INSTALLATION MANUAL
GAS-FIRED, DIRECT VENT,
CONDENSING, HOT WATER BOILER
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk, NY 14048
www.dunkirk.com
MEMBER: The Hydronics Institute
An ISO 9001-2000 Certified Company
P/N# 14683301, Rev. A [08/08]
90-50-100 GAS-FIRED BOILER
Model No.
90-50
90-75
90-100
These instructions
must be affixed on or
adjacent to the boiler.
! WARNING
Improper installation, adjustment, alteration, service,
or maintenance can cause injury or property damage.
Refer to this manual. For assistance or additional information consult a qualified installer, service agency,
or the gas supplier.
! CAUTION
Read all instructions carefully before starting the
installation.
Save this manual for reference.
2
Table Of Contents
Introduction............................................................................................................................................................ 6
Boiler Ratings & Capacities.................................................................................................................................... 7
Boilers For Use At High Altitude............................................................................................................................ 8
Rules For Safe Installation And Operation.......................................................................................................... 10
Before Installing The Boiler................................................................................................................................. 10
A. Codes............................................................................................................................................................................................... 10
B. Boiler Sizing . ................................................................................................................................................................................. 11
C. Considerations For Boiler Location............................................................................................................................................ 11
D. Locating The Boiler....................................................................................................................................................................... 12
E. Combustion Air And Vent Pipe Requirements......................................................................................................................... 12
F. Condensate Drain Requirements................................................................................................................................................. 13
G. Foundation Requirements............................................................................................................................................................ 14
H. Removal Of Existing Boiler From Common Vent System...................................................................................................... 14
Placing The Boiler................................................................................................................................................. 15
Near Boiler Piping................................................................................................................................................. 15
A. Supply And Return Lines............................................................................................................................................................. 15
B. Pressure Relief Valve..................................................................................................................................................................... 19
C. Expansion Tank And Make-Up Water........................................................................................................................................ 19
D. Condensate Drain Piping............................................................................................................................................................. 22
E. Filling Condensate Trap With Water ......................................................................................................................................... 23
F. Chilled Water Piping...................................................................................................................................................................... 23
Combustion Air and Vent Pipe............................................................................................................................. 23
A. Connections And Termination.................................................................................................................................................... 23
B. Installation...................................................................................................................................................................................... 29
Gas Supply Piping................................................................................................................................................. 29
A. Check Gas Supply.......................................................................................................................................................................... 29
B. Connecting The Gas Piping.......................................................................................................................................................... 30
C. Checking The Gas Piping............................................................................................................................................................. 30
Electrical Wiring.................................................................................................................................................... 31
A. Electric Power Supply.................................................................................................................................................................. 31
B. Install Your Thermostat................................................................................................................................................................. 32
C. Connect Circulator Pump Wiring............................................................................................................................................... 32
Controls and Accessories...................................................................................................................................... 36
A. Integrated Boiler Control (IBC)................................................................................................................................................. 36
B. Gas Control Valve......................................................................................................................................................................... 36
C. Hot Surface Igniter....................................................................................................................................................................... 36
D. High Limit Aquastat Control...................................................................................................................................................... 36
E. Draft Inducer Temperature Safety Switch.................................................................................................................................. 36
F. Casting Temperature Safety Switch.............................................................................................................................................. 36
3
Table Of Contents
G. Differential Pressure Air Proving Switch/Blocked Vent Safety Shutoff.................................................................................. 36
H. Draft Inducer................................................................................................................................................................................. 37
I. Circulator Pump............................................................................................................................................................................. 37
J. Drain Valve...................................................................................................................................................................................... 37
K. A.S.M.E. Rated Pressure Relief Valve......................................................................................................................................... 37
L. Blocked Vent Safety Shutoff......................................................................................................................................................... 37
M. External Condensate Pump (Optional) . .................................................................................................................................. 37
Water Treatment & Freeze Protection................................................................................................................ 38
Piping Recommendations................................................................................................................................................................. 38
Water Chemistry................................................................................................................................................................................. 38
Cleaning the Hydronic System......................................................................................................................................................... 39
Freeze Protection................................................................................................................................................................................ 39
Start Up.................................................................................................................................................................. 40
A – Filling Boiler With Water And Purging Air For Systems With Diaphragm Type Expansion Tanks............................... 40
B – Purging Air For Systems With Conventional Closed Type Expansion Tanks:.................................................................... 40
C - Placing Boiler In Operation........................................................................................................................................................ 41
Check Out Procedure and Adjustment................................................................................................................ 42
A. Verify Proper Sequence Of Operation....................................................................................................................................... 42
B. Inspect Venting And Air Intake System...................................................................................................................................... 43
C. Inspect Condensate Drain............................................................................................................................................................ 43
D. Inspect System Piping................................................................................................................................................................... 43
E. Test Ignition System Safety Shutoff Device................................................................................................................................. 43
F. Test High Limit Control And Adjust........................................................................................................................................... 44
G. Test Other Safety Controls........................................................................................................................................................... 44
H. Set Thermostat Heat Anticipator (If Used) And Verify Thermostat Operation................................................................... 44
I. Measure The Natural Gas Input Rate........................................................................................................................................... 44
J. Set Thermostat To Desired Room Temperature.......................................................................................................................... 45
K. Review All Instructions................................................................................................................................................................ 45
Maintanance And Cleaning.................................................................................................................................. 48
Beginning Of Each Heating Season................................................................................................................................................. 48
Daily During Heating Season........................................................................................................................................................... 48
Monthly During Heating Season...................................................................................................................................................... 49
Periodically During Heating Season................................................................................................................................................ 49
End Of Each Heating Season - Annual Shutdown Procedure...................................................................................................... 49
Annual Examination And Cleaning Of Boiler Components....................................................................................................... 49
Detailed Sequence Of Operation......................................................................................................................... 51
Troubleshooting................................................................................................................................................... 54
Differential Air Pressure Switch Check................................................................................................................ 62
Repair Parts........................................................................................................................................................... 64
4
Introduction
This appliance is a gas-fired direct vent hot water boiler with
cast aluminum boiler sections. A revolutionary cast aluminum
heat exchanger means better heat transfer and thermal storage
than similarly sized cast iron boilers, which results in higher
efficiency. The heating system water absorbs large amounts of
heat from the cast aluminum heat exchanger, cooling the flue
gases and causing condensation. Sealed combustion, premix
gas burner, and low flame temperature means drastically
reduced CO and NOx emissions, which contribute to a cleaner
and healthier environment.
This appliance, unlike normal residential atmospheric and
induced draft units, takes its combustion air directly from
the outdoors (sealed combustion) and does not compete with
building occupants for fresh air. Sealed combustion (also
known as “direct vent”) is the safest and best way to obtain
plenty of clean combustion air. The induced draft fan draws
in the outside combustion air, then takes the cooler flue gases
from the boiler unit and provides a positive removal of the flue
gases from the building through inexpensive and readily available PVC and CPVC pipes.
Figure 1
5
Boiler Ratings & Capacities
Model
TABLE #1 – SEA LEVEL RATINGS – NATURAL AND PROPANE GASES
Input
++ Heating Capacity
Net I=B=R Rating
Shipping
Flue Dia.
*(MBH)
Weight (lbs.)
*(MBH) *(MBH)
90-50
50
90-75
75
90-100
100
* 1 MBH = 1,000 Btuh
45
68
90
39
220
59
220
78
220
Btuh = British Thermal Units Per Hour
These low pressure gas-fired hot water boilers are design certified by CSA International for use with natural and propane
gases. The boilers are constructed and hydrostatically tested for
a maximum working pressure of 50 psig (pounds per square
inch gage) in accordance with A.S.M.E. (American Society of
Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.
2” CPVC & PVC
2” CPVC & PVC
2” CPVC & PVC
The Net I=B R Ratings shown are based on a piping and pickup
factor of 1.15 in accordance with the I=B=R Standard as published by the Hydronics Institute. The Net I=B=R Rating of the
boiler selected should be greater than or equal to the calculated
peak heating load (heat loss) for the building or area(s) served
by the boiler and associated hot water heating systems. The
manufacturer should be consulted before selecting a boiler for
installations having unusual piping and pickup requirements.
++ AFUE (Annual Fuel Utilization Efficiency) and Heating
Capacity is based on the D.O.E. (Department of Energy) test
procedure.
The boilers are factory equipped for operation at altitudes
ranging from 0-2,000 feet above sea level. For use of these boilers at altitudes above 2,000 feet above sea level, the gas input
ratings (MBH) automatically reduced.
The Boilers are certified in accordance with ANSI (American
National Standards Institute) Z21.13 standards as gas-fired,
direct vent, condensing, hot water boilers.
The Heating Capacity indicates the amount of heat available
after subtracting the losses up the stack. Most of this heat is
available to heat water. A small portion is heat from the jacket
and surfaces of the boiler, and it is assumed that this heat stays
in the structure. The Net I=B=R Rating represents the portion
of the remaining heat that can be applied to heat the radiation
or terminal units (i.e. finned tube baseboard, cast iron radiators, radiant floor, etc.). The difference between the Heating
Capacity and the Net I=B=R Rating, called the piping and
pickup allowance, establishes a reserve for heating the volume
of water in the system and offsetting heat losses from the piping.
6
Boilers For Use At High Altitude
The boilers (with the exception of the 90-75 LP product)
are factory equipped for operation at altitudes ranging from
0-10,000 feet above sea level. No changes to the 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 the gas
manifold pressure will need to be adjusted based upon calorific
(Btu) value of supply gas (contact local gas utility or distributor
for this value). For specific settings refer to Table #1 for natural
gas applications and Table #2 for LP gas applications. Instructions on how to adjust the gas manifold pressure settings are
shown in Figures #17 & #18.
Altitude in Ft.
Normal Input (MBH)
Manifold Pressure In W.C.
Orifice
Altitude in Ft.
Note that 90-75 LP applications for 5,000 - 10,000 feet above
sea level will require an orifice change as well as a gas manifold
pressure adjustment based upon calorific (Btu) value of supply
gas. Refer to Table #2 for altitude orifice kit part number. For
replacing the orifice refer to specific instructions included with
the kit.
TABLE #1: SERIES 90 NATURAL GAS
Series 90-50
Stock Factory
Btu Value of Natural Gas++
Settings
750
850
950
1000
0-5,000
5,000-10,000
50
–
–
–
–
2.5
4
4
3.5
2.5
43331094
43331094
Series 90-75
Stock Factory
Btu Value of Natural Gas++
Settings
750
850
950
1000
0-5,000
5,000-10,000
Normal Input (MBH)
75
–
–
Manifold Pressure In W.C.
Orifice
2.5
43331092
3.5
3.5
Altitude in Ft.
Series 90-100
Stock Factory
Settings
750
0-5,000
100
–
–
Manifold Pressure In W.C.
Orifice
2.5
43331090
3.5
3.5
7
2.5
43331092
–
2.5
43331090
–
2.5
1050
–
–
2.5
2.5
Btu Value of Natural Gas++
850
950
1000
5,000-10,000
Normal Input (MBH)
++Contact local gas utility or distributor for Btu value of gas.
–
1050
1050
–
–
2.5
2.5
Boilers For Use At High Altitude
NOTE: For model 90-75 LP units only at altitudes above 5,000 ft., install 90-75 High Altitude Orifice Kit
#550001810*. For all other altitudes use factory installed orifice.
Altitude in Ft.
Normal Input (MBH)
TABLE #2: SERIES 90 PROPANE GAS
Series 90-50
Stock Factory
Btu Value of LP Gas++
Settings
2300
2350
2400
2450
0-5,000
5,000-10,000
–
–
–
–
50
Manifold Pressure In W.C.
2.5
Orifice
43331095
Altitude in Ft.
Normal Input (MBH)
Manifold Pressure In W.C.
Orifice
3
3
2.5
2.5
2500
–
2.5
43331095
Series 90-75*
Stock Factory
Btu Value of LP Gas++
Settings
2300
2350
2400
2450
0-5,000
5,000-10,000
–
–
–
–
75
2.5
3.5
3.5
3.5
3
43331096*
43331093
2500
–
3
* For model 90-75 LP units only at altitudes above 5,000 ft., install 90-75 High Altitude Orifice Kit #550001810. For all other altitudes use factory installed orifice.
Altitude in Ft.
Normal Input (MBH)
Manifold Pressure In W.C.
Orifice
Series 90-100
Stock Factory
Btu Value of LP Gas++
Settings
2300
2350
2400
2450
0-5,000
5,000-10,000
–
–
–
–
100
2.5
3
3
3
2.5
43331091
43331091
++Contact local gas utility or distributor for Btu value of gas.
8
2500
–
2.5
Rules For Safe Installation And Operation
8. Follow a regular service and maintenance schedule for efficient and safe operation.
1. Read the entire installation manual before beginning the
installation. Failure to follow these rules for safe installation and operation and these instructions could cause
a malfunction of the boiler and result in death, serious
bodily injury, and/or property damage.
9. Keep boiler area clean of debris and free of combustible
and flammable materials.
10. Proper through the wall or through the roof combustion
venting shall be in accordance with the materials and
methods described in this manual. Installation must comply with local codes.
2. Check all applicable state and local building codes and
utility company requirements before installation. The
installation must conform with these requirements in their
entirety. In the absence of these codes, use NFPA Installation Codes and good industry practice.
11. This boiler and related hot water heating systems are not
do it yourself items. They must be installed and serviced by
qualified professionals.
3. Before servicing the boiler - allow the boiler to cool. Always shut off any electricity and gas supply connected to
the boiler prior to servicing.
4. Inspect gas line for leaks.
! WARNING
5. Be certain gas input rate is correct. Over firing may result
in early failure of the boiler sections. This may cause
dangerous operation. Under firing may result in too much
air for the pre-mix burner causing poor or loss of combustion.
