UH15B-K Cast Iron Gas Fired Boilers

Specifications:

• Model: 15B-K, UH15B-K
• Certification: C.S.A. Certified for Natural Gas or Propane
• Working Pressure: Tested for 50 psi. ASME
• Manufacturer: ECR International Inc.
• Address: 2201 Dwyer Avenue, Utica, NY 13501
• Contact: Tel. 800 325 5479, Website: www.ecrinternational.com

Product Usage Instructions:

1 – Physical Data:

Refer to the manual for detailed physical data such as
dimensions, weight, and other relevant information.

2 – Safety Symbols And Warnings:

Review the safety symbols and warnings provided in the manual to
ensure safe operation of the boiler.

3 – Locating The Boiler:

Follow the installation requirements outlined in the manual for
proper location of the boiler. Ensure minimum clearances to
combustible construction are maintained.

3.1 Installation Requirements:

Adhere to the installation requirements specified in the manual
to ensure proper functioning of the boiler.

3.2 Minimum Clearances To Combustible Construction:

Maintain minimum clearances to combustible construction as per
the guidelines provided in the manual.

3.3 Recommended Clearances For Service:

Recommended clearances for service should be followed to
facilitate maintenance and servicing of the boiler.

3.4 Boiler Location Considerations:

Consider various factors for determining the optimal location
for the boiler as detailed in the manual.

4 – Connecting Supply And Return Piping:

Follow the steps below for connecting supply and return
piping:

4.1 Connection Locations:

Identify and connect supply and return piping at the designated
locations specified in the manual.

4.2 Safety Relief Valve Installation:

Install the safety relief valve according to the instructions
provided to ensure proper operation of the system.

4.3 Flush And Rinse System:

Flush and rinse the system as outlined in the manual to remove
any impurities before operation.

4.4 Water Treatment:

Implement water treatment measures as recommended to maintain
the efficiency and longevity of the boiler.

4.5 Supply And Return Requirements:

Ensure that supply and return requirements are met to optimize
performance and efficiency.

4.6 Special Conditions:

Take into account any special conditions specified in the manual
for proper installation and operation.

Frequently Asked Questions (FAQ):

Q: Where can I find the parts list for the boiler?

A: Refer to manual 240013663 included with your boiler
literature package for the parts list.

Q: How often should I check for updates on the manufacturer’s

website?

A: It is recommended to check the manufacturer’s website
frequently for updates related to your boiler model.

CAST IRON GAS FIRED BOILERS FOR FORCED HOT WATER
With Hydrolevel 4200 Control
INSTALLATION, OPERATION & MAINTENANCE MANUAL

Models

15B-K

UH15B-K

C.S.A. Certified For Natural Gas Or
Propane

Tested For 50 psi. ASME
Working Pressure
Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 325 5479 www.ecrinternational.com PN 240013661 REV. B [02/10/2023]

VERIFY CONTENTS RECEIVED

Fully Assembled Boiler

Vent Damper

Draft Hood

Pump (Optional)

*Drain Valve

*ASME Safety Relief Valve

A. This Instruction, Parts List and User Manual
B.Warranty Information
C. Wire Diagram

*Tridicator

*Black Iron Fittings (see parts list for sizes
and use)

Document Package

*Junction Box

• Items found in parts box included with your boiler.

*Circulator Harness

For Parts lists see manual 240013663 included with your boiler literature package.

KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE
Check our website frequently for updates: www.ecrinternational.com
Information and specifications outlined in this manual in effect at the time of printing of this manual. ECR International reserves the right to discontinue, change specifications or system design at any time without
notice and without incurring any obligation, whatsoever.

2

PN 240013661 Rev. B [02/10/2023]

TABLE OF CONTENTS

1 – Physical Data ……………………………………………………………………………………………………………………… 4

2 – Safety Symbols And Warnings……………………………………………………………………………………………….. 5

3 – Locating The Boiler ……………………………………………………………………………………………………………… 7

3.1 Installation Requirements …………………………………………………………………………………………………… 7

3.2 Minimum Clearances To Combustible Construction

7

3.3 Recommended Clearances For Service……………………………………………………………………………………. 7

3.4 Boiler Location Considerations …………………………………………………………………………………………….. 8

4 – Connecting Supply And Return Piping …………………………………………………………………………………….. 9

4.1 Connection Locations ………………………………………………………………………………………………………… 9

4.2 Safety Relief Valve Installation

10

4.3 Flush And Rinse System ………………………………………………………………………………………………….. 11

4.4 Water Treatment …………………………………………………………………………………………………………… 11

4.5 Supply And Return Requirements ……………………………………………………………………………………….. 12

4.6 Special Conditions ………………………………………………………………………………………………………….. 12

5- Ventilation & Combustion Air ……………………………………………………………………………………………….. 19 5.1 Requirements………………………………………………………………………………………………………………… 19

6 – Vent System Modification ……………………………………………………………………………………………………. 20 6.1 Removal Of Existing Boiler From Venting System …………………………………………………………………….. 20

7 – Vent Installation ……………………………………………………………………………………………………………….. 21 7.1 Check Your Chimney ……………………………………………………………………………………………………….. 21 7.2 Requirements………………………………………………………………………………………………………………… 21 7.3 Chimney Inspection ………………………………………………………………………………………………………… 21 7.4 Vent Pipe……………………………………………………………………………………………………………………… 21

8 – Vent Damper Installation & Instructions……………………………………………………………………………….. 22 8.1 Vent Damper ………………………………………………………………………………………………………………… 22

9 – Connecting Gas Service ………………………………………………………………………………………………………. 24 9.1 General ……………………………………………………………………………………………………………………….. 24
9.2 Leak Check Gas Piping …………………………………………………………………………………………………….. 24

10 – Electrical ………………………………………………………………………………………………………………………… 25 10.1 Electrical Wiring……………………………………………………………………………………………………………. 25
10.2 Thermostat Installation…………………………………………………………………………………………………… 25

11 – Wiring Diagrams …………………………………………………………………………………………………………….. 26

12 – Lighting Instructions………………………………………………………………………………………………………… 28 12.1 Lighting Procedure For Boiler With Intermittent Pilot System……………………………………………………….28 12.2 Operating Instructions For Intermittent Pilot System…………………………………………………………………28 12.3 To Turn Off Gas To The Appliance ………………………………………………………………………………………. 28

13 – Normal Sequence Of Operation ………………………………………………………………………………………….. 29 13.1 General ……………………………………………………………………………………………………………………… 29

14 – General Maintenance And Care Instructions………………………………………………………………………… 30 14.1 Seasonal Startup ………………………………………………………………………………………………………….. 30 14.2 Clean Flue Gas Passageways …………………………………………………………………………………………… 30 14.3 General Maintenance……………………………………………………………………………………………………… 31 14.4 Adjusting Gas Input ………………………………………………………………………………………………………. 32

15 – Ratings And Capacities……………………………………………………………………………………………………… 33

Appendix A – Control Function ………………………………………………………………………………………………….. 34 A-1. Intermittent Pilot…………………………………………………………………………………………………………… 35

Appendix B – Vent Damper Installation ……………………………………………………………………………………… 37 B.1 Damper Installation ………………………………………………………………………………………………………… 37 B.2 Vent Damper ………………………………………………………………………………………………………………… 37 B.3 Vent Damper Harness – Molex Plugs…………………………………………………………………………………….. 38 B.4 Vent Damper Troubleshooting Guide…………………………………………………………………………………….. 39

3

PN 240013661 Rev. B [02/10/2023]

Model # Sections A Width with Jacket
B Vent Location (Half Width)
C Height
D Damper Height
E Depth w/o Draft Hood Installed
F Depth W/ Draft Hood Installed
G Flue Diameter Supply & Return Tappings Natural Gas Inlet Relief Valve NPT Drain Valve NPT Heating Water Content, Gal (Liters) Air Cushion Tank, Gal (Liters) Estimate.*
(Actual Based on System Size)
Boiler Weight, less pkg – Lbs (KG) Shipping Weight, lbs (KG)

15B-060K UH15B-060K
3 13-³/8″ 340 mm 6-³/4″ 171 mm 32-¹/8″ 816 mm
6″ 153 mm
22″ 559 mm
26″ 660 mm
4″ 102 mm 1-¹/4″ NPT 1/2″ NPT 3/4″ NPT 3/4″ NPT 1.9 (7.2)
15 (27)*
170 (77) 215 (98)

1 – PHYSICAL DATA

15B-095K UH15B-095K
4 13-³/8″ 340 mm 6-³/4″ 171 mm 32-¹/8″ 816 mm
6″ 153 mm
22″ 559 mm
26″ 660 mm
5″ 127 mm
1-¹/4″ NPT 1/2″ NPT 3/4″ NPT 3/4″ NPT 2.3 (8.8)

15B-120K UH15B-120K
5 16-1/4″ 411 mm 8-¹/8″ 206 mm 32-¹/8″ 816 mm 6-¹/2″ 165 mm
22″ 559 mm
26″ 660 mm
6″ 152 mm
1-¹/4″ NPT 1/2″ NPT 3/4″ NPT 3/4″ NPT 2.8 (10.5)

