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AAA SERIES GAS BOILERS

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3. dWnd avv annous 9 HOLIMS zal 440 NO quon mA INVIA TYNOLLdO a INVHOVIG SILVWSHOS AAA Series Gas Boiler Installation and Service Manual 30 AAA Series Gas Boiler Installation and Service Manual NOILINSI 9INOSIO93 13 HIM SVD ONILVINGOW TINA LL 61 791 3 ISAW 43108 3 TWNOLLWN ANVSS3O3N 31 ATEWASSV 10719 30VId3M 1314 LON 8350 38 LSAW SLI YO 2 501 HL HIM 3 SV 3MIM TVNI9IHO SHL JO ANY dl 3002 12071 YO IVIONIAOMd V l13Vd ONIDIAN3S MO QNV ON 140448 YAMOd LOANNOOSIC 3M3A3S ASN 722 v SIN3A3MIQnO3H 3002 1V901 MO 5 IVNOIIVN S3HIO0 ANY CNY OZ Vd3N 39NVQSOOOV NI G3TIVISNI HIV3G VO NYO QMVZVH MOOHS IVALON 34v SAXIM AYAI 1014 d3ovid3M 38 522232 9 SNY vsn 0 38 ISAW ONIMIM SALON ONIN3VM FTIVISNI NOSN3S uvas 5 I O aNd a 0325 1079 LH M A oo ot AN 9 assn
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5. Faulty aquastat thermostat or zone valve Check and replace if necessary Pilot not lit Poor flow in boiler or circulator failure Relight standing pilot For electronic ignition see Pilot flame will not light on electronic ignition Check pump for proper capacity amp flow direction Replace if necessary Thermostat heat anticipator or aquastat set too low Check and adjust Boiler oversized or insufficient radiation Check and adjust if necessary Wrong type of thermostat or controller Gas valve failure open position Check and replace if necessary Check gas valve replace if necessary Faulty wiring Check wiring of aquastats zone valves and thermostats for short circuits or incorrect wiring Faulty aquastat zone valve or thermostat Boiler is overheated and safety high limit aquastat fails to cut out Check and replace if necessary Check aquastats and adjust or replace if necessary Improper wiring Check and correct Foreign matter in heat exchanger Flush heat exchanger if necessary Poor circulation Check pump for correct flow Air trapped in heating system 32 Purge air Problem Gas odor Flame roll out on ignition or during operation Pilot outages with standing pilot Pilot flame will not light on electronic ignition Pilot lights but flame failure after trial for ignition Burner starts but
6. 20 4 6 Gheck Input amp OrifiCGs Dr HAC ERE EEG ERR SUPCR EVO 21 4 7 Check for Draft Hood Spillage ccc ttt t REPRE ERR Pede 22 4 8 Check ot Gontrols cedit caet e stay atrii cei entr Eee atte E 22 4 9 Check for Gas Leaks a en added uses doar ade eg 22 4 10 Installers Checklist nennen nennen nennen nene n sint nnns entes entere nnns 23 5 Service amp Maintenance 24 5 1 Service amp Maintenance 24 5 2 Gleaning Procedlle ne nn deti pe iade ep e bete eee 24 5 3 Seice Checkliste otto etapa Io eus OU ete wht n eet in ie 25 5 4 Caution Water Replenishment ssssssssssssssssssseseeee eene enne nnne enter 26 5 5 Refractory Handling 0444000 26 6 Replacement 27 7 MWiring Diagrams nee bed ne bestia ween de se II 29 8 Troubleshooting Guide iren Lecce decree 32 9 34 10 E
7. INSTALLATION AND SERVICE MANUAL AAA SERIES GAS BOILERS FOR MODELS AAA 480 TO AAA 3000 Featuring the BTC SERIES Controller on 1 amp 2 stage models See rear cover for Index WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or loss of life Please carefully read this manual For assistance or additional information consult a qualified installer service agency or the gas supplier Manufactured by Allied Engineering Company Division of E Z Rect Manufacturing Ltd Manufacturers of Gas and Electric Boilers Stainless Steel Tanks Heat Exchangers and Electric Boosters 94 Riverside Drive North Vancouver B C V7H 2M6 Telephone 604 929 1214 www alliedboilers com Branches Calgary Edmonton Toronto PN3362421 ALTERNATE SUPPLY OUTLET RETURN INLET The Super Hot product improvement program may r ALTERNATE RETURN INLET DIMENSIONS AND SPECIFICATIONS Standard Model Includes D GAS MALE NPT VATER CONNECTION CONNECTION F SIDE VIEW 44 cm 56 142 2 cm Electronic Ignition Stainless Steel Burners Gas Valve Redundant Gas Valve BTC SERIES Microcontroller single and two stage models only Operating Safety High Limit
8. TINGOW 55349 55349 NOILINO ANS vel d SYD MOTs SHO INIOd log os so Mo wv 54 54 151 o 93 AN 9 INVA ON ON D Sv INVA N3HM 5 INVONNGEY 2915 1915 HOLIMS SS3Md HOLIMS SS3ud lVISvnOv 035 N3HM 9 1 j Sv9 5 OML V ONILWY3d0 299 9 0AM 2 au 1 98 EB gt 55 S asna 5 2 2 ve A gt 2 8 90A vZ 5 INON WOL98S TIJMA3NOH P AT rg 2 9018 TWNINUAL EE NSO NO S SLOVINOD ANG 021 3AOW3N oom BEES 2 2 zo Tain aasn N3HM dhd 021 N3HM 110 Ind JNIOd GE nO HOLIMS MOTA N3lVM MOT VA Ov S3RSOJSNVL yva LS Sth CES he rosy errs 2 6 O p 2 550 5 n Lus CM Ln PIA YOLVOIONI YIMOd yvig ame n q38 a ama HOLMS HOLIMS 222 25 LDS 9 0 05 91735 30 440 NO 440 NO 2 5 5 915 6l HQ 0 108 21 555 2 g ENT S 5 915 00 NI 108 8 C IHM 4 A 4 a 3 INON C NINGL OL OZ e 2 23 X8 1N3Adino3 19712 ue Tahe op E SU3HLO A8 su3H10 A8 9 EHH ng u t z
9. 5 109 AAA M HOLMS ss3sd SS3Nd INISVnOV NWA SVO TINTON SVO MOT 5 9 NN NOLLINDI 504 AWA Sv9 ANVONNGSY d 021 1 E E e ok iori E 5 M3T10MINOO 0350 N3HM 440 102 oL HOIIMS MOT cht 255 3NNA 5 9 Mud O A M ok e E e e tt i ANA 5 9 E ONILVINGON soy si YOLVOIGNI YIMOd 5 HOLIMS HOLIMS 440 NO 440 NO e A A ws Att 58310 Ag 58310 Ag AVIY dNNd ya 90A 0601 V l 55 12 OJN 13 55 12 OdN ONIMIM 13 l SSVIO O3N AO 55 12 O3N AO JV IVd 1 Bde QN3931 HOLIMS 3 055344 5 9 5340038 u mg 0000062 83 0 3 3108 V N3HM 1 22018 WN LON N3HM 1 52018 VN 70 39018 NO 717 WANWA S HOlVAIOV JHL ONIMOTIOS x9018 VNIAH3L NO 8 M STWNIAYSL HOLIMS 1 NO 9 S 57 HOLIMS WnNvW O1nv ONISN NO v STWNINNSL OL AlddNS 25A OZI TINO SaSOdund 344 1531 l93NNOO 804 TIVO v ONINNG Q3HOv3N 5 AHL OL 300 SN3dO HOLIMS 34055344 5 9 YO IVISVnOV HOIH NAHM JAM
10. The abbreviated name of the selected item will be displayed in the item field of the display To view the next available item press and release the Item button Once you have reached the last available item in a menu pressing and releasing the Item button will return the display to the first item in the selected menu Adjust To make an adjustment to a setting in the control begin by selecting the Adjust menu by pressing and holding simultaneously all three buttons Then select the desired item using the Item button Finally use the A or V button to make the adjustment 14 AAA Series Gas Boiler Installation and Service Manual BTC Series Display Items in Installer Mode VIEW MENU Item Field in Mode Description OUTDR 4 5 Outdoor air temperature measured by outdoor sensor BOIL 1 2 3 4 5 Target boiler supply temperature the control is trying to maintain at the boiler TARGET supply sensor or the boiler outlet sensor BOIL SUP 2 5 Current boiler supply water temperature as measured by the boiler supply sensor BOIL OUT 1 3 4 6 Current boiler outlet water temperature as measured by the boiler supply sensor BOIL IN All Current boiler inlet water temperature as measured by the boiler inlet sensor BOIL AT All Current T temperature difference between the boiler outlet sensor and the boiler inlet sensor TANK 3 Current DHW tank temperature as measured by the DHW s
11. Avoid unnecessary replenishment of system water It can allow oxygen to enter the system and cause serious corrosion problems As well an excessive amount of minerals may be deposited in the heat exchanger Do not draw water from the heating system for cleaning flushing etc Any audible sounds in the boiler system may be indications of scaling or lack of sufficient water flow and the system should be checked without delay Scaling is due to improper maintenance It is not the fault of the boiler Scale damage is not covered by warranty 5 5 REFRACTORY HANDLING PROCEDURE WARNING The mineral block and fiberglass wool used in this product are RCFs Refractory Ceramic Fibers RCFs pose a possible cancer hazard by inhalation and can cause respiratory skin and eye irritation After mineral block has been fired it will produce increased levels of nuisance dust and poses increased carcinogenic risk Follow the precautionary measures below before attempting service or access PRECAUTIONARY MEASURES e Avoid breathing fibers and contact with skin and eyes e Use a National Institute for Occupational Safety and Health NIOSH approved dust mist respirator e Wear long sleeved loose fitting clothing gloves and eye protection e Wash work clothes separately from other clothing Rinse washer thoroughly e Operations such as sawing blowing tearout and spraying may generate airborne fiber concentration requiring additional protec
12. Gas piping has been purged and checked for leaks with a soap solution 2 2 2 4 4 9 System is filled with water and all air has been purged Only oxygen barrier 42 45 tubing has been used ro A manometer has been used to check the manifold pressure and gas supply 42 45 pressure against requirements printed on boiler rating plate NE Bypass or mixing valve has been used to prevent return water less than 2 10 135 F All applicable venting codes have been met Air openings sized to provide adequate supply air for combustion flue gas dilution and ventilation and will 2 2 2 5 2 6 2 7 not be blocked off Check for spillage at draft hood and other areas susceptible to spillage 4 7 Operate the boiler for 15 minutes then clock and calculate Btu h input rate The input rate must not exceed that specified on the boiler rating plate 4 6 Clocked BTU H Input Rate Set BTC Series Controller mode of operation and other applicable 31 32 33 34 parameters See BTC Series Controller Manual for detailed information Puy TETTE EA Perform check of temperature controls aquastat high limit aquastat and 4 4 4 8 thermostat Test any other controls as specified by the manufacturer Visually inspect main burners and pilot to ensure proper flame operating 43 characteristics and ignition extinction is ok Allow the boiler to cycle a few times to ensure functions are operating correctly Close main shut off valve and check