This boiler has been equipped for residential installations.
If used for commercial applications, any additional code
requirements must be adhered to for installation. This may
require additional controls including but not limited to a
low water cut off, a manual reset high temperature limit, and
wiring and/or piping modifications. The manufacturer is
not responsible for any field installation changes made to a
boiler installation which are not described or acknowledged
in this manual.
6. Never vent the products of combustion from this boiler
to an enclosed space. Always vent to the outdoors. Never
vent to another room or to inside a building.
7. Be sure there is adequate outdoor air supply to boiler for
complete combustion.
Before Installing The Boiler
Complete all of the following prior to installing the boiler.
Important - In the state of Massachusetts this product
must be installed by a licensed plumber or gas fitter and the
installation must be in accordance with 248 CMR.
A. Codes
This boiler product is a gas-fired, direct vent, condensing boiler
and must be installed in accordance with all applicable federal,
state and local building codes including, but not limited to the
following:
The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1 - latest revision.
United States - Installation shall conform with National Fuel
Gas Code (NFPA-54/ANSI Z223.1-latest edition)
Installers - Follow local regulations with respect to installation
of CO (Carbon Monoxide) Detectors. Follow maintenance
recommendations in this manual.
Canada - Installation shall be in accordance with CSA B 149.1
and .2. installation codes.
Installation Requirements Specific To The State Of
Massachusetts For Direct Vent, Mechanical Vent, And
Domestic Hot Water Appliances
For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the commonwealth and where the
side wall exhaust vent termination is less than seven (7)
Where required by the authority having jurisdiction, the installation must conform to the American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for
Automatically Fired Boilers, No.CSD-1.
9
BEFORE INSTALLING THE BOILER
feet above finished grade in the area of the venting, including but not limited to decks and porches, the following
requirements shall be satisfied:
5. Product-approved vent/air-intake: a product-approved
vent terminal must be used and, if applicable, a productapproved air intake must be used. Installation shall be in
strict compliance with the manufacturer’s instructions.
1. Installation of carbon monoxide detectors: at the time of
installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with
an alarm and battery back-up is installed on the floor level
where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery
operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the responsibility
of the property owner to secure the services of qualified
licensed professionals for the installation of hard wired
carbon monoxide detectors.
6. Installation instructions: a copy of all installation instructions for all product approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts
lists for venting instructions, and/or all venting design
instructions shall remain with the appliance or equipment
at the completion of the installation.
B. Boiler Sizing
Check to be sure you have selected the boiler with the proper
capacity before starting the installation. The I=B=R Rating of
the boiler selected should be greater than or equal to the calculated peak heating load (heat loss) for the building or area(s)
served by the boiler and associated hot water heating systems.
See the table “BOILER RATINGS AND CAPACITIES”.
A. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent
floor level.
Heat loss calculations should be based on approved industry
methods.
C. Considerations For Boiler Location
Before selecting a location for the boiler, the following should
be considered. Each boiler considered.
B. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply
with the above requirements; provided, however, that
during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
•Supplied with the correct type of gas (natural gas or propane).
•Connected to a suitable combustion air intake piping system to supply the correct amounts of fresh (outdoor) air
for combustion, refer to Combustion Air And Vent Pipe
section (near center of this manual) for details.
2. Approved carbon monoxide detectors: each carbon monoxide detector as required in accordance with the above
provisions shall comply with nfpa 720 and be ansi/ul 2034
listed and ias certified.
•Connected to a suitable venting system to remove the hazardous products of gas combustion, refer to Combustion
Air And Vent Pipe section (near center of this manual) for
details.
3. Signage: a metal or plastic identification plate shall be
permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in
line with the exhaust vent terminal for the horizontally
vented gas fueled heating appliance or equipment. The
sign shall read, in print size no less than one-half (1/2)
inch in size, “gas vent directly below. Keep clear of all
obstructions”.
•Connected to a suitable hot water heating system.
•Supplied with a suitable electrical supply for all boiler motors and controls.
•Connected to a properly located thermostat or operating
control. (not included with boiler)
•Placed on level surface (must NOT be installed on carpeting)
4. Inspection: the state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 cmr
5.08(2)(A)1 through 4.
•Condensate drain line must be pitched down to floor drain
or external condensate pump with reservoir at ¼” per foot
(wood frame or blocks may be used to raise boiler).
10
BEFORE INSTALLING THE BOILER
11. Equipment shall be installed in a location which facilitates
the operation of venting and combustion air intake piping
systems as described in this manual.
D. Locating The Boiler
7. Select a location which is level, central to the piping systems served and as close to the vent and air intake terminals as possible.
12. Advise owner of boiler to keep venting and combustion
air intake passages free of obstructions. both the venting
and combustion air intake piping systems connected to
the outdoors must permit flow through the piping systems
without restrictions for the boiler to operate.
8. Accessibility clearances, if more stringent (i.e. larger clearances) than required fire protection clearances, must be
used for the boiler installation. Accessibility clearances
may be achieved with the use of removable walls or partitions.
13. The boiler shall be installed such that the automatic gas ignition system components are protected from water (dripping, spraying, rain, etc.) during operation and service
(circulator replacement, control replacement, etc.).
9. The boiler is approved for installation in closets and on
combustible floors. This boiler shall NOT be installed on
carpeting.
E. 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 flue products are discharged to
outside atmosphere.
10. The clearances shown in Table #2 indicate required clearances per IAS listing. A minimum 1” clearance must be
maintained between combustible construction and each
of the left, top and back surfaces of the boiler. A minimum
8” clearance is required on the right side, to allow room
for the inlet air pipe. An 18” clearance must be maintained
at a side where passage is required to access another side
for cleaning or servicing, inspection or replacement of
any parts that normally may require such attention. Allow
at least 24” at the front and left side and 8” at the top for
servicing. No clearances are required to venting or combustion air intake piping.
Combustion air and vent pipe connections must terminate together in the same atmospheric pressure zone, either through
the roof or sidewall (roof termination preferred). See Figures
#9 & #10 (in Combustion Air And Vent Pipe section near
center of this manual) for required clearances.
TABLE #2 - BOILER CLEARANCES
Unit
Combustible Clearance
Inch (mm)
Accessibility, Cleaning, and Servicing
Inch (mm)
Top
1 (25.4)
8 (203.2)
Left Side
1 (25.4)
24 (609.6)
Right Side
8 (203.2)
-
Base
1 (25.4)
-
Front
0 (0)
24 (609.6)
Back
Intake/Vent Piping
1 (25.4)
0 (0)
-
Near Boiler Hot Water Piping
1 (25.4)
-
All distances measured from the cabinet of the boiler.
11
BEFORE INSTALLING THE BOILER
! CAUTION
F. Condensate Drain Requirements
Condensate drain line to be pitched down to floor drain at a
minimum of ¼” per foot. An external condensate pump (not
furnished) may be used if floor drain is not available. The
condensate pump must be designed for flue gas condensate
application.
Keep boiler area clean of debris and free of flamable and
combustible materials, vapors and liquids.
! WARNING
When vent pipe is exposed to temperatures below freezing,
such as when it passes through an unheated space or when
a chimney is used as a raceway, vent pipe must be insulated
with 1/2” Armaflex or equivalent. In extreme cold climate
areas, use ¾” Armaflex or equivalent.
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
fluorides, chlorides, phosphates, bromides and iodides.
These elements are found in aerosols, detergents, bleaches,
cleaning solvents, salts, air fresheners, paints, adhesives and
other household products.
Locate combustion 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 exactly as shown in Figure #9 or 10 (in Combustion
Air And Vent Pipe section near center of this manual).
Vent connections serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
Solvent cements are combustible. Keep away from heat,
sparks, and open flame. Use only in well ventilated areas.
Avoid breathing in vapor or allowing contact with skin or
eyes.
FAILURE TO FOLLOW THE AFOREMENTIONED
WARNINGS COULD RESULT IN FIRE, PROPERTY
DAMAGE, PERSONAL INJURY, OR DEATH.
Notes:
1. Condensate trap is built into the boiler, an external trap is
not required and should not be used.
2. Wood frame or blocks may be used to raise the boiler to
maintain drain pitch or to be above external condensate
pump reservoir.
3. There is a 115 Volt AC receptacle provided on the service
switch junction box which is located at the boiler right
side, to provide power for an external condensate pump (if
needed).
12
BEFORE INSTALLING THE BOILER
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. Close fire dampers.
G. Foundation Requirements
Boiler must be placed on level surface. Boiler is NOT to be
installed on carpeting.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliances
will operate continuously.
Notes:
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.
5. Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle, or the smoke from a cigarette, cigar or
pipe.
6. After it has been determined that each appliance remaining connected to the common venting system properly
vents when tested as outlined above, return doors, windows, exhaust fans and any other gas-burning appliance to
their previous condition of use.
H. 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.
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-latest revision, or section 5 of CSA-B 149 for Canadian standards.
When resizing any portion of the common venting system,
the common venting system should be resized to approach
the minimum size as determined using the appropriate
tables in part 11 in the National Fuel Gas Code, NFPA-54/
ANSI- Z223.1-latest revision, or section 5 of CSA-B 149
for Canadian standards.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage, or restrictions, leakage, corrosion and other deficiencies which
could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting
system are located and other spaces of the building. Turn
13
Placing The Boiler
The boiler should be placed to provide the most direct connections to the combustion air, vent and system piping as possible.
Place crated boiler as close to selected location as possible and
uncrate boiler. The uncrated boiler may be moved into position
with an appliance dolly or 2-wheel hand truck. The dolly or
hand truck should be inserted under the left hand side of the
boiler. It is possible to slide the boiler for a short distance on a
smooth floor or surface.
Note: refer to manual section “locating the boiler” for
required clearances for servicing and maintenance.
Near Boiler Piping
When the installation of the boiler is for a new heating system,
first install all of the radiation units (panels, radiators, baseboard, or tubing) and the supply and return mains. After all
heating system piping and components have been installed,
make final connection of the system piping to the boiler. A hot
water boiler installed above radiation level must be equipped
with a low water cut off device. A periodic inspection is necessary us is flushing of float type devices, per low water cut off
manufacturers specific instructions.
! CAUTION
Copper supply and return piping must NOT be installed directly into aluminum boiler section casings due to galvanic
corrosion between dissimilar metals. Iron or steel bushings
or pipe nipples should be used between copper system piping and boiler to make final connection to boiler. Also, the
use of dielectric unions is acceptable. The packaged boiler is
furnished with iron piping in the front boiler section for the
supply and return connections.
A. Supply And Return Lines
The packaged boiler unit is set up to receive 1 ¼” NPT supply
and return piping from top access. The boiler unit can also
be piped from the left side by turning the supply elbow, and
from the rear of the unit by removing plugs in the rear boiler
section.
NOTE: The circulator pump and isolation valves are furnished within a carton inside the boiler cabinet and can be
installed at the installer preferred location.
14
Near Boiler Piping
Figure 2 - Single Zone Boiler Piping
15
Near Boiler Piping
Figure 3 - Multi-zone Boiler Piping With Zone Valves
16
Near Boiler Piping
Figure 4 - Multi-Zone Boiler Piping With Circulators
NOTE: When zoning with circulators, the furnished circulator pump should be used as one of the zone
pumps. Each stripped end of the electrical wires for the circulator pump inside the junction box should be
taped or wire nutted to prevent short circuits. Unplug the circulator pump wiring at the integrated boiler
control.
17
Near Boiler Piping
Figure 5 - Single Zone Boiler Piping
B. Pressure Relief Valve
The boiler is furnished with a factory installed relief valve in
the top of the boiler. Provide ¾” piping from the supplied
relief valve to a local floor drain, but leave an air gap between
piping and drain. No shutoff of any description shall be placed
between safety relief valve and the boiler, or on the discharge
pipes between such safety valve and the atmosphere. Installation of the safety relief valve shall conform to ANSI/ASME
Boiler and Pressure Vessel Code, Section IV. The manufacturer
is not responsible for any water damage.
C. Expansion Tank And Make-Up Water
Determine required system fill pressure, system design temperature, and system water content. Boiler contains 2.6 gallons
(U.S.). Size expansion tank accordingly. Consult expansion
tank manufacturer for proper sizing information. Connect
properly sized expansion tank (not furnished) as shown in
Figure #6 for diaphragm type expansion tank and Figure #7
for conventional closed type expansion tanks. For diaphragm
type expansion tanks, adjust the tank air pressure to match the
system fill pressure. Install air vent (furnished) as shown for
diaphragm type expansion tank system only. Install makeup water connections as shown per local codes. If a pressure
reducing valve is used, adjust to match the system fill pressure.
In connecting the cold make-up water supply to the boiler,
make sure that clean water supply is available. When the water
supply is from a well or pump, sand strainer should be installed
at the pump.
18
Near Boiler Piping
Figure 6 - Diaphragm Type Expansion Tank Piping
19
Near Boiler Piping
Figure 7 - Conventional (closed type) Expansion Tank Piping
20
Near Boiler Piping
Figure 8 - Condensate Drain Piping
The ½” diameter schedule 40 PVC or CPVC condensate drain
and pipe fittings must conform to ANSI standards and ASTM
D 1785 or D2846. Schedule 40 PVC or CPVC cement and
primer must conform to ASTM D2564 or F493. In Canada,
use CSA or ULC certified schedule 40 PVC or CPVC drain
pipe cement.
D. Condensate Drain Piping
The condensate trap is built into the boiler, an external trap is
not required and should NOT be used.
Provide ½” PVC condensate drain and fittings. Condensate
drain to be pitched down to floor drain at a minimum of ¼”
per foot.
A condensate pump with a reservoir (not furnished) may be
used to remove condensate to a drain line (sanitary line) above
boiler if a floor drain is not available or its in accessible.
