Argo | AT1025 | Installation manual | Argo AT1025 Installation manual

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
"AT" SERIES ELECTRIC HOT WATER BOILERS
FOR FORCED HOT WATER
ARGO TECHNOLOGY, INC.
554 Berlin Turnpike
Berlin, CT 06037
Phone: (860) 828-6513
Fax: (860) 828-3856
www.argoindustries.com
An ISO 9001-2000 Certified Company
P/N I-80, Rev. 3.1 [08/04]
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
P/N# I-80, Rev. 1.0 [05/04] • Printed in USA • Made In USA
TABLE OF CONTENTS
SAFETY SYMBOLS
Safety Symbols .................................................... 2
Warnings .............................................................. 3
Introduction .......................................................... 3
Product Description .............................................. 3
Voltage Rating Tables .......................................... 4
Installation Procedure .......................................... 5
Design of Water Circulating System .................... 6
Connecting Supply and Return Piping ................. 6
Connecting Electrical Power Supply .................... 8
Wiring Diagrams ................................................ 11
Thermostat Installation ....................................... 15
Startup and Seasonal Maintenence ................... 15
Troubleshooting ................................................. 16
Maintenance ....................................................... 17
Parts List - 2 Element Electric Boilers ................ 18
Parts List - 4 Element Electric Boilers ................ 19
Additional Wiring Diagrams ............................... 20
Modular Boiler Piping ......................................... 23
Troubleshooting ................................................. 24
"AT" Series Boiler Dimensions ........................... 27
Homeowner's Reference Table.......................... 28
The following defined symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels.
!
DANGER
!
Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or
serious injury.
!
WARNING
!
Indicates a potentially hazardous situation
which, if not avoided, COULD result in death
or serious injury.
!
CAUTION
!
Indicates a potential hazardous situation
which, if not avoided, MAY result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
IMPORTANT: Read the following instructions
COMPLETELY before installing!!
16027
2
Tested For 30 LBS.
ASME
Working Pressure
WARNINGS
!
WARNING
INTRODUCTION
!
This manual is intended to familiarize the installer
and user of the Electric Hydronic Block with its
installation, operation and maintenance so as to
assure its normal trouble free operation.
1. BOILER SIZING IS CRUCIAL. The maximum
hourly heat loss for each heated space should
be calculated in accordance with the procedures describes in The Hydronics Institute
(I=B=R) manual H-22 (Heat Loss Calculation
Guide), or by any other method which is suitable for local conditions, provided the results
are in substantial agreement. Select the appropriate boiler based on accurate heat loss
calculation. DO NOT OVERSIZE THE BOILER,
AS SIZING IS CRITICAL FOR IN-FLOOR RADIANT HEAT APPLICATIONS.
Argo electric boilers are designed and manufactured
with quality components for maximum life and
durability and require minimum service. To insure a
satisfactory installation it is imperative that the
instructions be followed carefully before operating
the heating system. Failure to do so may result in
breach of warranty.
PRODUCT DESCRIPTION
2. Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids.
The Electric Hydronic Block is a heating device that
converts electrical energy to heat energy through
the medium of water. The simplified theory of this
conversion is as follows:
3. DO NOT obstruct air openings to the boiler
room.
Electrical Energy x Conversion Factor = Heat Energy
-orKilowatts Of Electricity Used Per Hour x 3412 = British
Thermal Units (BTUs) Available Per Hour For Heating
4. Modification, substitution or elimination of
factory equipped, supplied or specified components may result in property damage, personal injury or the loss of life.
This information is the basis used to establish Electric Hydronic Block ratings (See Table 1 on page 4).
Since the conversion process requires no combustion, the boiler operates with the highest possible
efficiency.
5. TO THE OWNER: Installation and service of
this boiler must be performed by a qualified
installer.
The Electric Hydronic Block is constructed with a
cast iron boiler that conforms to the American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code. The interior design allows just
enough water to be present for proper heating element operation - no excess water is stored which
would cause undersirable thermal losses and longer
recovery times.
6. TO THE INSTALLER: Leave all instructions
with the boiler for future reference.
7. When this product is installed in the Commonwealth of Massachusetts the installation
must be performed by a licensed plumber or
licensed gas fitter.*
* In other areas, consult your local codes.
!
WARNING
The control system is assembled in a modular package thus keeping the overall size and weight of the
Electric Hydronic Block to a minimum. The construction of the entire Electric Hydronic Block conforms to
Canadian Standards Association (CSA) Standards
for Safety for Electric Boilers.
!
All installations of boilers should be done only
by a qualified expert and in accordance with
the appropriate Argo manual. Installing a
boiler or any other electric appliance with
improper methods or materials may result in
serious injury or death due to fire.
3
The following important product information is located on the cabinet cover:
ARGO Electric Boilers are controlled by a electronic
temperature controller. The controller controls the
boiler water temperature with multiple stages and
turns stages on based on the heating demand, and
the preset boiler outlet water temperature. The controller also can control 120Vac circulating pumps
rated up to 5A. When the thermostat calls for heat,
the controller will operate the boiler to regulate the
water temperature at a pre-selected set point. The
system pump is on whenever there is a thermostat
calling for heat.
• Model Number
• Manufacturer's Serial Number
• BTU Rating
• Heating Element Ratings
• Water Pressure & Temperature Limits
• CSA Listing
• ASME Stamp
• Total Amps
• Clearance
VOLTAGE RATING TABLES
TABLE 1 - ELECTRIC HYDRONIC BLOCK RATINGS SPECIFICATIONS (SINGLE PHASE UNITS)
A - STANDARD 240V RATINGS
Model
AT0623
AT0824
AT1025
AT1226
AT1243
AT1644
AT2045
AT2446
Boiler
Operating Net Heat
Size
Voltage
Output
Nominal
(AC)
BTU/Hr.
KW
6
240
20,472
8
240
27,296
10
240
34,120
12
240
40,944
12
16
20
24
240
240
240
240
40,944
54,592
68,240
81,888
"AT" Series - 2 Element Boiler
Total
Power
Number Element Maximum Suggested Suggested
Heating
Amperage Wire Size Breaker Size
Input
of
Size
Element
Watts
Elements (Watts) Per Leg (1) (AWG) (2)(3)
(Amps) (3)
Amperage
6,000
25.0
2
3,000
31.0
8
40
8,000
33.3
2
4,000
39.3
6
50
10,000
41.7
2
5,000
47.7
6
60
12,000
50.0
2
6,000
56.0
4
70
"AT" Series - 4 Element Boiler
12,000
50.0
4
3,000
56.0
4
70
16,000
66.7
4
4,000
72.7
3
90
20,000
83.3
4
5,000
89.3
2
100
24,000
100.0
4
6,000
106.0
1
125
B - DE-RATED 208V RATINGS
Model
AT0623
AT0824
AT1025
AT1226
AT1243
AT1644
AT2045
AT2446
Boiler
Operating Net Heat
Size
Voltage
Output
Nominal
(AC)
BTU/Hr.
KW
6
208
15,377
8
208
20,502
10
208
25,628
12
208
30,753
12
16
20
24
208
208
208
208
30,753
41,005
51,256
61,507
"AT" Series - 2 Element Boiler
Total
Power
Number Element Maximum Suggested Suggested
Heating
Amperage Wire Size Breaker Size
Input
of
Size
Element
Watts
Elements (Watts) Per Leg (1) (AWG) (2)(3)
(Amps) (3)
Amperage
4,507
21.7
2
3,000
27.7
8
40
6,009
28.9
2
4,000
34.9
8
50
7,511
36.1
2
5,000
42.1
6
60
9,013
43.3
2
6,000
49.3
6
70
"AT" Series - 4 Element Boiler
9,013
43.3
2
3,000
49.3
6
70
12,018
57.8
2
4,000
63.8
4
90
15,022
72.2
2
5,000
78.2
3
100
18,027
86.7
2
6,000
92.7
1
125
(1) Allow s for 6A control and accessory load in addition to heat load
(2) Type "THW" w ire, copper only, check local codes (Sizes taken from C.E.C Table 2 & N.E.C. Table 310-16.)
