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Home My WebLink About44476-Z Q�gUFFOt,fco� Town of Southold 12/13/2019 P.O.Box 1179 53095 Main Rd o4, � Southold,New York 11971 CERTIFICATE OF OCCUPANCY No: 40924 Date: 12/13/2019 THIS CERTIFIES that the building AS BUILT ALTERATION Location of Property: 375 Farmers Rd, Mattituck SCTM#: 473889 Sec/Block/Lot: 139.-3-31.1 Subdivision: Filed Map No. Lot No. conforms substantially to the Application for Building Permit heretofore filed in this office dated 12/3/2019 pursuant to which Building Permit No. 44476 dated 12/3/2019 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is: "as built"oil to gas boiler conversion as applied for. I The certificate is issued to Skrezec, Susan&Orlowski,Peter of the aforesaid building. SUFFOLK COUNTY DEPARTMENT OF HEALTH APPROVAL ELECTRICAL CERTIFICATE NO. 44476 12/11/2019 PLUMBERS CERTIFICATION DATED l A t ed Signature 5o�nc c�a TOWN OF SOUTHOLD oG� BUILDING DEPARTMENT TOWN CLERK'S OFFICE oy o SOUTHOLD, NY BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES WITH ONE SET OF APPROVED PLANS AND SPECIFICATIONS UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) Permit#: 44476 Date: 12/3/2019 Permission is hereby granted to: Skrezec, Susan & Orlowski, Peter PO BOX 472 Mattituck, NY 11952 To: as bit" oil to gas boiler conversion as applied for. At premises located at: 375 Farmers Rd, Mattituck SCTM # 473889 Sec/Block/Lot# 139.-3-31.1 Pursuant to application dated 12/3/2019 and approved by the Building Inspector. To expire on 6/3/2021. Fees: AS BUILT - SINGLE F rr.v Ani\TION/AL-TERATION $400.00 CO -ALTERA TO DWELLIN $50.00 r' ELECT C $170.00 f otal: $620.00 f� l i B ilding Inspector Forin No.6 TOWN OF SOUTHOLD BUILDING DEPARTMENT TOWN HALL 765-1802 APPLICATION FOR CERTIFICATE OF OCCUPANCY This application must be filled in by typewriter or ink and submitted to the Building Department with the following. A. For new building or new use: 1. Final survey of property with accurate location of all buildings,property lines, streets, and unusual natural or topographic features. 2. Final Approval from Health Dept. of water-supply and sewerage-disposal (S-9 form). 3. Approval of electrical installation from Board of Fire Underwriters. 4. Sworn statement from plumber certifying that the solder used in system contains less than 2/10 of 1% lead. 5. Commercial building, industrial building,multiple residences and similar buildings and installations, a certificate of Code Compliance from architect or engineer responsible for the building. 6. Submit Planning Board Approval of completed site plan requirements. B. For existing buildings (prior to April 9, 1957) non-conforming uses, or buildings and "pre-existing"land uses: 1. Accurate survey of property showing all property lines, streets,building and unusual natural or topographic features. 2. A properly completed application and consent to inspect signed by the applicant. If a Certificate of Occupancy is denied,the Building Inspector shall state the reasons therefor in writing to the applicant. C. Fees 1. Certificate of Occupancy-New dwelling$50.00,Additions to dwelling$50.00,Alterations to dwelling$50.00, Swimming pool$50.00,Accessory building$50.00,Additions to accessory building$50.00,Businesses$50.00. 2. Certificate of Occupancy on Pre-existing Building- $100.00 3. Copy of Certificate of Occupancy- $.25 4. Updated Certificate of Occupancy- $50 00 5. Temporary Certificate of Occupancy-Residential$15.00, Commercial$15.00 Date. New Construction: 2 Old or Pre-existing Building: (check one) Location of Proper ✓ r nu r , t— House No. Street amlet Owner or Owners of Property Suffolk County Tax Map No 1000, Section Block Lot 1, Subdivision Filed Map. Lot: Permit No. Date of Permit. Applicant. Health Dept. Approval: Underwriters Approval: Planning Board Approval. Request for- Temporary Certificate Final Certificate: (check one) Fee Submitted- $ Applicant Sig ature pF SOU�g,®l Town Hall Annex ® Telephone(631)765-1802 54375 Main Road Fax(631)765-9502 P.O.Box 1179 G ® Q sean.devlin(a)-town.southold.ny.us Southold,NY 11971-0959 �° y BUILDING DEPARTMENT TOWN OF SOUTHOLD CERTIFICATE OF ELECTRICAL COMPLIANCE SITE LOCATION Issued To: Susan Skrezec Address: 375 Farmers Rd city Mattituck st: NY zip: 11952 Building Permit* 44476 section: 139 Block: 3 Lot. 31.1 WAS EXAMINED AND FOUND TO BE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE Contractor: DBA: AS BUILT License No- SITE DETAILS Office Use Only Residential X Indoor X Basement X Service Only Commerical Outdoor X 1 st Floor X Pool New Renovation 2nd Floor Hot Tub Addition X Survey X Attic Garage INVENTORY Service 1 ph X Heat Duplec Recpt 23 Ceding Fixtures 5 HID Fixtures Service 3 ph Hot Water GFCI Recpt 4 Wall Fixtures 3 Smoke Detectors 4 Main Panel 100A A/C Condenser Single Recpt Recessed Fixtures CO Detectors 1 Sub Panel A/C Blower Range Recpt Fluorescent Fixture Pumps Transformer Appliances Dryer Recpt Ceiling Fans 2 Time Clocks Disconnect Switches $ Twist Lock Exit Fixtures Combo SD/CO Other Equipment DW, Fridge, Oven, Hood, W/D Notes Pre- CO and AS BUILT ADDITION " NO VISUAL DEFECTS " Inspector Signature: /v Date: December 11, 2019 S Devlin-Cert Electrical Compliance Form.xls Uf SOUTyo� y� 1 —7 # # TOWN OF SOUTHOLD BUIL IZG5,DEPT. 765-1802 INSPECTION [ ] FOUNDATION 1ST [ ] ROUGH PLBG. [ ] FOUNDATION 2ND [ ] INSULATIOWCAULKING [ ] FRAMING /STRAPPING [ ] FINAL [ ] FIREPLACE & CHIMNEY- [ .] FIRE SAFETY INSPECTION ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH) ELECTRICAL (FINAL) [ ] CODE VIOLATION [ ] PRE C/O REMARKS: As !9 dN 7 C.gg: Gk- L=g iq -r- _ IA/ Wil= *01 Q�fit- DATE INSPECTOR TOWN OF SOUTHOLD BUILDING PERMIT APPLICATION CHECKLIST BUILDING DEPARTMENT Do you have or need the following,before applying? TOWN HALL Board of Health SOUTHOLD, NY 11971 4 sets of Building Plans TEL: (631) 765-1802 Planning Board approval FAX: (631) 765-9502 `� Survey Southoldtownny.gov PERMIT NO. ( Check Septic Form N Y.S.D.E.C. Trustees C.O.Application Flood Permit Examined '20 Single&Separate 2 Truss Identification Form Stone-Water Assessment Form J Contact: Approved 120( Mail to: Disapproved a/c Phone: Expiration_, �0- `" `," DEC — 3 2019 t —1ful—illni Inspector APPLICATION FOR BUILDING PERMIT r' Date ��'-,� , 20� INSTRUCTIONS a. This application MUST be completely filled in by typewriter or in ink and submitted to the Building Inspector with 4 sets of plans, accurate plot plan to scale.Fee according to schedule. b. Plot plan showing location of lot and of buildings on premises,relationship to adjoining premises or public streets or areas, and waterways. c. The work covered by this application may not be commenced before issuance of Building Permit. d. Upon approval of this application,the Building Inspector will issue a Building Permit to the applicant. Such a permit shall be kept on the premises available for inspection throughout the work. e.No building shall be occupied or used in whole or in part for any purpose what so ever until the Building Inspector issues a Certificate of Occupancy. f. Every building permit shall expire if the work authorized has not commenced within 12 months after the date of issuance or has,not been completed within 18 months from such date. If no zoning amendments or other regulations affecting the property have been enacted in the interim,the Building Inspector may authorize,in writing,the extension of the permit for an addition six months. Thereafter,a new permit shall be required. APPLICATION IS HEREBY MADE to the Building Department for the issuance of a Building Permit pursuant to the Building Zone Ordinance of the Town of Southold, Suffolk County,New York, and other applicable Laws, Ordinances or Regulations, for the construction of buildings,additions, or alterations or for removal or demolition as herein described. The applicant agrees to comply with all applicable laws,ordinances,building code,housing code,and regulations,and to admit authorized inspectors on premises and in building for necessary inspections. (Signature oRpphggt or name,if a corporation) �-P)nl-�- F( ch C(c (Mailing address of applicant) 1([� State whether applicant is owner, lessee, agent, architect, engineer, general contractor, electrician, plumber or builder C Name of owner of premises f�SC�YZ lJ� �_� E C— (As on the tax roll or latest deed) If applicant is a corporation, signature of duly authorized officer (Name and title of corporate officer) Builders License No. Plumbers License No. Electricians License No. Other Trade's License No. 1. Location of land on which proposed wor will be done: K 0 4 �� l House Number Street Hamlet County Tax Map No. 1000 Section f I Block'-' lock; _ '=� " Lot r/ Subdivision Filed Map No. Lot 2. State existing use and occupancy of premises and intended use and occupancy of proposed construction: a. Existing use and occupancy b. Intended use and occupancy L 461 - 1-2) �75 La 3. Nature of work(check which applicable): New Building Addition Alteration Repair Removal Demolition Other Work (Description) 4. Estimated Cost Fee (To be paid on filing this application) 5. If dwelling, number of dwelling units Number of dwelling units on each floor If garage, number of cars 6. If business, commercial or mixed occupancy, specify nature and extent of each type of use. 7. Dimensions of existing structures, if any: Front Rear Depth Height Number of Stories Dimensions of same structure with alterations or additions: Front Rear Depth Height Number of Stories t 8. Dimensions of entire new construction: Front Rear Depth Height Number of Stories 9. Size of lot: Front Rear Depth 10. Date of Purchase Name of Former Owner 11. Zone or use district in which premises are situated 12. Does proposed construction violate any zoning law, ordinance or regulation? YES NO 13. Will lot be re-graded? YES NO Will excess fill be removed from premises?YES NO 14. Names of Owner of premises Address Phone No. Name of Architect Address Phone No Name of Contractor Address Phone No. 15 a. Is this property within 100 feet of a tidal wetland or a freshwater wetland? *YES NO * IF YES, SOUTHOLD TOWN TRUSTEES &D.E.C. PERMITS MAY BE REQUIRED. b. Is this property within 300 feet of a tidal wetland? * YES NO * IF YES, D.E.C. PERMITS MAY BE REQUIRED. 16. Provide survey, to scale, with accurate foundation plan and distances to property lines. 17. If elevation at any point on property is at 10 feet or below, must provide topographical data on survey. 18. Are there any covenants and restrictions with respect to this property? * YES NO * IF YES, PROVIDE A COPY. STATE OF NEW YORK) C COUNTY 060 S 5ikSCl.r) '5/�-d -C—,ZC<f, being duly sworn, deposes and says that(s)he is the applicant (Name of individual signing contract) above named, (S)He is the ou)�Y_ K (Contractor,Agent, Corporate Officer, etc.) of said owner or owners,and is duly authorized to perform or have performed the said work and to make and file this application; that all statements contained in this application are true to the best of his knowledge and belief, and that the work will be performed in the manner set forth in the application filed therewith. Sworn to before me this Q day o (e1(1V� 20� Notary Pau is TRACEY L. DWYER At re App icant NOTARY PUBLIC,STATE OF NEW YORK NO.01 DW6306900 QUALIFIED IN SUFFOLK COUNTY COMMISSION EXPIRES JUNE 30,2� BUILDING DEPARTMENT- Electrical Inspector 22 TOWN OF SOUTHOLD o Town Hall Annex - 54375 Main Road - PO Box 1179 o - Southold, New York 11971-0959 yip_ Telephone (631) 765-1802 - FAX (631) 765-9502 rogerr(aD_southoldtownny.gov - sea ndCcDsoutholdtownny.gov APPLICATION FOR ELECTRICAL INSPECTION ELECTRICIAN INFORMATION (All Information Required) Date: Company Name: Name: License No.: email: Address: Phone No.: JOB SITE INFORMATION (All Information Required) Name: E-Z- 4E� C-- Address: S S Cross Street: jtl 0, Phone No.: — , Bldg.Permit#: email: Tax Map District:1000 Section: 3 J Block: Lot: 3 BRIEF DESCRIPTION OF WORK (Please Print Clearly) lmaa u r✓i ' U Au Circle All That Apply: Is job ready for inspection?: YES / NO Rough In Final Do you need a Temp Certificate?: YES / NO Issued On Temp Information: (All information required) Service Size 1 Ph 3 Ph Size: A # Meters Old Meter# New Service - Fire Reconnect- Flood Reconnect - Service Reconnected - Underground - Overhead # Underground Laterals 1 2 H Frame Pole Work done on Service? Y N Additional Information: PAYMENT DUE WITH APPLICATION Request for Inspection FormAs �� Y INSTALLATION; OPERATING AND SERVICE INSTRUCTIONS FOR P GTM .: - • Boiler �s'{��jY,3,,. Fed?�.,�ri,,ism•�r:>:�?�:�ya-�.,x,�s,.S�t_ti-�.?�: GYM` �tip bP ham.i .E 9 r r e Ci US �',T.�^ :49�.t r� �( �5 Y•'�.':Ys � (gip ` Y•"'�z � '�M14,;;='., Intertek 1, ,'�,:� +'.�;,?asr��.�'., ,,. �•:., .f;,�.:.,, 9700609 `�.,, .. '� A� J4•'ti+fir.�Y 'i L�.,�`a+' �S%r K:�5 111 t--?•G+p:.' As an ENE� TARO Partner, U.S. Boiler Company has determined that the PVG Series meets the ENERGY c�uideliges"for energy efficiency established by the United States-Environmental Protection Agency(EPA). ir�ece:-•.Yr,;w . - - t Fpt�la+5e or'repairs to boiler, call your heating contractor. When-seeking information on boiler, provide p,= ' Bbiler,_fI,i..Ce1:N tuber and Serial Number as shown on Rating Labbl. - ;Part Number Boiler Serial Number Installation Date s Heating Contractor Phone Number Address Boiler Company p 'e Price $5.00 103997-04-6/13 4 - ra ' Special Installation Requirements for Massachusetts IMPORTANT INFORMATION - READ CAREFULLY, ` A. For all side wall horizontally vented gas fueled equipment installed in every dwelling,building or structure used in whole or in part for residential purposes and where the side wall exhaust vent termination is less than seven(7)feet above grade,the °~ following requirements shall be satisfied: ,4 OTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the fir: installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction 1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of shall be consulted before installations are made. NFPA 720,NFPA 70 and the Massachusetts State Building Code in the residential unit served by the side wall horizontally r,. vented gas fueled equipment,a battery operated carbon monoxide detector with an alarm shall be installed in compliance All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. with the most current edition of NFPA 720,NFPA 70 and the Massachusetts State Building Code. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations. 2. In addition to the above requirements,if there is not one already present,a carbon monoxide detector with an alarm and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the detector on the floor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall comply with 527 CMR,ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event The City of New York requires a Licensed Master Plumber supervise the installation of this product. that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment, �a The Massachusetts Board of Plumbers and Gas Fitters has approved the PVGTM Series boiler. See the Massachusetts Board of the installer shall have a period of thirty(30)days to comply with this requirement;provided,however,that during said Plumbers and Gas Fitters website,http://Hcense.reg.state.ma.us/pubLic/pl_puoducts/pb_pre_form.asp for the latest Approval thirty(30)day period,a battery operated carbon monoxide detector with an alarm shall be installed in compliance with Code or ask your local Sales Representative. the most current edition of NFPA 720,NFPA 70 and the Massachusetts State Building Code. In the event that the side i- wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the carbon monoxide detector The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter. may be installed on the next adjacent habitable floor level. Such detector may be a battery operated carbon monoxide detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720,NFPA 70 and the Massachusetts State Building Code. s3. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height fr.' 4 of eight(8)feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled r, heating appliance or equipment. The sign shall read,in print size no less than one-half(1/2) inch in size,"GAS VENT The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, : ;} DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". or to important information concerning product life. 4. A final inspection by the state or local gas inspector of the side wall horizontally vented equipment shall not be performed until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of • '` `.` carbon monoxide detectors and alarms as required above. B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4: Indicates an imminently hazardous situation Indicates a potentially hazardous situati7w�ichr, which, if not avoided,will result in death,serious if not avoided, may result in moderate 1. The equipment listed in Chapter 10 entitled"Equipment Not Required To Be Vented"in the most current edition of NFPA injury or substantial property damage. injury or property damage. ;;_ 54 as adopted by the Board;and f} 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling,building or structure used in whole or in part for residential purposes. • t` C. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design Indicates a potentially hazardous situation which Indicates special instructions on installation, or venting system components with the equipment,the instructions for installation of the equipment and the venting system if not avoided,could result in death,serious injury operation, or maintenance which are important shall include: 1. A complete arts list for the venting system design or venting system; or substantial roe damage. but not related to personal in•u hazards. i:��` P P S Y � gand property�Y 9 P J �'Y ; ��_ 2. Detailed instructions for the installation of the venting system design or the venting system components. D. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting flue gases,but identifies"special venting systems",the following shall be satisfied: 1. The referenced"special venting system"instructions shall be included with the appliance or equipment installation instructions;and 2. The"special venting systems"shall be Product Approved by the Board,and the instructions for that system shall include a DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other parts list and detailed installation instructions. appliance. E. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,all venting If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use instructions,all parts lists for venting instructions,and/or all venting design instructions shall remain with the appliance or an hone in the building. Immediate) call the as supplier from a remote) located hone. Follow the as equipment at the completion of the installation. Y p g• Y� g PP Y P 9P supplier's instructions or if the supplier is unavailable,contact the fire department. J ` l:J. 2 " 3 n4fF 60'8c I. PRE-INSTALLATION F. Provide combustion and ventilation air in accordance with applicable provisions of local building codes, If you do not follow these instructions exactly, or: USA-National Fuel Gas Code,NFPA 54/ANSI (N -a fire-or-explosion may result causing property - -Z223.1,Air-for-Combustion and Ventilation; Q CO " " m - Canada-Natural Gas or Propane Installation Code Q _ N damage or personal injury. p , Z0 - - CAN/CSA-B149.1. U) w o a) CO v U') Co is Do not install boiler where gasoline or other o c� 0 0 0 Adequate combustion and ventilation air must 0 0 > > > > I flammable vapors or liquids, or sources of > a a a ! hydrocarbons(i.e. bleaches,cleaners,chemicals, be provided to assure proper combustion. ssprays, paint removers,fabric softeners, etc.)are o F w used or stored. The following guideline is based on the National Fuel Gas 3 W az w z X o Z7ZW U W Code,NFPA 54/ANSI 2223.1. a F W o0 a a 1. Determine volume of space(boiler room).Rooms V) t__ z communicating directly with space(through a �" C, openings not furnished with doors)are considered IL IL m Z m a Due to the low water content of the boiler, mis- part of space. sizing of the boiler with regard to the heating system load will result in excessive boiler cycling Volume[ft3]=Length[ft]x Width[ft]x Height[ft] W and accelerated component failure. U.S. Boiler 2. Determine Total Input of all appliances in space. c° a N DOES NOT warrant failures caused by mis-sized Round result to nearest 1,000 Btu per hour(Btuh). a c boiler applications. DO NOT oversize the boiler to the system. Modular boiler installations greatly 3. Determine type of space.Divide Volume by Total reduce the likelihood of boiler oversizing. Input. W a. If result is greater than or equal to 50 ft3 per ® 1,000 Btuh,space is considered an unconfined - N A. Installation must conform to the requirements of the space. L authority having jurisdiction.In the absence of such requirements,installation must conform to the National b. If result is less than 50 ft3 per 1,000 Btuh,space u, is considered a confined space. Fuel Gas Code,NFPA 54/ANSI Z223.1,and/or CAN/ 4. Determine building e A building of unusually CSA B 149.1 Installation Codes. g tyP g y J UJ - tight construction has the following characteristics: Z - x a J B. Appliance is design certified for installation on a. Walls and ceiling exposed to outside atmosphere W F D a m a > combustible flooring. Do not install boiler on W _> $ W J Z�, Z z carpeting. have a continuous water vapor retarder with a X z N a ?a= rating of 1 perm or less with openings gasketed WW � co o C. Provide clearance between boiler jacket and and sealed,and; combustible material in accordance with local fire b. Weather-stripping has been added on openable Z C' `" L�'8 L ordinance.Refer to Figure 1 for minimum listed windows and doors,and; O clearance from combustible material.Recommended c. Caulking or sealants applied in joints around W .o service clearance is 24 inches from left side,right window and door frames,between sill plates and 0 0 0'0� 7 side and front. Service clearances may be reduced to floors,between wall-ceiling joints,between wall p a o minimum clearances to combustible materials. panels,at plumbing and electrical penetrations, N 0 r A Install on level floor.For basement installation provide and at other openings. c6 _ r O solid base such as concrete,if floor is not level or if 5. For boiler located in an unconfined space in a z0 i o water may be encountered on floor around boiler. Floor building of other than unusually tight construction, v - Z � __`V __C� __ must be able to support weight of boiler,water and all adequate combustion and ventilation air is normally CL Z con '� - - ---� additional system components. provided by fresh air infiltration through cracks around windows and doors. O + E. Protect gas ignition system components from water U 6 M v En co 6. For boiler located within unconfined space in a 0 0 CD 0 (dripping,spraying,rain,etc.)during boiler operation o > > > > building of unusually tight construction or within > 5 a e o a W c,.. pZ•9 G and service(circulator replacement,condensate trap, confined space,provide outdoor air through two a 'Z W control replacement,etc.). a= L 6'LZ permanent openings which communicate directly or UJ O W W D] - � v 6 7 X. ARTABLE OF CONTENTS This boiler requires regular maintenance and service to operate safely. Follow the instructions contained I. Pre-Installation...............................7 in this manual. VIII-System Start-up......................................36 Improper installation,adjustment,alteration,service or maintenance can cause property damage,personal Il. Unpack ................................8 injury or loss of life. Read and understand the entire manual before attempting P IX. Operation.....................................40 1 ry p g installation, start-up operation, or service. Installation and service must be performed only by an experienced, skilled, and III. Venting...........................................9 X. Troubleshooting knowledgeable installer or service agency. ••••••••••••••••••••••-••••44 This boiler must be properly vented. IV Water Piping and Trim.................20 M. Service..........................................49 This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate ! V Gas Pim 26 Piping.................................... XII. Repair Parts..................................53 combustion and ventilation air. , The interior of the venting system must be inspected and cleaned before the start of the heating season VI. Electrical.......................................29 Appendix A-Figures........... 66 and should be inspected periodically throughout the heating season for any obstructions. A clean and unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life VII. Modular Installation....................34 Appendix B-Tables......................67 to vent safely and will contribute toward maintaining the boiler's efficiency. Installation is not complete unless a pressure relief valve is installed into the tapping located on top of appliance. -See the Water Piping and Trim Section of this manual for details. VENT VENT This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left SEE NOTE 3 t SEE NOTE 3 unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative. j This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this SEE NOTE 4 boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the SEE NOTE temperature and pressure of the boiler. This boiler contains components which become very hot when 1 the boiler is operating. Do not touch any components unless they are cool. VENTILATION AIR INLET OPENINGS e� Boiler materials of construction,products of combustion and the fuel contain alumina,silica,heavy metals, o o (SEE NOTE 2) carbon monoxide,nitrogen oxides,aldehydes and/or other toxic or harmful substances which can cause o death or serious injury and which are known to the state of California to cause cancer, birth defects and o o. other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing CLOSET DOOR »� or working nearby the appliance. o 'A' Failure to follow all instructions in the proper order can cause personal injury or death. Read all instruc- M ® VENTILATION AIR o INLET OPENINGS tions, including all those contained in component manufacturers manuals which are provided with the (SEE NOTE 2) boiler before installing,starting up, operating, maintaining or servicing. Keep boiler area clear' and free from combustible materials, gasoline and other flammable vapors or liquids. coFLOOR LINE All cover plates,enclosures and guards must be in place at all times. '`;" _I V, 4" I-- -� s" NOTES. 1. VENT PIPE MINIMUM CLEARANCE TO COMBUSTIBLE MATERIAL IS FOUR (4) INCHES WHEN VENT IS INSTALLED IN A FULLY ENCLOSED DIMENSIONAL DATA CHASED APPLICATION OR THREE (3) INCHES WHEN VENT IS INSTALLED MODEL A This boiler has a limited warranty, a copy of which is included with this boiler. It is the responsibility of WITH AT LEAST ONE SIDE OPEN, SIMILAR TO A JOIST BAY APPLICATION. PVG3 1165 p ty 2. AREA OF EACH OPENING, 1 SQ. INCH FOR EACH 1000 BTUH INPUT, the installing contractor to see that all controls are correctly installed and are operating properly when the WITH MINIMUM OF 100 SQ. INCHES. HEIGHT OF OPENING SHOULD BE PVG4 1472 installation is complete. HALF THE WIDTH. PVG5 17.78 3. USE DOUBLE WALL THIMBLE WHEN PENETRATING A COMBUSTIBLE WALL. PVG6 2084 4. 18 INCH CLEARANCE REQUIRED FOR CLOSET INSTALLATION 4 INCH CLEARANCE REQUIRED FOR OPEN INSTALLATION. Figure 1: Minimum Clearances to Combustibles 4 5 1. PRE-INSTALLATION (continued) III. VENTING ,3 e` by duct with the outdoors or spaces(crawl or attic) space(s)of sufficient volume such that combined freely communicating with the outdoors.Locate one volume of all spaces meet criteria for unconfined opening within twelve(12)inches of top of space. space. Size each opening for minimum free area Locate remaining opening within twelve(12)inches of one(1)square inch per 1,000 Btu per hour Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other of bottom of space.Minimum dimension of air input of all equipment in spaces,but not less than non AL29-4C®based vent systems. opening is three(3)inches.Size each opening per 100 square inches. Do not use a barometric damper or draft hood with this appliance. following: 7. Combustion AirNentilation Duct Louvers and a. Direct communication with outdoors.Minimum Grilles.Equip outside openings with louvers to Do not use vent dampers with this boiler. free area of one(1)square inch per 4,000 Btu per prevent entrance of rain and snow,and screens to Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should hour input of all equipment in space. prevent entrance of insects and rodents.Louvers and b. Vertical ducts.Minimum free area of one(1) grilles must be fixed in open position or interlocked {:; be in good repair(sealed, painted, etc.). square inch per 4,000 Btu per hour input of all with equipment to open automatically before burner This appliance needs fresh air for safe operation and must be installed so there are provisions for equipment in space.Duct cross-sectional area operation.Screens must not be smaller than%inch 4j adequate combustion and ventilation air. shall be same as opening free area. mesh. Read, understand and follow combustion air instruction restrictions contained in the Pre-Installation c. Horizontal ducts.Minimum free area of one(1) Consider the blocking effect of louvers,grilles and instructions of this manual. square inch per 2,000 Btu per hour input of all screens when calculating the opening size to provide equipment in space.Duct cross-sectional area the required free area.If free area of louver or grille ,` Do not operate appliance where gasoline or other flammable vapors or liquids,or sources of hydro- shall be same as opening free area. is not known,assume wood louvers have 20-25 carbons (i.e. bleaches, cleaners, chemicals,sprays, paint removers,fabric softeners, etc.) are used, Alternate method for boiler located within percent free area and metal louvers and grilles have stored and/or present in the air. confined space.Use indoor air if two permanent 60-75 percent free area. When installing vent pipe through chimney, no other appliance can be vented into the chimney. openings communicate directly with additional Do not exceed maximum vent lengths. Refer to Table 4. 1 Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. Via;` are present. If boiler is operated under these conditions,the burner interior and ports must be cleaned and y i inspected daily to insure proper operation. ;x Table 1: Vent System Options Additional Installation II. Un pack Boiler Option Description Vent Kit Drawing and p Specification Required (See Section) Power Vent(air from within building)the vent pipe terminates 1. Horizontal horizontally(through a sidewall). 45' Elbow D. Power Vent(air from within building)the vent pipe terminates Do not drop boiler. Do not bump boiler jacket Installation of this boiler should be undertaken E Z. Vertical vertically(through the roof). No E. against floor. only by trained and skilled personnel from a ; ; Power Vent(air from within building)the vent pipe terminates 3. Horizontal 45° Elbow F. qualified service agency. horizontally(snorkel through a side wall) A. Move boiler to approximate installed position. E. Tilt the boiler to its front side or back side and slide a B. Remove all crate fasteners. wooden slat under the three raised feet. 4� C. Lift and remove outside container. Save two of the F. Tilt the boiler in the opposite direction and slide wooden slats from the container sleeve for use in Steps another wooden slat under the three raised feet. Table 2: Vent System Components Included with Boiler Eand F. G. Slide the boiler left or right off the skid using the two A Remove all boiler hold-down fasteners. wooden slats as runners. t s_ R Gasketed Vent System Components Part Number Vent Terminal 8110701 H. Move boiler to its permanent location. P 8 ;< 9 i;. III. VENTING (continued) III. VENTING (continued) 'le 3: Vent System Components A. Vent Guidelines Due to Removal of an Existing Au moment du retrait dune chaudi6re existante, B. General Guidelines Boiler _k les mesures suivantes doivent etre prises pour 1. Vent system installation must be in accordance Part Equivalent chaque appareil toujours raccorde au syst6me Vent System Component E. IF AN EXISTING BOILER IS REMOVED- = with National Fuel Gas Code NFPA 54/ANSI y p Number Feet of Pipe <' d'evacuation commun et qui fonctionne alors que Z221.3,CAN/CSA B 149.1 Natural Gas or Propane When an existing boiler is removed from a common d'autres appareils toujours raccordes au syst6me Installation Code or applicable provisions of local ' 3"Dia. Pipe x 1 Ft 8116296U 1 venting system,the common venting system is likely d'evacuation ne fonctionnent pas: building codes. Contact local building or fire 3"Dia. Pipe x 3 Ft 8116298U 3 to be too large for proper venting of the appliances 1. Sceller toutes les ouvertures non utilisees du officials about restrictions and installation inspection 3"Dia. Pipe x 5 Ft 81163000 5 remaining to it. syst6me d'evacuation. in your area. Equal to At the time of removal of an existing boiler, the following steps shall be followed with each 2. Inspecter de facon visuelle le syst6me d'evcuation 2. Refer to the appropriate drawings in this section of 3"Dia.Pipe x Adjustable 8116319U Installed Length appliance remaining connected to the common pour determiner la grosseur et l'inclinaison this manual to determine.the proper configuration of (1.06 TO 1.64) horizontale qui conviennent et s'assurer que le venting system. See Table 1. venting system placed in operation,while the other � q q g Y i 3"Dia.90°Elbow 8116294U 5 syst6me est exempt d'obstruction,d'6tranglement, appliances remaining connected to the common =_ 3. This appliancerequires a Special GasVent.Theproduct de fuite,de corrosion et autres defaillances qui is designed to use U.S. Boiler supplied AL29-4C® 3"Dia.45°Elbow 8116292U 5 venting system are not in operation: } gn pp pourraient presenter des risques. Stainless components. 3"Dia. Horizontal Drain Tee 8116302U 2 1. Seal any unused openings in the common venting ess Steel vents system P onents.The following 3. Dans la mesure du possible,fermer toutes les manufacturers offer similar AL29-4C® components 3"Dia.Vertical Drain Tee 8116304U 7'/Z system. portes et les fenetres du batiment et toutes les and are approved for use with this product.Heat-Fab 3"Single Wall Thimble 8116116 -- 2. Visually inspect the venting system for proper i- portes entre 1'espace ofi les appareils toujours Inc.-Saf-T Vent(800-772-0739);Flex-LInternational 3"Double Wall Thimble 103877-01 __ size and horizontal pitch and determine there is no raccordes an syst6me d'evacuation sont installes Inc. - Star-34 (800-561-1980); Z-Flex U. S., Inc. - blockage or restriction,leakage,corrosion,and other et les autres espaces du batiment. Mettre en Z-Vent (800-654-5600)• and Protech Systems, Inc.- deficiencies which could cause an unsafe condition. marche les secheuses,tous les appareils non FasNSea1TM (800-766-3473) or equivalent. The use 3. Insofar as is practical,close all building doors and '' raccordes an syst6me d'evacuation commun ofthese alternate manufacturer's venting systems will windows and all doors between the space in which r " et tous les ventilateurs d'extraction comme les require adapters to connect to the U.S.Boiler supplied the appliances remaining connected to the common <` hottes de cuisiniere et les ventilateurs des salles de vent connector and vent terminal. These adapters are venting system are located and other spaces of the t' bain. S'assurer que ces ventilateurs fonctionnent not supplied with this unit and should be obtained from building.Turn on clothes dryers and any appliance Ys .; a la vitesse maximale. Ne pas faire fonctionner the supplier of the alternate manufacturer's venting not connected to the common venting system. }a: r: les ventilateurs d'ete. Fermer les registres des system. See Table 3 for complete list of U.S.Boiler Turn on any exhaust fans,such as range-hoods and cheminees. Vent System Components. _ Table 4' Vent Length bathroom exhausts,so they will operate at maximum ;r 4. Mettre 1'appareil inspecte en marche. Suivre les 4. Horizontal vent pipe must maintain a minimum speed.Do not operate a summer exhaust fan.Close instructions d'allumage. Regler le thermostat de inch per foot slope away from boiler. 