INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS ADVANTAGE DV SERIES CAST IRON GAS-FIRED BOILER

Transcription

1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS ADVANTAGE DV SERIES CAST IRON GAS-FIRED BOILER For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Boiler Model Number Boiler Serial Number Installation Date AGDV_-H_ Heating Contractor Phone Number Address /14

2 The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Advantage DV Series Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, for the latest Approval Code or ask your local Sales Representative. The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage. NOTICE Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. TABLE OF CONTENTS I. Pre-Installation...4 II. Unpack Boiler...4 III. Water Piping and Trim...5 IV. Gas Piping...8 V. Venting...9 VI. Electrical...19 VII. System Start-up and Checkout...21 VIII. Operation...24 IX. Service and Maintenance...26 X. Troubleshooting...29 XI. Repair Parts...31 Table 1A: Ratings Advantage Gas Ratings Boiler Model Input (MBH) DOE Heating Capacity (MBH) Net AHRI Rating Water (MBH) (1) AFUE (%) AGDV AGDV AGDV AGDV (1) Net AHRI Water Ratings shown are based on a piping and pickup allowance of Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc. Table 1B: Dimensions and Connections Boiler Model Supply NPT (inch) Return NPT (inch) Vent (inch) Air Inlet (inch) Gas NPT (inch) Relief Valve NPT (inch) Drain NPT (inch) AGDV3 1¼ 1¼ 3 3 ½ ¾ ¾ AGDV4 1¼ 1¼ 3 3 ½ ¾ ¾ AGDV5 1¼ 1¼ 3 4 ½ ¾ ¾ AGDV6 1¼ 1¼ 3 4 ½ ¾ ¾ Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valve. 2

3 Figure 1: Minimum Clearance to Combustible Materials 3

4 I. PRE-INSTALLATION WARNING Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. A. Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of boiler to carrier in good condition. Any claim for damage or shortage in shipment must be filed immediately against carrier by consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment. B. Installation must conform to the requirements of the authority having jurisdiction. In the absence of such requirements, installation must conform to National Fuel Gas Code, ANSI Z223.1/NFPA 54. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. D. Provide clearance between boiler jacket and combustible material in accordance with local fire ordinance. Refer to Figure 1 for minimum clearance from combustible material for closet installation. Provide 1/2" clearance from water piping to combustible materials. E. Provide practical service clearances. A minimum of 24" from the left side and front jacket panels is recommended for servicing but may be reduced to minimums shown in Figure 1. F. Install on level floor. For basement installation provide concrete base if floor is not level or if water may be encountered on floor around boiler. G. Protect gas ignition system components from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.). H. Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored. C. Appliance is design certified for installation on combustible flooring. The boiler must not be installed on carpeting. II. UNPACk BOILER CAUTION Do not drop boiler. Do not bump boiler jacket against floor. A. Move boiler to approximate installed position. B. Remove all crate fasteners. C. Lift outside container and remove with all other inside protective spacers and bracing. Save two of the wooden slats from the container sleeve for use in Steps E and F. D. Remove all boiler hold-down fasteners. E. Tilt the boiler to one side and slide a wooden slat under the two raised feet. F. Tilt the boiler to the other side and slide another wooden slat under the two raised feet. G. Slide the boiler forward or backward off the skid using the two wooden slats as runners. H. Move boiler to its permanent location. 4

5 III. WATER PIPING AND TRIM WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or building. A. Design and install boiler and system piping to prevent oxygen contamination of boiler water. Oxygen contamination sources are system leaks requiring addition of makeup water, fittings, and oxygen permeable materials in distribution system. Eliminate oxygen contamination by repairing system leaks, repairing fittings, and using non-permeable materials in distribution system. B. Install circulator with flanges, gaskets and bolts provided. C. Install Safety Relief Valve. See Figure 2. Safety Relief Valve must be installed with spindle in vertical position. WARNING Safety relief valve discharge piping must be piped near floor to eliminate potential of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves. D. Connect system supply and return piping to boiler. Refer to Figures 2, 3, 4 and 5. Maintain minimum ½ inch clearance from hot water piping to combustible materials. E. If boiler is used in connection with refrigeration systems, boiler must be installed with chilled medium piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering boiler. See Figure 3. F. If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, boiler piping must be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during operation of cooling system. G. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e. converted gravity circulation system, etc.). Remove circulator and install pipe tee between circulator and boiler return along with second tee in supply piping as shown in Figures 4 and 5. Bypass should be same size as the supply and return lines with valves located in bypass and supply outlet as illustrated in Figures 4 and 5 in order to regulate water flow to maintain higher boiler water temperatures. Set by-pass and boiler supply valves to half throttle position to start. Operate boiler until system water temperature reaches normal operating range. Adjust valves to provide 180 to 200 F supply water temperature. Opening the boiler supply valve will raise system temperature, while opening by-pass valve will lower system supply temperature. H. If it is required to perform a long term pressure test of the hydronic system, the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler. To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler. A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air. Figure 2: Near Boiler Piping Figure 3: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems 5

