Install Instructions

Part number 550-100-131/0715
– 4 –
™
GAS-FIRED WATER BOILER — Boiler Manual
Contents
The Evergreen Gas-fired water boilers . . . . . . . . . . . . 2
Please read before proceeding . . . . . . . . . . . . . . . . 5
Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . 6
Prepare boiler location. . . . . . . . . . . . . . . . . . . . . 8
Wall-mounting the boiler. . . . . . . . . . . . . . . . . . . . 8
Boiler hydrostatic test . . . . . . . . . . . . . . . . . . . . 10
Gas conversions . . . . . . . . . . . . . . . . . . . . . . . 12
Gas piping — sizing gas lines . . . . . . . . . . . . . . . . 16
Venting/air piping — general . . . . . . . . . . . . . . . . 17
Commonwealth of Massachusetts installations . . . . . . 20
Vent termination requirements . . . . . . . . . . . . . . . 21
Boiler room air openings. . . . . . . . . . . . . . . . . . . 22
DIRECT VENT — Sidewall with separate pipes . . . . . . . 23
DIRECT VENT — Sidewall with W-M vent/air plate . . . . . 25
DIRECT VENT — Sidewall concentric . . . . . . . . . . . . 27
DIRECT VENT — Vertical with separate pipes. . . . . . . . 29
DIRECT VENT — Vertical concentric. . . . . . . . . . . . . 31
Concentric termination, typical (sidewall or vertical). . . . 33
DIRECT VENT — Vertical vent / sidewall air. . . . . . . . . 34
Vent and air piping and boiler connections . . . . . . . . . 36
Install water piping . . . . . . . . . . . . . . . . . . . . . 37
Expansion tank . . . . . . . . . . . . . . . . . . . . . . . 40
Install condensate line . . . . . . . . . . . . . . . . . . . 47
Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Field wiring (see wiring diagram, Figure 62, page 57) . . . 50
Wiring diagram — schematic . . . . . . . . . . . . . . . . 57
Wiring diagram — ladder . . . . . . . . . . . . . . . . . . 58
Zoning with the EVG Control . . . . . . . . . . . . . . . . . 59
Evergreen Control operation . . . . . . . . . . . . . . . . . 61
EXPRESS SETUP — Example A . . . . . . . . . . . . . . . 66
EXPRESS SETUP — Example B . . . . . . . . . . . . . . . 68
EXPRESS SETUP — Example C . . . . . . . . . . . . . . . 70
Available control settings and system presets . . . . . . . 72
CONTRACTOR menus. . . . . . . . . . . . . . . . . . . . . 73
BOILER SETTINGS menu, BASIC mode . . . . . . . . . . . . 74
PRIORITY 1, 2, 3 menus, BASIC mode . . . . . . . . . . . . 75
ASSIGN INPUTS menu, BASIC mode . . . . . . . . . . . . . 76
DIAGNOSTIC menu . . . . . . . . . . . . . . . . . . . . . . 78
MAINTENANCE, DATE AND TIME menus . . . . . . . . . . . 83
Startup — fill the system . . . . . . . . . . . . . . . . . . 84
Startup — final checks . . . . . . . . . . . . . . . . . . . 86
Check-out/startup verification. . . . . . . . . . . . . . . . 90
Annual startup and general maintenance . . . . . . . . . . 91
Annual startup . . . . . . . . . . . . . . . . . . . . . . . . 92
Manual Test Mode for Single and Multiple Boilers . . . . . 99
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 100
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cleaning heat exchanger flue side . . . . . . . . . . . . . 109
Replacement parts . . . . . . . . . . . . . . . . . . . . . . 114
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Ratings — Multiple boilers . . . . . . . . . . . . . . . . . 128
Installation and Service Certificate . . . . . . . . . . . . . 129
Gas Boiler Data Collection Sheet . . . . . . . . . . . . . . 130
DO NOT SERVICE THE BOILER
WITHOUT A Evergreen
MAINTENANCE KIT AVAILABLE
The
Evergreen maintenance kit includes components that
may have to be replaced when accessing or disassembling
parts of the boiler. Failure to replace damaged components
and to use only the parts specifically intended for the boiler
can result in severe personal injury, death or substantial
property damage. See Figure 108, page 115 for part number.