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Lennox International Inc. Water Dispenser Gas-Fired Hot Water Boiler User's Manual

1. E 30 Controls And Accessories 4 4 4 35 wir TTE 3 1 111 36 293613 Integrated Boiler Control Operation And 39 Maintenance And Cleaning heh nnmehahnn anna enar nasa enne 45 WPOUDICS COMING TETTE TUTTI 47 Differential Air Pressure Switch Check EVE 49 Appendix A Water Quality Water Treatment And Freeze 50 Installation And Check Out Certificate 2 2 2 22 6 6 6 54 ntroduction This appliance is a gas fired direct vent hot water boiler e Induced draft fan draws in outside combustion air with cast aluminum boiler sections takes cooler flue gases from boiler unit and provides The heating system water absorbs large amounts of positive removal of flue gases from the building heat from the cast aluminum heat exchanger cooling through readily available PVC and CP
2. L2 N 120 VAC Li L120 VAC 0 gt ru 4 et a 34 CONTROLS AND ACCESSORI ES This section provides a brief description of the key controls and accessories found in this boiler See Figure 26 Page 41 for detailed sequence of operation See the Repair Parts Manual for locations of all control components and accessories described I ntegrated Boiler Control Integrated Boiler Control IBC is a microprocessor based controller for high efficiency gas boiler that monitors all safety controls and which controls operation of the combustion air blower circulator pump burner and a combination direct spark igniter flame sensor This controller is not intended for use with a vent damper Controller is mounted on control panel inside of boiler and contains a three character user interface display High Limit Control High Limit Control determines maximum boiler water temperature and also provides means for protecting boiler and heating system from unsafe operating conditions which could damage boiler Limit control sensor is mounted in 34 NPT control well on top of the front boiler section at hot water outlet Limit control is incorporated in IBC and is field adjustable between 80 F and 190 F Field setpoint adjustment for each installation depends on heating system requirements Limit Control automatically resets when boiler water tempe
3. Adjusting Settings To discourage unauthorized changing of settings a procedure to enter the adjustment mode is required To enter the adjustment mode press the UP DOWN and I buttons simultaneously for three seconds Press and release the I button until the parameter requiring adjustment is displayed Then press the UP or DOWN button until the parameter has reached the desired value After 60 seconds without any button inputs the control will automatically return to the READ mode Display In RUN mode status items and parameters are viewable To read settings press and release the I Key to find the parameter of interest For example press and release until setpoint sp is displayed followed by a three digit number i e 220 followed by F See Display Readout Figure 25 39 49 o Thermal purging minimal temperature 120 to 160 F Parameter is available only if outdoor temperature is invalid 1 to 10 minutes Maximal Thermal Purge time Parameter is available only if outdoor temperature is invalid NA Reset Lockout Figure 25 Display DESCRIPTION STATUS SEE STATUS NUMBERS BOILER TEMPERATURE ht OPERATING SETPOINT GP HIGH LIMIT SETPOINT HL DIFFERENTIAL SETPOINT HdF FLAME CURRENT FLR RUN TIME HOURS ruri BOILER CYCLES L JL ERROR SEE ERROR NUMBERS Err 59381 INTEGRATED BOILER CONTROL OPERATI AND AD USTMENTS Table 9 State Code Definitions State Gener
4. DO NOT try to light the burner by hand Figure 24 Gas Valve 4 Remove the front jacket panel Turn the gas control knob clockwise to OFF 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go on to next step 7 Turn the gas control knob counterclockwise y to ON 8 Replace front jacket panel 9 Turn on all electrical power to the appliance gt 10 Set the thermostat to desired setting 11 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier m 38 5938 INTEGRATED BOILER CONTROL OPERATI AND ADJ USTMENTS 59381 control has a number of user adjustable parameters as shown in Table 8 Table 8 User Parameters eem Emm Screen 2nd Screen Screen Default Range Description HL lt High Limit gt 1 For 180 1905220 IHdF lt High Limit Differential Fort 15 10t030 F High Limit Differential Fort 55 lt ODR minimal temp minimal water temp Fort Fort 10 40 to 70 F Maximal outdoor temperature 2 40 to 40 F Minimal outdoor temperature 130 to 150 F Minimal boiler temperature minimal boiler temp UT rs res eiim
5. Do not use matches candles open flames or other methods providing ignition source Failure to comply will result in death or serious injury Leak Check Gas Piping Pressure test boiler and gas connection before placing boiler in operation e Disconnect boiler and its individual gas shutoff valve from gas supply system e Isolate boiler from gas supply system by closing manual gas shutoff valve See Figure 19 Page 29 e Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods providing ignition source e Correct leaks immediately and retest Table 6 Gas Supply Pressure NATURAL PROPANE GAS GAS MAXI MUM GAS qne SUPPLY PRESSURE 28 NIMUM GAS SUPPLY 4 W 10 w PRESSURE GAS SUPPLY PIPING Table 7 Gas Pipe Sizes NATURAL GAS Length of Pipe Capacity BTU Per Hour Input Includes Fittings Pipe Ft 1 2 3 4 1 ay ae 20 92 000 190 000 350 000 625 000 20 63 000 130 000 245 000 445 000 60 50 000 105 000 195 000 365 000 PROPANE GAS Length of Pipe Capacity BTU Per Hour Input Includes Fittings Pipe Ft Copper Tubing Iron Pipe 58 34 0 131000 216000 189000 395000 40 90000 145000 129000 267000 60 72000 121000 105000 217000 Outs
6. Ignition activation Inter purge Retry Recycle Delay N Wait for pressure switch to open The inducer is still off and the pressure switch has not opened at the beginning of the heat cycle An alarm message is sent but the control is not in lockout failed closed Wait for pressure SW to close failed open Soft Lockout 13 System is shutdown and will re start following an enforced delay The inducer is still on waiting time for pressure switch to close expired An alarm message is sent but the control is not in lockout Hard Lockout non 14 System is locked out A manual reset is required to be able to light off again volatile Wait for Limit to There may be call for heat from the thermostat but the limit switch is open Close flame out of Flame signal sensed before trial for ignition Appropriate alarm is Flame present out sequence before sent of sequence trial flame out of Flame out of sequence during postpurge Appropriate alarm is sent sequence after Flame signal still present when not expected Appropriate alarm is sent trial HW self check check of connected periphery it is performed at Wait for flame loss start up in the beginning of the heat cycle and in the Wait For Leakage Detection 17 Self Test Recovery state Wait For Recovery There is an external error and the control is waiting to recover Self Test lockout 4
7. 6 Advise owner to keep venting and combustion air intake passages free of obstructions Both venting and combustion air intake piping systems connected to outdoors must permit flow through piping systems without restrictions for boiler operation 7 Install boiler such that the automatic gas ignition system components are protected from water dripping spraying rain etc during operation and service circulator replacement condensate trap control replacement etc e When vent pipe is exposed to temperatures below freezing such as when it passes through an unheated space or when chimney is used as a raceway vent pipe must be insulated with 1 2 Armaflex or equivalent In extreme cold climate areas use 34 Armaflex or equivalent Solvent cements are combustible Keep away from heat sparks and open flame Use only in well ven tilated areas Avoid breathing in vapor or allowing contact with skin or eyes Failure these instructions could result in fire personal injury or death e Combustion air must be clean outdoor air Combustion air must not be taken from inside structure because that air frequently is contaminated by halogens which include fluorides chlorides phosphates bromides and iodides These elements are found in aerosols deter gents bleaches cleaning solvents salts air fresheners paints adhesives and other household products Locate combustion air inlet as far away as possible from swimming pool
8. Hard lockout on CSD 1 models E rr b j Soft Lockout maximum number of recycles exceeded F rr 54 Soft Lockout electronics failure Caused by general electronics failure such as relay open or shorted contacts flame sensing circuit error or A to D error Hard lockout on CSD 1 models E rr Over temperature error Sensors measured temperature excess of ECO limit Hard lockout on CSD 1 models 48 DIFFERENTIAL AIR PRESSURE SWITCH CHECK e Following steps and diagram indicate locations of connection points required to check differential air BOILER DIFFERENTIAL STATUS PRESSURE W C CONNECTS e Differential air pressure switch is safety device which prevents boiler from firing if there is air intake boiler heat exchanger or vent blockage Not Running Normally Open e Turn off service switch or lower thermostat setting 1 1 00 for Model 100 1 00 for Model 100 Model 100 e Remove vinyl caps from Tee and 4 way connector Setpoint 1 60 for Model 75 e Install testing lines as shown to inclined manometer or 2 10 for Model 50 differential pressure gauge with ability to read 0 01 to Running 3 0 w c Greater Than Setpoints e Turn on service switch and set thermostat to call for Blockage Running Less Than or Equal to With Setpoints Blockage If manometer readings do not correspond to chart above check for possible causes e Blockage or moisture in suction lines Diff
9. VALVE 15 A ALTERNATE PUMP 7 LOCATION k BALL VALVE 5e ZONE VALVE AIR SEPARATOR HOSE BIB NEAR BOILER PI PING Figure6 Piping and Wiring Primary Secondary Multi Zone System Piping With Zone Valves And Domestic Hot Water With Zone Valve ZONE 4 5 p LI 5 ZONE 3 S ZONE 2 LJ O x J ZONE 1 PRIORITY ZONE USE FULL PORT ZONE VALVE FOR OPTIMUM TANK YS 7 12 MAXAPART y TO PREVENT FORCE FLOW IN SECONDARY PES 8 WATER INLET XM gt q EXPANSION UN zie CIRCULATOR b ALTERNATE BOILER BOILER VM CIRCULATOR LOCATION 16 NEAR BOILER PI PING Figure7 Piping And Wiring Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator USE FULL PORT ZONE VALVE E ZONE 4 p O X lt P ZONE 3 OX p ZONE 2 A LLL S CH CIRCULATOR PUMP lt ZONE 1 PRIORITY ZONE gt CIRCULATOR PUMP 12 MAX APART TO PREVENT FORCE y FLOW IN SECONDARY PA WATER INLET KH 5174 8 gt EXPANSION TANK BOILER PUMP gt ALTERNATE PRIMARY PUMP BOILER LOCATION 17 NEAR BOILER PI PING Figure 8 Reli
10. Wiring Schematic NOTI CE If any of original wire as supplied with this appliance must be replaced it must be replaced with type 105 C Thermoplastic wire or its equivalent HIGH LIMIT TEMPERATURE SENSOR 87 E BOILER CONTROL GAS VALVE O BBB BRN 3 araa CASTING INDUCER TEMP SWITCH TEMP SWITCH d RED a 5 9 2 1 79 e PRESSURE 0 0 SWITCH 120VAC PRI eH TO 24VAC SEC 29 r THERMOSTAT TRANSFORMER ns T BOILER YEL JUNCTION BOX lt D YEL S INDUCER GRN dE BAL WHT E v ARE BLK gt 70 CIRCULATOR gt 1 x 48 3 ATO es P SPARK IGNITER FLAME SENSE 120V AC FIELD CONNECTIONS ACCORDANCE WITH NEC CEC AND LOCAL CODES USE COPPER CONDUCTORS ONLY N Luce 31 ELECTRI CAL WI RI NG Figure 21 Ladder Wiring Diag