6 III. Water Piping and Trim (continued) Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems 6

7 III. Water Piping and Trim (continued) Figure 5: Recommended Water Piping for Circulator Zoned Heating Systems 7

8 IV. GAS PIPING A. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for additional information. Minimum gas valve inlet pressure is listed on rating label. 2. Maximum gas demand. Consider existing and expected future gas utilization equipment (i.e. water heater, cooking equipment). B. Connect boiler gas valve to gas supply system. 1. Use methods and materials in accordance with local plumbing codes and requirements of gas supplier. In absence of such requirements, follow National Fuel Gas Code, ANSI Z223.1/NFPA Use thread (joint) compounds (pipe dope) resistant to action of liquefied petroleum gas. 3. Install sediment trap, ground-joint union and manual shut-off valve upstream of boiler gas control valve. See Figure All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, ANSI/NFPA 70. C. Pressure test. The boiler and its gas connection must be leak tested before placing boiler in operation. 1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler's individual manual shutoff valve. 2. Locate leaks using approved combustible gas detector, soap and water, or similar nonflammable solution. Do not use matches, candles, open flames, or other ignition source. 8 Figure 6: Pilot and Gas Piping

9 V. Venting WARning Vent this boiler according to the instructions. Failure to do so may cause products of combustion to enter the building resulting in severe property damage, personal injury or death. CAUtiOn install this boiler according to this manual and the national Fuel gas Code, AnSi Z223.1/nFPA 54, or applicable provisions of the local building codes. Contact local building or fire officials about restrictions and installation inspection in your area. CAUtiOn Failure to install a condensate drain line could cause boiler to shutdown unexpectedly. Direct Vent Direct vent is also called sealed combustion. All combustion air is drawn from outside the building directly into the boiler. The boiler vents vertically or horizontally, assisted by a fan in the boiler. Gas vent must resist temperature and corrosion and be sealed against leakage of flue gases and condensate. Approved materials include AL29-4C stainless steel. Combustion air provided by a separate PVC or galvanized steel pipe. Power Vent Similar to Direct Vent, but some or all combustion air is drawn from inside the building. May draw air directly from the boiler room without the use of a combustion air pipe. Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure. a. General If An existing boiler IS removed When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation: 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition. 3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliance being inspected. follow the Lighting (or operating) Instructions. Adjust thermo stat so appliance will operate continuously. 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. 6. After it has been determined that each appliance remain ing connected to the common venting system properly vents when tested as outlined above, return doors, win dows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use. 7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/nfPA 54. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/nfPA 54. 9

10 V. VENTING (continued) 10 WARNING Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other non AL29-4C based vent systems. Installing Stainless Steel Vent AL 29-4C stainless steel vent systems resist the corrosive effects of high temperature acidic flue gas condensate and are leak-tight. Alternate stainless steel venting systems require special adaptors to connect to the parts supplied with the boiler. Obtain the adaptors from the supplier of the alternate manufacturer s venting system. Approved alternate brands are: (1) Heat-fab Inc Saf-T- Vent (2) Flex L International Inc. Star (3) Z-Flex U.S. Inc. Z-Vent (4) Protech Systems, Inc. FasNSeal Follow all general warnings and instructions for Direct Vent systems described in the beginning of this section. Start at the vent connector on the boiler and work towards the vent terminal. 2. Select stainless steel vent components from Table Verify that the vent and air intake components do not exceed the boiler s maximum allowable equivalent venting length, and do not fall below the boiler s minimum equivalent venting length, using the worksheet on Page 13. Table 2: Vent System and Air Intake System Components Vent System Component Part Number 3 Dia. Pipe x 1 Ft U 3 Dia. Pipe x 3 Ft U 3 Dia. Pipe x 5 Ft U 3 Dia. Pipe x Adjustable U 3 Dia. 90 Elbow U 3 Dia. 45 Elbow U 3 Dia. Horizontal Drain Tee U 3 Dia. Vertical Drain Tee U 3 Single Wall Thimble Double Wall Thimble If a non-standard length is required, there are two options: a. Select adjustable length pipe from Table 2. The pipe adjusts 7 from 12 ¾ to 19 ¾. Or, b. Cut the non-gasketed end of a standard straight length. Make a square cut and file the end smooth. 5. Remove dirt and grease from the male end of the joint using an alcohol pad. 6. Align weld seams in pipes and use a slight twisting motion to fully insert the male end into the female end of the joint. WARNING Insufficient combustion air supply may result in the production and release of deadly carbon monoxide (CO) into the home. Provide Combustion Air CAUTION Do not dislodge, scratch or cut the factory gasket. 7. Tighten locking band by hand with a 5/16 nut driver, plus ¼ turn past snug, ensuring that the locking band fully captures the bead in the pipe. Provide combustion and ventilation air in accordance with the section "Air for Combustion and Ventilation," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes. Like all fuel-burning appliances, boilers need air to operate reliably and safely. 1. If equipping for direct vent (sealed combustion), provide combustion air according to Paragraph B Direct Vent. 2. If not equipping the Advantage DV for direct vent, provide combustion air from the boiler room according to Paragraph C Combustion Air.

