Aspen ASPN-320 Installation, Operating And Service Instructions Download Page 1

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107750-01 - 9/17

Price - $5.00

9700609

As an ENERGY STAR

Partner, U.S. Boiler Company has determined that the ASPEN™ Series meets the ENERGY

STAR

guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

ASPEN

™

CONDENSING HIGH EFFICIENCY

DIRECT VENT

GAS - FIRED HOT WATER BOILER

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or

loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas

supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

Models:

• ASPN-320

• ASPN-399

TO THE INSTALLER: Affix these instructions adjacent to boiler.

TO THE CONSUMER: Retain these instructions for future reference.

Summary of Contents for ASPN-320

Page 1: ...CIENCY DIRECT VENT GAS FIRED HOT WATER BOILER WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or loss of life For assistance or additional information consult a qualified installer service agency or the gas supplier This boiler requires a special venting system Read these instructions carefully before installing Models ASPN 320 ASPN 399 T...

Page 2: ...ubstantial property damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage NOTICE Indicates special instructions on installation operation or maintenance which are important bu...

Page 3: ... This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler to prevent scald injuries Do not rely on the pressure and temperature gauges to determine...

Page 4: ...late shall be permanently mounted to the exterior of the building at a minimum height of eight 8 ft above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 A final inspection by the state or local...

Page 5: ...EAD THIS ENTIRE MANUAL before attempting installation start up or service Improper installation adjustment alteration service or maintenance may cause serious property damage personal injury or death DO NOT DISCONNECT PIPE FITTINGS on the boiler or in the heating system without first verifying that the system is cool and free of pressure and that your clothing will protect you from a release of ho...

Page 6: ...stems 57 H Assembly of Centrotherm InnoFlue Vent Systems 61 I Assembly of Stainless Steel Vent Systems 65 J Condensate Trap and Drain 67 K Removing An Existing Boiler From Common Chimney 69 VIII Gas Piping 70 IX System Piping 72 A General System Piping Precaution 72 B Standard Piping Installation Requirements 73 C Near Boiler Piping Design 75 D Piping For Special Situations 82 X Wiring 84 XI Start...

Page 7: ...tion on a floor or wall This boiler may be vented verti cally or horizontally with combustion air supplied from outdoors It is not designed for use in gravity hot water systems or systems containing significant amounts of dissolved oxygen Models ASPN 320 and 399 provide central space heating and or indirect domestic hot water DHW heating I Product Description II Specifications Figure 2 1 General C...

Page 8: ...essure PSI ASPN 320 32 320 304 264 95 0 7 0 1 1 2 3 4 270 80 ASPN 399 39 9 399 379 330 95 0 6 7 1 1 2 3 4 275 80 The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1 15 The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc Figure 2 ...

Page 9: ...t be exceeded in the planned installation Also verify that the vent terminal can be located in accordance with Section VII Venting 3 Make sure that the boiler is correctly sized For heating systems employing convection radiation baseboard or radiators use an industry accepted sizing method such as the I B R Guide RHH published by the Air Conditioning Heating and Refrigeration Institute AHRI For ne...

Page 10: ...combustible construction as well as non combustible walls floors ceilings and doors 2 Note the recommended service clearances in Figure 4 1 These service clearances are recommended but may be reduced to the combustible clearances provided a Access to the front of the boiler is provided through a door b Access is provided to the condensate trap located beneath the boiler Note that servicing the boi...

Page 11: ...11 107750 01 9 17 IV Locating the Boiler continued Figure 4 1 Minimum Clearances To Combustible Construction ...

Page 12: ...e Figure 5 1 to locate holes A and B Make sure that the horizontal centerline of these holes is level Holes C and D may also be drilled at this time or after the boiler is hung on the wall If the 5 16 x 2 lag screws are used drill 3 16 pilot holes 6 The wall mounting hook is used to secure the boiler to the shipping pallet Remove this hook from the pallet and secure to the wall using the 5 16 x 2 ...

Page 13: ...13 107750 01 9 17 Figure 5 1 Wall Layout Mounting Hole Location V Mounting The Boiler continued ...

Page 14: ...14 107750 01 9 17 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting V Mounting The Boiler continued ...

Page 15: ...ith other appliances provide adequate air for combustion and or ventilation air in accordance with the manufacturer s installation manual or applicable code VI Air for Ventilation WARNING Outdoor combustion air must be piped to the air intake Never pipe combustion air from areas containing contaminates such as swimming pools and laundry room exhaust vents Contaminated combustion air will damage th...

Page 16: ...tems WARNING Asphyxiation Hazard Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage personal injury or death Do not interchange vent systems or materials unless otherwise specified The use of thermal insulation covering vent pipe and fittings is prohibited Do not use a barometric damper draf...

Page 17: ...17 107750 01 9 17 Figure 7 0c Split Venting VII Venting A Vent System Design continued Figure 7 0a Horizontal Twin Pipe Figure 7 0b Vertical Twin Pipe ...

Page 18: ... 7 13 or 7 21 for the maximum vent lengths These maximum lengths apply to both the vent and intake piping e g Option 1 may have up to 60ft of intake and 60ft of vent piping For all vent systems the lengths shown in Tables 7 5 7 13 and 7 21 are in addition to the first 90 elbow If more elbows are desired the maximum allowable vent length must be reduced by the amount shown in Table 7 1 for each add...

Page 19: ... of Horizontal Vent Piping Pitch all horizontal vent piping so that any condensate which forms in the piping will run towards the boiler Pitch CPVC PVC vent piping 1 4 per foot 21mm m Pitch PolyPropylene vent piping 5 8 per foot 53mm m For Category I II and IV boilers have horizontal runs sloping upwards not less than 1 4 inch per foot 21 mm m from the boiler to the vent terminal Les chaudières de...

Page 20: ...n For CPVC PVC pipe design the vent system to allow 3 8 of thermal expansion for every 10ft of CPVC PVC pipe The boiler will always act as an anchor to one end of the vent system If at all possible select and install hangers and wall thimbles so that the vent system can expand towards the terminal When a straight run of pipe exceeds 20ft and must be restrained at both ends an offset or expansion l...

Page 21: ...21 107750 01 9 17 VII Venting A Vent System Design continued Figure 7 3 Expansion Loops for CPVC PVC Pipe Figure 7 3b Figure 7 3a Figure 7 3c Figure 7 4 Wall Penetration Clearances for PVC Vent Pipe ...