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14. CM Outdoor Optional Outdoor Sensor for Mode 4 and 5 only Connect Sensor Outdoor Sensor 070 to terminals OS and CM common The Outdoor Sensor is installed on an exterior wall typically facing North and above the snow line It should be shielded from effects of heat or cold to prevent false outdoor temperature readings Avoid direct sunlight exhaust fans appliance vents and excessive moisture SD amp CM Supply DHW Optional for Modes 2 3 and 5 only Connect a Supply or Sensor DHW Sensor 071 to terminals SD and CM common The Supply DHW sensor is inserted into a thermowell on the DHW tank or attached using a cable tie to the supply pipe AL amp AL Alarm Optional The alarm contacts are a powered output do not apply power Connect an alarm beeper light or relay with a rating of 24 Vac and maximum 0 45 A to terminals AL and AL FS amp FS Flow Switch Not used Leave Jumper 5 6 on TB4 For convenience the Flow Switch terminals have been relocated to terminal block TB2 poles T1 amp S Do not apply power ST amp R Setpoint DHW Optional Domestic Hot Water Aquastat for Modes 4 and 5 Demand only Connect domestic hot water aquastat to terminals ST and R Closed is activation Do not apply power HT amp R Heat Demand Connect Thermostat or Zone Valve End Switch to terminals HT and R Closed is activation Do not apply power AAA Series Gas Boiler Installation and Service Manual BTC SERIES Controller Information Se
15. Mode 5 Outdoor reset with reset override using primary secondary piping Operates stages to maintain an outdoor reset temperature at the boiler supply sensor When there is a call for reset override from the DHW aquastat i e ST amp R is closed the control operates the stages to maintain a setpoint temperature at the boiler supply sensor If both heat demand and setpoint DHW demand are present at the same time the controller targets the higher of the two requirements Mode 6 External boiler control This mode can be used when connecting multiple boilers to an external boiler control or an energy management system EMS The BTC series is used to provide boiler pump control and operates stage 1 and pump when a heat demand is present The stage 1 terminals on the external boiler control must be connected to the heat demand terminals HT amp R of terminal block TB4 on the boiler Next the 5 amp 6 jumper wire of terminal block TB1 on the boiler must be removed and the stage 2 terminals on the external boiler control connected to 6 and 24Vac R See wiring diagram for details When there is a heat demand or DHW demand the controller will switch on the system pump If the sensor is not satisfied the controller will switch on additional stage s in sequence and based on PID proportional integral derivative logic The controller continuously monitors the sensors and examines the difference between the target temperature and the sensor
16. ON OFF SWITCH amp CONTROLLER MOUNTING PANEL 32 REAR BURNER SUPPORT 3 LEFT SIDE REAR PANEL 18 CONTROL PANEL 33 BURNER TRAY 4 LEFT FRONT REFRACTORY HOLDER 19 BOTTOM REFRACTORY HOLDER FRONT 34 BASE TOP PLATES LEFT SIDE 5 SIDE REFRACTORY PANELS 20 FRONT REFRACTORY 35 BASE ASSEMBLY 6 SIDE SUPPORT 21 TOP REFRACTORY HOLDER FRONT 36 BASE TOP PLATE RIGHT SIDE 7 REFRACTORY TOP CHANNEL 22 REFRACTORY JOINT CLIP 37 RIGHT FRONT REFRACTORY HOLDER 8 LEFT REAR REFRACTORY HOLDER 23 FRONT SEAL 38 REFRACTORY TOP CHANNEL 9 TOP PANEL 24 HEAT EXCHANGER ASSEMBLY 39 SIDE REFRACTORY PANELS 10 FLUE COLLECTOR 25 BAFFLE 40 RIGHT REAR REFRACTORY HOLDER 11 MANIFOLD 26 REAR SEAL 41 RIGHT SIDE FRONT PANEL 12 BURNER 27 REAR REFRACTORY 42 RIGHT SIDE REAR PANEL 13 CONTROL PANEL ENCLOSURE 28 TOP REFRACTORY HOLDER REAR 43 SIDE PANEL SUPPORT 14 SIDE EXTENSION OPTIONAL 29 BOTTOM REFRACTORY HOLDER REAR 44 FRONT LOWER COVER PANEL 15 INSPECTION DOOR 30 REAR PANEL 45 INSULATION NOT ILLUSTRATED AAE U 001 03 FIGURE 8 AAE SERIES BOILER GENERAL ASSEMBLY PARTS LIST 28 AAA Series Gas Boiler Installation and Service Manual 7 ion Sect iring W NOILINO OINOY LOFTS ANWA SVO OO NON 39VIS dIO9NIS 6 00 792 M 3wW Al 18 4355 10114 32 143 318 32 14384 01341 LON 38v S3MIM Qv31 1014 GASN 38 ISAW 5
17. Series Gas Boiler Installation and Service Manual 7 Turn Gas Valve to ON When power is supplied to the controller the LCD displays When the thermostat calls for heat the screen is replaced with the boiler target temperature Next pilot burner should ignite followed by main burners and as BTC series energizes stages indicated by the stage indicator Once the boiler water temperature reaches the setpoint the controller will regulate the boiler water temperature using the two stages The number of stages that switch on is based on the heating demand and user settings Check main and pilot burners and adjust pilot if necessary as described in Section 4 3 After all room thermostats are satisfied the controller de energizes the two stages in sequence 8 Assure that all other gas appliances are turned off including their pilot flames 9 Check manifold pressure reading on the manometer and make necessary adjustments Check burner input to match rating plate input 10 Return thermostat and controls to normal operation settings AAA Series Gas Boiler Installation and Service Manual 4 3 CHECK BURNER SYSTEM To maintain safe and efficient operation examine the burner system regularly through the inspection hole near the pilot tube Check condition of burner system Check ignition and extinction It is possible for parts of the burners system to Ignition should flow quickly and smoothly across become plug
18. and monitor the operation of your system The BTC series uses three push buttons Item A V for selecting and adjusting settings As you program your control record your settings for future reference Item Field Number Field Displays an abbreviated Displays the current value of the selected item name of the selected item SN OUTDR DSGN DIFF ADJUST BOILSUPINOUT AT 1T START MINMAX z e min current menu TARGETMASS 12 ATONOFFDLY WWSD 723 TANKSTG MODE Stage Displays when stage 1 and or 2 3 relay is turned on Displays when the boiler Displays the current status of the control s inputs outputs and operation Buttons Selects Menus Items and adjusts settings Figure 3 BC1 Controller LCD Display Menu All of the items displayed by the control are organized into two menus These menus are listed on the upper right hand side of the display Menu Field The default menu for the BTC series is the View menu While in the View menu the VIEW segment is displayed To select the Adjust menu press and hold simultaneously all three buttons for 1 second The display then advances to the Adjust menu and the ADJUST segment is turned on in the display The display will automatically revert back to the View menu after 20 seconds of keypad inactivity Once in a menu there will be a group of items that can be viewed within that menu Item
19. flame will not stay established Boiler carbonizes forms soot quickly Boiler overheats and system remains cold Boiler and heating system overheat AAA Series Gas Boiler Installation and Service Manual Possible Cause Negative draft Solution Incorrect vent size or blocked vent Insufficient combustion air to boiler Check combustion and ventilation air opening in boiler room meets installation code requirements and combustion air flow openings in the boiler base and burner tray are not blocked Leak in gas system Carbon build up on the heat exchanger caused by improper venting ventilation air or low return water temperature See What to do if you smell gas on cover Have gas fitter test system and repair leaks Have a qualified service technician inspect and clean the heat exchanger and check and adjust the system Negative draft Improper pilot flame Check venting Adjust pilot flame Thermocouple lead to gas valve is loose Check and tighten lead Thermocouple is defective No spark Replace thermocouple High voltage wiring is loose broken or grounded Repair wiring Ignition electrodes are damaged Replace electrodes Ignition electrodes improperly adjusted Correct adjustment of electrode Faulty electronic ignition controller Replace controller No gas Confirm supply of gas to pilot and repair if necessary Gas suppl
20. have the boiler inspected by qualified service technician or gas supplier s service person at least once every year at the beginning of the heating season for continued safe operation Note that some operating conditions may require more frequent inspections The qualified service technician or gas supplier s service person should follow the Service Checklist The Service Checklist must only be used by a qualified service technician or gas suppliers service person Verify proper operation after servicing 5 2 CLEANING PROCEDURE 1 Shutdown the boiler as described in the lighting instructions in Section 1 4 2 Inspect flue gas passages and burners for the presence of soot rust or scale 3 If necessary use a wire brush and vacuum to clean and remove any blockages Plugged burner ports must be cleared 4 Replace any parts which have severely corroded 5 Reassemble parts removed during cleaning as they were before ensuring air tightness of flue gas passages 6 Corrosion can be caused by low return water temperature or a contaminated air supply Sooting can be caused by improper burner adjustment Check and adjust as necessary T Return boiler to operation following lighting instructions in Section 1 4 24 AAA Series Gas Boiler Installation and Service Manual 5 3 SERVICE CHECKLIST Reference Section Do not store anything against the boiler or allow dirt or debris to accumulate in the area immediately surroundi
