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Utica Boilers UB90-100 Operation and Installation Manual

1. 2 2 1 66 6 6 42 Differential Air Pressure Switch Check All 5 1 1 1 0 7 45 Negative Pressure Switch Check MI FOU M NEUE 46 Maintenance And Cleaning PRE ES dd 47 TOPPEN 49 Troubleshooting High Limit Control And LWCO 2 2 2 50 Troubleshooting Hydrostat High Limit Control And LWCO 7 1202 2 02 51 Appendix A Water Quality Water Treatment And Freeze Protection 58 Installation And Check Out Certificate 2 20207 4 2 01 62 Introduction e This appliance is a gas fired direct vent hot water boiler e Induced draft fan draws in outside combustion with cast aluminum boiler sections air takes cooler flue gases from boiler unit and e The heating system water absorbs large amounts of provides positive removal of flue gases from the heat from the cast aluminum heat exchanger cooling building through readily available PVC CPVC and PP flue gases and causing condensation Polypropylene pipes e Sealed combustion premix gas burner and low flame e These low pressure gas fired hot water boilers are temperature means reduced CO and NOx emissions design certified by CSA Intern
2. e Connected to suitable combustion air intake piping system to supply correct amounts of fresh outdoor air for combustion refer to Combustion Air and Vent Pipe on page 22 for details e Connected to suitable venting system to remove hazardous products of gas combustion refer to Combustion Air and Vent Pipe on page 22 for details e Connected to suitable hot water heating system e Supplied with suitable electrical supply for all boiler motors and controls e Connected to properly located thermostat or operating control Not included with boiler e Placed on level surface e Condensate drain line must be pitched down to floor drain or external condensate pump with reservoir at per foot wood frame or blocks may be used to raise boiler Minimum Clearances Combustible Construction 4 1 26MM 5 2 Boiler 3 11 26MM 7 280MM cx D 1 26MM BOILER INSTALLATION Locating The Boiler Combustion Air And Vent Pipe Requirements 1 Place crated boiler as close to selected location as This boiler requires a dedicated direct vent system In a possible and un crate boiler Boiler may be moved into direct vent system all air for combustion is taken directly position with appliance dolly or 2 wheel hand truck from outside atmosphere and all flue products are Insert dolly or hand truck under left hand side of discharged to outside atmosphere boil
3. ANSI ASTM D2241 NOT APPROVED FOR CANADA ANSI ASTM D2661 Vent Pipe SDR 21 amp SDR 26 PVC and Fittings ABS DWV Schedule 40ABS ANSI ASTM F628 PP Polypropylene Pipe and Components ULC S636 08 ANSI ASTM 02564 CPVC ANSI ASTM F493 Schedule 40 ABS ANSI ASTM 02235 e is approved vent manufacturer in Canada listed to ULC S636 CJ Pipe Cement Primer IPEX System 636 Cements and Primers are approved in Canada listed to ULC S636 Use of cellular core PVC ASTM F891 cellular core CPVC or Radel Polyphenolsulfone in venting systems shall be prohibited NOTICE Use of PP piping follow manufacture s installation instructions and requirements 2 Canadian installations First 3 feet 900mm of venting must be readily available for visual inspection Specified primers and glues of certified vent system must be from single manufacturer and not intermixed with other manufacturer s vent system parts Components of the certified system must not be interchanged with other vent systems or unlisted pipe and or fittings NOTI CE Transition from 2 pipe to 3 pipe must be made in vertical run 3 Boiler combustion air and vent piping connections are sized for 2 pipe Any pipe size change to 3 must be made outside of boiler casing in vertical run of pipe to allow for proper drainage of vent condensate Due to potential for flue gas temperatures over 155
4. control well on top of front boiler section at hot water outlet Control is tied in with IBC and factory set at 190 F water temperature High limit set point is field adjustable and may be set between 100 F and 190 F Field set point adjustment for each installation depends on heating system requirements Differentials are automatic vary based on control settings and boiler temperature Refer to limit manufacturer instructions provided with limit control Figure 23 Indicator Lights 34 A Setting High Limit To adjust turn HI TEMP dial until desired setting is displayed Overall range of High limit setting is from 100 F to 220 F 82 C to 104 C High limit HL on limit control is factory set at 190 F Temperature setting may be varied to suit requirements of installation Differentials are automatic and will vary based on control settings and boiler temperature See Figure 23 B Setting Economy Feature e Economy feature is factory set for 1 zone heating system To adjust turn ECONOMY dial until number displayed equals number of heating zones Do not include indirect water heaters in number of heating zones Economy feature conserves fuel by reducing boiler temperature If heating system is unable to supply needed heat to house ECONOMY dial should be turned to lower setting example in a three zone house turn dial to 2 or 1 Conversely if boiler provides adequate heat added
5. BLACK 120 VOLTS NEUTRAL 60 HZ 1 GROUND POWER SUPPLY FIELD WIRING CONNECTIONS 31 ELECTRICAL WIRING Figure 21 Wiring Schematic Q A X lt X D Q gt W O gt must replaced must be replaced with type 105 C Thermoplastic wire or its equivalent NOISIA38 LETOTOOPZ N d HNALYTIVLSNIT SVE YATIVISNI Ad 39V110A YNSLVTWLSNI 39V110A 30 YSTIVLSNI SOVLIOA ANN INISNT SDVLIOA SVE 0197 4 A8 399110A MOT 39V110A 30 AHOLOV Ad 359 v18y9 SNIHIM NYYDVIG avia 9 3ATVA 8 HOLINSI 4 4 5 S1H9I1301V9IONI 0 AYVON W3NHOJSNYHL OWA JILSONSVIQ HOLYTNIHID 00091 0938 1O81NOO 331108 d31VH931NI LOH aunssaud HILIMS HOLIMS HOLIMS 57900 JUNLYVANEL 3wuniruvaw3i 52706 9 001 06 ONILSVO yamo ATNO SYOLONGNOD 834402 ISN 310N NOIL NAF Y37109 L 3NI1 APZ 1V3H TWYLNI3D 32 ELECTRICAL WIRING Figure 22 Ladder Diagram for Figure 22 LADDER DIAGRAM UT 1013 BOILER CONTROL PT 2 PRA LO PRESSURE s 53
6. Connector PRESSURE SWITCH CONNECTS BOILER STATUS NEGATIVE PRESSURE W C 0 50 Setpoint for Models 100 8 075 Running Without Blockage Running With Blockage Less Negative than Setpoint More than Setpoint OPEN Models 075 and 100 Negative Pressure Switch gt gt Differential Air Pressure Switch lt gt E Red Transparent Vinyl Tubing Air Inlet Sution Port vinyl Cap All pressure switch tubing is clear vinyl tubing unless otherwise noted Inclined Manometer Differential Pressure Gauge MAINTENANCE AND CLEANING Maintenance As Outlined Below Can Be Performed By Owner Unless Otherwise Noted The acidic nature of flue gasses condensing on aluminum boiler sections may cause formation of aluminum oxide This oxide formation is normal is generally uniform throughout boiler sections and represents negligible mass of aluminum that is consumed by oxidation during life of the boiler If left unchecked this buildup may eventually cause blockage of flue gas passages in boiler sections reducing efficiency and ultimately shutting down the boiler due to lack of combustion air flow Regular service and maintenance by a qualified service agency must be performed to assure safe trouble free operation and maximum efficiency Beginning Of Each Heating Season 1 Annual service call by qualified service agen
7. FOR CORRECT SIZE IS GAS ORIFICE CLEAR OF BLOCKAGE YES DOES THE UNIT USE LP GAS NO ADJUST RATE AS DESCRIBED IN THE CHECK OUT PROCEDURE AND ADJUSTMENT SECTION OF THE MANUAL NO REPLACE WITH CORRECT AIR BAFFLE REPLACE BURNER YES REPLACE IBC NO BOILER OFF ON HIGH LIMIT IS BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT ARE HI LIMIT ACTUAL BOILER WATER TEMP GREATER THAN HI LIMIT SET POINT MINUS CONTROL DIFFERENTIAL AQUASTAT CONTACTS CLOSED YES SEE TROUBLESHOOTING PATH 2 ABOVE REPLACE AQUASTAT ARE CONTACTS OPEN REPLACE THERMOSTAT YES REPLACE IBC REMOVE WIRING HARNESS CONNECTION CN9 FROM GAS CONTROL DOES GAS CONTROL CLOSE YES NO REPLACE IBC 57 GAS CONTROL APPENDIX WATER QUALITY WATER TREATMENT AND FREEZE PROTECTION Aluminum Series High Efficiency Gas Fired Boiler DIELECTRIC ISOLATION amp ANTIFREEZE PROTECTION Follow these instructions to prevent damage to boiler s heat exchanger caused by inadequate dielectric isolation incorrect water treatment or antifreeze application Failure to comply could result in death or serious injury Install boiler so gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement etc DIELECTRIC ISOLATION Two 2 1 1 4 X 1 1 4 Female t
8. 2 Cleaning Flue passages between boiler sections A Any buildup of sediment or aluminum oxide white powdery or flaky substance in flue passages must be cleaned as follows Remove jacket front and top panels Disconnect condensate drain line from barbed fitting on bottom of boiler Keep open end of drain line above water level in condensate trap to prevent trap from draining Disconnect pressure switch hose from barbed fitting on gas valve Disconnect 172 x 2 flexible coupling from air inlet Disconnect air by pass 1 transparent vinyl tube from bottom of mixer Remove air baffle from 7 x 2 flexible coupling and clean air baffle if necessary Refer to repair parts diagram mixer and pressure switch assembly Confirm manual gas valve is closed and disconnect gas line to gas valve at union Disconnect wires to gas valve and igniter Loosen but do not remove five 5 nuts attaching mixer assembly to boiler Remove two 2 igniter screws and remove igniter Remove five 5 nuts and remove mixer assembly Remove burner and mixer gasket Aluminum oxide deposits are water soluble and may be rinsed away with spraying or running water Before rinsing connect 72 I D hose to barbed fitting on bottom of boiler and run hose to bucket or drain After rinsing remove any remaining loosened sediment using shop vacuum with snorkel attachment Inspect burner for any foreign matter in flame ports or inside burner Any foreign matt
9. 3 COMBUSTION AIR INTAKE PIPING SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS 2 CPVC COUPLING FURNISHED 2 CPVC VENT PIPING FURNISHED 3 76 2mm Diameter Vent And Combustion Air I ntake Piping 92 ft 28m maximum total equivalent length for 90 100 models TRANSITION FITTING SEDET S DEIN E 15 ft 4 6m minimum total equivalent length VERTICAL RUN 1 52m for 90 100 models 112 ft 34m maximum total equivalent length for 90 50 and 90 75 models 20 ft 6m minimum total equivalent length for 90 50 and 90 75 models EXHAUST ELBOW FURNISHED 27 GAS SUPPLY PIPING WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow gas supplier s instructions e If you cannot reach your gas supplier call the fire department Check Gas Supply Gas pipe to your boiler must be correct size for length of run and for total Btu per hour input of all gas utilization equipment connected to it See Table 7 Page 29 Boiler and its individual shutoff valve must be disconnected from gas supply piping system during any system pressure testing at test pressures in excess of V psig 3 5kpa Boiler must be isolated from gas supply piping system by closing its individual manual shutoff valve during any pressure testing of gas supply piping system a
10. AND 24V THERMOSTAT BOILER WATER TEMPERATURE AND PRESSURE GAUGE 36 1 4 921mm 32 1 4 FRONT PANEL DOOR PULL 10 5 8 270mm ALTERNATE BOILER LEVERING WATER RETURN LEFT SIDE FRONT 17 3 8 441mm 2 5 8 321mm GAS SUPPLY 1 2 NPT COMBUSTION AIR INTAKE PIPE 2 PVC 39 5 8 1006 mm 38 1 4 33 972mm 838mm 23 1 8 587mm 40 5 7 8 149 CONDENSATE DRAIN 53 07 FITTING 1 2 PVC 146mm 714mm RIGHT SIDE BACK NOTICE Draft inducer blower may be i BOILER WATER SUPPLY rotated 90 180 to oreng NET CONNECTIONS x 3 connection towards right IDE BOILER S side or rear VENT CONNECTION 2 CPVC INTRODUCTION Digicel RETIRO E 2 O ON 3 NNN TG 4 Boiler Ratings amp Capacities Ne 5 Boilers For Use At High Altitude United States Installations 6 Before Installing The BOW PA 8 ETNE 9 Near Boer PIDIN Eom 11 Combustion ANN PN 22 Gas PN 28 iHi RETE mo 30 Controls 0 SEE EE 34 SL _ 36 JE ENN 37 Detailed Sequence Of Operation Lagan seeks UR o ws d 38 Verification Procedure And
11. CONTACTS OPEN NO 3 IF THE ANSWER IS NO CHOOSE THE APPROPRIATE PATH 1 42 OR 3 BASED ON SYMPTOMS SHOWN RUNS SMOOTHLY FOR ABOUT 6 SECONDS THEN SHUTS OFF INDICATES POOR FLAME SIGNAL CHECK IGNITER SENSOR POSITION TIP SHOULD BE SLANTED TOWARDS BURNER CHECK FLAME SIGNAL gt 0 6uA CONSULT BOILER MFGR FOR SPECIFIC INSTRUCTIONS REQUIRES SPECIAL TOOLS CLEAN MIXER AND BURNER PER MAINTENANCE AND CLEANING INSTRUCTIONS REPLACE BURNER RESTORE IGNITER SENSOR TO CORRECT POSITION DO NOT RELOCATE YES OXIDE COATING ON IGNITER PREVENTING FLAME SIGNAL REPLACE IGNITER SENOR YES REPLACE IBC CHART 6 CHART 6 CHART 6 Troubleshooting Chart 6 CHART 5 YES 8 BELOW ROOM TEMPERATURE END CALL FOR HEAT YES DOES CIRCULATOR PUMP STOP YES VALE LIGHT IS OFF DOES DRAFT BLOWER STOP AFTER 30 SECOND POST PURGE YES SYSTEM OK NO TROUBLESHOOTING CHART 5 CHART 5 NO 3 NO 2 RUNS FOR 25 50 SECONDS THEN TURNS OFF CHECK FIRING RATE OF UNIT IS UNIT FIRING AT THE CORRECT RATE YES CHECK BURNER FOR ANY DETERIORATION IN THE FLAME PORTS ARE BURNER PORTS IN GOOD CONDITION YES CHECK FLAME SIGNAL gt 0 6uA CONSULT BOILER MFGR FOR SPECIFIC INSTRUCTIONS REQUIRES SPECIFIC TOOLS REPLACE GAS CONTROL YES CHECK GAS ORFICICE SIZE IS GAS ORIFICE SIZE CORRECT CHECK REPAIR PARTS LIST
