U.S. Boiler Company ASPEN ASPN-085 Installation, Operating And Service Instructions
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U.S. Boiler Company ASPEN ASPN-085 Installation, Operating And Service Instructions

Condensing high efficiency direct vent, gas-fired hot water boiler
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
CONDENSING HIGH EFFICIENCY
GAS - FIRED HOT WATER BOILER
9700609
Space Heating Models:
• ASPN-085
• ASPN-110
• ASPN-155
• ASPN-205
• ASPN-270
Combi Domestic Hot Water
and Space Heating Model:
• ASPNC-155
TO THE INSTALLER: Affix these instructions adjacent to boiler.
TO THE CONSUMER: Retain these instructions for future reference.
As an ENERGY STAR
®
STAR
guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
®
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or
loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas
supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
107362-01 - 8/17
ASPEN™
DIRECT VENT
Partner, U.S. Boiler Company has determined that the ASPEN™ Series meets the ENERGY
WARNING
Price - $5.00
1

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Summary of Contents for U.S. Boiler Company ASPEN ASPN-085

  • Page 1 TO THE INSTALLER: Affix these instructions adjacent to boiler. TO THE CONSUMER: Retain these instructions for future reference. As an ENERGY STAR Partner, U.S. Boiler Company has determined that the ASPEN™ Series meets the ENERGY ® STAR guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
  • Page 2 IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.
  • Page 3 WARNING Asphyxiation Hazard. Fire Hazard. Explosion Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. WARNING Asphyxiation 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 4 Special Installation Requirements for Massachusetts A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) ft. above grade, the following requirements shall be satisfied: 1.
  • Page 5 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings unless alarms or other safeguards are in place to printed in this manual and posted on the boiler. prevent such damage. MAINTAIN THE BOILER. To keep your boiler safe DO NOT BLOCK AIR FLOW into or around the and efficient, have a service technician maintain boiler.

  • Page 6: Table Of Contents

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

  • Page 7: 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.
  • Page 8 II. Specifications (continued) Combustion Air Blower Air Proving Switch Gas Valve Programmed Transformer Display Supply Sensor Blocked Vent Switch 24V Fuse Circulator Fuse Return Sensor Flue Temperature Low Voltage PCB Sensor High Voltage PCB Figure 2.2: Boiler Internal Component Locations Table 2.3: Specifications Maximum D.O.E.

  • Page 9: Before Installing

    II. Specifications (continued) Table 2.4: Vent Lengths Nominal Approx. Model Min Vent Length Max Vent Vent/Intake Size Derate at Max Vent Size (in) Length (ft) (in) 11.3 See Section VII “Venting” for additional requirements and details. III. Before Installing 1. Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction.

  • Page 10: Locating The Boiler

    III. Before Installing (continued) DANGER • Do not attempt to operate this boiler on LP gas without converting it using the proper conversion kit. • Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer. •...
  • Page 11 IV. Locating the Boiler (continued) 2 " This boiler is listed for closet installation with the following clearances from the boiler jacket to combustible construction: Top: 11-5/8", Sides: 1/2", Front: 1/2", Bottom: 6" This above clearances also apply to non-combustible walls, doors, ceilings and oors.

  • Page 12: Mounting The Boiler

    V. Mounting The Boiler A. Wall Mounting CAUTION • 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 filled with water. Jurisdictions in areas subject to earthquakes may have special requirements for supporting this boiler.
  • Page 13 V. Mounting The Boiler (continued) Figure 5.1 Wall Layout / Mounting Hole Location 107362-01 - 8/17...
  • Page 14 V. Mounting The Boiler (continued) Figure 5.2 Boiler Mounting Bracket Installation / Boiler Wall Mounting 107362-01 - 8/17...

  • Page 15: Air For Ventilation

    VI . Air for Ventilation WARNING Outdoor combustion air must be piped to the air intake. Never pipe combustion air from areas containing contaminates such as swimming pools and laundry room exhaust vents. Contaminated combustion air will damage the boiler and may cause property damage, personal injury or loss of life. Air for combustion must always be obtained directly from outdoors.

  • Page 16: 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. The use of thermal insulation covering vent pipe and fittings is prohibited.
  • Page 17 VII. Venting A. Vent System Design (continued) Figure 7.0a: Horizontal Twin Pipe Figure 7.0b: Vertical Twin Pipe Figure 7.0c: Split Venting 107362-01 - 8/17...
  • Page 18 VII. Venting A. Vent System Design (continued) 1. Listed Vent Systems and Materials – The following materials and vent systems may be used to vent this boiler: • CPVC – Use only CPVC listed to ASTM F441. In Canada, this pipe must also be listed to ULC S636. •...
  • Page 19 VII. Venting A. Vent System Design (continued) NOTICE Do not exceed maximum vent/combustion air system length. Refer to Tables 7.1 and 7.13 in this section for maximum vent/combustion air system length. Use only vent and combustion air terminals and terminal locations shown in Tables 7.5, 7.13, and 7.21 and related Figures in this section.
  • Page 20 VII. Venting A. Vent System Design (continued) Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported. Maximum support spacing is as follows: • Support CPVC/PVC horizontally and vertically every 4 feet. • Support DuraVent PolyPro horizontally near the female end of each straight section of pipe and vertically every 10 feet. •...
  • Page 21 VII. Venting A. Vent System Design (continued) Figure 7.3a Figure 7.3b Figure 7.3c Figure 7.3: Expansion Loops for CPVC/PVC Pipe Figure 7.4: Wall Penetration Clearances for PVC Vent Pipe 107362-01 - 8/17...

