Velocity Shadow Series Installation And Operating Instructions Manual Download Page 84

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XV Parts

All Shadow Series Repair Parts may be obtained through your local Velocity Boiler Works Wholesale distributor. Should you

require assistance in locating a Velocity Boiler Works Distributor in your area, or you have questions regarding the avail-

ability of Velocity Boiler Works products or repair parts, please contact Velocity Boiler Works Customer Service at (215)

535-8900 or Fax (215) 535-9736 or at www.velocityboilerworks.com

Summary of Contents for Shadow Series

Page 1: ...for energy ef ciency established by the United States Environmental Protection Agency EPA Velocity Boiler Works LLC P O Box 14818 3633 I Street Philadelphia PA 19134 9700609 WARNING Improper installat...

Page 2: ...ED to install or service boilers do not install or service this one THE BOILER MAY LEAK WATER at the end of its useful life Be sure to protect walls carpets and valuables from water that could leak fr...

Page 3: ...the boiler See the Water Piping and Trim Section of this manual for details This boiler is supplied with safety devices which may cause the boiler to shut down and not re start without service If dama...

Page 4: ...PVC PVC Vent Systems 27 F Condensate Trap and Drain 34 G Removing An Existing Boiler From Common Chimney 35 VIII Gas Piping 36 IX System Piping 38 A General System Piping Precaution 38 B Near Boiler P...

Page 5: ...r designed for use in forced hot water heating systems requiring supply water temperatures of 180 F or less It is designed for installation on a wall This boiler may be vented vertically or horizontal...

Page 6: ...ons III Before Installing 1 Safe reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the auth...

Page 7: ...space as the boiler 5 The boiler should be located so as to minimize the length of the vent system 6 The combustion air piping must terminate where outdoor air is available for combustion and away fr...

Page 8: ...boiler onto the wall mounting hook Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when filled with water Jurisdictions...

Page 9: ...holes C and D using the obround slots in the bottom mounting flange Secure the bottom flange to the wall using the 5 16 x 2 lag screws or other fasteners as appropriate Figure 5 2 9 Verify that the f...

Page 10: ...9 Figure 5 1 Wall Layout Mounting Hole Location...

Page 11: ...10 Figure 5 2 Boiler Mounting Bracket Installation Boiler Wall Mounting...

Page 12: ...mper with this boiler When using the CPVC PVC vent option the use of CPVC is required when venting in vertical or horizontal chase ways Any CPVC vent materials supplied with this boiler do not comply...

Page 13: ...win Pipe Vent Systems C Design Requirements Unique to Vertical Twin Pipe Vent systems D Design Requirements Unique to Split Vent Systems 1 Approved Vent Systems and Materials The following materials a...

Page 14: ...sweep elbows are treated as having the same equivalent length Example A 3 twin pipe horizontal CPVC PVC vent system is planned for a horizontally vented 120MBH model which has the following components...

Page 15: ...erly supported Maximum support spacing is 4 feet Les instructions d installation du syst me d vacuation doivent pr ciser que les sections horizontales doivent tre support es pour pr venir le fl chisse...

Page 16: ...the boiler as measured along the vent b The wall is 12 thick or less c An airspace of at least that shown in Figure 7 4 is maintained around the OD of the vent If any of these conditions cannot be met...

Page 17: ...16 FIGURE 7 4 WALL PENETRATION CLEARANCES FOR PVC VENT PIPE...

Page 18: ...7 3 x 32 CPVC 197117 3 x 44 CPVC See Part VII E of this manual and the Ipex instructions provided with the terminal for installation details Terminal Option E Diversitech Concentric Terminal This term...

Page 19: ...ake Elbow w Screen Note 3 Elbow w Screen Note 3 Terminal Option B Ipex Low Profile Ipex 196984 Ipex 196985 Terminal Option C Diversitech HVENT HVENT 2 HVENT 3 Terminal Option D Ipex FGV Concentric Ipe...

Page 20: ...to damage by flue gas condensate they should be moved or protected Install the vent and air intake terminals on a wall away from the prevailing wind Reliable operation of this boiler cannot be guaran...

Page 21: ...FIGURE 7 8 HORIZONTAL CPVC PVC VENTING WITH LOW PROFILE TERMINAL VENT OPTIONS 1 2 TERMINAL OPTIONS B C FIGURE 7 9 HORIZONTAL CPVC PVC WITH CONCENTRIC VENT TERMINAL VENT OPTIONS 1 2 TERMINAL OPTIONS D...

