Inst alla t Ion, opera t Ion and ma Inten ance man U al

Inst alla t Ion, opera t Ion and ma Inten ance man U al
Installation, operation and maintenance MANUAL
Q90 125-200 GAS-FIRED, DIRECT VENT,
CONDENSING, HOT WATER Boiler
ECR International Ltd.
Olsen Division
P.O. Box 900, 6800 Base Line
Wallaceburg, ON N8A 5E5
Canada
www.ecrltd.com
MEMBER: The Hydronics Institute
An ISO 9001-2000 Certified Company
P/N 240004826B, Rev. A [10/08]
90 125-200 CAST ALUMINUM BOILER
Installation Manual and Operating Instructions
TABLE OF CONTENTS
The forced draft fan draws in the outside combustion
air to mix with gas, which flows into the pre-mix
burner and combusts. The fan then forces the
resulting 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 vent pipes.
I. Introduction.............................................................. 2
II. Safety Symbols...................................................... 2
III. Rules For Safe Installation and Operation............... 3
IV. Boiler Ratings and Capacities............................... 4
V. Before Installing The Boiler.................................... 5
VI. Placing The Boiler................................................. 9
VII. Near Boiler Piping.............................................. 10
VIII. Combustion Air and Vent Pipe.......................... 13
IX. Gas Supply Piping.............................................. 15
X. Electrical Wiring................................................... 16
XI. Controls and Accessories................................... 20
XII. Startup............................................................... 22
XIII. Checkout Procedures and Adjustments.............. 26
XIV. Maintenance and Cleaning............................... 29
XV. Detailed Sequence of Operation........................ 31
XVI. Troubleshooting................................................ 34
XVII. Installation and Checkout Certificate............... 43
II. SAFETY SYMBOLS
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, serious injury or substantial property damage.
KEEP THIS MANUAL NEAR BOILER AND
RETAIN FOR FUTURE REFERENCE.
I. INTRODUCTION
! WARNING
This appliance is a gas-fired direct vent cast aluminum
hot water boiler. 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.
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property damage.
!
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or property damage.
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.
IMPORTANT: Read the following instructions
COMPLETELY before installing!
2
III. Rules For Safe Installation and Operation
! WARNING
This appliance has been equipped for residential installations. If used for commercial applications,
any and all additional code requirements must be adhered to for installation. This may require
additional controls, including but not limited to a manual reset 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.
Figure #1
BOILER JACKETS
IMPORTANT:
Failure to follow these instructions could cause
a malfunction of the boiler and result in death,
serious bodily injury, and/or property damage.
2. Before servicing the boiler, allow it to cool. Always
shut off any electricity and gas supply connected to
the boiler prior to servicing.
For assistance or additional information, consult
a qualified installer, service agency, or the gas
supplier.
4. Be certain gas input rate is correct. Overfiring may
result in early failure of the boiler components. This
may cause dangerous operation. Underfiring may
result in too much air for the pre-mix burner causing
poor or loss of combustion.
3. Inspect gas line for leaks.
1. Check all applicable state and local building codes and
utility company requirements before installation. This
installation must conform with these requirements
in their entirety. In the absence of these codes,
use NFPA installation codes and good industry
practice.
5. 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.
6. Be sure there is adequate outdoor air supply to boiler
for complete combustion.
3
III. Rules For Safe Installation and Operation
7. Follow a regular service and maintenance schedule
for efficient and safe operation.
materials and methods described in this manual.
Installation must comply with local codes.
8. Keep boiler area clean of debris and free of
combustible and flammable materials.
10. This boiler and related hot water heating systems
are not do-it-yourself items. They must be installed
and serviced by qualified professionals.
9. Proper through-the-wall or through-the-roof
combustion venting shall be in accordance with the
IV. BOILER RATINGS & CAPACITIES
TABLE #1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES)
Model
Input
(MBH)(1)
Heating Capacity
(MBH)(1)(2)
Net I=B=R Rating
(MBH)(1)
125
125
112.5
98
284
90
2” CPVC & 3” PVC
150
150
135
117
284
90
2” CPVC & 3” PVC
175
175
157.5
137
284
90
2” CPVC & 3” PVC
200
200
180
157
284
90
2” CPVC & 3” PVC
Shipping
AFUE
(2)
Weight (lbs.)
Flue Diameter
1 MBH = 1,000 Btuh (British Thermal Units Per Hour)
(2)
AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on Department of Energy test procedure.
(1)
Ratings shown are for sea level applications. The boiler automatically derates input as altitude increases.
No alterations to boiler are required for altitudes above sea level.
TABLE #2 - NATURAL GAS
Nominal Input
200,000
175,000
150,000
125,000
Vent Lengths
Vent Lengths
Vent Lengths
Vent Lengths
Altitude
Min
Max
Min.
Max
Min.
Max
Min.
Max
0
200,000
200,000
175,000
175,000
150,000
150,000
125,000
125,000
1,000
197,000
196,500
172,400
172,200
147,800
147,400
123,500
123,000
2,000
194,000
193,000
169,800
169,400
145,600
144,800
122,000
121,000
3,000
191,000
189,500
167,200
166,600
143,400
142,200
120,500
119,000
4,000
188,000
186,000
164,600
163,800
141,200
139,600
119,000
117,000
5,000
185,000
182,500
162,000
161,000
139,000
137,000
117,500
115,000
6,000
182,000
179,000
159,400
158,200
136,800
134,400
116,000
113,000
7,000
179,000
175,500
156,800
155,400
134,600
131,800
114,500
111,000
8,000
176,000
172,000
154,200
152,600
132,400
129,200
113,000
109,000
9,000
173,000
168,500
151,600
149,800
130,200
126,600
111,500
107,000
10,000
170,000
165,000
149,000
147,000
128,000
124,000
110,000
105,000
4
IV. BOILER RATINGS & CAPACITIES
TABLE #3 - LP GAS
Nominal Input
200,000
175,000
150,000
125,000
Vent Lengths
Vent Lengths
Vent Lengths
Vent Lengths
Altitude
Min.
Max
Min.
Max
Min.
Max
Min.
Max
0
200,000
200,000
175,000
175,000
150,000
150,000
125,000
125,000
1,000
195,900
195,750
171,900
171,200
146,900
146,700
123,050
122,250
2,000
191,800
191,500
168,800
167,400
143,800
143,400
121,100
119,500
3,000
187,700
187,250
165,700
163,600
140,700
140,100
119,150
116,750
4,000
183,600
183,000
162,600
159,800
137,600
136,800
117,200
114,000
5,000
179,500
178,750
159,500
156,000
134,500
133,500
115,250
111,250
6,000
175,400
174,500
156,400
152,200
131,400
130,200
113,300
108,500
7,000
171,300
170,250
153,300
148,400
128,300
126,900
111,350
105,750
8,000
167,200
166,000
150,200
144,600
125,200
123,600
109,400
103,000
9,000
163,100
161,750
147,100
140,800
122,100
120,300
107,450
100,250
10,000
159,000
157,500
144,000
137,000
119,000
117,000
105,500
97,500
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 gauge) in accordance with A.S.M.E. (American Society of Mechanical
Engineers) Boiler and Pressure Vessel Code, Section
IV Standards for heating boilers.
the structure. The Net I=B=R Rating represents the
portion of the remaining heat that can be applied to
heat the radiation or terminal units (i.e. Finned tube
baseboard, cast iron radiators, radiant floor, etc.). The
difference between the Heating Capacity and the Net
I=B=R Rating, called the piping and pickup allowance,
establishes a reserve for heating the volume of water
in the system and offsetting heat losses from the piping. The Net I=B=R Ratings shown are based on a
piping and pickup factor of 1.15 in accordance with
the I=B=R Standard as published by the Hydronics Institute. The Net I=B=R Rating of the boiler selected
should be greater than or equal to the calculated peak
heating load (heat loss) for the building or area(s)
served by the boiler and associated hot water heating
systems. The manufacturer should be consulted before selecting a boiler for installations having unusual
piping and pickup requirements.
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 loss from the jacket and surfaces of
the boiler, and it is assumed that this heat stays in
V. BEFORE INSTALLING THE BOILER
United States - Installation shall conform with
National Fuel Gas Code (NFPA-54/ANSI Z223.1
- latest revision)
Complete all of the following prior to installing the boiler.
CODES
This boiler product is a gas-fired, direct vent, condensing boiler and must be installed in accordance with all
applicable federal, state and local building codes including, but not limited to the following:
Canada - Installation shall be in accordance with
CSA-B149.1 and .2 installation codes.
Where required by the authority having jurisdiction, the
installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, No.CSD-1.
5
V. BEFORE INSTALLING THE BOILER
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.
LOCATING THE BOILER
1. Select a location which is level, central to the piping
systems served and as close to the vent and air
