U.S. Boiler Company Citadel CTD 1250 Installation, Operation And Maintenance Manual
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U.S. Boiler Company Citadel CTD 1250 Installation, Operation And Maintenance Manual

1250-1500 mbh hot water boiler
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INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL
1250-1500 MBH Hot Water Boiler
Citadel Boiler Models
Model:
Installation Date:
Heating Contractor:
Address:
U.S. Boiler Company, LLC
CTD 1250
CTD 1500
WARNING: If the information in these instructions
is not followed exactly, a fire or explosion may
result causing property damage, personal injury
or death.
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
Serial Number:
System Type:
Phone/Email:
Lancaster, PA
PN: 111959-04
Save this manual for future reference.
 WARNING
WARNING
 DANGER
DANGER
REV. 0, 4/23
www.usboiler.net

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Summary of Contents for U.S. Boiler Company Citadel CTD 1250

  • Page 1 CTD 1250 the fire department. CTD 1500 Installation and service must be performed by a qualified installer, service agency or the gas supplier. Model: Serial Number: Installation Date: System Type: Heating Contractor: Phone/Email: Address: U.S. Boiler Company, LLC Lancaster, PA www.usboiler.net...

  • Page 2: Table Of Contents

    Table of Contents I. Hazard Definitions II. Read Before Proceeding Local Codes Warranty Shipment Damage Connecting Gas Supply Line Gas Leakage (If you detect or smell gas...) Maintenance Freeze Protection Fluids and Treatments Product Identification Label Factory Test and Inspections Disclaimers and Local Codes III. Product Rating, Specifications, and Dimensional Data IV. Citadel Component Identification V. Unpacking The Citadel Unpacking and Inspection Installation and Operation Manual VI. Pre-Installation and Mounting General Installation Appliance Mounting Clearances Clearances (French) Closet and Alcove installation VII. Venting...
  • Page 3 Table of Contents Standard Piping Components Water Quality and Treatments Oxygen Contamination X. Heating Boiler Piping diagrams XI. Gas Piping Guidelines and Requirements XII. Electrical General Power Requirements Appliance Wiring XIII. System Start-up Check System Setup Start the Citadel Combustion Air/Fuel Adjustment Field Conversion of Gas Type Pump Control Check Thermostat Operation Adjust Supply Water Temperature Testing of Controls and Safety Devices XIV. Service and Maintenance General Maintenance Monthly Inspection Annual Inspections and Service Restarting after Prolong Shutdown Troubleshooting APPENDIX A: Tables APPENDIX B: Figures APPENDIX C: Default Light-off and Modulation Rates CTD 1250/1500 I&O Manual...

  • Page 4: Hazard Definitions

    I. Hazard Definitions 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. It is critical all personnel read and adhere to all information contained in DANGER, WARNING, and CAUTIONS. All DANGERS, WARNINGS, and CAUTIONS are for reference and guidance purpose, and, therefore, do not substitute for strict adherence to applicable jurisdictional and professional codes and regulations.  DANGER DANGER  CAUTION CAUTION   Indicates an imminently hazardous situation which, if not Indicates a potentially hazardous situation which, if avoided, will result in death, serious injury or substantial not avoided, may result in moderate or minor injury, or property damage. property damage.  WARNING WARNING NOTICE NOTICE  Indicates a potentially hazardous situation which, if Indicates special instructions on installation, operation, not avoided, could result in death, serious injury, or or maintenance which are important but not related to...

  • Page 5: Read Before Proceeding

    II. Read Before Proceeding A. Local Codes  DANGER DANGER  1. This unit shall be installed in accordance with those This appliance MUST NOT be installed in any location installation regulations enforced in the area where where gasoline or flammable vapors are likely to be the installation is to be made. These regulations present or, in an environment that contains corrosive shall be carefully followed in all cases. Authorities contaminants (see Table 4). having jurisdiction shall be consulted prior to Do not block or restrict in any way the flow of combustion installation.

  • Page 6: Product Identification Label

    II. Read Before Proceeding (continued) H. Product Identification Label  WARNING WARNING 1. A nameplate, in accordance with the ASME code  Section IV, is permanently attached to the heat This product can expose you to chemicals, exchanger. including chromium, which are known to the state 2. To access the nameplate, remove front jacket panel of California to cause cancer and birth defects or from the appliance.