11. all times un OUTLET PRESSURE INLET PRESSURE TAP less adjusting manifold pressure Firing rate and manifold TAP pressure must only be measured with cover screw firmly installed INLET 8 B OUTLET GAS CONTROL KNOB 44 MAI NTENANCE AND CLEANI Maintenance As Outlined Below Can Be Performed By Owner Unless Otherwise Noted e The acidic nature of flue gasses condensing on aluminum boiler sections may cause formation of aluminum oxide This oxide formation is normal is generally uniform throughout boiler sections and represents negligible mass of aluminum that is consumed by oxidation during life of the boiler If left unchecked this buildup may eventually cause blockage of flue gas passages in boiler sections reducing efficiency and ultimately shutting down the boiler due to lack of combustion air flow Regular service and maintenance by a qualified service agency must be performed to assure safe trouble free operation and maximum efficiency Beginning Of Each Heating Season 1 Annual service call by qualified service agency which includes A Examine flue passages between boiler sections burner and condensate lines and clean if necessary following Annual Examination And Cleaning Of Boiler Components on page 46 B Visually inspect venting and air intake system for proper function deterioration or leakage If vent or air intake show any signs of deterioration or leakage repair or rep
12. can be installed to pump the condensate to a remote tie in point to a sanitary sewer system For this application the boiler must be installed so that proper pitch of piping to the external condensate reservoir sump can be accomplished Use wood frame or blocks to raise boiler as required for proper installation 36 START UP Water Quality Water Treatment and Freeze Protection see Appendix A Filling Boiler With Water And Purging Air For Systems With Diaphragm Type Expansion Tanks Refer to the appropriate diagrams Near Boiler Piping on page 11 for more information 1 Close all zone service valves on the supply and return piping Open the feed valve and fill boiler with water Make sure air vent is open Hold relief valve open until water runs air free for five seconds to rapidly bleed air from boiler then let the relief valve snap shut 2 Open the zone service valve on the supply pipe for the first zone Open the purge valve on the first zone Feed water will fill the zone pushing air out the purge valve Close the purge valve when the water runs air free Close the zone service valve 3 Repeat step 2 for all remaining zones 4 Open all service valves Any air remaining trapped in the return lines between the service valves and the boiler will be pushed towards the air vent when the boiler is placed in operation 5 Inspect piping system Repair any leaks immediately Purging Air For Systems With Conventional Cl
13. connection of system piping to boiler A hot water boiler installed above radiation level or as required by the Authority having jurisdiction must be equipped with low water cut off device e Periodic inspection is necessary for flushing of float type devices per low water cut off manufacturers specific instructions 11 Supply And Return Lines Boiler is set up to receive 1 supply and return piping from top access Boiler may be piped from left side by turning supply elbow Install furnished dielectric unions at boiler supply and return lines prior to making system piping connections Do Not install copper supply and return piping directly into aluminum boiler section casings due to galvanic corrosion between dissimilar metals Must use provided dielectric unions between copper system piping and boiler to make final connection to boiler Furnished circulator pump can be installed at installer preferred location NEAR BOILER Figure 2 Single Zone Boiler Piping RETURN FROM a SYSTEM PURGE DRAIN VALVE Weer UP X SERVICE To VALVE S S y lt SERVICE e VALVE CIRCULATOR 12 NEAR BOILER PI PING Multi Zone Systems Multi zone systems with two zones are typically piped as shown in figures 3 or 4 Multi zone systems with more than two zones are likely to have small zones with very low heat and flow requirements compared to full heating capaci
14. from air inlet Disconnect air by pass 2 transparent vinyl tube from bottom of mixer Remove air baffle from 1 x 2 flexible coupling and clean air baffle if necessary Refer to repair parts diagram mixer and pressure switch assembly Confirm manual gas valve is closed and disconnect gas line to gas valve at union Disconnect wires to gas valve and igniter Loosen but do not remove five 5 nuts attaching mixer assembly to boiler Remove two 2 igniter screws and remove igniter Remove five 5 nuts and remove mixer assembly Remove burner and mixer gasket Aluminum oxide deposits are water soluble and may be rinsed away with spraying or running water Before rinsing connect 2 I D hose to barbed fitting on bottom of boiler and run hose to bucket or drain After rinsing remove any remaining loosened sediment using shop vacuum with snorkel attachment Inspect burner for any foreign matter in flame ports or inside burner Any foreign matter should be removed by blowing with compressed air or vacuuming Inspect interior of mixer for any signs of sediment or aluminum oxide and clean if necessary K Reinstall burner and mixer gasket and position mixer assembly over studs Install five 5 nuts but do not tighten Reinstall igniter and igniter gasket and fasten with two 2 screws Use care when installing the igniter Tighten five 5 nuts holding mixer assembly Connect e Gas line to gas valve e Condensate dr
15. into operation and observe operation through several cycles Follow remaining steps in this section to insure boiler is operating correctly First couple of cold starts may be rough due to gas line not being completely purged of air causing low firing rate and high excess air levels Inspect Venting And Air ntake System Operate boiler and verify all vent air intake connections are gas tight and watertight Repair any leaks immediately Inspect Condensate Drain Verify all connections are watertight and that condensate flows freely Repair any leaks immediately Inspect System Piping Verify all connections are watertight Repair any leaks immediately Test gnition System Safety Shutoff Device 1 Turn off manual gas valve Set thermostat to call for heat Boiler begins normal sequence of operation After approximately 20 seconds pre purge state code 4 gas valve is powered state code 6 After 13 second trial for ignition gas valve closes state code 10 as integrated boiler control senses that flame is not present After about 30 seconds control will go back to step 4 and make two more attempts to light the burner then go into soft lockout and display Error code 62 To restart system open manual gas valve that was closed in Step 1 Reset lockout by breaking and restoring power to boiler Observe normal operation 2 3 4 Test High Limit Control And Adjust While burner is operating adjust high limit set
16. touch any electrical switch do not use e This appliance is equipped with an ignition device any phone in your building which automatically lights burner Do NOT try to light this burner by hand e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s e Before operating smell all around appliance area instructions for gas Be sure to smell next to floor because some gas is heavier than air and will settle to the floor e If you cannot reach your gas supplier call the fire department Use only your hand to turn the gas shutoff To Turn Off Gas To Appliance valve Never use tools If valve will not turn 1 Setthe thermostat to lowest setting by hand do not try to repair it call a qualified 2 service technician Force or attempted repair may result in fire or explosion Turn off all electric power to the appliance if service is to be preformed 3 Remove the front jacket panel Do not use this appliance if any part has 4 Turn gas control knob clockwise to OFF been under water Immediately call a qualified 5 Replace the front jacket panel service technician to inspect appliance and to replace any part of control system and any gas control which has been under water Stop Read Safety information above 1 Set thermostat to lowest setting 2 Turn off all electric power to the appliance 3 This appliance is equipped with an ignition device which automatically lights the burner
17. vent pipe roof and sidewall termination Roof termination is preferred Combustion air and vent pipes must terminate together in same atmospheric pressure zone as shown 2 Construction through which vent and air intake pipes may be installed is maximum 24 inches minimum 1 4 thickness 3 Combustion air and vent pipe fittings must conform to American National Standards Institute ANSI standards and American Society for Testing and Materials ASTM standards D1784 schedule 40 CPVC D1785 schedule 40 PVC D2665 PVC DWV D2241 SDR 21 and SDR 26 PVC D2661 ABS DWV or F628 schedule 40 ABS Pipe cement and primer must conform to ASTM standards D2564 PVC or D2235 ABS 4 Canada construct all combustion air and vent pipes for this unit of ULC S636 listed schedule 40 CPVC schedule 40 PVC PVC DWV ABS DWV pipe and pipe cement SDR pipe is not approved in Canada e First 3 feet 900mm of venting must be readily available for visual inspection e Specified primers and glues of certified vent system must be from single manufacturer and not intermixed with other manufacturer s vent system parts e Components of the certified system must not be interchanged with other vent systems or unlisted pipe and or fittings Transition from 2 pipe to 3 pipe must be made in vertical run 5 Boiler combustion air and vent piping connections are sized for 2 pipe Any pipe size change to 3 m
18. vertical distance of a 7 15 ft 9 5m 12 Support combustion air and vent piping minimum of every 5 feet using pre formed metal hanging straps Vent shall n min hin 3 ft mm of Or pe 6 expansion and contraction any non mechanical air supply inlet to any building or pan l s of combustion air inlet of any other appliance 13 Slope horizontal portion of combustion air and vent pipes toward boiler minimum of 1 4 per linear ft 21mm m with no sags between hangers 14 Use appropriate methods to seal openings where vent and combustion air pipes pass through roof or side wall 23 COMBUSTI ON AIR AND VENT Figure 12 Roof Vent Intake Terminations 8 MINIMUM VERTICAL SEPARATION BETWEEN COMBUSTION AIR INTAKE AND VENT MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL USA 12 300mm Canada 18 450mm COMBUSTION AIR 24 COMBUSTI ON AIR AND VENT Figure 13 Side Wall Vent Intake terminations Less Than 12 Clearance Above Grade Less Than 12 Clearance 12 p MINIMUM 7 _ SEPARATION 18 MAXIMUM Figure 14 Side Wall Vent Intake Terminations 12 Or Clearance Above Grade 12 Or More Clearance 42 MINIMUM COMBUSTION AIR AND VENT PIPE Figure 15 Concentric Vent Terminations 1 2 54cm Maximu
19. 0 59381 INTEGRATED BOILER CONTROL OPERATI ON AND ADJ USTMENTS Figure 26 Sequence of Operation IGNITION CIRCULATOR SEQUENCE CONTROL IDLE IDLE ALL OUTPUTS OFF ALL OUTPUTS OFF WATER TEMPERATURE LOW AND THERMOSTAT ACTIVE THERMOSTAT CALL FOR HEAT ACTIVE WATER TEMP CHECK LEAKAGE HIGH OR CALL SET FLAME BIAS CIRCULATOR ON FOR HEAT LOST BIAS DONE THERMOSTAT CALL FOR HEAT LOST TIME OUT OR WAIT LIMIT MANUAL RESET CIRCULATOR OFF SWITCH CLOSE LIMIT SWITCH CLOSE LIMIT SWITCH OPEN CHECK DAMPER PRESSURE SWITCH OPEN SWITCH OPEN DRIVE DAMPER INDUCER WAIT FOR SWITCH CLOSE SWITCH CLOSE SWITCH OPEN MANUAL FLAME DEB ON RESET HECK FLAME TIME OUT TIME QUT PREPURGE E SOFT LOCKOUT TIME OLIT MAX NUMBER OF RETRIES EXCEEDED DSI MODEL SPARK NOT FOR 081 TIME OUT IGNITION BEGINS AND TURN PILOT TIME QUT RETRY DELAY MAIN VALVE OPENS VALVE ON DSI TIME OUT FLAME SENSED CSD 1 NOT FOR DSI MODEL HARD LOCKOUT PROVE FLAME STOP SPARKING m MAX NUMBER OF DSI FLAME PROVED RECYCLES EXCEEDED DAMPER PRESSURE FLAME STABILIZATION SWITCH OPEN TURN MAIN VALVE RECYCLE DELAY TIME OUT FLAME LOST WATER TEMPERATURE HIGH OR THERMOSTAT CALL FOR HEAT LOST FLAME DEB CHECK FLAME POSTPURGE FLAME DEB OFF POST TRIAL 33801 41 CHECK OUT PROCEDURE AND ADJUSTMENT Verify Proper Sequence Of Operation Place boiler