21. rate FOR CANADA Natural Gas Propane Model 0 to 2 000 feet 2 000 to 4 500 feet 0 to 2 000 feet 2 000 to 4 500 feet 28 orifice Contact Allied Eng sales 0 Contact Allied Eng AAA standard input office for details 46 orifice sales office for details FOR UNITED STATES Natural Gas Propane Model 0 to 2 000 feet Over 2 000 feet 0 to 2 000 feet Over 2 000 feet 28 orifice Input must be reduced Input must be reduced AAA standard inst 4 for each 1000 ft 46 orifice 4 for each 1000 ft above sea level above sea level Reference National Fuel Gas Code ANSI 2223 1 8 1 2 High Altitude Small adjustments to the input rate can be made by varying the manifold pressure Normally it should be adjusted no more than 0 2 inch w c for natural gas or 0 5 inch w c for propane from the manifold pressure specified on the rating plate WARNING Exceeding the allowable input rate can produce dangerous concentrations of carbon monoxide and cause the boiler to overheat resulting in severe personal injury death or substantial property damage Carbon monoxide is a lethal colorless and odorless gas Input Rate Test Consult gas company to determine the heating value of the gas supplied in Btu per cubic feet Operate boiler for 15 minutes starting with all parts at room temperature and check input by clocking gas meter with all other gas appliances turned off including their pilot flames Us
22. 11 MO 2 601 3dAL Q3Vi1d3M 38 ISAW 831108 HLM 34405 SV 3 TWNIDINO 3HL 40 i TWNOILWN 43H10 ANY CNV 1 Luvd MO AVIS IVNOLLVN 33H10 CNV OZ Wd4N ISNV vsn 0 HLM NI GSTIWLSNI 38 1SnW ONISIM TIV 1 SNITIVISNI 380438 YSMOd LOANNOOSIC 3H3A3S 350 2 OMVZVH X20HS WILO 55323 SININFYINDIY 3000 7 201 YO IIONIAONd 1222 272 4 SIN3W3HIn03H 3009 1V201 SION ONINSVM ONIDIAN3S NO QNV HiV3d 0 MOSN3S A HAYAS 5 AWA o 2 a 1014 AW ONS 0 INISVDOY 5 HOLIMS HOLIMS lviSvnov TINON 55444 5533 HOIH ANS NOLIN Sv9 MOT 5 9 H9IH SVO SVO 1915 INVONNGSY 39 15 319NIS 90 1 98 90A 92 ISNA 021 ar N3HM aasn N3HM 340 102 HOLIMS MOTA MOT MOLVOIONI Y3MOd O HOLMS HOLIMS 440 NO 440 NO 1 4 129 SX3H10 A8 5 10 8 1N3Wdino3 dWnd 90A 021 n INVHOVIO 3OQVT HOLMS JYNSS3Yd SVO V 53 u mg 00070052 YIAO INANI ALON
23. 2 2 For boilers for connection to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or Section 7 Venting Systems and Air Supply for Appliances of the CAN CGA B149 Installation Codes or applicable provisions of the local building codes The venting shall be supported as required by applicable code s Horizontal runs shall slope upward not less than inch per foot 21 mm m from the boiler to the vent terminal This unit must be installed with the factory supplied draft hood in place The draft hood is a safety device designed to control chimney drafts that might affect combustion or blow out the pilot The draft hood supplied with the boiler must not be altered The minimum skirt height as indicated on the draft hood must be maintained Vent connectors serving the boiler must not be connected into any portion of mechanical draft systems operating under positive pressure Vent Terminal Information The minimum distance from the termination of a vent terminal to adjacent public walkways adjacent buildings operable windows and building openings shall be not less than those values specified in the National Fuel Gas Code ANSI Z223 1 and or CAN CGA Installation Codes For proper operation the vent terminal must be kept free of snow and other debris at all times To prevent discoloration and degradation of building materials by flue gases and flue
24. 3 482 1050 477 AAA1320 1320 387 1122 329 33 5 45 1143 10 5 267 18 457 773 1963 225 572 11 4 13 92 52 7 1140 518 1440 1440 422 1224 359 366 48 1219 105 267 18 457 773 1963 240 610 11 4 15 12 572 1205 548 AAA1560 1560 457 1326 389 396 51 1289 5 10 5 267 18 457 773 1963 255 648 11 4 16 31 61 7 1270 577 AAA1680 1680 492 1428 419 427 54 1372 105 267 20 508 787 199 9 270 686 11 2 1751 663 1350 614 AAA1800 1800 528 1530 448 457 57 1448 105 267 22 559 80 7 2050 285 724 11 2 18 70 70 8 1440 655 AAA1920 1920 563 1632 478 48 8 60 1524 10 5 267 22 559 807 2050 300 762 11 2 19 90 75 3 1520 691 2040 2040 598 1734 508 51 8 160 0 10 5 267 24 826 2098 315 800 11 2 21 09 79 8 1605 730 AAA2160 2160 634 1836 538 549 66 1676 10 5 267 24 826 2098 330 83 8 11 2 2228 84 3 1645 748 2280 2280 669 1938 568 57 9 69 1752 10 5 267 24 826 209 8 345 876 11 2 23 48 88 9 1690 768 AAA2400 2400 703 2040 598 61 0 72 1829 105 267 24 610 826 2098 360 914 11 2 2467 934 1770 805 AAA2495 2495 731 2121 622 63 4 75 190 5 12 0 30 5 2x18 2x457 78 8 200 2 2 18 25 2x46
25. 4 2 25 87 979 1850 841 AAA2640 2640 774 2244 658 67 1 78 1981 12 0 30 5 2x18 2 45 7 78 8 200 2 2x19 75 2x50 2 2 27 06 102 4 1890 859 AAA2760 2760 809 2346 688 70 1 81 2057 12 0 30 5 2x18 2 45 7 78 8 200 2 2 20 25 2x514 2 28 26 107 0 1935 880 AAA2880 2880 845 2448 717 73 2 84 2134 12 0 30 5 2x18 2 45 7 78 8 200 2 2 21 00 2x53 3 2 29 45 111 5 1975 898 3000 2550 747 762 87 2210 12 0 30 5 2x18 2x457 78 8 200 2 2 21 75 2x55 3 2 30 65 116 0 2020 918 For Propane models derate input 1096 In Canada For altitudes above 2 000 feet contact the factory for the appropriate Input derate In U S A For altitudes above 2 000 feet reduce input 4 for each 1000 feet above sea level Add 3 to dimension A 1 1 2 to each side of boiler to allow for 3 NPT water connections AAA2495 and above use dual draft hoods and Dimension E is measured from both left and right hand sides Options e Natural Gas models add suffix N Propane models add suffix P e Electronic Ignition add suffix E e High Low fire add suffix M Full Modulation add suffix MOD AAA Series Gas Boiler Installation and Service Manual Boiler Water Flow Data NOTE The boiler should be properly sized for its heating application and maintain an adequate water flow rate du
26. Aquastat Safety High Limit Aquastat Temperature Pressure Gauge A S M E Pressure Relief Valve 30 p s i Drain Valve Draft Hood Transformer Control Panel Enclosure Main On Off Switch with Indicator Light esult in changes to the design and or specifications being made without notice ionii INPUT OUTPUT DIM A DIM B DIM C DIM D DIM E CON CONTENT SEGHE NUMBER kw MBH kw HP in cm in cm cm in cm in cm nme Gat L Ib Kg 480 480 141 408 120 122 24 610 105 267 10 254 689 1750 120 305 1 556 210 675 307 AAA600 600 176 510 149 152 27 686 105 267 12 254 689 1750 135 343 1 675 255 725 330 AAA720 720 211 612 179 183 762 105 267 12 305 712 1810 150 381 1t 7 95 30 1 790 359 AAA840 840 246 714 209 213 838 105 267 14 356 729 185 1 165 41 9 1 944 34 6 391 AAA960 960 281 816 239 244 36 914 105 267 14 356 729 185 180 457 11 4 10 34 39 1 940 427 AAA1080 1080 317 918 269 274 39 99 0 10 5 267 16 406 76 0 1930 195 495 11 4 11 53 43 6 990 450 AAA1200 1200 352 1020 299 30 5 42 1067 105 267 16 406 760 1930 210 533 11 4 12 7
27. GE BOILERS NPUT OVER 2500 S CSD 1 WITH AN INPUT OVER 2500 M B H ITEM DESCRIPTION ITEM DESCRIPTION 1 MAIN ON OFF SWITCH amp CONTROLLER MOUNTING PANEL 11 MANUAL SHUT OFF VALVE FIRING VALVE 2 BC 1 CONTROLLER 121 HIGH GAS PRESSURE SWITCH WHEN USED 3 IGNITION CONTROL MODULE ELECTRONIC IGNITION ONLY 13 MAIN GAS VALVE 4 TRANSFORMER 14 REDUNDANT GAS VALVE 5 OPERATING HIGH LIMIT AQUASTAT 15 P2S PILOT SHUT OFF VALVE 6 TEMPERATURE PRESSURE GAUGE 16 MANUAL MAIN SHUT OFF VALVE AB COCK 7 SAFETY HIGH LIMIT AQUASTAT 171 LOW GAS PRESSURE SWITCH WHEN USED 8 PILOT REGULATOR SOLENOID 18 MANIFOLD ASSEMBLY 9 1 4 TEE amp PLUG 19 PILOT BURNER UNIT 10 90 ELBOW Clo P AIO 6 i GAS T 9 PE INLET amp SEDIMENT TRAP NOT SUPPLIED OUTER CASING BASE ASSEMBLY Fd NOTES 1 SOME MODELS MAY BE SUPPLIED WITH A COMBINATION GAS VALVE 2 SOME MODELS MAY BE SUPPLIED WITH A DUAL OPERATING SAFETY HIGH LIMIT AQUASTAT AAE U 021 05 3 ITEMS SHOWN MAY NOT BE PRESENT ON ALL MODELS FIGURE 7 TYPICAL GAS TRAIN ASSEMBLY AND CONTROL COMPONENT LAYOUT FOR COMMERCIAL INSTALLATIONS 27 AAA Series Gas Boiler Installation and Service Manual NO DESCRIPTION NO DESCRIPTION NO DESCRIPTION 1 DRAFT HOOD 16 ROLL OUT SHIELD 31 FRONT BURNER SUPPORT 2 LEFT SIDE FRONT PANEL 17 MAIN
28. IA OL 300 LNO 033201 51 SN3dO LINDYID JAVA 10114 N3HM 35012 SIOVINOO Wavy O N JAV VW 7 SIOVINOO Waviv NOlv1n93N SV9 380438 31 201 J 3NVdOMd 304 NI 69 5 9 TWYNLYN 303 IM dNvdOMd YO4 722 5 WYNLWN 303 NI 506 1Y SANTWA TONLNOD 31V901 SAVM TV AdO8 SAIWA 86605 TI3MA3NOH JOlVino3H SVD 1 Q31v9O dl 3NvdOSd 304 NI 65 SVD N03 NI 5 71 155 IV 145 M NI 91 135 VGSO6A TI3MA3NOH Y V NMOUG V 1NIOd STSGOW NOILWINGOW TINA M a M z 2018 DA 021 TVNINYL OL ig y 23 ove Xd CSHOWLIV afr n Y vila 3ma HOLINS IVNNVA OINY 9NISP NAVIY JANTA INVIA WNOLLdO NAHM NOILOJNNOO AMOLO