  • Page 7: Product Rating, Specifications, And Dimensional Data

    III. Product Rating, Specifications, and Dimensional Data not designed for use in gravity hot water space heating Citadel boilers are condensing, high-efficiency, gas-fired, systems or systems containing significant amount of hot water boilers designed for space heating systems or dissolved oxygen (swimming pool water heating, direct indirect domestic water heating, where supply water domestic water heating, etc.). temperature does not exceed 190°F. These boilers have special coil type stainless steel heat exchangers, constructed, tested, and stamped per Section IV of the ASME Boiler and Pressure Vessel Code, which provide maximum heat transfer and simultaneous protection...
  • Page 8 III. Product Rating, Specifications, and Dimensional Data (continued) Table 3: Product Dimensions Citadel Model Dimensions (in.) 1250 1500 45-1/2 66-1/8 72-1/2 55-7/8 76-1/2 34-1/4 34-1/4 13-3/8 13-3/8 42-3/4 42-3/4 36-1/8 36-1/8 3-1/4 6-7/8 18-7/8 10-3/8 10-3/8 8-3/4 6-5/8 40-1/2 40-1/2 44-3/8 44-3/8 2-1/8 2-1/8...
  • Page 9 III. Product Rating, Specifications, and Dimensional Data (continued) SUPPLY NOZZLE RETURN NOZZLE GAS TRAIN CONNECTION SUPPLY NOZZLE LIFTING LUGS RETURN NOZZLE (Z-COG) (Y-COG) DRAIN VENT AIR SUPPLY (Z-COG) (X-COG) 1" CONDENSATE DRAIN Figure 1: Citadel Boiler Dimensions CTD 1250/1500 I&O Manual...

  • Page 10: Citadel Component Identification

    IV. Citadel Component Identification Communication Interface (Concert Control) 15. Gas supply line The Citadel series is equipped with the Concert Control Provides a means of connection for incoming gas line to display which provides easy access for viewing and the gas train assembly. See Table 29 for model specific adjusting operational parameters and alarms/lockouts, pipe sizes. and monitoring historical performance characteristics. 16.
  • Page 11 IV. Citadel Component Identification (continued) Figure 2: Component Identification CTD 1250/1500 I&O Manual...
  • Page 12 IV. Citadel Component Identification (continued) Figure 3: Component Identification CTD 1250/1500 I&O Manual...

  • Page 13: Unpacking The Citadel

    V. Unpacking The Citadel A. Unpacking and Inspection  DANGER DANGER  1. Move appliance to approximate installation Failure to assure the lifting forks are long enough location. to extend at least half way through the base will 2. Remove all crate fasteners. result in the appliance tipping and potentially 3. Lift and remove outside container. falling. This could result in severe personal injury, death, or substantial property damage. 4. Account for all loose shipped items. 5. Remove cardboard positioning sleeves on shipping Do not operate this appliance if any part has been skid.

  • Page 14: Pre-Installation And Mounting

    VI. Pre-Installation and Mounting A. General Installation 1. Installation must conform to the requirements of  WARNING WARNING  the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Apply supplied silicone lubricant to the gasket Code, ANSI Z223.1/NFPA 54, and/or Natural Gas inside the vent connector. Failure to apply lubricant and Propane Installation Code, CAN/CSA B149.1. could result in flue gas leaks or gasket deterioration.

  • Page 15: Appliance Mounting

    VI. Pre-Installation and Mounting (continued) B. Appliance Mounting 1. The Citadel is intended for installation in an area Table 4: Corrosive Combustion Air Contaminants with a floor drain, or in a suitable drain pan to Contaminants to Avoid: prevent any leaks or pressure relief valve discharge resulting in property damage. Spray cans containing chlorofluorocarbons (CFC’s) 2. This appliance is not intended to support external piping or venting. All external piping and venting Permanent wave solutions must be supported independently of the appliance.

  • Page 16: Clearances

    VI. Pre-Installation and Mounting (continued) C. Clearances NOTICE NOTICE 1. The Citadel is approved for 0" clearance to combustible materials. The clearances for This appliance is approved for zero inch clearance to combustible or noncombustible material, but serviceability are found in Table 5. installing the appliance with smaller than the 2. Minimum clearances from combustible or clearances for serviceability will limit access for noncombustible construction, 0" sides, 0" back, maintenance.

