Burnham 8B Series Specifications

INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
SERIES 3™
Gas - Fired Boiler
9700609
For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
Boiler Serial Number
Installation Date
30__B
Heating Contractor
Phone Number
Address
103796-04 - 3/13
Price - $5.00
WARNINGS FOR ThE hOMEOWNER
FOLLOW ALL INSTRUCTIONS and warnings
printed in this manual and posted on the boiler.
INSPECT THE BOILER ANNUALLY. To keep your
boiler safe and efficient, have a service technician
follow the Service checklist near the end of this
manual.
IF YOU ARE NOT QUALIFIED to install or service
boilers, do not install or service this one.
THE BOILER MAY LEAK WATER at the end of
its useful life. Be sure to protect walls, carpets,
and valuables from water that could leak from the
boiler.
PROTECT YOUR HOME IN FREEZING
WEATHER. A power outage, safety lockout, or
component failure will prevent your boiler from
lighting. In winter, your pipes may freeze and cause
extensive property damage. If you must leave
your home unattended for an extended time when
outdoor temperatures are below 32°F, first turn off
your home’s main water supply and drain the water
from all pipes.
DO NOT BLOCK AIR FLOW into or around the
boiler. Insufficient air may cause the boiler to
produce carbon monoxide or start a fire.
KEEP FLAMMABLE LIQUIDS AWAY from the
boiler, including paint, solvents, and gasoline.
The boiler may ignite the vapors from the liquids
causing explosion or fire.
KEEP CHILDREN AND PETS away from hot
surfaces of the boiler, boiler piping, and vent pipe.
CARBON MONOXIDE (CO) is an odorless, deadly
gas that may be introduced into your home by
any malfunctioning fuel-burning product or vent
system failure. Consider installing CO alarms near
bedrooms in all levels of the building to warn you
and your family of potential CO exposure.
WARNINGS FOR ThE INSTALLER
READ THIS ENTIRE MANUAL before attempting
installation, start-up, or service. Improper
installation, adjustment, alteration, service, or
maintenance may cause serious property damage,
personal injury, or death.
DO NOT DISCONNECT PIPE FITTINGS on the
boiler or in the heating system without first verifying
that the system is cool and free of pressure and
that your clothing will protect you from a release
of hot water or steam. Do not rely solely on the
boiler’s temperature and pressure gage when
making this judgment.
USE PROPER PERSONAL PROTECTION
EQUIPMENT when servicing or working near the
boiler. Materials of construction, flue products, and
fuel contain alumina, silica, heavy metals, carbon
monoxide, nitrogen oxides, and/or other toxic or
harmful substances that can are hazardous to
health and life and that are known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
INSTALL ALL GUARDS, cover plates, and
enclosures before operating the boiler.
THIS INSTALLATION IS NOT COMPLETE until
the front air dam is installed (See Figure 2-a).
Product performance will be negatively affected if
2
the front air dam is not installed which can cause
serious property damage, personal injury or death.
SIZE THE BOILER PROPERLY relative to the
design heat load or, if using domestic hot water
priority, the peak hot water load, whichever
is larger. A grossly oversized boiler will cycle
excessively and this will lead to premature failure
of the boiler and its components. Our warranty
does not apply to damage from excessive cycling.
ADHERE TO ALL LOCAL CODE
REQUIREMENTS. Contact your local code
inspector prior to installation. In the absence of
a local code, adhere to the National Fuel Gas
Code ANSI Z223.1/NFPA 54 or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
ALL WIRING must comply with the National
Electrical Code ANSI/NFPA 70 (in the USA) or the
Canadian Electrical Code CSA C22.1 (in Canada)
and any local regulations.
IT IS THE RESPONSIBILITY OF THE INSTALLING
CONTRACTOR to see that all controls are correctly
installed and are operating properly when installation
is complete including verifying that the limit sensor
is fully installed.
Failure to properly install Limit Sensor may result in
property damage, personal injury or loss of life due to
elevated operating temperatures and/or pressures.
Congratulations on your purchase of a new Series 3™ boiler—designed and constructed to provide you
with years of reliable service.
•
ENERGY STAR™ efficiency – friendly on the environment and your wallet.
•
Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger.
•
IQ Control™ – the most advanced and easiest to use control available.
• System-friendly – built-in protection from condensation and thermal shock.
*IQ Control System Overview
Series 3 Boiler uses a microprocessor based control system called the "IQ Control System". This "IQ
Control System" consists of an Intelligent Hydronic Control (Control) and an IQ Option Panel (Option
Panel) with optional "plug-in" IQ Option Cards (Option Card). The IQ Control System fully integrates both
factory and field installed components, simplifying installation and troubleshooting. The IQ Control System
is designed to efficiently operate the entire boiler system to save energy, installation and setup time while
ensuring adequate supply of heat and domestic hot water.
What's in the crate?
1. q
Series 3™ Boiler
2. q
Vent Damper w/ Carton
 4” Damper  303B (102284-01)
5. q
Instruction Envelope (103795-01)
q
Instruction & Operation Manual
(103796-04)
q
Boiler Warranty Sheet (103203-01)
q
Boiler Warranty Card (103204-02)
 5” Damper  304B (102284-02)
 6” Damper  305B & 306B (102284-03)
 7” Damper  307B & 308B (102284-04)
 8” Damper  309B (102284-05)
3. q Circulator & Gasket Kit
 Taco 007-2 (8056170)
 Grundfos UP-15 (102805-02)
 B & G NRF-22 (8056174)
4. q
Miscellaneous Parts Bag (102627-01)
q
Temperature/Pressure Gage; ¼” NPT
(100282-01)
q
Circulator Mounting Hardware Kit,
1-1/4” NPT (6056007)
q
Drain Valve; ¾” NPT (102802-01)
q
Pressure Relief Valve; 30 psi
(81660363)
q
Water Manifold for Pressure Relief/
Temp. Gage (80607001)
3
SPECIFICATIONS
Ratings
Series 3
Input (MBH)
Boiler Model
303B
304B
305B
306B
307B
308B
309B
DOE Heating Capacity (MBH) Net AHRI Rating (MBH)
70
105
140
175
210
245
280
59
88
117
146
176
205
234
AFUE (%)
51
77
102
127
153
178
203
84
84
84
84
84
84
84
Electrical Requirements: 120VAC, 60 hz, 1-ph, 15A
Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valved.
Dimensions and Connections
Boiler
Model
Depth
303B
304B
305B
306B
307B
308B
309B
33
33
33
33
33
33
33
Width Height
12¾
15½
18½
21½
24¾
27¾
30¾
41
41
41
41
41
41
41
Supply NPT Return NPT Vent Gas NPT Relief Valve
Drain
(inch)
(inch)
(inch)
(inch)
NPT (inch) NPT (inch)
1¼
1¼
1¼
1¼
1¼
1¼
1¼
1¼
1¼
1¼
1¼
1¼
1¼
1¼
4
5
6
6
7
7
8
½
½
½
½
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
Water Temperatures and Flows
Boiler Model
Allowable Supply
Minimum Return
Water Temperature Water Temperature
(°F)
(°F)
303B
304B
305B
306B
307B
308B
309B
130-220
130-220
130-220
130-220
130-220
130-220
130-220
Minimum Flow
(GPM)
Waterside Pressure Drop
at 20°F DT
(Ft. of Head)
None
None
None
None
None
None
None
<1
<1
<1
<1
<1
<1
<1
110
110
110
110
110
110
110
Weights and Volume
4
Boiler
Model
Shipping Weight
(lbs)
Empty Weight
(lbs)
Water Content
(gal)
303B
304B
305B
306B
307B
308B
309B
254
304
357
405
462
518
564
180
231
284
332
382
438
484
2
3
4
5
5
6
7
SPECIFICATIONS (continued)
Figure S-1: Minimum Clearances to Combustibles and Alcove Dimensions
5
BOILER QUICk-START
Installation:
1.
Unpack the crate ............................................................................................. 7
2.
Position the boiler ............................................................................................ 8
3.
Provide combustion air .................................................................................... 9
4.
Connect venting ............................................................................................... 9
5.
Connect gas piping ........................................................................................ 10
6.
Connect boiler water piping ........................................................................... 10
7.
Connect electrical wiring ................................................................................ 12
8.
Program the controls ..................................................................................... 13
9.
Check for gas and water leaks ...................................................................... 16
10.
Perform startup checks and adjustments ...................................................... 17
Annual Maintenance Checklist............................................................................ 18
Troubleshooting.................................................................................................... 19
Repair Parts List ................................................................................................... 25
Internal Wiring....................................................................................................... 31
Appendices:
A – Combustion Air.................................................................................................. 35
B – Venting .............................................................................................................. 36
C – Gas Piping ........................................................................................................ 40
D – System Piping ................................................................................................... 41
E – Filling the System and Checking for Leaks ....................................................... 45
F – Adjusting Gas Input Rate .................................................................................. 46
G – Checking Draft and Combustion ....................................................................... 47
H – Operation .......................................................................................................... 48
I – IQ Control System .............................................................................................. 49
6
1. UNPACk ThE CRATE
THE BOILER IS TOP-HEAVY. Do not
allow it to tip over.
4. Tip the boiler and shimmy it off the skid
(Figure 1-b).
1. Remove the sleeve.
2. Remove the contents from the skid, except
the boiler.
3. Remove the four (4) hex-drive lag screws
holding the boiler to the skid (Figure 1-a).
DO NOT DAMAGE front air dam. It is
required for proper operation of the boiler.
1-a
1-b
7
2. POSITION ThE BOILER
WARNINGS
OBSERVE MINIMUM CLEARANCES to
combustible walls and ceilings to avoid potential
fire hazard.
CLEAN BURNERS DAILY if operating the boiler in
a dusty environment.
DO NOT INSTALL ON CARPET. This may cause
a fire.
PROTECT IGNITION SYSTEM COMPONENTS
from sources of water that may spray, drip, or rain
on them during installation or service.
INSTALLING THE BOILER NEAR A SOURCE OF
FLAMMABLE LIQUIDS or gases may cause fire or
explosion.
1. Slide the boiler into desired location.
4. Level the boiler, using shims as necessary.
2. Meet the minimum clearances to
5. Assure that the front air dam (applicable to
combustible construction per the
Specification Section of this manual.
5-section thru 9-section boilers only) is in
place and undamaged. See Figure 2-a.
3. Allow 24" service clearance in front and on
the left side of the boiler.
CAUTION
ASSURE THAT THE FRONT AIR DAM is in place and undamaged. A damaged front air dam will
negatively affect the performance of this boiler, which can cause serious property damage, personal injury
or death.
Note: Front Air Dam applicable
to Models 305B thru
309B only
2-a
8
3. PROVIDE COMBUSTION AIR
INSUFFICIENT COMBUSTION AIR
SUPPLY may result in the production and
release of deadly carbon monoxide (CO) into the
home which can cause severe personal injury or
death.
Like all fuel-burning appliances, boilers need air to
operate reliably and safely.
Provide combustion air using the instructions in
Appendix A—Combustion Air.
4. CONNECT VENTING
IMPROPER VENTING may result in property
damage and the release of flue gases which
contain deadly carbon monoxide (CO) into the home,
which can cause severe personal injury, death or
substantial property damage.
INSPECT EXISTING CHIMNEY before
installing boiler. Failure to clean or replace
perforated pipe or tile lining will cause severe injury
or death.
The vent system shall be designed and constructed
in accordance with NFPA 54 and applicable local
codes to develop a positive flow adequate to convey
flue or vent gases to the outdoors, while ensuring
that flue gases do not cool prematurely.
Observe all general venting guidelines provided in
Appendix B—Venting. Additionally:
1. This appliance shall be vented into a listed
gas vent, masonry, metal, or factory-built
4-a
chimney as required by NFPA 54 and
applicable local codes for Category I
appliances. If venting this appliance into
a masonry chimney, the chimney must be
lined with approved clay flue lining, a listed
chimney lining system, or other approved
material as required by NFPA 54 and
applicable local codes.
