U.S. Boiler Company ASPEN ASPN-085 Installation, Operating And Service Instructions Download Page 1

Page: 1 / 180

107362-01 - 8/17

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.

Space Heating Models:

• ASPN-085

• ASPN-110

• ASPN-155

• ASPN-205

• ASPN-270

Combi Domestic Hot Water

and Space Heating Model:

• ASPNC-155

TO THE INSTALLER: Affix these instructions adjacent to boiler.

TO THE CONSUMER: Retain these instructions for future reference.

Summary of Contents for ASPEN ASPN-085

Page 1: ...NG 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 ag...

Page 2: ...bstantial 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 s...

Page 3: ...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...

Page 4: ...ate 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 he...

Page 5: ...AD 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 D...

Page 6: ...trotherm 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...

Page 7: ...0 provide central space heating and or indirect domestic hot water DHW heating Model ASPNC 155 provides economical tankless domestic hot water DHW heating in addition to central space heating I Produc...

Page 8: ...30 ASPN 205 205 20 5 189 164 95 5 1 1 1 2 135 80 ASPN 270 270 27 252 219 95 4 6 1 1 2 145 80 The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1 15 The manufacturer should...

Page 9: ...l not 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 system...

Page 10: ...to 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 reduc...

Page 11: ...installation with the following clearances from the boiler jacket to combustible construction Top 11 5 8 Sides 1 2 Front 1 2 Bottom 6 This above clearances also apply to non combustible walls doors c...

Page 12: ...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...

Page 13: ...13 107362 01 8 17 Figure 5 1 Wall Layout Mounting Hole Location V Mounting The Boiler continued...

Page 14: ...14 107362 01 8 17 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting V Mounting The Boiler continued...

Page 15: ...th 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 combu...

Page 16: ...ems 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...

Page 17: ...17 107362 01 8 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: ...ize See Tables 7 5 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 v...

Page 19: ...ng so that any condensate which forms in the piping will run towards the boiler Pitch CPVC PVC vent piping 1 4 per foot Pitch PolyPropylene vent piping 5 8 per foot For Category I II and IV boilers ha...

Page 20: ...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...

Page 21: ...21 107362 01 8 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: ...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...

Page 23: ...3 or ISEP0339 w screen Intake Elbow w screen Note 3 Elbow w screen Note 3 Elbow w screen Elbow w screen Elbow w screen Elbow w screen Elbow w screen Elbow w screen Terminal Option B Ipex Low Profile I...

Page 24: ...ors 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 locate the vent ter...

Page 25: ...th 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 Requiremen...

Page 26: ...trotherm 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...

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 Me...

Page 28: ...esistant Use of rodent screens is generally recommended for both terminations Two rodent screens are included within the available 2 and 3 vent kits or can be fabricated from 1 2 stainless steel mesh...

Page 29: ...UV or 2PF 39UV w Screen 3PF 10UV or 3PF 39UV w Screen ISEP02 or ISEP0239 w Screen ISEP03 or ISEP0339 w Screen Intake 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elbow w Screen 180 Elb...

Page 30: ...135ft Vent Manufacturer s PN for Flex Termination Components Required 2PPS VFT 2PPS BV 2PPS FLEX 3PPS VFT 3PPS BV 3PPS FLEX IFBK02 IAWP02B IFBK03 IAWP03B Specify size of B vent e g 2PPS BV6 is for us...

Page 31: ...from an outside wall see Part VII D for additional details All venting is PolyPropylene supplied by the vent manufacturer shown in Table 7 13b The portion of this venting within the B vent is flexible...

Page 32: ...rotherm InnoFlue Flex 2 0 ft 2 Selkirk Polyflue 2 0 ft 3 DuraVent PolyPro Flex 2 0 ft 3 Centrotherm InnoFlue Flex 2 3 ft 3 Selkirk Polyflue 2 3 ft 3 DuraVent FasNSeal Flex 1 0 ft B Vent Air Chase 1ft...

Page 33: ...C 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 Uni...

Page 34: ...otherm 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 Ven...

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 Sys...

Page 36: ...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 sho...

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 adjacen...