(3) Actual w ire and breakers need to be sized based on specific installation requirements in accordance w ith National Electrical Code (NEC), Canadian
Electrical Code (CEC), and local codes (w here applicable).
4
INSTALLATION PROCEDURE
to wall surface on the right or more, depending on
plumbing. Allow sufficient room from the front of the
unit to a door or wall to remove cover - at least 12
inches minimum. Install unit with a minimum
clearance from top of unit to ceiling of 16 inches. If
minimum requirements of space are used, it is
suggested that the enclosure be exposed to some
means of ventilation. The electric Hydronic Block
unit must be mounted level, using the top of the back
plate as a leveling point.
Improper installation, adjustment, alteration, service
or maintenance can cause injury or property damage.
1. The installation must conform to the requirements
of the authority having jurisdiction or, in absence of
such requirements, to the latest revision of the
Canadian Electrical Code, CSA C22.1 Part 1, and/or
any local regulations in Canada, or the National
Electrical Code, ANSI/NFPA to (Latest Edition) and/
or any local regulations and codes in the USA.
Reference should also be made to local Electric
utility regulations and other codes in effect in the
area in which the installation is to be made.
6. When installed in utility room, the door should be
wide enough to allow the largest boiler part to enter,
or to permit replacement of another appliance such
as a water heater.
2. Where required by the authority having jurisdiction,
the installation must conform to American Society of
Mechanical Engineers Safety Code for Controls and
Safety Devices for Automatically Fired Boilers, ANSI/
ASME No. CSD-1.
Minimum clearances to combustible constructions
are:
TOP .................................................. 16 IN.
FRONT ............................................. 12 IN.
LEFT SIDE ....................................... 20 IN.
RIGHT SIDE ..................................... 20 IN.
REAR ................................................. 0 IN.
3. The Boiler is intended for indoor installation
only and not subject to water spray or leakage.
!
CAUTION
!
BOILER LOCATION & CLEARANCE DIMENSIONS
Do not install boiler UNDER potential water
source.
(RULE OF THUMB: Water Under Wires.)
4. Electric Hydronic Block units are provided with
mounting brackets for easy wall mounting. The unit
may be mounted directly on the wall by the use of lag
screws or anchor bolts through holes provided, or on
a 3/4" plywood panel. On uneven walls, it is suggested
that a mounting surface be provided such as two 2 x
4’s.
5. Any surface of the Electric Hydronic Block except
the back shall be mounted no closer than 20 inches
to the wall surface on the left and 20 inches minimum
NOTE: Greater clearances for access should
supercede fire protection clearance.
5
the bottom of the unit. Reverse flow will result in a
noisy operation and cause very early element failure.
The drain cock is to be located at the lowest point of
piping.
DESIGN OF WATER
CIRCULATING SYSTEM
System should be designed as primary/secondary
piping and to operate with a maximum output temperature of 180º F or lower and a temperature rise
across the unit of 20º F or lower. Refer to tables
below and Figures 2 & 3.
5. The outlet or supply pipe line to the radiation is
located at the top of unit. A combination temperature
pressure (altitude) gauge is provided with each unit
and should be installed close to the boiler outlet. It is
important that the gauge sensor be completely
immersed in the flowing water so as to assure
correct temperature readings. Manual or automatic
water make up supply may be located in this area
below. The circulator pump should be installed on
the supply side (pumping away).
"AT" Series - 2 Element Boiler
KW
Minimum Flow Rate
Capacity
(GPM)*
6
2.0
8
2.7
10
3.4
12
4.1
"AT" Series - 4 Element Boiler
KW
Minimum Flow Rate
Capacity
(GPM)*
12
4.1
16
5.5
20
6.8
24
8.2
6. Gate valves should be installed at the locations
shown in Figures 2 & 3, so that any boiler servicing
requiring removal of water can be done quickly and
easily. Not illustrated but also highly recommended
is the installation of air vents at the high points of the
hydonic system. These devices will reduce initial
start up time and help avoid element burnout during
the entire life of the heating system.
* Flow rate based on 20°∆T
NOTE: To prevent condensation, the return water temperature must be higher than the room
temperature in which the boiler is installed.
7. A pressure relief valve is supplied with each
Electric Hydronic Block and should be installed at the
location and discharge direction shown in Figure 1,
using pipe nipple and elbow supplied. Piping should
be added so that any water that may be discharged
will not damage the boiler or other system
components.
CONNECTING SUPPLY
AND RETURN PIPING
1. Maintain a minimum clearance of one inch to hot
water pipes.
PLUMBING AND
ACCESSORY
INSTALLATION
2. Hot water boilers installed above radiation level
must be provided with a low water cutoff device
either as part of the boiler or at the time of boiler
installation.
NOTE: In some states a low water cutoff device
(LWCO) may be required. Check your local codes.
3. When a boiler is connected to a heating system
that utilizes multiple zoned circulators, each circulator
must be supplied with a flow control valve to prevent
gravity circulation.
NOTE: Reduced pressure back flow provender
must be present under provisions required by the
Environmental Protection Agency, (EPA).
FIGURE 1
8. For further piping information refer to The Hydronics
Institute (I=B=R) manual 200 (Installation Guide for
Residential Hydronics).
4. Suggested plumbing arrangements are illustrated
in Figures 2 & 3. The inlet or return pipe is located at
6
PRIMARY/SECONDARY PIPING FOR
MULTIPLE ZONING WITH CIRCULATORS
FIGURE 2
PRIMARY/SECONDARY PIPING FOR
MULTIPLE ZONING WITH ZONE VALVES
FIGURE 3
7
CONNECTING ELECTRICAL POWER SUPPLY
THERMOSTAT: Connect thermostat or zone valve
end switch to terminals TT and TT (Figure 4). Do not
apply an external power source to these
terminals!! Strip wire ends before inserting into
terminal block. Tighten terminal screw clamps.
WIRING THE BOILER
!
WARNING
!
DO NOT USE ALUMINUM WIRE!!
Argo Electric Hydronic Boilers are pre-wired for use
with 240-volt, 3 wire, single-phase, 50/60-hertz power.
Refer to Table 1B on page 4 for the reduction in boiler
capacity when the line voltage is less than 240 volts.
An opening is provided in the jacket bottom panel for
the field wiring, refer to the rating chart for
recommended wire sizes.
All electrical wiring must be done in accordance with
the Canadian Electrical Code, CSA C22.1 Part 1,
and /or any local regulations and codes in Canada,
or the National Electrical code, ANSI/NFPA 70 (Latest
edition) and/or any local regulations and codes in
USA. Verify the nameplate rating and check the
related codes to properly size conductors, switches
and over current protection. Several openings are
provided on the bottom of the cabinet for different
voltage connections. For wire connections refer to
the wiring diagram on the inside of the boiler front
cover. Do not use aluminum wire!!
FIGURE 4
All circuit breakers or disconnects ahead of the boiler
must be OFF. If boiler contains integral breakers
(depending on option), it is recommended that they
are also turned off at this time. Remove the boiler
front cover by removing 4 screws from the top and
sides.
LIMIT CONTROL OPERATION
FIGURE 5
1. When the boiler water temperature exceeds
the high limit setting on the aquastat, all heating
element control relays are instantly de- energized.
Circulator continues to operate until call for heat
ends. When water temperature drops below
aquastat re-set differential, heating element power
relays close as per time delay sequence.
When a boiler is used in a zoned system, the zone
valves must be powered from an independent source
and have electrically isolated end switches or isolating
relays wired in parallel to the boiler thermostat
terminals. Do not attempt to power zone valves
from the transformer in the boiler control system!!