  • Page 22: Design Requirements Unique To Horizontal Twin Pipe Venting Systems

    VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 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 7.6 –...
  • Page 23 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) Table 7.5: Summary of Horizontal Twin Pipe Venting Options Vent Option 7.6, 7.7, 7.6, 7.7, Illustrated in Figure 7.9, 7.10 7.9, 7.10 Pipe Vent Wall Wall Wall Wall Wall Wall...
  • Page 24 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 2. Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location (also see Figure 7.11). When locating a concentric terminal, observe the limitations outlined below for “vent terminals”. •...
  • Page 25 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) Figure 7.7: Horizontal CPVC/PVC Venting with Low Profile Terminal, (Vent Options #1 & 2, Terminal Options B & C) Figure 7.8: Horizontal CPVC/PVC Venting with Concentric Vent Terminal, (Vent Options #1 &...
  • Page 26 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) Figure 7.9: Duravent PolyPro, Selkirk, Polyflue or Centrotherm InnoFlue Horizontal Venting (Vent Option #3 - 8, Terminal Option A) Figure 7.10: Duravent PolyPro Horizontal Venting with Concentric Terminal, (Vent Options #3 &...
  • Page 27 VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued) 107362-01 - 8/17...

  • Page 28: Design Requirements Unique To Vertical Venting Systems

    VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Figure 7.12: Snorkel Terminal Configuration (CPVC/PVC Vent Systems Only) C. Design Requirements Unique to Vertical Venting Systems Table 7.13a summarizes all vertical twin pipe vent options. Table 7.13.b summarizes vent options in which an abandoned B-vent chimney is used both as a chase for the vent pipe and as a conduit for combustion air.
  • Page 29 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Table 7.13a: Summary of Vertical Twin Pipe Venting Options Option Illustrated in Figure 7.15, 717 7.15, 7.17 7.17, 7.18 7.17, 7.18 7.17 7.17 7.17 7.17 Pipe Vent Roof Roof Roof Roof Roof...
  • Page 30 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Table 7.13b: Summary of Vertical “B-Vent Air Chase” Vent Options (B-Vent Chase MUST Be Sealed) Option Illustrated in Figure 7.19 7.19 7.20 7.20 Vent Roof Roof Roof Roof Pipe Penetration Through Structure Intake Roof...
  • Page 31 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Terminal Option J: Diversitech Concentric Terminal (Acceptable for Vent Options 10 & 11) - This terminal is shown in Figure 7.16 and may be used with CPVC/PVC vent systems. See Part VII-E of this manual and the Diversitech instructions provided with the terminal, for installation details.
  • Page 32 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Table 7.14: Equivalent Length of Flex Pipe Equivalent Length (ft) Flex Vent (1 ft): 2" DuraVent PolyPro Flex 2.0 ft 2" Centrotherm InnoFlue Flex 2.0 ft 2" Selkirk Polyflue 2.0 ft 3"...
  • Page 33 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Figure 7.15: Vertical CPVC/PVC Venting (Vent Options 10 & 11, Terminal Option H) Figure 7.16: Vertical CPVC/PVC Venting with IPEX Concentric Vent Terminal (Vent Options #10 & 11, Terminal Option I, J) 107362-01 - 8/17...
  • Page 34 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Figure 7.17: Duravent PolyPro, Selkirk Polyflue or Centrotherm InnoFlue Vertical Single Wall PP Venting (Vent Options #12-17, Terminal Option H) Figure 7.18: Duravent PolyPro Vertical Venting with Concentric Terminal (Vent Options #12 &...
  • Page 35 VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued) Figure 7.19: Duravent PolyPro B-Vent Air Chase System (Vent Options #18 & 19) Figure 7.20: Centrotherm InnoFlue B-Vent Air Chase System (Vent Options #20 & 21) 107362-01 - 8/17...

  • Page 36: Design Requirements Unique To Split Vent Systems

    VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) D. Design Requirements Unique to Split Vent Systems Table 7.21 summarizes all split vent options. Illustrations of split vent systems are shown in Figures 7.22, 7.23, and 7.24. In addition to the requirements in Part VII-A, observe the following design requirements: 1.
  • Page 37 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Example: A 110MBH model is to be installed as using Vent Option 34 in a masonry chimney as shown in Figure 7.23. The following components are used: Vent: 3" DuraVent Poly-Pro (Rigid) – 4ft 3"...
  • Page 38 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options Option # Illustrated in Figure 7.22 7.22 7.22 7.22 7.22 7.22 Vent Roof Roof Roof Roof Roof Roof Pipe Penetration Through Structure Intake Wall Wall...
  • Page 39 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Table 7.21: Summary of Split Vent System Options (continued) Option # Illustrated in Figure 7.22 7.22 7.23, 7.24 7.23, 7.24 Vent Roof Roof Roof Roof Pipe Penetration Through Structure Intake Wall Wall...
  • Page 40 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Option # Illustrated in Figure 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 Vent Roof Roof Roof Roof Roof Pipe Penetration Through Structure Intake Wall Wall Wall Wall Wall Selkirk...
  • Page 41 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Figure 7.22: Split Rigid Vent System (Vent Options 25-32) Figure 7.23: Split Vent System (Flex in B-Vent Chase) Vent Options 33-38) 107362-01 - 8/17...
  • Page 42 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Figure 7.24a: Split Vent System (PP Flex in Abandoned Masonry Chimney) (Vent Options 33-38) 107362-01 - 8/17...
  • Page 43 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) WARNING Venting of Other Appliances (Or Fireplace) into Chase or Adjacent Flues Prohibited! Figure 7.24b: Flexible PP Masonry Chimney Chase Requirements 107362-01 - 8/17...
  • Page 44 VII. Venting D. Design Requirements Unique to Split Vent Systems (continued) Figure 7.25a: Split Vent System (SS Flex in Abandoned Masonry Chimney) (Vent Option 39) WARNING Venting of Other Appliances (Or Fireplace) into Chase Prohibited! Figure 7.25b: Flexible SS Masonry Chimney Chase Requirements 107362-01 - 8/17...

