CAD-I-S Rev H Installation & Service Manual Models: 40 - 120 WARNING This manual must only be used by a qualified heating installer / service technician. Read all instructions, in this manual before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage. Save this manual for future reference.
Contents HAZARD DEFINITIONS .................................................... 2 PLEASE READ BEFORE PROCEEDING ........................ 3 THE CADET HEATING BOILER-- HOW IT WORKS............ 4-5 RATINGS ........................................................................... 6 1. DETERMINE BOILER LOCATION Provide Clearances ............................................................ 7 Provide Air Openings to Room .......................................... 9 Wall Mounting Location ......................
Installation & Service Manual Please read before proceeding WARNING Installer – Read all instructions, in this manual before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference. Have this boiler serviced/inspected by a qualified service technician, at least annually.
Installation & Service Manual The Cadet Heating Boiler - How it works... 1. Heat exchanger Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process. 2. Combustion chamber access cover Allows access to the combustion side of the heat exchanger coils. 3. Blower The blower pulls in air and gas through the venturi (item 5).
Installation & Service Manual The Cadet Heating Boiler - How it works...
Installation & Service Manual Ratings A S M E H LOW LEAD CONTENT Cadet Heating Boiler AHRI Rating Model Number Input MBH Note: Change “N” to “L” for L.P. gas models. (Note 5) Other Specifications Heating Capacity MBH Net AHRI Ratings Water, MBH AFUE % (Note 2, 8 (Note 3, 8) (Note 1, 8) Boiler Water Water Gas Content Connections Connections Gallons Vent/Air Size (Note 4) Min Max CDN040 9 40 37 32 94.0 .3 3/4" 1/2" 2" CDN070 14 70 65 57 94.0 .
Installation & Service Manual 1 Determine boiler location Installation must comply with: WARNING • Local, state, provincial, and national codes, laws, regulations, and ordinances. • National Fuel Gas Code, ANSI Z223.1 – latest edition. • National Electrical Code. • For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes. Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.
Installation & Service Manual 1 Determine boiler location Figure 1-1 Closet Installation - Minimum Required Clearances LEFT 12" SERVICE 0" MINIMUM TOP 6" MINIMUM WARNING 6" RIGHT 12” SERVICE 0" MINIMUM 1" MINIMUM CLEARANCE AROUND VENT PIPE Required Combustible Clearances Location Clearances Top 6" Bottom 0" Left 0" Right 0" * VENTILATING OPENING CLOSED DOOR 6" FRONT 24" SERVICE 6" MINIMUM BOTTOM 24" SERVICE 0" MINIMUM 1/4" MINIMUM CLEARANCE AROUND HOT WATER PIPES VENTILATING OPENING For c
Installation & Service Manual 1 Determine boiler location (continued) Provide air openings to room: Residential garage installation Cadet heating boiler alone in boiler room Precautions 1. No air ventilation openings into the boiler room are needed when clearances around the Cadet heating boiler are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1.
Installation & Service Manual 1 Determine boiler location Table 1A Corrosive Contaminants and Sources Products to avoid: Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, detergents
Installation & Service Manual 1 Determine boiler location (continued) When removing a boiler from existing common vent system: DANGER Do not install the Cadet heating boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
Installation & Service Manual 2 Prepare boiler Gas conversions WARNING The gas conversion procedure should be accomplished BEFORE the boiler is installed. For a boiler already installed, you must turn off gas supply, turn off power, and allow the boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under Start-up, Section 10 of this manual. You must install the propane orifice to fire the Cadet heating boiler on propane.
Installation & Service Manual 2 Prepare boiler (continued) 3. Remove the two (2) lag bolts securing the wall bracket to the wood pallet. Be certain not to lose the wall bracket as it will be needed for securing the boiler to the wall (FIG. 2-4). Do not drop the boiler. Damage to the NOTICE boiler can result. Figure 2-3 Acceptable Lifting Locations IMG00268 Figure 2-4 Boiler Mounted on Shipping Pallet 2. Mount the wall bracket using the 2 1/4" lag bolts provided.