29. IN amp OUT SENSORS CONNECTED MODE 2 HEATING WITHOUT OUTDOOR RESET USING PRIMARY SECONDARY PIPING BOILER IN OUT amp SUP DHW SENSORS CONNECTED MODE 3 DEDICATED DOMESTIC HOT WATER ONLY USING PARALLEL PIPING BOILER IN OUT amp SUP DHW SENSORS CONNECTED MODE 4 HEATING WITH OUTDOOR RESET USING PARALLEL PIPING BOILER IN OUT amp OUTDOOR SENSORS CONNECTED MODE 5 HEATING WITH OUTDOOR RESET USING PRIMARY SECONDARY PIPING BOILER IN OUT SUP DHW amp OUTDOOR SENSORS CONNECTED Figure 1 Field wiring to terminal block TB4 11 AAA Series Gas Boiler Installation and Service Manual Electrical Connections For all electrical connections Strip wire ends and insert into the terminal block Tighten terminal screw clamps to securely hold the wire CAUTION Risk of damage to the controller Do not apply power to any connections on terminal block TB4 24 Vac has been factory wired to terminals C 1 and HL 15 Terminal Connections Name Description Comments Block TB4 BO amp CM Boiler Outlet Connect boiler outlet water temperature sensor to terminals Sensor BO and CM common The Boiler Outlet Sensor must be attached using a cable tie to the boiler outlet pipe BI amp CM Boiler Inlet Connect inlet water temperature sensor to terminals and Sensor CM common The Boiler Inlet Sensor must be attached using a cable tie to the boiler inlet pipe OS amp
30. MOSPHERES If a gas boiler is to be installed near a corrosive or potentially corrosive air supply the boiler should be isolated from it and outside air should be supplied as recommended in Section 2 5 Chemical vapors from products containing chlorine or fluorine must be avoided Even though these chemicals may be safe to breathe corrosive substances can become liberated when passed through a gas flame Even at low concentrations these chemicals can significantly contaminate the air supply and shorten the life of any gas burning appliance The following is a list of some of the products which should be avoided e bleaches and chlorinated cleaning products paints and sprays water softeners calcium or sodium chloride leaking refrigeration equipment freon from common aerosol dispensers These chemicals are especially common near swimming pools beauty shops dry cleaning establishments laundry areas workshops and garages The warranty is void when failure is due to corrosion AAA Series Gas Boiler Installation and Service Manual 2 7 VENTING The responsibility of providing a suitable vent of adequate draft capacity and in good usable condition is that of the gas fitter installer Interference with the air supply for the boiler shall be prohibited Vent installation and type of gas vent or vent connector MUST follow all applicable national provincial state and local codes laws regulations and ordinances as described in Section
31. TI3NA3NOH es n SIOVINOD ANC aasn 2 Ninsa MS NMOUE 3HL NO S NN 091 YIAN MONIY oom f GE 5 007 diii 8 40 Y INIOd E 18 NYO PARE Soviet 95 Si HR DS fcc o E er nJ 1 215 91 P VA OF 1 ri m Y p gy 05 uhh 50 mne leled lled VNMO NISUS 201581 0 405 9 2 59 10 5 hys THIRD B we N3385 BERLE SA 915 00 108 8 2 2 5 021 qu 8 S g 55 N02 8 5 EET TWNINYEL OL zi my 90 021 Tama H E ee ee N e X8 mB navy seer 9 oF TOIS 440 NO zal WV INV aen 29 21 0419414 HIIM 3AIVA SV9 NOLIVNIBWOO NON JOVLS OL 90914
32. The units of measure that all of the temperatures are to be displayed in by the control 15 AAA Series Gas Boiler Installation and Service Manual 3 3 CONTROLLER OPERATION When the controller is powered the controller enters the operating mode if there are no sensor or high limit errors present The user should select one of the following modes from the controller adjust menu Mode 1 Setpoint operation using parallel piping Operates boiler stages to maintain fixed temperature at boiler outlet sensor when a heat demand is present Mode 2 Setpoint operation using primary secondary piping Operates boiler stages to maintain fixed temperature at boiler supply sensor when a heat demand is present Mode 3 Dedicated DHW Generation Operates boiler stages to maintain fixed temperature at the boiler outlet sensor when an internal demand for DHW is generated based on the DHW sensor An indirect hot water tank must be used to separate the AAA from an open system Mode 4 Outdoor reset with reset override using parallel piping Operates stages to maintain an outdoor reset temperature at the boiler outlet sensor When there is a call for reset override from the DHW aquastat i e ST amp R is closed the control operates the stages to maintain a setpoint temperature at the boiler outlet sensor If both heat demand and setpoint DHW demand are present at the same time the controller targets the higher of the two requirements
33. V4 1 M AG 0351 N3HM SASS z wood t FHL NO S IL 3AOWGH a syon qud LOOM Le 211 asn vum mswnov gt HO INNON HOLMS IHON SNuveid0 1 INOd 1 TWNINYAL 7 s E GloNos xw 3NNA 5 9 ge IZ 3015 TIONIS 021 390 N3HM INVONNOSY HOLIMS 5534 eno ELI TWNOILYOdOYd 31661 TI3MA3NOH V 1 M3AHOJSNVML ssvio on 390 N3HM HOLIMS 5534 emo 1 auton m 59 MOT B I NGISAS IHM 21 6 NMOC_INHS L 01 JLAM XWIB D 2 QNNOYD 9 Ey XE 815970 S066A 301 aMASNOH EUN X18 0 F Gon aow 40078 TRENOS La F wma V suHi0 440 NO TOYLNOD SOC NRG 01985 02 900 300 7ONINOO TVLIA 123410 WNOLLdO WVYOVIC OLLVIN3HOS 31 AAA Series Gas Boiler Installation and Service Manual Troubleshooting Guide Section 8 Problem BTC series display is blank BTC series displays an error message Boiler will not fire Boiler goes on and off at frequent intervals Boiler fires continuously Rumbling and moaning sound
34. ada the installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the CAN CSA B149 Installation Codes current edition All electrical wiring must be in accordance with the Canadian Electrical Code CSA C22 1 Part 1 current edition and applicable local codes In the United States of America the installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 current edition All electrical wiring must be in accordance with the National Electrical Code ANSI NFPA 70 current edition and applicable local codes Where required by the authority having jurisdiction follow the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 current edition 2 3 LOCATION AAA boilers are intended for indoor installation only Observe the following minimum clearances from the boiler to combustible materials Clearances to Combustible Materials Sides Rear Top Front service Model in mm in mm in mm in mm AAA 6 153 6 153 36 915 40 1016 e Maintain a clearance of 6 153 mm from draft hood and the flue pipe in any direction e Allow ample space for boiler inlet and outlet connections and gas connection e Boiler must be installed on a stable and level foundation e AAA Series boilers must be installed on a Non Combust
35. ction 3 WARNING The following section summarizes information found in the BTC Series Controller Manual Read all instructions in this manual and the BTC Series Controller Manual before placing the boiler in operation or making adjustments to the controller Adjustments must be made by a qualified heating technician 3 1 CONTROLLER INFORMATION Control Board Dimensions 4 3 4 L x 2 7 8 W x 1 7 8 H Power Outputs Boiler Stage outputs from 15 STG1 and 17 STG2 terminals are 24 Vac 60 Hz when factory wired Alarm output from 23 ALARM terminal is 24 Vac 60 Hz eter Comes 0 45 A maximum when factory wired Alarm is wired to ver eur terminal block TB4 terminals AL amp AL Item A Signal Inputs Do not apply external power The following signal inputs are located on terminal block TB4 Figure 2 BTC SERIES HT amp R Room thermostat or zone valve end switch 24Vac switching input closed is activation ST amp R Setpoint DHW aquastat 24Vac switching input closed is activation FS amp FS Flow switch 24Vac switching input closed is activation Thermistor Sensors BO amp CM Boiler outlet sensor BI amp CM Boiler inlet sensor OS amp CM Outdoor sensor SD amp CM Supply DHW sensor AAA Series Gas Boiler Installation and Service Manual 3 2 CONTROLLER DISPLAY The BC1 uses a Liquid Crystal Display LCD as a method of supplying information You use the LCD in order to setup
36. d cause serious corrosion problems As well minerals dissolved in the water supply will precipitate when heated minerals preferentially deposit in the heat exchanger Do not draw water from the heating system for cleaning flushing etc Super Hot AAA series boilers are designed for use in closed loop systems and are not intended for open Systems as in heating pool water or systems where water is constantly replenished Operating the boiler in an open system will result in premature failure of the heat exchanger Super Hot boilers may be used to heat water in open systems indirectly by installing a heat exchanger such as the Super Hot C Coil to separate open and closed systems Heating systems with low temperature return water may cause flue gas moisture to condense on the boiler heat transfer surfaces causing corrosion and restricting flue gas flow Also low temperature return water may overcool the flue gases resulting in reduced vent suction These are natural phenomena and are independent of the boiler design As a guide to avoiding such corrosion and draft problems it is imperative that the return water be not less than 135 F 57 C AAA SERIES BOILERS MUST ALWAYS BE USED WITH FORCED SYSTEM CIRCULATION AAA Series Gas Boiler Installation and Service Manual 2 11 PRESSURE RELIEF VALVE A pressure relief valve is supplied as standard equipment The pressure relief valve is extra protection against damage that could be caused by malf
