SPARQ 112364-05 Electric Hot Water Boiler Instruction Manual Electric Hot Water Boiler
- March 16, 2024
- SPARQ
Table of Contents
- 112364-05 Electric Hot Water Boiler
- Electric Hot Water Boiler
- Specifications
- Product Usage Instructions
- 1. Locating Boiler
- 2. Hydronic Piping
- 3. Water Quality
- 4. Electrical Connections/Wiring
- 5. Start-up
- 6. General Maintenance
- 7. Troubleshooting
- Q: Is it safe to install the boiler without professional
- Q: What should I do if I detect a gas leak near the
- Q: How often should I perform general maintenance on the
112364-05 Electric Hot Water Boiler
Electric Hot Water Boiler
Specifications
- Model Number: 112364-05
- Date: 11/23
- Serial Number: 9700609
- Approval: Listed with Massachusetts Board of Plumbers and Gas
Fitters
Product Usage Instructions
1. Locating Boiler
Choose a suitable location for the boiler that complies with
local regulations and provides proper ventilation.
2. Hydronic Piping
Ensure proper installation of hydronic piping to and from the
boiler according to manufacturer specifications.
3. Water Quality
Maintain water quality within recommended parameters to prevent
damage to the boiler and ensure efficient operation.
4. Electrical Connections/Wiring
Follow the electrical connection guidelines provided in the
manual to ensure safe and proper wiring of the boiler.
5. Start-up
Follow the startup procedures outlined in the manual to
initialize the boiler correctly and ensure optimal performance.
6. General Maintenance
Regularly perform maintenance tasks as described in the manual
to prolong the lifespan of the boiler and prevent issues.
7. Troubleshooting
Refer to the troubleshooting section if you encounter any issues
with the boiler to identify and resolve common problems.
Frequently Asked Questions (FAQ)
Q: Is it safe to install the boiler without professional
assistance?
A: No, the Commonwealth of Massachusetts requires installation
by a licensed Plumber or Gas Fitter for safety and compliance.
Q: What should I do if I detect a gas leak near the
boiler?
A: Immediately evacuate the area, do not operate any electrical
devices, and contact emergency services.
Q: How often should I perform general maintenance on the
boiler?
A: Regular maintenance should be conducted at least annually or
as per the manufacturer’s recommendations.
Electric Installation, Operating & Service Manual
Electric Hot Water Boiler
Installation, Operating and Service Instructions
Models: · SWA16 · SWA20 · SWA24
4 D
Manual Contents
Page
1. Read Before Proceeding. . . . . . . . . . . . . . . . . 2
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Locating Boiler . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Hydronic Piping. . . . . . . . . . . . . . . . . . . . . . . . 7
6. Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . 10
7. Electrical Connections/Wiring . . . . . . . . . . . 11 C
8. Sequence of Operation. . . . . . . . . . . . . . . . . 16
9. Control Operation . . . . . . . . . . . . . . . . . . . . . 17
10. Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11. General Maintenance . . . . . . . . . . . . . . . . . . 21
12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 22
13. Service Parts . . . . . . . . . . . . . . . . . . . . . . . . 25
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
B
TO THE INSTALLER:
Affix these instructions adjacent to boiler. Provide model number and serial
number when seeking information and support.
TO THE CONSUMER:
Retain these instructions for future reference. Contact heating installer or
technician for all issues and support.
A
4
112364-05 – 11/23
9700609
3
2
3
2
1
1 Read Before Proceeding
Electric Installation, Operating & Service Manual
Read and understand this document before proceeding with installation or
maintenance.
Boiler is listed with Massachusetts Board of Plumbers and Gas Fitters. See
Massachusetts Boards of Plumbers and Gas Fitters website for the latest
Approval Code
(https://licensing.reg.state.ma.us/pubLic/pl_products/pb_pre_form. asp).
Commonwealth of Massachusetts requires this product to be installed by a
licensed Plumber or Gas Fitter.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.
! DANGER
Indicates a hazardous situation that, if not avoided, will result in death or
serious injury.
! CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
! WARNING
Indicates a hazardous situation that, if not avoided, could result in death or
serious injury.
NOTICE: Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
! DANGER
Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or
liquids in the vicinity of this or any other appliance.
· If you smell gas, DO NOT try to operate any appliance – DO NOT touch any
electrical switch or use any phone in the building. Immediately, call the gas
supplier from a remotely located phone.
! WARNING
This boiler must only be serviced and repaired by qualified installer, service
agency, gas supplier, or electrician. · Replace controls with manufacturer-
suggested replacements. · Read, understand and follow all instructions and
warnings in this manual’s sections. · If any electrical wires are disconnected
during service, clearly label wires, and assure wires are correctly connected.
· Never jump out or bypass any safety or operating control or component. ·
Assure all safety and operating controls are working correctly before placing
boiler back in service. · Annually inspect boiler.
NOTICE: Keep these instructions near boiler for future reference.
2
112364-05 – 11/23
1 Read Before Proceeding (continued)
Installer or Qualified Service Agency Read Before Proceeding
! WARNING
Burn and Electrical Shock Hazard.
1. Carefully read all instructions in literature packet and labels posted on
boiler before attempting installation, startup, or service of this boiler.
Perform steps in order given. Failure to follow all instructions in proper
order could result in severe personal injury, death or substantial property
damage.
2. Use proper personal protective equipment when installing, servicing, or
working near this boiler. Materials of construction contain heavy metals
and/or other toxic or harmful substances that can be hazardous to health and
life and that are known to the State of California to cause cancer, birth
defects, and other reproductive harm.
3. Do not disconnect pipe fittings on boiler or in heating system without
first verifying system is cool and free of pressure and that your clothing
will protect you from a release of hot water or steam. Do not rely solely on
boiler temperature and pressure gauge when making this judgement. · Disconnect
electrical supply before installing or performing maintenance. · Install all
guards, cover plates, and enclosures before leaving boiler in operation.
NOTICE: Size boiler properly relative to design heat load or, if using DHW
priority, the peak hot water load, whichever is larger. A grossly oversized
boiler will cycle excessively leading to premature failure of boiler and its
components. Warranty does not cover damage from excessive
cycling.
4. For heating system employing convection radiation (baseboard or
radiators), use an industry accepted sizing method such as the I=B=R Guide RHH
published by the Air Conditioning, Heating and Refrigeration Institute (AHRI).
5. For new radiant heating systems, refer to radiant tubing manufacturer’s
boiler size guidelines.
6. For system including indirect water heater, ensure boiler has output
called for per indirect water heater manufacturer’s instructions.
7. A hot boiler installed above radiation level or as required by the
authority having jurisdiction must be provided with a low water cutoff (LWCO)
device. A UL353 listed flow switch is provided with this boiler.
112364-05 – 11/23
Electric Installation, Operating & Service Manual
8. Inspect shipment carefully for signs of damage. Any claim for damage for
shortage in shipment must be filed immediately against carrier by consignee.
No claims for variances or shortages will be allowed by boiler manufacturer,
unless presented within 60 days.
User/Homeowner Read Before Proceeding ! WARNING
Burn and Electrical Shock Hazard. 1. A skilled and experienced service
technician
should annually inspect boiler and replace any component exhibiting damage or
deterioration.
! CAUTION
Burn and Electrical Shock Hazard. Keep children and pets away from hot
surfaces of the boiler including boiler piping, vent piping, and vent
terminal. NOTICE: Boiler may leak water at the end of its useful life. Be sure
to protect walls, carpets, and valuables from water that could leak from
boiler. Protect your home in freezing weather. Do not leave heating system
unattended during cold weather unless alarms or other safeguards are in place
to prevent such property damage.
3
2 Introduction
Introduction
· Size boiler based on total heat load of the building.
· Calculate maximum hourly heat loss for each heated space following
procedures described in The Hydronic Institute Manual H-22 (Heat Loss
Calculation Guide) or a method suitable for local conditions.
· Do not oversize the boiler–correct boiler sizing is critical for in-floor
radiant heating applications.
Unpacking
· Remove packing and inspect unit for damage or missing parts.
· Check packing list and verify all shipped loose items are received.
· Report any concealed damage or claims to carrier immediately.