  • Page 17: Venting

    NOTICE of the installer or vent supplier to use compatible adapters and materials. Common venting with other manufacturers' a. It is recommended to consult with venting appliances or different U.S. Boiler Company professionals and designers when determining models is prohibited. the vent system for this appliance. It is the Responsibility of the installing contractor 4. Enclose vent passing through occupied or...

  • Page 18: Field Installation

    VII. Venting (continued) C. Field Installation 1. A factory installed cast aluminum or steel ring  WARNING WARNING  provides a means for air intake connection. 2. A factory installed vent connector provides a means Failure to follow these instructions could cause for connection to stainless steel venting. products of combustion to enter the building, 3. Vent and combustion air intake pipe must be resulting in severe property damage, personal supported to allow uniform flow of combustion...
  • Page 19 VII. Venting (continued) Table 8: Vent and Combustion Air Equivalent Length Calculation Worksheet Combustion Air Vent Equivalent Subtotal Equivalent Subtotal Component Length Per x Quantity Equivalent Length x Quantity Equivalent Piece Length Per Piece Length Straight Pipe 90° Elbow 45° Elbow Combustion Air Total Vent Total Equivalent Length...

  • Page 20: General Termination

    VII. Venting (continued) Table 12: Polypropylene Vent Adapters Vent Centrotherm Part # Z-Flex Part # Model Diameter (in.) (Innoflue PP System) (Z-DENS PP Systems) 1250 ISSA0808 2ZDAHF8 1500 Table 13: Stainless Steel Vent and Intake Terminations Vent Heat Fab Part # Z-Flex Part # Style Model Diameter (in.)
  • Page 21 VII. Venting (continued) Table 15: Recommended Venting Configurations and Material Options Vent & Intake Vent Penetration Reference Termination Parts Table Materials Option Through Structure Figure Intake Horizontal Sidewall 90° elbow Figure 6 Two Pipe Vent Horizontal Sidewall Tee or 45° elbow Intake Horizontal Sidewall 90°...
  • Page 22 VII. Venting (continued) 11. Top of terminal must be at least 24 in. (600 14. Under certain conditions, water in the flue gas may mm) below ventilated eaves, soffits, and other condense, and possibly freeze, on objects around overhangs. In no case may the overhang exceed the terminal including on the structure itself. If 48 in. (1200 mm). Where permitted by the these objects are subject to damage by flue gas authority having jurisdiction and local experience, condensate, they should be moved or protected.
  • Page 23 VII. Venting (continued) Table 16: Direct Vent Terminal Clearances Canadian Installations US Installations Clearance above grade, veranda, 18 in. (46 cm) 12 in (30 cm) porch, deck, or balcony 6 in (15 cm) for appliances ≤ 6 in (15 cm) for appliances 10,000 Btuh (3 kW), 12 in (30 ≤...
  • Page 24 VII. Venting (continued) Table 17: Other than Direct Vent Terminal Clearances Canadian Installations US Installations Clearance above grade, veranda, 18 in (46 cm) 12 in (30 cm) porch, deck, or balcony 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 12 in (30 4 ft (1.2 m) below or to side of Clearance to window or door that cm) for appliances >...
  • Page 25 VII. Venting (continued) Table 18: Table of Acceptable Terminations Flue Gas Vent Terminations Sidewall Roof Straight Termination Tee Termination Vertical Run Tee Termination Vertical Run 20°-45° Elbow Terminated Downward Velocity Cone Combustion Air Intake Terminations Sidewall Roof Two 90° Elbows Terminated Downward 90°...

  • Page 26: Vent And Combustion Air Terminations

    VII. Venting (continued) NOTICE NOTICE E. Vent and Combustion Air Terminations 1. Vent Piping Methods of securing and sealing terminals to a. Install fire stops where vent passes through the outside wall must not restrain the thermal floors, ceilings or framed walls. The fire stop expansion of the vent pipe.
  • Page 27 VII. Venting (continued) 6 Pipe Diameters Min. 24 in. Min. Bird Screen From Intake Vent & Intake Bird Screen Vent Vent & Intake 12 in. Min. Above Snow Line 4 Pipe Diameters min. Vent Combustion Combustion Grade/Snow Line 12 in. min. Above Snow Line Figure 6: Horizontal Sidewall Termination Figure 7: Slopped Roof Termination...