20. 01 www rhomarwater com Tel 800 543 5975 Fax 417 862 6410 Pro Tek 922 Inhibitor may be used to adjust the pH level of the hydronic system but on occasion may not resolve the pH issue In these cases flush the system and refill with untreated water and antifreeze suitable for aluminum heat exchangers as listed in this supplement I ntercool NFP 30 40 50 AA I ntercool RPH 15 Hercules cryo tek 100 Al Hydronic Agencies Ltd Fernox North Distributor 15363 117 Avenue Edmonton T5M 3X4 Canada www hydronicagencies com Tel 780 452 8661 Fax 780 488 2304 Fernox www fernox com Interstate Chemical 2797 Freedland Road P O Box 1600 Hermitage PA 16148 0600 www interstatechemical com Tel 800 422 2436 Fax 724 981 8383 Hercules Chemical Company Inc 111 South Street Passaic NJ 07055 www herchem com Tel 800 221 9330 Fax 800 333 3456 This product may be used to adjust pH level of hydronic system but on occasion may not resolve pH issue In these cases it is recommended to flush system and refill with untreated water and new boiler manufacturer approved antifreeze suitable for Aluminum heat exchangers 33 INSTALLATI ON AND CHECK OUT CERTI FI CATE gl INSTALLATION AND CHECK OUT CERTIFICATE Boiler Model Serial Date Installed Measured BTU HR input O Installation instructions have been followed 3 Checkout procedure and adjustments performed 3 Maintenance and Service issues rev
21. FURNISHED IN PARTS BAG 20 NEAR BOILER PI PING Condensate Drain Piping Boiler is factory equipped with a condensate trap An additional trap is not required and should NOT be used 1 Provide 2 PVC condensate drain and fittings Condensate drain to be pitched down to floor drain at a minimum of 1 4 per foot Install 1 PVC tee to overflow fitting as shown in Figure 11 The 12 diameter schedule 40 PVC or CPVC condensate drain and pipe fittings must conform to ANSI standards and ASTM D 1785 or D2846 Schedule 40 PVC or CPVC cement and primer must conform to ASTM D2564 or F493 In Canada use CSA or ULC certified schedule 40 PVC or CPVC drain pipe cement Condensate pump with reservoir not furnished may be used to remove condensate to a drain line sanitary line above boiler if floor drain is not available or is not accessible Figure 11 Condensate Drain Piping PVC PVC TEE 1 2 SLIP X 1 2 SLIP X 1 2 SLIP DRAIN Filling Condensate Trap With Water On initial start up condensate trap must be manually filled with water Following are the steps required to initially fill condensate trap for start up Steps are only required at initial start up or if maintenance requires draining of condensate trap 1 Disconnect vent condensate drain line from vent pipe connector on outlet of induced draft blower 2 Pour about 1 cup of cold tap water into vent drain line with funnel 3 Excess w
22. LENNOX INSTALLATION PRODUCT LITERATURE H U CTI S Dallas Texas GWBO9 050lH 2 9 075 2 GWB9 100IH 2 GAS FIRED DIRECT VENT CONDENSING HOT WATER BOILER ENERGY STAR RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions must be affixed on or adjacent to the boiler Improper installation adjustment alteration service or maintenance could result in death or serious injury Refer to this manual for assistance For additional information consult a qualified installer service agency or the gas Supplier GAS FIRED HOT WATER BOILERS These low pressure gas fired hot water boilers are design certified by CSA Canadian Standards Association for use with natural and propane gases 100 MBH model is certified for natural gas only They are constructed and hydrostatically tested for a maximum working pressure of 50 psi pounds per square inch in accordance A LIED CERTIFIED with A S M E American Society of Mechanical www ahridirectory org Engineers Boiler and Pressure Vessel Code Section IV Standards for Heating Boilers CERTIFIED This boiler cannot be used with all types of chimneys Read these instructions carefully before installing P N 240009449 Rev A 07 2012 Figure 1 Boiler Dimensions 11 3 4 36 1 4 32 1 4 10 5 8 ALTERNATE BOILER WATER RETURN LEFT SIDE 17 3 8 12 5 8 GAS SUPP
23. LY 1 2 NPT COMBUSTION AIR INTAKE PIPE 2 PVC 33 eo ale 21 1 4 CONDENSATE DRAIN FITTING 1 2 PVC RIGHT SIDE BOILER WATER SUPPLY AND RETURN OPENINGS 1 14 NPT CONNECTIONS PROVIDED INSIDE BOILER CABINET ALTERNATE BOILER WATER SUPPLY DI MENSI ONS 17 3 4 r JUNCTION BOX FOR 120V POWER 120V CIRCULATOR AND 24V THERMOSTAT BOILER WATER TEMPERATURE AND PRESSURE GAUGE FRONT PANEL DOOR PULL LEVELING FEET 39 5 8 38 1 4 VENT CONNECTION 2 CPVC TOP INTRODUCTI ON DIMEN ION eT eee UTI 2 erod ON SE PIU PET 3 Important 1 8 Morro 8 4 Boiler Ratings amp Capacities va ka dato Rcg trs i 5 Boilers For Use 5 Before Installing FNC TO sani 8 9 Near Boiler Piping 11 Combustion Air And Vent Pipe sas qu Rs Unt ctii RU d OS ER COP AR rd a 22 Gas SWPP 28
24. VC pipes flue gases and causing condensation e These low pressure gas fired hot water boilers are Sealed combustion premix gas burner and low flame design certified by CSA International for use with temperature means reduced CO and NOx emissions natural gas and propane gases 90 100 model is which contribute to cleaner and healthier environment certified for natural gas only This appliance takes its combustion air directly from e Boilers are constructed and hydrostatically tested outdoors sealed combustion and does not compete for maximum working pressure of 50 psig pounds with building occupants for fresh air per square inch gage in accordance with A S M E American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section IV Standards for heating boilers Sealed combustion also known as direct vent is safest and best way to obtain plenty of clean combustion air IMPORTANT SAFETY INFORMATI ON General Boiler installation shall be completed by qualified agency See glossary for additional information Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation Keep this manual near boiler Retain for future reference Become familiar with symbols identifying potential hazards This is the safety alert symbol Symbol alerts you to potential personal injur
25. ain line to boiler e Pressure switch hose to gas valve e Air by pass to mixer e 1 i x 2 flexible coupling to air inlet and make sure to put air baffle back to correct position e Igniter wires e Gas valve wires Visually inspect condensate lines leading from boiler sections and vent pipe connector to condensate trap Refer to repair parts diagrams Any foreign material or debris visible in condensate lines needs to be cleaned out as follows E F Disconnect condensate drain lines from condensate trap Remove condensate trap and drain all water from trap Disconnect condensate lines from fitting on bottom of boiler and vent pipe connector Run cold water through condensate lines and trap to thoroughly flush out any sediment or debris Reinstall condensate trap and condensate lines Follow instructions under Near Boiler Piping for filling condensate trap with water Inspection of flue connector requires following steps Refer to repair parts diagram Verify proper operation after servicing Loosen the clamp on the draft inducer end of the 2 vent pipe connector that connects the vent to the draft inducer Disconnect unplug wiring harness from draft inducer motor and draft inducer temperature safety switch Remove four 4 bolts that attach draft inducer to flue connector Remove draft inducer and gasket from top of flue connector Inspect interior of flue connector Any buildup of sediment
26. aintenance recommendations Maintenance And Cleaning on page 45 BOILER RATINGS CAPACITIES Tle CERTIFIED Table 1 SEA LEVEL RATI NGS NATURAL AND PROPANE GASES www ahridirectory org Input Heating Capacity Net AHRI Rating Shipping ome MBH MBH MBH Weight Ibs Flue Diameter 90 50 2 CPVC 8 PVC 90 75 75 68 59 2 CPV PVC 90 100 100 05 8 20 2 1 MBH 1 000 Btuh Btuh British Thermal Units Per Hour 90 100 model is certified for natural gas only AFUE Annual Fuel Utilization Efficiency and Heating Capacity is based on the D O E Department of Energy test procedure Heating Capacity indicates the amount of heat available after subtracting losses up the stack Most of this heat is available to heat water A small portion is heat from jacket and surfaces of the boiler and it is assumed that this heat stays in the structure Net AHRI rating represents portion of remaining heat that can be applied to heat radiation or terminal units i e finned tube baseboard cast iron radiators radiant floor etc The difference between Heating Capacity and Net AHRI Rating called piping and pickup allowance establishes reserve for heating volume of water in system and offsetting heat losses from piping Net AHRI ratings shown are based on piping and pickup factor of 1 15 in accordance with AHRI Standard as published by Hydronics Institute Net AHRI rating o
27. al Specific Description Description The boiler is in standby no call for heat Standby scum circulator Heat request present but boiler temp sufficiently high to run circulator pump only no ignition sequence The inducer is off and the control waits for the pressure switch to open This is checked at the beginning of a heat cycle before turning on the inducer If the pressure switch doesn t open in 60 seconds the control goes to state 11 Wait for pressure switch to open Wait for pressure switch to close The inducer is turned on The control is waiting for the pressure switch to close at the beginning of a cycle If the pressure switch doesn t close within 60 seconds the control goes to state 12 3secs safety relay test delay time when status 4 or 6 is interrupted pressure switch to open Then control goes to state 12 System is purging before ignition trial safety relay diagnostics followed safety relay switch on during last 2 secs this state System is sparking permanently 13 seconds whilst main valve relay is turned on System is proving flame signal typically 2 seconds System is in running mode flame signal must be present System is purging at the end of a call for heat If the control loses flame signal during state 7 or 8 it will recycle Re Start delay due through the 30 seconds purge time and last 2secs part of prepurge to flame failure time Prepurge includes 4 PV short diagnostics Spark
28. als so all moisture in combustion air and vent piping drains to boiler Pitch pipes continuously with no sags or low spots where moisture can accumulate and block flow of air or flue gas Combustion air and vent pipes must be airtight and watertight Consider following when determining appropriate location for termination of combustion air and vent piping Position termination where vent vapors will not damage plants shrubs or air conditioning equipment Position termination as to not be effected by wind eddy air born leaves snow or recirculated flue gases Position termination where it will not be subjected to potential damage by foreign objects such as stones balls etc Position termination should where vent vapors are not objectionable Place vent on wall away from prevailing wind Locate or guard vent to prevent accidental contact with people or pets Terminate vent above normal snowline Avoid locations where snow may drift and block vent Ice or snow may cause boiler to shut down if vent becomes obstructed COMBUSTION AIR AND VENT PIPE Table 5 Combustion Air And Vent Piping Lengths Total Equivalent Length BOILER 2 PIPE MINIMUM 2 PIPE MAXIMUM 3 PIPE MINIMUM 3 PIPE MAXIMUM SIZE VENTING VENTING VENTING VENTING 100 2 FEET 21 FEET 15 FEET 92 FEET 75 amp 50 2 FEET 26 FEET 20 FEET 112 FEET e Under certain conditions flue gas will condense e Vent shall not terminate underneath veranda porch or f
