6 01 2 07/ 2 v. e 9 r 8 7 9 7 0 0 - c o D d. o c Array AR 3000 - AR 4000 US INSTALLATION AND OPERATION MANUAL RANGE Dear heating engineer, Congratulations for proposing a R boiler. This appliance ensures maximum comfort for an extended period, with high reliability, MODEL CODE efficiency, quality and safety. Array AR 3000 20115025 This manual provides information that is essential to the in- stallation of the appliance. Used in conjunction with your own Array AR 4000 20115026 knowledge and expertise it will enable you to install the appliance quickly, easily, and correctly. Please accept our thanks and our congratulations on your choice 9 WARNING: If the information in these instructions is not fol- of product. lowed exactly, a fire or explosion may result causing property R S.p.A. damage, personal injury or death. 9 WARNING: Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appli- CONFORMITY ance. WHAT TO DO IF YOU SMELL GAS: − Do not try to light any appliance, − Do not touch any electrical switch; do not use any phone in your building, Commercial Boilers − Immediately call your gas supplier from a neighbor’s AHRI Standard BTS-2000 phone. Follow the gas supplier’s instructions, in progress in progress − If you cannot reach your gas supplier, call the fire depart- ment. Qualified installer, service agency or the gas supplier must per- form installation and service. The information contained in this manual is subject to change without notice from R SpA. R makes no warranty of any kind with respect to this material, including but not limited to implied 9 FOR YOUR SAFETY: Improper installation and/or operation warranties of merchantability and fitness for a particular appli- could create carbon monoxide gas in flue gases which could cation. R is not liable for errors appearing in this manual. Nor cause serious injury, property damage, or death. Improper in- for incidental or consequential damages occurring in connection stallation and/or operation will void the warranty. with the furnishing, performance, or use of this material. ENGLISH 2 CONTENTS 1 GENERAL 4 4 OPERATION 24 1.1 Warnings & cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .4 4.3 Touchscreen control panel menus . . . . . . . . . . . . . . . . 24 1.2 Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . .5 4.3.1 Riello Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1.3 Prolonged shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . .5 4.3.2 Cascade Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4.3.3 Boiler Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2 INSTALLATION 6 4.3.4 Module Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4.3.5 Performance Screen . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.2 Receiving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4.3.6 Error Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4.3.7 Service Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.4 Site preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 4.3.8 Module Test Screen. . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.4.1 Installation clearances . . . . . . . . . . . . . . . . . . . . . . . . 7 2.4.2 Setting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 SHUTDOWN 27 2.5 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 5.1 Shutting down the heating system. . . . . . . . . . . . . . . . 27 2.6 Supply and return piping. . . . . . . . . . . . . . . . . . . . . . . .9 5.2 Shutting down the heating system in an emergency . . 27 2.7 Low water cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.8 High limit safety switch . . . . . . . . . . . . . . . . . . . . . . . . 10 6 ENVIRONMENTAL PROTECTION/DISPOSAL 27 2.11.1 Gas Supply Specifications . . . . . . . . . . . . . . . . . . . . . .11 2.11.2 Manual Gas Shutoff Valve . . . . . . . . . . . . . . . . . . . . . .11 APPENDIX 2.11.3 External Gas Supply Regulator. . . . . . . . . . . . . . . . . . 12 Appendix A - Wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . 28 2.11.4 Gas Type Conversion . . . . . . . . . . . . . . . . . . . . . . . . . 12 Appendix B - Size and connections. . . . . . . . . . . . . . . . . . . 33 2.11.5 Adjusting and setting CO2 limits. . . . . . . . . . . . . . . . . 13 Appendix C - Connection diagram. . . . . . . . . . . . . . . . . . . . 34 2.12 AC electrical power wiring . . . . . . . . . . . . . . . . . . . . . . 13 Appendix D - Technical data . . . . . . . . . . . . . . . . . . . . . . . . 