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Velocity Shadow Series Installation And Operating Instructions Manual

High efficiency gas-fired hot water direct vent condensing boilers
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High Effi ciency Gas-Fired Hot Water
INSTALLATION AND OPERATING INSTRUCTIONS
These instructions must be affi xed on or adjacent to the boiler and
retained for future reference.
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
injury, or loss of life. For assistance or additional information, consult a qualifi ed installer, service
agency or the gas supplier. This boiler requires a special venting system. Read these instructions
carefully before installing.
9700609
106916-02 - 6/16
Direct Vent Condensing Boilers
As an ENERGY STAR
SHADOW Series meets the ENERGY STAR
established by the United States Environmental Protection Agency (EPA).
Partner, Velocity Boiler Works has determined that the
®
guidelines for energy effi ciency
®
WARNING
VELOCITY LOGO CMYK COLORS
Velocity Boiler Works, LLC
P.O. Box 14818
3633 I Street
Philadelphia, PA 19134

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  • Page 1 These instructions must be affi xed on or adjacent to the boiler and retained for future reference. As an ENERGY STAR Partner, Velocity Boiler Works has determined that the ® SHADOW Series meets the ENERGY STAR guidelines for energy effi ciency ®...
  • Page 2 IMPORTANT INFORMATION - READ CAREFULLY 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 CAUTION Indicates an imminently hazardous situation Indicates a potentially hazardous situation which, if not avoided, will result in death, serious which, if not avoided, may result in moderate or injury or substantial property damage.
  • Page 3 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 vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building.

  • Page 4: Table Of Contents

    Table of Contents Product Description II. Specifications 4 III. Before Installing Locating The Boiler Mounting The Boiler Air For Ventilation VII. Venting A. General Vent System Design B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems C. Design Requirements Unique to Vertical Venting Systems D.

  • Page 5: Product Description

    I Product Description This boiler is a stainless steel gas fired condensing boiler designed for use in forced hot water heating systems requiring supply water temperatures of 180°F or less. It is designed for installation on a wall. This boiler may be vented vertically or horizontally with combustion air supplied from outdoors. It is not designed for use in systems containing significant amounts of dissolved oxygen. II Specifications FIGURE 2.1: GENERAL CONFIGURATION...

  • Page 6: Before Installing

    Table 2.2: Specifi cations SHADOW Series Other Specifi cations AHRI Ratings SUPPLY & APPROX. MAXIMUM MINIMUM HEATING NET AHRI WATER VENT AFUE RETURN MODEL* INPUT INPUT CAPACITY RATING* VOLUME COLLAR CONNECTION CONNECTION WEIGHT (MBH) (MBH) (MBH) (MBH) (Gal.) DIA. SIZE (NPT)

  • Page 7: Locating The Boiler

    4) All boilers are shipped from the factory configured for use with natural gas. They may be converted for use with LP gas (“propane”) using a combustion analyzer in accordance with the instructions in Appendix A. DANGER • Do not attempt to operate this boiler on LP gas without converting it in accordance with the instructions shown in Appendix A. • Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer.

  • Page 8: Mounting The Boiler

    Figure 4.1: Minimum Clearances To Combustible Construction V Mounting The Boiler CAUTION This boiler weighs as much as 111 pounds: • Two people are required to safely lift this boiler onto the wall mounting hook. • Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when fi lled with water.

  • Page 9: Air For Ventilation

    1) If the boiler is installed on a framed wall, minimum acceptable framing is 2 x 4 studs on 16” centers. The boiler mount- ing holes are on 16” centers for installation between two studs at the standard spacing. In cases where the boiler cannot be centered between the studs, or where the studs are spaced closer than 16”...
  • Page 10 Figure 5.1 Wall Layout/Mounting Hole Location...
  • Page 11 Figure 5.2 Boiler Mounting Bracket Installation / Boiler Wall Mounting...

