Utica Boilers Ub90 100 Operation And Installation Manual 240010135.indb

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P/N# 240010135 Rev. C [05/2013]

An ISO 9001-2008 Certified Company

Models

UB90-50

UB90-75

UB90-100

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13504-4729

web site: www.ecrinternational.com

UB90-50/75/100 Series 4

GAS-FIRED, DIRECT VENT,

CONDENSING,

HOT WATER BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

2

DIMENSIONS

2

Figure 1 - Boiler Dimensions

NOTICE

Draft inducer (blower) may be

rotated 90° or 180° to orient

vent connection towards right

side or rear.

3

INTRODUCTION

Introduction

• This appliance is a gas-fi red direct vent hot water boiler

with cast aluminum boiler sections.

• The heating system water absorbs large amounts of

heat from the cast aluminum heat exchanger, cooling

fl ue gases and causing condensation.

• Sealed combustion, premix gas burner, and low fl ame

temperature means reduced CO and NOx emissions,

which contribute to cleaner and healthier environment.

• This appliance takes its combustion air directly from

outdoors (sealed combustion) and does not compete

with building occupants for fresh air.

• Sealed combustion (also known as “direct vent”)

is safest and best way to obtain plenty of clean

combustion air.

Dimensions .................................................................................................................... 2

Introduction ................................................................................................................... 3

Important Safety Information ...........................................................................................4

Boiler Ratings & Capacities ..............................................................................................5

Boilers For Use At High Altitude - United States Installations ................................................ 6

Before Installing The Boiler .............................................................................................. 8

Boiler Installation ...........................................................................................................9

Near Boiler Piping ......................................................................................................... 11

Combustion Air And Vent Pipe ........................................................................................ 22

Gas Supply Piping ......................................................................................................... 28

Electrical Wiring ........................................................................................................... 30

Controls And Accessories ............................................................................................... 34

Start Up ...................................................................................................................... 36

Operating Instructions ................................................................................................... 37

Detailed Sequence Of Operation ..................................................................................... 38

Verifi cation Procedure And Adjustment ............................................................................ 42

Differential Air Pressure Switch Check - All Models ............................................................ 45

Negative Pressure Switch Check ..................................................................................... 46

Maintenance And Cleaning ............................................................................................. 47

Troubleshooting ............................................................................................................ 49

Troubleshooting - High Limit Control And LWCO ............................................................... 50

Troubleshooting -Hydrostat High Limit Control And LWCO .................................................. 51

Appendix A - Water Quality, Water Treatment And Freeze Protection ........................58

Installation And Check-Out Certifi cate ............................................................................. 62

• Induced draft fan draws in outside combustion

air, takes cooler fl ue gases from boiler unit and

provides positive removal of fl ue gases from the

building through readily available PVC, CPVC and PP

(Polypropylene) pipes.

• These low pressure gas-fi red hot water boilers are

design certifi ed by CSA International for use with

natural gas and propane gas.

• Boilers are constructed and hydrostatically tested for

maximum working pressure of 50 psig (pounds per

square inch gage) in accordance with A.S.M.E. Boiler

and Pressure Vessel Code Section IV Standards for

heating boilers.

4

Installation shall conform to requirements of

authority having jurisdiction or in absence of such

requirements:

•

United States

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

.

• National Electrical Code, NFPA 70.

• Canada

• Natural Gas and Propane Installation Code, CAN/CSA

B149.1.

• Canadian Electrical Code, Part I, Safety Standard for

Electrical Installations, CSA C22.1

Where required by authority having jurisdiction,

installation shall conform to Standard for Controls

and Safety Devices for Automatically Fired Boilers,

ANSI/ASME CSD-1.

Additional manual reset low water cutoff and/or manual

reset high limit may be required.

Requirements for Commonwealth of

Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is not

limited to:

• Installation by licensed plumber or gas fi tter.

Installers - Follow local regulations with respect to

installation of CO (Carbon Monoxide) Detectors. Follow

maintenance recommendations “Maintenance And Cleaning”

on page 47 .

NOTICE

Used to address practices not related to personal

injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

!

!

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

!

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury

!

This is the safety alert symbol. Symbol alerts you to

This is the safety alert symbol. Symbol alerts you to

potential personal injury hazards. Obey all safety messages

potential personal injury hazards. Obey all safety messages

following this symbol to avoid possible injury or death.

following this symbol to avoid possible injury or death.

Become familiar with symbols identifying

Become familiar with symbols identifying

potential hazards.

potential hazards.

General

Boiler installation shall be completed by qualifi ed agency.

See glossary for additional information.

WARNING

Fire, explosion, asphyxiation and electrical shock

hazard. Improper installation could result in death

or serious injury. Read this manual and understand

all requirements before beginning installation.

!

IMPORTANT SAFETY INFORMATION

Keep this manual near boiler

Retain for future reference

5

Table 1 - SEA LEVEL RATINGS – NATURAL AND PROPANE GASES

Model Input

*(MBH) ++ Heating Capacity

*(MBH) Net AHRI Rating

*(MBH) Shipping

Weight (lbs.) AFUE

90-50 50 45 39 220 90.0

90-75 75 68 59 220 90.0

90-100 100 90 78 220 90.0

* 1 MBH = 1,000 Btuh Btuh = British Thermal Units Per Hour

BOILER RATINGS & CAPACITIES

++ AFUE (Annual Fuel Utilization Effi ciency) and Heating Capacity is based on the D.O.E. (Department of Energy) test

procedure.

Heating Capacity indicates the amount of heat available after subtracting losses up the stack. Most of this heat is available

to heat water. A small portion is heat from jacket and surfaces of the boiler, and it is assumed that this heat stays in the

structure.

Net AHRI rating represents portion of remaining heat that can be applied to heat radiation or terminal units (i.e. fi nned

tube baseboard, cast iron radiators, radiant fl oor, etc.). The difference between Heating Capacity and Net AHRI Rating,

called piping and pickup allowance, establishes reserve for heating volume of water in system and offsetting heat losses

from piping.

Net AHRI ratings shown are based on piping and pickup factor of 1.15 in accordance with AHRI Standard as published

by Hydronics Institute. Net AHRI rating of boiler selected should be greater than or equal to the calculated peak heating

load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. Consult manufacturer

before selecting a boiler for installations having unusual piping and pickup requirements.

Boilers for use at high altitude

Canada - Boilers are factory equipped for operation at altitudes ranging from 0-4,500 feet above sea level. Contact

Provincial authority having jurisdiction for installations above 4,500 feet (1,350m) above sea level.

United States - See “Boilers For Use At High Altitude” on page 6.

6

Table 2 - NATURAL GAS

MODEL 90-50

Stock Factory Btu Value of Natural Gas++

Settings 750 850 950 1000 1050

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 50 – – – – –

Combustion Setting (CO

2

)8.7 - 9.7% (CO < 100 ppm)

Orifi ce 43331094 43331094

MODEL 90-75

Stock Factory Btu Value of Natural Gas++

Settings 750 850 950 1000 1050

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 75 – – – – –

Combustion Setting (CO

2

)8.7 - 9.7% (CO < 100 ppm)

Orifi ce 43331092 43331092

MODEL 90-100 /

Stock Factory Btu Value of Natural Gas++

Settings 750 850 950 1000 1050

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 100 – – – – –

Combustion Setting (CO

2

)8.7 - 9.7% (CO < 100 ppm)

Orifi ce 43331090 43331090

++Contact local gas utility or distributor for Btu value of gas.

BOILERS FOR USE AT HIGH ALTITUDE - UNITED STATES INSTALLATIONS

• Boilers (with exception of 90-75 propane (LP) product)

are factory equipped for operation at altitudes ranging

from 0-10,000 feet above sea level.

• No changes to factory settings are required for

installations from 0-5,000 feet above sea level.

• For altitudes from 5,000-10,000 feet above sea level

gas manifold pressure needs to be adjusted based upon

calorifi c (Btu) value of supply gas (contact local gas

utility or distributor for this value).

• For specifi c settings refer to Table 2 for natural gas

applications and

Table 3, Page 7

for propane (LP) gas

applications.

• Instructions on how to adjust gas manifold pressure

settings see

Figure 25 and Figure 26, Page 44

.

Note 90-75 propane (LP) applications for 5,000 - 10,000

feet above sea level require orifi ce change as well as gas

manifold pressure adjustment based upon calorifi c (Btu)

value of supply gas.

Refer to

Table 2

and Table 3 for high altitude orifi ce

part numbers. For replacing an orifi ce refer to specifi c

instructions included with conversion kit.

7

Table 3 - PROPANE GAS

MODEL 90-50

Stock Factory Btu Value of Propane Gas++

Settings 2300 2350 2400 2450 2500

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 50

–– – – –

Combustion Setting (CO

2

)

10.0 -11.1% (CO < 100 ppm)

Orifi ce 43331095 43331095

MODEL 90-75*

Stock Factory Btu Value of Propane Gas++

Settings 2300 2350 2400 2450 2500

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 75

–– – – –

Combustion Setting (CO

2

)

10.0 -11.1% (CO < 100 ppm)

Orifi ce 43331093

43331096*

* For model 90-75 Propane units only at altitudes above 5,000 ft., install 90-75 High Altitude Orifi ce Kit #550002629 For all other

altitudes use sea level orifi ce.

MODEL 90-100 **

Stock Factory Btu Value of Propane Gas++

Settings 2300 2350 2400 2450 2500

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 100

–– – – –

Combustion Setting (CO

2

)

10.0 -11.1% (CO < 100 ppm)

Orifi ce 43331091

43331091

++Contact local gas utility or distributor for Btu value of gas.

BOILERS FOR USE AT HIGH ALTITUDE - UNITED STATES INSTALLATIONS

Model 90-75 propane (LP) units only at altitudes

above 5,000 ft., install 90-75 High Altitude Orifi ce Kit

#550002629*.

For all other altitudes use sea level orifi ce

8

Boiler Sizing

Check to be sure you have selected boiler with proper

capacity before starting installation. AHRI Rating of boiler

selected should be greater than or equal to calculated

peak heating load (heat loss) for building or area(s) served

by boiler and associated hot water heating systems. See

Table 1, Page 5 .

Heat loss calculations should be based on approved

industry methods.

Boiler Location Considerations

Before selecting boiler location consider following.

• Supplied with correct type of gas (natural gas or

propane).

• Connected to suitable combustion air intake piping

system to supply correct amounts of fresh (outdoor)

air for combustion, refer to “Combustion Air and Vent

Pipe” on page 22 for details.

• Connected to suitable venting system to remove

hazardous products of gas combustion, refer to

“Combustion Air and Vent Pipe” on page 22 for details.

• Connected to suitable hot water heating system.

• Supplied with suitable electrical supply for all boiler

motors and controls.

• Connected to properly located thermostat or operating

control. Not included with boiler.

• Placed on level surface.

• Condensate drain line must be pitched down to fl oor

drain or external condensate pump with reservoir at ¼”

per foot (wood frame or blocks may be used to raise

boiler).

1.

Boiler is 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 an additional low water cut off, a manual

reset high temperature limit, and wiring and/or piping

modifi cations.

2.

Before servicing boiler - allow boiler to cool. Shut off

electricity and gas supply connected to boiler prior to

servicing.

3.

Inspect gas line for leaks.

4.

Verify gas input rate is correct. Over fi ring may result

in early failure of boiler sections. This may cause

dangerous operation. Under fi ring may result in too

much air for pre-mix burner causing poor or loss of

combustion.

5.

Never vent products of combustion from this boiler to

enclosed space. Always vent to outdoors. Never vent to

another room or to inside building.

6.

Be sure there is adequate outdoor air supply to boiler

for complete combustion.

7.

Follow regular service and maintenance schedule for

effi cient and safe operation.

8.

Keep boiler area clean of debris and free of combustible

and fl ammable materials.

9.

Proper through wall or through roof combustion venting

shall be in accordance with materials and methods

described in this manual. Installation must comply with

local codes.

10.

Boiler and related hot water heating systems are not do

it yourself items they must be installed and serviced by

qualifi ed professionals.

BEFORE INSTALLING THE BOILER

Minimum Clearances To Combustible Construction

8”

Boiler

Rear

Front

Control Side

Opposite Side

1”

(26MM) 11”

(280MM)

1”

(26MM)

1”

(26MM)

9

Table 4 -

Required Clearances

Unit Combustible

Clearance

Accessibility,

Cleaning, and

Servicing

Top 1” (26mm) 8” (204mm)

Left Side 1 “ (26mm) -

Right Side 11” (280mm) -

Base 1” (26mm) -

Front 1” (26mm) 24” (610mm)

Back 1” (26mm) -

Intake/Vent Piping 0 (0) -

All distances measured from the cabinet of the boiler.

Locating The Boiler

1.