Installation & Service Manual 3 General venting Direct venting options - Sidewall Vent IMG00267 IMG00219 Figure 3-1 Two-Pipe Sidewall Termination - See page 22 for more details Figure 3-2 PVC/CPVC Concentric Sidewall Termination - See page 25 for more details Direct venting options - Vertical Vent IMG00223 IMG00220 IMG00222 Figure 3-3 Two-Pipe Vertical Figure 3-4 PVC/CPVC Concentric Figure 3-5 Vertical Vent, Sidewall Termination - See page 28 for more Vertical Termination - See page 30 Air - See
Installation & Service Manual 3 General venting (continued) Install vent and combustion air piping The Cadet boiler must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Installation & Service Manual 3 General venting Sizing The Cadet boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below.
Installation & Operation Manual 3 General venting (continued) Materials Air inlet pipe materials: The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list: PVC, CPVC, Polypropylene or ABS Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.
Installation & Service Manual 3 General venting Optional room air NOTICE Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications. Commercial applications utilizing the Cadet heating boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room.
Installation & Service Manual 3 General venting (continued) PVC/CPVC: 1. This product has been approved for use with the PVC/CPVC vent materials listed in Table 3D. Installing vent and air piping 2. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.
Installation & Service Manual 3 General venting Polypropylene: NOTICE This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3E. All terminations must comply with listed options in this manual and be a single-wall vent offering. Insulation should not be used on polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.
Installation & Service Manual 3 General venting (continued) Stainless steel vent: NOTICE This product has been approved for use with stainless steel using the manufacturers listed in Table 3G. WARNING Use only the materials, vent systems, and terminations listed in Tables 3G and 3H. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.
Installation & Service Manual 4 Sidewall direct venting Vent/air termination – sidewall Follow instructions below when WARNING determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. WARNING A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks.
Installation & Service Manual 4 Sidewall direct venting (continued) Vent/air termination – sidewall Figure 4-2A Clearance to Gravity Air Inlets w/Field Supplied Fittings Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings TO BOILER INTAKE AIR CONNECTION COUPLING 12” MIN 12” MIN 15” MAX FROM BOILER VENT PIPE CONNECTION BIRD SCREEN (TYPICAL) BIRD SCREEN 12” MIN 12” MIN BIRD SCREEN GRADE OR SNOW LINE ALTERNATE VENTING ARRANGEMENT (IF SPACE PERMITS) 12” MIN Figur
Installation & Service Manual 4 Sidewall direct venting Prepare wall penetrations 1. 2. 3. 4. 5. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. Vent pipe penetration: a. Cut a hole for the vent pipe.
Installation & Service Manual 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent Description and usage The manufacturer offers optional concentric combustion air and vent pipe termination kits (Factory Kit #CVK3003 - 3" or #CVK3008 - 2"). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-6.
Installation & Service Manual 4 Sidewall direct venting Sidewall termination – optional concentric vent models Figure 4-8 Concentric Vent Dimensional Drawing NOTICE Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-9).
Installation & Service Manual 4 Sidewall direct venting (continued) Sidewall termination – optional concentric vent Figure 4-10 Concentric Vent Sidewall Attachment CAUTION DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation. 8. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-10 for proper pipe attachment. 9.
Installation & Service Manual 5 Vertical direct venting Vent/air termination – vertical WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. Determine location Locate the vent/air terminations using the following guidelines: 1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual.
Installation & Service Manual 5 Vertical direct venting (continued) Vent/air termination – vertical Prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a. Cut a hole for the vent pipe.
Installation & Service Manual 5 Vertical direct venting Vertical termination – optional concentric vent Description and usage The manufacturer offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4. Field supplied pipe and fittings are required to complete the installation.