36 2.12.1 Electrical Power Requirements . . . . . . . . . . . . . . . . . 14 Appendix E - Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2.13 Field control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Appendix F - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.13.1 Room Thermostat Connection (Enable/Disable). . . . . 15 Appendix G - Head available for the system . . . . . . . . . . . . 40 2.13.2 Air Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Appendix H - De-rating for altitude installation . . . . . . . . . 41 2.13.3 Outdoor Temperature Sensor. . . . . . . . . . . . . . . . . . . 15 Appendix I - Efficiency Curves . . . . . . . . . . . . . . . . . . . . . . . 42 2.14 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Appendix J - Troubleshooting table. . . . . . . . . . . . . . . . . . . 43 2.15 Combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Appendix K - Cascade Installation (example drawing). . . . . 49 2.15.1 Combustion air from outside the building. . . . . . . . . 19 Appendix L - Ladder diagram . . . . . . . . . . . . . . . . . . . . . . .50 2.15.2 Combustion air from inside the building. . . . . . . . . . 19 Appendix M - Exhaust terminals and Air inlet Clearances. . . 61 2.15.3 Ducted combustion air . . . . . . . . . . . . . . . . . . . . . . . 19 Appendix N - Sensor Resistance . . . . . . . . . . . . . . . . . . . . . 63 3 COMMISSIONING 20 3.4.1 Confirming the Unit’s Gas Type . . . . . . . . . . . . . . . . . 20 3.4.2 Gas Type Conversion . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.5 Boiler startup procedure . . . . . . . . . . . . . . . . . . . . . . . 21 3.5.1 Minimum Water Flow (Heat Exchanger Protection) . . 22 3.5.2 Heating System Pressure Test. . . . . . . . . . . . . . . . . . . 22 3.6 Boilers’ cascade installation and start-up . . . . . . . . . . 23 3.6.1 Boilers Cascade: Set Boiler Address . . . . . . . . . . . . . . 23 3.6.2 Boilers Cascade: Set Power switch S1 . . . . . . . . . . . . 23 The following symbols are used in this manual: 9 CAUTION! = Identifies actions that require caution and ad- equate preparation. 0 STOP! = Identifies actions that you MUST NOT do. This manual, Cod Doc-0079789 - Rev.2 (07/2016) comprises 64 pages 3 GENERAL 1 GENERAL 1.1 Warnings & cautions The R Array AR 3000 and AR 4000 MBH Boilers are modulating Installers and operating personnel MUST, at all times, observe all and condensing units. They represent a true industry advance that safety regulations. The following warnings and cautions are gen- meets the needs of today’s energy and environmental concerns. eral and must be given the same attention as specific precautions Designed for application in any closed loop hydronic system, the included in these instructions. Array’s modulating capability matches energy input directly to In addition to all the requirements included in this R Instruc- fluctuating system loads. The turn down ratio for these models tion Manual, the installation of units MUST conform with local is 30:1 for AR 3000 and 40:1 for AR 4000. These Array models pro- building codes, or, in the absence of local codes, ANSI Z223.1 (Na- vide extremely high efficiency operation and are ideally suited for tional Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers modern low temperature, as well as, conventional heating sys- and ANSI/NFPASB for LP gas-fired boilers. tems. Where applicable, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for The Array Models AR 3000 and AR 4000 operate within the follow- the class; which should be carefully followed in all cases. ing input and output ranges: Authorities having jurisdiction should be consulted before instal- lations are made. Array Input Range (BTU/hr.) Output Range(*) (BTU/hr.) See pages 10 - 11 for important information regarding installation of model Minimum Maximum Minimum Maximum units within the Commonwealth of Massachusetts. AR 3000 100,000 3,000,000 96,100 2,883,000 9 AR 4000 100,000 4,000,000 96,100 3,844,000 IMPORTANT: This Instruction Manual is an integral part of the (*) The output of the boiler is a function of the unit’s firing rate, product and must be maintained in legible condition. It must return water temperature and BTU content of gas supply. be given to the user by the installer and kept in a safe place for future reference. Array Series of hot water boilers has been designed in compliance 9 with the CSD-1 code. WARNING: Do not use