2. Attach the vent damper with three sheetmetal
screws around the perimeter of the flue collar
(Figure 4-a), oriented so that the position
indicator is visible. The vent damper may
also be mounted anywhere between the flue
outlet and the chimney within reach of the
electrical harness.
3. Vent connector shall meet the requirements
of NFPA 54 and applicable local codes.
Using sheetmetal screws, attach the vent
connector between the vent damper and the
vertical chimney (Figure 4-b).
4-b
DAMPER MUST BE OPEN when the main burner is firing.
9
5. CONNECT GAS PIPING
Size gas piping according to Appendix C – Gas
Piping
SHUT OFF GAS SUPPLY before
servicing the boiler.
nipples and street ells are not approved for
use as gas piping.
3. Pipe through the left jacket panel, and
complete drip leg as shown (Figure 5-a).
ALL GAS PIPING MUST BE GAS
TIGHT. Use gas rated thread compound
on all threaded joints to avoid leaks, which may
result in fire or explosion.
SIZE GAS PIPING, regulators, valves,
and meters so as to provide an adequate
gas flow and pressure to the boiler during
operation. Failure to do so may cause poor
combustion, noise, injury, or death.
1. Remove boiler door, locate gas valve and
remove plastic shipping plug.
2. Thread a ¾" x 1½" nipple, a 90° street
elbow, or a Honeywell flange onto the gas
valve and pipe through the slot in the left
jacket panel (Figure 5-a). In Canada, close
5-a
6. CONNECT BOILER WATER PIPING
General system piping guidelines are included in
Appendix D—System Piping.
2. Screw the water supply manifold into the
Additionally, for this particular boiler install piping
shown below (Figure 6-a).
3. Orient the manifold with the relief valve on
top.
4. Screw the relief valve into manifold tapping
RV
“RV”.
O
S
G
R
boiler outlet tapping “O.”
i
This installation is not complete until the
relief valve is installed.
PIPE THE RELIEF VALVE DISCHARGE
to a location where it will not harm
people or damage property. The relief valve may
discharge scalding hot water or steam.
BLOCKING THE RELIEF VALVE may
result in boiler explosion.
D
6-a
1. Apply sealant to all threads.
10
5. Screw the temperature-pressure gage into
manifold tapping “G”.
6. Connect the system supply to the open end
of the manifold "S" using a 1¼” male NPT
fitting.
6. CONNECT BOILER WATER PIPING (continued)
7. Screw an installer-supplied 1¼” pipe or
9. See Figure 6b for suggested near boiler
nipple into the water return tapping “R”.
piping of IQ Options.
8. Screw the supplied drain valve into tapping
“D”.
6-b
Item
Description
Part Number
1
1¼ x 1¼ x ½ Tee
806601021
2
Immersion Well, ½ NPT
80160456
3
1¼ x 6 Nipple
806600029
4
1¼ Tee
806601030
5
1¼ x ¾ Bushing
806600504
6
LWCO Sensor, ¾ NPT
102305-01
7
1¼ x 3 Nipple
806600005
8
1¼ Elbow
806601528
11
7. CONNECT ELECTRICAL WIRING
DISCONNECT ELECTRICAL POWER
to the boiler and heating system before
servicing. Positively assure that no voltage is
present. Lock electrical boxes to prevent someone
from inadvertently restoring power before the
heating system is safe to operate.
NEVER DEFEAT OR JUMP OUT safety
devices.
device.
PROTECT EACH BOILER circuit with a
properly sized over-current protection
MAKE ELECTRICAL CONNECTIONS
CAREFULLY according to the boiler’s
wiring diagram and instructions
7-a
Refer to the Internal Wiring diagrams later in this
manual.

1. Locate the wiring box on the left side of the
boiler and open the cover (Figure 7-a).
2. Install a 120V disconnect near the boiler.
3. Connect the 120V wiring from the disconnect
to the boiler's white (neutral), black (hot),
and green (ground) labeled "120VAC Power
supply". Do not reverse polarity.
1
1
4. Connect the 120V wiring from the circulator
2
3
T
T
to the white (neutral) yellow (hot) wires
marked "circulator".
WIRE AN ADDITIONAL SAFETY LIMIT
such as a low water cutoff or temperature
limit device, other than an IQ™ Control device,
in series with the 120V circuit used to power the
boiler. Do not alter the boiler’s factory wiring when
adding an additional limit.
5. Connect the 24V wiring from the thermostat
to the "T-T" terminals on the Option Control
Panel.
6. To connect other external devices, refer to
the instructions included with these devices.
12
7-b
THE MAXIMUM ALLOWABLE
CURRENT for each circulator is 5 amps at
120V AC. For circulators with higher amp ratings,
you must install a circulator relay or starter coil to
provide line voltage to the circulator and connect
only the relay or starter coil to boiler terminals.
The combined boiler and circulator amperage must
not exceed 15 amps.
Install over-current protection in accordance with
authority having jurisdiction or, in the absence of
such requirements, follow the National Electric
Code, NFPA 70, and/or CSA C22.1 Electrical
Code. Do not provide over-current protection
greater than 15 amperes.
8. PROGRAM ThE CONTROLS
Using Intelligent Hydronic Control Display
1. Press and release the “I” key on the
control to change from one parameter to
the next. Each setting will alternately flash
between the relevant display code and its
corresponding value.
The Intelligent Hydronic Control (control) is located
inside the boiler front door, just above the IQ
Option Panel (Figure 8-a).
Operating Mode Options
Intelligent
Hydronic Control
IQ Option Panel
StA
bt
SP
HL
HdF
tt
dh
FLA
rUn
CYC
Err
Status
Boiler Temperature
Operating Setpoint (Outdoor Reset)
High Limit Setting
High Limit Differential
Heat Request Status
DHW Heat Request Status
Flame Current
Run Time Hours
Boiler Cycles
Error (see Error Numbers)
The STA (status) display code has the below listed
values. This list is also available on the control
cover.
Status Code Displayed in STA Mode
8-a
The control display, along with Up ñ, Down ò,
and “I” keys may be used to view boiler operating
status (Figure 8-b). Please note that these keys
look similar to the keys on the IQ Option Panel
but are in a different orientation, and they perform
different functions.
Intelligent Hydronic Control
8-b
1
4
6
7
8
10
13
14
15
16
17
18
20
Standby
Prepurge
Spark
Flame Proving
Running
Retry/Recycle Delay
Soft Lockout
Hard Lockout
Waiting for Limit to Close
Flame Present Out of Sequence
Self Test
Waiting for Damper to Open
Damper Failure to Open
For example, when the “I” key is pressed on the
control until “bt” is displayed, it will then flash a
three digit number (such as “180”) followed by
either “F” (or “C”). This indicates that the boiler
water temperature is 180°F. Other operating
parameters display the information in a similar
fashion.
Viewing the Operating Mode Options
In operating mode the user may view (but not
change) boiler operating status, settings and
troubleshooting information. To view control
display information:
1 sec
Sample
Display
1 sec
Unit Display
OR
1 sec
13
8. PROGRAM ThE CONTROLS (continued)
Please note that in operating mode to hold the
display on the value the user can press and hold
either the Up ñ or Down ò keys and the value
will be continuously shown. This may be helpful in
watching a value “live”.
Changing the Adjustable Parameters
To adjust the Parameters such as High Limit
Setpoint and High Limit Differential:
1. Access the adjustment mode by pressing
and holding the Up ñ, Down ò, and “I”
keys simultaneously for three (3) seconds.
This procedure is intended to discourage
unauthorized changes or accidental changes
to limit settings.
2. Press the "I" key to display available
Adjustment Mode options. Select an option.
Adjustment Mode Options
HL_
dF_
Or_
PP_
St_
Pt_
dh_
rst
f-C
bac
140-220°F
10-30°F
Adjust High Limit Setting
Adjust High Limit Differential
0-10 minutes
Circulator Overrun Time
2-20 minutes
Circulator Pre-purge Time
140-180°F
Start Temperature
On or off
Priority time
dh or tt2
DH Terminal Function
Reset Lockout
F or C
Select degrees F or C Mode
Back to Operating Mode
3. Press the Up ñ and Down ò keys to adjust
the displayed item to the desired value.
4. To return to the normal operating mode from
the Adjustment Mode, when the "bAc” option
is displayed, press either the Up ñ or Down
ò key. If no keys are pressed, after five (5)
minutes the control will automatically return
to the Operating Mode.
More Information about Adjustable Parameters
1. High Limit (HL_)
The control is factory programmed with a
High Limit Setpoint of 180°F. The burner
turns "off" when the boiler temperature (bt)
is above Operating Setpoint. The Operating
Setpoint (SP) will equal the High Limit
Setpoint unless an IQ Outdoor Reset IQ
Option Card is installed.
14
The Outdoor Reset IQ Option Card reduces
the Operating Setpoint to regulate heat
delivery, increase home comfort and
save energy. Refer to the Appendix I for
additional information. The High Limit
Setpoint is adjustable between 140° and
220°F.
2. Differential (df_)
The control is factory programmed with a
Differential of 15°F. The Differential is the
number of degrees the boiler temperature
must decrease below the Operating Setpoint
before the boiler can restart. The differential
is adjustable between 10° through 30°F.
3. Circulator Overrun Time (OR_)
The control is factory programmed with
a Circulator Overrun Time of 0 minutes.
Circulator Overrun Time (also called
“circulator off delay” or “circulator post
purge”) continues circulator operation after
a call for heat has ended, sending excess
heat from the boiler into the system. Ensure
system piping and zone panel settings allow
water flow to the priority zone after the call
for heat ends. The Circulator Overrun Time
is adjustable between 0 through 10 minutes.
4. Circulator Pre-purge Time (PP_)
When the boiler is warm (boiler water
temperature higher than 140°F (adjustable
using Start Temperature parameter)) and
there is a thermostat call for heat, the
system circulator is started and boiler firing
is delayed Circulator Pre-purge minutes. If
the temperature drops below 140°F or there
is a DHW call for heat the boiler is started
without delay. Additionally, the boiler is
started without delay if the thermostat call
for heat is initiated when the boiler water
temperature is less than 140°F. This
feature helps save energy by satisfying
home heating needs with residual boiler
heat rather than cycling the boiler. The
Circulator Pre-purge time has a factory
setting of 2 minutes and is field adjustable
between 2 and 20 minutes. When reset card
is installed, pre-purge time may be adjusted
down to zero (0) minutes. Refer to Table 8a.
8. PROGRAM ThE CONTROLS (continued)
Table 8a: Circulator Pre-purge Time example,
(PP_ = 2 minutes)
Call for
Heat
Source
TT = on
TT = on
DHW = on
DHW = on
DHW = on
DHW = on
DHW
Boiler
Terminal
Temperature
Selection
tt2
tt2
dh
dh
<140
>140
<140
>140
<140
>140
7. Domestic Hot Water (DHW) Terminal
Function (dh_)
The control allows configuration of the
DHW Circulator output functionality to help
the Boiler integrate into each installation
more effectively. The DHW Circulator
output can be connected to a domestic hot
water circulator or a second heating zone
circulator. These applications are selected
as follows:
Burner Status
Start with no delay
Start after 2 minute delay
Start with no delay
Start after 2 minute delay
Start with no delay
Start with no delay
a. When dh_ is set equal to Domestic Hot
Water Demand (h)
When there is an Indirect Water Heater
(IWH) the control provides “DHW” input
terminals for the IWH Aquastat and “DHW
Circulator” output terminals for the DHW
Circulator. When there is a DHW call for
heat, the System Circulator is “forced off”,
the DHW Circulator terminal is energized
and the circulator pre-purge time delay
control logic is bypassed to allow the
boiler to fire without delay. When DHW
demand ends the System Circulator
“force off” is removed, the circulator
can respond normally, and the DHW
Circulator is de-energized. The DHW
call for heat is detected by a voltage on
to the "DHW" terminal. When the Priority
Time parameter is set to “off” the System
Circulator is not forced off for a DHW call
for heat. Refer to Table 8b.
5. Start Temperature (St_)
Amount of “Heat available” is calculated
by taking the difference between measured
boiler water temperature and the Start
Temperature setting. Useful “Heat
Available” is dependent on the type of
heating emitter installed in the home.