Installation & Service Manual 5 Vertical direct venting (continued) Vertical termination – optional concentric vent WARNING Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death. CAUTION 6.
Installation & Service Manual 5 Vertical direct venting Alternate vertical concentric venting This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing. Figure 5-8 Concentric Vent Example 1 FLUE EXHAUST SEAL Concentric Venting Arrangement The venting is to be vertical through the roof. The annular space between the O.D.
Installation & Service Manual 5 Vertical direct venting (continued) Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual. Figure 5-10 Existing Vent as a Chase FLUE EXHAUST AIR INLET WITH SCREEN SEAL EXISTING SEAL SEALED CAP *For concept illustration only. Individual installations IMG00236 may vary due to job site specific equipment.
Installation & Service Manual 6 Hydronic piping System water piping methods General piping information The Cadet heating boiler is designed to function in a closed loop pressurized system not less than 12 psi. A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet. Basic steps are listed below along with illustrations on the following pages (FIG.
Installation & Service Manual 6 Hydronic piping (continued) Near boiler piping components 1. Boiler system piping: Boiler system piping MUST be sized per the pipe requirements listed in Table 6A. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance. Flow rates are based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves. 2. Boiler circulating pump: Field supplied.
Installation & Service Manual 6 Hydronic piping Near boiler piping connections Figure 6-2A Near Boiler Piping w/Y-Strainer VENT AIR CONDENSATE DRAIN TO FLOOR DRAIN DOMESTIC HOT WATER PUMP FROM TO CHECK VALVE BOILER PUMP Y-STRAINER (RECOMMENDED) AIR SEPARATOR FROM SYSTEM INDIRECT DOMESTIC HOT WATER TANK TO SYSTEM SYSTEM PUMP EXPANSION TANK IMG00237 36
Installation & Service Manual 6 Hydronic piping (continued) Near boiler piping connections (cont’d) Figure 6-2B Near Boiler Piping w/Low Loss Header VENT AIR CONDENSATE DRAIN TO FLOOR DRAIN DOMESTIC HOT WATER PUMP FROM TO CHECK VALVE INDIRECT DOMESTIC HOT WATER TANK BOILER PUMP AIR SEPARATOR SYSTEM PUMP TO SYSTEM Y-STRAINER (RECOMMENDED) FROM SYSTEM LOW LOSS HEADER EXPANSION TANK IMG00238 Circulator sizing The Cadet heating boiler heat exchanger does have a pressure drop, which must be con
Installation & Service Manual 6 Hydronic piping Figure 6-3 Pressure Drop vs. Flow 30 PRESSURE DROP (FEET OF HEAD) 25 20 40 Model 70 Model 15 100 Model 120 Model 10 5 0 0 2 4 6 8 10 12 FLOW RATE (GPM) Table 6A Circulator Recommendations for Temperature Rise Applications_20°, 25°, and 35° 20°F Temperature Rise Applications Pump Model GPM FT/HD Minimum Pipe Size Grundfos TACO B&G Armstrong 40 70 100 120/120( C ) 3.7 6.5 9.3 11.2 10.2 17.1 24.5 25.
Installation & Service Manual 6 Hydronic piping (continued) Figure 6-4 Single Boiler - Primary / Secondary Piping PRESSURE REDUCING VALVE PRESSURE GAUGE BACKFLOW PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR (OPTIONAL) AIR SEPARATOR MAY SUBSTITUTE LOW LOSS HEADER TO SYSTEM BALL VALVE (TYPICAL) FROM SYSTEM NOT TO EXCEED 4 PIPE DIA OR MAX.