  • Page 12: Venting

    VII Venting WARNING • Asphyxiation Hazard. Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death. • Do not interchange vent systems or materials unless otherwise specified. •...
  • Page 13 FIGURE 7.0 BASIC VENT OPTIONS FIGURE 7.0a: HORIZONTAL TWIN PIPE FIGURE 7.0b: VERTICAL TWIN PIPE FIGURE 7.0c: SPLIT VENTING All of these systems are considered “direct vent” because the air for combustion is drawn directly from the outdoors into the boiler.
  • Page 14 When CPVC and/or PVC pipe is used, it must be joined using primer and cement that is listed for use with the pipe material being joined (PVC, CPVC, or CPVC to PVC). Vent Kits Available for Use with this Boiler – The following vent kits are available for CPVC/PVC vent systems installed with this boiler in the USA: •...
  • Page 15 TABLE 7.1: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH CPVC/PVC FITTING EQUIVALENT LENGTH (ft) 2” 90 ELBOW (“SANITARY BEND”) 3” 90 ELBOW (“SANITARY BEND”) 2” 90 ELBOW (“SHORT BEND” ) 3” 90 ELBOW (“SHORT BEND”) 10.0 2” 45 ELBOW 3” 45 ELBOW 2”...
  • Page 16 Running PVC Vent Pipe Inside Enclosures and Through Walls - PVC vent pipe must be installed in a manner that permits adequate air circulation around the outside of the pipe: • Do not enclose PVC venting - Use CPVC in enclosed spaces, even if PVC is installed upstream. •...
  • Page 17 FIGURE 7.4: WALL PENETRATION CLEARANCES FOR PVC VENT PIPE...

  • Page 18: Design Requirements Unique To Horizontal Twin Pipe Venting Systems

    B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems Table 7.5 summarizes all horizontal twin pipe vent options. Illustrations of horizontal twin pipe vent systems are shown in Figures 7.7 – 7.9. In addition to the requirements in Part VII-A, observe the following design requirements: 1. Permitted Terminals for Horizontal Venting: Terminal Option A: Fittings – Vent terminates in a plain end. Intake terminates in a PVC 90 sweep elbow pointing down. Outer edge of both terminals must be within 10”...
  • Page 19 Table 7.5: Summary of Horizontal Twin Pipe Venting Options Vent Option Illustrated in Figure 7.7, 7.8, 7.9 7.7, 7.8, 7.9 Pipe Vent Wall Wall Penetration through Intake Wall Wall Structure CPVC/PVC CPVC/PVC Vent (Note 2) (Note 2) Material Intake Vent 2”...
  • Page 20 • Under certain conditions, water in the fl ue gas may condense, and possibly freeze, on objects around the vent terminal including on the structure itself. If these objects are subject to damage by fl ue gas condensate, they should be moved or protected. • Install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph. •...
  • Page 21 FIGURE 7. 8: HORIZONTAL CPVC/PVC VENTING WITH LOW PROFILE TERMINAL, (VENT OPTIONS #1 & 2, TERMINAL OPTIONS B & C) FIGURE 7.9: HORIZONTAL CPVC/PVC WITH CONCENTRIC VENT TERMINAL, (VENT OPTIONS #1 & 2, TERMINAL OPTIONS D & E)

  • Page 23: Design Requirements Unique To Vertical Venting Systems

    C. Design Requirements Unique to Vertical Venting Systems Table 7.11 summarizes all vertical twin pipe vent options. In addition to the requirements in Part VII-A, observe the following design requirements: 1. Permitted Terminals for Vertical Venting Terminal Option H: Fittings – Vent terminates in a plain end (coupling for PVC. Intake terminates in a PVC 180 elbow pointing down (two sweep 90’s may be substituted). Observe the clearances from the roof, and normal snow line on the roof, shown in Figures 7.12 and 7.13.
  • Page 24 Table 7.11: Summary of Vertical Twin Pipe Venting Options Option Illustrated in Figure 7.12, 713 7.12, 7.13 Pipe Vent Roof Roof Penetration through Intake Roof Roof Structure CPVC/PVC CPVC/PVC Vent (Note 2) (Note 2) Material Intake Vent 2” 3” (Note 4) Nominal Diameter Intake...
  • Page 25 FIGURE 7.12: VERTICAL CPVC/PVC VENTING, (VENT OPTIONS 10 & 11, TERMINAL OPTION H) FIGURE 7.13: VERTICAL CPVC/PVC VENTING WITH IPEX CONCENTRIC VENT TERMINAL, (VENT OPTIONS #10 & 11, TERMINAL OPTIONS I, J)