Page 22: ...e may not be snorkeled Terminal Option B Ipex Low Profile Terminal Acceptable for Vent Options 1 2 This terminal is shown in Figure 7 7 If the terminal is oriented vertically alternate orientation shown in Fig 7 7 the exhaust opening must be on the top as shown See Part VII E of this manual and the Ipex instructions provided with the terminal for installation details Terminal Option C Diversitech ...

Page 23: ...w w screen Elbow w screen Elbow w screen Terminal Option B Ipex Low Profile Ipex 196985 Ipex 196986 Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Terminal Option C Diversitech HVENT HVENT 3 Not Available Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Terminal Option D Ipex FGV Concentric Ipex 196006 Ipex 196021 Not Permitte...

Page 24: ...minal must be at least 3 feet above any forced air inlet located within 10 feet USA Only A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters electric meters regulators and relief equipment Do not install vent terminal over this equipment In Canada refer to B149 1 Installation Code for clearance to meters regulators and relief equipment Do not loc...

Page 25: ...ith Low Profile Terminal Vent Options 1 2 Terminal Options B C Figure 7 8 Horizontal CPVC PVC Venting with Concentric Vent Terminal Vent Options 1 2 Terminal Options D E VII Venting B Design Requirements Unique to Horizontal Twin Pipe Venting Systems continued ...

Page 26: ...ntrotherm InnoFlue Horizontal Venting Vent Option 3 8 Terminal Option A Figure 7 10 Duravent PolyPro Horizontal Venting with Concentric Terminal Vent Options 3 4 Terminal Option F VII Venting B Design Requirements Unique to Horizontal Twin Pipe Venting Systems continued ...

Page 27: ... Note Air intake termination not shown refer to Venting Section in Installation Instructions supplied with the boiler Figure 7 11 Location of Vent Terminal Relative to Windows Doors Grades Overhangs Meters and Forced Air Inlets Two Pipe System Vent Terminal Shown Two Pipe System Air Intake Terminal Not Shown ...

Page 28: ... must be UV resistant Use of rodent screens is generally recommended for both terminations Two rodent screens are included within the available 4 vent kit or can be fabricated from 1 2 stainless steel mesh screen Rodent screens bird guards for PolyPro Polyflue and InnoFlue are as follows Size Vent System Rodent Screen Bird Guard 3 PolyPro DuraVent 3PPS BG 4 Poly Pro DuraVent 4PPS BG 3 Polyflue Sel...

Page 29: ... Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen Terminal Option I Ipex FGV Concentric Ipex 196006 Note 3 Ipex 196021 Note 3 Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted Terminal Option J Diversitech CVENT Concentric CVENT 3 CVENT 4 Not Permitted Not Permitted ...

Page 30: ...ximum allowable vent length See equivalent lengths for flex vent shown in Table 7 14 and sizing example on page 32 VII Venting C Design Requirements Unique to Vertical Venting Systems continued Table 7 13b Summary of Vertical B Vent Air Chase Vent Options B Vent Chase MUST Be Sealed NOTICE Vertical venting and combustion air roof penetrations where applicable require the use of roof flashing and s...

Page 31: ...offsets may not exceed 45 degrees Because the flex pipe is corrugated it has a higher pressure drop than the rigid pipe used elsewhere in the vent system Equivalent lengths for flex venting are shown in Table 7 14 Reduce the maximum allowable vent length shown in Table 7 13b by this equivalent length for each foot of flex pipe used as well as for each elbow in addition to the first The termination...

Page 32: ...trotherm InnoFlue Flex 2 3 ft 3 Selkirk Polyflue 2 3 ft 3 DuraVent FasNSeal Flex 1 0 ft 4 DuraVent Poly Pro Flex 2 0 ft 4 Centrotherm InnoFlue Flex 2 3 ft 4 Selkirk Polyflue 2 3 ft B Vent Air Chase 1ft 3 Flex Vent in 6 or larger B Vent 1 0 ft 4 Flex Vent in 6 or larger B Vent 1 0 ft Note Up to four 45 degree bends may be made in flex pipe or air chase These bends are not counted when figuring equi...

Page 33: ...VC PVC Venting Vent Options 10 11 Terminal Option H Figure 7 16 Vertical CPVC PVC Venting with IPEX Concentric Vent Terminal Vent Options 10 11 Terminal Option I J VII Venting C Design Requirements Unique to Vertical Venting Systems continued ...

Page 34: ...rotherm InnoFlue Vertical Single Wall PP Venting Vent Options 12 17 Terminal Option H Figure 7 18 Duravent PolyPro Vertical Venting with Concentric Terminal Vent Options 12 13 Terminal Option J VII Venting C Design Requirements Unique to Vertical Venting Systems continued ...

Page 35: ... Venting C Design Requirements Unique to Vertical Venting Systems continued Figure 7 19 Duravent PolyPro B Vent Air Chase System Vent Options 18 19 Figure 7 20 Centrotherm InnoFlue B Vent Air Chase System Vent Options 20 21 ...

Page 36: ...l Location Observe the following limitations on the intake terminal location also see Figures 7 22 7 23 or 7 24 The bottom of all terminals must be at least 12 above the normal snow line In no case should they be less than 12 above grade level If possible install the intake terminal on a wall away from the prevailing wind Reliable operation of this boiler cannot be guaranteed if the intake termina...

Page 37: ...re 7 25a When using this observe the following requirements When a masonry chimney containing multiple flues is used as a chase the flexible stainless vent installation is permitted through an adjacent UNUSED flue providing local authority having jurisdiction approves such installation Figure 25b Masonry chimney used as a chase must be structurally sound and in good repair All venting is stainless...

Page 38: ...lbow w Screen 90 Elbow w Screen Flex Termination Components Masonry Chimney Chase Note 3 Vent Not Permitted Intake Flex Termination Components B Vent Chimney Chase Vent Not Permitted Intake VII Venting D Design Requirements Unique to Split Vent Systems continued Table 7 21 Summary of Split Vent System Options Specify size of B vent e g 3PPS BV6 is for use with 6 B vent Specify length in feet Speci...

Page 39: ... 4PPS FLEX Intake 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components B Vent Chimney Chase Vent Not Permitted 3PPS VFT 3PPS BV 3PPS FLEX 4PPS VK 4PPS FLEX Intake 90 Elbow w Screen 90 Elbow w Screen Table 7 21 Summary of Split Vent System Options continued Specify size of B vent e g 3PPS BV6 is for use with 6 B vent Specify length in feet Specify Flex length and B vent diameter e g IFBK...