intake terminals as possible.
In the State of Massachusetts:
2. Accessibility clearances, if more stringent (i.e. larger
clearances) than required fire protection clearances, must be used for the boiler installation. Accessibility clearances may be achieved with the use of
removable walls or partitions.
•
This product must be installed by a licensed plumber or gas fitter.
• When flexible connectors are used, the maximum
length shall not exceed 36 inches.
• When lever type gas shut-offs are used, they shall
be T-handle type.
Installers -Follow local regulations with respect
to installation of CO (Carbon Monoxide) Detectors. Follow maintenance recommendations in
this manual.
3. The boiler is approved for installation in closets and
on combustible floors. This boiler shall NOT be installed on carpeting.
TABLE #4 - BOILER CLEARANCES
BOILER SIZING
Unit
• Check to be sure you have selected the boiler with
the proper capacity before continuing 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 Section IV, “Boiler Ratings and Capacities,” for
more information.
• Heat loss calculations should be based on approved
industry methods.
CONSIDERATIONS FOR boiler LOCATION
Before selecting a location for the boiler, the following should be considered. Each boiler considered for
installation must be:
Combustible Accessibility, Cleaning,
Clearance
and Servicing
Top
1”
8”
Left Side
8”
24”
Right Side
1”
-
Base
1”
-
Front
0”
24”
Back
1”
-
Intake/Vent
Piping
0”
-
Near Boiler Hot
Water Piping
1”
-
All distances measured from the cabinet of the boiler.
• 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 (max. length 60’).
• Connected to a suitable venting system to remove
the hazardous products of gas combustion (max.
length 60’).
• 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)
• 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).
4. The clearances shown in Table 4 indicate required
clearances per CSA listing. A min.. 1” clearance must
be maintained between combustible construction and
each of the right, top and back surfaces of the boiler.
A min.. 8” clearance is required on the left side, to allow room for the inlet air pipe. An 18” clearance must
be maintained at the front where passage is required
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 combustible clearances are
required to venting or combustion air intake piping.
! CAUTION
keep boiler area clean of debris and free of flammable
and combustible materials, liquids and vapors.
6
V. BEFORE INSTALLING THE BOILER
5. Equipment shall be installed in a location which facilitates the operation of venting and combustion air
intake piping systems as described in this manual.
Figure #2
SIDEWALL VENT/INTAKE TERMINATIONS
6. Advise owner of boiler to keep venting and combustion air intake passages free of obstructions. Both
the venting and combustion air intake piping systems connected to the outdoors must permit flow
through the piping systems without restrictions for
the boiler to operate.
OVERHANG
12"
MINIMUM
7. The boiler shall be installed such that the automatic
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, control
replacement, etc.).
90°
VENT
8. The boiler must be located where ambient temperatures (minimum possible room temperatures where
boiler is installed assuming boiler is not in operation and therefore contributes no heat to the space)
are always at or above 32°F to prevent freezing of
liquid condensate.
Less Than 12” Clearance
3"
MAXIMUM
OVERHANG
SEPARATION
12"
MINIMUM
15"
MAXIMUM
12" MINIMUM
VENT
12"
MINIMUM
COMBUSTION AIR/VENT PIPE REQUIREMENTS
18"
MAXIMUM
90°
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
LESS THAN 12" CLEARANCE
BRACKET
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.
3"
MAXIMUM
SEPARATION
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHES
ANTICIPATED SNOW LEVEL
GRADE
12” or More Clearance
Figure #1
18"
MAXIMUM
If the concentric vent termination
is being
used, refer
12" OR MORE
CLEARANCE
to Figure #3 for proper setup.
ROOF VENT / INTAKE TERMINATIONS
15'' MAXIMUM
Figure #3
3'' MAXIMUM
SEPARATION
8" MINIMUM
VERTICAL SEPARATION
BETWEEN COMBUSTION
AIR INTAKE AND VENT
12" MINIMUM
12"
MINIMUM
CONCENTRIC VENT TERMINATIONS
12''
MIMIMUM
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
COMBUSTION
AIR
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 #1 and #2 for required clearances.
7
V. BEFORE INSTALLING THE BOILER
COMBUSTION AIR/VENT PIPE REQUIREMENTS continued
Figure #5
! WARNING
Failure to follow these warnings could
result in fire, property damage, personal
injury, or death.
CONCENTRIC VENT ROOF INSTALLATION
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 chaseway, vent
pipe must be insulated with 1/2”Armaflex or equivalent.
In extremely cold climate areas, use 3/4”Armaflex or
equivalent.
Combustion air must be clean outdoor air. Combustion air
must not be taken from inside the structure because that
air is frequently 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 Figures #1 – #2. If a
concentric vent termination is being used, refer to Figures
#3 – #5 for proper setup.
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, or open flame. Use only in well ventilated
areas. Avoid breathing in vapor or allowing contact with
skin or eyes.
Figure #4
CONCENTRIC VENT
8
V. BEFORE INSTALLING THE BOILER
the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryer and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhaust, so they will operate
at maximum speed. Do not operate a summer exhaust fan. Close fire dampers.
FOUNDATION REQUIREMENTS
Boiler must be placed on level surface. Boiler is NOT
to be installed on carpeting.
NOTES:
1. 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.
4. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliances will operate continuously.
2. 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.
REMOVAL OF EXISTING BOILER FROM COMMON
VENT SYSTEM
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.
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-B149 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-B149 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 restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.
3. When it is practical, close all building doors and
windows and all doors between the space in which
vi. Placing the boiler
The boiler should be placed to provide the most direct
connections to the combustion air, vent and system
piping as possible.
be inserted under the right hand side of the boiler. It
is possible to slide the boiler for a short distance on a
smooth floor or surface.
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
NOTE: Refer to “Locating The Boiler” in Section
V for required clearances for servicing and maintenance.
9
vII. Near boiler piping
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. For diaphragm type
expansion tanks, adjust the tank air pressure to match
the system fill pressure. Install air vent (furnished) as
shown for diaphragm type expansion tank system only.
Install make-up water connections as shown and 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, a sand strainer should be
installed at the pump.
! CAUTION
Copper supply and return piping must NOT be installed directly into aluminum boiler section castings
due to galvanic corrosion between dissimilar metals.
Iron or steel bushings or pipe nipples should be used
between copper system piping and boiler to make
final connection to boiler. Also, the use of dielectric
unions is acceptable. The packaged boiler is furnished with iron piping in the front boiler section for
the supply and return connections.
When the installation of the boiler is for a new heating system, first install all of the radiation units (panels,
radiators, baseboard, or tubing) and the supply and return mains. After all heating system piping and components have been installed, make final connection of the
system piping to the boiler.
PRESSURE RELIEF VALVE / TEMPERATURE
PRESSURE GAUGE
The boiler is furnished with a relief valve and temperature pressure gauge in the boiler parts bag. Install
vent relief valve as shown in Figure #7. Provide ¾”
piping from the 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.
A hot water boiler installed above radiation level must
be equipped with a low water cut off device (included
with boiler). A periodic inspection is necessary, as is
flushing of float type devices, per low water cut off manufacturers specific instructions.
EXPANSION TANK AND MAKE-UP WATER
Determine required system fill pressure, system design temperature, and system water content. Boiler
Figure #6
DIAPHRAGM TYPE EXPANSION TANK PIPING
Figure #7
RELIEF VALVE DISCHARGE PIPING
10
vII. near boiler piping
Figure #9b
Figure #8
MULTI ZONE BOILER PIPING WITH ZONE VALVES
SINGLE ZONE BOILER PIPING
Figure #9a
multizone boiler piping
with circulators
SUPPLY AND RETURN LINES
The packaged boiler unit is set up to receive 1¼” NPT
supply and return piping from top access.
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.
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.
11
vII. near boiler piping
Condensate drain piping
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.
The condensate trap is to be field installed as previously shown in Figure #10. Provided are ½” PVC fittings for the condensate drain trap (assembled in the