11 V. VENTING (continued) WARNING DRAFT HOODS, VENT DAMPERS and other obstructions or openings in the vent system are prohibited. DO NOT REDUCE THE DIAMETER of the vent pipe. MOISTURE AND ICE may collect around and below the vent terminal. keep the area in good repair. IF USING A CHIMNEY AS A CHASE for the vent, do not vent any other appliance into the space between the chimney wall and the vent. ELIMINATE LOW SPOTS in the vent where flue gas condensate may pool. DO NOT PENETRATE VENT PIPE with holes or fasteners. B. Direct Vent Planning a Direct Vent System 1. Avoid contact with plumbing or electrical wires. 2. Horizontal vent pipe must maintain a minimum ¼ inch per foot slope down towards boiler. 3. Any condensate forming in the vent will return to the boiler. Provide for a condensate trap or siphon near the boiler to remove condensate from the vent. 4. Support the piping to maintain vent location, prevent sag and prevent accumulation of condensate. The vent and/or air intake piping must be adequately supported with straps or supports with a maximum spacing of five (5) feet on horizontal runs. 5. Adhere to the boiler s maximum and minimum allowable vent lengths. Vent length is provided in terms of equivalent length of straight pipe plus equivalent length of fittings, including both the vent and the combustion air piping, but not including vent or intake terminals. 6. Maintain minimum allowable clearances between the vent pipe and combustible materials as specified by the vent pipe supplier, this manual, and applicable building codes. 7. Do not install venting system components on the exterior of the building except as specifically required by these instructions. 8. Locate the vent terminal per these restrictions and Figure 7: a. Minimum twelve (12) inches above grade plus normally expected snow accumulation level, or seven (7) feet above grade, if located adjacent to public walkway. Do not install over public walkway where local experience indicates appliance flue gas vapor or condensate creates a nuisance or hazard. b. Minimum three (3) feet above any forced air intake located within ten (10) feet. Exception: Combustion air intake of direct vent system. c. Minimum 4 ft. horizontally from, and in no case above or below, unless a 4 ft. horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment. d. Minimum twelve (12) inches from overhangs or corners of buildings. e. If window and/or air inlet is within four (4) feet of an inside corner, then vent terminal must be at least six (6) feet from adjoining wall of inside corner. f. Minimum one (1) foot below, one (1) foot horizontally from, or one (1) foot above any door, window, gravity air inlet, or other air opening into building. 9. Locate the combustion air terminal on the same face of the building as the vent termination to prevent nuisance boiler shutdowns. However, boiler may be installed with vertical venting and sidewall combustion air inlet or visa versa, if installation conditions do not allow alternate arrangement. 10. If the vent passes through interior spaces in floors above the boiler room, enclose the vent with material having a fire resistance rating at least equal to the rating of the adjoining floor or ceiling. Maintain minimum clearances to combustible materials between the enclosure and the vent. 11. Use appropriate designed thimbles when passing through combustible walls (thimble use is optional for noncombustible walls). Ensure thimble is sealed to prevent moisture from entering structure. 12. Protect building materials from degradation from flue gases or flue gas condensate. 11