  • Page 45: Assembly Of Cpvc/Pvc Vent Systems

    VII. Venting E. Assembly of CPVC/PVC Vent Systems E. Assembly of CPVC/PVC Vent Systems WARNING Failure to follow this warning could result in asphyxiation and/or carbon monoxide poisoning. Correct venting material and installation is required for proper vent operation. PVC Vent Systems must include at least 30 inches of CPVC and one CPVC elbow between the boiler and PVC vent piping.
  • Page 46 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.26: Vent Connections and Flue Gas Sample Cap Location h. Maintain the clearances from the vent pipe outlined in Part VII-A of this manual. If exiting the exterior wall using PVC pipe, use half of an appropriately sized wall thimble (or a sheet metal plate) on the exterior of the building, to provide a weather tight seal while maintaining the proper clearance in the wall penetration.
  • Page 47 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.27: Installation of Standard Horizontal Terminals Figure 7.28: Installation of Standard Vertical Terminals 107362-01 - 8/17...
  • Page 48 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) 4. Installation of Vertical Fitting Terminals (Terminal Option H): a. See Figure 7.28 for the proper orientation of twin pipe vertical terminals. b. The coupling is used to secure the rodent screen to the end of the vent pipe. c.
  • Page 49 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.29: Installation of IPEX Low Profile Terminal Through Sidewall Figure 7.30: Installation of Diversitech Low Profile Terminal Through Sidewall 107362-01 - 8/17...
  • Page 50 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.31: Cutting IPEX and Diversitech Concentric Vent Terminals Figure 7.32: Installation of IPEX and Diversitech Concentric Terminal through Sidewall 107362-01 - 8/17...
  • Page 51 VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued) Figure 7.33: Installation of IPEX and Diversitech Concentric Terminal Through Roof b. For vertical installations, cut a hole in the roof large enough to clear the concentric terminal at the location of the terminal (see Part VII-C of this manual for permitted terminal locations).

  • Page 52: Assembly Of Duravent Polypro Vent Systems

    VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) F. Assembly of DuraVent PolyPro Vent Systems 1. This boiler has been listed for use with the DuraVent PolyPro single wall PolyPropylene vent system to be provided by the installer. WARNING Asphyxiation Hazard.
  • Page 53 VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) 3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: a.
  • Page 54 VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) Figure 7.35: Installation of Duravent PolyPro UV Resistant Single Wall Horizontal Terminal Figure 7.36: Installation of Duravent PolyPro UV Resistant Single Wall Vertical Terminal 107362-01 - 8/17...
  • Page 55 VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) 6. Installation of DuraVent PolyPro Horizontal Concentric Vent Terminal (Terminal Option D) - Install PolyPro Horizontal Concentric Termination Kit #2PPS-HK or #3PPS-HK (Figure 7.38) as follows: a. At the planned location cut a 4-1/8" round hole for the 2" terminal or a 5-1/8" round hole for the 3" terminal in the exterior wall.
  • Page 56 VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) Figure 7.38: Installation of Duravent PolyPro Concentric Vent Terminal Through Sidewall Figure 7.39: Installation of Duravent PolyPro Concentric Terminal Through Roof 107362-01 - 8/17...

  • Page 57: Assembly Of Selkirk Polyflue Vent Systems

    VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued) Installations using PolyPro-flex (Vent Options 18,19,33,34): WARNING Asphyxiation Hazard. When using PolyPro flex, observe the following precautions: • PolyPro flex may be damaged by handling at low temperatures. Do not bend, uncoil, or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.
  • Page 58 VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued) e. Support each pipe section as described in Polyflue manual at intervals not exceeding the following: Pipe size Horizontal Vertical 2" 30in 16ft 3" 39in 16ft 3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: a.
  • Page 59 VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued) 6. Installations using flexible Polyflue (Vent Options 35,36): WARNING Asphyxiation Hazard. When using Polyflue flex, observe the following precautions: • Polyflue flex may be damaged by handling at low temperatures. Do not bend, uncoil or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.
  • Page 60 VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued) Figure 7.41: Installation of Selkirk Polyflue UV Resistant Single Wall Horizontal Terminal Figure 7.42: Installation of Selkirk Polyflue UV Resistant Single Wall Vertical Terminal 107362-01 - 8/17...

