drain piping ................................................................................................
E. filling condensate
16
19
trap ....................................................................................................
19
F. chilled water piping ........................................................................................................
20
COMBUSTION
AIR AND VENT PIPE ..................................................................................
A. connections
and terminations
B. installation
........................................................................................
21
21
......................................................................................................................
22
PIPING ..........................................................................................................
25
A. check gas supply ...........................................................................................................
25
B. connecting the gas piping ..............................................................................................
C. checking the gas piping .................................................................................................
ELECTRICAL
WIRING .........................................................................................................
25
26
27
GAS SUPPLY
A.
B.
C.
D.
electric power supply .....................................................................................................
install your thermostat ....................................................................................................
field wiring connections
.................................................................................................
schematic wiring diagram ..............................................................................................
E. ladder wiring diagram .....................................................................................................
CONTROLS
AND ACCESSORIES
A. UT 1013-10
integrated
......................................................................................
boiler control ............................................................................
27
28
29
30
31
32
32
B. gas control valve ............................................................................................................
32
C. hot surface
32
D. L4006A
igniter ..........................................................................................................
high limit aquastat
E. draft inducer temperature
control
................................................................................
safety switch .........................................................................
32
32
F. casting temperature
safety switch ..................................................................................
33
G. differential
air proving switch ..........................................................................
33
pressure
1
H. draft inducer ......................................................................................................................
33
I. circulator pump ..................................................................................................................
J. drain valve .........................................................................................................................
K. relief valve ........................................................................................................................
33
33
34
L. flame rollout safety shutoff ................................................................................................
34
M. external
34
START-UP
condensate
pump ...............................................................................................
..............................................................................................................................
A. water treatment
and freeze
34
protection ..............................................................................
B. filling boiler with water and purging
air with diaphragm
C. filling boiler with water and purging air with conventional
type expansion
34
tanks ..................
closed type expansion
35
tanks .... 35
D. boiler in placing ..................................................................................................................
36
I. for your safety read before operating
II. operating instructions
III. to turn off gas to appliance
CHECK-OUT
PROCEDURES
AND ADJUSTMENTS
A.
B.
C.
D.
E.
F.
G.
H.
............................................................
verify proper sequence of operation ..................................................................................
inspect venting and air intake system ................................................................................
inspect condensate drain ...................................................................................................
inspect system piping .........................................................................................................
test ignition system safety shutoff ......................................................................................
test high limit control and adjust .........................................................................................
test other safety controls ....................................................................................................
set thermostat heat ............................................................................................................
1. measure the gas input rate ................................................................................................
J. set thermostat to desired room temperature ......................................................................
K. review all instructions ........................................................................................................
L. installation and check-out certificate ..................................................................................
MAINTENANCE
AND CLEANING ..........................................................................................
A.
B.
C.
D.
E.
beginning of each season ..................................................................................................
daily during heating season ...............................................................................................
monthly during heating ......................................................................................................
periodically during heating .................................................................................................
end of each heating season -annual shut down procedure ...............................................
F. annual examination
SERVICE
of boiler components
....................................................
HINTS ......................................................................................................................
A flow chart/detailed
B. trouble
sequence
of operation .........................................................................
shooting .................................................................................................................
C. differential
REPAIR
and cleaning
air pressure
switch check .................................................................................
PARTS .......................................................................................................................
37
37
38
38
38
38
38
39
39
39
41
41
41
43
43
43
44
44
44
44
47
47
50
58
59
A. jacket and base ..................................................................................................................
59
B. condensate
61
drain trap assembly
.......................................................................................
C. block and piping assembly .................................................................................................
62
D. mixer and air pressure
64
E. flue adapter
switch assembly ............................................................................
and exhauster
assembly ................................................................................
66
This appliance is a gas-fired
revolutionary cast aluminum
direct vent hot water boiler with cast aluminum boiler sections. A
heat exchanger means better heat transfer and thermal storage than
similarly sized cast iron boilers, which results in higher efficiency. The heating system water absorbs
amounts of heat from the cast aluminum heat exchanger, cooling the flue gases and causing
condensation.
Sealed combustion,
premix gas burner, and low flame temperature means drastically
reduced CO and NOx emissions, which contribute to a cleaner and healthier environment.
large
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
air. Sealed combustion
(also known as "direct vent") is the safest and best way to obtain plenty of clean
combustion air. 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 pipes.
-- 19 3/_:-_
(5021nrn}
4"
_
.oSL
ALTERNATE
RETURN
(1-_./l"
SUPPLY
0PENINGN
NPT (31.75_)
_
/_
ALTEI_NATE
OPENING
FOR
GAS SUPPLY
V
0
1
--
28"
--
(711ram)
---
&
PRESS1TI_E
GAUCcE
------------
_5"
t*RONT
pROVIDBD IN_ION
I
I
I (76,Stun:t)
PANEL
DOOR
PULL ............... --
_©
VENT
....
/
I I I
ACCESS
PANfL
(127ram)
_
_
I
[
I •
-I
SIDE
(_o.a=_)
o i/s"
FRONT
I\
\__
LEFT
CONNECTION
cpvc)
(Z4LSmm
i) J
(l_Tmm)
(g"
ALTEERATE
BOILER
WATER
RETb_N
(f-l/4
pR0_ED
_
NPT
(fll.7_mm)
_IONNE_IDNS
_tS]DE
TOP
FIGURE
1
CONDENSATE
TABLE
Model
5O
75
1
SEA LEVEL
RATINGS
-NATURAL
AND PROPANE
++ Heating
Net I=B=R
Input *(MBH)
Capacity
Rating
Weight
50
75
*(MBH)
45
68
*(MBH)
39
59
(tbs.)
220
220
100
100
* 1 MBH = 1,000 Btuh
90
78
Shipping
GASES
Flue
Dia.
2" C PVC & PVC
2" C PVC & PVC
220
2" C PVC & PVC
Btuh = British Thermal Units Per Hour
These low pressure gas-fired hot water boilers are design certified by CSA International for use
with natural and propane gases. The boilers are constructed and hydrostatically
tested for a
maximum working pressure of 50 psig (pounds per square inch gage) in accordance with
AS.ME
(American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section
IV Standards for heating boilers.
++ AFUE (Annual Fuel Utilization Efficiency)
(Department of Energy) test procedure.
and Heating Capacity
is based on the D.O.E.
The Boilers are certified in accordance with ANSI (American National Standards
Z21.13 standards as gas-fired, direct vent, condensing, hot water boilers.
Institute)
The Heating Capacity indicates the amount of heat available after subtracting the losses up the
stack. Most of this heat is available to heat water. A small portion is heat from the jacket and
surfaces of the boiler, and it is assumed that this heat stays in the structure. The Net I=B=R
Rating represents the portion of the remaining heat that can be applied to heat the radiation or
terminal units (i.e. finned tube baseboard, cast iron radiators, radiant floor, etc.). 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 piping. The Net I=B R Ratings shown are based on a piping and pickup
factor of 1.15 in accordance with the I=B=R Standard as published by the Hydronics Institute.
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 systems. The manufacturer
should be consulted before selecting a boiler for
installations having unusual piping and pickup requirements.
BOILERS
FOR USE AT HIGH ALTITUDE
The boilers are factory equipped for operation at altitudes ranging from 0-2,000 feet above sea
level. For use of these boilers at altitudes above 2,000 feet above sea level, the gas input
ratings (MBH) must be reduced.
U.S.A. 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
boilers. Reduced input ratings are achieved by the natural deration of the gas at higher
elevations and fine tuned by adjusting the manifold pressure.
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 kit. 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 149.1 and CSA-B 149.2
Installation Codes. The certified field conversion kit includes a conversion data plate, indicating
that the boiler has been converted for high altitude use. The correct conversion information must
be entered on the conversion data plate.
TABLE
1A MODEL-50
ELEVATION
NOMINAL
(FEET)
INPUT
HEAT CAPCITY
(MBH)
(MBH)
NET I=B=R RATING
GAS ORIFICE
MANIFOLD
(INCHES
PRESSURE
PRESSURE
TABLE
WATER
INPUT
MANIFOLD
PROPANE
(MBH)
(MBH)
NET I=B=R RATING
GAS ORIFICE
(MBH)
DRILL SIZE
PRESSURE
WATER
PRESSURE
0-2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,500
50.0
48.0
47.8
47.5
46.0
44.0
43.5
42.0
450
43.2
43.0
42.8
41.4
39.6
39.2
37.8
39.0
37.4
37.3
37.1
35.9
34.3
34.0
32.8
.0615
.0615
.0615
.0615
.0615
.0615
.0615
.0615
2.5
2.7
3.0
3.2
3.1
3.0
2.8
2.7
1.55
1.55
1.55
1.55
1.55
1.55
1.55
1.55
GAS HIGH ALTITUDE
RATINGS
0-2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,500
50.0
49.0
49.0
49.0
48.0
46.5
46.0
44.0
450
44.1
44.1
44.1
43.2
41.9
41.4
39.6
39.0
38.2
38.2
38.2
37.4
36.3
35.9
34.3
.0492
.0492
.0492
.0492
.0492
.0492
.0492
.0492
2.5
2.8
3.1
3.4
3.4
3.5
3.5
3.5
1.55
1.55
1.55
1.55
1.55
1.55
1.55
1.55
COLUMN)
SWITCH
WATER
RATINGS
COLUMN)
(FEET)
HEAT CAPCITY
(INCHES
SETPOINT
1B MODEL-50
NOMINAL
GAS HIGH ALTITUDE
COLUMN)
SWITCH
ELEVATION
(INCHES
(MBH)
DRILL SIZE
WATER
(INCHES
NATURAL
SETPOINT
COLUMN)
TABLE lC
MODEL-75
ELEVATION
NOMINAL
(FEET)
INPUT
HEAT CAPClTY
NET I=B=R
(INCHES
DRILL SIZE
1D
HEAT CAPClTY
DRILL SIZE
INPUT
NET I=B=R
(INCHES
(MBH)
(MBH)
DRILL SIZE
PRESSURE
WATER
PRESSURE
(INCHES
(MBH)
RATING
GAS ORIFICE
MANIFOLD
NATURAL
(FEET)
HEAT CAPClTY
COLUMN)
SWITCH
WATER
SETPOINT
NOMINAL
HEAT CAPClTY
NET I=B=R
(MBH)
(MBH)
RATING
GAS ORIFICE
MANIFOLD
PROPANE
(FEET)
INPUT
(MBH)
DRILL SIZE
PRESSURE
WATER
PRESSURE
COLUMN)
SWITCH
WATER
GAS HIGH ALTITUDE
RATINGS
0-2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,500
75.0
70.0
69.0
68.0
63.5
58.0
56.5
52.0
68.0
63.0
62.1
61.2
57.2
52.2
50.9
46.8
58.9
54.6
53.8
53.0
49.6
45.2
44.1
40.6
.0760
.0760
.0760
.0760
.0760
.0760
.0760
.0760
2.5
2.7
2.8
3.0
2.8
2.6
2.3
2.1
1.35
1.35
1.35
1.35
1.35
1.35
1.35
1.35
GAS HIGH ALTITUDE
RATINGS
0-2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,500
75.0
70.0
69.0
67.0
66.0
64.5
64.0
62.0
68.0
63.0
62.1
60.3
59.4
58.1
57.6
55.8
58.9
54.6
53.8
52.3
51.5
50.4
49.9
48.4
.0605
.0605
.0605
.0605
.0605
.0605
.0605
.0605
2.5
2.4
2.3
2.2
2.2
2.2
2.3
2.3
1.35
1.35
1.35
1.35
1.35
1.35
1.35
1.35
GAS HIGH ALTITUDE
RATINGS
0-2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,500
100.0
97.0
96.0
95.0
90.0
84.0
82.0
76.0
90.0
87.3
86.4
85.5
81.0
75.6
73.8
68.4
78.0
75.7
74.9
74.1
70.2
65.5
64.0
59.3
.0860
.0860
.0860
.0860
.0860
.0860
.0860
.0860
2.5
2.9
3.3
3.7
3.4
3.2
2.9
2.6
1.17
1.17
1.17
1.17
1.17
1.17
1.17
1.17
COLUMN)
1F MODEL-100
ELEVATION
(INCHES
SETPOINT
COLUMN)
1E MODEL-100
NOMINAL
(INCHES
COLUMN)
SWITCH
WATER
ELEVATION
TABLE
(MBH)
PRESSURE
PRESSURE
TABLE
(MBH)
WATER
(INCHES
PROPANE
(MBH)
RATING
GAS ORIFICE
MANIFOLD
COLUMN)
(FEET)
INPUT
NET I=B=R
SETPOINT
MODEL-75
ELEVATION
NOMINAL
COLUMN)
SWITCH
WATER
(INCHES
(MBH)
PRESSURE
PRESSURE
TABLE
(MBH)
WATER
(INCHES
(MBH)
RATING
GAS ORIFICE
MANIFOLD
NATURAL
SETPOINT
COLUMN)
GAS HIGH ALTITUDE
RATINGS
0-2,000
3,000
4,000
5,000
6,000
7,000
7,500
8,500
100.0
95.0
94.0
92.0
92.0
91.5
91.5
91.0
90.0
85.5
84.6
82.8
82.8
82.4
82.4
81.9
78.0
74.1
73.3
71.8
71.8
71.4
71.4
71.0
.0670
.0670
.0670
.0670
.0670
.0670
.0670
.0670
2.5
2.7
2.9
3.1
3.2
3.3
3.4
3.5
1.17
1.17
1.17
1.17
1.17
1.17
1.17
1.17
I.
2.
3.
Read the entire installation manual before beginning the installation. 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 damage.
Check all applicable state and local building codes and utility company requirements
before installation. The installation must conform with these requirements
in their
entirety. In the absence of these codes, use NFPA Installation Codes and good
industry practice.
Before servicing the boiler - allow the boiler to cool. Always shut off any electricity and
gas supply connected to the boiler prior to servicing.
4.
Inspect gas line for leaks.
5.
Be certain gas input rate is correct. Over firing may result in early failure of the boiler
sections. This may cause dangerous operation. Under firing may result in too much air
for the pre-mix burner causing poor or loss of combustion.
6.
Never vent the products of combustion from this boiler to an enclosed space. Always
vent to the outdoors. Never vent to another room or to inside a building.
7.
Be sure there is adequate
8.
Follow a regular service and maintenance schedule for efficient and safe operation.
Keep boiler area clean of debris and free of combustible and flammable materials.
outdoor
air supply to boiler.for
complete
combustion.
9.
10. Proper through the wall or through the roof combustion venting shall be in accordance with the
materials and methods described in this manual. Installation must comply with local codes.
11. This boiler and related hot water heating systems are not do it yourself
must be installed and serviced by qualified professionals.
items. They
WARNING
This boiler has been equipped for residential installations. If used for commercial applications, any
additional code requirements must be adhered to for installation. 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 modifications. The manufacturer
is not responsible for any field installation
changes made to a boiler installation which are not described or acknowledged
in this manual.
