Cadet 40 - 120, Installation And Service Manual

Page 1: ...ed by a qualified heating installer service technician Read all instructions in this manual before installing Perform steps in the order given Failure to comply could result in severe personal injury...

Page 2: ...Sizing 16 Max Allowable Vent Piping Lengths 16 Materials 17 Optional Room Air 18 PVC CPVC 19 Polypropylene 20 Stainless Steel Vent 21 4 SIDEWALL DIRECT VENTING Vent Air Termination Sidewall 22 25 Det...

Page 3: ...failure Addition of oxygen carried in by makeup water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent makeup water Freeze protection fl...

Page 4: ...oiler and entering the system 14 Water inlet system return The water inlet is the water connection for water entering the boiler from the system 15 Gas connection pipe Threaded pipe connection of 1 2...

Page 5: ...16 18 19 20 21 25 28 31 26 30 27 IMG00205 FRONT OF BOILER 15 13 14 18 21 22 26 29 Right Side inside unit The Cadet Heating Boiler How it works continued 5 Models 40 120 Installation Service Manual Bot...

Page 6: ...with a different control module for altitude operation but the operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the u...

Page 7: ...G This appliance is certified as an indoor appliance Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100 F F...

Page 8: ...MUM Figure 1 1 Closet Installation Minimum Required Clearances WARNING For closet installations CPVC polypropylene or stainless steel vent material MUST BE used in a closet structure due to elevated t...

Page 9: ...Installation Code Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners an...

Page 10: ...the manufacturer of the installed vent Seal With prior requirements met the system should be tested to the procedure listed in parts c through f of the Removal of an Existing Boiler Section on page 1...

Page 11: ...nd any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan...

Page 12: ...ng then place the black rubber coupling on the smooth male fitting of the gas valve and secure to the venturi see FIG 2 1 7 Reposition the gas valve against the venturi and replace the two 2 screws re...

Page 13: ...enter FIG 2 5 For other stud spacing a solid mounting surface must be provided by the installer WARNING Do not mount the boiler to a hollow wall Be sure to mount the boiler to the studs only Mounting...

Page 14: ...5 for more details Direct venting options Sidewall Vent IMG00220 IMG00223 Figure 3 3 Two Pipe Vertical Termination See page 28 for more details Figure 3 5 Vertical Vent Sidewall Air See page 28 for mo...

Page 15: ...for final connection Combustion air piping must be supported per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG s 3 6 thru 3 8...

Page 16: ...kit CVK3003 49 equivalent feet of piping The appliance output rating will reduce by up to 1 5 for each 25 feet of vent length NOTICE Model Kit Number Equivalent Vent Length 40 100 CVK3008 3 feet 120 C...

Page 17: ...tal runs c Secure all joints with a minimum of three 3 sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe d Ensure th...

Page 18: ...to assure adequate combustion air Please refer to instructions provided with the room air kit There will be a noticeable increase in the noise level during normal operation from the inlet air opening...

Page 19: ...e f While the cement is still wet insert the pipe into the fitting if possible twist the pipe a 1 4 turn as you insert it NOTE If voids are present sufficient cement was not applied and joint could be...

Page 20: ...to standard diameter and equivalent length requirements established When determining equivalent combustion air and vent length for polypropylene flex piping 1 foot of Duravent 3 inch flex is equivale...

Page 21: ...ly with applicable national state and local codes Stainless steel vent systems must be listed as a UL 1738 approved system for the United States and a ULC S636 approved system for Canada NOTICE Instal...

Page 22: ...ance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas TO BOILER INTAKE AIR CONNECTION FROM...

Page 23: ...ect to buildup of leaves or sediment Vent air termination sidewall ALTERNATE VENTING ARRANGEMENT IF SPACE PERMITS BIRD SCREEN 12 MIN 12 MIN 15 MAX COUPLING TO BOILER INTAKE AIR CONNECTION FROM BOILER...

Page 24: ...for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration a Cut a hole for the vent pipe For either combustible or noncombustible constructio...

Page 25: ...ure 4 7 Kit Contents 3 Cutone 1 hole 5inchdiameterfor CVK3003installations or 4 inch diameter for CVK3008 installations into the structure to install the termination kit 4 Partially assemble the conce...