Page 40: ... 90 elbow w screen 90 elbow w screen Flex Termination Components B Vent Chimney Chase Vent 3PF 10UV or 3PF 39UV w Screen 3PF BVSC Note 4 4PF 10UV OR 4PF 39UV w Screen 4PF BVSC Note 4 IFBK03 IFBK04 Not Permitted Intake 90 elbow w screen 90 elbow w screen 90 elbow w screen 90 elbow w screen VII Venting D Design Requirements Unique to Split Vent Systems continued Specify size of B vent e g 3PPS BV6 i...

Page 41: ...50 01 9 17 VII Venting D Design Requirements Unique to Split Vent Systems continued Figure 7 22 Split Rigid Vent System Vent Options 25 32 Figure 7 23 Split Vent System Flex in B Vent Chase Vent Options 33 38 ...

Page 42: ...42 107750 01 9 17 VII Venting D Design Requirements Unique to Split Vent Systems continued Figure 7 24a Split Vent System PP Flex in Abandoned Masonry Chimney Vent Options 33 38 ...

Page 43: ...II Venting D Design Requirements Unique to Split Vent Systems continued Figure 7 24b Flexible PP Masonry Chimney Chase Requirements WARNING Venting of Other Appliances Or Fireplace into Chase or Adjacent Flues Prohibited ...

Page 44: ... Unique to Split Vent Systems continued Figure 7 25a Split Vent System SS Flex in Abandoned Masonry Chimney Vent Option 39 Figure 7 25b Flexible SS Masonry Chimney Chase Requirements WARNING Venting of Other Appliances Or Fireplace into Chase Prohibited ...

Page 45: ...iter saw or a saw designed to cut PVC pipe Use a miter box or other method to cut pipe squarely De burr both the inside and outside of the cut end c Dry fit all vent components before assembly d The vent adaptor has three different inside diameters The larger upper inside diameter accepts 4 CPVC pipe and is used in this application the middle inside diameter accepts 4 nominal PolyPro Polyflue or I...

Page 46: ...to the air intake connection and drill a 1 8 tap hole into the PVC which lines up with the 7 32 clearance hole and secure them together with a 10 x 1 sheet metal screw Seal the joint between the intake pipe and the adaptor with RTV b All intake piping may be PVC c There is a 0 minimum clearance between the air intake piping and all types of construction d To the extent possible pitch horizontal ai...

Page 47: ...47 107750 01 9 17 Figure 7 28 Installation of Standard Vertical Terminals Figure 7 27 Installation of Standard Horizontal Terminals VII Venting E Assembly of CPVC PVC Vent Systems continued ...

Page 48: ... Slide both vent and intake air pipes through the holes and cement them to the base of the vent termination kit using a primer and cement listed for use with PVC c Fasten the vent base to the wall using the supplied screws and anchors The anchors require the drilling of a 3 16 hole x 1 3 16 deep Locate the holes using the vent base as a template d Screw the vent cap to the vent base using the supp...

Page 49: ...1 9 17 Figure 7 30 Installation of Diversitech Low Profile Terminal Through Sidewall Figure 7 29 Installation of IPEX Low Profile Terminal Through Sidewall VII Venting E Assembly of CPVC PVC Vent Systems continued ...

Page 50: ...9 17 VII Venting E Assembly of CPVC PVC Vent Systems continued Figure 7 32 Installation of IPEX and Diversitech Concentric Terminal through Sidewall Figure 7 31 Cutting IPEX and Diversitech Concentric Vent Terminals ...

Page 51: ...izontal installations orient so that the side outlet on the Wye is on or above the horizontal plane g For horizontal installations seal the gap between the OD of the outer pipe and the exterior side of the wall with RTV sealant h Cement the rain cap onto the inner pipe If desired the rain cap can be attached to the inner pipe with the supplied stainless steel screw and nut so that it can be later ...

Page 52: ...e vent adaptor has three different inside diameters The middle inside diameter accepts 4 nominal PolyPro Figure 7 26 Lubricate the gaskets in the vent adaptor with soapy water and insert the first piece of 4 PolyPro into the adaptor until it bottoms out Tighten band clamp on vent adapter to secure vent pipe b If 3 PolyPro is to be used for the vent system reduce the first piece of 4 PolyPro instal...

Page 53: ... installation instructions included by the original PolyPropylene venting component manufacturer M G DuraVent PolyPropylene pipe sections must be disengaged 1 4 to 5 8 in 6 mm to 16 mm per joint to allow for thermal expansion 4 Installation of Horizontal Fitting Terminals Terminal Option A a See Figure 7 35 for proper orientation of twin pipe horizontal terminals Outer edge of exhaust coupling mus...

Page 54: ...Installation of Duravent PolyPro UV Resistant Single Wall Horizontal Terminal Figure 7 36 Installation of Duravent PolyPro UV Resistant Single Wall Vertical Terminal VII Venting F Assembly of DuraVent PolyPro Vent Systems continued ...

Page 55: ...e e Seal the termination to the exterior wall plate with weather resistant RTV f Slide the interior wall plate over the termination and attach to the wall from inside the room g Attach the interior wall plate to the termination with the provided hardware h Install gaskets into co linear adapter i Attach co linear adapter to horizontal termination and orient so that the side outlet on the adapter i...

Page 56: ...e 7 38 Installation of Duravent PolyPro Concentric Vent Terminal Through Sidewall VII Venting F Assembly of DuraVent PolyPro Vent Systems continued Figure 7 39 Installation of Duravent PolyPro Concentric Terminal Through Roof ...

Page 57: ...described in the DuraVent PolyPro Flex instructions Connection of the PVC air intake pipe to the side outlet of the tee is made using a cap and a PVC socket x male thread adaptor 3 or 4 depending on the Vent Option Cut a clearance hole in the cap for the male threads Secure the adaptor to the cap using a 3 or 4 electrical conduit lock nut Seal all joints with RTV G Assembly of Selkirk Polyflue Ven...

Page 58: ... coupling and insert Selkirk 3PF HVST or 4PFHVST in its place c A 180 bend or two 90 elbows are installed on the top of the air intake pipe If two 90 elbows are used the rodent screen provided can be installed between them Figure 7 42 If a 180 bend is used install the rodent screen in the open side of the bend using a ring made of PVC pipe If desired the termination fittings can be attached to the...

Page 59: ...eference the Selkirk Polyflue instruction manual Not all vent configurations shown in the Selkirk vent manual are listed for use with this boiler Refer to Selkirk Polyflue Instructions for assembly of all flex components including the chimney cap and the adaptor to rigid Polyflue at the base of the masonry or B vent chimney In addition observe the following requirements a Refer to the appropriate ...

