Allied Engineering SC-35 Service manual

INSTALLATION AND SERVICE MANUAL
SC SERIES GAS BOILERS
FOR MODELS SC-35 TO SC-280
SEE REAR COVER FOR INDEX
This manual must only be used by a qualified heating installer,
service technician or gas supplier.
See Section 3.11 for Installer’s Checklist
See Section 4.3 for Service Checklist
Manufactured by
Allied Engineering Company
Division of E-Z-Rect Manufacturing Ltd.
Manufacturers of Gas and Electric Boilers, Stainless Steel Tanks, Heat Exchangers and Electric Boosters.
94 Riverside Drive, North Vancouver, B.C. V7H 2M6 • Telephone (604) 929-1214 • FAX (604) 929-5184
Branches: Calgary • Edmonton • Toronto
PN9182778
Price: $10
SC SERIES BOILERS
DIMENSIONS AND SPECIFICATIONS
MODEL
NUMBER
INPUT*
OUTPUT
DIM A
DIM B
SHIPPING
WEIGHT
MBH
kW
MBH
kW
In
cm
in
cm
lb
kg
SC-35
35
10.3
30.2
8.9
8.7
22.1
3
7.6
166
75
SC-70
70
20.5
60.5
17.7
11.7
29.7
3
7.6
198
90
SC-105
105
30.8
90.9
26.6
14.7
37.3
3
7.6
230
104
SC-140
140
41.0
121.3
35.5
17.7
44.9
3
7.6
262
119
SC-175
175
51.3
151.6
44.4
20.7
52.5
4
10.2
294
133
SC-210
210
61.6
182.2
53.4
23.7
60.1
4
10.2
326
148
SC-245
245
71.8
212.8
62.3
26.7
67.8
4
10.2
362
164
SC-280
280
82.1
242.9
71.2
29.7
75.4
4
10.2
398
181
* For altitudes above 2,000 feet, refer to section 4.7 to determine the appropriate Input
derate or contact the factory.
Minimum clearances from boiler outer case to combustible material: Top 13” (33 cm),
Right Side 1/2” (1.27 cm), Left Side 9” (22.9 cm), Rear 1/2” (1.27 cm),
Front 2.5” (6.4 cm). A minimum service clearance of 18” (46 cm) is recommended for
the front and left side. Approved for Combustible Floors (not directly on carpeting),
Alcove & Closet installation.
Model Number Suffixes:
“N” = Natural Gas
“HS” = Hot Surface Ignition
“P” = Propane
“PS” = Packaged Boiler
The Super Hot product improvement program may result in changes to the design
and/or specifications being made without notice.
2
Packaged Boiler Includes:
• Combination Gas Valve / Direct
Ignition
• Temperature / Pressure Gauge
• Zone Control Board for 4 Zones
c/w transformer
• Pressure Relief Valve 30 PSI
• Drain Valve 3/4” NPT
• Dual Aquastat
• Stainless Steel Burners Low
NOx
• Hot Surface Ignition
• Air Differential Pressure
Switches
• Super Hot Cast Iron Pump
Adapter
• Combustion Air Blower / Fan
• Sidewall Vent Termination Cap
• 1 1/4” Circulator / Pump
(mounted and wired)
• Expansion Tank
• Air Purger
• Automatic Air Vent
• Combination Fill Valve /
Regulator
• Rated 86% AFUE
SC Series Boilers – Installation and Service Manual
ABOUT OUR MANUALS
Your Super Hot boiler has been provided with two manuals:
•
User's Information Manual - This manual is intended for the owner or user of the boiler and provides
information on routine operation and maintenance, and emergency shutdown.
•
Installation and Service Manual - This manual must only be used by a qualified heating installer,
service technician or gas supplier. Installation or service by anyone unqualified to do so may
result in severe personal injury, death or substantial property damage.
Both manuals should be kept in the envelope provided and affixed adjacent to the boiler so that they are
readily available for future reference.
Lighting Instructions
Section 1
This boiler is always equipped with an ignition device which automatically and directly lights the main
burners (there is no pilot burner).
There are two possible ignition systems:
1. direct spark ignition with combination gas valve (equipped with gas control knob) and module.
2. hot surface ignition with combination gas valve (equipped with gas control knob) and module.
The lighting instructions shown in this section apply to both ignition systems. In addition, the lighting
instructions have been printed on a label attached to the boiler. If you are unsure which type of gas valve
or ignition system your boiler is equipped with, check the wiring diagram sticker on the boiler or contact
the factory.
WARNING
Should boiler overheat, or the gas supply fail to shut off, do not turn off or disconnect the
electrical supply to the circulating pump. Instead, shut off the gas supply at a location external
to the boiler.
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SC Series Boilers – Installation and Service Manual
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
A. This appliance does not have a pilot. It is
• If you cannot reach your gas supplier,
equipped with an ignition device which
call the fire department.
automatically lights the burner. Do not try C. Use only your hand to push in or turn the
to light the burner by hand.
gas control knob. Never use tools. If the
B. BEFORE OPERATING smell all around the
knob will not push in or turn by hand, don't
appliance area for gas. Be sure to smell
try to repair it, call a qualified service
next to the floor because some gas is
technician. Force or attempted repair may
heavier than air and will settle on the floor.
result in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS
D. Do not use this appliance if any part has
• Do not try to light any appliance
been under water.
Immediately call a
• Do not touch any electrical switch; do
qualified service technician to inspect the
not use any phone in your building.
appliance and to replace any part of the
• Immediately call your gas supplier from
control system and any gas control which
a neighbor's phone. Follow the gas
has been under water.
supplier's instructions.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above 6. Turn gas control knob clockwise 3 to
on this label.
"OFF".
2. Turn off all electrical power to the appliance. 7. Wait five (5) minutes to clear out any gas.
Then smell for gas, including near the floor.
If you smell gas, STOP! Follow "B" in the
safety information above on this label. If
you don't smell gas, go to the next step.
3. Set the room thermostat to lowest setting.
4. This appliance is equipped with an ignition
device which automatically lights the
burner. Do not try to light the burner by
hand.
8. Turn gas control knob counterclockwise
to "ON".
5. Remove control access panel.
4
9. Replace control access panel.
10. Set room thermostat to desired setting.
11. Turn on all electrical power to the appliance.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance"
and call your service technician or gas
supplier.
TO TURN OFF GAS TO APPLIANCE
1. Turn off all electrical power to the appliance 4. Turn gas control knob clockwise
if service is to be performed.
"OFF". Do not force.
2. Set the room thermostat to lowest setting.
5. Replace control access panel.
3. Remove control access panel.
4
3
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SC Series Boilers – Installation and Service Manual
Installation Instructions
2.1
Section 2
RECEIVING
INSPECT SHIPMENT FOR POSSIBLE DAMAGE. All goods are carefully manufactured, inspected,
checked and packed by experienced workers. The manufacturer's responsibility ceases upon delivery of
goods to the carrier in good condition. Any claims for damage and/or shortage in shipment or nondelivery must be filed immediately against the carrier by the consignee.
Use care when receiving and unpacking the boiler. Dropping the boiler may cause damage and prevent
safe and proper operation.
2.2
INSTALLATION CODES AND REQUIREMENTS
All applicable national, provincial/state, and local codes, laws, regulations, and ordinances must be
followed. They expand on and take precedence over any recommendations in this booklet. Authorities
having jurisdiction shall be consulted before installations are made.
In Canada, the installation must conform to the requirements of the authority having jurisdiction or, in the
absence of such requirements, to the CAN/CSA B149 Installation Codes (current edition). All electrical
wiring and grounding must be in accordance with the Canadian Electrical Code, CSA C22.1 Part 1
(current edition) and applicable local codes.
In the United States of America, 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
(current edition). All electrical wiring and grounding must be in accordance with the National Electrical
Code, ANSI/NFPA 70 (current edition) and applicable local codes.
Where required by the authority having jurisdiction, follow the Standard for Controls and Safety Devices
for Automatically Fired Boilers, ANSI/ASME CSD-1 (current edition).
If there is any conflict in the above requirements, the more stringent requirement applies.
The installation and service must also conform to the additional requirements in this manual. If there is
any conflict with a requirement in this manual and a Code requirement, the Code requirement must be
followed.