  • Page 61: Assembly Of Centrotherm Innoflue Vent Systems

    VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems 1. This boiler has been listed for use with the Centrotherm InnoFlue single wall PolyPropylene vent system to be provided by the installer. WARNING Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original PolyPropylene venting component manufacturers, Centrotherm.
  • Page 62 VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems 3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: a.
  • Page 63 VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems Figure 7.44: Installation of Centrotherm InnoFlue UV Stabilized Single Wall Horizontal Terminal Figure 7.45: Installation of Centrotherm InnoFlue UV Stabilized Single Wall Vertical Terminal 107362-01 - 8/17...
  • Page 64 6. Installations using InnoFlue Flex (Vent Options 20,21,37,38): WARNING Asphyxiation Hazard. When using InnoFlue Flex, observe the following precautions: • InnoFlue Flex may be damaged by handling at low temperatures. Do not bend, uncoil or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.

  • Page 65: Assembly Of Stainless Steel Vent Systems

    This boiler has been listed for use with DuraVent FasNSeal Flex Stainless Steel vent systems to be provided by the installer. WARNING Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original stainless steel venting component manufacturer, DuraVent. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death.
  • Page 66 d. When flexible stainless steel pipe is used for combustion product venting, it must be installed at vertical or near vertical orientation. This will insure proper condensate flow back towards the boiler. e. Follow flexible stainless steel pipe manufacturer specific instructions regarding application/listing, permits, minimum clearances to combustibles, installation details (proper joint assembly, pipe support and routing, gasket and fitting installation, optional tooling availability/usage, routing through masonry combustion of combustion product venting and combustion air supply).

  • Page 67: Condensate Trap And Drain

    VII. Venting J. 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 field-installed condensate trap. This trap allows condensate to drain from the heat exchanger while retaining flue gases in the boiler.
  • Page 68 VII. Venting J. Condensate Trap and Drain Line (continued) Condensate Drain Bottom of Boiler Connector through knockout to low voltage wiring harness. Float Switch Worm Gear Condensate Trap Bracket Assembled Condensate Trap #8-18 Thread Forming Screw (1/4" Long) Connector from Low Voltage Wiring Harness To Low...

  • Page 69: Removing An Existing Boiler From Common Chimney

    VII. Venting K. Removing an Existing Boiler From a Common Chimney K. 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 70: 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. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load.
  • Page 71 VIII. Gas Piping (continued) 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 ft.

  • Page 72: 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 73: Standard Piping Installation Requirements

    IX. System Piping (continued) B. 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 9.1. ASME Section IV currently requires that this relief valve be installed above the heat exchanger as shown.
  • Page 74 IX. System Piping (continued) CAUTION Do not reverse supply/inlet and return/outlet piping. Reverse piping will cause premature heat exchanger failure. Positively assure supply/inlet and return/outlet pipes are properly connected as shown in this manual. NOTICE For combi model ASPNC-155, only the inlet bottom/outlet bottom piping configuration may be used. Refer to Appendix B for combi piping.

  • Page 75: Near Boiler Piping Design

    IX. System Piping (continued) Remove Plug To Install Optional Low Water Cutoff Figure 9.2: LWCO Location C. Near Boiler Piping Design Proper operation of this boiler requires that the water flow rate through it remain within the limits shown in Table 9.3 any time the boiler is firing.
  • Page 76 IX. System Piping (continued) Method 1: Primary/Secondary Piping (Strongly Recommended) This method can be used in heat-only applications as shown in Figure 9.7a or 9.8a or with an indirect water heater as shown in Figure 9.7b, 9.7c, 9.8b, 9.8c. In this system, the flow rate through the boiler (“secondary loop”) is completely independent of the flow rate through the system (“primary loop”).
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  • Page 78 IX. System Piping (continued) 3) Indirect Water Heater Loop Piping – If an indirect water heater is used, install it as shown in Figure 9.7b, 9.7c, 9.8b, 9.8c. Refer to the indirect water heater installation manual for the proper sizing the indirect water heater loop pump and piping. 4) Hydraulic Separators –...
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  • Page 86 IX. System Piping (continued) Method 2: Direct Connection to Heating System (Generally NOT Recommended) In some cases it may be possible to connect this boiler directly to the heating system as is done with conventional boilers (Figure 9.9). If this is done, the flow rate through the boiler will equal the flow rate through the system. The flow rate through the system must therefore always remain within the limits shown in Table 9.3.
  • Page 87 IX. System Piping (continued) From Convection System Flow Check Balancing (Can be incorporated Valve with System Circulator) Convection Y-Strainer Full Port Isolation Valves System (Recommended) Relief Valve System Circulator Temperature/Pressure Gauge Air Separator & Air Vent Fill Valve Backflow Preventer Secondary Unions Cold Water Line (Not Required;...

  • Page 88: Piping For Special Situations

    IX. System Piping (continued) D. Piping for Special Situations 1) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a this boiler. Some examples include: • Radiant systems that employ tubing without an oxygen barrier. •...