12 V. VENTING (continued) Figure 7: Approved Terminal Locations Vent-Air Intake system may be installed through wall 3" - 24" thick. Planning Vertical Installations 1. Install fire stop where vent and air intake passes through floors, ceilings or framed walls. The fire stop must close the opening between the vent and/or air intake pipe and the structure. 2. Size roof opening to allow easy insertion of vent and air intake piping to allow proper installation of flashing and storm collar to prevent moisture from entering the structure 3. Use appropriately designed vent flashing when passing through roofs. Follow flashing manufacturers instructions for procedures. 4. Ensure there is a weather-tight seal between the vent and/or air intake piping were it penetrates the storm collar and roof flashing. 5. Extend the vent and air intake pipe to maintain a minimum vertical and horizontal distance of twelve (12) inches from the roof surface. Allow additional vertical distance for expected snow accumulation. Brace as required. Horizontal Stainless Steel Vent Installations 1. Install vent and intake piping per Figure Where the vent pipe penetrates any combustible wall (Figure 9): a. Insert the wall thimble from the outside of the wall, and secure the outside flange to the wall using nails or screws. b. Seal any exterior openings in the wall thimble, or between the thimble and the wall, using a weatherproof sealant. c. Install the inside thimble flange and secure the flange to the inside wall using screws or nails. 3. Maintain 12" separation between vent and intake terminals. Where the intake air pipe penetrates the external wall, seal the opening with weatherproof sealant (Figure 9). 4. To install a vertical snorkel exterior to the building, refer to Figure 10 or 11.

13 V. VENTING (continued) Vent/Combustion Air, Equivalent Length Work Sheet This sheet is supplied to assist in vent/combustion air, equivalent length calculating Combustion Air (PVC shown) 90 elbow(s) PVC 90 elbow(s) Vent (stainless special gas vent) Quantity = x 5 = equiv. ft. a. Quantity = x 5 = equiv. ft. a. 45 elbow(s) PVC 45 elbow(s) Quantity = x 2.5 = equiv. ft. b. Quantity = x 5 = equiv. ft. b Straight pipe PVC Straight pipe Length ft. = x 1 = equiv. ft. c. Length ft. = x 1 = equiv. ft. c. Horizontal drain tee Length ft. = x 2' = equiv. ft. d. Vertical drain tee Length ft. = x 7' = equiv. ft. e. Total* a.+b.+c. = equiv. ft. Total* a.+b.+c.+d.+e.= equiv. ft. * Total length cannot exceed 50 equivalent feet length (AGDV3 through AGDV6). Vent and combustion air terminals do not count towards total equiv. ft. Figure 8: Separate Horizontal Vent/Air Intake Installation 13

14 V. VENTING (continued) 5. An optional concentric adapter kit (P/N ) is available for 3 & 4 stainless steel vents to provide a single exterior wall penetration accommodating both the intake and exhaust. Refer to the installation instructions provided with the concentric adapter. 6. Install the intake air terminal supplied with the boiler onto the outdoor end of the air intake pipe per the instructions in this manual. See Figures 9 and Install the vent terminal supplied with the boiler onto the outdoor end of the vent pipe per the boiler-specific instructions in this manual. See Figures 9 and 10. NOTICE Storm collar, flashing and sealant for roof penetration, and vertical vent tee for collection of condensate are required for vertical venting and are not supplied with the boiler. Vertical Stainless Steel Vent Installations 1. Install vent and intake piping per Figures 11 thru Install the storm collar onto the vent pipe immediately above the flashing. 3. Apply Dow Corning Silastic 732 RTV Sealant between the vent pipe and the storm collar to provide a watertight and heat-resistant seal. 4. Install the vent terminal per the boiler-specific instructions in Figure 12 in this manual. 5. Install the air intake terminal per the boiler-specific instructions in Figure 12 in this manual. 6. An optional concentric adapter kit (P/N (3 ) is available to accommodate both intake and exhaust piping in a single roof penetration. This kit is compatible only with Saf-T Vent SC gas vent produced by Heat-Fab. Refer to the installation instructions included with the kit. Figure 9: Separate Horizontal Air Intake Terminal Installation 14

15 V. VENTING (continued) Figure 10: Optional Separate Horizontal Vent Terminal Installation Figure 11: Typical Vertical Stainless Steel Venting 15

16 V. VENTING (continued) Figure 12: Vertical Vent/Air Termination Details for Stainless Steel Direct Vent Extend Vent/Air Intake Piping to maintain minimum vertical ( X ) and minimum horizontal ( Y ) distance of twelve (12) inches from roof surface. Allow additional vertical ( X ) distance for expected snow accumulation. 16