field). The condensate drain is to be pitched down to
the floor drain at a minimum of ¼” per foot.
The ½” diameter schedule 40 PVC condensate drain
piping and pipe fittings must conform to ANSI standards and ASTM D1785 or D2846. Schedule 40 PVC
cement and primer must conform to ASTM D2564 or
F493. In Canada, use CSA or ULC certified schedule
40 PVC drain pipe and cement.
Figure #10
CONDENSATE DRAIN PIPING
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 is inaccessible.
FILLING CONDENSATE TRAP WITH WATER
On initial start up the CONDENSATE
TRAP must be manually filled with
water.
The following are the steps required to initially fill the
condensate trap for start up, these steps are only required at the initial start up or if maintenance requires
draining of the condensate trap:
1. Pour about 1 cup of cold tap water into the condensate trap vent.
2. Excess water should go through the condensate
drain line. Verify proper operation of the drain line
(and external condensate pump if used).
CHILLED WATER PIPING
NOTES:
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.
1. Condensate trap is to be built in the field per
Figure #10
2. Wood frame or blocks may be used to raise the
boiler to maintain drain pitch or to be above external condensate pump reservoir.
The boiler piping system of a hot water boiler connected to heating coils located in air handling units
where they may be exposed to refrigerated air circulation must be equipped with flow control valves or
other automatic means to prevent gravity circulation
of the boiler water during the cooling cycle.
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
VIII. COMBUSTION AIR AND VENT PIPE
pipe and pipe cement. SDR pipe is NOT approved in
Canada.
CONNECTIONS AND TERMINATION
Important: To prevent damage to the gas burner
and ensure proper operation of the unit, installer
must clean and remove all shavings from the interior of all PVC pipe used on the air intake.
For Canadian installations all plastic venting material
must be listed to ULC S636.
3. Combustion air and vent piping connections on
boiler are 2”, but must increase to 3”. Due to potential for flue gas temperatures over 155°F, the
first 5 feet of vent pipe must be CPVC (furnished),
the remaining vent pipe can be PVC. If any elbows are employed within the first 2 ½’ of vent,
they must be CPVC. Two 30” pieces of 2” CPVC
pipe and one 2” CPVC coupling are furnished with
the boiler. (Figure #11)
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
Z223.1-latest revision, CSA-B149.1 and B149.2, and
applicable provisions of the local building codes.
Provisions for combustion and ventilation air must be
in accordance with section 5.3, Air For Combustion
and Ventilation, of the National Fuel Gas Code, ANSI
Z223.1-latest revision, CSA-B149.1 and B149.2, or
applicable provisions of the local building code.
Figure #11
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.
1. See Figures #1 – #2 in Section V, “Combustion Air
and Vent Pipe Requirements,” for standard two-pipe
roof and sidewall terminations and Figures #3 – #5
(same section) for concentric vent terminations (roof
termination is preferred). Combustion air and vent
pipes must terminate together in same atmospheric pressure zone as shown. Construction through
which vent and air intake pipes may be installed is a
minimum ¼” and maximum 24” thickness.
2. Combustion air and vent pipe fittings must conform
to one of the following American National Standards
Institute (ANSI) and American Society for Testing and
Materials (ASTM) standards:
Combustion Air & Vent Piping
NOTE: The exhaust transition from 2” pipe to 3”
pipe must be made in a vertical run. (Transition
pieces not included.)
• D1784 (schedule-40 CPVC)
• D1785 (schedule-40 PVC)
• D2665 (PVC-DWV)
• D2241 (SDR-21 and SDR-26 PVC)
• D2661 (ABS-DWV)
• F628 (schedule-40 ABS).
3 in. Pipe
Minimum Venting
3 in. Pipe
Maximum Venting
6 ft. in length plus four (4)
90° elbows
60 ft. in length and up to
four (4) 90° elbows
The length of pipe is counted from the boiler jacket
(air intake pipe) or from vent tee (vent pipe). The first
five feet of “Total Equivalent Length” of vent pipe must
be CPVC.
Pipe cement and primer must conform to ASTM standards D2564 (PVC) or D2235 (ABS).
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
Reduce the maximum vent length 5 feet per each additional elbow.
13
VIII. COMBUSTION AIR AND VENT PIPE
vegetation. The venting system shall terminate at
least 4 feet horizontally from, and in no case above
or below electric meters, gas meters, regulators,
and relief equipment.
4. 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.
If multiple terminations are used, there must be a
minimum of 12 inches between the exhaust of one
termination and the air intake of the next termination. See Figures #1 – #3 in Section E5 for illustrations.
5. Consideration for the following should be used when
determining an appropriate location for termination
of combustion air and vent piping:
NOTE: All field installed vent pipe must be 3”.
• Comply with all clearances required as stated
in paragraph 6 (below)
INSTALLATION
1. Attach combustion air intake piping to supplied
Fernco 2” coupling on CVI gas valve. Attach vent
piping to furnished 2” CPVC vent tee on draft inducer outlet.
• Termination should be positioned where vent
vapors will not damage plants/shrubs, air conditioning equipment, or siding on the house.
• Termination should be positioned so that it will
not be effected by wind eddy, air born leaves,
snow, or recirculated flue gases.
NOTE: All pipe joints are to be water tight.
• Termination should be positioned where it will
not be subjected to potential damage by foreign objects, such as stones, balls, etc.
2. Working from the boiler to the outside, cut pipe to
required length(s).
• Termination should be positioned where vent
vapors are not objectionable.
3. Deburr inside and outside of pipe. Remove all chips
and shavings.
• Put vent on a wall away from the prevailing
winter wind. Locate or guard the vent to prevent accidental contact with people or pets.
4. Chamfer outside edge of pipe for better distribution
of primer and cement.
5. Clean and dry all surfaces to be joined.
• Terminate the vent above normal snowline.
Avoid locations where snow may drift and
block the vent. Ice or snow may cause the
boiler to shut down if the vent becomes obstructed.
6. Check dry fit of pipe and mark insertion depth on
pipe.
NOTE: It is recommended that all pipes be cut,
prepared, and pre-assembled before permanently
cementing any joint.
• 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. 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.
6. 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
8. While cement is still wet, insert pipe into socket with
a 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.
14
VIII. COMBUSTION AIR AND VENT PIPE
10. Handle pipe joint carefully until cement sets.
12. Slope combustion air and vent pipes toward boiler
a minimum of ¼” per linear foot with no sags between hangers.
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 for movement due to expansion and contraction.
13. Use appropriate methods to seal openings where
vent and combustion air pipes pass through roof
or side wall.
NOTE: Rigid supports will cause excess noise in vent piping.
IX. GAS SUPPLY PIPING
CHECK GAS SUPPLY
IMPORTANT: The length of pipe or tubing should
be measured from the gas meter or propane second
stage regulator.
Table #5 - Gas Supply Pressure
Pressure
Natural Gas Propane Gas
Minimum
4” w.c.
10” w.c.
CONNECTING THE GAS PIPING
Maximum
10” w.c.
14” w.c.
Refer to Figure #12 for the general layout at the boiler. The gas line enters the boiler through the left side
panel.
Please check line pressure while unit is running.
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 Tables #6A & #6B for proper size. Be sure your
gas line complies with local codes and gas company
requirements.
Figure #12
GAS PIPING
TABLE #6A - NATURAL GAS PIPING SIZES
Pipe
Length
Pipe Capacity - BTU/Hr. Input (1)
½”
¾”
1”
1¼”
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
TABLE #6B - PROPANE GAS PIPING SIZES
Pipe
Length
(1)
Pipe Capacity - BTU/Hr. Input (1)
Copper Tubing (2)
Iron Pipe
⅝”
¾”
½”
¾”
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
Includes Fittings
(2)
The boiler is equipped with a ½” NPT connection on
the gas valve for supply piping and ½” NPT ball cock
for manual shut off. The following rules apply:
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 Z223.1latest revision. In Canada, follow the CAN/CGA
B149.1 and .2 Installation Codes for Gas Burning
Appliances and Equipment.
Outside Diameter
The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during
any pressure testing of that system at test pressures
in excess of ½ psig (3.5kPa).
15
IX. GAS SUPPLY PIPING
10. Propane gas piping should be checked out by the
propane installer.
CONNECTING THE GAS PIPING continued
2. Use pipe joint compound suitable for liquefied petroleum gas on male threads only.
11. It is recommended to use a ½” union suitable for
natural and propane gas after the ball cock to facilitate service on the unit.
3. Use ground joint unions.
4. Install a sediment trap upstream of gas controls.
CHECKING THE GAS PIPING