12. The igniter also serves as means for proving main burner flame by flame rectification In the event of a lack of flame signal on three 3 consecutive trials for ignition IBC will flash the VALVE light when locked out due to failed ignition 5 Draft Inducer Temperature Safety Switch Draft Inducer Temperature Safety Switch is a disc thermostat 1809F setpoint located on induced draft fan outlet port Switch protects inducer and vent pipe from potential high temperature condition for discharging flue gases Condition would typically be result of higher high limit control setting or over firing Temperature safety switch automatically resets when the vent temperature decreases 159F switch differential 6 Casting Temperature Safety Switch In event of lack of or loss of water in boiler Casting Temperature Safety Switch 300 F setpoint installed on top of the aluminum boiler section shuts off boiler by shutting off power to Integrated Boiler Control IBC This fault requires manual reset of casting temperature safety switch to restart the boiler Verify that boiler is properly filled with water before resetting this switch Never run cold water into a hot empty boiler 35 7 Differential Pressure Air Proving Switch Blocked Vent Safety Shutoff Differential pressure switch monitors air flow by sensing differential pressure measured in inches of water w c Pressure switch contacts close when draft inducer is running
13. While cement is still wet insert pipe into socket with figures 13 and 14 page 25 1 4 turn twist Be sure pipe is fully inserted into fitting socket Figure 12 Roof Vent Intake Terminations 15 MAXIMUM 8 203mm Minimum U lt Vertical Separation pu Between Combustion Air Intake and Vent 12 305mm US 18 458mm Canada S pu AIR INTAKE s Minimum Above Anticipated Snow Line Se COMBUSTION LP AIR 24 COMBUSTION AIR VENT PIPE 2 Less Than 12 Clearance AIR INTAKE AND N N OF VENT EAR ABOVE HIGHEST OW LEVEL OR GRADE Figure 14 Side Wall Vent Intake Terminations 12 Or More Clearance Above Grade OVERH ANG 12 Or More Clearance m MIN UM IN TAIN 12 M EAR ABOVE HIGHEST OW LEVEL OR GRADE 25 COMBUSTI ON AIR AND VENT PIPE Figure 15 Concentric Vent Terminations 1 25 4mm Maximum 1 Combustion Air 1 25 4 Maximum 41712 305mm Minimum ERU 36 0 5m Minimum crm See Note Below 2 Maintain US T2 305mm Canada 18 457mm clearance above highest anticipated snow level or grade Combustion Air Must be less than 4 102mm or greater than 24 610mm Horizontal distance between end bells of each air intake to prevent flue gas recirculation Figure 16 Con
14. on page 62 43 VERIFICATION PROCEDURE AND AD USTMENT Figure 25 Manifold Pressure Measurement Detail Following steps and diagram indicate location of the Refer to Differential Air Pressure Switch Check all connection points required to measure manifold pressure models on page 45 when reading manifold pressure Manifold pressure may be measured using a U Tube When measurement is complete disconnect U Tube Manometer or Differential Pressure Gauge Diagram shows Manometer or Differential Pressure Gauge Be sure to connection of both measuring devices Only ONE DEVICE IS reinstall plug using appropriate pipe thread sealant REQUIRED to measure manifold pressure approved for use with natural and liquefied Petroleum Remove plug Install appropriate barbed fitting and connect gases pressure side line from U Tube Manometer or Differential Pressure Gauge PRESSURE REGULATOR ADJUSTMENT UNDER COVER SCREW GAS VALVE VENT OUTLET PRESSURE TAP 1 8 PLUG CROSS CONNECTOR W CAP TO PRESSURE SWITCH PRESSURE WHITE TRANSPARENT VINYL TUBING EE REFERENCE PRESSURE DIFFERENTIAL PRESSURE U TUBE GAUGE MANOMETER Figure 26 Gas Valve PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW WIRING TERMINALS 2 N OTI C E VR8205 Regulator cover screw must be installed at all times OUTLET PRESSURE INLET PRESSURE TAP unless adjusting manifold pressure Firing rate and TAP manifold pressure must onl
15. some gas is heavier than air and will settle to the floor e If you cannot reach your gas supplier call the fire department Use only your hand to turn the gas shutoff To Turn Off Gas To Appliance valve Never use tools If valve will not turn 1 Setthe thermostat to lowest setting by hand do not try to repair it call a qualified 2 service technician Force or attempted repair may result in fire or explosion Turn off all electric power to the appliance if service is to be preformed 3 Remove the front jacket panel Do not use this appliance if any part has 4 Turn gas control knob clockwise W to OFF been under water Immediately call a qualified 5 Replace the front jacket panel service technician to inspect appliance and to replace any part of control system and any gas control which has been under water Stop Read Safety information above 1 Set thermostat to lowest setting 2 Turn off all electric power to the appliance 3 This appliance is equipped with an ignition device which automatically lights the burner DO NOT try to light the burner by hand Figure 24 Gas Valve 4 Remove the front jacket panel Turn the gas control knob clockwise to OFF 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go on to next step 7 Turn the gas control knob cou
16. 0 Maintain water hardness below 7 grains hardness Filing with chlorinated potable water is acceptable DO NOT fill boiler with water containing chlorine in excess of 100 ppm DO NOT use inhibitors or other additives that are not listed in this addendum Consult local water treatment specialist for recommendations if any of above requirements is outside stated ranges 59 Eliminate System Leaks Continuous addition of make up water will constantly add oxygen to system Eliminate all system leaks All system leaks must be repaired immediately DO NOT use stop leak compounds Leaks in threaded connections in aluminum boiler sections must be repaired immediately Aluminum threads will not seal themselves Verify expansion tank is operational and properly sized Undersized expansion tanks cause relief valve weeping and substantial make up water addition Operation of this boiler in system containing significant amounts of dissolved oxygen can cause severe heat exchanger corrosion damage This boiler is not designed for use in systems containing regular additions of make up water Regular additions of make up water may cause severe heat exchanger damage System leaks may not always be visible An unseen system leak will become obvious if boiler pressure decreases when make up valve is closed This boiler is designed for closed loop hydronic heat system ONLY This boiler is not suitable for natural gravity type installations or
17. 1050 Womamue 10 1 8 7 9 7 lt 100 ppm BOILERS AT HIGH ALTITUDE UNITED STATES INSTALLATIONS Model 90 75 propane LP units only at altitudes above 5 000 ft install 90 75 High Altitude Orifice Kit 550002629 For all other altitudes use sea level orifice Table 3 PROPANE GAS MODEL 90 50 Settings 2300 2350 2400 2450 2500 Nomalnpt MBH 30 10 0 11 1 CO lt 100 ppm MODEL 90 75 Settings 2300 2350 2400 2450 2500 Nommallnput MBH 75 10 0 11 1 CO lt 100 ppm For model 90 75 Propane units only at altitudes above 5 000 ft install 90 75 High Altitude Orifice Kit 4550002629 For all other altitudes use sea level orifice MODEL 90 100 ea Settings 2300 2350 2400 2450 2500 Normalinput MBH 10 gt 10 0 11 1 CO lt 100 ppm 10 BEFORE INSTALLING THE BOILER Boiler is equipped residential installations If used for commercial applications any additional code requirements must be adhered to for installation This may require additional controls including but not limited to an additional low water cut off a manual reset high temperature limit and wiring and or piping modifications Before servicing boiler allow boiler to cool Shut off electricity and gas supply connected to boiler prior to servicing Inspect gas line for leaks Verify
18. Closed switch indicates there is adequate air flow for combustion Pressure switch shuts off main burner if differential pressure is inadequate due to blocked vent pipe blocked air intake blocked boiler sections or blocked draft inducer If pressure switch does not close within 5 minutes of blower being turned on control locks out with PURGE light flashing to indicate pressure switch fault 8 Draft Inducer Draft inducer blower provides means for pulling combustion air into and through the mixer burner flue ways of cast aluminum boiler sections and flue adapter before being discharged through vent piping to outdoors See applicable sections for proper sizing and installation of combustion air and vent piping in this manual 9 Circulator Pump Optional Every forced hot water system requires at least one circulating pump Circulating pump imparts the necessary energy to move water through closed loop supply and return piping systems terminal heating equipment i e finned tube radiators etc and back through boiler for reheating To provide required hot water flow rates circulator pump must be properly sized to overcome frictional losses usually measured in feet of water also referred to as pump head loss of supply and return piping systems and boiler The circulator pump is furnished for single zone or zone valve controlled heating system and should be located on downstream i e pumping away side of expansion tank
19. F first five 5 feet of vent pipe must be CPVC the remaining vent pipe can be PVC If any elbows are employed within the first 5 feet of vent they must be CPVC also Two 2 30 pieces of 2 CPVC pipe 212 piece of 2 CPVC pipe 2 CPVC elbow and 2 CPVC pipe coupling are furnished with the boiler No requirement when using PP pipe 4 Combustion air and vent piping lengths Table 5 Page 23 If vent exceeds 5 ft first 5 ft of vent piping run must be 2 CPVC Length of pipe is counted from boiler jacket air intake pipe or from vent pipe connector vent pipe Termination is not counted toward the Total Equivalent Length For elbows reduce maximum vent length as shown 2 90 elbow 2 ft per elbow 3 90 elbow 3 ft per elbow Example To add two 2 90 elbows to a 3 pipe for a 75 boiler Each elbow is 3 ft per 90 elbow for a total of 6 ft 1 elbow 3 ft 1 elbow 3 ft 6 equivalent ft of pipe Total additional pipe is then subtracted from maximum allowable pipe length to give new maximum length of 112 6 106 ft with two 2 90 elbows TOTAL EQUIVALENT LENGTH Original 112 ft max 6 equivalent ft for 2 elbows new 106 ft maximum length COMBUSTION AIR AND VENT PIPE Table 5 Combustion Air And Vent Piping Lengths Total Equivalent Length 2 PIPE MINIMUM x BOILER SIZE 100 VENTING VENTING 75 amp 50 2 FEET 26 FEET 20 FEET 112 FEET
20. For pump controlled system where there is a circulator for each zone circulator provided with boiler can work for one zone For more details on piping and circulators see Near Boiler Piping on page 11 10 Drain Valve Manual drain valve provides means of draining water in heating system including boiler and hot water supply and return piping systems installed above drain valve This drain valve is installed in 34 tapping at bottom of front boiler section Any piping installed below elevation of this drain valve will require additional drain valves to be installed at low points in piping systems in order to drain entire system START UP Water Quality Water Treatment and Freeze Protection see Appendix A Filling Boiler With Water And Purging Air For Systems With Diaphragm Type Expansion Tanks Refer to the appropriate diagrams Near Boiler Piping on page 11 for more information 1 Close all zone service valves on the supply and return piping Open the feed valve and fill boiler with water Make sure air vent is open Hold relief valve open until water runs air free for five seconds to rapidly bleed air from boiler then let the relief valve snap shut 2 Open the zone service valve on the supply pipe for the first zone Open the purge valve on the first zone Feed water will fill the zone pushing air out the purge valve Close the purge valve when the water runs air free Close the zone service valve 3 Repeat step 2
21. Haven MI 49417 www noblecompany com Tel 800 878 5788 Fax 231 799 8850 Rhomar Water Management Inc P O Box 229 Springfield MO 65801 www rhomarwater com Tel 800 543 5975 Fax 417 862 6410 Pro Tek 922 Inhibitor may be used to adjust the pH level of the hydronic system but on occasion may not resolve the pH issue In these cases flush the system and refill with untreated water and antifreeze suitable for aluminum heat exchangers as listed in this supplement Intercool NFP 30 40 50 AA Intercool RPH 15 Hercules Cryo tek 100 Al Hydronic Agencies Ltd Fernox North Distributor 15363 117 Avenue Edmonton AB T5M 3X4 Canada www hydronicagencies com Tel 780 452 8661 Fax 780 488 2304 Fernox www fernox com Interstate Chemical 2797 Freedland Road P O Box 1600 Hermitage PA 16148 0600 www interstatechemical com Tel 800 422 2436 Fax 724 981 8383 Hercules Chemical Company Inc 111 South Street Passaic NJ 07055 www herchem com Tel 800 221 9330 Fax 800 333 3456 This product may be used to adjust pH level of hydronic system but on occasion may not resolve pH issue In these cases it is recommended to flush system and refill with untreated water and new boiler manufacturer approved antifreeze suitable for Aluminum heat exchangers 61
22. LA SWITCH PT 1 32 Om ms Lo x GAS VALVE CIRCULATOR EGH PRB 3 CASTING BLOWER TEMP TEMP L c SWITCH SWITCH BLOWER 1 40 NAN HOT SURFACE 8 CENTRAL HEAT IGNITOR THERMOSTAT HYDROLEVEL 3000 CONTROL LEFT 2 CH LEFT 3 1 LEFT DHW LEFT 2 4 0 THERMOSTAT HIGH LIMIT TEMPERATURE SENSOR amp LWCO GROUND 90 100 amp 90 75 SERIES 4 Q PRESSURE SWITCH WIRING 120VAC 24VAC 50VA NEGATIVE DIFFERENTIAL TRANSFORMER 7000 bed pu SWITCH 1 _ 3 1 M 1 3 1 z L P3 3 33 CONTROLS AND ACCESSORIES 1 Integrated Boiler Control IBC Integrated Boiler Control IBC is microprocessor based controller for high efficiency gas boilers e Controller monitors all safety controls which control operation of combustion air blower circulator pump burner and combination hot surface igniter flame sensor e Controller is not intended for use with vent damper Controller is mounted on control panel inside boiler Contains five diagnostic indicator lights 2 High Limit Control NOTICE Maximum set point of limit control must not exceed 1909 e High limit control determines maximum boiler water temperature and provides means for protecting boiler and heating system from unsafe operating conditions which could damage boiler Control is mounted in