15B-150K UH15B-150K
6 19″ 483 mm 9-¹/2″ 241 mm 32-¹/8″ 816 mm 6-¹/2″ 165 mm 22″ 559 mm 26″ 660 mm 6″ 152 mm 1-¹/4″ NPT 1/2″ NPT 3/4″ NPT 3/4″ NPT 3.2 (12.2)

30 (114)*

30 (114)*

30 (114)*

210 (96) 250 (114)

250 (114) 295 (134)

280 (128) 335 (152)

15B-175K UH15B-175K
7 21-7/8″ 555 mm 10-¹5/16″ 278 mm 32-¹/8″ 816 mm
7″ 178 mm
22″ 559 mm
26″ 660 mm
7″ 178 mm 1-¹/4″ NPT 1/2″ NPT 3/4″ NPT 3/4″ NPT 3.7 (13.9)
30 (114)*
320 (145) 385 (175)

15B-205K UH15B-205K
8 27-¹/2″ 700 mm 13-³/4″ 349 mm 32-¹/8″ 816 mm
7″ 178 mm
22″ 559 mm
26″ 660 mm
7″ 178 mm 1-¹/4″ NPT 3/4″ NPT 3/4″ NPT 3/4″ NPT 4.1 (15.6)
30 (114)*
350 (159) 420 (191)

15B-235K UH15B-235K
9 27-¹/2″ 700 mm 13-³/4″ 349 mm 32-¹/8″ 816 mm
7″ 178 mm
22″ 559 mm
26″ 660 mm
7″ 178 mm 1-¹/4″ NPT 3/4″ NPT 3/4″ NPT 3/4″ NPT 4.6 (17.3)
30 (114)*
390 (177) 465 (211)

Figure 1 – Dimensions Front View
“A” “B”
“G”

Right Side View “F”
“E”

“D”
2″ (50.8 mm)

“C”

21/8″ (549.3 mm)

7″ (117.8mm)

12¹/2″ (317.5 mm)

4

GAS SUPPLY

16³/8″ (416mm)

23″ (584mm) 7¹/8″ (181mm)
PN 240013661 Rev. B [02/10/2023]

2 – SAFETY SYMBOLS AND WARNINGS

Become familiar with symbols identifying potential hazards. FOR YOUR SAFETY READ BEFORE OPERATING

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

! DANGER

! DANGER
Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Used to address practices not related to personal injury.
2.1. Safety Information
Boiler installation shall be completed by qualified agency.
! WARNING
Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.
! WARNING
Do not tamper with or use this boiler for any purpose other than its intended use. Failure to follow these instructions could result in death or serious injury. Use only manufacturer recommended parts and accessories.
! CAUTION
Laceration, burn hazard. Metal edges and parts may have sharp edges and/or may be hot. Use appropriate personal protection equipment to include safety glasses and gloves when installing or servicing this boiler. Failure to follow these instructions could result in minor or moderate injury.

Hot Water Can Scald! Water heated to temperature for clothes washing, dish washing and other sanitizing needs can scald and cause permanent injury.
Children, elderly, and infirm or physically handicapped persons are more likely to be permanently injured by hot water. Never leave them unattended in bathtub or shower. Never allow small children to use a hot water tap or draw their own bath.
If anyone using hot water in the building fits the above description, or if state laws or local codes require certain water temperatures at hot water taps, you must take special precautions:
· Use lowest possible temperature setting.
· Install some type of tempering device, such as an automatic mixing valve, at hot water tap or water heater. Automatic mixing valve must be selected and installed according to manufacturer’s recommendations and instructions.
· Water passing out of drain valves may be extremely hot. To avoid injury: · Make sure all connections are tight. · Direct water flow away from any person.

Water
Temperature Setting 120° F

1st Degree Burn Exposure Time For
An Adult
1 minute

2nd and 3rd Degree Burn Exposure Time For An Adult 5 minutes

130° F

5 seconds

30 seconds

140° F

2 seconds

5 seconds

150° F

1 second

1.5 seconds

160° F

Instantaneous

0.5 seconds

Note: Warning for Infants, Children, and Elderly: Great care must be taken when exposing the aforementioned groups to warm or hot water as they can be badly burned in exposure times less than half of the time for an adult.

5

PN 240013661 Rev. B [02/10/2023]

2 – SAFETY SYMBOLS AND WARNINGS

! WARNING
Combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group1). Avoid breathing dust and contact with skin and eyes. Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website https://www.cdc.gov/niosh/topics/ silica/. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website. Wear long- sleeved, loose fitting clothing, gloves, and eye protection. Apply enough water to the combustion chamber lining to prevent dust. Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid. Eye: Irrigate immediately. Breathing: Fresh air.
! WARNING
Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids. DO NOT obstruct air openings to the boiler room. Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. Installation and service of this boiler shall be performed by a qualified installer. When this product is installed in the Commonwealth of Massachusetts the installation shall be performed by a Licensed Plumber or Licensed Gas Fitter.

!! WARNING
This product contains Fibrous glass. Fibrous glass is a synthetic fiber made from tiny particles of glass. Fibrous glass has been classified as a possible human carcinogen. When disturbed as a result of servicing or repair, fibrous glass becomes airborne and, if inhaled, may be hazardous to your health. It can harm the eyes, skin, and the lungs. Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation. Adhere to the following precautions and procedures. Avoid breathing dust and contact with skin and eyes. Use NIOSH certified dust respirator (e.g., N95). Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website https://www.cdc.gov/niosh/ Approved respirators, manufacturers, and phone numbers are also listed on this website. Wear appropriate personal protective clothing to prevent skin contact, as well as gloves and eye protection. Wash skin daily at end of each work shift, and prior to eating, drinking, smoking, etc. Workers whose clothing may have been contaminated should change into uncontaminated clothing before leaving the work premises. Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly. Follow all Local, State and Federal guidelines for disposal.
NIOSH stated First Aid. Eye: Irrigate immediately. Breathing: Fresh air.
! WARNING
Fire, Explosion, Asphyxiation, Electrical shock hazard! Flooding will result in damages such as electrical problems, corrosion, inoperative parts, mold and other unforeseen issues which can occur over time. Any equipment determined by a professional as damaged by a flood, defined as excess of water or other liquid, shall be replaced. Failure to follow these directions will result in a Hazardous Situation.

2.2 For Your Safety Installer shall verify that at least one carbon monoxide alarm has been installed within a residential living space or home, following the alarm manufacturer’s instructions and applicable codes before putting the appliance into operation.

6

PN 240013661 Rev. B [02/10/2023]

3 – LOCATING THE BOILER

! WARNING
Fire hazard! Do not install boiler on carpeting. Failure to follow these instructions could result in death or serious injury.
! CAUTION
Boiler weight exceeds 200 pounds (90.7 kg). Do not lift boiler without assistance.
3.1 Installation Requirements
1. Installation shall 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/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically fired Boilers, ANSI/ASME CSD-1.
2. Boiler series is classified as a Category I. Vent installation shall be in accordance with “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or “Venting Systems and Air Supply for Appliances,” of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
3. Boiler has met safe lighting and other performance criteria with the gas manifold and control assembly on the boiler per the latest revision of ANSI Z21.13/CSA 4.9.
4. Install boiler such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service, (circulator replacement, condensate trap, control replacement, etc.).
5. Locate boiler on level, solid base as near chimney as possible and centrally located with respect to heat distribution system as practical.
6. Horizontal vent run to chimney shall be as short as practicable. Refer to NFPA 54 to determine maximum permissible horizontal run for chimney type and height.
7. Verify floor will support weight of boiler, water and equipment.
8. Boiler may be installed on combustible floor. Do not install boiler on carpeting.
9. Do not install where gasoline or other flammable liquids or vapors will be stored or used. See Table 3-1 page 8, Contaminants.
10. Chimney shall be lined in a manner acceptable to the authority having jurisdiction.
11. Garage installation boiler shall be 18″ above floor.

3.2 Minimum Clearances to Combustible Construction
1. Minimum clearances to combustible construction are:

Top Front Flue Connector Rear Both Sides Hot Water Piping

10 inches (254mm) Alcove* 6 inches (152mm) 6 inches (152mm) 2 inches (51 mm) Per Local Code

• Definition of Alcove is three sided space with no wall in front of boiler. ANSI standard for alcove is 18 inches from front of appliance to leading edge of side walls as shown below.
  Minimum Clearances to Combustible Construction (as seen from above)
  6″

2″

2″

BOILER

18″
Front NOTE: Greater clearances for access and servicing should
supersede fire protection clearances.
3.3 Recommended Clearances for Service 1. Allow 24 inches (610 mm) at front and one side for
servicing and cleaning. 2. When installed in utillity room, door should be wide
enough to allow largest boiler part to enter, or to permit replacement of another applicance such as a water heater.