2. MAIN POWER SUPPLY: Depending on model
designation, the electric Hydronic Block may be
energized by the following alternating current
service entrances: 240 volt single phase 50 or 60
cycle 3 wire. The wire size required may be
selected from Table 1. The sizes listed for various
capacity units include total amperes necessary to
operate elements, circulator and zone valves
where used. Wire sizes specified conform to the
Canadian Electrical Code (Canada) or National
Electric Code (USA) and include derating for
ampacity and temperature. Use copper wire
WIRING ON CONTROL
PUMP: Connect only 120 Vac 1/6 HP (maximum)
pump to terminals C1(L) and C2(N) on the controller.
Strip wire ends before inserting into terminal block.
Tighten terminal screws. Do not use a pump
requiring greater than 5 amps!!
8
only with insulation rated for 75 °C. Check
state and local requirements.
LED DISPLAY LIGHTS (Figure 6): A total of 8 LED
indicator lights display the following information:
NOTE: Read the data name plate before
connecting unit so that you will become
familiar with the specifications. All electrical
connections to the unit are provided and
located for ease of proper installation.
(1) T-T (Green): LED is lit when thermostat is
calling for heat.
(2) Fault (Red): LED is lit/flashes when there is an
operating error/safety fault.
(3) Safety Switch (Green): LED is lit when there
are no safety faults.
(4) Circ (Green): LED is lit when circulator terminals are energized.
(5) Heating Element#1 (Green): LED is lit when
element#1 is energized.
(6) Heating Element#2 (Green): LED is lit when
element#2 is energized.
(7) Heating Element#3 (Green): LED is lit when
element #3 is energized.
(8) Heating Element#4 (Green): LED is lit when
element#4 is energized.
IMPORTANT: Use only copper wire of proper
size and make sure all terminations are very
tight. Do not use aluminum wire!!
3. CIRCULATOR POWER SUPPLY: Terminals
identified as C1(L) and C2(N) at the bottom of
the control panel (Figure 5) may be used to supply
one circulator pump power. The circulator motor
shall not be larger than 1/6 horsepower with a
maximum 5.0 amp rating. Wiring from the control
panel to the pump should have insulation rated
at 75°C. Circuit protection is provided by a 15
amp breaker or fuse (depending on option) on
the control board.
NOTE: If the circulator pump is larger than
the maximum size listed above, then a
separate circulator pump relay must be
provided with separate overload protection.
Where more than one circulator is used for
zoning, it must be installed and protected
according to approved electrical codes.
CONTROL INFORMATION
CONTROL BOARD SPECIFICATIONS:
Dimensions: 5-7/8"(W) x 9-3/8" (L) x 1-5/8" (H)
Operating Control Outlet Water Temperature:
90°F - 180°F (adjustable)
High Limit Control Outlet Water Temperature:
200°F (fixed)
Control Input Voltage: 120V ac
Control Output Voltage: 120V ac, 5A max.
(circulator terminal)
FIGURE 6
SIGNAL/CONTROL INPUTS:
POWER OUTPUT: One 120V ac pump output is
switched by an onboard circulator relay. The load
current is limited and must not exceed 5A.
TT: Thermostat or zone valve end switch, switching input, closed is activation.
HL: High limit temperature sensors (factory installed), normally closed.
LWC: Low water cutoff (optional) end switch,
normally closed (factory installed jumper).
CONTROL BOARD POWER CONSUMPTION: 0.8A
max.
9
FLOW: Flow switch (optional) end switch, normally closed (factory installed jumper).
After 3 minutes the control will de-energize the
circulator ("Circ" LED turns off).
TEMPERATURE CONTROL RANGES:
If at any time during the start-up of the boiler or
during operation a safety end switch opens its
respective contact, the control de-energizes all
elements, continues to energize the circulator, and
flashes a visible fault code ("Fault" LED flashes)
along with an audible fault code. (See fault codes
(below)) The control has a built-in reset function.
Temperature: Degrees Fahrenheit
Operating Temperature Range:
90°F - 180°F
(Factory Setting: 180°F)
Operating Temperature Differential Range:
+/- 4°F - +/- 20°F
(Factory Setting: 12°F)
Fixed High Limit Temperature: 200°F
OPERATING TEMPERATURE AND DIFFERENTIAL ADJUSTMENTS: Internal temperature potentiometer on the control.
CONTROL OPERATION: When the control switch
is in the "On" position and all safety end switches are
closed, the "Safety Switch" LED is lit. Once in operating mode, the control uses the well-mounted (RTD)
sensor to continuously monitor the boiler water temperature.
When the thermostat calls for heat ("TT" LED is lit),
the control will energize the circulator ("Circ" LED is
lit) for 30 seconds to establish flow. Next the control
will measure water temperature and differential setting, perform a check for an "open" or "shorted" RTD
sensor, check that all safety end switches are
"closed," and check for stuck or welded element
relay contacts. Next, the control will energize only
one element ("Element" LED is lit) and monitor water
temperature for 60 seconds. The control will energize additional elements at 30 second intervals to
bring the system up to set point temperature in 5
minutes.
TEMPERATURE SETTING: The water "Set point"
temperature adjustment dial on the control should
always be set at the designed boiler water
temperature.
CONTROL MOUNTING: The control is mounted
using 1/2" tall plastic standoffs. The indicator LEDs
are visible through a clear polycarbonate viewing
window on front cover of the boiler.
PROTECTION FROM LIQUIDS: The control and
other components located within the control panel
are sensitive to water and other liquids. Measures
must be taken to fully protect components on panel
from contact with liquids.
FAULT CODES (VISUAL/AUDIBLE):
Number of
Flashes/Pulses
1
2
3
4
Description
Safety switch fault
Stuck/welded element relay contact
RTD short
RTD open
RTD SENSOR:
To confirm that the RTD sensor is functioning properly, follow the steps below.
Once the system reaches the set point temperature
and there is still a call for heat, the control will
modulate the number of elements on and off in order
to maintain the set point temperature. The required
number of elements which are energized is determined by heating demand, which is the difference
between actual boiler water temperature and set
point temperature.
1. Remove both RTD leads from the terminal
block on the boiler control board.
After the call for heat has been satisfied, the elements will be de-energized ("Element" LEDs turn
off) by the control and the circulator will continue
to be energized for 3 minutes to purge the boiler.
3. Replace RTD if necessary.
10
2. Use a multimeter to take an ohm reading
across the RTD leads. A properly functioning RTD
will produce a reading of approximately 1000
ohms at 70° F. A faulty RTD will read either 0 or 1
on your multimeter.