Heat emitters require a certain minimum
temperature to operate effectively. Our
default settings reflect cast iron radiators.
Fan Coils may require a start temperature
setting of 180°F or 160°F before providing
heat to the home. The Start Temperature
has a factory setting of 140°F and is field
adjustable between 140°F and 180°F.
6. Priority Time (Pt_)
When the Priority Time parameter is set
to “on” and Domestic Hot Water (DHW)
call for heat is “on” the DHW demand will
take “Priority” over home heating demand.
During Priority Time the system circulator
will be forced “off”. Priority Time ends and
the system circulator is released to service
home heating demand when Domestic Hot
Water call for heat is over. When Priority
Time parameter is set to “Off” the DHW
call for heat does not force “off” the system
circulator. The Priority Time has a factory
setting of “On” and is field adjustable
between “On” and “Off” Refer to Table 8b.
Table 8b: DhW Terminal Function (dh_)
Selection = Domestic hot Water Demand,
(Parameter dh_ = dh)
Call for heat
Circulator Status
T-T
Input
DHW
Input
Priority
Time
(Pt_)
System
Circulator
Output
DHW
Circulator
Output
on
off
On
on
off
on
on
On
off
on
off
on
On
off
on
on
off
OFF
on
off
on
on
OFF
on
on
off
on
OFF
off
on
15
8. PROGRAM ThE CONTROLS (continued)
b. When dh_ is set equal to Second Heating
Zone (tt2)
When there is no IWH the “DHW
Circulator” output may be configured to
control a second heating zone. This is
particularly helpful when the home uses
only two heating zones. The control
replaces the need for a two circulator
zone panel. When DHW Terminal
Function (dh_) is set to “tt2" the control’s
two circulator outputs are used to control
two independent heating zones. Refer
to Table 8c. A “TT” input causes a call
for heat and energizes the “System
Circulator” output to service heating zone
1 and a second zone's thermostat wired
to the “DHW” input causes a call for heat
and energizes heating zone 2 circulator
wired to the "DHW Circulator" output.
When there is a Second Heating Zone
(call for heat) the boiler is started and the
DHW Circulator terminal is energized.
When Second Heating Zone is deenergized the call for heat is ended and
the Second Heating Zone Circulator is
de-energized. A Second Heating Zone
is detected by sensing a voltage on the
DHW terminal.
Using the IQ Option Panel
IQ Option Cards are available from U.S. Boiler
Company distributors and are the simplest way
to add functionality, safety and efficiency to your
heating system. The IQ Option Panel provides
an easy and convenient means to "plug-in" an
Auxiliary High Limit, Low Water Cut-off and/or
Outdoor Reset function.
For installation, programming, and troubleshooting
instructions, refer to the instructions supplied with
those cards.
Using the Optional LCD Display Kit
The LCD Display is an easy to use touch screen
type display that allows a technician to monitor and
adjust the control and connected IQ Option Cards.
All boiler settings, status and error codes are
displayed in full text. All Outdoor Reset IQ Option
Card parameters are adjustable with graphic and
help information screens. The LCD Display Kit
includes a mounting bracket and wiring harness
to allow mounting in the boiler plastic hood above
the front door. For installation, programming,
and troubleshooting instructions, refer to the
instructions supplied with the display.
Table 8c: DhW Terminal Function (dh_)
Selection = Second heating Zone,
(Parameter dh_ = tt2)
Call for heat
Circulator Status
T-T
Input
DHW
Input
System
Circulator
Output
(Zone 1)
off
off
off
DHW
Circulator
Output
(Zone 2)
off
on
off
on
off
on
on
on
on
off
on
off
on
9. ChECk FOR GAS AND WATER LEAkS
GAS LEAKS may result in fire or
explosion.
WATER LEAKS may cause extensive
property damage.
16
Refer to Appendix E – Filling the System and
Checking for Leaks
10. PERFORM STARTUP ChECkS AND ADjUSTMENTS
FAILURE TO PERFORM THESE
CHECKS of the boiler's combustion and
safety systems may result in serious property
damage, injury, or death.
IF YOU SMELL GAS, STOP and repair
the leak. Lighting the boiler when gas is
leaking may cause explosion or fire.
Follow the checklist below:
1. Verify that the venting, water piping, gas
piping, and electrical systems are properly
installed and checked.
2. Apply power to the boiler.
3. Adjust zone thermostat to maximum setting.
10-b
4. Allow gas line to purge of air.
q Boiler lights cleanly within 60 seconds.
5. Adjust gas input rate. See Appendix F
– Adjusting Gas Input Rate
8. Adjust zone thermostat to minimum setting.
q Boiler shuts off.
9. Adjust zone thermostat to maximum setting.
10. Observe temperature gage as boiler heats.
11. Adjust the high limit setting to its minimum
level (see "Programming High Limit" in
Section 8).
q Boiler shuts off when temperature gage
reads within 15°F of high limit setting.
12. Return high limit to the desired setting (see
"Programming High Limit" in Section 8).
13. Check draft. See Appendix G
– Checking Draft and Combustion.
10-a
q Pilot and main burner flames appear
clean and blue.
6. Disconnect pilot lead wires from gas valve
(Figure 10-b).
q Boiler shuts off.
7. Reconnect pilot lead wires to gas valve.
q Boiler restarts.
q No spillage observed.
14. Check combustion in the vent stack and
record results in the spaces provided below.
_____ CO2
(less than 7%)
_____ O2
(more than 9%)
_____ CO
(less than 50 ppm, air free)
ANY FAILED STARTUP CHECK
Must be corrected before placing the boiler
in service.
17
ANNUAL MAINTENANCE ChECkLIST
WARNINGS
THE BOILER CONTAINS REFRACTORY
CERAMIC FIBER, a possible human carcinogen
Use a NIOSH approved respirator when servicing
high-temperature insulation and gasket materials.
Wash exposed skin gently with soap and water
after contact Wash exposed clothing separate
from normal laundry.
LABEL ALL WIRES prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation
FAILURE TO MAINTAIN THE BOILER in proper
working condition may lead to fire, explosion,
Equipment you will need:
personal injury or death, and extensive property
damage.
TURN OFF ALL GAS AND ELECTRIC power
supplies to the boiler before servicing. Contact with
or release of dangerous flammable gas, electrical
voltage, moving parts, and very hot water under
pressure may cause serious personal injury,
property damage, or death.
LOCK ELECTRICAL BOXES AND GAS VALVES
CLOSED to prevent someone from inadvertently
restoring power or gas before the heating system is
safe to operate.
(7) Hold burner at throat. Lift front of burner
to clear orifice (Figure AM-1). The
burner that holds the pilot can only be
removed by first lifting the burner
adjacent to its right.
q Soft bristle brush
q Bristle flue brush
q Vacuum with brush attachment
Perform these tasks each year:
1. Clean low water cutoff probe (if applicable).
2. Inspect vent for obstruction and signs of
condensation, distortion, overheating or gas
leakage.
3. Clean vent terminal and air intake screens.
4. Inspect boiler flue passages:
(1) Remove vent pipe, damper.
(2) Remove top panel and hood.
(3) Remove blocked vent switch and
canopy.
(4) Examine all flue passageways. Using
bristle flue brush and vacuum,
remove any soot or obstructions.
6. Perform Startup Checks and Adjustments
described earlier in this manual.
7. Check operation of airflow sensing switches.
8. Check for water leaks on the boiler or water
pooling around boiler.
9. Manually operate the relief valve. If the
water is grey or black, there is excessive
oxygen in the system. Oxygen is corrosive
to boilers. Eliminate any source of oxygen.
10. Verify proper operation after servicing.
5. Remove and clean main burners:
(1) Remove jacket front panel.
(2) Disconnect pilot tubing at gas valve.
(3) Disconnect pilot lead wires at gas valve.
(4) Remove wires from flame roll-out switch.
(5) Remove burner access panel.
(6) Mark location of the pilot main burner on
the manifold if the marking on manifold
is missing or obliterated.
18
AM-1
TROUBLEShOOTING
wiring diagram in Figures IW-1 and IW-2.
Ensure that incoming 120 Vac power polarity
is correct and that the boiler is properly
grounded. Further, ensure that the control
power supply is 24 VAC (minimum 18 VAC
to maximum 30 VAC) and polarity is correct.
Before troubleshooting
The following pages contain trouble shooting
tables for use in diagnosing control problems.
When using these tables the following should
be kept in mind:
1. This information is only meant to be used by
a professional heating technician as an aid
in diagnosing boiler problems.
4. All controls on the boiler are tested at least
once in the manufacturing process and a
defective control or component is generally
the least likely cause. Before replacing a
component, try to rule out all other possible
causes.
2. Where applicable, follow all precautions
outlined in Section 10, 'Perform Startup
Checks and Adjustments' on page 17.
3. In general, these tables assume that
there are no loose or miswired electrical
connections. Before using these tables
inspect all electrical connections on the
boiler to make sure that they are tight. Also,
check the wiring on the boiler against the
5. When checking voltage across wiring
harness pins be careful not to insert
the meter probes into the pins. Doing
so may damage the pin, resulting in a
loose connection when the harness is
reconnected.
Press “I” key on the control to change
from one parameter to the next. Each
setting will alternate between display
code (for example STA) and value.
When Err (error) is shown:
Value
Description
Possible STA (status) values:
Value
Description
4
Flame current lower than threshold
1
Standby
6
Flame Out of Normal Sequence
4
Pre-purge
18
Electronics Failure
6
Spark
23
Flame Sensed During Pre-purge
7
Flame Proving
32
Temperature Sensor Failure
8
Running
55
Damper Failed to Open
10
Retry/Recycle Delay
57
Flame Rod Shorted to Ground
13
Soft Lockout
58
AC Line Frequency
14
Hard Lockout
59
Line Voltage Error
15
Waiting for Limit to Close
60
Thermostat input higher than threshold
16
Flame Present Out of Sequence
61
Line Voltage Unstable
17
Self Test
63
Soft Lockout – Recycles Exceeded
18
Waiting for Damper to Open
64
Soft Lockout – Internal Failure
20
Damper Failure to Open
19
TROUBLEShOOTING (continued)
Use Control Display ERR (error) Number To Direct Troubleshooting Efforts
If the control detects an error it will flash “Err” (error) followed by a number. Use this number to identify
the boiler problem and corrective action in the table below. If there is no Err display proceed to next
Section:
Display
Blank
Err
4
Err
6
Err
18
Err
23
Err
32
eRR
35
Err
55
Err
57
Status
Recommended Corrective Action
No 120 Vac Power at boiler, check breaker and wiring between breaker
panel and boiler
Flame Current Lower than Threshold
Check pilot assembly. Refer to Troubleshooting Section, 6.
Flame sensed out of normal sequence (before opening gas valve or after
Flame Sensed Out of Normal Sequence
closing gas valve). Check gas valve for proper operation.
Electronics Failure
Cycle power to control. Replace control if problem persists.
Flame sensed during post-purge (before gas valve signaled open). Check
Flame Sensed During Pre-purge
the gas valve for proper operation. Replace gas valve if problem persists.
Temperature sensor or interface failure (open or short connection, increased
connection resistance, dual sensor mismatch) or control hardware failure.
Temperature Sensor Failure
- Check sensor is securely attached to control P7 connector.
- If secure, replace sensor.
- If problem persists, replace control.
Duplicate Zone Alarm
Refer to IQ Zone Panel Instructions.
Atmospheric Damper End Switch failed to close (end switch contacts stuck
Damper Failed to Open
open). Refer to Troubleshooting Section, 5.
Flame Rod shorted to burner ground, this can result from excessive flue gas
condensation.
Flame Rod Shorted to Burner Ground
- Check for excessive condensate. Dry pilot. Adjust setpoint higher.
- Check for loose or damaged ignition wire.
Boiler or Control is not powered
Err
58 AC Line Frequency
Err
Err
59 Line Voltage Error
AC voltage out of specification high or low. Check supply voltage.