Control Standard Features
· Three-character LED display
· Three button User Interface
· Error code display
· Element Staging and Element Start Rotation
· Dual set points for space heating and domestic hot water
· Setting for Fahrenheit or Centigrade temperature scales
· Water temperature heating range 90°-180°F (32°82°C)
· Dry fire protection
· Connections for provided flow switch
· Low water cutoff connections
· Load management control connection with auxiliary heat source connection
· Freeze protection
· Circulator pump terminals
· 40VA transformer
· Three-wire thermostat connection
· Audible alarm
· Pump exercising
· Relay contact monitoring
· Non-Volatile memory
Electric Installation, Operating & Service Manual
Product Description
Electric Boiler is a heating device that converts electrical energy to hot
water. Kilowatts of Electricity Used per Hour x 3412 = British Thermal Units
(BTUH) Available Per Hour for Heating. · Follow information in Table 3-1. ·
Electric Boiler is constructed to conform to
American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code,
Section IV. · Maximum Allowable Working Pressure Water (MAWP) 30 PSI. ·
Construction conforms to Canadian Standards Association (CSA) Standards
Electric Boilers, C22.2. · Important product information on boiler: Model
number Manufacturer’s serial number BTU rating Heating element ratings Water
pressure & temperature limits CSA listing ASME stamp Total Amps Clearances ·
Boiler is operated by control board maintaining water temperature. Control
cycles heating elements based on heating demand and preset boiler outlet water
temperature. · Control also operates 120 VAC circulator pump rating up to 5A.
When thermostat calls for heat, control will operate boiler to regulate water
temperature at pre-established set point. System pump is on whenever
thermostat calls for heat.
4
112364-05 – 11/23
3 Specifications
Electric Installation, Operating & Service Manual
Table 3-1: Electrical Specifications, 4 Element Boiler Operating at 240 VAC
Model Number
Boiler Size (kW)
Voltage (AC)
Output Power (Watts)
Output Power BTU/hr.
Amps
Element Size
(Watts)
Total Amps
MCA
MOP
SWA16 16 SWA20 20 SWA24 24
240 16,000 54,600 66.7 4,000 72.7 90.8 100 240 20,000 68,200 83.3 5,000 89.3 111.7 125 240 24,000 82,000 100.0 6,000 106.0 132.5 150
*Recommended Copper Wire
140oF (60oC) AWG
167oF (75oC) AWG
2
3
1/0
2
2/0 1/0
*Recommended Aluminum Wire 140oF 167oF (60oC) (75oC) AWG AWG
1/0 1
2/01 2/0 4/0 3/0
! WARNING
- Minimum Recommended Field Wire Size per National Electric Code (NEC). Check with latest version of NEC and local codes.
**Recommended aluminum wire (not for use in Canada). It is recommended to apply antioxidant paste for aluminum conductors. Aluminum is more malleable than copper–avoid cuts or nick during termination.
Based on ambient temperature of 86ºF (30ºC). Other ambient temperature see NEC or CEC for correction factors. UL-834, Section 14.2. No more than three (3) current-carrying conductors in raceway.
Table 3-2: Dimensions and Connections
Model Height Number (in.)
Width (in.)
Depth (in.)
Water Inlet (in.)
Water Outlet (in.)
Water Volume (gal.)
Ship Loose Items
Approx. Shipping Weight (lb.)
Flow Switch
Tee (NPT)
Air Vent (in.)
Relief Valve (in.)
Temp./ Pres. Gauge (in.)
SWA16 24
19
10
3/4
3/4
2.20
54
3/4 3/4 3/4 1/4
SWA20 24
19
10
3/4
3/4
2.20
54
3/4 3/4 3/4 1/4
SWA24 24
19
10
3/4
3/4
2.20
54
3/4 3/4 3/4 1/4
All dimensions are approximate. Manufacturer reserves the right to change dimensions and/or specifications without notice.
! WARNING
Follow NEC and local building code when selecting wires and insulation.
What is MCA? Minimum Circuit Ampacity (MCA) is a calculated value that specifies the minimum primary power wire size to determine the minimum wire size required for a field wired product. The specification is necessary to guarantee the wire will not overheat under expected operating conditions. The wire size takes into account the normal current draw, aging of components and anticipated faults. When operating correctly, the MCA is the highest steady- state electrical current the unit should see.
What is MOP? Maximum Over-Current Protection (MOP) is a calculated value that determines the maximum size of the over-current protection device (fuse or beaker). Depending on your application, there are different MOP equations, to determine maximum breaker size required to adequately protect equipment under anticipated fault conditions. In addition, the MOP takes into account the startup surges and components.
Supply wiring must be rated to carry the amps shown as MCA. By comparison, the over-current protection (a breaker or fuse) must be sized to prevent the unit from drawing more current than the MOP.
112364-05 – 11/23
5
4 Locating Boiler
! WARNING
Electrical Shock Hazard. Do not install boiler underneath a water source.
Failure to do so could result in severe personal injury and death.
1. Boiler is intended for indoor installation only and should not be subject
to water spray or leakage.
2. Boiler is intended to be wall mounted and is provided with mounting
brackets. Use lag screws or anchor bolts through holes provided or on 3/4 in.
plywood panel.
3. Boiler must be installed with heat exchanger vertical.
4. On uneven walls, suggest mounting surface be provided such as two 2 x 4’s.
5. Mount boiler no closer than 12 inches to wall surface on left and 12
inches to wall surface on right or more, depending on plumbing.
6. Maintain 19 inches top clearance for element removal and 15 inches bottom
clearance for drain connections.
7. Allow sufficient room from front of unit to door or wall to remove cover –
at least 12 inches.
! WARNING
Failure to provide minimum clearance between boiler and combustible material
may result in fire.
8. When installed in utility room, door should be wide enough to allow
largest boiler part to enter or to permit replacement of another appliance
such as water heater.
9. Boiler room should be vented to maintain an operating temperature between
45-80°F (7-27°C).
Electric Installation, Operating & Service Manual
10. Minimum clearances to combustible surfaces: TOP……………………………….. 9 in.
FRONT…………………………… 2 in. LEFT SIDE……………………… 12 in. RIGHT SIDE…………………… 12 in.
REAR……………………………. 0 in. BOTTOM………………………. 10 in.
11. Minimum service clearance: TOP……………………………… 19 in. FRONT…………………………. 12 in.
LEFT SIDE……………………. 18 in. RIGHT SIDE…………………. 18 in. REAR…………………………… 0 in.
BOTTOM……………………… 15 in.
6
112364-05 – 11/23
5 Hydronic Piping
Circulating System
1. Size circulator(s) based on total hydronic system pressure drop and
designed flow rate.
2. To prevent rapid cycling on the high limit, adequate flow is required.
3. Maintain 15-25 PSI system pressure. 4. These water trim components are
shipped loose
with each boiler: · Water flow switch · Pressure relief valve (30 PSIG) · Air
vent · Temperature/pressure gauge · Pipe nipples 5. Provided flow switch opens
at approximately 3.0 GPM. Flow switch is intended for “No Flow” situations. 6.
Install flow switch vertically in horizontal pipe with at least five straight
pipe diameters on either side. See Figure 5-1. 7. Low water cut-off device may
be required to satisfy additional local and national code requirements.
Figure 5-1: Flow Switch Direction 112364-05 – 11/23
Electric Installation, Operating & Service Manual
Table 5-2: Maximum Temperature Rise °F
Boiler Model
@ 3.0 GPM
SWA16
37
SWA20
45
SWA24
55
Table 5-3: Flow Rate to Achieve 20°F
Boiler Model SWA16 SWA20 SWA24
GPM 5.5 6.8 8.3
Connecting Supply and Return Piping
8. When boiler is connected to heating system utilizing multiple zone
circulator, each circulator must be supplied with a flow control valve to
prevent gravity circulation.
9. Reduce pressure back flow preventer must be present under provisions
required by Environmental Protection Agency (EPA).
10. A pressure relief valve is supplied with each boiler and must be
installed vertically. Install at location and discharge direction shown using
pipe nipple and elbow supplied. See Figure 5-1. Add piping so any water
discharge will not damage boiler or other system components.