  • Page 28: Multiple Appliance Terminations

    VII. Venting (continued) F. Multiple Appliance Terminations 1. Vent Piping Terminations  WARNING WARNING  a. Multiple appliance vent terminations are shown in Figure 9. The joint between the terminal and the last piece b. Each individual appliance must have its own of pipe must be outside of the building. vent pipe and vent terminal unless a common The vent for this appliance shall not terminate: venting system is used following the guidlines 1. Over public walkways; or of the "Engineered Venting Method" section in 2. Near soffit vents or crawl space vents or...
  • Page 29 VII. Venting (continued) 6D Min.  WARNING WARNING  The required spacing between vent and combustion air terminals is to prevent flue gas recirculation. 4D Min. Recirculation of flue gas products into the combustion air supply can cause damage to property or the appliance. Grade/ Snow Line 12 in.

  • Page 30: Polypropylene Venting

    VII. Venting (continued) H. Polypropylene Venting  WARNING WARNING  1. Running Flexible Polypropylene Vent (Liner) Asphyxiation Hazard. Vent systems made by listed Through Unused Chimney Chase PP vent system manufacturers rely on gaskets for a. It is the responsibility of the installing contractor proper sealing. When this type of vent system is to procure polypropylene vent system pipe and used, take the following precautions: related components. Make sure that gasket is in position and undamaged b. A l l l i s t e d p o l y p ro p y l e n e v e n t sy s t e m in the female end of the pipe.
  • Page 31 VII. Venting (continued) NOTICE NOTICE Pressure drop for flexible polypropylene line is 20 % greater than from rigid pipe. Multiply measured flexible polypropylene liner length by 1.2 to obtain equivalent length. Maximum equivalent vent length of flexible polypropylene liner is 48 ft. (14.6 m). Installation of a polypropylene vent system should adhere to the vent manufacturer's installation instructions supplied with the vent system.  WARNING WARNING  DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.
  • Page 32 VII. Venting (continued) c. When an air supply duct is used to supply b. Natural gas and propane installation code specifies combustion air, its discharge opening shall be venting systems and air supply for appliances. Air located where there is no possibility of cold air supply shall be provided when either an appliance affecting steam/water lines or other temperature or a combination of appliances has a total input sensitive equipment. exceeding 400,000 Btu/h. 4. Combustion Air Supply Dampers, Louvers, and c. Air supply is defined as combustion air, excess air, Grilles flue gas dilution air, primary air, secondary air, a.

  • Page 33: Removing Existing Appliance

    VII. Venting (continued) J. Removing Existing Appliance NOTICE NOTICE When an existing appliance is removed from a common Please note that the information provided in venting system, the common venting system is likely to be this manual relative to the Canadian Standard is too large for proper venting of the remaining appliances. At not meant to be all-inclusive. Reading the entire the time of removal of an existing appliance, the following Standard is strongly suggested. The final approval steps should be performed with each appliance remaining of all system designs must be acceptable to the connected to the common venting system. Make sure the authority having jurisdiction. appliances are not in operation while carrying out these steps. 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and ensure there is no blockage or restriction, leakage, corrosion, or other...

  • Page 34: Special Installation Requirements For Massachusetts

    VII. Venting (continued) K. Special Installation Requirements for Massachusetts 1. 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) feet above grade, the following requirements shall be satisfied: a. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. b. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the detector on the floor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment, the installer shall have a period of thirty (30) days to comply...

  • Page 35: Condensate Disposal

    VIII. Condensate Disposal A. General B. Condensate Drain Assembly 1. Note the following when disposing of the 1. Locate the condensate trap assembly shipped loose condensate: with this appliance. a. Condensate is slightly acidic, typical pH around 2. Install the condensate trap on the lower rear of the 3.5 - 4.5. Do not route the drain line through areas appliance as shown in Figure 11. that could be damaged by leaking condensate.

  • Page 36: Condensate Neutralizer Installation

    VIII. Condensate disposal (continued) C. Condensate Neutralizer Installation  WARNING WARNING  1. Some jurisdictions may require that the condensate be neutralized before being disposed of. Follow Failure to install the condensate drain in accordance local codes pertaining to condensate disposal. with the above instructions could cause flue gas 2. A condensate neutralizer kit is available from to enter the building, resulting in personal injury factory as optional equipment. Refer to Table 20 for or death.