37. e a copio Mee cep RE tee th 8 2 8 Boiler Piping nie e e te e a e 9 2 9 Corrosion Prevention Internal ssessssssssssseseeseeeeee nennen nennen nennen nenne nnn entrent nennen 9 2 10 System Operating Requirements ssssssssssssssssesseeeenee nennen entes n nenne 9 2 11 Pressure Helief Valve rrt rtr RU m ere ee eren ep RT 10 2 12 Electrical WIFIDO s sie re eto e edo et M eed duda 10 2 13 BTC Series Controller Wiring 10 3 BTC Series Controller Information 13 3 1 Controller Information esses enne nnne nenne nnne entren tnt snnt st nnns entres 13 X2 lt Controller BIS V MEET 14 3 3 Controller Operation nnr 16 3 4 Reset RR 16 3 5 Controller 0 18 4 Startup Instructions conicere cs 18 4 1 Bre StartUp cs cere he reU e eR e ie o c td oe 18 2 18 4 3 Cheek Bumer 20 4 4 Aquastat Agj stmerit aceti c E ee 20 4 5 Gas Mahifold nn P de eda ead es cue ena a v
38. e controller mounting plate on the control panel using a sheet metal screw The LCD and buttons should be visible and accessible from outside the front of the boiler casing To remove the controller 1 remove the front casing panel 2 pull off the black plastic top cover of the controller 3 unscrew the sheet metal screw 4 lift the controller slightly out of the rectangular cutout in the mounting plate 5 pull off the Molex connector while simultaneously holding down the tab on the left side Startup Instructions Section 4 41 PRE STARTUP Fill entire heating system with water and vent or purge air from system Add water as needed to reach boiler operating pressure Water should be of suitable quality Do not use water with high hardness Check for and repair any leaks in water piping Check burners to see that they are not dislodged Check for proper installation of pressure relief valve draft hood and venting Check that the electrical wiring matches the wiring diagram in this manual or on the boiler Use a soap solution to check for leaks in gas piping from meter to boiler pilot and manifold Repair and retest any leaks found g Operate circulating pump and vent all radiation units and high points in system piping rm opo 4 2 STARTUP WARNING The following instructions are intended as a guide for qualified persons Before lighting the boiler the pre startup instructions of Section 4 1 MUST be performed If y
39. e main and pilot manual gas shut off valves turn off all electric power to the boiler and wait for five minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow safety instructions in Section 1 1 If you don t smell gas go to the next step Set the thermostat above room temperature and turn on all electric power to the boiler to energize the electronic ignition and pilot valve After a few seconds control system should lockout and all functions are off To take the control system out of lockout either press the reset button or interrupt power to the boiler depending on the boiler controller Some controllers will retry ignition automatically after 5 minutes lockout Start System 1 Turn on the main and pilot manual gas shut off valves 2 Set thermostat above room temperature and turn on all electrical power to the boiler 3 Once the pilot flame is proven the controller opens the main burner gas valves The pilot flame will ignite the gas as it exits the main burner ports 4 Set thermostat to the desired setting to put System back in service Relight Operation Five minutes complete shut off period is required before attempting to relight the boiler To relight the boiler follow the Start System procedure above To turn off gas to boiler or emergency shut off Follow Section 1 4 1 4 TO TURN OFF GAS TO THE BOILER OR EMERGENCY SHUT OFF WARNING Sh
40. e technician Force or attempted repair may result in a fire or explosion Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Your boiler is equipped with an intermittent electronic ignition system which will automatically light a pilot burner allowing the pilot burner to ignite the main burner the boiler After the module senses the pilot flame the main gas valve and redundant valve will open The following section provides instructions for lighting AAA Series Gas Boiler Installation and Service Manual 1 3 1 2 LIGHTING INSTRUCTIONS FOR INTERMITTENT ELECTRONIC IGNITION WITH NON COMBINATION GAS VALVE This boiler is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Before turning on the electrical power switch be sure all gas supply lines are purged of air and power supply to control is the correct voltage If the pilot or main burners are not lit or the control system is locked out due to flame failure close the main and pilot gas shut off valves and call your service technician or gas supplier If you smell gas STOP Follow A in the safety instructions in Section 1 1 Check Control Operation STOP Read the safety instructions in Section 1 1 For 100 shut off check clos
41. e the following formula 3600 x Heating Value of Gas x Number of Cubic Feet Timed Seconds Clocked To ensure accuracy for rating clock enough cubic feet of gas so that there is at least one revolution of the test dial and the clocked time is at least 60 seconds Two Stage or Full Modulating Gas Valve When a two stage or modulating gas valve is used it must be checked for correct input at both High and Low fire settings The clocked input rate MUST be within the Minimum Input and the Input as specified on the boiler s rating plate To force a two stage or full modulating gas valve to low fire see the valve manufacturer s instructions Perform the Input Rate Test described above and adjust manifold pressure of High and Low settings as necessary For altitudes above 2000 feet DO NOT derate the Minimum Input rate INPUT Btu h 21 AAA Series Gas Boiler Installation and Service Manual 4 7 CHECK FOR DRAFT HOOD SPILLAGE WARNING Continuous spillage at the draft hood relief opening may result in severe personal injury death or substantial property damage After the main burners have operated for 5 minutes check to see that combustion products are going up the chimney or gas vent properly by passing a lighted match or smoke from a cigar cigarette or pipe around the edge of the relief opening of the draft hood If the chimney or gas vent is drawing properly the match flame or smoke will be drawn int
42. ensor BOIL ON All The total number of running hours of the boiler since this item was last cleared ADJUST MENU Item Field Default Description MODE 1 Sets the operating mode for the control Mode 1 parallel setpoint Mode 2 primary secondary setpoint Mode 3 parallel dedicated DHW generation only Mode 4 parallel outdoor reset with optional DHW override Mode 5 primary secondary outdoor reset with optional DHW override BOIL 180 F Minimum boiler target temperature during reset override setpoint or DHW TARGET operation TANK 140 F Sets the DHW storage tank s temperature Used in Mode 3 only TARGET TANK 5 F Sets the differential for the DHW storage tank DIFF OUTDR 70 F The outdoor starting temperature used in the reset ratio for the heating system START OUTDR 25 F The design outdoor air temperature used in the heat loss calculations for the DSGN heating system BOIL 70 F The starting water temperature used in the reset ratio calculation for the START heating system BOIL 180 F The design water temperature used in the heat loss calculations for the heating DSGN system BOIL MAX 210 F The maximum boiler target water temperature BOIL 2 The thermal mass of the boiler used Always use 2 for the Super Hot AAA MASS Boiler DIFF 20 F The differential that the control is to use when it is operating the boiler 0 30 min Determines when to stop purging the pump WWSD 70 F The system s warm weather shut down F C F
43. er Installation or service by anyone unqualified to do so may result in severe personal injury death or substantial property damage BTC Series Controller Manual This manual must only be used by a qualified heating installer or service technician BTC Series Controller Manual contains detailed information on controller operation applicable to single stage and two stage AAA boilers All manuals should be kept in the envelope provided and affixed adjacent to the boiler so that they are readily available for future reference Lighting Instructions 1 1 SAFETY INSTRUCTIONS Section 1 da WARNING If you do not follow these instructions exactly a fire or explosion may result causing property mage personal injury or loss of life A 1 2 BEFORE LIGHTING smell all around the boiler area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance 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 the gas supplier s instructions e f you cannot reach your gas supplier call the fire department LIGHTING INSTRUCTIONS Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified servic
44. gas condensation ensure that the vent terminal is installed clear of nearby obstacles In all cases installation shall be in accordance with code Maintain a minimum clearance of 4 feet 1 22 m horizontally and in no case above or below unless a 4 foot 1 22 m clearance is maintained from electric meters gas meters regulators and relief equipment Removal of an Existing Boiler 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 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 a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition C Insofar 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 dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts s