Place crated boiler as close to selected location as

possible and un-crate boiler. Boiler may be moved into

position with appliance dolly or 2 wheel hand truck.

Insert dolly or hand truck under left hand side of

boiler. It is possible to slide boiler for short distance on

smooth fl oor or surface.

2.

Select level location central to piping systems served

and as close to vent and air intake terminals as

possible.

3.

Accessibility clearances, if more stringent (i.e. larger

clearances) than required fi re protection clearances,

must be used for boiler installation. Accessibility

clearances may be achieved with the use of removable

walls or partitions.

4.

Boiler is approved for installation in closets and on

combustible fl oors. This boiler shall NOT be installed on

carpeting.

5.

Clearances shown in Table 4

indicate required

clearances. Maintain minimum 1” clearance between

combustible construction and each of left, top and

back surfaces of the boiler. Minimum 11” clearance is

required on right side, to allow room for induced draft

blower. Allow 24” at front and 8” at top for servicing.

No clearances are required to venting or combustion air

intake piping.

6.

Install equipment in location which facilitates operation

of venting and combustion air intake piping systems

as described in this manual. Draft inducer (blower)

may be rotated 90° or 180° to orient vent connections

towards right side or rear. Remove blower mounting

screws. Orient blower and install mounting screws. Do

not overtighten screws.

7.

Advise owner to keep venting and combustion air

intake passages free of obstructions. Both venting

and combustion air intake piping systems connected

to outdoors must permit fl ow through piping systems

without restrictions for boiler operation.

8.

Install boiler such that the automatic gas ignition

system components are protected from water

(dripping, spraying, rain, etc.) during operation and

service (circulator replacement, condensate trap,

control replacement, etc.).

9.

Keep boiler area clean of debris and free of fl ammable

and combustible materials, vapors and liquids.

10.

Locate boiler where minimum possible room

temperature where boiler is installed, assuming boiler

is not in operation and therefore contributes no heat

to space, is always at or above 32°F (0°C) to prevent

freezing of liquid condensate.

Combustion Air And Vent Pipe Requirements

This boiler requires a dedicated direct vent system. In a

direct vent system, all air for combustion is taken directly

from outside atmosphere, and all fl ue products are

discharged to outside atmosphere.

Terminate combustion air and vent pipe connections in

same atmospheric pressure zone, through roof or sidewall

(roof termination preferred). See Figure 12 thru Figure 14 ,

pages 24 and 25 for required clearances.

WARNING

Solvent cements are combustible. Keep away from

heat, sparks, and open fl ame. Use only in well

ventilated areas. Avoid breathing in vapor or allowing

contact with skin or eyes. Failure to follow these

instructions could result in fi re, serious injury, or death.

!

• Combustion air must be clean outdoor air. Combustion

air must not be taken from inside structure because

that air frequently is contaminated by halogens, which

include fl uorides, 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 air inlet as far away as possible

from swimming pool and swimming pool pump house.

• All combustion air and vent pipes must be airtight and

watertight. Combustion air and vent piping must also

terminate as shown in

“Combustion Air and Vent

Pipe”

section.

• Vent connections serving appliances vented by

natural draft shall not be connected into any portion

of mechanical draft systems operating under positive

pressure.

BOILER INSTALLATION

10

Condensate Drain Requirements

• Pitch condensate drain line down to fl oor drain at

minimum of ¼” per foot. External condensate pump

(not furnished) may be used if fl oor drain is not

available. Installation shall conform to requirements

of authority having jurisdiction, check local codes for

requirements.

• Condensate pump must be designed for fl ue gas

condensate application.

• Condensate trap provided with boiler, an additional trap

is not required and should not be used.

• Wood frame or blocks may be used to raise boiler

to maintain drain pitch or to be above external

condensate pump reservoir.

Foundation Requirements

• Install boiler on level surface.

WARNING

Fire hazard. Do not install boiler on carpeting.

Failure to follow these instructions could result in

death or serious injury.

!

• Boiler is NOT to be installed on carpeting.

• If boiler is not level condensate drain lines will not

function properly. Adjustable feet are located on the

boiler to make up for minor surface irregularities or tilt.

• Wood frame or blocks may be used to raise boiler

to maintain drain pitch or to be above external

condensate pump reservoir.

Removal of Existing Boiler From Common Vent

System

When an existing boiler is removed from a common

venting system, the common venting system is likely to be

too large for proper venting of the appliances remaining

connected to 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 defi ciencies

which could cause an unsafe condition.

BOILER INSTALLATION

3.

In-so-far 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 fi re dampers.

4.

Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so

appliances will operate continuously.

5.

Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the fl ame 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, fi re place dampers,

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 -Z223.1 and/

or the Natural Gas and Propane Installation Code,

CAN/CSA B149.1. When re-sizing any portion of the

common venting system, the common venting system

should be re-sized to approach the minimum size as

determined using the appropriate of the National Fuel

Gas Code, NFPA-54/ANSI- Z223.1 and/or the Natural

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

11

Near Boiler Piping

• When boiler installation is for new heating system,

install all of radiation units (panels, radiators,

baseboard, or tubing) and supply and return mains.

• After all heating system piping and components

have been installed, make fi nal connection of system

piping to boiler. Hot water boiler installed above

radiation level, or as required by the Authority having

jurisdiction, must be equipped with low water cut off

device.

• Periodic inspection is necessary for fl ushing of fl oat

type devices, per low water cut off manufacturers

specifi c instructions.

Clean System First

Before

connecting boiler to heating system, clean and fl ush

system thoroughly. Verify system is free of sediment, fl ux

and any residual boiler water additives.

Systems having antifreeze not recommended must be

completely fl ushed to insure no old antifreeze remains.

In older systems obviously discolored, murky or dirty

water; or pH reading outside acceptable range (between

7.0 and 8.0) are indications the system should be cleaned

or treated. Thoroughly fl ush system with clean water to

remove any sediment or contaminants. Sludge and iron

oxide deposits can cause rapid breakdown of inhibitors.

Flushing with clean water. If chemical cleaners are used,

use only those recommended for use with aluminum

boilers. Follow chemical cleaner manufacturer’s instructions

completely.

DO NOT

mix different manufacturer’s

products.

NEAR BOILER PIPING

Supply And Return Lines

• Boiler is set up to receive 1¼” NPT supply and return

piping from top access.

• Boiler may be piped from left side by turning supply

elbow.

• Install furnished dielectric unions at boiler supply and

return lines prior to making system piping connections

• Do not install copper supply and return piping directly

into aluminum boiler section casings due to galvanic

corrosion between dissimilar metals.

• Must use provided dielectric unions between copper

system piping and boiler to make fi nal connection to

boiler.

• Circulator pump can be installed at installer preferred

location.

12

NEAR BOILER PIPING

Figure 2 - Single Zone Boiler Piping

SAFETY RELIEF VALVE - SEE PAGE 18

FOR REQUIREMENTS

13

Figure 3 - Two Zone Boiler Piping With Zone Valves

NEAR BOILER PIPING

Multi-Zone Systems

Multi-zone systems with two zones are typically piped as

shown in Figures 3 or 4. Multi-zone systems with more than

two zones are likely to have small zones with very low heat

and fl ow requirements compared to full heating capacity of

the boiler. This can result in very low fl ow in the boiler if

only one small zone is calling for heat.

Primary Secondary Piping is recommended for multi-zone

systems with more than two zones to insure proper water

fl ow through the boiler at all times. See Figures 5, 6 and 7

for typical primary secondary piping confi gurations.

SAFETY RELIEF VALVE - SEE PAGE 18

FOR REQUIREMENTS

14

Figure 4 - Two Zone Boiler Piping With Circulators

NEAR BOILER PIPING

SAFETY RELIEF VALVE - SEE PAGE 18

FOR REQUIREMENTS

15

NEAR BOILER PIPING

Figure 5 - Primary/Secondary Piping With Circulators And Domestic Hot Water

16

NEAR BOILER PIPING

Figure 6 - Piping Primary/Secondary Multi Zone System Piping With Zone Valves And

Domestic Hot Water (With Zone Valve)

17

NEAR BOILER PIPING

Figure 7 - Piping Primary/Secondary Piping With Zone Valves And Domestic Hot Water

(With Circulator)

18

Safety Relief Valve

Installation of safety relief valve shall conform to ANSI/

ASME Boiler and Pressure Vessel Code, Section IV.

• Install furnished safety relief valve using 3/4” x 4½”

pipe provided with boiler. See Figure 8 .

• Install safety relief valve with spindle in vertical

position.

• Do not install shutoff valve between boiler and safety

relief valve.

• Install discharge piping from safety relief valve. See

Figure 8 .

• Use ¾” or larger pipe.

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

greater.

• Individual boiler discharge piping shall be independent

of other discharge piping.

• Size and arrange discharge piping to avoid reducing

safety relief valve relieving capacity below minimum

relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location

protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve

outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

Expansion Tank And Make-Up Water

Determine required system fi ll 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).

Diaphragm type expansion tank see Figure 9, Page 19 .

See Figure 10, Page 20 for conventional closed type

expansion tanks.

• For diaphragm type expansion tanks, adjust tank

air pressure to match system fi ll pressure. Install

furnished air vents shown for diaphragm type

expansion tank system only.

• Install make-up water connections as shown per local

codes.

• If pressure reducing valve is used, adjust to match

system fi ll pressure.

• Verify clean water supply is available. When water

supply is from well or pump, install sand strainer at

pump

Figure 8 - Relief Valve Boiler Piping

NEAR BOILER PIPING

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from fl oor

or allowable

safe point of

discharge.

WARNING

Burn and scald hazard. Safety relief valve could

discharge steam or hot water during operation.

Install discharge piping per these instructions.

!

19

Figure 9 - Diaphragm Type Expansion Tank Piping

NEAR BOILER PIPING

SAFETY RELIEF VALVE - SEE PAGE 18

FOR REQUIREMENTS

20

Figure 10 - Conventional (Closed Type) Expansion Tank Piping

NEAR BOILER PIPING

SAFETY RELIEF VALVE

SEE PAGE 18 FOR

REQUIREMENTS

21

Condensate Drain Piping

Boiler is factory equipped with a condensate trap. An

additional trap is not required and should NOT be used.

1.

Provide ½” PVC condensate drain and fi ttings.

Condensate drain to be pitched down to fl oor drain at

a minimum of ¼” per foot. Installation shall conform

to requirements of authority having jurisdiction, check

local codes for requirements.

2.

Install ½” PVC tee to overfl ow fi tting as shown in

Figure 11 .

3.

The ½” diameter schedule 40 PVC or CPVC condensate

drain and pipe fi ttings must conform to ANSI standards

and ASTM D 1785 or D2846.

4.

Schedule 40 PVC or CPVC cement and primer must

conform to ASTM D2564 or F493.

5.

In Canada, use CSA or ULC certifi ed schedule 40 PVC

or CPVC drain pipe cement.

6.

Condensate pump with reservoir (not furnished) may

be used to remove condensate to a drain line (sanitary

line) above boiler if fl oor drain is not available or is not

accessible.

Figure 11 - Condensate Drain Piping

NEAR BOILER PIPING

Filling Condensate Trap With Water

On initial start up condensate trap must be manually fi lled

with water.

Following are the steps required to initially fi ll condensate

trap for start up. Steps are only required at initial start up

or if maintenance requires draining of condensate trap.

1.

Disconnect vent condensate drain line from vent pipe

connector on outlet of induced draft blower.

2.

Pour about 1 cup of cold tap water into vent drain line

with funnel.

3.

Excess water should go through overfl ow and out

through condensate drain line. Verify proper operation

of drain line (or external condensate pump if used).

4.

Reinstall vent drain line.

Chilled Water Piping

Install boiler, when used in connection with refrigeration

system, so chilled medium is piped in parallel with boiler

with appropriate valves to prevent chilled medium from

entering boiler.

Boiler piping system of hot water boiler connected to

heating coils located in air handling units where they may

be exposed to refrigerated air circulation must be equipped

with fl ow control valves or other automatic means to

prevent gravity circulation of the boiler water during cooling

cycle.

FROM BLOWER

TO DRAIN

OPEN

PVC TEE 1/2”SLIP X

1/2” SLIP X 1/2” SLIP

1/2” PVC

CONDENSATE

DRAIN

PITCH DRAIN PIPE

DOWN TO FLOOR

DRAIN AT MINIMUM

1/4” PER FOOT

22

Connections And Termination

Provisions for combustion and ventilation air must be

in accordance with section, Air For Combustion and

Ventilation, of the National Fuel Gas Code,ANSI 2223.1/

NFPA54, or National Gas and Propane Installation Code,

CAN/CGA-B 149.1, or applicable provisions of the local

building code.

Boilers require dedicated direct vent system. All air for

combustion is taken directly from outdoors through

combustion air intake pipe. All fl ue products are discharged

to outdoors through vent pipe.