matches, candles, flames, or other sources of ignition to check for gas leaks. When installed and operated in accordance with this Instruction 9 Manual, these boilers comply with the NOx emission standards WARNING: Fluids under pressure may cause injury to person- outlined in: nel or damage to equipment when released. Be sure to shut off all incoming and outgoing water shutoff valves. Careful- South Coast Air Quality Management District (SCAQMD), Rule 1146.2 ly decrease all trapped pressures to zero before performing maintenance. Whether used in singular or modular arrangements, the AR 3000 9 and AR 4000 offer the maximum venting flexibility with mini- WARNING: Before attempting to perform any maintenance on mum installation space requirements. These Boilers are Category the unit, shut off all gas and electrical inputs to the unit. IV, positive pressure appliances. Single and/or multiple breeched 9 units are capable of operation in the following vent configura- WARNING: The exhaust vent pipe of the unit operates under tions: a positive pressure and therefore must be completely sealed to prevent leakage of combustion products into living spaces. − Conventional, Vertical Conventional, 9 − Sidewall Conventional, Direct Vent, WARNING: Electrical voltages up to 120 vac maybe used in this − Vertical Sealed, Direct Vent, Horizontal equipment. Therefore the cover on the unit’s power box (lo- cated behind the front panel door) must be installed at all These boilers are capable of being vented utilizing PP, CPVC, Stain- times, except during maintenance and servicing. less steel AL29-4C vent systems. 9 CAUTION: Many soaps used for gas pipe leak testing are cor- The Array’s advanced electronics are available in several selectable rosive to metals. The piping must be rinsed thoroughly with modes of operation offering the most efficient operating methods clean water after leak checks have been completed. and energy management system integration. 0 CAUTION: DO NOT use this boiler if any part has been under wa- ter. Call a qualified service technician to inspect and replace 9 IMPORTANT: Unless otherwise specified, all descriptions and any part that has been under water. procedures provided in this Installation & Operation Manual apply to the Array series of boiler. 4 GENERAL 1.2 Emergency shutdown a. In the event that the side wall horizontally vented gas fueled If overheating occurs or the gas supply fails to shut off, close the equipment is installed in a crawl space or an attic, the hard manual gas shutoff valve (Fig. 1) located external to the unit. wired carbon monoxide detector with alarm and battery back- up may be installed on the next adjacent floor level. NOTE: The Installer must identify and indicate the location of the b. In the event that the requirements of this subdivision cannot emergency shutdown. be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) days period, a battery operated carbon monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of Fig. 1 Manual Gas Shutoff Valve eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in 1.3 Prolonged shutdown size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. 4. INSPECTION The state or local gas inspector of the side wall horizontally vented After prolonged shutdown, it is recommended that the startup gas fueled equipment shall not approve the installation unless, procedures and the safety device test procedures of this manual upon inspection, the inspector observes carbon monoxide detec- be performed, to verify all system-operating parameters. tors and signage installed in accordance with the provisions of 248 If there is an emergency, turn off the electrical power supply to the CMR 5.08(2)(a)1 through 4. R boiler and close the manual gas valve located upstream the unit. The installer must identify the emergency shut-off device. (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 IMPORTANT - FOR MASSACHUSETTS INSTALLATIONS through 4: Boiler Installations within the Commonwealth of Massachusetts 1. The equipment listed in Chapter 10 entitled “Equipment Not must conform to the following requirements: Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and − Boiler must be installed by a plumber or a gas fitter who is 2. Product Approved side wall horizontally vented gas fueled licensed within the Commonwealth of Massachusetts. equipment installed in a room or structure separate from the − Prior to unit operation, the complete