2.3
LOCATION
This boiler is intended for indoor installation only. Observe the following minimum clearances from the
boiler to combustible materials:
Minimum Clearances to Combustible Materials
Left Side with piping
Right Side without piping
Rear
Top
Front
Flue Pipe
in.
mm
in.
mm
in.
mm
in.
mm
in.
mm
in
mm
9
229
0.5
12.7
0.5
12.7
13
330
2.5
64
2.5
64
•
A minimum service clearance of 18 in. is recommended for the Front and Left Side (with piping).
•
Maintain a clearance of 2-1/2" from the flue pipe in any direction to combustible materials.
•
Allow ample space for the boiler water inlet and outlet connections, and the gas connection.
•
Boiler must be installed on a stable and level foundation.
•
The boilers can be installed on a combustible floor but must not be installed directly on carpeting.
•
A hot water boiler installed above radiation level, or as required by the authorities having
jurisdiction, must be provided with a low water cutoff device at the time of boiler installation.
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SC Series Boilers – Installation and Service Manual
•
This boiler must be installed such that gas ignition system components are protected from water
(dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement,
condensate trap, control replacement, etc.).
•
Structure through which venting will pass must be free and clear for opening (i.e. no hidden conduit,
telephone cables or other obstructions).
2.4
GAS SERVICE PIPING
Make sure the gas on which the boiler will operate is the same as that specified on the boiler rating plate.
Do not install the boiler if equipped for a different type gas. Consult your gas supplier to get gas
information.
To prevent damage, care must be taken not to apply too much torque when attaching gas supply pipe to
gas valve gas inlet. Use a wrench on the square ends of the gas valve to hold it when connecting the gas
supply pipe.
The boiler and its gas connection must be leak tested before placing the boiler in operation. The gas
controls furnished are suitable for a maximum operating gas pressure of 1/2 psi (14 inches water
column).
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 1/2 psig (14 inches water column).
The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff
valve during any pressure testing at test pressures equal to or less than 1/2 psig (14 inches water
column).
A manual main shut-off valve must be installed in the gas line outside the boiler jacket and as required in
Section 2.2. The valve should be readily accessible for turning on and off.
A drip pocket or sediment trap must be installed in the gas supply line upstream of the gas controls and
as close to the boiler as possible (example shown in Figure 3 in Section 6).
The pipe compound used should be resistant to the action of liquefied petroleum gases. Check for gas
leaks in piping before placing the boiler in operation by using a soap and water solution. Also check the
gas leaks of the joint between the gas valve outlet and manifold when the boiler is on. DO NOT USE AN
OPEN FLAME.
INSTALLER MUST IDENTIFY EMERGENCY SHUT-OFF DEVICES.
All piping and fittings must be installed as per codes in Section 2.2.
2.5
CORROSIVE ATMOSPHERES
If a gas boiler is to be installed near a corrosive or potentially corrosive air supply, the boiler should be
isolated from it and outside air should be supplied as recommended in Section 2.6.
Chemical vapors from products containing chlorine or fluorine must be avoided. Even though these
chemicals may be safe to breathe, corrosive substances can become liberated when passed through a
gas flame. Even at low concentrations, these chemicals can significantly contaminate the air supply and
shorten the life of any gas-fired appliance. The following is a list of some of the products which should be
avoided:
•
bleaches and chlorinated cleaning products
•
paints and sprays
•
water softeners (calcium or sodium chloride)
•
leaking refrigeration equipment
•
freon from common aerosol dispensers
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SC Series Boilers – Installation and Service Manual
These chemicals are especially commons near swimming pools, beauty shops, dry cleaning
establishments, laundry areas, workshops, and garages. The warranty is void when failure is due to
corrosion.
2.6
VENTING AND COMBUSTION AIR
Definitions:
A direct vent system operates so that all air for combustion is obtained from the
outdoor atmosphere and all flue gases are discharged to the outdoor
atmosphere.
A non-direct vent system operates so that all air for combustion is obtained
from the boiler room and all flue gases are discharged to the outdoor
atmosphere.
This boiler is certified as a Category III appliance only. This boiler can be installed similar to a Direct
Vent Appliance (with an inlet air duct and a venting duct) but it shall have the same air supply as a
Category III appliance is required to have.
Combustion Air Supply
For a non-direct vent or direct vent installations, a sufficient air supply MUST be provided to the boiler
room and to the boiler. Air opening(s) to the boiler room provide the air for combustion and ventilation
and are always required. The air opening size and location (as well as other air supply considerations)
must conform to Section 2.2.
The boiler room must never be under a negative pressure in all applications, including direct vent alike.
Always provide air openings sized not only to the dimensions required for the total input of all fuel-fired
appliances in the boiler space, but also to handle the air movement rate of any exhaust fans or air
movers using air from the building or space.
The venting terminations must always be kept clear of obstructions (i.e. snow, ice, etc.). Louvers and
grilles used in the air supply and ventilation system must conform to Section 2.2 and should be kept clear
of any dust, dirt, or debris, which will block proper airflow.
The responsibility of providing a suitable venting and air intake pipe of adequate draft capacity and in
good usable condition is that of the gas fitter/installer. Interference with the air supply for the boiler shall
be prohibited.
For boilers to be connected to gas vents or chimneys, vent sizing, installation and termination shall be in
accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1 or Section 7,
Venting Systems and Air Supply for Appliances, of the CAN/CSA B149, Installation Codes, and all
applicable provisions of the local building codes. Contact local building or fire officials about restrictions
and installation inspection in your area.
Air Intake System
When the boiler is installed as a direct vent system, ABS, PVC schedule 40 pipe, galvanized steel pipe,
PVC pipe and CPVC pipe can be used for air intake pipe. The air intake pipe may be sealed using
appropriate sealants.
Exhaust Vent System
This boiler is certified as Category III and requires stainless steel exhaust venting suitable for positive
pressure. The following manufacturers offer components approved for use with this boiler:
•
Flexmaster Canada Ltd.: Z-Vent
•
Z-Flex U.S.,Inc.: Z-Vent
•
Heat-Fab Inc.: Saf-T-Vent
•
Flex-L International Inc.: StaR-34
•
Protech Systems, Inc.: FasNSealTM
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SC Series Boilers – Installation and Service Manual
The use of these manufacturers' venting systems for sidewall venting will require the vent terminal
supplied by Allied Engineering Company. The vent terminal for vertical venting and these venting
systems may be not supplied with this unit and should be obtained from the supplier of the venting
system listed above.
Condensate Trap
All boilers with vertical venting installations require a condensate drain
and drain trap. Do not operate the boiler without installing this trap and
filling with water.
The condensate drain should be installed as close to the boiler as
possible and must be equipped with a drain trap. The drain tap should
be formed by attaching 3/8” I.D. high temperature tubing, such as
silicone, to the drain assembly, making a loop of approximately 4”
diameter and securing it with a cord or tie wrap where the tube crosses
over itself. Do not squash the tube or over-tighten it, see Figure 1. The
loop must then be filled with water to form a liquid-filled trap. This trap
allows condensate to drain while preventing exhaust gases from
escaping.
Figure 1 – Condensate trap
Periodic inspection and cleaning should be made of this assembly. Check for deterioration of the tubing
and to ensure that the trap is filled with water. If the tube is plugged or appears to have excessive
sediment in it, it should be removed from the condensate drain pipe, straightened out to clear the
obstruction, reformed, filled with water and reinstalled as before. The drain should extend to a floor drain,
condensate pump or to a plastic container which may require emptying periodically. Condensate
disposal must be acceptable to the authority having jurisdiction.
Vent Terminal Information
The minimum distance from the termination of a vent terminal to adjacent public walkways, adjacent
buildings, openable windows and building openings shall be not less than those values specified in the
National Fuel Gas Code, ANSI Z223.1 and/or CAN/CSA Installation Codes.
Flue gas condensate can freeze on the exterior walls or on the vent cap. Frozen condensate on the vent
cap can result in a blocked flue condition. Some discoloration to exterior building surfaces can be
expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.
To prevent discoloration and degradation of building materials by flue gases and flue gas condensation,
ensure that the vent terminal is installed clear of nearby obstacles. In all cases, installation shall be in
accordance with code.