1.

Venting Materials:

WARNING

Use of cellular core PVC (ASTM F891), cellular core

CPVC, or Radel® ,(Polyphenolsulfone) in venting

systems could result in death, or serious injury.

!

WARNING

Covering non-metallic vent pipe and fi ttings with

thermal insulation shall be prohibited. Use in venting

system could result in death or serious injury.

!

Table 4 - Combustion air and vent pipe fi ttings

must conform with the following:

Item Material Standards

Vent Pipe

and Fittings

PVC schedule 40 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

CPVC schedule 40 ANSI/ASTM D1784/

F441

SDR-21 & SDR-26 PVC

ANSI/ASTM D2241

NOT APPROVED FOR

CANADA

ABS-DWV ANSI/ASTM D2661

Schedule 40ABS ANSI/ASTM F628

PP (Polypropylene)

Pipe and Components

UL 1738

ULC S636-08

Pipe

Cement/

Primer

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Schedule 40 ABS ANSI/ASTM D2235

• IPEX is approved vent manufacturer in Canada listed

to ULC-S636.

• IPEX System 636 Cements and Primers are approved

in Canada listed to ULC-S636.

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

(Polyphenolsulfone) in venting systems shall be prohibited.

2.

Canadian installations:

• First 3 feet (900mm) of venting must be readily

available for visual inspection.

• Specifi ed primers and glues of certifi ed vent

system must be from single manufacturer, and not

intermixed with other manufacturer’s vent system

parts.

• Components of the certifi ed system must not be

interchanged with other vent systems, or unlisted pipe

and/or fi ttings.

NOTICE

Transition from 2” pipe to 3” pipe must be made in

vertical run.

3.

Boiler combustion air and vent piping connections are

sized for 2” pipe. Any pipe size change (to 3”) must be

made outside of boiler casing in vertical run of pipe to

allow for proper drainage of vent condensate. Due to

potential for fl ue gas temperatures over 155°F, fi rst fi ve

(5) feet of vent pipe must be CPVC, the remaining vent

pipe can be PVC. If any elbows are employed within the

fi rst 5 feet of vent, they must be CPVC also. Two (2) - 30”

pieces of 2” CPVC pipe. 2½” piece of 2” CPVC pipe, a 2”

CPVC elbow and 2” CPVC pipe coupling are furnished with

the boiler. No requirement when using PP pipe.

4.

Combustion air and vent piping lengths. Table 5,

Page 23 . If vent exceeds 5 ft. fi rst 5 ft. of vent piping

run must be 2” CPVC:

Length of pipe is counted from boiler jacket (air

intake pipe) or from vent pipe connector(vent pipe).

Termination is not counted toward the “Total Equivalent

Length”.

For elbows, reduce maximum vent length as shown:

• 2” 90° elbow - 2 ft. per elbow.

• 3” 90° elbow - 3 ft. per elbow.

Example:

To add two (2) 90° elbows to a 3” pipe for a 75 boiler.

Each elbow is 3 ft. per 90° elbow for a total of 6 ft.

(1 elbow @ 3 ft. + 1 elbow @ 3 ft. = 6 equivalent ft. of

pipe)

Total additional pipe is then subtracted from maximum

allowable pipe length to give new maximum length of

112-6=106 ft. with two (2), 90° elbows.

“TOTAL EQUIVALENT LENGTH”:

Original 112 ft. max. - 6 equivalent ft. for 2 elbows =

new 106 ft. maximum length.

COMBUSTION AIR AND VENT PIPE

NOTICE

Use of PP piping, follow manufacture”s installation

instructions and requirements.

23

5.

See Figure 12 thru Figure 17, Pages 24 thru 26

for combustion air and vent pipe roof and sidewall

termination. Roof termination is preferred. Combustion

air and vent pipes must terminate together in same

atmospheric pressure zone as shown.

6.

Construction through which vent and air intake pipes

may be installed is maximum 24 inches, minimum ¼”

thickness.

7.

Optional- Rotate draft inducer (blower) 90° or 180°

to orient vent connection towards right side or rear.

Remove blower mounting screws, re-orient blower.

Reinstall mounting screws. Do not overtighten screws.

8.

Pitch combustion air and vent piping back to boiler at

minimum ¼” per ft. (21 mm/m) from intake and vent

terminals so all moisture in combustion air and vent

piping drains to boiler. Pitch pipes continuously with no

sags or low spots where moisture can accumulate and

block fl ow of air or fl ue gas. Combustion air and vent

pipes must be airtight and watertight.

9.

Consider following when determining appropriate

location for termination of combustion air and vent

piping.

• Position termination where vent vapors will not damage

plants/shrubs or air conditioning equipment.

• Position termination as to not be effected by wind eddy,

air born leaves, snow, or recirculated fl ue gases.

• Position termination where it will not be subjected to

potential damage by foreign objects, such as stones,

balls, etc..

• Position termination should where vent vapors are not

objectionable.

• Place vent on wall away from prevailing wind. Locate or

guard vent to prevent accidental contact with people or

pets.

• Terminate vent above normal snow line. Avoid locations

where snow may drift and block vent. Ice or snow may

cause boiler to shut down if vent becomes obstructed.

• Under certain conditions, fl ue gas will condense, forming

moisture, and may be corrosive. Take steps to prevent

building materials at vent from being damaged by

exhaust of fl ue gas.

• Vent shall not terminate where it may cause hazardous

frost or ice accumulations on adjacent property surfaces.

10.

Venting Requirements:

• Venting system shall terminate at least 3 ft. (0.9m)

above any forced air inlet (except boiler’s combustion

air inlet) within 10 ft.(3m).

COMBUSTION AIR AND VENT PIPE

Table 5 - Combustion Air And Vent Piping Lengths - Total Equivalent Length

BOILER

SIZE

2” PIPE MINIMUM

VENTING

2” PIPE MAXIMUM

VENTING

3” PIPE MINIMUM

VENTING

3” PIPE MAXIMUM

VENTING

100 2 FEET 21 FEET 15 FEET 92 FEET

75 & 50 2 FEET 26 FEET 20 FEET 112 FEET

NOTE: Follow venting lengths strictly, to avoid nuisance pressure switch trips.

• Venting system shall terminate at least 12 in. from any

air opening into any building.

• Vent bottom shall be located at least 12 in. above

grade.

• Termination of the vent shall be not less than 7 ft.

(2.1m) above adjacent public walkway or paved

driveway.

• Vent terminal shall not be installed closer than 3 ft.

from inside corner of L shaped structure.

• Vent termination should be kept at least 3 ft. away

from vegetation.

• Venting system shall terminate at least 4 ft.

horizontally from, and in no case above or below,

unless 4 ft. (1.22m) horizontal distance is maintained,

from electric meters, gas meters, regulators, and relief

equipment.

• Canada only.

• Venting system shall terminate at least 6 ft. (1.83m)

horizontally from, in no case above or below, unless a

6 ft. (1.83m) horizontal distance is maintained, from

electric meters, gas meters, regulators, and relief

equipment.

• Vent shall not terminate within 6 ft. (1.8m) of

mechanical air-supply inlet to any building.

• Vent shall not terminate above regulator within 3

ft. (900 mm) horizontally of vertical center line of

regulator vent outlet to maximum vertical distance of

15 ft. (9.5m).

• Vent shall not terminate within 1 ft (305mm) for

inputs up to and including 100,000 btu/hr and 3 ft.

(900mm) for inputs exceeding 100,000 btu/hr of

window or door that can be opened in any building, or

any non-mechanical air-supply inlet to any building, or

of combustion air inlet of any other appliance.

• Vent shall not terminate underneath veranda, porch

or deck unless,

(a) veranda, porch or deck is fully open on minimum of

two sides beneath fl oor, and

(b) distance between top of vent termination and

underside of veranda, porch or deck is greater than

1 ft. (300mm).

See fi gures 12 and 13 and 14 for two pipe terminations.

See fi gures 15, 16 and 17 for concentric vent terminations.

24

Figure 12 - Roof Vent / Intake Terminations

Installation

1.

Attach combustion air intake piping using fi eld supplied

2” fl exible coupling. Attach vent piping to furnished 2”

vent pipe connector on draft inducer outlet.

2.

All pipe joints are to be water tight

3.

Working from boiler to outside, cut pipe to required

length(s).

4.

Deburr inside and outside of pipe.

5.

Chamfer outside edge of pipe for better distribution of

primer and cement.

6.

Clean and dry all surfaces to be joined.

7.

Check dry fi t of pipe and mark insertion depth on pipe.

8.

After pipes have been cut and pre-assembled, apply

cement primer to pipe fi tting socket and end of pipe to

insertion mark. Quickly apply approved cement to end

of pipe and fi tting socket (over primer). Apply cement

in light, uniform coat on inside of socket to prevent

buildup of excess cement. Apply second coat.

9.

While cement is still wet, insert pipe into socket with

¼ turn twist. Be sure pipe is fully inserted into fi tting

socket.

COMBUSTION AIR AND VENT PIPE

VENT

AIR INTAKE

12” (305mm)/18”

1

2”

(

305mm

)

/18

”

12" (305mm) US,

18" (458mm) Canada

Minimum Above

Anticipated Snow Line

8” (203mm) Minimum

Vertical Separation

Between Combustion

Air Intake and Vent

10.

Wipe excess cement from joint. Continuous bead of

cement will be visible around perimeter of properly

made joint.

11.

Handle pipe joint carefully until cement sets.

12.

Support combustion air and vent piping minimum of

every 5 feet using pre-formed metal hanging straps.

Do not rigidly support pipes. Allow movement due to

expansion and contraction.

13.

Slope horizontal portion of combustion air and vent

pipes toward boiler minimum of ¼” per linear ft.

(21mm/m) with no sags between hangers.

14.

Use appropriate methods to seal openings where vent

and combustion air pipes pass through roof or side

wall.

NOTICE

To avoid nuisance trips under high wind conditions,

an inlet tee is required for side wall venting. See

fi gures 13 and 14 page 25.

25

Figure 13 - Side Wall Vent / Intake terminations - Less Than 12” Clearance Above Grade

Figure 14 - Side Wall Vent/Intake Terminations - 12” Or More Clearance Above Grade

COMBUSTION AIR AND VENT PIPE

Less Than 12” Clearance

12” Or More Clearance

OVERHANG

12"MINIMUM

90°

VENT

12"SEPARATION

BETWEENBOTTOM

OFAIRINTAKEAND

BOTTOMOFVENT

MAINTAIN12"MIN

CLEARABOVEHIGHEST

SNOWLEVELORGRADE

3"

MAXIMUM

SEPARATION

18"

MAXIMUM

15"

MAX

12"

MINIMUM

12"

MINIMUM

36"MIN

90°

BRACKET

VENT

18"

MAXIMUM

MAINTAIN12"MIN

CLEARABOVEHIGHEST

SNOWLEVELORGRADE

12"SEPARATION

BETWEENBOTTOM

OFAIRINTAKEAND

BOTTOMOFVENT

12"MINIMUM

OVERHANG

3"

MAXIMUM

SEPARATION

12"

MINIMUM

12"

MINIMUM

36"MIN

26

Figure 15 - Concentric Vent Terminations

Combustion

Air

Vent

1" (25.4mm)

Maximum

Maintain 12"

clearance above

highest anticipated

snow level or grade

* See Note

Below

Vent

Combustion

Air

36"(0.9m) Minimum

Maintain US 12"(305mm)

Canada 18” (457mm)

clearance above highest

anticipated snow level or

grade

12" (305mm) Minimum

*Must be less than 4" (102mm) or greater than 24"

(610mm) Horizontal distance between end bells of each air

intake to prevent fl ue gas recirculation.

1" (25.4mm)

Maximum

Overhang

Figure 16 - Concentric Vent

COMBUSTION AIR AND VENT PIPE

Figure 17 - Concentric Vent Roof

Installation

AELBOW

(FIELD SUPPLIED)

BSTRAP

(FIELD SUPPLIED)

C 1” (26mm) Max.

27

Figure 18 - Combustion Air and Vent Piping - Boiler Connections

COMBUSTION AIR AND VENT PIPE

2” (50.8mm) Diameter Vent And Combustion

Air Intake Piping

- 21 ft (6.4m)maximum total equivalent length

for 90-100 models

-26 ft (7.9m) maximum total equivalent length

for 90-50 and -90-75 models

- 2 ft (0.6m) minimum total equivalent length

for all models

TRANSITION FITTING

2” (50.8mm) ⊘ to 3” (76.2mm)

⊘ IN VERTICAL RUN

3” (76.2mm) Diameter Vent And Combustion

Air Intake Piping

- 92 ft (28m) maximum total equivalent length

for 90-100 models

- 15 ft (4.6m) minimum total equivalent length

for 90-100 models

- 112 ft (34m) maximum total equivalent

length for 90-50 and 90-75 models

- 20 ft. (6m) minimum total equivalent length

for 90-50 and 90-75 models

SAFETY RELIEF

VALVE SEE

PAGE 18 FOR

REQUIREMENTS

3”

SAFETY RELIEF

VALVE SEE

PAGE 18 FOR

REQUIREMENTS

28

Check Gas Supply

Gas pipe to your boiler must be correct size for length of

run and for total Btu per hour input of all gas utilization

equipment connected to it. See Table 7, Page 29 .