23. Lines Boiler is set up to receive 114 NPT supply and return piping from top access Boiler may be piped from left side by turning supply elbow Install furnished dielectric unions at boiler supply and return lines prior to making system piping connections Do not install copper supply and return piping directly into aluminum boiler section casings due to galvanic corrosion between dissimilar metals Must use provided dielectric unions between copper system piping and boiler to make final connection to boiler Circulator pump can be installed at installer preferred location NEAR BOILER PIPING Figure 2 Single Zone Boiler Piping RETURN FROM SYSTEM PURGE DRAIN VALVE S N 1 m SUPPLY TO SERVICE SERVI Z SYSTEM gt E VALVE SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS 12 NEAR BOILER PIPING Multi Zone Systems Multi zone systems with two zones are typically piped as shown in Figures 3 or 4 Multi zone systems with more than two zones are likely to have small zones with very low heat and flow requirements compared to full heating capacity of the boiler This can result in very low flow in the boiler if only one small zone is calling for heat Primary Secondary Piping is recommended for multi zone systems with more than two zones to insure proper water flow through the boiler at all times See Figures 5 6 and 7 for typical primary secondary piping
24. any other open type system System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas Fired Water Boilers General Guidelines When Using Antifreeze Use only antifreeze products recommended for use with aluminum boilers as listed in this addendum See Table 8 Continuous addition of make up water will dilute power of antifreeze and change buffers ability to maintain pH Flush old antifreeze from system Flush boiler and system separately Do not use antifreeze unless required Antifreeze if needed must be of type listed on next page due to their operational characteristics of type 356 T6 aluminum at operating temperatures between 20 6 7 C and 250 F 121 C See Table 8 for allowable products Always clean system prior to using antifreeze as stated in this supplement Follow antifreeze manufacturer s instructions for use safe handling and storage of their products Refer to MSDS Material Safety Data Sheets provided by antifreeze manufacturer for potential hazards and first aid procedures for exposure or ingestion Antifreeze will raise pH of hydronic solution in heating system above recommended level due to corrosion inhibitors Solution must be treated to maintain a pH within recommended level Follow antifreeze manufacturer s instructions to adjust pH If system has leaked water and antifreeze chemistry will need to be adjusted To avoid damage to boiler check pH and chemistry o
25. configurations Figure 3 Two Zone Boiler Piping With Zone Valves RETURN FROM ZONES P gt ZONE SERVICE _ TAN 22 O 22 PURGE DRAIN RAK VALVES pP ZONE SERVICE v DV VALVE Boy MATS a CIRCULATOR SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS 13 NEAR BOILER PIPING Figure 4 Two Zone Boiler Piping With Circulators RETURN FROM ZONES ZONE SERVICE LEN DD VALVE 5007 O lt lt PURGE DRAIN W 277 VALVES k ZONE SERVICE Q 2 52 if VALVE x SUPPLY TO ZONES C ZONE SERVICE VALVE FLOW CHECK VALVE SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS 14 NEAR BOILER PIPING Figure 5 Primary Secondary Piping With Circulators And Domestic Hot Water ZONE 1 PRIORITY ZONE 4 4 X DIAMETER CLOSELY SPACED TEES WATER INLET gt EXPANSION TANK BOILER BOILER PUMP FLOW CONTROL VALVE PRESSURE BALL VALVE CIRCULATOR VALVE SHUT OFF gt lt 1 CHECK VALVE ZONE VALVE H HOSE BIB 15 NEAR BOILER PIPING Figure 6 Piping Primary Secondary Multi Zone System Piping With Zone Valves And Domestic Hot Water With Zone Valve ZONE 4 lt ZONE 3 mn OX E ZONE 2 u u Of DK 8 J ZONE 1 PRIORITY m USE FULL POR
26. for all remaining zones 4 Open all service valves Any air remaining trapped in the return lines between the service valves and the boiler will be pushed towards the air vent when the boiler is placed in operation 5 Inspect piping system Repair any leaks immediately Purging Air For Systems With Conventional Closed Type Expansion Tanks Refer to the appropriate diagrams Near Boiler Piping on page 11 for more information 1 Close all zone service valves on the supply and return piping and close the expansion tank service valve Drain expansion tank Open the feed valve and fill boiler with water Hold relief valve open until water runs air free for five seconds to rapidly bleed air from boiler then let the relief valve snap shut 2 Open the zone service valve on the supply pipe for the first zone Open the purge valve on the first zone Feed water will fill the zone pushing air out the purge valve Close the purge valve when the water runs air free Close the zone service valve 3 Repeat step 2 for all remaining zones 4 Open the expansion tank service valve and the tank vent Fill the tank to the proper level and close the tank vent Remove the handle from the expansion tank service valve so the homeowner doesn t accidentally close it 5 Open all service valves Any air remaining trapped in the return lines between the service valves and the boiler will be pushed towards the expansion tank when the boiler is placed in op
27. heat control goes into normal light off sequence CI RCULATOR PUMP Circulator is energized as long as thermostat calls for heat during lockout Recovery from any lockout requires reset which can be accomplished by a Removing and re establishing thermostat s call for heat or turning service switch off and back on or b Waiting for control to automatically reset after 15 minutes for loss of combustion airflow or one hour for loss of flame VERIFICATION PROCEDURE AND AD USTMENT Verify Proper Sequence Of Operation Place boiler into operation and observe operation through several cycles Follow remaining steps in this section to insure boiler is operating correctly First couple of cold starts may be rough due to gas line not being completely purged of air causing low firing rate and high excess air levels Inspect Venting And Air Intake System Operate boiler and verify all vent air intake connections are gas tight and watertight Repair any leaks immediately Inspect Condensate Drain Verify all connections are watertight and that condensate flows freely Repair any leaks immediately Inspect System Piping Verify all connections are watertight Repair any leaks immediately Test High Limit Control And Adjust While burner is operating adjust high limit setpoint below actual boiler water temperature Burner should go off while circulator continues to operate Raise limit setting above boiler water temperatur
28. standard cubic foot 4 Operate boiler for 5 minutes 5 Turn off all other gas appliances extinguishing standing pilots where applicable 6 Atgas meter measure time in seconds required to use one cubic foot of gas 7 Calculate input rate according to the following formula 3600 x heating value from step 3 Btuh in put rate time from step 6 8 Measured input rate should be within 2 of input rating from step 2 If within 296 go to step 9 If not adjustment is required proceed as follows A Turn boiler off B Set up U tube manometer or differential pressure gauge for measuring manifold pressure See Figure 25 Page 44 C Manometer or gauge must be able to read at least 0 0 to 3 0 inches water column of pressure and resolve to at least 0 1 inches water column D Turn boiler on Manifold pressure has been nominally set at 2 5 inches w c Manifold pressure and input rate must always be measured with pressure regulator cover screw installed Cover screw must be removed for adjustment Manifold pressure reading will change increase when cover screw is removed F After adjusting input rate turn boiler off remove manometer or pressure gauge reinstall 1s plug on gas valve Turn boiler on G Boiler should typically operate between e 8 5 10 0 CO2 on Natural Gas e 9 5 11 0 CO2 on Propane Gas Under all conditions CO level should not exceed 100 ppm 9 Restore all gas appliances that may have been shut of
29. temperature to conserve fuel Economy feature is activated using the ECONOMY dial 9 TARGET When feature is active control continually sets target temperatures below high limit setting to maximize fuel efficiency When boiler reaches target temperature LED illuminates and burner shuts down Boiler water continues to circulate and heat the house as long as thermostat call continues LED stays lit until boiler temperature drops below differential at which point boiler will be allowed to fire again Note LED illuminates regularly during normal boiler operation Q PURGE Control is purging latent heat from boiler and will not fire until temperature drops to 135 F SETTING to Test LWCO Press and hold TEST button Red Low Water light will illuminate and burner circuit will de energize 50 x 6 115 y 19 7 90 HI LIMIT LWCO TEST 234 1 5 TOS OFF ECONOMY TROUBLESHOOTING HYDROSTAT HIGH LIMIT CONTROL AND LWCO Troubleshooting Flow Chart Burner Will Not Fire See Flow Chart this page If installed with indirect water heater insure end switch in relay box controlling indirect water heater is properly connected to Cable 2 This will insure domestic water calls are prioritized If Cable 2 is not used turn Economy Feature OFF No Insufficient Domestic Hot Water Check for air bound radiators Check thermostat settings including heat anticipator set
30. 050 075 100 FIELD CONVERSION INSTRUCTIONS DSI TO HSI Kit s 550002825 550002826 550002827 550002828 550002829 Keep this manual near boiler Tools needed for Kit applications Retain for future reference Screw Drivers Phillips and Flat Replacement Installation Operation Wire Cutters and Maintenance Manual included with Pliers Kit Instructions Nut Drivers 5 16 amp 7 16 Drill Bit Set Kit installation shall be completed by qualified agency 1 Hole Saw or Step Drill Marker Adjustable Wrench Combustion Analyzer Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious injury Read this instruction and understand all requirements including A FW requirements of authority having jurisdiction before beginning installation Installation not complete until appliance operation verified per Installation Operation amp Maintenance Manual provided with boiler NOTICE Draining boiler is not necessary for this process Kit Contents Boiler MBH _ 50MBH 75MBH 75 MBH 100 MBH S3 100 MBH S2 NAT LP LP NAT LP NAT LP 550002825 550002826 550002828 550002827 550002829 AT x x x X me fps refte 05 Removal Kit installation shall be completed by qualified agency Figure 1 Sight Glass Casting Temperature Switch Gas Valve Igniter Fire explosion asphyxiation and e
31. Disconnect boiler and its individual gas shutoff valve from gas supply system e Isolate boiler from gas supply system by closing manual gas shutoff valve See Figure 19 Page 29 e Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods providing ignition source Correct leaks immediately and retest Table 6 Gas Supply Pressure NATURAL PROPANE GAS GAS Maximum Gas Supply 10 w c 14 W C Pressure 7 28 Minimum Gas Supply A W 10 W Pressure 7 GAS SUPPLY PIPING Table 7 Gas Pipe Sizes NATURAL GAS Length of Pipe Capacity BTU Per Hour Input Includes Fittings Pipe Ft PL 3 4 1 114 92 000 190 000 350 000 625 000 63 000 130 000 245 000 445 000 50 000 105 000 195 000 365 000 PROPANE GAS Length of Pipe Capacity BTU Per Hour Input Includes Fittings Pipe Ft Copper Iron Pipe S 989 34 127 J 36 60 72000 121000 105000 217000 Outside diameter Figure 19 Gas Piping SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS GAS SUPPLY PIPING MANUAL SHUT OFF VALVE 3 76mm MINIMUM SEDIMENT TRAP GROUND JOINT UNION 29 ELECTRICAL WIRING Connect Circulator Pump Wiring See Figure 20 Page 31 for circulator pump field wiring connections Supplied 5 foot wiring harnes
32. G Near Boiler Piping When boiler installation 15 for new heating system install all of radiation units panels radiators baseboard or tubing and supply and return mains After all heating system piping and components have been installed make final connection of system piping to boiler Hot water boiler installed above radiation level or as required by the Authority having jurisdiction must be equipped with low water cut off device Periodic inspection is necessary for flushing of float type devices per low water cut off manufacturers specific instructions Clean System First Before connecting boiler to heating system clean and flush system thoroughly Verify system is free of sediment flux and any residual boiler water additives Systems having antifreeze not recommended must be completely flushed to insure no old antifreeze remains In older systems obviously discolored murky or dirty water or pH reading outside acceptable range between 7 0 and 8 0 are indications the system should be cleaned or treated Thoroughly flush system with clean water to remove any sediment or contaminants Sludge and iron oxide deposits can cause rapid breakdown of inhibitors Flushing with clean water If chemical cleaners are used use only those recommended for use with aluminum boilers Follow chemical cleaner manufacturer s instructions completely DO NOT mix different manufacturer s products 11 Supply And Return