Page 22: ...OCATION 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 Note Air intake termi...

Page 23: ...these vent options are as follows Ipex PN FGV Concentric Terminal Description 196005 2 x 16 PVC 196105 2 x 28 PVC 196125 2 x 40 PVC 196006 3 x 20 PVC 196106 3 x 32 PVC 196116 3 x 44 PVC 197107 3 x 32...

Page 24: ...ake 180 Elbow w Screen 180 Elbow w Screen Terminal Option I Ipex FGV Concentric Ipex 196105 Note 3 Ipex 196006 Note 3 Terminal Option J Diversitech CVENT Concentric CVENT 2 CVENT 3 Notes 1 Max vent le...

Page 25: ...24 FIGURE 7 12 VERTICAL CPVC PVC VENTING VENT OPTIONS 10 11 TERMINAL OPTION H FIGURE 7 13 VERTICAL CPVC PVC VENTING WITH IPEX CONCENTRIC VENT TERMINAL VENT OPTIONS 10 11 TERMINAL OPTIONS I J...

Page 26: ...nation 2 Vent Terminal Location Observe the following clearances from roof mounted vent terminals also see Figure 7 14 Bottom of terminal must be at least 12 above the normal snow line anticipated on...

Page 27: ...50 52 180 52 Max Equivalent Vent Length Note 1 Models 080 60ft 135ft 100 60ft 135ft 120 Not Permitted 135ft 150 135ft 180 135ft Rigid Vent Terminals Vent Coupling w Screen Coupling w Screen Intake 90...

Page 28: ...cementing Cement the vent system together starting at the boiler and following the instructions provided on the cans of cement and primer Use a field supplied cement and primer that is listed for use...

Page 29: ...y can be later removed for cleaning and inspection If this is done drill a clearance hole in these fittings and a tap hole in the end of the vent intake pipes to accept these screws d Use roof flashin...

Page 30: ...29 FIGURE 7 19 INSTALLATION OF STANDARD VERTICAL TERMINALS FIGURE 7 18 INSTALLATION OF STANDARD HORIZONTAL TERMINALS RODENT SCREENS ARE SUPPLIED BY INSTALLER RODENT SCREENS ARE SUPPLIED BY INSTALLER...

Page 31: ...Cement the inner pipe section of PVC pipe supplied with this kit to the Wye fitting using a primer and cement listed for use with PVC e Cement the outer pipe to the Wye being careful to keep the inne...

Page 32: ...31 FIGURE 7 21 INSTALLATION OF DIVERSITECH LOW PROFILE TERMINAL THROUGH SIDEWALL FIGURE 7 20 INSTALLATION OF IPEX LOW PROFILE TERMINAL THROUGH SIDEWALL...

Page 33: ...32 FIGURE 7 23 INSTALLATION OF IPEX AND DIVERSITECH CONCENTRIC TERMINAL THROUGH SIDEWALL FIGURE 7 22 CUTTING IPEX AND DIVERSITECH CONCENTRIC VENT TERMINALS...

Page 34: ...33 FIGURE 7 24 INSTALLATION OF IPEX AND DIVERSITECH CONCENTRIC TERMINAL THROUGH ROOF...

Page 35: ...If the corrugated condensate drain line must be extended construct the extension from PVC or CPVC pipe Insert the hose provided with the boiler into the end of the extension as shown in Figure 7 25 2...

Page 36: ...the National Fuel Gas Code ANSI Z223 1 Au moment du retrait d une chaudi re existante les mesures suivantes doivent tre prises pour chaque appareil toujours raccord au syst me d evacuation commun et q...

Page 37: ...ures of 1 2 psi 3 5kPa or less isolate the boiler from the gas supply system by closing its individual manual shut off valve Locate leaks using approved combustible gas non corrosive leak detector sol...

Page 38: ...er It is very important that the gas line is properly purged by the gas supplier or utility company FIGURE 8 1 GAS CONNECTION TO BOILER TABLE 8 2 MINIMUM AND MAXIMUM INLET PRESSURES MODEL MAX NATURAL...

Page 39: ...t guideline 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 sys...