45. ged cracked eroded and or all the burners Popping noises or explosions dislodged resulting in unsafe operation from the burners during ignition extinction or Pilot Flame normal burner operation indicate the need for service Remove screw cover on gas valve then adjust gas flow to the point where the sensor rod is completely enveloped by the flame Figure 6 but not necessarily glowing red Replace Check flame color An extremely yellow flame as seen on a burning candle or match is an indication of incomplete combustion and is usually accompanied by the formation of soot and carbon monoxide carbon monoxide is a lethal colorless and odorless gas If soot is allowed to accumulate it will partially restrict free passage of products of and tighten cap FIGURE 6 PILOT FLAME combustion to the flue Under typically operating Check for lifting ADJUSTMENT conditions the flame should have a distinct bright blue inner cone and a blue orange outer Flames should not lift excessively from the burner ports The flames may lift slightly during ignition or when the burners are cold cone If any of the above problems are observed or the burner system does not operate properly immediately take corrective measures 4 4 AQUASTAT ADJUSTMENT The factory mounted aquastat controls main burner firing by sensing outlet water temperature To set the temperature of this control adjust
46. ible floor A hot water boiler installed above radiation level must be provided with a low water cutoff device at the time of boiler installation e This boiler must be installed such that gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service AAA Series Gas Boiler Installation and Service Manual 2 4 GAS SERVICE PIPING The boiler and its gas connection must be leak tested before placing the boiler in operation The gas controls furnished are suitable for a maximum operating gas pressure of 1 2 psi 14 inches water column The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 14 inches water column The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing at test pressures equal to or less than 1 2 psig 14 inches water column A manual main shut off valve should be installed in the gas line outside the boiler jacket and as required in Section 2 2 The valve should be readily accessible for turning on and off A drip pocket or sediment trap should be installed in the gas supply line upstream of the gas controls and as close to the boiler as possible example shown in Figure 7 in Section 6 Some pressure regulators or pressure regulating sections of gas va
47. in boiler Possible Cause Incorrect supply power Solution Check for 115V AC across L1 and L2 Faulty transformer Check for 24V AC across terminals C 1 and HL 15 Internal control fault E01 Controller unable to read from its EEPROM Replace controller Verify all the settings in the adjust menu are correct Shr Controller is unable to read from of the sensors Check for short circuit at the sensor which is displayed on the LCD OPn Controller is unable to read from one of the sensors Check for loose connection open circuit at the sensor which is displayed on the LCD Defective sensor or controller No power Perform Test the Sensors described in BTC Series Controller Manual Check power switches and wiring No gas supply to boiler Check gas source and pressure Gas supply pipes are not purged of air Purge gas line No heat demand Check if thermostat setting is above room temperature and aquastat setting is above boiler water temperature Flow switch or low water cut off Check pump capacity amp flow direction Check for correct water levels and air locks Gas valve failure closed position Check gas valve and replace if necessary Thermocouple failure Check thermocouple and replace if necessary Faulty wiring Check wiring of aquastats zone valves and thermostats for loose or broken wires and repair
48. k for leaks Note Propane is heavier than air and pools in a low area in the event of a leak 4 9 Inspect for leaks in the water piping and at water piping connections Circulating pumps used with hot water heating systems should be inspected for water leaks Check for weeping at pressure relief valve outlet during normal operation Listen for unusual audible sounds in the boiler Any audible sounds in the boiler system may be indications of scaling or lack of sufficient water flow and the system should be checked without delay Scaling is due to improper maintenance and it is not the fault of the boiler Scale damage is not covered by warranty 2 10 Check the temperature and pressure gauge and expansion tank pressure is within an acceptable range for the heating system Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Combustible materials gasoline and other flammable vapors and liquids should not be stored in the area of the boiler Checks should be made on the ignition system operation controls and safety shut off valves for gas tightness 2 9 If applicable inspect low water cutoff flow switch for proper operation The emergency shut off devices are identified the owner is aware of their location and method of operation 25 AAA Series Gas Boiler Installation and Service Manual 5 4 CAUTION WATER REPLENISHMENT
49. lt ANY ONY 1 Lud 1722 VS 030 4 Lr SSCA aC SIN3W3NInO3H 3002 1001 WOlvin938 SVO YALA 319207 31 INVdOYd 804 NI S S 5 9 5 23H10 ANY OL YddN ISNY VSN TWUNLYN O R NI SET LV 135 NOLVINDIY 5 9 380438 31 901 3i V clie 1909 NO TIOR Sade ARI ION FF F 39078 JONVCYOOOV NI C3TWISNI 38 5 9 TW 1 3NvdONd 304 NI 59 SVD 804 NI S E 135 SION TT dd A8 ONINOO NO Zi 17 OL AlddnS 021 103802 ONSAS NO CINY NI LV 135 S3ATWA TOMINOD X3L3V 31 201 SAVATW 39N S OME NOLHO A ING See Hc dr ONITIVISNI 340439 LOANNOOSIC MSN 3N3A3S 35 2 NVO QNVZVH WILONA HOLIMS ONI 3ATVA INOZ NISONS3HL ree INWA 5 9 SES ES E et mE 3991 TIONIS Shh Svo 1 5 Se PR MHO 4ns Nvv M ORNS A BW3SSv 1078 39 15 2 10 108 TWNOILdO WNOILdO Navas 1014 vcvgo BE I I 5 1 0 8150 3 oono Ad TIMA3NOH 9 7740090 RE La zo o L o 10 60 10 020 M AN OE O casn 35 IVISYNOY 0 me ca HOLIMS Hols 1visvnov TE
50. lves are provided with an integral vent limiter and threaded connection A bleed or gas relief line should be connected to it and piped to the outdoors The pipe compound used should be resistant to the action of liquefied petroleum gases Check for gas leaks in piping before placing the boiler in operation by using a soap and water solution DO NOT USE AN OPEN FLAME INSTALLER MUST IDENTIFY EMERGENCY SHUT OFF DEVICES All piping and fittings must be installed as per codes in Section 2 2 2 5 AIR SUPPLY FOR COMBUSTION AND VENTILATION A sufficient air supply MUST be provided to this boiler Air openings to the boiler room provide the air for combustion flue gas dilution and ventilation and are always required regardless whether the air is taken from inside or outside The air opening size and location as well as other air supply and venting considerations must conform to Section 2 2 The boiler room must never be under a negative pressure Always provide air openings sized not only to the dimensions required for the total input of all fuel fired appliances in the boiler space but also to handle the air movement rate of any exhaust fans or air movers using air from the building or space The venting terminations must always be kept clear of obstructions i e snow ice etc Louvers and grilles used in the air supply and ventilation system should be kept clear of any dust dirt or debris which will block proper air flow 2 6 CORROSIVE AT
51. ng the boiler The flow of supply and exhaust air must not be obstructed 2 5 Check air openings are not restricted and complies with applicable code s Adequate supply air is necessary for combustion flue gas dilution and ventilation 2 2 2 5 2 6 2 7 When the boiler has operated for several minutes check for spillage at draft hood venting ducts and other areas susceptible to spillage 4 7 Check externally the draft hood and vent system for soot rust scale or corrosion Check for dislodged venting or possible leaks in venting ducts Remove the draft hood from the boiler and inspect the flueways for the presence of soot or rust scale Inspect the draft hood and smoke pipe connecting the draft hood to the flue for rust or corrosion before replacing the draft hood The presence of soot rust scale or corrosion indicates misadjustment 5 2 Inspect and if necessary clean the pilot burner and main burner Check burners to see that they are not cracked or dislodged 4 3 5 2 Visually check the pilot and main burner flames A yellow flame caused by improper adjustment is always accompanied by formation of soot which if allowed to continue will partially restrict free passage of products of combustion to the flue 4 3 Check that gas piping is secured Smell for gas leaks around boiler and gas piping connections Gas leaks can also be checked for using a soap solution do not use an open flame to chec
52. o the draft hood If not the combustion products will tend to extinguish this flame If the combustion products are escaping from the relief opening of the draft hood IMMEDIATELY shutdown the boiler and make proper adjustments or repairs 4 8 CHECK OF CONTROLS After the unit has been operated for awhile lower the aquastat setting below the setpoint and burner should shut off Rotate the aquastat higher than setpoint and the main burner should ignite Return the aquastat to its original setpoint and make sure boiler cycles normally Repeat this type of check on the safety high limit aquastat thermostat and other system controls to ensure all work satisfactorily If any of the safety or controls do not function necessary corrections should be made immediately 4 9 CHECK FOR GAS LEAKS To identify gas leaks smell for gas around boiler area and gas piping connections See Section 1 1 To check a specific area for leakage spray a mixture of soap and water onto the suspected area active bubbling indicates a gas leak DO NOT TEST FOR LEAKS WITH AN OPEN FLAME Gas leaks must be repaired immediately 22 AAA Series Gas Boiler Installation and Service Manual 4 10 D D DU D ooo Ooo INSTALLER S CHECKLIST Reference Section The information printed on the boiler rating plate matches the application i e 46 altitude and fuel type All applicable electrical codes have been met 2 2 2 12