29. and swimming pool pump house All combustion air and vent pipes must be airtight and watertight Combustion air and vent piping must also terminate as shown in Combustion Air and Vent Pipe section Vent connections serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure Table 4 Required Clearances Combustible Cleaning and Clearance P Servicing 8 548 Left Side 1 26mm 24 610mm Right Side 11 280mm Combustion Air And Vent Pipe Requirements This boiler requires a dedicated direct vent system In a direct vent system all air for combustion is taken directly from outside atmosphere and all flue products are discharged to outside atmosphere Terminate combustion air and vent pipe connections in same atmospheric pressure zone through roof or sidewall roof termination preferred See Figure 12 thru Figure 14 pages 24 and 25 for required clearances e Keep boiler area clean of debris and free of flammable and combustible materials vapors and liquids remt 1 Intake Vent Piping 0 0 Near Boiler Hot Water Piping m All distances measured from the cabinet of the boiler BOILER I NSTALLATI ON Condensate Drain Requirements 3 e Pitch condensate drain line down to floor drain at mini mum of 14 per foot External condensate pump not furni
30. ater should go through overflow and out through condensate drain line Verify proper operation of drain line or external condensate pump if used 4 Reinstall vent drain line Chilled Water Piping Install boiler when used in connection with refrigeration system so chilled medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler Boiler piping system of hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during cooling cycle FROM BLOWER PITCH DRAIN PIPE DOWN TO FLOOR DRAIN AT MINIMUM 1 4 PER FOOT TO DRAIN CONDENSATE 21 COMBUSTION AIR AND VENT PIPE Connections And Termination Provisions for combustion and ventilation air must be in accordance with section Air For Combustion and Ventilation of the National Fuel Gas Code ANSI 2223 1 NFPA54 or Sections 8 2 8 3 or 8 4 of National Gas and Propane Installation Code CAN CGA B 149 1 or applicable provisions of the local building code Boilers require dedicated direct vent system All air for combustion is taken directly from outdoors through combustion air intake pipe All flue products are discharged to outdoors through vent pipe 1 See Figure 12 thru Figure 14 Pages 24 and 25 for combustion air and
31. ced by qualified professionals Boiler Sizing Check to be sure you have selected boiler with proper capacity before starting installation AHRI Rating of boiler selected should be greater than or equal to calculated peak heating load heat loss for building or area s served by boiler and associated hot water heating systems See Table 1 Page 5 Heat loss calculations should be based on approved industry methods Boiler Location Considerations Before selecting boiler location consider following e Supplied with correct type of gas natural gas or propane e Connected to suitable combustion air intake piping system to supply correct amounts of fresh outdoor air for combustion refer to Combustion Air and Vent Pipe on page 22 for details e Connected to a suitable venting system to remove the hazardous products of gas combustion refer to Combustion Air and Vent Pipe on page 22 for details e Connected to a suitable hot water heating system e Supplied with a suitable electrical supply for all boiler motors and controls e Connected to a properly located thermostat or operating control Not included with boiler e Placed on level surface DO NOT install on carpeting e Condensate drain line must be pitched down to floor drain or external condensate pump with reservoir at per foot wood frame or blocks may be used to raise boiler BOILER I NSTALLATI ON Locating The Boiler 1 Place crated boi
32. cessary Follow antifreeze inhibitor manufacturer s instructions for details on how to adjust pH Antifreeze solutions can break down over time Failure to check antifreeze chemistry on annual basis may result in accelerated corrosion of boiler and other system components Consult with antifreeze manufacturer for recommendations Use of antifreeze in any boiler will reduce heating capacity as much as 10 20 Take into consideration when sizing heating system pumps and expansion tank Consult antifreeze manufacturer s literature for specific information on reduced capacity Using antifreeze manufacturer s instructions determine freezing temperature needed and use correct amount of antifreeze Never exceed 50 antifreeze by volume Boiler operating pressure must remain below 15 psi for antifreeze solutions that specify a maximum of 250 F 121 C Otherwise increase system operating tank pressure to 20 psig Note Refer to expansion tank manufacturer instructions for adjusting tank pressure System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas Fired Water Boilers Table 11 Antifreeze Products Compatible Aluminum Antifreeze amp Inhibitor Suppliers Noburst AL Antifreeze Rhogard Antifreeze amp Pro Tek 922 Inhibitor Noble Company P O Box 350 Grand Haven MI 49417 www noblecompany com Tel 800 878 5788 Fax 231 799 8850 Rhomar Water Management Inc Box 229 Springfield MO 658
33. consecutive tri als for ignition IBC will lockout and display Error Code 62 Draft Temperature Safety Switch Draft Inducer Temperature Safety Switch is a disc thermostat 180 F setpoint located on induced draft fan outlet port Switch protects inducer and vent pipe from potential high temperature condition for discharging flue gases Condition would typically be result of higher high limit control setting or over firing Temperature safety switch automatically resets when the vent temperature decreases 15 F switch differential CONTROLS AND ACCESSORI ES Casting Temperature Safety Switch In event of lack of or loss of water in boiler Casting Temperature Safety Switch 300 F setpoint installed on top of the aluminum boiler section shuts off boiler by shutting off power to Integrated Boiler Control IBC This fault requires manual reset of casting temperature safety switch to restart the boiler Verify that boiler is properly filled with water before resetting this switch Never run cold water into a hot empty boiler Differential Pressure Air Proving Switch Blocked Vent Safety Shutoff Differential pressure switch monitors air flow by sensing differential pressure measured in inches of water w c Pressure switch contacts close when draft inducer is running Closed switch indicates there is adequate air flow for combustion Pressure switch shuts off main burner if differential pressure is inadequate du
34. d be 15 ampere circuit 2 See Figure 20 Page 31 for diagram showing service COLD SPOTS HOT SPOTS switch junction box and power supply connection Concealed points Concealed pipes or ducts mW Fireplace 3 Locate service switch in vicinity of boiler Verify it is turned OFF during service or maintenance Stairwells drafts Radios e Connect black hot lead from power supply to black adios wire labeled L 120 VAC Lamps Unheated rooms on e Connect white neutral lead from power supply to Direct sunlight other side of wall white wire labeled N 120 VAC e Connect green ground lead from power supply to green wire labeled G 120 VAC 4 Run 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod Thermostat I nstallation e Thermostat location has important effect on operation of boiler system e Follow instructions included with your thermostat e Locate thermostat about five feet above floor on inside wall e Mount directly on wall or on vertical mounted outlet box e It should be sensing average room temperature Set heat anticipator where applicable at 0 7 amps Connect 24 Volt thermostat leads to two 2 yellow wires located in junction box located on outer jacket of boiler See Figure 20 Page 31 for junction box and thermostat field wiring connections 30 ELECTRI CAL WI RI NG Figure 20
35. d be lubricated according to the pump and or motor manufacturer s instruction Daily During Heating Season 1 Check for and remove any obstruction to the flow of combustion air or venting of flue gases 2 Check boiler area is free from combustible materials gasoline and other flammable vapors and liquids Monthly During Heating Season 1 Remove jacket front and top panels and check for piping leaks around relief valve and other fittings If found contact qualified service agency to repair DO NOT use stop leak compounds 2 Test relief valve Refer to valve manufacturers instructions packaged with relief valve 3 Visually inspect venting and air intake system for proper function deterioration or leakage If vent or air intake show any signs of deterioration or leakage contact a qualified service agency to repair or replace immediately and to insure proper reassembly and resealing of vent and air intake system 4 Visually inspect clear vinyl condensate lines and PVC condensate drain pipe for proper operation leakage and deterioration If condensate lines or drain pipe show any signs of blockage leakage or deterioration contact a qualified service agency to clean repair or replace them immediately Periodically During Heating Season Where low water cutoffs are used periodic inspection of low water cut off is necessary including flushing of float type devices Refer to low water cut off manufacturer s specific in
36. dels 26 feet maximum total equivalent length for 90 50 and 90 75 models 2 feet minimum total equivalent length for all models EXHAUST ELBOW FURNISHED VENT INTAKE TERMINATIONS 3 COMBUSTION AIR _ INTAKE PIPING 3 VENT PIPING TRANSITION FITTING TRANSITION FITTING 2 TO 3 IN 2 50 8mm Q to 3 76 2mm VERTICAL RUN IN VERTICAL RUN 3 76 2mm DIAMETER VENT AND COMBUSTION AIR INTAKE PIPING 92 feet maximum total equivalent length for 90 100 models 15 feet minimum total equivalent length for 90 100 models 112 feet maximum total equivalent length for 90 50 and 90 75 models 20 feet minimum total equivalent length for 90 50 and 90 75 models 2 CPVC VENT PIPING FURNISHED 2 CPVC COUPLING FURNISHED TRANSITION FITTING 2 3 IN VERTICAL RUN EXHAUST ELBOW FURNISHED 27 GAS SUPPLY PIPING WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow gas supplier s instructions e If you cannot reach your gas supplier call the fire department Check Gas Supply Gas pipe to your boiler must be correct size for length of run and for total Btu per hour input of all gas utilization equipment connected to it See Table 7 Page 29 Boiler and its individual shutoff valve must be disconnected from gas supp
37. dition i boiler control IBC Touch metal surface to discharge State Conditions shown in Table 9 Page 40 provide static electricity before touching IBC suggestions for servicing these potential errors 4 IBC cannot be repaired If it malfunctions it must be replaced 5 Only trained service technicians should service IBC systems Following troubleshooting check out system following sequence of operation for a normal light off sequence 6 All controls are factory tested in the assembly process and a defective control is generally the least likely cause If you suspect you have a defective control read through this section before you replace it 7 Itis extremely unlikely that the two consecutive controls are defective If it seems to be happening chances are that either there is nothing wrong with the control or it is being damaged by some other problem an electrical short burning out a transformer for example I nitial Service Checks 1 Before troubleshooting A Make sure that circuit breaker is on or fuse is ok at electrical panel B Make sure that service switch is on C Make sure that gas is on at the gas meter at all appropriate manual shutoff valves and at the gas control valve D Make sure that the thermostat is calling for heat E Check that wire connectors at the integrated boiler control and at the originating control are securely plugged in or connected F Check that hoses are securely conn