33. NED OFF TO THE HOT SURFACE IGNITER IGNITER LIGHT IS OFF GAS VALVE OPENS FOR 5 SEC TRIAL FOR IGNITION BLUE ORANGE GLOW OF THE BURNER CAN BE SEEN THRU OBSERVATION PORT CONTROL LOCKOUTPURGE LIGHT BLINKS RESET REQUIRED CIRCULATOR GAS VALVE ENERGIZED THRU 3K1 AND 4K1 REMAINS ENERGIZED AS LONG AS CONTACTS VALVE LIGHT IS ON THERMOSTAT CONTINURES TO CALL FOR HEAT PURGE LIGHT GOES OUT HOT SURFACE IGNITER POWERED THRU 5K1 5K2 CONTACTS FOR 20 SEC IGNITER WARMUP BRIGHT YELLOW ORANGE GLOW OF THE HOT SURFACE IGNITER CAN BE OBSERVED THRU THE OBSERVATION PORT IN FRONT OF BOILER SECTION JUST ABOVE IGNITER IGNITOR LIGHT IS ON PURGE LIGHT IS ON AIRFLOW PROVED DRAFT INDUCER RUNS FOR 15 SEC PREPURGE DETAILED SEQUENCE OF OPERATI ON End Of Normal Sequence Of Operation Thermostat ends call for heat Gas valve and circulator pump are de energized valve and flame lights go out Blower runs for 30 seconds post purge purge light is on Blower is de energized after 30 seconds purge light shuts off Boiler stand by for next call for heat 39 DETAILED SEQUENCE OF OPERATI ON Sequence Of Operation Diagnostics Follow sequence using the diagnostic indicator lamps on Integrated Boiler Control IBC See Controls And Accessories on page 34 for normal sequence of operation Detailed sequence of operation containing potential faults can be found in service hints section A Power B Purge C Igniter D Valve E Fla
34. NOTE Follow venting lengths strictly to avoid nuisance pressure switch trips 5 10 See Figure 12 thru Figure 17 Pages 24 thru 26 for combustion air and vent pipe roof and sidewall termination Roof termination is preferred Combustion air and vent pipes must terminate together in same atmospheric pressure zone as shown Construction through which vent and air intake pipes may be installed is maximum 24 inches minimum 1 4 thickness Optional Rotate draft inducer blower 90 or 1809 to orient vent connection towards right side or rear Remove blower mounting screws re orient blower Reinstall mounting screws Do not overtighten screws Pitch combustion air and vent piping back to boiler at minimum 14 per ft 21 mm m from intake and vent terminals so all moisture in combustion air and vent piping drains to boiler Pitch pipes continuously with no sags or low spots where moisture can accumulate and block flow of air or flue gas Combustion air and vent pipes must be airtight and watertight Consider following when determining appropriate location for termination of combustion air and vent piping Position termination where vent vapors will not damage plants shrubs or air conditioning equipment Position termination as to not be effected by wind eddy air born leaves snow or recirculated flue gases Position termination where it will not be subjected to potential damage by foreign objects such as stones balls e
35. RING YES 24 VAC AT TRANSFORMER SECONDARY NO REPLACE TRANSFORMER YES NO 24 VAC AT WIRING HARNESS PLUG 2 PUSH RESET BUTTON ON CASTING TEMP SAFETY SWITCH YES CHECK CONTINUITY OF CASTING TEMP SAFETY SWITCH CONTACTS CONTACTS CLOSED OPEN REPLACE CAST TEMP SAFETY SWITCH REPLACE REPAIR WIRING FROM TRANSFORMER TO IBC NO CHECK FOR 120 VAC BETWEEN TERMINALS NO 1 AND 3 AT CONNECTOR 5 ON IBC REPLACE IBC CHART 1 YES NO REPLACE REPAIR WIRING FROM CHECK FOR 120 VAC AT CIRCULATOR 2 0 YES REPAIR REPLACE CIRCULATOR 53 TROUBLESHOOTING Troubleshooting Chart 3 CHART 1 OPEN NO CHECK FOR VAC BLOWER STARTS BETWEEN TERMINALS 1 AND REPLACE IBC AT CONNECTOR CN4 ON IBC YES YES CHECK FOR 120 VAC AT BLOWER LEADS ON WIRING HARNESS YES REPAIR REPLACE BLOWER REPAIR REPLACE WIRING FROM IBC TO BLOWER PRESSURE SWITCH CONTACTS OPEN IBC WAITS UP TO 5 MINUTES FOR NORMALLY OPEN AIR PRESSURE SWITCH CONTACTS TO CLOSE INDICATING BLOWER SUCTION IS PRESENT ARE ORIFICE IN NO NEGATIVE PRESSURE NO CLEAN OUT BLOCKAGE IBC PURGE LIGHT ON AT ORIFICE HOSE CLEAR YES CLEAN OUT VENT PIPE AND OR AIR INTAKE PIPE CHECK FOR SAGS OR LOW SPOTS WHERE CONDENSATE MAY PUDDLE AND BLOCK YES THE VENT ARE VENT PIPE AND AIR INTAKE PIPE CLEAR NO BLOCKAGE CHECK AIR PRESSURE SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERL
36. Switch Inducer Gas Valve p E E _ E ARUP niter Ground and Ground Wire 9 10 11 HSI Installation Run wire bundle with power wires to center of knock out of junction box Snap black strain relief in place See figure 19 Run thermostat control wires to upper left knock out Snap grey strain relief in place See figure 19 Insert supplied temperature sensor into thermo well Ensure it is inserted in all the way The temperature sensor serves as the LWCO and must have contact with the sidewall of the well for operation See figure 20 F F igure 20 igure 19 Connect Thermostat and Power Wires Low Voltage CH amp DHW Wires Insert Sensor and Install Sensor Cli Insert Sensor Re install clip HSI Installation 12 Connect pressure tubes See figure 21 13 Wire junction box internal wires and cover plate A Site glass run tube over gas valve assembly See figure 19 and or piping creating an inverted u trap Translucent silicone tubing coming from a tee B Gas valve reference port Clear silicone tube coming from Cross C Air intake Clear silicone tube coming from the Cross Figure 21 Pressure Tube Routing Pay special attention to the x hose routing over the gas valve HSI Installation Figure 23 Label Placement 14 Install top boiler panel 15 Turn on electric and gas to boiler Sign Date A
37. T ZONE VALVE FOR OPTIMUM TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR CLOSLEY SPACED MAX 4X DIAMETER y TEES SmO WATER INLET m HN e EXPANSION TANK ZN BOILER BOILER PUMP 16 NEAR BOILER PIPING Figure 7 Piping Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator ZONE VALVE p ZONE 4 e nm D ZONE 3 0 5 N e WE ZONE 2 5 5 CH CIRCULATOR JN PUMP C ZONE 1 PRIORITY ZONE N CIRCULATOR MAX 4XDIAMETER CLOSELY SPACED TEES WATER INLET H E EXPANSION TANK BOILER BOILER PUMP 17 NEAR BOILER PIPING Figure 8 Relief Valve Boiler Piping Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Install discharge piping per these instructions Safety Relief Valve DI SCHARGE p i LINE 27 A RELIEF VALVE Installation of safety relief valve shall conform to ANSI ASME Boiler Pressure Vessel Code Section IV e Install furnished safety relief valve using 3 4 x 472 di pipe provided with boiler See Figure 8 Install safety relief valve with spindle in vertical position Do not install shutoff valve between boiler and safety Check local relief valve u re BOILER Install discharge piping from safety relief valve See SI maximum Figure 8 distance e Use 3 4 or larger pi
38. TER THAN 4 0 W C YES CHART 5 55 REPLACE IBC REPAIR REPLACE WIRING FROM IBC TO IGNITER SENSOR REPLACE IGNITER SENSOR CHECK FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON IBC WHILE THE VALVE FLAME LED IS LIT NO REPLACE IBC YES REPAIR REPLACE WIRING BETWEEN IBC AND GAS CONTROL RESTORE IGNITER SENSOR TO CORRECT POSITION DO NOT RELOCATE ARE ALL MANUAL SHUT OFFS IN THE GAS SUPPLY LINE AND ON THE GAS CONTROL IN THE OPEN OR ON POSITION OPEN OR TURN ON ALL MANUAL SHUTOFFS YES CONTACT THE GAS UTILITY TO TURN THE GAS ON TROUBLESHOOTING Troubleshooting Chart 5 CHART 4 CHART 4 YES YES POSSIBLY MIXTURE TOO LEANI CHECK GAS LINES DOWNSTREAM OF GAS VALVE FOR BLOCKAGE ARE GAS LINES CLEAR IS GAS VENTURI VALVE CORRECT SIZE SEE REPAIR PARTS DIAGRAM YES POSSIBLY MIXTURE TOO RICH CHECK FLUE PASSAGES IN BOILER PER MAINTENANCE AND CLEANING ARE FLUE PASSAGES IN BOILER CLEAN CLEAN REPLACE GAS LINES BE SURE TO USE CORRECT GAS VENTURI VALVE SIZH CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCTIONS YES CHECK MIXER AND BURNER FOR BLOCKAGE PER MAINTENANCE AND CLEANING INSTRUCTIONS ARE AIR PASSAGES IN MIXER AND BURNER CLEAN CHECK AIR ORIFICE AT BURNER INLET FOR CORRECT SIZE SEE REPAIR PARTS DIAGRAM IS ORIFICE CORRECT SIZE NO 1 DOES MAIN BURNER RUN UNTIL CALL FOR HEAT ENDS OR HI NO 2 LIMIT AQUASTAT
39. Y CLEAN OUT SAMPLING LINES OR REPLACE DEFECTIVE SWITCH YES CHECK FLUE PASSAGES IN BOILER PER AND CLEANING ARE FLUE PASSAGES IN BOILER CLEAN CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCTIONS YES CHECK DRAFT INDUCER NO REPLACE MOTOR RPM IS IT BLOWER 3400 3600 YES CHECK FOR BROKEN OR LOOSE IMPELLER ON DRAFT INDUCER AND REPLACE BLOWER IF FOUND TO BE BROKEN OR LOOSE 15 SECOND PRE PURGE COMPLETE IBC PURGE LIGHT IS OFF SIMULTANEOUSL IGNITOR LIGHT IS ON AS IGNITOR CIRCUIT REPLAGE IBC IS ENERGIZED CHART 4 54 Troubleshooting Chart 4 3 YES IGNITER SENSOR WARMS UP AND GLOWS YELLOW ORANGE DURING 20 SECOND WARM UP YES AFTER 20 SECOND IGNITER WARM UP GAS VALVE IS ENERGIZED VALVE LIGHT IS ON 2 SECONDS LATER POWER IS REMOVED FROM IGNITER SENSOR IGNITER LIGHT IS OFF DOES MAIN BURNER LIGHT YES CHART 5 TROUBLESHOOTING CHECK FOR 120 VAC BETWEEN TERMINALS 1 AND 2 AT CONNECTOR CN1 ON IBC DURING IGNITER WARM UP YES CHECK FOR 120 VAC AT IGNITER SENSOR LEADS ON WIRING HARNESS DURING IGNITER WARM UP YES CHECK FOR 24 VAC ACROSS TERMINALS MV ON THE GAS CONTROL WHILE VALVE FLAME INDICATOR LIGHT IS ON YES CHECK IF IGNITER SENSOR POSITION IS OK TIP SHOULD BE SLANTED TOWARDS BURNER YES CHECK GAS SUPPLY PRESSURE AT INLET PRESSURE TAPPING ON GAS CONTROL IS GAS PRESSURE GREA
40. ational for use with which contribute to cleaner and healthier environment natural gas and propane gas e This appliance takes its combustion air directly from Boilers are constructed and hydrostatically tested for outdoors sealed combustion and does not compete maximum working pressure of 50 psig pounds per with building occupants for fresh air square inch gage in accordance with A S M E Boiler and Pressure Vessel Code Section IV Standards for heating boilers Sealed combustion also known as direct vent is safest and best way to obtain plenty of clean combustion air IMPORTANT SAFETY INFORMATION General Boiler installation shall be completed by qualified agency See glossary for additional information Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation Keep this manual near boiler Retain for future reference Become familiar with symbols identifying potential hazards This is the safety alert symbol Symbol alerts you to potential personal injury hazards Obey all safety messages following this symbol to avoid possible injury or death A DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardo
41. ce Cleaning and system components are protected from water Servicing dripping spraying rain etc during operation and service circulator replacement condensate trap 1 26mm 8 204mm control replacement etc Left Side 1 26mm 9 Keep boiler area clean of debris and free of flammable and combustible materials vapors and liquids Right Side 11 260mm 10 Locate boiler where minimum possible room 1 2 WzZIGIoISIAI temperature where boiler is installed assuming boiler 5 is not in operation and therefore contributes no heat 1 26mm 24 610mm to space is always at or above 32 F 09C to prevent 1 26mm 7 f f liquid d te s reezing of liquid condensate Intake Vent Piping 0 0 ss All distances measured from the cabinet of the boller Table 4 Required Clearances BOILER INSTALLATION Condensate Drain Requirements e Pitch condensate drain line down to floor drain at minimum of 1 4 per foot External condensate pump not furnished may be used if floor drain is not available Installation shall conform to requirements of authority having jurisdiction check local codes for requirements Condensate pump must be designed for flue gas condensate application Condensate trap provided with boiler an additional trap is not required and should not be used Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reser
42. centric Vent A ELBOW FIELD SUPPLIED STRAP FIELD SUPPLIED 1 26mm Max COMBUSTION AIR NOTE SECURING STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT IN SIDE WALL 26 Figure 17 Concentric Vent Roof Installation NOTE VENI SUPPORT MUST BE FIELD INSTALLED TO SECURE TERMINATION KIT TO STRUCTURE COMBUSTION AIR ROOF BOOT FLASHING FIELD SUPPLIED 6 ELBOW FIELD SUPPLIED SUPPORT c FIELD SUPPLIED MAINTAIN 12 IN 18IN FOR CANADA COM MINIMUM CLEARANCE VENT AIR ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN ABOVE COMBUSTION AIR AND VENT PIPE Figure 18 Combustion Air and Vent Piping Boiler Connections VENT INTAKE 2 COMBUSTION AIR x TERMINATIONS INTAKE PIPING C SAFETY RELIEF Q VALVE SEE 4 2 CPVC VENT PIPING L IS PAGE 18 FOR FURNISHED T REQUIREMENTS 2 CPVC COUPLING FURNISHED 2 50 8mm Diameter Vent And Combustion Air Intake Piping 21 ft 6 4m maximum total equivalent length v for 90 100 models 26 ft 7 9m maximum total equivalent length for 90 50 and 90 75 models 2 ft 0 6m minimum total equivalent length for all models EXHAUST ELBOW FURNISHED VENT INTAKE TERMINATIONS lt d 3 VENT PIPING TRANSITION FITTING TRANSITION FITTING 2 50 8mm Q to 3 76 2mm 2 TO 3 IN VERTICAL RUN IN VERTICAL RUN
43. cy which includes A Examine flue passages between boiler sections burner and condensate lines and clean if necessary following Annual Examination And Cleaning Of Boiler Components on page 48 B Visually inspect venting and air intake system for proper function deterioration or leakage If vent or air intake show any signs of deterioration or leakage repair or replace them immediately Insure proper reassembly and resealing of vent and air intake system C Check for and remove any obstruction to flow of combustion air or venting of flue gases Check air baffle located inside 172 x 2 flexible coupling on mixer clean if necessary and make sure to put it back Refer to repair parts diagram of mixer and pressure switch assembly for exact location D Follow instructions Instructions on page 37 E Follow instructions for verification Procedure and Adjustment on page 42 F Visually inspect condensate drain lines for proper operation and deterioration Check for plugged condensate drain lines G Check silicone rubber seals between boiler sections Insure that there are no leaks Use RTV silicone rubber adhesive sealant rated for at least 400 F to replace or repair seals in locations where original seals have deteriorated H Check all gasketed joints for leakage and tighten bolts or replace gaskets if necessary I Remove jacket front and top panels and check for piping leaks around relief valve a