Page 26: ...lt in product damage or improper operation personal injury or death Figure 4 9 Rain Cap to Vent Pipe Alternate Assembly 5 Install the Y concentric fitting and pipe assembly through the structure s hol...

Page 27: ...nt terminations be made as shown to avoid recirculation of flue gases VENT COMBUSTION AIR 12 MINIMUM Figure 4 11 Concentric Vent and Combustion Air Termination Figure 4 10 Concentric Vent Sidewall Att...

Page 28: ...following guidelines 1 The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual 2 Prepare the vent termination and the air t...

Page 29: ...ngs and roofs 5 Provide flashing and sealing boots sized for the vent pipe and air pipe Multiple vent air terminations 1 When terminating multiple boilers terminate each vent air connection as describ...

Page 30: ...r when field disassembly is desired for cleaning see FIG 4 9 page 26 When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the scr...

Page 31: ...o 2 or more direct vent appliances are vented near each other each appliance must be individually vented see FIG 5 7 NEVER common vent or breach vent this appliance When two 2 or more direct vent appl...

Page 32: ...rements and with the National Fuel Gas Code The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section If an existi...

Page 33: ...ontinued Existing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths Use only approved venting materials listed in the General Venting Section of thi...

Page 34: ...onic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems WARNING Installation Service Manual General piping information Basic steps are listed below along with i...

Page 35: ...e on the boiler water outlet 10 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications 11 Boiler purge valve Field supplied The boiler purge valve is used to...

Page 36: ...tions VENT AIR Y STRAINER RECOMMENDED DOMESTIC HOT WATER PUMP CONDENSATE DRAIN SYSTEM PUMP BOILER PUMP FROM SYSTEM TO SYSTEM TO FROM INDIRECT DOMESTIC HOT WATER TANK TO FLOOR DRAIN AIR SEPARATOR EXPAN...

Page 37: ...OR DRAIN AIR SEPARATOR EXPANSION TANK LOW LOSS HEADER IMG00238 CHECK VALVE Figure 6 2B Near Boiler Piping w Low Loss Header 6 Hydronic piping continued Circulator sizing The Cadet heating boiler heat...

Page 38: ...plications Model GPM FT HD Minimum Pipe Size Pump Grundfos TACO B G Armstrong 40 3 0 6 9 3 4 UPS15 58FC 007 IFC NRF 22 E7 70 5 2 10 9 1 UPS15 58FC 008 IFC NRF 36 E7 100 7 4 15 7 1 UPS26 99FC 0014 IFC...

Page 39: ...T DHW TANK DOMESTIC HOT WATER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE ANTI SCALD MIXING VALVE COLD WATER IN TEMPERATURE PRESSURE GAUGE AIR SEPARATOR EXPANSION TANK BALL VA...

Page 40: ...TIC HOT WATER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE ANTI SCALD MIXING VALVE COLD WATER IN TEMPERATURE PRESSURE GAUGE AIR SEPARATOR EXPANSION TANK ZONE 2 BALL VALVE TYPIC...

Page 41: ...NTI SCALD MIXING VALVE AIR SEPARATOR EXPANSION TANK BALL VALVE TYPICAL DRAIN POINT TYPICAL MAKE UP WATER ZONE CIRCULATORS TYPICAL FLOW CHECK VALVE TYPICAL NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART B...

Page 42: ...m the gas supply piping 4 Before placing the boiler in operation check the boiler and its gas connection for leaks a Close manual main shutoff valve during any pressure testing at more than 14 inches...

Page 43: ...al gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on Minimum 4 inches w c with gas flowing verify du...

Page 44: ...he manual gas valve in the gas piping to the appliance WARNING 3 Loosen the set screw one 1 full turn from inside the pressure tap on top of the gas valve Place the tubing of the manometer over the ta...

Page 45: ...boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure The...

Page 46: ...Box Cover Low voltage connections 1 Route all low voltage wires through the knockouts in the bottom front right side just under the control panel as shown in FIG 8 2 2 Connect low voltage wiring to l...