7

PN 240013661 Rev. B [02/10/2023]

3 – LOCATING THE BOILER

3.4 Boiler Location Considerations · Ambient room temperature always above 32°F (0°C) to prevent the potential of freezing.
· Drainage of water (or water/ antifreeze solution) during boiler service or from safety relief valve discharge.
· Access to system water piping, gas supply, and electrical service.
· Boiler shall be installed on flat level surface which is capable of supporting the weight of the boiler, water, and equipment.
· Raise boiler above the floor on blocks if floor may get wet.
· Water, gas, and electrical may connect to either side of boiler as desired.
· Horizontal run to chimney shall be as short as possible.

· System piping exposed to freezing conditions: Use
inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system. Do not use automotive or ethylene glycol. Maximum recommended mixture 50% glycol.

Table 3-1: CONTAMINANTS

Items to Avoid Chlorine, Fluorine, and Compounds

Products Which May Contain These Items
Spray cans containing chlorofluorocarbons Chlorinated waxes/cleaners Chlorine- based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Swimming pool or spa chemicals De-icing salts or chemicals Carbon Tetrachloride

Areas Where These Items May Be Found
Swimming pools and pool storage areas Laundry room (Note 2) Confined storage areas

Airborne Particulates

Drywall dust Road or gravel dust Dryer lint Cat litter

Construction or remodelling areas (Note 1) Laundry room (Note 2)

Acids, Solvents, etc.

Paint, Varnish, Turpentine, etc. Cleaning Solvents Hydrochloric acid/muriatic acid Cements, adhesives and glues

Photo processing plants Garages with workshops Furniture refinishing areas and establishments

Laundry Chemicals Other Notes:

Laundry detergents, bleaches, fabric softeners, etc.
Antistatic fabric softeners (dryer sheets)

Dry cleaning/laundry areas and establishments

Permanent wave solutions
Refrigerants (Freon, etc) (only where the refrigerant may be leaking from the appliance)

Beauty shops Refrigeration repair shops

1. It is recommended the boiler be isolated and not operated during construction/ renovation. Excessive particles ingested by the boiler may accumulate in the flueway passages possibly resulting in unsafe operation. In this case, unit servicing shall include cleaning of flueway passages and burner ports.
2. If locating boiler in laundry room is unavoidable, it is manufacturer recommended the room be generously ventilated (well in excess of combustible air requirements), and homeowner seal laundry supply containers, and minimize room vapors.
3. Piping allowing fresh air in should also be considered. See Section 5-1.

8

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING

! WARNING
Burn and scald hazard. Boiler supplied with dust caps on supply and return tappings (4). Shall remove all four (4) caps and plumb before filling boiler with water. Failure to follow these instructions could result in death or serious injury.
4.1 Connection Locations
· Boiler has one supply and one return tapping on each side (4 total). Boiler supplied with dust caps only. Remove all four (4) caps and plumb before filling boiler with water.

· Supply and return may be piped to either side of boiler, as desired. Both supply and return shall be on same side of boiler. Do not “cross pipe” as boiler may not deliver adequate heat with cross piping.
· ASME relief valve may be located off unused supply tapping IN UPRIGHT POSITION ONLY.
· Drain valve may be located off of unused return tapping using a contractor supplied tee, piped right or left side as desired. See Figure 4-3
· Unused supply and return tappings may be capped, as desired. Relief valve and drain valve may be located on near boiler piping using contractor supplied tees with no valves.

Figure 4-1 Piping Options
PIPING OPTIONS THIS BOILER HAS TWO SUPPLY (OUTLET) AND TWO RETURN (INLET)
TAPPINGS. PIPE SUPPLY AND RETURN ON THE SAME SIDE (SEE FIG. A AND B)
DO NOT CROSS PIPE – (SEE FIG. C AND D)

SUPPLY

FRONT

FRONT

SUPPLY

RETURN
FIG.1A.

RETURN
FIG. 2B

FRONT

FRONT

FIG .3C.

FIG.4D.

9

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING

! WARNING
Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. Failure to follow these instructions could result in death or serious injury.
! WARNING
Burn and scald hazard. Safety relief valve shall be installed with spindle in upright position only, following ASME BPV code. Failure to follow these instructions could result in death or serious injury.

Figure 4-2 – Safety Relief Valve

RELIEF VALVE On Opposite side of supply
DISCHARGE LINE

Alternate Location Piped in Supply Line
(Contractor supplied fittings)

4.2 Safety Relief Valve Installation See Figure 4-2
Discharge line shall be installed to relief valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation. Discharge line shall:
A. connect to relief valve outlet and piped down to safe point of disposal. Check local codes for
maximum distance from floor or allowable safe point of discharge. B. be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line; C. have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or place any obstruction in discharge line. D. terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing; E. allow complete drainage of the valve and the discharge line; F. be independently supported and securely anchored to avoid applied stress on the relief valve; G. be as short and straight as possible; H. terminate with plain end (not threaded); I. be constructed of material suitable for exposure to temperatures of 375° F (191°C); or greater. J. Terminate freely to atmosphere where discharge is clearly visible and no risk of freezing.
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements.

Check local codes for maximum distance from floor or allowable
safe point of discharge.
Do Not Install Pressure
Relief Valve Horizontally

Figure 4-3 Optional Locations for Drain Valve

Left Side Drain Valve Location With
Standard
Manufacturer Supplied Hardware

Optional Right side Drain Valve Location
with Contractor Supplied Tee

10

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING

! WARNING
· Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol.
· Never use automotive or standard glycol antifreeze, even ethylene glycol made for hydronic systems.
· Ethylene glycol can attack gaskets and seals used in hydronic systems.
· Do not use petroleum based cleaning or sealing compounds boiler system.
· Do not fill boiler or boiler system with softened water.
· Use only inhibited propylene glycol solutions certified by fluid manufacturer as acceptable for use with closed water heating system.
· Thoroughly clean and flush any system that used glycol before installing new Boiler.
· Provide user with Material Safety Data Sheet (MSDS) on fluid used.

4.4 Water Treatment

Manufacturer recommends a water analysis be done on
water used to fill the system. Treatment may be required based on the analysis results.

For hard water or pH below 7.0 consult your local water treatment company.

· If CH water is very hard or full of impurities, it must be
adequately filtered and treated, otherwise damage and/ or malfunction could be caused. Recommended water quality is:

o Hardness

Less than 150 mg/L

o Acidity level 7-8 pH

o Sediments Particle size less than 50 micron

· If the water quality is outside these ranges, consult a local water treatment specialist for recommendations.

· If the water is treated, do not use petroleum based products or products containing mineral oil or hydrocarbons in order to avoid likely damage to parts made from rubber compounds (o-rings).

NOTICE
If damage due to frozen pipes is a possibility, install appropriate safeguards and alarms on the heating system to prevent property damage due to frozen and burst pipes should the boiler heating system become inoperative due to a power outage, safety lockout or component failure.

4.3 Flush and Rinse System
Flush the entire system and rinse thoroughly to ensure no sludge will be introduced into the heating body of the boiler.

11

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING

4.5 Supply and Return Requirements
1. Boiler used in connection with refrigeration system, install so chilled medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler. See Figure 4-4 page 13.
2. Boiler piping system of hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.
3. Hot water boilers installed above radiation level or as required by authority having jurisdiction shall be provided with low water cut-off device (Factory equipped).
4. Boiler connected to heating system utilizing multiple zoned circulators, each circulator must be supplied with flow control valve to prevent gravity circulation.
5. Hot water boilers and system must be filled with water and maintained to minimum pressure of 12 psi.
! WARNING
Asphyxiation hazard! Gradual flueway blockage resulting from condensate induced corrosion may block boiler passages, resulting in carbon monoxide and or flame rollout. Install bypass piping if return temperature is under 130° F. Failure to follow these instructions could result in death or serious injury.

7. Installation using circulators and zone valves are shown in Figures 4-4 through 4-9. For further piping information refer to AHRI Installation and Piping Guide.
8. Install discharge piping from safety relief valve. See Warning, Page 10 and Figure 4-2.

4.6 Special Conditions

Note

Do not expose boiler and piping to freezing temperatures.

· System piping exposed to freezing conditions: Use inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system. Do not use automotive or ethylene glycol.
· Boiler installed above radiation level (or as required by authority having jurisdiction). Integral low water cutoff is provided in boiler.
· Boiler used in connection with refrigeration system. Install piping in parallel with boiler, with appropriate valves to prevent chilled medium from entering boiler.
· System piping connected to heating coils located in air handling unit exposed to refrigerated air circulation. Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

6. Bypass piping gives ability to adjust boiler water temperature to fit system or condition of installation. This method of piping, however, is not typically required for baseboard heating systems. Typical installations where bypass piping is required are as follows:
A. This method is used to protect boilers from condensation forming due to low temperature return water (Below 130° F). Generally noticed in large converted gravity systems other large water volume systems, and in-floor heating systems. Figures 4-5 and 4-6 pages 14-15.
B. These methods are used to protect systems using radiant panels and material they are encased in from high temperature supply water from boiler and protect boiler from condensation.
NOTE#1: When using bypass piping, adjust valves V1 & V2 until desired system temperature is obtained.
NOTE#2: Bypass loop must be same size piping as supply and return piping.