5. Use two pipe wrenches when making the connection to the gas valve to keep it from turning.
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.
6. Install a manual shutoff valve in the vertical pipe
about 5 feet above floor outside the boiler jacket.
7. Tighten all joints securely.
8. Propane gas connections should only be made by
a licensed propane installer.
! WARNING
9. Two stage regulation should be used by the propane installer.
Never use a match or open flame to test for leaks.
x. ELECTRICAL WIRING
Figure #13
! 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/NFPA-70, latest
revision. In Canada, electrical wiring shall comply with
the Canadian Electrical Codes, CSA-C22.1 and .2.
ELECTRIC POWER SUPPLY
Prior to making any line voltage connections, service
switch at boiler should be in the off position and the
power turned off at the fuse box.
Run a 120 volt circuit from a separate over current protection device in the electrical service entrance panel.
NOTE: Use copper conductors only.
This should be a 15 ampere circuit. A service switch
has been pre-wired and located on the exterior boiler
jacket. See Figure #13 for diagram showing location of service switch junction 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
16
X. ELECTRICAL WIRING
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.
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.
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.
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.
Connect Circulator Pump Wiring
See Figures #14A & #14B (following page) for service switch junction box and circulator pump field wiring connections. 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.
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.
INSTALLING THE 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.
Avoid the Following
Dead Spots
corners
alcoves
behind doors
Cold Spots
Concealed pipes or ducts
Stairwells - drafts
Unheated rooms on the other side
of the wall
Hot Spots
Concealed pipes
Fireplaces
TVs or radios
Lamps
Direct sunlight
Kitchens
17
X. ELECTRICAL WIRING
Figure #14A
Schematic wiring connections
NOTE: 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.
1013-10 INTEGRATED BOILER CONTROL
CASTING TEMPERATURE SAFETY SWITCH (MANUAL RESET)
P2
1
Y
1
2
1
3
2
Y
V
HI LIMIT
AQUASTAT
CONTROL
DIFFERENTIAL
AIR PRESSURE
SWITCH (N.O.)
SET AT
+ 0.5" WC
DIFFERENTIAL
AIR PRESSURE
SWITCH (N.C.)
SET AT
+ 3.5" WC
BL
BL
BR
BR
V
W
BR
Y
Y
24 VAC
120
VAC
COMMON
1
GAS VALVE
RECTIFIER PLUG
EAEF03801
CONTROL
TRANSFORMER
2
3
BLOWER
BK
P3
CONTROL
BR
V
1
4
7
2
5
8
3
6
9
4
3
2
24 VAC
TRANSFORMER
SECONDARY
Y
P4
CIRCULATOR
1
BK
BK
W
4
G
W
TO
CASTING
1
BK
W
P10 BLOWER
3
1
2
3
2
1
G
P5
BLOWER
P1
TRANSFORMER
PRIMARY
P6
2
R
1
R
120 VAC
60 HZ, 1 Ø
HOT (L1)
ON/OFF SWITCH
1
CIRCULATOR
PUMP
1
2
24V THERMOSTAT
2
3
RW
3
LWCO
BK (PS-122)
G
Y
W
W
BK
Y
Y
G
W
2
IGNITER
3
2
1
P7
120VAC
DIAGNOSTIC INDICATOR LIGHTS
G POWER
G
NEUTRAL (L2)
BK
R PURGE
W
R IGNITOR
R VALVE
GROUND
R FLAME
(NOTE: USE COPPER CONDUCTORS ONLY)
18
x. ELECTRICAL WIRING
Figure #14B
LADDER WIRING DIAGRAM
NOTE: 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.
120 VOLT POWER SUPPLY
(NOTE: USE COPPER CONDUCTORS ONLY)
L2
L1
HOT
ON/OFF
SWITCH
BLK
WHT
LWCO
(PS-122)
P7-1
2K1
P7-2
P4-1
P4-3
P10-1
1K1
CIRCULATOR FIELD WIRED
P10-2
P5-1
5K1
P6-1
P12-1
BLOWER
HOT SURFACE IGNITER
3
P1-1
P2-1
120 VAC
4
CASTING TEMPERATURE
SAFETY SWITCH
(MANUAL RESET)
DIFFERENTIAL
AIR PRESSURE
SWITCH (N.O.)
SET AT
+ 0.5" WC
24 VAC
5
P2-2
P3-2
P3-1
MICROPROCESSOR
ELECTRONIC
LOGIC & TIMERS
1
3
2
INDICATOR LIGHTS
POWER
PURGE
IGNITER
P3-6
VALVE
HIGH LIMIT
AQUASTAT
CONTROL
P3-7
5K2
P1-3
P3-5
P3-3
W
1
P10-3
GAS VALVE
1
R
P6-2
TRANSFORMER
4K1 3K1
P3-9
P12-2
FLAME
1013-10 CONTROL
P3-4
P1-2
THERMOSTAT
19
5K
4K
3K
2K
1K
P7-3
P5-3
XI. CONTROLS AND ACCESSORIES
a lack of flame signal on three consecutive trials for ignition, the IBC will lock out. The “Valve” and “Flame” diagnostic indicator lamps (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.
This section provides a brief description of the key
controls and accessories found in this boiler.
See Section XVII, “Troubleshooting,” in this installation manual for detailed sequences of operation and
troubleshooting procedures. See the separately provided “Repair Parts Manual” for locations of all control
components and accessories described.
Figure #16
INTEGRATED BOILER CONTROL (IBC)
INDICATOR LIGHTS
The Integrated Boiler Control (IBC) is a microprocessor based controller for high efficiency gas boilers 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 the boiler and contains five diagnostic indicator lights.
GAS CONTROL VALVE
The electronic 24 volt gas control valve contains a 1:1
gas/air pressure regulator to control gas flow to the main
burner of the appliance, is suited for both natural and LP
gas, and is rated in accordance with ANSI Z21.21 - latest revision and CGA-6.5-M95.
Figure #15
GAS VALVE
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”
x ½” bushing on the top of the front boiler section at the
hot water outlet. The aquastat is tied in with the IBC and
is factory set at 180°F water temperature. The high limit
setpoint is field adjustable and may be set anywhere
between 100°F and 200°F. The field setpoint adjustment for each installation depends on heating system
requirements. The aquastat automatically resets when
the boiler water temperature drops 20°F below the setpoint value. This reset value can be field adjusted within
a range of 5-30°F.
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
NOTE: The maximum setpoint of the aquastat
must not exceed 200°F.
20
XI. CONTROLS AND ACCESSORIES
CASTING TEMPERATURE SAFETY SWITCH
DRAIN VALVE
In the event of lack of or loss of water in the boiler, the
casting temperature safety switch (230°F setpoint) installed on the top of the aluminum boiler section behind the supply piping shuts off the boiler by shutting
off power to the 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.
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 boiler. 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.
A.S.M.E. RATED PRESSURE RELIEF VALVE
! WARNING
The diaphragm type differential pressure switches are
connected by vinyl tubing to the gas valve and the air
inlet connection on the negative side and the sight glass
adapter on the positive side. The pressure switches
monitor air flow by sensing the differential pressure
measured in inches of water (” w.c.). The factory settings on these switches are 0.5” w.c. on the normally
open switch and 3.5” w.c. for the normally closed switch.
See Section XVI, “Detailed Sequence of Operation,”
for details on the operation of the differential pressure
switches.
Each boiler must have a properly sized and installed
A.S.M.E. 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 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 the 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.
BLOWER
BLOCKED VENT SAFETY SHUTOFF
Never run cold water into a hot, empty boiler.
DIFFERENTIAL PRESSURE SWITCHES
The blower provides a means for pushing combustion
air into and through the mixer, the burner, the flue ways
of the cast aluminum boiler section before being discharged through the vent piping to the outdoors.
The boiler is equipped with a blocked vent safety shutoff
which shuts off the main burner gas in the event that the
airflow of combustion products through the flue-way is
reduced. In the event of a blocked flue-way, enough air
will not be available to support combustion and the IBC
will lock out due to loss of adequate air flow.
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 (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. The circulator(s) should always be located on
the downstream (i.e., “pumping away”) side of the expansion tank.
Pressure switches monitor air flow by sensing differential pressure. The contacts are normally open and close
when the draft inducer is running and causing the differential pressure at the switch to exceed its setting.
The closed switch proves there is adequate air flow for
combustion.
The pressure switch shuts off the main burner if the differential pressure is inadequate due to a blocked vent
pipe, a blocked air intake, a blocked boiler section, or a
blocked air inducer. After 5 minutes of inadequate differential pressure, the IBC will lock out.
21
XI. CONTROLS AND ACCESSORIES
EXTERNAL CONDENSATE PUMP (Optional)
The “Purge” indicator lamp (see Figure #16) will blink,
indicating a failure to prove adequate combustion air
flow or flue gas flow. The IBC will automatically reset
after 15 minutes or can be manually reset as noted in
the section titled “Hot Surface Igniter.” If the boiler cannot be restored to normal operating condition by resetting the control, contact a qualified service agency to
check the heat exchanger flue-ways for blockage.
For installations where there is no floor drain or other appropriate drainage available to receive condensate from
the boiler, an external float activated condensate pump
with integral sump (supplied by others) is required.
The condensate pump can be piped 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 (not
factory supplied) to raise boiler as required for proper
installation.
LOW WATER CUT OFF
This unit is equipped with a low water cut off control
that protects against dry firing. This control provides