60 Thermostat Input Higher than Threshold Check thermostat wiring.
Possibly too many heavy loads switching on and off cause erratic supply
61 Line Voltage Unstable
voltage. Check supply voltage.
Soft Lockout – Maximum Recycles
63
Maximum number of recycles exceeded. Refer to Troubleshooting Section, 6.
Exceeded
The electronics has detected an error. This can be caused by an actual
controller internal fault or wiring fault:
- Check vent damper, cycle power with vent damper disconnected. If error
64 Soft Lockout – Internal Failure
is cleared, reconnect the vent damper and refer to Recommended
Corrective Action listed under stA 20, damper failed to open.
- Check pilot assembly,
- If problem persists, replace the control.
89 Communication Lost
Check wiring between control and IQ Zone Panel or IQ Reset Card.
Err
Err
Err
Err
20
Error AC Signal is too noisy or frequency is incorrect. Check supply voltage.
TROUBLEShOOTING (continued)
Use STA (status) Number To Guide Troubleshooting
The control will flash “STA” followed by a number. Use this number to identify the boiler problem in the
table below:
1. Boiler and Circulator Off
Recommended Corrective Action
Display / Status
The boiler has not detected a call for heat (tt = off and dh = off).
STA1
Standby
Burner off
Circulator off
Check the thermostat:
- When a thermostat call for heat is detected control display “tt” will show “on”
- Make sure thermostat is calling for heat and contacts (including appropriate zone controls)
are closed. Check for loose connection.
Check the DHW demand:
- When a domestic call for heat is detected “dh” will show “on”
- Make sure the DHW aquastat contact is closed. Check for loose connection.
2. Circulator is On, But Boiler is Off
Display / Status
STA1
Circulator
Pre-purge
Burner off
Circulator on
Recommended Corrective Action
The boiler is warm and circulator is providing residual boiler heat to building:
Check boiler temperature
- The boiler will not start until boiler water temperature is less than the Setpoint (SP) minus differential (df)
- If boiler water temperature is higher than Start Temperature (ST_, default = 140 F) and the Circulator Pre-purge
(PP_, default = 2 minutes) time has not expired, boiler start will be delayed until water temperature drops or time
expires. To permit the boiler to start sooner increase Start Temperature parameter. Refer to Operation Section
for additional information.
3. Boiler is On, But Circulator is Off
Display / Status
StA 8
Burner on
Circulator off
Recommended Corrective Action
Domestic Hot Water (DHW) Priority Forcing Circulator Off
- When there is a DHW heat request wired to the control’s DHW terminal the System Circulator will be
“forced off” for the duration of the DHW heat request. When the DHW heat request ends the System
Circulator “force off” is removed, the circulator can respond normally. When the Priority Time, (PT_)
Parameter is set to “off” the System Circulator is not “forced off” for a DHW call for heat.
- When there is DHW heat request and an Outdoor Air Reset IQ Card is installed the System Circulator will be
forced off for the duration of the Reset Card’s Priority Time (PT_) parameter. Check Priority Time (PT_)
parameter using the Outdoor Air Reset IQ Option Card Adjustment Mode (see Reset Card Adjustment Mode
Instructions).
Wiring / Circulator Issue:
- Check wiring for loose connection, miswiring
- Check circulator
4. Circulator is On But Damper is Not Open
Display / Status
Recommended Corrective Action
Waiting for Limit to Open.
STA15
Limit Open
- Check Blocked Vent Switch, in the event of a blocked vent or poor draft condition, the blocked vent switch
will open interrupting power to control P5-4. The main burners will be extinguished immediately and the
circulator will remain on until the thermostat is turned off. The source of blockage must be corrected by
trained and skilled personnel from a qualified service agency before resetting switch.
Blocked Vents are caused by a collapsed chimney resulting in full or partial blockage, chimney cross
sectional area too small, height insufficient or cold chimney causing sustained poor draft. Always follow
the recommendations in Section 4, Connect Venting and Appendix B and B1.
- Check Flame Rollout Switch, in the event of excessive blockage of the boiler section flue passageways
is developed the flame rollout switch will open interrupting power to control P5-4. The main burners will be
extinguished immediately and the circulator will remain on until the thermostat is turned off. If the flame rollout
switch is activated, do not attempt to place the boiler in operation. The source of the blockage must be
corrected and the identical flame rollout switch replaced by trained and skilled personnel from a qualified service
agency.
- Check External Limit. Check IQ Option Panel Display.
21
TROUBLEShOOTING (continued)
5. Circulator is On But Damper is Not Open
Display / Status
Recommended Corrective Action
The control is waiting for the damper to open. Damper end switch has failed to close (end switch contact is
stuck open). Combustion can never take place unless the damper blade is in the fully open position. Check the
following:
STA 20
Damper Failed
to Open
- During status “STA18" or “STA 20” the control terminal “P6 - 5” (yellow wire) is energized.
- Check for loose connection between control and vent damper, check damper harness.
- Check for obstruction in path of damper
- When damper is open (end switch closed) control terminal “P6 – 2” should receive power from the vent damper.
- Place jumper between control terminal P6-5 and P6-2. If error 55 does not clear, replace control.
- Defective harness or vent damper.
6. Circulator is On, Damper is Open But Boiler Fails to Start
Display / Status
STA 10
Retry / Recycle
Delay
STA 13
Soft Lockout
STA 14
Hard Lockout
STA 16
Flame Out of
Sequence
22
Description
The Boiler is in “Retry Delay”:
- The burner failed to light (no flame signal). After a 5 minute delay, control will attempt to light the burner again.
There is no limit to the number of retries.
Recycle Delay
- The burner loses flame during running mode, “STA 8”. After a 10 second delay, control will attempt to light the
burner again. If the burner loses flame during running mode, “STA 8” during the next six recycles, control will
progress to a soft lockout.
When a soft lockout occurs, boiler will shut down. Boiler automatically restarts once condition that caused the
lockout is corrected and the one-hour time delay is completed. Boiler can be restarted sooner than the time delay
by using Adjustment Mode and selecting the reset button (see Adjustment Mode instructions) or by cycling power.
Soft Lockout is caused by one of the following:
- Err 63, Maximum Recycles Exceeded – The burner lost flame during running mode,
“STA 8” six times in a row. Refer to recommended corrective actions on next page to help
determine the cause of the problem.
- Err 64, Internal Failure, refer to Error code listing for recommended corrective action.
- Err 23, Flame sensed during post-purge (before gas valve signaled open). Check the gas
valve for proper operation. Replace gas valve is problem persists.
When a hard lockout occurs boiler shuts down.
If flame is detected in pre-purge, control goes to Flame Out of Sequence Before trial, “Sta 16” and “err 23” is
reported. The control gives a flame 10 seconds to disappear. If flame goes away, control resumes heating cycle
from the beginning. If it doesn’t “err 23” is cleared and “err 6” is reported. When flame is off, control goes to
Soft Lockout and “err 6” is cleared.
TROUBLEShOOTING (continued)
Display / Status
Recommended Corrective Action
1. No Spark
a. Can you hear sparking while STA 6 is displayed?
- If there is no spark noise replace the control.
b. If you can hear spark noise check the following:
- Loose connection in ignition cable or ground wire
- Continuity of ignition cable
- Break in ignition cable insulation
- Loose ground connection
- Break in pilot ceramic insulator
- Incorrect pilot spark gap
StA 10
Retry / Recycle
Delay
StA 13
Soft Lockout
2. No Pilot Flame
a. If pilot does not light check the following:
- All manual gas valves are open
- Supply tubing is not plugged, kinked or leaking
- Gas line pressures are good
- Gas line is purged of air
- Pilot orifice is not plugged (pilot gas is flowing)
- Condensate quenching pilot
Note: It may be necessary to recycle the “call for heat” more than once to clear the pilot
supply tubes of air.
b. If no gas flow check the following:
- 24 volts across PV and MV/PV at gas valve, if voltage ok replace defective gas valve
- Check for break in wiring harness to gas valve
- 24 volts across control connector P5–2 and P5–5, if no voltage at control replace defective control
3. Spark does Not Stop When Pilot Lights
If the spark does not stop when the pilot lights check the following:
- Loose connection in ignition cable or ground wire
- Continuity of ignition cable
- Clean flame rod
- Pilot electrode porcelain cracked
- Pilot flame covers flame rod and is steady and blue, if not adjust pilot flame
- Low gas pressure at gas valve inlet
- Defective control
4. Main Flame Does Not Light
If the main burners do not light check the following:
- Check orifice size and/or blockage
- 24 volts across control terminals P5-8 and P5-5? If no voltage while in STA 7 defective control.
- 24 volts across MV and MV/PV at gas valve? Check for break in wiring harness to gas valve
- Defective gas valve
23
TROUBLEShOOTING (continued)
If Control Shows Status Code “STA 15": The control is “Waiting for Limit to Close” and the display on the
IQ Option Panel should be the first place to check. The IQ Option Panel display (lower display) will show
one of the following status codes:
IQ Option Panel Display Shows “ERR"
Display
Err
1
Status
Boiler / Control Action(s)
Low Input Voltage
AC voltage is too low
Err
2 - card #
IQ Option Card
Type Change
without Re-Learn
Whenever a new IQ Option Card is first installed into the IQ Option Panel, the IQ Option
Panel automatically “Learns” the card. This means it detects the specific card and lists
it as a card number (C1, C2, or C3). However, to help avoid errors or unauthorized
option card changes, once an IQ Option Card is initially installed, the IQ Option Panel
will not automatically “Learn” a different card in the same slot. In this situation, the IQ
Option Panel has to “Learn” about the new card manually. To have the IQ Option Panel
recognize or “Learn” about a different card, the user must press the “I” key on the IQ
Option Panel until “Lrn” is displayed. Then press and hold either the Up ñ or Down ò
key for at least three (3) seconds. The IQ Option Panel will then recognize and “Learn”
the new IQ Option Card.
Err
3 - card #
IQ Option Card
Communications
Error
The IQ Option Card is not installed properly or has an internal fault. Remove the card
and check for bent IQ Option Panel card interface pins. Straighten bent or misaligned
pins or choose another card slot and reinstall card. If problem persists, replace card.
Err
4 - card #
IQ Option Card
Hardware
Interface Error
The IQ Option Card is not installed properly, there is a option card or IQ Option Panel
fault. Remove the card and check for bent IQ Option Panel card interface pins.
Straighten bent or misaligned pins or choose another card slot and reinstall card. If
problem persists, replace card.
Err
5
Limit Output OFF
in ON State
Err
6
Incorrect Wiring
Err
7
Internal IQ Option
Panel Error
Err
8
Limit Output ON
in OFF State
Check limit string wiring, replace the IQ Option Panel.
Err
9
Hard lockout due
to repeated Err 8
Check limit string wiring, replace the IQ Option Panel.
Check limit string wiring, replace the IQ Option Panel.
Check boiler wiring.
Replace the IQ Option Panel.
If IQ Option Panel Display Shows “OL": The OL- “card number” indicates the card slot causing the Open
Limit. For example, “OL-C1" means open limit in the card located in card slot 1. To determine the cause of the
open limit the user must switch the display on the IQ Option Panel to show the view mode of the IQ Option Card
installed in Slot 1.
For example, if, while the boiler has a Heat Request, and the Aquastat IQ Option Card installed in Slot 1 has a
sensor failure the IQ Option Panel displays OL-C1 (Open Limit Card Slot 1). To investigate the status of option
card C1:
1. Press the “I” key on the IQ Option Panel. The display will go from “OL-C1” to C1 .
2. When the display shows C1, press either the Up ñ or Down ò keys to switch the display to show the
view mode of the Aquastat Limit Control IQ Option Card inserted in Slot 1. The display will now read Err
-119, Sensor Failure.
3. Check the sensor connections and when required replace the sensor.
4. When the sensor failure is corrected the IQ Option Panel will return to the “O.C.P" display and the control
start sequence will continue.
For additional information refer to the instruction manual supplied with the IQ Option Card.
If IQ Option Panel Display Shows “O.C.P": The Option Panel is in normal run or operating mode, the IQ Option
Panel display will show “O.C.P" (Option Card Panel) along with a floating decimal point that flashes on and off
(the “heartbeat” flash indicating the panel is functioning properly and there are no open limits or errors). The
Option Panel or the card installed in the option panel are not causing the open limit.