17 V. VENTING (continued) Combustion Air If the boiler is a Direct Vent boiler and exchanges all combustion air and combustion products directly with the outdoors, there are no special requirements for providing combustion, ventilation, and dilution air. If the boiler is chimney vented, power vented or induced draft and draws combustion air from within the building, follow the steps below to determine how to provide air to the boiler. Is the boiler located in a confined space?: 1. Calculate the floorspace (in square feet) of the boiler room and all rooms connected to the boiler room by passageways not furnished with doors. floorspace (sq. ft.) 2. Add up the input rates of all the combustion appliances installed in the same floorspace. combined appliance input (BTU/hr) 3. In the table below, find the Minimum Allowable Floorspace based on the Combined Input Rate from Step 2 and the ceiling height. If the Combined Input Rate is between two rates, use the next highest rate. minimum allowable floorspace (sq. ft.) Figure 13: Vertical Air Intake Piping for Direct Venting C. Power Vent Some direct vent boilers are also approved with use of indoor combustion air. If the boiler you are installing is approved for use with indoor combustion air, install the vent according to the instructions in Paragraph B, Direct Venting, but omit the optional indoor air piping and components. Specific instructions for configuring the boiler for indoor air appear in the boiler-specific instructions at the front of this manual. Locate vent terminal at least 4 ft. below, 4 ft. horizontally from, or 1 ft above any door, operable window, or gravity air inlet. Locate at least 10 ft. horizontally from an operable opening in an adjacent building. WARNING Provide enough air to ventilate the boiler room, dilute the flue gases, and sustain combustion. Ignition failure, overheating, fire, carbon monoxide, and spillage of flue gases may result from poor air supply. 4. If the Floorspace from Step 1 is less than the Minimum Floorspace from Step 3, then you must provide outdoor air to the boiler room. Proceed to Step 6. Is the boiler located in a building of unusually tight construction? 5. If the answer to all of the three questions below is yes, then you must provide outdoor air to the boiler room. Minimum Allowable Floorspace in the Boiler Room and Freely Connected Rooms (sq. ft.) Combined Appliance Input Rate (see Step 2) (BTU/hr) Ceiling Height , , , , , , , ,

18 V. VENTING (continued) Do the walls and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less, with openings gasket or sealed? Yes No Are operable windows and doors weatherstripped? Yes No Are exterior wall joints caulked or sealed? Yes No 6. If you must provide outdoor air to the boiler room, the top of the permanent opening into the boiler room must be within 12 of the ceiling, and the free area of the opening (sq. in.) must be no less than the Combined Appliance Input (from Step 2) divided by 3000 BTU/hr/sq. in. combined appliance input (Step 2) 7. Duct this opening vertically or horizontally directly to the outdoors, or directly to a space that communicates directly with the outdoors, such as an attic or crawlspace. For more details and options, refer to the National Fuel Gas Code (ANSI Z223.1/NFPA 54), or applicable provisions of local building codes BTU/hr/sq. in. Minimum Opening Size (sq. in.) 18

19 VI. ELECTRICAL A. General. Install wiring and electrically bond boiler to ground in accordance with requirements of authority having jurisdiction, or in absence of such requirements, with the National Electrical Code, ANSI/NFPA 70. B. Install thermostat. Locate on inside wall approximately 4 feet above floor. Do not install on outside wall, near fireplace, or where influenced by drafts or restricted air flow, hot or cold water pipes, lighting fixtures, television, or sunlight. Allow free air movement by avoiding placement of furniture near thermostat. C. Wire boiler. Boiler is rated for 120 VAC, 60 hertz, less than 15 amperes. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions. Connect to black and white wires and green ground screw. See Figures 14 and 15. D. For installations using zone valves provide separate transformer for zone valve wiring. Consult zone valve manufacturer for assistance. CAUTION This boiler contains controls which may cause the boiler to shut down and not restart without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative. Figure 14: Wiring Connection Diagram 19