12

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND:
Circulators in following illustrations are mounted on system supply side, mounting on system return side is also acceptable practice. Figure 4-4 – Circulators Mounted on Supply System, Boiler Used In Configuration with Chiller System. See Special Conditions, Below

13

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND:
Figure 4-5 – Bypass Piping With Automatic Mixing Valve
BACK FLOW VALVE ASME RELIEF VALVE

14

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND:

Figure 4-6 – Bypass Piping – Fixed Low Temp Only With Zone Valve

ASME RELIEF VALVE

• Manually adjust until proper system temperature is reached.

15

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND:
Figure 4-7 – Bypass Piping (4-Way Valve Option With Circulator On Supply side) FLOW CONTROL VALVE
ASME RELIEF VALVE
DRAIN VALVE

16

PN 240013661 Rev. B [02/10/2023]

4 – CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND:
Figure 4-8 – Single Zone System With DHW Priority
Back Flow Valve
ASME RELIEF VALVE

DRAIN VALVE

Purge Valve

17

PN 240013661 Rev. B [02/10/2023]

FROM SYSTEM

4 – CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND:

Figure 4-9 – Multi Zone System With Zone Valves And DHW Priority (With Zone Valve)

TO SYSTEM

Tank Sensor Optional Indirect DHW Tank DHW Pump

CH /System Pump Make-up Water Supply

Back Flow Valve

• Hot Water Supply Tempered

T & P Relief Valve to Drain

Cold Water Supply

1

ASME Relief Valve

Note

• Manufacturer requires all domestic hot water (DHW) installations use an anti-scald valve. Local codes may require additional equipment (expansion tank, relief valves, etc.) Select and size equipment to suit installation and meet code requirements.

Note Note

1

12 po (305 mm) Distance recommandée. Ne dépassez pas 12 po (305 mm).

Refer to pump manufacturer literature for proper pump sizing.

18

PN 240013661 Rev. B [02/10/2023]

5- VENTILATION & COMBUSTION AIR

5.1 Requirements
! WARNING
Asphyxiation Hazard! Provide enough air openings to boiler/combustion area to dilute flue gases and allow for consistent, guality combustion. Do not obstruct air openings. Follow instructions below, to maintain adequate combustion air. Failure to follow these instructions good result in ignition failure, overheating, carbon monoxide, and accumulation of flue gases.
Provide combustion air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes.
Provide make-up air where exhaust fans, clothes dryers, and kitchen ventilation equipment interfere with proper operation. If inadequate makeup air is suspected it is always acceptable to add additional ventilation.
National Fuel Gas Code recognizes several methods of obtaining adequate ventilation and combustion air. Requirements of the authority having jurisdiction may override these methods.
· Engineered Installations. Must be approved by authority having jurisdiction.
· Mechanical Air Supply. Provide minimum of 0.35 cfm per [(BTU/HR)/1,000] for all appliances located within space. Additional requirements where exhaust fans installed. Interlock each appliance to mechanical air supply system to prevent main burner operation when mechanical air supply system not operating.
· All Indoor Air. Calculate minimum volume for all appliances in space. Use a different method if minimum volume not available.
A. Standard Method. Cannot be used if known air infiltration rate is less than 0.40 air changes per hour. Use equation for multiple appliances. Volume 50 ft3 x Total Input [(BTU/HR)/1,000] Table 5-1 – Space With Boiler Only

B. Known Air Infiltration Rate. See Table 5-1 for space with boiler only. Use equation for multiple appliances. Do not use an air infiltration rate (ACH) greater than 0.60.
Volume 21 ft3/ACH x Total Input[(BTU/HR)/1,000] Refer to National Fuel Gas Code for opening requirements between connected indoor spaces.
· All Outdoor Air. Provide permanent opening(s) communicating directly or by ducts with outdoors.
A. Two Permanent Opening Method. Provide opening commencing within 12 inches of top and second opening commencing within 12 inches of bottom of enclosure.
Direct communication with outdoors or communicating through vertical ducts. Provide minimum free area of 1 in² per 4 [(BTU/ hr)/1,000] of total input rating of all appliances in enclosure.
Communicating through horizontal ducts. Provide minimum free area of 1 in² per 2 [(BTU/HR)/1,000] of total input rating of all appliances in enclosure.
B. One Permanent Opening Method. Provide opening commencing within 12 inches of top of enclosure. Provide minimum clearance of 1 inch on sides/back and 6 inches on front of boiler (does not supersede clearance to combustible materials).
· Refer to National Fuel Gas Code for additional requirements for louvers, grilles, screens and air ducts.
· Combination Indoor and Outdoor Air. Refer to National Fuel Gas Code for application information.
National Gas and Propane Installation Code Requires providing air supply in accordance with:
· Section 8.2 and 8.3 when combination of appliances has a total input of up to and including 400 [(BTU/ hr)/1,000] (120 kW).
· Section 8.4 when combination of appliances has total input exceeding 400 [(BTU/hr)/1,000] (120 kW).
· Refer to Natural Gas and Propane Installation Code for specific air supply requirements for enclosure or structure where boiler is installed, including air supply openings and ducts.

Room Cubic Feet Volume

Sections

3

Input BTU/HR
59,000

Standard Method
2950

Known Air Infiltration Rate Method (ACH – Air Changes Per Hour)

0.1

0.2

0.3

0.4

0.5

0.6

12390

6195

4130

3098

2478

2065

4

92,500

4625

19425

9712.5

6475

4856

3885

3238

5

120,000

6000

25200

12600

8400

6300

5040

4200

6

149,000

7450

31290

15645

10430

7823

6258

5215

7

175,000

8800

36960

18480

12320

9240

7392

6160

8

205,000

10250

43050

21525

14350

10763

8610

7175

9

235,000

11750

49350

24675

16450

12338

9870

8225

19

PN 240013661 Rev. B [02/10/2023]

6 – VENT SYSTEM MODIFICATION

6.1 Removal Of Existing Boiler From Venting System
When an existing boiler is removed from a common venting system, the system is likely too large for proper venting of appliances still connected to it. If this occurs, follow this test procedure:

Figure 6-1 – Typical Masonry Chimney Requirements

At time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
1. Seal an unused opening in the common venting system.
2. 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.
3. 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 other appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.
5. 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.
6. Minimum draft should be -.02″ w.c.
7. After it has been determined that each appliance remaining connected to a common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliances to their previous condition of use.
8. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.
9. Draft pressure must be negative under all conditions with all aplliances operating.

See NFPA for Installation Specifications Type B Vent Masonry Chimney Requirements

20

PN 240013661 Rev. B [02/10/2023]

7 – VENT INSTALLATION

! WARNING
Boiler and venting installations shall be performed

3. Boiler series is classified as a Category I. Vent installation shall be in accordance with “Venting of
Equipment,” of the National Fuel Gas Code, ANSI

by a qualified expert and in accordance with the appropriate manual. Installing or venting boiler or other gas appliance with improper methods or materials may result in serious injury or death due
to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.

Z223.1/NFPA 54, or “Venting Systems and Air Supply for Appliances,” of the Natural Fuel Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
4. Inspect chimney. Chimney shall be lined per NFPA 54/ ANSI Z223.1 or as required by local authority. Verify chimney is constructed according to NFPA 211 and ANSI

! WARNING

Z223.1/NFPA 54. Vent connector shall be Type B or metal pipe having resistance to heat and corrosion not

Do not connect boiler to any portion of mechanical draft system operating under positive pressure.
7.1 Check Your Chimney It must be clean, the right size, properly constructed and in good condition. A chimney shall be lined in a manner acceptable to the authority having jurisdiction.

less than that of galvanized sheet steel or aluminum not less than 26 gauge thick (24 gauge for 6 and 7 inch).
5. Connect flue pipe from draft hood to chimney. Bolt or screw joints together to avoid sags. Flue pipe should not extend beyond inside wall of chimney more than 1/4
inch. Do not install manual damper in flue pipe or reduce size of flue outlet except as provided by the latest revision of National Fuel Gas Code, ANSI ANSI Z223.1/

Chimney Sizing Chimney sizing, and vent installation must be in accordance with The National Fuel Gas Code, ANSI Z223.1/NFPA 54 or CAN/CSA B149.1, or applicable provisions of local building codes.

NFPA 54 or CAN/CSA B149.1. Protect combustible ceiling
and walls near flue pipe as required by National Fuel Gas Code. Where two or more appliances vent into a
common flue, the area of the common flue must be at least equal to the area of the largest flue plus 50 percent of the area of each additional flue.

This is a high efficiency boiler with low stack temperature. Following recommendations are in addition to requirements of the National Fuel Gas Code.