38. e Installation Code CAN CSA B149 1 When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code NFPA 54 ANSI 2223 1 and or the Natural Gas and Propane Installation Code CAN CSA B149 1 NEAR BOILER PI PING Clean the System First Before connecting boiler to heating system clean and flush system thoroughly Verify system is free of sediment flux and any residual boiler water additives Systems having antifreeze not recommended must be completely flushed to insure no old antifreeze remains In older systems obviously discolored murky or dirty water or pH reading outside acceptable range between 7 0 and 8 0 are indications the system should be cleaned or treated Thoroughly flush system with clean water to remove any sediment or contaminants Sludge and iron oxide deposits can cause rapid breakdown of inhibitors Flushing with clean water If chemical cleaners are used use only those recommended for use with aluminum boilers Follow chemical cleaner manufacturer s instructions completely DO NOT mix different manufacturer s products e When boiler installation is for new heating system install all of radiation units panels radiators baseboard or tubing and supply and return mains e After all heating system piping and components have been installed make final
39. e to blocked vent pipe blocked air intake blocked boiler sections or blocked draft inducer If pressure switch contacts fail to close control will display Error Code 29 Draft I nducer Draft inducer blower provides means for pulling combustion air into and through the mixer burner flue ways of cast aluminum boiler sections and flue adapter before being discharged through vent piping to outdoors See applicable sections for proper sizing and installation of combustion air and vent piping in this manual Circulator Pump Every forced hot water system requires at least one circulating pump Circulating pump imparts the necessary energy to move water through closed loop supply and return piping systems terminal heating equipment i e finned tube radiators etc and back through boiler for reheating To provide required hot water flow rates circulator pump must be properly sized to overcome frictional losses usually measured in feet of water also referred to as pump head loss of supply and return piping systems and boiler The circulator pump is furnished for single zone or zone valve controlled heating system and should be located on downstream i e pumping away side of expansion tank For pump controlled system where there is a circulator for each zone circulator provided with boiler can work for one zone For more details on piping and circulators see Near Boiler Piping on page 11 Drain Valve Manual drain
40. ected and are not plugged or damaged 47 TROUBLESHOOTING Table 10 Error Codes Segment Display Definition F rr C Pressure Switch failed to open contacts stuck closed F rr Low flame current F b Flame sensed out of normal sequence before opening gas valve or after closing gas valve rr IB Gas valve relays welded 5 consecutive soft lockouts A manual reset is required F 4 Flame sensed during prepurge before gas valve signaled opened rr 24 Flame sensed during postpurge before gas valve signaled closed er pu Pressure Switch failed to close contacts stuck open rr 32 Sensor 1 Error Temperature sensor or interface failure open or short connection increased connection resistance dual sensor pe or failure of A D conversion invalid offset or gain too many failures during A D conversion E rr 55 Atmospheric Damper End Switch failed to close end switch contacts stuck open F Atmospheric Damper End Switch failed to open end switch contacts stuck closed 51 Flame Rod shorted to burner ground H AC line frequency error signal is too noisy or frequency is incorrect F rr 59 Line voltage error voltage out of spec high or low Thermostat input higher than threshold E rr 5 Line voltage unstable possibly too many heavy loads switching on and off cause erratic supply voltage E rr b C Soft Lockout maximum number of retries exceeded
41. ef Valve Boiler Piping Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Install discharge piping per these instructions RELI EF VALVE Safety Relief Valve DI SCHARGE p Installation of safety relief valve shall conform to ANSI E ASME Boiler and Pressure Vessel Code Section IV e Install furnished safety relief valve using 3 4 x 42 pipe provided with boiler See Figure 8 e Install safety relief valve with spindle in vertical position Do not install shutoff valve between boiler and safety Check local relief Nae codes for BOILER e nstall discharge piping from safety relief valve See Figure 8 distance e Use 34 or larger pipe from floor e Use pipe suitable for temperatures of 375 F 191 C or or allowable greater safe point of e Individual boiler discharge piping shall be independent discharge of other discharge piping Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping Install union if used close to safety relief valve outlet Install elbow s if used close to safety relief valve outlet and downstream of union if used e Terminate pipe with plain end not threaded Expansion Tank And Make Up Water Determine required system f
42. em 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restrictions leakage corrosion and other deficiencies which could cause an unsafe condition 10 In so far as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryer and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhaust so they will operate at maximum speed Do not operate a summer exhaust fan Close fire dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliances will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or the smoke from a cigarette cigar Or pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fire place dampers and any other gas burning appliance to their previous condition of use Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Code NFPA 54 ANSI Z223 1 and or the Natural Gas and Propan
43. er For replacing orifice refer to specific instructions utility or distributor for this value included with conversion kit e For specific settings refer to Table 2 for natural gas applications and Table 3 Page 7 for propane LP gas applications Table 2 90 50 75 100 SERIES 2 NATURAL GAS MODEL 90 50 ee Settings 750 850 950 1000 1050 Normalinput MBH 50 MODEL 90 75 Stock Factory Btu Value of Natural Gas Settings 750 850 950 1000 1050 Normal input 7 Manifold Pressure In WC 13331092 13331092 MODEL 90 100 Settings 750 850 950 1000 1050 NWomamuB 14 Contact local gas utility or distributor for Btu value of gas BOILERS FOR USE AT HIGH ALTITUDE UNITED STATES INSTALLATIONS Model 90 75 propane LP units only at altitudes above 5 000 ft install 90 75 High Altitude Orifice Kit 550002629 For all other altitudes use sea level orifice Table 3 90 50 75 SERIES 2 PROPANE GAS MODEL 90 50 MEM Settings 2300 2350 2400 2450 2500 Nomalnpu MBH 50 J 90 75 Settings 2300 2350 2400 2450 2500 Nomalnpu MBH 75 For model 90 75 Propane units only at altitudes above 5 000 ft install 90 75 High Altitude Orifice Kit 550002629 For all other altitudes use sea level orifice 7 2 Contact local gas uti
44. erential Air Pressure Switch e Blockage in air intake or vent pipes an e Undersized air intake or vent pipes e Loose blower wheel or motor shaft To Sight Glass Silicone e ncorrect pressure switch or pressure switch setpoint Suction Port Tubing When pressure reading is proper and the pressure switch is Vin Tine operating properly remove testing lines and reinstall caps to Tee and 4 way connector Gas Valve Vent Red Transparent Vinyl Tubing 4 Way Connector ee Vinyl Cap TYP 2 White Transparent Vinyl Tubing Test Lines Inclined Manometer Or Differential Pressure Gauge 49 APPENDI X WATER QUALITY WATER TREATMENT AND FREEZE PROTECTION Aluminum Series High Efficiency Gas Fired Boiler DI ELECTRIC ISOLATI ON amp ANTI FREEZE PROTECTI ON ADDENDUM Follow these instructions to prevent damage to boiler s heat exchanger caused by inadequate dielectric isolation incorrect water treatment or antifreeze application Failure to comply could result in death or serious injury Install boiler so gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator re placement etc DI ELECTRIC I SOLATI ON Two 2 1 1 4 X 1 1 4 Female to female dielectric isolation unions are shipped loose in boiler parts bag Install Dielectric Isolation unions at boiler supply line and return
45. f boiler selected should be greater than or equal to the calculated peak heating load heat loss for building or area s served by boiler and associated hot water heating systems Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements Boilers are factory equipped for operation at altitudes ranging from 0 5 000 feet above sea level 4 500 feet in Canada Boilers for use at high altitude Canada Contact Provincial authority having jurisdiction for installations above 4 500 feet 1 350m above sea level United States See Boilers For Use At High Altitude on page 6 BOI LERS FOR USE AT HI GH ALTI TUDE UNITED STATES INSTALLATI ONS e Boilers with exception of 90 75 propane LP product e nstructions on how to adjust gas manifold pressure are factory equipped for operation at altitudes ranging settings see Figure 27 and Figure 28 Page 44 from 0 10 000 feet above sea level Note 90 75 propane LP applications for 5 000 10 000 No changes to factory settings are required for installa feet above sea level require orifice change as well as gas tions from 0 5 000 feet above sea level manifold pressure adjustment based upon calorific Btu e For altitudes from 5 000 10 000 feet above sea level value of supply gas gas manifold pressure needs to be adjusted based upon Refer to Table 2 and Table 3 for high altitude orifice part calorific Btu value of supply gas contact local gas numb
46. he local elevation Obtain yearly average heating value of local gas supply from gas utility At sea level elevation it should be approximately 1000 Btu s per standard cubic foot Operate boiler for 5 minutes Turn off all other gas appliances extinguishing standing pilots where applicable At gas meter measure time in seconds required to use one cubic foot of gas Calculate input rate according to the following formula 3600 x heating value from step 3 Btuh in put rate time from step 6 Measured input rate should be within 2 of input rating from step 2 If within 296 go to step 9 If not adjustment is required proceed as follows A Turn boiler off B Setup U tube manometer or differential pressure gauge for measuring manifold pressure See Figure 27 Page 44 C Manometer or gauge must be able to read at least 0 0 to 3 0 inches water column of pressure and resolve to at least 0 1 inches water column D Turn boiler on E Manifold pressure has been nominally set at 2 5 inches w c Manifold pressure and input rate must always be measured with pressure regulator cover screw installed Cover screw must be removed for adjustment Manifold pressure reading will change increase when cover screw is removed CHECK OUT PROCEDURE AND ADJUSTMENT F After adjusting input rate turn boiler off remove Set Thermostat To Desired Room Temperature Wo manometer or pressure gauge reinstall Ys plug Observe seve