Page 38: ...w Screen Intake 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components Masonry Chimney Chase Note 3 Vent Not Permitted...

Page 39: ...ney Chase Note 3 Vent Not Permitted 2PPS FK 2PPS FLEX 3PPS FK 3PPS FLEX Intake 90 Elbow w Screen 90 Elbow w Screen Flex Termination Components B Vent Chimney Chase Vent Not Permitted 2PPS VFT 2PPS BF...

Page 40: ...Intake 90 elbow w screen 90 elbow w screen 90 elbow w screen 90 elbow w screen 90 elbow w screen Flex Termination Components B Vent Chimney Chase Vent 2PF 10UV or 2PF 39UV w Screen 2PF BVSC 3PF 10UV...

Page 41: ...2 01 8 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 Option...

Page 42: ...42 107362 01 8 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: ...I 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 Adjace...

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...

Page 45: ...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 3 CPVC pipe and is use...

Page 46: ...o 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...

Page 47: ...47 107362 01 8 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 usin...

Page 49: ...8 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 Syste...

Page 50: ...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...

Page 51: ...zontal 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...

Page 52: ...The vent adaptor has three different inside diameters The middle inside diameter accepts 3 nominal PolyPro Figure 7 26 Lubricate the gaskets in the vent adaptor with soapy water and insert the first...

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 all...

Page 54: ...nstallation 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...

Page 55: ...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 wal...

Page 56: ...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 Concentr...

Page 57: ...for the male threads Secure the adaptor to the cap using a 2 or 3 electrical conduit lock nut Seal all joints with RTV G Assembly of Selkirk Polyflue Vent Systems WARNING Asphyxiation Hazard When usin...

Page 58: ...coupling and insert Selkirk 2PF HVST or 3PFHVST 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 i...

Page 59: ...ference 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...

Page 60: ...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...

Page 61: ...The middle inside diameter accepts 3 nominal InnoFlue Figure 7 26 Lubricate the gaskets in the vent adaptor with water and insert the first piece of 3 InnoFlue into the adaptor until it bottoms out T...

Page 62: ...ng 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...

Page 63: ...tallation 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 C...

Page 64: ...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 c...

Page 65: ...V 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 ou...

Page 66: ...ble stainless steel pipe manufacturer installation instructions and Boiler Installation Operating and Service Instructions the more restrictive instructions shall govern WARNING Asphyxiation Hazard Fl...

Page 67: ...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...

Page 68: ...ector through knockout to low voltage wiring harness Connector from Float Switch Connector from Low Voltage Wiring Harness To Low Voltage Harness Insert Bushing Supplied Condensate Neutralizer Optiona...

Page 69: ...de ANSI Z223 1 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 chaudi re existante les mesures su...

Page 70: ...from the 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...

Page 71: ...ly from the boiler gas connection fitting located on the bottom of the boiler If an additional regulator is used to reduce boiler inlet pressure below 1 2 psig 3 4 kPa it must be at least 6 to 10 ft u...

Page 72: ...ap 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 rema...

Page 73: ...sion Tank required 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...

Page 74: ...all Valve Ball Valve Temperature Pressure Gauge Drain Valve Return Inlet Supply Outlet INLET TOP OUTLET TOP Automatic Air Vent Temperature Pressure Gauge Relief Valve Drain Valve Copper Piping Cap Ret...

Page 75: ...uires that the water flow rate through it remain within the 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 m...

Page 76: ...g system as you would on any other heating system All piping between 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...

Page 77: ...9 7 0013 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 Circulat...

Page 78: ...able 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...

Page 79: ...diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Secondary Unions Not Requ...

Page 80: ...Line Y Strainer Recommended From System Full Port Isolation Valves Indirect Circulator Relief Valve Drain Valve Secondary Unions Not Required Optional Locations Shown Full Port Isolation Valves Flow C...

Page 81: ...Header Sensor As Close As Possible To Downstream Tee Y Strainer Recommended Secondary Unions Not Required Optional Location Shown Drain Valve Relief Valve Header Temperature Sensor When Used Indirect...

Page 82: ...n Relief Valve Drain Valve From System At least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight...

