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Savio Heat Only, Installation & Operation Instructions

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2  SAVIO HEAT ONLY MANUAL

Dear Customer:

Thank you for buying a SAVIO Heating Only Boiler System.

The SAVIO Heating Only is a high ef  ciency, non-condensing, wall mounted gas boiler which 

provides central heat supply water.

We realize that it is not possible to answer all questions about the SAVIO boiler system in this 

manual. Reading this installation manual does not make the reader an expert in all aspects 

of installation and operation, and does not replace the need for a quali  ed, licensed heating 

contractor. We urge you to contact your installing contractor or distributor if you are in question 

about any aspect of your boiler’s performance. Our main concern is that you are satis  ed with 

your boiler and its performance. We require that your contractor complete ef  ciency tests using 

instruments.

The external controls and accessories listed in this manual (excluding those supplied inside 

the boiler) are intended to serve as guidelines rather than speci  c recommendations. We re-

alize that other makes and models of such devices are available and can be used as suc-

cessfully as those we specify. The installing contractor is the best judge of a system’s speci  c 

requirements, as well as the local availability of certain makes and models of controls and 

accessories. The preceding does not apply, however, to the equipment that comes with every 

boiler, such as the overheat control and pressure relief valves. 

The installation of the spe-

ci  c devices supplied with every boiler is absolutely necessary to the safe operation of 

the boiler and protection of the heating system.

All SAVIO wall hung boilers are built in accordance with the ASME boiler and pressure vessel 

code, and bear the “H” stamp. The Entire range of applications for the SAVIO boiler has been 

tested to standard CSA 4.9 and is CSA compliant.

This SAVIO Heating Only boiler has a 2 year warranty on the boiler, and 10 years on the heat

exchanger a copy of which is provided with the boiler. Please be sure to return the warranty 

registration card as the warranty will be void without your boiler’s serial numbers (located on 

the ratings label af  xed to the boiler), date of installation and the name of your installer being on 

record in our   les.

Thank you for purchasing our SAVIO Heating Only boiler. If you have questions or comments, 

please don’t hesitate to contact us immediately. Our goal is 100% customer satisfaction.

BOYERTOWN inc.

Summary of Contents for Heat Only

Page 1: ... light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Fol low the gas supplier s instructions If you can not reach your gas supplier call the re department Installation and service must be performed by a quali ed installer service agency or the gas supplier WARNING If the information in this manual is ...

Page 2: ...ify The installing contractor is the best judge of a system s speci c requirements as well as the local availability of certain makes and models of controls and accessories The preceding does not apply however to the equipment that comes with every boiler such as the overheat control and pressure relief valves The installation of the spe ci c devices supplied with every boiler is absolutely necess...

Page 3: ...16 19 Restrictor Sizing 9 1 16 Fitting the Flue System 9 2 16 Choice of Flue 9 3 17 19 Pipe Connections 10 20 Gas Pipe Connections 11 21 Electrical Connections Wiring 12 22 24 Power Connection 12 1 22 Connection to the Electricity Supply 12 2 22 Room Thermostat Connection 12 3 23 Relay Panel Control Connection 12 4 23 Zone Valve Microswitch Connection 12 5 24 Circulator Sizing 13 25 Circ Cap as a ...

Page 4: ...ecking the Burner Ignition 15 6 32 Adjustment of the Useful c h Output 15 7 32 Labels Placement 15 8 33 Checking the Flue System and Comb 15 9 34 Instructing the User 15 10 34 Gas Conversion 16 35 Annual Maintenance 17 36 37 Warnings 17 1 36 Dismantelling the External Panels 17 2 36 Emptying the C h System 17 3 36 Cleaning the Primary Heat Exch 17 4 37 Checking the Pressuris in C h Vess 17 5 37 Cl...

Page 5: ...cinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your build ing Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you can not reach your gas supplier call the re department Installation and service must be performed by a quali ed installer s...

Page 6: ...often confused with those of in uenza and the highest incidence of poisoning occurs at the onset of cold weather or during u season A victim may not experience any symptoms only one symptom or a few symptoms Suspect the presence of carbon monoxide if symptoms tend to disappear when you leave your home The following signs may indicate the presence of carbon monoxide Hot gasses from appliance ventin...