For proper operation, the vent terminal must be kept free of snow, leaf dropping and other debris at all
times to ensure that no blockage occurs. Do not terminate the vent in a window well, stairwell, alcove,
courtyard, or other recessed area. The vent cannot terminate below grade and directly above a paved
sidewalk or paved driveway that is located between two single-family dwellings and serves both
dwellings. The vent shall not terminate underneath a veranda, porch, or deck unless the veranda, porch,
or deck is fully open on a minimum of two sides beneath the floor and the distance between the top of the
vent termination and the underside of the veranda, porch, or deck is greater than 1 foot (300 mm).
Do not locate the vent terminal directly under roof or deck overhangs to prevent icicles from forming.
Vent terminal should not allow flue gas discharge towards neighbor’s windows or where personal injury or
property damage can occur.
It is highly recommended that the vent terminal be located where it will not be exposed to normal
prevailing winds.
The vertical termination shall extend at least 3 feet (0.9 m) above the highest point where it passes
through a roof of a building and at least 2 feet (0.6 m) higher than any portion of a building within a
horizontal distance of 10 feet (3.0 m), or specified as local jurisdiction.
The vent terminal shall be located at least 3 feet from any building opening and above any forced air inlet
located within 10 feet. And the vent terminal shall not be located within 6 feet (1.8 m) of a mechanical air
supply inlet to any building.
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SC Series Boilers – Installation and Service Manual
Gas service meters: The vent terminal requires a clearance of 3 feet (0.9 m) and the air intake a
clearance of 10 feet (3.0 m) from any gas service regulator vent outlet. Vents are prohibited above the
gas meter assembly (not propane regulator vents) within 3 feet horizontally of the vertical center line of
the regulator to a vertical distance of 15 feet (4.6 m).
The bottom of the vent terminal and the air intake shall be located at least 12 inches above grade plus
height of the normal snow line.
Maintain a minimum clearance of 4 feet (1.2 m) below, 4 feet (1.2 m) horizontally from, or 1 foot (300 mm)
above any door, window, or gravity air inlet into any building.
A 4 feet (1.2 m) horizontal clearance should be maintained from electric meters, gas meters, regulators
and relief equipment and in no case above or below, unless a 4’ horizontal distance is maintained.
The terminal shall not be less than 7 feet above grade where located adjacent to a public walkway and
shall not terminate over public walkways or over an area where condensate or vapor could create a
nuisance of hazard or could be detrimental to the operation of regulators, relief valves, or other
equipment.
Equivalent Vent/Air Intake Pipe Length and Diameter
In order for the boiler to operate properly, the venting system, including air intake piping (if used), exhaust
vent piping and terminations, must not be excessively restrictive. Use Table 1 to find exhaust vent and air
intake pipe maximum and minimum equivalent length for a specified boiler model. The installation must
be designed so that exhaust vent equivalent length is within the Max. and Min. range of “Exhaust Vent
Equivalent Length”. Similarly, Air Intake Pipe must be within the Max. and Min. range of “Air Intake Pipe
Equivalent Length”. Use the notes in Table 1 to calculate the equivalent length in feet for exhaust vent
and air intake pipe.
Table 1. Equivalent Length of Venting System
Exhaust Vent
Equivalent Length in Feet
MODEL
Air Intake Pipe
Equivalent Length in Feet
3 inch diameter
4 inch diameter
3 inch diameter
4 inch diameter
Min.
8
Max.
40
Min.
Min.
0
Max.
45
Min.
Max.
SC-35
SC-70
8
40
0
45
SC-105
8
40
0
45
SC-140
8
40
0
45
Max.
SC-175
8
40
0
45
SC-210
8
40
0
45
SC-245
8
40
0
45
SC-280
8
40
0
45
NOTES:
1. Calculate the Equivalent Length by measuring the total centerline length in feet and
adding 6 feet for each 90-degree elbow used and adding 3 feet for each 45-degree
elbow used. The calculated Equivalent Length must be within the Max. and Min. limits
for the specified boiler model.
2. The air inlet and exhaust vent must remain 3 inch diameter for SC-35 to SC-140, and
4 inch diameter for SC-175 to SC-280.
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SC Series Boilers – Installation and Service Manual
Vent Installation
The boiler must be vented to the outdoors. Do not install the vent into a common venting system and do
not install a vent damper, or similar device to the venting system or the boiler. Vent connectors serving
the boiler must not be connected into any portion of
mechanical draft systems operating under positive
pressure. The venting can be installed as a direct
vent system in which the air for combustion is
obtained from the outdoor atmosphere directly or as
a non-direct vent in which all air for combustion is
obtained from the boiler room. The vent system will
have a positive pressure in the flue requiring that all
vent joints and seams be sealed gas-tight by
following the vent manufacturer’s instructions.
Follow the vent manufacturer’s instructions for
installation of the venting system, and firestop
spacers, thimbles, caps, roof flashing, storm collar,
supports, etc. The vent connector and firestop must Figure 2. Side Termination Installation
provide correct spacing to combustible surfaces, as
specified in the section 2.3. Venting is approved for combustible wall passage with a clearance of 2.5"
from the flue pipe in any direction.
Since the vent system will operate with a positive pressure in the exhaust vent pipe, it is critical that all
joints be properly cleaned and thoroughly sealed as per the vent manufacturer’s instructions. The
exhaust may condensate in the vent with a longer vent length installation. The condensate of exhaust is
acidic and can cause severe corrosion of ordinary venting materials. Boiler operation can be affected by
restrictive vent and combustion air supply piping. Therefore, the venting system must completely
conform to the requirements of Table 1. The specified minimum and maximum equivalent vent length
listed for each boiler model must be followed.
For a sidewall venting installation with one horizontal run and a short vertical section as shown in Figures
3, 4 and 5, the exhaust venting run must slope downward at least ¼ inch per foot from the beginning of
horizontal run to the vent termination. There should be no sagging of the vent. This is to ensure that any
condensate in the horizontal venting flows outside through the opening of the termination.
All horizontal runs for a vertical venting installation, as shown in Figures 6, 7 and 8, shall slope upward
not less than ¼ inch per foot. This is to ensure that any condensate in the venting flows back towards
the boiler so that the condensate can be disposed of through the condensate disposal system installed on
the venting horizontal section closest to the boiler. A condensation drain should be obtained from the
supplier of the venting system.
The venting shall be supported as required by applicable code(s) so that its weight does not bear on the
boiler. All vent pipes must be adequately supported with vent supports no less than five feet apart or as
per the vent system manufacturer’s instruction, and at smaller intervals if necessary to ensure that there
are no sagging sections along the horizontal runs. Noncombustible pipe strap or hangers suitable for the
weight can be used to support horizontal runs and maintain vent location.
Provide minimum 2.5 inches clearance from vent components to combustible materials. Use a wall
thimble when penetrating a combustible wall.
Example venting configurations are shown in Figures 3 – 8. (Follow supplier’s venting installation
instructions for all installations shown)
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SC Series Boilers – Installation and Service Manual
Figure 3 – Horizontal venting installed as a direct vent
Figure 4 – Horizontal venting installed as a direct vent
Figure 6 – Vertical venting installed as a direct vent
Figure 5 – Horizontal venting installed as non-direct
vent
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SC Series Boilers – Installation and Service Manual
Figure 7 – Vertical venting installed as a direct vent
2.7
Figure 8 – Vertical venting installed as non-direct vent
WATER PIPING
The water piping system of a 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.
The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium
is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the
boiler.
2.8
CORROSION PREVENTION (INTERNAL)
We specify the use of oxygen barrier tubing to protect the system and its components from corrosion.
Chemical inhibitors are not recommended, as their improper use or maintenance can cause accelerated
corrosion, resulting in premature failure of the boiler heat exchanger and/or system components.
Corrosion is a preventable condition and is not covered by the Super Hot product warranty. Should your
system include "non-oxygen-barrier-tubing" please contact the factory or your heating professional for
recommendations.
2.9
SYSTEM OPERATING REQUIREMENTS
WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
Avoid unnecessary replenishment of system water. It can allow oxygen to enter the system and cause
serious corrosion problems. As well, minerals dissolved in the water supply will precipitate when heated;
minerals preferentially deposit in the system and the heat exchanger. Do not draw water from the heating
system for cleaning, flushing, etc.