47. ide diameter Figure 19 Gas Piping gt GAS SUPPLY PIPING g 4 K uU MANUAL SHUT OFF VALVE SEDIMENT TRAP GROUND JOINT UNION 29 ELECTRI CAL WI RI NG Connect Circulator Pump Wiring See Figure 20 Page 31 for circulator pump field wiring con nections Supplied 5 foot wiring harness with flexible metal conduit for connection from circulator pump to junction box If two 120 Volt circulator wire terminals inside junction box are not used leave two wire nuts to prevent short circuit Electrical shock hazard Turn OFF electrical power supply at service panel before making electrical connections Failure to do so could result in death or serious injury Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction Refer to e USA National Electrical Code ANSI NFPA 70 NOTI CE e Canada Canadian Electrical Code Part I CSA 22 1 Label all wires prior to disconnection when servicing Safety Standard for Electrical Installations controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Electric Power Supply Prior to making any line Voltage connections turn OFf electrical power at fuse box Things to Avoid when Locating Thermostats DEAD SPOTS Corners and alcoves Behind doors 1 Run separate 115 Volt circuit from separate over current protection device in electrical service entrance panel This shoul
48. iewed with owner maintenance person O Installation booklet affixed on or adjacent to boiler Installer Company Address Phone Installer s Name Signature NOTES LENNOX PRODUCT LITERATURE Lennox Industries Inc Dallas Texas Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com
49. ill pressure system design temperature and system water content e Boiler contains 2 6 gallons U S Size expansion tank accordingly Consult expansion tank manufacturer for proper sizing information Connect properly sized expansion tank not furnished Diaphragm type expansion tank see Figure 9 Page 19 See Figure 10 Page 20 for conventional closed type expansion tanks For diaphragm type expansion tanks adjust tank air pressure to match system fill pressure Install furnished air vents shown for diaphragm type expansion tank system only Install make up water connections as shown per local codes If pressure reducing valve is used adjust to match system fill pressure Verify clean water supply is available When water supply is from well or pump install sand strainer at pump 18 NEAR BOILER PIPING Figure 9 Diaphragm Type Expansion Tank Piping AUTOMATIC AIR VENT MANUAL FILL COLD WATER VALVE FILL COMBINATION QUICK FILL VALVE STRAINER CHECK VALVE AND PRESSURE REDUCING VALVE DIAPHRAGM TYPE EXPANSION TANK 3 4 X 1 8 BUSHING 3 4 TEE 3 4 NIPPLE FURNISHED IN PARTS BAG 19 NEAR BOILER PIPING Figure 10 Conventional Closed Type Expansion Tank Piping CLOSED TYPE EXPANSION TANK MANUAL FILL VALVE COLD WATER FILL a AND PRESSURE REDUCING VALVE EXPANSION TANK SERVICE VALVE GATE VALVE OR FULL PORT BALL VALVE 3 4 TEE 3 4 NIPPLE
50. ing chlorine in excess of 100 ppm DO NOT use inhibitors or other additives that are not listed in this addendum Consult local water treatment specialist for recommendations if any of above requirements is outside stated ranges 51 Eliminate System Leaks Continuous addition of make up water will constantly add oxygen to system Eliminate all system leaks All system leaks must be repaired immediately DO NOT use stop leak compounds Leaks in threaded connections in aluminum boiler sections must be repaired immediately Aluminum threads will not seal themselves Verify expansion tank is operational and properly sized Undersized expansion tanks cause relief valve weeping and substantial make up water addition Operation of this boiler in system containing significant amounts of dissolved oxygen can cause severe heat exchanger corrosion damage This boiler is not designed for use in systems containing regular additions of make up water Regular additions of make up water may cause severe heat exchanger damage System leaks may not always be visible An unseen system leak will become obvious if boiler pressure decreases when make up valve is closed This boiler is designed for closed loop hydronic heat system ONLY This boiler is not suitable for natural gravity type installations or any other open type system System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas Fired Water Boilers General Guideli
51. ion for domestic hot water delivery In event the customer has a concern that it takes too long for hot water the situation may be resolved in three ways A Add a Domestic Hot Water Module ECR part Number 240009562 Honeywell part number W8375s1008 This control senses when hot water is being drawn and instructs the integrated boiler control to bypass the thermal purge operation until domestic how water draw ends Thermal purge will then be re enabled DHW module incorporates a temperature sensor installed at the indirect water heater s hot water supply fitting Note this sensor is in addition to not in place of the limit control on the hot water tank The Module is connected to the Enviracom terminals in the Integrated Boiler Control Thermal purge parameters may be adjusted higher thermal purge temperature limit and or shorter thermal purge time delay to bring the burner on sooner C Thermal purge function can be disabled B Gas Control Valve Electrically controlled Combination Gas Control Valve is designed to meet requirements for use with direct ignition systems found in this boiler Valve is piped to gas air mixer Direct Spark Igniter Direct spark igniter utilizes a spark gap to initiate gas combustion in the burner Igniter is mounted next to burner through gas air mixer The igniter also serves as means for proving main burner flame by flame rectification In the event of a lack of flame signal on three 3
52. lace them immediately Insure proper reassembly and resealing of vent and air intake system C Check for and remove any obstruction to flow of combustion air or venting of flue gases Check air baffle located inside 1 x 2 flexible coupling on mixer clean if necessary and make sure to put it back Refer to repair parts diagram of mixer and pressure switch assembly for exact location D Follow instructions Instructions on page 38 E Follow instructions for Check Out Procedure and Adjustment on page 42 F Visually inspect condensate drain lines for proper operation and deterioration Check for plugged condensate drain lines G Check silicone rubber seals between boiler sections Insure that there are no leaks Use RTV silicone rubber adhesive sealant rated for at least 400 F to replace or repair seals in locations where original seals have deteriorated H Check all gasketed joints for leakage and tighten bolts or replace gaskets if necessary I Remove jacket front and top panels and check for piping leaks around relief valve and other fittings Repair if found DO NOT use stop leak compounds 2 Check boiler area is free from combustible materials gasoline and other flammable vapors and liquids 3 Circulator pump and blower motor furnished with boiler are permanently lubricated from factory and require no further lubrication Additional or non factory supplied pumps and or motors shoul
53. ler as close to selected location as possible and un crate boiler Boiler may be moved into position with appliance dolly or 2 wheel hand truck Insert dolly or hand truck under left hand side of boiler It is possible to slide boiler for short distance on smooth floor or surface 1 Select level location central to piping systems served and as close to vent and air intake terminals as possible 2 Accessibility clearances if more stringent i e larger clearances than required fire protection clearances must be used for boiler installation Accessibility clearances may be achieved with the use of removable walls or partitions 3 Boiler is approved for installation in closets and on combustible floors This boiler shall NOT be installed on carpeting 4 Clearances shown in Table 4 indicate required clearances Maintain minimum 1 clearance between combustible construction and each of left top and back surfaces of the boiler Minimum 11 clearance is required on right side to allow room for induced draft blower Maintain 18 clearance at side where passage is required to access another side for cleaning or servicing inspection or replacement of parts Allow 24 at front and left side and 8 at top for servicing No clearances are required to venting or combustion air intake piping 5 Install equipment in location which facilitates operation of venting and combustion air intake piping systems as described in this manual
54. line Install isolation fittings nearest boiler prior to system piping connections WATER TREATMENT and ANTI FREEZE PROTECTI ON MUST be applied for ALL aluminum series high efficiency gas fired boilers using antifreeze protection 30 System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas Fired Water Boilers Clean System First BEFORE connecting boiler to heating system clean and flush system thoroughly Verify system is free of sediment flux and any residual boiler water additives Systems having antifreeze not recommended must be completely flushed to ensure no old antifreeze remains In older systems obviously discolored murky or dirty water or pH reading outside acceptable range between 7 0 and 8 0 are indications the system should be cleaned or treated Thoroughly flush system with clean water to remove any sediment or contaminants Sludge and iron oxide deposits can cause rapid breakdown of inhibitors Flushing with clean water If chemical cleaners are used use only those recommended for use with aluminum boilers Follow chemical cleaner manufacturer s instructions completely DO NOT mix different manufacturer s products Fill Water and Chemistry Verify water used to fill system meets these requirements System fluid pH maintained between 7 0 and 8 0 Maintain water hardness below 7 grains hardness Filing with chlorinated potable water is acceptable DO NOT fill boiler with water contain
55. lity or distributor for Btu value of gas 10 BEFORE INSTALLING THE BOILER Boiler is equipped for residential installations If used for commercial applications any additional code requirements must be adhered to for installation This may require additional controls including but not limited to a low water cut off a manual reset high temperature limit and wiring and or piping modifications Before servicing boiler allow boiler to cool Shut off electricity and gas supply connected to boiler prior to servicing Inspect gas line for leaks Verify gas input rate is correct Over firing may result in early failure of boiler sections This may cause dangerous operation Under firing may result in too much air for pre mix burner causing poor or loss of combustion Never vent products of combustion from this boiler to enclosed space Always vent to outdoors Never vent to another room or to inside building Be sure there is adequate outdoor air supply to boiler for complete combustion Follow regular service and maintenance schedule for efficient and safe operation Keep boiler area clean of debris and free of combustible and flammable materials Proper through wall or through roof combustion venting Shall be in accordance with materials and methods described in this manual Installation must comply with local codes Boiler and related hot water heating systems are not do it yourself items they must be installed and servi