24
REPAIR PARTS LIST
Key
No.
[Quantity] Part Number
Description
1A
Block Assembly
1B
Canopy Gasket Kit
1C
Canopy Assembly
Blocked Vent Switch
(not shown)
303B
304B
305B
306B
307B
308B
309B
102287-03
102287-04
102287-05
102287-06
102287-07
102287-08
102287-09
102554-03
102554-04
102554-05
102554-07
103860-08
102554-09
6206001
102554-06
80160157
25
REPAIR PARTS LIST (continued)
Key
No.
Description
303B
304B
[Quantity] Part Number
305B
306B
307B
308B
309B
2A
Base Wrapper
71807031
71807041
71807051
71807061
71807071
71807081
71807091
2B
Base Tray
102543-03
102543-04
102543-05
102543-06
102543-07
102543-08
102543-09
2C
Burner Tray Assembly
61807031
61807041
61807051
61807061
61807071
61807081
61807091
2D
Base Front Panel
102705-03
102705-04
102705-05
102705-06
102705-07
102705-08
102705-09
2E
Burner Access Panel
102707-03
102707-04
102707-05
102707-06
102707-07
102707-08
102707-09
2F
Base Gasket Kit
2G
Base Side Insulation
2H
Base Rear Insulation
72007031
72007041
72007051
72007061
72007071
72007081
72007091
2J
Base Front Insulation
72007032
72007042
72007052
72007062
72007072
72007082
72007092
103718-07
103718-08
103718-09
2K
Base Leg Assembly
2L
Flame Roll-out Switch
2M
Manifold Support Bracket
2N
Front Air Dam
26
6206002
[2] 72007001
[4] 6186001
80160044
718070001
N/A
N/A
103718-05
103718-06
REPAIR PARTS LIST (continued)
Key
No.
3A
3B
Description
Gas Valve (Natural Gas),
Honeywell VR8204P1171
Gas Valve (Natural Gas),
Honeywell VR8304P4496
Gas Valve (LP Gas), Honeywell
VR8204C3015
Gas Valve (LP Gas), Honeywell
VR8304P4314
½" Gas Manifold
¾" Gas Manifold
Burner Orifices - Natural Gas #47
3C
Burner Orifices - LP Gas 1.20mm
3D
3E
Pilot Burner
Pilot Assembly - Natural Gas
Pilot Assembly - LP Gas
3F
Main Burner
3G
3H
Pilot Tubing
Ground Wire Assembly
303B
82207031
[Quantity] Part Number
305B
306B
307B
304B
308B
81660282
N/A
N/A
81660283
81660146
N/A
N/A
81660160
82207041 82207051
N/A
[6]
[8]
822710
822710
[6]
[8]
822792
822792
82207061
309B
N/A
82207081
[14]
822710
[14]
822792
82207071
82207091
[10]
[12]
[16]
822710
822710
822710
[10]
[12]
[16]
822792
822792
822792
100147-01
8236163
8236164
[3]
[5]
[7]
[9]
[11]
[13]
[15]
100146-01 100146-01 100146-01 100146-01 100146-01 100146-01 100146-01
8236122
103776-01
[4]
822710
[4]
822792
27
REPAIR PARTS LIST (continued)
Key
No.
28
Description
303B
304B
[Quantity] Part Number
305B
306B
307B
4A
Control
103660-01
4B
IQ Option Panel
102291-01
4C
Transformer
102516-01
4D
Temperature Sensor
102411-01
Temperature Sensor Spring Clip (not shown)
102422-01
308B
309B
REPAIR PARTS LIST (continued)
Key
No.
Description
303B
304B
[Quantity] Part Number
305B
306B
307B
308B
309B
5A
Jacket Left Side Panel
5B
Jacket Right Side Panel
5C
Jacket Rear Panel
102569-03
102569-04
102569-05
102569-06
102569-07
102569-08
102569-09
5D
Jacket Vestibule Panel
102565-03
102565-04
102565-05
102565-06
102565-07
102565-08
102565-09
5E
Jacket Top Panel
102568-03
102568-04
102568-05
102568-06
102568-07
102568-08
102568-09
5F
Jacket Front Door
102576-03
102576-04
103717-05
103717-06
103717-07
103717-08
103717-09
5G
Jacket Rear Discharge
102549-03
102549-04
102549-05
102549-06
102549-07
102549-08
102549-09
Jacket Poly Front Cover
102600-03
102600-04
102600-05
102600-06
102600-07
102600-08
102600-09
5H
102566-01
102567-01
Grilles (not shown):
Upper Poly Grille
102621-01
N/A
Lower Poly Grille
103477-01
N/A
29
REPAIR PARTS LIST (continued)
Key
No.
Description
303B
304B
[Quantity] Part Number
305B
306B
307B
6A
Supply Water Manifold
80607001
6B
Temperature/Pressure Gauge
100282-01
6C
30 PSI Relief Valve
81660363
6D
Drain Valve
102802-01
6E
Vent Damper
102284-01
102284-02
102284-03
Circulator (not shown):
Taco 007-2
Grundfos UP-15
B & G NRF-22
30
8056170
102805-02
8056174
308B
102284-04
309B
102284-05
INTERNAL WIRING
Figure IW-1: Wiring Diagram
31
INTERNAL WIRING (continued)
Figure IW-2: Wiring Schematic
32
INTERNAL WIRING (continued)
Figure IW-3: Multiple Zone System with Zone Circulators
Figure IW-4: Multiple Zone System with Zone Valves
33
INTERNAL WIRING (continued)
Figure IW-5: Multiple Zone System with Zone Circulator Panel
POWER
SUPPLY
120/60/1
DHW AQUASTAT
(L4006, L4080)
(SUPPLIED BY OTHERS)
L2
L1
THERMOSTAT
THERMOSTAT THERMOSTAT
24V
TRANSFORMER
MODE
ZONE 4 PRIORITY
DOMESTIC HOT WATER PRIORITY IS
SELECTED USING ZONE PANEL SWITCH
NORMAL RESET
OFF
POWER IN
T T
ZONE 1
T T
ZONE 2
FUSE (3 AMP MAX.)
L1
L2
MAIN EXTRA
END
END
SWITCH SWITCH
N/O COM N/C
ZONE 4 RELAY
MAIN EXTRA
END
END
SWITCH SWITCH
N/O COM N/C
ZONE 4 RELAY
T T
ZONE 3
T T
ZONE 4
T STAT 1
VALVE 1
T STAT 2
VALVE 2
T STAT 3
VALVE 3
T STAT 4
VALVE 4
POWER
TACO ZVC 404 (OR EQIV.)
FOUR ZONE ZONE VALVE CONTROL
WITH OPTIONAL PRIORITY
1
ZONE 1
2 3 4
1
ZONE 2
2 3 4
1
ZONE 3
2 3 4
IQ OPTION PANEL
ON
1
1
3
1
2
3
2
3
DHW
CIRCULATOR
(SUPPLIED BY
OTHERS)
DHW
CIRCULATOR
(SUPPLIED BY
OTHERS)
2 WIRE ZONE
VALVE
(NO END SWITCH)
2 WIRE ZONE
VALVE
(NO END SWITCH)
4 WIRE ZONE
VALVE
(POWER OPEN,
SELF CLOSING)
BOILER JACKET
PANEL
SYSTEM
CIRCULATOR
(SUPPLIED BY OTHERS)
WIRING USED WHEN DOMESTIC
HOT WATER PRIORITY NOT DESIRED
SYSTEM
CIRCULATOR
(SUPPLIED BY OTHERS)
WIRING USED WHEN DOMESTIC
HOT WATER PRIORITY IS DESIRED
LINE VOLTAGE FACTORY WIRING SIZE 14 AWG TYPE TW OR TEW/AWM WIRE
LINE VOLTAGE FIELD WIRING
Figure IW-6: Multiple Zone System with Zone Valve Panel
34
1
6
2
7
8
3
4
ZONE 4
2 3 4
JUMPER
3&4
PRIORITY
ZONE
JUMPER
3&4
5
1
2
T
T
APPENDIX A – COMBUSTION AIR
PROVIDE ENOUGH AIR to ventilate the
boiler room, dilute the flue gases, and
sustain combustion. Ignition failure, overheating,
fire, carbon monoxide, and spillage of flue gases
may result from poor air supply.
If the boiler is a Direct Vent boiler and exchanges
all combustion air and combustion products
directly with the outdoors, there are no special
requirements for providing combustion, ventilation,
and dilution air.
If the boiler is chimney vented, power vented or
induced draft and draws combustion air from within
the building, follow the steps below to determine
how to provide air to the boiler.
1. Calculate the floorspace (in square feet) of
the boiler room and all rooms connected
to the boiler room by passageways not
furnished with doors.
combined appliance
___________ input (BTU/hr)
3. In the table below, find the Minimum
Allowable Floorspace based on the
Combined Input Rate from Step 2 and the
ceiling height. If the Combined Input Rate
is between two rates, use the next highest
rate.
Do the walls and ceilings exposed to the
outside atmosphere have a continuous
water vapor retarder with a rating of 1 perm
or less, with openings gasketed or sealed?
Are operable windows and doors
weatherstripped?
6. If you must provide outdoor air to the boiler
room, the top of the permanent opening
into the boiler room must be within 12” of
the ceiling, and the free area of the opening
(sq. in.) must be no less than the Combined
Appliance Input (from Step 2) divided by
3000 BTU/hr/sq. in.
combined appliance
__________ input (Step 2)
÷
3000
BTU/hr/sq. in.
Minimum Opening Size
_____ (sq. in.)
minimum allowable
___________ floorspace (sq. ft.)
Minimum Allowable Floorspace in the Boiler Room
and Freely Connected Rooms (sq. ft.)
Ceiling Height
(BTU/hr)
below is “yes”, then you must provide
outdoor air to the boiler room.
 Yes  No
appliances installed in the same floorspace.
(see Step 2)
5. If the answer to all of the three questions
Are exterior wall joints caulked or sealed?
2. Add up the input rates of all the combustion
Input Rate
Is the boiler located in a building of unusually tight
construction?
 Yes  No
___________ floorspace (sq. ft.)
Combined
Appliance
Minimum Floorspace from Step 3, then you
must provide outdoor air to the boiler room.
Proceed to Step 6.
 Yes  No
Is the boiler located in a confined space?:
50,000
4. If the Floorspace from Step 1 is less than the
7’
8’
9’
10’
357
313
278
250
100,000
714
625
556
500
150,000
1071
938
833
750
200,000
1429
1250
1111
1000
250,000
1786
1563
1389
1250
300,000
2143
1875
1667
1500
350,000
2500
2188
1944
1750
400,000
2857
2500
2222
2000
7. Duct this opening vertically or horizontally
directly to the outdoors, or directly to a
space that communicates directly with the
outdoors, such as an attic or crawlspace.
For more details and options, refer to your local
building code, the National Fuel Gas Code (NFPA
54 and ANSI Z223), and the Canadian Natural Gas
Installation Code CAN/CGA-B149.1 or Propane
Installation Code CAN/CGA-B149.2.
35
APPENDIX B – VENTING
VENT THIS BOILER according to the instructions. Failure to do so may cause products of
combustion to enter the building resulting in severe property damage, personal injury or death.
Install this boiler according to this manual and the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the
i the
local building codes. Contact local building or fire officials about restrictions and installation
inspection in your area. In addition to previously mentioned vent codes of the main general guidelines,
atmospheric vented installations must also be in accordance with the Standard for Chimneys, Fireplaces,
Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211. For Canada installations, refer to the Natural
Gas and LP Installation Code, CAN/CSA- B149.1.
1. Per ANSI Z223.1/NFPA 54 the vent terminal
shall have a minimum clearance of 4 feet
horizontally from, and in no case above or
below, unless a 4 feet horizontal distance
is maintained, from electric meters, gas
meters, regulators and relief equipment for
U.S. installations. Per B149.1 this minimum
distance shall be 6 feet for Canadian
installations.