Complete
A=
all of the following
prior to installing
the boiler.
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
Canada
States
-
-Installation shall conform with National Fuel Gas Code (NFPA-54/ANSl
Z223. l-latest edition)
Installation shall be in accordance with CSA B 149.1 and .2. installation
codes.
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, No.CSD-1.
The installationmust conform to the requirementsof the authorityhavingjurisdiction or, in the
absence of such requirements,to the NationalFuel Gas Code,ANSI Z223.1 - latest revision.
Installers -
Follow local regulations with respect to installation of CO (Carbon
Monoxide) Detectors. Follow maintenance recommendations in this manual.
Techniciens -Veuillez vous conformer a la reglementation en vigueur concernant 1'
installations des detecteurs d'oxyde de carbone. Suivre les consignes
d'entretien figurant dans le manuel d'instruction ci-joint.
B. BOILER
SIZING
Check to be sure you have selected the boiler with the proper capacity before starting
the installation. 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 systems. See the table "BOILER RATINGS
AND CAPACITIES".
•
Heat loss calculations
C. CONSIDERATIONS
should be based on approved
FOR BOILER
Before selecting
considered.
industry methods.
LOCATION
a location for the boiler, the following
with the correct type of gas (natural
should be considered.
Each boiler
•
Supplied
•
Connected to a suitable combustion air intake piping system to supply the correct
amounts of fresh (outdoor) air for 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 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
•
Supplied
•
Connected
boiler)
•
Placed on level surface
•
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).
to a suitable
with a suitable
to a properly
gas or propane).
hot water heating system
electrical
supply for all boiler motors and controls.
located thermostat
or operating
(must NOT be installed
control.
(not included
with
on carpeting)
D. LOCATING
TABLE
THE BOILER
2
BOILER
UNIT
CLEARANCES
COMBUSTIBLE
ACCESSIBILITY/
CONSTRUCTION
CLEANING
SERVICING
TOP
1"
8"
8"
LEFT SIDE
1"
1"
1"
RIGHT SIDE
8"
BASE
1"
FRONT
0"
24"
24"
BACK
1"
INTAKE/VENT
PI PI NG
0"
NEAR BOI LER HOT WATER
WATER
PIPING
1"
1. Select a location which is level, central to the piping systems served and as close to the
vent and air intake terminals as possible.
2. Accessibility clearances, if more stringent (i.e. larger clearances) than required fire protection
clearances, must be used for the boiler installation. Accessibility clearances may be achieved
with the use of removable walls or partitions.
3. The boiler is approved for installation in closets and on combustible floors. This boiler
shall NOT be installed on carpeting.
4. The clearances shown in Table 2 indicate required clearances per IAS listing. A minimum
1" clearance must be maintained between combustible construction and each of the left,
top and back surfaces of the boiler. A minimum 8" clearance is required on the right side,
to allow room for the inlet air pipe. 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 attention. Allow at least 24" at
the front and left side and 8" at the top for servicing. No clearances are required to
venting or combustion air intake piping.
5. Equipment shall be installed in a location which facilitates the operation of venting and
combustion air intake piping systems as described in this manual.
6. Advise owner of boiler to keep venting and combustion air intake passages free of obstructions.
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 operate.
7. The boiler shall be installed such that the automatic gas ignition system components are
protected from water (dripping, spraying, rain, etc.) during operation and service
(circulator replacement,
control replacement, etc.).
E. COMBUSTION
AIR AND VENT
PIPE REQUIREMENTS
This boiler requires a dedicated direct vent system. In a direct vent system, all air for
combustionis taken directly from outside atmosphere, and all flue products are discharged
outside atmosphere.
to
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 Fig.9 & 10
for required clearances.
CAUTION
KEEP BOILER
MATERIALS,
AREA CLEAN
VAPORS
OF DEBRIS
AND FREE OF FLAMABLE
AND COMBUSTIBLE
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"
Armafiex or equivalent. In extreme cold climate areas, use 3/4" Armafiex or equivalent.
Combustion
air must be clean outdoor
air. 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 iodides. These elements are found in aerosols, detergents, bleaches,
cleaning solvents, salts, air fresheners, paints, adhesives and other household products.
Locate combustion
pump house.
air inlet as far away as possible
from swimming
All combustion air and vent pipes must be airtight and watertight.
piping must also terminate exactly as shown in Fig.9 or 10.
pool and swimming
Combustion
pool
air and vent
Vent connections serving appliances vented by natural draft shall not be connected
portion of mechanical draft systems operating under positive pressure.
into any
Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in
well ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.
FAILURE TO FOLLOW
PROPERTY DAMAGE,
F. CONDENSATE
THE AFOREMENTIONED
WARNINGS
PERSONAL INJURY, OR DEATH.
COULD
RESULT
IN FIRE,
DRAIN REQUIREMENTS
Condensate drain line to be pitched down to floor drain at a minimum of I/4" per foot. An external
condensate pump (not furnished) may be used if floor drain is not available. The condensate
pump must be designed for flue gas condensate application
NOTE:I.
Condensate
be used.
trap is built into the boiler, an external
trap is not required
and should not
2. Wood frame or blocks may be used to raise the boiler to maintain drain pitch or to be
above external condensate pump reservoir.
3. 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).
G. FOUNDATION
REQUIREMENTS
Boiler must be placed on level surface.
Boiler is NOT to be installed
10
on carpeting.
NOTE:
1. If boiler is not
feet are located
2. Wood frame or
above external
H. REMOVAL
OF EXISTING
level condensate drain lines will not function properly. Adjustable
on the boiler to make up for minor surface irregularities or tilt.
blocks may be used to raise boiler to maintain drain pitch or to be
condensate pump reservoir.
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 it.
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 operation.
1. Seal any unused openings
in the common
venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine
there is no blockage, or restrictions, leakage, corrosion and other deficiencies which could
cause an unsafe condition.
3. Insofar as is practical, close all. 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 building. Turn on clothes dryer and any appliance not
connected to the common venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhaust, so they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fire dampers.
4. Place in operation the appliance being inspected.
thermostat so appliances will operate continuously.
Follow
the lighting
instructions.
Adjust
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation.
Use the flame of a match or candle, or the smoke from a cigarette, cigar or pipe.
6. 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 use.
7. Any improper operation of the common venting system should be corrected so the
installation conforms with the National Fuel Code, NFPA-54/ANSI
-Z223. l-latest revision,
or section 5 of CSA-B 149 for Canadian standards. 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/ANSIZ223.1-1atest revision, or section 5 of CSA-B 149 for
Canadian standards.
The boiler should be placed to provide the most direct connections
and system piping as possible.
Place
boiler
truck
short
to the combustion
air, vent
crated boiler as close to selected location as possible and uncrate boiler. The uncrated
may be moved into position with an appliance dolly or 2-wheel hand truck. The dolly or hand
should be inserted under the left hand side of the boiler. It is possible to slide the boiler for a
distance on a smooth floor or surface.
NOTE:
Refer to manual section
ing and maintenance.
"LOCATING
THE BOILER"
for required
clearances
for servic
CAUTION
Copper supply and return piping, must NOT be installed directly into aluminum boiler section
casings due to galvanic corrosion between dissimilar metals. Iron or steel bushings or pipe
nipples should be used between copper system piping and boiler to make final connection to
boiler. Also, the use of dielectric unions is acceptable. The packaged boiler is furnished with iron
piping in the front boiler section for the supply and return connections.
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 mains. After all heating
system piping and components have been installed, make final connection of the system piping
to the boiler. A hot water boiler installed above radiation level must be equipped with a low water
cut off device. A periodic inspection is necessary us is flushing of float type devices, per low
water cut off manufacturers
specific instructions.
A. SUPPLY AND RETURN LINES
The packaged boiler unit is set up to receive 1 1/4" NPT supply and return piping from top
access. 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 section.
NOTE: The circulator pump and isolation valves are furnished within a carton inside the boiler
cabinet and can be installed at the installer preferred location.
12
SERVICE
VALVE
SUPPLY
SYSTEM
\
'_
_/_
CIRCULATOR
RETURN
SYSTEM
PURGE
VALVE
SERVICE
VALVE
FIGURE
2
SINGLE
TO
ZONE BOILER
13
PIPING
FROM
(DRAIN)
//--
ZONE
VALVE
VALvEZONE
SERVICE
/
SUPPLY
ZONES
TO
ZONE SERVICE
VALVE
CIRCULATOR
RETURN
ZONES
FROM
PURGE
(DRAIN)
VALVE S
SERVICE
//
_-/ZONE
VALVE
¢P
FIGURE
3
MULTI ZONE BOILER
14
PIPING WITH ZONE VALVES
////-
ZONE
SERVICE
VALVE
SUPPLY
-_7
TO
ZONES
ZONE
SERVICE
VALVE
CIRCULATORS
FLOW CHECK
VALVE
FROM
ZONES
PURGE
VALVES
(DRAIN)
SERVICE
ZONE
VALVE
_9
jJ
j"
J
j_
jJ
J
NOTE: When zoning with circulators, the furnished circulator pump should be used as one of the
zone pumps. Each stripped end of the electrical wires for the circulator pump inside the junction
box should be taped or wire nutted to prevent short circuits. Unplug the circulator pump wiring at
the integrated
boiler control.
FIGURE
4
MULTI ZONE
BOILER
15
PIPING
WITH CIRCULATORS
RELIEF VALVE _._
DISCHARGE
PIPING
'\.
)
"\\
\\
FIGURE
B. PRESSURE
5
SINGLE
ZONE BOILER
PIPING
RELIEF VALVE
The boiler is furnished with a factory installed relief valve in the top of the boiler. Provide ¾"
piping from the supplied relief valve to a local floor drain, but leave an air gap between piping
and drain. 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 atmosphere.
Installation
of the safety relief valve shall conform to ANSl/ASME
Boiler and Pressure Vessel Code,
Section IV. The manufacturer
is not responsible for any water damage.
C. EXPANSION
TANK AND MAKE-UP
WATER
Determine required system fill pressure, system design temperature,
and system water
content. Boiler contains 2.6 gallons (U.S.). Size expansion tank accordingly.
Consult
expansion tank manufacturer
for proper sizing information.
Connect properly sized
expansion tank (not furnished) as shown in Fig. 6 for diaphragm type expansion tank and
Fig. 7 for conventional closed type expansion tanks. For diaphragm type expansion tanks,
adjust the tank air pressure to match the system fill pressure.
Install air vent (furnished) as
shown for diaphragm type expansion tank system only. Install make-up water connections
as shown per local codes. If a pressure reducing valve is used, adjust to match the system
fill pressure.
In connecting the cold make-up water supply to the boiler, make sure that clean
water supply is available. When the water supply is from a well or pump, sand strainer
should be installed at the pump.
16
_---- MANUAL
VALVE
FILL
////
AUTOMATIC
VENT*
AIR
3/4"
TEE*
3//4 '' NIPPLE
(FURNISHED
AND INSTALLED
ON
PACKAGED BOILER)
COLD WATER
FILL
3/4"
* -
STREET
FURNISHED
IN
PARTS BAG.
/
/
//
/
_JDIAPHRAGM
EXPANSION
TYPE
TANK
/
//
COMBINATION
QUICK FILL
VALVE, STRAINER,
CHECK
VALVE AND PRESSURE
REDUCING
VALVE
FIGURE
6
DIAPHRAGM
TYPE EXPANSION
17
TANK
ELL*
PIPING
CLOSED
/_
/_--_-'_
"\\
_'f
EXPANSION
TYPE
TANK
/
j_
_EXPANSION
TANK
SERVICE
VALVE
(GATE
VALVE
OR
FULL PORT
BALL VALVE)
MANUAL
VALVE
COLD
FILL
L_
FILL
WATER=_
\
CHECK
AND PRESSURE
REDUCING
VALVE
FIGURE
7
CONVENTIONAL
(closed type) EXPANSION
18
TANK PIPING
_
OPEN
DRAIN PIPE TO
BE PITCHED
DOWN
TO FLOOR DRAIN
AT A MINIMUM
1/4"
PER FOOT
"'- .....
TO
DRAIN
THREADED
NIPPLE
(INSTALLED)
FIGURE
D. CONDENSATE
CONDENSATE
drain and fittings.
½" PVC tee to overflow
The ½" diameter
/2"SLIPxl
!2"NPT
IN PARTS BAG
- DRAIN PIPING
trap is not required
Condensate
and should NOT be used.
drain to be pitched down to floor drain at
schedule
fitting as shown in Fig. 8.
40 PVC or CPVC condensate
and ASTM D 1785 or D2846.
to ASTM D2564 or F493.
cement.
A condensate
(sanitary
8
PVC TEE
1/2"SLIPxI
FURNISHED
of ¼" per foot.
Install furnished
standards
/
trap is built into the boiler, an external
½" PVC condensate
a minimum
(PVC)
DRAIN PIPING
The condensate
Provide
CONDENSATE
DRAIN
In Canada,
pump with a reservoir
Schedule
drain and pipe fittings
40 PVC or CPVC cement
use CSA or ULC certified
(not furnished)
to ANSI
40 PVC or CPVC drain pipe
may be used to remove
line) above boiler if a floor drain is not available
19
schedule
must conform
and primer must conform
or its in accessible.
condensate
to a drain line
E. FILLING CONDENSATE
TRAP WITH WATER ON THE INITIAL
SATE TRAP MUST BE MANUALLY FILLED WITH WATER
START
UP THE CONDEN
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:
1. Disconnect
the vent condensate
drain line from the bottom of the vent tee on the boiler.
2. Pour about 1 cup of cold tap water into the vent drain line with a proper funnel.
3. Excess water should go through the overflow and out through the condensate drain line.
Verify proper operation of the drain line (or external condensate pump if used).
4. Reinstall
F. CHILLED
the vent drain line.
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 boiler.
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 cycle.
A. 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 2223. l-latest revision,
CAN/CGA-B
149.1 and B 149.2, and applicable provisions of the local building codes.
Provisions for combustion and ventilation air must be in accordance with section 5.3, Air For
Combustion and Ventilation, of the National Fuel Gas Code,ANSI 2223. l-latest revision,
CAN/CGA-B
149.1 and B 149.2, or applicable
provisions
of the local building code.
These boilers require a dedicated direct vent system. All air for combustion
is taken directly
from outdoors through the combustion air intake pipe. All flue products are discharged to the
outdoors through the vent pipe.
.
.
See Fig.9 & 10 for combustion air and vent pipe roof and sidewall termination. (Roof termi
nation is preferred) Combustion air and vent pipes must terminate together in same atmo
spheric pressure zone as shown. Construction through which vent and air intake pipes
may be installed is a maximum 24 inches, minimum I/4" thickness.
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).