  • Page 89: 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 or, in the absence of such requirements, with the National Electrical Code /NFPA 70).
  • Page 90 X. Wiring (continued) The use of the pump outputs are as follows: a) System Pump - Pumps water through the radiation. This pump is hydraulically separated from the boiler pump, either by closely spaced tees, or by a hydraulic separator. The system pump is always on when the system is responding to a call for CH.
  • Page 91 X. Wiring (continued) 120 VAC Connections Pump Fuse Spare Pump Fuse System Boiler 120 V Line Pump Pump Pump OVERCURRENT PROTECTION/ DISCONNECT (BY INSTALLER) 120VAC/60HZ BOILER SYSTEM POWER PUMP PUMP PUMP SUPPLY Figure 10.2: High Voltage PCB Terminal Connections Low Voltage Connections Fuse F1 250 V 1.6A Slow-Blow 5x20mm MODBUS EnviraCOM...
  • Page 92 X. Wiring (continued) With the exception of the alarm contacts, external power must not be applied to any of the low voltage terminals - doing so may damage the boiler control. Also note the following: a) External Limit - The external limit terminals are intended for use with a field supplied safety device, such as a manual reset high limit.
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  • Page 94 X. Wiring (continued) Figure 10.5: Internal Wiring Ladder Diagram 107362-01 - 8/17...
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  • Page 98 X. Wiring (continued) NOTICE System Pump hot must be wired HEATING THERMOSTATS to ZC as shown for optimal combi performance. PRIORITY OFF ZONE 4 TACO SR504 PRIORITY (OR EQUIVALENT) ZONE 1 ZONE 2 ZONE 3 ZONE 4 FOUR ZONE SWITCHING RELAY WITH OPTIONAL PRIORITY POWER ZONE 1...
  • Page 99 X. Wiring (continued) HEATING THERMOSTATS RJ45 CONNECTOR END SWITCH 24 VAC THERMOSTATS PRIORITY SLAVE MASTER MAIN PRIORITY EXPANSION ZONE 1 ZONE 2 ZONE 3 ZONE 4 PRIORITY ON RESET NORMAL PRIMARY PUMP ON POST PURGE ON PRIOR. PROTECT ON ZONE CONTROL INDICATORS PUMP EXERCISE ON POWER...

  • Page 100: 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 ANSI Z21.13. Use the following procedure for initial start-up of the boiler: Verify that the venting, water piping, gas piping and electrical system are installed properly.
  • Page 101 XI. Start-Up and Checkout (continued) DANGER Asphyxiation Hazard. Failure to properly convert this boiler for use on LP Gas (propane) 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”...
  • Page 102 XI. Start-Up and Checkout (continued) Start the boiler using the operating instructions on page 106. With the boiler powered up, and with no call for heat, the display should look like Figure 11.1a. Once a call for heat is present, it will look like Figure 11.1b. The boiler should attempt to fire approximately 30 seconds after a call for heat appears.
  • Page 103 Figure 11.2: Burner Flame 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 104 XI. Start-Up and Checkout (continued) WARNING • Do not attempt to operate this boiler on LP gas without converting it using the proper conversion kit. • Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer. •...
  • Page 105 XI. Start-Up and Checkout (continued) 19) Refer to the Operation Manual to set-up the control for the system in which the boiler is installed. Some common set-up tasks include: • Setting the CH and DHW temperature set-points (as shipped, both setpoints are set to 180°F). •...
  • Page 106 XI. Start-Up and Checkout (continued) Operating Instructions 107362-01 - 8/17...