3"Vent Ft.(Equiv.Pipe E fireplace dampers. Model p ( q ) facon que 1'appareil fonctionne de facon continue. 5. Use noncombustible 3/a inch pipe strap to support Min. Max. 4. Place in operation the appliance being inspected. _ 5. Faire fonctionner le bruleur principal pendant 5 horizontal runs and maintain vent location and PVG3 Follow the Lighting(or Operating)Instructions. '>'.- min ensuite determiner si le cou a-tira a deborde slope while preventing sags in pipe. Do not restrict Adjust thermostat so appliance will operate g.; a Fouverture de decharge. Utiliser la flamme d'une thermal expansion or movement of vent system. PVG4 continuously. . ; 8 50 all_umette ou d'une chandelle ou la fumee d'une Maximum support spacing is five(5)feet. Do not PVG5 5. Test for spillage at the draft hood relief opening after cigarette,d'un ci are ou d'une pipe. penetrate any Part of the vents stem with fasteners. PVG6 5 minutes of main burner operation.Use the flame ': 6. Une fois qu'il a ete determine,selon la m6thode 6. Vent length restrictions are based on equivalent of a match or candle,or smoke from a cigarette, indiquee ci-dessus,que chaque appareil raccorde length of vent pipe(total length of straight pipe cigar or pipe. '~ 'r" an syst6me d'evacuation est mis a fair libre de plus equivalent length of fittings). Maximum 6. After it has been determined that each appliance ?:;:' s facon adequate. Remettre les portes et les fenetres, vent lengths are listed in Table 4. Do not exceed remaining connected to the common venting system les ventilateurs,les registres de cheminees et les maximum vent lengths. Table 3 lists equivalent properly,vents when tested as outlined above,return appareils au gaz a leur position originale. lengths for fittings. Do not include vent terminals in doors,windows,exhaust fans,fireplace dampers and 7. Tout mauvais fonctionnement du syst6me equivalent feet calculations. any other gas burning appliance to their previous d'evacuation commun devrat etre corrige de 7. Provide and maintain vent pipe minimum clearances conditions of use. `E facon que Pinstallation soit conforme au National to combustible materials. Vent pipe minimum 7. Any improper operation of the common venting . Fuel Gas Code,ANSI Z223.1 et(ou)aux codes clearance to combustible material is four(4) system should be corrected so the installation d'installation CAN/CSA-B 149.1. Si la grosseur inches when vent is installed in a fully enclosed conforms with the National Fuel Gas Code,ANSI d'une section du syst6me d'evacuation doit etre (chase)application or three(3)inches when vent Z223.1 and/or CAN/CSA B 149.1,Installation ,t m6difiee,le syst6me devrait etre modifie pour is installed with at least one side open,similar to a Codes. When resizing any portion of the common respecter les valeurs minimales des tableaux oist ba application. Use double wall thimble(U.S. P j Y PP venting system, the common venting system x a` pertinents de 1'appendice F du National Fuel Gas Boiler Part No. 103877-01)when penetrating a `. f should be resized to approach the minimum size *; Code,ANSI Z223.1 et(ou)des codes d'installation combustible wall. as determined using the National Fuel Gas Code, CAN/CSA-B149.1. ANSI Z223.1 and/or CAN/CSA B 149.1,Installation Codes. f 10 7 Ill. VENTING (continued) III. VENTING (continued) 8. Do not install venting system components on sealant material. Install inside flange to inside wall, the exterior of the building except as specifically required by these instructions. The vent termination secure with nails or screws,and seal with sealant material. location is restricted as follows: Never exceed maximum installed length of 193/4 a. Minimum twelve(12)inches above grade plus inches for adjustable length pipe. 5. For noncombustible wall application when thimble Risk of flue gas leakage is possible. is not used,size opening such that bell with locking normally expected snow accumulation level,or band attached cannot pass through. seven(7)feet above grade if located adjacent to public walkway. Do not install over public 6. Join vent terminal to vent pipe. See Figure 5. walkway where local experience indicates 7. Insert vent pipe through thimble/opening from appliance flue gas vapor or condensate creates a Cut must be square with pipe and filed or outside and join to vent system. Apply sealant nuisance or hazard. sanded smooth before joining. Carefully ensure between vent pipe and opening/thimble to provide b. Minimum three(3)feet above any forced air roundness of cut pipe by hand with gloves before weathertight seal. inlet located within ten(10)feet. installing. Seal joint with RTV specified in this c. Minimum four(4)feet below,four(4)feet manual. F. horizontally from,or four(4)feet above any door,window,or gravity air inlet. C. Install Vent Pipe,U.S.Boiler Gasketed Vent System. d. Minimum four(4)feet horizontally from electric 1. Procedure for Joining U.S.Boiler Gasketed Vent meters,gas meters,regulators,and relief valves. Pipe and Fittings. See Figure 3. ENSURE BEAD IN MALE END FEMALE (BELL) END This distance may be reduced if equipment is a. Wipe the male end of each joint using an alcohol REST AGAINST END OF FEMALE PIPE GASKE7ED VENT MALE (BEAD) END SYSTEM protected from damage due to condensation or pad to remove any dirt and grease. GASKETED VENTSYSTEM vapor by enclosure,overhangs,etc. b. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into e. Minimum twelve(12)inches from overhang or comer of building. female end of joint. Ensure bead in male end 4 9 of the Enclose vent passing through occupied or pipe is below locking band and rest against unoccupied spaces above the boiler with material end of the female pipe. Verify the factory- -W X having a fire resistance rating of at least equal to the installed gasket is not dislodged or cut. It— t 10— rating of the adjoining floor or ceiling. Maintain c. Tighten locking band by ELAND with a 5/16" minimum clearances to combustible materials. See nut driver until snug plus%4 turn. DO NOT 41 Figure 1. SECURE JOINTS WITH SHEET METAL LOCKING BAND TIGHTEN Note: For one or two family dwellings,fire SCREWS OR POP RIVETS. DO NOT BY HAND WITH j%- NUT —TOWARD BOILER resistance rating requirement may not need to be PUNCTURE THE VENT SYSTEM! DRIVER UNTIL SNUG PLUS J TURN JA DO NOT USE SHEET METAL met,but is recommended. d. Once the installation is complete,operate z s SCREWS TO SECURE JOINTS 8 appliance and inspect all joints to ensure that flue 10. Plan venting system to avoid possible contact with plumbing or electrical wires. Start at vent connector gases and/or liquid condensate will not escape. Figure 3: U.S. Boiler Gasketed Vent Joint Detail on top of boiler and work towards vent terminal. D. Separate Horizontal Venting System. See Figures 4A, 11. Once a vent pipe manufacturer and system is chosen 4B and 5. See Figure 28 for Blower Vent Connector never mix and match vent systems. Assembly. 12. If a non-standard length pipe is required: Vent Piping– {"w Gasketed Vent System:The use of the adjustable 1. This boiler is supplied with components as standard length pipe(P/N 8116319U)is recommended to equipment for installation of the separate horizontal complete a non-standard pipe length. This pipe venting system. requires a minimum installed length of 12%inch 2. Do not exceed maximum vent lengths. Refer to and can adjust across a 7 inch gap up to a maximum of 19%inch long. (Note for the adjustable pipe Table 4. the installed length should be measured from the 3. Recommended horizontal installation consists centerline of the bead on the male end of the first of vent being sloped down V4 inch per foot away pipe to the end of the female pipe excluding the from boiler. See Figure 4A. See Figure 4B for an locking band of the second pipe with a single alternate horizontal installation. gasket.) Only in the event the adjustable length pipe 4. Use appropriate designed thimbles when passing is not sufficient a standard length pipe may be cut through combustible walls(thimble use optional for using the procedure outlined below for the Gasket- noncombustible walls). Insert thimble through wall Less Vent System. from outside. Secure outside flange to wall with nails or screws,and seal ID,OD and vent holes with 12 13 t III. VENTING (continued) 5 FT. MAX. 5 FT. MAX. (TYP) VENT TERMINA� FLUE GAS 12" MIN. SUPPORT FLOW STRAPS GRADE + MAX. SNOW ACCUMULATION \��j\�j VENT PIPE: HORIZONTAL RUNS VENT PPE MUST SLOPE AWAY FROM BOILER PER FOOT MINIMUM "a &00 000" /\\ DOUBLE WALL THIMBLE REQUIRED FOR COMBUSTIBLE WALL; SINGLE WALL THIMBLE p 0 OPTIONAL FOR NON—COMBUSTIBLE WALL Figure 4A: Recommended Horizontal— Vent Installation ?.'��'- ..r= -.i s. _;-:.^,"^ .^:l n- e.,�.� .,e.;^ :F:-�+:. ^+ty. r„.^+..•;;,-.,- ^!'�%sSk gip,? ^rt%en..;::.i w- "a.m -... .,+.r,^-,+_:k,•",'::z'•.r..:d-•.,- t', 'nom ,. ....,.�'_ .. "a.. _!.f�'t;=, _ti.4�:::;'�',7?.:•,;,, z^5..., '.Y.., .. ... i�..-•': �'t.ry,. .,...,:,.; .,. ,'{., -,r=+:'..,Fi'-t ec;✓', „w .. k,-,_. r,. .£. ,,:'?.� III. VENTING (continued) 5 FT. MAX. 5 FT. MAX. CONDENSATE (TYP) DRAIN TEE VENT TERMINAL _ CONDENSATE FLUE GAS DRAIN TUBE— SUPPORT FLOW TO FLOOR DRAIN 12” MIN. STRAPS OR PUMP GRADE + MAX. SNOW , ACCUMULATION \ VENT PIPE: SEE NOTE 1 V NT VENT E PPE —�� ffl 00 oo' DOUBLE WALL THIMBLE REQUIRED FOR COMBUSTIBLE WALL; SINGLE WALL THIMBLE p 0 OPTIONAL FOR NON—COMBUSTIBLE WALL SIE VENT PIPE MINIMUM CLEARANCE TO COMBUSTIBLE MATERIAL IS LEFT SIDE VIEW FOUR (4) INCHES WHEN VENT IS INSTALLED IN A FULLY ENCLOSED (CHASE) APPLICATION OR THREE (3) INCHES WHEN VENT IS INSTALLED WITH AT LEAST ONE SIDE OPEN, SIMILAR TO A JOIST BAY APPLICATION. ONTE1: HORIZONTAL RUNS MUST SLOPE TOWARD THE BOILER 1/4" PER FOOT MIN. WHEN USING A CONDENSATE TEE. Figure 413: Alternate Horizontal— Vent Installation Cn 1 T' s4 III. VENTING (continued) _ n. w " W z Z J 0 C, O 5" MIN. WEATHERPROOF L=J0° `" z ckf w/SILICONE CAULK ` j o w 8-3"MAX. Y, a o Q : o a 4 Y Cn w >- 0 0 ¢ LOCKING BAND . , D� ,� g < Of F_ v CO _ iN 45° ELBOW a 0 4 z bi Q Z a (SUPPLIED BY m _z M o Z: tINSTALLER) w o w ow o m J W(n FLUE GAS :r-{, •, ,.. .,. o J FLOW ' '' '' ot VENT TERMINAL - w _� c) N z " > , ' tzo (INCLUDED z � v- �z V W/BOILER) 4 af o cn w Q CCD w; Q 0 (D 00 Q z z F- z t� o Cao <; ``ao Q� > �Qo WJ ^' 4; WJ _,Q W WZ —�=Q C1 I- ; '! D W a Q THIMBLE ;; x: ,: J �'- o o v w A (REQUIRED IF " `` ¢moo J a- co o COMBUSTIBLE WALL) V) u)w Q = Q J< 17 MIN. w : ,a. °: z vV) 29" MAX. fs.p t; w.�o Z v~i EXTERIOR WALL -q- L o ` ¢ W OZWO 99 a. > LL W>H 3 HORIZONTAL VENT TERMINAL � &, � �(n Figure 5: Horizontal- Vent Terminal Configuration a' o >`= < a d� s'. E. Separate Vertical Venting System - See Figures 6,7 and 8. _:'; _ _ _ _ _ �. w Ld • A Q o- w land of penetrations require the use of roof flashing o- .ys � o z storm collar-not supplied with boiler. J w w w ,r co¢ a. > Q ;' W 0 Z V) J (n L` a. � �( CL'—N 0 Q Z Vertical Venting - P o a a_ - o 5. Whenever possible,install vent straight through r.d. :,; the roof. Refer to Figure 7 if offset is necessary. , ' o g W „, ; z _z. ,l 1. See Figure 28 for Blower Vent Connector Q o LL �;:: > o = Assembly. Do not exceed maximum vent lengths. Maintain minimum clearance to combustible £.. 3? w yx w w 2 Refer to Table 4. materials. o .< cn =rr', ` LL a 6. Install Vent Terminal 2. Installation of a vertical vent drain tee 8116304U is required on all vertical vent applications. See a. Size roof opening to maintain minimum .v tt Figures 6 and 7. Attach vertical vent drain tee clearance from combustible materials. "' _'` � =°' -- _.. .. __._._- '—' F'li. •,.; � a- e^�eY�- `.T.A'i w'+ dl-`.�.•F'1^itZl::'.9`'4b�7.*}:y, � c directly to elbow or horizontal pipe from an elbow b. Extend vent pipe to maintain minimum vertical - - .aor..,�,ibS;{i:"" ;£* ..t„•:A,i- t.fe^'c ;'%«;`:'.,..dp - Y-b ` Y P P a"rQ'w;':.r'•. .,� ? :i,fi,,.' f; and horizontal distance of twelve(12)inches immediately after vent connector. O a Z fn from roof surface.Allow additional vertical ? o o c := �G,r-E,;® =„x =� K:d ►--i 3. Slope horizontal runs minimum /a inch per foot. J .,r W o Slope towards vertical vent drain tee. Position weld distance for expected snow accumulation. of =0 r ,• Q D p '; o o-m LU o Provide brace as required. Refer to Figure 8. seams in vent pipes,in all horizontal runs,at the top q g to avoid condensate from lying on the seams. c. Install storm collar on vent pipe immediately 4. Install fire stops where vent passes through floors, above flashing. Apply Dow Corning Silastic 732 s;: Z > cn� z W F ^M; a 0 RTV Sealant between vent pipe and storm collar W =u Z o ° W ;.' ti ceilings or framed walls. The fire stop must close 4 the opening between the vent pipe and the structure. to provide weathertight seal. r�0 d. Attach vent terminal. U) Ld 16 ,, 17 8 in. vEN— 'ING (continued) VENT TERMINAL BRACE (IF REQ'D) BAND SUPPORT COLLAR FOR BRACE f° 3 VENT PIPE STORM COLLAR FLASHING .".'u,� yeah yi4�'d r `I u� F`:^a• FLUE GAS FLOW k VERTICAL �a VENT TERMINAL VENT PIPE MINIMUM CLEARANCE TO COMBUSTIBLE MATERIAL IS FOUR (4) INCHES WHEN VENT IS INSTALLED IN A FULLY ENCLOSED (CHASE) APPLICATION OR THREE (3) INCHES WHEN VENT IS INSTALLED WITH AT LEAST ONE SIDE OPEN, SIMILAR TO A JOIST BAY APPLICATION. Figure 8: Vertical Vent Termination Extend Vent Piping to maintain minimum vertical("X")and minimum horizontal ("Y")distance of twelve(12)inches from roof sur- face. Allow additional vertical("X")distance for expected snow accumulation. . ,.r. �; .+'r�'^;'t;. ;�r�,,�. .z;°'•f'";r.=?:s�`;.;t• - .�-'!.,.�: »a,=`t£�-:::,f'.6z,�r'.;.,'ri3i`'k,..�,�c�sr,".-{.'•`. .,„.,,sx�c::�.,.,�.v„•;}..,.....,,;.- - .• ” ,_. .,.> .w...-.n�.3=�.,�,�.r.:n-^,'i .. :'�5.::,..�.1'..:•vx�x...,.k;::-,=.::":;�.:.:....;7'_,..y::�...�_..h%::: .tea±«r...necr...»R:::y•'.Y:.:":k:�t3t'a,'tE,H'x',_ .-Pw.,,d�a�:4;a"�.+.��.=.�,_.�:-r.,a:�,k.:x-'.',�.:.:_;^«,K,:':��;'it��t?:;!'=,>r:s•.�^:e;,3�,w-a;..s...�tFrTH>3',r°..r":�'�p.r�.:.:cY:c*•:�--•: �- .— - _.._.._.____-' _,r .r.......,�.< Fm w (0 iD N G qa �' p �• ,-� C7 b S, m ^ lODmay” CL .* �O-h C G �1 '~ •�� CyCO CD O .K n OCD N ICD C�l . N N Y/ O eD c"u IR 2 uo o E' qo c • ° td 'ti C ty O' y UQ M �- '• O A7 CD � 0 r' CD O v1 C C CL d. C " ee 2, N CL E cCo CCD C1S. coo CD CD c, 00 e Coll C5O C �' A v� O epi i.� y o aha c y H o 0 0 CD 0 0 p .n NC T < 0 0 = O r7 � -Z N M U D K frrt CD \\\/� C O0, C / r z a m n I W LU O D �1 r w �m m M g-p D D A AZD X om m 0 co N[n 0�� -a r m I �O M o p n •}9 to IV. WATER PIPING AND TRIM IV. WATER PIPING AND TRIM (continued) 5. When constructing a piping tree to install LWCO 2. The recommended location for an Auxiliary Limit WARNING select fittings(tees,elbows etc)and nipples to have on gas hot water boilers is in the supply piping. See the same size(NPT)as boiler supply connection. Figure 11 for recommended location. Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. At minimum, 1-1/4"tee with 3/4"branch outlet is i 3. Piping and fittings required to install an Auxiliary required to connect the probe LWCO to the supply Limit are field supplied. Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and j; piping. See Figure 10.DO NOT REDUCE THE can lead to boiler failure. U.S. Boiler's Standard Warranty does not cover problems caused by oxygen SIZE OF NEAR BOILER SUPPLY FITTINGS 4. When constructing a piping tree to install an Auxiliary Limit select fittings(tees,elbows etc contamination of boiler water or scale(lime) build-up caused by frequent addition of water. AND NIPPLES. Aux ) and nipples to have the same size(NPT)as boiler 6. Installation of manual shutoff valve located above supply connection.At minimum, 1-1/4"tee with A. Design and install boiler and system piping to B. Optional Probe LWCO Installation the LWCO and the boiler is recommended to allow 1/2"branch outlet is required to install the limit prevent oxygen contamination of boiler water and servicing. Thus LWCO probe can be removed for P Yg ; well into the supply piping. See Figure 11.DO frequent water additions. - inspection without draining the heating system.An NOT REDUCE THE SIZE OF NEAR BOILER x annual inspection of the probe is recommended. 1. There are many possible causes of oxygen �r SUPPLY FITTINGS AND NIPPLES. DO NOT ATTEMPT to cut factory wires to 7. The presence of water covering properly installed contamination such as: install an aftermarket Low Water Cut Off ; 5. When boiler water temperature reaches or exceeds a. Addition of excessive make-up water as a result LWCO probe will cause the normally open contact AuxiliLimit settin of system leaks. (LWCO). Only use connections specifically of the LWCO to close,thus providing continuity of �' g,t he limit normally closed Y identified for Low Water Cut Off. contact will open,thus interrupting the 24 VAC b. Absorption through open tanks and fittings. m the 24 VAC service to the boiler gas valve.When service to the boiler gas valve.When boiler water c. Oxygen permeable materials in the distribution In all cases,follow the Low Water Cut Off K water level drops below probe,LWCO contact temperature drops s below limit differential limit (LWCO) manufacturer's instructions. opens up breaking 24V supply to gas valve and tem system. contact closes restoring 24V supply to gas valve and preventing the boiler to fire. 2. In order to insure long product life,oxygen sources1. A low water cutoff is required to protect allowing the boiler to fire. fished b 8. 