Page 40: ...esign flow rate through the heating 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 rat...

Page 41: ...40 FIGURE 9 2 NEAR BOILER PIPING HEATING ONLY BOILER LOOP PIPING SHOWN SHADED...

Page 42: ...41 FIGURE 9 3a NEAR BOILER PIPING HEATING PLUS INDIRECT WATER HEATER...

Page 43: ...42 FIGURE 9 3b NEAR BOILER PIPING HEATING PLUS INDIRECT WATER HEATER...

Page 44: ...e 9 1 They also generally provide effective connection points for automatic air elimination devices and an expansion tank These separators are available from several sources and may be used in place o...

Page 45: ...can generally be reused If the expansion tank must be replaced consult the expansion tank manufacturer s literature for proper sizing 5 Fill Valve required Either a manual or automatic fill valve may...

Page 46: ...d Failure to do this may result in nuisance boiler shut downs due to small amounts of air trapped around the probe FIGURE 9 6 FACTORY SUPPLIED PIPING AND TRIM INSTALLATION D Piping for Special Situati...

Page 47: ...46 This page is intentionally left blank...

Page 48: ...ing diagram of any controls used with the boiler Read understand and follow all wiring instructions supplied with the controls NOTICE This boiler is equipped with a listed high water temperature limit...

Page 49: ...rom left to right 1 Heat T Stat 24VAC heating thermostat 2 Heat T Stat 24VAC heating thermostat 3 DHW Stat 24VAC domestic hot water thermostat 1 4 DHW Stat 24VAC domestic hot water thermostat 2 5 Exte...

Page 50: ...49 FIGURE 10 2 LINE VOLTAGE FIELD CONNECTIONS FIGURE 10 3 LOW VOLTAGE PCB TERMINAL CONNECTIONS...

Page 51: ...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 c Low water cut off wiring Although not necessary to prote...

Page 52: ...51 FIGURE 10 4a 120V LWCO FIELD WIRING FIGURE 10 4b 24V LWCO FIELD WIRING...

Page 53: ...nal 120VAC 60Hz 1Ph L3 1 J4 4 J4 2 J4 6 J4 3 J4 5 J4 7 Combustion Fan 120V Conn 1 3 2 J8 6 J8 10 J8 4 J8 9 J8 8 J8 11 J8 5 J10 7 J10 8 Outdoor Temp J6 7 J6 8 1 2 3 Flue Gas Sensor 1 DC 2 Tach 4 PWM 5...

Page 54: ...53 FIGURE 10 6 INTERNAL WIRING CONNECTIONS DIAGRAM...

Page 55: ...54...

Page 56: ...e system to at least 12 psi at the boiler 6 Bleed air from the heat exchanger using the manual air vent in the top left side of the heat exchanger Figure 11 1 To do this install a piece of ID clear tu...

Page 57: ...for required dosage In general these products are a blend of glycol for freeze protection and inhibitors to protect the glycol from attacking metallic system components Do not add any more antifreeze...

Page 58: ...efore attempting another ignition sequence This Hold can be reset by interrupting power to the boiler for a few seconds Once a flame has been established for the first time subsequent calls for burner...

Page 59: ...ll for Heat FIGURE 11 2b HOME SCREEN ON HEAT DEMAND FIGURE 11 2c HOME SCREEN WITH ACTIVE FAULT Outlet Supply Temp Demand Code Demand Codes CH Heat dH Domestic Hot Water FP Frost Protection Alternate F...

Page 60: ...may result in damage to the gas valve and cause property damage personal injury or loss of life due to carbon monoxide CO poisoning WARNING Asphyxiation Hazard Each boiler is tested at the factory an...

Page 61: ...ton The boiler will return to automatic modulation from either screen after 15 minutes if no buttons are pressed 17 Perform a check of the ignition safety shut off device With the burner firing carefu...

Page 62: ...61 Lighting and Operating Instructions...

Page 63: ...the display shows the home screen shown in Figure 12 0 By pressing the LH or RH buttons at the bottom of the screen it is possible to navigate to other User Mode screens See Figure 12 1 for a descript...

Page 64: ...f the conditions listed in the IMPORTANT box below is met If ODR is turned off the screens for adjusting LBT HOD and LOT are not visible LBT S3 Low Boiler Temperature See Figure 12 3 and the Odr discu...