44. d yellow LEDs are off and there is call to fire burner there will be 120 VAC in terminals Replace Control B1 and B2 gt 120 is not present replace control 51 TROUBLESHOOTING GREEN POWER INDICATOR LIGHT IS NS ILLUMINATED ON THE IBC CHART 2 YES Troubleshooting Chart 1 CHECK SYSTEM STATUS IF LOCKED OUT NOTE FAILURE MODE WHICH INDICATOR LIGHT IS BLINKING RESET SYSTEM BY TURNING SERVICE SWITCH OFF THEN ON IF NOT LOCKED OUT SET THERMOSTAT TO CALL FOR HEAT NO CIRCULATOR STARTS YES CHART 2 FALSE POSITIVE PROOF OF AIRFLOW CHECK AIR PRESSURE SWITCH CONTACTS CLOSED IBC CHECKS NORMALLY OPEN AIR IF CONTACTS ARE CLOSED WITH NO AIRFLOW REPLACE PRESSURE SWITCH PRESSURE SWITCH CONTACTS OPEN CHART 3 52 TROUBLESHOOTING Troubleshooting Chart 2 NO CHECK THAT CIRCUIT BREAKER IS ON OR FUSES ARE OK AT THE ELECTRICAL PANEL CHART 1 OK CHECK THAT SERVICE SWITCH IS ON OK CHECK CASTING TEMPERATURE SAFETY CHECK WATER LEVEL IN BOILER CHECK SWITCH PUSH RESET BUTTON ON SWITCH OPEN FOR AIR TRAPPED IN TOP OF BOILER CONTACTS OPEN BUTTON UP OR CLOSED CONTACTS WILL NOT STAY CLOSED UNTIL BUTTON DOWN BOILER COOLS OFF CLOSED CHECK WIRING TO IBC 120 VAC BETWEEN NO TERMINAL 1 AND 3 AT WIRING HARNESS RERLAGE SERGE PLUG CN7 YES 120 VAC BETWEEN TERMINALS 1 AND 3 AT NO CONNECTOR CN3 ON IBC REPLACE IBG YES 120 VAC AT TRANSFORMER PRIMARY NO REPAIR WI
45. e and burner should reignite after inter purge retry delay Set high limit control to design temperature requirements of system Maximum high limit setting is 190 F Minimum high limit setting is 1009F Test Other Safety Controls If boiler is equipped with low water cut off manual reset high limit or additional safety controls test for operation as outlined by control manufacturer Burner should be operating and should go off when controls are tested When safety controls are restored burner should reignite Set Thermostat Heat Anticipator If Used And Verify Thermostat Operation For single thermostat connected to yellow thermostat lead wires in furnished field wiring junction box heat anticipator should be set at 0 7 amps For other wiring configurations refer to instructions provided by thermostat manufacturer regarding adjustment of heat anticipator Cycle boiler with thermostat Raise thermostat to highest setting and verify boiler goes through normal start up cycle Lower thermostat to lowest setting and verify boiler goes off Measure Natural Gas Input Rate Correct input rate is essential for proper and efficient operation of the burner and boiler 1 Determine elevation at installation site 2 Table 1 and Table 2 Page 6 to determine correct input rate for the local elevation 3 Obtain yearly average heating value of local gas supply from gas utility At sea level elevation it should be approximately 1000 Btu s per
46. e piping using field supplied cement will be visible around perimeter of properly 2 flexible coupling Attach vent piping to furnished 2 made joint vent pipe connector on draft inducer outlet 11 Handle pipe joint carefully until cement sets 2 All pipe joints are to be water tight 12 Support combustion air and vent piping minimum of 3 Working from boiler to outside cut pipe to required every 5 feet using pre formed metal hanging straps length s Do not rigidly support pipes Allow movement due to expansion and contraction 13 Slope horizontal portion of combustion air and vent pipes toward boiler minimum of 14 per linear ft 4 Deburr inside and outside of pipe 5 Chamfer outside edge of pipe for better distribution of primer and cement 8 21mm m with 5 between 5 6 Clean and dry all surfaces to be joined 14 Use appropriate methods to seal openings where vent 7 Check dry fit of pipe and mark insertion depth on pipe and combustion air pipes pass through roof or side 8 After pipes have been cut and pre assembled apply wall cement primer to pipe fitting socket and end of pipe to insertion mark Quickly apply approved cement to end of pipe and fitting socket over primer Apply cement NOTICE in light uniform coat on inside of socket to prevent To avoid nuisance trips under high wind conditions buildup of excess cement Apply second coat an inlet tee is required for side wall venting See 9
47. er It is possible to slide boiler for short distance Terminate combustion air and vent pipe connections in smooth floor or surface same atmospheric pressure zone through roof or sidewall 2 Select level location central to piping systems served roof termination preferred See Figure 12 thru Figure 14 and as close to vent and air intake terminals as pages 24 and 25 for required clearances possible 3 Accessibility clearances if more stringent i e larger clearances than required fire protection clearances Solvent cements are combustible Keep away from must be used for boiler installation Accessibility heat sparks and open flame Use only in well clearances may be achieved with the use of removable ventilated areas Avoid breathing in vapor or allowing walls or partitions contact with skin or eyes Failure to follow these 4 Boiler is approved for installation in closets and on instructions could result in fire serious injury or death combustible floors This boiler shall NOT be installed on carpeting Combustion air must be clean outdoor air Combustion air must not be taken from inside structure because 5 Clearances shown in Table 4 indicate required that air frequently is contaminated by halogens which clearances Maintain minimum 1 clearance between include fluorides chlorides phosphates bromides combustible construction and each of left top and and iodides These elements are found in aerosols back surface
48. er should be removed by blowing with compressed air or vacuuming Inspect interior of mixer for any signs of sediment or aluminum oxide and clean if necessary K Reinstall burner and mixer gasket and position mixer assembly over studs Install five 5 nuts but do not tighten Reinstall igniter and igniter gasket and fasten with two 2 screws Use care when installing the igniter Tighten five 5 nuts holding mixer assembly Connect e Gas line to gas valve e Condensate drain line to boiler e Pressure switch hose to gas valve e Air by pass to mixer e 1 1 2 x 2 flexible coupling to air inlet and make sure to put air baffle back to correct position e Igniter wires e Gas valve wires Visually inspect condensate lines leading from boiler sections and vent pipe connector to condensate trap Refer to repair parts diagrams Any foreign material or debris visible in condensate lines needs to be cleaned out as follows A B E F Disconnect condensate drain lines from condensate trap Remove condensate trap and drain all water from trap Disconnect condensate lines from fitting on bottom of boiler and vent pipe connector Run cold water through condensate lines and trap to thoroughly flush out any sediment or debris Reinstall condensate trap and condensate lines Follow instructions under Near Boiler Piping for filling condensate trap with water Inspection of flue connector requires following steps Re
49. eration 6 Inspect piping system Repair any leaks immediately Control System Startup At initial start up with the Economy feature active the control establishes a 14591 target temperature To test the high limit shut off function the Economy dial must be turned to OFF Once tested restore the Economy setting If the heating demand is high the target will increase over time to satisfy the heat load How Thermal Targeting Works Thermal targeting technology analyzes thermostat activity and continually evaluates how much heat the house requires When it is very cold outside heat demand is high and limit control will raise boilers target temperature to provide heat When outside temperature is mild heat demand is low Limit control will lower boiler s target temperature saving fuel 36 OPERATING INSTRUCTIONS If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use e This appliance is equipped with an ignition device any phone in your building which automatically lights burner Do NOT try to light this burner by hand e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s e Before operating smell all around appliance area instructions for gas Be sure to smell next to floor because
50. f while measuring boiler input rate to normal operating conditions I Remove regulator cover screw on top of gas valve and insert an appropriate screwdriver into adjustment screw m II Turn adjustment screw clockwise to increase input rate or counter clockwise to decrease input rate III Replace cover screw or cover hole temporarily with your finger to check new manifold pressure setting Do not set manifold pressure lower than 2 0 inches w c or higher than 3 0 inches w c when adjusting input rate 42 VERIFICATION PROCEDURE AND AD USTMENT IV Measure new input rate cover screw must be installed Repeat steps I IV until the input rate is within 2 of the nameplate input rating V If the actual input rate can not be set to within 2 of the correct input rating by adjusting manifold pressure change in gas orifice size is required Consult the boiler manufacturer for information on correct orifice sizing The specific gravity G and the higher heating value HHV of the local natural gas must be obtained from the local gas utility in order to determine the proper orifice size Set Thermostat To Desired Room Temperature Observe several operating cycles to verify proper operation Review All Instructions Review all instructions shipped with this boiler with owner or maintenance person Instructions must be affixed on or adjacent to the boiler Complete and sign the Installation and Check Out Certificate
51. f boiler solution and consult the antifreeze manufacturer for recommendations 60 Recommend taking pH reading annually and adjusted as necessary Follow antifreeze inhibitor manufacturer s instructions for details on how to adjust pH Antifreeze solutions can break down over time Failure to check antifreeze chemistry on annual basis may result in accelerated corrosion of boiler and other system components Consult with antifreeze manufacturer for recommendations Use of antifreeze in any boiler will reduce heating capacity as much as 10 20 Take into consideration when sizing heating system pumps and expansion tank Consult antifreeze manufacturer s literature for specific information on reduced capacity Using antifreeze manufacturer s instructions determine freezing temperature needed and use correct amount of antifreeze Never exceed 50 antifreeze by volume Boiler operating pressure must remain below 15 psi for antifreeze solutions that specify a maximum of 250 F 121 C Otherwise increase system operating tank pressure to 20 psig Note Refer to expansion tank manufacturer instructions for adjusting tank pressure System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas Fired Water Boilers Table 8 Antifreeze Products Compatible Aluminum Antifreeze amp Inhibitor Suppliers Noburst AL Antifreeze Rhogard Antifreeze amp Pro Tek 922 Inhibitor Noble Company P O Box 350 Grand
52. fer to repair parts diagram A Verify proper operation after servicing Loosen the clamp on the draft inducer end of the 2 vent pipe connector that connects the vent to the draft inducer Disconnect unplug wiring harness from draft inducer motor and draft inducer temperature safety switch Remove four 4 bolts that attach draft inducer to flue connector Remove draft inducer and gasket from top of flue connector Inspect interior of flue connector Any buildup of sediment or aluminum oxide on inside surface must be cleaned Position draft inducer gasket and draft inducer and fasten with four 4 screws Be sure to connect ground wire from draft inducer motor to one of four mounting screws Connect wiring harness leads to draft inducer motor and draft inducer temperature safety switch Connect vent pipe connector to draft inducer outlet NOTICE Fire explosion shock hazard Do not attempt to B modify the physical or electrical characteristics of this boiler in any way Failure to comply could result in death or serious injury TROUBLESHOOTING 2 Troubleshooting tools Voltmeter to check 120 vac and 24 vac Continuity tester C Inclined manometer or pressure gauge with 0 3 0 Range 0 01 Scale for measuring suction pressures at pressure switch D U tube manometer or differential pressure gauge m with 0 14 range 0 1 Scale measuring inlet 1 In reset from lockout co
53. flame signal is relayed to integrated boiler control fully illuminating Lamp E 8 Thermostat ends its call for heat Integrated boiler control de energizes gas valve and system circulator Lamp D is extinguished while unit enters 30 second post purge mode indicated by illumination of Lamp B Lamp E will remains illuminated as remainder of gas in blower is burned off approximately 2 seconds During post purge blower remains powered and clears out any residual products of combustion 9 After post purge mode draft inducer is de energized Unit goes into standby mode until next call for heat from thermostat NOTE First one two starts may due to gas line not being completely purged of air causing low firing rate and high excess air levels 40 DETAILED SEQUENCE OF OPERATI ON DRAFT I NDUCER TEMPERATURE SAFETY SWITCH If draft inducer temperature reaches temperature safety switch set point safety switch contacts open immediately closing gas valve light goes out Draft inducer runs through 30 second post purge and switches OFF Circulator runs with thermostat on call for heat When temperature safety switch contacts connect before end of call for heat control goes in normal light off sequence LOSS OF FLAME SI GNAL If established flame signal is lost while control expects burner is operating cont