11. Install gate valves at locations in Figures 5-1 and Table 5-2, so any
boiler servicing requiring removal of water can be done quickly and easily.
Not illustrated but recommended is installation of air vents at high points of
hydronic system to reduce initial startup time and help avoid element burnout
during entire life of heating system.
12. Follow piping arrangement as illustrated in Figure 5-1 and Table 5-2.
Inlet or return pipe is located at bottom of unit. Reverse flow will cause
noisy operation and cause very early element failure. Drain cock is to be
located at the lowest point of piping.
13. Pipe discharge outlet of pressure relief valve within 6 in. of the floor
or drain. No threads should be present on discharge pipe end.
14. Outlet or supply pipe line to radiation is located at top of unit. A
combination temperature/pressure gauge is provided and should be installed
close to boiler outlet.
15. For further piping information, refer to an industry accepted sizing
method such as the I=B=R Guide RHH published by the Air Conditioning, Heating
and Refrigeration Institute (AHRI).
7
5 Hydronic Piping (continued)
8
Notes: 1. Unions and full port service isolation valves vary with each installation. 2. Refer to wiring diagram 7.2 and 7.3.
To System
Full Port
Isolation
Valves
Air Separator
Zone Circulators & Air Vent
Full Port Isolation Valves
Zone Circulators Full Port Isolation Valve
Full Port Isolation
Valves System
Zone Valves
To System
Full Port Isolation Valves System Zone Valves
Flow Check IWH Circulator
System Return
Full Port Isolation
Valves Full Port Isolation
Valves
Drain Valve
Provided Flow Switch
Pressure Relief Valve
Fill Valve Cold Water Return
Backflow Preventer
Expansion Tank Full Port Isolation Valve
Union Full Port Isolation Valves
Pipe within 6″ of floor or Drain No Threads on Drain End
Drain Valve Wye
Electric Installation, Operating & Service Manual
112364-05 – 11/23
System Circulator
Indirect Water Heater (IWH)
Figure 5-4: Typical Water Piping
5 Hydronic Piping (continued)
To System
Electric Installation, Operating & Service Manual
Flow Check Valves Optional Full Port Isolation Valves Heating Circulators Optional Full Port Isolation Valves
Flow Check Valves
Optional Full Port Isolation Valves
Heating Circulators Optional Full Port Isolation Valves Fill Valve Backflow
Preventer
12″ max
Air Separator Expansion Tank
From System
Pump
Full Port Isolation
Valves
Dirt & Magnetic Filter (High Recommended)
Provided Flow Switch
Union
Pressure Relief Valve
Full Port Isolation
Valves Notes:
1. Unions and full port service isolation valves vary with each installation.
2. Refer to wiring diagram 7.2 and 7.3.
Union
Drain Valve
Pipe within 6″ of floor or Drain No Threads on
Drain End
Figure 5-5: Primary/Secondary Piping with Zone Pumps
112364-05 – 11/23
9
6 Water Quality
1. Poor water quality causes oxidation, scaling, corrosion, and fouling,
which can severely damage the heating element and pressure vessel.
NOTICE: Warranty does not cover component failure caused by scale build-up or
poor water conditions.
2. Since water quality varies by location, the installer should consult a
qualified water treatment expert about developing a water treatment plan.
3. A proper water treatment plan and regular boiler maintenance extend the
boiler’s working life. Refer to Table 6-1 for water quality requirements.
Table 6-1: Water Quality
Oxygen pH Chlorides Total Water Hardness
Less than 250 ppb 8.0-10.5 Less than 250 ppm Less than 150 ppm
Note: Softened water is not recommended.
4. Adhere to the following installation recommendations to prevent excess
dissolved gas and minerals from entering the heating loop.
5. Adhere to the following installation recommendations to prevent excess
dissolved gases and minerals from entering the heating loop.
· Install system makeup water valve with backflow preventer.
· Install air-vent provided with this unit at highest point on near boiler
piping.
· Install an expansion tank designed for system total water volume.
· Makeup water should be added at the boiler outlet and not fed directly to
the boiler.
· Keep makeup water at a minimum to prevent scale build-up.
· Immediately repair leaks and maintain 14-25 psi system pressure.
Electric Installation, Operating & Service Manual
10
112364-05 – 11/23
7 Electrical Connections/Wiring
Boiler Wiring
! WARNING
DO NOT alter any internal wiring or bypass any built-in safety limit controls.
Doing so will result in unsafe operation.
1. This boiler uses 240-volt, 3 wire, single-phase, 50/60-hertz power.
2. Electrical wiring should be in accordance with requirements of authority
having jurisdiction. Refer to: · Canada-Canadian Electrical Code, CSA C22.1
Part 1, Safety Standards for Electrical Installations. · USA-National
Electrical Code, ANSI/NFPA 70.
3. Verify nameplate rating and related codes to properly size conductors,
switches, and over current protection.
! WARNING
All circuit breakers or disconnects ahead of boiler must be OFF. Turn integral
boiler breakers off at the same time as well.
4. Remove boiler front cover by removing 4 screws from top and bottom.
5. For boilers used in multiple zone system, zone valves must be powered from
an independent source and have electrically isolated end switches or isolating
relays wired in parallel to boiler thermostat terminals.
! CAUTION
· Do not power zone valves from transformer in boiler control.
· Control does not support secondary pump. See Figure 7-4.
Field Wiring
1. All field wiring should be in accordance with NEC or CEC standards.
2. Minimum Circuit Ampacity (MCA) and recommended Maximum Over-current
Protection (MOP) are listed on nameplate of unit. See Table 3-1.
Line Connections AWG 8
AWG 6 to 2/0
lb.-in. 40 120
Conductor Copper or Aluminum Copper or Aluminum
Electric Installation, Operating & Service Manual
! CAUTION
Use torque device to properly tighten line to prevent overheating.
3/16″ allen screws Figure 7-1: Power Distribution Block
112364-05 – 11/23
11
7 Electrical Connections/Wiring (continued)
System Wiring
Electric
Installation, Operating & Service Manual
! CAUTION
Follow directions and wiring diagrams from accessory relay panel
manufacturers. Do not use the 24 VAC transformer to power zone valves or other
accessories.
R(T) and top DHW are electrically connected on the control board.
R(T)
W(T)
C DHW
IWH T-Stat
DHW
ODT ODT LMC LMC W(T)
R W 24 Vac T T COM
ONE ZONE SWITCHING RELAY
LED INDICATOR Power
Zone
6A Fuse
6A Fuse
120 Vac Input
N H
COM N/O N/C
3
4 4
N/O N/C COM
6
6 5
Multizone Wiring
T
Thermostat
R W 24 Vac T T COM
See Note 1
ZONE 1
ONE ZONE SWITCHING RELAY
6A Fuse
LED INDICATOR Power Zone
6A Fuse
120 Vac Input
N H
COM N/O N/C
3 4
4
N/O N/C COM 6 6 5
120 VAC Wiring Low Voltage wiring
T
Thermostat
See Note 1
See Note 2
ZONE 2
R W 24 Vac
T T COM
ONE ZONE SWITCHING RELAY
LED INDICATOR Power
Zone
6A Fuse
6A Fuse
120 Vac Input
N H
COM 3
N/O N/C 4 4
N/O N/C COM 6 6 5
C3
C2
120
N
VAC
H
Control has two TT inputs for two temperature
operations:
C2
1. R&W typically for central heat
2. DHW for a second operating temperature
Example, 100ºF set point for radiant floor and 180ºF set point for a fan coil
or indirect water heater.
The pump electrical output, limited to 120 VAC at 5 amps, turns on when either
TT makes a call for heat. It is possible to set the control for domestic
priority.
It is important to configure wiring with accessory zone controls to address
pump or zone valve operation as well as domestic water or other system
temperature priorities.
NOTE 1: Domestic Hot Water Priority When IWH calls for heat it disconnects one
control from making a call for heat at a different temperature and preventing
zone pumps from running.
NOTE 2: Taco Zone Valve control panel or similar products.