Page 65: ...G Burn Hazard Water temperatures over 125 F can cause personal injury or death due to scalding Children Disabled and Elderly are at most risk of being scalded This boiler is not designed to directly c...

Page 66: ...S1 Outdoor Reset Odr On Outdoor Reset Odr Off See Table 12 4 and text for a description of settings Set up Mode Button Usage LH Done Save return to User Mode RH Next Save move to next screen UP DWN Ch...

Page 67: ...t point upon a call for space heat 180F 32 191F S2 Odr Outdoor Reset Enable On On or Off S3 LBT Low boiler temp Fig 12 3 130F 69 191F S4 HOD High outdoor temp Fig 12 3 70F 31 101F S5 LOD Low outdoor t...

Page 68: ...r heat The boiler will once again use the CH target temperature when the call for DHW ends D Frost Protection Frost Protection starts the boiler and system pump and fires the boiler when low supply wa...

Page 69: ...un at low fire if it is on used for combustion testing Pressing the LH Done button returns the user to User mode and also returns the burner to automatic modulation If no button on pressed while on th...

Page 70: ...omponent of this boiler Assure that all safety and operating controls and components are operating properly before placing the boiler back in service Annually inspect all vent gaskets and replace any...

Page 71: ...the gas shutoff shown in Figure 8 1 is closed e Disconnect the union under the boiler Figure 8 1 f Remove the 8 32 nuts securing the gas escutcheon plate to the bottom cabinet panel g Unplug the elect...

Page 72: ...actory insulation on the inside of the door see Refractory Warning on next page or the electrodes l Inspect the heat exchanger combustion chamber and vacuum any debris found on the coil surfaces If ne...

Page 73: ...ect all rubber and plastic components on the blower gas valve assembly looking for deterioration Replace blower and or gas valve if deterioration is found q Inspect and clean the condensate trap Place...

Page 74: ...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 separatel...

Page 75: ...boiler water additives v Test the flow switch To do this Start with the boiler in standby Close a shut off valve in the boiler loop Initiate a call for heat and confirm that the boiler shows Hold 137...

Page 76: ...ure and the Lockout Code as shown A list of these codes and their meanings are shown in Table 14 4 Codes used for Holds and Lockouts are the same and in some cases a hold condition that lasts long eno...

Page 77: ...valve is closed the APS is monitoring the pressure drop across gas air mixer venturi for the 80 120 swirl plate on the 150 and 180 Greater air flow through the mixer causes this pressure reading to i...

Page 78: ...ween the readings Return Sensor The boiler control infers the return temperature based on the resistance measured across a single thermistor in the return sensor Table 14 8a shows this resistance as a...

Page 79: ...g rate There are two electrical connections at this fan 120V Plug Supplies 120VAC Power to the Fan Speed Control Plug Delivers a PWM speed control signal from the boiler control to the fan This plug a...

Page 80: ...ture rise across boiler exceeded 63F Inadequate water flow through boiler see causes for Error code 67 82 Flue gas temperature exceeded 214F Dirty heat exchanger Incorrect air fuel ratio Excessive fir...

Page 81: ...blue and yellow terminals on boiler control Is 24VAC present across transformer secondary brown and pink wires at plug L3 Is 120VAC present across black and white wires at plug L2 Loose or mis wired c...

Page 82: ...81 FIGURE 14 6 CONTROLS LOCATION FIGURE 14 7 PRESSURE SWITCH TUBING CONNECTIONS...

Page 83: ...58 70 1748 176 80 1252 194 90 912 212 100 674 230 110 506 248 120 384 Table 14 8b Outdoor Air Temperature Sensor Temperature versus Resistance Outdoor Temperature Ohms of Resistance F C 20 28 9 106926...

Page 84: ...tor Should you require assistance in locating a Velocity Boiler Works Distributor in your area or you have questions regarding the avail ability of Velocity Boiler Works products or repair parts pleas...

Page 85: ...EPAIR KIT includes flame rod gasket and hardware 105880 01 1 EA 1 EA 1 EA 1 EA 1 EA 12A 12B 11c IGNITION ELECTRODE REPAIR KIT includes electrode gasket and hardware 105881 01 1 EA 1 EA 1 EA 1 EA 1 EA...

