Installation InstructionTable of ContentsPART 1 – GENERAL SAFETY INFORMATION8A. PRECAUTIONS8B. IMPROPER COMBUSTION8C. GAS8D. WHEN SERVICING THE BOILER8E. BOILER SYSTEM8F. BOILER WATER CHEMISTRY9G. FREEZE PROTECTION FLUIDS9PART 2 – BEFORE YOU START9A. WHAT’S IN THE BOX9B. HOW BOILER OPERATES10C. OPTIONAL EQUIPMENT11PART 3 – PREPARE BOILER LOCATION11A. BEFORE LOCATING THE BOILER11B. LEVELING12C. CLEARANCES FOR SERVICE ACCESS12D. RESIDENTIAL GARAGE, CLOSET, AND ALCOVE INSTALLATIONS15E. EXHAUST VENT AND INTAKE PIPE151. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE152. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE15F. PREVENT COMBUSTION AIR CONTAMINATION16G. REMOVING AN BOILER FROM A COMMON VENT SYSTEM17PART 4 – PREPARE BOILER17A. REMOVE THE BOILER FROM PACKAGING17B. WALL MOUNTING CONSIDERATIONS18C. WALL MOUNTING INSTRUCTIONS181. MOUNTING TO A WOOD STUDDED WALL182. MOUNTING TO A METAL FRAME19PART 5 – BOILER PIPING19A. GENERAL PIPING INFORMATION20B. RELIEF VALVE20C. BACKFLOW PREVENTER21D. SYSTEM WATER PIPING METHODS21E. CIRCULATORS21F. HYDRONIC PIPING WITH CIRCULATORS, ZONE VALVES, AND MULTIPLE BOILERS22G. PIPING DETAILS22H. PIPING INSTALLATION30I. CIRCULATOR SIZING30J. CHECK/CONTROL WATER CHEMISTRY31K. FILL AND PURGE HEATING SYSTEM32L. GLYCOL ANTIFREEZE SOLUTIONS33M. ZONING WITH ZONE VALVES33N. ZONING WITH CIRCULATORS33O. MULTIPLE BOILERS33PART 6 – VENTING, COMBUSTION AIR, AND CONDENSATE REMOVAL34A. GENERAL34B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE PIPE35C. REQUIREMENTS FOR INSTALLATION IN CANADA35D. EXHAUST VENT AND INTAKE PIPE LOCATION36E. EXHAUST VENT AND INTAKE PIPE SIZING40F. LONGER VENT RUNS41G. EXHAUST VENT AND INTAKE PIPE INSTALLATION41H. VENTING DRAWINGS421. DIRECT VENT INSTALLATION OF EXHAUST VENT AND INTAKE PIPE422. VENTING THROUGH AN EXISTING SYSTEM453. INDOOR COMBUSTION AIR INSTALLATION IN CONFINED OR UNCONFINED SPACE47PART 7 – GAS PIPING49A. GAS CONNECTION49B. GAS PIPING49C. CHECK INLET GAS PRESSURE50D. BOILER GAS VALVE51PART 8 – FIELD WIRING52A. INSTALLATION MUST COMPLY WITH:52B. FIELD WIRING TERMINATIONS52C. FIELD WIRING52D. LINE VOLTAGE WIRING FOR STANDARD BOILER53E. ALARM CONNECTIONS53F. LOW VOLTAGE CONNECTIONS FOR STANDARD BOILER53G. THERMOSTAT53H. OUTDOOR SENSOR54I. INDIRECT SENSOR54J. OPTIONAL 0-10 VOLT BUILDING CONTROL SIGNAL54K. OPTIONAL UL353 LOW WATER CUT-OFF INTERFACE KIT55L. WIRING OF CASCADE SYSTEM COMMUNICATION BUS55M. CASCADE MASTER PUMP AND SENSOR WIRING56N. CASCADE FOLLOWER PUMP AND SENSOR WIRING56PART 9 – START-UP PREPARATION59A. CHECK / CONTROL WATER CHEMISTRY59B. CHECK FOR GAS LEAKS60C. FREEZE PROTECTION (WHEN USED)60D. FILL AND TEST WATER SYSTEM60E. PURGE AIR FROM WATER SYSTEM61F. CHECK THERMOSTAT CIRCUIT(S)61G. CONDENSATE REMOVAL61H. FINAL CHECKS BEFORE STARTING BOILER62I. CASCADE SYSTEM62J. LOCKOUT CONDITION63PART 10 – START-UP PROCEDURE63A. CONTROL OVERVIEW63B. NAVIGATION OF THE DISPLAY63C. OPERATING INSTRUCTIONS64D. PROGRAMMING BOILER SETTINGS64E. PROGRAMMING THE SYSTEM SETTING65F. SYSTEM SETTING PROGRAM NAVIGATION65G. RESETTING THE MAINTENANCE SCHEDULE68PART 11 – START-UP PROCEDURES FOR INSTALLER68A. BOILER CONTROL STATUS MENU68B. CASCADE MENU70C. BOILER TEST MODE70PART 12 – SHUTDOWN71A. SHUTDOWN PROCEDURE71B. VACATION PROCEDURE71C. FAILURE TO OPERATE71PART 13 – TROUBLESHOOTING72A. BOILER ERROR CODE72B. BOILER ERROR72C. BOILER FAULT72D. USER INTERFACE DISPLAY73PART 14 – MAINTENANCE77A. MAINTENANCE PROCEDURES77B. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS FOR BOILER78C. CLEANING WATER SIDE OF HEAT EXCHANGER78D. MAINTAINING THE CONDENSATE SYSTEM79BOILER START-UP REPORT85MAINTENANCE REPORT85MAINTENANCE NOTES89CUSTOMER INSTALLATION RECORD FORM90Size: 6.94 MBPages: 90Language: EnglishOpen manual