Page 60: ...G Assembly of Selkirk Polyflue Vent Systems continued Figure 7 41 Installation of Selkirk Polyflue UV Resistant Single Wall Horizontal Terminal Figure 7 42 Installation of Selkirk Polyflue UV Resistant Single Wall Vertical Terminal ...

Page 61: ...e middle inside diameter accepts 4 nominal InnoFlue Figure 7 26 Lubricate the gaskets in the vent adaptor with water and insert the first piece of 4 InnoFlue into the adaptor until it bottoms out Tighten band clamp on vent adapter to secure vent pipe b If 3 InnoFlue is to be used for the vent system reduce the first piece of 4 InnoFlue installed in Step a to 3 using Centrotherm ISRD0403 Otherwise ...

Page 62: ...ing component manufacturer Centrotherm PolyPropylene pipe sections must be disengaged 1 4 in 6mm per joint to allow for thermal expansion 4 Installation of Horizontal Fitting Terminals Terminal Option A a See Figure 7 44 for proper orientation of twin pipe horizontal terminals Outer edge of end pipe must be 10 or less from the wall surface Figure 7 5 b Use plain end UV stabilized Centrotherm 3 pip...

Page 63: ...stallation of Centrotherm InnoFlue UV Stabilized Single Wall Horizontal Terminal Figure 7 45 Installation of Centrotherm InnoFlue UV Stabilized Single Wall Vertical Terminal VII Venting H Assembly of Centrotherm InnoFlue Vent Systems ...

Page 64: ...n Tables 7 13b or 7 21 for a list of the principle flex components required Rigid vent pipe by the same manufacturer will also be required for the run from the boiler to the base of chimney b Masonry chimneys cannot be used for an air chase c B vent chimneys can only be used for an air chase Vent options 20 21 if the B vent has the minimum size shown in Table 7 13b and is fully accessible for seal...

Page 65: ...TV b All intake piping may be PVC c There is a 0 minimum clearance between the air intake piping and all types of construction d To the extent possible pitch horizontal air intake piping towards the outside WARNING Asphyxiation Hazard Vent systems made by DuraVent rely on gaskets for proper sealing When these vent systems are used take the following precautions Make sure that gasket is in position...

Page 66: ...ible stainless steel pipe manufacturer installation instructions and Boiler Installation Operating and Service Instructions the more restrictive instructions shall govern WARNING Asphyxiation Hazard Flexible stainless steel vent must be installed only in an UNUSED chimney flue A chimney flue is considered UNUSED when it is not being used for any appliance venting If chimney is a multiple flue type...

Page 67: ...ightlyacidic 3 5 4 5 Donotusemetallicpipeorfittingsinthecondensatedrainline Donotroutethe drain line through areas that could be damaged by leaking condensate 8 Some jurisdictions may require that the condensate be neutralized before being disposed of Dispose of condensate in accordance with local codes 9 Do not route or terminate the condensate drain line in areas subjected to freezing temperatur...

Page 68: ...68 107750 01 9 17 VII Venting J Condensate Trap and Drain Line continued Figure 7 47 Float Switch Connection to Wire Harness Figure 7 48 Condensate Trap Installation ...

Page 69: ...NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Codes VII Venting K Removing an Existing Boiler From a Common Chimney WARNING Never common vent this boiler with other appliances Au moment du retrait d une chaudière existante les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d evacuation commun et qui fonctionne alors que d autres apparei...

Page 70: ...e gas supply system by closing its individual manual shut off valve Locate leaks using appropriate combustible gas non corrosive leak detector solution VIII Gas Piping WARNING Explosion Hazard Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler ga...

Page 71: ...upport the weight of the gas line piping independently from the boiler gas connection fitting located on the left side of the boiler If an additional regulator is used to reduce boiler inlet pressure below 1 2 psig 3 5 kPa it must be at least 6 to 10 ft upstream of the boiler It is very important that the gas line is properly purged by the gas supplier or utility company Figure 8 1 Gas Connection ...

Page 72: ...Tap water contains dissolved oxygen which causes corrosion In a tight system this oxygen comes out of solution and is quickly removed from the system through the automatic air vent The system then remains essentially free of oxygen If the system is not tight however frequent additions of make up water can expose the heat exchanger to oxygen on a continuous basis In addition frequent additions of h...

Page 73: ...quired If this boiler is replacing an existing boiler with no other changes in the system the old expansion tank can generally be reused If the expansion tank must be replaced consult the expansion tank manufacturer s literature for proper sizing If using antifreeze account for additional expansion of glycol solution when sizing an expansion tank In a typical residential heating system a glycol mi...

Page 74: ... Low Water Cut off may be required by local jurisdiction Auto Reset Low Water Cut off Kit P N 105591 01 is available Alternatively use Hydrolevel Safgard 1100 Taco LTR Series or equivalent Manual Reset Low Water Cut off Kit P N 108182 01 is available Alternatively use Hydrolevel Safgard 1100M LWCO plugs into the low voltage wire harness refer to Section X Wiring Install the low water cut off in a ...

Page 75: ... limits shown in Table 9 3 any time the boiler is firing At flow rates below the minimum shown the boiler s temperature rise limit function may prevent the boiler from firing Flow rates through the boiler in excess of the maximum shown in Table 9 3 can result in excessive noise or erosion damage to piping There are two basic methods that can be used to pipe this boiler into the system Method 1 pri...

Page 76: ... the expansion tank and secondary connection tees must be at least 1 In order to keep the flow rates in the system and boiler loops independent of each other provide at least 8 diameters of straight pipe upstream of the first tee and 4 diameters downstream of the second tee Keep the distance between the expansion tank and the first secondary tee as short as practical 2 Boiler Loop Piping Size boil...

Page 77: ...0 60 37 1 8 2 2400 65 Table 9 5b Recommended Grundfos Circulators for 60 Equivalent ft Boiler Loop Piping Boiler Model Minimum Pipe Size in T 35 F T 30 F T 25 F T 20 F Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boiler Piping Head Loss ft Circulator Model Flow GPM Boiler Piping Head Loss ft Circulator Model ASPN 320 1 1 2 17 0 ...