53. o the requirements in Section 2 2 Run a separate circuit from the electrical service panel through a fused disconnect switch to the boiler This boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 current edition and and or the Canadian Electrical Code CSA C22 1 Part 1 current edition Field wiring shall conform to Section 2 2 and to the temperature limitations of Type T 63 F 35 C rise or better Make field connections as shown in the wiring diagrams provided with this manual or on the sticker placed on the inside of the door panel of the boiler 2 13 BTC SERIES CONTROLLER WIRING The BTC series controller is supplied as standard option with two stage and single stage boilers it is not supplied with boilers equipped with a full modulating gas valve For convenience the BTC series controller is factory wired to terminal block TB4 and ready for field wiring connections The field wiring to TB4 is determined based on the operating mode selected i e mode 1 to 6 the heating application and the piping arrangement i e parallel or primary secondary Refer to Figure 1 for the wiring diagram for each mode For a detailed explanation of the modes and controller operation refer to the BTC Series Controller Manual AAA Series Gas Boiler Installation and Service Manual Field wiring to
54. o they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the boiler being inspected Follow the lighting instructions Adjust the thermostat So the boiler will operate continuously e 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 smoke from a cigarette cigar or pipe AAA Series Gas Boiler Installation and Service Manual f 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 fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI 2223 1 and or CAN CGA Installation Codes When re sizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI 2223 1 and or CAN CGA Installation Codes 2 8 BOILER PIPING SYSTEM The boiler piping system of a 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 gravi
55. ou do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life Intermittent pilot This boiler does not have a continuous pilot flame It is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand In the event of failure of any component either the system will not operate or it will go into safety lockout 1 Make sure the Gas Valve and all electrical power to the boiler are OFF 2 Set room thermostat to the lowest setting 3 Connect a manometer at pressure tapping on downstream section of gas valve 4 Wait five minutes to clear out any gas If you smell gas STOP Follow the safety instructions provided in Section 1 1 under WHAT TO DO IF YOU SMELL GAS Remember that propane does not vent upward naturally 5 Check the ignition control module as follows a Setthermostat above room temperature to call for heat and turn power on for the boiler b Watch for spark at pilot burner on units equipped with spark ignition All models will automatically lockout if no pilot flame is detected within 15 seconds Automatic retry will occur in 5 minutes 6 Press and hold three keys found below the LCD screen of the controller until Adjust is displayed Figure 3 In adjust mode enter the desired settings for your heating application see BTC Series Boiler Controller Manual tor more information 18 AAA
56. ould boiler overheat or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the circulating pump Instead shut off the gas supply at a location external to the boiler m go m oc Set the thermostat to the lowest setting Turn all electrical power to the boiler off Remove control access panel on the boiler if necessary Close the main and pilot manual gas shut off valves The valve is OFF when handle is perpendicular to the direction of gas flow Replace control access panel if necessary AAA Series Gas Boiler Installation and Service Manual Installation Instructions Section 2 2 1 RECEIVING INSPECT SHIPMENT FOR POSSIBLE DAMAGE All goods are carefully manufactured inspected checked and packed by experienced workers The manufacturer s responsibility ceases upon delivery of goods to the carrier in good condition Any claims for damage shortage in shipment or non delivery must be filed immediately against the carrier by the consignee Use care when receiving and unpacking the boiler Dropping the boiler may cause damage and prevent safe and proper operation 2 2 INSTALLATION CODES AND REQUIREMENTS All applicable national provincial state and local codes laws regulations and ordinances must be followed They expand on and take precedence over any recommendations in this booklet Authorities having jurisdiction shall be consulted before installations are made In Can
57. ring operation Significantly oversizing the boiler or decreasing boiler water flow rate will cause excessive stage cycling and may result in premature failure of components Typical Water Flow Versus Pressure Drop Across Boiler Model 20 F T D 30 F T D Number U S GPM P D FT U S GPM P D FT AAA480 41 0 3 0 27 3 1 35 600 51 2 3 0 34 1 1 35 720 61 4 3 0 41 0 1 35 AAA840 Als 3 0 47 8 1 35 AAAQ60 81 9 3 0 54 6 1 35 AAA1080 92 2 3 0 61 4 1 35 AAA1200 102 4 3 0 68 3 1 35 AAA1320 112 7 3 0 75 1 1 35 1440 122 9 3 0 81 9 1 35 AAA1560 133 1 3 0 88 8 1 35 AAA1680 143 4 3 0 95 6 1 35 AAA1800 153 6 3 3 102 4 1 35 AAA1920 163 9 3 3 109 2 1 5 AAA2040 174 1 3 5 116 1 1 6 AAA2160 184 3 3 5 122 9 1 6 AAA2280 194 6 3 8 129 7 1 7 AAA2400 204 8 3 8 136 5 1 7 AAA2495 212 9 3 8 142 0 1 7 2640 225 3 3 8 150 2 1 7 AAA2760 235 5 3 8 157 0 157 AAA2880 245 8 3 8 163 9 1 7 AAA3000 256 0 3 8 170 7 17 AAA Series Gas Boiler Installation and Service Manual ABOUT OUR MANUALS Your Super Hot boiler has been provided with the following manuals User s Information Manual This manual is intended for the owner or user of the boiler and provides information on routine operation and maintenance and emergency shutdown Installation and Service Manual This manual must only be used by a qualified heating installer service technician or gas suppli
58. s Boiler Installation and Service Manual flow to the space heating loop e g radiant in floor and redirect it to the DHW heating loop during a Setpoint DHW Demand See Figure 4 and Figure 5 MODE 4 ONLY Outdoor reset and reset override 51 Boiler Outlet Sensor 071 S2 Boiler Inlet Sensor 071 Pump1 Boiler Pump Pump2 DHW Pump A1 DHW Aquastat T1 Thermostat DHW Tank Figure 4 Typical piping diagram Mode 4 Sequence of Operation Thermostat T1 closed Thermostat creates a Heat Demand resulting in a boiler target based on the outdoor reset settings The boiler pump Pump1 operates DHW Aquastat A1 closed DHW Aquastat creates Setpoint DHW Demand and activates external pump relay The external pump relay causes the following actions 1 Power for the boiler pump Pump1 is broken Pump1 does not operate 2 Power for the DHW pump Pump2 is made Pump2 operates 3 Setpoint DHW Demand creates a boiler target based on the higher requirement of the outdoor reset and reset override setting L1 L2 P1 P2 tekmar Relay 003 A1 External Class Transformer Figure 5 Wiring diagram illustrating use of an External Relay to control pump operation 17 AAA Series Gas Boiler Installation and Service Manual 3 5 CONTROLLER MOUNTING The BTC series controller mounts on th
59. stallation and Service Manual NOTES Section 9 35 AAA Series Gas Boiler Installation and Service Manual INDEX Section 10 Section Page Dimensions and Specifications AAA Series Boilers 2 Boiler Water Flow nsn 3 About Our Manuals zs ini ated 4 1 Lighting In Su ctlohs E 4 Safety InStrUctlons oett nire OO C eee 4 1 2 Lighting 4 1 3 Lighting Instructions for Intermittent Electronic Ignition with Non combination Gas Valve 5 1 4 To Turn off Gas to the Boiler or Emergency 5 2 Installation Instructions ccseeeeseeeeeeeneneeeeeneneeeeeneneeeeeneeeeeeenseneeeeaseneeeenseeeeeeeseneeeensseeeeeeseeeeeenseneenens 6 a ILI uNe E 6 2 2 Installation Codes and 5 6 2 9 SLOCATOM eie a ut i edt 6 24 Gas Service Piping E a aE a 7 2 5 Air Supply for Combustion and Ventilation enne nnne 7 2 6 Corrosive Atmospheres sssssssssssssseseseseenene enne 7 2 7 Menting4iu Pe ORO Ep cip edt c
60. temperature Depending on the difference in temperature proportional the time integral and how fast or slow the temperature is changing derivative it will determine when to switch a stage on or off This feature prevents short cycling which can quickly wear out contactors and cause rapid temperature fluctuations The heating routine will operate until the water temperature reaches the user defined temperature setting Once reached the control will automatically cycle the stage s of the boiler on or off as necessary to maintain the supply water temperature The required number of stages which are activated is determined by the controller After the call for heat has been satisfied the stage s of the boiler will switch off in sequence followed by the pump 3 4 RESET OVERRIDE WARNING If both Heat Demand and Setpoint DHW Demand are present at the same time the controller targets the higher temperature of the two requirements This may result in higher than intended water temperatures in either space heating loop or domestic hot water DHW heating loop Use pipe rated for use at the highest possible water temperature The BTC Series Controller has one pump relay which is normally open and will close i e pump energized when either a Heat Demand or Setpoint DHW Demand is present When using Reset Override a switching external pump relay e g tekmar Relay 003 should be utilized to stop hot water 16 AAA Series Ga