  • Page 26: Design Requirements Unique To Split Vent Systems

    D. Design Requirements Unique to Split Vent Systems Table 7.15 summarizes all split vent options. Illustrations of split vent systems are shown in Figure 7.14. In addition to the requirements in Part VII-A, observe the following design requirements: 1. Permitted Terminals for Split Venting: Rigid Vent Systems (Vent Options 25-26) – Vent terminates in a plain end (coupling for PVC). Intake terminates in a PVC 90 sweep elbow pointing down.
  • Page 27 Table 7.15: Summary of Split Vent System Options Option # Illustrated in Figure 7.14 7.14 Vent Roof Roof Pipe Penetration Through Structure Intake Wall Wall CPVC/PVC CPVC/PVC Vent (Note 2) (Note 2) Material Intake Vent 2” 3” (Note 3) Nominal Diameter Intake 2”...

  • Page 28: Assembly Of Cpvc/Pvc Vent Systems

    E. Assembly of CPVC/PVC Vent Systems WARNING • Asphyxiation Hazard. Failure to follow these instructions could cause products of combustion to enter the building, resulting in severe property damage, personal injury, or death. • A CPVC elbow and a 30” straight section of CPVC (not supplied) must be installed at the boiler end of the vent system before transitioning to Schedule 40 PVC pipe (ASTM 2665) components for remainder of vent system.
  • Page 29 FIGURE 7.17: VENT CONNECTIONS AND FLUE GAS SAMPLE CAP LOCATION If desired, the terminals can be attached to the end of the vent and/or intake pipes with fi eld supplied stainless steel screws so that they can be later removed for cleaning and inspection. If this is done, drill a clearance hole in the coupling or elbow and a tap hole in the end of the vent/intake pipes to accept these screws. If these terminals are installed on snorkels, assemble the snorkels as shown in Figure 7.6.
  • Page 30 RODENT SCREENS ARE SUPPLIED BY INSTALLER FIGURE 7.18: INSTALLATION OF STANDARD HORIZONTAL TERMINALS RODENT SCREENS ARE SUPPLIED BY INSTALLER FIGURE 7.19: INSTALLATION OF STANDARD VERTICAL TERMINALS...
  • Page 31 Drill two 3-1/8 holes through the wall for the vent and intake pipes. Drill four 3/16 holes for the mounting screws. Install the vent and intake pipe sections passing through the wall. Cut the pipes so that they protrude the following distances from the surface on which the vent plate will be mounted: •...
  • Page 32 FIGURE 7.20: INSTALLATION OF IPEX LOW PROFILE TERMINAL THROUGH SIDEWALL FIGURE 7.21: INSTALLATION OF DIVERSITECH LOW PROFILE TERMINAL THROUGH SIDEWALL...
  • Page 33 FIGURE 7.22: CUTTING IPEX AND DIVERSITECH CONCENTRIC VENT TERMINALS FIGURE 7.23: INSTALLATION OF IPEX AND DIVERSITECH CONCENTRIC TERMINAL THROUGH SIDEWALL...
  • Page 34 FIGURE 7.24: INSTALLATION OF IPEX AND DIVERSITECH CONCENTRIC TERMINAL THROUGH ROOF...

  • Page 35: Condensate Trap And Drain

    F. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system passes through the heat exchanger and out of a bottom drain port which is connected to the condensate trap with a hose. This trap allows condensate to drain from the heat exchanger while retaining flue gases in the boiler. This trap is an integral part of the boiler but must be connected to a drain pipe as shown in Figure 7.25.

  • Page 36: Removing An Existing Boiler From Common Chimney

    G. Removing an Existing Boiler From a Common Chimney This section only applies if this boiler is replacing an existing boiler that is being removed from a common chimney. In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances.

  • Page 37: Gas Piping

    VIII Gas Piping WARNING Explosion Hazard. Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas. • Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping.
  • Page 38 CAUTION • Support the weight of the gas line piping independently from the boiler gas connection fitting located on the bottom of the boiler. • If an additional regulator is used to reduce boiler inlet pressure below 1/2 psig (3.4 kPa) it must be at least 6 to 10 feet upstream of the boiler.

  • Page 39: System Piping

    IX System Piping A. General System Piping Precautions WARNING • Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. • Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.).