  • Page 107: Operation

    XII. Operation IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: •...
  • Page 108 XII. Operation (continued) 7. Warm Weather Shutdown (WWSD) Table 12.1: Order of Priority Some boilers are used primarily for heating buildings, Status Screen Priority Boiler Responding to: and the boilers can be automatically shutdown when Display the outdoor air temperature is warm. When outside air Sequencer The boiler is connected to the peer- temperature is above the WWSD setpoint, this function...
  • Page 109 XII. Operation (continued) 5. Outdoor Air Reset C. Boiler Protection Features If an outdoor temperature sensor is connected to 1. Supply Water Temperature High Limit the boiler and Outdoor Reset is enabled, the Central The control is equipped with internal operating Heat setpoint will automatically adjust downwards as control and high limit features.
  • Page 110 XII. Operation (continued) D. Multiple Boiler Control Sequencer 5. Boiler Mounted Limit Devices The control monitors individual limit devices: External 1. “Plug & Play” Multiple Boiler Control Limit, Optional Low Water Cut-Off (LWCO), Blocked Sequencer Vent Switch, and Condensate Float Switch. If any of When multiple boilers are installed, the Control’s these limits open the boiler will shut down and an open Sequencer may be used to coordinate and optimize...
  • Page 111 XII. Operation (continued) 10. Innovative Condensing Boiler Control 5. Customized Sequences During low loads, the Sequence Master limits firing rates Normally, boilers are started and stopped in numerical to a “Base Load Common Rate” to ensure modulating order. However, custom sequences may be established condensing boiler peak operating efficiency.
  • Page 112 XII. Operation (continued) E. Boiler Sequence of Operation 1. Normal Operation Table 12.3: Boiler Sequence of Operation Status Screen Display Description Priority: (burner Off, circulator(s) Off) Standby Boiler is not firing and there is no call for heat, priority equals standby. The boiler Status: is ready to respond to a call for heat.
  • Page 113 XII. Operation E. Boiler Sequence Of Operation (continued) 2. Using The Display The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen navigation “buttons” and symbols. The “Home Screen” and menu selections are shown below. When no selection is made, while viewing any screen, the display reverts to the “Home Screen”...
  • Page 114 XII. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status” button from the “Home”...
  • Page 115 XII. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Bargraph Screen The bargraph screen presents measured values for easy comparison. An information screen provides monitoring of "Rate Demand To Fan" and "Fan Speed Feedback". These additional monitoring points are provided to help monitor blower performance.
  • Page 116 XII. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Zone Control Status Screens Zone Control Status Screen provides status and a page links for up to four Active zones are shown by bold zone panels. Individual zone Zone Control Status &...
  • Page 117 XII. Operation E. Boiler Sequence Of Operation (continued) 5. Multiple Boiler Sequencer Screens available When the Sequence Master is enabled the following screen is The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled. 107362-01 - 8/17...
  • Page 118 XII. Operation (continued) F. Changing Adjustable Parameters Adjust Mode 1. Entering Adjust Mode Warning! Improper settings or service The Control is factory programmed create risk of property For Service Contact: to include basic modulating boiler damage, injury or death. CONTRACTOR NAME functionality.
  • Page 119 XII. Operation F. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) The following pages describe the Control’s adjustable parameters. Parameters are presented in the order they appear on the Control’s Display, from top to bottom and, left to right. From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode): System “Press”...
  • Page 120 XII. Operation F. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) WARNING Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
  • Page 121 XII. Operation F. Changing Adjustable Parameters (continued) Table 12.10: Parameters Changed Using the Boiler Type Parameter Selections: Control Service 107877-01 107877-02 Part Altitude 0-2,000 ft. Model ASPN-085-02-N ASPN-110-02-N ASPN-155-02-N ASPNC-155-02-N ASPN-205-02-N ASPN-270-02-N Maximum Heat Rate 6,500 6,700 7,500 7,500 7,100 6,900 (RPM) Minimum Heat Rate...
  • Page 122 XII. Operation F. Changing Adjustable Parameters (continued) Table 12.10: Parameters Changed Using the Boiler Type Parameter Selections: (continued) Control Service 107877-01 107877-02 Part Altitude 6,001-7,800 ft. Model ASPN-085-67-N ASPN-110-67-N ASPN-155-67-N ASPNC-155-67-N ASPN-205-67-N ASPN-270-67-N Maximum Heat 8,450 8,800 8,500 8,500 8,250 9,000 Rate (RPM) Minimum Heat...
  • Page 123 XII. Operation F. Changing Adjustable Parameters (continued) Expected Heat Rate Adjustment Screens (HeatMatch Software) The Control is shipped with defaults that will provide improved operation. Adjustment is only required to optimize setup. The expected heat rate adjustment is used to better match boiler output to the home heating needs. After receiving a “call for heat”...
  • Page 124 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Setting Range / Choices Parameter and Description System Pump run pump for: Activates the system pump output according to selected function. Never: Pump is disabled and not shown on status screen. Never, Any Demand: Pump Runs during any call for heat.
  • Page 125 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections: Single boiler with no Indirect Water Heater At least eight pipe diameters upstream of first tee. Relief Valve No further apart than 12" (~30 cm) or four pipe diameters, whichever is smaller. From At least 18"...
  • Page 126 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single Boiler with Supply Piped IWH, System and DHW Wired to Master Parameter Selections: At least eight pipe diameters upstream of first tee. No further apart than 12" (~30 cm) or four pipe diameters, whichever is smaller. At least 18"...
  • Page 127 XII. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Thermostat DHW call for heat System pump DHW pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master...
  • Page 128 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Setting Range / Choices Parameter and Description Contractor Name User defined Contractor Name Address Line 1 User defined Contractor Address Line 1 Address Line 2 User defined Contractor Address Line 2 Phone...
  • Page 129 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Central Heat Setpoint 180°F 60°F to 190°F (82.2°C) (16°C to 87.8°C) Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Diff Above The boiler stops when the water temperature rises ‘Diff Above’...
  • Page 130 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Setpoint 180°F 60°F to 190°F Target temperature for the Auxiliary Heat priority. Value also used by the outdoor air reset (82.2°C) (16°C to 87.8°C) function.
  • Page 131 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Domestic Hot Water Setpoint 170°F 60°F to 190°F The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water (76.7°C) (16°C to 87.8°C) temperature setpoint that is used when DHW heat demand is “on”.
  • Page 132 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Central Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 12.13.
  • Page 133 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 12.13.
  • Page 134 XII. Operation F. Changing Adjustable Parameters (continued) Figure 12.13: Outdoor Reset Curve Central Heat Central Heat Heating Element Type Heating Element Type Setpoint Setpoint 180°F to 190°F 100°F to 140°F In Slab Radiant High Fan Coil (82.2°C to 87.8°C) (37.8°C to 60°C) Mass Radiant Convection 160°F to 190°F...
  • Page 135 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Master Enable/Disable Enable, Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Disable Warning! enable ONLY one Sequence Master.
  • Page 136 XII. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Parameter and Description Setting Choices Central Heat Modulation Source This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off demand directly without using the internal setpoint.