Page 47: ...the tank thermostat is ignored Flow switch 1 A flow switch is used to guarantee flow through the boiler before allowing it to fire The flow switch must be installed at the boiler outlet 2 Connect the...

Page 48: ...SWITCH FIELD SUPPLIED AUXILIARY LIMIT FIELD SUPPLIED LOW WATER CUT OFF OPTIONAL IMG00247 Connection Board Configurations OJ1 OJ2 Standard Altitude Standard Non Combi Cut Connected Standard Altitude Co...

Page 49: ...STAT ZONE CONTROL FLOW SWITCH SYSTEM SENSOR OUTDOOR SENSOR LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HIGH LIMIT SENSOR FLUE GAS SENSOR FLAME SENSOR LOW WATER CUTOFF DISP...

Page 50: ...50 8 Field wiring Installation Service Manual LOW VOLTAGE CONNECTION BOARD BOILER CONTROL MODULE BOILER PUMP DHW PUMP IGNITOR BLOWER GAS VALVE DISPLAY PANEL IMG00259 Figure 8 5 Control Outputs...

Page 51: ...th ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement 6 A condensate removal pump is required if the boiler is below the drain When installing a condensate pum...

Page 52: ...t exchanger reducing heat transfer overheating the heat exchanger and causing heat exchanger failure Purge air from water system 1 Purge air from system a Connect a hose to the purge valve see purge d...

Page 53: ...it wires to the connection board Inspect condensate system Inspect check condensate lines and fittings Inspect the condensate drain line condensate PVC fittings and condensate trap CONDENSATE DRAIN RE...

Page 54: ...eam of air piping and vent piping Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas pipin...

Page 55: ...10 Start up continued LBL20274 REV A Figure 10 2 Operating Instructions 55 Installation Service Manual...

Page 56: ...r a short period of time This pump delay is factory set to 30 seconds Adjust set point temperature 1 Press the ENTER key and hold for five seconds until u01 appears in the middle of the screen 2 Press...

Page 57: ...he next burner cycle for a set time period The time delay will be bypassed if the inlet water temperature drops too far during the delay Boiler pump control The boiler pump will run whenever the burne...

Page 58: ...tomatic reset high limit has a maximum set point of 200 F and the manual reset high limit has a set point of 210 F When the outlet temperature exceeds 200 F the automatic high limit action occurs The...

Page 59: ...Turn On or Off Unit Press ENTER for 5 seconds to Enter User Parameters Set Degrees in C or F by Pressing UP or DOWN Set Space Heat Mode Setpoint by Pressing UP or DOWN Based on System Sensor if Insta...

Page 60: ...Set Auto Reset High Limit Temperature Press UP or DOWN to Change Temperature Press ENTER Set DHW Boiler Setpoint Press UP or DOWN to Change Temperature Press ENTER Set MAX Space Heat Setpoint Press UP...

Page 61: ...re When the outdoor air temperature rises to or above 70 F the calculated set point will be at this setting This parameter can be changed by the installer by accessing parameter P02 Temperature range...

Page 62: ...mit E07 Air Pressure Switch E08 Heat Exchanger Limit E09 Auxiliary Limit E11 No Flame Running E12 No Flame Ignition E13 Flue Temperature Limit E15 Manual Reset Hi Limit E18 Outlet Sensor Differential...

Page 63: ...ON RESET BUTTON SERVICE MODE FREEZE PROTECTION DOMESTIC HOT WATER PUMP DOMESTIC HOT WATER DEMAND SPACE HEAT DEMAND BOILER PUMP DISPLAY SCREEN UP BUTTON Figure 11 1 Control Panel Indicators Use the con...

Page 64: ...table uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature If combustion or performance indicate need C...

Page 65: ...any obstructions Clean condensate trap 1 Remove the clean out cap on the bottom of the trap Let the condensate and any debris drain out 2 Replace the clean out cap and resume operation Eliminate all s...

Page 66: ...following the warning directions in this manual if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over p...

Page 67: ...tions 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 Group 1 No...