  • Page 40: Near Boiler Piping Design

    B. Near Boiler Piping Design Proper operation of this boiler requires that the water flow rate through it remain within the limits shown in Table 9.1 any time the boiler is firing. At flow rates below the minimum shown, the boiler’s flow switch and/or temperature rise limit function may prevent the boiler from firing. Flow rates through the boiler in excess of the maximum shown in Table 9.1 can result in excessive noise or erosion damage to piping Use of primary-secondary piping (described below) is strongly recommended for connection of the boiler to the system. Additional information on hydronic system design can be found in the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI).
  • Page 44 Example – A 120MBH model is to be connected to a heating system as shown in Figure 9.2. A total of 20 ft of straight pipe will be installed between the boiler and the system loop. Count all fittings in the boiler loop (shaded in Figure 9.2): 4 90 Elbows 2 Turn in Tee (under boiler- primary-secondary tees not counted) 2 Isolation Valves 1 Y Strainer having a Cv of 30.

  • Page 45: Standard Piping Installation Requirements

    C: Standard Piping Installation Requirements Observe the following requirements when installing the boiler piping: 1) Relief Valve (Required) – The relief valve is shipped loose and must be installed in the location shown in Figure 9.6, using the side outlet Tee and other fittings provided. ASME Section IV currently requires that this relief valve be installed above the heat exchanger as shown. Pipe the outlet of the relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in unthreaded pipe.

  • Page 46: Piping For Special Situations

    11) Low Water Cut-off (may be required by local jurisdiction) – Protection of this boiler against low water and/or inadequate flow is provided by the UL353 certified flow switch built into the boiler. This is a water tube boiler and this flow switch is therefore the only effective way to provide such protection. Section HG614(c ) of the 2015 ASME boiler and Pressure Vessel Code recognizes the use of a listed flow switch in lieu of a low water cut-off on water tube boilers. In the event that a local jurisdiction insists upon the installation of a low water cut-off with this boiler, refer to Part X and the low-water cut-off manufacturer’s instructions for proper wiring. Install the low water cut-off in the supply piping at the point prescribed by the local jurisdiction (generally at a point above the boiler). If a probe type low water cut-off is used, be certain that it is located at a point in the piping from which air can escape to an automatic air vent.
  • Page 47 This page is intentionally left blank.

  • Page 48: Wiring

    X Wiring DANGER Electrical Shock Hazard. Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction ...
  • Page 49 The use of the pump outputs are as follows: a) Boiler pump - Pumps water through the boiler. It is on whenever there is a call for CH or DHW. b) DHW Pump (“IWH Circulator”) - Pumps water directly through the indirect water heater. c) System Pump - Pumps water through the radiation.
  • Page 50 FIGURE 10.2: LINE VOLTAGE FIELD CONNECTIONS FIGURE 10.3: LOW VOLTAGE PCB TERMINAL CONNECTIONS...
  • Page 51 b) Outdoor Sensor - Use only the Tasseron TSA00AA outdoor sensor supplied with the boiler. When this sensor is con- nected and enabled, the boiler will adjust the target supply water temperature downwards as the outdoor air temperature increases. This sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house.
  • Page 52 FIGURE 10.4a: 120V LWCO FIELD WIRING FIGURE 10.4b: 24V LWCO FIELD WIRING...
  • Page 53 120VAC/60Hz/1Ph R7910B Boiler  Control J4‐2 J4‐3 P1‐4 Ground screw in  boiler J‐box P1‐2 DHW Pump J4‐4 J4‐5 P1‐3 P1‐1 Boiler Pump J4‐6 J4‐7 P1‐5 System Pump Combustion Fan  P3‐8 P3‐7 (120V Conn.) Internal, non  replaceable 2 amp L2‐1 L2‐3 Ground screw  AT140B on boiler frame L3‐1 L3‐2 P3‐5 P3‐2 J8‐1 J8‐2 P3‐10 P2‐1 CH T’stat J4‐10 T1‐1 T1‐2 P2‐4 J8‐3...
  • Page 54 FIGURE 10.6: INTERNAL WIRING CONNECTIONS DIAGRAM...