Install furnished ½” PVC tee to overflow fitting as shown in
Figure #8.
21
Near Boiler Piping
E. Filling Condensate Trap With Water
On The Initial Start Up The Condensate Trap Must Be Manually Filled With Water.
F. Chilled Water Piping
The boiler, when used in connection with a refrigeration system, must be installed so the chiller medium is piped in parallel with the boiler with appropriate valves to prevent the chilled
medium from entering the boiler.
The following are the steps required to initially fill the condensate trap for start up, these steps are only required at the initial
start up or if maintenance requires draining of the condensate
trap:
The boiler piping system of a hot water boiler connected to
heating coils is located in air handling units where they may be
exposed to refrigerated air circulation must be equipped with
flow control valves or other automatic means to prevent gravity
circulation of the boiler water during cooling cycle.
1. Disconnect the vent condensate drain line from the bottom of the vent tee on the boiler.
2. Pour about 1 cup of cold tap water into the vent drain line
with a proper funnel.
3. Excess water should go through the overflow and out
through the condensate drain line. Verify proper operation of the drain line (or external condensate pump if
used).
4. Reinstall the vent drain line.
Combustion Air and Vent Pipe
A. Connections And Termination
For boilers connected to gas vents or chimneys, vent installations shall be in accordance with part 7, Venting of Equipment,
of the National Fuel Gas Code, ANSI 2223.1-latest revision,
CAN/CGA-B 149.1 and B 149.2, and applicable provisions of
the local building codes.
1. Refer to Combustion Air And Vent Pipe section that
follows, also see Figures #9 & #10 for combustion air and
vent pipe roof and sidewall termination. (Roof termination is preferred) Combustion air and vent pipes must
terminate together in same atmo spheric pressure zone as
shown. Construction through which vent and air intake
pipes may be installed is a maximum 24 inches, minimum
¼” thickness.
Provisions for combustion and ventilation air must be in accordance with section 5.3, Air For Combustion and Ventilation, of
the National Fuel Gas Code,ANSI 2223.1-latest revision, CAN/
CGA-B 149.1 and B 149.2, or applicable provisions of the local
building code.
2. Combustion air and vent pipe fittings must conform to
American National Standards Institute (ANSI) standards
and American Society for Testing and Materials (ASTM)
standards D1784 (schedule-40 CPVC), D1785 (schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and
SDR-26 PVC), D2661 (ABS-DWV), or F628 (schedule-40
ABS). Pipe cement and primer must conform to ASTM
standards D2564 (PVC) or D2235 (ABS).
These boilers require a dedicated direct vent system. All air
for combustion is taken directly from outdoors through the
combustion air intake pipe. All flue products are discharged to
the outdoors through the vent pipe.
In Canada construct all combustion air and vent pipes for this
unit of CSA or ULC certified schedule-40 CPVC, schedule-40
PVC, PVC-DWV or ABS-DWV pipe and pipe cement. SDR
pipe is NOT approved in Canada.
22
Combustion Air and Vent Pipe
3. Combustion air and vent piping connections on boiler
are sized for 2” pipe. Any pipe size change (to 3”) must be
made outside of the boiler casing in a vertical run of pipe
to allow for proper drainage of vent condensate. Due to
potential for flue gas temperatures over 155°F, the first five
(5) feet of vent pipe must be CPVC, the remaining vent
pipe can be PVC. If any elbows are employed within the
first 5 feet of vent, they must be CPVC too. Two (2) - 30”
pieces of 2” CPVC pipe are furnished with the boiler.
NOTE: The transition from 2” pipe to 3” pipe must be made
in a vertical run.
Maximum Allowable Temperatures
Of Typical Non-Metallic Vent Material
Material
HDT
°F
RTI
°C
°F
°C
PVC
158
70
–
–
CPVC
210
100
–
–
ABS
180
82
–
–
Radel - A200
414
212
–
–
Standard
ASTM F891 *
ASTM D2665 **
ASTM D1785 **
ASTM D2241 **
ASTM D2846 **
ASTM F441 **
ASTM F442 **
ASTM D2661 ***
ASTM F628 ***
UL-1738
ULC S636
* Allowable temperatures based on Classifications covered in ASTM D4396 [Deflection Temperatures under Load
(264 psi) (1819KPa)].
** Allowable temperatures based on Classifications covered in ASTM D1784 [Deflection Temperatures under Load
(264 psi) (1819KPa)].
*** Allowable temperatures based on Classifications covered in ASTM D3965 [Deflection Temperatures under Load
(264 psi) (1819KPa)].
23
Combustion Air and Vent Pipe
4. Combustion air and vent piping lengths:
Combustion air and vent piping lengths
BOILER
SIZE
2” PIPE MINIMUM
VENTING
2” PIPE MAXIMUM
VENTING”
3” PIPE MINIMUM
VENTING
3” PIPE MAXIMUM
VENTING”
100
8 FEET
21 FEET
27 FEET
92 FEET
75 & 50
8 FEET
26 FEET
32 FEET
112 FEET
The first 5 feet of “TOTAL EQUIVALENT LENGTH” of vent
piping run must be CPVC:
The length of pipe is counted from the boiler jacket (air intake
pipe) or from vent tee (vent pipe) the termination is not
counted toward the “Total Equivalent Length”.
For additional elbows, reduce the maximum vent length as
shown:
• 2” 90 degree elbow -1 ½ feet per additional elbow. • 3” 90 degree elbow - 3 feet per additional elbow.
Example:
To add 2 additional 90 degree elbows to a 3” pipe for a 75 boiler.
Each elbow is 3 additional feet per 90 degree elbow for a total of 6 feet.
(1 elbow @ 3 feet + 1 elbow @ 3 feet = 6 additional feet of pipe)
The total additional pipe is then subtracted from the maximum allowable pipe length to give the new maximum length of 94
feet with 6, 90 degree elbows.
(“TOTAL EQUIVALENT LENGTH”):
Original 100 feet max. - 6 feet for 2 additional elbows = new 94 feet maximum length.
5. Combustion air and vent piping to be pitched back to boiler at minimum ¼” per foot from intake and vent terminals
so that all moisture in combustion air and vent piping
drains to boiler. Pipes must be pitched continuously with
no sags or low spots where moisture can accumulate and
block the flow of air or flue gas. Combustion air and vent
pipes must be airtight and watertight.
24
Combustion Air and Vent Pipe
snow may cause the boiler to shut down if the vent becomes obstructed.
6. Consideration for the following should be used when
determining an appropriate location for termination of
combustion air and vent piping.
•Under certain conditions, flue gas will condense, forming moisture, and may be corrosive. In such cases, steps
should be taken to prevent building materials at the vent
from being damaged by exhaust of flue gas.
7. The venting system shall terminate at least 3 feet above any
forced air inlet (except the boiler’s combustion air inlet)
within 10 feet. The venting system shall terminate at least
12 inches from any air opening into any building. The
bottom of the vent shall be located at least 12 inches above
grade. Termination of the vent shall be not less than 7 feet
above an adjacent public walkway. The vent terminal shall
not be installed closer than 3 feet from the inside corner of
an L shaped structure. Termination of the vent should be
kept at least 3 feet away from vegetation. The venting system shall terminate at least 4 feet horizontally from, and in
no case above or below, unless a 4 foot horizontal distance
is maintained, from electric meters, gas meters, regulators,
and relief equipment.
•Comply with all clearances required as stated in paragraph
7.
•Termination should be positioned where vent vapors will
not damage plants/shrubs or air conditioning equipment.
•Termination should be positioned so that it will not be effected by wind eddy, air born leaves, snow, or recirculated
flue gases.
•Termination should be positioned where it will not be
subjected to potential damage by foreign objects, such as
stones, balls, etc..
•Termination should be positioned where vent vapors are
not objectionable.
•Put vent on a wall away from the prevailing winter wind.
Locate or guard the vent to prevent accidental contact
with people or pets.
•Terminate the vent above normal snowline. Avoid locations where snow may drift and block the vent. Ice or
Figure 9 - Roof Vent / Intake terminations
25
Combustion Air and Vent Pipe
Figure 10 - Side Wall Vent / Intake terminations
Less Than 12” Clearance
12” Or More Clearance
26
Combustion Air and Vent Pipe
Figure 11 - Combustion Air and Vent Piping
27
Combustion Air and Vent Pipe
B. Installation
1. Attach combustion air intake piping to supplied Fernco
2” coupling on mixer. Attach vent piping to furnished 2”
CPVC vent tee on draft inducer outlet.
8. While cement is still wet, insert pipe into socket with ¼
turn twist. Be sure pipe is fully inserted into fitting socket.
9. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made
joint.
NOTE: All pipe joints are to be water tight.
2. Working from the boiler to the outside, cut pipe to required length(s).
10. Handle pipe joint carefully until cement sets.
11. Support combustion air and vent piping a minimum of
every 5 feet using pre-formed metal hanging straps. Do
not rigidly support pipes. Allow movement due to expansion and contraction.
3. Deburr inside and outside of pipe.
4. Chamfer outside edge of pipe for better distribution of
primer and cement.
12. Slope combustion air and vent pipes toward boiler a minimum of ¼” per linear foot with no sags between hangers.
5. Clean and dry all surfaces to be joined.
6. Check dry fit of pipe and mark insertion depth on pipe.
13. Use appropriate methods to seal openings where vent and
combustion air pipes pass through roof or side wall.
NOTE: It is recommended that all pipes be cut, prepared,
and pre-assembled before permanently cementing any joint.
7. After pipes have been cut and pre-assembled, apply cement primer to pipe fitting socket and end of pipe to
insertion mark. Quickly apply approved cement to end
of pipe and fitting socket (over primer). Apply cement
in light, uniform coat on the inside of socket to prevent
buildup of excess cement. Apply second coat.
Gas Supply Piping
A. Check Gas Supply
The gas pipe to your boiler must be the correct size for the
length of run and for the total Btu per hour input of all gas utilization equipment connected to it. See Table #3 for the proper
size (next page). Be sure your gas line complies with local
codes and gas company requirements.
system during any pressure testing of that system at test pressures in excess of ½ psig (3.5kpa).
The boiler must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures
equal to or less than ½ psig (3.50ka).
The boiler and its individual shutoff valve must be disconnected from the gas supply piping
NATURAL GAS
PROPANE GAS
MAXIMUM GAS SUPPLY PRESSURE
10” w.c.
14” w.c.
MINIMUM GAS SUPPLY PRESSURE
4” w.c.
10” w.c.
28
Gas Supply Piping
B. Connecting The Gas Piping
Refer to Figure #12 (on following page) for the general layout at the boiler. It shows the basic fittings you will need. The
gas line enters the boiler from the right side jacket panel. The
boiler may receive the gas supply pipe through the left side, or
rear jacket panel by relocating the gas valve connector and pipe
assembly. The boiler is equipped with a ½” NPT connection on
the gas valve for supply piping. The following rules apply:
8. 8.Propane gas connections should only be made by a
licensed propane installer.
9. 9.Two stage regulation should be used by the propane
installer.
10. 10. Propane gas piping should be checked out by the
propane installer.
C. Checking The Gas Piping
After all connection have been made, check immediately
for leaks. Open the manual shutoff valve. Test for leaks by
applying soap suds (or a liquid detergent) to each joint.
Bubbles forming indicate leak. CORRECT EVEN THE
SMALLEST LEAK AT ONCE.
1. 1.Use only those piping materials and joining methods
listed as acceptable by the authority having jurisdiction, or
in the absence of such requirements, by the National Fuel
Gas Code, ANSI Z223.1- latest revision. In Canada, follow
the CSA- B 149.1 and .2 Installation Codes for Gas Burning Appliances and Equipment.
2. 2.Use pipe joint compound suitable for liquefied petroleum gas on male threads only.
! WARNING
3. 3.Use ground joint unions.
Never use a match or open flame to test for leaks.
4. 4.Install a sediment trap upstream of gas controls.
5. 5.Use two pipe wrenches when making the connection to
the gas valve to keep it from turning.
6. 6.Install a manual shutoff valve in the vertical pipe about 5
feet above floor.
7. 7.Tighten all joints securely.
Table #3 – Gas Pipe Sizes
NATURAL GAS
Pipe Capacity - BTU Per Hour Input Includes Fittings
Length of
Pipe - Ft.
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
Pipe Capacity - BTU Per Hour Input Includes Fittings
Length of
Pipe - Ft.
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
29
Gas Supply Piping
Figure 12 - Gas Piping
Electrical Wiring
box and power supply connection points. Connect black
(hot) lead from the power supply to either of the unused
brass screws on the service switch. Connect the white
(neutral) lead from the power supply to the white screw on
the service switch. Connect the green (ground) lead from
the power supply to the ground (green) screw on the service switch. The receptacle on the service switch is always
powered regardless of whether the switch is on or off, and
could be used as a power supply for an external condensate
pump if one is used.
! WARNING
Turn off electrical power at fuse box before making any line
voltage connections. Follow local electrical codes.
All electrical work must conform to local codes as well as the
National Electrical Code, ANSI/NFPA70, latest revision. In
Canada, electrical wiring shall comply with the Canadian Electrical Codes, CSAC22.1 and .2
A. Electric Power Supply
Prior to making any line Voltage connections, service switch at
boiler should be in the off position and the power turned off at
the fuse box.
The boiler, when installed, must be electrically grounded in
accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements,
with the National Electrical Code, ANSI/NFPA-70, latest
revision. In Canada, electrical wiring shall comply with the
Canadian Electrical Codes, CSA-C22.1 and .2.
Run a separate 120 Volt circuit from a separate over current
protection device in the electrical service entrance panel. This
should be a 15 ampere circuit. A service switch has been prewired and located on the exterior boiler jacket. See Figure
#13 for diagram showing location of service switch junction
Run a 14 gauge or heavier copper wire from the boiler to
a grounded connection in the service panel or a properly
driven and electrically grounded ground rod.