(4)
2. IF AN EXISTING BOILER IS REMOVED
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
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:
(5)
(6)
(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, and
other deficiencies which could cause an
unsafe condition.
(3) Insofar as is practical, close all
building doors and windows and all
doors between the space in which the
appliances remaining connected to the
common venting system are located
and other spaces of the building. Turn
36
(7)
on clothes dryers and any appliance
not connected to the common venting
system. Turn on any exhaust fans, such
as range-hoods and bathroom exhausts,
so they will operate at maximum speed.
Do not operate a summer exhaust fan.
Close fireplace dampers.
Place in operation the appliance
being inspected. Follow the Lighting
(or Operating) Instructions. Adjust
thermostat so appliance will operate
continuously.
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 smoke from a cigarette, cigar
or pipe.
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, fireplace
dampers and any other gas burning
appliance to their previous conditions of
use.
Any improper operation of the common
venting system should be corrected
so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1
and/or CAN/CSA B149.1, Installation
Codes. 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 National Fuel Gas
Code, ANSI Z223.1 and/or CAN/CSA
B149.1, Installation Codes.
APPENDIX B – Venting (continued)
(1)
(2)
(3)
(4)
(5)
Au moment du retrait d’une chaudière
existante, les mesures suivantes doivent
être prises pour chaque appareil toujours
raccordé au système d’evacuation
commun et qui fonctionne alors que
d’autres appareils toujours raccordés au
système d’évacuation ne fonctionnent
pas:
Sceller toutes les ouvertures non
utilisées du système d’évacuation.
Inspecter de facon visuelle le système
d’évcuation pour déterminer la
grosseur et l’inclinaison horizontale qui
conviennent et s’assurer que le système
est exempt d’obstruction, d’étranglement,
de fuite, de corrosion et autres
défaillances qui pourraient présenter des
risques.
Dans la mesure du possible, fermer
toutes les portes et les fenêtres du
bâtiment et toutes les portes entre
l’espace où les appareils toujours
raccordés au système d’évacuation
sont installés et les autres espaces
du bâtiment. Mettre en marche les
sécheuses, tous les appareils non
raccordés au système d’évacuation
commun et tous les ventilateurs
d’extraction comme les hottes de
cuisinière et les ventilateurs des salles
de bain. S’assurer que ces ventilateurs
fonctionnent à la vitesse maximale. Ne
pas faire fonctionner les ventilateurs
d’été. Fermer les registres des
cheminées.
Mettre l’appareil inspecté en marche.
Suivre les instructions d’allumage.
Régler le thermostat de facon que
l’appareil fonctionne de facon continue.
Faire fonctionner le brùleur principal
pendant 5 min ensuite, déterminer si
le coupe-tirage déborde à l’ouverture
de décharge. Utiliser la flamme d’une
allumette ou d’une chandelle ou la fumée
d’une cigarette, d’un cigare ou d’une
pipe.
(6) Une fois qu’il a été déterminé, selon
la méthode indiquée ci-dessus, que
chaque appareil raccordé au système
d’évacuation est mis à l’air libre de facon
adéquate. Remettre les portes et les
fenêtres, les ventilateurs, les registres de
cheminées et les appareils au gaz à leur
position originale.
(7) Tout mauvais fonctionnement du
système d’évacuation commun devrat
être corrigé de facon que l’installation
soit conforme au National Fuel Gas
Code, ANSI Z223.1 et (ou) aux codes
d’installation CAN/CSA-B149.1. Si la
grosseur d’une section du système
d’évacuation doit être modifiée, le
système devrait être modifié pour
respecter les valeurs minimales des
tableaux pertinents de l’appendice F du
National Fuel Gas Code, ANSI Z223.1 et
(ou) des codes d’installation CAN/CSAB149.1.
3. Horizontal portions of the venting system
shall be supported to prevent sagging.
Follow venting Manufacturer's instructions.
For Category I, II and IV boilers, have
horizontal runs sloping upwards not less
than 1/4 inch per foot (21 mm/m) from the
boiler to the vent terminal.
Les sections horizontales doivent être
supportées pour prévenir le fléchissement.
Suivez les instructions de ventilation
Manufacturer.
Les chaudières de catégories I, II et IV
doivent présenter des troncons horizontaux
dont la pente montante est d'au moins 1/4
po par pied (21 mm/m) entre la chaudière et
l'évent.
4. Damper must be in open position when
appliance main burner(s) is operating.
Le registre doit être ouvert lorsque le brûleur
principal de l'appareil fonctionne.
37
APPENDIX B1 – ATMOSPhERIC VENTING
GENERAL WARNINGS FOR ATMOSPhERIC VENTING SYSTEMS
USE ATMOSPHERIC VENTING only with
boilers approved for atmospheric venting as
noted in the Specifications Section of this
manual.
INSPECT EXISTING CHIMNEY for obstructions
and deterioration and repair or line the chimney
prior to placing the boiler in service.
UNLINED MASONRY CONSTRUCTION is
prohibited for use as a chimney.
FIREPLACES AND FAN-ASSISTED GAS
APPLIANCES must not be vented into the same
chimney space as this boiler.
DO NOT REDUCE THE DIAMETER of the vent
connector between the boiler and the chimney. It
must not be smaller than the outlet on the draft
hood, damper, or vent reducer supplied with the
boiler.
UNLISTED VENT DAMPERS AND
OBSTRUCTIONS in the vent pipe are prohibited.
THE VENT DAMPER supplied with the boiler
shall not be used to block the vent of any other
appliance.
Install vent and vent connector (Figure B-1). Comply with all design and installation requirements in the
Connect Venting Section of this manual, local code, and the National Fuel Gas Code or Can/CSA B149.1.
Clay flue lined masonry chimneys do not meet the venting requirements for this appliance.
Figure B-1: Typical Atmospheric Vent Installation
38
APPENDICE B1 – SYSTÈMES D’ÉVACUATION DES PRODUITS DE LA
COMBUSTION DU GAZ DANS L’ATMOSPhÈRE
AVERTISSEMENTS GÉNÉRAUX POUR LES SYSTÈMES D’ÉVACUATION
DES PRODUITS DE LA COMBUSTION DU GAZ DANS L’ATMOSPhÈRE
N’ÉVACUEZ LES PRODUITS DE LA
COMBUSTION DU GAZ DANS L’ATMOSPHÈRE
que dans le cas de chaudières approuvées pour
cela comme le stipule la section Spécifications de
ce manuel.
VÉRIFIER SI LA CHEMINÉE EXISTANTE n’est
pas obstruée ou détériorée et la réparer ou la
chemiser avant de mettre la chaudière en service.
L’USAGE D’UN OUVRAGE DE MAÇONNERIE
NON CHEMISÉ comme cheminée est interdit.
LES PRODUITS DE COMBUSTION DU GAZ DES
FOYERS ET DES APPAREILS À GAZ VENTILÉS
ne doivent pas être évacués dans la même
cheminée que ceux de la chaudière.
NE PAS RÉDUIRE LE DIAMÈTRE du conduit
d’évacuation des produits de la combustion du gaz
entre la chaudière et la cheminée. Ce diamètre
ne doit pas être plus petit que l’orifice de sortie
du coupe-tirage ou du registre ou du réducteur
d’évacuation fourni avec la chaudière.
LES REGISTRES D’ÉVACUATION ET
LES OBSTRUCTIONS NON INSCRITS AU
RÉPERTOIRE sont interdits.
LE REGISTRE D’ÉVACUATION fourni avec la
chaudière ne doit pas être utilisé pour bloquer
l’évacuation des produits de combustion du gaz de
tout autre appareil.
Installer le conduit d’évacuation des produits de la combustion du gaz et son raccord (figure B-1). Respecter
toutes les instructions d’installation et de conception exposées dans la section Raccordement du système
d’évacuation de ce manuel, dans le code local et le National Fuel Gas Code ou CAN/CSA B149.1.Les
cheminées en maçonnerie revêtues intérieurement d’argile ne respectent pas les exigences d’évacuation de
cet appareil.
Figure B-1 Installation type d’évacuation dans l’atmosphère
39
APPENDIX C – GAS PIPING
Table C-3: Specific Gravity Correction Factors For
Natural Gas
ASSURE GAS PIPING IS LEAK FREE
AND OF PROPER SIZE and type for the
connected load.
SHUT OFF MAIN GAS SUPPLY prior to
installing or servicing boiler gas piping.
Specific
Gravity
Correction
Factor
Specific
Gravity
Correction
Factor
0.50
1.10
0.85
0.81
0.55
1.04
0.90
0.82
0.60
1.00
1.00
0.78
0.65
0.96
1.10
0.74
0.70
0.93
1.20
0.71
0.75
0.90
1.30
0.68
0.80
0.87
1.40
0.66
1. Determine the boiler’s maximum gas
demand and minimum gas supply pressure
(printed on the boiler’s rating label) and the
demand of other gas appliances served by
the same gas meter.
2. Ensure that gas piping, fittings, and gas
meter capacities can supply the maximum
gas demand of all appliances at pressures
above their minimum allowable gas
pressure. Tables C-1 and C-2 provide typical
capacities of gas pipes and fittings.
Code, NFPA 54/ANSI Z223.1, or size the
system using standard engineering methods
acceptable to authority having jurisdiction.
USE PROPER THREAD COMPONENTS
on all gas connectors.
3. Derate the gas flow through pipes by
multiplying by a correction factor in Table
C-3 based on the specific gravity of the gas.
USE THREAD (JOINT) COMPOUNDS
(pipe dope) rated for liquefied petroleum
gas.
4. For materials or conditions other than those
listed above, refer to the National Fuel Gas
Table C-1: Maximum Capacity of Schedule 40 Pipe in Cubic Feet Per hour (CFh)*
0.3” w.c. Pressure Drop
¾
1
0.5” w.c. Pressure Drop
¾
1
Length
(Feet)
½
1¼
½
10
132
278
520
1050
175
360
680
1400
20
92
190
350
730
120
250
465
950
30
73
152
285
590
97
200
375
770
40
63
130
245
500
82
170
320
660
50
56
115
215
440
73
151
285
580
60
50
105
195
400
66
138
260
530
70
46
96
180
370
61
125
240
490
80
43
90
170
350
57
118
220
460
90
40
84
160
320
53
110
205
430
100
38
79
150
305
50
103
195
400
1¼
*1 CFH of Natural Gas is approximately equal to 1000 BTU/hr; 1 CFH of LP is approximately equal to 2500 BTU/hr.
Table C-2: Equivalent Lengths (ft) Of Standard Pipe Fittings & Valves
40
Pipe
Size
Gate
Globe
Angle
Swing
Check
90°
Elbow
45°
Elbow
90° ‘T’, Flow
Through Run
90° ‘T’, Flow
Through Branch
½”
0
¾”
0
19
9
4
2
1
1
3
23
12
5
2
1
1
4
1”
1
29
15
7
3
1
2
5
1 ¼”
1
39
20
9
4
2
2
7
1 ½”
1
45
22
11
5
3
3
8
APPENDIX C – Gas Piping (continued)
5. Bond all above-ground gas piping to a
grounding electrode and ensure the piping is
electrically continuous.
DO NOT USE GAS PIPING AS A
GROUNDING ELECTRODE. Refer to
National Electrical Code, NFPA 70.
6. Install sediment trap, ground-joint union and
manual shut-off valve upstream of boiler gas
control valve and outside jacket.
7. When the piping is completed, test it for
leaks.
(2) When testing at ½ psig or less, isolate
boiler from gas supply piping by closing
boiler’s individual manual shut-off valve.
(3) Locate leaks using approved
combustible gas detector or
nonflammable, non-corrosive leak
detection solution.
DO NOT CHECK FOR LEAKS USING
OPEN FLAMES such as matches or
candles or devices that spark.
8. Repair any detected leaks.
(1) When testing over ½ psig, disconnect
the boiler and its individual shut-off valve
from the gas supply piping.
APPENDIX D – SYSTEM PIPING
USE PROPER DESIGN AND INSTALLATION PRACTICES and observe all local codes when
installing system piping. Property damage and injury may result from an improperly piped or
designed heating system.
i
Boiler damage caused by flawed system design or operation is excluded from our warranty.