C1
To system To system
C1
From system From system
C3
Figure 7-2: Wiring Diagram for Direct Connection Piping with Zone Pumps and Indirect Water Heater
12
112364-05 – 11/23
7 Electrical Connections/Wiring (continued)
System Wiring
Electric
Installation, Operating & Service Manual
! CAUTION
Follow directions and wiring diagrams from accessory relay panel
manufacturers. Do not use the 24 VAC transformer to power zone valves or other
accessories.
BOILER CONTROL
[C1] [C2] 120V CIRC
R(T) W(T)
C DHW DHW ODT ODT LMC LMC W(T)
C1
Multizone Wiring
T-Stat Power
T-Stat Power
T-Stat Power
Thermostat
SEE NOTE 1
C3
Thermostat
Thermostat
ZONE PUMP PANEL
C3
C3
H
N
SEE NOTE 2
120 VAC
120 VAC Wiring Low Voltage Wiring
IWH T-Stat
R W 24 Vac
T
T COM
ONE ZONE
LED INDICATOR
SWITCHING RELAY
Power
Zone
6A Fuse
6A Fuse
H
120
VAC
N
120 Vac Input
COM N/O N/C
N
H3 4
4
C2
N/O N/C COM 6 6 5
Figure 7-3: Wiring Diagram Primary Secondary Piping with Zone Pumps and Indirect Water
Control has two TT inputs for two temperature operations: 3. R&W typically for
central heat 4. DHW for a second operating temperature
Example, 100ºF set point for radiant floor and 180ºF set point for a fan coil
or indirect water heater.
The pump electrical output, limited to 120 VAC at 5 amps, turns on when either
TT makes a call for heat. It is possible to set the control for domestic
priority.
It is important to configure wiring with accessory zone controls to address
pump or zone valve operation as well as domestic water or other system
temperature priorities.
NOTE 1: Domestic Hot Water Priority When IWH calls for heat it disconnects one
control from making a call for heat at a different temperature and preventing
zone pumps from running.
NOTE 2: Taco Zone Valve control panel or similar products.
112364-05 – 11/23
13
Electric
7 Electrical Connections/Wiring (continued)
Installation, Operating & Service Manual
N/O COM
N/O COM
N/O COM
N/O COM
N/O COM
N/O COM
N/O COM
N/O COM
ELEMENT 4
ELEMENT 3
ELEMENT 2
ELEMENT 1
Heating Elements R(T)
W(T)
C
DHW
DHW
ODT
ODT
Boiler
LMC
Control Board LMC
TAUX TAUX
HI HI FLO FLO LWC LWC WT LWC
5A Fuse
[C1] [C2] 120V CIRC N N L L
24 VAC
COM
G G L1 N
System Pump Connection
Figure 7-4: Wiring Control Board
R(T) W(T)
C DHW ODT LMC
HL FLO *LWC WT
Control Inputs (NEC Class – 2 Low Voltage)
Thermostat Input (R W C) or zone valve end switch (R W), Dry Contract Close
R-W Activation, 24 VAC R-C
Domestic Hot Water – Thermostat Input. Dry Contact Close Activation DHW – DHW
Not used Load Management Control Input. Dry Contact Normally Close LMC – LMC
High Limit Input (factory installed) Flow Switch Input (provided with boiler)
Low Water Cutoff Input – Installer supplied. Dry Contract Normally Closed LWC
– LWC Water Temperature Sensor Input (Factory Installed)
Control Output (NEC Class-2 Low Voltage) T Aux Auxiliary Heating Appliance Thermostat Connection *Factory Jumper Installed
System Pump Connection (120 VAC 60Hz, 1ph, 5A)
C1
Pump Hot (L1)
C2
Pump Neutral (N)
G
Pump Ground (G)
14
112364-05 – 11/23
8 Wiring Diagram
112364-05 – 11/23
BK/WH WH/BK
BK/WH WH/BK
BK/WH WH/BK
BK/WH WH/BK
NOTE:
1. If any of the original wire supplied with boiler must be replaced, it must
be replaced with the same type shown or its equivalent.
2. Install over-current protection in accordance with Authority Having
Jurisdiction or, in the absence of such requirements, follow The National
Electric Code, NFPA 70. Do not provide over-current protection greater than 15
Amperes.
3. Ensure “white strip” side of diode connects to terminal 2 with T(W) wire.
Wire Types
Line voltage (240) Factory wiring size 10 AWG Type TEM/AWM Standard wire, 105
0C Line voltage (240) Field wiring
Line voltage Factory wiring size 18 AWG Type TEM/AWM Standard wire, 105 0C
Line voltage Field wiring
Low voltage Factory wiring size 18 AWG Type TEM/AWM Standard wire, 105 0C Low
voltage Field wiring
Wire Color
BK/WH
BK WH GR RD PR
White with Black strip Black White Green Red
Purple
Low Voltage Connections
R(T)
W(T) C
DHW ODT LMC TAux HL FLO LWC WT
Comfort Heating Thermostat
Domestic Hot Water Not Used
Load Management Control Axillary Equipment High Limit Flow Alarm
Low Water Cutoff Alarm Water Temperature Sensor
Circulator (By Others)
Power Distribution Block
Service Switch (Optional by Installer)
Over-current Protection/ Disconnect (By Installer)
WH/BK WH/BK
WH/BK WH/BK
WH/BK WH/BK
WH/BK WH/BK
60A
60A
Circuit Breaker 1 Circuit Breaker 2
BK/WH BK/WH BK/WH BK/WH
BK/WH BK/WH BK/WH BK/WH
N/O COM
N/O COM
N/O COM
N/O COM
N/O COM
N/O COM
N/O COM
N/O COM
ELEMENT 4
ELEMENT 3
ELEMENT 2
ELEMENT 1
Heating Elements R(T)
PR
W(T)
WH
C
BK
DHW DHW
ODT
ODT
Boiler
LMC
Control Board LMC
TAUX TAUX
HI
HI
FLO
PR
FLO
PR
LWC
LWC
WT
RD
LWC
RD
5A Fuse
[C1] [C2] 120V CIRC N N L L
24 VAC
COM
GR WH
BK
Power Supply 240 AC
LL 12
GND
Fan
T-State (By Others)
SEE NOTE 3
High Limit (Manual Reset)
Flow switch
Optional (By Installer)
Water Temperature
Sensor
BK WH
24Vac Transformer
Electric Installation, Operating & Service Manual
15
Figure 8-1: Wiring Diagram
8 Sequence of Operation
Electric Installation, Operating & Service Manual
HEATING ELEMENTS 1 2 3 4
3
Heating Element LED Indicators
(Green)
2 Heating Demand
LED Indicator (Green)
1 Mode and Power Selection Button
DEMAND
PUMP
MODE/PWR UP
DOWN
4
Pump LED Indicator
(Green)
5
LED Display (Red)
6
Up and Down Adjustment Buttons
Figure 8-2: Boiler Controller
1 Mode and Power Selection Button – Turns boiler on and off, selects mode and
configuration settings 2 Heating Demand LED Indicator – Energized with call
for space heating or domestic hot water 3 Heating Element LED Indicator –
Energized with corresponding heating element 4 Pump LED Indicator – Energized
with boiler pump relay 5 LED Display – Indicates water temperature, set point,
mode, and error codes 6 Up and Down Adjustment Buttons – Used to select
temperature set point for space heating, domestic hot
water, and configuration settings
Boiler Display Codes
Display ON OFF
Description Boiler in On mode Boiler in Off mode
CHS Space Heating Setting
dHS Domestic Hot Water Setting
dFS Differential Setting dEg Degrees Temperature scale Stg Heating Element
Stages dFt Dry Fire Test
LdC Load Management
F Degrees Fahrenheit C Degrees Centigrade
Range
90-180oF (32-82oC) 90-180oF (32-82oC) 4-20oF (2-11oC) F or C 4
Displayed when LMC terminals open
Note
Control prevents setting from being higher than Domestic Hot Water Setting
Control prevents setting from being lower than Domestic Hot Water Setting
Applies to CHS and dHS
Displayed when power initially applied De-activates heating elements. Diverts
TT to TTAux for secondary appliance.
16
112364-05 – 11/23
9 Control Operation
Initial Start Up
· When electrical power is applied control displays firmware revision code. It
will then revert to mode it was in prior to power loss (factory setting in OFF
mode).