61. terminal block TB4 WHT ST R IFS FS AL AL OS SD BO BI CH HL TB4 5 A B IN 24VAC COM THERMOSTAT OPTIONAL BOIL OUT 24 HOT TB1 POLE 2 ZONE VALVE ALARM TB1 POLE 1 END SWITCH C HT I ST FS FS AL AL OS SD BO BI CM HL HL TB4 1121314115 1617 18 19 1011111121113 14 115 16 Iw gl E a BOIL IN 24VAC COM THERMOSTAT OPTIONAL SUP DHW BOIL OUT 24 HOT TB1 POLE 2 ZONE VALVE ALARM TB1 POLE 1 END SWITCH C HT ST IFS FS AL AL CM OS SD BO BI CM HL HL TB4 lan 24VAC COM OPTIONAL SUP DHW BOIL OUT 24 HOT TB1 POLE 2 ALARM TB1 POLE 1 C WHT STH R FS FS AL AL CM OS SD BO BI CH HL TB4 5 N BOIL IN OPTIONAL 24VAC COM OPTIONAL OUTDOOR BOIL OUT 24 HOT TB1 POLE 2 ALARM TB1 POLE 1 THERMOSTAT ZONE VALVE END SWITCH eee te C E OUTDOOR BOIL IN OPTIONAL LN 24 NN OPTIONAL SUP DHW BOIL OUT 24 HOT TB1 POLE 2 ALARM TB1 POLE 1 THERMOSTAT ZONE VALVE END SWITCH MODE 1 HEATING WITHOUT OUTDOOR RESET USING PARALLEL PIPING BOILER
62. that burners and pilot flame extinguish Clearly identify emergency shut off devices and make the user or owner aware of their location and method of operation Fill in the contact information on the cover of the User s Information Manual and leave both manuals in the envelope adjacent to the boiler NOTE INSTALLER S RESPONSIBILITY Before leaving installations installers shall ensure that an appliance accessory component or equipment installed by them comply with the Code requirements and the person initially activating the appliance shall ensure that the appliance is in safe working order CSA B149 1 00 Natural Gas and Propane Installation Code 23 AAA Series Gas Boiler Installation and Service Manual Service amp Maintenance Instructions Section 5 5 1 SERVICE amp MAINTENANCE INSTRUCTIONS WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation WARNING If any part of this boiler has been under water inspect the boiler and replace any part of the control system and any gas control which has been under water This boiler has been designed to provide years of trouble free performance in normal installations The owner or user should conduct a general external examination covering all items on the User Checklist at the beginning of each heating season and in mid heating In addition the owner or user will
63. the dial until indicator points to the temperature Setpoint at which the gas valve will close The gas valve will open at setpoint less the differential The Safety High Limit aquastat may be fixed or adjustable If it is adjustable it should be set a minimum of 20 F 10 C above the setting of the Operating High Limit aquastat If the BTC series controller is used set both aquastats a minimum of 10 F 5 C above the controllers maximum target temperature see BOIL MAX setting in order to avoid nuisance shut downs 4 5 GAS MANIFOLD PRESSURE The designated manifold pressures are as shown in the table below A 1 8 NPT tapping is provided on the manifold or gas valve for connecting a manometer to check this pressure Both natural gas and propane models are furnished with gas valves which have a built in gas pressure regulator If necessary adjust to the proper value by removing cap and turning adjusting screw clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure Model Natural Gas Propane AAA 3 7 W C 8 7 W C 20 AAA Series Gas Boiler Installation and Service Manual 4 6 CHECK INPUT amp ORIFICES For safety the input shown on rating plate must not be exceeded Check with the table below that the orifice size and input rate shown on your boiler rating plate match your application i e boiler model fuel type and altitude See AAA Specifications to find a boiler model s input
64. tion e Use a vacuum with a HEPA filter for clean up Dispose of all RCF scrap and dust a closed airtight plastic bag FIRST AID MEASURES e Eye contact Flush eyes with water to remove dust for at least 15 minutes If irritation persists seek immediate medical attention e Skin contact Wash affected area gently with soap and warm water after handling Difficulty breathing Move to an area of clean fresh air Seek immediate medical attention if difficulties persist e Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 26 AAA Series Gas Boiler Installation and Service Manual Replacement Parts NOTE To supply the correct part it is important that you state the boiler model number serial number and type of gas when applicable Any part returned for replacement under standard company warranties must be properly tagged with Section 6 Return Goods Authorization Form R G A completely filled in with the boiler serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty the part will be returned in kind or equal substitution freight collect Credit will not be issued Refer to Figures 7 and 8 for replacement parts ITEM 2 IS PROVIDED ON SINGLE AND TWO 5 t 12 IS REQUIRED ON BOILERS WITH AN t ITEM 12 amp 17 ARE REQUIRED ON 0 5 BOILER A
65. ty circulation of the boiler water during the cooling cycle The boiler when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler 2 9 CORROSION PREVENTION INTERNAL The use of oxygen barrier tubing is recommended to protect the system and its components e g pump from corrosion Should your system include non oxygen barrier tubing please contact the factory or a heating professional for recommendations If freeze protection is required use an inhibited propylene glycol solution which is specifically designed for hydronic heating systems and always maintained at a neutral pH e g Fernox Alphi 11 or equivalent Follow the supplier s instructions for proper use and maintenance Do not use automotive antifreeze Some types of chemical additives can cause problems such as accelerated corrosion and result in premature failure of the boiler heat exchanger and or system components especially when not properly used or maintained Corrosion is a preventable condition and is not covered by the product warranty 2 10 SYSTEM OPERATING REQUIREMENTS WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life Avoid unnecessary replenishment of system water It can allow oxygen to enter the system an
66. unctioning controls or excessive water pressure If a pressure relief valve is not used the warranty is void The pressure relief valve should be installed on the boiler outlet with its spindle vertical The connection between the boiler and the relief valve must have at least the area of the valve inlet A discharge pipe should be used The discharge pipe outlet should be positioned over a suitable drain and so arranged that there will be no danger of being scalded The discharge pipe must pitch down from the pressure relief valve and should be no smaller than the outlet of the valve The end of the discharge pipe should not be concealed or threaded and should be protected from freezing Extensive runs traps or bends could reduce the capacity of the pressure relief valve No valve of any type should be installed between the pressure relief valve and unit or in the discharge pipe The pressure relief valve is a code requirement Field installation of the relief valve must be consistent with the ANSI ASME Boiler and Pressure Vessel Code Section IV Avoid contact with the hot water discharged to prevent personal injury 2 12 ELECTRICAL WIRING WARNING Risk of electric shock This boiler may be connected to more than one electrical circuit Turn off all electric power supply circuits at the electrical service panel or supply source Failure to do so may result in severe personal injury or death All electrical wiring must conform t
67. y pipes not purged of air Purge gas line Low pilot gas pressure Adjust pressure Dirt or foreign material in pilot Incorrect pilot flame pressure Clean Set pilot pressure to correct pressure Poor connections in wiring to flame sensor Repair wiring Electrodes are damaged Replace electrodes Ignition electrodes improperly adjusted Ignition electrodes are wet dirty or improperly adjusted for electronic ignition only Correct adjustment of electrodes Check clean change and or adjust the electrodes Poor connections in wiring to flame sensor Incorrect orifice sizing Repair wiring Check orifice and replace if necessary Inadequate combustion and ventilation air Check and adjust Dusty environment Clean Low return water temperature Adjust system Manifold pressure too high Insufficient circulation Adjust manifold pressure Check pump clean and replace if necessary Air trapped in piping Purge system Improper system wiring Faulty thermostat or controller Test and correct Check adjust and replace if necessary Faulty aquastat and or safety high limit aquastat Check adjust and replace if necessary Faulty wiring 33 Check wiring for short circuits and repair AAA Series Gas Boiler Installation and Service Manual NOTES Section 9 34 AAA Series Gas Boiler In

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