20
In Canada construct all combustion air and vent pipes for this unit of CSA or ULC certified
schedule-40 CPVC, schedule-40 PVC, PVC-DVVV or ABS-DVVV pipe and pipe cement.
SDR pipe is NOT approved in Canada.
.
Combustion air and
change (to 3") must
for proper drainage
155°F, the first five
PVC. If any elbows
Two (2) - 30" pieces
vent piping connections on boiler are sized for 2" pipe. Any pipe size
be made outside of the boiler casing in a vertical run of pipe to allow
of vent condensate. Due to potential for flue gas temperatures
over
(5) feet of vent pipe must be CPVC, the remaining vent pipe can be
are employed within the first 5 feet of vent, they must be CPVC too.
of 2" CPVC pipe are furnished with the boiler.
NOTE: The transition
4.
Combustion
from 2" pipe to 3" pipe must be made in a vertical run.
air and vent piping lengths,
2 FEET
IN
LENGTH
20 FEET IN
LENGTH
20 FEET IN
LENGTH
100 FEET IN
LENGTH
+
AND UP TO
+
AND UP TO
4-90 °
4-90 °
4-90 °
4-90 °
ELBOWS
ELBOWS
ELBOWS
ELBOWS
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 elbow.
3" 90 degree elbow - 3 feet per additional elbow.
Example: To add 2 additional 90 degree elbows to a 3" pipe for a 75 boiler.
Each elbow is 3 additional feet per 90 degree elbow for a total of 6 feet. (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 elbows. ("TOTAL EQUIVALENT
LENGTH":
Original 100
feet max. - 6 feet for 2 additional elbows = new 94 feet maximum length).
.
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
boiler. Pipes must be pitched continuously with no sags or low spots where moisture can
accumulate and block the flow of air or flue gas. Combustion air and vent pipes must be
airtight and watertight.
21
.
Consideration
for termination
for the following should be used when determining
of combustion air and vent piping.
• Comply with all clearances
• Termination
conditioning
required
should be positioned
equipment.
as stated in paragraph
where vent vapors will not damage
• Termination should be positioned where it will not be subjected
foreign objects, such as stones, balls, etc..
should be positioned
location
7.
• Termination should be positioned so that it will not be effected
leaves, snow, or recirculated flue gases.
• Termination
an appropriate
plants/shrubs
or air
by wind eddy, air born
to potential
damage
by
where vent vapors are not objectionable.
• Put vent on a wall away from the prevailing winter wind. Locate or guard the vent to
prevent accidental contact with people or pets.
• Terminate the vent above normal snowline. Avoid locations where snow may drift and
block the vent. Ice or snow may cause the boiler to shut down if the vent becomes
obstructed.
• Under certain conditions, flue gas will condense, forming moisture, and may be corrosive.
In such cases, steps should be taken to prevent building materials at the vent from being
damaged by exhaust of flue gas.
.
The venting system shall terminate at least 3 feet above any forced air inlet (except the
boiler's combustion air inlet) within 10 feet. The venting system shall terminate at least 12
inches from any air opening into any building. The bottom of the vent shall be located at
least 12 inches above grade. Termination of the vent shall be not less than 7 feet above an
adjacent public walkway. The vent terminal shall not be installed closer than 3 feet from the
inside corner of an L shaped structure. Termination of the vent should be kept at least 3
feet away from vegetation. 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,
VERTICAL
BETWEEN
regulators,
and relief equipment.
COMBUSTION
8" MINIMUM
SEPERATION
COMBUSTION
AIR INTAKE AND VENT
MAINTAIN
12" MINIMUM
CLEARANCE
ABOVE HIGHEST
ANTICIPATED
SNOW LEVEL
FIGURE
9 ROOF VENT/INTAKE
22
TERMINATIONS
J
MAINTAIN
12" MINIMUM
CLEARANCE
ABOVE
HIGHEST
.
_
ANTICIPATED
GRADE
J'_
SNOW
MAXIMUM
SEPERATION
15"
.----," J_MAXIMUM
18"
MAXIMUM
I
LESS THAN 12" CLEARANCE
I
12" MINIMUM
__"
j_,
12" SEPERATION
j-
_'90o_
// 0_AOKET--_I_
OOMBUST_ON
AIR
INTAKE_
J
BETWEEN
BOTTOM
OF
AND
BOTTOM
O_
VE__
/
f/J
MAINTAIN
_-_
/
MAXIMUIvl
-'_
SEPERATION
J
CLEARAN
12" MINIMUM
CE A BOVE
ANTICIPATED
GRADE
SNOW
H IGHEST
LEVEL
OR
18"
_
MAXIMUM
I
FIGURE
12" OR MORE CLEARANCE
10 SIDEWALL
VENT/INTAKE
23
I
TERMINATIONS
LEVEL
OR
VENT/INTAKE
2"
(50.8ram)
COMBUSTION
INTAKE
AIR
PIPING
S
"\_
_/]7
/
/
TERMINATIONS
/
2"
(50.8mm)
CPVC
VENT
PIPING
(FURNISHED)
--x
\
x
2"
(50.8ram)
CPVC
COUPLING
(FURNISHED)
\\
2" (50.8mm)
DIAMETER
COMBUSTION
/_/s/\\\\\\
PIPING
-
15' (4.57m)
WITH
5'
VENTAND
AIR INTAKE
MAXIMUM
LENGTH
4 - 900 ELBOWS
TOTAL
FOR Kg0-100
20' (6.10m) MAXIMUM
LENGTH TOTAL WITH
4 - 90 ° ELBOWS
FOR K90 - 75 AND K90 - 50
1.52m
2' (.61m) MINIMUM
LENGTH TOTAL
WITH 4 - 90 ° ELBOWS
FORALL
\
4
EXHAUST
TEE
(FURNISHED)
3" (76.2mm) COMBUSTION
INTAKE PIPING
AIR
/?
,/ /
/
/
/
/
/
/
_\
_.
\
\,
2" (50.8mm) CPVC VENT PIPING
(FURNISHED)
/_
VENT/INTAKE
TERMINATIONS
_--
3" (76.2mm)
_
_
2" (50.8mm)
CPVC
COUPLING
VENT
PIPING
_
\
_
TRANSITION
2" (5O.8mm)
VERTICAL
FITTING
O TO 3" (76.2mm)
O IN
RUN
(FURNISHED)
3" (7B.2mm)
COMBUSTION
FOR
K90 - 100
80' (24,38m)
WITH
5'
1.52m
MINIMUM
K90
lOB'
(30.48m)
- 75 AND
TRANSITION
2" (50.8ram)
VERTICAL
\_
/i
LENGTH
K90
MAXIMUM
11
COMBUSTION
24
TOTAL
- 50
LENGTH
MINIMUM
LENGTH
4 - 90 _ ELBOWS
FITTING
!21TO
RUN
3" (76.2mm)
O IN
EXHAUST TEE
(FURN SHED)
/-
FIGURE
TOTAL
TOTAL
4 -90 ° ELBOWS
20' (6.10m)
WITH
LENGTH
4 -90 ° ELBOWS
FOR
WITH
MAXIMUM
4 - 90 ° ELBOWS
15' (6.10m)
WITH
DIAMETER
VENT AND
AIR INTAKE
PIPING
AIR AND VENT PIPING
TOTAL
B. INSTALLATION
1.
Attach combustion air intake piping to supplied Fernco 2" coupling on mixer. Attach
vent piping to furnished 2" CPVC vent tee on draft inducer outlet.
NOTE: All pipe joints are to be water tight.
2.
Working from the boiler to the outside, cut pipe to required length(s).
3. Deburr inside and outside of pipe.
4.
Chamfer outside edge of pipe for better distribution of primer and cement.
5. Clean and dry all surfaces to be joined.
6.
Check dry fit of pipe and mark insertion depth on pipe.
NOTE: It is recommended
that all pipes be cut, prepared, and pre-assembled
before
permanently cementing any joint.
7. After pipes have been cut and pre-assembled,
apply cement primer to pipe fitting
socket and end of pipe to insertion mark. 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 cement. Apply second coat.
8. While cement is still wet, insert pipe into socket with a'/a turn twist. Be sure pipe is fully
inserted into fitting socket.
9. Wipe excess cement from joint. A continuous bead of cement will be visible around
perimeter of a properly made joint.
10. Handle pipe joint carefully until cement sets.
11. Support combustion air and vent piping a minimum of every 5 feet using pre-formed
metal hanging straps. Do not rigidly support pipes. Allow movement due to expansion
and contraction.
12. Slope combustion air and vent pipes toward boiler a minimum of I/4" per linear foot with
no sags between hangers.
13. Use appropriate methods to seal openings where vent and combustion air pipes pass
through roof or side wall.
A. 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 it. See Table 3 for the
proper size. Be sure your gas line complies with local codes and gas company
requirements.
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 (3.5kpa).
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 (3.50ka).
NATURAL
MAXIMUM
GAS SUPPLY
MINIMUM
GAS SUPPLY
PRESSURE
PRESSURE
25
GAS
PROPANE
10" w.c.
14" w.c.
7" w.c.
10" w.c.
GAS
B. CONNECTING
THE GAS PIPING
Refer to Fig.12 for
The gas line enters
supply pipe through
and pipe assembly.
supply piping. The
1.
the general layout at the boiler. It shows the basic fittings you will need.
the boiler from the right side jacket panel. The boiler may receive the gas
the left side, or rear jacket panel by relocating the gas valve connector
The boiler is equipped with a '/z" NPT connection on the gas valve for
following rules apply:
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 Z223.1- latest revision. In Canada, follow the CSA- B 149.1 and .2
Installation Codes for Gas Burning Appliances and Equipment.
2.
Use pipe joint compound suitable for liquefied petroleum gas on male threads only.
3. Use ground joint unions.
4.
Install a sediment trap upstream of gas controls.
5. Use two pipe wrenches when making the connection to the gas valve to keep it from
turning.
6.
Install a manual shutoff valve in the vertical pipe about 5 feet above floor.
7. Tighten all joints securely.
8. Propane gas connections should only be made by a licensed propane installer.
9. Two stage regulation should be used by the propane installer.
10. Propane gas piping should be checked out by the propane installer.
C. CHECKING
THE GAS PIPING
After all connection have been made, check immediately for leaks. Open the manual shutoff
valve. Test for leaks by applying soap suds (or a liquid detergent) to each joint. Bubbles forming
indicate leak. CORRECT EVEN THE SMALLEST
LEAK AT ONCE.
WARNING
NEVER
USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS.
TABLE
3 GAS PIPE SIZES
NATURAL
Length
of
Pipe Capacity-
GAS
BTU Per Hourlnputlncludes
FiRings
Pipe - Ft.
20
40
1/2"
92,000
63,000
3/4"
190,000
130,000
1"
350,000
245,000
1 1/4"
625,000
445,000
60
50,000
105,000
PROPANE GAS
195,000
365,000
Length
of
Pipe - Ft.
Pipe CapacityCopper Tubing*
BTU Per Hourlnputlncludes
Fittings
Iron Pipe
5/8"
3/4"
1/2"
20
131,000
216,000
189,000
393,000
40
60
* Outside diameter
90,000
72,000
145,000
121,000
129,000
103,000
267,000
217,000
26
3/4"
The length of pipe or tubing should be measured
from the gas meter or propane
second stage regulator.
GAS SUPPLY
"
,/
PIP ING
//z
SHIrT-OFF
VALVE
J
SEDIMENT
TRAP
GROUND
UNION
JOINT
/-
FIGURE
12
GAS PIPING
WARNING
TURN OFF ELECTRICAL
POWER AT FUSE BOX BEFORE MAKING ANY LINE
VOLTAGE CONNECTIONS.
FOLLOW LOCAL ELECTRICAL
CODES.
All electrical
work must conform
to local codes as well as the National
NFPA70, latest revision. In Canada,
Codes, CSAC22.1 and .2
A.
ELECTRIC
POWER
electrical
Electrical
Code, ANSI/
wiring shall comply with the Canadian
Electrical
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 panel. This should be a 15 ampere circuit. A service switch has
been pre-wired and located on the exterior boiler jacket. See Fig. 13 for diagram showing
location of service switch junction box and power supply connection points. Connect black
(hot) lead from the power supply
27
to either of the unused brass screws on the service switch. Connect the white (neutral) lead from
the power supply to the white screw on the service switch. Connect the green (ground) lead
from the power supply to the ground (green) screw on the service switch. 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 used.
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 Electrical Code, ANSI/NFPA-70,
latest revision. In Canada, electrical wiring shall comply with the
Canadian Electrical Codes, CSA-C22.1 and .2.
Run a 14 gauge or heavier copper wire from the boiler to a grounded
panel or a properly driven and electrically grounded ground rod.
B. INSTALL
connection
in the service
YOUR THERMOSTAT
The thermostat location has an important effect on the operation of your boiler system.
SURE TO FOLLOW THE INSTRUCTIONS
INCLUDED WITH YOUR THERMOSTAT.
BE
Locate the thermostat about five feet above the floor on an inside wall. It may be mounted directly on the wall or on a vertical mounted outlet box. It should be sensing average room temperature. Avoid the Following:
DEAD SPOTS:
Behind doors
Comers and alcoves
COLD SPOTS:
HOTSPOTS:
Concealed pipes or ducts
Stairwells - drafts
Unheated rooms on
other side of wall
Concealed
Fireplace
TV sets
Radios
pipes
Lamps
Direct sunlight
Kitchens
Set heat anticipator at 0.7 amps. Connect 24 volt thermostat leads to the two(2) yellow wires
located in service switch junction box, located on outer jacket of boiler. See Fig. 13 for service
switch junction box and thermostat field wiring connections.
C. Connect
Circulator
Pump Wiring
See Fig.13 for service switch junction box and circulator pump field wiring connections. A 5 feet
wiring harness with flexible metal conduit is supplied to connect the circulator pump to the service switch junction box. 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 circuit.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION
WHEN SERVICING CONTROLS. WIRING
ERRORS CAN CAUSE IMPROPER AND DANGEROUS
OPERATION.
VERIFY PROPER
OPERATION AFTER SERVICING.