30
Electrical Wiring
B. Install Your Thermostat
The thermostat location has an important effect on the operation of your boiler system. BE SURE TO FOLLOW THE
INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT.
! CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION
WHEN SERVICING CONTROLS. WIRING ERRORS
CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
Locate the thermostat about five feet above the floor on an
inside wall. It may be mounted directly on the wall or on a
vertical mounted outlet box. It should be sensing average room
temperature. Avoid the Following:
Set heat anticipator at 0.7 amps. Connect 24 Volt thermostat
leads to the two(2) yellow wires located in service switch junction box, located on outer jacket of boiler. See Figure #13 for
service switch junction box and thermostat field wiring connections.
Things to Avoid when Locating Thermostats
DEAD SPOTS:
Corners and alcoves
Behind doors
COLD SPOTS:
HOT SPOTS:
Concealed pipes
Concealed pipes or ducts
Fireplace
TV sets
Stairwells - drafts
Radios
Lamps
Unheated rooms on
Direct sunlight
other side of wall
Kitchens
C. Connect Circulator Pump Wiring
See Figure #13 (following page) for service switch junction
box and circulator pump field wiring connections. A 5 feet wiring harness with flexible metal conduit is supplied to connect
the circulator pump to the service switch junction box. If the
two 120 Volt circulator wire terminals inside the junction box
are not used, please leave the two wire nuts to prevent the short
circuit.
31
Electrical Wiring
Figure 13 - Field Wiring Connections
32
33
NEUTRAL
GRIUND
HOT
1
120 VAC
60 HZ
1Ø
24V
THERMOSTAT
R W
3
1
120
VAC
4
5
VAC
Y 24 Y
3
MV
MV
*
CIRCULATOR
PUMP
W
BK
PUR
PUR
CONTROL
TRANSFORMER
AT14081297
CN9
2
GAS
VALVE
HI LIMIT
AQUASTAT
CONTROL
CASTING TEMPERATURE SAFETY SWITCH
(MANUAL RESET)
W
V
IGNITER
CN12
2
1
DRAFT INDUCER
CN10
HOT SURFACE
IGNITER
DRAFT INDUCER
2
1
DIFFERRENTIAL AIR
PRESSURE SWITCH (N.O.)
BLOWER TEMPERATURE
SAFETY SWITCH
BK
W
G
BK
W
PUR
PUR
BR V
BR
2
2
2
9
8
7
3
2
120VAC
3
3
3
6
5
4
1
1
TRANSFORMER
PRIMARY
4
4
3
2
1
Y
1
1
BK
Y
1
2
1
R
R
R
G
VALVE/FLAME
IGNITER
PURGE
POWER
DIAGNOSTIC
INDICATOR LIGHTS
CN3
R
CN1
IGNITER
CN4
INDUCER
R
Y
24 VAC
TRANSFORMER
2
CN5
CIRCULATOR
CN7
CN6
CONTROL
Y
CH2
1013-10 INTEGRATED BOILER CONTROL
POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLODE PROTECTION AS REQUIRED
USE ONLY COPPER WIRE BETWEEN
DISCONNECT AND THE UNIT.
120 VOLT FIELD WIRING
120 VOLT WIRING
24 VOLT FIELD WIRING
24 VOLT WIRING
NOTE: "CN" LABEL REFERENCE
LOCATION OF CONNECTOR PLUG
BETWEEN SCHEMATIC AND LADDER
DIAGRAM.
1
W = WHITE
BK = BLACK
Y = YELLOW
G = GREEN
R = RED
V = VIOLET
BR = BROWN
PUR =PUPPLE
COLOR DESIGNATION
Electrical Wiring
Figure 14 - D - Schematic Wiring Diagram
If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C
Thermoplastic wire or its equivalent
Electrical Wiring
Figure 15 - E - Ladder Wiring Diagram
120 VOLT
POWER SUPPLY
1
L1
L2
HOT
WHT
BLK
ON/OFF SWITCH
*
P7-1
2K1
P4-3
P4-1
1K1 P10-1
P5-1
CIRCULATOR MOTOR
P6-1
HOT SURFACE IGNITER
P12-1
P1-1
3 VAC
1
24
VAC
5
CASTING TEMPERATURE
SAFETY SWITCH
(MANUAL RESET)
1
1
P3-5
R
W
P3-7
THERMOSTAT
P2-2
P9-3
P3-1
DIFFERENTIAL AIR
PRESSURE SWITCH
MV
P9-2 P3-2
INDICATOR LIGHTS
POWER
PURGE
IGNITER
VALVE
FLAME
P3-3
P3-6
BLOWER
TEMPERATURE
SAFETY SWITCH
P3-4
MV
MICROPROCESSOR
ELECTRONIC
LOGIC & TIMERS
HIGH LIMIT
AQUASTAT
CONTROL
P3-9
P1-3
GAS VALVE
VR8205A
3
2
5K2
TRANSFORMER
4
4K1 3K1
P6-2
P12-2
120
P2-1
P5-3
P10-2
DRAFT INDUCER
5K1
P7-3
5K
4K
3K
2K
1K
1013-10 CONTROL
1
POWER SUPPLY. PROVIDE
DISCONNECT MEANS AND
OVERLOAD PROTECTION AS
REQUIRED USE ONLY COPPER
WIRE BETWEEN DISCONNECT
AND THE UNIT
NOTE: "P" LABEL REFERENCE
LOCATION OF CONNECTOR PLUG
BETWEEN SCHEMATIC AND
LADDER DIAGRAM
* CAUTION: RECEPTACLE IS LIVE WHEN
BOILER SWITCH IS OFF
REFERENCES PLUG CONNECTION
34
P7-2
Controls and Accessories
and may be set anywhere between 100 °F and 200 °F. The field
setpoint adjustment for each installation depends on heating
system requirements. The aquastat automatically resets when
the boiler water temperature decreases (5-30 °F adjustable
differential). The differential can be adjusted with the (white)
Differential Adjustment Wheel on the aquastat and gives the
flexibility for boiler operation. The larger the differential, the
longer the run cycle of the boiler.
NOTE: The maximum setpoint of the Aquastat must not
exceed 200 °F.
This section provides a brief description of the key controls
and accessories found in this boiler.
See the Troubleshooting section of the Service Hints chapter
of this installation manual for detailed sequences of operation
and troubleshooting procedures. See the Repair Parts chapter
of this manual for locations of all control components and accessories described.
A. Integrated Boiler Control (IBC)
The Integrated Boiler Control (IBC) is a microprocessor based
controller for a high efficiency gas boiler that monitors all
safety controls and which controls the operation of the combustion air blower, circulator pump, burner, and a combination
hot surface igniter/flame sensor. This controller is not intended
for use with a vent damper. This controller is mounted on the
control panel inside of the boiler and contains five (5) diagnostic indicator lights.
E. Draft Inducer Temperature Safety Switch
The Draft Inducer Temperature Safety Switch is a disc thermostat (180 °F setpoint) located on the induced draft fan outlet
port. The switch protects the inducer and vent pipe from a
potential high temperature condition for the discharging flue
gases. This condition would typically be a result of higher
aquastat setting or over firing. The temperature safety switch
automatically resets when the higher aquastat setting or over
firing. The temperature safety switch automatically resets when
the vent temperature decreases. (15 °F switch differential).
B. Gas Control Valve
The electrically controlled 24 Volt Honeywell Model VR8205
Combination Gas Control Valve is designed to meet the requirements for use with hot surface ignition systems found in
this boiler. The valve is piped to the gas/air mixer.
F. Casting Temperature Safety Switch
In the event of lack of or loss of water in the boiler, the Casting Temperature Safety Switch (300 °F setpoint) installed on
the top of the aluminum boiler section shuts off the boiler by
shutting off power to the Integrated Boiler Control (IBC) and
causes the Power Indicator Light to go out. This fault requires
manual reset of the casting temperature safety switch to restart
the boiler. Verify that the boiler is properly filled with water
before resetting this switch. WARNING-Never run cold water
into a hot empty boiler.
C. Hot Surface Igniter
The 120 Volt Hot Surface Igniter heats up to 1800 °F to initiate
combustion of the gas in the burner. The igniter is mounted
next to the burner through the gas/air mixer. The igniter also
serves as a means for proving the main burner flame by flame
rectification. In the event of a lack of flame signal on three
(3) consecutive trials for ignition, the IBC will lockout. The
“VALVE” and “FLAME” diagnostic indicator lamps (lamp “D”
and “E” on the IBC, See Figure #16) will blink indicating the
failure mode as a lack of flame signal. The IBC is manually
reset from lockout by either removing and reestablishing the
thermostat’s call for heat, or by turning the service switch off,
then back on.
G. Differential Pressure Air Proving Switch/Blocked
Vent Safety Shutoff
All 90 Series Hot Water Boilers come equipped with either one
(100 Series) or two (200 Series) diaphragm-type differential
pressure switches. The differential pressure switch monitors air
flow by sensing the differential pressure measured in inches
of water (” w.c.). The pressure switch contacts close when the
draft inducer is running. The closed switch proves there is
adequate air flow for combustion. The pressure switch shuts off
the main burner if the differential pressure is inadequate due
to a blocked vent pipe, a blocked air intake, blocked boiler sections, or a blocked draft inducer. After five (5) minutes of lack
of adequate differential pressure, the IBC will lock out and the
“Purge” indicator light will blink, indicating a failure to prove
D. High Limit Aquastat Control
The High Limit Aquastat Control determines the maximum
boiler water temperature and also provides a means for
protecting the boiler and heating system from unsafe operating conditions which could damage the boiler. The aquastat
is mounted in the ½” NPT control well and ¾”x½” bushing
on the top of the front boiler section at the hot water outlet.
The aquastat is tied in with the IBC and is factory set at 180 °F
water temperature. The high limit setpoint is field adjustable
35
Controls and Accessories
adequate combustion air flow or flue gas flow. The IBC will be
automatically reset after fifteen (15) minutes or can be manually reset from lockout by (a) removing and reestablishing the
thermostat call for heat or (b) by turning the service switch off
and back on again. If the boiler cannot be restored to normal
operating conditions by resetting the control, contact a quallified service agency to check the heat exchanger flue-ways for
blockage.
K. A.S.M.E. Rated Pressure Relief Valve
Each boiler must have a properly sized and installed American
Society of Mechanical Engineers rated pressure relief valve.
Water expands as it is heated by the burner/boiler sections.
If there is no place for the water to expand its volume, (i.e.
a properly sized and properly functioning expansion tank)
pressure on the inside of the boiler and heating system will
increase. The furnished relief valve will automatically open at
30 psig pressure to relieve the strain on the boiler and heating
system from the increasing pressure. The pressure relief valve
discharge must be piped with piping same size as the valve
discharge opening to an open drain, tub or sink, or other suitable drainage point not subject to freezing, in accordance with
A.S.M.E. specifications. Failure to provide the pressure relief
valve with piping as herein described may cause water damage
and/or serious bodily injury. The boiler manufacturer is not
responsible for any water damage or personal injury.
H. Draft Inducer
The draft inducer (blower) provides a means for pulling combustion air into and through the mixer, the burner, the flue
ways of the cast aluminum boiler sections and the flue adapter
before being discharged through the vent piping to the outdoors. See applicable sections for proper sizing and installation
of combustion air and vent piping in this manual.
I. Circulator Pump
Every forced hot water system requires at least one circulating pump. The circulating pump imparts the necessary energy
to move the water through the closed loop supply and return
piping systems, terminal heating equipment (i.e. finned tube
radiators, etc.) and back through the boiler for reheating. To
provide the required hot water flow rates, the circulator pump
must be properly sized to overcome frictional losses (usually
measured in feet of water, also referred to as “pump head loss”)
of the supply and return piping systems and boiler. The circulator pump is furnished in a carton within the boiler cabinet
for a single zone or zone valve controlled heating system and
should be correctly located on the downstream (i.e., pumping away) side of the expansion tank. For a pump controlled
system (where there is a circulator for each zone) the circulator
provided with the boiler can work for one zone. For more details on piping and circulators, see Near Boiler Piping section
of this manual.
L. Blocked Vent Safety Shutoff
This boiler is equipped with a blocked vent safety shutoff
means, which shuts off main burner gas in the event that the
flow of combustion products through the flueways is reduced.
In the event of blocked flueways, enough air will not be available to support combustion, and the S9301 Integrated Boiler
Control (IBC) will lockout due to loss of adequate air flow
(after 3 trials for ignition). The “PURGE” diagnostic indicator
lamp (lamp “B” on the IBC, see Figure16) will blink indicating the failure mode as a lack of adequate air flow. The IBC is
manually reset from lockout by either removing and reestablishing the thermostat’s call for heat, or by turning the service
switch off, then back on. If the boiler cannot be restored to
normal operating condition by resetting the control, contact a
qualified service agency to check heat exchanger flueways for
blockage.
M. External Condensate Pump (Optional)
For installations where there is no floor drain or other appropriate drainage receptacle available to receive condensate from
the boiler, an external float activated condensate pump with integral sump is required. This unit can be installed to pump the
condensate to a remote tie in point to a sanitary sewer system.
For this application, the boiler must be installed so that proper
pitch of piping to the external condensate reservoir (sump) can
be accomplished. Use wood frame or blocks to raise boiler as
required for proper installation.
J. Drain Valve
The manual drain valve provides a means of draining the water
in the heating system, including the boiler and hot water supply and return piping systems installed above the drain valve.
This drain valve is installed in the ¾” tapping at the bottom of
the front boiler section. Any piping installed below the elevation of this drain valve will require additional drain valves
to be installed at low points in the piping systems in order to
drain the entire system.
36
Water Treatment & Freeze Protection
When filling the boiler water is the preferred heating solution.