2012 compliant PVG gas hot water boilers have must be eliminated. This can be accomplished Y a gas-fired hot water boiler when any 6. Gas hot water boilers equipped with Intelligent taking the following measures: connected heat distributor(radiation)is =; a"plug-in"provision in factory wiring that will Hydronic Control have a"plug-in"provision in accept optional 24VAC probe LWCO harness a. Repairing system leaks to eliminate the need for installed below the top of the hot water x; factory wiring that will accept optional 24VAC addition of make-up water. boiler(i.e.baseboard on the same floor connector.The optional LWCO kit(P/N 104083- Auxiliary Limit harness connector.The optional level as the boiler). In addition,some r 01)includes 24VAC probe LWCO,Harness and Auxiliary Limit kit /N 103696-01 includes b. Eliminating open tanks from the system. ) � �' � ) • Instructions addressing piping,wiring and testing 24VAC Auxiliary , c. Eliminatingand/or repairing fittings which allow jurisdictions require the use of a LWCO ary Limit Well Harness and P g g =, after installation. Instructions addressing wiring and testing after oxygen absorption. with a hot water boiler as a redundant safety d. Use of non-permeable materials in the control. t C. Optional Auxiliary Limit Installation installation. distributions stem. It is recommended that the LWCO control 1. Some jurisdictions may require the use of an D. Connects stem supply and return piping to Y j Y q Y PP Y P�P� g is installed above the boiler to provide , e. Isolating the boiler from the system water by Auxiliary Limit control with a hot water boiler as a boiler. See Figures 14 and 15.Maintain minimum installing a heat exchanger. the highest level of protection. However, ; redundant safety control. inch clearance from hot water piping to combustible f. Use properly designed and operating air where the LWCO control is approved by the materials. elimination devices in water piping. LWCO control manufacturer for installationIN in a high boiler tapping of a water boiler,the . TO SYSTEM use of the listed LWCO control is permitted SUPPLY REDUCING TEE TO SYSTEM when it is installed according to the LWCO AUXILIARY LIMIT SUPPLY manufacturer's instructions. 1 _ AND WELL RECOMMENDED MANUAL 2. The recommended location for a LWCO on CD (LOCATION B) SHUT-OFF VALVE r TEE gas hot water boilers is above the boiler,in the supply piping. The minimum safe water £ o PROBE LWCO 8" MIN O level of a water boiler is at the uppermost 22" MAX 22" MAX O top of the boiler;that is,it must be full of o - (PROBE MUST BE 0 owater to operate safely. ABOVE JACKET TOP) SECTION TOP (MINIMUM SAFE 3. Typically,in residential applications,a probe \•. WATER LINE) type LWCO is used instead of a float type, o BOILER SUPPLY due to their relative costs and the simplicity o MANIFOLD of piping for a probe LWCO. CONNECTION BOILER SUPPLY O Q MANIFOLD 4. Piping and fittings required to install LWCO CONNECTION are field supplied. AUXILIARY LIMIT AND WELL • t (LOCATION A) Figure 10: Recommended Probe LWCO Location 12" MAX 12" MAX Figure 11: Recommended Auxiliary Limit Location 20 x 21 lb - --------- ---- - --- - IV. WATER PIPING AND TRIM (continued) IV. WATER PIPING AND TRIM (continued) L. If it is required to perform a long term pressure To perform a long term pressure test including the NOTICE WATER � > boiler s CHILLER test of the hY Y dromic system,the hould first be boiler,ALL trapped air must first be removed from the isolated to avoid a pressure loss due to the escape of air boiler. U.S. Boiler recommends sizing the system trapped in the boiler.i? circulatorto supply sufficient flow(GPM)to allow a HEATING A loss of pressure during such a test,with no visible SHUT-OFF BOILER SHUT-OFF water leakage,is an indication that the boiler contained 20°F temperature differential in the system. When VALVES VALVES sizing the system circulator,the pressure drop of trapped air. all radiators,baseboard and radiant tubing and all connecting piping must be considered. AIR CUSHIONTANKI E. Install circulator with flanges,gaskets and bolts provided. Circulator harness allows circulator to be CIRCULATOR mounted on supply or return. Connect harness to SUPPLY MAIN TO RETURN MAIN FROM circulator and secure any excess Conduit. COMBINED HEATING COMBINED HEATING & COOLING SYSTEM & COOLING SYSTEN F. Install supply manifold,pressure/temperature gauge Figure 13: Recommended Piping for Combination r r. and pressure relief valve. Heating &Cooling See Figure 12.Pressure Relief Valve must be installed (Refrigeration)System y: with spindle in vertical position. Installation of the relief valve must comply with the ASME Boiler and H. If boiler is used in connection with refrigeration Pressure Vessel Code,Section IV systems,boiler must be installed with chilled medium piped in parallel with the heating boiler using PRESSURE — _ appropriate valves to prevent chilled medium from .} '<" "_ : enterin boiler,see Figure 13. RELIEF VALVE g g OUTLET WATER I. If boiler is connected to heating coils located in MANIFOLD -- � air handling units where they may be exposed to . refrigerated air,boiler piping must be equipped with flow control valves to prevent gravity circulation of TO SYSTEM boiler water during operation of cooling system. SUPPLY n' ? TEMPERATURE/ Use a boiler bypass if the boiler is to be operated PRESSURE GAUGE :„ in a system which has a large volume or excessive radiation where low boiler water temperatures may beF encountered(i.e.converted gravity circulation system, ,t etc.). Install pipe tee between circulator and boiler return ; �# d along with second tee in supply piping as shown in Figure 14 or 15.Bypass should be same size as the supply and return lines with valves located in bypass Figure 12: Supply Water Manifold Piping and supply outlet as illustrated in Figure 14 or 15 in order to regulate water flow to maintain higher boiler water temperatures. After the boiler is operational(reference Section VIII. `} Pressure relief valve discharge piping must be System Start-Up)set by-pass and boiler supply valves piped such that the potential of severe burns to half throttle position to start.Operate boiler until i3 system water temperature reaches normal operating is eliminated. DO NOT pipe in any area where range. freezing could occur. DO NOT install any shut-off valves, plugs or caps. Consult Local Codes for Adjust valves to provide 180°to 200°F supply water temperature. Opening the boiler supply valve will raise proper discharge piping arrangement. system temperature,while opening the by-pass valve G. Space heating and domestic water heating with will lower system supply temperature. Alliance SLTM water heater.Install Alliance SLIM water K. After the boiler and system have been cleaned and z heater as a separate heating zone.,Refer to Alliance flushed,and before refilling the entire system add ( SLTM Installation,Operating and Service Instructions I- for additional information. appropriate water treatment chemicals,if necessary,to bring the pH between 7 and 11. (r, 22 23 �t. IV WATER PIPING AND TRIM (continued) +- FROM ADDITIONAL ZONES TO ALLIANCE TO TO WATER HEATER ZONE 1 ZONE 2 FROM ZONE 2 (IF USED) FROM ALLIANCE WATER SHUT-OFF SHUT-OFF HEATER OR ZONE 1 VALVE 14 VALVES f f f FLOW CONTROL VALVE PURGE 18" MIN. AIR VENT VALVE (IF CONVENTIONALQQ .Q CIRCULATOR AIR SCOOP IS USED) AIR SCOOP T BYPASS REDUCER VALVE 14 - 14 T T TO ADDITIONAL BALL VALVE ZONES - 14 (FULL PORT) SYSTEM LIMIT PRESSURE SHUT-OFF CHECK VALVE (IF REQUIRED) REDUCING VALVE (IF REQUIRED) 'ISOLATION VALVE VALVES LOW WATER COLD WATER CUT-OFF SUPPLY (OPTIONAL) EXPANSION l TANK SYSTEM RETURN SYSTEM SUPPLY PRESSURE RELIEF VALVE I PIPE WITHIN U j 6" OF FLOOR U FRONT OF BOILER LEFT SIDE VIEW i I II Figure 14: Recommended Boiler Piping For Circulator Zoned Heating Systems I I 1-7 IV WATER PIPING AND TRIM (continued) II I FROM ADDITIONAL ZONES I FROM ZONE 2 TO ALLIANCE TO TO WATER HEATER ZONE 1 ZONE 2 (IF USED) FROM ALLIANCE WATER I, SHUT-OFF HEATER OR ZONE 1 'j 14 VALVES li 18" MIN. 1 BALANCING VALVE PURGE (IF CONVENTIONAL AIR VENT IT VALVE AIR SCOOP IS USED) AIR SCOOP ZONE VALVE �t BYPASS SYSTEM VALVE 14 CIRCULATOR 14 TO IOI ADDITIONAL 1 BALL VALVE ZONES T 14 (FULL PORT) +- SYSTEM LIMIT PRESSURE SHUT-OFF CHECK VALVE (IF REQUIRED) REDUCING VALVE (IF REQUIRED) ISOLATION j VALVE VALVES LOW WATER COLD WATER CUTSUPPLY OFF EXPANSION (OPTIONAL) TANK I SYSTEM RETURN SYSTEM SUPPLY PRESSURE RELIEF VALVE PIPE WITHIN U 6" OF FLOOR I U FRONT OF BOILER I I I LEFT SIDE VIEW I • I i I I N Figure 15: Recommended Water Piping for Zone Valve Zoned Heating Systems w I I V. GAS PIPING V. GAS PIPING (continued) Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Natural Gas Pressures of 0.5 psig or Less WARNING 3. Length of piping and number of fittings.Refer to Table 7 for maximum capacity of Schedule 40 pipe. Length 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop Failure to properly pipe gas supply to boiler may Table 8 lists equivalent pipe length for standard [Feet] 1/Z % 1 1'/ '/ % 1 1'/ result in improper operation and damage to the fittings. 10 132 278 520 1,050 175 360 680 1,400 boiler or structure. Always assure gas piping is 4. Corrections for the specific gravity of natural gas 20 92 190 350 730 120 250 465 950 absolutely leak free and of the proper size and can be found in Table 6. 30 73 152 285 590 2 200 375 770 type for the connected load. An additional gas pressure regulator may be Table 6: Specific Gravity Correction Factors for 40 63 130 245 500 82 170 320 660 needed. Consult gas supplier. Natural Gas ( 50 56 115 215 440 73 151 285 580 Specific Correction Specific Correction 60 50 105 195 400 66 138 260 530 A. Size gas piping.Design system to provide adequate gas 70 46 96 180 370 61 125 240 490 supply to boiler.Consider these factors: Gravity Factor Gravity Factor - --- 0.85 0.81 80 43 90 170 350 57 118 220 460 1. Allowable pressure drop from point of delivery to 0.90 0.82 90 40 84 160 320 53 110 205 430 boiler.Maximum allowable system pressure is%s 100 38 79 150 305 50 103 195 400 si Actual point of delivery pressure may be less; 0.60 1.00 1.00 0.78 P g• P � rY P Y >; contact gas supplier for additional information. 0.65 0.96 1.10 0.74 1 CFH of Natural Gas is approximately equal to 1 MBH. Minimum gas valve inlet pressure is stamped on 0.70 0.93 1.20 0.71 Contact your gas supplier for the actual heating value of your gas. the rating label located in the boiler's vestibule 0.75 0.90 1.30 0.68 compartment. B. Connect boiler gas valve to gas supply system. 4. All above ground gas piping upstream from manual 0.80 0.87 1.40 0.66 shut-off valve must be electrically continuous and 2. Maximum gas demand.Refer to the boiler's input as bonded to a grounding electrode.Do not use gas printed on its rating label.Also consider existing and For materials or conditions other than those listed ' piping as grounding electrode.Refer to National expected future gas utilization equipment(i.e.water above,refer to National Fuel Gas Code,NFPA54/ANSI Failure to use proper thread compounds on all Electrical Code,NFPA 70 or Canadian Electrical heater,cooking equipment). Z223.1 CAN/CSA B 149.1 Natural Gas or Propane 1' Code CSA-C22.1. p gas connectors may result in leaks of flammable Installation Code or size system using standard gas. engineering methods acceptable to authority having MANUAL jurisdiction. SHUT-OFF . - VALVE lab supply to boiler and system must be GROUND Table 5: Gas Ratings olutely shut off prior to installing or servicing JOINT er gas piping. UNION Minimum Natural Natural Maximum Natural Manifold TEE Gas Pressure 1. Use methods and materials in accordance with local Gas Pressure Pressure plumbing codes and requirements of gas supplier.InModel (in. w.c.) i (in.w.c.) (in.w.c.) Inlet to Gas Valve absence of such requirements,follow National Fuel =_ Gas Code,NFPA 54/ANSI Z223.1 or CAN/CSA PVG3 i B 149.1 Natural Gas or Propane Installation Code. 3" MIN. PVG4 14 4.5 3.5 i� 2. Use thread(jomt)compounds(pipe dope)resistant PVGS to action of liquefied petroleum gas. PVG6 3. Install sediment trap,ground joint union and manual CAP shut-off valve upstream of boiler gas control valve I and outside jacket. See Figure 16. Y I Figure 16: Recommended Gas Piping i Table 8: Equivalent Lengths of Standard Pipe Fittings&Valves I; VALVES FULLY OPEN } Pipe I.D. Gate Globe Angle Swing 900 450 90'Tee, Flow 90'Tee, Flow Size Inches Check Elbow Elbow Through Run Through Branch '/" 0.622 0.35 18.6 9.3 4.3 1.6 0.78 1.0 3.1 a %11 0.824 0.44 23.1 11.5 5.3 2.1 0.97 1.4 14.1 I 1° 1 1.049 0.56 29.4 14.7 1 6.8 2.6 1.23 1.8 5.3 1 W 1 1.380 0.74 38.6 19.3 8.9 3.5 1.60 2.3 6.9 26 27 V. GAS PIPING (continued) VI. ELECTRICAL . Pressure test.The boiler and its gas connection must 2. Locate leaks using approved combustible gas be leak tested before placing boiler in operation. detector,soap and water,or similar nonflammable r !electrical sitively assure all electrical connections are unpowered before attempting installation or service of 1. Protect boiler gas control valve.For all testing over solution. components or connections of the boiler or building. Lock out all electrical boxes with padlock %psig,boiler and its individual shutoff valve must e power is turned off. be disconnected from gas supply piping.For testing at%2 psig or less,isolate boiler from gas supply Do not use matches, candles, open flames or piping by closing boiler's individual manual shutoff other ignition source to check for leaks. valve. Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work. ? Each boiler must be protected with a properly sized over-current device. IY� Never jump out or make inoperative any safety or operating controls. Y The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls used with the boiler. Read, understand and follow all wiring instructions supplied with the controls. ,r " A. General.Install wiring and electrically ground boiler Heat Anticipator in Thermostat should be set to 0.6 in accordance with authority having jurisdiction or,in amp. If system tends to overheat above the thermostat's the absence of such requirements,follow the National temperature setting,reduce heat anticipator setting by Electrical Code,NFPA 70,and/or CSA C22.1 Electrical 1 or.2 amps. If system tends to short cycle without ' Code. reaching desired room temperature,increase heat B. A separate electrical circuit must be run from anticipator setting by.1 or.2 amps. the main electrical service with an over-current D. For zone valve wiring,a separate 24V transformer device/disconnect in the circuit. A service switch is is required rather than attempting to use the boiler recommended and may be required by some local mounted control.Consult zone valve manufacturer for jurisdictions.Install the service switch in the line assistance. }' voltage"Hot"leg of the power supply. Locate the service switch such that the boiler can be shut-off without exposing personnel to danger in the event of t, The combined boiler and circulator amperage tf an emergency. Connect the main power supply and must not exceed 15 amps. ground to the three(3)boiler wires(black,white and Install over-current protection in accordance with green)located in the junction box at the inside top of authority having jurisdiction or, in the absence of ' the boiler jacket. such requirements,follow the National Electric C. INSTALL A ROOM THERMOSTAT on an Code, NFPA 70, and/or CSA C22.1 Electrical inside wall about four feet above floor.Never install Code. Do not provide over-current protection ju thermostat on an outside wall or where it will be greater than 15 amperes. influenced by drafts,hot or cold water pipes,lighting If fixtures,television,rays of the sun or near a fireplace. Keep large furniture away from thermostat so there will E. Refer to Figures 17 and 18 for details on the internal be free movement of room air around this control. boiler wiring. • This boiler is equipped with a high water temperature limit rated sensor located inside the internal wiring of the boiler. This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the limit control. Certain Local Codes require an additional water temperature limit. In addition, _ certain types of systems may operate at temperatures below the minimum set point of the limit contained in E> the boiler. U y If this occurs, install an additional water temperature limit(Honeywell L4006 Aquastat) located in the system piping as shown in the Water Piping and Trim Section of this manual. Wire as indicated in the Electrical r, Section of this manual. 28 29 i VI. ELECTRICAL (continued) VI. ELECTRICAL (continued) IER OVERCURRENT SERVICE INTERNAL J-BOX ' GREEN GROUND SUPPLY PROTECTION/ SWITCH I SCREW All wire wire nuts controls etc. are installer supplied unless otherwise noted. -- I DISCONNECT (OPTIONAL) > > pP 120/60/1 (BY INSTALLER) (BY INSTALLER GR GND lily- .——————————---— —— If an additional system limit is used, install in series with the auxiliary limit jumper shown in the BK drawing below. L2 GND SUPL2 —— ——— 1 WH ® • PO 2WE0160/1 • • Ilr Internal BY INSTALLER) Internal OVERCURRENT Junction Junction PROTECTION! B0% OUTPUT RATINGS IN AMPERES AT 120 VAC Boz --- �� DISCONNECT 1"'—---------- ( ( OUTPUT FULL LOAD LOCKED ROTOR t (BY INSTALLER) DHW Q——— —.J I SERVICE SWITCH SYSTEM CIRCULATOR 74 444 CIRCULATOR SYSTEM i (OPTIONAL) DHW CIRCULATOR 74 444 (SUPPLIED BY CIRCULATOR YE i (BY INSTALLER) OTHERS) — ———— j — INDUCER 6 175 RD ':•,T�' d'r,. .tea{: '.4r .r-,iS.;:, ..i _ ..._- - WIRE CODE P m ONlOFF, .f„iz` ..-• �� ",et �Rm_ N(.GI-RCULATOR"�`.. a • pSystomCkmtlatti�>'' -•j.-sg::.�4k,,fy:f?,. BL-BLUE .r a t „s,`;r`'6 ,. �� BK-BLACK Une Input ��, .,;';;S. t,'`.3';,. ;'iY'a*,4. '•'a' t- �.°... 4"'i;T"., _ Neutral BR-BROWN BOILER CONTROL T1 ;p1'�a�� = P1 -�" GR-GREEN :a :.3` ��' ry( _: , GY-GRAY )•• '_?”�,,�:,.DFIV}+�C fiFj7'� - 4'"_ OR-ORANGEBLO ,tCt11A0RV�- --.!,,w, '.L. .(Su)i{ikjeiitn�:OUwtc),3.Fx: i :•C,. PI-PINK .�."w RD-RED �, g�' � '•P_1;,.,.«::� ;:: - " WH-WHITE .�:o.�.€c'��'='YON/OF ,.,c:'k�X'-��;.LmsSti ,cgY r-�."."_..z,..V°.0. °.i^ �.$; ,,• f�.. YE-YELLOW I:k -1' .o "'tIND1lCR.�;.}-;:i;ro° `ei,':• a �.) kTZi "_*«�° y Ysr1,Gy. BKlWH-BLACK W/ WHITETRACE dt ,4,r.,... »•- r. .----- ^- - i.9. "'�� , P7 P5 P2 PIA ��n❑I {' k``.} -'Sri. e. e:01 r 11 p �T Y� DHW 8 5 2 P9 U U 24V TRANSFORMER 11 1 2 7 4 1 1 2 3 P4 1 2 3 BOILER LIMIT ®®® 1 2 L2 GND L1 TEMSENSOR PERATURE -h-�—� ENVIRACOM Pi %L AUXILIARY LOW WATER LU mm >3 m W o . m INDUCER 11, IM R CUTOFF OPTION OPTION (PIN 103696-01) (PIN 104083-01) BKUBR DHAQUASW(BYOTHERS)PRESSURESWITCH BL PI �, i'1J.az '.,. hty li"t.•'":k�.y' _ : 1_14i to'S'i rPK{�;•'t2 }�qy.. t(. - .jtn^"''X="S-Y" {.�u`k, :` t.kt e^"- .ti;."•. .,i,sa ,,y,,t^f;ra�¢7yt,fF:'Y ^� .,",. NO L 4H BL e "x`< l'h :.?.y ..y" ,: •_t,7*,`0 :'xv-`;"•G'2' ;t�, Al J-BOX ` 't' _ _ ,r.'4 �.;3�• _ x.' ,%.