Page 83: ...east eight pipe diameters upstream of first tee A No further apart than 12 30 cm or four pipe diameters whichever is smaller B At least 18 46 cm of straight pipe for Conventional Air Scoop C Boiler Ci...

Page 84: ...ired Optional Locations Shown Drain Valve Heating Circulators Flow Check To System Full Port Isolation Valve At least eight pipe diameters upstream of first tee A No further apart than 12 30 cm or fou...

Page 85: ...irect Domestic Water Heater IWH Close Nipple Locate Header Sensor as close as possible to downstream tee From System A At least eight pipe diameters upstream of first tee B No further apart than 12 30...

Page 86: ...ntire 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...

Page 87: ...stem Circulator Y Strainer Recommended Balancing Valve From Convection System To Convection System Air Separator Air Vent Fill Valve Backflow Preventer Cold Water Line Expansion Tank Secondary Unions...

Page 88: ...equirements 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 i...

Page 89: ...ING All 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...

Page 90: ...A 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 liste...

Page 91: ...50 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...

Page 92: ...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 Operati...

Page 93: ...Heating Circulators DETAIL B SCALE 1 4 Header Temperature Sensor Honeywell 32003971 003 Well Should Extend Into Header Flow As Far As Possible Use Extension Only If Necessary Close Nipple Locate Head...

Page 94: ...94 107362 01 8 17 Figure 10 5 Internal Wiring Ladder Diagram X Wiring continued...

Page 95: ...95 107362 01 8 17 PAGE LEFT INTENTIONALLY BLANK...

Page 96: ...96 107362 01 8 17 X Wiring continued CONDENSATE FLOAT SWITCH...

Page 97: ...97 107362 01 8 17 X Wiring continued Figure 10 6 Internal Wiring Connections Diagram...

Page 98: ...ions 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 Conne...

Page 99: ...F 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 ZO...

Page 100: ...tion on testing and purging gas lines 8 Confirm vent system is complete and free of obstructions before attempting to fire boiler 9 Inspect all wiring for loose uninsulated or miswired connections 10...

Page 101: ...ection 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 r...

Page 102: ...ore the first try for ignition or if the boiler fails to light after four tries for ignition the blinking red screen with HELP highlighted on the Home screen Figure 11 1c Touching this HELP button wil...

Page 103: ...re adjustments could result in property damage personal injury or loss of life due to carbon monoxide CO poisoning Figure 11 2 Burner Flame Main Flow Throttle Outlet Tap Tube to Air Proving Switch Gas...

Page 104: ...burner at low fire adjust offset regulator as needed to obtain CO2 or O2 setting shown in Table 11 4 To reduce the CO2 increase the O2 turn offset regulator counter clockwise To increase the CO2 redu...

Page 105: ...5 155 13 0 205 20 0 270 5 50 Boiler Size High Fire CO2 Low Fire CO2 Maximum CO Air Free Range Target Range Target 85 9 0 to 9 7 9 5 8 7 to 9 5 9 5 200ppm 110 155 205 270 Ensure low fire CO2 reading is...

Page 106: ...106 107362 01 8 17 Operating Instructions XI Start Up and Checkout continued...

Page 107: ...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 equ...

Page 108: ...and The Control accepts a call for heat demand from multipleplacesandrespondsaccordingtoit s Priority Whenmorethan1demandispresentthehigherpriority demand is used to determine active boiler settings P...

Page 109: ...iler 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 th...

Page 110: ...ction 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 re...

Page 111: ...ial 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 set...

Page 112: ...ator 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...

Page 113: ...ymbol 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...

Page 114: ...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 St...

Page 115: ...his 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...

Page 116: ...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 b...

Page 117: ...reens 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 O...

Page 118: ...nstaller 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 Edi...

Page 119: ...ther 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...

Page 120: ...rol 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 spe...

Page 121: ...ASPN 270 02 P Maximum Heat Rate RPM 6 400 6 500 6 950 6 950 7 100 6 800 Minimum Heat Rate RPM 1 650 1 700 1 800 1 800 1 500 1 000 Default Light off Rate RPM 4 000 4 000 4 000 4 000 4 000 3 000 Altitud...