· Pressing MODE/PWR button for 2 seconds, unit will enter ON mode. Pressing
MODE/PWR button again for 2 seconds will return unit to OFF mode.
· Once in ON mode control automatically begins a DRY Fire Test (DFt is set to
Y in the configuration) where pump is energized and first element is pulsed
(see Dry Fire Test Mode).
· Dry Fire Test is only initiated after power loss. To by-pass Dry Fire Test
Mode and enter heating mode, press up and down arrow buttons for 2 seconds.
Two Temperature Operation
· Boiler is designed to control two loads with independent temperature control
such as a comfort heating zone (CHS) and indirect domestic hot water tank
(DHS).
Setting Water Temperature
· To set boiler water temperature, place boiler in ON mode and then select
temperature setting mode by pressing MODE/PWR button. Use up or down arrow
buttons to set temperatures for heating “CHS”, domestic hot water setting
“dhs” and differential setting “dFS”.
NOTICE: Setting for CHS cannot exceed setting for DHW. Setting for DHW cannot
be set below setting for CHS.
Heating Operation Sequence
· To begin heating sequence control board must be “On” for boiler operation.
All safety inputs must be closed (HL, LWC, FLO) as well as Load Management
Control (LMC) terminals. Set point temperature for either CHS or dHS above
current water temperature.
· To start boiler heating sequence thermostat or pump end switch will close
connection between terminals [heat – R & W (T & T)] or [Domestic hot water –
DHW_T &T] on control.
· Pump relay energizes for 30 seconds prior to electric elements while a check
of safety circuit and water temperature is conducted. (Note: Flow and LWCO
circuits check is conducted after pump starts, since water flow and water
level are dependent of pump being energized).
· If heating load is satisfied by residual boiler heat during 30 second pre-
purge period elements will not energize. Heating element(s) will begin to
energize after 30 second pre-purge is complete.
112364-05 – 11/23
Electric Installation, Operating & Service Manual
· LED’s for heating elements, pump status and heat call will illuminate as
each is energized. If safety circuit is open, elements will not energize and
error code is displayed.
· During heating operation, safety circuit is monitored. If no faults exist,
first element will energize, and rate of water temperature rise is calculated.
· Control will energize elements in sequence based on temperature rise of
water and target time of 5 minutes to reach set point. Minimum on and off
times apply to each element.
· When water temperature approaches set point, temperature heating elements
will de-energize to prevent water temperature from exceeding set point
temperature. When water temperature reaches set point, all remaining heating
elements will de-energize.
· Control will cycle elements on and off to maintain set point temperature. At
start of each heating cycle, lead element to energize will rotate to allow for
even duty cycle time for all elements.
· Pump will remain energized while there is call for heat (TT or DHW-TT
closed). When call for heat is satisfied, unit enters post purge period. Pump
will remain energized for 3 minutes, starting at a point in which last element
de-energized.
· Differential set point setting is used to determine point at which heating
elements are energized or de-energized. Increasing differential setting will
de-energize heating elements sooner and reduce potential for temperature
overshoot. A larger differential will also reduce cycles per hour of the
boiler.
· Decreasing differential set point setting will keep heating elements on
longer and allows for tighter set point control increasing potential for
temperature overshoot. A small differential also increases boiler cycles per
hour.
· Starting point for differential setting is 10ºF (5.5oC). Depending on
application, boiler size, number of heating zones and whether or not there is
domestic hot water application, differential setting can be adjusted to
accommodate installation.
Dry Fire Test
· Dry Fire Test detects presence or lack of water in the boiler and prevents
elements from energizing if dry condition exists.
· Dry Fire Test Mode is initiated following power outage and can take from 5
to 10 minutes to complete.
17
9 Control Operation (continued)
· Boiler must be ON and configuration setting for dFt must be set to Y. During
Dry Fire Test pump is energized and first heating element is pulsed while
temperature sensor is monitored to determine if water is present in the
boiler. If failure occurs, “DIFF” is displayed and a retry occurs.
· After three consecutive failures, an audible alarm will sound and pump will
stop. Power must be removed and dry condition corrected to clear the fault
code.
· Once initiated, Dry Fire Test can be canceled by pressing up or down arrow
buttons simultaneously for 2 seconds.
NOTICE: This bypass feature is intended for installer and should only be used
when dry condition does not exist.
· Dry Fire Test is selectable in configuration mode and can be set to Y or N.
To prevent Dry Fire testing from automatically occurring, change setting for
dFt to N in configuration mode. Do not change setting unless special
circumstances exist with application where conducting of Dry Fire Test does
not accurately detect presence of water in the boiler.
Load Management Control (LMC)
· Load Management (LMC) feature can deactivate boiler and temporarily place it
in standby mode. Some utility companies use this feature during peak demand
periods to load trim utility’s power grid.
· Control is equipped with an auxiliary set of contacts (T Aux) which can be
used to connect a secondary heating appliance. While the load management
terminals (LMC) are open, heating elements are prevented from energizing, and
“LdC” is displayed. The call for heat on TT or DHW terminals is then diverted
to the T Aux terminals to energize a secondary heating appliance.
· When LMC is open and TT or DHW_TT is closed, the pump shall remain off
except for post-purge mode.
· LMC terminals on boiler are intended to be connected to low voltage,
normally closed dry contacts of the utility LMC unit. Do not connect power to
LMC terminal.
· To connect utility LMC system, first remove jumper from LMC terminals on
boiler control, then connect LMC unit to terminals.
Flow Switch Input (FLO) (provided with boiler)
· Control is equipped with a set of contacts (FLO) which are used to connect
provided water flow switch. While the flow switch terminals (FLO)
18
Electric Installation, Operating & Service Manual
are open, heating elements are prevented from energizing and “FLO” is
displayed. Sensor input is only active while control is attempting to energize
heating element(s). Flow switch input IS NOT active during pre-and post-purge
modes. · Boiler FLO terminals are intended to be connected to low voltage,
normally closed dry contacts of water flow switch.
Low Water Cutoff
· Low Water Cutoff Sensor feature can be used to connect an installer provided
low water cutoff to de-activate boiler if water is not present at the sensor
(abnormal condition).
· Control is equipped with an auxiliary set of contacts (LCO) which can be
used to connect a low water cutoff sensor. While low water cutoff terminals
(LCO) are open, heating elements are prevented from energizing and “LCO” is
displayed.
· The sensor input is only active while the control attempts to energize
heating element(s). The low water cutoff sensor input IS NOT active during the
pre-and post-purge modes. LOC terminals on boiler are intended to be connected
to low voltage, normally closed dry contacts of the water flow switch.
· To connect a low water cutoff sensor, first remove factory installed jumper
from the LCO terminals. Then connect alarm output, dry contact, and normally
closed low water cutoff sensor terminals to LCO terminals.
· Low Water Cutoff alarm will only be monitored during the heating cycle while
elements are energized. An open Low Water Cutoff has no effect while heating
elements are off. If Low Water Cutoff opens while elements are energized or
attempting to be energized, control switch off all elements and enter 60
seconds purge mode. The audible alarms sound and “LCO” is displayed for
minimum of 30 seconds and until the error clears or demand for heat ceases.
The pump will remain on for minimum of 30 seconds after fault clears.
Anti-Short Cycle Timer, Heating Call Satisfied
· After completion of a space heating or domestic hot water cycle, heating
elements will remain off for a minimum of 3 minutes. ASCT time begins when the
last heating element de-energizes. Pump will be allowed to run during the ASCT
period.
112364-05 – 11/23
9 Control Operation (continued)
Anti-Short Cycle Timer, Water Temperature Satisfied
· While a heating call exists (TT or DHW-TT closed) and an element cycles off
to maintain set point temperature, it will not re-energize for 90 seconds.
Pump Exercising
· After 24 hours of pump inactivity, the pump will turn on for 60 seconds.
Boiler must be in ON mode for pump exercising to occur.
Non-Volatile Memory
· If power is lost, after it is restored, unit will return to mode it was in
before power loss. In addition, all user settings will be retained and
restored.
Boiler Fault Codes
Freeze Protection · If water temperature falls below 45ºF (7ºC),
the control will automatically initiate a heat call sequence RW (TT) until
water temperature reaches 5ºF (13ºC). Boiler must be in ON mode for freeze
protection to occur.