28
J
WIRE
120 VOLT
CIRCULATOR
Y
ZzzzD--Y
24 VOLT
THERMO STAT
W
BOILER
WIRING
IN
BK
J-BOX
G
CODE
NEUTRAL
HOT
--120
VOLTS
60 HZ i O
POWER SUPPLY
GROUND
--i
SERVICE
COLOR
BK -- BLACK
W = WHITE
G -- GREEN
Y = YELLOW
SWITCH
FIELD
WIRING
\
CONNECTIONS
\
\
\
SERVICE
//_
/
\
J
jJ
_jJ
C_
FIGURE
13
FIELD WIRING
29
CONNECTIONS
/
JUNCTION
SB_TCH
BOX
z
_2
D"
@
®,
D
If any of the original wire as supplied with this appliance
with type 150°C Thermoplastic
wire or its equivalent
D=
FIGURE 14 SCHEMATIC
30
must be replaced,
WIRING
DIAGRAM
it must be replaced
120 VOLT
POWER
SUPPLY
L1
L2
HOT
I
ON/OFF
i
BLK
SWITCH
WHT
P7-2
P7-1
P7-3
2K1
P4-I
CIRCULATOR
MOTOR
P5-3
DRAFT
)>
PI0-2
INDUCER
ROT
5K1
P6-1
SURFACE
P12-1
IGNITER
P12-2
120
PB-2
5K2
H
P1-3
TRANSFORMER
CASTING
TEMPERATURE
SAFETY
SWITCH
(MANUAL
RESET)
,
4K1
3K1
2
GAS VALVE
VRB205A
P3-5
P9-3_
<(
P3-2
P9-2
r
0_c4
• P3-1
@
@
k_ICROPR OCESSOR
ELECTRONIC
LOGIC
_ ]I_ER S
l
DIFFERENTIAL _jR
@
_
PR EESU RE S_5_lmH
P3-3
A;:L
UM,T
P3-9
_}
POWEN
O
PURGE
IGNITER
M_LVE
INDICATOR
LIGHTS
F LA _,'IE
O
O
5__
QUASTAT
CONTROL
_
P3-7
1013-10 CONIROL
BLOWER
../.!_ POWER SUPPLY. PROVIDE
DISCONNECT
MEANS AND
OVERLOAD
PROTECTION AS
REQUIRED USE ONLY COPPER
_" P3-4
THERMOSTAT
WIRE BETWEEN
AND THE UNIT
DISCONNECT
NOTE: "P" LABEL REFERENCE
LOCATION OF CONNECTOR
PLUG
BETWEEN SCHEMATIC AND
LADDER
* CAUTION:
RECEPTACLE
BOILER
--÷_---
DIAGRAM
REFERENCES
FIGURE 15 LADDER WIRING
31
IS LIVE WHEN
SWITCH
IS OFF
PLUG CONNECTION
DIAGRAM
This section provides
a brief description
See the Troubleshooting
sequences of operation
locations
and accessories
found in this boiler.
section of the Service Hints chapter of this installation manual for detailed
and troubleshooting
procedures. See the Repair Parts chapter of this manual
of all control components
A. INTEGRATED
of the key controls
BOILER
and accessories
CONTROL
for
described.
(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
sensor. This controller is not
intended for use with a vent damper. This controller is mounted on the control panel inside of the
boiler and contains four (5) diagnostic indicator lights.
B. 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 boiler.
The valve is piped to the gas/air mixer.
C. HOT SURFACE
IGNITER
The 120 volt Hot Surface Igniter heats up to 1800
The igniter is mounted next to the burner through
means for proving the main burner flame by flame
on three (3) consecutive trials for ignition, the IBC
°F to initiate combustion of the gas in the burner.
the gas/air mixer. The igniter also serves as a
rectification. In the event of a lack of flame signal
will lockout. The "VALVE" and "FLAME" diagnostic
indicator lamps (lamp "D" and "E" on the IBC, See Fig. 16) wilt blink indicating the failure mode as a
lack of flame signal. 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 on.
D. 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 boiler. 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 outlet. The aquastat is tied in with the
IBC and is factory set at 180 °F water temperature.
The high limit setpoint is field adjustable and may
be set anywhere between 100 °F and 200 °F. The field setpoint adjustment for each installation
depends on heating system requirements.
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
larger the differential, the longer the run cycle of the boiler.
NOTE: The maximum
E. DRAFT
INDUCER
setpoint
of the Aquastat
TEMPERATURE
The Draft Inducer Temperature
SAFETY
must not exceed
for boiler operation.
The
200 °F.
SWITCH
Safety Switch is a disc thermostat
(180 °F setpoint)
located
on the
induced draft fan outlet port. The switch protects the inducer and vent pipe from a potential high
temperature
condition for the discharging flue gases. This condition would typically be a result of
higher aquastat setting or over firing. The temperature
safety switch automatically
resets when the
32
higher aquastat setting or over firing. The temperature safety switch automatically
when the vent temperature decreases. (15 °F switch differential).
F. CASTING
TEMPERATURE
SAFETY
resets
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 out. This fault requires manual reset of the casting temperature
safety switch to restart
the boiler. Verify that the boiler is properly filled with water before resetting this switch.
WARNING-Never
run cold water into a hot empty boiler.
G. DIFFERENTIAL
PRESSURE
AIR PROVING
SWITCH
The diaphragm type differential pressure switch is connected by vinyl tubing to the pressure
signal hose adapters. The pressure switch monitors air flow by sensing the diffential
pressure measured in inches of water(" w.c.). The factory settings on these switches are
1.00 "w.c. for Model-100, 1.35 "w.c. for Model-75 and 1.55 "w.c. for Model-50. The contacts
are normally open, and close when the draft inducer is running and causing the diffential
pressure at the switch to exceed the setting. The closed switch proves there is adequate air
flow for combustion. 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 inducer. After five (5) minutes of lack of the adequate differential pressure, the
IBC will lockout. The "PURGE" indicator light will blink, indicating a failure to prove adequate
combustion air flow or flue gas flow. The IBC is manually reset from lockout as described in
the Sequence of Operation section of this chapter.
H. 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 outdoors. See applicable sections for
proper sizing and installation of combustion air and vent piping in this manual.
CIRCULATOR
PUMP
Every forced hot water system requires at least one circulating pump. The circulating pump
imparts the necessary energy to move the water through the closed loop supply and return
piping systems, terminal heating equipment (i.e. finned tube radiators, etc.) and back
through the boiler for reheating. 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
boiler. 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
(i.e., pumping away) side of the expansion tank. For a pump controlled system (where there
is a circulator for each zone) the circulator provided with the boiler can work for one zone.
For more details on piping and circulators, see Near Boiler Piping section of this manual.
J. 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 valve. This
drain valve is installed in the 3/4" tapping at the bottom of the front boiler section. 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 system.
33
K. A.S.M.E.
RATED
PRESSURE
RELIEF
VALVE
Each boiler must have a properly sized and installed American Society of Mechanical Engineers rated pressure relief valve. Water expands as it is heated by the burner/boiler sections.
If there is no place for the water to expand its volume, (i.e. a properly sized and properly
functioning expansion tank) pressure on the inside of the boiler and heating system will
increase. The furnished relief valve will automatically open at 30 psig pressure to relieve the
strain on the boiler and heating system from the increasing pressure. 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 A.S.M.E. specifications.
Failure to provide the pressure relief valve with piping as herein
described may cause water damage and/or serious bodily injury. The boiler manufacturer
is
not responsible for any water damage or personal injury.
L. 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 reduced. In the event of blocked flueways, enough air will not be available to
support combustion,
and the $9301 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 Fig.16) will blink indicating the failure mode as a lack of adequate air flow.
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 on. 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 blockage.
M. (OPTIONAL)
EXTERNAL
CONDENSATE
PUMP
For installations where there is no floor drain or other appropriate drainage receptacle available to receive condensate from the boiler, an external float activated condensate pump with
integral sump is required. This unit can be installed to pump the condensate to a remote tie
in point to a sanitary sewer system. For this application, the boiler must be installed so that
proper pitch of piping to the external condensate reservoir (sump) can be accomplished.
Use
wood frame or blocks to raise boiler as required for proper installation.
A. WATER
.
TREATMENT
AND FREEZE
PROTECTION
When filling the boiler and heating system, water treatment is generally not required or
desired. For localities where the water is unusually hard (above 7 grains hardness) or for
low pH water conditions (below 7.0), consult a local water treatment specialist.
a. This boiler is designed for use in a closed hydronic heating system ONLY!
b. Excessive feeding of fresh make-up water to the boiler may lead to premature
of the boiler sections.
.
Use clean fresh tap water for initial fill and make-up
a.
b.
failure
of boiler.
A sand filter must be used if fill and make-up water from a well is to be used.
Consideration
should be given to cleaning the heating system, particularly in
retrofit situations, where a new boiler is being installed in an older piping system.
34
c.
In older system, obviously discolored, murky, or dirty water, or a pH reading
indications that the system should be cleaned.
A pH reading between 7 and 8 is preferred.
d.
3.
below 7, are
Antifreeze if needed, must be of a type specifically designed for use in closed hydronic
systems and with aluminum.
a. Choice and use of antifreeze must be in accordance with local plumbing codes.
heating
b
Only INTERCOOL
NFP-50 is approved for use.
• Use of any antifreeze other than INTERCOOL
NFP-50 will void warranty.
• Antifreeze must be maintained per manufacturers
specifications,
failure to do so will
result in the warranty being voided.
c.
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 efficiency.
Consult antifreeze manufacturer's
literature for compatibility
of antifreeze with
aluminum
boiler.
For approved manufactured
antifreeze (INTERCOOL
NFP-50 Coolant)
please contact Interstate Chemical Co. New York Customer Service at 1-800-422-2436.
d.
Some brands have corrosion inhibitors that break down more rapidly or become ineffective at
higher operating temperatures
when used with aluminum.
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
year.
Use of antifreeze in any boiler will reduce capacity by as much as 10 to 20%, due to differing
heat transfer and pumping characteristics.
This must be taken into consideration when sizing
the heating system, pump(s), and expansion tank. Consult antifreeze manufacturer's
literature
for specific information on reduced capacity.
Water content of the boiler is 2.6 gallons. (10 liters)
e.
f.
B.
FILLING
TYPE
BOILER
EXPANSION
WITH
WATER
AND
PURGING
ARE
FOR
Refer to appropriate
"Near Boiler Piping" diagrams.
1. Close all zone service valves on the supply and return piping.
2.
3.
4.
5.
C.
BOILER
Refer to appropriate
Open the feed valve and fill boiler
WITH
WATER
CLOSED
TYPE
AND
PURGING
EXPANSION
AIR
FOR
SYSTEMS
valves
WITH
TANKS
"Near Boiler Piping" diagrams.
Close all zone service valves on the supply and return piping and close the expansion tank service
valve. Drain expansion tank. Open the feed valve and fill boiler with water. Hold relief valve open
until water runs air free for five seconds to rapidly bleed air from boiler, then let the relief valve
snap shut.
Open the zone service valve on the SUDDIv pipe for the first zone. Open the purge valve on the
first zone. Feed water will fill the zone, pushing air out the purge valve.
when the water runs air free. Close the zone service valve.
3.
DIAPHRAGM
Repeat step 2 for all remaining zones.
Open all service valves. Any air remaining trapped in the return lines between the service
and the boiler will be pushed towards the air vent when the boiler is placed in operation.
Inspect piping system. Repair any leaks immediately.
CONVENTIONAL
2.
WITH
with water. Make sure air vent is open. Hold relief valve open until water runs air free for five
seconds to rapidly bleed air from boiler, then let the relief valve snap shut.
Open the zone service valve on the SUDDIv pipe for the first zone. Open the purge valve on the
first zone. Feed water wilt fill the zone, pushing air out the purge valve. Close the purge valve
when the water runs air free. Close the zone service valve.
FILLING
1.
SYSTEMS
TANKS.
Repeat
step 2 for all remaining
zones.
35
Close the purge valve
4. Open the expansion tank service valve and the tank vent. Fill the tank to the proper level
and close the tank vent. Remove the handle from the expansion tank service valve so
the homeowner doesn't accidentally close it.
5. Open all service valves. 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 operation.
6.
Inspect piping system.
NOTE:
Repair any leaks immediately.
DO NOT use stop leak compounds.
Leaks in threaded
aluminumboiler
sections must be repaired immediately.
seal themselves.
D. PLACING
BOILER
connections in the
Aluminum threads
will not
IN OPERATION
FOR YOUR
SAFETY
READ BEFORE
OPERATING
I
WARNING: If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury or loss of life
This appliance
is equipped
automaticaJly
with an ignition device which
lights the pilot
If you cannot reach
Do not try to light the pilot
I
your gas supplier,
call the fire
department
by hand
Use only your hand to move the system control switch
BEFORE
OPERATING
smefl a]l around
the appliance
Never use tools
If the switch wifl not move by hand,
area for gas Be sure to smell next to the floor because
don't try to repair it, call a qualified
some gas is heavier than air and will setfle on the floor
Force
WHAT
explosion
TO DO IF YOU SMELL
GAS
or attempted
repair
Do not try to ]ight any appliance
Do not use this appliance
Do not touch any electrical
water
switch: do not use any phone
in your building
Immediately
phone
call your gas supplier
Follow the gas supplier's
1
STOP!
2
Set thermostat
Read
3
Turn off all electric
the safety information
from a neighbor's
automatically
control
instructions
is equipped
above on this label
and any gas control
5
technician
any part of the
which
has been
Remove the front jacket panel
7 Wait five (5) minutes
DONOT
service
and to replace
6 Turn the gas control knob clockwise
with an ignition
the burner
or
INSTRUCTIONS
power to the appliance
lights
technician
in a fire
if any part has been under
call a qualified
the appliance
system
service
may result
under water
to lowest setting
4 This appliance
Immediately
to inspect
OPERATING
burner
I
device
gas, including
which
try to light the
near the floor
to "OFF"
Then smell for
If you smell
Follow "B" in the safety information
by hand
_
to clear out any gas
gas, STOP!
above on this label
If
you don't smell gas go on to next step
8
Turn the gas control knob
counter
clockwise
_
to
"ON"
9
Replace front jacket panel
10 Turn on all electrical
11 Set the thermostat
12 If the appliance
power to the appliance
to desired
wifl not operate
Turn Off Gas To Appliance"
setting
foNowthe instructions
"To
and call your service t echnician
or gas supplier
TO TURN OFF GAS TO APPLIANCE
1
Set the thermostat
to lowest setting
2
Turn off all electric
power to the appliance
4 Turn gas control knob clockwise
if service
is to
5
Replace
__
to "OFF"
the front jacket panel
be preformed
3
Remove
the front jacket panel
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 Z21.13-latest revision.
36
DIAGNOSTIC
®
©
®
®
INDICATOR
VALVE /
LAMPS
FLAME
IGN_ER
PURGE
POWER
CONTROL PANEL
MR PRESSURE
SWITCH
TRANSFORMER
FIGURE
A. VERIFY
PROPER
SEQUENCE
16
INDICATOR
LAMPS
OF OPERATION
The sequence can be followed via the diagnostic indicator lamps on the Honeywell $9301A
integrated boiler control in Fig. 16. This is the normal sequence of operation.
A more detailed
sequence
of operation
containing
potential
SEQUENCE
faults can be found in the service
calls for heat, energizing
Integrated boiler control goes through
and energizes draft inducer
DIAGNOSTIC
INDICATOR
LAMPS
OF OPERATION
Power ON, boiler standing by. Lamp A is illuminated
being supplied to the integrated control.