20 VI. Electrical (continued) 20 Figure 15: Schematic Ladder Diagram

21 VII. SYSTEM START-UP AND CHECkOUT IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: An external energy management system is installed that reduces the boiler water temperature as 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 with a tankless coil. A. Main Burner Check - Check main burners to see that they were not dislodged during shipment. Rear of burners should be in the vertical slots in the rear of burner tray and the front of the burners should be seated completely on the orifices. B. Initial start - 1. Fill entire heating system with water and vent air from system. Use the following procedure on a System equipped with zone valves. a. Close isolation valve in boiler supply piping. b. Isolate all circuits by closing zone valves or balancing valves. c. Attach a hose to hose bib located just below isolation valve in boiler supply piping. (Note - Terminate hose in five gallon bucket, at a suitable floor drain, or outdoor area). d. Starting with one circuit, open zone valve. e. Open hose bib. f. Open fill valve (Make-up water line should be located directly above isolation valve in boiler supply piping). g. Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds. h. Open zone valve to the second zone to be purged, then close the first. Repeat this step until all zones have been purged, but always have one zone open. At completion, open all zone valves. i. Close hose bib, continue filling the system until the pressure gauge reads 12 psi. Close fill valve. (Note - If make-up water line is equipped with pressure reducing valve, system will automatically fill to 12 psi. Leave globe valve open). Figure 16: Top View of Honeywell Gas Valves j. Open isolation valve in boiler supply piping. k. Remove hose from hose bib. 2. Turn ROOM THERMOSTAT to lowest setting. 3. Be sure that gas to pilot and main burners has been off for at least five minutes and vent damper has been in the open position. 4. Turn "OFF" the electric switch serving boiler. 5. Open valve on main gas line at meter. 6. PURGE AIR FROM GAS PIPING. Adequate ventilation must be provided and no smoking or open flame permitted. 7. Turn "ON" electric switch serving boiler. 8. Open Manual Shut-off Valve upstream of Combination Gas Valve. 9. Loosen or remove Inlet Pressure Tap Plug in Combination Gas Valve and when purging is complete, tighten or replace plug. (See Figure 16). 10. Check pipe and fittings from meter to Combination Gas Valve using soap solution or other approved methods. 21

22 VII. System Start-up and Checkout (continued) CAUTION 11. Test gas piping and connections between Combination Gas Valve and manifold, orifices, and pilot piping for leaks after boiler is operating. Use soap solution or other approved method. C. Check Gas Input to Boiler 1. Input Rate and Maximum Inlet Pressure shown on Rating Label must not be exceeded. Inlet pressure must not be lower than minimum inlet pressure shown on Rating Label. 2. All Rate checks and all adjustments are to be made while boiler is firing - all other appliances connected to the same meter as the boiler must be off. 3. With boiler off, water Manometer or water column gauge should be connected to a shut-off valve installed in the 1/8" outlet pressure tap in the gas valve (See Figure 16). By installing gas valve upstream of manometer, gas pressure can be introduced gradually - without shut-off valve; surge of pressure when boiler is turned on, could blow liquid out of manometer. Replace plug in gas valve when rate check is finished. 4. LP Gas Input: Adjust Regulator on Gas Valve so that manifold pressure is 10 inches water column. Turning Regulator Adjusting Screw Clockwise increases pressure. Counterclockwise rotation decreases pressure. 5. Natural Gas Input a. Approx. Input - Adjust regulator on Gas Valve so that manifold pressure is 3½ inches water column. Turning Regulator Adjusting Screw Clockwise increases pressure, Counter-clockwise rotation decreases pressure. D. Check Main Burner Flame. See Figure 17. Flame should have a clearly defined inner cone with no yellow tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping. Figure 17: 1 Inch Main Burner Flame Figure 18: Pilot Burner Flame CAUTION Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation. 22

23 VII. System Start-up and Checkout (continued) E. Check Pilot Burner Flame. 1. See Figure 18. The pilot burner should be lit only if thermostat is calling for heat. The pilot burner produces three (3) flames. The center flame should be steady, medium hard blue enveloping 3/8 to 1/2 inch of thermocouple. F. Check Ignition System Safety Shut-off Device. Remove 3-wire plug from gas valve. If burners do not shut down determine cause of malfunction. Replace necessary items and check operation. G. Check High Limit Control. Jumper Thermostat connections 'T' and 'TV' in HydroStat Control. See Figure 14 and 15. Allow burners to operate until shutdown by limit. REMOVE JUMPER. I. Combustion Chamber Burn-off 1. The mineral wool combustion chamber panels may contain a cornstarch based binder that must be burned out at installation to prevent odors during subsequent boiler operation. 2. Ventilate the boiler room, set the high limit to its maximum setting, set the thermostat to call for heat. Allow the boiler to fire for at least an hour or until the odor from the cornstarch has dissipated. 3. Return the high limit and thermostat to their desired settings. J. Review User's Information Manual and system operation with owner or operator. K. Post instructions near boiler for reference by owner and service personnel. H. Check Thermostat Operation. Raise and lower temperature setting to start and stop boiler operation. Adjust thermostat to normal setting. 23