Relay Failure Alarm · If a heating element relay fails, control will switch
off all heating elements and energize the pump. Audible alarm sound and the
relay designator, “r1”, “r2”, “r3”, “r4” will display for a minimum if 30
seconds and until error clears.
Temperature Sensor Failure · Water temperature sensor is always monitored
(on and off modes). If sensor is open “tSO” will be displayed. If the sensor
is shorted, “tSS” be displayed. In both cases, the control switches off
heating elements. Audible alarm sound for a minimum of 30 seconds and until
error clears.
Abnormal Power Alarm · Incoming power is always monitored (on and off
modes). If power to control falls below 18 VAC, the control switches off. ·
Audible alarm will sound for a minimum of 30 seconds until voltage is above 18
VAC.
Flow Alarm · Flow alarm monitored during heating cycle while
elements are energized or attempting to be energized. An open flow switch has
no effect while heating elements are off. If flow switch opens while elements
are energized or attempting to be energized, control will switch off all
elements and enter 60 second purge mode. Audible alarm will sound and “FLO”
will displayed for minimum of 30 seconds and until error clears or demand for
heat ceases. Pump will remain on for a minimum of 30 seconds after fault
clears.
112364-05 – 11/23
Electric Installation, Operating & Service Manual
High Limit Alarm · High-limit alarm is always monitored except while
LMC terminals are open. If the High Limit switch opens, control will switch
off all elements and enter a 60 second purge mode. · Audible alarm will sound,
and “HL” will be displayed for a minimum of 30 seconds and until error clears.
Pump will remain on for a minimum of 30 seconds after the fault clears.
Control Hardware Failure · Control hardware monitoring system is active while
control is on. If control hardware failure is detected, control will switch
off boilers. Audible alarm will sound and “CHF” is displayed for minimum of 30
seconds and until the error clears. Test Mode · Test mode is intended for
installer verification of electric boiler control. It is used to reduce time
required to conduct comprehensive functional test. Initiation of test mode can
be accessed through the user interface and is not intended for unauthorized
personnel. · To enter test mode, unit must be energized and in OFF mode. Press
and hold up arrow button for 4 seconds. Firmware version is displayed for 3
seconds then element configuration (“2” or “4”) is displayed. Pressing either
up or down arrow buttons changes element configuration (2 or 4). Select
configuration that coincides with boiler. Press MODE/PWR button, display will
illuminate all segments 8.8.8 along with demand LED (TT). · Pressing MODE/PWR
button again, “tSt” is displayed. Check is made of flow switch circuit, low
water cutoff sensor circuit, high limit circuit, load management circuit and
water temperature sensor. If any circuit is open or temperature sensor is
shorted, display will indicate an error code (FLO, LCO, HL, tSO, tSS) and
audible alarm will sound. · Pressing MODE/PWR button again enters element
check sequence. Each element heating circuit is checked for power. If element
does not have power, error is displayed (“r1”, “r2”, “r3”, “r4”) and audible
alarm will sound. · When test is completed “dOn” is displayed. Pressing
MODE/PWR button will repeat the test. Pressing up arrow button exits test mode
and returns to OFF mode. Control automatically exits test after 4 minutes.
Removing power exits test mode.
19
10 Start-up
! WARNING
Use a qualified service agency for annual inspection of boiler and heating
system. Wiring errors can cause improper and dangerous operation.
1. Verify boiler circuit breaker and switch at service entrance and hydronic
block circuit breakers within unit are in “Off” position.
2. Label all wires prior to disconnection when servicing controls. Also,
verify proper orientation after service. Place Hydronic Block into service.
NOTICE: Only propylene glycol can be used in heating system to prevent
freezing.
3. Recommendation is maximum 40% or less propylene glycol mixture to ensure
proper boiler operation.
4. Fill heating system until pressure is 15-25 PSIG. Check for leaks, repair
if necessary, purge all air from system.
! CAUTION
Failure to vent and keep air out of the heating system will result in damage
to heating elements. Damage due to element dry fire is not covered by
warranty.
1. Turn on circuit breaker at service entrance and/ or disconnect switch and
all circuit breakers on boiler.
2. Set boiler operating temperature to desired heating water temperature. See
Sequence of Operation.
3. Set room thermostat above room temperature. Circulator pump will operate.
4. Check system again for leaks. Allow circulator pump to run until all air
has been vented from system. Gurgling or rushing sound indicates presence of
air.
5. Do not allow electric elements to fire until all air is purged from
system. Reset room thermostat if needed. Re-purge boiler if necessary.
Electric Installation, Operating & Service Manual
6. Boiler will start to produce heat. Listen for air passing through system
as water temperature increases. Water pressure will rise somewhat as
temperature increases-this is normal as long as pressure remains less than 25
PSIG. Excessive pressure increase indicates flooded or undersized expansion
tank.
7. When thermostat calls for heat, circulator will energize and green pump
LED will light. Heating elements are energized with green heating element
LEDs. Once boiler water temperature reaches set point temperature, controller
will regulate water temperature by staging its elements. Number of element(s)
that stays on is based on heating demand and set point of boiler water
temperature.
8. After thermostats are satisfied, controller deenergizes element one after
another and switches pump off after 3 minutes.
20
112364-05 – 11/23
11 General Maintenance
Electric Boiler requires periodic maintenance. Annual maintenance allows for
trouble-free operation.
! WARNING
Electrical Shock Hazard. Turn OFF electrical power supply at main power switch
before servicing unit. A qualified service agent should perform service.
Failure to do so could result in death or serious injury.
1. Conduct general external examination at beginning of each heating season
and midheating season to assure good working performance continues. A
qualified service technician should examine at least once every year.
2. Do not store anything against boiler or allow dirt or debris to accumulate
in area surrounding boiler.
3. Elements will burn out if boiler is not adequately filled with water when
electrical power turned on.
NOTICE: Do not connect thermostat wire until system has been filled with
water.
4. Drain water out of system only when necessary to make repairs or prevent
freeze-up during extended cold weather shutdown.
5. Check temperature and pressure gauge frequently. During normal operating
conditions, pressure should be stable throughout heating season. If pressure
under normal operating conditions consistently rises and falls over a period
of time, this can indicate fill valve leak, system, or expansion tank
malfunction. Leaks anywhere must be repaired immediately. If leaks or
significant pressure fluctuations are observed, call for service immediately.
6. Check field entrance wire connections to unit for any sign of looseness
and securely tightened.
7. Check all heating element wiring for signs of dark of damaged connections.
Replace if necessary.
Electric Installation, Operating & Service Manual
112364-05 – 11/23
21
12 Troubleshooting
This section is to assist service technicians when troubleshooting the
electric boiler. Control error codes can help identify cause of problem. If
you suspect a wiring fault, check all external wiring and wiring connections
following wiring diagram label on the side of the boiler’s cover. Additional
wiring diagrams are included in this manual.
! WARNING
Electrical Shock Hazard.
Turn OFF electrical power supply at service panels before making electrical
connections. Failure to do so could result in death or serious injury.
Noisy Boiler
· Check water pressure of boiler. Should be 14-25 PSIG.
· Check for air within system. Install proper air vents and purge unit as
necessary.
Heating Element Change
! WARNING
Burn and Electrical Shock Hazard.
Turn OFF electrical power supply at service panels before making electrical
connections. Failure to do so could result in death or serious injury.
Heating element change, use following procedure:
1. Turn off boiler circuit breaker at service entrance and/or disconnect
switch.
2. Close valves near inlet and outlet hydronic block.
3. Isolate boiler by closing valves at inlet and outlet piping.
4. Open drain valve and allow water to drain from boiler. This allows for
minimum system draining to replace element. Manual operation of relief valve
will assist drainage by allowing air to enter.
5. Remove jacket cover. Remove element wires one element at a time.
6. Elements are installed on top of the heat exchanger.
Electric Installation, Operating & Service Manual
Figure 12-1: Element Connections
7. Remove element wires one element at a time. See Figure 12-1.
8. Using Ohm meter to check element resistance.
Table 12-2: Element Connections
Boiler Model
SWA16 SWA20 SWA24
Element (kW) 4 5 6
Resistance Ohms @ Room Temp 14 to 14.5 11 to 12 9 to 10
9. After element has been removed, carefully clean any remaining gasket
material from casting surface. Take care not to scratch or score surface.
