Page 2 - DIMENSIONS; Figure 1 - Boiler Dimensions
Page 3 - INTRODUCTION; Introduction; fl
3 INTRODUCTION Introduction • This appliance is a gas- fi red direct vent hot water boiler with cast aluminum boiler sections. • The heating system water absorbs large amounts of heat from the cast aluminum heat exchanger, cooling fl ue gases and causing condensation. • Sealed combustion, premix gas...
Page 4 - NOTICE; CAUTION; This is the safety alert symbol. Symbol alerts you to; WARNING; IMPORTANT SAFETY INFORMATION; Keep this manual near boiler
4 Installation shall conform to requirements of author- ity having jurisdiction or in absence of such require- ments: • United States • National Fuel Gas Code, ANSI Z223.1/NFPA 54. • National Electrical Code, NFPA 70. • Canada • Natural Gas and Propane Installation Code, CAN/CSA B149.1. • Canadian E...
Page 5 - Table 1 - SEA LEVEL RATINGS – NATURAL AND PROPANE GASES; * 1 MBH = 1,000 Btuh Btuh = British Thermal Units Per Hour; BOILER RATINGS & CAPACITIES; ed for natural gas only.
5 Table 1 - SEA LEVEL RATINGS – NATURAL AND PROPANE GASES Model Input *(MBH) ++ Heating Capacity *(MBH) Net AHRI Rating *(MBH) Shipping Weight (lbs.) Flue Diameter 90-50 50 45 39 220 2” CPVC & PVC 90-75 75 68 59 220 2” CPVC & PVC 90-100** 100 90 78 220 2” CPVC & PVC * 1 MBH = 1,000 Btuh ...
Page 6 - Stock Factory; Stock Factory; Orifi ce; BOILERS FOR USE AT HIGH ALTITUDE - UNITED STATES INSTALLATIONS
6 Table 2 - 90 - 50/75/100 SERIES 2 NATURAL GAS MODEL 90-50 Stock Factory Btu Value of Natural Gas++ Settings 750 850 950 1000 1050 Altitude in Ft. 0-5,000 5,000-10,000 Normal Input (MBH) 50 – – – – – Manifold Pressure In W.C. 2.5 4 4 3.5 2.5 2.5 Orifi ce 43331094 43331094 MODEL 90-75 Stock Factory ...
Page 7 - ce Kit
7 Table 3 - 90 - 50/75 SERIES 2 PROPANE GAS MODEL 90-50 Stock Factory Btu Value of Propane Gas++ Settings 2300 2350 2400 2450 2500 Altitude in Ft. 0-5,000 5,000-10,000 Normal Input (MBH) 50 – – – – – Manifold Pressure In W.C. 2.5 3 3 2.5 2.5 2.5 Orifi ce 43331095 43331095 MODEL 90-75* Stock Factory ...
Page 8 - BEFORE INSTALLING THE BOILER
8 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. S...
Page 9 - Required Clearances; Unit; All distances measured from the cabinet of the boiler.; Locating The Boiler; Solvent cements are combustible. Keep away from; BOILER INSTALLATION
9 Table 4 - Required Clearances Unit Combustible Clearance Accessibility, Cleaning, and Servicing Top 1” (26mm) 8” (204mm) Left Side 1 “ (26mm) 24” (610mm) Right Side 11” (280mm) - Base 1” (26mm) - Front 1” (26mm) 24” (610mm) Back 1” (26mm) - Intake/Vent Piping 0 (0) - Near Boiler Hot Water Piping 1...
Page 10 - Condensate Drain Requirements; Foundation Requirements; Fire hazard. Do not install boiler on carpeting.; Removal of Existing Boiler From Common Vent
10 Condensate Drain Requirements • Pitch condensate drain line down to fl oor drain at mini- mum of ¼” per foot. External condensate pump (not furnished) may be used if fl oor drain is not available. • Condensate pump must be designed for fl ue gas con- densate application. • Condensate trap provide...
Page 11 - NEAR BOILER PIPING; Supply And Return Lines
11 Clean the System First Before connecting boiler to heating system, clean and fl ush system thoroughly. Verify system is free of sediment, fl ux and any residual boiler water additives. Systems having antifreeze not recommended must be completely fl ushed to insure no old antifreeze remains. In ol...
Page 12 - Figure 2 - Single Zone Boiler Piping
12 NEAR BOILER PIPING Figure 2 - Single Zone Boiler Piping
Page 13 - Figure 3 - Two Zone Boiler Piping With Zone Valves
13 Figure 3 - Two Zone Boiler Piping With Zone Valves NEAR BOILER PIPING Multi-Zone Systems Multi-zone systems with two zones are typically piped as shown in fi gures 3 or 4. Multi-zone systems with more than two zones are likely to have small zones with very low heat and fl ow requirements compared...