  • Page 37: Hydronic Piping

    IX. Hydronic Piping A. Citadel Boiler Piping  WARNING WARNING  Citadel boilers are designed to operate in a closed loop pressurized system. Minimum pressure in the Failure to properly pipe boiler may result in boiler must be 14.5 psi (100 kpa). Proper operation improper operation and damage to the boiler or requires a piping system that can provide sufficient structure. water flow through the boiler and meet the water Install boiler so that the gas ignition system quality requirements. components are protected from water (dripping, B.

  • Page 38: Temperature Rise And Heat Exchanger Head Loss

    IX. Hydronic Piping (continued) D. Temperature Rise and Heat Exchanger Head Loss 1. The Citadel heat exchanger adds pressure drop to the system which must be accounted for in the design of the piping configuration and pump selection. 2. For systems with glycol mixture, the flow rate specified in Table 21 will increase as specified in Table 25 due to the extra frictional loss introduced by the glycol. Size pump accordingly. 3. Strictly follow glycol manufacturer’s guidelines and recommendations when adding glycol in the heating system. 4. The system should be designed to maintain the recommended water flow rate shown in Table 21 while never exceeding the range of absolute flow rates shown in Table 24. Exceeding the maximum water flow rates can cause pipe erosion, damage the flow switch, and allow unsafe operation. a. Maintaining sufficient flow through the boiler will help prevent the buildup of scale. Table 21: Temperature rise, flow rate, and head loss Recommended Range Delta 20 °F Delta 25 °F Delta 30 °F Delta 35 °F...

  • Page 39: Standard Piping Components

    IX. Hydronic Piping (continued) E. Standard Piping Components  DANGER DANGER  1. Pressure Relief Valve (Required) Scald Hazard. Pressure relief valve discharge shall a. The pressure relief valve must be installed with be piped in such a way to prevent or eliminate spindle in vertical position. Installation of the potential burn risk. pressure relief valve must comply with ASME DO NOT pipe in any area where freezing could Boiler and Pressure Vessel Code, Section IV. For occur.

  • Page 40: Water Quality And Treatments

    IX. Hydronic Piping (continued) F. Water Quality and Treatments 1. The water directly in contact with the appliance  CAUTION CAUTION must meet the requirements in this section. Failure  to adhere to the water treatment requirements The Citadel heat exchanger is made from stainless in this manual can cause damage not covered steel tubular double coil having relatively narrow by warranty to the appliance, pumps, or other waterways. Once filled with water, it will be...

  • Page 41: Oxygen Contamination

    IX. Hydronic Piping (continued) 7. Before connecting the boiler, ensure the system is  CAUTION CAUTION  free of impurities, grease, sediment, construction dust, and any residual boiler water additives. Water temperatures over 140 °F (60 °C) greatly a. Flush the system thoroughly and repeatedly, if increase the affects of corrosive chemicals. needed, with clear water mixed with concentrated Chlorine and Chloride have different levels rinse agent to remove these contaminants of corrosion effects on stainless steel.
  • Page 42 IX. Hydronic Piping (continued) Table 22: Corrosion/Scale Inhibitors and Removal Agents Producers Fernox Sentinel Sotin ADEY Inhibitors Protector F1/Alphi 11 X100, X500 Sotin 212 MC1+ Noise reducer X200 Universal Restorer X300 Cleaner Sludge remover Protector F1, Cleaner F3 X400 Sotin 212 Antifreeze Alphi 11 X500...

  • Page 43: Heating Boiler Piping Diagrams

    X. Heating Boiler Piping diagrams Figure 13: Single Boiler, Primary/Secondary Piping Single AMP/BFIT Primary/Secondary Piping System Circulator To System Pressure Reducing Valve Isolation Valve Air Vent Purge Valve Make Up Water From System Factory Supplied Manifold Isolation Valve Expansion Tank Check Valve Boiler Circulator Y-Strainer No more than 12 inches or 4 pipe diameters...
  • Page 44 X. Heating Boiler Piping Diagrams (continued) Figure 14: Multiple Boiler, Primary/Secondary with Common Header Piping AMP Pipng with Common Header System Circulator To System Air Vent Make Up Water Purge Valve From System Check Valve Pressure Reducing Valve Expansion Tank Isolation Valve Check Valve Factory Supplied Manifold Y-Strainer...
  • Page 45 X. Heating Boiler Piping Diagrams (continued) Figure 15: Multiple Boiler, Primary Reverse-Return Piping Air Vent From System System Pump Full Port Isolation Valve Expansion Tank Y-Strainer Motorized isolation Valve Pressure Reducing Valve Make Up Water Factory Supplied Manifold Check Valve To System AMP Variable Primary Piping 8/30/2019 1.
  • Page 46 X. Heating Boiler Piping Diagrams (continued) Multiple AMP Boiler Piping with Hydraulic Separator 11/12/2018 Figure 17: Multiple Boiler, Primary Secondary Piping with Hydronic Separator System Circulator Hydraulic Separator Isolation Valve To System Check Valve From System Make Up Water Check Valve Pressure Reducing Valve Expansion Tank Boiler Circulator...