10. Install new gasket and heating element while assuring element is
correctly positioned.
Manual High Limit Sensor
Follow the steps below to replace or reset high limit sensor.
1. Turn off power before replacing or resetting high limit.
2. Remove front and top jacket panel for better access.
3. Locate high limit sensor installed on top of heat exchanger.
4. To reset high limit, wait until water temperature drops below 200ºF, then
press reset button.
5. To replace, follow instructions provided with high limit replacement kit.
22
112364-05 – 11/23
12 Troubleshooting (continued)
Electric Installation, Operating & Service Manual
Fault
HL – High Limit Trip
AbP – Abnormal Power Alarm
Water Temperature Overshoots Setpoint Temperature
DFF – Dry Fire Alarm tSO, tSS Temperature sensor failure. CHF Control Hardware
Failure
Circuit Breakers Trip
r1, r2, r3, r4 Relay Failure Codes
Possible Cause
Corrective Action
Is circulator pump functional?
Check power to pump and replace as necessary.
Check temperature rise across boiler.
Maintain a minimum of 3 GPM. Refer to Table 5-1. Increase flow rate by using larger pump or pipe size. Radiant installation requires maximum 20 ºF temperature rise.
Check for temperature overshoot after If greater than 10oF then increase differential
completion of heating cycle.
setting.
Check that HL screw terminals on control board are tight.
Are high limit switches open while water temperatures less than 200oF (<200oF)
Check high limit switches with Ohm meter. Replace high limit(s) open.
Is heat load too small?
Check heat load calculations.
Power too high or too low?
Check incoming power is between 179 VAC and 240 VAC (197<IP<240 VAC). If power outside range, contact electrician to have power corrected.
Power is OK while unit is off but drops when unit is on.
Check for adequate wiring and breaker size.
A small overshoot is normal, however Check temperature rise across boiler is less than
if overshoot is greater than 10oF
20oF. If too high then increase flow rate through
(OS>10oF) then check the following. boiler, use larger boiler pump if necessary.
Boiler is oversized for heating zone? Check heat load calculations.
Differential is too low?
Increase differential temperature setting.
Purge boiler until all air is removed.
Air in boiler?
Check that adequate air vents are located in critical system high points. Add vents as necessary.
Check resistance value of sensor using R/T chart.
Good – Check for loose WT terminals on control board.
Bad – Replace sensor.
Check all wiring for damage or loose connections.
Bad – Tighten any loose terminals. Replace damaged wiring.
Good – Replace control.
Inspect wiring for damage or short circuits.
Bad – tighten any loose terminals. Replace damaged wiring.
Inspect heating elements, check element resistance value is between 9 Bad – replace heating element(s). and 20 (Ohms).
Is current draw between 12 and 25A (Amps) per element?
Bad – replace heating element(s).
Is heating element wiring loose or
Bad – tighten any loose terminals. Replace
damaged. Use clamp meter to check. damaged wiring.
Is heat relay stuck closed?
With power removed check relay contacts with an Ohm meter. Replace control if relay is stuck closed.
112364-05 – 11/23
23
12 Troubleshooting (continued)
Electric Installation, Operating & Service Manual
Fault
Possible Cause
FLO Flow Switch Alarm
Is flow switch installed?
LWC Low Water Cutoff Alarm
Is LWCO installed?
Is electrical power applied to unit?
Field service circuit breakers tripped?
Control Display Dark/ Un-responsive
Is control transformer functioning?
Is wiring loose or damaged? Heating element(s) failed?
Control functions correctly however does not heat water.
Boiler 60A breaker tripped?
Corrective Action
N -Check control board jumper is in place and secure. Tighten FLO screws if
needed.
Y -System air locked – Purge system and add venting as needed.
Y – Check that flow switch is functioning properly. Conduct self test on flow
switch (consult manufacturer’s instructions). Check for proper operation of
boiler and system pump.
N – Check control board jumper is in place and secure. Tighten LWC screws if
needed.
Y – System air is locked – Purge system, add venting as needed.
Y -System low on water. Check water feed to boiler, check for leaks. Repair as
needed.
Y – Check that LWCO is functioning properly. Conduct self test on LWCO switch
(consult manufacturer’s instructions).
Check incoming power is between 197 VAC and 240 VAC (197<IP<240 VAC). If power
outside range, contact electrician to have power corrected.
Check for loose or damaged wiring. Replace wiring if damaged.
Check heating element resistance within 9-20 (Ohms). Replace element if
outside range.
Check for 24 VAC on R and C terminals of control board. If less than 18 VAC on
R & C with primary side between 104 and 130 VAC then replace transformer.
With power removed, check control transformer primary and secondary windings
for open or short. If windings are open or short, replace transformer.
With power removed, check 5A fuse on control board. If bad, replace fuse.
Inspect all thermostat wiring for damage loose connections or damage. Replace
wiring if necessary.
Check heating element resistance within 9-20 (Ohms). Replace element if
outside range.
Check for loose or damaged wiring. Replace wiring if damaged.
Check heating element resistance within 9-20 (Ohms). Replace element if
outside range.
Check control board for damaged heat relay(s).
Check boiler pump is operational. Replace if necessary.
24
112364-05 – 11/23
13 Service Parts
Part Number
Jacket Front Cover Kit
112356-01
Electric Installation, Operating & Service Manual
Boiler Models
Kit Contents
Qty
Left side jacket panel
1
Right side jacket panel
1
SWA16
Boiler logo
1
SWA20
Door trim bezel
1
SWA24
Breaker trim bezel
1
Screw
4
Instructions Breaker Trim Bezel
Left Side Jacket Panel
Door Trim Bezel
Right Side Jacket Panel
Part Number
Boiler Models
Kit Contents
Qty
Heat exchanger
1
SWA16
Bolts
4
Heat Exchanger
112022-01
SWA20
SWA24
Washers
4
Instructions
Heat Exchanger
Washers Bolts
112364-05 – 11/23
25
13 Service Parts (continued)
Heating Element
Part Number 111999-01 111999-02 111999-03
Element
Electric Installation, Operating & Service Manual
Boiler Models
Kit Contents
Qty
SWA16
Element
4
SWA20
Gasket
4
SWA24
Instructions
Gasket
Part Number
Boiler Models
Kit Contents
Qty
SWA16
Boiler Control
1
Boiler Control
112003-01
SWA20
Screws
8
SWA24
Instructions
Boiler Control
Part Number
Boiler Models
Kit Contents
Qty
SWA16
Power Block
1
Power Block
112021-01
SWA20
Screws
4
SWA24
Instructions
26
112364-05 – 11/23
Power Block
13 Service Parts (continued)
Part Number
Power Breaker
112002-01
Electric Installation, Operating & Service Manual
Boiler Models
Kit Contents
Qty
SWA16
Power Breaker
1
SWA20
Screws
4
SWA24
Instructions
Power Breaker
Part Number
Boiler Models
Kit Contents
Qty
SWA16
Flow Switch
1
Flow Switch
112147-01
SWA20
SWA24
Instructions
Flow Switch
Part Number
Boiler Models
Kit Contents
Qty
High Temperature Sensor
112023-01
SWA16 SWA20 SWA24
Temperature Sensor Nuts Instructions
1 2
Nut
High Temp Sensor
112364-05 – 11/23
27
13 Service Parts (continued)
Part Number
Water Temperature Sensor
112019-01
Electric Installation, Operating & Service Manual
Boiler Models
Kit Contents
Qty
SWA16
Temperature Sensor
1
SWA20
SWA24
Instructions
Water temp. sensor
Part Number
Boiler Models
Kit Contents
Qty
Fan
1
SWA16
Screws
4
Cooling Fan
112005-01
SWA20
SWA24
Locknut
4
Instructions
Cooling Fan
Part Number
Boiler Models
Kit Contents
Qty
SWA16
Transformer
1
Transformer
112024-01
SWA20
Screws
2
SWA24
Instructions
24vAC Transformer
28
112364-05 – 11/23
13 Service Parts (continued)
Power Block Wire Harness
Part Number 112163-01
High Voltage Harness Element 1 & 2
Part Number 112164-01
High Voltage Harness Element 3 & 4
Part Number 112165-01
Low Voltage Harness
Part Number 112365-01
Fan Terminal Wire Harness
Part Number 112169-01
Electric Installation, Operating & Service Manual
Boiler Models
Kit Contents
Qty
SWA16
Wire Harness
1
SWA20
SWA24
Instructions
Boiler Models
Kit Contents
Qty
SWA16
Wire Harness
1
SWA20
SWA24
Instructions
Boiler Models
Kit Contents
Qty
SWA16
Wire Harness
1
SWA20
SWA24
Instructions
Boiler Models
Kit Contents
Qty
SWA16
Wire Harness
1
SWA20
SWA24
Instructions
Boiler Models
Kit Contents
Qty
SWA16
Wire Harness
1
SWA20
Screws
2
SWA24
Instructions
112364-05 – 11/23
29
Electric Installation, Operating & Service Manual
Limited Warranty
For SPARQ Electric Boilers
Subject to the terms and conditions set forth below, Velocity Boiler Works
(VBW), Philadelphia, PA USA hereby extends the following limited warranties to
the original owner of a SPARQ electric boiler or VBW supplied parts and/or
accessories for SPARQ electric boilers manufactured and shipped on or after
June 1, 2023:
LIMITED WARRANTY ON BOILERS AND PARTS / ACCESSORIES SUPPLIED BY VELOCITY
BOILER WORKS. VBW warrants to the original owner that its electric boiler and
associated parts/accessories comply at the time of manufacture with recognized
hydronic industry standards and requirements then in effect and will be free
of defects in material and workmanship under normal usage for a period of two
years from the date of original installation. If any part of a boiler or any
part or accessory provided by VBW is found to be defective in material or
workmanship during this two year period, VBW will, at its option, repair or
replace the defective part. NOTE: Repair/replace option does not include labor
charges incurred during the repair/replace procedure.