1. Type B double wall vent pipe is recommended for vent
   connector. Single wall vent connectors should not be used unless following conditions are true:
   a. Except for basement, boiler is not installed in

7.3 Chimney Inspection
Chimney must be clean, right size, properly constructed and in good condition. Installation must conform to requirements of the authority having jurisdiction or, in absence of such requirements, to The National Fuel Gas Code, ANSI Z223.1/NFPA 54.

unheated space.
b. Total horizontal portion of vent connector, not including elbows is less than 5 feet in length.
2. Outside chimneys (i.e. chimneys exposed to outdoors below roof line on one or more sides) do not use unless they are:
a. enclosed in a chase, or
b. lined with type B vent pipe, or listed flexible vent liner, or other certified chimney lining system.
3. Where possible it is recommended to common vent boiler and water heater.
4. For multiple Category I boiler installations, consult boiler manufacturer for venting recommendations.
5. Minimize horizontal vent length.

7.4 Vent Pipe · Connect draft hood to boiler using 2 screws (provided)
onto flue collector. Connect two safety circuit wires (attached to vent damper harness) to blocked vent switch. See Figure 13-1. · Fasten sections of vent pipe with 3 sheet metal screws at each joint to make piping rigid. · Support horizontal portions of vent system to prevent sagging. · Use stove pipe wires or metal strapping every 5′ to support pipe from above. · Vent pipe through crawl space, use double wall vent pipe. · Vent pipe passing through combustible wall or partition, use ventilated metal thimble. Thimble should be 4″

larger in diameter than vent pipe.

7.2 Requirements

1. Vent pipe must slope upward from the boiler not less

NOTICE

than ¼ inch for every 1 foot (21 mm/m) to verticle

Minimum Vent Pipe Clearance – Wood and other

vent terminal.

combustible materials must not be closer than 6″

2. Horizontal portions of venting system shall be supported rigidly every 5 feet and at the elbows. No

from any surface of single wall metal vent pipe. Listed Type B vent pipe or other listed venting

portion of vent pipe should have any dips or sags.

systems shall be installed in accordance with their

listing.

21

PN 240013661 Rev. B [02/10/2023]

8 – VENT DAMPER INSTALLATION & INSTRUCTIONS

8.1 Vent Damper Connecting The Vent Damper And Vent Connector Refer to page 4 for size and location of vent (flue opening).
NOTICE Damper blade on furnished vent damper has 1/2 square inch hole (approximately 3/4″ diameter). Boilers equipped with intermittent ignition, hole should be plugged by using plug supplied with vent damper.

Fasten sections of vent pipe with sheet metal screws to make piping rigid. Support horizontal potions of vent system to prevent sagging. Use stovepipe wires every 5′ to support pipe from above. Use double wall vent pipe if vent pipe must go through crawl space. Where vent pipe passes through combustible wall or partition, use ventilated metal thimble. Thimble should be 4 inches larger in diameter than vent pipe.
Figure 8-1 – Vent Damper Installation

1. Follow damper installation instructions provided with damper.
2. Position furnished vent damper on top of flue outlet collar. Fasten damper securely to flue outlet collar with sheet metal screws. Verify damper blade has clearance to operate inside of diverter. Do not modify either draft diverter or vent damper during installation.
As An Option
Damper may be installed in horizontal or vertical position, closer to flue outlet collar preferred. See Figures 8-1, 8-2, 8-3 and enclosed vent damper instructions.
3. Install vent damper to service only single boiler for which it is intended. Damper position indicator shall be in visible location following installation. Locate damper so it is accessible for servicing. See Figure 8-2 page 22.
4. Damper must be in the open position when appliance main burners are operating.
5. Boiler is equipped with factory wired harness that plugs into vent damper.
6. Slope pipe up from boiler to chimney not less than 1/4″ per foot.
7. Run pipe as directly as possible with as few elbows as possible.
8. Do not connect to fireplace flue.
9. End of vent pipe must be flush with inside face of chimney flue. Use a sealed-in thimble for chimney connection.
10. Clearance of not less than 6 inches (152mm) between Vent Damper and combustible material must be maintained. Additional clearance should be allowed for service of Vent Damper.
11. Vent Damper position indicator must be in visible location following installation.

22

PN 240013661 Rev. B [02/10/2023]

8 – VENT DAMPER INSTALLATION & INSTRUCTIONS Figure 8-2 – Vent Damper Placement

Figure 8-3 – Vent Damper Position Indicator

23

PN 240013661 Rev. B [02/10/2023]

9 – CONNECTING GAS SERVICE

! DANGER
Fire Hazard. Do not use matches, candles, open flames, or other methods providing ignition source. Failure to comply will result in death or serious injury.
! CAUTION

Table 9-1 Min. Supply Pressure Max. Supply Pressure

Natural Gas 5″ w.c.
13.5″ w.c.

Manifold Pressure

3.5″ w.c.

Propane 11″ w.c.
13.5″ w.c.
10″ w.c. (4 sec. only)
10.5″ w.c.

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. · Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s instructions. · If you cannot reach your gas supplier, call the fire department.
! WARNING
Fire, explosion, asphyxiation and burn hazard. Boiler piping and gas connections shall be leak tested before placing boiler in operation. Failure to follow these instructions and or improper installation could result in death or serious injury.
NOTICE Use of CSA approved corrugated, semi-rigid stainless steel tubing with polyethylene jacketing is approved for use with boilers following tubing manufacturer’s instructions. Use of flexible appliance gas tubing also known as a “whip” is not allowed per NFPA 54.

9.2 Leak Check Gas Piping
Pressure test boiler and gas connection before placing boiler in operation. · Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from gas supply system. · Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler from gas supply system by closing manual gas
shutoff valve. · Locate leakage using gas detector, non-corrosive
detection fluid, or other leak detection method acceptable to authority having jurisdiction. Do not
use matches, candles, open flames, or other methods providing ignition source. · Correct leaks immediately and retest.

Figure 9-1 – Gas Piping
Union Recommended
for service

INSTALL MANUAL VALVE WITHIN 6 FT. (183 cm) OF BOILER AND 5 FT. (152 cm) ABOVE THE FLOOR WHERE REQUIRED BY LOCAL CODES

3″ (8 cm) Minimum Sediment Trap

9.1 General

To Gas Control Inlet

· Use piping materials and joining methods acceptable to authority having jurisdiction. In absence of such requirements: USA – National Fuel gas Code, ANSI Z223.1/NFPA 54
· Size and install gas piping system to provide sufficient gas supply to meet maximum input at not less than minimum supply pressure. See Table 9-1.
· Support piping with hooks, straps, bands, brackets, hangers, or building structure components to prevent or dampen excessive vibrations and prevent strain on gas connection. Boiler will not support piping weight.
· Use thread (joint) compound (pipe dope) suitable for
liquefied petroleum gas. · Install field sourced manual main shutoff valve, ground
joint union, and sediment trap upstream of gas valve. See Figure 9-1.

MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS/HOUR (Gas Pressure = 0.5 psig or less, Pressure Drop = 5 in. w/c)

Table 9-2

Length of Pipe (Feet)

½”

Nominal Iron Pipe Size

¾”

1″

1¼”

10

175

360

680

1400

20

120

250

465

950

30

97

200

375

770

40

82

170

320

660

60

66

138

260

530

80

57

118

220

460

100

50

103

195

400

For additional information refer to the National Fuel Gas Code Handbook.

24

PN 240013661 Rev. B [02/10/2023]

10 – ELECTRICAL

! WARNING
Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.
! WARNING
Fire, electrical shock hazard. Verify all electrical connections are secure. Failure to do so could result in death or serious injury.

8. There are two (2) options when using Zone 2 for an indirect tank or heating zone using the IC control to power the Zone 2 pump:
a. A Zone 2 wiring kit is available see parts list. This plugs into the Molex connector for the Zone 2 pump and provides power leads for the pump.
b. Cut off the end of the Molex connector and wire the Zone 2 pump leads directly using wire nuts or other approved electrical connectors.
c. Refer to Zone 2 Settings section of Hydrostat IC instructions (enclosed separately in literature package) for setting options.

10.1 Electrical Wiring
If an external electrical source is utilized, the boiler, when installed, 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, and/or the See wiring diagrams on the following pages for details.
· J-box and circulator harness are shipped in parts box, and may be wired on either side of boiler as desired.
· Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction.
Refer to: USA – National Electrical Code, ANSI/NFPA 70. · Aluminum wiring/conductors not permitted.

10.2 Thermostat Installation
1. Use a thermostat with dry contacts which does not pull any load from the control. Use a separate transformer for zone valve wiring.
2. Thermostat should be installed on inside wall about four feet above floor.
3. NEVER install thermostat on outside wall.
4. Do not install thermostat where it will be affected by drafts, hot or cold pipes, sunlight, lighting fixtures, televisions, fireplace, or chimney.
5. Check thermostat operation by raising and lowering thermostat setting as required to start and stop burners.
6. Instructions for final adjustment of thermostat are packaged with thermostat (adjusting heating anticipator, calibration, etc.)
7. Thermostat’s heat anticipator must be adjusted to match total current draw of all controls associated with boiler during heating cycle.