ELE MEN T #2
(ÉLÉ MEN T #2)
L1
E LEME N T #1 RE LAY S
H1
WH
WH T
T (B
(B LAN
LAN C
C ))
L1
L2
WH T (B LAN C )
FIGURE 7A
11
(N O N UTILIS É)
N O T U SE D
(N O N UTILIS É)
N O T U SE D
N O T U SE D
(N O N UTILIS É)
N O T U SE D
(N O N UTILIS É)
H2
L2
(R ELA IS D E LÉ LÉME NT #2)
E LEME N T #2 RE LAY S
H2
H1
(R ELA IS D E LÉ LÉME NT #1)
W HT /BLK ( BLA NC /NO IR )
(ÉLÉ MEN T #1)
EL EMEN T #1
W HT /BLK ( BLA NC /NO IR )
3
DIFFER EN TIAL
( DIFFÉ REN TIEL)
S AFETY SWITC HES
(IN TER RU PTEU RS
D E SÉ CU RITÉ)
T- T
RT D
IN PU T
(E NTR É E)
W HT /BLK ( BLA NC /NO IR )
R TD W AT ER TEMP ER ATU R E S EN SO R
N
BLK (N O IR)
L2
1
SO U RC E P O WE R, 120V /60HZ /1PH , BY O THE R S
O PT IO NA L FLO W S WITC H , BY OT HE RS
O PT ION A L LWC O, BY OT HE RS
(LW C O - FAC U LTATIF - O U AU TR ES)
(SO U RC E D U CO U RA N T, 120V/60H Z/1P H, OU AU TR ES )
(TE NO N DE PR ISE Á LA TER R E D E L É Q UIP MEN T)
(SO U RC E D U CO U RA N T, 240V/60H Z/1P H 3-F ILS, OU AU TR ES )
(DIAGRAMME SCHÉMATIQUE DE LA POSE DES
FILS D'UNE CHAUDIÈRE À 2 ÉLÉMENTS)
ARGO "AT" ELECTRIC BOILER
SCHEMATIC WIRING DIAGRAM
2 ELEMENT BOILER,
WITH BREAKERS
- 120 V O LT FIE LD W IR ING (P O SE DE S FILS 120 VO LT S UR LE C HA MP)
- 240 V O LT WIR IN G (PO S E D ES FILS 240 V OLT )
- 240 V O LT FIE LD W IR ING (P O SE DE S FILS 240 VO LT S UR LE C HA MP)
- D RY C ON TA CT WIR ING (P O SE DE S FILS DE CO N TA CT S EC )
- D RY C ON TA CT FIELD WIR IN G ( PO SE D ES F ILS D E C O NTA C T SE C S UR LE C H AMP )
- 120 V O LT WIR IN G (PO S E D ES FILS 120 V OLT )
W IRE LEG EN D / (LÉG E ND E D ES FILS )
(IN TER RU P TEU R D E D É BIT - FAC U LTATIF , O U A UT RE S)
E Q UIP MEN T G R O UN DIN G LU G
S O UR C E PO W ER , 240V/60H Z/1P H 3- WIR E, B Y O TH ER S
L1
2
LO AD C EN TER
(C EN TR E D E C H AR GE )
( INT ER RU PT EU R D E S ÉC U RITÉ H AU TE LIMIT E,
RE MISE EN MAR C HE AU TO MATIQ U E )
HIG H LIMIT S AFE TY S WIT CH , A UTO R ES ET
RE D ( RO U G E)
( INT ER RU PT EU R D E S ÉC U RITÉ H AU TE LIMIT E,
RE MISE EN MAR C HE AU TO MATIQ U E )
HIG H LIMIT S AFE TY S WIT CH , A UTO R ES ET
(JAR RE TIÉ RE S IN STA LLÉE S Á LUS INE )
F AC TO RY INS TA LLED JU MP ER S
R E D (R O UG E )
R E D (R O UG E )
TH ER MO STA T, BY O TH ER S
( THE R MOS TA T, O U A UT RE S)
( DÉ TEC TE UR D E LA T EMP ÉR ATU R E D E LE AU R TD)
N EU TR AL B LOC K
( BLO C N E UTR E)
W HT (BLA NC )
WH T (B LAN C)
N
L
120VA C
C IR C
N
( FER MÉ)
O FF
ON
(O U VE RT )
C1
C2
120VA C
L
C IRC U LATO R PU MP, BY O T HE RS
( PO MPE DU C IRC U LATE UR , O U AU TR ES)
CIR C ULA TO R R ELA Y
(R ELA IS D U
CIR CU LA TEU R)
C IR C
TR AN SFO R MER
(TR A NS FO RMA TEU R )
TT
TT
HL
HL
LW C
LW C
FLO W
FLO W
C O NTR O L
(CO N TR Ô LE)
A R GO E LEC TR ON IC BO ILER C O NTR O L
( CO N TR Ô LE ÉLE CT RO N IQ UE DE LA C H AU DIÈ RE AR G O )
ÉLÉME NTS D E
CH AU FFAG E)
FA ULT
2
4
(D ÉFAILLAN CE )
HEA TING ELEMEN TS
EN ERG IZED
(A CTIVA TION DE S
1
SETPO IN T
(RÉ GLAG E)
WH T (B LAN C)
WH T/BLK (B LAN C/N O IR)
WIRING DIAGRAMS
(É LÉME N T #2)
E LEME NT #2
H1
L1
WH T (B LAN C )
L1
L2
WH T (B LAN C )
12
FIGURE 7B
NO T U S ED
( NO N U TILISÉ )
( NO N U TILISÉ )
NO T U S ED
NO T U S ED
( NO N U TILISÉ )
( NO N U TILISÉ )
NO T U S ED
H2
L2
ELE MEN T #2 R ELA YS
(R ELA IS D E LÉLÉ MEN T #2)
H2
H1
ELE MEN T #1 R ELA YS
(R ELA IS D E LÉLÉ MEN T #1)
WH T/B LK ( BLA NC /N O IR)
E LEM EN T #1
(É LÉME N T #1)
WH T/B LK ( BLA NC /N O IR)
2
3
4
SA FETY S WITC HES
(IN TER RU PTEU RS
D E SÉ CU RITÉ)
T-T
RT D
C2
N
1 20VA C
C IRC
C1
L
C IRC U LAT OR P UMP , BY O TH ER S
(P O MPE DU C IRC U LAT EU R, O U AU TR E S)
(R ELA IS D U
CIR C ULA TE UR )
CIR C ULA TO R RE LAY
C IR C
TR A NS FO R MER
(T RA N SFO R MAT EU R)
RT D W AT ER TE MPE RA TU RE SE NS O R
L
WH T/B LK (BLA NC /N O IR)
W HT (BLA N C)
WH T (B LAN C )
N EU TR A L BLO C K
( BLO C N EU TR E)
( FER MÉ )
O FF
N
L1
L2
F ILS D' UNE CHAUDI È RE À 2 É LÉ ME NTS )
(DI AG RAM ME SCHÉ M AT IQUE DE LA P OS E DES
ARGO "AT" ELECTRIC BOILER
SCHEMATIC WIRING DIAGRAM
2 ELEMENT BOI LER,
WITH POWER BLOCK
- 240 VO LT FIELD W IRIN G (P O SE DE S F ILS 240 V O LT SU R LE C H AMP)
- 120 VO LT WIR IN G ( PO S E D ES FILS 12 0 VO LT)
- 120 VO LT FIELD W IRIN G (P O SE DE S F ILS 120 V O LT SU R LE C H AMP)
- 240 VO LT WIR IN G ( PO S E D ES FILS 24 0 VO LT)
- DR Y C O N TAC T W IR ING ( PO SE D ES FILS D E CO N TAC T S EC )
- DR Y C O N TAC T F IELD W IRIN G (P O SE DE S FIL S D E C O NT AC T SE C SU R LE C HA MP)
W IR E LE G EN D / (LÉG E ND E DE S FILS )
( INT ER RU P TEU R DE D ÉB IT - FA C ULT ATIF , O U A UT RE S)
O P TIO NA L FLO W SW ITC H, B Y O T HE RS
(LW C O - FA CU LTA TIF - OU A UT RE S)
O PT IO NA L LWC O , BY O TH ER S
SO U RC E P O WE R, 120V/60H Z/1P H , BY O THE R S
( SO U RC E DU C O UR AN T, 12 0V/60H Z/1P H, O U AU TR ES )
EQ U IPME NT G RO U N DIN G LUG
(TE NO N D E P RIS E Á LA T ER RE D E L É Q UIP MEN T)
PO W ER BLO C K
(B LO C DE PU ISS AN C E)
S O UR C E P OW ER , 240V /60H Z/1PH 3-W IR E, B Y O TH ER S
( SO U RC E DU C O UR AN T, 24 0V/60H Z/1P H 3- FILS, OU A UT RE S)
FU SE BLO C K
( BLO C DE FU SIB LE)
BLK (N OIR )
ON
HIG H LIMIT SAF ETY SW ITC H, AU TO R ES ET
(IN TE R RU PT EU R D E SÉ CU R ITÉ HA UT E LIMITE ,
RE MISE EN MA RC H E A UT OMA TIQ U E)
R ED (R O U GE )
HIG H LIMIT SAF ETY SW ITC H, AU TO R ES ET
(IN TE R RU PT EU R D E SÉ CU R ITÉ HA UT E LIMITE ,
RE MISE EN MA RC H E A UT OMA TIQ U E)