Thermostat
hints section.
indicating
2 volt power is
system circulator
A. •
B O
C.O
DO
E O
self check of internal circuitry
Draft inducer comes up to speed and establishes
combustion
(1-2 seconds)
airflow, causing the
normally open differential pressure air proving switch contacts to close. Lamp B is
illuminated indicating that combustion airflow is proved and the 15 second pre purge
cycle is under way.
37
A. •
B. O
C.O
DO
E O
A. •
B. O
C.O
DO
E O
A. •
B. •
C. o
DO
E. O
After pre purge, Lamp B goes out and Lamp C illuminates,
igniter is powered
for the 20 second
glow of the hot surface
front boiler section
igniter
igniter warm-up
can be observed
indicating
the hot surface
A.O
B.O
C.O
D.O
E.O
period. The bright yellow orange
through
the observation
port in the
just above the igniter.
After igniter warm-up, the gas valve is energized, and opens on the normal firing rate
regulator (2.5" w.c.) for a 6 second trial for ignition. Lamp D illuminates. The blue orange
glow of the burner can be seen through the observation port.
A.O
B.O
C.O
D.O
E.®
Two seconds later, Lamp C
During the last two seconds
proven by flame rectification
rectification to the integrated
remains energized, and the
goes out as power is turned off to the hot surface igniter.
of the 6 seconds trial for ignition, main burner flames is
through the hot During surface igniter, providing flame
boiler control and fully illuminating Lamp E.. The gas valve
boiler runs.
A.O
B.O
C.O
D.O
E.O
Thermostat ends call for heat, de-energizing gas valve and system circulator. Burner
stops firing, and Lamp D goes out. Draft inducers remains powered. Lamp B illuminates,
indicating draft inducer is running for 30 second postpurge.
A.O
B.O
C.O
D.O
EO
After 30 seconds, draft inducer is de-energized
next call for heat.
A.O
B.O
C.O
D.O
E.O
NOTE:
Lamp B goes out. Boiler stands by for
First couple of cold starts may be rough due to gas line not being completely
of air, causing low firing rate and high excess air levels..
B. INSPECT
VENTING
AND AIR INTAKE
SYSTEM
Operate the boiler and verify that all vent/air
Repair any leaks immediately.
C. INSPECT
CONDENSATE
Verify that all connections
immediately.
D. INSPECT
SYSTEM
intake connections
are gastight
and watertight.
DRAIN
are watertight,
and that condensate
flows freely. Repair any leaks
PIPING
Verify that all connections
E. TEST IGNITION
purged
SYSTEM
are watertight.
SAFETY
Repair any leaks immediately.
SHUTOFF
DEVICE
1.
2.
Turn off manual gas valve
Set thermostat to call for heat
3.
4.
Boiler begins normal sequence of operation
After approximately 40 seconds (pre purge and igniter warm-up period), lamp D illumi
nates, indicating gas valve is powered
After 6 seconds, gas valve closes, lamp D goes out as integrated boiler control senses
that flame is not present
To restart system, follow operating instructions under "START-UP PLACE IN OPERATION"
5.
6.
38
F. TEST HIGH LIMIT CONTROL
AND ADJUST
While burner is operating, move indicator on high limit control below actual boiler water
temperature.
Burner should go off while circulator continues to operate. Raise limit setting
above boiler water temperature and burner should reignite after pre purge and igniter warmup period. Set the high limit control to the design temperature
requirements of the system.
Maximum high limit setting is 200°F. Minimum high limit setting is 100°F.
G. 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 manufacturer.
Burner should be operating and should go off when controls are tested. When safety controls are restored, burner
should reignite.
H. 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 0.7 amps. For other wiring configurations, refer to the instructions provided by the thermostat manufacturer
regarding adjustment
of heat anticipator. Cycle boiler with thermostat. Raise the thermostat to the highest setting
and verify boiler goes through normal start up cycle. Lower thermostat to lowest setting and
verify boiler goes off.
MEASURE
THE NATURAL
GAS INPUT RATE
Correct input rate is essential for proper and efficient
1. Determine elevation at installation site.
operation
of the burner and boiler.
2. See page 4 and 5 of this manual to determine the correct input rate for the local elevation.
3. Obtain the yearly average heating value of the local gas supply from the gas utility. At sea
level elevation, it should be approximately
1000 Btu's per standard cubic foot.
4. Operate boiler for 5 minutes.
5. Turn off all other gas appliances, extinguishing standing pilots where applicable.
6. At gas meter, measure time in seconds required to use one cubic foot of gas.
7. Calculate input rate according to the following formula:
3600xheatinq
B tuh input rate
.
=
value
time
from step 3
from
step
6
Measured input rate should be within +/-2% of the input rating from step 2. If within 2%, go
to step 9. If not, adjustment is required, proceed as follows:
a. Turn boiler off
b. Set up U-tube manometer
sure, see FIG. 17.
or differential
pressure
gauge for measuring
manifold
pres
c. Manometer or gauge must be able to read at least 0.0 to 3.0 inches water column of
pressure, and resolve to at least 0.1 inches water column.
d. Turn boiler on.
e. Manifold pressure has been nominally set at 2.5 inches w.c. Manifold pressure and input
rate must always be measured with pressure regulator cover screw installed..Cover
screw
must be removed for adjustment. Manifold pressure reading will change (increase) when
cover screw is removed.
39
PRESSURE
(UNDER
REGULATOR
ADJUSTMENT_
COVER SCREW)
_--GAS
VALVE
VENT
j/
",
OUTLET PRESSURE TAP
(1/8" PLUG)
_
J
4-WAY CONNECTOR
PRESSURE
WHITE TRANSPARENT
VINYL TUBING
\
/
REFERENCE
PRESSURE
...._DIFFERENTIAL
:
%'
PRESSURE
U-TUBE
MANOMETER
GAUGE
THE FOLLOWING
POINTS
STEPS AND DIAGRAM
REQUIRED
THE MANIFOLD
DIFFERENTILA
MEASURING
PRESSURE•
© REMOVE
TO MEASURE
PRESSURE
PRESSURE
DEVICES
INDICATE
THE MANIFOLD
MAY BE MEASURED
REFER TO "CHECK
MANIFOLD
WHEN
OUT PROCEDURE
SEALANT
TO MEASURE
GAUGE.
BARBED FITTING AND CONECT
OR THE DIFFERENTIAL
AND ADJUSTMENTS"
APPROVED
IS COMPLETE,
DISCONNECT
BE SURE TO REINSTALL
FOR USE WITH
FIGURE
THE PRESSURE
PRESSURE
GAUGE.
IN THIS MANUAL
WHEN
17 MANIFOLD
U-TUBE
MANOMETER
READING
OR DIFFERENTIAL
1/8" PLUG, USING APPROPRIATE
NATURAL
AND LIQUIFIED
PRESSURE
PETROLEUM
MEASUREMENT
Top view
NOTE:
OF BOTH
THE MANIFOLD
PRESSURE.
MEASUREMENT
PRESSURE
OR A
SHOWS THE CONNECTION
IS REQUIRED
THE PLUG• INSTALL APPROPRIATE
SIDE LINE FROM THE U-TUBE MANOMETER
OF THE CONNECTION
USING A U-TUBE MANOMTERE
GAUGE. THE DIAGRAM
BUT ONLY ONE DEVICE
THE LOCATION
PRESSURE•
Regulator cover screw must be installed
at all times unless adjusting manifold
pressure. Firing rate and manifold
pressure must only be measured with
cover screw firmly installed.
PIPE THREAD
GASES.
DETAIL
of gas control
VR8205
PRESSURE
REGUAITOR
WIRING
ADJUSTMENTIUNDER
TERMINALS
CAPSCREW)
PRESSURE
PRESSURETAP
TAP
INLET i_
:
_ OUTLET
?
GAS
FIGURE
18 GAS
40
(2)
OUTLET
INLET
VALVE
CONTROl
KNOB
I.
Remove regulator cover screw on top of gas valve, and insert an appropriate screwdriver into adjustment screw.
II. Turn adjustment screw clockwise to increase input rate, or counter clockwise to decrease input rate.
III. Replace cover screw, or cover hole temporarily with your finger to check new manifold pressure setting. Do not set manifold pressure lower than 2.0 inches w.c. or
higher than 3.0 inches w.c. when adjusting input rate.
IV. Measure new input rate (cover screw must be installed). Repeat steps I.-IV until the
input rate is within +/-2% of the nameplate input rating.
V. If the actual input rate can not be set to within 2% of the correct input rating by adjusting manifold pressure, a change in gas orifice size is required. Consult the boiler
manufacturer
for information on correct orifice sizing. 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 size.
f. After adjusting input rate, turn boiler off, remove manometer or pressure gauge, reinstall
1/8" plug on gas valve. Turn boiler on.
9.Restore all gas appliances that may have been shut off (while measuring boiler input
rate) to normal operating conditions.
J. SET THERMOSTAT
Observe
TO DESIRED
several operating
K REVIEW
ROOM TEMPERATURE
cycles to verify proper operation.
ALL INSTRUCTIONS
Review all instructions
shipped with this boiler with owner or maintenance
must be affixed on or adjacent
person.
Instructions
to the boiler.
L. COMPLETE AND SIGN THE INSTALLATION
FOLLOWING
PAGE.
AND CHECK-OUT
41
CERTIFICATE
ON THE
INSTALLATION
Boiler Model
Measured
Serial #
BTU/HR
©
Installation
©
Checkout
©
Maintenance
©
Installation
Installer
AND CHECK-OUT
Date Installed
input
instructions
procedure
and adjustments
and Service
booklet
have been followed
performed
issues reviewed
affixed on or adjacent
(Company)
Address
Phone
Installer's
CERTIFICATE
Name
Signature
42
with owner/maintenance
to boiler
person
Maintenance
as outlined
below can be performed
by the owner unless otherwise
noted.
The acidic nature of flue gasses condensing on the aluminum boiler sections will cause the
formation of aluminum oxide. 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 boiler. 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 flow. Regular service and maintenance by a qualified service
agency must be performed to assure safe trouble free operation and maximum efficiency.
A. BEGINNING
,
Annual
OF EACH
HEATING
SEASON
service call by a qualified
service
agency, which includes:
a. 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 page.
b. Visually inspect venting and air intake system for proper function, deterioration
or
leakage. If the vent or air intake show any signs of deterioration or leakage, repair or
replace them, immediately. Insure proper reassembly and resealing of the vent and air
intake system, c.Check for and remove any obstruction to the flow of combustion air
or venting of flue gases. 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 back. Refer to repair parts
diagram of mixer and pressure switch assembly for exact location.
d. Follow instructions
e. Follow instructions
f.
for "PLACING
BOILER
IN OPERATION".
for" CHECK OUT PROCEDURE
AND ADJUSTMENTS".
Visually inspect condensate drain line for proper operation
for plugged condensate drain line.
and deterioration.
Check
g. Check the silicone rubber seals between boiler sections. Insure that there are no
leaks. 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 deteriorated.
h. Check all gasketed
i.
joints for leakage, and tighten bolts or replace gaskets if necessary.
Remove jacket front and top panels and check for piping leaks around relief valve and
other fittings. Repair, if found. DO NOT use stop leak compounds.
2. Check that boiler area is free from combustible
vapors and liquids.
materials,
gasoline,
3. Circulator pump and blower motor furnished with boiler are permanently
factory and require no further lubrication. Additional
and other flammable
lubricated from
or non-factory supplied pumps and/or
motors should be lubricated according to the pump and/or motor manufacturer's
B. DAILY DURING
HEATING
instruction.
SEASON
1. Check for and remove any obstruction
to the flow of combustion
2. Check that boiler area is free from combustible
vapors and liquids.
43
materials,
air or venting of flue gases.
gasoline,
and other flammable
C. MONTHLY
DURING
HEATING
SEASON
1. Remove jacket front and top panels and check for piping leaks around relief valve and
other fittings. If found, contact a qualified service agency to repair. DO NOT use stop leak
compounds.
2. Test relief valve. Refer to valve manufacturers
instructions
packaged
with relief valve.
3. Visually inspect venting and air intake system for proper function, deterioration,
or
leakage. 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 system.
4. Visually inspect the clear vinyl condensate lines and the PVC condensate drain pipe for
proper operation, leakage, and deterioration.
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 immediately.
5. Check the air baffle located inside 1 1/2"x 2" flexible coupling, clean it if necessary and
make sure to put it back. Refer to repair parts diagram, mixer and pressure switch
assembly.
D. PERIODICALLY
DURING
HEATING
SEASON
1. Where low water cut offs are used, a periodic inspection of the low water cut off is
necessary, including flushing of float type devices. Refer to low water cut off
manufacturer's
specific instructions.
E. END OF EACH HEATING
SEASON
- ANNUAL
SHUTDOWN
PROCEDUR
1. Follow instructions "TO TURN OFF GAS TO APPLIANCE".
2. If heating system is to remain out of service during freezing weather, and does not contain
antifreeze, drain system completely. If boiler will be exposed to freezing temperatures,
drain condensate lines. Otherwise, do not drain system or boiler.
F. ANNUAL
EXAMINATION
AND CLEANING
OF BOILER
COMPONENTS
The following service procedures must be performed only by a qualified
agency. Boiler owner should not attempt these procedures.
service
1. Before Servicing, turn off electrical power to boiler at service switch. Close manual
valve to turn off gas supply to boiler.
2. Cleaning
Flue passages
between
gas
boiler sections.
&Any buildup of sediment or aluminum oxide (white powdery
flue passages must be cleaned as follows:
or flaky substance)
in the
b.Remove jacket front and top panels. Disconnect condensate drain line from the barbed
fitting on the bottom of the boiler. Keep the open end of the drain line above the water
level in the condensate trap to prevent the trap from draining. Disconnect pressure switch
hose from barbed fitting on gas valve. Disconnect 11/=x 2" flexible coupling from air inlet.
Disconnect air by-pass (½" transparent vinyl tube) from the bottom of the mixer.
44
c,
d,
e,
f.
Remove air baffle from 1%z" x2" flexible coupling and clean air baffle if necessary.
Refer to repair parts diagram, mixer and pressure switch assembly.
Confirm that manual gas valve is closed and disconnect
Disconnect wires to gas valve, and igniter.
gas line to gas valve at union.
Loosen but do not remove five (5) nuts attaching mixer assembly to boiler. Remove
two (2) igniter screws and very carefully remove the igniter. Use care when removing
the igniter, it is very brittle!!
Remove five (5) nuts and remove mixer assembly.
Remove
burner and mixer gasket.
g. Aluminum oxide deposits are water soluble and may be rinsed away with spraying
running water. Before rinsing, connect a '/z" I.D. hose to the barbed fitting on the
bottom of the boiler and run the hose to a bucket or drain.
h. After rinsing, remove any remaining
snorkel attachment.
loosened
sediment
or
using a shop vacuum with a
Inspect burner for any foreign matter in the flame ports or inside the burner. Any foreign matter should be removed by blowing with compressed air or vacuuming.