25

PN 240013661 Rev. B [02/10/2023]

11 – WIRING DIAGRAMS
! WARNING
Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. Figure 11-1 – 4200 Fuel Smart Hydrostat IC Control
(REFER TO PARTS LIST)

26

PN 240013661 Rev. B [02/10/2023]

11 – WIRING DIAGRAM Figure 11-2 – 4200 Fuel Smart Hydrostat IC Control – ladder

27

PN 240013661 Rev. B [02/10/2023]

12 – LIGHTING INSTRUCTIONS

! WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. · This appliance is equipped with an ignition device
which automatically lights burner. Do NOT try to light this burner by hand.
· Before operating smell all around appliance area for gas. Be sure to smell next to floor because some gas is heavier than air and will settle to the floor.
· Use only your hand to turn the gas shutoff valve. Never use tools. If valve will not turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in fire or explosion.
· Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect appliance and to replace any part of control system and any gas control which has been under water.

12.2 Operating Instructions For Intermittent Pilot System
1. STOP! Read and follow all safety information. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot by hand. 5. Lift and remove front panel.
Figure 12-1 – Intermittent Pilot

NOTICE
Before lighting any type of pilot burner, verify the hot water boiler and system are full of water to minimum pressure of 12 psi in the system, also verify system is vented of air. Set operating control of thermostat to “below” normal setting. Refer to following appropriate lighting instruction.

6. Turn gas control knob clockwise

to “OFF.”

7. Wait (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “What To Do If You Smell Gas” in the safety information to the left. If you don’t smell gas, go on to the next step.

8. Turn gas control knob counterclockwise

to “ON.”

12.1 Lighting Procedure For Boiler With Intermittent Pilot System This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the appliance by hand.
! CAUTION
WHAT TO DO IF YOU SMELL GAS
· Do not try to light any appliance.
· Do not touch any electrical switches; do not use any phone in your building.
· Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
· If you cannot reach your gas supplier, call the fire department.

9. Turn on all electric power to the appliance.
10. Set thermostat to desired setting.
11. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” , and call qualified service technician or your gas supplier.
12. Replace front panel
12.3 TO TURN OFF GAS TO THE APPLIANCE
1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance if service is
to be performed. 3. Lift and remove front panel. 4. Push in gas control knob slightly and turn clockwise
to “OFF.” DO NOT FORCE. 5. Call qualified service technician.

28

PN 240013661 Rev. B [02/10/2023]

13 – NORMAL SEQUENCE OF OPERATION

! WARNING
Burn Hazard. View port on burner door may be hot. Wear personal protection when servicing this boiler.
! WARNING
Fire and Asphyxiation hazard. Do not attempt to place boiler in operation if safety switches shut the main burner gas off. Contact a qualified service agency. Failure to follow these instructions could result in death or serious injury.
13.1 General
1. Thermostat actuates on call for heat, completing circuit to control. A. Completed circuit to control will energize the vent damper. The circulator will be energized if the boiler water temperature is above 125°F. B. When the vent damper is fully open the damper end switch completes the circuit to ignition system, ignition takes place.
2. In event the boiler water temperature exceeds high limit setting on the boiler mounted high limit control, power is interrupted between control system and ignition system.
Figure 13-1 Blocked Vent Safety Switch, Roll-out Safety Switch (Front Panel Removed)
Integral Draft Hood

A. Power remains off until boiler water temperature drops below high limit setting.
B. Circulator continues to operate under this condition until thermostat is satisfied.
3. In event the flow of combustion products through the boiler venting system becomes blocked: A. Blocked vent safety switch shuts main burner gas off.
B. If boiler flue-way becomes blocked: flame rollout safety switch shuts main burner gas off. See Figure 13-1.
4. 2-Zone Capability: The Hydrostat IC is equipped with a second zone for use with a 120-volt circulator. This zone is factory set to function with an indirect water heater for domestic hot water (DHW). The control allows the boiler to run up to high limit setting to satisfy calls from this zone. The control will allow the Smart DHW Priority feature to prioritize domestic hot water. The second zone can also be used for a heating zone ­ in which case it should not be prioritized. See Zone 2 settings in the Hydrolevel Manual provided with your boiler.
If either of these condition A or B exist: Do not attempt to place boiler back into operation. Contact certified service agency. Do Not jumper safety switch(s).
For detailed sequence of control, see Appendix A.

Hydrolevel Control

Blocked Vent Safety Switch

Burner Door
Gas Valve
Igniter

View Port

Rollout Switch

Burners

Base 29

PN 240013661 Rev. B [02/10/2023]

14 – GENERAL MAINTENANCE AND CARE INSTRUCTIONS

! WARNING
Label all wires prior to disconnection when servicing controls. Wiring errors could cause improper and dangerous operation.
14.1 Seasonal Startup · Before seasonal start-up, have a certified service agency
check boiler for soot and scale in flues, clean burners and check gas input rate to maintain high operating efficiency. · Verify proper operation after servicing.
· Service agency will verify system is filled with water to minimum pressure and open air vents, if used, to expel any air accumulated in the system. Check entire piping system and, if any leaks appear, have them repaired.
· Circulators need to be checked and maintained. Refer to circulator manufacturer’s instructions.
· Inspect venting system at the start of each heating season.
Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints. Repair if necessary.
Remove vent pipe at base of chimney or flue and using a mirror, check vent for obstruction and verify vent is in good working order.
· Boiler flue gas passageways may be inspected by a light and mirror.
Remove burner door. See Figure 13-1 page 29.
Place trouble lamp in flue collector through draft relief opening or flue inspection cover.
With mirror positioned above burners, flue gas passageways can be checked for soot or scale

14.2 Clean Flue Gas Passageways
Follow this procedure to clean flue gas passageways:
1. Remove burner tray from heat exchanger by disconnecting the gas supply, by removing two (2) nuts. Pull out the assembly. see Figure 14-1 page 31.
2. Remove top jacket panel.
3. Remove flue inspection cover.
4. Place sheet of heavy paper or similar material over bottom of base and brush down flue passageways. Soot and scale will collect on paper and is easily removed with the paper.
5. With paper still in place in base, clean top of boiler castings of boiler putty or silicone used to seal between castings and flue collector. Verify chips are not lodged in flue passageways.
When cleaning process is complete, restore boiler components to their original position. Use IS-808 GE silicone (available from distributor) to seal around flue collector, and inspection cover if required.

30

PN 240013661 Rev. B [02/10/2023]

14 – GENERAL MAINTENANCE AND CARE INSTRUCTIONS

14.3 General Maintenance

Figure 14-1 – Burner Tray

· Visually inspect main burner and pilot flames at start of heating season and again in mid-season.
Main burner flame should have well defined inner blue mantel with lighter blue outer mantel.
Check burner throats and burner orifices for lint or dust obstruction. Figures 14-1 and 14-3.

GAS VALVE

BURNERS

· Pilot flame should envelop to ½ inch of tip of ignition/sensing electrode. See Figure 14-2.

· To adjust pilot flame: remove pilot adjustment

cover screw and turn inner adjustment screw

counterclockwise

to increase or clockwise

to decrease pilot flame. Replace cover screw after

adjustment to prevent possible gas leakage. See

Figure 12-1, Page 28.

· Check burners and pilot for signs of corrosion, rust or scale buildup.

· Area around boiler shall be clear and free of
combustible materials, gasoline and other flammable vapors and liquids.

ORIFICES

Figure 14-2 – Gas Burner Pilot Assembly Proper Flame Adjustment
Shown

(9.53/t8o”1to2.17/m2m” )

PILOT LINT SCREEN

· Free flow of combustion and ventilating air to boiler and boiler room shall not be restricted or blocked.

· Inspect factory supplied and field sourced low water cutoffs annually, or as recommended by low water cutoff manufacturer. Flush float type low water cutoffs per manufacturer’s instructions.

· Contact a Qualified Service Agency to make annual inspection of boiler and heating system. This should include:
1. Check casting and vent for signs of corrosion from condensate.
2. Examine pilot lint screen and clean if needed.
3. Check venting for any signs of corrosion, rust, damage or deterioration. Contact a Qualified Service Agency immediately if you observe any of these conditions.
4. Clean oxidation on the igniter/flame sensor with an abrasive cloth.

Figure 14-3 – Gas Burner Flame

INNER BLUE MANTEL

LIGHT BLUE OUTER MANTEL

31

PN 240013661 Rev. B [02/10/2023]

14 – GENERAL MAINTENANCE AND CARE INSTRUCTIONS

14.4 Adjusting Gas Input

1. Adjust gas input to boiler by removing protective cap on

pressure regulator, and turning screw clockwise

to

increase input and counterclockwise

to decrease

input. See Figure 12-1 page 28.

2. Manifold pressures are taken at outlet side of gas valve. See Pg 24 for proper pressure recommendations.

3. To check for proper flow of natural gas to boiler, divide input rate shown on rating plate by heating value of gas obtained from local gas company. This determines number of cubic feet of gas required per hour.

4. Determine flow of gas through meter for two minutes and multiply by 30 to get hourly rate with all other gas
appliances off.

5. Make minor adjustments to gas input as described above. See Figure 12-1 page 28.

6. Change burner orifices if final manifold pressure varies more than plus or minus 0.3 inches water column from
specified pressure listed on boiler rating plate.