54. fuel savings can be achieved by selecting higher setting example 4 or 5 If heating and indirect water heater signals were not separated when wiring the control Economy feature should be turned off to ensure the boiler supplies adequate temperature to heat indirect tank DIAGNOSTIC INDICATOR LAMPS POWER FN B PURGE IGNITOR D VALVE E FLAME HITEMP pA L D WATER ACTIVE PURGE CONTROLS AND ACCESSORIES Disables economy function Will allow boiler to fire until hi limit temp is reached and re fire with 109 subtractive differential Provides lowest level of fuel savings Use this set ting only if the house does not stay warm at higher settings Recommended setting for single zone systems Recommended setting for Two zone systems Recommended setting for Three zone systems Recommended setting for Four zone systems Recommended setting for Five zone systems Provides highest level of fuel savings C Differentials Differentials are automatic and will vary based on the control settings and boiler temperature 3 Gas Control Valve Electrically controlled Combination Gas Control Valve is designed to meet requirements for use with hot surface ignition found in this boiler Valve is piped to gas air mixer 4 Hot Surface Igniter Igniter is mounted next to burner through gas air mixer
55. gas input rate is correct Over firing may result in early failure of boiler sections This may cause dangerous operation Under firing may result in too much air for pre mix burner causing poor or loss of combustion Never vent products of combustion from this boiler to enclosed space Always vent to outdoors Never vent to another room or to inside building Be sure there is adequate outdoor air supply to boiler for complete combustion Follow regular service and maintenance schedule for efficient and safe operation Keep boiler area clean of debris and free of combustible and flammable materials Proper through wall or through roof combustion venting shall be in accordance with materials and methods described in this manual Installation must comply with local codes Boiler and related hot water heating systems are not do it yourself items they must be installed and serviced by qualified professionals Boiler Sizing Check to be sure you have selected boiler with proper capacity before starting installation AHRI Rating of boiler selected should be greater than or equal to calculated peak heating load heat loss for building or area s served by boiler and associated hot water heating systems See Table 1 Page 5 Heat loss calculations should be based on approved industry methods Boiler Location Considerations Before selecting boiler location consider following e Supplied with correct type of gas natural gas or
56. gas is on at the gas meter at all appropriate manual shutoff valves and at the gas control valve Make sure that the thermostat is calling for heat E Check that wire connectors at the integrated boiler control and at the originating control are securely plugged in or connected F Check that hoses are securely connected and are not plugged or damaged 49 TROUBLESHOOTING HIGH LIMIT CONTROL AND LWCO LED Legend and LWCO Test Button Figure 27 LED Legend HI TEMP illuminates when boiler water temperature reaches high limit setting Remains lit until water temperature falls 10 F below high limit setting Limit prevents burner operation while this LED is on 9 Indicates low water cut off function is active When control is installed with Electro well LED is on at all times when control is powered If the control is installed with well other than Electro well LED will not illuminate indicating the control is not providing low water cutoff functionality Burn and scald hazard Do not add water until boiler has fully cooled Failure to follow these instructions could result in death or serious injury 9 LOW WATER Illuminates if boiler is in low water condition Control will prevent burner operation during this condition Important System must be checked by qualified service agency prior to resuming operation Indicates that thermal targeting function is active and control reduces boiler
57. ining connected to the common venting system are located and other spaces of the building Turn on clothes dryer and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhaust so they will operate at maximum speed Do not operate a summer exhaust fan Close fire dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliances 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 the 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 fire place dampers and any other gas burning appliance to their previous condition of use Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Code NFPA 54 ANSI Z223 1 and or the Natural Gas and Propane Installation Code CAN CSA B149 1 When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as determined using the appropriate of the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or the Natural Gas and Propane Installation Code CAN CSA B149 1 NEAR BOILER PIPIN
58. lean water supply is available When water supply is from well or pump install sand strainer at pump 18 NEAR BOILER PIPING Figure 9 Diaphragm Type Expansion Tank Piping AUTOMATIC AIR VENT SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS MANUAL FILL COLD WATER VALVE FILL COMBINATION QUICK FILL VALVE STRAINER CHECK VALVE AND PRESSURE REDUCING VALVE DIAPHRAGM TYPE EXPANSION TANK 3 4 X 1 8 BUSHING 3 4 TEE 3 4 NIPPLE FURNISHED IN PARTS BAG 19 NEAR BOILER PIPING Figure 10 Conventional Closed Type Expansion Tank Piping CLOSED TYPE EXPANSION TANK MANUAL FILL VALVE COLD WATER FILL SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS i AND PRESSURE REDUCING VALVE EXPANSION TANK SERVICE VALVE GATE VALVE OR FULL PORT BALL VALVE 3 4 TEE 3 4 NIPPLE FURNISHED IN PARTS BAG 20 NEAR BOILER PIPING Condensate Drain Piping Boiler is factory equipped with condensate trap An additional trap is not required and should NOT be used 1 Provide 1 2 condensate drain and fittings Condensate drain to be pitched down to floor drain at a minimum of per foot Installation shall conform to requirements of authority having jurisdiction check local codes for requirements 2 Install 1 PVC tee to overflow fitting as shown Figure 11 3 The 7 diameter schedule 40 PVC or CPVC condensate drain and pipe fittings must confor
59. lectrical shock hazard Improper installation could result in death or serious injury Read these instructions and understand all requirements including requirements of authority having jurisdiction before beginning installation Installation is not complete until appliance operation is verified per Installation Operation amp Maintenance Manual provided with boiler DSI Removal 1 Follow instructions to TURN OFF GAS TO APPLI ANCE found on Operating Instructions label on boiler or in Installation Operation amp Maintenance Manual Verify all electrical power to boiler is turned off 3 Inspect combustion chamber through sight glass Verify flame is not present See figure 1 4 Disconnect wires at A Casting temperature switch See figure 1 B Gas Valve C Igniter ground and ground wire D Inducer Temperature Switch See figure 2 P N 240010144 Rev A 05 2013 05 Removal Conti 5 Remove temperature sensor from thermo well Figure 3 Temperature Sensor Clip and Well save clip See figure 3 6 Locate wire bundle going to external junction box Cut the wire bundle See figure 4 7 Disconnect pressure hoses at See figure 5 4 Remove and save clip PN pull out sensor A Gas valve reference port B site glass C intake Figure 4 Wire Bundle to External Junction Box Fiqure 5 Pressure Hoses Cut Wires 05 Removal Conti 8 Lift twist and remove cont
60. m to ANSI standards and ASTM D 1785 or 02846 4 Schedule 40 PVC or CPVC cement and primer must conform to ASTM D2564 or F493 5 In Canada use CSA or ULC certified schedule 40 PVC or CPVC drain pipe cement 6 Condensate pump with reservoir not furnished may be used to remove condensate to a drain line sanitary line above boiler if floor drain is not available or is not accessible Figure 11 Condensate Drain Piping 2 PNC T 2 a PVC TEE 1 2 SLIP X 1 2 SLIP X 1 2 SLIP Filling Condensate Trap With Water On initial start up condensate trap must be manually filled with water Following are the steps required to initially fill condensate trap for start up Steps are only required at initial start up or if maintenance requires draining of condensate trap 1 Disconnect vent condensate drain line from vent pipe connector on outlet of induced draft blower 2 Pour about 1 cup of cold tap water into vent drain line with funnel 3 Excess water should go through overflow and out through condensate drain line Verify proper operation of drain line or external condensate pump if used 4 Reinstall vent drain line Chilled Water Piping Install boiler when used in connection with refrigeration system so chilled medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler Boiler piping system of hot water boiler connected to heating coils located in ai
61. me DIAGNOSTIC SEQUENCE OF INDICATOR LAMPS gt 1129 1 Lamp is illuminated indicating integrated control is receiving 24 volts and is in standby waiting for thermostat call for heat 2 Thermostat calls for heat energizing system circulator 3 Integrated boiler control performs self check of internal circuitry approximately two seconds energizing draft inducer 4 Draft inducer comes up to speed and establishes combustion airflow causing normally open differential pressure air proving switch contacts to close When combustion airflow is proved Lamp B illuminates indicating 15 second pre purge cycle has begun 5 After pre purge completion Lamp B is extinguished and Lamp C is illuminated indicating power is being delivered to hot surface igniter for 20 second igniter warm up period Observe bright yellow orange glow of hot surface igniter through observation port on boiler 6 After igniter warm up period integrated boiler control energizes gas valve initiating 6 second trial for ignition mode indicated by illumination of Lamp D Lamp C extinguishes after 2 second delay Integrated boiler control stops sending power to hot surface igniter 7 Low level illumination of Lamp E indicates initiation of flame proving During last 2 seconds of trial for ignition mode main burner flame is proven by flame rectification through hot surface igniter providing
62. nd Attach Upgrade Label 16 Resume operation using OPERATING INSTRUCTIONS found on Operating Instructions label on boiler or in Installation Operation amp Maintenance Manual 17 Verify proper operation by following START UP PROCEDURE in Installation Operation amp Maintenance Manual 18 Verify Combustion A Adjust gas pressure for optimal A F ratio Gas pressure and flow will be lower after kit Installation Refer to table 1 for combustion settings B Install adjustment screw and cover Verify settings C Operate boiler thru several cycles after setting the gas pressure to verify ignition quality 19 Attach upgrade label next to rating plate See figure 23 20 Install front jacket panel s Table 1 Manufacturer Settings Co _ co 87 97 lt 100 so 100 111 75 100 111 100 MBH 50 75 8797 100 8797 10 0 11 1 lt 100 10 IMPORTANT Prior to leaving job site review supplied instructions for 1 Proper Venting Material 2 Proper Venting Size 3 Proper Venting Installation 4 Review Control Setup and Operation Questions Contact Technical Support 800 241 5501 NOTES 11 SERVICE RECORD 55 ueduio5 9 SWEN Auedwoy 931 495 DIMENSIONS Figure 1 Boiler Dimensions 17 3 4 451mm ALTERNATE BOILER WATER SUPPLY JUNCTION BOX FOR 120V POWER 120V CIRCULATOR
63. nd other fittings Repair if found DO NOT use stop leak compounds J Check igniter for cracks and deterioration Replace if necessary K Check for water in pressure switch tubing Drain if necessary 2 Check boiler area is free from combustible materials gasoline and other flammable vapors and liquids 3 Circulator pump and blower motor furnished with boiler are permanently lubricated from factory and require no further lubrication Additional or non factory supplied pumps and or motors should be lubricated according to the pump and or motor manufacturer s instruction Daily During Heating Season 1 Check for and remove any obstruction to the flow of combustion air or venting of flue gases 2 Check boiler area is free from combustible materials gasoline and other flammable vapors and liquids Monthly During Heating Season 1 Remove jacket front and top panels and check for piping leaks around relief valve and other fittings If found contact qualified service agency to repair DO NOT use stop leak compounds 2 Test relief valve Refer to valve manufacturers instructions packaged with relief valve 3 Visually inspect venting and air intake system for proper function deterioration or leakage If vent or air intake show any signs of deterioration or leakage contact a qualified service agency to repair or replace immediately and to insure proper reassembly and resealing of vent and air intake system 4 Visuall
64. ndition all electrical meter miano yas readings at the gas control valve 24 vac must be ge l taken within trial for ignition period 3 System Status 2 If any component does not function properly make sure A Consult System Status on pages 40 and 50 it is correctly installed and wired before replacing it B See Figure 23 Page 34 for location of boiler 3 Static electricity discharge can damage integrated Diagnostic Indicator Lamps boiler control IBC Touch metal surface to discharge static electricity before touching IBC 4 IBC cannot be repaired If it malfunctions it must be replaced 5 Only trained service technicians should service IBC systems Following troubleshooting check out system following sequence of operation for a normal light off sequence All controls are factory tested in the assembly process and a defective control is generally the least likely cause If you suspect you have a defective control read through this section before you replace it It is extremely unlikely that the two consecutive controls are defective If it seems to be happening chances are that either there is nothing wrong with the control or it is being damaged by some other problem an electrical short burning out a transformer for example Initial Service Checks 1 Before troubleshooting A Make sure that circuit breaker is on or fuse is ok at electrical panel B Make sure that service switch is on Make sure that