Training and experience is required to design and install a piping system that will protect the boiler and
provide many years of comfort to the building occupants. Be sure to protect the boiler from the following
problems:
1. Corrosion
(6) Do not fill the boiler with softened water
unless makeup water is extremely hard
(1) Comply with the boiler’s specific
and it is not possible to eliminate all
water quality requirements. See the
system leaks. If filling the boiler with
Specifications Section of this manual.
softened water, test regularly the water
(2) Pressurize the system above the highest
softener regularly to ensure that brine
net positive suction head (NPSH)
solution is not entering the boiler’s water
required for each circulator and ensure
supply.
positive pressure at the uppermost point
in the system.
2. Lime scale
(3) Maintain a closed boiler system using
(1) Repair leaking pipes, fittings, and vents
heat exchangers to transfer heat to
to minimize the need to add makeup
open systems, such as domestic hot
water.
water systems.
(2) Comply with the boiler’s specific
(4) Purge the system completely of
water quality requirements. See the
dissolved oxygen by bleeding all
Specifications Section of this manual.
radiators and installing a properly
(3) Comply with the boiler’s specific
installed air scoop or air vent.
requirements for minimum water flow
(5) Repair leaking pipes, fittings, and vents
through the boiler, installing a system
to minimize the need to add makeup
bypass or primary-secondary loop if
water.
necessary to maintain flow through the
boiler when serving small zones.
41
APPENDIX D – System Piping (continued)
3. Overpressure
(1) Install a properly sized expansion tank.
(2) Do not exceed the boiler’s specific
requirements for maximum allowable
working pressure.
(3) Do not plug or block the relief valve.
4. Freezing
(1) Run all portions of the system piping
inside a heated space unless the system
is properly protected with an inhibited
antifreeze solution.
5. Overheating
(1) Comply with the boiler’s specific
requirement for minimum water flow
through the boiler. See the
Specifications Section of this manual.
(2) Install a low-water cutoff device
whenever the boiler is installed above
the level of the lowest heat emitter
or radiator. Also add a low-water
cutoff when required by local code
requirements.
It is recommended that the LWCO control
is installed above the boiler to provide
the highest level of protection. However,
where the LWCO control is approved
by the LWCO control manufacturer for
installation in a high boiler tapping of a
water boiler, the use of the listed LWCO
control is permitted when it is installed
according to the LWCO manufacturer's
instructions.
temperature requirements. Install a
boiler bypass, system bypass, or
primary-secondary loop when needed to
maintain water temperatures and flows
within the specified limits.
(3) Do not allow chilled water to enter the
boiler during the heating cycle, or heated
water to enter chilled water coils during
the cooling cycle.
8. Dry Fire
Install a low-water cutoff when the boiler
is installed above the level of the lowest
radiator and when required by local code.
9. Combination Heating and Cooling Systems
If this boiler is used in connection with
refrigeration systems, the boiler must be
installed so that the chilled medium is piped
in parallel with the heating boiler using
appropriate valves to prevent the chilled
medium from entering the boiler, see Figure
D-W1. Also consult Residential Hydronic
Heating Installation and Design I=B=R
Guide.
If this Boiler is connected to heating coils
located in air handling units where they may
be exposed to refrigerated air, the boiler
piping must be equipped with flow control
valves to prevent gravity circulation of boiler
water during the operation of the cooling
system.
6. Thermal shock
(1) Do not over-pump. Adhere to the design
flow requirements for each zone.
(2) Install a boiler bypass, system bypass,
or primary-secondary loop when needed
to avoid returning large volumes of cold
water directly to a hot boiler.
7. Condensation
(1) Do not over-pump. Adhere to the design
flow requirements for each zone.
(2) Adhere to the boiler’s specific
minimum return water and supply water
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Figure D-W1: Recommended Piping for
Combination heating & Cooling
(Refrigeration) Systems
The following system diagrams are intended to provide a minimum level of guidance for a
successful and trouble-free installation of the boiler in common applications. They do not substitute
for proper design, evaluation, and installation by a trained and qualified installer using the proper
tools, techniques, and design expertise. Not all options are available with every boiler.
43
Figure D-W2: Recommended Water Piping for Zone Valve Zoned heating Systems
APPENDIX D – System Piping (continued)
44
Figure D-W3: Recommended Water Piping for Circulator Zoned heating Systems
APPENDIX D – System Piping (continued)
APPENDIX E – FILLING ThE SYSTEM AND ChECkING FOR LEAkS
Fill entire heating system with water and vent air from system. Use the following procedure on a
Series Loop or multi-zoned system installed as per the figure below. Remove air from system when filling.
1. Close full port ball valve located between
vertical hose bib and air scoop in boiler
supply piping (see Appendix D – System
Piping.
11. Open the zone valve or shut-off valve
for the next zone to be purged. Repeat
the previous steps until all zones have
been purged. At completion, open all
zone valves or shut-off valves.
2. Isolate all zones by closing zone valves or
shut-off valves in supply and return of each
zone(s).
12. Close hose bib, continue filling the system
until the pressure gauge reads 12 psi.
Close fill valve.
3. Attach a hose to the vertical hose bib located
prior to the full port ball valve in the system
supply piping.
i
Terminate hose in five-gallon bucket at
a suitable floor drain or outdoor area.
4. Starting with one circuit at a time, open zone
valve or shut-off valve in system supply and
return piping.
5. Open hose bib.
6. Open fill valve (Make-up water line should
be located directly after full port ball valve in
system supply piping between air scoop and
expansion tank).
7. Allow water to overflow from bucket until
discharge from hose is bubble free for 30
seconds.
8. Close hose bib, continue filling the system
until the pressure gauge reads 12 psi. Close
fill valve.
9. Starting with the first convector in the loop,
open air vent to purge air until a steady
stream of water flows into container for
approximately 5 seconds. Proceed to next
convector and repeat procedure until all
convectors in the loop are purged of air
10. Close the opened zone valve or shut-
off valve for the zone being purged of
air.
i
If make-up water line is equipped
with pressure reducing valve, system
will automatically fill to 12 psi. Follow fill
valve manufacturer’s instructions.
13. Open isolation valve in boiler supply piping.
14. Remove hose from hose bib.
Confirm that the boiler and system have no
water leaks.
1. Check Rating Label for maximum operating
pressure of this boiler. Never exceed this
pressure during leak test. Do not plug or
change pressure relief valve. Perform visual
inspection for leaks or weeping joints after
initial fill and during boiler warm-up period.
Repair all leaks before placing boiler into
permanent operation.
2. If it is required to perform a long-term
pressure leak test of the hydronic system,
the boiler should first be isolated to avoid
a pressure loss due to the escape of air
trapped in the boiler.
3. To perform a long-term pressure test
including the boiler, all trapped air must
be removed from the boiler and system as
prescribed above. A loss of pressure during
such a test, with no visible leakage, is an
indication that the boiler or system contained
trapped air.
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APPENDIX F – ADjUSTING GAS INPUT RATE
Check Manifold Pressure:
1. Note the rated manifold gas pressure listed
on the boiler’s rating label.
2. Connect Manometer to manifold pressure
tapping on Gas Valve (Figure F-1).
3. Light main burners by adjusting thermostat
to highest setting.
F-2
DO NOT EXCEED the boiler’s rated gas
input.
6. Recheck Main Burner Flame.
Leak Test Gas Piping:
F-1
4. Gas valve has step-opening regulator,
which initially opens at a lower manifold
pressure and then steps to full pressure after
approximately 30 seconds. Check manifold
pressure after step has occurred.
5. If required, adjust gas manifold pressure to
the rated setting by turning the gas valves
adjustment screw clockwise to increase
manifold pressure or counterclockwise to
decrease manifold pressure (Figure F-2).
Several turns may be required.
Do not force the adjustment screw.
46
THE BOILER AND ITS GAS
CONNECTIONS must be leak tested and
leak free before placing boiler in operation.
FOR LEAK TESTING OVER ½ PSIG,
disconnect boiler and its individual shut-off
valve from gas supply piping.
1. For testing at ½ psig or less, isolate boiler
from gas supply piping by closing boiler’s
individual manual shut-off valve.
2. Check for gas leaks in all piping joints,
valves, and fittings using a non-corrosive
leak detection solution or an electronic leak
detector.
3. Repair any leaks.
APPENDIX G – ChECkING DRAFT AND COMBUSTION
CHECK DRAFT (GAS BOILERS WITH DRAFT HOODS)
6. After 5 minutes of main burner operation,
1. Insofar as is practical, close all doors and
test for spillage at the draft hood relief
opening, using a lighted match, candle,
cigarette, etc.
windows in the building.
2. Turn on all appliances not connected to the
same venting system as the boiler being
checked.
7. Repeat this test for each appliance
connected to the common venting system.
3. Turn on all exhaust fans (such as range
8. If any appliance does not vent properly, per
hoods and bathroom exhausts) to their
maximum speed. Do not turn on any
summer exhaust fans.
the above test, make corrections, so that the
installation conforms to the National Fuel
Gas Code, NFPA 54/ANSI Z223.1, and/or
Installation Codes, CAN/CSA B149.1.
4. Close all fireplace dampers.
5. Operate the appliance being checked.
9. Return doors, windows, exhaust fans,
Follow lighting instructions.
fireplace dampers, and any other gasburning appliance to their previous condition
of use.
CHECK COMBUSTION
1. Use a flue gas analyzer that accurately
measures CO2, O2, CO, and flue gas
temperature.
2. Operate the boiler at its rated (high fire)
input.
3. With the analyzer, check the CO2 (or O2),
CO and temperature of the flue gases
exiting the boiler.
4. Confirm that the measured CO2 (or O2)
matches the required CO2 (or O2) specified
for the boiler.
If CO2, O2, or CO fall outside of the
range specified for the boiler, review the
installation and startup instructions and make any
necessary adjustments to the boiler or associated
venting
or piping systems.
.
Note the gross flue gas temperature for
future reference. Significant changes in
flue gas temperature can indicate changes
in the boiler’s operating efficiency.
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APPENDIX h – OPERATION
Boiler Sequence of Operation
NORMAL OPERATION
1. The boiler is equipped with an Intelligent
Hydronic Control (control). This control
replaces the traditional separate ignition
control, high limit switch and circulator relay
and adds energy saving thermal purge
features. Energy is saved by starting the
circulator and delaying the burner start when
there is residual heat available in the boiler.
2. The boiler’s sequence of operation is shown
in Table 4.
Table 4: Sequence of Operation
Status Codes displayed in STA Mode
Status
STA
Standby
(Burner off
Circulator off)
1
No call for heat detected
Circulator
Pre-purge
(burner off
circulator on)
1
Either condition is true:
a. Call for heat detected and boiler
temperature higher than operating
setpoint.
b. Call for heat detected and boiler
temperature higher than Start
Temperature (140°F default) and
Circulator Pre-purge Time has not
expired.
Self Test
17
Control internal checking
Drive Damper
Open
18
The damper is energized. The control
is waiting for the damper switch to
close. If the damper end switch
doesn't close within 60 seconds, the
control goes to STA 20
Pre-purge
4
Damper is open for a 2 second delay
Spark
6
The pilot fuel valve is open and
sparking is started.
Flame
Proving
7
The main fuel valve is open and flame
is being proven.
Running
8
The burner runs until the call for heat
is satisfied or the operating setpoint is
reached.
3. When the thermostat calls for heat the
control starts the system circulator and
the thermal purge (circulator Pre-purge
time) begins. If the time is completed or
boiler temperature is less than the Start
Temperature (140°F default) the start
sequence continues by energizing the vent
damper. Once the vent damper is fully open
the ignition sequence is started allowing gas
flow and ignition of the burners.
4. If the thermostat is not satisfied and the
operating setpoint is reached the system
circulator will continue to operate and the
burner will stop. When the boiler water
temperature drops below the setpoint less
the differential setting the burner will restart.
5. After the thermostat is satisfied the burner
and circulator are stopped and vent damper
is closed.