Page 14 - Figure 4 - Two Zone Boiler Piping With Circulators
14 Figure 4 - Two Zone Boiler Piping With Circulators NEAR BOILER PIPING
Page 15 - Water
15 NEAR BOILER PIPING Figure 5 - Primary/Secondary Piping And Wiring With Circulators And Domestic Hot Water
Page 16 - Valves And Domestic Hot Water (With Zone Valve)
16 NEAR BOILER PIPING Figure 6 - Piping and Wiring Primary/Secondary Multi Zone System Piping With Zone Valves And Domestic Hot Water (With Zone Valve)
Page 18 - Burn and scald hazard. Safety relief valve could
18 Safety Relief Valve Installation of safety relief valve shall conform to ANSI/ ASME Boiler and Pressure Vessel Code, Section IV. • Install furnished safety relief valve using 3/4” x 4½” pipe provided with boiler. See Figure 8 . • Install safety relief valve with spindle in vertical position. • Do...
Page 19 - Figure 9 - Diaphragm Type Expansion Tank Piping
19 Figure 9 - Diaphragm Type Expansion Tank Piping NEAR BOILER PIPING
Page 20 - Figure 10 - Conventional (Closed Type) Expansion Tank Piping
20 Figure 10 - Conventional (Closed Type) Expansion Tank Piping NEAR BOILER PIPING
Page 21 - Condensate Drain Piping; Figure 11 - Condensate Drain Piping; Filling Condensate Trap With Water; Chilled Water Piping
21 Condensate Drain Piping Boiler is factory equipped with a condensate trap. An additional trap is not required and should NOT be used. 1. Provide ½” PVC condensate drain and fi ttings. Condensate drain to be pitched down to fl oor drain at a minimum of ¼” per foot. 2. Install ½” PVC tee to over fl...
Page 22 - Connections And Termination; Canada; Transition from 2” pipe to 3” pipe must be made in; COMBUSTION AIR AND VENT PIPE
22 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 appli...
Page 23 - BOILER; FEET; Installation
23 • Under certain conditions, fl ue gas will condense, forming moisture, and may be corrosive. Take steps to prevent building materials at vent from being damaged by exhaust of fl ue gas. • Vent shall not terminate where it may cause hazardous frost or ice accumulations on adjacent property surface...
Page 24 - Figure 12 - Roof Vent / Intake Terminations
24 Figure 12 - Roof Vent / Intake Terminations COMBUSTION AIR AND VENT PIPE VENT AIR INTAKE
Page 25 - Less Than 12” Clearance
25 Figure 13 - Side Wall Vent / Intake terminations - Less Than 12” Clearance Above Grade Figure 14 - Side Wall Vent/Intake Terminations - 12” Or More Clearance Above Grade COMBUSTION AIR AND VENT PIPE Less Than 12” Clearance 12” Or More Clearance
Page 26 - Figure 15 - Concentric Vent Terminations; Combustion; Figure 16 - Concentric Vent; Figure 17 - Concentric Vent Roof
26 Figure 15 - Concentric Vent Terminations Combustion Air Vent 1" (2.54cm) Maximum Maintain 12" clearance above highest anticipated snow level or grade * See Note Below Vent Combustion Air 36"(0.9m) Minimum Maintain 12"(30cm) clearance above highest anticipated snow level or grade 1...
Page 27 - Figure 18 - Combustion Air and Vent Piping - Boiler Connections; length for all models
27 Figure 18 - Combustion Air and Vent Piping - Boiler Connections COMBUSTION AIR AND VENT PIPE 2” (50.8mm) DIAMETER VENT AND COMBUSTION AIR INTAKE PIPING - 21 feet maximum total equivalent length for 90-100 models-26 feet maximum total equivalent length for 90-50 and -90-75 models- 2 feet minimum t...
Page 28 - GAS SUPPLY PIPING
28 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 supply piping system during any system pr...
Page 29 - Table 7 – Gas Pipe Sizes; NATURAL GAS; Figure 19 - Gas Piping
29 Table 7 – Gas Pipe Sizes NATURAL GAS Length of Pipe - Ft. Pipe Capacity - BTU Per Hour Input Includes Fittings 1/2” 3/4” 1” 1 1/4” 20 92,000 190,000 350,000 625,000 40 63,000 130,000 245,000 445,000 60 50,000 105,000 195,000 365,000 PROPANE GAS Length of Pipe - Ft. Pipe Capacity - BTU Per Hour In...
Page 30 - Electric Power Supply; ELECTRICAL WIRING; Thermostat Installation; Connect Circulator Pump Wiring; Electrical shock hazard. Turn OFF electrical power
30 Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to: • USA- National Electrical Code, ANSI/NFPA 70.• Canada - Canadian Electrical Code, Part I, CSA C22.1: Safety Standard for Electrical Installations. Electric Power Supply Prior to making ...
Page 31 - Figure 20 - Wiring Schematic; If any of original wire as supplied with this appliance
31 Figure 20 - Wiring Schematic ELECTRICAL WIRING NOTICE If any of original wire as supplied with this appliance must be replaced, it must be replaced with type105°C Thermoplastic wire or its equivalent
Page 32 - Figure 21 - Ladder Wiring Diagram
32 Figure 21 - Ladder Wiring Diagram ELECTRICAL WIRING
Page 33 - System with Circulators Using Argo AR822II Pump Relay
33 Figure 22 - Suggested Wiring Schematic for Domestic Hot Water Priority Two Zone System with Circulators Using Argo AR822II Pump Relay ELECTRICAL WIRING
Page 34 - Figure 23 - Ladder Diagram for Figure 22
34 Figure 23 - Ladder Diagram for Figure 22 ELECTRICAL WIRING
Page 35 - For Installations using Indirect Hot Water Heater; Gas Control Valve; CONTROLS AND ACCESSORIES
35 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. Integrated Boiler Control (IBC) Integrated B...