gas train and all con- dwelling, building or structure used in whole or in part for res- nections must be leak tested using a non-corrosive soap. idential purposes. − The vent termination must be located a minimum of 4 feet above grade level. If side-wall venting is used, the installa- tion must conform to the following requirements extracted from 248 CMR 5.08 (2): (a) For all side wall horizontally vented gas fueled equipment in- stalled in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent ter- mination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porch- es, the following requirements shall be satisfied: 1. INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall ob- serve that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, build- ing or structure served by the side wall horizontal vented gas fu- eled equipment. It shall be the responsibility of the property own- er to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. 5 GENERAL 2 INSTALLATION (c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYS- TEM PROVIDED When the manufacturer of Product Approved side wall horizon- tally vented gas equipment provides a venting system design or 2.1 Introduction venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment This Chapter provides the descriptions and procedures neces- and the venting system shall include: sary to unpack, inspect and install the R Array Boiler Model AR 3000 and AR 4000. 1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting 2.2 Receiving the unit system. Each Array Boiler System is shipped as a single crated unit. The unit (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYS- must be moved with the proper lifting equipment for safety and to TEM NOT PROVIDED avoid equipment damage. The unit should be completely inspect- When the manufacturer of a Product Approved side wall horizon- ed for evidence of shipping damage and shipment completeness tally vented gas fueled equipment does not provide the parts for at the time of receipt from the carrier and before the bill of lading venting the flue gases, but identifies “special venting systems”, is signed. the following requirements shall be satisfied by the manufacturer: NOTE: R is not responsible for lost or damaged freight. Any vi- 1. The referenced “special venting system” instructions shall be sual damage to the packaging materials should be made clear to included with the appliance or equipment installation instruc- the delivering carrier. tions; and 2. The “special venting systems” shall be Product Approved by the 2.3 Unpacking Board, and the instructions for that system shall include a parts list and detailed installation instructions. Carefully unpack the unit, pay particular attention not to damage (e) A copy of all installation instructions for all Product Approved the unit enclosure when cutting away packaging materials. side wall horizontally vented gas fueled equipment, all venting in- After unpacking, a close inspection of the unit should be made structions, all parts lists for venting instructions, and/or all venting to ensure that there is no evidence of damage. The freight carrier design instructions shall remain with the appliance or equipment should be notified immediately if any damage is detected. at the completion of the installation. The following accessories come standard with each unit and are [End of Extracted Information From 248 CMR 5.08 (2)] either packed separately within the unit’s shipping container or are factory installed on the unit: − Pressure/Temperature Gauge − ASME Pressure Relief Valves − Condensate Drain Traps − Outdoor Sensor − System Supply Sensor (length: 20”) − Connection Cable between 905PB internal display and 905MN boards − Venting adapter 10” down to 8” − Stainless steel air intake adapter 8” When optional accessories are ordered, they may be packed with- in the unit’s shipping container, factory installed on the unit, or packed and shipped in a separate container. Any standard or op- tional accessories shipped loose should be identified and stored in a safe place until ready for installation or use. 2.4 Site preparation Ensure that the site selected for installation of the Array AR 3000 and AR 4000 Boiler includes: − Access to AC Input Power at 230 VAC, Phase-Phase, 60 Hz @ 24 FLA − Access to Natural Gas line at a recommended minimum pressure of 8 inches W.C. for 3,000,000 BTU/hr energy input for the AR 3000 OR 4,000,000 BTU/hr energy input for the AR 4000. 