Page 78: ... 9 3 IX System Piping continued Table 9 6 Fitting and Valve Equivalent Length Copper Fitting and Sweat Valve Equivalent Length Ft Fitting or Valve Description Copper Pipe or Valve Size 1 1 1 2 90 Elbow 2 5 3 0 4 0 5 5 45 Elbow 1 0 1 2 1 5 2 0 Tee through flow 0 5 0 6 0 8 1 0 Tee Branch flow 4 5 5 5 7 0 9 0 Diverter Tee typical 23 5 25 0 23 0 23 0 Gate Valve 0 3 0 4 0 5 0 7 Globe Valve 25 0 36 0 46...

Page 79: ...iler Piping Heating Only HX Inlet Bottom Connection HX Outlet Bottom Connection IX System Piping continued CAUTION It is the installers responsibility to select boiler piping configurations that provide the proper flow rates and performance for the boiler ...

Page 80: ... Piping Heating Plus Supply Piped Indirect Water Heater HX Inlet Bottom Connection HX Outlet Bottom Connection CAUTION It is the installers responsibility to select boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater ...

Page 81: ... Piped Indirect Water Heater HX Inlet Bottom Connection HX Outlet Bottom Connection IX System Piping continued CAUTION It is the installers responsibility to select boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater ...

Page 82: ...l equal the flow rate through the system The flow rate through the system must therefore always remain within the limits shown in Table 9 3 For this reason the pressure drop through the entire system must be known This method is generally not recommended because it is often very difficult to accurately calculate the pressure drop through the system In replacement installations it may be impossible...

Page 83: ...ygenated water being heated with a heat exchanger as shown in Figure 9 10 Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements All components on the oxygenated side of the heat exchanger such as the pump and expansion tank must be designed for use in oxygenated water 2 Piping with a Chiller If the boiler is used in conjunction with a...

Page 84: ...ll wiring and grounding must be done in accordance with the authority having jurisdiction or in the absence of such requirements with the National Electrical Code NFPA 70 In Canada all wiring and grounding must be done in accordance with the Canadian Electrical Code Part 1 CSA C22 1 latest edition Failure to properly wire electrical connections to the boiler may result in serious physical harm Ele...

Page 85: ...culators is 6 3 FLA See Section XII Operation for information on setting up the pump operation 2 Low Voltage Field Connections Low voltage field connections on the low voltage PCB are shown in Figure 10 3 and are listed from top to bottom Heat T Stat 24VAC heating thermostat R 24V Hot Heat T Stat 24VAC heating thermostat W Energized or Call for Heat Heat T Stat 24VAC heating thermostat C 24V Commo...

Page 86: ...250 V 6 3 A Slow Blow 5x20mm N L N L N L N L G OUTDOOR SENSOR HONEYWELL 32003971 003 HEADER SENSOR if used TO MODBUS DEVICE if used 24 VOLT HEATING THERMOSTAT DHW THERMOSTAT if used EXTERNAL LIMIT S if used TO ALARM SYSTEM EnviraCOM THERMOSTAT Optional Replaces Heating Thermostat By Others 1 REMOVE THIS JUMPER IF EXTERNAL LIMIT IS USED 1 Low Voltage Connections Fuse F1 250 V 1 6A Slow Blow 5x20mm ...

Page 87: ...t is impossible to avoid such noise sources wire the sensor using a 2 conductor UL Type CM AWM Style 2092 shielded cable Connect one end of the shielding on this cable to ground See Section XII Operation for information on enabling the outdoor reset sensor e Header Sensor When this sensor is installed and enabled the boiler will attempt to maintain the target water temperature in the header rather...

Page 88: ...88 107750 01 9 17 Figure 10 4 Proper Installation of Header Sensor X Wiring continued ...

Page 89: ...89 107750 01 9 17 Figure 10 5 Internal Wiring Ladder Diagram X Wiring continued ...

Page 90: ...90 107750 01 9 17 X Wiring continued CONDENSATE FLOAT SWITCH ...

Page 91: ...91 107750 01 9 17 X Wiring continued Figure 10 6 Internal Wiring Connections Diagram ...

Page 92: ... L N 120V DHW AQUASTAT Low Voltage Connections Fuse F1 250 V 1 6A Slow Blow 5x20mm EnviraCOM MODBUS Boiler To Boiler Communication Network V B A Header Sensor Outdoor Sensor Heat T stat DHW T stat External Limit Alarm Spare Fuse 120 VAC Connections Pump Fuse 120 V Line System Pump DHW Pump Boiler Pump Spare Pump Fuse POWER INPUT ZONE 4 ZONE 3 ZONE 2 ZONE 1 120 VOLT CIRCULATORS ZR ZC X X END SWITCH...

Page 93: ...FF 4 MIN 24 HR OFF SLAVE PRIORITY ON RESET PRIMARY PUMP ON POST PURGE ON PRIOR PROTECT ON PUMP EXERCISE ON 30 SEC 2 WK LOW LIMIT ZC ON MAIN PRIORITY X X X X END SWITCH EXPANSION ZONE 1 ZONE 2 ZONE 3 ZONE 4 NET A B C C W R R R R 1 W W W C C C 2 THERMOSTATS 24 VAC PRIORITY BT LT ZC4 ZC3 ZC2 ZC1 1 2 3 OFF ON ZONE CONTROL CIRCULATOR PANEL CAT 5 Cable Supplied with Zone Control HEATING THERMOSTATS RJ45...

Page 94: ...ressure on the heat exchanger ASME plate DANGER Explosion Hazard Do not use matches candles open flames or other ignition source to check for leaks Make sure that the area around the boiler is clear and free from combustible materials gasoline and other flammable vapors and liquids WARNING Completely read understand and follow all instructions in this manual before attempting start up NOTICE Safe ...

Page 95: ...tection and inhibitors to protect the glycol from attacking metallic system components Do not add any more antifreeze than is necessary to protect the system from freeze damage Many of these products require annual testing of the system water to ensure that the inhibitors are still active consult the manufacturer s instructions for maintenance requirements Allowance must be made for the additional...

Page 96: ...ting power to the boiler for a few seconds Once a flame has been established for the first time subsequent calls for burner operation should result in a flame on the first try 13 If there is a problem that appears before the first try for ignition or if the boiler fails to light after four tries for ignition the HELP will blink on the Home screen Figure 11 1c Touching this HELP button will take th...

Page 97: ...to LP gas without the use of a combustion analyzer Failure to follow the conversion instructions will result in operation of the boiler at unsafe Carbon Monoxide CO levels and may result in personal injury or loss of life Improper conversion may also result in unreliable operation resulting in property damage Before attempting to operate this boiler at altitudes above 2000 ft follow instructions s...