  • Page 56: Start-Up And Checkout

    XI Start-up and Checkout WARNING Completely read, understand and follow all instructions in this manual before attempting start-up. NOTICE Safe lighting and other performance criteria were met with the gas train assembly provided on the boiler when the boiler underwent the test specified in Z21.13. Use the following procedure for initial start-up of the boiler: 1) Verify that the venting, water piping, gas piping and electrical system are installed properly.
  • Page 57 DANGER Asphyxiation Hazard. Failure to properly convert this boiler for use on lp gas can cause unreliable operation at elevated carbon monoxide (CO) levels, resulting in personal injury or death. NOTICE To minimize the risk of premature heat exchanger failure, observe the following water chemistry requirements: 1) Minimize the introduction of make-up water, dissolved oxygen, and contaminants into the boiler by following the installation guidelines shown in the Water Quality and Boiler Water Additives Note on Page 38.
  • Page 58 MANUAL AIR VENT ATTACH 1/4" ID CLEAR TUBING TO HOSE BARB AND ROUTE TO SAFE PLACE AWAY FROM CONTROLS BEFORE OPENING VENT. FIGURE 11.1: LOCATION OF MANUAL AIR VENT 10) If the boiler is to be converted to propane (LP gas), start-up and adjust throttle as described in Appendix A. 11) Start the boiler using the lighting instructions on page 61.
  • Page 59 Power Present for Software ver. Home Screen approx. 2s flashes for with no approx. 80s demand FIGURE 11.2a: HOME SCREEN AT POWER-UP (No Call for Heat) Alternate Flash Demand Codes: CH = Heat dH = Domestic Hot Water FP = Frost Protection Outlet (Supply) Demand Code Temp.
  • Page 60 WARNING Asphyxiation Hazard. Each boiler is tested at the factory and adjustments to the air-fuel mixture are normally not necessary when operating on natural gas at sea level. Consult the factory before attempting to make any such adjustments. Improper gas valve or mixture adjustments could result in property damage, personal injury or loss of life due to carbon monoxide (CO) poisoning.
  • Page 61 16) Perform a combustion test. Boilers are equipped with a screw cap in the vent adapter. Be sure to replace this cap when combustion testing is complete. Check CO (or O ) and CO at both high and low fire. The boiler may be temporarily locked into high or low fire as follows: a) From the home screen, press and hold both the LH and RH buttons for 3s. The screen will change to into Diagnostic mode and show the flame signal (Figure 12.7).
  • Page 62 Lighting and Operating Instructions...

  • Page 63: Operation

    XII Operation A. General Information This boiler uses the microprocessor based Honeywell R7910B (“boiler control”) to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the control’s memory; one for space heating (CH) and one for domestic hot water (DHW) production. If an outdoor temperature sensor is connected to the boiler, and enabled, the space heating supply set point will automatically shift downward as the outdoor temperature increases.
  • Page 64 LH (”Done”/”Reset”) RH (“Next”) Default Mode = User Mode To Reach Set‐up Mode: Press and hold both UP and DWN for 3s To reach Diagnostic Mode: Press and Hold LH and RH for 3s. FIGURE 12.0: CONTROL PANEL When Odr is on, and when the boiler is responding to a call for space heat, the target water temperature will adjust downward (within certain limits) as the outdoor temperature increases.
  • Page 65 WARNING Burn Hazard. Water temperatures over 125°F can cause personal injury or death due to scalding. Children, Disabled, and Elderly are at most risk of being scalded. This boiler is not designed to directly control domestic water temperature. • Use only the thermostat recommended by the indirect water heater manufacture to control the DHW temperature.
  • Page 66 From User Mode Alternate Flash Alternate Flash Outdoor Reset (Odr) On Outdoor Reset (Odr) Off Alternate Flash See Table 12.4 and text for a description  of settings Set‐up Mode Button Usage: LH (Done) – Save & return to User Mode RH (Next) – Save & move to next screen UP/DWN – Change setting  FIGURE 12.2: SET-UP MODE SCREENS...
  • Page 67 FIGURE 12.3: OUTDOOR RESET CURVE (DEFAULT SETTINGS SHOWN) TABLE 12.4: Default Settings and Ranges Scr. # Description on Screen Description Default Value Allowable Range “F” or “C” Temperature Units F or C Heating set point (max temperature “CH” 180F 32 - 191F set-point upon a call for space heat) “Odr”...
  • Page 68 C. Pump Control and DHW Priority Pump operation in response to different demands is shown in Table 12.5. This behavior cannot be changed. Like all boilers, this one is capable of regulating only one target boiler water temperature at any given time. This means that priority must be given to either the CH or DHW target temperature.
  • Page 69 E. Diagnostic Mode Enter Diagnostic Mode by pressing and holding both the LH and RH buttons for at least 3s. The RH (“Next”) button navigates between screens. The LH (“Done”) button returns to User Mode. All Diagnostic Mode screens are shown in Figure 12.7. A description of each is below.