6 INSTALLATION 2.4.1 Installation clearances 9 WARNING: Keep the unit area clear and free from all combus- The Array models AR 3000 and AR 4000 are packaged in an enclo- tible materials and flammable vapors or liquids. sure having identical size. The unit must be installed with the prescribed clearances for ser- 9 CAUTION: While packaged in the shipping container, the unit vice as shown in Fig. 2. The minimum clearance dimensions, re- must be moved by pallet jack or forklift from the SIDE ONLY. quired by R, are listed below. However, if Local Building Codes require additional clearances, these codes shall supersede R’s FOR MASSACHUSSETTS ONLY: requirements. Minimum acceptable clearances required are as follows: For Massachusetts installations, the unit must be installed by a plumber or gasfitter licensed within the Commonwealth of Mas- Minimum acceptable clearances required are as follows: sachusetts. In addition, the installation must comply with all re- − Sides: 24 inches quirements specified in “Warnings & cautions” pag. 4. − Front: 31.5 inches − Rear: 24 inches 2.4.2 Setting the Unit − Top: 24 inches Remove the top and side wooden panels, the plastic film and the All gas piping, water piping and electrical conduit or cable must polystyrene sheets. Remove the lag screws securing the unit to the be arranged so that they do not interfere with the removal of any shipping skid. Lift the unit off the shipping skid with a forklift and panels, or inhibit service or maintenance of the unit. position it on the floor in the desired location. 9 WARNING: When lifting or moving the boiler: do not attempt to manipulate the boiler using the top water flanges or any 4” 72.8” 2 other component of the boiler. 9 WARNING: When lifting or moving the boiler with a forklift: make sure the forks are longer than the boiler size (width or depth) so that forks stick out as per Fig. 3. ” 3 8 ” 4 2 24” 24” Fig. 3 Array AR 3000 and AR 4000 Forklift Handling If a crane is required, the boiler must be lifted through bands. ” 5 1. 3 9 WARNING: When lifting the boiler with crane: use bands, no chains. Bands must comply with federal, state and local rules. Fig. 2 Array AR 3000, AR 3000 Clearances 9 WARNING: When lifting the boiler with crane: the bands must be positioned according to the Fig. 4. 7 INSTALLATION In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space for piping connections and future service/maintenance requirements must also be taken 32.9” ienxtpoa ncosniosnid.eration. All piping must include ample provisions for 2.8” 2.8” ” 3 0. 7 FRONT Fig. 6 Array AR 3000 and AR 4000 Anchoring bolts 2.5 Boiler location − This boiler is suitable for indoor installations. − To operate properly and safely this boiler requires a con- tinuous supply of air for combustion. Install this boiler in a clean, dry location with adequate air supply. − Do not locate this boiler in an area where it will be subject 29.9” 13.8” to freezing. − The boiler should be located close to a floor drain in an area where leakage from the appliance or connections will Fig. 4 Array AR 3000 and AR 4000 Crane Lifting Handling not result in damage to the adjacent area or to lower floors in the structure. The unit must be installed on a concrete flat floor, with no gra- − DO NOT install this appliance in any location where gasoline dient in any direction, to ensure proper condensate and water or flammable vapors are likely to be present. drainage (see Fig. 5). If anchoring the unit, refer to Fig. 6 for an- − DO NOT install this appliance on top of carpet flooring. chor locations. − Appliance must be installed on a level floor. − Maintain required clearances from combustible surfaces. Fig. 5 Array AR 3000 and AR 4000 Installation 8 INSTALLATION 2.6 Supply and return piping − Use only untreated water to fill the system. − Do not use TSP (tri-sodium phosphate). The Array Boiler utilizes 4” flanges, for both models AR 3000 and − Do not use fill water treated with salt bedding type ex- AR 4000, for the water system supply and return piping connec- changers (ion exchanger). tions. The physical location of the supply and return piping con- − Never introduce non-approved boiler treatment or similar nections is on the top of the unit as shown in Fig. 7. additives. − Consult a local water treatment specialist for recommenda- tions if any of the above is outside the stated ranges. Water − When using oxygen permeable PEX, the system must be separated from the boiler by a heat exchanger. Return Gas − A correctly sized and working expansion vessel must be in- connection stalled. − Do not exceed the maximum permissible flow rate through the boiler. Excessive flow can cause erosion damage to the Water heat exchanger. Supply 9 CAUTION: Before connecting the boiler to the heating system, flush the heating system to remove sediment, flux, dirt, and other foreign matter. The heat exchanger may be damaged by sediment or corrosion. 