Install Instructions

USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . . .2
C. ACCESSIBILITY CLEARANCES . . . . . . . . . . . .3
D. COMBUSTION & VENTILATION AIR . . . . . . . .4
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6
2. BOILER SET-UP 8
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
B. WALL MOUNTING . . . . . . . . . . . . . . . . . . . . . .8
C. FLOOR STANDING INSTALLATION . . . . . . . . .8
3. VENTING & AIR INLET PIPING 9
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
B. APPROVED MATERIALS . . . . . . . . . . . . . . . . .9
C. EXHAUST VENT/AIR INTAKE
PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . . .9
D. EXHAUST VENT/AIR INTAKE PIPE SIZING . .14
E. EXHAUST VENT/AIR INTAKE PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .14
F. EXHAUST TAPPING FOR VENT SAMPLE . .15
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .15
4. WATER PIPING AND CONTROLS 17
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
B. OPERATING PARAMETERS . . . . . . . . . . . . . .17
C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .17
D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .21
E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .21
F. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . .27
5. FUEL PIPING 28
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .28
C. GAS SUPPLY PIPING – INSTALLATION . . . .28
D. GAS SUPPLY PIPING – OPERATION . . . . . . .29
E. MAIN GAS VALVE – OPERATION . . . . . . . . .30
6. CONDENSATE DRAIN PIPING 31
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .31
C. CONDENSATE DRAIN PIPE MATERIAL . . . .32
D. CONDENSATE DRAIN PIPE SIZING . . . . . . .32
E. CONDENSATE DRAIN PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .32
7. ELECTRICAL CONNECTIONS 33
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .33
B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .33
C. ZONE CIRCULATOR WIRING . . . . . . . . . . . . .34
D. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .34
8. BOILER CONTROL: INTERNAL
WIRING & OPERATION 38
A. CONTROL OVERVIEW . . . . . . . . . . . . . . . . . .38
B. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .40
C. BOILER CONTROL . . . . . . . . . . . . . . . . . . . . .42
D. CENTRAL HEATING . . . . . . . . . . . . . . . . . . . .42
E. DOMESTIC HOT WATER (DHW) . . . . . . . . . .46
F. SERVICE NOTIFICATION . . . . . . . . . . . . . . . .47
G. SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . .48
H. STATUS & FAULT HISTORY . . . . . . . . . . . . . .48
I. SENSOR RESISTANCE . . . . . . . . . . . . . . . . .49
J. MULTIPLE BOILERS . . . . . . . . . . . . . . . . . . . .49
K. DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . .54
9. START-UP PROCEDURE 55
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .55
C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .55
D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .55
E. LIGHTING & OPERATING PROCEDURES . . .57
10. TROUBLESHOOTING 58
A. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .58
B. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . . .58
C. ERROR MESSAGES IN A CASCADE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
D. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .62
11. MAINTENANCE 64
A. GENERAL (WITH BOILER IN USE) . . . . . . . .65
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .65
C. ANNUALLY (BEFORE START OF HEATING
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
D. CONDENSATE CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .65
E. COMBUSTION CHAMBER COIL CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .66
12. BOILER DIMENSIONS & RATINGS 67
13. REPAIR PARTS 70
APPENDIX A. STATUS SCREENS 78
APPENDIX B. USER MENU 82
APPENDIX C. INSTALLER MENU 83
APPENDIX D. COMBUSTION TEST
RECORD 88
TABLE OF CONTENTS
TABLE OF CONTENTS