FA CT O RY IN STA LLED JU MPER S
(JA RR E TIÉR E S IN STA LLÉ ES Á LU SIN E)
R ED (R O U GE )
R ED (R O U GE )
T HE R MO STA T, B Y O TH ER S
(T HE RM OS TA T, O U AU TR ES )
(D ÉT EC TEU R D E LA TEM PÉR A TUR E DE LEA U RTD )
(O U VE RT )
12 0VA C
INP U T
(EN TR ÉE )
N
TT
TT
HL
HL
L WC
L WC
FLO W
FLO W
C O NT RO L
(CO N TR Ô LE)
A R GO E LEC TR O N IC B O ILER C ON TR O L
(C O N TR ÔL E É LEC TR O NIQ U E D E LA C H AU DIÈ RE AR G O )
ÉLÉMEN TS D E
CH AUF FAG E)
FAU LT
(D ÉFA ILLA NC E)
DIFFE REN TIAL
(DIFFÉ RE NTIEL)
H EAT ING ELEMEN TS
EN ERG IZED
(AC TIVA TION DE S
1
S ETPO INT
( RÉG LAG E)
W H T (B LAN C)
W HT /BLK (BL AN C/N O IR )
WIRING DIAGRAMS
WH T (BL ANC )
13
FIGURE 8A
WH T (BL ANC )
ELE MEN T #4
(É LÉMEN T #4)
H2
H1
L1
L2
H3
H2
L1
L2
WH T (BL ANC )
L1
L2
H4
L2
WH T (BLA NC )
WH T/BLK (BLA NC /N OIR )
WH T (BL ANC )
( RE LAIS D E LÉ LÉME NT #4)
ELE MEN T #4 RE LAY S
H4
H3
ELE MEN T #3 RE LAY S
( RE LAIS D E LÉ LÉME NT #3)
W HT/B LK (B LAN C/N O IR)
(É LÉMEN T #3)
ELE MEN T #3
L1
ELE MEN T #2 RE LAY S
( RE LAIS D E LÉ LÉME NT #2)
W HT/B LK (B LAN C/N O IR)
ELE MEN T #2
(É LÉMEN T #2)
H1
ELE MEN T #1 RE LAY S
( RE LAIS D E LÉ LÉME NT #1)
W HT/B LK (B LAN C/N O IR)
E LEME NT #1
(É LÉMEN T #1)
W HT/B LK (B LAN C/N O IR)
3
RT D
SAFET Y SWITC HES
(INTER RU PTEU RS
DE S ÉCU RITÉ)
T -T
N
C2
C1
120V AC
CIR C
L
CIR CU LAT OR PU MP, BY O TH ER S
(P OMP E D U C IRC U LATE UR , O U A UTR ES )
C IRC ULA TO R R ELA Y
(R ELA IS D U
CIR C ULA TEU R)
CIR C
TR AN SFO R MER
(TR AN SF OR MAT EU R)
TT
TT
HL
HL
LWC
LWC
FLO W
FLO W
NE UT RA L BLO CK
(BL OC NE UT RE )
W HT ( BLAN C )
W HT /BLK ( BLAN C /NO IR)
WH T (B LAN C)
(E NTR ÉE )
N
L
120VAC
IN PU T
(F ER MÉ)
O FF
ON
(O U VER T)
(CO N TR ÔLE )
C ON TR O L
(C O NTR Ô LE É LEC TRO N IQU E D E LA CH AU D IÈR E AR G O )
AR GO E LEC TRO N IC B O ILER CO N TRO L
É LÉMENTS DE
C HA UFFAG E)
FA ULT
2
4
(D ÉFAILLAN CE)
H EATIN G E LE MENTS
ENER G IZ ED
(AC TIVATIO N D ES
1
DIFFER EN TIAL
(DIFFÉR EN TIEL)
SE TPO IN T
(R ÉG LAGE )
WH T (N O IR)
W HT (BLA NC )
W HT /BLK ( BLAN C /NO IR )
N
BLK (N OIR )
L2
E Q UIP MEN T G RO U ND ING LU G
(TE NO N DE PR ISE Á LA T ER RE DE L ÉQ UIP MEN T)
S O UR CE PO WE R, 240V /60HZ /1PH 3-WIR E, B Y O TH ER S
(SO U RC E D U CO U RA NT, 240V /60HZ /1PH 3- FILS, O U AU TR ES)
L1
AR G O LOA D C EN TER
(C EN TR E D E C HA RG E A RG O )
HIG H LIMIT SA FETY SW ITCH , AU TO R ESE T
( INTE RR U PTE UR DE SÉC U RITÉ HA UT E LIMITE ,
R EMIS E E N MA RC HE AU TO MATIQ U E)
RE D ( RO U GE )
( INTE RR U PTE UR DE SÉC U RITÉ HA UT E LIMITE ,
R EMIS E E N MA RC HE AU TO MATIQ U E)
HIG H LIMIT SA FETY SW ITCH , AU TO R ESE T
(JAR RE TIÉR ES INS TALLÉ ES Á LUS INE )
FA CT OR Y IN ST ALLED JUMP ER S
R ED (R O UG E)
R ED (R O UG E)
THE RMO S TAT, B Y O TH ER S
( THE RMO ST AT, O U AU TRE S)
R TD W ATE R TE MPE RA TUR E S EN SO R
(DÉ TEC TEU R DE LA TE MPÉR AT UR E D E LE AU RTD )
WH T/BLK (BLA NC /NO IR )
D R Y C ON TA CT W IRIN G (PO SE DE S FILS DE CO N TAC T S EC)
D R Y C ON TA CT FIE LD W IRIN G (PO S E D ES F ILS D E C ON TA CT S EC SU R LE CH AMP )
120 V O LT WIR ING (P OS E D ES FILS 120 V OLT )
120 V O LT FIELD WIR IN G ( PO SE DE S FILS 120 VO LT SU R LE CH AMP )
FI LS D'UNE CHA UDIÈRE À 4 ÉLÉ ME NTS)
(DIA GRAM ME S CHÉM ATI QUE DE LA POS E DES
ARG O "AT" ELECTR IC BO ILER
SCHEMAT IC W IR ING DIAG RAM
4 ELEMENT BO ILER,
W ITH BREAKERS
- 240 V O LT WIR ING (P OS E D ES FILS 240 V OLT )
- 240 V O LT FIELD WIR IN G ( PO SE DE S FILS 240 VO LT SU R LE CH AMP )
-
WIRE LE GEND / (LÉ GE NDE DE S FILS )
O PT ION AL F LOW SW ITCH , BY O THE RS
(IN TER R UP TEU R D E D ÉB IT - FA CU LTAT IF, O U A UTR ES )
O PT ION AL LW CO , B Y O TH ER S
( LWC O - FAC ULT ATIF - OU AU TR ES )
SO U RC E P OW ER , 120V/60H Z/1PH , BY O THE RS
(SO U RC E D U CO UR AN T, 120V /60HZ/1P H, OU AU TR ES )
WIRING DIAGRAMS
WH T (B LAN C)
14
FIGURE 8B
WH T (B LAN C)
(ÉLÉ MEN T #4)
ELE MEN T #4
H2
H1
L1
L2
L1
E LEME NT #3 R ELA YS
H3
H2
L2
WH T (B LAN C)
L1
L2
L2
WH T (B LAN C )
H4
WH T/B LK (B LAN C/N O IR)
WH T (B LAN C)
(R ELAIS DE LÉLÉ MEN T #4)
E LEME NT #4 R ELA YS
H4
H3
(R ELAIS DE LÉLÉ MEN T #3)
W HT /BLK ( BLAN C /NO IR )
(ÉLÉ MEN T #3)
ELE MEN T #3
L1
E LEME NT #2 R ELA YS
(R ELAIS DE LÉLÉ MEN T #2)
W HT /BLK ( BLAN C /NO IR )
(ÉLÉ MEN T #2)
ELE MEN T #2
H1
E LEME NT #1 R ELA YS
(R ELAIS DE LÉLÉ MEN T #1)
W HT /BLK ( BLAN C /NO IR )
E LEME NT #1
(ÉLÉ MEN T #1)
W HT /BLK ( BLAN C /NO IR )
3
D IFFER ENTIA L
(D IFFÉR ENT IEL)
DE S ÉCU RITÉ )
SAFE TY SWITC HES
(INTE RRU PTE URS
T -T
R TD
N
C1
C2
120V AC
CIR C
L
C IR CU LATO R PU MP, B Y O TH ER S
( PO MPE DU C IRC U LATE UR , O U A UTR ES )
CIR C ULA TO R R ELA Y
(R ELAIS D U
C IR CU LAT EU R)
CIR C
(TR AN SF OR MAT EU R)
TRA NS FO R MER
TT
TT
HL
HL
LW C
LW C
FLO W
FLO W
W H T/BLK (BLA NC /N OIR )
W HT (BLA NC )
N
B LK (N O IR)
L1
D R Y C ON TA CT WIR ING (P OS E D ES FILS D E C O NT AC T SE C)
D R Y C ON TA CT FIELD WIR ING (P O SE DE S FILS DE CO N TAC T S EC SU R LE CH AMP )
120 V O LT WIR IN G (PO SE DE S FILS 120 VO LT)
120 V O LT FIE LD W IRIN G (P OS E D ES FILS 120 V OLT SU R LE CH AMP )
FI LS D'UNE CHA UDIÈ RE À 4 É LÉM ENTS )
(DIA GRAM ME S CHÉM AT IQUE DE LA P OS E DES
ARG O "AT" ELEC TRIC BOILER
SCHEMATIC W IRING DIAGRAM
4 ELEMENT BOILER,
W ITH PO W ER BLO CK
- 240 V O LT WIR IN G (PO SE DE S FILS 240 VO LT)
- 240 V O LT FIE LD W IRIN G (P OS E D ES FILS 240 V OLT SU R LE CH AMP )