24 VIII. OPERATION A. Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. B. Electronic Ignition Module See Figure 19 for electronic ignition (EI). Electronic Ignition Modules with LED indicators. Table 3 crossreferences the ignition module terminal designations to the ignition terminal numbers in the wiring ladder diagrams. Table 4 provides green LED status codes and recommended service action where applicable.. See Figure 19 for Location of LED. See Figure 22 for Troubleshooting Guide. Figure 20: Measuring Pilot Flame Current with Micro-ammeter Figure 19: Location of LED Table 3: Ignition Module Terminal Cross- Reference Ignition Module Terminal Designation Wiring Ladder Diagram Terminal Number MV 1 MV/PV 2 PV 3 GND 4 24V (GND) 5 24V 6 SPARK SPARK 1. Flame Current Measurement Procedure. See Figure 20 Measuring pilot flame current with micro-ammeter a. Pilot flame current in micro amps can be measured using any standard micro-ammeter by inserting the meter probes into the module holes labeled FLAME CURRENT as shown in Figure 20. b. Flame current must be measured with pilot valve open/pilot lit but the main valve closed. c. Disconnect MV lead wire from the module before measuring flame current. Trying to measure the pilot flame current in series with the wiring will not yield the accurate reading. d. The minimum steady pilot flame signal must be 1 μamp (microampere) DC (direct current). e. For reliable operation the flame current should be 2 μamp or greater. f. To ensure adequate flame current: i. Turn off boiler power at circuit breaker or fuse box ii. Clean the flame rod with emery cloth if required iii. Make sure electrical connections are clean and tight, and wiring not damaged, repair/replace as needed iv. Check for igniter/sensor cracked ceramic insulator, replace if needed 24

25 VIII. Operation (continued) v. Check the pilot flame. It must be blue, steady and envelop the flame sensing rod 3/8 to ½. vi. If needed, adjust pilot flame by turning the gas valve pilot adjustment screw clockwise to decrease or counterclockwise to increase pilot flame. Always reinstall pilot adjustment screw cover and tighten securely upon completion to assure proper gas valve operation. g. Reconnect MV lead wire to the module upon satisfactory completion of pilot flame current measurement. h. Check the pilot burner operation/ignition sequence during ignition cycle: i. Restore boiler power at circuit breaker or fuse box. ii. Set thermostat to call for heat. iii. Watch ignition sequence at burner. iv. If spark does not stop after pilot lights, replace ignition module. v. If main burners do not light or if main burners light but system locks out, check the module ground wire and gas control as described in Figure 22 Honeywell Electronic Ignition Troubleshooting Guide. Table 4: Green LED Flame Codes Green LED Flash Indicates Next System Action Recommended Service Action Code a OFF No Call for Heat N/A None Flash Fast Power up - internal check N/A None Heartbeat 4 Seconds ON then x flashes 2 3 Normal startup - ignition sequence started (including prepurge) Device in run mode. x = flame current to the nearest µa. 5 minute Retry Delay - Pilot flame not detected during trial for ignition Recycle - Flame failed during run 4 Flame sensed out of sequence 6 Control Internal Error 7 Flame rod shorted to ground 8 a Flash Code Descriptions: Low secondary voltage supply- (below 15.5 Vac) N/A N/A Initiate new trial for ignition after retry delay completed. Initiate new trial for ignition. Flash code will remain through the ignition trial until flame is proved. If situation self corrects within 10 seconds, control returns to normal sequence. If flame out of sequence remains longer than 10 seconds, control will resume normal operation 1 hour after error is corrected. Control remains in wait mode. When the fault corrects, control resumes normal operation. Control remains in wait mode. When the fault corrects, control resumes normal operation. Control remains in wait mode. When the fault corrects, control resumes normal operation. None None If system fails to light on next trial for ignition check gas supply, pilot burner, spark and flame sense wiring, flame rod contamination or out of position, burner ground connection. If system fails to light on next trial for ignition, check gas supply, pilot burner, flame sense wiring, contamination of flame rod, burner ground connection. Check for pilot flame. Replace gas valve if pilot flame present. If no pilot flame, cycle Call for Heat. If error repeats, replace control. Cycle Call for Heat. If error repeats, replace control. Check flame sense lead wire for damage or shorting. Check that flame rod is in proper position. Check flame rod ceramic for cracks, damage or tracking. Check transformer and AC line for proper input voltage to the control. Check with full system load on the transformer. - Flash Fast: rapid blinking - Heartbeat: Constant ½ second bright, ½ second dim cycles. - 4 second solid on pulse followed by x 1 second flashes indicates flame current to the nearest µa. This is only available in run mode. - A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then repeats the sequence. 25

26 IX. SERVICE AND MAINTENANCE Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805 F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health. AVOID Breathing Fiber Particulates and Dust Precautionary Measures: Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear: 1. A National Institute for Occupational Safety and Health (NIOSH) approved 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 are not classified as hazardous wastes in the United States and Canada. First Aid Procedures: If contact with eyes: Flush with water for at least 15 minutes. Seek immediate medical attention if irritation persists. If contact with skin: Wash affected area gently with soap and water. Seek immediate medical attention if irritation persists. If breathing difficulty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing difficulties persist. Ingestion: Do not induce vomiting. Drink plenty of water. Seek immediate medical attention. 26