J,
Inspect interior of mixer for any signs of sediment or aluminum oxide and clean if necessary.
k. Reinstall burner and mixer gasket and position mixer assembly over studs. Install five
(5) nuts but do not tighten. Reinstall igniter and igniter gasket and fasten with two (2)
screws. Use care when installing the igniter. It is very brittle!! Tighten five (5) nuts
holding mixer assembly.
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
Visually inspect condensate lines leading from the boiler sections and the vent tee to the
condensate trap. Refer to repair parts diagrams. Any foreign material or debris that is
visible in the condensate lines needs to be cleaned out as follows:.
a.
Raise condensate
trap and drain condensate
lines completely.
b.
Once the condensate trap is emptied of water, disconnect condensate
fittings on the boiler, the vent tee, and the condensate outlet.
c.
Remove the condensate trap and run cold water through
thoroughly flush out any sediment or debris in the lines.
45
the condensate
lines from the
lines to
d. Reinstall and connect the condensate trap, using the hose clamps to secure the various
condensate lines to their fittings.
e. Follow the instructions under "NEAR BOILER PIPING" for"filling condensate trap with
water"
4.
Inspection
a.
requires the following
steps (Refer to the repair parts diagram.)
Loosen the clamp on the draft inducer end of the 2" flexible coupling that connects the
vent tee to the draft inducer. Disconnect (unplug) wiring harness from draft inducer motor
and draft inducer temperature
safety switch. Remove four (4) bolts that attach draft in
ducer to flue connector.
b. Remove
C.
of the flue connector
draft inducer and gasket from top of flue connector.
Inspect interior of flue connector. Any buildup of sediment or aluminum oxide on the
inside surface must be cleaned. Position the draft inducer gasket and the draft inducer
and fasten with four (4) screws. Be sure to connect ground wire from draft inducer motor
to one of the four mounting screws.
d. Connect wiring harness
ture safety switch.
e. Connect
leads to the draft inducer motor and the draft inducer tempera
the 2" flexible coupling
to the draft inducer outlet.
46
P O_ll ER ON
STA ND BY
4,
THERMOSTAT
CALLS
FOR HEAT
IF MAIN
CIRCULATOR
ENERGIEES
BURNER
DOESNOTPROVE
FLAME
IN 3 TRIALS,
LOCKOUT
VALVEIFLAME
CONTROL
LIGHT RLINKS
,
RESET
IS REQUIRED
THIS PROBLEMISA
RESULT
OF NOT ESTABLISHINGFLAME
SIG1"_AL
THRU
2K1 CONTACTS
4,
ISC
SELFCHECK
INTERNAL
OF
CONTROL
A DDITTIONAL
CIRCUITRY'
1-2 SEC
//
CHECKS
E/_
POSITIVE
PROOF
",
SURNER
BED
FLAME
SWITCH
CONTACTS
f
\
DURING
THE LAST
TRIAL MAIN
BURNER
\
RECTIFICATION
WAITS
FOR
UP TO 5 MINUTES
A
REMAINS
2 SEC
INTO
IS-[URNED
"\.
ENERGIZED
THE
IGNITION
BY FLAME
SIGNALTOIBC
5 SEC
BOILER
IGNITION
GASVALVE
RUNS
TRIAL
PC¢_llER
OFF TOTHE
HOT SURFACEIGNITER.
1G;t ITER LIGHT IS OFF.
/
GAS
OPEN
CONTROL
BLI;1KS,
2 BEG OFTHE5SEC
FLAME IS PROVED
FLAME
/
"--..
RESET
LOCKOUT
REQUIRED
_V
PURGE
VALVE
IGNI]ION.
CAN
OPENS
FOR
5SEGTR_LFOR
BLUE
ORANGE
GLOW C_]HE
BE SEEN THRU OBSERVATION
BURNER
PORT
LIGHT
CIRCULATOR
GAS
VALVE
ENERGEED
CONTADTS,
REMAINS
ENERGEED
AS LONG AS
TH ER M OSTAT C ONTIN URES TO CA LL FOR
HEAT
PURGE
LIGHT
GOES
VALVE
OUT
1NR
U 3}<,1 AN D 4K 1.
LIGHTtS
ON.
HQTSURFACEIG_ITER
POWERED
THRU 5KI 5K2CONTACTSFOR2O
SEC IGNITER
WARMUP
BRIGHTYELLOW
PURGE
LIGHT
ISO;1, AIRFLOW
PROVED.
DRAFT
INDUCER
RUNS FOR I5 SEC PREPURGE
\\YEB_
/
DRAFTINDUBER
ENERGEES
THRU
IKI CONTACTS
IBC
PROVE
WITHIN
INITIAL /,,;_
TRIAL
FOR
/
IGNITION
/
PEN
//
\
",,
PRESSURE
'_
PREPURGE
MAIN
OF
N O. AIR
",,
WITH
!F2""-,
\
J
WILL A F]'EMPT 2
IGNITION
SEQUENSES
STA RTING
ORANGE
GLOW OF THE
HOT SURFACEIGNITER
CAN BE OBSERVED
THRU THE OBSERVATION
PORT
IN FRONT
ABOVE
47
IGNITER,
OF BOILER
IG;11TOR
SECTION
JUST
LIG;1TIS
O;1
[
NORMAL
OPERATION
DRAFT INDUCER TEMPERATURE
CASTING
SAFETY SWITCH
TEMPERATURE
IF BURN ER OPERATES
IF DRAFTINDUCER
TEMPERATURE
REACHES
WATER=
TE_,'IPERATURE
SAFETY" SWITCH SETPOINT,
SAFETY SWITCH CONTACTS
OPEN IMMEDIATELY
CLOSING
GAS VALVE (LIGHT
CASTING TEMPERATURE
SAFETY SWITCH
CONTACTS
WILL OPEN BR EAKING 24 VOLT POWER TO IBC
POWER INDICATOR
REQUIRES
MANUAL
INDUCER RUNS THRU 30 SECOND POST
PURGE AN])
S_,JZTCHES
OFF.
CONTAC]S_
4,
CIRCULATOR
WHEN BOILER HAS NO
ALUMINUM
BOILER SEC]IONS
HEAT UP RAPIDLY
GOES OUT)
4,
DRAFT
SAFETY SWITCH
CALLR
UN SONFoR
W ITH
HEAT
]HER k'IOSTAT
LIGHT GOES OUT
RESEI'TO RE+CLOSE
POWER
LIGHTGOES
OUT_
]
WHEN TEMPERATURE
SAFETY SWITqH
CONTACTS
REMAKE BEFORE END OF CALL
HI LIMIT CONTROL
FOR HEAT= CONTROL GOES INTO NORMAL
LIGHT+OFF SEQUENCE
IF BOILER
WATER TEMPERA]URE
REACHES
HI Ltk'11T (AQUASTAT)
SETPOINT HI LIke]IT
NC CONTACTS
OPEN tMMEDLATELY,
CLOSING GASVALVE
VALVE LIGHTGOESOUT.
LOSS OF FLAME SIGNAL
DRAFT
INDUCER
SECOND
tF AN ESTABLISHED
CONTINUES
WHILE CONTROL
EXPECTS]HATTHEBURNER
IS OPERATING
CONTROLWILLIMMEDIA]tELY
DE=ENERGIZE
GAS_'ZALVE VALVE LIGHTGOESOUT
CIRCULATOR
RUNS
CALLS
4,
DRAFT
INDUCER
RUNS THRU 3C_SECOND POST
PURGE
4,
CONTROL
WILL ,ATTEMPT
TO RE-UGHT BOILER
3 TIMES IF FLAME IS NOTPROVEN, CONTROL
LOCKOUT - PROBLEM ES]:ABL]SHING A
FLAME
SIGNAL,
TO RUN FOR 30
POST PUR GE ,AND SWI]_2-H OFF
FLAME SIGNAL IS LOST
VALVE
LIGHT
ISBIJI_IqNG,
1
l
,AS LONG
FOR
ASTHERMOS]AT
HEAT
WHEN HI LIMIT CONTACTS
REM,AKEBEFORE END
OF GALL FOR HEAT- CONTROL GOES INTO
A NORMAL LIGHT OFFSEQUENCE
CIRCULATOR
PUMP
CIRCULATOR WILL BE ENERGIZED .AS LONG ,AS
TH ER MOST,AT CALLS FOR HEAT DURING LOCKOUT
LOSS OF COMBUSTION
AIRFLOW
RECOVERY
IF COMBUSTtON
IS FtRING
,AIRFLOW
_SLOSTWHILE
(DIFFERENTIALAIR
PRESSURE
SWITCH CONTACTS
OPEN) GASVALVEWILL
BE DE-ENERGIZED
VALVE LIGHTGOESDUT.
4,
DRAFT
INDUCER
RUNS THRU 30 SECOND POST
PURGE
IF CALL FOR HEAT REMAINS IBC ,5/AITS
5 MINUTES
FOR AIRFLOW TO BE RE-ESTABLISHED
4,
IF ,AIR FLOW DOES NOTRE+ES]:ABL]SH
CONTROL LOCKOUT - PROBLEM WITH
COMBUSTION
AIRFLOW
PURGE
LIGHTBU_KS
FR O_,_1
ANY LOCKOUTREQUIRES
RESET
WHICH I S ACCOMPL] SH ED BY REMOVING AND
R EA P PYI NG TH E TH ER M O STAT CALL FOR HEAT
OR POWER TO CONTROL
BURNER
1
48
END OF NORMAL SEQUENCE
THERMOSTAT
GAS VALVE
BLOWER
ENDS CALL FOR HEAT.
AND CIRCULATOR
RUNS FOR 30 SECOND
PURGE,
OF OPERATION
PURGE
PUMP
POST
LIGHT IS ON.
4,
AFTER
BOILER
BLOWER IS DE-ENERGIZED
30 SECONDS,
PURGE LIGHT SHUTS OFF.
STANDS
BY FOR NEXT CALL FOR HEAT.
49
!!WARNING!!
FIRE, EXPLOSION
OR SHOCK HAZARD MAY CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
DO NOT ATTEMPT TO MODIFY THE PHYSICAL OR ELECTRICAL
CHARACTERISTICS
OF THIS BOILER IN ANY WAY.
IMPORTANT
.
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 PERIOD.
2.
IFANY COMPONENT DOES NOT FUNCTION PROPERLY, MAKE SURE IT IS CORRECTLY INSTALLED
AND WIRED BEFORE REPLACING IT.
3.
STATIC ELECTRICITY DISCHARGE CAN DAMAGE THE INTEGRATED BOILER CONTROL (IBC).
TOUCH METAL SURFACE TO DISCHARGE STATIC ELECTRICITY BEFORE TOUCHING IBC.
4.
THE IBC CANNOT BE REPAIRED.
5.
ONLY TRAINED, EXPERIENCED SERVICE TECHNICIANS SHOULD SERVICE THE IBC SYSTEMS.
FOLLOWING TROUBLESHOOTING,
CHECK OUT THE SYSTEM FOLLOWING THE SEQUENCE OF
OPERATION SECTION OF THIS CHAPTER FOR A NORMAL LIGHT OFF SEQUENCE.
IF IT MALFUNCTIONS
IT MUST BE REPLACED.
ALL CONTROLS ARE FACTORY TESTED IN THE ASSEMBLY PROCESS AND A DEFECTIVE
CONTROL IS GENERALLY THE LEAST LIKELY CAUSE. IF YOU SUSPECT YOU HAVE A DEFECTIVE
CONTROL, READ THROUGH THE TROUBLESHOOTING CHART BEFORE YOU REPLACE IT.
IT IS EXTREMELY UNLIKELY THAT THE TWO CONSECUTIVE CONTROLS ARE DEFECTIVE. 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
BEFORE TROUBLESHOOTING:
A. MAKE SURE THAT CIRCUIT BREAKER IS ON OR FUSE IS OKAT ELECTRICAL PANEL.
B. MAKE SURE THAT SERVICE SWITCH IS ON.
C. MAKE SURE THAT GAS IS ON AT THE GAS METER, AT ALL APPROPRIATE MANUAL
SHUTOFF VALVES AND AT THE GAS CONTROL VALVE.
D. MAKE SURE THAT THE THERMOSTAT IS CALLING FOR HEAT.
E. CHECK THAT WIRE CONNECTORS AT THE INTEGRATED BOILER CONTROL AND AT THE
ORIGINATING CONTROL ARE SECURELY PLUGGED IN OR CONNECTED.
F. CHECK THAT HOSES ARE SECURELY CONNECTED AND ARE NOT PLUGGED IN OR
DAMAGED.
2. TROUBLESHOOTING TOOLS:
A. VOLTMETER TO CHECK 120 VAC AND 24 VAC
B. CONTINUITY TESTER.
C. INCLINED MANOMETER OR PRESSURE GAUGE WITH 0-2.0" RANGE (0.01" SCALE) FOR
MEASURING SUCTION PRESSURES AT PRESSURE SWITCH.
D. U-TUBE MANOMETER OR DIFFERENTIAL PRESSURE GAUGE WITH 0-14" RANGE (0.1"
SCALE) FOR MEASURING INLET AND MANIFOLD GAS PRESSURES.
3. WHAT IS SYSTEM STATUS?
A. CONSULT THE CHART ON THE FOLLOWING PAGE.
B. FIGURE 15 ON PAGE 29 SHOWS THE LOCATION ON THE BOILER OF THE DIAGNOSTIC
INDICATOR LAMPS.
5O
SYSTEM STATUS
THE INDICATOR LIGHTS TRACK THE OPERATING
SEQUENCE.
IF THE SYSTEM LOCKS
OUT, THE LIGHTS INDICATE THE POINT IN THE SEQUENCE OF OPERATION
LOCKOUT OCCURS.
BOILER MALFUNCTION
IF THIS TABLE DOES NOT READILY PROVIDE THE REASON FOR
OR NON-OPERATION,
REFER TO THE FOLLOWING
MORE DETAILED TROUBLESHOOTING
LIGHT
STATUS
ON
POWER
OFF
BLINKING
ON
WHERE
PAGES FOR
PROCEDURES.
INDICATES
IBC IS ENERGIZED THROUGH 24 VOLT TRANSFORMER.
IBC IS NOT ENERGIZED.
IBC RECEIVES MORE THAN 40 VAC
IBC IS ENERGIZING THE DRAFT INDUCER AND AIR FLOW IS PROVEN.
OFF DURING PURGE CYCLE-DRAFT INDUCER IS NOT POWERED OR AIR FLOW
IS NOT PROVEN.
PURGE
OFF
OFF DURING IGNITER AND RUN CYCLE-NORMAL OPERATION, PURGE
CYCLE COMPLETE.