7. Primary air adjustment is not necessary, therefore air shutters are not furnished.

CHECK SAFETY CONTROL CIRCUIT. Test ignition
system safety shutoff device after placing boiler in operation. Blocked vent switch and rollout switch. can be tested by removing one of the wires. See Figure 12-1 page 28.

8. Intermittent Pilot: With main burner operating, turn

pilot gas adjusting screw clockwise

until pilot

gas is turned off. Within 90 seconds main gas control

closes, shutting off gas to main burner.

9. High Limit Control: Remove front cover and note temperature setting. Refer to appendix A for adjustment procedure. Decrease setting to minimum and operate boiler. When boiler water temperature exceeds control temperature setting, control will open circuit, closing automatic main gas valve.

32

PN 240013661 Rev. B [02/10/2023]

15 – RATINGS AND CAPACITIES

Table 15-1 – Ratings and Capacities

Boiler Model 15B-060K UH15B-060K 15B-095K UH15B-095K 15B-120K UH15B-120K 15B- 150K UH15B-150K 15B-175K UH15B-175K 15B-205K UH15B-205K 15B-235K UH15B-235K

Number of
Sections 3
4
5
6
7
8
9

(1)
Input Btu/hr 59,000
92,500
120,000
149,000
175,000
205,000
235,000

(1)
Heating Capacity Btu/hr 50,000
78,000
101,000
125,000
147,000
172,000
197,000

(2)
Net AHRI Rating Water
Btu/hr 43,000
68,000
88,000
109,000
128,000
150,000
171,000

AFUE
84.0 84.0 84.0 84.0 84.0 84.0 84.0

Flue Diameter
Inches
4 5 6 6 7 7 7

(1)
High Altitude Input
Btu/hr
53,100

(3)
Recommended Air Cushion Tank
15

83,200

30

108,000

30

134,100

30

157,500

30

184,500

30

211,500

30

EXPLANATORY NOTES — All boilers are design certified for installation on noncombustible floor. — Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be
reduced to 10 feet. Refer to the latest revision of National Fuel Gas Code ANSI Z223.13/NFPA 54 part 11. — Electric service to be 120 Volts, 15 Amps, 60 Hz. — The MEA number for the this boiler is 19-79-E.
(1) Input rating for sea level to 2,000 ft. (610m) above sea level. United States, over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m) above sea level.
(2) Net AHRI Water Ratings shown based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc. For forced hot water systems where boiler and all piping within area to be heated, boiler may be selected on basis of its heating capacity.
(3) Tank sized for non-ferrous baseboard or radiant panel systems. Increase size for cast iron baseboard and radiation.
STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, High Limit Control, Intermittent Electric Ignition Pilot System, Vent Damper Relay, Main Gas Burners, Gas Control (Includes Automatic Gas Valve, Intermittent Pilot, Safety Shutoff, Pilot Flow Adjustment, Pilot Filter), A.S.M.E. Relief Valve, Drain Valve, Spill Switch, Rollout Switch, Automatic Vent Damper, Wiring Harness, Safety Pilot.

33

PN 240013661 Rev. B [02/10/2023]

APPENDIX A – CONTROL FUNCTION

! WARNING
Burn and scald hazard. Do not add water until boiler has fully cooled. Failure to follow these instructions could result in death or serious injury.
Control – LED legend

6 ECONOMY TARGET When the Economy feature is active, the Fuel Smart HydroStat continually sets target temperatures below the high limit setting
to maximize fuel efficiency. When the boiler water reaches the target temperature, the LED illuminates and the burner will shut down. The boiler water will continue to circulate and heat the house as long as the thermostat call continues. The LED will stay lit until
the boiler temperature drops below the differential set point at which point the boiler will be allowed to
fire again. See Differential explanation on page 6 of Hydrolevel Manual. NOTE: This LED illuminates regularly during normal boiler operation

1 TEMP ACTIVE Indicates the Fuel Smart HydroStat control is powered and the temperature function is active.
2 TEMP HI TEMP Illuminates when the boiler water temperature reaches the high limit setting. It will remain lit until the water temperature falls 10°. The Fuel SmartHydroStat prevents burner operation while this LED is on. See Differential explanation on page 6 of Hydrolevel Manual.
3 LWCO ACTIVE Indicates the low water cut-off (LWCO) function of the Fuel Smart HydroStat is active. When the control is installed with a Hydrolevel Electro-Well, this LED will be on at all times when the control is powered. IMPORTANT: If the control is installed with a well other than the Electro- Well, this LED will not illuminate indicating the control is not providing low water cut-off functionality.
4 LWCO LOW WATER Indicates the boiler is in a low water condition. The HydroStat control will prevent burner operation during this condition. If the LOW WATER light is blinking, the control has been programmed to provide lockout protection in the event a low water condition is detected. (see Manual Reset Low Water Cut-Off on page 8 of Hydrolevel manual). Pressing the TEST/SETTINGS button will reset the control.
IMPORTANT: The system must be checked by a qualified heating professional prior to resuming operation.

7 TEST/SETTINGS Button

To Test Low Water Cut-Off: Press and hold the Test/ Settings button for 5 seconds. The display will read

LCO.

LWCO TEST LCO

The red Low Water light should illuminate and the

burner circuit should de-energize. NOTE: The control

must be installed with a Hydrolevel Electro-Well for

low water cut-off functionality (SEE Hydrolevel manual for more details).

To View Current Settings: Press and release the Test/Settings Button in short intervals to sequentially
display the following settings:

HIGH LIMIT SETTING HL

LOW LIMIT SETTING LL

ECONOMY SETTING ECO

CURRENT TARGET TEMPERATURE ooo

FLAME CURRENT FLA
The display will return to boiler temperature (default) if Test/Settings Button in not pressed for 5 seconds.

NOTE: flame current reading will remain in the display for 30 seconds to allow for pilot adjustment.

5 ECONOMY ACTIVE Indicates the Thermal Targeting function is active and the Fuel Smart HydroStat will reduce boiler temperature to conserve fuel. The Economy feature is activated using the ECONOMY dial.
34

PN 240013661 Rev. B [02/10/2023]

Ignition – LED Legend

APPENDIX A – CONTROL FUNCTION
A-1. Intermittent Pilot Ignition System Checks

1 LIMITS illuminates on a call for heat to indicate the external limits are satisfied. (External limits may include flame rollout, spill switch, secondary low water cut-off etc.). If the external limits are open, the LIMITS light will blink.
2 V-PWR Indicates power has been sent to the vent damper.
3 V-SW Illuminates when the vent damper switch an has made. If the damper end switch fail to make in 30 seconds, the V-SW light will blink.
4 FLAME Illuminates when the pilot flame is lit. If the pilot flame is not sensed within 75 seconds or if flame is lost, the FLAME light will blink.
! DANGER
Carbon Monoxide Hazard: If the burner fires when the vent damper is not fully opened or there is any other blockage in the flue, dangerous flue products, such as carbon monoxide, will escape into the living space causing severe personal injury or death. The flue as well as the vent damper must be checked for proper operation before allowing the system to operate.

STEP 1: Check ignition cable. a. Verify ignition cable does not make contact with metal surfaces. b. Verify only factory supplied Ignition cable (or approved replacement) is used. c. Verify connections to ignition module and igniter or igniter-sensor are clean and tight. d. Verify ignition cable provides good electrical continuity.
STEP 2: Verify ignition system grounding. Nuisance shutdowns are often caused by poor or erratic grounding. Common ground is required for module and pilot burner/ igniter sensor.
Check for good metal-to-metal contact between pilot burner bracket and the main burner.
Check ground lead from GND (BURNER) terminal on module to pilot burner. Verify connections are clean and tight. If wire is damaged or deteriorated, replace with No. 14-18 gauge, moisture-resistant, thermoplastic insulated wire with 105°C [221°F] minimum rating.
Check ceramic flame rod insulator for cracks or evidence of exposure to extreme heat, which can permit leakage to ground. Replace pilot burner/ igniter sensor and provide shield if necessary.
If flame rod or bracket is bent out of position, restore to correct position.

35

PN 240013661 Rev. B [02/10/2023]

APPENDIX A – CONTROL FUNCTION

STEP 3: Check spark ignition circuit.
! WARNING
Electrical shock hazard. Ignition circuit generates over 10,000 volts. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.
Energize module and listen for audible sparking noise. When operating normally, there should be a buzzing noise that turns on and off twice per second for duration of 1­7 seconds depending on model. Reconnect ignition cable.

4. Recheck ignition sequence as follows: a. Adjust thermostat above room temperature. b. Verify ignition sequence at burner.