-
WI RE LE GEND / (LÉ GE NDE DE S FI LS)
O PT ION AL F LOW SW ITC H, B Y O TH ER S
(IN TER RU PT EU R D E D ÉB IT - FA CU LTA TIF, O U AU TRE S)
O PT ION AL LW CO , B Y O TH ER S
(LW CO - FAC ULT ATIF - O U A UTR ES )
SO U RC E P OW ER , 120V/60H Z/1P H , B Y O TH ER S
(SO U RC E D U CO U RA NT , 120V/60H Z/1PH , O U A UT RE S)
EQ UIP MEN T G R OU N DIN G LUG
(TE NO N DE PR ISE Á LA TER R E D E L ÉQ U IPME NT )
PO WE R B LO CK
(B LO C D E P UIS SAN C E)
S OU R CE PO W ER , 240V/60H Z/1PH 3-WIR E, B Y O TH ER S
(SO U RC E D U CO U RA NT , 240V/60H Z/1PH 3-FILS , O U A UTR ES )
FU S E BLO C K
(BLO C DE FU SIBLE )
H IG H LIMIT SAF ETY SW ITCH , AU TO R ESE T
(IN TER R UP TEU R DE SÉC U RITÉ HA U TE LIMITE ,
R EMIS E EN MAR C HE AU TO MATIQ U E)
R ED (R O UG E)
H IG H LIMIT SAF ETY SW ITCH , AU TO R ESE T
(IN TER R UP TEU R DE SÉC U RITÉ HA U TE LIMITE ,
R EMIS E EN MAR C HE AU TO MATIQ U E)
FAC TO R Y IN STA LLED JUMP ER S
(JA RR ETIÉ R ES IN ST ALLÉ ES Á LUS INE )
R ED (RO U G E)
R ED (RO U G E)
TH E RMO ST AT, B Y O TH ER S
(TH ER MO STA T, O U AU TRE S)
L2
W HT /BLK (BLA NC /NO IR )
R TD WA TER TE MPE RA TUR E S EN SO R
(D ÉTE C TEU R D E LA TE MPÉR AT UR E D E LE AU RT D)
N EU TR AL BLO C K
(B LO C N EU TR E)
W HT (BLA NC )
WH T ( BLAN C )
(E NT RÉ E)
N
L
120VA C
IN PU T
( FER MÉ)
O FF
ON
(O U VE RT )
(C ON TR Ô LE)
C O NTR O L
A RG O EL EC TRO N IC B O ILER CO N TR OL
(CO N TR ÔLE ÉLE CT RO N IQU E DE LA C HA UD IÈR E A RG O )
FAU LT
2
4
(DÉ FAILLANC E)
HE ATING ELEMEN TS
EN ER GIZE D
(A CTIVA TION DE S
ÉLÉME NTS D E
C HAU FFAG E)
1
SETP OIN T
(RÉ GLAG E)
W HT (NO IR )
WH T/B LK (B LAN C/N O IR)
WIRING DIAGRAMS
THERMOSTAT INSTALLATION
1. Thermostat should be installed on an inside wall
about four feet above the floor.
2. NEVER install a thermostat on an outside wall.
4. Instructions for final adjustment of the thermostat
(adjusting heating anticipator, calibration, etc.) are
packaged with the thermostat. Recommended setting for the heating anticipator is 0.1 amps.
3. Do not install a thermostat where it will be affected by sunlight, drafts, televisions, lighting fixtures,
hot or cold pipes, fireplaces, or chimneys.
IMPORTANT: “TT” Terminals on the control board
are designed for 24V thermostat connections
only!!
STARTUP AND SEASONAL MAINTENANCE
!
It is suggested that a qualified service agency be
employed to make an annual inspection of the boiler
and the heating system. They are experienced in
making the inspection outlined below. In the event
repairs or corrections are necessary they can make
the proper changes for safe operation of the boiler.
!
CAUTION
!
CAUTION
!
Failure to vent and keep air out of the heating
system will result in damage to heating
elements in the hydronic block. Damage of
this type is not covered by the manufacturer's
warranty.
3. Set the boiler operating temperature to designed
heating water temperature by adjusting the
potentiometer dial located on the top center of the
controller (Figure 4). Adjust arrow on temperature
adjustment dial to the water temperature required.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
Verify proper operation after service.
NOTE: This boiler is also equipped with a highlimit temperature device set at 200°F as a safety
limit control. The high limit temperature device
has an automatic reset function and will reset at
170°F.
After all the procedures have been carefully followed
and completed, the hydronic block is now ready to be
put into service.
1. Check hydronic block circuit breaker or switch at
the service entrance and, depending on the option,
the hydronic block circuit breakers within the unit to
assure that they are in the "Off" position.
!
WARNING
!
4. Turn on the hydronic block circuit breaker at the
service entrance and/or disconnect switch and,
depending on the option, the 15 amp circuit breaker
on the hydronic block.
5. Set one thermostat above room temperature. The
circulator pump will now operate.
Only propylene glycol can be used in heating
system to prevent freezing. Recommendation
is a maximum 40% or less propylene glycol
mixture to ensure proper operation of electric
boiler.
6. Check system again for leaks. Allow circulator
pump to run until all air has been vented from the
system. A gurgling or rushing sound indicates the
presence of air.
2. Fill the heating system with water until the pressure
reaches 10-15 PSI. Check for leaks, repair if
necessary, and purge all air from system.
7. The hydronic block will now start to produce heat.
As the water temperature increases, listen for air
passing through the system. Water pressure will rise
somewhat as temperature increases - this is normal
as long as the pressure remains less than 25 PSI.
15
8. When the thermostat calls for heat, the circulator
will be energized and the indicator LED will light up.
Next, the heating elements are energized along with
the element indicator LEDs. Once the boiler water
temperature reaches the set point on the temperature
adjustment dial, the controller will regulate the boiler
by staging its elements. The number of elements
which stay on is based on the heating demand and
the set point of the boiler water temperature. After all
room thermostats are satisfied with the heat, the
controller de-energizes the elements one after
another, and then switches the pump off after 3
minutes.