  • Page 70: Service And Maintenance

    XIII. Service and Maintenance WARNING • Asphyxiation Hazard. Fire Hazard. Explosion Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. • Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
  • Page 71 NOTICE Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specified. 1) Continuously: Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids. Keep the area around the combustion air inlet terminal free from contaminates. Keep the boiler room ventilation openings open and unobstructed.
  • Page 72 BURNER DOOR MOUNTING NUT (FOUR PLACES) FLAME ROD IGNITION ELECTRODE FIGURE 13.1: FLAME IONIZATION ELECTRODE AND IGNITION ELECTRODE LOCATION FIGURE 13.2: IGNITION ELECTRODE GAP Unplug the ignition, ground, and flame rod wires from the ignition electrode and the flame rod (Figure 13.1). k. Use a 10mm wrench to remove the four nuts securing the fire door to the heat exchanger (Figure 13.1). Carefully remove the door/blower/gas valve assembly from the heat exchanger, being careful not to damage the refractory insulation on the inside of the door (see Refractory Warning on next page) or the electrodes.
  • Page 73 o. Inspect the ignition electrode and flame rod for deposits. Clean any found with steel wool. Do not use sand paper or Emory cloth for this cleaning. Inspect the ceramic portion of both of these parts for cracks and replace if any are found.
  • Page 74 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 75 FIGURE 13.3: CONDENSATE TRAP EXPLODED PARTS VIEW Replace any wiring which has been disconnected. u. Inspect the hydronic system. Look for leaks and repair any found. If system contains antifreeze, or other additives, test and/or maintain them as directed by the additive manufacturer. See Part XI (Start-up and Checkout) for important information on boiler water and the use of boiler water additives.

  • Page 76: Troubleshooting

    XIV. Troubleshooting DANGER • Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service.
  • Page 77 B. Troubleshooting when the Display is Blank Use the flow chart in Figure 14.5 to locate the problem when the display is blank or is not readable. C. Operation and Troubleshooting of Boiler Limits, Switches and Sensors For the location of the controls described below, see Figure 14.6. Thermal Fuse – The thermal fuse is designed to prevent boiler operation in the event that the heat exchanger is damaged by excessive flue gas temperatures. It is set to open at 358F and is a one shot non-replaceable device. If this fuse opens, the heat exchanger must be replaced. The thermal fuse is essentially a back-up to the flue gas sensor, which is designed to prevent boiler operation if the flue gas temperature exceeds 210F. Note, however, that it is possible for the thermal fuse to open even though the flue temperature limit is working properly. If the thermal fuse is suspected of having opened, unplug the wire heading to it and check continuity directly across the thermal fuse. If no continuity is present, the heat exchanger needs to be replaced. If continuity is present, the fault lies elsewhere.
  • Page 78 “Hold”  Illuminated FIGURE 14.0: HOLD SCREEN Alternate  Flash Outlet (Supply)  Hold Code Temp FIGURE 14.1: SUSTAINED HOLD Alternate  Flash Outlet (Supply)  Lockout Code Temp Lockout FIGURE 14.2: LOCKOUT SCREEN Supply Sensor – The boiler control infers the supply temperature based on the resistance measured at the supply sensor. Table 14.8a shows this resistance as a function of water temperature. Because the control/supply sensor is used as the boiler’s water temperature limit control, there are actually two “thermistors” in the supply sensor wired in parallel (Figure 10.5). The control compares the resistances across these two thermistors and prevents boiler operation if there is a significant difference between the readings.
  • Page 79 LH (”Reset”) FIGURE 14.3: RESET BUTTON Condensate Trap – The condensate trap allows condensate to leave the boiler while containing flue gasses. In the event that this trap becomes blocked, condensate will start to back up in the trap. To prevent a rising condensate level from backing up into the heat exchanger, both a ground wire and the flame rod wire are bonded to this trap in such a way that an abnormally high condensate level will conduct flame current directly to ground (Figure 10.5). The boiler control will interpret this as a loss of flame and enter a Hold. See Figures 7.25 or 13.3 for trap location. Combustion Fan – The combustion fan pushes air-fuel mixture into the burner and the speed of this blower determines the firing rate. There are two electrical connections at this fan: •...
  • Page 80 FIGURE 14.4: LOCKOUT/HOLD CODES Code Meaning Possible Causes/Remedies No hold or lockout present • Damaged flame rod Flame rod to ground leakage • Blocked condensate drain • Shorted or mis-wired flame rod wiring • Line voltage supply to boiler is outside acceptable range. Voltage supplied to control is outside of acceptable range.
  • Page 81 START Is display  See Figures 10.5 and 10.6 for  completely  the location of connectors  dark? referenced here  Verify that display is not still in  power‐up ” process (Figure  11.2a)  Loose or mis‐wired   connection between the  Is boiler control’s green  display and terminal J3 on the  power light on? boiler control  Defective display   Loose or mis‐wired   Is boiler fan  connection between the  running at high  display and terminal J3 on  speed? the boiler control  Defective display Is 120V present across  black and white boiler  line voltage  connection leads? Is 24VAC present  between J8‐1 and J8‐2  (blue and yellow)  terminals on boiler  control?  Loose plug P1 ...
  • Page 82 FIGURE 14.6: CONTROLS LOCATION FIGURE 14.7: PRESSURE SWITCH TUBING CONNECTIONS...
  • Page 83 Table 14.8b: Outdoor Air Temperature Sensor Table 14.8a: Supply, Return and Flue Temperature versus Resistance Temperature Sensor Temperature versus Resistance Outdoor Temperature Ohms of Resistance Temperature Ohms of °F °C Resistance -28.9 106926 °F °C -23.3 80485 32624 19897 -17.8 61246 -12.2 47092...