burner cut off if there is an unsafe water loss, which can
result from a broken or leaking radiator, pipe, or boiler.
A water/glycol mixture up to 50% concentration may be
used with the low water cut off.
XII. STARTUP
num at operating temperatures between 20°F and
250°F.
WATER TREATMENT AND FREEZE PROTECTION
1. Consult local water treatment specialist for recommendations if your water pH levels are below of 7.0
or hardness is above 7 grains hardness.
a. Use of antifreeze must be in accordance with
local plumbing codes.
a. This boiler is designed for use in a closed hydronic heating system ONLY!
b. Pure glycol solutions are very corrosive,
therefore hydronic system antifreeze typically contains corrosion inhibitors. Different
brands of hydronic system antifreeze contain
different types of corrosion inhibitors. Some
brands have corrosion inhibitors that break
down more rapidly or become ineffective at
higher temperatures when used with aluminum. This could lead to premature failure of
the aluminum boiler. Consult the antifreeze
manufacturer on the compatibility of their
product with aluminum.
b. Excessive feeding of fresh make-up water to
the boiler may lead to premature failure of
the boiler sections.
2. Use clean fresh tap water for initial fill and periodic
make-up of boiler.
a. A sand filter must be used if fill and make-up
water from a well is to be used.
b. Consideration should be given to cleaning
the heating system, particularly in retrofit situations where a new boiler is being installed
in an older piping system.
c. Follow the antifreeze manufacturer’s instructions on determining proper ratio of antifreeze
to water for the expected low temperature
conditions, and for maintaining the quality of
the antifreeze solution from year to year. Improperly maintained antifreeze solutions will
gradually lose their ability to protect the aluminum boiler from corrosion.
c. In older systems, obviously discolored, murky,
or dirty water, or a pH reading below 7, are indications that the system should be cleaned.
d. A pH reading between 7 and 8 is preferred
when antifreeze is not used in the system.
d. The recommended premixed antifreeze
solution is INTERCOOL NFP-50. This product is sold direct to distributors by the manufacturer. Please contact Interstate Chemical
3. Antifreeze, if needed, must be of a type specifically
designed for use in closed hydronic heating systems and be compatible with type 356 T6 alumi22
XII. STARTUP
Company at 1-800-422-2436 or your distributor for more information.
to rapidly bleed air from boiler, then let the relief
valve snap shut.
Use of an alternate manufacturer’s premix antifreeze is acceptable if the product specifications are comparable with those of the recommended premix antifreeze and the antifreeze is
compatible with type 356 T6 aluminum. Use of
incompatible antifreeze could damage the heat
exchanger and will void the product warranty.
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.
The antifreeze must be maintained per the
specifications of the manufacturer. Failure to do
so will result in the warranty being voided. Follow the antifreeze manufacturer’s instructions
on determining the proper ratio of antifreeze to
water for the expected low temperature conditions and for maintaining the antifreeze solution
from year to year.
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.
3. Repeat step 2 for all remaining zones.
5. Inspect piping system. Repair any leaks immediately.
FILLING BOILER WITH WATER AND PURGING AIR
FOR SYSTEMS WITH CONVENTIONAL CLOSED
TYPE EXPANSION TANKS
e. DO NOT USE AUTOMOTIVE ANTIFREEZE,
as the type of corrosion inhibitors used will
coat the boiler’s heat transfer surfaces and
greatly reduce capacity and efficiency.
Refer to the appropriate diagrams in Section VII, “Near
Boiler Piping,” for more information.
f. Use of antifreeze in any boiler will reduce heating capacity by as much as 10-20% due to
differing heat transfer and pumping characteristics. This must be taken into consideration
when sizing the heating system, pump(s) and
expansion tank. Consult antifreeze manufacturer’s literature for specific information on reduced capacity.
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 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.
g. Water content of the boiler is 2.6 gallons (10
liters).
h. Antifreeze will raise the pH of the water in a
heating system to between 8.0 and 10.0. This
is due to the corrosion inhibitors in the antifreeze.
3. Repeat step 2 for all remaining zones.
4. Open the expansion tank service valve and the tank
vent. Fill the tank to the proper level and close the
tank vent. Remove the handle from the expansion
tank service valve so the homeowner doesn’t accidentally close it.
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.
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.
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
6. Inspect piping system. Repair any leaks immediately.
23
XII. STARTUP
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.
4. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights
the burner. Do NOT try to light this burner by
hand.
PLACING BOILER IN OPERATION
5. Remove the front jacket panel.
READ BEFORE OPERATING APPLIANCE
6. Turn off the gas shut off valve. Valve handle should
be perpendicular to the gas pipe.
1. This appliance does not have a pilot. It is equipped
with an ignition device which automatically lights the
burner. Do NOT try to light this burner by hand.
7. Wait five minutes for any gas to clear. Then smell
for gas, including near the floor. If you smell gas,
STOP! Follow instructions at left under “What To
Do If You Smell Gas.” If you do not smell gas, go
to the next step.
2. 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
to the floor.
8. Turn the gas shut off valve to the “On” position.
The handle on the valve should be parallel to the
gas pipe.
WHAT TO DO IF YOU SMELL GAS
9. Replace the front jacket panel.
• Do not try to light any appliance.
• Do not touch any electric switch or use any
phone in the building.
10. Turn on all electrical power to the appliance.
11. Set thermostat to desired setting.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
12. If the appliance will not operate, follow the instructions in “To Turn Off Gas To Appliance” (below)
and call your service technician or gas supplier.
• If you can not contact your gas supplier, call the
fire department.
TO TURN OFF GAS TO APPLIANCE
3. Use only your hand to turn the gas shut off valve.
Never use tools. If the valve will not turn by hand,
do not try to repair it, call a qualified service technician. Force or attempted repair may cause fire
or explosion.
1. Set the thermostat to the lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Remove the front jacket panel.
4. 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.
4. Turn gas shut off valve off. Handle should be perpendicular to the gas pipe.
5. Replace the front jacket panel.
OPERATING INSTRUCTIONS
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.
1. STOP! Read the safety information above before
operating this appliance.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
24
XII. STARTUP
If Burner Appears To Pulsate During
Ignition:
1. Turn off boiler power and shut off gas supply to the boiler.
2. Take the burner assembly apart by removing the combustion air blower and gas valve/venturi assembly from the
boiler and visually inspect the inside of the burner. Look for
any debris (PVC shavings, etc.) and if anything is present,
remove it.
3. Reassemble burner assembly, turn gas supply and boiler
power back on, and relight boiler.
If burner still pulsates or fails to light:
1. Check for proper vent and intake pipe sizing and for proper
vent lengths and vent configuration by referring to, “Before
Installing The Boiler,” and “Combustion Air and Vent Pipe,”
sections in this manual.
2. Check for proper gas supply pressure and proper gas line
sizing to the boiler by referring to, “Gas Supply Piping,” section in this manual.
3. Check for orifice in negative pressure hose at gas valve and
2” air intake pipe upstream of gas valve.
4. Relight boiler.
5. If boiler still does not light, the air inlet pipe may need to be
disconnected to allow the boiler to start in order to verify
the boiler firing rate and combustion properties. The inlet
air pipe can be disconnected by removing the PVC inlet air
piping from the Fernco fitting located on the air inlet of the
gas valve/venturi assembly. Relight boiler.
6. When the boiler lights, the firing rate and combustion should
be checked per the “Adjustments and Checkout” procedure
Section of this manual. If the air inlet piping was disconnected in step 4 (above), leave it disconnected and make
first adjustment. Then reconnect air inlet piping, recheck
combustion CO2, and adjust again if necessary.
7. If burner pulsation continues or boiler fails to light after performing the above procedures, please contact Technical
Service at 1-800-325-5479 for further assistance.
25
XIII. Checkout procedure & adjustments
Verify proper sequence of operation
The sequence can be followed via the diagnostic indicator lamps on the Integrated Boiler Control in
Figure #16 (Section XI). 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
A.