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SC Series Boilers – Installation and Service Manual
Super Hot SC series boilers are designed for use in closed loop systems and are not intended for open
systems, as in heating pool water or systems where water is constantly replenished. Operating the boiler
in an open system will result in premature failure of the heat exchanger. Super Hot boilers may be used
to heat water in open systems indirectly by installing a heat exchanger, such as the Super Hot C-Coil, to
separate open and closed systems.
Heating systems with low temperature return water may cause flue gas moisture to condense on the
boiler heat transfer surfaces, causing corrosion and restricting flue gas flow. Also, low temperature return
water may overcool the flue gases, resulting in reduced vent suction. These are natural phenomena and
are independent of the boiler design. As a guide to avoiding such corrosion and draft problems, it is
imperative that the return water be not less than 135°F (57°C).
THE BOILERS MUST ALWAYS BE USED WITH FORCED SYSTEM CIRCULATION.
2.10
PRESSURE RELIEF VALVE
A pressure relief valve is supplied as standard equipment. The
pressure relief valve is extra protection against damage that could
be caused by malfunctioning controls or excessive water pressure.
If a pressure relief valve is not used, the warranty is void.
The pressure relief valve should be installed on the boiler outlet
with its spindle vertical. The connection between the boiler and the
relief valve must have at least the area of the valve inlet.
A discharge pipe should be used. The discharge pipe outlet should
be positioned over a suitable drain and so arranged that there will
be no danger of being scalded. The discharge pipe must pitch
down from the valve and should be no smaller than the outlet of the
valve. The end of the discharge pipe should not be concealed or
threaded and should be protected from freezing. Extensive runs,
traps or bends could reduce the capacity of the pressure relief
valve.
No valve of any type should be installed between the pressure relief valve and unit or in the discharge
pipe. The pressure relief valve is a code requirement. Field installation of the relief valve must be
consistent with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV.
Avoid contact with the hot water discharged to prevent personal injury.
2.11
ELECTRICAL WIRING
All electrical wiring must conform to the requirements in Section 2.2.
Run a separate circuit from the electrical service panel through a fused disconnect switch to the boiler.
This boiler must be electrically bonded to ground 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 (current edition) and and/or the Canadian Electrical Code, CSA C22.1 Part 1 (current edition). Field
wiring shall conform to Section 2.2 and to the temperature limitations of Type T [63°F (35°C) rise] or
better.
Make connections as shown in the wiring diagrams provided. For details of electrical wiring for different
ignition controls, refer to wiring diagrams included in this manual on page 29 to 31.
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SC Series Boilers – Installation and Service Manual
Startup Instructions
3.1
Section 3
PRE-STARTUP
a. Fill entire heating system with water and vent or purge air from system. Add water as needed to
reach boiler operating pressure. Water should be of suitable quality. Do not use water with high
hardness.
b. Check that the venting condensate drain trap is filled with water.
c.
d.
e.
f.
g.
Check that the tubes tightly and correctly connect the air pressure switches with air chamber.
Check for and repair any leaks in water piping.
Check for proper installation of pressure relief valve and venting.
Check that the electrical wiring matches the wiring diagram in this manual or on the boiler.
Use a soap solution to check for leaks in gas piping from meter to gas manifold. Repair and retest
any leaks found.
h. Operate circulating pump and vent all radiation units and high points in system piping.
3.2
STARTUP
WARNING
The following instructions are intended as a guide for qualified persons. Before lighting the
boiler, the pre-startup instructions of Section 3.1 MUST be performed. If you do not follow these
instructions exactly, a fire or explosion may result causing property damage, personal injury or
loss of life.
WARNING
Should boiler overheat, or the gas supply fail to shut off, do not turn off or disconnect the
electrical supply to the boiler or circulating pump. Instead, shut off the gas supply at a location
external to the boiler.
a. Direct Spark Ignition Or Hot Surface Ignition
This boiler does not have a pilot flame. It is equipped with a direct ignition device which automatically
lights the main burner. Do not try to light the main burner by hand.
In the event of failure of any component, either the system will not operate or it will go into safety lockout.
1)
2)
3)
4)
Make sure the Gas Valve and all electrical power to the boiler are "OFF".
Set room thermostat to the lowest setting.
Connect a manometer at pressure tapping on downstream section of gas valve.
Wait five minutes to clear out any gas. If you smell gas, STOP! Follow the safety instructions
provided in Section 1.1 under WHAT TO DO IF YOU SMELL GAS. Remember that propane does
not vent upward naturally.
5) Check the ignition control as follows:
a) Set room thermostat above room temperature to call for heat and turn power on for the boiler.
b) Watch/listen for spark or watch for hot surface to glow bright in the combustion chamber from
the inspection hole in the front of boiler after 30 seconds pre-purge. If no flame is detected
within 4 seconds, two or three retries will automatically occur after a 30 second inter-purge. If
no flame is detected after three or four tries for ignition, all models will automatically lockout
and restart the ignition sequence after one hour, or after the power is reset. However, if the
lockout is caused by a blockage of the heat exchanger, venting or air inlet pipe, the controller
14
SC Series Boilers – Installation and Service Manual
6)
7)
8)
9)
10)
b)
will not restart the ignition sequence and the boiler will be able to be put back into operation
only by removing the blockage and resetting the electrical power to the controller.
Turn Gas Valve to ON. Main burner(s) should ignite. Check main burners and adjust the airflow,
if necessary, as described in Section 3.3 and 3.5.
Check for gas leaks of the joint between the gas valve outlet and manifold.
Assure that all other gas appliances are turned off, including their pilot flames.
Check manifold pressure reading on the manometer and make necessary adjustments. Check
burner input matches the rating plate input or is correctly derated for high altitude installations, as
described in Section 3.6 and 3.7.
Return thermostat and controls to normal operating settings.
Sequence of Control System operation
The sequence of control system operation is as shown in the following chart:
15
SC Series Boilers – Installation and Service Manual
Chart 1: Operation Sequence for Spark and Hot Surface Ignition Control System.
16
SC Series Boilers – Installation and Service Manual
3.3
CHECK BURNER SYSTEM
To maintain safe and efficient operation, examine the burner system regularly through the inspection
window in the front of the boiler behind the door.
Check condition of burner system
It is possible for parts of the burners system to
become plugged, cracked, eroded and/or
dislodged resulting in unsafe operation.
Check for lifting
Flames should not lift excessively from the
burner ports. The flames may lift slightly during
ignition or when the burners are cold.
Check ignition and extinction
Ignition should flow quickly and smoothly across
all the burners. Popping noises or explosions
from the burners during ignition, extinction or
abnormal burner operation indicates the need
for service.
Check flame color
An extremely yellow flame, as seen on a burning
candle or match, is an indication of incomplete
combustion and is usually accompanied by the
formation of soot and carbon monoxide (carbon
monoxide is a lethal, colorless and odorless
gas). If soot is allowed to accumulate, it will
partially restrict free passage of products of
combustion to the flue. Under typical operating
conditions, the flame should have a distinct
bright blue inner cone and a blue/light orange
outer cone.
If any of the above problems are observed or the burner system does not operate properly,
immediately take corrective measures following in section 1.1 and 1.3.
3.4
AQUASTAT ADJUSTMENT
The factory mounted aquastat controls main burner firing by sensing outlet water temperature. To set the
temperature of this control, adjust the dial until indicator points to the temperature (setpoint) at which the
gas valve will close. The gas valve will open at setpoint less the differential. The automatic reset safety
high-limit aquastat is either fixed or, if adjustable, should be set a minimum of 20°F (10°C) above the
setting of the aquastat.
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SC Series Boilers – Installation and Service Manual
3.5
AIR SWITCHES AND AIRFLOW ADJUSTMENT
The boiler is equipped with two differential air pressure switches:
1. MINIMUM AIRFLOW (Red Light). The first air pressure switch closes and the indicator is on when
there is enough combustion air supplied to the boiler for safe operation. The Minimum Airflow switch
senses positive combustion air differential pressures (∆P) between the air chamber and burner
venturi inlet. It acts as a safety device to prevent the boiler from firing when the airflow to the
combustion chamber is too low. Low airflow can result in high levels of carbon monoxide, flashback
and inefficient combustion. The minimum airflow switch is normally open and will close when the
differential pressure of the air is above the switch's set-point. The actual airflow to make the boiler
operate is slightly above the Minimum Airflow switch's set-point.