Boiler and its individual shutoff valve must be disconnected

from gas supply piping system during any system pressure

testing at test pressures in excess of ½ psig (3.5kpa).

Boiler must be isolated from gas supply piping system

by closing its individual manual shutoff valve during

any pressure testing of gas supply piping system at test

pressures equal to or less than ½ psig (3.50ka).

Table 6 - Gas Supply Pressure

NATURAL

GAS PROPANE

GAS

Maximum Gas Supply

Pressure

10” w.c. 14” w.c.

Minimum Gas Supply

Pressure

4” w.c. 10” w.c.

GAS SUPPLY PIPING

Connecting The Gas Piping

See Figure 19, Page 29 for general layout at boiler.

Gas line enters boiler from right side jacket panel.

Boiler is equipped with ½” NPT connection on gas valve for

supply piping.

Following rules apply:

1.

Use piping materials and joining methods acceptable

to authority having jurisdiction. In absence of such

requirements:

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

• Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1

2.

Size and install gas piping system to provide suffi cient

gas supply to meet maximum input at not less than

minimum supply pressure. See Table 7, Page 29

3.

Use ground joint unions.

4.

Provide sediment trap up stream of gas valve.

5.

Use two pipe wrenches when making the connection to

gas valve to keep it from turning.

6.

Install a manual shutoff valve in the vertical pipe about

5 feet above fl oor.

7.

Tighten all joints securely.

8.

Propane gas connections should only be made by

licensed propane installer.

9.

Two stage regulation should be used by propane

installer.

10.

Propane gas piping should be checked out by propane

installer.

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the fi re

department.

!

!

DANGER

Fire Hazard. Do not use matches, candles, open

fl ames, or other methods providing ignition source.

Failure to comply will result in death or serious

injury.

!

Leak Check Gas Piping

Pressure test boiler and gas connection before placing

boiler in operation.

•

Disconnect boiler and its individual gas shutoff

valve from gas supply system.

•

Isolate boiler from gas supply system by closing

manual gas shutoff valve. See Figure 19,

Page 29 .

•

Locate leakage using gas detector, noncorrosive

detection fl uid, or other leak detection method

acceptable to authority having jurisdiction. Do

not use matches, candles, open fl ames, or other

methods providing ignition source.

•

Correct leaks immediately and retest.

29

Table 7 – Gas Pipe Sizes

NATURAL GAS

Length of

Pipe - Ft.

Pipe Capacity - BTU Per Hour Input Includes Fittings

1/2” 3/4” 1” 1 1/4”

20 92,000 190,000 350,000 625,000

40 63,000 130,000 245,000 445,000

60 50,000 105,000 195,000 365,000

PROPANE GAS

Length of

Pipe - Ft. Pipe Capacity - BTU Per Hour Input Includes Fittings

Copper Tubing* Iron Pipe

5/8” 3/4” 1/2” 3/4”

20 131,000 216,000 189,000 393,000

40 90,000 145,000 129,000 267,000

60 72,000 121,000 103,000 217,000

* Outside diameter

GAS SUPPLY PIPING

Figure 19 - Gas Piping

3” (76mm) MINIMUM

SAFETY RELIEF

VALVE SEE

PAGE 18 FOR

REQUIREMENTS

30

Electrically bond boiler to ground in accordance with

requirements of authority having jurisdiction. Refer to:

• USA- National Electrical Code, ANSI/NFPA 70.

• Canada - Canadian Electrical Code, Part I, CSA C22.1:

Safety Standard for Electrical Installations.

Electric Power Supply

Prior to making any line Voltage connections, turn OFf

electrical power at fuse box.

1.

Run separate 115 Volt circuit from separate over

current protection device in electrical service entrance

panel. This should be 15 ampere circuit.

2.

See

Figure 20, Page 31 for diagram showing service

switch junction box and power supply connection

points.

3.

Locate service switch in vicinity of boiler. Verify it is

turned OFF during service or maintenance.

• Connect black (hot) lead from power supply to black

wire labeled L 120 VAC.

• Connect white (neutral) lead from power supply to

white wire labeled N 120 VAC.

• Connect green (ground) lead from power supply to

green wire labeled G 120 VAC.

4.

Run 14 gauge or heavier copper wire from boiler to

grounded connection in service panel or properly driven

and electrically grounded ground rod.

ELECTRICAL WIRING

Thermostat Installation

• Thermostat location has important effect on operation

of boiler system.

• Follow instructions included with your thermostat.

• Locate thermostat about fi ve feet above fl oor on inside

wall.

• Mount directly on wall or on vertical mounted outlet

box.

• It should be sensing average room temperature.

Set heat anticipator (where applicable) at 0.7 amps.

Connect 24 Volt thermostat leads to two(2) yellow wires

located in junction box, located on outer jacket of boiler.

See Figure 20, Page 31 for junction box and thermostat

fi eld wiring connections.

Things to Avoid when Locating Thermostats

DEAD SPOTS:

Corners and alcoves Behind doors

COLD SPOTS: HOT SPOTS:

Concealed pipes or ducts Concealed pipes

Fireplace

Stairwells - drafts TV sets

Radios

Unheated rooms on

other side of wall

Lamps

Direct sunlight

Kitchens

Connect Circulator Pump Wiring

See Figure 20, Page 31 for circulator pump fi eld wiring

connections.

Supplied 5 foot wiring harness with fl exible metal conduit

for connection from circulator pump to junction box.

If two 120 Volt circulator wire terminals inside junction box

are not used, leave two wire nuts to prevent short circuit.

WARNING

Electrical shock hazard. Turn OFF electrical power

supply at service panel before making electrical

connections. Failure to do so could result in death

or serious injury.

!

NOTICE

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and

dangerous operation. Verify proper operation after

servicing.

31

Figure 20 - Field Wiring Connections

ELECTRICAL WIRING

SAFETY RELIEF VALVE

SEE PAGE 18 FOR

REQUIREMENTS

32

ELECTRICAL WIRING

Figure 21 - Wiring Schematic

NOTICE

If any of original wire as supplied with this appliance

must be replaced, it must be replaced with type

105°C Thermoplastic wire or its equivalent

33

Figure 22 - Ladder Diagram for Figure 22

ELECTRICAL WIRING

34

1 - Integrated Boiler Control (IBC)

• Integrated Boiler Control (IBC) is a microprocessor

based controller for high effi ciency gas boilers.

• Controller monitors all safety controls which control

operation of combustion air blower, circulator pump,

burner, and combination hot surface igniter/fl ame

sensor.

• Controller is not intended for use with vent damper.

Controller is mounted on control panel inside boiler.

Contains fi ve diagnostic indicator lights.

2 - High Limit Control

NOTICE

Maximum set-point of limit control must not exceed

190°F.

• High limit control determines maximum boiler water

temperature and provides means for protecting boiler

and heating system from unsafe operating conditions

which could damage boiler.

• Control is mounted in ¾” NPT control well on top of front

boiler section at hot water outlet.

• Control is tied in with IBC and factory set at 190°F water

temperature.

• High limit set-point is fi eld adjustable and may be set

between 100°F and 190°F.

• Field set-point adjustment for each installation depends

on heating system requirements.

• Differentials are automatic, vary based on control

settings and boiler temperature.

• Refer to limit manufacturer instructions provided with

limit control.

CONTROLS AND ACCESSORIES

Figure 23 - Indicator Lights

A - Setting High Limit

To adjust, turn HI TEMP dial

1

until desired setting

is displayed. Overall range of High limit setting is from

100°F to 220°F (82° C to 104° C). High limit (HL) on limit

control is factory set at 190°F. Temperature setting may be

varied to suit requirements of installation. Differentials are

automatic and will vary based on control settings and boiler

temperature. See Figure 23.

B - Setting Economy Feature

• Economy feature is factory set for 1 zone heating

system. To adjust, turn ECONOMY dial until number

displayed equals number of heating zones.

• Do not include indirect water heaters in number of

heating zones.

• Economy feature conserves fuel by reducing boiler

temperature. If heating system is unable to supply

needed heat to house, ECONOMY dial should be turned

to lower setting. (example: in a three zone house, turn

dial to 2 or 1).

• Conversely, if boiler provides adequate heat, added

fuel savings can be achieved by selecting higher setting

(example: 4 or 5).

• If heating and indirect water heater signals were not

separated when wiring the control, Economy feature

should be turned off to ensure the boiler supplies

adequate temperature to heat indirect tank.

35

SETTING

OFF

Disables economy function. Will allow boiler to fi re

until hi-limit temp is reached and re-fi re with a 10°

subtractive differential.

LO

Provides lowest level of fuel savings. Use this set-

ting only if the house does not stay warm at higher

settings.

1

Recommended setting for single zone systems.

2

Recommended setting for Two zone systems.

3

Recommended setting for Three zone systems.

4

Recommended setting for Four zone systems.

5

Recommended setting for Five zone systems.

HI

Provides highest level of fuel savings.

C - Differentials

Differentials are automatic and will vary based on the

control settings and boiler temperature.

3 - Gas Control Valve

Electrically controlled Combination Gas Control Valve is

designed to meet requirements for use with hot surface

ignition found in this boiler. Valve is piped to gas/air mixer.

4 - Hot Surface Igniter

Igniter is mounted next to burner through gas/air mixer.

The igniter also serves as means for proving main burner

fl ame by fl ame rectifi cation. In the event of a lack of fl ame

signal on three (3) consecutive trials for ignition, IBC will

fl ash the VALVE light when locked out due to failed ignition.

5 - Draft Inducer Temperature Safety Switch

Draft Inducer Temperature Safety Switch is a disc

thermostat (180°F setpoint) located on induced draft fan

outlet port. Switch protects inducer and vent pipe from

potential high temperature condition for discharging fl ue

gases. Condition would typically be result of higher high

limit control setting or over fi ring. Temperature safety

switch automatically resets when the vent temperature

decreases. (15°F switch differential).

6 - Casting Temperature Safety Switch

In event of lack of or loss of water in boiler, Casting

Temperature Safety Switch (300 °F setpoint) installed

on top of the aluminum boiler section shuts off boiler by

shutting off power to Integrated Boiler Control (IBC). This

fault requires manual reset of casting temperature safety

switch to restart the boiler. Verify that boiler is properly

fi lled with water before resetting this switch.

Never run cold water into a hot empty boiler.

CONTROLS AND ACCESSORIES

7 - Differential Pressure Air Proving Switch/

Blocked Vent Safety Shutoff

Differential pressure switch monitors air fl ow by sensing

differential pressure measured in inches of water (” w.c.).

Pressure switch contacts close when draft inducer is

running. Closed switch indicates there is adequate air fl ow

for combustion. Pressure switch shuts off main burner if

differential pressure is inadequate due to blocked vent pipe,

blocked air intake, blocked boiler sections, or blocked draft

inducer. If pressure switch does not close within 5 minutes

of blower being turned on, control locks out with PURGE

light fl ashing to indicate pressure switch fault.

8 - Draft Inducer

Draft inducer (blower) provides means for pulling

combustion air into and through the mixer, burner, fl ue

ways of cast aluminum boiler sections and fl ue adapter

before being discharged through vent piping to outdoors.

See applicable sections for proper sizing and installation of

combustion air and vent piping in this manual.

9 - Circulator Pump (Optional)

Every forced hot water system requires at least one

circulating pump.

Circulating pump imparts the necessary energy to move

water through closed loop supply and return piping

systems, terminal heating equipment (i.e. fi nned tube

radiators, etc.) and back through boiler for reheating.

To provide required hot water fl ow rates, circulator pump

must be properly sized to overcome frictional losses

(usually measured in feet of water, also referred to as

“pump head loss”) of supply and return piping systems and

boiler.

The circulator pump is furnished for single zone or zone

valve controlled heating system and should be located on

downstream (i.e., pumping away) side of expansion tank.

For pump controlled system (where there is a circulator for

each zone) circulator provided with boiler can work for one

zone. For more details on piping and circulators, see “Near

Boiler Piping” on page 11 .

10 - Drain Valve

Manual drain valve provides means of draining water in

heating system, including boiler and hot water supply and

return piping systems installed above drain valve. This

drain valve is installed in ¾” tapping at bottom of front

boiler section. Any piping installed below elevation of

this drain valve will require additional drain valves to be

installed at low points in piping systems in order to drain

entire system.