-r - OAS'. GND. 24V 24VAC n - ' -c 'a, _ i''':i:^ �' _ V ;,Sw- •1'_.. SCREW C TRANSFORMER t �`*,r?'n` �::k PER. YE PV INPUT _ PILOT .s' .gyp.. _r0..:'»^D•=!:'...' ,w.Fw:.�..' �"r,;^: :,i' 4.6, "kms�L- ".i m ASSEMBLY "eP4:. - '"-(}e '1.: ?:.pS, .. ^' ..a „«:: 1.r'; '1=t.�ri,•. :; 1 r. v P5'•di.C'x =hl4wx 5 x (5 s p' 2 5. FLAME WH - �fi 4{r_:6,'® tty "F.t?iMu,`,t 4•.?�=",`3`'''.P.RESSURE- -�1.-"`:c.,: '`•'a. . _PV/MV :1 ( }'ROLLO T'v:'a. :,:!,," i L z:._—__ __ . ROLL-OUT W W ;i �I;t'`k _ _:.z; °eSWkTGH7 .,a:' - •�1M1?FTQti':;or ',�.°T' ~;='. SWITCH > > H'�", .'c°'.`-;,��'• 'r":"�' rr'n"^ '-F'a :I'..z�,t .'z ,ti.`c,a .,pZ'. •?:u:s` OR -Mv GR '"k:* " Iso- =.Y. tl'�'s _r;.,,, .t,:#:, ye... •) "„tv'. •fr4{rJpyt�:: :.'y`;2:- ,+,.1.., sna. vt”„K r.J-�`,.:�_.y,�.�,"e. :a. �;�, ,s_- '" BOILER _ `.Ii �>` sv`tet. . - ;p:,✓ _ - ' R'`� y .I.. '; :,.k-.'-' xd Pb, -3(.� J 2 J LIMB 4�..'-^_ _ _ R-•,x,_t,. _ _ tlr�-' 9°.� �€_s `r ' m m GAS VALVE =;-' TEMPERATURE 47 r `,l`t Y 1,_..._ ,:tar :: �°4_is..�._x=:..y _ _ .,:3_: - :�'tY✓,:'�J 1 SENSOR ,:'".�.�;Wid is • 2. :,g” y`;.w..:t.. :^f. .3 .(s,j'-} ;i,(r� CD O NOTES •',jr�_1 Au -.(,', .<:%'.` ' (>.;k„r.,,;...”. . -^thy �•r.'?,. 1 IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THE APPLIANCE MUST r ,gip.;-.-.�.; - ,t. ,-.y'.;;% 6'41j r.,?;, ,"-+' =`n k i('.'' '.,�,"y„y Y(,), - .p.:z �k,,;P 24V BE REPLACED,IT MUST BE REPLACED WITH THE SAME TYPE SHOWN P77_=r?;, rs xk;,ry',;,,, ..;GM''^.: _ :,: ki✓�I;j.A„;,; i;rerk, (r^,;`4�;:" ' - ",:ati"FiAME5ENSE'�:.'`�_ (''.- PILOT OR ITS EQUIVALENT.S'IL FAUT REMPLACER UN FIL QUELCONQUE Y, „,', :.,PB;"f? - '„."b, �'�e/e_".r7;r' '" .,' ;*:1� '"-is {: '•? ).:•;; `z;' -:+ ,,:,, --"t:,P,.-t ASSEMBLY THERMOSTAT "E �r•:1�r:",, PSq, '•:- 4-•k<'-.. ;.r'f?3 'j, � - .t- A,a' t*�:;w °+'=` •- II D'ORIGINEFOURNIAVEC L'APPAREIL,UTILISER OBLIGATOIREMENTUN a,: ^ (; 1'2 `,a a: = 7 g., ri ;• . bt z,g::".;�•x, : t: �•. `'y ;.5 <<,,,' �_- • ";':': (BY OTHERS) FIL DE MEMS TYPE DONNA OU SON EQUIVALENT `"';�,.-�..�, d;t��,.,��:�,'A't'"-',.': 'a• t J+ ,s,• ,.^. m,".."2-a";.�;' _ , LIMIT JUMPER 7 TBL (REMOVE PEROPTIONAL KIT WIRE TYPE LEGEND INSTRUCTIONS) LOW VOLTAGE FACTORY WIRING SIZE 18 AWG TYPE TEW/AWM STRANDED WIRE,105-C /\ —LOW VOLTAGE FIELD WIRING ♦ LINE VOLTAGE FACTORY WIRING SIZE 14 AWG TYPE TW OR TEW/AWM WIRE ' ♦ —LINE VOLTAGE FIELD WIRING ` I \ LOW VOOLTAG FACTORY WIRING SIZE 18 AWG TYPE CL2(X)OR CL3R STRANDED WIRE,75 TO 105'C I ♦ � DHW AQUASTAT 24V THERMOSTAT _I— ` —— (By Others) (By Others) AUXILIARY LIMIT 24V LOW WATER CUTOFF OPTION KIT OPTION KIT _ OUTPUT RATINGS IN PM 103696-01 P/N 10408301 AMPERES AT 24 VAC LADDER DIAGRAM LEGEND (SEE KIT INSTRUCTIONS (SEE KIT INSTRUCTIONS ----- 120 VAC,PCB Internal Traces FOR WIRING DETAILS) FOR WIRING DETAILS) i OUTPUT MAX 120 VAG Winng —— —— ± PILOT VALVE 2 ------ Low Voltage,PCB Intemal Traces MAIN VALVE 2 Low Voltage Wiring Figure 17: Wiring Connection Diagram m WImNut ;y ❑ Molex Connecbon ® Screw Terminal Figure 18: Wiring Ladder Diagram 30 31 L VI. ELECTRICAL (continued) k VI. ELECTRICAL (continued) OVERCURRENT SERVICE INTERNALJ-BOX GREEN • • SUPPLY PROTECTION/ SWITCH SCREW GROUND All wire, re f wire nuts controls etc. are installer supplied unless otherwise noted. 120/60/1 DISCONNECT (OPTIONAL) GND ILII--a-... (BY INSTALLER) —(-Y1=ST=LLER� —— GR If an additional system limit is used, install in series with the auxiliary limit jumper shown in the Jk BK drawing below. I L1 a--- o'er --�" ----- m I L2 GND (//��r II WH ® POWER POWER SUPPLY III L_- - —_ --—- - J Internal (BY INSTALLER) Internal OVERCURRENT Junceon Junction Boz OUTPUT RATINGS IN AMPERES AT 120 VAC Boz —————————————— �� PROTECTION/ b f"' II (BYSNSTAL ER) ( OUTPUT FULL LOAD LOCKED ROTOR DHW0� _JsERvlcESWITCH SYSTEM CIRCULATOR 7A 444 CIRCULATOR SYSTEM (OPTIONAL) t] DHW CIRCULATOR 74 444 (SUPPLIED BY CIRCULATOR YE (BY INSTALLER) OTHERS) �--' ———— INDUCER 6 175 L—————————————— RD �F '3�,`.:•.g_;g*;861L.E[2 CONTROtI'. 't�dj,`,;F,:-.,-. .•,,, _ .:. '; E.. ,`'�.1 .',:.j:».j?. �: xx ' ,,, ;s.• )�I.om CiiaAuf >y-,t r a ''_ WIRE CODE s -'SYSTEM C2RCULA I .�• $- BL-BLUE BLACK Line Input z q,4- y 3 s= a °F^ _ ,__• Neutral BOILER CONTROL " BR-BROWN �s .P�; .. - {-#_<;'...�`"r: .. _ s,^.c..: ,-.x•••at-,. GR-GREEN I,`"$�` `' .> ,fib`.1' y ,' ';'�•�',' ;.6� :np', "' GY-GRAY OR-ORANGE BL "'• "'� �' liYldlRCutA70t2;iF,� _ a� n .z.r��w l�!A'R?N,od,by"'Ofpere}.y:. ;;�'. _ Ir. �},_. e•`'_i:;'- '''kV a-: _ -c�": ;a 'iwyN.µ:. r. RD-RED �. 'y�� )}� PI-PINK f '• " '>I,xi';� _rk' P4 a* ;:�°::„,'•y.3:..:. n.2i,.�•.' ;,:s�,,s" �*i`✓:m}"'s`, WH-WHITE M .° ": • �. ;<'-,_ '} i "�'`.- •. YE-YELLOW '5'''':t `�" _; duca•>4 c. - ';�' IND'CIGF£trr �: °:. `w`. ' `»^"°. BKNVH-BLACK W/ WHITETRACE P.7 3 P5 P2 �:± :.',��. _ _f - , <-.�.; •;p2.'�`- c r `;:1,;.._.�„.�. ° � T� 1 QQ3 Q5 et 9 6 3 1 4 FO-], b❑ 8 8 5 2 1 Pg 3 P4 U U RD 24VTRANSFORMER 7 4 1 1 2 3 4 5 YE BOILER LIMIT ®®® 1 2 L2 GND L1 -- -- TEMPERA SENSORR ��-FYY� ENVIRACOM P i y' AUXILIARY LOW WATER CoLIMIT CUTOFF w >3 m> a m INDUCER OPTION OPTION (PM 103696-01) (PN 104083-01) BK 2 �� a— - DHW � AQUASTAT (BY OTHERS)�� R=. w^' ":1:, ;._r' +fvBOiLER?wON„�R(7L�=,y;;.{,:, ...,:iM1 :;�i.-.;,`•:t s,� -,,:" '. �r,',"., PRESSURE _ .r. t „e•> 5' _. �'� J � �Sx : SWITCH BL PI r - r i `s -s°'I "'Fs, -•`+�t ,'8."t' "•, _ „r, .s�°;', .r:''.. NO �.i �-. _ P<>.td.">.i •`ts.;••.;;. _ .1' 2} ' BL J-BOX a , GND O 24V 24VAC ti+. _ - .�--- - ':r,v. :1 ;.g:_ -; '� - j A}'VE ,'„+.,'i. i $CREYJ TRANSFORMER _ »� ^? ' `J '- _ YE PV PILOT I r INPUT `;<-,;: m ASSEMBLY f ;P4, ._p5•',;i,- �;s"' 'jt, V. I,a 1. 4.�Wh4Es''' '`P6+� 'F?5-'.': C.: .'t�0•'.t_P5-~-•-..'f: <.-<.'. :„`7 _ P5:: V�_ i= . FLAME WH 'r a �'}, _>�.- �.�.{ CLCNJ• ; -r3;"-„,PRESSUf2E'`.'I..a ,;'?,''•e: -'I __isi'x::" vS=:L;;pVb.°' •,F t::�:, PV/MV ROLL-OUT w W 1 J,-'rs =-r' i,'.t` `�' :S{A(}TCfi`' •3$YITCH;� 3%s,' N4°f ~a°v 3;PS,�"�s' SWITCH Y Y _�'lr n =.: - e '�„ µ • Y ?i';. •.'2..: ty OR B jr' `ti:fr ^�'3: . ;;c,_ ,?g;a. `;s's.s=;a.:':” �'i,.r_. tA.'= ,•'",,�. ? tllVtfW+- .;'»�}y' ''zm: Mv GR BOILER m mr LIMIT .'I�.. L'^° .�."'.ys" -"<�'•v`:,' GAS VALVE .d TEMPERATUR E f _ - _ ,"';Q,"",- s""G^v. r.p.�.•:.:.L_... ��' -.^.''T,, -�"f`,�r ass;;; _-'r r Y SENSOR X. "'I _ ,1. p_ .. :'.}t-{-;•-=""',i-,_._.. _-rte:,.- ._�`^ sx-.J'. NOTES. ;�'PTr;" 'r`•x^ �'.^,. 't s,=, 1. IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THE APPLIANCE MUST •-s_ ,,i; -'s; I> - ;^{}j^f- z�,,,1.,},_ _ = K'',,, e�r'':,?•t. �-nTN= - _ �, -' °'4...' •':l� ,.. �}: SFZAgkC R06.Fi, BE REPLACED,IT MUST BE REPLACED WITH THE SAME TYPE SHOWN iA.7-3`'•^'s:%' "a�`.'•1 "it=` '�°r,v r�^ }» r :"a'7-. ^a' SENBE,f';."";', PILOT 24V »i'i"c.:t;.:i�l,,:}_- .r;,`-'`"e.y`*"$`?.11�r.'.,':'i,'r„{�: r;Ia,:[;;:. ns,` =."ti1:0= :r=:::4*a.” ?q ,,,FiAMEJ,`:.•-..•.. :j"c,' OR ITS EQUIVALENT.S'ILFAUTREMPLACERLIN FILQUELCONQUE y,. ,<;.a-4.:P8,cAd: •;„�:,- -"-�rp5*}' "�; .- - -rri_•)}• � '-p?a-•,'.'x',- p - =u"•,aa� •.fit :;,' ASSEMBLY THE .�• sw• D'ORIGINE FOURNI AVEC L'APPAREIL,UTILISER OBLIGATOIREMENT UN { »11==.2,t'''t;,;;i;^.°;,, } 1' �' a•a: y„' ~` �-'�''� ”' (BY OTHERS) ` FIL DE MEMF TYPE DONNE OU SON EQUIVALENT. - •:s^,�;Ot f" :i,= 4 s'r: + -'z;`;« `:t2k�J ii ErtX'ftaGOM' LIMITJUMPER O I (REMOVE PER I OPTIONAL KIT } WIRE TYPE LEGEND INSTRUCTIONS) BL LOWVOLTAGE FACTORY WIRING SIZE 18 AWG TYPE TEWIAWM STRANDED WIRE,105"C ' LOW VOLTAGE FIELD WIRING LINE VOLTAGE FACTORY WIRING SIZE 14 AWG TYPE TW OR TEW/AWM WIRE LNE VOLTAGE FIELD WIRING f 'E) E)-IGNITOR-250°C LOW VOLTAGE FACTORY WIRING SIZE 18 AWG TYPE CL2(X)OR CL3R STRANDED WIRE,75 TO 105-C 1 I �\ DHW AQUASTAT 24V THERMOSTAT (By Others) (By Others) AUXILIARY LIMIT 24V LOW WATER CUTOFF OPTION KIT OPTION KIT �' I OUTPUT RATINGS IN LADDER DIAGRAM LEGEND PIN 103696-01 P/N 104083-01 g: AMPERES AT 24 VAC [FOR E KIT INSTRUCTIONS SEE KIT INSTRUCTIONS #' OUTPUT MAX ,,---� ( 120 VAC,PCB Internal Tues WIRING DETAILS) FOR WIRING DETAILS) ti: 120 VAC Wl.ng vs PILOT VALVE 2 ------ Low Voltage,PCB Internal Traces Low Voltage Winng Figure 17: Wiring Connection Diagram `i MAN VALVE 2 1 Wire Nut t ❑ Molex Connection ® Screw Terminal Figure 18: Wiring Ladder Diagram 30 `A 31 1 I N VI. Ell�LCTRICAL (continued) 24V 24V 24V 24V 24V 24V THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT ZONE #1 ZONE #2 ZONE #3 ZONE #1 ZONE #2 ZONE #3 I I I I I I I I I I I I I I II I I I I I I I I TO BOILER I I I I I I I I I I I I --- X1 ---1 -- T----------r�--t-------r--I-- x1 ---I- r------rt----r 1-------r----7 -r------, HARNESS 'T-T' - ---------� -L -1--------J -I- I 1-1 -- ----J-L-- --- -----L1-- CONNECTIONS --- X2 ---1-L� y � X2 -- t" I I I t I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I T T (X) X T T X T T X T T I I T T I I (bd) 4 � I 4 � 1 I I I I I I I I I 2 1 3 z 1 3 �4 2 1 3 tJ4 2 1 3 6 -� 2 1 3 JUMPER /, I , JUMPER /, I , JUMPER N �---- X3 - -------4-1-J-t-------J 1 I I X3 -L-f-L-1---------�-1-1--1---------J 1 1 1 1 1 1 I I I 11 1 1 1 1 I I I Lt O� X4 ---I + I 1 . I I I 1 X4 I I I I I I I ---- r T-----------r T---------�� , ---r- -1-----------i- ,-----------rte , I I 1 I I 1 I I I 1 I I POWER SUPPLY rJ LI rJ L-I rJ L, r LI r L-I r L-I 120/60/1 1 1 1 1 1 1 1 1 1 1 1 1 L.eJ IL J L J L J LeJ ILe J CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR CIRCULATOR ZONE #1 ZONE #2 ZONE #3 ZONE #1 ZONE #2 ZONE #3 HONEYWELL RA832A RELAYS HONEYWELL R845A RELAYS WIRE TYPE LEGEND —LOW VOLTAGE FACTORY WIRING SIZE 18 AWG TYPE TEW/AWM STRANDED WIRE,105°C --LOW VOLTAGE FIELD WIRING —LINE VOLTAGE FACTORY WIRING SIZE 14 AWG TYPE TW OR TEW/AWM WIRE --LINE VOLTAGE FIELD WIRING Figure 19: Circulator Zoned System Wiring Diagram VI. ELECTRICAL (continued) FIELD INSTALLED 40VA TRANSFORMER 2 WIRE(24V)THERMOSTATS (SEE NOTE) F W/HEAT ANTICIPATOR SET i I AT 0.9 AMPS(40VA REQ'D POWER L1 Q------ ------X1------------- q q q FOR EVERY 3 ZONE VALVES) SUPPLY � III 120/60/1 N LJ----- ------X2--------- I I I I I I I I I I I I I TACO ZONE VALVES I I I I (SEE NOTE) -----------------X3------ j 1 I 1 TO BOILER I I HARNESS'T-T' j L--- _�= 2 --- --- --- --- 2 CONNECTIONS -----------------X4-------------- - 3 - ------ ----- - -----------� r----------- 2 WIRE(24V)THERMOSTATS W/HEAT ANTICIPATOR SET i � r� AT 0.5 AMPS(40VA REQ'D X1------------- qQ iQ FOR EVERY 4 ZONE VALVES) X2--------, I r I FLAIR"VJ" i i YE i YE i YE ZONE VALVES X3----- L_YE HONEYWELL V8043E (SEE NOTE) j ____ YE ___ _____YE ZONE VALVES X4---- -- a-- ----- -- 30-- ----- --�3 L--- RD --- -------- -----R X3---- -�� -- ----- -- 20-- ----- --�2 ------------ -- ----- ---Q1 X4----------------- ------------ --------� 2 WIRE(24V)THERMOSTATS I t I I I I W/HEAT ANTICIPATOR SET I i i i I 2 WIRE(24V)THERMOSTATS AT 0.3 AMPS(40VA REQ'D W/HEAT AT 0.9 AM ST(40VA REQ DETggq FOR EVERY 4 ZONE VALVES) I I I I I FOR EVERY 6 ZONE VALVES) I I I I I I WHITE-102 16R0GERS 2 I 2 -� ZONE VALVES r------- I I I T T 4 WIRE TYPE LEGEND T X1 r------ 1 3 1 3 1 306 —LOW VOLTAGE FACTORY WIRING SIZE 18 AWG TYPE TEW/AWM STRANDED WIRE,105°C I --LOW VOLTAGE FIELD WIRING X2------� \`�- ----� �`� -�;----- —LINE VOLTAGE FACTORY WIRING SIZE 14 AWG TYPE TW OR TEW/AWM WIRE X3--------------- -------- \-------- --LINE VOLTAGE FIELD WIRING I <<"',, Figure 20: Zone Valve Zoned System Wiring Schematic Cn iNODULAR INSTALLATION co } E. Gas Piping a & General Guidelines 1. Refer to National Fuel Gas Code,Local Codes and 1. Read and follow all venting,combustion au, Tables 7 and 8 for gas pipe sizing. water piping,gas piping and electrical instructions _ contained in this manual unless otherwise instructed Table 9: Modular Boiler Water Manifold Sizingw in this section. Combined Output Recommended Minimum 2. Consult Local Building Codes or National Fuel Gas Common Water Manifold ° Code,NFPA 54/ANSI Z222.3 for restrictions and (MBH) Size(NPT) instructions on modular boiler installations. < 166 1%" m B. Module Sizing <260 1%' U.S.Boiler recommends sizing each boiler in a modular <550 2" ij system to provide 20%of the combined heating load – <900 2'�Z" where ever possible. <2000 3" c� C. Venting Z 1. Each boiler must have an individual vent pipe. w~ w a J N� Refer to Venting Section of this manual for venting 2. Each boiler must be piped as shown in Figure 16. > 0- !''.• guidelines and options. z_w N w w Q J J J N O � WARNING 0> m � �0 is WARNING Q C If gas pressure in the building is above'/2 psigx N Q- Do not manifold vent pipes together. an additional gas pressure regulator is required. °L. ' " Using one additional regulator for multiple W ' 2. The maximum vent length for each boiler is fifty g m 'o (50)equivalent feet. boilers may result in unsafe boiler operation. op _ The additional regulator must be able to properly 3. The minimum horizontal distance between vent regulate gas pressure at the input of the smallest ` terminations is one(1)foot. Additional horizontal 3 boiler. If the regulator cannot do this,two or J o distance is desirable to avoid frost damage to the a UX Q } more additional regulators are required. Consult ., !I building. Vent terminations must be at least twelve regulator manufacturer and/or local gas supplier Zo (12)inches above the ground plus the expected for instructions and equipment ratings. > – > 0 N L. snow accumulation. V Z O J J 3 F. Electrical o m D 'r' ON CAUTI 1. Each boiler must be provided with a fused a Installing multiple vent terminations close disconnect and service switch. 0 together promotes frost buildup on buildings. 2. Install wiring in accordance with requirements of q( C To minimize this possibility,extend the distance authority having jurisdiction. In the absence of such v o t I from the building to the end of the vent requirements,follow the National Electric Code, J �i termination and increase the horizontal distance NFPA 70 and/or CSA C22.1 Electric Code. Z i ¢a 7 m between terminations. Q r w~ G. Modular Boiler Control Systems �Z ``' orZw 1 i+ 4. Multiple vertical vent pipes may be piped through Contact a controls manufacturer such as Honeywell or Q w Q o o '' t, a common conduit or chase so that one roof Telcmar to properly apply a modular control system. J > V w o • N `` ' w t� penetration may be made. Each vent termination must be one 1 foot from other terminations. Common systems may use outdoor temperature,return t, Q a V; }.3 ( ) water temperature or both to stage the boilers. r—~J _D _ a >> ~ A Water Piping(See Table 9 and Figure 21) Z ow w o co N o w 0 OSO>Z Yw 1 4 O �o E Installing a low water cutoff in the system piping of — N Q w J 1 z W W modular systems is strongly recommended and maybe Q o>a a > U> O Z� U Z> required by Local Codes. J U- m= 51CD S U z�U y Q 0000 Ld g Z 3 OL� fr Zam i' Ozg 09w O �z a -kr- 35 VIII. SYSTEM START-UP (continued) '~SYSTE9VI START-UP k. Verify that the venting,water piping,gas piping and 6. Open fill valve(Make-up water line should be F O R YOUR SA F E TY READ BEFORE O P E RAT I N G electrical system are installed properly. Refer to located directly after full port ball valve in system i installation instructions contained in this manual. supply piping between air scoop and expansion WARNING: If you do not follow these instructions exactly,a fire or explosion may result B. Confirm all electrical,water and gas supplies are tom)' causing property damage,personal injury,or loss of life. 7. Allow water to overflow from bucket until discharge turned off at the source and that vent is clear of A. This appliance is equipped with an ignition device > If you cannot reach your gas supplier fire obstructions. from hose is bubble free for 30 seconds. , call the which automatically lights the pilot. Do not try to light department. 8. Close the opened zone valve or shut-off valve for the pilot by hand. C. Confirm that all manual shut-off gas valves between the zone being purged of air,then open the zone C. Use only your hand to push in or turn the gas control the boiler and gas source are closed. valve or shut-off valve for the next zone to be B. BEFORE OPERATING smell all around the appliance knob. Never use tools.If the knob will not push in or purged. Repeat this step until all zones have been area for gas. Be sure to smell next to the floor turn by hand,don't try to repair it,call a qualified purged. At completion,open all zone valves or because some gas is heavier than air and will settle service technician.Force or attempted repair may B on the floor. result in a fire or explosion. ' Completely read, understand and follow all shut-off valves. instructions in this manual before attempting 9. Close hose bib,continue filling the system until the WHAT TO DO IF YOU SMELL GAS D. Do not use this appliance if any y part has been under start up. pressure gauge reads 12 psi. Close fill valve. > Do not try to light any appliance. water.Immediately call a qualified service technician (Note-If make-up water line is equipped with > Do not touch any electric switch; do not use any to inspect the appliance and to replace any part of the D. Fill entire beatingsystem with water and vent air phone in your building. control system and any gas control which has been Y pressure reducing valve,system will automatically > Immediately call your gas supplier from a neigh- under water. from system. Use the following procedure on a Series fill to 12 psi. Follow fill valve manufacturer's bor's phone. Follow the gas supplier's instructions. Loop or multi-zoned system installed as per Figure 14 'I instructions). stem when filling. or 15 to remove air from s � Y ,. 10.open isolation valve in boiler supply piping. OPERATING INSTRUCTIONS 11.Remove hose from hose bib. 1. STOP! Read the safety information above on this 7. Rotate gas control knob clockwise from"ON" The maximum operating pressure of this boiler E. Confirm that the boiler and system have no water label. position to"OFF". Make sure knob rests against stop. is 30 psig. Never exceed this pressure. Do not leaks. 2. Set the thermostat to lowest setting. 8. Wait five(5)minutes to clear out any gas. Then smell plug or change pressure relief valve. F. Prepare to check operation. for gas,including near the floor. If you smell gas, 1. Obtain gas heating value(in Btu per cubic foot) s, 3. Turn off all electric power to the appliance. STOP! Follow"B"in the safety information above on this label.If you do"not smell gas,go to the next step. • from gas supplier. 