Most potable water supplies may be used to charge and re-fill
provided the chlorine and chloride ions levels are less than 100
ppm.
Piping Recommendations
System leaks may not always be visible. An unseen system leak
will become obvious if boiler pressure decreases when make up
valve is closed.
Antifreeze may be used in most applications provided all of the
following conditions are met:
All system leaks must be repaired immediately. Constant introduction of make up water will introduce dissolved oxygen,
resulting in accelerated boiler corrosion.
1. Unless a strict schedule of sampling, analysis and maintenance of the antifreeze solution is followed, the boiler
must be piped as a primary loop connected to secondary
loop as shown in the Piping & Wiring Diagram Appendix.
Failure to perform regular maintenance to the antifreeze
manufacturer’s instructions will result in damage to the
heat exchanger and the voiding of boiler warranty.
It is recommended that Primary/Secondary piping be used
with any of the recommended antifreeze solutions found in
this manual. See the Piping & Wiring Diagram Appendix.
Water Chemistry
This boiler is designed for a closed loop hydronic heat system
ONLY! This boiler is not suitable for natural gravity type installations, or any other open type system.
2. Only the antifreeze manufacturers listed below are selected.
System fluid pH must be maintained between 7.0 and 8.0.
3. At installation of a new or replacement boiler and at least
on an annual basis the system antifreeze must be analyzed
by the antifreeze supplier or their recommended laboratory.
Maintain water hardness below 7 grains hardness.
Filling with chlorinated fresh water should be acceptable since
drinking water chlorine levels are typically less than 5 ppm. Do
not fill boiler with water containing chlorine and chloride ions
levels greater than 100 ppm.
4. Adjustments to the system antifreeze must be made according to the antifreeze manufacturers recommendations
using only their recommended products.
Do not use inhibitors or other additives that are not specifically
approved by the antifreeze manufacturer for this product.
5. All existing systems MUST be flushed of ALL old system
fluid. Failure to do so may void the boiler warranty if evidence of improper flushing is revealed. Consult with your
heating professional for recommendations.
Consult the antifreeze manufacturer if any of the above are
outside the stated ranges.
37
WATER TREATMENT & FREEZE PROTECTION
Cleaning the Hydronic System
IMPORTANT: Do not mix different manufacturers’ products.
Doing so will void the warranty of the boiler.
Freeze Protection
Aluminum Safe Antifreeze, Treatments and Additive
Guidelines:
Consideration MUST be given to cleaning the heating system,
particularly in retrofit situations where a new boiler with an
aluminum heat exchanger is being installed in an existing piping system.
Antifreeze, if required, must be one of the antifreeze manufacturers listed in this manual. See the “Recommended Aluminum Antifreeze & Inhibitor Suppliers” section of this manual
for a list of boiler manufacturer approved products.
All existing systems must be cleaned and flushed according to
the antifreeze manufacturer’s recommendations.
Always clean system prior to using antifreeze, refer to the
Cleaning the Hydronic System section of this manual for
details.
Systems that have antifreeze that is not recommended by the
boiler manufacturer must be completely flushed to ensure no
unapproved antifreeze remains according to the recommended
antifreeze manufactures recommendations. Evidence of an
alternate antifreeze in the system may void the boiler warranty.
Only use the antifreeze manufacturers’ products outlined in
this document.
Use of antifreeze must be in accordance with local plumbing
codes.
In older systems obviously discolored, murky or dirty water;
or a pH reading outside the boiler manufacturer’s stated acceptable range (pH 7.0 to 8.0) are indications that the system
should be cleaned or treated.
Dispose of old antifreeze and boiler system water in accordance with local authorities.
Antifreeze will raise the pH of the hydronic solution in a
heating system above the recommended level due to the
corrosion inhibitors in the antifreeze. The solution must
be treated to maintain a pH within the boiler manufacturer’s
recommended level to avoid damage to the heat exchanger.
Follow antifreeze manufacturer’s instructions for details on
how to adjust the pH.
1. Measure total capacity of the system including the piping, tanks, boiler, collector plates, etc. The most accurate
method of measuring fluid capacity is to fill the system
and then completely drain it, volumetrically measuring the
fluid drained.
2. Thoroughly flush the system with clean water to remove
any sediment or contaminants. Sludge and iron oxide
deposits can cause rapid breakdown of inhibitors.
If the system has leaked for some reason, the water and antifreeze chemistry will need to be adjusted. To avoid damage to
the boiler, check the pH and chemistry of the boiler solution
and consult the antifreeze manufacturer for recommendations.
3. Cleaning fluid – Flushing with clean water is preferred. If
cleaning fluid is used, only use cleaner specifically approved for use with aluminum boilers. Use only cleaning
fluids and the procedure recommended by the antifreeze
manufacturer.
It is recommended that a pH reading is taken annually, and adjusted as necessary. Follow antifreeze / inhibitor manufacturer’s
instructions for details on how to adjust the pH.
• Use of antifreeze in any boiler will reduce heating capacity
as much as 10-20%. This must be taken into consideration
when sizing the heating system, pumps and expansion tank.
Consult antifreeze manufacturer’s literature for specific information on reduced capacity.
• Using the antifreeze manufacturer’s instructions to determine
the freezing temperature needed and use the correct amount of
antifreeze. Never exceed 50% antifreeze by volume.
NOTICE
Antifreeze solutions can breakdown over time. Failure to
check antifreeze chemistry, including inhibitors, annually
may result in accelerated corrosion of boiler and other system components. Consult with the antifreeze manufacturer
for recommendations.
• The boiler operating pressure must remain below 15 psi
for antifreeze solutions that specify a maximum of 250˚F
(121˚C).
38
XII - Water Treatment & Freeze Protection
Recommended Aluminum Antifreeze
Recommended Products
& Inhibitor Suppliers
Interstate Chemical
2797 Freedland Road
P.O. Box 1600 Hermitage, PA 16148-0600
www.interstatechemical.com
Tel: 800-422-2436
Intercool NFP-30,40,50 AA
Intercool RPH-15*
Fax: 724-981-8383
Noble Company
PO Box 350 Grand Haven, MI 49417
www.noblecompany.com
Tel: 800-878-5788
Noburst AL Antifreeze
Fax: 800-272-1519
Rhomar Water Management, Inc.
PO Box 229 Springfield, MO 65801
Rhogard Antifreeeze
www.rhomarwater.com
Pro-Tek 922 Inhibitor*
Tel: 800-543-5975
Fax: 417-862-6410
* These products may be used to adjust the pH level of the hydronic system, but on occasion may not resolve the pH issue.
In these cases it is recommended to flush the system and refill with untreated water and new boiler manufacturer approved antifreeze suitable for Aluminum heat exchangers.
IMPORTANT: Regardless of antifreeze or inhibitors used, be sure to follow the antifreeze manufacturer’s instructions for
use, safe handling and storage of their products. Refer to the MSDS (Material Safety Data Sheets) provided by the antifreeze manufacturer for potential hazards and first aid procedures for exposure or ingestion.
Antifreeze Testing Services: Each of the recommended antifreeze manufacturers have developed a sampling program
available to the homeowner and contractor. Contact the antifreeze manufacturer regarding their sampling plan procedure.
Consult the antifreeze manufacturer for details on sample requirements and recommendations.
The boiler manufacturer reserves the right to make changes without notice.
39
Start Up
zone. Open the purge valve on the first zone. Feed water
will fill the zone, pushing air out the purge valve. Close the
purge valve when the water runs air free. Close the zone
service valve.
A – Filling Boiler With Water And Purging Air For
Systems With Diaphragm Type Expansion Tanks
Refer to the appropriate diagrams in Section VII, “Near Boiler
Piping,” for more information.
1. Close all zone service valves on the supply and return piping. Open the feed valve and fill boiler with water. Make
sure air vent is open. Hold relief valve open until water
runs air free for five seconds to rapidly bleed air from
boiler, then let the relief valve snap shut.
3. Repeat step 2 for all remaining zones.
2. Open the zone service valve on the supply pipe for the first
zone. Open the purge valve on the first zone. Feed water
will fill the zone, pushing air out the purge valve. Close the
purge valve when the water runs air free. Close the zone
service valve.
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.
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.
6. Inspect piping system. Repair any leaks immediately.
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.
Note:
DO NOT use stop leak compounds. Leaks in threaded connections in the aluminum boiler sections must be repaired
immediately. Aluminum threads will not seal themselves.
5. Inspect piping system. Repair any leaks immediately.
B – Purging Air For Systems With Conventional Closed
Type Expansion Tanks:
Refer to the appropriate diagrams in Section VII, “Near Boiler
Piping,” 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 fill boiler with
water. Hold relief valve open until water runs air free for
five seconds to rapidly bleed air from boiler, then let the
relief valve snap shut.
2. Open the zone service valve on the supply pipe for the first
40
Start Up
C - Placing Boiler In Operation
! WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss
of life
A. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot
by hand.
•If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to move the system control switch.
Never use tools. If the switch will not move by hand,
don’t try to repair it, call a qualified service technician.
Force or attempted repair may result in a fire or explosion.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
What To Do If You Smell Gas
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control
system and any gas control which has been under water.
•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.
Operating Instructions
1. STOP! Read the safety information above on this label.
7. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor. 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.
2. Set thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the burner. DO NOT try to light the
burner by hand.
8. Turn the gas control knob counterclockwise
“ON”.
9. Replace front jacket panel.
5. Remove the front jacket
panel.
6. Turn the gas control
knob clockwise
to
“OFF”.
to
10. Turn on all electrical power to the appliance.
11. Set the thermostat to desired setting.
INLET
12. If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.
ON
OFF
GAS CONTROL KNOB
SHOWN IN "ON" POSITION
To Turn Off Gas To Appliance
1. Set the thermostat to lowest setting.
3. Remove the front jacket panel.
2. Turn off all electric power to the appliance if service is to
be preformed.
4. Turn gas control knob clockwise
to “OFF”.
5. Replace the front jacket panel. Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler
when the boiler underwent tests specified in ANSI Z21.13-latest revision.
41
Check Out Procedure and Adjustment
Figure 16 - Indicator Lamps
A. Verify Proper Sequence Of
Operation
The sequence can be followed via the
diagnostic indicator lamps on the Honeywell S9301A integrated boiler control
in Figure #16. This is the normal
sequence of operation. A more detailed
sequence of operation containing potential faults can be found in the service
hints section.
SEQUENCE OF OPERATION
“DIAGNOSTIC
INDICATOR
LAMPS”
“Power ON, boiler standing by. Lamp A is illuminated
indicating 2 Volt power is being supplied to the integrated control.”
A. 
B. 
C. m
D. m
E. m
Thermostat calls for heat, energizing system circulator
A. l
B. m
C. m
D. m
E. m
“Integrated boiler control goes through self check of
internal circuitry (1-2 seconds) and energizes draft
inducer”
A. l
B. m
C. m
D. m
E. m
“Draft inducer comes up to speed and establishes combustion airflow, causing the normally open differential
pressure air proving switch contacts to close. Lamp B is
illuminated indicating that combustion airflow is proved
and the 15 second pre purge cycle”
A. l
B. l
C. m
D. m
E. m
42
Check Out Procedure and Adjustment
SEQUENCE OF OPERATION
“DIAGNOSTIC INDICATOR LAMPS”
After pre purge, Lamp B goes out and Lamp C illuminates, indicating the hot surface igniter is powered for the 20 second
igniter warm-up period. The bright yellow orange glow of the
hot surface igniter can be observed through the observation
port in the front boiler section just above the igniter.
A. 
B. 
C. l
D. m
E. m
After igniter warm-up, the gas valve is energized, and opens
on the normal firing rate regulator (2.5” w.c.) for a 6 second trial
for ignition. Lamp D illuminates. The blue orange glow of the
burner can be seen through the observation port.
A. l
B. m
C. 
D. 
E. 
Two seconds later, Lamp C goes out as power is turned off to the
hot surface igniter. During the last two seconds of the 6 seconds
trial for ignition, main burner flames is proven by flame rectification through the hot surface igniter, providing flame rectification
to the integrated boiler control and fully illuminating Lamp E. the
gas valve remains energized, and the boiler runs.
A. l
B. m
C. m
D. l
E. l
Thermostat ends call for heat, de-energizing gas valve and
system circulator. Burner stops firing, and Lamp D goes out.
Draft inducers remains powered. Lamp B illuminates, indicating
draft inducer is running for 30 second post-purge.
A. l
B. l
C. m
D. m
E. m
After 30 seconds, draft inducer is de-energized. Lamp B goes
out. Boiler stands by for next call for heat.
A. l
B. m
C. m
D. m
E. m
NOTE: First couple of cold starts may be rough due to gas line not being completely purged of air, causing low
firing rate and high excess air levels.
E. Test Ignition System Safety Shutoff Device
1. Turn off manual gas valve
B. Inspect Venting And Air Intake System
Operate the boiler and verify that all vent/air intake connections are gas-tight and watertight. Repair any leaks immediately.
2. Set thermostat to call for heat
3. Boiler begins normal sequence of operation
4. After approximately 40 seconds (pre purge and igniter
warm-up period), lamp D illuminates, indicating gas valve
is powered
C. Inspect Condensate Drain
Verify that all connections are watertight, and that condensate
flows freely. Repair any leaks immediately.
5. After 6 seconds, gas valve closes, lamp D goes out as integrated boiler control senses that flame is not present
D. Inspect System Piping
Verify that all connections are watertight. Repair any leaks
immediately.
6. To restart system, follow operating instructions under
“START-UP PLACE IN OPERATION”
43
Check Out Procedure and Adjustment
5. Turn off all other gas appliances, extinguishing standing
pilots where applicable.