56. ly piping system during any system pressure testing at test pressures in excess of V psig 3 5kpa Boiler must be isolated from gas supply piping system by closing its individual manual shutoff valve during any pressure testing of gas supply piping system at test pressures equal to or less than psig 3 50ka Connecting The Gas Piping See Figure 19 Page 29 for general layout at boiler Gas line enters boiler from right side jacket panel Boiler is equipped with 2 NPT connection on gas valve for supply piping Following rules apply 1 Use piping materials and joining methods acceptable to authority having jurisdiction In absence of such requirements e USA National Fuel Gas Code ANSI Z223 1 NFPA 54 e Canada Natural Gas and Propane Installation Code CAN CSA B149 1 Size and install gas piping system to provide sufficient gas supply to meet maximum input at not less than minimum supply pressure See Table 7 Page 29 Use ground joint unions Provide sediment trap up stream of gas valve Use two pipe wrenches when making the connection to gas valve to keep it from turning Install a manual shutoff valve in the vertical pipe about 5 feet above floor Tighten all joints securely Propane gas connections should only be made by licensed propane installer Two stage regulation should be used by propane installer Propane gas piping should be checked out by propane installer 10 A DANGER Fire Hazard
57. m gt lt ye ui Combustion 2 Air 1 2 54cm 4 7 at Maximum p uides a p 12 30cm Minimum 5 36 0 5m Minimum _ Maintain clearance above highest anticipated snow level or grade Combustion Air Must be less than 4 or greater than 24 Horizontal dis tance between end bells of each air intake to prevent flue gas recirculation Figure 16 Concentric Vent A STRAP FIELD SUPPLIED ELBOW FIELD SUPPLIED 1 MAXIMUM COMBUSTION AIR NOTE SECURING STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT IN SIDE WALL 26 Figure 17 Concentric Vent Roof 1 nstallation NOTE VENT SUPPORT MUST BE FIELD INSTALLED TO T D SECURE TERMINATION KIT TO STRUCTURE o COMBUSTION AIR FIELD SUPPLIED Dr FIELD SUPPLIED SUPPORT FIELD SUPPLIED MAINTANIN 12 IN 18IN FOR CANADA MINIMUM CLEARANCE VENT ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN ABOVE ROOF COMBUSTION AIR AND VENT PIPE Figure 18 Combustion Air and Vent Piping Boiler Connections VENT INTAKE 2 COMBUSTION AIR TERMINATIONS INTAKE PIPING 2 CPVC VENT PIPING FURNISHED 2 CPVC COUPLING FURNISHED 2 50 8 DIAMETER VENT AND COMBUSTION AIR INTAKE PIPING 21 feet maximum total equivalent length for 90 100 mo
58. n should be kept at least 3 ft away primer and cement from vegetation 6 Clean and dry all surfaces to be joined USA only Venting system shall terminate at least 4 7 Check dry fit of pipe and mark insertion depth on pipe ft horizontally from and in no case above or below unless 4 ft 1 22 horizontal distance is maintained 8 After pipes have been cut and pre assembled apply from electric meters gas meters regulators and relief cement primer to pipe fitting socket and end of pipe to equipment insertion mark Quickly apply approved cement to end Canada only Venting system shall terminate at of pipe and fitting socket over primer Apply cement least 6 ft 1 83m horizontally from in no case above in light uniform coat on inside of socket to prevent pe 4 buildup of excess cement Apply second coat or below unless a 6 ft 1 83m horizontal distance M 2 9 While cement is still wet insert pipe into socket with is maintained from electric meters gas meters oe regulators and relief equipment mE twist Be sure pipe is fully inserted into fitting Vent shall not terminate within 6 ft 1 8m of 10 Wipe excess cement from joint Continuous bead of NM cement will be visible around perimeter of properly Vent shall not terminate above regulator within 3 made joint TE 00 vertical line oP 11 Handle pipe joint carefully until cement sets regulator vent outlet to maximum
59. nes When Using Antifreeze Use only antifreeze products recommended for use with aluminum boilers as listed in this addendum See Table 11 Continuous addition of make up water will dilute power of antifreeze and change buffers ability to maintain pH Flush old antifreeze from system Flush boiler and system separately Do not use antifreeze unless required Antifreeze if needed must be of type listed on next page due to their operational characteristics of type 356 T6 aluminum at operating temperatures between 20 F 6 79C and 250 F 1219C See Table 11 for allowable products Always clean system prior to using antifreeze as stated in this supplement Follow antifreeze manufacturer s instructions for use safe handling and storage of their products Refer to MSDS Material Safety Data Sheets provided by antifreeze manufacturer for potential hazards and first aid procedures for exposure or ingestion Antifreeze will raise pH of hydronic solution in heating system above recommended level due to corrosion inhibitors Solution must be treated to maintain a pH within recommended level Follow antifreeze manufacturer s instructions to adjust pH If system has leaked water and antifreeze chemistry will need to be adjusted To avoid damage to boiler check pH and chemistry of boiler solution and consult the antifreeze manufacturer for recommendations 52 Recommend taking pH reading annually and adjusted as ne
60. or aluminum oxide on inside surface must be cleaned Position draft inducer gasket and draft inducer and fasten with four 4 screws Be sure to connect ground wire from draft inducer motor to one of four mounting screws Connect wiring harness leads to draft inducer motor and draft inducer temperature safety switch Connect vent pipe connector to draft inducer outlet TROUBLESHOOTI 2 Troubleshooting tools A Voltmeter to check 120 vac and 24 vac Fire explosion or shock hazard Do not attempt to B Continuity tester C Inclined manometer or pressure gauge with 0 3 0 Range 0 01 Scale for measuring suction pressures at pressure switch D U tube manometer or differential pressure gauge with 0 14 range 0 1 Scale for measuring inlet and manifold gas pressures modify the physical or electrical characteristics of this boiler in any way Failure to comply could result in death or serious injury Important 1 In reset from lockout condition all electrical meter readings at the gas control valve 24 vac must be taken within trial for ignition period 3 IBC Error Codes 2 If any component does not function properly make A IBC uses advanced diagnostic capability to assist in sure it is correctly installed and wired before replacing troubleshooting error conditions Table 10 Page 48 it shows error codes that may arise during fault 3 Static electricity discharge can damage integrated con
61. orming moisture and may be corrosive Take steps to deck unless prevent building materials at vent from being damaged by exhaust of flue gas a veranda porch or deck is fully open on minimum of two sides beneath floor and e Vent shall not terminate where it may cause hazardous b distance between top of vent termination and ice accumulations on adjacent property underside of veranda porch or deck is greater than 1 ft 300mm Venting system shall terminate at least ft 0 9m See figures 12 and 13 and 14 for two pipe terminations above id forced air inlet except boiler s combustion See figures 15 16 and 17 for concentric vent terminations air inlet within 10 ft 3m Venting system shall terminate at least 12 in from Installation air opening into any building 1 Attach combustion air intake piping using field supplied e Vent bottom shall be located at least 12 in above 2 flexible coupling Attach vent piping to furnished 2 grade vent pipe connector on draft inducer outlet e Termination of the vent shall be not less than 7 ft 2 All pipe joints are to be water tight 2 1m above adjacent public walkway or paved 3 Working from boiler to outside cut pipe to required driveway length s e Vent terminal shall not be installed closer than 3 ft 4 Deburr inside and outside of pipe URB al 5 Chamfer outside edge of pipe for better distribution of e Vent terminatio
62. osed Type Expansion Tanks Refer to the appropriate diagrams Near Boiler Piping on page 11 for more information 1 Close all zone service valves on the supply and return piping and close the expansion tank service valve Drain expansion tank Open the feed valve and fill boiler with water Hold relief valve open until water runs air free for five seconds to rapidly bleed air from boiler then let the relief valve snap shut 2 Open the zone service valve on the supply pipe for the first zone Open the purge valve on the first zone Feed water will fill the zone pushing air out the purge valve Close the purge valve when the water runs air free Close the zone service valve 3 Repeat step 2 for all remaining zones 4 Open the expansion tank service valve and the tank vent Fill the tank to the proper level and close the tank vent Remove the handle from the expansion tank service valve so the homeowner doesn t accidentally close it 5 Open all service valves Any air remaining trapped in the return lines between the service valves and the boiler will be pushed towards the expansion tank when the boiler is placed in operation 6 Inspect piping system Repair any leaks immediately 37 OPERATI NG I NSTRUCTI ONS If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not
63. point below actual boiler water temperature Burner should go off while circulator continues to operate Raise limit setting above boiler water temperature and burner should reignite after inter purge retry delay Set high limit control to design temperature requirements of system Maximum high limit setting is 190 F Minimum high limit setting is 80 F 42 Test Other Safety Controls If boiler is equipped with low water cut off manual reset high limit or additional safety controls test for operation as outlined by control manufacturer Burner should be operating and should go off when controls are tested When safety controls are restored burner should reignite Set Thermostat Heat Anticipator If Used And Verify Thermostat Operation For single thermostat connected to yellow thermostat lead wires in furnished field wiring junction box heat anticipator should be set at 0 7 amps For other wiring configurations refer to instructions provided by thermostat manufacturer regarding adjustment of heat anticipator Cycle boiler with thermostat Raise thermostat to highest setting and verify boiler goes through normal start up cycle Lower thermostat to lowest setting and verify boiler goes off Measure Natural Gas nput Rate Correct input rate is essential for proper and efficient operation of the burner and boiler 1 Determine elevation at installation site 2 Table 1 and Table 2 Page 6 to determine correct input rate for t
64. ral operating cycles to verify proper operation on gas valve Turn boiler on G Boiler should typically operate between e 8 5 10 0 CO2 on Natural Gas Review All nstructions Review all instructions shipped with this boiler with owner e 9 5 11 0 CO2 on Propane Gas or maintenance person Instructions must be affixed on or Under all conditions CO level should not exceed 100 adjacent to the boiler ppm Complete and sign the I nstallation and Check Out 9 Restore all gas appliances that may have been shut off Certificate on page 54 while measuring boiler input rate to normal operating conditions I Remove regulator cover screw on top of gas valve and insert an appropriate screwdriver into adjustment Screw IT Turn adjustment screw clockwise to increase input rate or counter clockwise to decrease input rate III Replace cover screw or cover hole temporarily with your finger to check new manifold pressure setting Do not set manifold pressure lower than 2 0 inches w c or higher than 3 0 inches w c when adjusting input rate IV Measure new input rate cover screw must be installed Repeat steps I IV until the input rate is within 2 of the nameplate input rating V If the actual input rate can not be set to within 2 of the correct input rating by adjusting manifold pressure a change in gas orifice size is required Consult the boiler manufacturer for information on correct orifice sizing The specific g