Page 98: ...btain CO2 or O2 setting shown in Table 11 4 To reduce the CO2 increase the O2 turn throttle clockwise To increase the CO2 reduce the O2 turn throttle counter clockwise Make adjustments in increments of 1 8 and 1 4 turns and allow the boiler at least a minute to respond to each adjustment ii With the burner at low fire adjust offset regulator as needed to obtain CO2 or O2 setting shown in Table 11 ...

Page 99: ...ulator adjustment is 1 turn from factory setting Table 11 5 Starting Number of Throttle Turns for Natural Gas Model Size No Counter clockwise Turns From Fully Closed 320 5 5 399 7 0 Boiler Size High Fire CO2 Low Fire CO2 Maximum CO Air Free Range Target Range Target 320 9 0 to 9 7 9 5 8 7 to 9 5 9 5 200ppm 399 Ensure low fire CO2 reading is less than or equal to high fire CO2 reading Boiler Size H...

Page 100: ...100 107750 01 9 17 Operating Instructions XI Start Up and Checkout continued ...

Page 101: ... the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped as a combi unit 4 HeatMatchTM Software When the boiler is installed with a Sage Zone Control Panel Zone Control into a multiple zone home the Control uses a patent pending HeatMatch Software to...

Page 102: ...mand The Control accepts a call for heat demand from multipleplacesandrespondsaccordingtoit s Priority Whenmorethan1demandispresentthehigherpriority demand is used to determine active boiler settings Priority Status Screen Display Boiler Responding to 1st Sequencer Control The boiler is connected to the peer to peer network The boiler accepts demand from the Sequencer Master 2nd Domestic Hot Water...

Page 103: ...oiler Protection Features 1 Supply Water Temperature High Limit The control is equipped with internal operating control and high limit features The control monitors a dual element temperature sensor that is mounted in the supply water manifold and provides UL353 and UL1998 internal safety algorithms If supply water temperatureincreasesabovetheactivesetpointplusdiff above default 190 F 87 7 C the b...

Page 104: ...ection for the boiler water Boiler flue gas condensate drain is not protected from freezing Since the Control only controls the system and boiler circulators individual zones are not protected It is recommended that the boiler be installed in a location that is not exposed to freezing temperatures D Multiple Boiler Control Sequencer 1 Plug Play Multiple Boiler Control Sequencer When multiple boile...

Page 105: ...tial firing rate is 100 2 or 50 when the third boiler is started the firing rate starts at 200 3 or 66 After the initial start the Sequence Master develops a unison firing rate demand based on it s setpoint and sensed header temperature 10 Innovative Condensing Boiler Control Duringlowloads theSequenceMasterlimitsfiringrates to a Base Load Common Rate to ensure modulating condensing boiler peak op...

Page 106: ...lator s On After flame is proven the sequence continues with run stabilization and low fire hold time Once the field adjustable low fire hold time is completed normal boiler operation begins modulation rate depending on temperature and setpoint selections Priority Domestic Hot Water Status Running If the Central Heat call for heat is active and a Domestic Hot Water DHW call for heat received the D...

Page 107: ...symbol will always return the display to the Home screen Arrow Symbol The Arrow symbol links together all screens in the selected group For example repeated pressing the right Arrow symbol will rotate the display around all the screens in the Status group Using this feature the user can review all the boiler status and adjustment mode screens Fault Symbols Active Fault and Rate Limit symbols provi...

Page 108: ...y repeatedly selecting the right or left arrow symbol These screens are accessed by selected the Status button from the Home screen XII Operation E Boiler Sequence Of Operation continued Figure 12 6 Status Screens Figure 12 7 Boiler Status Screen Definitions NOTE Only visible if Zone Panel is connected Zone Panel 1 and 2 shown typical for 1 through 4 ...

Page 109: ...This screen provides the status of the boilers five 5 possible heat demands When demand is off the Control has not detected the call for heat This screen allows the user to determine which demands are present when more than one demand is present Bargraph Screen The bargraph screen presents measured values for easy comparison An information screen provides monitoring of Rate Demand To Fan and Fan S...

Page 110: ... continued Figure 12 8 Detail Screen Overview Zone Control Status press for zone cycles i Zone Panel 1 Demand Cycles KITCHEN 45 BEDROOMS 20 BASEMENT 12 DOMESTIC HOT WATER 26 Active zones are shown by bold underlined numbers Press the zone panel to view zone cycle counts To reset all zone cycle counts press Reset Cycle Counts NOTE Only visible is Zone Panel is connected Zone Panel 1 and 2 shown typ...

Page 111: ...creens When the Sequence Master is enabled the following screen is available The Sequencer Status screen is selected by pressing Status button from the Home screen when Sequence Master is enabled XII Operation E Boiler Sequence Of Operation continued ...

Page 112: ...Installer Password is 86 and press the return arrow to close the keypad Press the Save button Press the Adjust button to enter Adjustment mode Figure 12 9 Adjust Mode Screens 2 Adjusting Parameters Editing parameters is accomplished as follows Login to Access Adjustment Mode For Service Contact CONTRACTOR NAME ADDRESS LINE 1 ADDRESS LINE 2 PHONE NUMBER Contractor Adjust Access Level Installer Adju...

Page 113: ...ather Shutdown WWSD is not used Enable The boiler and pumps will not be allowed to start in response to a central heat call for heat if the outside temperature is greater than the WWSD setpoint WWSD is initiated as soon as outside air temperature is above WWSD Setpoint The control does not require call for heat to be satisfied The boiler will still start in response to a Domestic Hot Water call fo...

Page 114: ...trol will go to during a Domestic Hot Water call for heat If the rated input of the indirect water heater is less than the maximum output of the boiler change the DHW Maximum Expected Heat Rate fan speed setting to limit the boiler output accordingly 100 Minimum to Maximum Heat Rate Auxiliary Maximum Expected Heat Rate This parameter defines the highest modulation rate the Control will go to durin...

Page 115: ...2 P ASPN 399 02 P ASPN 320 26 P ASPN 399 26 P Maximum Heat Rate RPM 6 500 6 800 7 800 8 500 Minimum Heat Rate RPM 1 300 1 250 2 350 2 500 Default Light off Rate RPM 3 000 3 000 4 000 4 000 Altitude 6 001 7 800 ft 7 801 10 100 ft Model ASPN 320 67 N ASPN 399 67 N ASPN 320 70 N ASPN 399 70 N Maximum Heat Rate RPM 8 900 8 575 8 400 8 400 Minimum Heat Rate RPM 2 500 2 650 2 550 2 600 Default Light off...