F. Test High Limit Control And Adjust
While burner is operating, move indicator on high limit
control below actual boiler water temperature. Burner should
go off while circulator continues to operate. Raise limit setting
above boiler water temperature and burner should reignite
after pre purge and igniter warm-up period. Set the high limit
control to the design temperature requirements of the system.
Maximum high limit setting is 200°F. Minimum high limit setting is 100°F.
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:
3600xheating value from step 3
Btuh inputrate = time from step 6
8. Measured input rate should be within +/-2% of the input
rating from step 2. If within 2%, go to step 9. If not, adjustment is required, proceed as follows:
G. Test Other Safety Controls
If the boiler is equipped with a low water cut off, a manual
reset high limit, or additional safety controls, test for operation as outlined by the control manufacturer. Burner should
be operating and should go off when controls are tested. When
safety controls are restored, burner should reignite.
A. Turn boiler off
B. Set up U-tube manometer or differential pressure gauge
for measuring manifold pressure, see Figure #17.
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.
H. Set Thermostat Heat Anticipator (If Used) And Verify
Thermostat Operation
For a single thermostat connected to the yellow thermostat
lead wires in the furnished field wiring junction box, the heat
anticipator should be set at 0.7 amps. For other wiring configurations, refer to the instructions provided by the thermostat
manufacturer regarding adjustment of heat anticipator. Cycle
boiler with thermostat. Raise the thermostat to the highest
setting and verify boiler goes through normal start up cycle.
Lower thermostat to lowest setting and verify boiler goes off.
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.
I. Measure The Natural Gas Input Rate
Correct input rate is essential for proper and efficient operation
of the burner and boiler.
9. Restore all gas appliances that may have been shut off
(while measuring boiler input rate) to normal operating
conditions.
1. Determine elevation at installation site.
2. See page 6 and 7 of this manual to determine the correct
input rate for the local elevation.
I. Remove regulator cover screw on top of gas valve, and
insert an appropriate screwdriver into adjustment screw.
II. Turn adjustment screw clockwise to increase input rate,
or counter clockwise to decrease input rate.
III. Replace cover screw, or cover hole temporarily with
your finger to check new manifold pressure setting. Do
not set manifold pressure lower than 2.0 inches w.c. or
higher than 3.0 inches w.c. when adjusting input rate.
3. Obtain the yearly average heating value of the local gas
supply from the gas utility. At sea level elevation, it should
be approximately 1000 Btu’s per standard cubic foot.
4. Operate boiler for 5 minutes.
44
Check Out 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 orifice size is required. Consult the boiler
manufacturer for information on correct orifice sizing.
The specific gravity (G) and the higher heating value
(HHV) of the local natural gas must be obtained from the
local gas utility in order to determine the proper orifice
size.
J. Set Thermostat To Desired Room Temperature
Observe several operating cycles to verify proper operation.
K. Review All Instructions
Review all instructions shipped with this boiler with owner or
maintenance person. Instructions must be affixed on or adjacent to the boiler.
L. Complete and sign the installation and check-out certificate found in this manual.
45
Check Out Procedure and Adjustment
Figure 17 - Manifold Pressure Measurement Detail
The following steps and diagram indicate the location of the
connection points required to measure the manifold pressure.
The manifold pressure may be measured using a U-Tube Manometer or a Differential Pressure Gauge. The diagram shows
the connection of both measuring
devices. Only ONE DEVICE IS
REQUIRED to measure the manifold pressure.
Remove the plug. Install the
appropriate barbed fitting and
connect the pressure side line
from the U-Tube Manometer or
Differential Pressure Gauge.
Refer to “CHECK OUT PROCEDURE AND ADJUSTMENTS”
in this manual when reading the
manifold pressure.
When measurement is completed,
disconnect the U-Tube Manometer or Differential Pressure Gauge.
Be sure to reinstall the ⅛” plug,
using appropriate pipe thread sealant approved for use with
natural and liquefied Petroleum gases.
Figure 18 - Gas Valve
PRESSURE REGULATOR
ADJUSTMENT (UNDER CAP SCREW)
INLET
PRESSURE
TAP
VR8205
WIRING TERMINALS (2)
OUTLET
PRESSURE
TAP
NOTE: Regulator cover screw must be installed at all
times unless adjusting manifold pressure. Firing rate and
manifold pressure must only be measured with cover screw
firmly installed.
OUTLET
INLET
ON
OFF
GAS CONTROL KNOB
46
INSTALLATION AND CHECK-OUT CERTIFICATE
Boiler Model
Serial #
Date Installed___________
Measured BTU/HR input____________
Installation instructions have been followed
Checkout procedure and adjustments performed
Maintenance and Service issues reviewed with owner/ maintenance person
Installation booklet affixed on or adjacent to boiler
Installer (Company)
Address
Phone
Installer’s Name
Signature
47
Maintanance And Cleaning
Maintenance as outlined below can be performed by the
owner unless otherwise noted.
Insure that there are no leaks. Use RTV silicone rubber
adhesive sealant (available in caulking gun tubes) rated
for at least 400° F to replace or repair seals in locations
where original seals have deteriorated.
The acidic nature of flue gasses condensing on the aluminum
boiler sections will cause the formation of aluminum oxide.
This oxide formation is normal, is generally uniform throughout the boiler sections, and represents a negligible mass of
aluminum that is consumed by oxidation during the life of
the boiler. If left unchecked, this buildup may eventually cause
blockage of the flue gas passages in the boiler sections, reducing efficiency, and ultimately shutting down the boiler due to
lack of combustion air flow. Regular service and maintenance
by a qualified service agency must be performed to assure safe
trouble free operation and maximum efficiency.
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 fittings. Repair, if
found. DO NOT use stop leak compounds.
2. Check that boiler area is free from combustible materials,
gasoline, and other flammable 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.
Beginning Of Each Heating Season
1. Annual service call by a qualified service agency, which
includes:
A. Examine flue passages between boiler sections, burner,
and condensate lines, and clean if necessary following
the annual examination and cleaning instructions in para
graph “F” on the next page.
Daily During Heating Season
1. Check for and remove any obstruction to the flow of combustion air or venting of flue gases.
2. Check that boiler area is free from combustible materials,
gasoline, and other flammable vapors and liquids.
B. Visually inspect venting and air intake system for proper
function, deterioration or leakage. If the vent or air intake
show any signs of deterioration or leakage, repair or
replace them, immediately. Insure proper reassembly and
resealing of the vent and air intake system
C. Check for and remove any obstruction to the flow of
combustion air or venting of flue gases. Check the air
baffle located inside 1½” x 2” flexible coupling on the
mixer, clean it if necessary and make sure to put it back.
Refer to repair parts diagram of mixer and pressure
switch assembly for exact location.
D. Follow instructions for “PLACING BOILER IN OPERATION”.
E. Follow instructions for” CHECK OUT PROCEDURE
AND ADJUSTMENTS”.
F. Visually inspect condensate drain line for proper operation and deterioration. Check for plugged condensate
drain line.
G. Check the silicone rubber seals between boiler sections.
48
MAINTANANCE AND CLEANING
Monthly During Heating Season
1. 1. Remove jacket front and top panels and check for piping leaks around relief valve and other fittings. If found,
contact a qualified service agency to repair. DO NOT use
stop leak compounds.
Annual Examination And Cleaning Of Boiler
Components
The following service procedures must be performed only
by a qualified service agency. Boiler owner should not attempt these procedures.
2. 2. Test relief valve. Refer to valve manufacturers instructions packaged with relief valve.
1. Before Servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn off gas supply
to boiler.
3. 3. Visually inspect venting and air intake system for
proper function, deterioration, or leakage. If the vent
or air intake show any signs of deterioration or leakage,
contact a qualified service agency to repair or replace them
immediately and to insure proper reassembly and resealing of the vent and air intake system.
2. Cleaning Flue passages between boiler sections.
A. Any buildup of sediment or aluminum oxide (white
powdery or flaky substance) in the flue passages must be
cleaned as follows:
4. 4. Visually inspect the clear vinyl condensate lines and the
PVC condensate drain pipe for proper operation, leakage,
and deterioration. If the condensate lines or drain pipe
show any signs of blockage, leakage, or deterioration contact a qualified service agency to clean, repair, or replace
them immediately.
B. Remove jacket front and top panels. Disconnect condensate drain line from the barbed fitting on the bottom
of the boiler. Keep the open end of the drain line above
the water level in the condensate trap to prevent the trap
from draining. Disconnect pressure switch hose from
barbed fitting on gas valve. Disconnect 1½ x 2” flexible
coupling from air inlet. Disconnect air by-pass (½” transparent vinyl tube) from the bottom of the mixer.
5. 5. Check the air baffle located inside 1 ½” x 2” flexible
coupling, clean it if necessary and make sure to put it back.
Refer to repair parts diagram, mixer and pressure switch
assembly.
C. Remove air baffle from ½” x 2” flexible coupling and
clean air baffle if necessary. Refer to repair parts diagram,
mixer and pressure switch assembly.
Periodically During Heating Season
Where low water cut offs are used, a periodic inspection of
the low water cut off is necessary, including flushing of float
type devices. Refer to low water cut off manufacturer’s specific
instructions.
D. Confirm that 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 five (5) nuts attaching mixer
assembly to boiler. Remove two (2) igniter screws and
very carefully remove the igniter. Use care when removing the igniter, it is very brittle!
End Of Each Heating Season - Annual Shutdown
Procedure
Follow instructions “TO TURN OFF GAS TO APPLIANCE”.
F. Remove five (5) nuts and remove mixer assembly. Remove burner and mixer gasket.
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.
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 the barbed fitting on
the bottom of the boiler and run the hose to a bucket or
drain.
49
MAINTANANCE AND CLEANING
C. Remove the condensate trap and run cold water through
the condensate lines to thoroughly flush out any sediment or debris in the lines.
H. After rinsing, remove any remaining loosened sediment
using a shop vacuum with a snorkel attachment.
I. Inspect burner for any foreign matter in the flame ports
or inside the burner. Any foreign matter should be removed by blowing with compressed air or vacuuming.
D. Reinstall and connect the condensate trap, using the hose
clamps to secure the various condensate lines to their
fittings.
J. Inspect interior of mixer for any signs of sediment or
aluminum oxide and clean if necessary.
E. Follow the instructions under “NEAR BOILER PIPING”
for” filling condensate trap with water”
K. Reinstall burner and mixer gasket and position mixer assembly over studs. Install five (5) nuts but do not tighten.
Reinstall igniter and igniter gasket and fasten with two
(2) screws. Use care when installing the igniter. It is very
brittle! Tighten five (5) nuts holding mixer assembly.
4. Inspection of the flue connector requires the following steps
(Refer to the repair parts diagram.)
A. Loosen the clamp on the draft inducer end of the 2”
flexible coupling that connects the vent tee to the draft
inducer. Disconnect (unplug) wiring harness from draft
inducer motor and draft inducer temperature safety
switch. Remove four (4) bolts that attach draft inducer to
flue connector.
L. Connect:
•Gas line to gas valve
•Condensate drain line to boiler
B. Remove draft inducer and gasket from top of flue connector.
•Pressure switch hose to gas valve
•Air by-pass to mixer
C. Inspect interior of flue connector. Any buildup of sediment or aluminum oxide on the inside surface must be
cleaned. Position the draft inducer gasket and the draft
inducer and fasten with four (4) screws. Be sure to connect ground wire from draft inducer motor to one of the
four mounting screws.
•1 ½” x 2” flexible coupling to air inlet and make sure to
put air baffle back to correct position
•Igniter wires
•Gas valve wires
3. Visually inspect condensate lines leading from the boiler
sections and the vent tee to the condensate trap. Refer to
repair parts diagrams. Any foreign material or debris that
is visible in the condensate lines needs to be cleaned out as
follows:
D. Connect wiring harness leads to the draft inducer motor
and the draft inducer temperature safety switch.
E. Connect the 2” flexible coupling to the draft inducer
outlet.
A. Raise condensate trap and drain condensate lines completely.
B. Once the condensate trap is emptied of water, disconnect
condensate lines from the fittings on the boiler, the vent
tee, and the condensate outlet.
50
Detailed Sequence Of Operation
Service Hints
POWER ON
STAND BY
THERMOSTAT
CALLS FOR HEAT
IF MAIN BURNER DOES NOT PROVE FLAME IN
3 TRIALS, CONTROL LOCKOUT. VALVE/FLAME
LIGHT BLINKS. MANUAL RESET IS REQUIRED OR
CONTROL WILL AUTOMATICALLY RESET AFTER
1 HOUR. THIS PROBLEM IS A RESULT OF NOT
ESTABLISHING A FLAME SIGNAL.
CIRCULATOR
ENERGIZES THRU
2K1 CONTACTS
IBC SELFCHECK OF
INTERNAL CIRCUITRY
1-2 SEC
CONTROL WILL ATTEMPT 2
ADDITTIONAL IGNITION SEQUENCES.
STARTING WITH PREPURGE.
IBC
CHECKS
N.O. AIR
PRESSURE
SWITCH
CONTACTS
CLOSED
FALSE
POSITIVE
PROOF OF
AIRFLOW. IBC WAITS
FOR 45 SEC
FOR AIR PRESSURE
SWITCH CONTACTS
TO OPEN
OPEN
NO
CLOSED
DOES
MAIN
BURNER PROVE
FLAME WITHIN INITIAL
TRIAL FOR
IGNITION
PERIOD?
OPEN
DRAFT INDUCER
ENERGIZES THRU
1K1 CONTACTS
CLOSED
IBC
WAITS FOR
UP TO 5 MINUTES
FOR AIR PRESSURE
SWITCH CONTACTS TO CLOSE
INDICATING FAN
SUCTION
PRESENT
OPEN
CONTROL LOCKOUT. PURGE LIGHT BLINKS.