65. nterclockwise y to ON 8 Replace front jacket panel 9 Turn on all electrical power to the appliance 1 10 thermostat desired setting 11 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier d 37 DETAILED SEQUENCE OF OPERATI ON SERVI CE HINTS POWER ON STAND BY THERMOSTAT CALLS FOR HEAT IF MAIN BURNER DOES NOT PROVE FLAME IN 3 TRIALS CONTROL LOCKOUT VALVE FLAME LIGHT BLINKS RESET IS REQUIRED THIS PROBLEM IS A RESULT OF NOT ESTABLISHING FLAME SIGNAL CIRCULATOR ENERGIZES THRU 2K1 CONTACTS IBC SELFCHECK OF INTERNAL CIRCUITRY 1 2 SEC CONTROL WILL ATTEMPT 2 ADDITTIONAL IGNITION SEQUENCES STARTING WITH PREPURGE NO FALSE DOES IBC POSITIVE MAIN CHECKS PROOF OF BURNER PROVE N O AIR CLOSED AIRFLOW IBC WAITS CLOSED FLAME WITHIN INITIAL YES NORMAL PRESSURE FOR 45 SEC TRIAL FOR OPERATION SWITCH FOR AIR PRESSURE IGNITION CONTACTS SWITCH CONTACTS TO OPEN PERIOD DRAFT INDUCER ENERGIZES THRU 1K1 CONTACTS DURING THE LAST 2 SEC OF THE 5 SEC IGNITION TRIAL MAIN BURNER FLAME IS PROVED BY FLAME RECTIFICATION A FLAME SIGNAL TO IBC GAS VALVE REMAINS ENERGIZED BOILER RUNS IBC WAITS FOR UP TO 5 MINUTES FOR AIR PRESSURE SWITCH CONTACTS TO CLOSE INDICATING FAN SUCTION PRESENT 2 SEC INTO THE 5 SEC IGNITION TRIAL POWER IS TUR
66. o female dielectric isolation unions are shipped loose in boiler parts bag Install Dielectric Isolation unions at boiler supply line and return line Install isolation fittings nearest boiler prior to system piping connections WATER TREATMENT and ANTI FREEZE PROTECTI ON MUST be applied for ALL aluminum series high efficiency gas fired boilers using antifreeze protection 58 System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas Fired Water Boilers Clean System First BEFORE connecting boiler to heating system clean and flush system thoroughly Verify system is free of sediment flux and any residual boiler water additives Systems having antifreeze not recommended must be completely flushed to ensure no old antifreeze remains In older systems obviously discolored murky or dirty water or pH reading outside acceptable range between 7 0 and 8 0 are indications the system should be cleaned or treated Thoroughly flush system with clean water to remove any sediment or contaminants Sludge and iron oxide deposits can cause rapid breakdown of inhibitors Flushing with clean water If chemical cleaners are used use only those recommended for use with aluminum boilers Follow chemical cleaner manufacturer s instructions completely DO NOT mix different manufacturer s products Fill Water and Chemistry Verify water used to fill system meets these requirements System fluid pH maintained between 7 0 and 8
67. ole For Junction Box 05 Removal Conti 19 Kit 550002829 100 MBH ONLY Figure 13 Install Replacement J unction Box A Remove inducer assembly 4 screws See figure 2 B Remove air baffle plate inside fernco fitting See figure 8 HSI Installation 1 Attach junction box to side of boiler panel with two screws See figure 13 Figure 14 Install Supplied Replacement Control Panel Assembl 2 Install replacement control panel assembly See figure 14 3 Install supplied burner plate and gasket 4 Attach burner ground spade to outside stub Verify ground spade is between burner orifice plate and gasket See figure 15 Fiqure 15 Mixer Ground and Gasket F HSI Installation Attach gas valve body Leave nuts loose See Figure 16 Attach Gasket and Gas Mixing Valve figure 16 Install supplied hot surface igniter with two screws Tighten all screws holding gas mixer in place Ensure wire crimp of grounding spade is under the gasket See figure 17 Kit 550002829 100 MBH only Install supplied inducer with 4 pin connector 1 Install supplied air baffle plate marked 100 S3 inside Fernco fitting See figure 8 Figure 17 Insta Il Hot Surface Iqniter Connect wires at See figure 18 A Casting temperature switch 2 Inducer temperature switch C Gas Valve Igniter ground and ground wire ure 18 Connect to Casting Temperature
68. or maintenance Stairwells drafts Radios Connect black hot lead from power supply to black adios wire labeled L 120 VAC Lamps Unheated rooms on Connect white neutral lead from power supply to Direct sunlight U other side of wall white wire labeled N 120 VAC e Connect green ground lead from power supply to green wire labeled G 120 VAC 4 Run 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod Thermostat I nstallation e Thermostat location has important effect on operation of boiler system Follow instructions included with your thermostat e Locate thermostat about five feet above floor on inside wall e Mount directly on wall or on vertical mounted outlet box e It should be sensing average room temperature Set heat anticipator where applicable at 0 7 amps Connect 24 Volt thermostat leads to two 2 yellow wires located in junction box located on outer Jacket of boiler See Figure 20 Page 31 for junction box and thermostat field wiring connections 30 ELECTRICAL WIRING Figure 20 Field Wiring Connections SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS 120 VOLT CIRCULATOR WIRE COLOR CODE BK BLACK CENTRAL HEATING W WHITE THERMOSTAT G GREEN Y YELLOW BOILER R RED WIRING BR BROWN IN J BOX DOMESTIC HOT WATER
69. pe from floor e Use pipe suitable for temperatures of 375 F 191 C or or allowable greater safe point of e Individual boiler discharge piping shall be independent discharge of other discharge piping Size and arrange discharge piping to avoid reducing p safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping Install union if used close to safety relief valve outlet Install elbow s if used close to safety relief valve outlet and downstream of union if used e Terminate pipe with plain end not threaded Expansion Tank And Make Up Water Determine required system fill pressure system design temperature and system water content e Boiler contains 2 6 gallons U S Size expansion tank accordingly Consult expansion tank manufacturer for proper sizing information Connect properly sized expansion tank not furnished Diaphragm type expansion tank see Figure 9 Page 19 See Figure 10 Page 20 for conventional closed type expansion tanks For diaphragm type expansion tanks adjust tank air pressure to match system fill pressure Install furnished air vents shown for diaphragm type expansion tank system only Install make up water connections as shown per local codes If pressure reducing valve is used adjust to match system fill pressure Verify c
70. r handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during cooling cycle FROM BLOWER PITCH DRAIN PIPE DOWN TO FLOOR DRAIN AT MINIMUM 1 4 PER FOOT TO DRAIN x CONDENSATE DRAIN 21 COMBUSTION AIR VENT PIPE Connections And Termination Provisions for combustion and ventilation air must be in accordance with section Air For Combustion and Ventilation of the National Fuel Gas Code ANSI 2223 1 NFPA54 or National Gas and Propane Installation Code CAN CGA B 149 1 or applicable provisions of the local building code Boilers require dedicated direct vent system All air for combustion is taken directly from outdoors through combustion air intake pipe All flue products are discharged to outdoors through vent pipe 1 Venting Materials Use of cellular core PVC ASTM F891 cellular core CPVC or Radel Polyphenolsulfone in venting systems could result in death or serious injury Covering non metallic vent pipe and fittings with thermal insulation shall be prohibited Use in venting system could result in death or serious injury Table 4 Combustion air and vent pipe fittings must conform with the following Material Standards PVC schedule 40 ANSI ASTM D1785 PVC DWV ANSI ASTM D2665 CPVC schedule 40 AA D1784
71. rol immediately de energizes gas valve Valve and flame lights go out Draft inducer runs through 30 second post purge Control attempts to light boiler 3 times If flame is not proven control lockout problem establishing flame signal Valve light is blinking Control automatically resets after 1 hour LOSS OF COMBUSTI ON AIRFLOW If combustion airflow is lost while burner is firing Differential air pressure switch contacts open gas valve is de energized Valve and flame lights go out Draft inducer runs through 30 second post purge If call for heat remains IBC waits 5 minutes for airflow to be re established If airflow does not re establish control lockout problem with combustion airflow Purge light blinks Control automatically reset after 15 minutes 41 CASTI NG TEMPERATURE SAFETY SWITCH If burner operates when boiler has no water aluminum boiler sections heat up rapidly Casting temperature safety switch contacts will open breaking 24 volt power to IBC Power indicator light goes out Requires manual reset to re close contacts Power light goes out HI GH LIMIT CONTROL If boiler water temperature reaches high limit setpoint high limit n c contacts open immediately closing gas valve Valve and flame lights go out Draft inducer continues to run for 30 second post purge and switch OFF Circulator runs as long as thermostat calls for heat When high limit contacts connect before end of call for
72. rol panel assembly See Figure 6 Remove Existing Control Panel Asembly figure 6 Lift Twist and 9 Remove existing igniter See figure 7 10 Disconnect air intake at Fernco connection Remove nuts holding mixing valve to casting See figure 8 Figure 7 Remove Existing laniter Remove Fiqure 8 Fernco Connection ta 7 nuts holding mixing body For Kit 550002829 Replace Air baffle Disconnect Fernco connection DSI Removal Conti 11 Remove mixing valve body and first gasket See figure 9 12 Remove existing burner plate Remove Gas 13 Disconnect all wires connected inside the junction ae Mixer and First box x a Gasket 14 Remove small conduit knockout from upper left of junction box See figure 10 15 Mark hole from knockout on panel for location See figure 10 Figure 10 Mark Knockout Hole on Sheet Metal 16 Remove two screws holding junction box Remove junction box Save screws and junction box for use Remove and Mark 17 Drill out 1 inch hole in center of hole marked from knockout deburr Predrill to avoid scratching sheet metal See figure 12 Note Additional hole is required for low voltage wires 18 Remove strain relief attached to junction box Dispose of cut wires and strain relief See figure Fiaure 11 Remove Wire Strain Relief 11 Figure 12 Drill H
73. s For Use At High Altitude on page 6 BOILERS AT HIGH ALTITUDE UNITED STATES INSTALLATIONS e Boilers with exception of 90 75 propane LP product e Instructions on how to adjust gas manifold pressure are factory equipped for operation at altitudes ranging settings see Figure 25 and Figure 26 Page 44 from 0 10 000 feet above sea level Note 90 75 propane LP applications for 5 000 10 000 e No changes to factory settings are required for feet above sea level require orifice change as well as gas installations from 0 5 000 feet above sea level manifold pressure adjustment based upon calorific Btu For altitudes from 5 000 10 000 feet above sea level value of supply gas gas manifold pressure needs to be adjusted based upon Refer to Table 2 and Table 3 for high altitude orifice calorific Btu value of supply gas contact local gas part numbers For replacing an orifice refer to specific utility or distributor for this value instructions included with conversion kit For specific settings refer to Table 2 for natural gas applications and Table 3 Page 7 for propane LP gas applications Table 2 NATURAL GAS MODEL 90 50 Settings 750 850 950 1000 1050 Normalinput MBH 3 0 MODEL 90 75 Settings 750 850 950 1000 1050 7 1 MODEL 90 100 Settings 750 850 950 1000
74. s of the boiler Minimum 11 clearance is detergents bleaches cleaning solvents salts air required on right side to allow room for induced draft fresheners paints adhesives and other household blower Allow 24 at front and 8 at top for servicing products are required to venting combustion air e Locate combustion air inlet as far away as possible from swimming pool and swimming pool pump house 6 Install equipment in location which facilitates operation of venting and combustion air intake piping systems as described in this manual Draft inducer blower may be rotated 909 or 1809 to orient vent connections towards right side or rear Remove blower mounting screws Orient blower and install mounting screws Do Vent connections serving appliances vented by not overtighten screws natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure All combustion air and vent pipes must be airtight and watertight Combustion air and vent piping must also terminate as shown in Combustion Air and Vent Pipe section 7 Advise owner to keep venting and combustion air intake passages free of obstructions Both venting and combustion air intake piping systems connected to outdoors must permit flow through piping systems bil icti ccessibilit without restrictions for boiler operation Combustible V 8 Install boiler such that the automatic gas ignition Clesran
