2
Vertical Installation Requirements .............................................18
Horizontal Installation Requirements ........................................18
Direct Vent Installation Requirements ......................................18
Installation Requirements for the Commonwealth of Mass ....20
SYSTEM INSTALLATION .................................................................23
General .........................................................................................23
Hot Water Heating (Hydronic) System .........................................23
Internal Contaminants ...................................................................24
Hot Water Supply System General Water Line Connections ......24
Hard Water Conditions .................................................................25
Thermal Expansion (Closed System). ...........................................25
Gas Connections ...........................................................................25
Field Wiring ...................................................................................26
SUGGESTED PIPE SIZING TABLES ................................................27
PIPING DIAGRAMS ......................................................................28-30
SCHEMATIC DIAGRAM .....................................................................31
WIRING DIAGRAM .......................................................................32-33
OPERATION .......................................................................................34
Important ........................................................................................34
General .........................................................................................34
Filling and Purging for Heating Boiler Installation .........................34
Filling for Hot Water Supply Boiler Installation ..............................34
Purging Gas Line ..........................................................................34
Inlet Gas Pressure ........................................................................34
Water Temperature Regulation ......................................................35
Manifold Pressure Connections ...................................................35
LIGHTING AND OPERATING INSTRUCTIONS ...............................36
Adjustment .....................................................................................37
Setting of the Test Mode ................................................................37
Control System ..............................................................................37
Inputs to MCB ................................................................................38
Dipswitches ...............................................................................38-39
Operating Sequence ......................................................................39
Operating Setpoint Adjustment Procedure ....................................41
TROUBLESHOOTING IGNITION SYSTEM ......................................43
Troubleshooting Gas Valve ............................................................44
PREVENTATIVE MAINTENANCE .....................................................44
Main Burner ..............................................................................44-45
Relief Valve ....................................................................................45
Blower Compartment .....................................................................45
Burner Maintenance ......................................................................45
Condensate Removal System .......................................................45
Venting Maintenance .....................................................................46
Heat Exchanger Preventive Maintenance .....................................46
Tube Cleaning Procedure .............................................................46
Replacement Parts ........................................................................46
LIMITED WARRANTY ........................................................................43
TABLE OF CONTENTS .......................................................................2
SAFE INSTALLATION, USE, AND SERVICE ...................................3
APPROVALS ..........................................................................................3
GENERAL SAFETY........................................................................... 4-5
INTRODUCTION ..................................................................................6
DIMENSION AND CAPACITY DATA ............................................ 6-7
CAPACITY AND FLOW DATA .............................................................8
CONTROL COMPONENTS ............................................................ 8-9
The Control System .........................................................................8
Hot Surface Igniter .........................................................................8
Pressure Switches ..........................................................................8
Low Gas Switch .............................................................................9
Low Gas Pressure Switch ..............................................................9
Gas Valve ..........................................................................................9
Flow Switch .......................................................................................8
Flame Sensor....................................................................................9
Water Temperature Limit Controls ................................................10
On/Off Switch ..................................................................................10
Circulating Pump ............................................................................10
Temperature Probes .......................................................................10
Low Water Cutoff (Optional) .........................................................10
Pressure Relief Valve ...............................................................10-11
GENERAL
Required Ability ...............................................................................11
Location ..........................................................................................11
Replacing Existing Common Vented Boiler ...........................11-12
Panels and Covers ........................................................................12
Chemical Vapor Corrosion ..........................................................12
Installation Clearances .................................................................12
Leveling ..........................................................................................12
Air Requirements ............................................................................12
Unconfined Space
..........................................................................12
Confined Space
..............................................................................12
Fresh Air Openings For Confined Spaces
.................................13
Outdoor Air Through Two Openings............................................13
Outdoor Air Through One Opening .............................................13
Outdoor Air Through Two Horizontal Ducts ...............................13
Outdoor Air Through Two Vertical Ducts ....................................14
Air From Other Indoor Spaces ....................................................14
Termination Clearances Sidewall Power Vent ............................15
Termination Clearances Sidewall Direct Vent .............................16
VENTING ..............................................................................................17
Special Installation Considerations . ............................................17
Venting System Using AL 29-4C® ............................................17
General Exhaust Vent Installation Procedure .............................17
Connecting Vent to Boiler ...........................................................17
Venting Supports ..........................................................................18
TABLE OF CONTENTS