BLINKING
IGNITER
OF AIR FLOW. BLOCKED VENT OR INTAKE AIR PIPE OR FLUE WAY.
ON
IBC IS ENERGIZING IGNITER
OFF
IGNITER IS NOT ENERGIZED
ON
IBC IS ENERGIZING GAS CONTROL VALVE TO OPEN.
OFF
GAS CONTROL VALVE IS CLOSED.
VALVE
IBC IS LOCKED OUT. PROBLEM IS FLAME HAS NOT BEEN PROVEN IN
BLINKING
FLAME
IBC IS LOCKED OUT. PROBLEM COULD INDICATE FALSE POSITIVE PROOF
THREE (3) IGNITION A-I-TEMPTS. MAY BE DUE TO BROKEN IGNITER OR
LACK OF OR LOW FLAME SIGNAL, OR NO GAS.
ON
FLAME PROVEN
OFF
FLAME UNPROVEN
51
TROUBLESHOOTING
!!WARNING!!
CHART 1
GREEN
POWER
INDICATOR
ILLUMINATED
LIGHT IS
NO
ON THE IBC,
ELECTRICAL SHOCK HAZARD MAY CAUSE
SERIOUS INJURY OR DEATH.
YES
THE FOLLOWING PROCEDURES MAY EXPOSE YOU TO
DANGEROUS LINE VOLTAGE. USE CAUTION TO AVOID
TOUCHING LIVE ELECTRICAL CONTACTS. SERVICE
MUST BE PERFORMED BY A TRAINED, EXPERIENCED
SERVICE TECHNICIAN.
CHECK SYSTEM STATUS.
IF LOCKED
OUT NOTE FAILURE
MODE. WHICH
INDICATOR
LIGHT
IS BLINKING?
RESET SYSTEM BY TURNING SERVICE
SWITCH OFF THEN ON, IF NOT
LOCKED
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 BUILIDNG.
•
IMMEDIATLEY
CALL YOUR GAS SUPPLIER
FROM A NEIGHBOR'S PHONE. FOLLOW THE GAS
SUPPLIER'S INSTRUCTION.
"
IF YOU CAN NOT REACH YOUR GAS SUPPLIER,
CALL THE FIRE DEPARTMENT.
OUT, SET THERMOSTAT
CALL FOR HEAT.
TO
NO
CIRCULATOR
STARTS?
YES
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY
FAIL TO SHUT OFF, DO NOT TURN OFF OR DISCONNECT
THE ELECTRICAL
SUPPLY TO THE PUMP. INSTEAD,
SHUT OFF THE GAS AT A LOCATION EXTERNAL TO THE
APPLIANCE.
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 WATER.
USE ONLY YOUR HAND TO TURN THE
KNOB. NEVER USE TOOLS. IF THE KNOB
BY HAND. DON'T TRY TO REPAIR
ATTEMPTED
REPAIR MAY RESULT
EXPLOSION.
GAS CONTROL
WILL NOT TURN
IT. FORCE OR
IN A FIRE OR
CHART2
v
FALSE
POSITIVE
PROOF
OFAIRFLOW.
CHECK
IBC CHECKS
AIR PRESSURE
SWITCH CONTACTS,
IF CONTACTS
ARE CLOSED WITH NO
AIRFLOW,
REPLACE
PRESSURE
SWITCH,
PRESSURE
t
NORMALLY
SWITCH
OPEN AIR
CONTACTS
CLOSED
OPER
CHART3
52
TROUBLESHOOTING
cHA
CHART 2
CHECK THAT CIRCUIT BREAKER IS ON OR
FUSES ARE OK ATTHE ELECTRICAL PANEL
OK
CHECK THAT SERVICE
SWITCH IS ON
OK
CHECK CASTING TEMPERATURE
SAFETY
SWITCH. PUSH RESET BUTTON ON SWITCH.
CONTACTS OPEN (BUTTON UP) OR CLOSED
(BUTTON
CHECK WATER LEVEL IN BOILER. CHECK
FOR AIR TRAPPED IN TOP OF BOILER
CONTACTS WILL NOT STAY CLOSED UNTIL
BOILER COOLS OFF.
OPEN
DOWN)?
CLOSED
CHECK WIRING TO IBC 120 VAC BE'C_NEEN
TERMINAL
1 AND 3ATWIRINGRARNESS
PLUG CN7?
NO
REPLACE/RE
PAl R W IRI NG FROM S ERV ICE
SWITCH TO IBC
YES
120VAC
BETWEENTERMINALS
1 AND 3 AT
CONNECTOR
CN3 ON tBC?
NO
REELACEIBC
YES
120 VAC AT TRANSFORMER
TERMINALS?
PRIMARY
NO
REPAIR WIRING TO TRANSFORMER
YES
24 VAC AT TRANSFORMER
TERMIRALS?
SECONDARY
NO
REPLACE
TRANSFORMER
YES
NO
24 VAC AT WIRING
HARNESS PLUG CN2?
PUSH RESET BUTTON ON CASTING TEMP,
SAFETY SWITCH.
YES
REPLACE
CHECK CONTINUITY OF CASTINGTEMP.
SAFETY SWITCH COBITACTS, COi'_ITACTS
OPEN OR CLOSED?
IBC
V
REPLACE CAST, TEMF,
SAFETY SWITCH,
'4F OEEN
CLOSED
REPLACE/REPAIR
"_ IRING FROM
TRANSFORMER TO IBC
CHECK FOR 120 VAC B E"PA EEN TERMIRALS
1 AND 3 AT CONNECTOR CN5 ON IBC?
REPLACE
NO
IBC
CHART 1
YES
NO
CHECK FOR 120 VAC AT CIRCULATOR
YES
REFAtPJ REPLACE CIRCULATOR
53
,I
REPLACE/REPAIR
WIRING FROM
IBC TO CIRCULATOR
TROUBLESHOOTING
CHART 3
CHART I
OPEN
,l
REPLACE
BLOWER STARTS
YES
tBC
YES
CHECK FOR 120VACAT
BLOWER LEA D S ON I/IIIRING
HARNESS
NO
I
REPAIR/REPLCE
WIRING
TO
FR OMIIBC
BLOWER
YES
R EPAIR/REPLACE
SLOWER
CONTACTS
IBC WAITS
UPTO5
NO
FOR NOR_,'IALL"t
OPEN AIR
PRESSURE SWITCH
CON TA CTS TO CLOSE,
INDICATING BLOW ER
SUCTION IS
PRESENT
CLEAN OUT VENT PIPE
AND/OR AIR INTAKE PIPE
CHECK FOR SAGS OR
LOW SPOTSWHERE
CONDENSATE _'IAY
PUDDLEAND
BLOCK
THEVENT
MINUTES
ARE VENT PIPE AND AIR
OPENINTAKE PIPE CLEAR
(NO BLOCKAGE)
1
4,
CHECK AIR
PRESSURE SWITCH PER
INSTRUCTIONS ON
FOLLOWING PA GES.ARE
SA _'IPLtN G LINES CL_f_R
AND CONNECTED
PROPERLY'?
CLEAN OUT SAMPLING
LINES OR REPLACE
DEFECTIVE SWITCH
YES
CHECK FLUE PASSAGES
IN BOILER PER
CLEAN BOILER FLUE
PASSAGES PER
MAINTENANCE AND
CLEANING INSTRUCTIONS
"k_INTENA CE AND
CLEANING"
ARE FLUE
PASSAGES IN BOILER CLSAN?
YES
MOTOR RPM. BIT
CHECK 3400-3600?
DRAFTINDUCER
YES
CHECK FOR BROKEN OR
LOOSE IMPELLER ON DRAFT
INDUCER AND REPLACE
BLOWER IF FOUND TO
BE BROKEN OR LOOSE
15 SECOND PRE PURGE COMPLETE
PURGE
IGNITOR
LIGHT IS OFF SIk4ULTANEOUSL"t
LIGHT tS ON AS IGNITOR CIRCUIT
tS ENERGIZED.
REPLACE IBC
54
t_
REPLACE
BLOWER
TROUBLESHOOTING
CI_RT
"_"
CHART 4
3
YES
CHECK FOR 120VAC
UP AND GLOWS
Y ELLOW/ORA HGE
B E_A_E EN T E RMli',IALS 1
AND 2 AT CONNECTOR
DURING 20 SECOND
IGNITER/SENSOR
WARMS
WARM UP
CN1 ON tBC (DURING
IGNITER WARM UP)
REPLACE
IBC
]
YES
I_YES
CHECK
FOR 12C*VAC AT
IGNITER/SENSOR
ON WIRING
LEADS
REPAIPJ REP LACE WIRING
FROM IBC
HARNESS
(DURING
IGNITER
WARM
TO IGNITE _ SENSOR
UP)
YESI
REPLACE
IGNITEPJ SENSOR
AFTER 20 SECOND
IGNITER WARM UP, GAS
VALVE IS ENERGIZED
VALVE
LIGHT
1 SECOND
LATER POWER
IS REMOVED
IGNITERtS
IS ON
FROM
ENSOR
CHE CK FOR 24 VAC
ACROSS TERMINALS
MV
CHECK FOR 24VAC
ACROSS TERMINALS
OH THE GAS CONTROL.
WHILE VALVE/FLAME
INDICATOR
POWER LIGHT IS OFF
DOES MAIN BURNER
CN8-2
AND CN6-5 ON
REPLACE
IBC
IBC, WHILE THE VALVE/
FLAME LED IS LIT
LIGHT IS ON
YES
yYES
LIGHT?
REPAIR/REPLACE
WIRING
BETWEEN IBC AND
GAS CONTROL
YES
CHECK IF IGNITER/
SENSOR POSITION IS OK?
TIP SHOULD
TOWARDS
BE SLANTED
TO CORRECT POSITION.
RESTORE
IGNITER/SENSOR
DO NOT
RELOCATE
BURNER
YES
CHECK GAS SUPPLY
PRESSURE AT INLET
SHUT-OFFS
PRESSURE TAPPING ON
GAS CONTROL IS GAS
PRESSURE
GREATER
IN THE GAS
SUPPLY LINE AND ON
THE GAS CONTROL IN
N_
THAN 4,0" W,C.?
THE
OR ON
ARE OPEN
ALL MANUAL
POSITION?
YES
YES
CONTACT
THE GAS UTILITY
TO TURN THE GAS ON
CH& RT 5
CHART
5
55
OPEN OR TURN ON ALL
MANUAL SHUTOFFS
TROUBLESHOOTING
CHART 5
CHART4
YES
CHART4
YES
POSSIBLY
CHECK
GAS
MIXTURE
LINES
VALVE
ARE
FOR
GAS
LEAN!
CLEAN/REPLACE
CLEAR?
VALVE
REPAIR
OF GAS
BLOCKAGE.
LINES
IS GAS/VENTURI
SEE
TOO
DOWNSTREAM
BE SURE
CORRECT
PARTS
TO
USE
GAS
CORRECT
LINES.
GAS/VENTURI
VALVE
SIZE.
SIZE?
DIAGRAM,
_r YES
POSSIBLY
CHECK
MITURE
FLUE
"MA INTENANCE
FLUE
TOO
PASSAGES
AND
PASSAGES
RICH!
IN BOILER
CLEANING",
iN BOILER
PER
CLEAN
BOILER
ARE
FLUE
AND
PASSAGES
CLEANING
PER
MAINTENANCE
INSTRUCTIONS
CLEAN?
_IF YES
CHECK
MIXER
BLOCKAGE
AND
PER
CLEANING
BURNER
INSTRUCTIONS
PASSAGES
FOR
MAINTENANCE
IN MIXER
AND
CLEAN
AREAIR
AND
MIXER
AND
BURNER
CLEANING
PER
iVIAINTENANCE
AND
INSTRUCTIONS
BURNER
CLEAN?
CHECK
FOR
AIR
ORIFICE
CORRECT
DIAGRAM
SIZE,
AT BURNER
INLET
SEE
PARTS
IS ORIFICE
REPAIR
CORRECT
REPLACE
BURNER
SIZE?
NO#1
RUNS
DOES
RUN
MAiN
UNTIL
HEAT
CALL
ENDS
NO #2
OR HI
POOR
CHECK
ABOUT
SHUTS
5
OFF,
FLAME
RESTORE
SIGNAL,
IGNITER/SENSOR
IGN JTER/SENSOR
POSITION.
SLANTED
OPEN?
FOR
THEN
INDICATES
FOR
LIM IT AQUASTAT
CONTACTS
SMOOTHLY
SECONDS
BURNER
TIP SHOULD
TOWARDS
TO
BE
CORRECT
POSITION,
DO NOT RELOCATE
BURNER
NO ,#,3
q
IF YES
* IF THE ANSWER
CHOOSE
THE
CHECK
IS NO,
APPROPRIATE
PATH
(#1, #2, OR #3) BASED
SYMPTOMS
SHOWN,
FLAME
CONSULT
ON
SIGNAL
BOILER
SPECIFIC
REQUIRES
OXIDE
>O,6uA?
MFGR.
FLAME
INSTRUCTIONS.
SPECIAL
TOOLS.
CHART6
CHART
6
CHART
6
56
IBC
J
ON
PREVENTING
SIGNAL
REPLACE
IGNITER/SENOR
YES
REPLACE
COATING
IGNITER
FOR
TROUBLESHOOTING
CHART5
YES
CHART 6
CHART
CHART
NO#3
5
CLEAN
_
RUNS
FOR
THEN
MANIFOLD
PER FIGURE
+
]
CHECK
REPAIR
PARTSLISTFOR
CORRECT
ShEE IS GAS ORIFICE
CLEAN OF BLOCK_,GE?
17
PRESSURE
TO OBE_IN NOR_,_t_L
FIRING
RATE¸
CAN GASVALVE
BE
A OJ USTE D TO N OR _IAL INPUT RAIE?
L
GASORIFICE
_¢_JRE
TOO LE_N NOT ENOUGH
GAS CHECK
GAS ORIFICESIZE
IS GAS ORIFICE
SIZE CORRECT?
_
AND "CHECK
OUT PROCEDURES
AN [3 ADJ U STME N TS" PARAGRAPH
1 B ADJUST_,_NIFOLO
[
REPLACE
rYES
25 50 SECONDS
TURNS OFF
CHECK
PRESSURE
OR
NO#2
REPLACE
GAS CONTROL
J
YES
SIZE¸ SEE REPAIR
PARIS
DIAGRAk_I
CHISECK
AIR A_R
BAFFLE
BAFFLE
CORRECTSI_?
FOR CORRECT
CHECK
AIR ORIFICEATSURNER
INLET
FOR CORRECTSI,_
SEE REPAIRS
IS AIR ORIFICE
REPLACE_IR WITH
CORRECT
S_FFLE_
_
]
_
DIAGRAk&
CORRECT_
REPLACE
BURNER
1
REPLACE
BURNER
1
IG RITER/SENSOR
1
/
CHECN
BURNER
FOR ANYO_R_OR_A_ON
IN THE FLA_E
PORTB_ _ARE SURNER
PORTS
IN GOOO CONDI1]OR?