B.

(2) Thermostat calls for heat, energizing the system circulator.
C.

(3) Integrated boiler control performs self check of internal circuitry, lasting
approximately two seconds, and energizes the draft inducer.
D.

E.

A.

B.

C.

D.

E.

A.

B.

C.

D.

E.

A.

B.

C.

D.

E.

A.

B.

C.

D.

E.

A.

B.

C.

D.

E.

A.

B.

C.

D.

E.

(1) Lamp A is illuminated, indicating that the integrated control is receiving 24 volts
and is in standby waiting for the thermostat to call for heat.
(4) The draft inducer comes up to speed and establishes combustion airflow,
causing the normally open differential pressure air proving switch contacts to
close. When combustion airflow is proved, Lamp B is illuminated indicating
that the 15 second pre-purge cycle has begun.
(5) After the pre-purge has completed, Lamp B is extinguished and Lamp C is
illuminated, indicating power is being delivered to the hot surface igniter 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 on the boiler.
(6) After the igniter warm-up period the integrated boiler control energizes the
gas valve, initiating a 6 second trial for ignition mode which is indicated by the
illumination of Lamp D. Two seconds later, Lamp C will extinguish when the
integrated boiler control stops sending power to the hot surface igniter.
(7) A low level illumination of Lamp E indicates the initiation of flame proving. During
the last 2 seconds of the trial for ignition mode, main burner flame is proven by
flame rectification through the hot surface igniter, providing a flame signal that is
relayed to the integrated boiler control, fully illuminating Lamp E.
(8) The thermostat ends its call for heat, causing the integrated boiler control to
de-energize the gas valve and system circulator. Lamp D is extinguished while
the unit enters the 30 second post purge mode, indicated by the illumination
of Lamp B. Lamp E will remain illuminated as the remainder of the gas in the
blower is burned off (approximately 2 seconds). During post purge the blower
remains powered and clears out any residual products of combustion.
(9) After the post purge mode the draft inducer is de-energized and the unit goes
into standby mode until the next call for heat from the thermostat.
NOTE: The first one or two cold starts may be rough due to the gas line not being completely
purged of air, causing low firing rate and high excess air levels.
26
XIII. Checkout procedure & adjustments
Inspect venting & air intake system
Set thermostat heat anticipator (if used)
and verify thermostat operation
Operate the boiler and verify that all vent/air intake
connections are gastight and watertight. Repair any
leaks immediately.
Verify that all connections are watertight. Repair any
leaks immediately.
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.
Test ignition system safety SHUTOFF
MEASURE NATURAL GAS INPUT RATE
1. Turn off manual gas shut off valve.
Correct input rate is essential for proper and efficient
operation of the burner and boiler.
INspect condensate drain
Verify that all connections are watertight, and that condensate flows freely. Repair any leaks immediately.
Inspect system piping
2. Set thermostat to call for heat.
1. Determine the elevation at the installation site.
3. Boiler begins normal sequence of operation.
2. See Table 2 in Section IV of this manual to determine the correct approximate input rate for the local elevation.
4. After approximately 30 seconds (pre purge and igniter warm-up period), lamp D illuminates, indicating gas valve is powered.
3. Obtain the yearly average heating value of the local
gas utility. At sea level elevation, it should be approximately 1000 BTU per standard cubic foot.
5. After 4 seconds, gas valve closes, lamp D goes out
as integrated boiler control senses that flame is not
present.
4. Operate boiler for 5 minutes.
6. To restart system, follow operating instructions in
Section XII, “Start Up.”
5. Turn off all other gas appliances, extinguishing
standing pilots where applicable.
Test and adjust high limit control
6. At the gas meter, measure the time in seconds required to use one cubic foot of gas.
Set high limit differential to minimum setting. While
burner is operating, adjust setting 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.
Return high limit differential to original setting (20°F)
7. Calculate the “input rate” according to the following
formula:
Btuh input rate = 3600 x heating value from step 3
Time in seconds from step 6
8. The measured input rate should be within +0/-2%
of the input rating found in step 2. If not, see “Adjustments and Checkout” on next page.
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.
27
XIII. Checkout procedure & adjustments
ADJUSTMENTS AND CHECKOUT
It is important that this appliance operate between 8.5 and 10% CO2. To verify that the
appliance is operating in this range, follow the steps below.
Important: Under all conditions CO levels should not exceed 100ppm.
1. Check incoming gas pressure to the appliance using a pressure gauge with a resolution of 0.1” w.c. or better and a range from 0” to at least 14” w.c. Close the gas shut-off
inside the boiler jacket. Locate the inlet pressure tap on the gas valve (see Figure #15
in Section XI). Open the inlet pressure tap screw ½ turn and connect the positive side of
the pressure gauge to the inlet pressure tap. Open the gas shut-off. The gas pressure
should read between 4” and 10” w.c. for natural gas and between 10” and 14” w.c. for
propane gas.
2. Drill a hole in the plastic CPVC vent pipe or exhaust tee, just large enough to allow
access for the sample probe of your combustion analyzer.
3. Turn the thermostat to the closed position so the appliance is activated.
4. Allow the appliance to run for approximately 5 minutes.
5. Insert the sample probe of your combustion analyzer into the hole you drilled in step 2
above, about halfway into the exhaust gas stream. Take a flue gas reading and observe
the CO2 value. Adjust the throttle screw until the CO2 value is between 8.5 and 10%.
(O2 between 5.5% and 2%) Turning the throttle screw counterclockwise increases the
rate and the CO2 value. Turning the throttle screw clockwise decreases the rate and
the CO2 value. Allow the appliance to stabilize for approximately 1 minute after adjusting the throttle screw before you take a reading with your combustion analyzer.
6. After adjustments are made stop the appliance, disconnect the pressure gauge, tighten the inlet pressure tap on the gas valve, remove the CO2 meter from the CPVC pipe,
and seal the hole with an appropriate material.
7. Return the thermostat switch to its original position.
Final checkout of the installation
After any adjustment to the appliance, observe several complete cycles to ensure that all
components function correctly.
Set thermostat TO DESIRED TEMPERATURE
FINAL REVIEW and sign-off
Set thermostat to desired room temperature and observe
several complete cycles to verify proper operation.
Review all instructions shipped with this boiler with
owner or maintenance person. Instructions must be
affixed on or adjacent to the boiler. Then complete
and sign the “Installation and Checkout Certificate” at
the end of this manual.
28
XIV. maintenance and cleaning
Maintenance as outlined below can be performed
by the owner unless otherwise noted.
2. Check that boiler area is free from combustible materials, gasoline, and other flammable vapors and
liquids.