36

Water Quality, Water Treatment and Freeze

Protection - see Appendix A

Filling Boiler With Water And Purging Air For

Systems With Diaphragm Type Expansion Tanks

Refer to the appropriate diagrams, “Near Boiler Piping” on

page 11 for more information.

1.

Close all zone service valves on the supply and return

piping. Open the feed valve and fi ll boiler with water.

Make sure air vent is open. Hold relief valve open until

water runs air free for fi ve seconds to rapidly bleed air

from boiler, then let the relief valve snap shut.

2.

Open the zone service valve on the supply pipe for the

fi rst zone. Open the purge valve on the fi rst zone. Feed

water will fi ll the zone, pushing air out the purge valve.

Close the purge valve when the water runs air free.

Close the zone service valve.

3.

Repeat step 2 for all remaining zones.

4.

Open all service valves. Any air remaining trapped in

the return lines between the service valves and the

boiler will be pushed towards the air vent when the

boiler is placed in operation.

5.

Inspect piping system. Repair any leaks immediately.

Purging Air For Systems With Conventional

Closed Type Expansion Tanks:

Refer to the appropriate diagrams “Near Boiler Piping” on

page 11 for more information.

1.

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 fi ll

boiler with water. Hold relief valve open until water

runs air free for fi ve seconds to rapidly bleed air from

boiler, then let the relief valve snap shut.

2.

Open the zone service valve on the supply pipe for the

fi rst zone. Open the purge valve on the fi rst zone. Feed

water will fi ll the zone, pushing air out the purge valve.

Close the purge valve when the water runs air free.

Close the zone service valve.

3.

Repeat step 2 for all remaining zones.

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. Repair any leaks immediately.

Control - System Startup

At initial start up, with the Economy feature active, the

control establishes a 145°F target temperature. To test

the high limit shut-off function, the Economy dial must be

turned to OFF. Once tested, restore the Economy setting.

If the heating demand is high, the target will increase over

time to satisfy the heat load.

How Thermal Targeting Works

Thermal targeting technology analyzes thermostat activity

and continually evaluates how much heat the house

requires.

When it is very cold outside, heat demand is high and limit

control will raise boilers target temperature to provide

heat.

When outside temperature is mild, heat demand is low.

Limit control will lower boiler’s target temperature saving

fuel.

START UP

37

Stop! Read Safety information above.

1.

Set thermostat to lowest setting.

2.

Turn off all electric power to the appliance.

3.

This appliance is equipped with an ignition device which

automatically lights the burner. DO NOT try to light the

burner by hand.

4.

Remove the front jacket panel.

5.

Turn the gas control knob clockwise to “OFF”.

6.

Wait fi ve (5) minutes to clear out any gas. Then smell

for gas, including near the fl oor. If you smell gas,

STOP! Follow “B” in the safety information above on

this label. If you don’t smell gas go on to next step.

7.

Turn the gas control knob counterclockwise to

“ON”.

8.

Replace front jacket panel.

9.

Turn on all electrical power to the appliance.

10.

Set the thermostat to desired setting.

11.

If the appliance will not operate, follow the instructions

“To Turn Off Gas To Appliance” and call your service

technician or gas supplier.

To Turn Off Gas To Appliance

1.

Set the thermostat to lowest setting.

2.

Turn off all electric power to the appliance if service is

to be preformed.

3.

Remove the front jacket panel.

4.

Turn gas control knob clockwise to “OFF”.

5.

Replace the front jacket panel.

OPERATING INSTRUCTIONS

WARNING

If you do not follow these instructions

exactly, a fi re or explosion may result causing

property damage, personal injury or loss of

life.

• This appliance is equipped with an ignition device

which automatically lights burner. Do NOT try to

light this burner by hand.

• Before operating smell all around appliance area

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

some gas is heavier than air and will settle to the

fl oor.

• Use only your hand to turn the gas shutoff

valve. Never use tools. If valve will not turn

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

service technician. Force or attempted repair may

result in fi re or explosion.

• Do not use this appliance if any part has

been under water. Immediately call a qualifi ed

service technician to inspect appliance and to

replace any part of control system and any gas

control which has been under water.

!

OFF

ON

INLET

GAS CONTROL KNOB

SHOWN IN "ON" POSITION

Figure 24 - Gas Valve

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the fi re

department.

!

!

38

DETAILED SEQUENCE OF OPERATION

SERVICE HINTS

POWER ON

STAND BY

THERMOSTAT

CALLS FOR HEAT

CIRCULATOR

ENERGIZES THRU

2K1 CONTACTS

IBC SELFCHECK OF

INTERNAL CIRCUITRY

1-2 SEC

IBC

CHECKS

N.O. AIR

PRESSURE

SWITCH

CONTACTS

FALSE

POSITIVE

PROOF OF

AIRFLOW. IBC WAITS

FOR 45 SEC

FOR AIR PRESSURE

SWITCH CONTACTS

TO OPEN

CLOSED CLOSED

DRAFT INDUCER

ENERGIZES THRU

1K1 CONTACTS

OPEN

IBC

WAITS FOR

UP TO 5 MINUTES

FOR AIR PRESSURE

SWITCH CONTACTS TO CLOSE

INDICATING FAN

SUCTION

PRESENT

CLOSED

CONTROL LOCKOUT. PURGE LIGHT

BLINKS. RESET REQUIRED. CIRCULATOR

REMAINS ENERGIZED AS LONG AS

THERMOSTAT CONTINURES TO CALL FOR

HEAT

OPEN

PURGE LIGHT IS ON. AIRFLOW PROVED.

DRAFT INDUCER RUNS FOR 15 SEC PREPURGE

OPEN

PURGE LIGHT GOES OUT. HOT SURFACE IGNITER

POWERED THRU 5K1 5K2 CONTACTS FOR 20

SEC IGNITER WARMUP. BRIGHT YELLOW

ORANGE GLOW OF THE HOT SURFACE IGNITER

CAN BE OBSERVED THRU THE OBSERVATION

PORT IN FRONT OF BOILER SECTION JUST

ABOVE IGNITER, IGNITOR LIGHT IS ON

GAS VALVE ENERGIZED THRU 3K1 AND 4K1.

CONTACTS, VALVE LIGHT IS ON.

GAS VALVE OPENS FOR 5 SEC TRIAL FOR

IGNITION. BLUE ORANGE GLOW OF THE BURNER

CAN BE SEEN THRU OBSERVATION PORT.

2 SEC INTO THE 5 SEC IGNITION TRIAL. POWER

IS TURNED OFF TO THE HOT SURFACE IGNITER.

IGNITER LIGHT IS OFF.

DURING THE LAST 2 SEC OF THE 5 SEC IGNITION

TRIAL MAIN BURNER FLAME IS PROVED BY FLAME

RECTIFICATION A FLAME SIGNAL TO IBC. GAS VALVE

REMAINS ENERGIZED. BOILER RUNS.

DOES

MAIN

BURNER PROVE

FLAME WITHIN INITIAL

TRIAL FOR

IGNITION

PERIOD?

CONTROL WILL ATTEMPT 2

ADDITTIONAL IGNITION SEQUENCES.

STARTING WITH PREPURGE.

IF MAIN BURNER DOES NOT PROVE

FLAME IN 3 TRIALS, CONTROL

LOCKOUT. VALVE/FLAME LIGHT BLINKS,

RESET IS REQUIRED. THIS PROBLEM IS A

RESULT OF NOT ESTABLISHING FLAME SIGNAL.

NORMAL

OPERATION

YES

NO

39

DETAILED SEQUENCE OF OPERATION

End Of Normal Sequence Of Operation

Thermostat ends call for heat.

Gas valve and circulator pump are

de-energized, valve and fl ame lights go out.

Blower runs for 30 seconds post purge,

purge light is on.

Blower is de-energized after 30 seconds,

purge light shuts off.

Boiler stand by for next call for heat.

40

Sequence Of Operation Diagnostics

Follow sequence using the diagnostic indicator lamps on Integrated Boiler Control (IBC).

See “Controls And Accessories”

on page 34 for normal sequence of operation. Detailed sequence of operation containing potential faults can be found in

service hints section.

SEQUENCE OF OPERATION DIAGNOSTIC

INDICATOR LAMPS

(1) Lamp A is illuminated, indicating integrated control is receiving 24 volts and is in

standby waiting for thermostat call for heat.

(2) Thermostat calls for heat, energizing system circulator.

(3) Integrated boiler control performs self check of internal circuitry, approximately

two seconds, energizing draft inducer.

A. 

B. 

C. 

D. 

E. 

(4) Draft inducer comes up to speed and establishes combustion airfl ow, causing

normally open differential pressure air proving switch contacts to close. When

combustion airfl ow is proved, Lamp B illuminates indicating 15 second pre-

purge cycle has begun.

A. 

B. 

C. 

D. 

E. 

(5) After pre-purge completion, Lamp B is extinguished and Lamp C is illuminated,

indicating power is being delivered to hot surface igniter for 20 second igniter

warm-up period. Observe bright yellow-orange glow of hot surface igniter

through observation port on boiler.

A. 

B. 

C. 

D. 

E. 

(6) After igniter warm-up period, integrated boiler control energizes gas valve,

initiating 6 second trial for ignition mode, indicated by illumination of Lamp

D. Lamp C extinguishes after 2 second delay. Integrated boiler control stops

sending power to hot surface igniter.

A. 

B. 

C. 

D. 

E. 

(7) Low level illumination of Lamp E indicates initiation of fl ame proving. During

last 2 seconds of trial for ignition mode, main burner fl ame is proven by fl ame

rectifi cation through hot surface igniter, providing fl ame signal is relayed to

integrated boiler control, fully illuminating Lamp E.

A. 

B. 

C. 

D. 

E. 

(8) Thermostat ends its call for heat. Integrated boiler control de-energizes gas

valve and system circulator. Lamp D is extinguished while unit enters 30

second post purge mode, indicated by illumination of Lamp B. Lamp E will

remains illuminated as remainder of gas in blower is burned off (approximately

2 seconds). During post purge blower remains powered and clears out any

residual products of combustion.

A. 

B. 

C. 

D. 

E. 

(9) After post purge mode draft inducer is de-energized. Unit goes into standby

mode until next call for heat from thermostat.

A. 

B. 

C. 

D. 

E. 

NOTE:

First one or two cold starts may be rough due to gas line not being completely purged of air,

causing low fi ring rate and high excess air levels.

A - Power, B - Purge, C - Igniter, D - Valve, E - Flame

DETAILED SEQUENCE OF OPERATION

41

DRAFT INDUCER TEMPERATURE SAFETY

SWITCH

Draft inducer runs through 30 second post purge and

switches OFF.

Circulator runs with thermostat on call for heat.

When temperature safety switch contacts connect

before end of call for heat, control goes in normal

light-off sequence.

LOSS OF COMBUSTION AIRFLOW

If combustion airfl ow is lost while burner is fi ring

(Differential air pressure switch contacts open) gas

valve is de-energized.

Valve and  ame lights go out.

Draft inducer runs through 30 second post purge.

If call for heat remains, IBC waits 5 minutes for airfl ow

to be re-established.

If airfl ow does not re-establish control lockout problem

with combustion airfl ow.

Purge light blinks

.

Control automatically reset after 15 minutes.

LOSS OF FLAME SIGNAL

If established fl ame signal is lost while control expects

burner is operating, control immediately de-energizes

gas valve.

Valve and  ame lights go out.

Draft inducer runs through 30 second post purge.

Control attempts to light boiler 3 times. If fl ame is not

proven, control lockout problem establishing fl ame

signal.

Valve light is blinking

.

Control automatically resets after 1 hour.

HIGH LIMIT CONTROL

If boiler water temperature reaches high

limit setpoint, high limit n.c. contacts open

immediately, closing gas valve.

Valve and  ame lights go out.

Draft inducer continues to run for 30 second post

purge and switch OFF.

Circulator runs as long as thermostat calls for

heat.

When high limit contacts connect before end of

call for heat - control goes into normal light-off

sequence.

CASTING TEMPERATURE SAFETY SWITCH

If burner operates when boiler has no water,

aluminum boiler sections heat up rapidly.

Casting temperature safety switch contacts will

open, breaking 24 volt power to IBC.

Power indicator light goes out.

Requires manual reset to re-close contacts.

Power light goes out.

CIRCULATOR PUMP

Circulator is energized as long as thermostat calls

for heat during lockout.

Recovery from any lockout requires reset, which

can be accomplished by:

(a) Removing and re-establishing thermostat’s

call for heat or turning service switch off

and back on;

or

(b) Waiting for control to automatically reset after

15 minutes for loss of combustion airfl ow or one

hour for loss of fl ame.