  • Page 137: Service And Maintenance

    XIII. Service and Maintenance Important Product Safety Information Refractory Ceramic Fiber Product WARNING The Service 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 138 XIII. Service and Maintenance (continued) 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 139 XIII. Service and Maintenance (continued) 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.
  • Page 140 XIII. Service and Maintenance (continued) When disconnecting flexible gas line, place backup wrench on this nut to prevent damage to gas valve. Connection Flexible Gas Line Figure 13.1: Disconnecting Flexible Gas Line Flame Sensor Igniter Figure 13.2: Igniter and Flame Sensor Location 107362-01 - 8/17...
  • Page 141 XIII. Service and Maintenance (continued) Unplug the igniter, ground, and flame sensor wires from the ignition electrode and the flame sensor (Figure 13.2). Use a 10 mm wrench to remove fire door to the heat exchanger (Figure 13.2). 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 page 137) or the electrodes.
  • Page 142 XIII. Service and Maintenance (continued) 0.177in±0.02 4.5mm±0.5 Figure 13.3: Igniter Gap Condensate Drain Bottom of Boiler Connector through knockout to low voltage wiring harness. Float Switch Worm Gear Condensate Trap Bracket Assembled Condensate Trap #8-18 Thread Forming Screw (1/4" Long) Figure 13.4: Condensate Trap Exploded Parts View 107362-01 - 8/17...
  • Page 143 XIII. Service and Maintenance (continued) Refer Section VII “Venting” to re-assemble any vent system components that are disassembled during this inspection and for details on supporting, pitching, and terminating the vent system. Reconnect any wiring which has been disconnected. 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.

  • Page 144: Troubleshooting

    XIV. Troubleshooting WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. A. Troubleshooting problems where no error code is displayed. Condition Possible Cause Boiler not responding to call for heat, “Status” and Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, “Priority”...
  • Page 145 XIV. Troubleshooting (continued) C. Help Screen Faults Indication Condition Possible Cause Zone Panel 1 communication lost, typical for Panel 1 through 4: The zone panel’s communication was established and then lost. Check the following to correct the Zone Panel 1 issue: •...
  • Page 146 XIV. Troubleshooting (continued) E. Active Fault Screen Faults Indication Condition Possible Cause The Limit String Status screen shows the safety limit status. A contact icon, either “open” or “closed”, graphically represents each safety limit. The “closed” contact icon Limit String Status is steady;...
  • Page 147 XIV. Troubleshooting (continued) F. Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the soft lockout.
  • Page 148 XIV. Troubleshooting (continued) Soft Lockout Codes Displayed (continued) Lockout Condition Possible Cause Number • Shorted or mis-wired flame rod wiring. Flame rod • Flame rod shorted to ground • Defective flame rod. shorted to ground • Inadequate boiler water flow. Verify that circulator is operating and that Differential Temperature rise between supply and return circulator and piping are sized per Water Piping and Trim Section of this...
  • Page 149 XIV. Troubleshooting (continued) G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the Hard Lockout.

  • Page 150: Service Parts

    XV. Service Parts All ASPEN™ Series Service Parts may be obtained through your local U.S. Boiler Wholesale distributor. Should you require assistance in locating a U.S. Boiler distributor in your area, or have questions regarding the availability of U.S. Boiler products or service parts, please contact U.S. Boiler Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 151 Space Heating Models Heat Exchanger and Piping Service Parts Part Number (Qty) Description ASPN-085 ASPN-110 ASPN-155 ASPN-205 ASPN-270 Heat Exchanger Contact U.S. Boiler Company. Provide boiler serial number. Burner (includes burner and screws) 108035-01 108035-02 108035-03 108035-04 108035-05 Burner Plate Insulation 108036-01 108036-02...
  • Page 152 Service Parts (continued) Space Heating Models: • ASPN-085 • ASPN-110 • ASPN-155 • ASPN-205 • ASPN-270 107362-01 - 8/17...
  • Page 153 Service Parts (continued) Size 155 MBH Combi Heat Exchanger and Piping Service Parts Part Number (Qty) Description ASPNC-155 Contact U.S. Boiler Company. Heat Exchanger Provide boiler serial number. Burner (includes burner and screws) 108035-03 Burner Plate Insulation 108036-02 Flame Sensor (includes electrode, gasket, and hardware)
  • Page 154 XV. Service Parts (continued) Combi Domestic Hot Water and Space Heating Model: • ASPNC-155 107362-01 - 8/17...
  • Page 155 Service Parts (continued) All Models MBH Blower and Gas Train Service Parts Part Number (Qty) Description ASPN-155 & ASPN-085 ASPN-110 ASPN-205 ASPN-270 ASPNC-155 Natural Gas (NG) Combustion Assembly (includes Blower, NG Venturi Assembly, Gas Valve, and 107944-01 107945-01 107946-01 107947-01 107948-01 Hardware) LP (Propane) Combustion Assembly (includes...
  • Page 156 Service Parts (continued) All Models 107362-01 - 8/17...
  • Page 157 Service Parts (continued) All Models Jacket Service Parts Part Number (Qty) Description ASPN-085 ASPN-110 ASPN-155 ASPNC-155 ASPN-205 ASPN-270 Front Door Assembly (includes door, 108037-01 plastic trim and hardware) Door Latch (includes 2 Catch and 107199-01 Keeper) Gas Train Support Bracket (includes 108038-01 108038-02 108038-01...
  • Page 158 107362-01 - 8/17...
  • Page 159 Service Parts (continued) All Models Control Panel Service Parts Part Number (Qty) Description ASPN-155 & ASPN-085 ASPN-110 ASPN-205 ASPN-270 ASPNC-155 Transformer 106034-01 High Voltage PCB (includes PCB, fuses, 107020-01 cover, and screws) Programmed Control 107877-01 107877-02 Square Control Panel Gaskets 108052-01 Low Voltage PCB (includes PCB, fuses, 107035-01...
  • Page 160 107362-01 - 8/17...
  • Page 161 Service Parts (continued) All Models Wire Harness Service Parts Part Number (Qty) Key No. Description ASPN-155 & ASPN-085 ASPN-110 ASPN-205 ASPN-270 ASPNC-155 Low Voltage / Communication Harness 108039-01 108039-02 High Voltage Harness 107037-01 Ignition Cable Harness 107211-01 Blower Control (4 pin) and Blower Power (3 pin) 108044-01 Harness DHW to Circulator and Zone Valve Harness...