  • Page 47: Gas Piping

    XI. Gas Piping A. Guidelines and Requirements 10. If the high or low gas pressure switch tripped, it All installation must conform to the National Fuel must be manually reset before the appliance can Gas Code ANSI Z223.1/NFPA54, and/or local codes. be restarted. (See Figure 20) In Canada, installation must conform to the latest 11. Gas piping shall be supported by fixed hangers or edition of CSA B149.1 National Gas and Propane Gas stands and not by the appliance.
  • Page 48 XI. Gas Piping (continued) Maximum capacity of schedule 40 black pipe in CFH* Table 26:  Natural Gas, Inlet Pressure 14.0 in wc (3.4 kPa)or less; 0.5 in wc (0.12 kPa) Pressure Drop Nominal Inside Length of Pipe (Ft) Pipe Size Diameter (In) (In)
  • Page 49 XI. Gas Piping (continued)  WARNING WARNING Table 28: Specific Gravity Correction Factors  Specific Correction Specific Correction Failure to properly pipe gas supply to appliance may Gravity Factor Gravity Factor result in improper operation and damage. Always assure gas piping is absolutely leak free and of the 0.60 1.00 0.90 0.82 proper size and type for the connected load. 0.65 0.96 0.78 An additional gas pressure regulator may be 0.70 0.93 1.10...

  • Page 50: Electrical

    XII. Electrical A. General  DANGER DANGER  Install wiring and electrically ground the appliance in accordance with authority having jurisdiction or, in the Electrical Shock Hazard: Ensure all electrical absence of such requirements, follow the National connections are disconnected before attempting Electrical Code, NFPA 70, and/or Canadian Electrical installation or service of electrical components or Code Part 1, CSA C22.1. connections of the appliance or building. Lockout 1. A separate electrical circuit must be run from all electrical boxes with padlock once power is the main electrical service with an over-current turned off.

  • Page 51: Appliance Wiring

    XII. Electrical (continued) C. Appliance Wiring c. Avoid placing senors near potential sources of electrical noise such as transformers, power lines, 1. Connect to field wiring inside the control box. . and fluorescent lighting. Wire the sensor to the I I nside the control box are five printed circuit boards appliance using 22 gauge or larger wire. As with (PCB’s). the sensor, the sensor wiring should be routed away from sources of electrical noise. Where it is Table 31: Citadel PCB's impossible to avoid such noise sources, wire the sensor using a 2 conductor, UL Type CM, AWM Printed Circuit Functions/Connection Style 2092, 300 Volt 60 C shielded.
  • Page 52 XII. Electrical (continued) Boiler must be grounded in accordance with ANSI National Electric Code. Connect to V/C/P Primary Power Supply To Grounding Fuses Ground Screw Conductor Blower Terminal Combustion Blower Power Fuses Fuses used for only 208 V and 230 V Transformer used for only 208 V and 230 V...
  • Page 53 XII. Electrical (continued) Boiler must be grounded in accordance Connect to V/C/P with ANSI National Electric Code. Power Supply Primary To Grounding Fuses Ground Screw Conductor Blower Terminal Fuses Combustion Blower Power Transformer 120vac 24vac Continue to low Concert Boiler voltage circuit PCB-01 Control (A1167)
  • Page 54 XII. Electrical (continued) PCB-01 (3A Slow Blow) PCB-05 Continue from high voltage circuit P4b-1 P18a-4 Central Heat P5-11 Concert Boiler 24vac Enable/ Control (A1167) J17/W1 Disable Input (STAT) J8-3 P5-8 P4b-2 P18a-3 J8-6 P5-2 P4b-4 P18a-2 Setpoint or Modulation J8-7 P5-1 P18a-1 P4b-3...
  • Page 55 XII. Electrical (continued) Concert Boiler Control (A1167) PCB-02 F2 (6.3A Slow Blow) J4-6 P31-4 Power Supply (120 or 24 VAC) P31-5 J4-7 System Pump (Supplied by others) Spare F3 (6.3A Slow Blow) J4-4 P31-2 Power Supply (120 or 24 VAC) P31-6 J4-5 Boiler Pump/Circulator...