MANUAL RESET IS REQUIRED OR CONTROL
WILL AUTOMATICALLY RESET AFTER 15
MINUTES. CIRCULATOR REMAINS ENERGIZED
AS LONG AS THERMOSTAT CONTINUES
TO CALL FOR HEAT.
PURGE LIGHT IS ON.AIRFLOW PROVED.
DRAFT INDUCER RUNS FOR 15 SEC PREPURGE
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.
2 SEC INTO THE 5 SEC IGNITION TRIAL. POWER
IS TURNED OFF TO THE HOT SURFACE IGNITER.
IGNITER LIGHT IS OFF.
GAS VALVE OPENS FOR 5 SEC TRIAL FOR
IGNITION. BLUE ORANGE GLOW OF THE BURNER
CAN BE SEEN THRU OBSERVATION PORT.
GAS VALVE ENERGIZED THRU 3K1 AND 4K1.
CONTACTS, VALVE LIGHT IS ON.
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
51
YES
NORMAL
OPERATION
DETAILED SEQUENCE OF OPERATION
DRAFT INDUCER TEMPERATURE SAFETY SWITCH
CASTING TEMPERATURE SAFETY SWITCH
IF DRAFT INDUCER TEMPERATURE REACHES
TEMPERATURE SAFETY SWITCH SETPOINT,
SAFETY SWITCH CONTACTS OPEN IMMEDIATELY
CLOSING GAS VALVE (LIGHT GOES OUT)
IF BURNER OPERATES WHEN BOILER HAS NO
WATER, ALUMINUM BOILER SECTIONS HEAT UP
RAPIDLY.
CASTING TEMERATURE SAFETY SWITCH CONTACS WILL OPEN BREAKING 24 VOLT POWER
TO IBC. POWER INDICATOR LIGHT GOES OUT.
REQUIRES MANUAL RESET TO RE-CLOSE CAONTACTS. POWER LIGHT GOES OUT.
DRAFT INDUCER RUNS THRU 30 SECOND
POST PURGE AND SWITCHES OFF.
CIRCULATOR RUNS WITH THERMOSTAT ON
CALL FOR HEAT.
WHEN TERMPERATURE SAFETY SWITCH
CONTACTS REMAKE BEFORE END OF CALL
FOR HEAT, CONTROL GOES INTO NORMAL
SEQUENCE.
HIGH LIMIT CONTROL
IF BOILER WATER TEMPERATURE REACHES HI
LIMIT (AQUASTAT) SETPOINT, HI LIMIT N.C. CONTACTS OPEN IMMEDIATLEY, CLOSING GAS VALVE.
VALVE AND FLAME LIGHTS GO OUT.
loss of flame signal
if an established flame signal is lost while
control expects that the burner is operating, control will immediately de-energize
gas valve. valve and flame lights go out.
DRAFT INDUCER CONTINUES TO RUN FOR 30
SECONDS POST PURGE AND SWITCH OFF.
draft inducer runs through 30 second
post purge.
CIRCULATOR RUNS AS LONG AS THERMOSTAT
CALLS FOR HEAT.
control will attempt to relight boiler
3 times. if flame is not proven, control
lockout - problem establishing a flame
signal. valve light is blinking. control
will automatically reset after 1 hour.
WHEN HI LIMIT CONTACTS REMAKE BEFORE
END OF CALL FOR HEAT, CONTROL GOES INTO
A NORMAL LIGHT OFF SEQUENCE.
loss of combustion airflow
if combustion airflow is lost while burner
is firing (Differential air pressure switch
contacts open) gas valve will be de-energized. valve and flame lights go out.
circulator pump
circulator will be energized as long as
thermostat calls for heat during lockout.
recovery from any lockout requires
reset, which can be accomplished by:
(a) removing and reestablishing the
thermostat’s call for heat or turning
the service switch off and back on;
or (b) waiting for the control to
automatically reset after 15 minutes
for loss of combustion airflow or
one hour for loss of flame.
draft inducer runs through 30 second
post purge.
if call for heat remains, ibc waits 5 minutes for airflow to be re-established.
if airflow does not re-establish control lockout - problem with combustion
airflow. purge light blinks. control will
automatically reset after 15 minutes.
52
DETAILED SEQUENCE OF OPERATION
53
Troubleshooting
! WARNING
Fire, explosion or shock hazard may cause property damage, severe injury or death. Do not attempt to modify the
physical or electrical characteristics of this boiler in any
way.
Important
1. In a reset from lockout condition, all electrical meter readings at the gas control valve (24 vac) must be taken within the
trial for ignition period.
2. If any component does not function properly, make sure it is correctly installed and wired before replacing it.
3. Static electricity discharge can damage the integrated boiler control (IBC). Touch metal surface to discharge static electricity
before touching IBC.
4. The IBC cannot be repaired. If it malfunctions it must be replaced.
5. Only trained, experienced service technicians should service the IBC systems. Following troubleshooting, check out the
system following the sequence of operation section of this chapter for a normal light off sequence.
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 the troubleshooting chart 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 contorl 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 in or damaged.
2. Troubleshooting tools:
A. Voltmeter to check 120 vac and 24 vac
B. Continuity tester.
C. Inclined manometer or pressure gauge with 0-2.0” Range (0.01” Scale) for measuring suction pressures at pressure switch.
D. U-tube manometer or differential pressure gauge with 0-14” range (0.1” Scale) for measuring inlet and manifold gas pressures.
3. What is system status?
A. Consult the chart on the following page.
B. Figure #16 shows the location on the boiler of the diagnostic indicator lamps.
54
TROUBLESHOOTING
System Status
THE INDICATOR LIGHTS TRACK THE OPERATING SEQUENCE. IF THE SYSTEM LOCKS OUT, THE LIGHTS
INDICATE THE POINT IN THE SEQUENCE OF OPERATION WHERE LOCKOUT OCCURS. IF THIS TABLE
DOES NOT READILY PROVIDE THE REASON FOR BOILER MALFUNCTION OR NON-OPERATION, REFER
LIGHT
POWER
STATUS
INDICATES
ON
IBC IS ENERGIZED THROUGH 24 VOLT TRANSFORMER.
OFF
IBC IS NOT ENERGIZED.
BLINKING
ON
IBC RECEIVES MORE THAN 40 VAC
IBC IS ENERGIZING THE DRAFT INDUCER AND AIR FLOW IS PROVEN.
OFF DURING PURGE CYCLE-DRAFT INDUCER IS NOT POWERED OR AIR FLOW
PURGE
OFF
IS NOT PROVEN.
OFF DURING IGNITER AND RUN CYCLE-NORMAL OPERATION, PURGE
CYCLE COMPLETE.
BLINKING
IGNITER
IBC IS LOCKED OUT. PROBLEM COULD INDICATE FALSE POSITIVE PROOF
OF AIR FLOW. BLOCKED VENT OR INTAKE AIR PIPE OR FLUE WAY.
ON
IBC IS ENERGIZING IGNITER
OFF
IGNITER IS NOT ENERGIZED
ON
IBC IS ENERGIZING GAS CONTROL VALVE TO OPEN.
OFF
GAS CONTROL VALVE IS CLOSED.
VALVE
IBC IS LOCKED OUT. PROBLEM IS FLAME HAS NOT BEEN PROVEN IN
BLINKING
THREE (3) IGNITION ATTEMPTS. MAY BE DUE TO BROKEN IGNITER OR
LACK OF OR LOW FLAME SIGNAL, OR NO GAS.
FLAME
ON
FLAME PROVEN
OFF
FLAME UNPROVEN
55
TROUBLESHOOTING
TROUBLESHOOTING CHART 1
! WARNING
Electrical shock hazard may cause
Serious injury or death.
The following procedures may expose you to dangerous line
voltage. Use caution to avoid touching live electrical contacts. Service must be performed by a trained, experienced
service technician.
What to do if you smell gas:
• Do not try to light any appliance
• Do not touch any electrical switch; do not use any
phone in your builidng.
• Immediatley call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instruction.
• If you can not reach your gas supplier, call the fire
department.
Should overheating occur or the gas supply fail to shut off,
do not turn off or disconnect the electrical supply to the
pump. Instead, shut off the gas at a location external to the
appliance.
Do not use the boiler if any part of the gas control system
has been under water a qualified service technician should
inspect the boiler and replace any part of the control system
and any gas control which has been under water.
Use only your hand to turn the gas control knob. Never use
tools. If the. Knob will not turn by hand. Don’t try to repair
it. Force or attempted repair may result in a fire or explosion.
56
TROUBLESHOOTING
TROUBLESHOOTING CHART 2
!"
#
" "
"
"!
"# "!"
"
"!
"
#
!"
#
!#
"
#
!#
#
!" #"
#
#"
#
#"
"
!"
#
! #
57
"
TROUBLESHOOTING
TROUBLESHOOTING CHART 3
"
% !" "!
$
"%" !
"" &!
&!
$"
% !% !!
% "%
&!
%
!!# !%"
""!
# "
&!
%"!#"
#"! &
!!# !%"
""!"!
"%
!#"!
!"
$" " &!
!!# !%" !" #"!
%! !! "
&
#"$"
"
!! %!"!% !"&
#
"$"
#"!
! "$!%"
&!
#!!!
"
#
!!! #
!!! "
!" #"!
&!
"#
" !"
&!
! "
# % #"
!
! # "
# "!!#"#!&
" "!!" #"
! '
&!
"
58
%
TROUBLESHOOTING
TROUBLESHOOTING CHART 4
CHART 3
YES
IGNITER/SENSOR WARMS
UP AND GLOWS
YELLOW/ORANGE
DURING 20 SECOND
WARM UP
NO
CHECk FOR 120 VAC
BETWEEN TERMINALS 1
AND 2 AT CONNECTOR
CN1 ON IBC (DURING
IGNITER WARM UP)
YES
NO
REPLACE IBC
YES
CHECk FOR 120 VAC AT
IGNITER/SENSOR LEADS
ON WIRING HARNESS
(DURING IGNITER
WARM UP)
NO
YES
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?
NO
REPAIR/REPLACE WIRING
FROM IBC
TO IGNITER/SENSOR
REPLACE IGNITER/SENSOR
CHECk FOR 24 VAC
ACROSS TERMINALS MV
ON THE GAS CONTROL.
WHILE VALVE/FLAME
INDICATOR LIGHT IS ON
NO
YES
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
NO
RESTORE IGNITER/SENSOR
TO CORRECT POSITION.
DO NOT RELOCATE
YES
CHECk GAS SUPPLY
PRESSURE AT INLET
PRESSURE TAPPING ON
GAS CONTROL IS GAS
PRESSURE GREATER
THAN 4.0" W.C.?
NO
YES
ARE ALL MANUAL
SHUT-OFFS IN THE GAS
SUPPLY LINE AND ON
THE GAS CONTROL IN
THE OPEN OR ON
POSITION?
YES
CONTACT THE GAS UTILITY
TO TURN THE GAS ON
CHART 5
CHART 5
59
NO
OPEN OR TURN ON ALL
MANUAL SHUTOFFS
TROUBLESHOOTING
TROUBLESHOOTING CHART 5
#%
*$
#%
*$
! $$*)%&#%
$$ ($%# $
'' # #$$#
$$
'%&#'' ##%$+
$#!#!#%$#
#!$$
$&#% &$ ##%$
'%&#''$+
*$
! $$*%&#%
#
&!$$$ #!#
%#
&!$$$ #
#&!$$$!#%
$%#&% $
*$
)#&## #
!#%
$%#&% $##
!$$$)#&##
# #%&##%
# ##%$+$#!#!#%$
#$ # ##%$+
$&##
#&&% #
%$ #
%"&$%%
%%$ !
)#&##!#%
$%#&% $
#!&##
#&$$
%* # &%
$ $%$&%$ %$!
#$
%#
$$ #
! $% %!$ &
$%% (#$&##
$,
$&% ## #
$!$%#&% $
#"&#$$!%
$
*$
#!
#%
#$% #
%#
$$ #
% ##%! $% %# %
*$
%$(#$ $%!!# !#%
!% #$ $*!% $$ (
#%
#%
60
) % %#!#'%
$
#!
%#
$ #
TROUBLESHOOTING
TROUBLESHOOTING CHART 6
CHART 5
YES
CHART 5
NO #2
CHART 5
NO #3
REPLACE GAS CONTROL.
YES
CHECk GAS ORFICICE SIzE.
IS GAS ORIFICE SIzE CORRECT.
CHECk REPAIR PARTS LIST
FOR CORRECT SIzE. IS GAS ORIFICE
CLEAR OF BLOCkAGE.
RUNS FOR 25-50 SECONDS,
THEN TURNS OFF.
CHECk FIRING RATE OF UNIT.
IS UNIT FIRING AT THE CORRECT RATE?
YES
NO
DOES THE UNIT USE LP GAS.
NO
ADJUST RATE AS DESCRIBED IN THE
CHECk OUT PROCEDURE AND
ADJUSTMENT SECTION
OF THE MANUAL.
YES
CHECk BURNER FOR ANY DETERIORATION
IN THE FLAME PORTS. ARE BURNER PORTS
IN GOOD CONDITION.
NO
REPLACE WITH CORRECT
AIR BAFFLE.
YES
NO
CHECk FLAME SIGNAL > 0.6uA?
CONSULT BOILER MFGR. FOR
SPECIFIC INSTRUCTIONS. REqUIRES
SPECIFIC TOOLS.
REPLACE BURNER
YES
REPLACE IBC
NO
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
YES
SEE TROUBLESHOOTING PATH
#2 ABOVE
SET THERMOSTAT BELOW ROOM
TEMPERATURE TO END CALL FOR
HEAT
YES
NO
DOES CIRCULATOR PUMP STOP?
NO
ARE THERMOSTAT CONTACTS OPEN?
