USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . . .2
C. ACCESSIBILITY CLEARANCES . . . . . . . . . . . .3
D. COMBUSTION & VENTILATION AIR . . . . . . . .3
2. BOILER SET-UP 7
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
B. MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3. VENTING & AIR INLET PIPING 8
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
B. APPROVED MATERIALS . . . . . . . . . . . . . . . . .8
C. EXHAUST VENT/AIR INTAKE
PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . . .9
D. EXHAUST VENT/AIR INTAKE PIPE SIZING . .12
E. EXHAUST VENT/AIR INTAKE PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .13
F. EXHAUST
TAPPING FOR VENT SAMPLE
. . .14
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .14
4. WATER PIPING AND CONTROLS 16
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
B. OPERATING PARAMETERS . . . . . . . . . . . . . .16
C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .16
D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .18
E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .19
5. FUEL PIPING 23
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .23
C. GAS SUPPLY PIPING – INSTALLATION . . . .23
D. GAS SUPPLY PIPING – OPERATION . . . . . . .24
E. MAIN GAS VALVE – OPERATION . . . . . . . . .24
6. CONDENSATE DRAIN PIPING 26
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .26
7. ELECTRICAL CONNECTIONS 27
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .27
C. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .27
8. BOILER CONTROL: INTERNAL
WIRING & OPERATION 30
A. CONTROL OVERVIEW . . . . . . . . . . . . . . . . . .30
B. AVAILABLE CENTRAL HEAT MODES . . . . . .30
C. AVAILABLE DOMESTIC HOT WATER
MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
D. DISPLAY UTILIZATION . . . . . . . . . . . . . . . . .31
E. USER MENU . . . . . . . . . . . . . . . . . . . . . . . . . .33
F. STATUS MENU–1000 LEVEL . . . . . . . . . . . . .33
G. INSTALLER MENU–2000 LEVEL . . . . . . . . . .35
H. MENU LEVELS 3000, 4000 & 5000 . . . . . . . .37
I. OUTDOOR RESET OPERATION . . . . . . . . . .38
J. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .39
K. ADDITIONAL SAFETY FUNCTIONS . . . . . . .40
9. START-UP PROCEDURE 41
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .41
C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .41
D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .41
E. LIGHTING & OPERATING PROCEDURES . . .43
10. TROUBLESHOOTING 44
A. LOCKOUT ERRORS . . . . . . . . . . . . . . . . . . . .44
B. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .44
C. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .44
D. TYPICAL OPERATION CYCLE–
CENTRAL HEAT . . . . . . . . . . . . . . . . . . . . . . .44
E. TYPICAL OPERATION CYCLE–DHW . . . . . . .44
11. MAINTENANCE 49
A. GENERAL (WITH BOILER IN USE) . . . . . . . .50
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .50
C. ANNUALLY (BEFORE START OF
HEATING SEASON) . . . . . . . . . . . . . . . . . . . .50
D. CONDENSATE CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .50
E. INSPECTION AND CLEANING OF
COMBUSTION CHAMBER COILS . . . . . . . . .50
F.
HEAT EXCHANGER GASKET
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . .51
G. FLOW RESTRICTOR MAINTENANCE . . . . . .51
H. PLATE HEAT EXCHANGER
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .52
12. BOILER DIMENSIONS & RATINGS 53
13. REPAIR PARTS 56
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