4. This appliance is equipped with an ignition device 2. Connect manometer to pressure tap on gas valve. ;;� which automatically lights the pilot. Do not try to 9. Rotate gas control knob counterclockwise from If it is required to perform a long term pressure Use 1/8 NPT tapping rovided. light the pilot by hand. "OFF"to"ON".Make sure knob rest against stop.Do test of the hydronic system,the boiler should pp g p first be isolated to avoid a pressure loss due to 3. Temporarily turn off all other gas-fired appliances. not force. 5. Remove front door. GAS CONTROL KNOB the escape of air trapped in the boiler. 4. Turn on gas supply to the boiler gas piping. Y 10.Replace front door. 6. Locate the gas control To perform a long term pressure test including 5. Confirm that the supply pressure to the gas valve is valve at the end of the 11.Turn on all electric power to the appliance. i the boiler,ALL trapped air must first be removed 14 in.wc.or less. Refer to Table 5 for minimum gas supply pipe going from the boiler. supply pressure. into the boiler.The GAS 12.Set thermostat to desired setting. {; A loss of pressure during such a test,with no g gas control knob is the INLET o 6. Open the field installed manual as shut-off valve brown or blue plastic 13.If the Dance will not o visible water leakage, is an indication that the cl P -� appliance perste,follow the g located upstream of the gas valve on the boiler. »� knob located on top of o�F instructions"TO TURN OFF GAS TO APPLIANCE" boiler contained trapped air. 7. Using soap solution,or similar non-combustible f the gas control valve. and call your service technician or gas supplier. solution,electronic leak detector or other approved ` 1. Close full port ball valve in boiler supply piping. method. Check that boiler gas piping valves,and TO TURN OFF GAS TO APPLIANCE 2. Isolate all zones by closing zone valves or shut-off all other components are leak free. Eliminate any valves in supply and return of each zone(s). lei 1. Set the thermostat to lowest setting. 4. Rotate gas control knob clockwise rl from"ON" 3. Attach a hose to the vertical hose bib located prior to position to"OFF". Make sure knob rests against stop. i - _ 2. Turn off all electric power to the appliance if service is the full port ball valve in the system supply piping. to be performed. 5. Replace front door. (Note-Terminate hose in five gallon bucket at a suitable floor drain or outdoor area). IDonotuse matches, candles, open flames or ker ignition source to check for leaks. 3. Remove front door. 4. Starting with one circuit at a time, open zone valve or shut-off valve in system supply and return piping. 8. Purge gas line of air. ti Operating 22: O S. Open hose bib. G. Operating Instructions �° Figure p g Instructions Follow Operating Instructions to place boiler in _ operation.See Operation Section for details. 1 X36 37 VIII. SYSTEM START-UP (continued) VIII. SYSTEM START-UP (continued) H. Check pilot burner flame.See Figure 24. Flame 3. Main burners and pilot burner will extinguish and b. Increase input rate if less than 98%of rating should be steady,medium hard blue enveloping 3/8 to blower will stop when water level drops below low plate input.Increase manifold gas pressure no inch of sensing probe. water cutoff probe.Verify limit,thermostat or other Failure to properly adjust gas input rate will result more than 0.3 inch W.C.If measured input rate is I. Check main burner flame.See Figure 23. Flame controls have not shut off boiler. in over firing or under firing of the appliance. still less than 98%of rated input: should have clearly defined inner cone with no yellow 4. Adjust thermostat to lowest setting.Refill boiler. Improper and unsafe boiler operation may result. i. Remove Main Burners per procedure in tipping.Orange-yellow streaks should not be confused i Section XI: Service. with true yellow ti M. Check limit. 4. Determine Input Rate.Multiply gas flow rate by gas ii. Remove gas orifices.Drill one(1)drill size Y tipping. Jumper Thermostat connections in boiler wiring heating value. INCANDESCENT OUTER MANTLE harness. Allow burners to operate until shutdown b larger(drill size is stamped on orifice,or see BLUE WITH OCCASIONAL limit. REMOVE JUMPER. Y 5. Compare measured input rate to input rate stated on Section XII: Repair Parts). ORANGE FLASHING rating plate. iii. Reinstall gas orifices and main burners. Ak, °", N. Adjust gas input rate to boiler. a. Boiler must not be over fired.Reduce input rate Measure input rate. OUTER CONE ..a Vii,': ° Y ',:. : . $> DARKER TRANSPARENT BLUE r"$ "ss =~ "t' 1. Ad by decreasing manifold pressure.Do not reduce 6. Recheck Main Burner Flame. just thermostat to highest setting. « '>, h' more than 0.3 inch w.c.If boiler is still overfired, 7. Return other gas-fired appliances to previous ' 2. Check manifold as pressure. See Table 5 or ratio s= _� �' g p g contact your U.S.Boiler distributor or Regional conditions of use. INNER CONE t ?._ label located in the boiler's vestibule compartment. Office for replacement Gas Orifice. 5,z'a.Y+.,pMiY-. � -laaw�5'..y SHARPLY OUTLINED WITH r _ O. BRIGHT LIGHT BLUE ,�. Y F;°�: `� Adjust gas valve pressure regulator as necessary Review User's Information Manual and system kr: (turn adjustment screw counterclockwise to operation with owner or operator. FLAME RETENTION INNER CONE f decrease manifold pressure,or clockwise to increase PARTIALLY LIFTED FROM BURNER manifold pressure).If pressure cannot be attained, check gas valve inlet pressure.If less than minimum indicated in Table 5 or boiler's rating label,contact gas supplier for assistance. 3• Clock gas meter for at least 30 seconds.Use Table Figure 23: 1 Inch Main Burner Flame 10 to determine gas flow rate in Cubic Feet per CENTER Hour. FLAME COMBINATION IGNITION ELECTRODE/SENSING PROBE Table 10: Gas Flow Rate in Cubic Feet 0.38 Per Hour i.38 Seconds Size of Gas Meter Dial r for One ' s One-Half ;;120 e Two GROUND LEAD #'`.,, Revolution Cu. Ft. Ft. Cu. Ft. (WHEN REQ'D) �"T ' GROUND STRAP 30 60 240 d FIBERGLASS SLEEVE 32 56 113 225 PILOT TUBING 34 53 106 212 36 50 100 200 38 47 95 189 IGNITER/SENSOR LEAD 40 45 90 180 (BLUE) 42 43 86 172 Figure 24: Pilot Burner Flame 44 41 82 164 J. Check thermostat operation.Raise and lower 46 39 78 157 temperature setting to start and stop boiler operation. 48 37 75 150 K. Check ignition control module shut-off.Disconnect 50 36 72 144 pilot lead wires from gas valve. If burners do not 52 35 69 138 shutdown,determine cause of malfunction. Replace 54 33 67 133 necessary items and check operation. 56 32 _ 64 129 L. Check low water cutoff(if so equipped). 58 31 62 124 1. Adjust thermostat to highest setting. 60 30 60 120 2. With boiler operating,open drain valve and slowly drain boiler. 38 39 IX. OPERATION IX. OPERATION (continued) { The SER(status)display code has the below listed values. A. Boiler Sequence of Operation Table 11: Sequence of Operation li This list is also available on the control cover. NORMAL OPERATION _� �,:�-;�_.w.:•�:�.::�L:�.,Y;:�,:;:a- �-g Status Codes displayed in SER Mode I. The �:: w r Status Code Displayed in SEA Mode PVG Boilers are equipped with an Intelligent Status SER Descri i .ri O, _ o:y :r - :y H dronic Control control pt on , �;`�,.,' ;x1 ';.Standb s Y (control). This control replaces the Standby _- .. 2 'Waiting for Pressure Switch to Open traditional separate ignition control,high limit switch (Burner off I No call " _ for heat detected F1.11 K: s: �~ ,T,� blowerand circulator 'W °'3` "'. re: to:Close „ "�` Circulator o ;� � � .�R;`" '�k`' w t-,.... .�Waiting'for�Pressii�Switchiu�,µ....._..� ._..,.,...._..�°.,�,,.� relay relay and adds energy off) " • .k,._ .. _. __ saving thermal purge features. Energy b f" tO" ;l O;'r 4 Prepurge z:.. P $ rgy is saved y Either condition is true: O � starting =;a., r'�� :F:,,;•::r;��-.�M ..{,,,,--:�<-.--R M1,Y,.;_,:� the circulator and del #' 4,6 S ark: .'" =u.,• - ' -;_, delaying the burner start � a. Call for heat detected and boiler .�`�`'�`�.�.'.''�.,:_t -•ter..==_-�-�-..--n._._«.... �,,..... . .....,�_..v.___._.�;xu...._..�v.,. when there is residual heat available in the boiler. temperature higher than 3 7 Flame Proving ,F� -- Circulator � z:�8.�:�`Runnin-:� :�.�,.w:;F«,,��. �. .5-`��:�:x-��}.,•:a:^yY�4'r. 't" „-t 2. The boiler's sequence ofoperation is shown inTable 11. Pre-purge operating setpoint. 3. When the thermostat calls for heat the control (burner off I b. Call for heat detected and boiler Figure 26: Boiler Display 10 Retry/Recycle Delay .z,- - _ r... ,. -� circulator on temperature higher than Start "Ell 11 ?ressure Switch Fai ed�-toOpen. ._,.. starts the system circulator and the thermal purge ) The control display, along with Up 4, Down 4, and - ._. _ P g Temperature(140°F default)and 12 Pressure Switch Failed to Close keys may be used to view boiler operating status(Figure 26). ;-•..->� -a- U•� �=. •x � G� •, (circulator Pre-purge time) begins. If the time is Circulator Pre-purge Time has completed or boiler temperature is less than the not expired. Start Temperature(140°F default)the start sequence Self Test Il A VIEWING THE OPERATING MODE OPTIONS 14 Hard Lockout Control internal checking continues by energizing the blower. Once theWaiting for i =15.gr:Waittng',fo .Limit :Close. _ ., .: In operating mode the user may view(but not change)boiler 16 Flame Present Out of Sequence pressure switch is proven, the ignition sequence is Pressure The blower is turned on. The operating status settings and troubleshooting information. -"Wf . - -_ .N-P�-- - =F. :� q P g g g _ .-T started allowingas flow and i 3 control is waiting for the pressure :17..<. Self>'i'esf: '.< •.:.x t'}"4` ,"�; 'v'- t0.�,;;'�'>:f '�,:: 1 =� :fXOPRATION (continued) IX. OPERATION (continued) E. CHANGING THE ADJUSTABLE PARAMETERS panel settings allow water flow to the priority zone To adjust parameters such as High Limit Setpoint and after the call for heat ends. The Circulator Overrun 7.Domestic Hot Water(DHW)Terminal Function(dh_) Table 14: DHW Terminal Function (dh-) Time is adjustable between 0 through 10 minutes. - High Limit Differential: J gh The control allows configuration of the DHW Selection = Domestic Hot Water Demand, 1. Access the adjustment mode by pressing and 4.Circulator Pre-purge Time(PP-) Circulator output functionality to help the PVG (Parameter dh_= dh) holding the Up 4,Down ll,and Eintegrate into each installation more effectively.keys When the boiler is warm (boiler water temperature i Call for Heat Circulator Status The DHW Circulator output can be connected to a simultaneously for three(3)seconds. This higher than 140°F(adjustable using Start Temperature domestic hot water circulator or a second heating Priority System DHW procedure is intended to discourage unauthorized parameter))and there is a thermostat call for heat,the T T DHW zone circulator. These applications are selected as Time Circulator Circulator changes or accidental changes to limit settings. system circulator is started and boiler firing is delayed Input Input 2. Press the "E"key to display available Adjustment CirculatorPre-purge minutes.Ifthe temperature drops follows: (PE_) Output Output Mode options.Select an option. below 140°F or there is a DHW call for heat the boiler a. When dh_ is set equal to Domestic Hot Water on off On on off is started without delay. Additionally, the boiler is Demand(dh) on on 0n off on Adjustment Mode Options started without delay if the thermostat call for heat is When there is an Indirect Water Heater(IWH) off on On off on HL=_:< ~ "`140=220tF :;`rAii ustHi'"hYLimitSettin ^.: :", "DHW"initiated when the boiler water temperature is less than the control provides DHW' input terminals for on off OFF on off (; dF_ 10-30°F Adjust High Limit Differential 140°F. This feature helps save energy by satisfying the IWH Aquastat and"DHW Circulator"output T- RM terminals for the DHW Circulator. on on OFF on on ;b°,°' >_ ,., ,,. home heating needs with residual boiler heat rather • :O.T_` -.,11,0:10 miriutes .a Clrculatbr.;OferrunTime ,. g PP_ 2-20 minutes Circulator Pre-purge Time than cycling the boiler. The Circulator Pre-purge When there is a DHW call for heat,the System off on OFF off on time has a factory setting of 2 minutes and is field x Circulator is"forced off',the DHW Circulator !� Pl=_ On or oFF Priority time adjustable between 2 and 20 minutes.Referto Table 13. terminal is energized and the circulator pre-purge ' dF+ , _ •clti:ortEi? DHTemiinaunction _• s,wy � 5. Start Temperature(SE_) time delay control logic is bypassed to allow j SSE Reset Lockout the boiler to fire without delay. When DHW r T - .- ;_ Table 13: Circulator Pre-purge Time example, !I -{E For;C sSeisDegreestFror4G Mode, .;; demand ends the System Circulator"force off' Table 15: DHW Terminal Function (dh-) 1 bHc Back to Operating Mode (PP- =2 minutes) is removed,the circulator can respond normally, Selection = Second Heating Zone, Call for DHW and the DHW Circulator is de-energized. The (Parameter dh_=tt2) 3. Press the U -D and Down 11 keys to adjust the Boiler P Y J Heat Terminal Burner Status DHW call for heat is detected by a voltage on to displayed item to the desired value. Source Selection Temperature Call for Heat Circulator Status the DHW' terminal. When the Priority Time 4. To return to the normal operating mode from TT=on - <140 Start with no delay parameter is set to"oFF"the System Circulator System DHW the Adjustment Mode when the"bFic"option is TT=on - >140 Start after 2 minute delay is not forced off for a DHW call for heat. Refer J P T T DHW Circulator Circulator displayed,press either the Up 4 or Down G key. DHW=on tE2 <140 Start with no delay to Table 14. Input Input Output Output If no keys are pressed,after five(5)minutes the DHW=on l E2 >140 Start after 2 minute delay b. When dh_ is set equal to Second Heating Zone (Zone 1) (Zone 2) ! control will automaticallyreturn to the Operating DHW=on dh <140 Start with no delay p g j on dh >140 Start with no delay (EE2) off off off off Mode. DHW= When there is no IWH the"DHW Circulator" on off on off F. MORE INFORMATION ABOUT ADJUSTABLE Amount of"Heat available" is calculated by taking t output may be configured to control a second on on on on PARAMETERS the difference between measured boiler water heating zone. This is particularly helpful when off on off on 1. High Limit(HL_) temperature and the Start Temperature setting. Useful the home uses only two heating zones. The i I The control is factory programmed with a High "Heat Available"is dependent on the type of heating control replaces the need for a two circulator ' Limit Setpoint of 180°F. The burner turns emitter installed in the home. Heat emitters require a zone panel. When DHW Terminal Function " certain minimum temperature to operate effectivel dh_ is set to"EE2"the control's two circulator off' when the boiler water temperature (bE) Our default settings reflect cast iron radiators. Fan outputs are used to control two independent is above this value. The High Limit setpoint is Coils may require a start temperature setting of heating zones. Refer to Table 15. A"TT"input j adjustable between 1400 and 220°F. The Operating 180°F or 160°F before providing heat to the home. causes a call for heat and energizes the"System Setpoint (SP) will equal the High Limit Setpoint. The Start Temperature has a factory setting of 140°F Circulator"output to service heating zone 1 and 2. Differential(dF_) and is field adjustable between 140°F and 180°F. a second zone's thermostat wired to the"DHW" ! The control is factory programmed with a Differential 6.Priority Time(PE_) input causes a call for heat and energizes heating !; of 15°F. The Differential is the number of degrees zone 2 circulator wired to the"DHW Circulator" the boiler temperature must decrease below the When the Priority Time parameter is set to on and Domestic Hot Water(DHW)call for heat is"on"the output. Operating Setpoint before the boiler can restart. The When there is a Second Heating Zone(call 9 DHW demand will take"Priority"over home heating for heat)the boiler is started and the DHW 4= I differential is adjustable between 10° through 30°F. • demand. During Priority Time the system circulator t 3. Circulator Overrun TimeOr_ ( ) will be forced"off'. Priority Time ends and the system Circulator terminal is energized.When Second 1 ' The control is factory programmed with a Circulator circulator is released to service home heating demand Heating Zone terminal is de-energized the call Ifor heat is ended and the DHW Circulator is de- Overrun Time of 0 minutes. Circulator Overrun Time when Domestic Hot Water call for heat is over. When - i!1_ energized.A Second Heating Zone is detected by (also called"circulator off delay"or"circulator post Priority Time parameter is set to Off the DHW call purge")continues circulator operation after a call for for heat does not force"off'the system circulator.The sensing a voltage on the DHW terminal. heat has ended, sending excess heat from the boiler Priority Time has a factory setting of"On"and is field Il into the system. Ensure system piping and zone adjustable between"On"and"Off'Refer to Table 14. i 42 43 46" ra OfUBL88"H661 ING k X. TROUBLESHOOTING (continued) A. Before troubleshooting check the wiring on the boiler against the wiring Use Control Display Err (error) Number To Direct TroubleShooting Efforts The following pages contain trouble shooting tables for diagram in Figures 17 and 18. Ensure that incoming If the control detects an error it will flash"Err"(error)followed by a number. Use this number to identify use in diagnosing control problems. When using these fy the boiler problem 120 Vac power polarity is correct and that the boiler and corrective action in the table below. If there is no Err display proceed to next Section: tables the following should be kept in mind: is properly grounded.Further, ensure that the control 1. This information is only meant to be used by power supply is 24 VAC(minimum 18 VAC to a professional heating technician as an aid in maximum 30 VAC)and polarity is correct. diagnosing boiler problems. 