Page 7: ...ler area clean and free of all re hazards Please read the literature and warranties supplied by the manufacturers of the various accessory equipment This equipment is warranted by the respective manufacturers not by Boyertown Inc Each piece of equipment must be installed and used according to the recommendations of the manufacturer Codes and Regulations Installation of the boiler and related equip...

Page 8: ...e a lack of water in the system Frost protection contains an integral frost protection system to prevent frost dam age which can occur in areas susceptible to very cold weather conditions Boiler operation recognition system should the boiler not be used for longer than 24 hours it then performs a control led system test to ensuring the motorized components within the boiler do not be come inoperab...

Page 9: ...9 0 5 2 FLUE DESIGN Minimum Venturi pressure inwc 0 64 Flue pipe diameter Coaxial in 2 25 4 3 25 5 Twin split pipes in 3 25 3 25 Nominal heat ow rate 0 2000ft MBH 122 8 Nominal heat ow rate 2000 4500ft MBH 116 7 Min Exhaust temperature F 262 Max Exhaust temperature F 324 INJECTORS No Size Natural 14 130 Propane 14 89 GAS FLOW RATE Gas Min Max Natural ft h 48 7 121 1 Propane lb h 2 23 5 55 CLEARANC...

Page 10: ...fety thermostat 14 Modulation operator 15 Gas valve outlet pres Test point 16 Gas valve inlet pres Test point 17 Central heating expansion vessel 18 Central heating temp Probe NTC 19 Central heating pressure relief valve 20 Primary circuit ow switch 21 Main circuit drain cock 22 By pass valve 23 Venturi device 24 Flue outlet pipe 25 Air Intake Pipe 26 Control panel 27 Safety thermostat probe 28 Pr...

Page 11: ...Y MANUAL 11 Internal Piping Parts List 4 23 11 25 24 20 9 6 15 1 4 16 3 22 17 10 5 18 14 27 7 21 28 29 30 19 31 Note Pressure Relief Valves 19 should be piped to a drain or to the oor as lose as pos sible to a drain ...

Page 12: ...IO HEAT ONLY MANUAL Electric Diagrams 5 Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause im proper and dangerous operation Verify proper operation after servicing ...

Page 13: ...uvers installed There should be two louvers place each within 12 of the ceiling and oor respectively Each vent will have a free area of 54 square inches 8 0 in 27 7 in 12 8 in 3 0 in 18 0 2 0 in 15 8 in 10 0 in 2 0 in CLOSET INST ALLATION MINIMUM PERM ANANT CLEARANCE FRONTV I S W E I DE VIEW CLOSET INST ALLATION CLOSET INST ALLATION SERVICECLEARANCE Figure 6 2 Outside Air Opening Air Opening Each ...

Page 14: ...window or gravity inlet into any building The Vent hood shall not be less than 2 feet from an adjacent building 3 The Vent hood shall be not less than 7 feet above grade when located adjacent to public 4 walkway The Vent hood shall be located so that ue gasses are not directed to jeopardize people 5 overheat combustible structures materials or enter buildings Minimum of 4 feet horizontal clearance...

Page 15: ...he particular wall construction Mounting Steps Tape the paper template to the wall in the chosen location Be sure to level the 1 template Pre drill two holes in the center of the oval slots on the mounting bracket sized for 2 the hardware being used Mount the bracket to the wall Be sure to level the bracket by adjusting the screw in 3 the vertical slot Pre drill the remaining hole in the mounting ...

Page 16: ...rements Depending on the nal ue pipe length an alternative restrictor may be required Refer to the tables 9 1 for proper restrictor ring sizing Figure 9 1 Coaxial 2 5 4 0 Restrictor Size From 1 65 to 3 30 ft 41 From 3 30 to 8 86 ft 44 Separate 3 25 3 25 Restrictor Size For 1 65 in and 1 65 out 38 From 3 30 to 39 40 in out 41 Table 9 1 Fitting the flue system 9 2 In general it has to be taken in co...