2. OPTIMUM AIRFLOW (Red Light). The second air pressure switch and indicator light allows the
installer to easily adjust the blower to the optimum combustion airflow for any installation and venting
configuration, and without the need of an inclined manometer or other such instrument. This switch
only operates the indicator light and is only for the installer's use during setup. It is not a safety
device and does not prevent the boiler from firing.
Both indicators are off when there is no call for heat. When there is a call for heat, the blower switches
on and comes up to speed. If the Minimum Airflow switch senses enough airflow, it will close (red light
ON) and allow the boiler to fire. Normally the Optimum Airflow switch will close (red light ON) but it may
be on or off depending on operating conditions.
There are two tubes connecting the air pressure switches with the air chamber and burner inlet. The clear
tube connected to the air chamber should be connected to the positive side (P1) of the switch and the red
tube connected to the burner inlet should be connected to the negative side (P2) of the switch, as
indicated on the pressure switch casing and as shown in Figure 9.
Figure 10 – Blower and air shutter
Figure 9 – Air differential pressure switch
connections
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SC Series Boilers – Installation and Service Manual
Airflow Adjustment
After the boiler and its venting system have been installed, use the following procedure to adjust the
boiler to the proper airflow:
a) The airflow adjustment can only be done correctly when the boiler is hot.
b) Turn gas valve off.
c) Turn the air adjustor screw located on the blower inlet clockwise to slide the air adjustor closed.
(Airflow adjustments are made by slowly turning the screw which slides the air adjustor located
on the blower inlet to more open or more closed positions as shown in Figure 10.)
d) Set room thermostat above room temperature to call for heat and turn on power to the boiler.
e) The blower will start.
f)
Slowly open the air adjustor to make the RED Minimum Airflow indicator light switch on.
Continue to very slowly open the air adjustor until the RED Optimum Airflow light JUST switches
on. Then immediately STOP moving the air adjustor. If the blower turns off before finishing the
setting, the main electric power to the boiler has to be switched off and on to reset the controller.
g) Turn the gas valve on. Reset the main electric power, if necessary. The boiler should ignite
smoothly. The burner flames should be stable with no lift off or surges, and have a distinct bright
blue "V"-shaped flame with a blue/light orange outer mantle.
h) Let boiler run about 20 minutes, then slowly close the air adjustor to make the RED Optimum
Airflow light switch off if it is still on. Shut boiler off and restart it immediately. Make sure that the
boiler relights and the RED Minimum Airflow light switches on. The RED Optimum Airflow light
may switch on or off and should be ignored. If the burner flames are not stable with lift off or
surges, turn the screw clockwise a few turns to close the air adjustor and relight the boiler.
i)
Check the flame again. If the air adjustor is opened too much so the airflow is too high,
ignition/flame failure may occur when the boiler is cold. The optimum operating condition of
boiler should be the Minimum Airflow light switch ON and Optimum Airflow light switch OFF when
the boiler is hot.
Too much airflow can result in inefficient combustion, flame lift off and ignition/flame failure. The Optimum
Airflow switch is normally open and will close to turn the Optimum Airflow indictor light on when the actual
airflow is above its set-point. The Minimum Airflow indictor light will always stay on when the boiler is
firing. The indicator lights may be on or off during normal boiler operation. The status of the indicator
lights for airflow is shown below.
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SC Series Boilers – Installation and Service Manual
3.6
GAS MANIFOLD PRESSURE
These boilers are factory equipped for operation at altitudes ranging from 0 to 2,000 feet above sea level.
The designated manifold pressures for sea level application are as shown in the table below.
Model
Natural Gas
Propane
All Models for 0 to 2,000 feet altitude
3.5” W.C.
9” W.C.
Please note that the manifold pressure must be measured without referencing the gas valve
venter to the air chamber (see Manifold Pressure Adjustment below). A 1/8” NPT tapping is provided
on the gas valve for connecting a manometer to check this pressure. Both natural gas and propane
models are furnished with gas valves which have a built in gas pressure regulator. If necessary, adjust to
the proper value by removing cap and turning adjusting screw clockwise to increase manifold pressure or
counterclockwise to decrease manifold pressure.
Use at Altitudes above 2000 feet
For altitudes above 2,000 feet above sea level, the input rating of the boiler must be reduced as shown in
the table in Section 3.7.
In Canada, for boiler applications at altitudes in the range of 2000 to 4500 feet above sea level, the high
altitude input rate must be achieved by changing the orifice size. The manifold pressure should be
adjusted to the value as shown in the table above.
In USA, for boiler installations at altitudes above 2000 feet, the input rating of the boiler may be achieved
by adjusting the manifold pressure or by changing orifice size.
The conversion of a boiler from sea level to high altitude must be performed by a qualified heating
installer, service technician or gas supplier and in accordance with the requirements of Section 2.2 of this
manual. A conversion data plate, indicating that the boiler has been converted for high altitude use, shall
be attached adjacent to the rating plate. The correct conversion information must be entered on the
conversion data plate by the installer.
After the boiler has been converted for high altitude use, the input must be verified following the input rate
test as described in Section 3.7.
Manifold Pressure Adjustment
1. Adjust airflow as per section 3.5 of the manual
2. Ensure gas inlet pressure is set correctly
3. Connect a manometer to the gas valve outlet
pressure tap
4. With the boiler running for few minutes, disconnect
the tube B from the orifice on the gas valve venter
and plug or clamp shut the end of tube B. The
manometer should show the manifold pressure
required on the rating plate or conversion data
plate.
5. If the manifold pressure is not equal to the value
required, remove the pressure regulator adjustment
cap screw on the gas valve
6. Using a screwdriver turn the inner adjustment
screw clockwise 3 to increase or counterclockwise
4 to decrease it
7. Replace cap screw and tighten firmly
8. Reconnect tube B to the regulator vent orifice A.
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SC Series Boilers – Installation and Service Manual
3.7
CHECK INPUT & ORIFICES
For safety, the input shown on rating plate must not be exceeded. Check with the following table
that the orifice size and input rate shown on your boiler rating plate match your application, i.e. boiler
model, fuel type, and altitude. To adjust manifold pressure, follow the procedure described in Section
3.6. If the derated input rating for high altitude requires a change in orifice size, contact the boiler
manufacturer.
FOR CANADA
Natural Gas
Propane
Model
All
0 to 2,000 feet
2,000 to 4,500 feet
0 to 2,000 feet
2,000 to 4,500 feet
φ7/64” orifice
standard input
#36 orifice
10% derate input by
adjusting manifold
pressure
#50 orifice
standard input
#51 orifice
10% derate input by
adjusting manifold
pressure
NOTE: For elevations above 4,500 feet reduce high altitude input 4% for each additional 1000 feet.
Reference Natural Gas and Propane Installation Code B149.1, 3.22 High Altitude Installations
Example of High Altitude Derate
Boiler:
SC-140
Altitude: 5,500 feet
Standard Input (0-2,000 ft)
High Altitude Input (2000 to 4,500 ft)
% Reduction for additional 1000 ft
Input at 5,500 ft
= 140,000 Btu/h
= 140,000 x 0.90 = 126,000 Btu/h
= 4% x 1 = 4%
= Derate High Altitude Input by 4%
= 126,000 Btu/h x (1 - 0.04)
= 126,000 Btu/h x 0.96
= 120,960 Btu/h
FOR UNITED STATES
Natural Gas
Propane
Model
All
0 to 2,000 feet
Over 2,000 feet
0 to 2,000 feet
Over 2,000 feet
φ7/64” orifice
standard input
Input must be reduced
4% for each 1000 feet
above sea level. *
#50 orifice
standard input
Input must be reduced
4% for each 1000 feet
above sea level. *
*Reference National Fuel Gas Code ANSI Z223.1, 8.1.2 High Altitude.