Page 68: ...ed with warm water Rinse out debris with a low pressure water supply 10 Allow the heat exchanger to thoroughly dry 11 Remove the field supplied rear refractory cover from the back of the combustion ch...

Page 69: ...c natural and LP with no flow lockup or with boiler on Minimum 4 inches w c natural 8 inches w c LP with gas flowing verify during boiler startup Check control module fuses ALWAYS check control module...

Page 70: ...temperature set point satisfied Review temperature setting Remote thermostat satisfied Review remote thermostat setting Outside air temperature above Warm Weather Shutdown WWSD set point for main cont...

Page 71: ...er Sensor Resistance vs Temperature Table 13 2D Flue Sensor Resistance vs Temperature Temperature Resistance Temperature Resistance 50 18 780 158 1 990 68 12 263 176 1 458 86 8 194 194 1 084 104 5 592...

Page 72: ...er door assembly as necessary Low water flow through the heat exchanger Refer to Section 6 Hydronic Piping for minimum flow rates Verify that the boiler is piped in a primary secondary fashion and tha...

Page 73: ...fuse Replace fuse F2 on the control board see page 69 of this manual E04 will require a manual reset once condition has been corrected Press the RESET button on the display to reset Either the option...

Page 74: ...ontrol board If the optional manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table 13 2A on page 71 of this manual Replace sensor if ne...

Page 75: ...board If 24 vac is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve a...

Page 76: ...120 vac to boiler pump motor on a call for heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for he...

Page 77: ...The temperature has reached the set point 10 F None b02 The main control board has received a call for heat too quickly after the previous call for heat has ended The control board will release the c...

Page 78: ...ck the DHW sensor and its associated wiring Repair or replace as needed n07 The inlet sensor has been disconnected Check the sensors and their associated wiring Repair or replace the sensor or wiring...

Page 79: ...place burner if necessary Gas Valve Adjustment Refer to this page of the manual for the gas valve adjustment procedure 13 Troubleshooting continued Table 13 5 Flue Products Natural Gas Propane CO2 O2...

Page 80: ...stic outlet water sensor A thermistor is located at the domestic outlet port of the brazed plate heat exchanger In Combi Mode this sensor acts as the controlling sensor 5 Manual air vent valve Allows...

Page 81: ...l minimum operating pressure of the potable water system 3 The equipment is permanently labeled to indicate that only additives recognized as safe by the FDA shall be used in the heat transfer medium...

Page 82: ...261 Connection Board Configurations OJ1 OJ2 Standard Altitude Standard Non Combi Cut Connected Standard Altitude Combi Cut Cut High Altitude Standard Non Combi Connected Connected High Altitude Combi...

Page 83: ...Boiler Primary Secondary w Combi Piping Diagram BOILER BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE ANTI SCALD MIXING VALVE REQUIRED COLD WATER SUPPLY TEMPERATURE PRESSURE GAUGE AIR SEPA...

Page 84: ...set point should be set at least 10 F below the maximum allowable temperature for the anti scald device Determine the maximum and minimum hot water supply temperatures required for the anti scald dev...

Page 85: ...rements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated f...

Page 86: ...X4 3 X4 12 X4 8 X4 2 X4 9 CN1 8 CN1 1 CN1 3 CN1 2 CN1 11 CN1 9 X4 7 X4 14 X4 6 X4 13 X4 5 X4 11 G WIRING DIAGRAM LBL20268 REV C SEE NOTE 4 SEE NOTE 5 Notes 1 All wiring must be installed in accordance...

Page 87: ...SA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Excepti...

Page 88: ...EPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING 24 VAC COM T T T T HIGH VOLTAGE LOW VOLTAGE 120 VAC HIGH VOLTAGE SPARK LEAD CAUTION OPERATING SENSOR S1a 120V SUPPLY FLAME SENSE SPARK ROD...

Page 89: ...89 Notes Installation Service Manual...

Page 90: ...90 Installation Service Manual Notes...

Page 91: ...91 Installation Service Manual Notes...

Page 92: ...the piping diagrams as well as changes for ECR R06076 to add more information on anti scald devices and setting DHW for Section 14 Combi on pages 80 83 and 84 Revision F ECO C12582 reflects updates m...