75. s with flexible metal conduit for connection from circulator pump to junction box If two 120 Volt circulator wire terminals inside junction box are not used leave two wire nuts to prevent short circuit Electrical shock hazard Turn OFF electrical power supply at service panel before making electrical connections Failure to do so could result in death or serious injury Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction Refer to e USA National Electrical Code ANSI NFPA 70 NOTICE e Canada Canadian Electrical Code Part I CSA C22 1 Label all wires prior to disconnection when servicing Safety Standard for Electrical Installations controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Electric Power Supply Prior to making any line Voltage connections turn OFf electrical power at fuse box Things to Avoid when Locating Thermostats DEAD SPOTS Corners and alcoves Behind doors 1 Run separate 115 Volt circuit from separate over current protection device in electrical service entrance panel This should be 15 ampere circuit 2 566 Figure 20 Page 31 for diagram showing service COLD SPOTS HOT SPOTS switch junction box and power supply connection Concealed 7 points Concealed pipes or ducts oa n Fireplae 3 Locate service switch in vicinity of boiler Verify it is turned OFF during service
76. t test pressures equal to or less than 72 psig 3 50ka Connecting The Gas Piping See Figure 19 Page 29 for general layout at boiler Gas line enters boiler from right side jacket panel Boiler is equipped with 1 2 NPT connection on gas valve for supply piping Following rules apply 1 Use piping materials and joining methods acceptable to authority having jurisdiction In absence of such requirements e USA National Fuel Gas Code ANSI Z223 1 NFPA 54 e Canada Natural Gas and Propane Installation Code CAN CSA B149 1 Size and install gas piping system to provide sufficient gas supply to meet maximum input at not less than minimum supply pressure See Table 7 Page 29 Use ground joint unions Provide sediment trap up stream of gas valve Use two pipe wrenches when making the connection to gas valve to keep it from turning Install a manual shutoff valve in the vertical pipe about 5 feet above floor Tighten all joints securely Propane gas connections should only be made by licensed propane installer Two stage regulation should be used by propane installer Propane gas piping should be checked out by propane installer 10 A DANGER Fire Hazard Do not use matches candles open flames or other methods providing ignition source Failure to comply will result in death or serious injury Leak Check Gas Piping Pressure test boiler and gas connection before placing boiler in operation e
77. tc Position termination should where vent vapors are not objectionable Place vent on wall away from prevailing wind Locate or guard vent to prevent accidental contact with people or pets Terminate vent above normal snow line Avoid locations where snow may drift and block vent Ice or snow may cause boiler to shut down if vent becomes obstructed Under certain conditions flue gas will condense forming moisture and may be corrosive Take steps to prevent building materials at vent from being damaged by exhaust of flue gas Vent shall not terminate where it may cause hazardous frost or ice accumulations on adjacent property surfaces Venting Requirements Venting system shall terminate at least 3 ft 0 9m above any forced air inlet except boiler s combustion air inlet within 10 ft 3m 2 PIPE MAXIMUM 23 3 PIPE MAXIMUM VENTING PIPE MINIMUM VENTING 2 FEET 21 FEET 15 FEET 92 FEET Venting system shall terminate at least 12 in from any air opening into any building Vent bottom shall be located at least 12 in above grade Termination of the vent shall be not less than 7 ft 2 1m above adjacent public walkway or paved driveway Vent terminal shall not be installed closer than 3 ft from inside corner of L shaped structure Vent termination should be kept at least 3 ft away from vegetation Venting system shall terminate at least 4 ft horizontally from and in no case above or below
78. tilization Efficiency and Heating Capacity is based on the D O E Department of Energy test procedure Heating Capacity indicates the amount of heat available after subtracting losses up the stack Most of this heat is available to heat water A small portion is heat from jacket and surfaces of the boiler and it is assumed that this heat stays in the structure Net AHRI rating represents portion of remaining heat that can be applied to heat radiation or terminal units i e finned tube baseboard cast iron radiators radiant floor etc The difference between Heating Capacity and Net AHRI Rating called piping and pickup allowance establishes reserve for heating volume of water in system and offsetting heat losses from piping Net AHRI ratings shown are based on piping and pickup factor of 1 15 in accordance with AHRI Standard as published by Hydronics Institute Net AHRI rating of boiler selected should be greater than or equal to the calculated peak heating load heat loss for building or area s served by boiler and associated hot water heating systems Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements Boilers for use at high altitude Canada Boilers are factory equipped for operation at altitudes ranging from 0 4 500 feet above sea level Contact Provincial authority having jurisdiction for installations above 4 500 feet 1 350m above sea level United States See Boiler
79. tings common on non digital House Will Not Get or thermostats Stay Warm Check Economy setting Economy feature like outdoor reset controls lowers average boiler temperature and can slow or in some cases prevent the house from coming up to temperature Move to lower setting CAUTION ALWAYS ALLOW BOILER TO COOL BEFORE Burner will not fire until low water condition is satisfied Control is gt Verify system filled with water Sensing Low Water Is Red LED LOW WATER gt Verify sensor is inserted into well Note Use of heat conductive grease may interfere with contact between spring clip and copper well tube gt Verify control is tightly clamped to well Control is i TENA s Yellow LED rol I Burner will not fire until boiler water has dropped to high HI TEMP Sensing High limit differential set point 109 below high limit setting Temperature gt Verify high temperature setting is correct When ECONOMY function is active control monitors Boiler Reached heating demand and establishes Target boiler temperatures below high limit setting to conserve fuel Burner will not fire until boiler temperature drops to Target Temperature Differential Is Yellow LED TARGET On Target Temperature Boiler in Purge Mode and will not fire until temperature drops to 15 PURGE LED on 140 F See Purge page 36 NO Both red an
80. uction Port Tubing When pressure reading is proper and the pressure switch is operating properly remove testing lines and reinstall vinyl caps to Tee and 4 way connector White Transparent Vinyl Tubing Gas Valve Vent Red Transparent Vinyl Tubing 4 Way Connector Tee Vinyl Cap TYP 2 White Transparent Vinyl Tubing Test Lines l inclined Manometer Differential Pressure Gauge 45 NEGATIVE PRESSURE SWITCH CHECK For use on Model 100 boilers only Following steps and diagram indicate locations of connection points required to check negative pressure Negative pressure switch is safety device which prevents boiler from firing if there is air intake blockage Turn off service switch or lower thermostat setting Remove vinyl cap from 4 way connector Install test line as shown to inclined manometer or differential pressure gauge with ability to read 0 01 to 5 0 w c Turn on service switch and set thermostat to call for heat If manometer readings do not correspond to chart check for possible causes A Blockage in air intake B Undersized air intake C Loose blower wheel or motor shaft D Incorrect pressure switch or pressure switch setpoint When pressure reading is correct and the pressure switch is operating properly remove test line and reinstall vinyl cap to 4 way connector White Silicone Tubing To Sight Glass Suction Port To Gas Valve Vent lt 4
81. unless 4 ft 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Canada only e Venting system shall terminate at least 6 ft 1 83m horizontally from in no case above or below unless a 6 ft 1 83m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Vent shall not terminate within 6 ft 1 8m of mechanical air supply inlet to any building Vent shall not terminate above regulator within 3 ft 900 mm horizontally of vertical center line of regulator vent outlet to maximum vertical distance of 15 ft 9 5m Vent shall not terminate within 1 ft 305mm for inputs up to and including 100 000 btu hr and 3 ft 900mm for inputs exceeding 100 000 btu hr of window or door that can be opened in any building or any non mechanical air supply inlet to any building or of combustion air inlet of any other appliance Vent shall not terminate underneath veranda porch or deck unless a veranda porch or deck is fully open on minimum of two sides beneath floor and b distance between top of vent termination and underside of veranda porch or deck is greater than 1 ft 300mm See figures 12 and 13 and 14 for two pipe terminations See figures 15 16 and 17 for concentric vent terminations COMBUSTION AIR VENT PIPE Installation 10 Wipe excess cement from joint Continuous bead of 1 Attach combustion air intak
82. us situation which if not avoided could result in minor or moderate injury NOTI CE Used to address practices not related to personal injury I nstallation shall conform to requirements of authority having jurisdiction or in absence of such requirements e United States e National Fuel Gas Code ANSI Z223 1 NFPA 54 National Electrical Code 70 e Canada e Natural Gas and Propane Installation Code CAN CSA B149 1 e Canadian Electrical Code Part I Safety Standard for Electrical Installations CSA 22 1 Where required by authority having jurisdiction installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Additional manual reset low water cutoff and or manual reset high limit may be required Requirements for Commonwealth of Massachusetts Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to e Installation by licensed plumber or gas fitter Installers Follow local regulations with respect to installation of CO Carbon Monoxide Detectors Follow maintenance recommendations Maintenance And Cleaning on page 47 BOILER RATINGS amp CAPACITIES Fareed Stal Table 1 SEA LEVEL RATINGS NATURAL AND PROPANE GASES www ahridirectory org Input Heating Capacity Net AHRI Rating Shipping MBH Weight 165 1 MBH 1 000 Btuh AFUE Annual Fuel U
83. voir Foundation Requirements e Install boiler on level surface Fire hazard Do not install boiler on carpeting Failure to follow these instructions could result in death or serious injury e Boiler is NOT to be installed on carpeting e f boiler is not level condensate drain lines will not function properly Adjustable feet are located on the boiler to make up for minor surface irregularities or tilt e Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reservoir Removal of Existing Boiler From Common Vent System When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restrictions leakage corrosion and other deficiencies which could cause an unsafe condition 3 10 In so far as is practical close all building doors and windows and all doors between the space in which the appliances rema
84. y be measured with cover screw firmly installed INLET OUTLET GAS CONTROL KNOB 44 DIFFERENTIAL AIR PRESSURE SWITCH CHECK ALL MODELS e Following steps and diagram indicate locations of connection points required to check differential air BOILER DIFFERENTIAL pressure STATUS PRESSURE W C CONTACTS e Differential air pressure switch is safety device which prevents boiler from firing if there is air intake boiler heat exchanger or vent blockage Not Running Normally Open e Turn off service switch or lower thermostat setting itch ing 1 80 for Model 100 1 80 for 75 0 Model 75 Install testing lines as shown to inclined manometer or 2 10 forModel 50 PRESSURE e Remove vinyl caps from Tee and 4 way connector differential pressure gauge with ability to read 0 01 to Running 5 0 w c Without Closed Turn on service switch and set thermostat to call for Blockage heat Running Less Than or Equal to Setpoints Open Blockage If manometer readings do not correspond to chart above Model 050 check for possible causes e Blockage or moisture in suction lines Differential Air Pressure Switch Blockage in air intake or vent pipes White Transparent Undersized air intake or vent pipes Vinyl Tubing Loose blower wheel or motor shaft To Sight Glass Silicone e ncorrect pressure switch or pressure switch setpoint S
85. y inspect clear vinyl condensate lines and PVC condensate drain pipe for proper operation leakage and deterioration If condensate lines or drain pipe show any signs of blockage leakage or deterioration contact a qualified service agency to clean repair or replace them immediately Periodically During Heating Season Where low water cutoffs are used periodic inspection of low water cut off is necessary including flushing of float type devices Refer to low water cut off manufacturer s specific instructions End of Each Heating Season Annual Shutdown Procedure Follow instructions To Turn Off Gas To Appliance on page 37 If heating system is to remain out of service during freezing weather and does not contain antifreeze drain system completely If boiler will be exposed to freezing temperatures drain condensate lines Otherwise do not drain system or boiler 47 MAINTENANCE AND CLEANING Annual Examination And Cleaning Of Boiler Com onents A DANGER Before servicing turn off electrical power to boiler at service switch Close manual gas valve to turn gas supply OFF to boiler Failure to comply will result in death or serious injury NOTICE Have qualified service agency perform the following service procedures Boiler owner should not attempt these procedures 1 Before Servicing turn off electrical power to boiler at service switch Close manual gas valve to turn off gas supply to boiler

Utica Boilers UB90-100 Operation and Installation Manual

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