  • Page 56: System Start-Up

    XIII. System Start-up A. Check System Setup  DANGER DANGER  1. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer Do not use matches, candles, or other open flame to installation instructions contained in this manual. ignition sources to check for leaks. 2. Confirm all electrical, water, and gas supplies are Make sure that the area around the appliance is turned off at the source and that venting is clear clear and free from combustible materials, gasoline of obstructions. and other flammable vapors and liquids. 3. Flush the system to remove sediment, flux, and other contaminants. This must be done with the appliance isolated from the system.
  • Page 57 XIII. System Start-up(continued) FOR YOUR SAFETY READ BEFORE OPERATING/P OUR VOTRE SECURITE LISEZ AVANT DE METTRE EN MARCHE     WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. AVERTISSEMENT: Quiconque ne respecte pas à...

  • Page 58: Combustion Air/Fuel Adjustment

    XIII. System Start-up(continued) C. Combustion Air/Fuel Adjustment 6. Verify O (or CO ) and CO concentration are within limits specified in Table 32. Note: the values in 1. For high fire adjustment this table are for sea level only. For high altitude a. Lock the appliance in high fire and allow fan speed installation, above 2000 ft. consult factory. and combustion analyzer reading to stabilize before taking combustion readings. To lock in high fire, select MAIN MENU >> OPERATION.

  • Page 59: Field Conversion Of Gas Type

    XIII. System Start-up(continued) D. Field Conversion of Gas Type  WARNING WARNING  This appliance is factory tested and set up for the gas type selected but can be field converted with the Make sure that all adjustments at high fire are following steps. made with the throttle, not offset screw. 1. Connect the new gas supply to the appliance, check The offset screw has been factory set using for leaks, and purge the gas line in accordance with precision instruments and must never be adjusted the National Fuel Gas Code, ANSI Z223.1/NFPA...

  • Page 60: Pump Control

    XIII. System Start-up(continued) E. Pump Control H. Testing of Controls and Safety Devices Ensure the appropriate pump parameters are selected Prior to placing the appliance in operation, the in the Pumps menu of the Concert control. Refer to installing contractor or other responsible personnel the Concert Control manual for more information. must perform safety and control device limit tests to ensure proper operation of the appliance. Refer F. Check Thermostat Operation to Table 34 for recommended method(s) of carrying Verify that the appliance starts and stops in response out these safety limit devices tests.

  • Page 61: Service And Maintenance

    XIV. Service and Maintenance IMPORTANT PRODUCT SAFETY INFORMATION IMPORTANT PRODUCT SAFETY INFORMATION REFRACTORY CERAMIC FIBER PRODUCT REFRACTORY CERAMIC FIBER PRODUCT  WARNING 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 temperature above 1805 °F, such as during direct flame contact, RCF changes into crystaline silica, a know carcinogen. When disturbed as a result of servicing or repair, these substances became airborne and, if inhaled, may be hazardous to your health. AVOID Breathing Fiber Particulates and Dust Precautionary Measures: Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gears: 1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator 2. Long sleeved, loose fitting clothing 3. Gloves 4. Eye Protection •...

  • Page 62: General Maintenance

    XIV. Service and Maintenance A. General Maintenance  WARNING WARNING  1. Keep the area around the appliance free from combustible materials. (Gasoline and other Read and understand the entire manual before flammable vapors and liquids) attempting installation, start-up, operation, or 2. Keep the area around the combustion air inlet service. Installation and service must be performed terminal free from contaminants.
  • Page 63 XIV. Service and Maintenance (continued) 2. Igniter Electrode  DANGER DANGER  a. Disconnect power to the unit and remove ignition electrode from the burner door. This appliance uses flammable gas, high voltage electricity, moving parts, and very hot water under b. Visually inspect igniter assembly (ceramic high pressure. Ensure that all gas and electric power insulators, bracket, and graphite gasket) for damage. Replace igniter assembly if the electrodes supplies are off and that the water temperature is are deformed or ceramic insulators are cracked. cool before attempting any disassembly or service. Do not attempt any service work if gas is present in the air around the appliance. Never modify, remove or tamper with any control device.
  • Page 64 XIV. Service and Maintenance (continued)  DANGER DANGER 3. UV Scanner/ Flame Sensor  a. Inspect ultra-violet (uv) scanner lens and Failure to properly secure the burner/blower/gas remove any debris with a soft cloth. If valve assembly to the heat exchanger could lead condensate or fog is observed on the glass, to property damage, personal injury or loss of life. the gaskets may need to be replaced. Read, understand and follow all the instructions and warnings contained in ALL of the component instruction manuals.