27 IX. Service and Maintenance (continued) Figure 21: Operating Instructions 27

28 IX. Service and Maintenance (continued) WARNING SERVICE on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. LABEL ALL WIRES prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation FAILURE TO MAINTAIN THE BOILER in proper working condition may lead to fire, explosion, personal injury or death, and extensive property damage. TURN OFF ALL GAS AND ELECTRIC power supplies to the boiler before servicing. Contact with or release of dangerous flammable gas, electrical voltage, moving parts, and very hot water under pressure may cause serious personal injury, property damage, or death. LOCk ELECTRICAL BOXES AND GAS VALVES CLOSED to prevent someone from inadvertently restoring power or gas before the heating system is safe to operate. A. General. Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 21. Equipment you will need: q Soft bristle brush q Bristle flue brush q Vacuum with brush attachment B. Perform these tasks each year. 1. Clean low water cutoff probe (if applicable). 2. Inspect vent for obstruction and signs of condensation, distortion, overheating or gas leakage. 3. Clean vent terminal and air intake screens. 4. Clean condensate collection and disposal system. 5. Inspect boiler flue passages: a. Remove vent pipe. b. Remove top panel and hood. c. Remove canopy. d. Examine all flue passageways. Using bristle flue brush and vacuum, remove any soot or obstructions. e. Use installation procedure to reassemble and reseal air intake system and vent pipe. 6. Remove and clean main burners: a. Remove jacket front panel. b. Remove air box door. c. Disconnect pilot tubing at gas valve. d. Disconnect pilot lead wires at gas valve. e. Remove wires from flame rollout switch. f. Remove burner access panel. g. Mark location of the pilot main burner on the manifold if the marking on manifold is missing or obliterated. h. Hold burner at throat. Lift front of burner to clear orifice. The burner that holds the pilot can only be removed by first lifting the burner adjacent to its right. C. Perform Startup Checks and Adjustments. 1. Check operation of airflow sensing switches. 2. Check for water leaks on the boiler or water pooling around boiler. 3. Manually operate the relief valve. If the water is grey or black, there is excessive oxygen in the system. Oxygen is corrosive to boilers. Eliminate any source of oxygen. 4. Verify proper operation after servicing. Follow Paragraphs C through J from Section VII "System Start-Up and Checkout". D. Lubrication. There are no parts requiring lubrication by service technician or owner. 28

29 X. TROUBLESHOOTING A. Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. B. Electronic Ignition Module (see Figure 22) 29

30 X. Troubleshooting (continued) "CALL FOR HEAT." POWER TO MODULE? (24 V NOMINAL) NO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) IS MADE. YES 30 SECOND PREPURGE DELAY?(S8670 ONLY) NO REPLACE S8670 YES PULL IGNITION LEAD AND CHECK SPARK AT MODULE. SPARK OK? NO REPLACE MODULE SPARK ACROSS IGNITOR/ SENSOR GAP? NO YES YES TURN GAS SUPPLY ON AND RECYCLE "CALL FOR HEAT." CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND SPARK GAP AND CORRECT. CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING. TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES. PILOT BURNER LIGHTS? NO CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER ORIFICE IS NOT BLOCKED (PILOT GAS FLOWING). CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL. CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE, IF VOLTAGE IS OK, REPLACE GAS CONTROL. IF NOT, REPLACE MODULE. NOTE: IT MAY BE NECESSARY TO RECYCLE THE "CALL FOR HEAT" MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR. YES SPARK STOPS WHEN PILOT IS LIT? YES NO NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT." CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE. CLEAN FLAME ROD. CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE. CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR. CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE. ADJUST PILOT FLAME. IF PROBLEM PERSISTS, REPLACE MODULE. MAIN BURNER LIGHTS? NO CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE. CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED IN THE CIRCUIT. IF OKAY, REPLACE GAS CONTROL. YES SYSTEM RUNS UNTIL "CALL FOR HEAT" ENDS? YES NO NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT." CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE. NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT. CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE. PILOT FLAME MUST NOT BE MOVING AROUND DUE TO OUTSIDE AIR FLOWS, ETC. ADJUST PILOT FLAME. CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER IS ON AND ALL OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE. IF CHECKS ARE OKAY, REPLACE MODULE. "CALL FOR HEAT" ENDS SYSTEM SHUTS OFF? NO CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION. REMOVE MV LEAD AT MODULE. IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE GAS CONTROL. Figure 22: Troubleshooting Guide, Honeywell Electronic Ignition (EI) 30