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Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
ƽ DANGER
ƽ WARNING
ƽ CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
Contents
HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3-4
RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
THE SOLUTION --HOW IT WORKS . . . . . . . . . . . . . . . . . . . 6-8
1. DETERMINE BOILER LOCATION
Location of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . 10-12
2. VENTING
A Conventional Negative Draft Venting System . . . . . . . 13-14
Vertical Vent Termination Clearances . . . . . . . . . . . . . . . 15
Masonry Chimney Installation . . . . . . . . . . . . . . . . . . . . . 16
Inspection of a Masonry Chimney . . . . . . . . . . . . . . . 16
Automatic Vent Damper . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3. GAS CONNECTIONS
Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gas Manifold Pressure Adjustment Procedure . . . . . . . . 20
Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . . 21
Combination Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. WATER CONNECTIONS
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Water Flow Switch (if equipped) . . . . . . . . . . . . . . . . . . . 23
Low Water Cutoff (if equipped) . . . . . . . . . . . . . . . . . . . . 24
Typical Heating Boiler Installations . . . . . . . . . . . . . . . . . 24-25
Piping of the Boiler System . . . . . . . . . . . . . . . . . . . . . . . 25
Performance Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Primary/Secondary Boiler Piping . . . . . . . . . . . . . . . . . . . 27-28
Low Temperature Bypass Requirements . . . . . . . . . . . . . 28
Boiler Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Primary / Secondary Piping . . . . . . . . . . . . . . . . . . . . 29-31
Full System Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33
5. ELECTRICAL CONNECTIONS
Boiler Operating Temperature Control . . . . . . . . . . . . . . . 34
Room Thermostat or Remote Thermostat Connection . . 34
Auxiliary Device Connection to Terminal Strip . . . . . . . . . 34
Pump Wiring for a Heating Boiler . . . . . . . . . . . . . . . . . . 35
Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 35
Temperature Control Settings . . . . . . . . . . . . . . . . . . . . . 35
Maximum Set Point Determination . . . . . . . . . . . . . . . . . 36
Outdoor Air Reset Option . . . . . . . . . . . . . . . . . . . . . . . . 38
Additional Temperature Controls . . . . . . . . . . . . . . . . . . . 38
Blocked Vent and Flame Roll-Out / Flame Interlock Switch . 39
6. STARTUP
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Lighting Instructions for Spark Ignition Pilot Models (M9) . . . . 40
Safety Shutoff Test for Spark Ignition Pilot System . . . . . .41
Intermittent Pilot Spark Ignition System (M9) . . . . . . . . . . . . 42
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7. MAINTENANCE
Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 43-48
8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 49
9. DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50