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. It is recommended to service the appliance at least once
every 12 months.
3. Circulator pump and blower motor furnished with
boiler are permanently lubricated from the factory
and require no further lubrication. Additional or
non-factory supplied pumps and/or motors should
be lubricated according to the pump and/or motor
manufacturer’s instruction.
Daily during heating season
1. Check for and remove any obstruction to the 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.
Monthly during heating season
Beginning of each heating season
1. Remove jacket front and top panels and check for
piping leaks around relief valve and other fittings. If
found, contact a qualified service agency to repair.
DO NOT use stop leak compounds.
1. Schedule an 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 paragraph F (below).
2. Test relief valve. Refer to valve manufacturer’s instructions packaged with relief valve.
3. Visually inspect venting and air intake system for
proper function. 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.
b. Visually inspect venting and air intake system
for proper operation. 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.
4. Visually inspect the PVC condensate drain pipe for
proper operation. If the drain pipe shows any signs
of blockage, leakage, or deterioration contact a
qualified service agency to clean, repair, or replace
it immediately.
c. Check for and remove any obstruction to the
flow of combustion air or venting of flue gases.
d. Follow instructions for “Placing Boiler In Operation” in Section XII of this manual.
e. Follow “Checkout Procedures and Adjustments” on previous page.
5. Check air vent(s) for leakage.
Periodically during heating season
f. Visually inspect condensate drain line for proper
operation. Check for deteriorated or plugged
condensate drain line.
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.
g. Check all gasketed joints for leakage, and tighten bolts or replace gaskets if necessary.
h. 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.
29
XIV. maintenance and cleaning
heating surfaces of boiler (see “Repair Parts
Manual” for diagram). Be sure that brush
does not get stuck in heat exchanger!
Annual shut down procedure (End of each
heating season)
1. Follow the instructions in “To Turn Off Gas To Appliance” in Section XII.
j. After brushing and rinsing, remove any remaining loosened sediment using a shop
vacuum with a snorkel attachment.
2. If heating system is to remain out of service during
freezing weather, and does not contain antifreeze,
drain system completely. If boiler will be exposed
to freezing temperatures, drain condensate lines.
Otherwise, do not drain system or boiler.
k. 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.
Annual examination and cleaning of
boiler components
l. Reinstall burner and gaskets and position
blower adapter assembly over studs. Install
five nuts but do not tighten. Reinstall igniter and igniter gasket and fasten with two
screws. The igniter element is very sensitive. Do not touch the igniter element with
your fingers or hands as oils or debris
will cause premature failure Tighten five
nuts holding blower adapter assembly.
The following service procedures must be performed only by a qualified service agency. Boiler
owner should not attempt these procedures.
1. Before servicing, turn off electrical power to boiler
at service switch. Close manual gas valve to turn
off gas supply to boiler.
2. Examine flue passages by removing blower assembly from casting as shown in the separately
provided “Repair Parts Manual.” The procedure for
examining and cleaning the burner is described
below.
m. Connect gas line to gas valve; air inlet assembly to gas valve (using 2” x 1½” flexible
coupling); pressure switch hose to gas valve
and air inlet assembly; 2” flexible coupling
to boiler exhaust port; igniter wires; and gas
valve wires.
Any buildup of sediment or aluminum oxide (white
powdery or flaky substance) in the flue passages
must be cleaned as follows:
3. Visually inspect 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 described below.
a. Remove jacket front and top panels.
b. Confirm that manual gas valve is closed and
disconnect gas line to gas valve at union.
a. Inspect for sediment or blockage.
c. Disconnect wires to gas valve and igniter.
b. Flush out with water or vacuum.
d. Remove air inlet assembly from gas valve.
c. Follow the instructions under “Near Boiler
Piping” in Section XII for filling condensate
trap with water.
e. Loosen but do not remove five nuts attaching
blower adapter assembly to boiler.
f. Remove two igniter screws and very carefully
remove the igniter. The igniter element is
very sensitive. Do not touch the igniter element with your fingers or hands as oils
or debris will cause premature failure.
4. Inspection of the flue connector requires the following steps. Refer to the “Repair Parts Manual” for
diagram.
a. Loosen clamp on draft inducer end of 2” flexible coupling that connects vent tee to exhaust port.
g. Remove five nuts and blower adapter assembly. Remove burner and gaskets.
b. Inspect interior of vent tee. Any buildup of
sediment on the inside surface must be
cleaned.
h. Aluminum oxide deposits are water soluble
and may be rinsed away with spraying or running water.
c. Reconnect the 2” flexible coupling to the draft
inducer outlet.
i. Use a flexible handle nylon brush to loosen
sediment and aluminum oxide on all exposed
30
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
31
YES
NORMAL
OPERATION
DETAILED SEQUENCE OF OPERATION
SAFETY SEQUENCES DURING 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 temperature safety switch contacts will open,
breaking 24 volt power to ibc. power indicator light
goes out. Requires manual reset to re-close contacts.
Power light goes out.
Draft inducer runs through 30 second post purge and
switches off.
Circulator runs with thermostat on call for heat.
High limit control
When temperature safety switch contacts remake
before end of call for heat, control goes into normal
light-off sequence.
if boiler water temperature reaches high limit
(aquastat) setpoint, high limit n.c. contacts open
immediately, closing gas valve. Valve and flame
lights go out.
Loss of flame signal
Draft inducer continues to run for 30 second post
purge and switch off.
if an established flame signal is lost while control expects
that the burner is operating, control will immediately deenergize gas valve. Valve and flame lights go out.
Circulator runs as long as thermostat calls for heat.
When high limit contacts remake before end of call for
heat - control goes into a normal light-off sequence.
Draft inducer runs through 30 second post purge.
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.
Circulator will be energized as long as thermostat calls
for heat during lockout.
Loss of combustion airflow
Recovery from any lockout requires reset, which
can be accomplished by:
Circulator pump
(a) removing and reestablishing the thermostat’s
call for heat or turning the service switch off and
back on; or
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.
(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.
32
DETAILED SEQUENCE OF OPERATION
END OF NORMAL SEQUENCE OF OPERATION
Thermostat ends call for heat.
Gas valve and circulator pump are
de-energized, valve and flame lights go out.
blower runs for 30 seconds post purge,
purge light is on.
blower is de-energized after 30 seconds,
purge light shuts off.