Page 116: ... rates for the active turned on zones After establishing the maximum heat rate the Control then measures water temperature and fires the boiler only as hard as required for the heat demand Expected Heat Rate Adjustment Screens HeatMatch Software Example call for heat durations for a four zone house Maximum heat rate limits firing rate and prevents the Control from firing to 100 in response to a sm...

Page 117: ...Demand Never Any Demand Header Sensor Demand CH Off for DHW Boiler Pump run pump for Activates the boiler pump output according to selected function Never Pump is disabled and not shown on status screen Any Demand Pump Runs during any call for heat Header Sensor Demand Pump Runs when boiler is firing and when there is DHW demand Selected when Header Sensor is selected as modulation sensor and boil...

Page 118: ...ump must run for every call for heat CAUTION It is the installers responsibility to select boiler piping configurations that provide the proper flow rates and performance for the boiler and indirect water heater Example Pump Parameter selections Explanation This piping arrangement only services central heat When there is any demand both boiler and system pumps turn on CAUTION It is the installers ...

Page 119: ...r heater Parameter Selections System Pump Central Heat Optional Priority Boiler Pump any demand DHW Pump Primary Loop Piped IWH DHW Priority Enable is optional Explanation When call for Domestic Hot Water is received the DHW pump is turned on and the boiler pump is turned on This piping arrangement permits the system pump to run or not run when there is a domestic hot water call for heat Domestic ...

Page 120: ... optional It is permissible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat Example Pump Parameter selections continued XII Operation F Changing Adjustable Parameters continued Sequencer Master Boiler 1 Boiler 2 Wiring locations Thermostat X DHW call for heat X System pump X DHW pump X Boiler Pump X X Sequencer Master Parameter Selections ...

Page 121: ... Description Contractor Name User defined Contractor Name Address Line 1 User defined Contractor Address Line 1 Address Line 2 User defined Contractor Address Line 2 Phone User defined Contractor Phone Press button to access the following screen The Manual Speed Control speed screen allows the technician to set firing rate at low or high speed for combustion testing ...

Page 122: ...ature controller Proportion Integral Derivative PID values Higher values cause a larger firing rate change for each degree of temperature change If set too high firing rate overshoots required value increases to high fire causing the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change...

Page 123: ...ng the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature change If set too low the firing rate response will be sluggish and temperature will wander away from setpoint Disable Disable Enable Auxiliary Priority Over Central Heat This parameter allows the Auxiliary Heat demand to be higher o...

Page 124: ... rate response will be sluggish and temperature will wander away from setpoint 10 seconds 0 to 300 seconds Low Fire Hold Time Low Fire Hold Time is the number of seconds the control will wait at low fire modulation rate before being released to modulate After ignition and flame stabilization periods the firing rate is held at low fire for Low Fire Hold Time This delay allows heat to travel out to ...

Page 125: ... 70 F 21 1 C 32 F to 100 F 0 C to 37 8 C Central Heat High Outdoor Temperature The High Outdoor Temperature parameter is the outdoor temperature at which the Low Boiler Water Temperature is supplied This parameter is typically set to the desired building temperature 110 F 43 3 C 70 F to 190 F 21 1 C to 87 8 C Central Heat Low Boiler Water Temperature The Low Boiler Water Temperature parameter is t...

Page 126: ... to 100 F 40 C to 37 8 C Auxiliary Heat Low Outdoor Temperature The Low Outdoor Temperature parameter is also called Outdoor Design Temperature This parameter is the outdoor temperature used in the heat loss calculation It is typically set to the coldest outdoor temperature 70 F 21 1 C 32 F to 100 F 0 C to 37 8 C Auxiliary Heat High Outdoor Temperature The High Outdoor Temperature parameter is the...

Page 127: ...7 8 C Fan Coil 100 F to 140 F 37 8 C to 60 C In Slab Radiant High Mass Radiant 160 F to 190 F 71 1 C to 87 8 C Convection Baseboard Fin Tube Convective 130 F to 160 F 54 4 C to 71 1 C Staple up Radiant Low Mass Radiant 130 F to 160 F 54 4 C to 71 1 C Radiant Baseboard 140 F to 160 F 60 C to 71 1 C Radiators XII Operation F Changing Adjustable Parameters continued ...

Page 128: ...spond to rapid load increases 70 50 100 Base Load Common Rate To maximize condensing boiler efficiency the firing rate is limited to an adjustable value Boilers are kept at or below this firing rate as long as the boilers can handle the load After last available boiler has started the modulation rate limit is released up to 100 3 1 5 Response Speed This parameter adjusts the Sequence Master temper...

Page 129: ...ng two parameters may be used to adjust the signal range Modbus Modbus is used as the temperature setpoint 130 F 54 4 C 80 F 26 7 C Central Heat Setpoint Central Heat 4 20mAdc Setup 4 mA Water Temperature Sets the Central Heat Temperature Setpoint corresponding to 4mA for signal input on Control Terminals J8 6 and J10 8 Current below 4mA is considered invalid failed or incorrect wired input 180 F ...

Page 130: ... respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica...

Page 131: ...ls carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance Failure to follow all instructions in the proper order can cau...

Page 132: ...ify that the gas shutoff shown in Figure 8 1 is closed e Disconnect the gas line at the gas pipe union connection Figure 13 1 f Unplug the electrical connection to the gas valve g Disconnect the air proving switch tube from the gas valve outlet tap h Unplug the power and speed control cables from the blower NOTICE Warranty does not cover boiler damage or malfunction if the following steps are not ...

Page 133: ...133 107750 01 9 17 Figure 13 1 Disconnecting Flexible Gas Line Figure 13 2 Igniter and Flame Sensor Location XIII Service and Maintenance continued ...

Page 134: ... and free from debris If needed remove trap from heat exchanger and hanging bracket Flush any debris found in the trap with water do not use other cleaning agents Reassemble the trap as shown in Figure 13 4 XIII Service and Maintenance continued WARNING Asphyxiation Hazard Do not operate the boiler without the float switch in place Doing so could result in flue gas leakage into the indoors resulti...

Page 135: ...135 107750 01 9 17 Figure 13 3 Igniter Gap Figure 13 4 Condensate Trap Exploded Parts View XIII Service and Maintenance continued 0 177in 0 02 4 5mm 0 5 ...