  • Page 162: Appendix A: Instructions For High Altitude Installation

    Appendix A: Instructions for High Altitude Installations Above 2,000 ft. These instructions apply only to the following altitude ranges: 2001 - 6000, 6001 - 7800, 7801 - 10,100 operation. These instructions contain specific information to setup your boiler to ensure proper WARNING LP Conversions - boiler setup from factory is configured for use with natural gas installed from 0 - 2,000 ft.
  • Page 163 Appendix A - (continued) Table A.1: Altitude Adjustments (Above 2,000 ft. only) Approximate Derate per 1,000 ft. Model No. Fuel 2,001-6,000 ft 6,001-7,800 ft 7,801-10,1000 ft 1.0% 0.3% 0.0% 0.9% 1.0% 1.6% 0.7% 2.0% 2.5% 2.3% 3.0% 3.4% 1.2% 1.9% 2.2% 2.9% 0.0%...
  • Page 164 Appendix A - (continued) Table A.2: Acceptable Combustion Readings (Above 2000 ft. only) Measured CO (%)* Model Fuel Max. CO Air Free 2,001-6,000 ft 6,001-7,800 ft 7,801-10,100 ft 9.7-10.0 9.5-9.8 9.4-9.7 9.2-9.4 9.1-9.4 COAF readings 9.0-9.3 8.4-8.7 8.1-8.4 must be less than 200 ppm.
  • Page 165 Appendix A - (continued) Table A.3: Approximate Starting Number of Throttle Turns No. Counter- Clockwise Turns (From Fully Model Size Closed) 13.0 20.0 107362-01 - 8/17...

  • Page 166: Appendix B: Aspnc-155 Combi Instruction Manual

    Appendix B: ASPNC-155 Combi Instruction Manual – Product Description The ASPNC-155 provides economical, reliable, tankless domestic hot water (DHW) production in addition to central space heating provided by the ASPN high efficiency boiler. – Domestic Hot Water Basic Operation The ASPNC-155 Combi provides central heat through a high efficiency stainless steel heat exchanger and DHW through a flat plate heat exchanger.
  • Page 167 Appendix B - (continued) IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.
  • Page 168 Appendix B - (continued) 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. Water temperature above 120°F (49°C) can cause serious injury.
  • Page 169 Appendix B - (continued) – Introduction 1. Parts Included: 3 copper pipe assemblies, thermostatic mixing valve, flow switch, and miscellaneous parts bag. 2. Install boiler per installation instructions. Attach supply and return piping at bottom of jacket (See Figure C.1). 3.
  • Page 170 Appendix B - (continued) – Piping Diagram At least eight pipe diameters upstream of first tee. No further apart than 12" (~30 cm) or four pipe diameters, whichever is smaller. Y-Strainer From At least 18" (~46 cm) of straight pipe for Conventional Air Scoop. (Recommended) System Relief...
  • Page 171 Appendix B - (continued) NOTICE Do not install check valve(s) or pump with an integrated check valve in boiler loop piping. Use of check valve(s) may isolate boiler from expansion tank when zone valve closes during a call for DHW. CAUTION Application of excessive heat during sweating to repair piping could damage union gaskets or brazed joints on Combi piping.
  • Page 172 Appendix B - (continued) – DHW Section (on bench) 1. Unpack mixing valve, flow switch and three pipe assemblies. 2. Identify the hot water inlet "H", cold water inlet "C" and mixed water outlet "MIX" of the mixing valve (1)*. Orient the "H"...
  • Page 173 Appendix B - (continued) – Electrical WARNING Turn off all power before proceeding. 10. Remove door from boiler. Identify low voltage PCB on right side of compartment. 11. Remove a knockout near “DHW T’Stat” connection. Install a knockout strain relief. 12.
  • Page 174 Appendix B - (continued) WARNING To complete service and place boiler back into operation, follow “Start-up and Checkout” Section in this manual. XIII – Boiler Control Set-up 18. Turn on boiler power 19. From boiler home screen, select “Adjust” and login. 20.
  • Page 175 Appendix B - (continued) – Troubleshooting Enough Hot Check to see if hot water flowrate is greater than 0.54 gpm. Water Flow? Boiler priority In DHW settings, enable priority. Running? Flow switch Arrow on flow switch should point in direction of flow. installed (from mix valve to sweat connection) correctly?
  • Page 176 Appendix B - (continued) XVIII - Domestic Actuator Replacement 1. Switch power supplies OFF. Disconnect electrical leads, carefully noting the position and color of each lead. 2. Please the manual operating level in the manual open position. 3. Remove actuator by depressing locking button and lifting straight up. 4.

  • Page 177: Appendix C: Special Requirements For Side-Wall

    Appendix C: 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) ft.
  • Page 178 Appendix C - (continued) 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 179 107362-01 - 8/17...
  • Page 180 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 107362-01 - 8/17...

This manual is also suitable for:

Aspen aspn-110Aspen aspn-155Aspen aspn-205Aspen aspn-270Aspen aspnc-155

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