boiler stand by for next call for heat.
33
TROUBLESHOOTING
!
DANGER
Fire, Explosion or Shock Hazard may cause Property Damage, Sever
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 dose 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, by following the
Troubleshooting, Check Out The System and the Sequence Of Operation section of this chapter
for the normal Light Off Sequence.
6. All controls are factory tested in the assembly process. A defective control is generally the least
likely cause of malfunction. If you suspect the unit has a defective control, read through the
troubleshooting chart before replacing it.
7. It is extremely unlikely that two consecutive controls are defective. If this seems to be the case
chances are that the controls are not the cause but rather the malfunction is due to some other
problem such as an electrical short burning out a transformer.
INITIAL SERVICE CHECKS
1. Before Troubleshooting:
A. Make sure that the circuit breaker is on or fuse is OK at the electrical panel.
B. Make sure that the service switch is ON.
C. Make sure that the Gas is ON at the:
• Gas meter • All appropriate manual shutoff valves • Gas control valve
D. Make sure that the thermostat is calling for heat.
E. Make sure that the wire connections at the integrated boiler control and at the originating
control are securely plugged in or connected.
F. Check that the hoses are securely connected and are not plugged or damaged.
2. Troubleshooting Tools:
A. Voltmeter to check120 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 the 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 The System Status?
A. Consult the chart on the following page.
B. Figure #15 shows the location of the Diagnostic Indicator Lamps on the boiler.
34
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 were lockout occurs. If this table does not readily provide the reason for boiler
malfunction or non-operation, refer to the following pages for more detailed troubleshooting procedures.
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 on or air flow is not proven.
PURGE
Off
Off during igniter and run cycle - normal operation, purge cycle complete.
Blinking
IBC is locked out. Problem could indicate false positive proof of air flow. Blocked vent,
intake air pipe, flue way, or orifice in negative pressure hose.
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.
IGNITER
VALVE
Blinking
On Bright
FLAME
On Dim
Off
IBC is locked out. Problem is flame has not been proven in three (3) ignition attempts.
May be due to broken igniter or lack of/low flame signal, or no gas.
Flame proven.
Checking for flame signal (during trial for ignition)
Flame unproven.
35
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 electric switch
or use any phone in the building.
• Immediately call your gas supplier
from a neighbor’s phone. Follow
the gas supplier’s instructions.
• If you can not contact 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.
36
TROUBLESHOOTING
TROUBLESHOOTING CHART 2
!"
#
" "
"
"!
"# "!"
"
"!
"
#
!"
#
!#
"
#
!#
#
!" #"
#
#"
#
#"
"
!"
#
! #
37
"
TROUBLESHOOTING
TROUBLESHOOTING CHART 3
CHART 1
OPEN
BLOWER STARTS
NO
YES
CHECK FOR VAC
NO
BETWEEN TERMINALS 1 AND 3
AT CONNECTOR CN4 ON IBC
REPLACE IBC
YES
CHECK FOR 120 VAC AT
BLOWER LEADS ON WIRING
HARNESS
NO
REPAIR/REPLCE
WIRING FROM IBC
TO BLOWER
YES
REPAIR/REPLACE
BLOWER
PRESSURE SWITCH
CONTACTS
OPEN
PURGE LIGHT ON?
YES
NO
IBC WAITS UP TO 5
MINUTES FOR NORMALLY
OPEN AIR
PRESSURE SWITCH
CONTACTS TO CLOSE,
INDICATING BLOWER
SUCTION IS
PRESENT
ARE VENT PIPE AND AIR
INTAKE PIPE CLEAR
(NO BLOCKAGE)
NO
YES
CHECK AIR
PRESSURE SWITCH PER
INSTRUCTIONS ON
FOLLOWING PAGES. ARE
SAMPLING LINES CLEAR
AND CONNECTED
PROPERLY?
NO
CLEAN OUT VENT PIPE
AND/OR AIR INTAKE PIPE.
CHECK FOR SAGS OR
LOW SPOTS WHERE
CONDENSATE MAY
PUDDLE AND BLOCK
THE VENT
CLEAN OUT SAMPLING
LINES OR REPLACE
DEFECTIVE SWITCH
YES
CHECK FLUE PASSAGES
IN BOILER PER
NO
"MAINTENACE AND
CLEANING". ARE FLUE
PASSAGES IN BOILER CLEAN?
CLEAN BOILER FLUE
PASSAGES PER
MAINTENANCE AND
CLEANING INSTRUCTIONS
YES
CHECK DRAFT INDUCER
MOTOR RPM. IS IT
3400-3600?
YES
CHECK FOR BROKEN OR
LOOSE IMPELLER ON DRAFT
INDUCER AND REPLACE
BLOWER IF FOUND TO
BE BROKEN OR LOOSE
15 SECOND PRE PURGE COMPLETE.
PURGE LIGHT IS OFF. SIMULTANEOUSLY
IGNITOR LIGHT IS ON AS IGNITOR CIRCUIT
IS ENERGIZED.
NO
REPLACE IBC
YES
CHART 4
38
NO
REPLACE
BLOWER
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
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?
REPLACE IBC
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
39
NO
OPEN OR TURN ON ALL
MANUAL SHUTOFFS
TROUBLESHOOTING
TROUBLESHOOTING CHART 5
#%
*$
#%
*$
! $$*)%&#%
$$ ($%# $
'' # #$$#
$$
'%&#'' ##%$+
$#!#!#%$#
#!$$
$&#% &$ ##%$
'%&#''$+
*$
! $$*%&#%
#
&!$$$ #!#
%#
&!$$$ #
#&!$$$!#%
$%#&% $
*$
)#&## #
!#%
$%#&% $##
!$$$)#&##
# #%&##%
# ##%$+$#!#!#%$
#$ # ##%$+
$&##
#&&% #
%$ #
%"&$%%
%%$ !
)#&##!#%
$%#&% $
#!&##
#&$$
%* # &%
$ $%$&%$ %$!
#$
%#
$$ #
! $% %!$ &
$%% (#$&##
$,
$&% ## #
$!$%#&% $
#"&#$$!%
$
*$
#!
#%
#$% #
%#
$$ #
% ##%! $% %# %
*$
%$(#$ $%!!# !#%
!% #$ $*!% $$ (
#%
#%
40
) % %#!#'%
$
#!
%#
$ #
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.
YES
REPLACE BURNER
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
DOES CIRCULATOR PUMP STOP?
NO
YES
ARE THERMOSTAT CONTACTS OPEN?
NO
REPLACE THERMOSTAT
YES
REPLACE IBC
ValE lIgHt IS oFF
NO
YES
DOES DRAFT BLOWER
STOP AFTER 30
SECOND POST PURGE?
REMOVE WIRING HARNESS
CONNECTION CN9 FROM GAS
CONTROL DOES GAS CONTROL
CLOSE?
YES
NO
REPLACE IBC
YES
SYSTEM OK
41
NO
REPLACE GAS CONTROL
REPLACE
AQUASTAT
OK
TROUBLESHOOTING
Differential air pressure switch check
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.
Locations of the connection points required to check
the differential air pressure.
The following steps and diagram indicate the
location of the connection points required to
measure the offset pressure using an inclined
Manometer or a Differential pressure gauge.
Only one device is required to measure the
offset pressure.
1. Turn off service switch, or lower thermostat
setting.
2. Remove vinyl caps from Tee.
3. Install testing lines as shown to inclined manometer or differential pressure gauge with
the ability to read 0.01” to at least 6.0” w.c.
4. Turn on service switch and set thermostat
to call for heat.
5. If manometer readings do not correspond
to the chart at right, check for possible
causes:
• Blockage or moisture in suction lines to
switch.
• Blockage or moisture in orifice installed
in suction lines to switch.
• Blockage in air intake or vent pipes.
• Undersized air intake or vent pipes.
• Loose blower wheel on motor shaft.
• Incorrect pressure switch or pressure
switch setpoint.
• Gas valve out of adjustment.
6. When the pressure reading corresponds to
the chart at right and the pressure switch is
operating properly, remove the testing lines
and reinstall the vinyl caps to the Tee and
3-way connector.
Boiler Status
Differential Pressure
Not Running
0”
Running Without
Blockage
(Approximate minimum vent lengths)
Running With
Blockage
42
Switch
Contacts
3.5”
Closed
0.5”
Open
1.50” for Model 150
3.5”
Closed
1.50” for Model 175
0.5”
Closed
3.5”
Open
0.5”
Closed
1.00” for Model 125
2.00” for Model 200
Greater Than or Equal
To Setpoints
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 __________________________________________________
43
P.O. Box 900, 6800 Base Line
Wallaceburg, ON N8A 5E5, Canada
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