Page 122: ...ult Light off Rate RPM 4 000 4 000 4 000 4 000 4 000 3 000 Altitude 7 801 10 100 ft Model ASPN 085 70 N ASPN 110 70 N ASPN 155 70 N ASPNC 155 70 N ASPN 205 70 N ASPN 270 70 N Maximum Heat Rate RPM 8 8...

Page 123: ...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 Hea...

Page 124: ...ump 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 w...

Page 125: ...ble for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat CAUTION It is the installers responsibility to select boiler piping configurations that p...

Page 126: ...call for heat Domestic hot water priority is 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 Parameter Selections...

Page 127: ...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 Changi...

Page 128: ...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...

Page 129: ...ture 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 in...

Page 130: ...g 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 r...

Page 131: ...econds 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 stab...

Page 132: ...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 Th...

Page 133: ...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 hea...

Page 134: ...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...

Page 135: ...pond 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...

Page 136: ...g 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 Temperat...

Page 137: ...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 clot...

Page 138: ...s 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 defect...

Page 139: ...that the gas shutoff shown in Figure 8 1 is closed e Disconnect the flexible gas line at the gas valve flare connection Figure 13 1 f Unplug the electrical connection to the gas valve g Disconnect the...

Page 140: ...ible Gas Line Figure 13 2 Igniter and Flame Sensor Location XIII Service and Maintenance continued Flame Sensor Igniter When disconnecting flexible gas line place backup wrench on this nut to prevent...

Page 141: ...n the trap Unscrew the cap 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 Asp...

Page 142: ...ded Parts View XIII Service and Maintenance continued Float Switch Assembled Condensate Trap Condensate Trap Bracket Worm Gear Condensate Drain 8 18 Thread Forming Screw 1 4 Long Bottom of Boiler Conn...

Page 143: ...Turn the boiler off immediately Failure to do so could cause severe heat exchanger damage v Follow ALL instructions in Section XI Start up and Checkout to place the boiler back in service including th...

Page 144: ...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...

Page 145: ...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 f...

Page 146: ...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 Different...

Page 147: ...rminals 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...

Page 148: ...h 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...

Page 149: ...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 bl...

Page 150: ...h 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 ser...

Page 151: ...de gasket and hardware 103005 02 1F Flue Gasket Heat Exchanger or Flue Pipe 107000 01 107000 02 1G Silicone Tubing 106989 01 1H Blocked Vent Switch 105857 01 106988 02 105857 01 106988 02 1I Condensat...

Page 152: ...152 107362 01 8 17 XV Service Parts continued 1D 1E 1C 1B 1A 1G 1H 1I 1J 1K 1L 1F 1M 1F 1P 1P 1Q 1Q 1R 1S 1O 1N Space Heating Models ASPN 085 ASPN 110 ASPN 155 ASPN 205 ASPN 270...

Page 153: ...lue Sensor 107932 01 2M Supply Sensor 106994 01 2N 30 psi Relief Valve 81660319 2O Temperature Pressure Gauge 105894 01 2P Water Grommet includes 2 grommets 107257 01 2Q Water Gasket includes 2 gasket...

Page 154: ...362 01 8 17 2D 2E 2C 2B 2F 2A 2G 2H 2M 2L 2K 2F 2I 2J 2P 2R 2Q 2W 2T 2S 2V 2P 2U 2V 2X 2Y 2Z 2Z 2AA 2BB 2Z 2Z 2Z 2P 2O 2N XV Service Parts continued Combi Domestic Hot Water and Space Heating Model AS...

Page 155: ...r LP Venturi Assembly Gas Valve and Hardware 107939 01 107940 01 107941 01 107942 01 107943 01 Not Shown LP Propane Conversion Kit 107934 01 107935 01 107936 01 107937 01 107938 01 3B Blower Outlet Ga...

Page 156: ...156 107362 01 8 17 XV Service Parts continued 3J 3I 3E 3B 3A 3C 3F 3H 3G 3D 3A 3C 3D 3K 3E All Models...

Page 157: ...01 4C Gas Train Support Bracket includes hardware 108038 01 108038 02 108038 01 4D Vent Connector includes connector gaskets and hardware 107034 01 4E Air Intake Connector includes connector gasket a...