Installation & Service Manual 6 Hydronic piping Figure 6-5 Single Temperature Zoned with Circulators - DHW Priority ZONE #1 PRESSURE REDUCING VALVE PRESSURE GAUGE ZONE #2 ZONE #3 ZONE #4 BACKFLOW PREVENTER FLOW CHECK VALVE (TYPICAL) MAKE UP WATER SYSTEM SUPPLY SENSOR (OPTIONAL) ZONE CIRCULATORS (TYPICAL) AIR SEPARATOR EXPANSION TANK BALL VALVE (TYPICAL) DRAIN POINT (TYPICAL) MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DIA OR MAX.
Installation & Service Manual 6 Hydronic piping (continued) Figure 6-6 Multiple Boilers - Single Temperature Zoned with Circulators - DHW Priority Model 40 70 100 120 2 3 Number of Units 4 5 6 7 Required Pipe Sizes 8 1" 1-1/4" 1-1/4" 1-1/2" 2" 2" 2" 1-1/4" 1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 1-1/2" 2" 2" 2-1/2" 2-1/2" 3" 3" 2" 2" 2-1/2" 2-1/2" 3" 3" 3-1/2" ZONE #1 PRESSURE REDUCING VALVE BACKFLOW PREVENTER PRESSURE GAUGE ZONE #2 ZONE #3 ZONE #4 MAKE UP WATER FLOW CHECK VALVE (TYPICAL) SYSTE
Installation & Service Manual 7 Gas connections Connecting gas supply piping 1. Remove the front access panel and refer to FIG. 7-1 to pipe gas to the boiler. a. Install a field supplied sediment trap / drip leg upstream of the boiler gas controls. 2. Support piping with hangers, not by the boiler or its accessories. WARNING Figure 7-1 Gas Supply Piping The gas valve and blower will not support the weight of the piping.
Installation & Service Manual 7 Gas connections WARNING (continued) Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage. WARNING Cadet heating boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an orifice (see page 12).
Installation & Service Manual 7 Gas connections Table 7A Natural Gas Pipe Size Chart Natural Gas Pipe Capacity Chart Length of Pipe in Straight Feet for 1/2 PSI Nominal Iron Pipe Size (Inches) 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1/2 175 120 97 82 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74 1 697 477 384 328 292 267 246 236 210 200 179 164 149 138 1-1/4 1400 974 789 677 595 543
Installation & Service Manual 7 Gas connections (continued) 12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance. 13. Remove the manometer from the pressure tap on top of the gas valve. Re-tighten the set screw inside the pressure tap. WARNING When re-tightening the set screw, be sure to tighten securely to prevent gas leaks. Do not check for gas leaks with an open flame -- use the bubble test.
Installation & Service Manual 8 Field wiring WARNING NOTICE ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent.
Installation & Service Manual 8 Field wiring (continued) Outdoor temperature sensor In accordance with the United States Energy Policy and Conservation Act, this boiler is equipped with outdoor air reset, a feature that saves energy by reducing boiler water temperature as heating load decreases. To use this feature, the outdoor air sensor provided with the boiler must be properly installed. 1.
Installation & Service Manual 8 Field wiring Connection Board Configurations Standard Altitude,Standard (Non-Combi) Standard Altitude, Combi OJ2 Cut Connected Cut Cut Connected Connected High Altitude, Combi Connected Cut LOW WATER CUT OFF (OPTIONAL) AUXILIARY LIMIT (FIELD SUPPLIED) FLOW SWITCH (FIELD SUPPLIED) TANK THERMOSTAT (FIELD SUPPLIED) ROOM THERMOSTAT (FIELD SUPPLIED) TANK SENSOR (OPTIONAL) SYSTEM SUPPLY SENSOR (OPTIONAL) OUTDOOR SENSOR (FACTORY SUPPLIED) 48 OJ1 High Altitud
Installation & Service Manual 8 Field wiring (continued) Figure 8-4 Control Inputs TANK THERMOSTAT ROOM THERMOSTAT / ZONE CONTROL FLOW SWITCH LOW VOLTAGE CONNECTION BOARD SYSTEM SENSOR OUTDOOR SENSOR LOW WATER CUTOFF INLET TEMPERATURE SENSOR OUTLET TEMPERATURE / HIGH LIMIT SENSOR FLUE GAS SENSOR PRESSURE SWITCH FLAME SENSOR DISPLAY PANEL BOILER CONTROL MODULE IMG00258 49
Installation & Service Manual 8 Field wiring Figure 8-5 Control Outputs LOW VOLTAGE CONNECTION BOARD BOILER PUMP DHW PUMP IGNITOR BLOWER BOILER CONTROL MODULE GAS VALVE DISPLAY PANEL IMG00259 50
Installation & Service Manual 9 Condensate disposal Condensate drain NOTICE 1. This boiler is a high efficiency appliance that produces condensate. 2. The bottom of the boiler has a 3/4 inch pipe for connection of a 3/4 inch PVC pipe (FIG. 9-1). 3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. Condensate from the Cadet heating boiler will be slightly acidic (typically with a pH from 3 to 5).
Installation & Service Manual 10 Start-up Check/control water chemistry CAUTION Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies for hard water areas (above 7 grains hardness). Chlorine concentration less than 200 ppm 1.
Installation & Service Manual 10 Start-up (continued) Purge air from heat exchanger 1. Attach a 5/16" flexible clear tube (rated for a maximum temperature of 120°F) over the barbed nipple on the manual air vent as shown in FIG. 10-1. 2. Fasten a wire tie (field supplied) securely around the tube attached to the barbed nipple on the manual air vent to keep the plastic tube from separating from the barbed nipple when purging the system. 3. Turn the manual air vent to the open position as shown in FIG.
Installation & Service Manual 10 Start-up Final checks before starting the boiler Check vent piping and air piping Read this manual to familiarize yourself with boiler control module operation. Reference page 55 for proper steps to start boiler. 1. Check for gastight seal at every connection, seam of air piping, and vent piping. Verify the boiler and system are full of water and all system components are correctly set for operation.
Installation & Service Manual 10 Start-up (continued) Figure 10-2 Operating Instructions LBL20274 REV A 55
Installation & Service Manual 10 Start-up Check flame and combustion (continued) Please note that the brackets ([]) denote screen status. NOTICE 3. Place the boiler into the active position by pressing the UP button for five (5) seconds (FIG. 11-1, page 63). 4. Press ENTER plus the UP button for 5 seconds to enter Service Mode. 5. Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor. 6.
Installation & Service Manual 11 Operating information General How the boiler operates The Cadet heating boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping. The control module regulates blower speed to control the boiler firing rate.
Installation & Service Manual 11 Operating information The control monitors the temperature difference between the inlet and the outlet sensor. If this difference exceeds 55°F the control will reduce the maximum fan speed. If the temperature difference exceeds 60°F the control will shut the unit down. The unit will restart automatically once the temperature difference has dropped below 55°F and the minimum off time has expired. Freeze protection DO NOT install the boiler in a room likely to freeze.
Installation & Service Manual 11 Operating information (continued) User programming sequence ON/OFF Press UP for 5 seconds to either Turn On or Off Unit Base State Screen Show Status and Temperatures (Default is Outlet Temperature) Press ENTER for 5 seconds to Enter User Parameters Set Degrees in °C or °F by Pressing UP or DOWN Press ENTER Set Space Heat Mode Setpoint by Pressing UP or DOWN (Based A er Timeout on System Sensor if Installed, Otherwise Outlet Sensor) Press ENTER Set DHW Mode Setpoi
Installation & Service Manual 11 Operating information Installer programming sequence ON/OFF Press UP for 5 seconds to either Turn On or Off Base State Screen Show Status and Temperatures Press ENTER & DOWN for 5 seconds to Enter Installer Menu Set Space Heat Setpoint at MIN Outdoor Temperature - Press UP or DOWN to change Temperature Press ENTER Set Space Heat Setpoint at MAX Outdoor Temperature - Press UP or DOWN to change Temperature Press ENTER Set Outdoor Shutdown Temperature - Press UP or DOWN
Installation & Service Manual 11 Operating information (continued) Parameter table Table 11-1 This table lists boiler control module parameters and where to access them Code User Access Description Installer Access Display Modify Display Modify u01 Temperature Units (°C/°F) Yes Yes No No u02 Set SH Set point Temperature Yes Yes No No u03 Set DHW Tank Set point Yes Yes No No P01 Set SH Set point at Minimum Outdoor Temperature No No Yes Yes P02 Set SH Set point at Maximum
Installation & Service Manual 11 Operating information Table 11-2 Lockout, Blocking and Notification Codes Error Codes with Explanation Lockout Codes E00 Invalid Lockout E01 Memory Lockout E02 Fan Speed Fault E04 Flow Switch Fault E05 Flame Out of Sequence E06 Auto Reset Hi Limit E07 Air Pressure Switch E08 Heat Exchanger Limit E09 Auxiliary Limit E11 No Flame Running E12 No Flame Ignition E13 Flue Temperature Limit E15 Manual Reset Hi Limit E18 Outlet Sensor Differential E19 Flue Sensor Open/Short E21 O
Installation & Service Manual 11 Operating information (continued) Cadet heating boiler control module Use the control panel (FIG. 11-1) to set temperatures, operating conditions, and monitor boiler operation.
Installation & Service Manual 12 Maintenance Maintenance and annual startup Table 12A Service and Maintenance Schedules Owner maintenance Service technician (see the following pages for instructions) (see the Cadet Heating Boiler User’s Information Manual for instructions) General: • Address reported problems • Check boiler area • Inspect interior; clean and vacuum if necessary; Daily • Clean condensate trap • Check pressure/temperature gauge ANNUAL START-UP • Check for leaks (water, gas, flue,
Installation & Service Manual 12 Maintenance WARNING (continued) Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
Installation & Service Manual 12 Maintenance Check expansion tank 1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 6 - Hydronic Piping for suggested best location of expansion tanks and air eliminators. Check boiler relief valve 1. Inspect the relief valve and lift the lever to verify flow.
Installation & Service Manual 12 Maintenance (continued) Handling ceramic fiber materials Figure 12-2 Burner Assembly REMOVAL OF COMBUSTION CHAMBER LINING WARNING BURNER DOOR W/ BURNER NUTS (QTY. 4) IMG00263 Check flame signal 1. At high fire the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode.
Installation & Service Manual 12 Maintenance Cleaning boiler heat exchanger For recommended materials; including brush, appropriate extension(s), refractory cover, and detailed instructions see Table 12B - Heat Exchanger Cleaning Kits. 1. Shut down boiler: • Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup. • Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain. 2.
Installation & Service Manual 13 Troubleshooting WARNING WARNING Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the boiler before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage. Never jumper (bypass) any device except for momentary testing as outlined in the Troubleshooting chart.
Installation & Service Manual 13 Troubleshooting Table 13-1 Troubleshooting Chart - No Display FAULT CAUSE - No 120 vac supplied to unit. CORRECTIVE ACTION • Check external line switch, fuse, or breaker. • Check wiring harness connection between display board and main control board. Connect harness at both points. No Display - Bad display board. • Replace board. - Bad main control board. • Replace the main control board. - Blown fuse.
Installation & Service Manual 13 Troubleshooting (continued) Checking temperature sensors The boiler temperature sensors (inlet water, outlet water, system water, flue, and outdoor air) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature.
Installation & Service Manual 13 Troubleshooting Table 13-3 Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply gas problem. Natural gas • Refer to Section 7 - Gas Connections pressures should be between 4 inches w.c. detailed information concerning the gas supply. and 14 inches w.c. LP gas pressures should be between 8 inches w.c. and 14 inches w.c. Noisy Operation for - Gas/air mixture problem.
Installation & Service Manual 13 Troubleshooting (continued) Table 13-4 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface ERROR CODE DESCRIPTION CORRECTIVE ACTION • Reset control module. E00 Invalid lockout code. • Switch power OFF and ON. • Replace control module. E01 The control module has detected parameter settings that are corrupted. • Replace control module. • Vent/air intake lengths exceed the maximum allowed lengths.
Installation & Service Manual 13 Troubleshooting Table 13-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface ERROR CODE DESCRIPTION CORRECTIVE ACTION • Adjust the set point of the auto reset limit to a higher setting up to a maximum of 200°F. Reference Section 11 - Operating Information for adjusting procedures. • Verify that the system is full of water and that all air has been properly purged from the system.
Installation & Service Manual 13 Troubleshooting (continued) Table 13-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface ERROR CODE DESCRIPTION CORRECTIVE ACTION • Inspect spark electrode and associated wiring for damage and connection. Reference page 66 of this manual for removal and cleaning procedures. Replace if necessary. • Check for proper electrical grounding of the unit.
Installation & Service Manual 13 Troubleshooting Table 13-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface ERROR CODE DESCRIPTION CORRECTIVE ACTION The flue temperature has exceeded 250°F. • Inspect the heat exchanger. Reference page 68 of this manual for the procedure on how to clean the flue side of the heat exchanger. b05 The flue temperature has exceeded 240°F. • Inspect the flue sensor and associated wiring.
Installation & Service Manual 13 Troubleshooting (continued) Table 13-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface ERROR CODE DESCRIPTION E21 (will require a manual reset once the condition One or both of the outlet sensors has has been corrected. Press opened or shorted. the RESET button on the display to reset.) CORRECTIVE ACTION • Check the sensor and its associated wiring. Repair or replace the sensor or wiring if damaged.
Installation & Service Manual 13 Troubleshooting Table 13-4 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface ERROR CODE DESCRIPTION CORRECTIVE ACTION • Check 120 vac supply to the transformer. b06 120 vac input to the main control board has dropped below 80 vac. • Check wiring connections at the low voltage terminal strip. • Check the wire size/length to remote devices. • Replace the transformer. • Check 24V.
Installation & Service Manual 13 Troubleshooting (continued) Combustion Analysis Procedure WARNING 1. Turn the main power off to the boiler. 2. Remove the flue temperature sensor from the flue pipe connection. Note: Combustion measurements will be made at this point. 3. Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor. 4. Turn the main power on to the boiler. 5.
Installation & Operation Manual 14 Combi The Cadet Combi - How it works... 1. DHW pump A field-supplied anti-scald device MUST be WARNING installed as shown in FIG. 14-3. Anti-scald Begins operation when the domestic flow switch enables demand. An integral flow check prevents flow of the boiler water while in the space heat demand. 2. devices must be selected and installed in accordance to local codes. Failure to do so will result in scald or serious injury.
Installation & Service Manual 14 Combi (continued) Flow characteristics Basic operation The factory installed option of the Cadet with domestic heating capability includes a separate water circuit for the boiler water to instantaneously and indirectly meet the demand of domestic hot water. The domestic heating demand has priority over space heating in this configuration.
Installation & Service Manual 14 Combi 82 FLOW SWITCH DHW SENSOR IMG00261 Figure 14-2 Combi Low Voltage Field Wiring Connections Connection Board Configurations Standard Altitude,Standard (Non-Combi) Standard Altitude, Combi OJ1 OJ2 Cut Connected Cut Cut High Altitude, Standard (Non-Combi) Connected Connected High Altitude, Combi Connected Cut
Installation & Service Manual 14 Combi (continued) Water piping Field connections are to be made as represented in FIG. 14-3. A field-supplied anti-scald device MUST be installed as shown in FIG. 14-3. Anti-scald devices must be WARNING selected and installed in accordance to local codes. Failure to do so will result in scald or serious injury. The Combi is capable of supplying domestic water greater than 120°F which may scald.
Installation & Service Manual 14 Combi Setting DHW target temperature WARNING An excessively high DHW temperature set point can result in serious injury. The minimum effective temperature should be used. Verify the installed anti-scald device requirements to determine an appropriate DHW temperature range.
Installation & Service Manual 15 Diagrams Figure 15-1 Ladder Diagram (Standard) 120VAC NEUTRAL JUNCTION BOX 120V SUPPLY "L" GROUND 120V SUPPLY "N" INTEGRATED CONTROL X1-6 BOILER PUMP RELAY F1 X1-2 5A BOILER PUMP X1-3 F2 DHW PUMP "N" DHW PUMP "L" DHW PUMP RELAY 3.15A BOILER PUMP "N" BOILER PUMP "L" X1-1 1 BLOWER RELAY BLOWER X1-8 2 CHASSIS GROUND DHW PUMP 3 F3 BOX DEPICTS OPTIONAL ITEMS 24VDC SUPPLY 0.
Installation & Service Manual 15 Diagrams Figure 15-2 Wiring Diagram (Standard) DISPLAY BOX DEPICTS OPTIONAL ITEMS INTEGRATED CONTROL BOX DEPICTS DUAL SENSOR SINGLE HOUSING X7 LOW VOLTAGE 120 VAC HIGH VOLTAGE CONNECTION BOARD CN5 X6 1 2 3 4 5 6 SYSTEM SENSOR OUTDOOR SENSOR TANK SENSOR CAUTION CN4 TR2 SPARK ROD FLAME SENSE CN3 7 8 9 10 11 12 13 14 ROOM T'STAT TANK T'STAT FLOW SWITCH AUX LIMIT SWITCH X1-3 COM BK BR BK W X1-6 BK X1-5 W X1-8 X1-1 G G DHW PUMP G BOILER PUMP L GND
Installation & Service Manual 15 Diagrams (continued) Figure 15-3 Ladder Diagram (Combi) 120VAC NEUTRAL JUNCTION BOX 120V SUPPLY "L" GROUND 120V SUPPLY "N" INTEGRATED CONTROL X1-6 BOILER PUMP RELAY F1 BOILER PUMP "N" BOILER PUMP "L" X1-2 5A BOILER PUMP X1-3 2 1 DHW PUMP RELAY F2 3.15A CHASSIS GROUND 3 X1-1 1 BLOWER RELAY BLOWER X1-8 2 DHW PUMP 3 F3 BOX DEPICTS OPTIONAL ITEMS 24VDC SUPPLY 0.
Installation & Service Manual 15 Diagrams Figure 15-4 Wiring Diagram (Combi) DISPLAY BOX DEPICTS OPTIONAL ITEMS INTEGRATED CONTROL BOX DEPICTS DUAL SENSOR SINGLE HOUSING X7 LOW VOLTAGE 120 VAC HIGH VOLTAGE CONNECTION BOARD CN5 OUTDOOR SENSOR DHW OUTLET SENSOR X6 1 2 3 4 5 6 SYSTEM SENSOR -T CAUTION CN4 TR2 HIGH VOLTAGE SPARK LEAD SPARK ROD FLAME SENSE G CN3 DHW FLOW SWITCH AUX LIMIT SWITCH COM DHW PUMP G JUNCTION BOX X1-2 BR BK W CN2-1 CN2-2 CN2-3 CN2-4 24 VAC OR W 11 12 13
Installation & Service Manual Notes 89
Installation & Service Manual Notes 90
Installation & Service Manual Notes 91
Revision A (ECO #C10659) initial release. Revision B (ECO #C11102) reflects outdoor air reset updates along with changes made to Table 3B on page 16 (ECR R05655). Revision C (ECO #C11314) reflects edits made to the Combi Section on page 81. Revision D (ECO #C11736) reflects changes made to the ratings page (page 6).