TROUBLESHOOTING
This section is meant to assist the service technician when trouble shooting the electric boiler. As in
any trouble shooting procedure, it is important to
isolate as much as possible before proceeding. Often the control error codes can be a great help
indentifying cause of the problem. If you suspect a
wiring fault, carefully check all external wiring and
wiring connections following the wiring diagram label on the inside of the boiler's cover. An additional
wiring diagram is included with this manual.
1. Turn off hydronic unit circuit breaker at service
entrance and/or disconnect switch.
2. Close gate valves near inlet and outlet of hydronic
block.
NOISY BOILER
5. Remove cabinet cover and disconnect the two
wires attached to the effected heating element.
1. Check water pressure of boiler. It should be between 15-25 PSI.
2. Check for the direction of flow of the circulator
pump. The direction of flow (arrow on pump) must
be toward the lower right side of boiler.
WARNING
!
Extreme care must taken when the boiler
cover is removed. Turn “OFF” all service to
the boiler. "Power On” checks should be
made by a qualified electrician.
9. Close relief valve. Open feed line valve and check
for leaks. Open gate valves. Install heating element
wires and cabinet cover.
In the event it becomes necessary to change any
heating element, use the following procedure:
Cause
No heat when called by
thermostat and "TT" LED is
NOT lit
No power to board
"Circ" LED is NOT lit when
thermostat is calling
"Safety Switch" LED is NOT
lit when thermostat is calling
"FAULT" LED is flashing
Safety fault
No power to board
Safety fault
No power to board
Safety fault
Thermostat
6. Remove the four bolts that secure the heating
element to the casting and pry the element loose.
Take note of the markings on the element flange to
assure proper reinstallation.
8. Install new gasket and heating element while
assuring that the element is correctly positioned.
CHANGING A HEATING ELEMENT
Problem
4. Open drain valve and allow water to drain from
the boiler. Manual operation of the relief valve will
assist drainage by allowing air to enter.
7. After the element has been removed, carefully
clean any remaining gasket material from the casting
surface. Take care not to scratch or score this
surface.
3. Check for air within the system.
!
3. Close feed line valve if using automatic fill.
10. Refer to "Startup and Seasonal Maintenance"
for proper purging of air prior to energizing the
heating elements.
Solution
Disconnect thermostat from control, momentarily place a jumper across
terminal "TT" & "TT." If circulator starts, trouble is in thermostat.
Confirm control's On/Off switch is in "ON" position, check 15A circuit
breaker or fuse.
Check for open contact on safety's. Confirm continuity across terminals.
Confirm control's On/Off switch is in "ON" position
Check for open contact on safety's. Confirm continuity across terminals.
Confirm control's On/Off switch is in "ON" position.
Refer to "Fault" codes
16
MAINTENANCE
Because of its basic design, the hydronic block requires only a minimum of periodic maintenance. The
preventive maintenance tasks described below are
not difficult and when done a yearly basis, will aid
the unit to continue its trouble free operation.
!
CAUTION
!
For safety reasons, the main power switch to
the block should be turned off at the main
service entrance before any work requiring
removal of the cover is done. All work should
be performed by qualified service personnel
familiar with the unit's control system
operation.
a suitable container or drain. Manually operate the
pressure relief valve by pulling the lever at the end of
the valve until the lever is in line with the centerline
of the valve. (Figure 9) Quickly close the valve to
avoid losing an excessive amount of water. Repeat
this procedure several times on a quick cycling basis
to release any sediment that could block the relief
valve pressure sensing mechanism. On heating
system that use a manual water make-up or feed
mechanism, be sure not to allow the system pressure
to drop to 0 PSI when cycling the relief valve.
Allowing this condition to occur could cause air to
enter the system thus requiring a purging as described
in “Startup and Seasonal Maintenance" on page 15.
1. This boiler has been designed to provide years of
trouble free performance under normal operating
conditions. However, the owner should conduct a
general external examination at the beginning of
each heating season and at mid-heating seating
season to assure good working performance is
continued. In addition, a qualified service technician
should examine at least once every year.
2. Do not store anything against the boiler or allow
dirt or debris to accumulate in the area immediately
surrounding the boiler.
3. Elements will burn out if the boiler is not filled with
water when electrical power is turned on. Do not
connect thermostat wire until system has been filled
with water. Water should be drained out from system
only when absolutely necessary to make repairs or
prevent freeze-up during extended cold weather
shutdown.
4. The temperature and pressure gauge on the
system should be checked frequently. During normal
operating conditions, pressure should be relatively
stable throughout the heating season. If pressure
under normal operating conditions consistently rises
and falls over a period of time, this can indicate a fill
valve leak, system leak, or compression tank
malfunction. Leaks anywhere in the system must
be repaired without delay. If any leaks or significant
pressure fluctuations are observed, call for service
immediately.
5. Check pressure relief discharge piping to assure
that any discharged water will be properly routed to
FIGURE 9
If the relief valve fails to completely close after
cycling, it will be necessary to remove it for cleaning
or replacement. Turn off power to boiler and isolate
the hydronic block by shutting off the inlet and outlet
gate valves. Reduce the water pressure to zero by
opening the relief valve. Remove the relief valve and
inspect the valve disc and seat. Cleaning these parts
with a clean lint free cloth may be all that is necessary. If this procedure fails then replace the valve
with a new one of equal pressure and discharge
rating. After installing the cleaned or new relief valve,
open the gate valves and follow the procedure
described in “Startup and Seasonal Maintenance"
on page 15.
17
PARTS LIST - 2 ELEMENT ELECTRIC BOILERS
1
2
3
2 ELEMENT
BOILER
(SIDE VIEW)
4
5
4
5
8
8
9
10
2 ELEMENT
BOILER
WITH
BREAKERS
9
2 ELEMENT
BOILER
WITH
POWER BLOCK
7
6
7
6
2 Element Electric Boiler w/Breakers
Part
Item
Number
1 S-47
2 G-12
E-13
E-14
3
E-15
E-16
4 Z-300-2
5 Z-64
6 B-194
7 L-9
8 B-28
9 B-27
10 I-25
V-1
1260006
C-57
Z-302-A
10
2 Element Electric Boiler w/Power Block
Description
Item
Safety Limit Control (High Limit - Fixed Temp)
Gasket - Heating Element
Heating Element - 3 KW/240 Volt
Heating Element - 4 KW/240 Volt
Heating Element - 5 KW/240 Volt
Heating Element - 6 KW/240 Volt
Control Board - 2 Element Boiler
RTD Sensor
Neutral Terminal Block
Ground Connection Lug
Circuit Breaker 15 A - 1 Pole - G.E. THQP 115
Circuit Breaker 40 A - 2 Pole - G.E. THQP 240
Load Center Assembly - G.E. TLM812U2
Relief Valve - 30 PSI
Temperature/Pressure Gauge
Pressure Vessel - Cast Iron, 2 Element
Control Panel Assembly, 2 Element (Complete)
1
2
3
4
5
6
7
8
9
10
-
18
Part
Number
S-47
G-12
E-13
E-14
E-15
E-16
Z-300-2
Z-64
B-194
L-9
F-3
F-4
P-8
V-1
1260006
C-57
Z-313
Description
Safety Limit Control (High Limit - Fixed Temp)
Gasket - Heating Element
Heating Element - 3 KW/240 Volt
Heating Element - 4 KW/240 Volt
Heating Element - 5 KW/240 Volt
Heating Element - 6 KW/240 Volt
Control Board - 2 Element Boiler
RTD Sensor
Neutral Terminal Block
Ground Connection Lug
Fuse Block, 1/4" x 1-1/4" Fuse, 300V
Fuse, 10amp, Ceramic, ABC-10
Power Distribution Block
Relief Valve - 30 PSI
Temperature/Pressure Gauge
Pressure Vessel - Cast Iron, 2 Element
Control Panel Assembly, 2 Element (Complete)
PARTS LIST - 4 ELEMENT ELECTRIC BOILERS
1
2
3
4 ELEMENT
BOILER
(SIDE VIEW)
4
4
5
5
8
8
9
10
9
4 ELEMENT
BOILER
WITH
POWER BLOCK
4 ELEMENT
BOILER
WITH
BREAKERS
7
6
7
6
4 Element Electric Boiler w/Breakers
Part
Item
Number
1 S-47
2 G-12
E-13
E-14
3
E-15
E-16
4 Z-300
5 Z-64
6 B-194
7 L-9
8 B-28
9 B-27
10 I-25
V-1
1260006
C-32
Z-304-A
10
4 Element Electric Boiler w/Power Block
Description
Item
Safety Limit Control (High Limit - Fixed Temp)
Gasket - Heating Element
Heating Element - 3 KW/240 Volt
Heating Element - 4 KW/240 Volt
Heating Element - 5 KW/240 Volt
Heating Element - 6 KW/240 Volt
Control Board - 4 Element Boiler
RTD Sensor
Neutral Terminal Block
Ground Connection Lug
Circuit Breaker 15 A - 1 Pole - G.E. THQP 115
Circuit Breaker 40 A - 2 Pole - G.E. THQP 240
Load Center Assembly - G. E. TLM812U2
Relief Valve - 30 P.S.I.