Page 36 - Never run cold water into a hot empty boiler.
36 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 cast...
Page 37 - START UP
37 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 a...
Page 38 - OPERATING INSTRUCTIONS
38 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. DO NOT try to light the burner by hand. 4. Remove the front jacket panel. 5. Turn...
Page 39 - S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS; Table 8 - User Parameters
39 S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS S9381A control has a number of user adjustable parameters as shown in Table 8. Table 8 - User Parameters Adjusting Settings To discourage unauthorized changing of settings, a procedure to enter the adjustment mode is required. To enter th...
Page 40 - Table 9 - State Code Defi nitions
40 S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS Table 9 - State Code Defi nitions
Page 41 - Figure 26 - Sequence of Operation
41 S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS Figure 26 - Sequence of Operation
Page 42 - CHECK OUT PROCEDURE AND ADJUSTMENT
42 First couple of cold starts may be rough due to gas line not being completely purged of air, causing low fi ring rate and high excess air levels. Inspect Venting And Air Intake System Operate boiler and verify all vent/air intake connections are gas-tight and watertight. Repair any leaks immediat...
Page 43 - Set Thermostat To Desired Room Temperature
43 CHECK OUT PROCEDURE AND ADJUSTMENT F. After adjusting input rate, turn boiler off, remove manometer or pressure gauge, reinstall ⅛ ” plug on gas valve. Turn boiler on. G. Boiler should typically operate between: • 8.5% -10.0% CO2 on Natural Gas• 9.5% -11.0% CO2 on Propane Gas Under all conditions...
Page 44 - Figure 27 - Manifold Pressure Measurement Detail
44 Following steps and diagram indicate location of the connection points required to measure manifold pressure.Manifold pressure may be measured using a U-Tube Manometer or Differential Pressure Gauge. Diagram shows connection of both measuring devices. Only ONE DEVICE IS REQUIRED to measure manifo...
Page 45 - MAINTENANCE AND CLEANING
45 Maintenance As Outlined Below Can Be Performed By Owner Unless Otherwise Noted. • The acidic nature of fl ue 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 negligi...
Page 46 - Annual Examination And Cleaning Of Boiler; DANGER
46 K. Reinstall burner and mixer gasket and position mixer assembly over studs. Install fi ve (5) nuts but do not tighten. Reinstall igniter and igniter gasket and fasten with two (2) screws. Use care when installing the igniter. Tighten fi ve (5) nuts holding mixer assembly. L. Connect: • Gas line ...
Page 47 - TROUBLESHOOTING; Fire, explosion or shock hazard. Do not attempt to
47 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. 2. If any component does not function properly, make sure it is correctly installed and wired before replacing it. 3. Static electricity di...
Page 48 - Error Codes
Page 49 - DIFFERENTIAL AIR PRESSURE SWITCH CHECK
49 • Following steps and diagram indicate locations of connection points required to check differential air pressure. • Differential air pressure switch is safety device which prevents boiler from fi ring if there is air intake, boiler heat exchanger or vent blockage. • Turn off service switch, or l...
Page 50 - Aluminum Series; High Ef; DIELECTRIC ISOLATION & ANTIFREEZE PROTECTION; APPENDIX A - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION; • DIELECTRIC ISOLATION
50 Aluminum Series High Ef fi ciency Gas-Fired Boiler DIELECTRIC ISOLATION & ANTIFREEZE PROTECTION ADDENDUM APPENDIX A - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION WARNING Follow these instructions to prevent damage to boiler’s heat exchanger caused by inadequate dielectric isolation, ...
Page 51 - Eliminate System Leaks; Clean System First
51 System and Operating Precautions Applies to ALL Aluminum High Effi ciency Gas-Fired Water Boilers 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 compo...
Page 52 - General Guidelines When Using Antifreeze
52 System and Operating Precautions Applies to ALL Aluminum High Effi ciency Gas-Fired Water Boilers General Guidelines 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 wil...
Page 53 - Compatible Aluminum Antifreeze & Inhibitor Suppliers; Noburst AL Antifreeze; Table 11 - Antifreeze Products; System and Operating Precautions
53 Compatible Aluminum Antifreeze & Inhibitor Suppliers Noburst AL Antifreeze Noble Company P. O. Box 350 Grand Haven, MI 49417 www.noblecompany.com Tel: 800-878-5788 Fax: 231-799-8850 Rhogard Antifreeze & Pro-Tek 922 Inhibitor* Rhomar Water Management, Inc. P. O. Box 229 Spring fi eld, MO 6...
Page 54 - INSTALLATION AND CHECK-OUT CERTIFICATE
54 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner/ maintenance person Ins...
Page 55 - NOTES