9 CAUTION: Do not use cleaning fluids that are not compatible with the boiler materials, including acids (e.g. hydrochloric acid and similar ones) at any concentration. 9 CAUTION: Introducing fresh water to the system increases the oxygen presence and can cause corrosion of metallic compo- nents. Immediately repair any drips or leaks in the system to avoid constant introduction of air into the system. 9 CAUTION: Excessive fluctuation in pressure changes in the sys- tem can cause fatigue and stress on the heat exchanger. This is detrimental to the integrity of the boiler and system com- ponents, it is mandatory to maintain a constant operating pressure. 9 CAUTION: For freeze protection use only propylene glycol, with scale inhibitors, with a maximum volume [concentration] of 50% of glycol. Frost protection and inhibitor level has to be checked annually during the regular scheduled maintenance Fig. 7 Array AR 3000 and AR 4000 Connections of the condensing boiler. Excessive water hardness causing a lime buildup in the stainless A minimum water pressure is required for optimum performance. steel coils or tubes is not a fault of the appliance and is not cov- Minimum water pressure required: 7.25 psi (0.5 bar). ered by warranty. Water hardness must fall within the following limits: STEEL BOILERS - With furnace power > 150 kW Water used Water with for first filling system operating ph °fH 6 - 8 7.5 – 9.5 Hardness µS/cm < 5° < 5° Electrical Conduc- Mg/l < 100 tivity Chlorides Mg/l < 10 Sulphides Mg/l < 10 Nitrides Mg/l < 10 Oxygen in Solution Mg/l Iron Mg/l < 0.5 9 INSTALLATION 2.7 Low water cutoff 2.10 Condensate drain and piping A low water cut off (LWCO) is installed on each boiler. The Array Boiler is designed to condense water vapor from the flue products. Each module of the boiler is equipped with a conden- To check the functionality of LWCO go to the 905PB inner display, sate trap (see Fig. 9), while a syphon collects the condensate of the access the Settings menu, select Test mode, and then click on vertical flue manifold. LWCO1. On the screen will appear the error “MN: Low Water Cutoff Error”. At this point press the reset button. The error will turn off. 2.8 High limit safety switch A high limit safety switch is installed on each module of the boiler. To simulate a high limit lockout at 208°F go to the 905PB inner display, access the Settings menu, select Test mode, then click on Condensate Max temp. Trap The control will display “MN: Max. Thermostat Lock Error”. At this point press the reset button on the removable display to Condensate restart the module. Trap 2.9 Pressure relief valve installation Condensate ASME rated Pressure Relief Valves are factory installed in each Array Trap Boiler. The pressure rating for the relief valves is 75 PSI. The relief valves are installed on each hot water horizontal manifold of the boiler as shown in Fig. 8. The relief valves drain piping must be Condensate connected to a nearby floor drain. In multiple unit installations Trap the discharge lines must not be manifolded together. Each must be individually run to a suitable discharge location. Relief valves should be manually operated at least once a year. If a relief valve discharges periodically, this may be due to thermal Fill the syphon with expansion in a closed water supply system. water from the top Contact the water supplier or local plumbing inspector on how to of the vertical flue correct this situation. manifold BEFORE Do not plug the relief valve. to connect the vent piping Vertical Flue Manifold 75PSI Relief valve (one for each pair of modules) Syphon Fig. 9 Condensate Drain System Fig. 8 Pressure Relief Valve Location 9 WARNING: At the Start-up and after prolonged shutdown of the boiler, the condensate traps and the syphon must be filled with water prior to restart it, otherwise combustion gases will enter the room with a risk of an excessive level of carbon monoxide. 10