65. ram o DA P1 2 CO Pi 1 OH 4 CIRCULATOR Cr O 4 P1 5 3 1 P2 1 INDUCER OH 2 3 OH 2 5 P2 2 P2 4 2 6 CH P3 1 CH 3 2 CH p3 3 SPARK IGNITER FLAME SENSE OA T POS o 3 8 22 posg 4 7 1 27 2 27 3 4 2 4 OOO 120 24 5 TRANSFORMER 32 PRESSURE SWITCH INDUCER TEMP SWITCH CASTING TEMP SWITCH THERMOSTAT GAS VALVE HIGH LIMIT TEMPERATURE SENSOR ELECTRI CAL WI RI NG Figure 22 Suggested Wiring Schematic for Domestic Hot Water Priority Two Zone System with Circulators Using Argo AR82211 Pump Relay BOILER 24 VOLT CH THERMOSTAT DHW TEL AQUASTAT YEL CH CIRCULATOR DHW CIRCULATOR NOTE WHT REMOVE FACTORY INSTALLED JUMPER BETWEEN L1 AND 3 WHT ON AR822 II CONTROL d d gt gt E I mm BOILER JUNCTION BOX 33 ELECTRI CAL WI RI NG Figure 23 Ladder Diagram for Figure 22 BOILER 24 VOLT CH JUNCTION BOX THERMOSTAT AR822 II 6 NC T STAT 6 NO CIRCULATOR T3 CIRCL 2 7 DHW NO CIRCULATOR DHW AQUASTAT TW ast d Im
66. rature decreases 10 309 adjustable differential Differential can be adjusted to provide flexibility for boiler operation Larger the differential longer run cycle of boiler Thermal Purge Operation 1 Thermal purge feature complies with 2012 DOE and NRCan requirements that boiler control must incorporate automatic means to adjust water temperature Intent of thermal purge is to insure usable residual heat in the boiler is circulated until it is sufficiently depleted from the system before the burner is allowed to fire To that end on call for heat burner is held off while circulator runs until boiler temperature drops to thermal purge temperature limit or time delay is exceeded Both of these parameters are adjustable When boiler temperature falls below thermal purge temperature limit or time delay expires burner is allowed to fire In addition to thermal purge temperature and thermal purge time delay parameters two other conditions release integrated boiler controller from thermal purge and allow burner to run in order to maintain comfort in the space e Boiler temperature has dropped 10 F from boiler water temperature measured at beginning of the call for heat 35 e Boiler temperature is cooling at a rate greater than 5 F minute while circulator is running 4 For Installations using Indirect Hot Water Heater Depending on the specific installation thermal purge delay might or might not affect end user s expectat
67. ravity G and the higher heating value HHV of the local natural gas must be obtained from the local gas utility in order to determine the proper orifice size 43 CHECK OUT PROCEDURE AND ADJUSTMENT Figure 27 Manifold Pressure Measurement Detail Following steps and diagram indicate location of the Refer to Differential Air Pressure Switch Check on page connection points required to measure manifold pressure 49 when reading manifold pressure Manifold pressure may be measured using a U Tube When measurement is complete disconnect U Tube Manometer or Differential Pressure Gauge Diagram shows Manometer or Differential Pressure Gauge Be sure to connection of both measuring devices Only ONE DEVICE IS reinstall plug using appropriate pipe thread sealant REQUIRED to measure manifold pressure approved for use with natural and liquefied Petroleum Remove plug Install appropriate barbed fitting and connect gases pressure side line from U Tube Manometer or Differential Pressure Gauge PRESSURE REGULATOR ADJUSTMENT UNDER COVER SCREW ___ GAS VALVE VENT OUTLET PRESSURE TAP 1 8 PLUG _ CROSS CONNECTOR W CAP D TO PRESSURE SWITCH WHITE TRANSPARENT VINYL TUBING PRESSURE REFERENCE PRESSURE DIFFERENTIAL PRESSURE GAUGE MANOMETER Figure 28 Gas Valve PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW WIRING TERMINALS 2 N OTI C VR8205 Regulator cover screw must be installed at
68. shed may be used if floor drain is not available e Condensate pump must be designed for flue gas con densate application e Condensate trap provided with boiler an additional trap is not required and should not be used e Wood frame or blocks may be used to raise boiler 4 to maintain drain pitch or to be above external condensate pump reservoir 5 Foundation Requirements e nstall boiler on level surface 6 Fire hazard Do not install boiler on carpeting Failure to follow these instructions could result in death or serious injury e Boiler is NOT to be installed on carpeting 7 e f boiler is not level condensate drain lines will not function properly Adjustable feet are located on the boiler to make up for minor surface irregularities or tilt e Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reservoir Removal of Existing Boiler From Common Vent System When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in the common venting syst
69. structions End of Each Heating Season Annual Shutdown Procedure Follow instructions To Turn Off Gas To Appliance on page 38 If heating system is to remain out of service during freezing weather and does not contain antifreeze drain system completely If boiler will be exposed to freezing temperatures drain condensate lines Otherwise do not drain system or boiler 45 MAI NTENANCE AND CLEANI Annual Examination And Cleaning Of Boiler Com onents A DANGER Before servicing turn off electrical power to boiler at service switch Close manual gas valve to turn gas supply OFF to boiler Failure to comply will result in death or serious injury Have qualified service agency perform the following service procedures Boiler owner should not attempt these procedures 1 Before Servicing turn off electrical power to boiler at service switch Close manual gas valve to turn off gas supply to boiler 2 Cleaning Flue passages between boiler sections Any buildup of sediment aluminum oxide white powdery or flaky substance in flue passages must be cleaned as follows Remove jacket front and top panels Disconnect condensate drain line from barbed fitting on bottom of boiler Keep open end of drain line above water level in condensate trap to prevent trap from draining Disconnect pressure switch hose from barbed fitting on gas valve Disconnect 1 2 x 2 flexible coupling
70. ty of the boiler This can result in very low flow in the boiler if only one small zone is calling for heat Primary Secondary Piping is recommended for multi zone systems with more than two zones to insure proper water flow through the boiler at all times See figures 5 6 and 7 for typical primary secondary piping configurations Figure 3 Two Zone Boiler Piping With Zone Valves RETURN FROM ZONE SERVICE E ee VALVE a2 X PURGE DRAIN E VALVES NY SX A R A ZONE SERVICE d VALVE SUPPLY TO p um E P SERVICE VALVE ZONE VALVE us 13 NEAR BOILER PI PING Figure 4 Two Zone Boiler Piping With Circulators RETURN FROM AS ZONES ZONE SERVICE u amp 552 VG PA VALVE 7 55 xl n Ra VALVES SK ES 6 SS ZONE SERVICE 2 5522 VALVE SUPPLY TO E ZONES p ZONE SERVICE VALVE PURGE DRAIN FLOW CHECK VALVE 14 NEAR 801 LER PIPING Figure 5 Primary Secondary Piping And Wiring With Circulators And Domestic Hot Water WATER INLET ZONE 1 PRIORITY ZONE 12 MAX APART PREVENT FORCE FLOW IN SECONDARY B EXPANSION BOILER TANK PUMP T CH amp DHW BOILER FLOW CONTROL Cj VALVE PRESSURE CIRCULATOR 7 REDUCER VALVE SHUT OFF E CHECK
71. ust be made outside of boiler casing in vertical run of pipe to allow for proper drainage of vent condensate Due to potential for flue gas temperatures over 155 F first five 5 feet of vent pipe must be CPVC the remain ing vent pipe can be PVC If any elbows are employed within the first 5 feet of vent they must be CPVC too Two 2 30 pieces of 2 CPVC pipe 21 2 piece of 2 CPVC pipe a 2 CPVC elbow and 2 CPVC pipe coupling are furnished with the boiler 22 6 Combustion air and vent piping lengths Table 5 Page 23 First 5 ft of vent piping run must be 2 CPVC Length of pipe is counted from boiler jacket air intake pipe or from vent pipe connector vent pipe Termination is not counted toward the Total Equivalent Length For elbows reduce maximum vent length as shown e 2 90 elbow 1 ft per elbow e 3 90 elbow 3 ft per elbow Example To add two 2 90 elbows to a 3 pipe for a 75 boiler Each elbow is 3 ft per 90 elbow for a total of 6 ft 1 elbow 3 ft 1 elbow 3 ft 6 equivalent ft of pipe Total additional pipe is then subtracted from maximum allowable pipe length to give new maximum length of 106 ft with two 2 90 elbows TOTAL EQUIVALENT LENGTH Original 112 ft max 6 equivalent ft for 2 elbows new 106 ft maximum length 7 Pitch combustion air and vent piping back to boiler at 8 minimum per ft 21 mm m from intake and vent termin
72. valve provides means of draining water in heating system including boiler and hot water supply and return piping systems installed above drain valve This drain valve is installed in 34 tapping at bottom of front boiler section Any piping installed below elevation of this drain valve will require additional drain valves to be installed at low points in piping systems in order to drain entire system A S M E Rated Pressure Relief Valve Each boiler must have a properly sized and installed American Society of Mechanical Engineers rated pressure relief valve Water expands as it is heated by burner boiler sections If there is no place for water to expand its volume i e a properly sized and properly functioning expansion tank pressure on inside of boiler and heating system will increase Furnished relief valve automatically opens at 30 psig pressure to relieve strain on boiler and heating system from increasing pressure Pressure relief valve discharge must be piped with piping same size as valve discharge opening to open drain tub or sink or other suitable drainage point not subject to freezing in accordance with A S M E specifications and requirements of local jurisdiction External Condensate Pump Optional For installations where there is no floor drain or other appropriate drainage receptacle available to receive condensate from the boiler an external float activated condensate pump with integral sump is required This unit
73. y hazards Obey all safety messages following this symbol to avoid possible injury or death A DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Used to address practices related to personal injury Installation shall conform to requirements of author ity having jurisdiction or in absence of such require ments e United States e National Fuel Gas Code ANSI Z223 1 NFPA 54 e National Electrical Code NFPA 70 e Canada e Natural Gas and Propane Installation Code CAN CSA 5149 1 e Canadian Electrical Code Part I Safety Standard for Electrical Installations CSA C22 1 Where required by authority having jurisdiction installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Additional manual reset low water cutoff and or manual reset high limit may be required Requirements for Commonwealth of Massachusetts Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to e nstallation by licensed plumber or gas fitter I nstallers Follow local regulations with respect to installation of CO Carbon Monoxide Detectors Follow m

Lennox International Inc. Water Dispenser Gas-Fired Hot Water Boiler User's Manual

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