6. When an indirect water heater aquastat call
for heat is wired to the DHW input the control
starts the Domestic Hot Water circulator
and, if the boiler temperature is less than the
operating setpoint less differential, the vent
damper is energized without delay. Once
the vent damper is fully open, the ignition
sequence is started allowing gas flow and
ignition of the burners.
BOILER FAULT
In the event the boiler fails to start, the control
provides status information to help determine
the cause of the problem. Table 5 provides
a list of boiler status codes that are reported.
Refer to the Troubleshooting Section for more
information.
48
Description
Table 5: Sequence Fault
Status Codes displayed in STA Mode
STA
Description
Retry /
Recycle
Delay
10
If the burner fails to light off (no flame
signal), it waits 5 minutes and retries
or if the control loses flame signal
during running, it will wait 10 seconds
and then recycle.
Soft Lockout
13
System is shutdown and will restart
following a one hour enforced delay.
Hard Lockout
14
System is locked out. A manual or
power reset is required to be able to
light off again.
Limit Open
15
There is a call for heat from the
thermostat, but a Safety Limit is open.
Flame
Present Out
of Sequence
16
Flame signal is still present when
expected to be 0 (no flame).
Damper
Failed to
Open
20
Status
The damper is still energized and the
damper end switch has not closed.
APPENDIX I – IQ CONTROL SYSTEM
IQ Control System Overview
The “IQ Control System” consists of a control and
an IQ Option Panel with optional “plug in” cards:
• Fully integrates both factory and field
installed components, simplifying installation
and troubleshooting.
• Efficiently operates the entire boiler system
to save energy.
• Ensures adequate heat and supply of
domestic hot water.
• UL / CSA Listed or Recognized and tested
as part of a complete system.
• Communicate with other EnviraCom™
enabled components to provide a complete
system solution to maximize comfort and
energy efficiency.
Control: P/N 103660-01
The heart of IQ Control System is the Intelligent
Hydronic Control. The control replaces the
traditional separate ignition control, primary boiler
aquastat, as well as the fan and circulator relays.
The control stores two boiler supply temperature
setpoints in its memory; one setpoint is for the High
Limit Setting and the second is for the Operating
Setpoint.
When the optional Outdoor Air Reset Card is
installed in the IQ Option Panel, the Operating
Setpoint temperature is automatically adjusted
according to the outdoor temperature. For
example, as the outdoor temperature increases
the Operating Setpoint temperature is reduced
from the High Limit Setting to save energy
while improving home comfort. By better
matching boiler heat supply to actual home
heat demand, room air temperatures are more
closely maintained. In addition, when there is
a domestic hot water (DWH) heat request, the
Operating Setpoint temperature is automatically
adjusted to a DHW Setpoint to satisfy the DWH
heating requirements. When the Outdoor
Air Reset Card is not installed the Operating
Setpoint equals High Limit Setting.
IQ Option Panel: P/N 102291-01
The IQ Option Panel works together with the control to
provide an easy and convenient means to add factoryengineered auxiliary boiler control features. When
installed into the IQ Option Panel, IQ Option Cards
provide plug-'n-play high temperature limit, low water
cut-off and outdoor reset controls. A separate 3-digit
LED readout displays settings, status and diagnostic
information for all installed IQ Option Cards making
them simpler and functionally superior to stand alone
auxiliary controls. IQ Option Cards are available for
the following features:
• Outdoor Air Reset with Domestic Hot Water
Demand
• Auxiliary High Temperature Limit (available in
auto reset or manual reset versions)
• Low Water Cut-off (available in auto reset or
manual reset versions)
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APPENDIX I – IQ Control System (continued)
IQ Outdoor Reset Option Card: P/N 102723-01
Installing the IQ Outdoor Reset Option Card is the simplest way to maximize
the efficiency of any boiler. The IQ Outdoor Reset Card is a microprocessorbased control that regulates the water temperature of the heating system
based on the outdoor temperature. By modulating the water temperature of
the heating system, the boiler equipped with an IQ Outdoor Reset Option Card
will deliver annual fuel savings up to 16%, while increasing home comfort. The
IQ Outdoor Reset Option Card is simple to set up yet it includes a powerful list
of features that can be customized for any job.
IQ Oil Boiler Control Operating Setpoint is normally set to the High Limit Setpoint. However, when an IQ
Outdoor Reset Option Card is installed the Operating Setpoint may be reduced to the outdoor reset or
Domestic Hot Water (DHW) Setpoint. When an IQ Outdoor Reset Option Card is added the following user
defined setpoints are available:
• High Limit Setpoint - The High Limit becomes the upper limit for the operating setpoint. The
operating setpoint can not be set higher than this value. The High Limit is set to protect the boiler
and hydronic system from excessive temperature.
• DHW Setpoint - The Operating Setpoint is set to the DHW Setpoint when the Control or Outdoor
Reset Option Card DHW input is energized. This setpoint is set equal to the Indirect Water Heater
manufacturer's recommended water temperature.
• High Boiler Water Temperature - The High Boiler Water Temperature (also known as the "Boiler
Water Design Temperature") setpoint is set to the lowest boiler water temperature that will heat
the home on the home's design day. This adjustment typically depends on the type and quantity
radiation (heating element) installed in the home.
Kit Includes:
• IQ Outdoor Reset Option Card
• Outdoor temperature sensor w/mounting bracket & 60” lead
• Instructions
Major Features:
• Selectable DHWP
• Selectable/adjustable DHWP protection
• Selectable/adjustable boost feature
• Simple adjustment of reset curve
IQ LWCO Option Card (Auto Reset): P/N 102711-01
IQ LWCO Option Card (Manual Reset): P/N 102714-01
IQ LWCO Option Cards add a low water cut-off function to boilers. LWCO
Option Cards plug into the IQ Option Panel and connect to the system-mounted
sensor with a single-wire connection. IQ LWCO Option Cards feature built-in
diagnostics, probe signal strength display, and include a “Test” and “Reset”
feature in compliance with UL 353 and CSA 22.2 for CSD-1 Compliance in US
and Canada.
Kit Includes:
• IQ LWCO Option Card
• 3/4” NPT level sensor
• 36” wire sensor connector
• Instructions
50
Major Features:
• UL 353 approved
• Displays signal strength
• Warns when probe cleaning required
APPENDIX I – IQ Control System (continued)
IQ Hi Limit Option Card (Auto Reset): P/N 102717-01
IQ Hi Limit Option Card (Manual Reset): P/N 102720-01
IQ High Limit Option Cards add auxiliary temperature limit-rated controls
to boilers. High Limit Option Cards plug into the IQ Option Panel and
connect to a system-mounted probe with a single Molex connection. IQ
High Limit Option Cards feature an adjustable set point and differential, as
well as built-in diagnostics. Manual Reset models are UL 353 for CSD-1
Compliance in US and Canada.
Kit Includes:
• High Limit Option Card
• Limit-rated probe with 36” lead
• 1/2” well
• Probe retainer clip
• Instructions
Major Features:
• UL 353 approved
• Error code LED and display
• Temperature display
• Electronic adjustment of high limit and differential
3.5” Touch Screen Display: P/N 102728-01
The Display Kit provides a 3.5” LCD multi-color Touch Screen display for
mounting in the plastic “hood” above the front door of any boiler. The Display Kit
communicates with the IQ Boiler Control and all installed IQ Option Cards. All boiler
settings, status, and errors are displayed in full text on the bright, backlit display. All
adjustments are password protected to prevent unauthorized access. Display will
turn red and flash in the event of a boiler error or lock-out. Display features full-text
explanations of all features and settings, as well as help screens with diagnostics
and troubleshooting information.
• Full English descriptive alarm
Kit Includes:
Major Features:
displays with Recommended
• 3/4” Multi-color LCD touch screen • Fully assembled kit requires only 4
• Display software
mounting screws and a single Molex Corrective Action
• Real time trend displays
• Enviracom gateway
type connection
• Wiring harness connectors
• Adjusts all Outdoor Reset IQ Option • Extensive Help screens to
aid understanding of
• Mounting bracket
Card parameters with graphics and
terminology and setup
• Instructions
help information screens
EnviraCOM Thermostats:
Connected thermostats provide a red LED and
display the IQ Oil Boiler Control, Primary Control
or IQ Option Card Error Codes. A home owner is
alerted to a problem even before the water is cold.
When an Outdoor Reset card is installed with a
setback thermostat, “leave” or “sleep” modes are
used to shifts the reset curve to save energy while
the home is in a reduced room temperature mode.
Honeywell VisionPro IAQ Setback Thermostat
(Honeywell P/N TH942lc1004)
51
APPENDIX I – IQ Control System (continued)
System Parts List
Optional Components
Part Number
Item Description
102723-01
Outside Reset IQ Option Card, Domestic Hot Water Priority, for use with Option Control Panel, with Outside
Air Temperature Sensor with 60 inch lead, Instructions, Unit Pack. No additional pipe fittings required.
102294-01
Outdoor Reset IQ Option Card, Domestic Hot Water Priority, for use with IQ Option Panel, less Sensor.
102946-01
Outdoor Air Temperature Sensor, 10k ohm, 60 inch lead.
102711-01
LWCO IQ Option Card kit, Hot Water LF Module, Automatic Reset, for use with Option Control Panel, with
¾ inch NPT Probe, Instructions, Unit Pack. Additional pipe fittings are required.
102714-01
LWCO IQ Option Card kit, Hot Water LF Module, Manual Reset, for use with Option Control Panel, with ¾ inch
NPT Probe, Instructions, Unit Pack. Additional pipe fittings are required.
102301-01
LWCO IQ Option Card, Hot Water LF Module, Automatic Reset, for use with IQ Option Panel, less Probe.
102302-01
LWCO IQ Option Card, Hot Water LF Module, Manual Reset, for use with IQ Option Panel, less Probe.
102305-01
LWCO ¾ inch NPT Probe.
102720-01
Aquastat IQ Option Card, 130-220°F, Manual Reset for use with Option Control Panel, Temperature Sensor
with 36 inch lead, Well, Sensor Clip, Instructions, Unit Pack. Additional pipe fittings are required.
102717-01
Aquastat, IQ Option Card, 130-220°F, 15°F Adjustable Differential, Auto Reset, for use with Option Control
Panel, Temperature Sensor with 36 inch lead, Well, Sensor Clip, Instructions, Unit Pack. Additional pipe
fittings are required.
102292-01
Aquastat IQ Option Card, 130-220°F, Manual Reset for use with IQ Option Panel, less well, Less Sensor.
102293-01
Aquastat, IQ Option Card, 130-220°F, 15°F Adjustable Differential, Auto Reset, for use with IQ Option Panel,
less Well, less Sensor.
102295-01
Limit Rated Temperature Sensor, 36 inch length.
102296-01
Limit Rated Temperature Sensor, 48 inch length.
102728-01
IQ LCD Display, Boiler Exterior Mounted, STN Monochrome, White/Red backlight, 5Vdc Power Supply,
RS422 (RS485) Communication, Pure Black Bezel with Gateway, Wire Harness, Mounting Bracket, Logo Plate
and Instructions.
102725-01
IQ LCD Display, Boiler Exterior Mounted, STN Monochrome, White/Red backlight, 5Vdc Power Supply,
RS422 (RS485) Communication, Pure Black Bezel.
102495-01
Enviracom/Modbus RS422 Gateway and 5Vdc Power Supply for Communication Between the IQ Controls and
LCD Display, 24 Vac Power Supply Input.
Additional Information List
Aquastat IQ Option Card Instruction Sheet - part number 103589-01
Outdoor Reset IQ Option Card Instruction Sheet - part number 103590-01
Low Water Cut-off IQ Option Card Instruction Sheet - part number 103591-01
LCD Display Kit - part number 103592-01
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SERVICE RECORD
DATE
SERVICE PERFORMED
53
SERVICE RECORD
DATE
54
SERVICE PERFORMED
SERVICE RECORD
DATE
SERVICE PERFORMED
55
U.S. Boiler Company, Inc.
P.O. Box 3020
Lancaster, PA 17604
1-888-432-8887
www.usboiler.net
56