  • Page 65: Restarting After Prolong Shutdown

    XIV. Service and Maintenance (continued) b. Any accumulation of soot or debris should be thoroughly cleaned out. 6. Combustion air filter with air box a. Undo the latches on the filter box to lift the lid and access the filter. b. Clean the filter of dust and debris using compress air or water. c. Replace filter if it appears damaged or deteriorated. d. Reinstall filter and lid. 7. Combustion air filter without air box a. Remove air intake pipe to gain access to the filter. Blow compressed air though the filter to remove dust and debris.

  • Page 66: Appendix A: Tables

    APPENDIX A: Tables I. Hazard Definitions II. Read Before Proceeding III. Product Rating, Specifications, and Dimensional Data Table 1: Performance Ratings Table 2: Citadel Boiler Specifications Table 3: Product Dimensions IV. Citadel Component Identification V. Unpacking The Citadel VI. Pre-Installation and Mounting Table 4: Corrosive Combustion Air Contaminants Table 5: Clearances for Serviceability VII. Venting Table 6: Vent and Combustion Air Pipe Diameters and Maximum Lengths Table 7: Equivalent lengths of Vent and Combustion Air Components Table 8: Vent and Combustion Air Equivalent Length Calculation Worksheet Table 9: Flue Gas and Combustion Air Flow Rates Table 10: Listed Vent Manufacturers and Materials Table 11: Stainless Steel and CPVC Vent Adapters Table 12: Polypropylene Vent Adapters Table 13: Stainless Steel Vent and Intake Terminations Table 14: Polypropylene Vent and Intake Terminations Table 15: Recommended Venting Configurations and Material Options Table 16: Direct Vent Terminal Clearances Table 17: Other than Direct Vent Terminal Clearances Table 18: Table of Acceptable Terminations VIII. Condensate Disposal Table 19: Maximum Condensate Flow...

  • Page 67: Appendix B: Figures

    APPENDIX B: Figures I. Hazard Definitions II. Read Before Proceeding III. Product Rating, Specifications, and Dimensional Data Figure 1: Citadel Boiler Dimensions IV. Citadel Component Identification Figure 2: Component Identification Figure 3: Component Identification V. Unpacking The Citadel Figure 4: Lifting Lugs VI. Pre-Installation and Mounting VII. Venting Figure 5: Vent Terminal Clearances Figure 6: Horizontal Sidewall Termination Figure 8: Flat Roof Vent Terminations Figure 7: Slopped Roof Termination Figure 9: Multiple Appliance Direct Vent Termination Figure 10: Flexible Vent in Masonry Chimney with Separate Combustion Air Intake VIII. Condensate Disposal Figure 11: Condensate Trap Assembly IX. Hydronic Piping Figure 12: Factory Supplied Water Manifold X. Heating Boiler Piping diagrams Figure 13: Single Boiler, Primary/Secondary Piping Figure 14: Multiple Boiler, Primary/Secondary with Common Header Piping Figure 15: Multiple Boiler, Primary Reverse-Return Piping...

  • Page 68: Appendix C: Default Light-Off And Modulation Rates

    APPENDIX C: Default Light-off and Modulation Rates Citadel Model Parameter 1250 1500 Max Power MBTU 1250 1500 CH/DHW Max. Modulation Rate (RPM) 7600 4600 Minimum Modulation Rate (RPM) 2000 1250 Light-off (RPM) 2400 1900 Maximum Light-off (RPM) 2500 2000 Minimum Light-off (RPM) 2300 1800 Factory Default RPM...
  • Page 69 If a claim is made under this warranty during the “No Charge” period from the date of shipment, U.S. Boiler Company will, at its option, repair or replace the pressure vessel (not including labor).
  • Page 70 U.S. Boiler Company, LLC P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net...

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