4. All controls on the boiler are tested at least once in IQ Boiler Control Error Codes (when "Err" is flashing) } 2• Where applicable,perform startup checks and the manufacturing process and a defective control Display Status Boiler/Control Action(s) adjustments outlined or component is generally the least likely cause. Blalk. #BoilerandGitculatoi F =' ` ' r ;in Section VIII`System Y ¢ --- Start-Up'. Before replacing a component, � '-.v�� __, ., ck;b�eakeraritf_wlnng'sbetween`b'reake;.v a p g try to rule out all •'"" -` ' �` '' ' -- -. -�-.�:_.:..' .�..;��,_.��.,_ .panel<; rid=tibiler;Y� While the blower is"off the pressure switch failed to open(contact stuck closed). 3• In general,these tables assume that other possible causes. Err 2 Pressure Switch Failed - Check wirin there are no to Open g i loose or misw%red electrical connections. Before 5• When checking voltage across wiring harness pins � P - Kinked or blocked pressure switch tubing I I using these tables inspect all electrical connections be careful not to insert the meter probes into the us the P` 4, .. _ M A - Defective pressure switch boiler to pins. Doing so may damage t a :AFI e tg esu make sur hatg Y he in,resulting in I the arep g a •1.' ,.:�-- �- ar: - r.. _ _.:.z..;.�,�;..•.- Ytight. Also ! Ilota" 'x1: ~ a 7 loose connect' P far ion whenreconnected. ari•� o`Tro `� `��'-� _ the haThreshol -.,a... Y, ublesti" .� .tr•r=->=��; mess is ��•. - ` <: d<:�� ootiri'Sectio` •� :-�i'=;°� i; .. .�.,�._vyd-:�.,.�_._.�. :, '�, :�;_ .g. n,.6•- rr' - .�' i kA +_.4c`.�`.'r..ww....a.v.✓.s...u.�:?'.t..i _ 'i'C` .•`L'�'3::`"!:�•s' yaaP:r:..,`� ,.(`...^ _. i. "s.�i::?3.L.�a�'L..r._'��`'`-i�.::'?' ..>C'u+<�::�'Y._.:_='.�L=r::�:.: :•:.;��';�'-v..�'iSe Err 6 Flame Sensed Out of Flame sensed out of normal se uence before o enin after g II {,Operating Mode Parameters , •� ,� �--•- Normal Sequence valve). Check gas valve operat ( P g gas valve or r closing as StA Status (see Status NrmTbers :,�:;.� s; "�'""�..J4 iE`��'• lB �:.��-- �z�a=.-.n:,_`�'�:- :;,�.,.. �.. a,-,� --�,�-� •m- on. __ �'p 4 _ := �_a::: ,: •, � _ .- . Re lace'confrol' bE BaBerT -Temperature ,�_ _ p. �wp,rsists:--, - ,a°•�..<.=_ ";.{,: Flame Sensed During Flame sensed Burin ost- ur a before gas valve signaled o en„. Check the E i .° r : s. Err 23 g w s Sp Ofe ting Setpoint O .::' ;t :t:.. P g (Outdoor Reset) „ Pre-Purge for proper operation. Replace gas valve is problem ersists..p ) gas valve I; NL High Limit Setpoinf ,=_ ”,:.r_ai tf. . : ;, ,:: Yfr , s_-: ,'.'u::.;P; ��.,..,;: .•.:.;: Whr le, th�`� '�_ e.=tit` `ince' o H r`is� F on:�, d H ti `'" es" h *=�v' s- te, Limit r, s - Wlt. ,f-...: -,.. .,- Ch Ig p. a 1' Differen ,•.�:: i t fiat close - SQ "nt ..moi..' - ec < •,., t' n' !� oiii p;�.xs:; ° ate. r t` ��s r ass tib'. J e��sc t vuitc H P n.. E ea - f �_•� d• Itfe elft" Request :;. - essu� S r`� equ latus :=r' ter� IMUM �~ ttia F' ne Y I _,s rlll, �e e 'a t- t cep- - �- esu sur` ��,y D eL' dhStatus .;. Request p� eq Ch :�. hew tt1 b m' �r �s r;F $ ec"'��> ye; •�,,,... SCO ==�•' �•- Siiv'• g" rine• cte led -� .�Y ..can-� .-a�'r�'• .:=• LR Flame ,��.., �., Current Check if: bin Is`fre "., `.ti►,Close�+�-' ;-�: �. b�_ a.9 eagf clacks=ot�tales or Gond i �•.,a�a.::� ia,. un un Time t, - �. <' eHours x• .., rChecK:for• ee !! :y.4 .,: :. _•>.- <,,. �)Ocka C''9n:V <sr:rr ,e:'=:--..`;'" .:;af,:,�'a>'r.• f. , .. _.. : g x entlai :intake s ein I Press I keyon t `.��' _.� �: e- ,tom::, -:�:•:. Y� i CyC Boa! 1 to chane � ->_� �.,:'¢��="N�-; - n �:�: Boiler Cycles g "Vent s''sfeiltwrt f .�" _ -s""� :;C'. :.e='r •:7 .d. �,. d�nce:Wlth`• from oneEach .,.,.,...,�.. .w:;:•::�� _�wr`".._� parameter to the ,�,Y_., .,,_ ,��.•� P e next. c''" k.4 '':s; - I x . <•3 .x F. tr;:;'a , Err E .:�:� � 3;:,,� �y� "��=Wnii=at�fiorizon v '"�' • Error see ( Error N - I umbe setting will altdisplay _ .'a,_ ;-,.,•.:' �F, r�. :,�., _ �., g between - en ,�. 4- r , I cod _.:;, _ ::sem •:$ r `fir:•. r r_,:x>�'., I, e (for example 5t:R) and value. `Err 32 ~Temperature Sensor ~ Temperature sensor�or interface failure(open or short connection, increased connection Failure resistance, dual sensor mismatch)or control hardware failure. �' is When Err (error)i shown: E3 ( s s ,rip f�s a ZdneAlarm;.m a I Z - morie Panet.lristiuc#ions.:�.. •° Possible SER ii Value (status)values: Flame".... :. ..... , .:�:•::,:,, :._. - .,.:� �.:��.";r� . ';,:��.�•.'<'.;�_�t# - _ - ,; Description Rod shorted to burner ground,this can result from excessive flue gas Err S1 Flame Rod Shorted to condensation. 2 Pressure Switch Failed to Open Value Description Burner Ground - Check for excessive condensate, drAr y pilot. Adjust setpoint higher. 4 Flame current lower than threshold 1 Standby - Check for loose or damaged ignition wire. 6 2 Waiting for Pressure Switch to Open E! a5.8;":>AC3UneF�e uenc 3Erroc. 'g ` ' ' v Flame Out of Normal Sequenc P ; e 18 Electronics Failure 3 Waiting for Pressure Switch to Close ` Err S9 •ti Line Voltage Error AC voltage out of specification high or low. Check su I volts e. i 23 Flam 4 Pre-purge e� e Sensed Duri _ Tfieirrii?statrYnp - ng Pre it ;Et•i r `E©i �_ ;9. i '. ' =:_ `;< ', 'E" �:. .�t -;;- .>: r .,- = �.< 'Ghee` - =;.- .�•,.:«-, 2 at=Wlriri j - 9 ,. r Sark .._ e a sr:` s �:_, s .. S .� It Fa z4' Close ....:Z«'a:•:,.z'�'.;...^^'....a—._..t'�'-,=.`::.�Y'�s..�'�:.,a.:.:�'; I 32 7 Flame Proving Err 6 l Line Voltage Unstable Possibly too many heavy loads switching on and off cause erratic supply voltage. Check ill! Temperature Sensor Failure g supply voltage.35 Duplicate Zone Alar Running . :, ' ,a, :.y„ea;,=,. „r �., t•. to e. (; m `�'' Soft Lo n�.�� '� e ckout �Maximum' ��''��•�-E�,T :�.n,:.>;P-� ; ��: ��-x 57 Ere Fla 10 Retry/Re 63 ; me /Ree cle Dela �. Rod - d rY }I'Ulax' S -f h Y mum::n •,. '`�:�- d to Ground - .r:e,: ... clesEzceed �1-ate.•'�-- ,X_ xceedeo•=.R< .�: --.� _:�a ��•-:.;.;��--,-.�-:-r-:-- .:� .. , �-;,��. :�. .�,.�� '`: '�.==:t �->•-�` � -�_= ng�Section 5 - �-��: � i 58 AC Line Fre 11 Pressure Switch Failed to Open quency = The electronics has detected an error. This can be caused by an actual controller internal i 12 Pressure Switch Failed to Close ''s i 9 Line Voltage Error 5y Soft Lockout-Internal fault or wiring fault: ''" •'� Err 1 60 13 Soft Lockout k,-, .'_ Failure - Check pilot assembly, ;. Thermostat input higher than threshold 1 - problem persists, rept control. 6 Line Volta a Un 14 Hard Lockout : r�, ; If ro p ace the 9 stab Erb=- Q9', r GOi11tt7 Cat10 s a t-r a- ,.;, 4 So 15 - 9. en.co tr _ :•:` t q ft Loc Waitin for Limit to CI - - iilii q'Lo n of ahcl l - 63 sf x ;Check:-wirin =tietwe _._.__ kout-Recycles E 9 ose _ - GQ=Zone.Panel or IQ;Reset Y Exceeded ,r 64 Soft 16 Flame Present Out of Sequence ` Lockout-Internal Failure 17 Self Test `. •t; 44 " F- 45 1. 1 - Y- Y�M1buj'`Asr` I �- ' KUUBLESHOOTING (continued) Use 5ER(status) Number To guide Troubleshooting X. TROUBLESHOOTING (continued) The control will flash"SER"followed by a number. Use this number to identifyboiler the oiler problem in the table below: S. Circulator is On, Blower is On but Boiler Fails to Start 7. Boiler and Circulator Off Display/Status Description Display/ The Boiler is in"Retry Delay": Status Recommended Corrective Action SER '� --T The burner failed to light(no flame signal) After a 5 minute delay,control will attempt to light the burner again. There is no limit to the number of retries. g The boiler has not detected a call for heat EE =oFF Retry/Recycle Recycle Delay ( and dh= FF). Delay - The burner loses flame during running mode,"5ER B". After a 10 second delay,control will attempt to SER Check the thermostat: light the burner again. If the burner loses flame during running mode,"SER R"during the next six When a thermostat call for heat is detected control display EE"will show"on" recycles,control will progress to a soft lockout. Standby - Make sure thermostat is calling for heat and contacts(including a SER > Burner off Check for loose connection. ` 9 ppropriate zone controls)are Closed. Pressure Switch Refer to Troubleshooting Section,Err 2 for corrective action. Circulator off Check the DHW demand: Failed to Open - When a domestic call for heat is detected"dh"will show"on" s - Make sure the DHW aquastat contact is closed. Check for loose connection. SER 12 I n. Pressure Switch Refer to Troubleshooting Section,Err 29 for corrective action. 1 Failed to Close i' 2. Circulator is On When a soft lockout occurs,boiler will shut down.Boiler automatically restarts once condition that caused But Boiler is Off the lockout is corrected and the one-hour time delay is completed. Boiler can be restarted sooner than the ctio Display/Status time delay by entering Adjustment Mode and selecting the reset button(see Adjustment Mode ner than Recommended Corrective Action or by cycling power. Soft Lockout is caused by one of the following: ns) SEA 13 The boiler is warm and circulator is providing residual boiler heat to building: SERI - Err 63,Maximum Recycles Exceeded—The burner lost flame during running mode,"5ER (3"six times Check boiler temperature Soft Lockout in a row.Refer to recommended corrective actions on next page to help determine the cause of the Circulator - The boiler will not start until boiler water temperature is less than the Set o'140 problem. Pre-purge - Err 23,Internal Failure,refer to Error code listing for recommended corrective action. If boiler water temperature is higher than Start Temperature SE_ P Int(SP)minus differential(dF) Burner off pure PP_ - Err 23,Flame sensed during post-purge(before gas valve signaled open). Check the gas valve for Circulator on g ( default=2 minutes)time has not expired, boiler start will be delayed until dWater em the Circulator ature proper operation. Replace gas valve is problem persists. drops or time expires. To permit the boiler to start sooner increase Start Temperature parameter. Refer SER 1'-I to Operation Section for additional information. P When a hard lockout occurs boiler shuts down. Hard Lockout If flame is detected in pre-purge control goes to Flame Out of Sequence Before trial, "5ER 15"and 3• Boiler " On But Circulator is Off SER 16 "Err 23"is reported.The control gives a flame 10 seconds to disappear.If flame goes away,control I ,Display/Status ; Flame Out of Sequence resumes heating cycle from the beginning. If it doesn't "Err 23"is cleared and"Err 5"is reported. When flame is off control goes to Soft Lockout and"Err 5"is cleared. Check gas valve for proper operation. ecommended Corrective Action Domestic Hot Water(DHW)Priority Forcing Circulator Off When there is a DHW heat request wired to the control's DHW terminal the System Circulator will be SER "forced off"for the duration of the DHW heat request. When the DHW heat request ends the S fi Burner on Circulator"force off"is removed,the circulator can respond normal) . Parameter is set to"oFF"the System Circulator is not"forced off"for a DHW call for heat. System Circulator off Y When the Priority Time, will ) Wiring/Circulator Issue: - Check wiring for loose connection, miswiring - Check circulator . Circulator is On, But Blower is Not On J' Display/Status ; Recommended Corrective Action Waiting for Limit to Open. - Check Flame Rollout Switch, in the even t of excessive blockage of the boiler section flue le is developed the flame rollout switch will open interrupting i� SER 15 be extinguished immediately and the circulator will remain on until the therm b^ P g power to control P5-4.The maiLimit Open flame rollout switch isactivated,do not attempt to place fhe boiler in operation. The sourcostat is turnedblockage must be corrected and the identical flame rollout switch replaced by trained and skilledpersonnel from a qualified service agency. 6, 1 Check External Limit. 46 47 1, _ X. TROUBLESHOOTING (continued) i s. Circulator is On, Blower is On but Bo' XI. SERVICE Boiler Fails to Start (continued . Display/Status ) t Recommended Corrective Action 1. No SparkDANGER a. Can you hear sparking while SL13 6 is displayed? - If there is no spark noise replace the control. This boiler uses flammable gas, high voltage electricity, moving g parts, and very hot water under high b. If you can hear spark noise check the following: pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool ` - Loose connection in ignition cable or ground wire before attempting any disassembly or service. !; - Continuity of ignition cable Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify - Loose g - Break in round connection ignition cable insulation remove or tamper with any control device. � - Break in pilot ceramic insulator 1 i - Incorrect pilot spark gap 2. No Pilot Flame { a. If pilot does not light check the following: WARNING - All manual gas valves are open Supply tubing is notgged,kinked or leaking to I This boiler must only be serviced and repaired by skilled and experienced service technicians. P a - Gas line pressures are good - Gas line is purged of air If any controls are replaced, they must be replaced with identical models. SER !rJ - Pilot orifice is not plugged(pilot gas is flowing) Read, understand and follow all the instructions and warnings contained in all the ---------------- II Retry/Recycle - Condensate quenching pilot g sections ! Dela Note: It may be necessary to recycle the"c manual. of this Delay all for heat"more than once to clear the pilot If any electrical wires are disconnected Burin service clean supply tubes of air. g , y label the wires and assure that the wires SER 13 b. If no gas flow check the following: are reconnected properly. ! Soft Lockout - 24 volts across PV and MV/PV at gas valve,if voltage ok replace defective gas valve Never jump out or bypass any safety or operating control or component of this boiler. - Check for break in wiring harness to gas valve Read, understand and follow all the instructions and warnings contained in ALL'of the component 24 volts across control connector P5-2 and P5-5, if no voltage at control replace defective control 3. Spark does Not Stop When Pilot Lights instruction manuals. If the spark does not stop when the pilot lights check the following: Assure that all safety and operating controls and Components are operating !' - Loose connection in ignition cable or ground wire P properly before placing the boiler back in service. - Continuity of ignition cable - Clean flame rod - Pilot electrode porcelain cracked - Pilot flame covers flame rod and is steady and blue,if not adjust pilot flame A. General.Inspection and service should be conducted 4. Pipe must be supported at minimum five(5)foot Low gas pressure at gas valve inlet Defective control annually.Turn off electrical power and gas supply while intervals and must not sag. - 4. Main Flame Does Not Light conducting service or maintenance.Follow instructions 5. All vent joints must be secure and watertight. TO TURN OFF GAS TO APPLIANCE If the main burners . See Figure 22.do not light check the following: 6. All joints must be secure and airtight. Horizontal - Check orifice size and/or blockage B. Low water cutoff(if so equipped). vent tee drain or vertical vent tee drain(if used) - 24 volts across control terminals P5-8 and P5-5? age .r 24 volts across MV and MV/PV at gas valve? Check for break nhwleing hain rness togasvalvetrol Probe Type(Annual Service). Probe type LWCO must have minimum 6 inch trap and allow - Defective gas valve should be removed once a year,examined and condensate to flow freely. To Clean: cleaned of any dirt accumulations to assure proper a. Disconnect drain tube from drain fitting. operations. Do not attempt to repair mechanisms in the b. Flush drain tube with water.Fill trap with water. ,. field. Complete replacement mechanisms,including c. Securely fasten drain tube to drain fitting, necessary gaskets and installation instructions,are providing gas-tight and watertight seal. available from the manufacturer. 7. If pipe must be disassembled for removal of ' C. Vent System.Inspect for obstructions,soot obstructions or resealing of joint,see Section III, accumulation,proper support,and deterioration of pipe, Paragraph C. R fittings,and joints. A Boiler Flue Passages. Inspect for blockage or soot 1. Clean terminal screens.Terminals must be free of accumulation. obstruction,undamaged,with screens securely in place. I. Remove Main Burners. See Figure 29. 2. Terminal and wall thimbles(if used)must be a. Remove front door. weathertight. b. Disconnect pilot tubing and pilot lead wires at the gas valve. u 3. Pipe must be full round shape,and show no damage from impact or excessive temperature. c. Remove wires to Flame Roll-out Switch. 48 _ d. Remove Burner Access Panel. s'' - 49 ! XI. SERVICE (continued) e. Mark location of Main Burner with Pilot Bracket on gas manifold. Fr d _^'- ! f Hold Main Burner on throat. SELF DRILLING .�,�:�•,;;,_;:� � =�=. VENT CONNEC70R Lift front of SCREW - ;Y .; burners to clear orifice. h h ; ' ''°ry�s`, P J l Burner olds =•,��x=:;r�-�; ,,r i Pilot ,.ACKET TOP - '%' `'- .SU;+^•`• I---m p can be removed b lift " ` - ?x,E>> ';4� . •"x VE OPENING 1n z Q C y lifting the burner oANe Y >Q adjacent t .r.w-' ;:, % ,. , a r::ax4::Y JACKET Q J right first. Win:'".= w`'r. %r;, ;a>° nZl Q -mLU o 2. Disconnect Vent 'r Connector and Vent Pipe from om er;:�.` = _ rsa ^_:�y• '" •°.�, > nyQBlower Outlets 3. move Jacket Top panel. S�rw _ =� w I !,;! -'S. tet `i''"`:=:`�i K` '"Y`_d:+Ny.r'7 '-t' 'p .�_- v'f.,^a`.. `_FBF �.£F••,..�,,;„ ,�s. aa_.7:_'�•,'. _ - W_hr. _ a:s,`_ # .,. _- z4. Disconnect the Black and Gray Silicone Tubing from the Canopy. FRONT BLOWER 1 m F� T or y , ,_s I 5. Disconnect Wiring Harness from Blower Motor. BOILER � I Figure 28: Blower Vent Connector Assembly j. 6. Remove Canopy/BlowerAssembly. a. Loosen the(4)screws from Canopy. E. Main Burners and Firebox. I w 7. Remove Flue Gas Baffles. Inspect Flue Gas Baffles 1• Vacuum firebox.Exercise care-do not damage base I I (n J�� !' LU for deterioration. insulation. � I I mNW I I y�z 8. Inspect flue passages. Clean with flue brush. See 2. Clean main burners.Brush top of burners with soft 0 LA = i I Q W1 Z) Figure 29. bristle brush. See Figure 29.Vacuum to re Q W ~ �` I I w�m move any of az m m I I Q 9. Inspect heating surface in combustion chamber. dirt and lint. z I Clean with straight handle wire brush. 