Example of High Altitude Derate
Boiler:
SC-105
Altitude: 5,000 feet
Standard Input (0 to 2,000 ft)
% Reduction for 5,000 ft
Input at 5,000 ft
= 105,000 Btu/h (from page 2)
= 4% x 5 = 20%
= Derate Standard Input by 20%
= 105,000 Btu/h x (1 - 0.20)
= 105,000 Btu/h x 0.80
= 84,000 Btu/h
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SC Series Boilers – Installation and Service Manual
Adjustments to the input rate can be made by varying the manifold pressure. Normally it should be
adjusted no more than 0.1 inch w.c. for natural gas or 0.4 inch w.c. for propane from the manifold
pressure specified on the rating plate for that altitude application.
WARNING
Exceeding the allowable input rate can produce dangerous concentrations of carbon monoxide,
and cause the boiler to overheat resulting in severe personal injury, death or substantial
property damage. Carbon monoxide is a lethal, colorless and odorless gas.
Input Rate Test
Consult gas company to determine the heating value of the gas supplied in Btu per cubic foot. Operate
boiler for 15 minutes starting with all parts at room temperature and check input by clocking gas meter
with all other gas appliances turned off, including their pilot flames. Use the following formula:
INPUT (Btu/h) =
(3600) × (Heating Value of Gas) x (Number of Cubic Feet Timed)
Seconds Clocked
To ensure accuracy for rating, clock enough cubic feet of gas so that there is at least one revolution of the
test dial and the clocked time is at least 60 seconds.
3.8
CHECK OF CONTROLS
After the unit has been operated for a while, lower the aquastat setting below the setpoint or actual boiler
water temperature and burner should shut off. Rotate the aquastat higher than setpoint and the main
burner should ignite. Return the aquastat to its original setpoint and make sure boiler cycles normally.
Repeat this type of check on the safety high-limit aquastat, thermostat and other system controls to
ensure all work satisfactorily. If any of the safety or controls do not function, necessary corrections
should be made immediately.
3.9
CHECK FOR GAS LEAKS
To identify gas leaks, smell for gas around boiler area and gas piping connections (See Section 1.1). To
check a specific area, including the manifold joint connected to the gas valve, for leakage, spray a
mixture of soap and water onto the suspected area – active bubbling indicates a gas leak. The gas leaks
of the manifold joint connected to the gas valve outlet should be checked when the boiler is on. DO NOT
TEST FOR LEAKS WITH AN OPEN FLAME. Gas leaks must be repaired immediately.
3.10
CHECK THE CONDENSATE DRAIN TUBE
Check that the tube loop is approximately 4" diameter. The water should fill the loop to form a liquid-filled
trap and not be plugged with excessive sediment.
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SC Series Boilers – Installation and Service Manual
3.11
INSTALLER'S CHECKLIST
Reference
Section
The information printed on the boiler rating plate matches the application (i.e.
‰ altitude and fuel type).
‰ All applicable electrical codes have been met.
3.6
2.2, 2.12
Gas piping has been purged and checked for leaks with a soap solution,
‰ including the joint between the gas valve outlet and manifold when the boiler
2.2, 2.4, 3.9
is on.
System is filled with water and all air has been purged. Only oxygen barrier
‰ tubing has been used.
‰ Tubes of air differential pressure switch are connected tightly and correctly.
A manometer has been used to check the manifold pressure and gas supply
‰ pressure against requirements printed on boiler rating plate.
Bypass or mixing valve has been used to prevent return water less than
‰ 135°F.
2.9, 2.10
3.5
3.6
2.10
All applicable venting codes have been met. Air openings sized to provide
‰ adequate supply air for combustion and ventilation and will not be blocked
2.2, 2.5, 2.6, 2.7
off.
Operate the boiler for 15 minutes, then clock and calculate Btu/h input rate.
‰ The input rate must not exceed that specified on the boiler rating plate.
3.7
Clocked BTU/H Input Rate: _______________
Perform check of temperature controls: aquastat, high limit aquastat, and
‰ thermostat.
‰ Test any other controls as specified by the manufacturer.
Visually
inspect
main
burners
to
ensure
‰ characteristics and ignition/extinction is ok.
proper
flame
operating
3.4, 3.8
3.3
Allow the boiler to cycle a few times to ensure functions are operating
‰ correctly.
‰ Close main shut-off valve and check that burners flame extinguishes.
Clearly identify emergency shut-off devices and make the user or owner
‰ aware of their location and method of operation.
Fill in the contact information on the cover of the User's Information Manual
‰ and leave both manuals in the envelope adjacent to the boiler.
NOTE: INSTALLER'S RESPONSIBILITY
"Before leaving installations, installers shall ensure that an appliance, accessory, component, or
equipment installed by them comply with the Code requirements, and the person initially activating the
appliance shall ensure that the appliance is in safe working order."
CSA B149.1-00 Natural Gas and Propane Installation Code
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SC Series Boilers – Installation and Service Manual
Service & Maintenance Instructions
4.1
Section 4
SERVICE & MAINTENANCE INSTRUCTIONS
WARNING
Label all wires prior to disconnection when servicing controls. Wiring errors can cause
improper and dangerous operation.
WARNING
If any part of this boiler has been under water, inspect the boiler and replace any part of the
control system and any gas control which has been under water.
This boiler has been designed to provide years of trouble-free performance in normal installations. The
owner or user should conduct a general external examination covering all items on the "User Checklist" at
the beginning of each heating season and in mid-heating. In addition, the owner or user should have the
boiler inspected by qualified service technician or gas supplier’s service person at least once every year
at the beginning of the heating season for continued safe operation. Note that some operating conditions
may require more frequent inspections.
The qualified service technician or gas supplier's service person should follow the "Service Checklist".
The "Service Checklist" must only be used by a qualified service technician or gas supplier's service
person.
Verify proper operation after servicing.
4.2
1.
2.
3.
4.
5.
6.
7.
CLEANING PROCEDURE
Shutdown the boiler as described in the lighting instructions in Section 1.3.
Inspect flue gas passages and burners for the presence of soot, rust or scale.
If necessary, use a wire brush and vacuum to clean and remove any blockages. Plugged burner
ports must be cleared.
Replace any parts which have severely corroded or cracked.
Reassemble parts removed during cleaning as they were before, ensuring air tightness of flue gas
passages.
Corrosion can be caused by low return water temperature or a contaminated air supply. Sooting
can be caused by improper burner adjustment. Check and adjust as necessary.
Return boiler to operation following lighting instructions in Section 1.
24
SC Series Boilers – Installation and Service Manual
4.3
SERVICE CHECKLIST
Reference
Section
Do not store anything against the boiler or allow dirt or debris to accumulate in the
‰ area immediately surrounding the boiler. The flow of supply and exhaust air must
‰
‰
‰
‰
‰
‰
‰
‰
‰
not be obstructed.
Check air openings are not restricted and complies with applicable code(s).
Adequate supply air is necessary for combustion, flue gas dilution and ventilation.
Check all gasketed joints for leakage, and tighten bolts or replace gaskets if
necessary.
When the boiler has operated for several minutes, check for leakage around boiler
and along vent, and other areas susceptible to leakage.
Check externally the vent system for soot, rust scale or corrosion. Check for
dislodged venting or possible leaks in venting ducts.
Inspect the flueways and terminal cap for the presence of soot, rust scale or blockage.
The presence of soot, rust scale or corrosion indicates misadjustment. Clean the
Terminal Cap Screen.
Inspect and, if necessary, clean the main burner. Check burners to see that they are
not cracked or dislodged.
Visually check the main burner flames. A yellow flame caused by improper
adjustment is always accompanied by formation of soot which, if allowed to continue,
will partially restrict free passage of products of combustion to the flue.
Check that gas piping is secured. Smell for gas leaks around boiler and gas piping
connections. Gas leaks can also be checked for using a soap solution; do not use
an open flame to check for leaks. Note: Propane is heavier than air and pools in a
low area in the event of a leak.
Inspect for leaks in the water piping and at water piping connections.
2.5
2.2, 2.5,
2.6, 2.7
3.3, 4.2
3.3
3.9
Circulating pumps used with hot water heating systems should be inspected for
‰ water leaks.
‰ Check for weeping at pressure relief valve outlet during normal operation.
‰
‰
‰
‰
‰
Listen for unusual audible sounds in the boiler. Any audible sounds in the boiler
system may be indications of scaling or lack of sufficient water flow and the system
should be checked without delay. Scaling is due to improper maintenance. It is not
the fault of the boiler. Scale damage is not covered by warranty.