  • Page 84: Parts

    XV Parts All Shadow Series Repair Parts may be obtained through your local Velocity Boiler Works Wholesale distributor. Should you require assistance in locating a Velocity Boiler Works Distributor in your area, or you have questions regarding the avail- ability of Velocity Boiler Works products or repair parts, please contact Velocity Boiler Works Customer Service at (215)
  • Page 85 QUANTITY OR PART NUMBER KEY # DESCRIPTION QTY. OR PN FIXING CLAMP BRACKET HOLDING CLAMP CONTACT FACTORY; PROVIDE BOILER SERIAL NUMBER M4 x 7 FIXING CLAMP SCREW #10-32 X 1/2” THREAD CUTTING SCREW BARE HEAT EXCHANGER FLUE OUTLET GASKET 105882-01 1 EA 1 EA 1 EA...
  • Page 86 Blower/Gas Valve Assembly for 80, 100, 120 QUANTITY OR PART NUMBER KEY # DESCRIPTION QTY. OR PN 27, 28, BLOWER REPAIR KIT 1 EA 105809-01 105809-01 105810-01 105811-01 105811-01 29, 36 (includes blower, hardware and gasket) BLOWER OUTLET GASKET REPAIR KIT 106029-01 1 EA 1 EA...
  • Page 87 Blower/Gas Valve Assembly for 150, 180...
  • Page 88 QUANTITY OR PART NUMBER KEY # DESCRIPTION QTY. OR PN 51, 52, 53, CONDENSATE TRAP REPAIR KIT 54, 57, 59, 107144-01 1 EA 1 EA 1 EA 1 EA 1 EA (includes trap, trap ball, bracket, tubing, gasket, trap wires and hardware) 60, 61 BALL FOR CONDENSATE TRAP REPAIR KIT 105850-01...
  • Page 89 QUANTITY OR PART NUMBER KEY # DESCRIPTION QTY. OR PN 63, 64, 66, JUNCTION BOX ASSY (includes j-box, j-box mounting bracket, line voltage 107154-01 1 EA 1 EA 1 EA 1 EA 1 EA field connection harness and hardware) CONTROL BOX 106723-01 1 EA 1 EA 1 EA 1 EA...
  • Page 91 QUANTITY OR PART NUMBER KEY # DESCRIPTION QTY. OR PN 63, 64, 66, JUNCTION BOX ASSY (includes j-box, j-box mounting bracket, line voltage 107154-01 1 EA 1 EA 1 EA 1 EA 1 EA field connection harness and hardware) CONTROL BOX 106723-01 1 EA 1 EA 1 EA 1 EA...
  • Page 92 QUANTITY OR PART NUMBER KEY # DESCRIPTION QTY. OR PN 1”NPT x 2” NIPPLE 80600004 2 EA 2 EA 2 EA 2 EA 2 EA 1” NPT TEE 806601015 1 EA 1 EA 1 EA 1 EA 1 EA 3/4” NPT BOILER DRAIN VALVE 806603061 1 EA 1 EA...
  • Page 93 QUANTITY OR PART NUMBER KEY # DESCRIPTION QTY. OR PN REPAIR KIT, CONTROL BOX HARNESS 107142-01 1 EA 1 EA 1 EA 1 EA 1 EA REPAIR KIT, 120V FIELD CONNECTIONS HARNESS 107139-01 1 EA 1 EA 1 EA 1 EA 1 EA REPAIR KIT, DISPLAY HARNESS 107149-01...