Page 136: ... Turn the boiler off immediately Failure to do so could cause severe heat exchanger damage w Follow ALL instructions in Section XI Start up and Checkout to place the boiler back in service including the performance of a combustion test Outdoor Temperature Ohms of Resistance F C 20 28 9 106926 10 23 3 80485 0 17 8 61246 10 12 2 47092 20 6 7 36519 30 1 1 28558 40 4 4 22537 50 10 0 17926 60 15 6 1435...

Page 137: ... Help button flashes and the home screen turns a red color Continue to select flashing buttons to be directed to the Fault cause B Display Faults Indication Condition Possible Cause Display Completely Dark Fan off LWCO lights off no green power light on Control No 120Vac Power at Boiler Check breaker and wiring between breaker panel and boiler Blown high voltage fuse Replacement Fuse Kit part numb...

Page 138: ...s lost communication with the Sequence Master Check the following RJ 45 peer to peer network disconnected Sequencer Master was Enabled and then Disabled Master s Boiler has been powered down To clear fault restore communication or cycle power Boiler Size Setup Boiler Size Fault WARNING Boiler size setting may not match actual boiler size The Boiler size setting determines min max and light off blo...

Page 139: ...e firing rate is limited or reduced to help avoid a lockout or save energy Refer to Hard Lockout section for corrective actions High Stack Temperature Limit High Supply Temperature Limit High Differential Temperature Limit The following messages appear as part of normal start and stop sequences Minimum Modulation normal start stop sequence Low Fire Hold Rate Low fire hold rate is a normal start up...

Page 140: ...erminals J5 1 OPEN Blocked Vent Switch contact open check for blocked flue air intake NOTE Blocked Vent Switch Special Note Before a call for heat the air pressure switch is closed When there is a call for heat with a blocked vent the air pressure switch will open due to excessive pressure of the blower against a blocked flue pipe after the blower starts The control stops the start sequence and st...

Page 141: ...ch purge and light off setpoint Normal waiting for blower speed to match purge and light off setpoint 27 Undefined Fault Undefined Fault Consult Factory 28 or 53 Air Proving Switch Failed to Close Air Proving Switch Failed to Close The air proving switch has failed to close Check switch check switch connection and wiring Blocked vent blocked inlet blocked or disconnected air switch tube blocked he...

Page 142: ... Light off rate proving failed Blower is not running at Light off rate when it should or blower speed signal not being detected by Control Loose connection in 120 VAC blower wiring Loose or miswired blower speed harness Defective blower 19 Purge rate proving failed Blower is not running at Purge rate when it should or blower speed signal not being detected by Control Loose connection in 120 VAC bl...

Page 143: ...gh your local U S Boiler Wholesale distributor Should you require assistance in locating a U S Boiler distributor in your area or have questions regarding the availability of U S Boiler products or service parts please contact U S Boiler Customer Service at 717 481 8400 or Fax 717 481 8408 ...

Page 144: ...on 108036 04 1D Flame Sensor includes electrode gasket and hardware 105798 01 1E Ignitor includes electrode gasket and hardware 103005 02 1F Flue Gasket Heat Exchanger or Flue Pipe 107000 02 1G Silicone Tubing 106989 02 1H Blocked Vent Switch 106988 02 1I Condensate Float Switch 108048 01 1J Condensate Trap 108049 01 1K Return Sensor 106991 01 1L Flue Sensor 107932 01 1M Supply Sensor 106994 01 1N...

Page 145: ...145 107750 01 9 17 XV Service Parts continued ...

Page 146: ...1 108016 02 LP Propane Conversion includes O ring gsket and hardware 108015 01 108015 02 2C Blower Outlet Gasket 106029 01 2D Gas Valve 108014 01 2E Gas Adapter includes gasket 108170 01 2F Gas Adapter Gasket 108167 01 2G Gas Valve Flange 90 108103 01 2H Gas Valve Flange Straight 108104 01 2I Flare Fitting 108166 01 2J Gas Valve Rectifier Module 105830 01 2K Gas Line Flex Tube includes gasket 1070...

Page 147: ...147 107750 01 9 17 XV Service Parts continued All Models ...

Page 148: ...Catch and Keeper 108168 01 3C Jacket Panel includes left right side panels top panel top access panel left right top support brackets and hardware 108034 04 3D Vent Connector includes connector gaskets and hardware 107034 02 3E Air Intake Connector includes connector gasket and locknut 107017 02 3F Wall Hanging Bracket and Bottom Securing Bracket 108172 01 3G Leg leveler 5 16 with Nylon Glide Avai...

Page 149: ...149 107750 01 9 17 XV Service Parts continued All Models ...

Page 150: ... PCB includes PCB fuses cover and screws 107020 01 4C Programmed Control 107877 02 4D Square Control Panel Gaskets 108052 01 4E Low Voltage PCB includes PCB fuses and screws 107035 01 4F Programmed Display 107864 01 4G Control Panel includes control panel gaskets and hardware 108169 01 4H Control Panel Slides 108171 01 3 Not Shown High Voltage and Low Voltage Fuse Kit 105856 01 ...

Page 151: ...151 107750 01 9 17 XV Service Parts continued All models ...

Page 152: ...e Communication Harness 108039 03 5B High Voltage Harness 107037 02 5C Flame Sensor Harness 108045 01 5D Ignition Cable Harness 107211 01 5E Blower Control 4 pin and Blower Power 3 pin Harness 108044 01 Not Shown Outdoor Temperature Sensor 102946 01 Not Shown Header Sensor 103104 01 XV Service Parts continued 5A 5B 5D 5E 5C ...

Page 153: ...n selected proceed to Section XI Start up and Checkout to complete boiler setup See Table A2 for altitude combustion values See LP Gas Propane Conversion Instructions for LP Gas propane altitude combustion values WARNING LP Conversions boiler setup from factory is configured for use with natural gas installed from 0 2 000 ft above sea level only For conversion to LP use a proper conversion kit per...

Page 154: ...9 1 9 4 9 4 9 3 9 6 9 6 9 1 9 4 9 4 ASPN 399 NG 9 3 9 6 9 6 9 2 9 5 9 5 9 0 9 3 9 3 Low Fire Range and Target values are the same as High Fire above Ensure low fire CO2 reading is less than or equal to high fire CO2 reading Model No Fuel Measured O2 Max Co Air Free 2 001 6 000 ft 6 001 7 800 ft 7 801 10 100 ft COAF readings must be less than 200 ppm Range Target Range Target Range Target ASPN 320 ...

Page 155: ...a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A ...

Page 156: ...irements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for a...

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Page 160: ...160 107750 01 9 17 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...

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