Check the temperature and pressure gauge and expansion tank pressure is within
an acceptable range for the heating system.
Keep boiler area clear and free from combustible materials, gasoline and other
flammable vapors and liquids. Combustible materials, gasoline and other flammable
vapors and liquids should not be stored in the area of the boiler.
Check should be made on ignition system, operation controls and safety shut-off
valves for gas tightness.
Check the tubes connecting the air differential pressure switches with air chamber
are correct, secured, and good condition.
Check that the condensate drain tube is filled with water and not clogged.
‰
‰ If applicable, inspect low water cutoff for proper operation.
The emergency shut-off devices are identified and the owner is aware of their
‰ location and method of operation.
If applicable, periodically inspect the low water cutoff including flushing of float
‰ types.
25
2.11
2.10
3.5
2.7
2.3
SC Series Boilers – Installation and Service Manual
4.4
CAUTION: WATER REPLENISHMENT
Avoid unnecessary replenishment of system water. It can allow oxygen to enter the system and cause
serious corrosion problems. As well, an excessive amount of minerals may be deposited in the heat
exchanger. Do not draw water from the heating system for cleaning, flushing, etc.
Any audible sounds in the boiler system may be indications of scaling or lack of sufficient water flow and
the system should be checked without delay. Scaling is due to improper maintenance. It is not the fault
of the boiler. Scale damage is not covered by warranty.
4.5
REFRACTORY HANDLING PROCEDURE
WARNING
The mineral block and fiberglass wool used in this product are RCFs (Refractory Ceramic
Fibers). RCFs pose a possible cancer hazard by inhalation and can cause respiratory, skin and
eye irritation.
After mineral block has been fired, it will produce increased levels of nuisance dust and poses
increased carcinogenic risk.
Follow the precautionary measures below before attempting service or access.
PRECAUTIONARY MEASURES:
• Avoid breathing fibers and contact with skin and eyes.
• Use a National Institute for Occupational Safety and Health (NIOSH) approved dust/mist respirator.
• Wear long-sleeved, loose fitting clothing, gloves and eye protection.
• Wash work clothes separately from other clothing. Rinse washer thoroughly.
• Operations such as sawing, blowing, tear out and spraying may generate airborne fiber
concentration requiring additional protection.
• Use a vacuum with a HEPA filter for clean up.
• Dispose of all RCF scrap and dust in a closed airtight plastic bag.
FIRST AID MEASURES:
• Eye contact – Flush eyes with water to remove dust for at least 15 minutes. If irritation persists, seek
immediate medical attention.
• Skin contact – Wash affected area gently with soap and warm water after handling.
• Difficulty breathing – Move to an area of clean fresh air. Seek immediate medical attention if
difficulties persist.
• Ingestion – Do not induce vomiting. Drink plenty of water. Seek immediate medical attention.
Boiler Water Flow Data
Section 5
Typical Water Flow Versus Pressure Drop Across Boiler
20°F T.D.
30°F T.D.
Model
Number
U.S. GPM
P.D. FT.
U.S. GPM
P.D. FT.
SC-35
SC-70
SC-105
SC-140
SC-175
SC-210
SC-245
SC-280
3.0
6.0
9.0
12.0
15.0
18.0
21.0
24.0
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.8
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
26
SC Series Boilers – Installation and Service Manual
Replacement Parts
Section 6
NOTE: To supply the correct part it is important that you state the boiler model number, serial number
and type of gas when applicable.
Any part returned for replacement under standard company warranties must be properly tagged with
Return Goods Authorization Form (R.G.A.), completely filled in with the boiler serial number, model
number, etc., and shipped to the Company freight prepaid.
If determined defective by the Company and within warranty, the part will be returned in kind or equal
substitution, freight collect. Credit will not be issued.
Refer to Figures 11 and 12 for replacement parts.
FIGURE 11 – TYPICAL LAYOUT FOR REPLACEMENT PARTS
27
SC Series Boilers – Installation and Service Manual
FIGURE 12 - GENERAL ASSEMBLY PARTS LIST
28
SC Series Boilers – Installation and Service Manual
Wiring Diagrams
7.1
Section 7
Simplified Wiring Instructions
IMPORTANT
•
Disconnect power source to boiler before wiring zone control board.
•
All wiring must comply with applicable codes, ordinances and regulations.
•
The non-replaceable fuse on the board will be blown if 240 Vac is connected to the board or if the
24 Vac system is even momentarily shorted out.
A: Line Voltage Connections
Connect 120 Vac, 60 Hz, single phase power to terminals L1(HOT) and L2(NEUTRAL). Strip wire ends
to a maximum of 3/16" before inserting into terminal block. Tighten terminal screw clamps. Connect
ground wire to ground screw “G” on the boiler control panel or a green colored screw.
B: Zones
Remove zone one plug-in terminal block. Connect 24 Vac thermostat leads to terminals TH1 and TH2 on
plug-in terminal block. Connect normally closed zone valve 24 Vac motor leads to terminals ZV1 and
ZV2. Connect zone valve “end switch” leads to terminals ES1 and ES2. Strip wire ends to a maximum of
3/16" before inserting into terminal block. Tighten terminal screw clamps. Re-insert plug-in terminal
block into mating connector on Zone Control Board. Repeat for zones 2, 3, and 4 as required.
C: Jumpers
Jumpers J1 and J2 are factory set for a multi-zone installation.
D: For Single zone Applications
Install jumper J2 and connect 24 Vac thermostat leads to terminals TH1 and TH2 on Zone 1 plug-in
terminal block.
Manufactured exclusively by
Allied Engineering Company
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SC Series Boilers – Installation and Service Manual
Troubleshooting Guide
Section 8
8.1 Possible Causes and Solutions
Problem
Boiler will not fire.
Boiler goes on and off at
frequent intervals.
Boiler fires continuously.
Rumbling and moaning
sound in boiler.
Gas odor.
Flame flash back
Possible Cause
Solution
•
No power.
•
Check power switches and wiring.
•
No gas supply to boiler.
•
Check gas source and pressure.
•
Gas supply pipes are not purged of air.
•
Purge gas line.
•
Check if thermostat setting is above room
temperature and aquastat setting is above
boiler water temperature.
•
Check pump capacity & flow direction.
Check for correct water levels and air locks.
•
Check gas valve and replace if necessary.
•
Check wiring of aquastats, zone valves, and
thermostats for loose or broken wires and
repair.
•
No heat demand.
•
Flow switch or low water cut off.
•
Gas valve failure (closed position).
•
Faulty wiring.
•
Faulty aquastat, thermostat, or zone valve.
•
Check and replace if necessary.
•
Pressure switch failure or airflow blockage
in heat exchanger, venting, air inlet pipe or
termination.
•
Check pressure switch and replace if
necessary. Remove airflow blockages.
•
Faulty controller or control wiring.
•
See "Control trouble troubleshooting".
•
Check pump for proper capacity & flow
direction. Replace if necessary.
•
Poor flow in boiler or circulator failure.
•
Thermostat, heat anticipator, or aquastat
set too low.
•
Check and adjust.
•
Boiler oversized or insufficient radiation.
•
Check and adjust if necessary.
•
Wrong type of thermostat or controller.
•
Check and replace if necessary.
•
Gas valve failure (open position).
•
Check gas valve, replace if necessary.
•
Check wiring of aquastats, zone valves, and
thermostats for short circuits or incorrect
wiring.
•
Faulty wiring.
•
Faulty aquastat, zone valve or thermostat.
•
Check and replace if necessary.
•
Boiler is overheated and safety high limit
aquastat fails to cut out.
•
Check aquastats and adjust or replace if
necessary.
•
Improper wiring.
•
Check and correct.
•
Foreign matter in heat exchanger.
•
Flush heat exchanger if necessary.
•
Poor circulation.
•
Check pump for correct flow.
•
Air trapped in heating system.
•
Purge air.
•
Flue leaking.
•
Check venting and boiler if leaking.
•
•
Insufficient combustion air to boiler.
Check combustion and ventilation air
opening in boiler room meets installation
code requirements, and air differential
pressure if too low.
•
Leak in gas system.