3. Vacuum tip of pilot burner. I I cn m � I 10. Install Flue Gas Baffles. m I I . 4. Check gas orifices for lint and dirt.Clean as I I 11. Replace Canopy Assembly and seal. necessary. fr I I c I I 12. Connect Silicone Tubing between Pressure Fittings 5. Install main burners b reversin on Canopy Assembly and Pressure Switch. Route remove burners. Y g Procedure to ;; I I m through bushings in Vestibule Panel. See Figure I I I (I 27. a. Pilot burner must be installed in original ' 13. Install Jacket Top Rear Panel. location.See Table 16. �'——————— I C0 I�I ! I I I 14. Connect vent system. See Figure b• Main burners must be properly secured in burner gore 28. tray slot at rear of firebox and over gas orifice. I I I c ! 15. Connect Blower Motor Wiring Harness See Fi •; gore 29. c. Pilotas supply �^ g pp y and pilot lead wires must beLL ;I CANOPY reconnected. z d. Burnaccess panel must be securely in lace. ¢ .., rj �j FRONT ou e. Reconnect Flame Roll- t wires. p s^17� .:c, Afia R -s.�:;. �::�.. �.•-�;.• F. � U .;� .. I .� ` GRAY SILICONE TUBING °`{ " s� �} peration.Follow steps F through N from Check o a' Section VIII:System Start-up. i PRESSURE SWITCH -= `. r 'p- G. Procedure 4 ,:,; Jure for me di o F► @ ' g differentialpressure _�� @ @ O GRAM Figure 30). Se ;r� :` @ @ With boiler _ ,wa•=. t `` off,remove and Black ' <,:.••� rr„.�a ti Gray Hoses at ,�:�« •M� .;Y��.>.-��F4-�Z ��4:�r,a t9 @ � /y ®@ � I �, { differential pressure switch. :{ y d `" ,. zz„;w, sfaix';'a?.'f„.^i''X':..i.+:;:i•>*C'6'�,—— @O @@ @@@�-a@® @UA, @®@2. With tees and inch aluminum stubs,connect .. .. — Y•� s water BLACK SILICONE TUBING manometer as shown with additional tubing. •� }• — ------- `la - "°' Y,d BOILER JACKET 3. Start boiler and read Pressure on Manometer when boiler water temperature reaches operating C Figure 27: SilicoTOP VIEW temperature. Refer to Table 17 for minimum f `u" v ne Tubing Assembly readings. � ,`; � —' Y d J NOTE: If switch drops O W -out before boiler reaches temperature or if pressure differential readings are P F °° Y af z ao Qaf LL �. below minimums shown in Table 17,check for W cracks in hose or contact your nearest U.S.Boiler CO) representative. 50 ° 1 51 XI. SERVICE (continued) I Table 16: Pilot Burner Location XII. REPAIR PARTS ModelMain Burner with Pilot Bracket ween Main Burners All PVG Repair Parts may be obtained through your local U.S. Boiler Wholesale distributor. Should PVG3 Pilot Burner Located Bet * a. 2 you require assistance in locating a U.S. Boiler distributor in your area, or have questions regarding PVG4 3 2&3 the availability of U.S. Boiler products or repair parts, please contact U.S. Boiler Customer Service at PVG5 4 3&4 (717)481-8400 or Fax (717)481-8408. PVG6 5 4&5 *Main burners numbered left to right as viewed from front of boiler. 5&6 . �a r DIFFERENTIAL PRESSURE SWITCH v "GRAY TUBING" f, TO lil JACKE- CANOPY LEFT SIDE 5 PANEL 4. Stop boiler,remove manometer and reconnect hoses ' to differentialressure switch. See Figures gores 27 and 130. "BLACK TUBING" FITTING SENSITIVE MANOMETER Figure 30: Differential Pressure Measurement Table 17: Differential Pressure Switch Settings Model Minimum Differential Pressure Sea Level to PVG3 4999 Ft. jPVG4 1.32"W.C. 1.1 7°w.c. PVG5 - ?i 1.47 w.c. PVG6 1.25"w.c. - 52 _. X... 3e 53 t, xX11: . ` . . ` "if. Ep AIRYPgRT, continued ' 4FXII. REPAIR PARTS c Key [Quantity] Part Number Description No. PVG3 PVG4 PUGS ,L 4"':�1'P.y":254::' z• ..H.-.-ho.sy+-c." �.�.';.:,..,5 I. CASTING ASSEMBLY R; • : > -: ¢- Section Assembly '; ^ur °: .' :;: :;�;, ' .' ] 1 Y 61707031 617 _ 61707041 07051 �` �=' � 1471711-11111-, AILeft End Section 71707001 1BCenter Section [1] 71707003 [2]71707003 [3]71707003 - j 1 C`. Right End 71707002 1 D Slip Nipple #3 [4] [6 8] 10 ] [ l 806600009 806600009 806600009 806600009 1E Flue Gas Baffle [2] [3] I• ':� `-`' tF.. u, �� = 71107002 71107002 71107002 71107 1 F 002 Tie Rod, W-20 [2] [2] [2] [2] 100109-01 100108-05 100108-07 100108-13 Nut, Y<"-20 [4]8086 I' I \ "•t aa. =Sz.:d. l-,°.. w.. \ a \ ., =4`�._ 0407 I" .v ;.:j,iaN. �F.... ^f' -i��'..;,y.•''`,a\t<K' _"Y'^-°=„�{x.AF 3`sR ,~ � --m.,, R,v r5�, Ui .1.Rr�s:i {s�.,n%�4;¢N%'�.•:..�,r; \ f:� .r' �a.�>:�''_'.,,.`e" �fA: .�` ''�`•Y'-�".';a — :' `'�'..-t' `•,::.�• ,''�� -.y�;' �-awn^•..,yYy��1,; 2.:^'-S.. d ,.>"- I \ .: v$'� i hen �;�• �+ �'k�' Y� i QCD r , - ;' Vit:, +.Y Phi J.1� til x *_ LStEa�'— 54 55 Y; . ;: { XII. REPAIR PARTS continued f - XII. REPAIR PARTS (continued) t,_•, , Key Description [Quantity] Part Number No. . _ . :. 2F PVG3 PVG4PVG5 PVG6 2. BASE ASSEMBLY 2A Base Wrapper 71807031 71807041 71807051 71807061 2B Base Tray 71807032 71807042 71807052 71807062 '' 1 12C Burner Tray Assembly 61807031 61807041 61807051 61807061 2D Base Front Panel 102705-03 102705-04 102705-05 102705-06 213 a ,� 2F , u '" ",-ti: I `g•"' 1 I : " `' 2E Burner Access Panel 102707-03 102707-04 102707-05 102707-06 .` Y y ry •;.. .. I 1 ,:: Cerafel 2F i ,.^,•.,,;;f•, ,<�„��a�� I 1 ,,�s', t Gasket 1/2"x 2" 6206002 2G Cerafelt Gasket 1/2"x 2" 6206002 1- � I ,irf"' -i="' 'ar'",:ce.; :;�y`�� «"'F:�'�•2,�,,I I fn. r I +�.:�'s`^"r sem,;•C�r.i�t;.'�''_"';z;,'"t"a"a, ;Y��;��, �-T n rq i I „% q ; .k >:`•�: ,. ;�;;,�.-° F ,., 2H Base Side Insulation [2]72007001 2J Base Rear Insulation 72007031 72007041 72007051 72007061 �r' 1 w*::i •"�;,�R��w�'S,'G�i.T,i',i�� ?.%r^ir'�'<"�� ., �:..^ t,<:,.:M.u -:g ^•`�' :+.,. 2K Base Front Insulation 72007032 72007042 72007052 72007062 .,. f :fir•, aI &. i'�ii I /� �� ` .,; .41 n'Y'�^<z� "t+`"� tf'�,� ..-.'r�.i''�vi'�+�'.:�.x,,.�`x5`•'J''_ia.. •M, ��' - j g 2L Base Le 2D v ;aa.., .;'.. 'r== "'. bs, ''�'f.; ° - ;_.•'� •a ,�„'� Assembly [4]6186001 �,�. �I ,iw7 gC:c J•�zd�.•wl;'�','"�'a.•';a;xa��,':,"'.4 =:-�,s'..st",�s.;yd`�.'>-�.;,;:��v'r.y^r-� y"•"y f.. �,k;a�.�f - , � '7 st' e.� ki�X� �,70•.',� ;1,.,•^y4.'.,`<f�I�•'�.:r�• �`1'^b3 rz:�i;, Tapping Screw, 1/4"-20 x 1/2" [18]80860700 II I a :, ._° ri. ” ' =�' = �,yh... H:!', _:• ';_ 2M SelfT 4 it v: wx� I 2K 4i{ ��.-�',;t„ �*s»"- 1 v� ca g,;;:;,'e��,dti;��•:��•�� ',.r:;•]:°�..:.G'�+i-..o"�u;y.-;,�;'f•�'^'"`r'�`� L u, 2M 2N Flame Roll- out Switch 80160044 4Y i>Z.4 �'t: 3 •'w-' '' .ii.��" StE: f( :7�.,y""�°,f-5s q`«� .t.;;i �,' ,..a � .2�a'-::+' "�ti. �•'�,'•.:;: n;•.;r �i?.,'.� ,:�., tam:' 2Ht~ y ':t4 : �,°` rat °�'* ry 1L';:..�:: y:;.{I.. '°�1�=',• 2P Sheet Metal Screw,#8 x 3/4" 8086003 .,'.t.�\�irif} £=vl ,5�,<-,�'":'S t�..an � �•�I�i -� �..I�Y.*�-..".. 4wl.af' .?, k[? `v., 0 /]p y.�r,it+j=�.Y•a-f.. �Y` i ,e'..� _ r • "'- � 2Q Self Tapping Screw, 10-32 x 3/8" 5 80860705 6 8086070 7 "" r; ro ';w` � :e .:" �; r ►,•.•:«" I I .:; Self Tapping 2R Screw Hex Cap, 4. [..: [4]80860717 r z \Ya:.l ; `u s..`j : • . 5/16-18 x 1-1/4" !; 2N -,;y„ a,"�.��- ��;,�� sx' •,sr'�" C�•}•• .2�i S4,r�•_µ.��..,-' I I •% ?'�.. I 2 ,I: � -.�;"r> �. `;:sit°:. ��^r .t°��c` ''' �,.�, ,.'�''• I1 �..3-'�;�i,ar:ttc."�.;�.='.�`y"'��3`+•.'>t��%r`: d(` o.: "?7.'};.'�''' 2 .`l•L aWt„.da,t•,••'.' k;:i•",'f_.i•:3: Y'-♦M'9.fip5.4""'`w. F�a tr�:J+ <J;. I q.. „.+•;Y" Y Ay't 9t,.^..�. zhe•_" vx �l>.+y^-M1` '' Q .;�+w�:;Sr �>.a�;. ate`�'� �'T v `•,-.� 'f��..-,w i. tc 26 • � ,•� ,. .�� "'s`,::,'....�` K"`�.;Lz �'.,4".s�;:A'Ty.�`-,,L1yi�a. '°:��i>a_ `r` ps'i 1 i, � ':Y�y "�, `�•�+i��jw'� Q .&':zSd}r,�'r` ;�'tF.'L_,Y` tq 4G•S"":^'"•.h� 4�i�j' �,.,, Co- .d v> "'�ga eM'�' •�•>.��" -=z;...l ,:�}6: "� ^. 1 -�b%{:i ✓�xi'.., a';4a s'�*'°'•A a".�°.7,+...,..`^ ++,, ,'."t'k't` 2M .4'•'1:-AbY;-' u�"s�g.-fir' d� ., ...•ri;a`.+CCi'.�{k. ..fri'�' q' °'S^'.- f.+vn't�,��t..✓r,':�,f.�' .�:',�d+k Z J:.' r^�`� `^ �-: :; ..''-9--i:� ,fj, l xkn'.g"'.`. zn':�ti"w•=,$�" C �i �;• �A'- '_'�y; `t;�,f; r•3�.r''��i --. „�:.t7-;:�ir4� �. G«,;•:,'��0 r"' K`�2= - I t = :. 'i � ��L��1�:.r:-'i�:";�°�e�, i, n'^.j'}�j�r**+ °�. ;�{�1,?,�y o-s" x' •`''""' " I X rye '��"`_� ,.y�ro•-•sss.}��5�.;,�,<.�r%m,,,� '+r.`>.•YY•Jq�a§:"s°:'_ s• }'"`��*N A :.k 21- g ..j. 1i�$, `.},+ Ri .z y,.`�°'��f '?"-Ti,f..� ;,tdi`• -t Y`� "'°' y I 1 ${ ,1 I L 4.,.,' .�i. ..•�,t�i.."'j��'�`µ7-.r�. '�^<,e w,r 1 ��t�L: FE•�" 2M +t w 2M I 2M '; ' 56 XII. REPAIR " f u PARTS (continued) XII. REPAIR PARTS (continued) J 4D 3C 3C p 36 4A �. I _ mow., , �� a ,�",.K�,. ,,� � • :, 3D Re, 4E / .I % / \ j �sFt :',^',a:{%�A }Sx.u. •qty;" ao., i�:a.a„!!� .:."i,..' s ir.r.;�' `-:t:::':fit,ys, i � / / �;'.`•, "�"'g,'.., t`—`'�+�^' ".:sly, \ I °•In. :,-� :S. - � "�'•� S''„�`. K�,{a i. {•`� j j i j .�:P” '+/ s`:��fi,-'`.�^^ -s...;3,1 •w.iy4•�, \\ - -.;•i' - .�},. -:;°�.;°� .-sp{.^g:a.yY ^t ' � `�. ::x� i 'v``,b; `�'��'-„- j i/ .r%” �\\ I ,: _ - ,�^-,.., ;$t- ob.M'f•�. ,•'y s � F � �,G' _ , 'IIS •�-1� - r"• - -- R�¢+i.. _ . ?" i.7"_ � / \ ,,p .R�4. i ''i!:-i,. - •`S?= t'ht ,'.:.4'`'L�' 1�'..Pn�F =n pyEP'„� / \ P ' ;II / - `��y,.". '{_'y'Y -, �� ._ *, A.f'•rz % off@ 1'9 Y_.t` ./os�{'.qa� / 4i3 / L�4.+�'-:• (� • ��* ��•'�ri`_• � �,h N;„� I., 5 _ � 00�� @x-`�e..s V 4F �` �� ,��',�'��"`�,. `'.'�a:... ..s'µ., � - �8 s'"'f e r�� 'C�'v ,';.!i.",' ,�,+ '4y>r• r" Z-_ _ .. J : ; f<•F ,efts 1',� _'°t .,+:;��n.ra.,.,sy..;,,,'`='fir,'4:;,�,_�3,_, :..� � i�• -' 4H k� '._ n== [Quantity] Part Number i ;`= Key Description ' 3D :$ _ ' .:- s No. PVG3 PVG4 PVG5 TPVG6 4. FAN/CANOPY ASSEMBLY Canopy Assembly-Sea Level 61107031 61107041 61107051 61107061 3A 3D <`" 4A Canopy Assembly-High Altitude 61107032 61107042 61107052 61107062 4B Cerafelt 9206005 [4]80861512 4C U-Clip 4D Sheet Metal Screw,#10 x V [4]808600141 Key [Quantity] Part Number ` 4E Fan Gasket 8206085 Description mss' No. y PVG3 PVG4 PVG5 PVG6 , k,=^rte: 4F Fan 81161512 s;� : 3. BASE ASSEMBLY 4G Lock Washer,#10 [4]80860636 —777 3A Burner Cover 102033-03 102033-04 102033-05` 102033-06i°, h `.:.=$ 4H Machine Screw,#10-24 x 2-1/2" [4]808608982 3B Manifold Support Bracket 718070001 r 3C Sheet Metal Screw,#8 x 1/2" [2]80860000 ,' '- 3D Self Tapping Screw, 10-32 x 3/8" [6]80860705 II 58 4` 59 Y; R - XII. EP . - R R PARTS (continued) _ ��.�- •fit si i. Key [Quantity]Quantity] Pa == No. Description rt Number ',gas n};` ••:_ ,:...;. ..r�<,=.�;:.;n. 5. BURNER ASSEMBLY ( ="a f i:,, �r,..,3k i•A a: ~• '">>`..r.. ' ::;.• .y' Sa = ;s Gas Valve(Natural Gas), Honeywell 3i SA VR8204P1171 4 81660282 ! .•^ .,Si is :. 'L:t F:.J,mf%:i'UrL.,a�J=• _: ';fi: r4:�v:„•p ;.:, :: - ,; <;.:: 5B %"Gas Manifold 82207031 041 82207 82207051 61- `.{. 822070 - �rx• ',L°�#�.5`•' ;:iP<:. .1ixfr•"'1,..� •�•,•� v'�S?6"�•Y�q•�• �x '. .'� �kk; - ,.:, ~'"''. ` ••.`- 5C r Orifices- 4 Burne Natural Gas#47 [ ] [6] [8l �•>: r. f .+.^s; :: '..� =; "' ;.;;: :?• 822710 822710 822710 [10]822710 ;` ' . ,,. ,{,mom ;`..'.-.:• w ,:.v ;a;:e;:F _. 5D Pilot Assembly-Natur al Gas 103704-01 .,.:�, . .;;- �'' .�.:; s t>-�, �•b�:�: vi �, �,-_. 5E Burner w/Pilo r.,• 4.>';..z~ms`s rktr ,' > " s,;;,,.' t Bracket 100147-01 �'i `•' ;:��;:,� X", 5F Main Burner ] [5] [ ] [9] 100146-01 100146-01 100146-01 100146-01 r , ?��;�;r�=;��',r ::z;r� f��•; J �:;:- 5G Pilot Tubing 8236122 i .. ...;:_ . _•.�;;�gin;-1:�,.��.. ��: .�. 5H Self Tapping jh Screw, %-20 x'/" [6]80860700 5J Wire Assembly p '��•� ��a4; ':�"a _�' '3�. 103 Ground =z ;:3,. i• 776-01 _ ._^:.`its. ,i..�i%�rt*:"T:•^is:g`, iY �?f-_�".. LO z !k LO LO Wrap •; '^ " LOLO �'... L0 �i , a0 LO LU Co LO 4=q` 60 R �� 'i•`.K nzX� 61 - `; I iT XII. REPAIR PARTS (continued) XII. REPAIR PARTS (continued) t 'a r 7J 7E _ ,}-p r. „'"� y�r ..�;s:•t�•7'ts':"rk.'•5v`":j,`'`.vs`"• ,rt:i ;r .k:,r %i''`ce'- �,_'s. A •.,�re..'�i.re,,•ix .a"w"��":,s+;�.«:X-'i I \ moi_::.i'=',-p`,.,` �`:�'� ro'�;�'``:`.`•,.:.r ��: r' 70. � _ t'S. w:dEit,ai"L'-{"'•...J,'"srij. "�'" ..f�<s;..�'r �aG/'r'a •.3:� 5 Y�;�.�.•.:fi:.r�'-� '?. �:s�tr ..t,.�'b:tk;,;i�.,�''~�:�c.�;> i'-.. '��= t), �.a;; ••'z,>:�;r .st'+t.za' -zr;Y";�'..�i�<t•;;"_,=r.;- s,��. ..i t" e✓ y�M1,.'"'$��_ `\ .1�. ,.i`0 __�� 'x•ia'` - r .a-,�'.' ,F :g'i.t-c;x,,.,.;+_:,..`,: r::r ...�-, f: ..-", Y i ret•' +'�'1',�u:'''O,'�'r.3Y''�''-'"�<�i7�'-;� LT ly • 'y. S �..,.•y� 5 u1�/i'T" 'K, „r„'' f � is`-!•��'?:?-spy:°�'`...s, ' ,y;, � d.,•:n:. `"k'...e; _'j..� •x..� .p,°i; }iri.-tea...>�"i"a q`?rg;+ <.?"..2.�.:�>-:`w'":s�-"''''-��` "q3F}y a.s _*,:=-'`` •`?_:_:�'• •;;�"..,. rT .:ni:4•;, ;rt KIS: m�f.t.';ay r�,.�;,.o'j :;,r,.•,�• "" _ 613 i 6J 6 E 6A �:W �K�� : _ .r.' 7A ;:,y°• ��;';:�;:�n.w� p:�� 'Y,.�, x �<�� .'��,:a �> i r''^✓.,'%,�- Uri.°;� �. , ',g� �'3^.a::; M,. ,. O yr a .?�. '_';�+' MOUNTED ( IN CASTING1) ��- I / sem( :,yam- - ^�.;.x '=J' �:• '>�' ;g��,....��~�- ';K^.; r 'si:'�' Y° I r�. ..,k�Xsn,> ,:t� i .,.: iia z;�i,,;.• �: - <-„..t_r �,---`.,.i�. ��. I n''..,n�ds; .:,sy,.«,., �:: ,p;5:.;,��,t-., sip -f.. .,,.,e?i•,`i �'�"'r _ ,'S^��' ';t"`a�Ya ;:�+ :1x; i;; 'x:c::..: ��';;.,w' a.$,;$9'��"s:>r ."s �. ,t �� 3::z:�'�,.,�w`' fl�t:*' \ -��..,.:"�=•','`°:; / '*-:,;;�y""'.r:-t,,:;„; r'"�.A :,�.'.'a ,3sx»"_•,r S+z.' F.ex `� :{ .; .v��r� any: :�' 'i� .r��, - .s•�t�-fi,5'',`,`�`>'ri.'E'°�FgS�^� .rd-�Aa'2',e''""'t,�`,`i�:�..^t�,:;, � '-.>'.,_>'^ $ �� v,t'i't.. �`�i,'t�a t`7 ani` I 6H 60 et,�4.:w1��-��--l��.}�r°:D,,p..wm...q0`C0A®.,`.r-sO�LO'�O;"x�'es®.>�•®+^:;°r. 's�+:••_s�•,.`� �,y".�� 6`C 5.;tf��i.t�,.� _�3'�y VI � ,`Le \ r.v ��i�"rct✓�„`'-�"�i--'tS ±v i. _ 115Lg,,,,,,,, -.i - °:{;+,f^" a1%+ It d 'Y';1�^"•zK-,a�, �'.y,F .s +f �T y K+«<„.v-tXr:.-�".�,, v�`1•rv"u I ,g Via','-��`-i. k{e .,.� .•i .;. :a:;.' a'':�'t"'....y. ^i'�'r'" ".. �it y:t r%-,• d'" `SY;k,: `SSG ,'c'fso,'^ Frt?'?-#, i ''.'.N•'i �, v` ;` `I. Y��-'r,gtn.:y ,m*. Adv{`• ; [ Number ” , Key Description [Quantity] Part No. r PVG3 PVG4 PVG5 PVG6 6. CONTROL PANEL ASSEMBLY ' ` '''' 7G Limit Rated Temperature Sensor, 12", 6A Honeywell 50001464-001 103195-01 6B Transformer, Honeywell r x-° Key [Quantity] Part Number 102 6C Boiler Control, Induced Draft, Honeywell "":,, No. Description PVG3 PVG4 PVG5 PVG6 S9361A2075 103661-01 t. 7. JACKET PARTS 6D Control Panel _. ,` 7A Left Side Panel 60407002 103727-01 .a 6E Temperature Sensor Clip 713 Right Side Panel 60407001 102422-01 6F Differential Pressure Switch x 7C Rear Panel 60407033 60407043 60407053 60407063 Sea Level 0'-4999' 80160762 80160761 104576-01 104575-01 ' 7D Vestibule Panel 60407034 60407044 60407054 60407064 6G Junction Box 4"x 4"x 1%” k r ' 8136259 `', ",-:x 7E Top Panel 60407032 60407042 60407052 60407062 i 6H Junction Box Cover 8136180srt�, ,;:'A.�-�:. 7F Front Door 104148-03 104148-04 104148-05 104148-06 6J %"Immersion Well, -. ' 7G Handle 8056184 I Honeywell 123869A 80160456 7H Door Clip [2]7041921 ,y 7J Bushing 8136048 62 63 Y n-a XII. REPAIR PARTS (continued) = .x, Key Description [Quantity] Part Number � Refractory Ceramic Fiber Product T - .., PVG4 PVG5 PVG6 No. PVG3 ' 8. MISCELLANEOUS PARTS CARTON Warning: ;8A Water Manifold The Repai`r:Partslist designates parts that contain refractory ceramic fibers 80607001 . _.Temperature/Pressure Gauge 100282-01 (RCF). RGF has.been classified as a possiblehuman carcinogen. When A ,.tiG a ., -» :-tom...; OYY �" exposed°to'terrip-eraturesabout 1805 F, such as during direct flame contact, Circulator Wiring Harness 6130701 ,;: RCF chan�-�ps-into_;c, stalline silica, a known carcinogen. When disturbed as a .<<.. 9 4_. tiry.. g sD safety Relief valve result of`sere cing.,&repair, these substances become airborne and, if inhaled, 81660363 '' maybe haza�dous;to=;yqur health. 8E Boiler Drain Valve 806603061 8F Vent Terminal , _-- :�":"" ?'.ri-"•`; -B 8110701 , AVOID Breathing Fiber Particulates and Dust 8G Vent Connector 8110703 Precautionarr%Measures: r." Do not re {4i movez:or-replace RGF parts or attempt any service or repair work involving RCF�;vitfioutvieacng the following protective gear: gC National Instifute46rf Occupational Safety and Health (NIOSH) >Y approved:'respiator.-, 2. Long sleev,:cl :loo!e& itting clothing 3. Gloves ' 4. E , .. ,..,, , Eye Profectiorir.s • Take steps to`assure,add 'uate ventilation. 0 Wash all exposed body'a�eas gently with soap and water after contact. 8D 8B Wash work clothes.separately from other laundry and rinse washing machine after use to avoi&b6ntaminating other clothes. Discard used RCF sealing in an airtight plastic bag. RCF 8E and crystalline silica are n'otclassifed as.hazardous wastes in the United 8A States and Canada. err:`': . First Aid Procedures: If contact with eyes: Flush`witl rrvater for at least 15 minutes. Seek immediate medical attention�'if�i�titation persists. 8F _�Q0 0 If contact with skin: Wash,'affected area-gently with soap and water. ao� rt Seek immediate medicalatte�nton if irritation persists. • If breathing difficulty deve16p$.,-,L6ave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing ,- difficulties persist. v ' § Ingestion: Do not induce vomiting. Drink plenty of water. Seek 8G _`" , immediate medical attention. .- 64 `j, h i - • 65 APPENDIX A FIGURES x,°# P° _ TA A PENDIX TABLES ° Figure Page `K, s` Number Number Description a Table page NU!nbe�_ Nui r ber Description Figure 1 5 Minimum Clearances to Combustibles - _ Sectio'n;,lll-VentingU,, Figure 2 6 Dimensions ;r. .Table,1' ':rx Vent System Optionsµ9; Section III -Venting Vent System Components Included with Boiler Figure 3 13 U.S. Boiler Gasketed Vent Joint Detail Tatile 3 ,L:A10 " Vent System Components Figure 4A 14 Recommended Horizontal-Vent Installation Ta8le.4; 0. ;, Vent Length Figure 4B 15 Alternate Horizontal-Vent Installation 3 P Secti -' V:~-:GasPon > iping=r: - Gas RatingsTabl5 'I 4Figure 5 16 Horizontal-Vent Terminal Configuration T26 Figure 6 17 Vertical Vent Installation _ s Table 6_:Fs ,f_,2 _ '; Specific Gravity Correction Factors for Natural Gas Figure 7 17 Attic OffsetTable 7il:.; Via.."_Z7 ;, Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.5 psig or Less ' w I 8i` . ` 27 .R -r:Y Equivalent Lengths of Standard Pipe Fittings&Valves Figure 8 18 Vertical Vent Termination Table Figure 9 19 Horizontal Vent Terminal Installation "-,, SectionVII.-';Molular. lnstallation _ - Table 9': ;`„= '34. .�z�Modular Boiler Water Manifold Sizing Section IV-Water Piping and Trim .FV:;� '„� ,_�;.-.q g t : . Section VI'l,=�S ystbm St`t.t--, Figure 10 20 Recommended Probe LWCO Location ;�^--,+ _Y�. -tr.,hp Figure 11 '`` i 9 21 Recommended Auxiliary Limit Location Table 10,-�, -<, ya 38 ;`:,;,,Gas Flow Rate in Cubic Feet Per Hour F Y"ti, int. Figure 12 22 Supply Water Manifold Piping Section IX=Operatibnra. Table 11 °, ; 40, .. s: