Instructions / Assembly
Table Of Contents
- Part 1 - General Safety Information
- Part 2 - Before You Start
- Part 3 - Prepare the Boiler
- A. Locating the Boiler
- B. Structure
- C. Leveling
- D. Clearances for Service Access
- E. Wall Mounting Considerations
- F. Wall Mounting Instructions
- G. Residential Garage and Closet Installations
- H. Exhaust Vent and Intake Pipe
- I. Carbon Monoxide Detectors
- J. Prevent Combustion Air Contamination
- K. Removing a Boiler from a Common Vent System
- K. Water Chemistry Requirements*
- L. Technical Specifications
- Part 4 - Piping
- A. General Plumbing Information
- B. Relief Valve
- C. Backflow Preventer
- D. Potable Expansion Tank
- E. Circulators
- F. Hydronic Piping with Circulators, Zone Valves, and Multiple Boilers
- G. Circulator Sizing
- H. Check / Control Water Chemistry
- I. Plumbing
- J. Fill and Purge Heating System
- K. Glycol Antifreeze Solutions
- L. Zoning with Zone Valves
- M. Zoning with Circulators
- N. Multiple Boilers
- O. Applications*
- Part 5 - Venting
- Part 6 - Condensate Removal
- Part 7 - Wiring
- A. Installation Must Comply With
- B. Field Wiring Terminations
- C. Field Wiring
- D. Line Voltage Wiring for Standard Boiler
- E. Alarm Connections
- F. Low Voltage Connections for Standard Boiler
- G. Thermostat
- H. Outdoor Sensor
- I. Indirect Sensor
- J. Optional 0-10 Volt Building Control Signal
- K. Optional UL353 Low Water Cut-Off Interface Kit
- L. Wiring of Cascade System Communication Bus
- M. Cascade Master Pump and Sensor Wiring
- N. Cascade Follower Pump and Sensor Wiring
- Part 8 - Gas Connections
- Part 9 - Start-Up Preparation
- A. Check / Control Water Chemistry
- B. Check for Gas Leaks
- C. Freeze Protection (When Used)
- D. Fill and Test Water System
- E. Purge Air from Water System
- F. Check Thermostat Circuit(s)
- G. Condensate Removal
- H. Final Checks Before Starting Boiler
- I. Setting Up a Single Boiler
- J. Setting Up a Cascaded System
- K. Lockout Condition
- L. Cascade System Programming
- Part 10 - Start-Up Procedure
- Part 11 - Start-Up Procedures for the Installer
- Part 12 - Troubleshooting
- Part 13 - Maintenance
- Part 14 - Shutdown
- Part 15 - Installation Checklist
- Part 16 - Maintenance Report
- Part 17 - Replacement Parts
LP-387 Rev. 011 Rel. 006 Date 6.28.19
66
Inspection Activities Date Last Completed
Piping 1st Year 2nd Year 3rd Year 4th Year*
Near boiler piping
Check boiler and system piping for any sign of leakage; make sure
pipes are properly supported.
Vent
Check condition of all vent pipes and joints. Ensure the vent piping
terminations are free of obstructions and blockages.
System 1st Year 2nd Year 3rd Year 4th Year*
Visual Do a full visual inspection of all system components.
Functional Test all functions of the system (Heat, Safeties).
Temperatures
Verify safe settings on boiler or anti-scald valve.
Verify programmed temperature settings.
Electrical
Connections Check wire connections. Make sure connections are tight.
Smoke and CO
Detector
Verify devices are installed and working properly. Change batteries if
necessary.
Circuit Breakers Check to see that the circuit breaker is clearly labeled. Exercise circuit
breaker.
Switch and Plug Verify ON/OFF switch and convenience plug are both functional
Chamber / Burner 1st Year 2nd Year 3rd Year 4th Year*
Combustion
Chamber
Check burner tube and combustion chamber coils. Clean according
to maintenance section of manual. Vacuum combustion chamber.
Replace any gaskets that show signs of damage.
Spark Electrode Clean. Set gap at .156” Clean probe with plumbers cloth to remove
oxides.
Combination
Ignitor and Flame
Probe
Check ionization in uA (d7 in Status Menu in Start-Up Procedures).
Record high re and low re. Clean probe with plumbers cloth to
remove oxides.
Condensate 1st Year 2nd Year 3rd Year 4th Year*
Neutralizer Check condensate neutralizer. Replace if necessary.
Condensate Pipe Ensure the condensate trap is lled with water. Disconnect
condensate hose. Clean out dirt. Fill with water to level of outlet and
reinstall. (NOTE: Verify the ow of condensate, making sure that the
hose is properly connected during nal inspection.)
Gas 1st Year 2nd Year 3rd Year 4th Year*
Pressure Measure incoming gas pressure (3.5 to 14” WC).
Pressure Drop Measure drop in pressure on light o (no more than 1” WC).
Check Gas Pipe for
Leaks
Check gas piping. Test for leaks and signs of aging. Make sure all pipes
are properly supported.
Combustion 1st Year 2nd Year 3rd Year 4th Year*
CO / CO2 Levels Check CO and CO2 levels in exhaust. See Start-Up Procedures for
ranges. Record at high and low re.
Safeties 1st Year 2nd Year 3rd Year 4th Year*
ECO (Energy Cut
Out)
Check continuity on ue and water ECO. Replace if corroded.
Sensors Check wiring. Verify through ohms reading.
Final Inspection 1st Year 2nd Year 3rd Year 4th Year*
Check List Verify that you have completed entire check list. WARNING: FAILURE
TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.
Homeowner Review what you have done with the homeowner.
Table 32 - *Continue annual maintenance beyond the 4th year as required.