YES
REPLACE THERMOSTAT
YES
REPLACE IBC
NO
VALE LIGHT IS OFF
YES
REMOVE WIRING HARNESS
CONNECTION CN9 FROM GAS
CONTROL DOES GAS CONTROL
CLOSE?
YES
DOES DRAFT BLOWER
STOP AFTER 30
SECOND POST PURGE?
NO
REPLACE IBC
YES
SYSTEM Ok
61
NO
REPLACE GAS CONTROL
REPLACE
AqUASTAT
Ok
Differential Air Pressure Switch Check
What Is System Status?
The following steps and diagram
indicate the locations of the
connection points required
to check the differential air
pressure.
The differential air pressure
switch is a safety device which
will prevent the boiler from
firing if there is an air intake,
boiler heat exchanger or vent
blockage.
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
the ability to read 0.01” to 2.0”
w.c.
Turn on service switch and set
thermostat to call for heat.
Boiler Status
Not Running
Setpoint
Running Without Blockage
Running With Blockage
Differential Pressure (w.c.)
0”
1.00” for Model-100
1.35” for Model-75
1.55” for Model-50
Greater Than Setpoints
Less Than or Equal to Setpoints
Pressure Switch Connects
Normally Open
Closed
Open
If manometer readings do not correspond to the chart above, check for possible causes:
- Blockage or moisture in suction lines
- Blockage in air intake or vent pipes
- Undersized air intake or vent pipes
- Loose blower wheel or motor shaft
- Inncorect pressure switch or pressure switch setpoint
When pressure reading is proper and the pressure switch is operating properly, remove testing
lines and reinstall vinyl caps to Tee and 4-way connector.
62
REPAIR PARTS
UB90-50-100 GAS-FIRED, DIRECT VENT,
CONDENSING, HOT WATER Boiler
Model No.
UB90-50
UB90-75
UB90-100
Repair Parts
A. Jacket and Base Assembly
10
9
8
5
7
18
3
4
17
19
6
18
20
1
2
12
TYP OF 4
11
13
21
64
15
16
Repair Parts
JACKET AND BASE ASSEMBLY
KEY #
DESCRIPTION
QUANTITY
ITEM
NUMBER
1
FRONT PANEL
1
750001020
2
RIGHT PANEL
1
750001021
3
LEFT PANEL
1
750001022
4
BACK PANEL
1
750001023
5
TOP PANEL
1
750001024
6
BASE
1
750001025
7
CONTROL PANEL
1
650001026
8
AT140B1016 TRANSFORMER 24 VAC
1
550001339
----
----
10
9
UT 1013-10 INTEGRATED BOILER CONTROL
----
1
14662803
11
CO-2366 GLIDE
4
14631091
12
HEYCO OCB-1500 BUSHING
1
14631120
13
RACO 232 4´4´2 BOX
1
14631316
----
----
14
----
15
P&S SWITCH 691-I
1
14631319
16
COVER PLATE RACO 902-802
1
14631318
17
419-1AA1 2½” PLUG
2
14631174
18
415-1AA1 1½” PLUG
2
14631171
19
BPF 3 ½” PLUG
1
14631176
20
421-1AA1 3” PLUG
2
14631175
21
LOWER FRONT PANEL
1
750001027
22
Door Pulls
2
CI-001.03
‡
TACO CIRCULATING PUMP
1
750001027
‡
TACO ISOLATION VALVE SET
1
14626048
‡
GRUNDFOS CIRCULATING PUMP
1
14626045
‡
GRUNDFOS ISOLATION VALVE SET
1
14626046
‡
CIRCULATING PUMP HARNESS
1
43300826
‡
WIRING HARNESS
‡
JACKET COMPLETE
‡ - Not Shown
65
1
14631315
----
750001002
Repair Parts
B. Condensate Drain Trap Assembly
Connect to the drain port at
the bottom of boiler
3
Connect to the
drain port at
the exhauster
1
1
7
4
8
2
KEY #
1
2
3
4
5
6
7
8
DESCRIPTION
59019 ½”IDx1/8” THK VINYL TUBING
57134 ¾” SNAP GRIP CLAMP
62067 ½”ID HOSE TEE
62017 ½”NPTx ½”ID TUBE STRAIGHT
½” PVC COUPLING, SCH 80
½”´4” PVC NIPPLE, SCH 80
TEE PVC ½”SLIP x ½”SLIP x ½”NPT FEMALE
S. S. CLAMP, SIZE 16 (13/16”~1 ½”)
66
5
2
QUANTITY
AS REQUIRED
6
1
1
1
1
1
1
6
ITEM NUMBER
14631035
14631141
14631320
14631101
14631306
14631322
14631020
14631323
Repair Parts
C. Flue Adapter and Exhaust Assembly
KEY #
1
DESCRIPTION
EXHAUST TEE ASSEMBLY - 1-A,B,C,D,E & F
QUANTITY
ITEM NUMBER
1
43800001
1A
62017 1/2”NPTx1/2”ID TUBE STRAIGHT
1
14631101
1B
PVC 1 1/2” MALE SLIP x 1/2” FEMALE NPT
1
14631013
1C
PVC SCH 40 2”x1-1/2” REDUCER S636
1
240006817
1D
3/4’’ ALUMINUM FLAT WASHER
1
14695815
1E
2” CPVC TEE, SCH 80 S636
1
240006819
1F
2” CPVC PIPE´2-1/2’’, SCH 40 S636
1
240006821
2
VENT SWITCH GASKET
1
14631028
3
36TX11-22491 INDUCER TEMP SAFETY SWITCH
1
14631303
4
#4-20x1/4” HWH PLAST FORM SCREW
2
14695808
INDUCED DRAFT BLOWER KIT
1
2272065
6
BLOWER GASKET
1
14631026
7
FLUE CONNECTOR
1
12101021
8
RECOVERY COIL GASKET
1
14631027
1/4”-20 HEX NUT W/SERRATED WASHER BLOCK
4
14695810
1/8” NPT 1/4” HOSE ID BRASS BARB FITTING
1
14693804
5**
9
10***
11
62043 1/2’’ NPT´1/2’’ ID TUBE ELBOW
1
14631103
12
57134 3/4’’ SNAP GRIP CLAMP
2
14631141
13
59019 ½’’ ID´1/8 THK VINYL TUBE
AS REQUIRED
14631035
14
HOSE, 3” LONG 2-3/8” ID X 2-3/4” OD
1
14631301
15
S. S. CLAMP, SIZE 44
2
14631302
16
PC250-12 VINYL CAP
2
14631151
17
3/8” HOSE CLAMP HC-6ST
2
14631143
*
Vent Pipe 2” CPVC SCH-40 x 29½” long
2
240006821
*
Coupling CPVC SCH-80
1
240006822
* - Not shown
** - Includes items 2,3,4,5,6,16,17
*** - Combustion Test Port
67
Repair Parts
D. Boiler Block and Piping Assembly
30
20
29
21
22
9
23
24
10
16
25
3
19
TYP OF 5
12
5
6
4
18
14
TYP OF 5
28
28
1
27
2
15
17
TYP OF 8
14
TYP OF 4
11
TYP OF 4
8
13
TYP OF 4
2
15
68
26
Repair Parts
BOILER BLOCK AND PIPING ASSEMBLY
KEY #
ITEM NUMBER
DESCRIPTION
QUANTITY
1
41800650
KIT BLOCK REPL Q90-100 (INCLUDES #2 THRU #19)
1
2
14607044
NPL,1-1/4X2-1/2,BI,STD
2
3
14607201
NPL,3/4X2,BI,STD
1
4
14619002
OBSERVATION GLASS, 3/4”
1
5
14631000
SWITCH CASTING TEMP Q90 36T26-42930 300
1
6
14631004
ADAPTER, SIGHT GLASS
1
7
14631005
FITTING, 125HBL-4-2 1/8”X1/4”BR.B+
1
8
14631101
HOSE ADAPTER 62017 1/2”NPT X 1/2” ID
1
9
14693004
BSHG,3/4” X 1/2”, BLK, STD
1
10
14693040
ELG,ST,MALL,3/4”,90°
1
11
14695040
BOLT, 1/4-20 X 1-1/4”, CARRIAGE
4
12
14695802
SCR,8-32 X 3/16,RH,ALH,CAP
2
13
14684012
PLASTIC BAG 12” X 9”, 2 MIL
1
14
14695805
STUD, THREADED, 1/4-20 X 1 1/4”
9
15
1510001
TEE,RDCR,1-1/4” X 3/4” X 1-1/4”
2
16*
14693058
3/4” SQ HD PLUG
1
17*
14693056
1” HEX SOCKET PLUG
8
18*
14695801
SCR, 1/4-20 X 1-1/2”,RH,ALH,CAP
5
19*
14695810
NUT, 1/4-20,HWS
5
--- * NOTE: #16 THRU #19 INSTALLED IN HEAT EXCHANGER --20
1580006
VENT AIR PURGE Q SERIES
1
21
14693001
BSHG, 3/4” X 1/8”,BLK
1
22
14693076
TEE,BLK, 3/4”
1
23
14693040
ELB,ST,MALL,3/4”, 90°
1
24
14607002
NPL, 3/4” X 6-1/2”,BL,SCH 80, PS2
2
25
14622011
VLV,FLF,ASME,30PSI,3/4,10-408-05
1
26
14622000
VLV,DRN,3/4,MATCO,NORCA,204TM4
1
27
1260006
GAUGE,TEMP/PRESS,2” SHANK
1
28
14693001
BSHG,3/4” X 1/8” BLK
1
29
14662804
WELL CONTROL 1/2” 123869A B.P.
1
30
14631324
AQUASTAT L4006-2080
1
69
Repair Parts
E. Mixer and Air Pressure Switch Assembly
To Sight Glass
Adapter
1
28
2
27
3
15
21
16
24
19
14
19
23
13
22
4
12
28
17
11
5
10
26
19
18
20
21
4
14
21
14
19
9
25
6
7
8
70
Repair Parts
MIXER AND AIR PRESSURE SWITCH ASSEMBLY
KEY #
1
DESCRIPTION
BURNER GASKET
QUANTITY
ITEM NUMBER
1
14631023
2A
BURNER Kit, 50 &100 NAT/LP, 0’-10,000’ (Contains: 1, 2, 3, 7, 10, 11, 12 & 29)
1
550001811
2B
BURNER Kit, 75 NAT, 0’-10,000’ (Contains: 1, 2, 3, 7, 10, 11, 12 & 29)
1
550001811
2C
BURNER Kit, 75 LP, 0’- 5,000’ (Contains: 1, 2, 3, 7, 10, 11, 12 & 29)
1
550001811
2D
BURNER Kit, 75 LP, 5,000’-10,000’ (Contains:1, 2, 3, 7, 10, 11, 12, 27F & 29)
1
550001812
3
MIXER GASKET
1
14631025
4
¼”-20 HEX NUT W/SERRATED WASHER HEAD
5
14695810
5
MIXER CASTING MACHINED
1
12101008
6
2”´1½” FLEXIBLE COUPLING
1
14631311
7A
100 AIR BAFFLE
1
42531100
7B
75 AIR BAFFLE
1
42531101
7C
50 AIR BAFFLE
1
42531102
AIR INLET
1
43800007
8
9
2” FERNCO COUPLING
1
14631015
10
10-32”x3/8” MACHINE SCREW
2
14695809
11*
HOT SURFACE IGNITER KIT (FOR 50/75/100)
1
43800013
12
HOT SURFACE IGNITER GASKET
1
1250010
13
BUSHING With Hex, Q90 MIXER
1
1060007
14
1/8’’ NPT BRASS PLUG – 3/16’’ HEX SOCKET
3
14693804
15
HONEYWELL GAS VALVE VR8205
1
14631307
16
5/16-24´1/4 HOSE ID BRASS BARB FITTING
1
14631308
17
62064 ¼”ID TUBE TEE
1
14631104
18
¼”ID TUBE 4-WAY CONNECTOR
1
14631313
19
3/8” HOSE CLAMP HC-6ST
10
14631143
20
PC250-12VINYL CAP
2
14631151
21
59006 ¼”IDx3/8”OD VINYL TUBING
AS REQUIRED
14631033
22
1/4’’ID´3/8”OD VINYL TUBING (RED)
AS REQUIRED
14631314
23
1/4” ID SILICONE TUBING
AS REQUIRED
1552014
14631312
24A
PPS10111-2680 AIR PRESSURE SWITCH (100)
1
24B
PPS10111-2681 AIR PRESSURE SWITCH (75)
1
14631010
24C
PPS10111-2682 AIR PRESSURE SWITCH (50)
1
14631044
62043 ½’’ NPT´1/2”ID TUBE ELBOW
1
14631103
GAS ORIFICE NATURAL, 100N (0.0860, #44)
1
43331090
25
26A
26B
GAS ORIFICE NATURAL, 75N (0.0760, #48)
1
43331092
26C
GAS ORIFICE NATURAL, 50N (0.0615)
1
43331094
26D
GAS ORIFICE PROPANE, 100P (0.0670, #51)
1
43331091
26E
GAS ORIFICE PROPANE, 75P (0.0605)
1
43331093
26F
GAS ORIFICE PROPANE, 50P (0.0492)
1
43331095
26G
GAS ORIFICE PROPANE, 50P (0.0492)
1
43331095
Rotor Clamp
2
14631143
Restrictor Plate 90-50
1
109006405
27
28A
28B
Restrictor Plate 90-75
1
109006406
-
Natural to LP Conversion Kit, 50’, 0’-10,000’
1
43345200
-
Natural to LP Conversion Kit, 75, 0’-5,000’
1
43345201
-
Natural to LP Conversion Kit, 75, 5,000’-10,000’
1
550001810
-
Natural to LP Conversion Kit, 100, 0’-10,000’
1
43345202
* - Includes item numbers 10,11 & 12.
71
85 Middle Rd.
Dunkirk, NY 14048
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