  • Page 94: Appendix A: Lp Gas Conversion Instructions

    Appendix A: Instructions for Conversion of This Boiler for Use with LP Gas DANGER These instructions include a procedure for adjusting the air-fuel mixture on this boiler. This procedure requires a combustion analyzer to measure the CO2 and Carbon Monoxide (CO) levels in flue gas.
  • Page 95 WARNING • The throttle adjustments shown in Table A.2 are approximate. The final throttle setting must be found using a combustion analyzer. Leaving the boiler in operation with a CO level in excess of 200PPM air-free could result in injury or death from carbon monoxide poisoning. Leaving the boiler in operation with a CO2 level outside of the range shown in Table A.3 could also result in injury or death from carbon monoxide poisoning, even if the boiler is operating at an air-free CO level below 200PPM during this adjustment procedure.
  • Page 96 FIGURE A.1a: GAS VALVE DETAIL (80MBH THRU 120MBH) FIGURE A.1b: GAS VALVE DETAIL (150MBH, 180MBH) TABLE A.2: STARTING NUMBER OF THROTTLE TURNS FOR CONVERSION TO LP GAS MODEL # COUNTERCLOCKWISE TURNS (FROM FULLY CLOSED) 3-3/4 5-3/4 6-1/2...
  • Page 97 TABLE A.3: ACCEPTABLE COMBUSTION READINGS Allowable CO2 Readings (%) Max CO Model Fuel (PPM Air-Free) Sea Level - 2000 ft 2001 - 4500 ft 4501 - 7800 ft 7801 - 10200 ft Nat. Gas 8.7 - 9.3 10.1 - 10.3 Nat.

  • Page 98: Appendix B: Special Requirements For Side-Wall

    Appendix B: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed 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 termination is less than seven (7) feet above finished grade in the area of the venting, includ- ing but not limited to decks and porches, the following requirements shall be satisfied:...
  • Page 99 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 system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:...

  • Page 100: Appendix C: Control Set-Up Using Pim

    Appendix C: Control Set-up Using PIM This boiler’s control is equipped with a Program Module (PIM). This device is essentially a special “memory stick” containing a copy of the software parameters that were programmed into the control by the factory. This PIM has two uses: 1) If the control must be replaced, the data on this PIM may be transferred to a “universal” replacement control, so that it is correctly programmed with the parameters unique to the boiler at the installation.
  • Page 101 FIGURE C1: REMOVAL OF PIM Press and hold  both RH and DWN  for approx. 3s to  start upload  process  LH (”Done”/”Reset”) RH (“Next”) FIGURE C2: HOME SCREEN...
  • Page 102 From  Home  Press RH (“Confirm”)  Screen  “rES” flashes during  to start uploading  upload process  process Upload  successful? Confirm Error code  appears if  “rES” stops  upload fails.  Flashing if  See Table C.4  upload  for a list of  successful codes To Home  Screen FIGURE C3: UPLOADING PIM DATA TO CONTROL FIGURE C.4: PIM ERROR CODES Code Meaning Possible Causes/Remedies Correct display does not require a password, so this is a possible indication of incompatible display or control. Password not recognized.
  • Page 104 Velocity Boiler Works, LLC P.O. Box 14818 3633 I Street Philadelphia, PA 19134 www.velocityboilerworks.com 106916-02 - 6/16...

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