Page 86: ...1 2 NPT X 4 SCH 40 STEEL NIPPLE OBTAIN LOCALLY 1 EA 1 EA 1 EA 34B 1 2 NPT X 5 SCH 40 STEEL NIPPLE OBTAIN LOCALLY 1 EA 1 EA 35 GAS VALVE FLANGE REPAIR KIT 106887 01 1 EA 1 EA 1 EA 1 EA 1 EA 37 38A 39A...

Page 87: ...86 Blower Gas Valve Assembly for 150 180...

Page 88: ...07144 01 1 EA 1 EA 1 EA 1 EA 1 EA 53A BALL FOR CONDENSATE TRAP REPAIR KIT 105850 01 1 EA 1 EA 1 EA 1 EA 1 EA 55 56 VENT FITTING REPAIR KIT includes hose barb and nut 105859 01 1 EA 1 EA 1 EA 1 EA 1 EA...

Page 89: ...67 IGNITION CABLE REPAIR KIT 107152 01 1 EA 1 EA 1 EA 1 EA 1 EA 68 TRANSFORMER REPAIR KIT 106034 01 1 EA 1 EA 1 EA 1 EA 1 EA 71 REPLACEMENT CONTROL KIT SHADOW 107097 01 1 EA 1 EA 1 EA 1 EA 1 EA 71A PI...

Page 90: ...89...

Page 91: ...06849 01 106849 01 106849 01 106849 02 106849 02 82 RIGHT SIDE PANEL 1 EA 106850 01 106850 01 106850 01 106850 02 106850 02 83 DOOR REPAIR KIT 1 EA 107150 01 107150 01 107150 01 107150 02 107150 02 84...

Page 92: ...A 1 EA 1 EA 120 1 x 1 4 NPT HEX REDUCING BUSHING 806600529 1 EA 1 EA 1 EA 1 EA 1 EA 121 TEMPERATURE PRESSURE GAUGE REPAIR KIT 105894 01 1 EA 1 EA 1 EA 1 EA 1 EA 122 1 x 3 4 NPT HEX REDUCING BUSHING 80...

Page 93: ...IR KIT 120V FIELD CONNECTIONS HARNESS 107139 01 1 EA 1 EA 1 EA 1 EA 1 EA 132 REPAIR KIT DISPLAY HARNESS 107149 01 1 EA 1 EA 1 EA 1 EA 1 EA 133 REPAIR KIT INTERIOR AC HARNESS 1 EA 107140 01 107140 01 1...

Page 94: ...flue products from the tap in the front of the vent adaptor 6 While the burner is at high fire adjust the throttle as needed to obtain the CO2 settings shown in the Table A 3 To reduce the CO2 increas...

Page 95: ...tments shown in Table A 2 are approximate The final throttle setting must be found using a combustion analyzer Leaving the boiler in operation with a CO level in excess of 200PPM air free could result...

Page 96: ...DETAIL 80MBH THRU 120MBH FIGURE A 1b GAS VALVE DETAIL 150MBH 180MBH TABLE A 2 STARTING NUMBER OF THROTTLE TURNS FOR CONVERSION TO LP GAS MODEL COUNTERCLOCKWISE TURNS FROM FULLY CLOSED 080 3 3 4 100 3...

Page 97: ...BUSTION READINGS Model Fuel Allowable CO2 Readings Max CO PPM Air Free Sea Level 2000 ft 2001 4500 ft 4501 7800 ft 7801 10200 ft 80 Nat Gas 8 7 9 3 NOT PERMITTED 200 LP 10 1 10 3 200 100 Nat Gas 8 5 9...

Page 98: ...subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30...

Page 99: ...uirements 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 vent...

Page 100: ...control is being replaced also verify that the replacement control is intended for use on this boiler 2 If not already done power up the boiler with the new control in place and wait for the appearan...

Page 101: ...100 FIGURE C1 REMOVAL OF PIM LH Done Reset RH Next UP DWN Press and hold both RH and DWN for approx 3s to start upload process FIGURE C2 HOME SCREEN...

Page 102: ...mand from display not recognized Try upload again if problem persists replace display E98 Timeout Possible indication of incompatible display If display has been replaced verify that it is the correct...

Page 103: ...102...

Page 104: ...106916 02 6 16 Velocity Boiler Works LLC P O Box 14818 3633 I Street Philadelphia PA 19134 www velocityboilerworks com...

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