Figure A-1 – Troubleshooting Pilot Flame

APPEARANCE
SMALL BLUE FLAME

CAUSE
CHECK FOR LACK OF GAS FROM: · CLOGGED ORIFICE FILTER · CLOGGED PILOT FILTER · LOW GAS SUPPLY PRESSURE · PILOT ADJUSTMENT AT MINIMUM

STEP 4: Verify pilot and main burner light-off. 1. Initiate call for heat. Turn thermostat above room
temperature. Ignition sequence may be delayed by thermal purge up to 2 minutes.
2. Watch pilot burner during ignition sequence.
Verify ignition spark stops within a few seconds after pilot is lit.
Verify Main burner lights within a few seconds of pilot lighting
a. Check pilot flame. Verify it is blue, steady and envelops 3/8 to 1/2 in. [10 to 13 mm] of flame rod. See Figure A-1 for possible flame problems and causes.
b. If necessary, adjust pilot flame by turning pilot adjustment screw on gas control clockwise to decrease or counterclockwise to increase pilot flame. Following adjustment, always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation. Figure 12-1, page 28.
3. If pilot does not stay lit, ensure adequate flame current as follows.
Turn off boiler at circuit breaker or fuse box.
Clean flame rod with emery cloth.
Verify electrical connections are clean and tight. Replace damaged wire.
Check for cracked ceramic insulator, which can cause short to ground, and replace pilot if necessary.
Set temperature below room set-point to end call for heat.

LAZY YELLOW FLAME

CHECK FOR LACK OF AIR FROM: · DIRTY ORIFICE · DIRTY LINT SCREEN, IF USED · DIRTY PRIMARY AIR OPENING IF THERE IS ONE · PILOT ADJUSTMENT AT MINIMUM

WAVY BLUE FLAME

CHECK FOR: · EXCESSIVE DRAFT AT PILOT LOCATION
· RECIRCULATING PRODUCTS OF COMBUSTION

NOISY LIFTING BLOWING FLAME

CHECK FOR: · HIGH GAS PRESSURE

HARD SHARP FLAME

THIS FLAME IS CHARACTERISTIC OF MANUFACTURED GAS CHECK FOR:
· HIGH GAS PRESSURE
· ORIFICE TOO SMALL

Correct Pilot Flame: 3/8 to 1/2 inch in flame

36

PN 240013661 Rev. B [02/10/2023]

APPENDIX B – VENT DAMPER INSTALLATION

! WARNING
Asphyxiation, burn hazard. Improper operation of vent damper may result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.
B.1 Damper Installation Follow Damper installation instructions provided with damper. See Figure 1a & 1b.
1. Verify only boiler is serviced by Vent Damper. Figure 2.
2. Clearance of 6 inches (152 mm) between Vent Damper and combustible material shall be maintained. Allow additional clearance for service of Vent Damper.
3. Vent Damper shall be in the open position when appliance main burners are operating.
4. Vent Damper position indicator must be in visible location following installation.

Figure 1a – Horizontal Installations

Flow

NO

To Boiler

YES

YES

Vent Damper To Chimney

NO

Install vent damper with actuator to sides of vent only. Do not mount above or below vent

Figure B-1b – Vertical Installations

To Chimney

Flow To Boiler

Vent Damper

Actuator may be installed in any
position

Figure 2 – Alternate Vent Damper Installation

B.2 Vent Damper
Check vent damper and all flue product carrying areas of boiler annually for deterioration from corrosion or other sources. Contact your service agent for repairs.
Check Vent Damper Operation as follows:
1. When boiler is off, check vent damper position indicator points to closed position. See Figure 3.
2. Turn thermostat or controller up to call for heat and check vent damper indicator points to open position See Figure 3.
3. Turn thermostat or controller down again and check damper position indicator returns to closed position.
4. Return thermostat to desired position. 5. Place vent damper in open position to permit burner
operation by using “HOLD DAMPER OPEN” switch, located on damper controller. 6. Thermostat controls burner firing as before, while damper remains open. 7. DO NOT turn damper open manually, motor damage will result. 8. Set switch to “AUTOMATIC OPERATION” to close vent damper during burner off cycle. 9. For further information, and for vent damper troubleshooting guide, refer to manual packaged with vent damper.

Do not install Vent Damper within 6″ (152mm) of combustible material

Do Not Install Here

Install Damper Here

Boiler

Water Heater

Chimney

Figure 3 – Vent Damper Position Indicator

ROTATION OPEN
CLOSED Flue Gas Flow
ROTATION OPEN
CLOSED Flue Gas

Damper Closed

Damper Open

Open and Closed Positions Shown

37

PN 240013661 Rev. B [02/10/2023]

APPENDIX B – VENT DAMPER INSTALLATION

B.3 Vent Damper Harness – Molex Plugs
! WARNING
Follow all instructions regarding safety operational controls in this manual. Failure to follow these instructions could result in death or serious injury.

Figure 4

Note

When servicing controls, all wires must be labeled prior to disconnection. Wiring errors can cause improper and dangerous operation. Do not turn damper open manually or motor damage will result.

Do not cut plug off of damper motor assembly this will affect warranty coverage.

Verify Molex pins are fully seated in both ends of Molex plugs
Figure 5

Check Molex Plugs on Vent Damper Harness:

Note

Damper wiring harness is made up of 4 individual colored wires, Brown, Black, Yellow, and Orange. See Figure 4.

1. Disconnect thermostat wires. 2. Confirm the Molex plugs on each end of the damper
harness are wired and operating properly. See Figures 4 and 5. Damper end of wiring harness: A. Hold plug in hand with wiring harness behind Molex
with “V” slot on top. Verify wire colors are in proper position.
B. Take reading across brown and black wires in Molex plug, using test meter set for AC volts. 24 volts should be present.
i. IF NOT, source of the problem is not in damper; check line voltage and 24 volt supply.
ii. If 24 volts is present across brown and black, continue to step iii.
iii. Reconnect thermostat wires and turn up heat setting.
iv. Check voltage across black and orange wires in Molex plug. 24 volts AC should be present: · IF NOT, source problem is not the damper.
· If 24 volts is present continue on to step v.
v. Place jumper wire across orange and yellow wires in Molex plug (see Figure 4). This will create bypass of the damper, boiler should then ignite. · If boiler ignites: Go to section B.4 “Vent Damper Troubleshooting Guide”.
· If boiler does not ignite: Problem is not the damper. Go to Damper harness Molex on Aquastat, Step C.
NOTE: Prior to replacing the damper, be sure the problem is not with wire connections between damper and wiring harness.

Control End of wiring harness Hold plug in hand with wiring harness behind Molex with
“V” slot on top. Verify wires colors are in proper position

“V” Slot

Yellow

Black

Brown

OPEN

Orange

Black

Check Molex Plugs on Vent Damper Harness:
C. Remove damper harness from control. Jump Molex connector on control board between two center holes using ~ 18 ga. thermostat wire. See Figure 6 i. If boiler ignites, replace damper harness
ii. If boiler does not light, check for 24 volts at B1-B2 on aquastat. If no replace control.
iii. If 24 Volts are present Damper and Control are ok. Check ignition module, rollout switch, spill switch or gas valve.

Figure 6

Jumper two center pins

38

PN 240013661 Rev. B [02/10/2023]

APPENDIX B – VENT DAMPER INSTALLATION

B.4 Vent Damper Troubleshooting Guide
! WARNING
Follow all instructions regarding safety operational controls in this manual. Failure to follow these instructions could result in death or serious injury.

Note

When servicing controls, all wires must be labeled prior to disconnection. Wiring errors can cause improper and dangerous operation. Do not turn damper open manually or motor
damage will result and affect warranty coverage, use the service switch.

Normal Sequence of Operation

24 VAC Power
4 & 1
4 & 2
4 & 3

Power ON
All times Calling for Heat During combustion

Damper Position
Open or Closed Open or Opening Damper Open

Brown

Orange

Do not cut plug off of damper motor assembly this will affect warranty coverage.
Vent Damper Troubleshooting

Yellow

Black

Problem
NO POWER Between 4 & 1
NO POWER Between 4 & 2 POWER Between 4 & 1 When calling for heat POWER Between 4 & 1 Between 4 & 2 DAMPER OPEN

Possible Cause
1. Off on limit (120VAC) 2. Bad transformer 3. Loose or broken connections 4. Blown fuse or circuit breaker 5. Disconnect switch off 6. Harness not plugged into receptacle on aquastat

Recommended Solution
1. turn limit on 2. Replace transformer 3. Tighten, repair, or replace connection 4. Replace fuse or reset circuit breaker 5. Turn switch on 6. Plug harness in

1. Thermostat not calling for heat 2. Burned out heat anticipator 3. Loose or broken connections 4. Off/On operating limit, pressure control or low water cut off 5. Off/On blocked vent switch or flame roll out

1. Turn thermostat up to call for heat 2. Replace thermostat 3. Tighten, repair, or replace connection 4. Turn operating limit, pressure control, or low water cutoff ON 5. Reset or replace switch

1. Loose or broken connection 2. Defective damper motor

1. Tighten, repair, or replace connection 2. Replace damper motor assembly

39

PN 240013661 Rev. B [02/10/2023]

IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the
same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
· An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.
· This boiler is not used for any space heating · This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/hr or greater. · This boiler is equipped with a tankless coil.

2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com

All specifications subject to change without notice. ©2023 ECR International, Inc.

References

• A Family of Heating and Cooling Brands - ECR International / Granby
• National Institute for Occupational Safety & Health | NIOSH | CDC
• Workplace Safety and Health Topics | NIOSH | CDC

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>