If draft inducer temperature reaches temperature

safety switch set-point, safety switch contacts open

immediately, closing gas valve

(light goes out)

.

DETAILED SEQUENCE OF OPERATION

42

First couple of cold starts may be rough due to gas line not

being completely purged of air, causing low fi ring rate and

high excess air levels.

Inspect Venting And Air Intake System

Operate boiler and verify all vent/air intake connections are

gas-tight and watertight. Repair any leaks immediately.

Inspect Condensate Drain

Verify all connections are watertight, and that condensate

fl ows freely. Repair any leaks immediately.

Inspect System Piping

Verify all connections are watertight. Repair any leaks

immediately.

VERIFICATION PROCEDURE AND ADJUSTMENT

Verify Proper Sequence Of Operation

Place boiler into operation and observe operation through

several cycles. Follow remaining steps in this section to

insure boiler is operating correctly.

Test High Limit Control And Adjust

While burner is operating,adjust high limit setpoint 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

inter-purge (retry delay). Set high limit control to design

temperature requirements of system. Maximum high limit

setting is 190°F. Minimum high limit setting is 100°F.

Test Other Safety Controls

If boiler is equipped with low water cut off, manual reset

high limit, or additional safety controls, test for operation

as outlined by control manufacturer. Burner should be

operating and should go off when controls are tested. When

safety controls are restored, burner should reignite.

Set Thermostat Heat Anticipator (If Used) And

Verify Thermostat Operation

For single thermostat connected to yellow thermostat lead

wires in furnished fi eld wiring junction box, heat anticipator

should be set at 0.7 amps. For other wiring confi gurations,

refer to instructions provided by thermostat manufacturer

regarding adjustment of heat anticipator. Cycle boiler

with thermostat. Raise thermostat to highest setting and

verify boiler goes through normal start up cycle. Lower

thermostat to lowest setting and verify boiler goes off.

Measure Natural Gas Input Rate

Correct input rate is essential for proper and effi cient

operation of the burner and boiler.

1.

Determine elevation at installation site.

2.

Table 1 and Table 2, Page 6 to determine correct input

rate for the local elevation.

3.

Obtain yearly average heating value of local gas supply

from 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:

3600 x heating value from step 3

Btuh in put rate = time from step 6

8.

Measured input rate should be within +/-2% of 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 or differential pressure

gauge for measuring manifold pressure. See

Figure 25, Page 44 .

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.

F. After adjusting input rate, turn boiler off, remove

manometer or pressure gauge, reinstall ⅛” plug

on gas valve. Turn boiler on.

G. Boiler should typically operate between:

• 8.5% -10.0% CO2 on Natural Gas

• 9.5% -11.0% CO2 on Propane Gas

Under all conditions CO level should not exceed 100

ppm.

9.

Restore all gas appliances that may have been shut off

(while measuring boiler input rate) to normal operating

conditions.

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 fi nger 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.

43

VERIFICATION PROCEDURE AND ADJUSTMENT

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 orifi ce size is required.

Consult the boiler manufacturer for information on

correct orifi ce sizing. The specifi c 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 orifi ce size.

Set Thermostat To Desired Room Temperature

Observe several operating cycles to verify proper operation.

Review All Instructions

Review all instructions shipped with this boiler with owner

or maintenance person. Instructions must be affi xed on or

adjacent to the boiler.

Complete and sign the “Installation and Check-Out

Certifi cate” on page 62

.

44

Following steps and diagram indicate location of the

connection points required to measure manifold pressure.

Manifold pressure may be measured using a U-Tube

Manometer or Differential Pressure Gauge. Diagram shows

connection of both measuring devices. Only ONE DEVICE IS

REQUIRED to measure manifold pressure.

Remove plug. Install appropriate barbed fi tting and connect

pressure side line from U-Tube Manometer or Differential

Pressure Gauge.

OFF

ON

INLET OUTLET

GAS CONTROL KNOB

PRESSURE REGULATOR

ADJUSTMENT (UNDER CAP SCREW)

INLET

PRESSURE

TAP

VR8205 WIRING TERMINALS (2)

OUTLET

PRESSURE

TAP

Figure 25 - Manifold Pressure Measurement Detail

Figure 26 - Gas Valve

VERIFICATION PROCEDURE AND ADJUSTMENT

Refer to “Differential Air Pressure Switch Check - all

models” on page 45 when reading manifold pressure.

When measurement is complete, disconnect U-Tube

Manometer or Differential Pressure Gauge. Be sure to

reinstall ⅛” plug, using appropriate pipe thread sealant

approved for use with natural and liquefi ed Petroleum

gases.

NOTICE

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 fi rmly installed.

45

• Following steps and diagram indicate locations of

connection points required to check differential air

pressure.

• Differential air pressure switch is safety device which

prevents boiler from fi ring if there is air intake, boiler

heat exchanger or vent blockage.

• Turn off service switch, or lower thermostat setting.

• Remove vinyl caps from Tee and 4-way connector.

• Install testing lines as shown to inclined manometer or

differential pressure gauge with ability to read 0.01” to

5.0” w.c.

• Turn on service switch and set thermostat to call for

heat.

BOILER

STATUS DIFFERENTIAL

PRESSURE (W.C.)

PRESSURE

SWITCH

CONTACTS

Not Running 0” Normally Open

1.80” for Model -100

1.80” for Model-75

2.10” for Model-50

Running

Without

Blockage

Greater Than

Setpoints Closed

Running

With

Blockage

Less Than or Equal to

Setpoints Open

If manometer readings do not correspond to 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

• - Incorrect pressure switch or pressure switch setpoint

When pressure reading is proper and the pressure switch is

operating properly, remove testing lines and reinstall vinyl

caps to Tee and 4-way connector.

DIFFERENTIAL AIR PRESSURE SWITCH CHECK - ALL MODELS

Model 050

46

NEGATIVE PRESSURE SWITCH CHECK

BOILER

STATUS NEGATIVE

PRESSURE (W.C.)

PRESSURE

SWITCH

CONNECTS

Not Running 0” Normally

Closed

Setpoint -0.50”

for Models 100 & 075

Running

Without

Blockage

Less Negative than

Setpoint Closed

Running

With

Blockage

More Negative than

Setpoint Open

To Gas Valve Vent

G

as

V

al

ve

V

en

t

For use on Model - 100 boilers only.

• Following steps and diagram indicate locations of

connection points required to check negative pressure.

• Negative pressure switch is safety device which

prevents boiler from fi ring if there is air intake

blockage.

• Turn off service switch, or lower thermostat setting.

• Remove vinyl cap from 4-way connector.

• Install test line as shown to inclined manometer or

differential pressure gauge with ability to read 0.01” to

5.0” w.c.

• Turn on service switch and set thermostat to call for

heat.

• If manometer readings do not correspond to chart,

check for possible causes:

A. Blockage in air intake

B. Undersized air intake

C. Loose blower wheel or motor shaft

D. Incorrect pressure switch or pressure switch

setpoint

• When pressure reading is correct and the pressure

switch is operating properly, remove test line and

reinstall vinyl cap to 4-way connector.

Negative Pressure Switch

Differential Air Pressure Switch

Red Transparent Vinyl Tubing

Tee

Vinyl Cap

All pressure switch tubing

is clear vinyl tubing unless

otherwise noted.

Inclined Manometer

(Differential Pressure Gauge)

Test Line

To Air Inlet

Sution Port

To Sight Glass Suction Port

White Silicone Tubing

4-Way Connector

Models 075 and 100

47

Maintenance As Outlined Below Can Be

Performed By Owner Unless Otherwise Noted.

• The acidic nature of fl ue gasses condensing on

aluminum boiler sections may cause formation of

aluminum oxide. This oxide formation is normal,

is generally uniform throughout boiler sections,

and represents negligible mass of aluminum that is

consumed by oxidation during life of the boiler.

• If left unchecked, this buildup may eventually cause

blockage of fl ue gas passages in boiler sections,

reducing effi ciency, and ultimately shutting down the

boiler due to lack of combustion air fl ow.

• Regular service and maintenance by a qualifi ed service

agency must be performed to assure safe trouble free

operation and maximum effi ciency.

Beginning Of Each Heating Season

1.

Annual service call by qualifi ed service agency, which

includes:

A. Examine fl ue passages between boiler sections,

burner, and condensate lines, and clean if

necessary following “Annual Examination And

Cleaning Of Boiler Components” on page 48 .

B. Visually inspect venting and air intake system

for proper function, deterioration or leakage. If

vent or air intake show any signs of deterioration

or leakage, repair or replace them, immediately.

Insure proper reassembly and resealing of vent and

air intake system

C. Check for and remove any obstruction to fl ow of

combustion air or venting of fl ue gases. Check air

baffl e located inside 1½” x 2” fl exible coupling on

mixer, clean 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 for “Operating Instructions” on

page 37 .

E. Follow instructions for “verifi cation Procedure and

Adjustment” on page 42 .

F. Visually inspect condensate drain lines for proper

operation and deterioration. Check for plugged

condensate drain lines.

G. Check silicone rubber seals between boiler sections.

Insure that there are no leaks. Use RTV silicone

rubber adhesive sealant rated for at least 400° F to

replace or repair seals in locations where original

seals have deteriorated.

H. Check all gasketed joints for leakage, and tighten

bolts or replace gaskets if necessary.

I. Remove jacket front and top panels and check for

piping leaks around relief valve and other fi ttings.

Repair, if found. DO NOT use stop leak compounds.

J. Check igniter for cracks and deterioration. Replace

if necessary.

K. Check for water in pressure switch tubing. Drain if

necessary.

2.

Check boiler area is free from combustible materials,

gasoline, and other fl ammable vapors and liquids.

3.

Circulator pump and blower motor furnished with boiler

are permanently lubricated from factory and require no

further lubrication. Additional or non-factory supplied

pumps and/or motors should be lubricated according to

the pump and/or motor manufacturer’s instruction.

Daily During Heating Season

1.

Check for and remove any obstruction to the fl ow of

combustion air or venting of fl ue gases.

2.

Check boiler area is free from combustible materials,

gasoline, and other fl ammable vapors and liquids.

MAINTENANCE AND CLEANING

Monthly During Heating Season

1.

Remove jacket front and top panels and check for

piping leaks around relief valve and other fi ttings. If

found, contact qualifi ed 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 vent or

air intake show any signs of deterioration or leakage,

contact a qualifi ed service agency to repair or replace

immediately and to insure proper reassembly and

resealing of vent and air intake system.

4.

Visually inspect clear vinyl condensate lines and PVC

condensate drain pipe for proper operation, leakage,

and deterioration. If condensate lines or drain pipe

show any signs of blockage, leakage, or deterioration

contact a qualifi ed service agency to clean, repair, or

replace them immediately.

Periodically During Heating Season

Where low water cutoffs are used, periodic inspection of

low water cut off is necessary, including fl ushing of fl oat

type devices. Refer to low water cut off manufacturer’s

specifi c instructions.

End of Each Heating Season - Annual Shutdown

Procedure

Follow instructions “To Turn Off Gas To Appliance” on page

37 .

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.

48

K. Reinstall burner and mixer gasket and position

mixer assembly over studs. Install fi ve (5) nuts but

do not tighten. Reinstall igniter and igniter gasket

and fasten with two (2) screws. Use care when

installing the igniter. Tighten fi ve (5) nuts holding

mixer assembly.

L. Connect:

• Gas line to gas valve

• Condensate drain line to boiler

• Pressure switch hose to gas valve

• Air by-pass to mixer

• 1 ½” x 2” fl exible coupling to air inlet and make

sure to put air baffl e back to correct position

• Igniter wires

• Gas valve wires

3.

Visually inspect condensate lines leading from boiler

sections and vent pipe connector to condensate trap.

Refer to repair parts diagrams. Any foreign material or

debris visible in condensate lines needs to be cleaned

out as follows:

A. Disconnect condensate drain lines from condensate

trap.

B. Remove condensate trap and drain all water from

trap.

C. Disconnect condensate lines from fi tting on bottom

of boiler and vent pipe connector.

D. Run cold water through condensate lines and trap

to thoroughly fl ush out any sediment or debris.

E. Reinstall condensate trap and condensate lines.

F. Follow instructions under “Near Boiler Piping” for

fi lling condensate trap with water.

4.

Inspection of fl ue connector requires following steps. Refer

to repair parts diagram.

A. Loosen the clamp on the draft inducer end of the

2” vent pipe connector that connects the vent

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 inducer to fl ue connector.

B. Remove draft inducer and gasket from top of fl ue

connector.

C. Inspect interior of fl ue connector. Any buildup of

sediment or aluminum oxide on inside surface must

be cleaned. Position draft inducer gasket and draft

inducer and fasten with four (4) screws. Be sure to

connect ground wire from draft inducer motor to

one of four mounting screws.