_
CHECK FLAME SIGNAL
> _ 6uA?
CON SU LT BOI LER MFGR
FO R
SPECIFIC
INSTRUCTIONS¸
REQUIRES
SPECIFIC
I'OOLS
N_2_
REPLACE
R EPLZ_CE
IBO
]
'F
BOILER
SHUTS
OFF
CALL
FOR HEAT
AQ UAETAT
BEFOREENDOF
.ARE HI LIMIT
CONTACTS
BO_LER
I NO
OFF
ON
HIGH
LIkSIT _S
ACTU'_L
BOILER
WATER TEk_P
GREATER
THAN
HI LIMITSETPOINT
k,ll N U S 30 _F CON TR OL DIFFER EN_AL?
CLOSED?
N_
A_ U_S_T
1
REPLACE
]
oK
YES
INDUCER
ARE
INDUCER
TEMP
_FE3-_ r
SWITCH
CONTACTS
CLOSED?
I I_u
SAFEIS"SWITCH
TR I PP ED CH ECK FLU E GAS (VENT)
TEMP
IS IT > 1B0_F LE_.VING FAN?
_
_,¥ES
__)'ES
SEE
TEMP
ii_
TROUBLESHOO]]NG
#2 '_B OVE
P_TH
L
CHECK
SURFACES
J
ALL HEATTRANEFER
PER "_,_AIN_I_NANCE £_
CLEANER G" INSTR U CTIONS ARE HE_,T
TRANSFER
S U R FACES FOULED','
SETTHERMOSTATBELOWROOM
TEMPERATURE
TO END
HEAT
4,"EB
_ALL
FOR
CLEAN
ALL
BOILER
INDUCER
TR_P
REPLACE
S_ETY
SWITCH
CHECK
BOILER
INPUT
RATE PER
"CHECKOUT
PROCEDURE
AND
ADJ U STM EATS"
PARAGRARH
1
HEATTRANSFER
SURFACES
PER "MAINTLNANCE
CLEANING"
INSTR UC_ ORS
@,
YES
ODE S CIR CU L _TOR
PUMP S]I%}P?
_
ES
[
VALE
LIGHT I_ OFF
_
"€'ES
ARE
TH ER _,,_OS_'_,T CONT_',CTS
OPEN?
4 ES
R EPL'_.CE IBC
_
CONWECTION
ON9 FR O_._ GAS
CON1N OL DOES GAS CON/NOL
REMOVE
WIRING
HARNESS
CLOSE?
_
REPL_.CE
R EPLa, CE GAS CONTROL
_
IBC
_
7
YES
S'f STE_°I OK
57
]
1
__YES
STOP
AFTER 30
DOES
DRAFT
SECOND
POST BLOWER
PURGE?
R EP L,'_.CE TH ER _._OSEAT
]
1
\
\
The following
indicate
the
steps and diagram
locations
of the
\
\
\
\
connection points required to check
the differential air pressure.
VINYL TUBING
WHITE TRANSPARENT_
\\
TO SIGHT GLASS
SUCTION PORT
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
blockage.
DIFFERENTIALAIR
PRESSURE SWITCH
SILICONE TUBING
/
/
WRITE TRANSPANZNT
VINYL TUBING
_
f
TO GAS
.....
VALVE VSRT
.........
--
_
TRANSPARENT VINYL TUBN6
4-WAY CONNER[ON
/
/
TO AIR INLET
SUCTION PORT
WHITE TRANSPARENT
VHYZ TUBING
Turn
off service
thermostat
switch,
or lower
_ VINYL CAP
(EYP. 2)
setting.
i_
Remove
_
TESTING
LINES
vinyl caps from Tee and 4-
way connector.
J
INCLINED _AROMETER
(OR DIFFERENTIALPRESSURE GAUGE)
Install testing
lines as shown to
inclined manometer
or differential
pressure gauge with the ability
read 0.01" to 2.0" w.c.
Turn
on service
thermostat
switch
and
to
/
set
/
to call for heat.
Boiler Status
Differential
Not Running
0 _
Setpoint
1.00" for Model-100
1.35" for Model-75
1.55" for Model-50
Running Without
Blockage
Greater
Running With
Blockage
Less Than or Equal to
Setpoints
If manometer
-
/
readings
Pressure
(w.c.)
Than Setpoints
do not correspond
Pressure
Switch Connects
Normally
Open
Closed
Open
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
lines and reinstall vinyl caps to Tee and 4-way connector.
C,
58
properly,
remove testing
0
TYP
OF
4 _>/
//
.......................................
A.
JACKET
> ......
__J
AND BASE ASSEMBLY
59
J
//
JACKET
AND
BASE ASSEMBLY
QUANTITY
KEY #
ITEM NUMBER
DESCRIPTION
1
750001020
FRONT
2
750001021
RIGHT PANEL
3
750001022
LEFT PANEL
4
750001023
BACK
5
750001024
TOP PANEL
6
750001025
BASE
7
750001026
CONTROL
8
14662801
AT140B1016
9A
14631312
PPS10111-2680
AIR PRESSURE
SWITCH
(100)
AIR PRESSURE
SWITCH
(75)
1
PANEL
1
1
1
1
PANEL
1
1
PANEL
TRANSFORMER
24 VAC
1
1
1
1
9B
14631010
PPS10111-2681
9C
14631044
10
14662803
PPS10111-2682
AIR PRESSURE SWITCH (50)
UT 1013-10 INTEGRATED
BOILER CONTROL
11
14631091
C0_2366
12
14631120
HEYCO OCB-1500
13
14631316
RACO 232 4"4"2 BOX
1
15
14631319
P&S SWITCH
1
16
14631318
COVER
17
14631174
419-1AA1
2½" PLUG
2
18
14631171
415-1AA1
1½" PLUG
3
19
14631176
BPF 3 ½" PLUG
1
20
14631175
421-1AA1
2
21
750001027
LOWER
22
CI-001.03
TACO CIRCULATING
14626043
TACO ISOLATION
CI-006.01
GRUNDFOS
CIRCULATING
14626043
GRUNDFOS
ISOLATION
43300826
CIRCULATING
14631315
WIRING
HARNESS
750001002
JACKET
COMPLETE
GLIDE
1
4
1
BUSHING
14
691-1
PLATE
RACO 902-802
1
3" PLUG
FRONT PANEL
- BLUE
1
PUMP
VALVE
1
SET
1
PUMP
VALVE
PUMP HARNESS
SET
1
1
1
1
6O
TO THE DRAIN PORT AT
THE BOTTOM OF BOILER
CONNECT
TO THE DRAIN
AT THE EXHAUSTER
PORT
O
CONDENSATE
B=
DRAIN TRAP ASSEMBLY
CONDENSATE
DRAIN TRAP ASSEMBLY
KEY #
ITEM NUMBER
DESCRIPTION
1
14631035
59019
½"lDxl/8"
2
14631141
57134
¾" SNAP GRIP CLAMP
6
3
14631320
62067
½"ID HOSE TEE
1
4
5
14631101
14631321
62017
½"NPTx ½"ID TUBE STRAIGHT
1
1
6
14631306
7
14631020
½"'4" PVC NIPPLE, SCH 80
½"ID" ½"ID" ½"NPTTUBE TEE
8
14631323
S. S. CLAMP, SIZE 16 (13/16"~1
QUANTITY
THK VINYL TUBING
½" PVC COUPLING, SCH 80
61
AS REQUIRED
1
1
½")
1
!
I
TYP OF 5
TYP
OF 5
TYP
TYP
OF
OF d
8
TYP
OF 4
TYP OF 4
C,
BOILER
BLOCK AND PIPING
62
ASSEMBLY
BOILER
BLOCK AND PIPING ASSEMBLY
KEY #
ITEM NUMBER
DESCRIPTION
QUANTITY
1
14631156
HOFFMAN VENT #77
1
2
14693001
¾"x 1/8" BUSHING
1
3
14693076
¾" BLACK TEE
1
4
14693040
¾" x 90 ° STREET ELBOW
2
5
14607002
¾" x 6½" NIPPLE
2
6
14622011
¾" ASME RELIEF VALVE
1
7
14607201
¾"x 2" NIPPLE
1
8
14695810
¼"-20 HEX NUT W/SERRATED
WASHER
HEAD
9
9
14695802
8-32 x 3/16" SOC HD CAP SCREW
2
10
14631000
36T26-42930
1
11
14695801
¼"-20 x 1½" SOC HD CAP SCREW
5
12
14695805
¼"-20 x 1¼" STUD THREADED
9
13
41800910
TESTED BLOCK (INCLUDES
14
14695040
¼"x 1¼" CARRIAGE
15
14631101
62017 ½" NPT x ½" ID TUBE STRAIGHT
1
16
14607044
1¼" x2½"
NIPPLE BLACK
2
17
1510001
1¼" x¾"x
1¼" TEE
2
18
14622000
¾" DRAIN VALVE
CASTING TEMP. SAFETY SWITCH
8,11,14 AND 20,22)
BOLT
1
4
1
19
14693056
1" SQ SOCKET PLUG
20
14619002
EMPI RE SIGHT GLASS
12
1
21
14693058
¾" SQ HD PLUG
1
22
14693004
¾" x ½" BUSHING
1
23
14662804
123869A CONTROL WELL ½" NPT
1
24
14631324
L4006A 2155B HI LIMIT AQUASTAT
1
25
14693001
¾"x 1/8" BUSHING
1
26
1260006
TEMP & PRESSURE
27
14631004
SIGHT GLASS ADAPTER
1
28
14631005
1/8" NPT ¼" HOSE ID BRASS BARB FI-FFING
1
GAUGE
63
1
TO SIGHT
GLASS ADAPTER
D,
MIXER AND AIR PRESSURE
84
SWITCH
ASSEMBLY
KEY #
1
2A
2B
2C
3
4
5
6
7A
7B
7C
8
9
10
11A
11B
12
13
14
15
16
17
18
19
2O
21
22
23
24
25A
25B
25C
26
27A
27B
27C
27D
27E
27F
ITEM NUMBER
14631023
14631006
14631007
14631008
14631025
14695810
12101008
14631311
42531100
42531101
42531102
42531103
14631015
14695809
43800013
43800014
14631024
14631309
14607301
14693805
14631307
14631308
14631104
14631313
14631143
14631151
14631033
14631314
14629003
14631312
14631010
14631044
14631103
14631310
14631029
14631030
14631032
14631036
14631037
MIXER AND AIR PRESSURE SWITCH ASSEMBLY
DESCRIPTION
BURNER GASKET
100 BURNER IBSI!
75 BURNER !BSI)
50 BURNER IBSI)
MIXER GASKET
¼"-20 HEX NUT W/SERRATED WASHER HEAD
MIXER CASTING MACHINED
2'"1½" FLEXIBLE COUPLING
100 AIR BAFFLE
75 AIR BAFFLE
50 AIR BAFFLE
AIR INLET
2" FERNCO COUPLING
10-32"x3/8" MACHINE SCREW
HOT SURFACE IGNITER IFOR 50/75)
HOT SURFACE IGNITER !FOR 100)
HOT SURFACE IGNITER GASKET
MIXER BUSHING
½"" 3" STD BLACK NIPPLE
1/8" NPT BRASS PLUG - 3/16" HEX SOCKET
HONEYWELL GAS VALVE VR8205
5/16-24"1/4 HOSE ID BRASS BARB FITTING
62064 ¼"ID TUBE TEE
¼"ID TUBE 4-WAY CONNECTOR
3/8" HOSE CLAMP HC-6ST
PC250-12Vl NYL CAP
59006 ¼"IDx3/8"OD VINYL TUBING
1/4"lg'3/8"og VINYL TUBING IRED)
1/4" ID SILICONE TUBING
PPS10111-2680 AIR
PPS10111-2681 AIR
PPS10111-2682 AIR
62043 ½" NPT'I/2"ID
GAS
GAS
GAS
GAS
GAS
GAS
ORIFICEORIFICE ORIFICEORIFICE ORIFICE ORIFICE -
PRESSURE SWITCH !100)
PRESSURE SWITCH !751
PRESSURE SWITCH 150)
TUBE ELBOW
NATURAL,
NATURAL,
NATURAL,
PROPANE,
PROPANE,
PROPANE,
65
100N !0.0860, #44)
75N I0.0760, #48)
50N I0.0615)
100P !0.0670, #51)
75P I0.0605)
50P (0.0492)
QUANTITY
1
1
1
1
1
5
1
1
1
1
1
1
1
2
1
1
1
1
1
3
1
1
1
1
10
2
AS REQUIRED
AS REQUIRED
AS REQUIRED
1
1
1
1
1
1
1
1
1
1
TO
MIXER
FLUE ADAPTER
E,
AND EXHAUST
ASSEMBLY
FLUE ADAPTER AND EXHAUSTER ASSEMBLY
14683301
KEY#
ITEM NUMBER
1
1A
182009002
14631101
1B
DESCRIPTION
QUANTITY
EXHAUST TEE ASSEMBLY - 1-A,B,C,D,E & F
82017 1/2"NPTxl/2"ID TUBE STRAIGHT
1
1
14631013
PVC 1 1/2" MALE SLIP x 1/2" FEMALE NPT
1
1C
14631014
PVC SCH 40 2"x1-1/2" REDUCER
1
1D
14695815
3/4" ALUMINUM FLAT WASHER
1
1E
1F
2
14631305
14631304
14631028
2" CPVC TEE, SCH 80
2" CPVC PIPE'2-1/2", SCH 40
VENT SWITCH GASKET
1
1
1
3
14631303
36TXll-22491
4
5
14695808
14631077
#-4-20xl/4" HWH PLAST FORM SCREW
116516-11 INDUCED DRAFT BLOWER
INDUCER TEMP SAFETY SWITCH
2
1
1
6
14631026
BLOWER GASKET
1
7
12101021
FLUE CONNECTOR
1
8
14631027
RECOVERY COIL GASKET
1
9
14695810
1/4"-20 HEX NUT W/SERRATED WASHER BLOCK
4
10
11
14693804
14631103
1/8" NPT 1/4" HOSE ID BRASS BARB FI-FRNG
62043 1/2" NPT'I/2" ID TUBE ELBOW
1
1
12
14631141
57134 3/4" SNAP GRIP CLAMP
13
14631035
59019 ½" ID'1/8 THK VINYL TUBE
14
15
16
14631301
14631302
14631151
HOSE, 3" LONG 2-3/8" ID X 2-3/4" OD
S.S. CLAMP, SIZE 44
PC250-12 VINYL CAP
1
2
2
17
14631143
3/8" HOSE CLAMP HC-6ST
2
66
2
AS REQUIRED
Rev. 3, August 2003
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