Page 17: ... extensions This ue system can only be used to discharge horizontally it is not designed to enable termination in the vertical plane Installation Drill hole A on the wall template through the outside wall that is less than 18 thick Cut the pipes as necessary so that a no more than 6 protrudes from the house Slide the intake and exhaust pipes through the hole Slide one rubber wall trim piece on the...

Page 18: ...d then the maximum permis sible lenght of either pipe must be reduced by 3 0 ft or 5 4 ft respectively The sum of the lenghts of the two horizontal part must be less than 131 ft Installation Drill holes B C on the wall template through the outside wall Cut the pipes as necessary so that no more than 6 of intake pipe protrudes from the house and the exhaust pipe is a minimum of 4 inches longer than...

Page 19: ...3 0 ft or 5 4 ft respectively Note When utilizing this option see page 13 for room ventilation details Installation Drill hole C on the wall template through the outside wall Cut the pipe as necessary so that no more than 6 protrudes from the house Slide the exhaust pipe through the hole Slide one rubber wall trim piece on the pipe from inside and one from outside Attach each collar to the boiler ...

Page 20: ... 1 Thoroughly clean the connections Attach the supplied components to the boiler connections see Figures 10 1 Be sure to use the proper gaskets for the pipe connections Before connecting the boiler to the heating system piping review the suggested piping dia grams in Section 4 page 11 If the c h system is above the boiler level it is advisable to install c h cocks close to the boiler for servicing...

Page 21: ...l to conform to local codes if any Massa chusetts statecode requires gas shut off to be a tee handled gas cock Locate a drop pipe adjacent to but not in front of the boiler Locate a tee F in the drop pipe at the same elevation as the gas inlet connection to the boiler Extend the drop line with a nipple towards the oor and cap to form a sediment trap E Install a shut off valve A before the tee with...

Page 22: ...ions In the USA maintain a clearance of at least 4ft horizontally from the vent terminal to gas meters electric meters regulators and relief equipment In Canada maintain a 6ft clearance between the vent terminal and these devices Connection to the electricity supply 12 2 Connect the electrical supply cable coming from the fused spur isolation switch to the power supply terminal block of the boiler...

Page 23: ...om thermostat must be connected to the Control Terminal Block Fig 12 7 Figure 12 7 Connect the room thermostat between terminals 1 and 3 as shown in Fig 12 7 Power supply terminal block External controls terminal block T Room thermostat 1 2 L N 3 120V rating The relay control must be connected to the terminal block situated next to the control panel Figure 12 8 When connecting any type of relay co...

Page 24: ... terminal block J 120 VAC Control Terminal Block Figure 12 11 Connect the micro switch of the zone valve to terminals 1 and 3 as shown in g ure 12 11 Connect the zone valve switch to the room thermostat as shown in gure 12 11 120 VAC Control Terminal Block 1 L N 3 V T Zone Valve Room Thermostat Finishing 12 6 Route the electrical supply cord and the external control cord as illustrated in Fig 12 1...

Page 25: ...d ow rate using the graph above If the internal circulator is adequate direct system piping can be utilized See section 4 page 11 for suggested direct supply return piping If the internal circulator is inadequate a secondary circulator must be utilized See sections 14 for suggested primary secondary piping Expansion vessel 13 2 The height difference between the C h PRV 19 on page 10 and the highes...

Page 26: ...nts are to be supplied by the installer It is very important to use an hydraulic separator before secondary circulators 23 11 25 24 20 9 6 15 1 4 16 3 22 17 10 5 18 14 27 7 21 28 29 30 19 Max Spacing 4x Primary Pipe Dia Typ Min Spacing 12 Secondary Loops Secondary Circulator Hydraulic Separator ...

Page 27: ...s are to be supplied by the installer It is very important to use an hydraulic separator before secondary circulators 23 11 25 24 20 9 6 15 1 4 16 3 22 17 10 5 18 14 27 7 21 28 29 30 19 zone valve zone valve zone valve Secondary Circulator Supply Lines to System Zone Valve Return Lines from System Hydraulic Separator ...