D. Connect wiring harness leads to draft inducer motor

and draft inducer temperature safety switch.

E. Connect vent pipe connector to draft inducer outlet.

MAINTENANCE AND CLEANING

Annual Examination And Cleaning Of Boiler

Components

DANGER

Before servicing, turn off electrical power to boiler

at service switch. Close manual gas valve to turn

gas supply OFF to boiler. Failure to comply will result

in death or serious injury.

!

NOTICE

Have qualifi ed service agency perform the following

service procedures. Boiler owner should not attempt

these procedures.

1.

Before Servicing, turn off electrical power to boiler at

service switch. Close manual gas valve to turn off gas

supply to boiler.

2.

Cleaning Flue passages between boiler sections.

A. Any buildup of sediment or aluminum oxide (white

powdery or fl aky substance) in fl ue passages must

be cleaned as follows.

B. Remove jacket front and top panels. Disconnect

condensate drain line from barbed fi tting on bottom

of boiler. Keep open end of drain line above water

level in condensate trap to prevent trap from

draining. Disconnect pressure switch hose from

barbed fi tting on gas valve. Disconnect 1½ x 2”

fl exible coupling from air inlet. Disconnect air by-

pass (½” transparent vinyl tube) from bottom of

mixer.

C. Remove air baffl e from ½” x 2” fl exible coupling

and clean air baffl e if necessary. Refer to repair

parts diagram, mixer and pressure switch

assembly.

D. Confi rm manual gas valve is closed and disconnect

gas line to gas valve at union. Disconnect wires to

gas valve and igniter.

E. Loosen but do not remove fi ve (5) nuts attaching

mixer assembly to boiler. Remove two (2) igniter

screws and remove igniter.

F. Remove fi ve (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 or running

water. Before rinsing, connect a ½” I.D. hose to

barbed fi tting on bottom of boiler and run hose to

bucket or drain.

H. After rinsing, remove any remaining loosened

sediment using shop vacuum with snorkel

attachment.

I. Inspect burner for any foreign matter in fl ame

ports or inside 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.

NOTICE

Verify proper operation after servicing.

49

Important

1.

In reset from lockout condition, all electrical meter

readings at the gas control valve (24 vac) must be

taken within trial for ignition period.

2.

If any component does not function properly, make sure

it is correctly installed and wired before replacing it.

3.

Static electricity discharge can damage integrated

boiler control (IBC). Touch metal surface to discharge

static electricity before touching IBC.

4.

IBC cannot be repaired. If it malfunctions it must be

replaced.

5.

Only trained service technicians should service IBC

systems. Following troubleshooting, check out system

following sequence of operation for a normal light off

sequence.

6.

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 this section before you replace it.

7.

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

control or it is being damaged by some other problem

(an electrical short burning out a transformer, for

example).

Initial Service Checks

1.

Before troubleshooting:

A. Make sure that circuit breaker is on or fuse is ok at

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 or damaged.

TROUBLESHOOTING

2.

Troubleshooting tools:

A. Voltmeter to check 120 vac and 24 vac

B. Continuity tester.

C. Inclined manometer or pressure gauge with

0-3.0” 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.

System Status:

A. Consult “System Status” on pages 40 and 50.

B.

See Figure 23, Page 34,

for location of boiler

Diagnostic Indicator Lamps.

WARNING

Fire, explosion or shock hazard. Do not attempt to

modify the physical or electrical characteristics of

this boiler in any way. Failure to comply could result

in death or serious injury.

!

50

TROUBLESHOOTING - HIGH LIMIT CONTROL AND LWCO

LED Legend and LWCO Test Button

1

HI TEMP illuminates when boiler water temperature

reaches high limit setting. Remains lit until water

temperature falls 10°F below high limit setting. Limit

prevents burner operation while this LED is on.

2

ACTIVE Indicates low water cut-off function is active.

When control is installed with Electro-well, LED is on at all

times when control is powered. If the control is installed

with a well other than Electro-well, LED will not illuminate

indicating the control is not providing low water cutoff

functionality.

WARNING

Burn and scald hazard. Do not add water until boiler

has fully cooled. Failure to follow these instructions

could result in death or serious injury.

!

3

LOW WATER Illuminates if boiler is in low water

condition. Control will prevent burner operation during this

condition.

Important: System must be checked by qualifi ed service

agency prior to resuming operation.

4

ACTIVE Indicates that thermal targeting function is

active and control reduces boiler temperature to conserve

fuel. Economy feature is activated using the ECONOMY

dial.

5

TARGET When feature is active, control continually

sets target temperatures below high limit setting to

maximize fuel effi ciency. When boiler reaches target

temperature, LED illuminates and burner shuts down.

Boiler water continues to circulate and heat the house as

long as thermostat call continues. LED stays lit until boiler

temperature drops below differential at which point boiler

will be allowed to fi re again.

Note: LED illuminates regularly during normal boiler

operation.

6

PURGE Control is purging latent heat from boiler and

will not fi re until temperature drops to 135°F.

7

TEST/SETTING to Test LWCO: Press and hold TEST

button. Red Low Water light will illuminate and burner

circuit will de-energize.

Figure 27 - LED Legend

115

100

130

145

160

175

190

51

TROUBLESHOOTING -HYDROSTAT HIGH LIMIT CONTROL AND LWCO

Troubleshooting Flow Chart

Burner Will Not Fire See Flow Chart, this page.

No or Insuffi cient

Domestic Hot Water

If installed with indirect water heater, insure end switch in relay box controlling indirect water

heater is properly connected to Cable 2. This will insure domestic water calls are prioritized. If

Cable 2 is not used, turn Economy Feature OFF.

House Will Not Get or

Stay Warm

1.

Check for air-bound radiators.

2.

Check thermostat settings including heat anticipator settings (common on non-digital

thermostats).

3.

Check Economy setting. Economy feature, like outdoor reset controls, lowers average

boiler temperature and can slow or, in some cases, prevent the house from coming up to

temperature. Move to lower setting.

Is Red LED

(LOW WATER)

On?

Is Yellow LED

(HI TEMP)

On?

Is Yellow LED

(TARGET)

On?

Is

PURGE LED

on?

Replace

Control

Control is

Sensing Low

Water

Control is

Sensing High

Temperature

Boiler

Reached

Target

Temperature

Boiler in Purge Mode

and will not fi re until

temperature drops to

140°F.

See Purge page 36.

Both red and yellow LEDs are off and there is call

to fi re burner, there will be 120 VAC in terminals

B1 and B2.

►120 VAC is not present, replace control.

CAUTION- ALWAYS ALLOW BOILER TO COOL BEFORE

ADDING WATER

Burner will not fi re until low water condition is satisfi ed.

►Verify system fi lled with water.

►Verify sensor is inserted correctly into well.

Note: Use of heat-conductive grease may interfere with contact

between spring clip and copper well tube.

►Verify control is tightly clamped to well.

Burner will not fi re until boiler water has dropped to high

limit differential set-point (10° below high limit setting).

►Verify high temperature setting is correct.

When ECONOMY function is active, control monitors

heating demand and establishes Target boiler temperatures

below high limit setting to conserve fuel. Burner will not

fi re until boiler temperature drops to Target Temperature

Differential.

YES

YES

YES

YES

NO

NO

NO

NO

52









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

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

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



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





Troubleshooting Chart 1

TROUBLESHOOTING

53

Troubleshooting Chart 2

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



TROUBLESHOOTING

54

Troubleshooting Chart 3

CHECK FOR VAC

BETWEEN TERMINALS 1 AND 3

AT CONNECTOR CN4 ON IBC

NO NO

BLOWER STARTS

REPLACE IBC

CHART

1

OPEN

IBC PURGE LIGHT ON?

NO

YES

IBC WAITS UP TO 5

MINUTES FOR NORMALLY

OPEN AIR

PRESSURE SWITCH

CONTACTS TO CLOSE,

INDICATING BLOWER

SUCTION IS

PRESENT

YES

CHECK FOR 120 VAC AT

BLOWER LEADS ON WIRING

HARNESS

YES

REPAIR/REPLACE

BLOWER

NO REPAIR/REPLACE

WIRING FROM IBC

TO BLOWER

PRESSURE SWITCH

CONTACTS

OPEN

ARE VENT PIPE AND AIR

INTAKE PIPE CLEAR

(NO BLOCKAGE)

NO

CLEAN OUT VENT PIPE

AND/OR AIR INTAKE PIPE.

CHECK FOR SAGS OR

LOW SPOTS WHERE

CONDENSATE MAY

PUDDLE AND BLOCK

THE VENT

YES

CHECK AIR

PRESSURE SWITCH PER

INSTRUCTIONS ON

FOLLOWING PAGES. ARE

SAMPLING LINES CLEAR

AND CONNECTED

PROPERLY?

NO CLEAN OUT SAMPLING

LINES OR REPLACE

DEFECTIVE SWITCH

YES

CHECK FLUE PASSAGES

IN BOILER PER

"MAINTENACE AND

CLEANING". ARE FLUE

PASSAGES IN BOILER CLEAN?

NO CLEAN BOILER FLUE

PASSAGES PER

MAINTENANCE AND

CLEANING INSTRUCTIONS

YES

CHECK DRAFT INDUCER

MOTOR RPM. IS IT

3400-3600?

NO REPLACE

BLOWER

YES

CHECK FOR BROKEN OR

LOOSE IMPELLER ON DRAFT

INDUCER AND REPLACE

BLOWER IF FOUND TO

BE BROKEN OR LOOSE

YES

15 SECOND PRE PURGE COMPLETE.

IBC PURGE LIGHT IS OFF. SIMULTANEOUSLY

IGNITOR LIGHT IS ON AS IGNITOR CIRCUIT

IS ENERGIZED.

YES

C

HART 4

NO

REPLACE IBC

ARE ORIFICE IN

NEGATIVE PRESSURE

HOSE CLEAR?

NO

YES

CLEAN OUT BLOCKAGE

AT ORIFICE

TROUBLESHOOTING

55

Troubleshooting Chart 4

IGNITER/SENSOR WARMS

UP AND GLOWS

YELLOW/ORANGE

DURING 20 SECOND

WARM UP

CHART 3

YES

NO

CHECK FOR 120 VAC

BETWEEN TERMINALS 1

AND 2 AT CONNECTOR

CN1 ON IBC (DURING

IGNITER WARM UP)

NO

REPLACE IBC

YES

CHECK FOR 120 VAC AT

IGNITER/SENSOR LEADS

ON WIRING HARNESS

(DURING IGNITER

WARM UP)

NO REPAIR/REPLACE WIRING

FROM IBC

TO IGNITER/SENSOR

YES REPLACE IGNITER/SENSOR

AFTER 20 SECOND

IGNITER WARM UP, GAS

VALVE IS ENERGIZED

VALVE LIGHT IS ON

2 SECONDS LATER POWER

IS REMOVED FROM

IGNITER/SENSOR

IGNITER LIGHT IS OFF

DOES MAIN BURNER

LIGHT?

CHECK FOR 24 VAC

ACROSS TERMINALS MV

ON THE GAS CONTROL.

WHILE VALVE/FLAME

INDICATOR LIGHT IS ON

NO NO

CHECK FOR 24 VAC

ACROSS TERMINALS

CN6-2 AND CN6-5 ON

IBC, WHILE THE VALVE/

FLAME LED IS LIT

NO

REPLACE IBC

YES

REPAIR/REPLACE WIRING

BETWEEN IBC AND

GAS CONTROL

YES

CHECK IF IGNITER/

SENSOR POSITION IS OK?

TIP SHOULD BE SLANTED

TOWARDS BURNER

RESTORE IGNITER/SENSOR

TO CORRECT POSITION.

DO NOT RELOCATE

NO

YES

CHECK GAS SUPPLY

PRESSURE AT INLET

PRESSURE TAPPING ON

GAS CONTROL IS GAS

PRESSURE GREATER

THAN 4.0" W.C.?

NO

ARE ALL MANUAL

SHUT-OFFS IN THE GAS

SUPPLY LINE AND ON

THE GAS CONTROL IN

THE OPEN OR ON

POSITION?

OPEN OR TURN ON ALL

MANUAL SHUTOFFS

NO

YES

CONTACT THE GAS UTILITY

TO TURN THE GAS ON

YES

CHART 5 CHART 5

YES

YES

TROUBLESHOOTING

56

POSSIBLY MIXTURE TOO LEAN!

CHECK GAS LINES DOWNSTREAM OF GAS

VALVE FOR BLOCKAGE.

ARE GAS LINES CLEAR?

IS GAS/VENTURI VALVE CORRECT SIZE?

SEE REPAIR PARTS DIAGRAM.

CLEAN/REPLACE GAS LINES .

BE SURE TO USE CORRECT GAS/VENTURI VALVE SIZE.