•
See “What to do if you smell gas” on cover.
Have gas fitter test system and repair leaks.
•
Burner cracked or eroded
•
Check & replace if necessary.
•
Not enough combustion air or wrong air
switch setting
•
Adjust air shutter & check air switch
condition
•
The vent or air inlet blocked
•
Check & clean
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SC Series Boilers – Installation and Service Manual
Problem
Main burner will not light
Spark or hot surface
proves but flame failure
after trial for ignition.
Burner starts but flame
will not stay established.
Boiler carbonizes (forms
soot) quickly.
Boiler overheats and
system remains cold.
Boiler and heating system
overheat.
Possible Cause
Solution
•
High voltage wiring is loose, broken or
grounded. Repair wiring.
Ignition electrodes or H.S. are damaged.
•
Replace electrodes or igniter.
•
Ignition electrodes improperly adjusted.
•
Correct adjustment of electrode.
•
Faulty electronic ignition controller.
•
Replace controller.
•
Confirm supply of gas to pilot and repair if
necessary.
•
No spark or no hot surface glow.
•
•
No gas.
•
Gas supply pipes not purged of air.
•
Purge gas line.
•
Air pressure switch is damaged.
•
Replace air pressure switch.
•
Dirt or foreign material on the electrodes.
•
Clean.
•
Incorrect manifold pressure.
•
Set manifold pressure to correct pressure.
•
Poor connections in wiring to flame sensor.
•
Repair wiring.
•
Air differential pressure is set to high.
•
Adjust the air shutter and set air differential
pressure to correct pressure.
•
Ignition electrodes improperly adjusted.
•
Correct adjustment of electrodes.
•
Ignition electrodes are wet, dirty or
improperly adjusted (for electronic ignition
only).
•
Check, clean, change and/or adjust the
electrodes.
•
Reversed polarity of power supply.
•
Check the power supply polarity
•
Adjust the air shutter and set air differential
pressure to correct pressure.
•
Air differential pressure is too high.
•
Poor connections in wiring to flame sensor.
•
Repair wiring.
•
Incorrect orifice sizing.
•
Check orifice and replace if necessary.
•
Inadequate combustion air.
•
Check and adjust air differential pressure.
•
Dusty environment.
•
Clean.
•
Low return water temperature.
•
Adjust system.
•
Manifold pressure too high.
•
Adjust manifold pressure.
•
Insufficient circulation.
•
Check pump, clean and replace if necessary.
•
Air trapped in piping.
•
Purge system.
•
Improper system wiring.
•
Test and correct.
•
Faulty thermostat or controller.
•
Check, adjust, and replace if necessary.
•
Faulty aquastat and/or safety high limit
aquastat.
•
Check, adjust, and replace if necessary.
•
Faulty wiring.
•
Check wiring for short circuits and repair.
8.2 CONTROL TROUBLESHOOTING
8.2.1
Hot Surface and Direct Spark Ignition System with Fenwal Module
a) Fault Conditions of Hot Surface and Direct Spark Ignition System
Carefully note the red diagnostic indicator light located on the Fenwal Module. When a system failure
occurs, the indicator light will show a series of quick flashes followed by a short pause between the series
of quick flashes. Count the number of flashes that occur between the short no-flashing intervals. The
failure code for the number of flashes and service checks are shown in following tables.
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SC Series Boilers – Installation and Service Manual
Fenwal Module Fault Conditions:
LED Indication
Steady on
1 flash
2 flashes
3 flashes
Error Mode
Internal control
failure
Air flow fault
(hard lockout)
Flame with no call
for heat
Ignition lockout
(1 hour lockout)
The LED will flash on for ¼ second, then off for ¼ second during a fault condition. The pause between
fault codes is 3 seconds.
Troubleshooting Guides:
Symptom
1. Dead
2. Thermostat on – no blower
3. Pressure switch input okay but no trial for ignition after purge
delay
4. Valve on, no ignition or spark
5. Igniter or spark on, valve off
6. Flame okay during TFI, no flame sense (after TFI)
7. Flame with no call for heat
Cause/Cure
a.
b.
c.
d.
a.
b.
c.
d.
e.
a.
b.
c.
a.
b.
c.
d.
e.
a.
b.
c.
a.
b.
c.
d.
e.
f.
Miswired
Transformer faulty
Fuse/circuit breaker bad
Bad control (check LED for steady on)
Miswired
Bad thermostat no voltage @ terminal W
Bad control (check LED for steady on)
Aquastat is not close
Air different pressure switch is not open
Miswired (check psw terminal voltage)
Flame sense problem (existing flame-check LED – 2
flashes)
Bad control (check voltage between L1 & IND)
Shorted electrode (spark system)
Open HV cable (spark system)
Defective hot surface ignitor (hot surface)
Miswired
Bad control
Valve coil open
Open valve wire
Bad control (check voltage between V1 & V2)
Bad electrode (spark)
Bad S1 or HV wire (spark)
Defective hot surface igniter (hot surface)
Bad S1 wire (hot surface)
Poor ground at burner
Poor flame (check flame current)
a.
Stuck valve (check LED for 2 flashes)
b). Flame Sensor Current Check
Flame current is the current which passes through the flame from the sensor to ground. The minimum
flame current necessary to keep the system from lockout is 0.7 microamps (µA). To measure flame
current, connect an analog DC microammeter to the FC- FC+ test pins on the module. The meter should
read 0.7 µA or higher. If meter reads below “0”, meter leads are reversed. Disconnect power and
reconnect meter leads for proper polarity.
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SC Series Boilers – Installation and Service Manual
NOTES
Section 9
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SC Series Boilers – Installation and Service Manual
NOTES
Section 9
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NOTES
Section 10
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SC Series Boilers – Installation and Service Manual
INDEX
Section 10
Section
Page
Dimensions and Specifications – SC Series Boilers .................................................................................... 2
About Our Manuals ....................................................................................................................................... 3
1
Lighting Instructions......................................................................................................................... 3
For Your Safety Read Before Operating ............................................................................................. 4
Operating Instructions ......................................................................................................................... 4
To Turn off Gas to the Appliance ........................................................................................................ 4
2
Installation Instructions.................................................................................................................... 5
2.1 Receiving............................................................................................................................................. 5
2.2 Installation Codes and Requirements ................................................................................................. 5
2.3 Location ............................................................................................................................................... 5
2.4 Gas Service Piping.............................................................................................................................. 6
2.5 Corrosive Atmospheres....................................................................................................................... 6
2.6 Venting and Combustion Air ............................................................................................................... 7
2.7 Water Piping...................................................................................................................................... 12
2.8 Corrosion Prevention (Internal) ......................................................................................................... 12
2.9 System Operating Requirements ...................................................................................................... 12
2.10 Pressure Relief Valve........................................................................................................................ 13
2.11 Electrical Wiring................................................................................................................................. 13
3
Startup Instructions ........................................................................................................................ 14
3.1 Pre-startup......................................................................................................................................... 14
3.2 Startup ............................................................................................................................................... 14
3.3 Check Burner System ....................................................................................................................... 17
3.4 Aquastat Adjustment ......................................................................................................................... 17
3.5 Air Differential Pressure Switch......................................................................................................... 18
3.6 Gas Manifold Pressure...................................................................................................................... 20
3.7 Check Input & Orifices....................................................................................................................... 21
3.8 Check of Controls.............................................................................................................................. 22
3.9 Check for Gas Leaks......................................................................................................................... 22
3.10 Check the Condensate Drain Tube................................................................................................... 22
3.11 Installer’s Checklist............................................................................................................................ 23
4
Service & Maintenance Instructions ............................................................................................. 24
4.1 Service & Maintenance Instructions.................................................................................................. 24
4.2 Cleaning Procedure........................................................................................................................... 24
4.3 Service Checklist............................................................................................................................... 25
4.4 Caution: Water Replenishment ......................................................................................................... 26
4.5 Refractory Handling Procedure......................................................................................................... 26
5
Boiler Water Flow Data ................................................................................................................... 26
6
Replacement Parts .......................................................................................................................... 27
7
Wiring Diagrams.............................................................................................................................. 29
8
Troubleshooting Guide................................................................................................................... 34
9
Notes................................................................................................................................................. 37
10
Index ................................................................................................................................................. 40
40