Page 28: ... conn to radiators 14 3 All external piping components are to be supplied by the installer 23 11 25 24 20 9 6 15 1 4 16 3 22 17 10 5 18 14 27 7 21 28 29 30 19 System Return Manifold System Supply Manifold with zone valves or circulators By pass Valve Return Water Temperature Gauge Shut Off Valve ...

Page 29: ... valves on the c h system Inspect the boiler and the system for wa ter soundness and remedy any leaks dis covered Cold ush the system to remove any loose particles and any system debris before starting the boiler for the rst time Reassemble the front panel of the case Return ll valve to automatic position Lighting the boiler 15 2 Note If external controls are tted e g room thermostat ensure they c...

Page 30: ... call for heat Switch on the boiler Check the maximum gas pressure and com pare the value on the gauge with the value indicated in the Section 2 on page 9 gas pressures at the burner Check the maximum gas ow at the gas meter and compare the value indicated in the section 2 on page 9 gas ow rate Switch off the boiler Disconnect the gas modulator coil by remov ing the electrical connector E Figure 1...

Page 31: ...in Fig 15 5 until you obtain the required pressure by rotating clockwise the pressure increases Turn the boiler off and disconnect one of the two connectors E in Fig 15 5 Start the boiler and rotate the minimum gas pressure adjustment G in Fig 15 5 until you obtain the required pressure by rotating clockwise the pressure increases Turn the boiler off and re connect the wire to the modulating opera...

Page 32: ...15 9 Adjust the gas pressure at the injectors to the value indicated in the tables of section 2 By rotating the device clockwise the pressure in creases After the adjustment operations bring the se lector 3 of gure 15 9 back to the normal posi tion ON Reassemble the service panel Close the gas valve outlet pressure test point 15 gure 15 5 Reassemble the front pannel of the case Important after the...

Page 33: ...plete unless labels supplied are placed on the boil er as shown in Figure 15 10 All the labels supplied with the boiler are numbered for reference According to Figure 15 10 place all the labels on the boiler Use label numbered as 1 already installed in the front panel to begin the placement in the correct way 1 4 2 3 5 ...

Page 34: ...f switch Explain the proper use and adjustment of all system controls this will ensure the greatest possible safety and fuel economy Explain the function and use of the function switch Explain how to turn off the appliance for both short and long periods and advise on the pre cautions necessary to prevent damage should the appliance be inoperative when freezing conditions may occur Fill in the det...

Page 35: ...correctly Re assemble the burner the front panel of the combustion chamber and the lid of the sealed chamber Extract the control panel as explained in the section 12 1 of this manual Loosen the screws D and remove the ser vice panel gure 16 2 A A 7 Figure 16 2 Set correctly the dip switch 2 to the correct position Fig 16 3 in accordance with the following table Gas supply Position of the switch 2 ...

Page 36: ...he gas cock before carrying out any procedures what soever for cleaning maintenance opening or dismantling boiler panels Dismanteling the external panels 17 2 Front Panel Loosen the three screws A Fig 17 1 Lift and remove the panel Side Panels Loosen the screws B Figure 17 2 Bring the bottom of the panels away from the boiler and lift them freeing them from the top hooks Figure 17 1 A A Figure 17 ...

Page 37: ...special maintenance but it is suf cient to dust it with a bristle paintbrush Checking the ue 17 7 Have the integrity of the ue outlet pipe 24 on page 10 air intake pipe 25 on page 10 checked periodically the venturi device 23 on page 10 cleaned and the ef ciency of the ue safety circuit checked at least once a year For all the above maintenance operations it is ad visable to call an approved Servi...

Page 38: ..._______________________________________________________ Performance Tests GROSS STACK TEMPERATURE __________________ ROOM TEMPERATURE AMBIENT ________________ NET STACK TEMPERATURE _____________________ CO2 __________________ O2 ___________________ SMOKE READING ___________________ COMBUSTION EFFICIENCY _________________ COMMENTS ___________________________________________________________ ________...

Page 39: ...SAVIO HEAT ONLY MANUAL 39 ...

Page 40: ...17962 1507 0 2908 40A4 USA ...

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