NO

YES

POSSIBLY MIXTURE TOO RICH!

CHECK FLUE PASSAGES IN BOILER PER

"MAINTENANCE AND CLEANING". ARE

FLUE PASSAGES IN BOILER CLEAN?

NO CLEAN BOILER FLUE PASSAGES PER MAINTENANCE

AND CLEANING INSTRUCTIONS

CHART 4

YES

YES

CHECK MIXER AND BURNER FOR

BLOCKAGE PER MAINTENANCE AND

CLEANING INSTRUCTIONS. ARE AIR

PASSAGES IN MIXER AND BURNER

CLEAN?

NO CLEAN MIXER AND BURNER PER MAINTENANCE AND

CLEANING INSTRUCTIONS

CHECK AIR ORIFICE AT BURNER INLET

FOR CORRECT SIZE. SEE REPAIR PARTS

DIAGRAM. IS ORIFICE CORRECT SIZE?

REPLACE BURNER

NO

CHART 4

YES

DOES MAIN BURNER

RUN UNTIL CALL FOR

HEAT ENDS OR HI

LIMIT AQUASTAT

CONTACTS OPEN?

*

NO #1

NO #2

NO #3

RUNS SMOOTHLY FOR ABOUT 6

SECONDS THEN SHUTS OFF.

INDICATES POOR FLAME SIGNAL.

CHECK IGNITER/SENSOR

POSITION. TIP SHOULD BE

SLANTED TOWARDS BURNER

CHART 6

YES

CHECK FLAME SIGNAL >0.6uA?

CONSULT BOILER MFGR. FOR

SPECIFIC INSTRUCTIONS.

REQUIRES SPECIAL TOOLS.

YES

REPLACE IBC

* IF THE ANSWER IS NO.

CHOOSE THE APPROPRIATE

PATH (#1, #2, OR #3) BASED ON

SYMPTOMS SHOWN.

RESTORE

IGNITER/SENSOR

TO CORRECT POSITION

.

DO NOT RELOCATE.

NO

CHART 6 CHART 6

OXIDE COATING ON

IGNITER PREVENTING

FLAME SIGNAL.

REPLACE

IGNITER/SENOR.

NO

Troubleshooting Chart 5

TROUBLESHOOTING

57

Troubleshooting Chart 6

RUNS FOR 25-50 SECONDS,

THEN TURNS OFF.

CHECK FIRING RATE OF UNIT.

IS UNIT FIRING AT THE CORRECT RATE?

NO

DOES THE UNIT USE LP GAS.

YES

NO

CHECK GAS ORFICICE SIZE.

IS GAS ORIFICE SIZE CORRECT.

CHECK REPAIR PARTS LIST

FOR CORRECT SIZE. IS GAS ORIFICE

CLEAR OF BLOCKAGE.

ADJUST RATE AS DESCRIBED IN THE

CHECK OUT PROCEDURE AND

ADJUSTMENT SECTION

OF THE MANUAL.

CHART 5

NO #2

YES

CHECK BURNER FOR ANY DETERIORATION

IN THE FLAME PORTS. ARE BURNER PORTS

IN GOOD CONDITION.

NO REPLACE WITH CORRECT

AIR BAFFLE.

YES

CHECK FLAME SIGNAL > 0.6uA?

CONSULT BOILER MFGR. FOR

SPECIFIC INSTRUCTIONS. REQUIRES

SPECIFIC TOOLS.

NO

YES

REPLACE BURNER

REPLACE IBC

BOILER SHUTS OFF BEFORE END OF

CALL FOR HEAT. ARE HI LIMIT

AQUASTAT CONTACTS CLOSED?

NO BOILER OFF ON HIGH LIMIT. IS

ACTUAL BOILER WATER TEMP.

GREATER THAN HI LIMIT SET POINT

MINUS 30°F CONTROL DIFFERENTIAL?

NO

NO

REPLACE

AQUASTAT

OK

YES

SEE TROUBLESHOOTING PATH

#2 ABOVE

CHART 5

NO #3

CHART 5

YES

SET THERMOSTAT BELOW ROOM

TEMPERATURE TO END CALL FOR

HEAT

DOES CIRCULATOR PUMP STOP?

NO

ARE THERMOSTAT CONTACTS OPEN? REPLACE THERMOSTAT

NO

YES

REPLACE IBC

YES

VALE LIGHT IS OFF

REMOVE WIRING HARNESS

CONNECTION CN9 FROM GAS

CONTROL DOES GAS CONTROL

CLOSE?

NO

REPLACE GAS CONTROL

NO

YES

YES

DOES DRAFT BLOWER

STOP AFTER 30

SECOND POST PURGE?

NO

REPLACE IBC

YES

YES

SYSTEM OK

YES

REPLACE GAS CONTROL.

TROUBLESHOOTING

58

Aluminum Series

High Effi ciency Gas-Fired Boiler

DIELECTRIC ISOLATION & ANTIFREEZE PROTECTION

APPENDIX A - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION

WARNING

Follow these instructions to prevent damage to

boiler’s heat exchanger caused by inadequate

dielectric isolation, incorrect water treatment or

antifreeze application. Failure to comply could result

in death or serious injury.

!

• Install boiler so gas ignition system components are

protected from water (dripping, spraying, rain, etc)

during appliance operation and service (circulator

replacement, etc).

• DIELECTRIC ISOLATION

Two (2) 1-1/4” X 1-1/4” Female to female dielectric

isolation unions are shipped loose in boiler parts bag.

Install Dielectric Isolation unions at boiler supply line

and return line. Install isolation fi ttings nearest boiler

prior to system piping connections.

• WATER TREATMENT and ANTIFREEZE

PROTECTION

MUST be applied for ALL aluminum series high

effi ciency gas-fi red boilers using antifreeze

protection.

59

System and Operating Precautions

Applies to ALL Aluminum High Effi ciency Gas-Fired Water Boilers

Eliminate System Leaks

Continuous addition of make-up water will constantly add

oxygen to system. Eliminate all system leaks. All system

leaks must be repaired immediately.

DO NOT use stop leak compounds. Leaks in threaded

connections in aluminum boiler sections must be repaired

immediately. Aluminum threads will not seal themselves.

Verify expansion tank is operational and properly sized.

Undersized expansion tanks cause relief valve weeping and

substantial make-up water addition.

Operation of this boiler in system containing signifi cant

amounts of dissolved oxygen can cause severe heat

exchanger corrosion damage.

This boiler is not designed for use in systems containing

regular additions of make-up water. Regular additions of

make-up water may cause severe heat exchanger damage.

System leaks may not always be visible. An unseen system

leak will become obvious if boiler pressure decreases when

make-up valve is closed.

This boiler is designed for closed loop hydronic heat system

ONLY!

This boiler is not suitable for natural gravity type

installations, or any other open type system.

Fill Water and Chemistry

Verify water used to fi ll system meets these requirements:

System fl uid pH maintained between 7.0 and 8.0.

Maintain water hardness below 7 grains hardness.

Filling with chlorinated potable water is acceptable. DO

NOT fi ll boiler with water containing chlorine in excess of

100 ppm.

DO NOT use inhibitors or other additives that are not listed

in this addendum.

Consult local water treatment specialist for

recommendations if any of above requirements is outside

stated ranges.

Clean System First

BEFORE connecting boiler to heating system, clean and

fl ush system thoroughly. Verify system is free of sediment,

fl ux and any residual boiler water additives.

Systems having antifreeze not recommended must be

completely fl ushed to ensure no old antifreeze remains.

In older systems obviously discolored, murky or dirty

water; or pH reading outside acceptable range (between

7.0 and 8.0) are indications the system should be cleaned

or treated. Thoroughly fl ush system with clean water to

remove any sediment or contaminants. Sludge and iron

oxide deposits can cause rapid breakdown of inhibitors.

Flushing with clean water. If chemical cleaners are used,

use only those recommended for use with aluminum

boilers. Follow chemical cleaner manufacturer’s instructions

completely.

DO NOT mix different manufacturer’s products.

60

System and Operating Precautions

Applies to ALL Aluminum High Effi ciency Gas-Fired Water Boilers

General Guidelines When Using Antifreeze

• Use only antifreeze products recommended

for use with aluminum boilers, as listed in

this addendum. See Table 8.

• Continuous addition of make-up water will dilute

power of antifreeze and change buffers ability to

maintain pH.

• Flush old antifreeze from system. Flush boiler and

system separately.

• Do not use antifreeze unless required.

• Antifreeze, if needed, must be of type listed on

next page due to their operational characteristics

of : type 356 T6 aluminum at operating

temperatures between 20°F (-6.7°C) and 250°F

(121°C). (See Table 8 for allowable products.)

• Always clean system prior to using antifreeze as

stated in this supplement.

• Follow antifreeze manufacturer’s instructions for

use, safe handling and storage of their products.

Refer to MSDS (Material Safety Data Sheets)

provided by antifreeze manufacturer for potential

hazards and fi rst aid procedures for exposure or

ingestion.

• Antifreeze will raise pH of hydronic solution in

heating system above recommended level due to

corrosion inhibitors. Solution must be treated to

maintain a pH within recommended level. Follow

antifreeze manufacturer’s instructions to adjust

pH.

• If system has leaked, water and antifreeze

chemistry will need to be adjusted. To avoid

damage to boiler, check pH and chemistry of boiler

solution and consult the antifreeze manufacturer

for recommendations.

• Recommend taking pH reading annually, and

adjusted as necessary. Follow antifreeze/inhibitor

manufacturer’s instructions for details on how to

adjust pH.

• Antifreeze solutions can break down over time.

Failure to check antifreeze chemistry on annual

basis may result in accelerated corrosion of

boiler and other system components. Consult with

antifreeze manufacturer for recommendations.

• Use of antifreeze in any boiler will reduce

heating capacity as much as 10-20%. Take

into consideration when sizing heating system,

pumps and expansion tank. Consult antifreeze

manufacturer’s literature for specifi c information

on reduced capacity.

• Using antifreeze manufacturer’s instructions,

determine freezing temperature needed and use

correct amount of antifreeze. Never exceed 50%

antifreeze by volume.

• Boiler operating pressure must remain below 15

psi for antifreeze solutions that specify a maximum

of 250°F (121°C). Otherwise, increase system

operating/tank pressure to 20 psig.

Note: Refer

to expansion tank manufacturer instructions for

adjusting tank pressure.

61

Compatible Aluminum Antifreeze & Inhibitor Suppliers

Noburst AL Antifreeze

Noble Company

P. O. Box 350

Grand Haven, MI 49417

www.noblecompany.com

Tel: 800-878-5788

Fax: 231-799-8850

Rhogard Antifreeze &

Pro-Tek 922 Inhibitor*

Rhomar Water Management, Inc.

P. O. Box 229

Springfi eld, MO 65801

www.rhomarwater.com

Tel: 800-543-5975

Fax: 417-862-6410

* Pro-Tek 922 Inhibitor may be used to adjust the pH level of the hydronic system, but on occasion may not resolve the

pH issue. In these cases, fl ush the system and refi ll with untreated water and antifreeze suitable for aluminum heat

exchangers, as listed in this supplement.

Alphi-11

Hydronic Agencies, Ltd.

(Fernox North Distributor)

15363 117 Avenue

Edmonton, AB T5M 3X4

Canada

www.hydronicagencies.com

Tel: 780-452-8661

Fax: 780-488-2304

Fernox

www.fernox.com

Intercool NFP-30,40,50 AA

Intercool RPH-15*

Interstate Chemical

2797 Freedland Road

P.O. Box 1600

Hermitage, PA 16148-0600

www.interstatechemical.com

Tel: 800-422-2436

Fax: 724-981-8383

Hercules Cryo-tek™-100/Al

Hercules Chemical Company, Inc.

111 South Street

Passaic, NJ 07055

www.herchem.com

Tel: 800-221-9330

Fax: 800-333-3456

* This product may be used to adjust pH level of hydronic system, but on occasion may not resolve pH issue. In these

cases it is recommended to fl ush system and refi ll with untreated water and new boiler manufacturer approved

antifreeze suitable for Aluminum heat exchangers.

Table 8

- Antifreeze Products

System and Operating Precautions

Applies to ALL Aluminum High Effi ciency Gas-Fired Water Boilers

62

INSTALLATION AND CHECK-OUT CERTIFICATE

Boiler Model Serial # Date Installed___________

Measured BTU/HR input____________

Installation instructions have been followed

Checkout procedure and adjustments performed

Maintenance and Service issues reviewed with owner/ maintenance person

Installation booklet affi xed on or adjacent to boiler

Installer (Company)

Address

Phone

Installer’s Name

Signature

INSTALLATION AND CHECK-OUT CERTIFICATE

NOTES

UTICA BOILERS

2201 Dwyer Avenue

Utica NY 13501

web site: www.ecrinternational.com