Page 158: ...158 107362 01 8 17 4F 4F 4F 4F 4G 4G 4B 4A 4C 4E 4D 4B 4B 4B XV Service Parts continued All Models...

Page 159: ...55 ASPNC 155 ASPN 205 ASPN 270 5A Transformer 106034 01 5B High Voltage PCB includes PCB fuses cover and screws 107020 01 5C Programmed Control 107877 01 107877 02 5D Square Control Panel Gaskets 1080...

Page 160: ...160 107362 01 8 17 XV Service Parts continued All models 5G 5F 5B 5A 5D 5E 5C 5D...

Page 161: ...n Harness 108039 01 108039 02 6B High Voltage Harness 107037 01 6C Ignition Cable Harness 107211 01 6D Blower Control 4 pin and Blower Power 3 pin Harness 108044 01 6E DHW to Circulator and Zone Valve...

Page 162: ...oiler 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 con...

Page 163: ...mate Derate per 1 000 ft 2 001 6 000 ft 6 001 7 800 ft 7 801 10 1000 ft ASPN 085 NG 0 0 0 3 1 0 LP 0 9 ASPN 110 NG 1 0 1 6 LP 0 7 2 0 2 5 ASPN 155 ASPNC 155 NG 2 3 3 0 3 4 LP 1 2 1 9 2 2 ASPN 205 NG 2...

Page 164: ...ange 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 Appendix A continued Model No Fuel Measured O2 Max CO Air Free 2 001 6...

Page 165: ...165 107362 01 8 17 Appendix A continued Model Size No Counter Clockwise Turns From Fully Closed NG 85 7 0 110 9 5 155 13 0 205 20 0 270 5 5 Table A 3 Approximate Starting Number of Throttle Turns...

Page 166: ...nger and DHW through a flat plate heat exchanger DHW is activated by a flow switch Water temperatures are regulated by the boiler controls and a thermostatic mixing valve III Specifications ASPNC 155...

Page 167: ...lation regulations enforced in the area where the installation is to be made These regulations shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before instal...

Page 168: ...t alteration service or maintenance can cause property damage personal injury or loss of life Read and understand the entire ASPN boiler manual before attempting installation start up operation or ser...

Page 169: ...of boiler shown in Figure C 2 Please note there is no top and bottom supply return connection available on combi 155 boiler only bottom supply and return piping 4 Install DHW piping included in miscel...

Page 170: ...r May Be Substituted For Tees Y Strainer Recommended Cold Water Line Boiler Circulator Optional Full Port Isoltaion Valves At least eight pipe diameters upstream of first tee A No further apart than 1...

Page 171: ...head screwdriver Standard and small Small flat head screwdriver Pliers Adjustable wrench Electric drill with extension VI General Installation Instructions All connections in this kit require gaskets...

Page 172: ...the flow switch is installed in the vertical position Numbers is parenthesis refer to balloon numbers in Figure C 3 Figure C 3 DHW Assembly Diagram 3 5 4 2 1 H C MIX Ensure the flow switch is installe...

Page 173: ...ombi Consult local codes to determine if required XII System Readiness Consult preceding sections in this manual for boiler connections 13 Fill system Bleed air from main heat exchanger through top le...

Page 174: ...er s website customer honeywell com before proceeding 24 Measure water temperature using a thermometer or the thermostrip provided with mixing valve 25 Loosen hand wheel screw lift hand wheel and turn...

Page 175: ...per mixing valve operation Annual Flush DHW loop to remove scaling Vinegar can be used to remove scaling WARNING Follow boiler shut down procedure in the preceding Sections of this manual before clean...

Page 176: ...n the manual open position 3 Remove actuator by depressing locking button and lifting straight up 4 To Install Line up motor coupling to slot in shaft of body and fit the head onto the valve body ensu...

Page 177: ...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 AP...

Page 178: ...rements 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 ventin...

Page 179: ...179 107362 01 8 17...

Page 180: ...180 107362 01 8 17 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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U.S. Boiler Company ASPEN ASPN-085, Installation, Operating And Service Instructions

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