Pressure/Temperature Gauge
Pressure Vessel - Cast Iron, 4 Element
Control Panel Assembly, 4 Element (Complete)
1
2
3
4
5
6
7
8
9
10
-
19
Part
Number
S-47
G-12
E-13
E-14
E-15
E-16
Z-300
Z-64
B-194
L-9
F-3
F-4
P-8
V-1
1260006
C-32
Z-314
Description
Safety Limit Control (High Limit - Fixed Temp)
Gasket - Heating Element
Heating Element - 3 KW/240 Volt
Heating Element - 4 KW/240 Volt
Heating Element - 5 KW/240 Volt
Heating Element - 6 KW/240 Volt
Control Board - 4 Element Boiler
RTD Sensor
Neutral Terminal Block
Ground Connection Lug
Fuse Block, 1/4" x 1-1/4" Fuse, 300V
Fuse, 10amp, Ceramic, ABC-10
Power Distribution Block
Relief Valve - 30 P.S.I.
Pressure/Temperature Gauge
Pressure Vessel - Cast Iron, 4 Element
Control Panel Assembly, 4 Element (Complete)
ADDITIONAL WIRING DIAGRAMS
20
ADDITIONAL WIRING DIAGRAMS
21
ADDITIONAL WIRING DIAGRAMS
22
MODULAR BOILER PIPING
23
TROUBLESHOOTING - FLOWCHART#1
!
WARNING
!
Due to exposure to potentially dangerous voltages, troubleshooting should be performed by a
qualified installer or service agency only. Failure to do so could result in property damage,
personal injury, or loss of life.
Green T-T indicator LED is
on; there is a call for heat.
Yes
Is audible alarm sounding
and red fault LED flashing?
Yes (see Flowchart #3)
No (See Flowchart#2)
No
Verify the boiler control
board switch is on.
UNITS WITH CIRCUIT
BREAKERS
Verify that the 15amp/
120vac circuit breaker is on.
If breaker is off, turn it on.
OK
UNITS WITH POWER
BLOCKS
Verify that the ceramic fuse
is good. If fuse is blown,
replace it with a new one.
OK
Verify that the thermostat is
operational and calling for
heat. Disconnect TT/TT
wires from boiler control
board and replace with a
jumper if necessary. The
T-T indicator LED should
come on with the jumper
installed.
Lights come on with jumper
and elements then energize
Potentially bad thermostat.
Consult thermostat
manufacturer’s manual or
replace thermostat.
LED light/boiler off
with jumper installed
Verify 120vac is present at
the L-N terminals on the
printed circuit board labeled
“120vac Input.”
120vac not present
120vac
present
Replace control board.
Verify that 240vac is
present across L1 and L2.
240vac present
Replace circuit breaker or
power block, depending on
type of boiler.
24
240vac not present
Check service at main load
center.
TROUBLESHOOTING - FLOWCHART#2
No (From Flowchart#1)
Is the circulator indicator
LED on?
No
Verify power
supply to
system.
OK
Verify 120vac
power to
Board L-N.
OK
Yes
Verify that circulator is
operating properly.
No
Verify that 120vac is
present at the circulator
terminals.
No
Replace the boiler control
board.
Yes
Yes
Verify circulator wiring or
replace circulator.
OK
After 30 seconds does an
element energize?
No
Verify that 40 amp circuit
breakers are on.
Not On
All
On
Turn on all 40 amp circuit
breakers.
All
On
Verify that 240vac is present at the input to the boiler and the output
of all the boiler circuit breakers.
240vac present
240vac not present
Check
element for
power.
No
Power
Replace electric boiler
control board.
Yes
Is there an increase in
temperature?
Yes
Boiler functioning properly.
No
Verify that 240vac is
present at the element.
240vac
not
present
240vac present
Remove leads to elements
and verify ohm reading at
each element stud.
Reading should be
between 9-12 ohms at
each element.
OK
Replace element if ohm
reading is not within proper
charge.
25
Replace circuit breakers.
Check element wires, main
power supply, and/or
replace electric boiler
control board.
(From
Flowchart#1)
Yes
26
*RTD Part No. S-47
Replace high limit control
switches.*
Yes
Does visual/audible alarm
shut off with jumper
installed?
OK
Remove leads from HL-HL
terminals on control board
and test with a jumper.
OK
Safety Switch Fault.
Yes
Is visual/audible alarm
flashing/pulsing once?
No
No
OK (See
Flowchart#4)
Remove leads from
LWC-LWC and test with a
jumper.
Yes
Is a low water cut-off
installed?
OK
Remove jumper from
HL-HL terminals and
replace leads.
Stuck/welded element relay
contact. Replace electric
boiler control board.
Yes
Is visual/audible alarm
flashing/pulsing twice?
No
No
Yes
Is a flow switch installed?
RTD short. Follow steps on
page 10 to check RTD and
replace if necessary.*
Yes
Is visual/audible alarm
flashing/pulsing three
times?
No
No
A
B
RTD open. Follow steps on
page 10 to check RTD and
replace if necessary.*
Yes
Is visual/audible alarm
flashing/pulsing four times?
C
TROUBLESHOOTING - FLOWCHART#3
TROUBLESHOOTING - FLOWCHART#4
A
OK (From
Flowchart#3)
Does visual/audible alarm
shut off with jumper
installed?
No
Remove jumper from
LWC-LWC and replace
LWC-LWC leads.
B
C
OK
Yes
Check water supply and
water level in system. Fill
system if low. Does visual/
audible alarm shut off with
system full?
Remove leads from
flow-flow and test with a
jumper.
Yes
Check pump and flow rate
of system. Pump may
require replacement. Does
visual/audible alarm shut
off with a new pump?
No
Potentially bad low water
cut-off. Check wiring to
LWCO and consult LWCO
manufacturer if necessary.
Yes
OK
Yes
Does visual/audible alarm
shut off with jumper
installed?
No
No
Potentially bad flow switch.
Check wiring to flow switch
and consult flow switch
manufacturer if necessary.
Remove jumper from
flow-flow and replace leads.
OK
"AT" SERIES BOILER DIMENSIONS
D
C
A
E
B
A
14-5/8"
B
18-5/8 "
Dimensions
C
D
9-1/32"
14-3/8"
27
E
16-15/32"
Inlet & Outlet Approximate
Pipe Size
Shipping Wt.
1-1/4" NPT
70 lbs.
HOMEOWNER'S REFERENCE TABLE
Model Number: _____________________________________________
Serial Number: _____________________________________________
Date Installed: ______________________________________________
Contractor:_________________________________________________
Contact: ___________________________________________________
Address: ___________________________________________________
__________________________________________________________
Telephone Number: _________________________________________
After Hours Number: _________________________________________
If different from Installation Contractor:
Service Tech: _______________________________________________
Telephone Number: _________________________________________
After Hours Number: _________________________________________
28
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