HEAT EXCHANGER WARRANTIES VBW warrants to the original owner that the heat
exchanger of its boilers will remain free from defects in material and
workmanship under normal usage for twenty years from the date of installation.
This warranty applies to the original owner at the original place of
installation. If a warranty claim is made during this time, VBW will, at its
option, repair or replace the heat exchanger. NOTE: Repair/replace option does
not include labor charges incurred during the repair/replace procedure.
NOTE: If the heat exchanger involved is no longer available due to product
obsolescence or redesign, the value used to establish the retail price will be
the published price as shown in the SPARQ Products Repair Parts Pricing where
the heat exchanger last appeared or the current retail price of the then
nearest equivalent heat exchanger.
ADDITIONAL TERMS AND CONDITIONS 1. Applicability: The limited warranties set
forth above are extended only to the original owner at the
original place of installation within the United States and Canada. These
warranties are applicable to boilers, parts, or accessories provided by VBW
and installed in a single or two-family residential applications with boiler
ratings of 299 MBH and lower.
2. Components Manufactured by Others: Upon expiration of the one year limited
warranty on residential grade boilers, all boiler components manufactured by
others but furnished by VBW will be subject only to the manufacturer’s
warranty, if any.
3. Proper Installation: The warranties extended by VBW are conditioned upon
the installation of the boiler, parts, and accessories in strict compliance
with SPARQ installation instructions. VBW specifically disclaims liability of
any kind caused by or relating to improper installation.
4. Proper Use and Maintenance: The warranties extended by VBW conditioned
upon the use of the boiler, parts, and accessories for its intended purposes
and its maintenance accordance with VBW recommendations and hydronics industry
standards. For proper installation, use, and maintenance, see all applicable
sections of the Installation and Operating, and Service Instructions Manual
furnished with the unit.
5. This warranty does not cover the following: a. Expenses for removal or
reinstallation. The boiler owner will be responsible for the cost of removing
and reinstalling the alleged defective part or its replacement and all labor
and material connected therewith, and transportation to and from VBW. b.
Components that are part of the heating system but were not furnished by VBW
as part of the boiler. c. Improper adjustment, control settings, care or
maintenance. d. This warranty cannot be considered as a guarantee of
workmanship of an installer connected with the installation of the boiler, or
as imposing on VBW’s liability of any nature for unsatisfactory performance as
a result of faulty workmanship in the installation, which liability is
expressly disclaimed. e. Boilers, parts, or accessories installed outside the
48 contiguous United States, the State of Alaska and Canada.
f. Damage to the boiler and/or property due to installation or operation of
the boiler that is not in accordance with the boiler installation and
operating instruction manual.
g. Any damage or failure of the boiler resulting from hard water or scale
buildup in the heat exchanger.
h. Any damage caused by additives or contamination that may cause corrosion
and/or clogging of the heat exchanger.
i. Any damage resulting from air contaminated with particulate including but
not limited to sheetrock or plasterboard particles, dirt, and dust
particulate.
j. Any damage, defects or malfunctions resulting from improper operation,
maintenance, misuse, abuse, accident, negligence including but not limited to
operation with insufficient water flow, improper water level, improper water
chemistry, or damage from freezing.
k. Any damage caused by water side clogging due to dirty systems or corrosion
products from the system.
l. Any damage resulting from natural disaster. m. Damage or malfunction due to
the lack of required maintenance outlined in the
Installation and Operating Manual furnished with the unit.
6. Exclusive Remedy: VBW’s obligation for any breach of these warranties is
limited to the repair or replacement of its parts in accordance with the terms
and conditions of these warranties.
7. Limitation of Damages: Under no circumstances shall VBW be liable for
incidental, indirect, special or consequential damages of any kind whatsoever
under these warranties, including, but not limited to, injury or damage to
persons or property and damages for loss of use, inconvenience or loss of
time. VBW liability under these warranties shall under no circumstances exceed
the purchase price paid by the owner for the residential grade boiler
involved. Some states do not allow the exclusion or limitation of incidental
or consequential damages, so the above limitation or exclusion may not apply
to you.
8. Limitation of Warranties: These warranties set forth the entire obligation
of VBW with respect to any defect in a boiler, parts, or accessories and VBW
shall have no express obligations, responsibilities or liabilities of any kind
whatsoever other than those set forth herein. These warranties are given in
lieu of all other express warranties.
ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN
DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY,
APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL GRADE BOILER SHALL EXTEND TO
THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE HEAT EXCHANGER SECTION SHOWN
ABOVE AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NOT ALLOW
LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY
NOT APPLY TO YOU.
PROCEDURE FOR OBTAINING WARRANTY SERVICE In order to assure prompt warranty
service, the owner is requested to register their product online at
www.velocityboilerworks.com within ten days after the installation of the
boiler, although failure to comply with this request will not void the owner’s
rights under these warranties. Upon discovery of a condition believed to be
related to a defect in material or workmanship covered by these warranties,
the owner should notify the installer, who will in turn notify the
distributor. If this action is not possible or does not produce a prompt
response, the owner should write to Velocity Boiler Works, Attn: Customer
Service, P.O. Box 14818, Philadelphia, PA 19134, giving full particulars in
support of the claim. The owner is required to make available for inspection
by VBW or its representative the parts claimed to be defective and, if
requested by VBW to ship these parts prepaid to Velocity Boiler Works, 3633
“I” Street, Philadelphia, PA 19134 for inspection or repair. In addition, the
owner agrees to make all reasonable efforts to settle any disagreement arising
in connection with a claim before resorting to legal remedies in the courts.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER
RIGHTS WHICH VARY FROM STATE TO STATE.
Velocity Boiler Works P.O. Box 14818
Philadelphia, PA 19134
30
112364-05Ju-ne1,120/2233
DATE
Electric Installation, Operating & Service Manual
SERVICE RECORD
SERVICE PERFORMED
112364-05 – 11/23
31
Electric Installation, Operating & Service Manual
Velocity Boiler Works, LLC P.O. Box 14818 3633 I Street Philadelphia, PA 19134
www.velocityboilerworks.com
32
112364-05 – 11/23
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>